as the topic suggests, i have some oil leaking out the bottom of the engine, clutch side. Looking under the clutch, i can see oil drip forming off the exposed edge of the gasket.

I'd like to get a simple step by step remove and replace of the clutch case(dry)

All i have done is remove a few of the clutch plates, dont wanna go any futher till i know whats gonna fall out.

Im guessing remove the oil for a start, but, whats best?
_________________



Last edited by Kubira on Fri Jun 05, 2009 12:10 pm; edited 1 time in total

Drain the oil, remove the clutch plates, remove the large nut in the middle of the clutch (you'll need a tool to hold the clutch still or a rattle gun to zip it off).
Remove the clutch basket, it just pulls off.
Undo the 6 bolts holding the outer clutch. Remove the outer clutch. It just pulls off.
Remove the bolts holding the little plastic hose connector to the crank case, remove all the bolts holding the clutch cover on.
Give the cover a few gentle taps with a rubber mallet and it'll come off.

At some time in this operation the clutch push rod and/or the bearing that sits between the rod and the cap may come out. That little bearing has a habit of vanishing. Watch out for it.

Replacement is just a reversal of removal, be carefull with the outer basket, it has a hole that lines up with a peg on the primary (or vice versa) and can only go back on one way, you'll either crack it or it'll not sit straight if you tighten it up alligned wrongly, don't ask how I know.

_________________
Please do not PM me technical questions, if you can't find it on the Forum start a thread

awesome , thanks fontyyy, ill hop into that tomorrow.. Exactly what i was lookin for.
_________________

in order to take the crankcase off you'll need to drain the rad also and remove the hoses off the water pump, take the kick start off etc

job done, nice and tidy, no leaks after a run ... Beautiful.

Thanks to the fontyyy, and ricer

(edited title) Yep, the stator side leaks too. The workshop stripdown doesnt do justice to this side, imo, so a lil extra help may be required to do the same job.

I havent any idea where its coming from, as i havent removed the stator (is it stator or stato?), or the sprocket or the other stuff. Noticed a fair amount of mess around the gear shaft and kinda all over.

Im prep'd as far as a replacement gear shaft oil seal has been sourced, but thats about all....
_________________

you'll have to remove the cover from that side and check, the seal behind the stator is the cankseal, that wont be leaking as you'd notice it in terms of engine performance so it will either be the selector shaft oil seal, the driven shaft oil seal, the clutch actator oil seal or a slight (as in non existant) chance the gear position sensor o ring has had it. i'm pretty sure as in 99% sure they could all be changed with no disassembly to the engine other than removing the oil. as i said remove the cover and check

Have decided the gear selector shaft isn't leaking. But the drive shaft oil seal definately is...

Upon further observation, the bolt attached to the stand, goes thru to the other side, thru an engine mount. This has oil protruding also.

Is this a specific seal that is leaking, or caused by one of the seals mentioned above?
_________________

will be cuased by the above mate, there are no oil seals down there, only ones are the ones i mentioned, sound the driven shaft oil seal then.

How does this grab ya


1 more 180deg the other side, 2 pairs of pliers and hey presto

i havent done mine yet.....
_________________