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Old March 9th, 2019, 05:05 AM   #1
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From: japan
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I Ride: 2014 Hypermotard 821 / 2010 Streetfighter 1098S / 2018 Honda CBR 250RR
Ducabike Clear clutch cover install/clutch question

I need some advice. So Im installing the ducabike clear clutch cover. I have little time so I work on the bike sporadically. I forgot I loosened the 2 bolts that come with the kit that hold the clutches inner springs in so it doesn't pop off when you go to take off the spring retainer. And when I took the spring retainer out today the clutch all popped out. I believe the bike is in gear too.... I tried pushing the basket back in so I can get the 2 little holding bolts back in but those little inner springs are strong. It looks like I can just get a longer version of the 2 holding bolts and tighten them slowly to get the basket back in? It sucks when you can only do 10% of the installation each night. You forget your progress from the night before

These are the clutch holding bolts im talking about
https://youtu.be/PySdZxvGSck?t=91
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Old March 9th, 2019, 06:11 AM   #2
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I Ride: 2013 hypermotard/hyperstrada, 2005 zx6r, drz125, crf50 crf70
These are the clutch holding bolts im talking about
https://youtu.be/PySdZxvGSck?t=91[/QUOTE]

It is easier to run to the local bolt store(probably wont be at a home depot or menards. Misstate bolt is where I go, it's right up the road from me. Or order from McMaster Carr dot com)and buy a section of threaded rod and nuts. It cost me $5 for everything and I had enough material to make 3 kits. I gave the other pieces to friends with similar clutches. The threaded rod gives more flexibility to compress. Take the bolts you have with you to the bolt store and they will match thread and size if you dont already know it(it is also posted online in a few spots)You might be able to take the piece out, set it on a table and press down with your body weight as a friend trys and threads the bolts in. This does not need to be done on the bike. You are just putting the outer part together then sliding it back into the assembly.
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Old March 10th, 2019, 03:39 AM   #3
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I Ride: 2014 Hypermotard 821 / 2010 Streetfighter 1098S / 2018 Honda CBR 250RR
Thanks for the reply. I went and got the longer screws. It was a HUGE pita but I finally got the plate to align through all the clutch plates and got it to go all the way in. I would of cried if I had to take the whole clutch cover off again and then buy the clutch basket holding tool just to put the clutch pack in again..


I just wanted to make sure the last plate on the outside is offset from the rest of the clutch pack? It sits in the clutch basket teeth not aligned with the rest like in the picture?



https://i.ibb.co/Fh6ypjH/IMG-0230.jpg

Ive been having a rough build so far. Clutch snafu and now removing the alternator cover, it bent my home made cover remover and the cover only is half way off....fml

https://i.ibb.co/G52qrr2/IMG-0228.jpg

Last edited by saken; March 10th, 2019 at 05:12 AM.
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Old March 10th, 2019, 06:01 AM   #4
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I Ride: 2013 hypermotard/hyperstrada, 2005 zx6r, drz125, crf50 crf70
I offset my last plate too. That seems to be the norm but I dont think its necessary. As for the puller. You can run to the auto parts store and borrow a 2 arm puller/dampener pulley puller(I believe that is what it is called). It has 5 arms bit you just use the 2 holes with a couple bolts that fit your case cover. You were probably almost good with your homemade puller, make sure you have all the bolts out. Also, there are a couple tabs around the cover (just like on the clutch side cover) that are designed to be a pry point to help it all come apart. They are little ears that stick out cast right into the cover.
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Old March 10th, 2019, 08:37 AM   #5
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Personally, I would have just pulled the clutch pack and started over. You risk pulling a nut or bolt head through the thin aluminum service holes. The service screws are designed to hold the pack together once you've compressed it, not torque it down.
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