• Hi everyone,

    As you all know, Coffee (Dean) passed away a couple of years ago. I am Dean's ex-wife's husband and happen to have spent my career in tech. Over the years, I occasionally helped Dean with various tech issues.

    When he passed, I worked with his kids to gather the necessary credentials to keep this site running. Since then (and for however long they worked with Coffee), Woodschick and Dirtdame have been maintaining the site and covering the costs. Without their hard work and financial support, CafeHusky would have been lost.

    Over the past couple of weeks, I’ve been working to migrate the site to a free cloud compute instance so that Woodschick and Dirtdame no longer have to fund it. At the same time, I’ve updated the site to a current version of XenForo (the discussion software it runs on). The previous version was outdated and no longer supported.

    Unfortunately, the new software version doesn’t support importing the old site’s styles, so for now, you’ll see the XenForo default style. This may change over time.

    Coffee didn’t document the work he did on the site, so I’ve been digging through the old setup to understand how everything was running. There may still be things I’ve missed. One known issue is that email functionality is not yet working on the new site, but I hope to resolve this over time.

    Thanks for your patience and support!

Help! Debris found in my engine - 610/630 clutch issues

04asphalt said:
found this today, waiting on Indy for parts.
where to get the rivets, Hall's soaks you for shipping?
Click to expand...

Don't place your Hall's order online, it will automatically add the default freight charge. Call them and order on the phone, if you're only buying the rivets I'm sure they will treat you right for shipping as they did me. I ordered 6 rivets (two sets) and my grand total with shipping was under $9. You might need to politely remind them how small and lightweight the rivets are and that they can ship 1st Class Mail.

_
 
Yossarian and I have ordered up the parts to replace our spring cup washers (his 610, my 630) with the beefier ones from Indy Unlimited over on ADVRider.

Now I just need to find a place that will help us with the rivets and compressing the springs to get them back in there. I don't have a vise, or a way to put those big old rivets in.
 
SilverBullet said:
Don't place your Hall's order online, it will automatically add the default freight charge. Call them and order on the phone, if you're only buying the rivets I'm sure they will treat you right for shipping as they did me. I ordered 6 rivets (two sets) and my grand total with shipping was under $9. You might need to politely remind them how small and lightweight the rivets are and that they can ship 1st Class Mail.

_
Click to expand...
thanks for the tip:applause:
Parts from Indy have gone uo to $70 but still better than stockers
 
Is there anyone who can tell me exsact dimensions of those washers? I would like to make them by myself. They seem to be just turned or are they tempered? I still dont get it, what force makes them thiner :S
 
_luke_ said:
Is there anyone who can tell me exsact dimensions of those washers? I would like to make them by myself. They seem to be just turned or are they tempered? I still dont get it, what force makes them thiner :S
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I'd ask Indy Unlimited over on ADV for dimensions if you want to make your own.

Indy's washers are tempered tool steel and thicker than OEM. The OEM washers are thinner, and I don't believe they're tempered.

You'd save yourself a lot of hassle if you just bought them from him. He'll ship worldwide. I suppose if you factor in shipping it'll be pretty spendy, though.
 
_luke_ said:
Is there anyone who can tell me exsact dimensions of those washers? I would like to make them by myself. They seem to be just turned or are they tempered? I still dont get it, what force makes them thiner :S
Click to expand...

Machine turned and heat treated by Indy. Thicker than the stock Husky part and cheaper also. Can't imagine it being worth your time and expense to make them yourself. If you emailed Indy he would probably give you the specs. Clearly he is not making a fortune selling these, more of a service and covering costs plus beer money.

_
 
SilverBullet said:
Machine turned and heat treated by Indy. Thicker than the stock Husky part and cheaper also. Can't imagine it being worth your time and expense to make them yourself. If you emailed Indy he would probably give you the specs. Clearly he is not making a fortune selling these, more of a service and covering costs plus beer money.

_
Click to expand...
_luke_ is over in Europe, though. Once you factor in shipping, it is probably quite expensive to buy them from Indy. If he has the equipment and materials to make his own, more power to him.

Myself, I don't mind supporting a guy that has gone through the trouble of coming up with something useful.
 
jtemple said:
Yossarian and I have ordered up the parts to replace our spring cup washers (his 610, my 630) with the beefier ones from Indy Unlimited over on ADVRider.

Now I just need to find a place that will help us with the rivets and compressing the springs to get them back in there. I don't have a vise, or a way to put those big old rivets in.
Click to expand...

That's my problem.

I'd be happy to send my whole basket to someone and pay them to do the swap.
 
drilled out the rivets, scared up the clutch a bit and elongated one of the holes slightly.:banghead: think it will be an issue?:confused:
still waiting on the new rivets.
 
04asphalt said:
drilled out the rivets, scared up the clutch a bit and elongated one of the holes slightly.:banghead: think it will be an issue?:confused:
still waiting on the new rivets.
Click to expand...

Elongated isn't good, but luckily it's only one hole. Two holes elongated could easily allow movement. Post a photo so we can see how much. Put a drill bit in the elongated hole that is exactly the correct diameter so we can get a better gage of how much.

_
 
mekanik said:
Wouldn't a Rekluse solve all the clutch issues? Noob question- let the attack begin;)
Click to expand...

Nope. Rekluse only supplies you with a new clutch hub. Cup spring washers are on the drive plate. Rivets hold the clutch housing (basket) to the drive plate. Cannot remove the cup spring washers without first detaching the clutch basket. But if you've been thinking about installing a Rekluse now would be the time to do it when reassembling.

_
 
SilverBullet said:
Elongated isn't good, but luckily it's only one hole. Two holes elongated could easily allow movement. Post a photo so we can see how much. Put a drill bit in the elongated hole that is exactly the correct diameter so we can get a better gage of how much.

_
Click to expand...
will post some pics, thanks

Halls order didn't come in, are the rivets special to husky or could they be sourced at machine shop?
 
here's a couple pics, STILL waiting on halls
 

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I know it doesn't help you any now, but the instructions I got from Indy Unlimited were to use a grinder to grind the heads off of the rivets, then drive them out with a punch. That way, you aren't running a drill through those holes.

Here are Indy's instructions:

Here are the basic steps:
  • Drain oil from bike
  • Remove right side engine case
  • Remove 6 bolts from center clutch hubs and springs.
  • Remove the inner clutch hub.
  • Remove all fiber and metal clutch plates and keep them in the exact order and rotation ( tooth for tooth match)
  • Bend the washer tab back on the center of the inner hub of the clutch
  • Use an impact to loosen the main hub nut you may need a clutch tool or leather strap to keep the outer basket from turning.
  • Remove the outer clutch and before removing check for radial slop on shaft the brass bushing usually needs replacing every 10,000 miles.in the center of the outer basket.
  • Grind the 3 rivets holding the gear and clutch hub on the gear side. Use a disc grinder and grind the heads of the rivets off flush with the gear surface. It is OK to scratch the gear face up a little just keep it flush.
  • now press out the rivets from the gear side by supporting the inner part of the clutch with a large socket that the rivet can go into. This prevents cracking the clutch hub. Do all 3 rivets.
  • The gear now separates from the clutch hub and you can tap out the 6 springs and 12 cup washers from the gear.
  • Reuse the old springs and my 12 new cup washers
  • Place the spring and cup washer on each end in a vice with only a 1/3 bite on the cup washers
  • Now compress until the square hole in the gear slides over the spring and cup washers. Release the vice slowly and the spring will stay engaged about half way into the gear opening. Now tap the spring in the center gently and center the spring and cup washers in the gear.
  • Repeat for all other springs
  • Now match the clutch basket and gear with 3 new rivets.
  • Take the unit to a bike shop to rivet without damaging your clutch basket.
  • If you do it your self remember it takes 2 people to rivet this with an air hammer and anvil. You must support the head inside the basket and rivet the back side with the air hammer. I takes about an hour since the rivets are very good quality.
  • Reassemble by reversing all of the steps above.
  • No need for any gaskets since the husky uses reusable steel coated gaskets that are high quality.
Click to expand...
 
after I buggered the first one I used a dremel to grind down the last two:thumbsup:
I dropped all the plates in the oil pan while taking them off :banghead::banghead::censored: what should I do now that they are all shuffled up?:eek:

STILL waiting on halls for the rivets:thumbsdown:
 
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