Clutch plate replacement

Hi,
I'm planning on replacing the clutch plates on my 99 ZX-6R.
I have the service manual and I'm trying to anticipate exactly what I'll
need but I'm a little confused.
The manaul has instructions for removing/installing the cover, the release
shaft and the whole clutch but not just the plates.
By the looks of things the plates are exposed before any of the special
tools are needed for clutch removal.

Are the plates so trivial to remove that they don't need seperate
instructions or is the manual missing something?
Is the plate replacement a fairly trivial job? I've previously got as far
as valve inspections and swingarm re-lubing in my DIY maintanence quest.

Cheers,
Duncan.

PS. The clutch shudders on hard takeoffs, I'm hoping it'll last the 2000 km
before I do the next major service.

 

If just the plates to replace, then apart from a standard set of tools, you'll need a torque wrench for retorquing the half doz
bolts that bear down on the springs. (not under great tension either).

These usually aren;t very highly torqued but important not to overtighten and damage the threads.

Yes, otherwise it is quite easy. But I'm sure there should be reference in the transmission section to their replacement.

 

Depends on the bike though ... some bikes can be leaned over
far enough to change the clutch with the oil still in. On the
other hand, if you drop a bolt in ...

-----sharks

 

He might be able to get away with it...

....I just went outside to look at my own ZX6 for a couple of minutes (as you
do a few times over the course of a day...), and with the oil sightglass
integrated into the bottom of the clutch cover (flanges out at the bottom
rear corner), there's no oil showing with the bike on the stand. Leaning it
over a poofteenth more by, say, putting both wheels on bits of wood, should
slosh the oil far enough away to the left side of the cases for there to be
no Exxon Valdez episodes[1] once the cover comes off...

....and even if some oil does drip out, if Duncan still works on his bike on
the kitchen tiles, at least it'll be easy to wipe up


[1]Time for this metaphor to be updated, surely; after all, it's been 14
years. Can we start saying something like "Iraqi oil pipeline sabotage"?

 

Sharks might be right .. my bike can we leaned over far enough to remove the
clutch cover without draining the oil HOWEVER when removing the gasket,
little bits of gasket are more than likely to fall into the oil at that
angle .. it's just a bad idea, drain all the oil and do it with the bike
upright .. it's a nice new bike, why have shit floating around your engine
just to save a few dollars in oil and maybe a filter.

A little about gaskets, depending on how badly the old gaskets are caked on,
you may end up buying some gasket remover ($15 Aerosol) .. just spray it on
the gasket surface and WAIT for it to dissolve the gasket (15 minutes). DONT
get this stuff on your engine's paintwork !!

Matt

 

I think I would be able to, but it'll be part of a major service where
I'll be doing the oil as well.
I've been able to replace the alternator cover with the bike on a
stand with no oil leaks.

The first bit you accept, but after doing the radiator and finding
about 15 times that there was still a hose or cavity in the system
that had yet to dump it's fluid nearly had me throwing the thing down
the stairs.

Speaking of radiators, the one on the 6R is concave and mine is pretty
jammed up with mud. I've had it off and soaking in detergenty water
and given it a light spray of water but the gunk seems too packed in.
I've tried doing the fins one by one with a blade but as it is
squished up at the front it makes life very difficult.

Are there any techniques to get it out? Would a radiator type place
be able to give it a clean out? The 6R does not like getting hot so
anything to keep it cooler would be nice come summer.