Clutch replacement notes and questions.

BonChaton · 07-26-2012, 05:11 PM

Hello all,

I replaced the clutch friction plates, clutch springs, clutch spring screws, and clutch cover gasket in my 2006 gz250, because the clutch was slipping. (I'd hit a good bump and it would slip. Also at high speeds it would slip.) A few notes.

The clutch cover gasket was FUSED to the clutch cover. It took forever to get the old gasket off. See the fallout below. This was the most difficult part of the job. In the end I kind of slowly moved along with a razor trying my best not to scratch the cover. What a nightmare. Any suggestions for an easier way to get old gasket off?

The clutch springs were out of spec. They are supposed to be 1.61 inches (40.9mm) long. Mine were all about 1.55 inches. It made me wonder. Would the springs wear faster/slower than the fiber plates? What would cause that?

Here's a picture of the clutch new clutch going in. Notice the shiny new screws . I could have used the old screws I guess, but for a few bucks, what the hell.

Anyway everything is back together. No oil leaks. My clutch slippage is absolutely gone.
Hooray. :2tup:

EBC Brakes CK3358 Clutch Friction Plate Kit
(11482-38312) Gasket,clutch Cover
(21413-13F00) SPRING,CLUTCH
(09116-06167) BOLT (6X16)

- Bon Chaton

JWR · 07-26-2012, 09:15 PM

Gaskets are always a pain.

Nice job and good photos.

:2tup:

Water Warrior 2 · 07-26-2012, 09:38 PM

Well done and thanks for the pics. As a note for the future, I do believe most auto parts stores have a special plastic scraper for old gaskets that won't mark up the cases.

fuentes956 · 07-27-2012, 12:07 AM

Nice job, one question what did you use to hold the clutch hub so it would not spin when you are removing the bolts and springs from the pressure plate? Thanks

BonChaton · 07-27-2012, 01:51 PM

@Fuentes - I just used a long ratchet, put it across the clutch plates at a sharp angle (see below), and tapped at it. The bolt broke loose pretty easily. The screws are only spec'd to be torqued to 7 ft-lbs. That's not very tight at all. (So be careful about over tightening them ... I guess.)

Way · 09-20-2012, 07:04 PM

Awesome pics, thanks! :2tup:

I gingerly used a brass wire wheel on a drill last time I had a tough gasket. That was on an aluminum transmission case. Worked pretty well.

I did a search on the spray gasket removers, not sure about how I feel about them though based on the reviews:

http://www.amazon.com/s/ref=nb_sb_noss? ... et+remover

Not enough reviews to really get a feel for how effective they are. In the negative reviews, in the last one in the link, one guy said that PB Blaster works well as does Carb Cleaner which he links to. But I can't vouch for that personally.

http://www.amazon.com/Permatex-80645-6P ... ewpoints=0

A lot of folks in a Jeep forum recommended the roloc system which is basically a fiber disk on a grinder with the caution that this is not to be used where the dust could get into the bearings. Based on my experience with the wire wheel, I would guess this would work very well. Maybe less messy than having to wipe / scrape goopy gasket material off.

http://www.amazon.com/s/ref=nb_sb_noss? ... ords=roloc

I know that at one of our local (ha! 30 miles away) tool stores, they had a bunch of fiber wheels for like $1 each plus the adapter for $2-3. I would probably try to avoid the high speed grinders or the like unless you know what you are doing and have good control.

Maggie · 09-22-2012, 10:32 PM

Great pics Bon! I feel your pain...I recently replaced my clutch cover gasket due to an oil leak (and knew what to do thanks to other awesome pics and posts here!). So, I started out with the right advice, using a gasket remover goop, I was just too impatient to let it sit overnight as recommended by the guys here. So I had the wicked gasket (LOL) too. I think the gasket remover would have done its job had I given it the time. Oooooohhh but I am sooooo impatient! :retard: Nice shiny clutch bolts! :2tup:

07-26-2012, 05:11 PM	#1
BonChaton Junior Member Join Date: May 2012 Location: San Francisco Posts: 12	Clutch replacement notes and questions. Hello all, I replaced the clutch friction plates, clutch springs, clutch spring screws, and clutch cover gasket in my 2006 gz250, because the clutch was slipping. (I'd hit a good bump and it would slip. Also at high speeds it would slip.) A few notes. The clutch cover gasket was FUSED to the clutch cover. It took forever to get the old gasket off. See the fallout below. This was the most difficult part of the job. In the end I kind of slowly moved along with a razor trying my best not to scratch the cover. What a nightmare. Any suggestions for an easier way to get old gasket off? The clutch springs were out of spec. They are supposed to be 1.61 inches (40.9mm) long. Mine were all about 1.55 inches. It made me wonder. Would the springs wear faster/slower than the fiber plates? What would cause that? Here's a picture of the clutch new clutch going in. Notice the shiny new screws . I could have used the old screws I guess, but for a few bucks, what the hell. Anyway everything is back together. No oil leaks. My clutch slippage is absolutely gone. Hooray. :2tup: EBC Brakes CK3358 Clutch Friction Plate Kit (11482-38312) Gasket,clutch Cover (21413-13F00) SPRING,CLUTCH (09116-06167) BOLT (6X16) - Bon Chaton __________________ "Att'y: It's sort of a wild goose chase, more or less, but personally, we're dead serious. " - Fear and Loathing in Las Vegas, Hunter S. Thompson. Login or Register to Remove Ads
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07-26-2012, 09:15 PM	#2
JWR Senior Member Join Date: Jan 2009 Location: Louisville, TN Posts: 1,413	Re: Clutch replacement notes and questions. Gaskets are always a pain. Nice job and good photos. :2tup: __________________ Jerry Truth is there are lots of great bikes available and not nearly as many good riders out there riding them... "A man's got to know his limitations..."
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07-26-2012, 09:38 PM	#3
Water Warrior 2 Senior Member Join Date: Dec 2006 Location: Squamish B.C Canada Posts: 11,409	Re: Clutch replacement notes and questions. Well done and thanks for the pics. As a note for the future, I do believe most auto parts stores have a special plastic scraper for old gaskets that won't mark up the cases. Login or Register to Remove Ads
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07-27-2012, 12:07 AM	#4
fuentes956 Junior Member Join Date: Jul 2012 Location: South Texas Posts: 12	Re: Clutch replacement notes and questions. Nice job, one question what did you use to hold the clutch hub so it would not spin when you are removing the bolts and springs from the pressure plate? Thanks
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07-27-2012, 01:51 PM	#5
BonChaton Junior Member Join Date: May 2012 Location: San Francisco Posts: 12	Re: Clutch replacement notes and questions. @Fuentes - I just used a long ratchet, put it across the clutch plates at a sharp angle (see below), and tapped at it. The bolt broke loose pretty easily. The screws are only spec'd to be torqued to 7 ft-lbs. That's not very tight at all. (So be careful about over tightening them ... I guess.) __________________ "Att'y: It's sort of a wild goose chase, more or less, but personally, we're dead serious. " - Fear and Loathing in Las Vegas, Hunter S. Thompson. Login or Register to Remove Ads
	0

09-20-2012, 07:04 PM	#6
Way Senior Member Join Date: Jun 2011 Location: Northwestern VT Posts: 224	Re: Clutch replacement notes and questions. Awesome pics, thanks! :2tup: I gingerly used a brass wire wheel on a drill last time I had a tough gasket. That was on an aluminum transmission case. Worked pretty well. I did a search on the spray gasket removers, not sure about how I feel about them though based on the reviews: http://www.amazon.com/s/ref=nb_sb_noss? ... et+remover Not enough reviews to really get a feel for how effective they are. In the negative reviews, in the last one in the link, one guy said that PB Blaster works well as does Carb Cleaner which he links to. But I can't vouch for that personally. http://www.amazon.com/Permatex-80645-6P ... ewpoints=0 A lot of folks in a Jeep forum recommended the roloc system which is basically a fiber disk on a grinder with the caution that this is not to be used where the dust could get into the bearings. Based on my experience with the wire wheel, I would guess this would work very well. Maybe less messy than having to wipe / scrape goopy gasket material off. http://www.amazon.com/s/ref=nb_sb_noss? ... ords=roloc I know that at one of our local (ha! 30 miles away) tool stores, they had a bunch of fiber wheels for like $1 each plus the adapter for $2-3. I would probably try to avoid the high speed grinders or the like unless you know what you are doing and have good control. __________________ -- Wayne
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09-22-2012, 10:32 PM	#7
Maggie Senior Member Join Date: Jan 2010 Location: San Fernando Valley, CA Posts: 135	Re: Clutch replacement notes and questions. Great pics Bon! I feel your pain...I recently replaced my clutch cover gasket due to an oil leak (and knew what to do thanks to other awesome pics and posts here!). So, I started out with the right advice, using a gasket remover goop, I was just too impatient to let it sit overnight as recommended by the guys here. So I had the wicked gasket (LOL) too. I think the gasket remover would have done its job had I given it the time. Oooooohhh but I am sooooo impatient! :retard: Nice shiny clutch bolts! :2tup:
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