
Pic-01
I have the bike laid on its side and have already removed the brake return spring. I use an impact gun to remove the cover bolts for speed reasons. The impact is for removing bolts only. Never use an impact for tightening any bolt on a delicate assembly like a clutch.

Pic-02
I remove the cover and place it in a tub with the bolts still in the holes. Since the bolt lengths differ from one another it is easier to reinstall the cover this way. The wrong bolt in the wrong hole can cause problems.

Pic-03
Again the impact comes out for removing the bolts from the pressure plate. Break each bolt loose and work your way around the bolt circle backing each bolt a little at a time. Don't remove each bolt completely or your pressure plate will cock sideways.

Pic-04
I use two 90 degree o-ring picks to reach down into the engine cases to grab the bottom plate and pull the whole stack out at once. It is a tight fit in there and using just your fingers usually ends up with blood. When the stack comes out in on piece like this it is easy to see the clutch plate order making the installation of the new plates easy.

Pic-05
Inspect the tangs on the clutch basket and the grooves on the inner hub for chatter marks. Light marks or grooves can be worked out with some emery paper on the basket. Any serious grooving means your plates will hang up and clutch performance will suffer. At that point you will need to replace the basket and inner hub.

Pic-06
You need to soak your new plates in clean motor oil before you install them. Use either a zip-lock bag or small Tupperware container to do this. Never put dry clutch plates in your bike. Dry plate will be ruined within minutes of use.

Pic-07
I start here with a freshly oiled fibre plate. Always have a look at your manual to make sure there is no special plates that have to go into the stack in a certain sequence. There is some odds combinations out there so make sure you have your order right!

Pic-08
Here is the first aluminum plate going in, then it will be a fibre, then aluminum etc. Until you finish with a fibre. With the aluminum or steel plates you will be able to feel a smooth edge and a sharp edge on the plate if you run your finger on the inner teeth. The sharp edge is created by the stamping process when they make the plates. Always make sure the sharp edge of the plate faces out towards you while installing the plate.

Pic-09
Inspect the pressure plate area where it rides on the fibre clutch plate. You can see some of the coating on this pressure plate is coming off. While nothing to serious it is something I will keep an eye on. If it gets much worse I will replace it. Clean any small ridges or transitions up with emery paper and wash with contact cleaner.

Pic-10
Using a T-handle I have started snugging the bolts down a little at a time in a star pattern. Basically you want to tighten the pressure plate down evenly so work it slowly. Tighten two turns and skip a bolt and repeat till the bolts are snug.

Pic-11
Get out a torque wrench and tighten the bolts to the spec in your manual. This is critical to proper clutch operation and plate life. Again torque the bolts in a star pattern so the plate is being tightened down evenly.

Pic-12
Check the gasket or o-ring on the clutch cover and replace if necessary Once the bolts have be evenly tightened you are ready to ride. Be sure you have clean oil in your engine and be sure to warm the clutch up well before you start abusing it.






