Sunday, October 30, 2011
S90: Clutch Continued
A full morning tackling the S90's clutch.
Stripped a screw on the clutch outer cover which meant I had to cut into the cover itself in order to reslot it.
Cut off the custom made hand-control-to-rear-brake cable.
The lock washer was completely torn up.
Not exactly sure what the gold welds are for yet.
A better look at the corrosion on the primary driven gear.
Was able to use the valve compressor and a wrench to remove the clutch screws.
Clutch and friction plates looked pretty far gone.
And it appeared that one of the friction plates had shed all its material at some point.
Killed one of the spring screws trying to pry it out.
Stripped a screw on the clutch outer cover which meant I had to cut into the cover itself in order to reslot it.
Cut off the custom made hand-control-to-rear-brake cable.
The lock washer was completely torn up.
Not exactly sure what the gold welds are for yet.
A better look at the corrosion on the primary driven gear.
Was able to use the valve compressor and a wrench to remove the clutch screws.
And it appeared that one of the friction plates had shed all its material at some point.
Killed one of the spring screws trying to pry it out.
Sunday, October 16, 2011
S90: Clutch Cover Removal
All nine clutch cover screws were frozen, as expected. The impact driver got 7 and I had to re-slot the other 2 with the Dremel. Not too bad, considering how long the bike had been sitting.
Once I got the screws out, I was still having a lot of trouble prying off the cover. Figured the gasket had fused it shut. I yanked and hammered screwdrivers into the gaps for about 15 minutes until I finally realized that I'd neglected to take out one of the bottom screws (another lesson learned).
After that, the cover popped right off, but it wasn't very pretty on the inside. I cleaned out the old oil sludge but I left dismantling for another day.
Once I got the screws out, I was still having a lot of trouble prying off the cover. Figured the gasket had fused it shut. I yanked and hammered screwdrivers into the gaps for about 15 minutes until I finally realized that I'd neglected to take out one of the bottom screws (another lesson learned).
After that, the cover popped right off, but it wasn't very pretty on the inside. I cleaned out the old oil sludge but I left dismantling for another day.
Monday, October 10, 2011
S90: Airbox
The screws holding the covers on were fused solid. Not only did I have to do the usual re-slotting with the Dremel, but I had to unscrew them all the way out with the impact driver. They didn't reach a point where they could be turned by hand until they were almost all the way out.
Even after getting the screws out, I found that only one cover would come free. The other one was rusted tight. A couple whacks with the rubber mallet only succeeded in putting a dent in the body of the airbox (lesson learned).
But I don't think it's necessary to get both covers off in order to get a new filter in and make it functional. It's not pretty, but I think it'll do the job for now.
Even after getting the screws out, I found that only one cover would come free. The other one was rusted tight. A couple whacks with the rubber mallet only succeeded in putting a dent in the body of the airbox (lesson learned).
But I don't think it's necessary to get both covers off in order to get a new filter in and make it functional. It's not pretty, but I think it'll do the job for now.
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