Clutch replacement

[Plukey]

I replaced clutch plates and when I reinstalled I wasn’t getting any tension. I removed the casing a few times to make sure it was correct when I was torqueing down I broke off one of the bolts tried to remove with easy out just messed it more. The bike is a zs200gy-a 200cc it has 5 plates and 70 gears everywhere I look I can only find 73, but I don’t need the entire assembly jut the pc that uses the 4 bolts and springs. Everything else is useable. I will attempt to attach some pictures, I’m at work and I’m is my iPhone.

[bogieboy]

this link (https://www.ebay.com/itm/Motorcycle-Metal-Engine-Motor-Center-Clutch-Friction-Plates-Assembly-for-CG150/273106173945?epid=559780340&hash=item3f96657ff9) should drop right in your clutch basket and give you the better 6 disc clutch, and not have to worry about the tooth count of the gear...

[Plukey]

That’s exactly what I was wondering if could be done! That’s a big relief. Now for the first issue no tension/ I adjusted he cable maxed and it wouldn’t disengage at all. I thought I had the rod wrong. There’s something I’m missing, I removed old plates installed new plates and bolted case back on lined the lever up with the rod feels like a lot of play.

[Plukey]

What should be the torque on those bolts anyway?

[Megadan]

The actual Honda spec for the Derby bolts/pressure plate bolts for the old 4 bolt setups was 7ft-lbs/84in-lbs. The real key is to tighten them in stages slowly so as to keep the pressure even between all of the bolts. It's very tedious, but I recommend no more than 1 turn at a time per bolt in a criss cross pattern.

Edit:If that bolt torque seems rather small to you, then I can assure you as to how insignificant those bolts are in regard to being "tight". The GL1000 goldwing pressure plate bolts, a much stronger, higher pressure clutch setup, tightens these same bolts to a spec between 7 to 9 ft-lbs. It's actually a pretty universal torque spec range on most Honda clutches.

[Plukey]

Yeah, while I was at work I did a bunch of searches and I read where the plates may be stuck, the engine sat in my table for a while...anywho when I got home i put it back together minus the one bolt greased and turned few time tighten the case a little and damn sure enough they were stuck...lesson learned now I’m ordering the six plate that Bogieboy mentioned and start over. Ugh!!!!

[JerryHawk250]

Don't forget to soak the new plates and disk in oil before installing,

[Megadan]

Yeah, while I was at work I did a bunch of searches and I read where the plates may be stuck, the engine sat in my table for a while...anywho when I got home i put it back together minus the one bolt greased and turned few time tighten the case a little and damn sure enough they were stuck...lesson learned now I’m ordering the six plate that Bogieboy mentioned and start over. Ugh!!!!

It's pretty common for clutch plates and discs to stick together if they have sat for a decent length of time without oil touching them. If you ever run into that in the future you can sometimes get them free by idling the bike in neutral with the clutch lever zip tied back. If the clutch lever wont even move, with the bike on a stand, let it run in gear until it is warmed up and then apply the rear brake fairly firmly with pressure applied to the clutch lever. This can often "shock" the plates apart.

[Plukey]

Okay...so I’m looking online, at the center friction plates 5 & 6 I’m going to re-use the gear basket as Bogieboy suggested because I have 70 teeth rather than the common 73 . Is there a big difference between the two (5 plates vs 6)

[bogieboy]

As long as theres room in the case, 6 disc will perform better and longer, as theres more total clutch friction area, also should be smoother, due to the same...

[NzBrakelathes]

this link (https://www.ebay.com/itm/Motorcycle-Metal-Engine-Motor-Center-Clutch-Friction-Plates-Assembly-for-CG150/273106173945?epid=559780340&hash=item3f96657ff9) should drop right in your clutch basket and give you the better 6 disc clutch, and not have to worry about the tooth count of the gear...

to my knowledge different clutch plate counts needs the correct basket depth.
So I thought if you went to 6 plates etc you need a full set up

[Megadan]

to my knowledge different clutch plate counts needs the correct basket depth.
So I thought if you went to 6 plates etc you need a full set up

This is correct.


For the OP.

If you are able to wait a couple of weeks for them to arrive...

6 disc 70 tooth complete clutch assembly. https://www.aliexpress.com/item/Zongshen-Bashan-Loncin-CB200-Clutch-70Teeth-127mm-diameter/32377567797.html?spm=2114.search0104.3.99.7b7c2857 OU5MWI&ws_ab_test=searchweb0_0,searchweb201602_3_10065_10 068_10130_10890_10547_319_10546_317_10548_10545_10 696_453_10084_454_10083_10618_431_10307_537_536_10 059_10884_10887_100031_321_322_10103-10890,searchweb201603_52,ppcSwitch_0&algo_expid=79410a18-523c-4bc1-b30b-2708efa49f41-16&algo_pvid=79410a18-523c-4bc1-b30b-2708efa49f41

7 Disc 70 tooth
https://www.aliexpress.com/item/ATV-70-Gears-Clutch-With-7-Pillars-6-Slices-High-Performance-Motocross-Clutch-Fit-For-ZongShen/32815478563.html?spm=2114.search0104.3.171.7b7c285 7OU5MWI&ws_ab_test=searchweb0_0,searchweb201602_3_10065_10 068_10130_10890_10547_319_10546_317_10548_10545_10 696_453_10084_454_10083_10618_431_10307_537_536_10 059_10884_10887_100031_321_322_10103,searchweb2016 03_52,ppcSwitch_0&algo_expid=79410a18-523c-4bc1-b30b-2708efa49f41-27&algo_pvid=79410a18-523c-4bc1-b30b-2708efa49f41

Strangely, the 5 disc clutch is the hard one to find.

[NzBrakelathes]

If you give me some more info sizes etc I can get a set here with or without small parts - I need to compare sizes to be sure you get what is correct or I am out of the money and you loose time

[Plukey]

What about this one?

https://rover.ebay.com/rover/0/0/0?mpre=https%3A%2F%2Fwww.ebay.com%2Fulk%2Fitm%2F40 1506112058

[Plukey]

If you give me some more info sizes etc I can get a set here with or without small parts - I need to compare sizes to be sure you get what is correct or I am out of the money and you loose time

What do you need all help would be appreciated!?

[Megadan]

What about this one?

https://rover.ebay.com/rover/0/0/0?mpre=https%3A%2F%2Fwww.ebay.com%2Fulk%2Fitm%2F40 1506112058

That looks promising, although the listing says out of stock. That might be why you can't find one anywhere.

[Plukey]

That looks promising, although the listing says out of stock. That might be why you can't find one anywhere.

Yep...I purchased the last one, I figured 16 bucks why not...

[Plukey]

Well, got it in just now all fits except the bearing for the push rod...old bearing is around 35mm and new bearing is 29mm

[bogieboy]

:doh: that sucks.... maybe order one for the bike the clutch is out of, if you hadn't already thought of that...

[Megadan]

t shouldn't be too hard to find a bearing that will work. Just need the O.D., I.D., and width.

[Plukey]

t shouldn't be too hard to find a bearing that will work. Just need the O.D., I.D., and width.

I’m working with the seller now for help...thanks for your time!

[Plukey]

I purchased this one... the measurements look right...not all these sellers list the dimensions.. This has been sooo frustrating. I wish I could just enter my engine make & model and Abracadabra there’s my part...

US $15.99 | 70Teeth Clutch 127mm diameter,6 plate and 6 Column for Zongshen,Bashan,Loncin Lifan CB200 CG200 Water cooled engine
https://s.click.AliExpress.com/e/b1v3O7Cy

[humanbeing]

t shouldn't be too hard to find a bearing that will work. Just need the O.D., I.D., and width.

http://chinariders.net/showthread.php?p=297145#post297145

[Plukey]

I pulled the trigger.., and bought a 4 spring clutch from ebay, I have know patients sometimes...also, keep in mind I only need the four/ pressure plate thingy to replace the one I torqued down & snapped. well it fit PERFECT! after a few adjustments and few WTF it fired up. Side note I started this project before xmas just because I wanted a pc of mind on what type of mileage/ware the engine had since I bought it 2nd hand without speedometer/odometer several years ago... knowing what I know now, & how it looked it never needed a rebuild...but its done.

1st. I removed the engine completely, it had several scuffs & scratches so I decided to sand and (I know) krylon aluminum spray pant with a lacquer clear , well that didn't work it turned out like S&!% any advise??

2nd. Maybe its just my imagination, but I feel a little more pick me up on it..i have knock off Mukini 30mm carb & FMF muffler I don't remember the jets, but I know its running lean due to the plug...Im thinking of the Pumper Carb that seems to be the thing lately... should I leave well enough alone or will I be blown away by this carb...

3rd.. Is there an easier way to search parts for this bike??? its a 2004
ZS200GY-A 169FML stamped on the side...

[Plukey]

Oh yeah...the starter. It wont turn over unless I loosen the three bolts on the starter cap. once I snug them it just clicks. Cant figure it out for nothing.. Its the cap, gear rod and a spring & three bolts. I took it apart months ago and I think its put together correct.

[Megadan]

I pulled the trigger.., and bought a 4 spring clutch from ebay, I have know patients sometimes...also, keep in mind I only need the four/ pressure plate thingy to replace the one I torqued down & snapped. well it fit PERFECT! after a few adjustments and few WTF it fired up. Side note I started this project before xmas just because I wanted a pc of mind on what type of mileage/ware the engine had since I bought it 2nd hand without speedometer/odometer several years ago... knowing what I know now, & how it looked it never needed a rebuild...but its done.

1st. I removed the engine completely, it had several scuffs & scratches so I decided to sand and (I know) krylon aluminum spray pant with a lacquer clear , well that didn't work it turned out like S&!% any advise??

2nd. Maybe its just my imagination, but I feel a little more pick me up on it..i have knock off Mukini 30mm carb & FMF muffler I don't remember the jets, but I know its running lean due to the plug...Im thinking of the Pumper Carb that seems to be the thing lately... should I leave well enough alone or will I be blown away by this carb...

3rd.. Is there an easier way to search parts for this bike??? its a 2004
ZS200GY-A 169FML stamped on the side...

On the bright side, you have lots of extra clutch discs for the future.

1st. Advice would really come down to how it turned out badly?

2nd. The pumper carb is a great option to really wake up the throttle response, but it isn't necessary. If you already have the mikuni, take it apart, see what jets you have and go from there. Even if you got the pumper carb you would be doing the same thing.

3rd. I can't be much help there. Somebody more familiar with the bike you have would be a much better resource.

[Plukey]

Pant job started out 1/2 way decent, but I had a leak from the gas shut off and it leaked on the cover so now I have streaks. Can’t notice till ya get close just my OCD kicking in, but I live.

But I’m baffled at the starter, u tighten the cap down and it just clicks, but when I loosen the bolts and the cap pulls away it’ll turn over. The gear only goes in one way and I have the washers on both sides with a spring closest to the cap.

[Plukey]

Attached are two pictures one is the placement of a ground wire I’m not totally positive that’s where it’s supposed to be? 2nd is a spring I thought came from the electric start cap, once I removed it...it cranked effortlessly...so it went somewhere...?

[Plukey]

Also, I’m running 115/27.5 kick starting is not happening at all! I feel my age for sure! I’m in va it’s 47 right now...I thought it was running a little lean but after pulling the plug it looks more Rich. Slightly popping on Deceleration... I did notice exhaust leak from the original header to the aftermarket FMF pipe.