Doppler clutch pulley

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There have been reports of problems with the Doppler clutch pulleys. Here are some recommended steps one should take before installing a clutch pulley for the first time. These recommendations are based on tips from Naz. Basically, the point of all of this is to get grease to your one way bearing and lock everything down solid so that it will withstand the stress of super high revs.

  • The clutch pulley

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  • First remove the three 10mm nuts.

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  • Then flip the clutch pulley over and remove the nut holding the bell on the pulley, I used a 1.25" socket which is very similar to a 32mm wrench.

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  • Once the bell is removed, you will need to remove the three external circlips holding the clutch shoes to the pulley.

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  • You should now be able to wiggle the shoes off the pulley by sliding them up the studs.

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  • Once the shoes are removed, you will need to remove the big circlip on the internal shaft, it will then slide right out.

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  • Next, remove the studs. They will be tight, I used some vise gip pliers. The pliers scored the studs a bit, so i cleaned them up after reinstalling them with a little 600 grit wet/dry so that sliding the clutch shoes back on would go smoothly.

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  • You will notice that the one way bearing has almost no grease.

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  • Now that the pulley is stripped completely, replace the studs and use some blue loctite to make sure they stay in place.

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  • Then, add some grease to your one way bearing so you don't destroy it on your first ride. There are replacement bearings, but they cost around twenty bucks.

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  • I noticed that my clutch pads were not glued on to well and were starting to peel away from the shoes in places.

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  • I used super glue and lined the edges of the pads on both sides and bound the pads in place with a couple rubber bands while it dried. the superglue seemed to whick in under the pads pretty well.

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  • Replace the internal shaft and install the big circlip, poor quality circlip pliers will make this a much bigger hassle.
  • replace the 10mm nuts and use some blue loctite.
  • Slide the clutch shoes back on and replace the three small circlips.
  • Replace the bell and tighten doen the 32mm nut, again using blue loctite.

and, you're done.

P.S. If you have trouble removing the 32mm nut or want a strong grip for torquing down when retightening, a piece of scrap chain wrapped around the sprocket works well. Put into a vice, you can hold onto the sprocket without bending any teeth.

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A few hits with a rubber mallet works well to loosen the nut initially.

ADDED 16 September 2012 by IET

clutch shoes drilled and tapped to accept variator weights to adjust engagement, holes drilled in the clutch bell to change weights without disassembling clutch pulley (from the [1] g2doppler blog)

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