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Rotax Clutch Replacement - How not to do it.; The worng way to attempt a rotax clutch replacement.
Topic Started: Jan 13 2015, 02:19 PM (1,059 Views)
Grurple
Viscount
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A mate of mine brought his 640 Roadster round to mine on saturday to change the clutch as its been slipping trying to pull his weight plus all the mince pies he ate at xmas.

Our estimates varied from 5 minutes to an hour to remove clutch cover and 'pop' in some new plates.

Several hours later and with the winter light fading on my drive, the swearing was still going strong.

How to change a clutch in a rotax engine:

1. Turn up on bike with clutch plates and new oil.
2. Stare at engine before realising the clutch is on the other side.
3. Drain oil but leave some to decorate my drive with.
4. Start to remove clutch cover casing.
5. Slap forehead when you realise that the timing belt and pulleys need to come off.
6. Consider aborting mission and restart when we have all the tools and parts needed.
7. Persevere anyway with breathtaking optimism.
8. Struggle without correct tools until dark.
9. Make list of all the bits needed to finish job.
10. Stash dismantled bike in my garage until next weekend.
11. to be continued...

Notice that 'Look at manual' is missing from the list. Any advice on how to put it all back together once we get the gaskets in the post, gratefully received.
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ian6pot
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God
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Even though Haynes don't do a work shop manual for the Rotax they do have a saying in all there books.

Re assemble in reverse order......not very helpful I know :dirtbike:
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Gonzo250
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Working-class moto psycho
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Get the proper clutch holding tool. The 'universal' ones do not include Rotax engines in that list.
I drink too much, I swear too much, I ride too fast and I crash too often.

It is a universal impossibility for me to leave my tools alone and my bikes standard. 'It must go faster!!'
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ian6pot
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God
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Or impact gun...thats what I do.
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Gonzo250
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Working-class moto psycho
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Some of us aren't so lucky to have access to an impact gun, Mr. Posh Garage Owner. =p
I drink too much, I swear too much, I ride too fast and I crash too often.

It is a universal impossibility for me to leave my tools alone and my bikes standard. 'It must go faster!!'
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ian6pot
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God
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Ha...the only garage I have is stuck to the side of the house, and as for posh,nooo I have been known to eat from bins.

That said I work for a main dealer. :hug:
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Grurple
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My mate is going to bring the impact gun for reassembly. He didn't bring it initially because

a) the compressor was too heavy to carry on the bike
b) we didn't think we'd need it

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Sportax Racing
Anything & Everything ROTAX
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Good luck chaps! Remember a torque wrench 120Nm for the clutch nut and 100Nm for the bottom pulley...

Also loctite 222 and a new tab washer for clutch nut..
Edited by Sportax Racing, Jan 14 2015, 10:16 AM.
www.sportaxracing.co.uk
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Grurple
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Ace - thanks for the torque settings.
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