How to Repair Clutches in a 1987 Honda Motorcycle
With all the innovations and improvements to Honda motorcycles over the past few decades, one thing remains relatively constant: the clutch. The size of friction plates and metal clutch discs vary from the smaller CBX 250 to the VT 1100C Shadow, but the primary components and operation of the clutch are similar. The chances of finding factory components for an older motorcycle are slim. However, aftermarket clutch kits are available for 1984 Honda motorcycles. You will need to obtain a clutch kit for your particular model motorcycle that includes clutch plates, discs and clutch springs.
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Instructions
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1
Trace the path of the clutch cable from the hand lever to the clutch operating rod at the side of the engine crankcase. The circular cover behind the operating rod is the clutch cover. The clearance between the rod and the cover is sufficient to access the cover bolts and clutch components inside.
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2
Remove the hex-head bolts that hold the clutch cover on the crankcase by turning them counterclockwise with a metric socket and ratchet. Pull the clutch cover off. Save the cover and hex-head bolts.
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3
Loosen the smaller hex-head bolts on the face of the circular clutch pressure plate counterclockwise in a crisscross pattern until you can turn them by hand. The bolts are spring-loaded from behind, and it's necessary to loosen them in equal increments. Remove each bolt, washer and clutch spring one at a time by hand. Save the bolts and washers. Discard the springs.
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4
Grip the outside edges of the pressure plate with your fingers and work it off the push-rod that protrudes through the center of the plate. Most likely, the circular lifter that presses against the backside of the plate will come off with the plate. If not, slide the lifter off the push-rod. Save the pressure plate and the lifter.
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5
Pull the individual clutch plates and metal discs off the clutch wheel by hand and discard them. Clean the grooves in the clutch wheel with a stiff bristle brush to remove any debris.
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6
Install a new metal clutch disc onto the clutch wheel and push it against the back rim of the clutch wheel. Install a friction plate on the wheel and push it against the metal disc. Continue installing the remaining metal clutch discs and friction plates alternately onto the clutch wheel.
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7
Slide the saved lifter onto the push-rod. Push the pressure plate against the lifter and align the holes in the plate with the holes on the face of the clutch wheel.
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8
Put a saved washer and new clutch spring on each of the saved pressure plate bolts. Put the washer on first because it serves as a keeper for the spring.
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9
Insert the end of each bolt through the pressure plate and thread each clockwise into the holes on the clutch wheel by hand. Refer to the torque specifications provided with the clutch kit. Tighten the pressure plate bolts in a crisscross pattern to the specified torque using a torque wrench. Typical pressure plate torque is between 7 ft-lbs and 9 ft-lbs for each bolt.
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10
Align the holes in the clutch cover with the holes on the crankcase. Insert the clutch cover bolts through the cover and thread them into the crankcase holes clockwise by hand. Tighten each bolt with the socket and ratchet.
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Tips & Warnings
Some clutch plates require lubrication with motor oil prior to installation.
Refer to an owner's manual for additional information regarding clutch replacement for a particular year and model of motorcycle.
References
- Photo Credit motorcycles taxi stand image by Diorgi from Fotolia.com
