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Last Updated: November 25, 2014

FD125XRM clutch repair (clutch basket)

Too many problems may be felt within the clutch system of small commuter motorcycles if it is not given some time to be checked at least every 5 years depending on the mileage and the way the motorcycle is driven. Nowadays, friction plates are getting cheaper. but the process of inspecting this critical part of any motorcycle is not an easy task especially if it is a multi-plate, wet clutch system. Often times, clutch drag and slipping clutch is a very common problem we may encounter.

Photo shown came from a 10 year old 125cc motorcycle, it was never been inspected up until this writing. The friction plate provided the groove to where the rest during operation. Notice the four groove s only at one side of the clutch basket (the other side do not actually have it, since the motorcycle is being kept moving forward and the rotation is always clockwise).

This photo shows how the friction plates and the steel plates are netted together inside the outer clutch basket.

They are stack in a friction plate followed by steel plates alternately, and is covered by the inner plate with the clutch spring attached to it.

If you want to know how this system works.You can watch it here to be familiar with it.

The Outer clutch basket i think is in lieu for replacement, but up to this writing, with no enough resources to do so, i will re use it and instead will be modifying it to accept an additional steel plate and another friction plate to make it a FIVE (5) piece clutch system..

Note: The whole procedure of the modification will not be discussed, for the stock clutch basket is not intended for an additional friction plates. Replacing washers, taking the tight clearances of the whole basket must be considered and any miscalculation on anyone's part will be a disastrous one inside the engine. So this modification is not for the masses. 

The next photo will reveal that it is indeed too tight for an additional friction plates and steel plates on a stock hub or stock clutch basket.

The look of the STOCK with four plates attached.

The look of the MODDED stock basket with five plates installed.

Now I know many of you will ask?

What is the ADVANTAGE of having a stock four friction plate on a modded five friction plate installed?

Ans: I did try to test drive it to see if i can still shift to any gears, that because of the tight spaces between the friction plate and the steel plate, as i read from the internet, only a small gap is needed to release the tension on each and one of them to DISENGAGED the whole clutch system from driving the the drive shaft.

The torque of power transfer within the system improves. The motorcycle now pulls a lot of it during uphill climb that even on my third gear..

(By the way the stock sprocket of my motorcycle is 14/35 to where it was change to 16/34 prior to the modded clutch system and do not pull at third gear on uphill with four piece friction plates.)

I wanted to test it on a stock combination to feel the difference but up to this moment i am enjoying the current 16/34 (low speed sprocket ratio)..

Again, the POWER TRANSFER of the crankshaft to the drive shaft by the clutch was improved.

Lesson to be learned from here is that.

1. Often times when you are replacing the FRICTION plates on your motorcycle when it is time for the replacement, be sure to check the outer basket for groove. The groove makes the friction plate stick on it, thereby making it difficult to shift at many times, because when the plate is stuck they do not disengaged with the steel plates.So better check it.

2. Do not grind the groove, friction plate must not have slack on that area. if the groove is too much..replace the whole clutch basket, inner and outer is a MUST.


Christopher Howell said...

Definitely an impressive feat to do something like this for sure. I usually do most mechanic work on my own, but not for this project. I'll just stick to hiring a mechanic to get this thing fixed because they probably know a bit more on the subject.

Clyde nico Aranjuiz said...

Good day Po, if ever I will put five friction plate, it means that I will also add another steel plate to make it four steel plate,right?