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in order to remove my clutch plates i DO NOT need to remove the clutch release lever (which is the bit attached to the end of the clutch cable), in order to remove the front of the clutch cover...is this correct?

i have read about people not being able to put that lever back correctly, and the manual says only remove it if absolutely necessary...but i just wanted to be 100%.

so all i need to do is remove the 6-8 bolts that hold the front of the clutch cover on and i should be presented with the clutch basket, i dont need to do anything else...

Correct, disconnect cable, twist the lever towards the back of the bike and then you'll feel it disconnect and it should move down, if you remove it all the way you will probably have to replace the oil seal, undo the 10 bolts (I think its 10?) then take the casing off. You will then see 4 Allen key bolts (5mm) undo all 4 this will remove the springs, be careful not to lose the washers. Then remove the pressure plate, and you will see all the plates, just remove all of them and when you replace remember to alternate the last friction plate, easy peasy, lemon squeezy.

ah, so you do have to do something with the release lever, how far would you say it drops down by?

im picking up a car tomorrow from near cradleys, so if they have the parts in store ill pick them up on the way and do it all over this weekend

Just twist it towards the back of the bike, or clockwise if your looking straight at it from underneath, and just pull it down 5mm or so, it will drop out completely if your not careful, want me to take a quick video and put it on YouTube?

ross46 wrote:Just twist it towards the back of the bike, or clockwise if your looking straight at it from underneath, and just pull it down 5mm or so, it will drop out completely if your not careful, want me to take a quick video and put it on YouTube?

if you could, that would be excellent, if you make it a decent vid that shows how to safely drop the vid, im sure a mod will make it a sticky, highlight the bolts where the camchain tensioner is that you should NOT undo for peoples reference and it will be a good info source

Ok I've done a video but im waiting for it to load to YouTube, the quality isn't perfect but its ok, says not to touch cam chain tensioner bolts, where the bolts are to undo the casing, how to slacken clutch cable and to disengage the clutch rod and to alternate all the plates, so should be up in about an hour, enjoy!

star!

http://m.youtube.com/index?&desktop_uri ... vHMpe4g37Y

I'm a star do I get a gold sticker!!

the quality isn't perfect but everything I think is included, constructive criticism welcome, hope it helps

ross46 wrote:http://m.youtube.com/index?&desktop_uri ... vHMpe4g37Y

I'm a star do I get a gold sticker!!

the quality isn't perfect but everything I think is included, constructive criticism welcome, hope it helps

http://www.youtube.com/watch?v=xvHMpe4g37Y

thats the non-mobile version

Why thankyou, had to do it on here as the computer has been ed, everything covered ok?

spot on mate!

picking up the car, and the bike parts tomorrow (good old cradley is 5 miles from where im getting the car and everything is in stock), then ill swing by halfrauds for oil and a filter (actually, ill but the filter at cradleys too) and we will be all sorted! i dont even know what state the clutch is in, but ive abused it for 8000 miles and it might be an original for all i know, so it has potentially done 44000 miles...ill report back with the friction plate thicknesses once its all out

clutch not in bad nick actually, friction plates all ~2.85mm, steels looking ok, ive replaced the springs and the cable...the cable was particularly bad, all feels much better now

Yeah, mine was slipping bad, but my steels are blues, but I got a few more miles by using a new cable and heavy duty ebc springs, one of the other things to check is that the fingers on the clutch basket aren't grooved as that can cause slipping

Excellent video cheers for that Ross, looks the same as doing the clutch on a dt50 so should be a nice easy job
Many thanks

No problem, wish it wasn't raining at the time though!