Clutch replacement made easy

From: Brad Glustoff
Date: Tue, 5 Aug 1997 15:55:20 -0700
Subject: Clutch Replacement (easy)

Clutch replacement made easy. You don't need any special tools or impact
wrenches.

1. remove the exhaust system
2. drain the oil
3. remove the oil line from the side cover
4. remove the side cover (you might have to GENTLY tap it, to get it
loose)
5. remove the 4 bolts holding the pressure plate in place
6. un-stake the 27mm nut, holding the clutch center
7. with the springs in place, put a washer under each of the 4 bolts, and
GENTLY
snug them back down. (the washers now take the place of the pressure
plate)
8. put a rag in the gears between the clutch basket and the crankshaft
gear
9. loosen the 27mm nut
10. remove the 4 bolts, washers and springs
11. remove the 27mm nut
12. remove the clutch center
13. remove the clutch plates
14. reinstall the new clutch plates on the clutch center
15. hold everything in place and reinstall the 4 bolts, springs and washers
16. slide the clutch center into place
17. put the rag in the gears and torque the 27mm nut to 94 lbs
18. stake the nut in place
19. remove the 4 bolts and washers and install the pressure plate
20. torque the 4 bolts to 9 lbs
21. remove the rag
22. install the side cover, torque the bolts to 7.2 lbs in a criss cross
pattern.
23. install the oil line and torque to 12. lbs
24. install the exhaust system
25. put in about 2 1/5 quarts of oil (if you replaced the filter)
26. adjust the clutch cable
27 have fun doing wheelies with your new clutch

# 7. the washer trick, was supplied by Monique von Buttlar with this
you have no need for a clutch holding tool or an impact wrench.

if you have any questions, fell free to e-mail me at

brad.glustoff@airtouch.com
brad glustoff
So. Cal. USA