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WRENCHTECH W

IN STA L L I N G A C L U T CH B A S K E T G E A R W I T H D AV E D Y E

hat they never tell you when you purchase an aftermarket clutch basket is that you have to move your old primary gear from the used basket to the new basket. It isn’t an easy chore, but if you have a modicum of mechanical skill and some patience, you can do it yourself. Do not skip steps and work slowly. Be careful when using a hot plate or oven. Also, this technical feature begins with the clutch basket already removed from the bike.

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STEP 1 Clean the stock backing plate with contact cleaner and a lint-free rag. With a hammer and punch, make registration marks in the center of each rivet. Creating a small indentation on each rivet helps to prevent the drill bit from slipping off the rivet heads. Making registration marks isn’t necessary if you’re going to use a grinder to remove the backing plate. 168 www.motocrossactionmag.com

Punch Hammer Drill press Red Loctite Lint-free rag Oven mitts

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NECESSARY ITEMS:

Bucket of ice Rubber mallet Torque wrench Contact cleaner Hot plate or oven New clutch basket

• Appropriate wrench • Straight blade screwdriver • Appropriate size drill bit(s) • Grinder (optional) • Hand drill (optional)

TIME TO COMPLETE: 60-90 minutes

STEP 2 Use a drill press outfitted with the proper size drill bit to remove the rivets (the bit size should be slightly smaller in circumference than the rivet head). Drill through the center of each rivet, being careful not to drill into the steel primary gear. Once all of the rivets have been drilled through, punch or press the rivets out. A grinder can be used in place of a drill press. In fact, a hand drill can also be used—if done very carefully. Don’t worry about scratching or marking up the old basket or backing plate; you are going to toss it anyway.


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STEP 3 If you have difficultly removing the rivets from the backing plate, use a slightly larger drill bit to slowly drill through the center of each rivet. The rivet should easily separate from the backing plate.

STEP 4 With a straight blade screwdriver, remove the backing plate from the primary gear. Slowly work the screwdriver underneath the backing plate, carefully applying pressure. Once the backing plate lifts slightly, remove the screwdriver and follow the same procedure on the other side of the backing plate until the entire plate lifts up. Once the backing plate has been removed, take note of the placement of the primary gear and rubber cushions. Remove the primary gear from the stock clutch basket.

STEP 5 It is important to clean the threads in the new clutch basket, as well as the bolts. Make sure that the rubber cushions aren’t affixed to the clutch basket, and place the basket on a hot plate (tang side down). An oven will also work (set the temperature to 400 degrees). Warm up the clutch basket for 15 minutes. APRIL 2011 / MOTOCROSS ACTION 169


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WRENCHTECH

STEP 6 Clean the primary gear with contact cleaner and a lint-free rag. Place the gear in a bucket of ice (or a freezer) and let it sit for 15 to 30 minutes. This will ensure easier installation when seating the primary gear into the new clutch basket.

STEP 7 Using oven mitts, carefully remove the clutch basket from the hot plate and set it tang side down on a hard, flat surface. Remove the primary gear from the ice. Carefully place the gear on top of the clutch basket with the kickstarter gear facing up. Using a rubber mallet, gently tap down on the primary gear. Gently work your way around the primary gear to create uniform pressure on the gear. Once the gear is properly seated, apply liberal force with the mallet to ensure that the gear is seated into the clutch basket. Place a heavy weight on the gear to hold the basket in place as it cools. Allow the basket to cool for 15 minutes. 170 www.motocrossactionmag.com


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STEP 8 Clean the new backing plate with contact cleaner and a lint-free rag. Install the rubber cushions on the clutch basket. Lay the backing plate on top of the primary gear, making sure to line up the holes. Apply a generous amount of red Loctite to the threads of each screw, as well as each thread hole. Finger-tighten each screw. Tighten every screw to the recommended torque specification. Flip the clutch basket over so that the tangs are facing up. Wipe off any excess Loctite with a lint-free rag. Place the basket on top of a block of wood. This will prevent the gear from becoming damaged during the peening process. 172 www.motocrossactionmag.com

STEP 9 Using a hammer and punch, peen the edge of each screw to prevent the screws from coming loose. Strike the very edge of each screw head. Once the process is complete, the new clutch basket is ready to be installed in the bike. â?‘


Installing a Clutch Basket Gear