258 replies to this topic

[alexk243]

Get aftermarket wans....then we can keep this thread goin for an udder 2 years whilst ya rebuild it again.

 

What grrr box did ewe git in the end?

 

To be honest I cant even remember. I bought it used from someone and I have it installed haha. 

[alexk243]

I can find all of those (boats.net) except for the "Camshaft Cover Gasket" Where is that?

[Studley Ramrod]

On OEM Motorparts site it's in the cylinder head section and is called Gasket Head Cover 1.

[alexk243]

Ah, OK. I got that. I am used to those being called "Valve Cover Gaskets"

[alexk243]

Alright!!! Almost done. The bike is back together and I will upload some of the pictures of the process. Engine is back together and in the bike, but I ran into one issue, the clutch. Anyone know how many friction plates there are suppose to be? I feel like some disappeared when I went to rebuild it. In the manual it looks like 17, but I only have 15 and I can tell that it needs more. there is space between them and the float freely with the springs installed...

[alexk243]

[dapleb]

Well done.

 

Not sure aboot how many plates.  There should be an ezploded diagram on ajsutton site or aimilar what shows em.

 

Difficult to tell from piccy but non standard pistonias?  They dont seem to have the 3VD stamp or concavedness of standards?

[jonnyaztec]

I have a mkII engine in bits on the shed floor and there are 17 plates. Perhaps someone can confirm if mkI and mkII clutches are the same.

[dapleb]

There are small differences atwix mk I and II clutch but I would be pretty sure that the number of plates were the same and from Alexs description it sounds loike he's a coupla plates short of a clutch.

[TYREDNGRUMPEE]

Mk1 needs 16 plates sez here in manual. 8 friction and 8 plain = 16. Start with slick/plain plate and finish with the friction plate with the slot cut-out in one of its tabs if you have '91-93 model.

 

MK2/2a/TRX = 9 friction and 8 plain = 17.

 

So what are you missing Alex? Friction or plain?

Edited by TYREDNGRUMPEE, 01 May 2014 - 06:02 pm.

[alexk243]

I'm not sure, I will have to go out and look, but it seems like the spacing there is missing more than one plate to be functional. Ill try and get some better pictures of it when I check.

 

The pistons are what was in there before, I didnt replace them, just removed all the carbon build up from them and from the head. 

[alexk243]

OK, I have 8 and 8... What else could I be missing?

 

[TYREDNGRUMPEE]

Looks fine.

Would behave differently if friction material had been bathed in lube.

 

Questions to ask.

Pullrod bearing and thrust washer present?

Basket fingers not ridged?

Springs should still be okay. But are they? Washers on top?

Aligned marks on pressure plate and basket with each other?

 

The pressure plate has to move smoothly up and down the six guides. Anything stopping it?

 

It's difficult to say what your issue is from here. The photos are good tho.

 

My suggestion would be to bathe the friction plates in engine oil and pay close attention to reassembling the basket piece by piece.

 

Chuck oil at everything.

 

I'd fit the centre pressure plate without the plates and see what's going on too.

[TYREDNGRUMPEE]

I was just thinking.

 

If like you said, there is substantial clearance between the plates and everything else seems to be in order, then you should ask whether all the thrust washers are present behind the basket (x2) and clutch centre (x1).

 

Below is a Mk2 basket which will have one more plate than yours. Thrust washers etc. the same

 

[alexk243]

Dang, I would really hate to have to take the clutch basket off again, but I guess I need to check. Actually.. that wouldent matter since the springs tighten to #9 in the picture which is on the other side of the washer. The clearance is between #9 and #2 with the friction plates in, So I feel it has to be something between there. 

 

Also what are the line up marks you are talking about on the friction plates?

[TYREDNGRUMPEE]

Dang, I would really hate to have to take the clutch basket off again, but I guess I need to check. Actually.. that wouldent matter since the springs tighten to #9 in the picture which is on the other side of the washer. The clearance is between #9 and #2 with the friction plates in, So I feel it has to be something between there. 

 

Also what are the line up marks you are talking about on the friction plates?

 

This may solve itself if you chuck some engine oil at it.

 

I agree with your #2 + #9 observation, but you may not get the proper clutch release action if, say, #10 was missing.

 

How much clearance are we talking about here? is it just down to dry plates? Is it time for new friction plates?

 

MARKS- There's a circular mark on #2 and #9 that match. Also a cut out in the last friction plate.

[alexk243]

So I pulled the clutch basket off and re-checked everything. All the washers and bushings were correctly installed. I ended up ordering another friction plate because in my manual (for a 96) is shows 17 (9 friction and 8 plain) and I only have 16 (8/8). You guys mentioned that the mk1 only has 16, I am pretty sure mine is a mk1, but if the mk2 has 17, is it possible my engine is an mk2?

[erdferkel]

No, the MKII has a 270° crankshaft, sounds different. You'd need a MKII TCI as well and the oil reservoir must be swapped. The location is different. No dipstick but a looking glass.

In 1996 the MK II started. Perhaps you have the wrong year manual.

 

Glückauf

Ralf

[alexk243]

So you suggest not adding the additional friction plates? even though there appears to be clearance in there?

 

It does appear that I have the wrong year manual... however everything else in the manual was correct to my engine. 

Edited by alexk243, 27 July 2014 - 05:53 pm.

[erdferkel]

Sorry, I have no clue, if a MKII clutch will work. Gut feeling says it might work, because a lot of the parts are shared. But someone more knowledgeable will chime in soon, I think.

Glückauf

Ralf