PW80 clutch replacement

replaced the clutch pads on my daughters PW80

[@nardpuppy]

I had similar issue to this bike. Lurched forward when in gear and shifted hard into second. I replaced the clutch plates and it fixed those issues. It looks like the plates swell over time beyond spec and causes engagement earlier then you want. Easy job. Make sure you use a #3 Phillips to remove the clutch cover otherwise you’ll have stripped screws.

[@michaelmclennan6144]

My plates measured 3.3mm after reading comments I ground them down to 3mm with the bench grinder and now the autoclutch works perfect... before it was locked in gear clutch fully engaging never disengaging... so the secret is there has to be movement in the plates.. I also took out 2 ball bearings so it won't enact off moderately high idle as I'm.led to believe so yeah seems to work good ..

[@chelsashreve4111]

i see you didn’t soak the new clutches fibers in oil. how long did this clutch pack last?

[@MonsterMike816]

It lasted the entire time I had the bike with no issues, keep in mind I didn’t ride the bike for a couple of days so they could soak a little bit. Also, people change clutch packs all the time at the track to make the next race and nothing bad ever happens, even the pros do this.

[@stevesherry9776]

You want to soak the new clutch plates in oil first

[@lauraharbeson8964]

You suppose to soak them pads or you will be replacing them soon

[@alphapackoffroad]

I was thinking the same thing

[@stefanlee9753]

Hi, i am having a problem when riding the pw80 bike and you reving it, it sounds like the bike is riding yano when your clutch is riding on other bikes/with a clutch this is doing the same thing, have to build the revs up so the bike dosnt sound like its riding if you get me ?? Any ideas mate ??? Yano the saying " your clutch is riding " well the bikes doing it anyone help ???

[@nardpuppy]

Did replacing the clutch plates fix the shifting issue?

[@larrymiinch9670]

PW 80 does not have a cam chain or cam chain tensioner. You can remove the whole clutch by removing the center nut and simply pulling it off. You can rebuild or buy a complete new clutch from Ebay for less than $90.

[@jdchevy2285]

Nice video! I'm glad to see this is a simple repair. I'm getting ready to do this on a 2004 PW80. The compression springs for the clutch basket are about $20 total for the full set. I don't see many aftermarket options for those, but still available from OEM distributors. Did the replacement of the friction plates solve the shifting issue?

[@nardpuppy]

JD Chevy did it fix your shifting issue?

[@jdchevy2285]

@@nardpuppy Never had a shifting issue on my bike. I went ahead and swapped out the friction plates and springs using the same method in this video. The plates were not completely worn, but definitely no within spec of the factory manual. It still ran and shifted with no issues afterward.

[@Chloe_Deshon4L]

My pw80 got left in the rain while I was away out of state n water got in the casing from the gas tank n I can’t kick it over even after I took the top end off n found rust and water

[@Theferg1]

Same thing happened to my son pw80 and I took the motor apart I found a guy online to rebuild the crankshaft put a new rod on it and balanced it and all of that good stuff about new crank seals crank bearings gaskets Yama Bon for the crank half’s has the cylinder hone out 2over put Wiseco piston in it jeted the Carb I’m SO GLAD I DID!! He can ride willies on it now before it wouldn’t even get out of its own way!! It’s not hard to do you cannot buy crankshaft for those bikes anymore and don’t buy that cheap stuff that you see on the Internet it won’t last you just get on there and search for a guy by the name of (MR CRANKSHAFT) email him or call him he will get right back to you send him your crankshaft and he will do the work for you and send it back to you within a week cleaned up and rebuilt and still have the original crankshaft which is very important. Take your cylinder to the machine shop have them clean it up or whatever you want to have done to it by a new piston by your parts put it back together you’ll definitely be happy with it will last for a long time now hope this helps.

[@hashtag_moto_]

If I were to pull the whole basket off would it reveal the balls? Looking to do the ball mod on mine but I think the clutch plates are fine

[@MonsterMike816]

Rural Riding No, you need to pull the plates out! Not hard at all.

[@hashtag_moto_]

MyKHiller Hobbies thanks will do and I’ll just do the clutch plates while I’m there. How’d not soaking them turn out just in case I screw up and forget like you did. And thanks for the reply the video really helps me out!!

[@MonsterMike816]

Rural Riding No problem. Not soaking the plates is okay and it ran fine, however I did let it set and rotated the engine a couple days because we have other bikes to ride. We have changed clutches and thousands other people at the track and right back on with no problems, soaking is a perfect world and I suggest doing so but it’s not the end all be all. Good luck!

[@jenaby5803]

How much for a pw motor block please answer

[@MonsterMike816]

I have no idea, google or eBay it! I only paid like 300 for this bike so worst case scenario just look for a complete used bike

[@darinwilliams9184]

Can you remove the basket in whole?

[@MonsterMike816]

Darin Williams I'm pretty sure you can, there is a special tool for it or just use an impact to remove the nut in the center.

[@darinwilliams9184]

MyKHiller Hobbies thanks for the reply man. Kickstart is stuck but not locked so I thought I'd pull it and check the spring and gearing but it looks solid so im kinda scratching my head now.

[@MonsterMike816]

Darin Williams Check your timing chain tensioner, could be broke/bad/ or just need adjustment

[@JM-yx1lm]

Wow! How come you didnt soak the clutch frictions in oil first? In my opinion this is the wrong way to install.

[@MonsterMike816]

J M I agree you should soak the disks, you do it how you see fit. If you have ever raced then you might know at the track you replace the clutch all dry and straight to a race, never a problem and literally thousands of people do it this way. Ive never had an issue not soaking the pads first but that being said I do agree if you have time then soak them. This bike sat in the oil being rotated over for a week before it was even started so no issue at all. Everyone knows what’s going on with their own bikes so do what you need to do for it to be right for you!

[@johnboy1042]

Wen you done that what oil did you use 10 30w ?

[@MonsterMike816]

I used Yamalube 4, it is a 10W30.

[@johnboy1042]

@@MonsterMike816 thanks brother love from South London UK 🇬🇧

[@PaulsMom]

tha nks for video

[@bigwillystyle6448]

Hey got a starter question. Had to replace the kick starter and when I installed it the spring was very easy to clip on. I couldn't rotate it. When I start it it kicks but I have to rotate it myself back to the kick position

[@MonsterMike816]

It’s not lined up correctly inside the case, I haven’t had this bike for quite some time but I do remember that spring being a pain to get it in the correct position.

[@rickyhowell6817]

have you had the crank seals leak ? Do you know how hard it is to change them ?

[@MonsterMike816]

Ricky Howell I only owned the bike for a couple of months

[@Skidootoronto]

Ricky Howell it’s a pain in the ass to change the crank seals

[@Theferg1]

@Ricky Howell hey I know this is a late reply but I just saw this and I’m actually finishing up a complete rebuild on my sons 2006 PW80 the Crank seals are not hard. 1st take you a couple drywall screws and screw them into the seal not too far because you don’t want to hit the bearing then take a pair of vise grips or A pair of pliers and pull the old seal out. Then take a rag clean that area out and then take you a little bit of oil and coat around the crank and around the area where the seal goes here comes the trick that is to take a heat gun and heat the area up and while you’re doing that put the seal in a baggie with some dry ice!! You can get it from most any grocery store for three or four dollars it’s not expensive drop a little bit in the toilet or a glass of water the kids have a blast looking at it lol. Anya Seo will go in there damn near perfect if it does not go in all the way take your socket that is a little bit bigger than the inner ring on the seal once you’re looking at it you’ll see what I’m talking about and put that on there evenly and take your hammer and tap it on in!! It sounds like a job but it’s really not if you have to do crank bearings it’s the same way take a heat gun and heat the case up or you could put it in the oven if you have it apart that’s what I did and I have your new bearings in the dry ice in a baggie sandwich by the dry ice and as soon as you pull that bad boy out of the oven grab your crank bearing and it’ll drop right in place if it does not it’s OK you must did not have it hot enough put it back in the oven put the bearing back in the dry ice and heat it up again do you have an up to about 400 but put the cases in the oven before the oven gets hot there’s videos on it also if you look it up but that’s about how it goes and it’s real simple rebuilding the whole engine is real simple hope that helps someone!!!

[@ayaazjokhoe1387]

Pot the bals one space one

[@bxballa17]

What does that do?