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Old July 25th, 2009, 10:50 AM   #2
Purspeed
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Name: Purspeed
Location: Los Angeles, CA
Join Date: Nov 2008

Motorcycle(s): 2007 Ninja 250

Posts: 469
Now you will remove the clutch cover bolts and clutch pressure plate bolts. When removing these bolts, go in a "star" pattern when removing each individual bolt.

When installing, also install and torque (tighten with torque wrench) in a star pattern. Why? Because this way, you evenly distribute the load (pressure) and you won't have to deal with any leaks.

You will need to (carefully...it's soft aluminum) clean off the old paper gasket material. Take your time and use a bronze brush. A newer bike may not require much cleaning because the gasket will come off clean. But, if not, make sure that the mating surfaces are 100% clean of gasket material. This way, when you put on a fresh gasket, tighten and torque down the clutch cover plate (in a star pattern), you will not have any leaks. Also, you will not need to use any gasket sealer, either.

After you remove the clutch cover, clutch pressure plate bolts, washers and springs, clutch pressure plate...you can remove the clutch friction discs and metal plates. Easy!
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"This is my Ninja. There are many like it, but this one is mine..." ~ Purspeed (ca. Nov, 2008)
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