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1. Remove the front exhaust pipe and the frame
down tube right side floor board and master cylinder.
2. Remove 18 cover bolts from the clutch cover, pry off the clutch cover
and note: the starter thrush washer will fall, install it on the starter
drive.
3. Remove the retaining ring from the clutch cover retaining plate.
Now remove clutch hub nut with air impact wrench counter clock wise.
4. Now remove the pressure plate torque limiter springs friction plates
and steels.
5. Soak new friction plates in motor oil for ten minutes.
6. Make sure the clutch hub housing is meshed up with oil pump drive
gears on the back side of the clutch hub before new clutches are installed.
7. On the 1500's use five new steels and two of your best used steels/on
1600's use four new steels and three of your best used steels.
8. Install new frictions and steel plates in reverse order that they
came out. Note: The outer most friction plate is installed in the shallow
grooves in the clutch hub.
9. Use grease to hold the three torque limiter springs in place on the
back of the pressure plate assembly and remember two dish together like
a flying saucer and the third dishes outward.
10. Install the pressure plate with new spring that is provided in the
kit and torque nut to 108ft.lbs.
11. Now install the pressure plate cover and snap ring. Note: Push with
your hand steadily until snap ring is installed.
12. At this time operate the clutch handle and look for separation at
the clutch hub and if you see separation go to the next step.
13. Replace or silicone old gasket to the cover and don't forget the
starter thrush washer, install the cover and the screws.
14. Replace the frame section and the front exhaust pipe and top off
the motor oil.
15. Your done!
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