Replacing Clutch Adjustment Bolt

[Rickshaw]

Has anyone replaced a clutch adjustment bolt? Mine stripped when tightening well under spec torq stetting. I suspect cross threaded at factory. New parts on order, looking for tips from someone who has already worked through it? Thanks in advance!

 

[dmonkey]

For pulling the right side crankcase cover you will be dropping the pegs out of the way, I also detached the rear brake linkage to get that pedal out of the way. One way of detaching that linkage is a small cotter pin at the clevis, if you do it that way consider you might need to replace the cotter pin - can find most sizes at a hardware store if you don't want to order the Honda part. You may want to order a replacement right crankcase cover gasket for if the old one tears. The parts at the other side of that bolt will want to fall out with gravity when the cover is removed. You can suspend the bike sideways with straps or just gently lay it down on its side if you don't want the parts to fall out of place, it will make the reassembly much easier. Then for reassembly you can apply some grease to stick those parts in place so they don't easily fall out of place when putting the cover back on.

https://hondatrail125.com/index.php?threads/tips-and-tricks-for-closing-right-side-of-crankcase.541/

Sounds like something that shouldn't have happened. If you have a convenient and competent dealership service department you could ask them the chances of getting the work done under warranty if the bike still has coverage.

 

[DJ427]

Sounds like a warranty issue you should not have to fix yourself. And it sounds like Honda has a quality control problem at the jungle hut where the trails are made

 

[oldskool]

Sounds like a warranty issue you should not have to fix yourself. And it sounds like Honda has a quality control problem at the jungle hut where the trails are made

^^^^^^^^this.

 

[Rickshaw]

For pulling the right side crankcase cover you will be dropping the pegs out of the way, I also detached the rear brake linkage to get that pedal out of the way. One way of detaching that linkage is a small cotter pin at the clevis, if you do it that way consider you might need to replace the cotter pin - can find most sizes at a hardware store if you don't want to order the Honda part. You may want to order a replacement right crankcase cover gasket for if the old one tears. The parts at the other side of that bolt will want to fall out with gravity when the cover is removed. You can suspend the bike sideways with straps or just gently lay it down on its side if you don't want the parts to fall out of place, it will make the reassembly much easier. Then for reassembly you can apply some grease to stick those parts in place so they don't easily fall out of place when putting the cover back on.

https://hondatrail125.com/index.php?threads/tips-and-tricks-for-closing-right-side-of-crankcase.541/

Sounds like something that shouldn't have happened. If you have a convenient and competent dealership service department you could ask them the chances of getting the work done under warranty if the bike still has coverage.

For pulling the right side crankcase cover you will be dropping the pegs out of the way, I also detached the rear brake linkage to get that pedal out of the way. One way of detaching that linkage is a small cotter pin at the clevis, if you do it that way consider you might need to replace the cotter pin - can find most sizes at a hardware store if you don't want to order the Honda part. You may want to order a replacement right crankcase cover gasket for if the old one tears. The parts at the other side of that bolt will want to fall out with gravity when the cover is removed. You can suspend the bike sideways with straps or just gently lay it down on its side if you don't want the parts to fall out of place, it will make the reassembly much easier. Then for reassembly you can apply some grease to stick those parts in place so they don't easily fall out of place when putting the cover back on.

https://hondatrail125.com/index.php?threads/tips-and-tricks-for-closing-right-side-of-crankcase.541/

Sounds like something that shouldn't have happened. If you have a convenient and competent dealership service department you could ask them the chances of getting the work done under warranty if the bike still has

 

[Rickshaw]

For pulling the right side crankcase cover you will be dropping the pegs out of the way, I also detached the rear brake linkage to get that pedal out of the way. One way of detaching that linkage is a small cotter pin at the clevis, if you do it that way consider you might need to replace the cotter pin - can find most sizes at a hardware store if you don't want to order the Honda part. You may want to order a replacement right crankcase cover gasket for if the old one tears. The parts at the other side of that bolt will want to fall out with gravity when the cover is removed. You can suspend the bike sideways with straps or just gently lay it down on its side if you don't want the parts to fall out of place, it will make the reassembly much easier. Then for reassembly you can apply some grease to stick those parts in place so they don't easily fall out of place when putting the cover back on.

https://hondatrail125.com/index.php?threads/tips-and-tricks-for-closing-right-side-of-crankcase.541/

Sounds like something that shouldn't have happened. If you have a convenient and competent dealership service department you could ask them the chances of getting the work done under warranty if the bike still has coverage.

Thank you for the detailed help. Parts will be in Thursday. Hopefully I will get it fixed the following weekend.

 

[dmonkey]

Here's a good video from @x29Saab that details pulling the cover, in case you would like something more detailed than the parts diagram for a reference:

 

[Rickshaw]

Brother, thank you so much! Parts due in Thursday. Going camping Friday. Quick change out is the hope. This is the wifes bike. She will be stoked of it is running for our weekend camping.

 

[Backwoods]

Here's a good video from @x29Saab that details pulling the cover, in case you would like something more detailed than the parts diagram for a reference:

That was a good video, it would make the job doable for someone with even limited wrench experience. Many thanks to the mechanic and camera crew that make these instructional videos and post them here.

 

[Rickshaw]

Just got the parts in, installed and test rode. Super simple with your help. $20 in parts and didn’t need to wait on dealer. Thanks dmonkey and others who pitched in great help. Back on the road.