Changed my Cluch, now it sounds different!

[Brainsquishy]

Hello again everybody, it's been a while, but I finally got around to switching out the burnt out clutch on my HSUN200GY (SUNL)
I had ordered a clutch from Gio. The one for the 200cc T3. I used one on it previously (the one I burnt out being foolish trying to pull a deer) and it had gone in fine. Likely because I removed the clutch plates and just replaced them. This time I replace the whole basket, except the top spring retainer portion. I used the original one as the new one conflicted with something. Don't quite remember with what now. (must be getting old, or maybe that tree I hit last week on the T3!) I also had to put a "shim/washer" under the oil filter (spinny thing) to keep the basket from hitting it. Any way, after getting it all together it seems to pull very well and shift very well, but it's noisy. It idles a bit louder; sounds a bit like a knocking or it may be my valve needs adjusting. The most concerning thing is the "whirring" noise. Sounds like a manual transmission VW backing up at high speed. The noise occurs as soon as it is put into gear. As I have driven it around the neighborhood a few times, the noise is reducing. But is run nice!?
Any thoughts??? And yes, I'm not too worried if it blows up...

[gloud]

Sounds like the new clutch basket (and gear) may be a little too large.
The gears binding are causing the noise.

[Brainsquishy]

Thanks for the reply gloud.
Do you think it will cause damage, or wear in?
The bike is driving very well, just a bit noisy.

[Weldangrind]

It will clearance itself eventually, but there will be aluminum schrapnel as a result. When you mix it with oil, it sticks like anti-seize compound. On Honda clones, you need to remove the clutch cover periodically to dig the goo out of the oil pump pickup, and yours will likely clog that much faster. I'd switch to the factory basket and remove the shim.

[Brainsquishy]

OK, when I get a few minutes I will put the other basket in. Thanks guys.

[Weldangrind]

Please take pics of the process.

[Brainsquishy]

I know you guys are going to say " I told you so!", but I ran the bike one more time! Something broke. Imagine that.

I opened it up and found the little doo dad on the clutch cover that picks up the oil coming out of the filter, disintegrated. Likely because the shim was behind the oil filter and it caused too much force onto the pick up.

And, on top of that, I changed the clutch and as I was full of oil, didn't get the promised pics of the clutch process. Sorry Weld!

Any way, I now am in need of a clutch side engine cover now. Any recommended sources for this? Anyone with spare parts?





:oops:

[Weldangrind]

Bummer. I don't think I have a spare CG cover.

[Weldangrind]

I can check at Saga if you can't locate one. Let me know.

[Brainsquishy]

:oops:
I must have hit my head a little too hard a few weeks ago....it seems I already have a cover! The old one off my T3 smoker engine. Just need to figure out how to make the kick starter hole and bushing transfer. Any thoughts, previous experiences? Maybe better to buy one????

[Weldangrind]

That's a tall order, but if you don't care about sacrificing the cover, then give it a try.

Start by removing the seal, and then measure the diameter of the remaining hole. Determine if you can obtain a drill bit that is exactly the same size. If you can't, then determine the closest size you can find and then buy a seal to suit.

The seal has three measurements; OD, ID and thickness. Thickness isn't terribly important, but OD and ID are. The local bearing shop will be able to tell you what alternate OD seals are available.

Once you have the drill bit and seal obtained, you'll need to secure the cover to a drill press plate. Start with a small hole (maybe 1/4"), and work your way up to the final size in steps. Once you're there, de-burr the hole and tap the seal in.

Or, just buy a new cover.

[SpudRider]

Personally, I would buy a new clutch cover.

Spud

[Brainsquishy]

Well I haven't had much luck finding a cover.
I did dig up some interesting links though.
http://www.motosportsparts.com/s.nl/it.A/id.18085/.f

http://www.motosportsparts.com/s.nl/...e=61%2C80%2C88

http://www.motopartsmax.com/index.ph...ID/840//page/2

http://www.bikebandit.com/houseofmot...a=10#sch558176

The information in the last two links says the cover is the same/similar to a 2008 Honda CRF230L.

If anyone can direct me to a Chinese version available through the web, please let me know. If Saga has one, I would be very interested. Their site doesn't show one though.

Thanks,

[FastDoc]

Back in the days of my Pitster Pro 400 a Honda NX250 engine cover saved the day. I don't see why a Honda cover wouldn't work for you.

It's always a bit of a crapshoot for used parts on eBay but that's where my cover was sourced from.

That Honda part was the best part on that whole $%#ing bike. :evil:

[Weldangrind]

I'll take a look at Saga next time I'm in. Feel free to send me a PM if it seems like I've forgotten.