RD04 Clutch

[Faceplant]

Hi All,

Been mainly perving on the site, but now need some advice on my 04's clutch.
Just to introduce myself, I live and work in Tanzania, and have been here for more than ten years. There are quite a few AT's in town, very popular amongst the local Indo/Asians, and some very nice models too.
I bought mine from a dude who travelled up from Cape Town with the idea of selling here in Dar es Salaam. With duties paid $4000. Not too shabby me thinks.

Anyway, after riding a few weeks, I noticed lots of oil under the bike and all over the swingarm left side(hard not to notice the pools of Saidi's finest). Turns out the final drive bearing had collapsed. So studiously study the manual to see it's the last bit to come out of the engine on a strip-down. Not to be deterred, strip and proceed. I'm now at the stage of putting everything back together, but am confused by the clutch basket assembly. Got the clutch outer to seat with the 4 pins on the oil-pump drive and to mesh with the crank sprocket (another question there later). Next was installation of the pressure plate, all the fibre and steel plates, judder and spring plates and finally the clutch center. All looks good, except the plates are not snug against each other? No tension on them so to speak and they rattle around with about 3mm play. I've stripped and re-installed twice and can't get rid of the play. I don't think I'm missing any plates. (How many should there be)?

Am I missing something here?

Appreciate some help on this one.

Next is the primary drive gear assembly (according to the fiche on cmnsl.com). It comes in two parts. One big bugger and a smaller with spring tensioners. How is this supposed to go together. I take it the springs should be slightly under compression. Does that mean twisting the thin gear, locking it when it aligns with the bigger gear, then installing the clutch outer then releasing the lock bolt? What purpose does this serve anyway?

Thanks for all pending replies.

Steve Tanzania

[GSPD750]

Should be 7 friction plates. To align the primary drive sub-gear teeth with the main gear teeth you have to align them both and then
insert a 6mm bolt or suiltable rod in the hole on the primary gear....and yes you may have to twist the gears to align them. The gears
have to be aligned and held with that 6mm bolt prior to installing the clutch housing.

[Faceplant]

Thanks GS, just waiting for the hammer to drop and I'll be in the grudge checking everything out again.

[AlanH]

Next is the primary drive gear assembly (according to the fiche on cmnsl.com). It comes in two parts. One big bugger and a smaller with spring tensioners. How is this supposed to go together. I take it the springs should be slightly under compression. Does that mean twisting the thin gear, locking it when it aligns with the bigger gear, then installing the clutch outer then releasing the lock bolt? What purpose does this serve anyway?

Correct. You slightly twist the thinner one as you mesh it. It's an anti-backlash gear that takes up free-play and reduces rattles and primary gear noise.