Wednesday, Jun 1 2016 [3,852 miles]
Drying
I’m taking some time this afternoon to change the oil and check on the Neutral Sending Unit (NSU) mounting screws. But first I cleaned the bash plate and put it out in the sun to dry.
Ready to drain oil
Oil drain plugs
Used O-ring
New filter O-ring
Filter magnet
New cover O-ring
I’m installing a magnetic drain plug in place of the stock unit this oil change. I’m also trying out a magnet on the oil filter. Might have been a waste of a few dollars, but I don’t think it can hurt. Both O-rings — the filter O-ring and the filter cover O-ring — were changed. The old rings felt rough to my fingers.
Remove brake lever
Ready to remove clutch cover
I removed the brake lever to make side cover removal easier. I’m not sure if it is possible to remove the side cover without removing the brake lever, first. I detached the clutch cable and oil lines. The side cover is ready to come off. The bits of tape on cover are a reminder of where the shorter and longer mounting screws go. It’s a back-up. I layed the screws out in order as I removed them from the cover.
Bottom NSU screw
Almost perfect gasket
The bottom NSU screw can be accessed without removing the clutch basket. The clutch will come off to get at both screws. The cover gasket is almost perfect. There is one tiny tear on the outside of a screw hole.
I have a replacement gasket, but am going to try to re-use this one anyway. If it starts leaking I’ll pay the price of another tear down, perhaps with the bike on its side so I don’t waste the oil.
Clutch
Clutch basket
Ready to remove nut
Clutch removal is easy with an impact wrench. Folding up the safety washer to get at the nut was the hardest part of the job. I measured the clutch plates just because. They were OK at 3.0mm ~ 3.1mm.
NSU screw
One down, one to go
The NSU screws on my 14 were not loose, but it took very little force to break them free. My guestimate is 2-3 N-m of force! One at a time I removed, cleaned, applied blue loctite, and re-installed the screws.
50 N-m plus bent retaining tab
Ready to install clutch
Clutch installed
I re-installed the clutch making sure that the fiber gear was properly engaged. I torqued the nut to 50 N-m – then a little more to get a flat part of the nut where needed to bend down the safety washer. I also checked the torque of the left handed thread drive nut. Nice and tight at 100 N-m.
After getting the clutch installed I cleaned the mounting flange. Dumb. It would have been easier to do that before installing the clutch. Once I was sure that the flange was smooth and clean I put a thin layer of grease on the flange then mounted the side cover. That took a few tries before I got the clutch mechanism to properly catch.
Brake pivot love
Fresh oil
I applied a good amoung of grease to the brake pedal and used new split pins to instal the pedal to frame and master cylinder. It’s just easier that way. Last item for the day was to fill the engine with fresh oil.