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DIY: Assembling your Clutch!

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  • DIY: Assembling your Clutch!

    So a few weeks prior I had rebuilt my clutch but due to messy hands I didn't bother with taking enough pictures, though you can see a few if you look up my (Bajaj CT100B - Utilitarianism Redefined!)ownership thread.

    Anyhow, I did managed to take a few snaps of the thing being re-assembled, so here goes.

    The Clutch comprises of the following parts;


    Now most manuals online including the one above for some reason misses to mention the Judder Springs, so here goes;


    Now we get to business!

    Step 1:

    Make sure you have all the parts required to assemble a clutch and that they've been properly oiled(preferably Friction Plates dipped in oil overnight), also doesn't hurt to confirm with your workshop manual that all components are within their usable limit;


    Step 2:

    Install the Judder Springs(see orientation from the shop manual extract shown earlier), followed by the unusually small looking Friction Plate;


    The Springs sit snug within the small plate like this;


    Step 3:

    Install a Steel Plate followed by a Friction Plate, one by one, the last plate you'll deal with with obviously be a Friction Plate;


    After your done with the Steel Plates and the Friction Plates make sure to install the Pressure Plate, ensuring that the groves on it slot perfectly in place.

    Now carefully turn the assembly over ensuring that the Pressure Plate doesn't slip out of the groves. Using two regular spacer's for 10mm bolts install two of the springs and bolts, like this;


    This is done so that there's enough slack for the friction plates to be realigned while inserting the assembly into the clutch basket but at the same time there is enough pressure to ensure that the Pressure Plate doesn't sit misaligned.

    Step 4:

    Once the assembly is seated within the clutch basket(for illustration purposes my clutch is still in my bedroom ) you could remove the spacer's and install all the springs and then install the center piece;






    Step 5:

    Do note that the Center piece is made of aluminum and can crack at the slightest sneeze.


    So commonsense dictates that they should be sequentially torqued evenly in a Criss-Cross pattern, and you're done!;


    Here's a snap of how things'd look inside the motorcycle, do note that the clutch release bearing is inserted in the below photo:


    Here's a closer snap of the clutch nut with the release bearing removed;


    Extra Pointers

    Here's a snap of the clutch nut tool, remember that the clutch nut is reverse thread, same tool is used to undo the centrifugal filter rotor, though that one is regular thread, do make sure not to mix them up;


    A clutch holder gets the job done easy, cause chances are you'd be replacing a used up clutch and putting the bike in gear and using the rear brake to hold the basket in place would most probably not work as the clutch would start slipping under load;


    But since mines a Pulsar, I locked the clutch basket using the scissor gear holder for convenience;


    An old biker's tip would be to wrap a 5 Rupee coin in a piece of cloth and jam it between the primary and clutch basket, though not recommended.

    As for taking the clutch cover off, I'd advise that you look around the case for support tabs, the manufacturer intentionally leaves them so that the clutch cover can be leveraged off, though make sure to not do anything that'd scar the aluminum.

    A rubber mallet would help as well in the event you're not able to spot any of the tabs.

    So that's all folks!

    Happy DIY'ing!
    Regards,
    A.P.
    Motorcycling Experience:
    2000 ~ 2017 Y2K Kinetic Zoom (Disposed at 15k)
    2011 ~ 2015 Hero Honda Karizma R (Sold at 56.5k)
    2013 ~ 2014 Bajaj Discover 100 4G (Sold at 16.5k)
    2015 ~ 2017 TVS Wego (Totaled at 18k)
    2015 - Bajaj Pulsar 220F (Currently 31k) < Garage Queen!
    2017 - Bajaj CT100B (Currently 21k) < 'Golden Quadrilateral' Runner!

    The Ride was Good, but Life is short, spend it Wisely!
    Adios Comrades!
    A.P. 2018

  • #2
    Re: DIY: Assembling your Clutch!

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