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INSTALLING A NEW CLUTCH

Installing a New Clutch

1.       Check all plates for flatness. Make sure the stack height is correct. Make sure the springs are the correct height and tension. Check service manual for these specifications.

2.       Pre-oil or soak the clutch plates (if wet type) in clean oil for about 5-10 minutes. Soak in the same oil going into the bike.

3.       Make sure the plates slide into the basket and over the hub freely with no binding. If the basket is notched or fatigued where the clutch tabs go, it is best to repair or replace the basket or hub so further problems don't occur. Make sure the clutch basket and/or hub dampening unit (if bike is equipped with one) is working properly so it doesn't create a chattering problem. Have your local dealer check it for you if you're not sure.

4.       Install the plates as per your owner's manual and check specifications. Replacement plates should go in the same way the old plates came out. Determine the O.A.T. (Overall Thickness). This is the combined thickness of all steels and frictions. Basically, this must not vary to any great extent from stock. You can use more or fewer components, but stack height must remain the same. Too thin a stack may result in slippage, while too thick a stack may cause drag. Some bikes have a judder spring, clutch boss rings, rubber O-rings, or a wave washer. When using Barnett products, you may or may not have to disregard these items. Check your clutch kit for instructions pertaining to this.

5.       Install the pressure plate, making sure that if your bike has a dot, arrow, or notch marked by the factory, they must line up for proper function of the pressure plate. These marks are on some models but not all of them. The marks are on the clutch hub and pressure plate. Also, be sure to check the pressure plate along with the backing plate (the two surfaces the friction plates touch) for wear and flatness. An uneven or worn surface can ruin your clutch.

6.       When installing the clutch springs (coil or diaphragm), visually inspect your springs for uniformity and tension. Check your service manual for spring length. Weak springs can cause slipping - especially at high R.P.M. Check to make sure your release mechanisms, whether they are lever, cam, push-rod, or hydraulic types, are properly working and do not show excessive wear. This can cause improper clutch adjustment, dragging, hard to find neutral, or hard shifting problems.

7.       Lube cable, lever pivot and actuator, as needed. Make sure the cable is routed correctly and has no sharp bends or binding when turning the front forks from side to side. Remember, smooth operation will allow you to properly adjust the clutch.

8.       Be sure to torque all bolts to factory service manual specs. Use a new gasket when putting the clutch cover on, making sure to clean the gasket surface first.

9.       We recommend following the manufacturer's specifications on oil viscosities and quantity. Remember, the heavier the oil viscosity, the more the clutch plates tend to stick or drag when cold.