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Old November 20th, 2018, 03:50 PM   #1
Kennylxix
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08+ Clutch Swap Complete

Just finished swapping the newer style clutch into my 93. This was done to correct the clackety clack noise from degraded cushion bushing things in the old clutch.

Swap was a complete bolt in. The trick I think is to get every single piece between (but not necessarily including ) the washer that sits between the basket and the input shaft bearing and the actuator arm that sits in the clutch cover. This includes needing the newer push rod.

There are a ton of little differences between the two clutches but I don't think anything was changed between the two model as far as the engine case or clutch cover are concerned.

I saw reports of needing to make a spacer to get the clutch to fully disengage but didn't run into that. I think the people experiencing that issue may have been using the old push (actually pull) rod. The original is a bit longer than the new one and would cause problems with actuation.

To recap all I did was swap the entire assembly between the input bearing washer and the clutch cover cam arm thing. Everything aligned perfectly and the clutch is smooth and quiet.

Of course your experience may be different.
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Old November 20th, 2018, 03:51 PM   #2
Kennylxix
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Oh I also found a bunch of the old bushing material in my oil strainer so it's definitely a good idea to get in there and clean it out.
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Old November 20th, 2018, 04:12 PM   #3
Ceeloo Yello
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Congrats buddy.
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Old November 20th, 2018, 05:25 PM   #4
Kennylxix
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Thanks! I also wanted to mention that my clutch feel was and still is really wierd with engagement happening at the very end of lever travel and not very smoothly. (Yes everything is lubricated and adjusted)
Turns out that the little "fingers" on the actuator cam lever thing are really badly worn where they contact the puller rod. This is causing the feel to be really weird and engagement to not be right. I already ordered a replacement.
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Old December 3rd, 2018, 02:41 PM   #5
Ceeloo Yello
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So the clutch arm just pushes into the clutch cover? No retaining clip or anything?
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Old December 3rd, 2018, 02:46 PM   #6
Kennylxix
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Correct. The puller rod itself holds the clutch cam arm thing in.

I actually replaced my worn one without taking the cover off. I just disconnected the clutch cable, rotated the arm counter clockwise until it disengaged with the puller rod then pulled it straight out. The replacement went right in and reengaged with the rod (im sure it's possible for the rod to get out of alignment after removing the cam arm piece but it worked fine for me.
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Old December 3rd, 2018, 03:39 PM   #7
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Great project report! Thanks for returning to post your thoughts on the experience.

As I mentioned on your earlier forum thread I'm going to do this mod in late December or early January, hoping my swap goes as well as yours did.

I've got the parts standing by, waiting for the busy holiday season to end.
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Old December 3rd, 2018, 03:45 PM   #8
Kennylxix
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Yeah as long as you get every single piece between the washer behind the clutch and the clutch arm you should be fine.
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Old December 3rd, 2018, 04:15 PM   #9
Ceeloo Yello
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Thanx, me three gonna try this getting most of the parts from ebay.
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Old December 4th, 2018, 02:50 PM   #10
Ceeloo Yello
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Oh and did you need to use any special tools like the clutch tool to hold the basket while undoing the nut?
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