New Clutch

This info is not comprehensive.

CAUTION

• Try to use a good quality socket to remove the
  crankcase cover bolts as anything less may result
  in you rounding off the heads of the bolts.
• Once you have the bolts removed, the crankcase
  cover will still be stuck onto the crankcase,
  Do not attempt to lever off the cover by inserting
  anything under the cover because any damage to the
  mating surfaces will result in oil leaks later.
  There are "ears" on the crankcase cover that can be
  used to remove it.
• The clutch pressure plate is made of very weak
  aluminium and is very easy to break. Loosen the
  bolts in a criss cross pattern and do not tighten
  the bolts too hard.
• When removing the old gasket be carefull not to
  damage the mating surfaces of the crankcase cover.
• Before you tighten down the four lifter plate
  bolts be sure that the springs are pressing all the
  friction plates and steel plates together.
• Do not allow any foreign particles to enter the
  crank case while you have the cover removed.
  
• Soak the new clutch friction plates in fresh
  motor oil for several hours before fitting. Also
  coat the steel plates in motor oil before fitting.

What you need

• Full set of friction plates.
• Four springs.
• Clutch lock nut.
• Clutch cover gasket.
• You may need new steel plates if the old ones
  are scored or warped (unlikely).

Tools

• 8mm, 10mm and 27mm sockets.
• Tools to clean gasket mating surfaces.
• Something to unstake the clutch lock nut.
• Feeler gauge.
• Vernier caliper.
• Torque wrench
• Breaker bar and 27mm socket.
• Clutch center holder, You could avoid needing
  this tool if you just put the bike into gear.

Procedure

1. Remove the exhaust down pipe of the rear
   cylinder (you will need a long extension for
   your rachet to do this). Romove the bolt that
   secures the exhaust collector box to the right
   foot rest hanger so that the collector box will
   drop down 1 or 2 mm which will make it easier
   to remove and install the down pipe.
2. Remove the crankcase cover bolts in a
   criss cross pattern.
3. Use the "ears" on the cover to remove
   it from the engine.
4. Very carefully remove the four spring
   loaded lifter plate bolts, turn each bolt
   a quater a turn at a time, in a criss cross
   pattern, maintain equal pressure on each bolt.
   









5. Romove the lifter plate and springs.
6. Unstake and remove the clutch lock nut
   (27mm socket with breaker bar and extension),
   use the clutch center holder to hold the clutch
   unit OR put the bike into gear and press the
   rear brake to stop the clutch unit form turning.
   
   
   
   
   
   
   
   
   
   
   
   
   
   
   
   
   
   
   
   
   
   
   
   
   
7. Romove the clutch inner (The judder spring
   and it's seat should be on this)
   
8. Remove the Friction plates and the steel
   plates.
   
   
   
   
   
   
   
   
   
   
   
   
   
   
   
9. Inspect the steel plates for scoring or
   warpage, warpage service limit is 0.3mm.
   
   
   
   
   
   
   
   
   
   
   
   
   
   
   
10. Inspect clutch outer for damage.
    
    
    
    
    
    
    
    
    
    
    
    
    
    
    
    
    
    
    
    
    
11. Install the new friction plates and the
    steel plates in the same way the old plates
    were installed. Install a friction plate first
    followed by a steel plate and so on. The last
    friction plate is different to the others,
    this one goes on the outside. There are five
    friction plates of one kind (disc B) and one
    friction plate of a different kind (disc A)
    for the Bros 400. There are 7 friction plates
    of one kind (disc B) and one friction plate
    of a different kind (disc A) for the Bros 650.
12. Install the cluth inner with the judder spring
    and it's seat, look at picture to see how the
    Judder spring is orientated.
13. Check that the clutch outer and inner have
    seated properly.
    
    
14. Instal and tighten (130 Nm) and stake clutch
    lock nut.
15. Install springs, lifter plate and the four
    bolts, before you tighten down the bolts check
    that the springs are pressing all the friction
    plates and steel plates together. If the plates
    are not being pressed together then the clutch
    will not work and may break the pressure plate.
16. Very Very carefully tighten down the four lifter
    plate bolts in a criss cross pattern, turning each
    bolt 1/8 of a turn at a time, maintain equal spring
    pressure on each bolt, do not tighten the bolts hard
    as this will break the pressure plate, Simply seat
    the bolts and tighten them as little as possible,
    if you are worried about the bolts loousening then
    use weak thread locking agent. It is not possibe
    to give a torque because the bolts are under spring
    load.
17. Check that everthing has seated properly and
    that the friction/steel plates are being pressed
    together by the springs.
18. Make sure the oil nipple is in place.
    
    
19. Apply liberal amounts of grease to crank case
    mating surfaces and to the gasket.
20. Check that the cluch lifter is seated properly
    in the crankcase cover.
21. Insert the dowel pins into the crank case then
    apply the gasket followed by the crankcase cover.
22. Tighten the crank case cover bolts in a criss
    cross pattern.
23. Install exhaust down pipe
    
24. Apply copper grease to the threads of all bolts
    or nuts.

Torque values:

8mm oil bolt on R crankcase cover	23 Nm
Crankcase cover bolts	10 Nm
Clutch lock nut	130 Nm