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Power Block clutch CSI/Repair
http://www.pilotodyssey.com/PO/viewtopic.php?f=71&t=4538		 Page 1 of 2
Author:  hoser [ Wed Aug 27, 2008 7:26 pm ]
Post subject:  Power Block clutch CSI/Repair
Here is the clutch off Mudbogger's CO Pilot he had dropped off at my house viewtopic.php?t=4460 someone did not install the clutch properly so naturally its damaged, they did not line up the D washer with the D on the end of the shaft, many people mess this up for some reason..

This clutch like new it has no wear on it other than the damaged cover and shaft.

The plan is to cut off the bad part and make a spacer to replace the material removed then modify the cap to make it stronger, better.

Below is a picture how the end of the shaft should look, the pic is of my new spare Power Bloc.

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Author:  hoser [ Wed Aug 27, 2008 7:27 pm ]
Post subject: 
Here is Mudbogger's damaged shaft.

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Author:  hoser [ Wed Aug 27, 2008 7:27 pm ]
Post subject: 
I took a junk FL250 crank shaft and cut off the clutch end so I could use it for a holding tool in the lathe.

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Author:  hoser [ Wed Aug 27, 2008 7:28 pm ]
Post subject: 
It get put on the clutch and the clutch holding bolt torqued just like you would install the clutch on the Engine, then the holding bolt is removed so the end of the clutch can be machined.

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Author:  hoser [ Wed Aug 27, 2008 7:29 pm ]
Post subject: 
In the lathe.

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Author:  hoser [ Wed Aug 27, 2008 7:30 pm ]
Post subject: 
Skim cut with parting tool to check the hardness, not hard at all but tougher than mild steel.

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Author:  hoser [ Wed Aug 27, 2008 7:31 pm ]
Post subject: 
Damaged area completely removed .

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Author:  hoser [ Wed Aug 27, 2008 7:35 pm ]
Post subject: 
Ok now the damaged area is removed its shorter, here it is compared to a new clutch.

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Author:  hoser [ Wed Aug 27, 2008 7:36 pm ]
Post subject: 
See the difference in the ends of the shafts now

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Author:  hoser [ Wed Aug 27, 2008 7:40 pm ]
Post subject: 
Here is the shaft lengths.

Stock is 4.653 long

Mudbogger's after being machined is 4.481

The difference is .172 so I need a spacer or harden washer about .172 thick..

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Author:  hoser [ Wed Aug 27, 2008 7:41 pm ]
Post subject: 
Lets move on to the cap, the D washer is just riveted to the cap so you can grind down the rivets and take a punch and drive them out to remove.

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Author:  hoser [ Wed Aug 27, 2008 7:42 pm ]
Post subject: 
Inside the cap with the D washer removed

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Author:  hoser [ Wed Aug 27, 2008 7:45 pm ]
Post subject: 
I think I need to make a washer that is .172 thick out of some cold roll? steel as big as the D washer that was removed so I can tack weld it to the cover, I would like to make a harden washer larger than the one that comes with the clutch so the head of the bolt don't dig into the washer.

I will measure up and draw something later then add to this post.
Author:  shoubadaba [ Wed Aug 27, 2008 8:18 pm ]
Post subject: 
that's sweet mine is the exact same slight wear. Can I send mine to you also for the repair? I talked to hrd today and the clutch I picked up is for a pilot so I guess it will be going on imy pilot instead of the fl350.
Author:  hoser [ Wed Aug 27, 2008 8:22 pm ]
Post subject: 
shoubadaba wrote:
that's sweet mine is the exact same slight wear. Can I send mine to you also for the repair? I talked to hrd today and the clutch I picked up is for a pilot so I guess it will be going on imy pilot instead of the fl350.


You have pics of the damage? Please post...
Author:  mudbogger [ Wed Aug 27, 2008 9:06 pm ]
Post subject: 
will heating/welding on the outside cover cause any issues Hoser?Seeing as the pucks slide into the slots, the heat wont effect the placement of them?
Author:  hoser [ Wed Aug 27, 2008 9:25 pm ]
Post subject: 
Mudbogger wrote:
will heating/welding on the outside cover cause any issues Hoser?Seeing as the pucks slide into the slots, the heat wont effect the placement of them?


shouldn't, I will look into using pop rivets in the old holes first, I have a bunch of 3/16 stainless steel rivets.
Author:  shoubadaba [ Thu Aug 28, 2008 6:51 pm ]
Post subject: 
I cant post any pics because I need to get a new digital camera sorry.
Author:  hoser [ Thu Aug 28, 2008 7:36 pm ]
Post subject: 
Made a new washer for the outside, tack welded it to the cover so it cant spin, didnt use and filler material so it wont affect balance, tacks would be easy to remove if the washer ever needed changed.

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Author:  hoser [ Thu Aug 28, 2008 7:37 pm ]
Post subject: 
Masked it off for paint, don't want paint between the washer and the head of the bolt so it cant slip.

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Author:  hoser [ Thu Aug 28, 2008 7:38 pm ]
Post subject: 
Splashed a little RED paint on the cover so it wont rust.

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Author:  hoser [ Thu Aug 28, 2008 7:57 pm ]
Post subject: 
Made a new washer 1.00 OD x .072 thick to go under the cover.

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Author:  hoser [ Thu Aug 28, 2008 7:57 pm ]
Post subject: 
The washer makes up the difference in length I cut off.

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Author:  hoser [ Thu Aug 28, 2008 7:59 pm ]
Post subject: 
See the factory washer how the underside of the head of the bolt wears, as part of the mod I cut the bottom of the bolt so its smooth.

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Author:  hoser [ Thu Aug 28, 2008 8:05 pm ]
Post subject: 
The top bolt is the HONDA stock clutch bolt, the bottom is the one supplied by Power Bloc, anybody see a reason why I should not use the HONDA stock bolt the head is much LARGER (better) than the Power Bloc this will eliminate the damage to the outer washer problem.

Mudbogger you have any stock Pilot clutch bolts?



Service Honda says 90128-SG0-000 BOLT, FLG (12X142) and they are only $8.75 each... wonder if we can still get them wonder if we can get bolts with a large head like that else where 12mm x 142 mm actually the bolt could be 1/2" longer...


Number 12 in pic below

Image

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