Replacing A Worn Clutch Step By Step (pdf).

[james0133]

Here's an updated version of a step by step guide I put together for replacing your clutch.

Enjoy

[Fasduc]

Nice write up and thanks for the pics. I wish more people would document their work with photos....they're worth a thousand words.

[veteq]

thank you for documenting the process. I will give it a try when the time comes.

[amullo]

This thread is found WORTHY!

Moved to the Hall of Wisdom.

//amullo

[JCPakBikes]

Well Done!!

[snlsmith]

Handy Hint: Not sure if applies to the dry clutch also, but on my wet clutch: Don't pull the clutch lever while the plates are off!* Not a huge thing, but when I went to put the cover plate on, I could not get it to sit all the way on. Turns out the pin had pushed out a little when i pulled the lever, so I just had to push a little on the plate to seat it back down.

*After taking the clutch apart, I realized I had the wrong pack. I set the cover back on and went to change the front sprocket. It was in neutral, so I went to put it in gear ad pulled the lever. As soon as I did it, I remembered "Oh yeah, I've got no clutch".

[dutchthrone]

Stupid question, but should I drain the oil first? It says to use locktite on the basket bolts, to prevent oil from leaking in from the crankcase. I just don't want to make a bigger mess than I already have, if oil were to come through the bolt holes.

Great write-up by the way!

[james0133]

You do not need to drain the oil. It is only under engine running conditions, with high crank case pressure that oil can leak out.

Mind you I wouldn't go tipping the bike on its side with the basket off and it is better not to leave the basket bolts off for a long time as you could get condensation in your engine, especially in winter.

[Corse1]

Oh yeah thanks. Pulled the seal without checking orientation. You instruction has saved me :-)

[Ducatierv]

Great write up!