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banana4monkey

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I have known for a while the clutch was slipping on the Warrior. I adjusted the cable and it was still slipping. I am not surprised since this is the original clutch that is 28 years old. Time to take the clutch apart and inspect it. The captions under the pictures tell the procedure. Based on the wear limits listed in the manual the clutch plates and springs need replacement. I ordered a clutch kit that offers all of the parts needed. I will post a reply to show the installation once the parts come in.

  IMG_4772.JPG 
First drain the engine oil

IMG_4773.JPG 
Next remove the footpeg and brake lever
IMG_4774[1].JPG 
Next remove engine cover
IMG_4775.JPG 
Cover removed now remove pressure plate
IMG_4776.JPG 
Pressure plate removed
IMG_4777.JPG 
Bending lockwasher on clutch hub nut

IMG_4778.JPG 
Use clutch holding tool and remove clutch hub nut with impact gun
IMG_4779.JPG 
Clutch removed
IMG_4780.JPG 
clutch on bench ready for inspection

IMG_4783.JPG 
IMG_4785.JPG 
using a caliper to measure clutch plate thickness and spring free length


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banana4monkey

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Reassembled the clutch last night on the Warrior. Typically when I replace a clutch I will replace the friction plates, the steel plates, and the springs. This is a pretty simple task when you follow the manual. Make sure you coat the new clutch steel and friction plates in new oil. Also this Warrior has different thickness steel plates and one of the friction plates has a different inside diameter dimension. It is important to get the clutch stack up correct. The Clymer service manual does a good job with providing a diagram on this. See pics and captions for more details on this job.

IMG_4850.JPG 
Bluing due to excessive heat on the old clutch steel plates
IMG_4842.JPG 
New clutch kit
IMG_4843.JPG 
stack up diagram in manual
IMG_4844.JPG 
using clutch packaging to soak steel and friction plates in new oil
IMG_4845.JPG 
stacking up the plates

IMG_4846.JPG 
stack up complete

IMG_4847.JPG 
Install clutch into the basket noting the match marks seen here.
IMG_4848.JPG 
clutch nut and locking tab installed.
IMG_4849.JPG 
springs and pressure plate installed
IMG_4851.JPG 
cover and cable installed. Next you need to adjust the free-play and then you are ready to put the foot peg back on and fill the engine with new oil. Nice and easy install.


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