Question about 2008 kawasaki Ninja 250R

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Can't get clutch cover plate off.

Need to replace broken oil level window but can't remove the clutch cover plate from right side of engine. All bolts removed, cover will not lift; feels like cover plate is attached to something from inside. How do I free cover for removal?

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  • Master
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Seems like its sticking to the gasket, use a bit of force with a screwdriver with some tape on it to protect finish and pry it off

Posted on Jul 01, 2009

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How to replace clutch push rod seal on 07 hayabusa


Hi remove the slave cylinder on the left hand cover then withdraw the rod. If its broken on that side drain the engine oil and remove the clutch cover. Then the clutch pressure plate then you will have access to the rod. Regards Jim...

May 19, 2015 | Motorcycles

Tip

2004 Hyundai Tiburon Clutch.


First you need to remove the Transaxle.

Manual Transaxle System REMOVAL

1. Remove the engine cover.
2. Remove the battery terminal.
3. Remove the air duct.
4. Remove the battery tray.
5. Remove the air cleaner.
(1) Upper
(2) Lower
6. Remove the back-up lamp switch.
7. After removing the CKP sensor, O2 sensor and oil pressure switch wiring bracket, separate the connectors.
8. Remove the brake fluid leveling sensor connector.
9. Remove the speedometer driven gear connector.
10. Remove the clutch release cylinder mounting bolt.
11. Remove the cotter pin of the shift cable (transaxle side).
12. Remove the cotter pin of the select cable. (transaxle side)
13. Remove the clip of the shift cable (transaxle side).
14. Remove the clip of the select cable (transaxle side).
15. Separate the steering column shaft joint.
16. Separate the power steering oil pump hose.
Be careful not to leak after separating.
17. Separate the hose after removing the clip of the power steering return hose.
18. Remove the upper connecting transaxle bolt.
19. Separate the start motor.
20. Install the engine support fixture.
21. After removing the tire, remove the caliper.
22. Remove the transaxle side cover.
23. Remove the transaxle side under cover.
24. Separate the tie rod end.
25. Remove the wheel speed sensor and the knuckle mounting bolt.
26. Drain the oil.
27. Remove the transaxle mounting bracket.
(1) Insulator bolt
(2) Body side mounting bolt (Upper)
(3) Body side mounting bolt (Side)
(4) Transaxle side mounting bolt.
28. Remove the front roll stopper.
(1) Insulator bolt
(2) Stopper bolt (Upper)
(3) Stopper bolt (Lower)
29. Remove the rear roll stopper.
(1) Insulator bolt
(2) Stopper bolt
30. Remove the drive shaft.
31. Remove the front muffler.
32. Remove the sub frame mounting bolt.
33. Install the transaxle jack.
34. Remove the transaxle lower mounting bolt to the engine.
35. Remove the transaxle assembly.

INSTALLATION
Installation is the reverse of the removal.

Then inspect and replace the clutch place and pressure plate.

INSTALLATION
1. Apply multipurpose grease to the release bearing contact surfaces and the release cylinder contact surface of the clutch release fork assembly.
When installing the clutch, apply grease to each part, but be careful not to apply excessive grease. It can cause clutch slippage and judder.
2. Apply multipurpose grease into the groove of the release bearing.
3. Apply multipurpose grease to the clutch release lever fulcrum contact surface of the clutch release fork assembly.
4. Clean the surfaces of the flywheel and pressure plate thoroughly with fine sandpaper or crocus cloth, and make certain that all oil or grease has been removed.
5. Apply a small amount of multipurpose grease to the clutch disc splines and input shaft splines.
Do not apply more grease than necessary. Too much grease could cause clutch slip or judder.
6. Using the special tool, install the clutch disc to the flywheel. When installing the clutch disc, be sure that the surface having the manufactures stamp is towards the pressure plate side.
7. Install the the clutch cover assembly onto the flywheel and install the six (6) bolts through the clutch cover into the flywheel.
8. Tighten the bolts by one or two turns at a time, in succession, to avoid bending the cover flange.
If a special tool is not available, tighten the bolt temporarily and then torque to specification in diagonal torquing sequence indicated below.
TIGHTENING TORQUE
Single mass flywheel:
15~22 N·m (150~220 kg·cm, 11~16 lb·ft)
Dual mass flywheel:
20~27 N·m (200~270 kg·cm, 14~19 lb·ft)
9. Remove the special tool.
10. Install the transaxle. (Refer to GROUP - Manual Transaxle Assembly)
11. Adjust the clutch pedal free-play. (See CH-6)
INSPECTION
1. Check the diaphragm spring end for wear and uneven height.
Replace if wear is evident or height difference exceeds the limit.
2. Check the pressure plate surface for wear, cracks and color change.
3. Check the rivets for looseness and replace the clutch cover assembly if necessary.
CLUTCH DISC
1. Check the clutch facing for loose rivets, uneven contact, deterioration due to seizure, adhesion of oil, or grease, and replace the clutch disc if defective.
2. Measure the rivet sink and replace the clutch disc if it is out of specification
3. Check for torsion spring play and damage and if defective, replace the clutch disc.
4. Clean the splines on the input shaft and install the clutch disc.
If the disc does not slide smoothly or if play is excessive, replace the clutch disc and/or the input shaft.
CLUTCH RELEASE BEARING
The release bearing is packed with grease. Do not use cleaning solvent or oil.
1. Check the bearing for seizure, damage or abnormal noise. Also check the diaphragm spring contacting points for wear.
2. Replace the bearing if the release fork contacting points are worn abnormally.
INSTALLATION
Installation is the reverse of the removal.
Then remove pressure plate and Clutch plate.

1. Insert the special tool (that came with your clutch kit) in the clutch disc to prevent the disc from falling.
2. Loosen the bolts that attach the clutch cover to the flywheel in a star pattern.
3. Loosen the bolts in succession, one or two turns at a time, to avoid bending the cover flange.

on Jan 13, 2010 | Hyundai Tiburon Cars & Trucks

1 Answer

How do i get the clutch out of a kawasaki vulcan 800 2003 model with out taking off motor


You dont have to remove the complete engine to replace the clutch !
All you do is remove the clutch cover with about 10 bolts securing it , might have to remove the foot peg and brake lever also !
Once cover is off then you will see the clutch assy , remove the end cover with about 6 bolts and then slide out the clutch plates KEEPING THEM IN ORDER !
Put your new clutch plates in a bowl of engine oil for an hour to soak , then check each metal plate for wear unless you are replacing them as well ! If you find they are a blue colour then lightly clean them with emery cloth ( abraisive paper for metal ) wipe clean and place new fiber coated plates in place of old worn ones sliding them back in order they came out ! Ive not got any torque settings but you can find them on the internet for the end cover and side cover , then replace the side cover etc !
Try the clutch , might have to adjust cable or if hydrolic then bleed by undoing the bleed nipple which is on the slave cylinder on the side of engine , undo it and pull lever in and hold it , tighten nipple , release lever and do this 2 or 3 times ! MAKE SURE THE CYLINDER ON THE CLUTCH LEVER IS FULL BEFORE YOU START !! If a cable then adjust off the adjustment on the hand lever leaving about 5mil slack , pull lever several times then re adjust cable till 3mil clearence on lever and try again ! Start engine and select 1st gear and carefully take for a ride changing gears , might have to adjust again but now should be ready to go and play !

Feb 20, 2015 | kawasaki Motorcycles

1 Answer

How do you replace a clutch in a 1998-99 Geo metro


why not post symptoms first, (like, my clutch pedal is dead) or?
manual or automatic trans/ both have clutches.?????
metro ended in 97 and was then and a Chevrolet nameplate from 1998 to 2001
metro, is covered in all metro, FSM books
all metro forums
see vast links here
http://www.fixkick.com/swift.html

online:
and at alldata.com
mitchels.
dont know year, ?

my wild guess. on what is there, M/T stick shift car.

M/T stick
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2. Remove or disconnect the following:
    • Negative battery cable
    • Transmission assembly and matchmark the flywheel to the engine
    • Clutch pressure plate cover by slowly and evenly loosening the bolts until the spring tension is released
    • Clutch disc

Trans out,
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2. Drain the transmission fluid.
  3. Remove or disconnect the following:
    • Negative battery cable
    • Both front wheels
    • Backup lamp switch electrical connector
    • Clutch release lever from the clutch release shaft
    • Clutch cable bracket and move it aside
    • Negative battery cable and hanger from the transmission
    • Gearshift guide case bolts and set the engine wire harness and bracket aside
    • Speedometer cable
    • Starter motor
    • Two right side upper case-to-engine bolts
  4. Install an engine support fixture.
    • Both drive axles after properly supporting the transmission
    • Flywheel cover
    • Control joint shaft through bolt and separate the control shaft from the control joint
    • Gearshift control lever guide plate and separate the extension rod from the lever guide plate
  5. Support the transmission.
    • Bolts from the rear transmission mount
    • Left side mounting bracket bolts
    • Right side case-to-engine mounting bolts
    • Transmission through the left side of the engine compartment and make certain that the input shaft clears the clutch pressure plate

Feb 14, 2015 | Geo Cars & Trucks

1 Answer

Put clutch into gear but no movement


Replacing the clutch is fairly easy on most motorcycles. A factory repair manual is helpful and suggested, but in a nutshell, here's the proceedure.
There is a round cover on the right side of the engine, this is the clutch cover. After draining the oil, remove the cover and this will expose the clutch pressure plate that will be retained with a number of washered bolts and springs. Remove the pressure plate, and the clutch plates can be removed. There will be alternating friction and steel plates-remove them all and keep them in a stack in the order they were removed. Soak the new friction plates in oil before installation. Install the new plates starting and ending with friction, alternating a steel plate in between.Be aware that some motorcycles have a different first and last friction plate, your parts dealer should know that when you buy the parts.
After it's stacked reinstall pressure plate with new springs, bottom out the washered bolts and no additional torque is required. Reinstall cover with new gasket, fill with oil and adjust clutch lever so it has enough slack to slide a quarter in between the lever and perch. Good luck!

Jun 07, 2011 | Honda VTX 1800 R Motorcycles

1 Answer

How do i change my clutch and plates


Harley changed their clutch in 1998 and I don't think they've changed it since. To change the plates in your clutch:

First, disconnect your battery, Remove the floorboard on the primary side and drain the oil out of the primary. Remove the outer primary cover. Remove the six screws in the clutch assembly and remove the clutch plates and steel plates. Soak your new clutch plates in oil overnight. Replace the old parts with the new parts in the exact same order. Rinstall the bolts using Loctite 242 (medium strength blue) and torque the bolts to about 20 foot pounds. Adjust the clutch according to factory specs and reinstall the outer primary cover. Add oil and reconnect the battery. Put the floor board back on and you're ready to ride.

Ride Safe.
Steve

Jan 03, 2011 | 2008 Harley Davidson FLHX Street Glide

1 Answer

How do you change a clutch on a 85cr


1) Release the pressure on the system by unhooking the clutch handle from the cable
2) Identify which side of the crank holds the clutch mechanism. Probably opposite the chain drive sprocket which means the clutch is on the right side as you sit on the bike. Spray off sand or grit that may fall into the works as the case cover comes off.
3) Drain the gear case oil
4) Remove the kick starter by removing the bolt holding the lever onto the starter shaft. Carefully, maybe with a impact driver screwdriver, loosen and remove the screws holding the round clutch cover from the engine crankcase. There are probably five, maybe seven, Phillips screwheads or maybe with ten mm hex heads. They will be different lengths so remember which holes each came from. I always replace screws with hex head bolts 'cause the screws can be a pain to remove.
5) Remove the clutch cover. You may need to remove the footpeg. there may be a steel ball bearing about 8mm diameter roll out of the center of the basket, so watch for it.
6) The clutch will be covered by a 'basket' held down by probably six bolts recessed into the basket.
7) As you remove the basket, you will find rings made of metal alternating with rings of fiber. Remove these, noting the order. If the metal rings are not blued or scratched, you can use them again. The fiber ones will need to be replaced, at about $7 each. Oil them and put new fiber rings back, starting with fiber and ending with fiber. I smear oil on the fiber plates before I put them in. You will see notches in the teeth at the edge of the fiber plates, and want to not line these up with each other.
8) Put the cover back, usually using a new gasket, or at least silicone. Leaks here make a mess and it's worth taking time to get it sealed.
9) Fill with amount of oil specified on the side of the crankcase. Make sure you use 'cycle oil, with MA rating. Auto oils will allow the clutch to slip, and make it burnout quicker.

Oct 28, 2010 | 2002 Honda CR 125 R

2 Answers

Check the oil


There is a small glass inspection window on the lower flange of the clutch cover (r.h.s.)
Picture of part attached.

Leave bike to cool on the centre stand allowing all oil to drain to sump and inspect window for oil level. It should just cover the window when bike is level. If the window is blackened from oil stains and no oil movement is detected, drain oil, remove clutch cover and clean window from inside with solvent and replace, replace oil with 2200cc oil, Cheers.510a044.jpg

May 12, 2010 | 1980 Yamaha XJ 650

2 Answers

Just changed my gear box oil on my aprilia rs 125 2000 model and my clutch is sleeping how do i fix this and how much will it cocst thanks josh


i sure hope you didn't use car oil but bought motorcycle oil. The clutch is a wet-type system that uses engine oil to keep it cool. Motorcycle oil is formulated differently than car oil, which has detergents in it to add lubrication and engine life that will cause a motorcycle's clutch to slip. A new clutch is both inexpensive and easy to replace. When you buy a new clutch, don't forget the clutch cover gasket. i recommend EBC clutches.
1. Set up a little pan with MOTORCYCLE oil in it and place the new clutch discs and pressure plates in it so that they get well-covered with clean oil.
2. Drain the oil, remove the clutch cover and remove the bolts on the cover of the clutch basket.
3. Remove the old clutch parts and make sure you pay attention to what the last part is (disc or pressure plate).
4. Install the new clutch, starting with the last part you removed and alternate between the discs and pressure plates until you run out.
5. Reinstall the clutch basket's cover plate and re-torque the bolts to the specified setting, using a cross-sequence like you would on a wheel.
6. Clean all the old gasket off, install the clutch cove and new gasket and fill up your engine with oil.
7. Ride away happy because you just changed your first clutch!

Hope this helps,
matt

Hope

Sep 16, 2009 | Aprilia RS 125 Extrema Motorcycles

1 Answer

How do i replace my clutch kit. i burned it out


ello mate,,first drain the oil out,remove the right side lower fairing,,then remove the wot looks like a large circular engine casing,then remove the bolts with springs holding the clutch plates in,,take off the cover then u will see the plates and metal lookin clutch plates,, now take out the clutch plates one at a time,,,ie take one out then place on the bench,take a metal plate out and place that on top of the 1st plate u took out,and so on,, when u have the new fibre plates,,replace back in the bike as u took the old ones out,,ie, new fibre plate 1st then put a metal friction plate back in from your bench,,then a new fibre plate and so on,,each time u replace the new plate ,chuck away the old one,,wen u have done that ,on the clutch plate cover look at the face of the cover u will see a small arrow head or a dot stamped on the face of it,, that dot should line up with a dot thats stamped on the housing where the clutch plates are,put the plate casing on so that the dots line up ,,put the springs and bolts back on and do them up tight,,then replace the engine casing,,,put your oil back in,,if u have a hydrolic clutch u will have to remove the 3 screws and the clutch piston b4 taking the casing off ,,,to read this it will sound complicated m8,, but wen u start the job itl be quite easy,, take your time tho,,any probs m8 ,shout and il anserw u,, ok,, cheers now

Mar 30, 2009 | 2007 Suzuki GSX-R 600

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