The transmission is back in the bike and the clutch is adjusted. I adjusted the clutch for about 2mm play at the transmission, and 3mm play on the handlebar. I still need to refill the transmission with gear oil. You might notice that the rubber is missing from the foot peg and gear shift lever. I have new rubber for those.
The shift lever was disassembled, cleaned and greased with NLGI2. Same for the clutch arm. The clutch arm also received a new rubber boot.
The clutch piston was greased with general purpose grease (non moly), same as used for the throw-out bearing.
The job of removing the spline cup was easier than expected. When I dropped off the final drive at Hansen’s Motorcycle Shop I had a chance to chat with Craig Hansen about removing and installing the cup. To remove the cup, they use a chisel and just knock the heads off the rivets. I tried that, but couldn’t make it work. The chisel, hammer, or perhaps me, was just to wimpy.
What did work was to use an abrasive cutoff wheel in my Dremel tool to cut all around the edges of the rivets, but not quite all of the way through. Then I used a chisel to finish the job. Before driving the rivets through I used a grinding stone in the Dremel tool to make sure that the riviets were flush with the spline cup. That was done to ensure that the rivets were round and wouldn’t damage the wheel as I drove them out with a small punch.
In this picture you can just see the lip in the hub that keeps the spline cup centered (click to enlarge).
Here’s the before picture showing the rivets holding the spline cup. It was easy to cut most of the way around each rivet with the abrasive cutoff wheel. Since I was replacing the spline cup, I didn’t care what damage I might cause to it. Before deciding to do this with a Dremel tool I thought about grinding the heads off with a 4.5″ abrasive disk. However, I was worried about accidentally damaging the rim. The smaller Dremel tool was easy to control and the whole job took about 30 minutes, max.
Now the question is whether to use bolts or rivets when installing the new cup. Bolts I can do myself. Rivets I would have to have someone else do. Craig Hansen said that most of the problems they have seen occurred with bolts.
