Clutch basket how to (and not how to...)

[FireDog45]

This is my first attempt at doing a thread like this so bear with me, I see a few edits in my future.

First a little background: I decided to replace the noisy clutch basket on my '02 Vee and figured I could do this myself, especially after seeing the pictures that Dan O'Brian posted at VSRI http://www.vstrom.info/Smf/index.php/topic,7089.0.html[/URL]. After much reading I decided on installing the following new parts:

11482-06G10 - Clutch cover gasket $10.57
09263-35013 - Bearing 35x40x39.8 $19.01
09160-25074 - Washer, 25x52 $3.84
09159-24010 - Nut $7.06
21200-16820 - Gear Assy, Primary (AKA Clutch basket) $194.62
21410-06G00 - Hub, Clutch sleeve (This was a late addition as explained later) $72.xx
Clutch holding tool $32.00

(Prices are USD as of April '08 from MRCycles, Clutch sleeve from Mid-Ohio Suzuki and the clutch tool from Iron Pony)

Everything on this list, with the exception of the basket itself, are DL1000 parts. The basket is an SV1000 part.

I won't duplicate what Mr. O'Brian did so well documenting, I'll only offer up what I came across that may need some clarifying.

First, this is what your bike should look like after disassembly:

http://i150.photobucket.com/albums/s82/leis_photos/IMG_2435.jpg

It took me less than an hour to get to this point.

Here's the clutch baskets,

Old:
http://i150.photobucket.com/albums/s82/leis_photos/IMG_2441.jpg

New:
http://i150.photobucket.com/albums/s82/leis_photos/IMG_2440.jpg

The biggest difference I noted is the springs, the SV part seems more stout and initial feel seems to bear this out. Before I removed the old basket I was able to rotate it between 1/8" and 1/4". The new part I can barely even wiggle.

Now I'm sure you noticed in Dan's pictures the use of a special tool for holding the clutch hub (in case you didn't here's what it is: [URL]http://www.motionpro.com/motorcycle/tools/clutch_holding_tool/ (http://vstrom.info/faq/index.php?action=artikel&cat=3&id=17&artlang=en) ). I don't have this tool and I wasn't real keen on buying a tool that only did one thing so I improvised by jamming the part with a pair of 90 degree needle nose pliers and buzzed the nut off with an impact wrench. So far so good, until I attempted (this being the operative word) to reassemble everything.

I installed the washer (notice the bevel, it goes toward the engine):

http://i150.photobucket.com/albums/s82/leis_photos/IMG_2436.jpg

http://i150.photobucket.com/albums/s82/leis_photos/IMG_2437.jpg

Then the new bearing cage and sleeve (after oiling it thoroughly):

http://i150.photobucket.com/albums/s82/leis_photos/IMG_2438.jpg

At this point I'm feeling pretty good (this should've been a warning) and installed the new basket and hub sleeve and attempted (there's that word again) to torque the new nut down. I used a piece of steel stock to brace against the bosses where the pressure plate screws go so I could tighten everything down. That's when I heard a 'crack' and this is what I found:

http://i150.photobucket.com/albums/s82/leis_photos/Brokenhub.jpg

So now I'm waiting on the "21410-06G00 - Hub, Clutch sleeve" to arrive. At least I'll have time to go get the proper tool.

Moral of the story: Sometimes saving some money costs you more!

I'll update when the new parts and tools arrive, wish me luck.

(Note: not sure why 3 of these picts are so big, I've resized them at Photobucket but it doesn't seem to take. I'm tired of messing with it now, I'll attempt to fix it when I update.)

[BadTrainDriver]

Damn Steve........


Did you WASH YOUR BIKE?????:D



I've never seen your frame that clean!!!!

[FireDog45]

Thanks but I haven't cleaned that part yet. That'll be after I get her back together!

[handyhiker]

Dude, That REALLY SUCKS!!! Hope all else goes well. At least you got a center stand to work from. :mrgreen:

[MightyShep]

Sorry to hear about the break. You're not alone as I have heard of someone else doing what you did because of a lack of tools. MonkeyGrass mentioned that they jacked up an SV basket doing what you did.

[FireDog45]

Dude, That REALLY SUCKS!!! Hope all else goes well. At least you got a center stand to work from. :mrgreen:

Thanks to you!!!

Sorry to hear about the break. You're not alone as I have heard of someone else doing what you did because of a lack of tools. MonkeyGrass mentioned that they jacked up an SV basket doing what you did.

Luckily my attempt to secure the part didn't involve putting any force on the new basket. The upside is I'll have the correct tool for the next time or if anyone else will need it!

[xDownSetx]

Make sure you clean out the oil screen. I replaced the clutch on my NX650 and bolted it up, only then did I remember to clean out the screen:mad:.

[FireDog45]

Good catch! I've already done that but, as you can tell from the picts, I need to do a final wipe down of the innards.

[MZBuckeye]

Very interesting. Should be a nice improvement, what was the final cost for all the parts? Not that mine needs it, I'm just curious.

[FireDog45]

Before buying the additional part and tool; $251.60 delv'd from MR Cycles. Add another approx $100 for the brainfart pieces :banghead:

[FireDog45]

Cue the choir... "Hallelujah!"

After getting the proper tool AND the new part "Hub, Clutch sleeve" I put everything back together, put in fresh oil, put the old "new" anti-freeze back in, crossed my fingers and cranked 'er over.

What was the sound...? Oh it was the missing idle hammer! The hammer is GONE!! I let her warm up and did the tapping on the thermostat thing and checked for any leaks (none were to be found :mod2_punk:). After making sure that all the air bubbles were out, I shut everything down and commenced to hanging all the bodywork back on. I removed all the bodywork to attempt a fix for making my magnetic tank stick to the fairing, it didn't work, but that's a topic for another discussion.

I took a quick ride around the area to make sure everything worked and boy did it! As stated earlier the idle hammer is gone, as well as the chudder that was getting worse. This thing is so smoooooth now while both accelerating and just cruising, I was able to roll on the throttle from 2K rpm and there was no complaint, sputtering, jumping or any of the regular pissing and moaning she'd been doing.

If anyone has considered doing this and hasn't yet, don't wait! I can't, however, stress enough the importance of having the 'special tool'. Don't do what I did and try to save a few bucks, it'll end up costing you in the end.

[MZBuckeye]

Great job dude!

You gonna make that east V-strom get together? Handyhiker and I are planning on making the trip

[Big B]

That is friggin awesome news Steve, sorry about the lil setback you had.:var_32: I wish that I could have helped you, I would've loved to seen this procedure done. I'm glad your running so sweet now, I'm sure we'll be racking up some good miles this year. Nice write up and pics, I know that you've helped future troopers when their time comes.

BB

[FireDog45]

Thanks guys!

This is a pretty simple project but a couple of things you need to keep in mind.

1) Have the right tool (have I stressed that enough yet!). If you don't have it and I'm not using mine, get a hold of me, I might be in the mood to loan it out.

2) Like Dan mentioned in the VSRI article "The manual is your friend!" There are pieces that go in a specific order and in a specific way. The clutch pack uses three different pieces and there's a specific sequence that needs to be followed. I'm not sure why but I didn't want to be the one to find out.

If you've been thinking of tackling this project but have been reluctant, I hope that between Dan's article and this one you'll roll up your sleeves and jump in!

Ride safe!

[Scarlett Harlot]

The god of wrenching has blessed you my son. Go forth and turn hydrocarbons into forward motion.

And watch out for the bears. Owch!

[Koinz]

After much reading I decided on installing the following new parts:

11482-06G10 - Clutch cover gasket $10.57
09263-35013 - Bearing 35x40x39.8 $19.01
09160-25074 - Washer, 25x52 $3.84
09159-24010 - Nut $7.06
21200-16820 - Gear Assy, Primary (AKA Clutch basket) $194.62
$72.xx
Clutch holding tool $32.00

(Prices are USD as of April '08 from MRCycles, Clutch sleeve from Mid-Ohio Suzuki and the clutch tool from Iron Pony)

Everything on this list, with the exception of the basket itself, are DL1000 parts. The basket is an SV1000 part.


Firedog, Did you also replace the clutch plates or is that part of the basket.

[FireDog45]

Firedog, Did you also replace the clutch plates or is that part of the basket.

The clutch basket is the basket by itself. The manual gives specs regarding the clutch plates (both friction and drive plates). The specs for the clutch plates involve measuring the thickmess of the material as well as the width of the ears. The driven plates are checked for flatness. Mine all tested within spec as well as free length of the pressure plate springs so I didn't replace any of those.

[swingset]

Cool write up, I hope it comes in handy when my time comes....and lo and behold there's a guy 15 minutes from where I live with a new special tool! How's that for providence?

:D

[FireDog45]

Cool write up, I hope it comes in handy when my time comes....and lo and behold there's a guy 15 minutes from where I live with a new special tool! How's that for providence?

:D

Did I mention the $30 tool rental charge...:rolleyes: