Replace your clutch in 30 minutes!
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  1. #1
    Can Ride And Chew Gum
    My Bike(s)
    2004 Yamaha Warrior XV1700
    Location
    Cincinnati,Ohio
    Posts
    2,057

    Replace your clutch in 30 minutes!

    Well here it is.
    This was my 1st time,but it was so easy it makes me sick to spend 300 to have 1 put in.
    1st
    Drain your oil....then replace drain plug...Soak new plates in new oil for 30 minutes prior to install.
    2nd
    Remove the cover bolts size 8 mm. Put the bolts down in order you take them off,because there are a couple different sizes.
    3rd
    Remove the 4 pressure plate bolts that retain the 4 springs.
    Check your springs for size and damage.
    I dont remember the size but I think its a 10 mm socket on the 4 spring bolts.
    4th
    Remove the 7 friction plats ,and place them in order you take them off.
    Take note to the alignment of your current plates..some have numbers or letters mine had grooves,just line them up,and replace in the same order.
    1 plate is slightly wider then the rest,be sure this is the 1st plate.
    5th
    Replace the plates in order.
    6th
    Install your pressure plate.
    7th
    Install your NEW springs and the 4 bolts to retain those springs.Tighten the springs tight ,but not to tight,The tighter you make them,the sooner the clutch will grab.
    8th
    Align your cover,and install the bolts in the order they came out.
    9th
    Add oil
    The plate pics you see are to show you the difference in 1 plate ,just a little widwer then the rest.
    You should be able to zoom in with any picture editor to see a more defined picture.
    I rate this a 3 out of 5 wrenches difficulty. All that should only take under 1 hour if you struggle.
    Any questions PM me!
    CS

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  3. #2
    Kickstand Operator
    Location
    North Carolina
    Posts
    285
    Quote Originally Posted by burnchassis View Post
    Well here it is.
    This was my 1st time,but it was so easy it makes me sick to spend 300 to have 1 put it.
    1st
    Drain your oil....then replace drain plug
    2nd
    Remove the cover bolts size 8 mm. Put the bolts down in order you take them off,because there are a couple different sizes.
    3rd
    Remove the 4 pressure plate bolts that retain the 4 springs.
    Check your springs for size and damage.
    I dont remember the size but I think its a 12 mm socket on the 4 spring bolts.
    4th
    Remove the 7 friction plats ,and place them in order you take them off.
    Take note to the alignment of your current plates..some have numbers or letters mine had grooves,just line them up,and replace in the same order.
    1 plate is slightly wider then the rest,be sure this is the 1st plate.
    5th
    Replace the plates in order.
    6th
    Install your pressure plate.
    7th
    Install your springs and the 4 bolts to retain those springs.
    8th
    Align your cover,and install the bolts in the order they came out.
    9th
    Add oil
    The plate pics you see are to show you the difference in 1 plate ,just a little widwe then the rest.
    All that should only take under 1 hour if you struggle.
    You should be able to zoom in with any picture editor to see a more defined picture.
    Any questions PM me!
    CS
    Thanks for this! Why did you decide to change your clutch? I ask because I have a marauder that I am trying to put in el-perfecto working condition. I didn't think you would need to change the clutch unless you had a LOT of miles on it.
    2007 Vulcan 900 Custom

  4. #3
    Can Ride And Chew Gum
    My Bike(s)
    2004 Yamaha Warrior XV1700
    Location
    Cincinnati,Ohio
    Posts
    2,057
    Occasionally during a wheelie or riding 2 up in 5th gear,I could feel the clutch start to slip.
    It wasnt all the time ,but sometimes,and that was enough to make me want to replace it.
    I could also feel it surge forward alot while starting it in gear.Like 6 inches to 1 foot of surge on a cold startup.
    CS

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  6. #4
    Clunked into first gear
    My Bike(s)
    2005 Boulevard M50
    Location
    Minneapolis, MN
    Posts
    248
    I would have changed the springs to something like Barnett, KG Clutch Factory or EBC sinde the Japanese use music wire and the springs sack out after a while. The silicon chrome steel springs made by the above mentioned companies don't sack out even after extended usage.

    Ray Nielsen, in Minneapolis and going for a ride tomorrow!

  7. #5
    Supporting Member

    My Bike(s)
    2012 Ninja 1000 ABS, 2002 Bandit 1200 S, 2002 Honda XR50R, 1992 Honda CR125R
    Location
    St. Cloud, MN, USA
    Posts
    20,860
    Quote Originally Posted by burnchassis View Post
    Occasionally during a wheelie..




    'Busa shock, Racetech forks, Holeshot stage 1 & pipe, Hella headlights, CBRXX clipons, Givi E360 & V46, Zumo 550, Pilot Road 2CTs | Symtec grip heat
    Arai Signet GTR | Joe Rocket Meteor boots, Alter Ego pants, jacket
    | Gerbings liner | Alpinestars SP-1 gloves | Hanes boxer-briefs
    Gems for motorcyclists

  8. #6
    Clunked into first gear
    My Bike(s)
    2008 M50
    Posts
    235
    Well the M50 is not a wheelie machine like a Bandit or Speed Triple, but it can indeed wheelie:
    YouTube - M50 Wheelie

  9. #7
    Ditch Magnet
    My Bike(s)
    Suzuki M50
    Location
    Del Rio TX
    Posts
    156
    where did you get the clutch bc? did you order it online?

  10. #8

  11. #9
    Handlebar Consultant
    My Bike(s)
    '08 Suzuki Bandit S
    Location
    Barrie, Ont. Canada
    Posts
    642
    Quote Originally Posted by Clint View Post
    LOL i did that to clint but apparently it can wheelie, i've been proved wrong here already lets not open a can.
    M50 SOLD


    2008 Bandit 1250 S
    Full Farings
    GIVI top and side cases
    MRA VarioTouringScreen
    Oxford heated grips
    Pilot road 2's
    Garmin Zumo 550
    GIpro w-ATRE
    PIAA HID HEADLIGHT
    PIAA HID fork mounted driving lights
    CORBIN SEAT
    DALES STAGE 2

  12. #10
    TurtleWax Taster
    My Bike(s)
    2008 Suzuki Boulevard M50
    Location
    Lake County, IL
    Posts
    574
    So I can replace my clutch for 40 bucks... man, my truck with 2500... yet another reason to move to Nevada or Arizona and ride year round... Nice directions.... I can't make mine wheelie, or burn... maybe I'm just not trying hard enough (I'm fine with that). My M50 surges in gear, but only if its been sitting a while, if its only been an hour or two, starts smooth, but overnight, I take a hop if I'm in gear.
    2008 Suzuki M50 Custom Painted Satin Black an Sublime Green, OEM Engine Guard, MJ limited Risers, home brew light bar with driving lights, debadged, Küryakyn ISO flame grips, drag specialties clamp on highway pegs, custom crosshair radiator cover, lowered two inches with a set of stock pipes painted black and debaffled, demickeyed and chopped.
    In storage-Küryakyn XL saddlebags, Spitfire Windshield, Sissy bar/back rest, hand tooled sissybar pad cover,

  13. #11
    Fourth gear and illegal
    My Bike(s)
    2000 LC 1500, 2005 RED M-50
    Location
    Liverpool, New York
    Posts
    758
    Well fnally replaced the clutch today according to burnchassis's instructions. Had a few issues though:

    1. - Had to remove forward exhaust pipe ( I don't have those fancy ones like you burn)

    2. - Had to remove brake linkage to get my fat fingers in there for bottom case bolts.

    3. - Get the old plates off and new ones on...then realize Dennis Kirk shipped me the wrong springs!!

    Long story short, took me about 1 hour total with extra part removal and reassembly. Buddy of mine said button it back up with old springs, they look fine, so I did. He also recommended soaking the new clutch disks in oil for about half an hour prior to install...he said if i didn't i would run the risk of burning up the new ones.

    All in all i'm happy with the outcome, thanks for your help burnchassis, much appreciated.

  14. #12
    Can Ride And Chew Gum
    My Bike(s)
    2004 Yamaha Warrior XV1700
    Location
    Cincinnati,Ohio
    Posts
    2,057
    Good deal!
    however
    I HIGHLY recommend you replace your springs.
    I did my clutch,and re-used the stock springs,and burnt up a clutch is a few 1000 miles.
    Springs are about $4 each.
    Pretty easy though eh? I'd kick myself for paying the steeler $300+ to do it.
    I also did soak my plates,but forgot to mention that part.
    CS

  15. #13
    Seat Tester
    My Bike(s)
    2014 Moto Guzzi California 1400 Custom
    Location
    Savannah, TX
    Posts
    73
    burnchassis, a late question on this great write-up:
    When removing the cover (step 2) to access the clutch, is there a gasket that one should be mindful of?
    Would I have to get a replacement gasket, as it were, for the cover?

  16. #14
    Can Ride And Chew Gum
    My Bike(s)
    2004 Yamaha Warrior XV1700
    Location
    Cincinnati,Ohio
    Posts
    2,057
    There is a gasket yes..it can be reused if you're careful.Gasket maker material helps too.I've pulled my side of 3 or 4 times and its still the original though slightly ripped gasket.
    CS

  17. #15
    M-J Lifetime Achievement Award
    My Bike(s)
    1980 Yamaha XS850 - being dismantled; 1999 Kawaski Concours
    Location
    Washington County, WI
    Posts
    13,238
    saw this and just cannot resist asking the ultimate in stupid questions.

    Just how quickly does one normally wear out a clutch on these bikes?

    Let me post my frame of reference.

    1980 Honda CB 750 - 45 k - adjusted the clutch cable once, about a month later took it to the shop for something else, and the mech adjusted back to where it was.
    1980 Yamaha XS 850 - 62 k - never adjusted the clutch, well maybe once, 1/4 turn.

    What are these modern clutches made of? Fiberglass? Plaster?



    Couldn't put "fail" across Lolo's picture, but she did come in 4th in the 100 m hurdles - still one heck of an effort.


 
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