6.5CLUTCH
REMOVAL AND INSTALLATION
To remove the clutch without disassembly or for installation
instructions, see 6.3 DRIVE COMPONENTS, Removal.
CLUTCH PACK ONLY
Partial Disassembly
This procedure can be performed on the motorcycle without
removing the clutch shell or hub.
1. Remove primary chaincase cover. See 6.2 PRIMARY
CHAINCASE COVER, Removal.
2. See Figure 6-30. Remove six bolts (1) (metric) to release
diaphragm spring retainer (2) from clutch hub. Loosen
each bolt gradually and in a star sequence around the
hub.
3. Remove diaphragm spring retainer, diaphragm spring (3)
and pressure plate (4) from clutch hub.
4. Remove friction plates (5, 7), steel plates (6), damper
spring (8) and damper spring seat (9) from clutch hub (11).
Continue with Cleaning And Inspection.
Cleaning And Inspection
Compressed air can pierce the skin and flying debris from
compressed air could cause serious eye injury. Wear
safety glasses when working with compressed air. Never
use your hand to check for air leaks or to determine air
flow rates. (00061a)
1. Wash all parts in cleaning solvent, except for friction plates
and bearing, if removed. Blow parts dry with low pressure
compressed air.
2. Check friction plates as follows:
a. Blow off all lubricant from the friction plates. Do not
wipe off with a rag.
b. Measure the thickness of each plate with a dial caliper
or micrometer.
c. If the thickness of any plate is less than 0.143
in. (3.62 mm), discard all friction plates and replace
with an entirely new set.
d. Look for worn or damaged fiber surface material (both
sides).
NOTE
Replace all nine friction plates with an entirely new set if any
individual plate shows evidence of wear or damage. Submerge
and soak all friction plates in FORMULA+ TRANSMISSION
AND PRIMARY CHAINCASE LUBRICANT (Part No. 99851-
05, qt.) for at least five minutes.
3. Check the steel plates as follows:
a. Discard any plate that is grooved or bluish in color.
Blue plates are likely warped or distorted.
b. Check each plate for distortion. Lay the plate on a
precision flat surface. Insert a feeler gauge between
the plate and the flat surface in several places.
Replace any steel plate that is warped more than
0.006 in. (0.15 mm).
4. Holding the clutch hub, rotate the clutch shell to check
bearing for smoothness. Replace the bearing if it runs
rough, binds or has any end play.
5. Check the primary chain sprocket and the starter ring gear
on the clutch shell. Replace the clutch shell if either
sprocket or ring gear are badly worn or damaged.
6. Check the slots that mate with the clutch plates on both
the clutch shell and hub. Replace shell or hub if slots are
worn or damaged.
7. Check the diaphragm spring and diaphragm spring retainer
for cracks or bent tabs. Obtain a new diaphragm spring
or diaphragm spring retainer if either condition exists.
2008 Dyna Service: Drive 6-13
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