Roketa clutch slipping (FIXED) - Page 3

fatboy250 · 03-12-2007, 10:17 AM

Quote:

Originally Posted by ejcycles

Hey guys

I already have a A. Lifan 200 engine apart that had a Major Vibration problem. I'm already in the process of checking on the clutch plates.

Bruce

Are you cross referencing an xr200 clutch? It would be great to know it this is a direct drop in replacement.

Jason

FMYStreetRacer · 03-12-2007, 08:59 PM

well i fixed it. i only ran it for a minute. i forgot my camera at home so all the pics i took were with my cell phone. i e-mailed them to myself but the service is acting up. after i eat dinner i'll hook the cable up to the phone and upload them like that. i'll post pics and tell you guys what i did.

FMYStreetRacer · 03-12-2007, 10:51 PM

ok here's what i did:

i took the clutch cover off. once you get it off there is a plate that is bolted to the outside of the clutch basket. it is the release and also has the springs attached to it. i loosend the four bolts that held that together. once you take that off you can remove the clutch springs. i took some washers and drilled them out to be bigger that the posts that the springs went around. the first set i tried to use that were in our bolts bin at work were too large around. they need to fit in the cover that i removed so that the spring won't sit crooked. so i searched around and remembered that i saved all the extra bolts and washers from the assembly of my bike. what do you know, i found eight of them and they were the right size around but the center hole was super small. i drilled out the centers and deburred them. i decided to use two washers. i couldn't have used a 3rd. two washers made the springs almost complletly compressed. it worked out really well from what i can tell for the whole 2 clutch dumps i did.

anyways here's the pics.

spring assembly removed.

clutch disks. 5 disks just like a xr200 from what i can tell.

what is the hell is a plastic gear doing is here? someone please tell me what that is for.

the disks

this is for Bruce, i know we talked about you trying to see if the xr springs are the same.

this is the plate that holds the springs on. see where the face of the spring sits? the washers need to sit there, can't be bigger.

my nastey job of drilling out the holes. i had to do it by hand with a air drill. they look like shit but hey they work.

washers installed before everything is aligned and tightend down.

tightend down
[img]http://img84.imageshack.us/img84/2156/image154eq5.jpg[img]

tightend down side

.

i'm going to most likely take the bike to work tomorrow. i'll be sure to post up how much better the clutch is.

ambassador · 03-12-2007, 11:06 PM

Not much different from my XR except for the plastic gear, gotta be a part of the starter, maybe oil throw???

FMYStreetRacer · 03-12-2007, 11:08 PM

starter is on top. guy at my work said maybe it's for crank case vent. all i know is that i don't like that crap there at all.

liverchip · 03-13-2007, 12:47 AM

Maybe oil pump?

liverchip · 03-13-2007, 01:16 AM

Probably a dumb question, but were you guys looking for a supplier for clutches? I found mine TSM 200 (grey market Lifan pushrod) for 42$. No need for it as of yet, but I believe in being proactive. Now if only I could find brake pads.

fatboy250 · 03-13-2007, 09:04 AM

FMY,

Great job, I can't wait to hear how it works out for you!

Can you give the inner (i.d.) and outer(o.d.) diameter of the final washers. I may be able to find some that are that size that can be bought and I'll post them in the parts thread. Otherwise I will just do what you did.

Also, what was your final thickness with the two washers? I may just get Dad to machine the exact size washer (spacer) as one unit.

Thanks for you help.

Jason

cycleway4 · 03-13-2007, 10:13 AM

hi...yes, plastic gear drives the oil pump..........this is a typical set-up[for that purpose]

FMYStreetRacer · 03-13-2007, 12:26 PM

Quote:

Originally Posted by fatboy250

FMY,

Great job, I can't wait to hear how it works out for you!

Can you give the inner (i.d.) and outer(o.d.) diameter of the final washers. I may be able to find some that are that size that can be bought and I'll post them in the parts thread. Otherwise I will just do what you did.

Also, what was your final thickness with the two washers? I may just get Dad to machine the exact size washer (spacer) as one unit.

Thanks for you help.

Jason

the inner hole is 15/32 and the outter i didn't measure, just figure as wide as the spring..... 18.5 mm. let me see if i can dig up two more washers and i'll mic them real quick. na, i jusy looked and i can't find even one. guess Roketa just knew i would need them. if i ever take anything else out that uses that washer i'll mic it.

i drove the bike in today and just took it to lunch, so farso good. it feels really good now.

fatboy250 · 03-13-2007, 03:47 PM

The 15/32" comes out to just under 12mm. So, it sounds like a 12mm i.d. and 19mm o.d., or would 19mm be more than the surface area you had to work with on the plate? We're talking .728" (18.5mm) versus .748" (19mm). Thanks for the info.

Jason

FMYStreetRacer · 03-13-2007, 07:50 PM

the half milimeter might be too much.

Roketarider · 03-13-2007, 11:00 PM

I might be attempting this tomorrow, as my clutch is slipping bad in pretty much all gears.

liverchip · 03-13-2007, 11:57 PM

Streetracer, Is your motor the OHC or pushrod?

FMYStreetRacer · 03-14-2007, 12:31 AM

ohc

03-12-2007, 08:59 PM	#32
FMYStreetRacer Join Date: Nov 2006 Location: Ft. Myers, Fl. Posts: 416	well i fixed it. i only ran it for a minute. i forgot my camera at home so all the pics i took were with my cell phone. i e-mailed them to myself but the service is acting up. after i eat dinner i'll hook the cable up to the phone and upload them like that. i'll post pics and tell you guys what i did. __________________ Roketa DB-07a HID Headlight
	0

03-12-2007, 10:51 PM	#33
FMYStreetRacer Join Date: Nov 2006 Location: Ft. Myers, Fl. Posts: 416	ok here's what i did: i took the clutch cover off. once you get it off there is a plate that is bolted to the outside of the clutch basket. it is the release and also has the springs attached to it. i loosend the four bolts that held that together. once you take that off you can remove the clutch springs. i took some washers and drilled them out to be bigger that the posts that the springs went around. the first set i tried to use that were in our bolts bin at work were too large around. they need to fit in the cover that i removed so that the spring won't sit crooked. so i searched around and remembered that i saved all the extra bolts and washers from the assembly of my bike. what do you know, i found eight of them and they were the right size around but the center hole was super small. i drilled out the centers and deburred them. i decided to use two washers. i couldn't have used a 3rd. two washers made the springs almost complletly compressed. it worked out really well from what i can tell for the whole 2 clutch dumps i did. anyways here's the pics. spring assembly removed. clutch disks. 5 disks just like a xr200 from what i can tell. what is the hell is a plastic gear doing is here? someone please tell me what that is for. the disks this is for Bruce, i know we talked about you trying to see if the xr springs are the same. this is the plate that holds the springs on. see where the face of the spring sits? the washers need to sit there, can't be bigger. my nastey job of drilling out the holes. i had to do it by hand with a air drill. they look like shit but hey they work. washers installed before everything is aligned and tightend down. tightend down [img]http://img84.imageshack.us/img84/2156/image154eq5.jpg[img] tightend down side . i'm going to most likely take the bike to work tomorrow. i'll be sure to post up how much better the clutch is. __________________ Roketa DB-07a HID Headlight
	0

03-12-2007, 11:06 PM	#34
ambassador Join Date: Jan 2007 Location: Bradenton, Florida Posts: 1,200	Not much different from my XR except for the plastic gear, gotta be a part of the starter, maybe oil throw??? __________________ 06 Lifan 200 GY-5
	0

03-12-2007, 11:08 PM	#35
FMYStreetRacer Join Date: Nov 2006 Location: Ft. Myers, Fl. Posts: 416	starter is on top. guy at my work said maybe it's for crank case vent. all i know is that i don't like that crap there at all. __________________ Roketa DB-07a HID Headlight
	0

03-13-2007, 12:47 AM	#36
liverchip Join Date: Nov 2006 Location: Mystery Spot Posts: 1,223	Maybe oil pump? __________________ 2009 XR650L Big Red Pig Tusk bar risers 2007 X-Moto(Jetmoto) GY250 --mods--- 15/40 sprockets UNI Pod Filter 2007 Shineray TMS 200XYi--Betsy Betsy Mods:______________________ Acerbis DHH headlight FMF Powercore pipe Uni Pod Filter
	0

03-13-2007, 01:16 AM	#37
liverchip Join Date: Nov 2006 Location: Mystery Spot Posts: 1,223	Probably a dumb question, but were you guys looking for a supplier for clutches? I found mine TSM 200 (grey market Lifan pushrod) for 42$. No need for it as of yet, but I believe in being proactive. Now if only I could find brake pads. __________________ 2009 XR650L Big Red Pig Tusk bar risers 2007 X-Moto(Jetmoto) GY250 --mods--- 15/40 sprockets UNI Pod Filter 2007 Shineray TMS 200XYi--Betsy Betsy Mods:______________________ Acerbis DHH headlight FMF Powercore pipe Uni Pod Filter
	0

03-13-2007, 09:04 AM	#38
fatboy250 Join Date: Sep 2006 Location: COLUMBIA, SC Posts: 973	FMY, Great job, I can't wait to hear how it works out for you! Can you give the inner (i.d.) and outer(o.d.) diameter of the final washers. I may be able to find some that are that size that can be bought and I'll post them in the parts thread. Otherwise I will just do what you did. Also, what was your final thickness with the two washers? I may just get Dad to machine the exact size washer (spacer) as one unit. Thanks for you help. Jason __________________ 2008 Jonway MC-70-150 2007 Roketa DB-07B (RSM-200E) 2006 Roketa DB-07A (RSX-200E) 1995 Kawasaki Concours (ZG1000)
	0

03-13-2007, 10:13 AM	#39
cycleway4 Join Date: Feb 2007 Location: Virginia Posts: 269	hi...yes, plastic gear drives the oil pump..........this is a typical set-up[for that purpose] __________________ <div>Steve 2006 Roketa DB-07A/RSX-200E 2008 Roketa 250 Scooter 2019 Brozz 250
	0

03-13-2007, 03:47 PM	#41
fatboy250 Join Date: Sep 2006 Location: COLUMBIA, SC Posts: 973	The 15/32" comes out to just under 12mm. So, it sounds like a 12mm i.d. and 19mm o.d., or would 19mm be more than the surface area you had to work with on the plate? We're talking .728" (18.5mm) versus .748" (19mm). Thanks for the info. Jason __________________ 2008 Jonway MC-70-150 2007 Roketa DB-07B (RSM-200E) 2006 Roketa DB-07A (RSX-200E) 1995 Kawasaki Concours (ZG1000)
	0

03-13-2007, 07:50 PM	#42
FMYStreetRacer Join Date: Nov 2006 Location: Ft. Myers, Fl. Posts: 416	the half milimeter might be too much. __________________ Roketa DB-07a HID Headlight
	0

03-13-2007, 11:00 PM	#43
Roketarider Join Date: Jan 2007 Posts: 124	I might be attempting this tomorrow, as my clutch is slipping bad in pretty much all gears. __________________ Roketa DB-07A 200cc
	0

03-13-2007, 11:57 PM	#44
liverchip Join Date: Nov 2006 Location: Mystery Spot Posts: 1,223	Streetracer, Is your motor the OHC or pushrod? __________________ 2009 XR650L Big Red Pig Tusk bar risers 2007 X-Moto(Jetmoto) GY250 --mods--- 15/40 sprockets UNI Pod Filter 2007 Shineray TMS 200XYi--Betsy Betsy Mods:______________________ Acerbis DHH headlight FMF Powercore pipe Uni Pod Filter
	0

03-14-2007, 12:31 AM	#45
FMYStreetRacer Join Date: Nov 2006 Location: Ft. Myers, Fl. Posts: 416	ohc __________________ Roketa DB-07a HID Headlight
	0