Pre 03 Clutch Bushing Swap Soon

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Pre 03 Clutch Bushing Swap Soon

Post  Focker on Tue Nov 25, 2008 5:14 am

This topic is covered on the Pig Pen site but I want to get it going here since there is no Q&A on that site.

Anybody done the swap yet? I've got the parts to do it and if anyone's got some good tips for my swap day I would appreciate it. I plan on posting a detailed "How To" this winter.

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Re: Pre 03 Clutch Bushing Swap Soon

Post  Thunderchild on Thu Nov 27, 2008 1:41 am

I'm the third owner of my 2000. I'm lucky enough to know the two previous owners of the bike, so I know it's history some.

Mine has never had the later year model bushing installed. The plates have been replaced once, but that's about it on the clutch.

Knock on wood, and I hope I haven't jinxed myself, but I've never had any problems with mine. Yet.

You should do a write up and photos when you do yours. I know the PP has a how-to, but it would be a cool start to a how-to section on this site.
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Re: Pre 03 Clutch Bushing Swap Soon

Post  Focker on Thu Nov 27, 2008 5:18 am

If no one beats me to it I plan on providing a post of the procedure. The great thing is we'll have a tech day this winter in the warmth of Hodakaguy's garage!

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Re: Pre 03 Clutch Bushing Swap Soon

Post  Pikkos on Fri Nov 28, 2008 1:33 am

Afternoon all, Here are some pic' of the bush in question




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Re: Pre 03 Clutch Bushing Swap Soon

Post  Focker on Fri Nov 28, 2008 3:07 am

Thanks for posting some pics.

Could you include in your post any special tools or tool substitutes for us DIY guys. I would rather not have to buy pricey tools. I know there are other things you can use but if you have first hand knowledge that would help us that would be great. Also what's your best guess on the time frame for this swap?

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Re: Pre 03 Clutch Bushing Swap Soon

Post  Pikkos on Fri Nov 28, 2008 12:58 pm

Morning all, Heres a site i downloaded a manual http://www.freepdfmanual.com/2000-honda-xr650r-workshop-manual/ it explains thing you need and can make up mainly bearing pullers and punches, the clutch basket holder can be made up from some flat steel something like in the manual make a good one, the basket can break easy and are expensive. The clutch bush in mine was replaced by the previous owner and is the upgraded part and is still in good condition but i will replace it anyway. I think it was only the 2000/01 models that was affected and only when they were still new.


Last edited by Pikkos on Fri Nov 28, 2008 1:53 pm; edited 1 time in total (Reason for editing : Additions)
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Re: Pre 03 Clutch Bushing Swap Soon

Post  desertfox on Sat Nov 29, 2008 7:23 pm

From what my research has found if bushing failure did not occur early in the XR's life we do not need to do this update. Any comments about this would be appreciated. I have all the parts on hand to do this but wonder if it is truly needed.

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Re: Pre 03 Clutch Bushing Swap Soon

Post  Thunderchild on Mon Dec 01, 2008 11:42 pm

desertfox wrote:From what my research has found if bushing failure did not occur early in the XR's life we do not need to do this update. Any comments about this would be appreciated. I have all the parts on hand to do this but wonder if it is truly needed.

This is what I understand too.
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Clutch Bushing Upgrade

Post  Focker on Fri Jan 02, 2009 12:51 am

I decided to cut into my pig today and see if my 02 needed the clutch bushing (a.k.a. outer guide) replaced.
While I was in there I took a few photos for those interested.

If your wondering if it needed it...Read on.




Here's a quick rundown of what worked for me...As always attempt at your own risk.

  • I simply followed the service manual directions for removal and assembly. study
  • I didn't drain the oil but would recommend it...It would've been nice to see what kind of crud is in the bottom of the case.
  • When removing the lock nut (pg 10-3) we used an air gun to rattle it loose. I didn't want to buy the clutch holder tool.
  • To tighten the lock nut to spec...We put the bike in 5th gear, pressed the rear brake as well as holding the tire from slipping..."Click" no prob.
This swap job is truly easy and quick for anyone's skill level.
Oh ...Almost forgot...Turns out mine had the upgraded piece. Frustrated

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