CP3 Clutch Basket Repair Installation Guide

CP3 Clutch Basket Repair Installation Guide

Required Tools

Hand Tools

  • Metric socket set
  • 30 mm socket (clutch boss nut)
  • Torque wrench (ft-lb scale)
  • Clutch boss holding tool
  • Flathead screwdriver / pick (staking nut)
  • Snap ring pliers
  • Pry tool
  • Electric or hand drill
  • Adjustable locking pliers or tap handle
  • Allen keys (for clutch cover bolts)
  • Needle-nose pliers

Drill & Tap Tools

  • 1/8 in drill bit (pilot hole)
  • 1/2 in drill bit (remove rivet heads)
  • 9/32 in drill bit (backing plate clearance)
  • 13/32 in drill bit (deburr/chamfer backing plate)
  • M7 × 1.0 tap (included in kit)

Consumables

  • Thread sealant (included)
  • Engine oil (light coating)
  • Shop towels
  • Compressed air (recommended)

Torque Specifications

Component

Torque

M7 cushion bolts

7-9  ft-lb (9.5 - 12.2Nm)

Oil pump bolt

11 ft-lb (15 Nm)

Clutch boss nut

90 ft-lb (122 Nm)

Pressure plate bolts

7.2 ft-lb (10 Nm)

Clutch cover bolts

8.7 ft-lb (12 Nm)

Disassembly

  1. Remove clutch pull arm
    • Use snap ring pliers to remove the retaining clip and washer. Lift the pull arm and washer off the rod protruding from the side cover.

  1. Remove clutch cover
    • Remove clutch cover bolts 5mm allen.
    • Keep bike on side stand to avoid oil loss.
    • Remove cover and gasket (replace gasket if possible).
  1. Remove clutch pressure plate
    • Remove six 10mm bolts holding the springs against the pressure plate
    • Remove clutch plates in order, noting the sequence

  1. Unstake and remove clutch boss nut
    • Use pick or screwdriver to lift staked sections of nut.
    • Install the clutch boss holding tool.
    • Rest the clutch boss holding tool against the foot peg
    • Remove the nut using a 30 mm socket. Use a long ½” drive ratchet to make loosening easier. If nut does not loosen after significant effort, use a heat source to heat the nut to loosen it’s hold.
    • Remove washers (note orientation):
      • Plain washer
      • Washer marked “OUT” must face outward on reassembly.

  1. Remove clutch basket
    • Leave needle bearings and washers in place.
    • Drape oil pump chain over rear gear and slide basket off.

Clutch Basket Modification

Rivet Removal

  1. Drill 1/8 in pilot hole in center of each rivet.
  2. Drill 1/2 in to remove rivet heads.
  3. Remove backing plate with pry tool when all rivet heads are nearly gone.
  4. Remove worn rubber cushions.

Note spring orientation:

  • Conical spring: cone faces inward toward basket center
  • Flat washer: sits inside center pocket


Tapping Rivet Holes

  1. Clean holes.
  2. Oil tap lightly.
  3. Tap each hole with M7 × 1.0 tap:
    • Turn 2 turns forward, 1 turn back
    • Keep tap square to surface
  4. Tap until the threads on the tool are flush with surface.
  5. Clean chips and test fit bolt.
  6. Clean all parts in preparation for resassembly


Backing Plate Preparation

  1. Drill backing plate holes with 9/32 in bit so that M7 hardware passes through
  2. Deburr the rear side of the packing plate using a 13/32 in bit.

Reassembly – Clutch Basket

  1. Lightly oil:
    • Conical spring
    • Flat washer
  2. Install springs in original orientation.
  3. Install new clutch cushions:
    • Fat side facing right
  4. Install driven gear:
    • Lightly oil contact surfaces
    • Press fully into place
  5. Install backing plate.
  6. Apply thread sealant to M7 bolts.
  7. Torque M7 bolts to 7-9 ft-lb in crisscross pattern.

Reinstallation – Clutch Assembly

  1. Reinstall clutch basket:
    • Loop oil pump chain over rear gear
    • Slide onto needle bearings
    • Align with primary gear
  2. Install oil pump bolt:
    • Apply Loctite supplied in the kit
    • Torque to 11 ft-lb
  3. Install washers:
    • Plain washer first
    • Washer marked “OUT” facing outward
  4. Install clutch boss nut:
    • Torque to 90 ft-lb
    • Stake nut securely


Clutch Stack Installation

  1. Install friction plates:
    • Start with 2 thick tab plate
    • Then 2 thin tab plates
    • Remaining plates are thick
  2. Offset the final friction plate one slot over from the others.
  3. Align the final plate projection with the punch mark “A” on the housing.
  4. Install steel plates consistently (bevel direction consistent).
  5. Install the pressure plate.
  6. Torque pressure plate bolts to 7.2 ft-lb.

Clutch Cover & Cable

  1. Install clutch cover (replace gasket if possible).
  2. Ensure pull arm is correctly indexed:
    • Dot on shaft aligns with arrow on housing
  3. Torque clutch cover bolts to 8.7 ft-lb.
  4. Install clutch pull arm:
    • Turn the shaft fully counterclockwise
    • Install washer and snap ring

Final Adjustment

  • Set clutch lever free play to 10–15 mm
  • Adjust the bracket on the engine side as needed
  • Verify smooth operation before riding
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