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QLD ZXR250 Water Pump Shaft

Discussion in 'WANTED' started by DanoHosko, May 12, 2020.

  1. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    Follow the A-B model service manual as theres no clutch section in the C model manual

    https://www.2fiftycc.com/index.php?...-service-manual-section-5-clutch-english.373/

    Fibres and steel alternate ... but I cant see anywhere , including the C model parts list, how many there actually is of each
     
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  2. DanoHosko

    DanoHosko Well-Known Member Premium Member

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    Beauty thanks bud :D
    Clutch was working ok before but yeah not convinced that it should have the two metal plates next to each other...
    Leave it as is or remove a metal plate?
     
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    Last edited: May 14, 2020
  3. Andych

    Andych Moderator Staff Member Premium Member Contributing Member Dirty Wheel Club

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    There is freight coming from pretty much everywhere but is limited by and large to essential supplies because of limited flights and cost... Our company's air freight costs have risen 500% (we are not airfreighting at present unless the customer pays through the nose).
    I know that Zenmarket have advised DHL are back up for freight so it should open up a little more soon.. the issue is a lot of smaller freight used to come in on Passenger flights.. and they are few and far right now.

    As for the clutch... have you tried some localised heat (with a heat gun) and an Impact wrench?They generally are done up reasonably tight but also have a lock washer on there (well all the ones I have seen) so it really shouldnt be too hard to get it undone and off.
     
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  4. Andych

    Andych Moderator Staff Member Premium Member Contributing Member Dirty Wheel Club

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    Impex shows 2 part numbers for metal plates and it is quite common to have 2 metal plates next to each other... generally in the middle of the stack.
    This was for a 1989 ZXR250RR
    ZXR250.jpeg
     
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  5. DanoHosko

    DanoHosko Well-Known Member Premium Member

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    Ahh thats that's good news then!
    I'll try and get contact with megazip see if they can confirm dhl will deliver or not

    Not got a heat gun at the moment, might have to borrow one

    I will say the washer behind the nut doesn't look central which makes me think its somehow the wrong size washer...
     
  6. DanoHosko

    DanoHosko Well-Known Member Premium Member

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    Beauty I'll go with that then bud ;)
     
  7. Andych

    Andych Moderator Staff Member Premium Member Contributing Member Dirty Wheel Club

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    I know that Impex are not taking orders right now so not sure about Megazip... you could try Boats as well.. the shaft was only US$40 at Impex..
     
  8. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    @DanoHosko and I have been discussing the clutch plates in conversation .... and the plot thickens

    Heres what he has currently

    6 of each (starting from outside)
    F-M-F-M-F-M-F-M-F-M-M-F


    To me thats wrong ... too many for starters
    Going by this thread and heres a pic of a genuine kit it should be F S F S F S F S F

    https://2fiftycc.com/index.php?threads/zxr250-400-clutch-kits.9562/#post-105060

    c clutch.JPG

    Theres also this from the A model manual ( no C model clutch manual chapter)

    Untitled.png
     
  9. Andych

    Andych Moderator Staff Member Premium Member Contributing Member Dirty Wheel Club

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    Very confusing...
     
  10. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    The manual doesn't state this, but you start with a fibre, then a thick steel plate, fibre, thin steel plate, fibre.

    Basically you alternate the steel plates between thick and thin between each fibre plate until you fit the last fibre plate.

    The fibre plates must be fitted in the direction pictured, otherwise there will be too much oil drawn into the clutch.
     
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  11. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    Assuming the A and C clutches are the same ... theres 4 steels ... 2 thick and 2 thin going by the vague manual ... Id say the Impex listing should be 2 and 2 'required'

    Interesting the last fibre is offset

    offset.png

    Edit: @Linkin ... been waiting for u to take your lunch break and chime in :D
     
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  12. Andych

    Andych Moderator Staff Member Premium Member Contributing Member Dirty Wheel Club

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    That would make sense... Megazip dont show quantities required so makes it a bit difficult.
     
  13. Frankster

    Frankster NFI Staff Member Premium Member Ride and Events Crew

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    Nah, it's easy when you know how. Your post with the impex image is actually correct.

    There are 5 friction and 8 metal plates in a standard ZXR clutch pack. You can change the composition and layout for more grip, but you must keep the overall pack width the same. I did this on the Lucky Strike drag bike, but eventually went back to the standard layout which is F-MM-F-MM-F-MM-F-MM-F

    You use one thick metal plate and one thin metal plate in unison. Doesn't matter which way you lay them out (IMO), but I do try and make sure the best metal face is up against the friction plates. There are tiny indents in the metal plates (for oil I guess), so whichever side looks best I place against the friction plate. The only real must do is to make sure the direction is correct on the friction plates when packing the clutch. The last friction plate is offset as shown in the image the Chief used in his post a couple before this one. The metal plates will blue from heat, but as long as they are true and not warped, you'll be fine.

    Clutch plates.jpeg
     
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  14. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    Well this makes some sense now .... but only if you have done it before :commando:

    plates.png

    Just having the number and position as F-MM-F-MM-F-MM-F-MM-F in the manual would make it so much easier for first timers

    The FZR schematic shows every plate in the correct position and order

    And so what @DanoHosko has is incorrect ... too many fibres and not enough (and/or wrong) steels .... someones put in the wrong kit possibly
     
  15. Frankster

    Frankster NFI Staff Member Premium Member Ride and Events Crew

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    Wouldn't be the first time. Check the thickness of each metal plate and make sure you put a thick with a thin one between each friction plate.
     
  16. DanoHosko

    DanoHosko Well-Known Member Premium Member

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    Sorry missed notifications on this one
    Thanks guys for the investigations :cool:

    I'll measure up what i have tonight, pretty confident all my plates were the same thickness

    Wonder if theres any info on what the overall pack width should be? And what the thickness of the different plates is..?

    With the final friction plate being offset i had the same on my Aprillia back in the day :idk:
     
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  17. jack_lee

    jack_lee Member

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    Hi! Is there anyone succeeded in changing the shaft? I've accidentally broke the thread.
     
  18. DanoHosko

    DanoHosko Well-Known Member Premium Member

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    Hey mate, I did change the shaft on mine successfully, was a fairly simple job if i remember rightly, just had to replace the seals too

    From memory, you have to pull the clutch basket off then you can remove the circlip on the shaft and pull it out

    I'll see if i can dig out some photos etc
     
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  19. jack_lee

    jack_lee Member

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    Yeah... A photo win thousand words. I appreciated it.
     
  20. jack_lee

    jack_lee Member

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    I would like to ask. Does the gear drop out when we remove the circlip? Or it will just hang there?

    Screenshot_20230112_221826_com.ebay.mobile.jpg
     

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