If 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 plate combos.

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 cool too.

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 cutch 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 track!

If you have any questions or comments, please email me at stu@machineracing.com.

'Till next time, see you at the races!

Adam