I am putting new clutch plates in my Warrior. Is there any specific way the fiber discs should line up. What I mean is the lirrle notches on each "flange" of the disc. I am going to get a Clymer after the holidays, but would like to get here back together before then. I looked at the FSM .pdf but it wasn't any help at all.

Thanks
John

 

Line up all the marks on the friction plates together, then make sure the marks are in between the 2 marks on the clutch housing. You also want to make sure the arrow on the pressure plate lines up with the arrow on the clutch boss

 

holy crap..i thought it was a lot more strightforward than that. Let me get the terms straight here. If I have this understood right,
[*] the clutch housing is the part that the spring bolts bolt into? [*] the pressure plate is the metal part that presses on the springs?[*] and the "clutch boss" is what?

I didn't realize there were arrows and crap to line up, I think I should have gotten the manual BEFORE I strated. Live and learn I guess.

John

 

Ok I will try to explain this the best i can, it is hard to do without pics.

the clutch housing- this is the biggest part, it the the basket the hold everything together. It has the slits in it that the friction plates slide into.
the pressure plate- this is the part that has the 5 "poles" that the springs slide over top of.
The clutch boss- this is the top part of the assembly, not the spring plate. this has 5 holes that the"poles" from the pressure plate comes through.

The order from rear towards clutch cover is:
1 Clutch housing
2 Pressure plate
3 friction plate, drive plate, friction plate, .........
4 Clutch boss
5 Springs
6 Spring plate

 

okay i think I have it. I will go downstairs tomorrow and try to put it back together like you said. Thanks for you help!!!

 

yea a repair manual would be nice huh? you can download them for free from www.ridingthedunes.com i think but ya as far as the warrior goes the clutch notches should be lined up and aligned with the notch on the clutch case.

nice warrior crotts who did your port/valve job? im doing another project but having all new people do the mods.

 

Thanks, I had a local guy that my dad knows do it. He is a drag racer and he builds motors in the off season for race cars. I couldn't beat the price, $80 for everything.

 

oh local, heh thanks anyway, how bad do youstomp on 400ex's?

 

hey my old big bore kit wasnt done locally so does 85 stamped on the bottom of the piston mean the size of the piston or the bore?

 

I have never raced a ex so I dont know. The guys I ride with have a warrior and a shee. I kill my buddies warrior but it is stock and I beat a bored blaster before he totaled it. The shee just eats me alive. When I get my license back I am going to hit up the track and see how I do against some different quads. The 85 on your piston means 85mm is the size of your piston.