| Author | Message | ||
     Donaldb |
My bike is still under warranty but I didn’t want to have the bike down for weeks waiting for the dealership to get the parts, at 1500 miles my clutch started weeping but not bad. I bought the individual parts from an on-line dealership and not the whole kit that other are using. I got the parts in 13 days from order from the dealer. So this weekend I put my new Keda RT-3 on and decided to do the clutch re-build at the same time. My bike is an 08, and I was able to buy a slightly used new style cover from Ebay. Tools Required: 8MM socket and ratchet 14MM box end wrench 6mm Allen wrench 17MM short socket Vise grips Inside snap ring pliers Oil drain pan Service Manual Expendables Required Blue Locktite DOT 4 Brake Fluid Parts Needed X0087.3AM New Style Sleeve x 1 CR0001.3AM Piston seal, small x 1 CR0002.3am Piston seal, large x 1 CF0007.1AMA New Style Sleeve O-rings x 2 CF0001.1AM Spherical Nut O-ring x 1 First thing put an oil drain pan under the clutch cover. Remove the clutch hydraulic line from the cover using the 14mm wrench, fluid will drain so have the pan in the right place to catch it. Remove the puck from the cover using a small screw driver to pry it off. Clamp the vise grips onto the 17mm socket, put the allen wrench through the sock to hold the clutch release pin. Remove the spherical nut, and remove the the bolts around the clutch cover with the 8mm socket and ratchet. Oil will most likely start draining out especially if the bike is sitting straight up on a lift or stand. Remove the cover from the bike. Using the inside snap ring pliers remove the snap ring from the housing, securing the sleeve. Remove the sleeve from the housing and throw it away or keep it for posterity. Clean out the cover and the passages for the bleed and supply channels. Get your new sleeve and the two o-rings, lubricate them with DOT 4 fluid and install them on the sleeve. Notice that the sleeve has a half moon cut out that has to key to the one in the cover. This aligns the passages for the fluid to flow. Install the snap ring back into the clutch cover and re-install the cover onto the bike tightening the bolts to 89 in-lbs. Install the clutch line back onto the cover insuring you have a copper washer on both sides of the banjo fitting. Remove the o-rings from the piston and install the two new o-rings onto the piston lubricating with DOT 4, letters on the seals facing outwards toward the ends of the piston. Replace the o-ring on the spherical nut. Replace the spring back into the sleeve and install the piston back into the sleeve. Put a couple drops of blue locktite on the spherical nut threads and tighten the nut using the 17mm socket and 6mm allen wrench. Bleed the fluid using a manual method or a vacuum system. Install the puck back onto the cover. Ride it and have fun. | ||
| Avalaugh |
Top write dude, it's about time this was done, did you get any pics ? | ||
| Dcmortalcoil |
Instead of a vise grip wrench, the better tool is a GrearWrench Pass-Thru ratchet with its 17mm socket. The ratchet holds the socket from the outer periphery of the socket to permit insertion of tools or bolts to extend completely through the socket and ratchet. It's a great tool to have. A 3/8" set goes for around $50. | ||
| Thefleshrocket |
Donaldb, my '08 had the leaky slave cylinder but my dealership ordered the parts without having to see the bike first and got them installed in a few hours on a Saturday while I waited. You don't mention pricing, but I think I've seen a pricetag in the $300-$400 range for all of those parts. I'd have to REALLY not want to be without the bike AT ALL to fork over that kind of money if the bike was still under warranty. | ||
| Froggy |
About $140 for all the parts mentioned in the first post. | ||
| No_rice |
just remember, that list of parts depends on what version of clutch cover and piston you have on your particular bike. some people still havent updated their cover... i had to hunt down seals for a first run version the other day. those parts are no longer available from hd. | ||
| Avc8130 |
Really? I thought HD came out with improved seals for the Rev 1 cover. ac | ||
| Donaldb |
Actually only $117.26 plus shipping. No brainer in my opinion. donald | ||
| Parrick |
Good write up! Glad you mentioned the oil draining out of the clutch pack. I hadn't seen that mentioned before either here or in the service manual. I just did mine last night and the oil dump surprised me. For a minute I had that "Oh crap" moment thinking I might have a larger problem. | ||
| Dixopr |
Parrick, you got photos I believe you were going to take some pics from another thread. I'm still waiting on my clutch kit. | ||
| Dixopr |
Can we add this to the FAQ? | ||
| Froggy |
It will be relocated there (or at least linked) soon, I am going to steal those photos from the other thread and make a super post  | ||
| No_rice |
sweet! i just tore my 08 apart to replace the seals and noticed a very little chunk of metal resting in the piston sleeve behind the piston. small piece of the sleeve dislodged itself right in the wear area. guess that would explain my leak. whats even better is that i figured is swing into work and alteast get the part on order(day off) and its on back order until 10/29/10 sweet deal! | ||
| No_rice |
woo hoo found a part, atleast it will get the 08 on the road before winter! about 20 minutes worth of ringing peoples phones, but whatever. should work anyway. its not the new new revision sleeve in the 10 book, but im pretty sure it is a part that will work for my updated cover that got put in sometime late 08 early 09. guess i will see when it gets here. | ||
| Pmjolly |
I installed the repair kit (X2086.1AM)in my '08 with no problems. It looks like the same parts with different seals. I have my original clutch cover. No upgraded clutch cover was needed. | ||
| Smow |
I have an 08, but have not had the clutch problem (I know its gunna go) is this all the parts I need to do the replacement? http://www.americansportbike.com/shoponline/ccp0-p rodshow/18048A.html |
