Hi Folks, I bought a fairly good condition 4th Gen, though the clutch was slipping so I bought some friction plates and springs, removed the cover and pulled the clutch plates out. I require some advice! The friction plates were, we'll say well used. The metal plates were okay, a little blueing, but no scratches or warping so that was a plus, but the pushrod has rust on the end. Can this be polished away and how does that rust inside the engine? Or do I need a new one? The clutch basket is also scored a fair bit. I assume this needs to be replaced. The inner coggy bits are scored but not grooved, so only the outer one needs replaced but is it better/easier to replace the entire thing? The haynes manual says I need a special tool for removing it, is there a way to pull it without this tool? I'm rather short on cash and would rather not replace things that don't need replaced or buy things i dont need. Chances are I will never pull it out ever again if it is fixed right. Thanks for any and all help, info, ideas or tips.
The clutch basket needs to be replaced before you put new clutch plates in it, it is completely shot. As far as the clutch rod, just clean it up good make sure there are no deep grooves in it, put a coat of grease on it and put it back in.
tool can be made using the right-sized socket and a grinder to cut appropriately. i'd suggest green scotchbrite to clean the rod.
The EBC CT-014 clutch basket holder is all you need to break the nut loose and remove the inner and outer basket. They can be found for $20-$30 online. If you have access to a cordless impact, that helps to break the nut loose with minimal use of foul words. It will also allow you to hold everything when you go to reassemble and torque. The clutch nut socket can be found online relatively cheap. https://www.amazon.com/honda-clutch-tool/s?k=honda+clutch+tool
Thanks both. Will find a new basket, clean up the rod and put the new plates in. Hopefully this is all it needs!
Can anyone tell me what I've done wrong? I Reassembled the clutch with everything in the right place i think, everything torqued correctly. Started the bike and when i pulled the clutch lever in there was a weird noise from the clutch. Not quite a grinding sound but definitly not a good sound. So i killed the engine and opened it back up to find the springs that go onto the inner basket, the ones with the bolts through them, are grinding into the arms that the bolts go into. The arms are now totally scored by the springs and there was a little pile of ground aluminium dust at the bottom. I took it all apart again, checked everything and reassembled again but same problem - Pull the clutch lever = horrid noise... Anyone seen this before?
I'll take it off and check. Pretty sure its there, but you never know! edit: On the off chance that anybody has the same issue in future and looks here, check that the 4 holes on the back of the outer clutch basket match up with the points on the oil pump sprocket (i think that's what it is anyway - the cog behind the basket). That was my problem.