HOW TO: Clutch Replacement (PICTURE INTENSE) 56K, Don''t even try.
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HOW TO: Clutch Replacement (PICTURE INTENSE) 56K, Don''... - 4/4/2007 5:07:06 PM
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malbojah
Posts: 380
Joined: 3/10/2006
From: Cape Cod, MA
Status: offline
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This is a holder spot for a post I''m making for a step by step on a clutch replacement for a 93-96 CBR1000F. I will also do one on replacing the plastic speedo nut that wears out over time, but not until next week.
This is a step by step display of how to replace your clutch on a 93-96 CBR1000F. This is going to show as much as possible for those who don''''t know what they are doing. For those that do, skip down just a little.
Stuff you need:
1) Tools for removing you RIGHT SIDE fairing
2) 8mm socket for removing bolts on clutch cover
3) Big blade screwdriver for removing the clutch cover
4) New fiber plates and if your cautious, maybe a couple of steel plates
5) New clutch cover gasket
6) Long reach magnet
7) TORQUE WRENCH (unless you think your gifted and can tell when something is only at 9ft lbs and not 13 ft lbs.)
Stuff that you don''t necessarily need but helps:
1) New clutch springs
2) New clutch spring bolts
Ok, now that that''s out of the way, here we go.
First Step: Drain your oil (makes life easy)
Second Step: Soak New Clutch Fiber plates in clean oil
Some people will say just to throw them in dry, but I tend to sometimes follow the manufacturer''s directions.
Third Step: Remove RIGHT SIDE FARING
From this...
To This:
Fourth Step: Remove bolts on clutch cover and remove cover...
WARNING: When trying to remove the clutch cover, DO NOT use the dip stick hole as a leverage point. The threads cannot handle the weight and will quickly collapse (ask me how I know). There are two tabs on the cover that can be used as prying points. I highlighted them in red in the above picture. I used a large blade screwdriver and pried the cover off using the tab by the dipstick, using the rear brake pedal as a pivot point.
After the cover pops off comes...
STEP FIVE: Clean the old gasket off the cluch cover and the case
So that it looks like this:
This step will probably take the longest to accomplish, especially, if the gasket is embedded on there good. Mine took almost an hour to completely clean, with the cover taking the longest. The case came off relatively easily.
Now that the cleaning is done..
STEP SIX: Unbolt the clutch hub
See those 5 bolts? They''re 10mm heads. I unbolted them 1/2 turn at a time in a circular movement so as to not stress and one part of the clutch hub. After about 6 times around I could safely remove them one at a time.
STEP SEVEN: Remove the clutch hub and begin to remove the fiber and steel plates
This is where the magnet comes in. The first couple of fiber plates will be easy as you can just grab the tabs and remove them. But as you work further in, it will become more difficult as there is a band that covers up the tabs (that dark silver ring on the outer clutch hub). I used a pair of blade screw drivers and slowly lifter the fiber plates out.
NOTE: There is a small spring with the last fiber plate that fits snuggly around the inner hub. If it comes out and you don''t notice which way it was facing, the wider edge faces out.
Step EIGHT: Examine the steel plates
If all your doing is replacing the fiber plates, check out the steel plates to make sure they are not warped or burnt.
As you can see, the plate on the right is severely discolored (from doing full speed launches from my old job :D) I ended up replaced 4 of the steel plates.
Step Nine: Install the new clutch (sorry, no pictures)
Take the fiber plates and lay them out. One of them is different than the rest. That one goes in first, then a steel plate, then a fiber. Rinse, repeat until you are out of steel plates and the last plate is a fiber plate.
Put the clutch inner cover on:
You are going to need to push the cover back on. Because there was no pressure on the clutch pushrod, the clutch fluid has pushed it out just enough so that the clutch bolts won''t thread on. Once that''s done, install the springs and clutch bolts. I hand tighten them at first (to avoid cross-threading), then tighten them to 9FT LBS. I tighten them in a star pattern (tighten one, then the one across, so on and so forth).
Step Ten: Install clutch cover and new gasket
What I did was put all the bolts in the clutch cover, then put the new gasket on the bolts. This made it easier when putting it on the engine (kept the gasket in place) Tighten bolts (no torque spec listed) the two wire clips go on the upper and lower bolts on the right side. Refill with oil (if drained), reinstall plastics and GO RIDE.
Things I found out after:
1) if you do this job with the bike on the side stand, you do not need to drain the oil.
2) there was more here, but a forum crash took out everything after step 6
3) I''m so glad I have a lift now so I don''''''''t have to do this kind of job on the floor
4) Ignore the extra apostrophes, the forum software is still effing everything up
< Message edited by malbojah -- 9/23/2008 7:25:37 PM >
_____________________________
I''ll fix the HOW TO''s once the forums are fixed
HOW TO: Valve Adjustment
HOW TO: Plastic Speedo Gear Replacement
HOW TO: Clutch Replacement (PICTURE INTENSE)
http://www.cbrforum.com/m_266491/mpage_1/key_/tm.htm#266491
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RE: HOW TO: Clutch Replacement - 4/4/2007 5:17:07 PM
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idodirt
Posts: 729
Joined: 8/14/2006
From: South Florida, USA
Status: offline
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With pictures and everything.... ?
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RE: HOW TO: Clutch Replacement - 4/4/2007 5:47:19 PM
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malbojah
Posts: 380
Joined: 3/10/2006
From: Cape Cod, MA
Status: offline
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quote:
ORIGINAL: idodirt
With pictures and everything.... ?
Yup, just found out I need some steel plates so i won't be able to finish it until Friday.
_____________________________
I''ll fix the HOW TO''s once the forums are fixed
HOW TO: Valve Adjustment
HOW TO: Plastic Speedo Gear Replacement
HOW TO: Clutch Replacement (PICTURE INTENSE)
http://www.cbrforum.com/m_266491/mpage_1/key_/tm.htm#266491
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RE: HOW TO: Clutch Replacement - 4/4/2007 8:58:50 PM
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WhiteHawk
Posts: 92
Joined: 12/22/2006
From: Michigan, USA
Status: offline
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Cool, now I won't be so afraid to slip it!
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RE: HOW TO: Clutch Replacement - 4/4/2007 9:32:12 PM
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XXCBRChrisXX
Posts: 148
Joined: 2/20/2007
Status: offline
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i had a few that were a little ugly and some steel wool seemed to help but they were only half screwed up. not like the black on there.
i like my new clutch
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RE: HOW TO: Clutch Replacement - 4/4/2007 9:41:14 PM
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OldFatGuy
Posts: 1642
Joined: 12/15/2005
From: Missouri, good ol' USA
Status: offline
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Very nice!
Looking forward to the rest. Good job! 
_____________________________
'06 1000RR Red/Black
'04 1800 Goldwing Candy Black Cherry
'05 Shadow VLX Deluxe Pearl White (Wife's)
Ride Safe, Ride Often, Ride Far
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RE: HOW TO: Clutch Replacement (PICTURE INTENSE) 56K, D... - 4/4/2007 11:46:57 PM
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idodirt
Posts: 729
Joined: 8/14/2006
From: South Florida, USA
Status: offline
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Great job !! With this tutorial, this job goes from a mystery and not sure if you'd want to tackle, to it looks like a cake job. Maybe that's exaggerating, but it's well within the realm of the do-it youselfer. Can't wait for Chapter II.
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RE: HOW TO: Clutch Replacement (PICTURE INTENSE) 56K, D... - 4/5/2007 2:54:39 PM
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Motor_Fan
Posts: 44
Joined: 9/28/2006
From: Lisbon Portugal
Status: offline
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Great ideea. From now on I will always take pictures of what services I'm doing on the bike, and if we all do that (the ones that take care of the bikes themselves) we wount need to go to a shop anymore. As I am a harley mechanick, I know how some people pay a lot of money to the shops to take care of simple stuff, stuff that they can do themselves easyly....
Keep up the good work
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RE: HOW TO: Clutch Replacement (PICTURE INTENSE) 56K, D... - 4/7/2007 2:06:12 PM
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malbojah
Posts: 380
Joined: 3/10/2006
From: Cape Cod, MA
Status: offline
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Sorry about the lack of an update. I was 'volunteered' to work yesterday. However, I did get to the dealer today, so the clutch as well as the speedo nut are in. Tooks some more pictures and hope to have an update after I get out of work tonight.
_____________________________
I''ll fix the HOW TO''s once the forums are fixed
HOW TO: Valve Adjustment
HOW TO: Plastic Speedo Gear Replacement
HOW TO: Clutch Replacement (PICTURE INTENSE)
http://www.cbrforum.com/m_266491/mpage_1/key_/tm.htm#266491
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RE: HOW TO: Clutch Replacement (PICTURE INTENSE) 56K, D... - 4/8/2007 6:50:57 AM
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Noe
Posts: 321
Joined: 6/3/2006
From: Bramming, Denmark, Scandinavia
Status: offline
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This is just awesome! If all of you skilled "do it you self" guy's took pictures like this, we could all become skilled at it.
Would someone please make a post on how to replace CC and CCT ;-) Kinda the biggest issue on the Cane
_____________________________
Remeber this:
"4 wheels move the body,2 WHEELS MOVE THE SOUL!!!"
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RE: HOW TO: Clutch Replacement (PICTURE INTENSE) 56K, D... - 4/9/2007 11:25:13 PM
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malbojah
Posts: 380
Joined: 3/10/2006
From: Cape Cod, MA
Status: offline
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Updated the list. Maybe I'll start on the speedo gear that keeps on falling apart.
_____________________________
I''ll fix the HOW TO''s once the forums are fixed
HOW TO: Valve Adjustment
HOW TO: Plastic Speedo Gear Replacement
HOW TO: Clutch Replacement (PICTURE INTENSE)
http://www.cbrforum.com/m_266491/mpage_1/key_/tm.htm#266491
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RE: HOW TO: Clutch Replacement (PICTURE INTENSE) 56K, D... - 4/9/2007 11:44:31 PM
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collector
Posts: 469
Joined: 9/7/2006
From: Norwich UK
Status: offline
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Great job on the pics and discription. That takes the hassels of trying to understand the manual.
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THE LITTLE VOICE IN THE BACK OF MY HEAD IS GONNA GET ME HURT
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RE: HOW TO: Clutch Replacement (PICTURE INTENSE) 56K, D... - 4/10/2007 4:50:41 AM
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MarkR
Posts: 854
Joined: 8/20/2005
From: Gold Coast, Australia
Status: online
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So what did the job cost you and what would it have cost you if you took it to a shop
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RE: HOW TO: Clutch Replacement (PICTURE INTENSE) 56K, D... - 4/10/2007 7:36:00 AM
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malbojah
Posts: 380
Joined: 3/10/2006
From: Cape Cod, MA
Status: offline
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quote:
ORIGINAL: MarkR
So what did the job cost you and what would it have cost you if you took it to a shop
$60 for the fiber plates, $44.5 for the steel plates (you may not need them), $10 for the springs, and $8 for the gasket. So $122 with the steel plates or $80 without. If everything is setup just right, I could probably do the whole job in 45 minutes. Most shops would charge at least 1 hour, so add another $75
_____________________________
I''ll fix the HOW TO''s once the forums are fixed
HOW TO: Valve Adjustment
HOW TO: Plastic Speedo Gear Replacement
HOW TO: Clutch Replacement (PICTURE INTENSE)
http://www.cbrforum.com/m_266491/mpage_1/key_/tm.htm#266491
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RE: HOW TO: Clutch Replacement (PICTURE INTENSE) 56K, D... - 4/10/2007 10:30:24 AM
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cdrewferd
Posts: 162
Joined: 6/4/2006
From: Colorado, USA
Status: offline
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Any more updates? Also how do you know when your clutch needs work? My 91 CBR1000F has around 47,000 miles on it.
_____________________________
Drew
1991 CBR1000F
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