Clutch Kato 525exc 2005

Discussion in 'Thumpers' started by raycam01_au, Jul 6, 2013.

  1. raycam01_au

    raycam01_au Sir Ray!

    Joined:
    Feb 7, 2010
    Oddometer:
    1,082
    Location:
    CLontarf
    Hi Guy's
    I am just about to do the clutch in my Kato, ordered new kit and gaskets, it seems fairly straight forward, got my manual, and utubed a heap of stuff.
    I am handy and a scale of 1-10 bout a 5 on the DIY, but the clutch seems pretty simple, any hidden things i need to know before i embark :)
    i will log it for my own use and anyone out there :)

    [​IMG]

    :freaky
    #1
  2. Roll Cage

    Roll Cage Shippin' Up

    Joined:
    Jun 27, 2007
    Oddometer:
    39
    Location:
    Livermore, PRK
    Just did this myself! Best advice I can give is to make sure you have the right number of plates in it! Go ahead, ask me how I know...

    Should be 8 steels (1mm thick) and 7 friction plates (2mm thick). Total stack height of 22mm. Don't forget to soak the friction plates in oil over night.

    Torque all 6 spring retainer bolts to 8Nm. I'm a total dolt and tightened them to 8ft-lbs, which thankfully is about 10Nm. These bolts also need some blue loc-tite.

    That's all I got. Any other questions, just let me know.
    #2
  3. raycam01_au

    raycam01_au Sir Ray!

    Joined:
    Feb 7, 2010
    Oddometer:
    1,082
    Location:
    CLontarf
    OMG how did you know!!!!!!! :) i dun wanna find out the bad way lol

    Solid advice, I heard they need a good good soak


    thanks man

    didnt by any chance get some pics of it opened up for surgery?? i love pics

    That's all I got. Any other questions, just let me know.[/QUOTE]
    #3
  4. RideFreak

    RideFreak Torque Junkie

    Joined:
    Apr 17, 2009
    Oddometer:
    8,775
    Location:
    Out in the NM Dez somewhere
    Good time to retorque the primary nut on the crank, these are known to loosen up on the RFS motors.
    #4
  5. raycam01_au

    raycam01_au Sir Ray!

    Joined:
    Feb 7, 2010
    Oddometer:
    1,082
    Location:
    CLontarf

    thanks matey

    :D
    #5
  6. Roll Cage

    Roll Cage Shippin' Up

    Joined:
    Jun 27, 2007
    Oddometer:
    39
    Location:
    Livermore, PRK
    I'll second the retorquing. Just a convenient time since us earlier 525 owners aren't spoiled with a two piece clutch cover... :D

    And let's just say that I had a hell of a time diagnosing a slipping clutch for a few months :deal

    No pics sadly. Another tip: don't lose the pins/rollers that go between the plates and the inner clutch hub. Don't get freaked out, the remaining oil in the engine usually holds them in.

    It's really not a tricky job. Just take your time, and don't panic :wink:
    #6
  7. raycam01_au

    raycam01_au Sir Ray!

    Joined:
    Feb 7, 2010
    Oddometer:
    1,082
    Location:
    CLontarf
    all good on the panic side, ima pretty chilled and methodical, so far all very good advice, i will post some pretty pics up when i go to do it, fingers crossed i dont have any little bits left over when i put it together again :lol3
    #7
  8. raycam01_au

    raycam01_au Sir Ray!

    Joined:
    Feb 7, 2010
    Oddometer:
    1,082
    Location:
    CLontarf
    clutch goes in tomorrow, fingers crossed :)

    :rofl
    #8
  9. raycam01_au

    raycam01_au Sir Ray!

    Joined:
    Feb 7, 2010
    Oddometer:
    1,082
    Location:
    CLontarf
    hey guy's
    thanks for all the good advice,
    i got stuck for time and had a mate finish the job for me,


    removed a few bits
    [​IMG]


    found this
    [​IMG]

    put it all back together and she looked like this
    [​IMG]

    and man does she ride like a new bike :)

    shame there werent more pics :)

    :clap:freaky
    #9