Clutch reassembly

[Craizeehair]

I’m currently trying to figure why my clutch is so stiff, I’ve got myself ready to investigate and I’m getting myself more and more confused, there seem to be several different configurations and I’m not sure what I have and if it’s correct!

I have a spacer ring… If that’s the correct term?

I think it fits like between the last friction plate and the hub, if I am correct can anyone confirm if this is the correct orientation, with the tabs at the back and open space facing forward, if that makes sense?

I feel like I need to have a tea break!

[Craizeehair]

Having stepped away from it, it seems the more obvious way it has to go is the other way round… So bevels are facing the same way?

When I took the clutch apart it wasn’t locked on at all, so I am just trying to work it out.

Hondaman seems to say in his book that it goes after the last friction disk but the diagram seems to show it between the steel and last friction plate, that’s if I’m even reading the right bit!

Hopefully someone can make sense of my ramblings?

[K2-K6]

Which model bike is it ? KO, K1, K2 etc

The manual schematic aren't too clear to interpret from the example I've got.

Does your outer clutch basket have an external ring around it on the fingers near to the outermost (nearest to you when installing) position  ? Not clutch plates.

[Craizeehair]

Sorry, it’s a K0

Does this help, it’s the only pic I have to hand on the phone?

 

[K2-K6]

Yes image helps.

A long time since I've worked on K0 transmission, immediate recall of detail slow  the band in question is to hold centrifugal load on clutch basket, and replaced on later models with a welded outer band incorporated into the basket structure, I believe. Which may account for some confusion in various sources.

I've one of the original first edition Honda workshop manual, in which there's some detail but not hugely expanded to give absolute clarity.

General principle is that the ring you have can't be interactive with one of the metal clutch plates to the extent that even with clutch open it would connect metal friction plate (driving centre boss) to the outer (basket) when you pull the lever.

The schematic in the manual shows that metal band immediately underneath the outermost fibre friction disc ... appearing "concentric" with the metal friction disc which is next in line going in toward the gearbox.

Does that ring fit outside the basket, with it's teeth going into the gaps ? That's how it appears to go.

Can the metal friction disc pass through that metal ring, concentrically without being impeded ?

[K2-K6]

Ahaaaa! I get it now.

There's two different diameter clutch "friction" disc in this design.  All normal type are 151mm diameter, with that (last in) item being 148.5mm diameter as a single unique item. That one shares "tabs" locationwith the tabs on outer ring.

Its written in the manual using those words.

[Craizeehair]

Right… thank you.

Now that makes more sense. I must have the wrong disks? All of the seven disks are the same outer diameter, approximately 147mm.

[Craizeehair]

So I guess the question is, can I reassemble the clutch using the disks I have or do I need to find replacements for the six same sized and the one smaller disk originally used?

[K2-K6]

It should be OK to assemble with those plates, it's the tabs that should be shorter so friction area will be unaffected. That may have much longer implications in that it would be desirable to research what replacement plates you could get.

Its easier to assess with it in front of me, but I'd assemble as manual says with the external ring in place, then put the outer clamp plate on (by hand and not bolt up the springs to see if that ring then floats or stays in correct place. Look to see if (without the next friction plate being correct diameter) the outer ring can now move further into the clutch basket. That would tell you if that larger diameter plate, the next one back, was important in keeping this from happening. 

Exploratory loose assembly to find out more, in other words.

[Craizeehair]

Well it sits in there nicely, nothing moves about or feels like it’s going to float around or move position etc…

My initial thoughts are that it seems fine?

I think I will leave it at that for now, I’m still waiting on some bits to arrive but I think I will reassemble when they get here and try that.

Thank you

[K2-K6]

I can't quite get definite view from the photo, but have you got the vlutch outer ring tabs located in the same slots as the friction disc ?  And not the intermediate slots (the one's in the basket that have a rounded base ) as that view is not conclusive from the angle I can see.

The manual has note specifically directing to put the first six friction plates in, then the outer ring in those same slots, then that final friction plate to complete the sequence.

[Craizeehair]

Yes, the outer ring is in the same slots as the friction disks and has the last friction disk stacked on top of that, I’m sure it can’t break free as it is held in place with the friction disks?

[K2-K6]

Yes, that seems correct as manual describes.

[Craizeehair]

Lovely, thanks for your help.