you've ever had to change a clutch between motos, or even
after morning practice on race day, I don't have to tell
you how much of a drag it can be. Using a 2002 CR250R as
an example, here are a few simple steps to follow to make
the task go as quickly and as easily as possible. First,
make sure you turn the gas off on your bike, and then lean
it on the left side with the handlebar resting on a bike
stand (Photo 1). Next you'll
need a few tools: 10 and 8-millimeter t-handle wrenches,
and some shop rags.
To make sure the brake pedal stays out
of the way, push the rear caliper together (Photo 2 & 3).
This step may have to be repeated a few times during the
whole process. Now you can remove the clutch cover bolts.
The oil won't spill out because the bike is tipped on its
side. You'll have to hold the brake pedal out of the way
to lift the cover off. Make sure the inside of the cover
is wiped clean, as that's where you'll put the springs and
bolts so they won't get lost or dirty.
Next, remove the five pressure plate bolts
(Photo 4). They'll be tight,
so you might have to hold t-handle with one hand and tap
the handle with the other to crack them loose. When those
are out, lift the pressure plate and the clutch plates out
at the same time (Photo 5). Pay
close attention to which way the plates came out. On CR250's
and some Yamahas, there are different fiber steel/aluminum
The next step is to inspect the outer clutch
gasket and inner hub (Photo 6).
If there are any deep groves or notches in either, they
can usually be filed smooth with a small hand file. Refer
o your owner's manual for disassembly of he hub and basket
from the motor. If those two are in good shape you can proceed
installing the new plates.
If you have some time before you have
to ride, it would be best to let the fibre plates soak in
new motor oil, (preferably the same kind you're going to
put in your bike later). If there isn't any time, that's
Installing the plates is pretty simple,
just follow the steps in reverse order and everything should
go smoothly. After putting your bike back on the stand be
sure to turn the gas back on! Another crucial step is adjusting
the free-play at the clutch lever. After putting a new clutch
in, will be a ton of play in the cable. Also be sure to
pump the rear pedal before riding off! There's nothing worse
than smashing into something even before you get on the
next time, see you at the races!