Help. How do I get the clutch basket back in? 1299

endodoc · May 16, 2016

Hey guys,

I went to swap out the clutch last weekend and decided to drop in the ERV billet basket at the same time. Now i cant get the clutch basket back in. The shaft gear that mates with the ring gear on the basket has a spring loaded smaller gear in front of it that from what i can tell loads the ring gear. When you pull the basket out that little gear moves 1.5mm out of sync with main gear so now i cant slide the ring gear back on without loading that little gear. Without stating the obvious like I need to lock the crank with the flywheel tool is there an easier way to do this?

Thanks

endodoc · May 16, 2016

Here is what the gear looks like. You can see the first gear is spring loaded to "load" the mating ring gear when it is installed. When you pull the clutch basket ring gear past this assembly the little bugger springs into this position. You cannot slide the ring gear all the way on without sinking the two gears which means you have to lock the crankshaft, slide the basket with the ring gear on the shaft onto the small gear then slightly rotate the basket to turn the spring gear then you can slide the ring gear the rest of the way.

endodoc · May 16, 2016

Here is the whole picture

swort · May 16, 2016

Rotate the washer on the crank gear until you see a couple of holes that don't quite line up (one hole in the main gear, one hole in the split gear).

Find a screwdriver that fits in the holes, poke it in far enough so that its engaged on both the split gear (the thin one) and the main one (the thick one) and then twist it so that the teeth on the split gear line up with those on the main gear.

When you've got the split and main gear aligned, then you should be able to just slide the clutch on.

In reality, you don't need to get them perfectly aligned, just close enough to allow the clutch teeth to fit in the gap.

Good luck!

JDBeretta · May 16, 2016

Is there an emoji for way over my head?

Engine stuff, cool. Transmission stuff... Nope.

Sent from my iPhone using Tapatalk

endodoc · May 16, 2016

Hmmm. Ok that sounds like it should work. Issue is do I have the ability to get to that hole with the limited clearance between the basket and the case. The case is not off the bike only the clutch cover.

Gecko · May 16, 2016

I use a big flat screwdriver to align the theeth. No problem, does not harm the hardened thooth flanks.

endodoc · May 16, 2016

I cant do that without removing the whole side cover. Right now all that is off is the clutch cover

Gecko · May 17, 2016

endodoc said:
I cant do that without removing the whole side cover. Right now all that is off is the clutch cover

Aaah ...., I see. Did you try a little bit of brute force?

Help. How do I get the clutch basket back in? 1299

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