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.