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 How to repair/replace a burned clutch!

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Don T

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PostSubject: How to repair/replace a burned clutch!   Fri Jul 13, 2012 6:47 am

Last month during a week long enduro/offroad trip in Rumania the clutch on my WR250R died.
The bike had at that time 4500km on the clock - all of it hardcore offroad.

I've never before burned a clutch on any of my bikes so this was the first time I was going to repair/replace one - it turn out to be a piece of cake.

To do the job I needed the following parts:
6 clutch plates (part number 3XJ-16324-01)
7 friction plates (part number 3XJ- 16321-00)
1 clutch cover gasket (part number 3D7-15453-10)

Step 1:
Put the friction plates in a small bucket covered in the same engine oil as used on the bike to let them absorb some oil - let them soak for some hours.


Step 2:
Drain the engine oil from the bike.

Step 3:
Remove the brake pedal to make some room (not absolutely necessary).


Step 4:
Remove the clutch cover protector:


Step 5:
Remove the clutch cover:


Step 6:
Remove the pressure plate by loosening the 5 spring bolts:


The parts now removed:


Step 7:
Remove the old friction and clutch plates (easy - just pull them out)


Step 8:
Put in the new friction and clutch plates alternately starting and ending with a friction plate.
The clutch plates have an sharp and a dull edge - mount the plates with the sharp edge turning outward - I don't know exactly why that is, but it's what any seasoned mechanic I've spoken to recommends..?


Step 9:
Reinstall the pressure plate - tighten the spring bolts in a star pattern to 10 Nm.


Step 10:
Reinstalling the clutch cover (using the new gasket) and protector (all bolts tightened to 10Nm) and install the brake pedal.


Step 11:
Put new oil on the engine (I changede the oil filter when I was at it).


The entire operation (from step 2 to 11) can easily be carried out in less than half hour - without breaking a sweat

The tools neded to replace the clutch (the allen key was for the brake pedal only):


NB. The friction plates were all worn under spec - the clutch springs were as new.




Last edited by Don T on Fri Jul 13, 2012 2:44 pm; edited 6 times in total
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Delta_T

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PostSubject: Re: How to repair/replace a burned clutch!   Fri Jul 13, 2012 7:08 am

Nice write up. Thank you thumb
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motokid
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PostSubject: Re: How to repair/replace a burned clutch!   Fri Jul 13, 2012 7:23 am

Delta_T wrote:
Nice write up. Thank you thumb

Agreed. thumb bow


_________________
2008 WR250X
Gearing: 13t - 48t
Power Commander 5 / PC-V
Airbox Door Removed - Flapper glued - AIS removed
FmF Q4
Bridgestone Battlax BT-003rs
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Coop

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PostSubject: Re: How to repair/replace a burned clutch!   Fri Jul 13, 2012 7:39 am

Good job. Bike clutches are really easy. Many people worry because they assume it's a hard/complicated job. But really with the proper tools it's an easy job.
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chuckP




PostSubject: Re: How to repair/replace a burned clutch!   Fri Jul 13, 2012 2:25 pm

Awesome write up. Never knew it was that easy on a bike. thumb
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bracky72




PostSubject: Re: How to repair/replace a burned clutch!   Sat Jul 14, 2012 8:33 am

I am now confident to do my own if I ever need to. Thanks!!
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Fuzzy Wrench

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PostSubject: Re: How to repair/replace a burned clutch!   Sat Jul 14, 2012 9:23 pm

sweet....good write up, also check the fingers on the basket for notches where the clutch plates would "hang up"...
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saddletramp




PostSubject: Re: How to repair/replace a burned clutch!   Sun Jul 15, 2012 9:02 am

Thank you. Great step by step write-up and accompanying photos. Good job !
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Carbomb

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PostSubject: Re: How to repair/replace a burned clutch!   Sun Jul 15, 2012 5:01 pm

Did you need anything to hold the assembly from turning when loosening/tightening the spring bolts? On the WR250F, there is a special tool for holding everything in place. Thanks for the writeup!
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Don T

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PostSubject: Re: How to repair/replace a burned clutch!   Tue Jul 17, 2012 1:36 am

You don't need anything to hold the assembly from turning - only tools needed is the ones mentioned above.
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Kalani Prince

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PostSubject: Re: How to repair/replace a burned clutch!   Thu Jan 31, 2013 10:53 pm

Great tutorial!

PS: 10nm (newton meters) is equal to 7.5ft lbs

much love!


Last edited by Kalani Prince on Thu Jan 31, 2013 10:54 pm; edited 1 time in total (Reason for editing : Freudian clutch slip)
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Don T

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PostSubject: Thanks for the positiv feedback.   Fri Feb 01, 2013 4:26 am

As mentioned in the first post, the clutch died after 4.500km.
Maybe that doesn't sound like much, but compared to what I have exposed it to, it's very reasonable.

As I do a lot of hill climbing on small trails in the mountains, the clutch have been feathered A LOT - especially when the bike was new, before I modified it with, FMF Q4, FMF programmer, K&N airfilter, airbox mod and gearing (now running 13/50).
Besides that I rode with too little clutch free play for a while - I was not aware of how much the clutch expands during hard use.

I'm sure that the new clutch will last much longer than the first one.
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dmmcd

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PostSubject: Re: How to repair/replace a burned clutch!   Fri Feb 01, 2013 10:42 am

Very nice write up.

I am curious what type engine oil you use. I have heard that certain oils can contribute to clutch wear, especially standard automotive oils that are energy conserving and have 'friction modifiers' in them.
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Don T

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PostSubject: Re: How to repair/replace a burned clutch!   Fri Feb 01, 2013 12:51 pm

Since first service after break-in I've been using motorcycle specific semi synthetic engine oil.

Depending of the riding I do, I change oil (and filter) for every 4-800 km.
For the first few oil changes I used Motul 5100 10W40, and for the last two I've used Motorex Topspeed 4T 10W40 - both high quality products.

Bottom line - choice of oil had nothing to do with the short live span of the clutch, it was only due to abuse and maladjustment.
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motokid
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PostSubject: Re: How to repair/replace a burned clutch!   Tue Feb 19, 2013 6:29 am

Don T wrote:


Depending of the riding I do, I change oil (and filter) for every 4-800 km.


eeek eeek eeek

_________________
2008 WR250X
Gearing: 13t - 48t
Power Commander 5 / PC-V
Airbox Door Removed - Flapper glued - AIS removed
FmF Q4
Bridgestone Battlax BT-003rs
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Don T

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PostSubject: Re: How to repair/replace a burned clutch!   Tue Feb 19, 2013 11:59 am

motokid wrote:
Don T wrote:


Depending of the riding I do, I change oil (and filter) for every 4-800 km.


eeek eeek eeek

Bear in mind that I don't use my WRR as a dual sport but as a thoroughbred enduro bike.
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