SOAKING CLUTCH PLATES
TOOLS REQUIRED IN ADDITION TO NORMAL BIKE TOOL KIT.
Allen key and flat screwdriver for body panel removal
8mm & 10mm 1/4 inch drive set plus extension bar
Torque wrench to do 10Nm (unless you are good at feeling bolts!!)
tube clear silicone
(maybe a dab of loctite on the clutch spring bolts if you want to....)
Fresh engine oil and flat pan for plate soaking
GETTING TO THE PROBLEM
Park bike on a slope, sidestand down slope wheels up (just a little one is enough to stop oil coming out....)
In first gear, roll forward until it stops, else the clutch hub turns when undoing the spring bolts!)
RH Side plastic off
Unbolt bracket for idle adjust cable.
Undo bolts in clutch cover. Carefully remove, gently easing gasket off mating surface so it
Mark with Tipex pen or a tiny scratch orientation of pressure plate to clutch basket.....alternatively as it comes off note where the 3 raised dots go in
relation to the lockup mechanism at the back.....you'll see when you get in there!!
Undo clutch spring bolts and remove
Pull pressure plate off...careful not to loose the springs out the back as you stare in awe at the clutch mechanism!!
Careful of the washer. It might come off with the pressure plate, it might not....
Remove plates, both fibrous and metal (the back ones need hooking out gently!)
Check, note that the middle and outer ones are thicker than the rest?? remember that!!
Soak the fibrous plates in bike engine oil over night.
Reinstall same order as removed
Remember plate sequence?? NO?? well, here it is!!
Remember to put the last plate (a fibrous one) with its tang in the different slot on the clutch basket to the rest!!!!!(the shallow slot)
Put washer back in, line up pressure plate. Springs in, bolts in, hand tighten the bolts, Progressively tighten spring bolts DIAGONALLY to correct torque (10Nm, 7.0 lb-ft)
##** careful here, some have had these spring bolts shear. just do them up gently and to the correct torque and all should be okay!**##
Wipe clutch cover mounting gasket face dry of oil
Smear a little gasket compound around the gasket to make sure, offer up, finger tight bolts, torque down bolts (10NM, 7.0 lb-ft)
Bolt idle cable bracket back on
Move bike to a more normal parking position, Neutral, start engine, check for no leaks
Put fairing back on
Wipe of grubby paw prints