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Old 06-20-2002, 05:04 PM
xs11 xs11 is offline
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Join Date: Jun 2002
Posts: 130
Clutch Cleaning and Refurb

Clutch Cleaning and Refurb
by Ralf Koehler

A couple of weeks ago I was complaining about my dreadful clutch, hardly disengaging at all, grinding 1st and 2nd gear teeth... I found out that it was plain adhesion causing the stickyness!

I took it all apart and performed the following work:

  • Meticulous filing of all edges on friction plates, steel plates, hub & clutch basket
  • Light sanding of old friction plates (thickness after 60k = new value) with automotive 120 grit paper to get rid of the glaze
  • Medium sanding of steel plates with 80 grit; cleaned everything with turpentine
  • Mounted steel plates 180 degrees turned, so that rounded edges now face the crankcase
  • Added 0.070" shims to springs (yes, I've got strong hands)
  • Treated new gasket with PAM Spray (both sides)

The result is amazing; the clutch works almost like new. Works out my left hand too. Total investment was several hours of labour plus one cover gasket. Actually, I had to use hammer & chisel to knock loose the 27 mm nut.

One more tip: once you have that side cover off, don't miss the opportunity to clean the inside of the metal piece behind the oil level window!