Clutch Lifter Plate, Cam Plate, Clutch Ball Retainer Install

[mossman77]

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.

 

[CRF James]

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):

[mossman77]

Yes.  Perfect.  Thank you!

[mossman77]

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

 

 

 

[dirtbkr188]

That is the normal configuration, they all have a slight offset for some reason.

[mossman77]

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.

 

 

 

[dirtbkr188]

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

 

[mossman77]

I have everything back together and the bike started first kick ?.  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:

 

 

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 May 1, 2017 by mossman77

[CRF James]

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.

 

 

[mossman77]

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

 

 

 

Edited May 1, 2017 by mossman77

[CRF James]

[emoji1360] been there, done that

[mossman77]

[mossman77]

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.

[CRF James]

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.

[mossman77]

Is it like this small one with the taper?

 

[dirtbkr188]

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

[mossman77]

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 May 1, 2017 by mossman77

[dirtbkr188]

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.

[CRF James]

You still need a photo? I am home now.

[mossman77]

1 hour ago, CRF James said:

You still need a photo? I am home now.

Sure.