ZR468 wrote:Freddy, to get to the clutch basket is a 3 wrench job in the Haynes Manual. I am comfortable up to 2.5 wrench. I might have to go to a repair shop. How many hours do you think it would take for a professional to complete this job?
Kenny
About 2 hours if they know what they are doing. That's just pulling the clutch basket out and back, not counting the time to recondition the basket because as I haven't done it myself (I just bought a complete new one).
Yea the 3 wrenches assessment in a Haynes manual i.e. "Fairly difficult, suitable for a competent DIY mechanic" is probably accurate. BUT remember a 5 wrench is considered a job for a 'professional'. There are only 2 tasks that I would consider difficult in actually pulling the clutch basket off out and replacing it. They are ...
1. Disconnecting the clutch cable. It's not really difficult, and actually quite easy if you know the tricks. And exactly how to to is accurately described in the OEM manual. Don't know about the Haynes.
2. Undoing the clutch basket holding nut. As I said in a previous post, you needs the special holder tool, and preferable an impact gun and suitable size impact socket to undo it, it is tight. And doing it up again, holding tool and tension wrench.
Other than that, its just a systematic pretty straight forward process of draining the oil, undoing all the clutch cover bolts and giving it a couple bumps to dislodge, undo the clutch pressure plate bolts, clutch plates, and there is the clutch basket and nut. As they say in the manual, assembly is reverse. I'd recommend giving it a try, and based upon your own self-assessment, put your money toward getting a motorcycle engineering shop to do the clutch basket overhaul. Give them the basket, new rubbers, and documented procedure. They have the tools and equipment to surely be able to knock that task over in, my guess about 2 hours max.