Zongshen RX3: Clutch Assembly

[SpudRider]

Clutch System Access

To access the clutch you only need to remove the 5 bolts holding the clutch cover. You don't need to remove the entire right crankcase cover to service the clutch.

After removing the clutch cover, loosen the six bolts incrementally in a star pattern to remove the clutch pressure plate.

http://i442.photobucket.com/albums/qq146/spudrider/Zongshen%20RX3/clutch%20cover%20and%20clutch_zpsdsz0qi4r.jpg (http://s442.photobucket.com/user/spudrider/media/Zongshen%20RX3/clutch%20cover%20and%20clutch_zpsdsz0qi4r.jpg.html )

After removing the clutch pressure plate, remove the push rod cap, roller bearing, and washer. During clutch reassembly, the cap is placed over the push rod, the needle bearing is placed upon the push rod cap, and the washer is placed last, so it makes contact with the clutch pressure plate.

Verify the proper position of the clutch cover gasket by noting the small notch in the gasket located near the top bolt hole.

http://i442.photobucket.com/albums/qq146/spudrider/Zongshen%20RX3/clutch%20cover%20gasket%20and%20pushrod%20cap_zpsa w2i3efg.jpg (http://s442.photobucket.com/user/spudrider/media/Zongshen%20RX3/clutch%20cover%20gasket%20and%20pushrod%20cap_zpsa w2i3efg.jpg.html)

[SpudRider]

Inspecting the Clutch Pack

Remove the fiber discs and metal plates from the clutch basket. There are 6 fiber discs in the clutch pack. Replace the fiber disks if they are burnt, torn, or otherwise damaged. Also replace the fiber disks if they are beneath the minimum thickness.

http://i442.photobucket.com/albums/qq146/spudrider/Zongshen%20RX3/clutch%20fiber%20disc%20thickness%20chart_zpsizevv eap.jpg (http://s442.photobucket.com/user/spudrider/media/Zongshen%20RX3/clutch%20fiber%20disc%20thickness%20chart_zpsizevv eap.jpg.html)

There are 5 metal plates in the clutch pack. Replace the metal plates if they are warped, or otherwise damaged. Also replace the metal plates if they are beneath the minimum thickness.

http://i442.photobucket.com/albums/qq146/spudrider/Zongshen%20RX3/Clutch%20metal%20plate%20thickness_zps21461m9j.jpg (http://s442.photobucket.com/user/spudrider/media/Zongshen%20RX3/Clutch%20metal%20plate%20thickness_zps21461m9j.jpg .html)

http://i442.photobucket.com/albums/qq146/spudrider/Zongshen%20RX3/inspecting%20clutch%20discs%20and%20clutch%20plate s_zps4hrht1z1.jpg (http://s442.photobucket.com/user/spudrider/media/Zongshen%20RX3/inspecting%20clutch%20discs%20and%20clutch%20plate s_zps4hrht1z1.jpg.html)

[SpudRider]

Clutch Push Rod

The clutch pack is pushed apart, and disengaged by the clutch push rod. The clutch push rod is identical on both ends, and can be installed without concern regarding its orientation.

http://i442.photobucket.com/albums/qq146/spudrider/Zongshen%20RX3/clutch%20push%20rod%20installed_zpsq02rrm47.jpg (http://s442.photobucket.com/user/spudrider/media/Zongshen%20RX3/clutch%20push%20rod%20installed_zpsq02rrm47.jpg.ht ml)

http://i442.photobucket.com/albums/qq146/spudrider/Zongshen%20RX3/clutch%20push%20rod_zpss5e5qpjz.jpg (http://s442.photobucket.com/user/spudrider/media/Zongshen%20RX3/clutch%20push%20rod_zpss5e5qpjz.jpg.html)

The clutch system is actuated by a clutch lifter lever, which is located on the left side of the engine. Please note, the tab of the cable holder should be folded down to prevent the clutch cable from slipping out of the holder.

http://i442.photobucket.com/albums/qq146/spudrider/Zongshen%20RX3/clutch%20lifter%20lever_zpseo3m8iwz.jpg (http://s442.photobucket.com/user/spudrider/media/Zongshen%20RX3/clutch%20lifter%20lever_zpseo3m8iwz.jpg.html)

[SpudRider]

Clutch Basket

To remove the clutch basket you must unbend the tab of the safety washer. Secure the clutch center with a clutch holder, and loosen the 27 mm locking nut. Then remove the clutch center, clutch basket, bearings and washers.

http://www.triumphrat.net/attachments/sprint-forum/8994d1221798545-clutch-wont-disengage-clutch-tool.jpg

Inspect the clutch basket and clutch center for nicks, indentations, or abnormal wear from the clutch discs. Check both gears on the clutch basket for wear and damage. If wear is excessive in any area of the clutch basket, replace the clutch basket. If wear is excessive in any area of the clutch center, replace the clutch center.

Inspect the bushing, bearings and washers of the clutch basket.

To re-install the clutch basket, first place one of the bearing washers next to the crankcase. Install the bushing and 2 needle bearings. Install the clutch outer basket, and install the second bearing washer.

http://i442.photobucket.com/albums/qq146/spudrider/Zongshen%20RX3/clutch%20basket%20and%20bearings_zpsj9aznt2z.jpg (http://s442.photobucket.com/user/spudrider/media/Zongshen%20RX3/clutch%20basket%20and%20bearings_zpsj9aznt2z.jpg.h tml)

Next install the clutch center, and place a safety washer over the main shaft. Then install the 27 mm locking nut. Secure the clutch center with a clutch holder, and torque the locking nut to 59 foot-pounds (80 Nm).

After installing the clutch fiber discs and metal plates, install the push rod. Then install the push rod cap, roller bearing, and washer.

http://i442.photobucket.com/albums/qq146/spudrider/Zongshen%20RX3/clutch%20pushrod%20cap%20with%20bearing%20and%20wa sher_zps3zpc4xtm.jpg (http://s442.photobucket.com/user/spudrider/media/Zongshen%20RX3/clutch%20pushrod%20cap%20with%20bearing%20and%20wa sher_zps3zpc4xtm.jpg.html)

Install the clutch pressure plate. Then install the six springs with their associated bolts. Tighten the bolts incrementally in a star pattern. The final torque for each bolt is 9 foot-pounds (12 Nm). Be careful not to strip the threads in the clutch basket while tightening these bolts.

Install the clutch cover plate, and the job is finished.

[SpudRider]

The following video shows how a motorcycle clutch operates, and discusses proper oil selection. :)

https://www.youtube.com/watch?v=wuYO0oZr47w

[SpudRider]

The following video describes basic clutch operation in more detail. :)

https://www.youtube.com/watch?v=d74A37h4v6c

[SpudRider]

The following video shows how to change the clutch pack on a Honda CRF250R. The clutch assemble for this Honda motorcycle is very similar to the clutch assembly in your Zongshen RX3.

https://www.youtube.com/watch?v=7WIqGAeY12w

[SpudRider]

Here is another short video which shows how to change the clutch pack in your motorcycle.

https://www.youtube.com/watch?v=Eqg4OqRmHOs

[SpudRider]

Here is another video showing how to replace the clutch plates in a Honda CRF250R. ;)

https://www.youtube.com/watch?v=Hh7ENdusGPY

[SpudRider]

The clutch metal plates are stamped. On one side the edge of the plate is flat, and on the other side the edge of the plate is slightly curved. I don't think it matters which side faces the engine. However, I think it is best that all the metal plates face the same direction. ;) When inspecting the clutch plates, I suggest you note their orientation, and re-install them the in the same manner.

I have been informed the clutch bearings might be different from the photographs I have posted. I haven't yet removed my clutch basket, so I can't verify if the clutch bearings have been changed. I am using photographs taken from another source. ;) I will correct the photos if we learn a change has been made in this area. :)