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Clutch Lifter Plate, Cam Plate, Clutch Ball Retainer Install

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I pulled the right crankcase cover off a 2003 XR50R and a few clutch components fell off as I was removing the cover.  Are these components supposed to be held on by the cover or is something wrong?  I noticed the bolt in the center of the cover, but I didn't remove it (because the service manual didn't say to do so).  This bolt is aligned with the components that fell off after removing the case.

 

Screen Shot 04-03-17 at 01.16 PM.PNG

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If you are referring to #4, 5, and 9 then yes they will fall off when you open the right side.

Here is how they go back (disregard the red arrows):
IMG_2151.JPG

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Is the hole in the center of this bearing supposed to be offset like this?  Kind of looks damaged to me.

 

 

 

20170404_182454.jpg

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Okay.  Just wanted to be sure because there were no dowel pins when I removed the cover, so I was thinking maybe it got worn down unevenly over time (because the cover shifted).  Plus the off center portion is shiny and rough looking like it has been worn down.

 

 

 

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There is what is called an oil through and spring (parts #10 and #11 in the link below) that goes inside that from the front, you can see it in the pic that CRF James posted. It looks like a dowel pin but has a slightly closed end to keep the spring in place.

External clutch parts

 

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I have everything back together and the bike started first kick :thumbsup:.  However, I have small oil leak coming from the clutch adjusting screw/nut on the right cover.  Appears to be coming from between the screw and nut (as opposed to the nut and the cover).  Is there an o-ring or seal that needs to be replaced behind the cover?  There was a flimsy piece of rectangular shaped rubber behind the nut and that was it.

For reference:

 

XR50R_RightCover.jpg

 

Now that I'm looking at the diagram, is there supposed to be another small cover surrounding the clutch adjustment nut?  The bike I am working on has  what appears to be an aftermarket carbon fiber cover which is held on by the clutch adjustment screw lock nut.  Perhaps this is the reason I have a leak.

Edited by mossman77

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That flimsy piece of rectangular rubber is your o-ring. It goes under the nut and washer. Part 15 in the diagram. Part number is 91306-HB3-003.

 

IMG_2620.thumb.PNG.0f2f84e74cda50f6a119aaab23a5041f.PNG

 

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There definitely isn't an o-ring or a washer, but rather a makeshift seal.  I'll replace it with the proper parts. 

 

 

 

Edited by mossman77

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Does anyone happen to have a pic of the washer and o-ring?  There isn't a washer in the gasket kit, but I have a few o-rings.

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I can take a photo when I get home tonight. It is an odd shaped o-ring. Instead of having round profile, it has more of a triangular profile.

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No, that is a valve guide seal for the older Z50 models. The size for the o-ring is 8 x 1.7, if that helps. There is an 8mm flat washer that helps hold that o-ring in place

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Given that the oil is seeping out from between the screw and nut as opposed to the nut and cover, does it sound like I should replace the nut and/or adjusting screw as well?  You can clearly see how rusty it is.

 

Edited by mossman77

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No, you can clean up the nut and the adjuster stud on a wire wheel. the thing to do is ditch the carbon fiber cover and put everything back together.

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1 hour ago, CRF James said:

You still need a photo? I am home now.

Sure.

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