Looks like I will need to do some clutch maintenance. I'm assuming this will be the first time it has been done, so looking for recommendations on which parts to order. I have already read the How To sticky on how to replace the clutch too and it looks within my skill level.

I talked to the guy at the local dealer and he said about $400 for parts (fiber and steel, plates, springs, gasket. I am guessing I can do a bit better ordering the parts here, but not sure how many of each part I should get. Do I really need 8 each of the $18, $8, and $8 parts as the #REQ column seems to indicate?

I was thinking I would order fiber plates and the gasket, and see how everything else looks when I take it apart. How bad is that plan? ?

 

As long as you don't have a problem with the longer supply pipelne, i.e. don't mind the bike being down waiting on parts. That's a great way to do something like this.


I usuall try to do things like this in the cold season, when I'm often not riding for a few weeks at a time. Waiting to run my valves out on my 98F3 till the first snowfall, even though they'll be a couple of thousand over-due on the official maintenance schedule.

Try this site to verify the exact parts and quanity involved for your particular bike Discount Honda ATV Motorcycle and Scooter Parts

 

400$?!?!?! jesus dont do it! you can get a whole barnett kit for like 150ish. job is super easy.

i dont know what bike your running, but look for this http://compare.ebay.com/like/4001956...=sbar&_lwgsi=y

edit: didnt see the 1000f section, but you get the idea

 

Yeah I'd put it at no more than 225 bucks tops !

 

After much review of pricing for various sets of parts, the difference was big enough that I figured I would take the clutch apart tonight and then only order the parts I needed. $100 or more in savings is definitely worth 5 days off the bike.

So I have the parts out as in the picture. Looks like I need fiber plates as expected. I think the steel plates look OK as there are only a few small black spots, and the springs are questionably close to the minimum servicable spec so I will replace those too.

Thanks for the advice of looking at kits on eBay. I found fiber plates for $40 and springs for $9. Throw in a gasket for $10 and it could be a nice cheap repair.

 

I failed at assembly. I broke one of the clutch spring bolts. Then I broke the extractor inside of the bolt. (Drilling the hole in the bolt caused it to spin further in, and then I did not clean out the filings before trying to extract it, so things got pretty tight in there. Not smart.) Now I need a new clutch inner boss. Looks like they are about $45 on eBay so that is OK.

But I have a few questions.

Are all the years the same part? One of the listings says it is 91-96 compatible so are those years different?

There is a "staked" nut holding this beast on. Any tips on removing it? And I have to order a new one of those too, right?

 

Thought I would include two pictures to make you weep...

 

Got my parts yesterday and threw it together successfully in about 45 minutes. She seems to ride super smooth, but I'm not sure if anything actually changes in the rude quality or I was just so excited to be on the road after three weeks.

Some notes:
Getting the staked nut off wasn't too bad. I drilled it out a bit, put it in six gear, and held the rear brake and wrenched on it all by myself and didn't really even have to struggle. The wrench is maybe 18 inches long--my 120lbs torque wrench.

A hammer and punch works just fine for staking the new nut. No need to go big on the first swing as it will dent in fine with some small taps. I say thus as I had read somewhere that you have to just go for it as you only get one chance.

 

Well done Joker, glad it worked out for you and you're finally back on the road.

Horrible feeling when you know you've f*cked something up, but fixing it again feels sooo much better.

 

Nice save Joker, I done mine a few months back and had a couple of hairy moments. For some unknown reason I kept holding my breath which in itself creates issues lol.

Feels great when ya back out on the road and can open the throttle without the worry of any more clutch slip.

Well done