"You really can do it yourself guide"

 

Estimated Time Required - TBD

 

 

Step 1: Remove the front right fairing by removing the mounting bolts.  Once you have access to the engine, remove the distriubtor cover  held in with 3 bolts.

 

Step 2:  Remove all the bolts that hold the crankcase cover on.  I think there are 12.  Also remove the rotor by putting a wrench on the outer nut, and loosten the bigger nut.

 

 

Step 3:  Also, remove the 2 bolts hidden in the distributor.  Do not try to remove this by the screws, it is extremely hard to do and not nescessary.  The only hard part is the lower screw.

 

 

Step 4:  Gently loosten the case by prying the case off using the tabs on both side.  Note:  Oil will come out, so make sure to put an oil pan under the bike.

 

Step 5:  Once the case is off, locate the clutch,  It is the big "wheel" to the left. 

 

 

Step 6:  Remove the 6 bolts holding the clutch pack in place.  They must be pulled out all the way.

 

Step 7:  Remove the clutch

 

Inside the clutch basket, I found my problem - Peices of my clutch plates all over the engine.

 

 

The process of putting the clutch back together is the oposite of the removal.  Make sure the plates go back in the same way thet came out, alternating between black plate and friction plate.  Place the basket cover back on and tighten until it is snug (the exact torque is not important, as long as all the bolts are equally as tight).  I did not use a tourque wrench, so I am really not sure to be honest.

 

Replace all the covers, and adjust the clutch as usual.

 

That is all.  I saved $325 by doing this simple project myself.  The hardest part was adjusting the clutch properly. 

 

Note:  Make sure all bolts are snug and check for tightness after one week of driving.  I lost the ignition side cover because I did not tighten it tight enough.  Driving home, I knew it was loose, but I guessed that it will hold for the next 10 minutes...but it did not.

 

Hope it helps...Carl