258 replies to this topic

[Studley Ramrod]

Have you actually fitted the 16 plates and tried out the clutch, or are you just sensing there's a space there ?

[TYREDNGRUMPEE]

Have you actually fitted the 16 plates and tried out the clutch, or are you just sensing there's a space there ?

The last thing I would do would be to add an odd clutch plate. (I wouldn't do it)

If you do have a problem and are not just imagining there to be one, then check

your clutch spring lengths

the friction plate thickness

 

At the very end I'd be trying the pressure plate, springs, bolts and clutch plate positions in every combination I could think of.

 

Either way, this one ends with you slapping your forehead.

Edited by TYREDNGRUMPEE, 28 July 2014 - 07:24 am.

[alexk243]

Have you actually fitted the 16 plates and tried out the clutch, or are you just sensing there's a space there ?

 

I have, and I bolted in the springs and cover and the plates were loose in there... really odd. 

 

Oh and for sure.. I know it has to be me doing something odd. It shouldent be the difficult an I know I will be slapping myself after... Ill go tinker on it some more and take some pictures to report back with. 

[alexk243]

So everything is back together, clutch is fine (not sure what the issue was, put it all back in by the manual and it worked). Everything is looking good so I crank it over and oil comes pouring out of the driveshaft.... f me.... At this point I am just about done with it... I usually don't get this discouraged with a project, but its been two years and to get back to that point I would have to completely tear down the engine... debating my options now. 

[Studley Ramrod]

You can replace the output driveshaft oil seal in about 20 minutes Alex. No need to dismantle the engine.

 

http://www.jbx9.t15....ex.php?page=OIL

[alexk243]

Oh my god!!!! Thats the most amazing thing!!!! So Yeah, I dont even have that seal installed... I must have missed that part. No wonder oil was just pouring out!!!

[Studley Ramrod]

 

Got my fingers crossed for ya Alex, good luck !

[alexk243]

Thanks!!! Part ordered. 

[silas]

Following the thread, Alex !   great work to date, best of luck completing the job.  Thanks for the photos.  I've learned a lot here and may try this output shaft seal as my 92 850 is leaking quite a bit. I can't yet tell where from.

I'm waiting on the starter O-ring and pan gasket, will try those 1st.

I bought it in April-May this yr and am trying to get it going reliably.  

My bike came w/ a broken odo so no idea of its miles, but my 3rd gear is very clunky. It will not clunk at all if I short shift to 3rd before 2500 rpms, but a regular shift to 3rd makes quite a clunk at higher rpms. I hope it will last a while!

This level of work is uncharted territory for me.

 

silas- Atlanta,Ga.

[silas]

Alex-where did you order the part from? Looking for options-thx

Thanks!!! Part ordered.

[alexk243]

I have used boats.net for most of my stuff, some gaskets from ebay and people on this site, but for quick parts and a good oem catalog I use boats.net (was recommended to me by someone on here). 

[alexk243]

OK, New seal is in. Everything is for the most part back together (still need to get sprocket spaced right) and it should be good to go. Cranks no, but wont fire. Ill troubleshoot spark in my next garage session. 

[TYREDNGRUMPEE]

OK, New seal is in.

 

Correctly orientated?

Blue Hylomar / other suitable sealant to fix the little bugger?

 

Some advice from experience. It would be useful If you could leave the drive sprocket and chain exposed for the first 50 miles or so.

This is in order that you can quickly spot if the seal has come away and is pissing oil (ask my EXUP). Carry some standby Blue Hylomar.

If after 50 miles, all is well, then all will be well.

 

BTW, there appears to not be enough forehead slapping going on here. How did you solve the clutch plate clearance mystery?

[alexk243]

I think I used some sort of Hondabond to seal around it and yes, correctly oriented. Not too worried though, the reason it was leaking before was due to the non-existence of the seal haha (i forgot to install it)

 

Oh, as for the clutch plate.... Not really sure, ordered a new plate to replace a broken one, double checked everything to make sure I had the washers in all the right places (I did) and then installed it per the manual... it fit... Couldn't really tell you. All I do know though is that the manual I had was from a 96 and depicted the wrong number of plates (1 extra than I needed I think...) but that was not the issue as I had the correct number all along. I think it may have come down to me just not lining up the marks just right.  

Edited by alexk243, 02 September 2014 - 07:31 pm.

[alexk243]

UPDATE: Sorry guys, been real busy with work and haven't gotten the chance to post/fix the TDM. I am 99% done with it. It is all back together and doesn't start right now... haven't put much time into that so not real worried. 

 

Looking or advice on what I have left to do:

 

1. Best ADV dual sport tire (aggressive tread)

2. Crash Bars

3. R1 Fuel Pump Swap (dont need advice as there are a lot of write ups on this, have the fuel pump already). 

Oh and one issue I ran into that I am still trying to solve. The front sprocket... It was a small aftermarket one that was rigged in there because the threads on the main shaft were stripped, as I have installed a new transmission that main shaft now has good threads on it so the sprocket wont fit... The stock one wont fit the chain on there and the aftermarket one is way too thin (Ill post a picture of this). My thought is make-shift washers... thoughts? 

[Bythesea]

Hi, I've been following this topic for ages and am really impressed with what you've done, I really hope that when that engine fires up it will have been worth all the effort.

 

Good luck.

[Studley Ramrod]

A standard chain & sprocket kit should fit nicely.

[ChrisG]

I'm pretty sure several people were using a rear Sirac mounted backwards (strength for breaking rather than accelerating) on the front as choice of offroad tyres is a bit limited.

 

Masterbrewer is our resident Mk1 offroad expert so have search for some of his posts, and there'll be some older posts from Godzillamonster who rode his Mk1 from the UK to the antipodes.

[alexk243]

Hi, I've been following this topic for ages and am really impressed with what you've done, I really hope that when that engine fires up it will have been worth all the effort.

 

Good luck.

 

haha me too!

A standard chain & sprocket kit should fit nicely.

 

There are no issues with an aftermarket sprocket/chain kit having the front sprocket bounce around cause it is too thin? (I really need to get a picture of what it looks like)

Edited by alexk243, 07 April 2015 - 01:06 pm.

[Studley Ramrod]

I'm confused !  Are you implying that the drivechain isn't a standard one as a standard sprocket won't fit it ?