SAFETY FIRST: Protective gloves and eyewear are recommended at this point.
Clutch Removal
Place the motorcycle on a stand.
Drain the engine oil. See the Oil and Filter Change topic for more information.
Remove the rear brake master cylinder and pedal. See the Rear Brake Master Cylinder topic for more information.
Remove the water pump. See the Water Pump topic for more information.
Remove the bracket that holds the lower end of the clutch cable using an 8 mm wrench and remove the cable from the clutch release arm. Rotate the clutch release arm towards the rear of the motorcycle and pull out the release arm.
Remove the fifteen clutch cover bolts using an 8 mm wrench and pull off the clutch cover. If the cover is stuck, tap it gently using a rubber mallet. If the gasket tears, remove all traces of the old gasket from the engine case and the clutch cover. Inspect the clutch release lever oil seal and bearing. Replace the seal if the bearing is to be replaced.
Remove the oil seal with a seal pick.
Remove the release lever bearing with a suitable bearing puller.
Drive the new bearing into the clutch cover with a suitable bearing driver. The driver should have the same outside diameter as the new bearing. The markings on the bearing should face out.
Drive the new oil seal into place in the same manner. Lubricate the bearing with fresh engine oil and coat the lips of the oil seal in high temperature grease. Clean the oil strainer screen. See the Oil Strainer Screen topic for more information.
Loosen the five clutch spring bolts one turn at a time in a crisscross pattern until the spring pressure has been relieved.
Remove the five bolts and the clutch springs.
Pull off the clutch pressure plate.
Remove the clutch plates by pulling them out.
Caution: The edges of the clutch basket may be very sharp, be careful not to cut your fingers.
Remove the clutch push rod by pulling it out.
Use a clutch hub holding tool and loosen the clutch hub nut using a 30 mm wrench. Part number 08-0008.
Remove the clutch hub nut and discard it.
Remove the washer.
Pull the clutch hub off of the transmission shaft.
Remove the washer and the clutch basket.
Remove the clutch basket spacer and the thrust washer behind it.
Clutch Inspection
Clean all of the clutch components using aerosol brake cleaner and a lint free cloth.
Inspect the outer clutch basket for indentations in the fingers where the friction plate tabs fit. If they are not very deep, the fingers can be filed down, but if they are too deep the outer clutch basket must be replaced. Also check for other wear or damage.
Inspect the pressure plate, pressure plate bearing and clutch hub for wear or damage. Replace as necessary.
Measure the clutch spring free length using a caliper and compare your measurements with specification. If any clutch spring is not within specification, replace all of the clutch springs.
Clutch spring free length; no less than 31.7 mm or 1.25 inches
Measure the thickness of the friction plates using a caliper and compare your measurements with specification. If any of the friction plates are not within specification, replace all of the friction plates.
Clutch friction plate thickness: no less than 2.75 mm or .108 inches
Visually inspect the steel plates. If any of them have been turned blue by heat, replace all of the steel plates.
Clutch Assembly
Before installing new clutch plates, the friction plates should be coated in engine oil.
Place the thrust washer and the clutch basket spacer on the transmission shaft.
Slide the clutch basket onto the transmission shaft. Make sure the teeth on the back of the clutch basket mesh with the gear on the crankshaft.
Install the washer.
Slide the clutch hub onto the transmission shaft.
The washer has the word “outside” stamped into it. Install the washer with the wording facing out.
Hold the clutch with a clutch hub holding tool. Torque the clutch hub nut to specification using a 30 mm socket.
Clutch hub nut torque: 130 N-m or 98 ft-lb
Apply a thin film of grease on the clutch push rod and slide it into the transmission shaft.
Install the clutch plates (eight friction and seven steel plates), beginning with a friction plate, then a steel plate and alternating back and forth until all of the clutch plates are in place. Make sure the friction plates have been coated in engine oil.
Install the clutch pressure plate, making sure to align the notches in the pressure plate with the cutouts in the clutch hub.
Install the clutch springs and bolts. Tighten the bolts in a crisscross pattern so as to distribute the tension on the pressure plate evenly. Torque the bolts to specification.
Clutch spring bolt torque: 9.8 N-m or 7 ft-lb
Install a new gasket. Install the clutch cover and tighten the fifteen bolts securely using an 8 mm wrench.
Lubricate the bottom portion of the lifter lever shaft with molybdenum disulfide grease.
Insert the release lever shaft into the seal and bearing. Avoid damaging the oil seal.
Rotate the release arm forward to engage its shaft to the pusher piece.
Reattach the clutch cable and bolt the clutch cable bracket back into position using an 8 mm wrench. Adjust the clutch cable as necessary. See the Clutch Adjustment topic for more information.
Add engine oil. See the Engine Oil topic for more information. Start the engine and check for leaks.