Clutch upgrade

[Terryfyd]

Hello all! I have a 2005 Rocket, I upgraded the lifter piece, the bearing and of course the pressure plate to accommodate the thicker ball bearing. I see that the thrust washer (#19) is no longer needed with this assembly "Eng no 249177 - fitted with T3800082, needle bearing. NOT required with T1170067, deep groove bearing" and the regular washer (#27) is only sometimes needed. " Eng No 369111; Fitted with T1170029, T1170057 & T1170059 (issue1). NOT required with T1170059 (issue 2), T1170159 or T1172023 lifter pieces dut to 4.1mm shoulder width". Am I correct in assuming that the spacer (#23) and wavy washer (#3) are needed. The washer and wavy washer will not fit over the lifter piece as shown in the old diagram. Is there a clutch assembly diagram that I can refer to with the upgraded lifter piece and bearing. Even the 2022 diagrams are still showing the old needle bearing. Any insight would be appreciated. Thanks in advance!

 

[R-III-R Turbo]

That exploded parts diagram is a pest, it is so misleading.
All engines I've worked on (06 onwards) had (from front to back);

• the pressure plate
• the ball bearing
• the lifter piece/pull rod
• wavy washer

All that sits into the clutch assembly.

No sign of #19, #27 or #23. They might be part of the old needle roller bearing setup in the initial engines but I don't kno fo sho. Yours is 05 with a needle roller originally, and none of these three were in it when you opened it?




.

 

[Terryfyd]

That exploded parts diagram is a pest, it is so misleading.
All engines I've worked on (06 onwards) had (from front to back);

• the pressure plate
• the ball bearing
• the lifter piece/pull rod
• wavy washer

All that sits into the clutch assembly.

No sign of #19, #27 or #23. They might be part of the old needle roller bearing setup in the initial engines but I don't kno fo sho. Yours is 05 with a needle roller originally, and none of these three were in it when you opened it?




.

Thank you! That helps greatly!!!

 

[Terryfyd]

That exploded parts diagram is a pest, it is so misleading.
All engines I've worked on (06 onwards) had (from front to back);

• the pressure plate
• the ball bearing
• the lifter piece/pull rod
• wavy washer

All that sits into the clutch assembly.

No sign of #19, #27 or #23. They might be part of the old needle roller bearing setup in the initial engines but I don't kno fo sho. Yours is 05 with a needle roller originally, and none of these three were in it when you opened it?




.

Thank you for the clarification. Nothing else was there, but i started to second guess myself...did it drop on the garage floor? did i misplace it?

 

[Jim the rocket]

My Rocket was making a random squealing noise and it sounded like it was coming from the clutch area so I took it apart to see my pressure plate came off and it had the same set up as the above picture I also was confused because of the parts diagram mine only had the wavey washer I thought that the washers not being in the order as the diagram might be it, but after reading this forum I guess not .
haven't found what is making the noise yet any ideas?

 

[R-III-R Turbo]

My Rocket was making a random squealing noise and it sounded like it was coming from the clutch area so I took it apart to see my pressure plate came off and it had the same set up as the above picture I also was confused because of the parts diagram mine only had the wavey washer I thought that the washers not being in the order as the diagram might be it, but after reading this forum I guess not .
haven't found what is making the noise yet any ideas?

Does the squealing sound change when clutch lever is pulled in or let out?
Have you a pic of the lifter arm claw and the mating head on the pull rod?

 

[Jim the rocket]

Does the squealing sound change when clutch lever is pulled in or let out?
Have you a pic of the lifter arm claw and the mating head on the pull rod?

That exploded parts diagram is a pest, it is so misleading.
All engines I've worked on (06 onwards) had (from front to back);

• the pressure plate
• the ball bearing
• the lifter piece/pull rod
• wavy washer

All that sits into the clutch assembly.

No sign of #19, #27 or #23. They might be part of the old needle roller bearing setup in the initial engines but I don't kno fo sho. Yours is 05 with a needle roller originally, and none of these three were in it when you opened it?




.

 

[Jim the rocket]

It has never made the sound with the clutch pulled in that I can recall and it's usually in the higher gears while moving never at a stand still with clutch pulled in or in neutral.

 

[R-III-R Turbo]

I doubt anything wrong with clutch then.
Except you could replace that pull rod with the newer version of it (thicker head) while your'e in there.

What your sound might be is something a little loose maybe a rad cover or exhaust cover etc

 

[Jim the rocket]

I doubt anything wrong with clutch then.
Except you could replace that pull rod with the newer version of it (thicker head) while your'e in there.

What your sound might be is something a little loose maybe a rad cover or exhaust cover etc

Thank you for your input I really don't think it is external but if I find what it is I'll let you know. I am still going to pull the basket and check it out before I button it back up. Do you know the part number for the pull rod with the (thicker head) ?