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Changing Clutch Plates - 2Wheel Tech
author // Beth Dolgner
photographer // Beth Dolgner
Changing Clutch Plates

Want to know a secret? Installing new clutch plates is actually pretty easy. Jeff Walker of Cooper Performance walked us through the process using nothing more than a chest of basic tools. So as long as you have a screwdriver, some sockets and a torque wrench you can install a new clutch at home by simply following these instructions. 

Prior to starting, make sure to soak the new fiber clutch plates in oil for half an hour before installing them. Otherwise, they’ll burn when you start your bike, and you’ll have to reinstall new ones — again. 

If you are using a bike stand drain the oil before starting. If you opt to lean your bike over, the oil can stay in, just be prepared for possible spillage.
STEP 1
Changing Clutch Plates
Remove the clutch cover. You will typically need an 8mm socket to remove the bolts.
STEP 2
Changing Clutch Plates
Remove the dowel pins and existing gasket.
STEP 3
Changing Clutch Plates
Remove the clutch spring bolts. Typically the bolts require a 10mm socket.
STEP 4
Changing Clutch Plates
Pull the clutch springs out of the pressure plate.
STEP 5
Changing Clutch Plates
Pull off the pressure plate, revealing the clutch plates behind it.
STEP 6
Changing Clutch Plates
Stuff a rag or paper towels below the clutch plates to prevent any small parts from falling into the engine case.
STEP 7
Changing Clutch Plates
Pull out all of the clutch springs. A screwdriver works to pry them out, but dental picks are even easier. Just hook the ends of the picks around the plates and pull toward you.
STEP 8
Changing Clutch Plates
Remove the clutch plate washer and wave washer seat, which are the two thin circles of metal behind the clutch plates.
STEP 9
Changing Clutch Plates
Now that everything is out, the new pieces are ready to go in. The thin, flat circular piece is the wave washer seat, and it should be installed first. Slide the clutch plate washer in next, with the concave side out (the outer edge of the ring should stick out further than the inner edge).
STEP 10
Changing Clutch Plates
The first clutch plate to be installed is the fiber plate with the smallest width. The teeth on the fiber plates line up with the outer grooves on the clutch housing.
STEP 11
Changing Clutch Plates
Next, slide on a steel plate, lining up the teeth with the grooves on the inside of the clutch housing. On one side of the steel plates, the teeth have rounded edges. On the other, the teeth have straight edges. The side with the straight-edged teeth should be facing out.
STEP 12
Changing Clutch Plates
Continue inserting the plates, alternating fiber and steel plates until you have just one fiber plate remaining.
STEP 13
Changing Clutch Plates
The final fiber clutch plate should be inserted so that the teeth line up with the alternate grooves on the housing, opposite of the other plates.
STEP 14
Changing Clutch Plates
The clutch pusher, bearings and washer that sit in the center of the housing, may have come loose or completely out when you pulled off the pressure plate.
STEP 15
Changing Clutch Plates
If they need to be reinstalled, the clutch pusher should be inserted first, followed by the bearings, then the washer.
STEP 16
Changing Clutch Plates
Place the pressure plate back over the clutch plates.
STEP 17
Changing Clutch Plates
Replace each spring into the pressure plate, and insert the spring bolts. You can tighten the bolts by hand to get the thread started.
STEP 18
Changing Clutch Plates
A torque wrench is highly recommended for tightening the bolts. Check your user manual for proper torque value, but it will typically be about seven ft-lbs of pressure.
STEP 19
Changing Clutch Plates
Install a new gasket by placing it over the clutch housing and lining up the bolt holes. Replace the dowel pins that hold the gasket in place.
STEP 20
Changing Clutch Plates
Replace the clutch cover and bolts. The torque value for the clutch cover bolts is typically 7 ft-lbs. Check your user manual in case this number is different for your bike.
2WT recommmends proper training before working on your motorcycle. Procedures may vary for each bike. This article is considered a basic guide, use it at your own risk.


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