How to Replace a Clutch on a Suzuki Motorcycle

Removing the Old Clutch

1). Drain the engine oil and remove the right side outside cover, which should be round in shape and have about eight to twelve screws holding it on. Save the screws.
2). Remove the screws holding in the clutch springs. You should be able to find them pretty easily once the cover is removed, they'll likely be in a star pattern.
3). Remove the retaining plate that holds the clutch plates in the clutch basket.
4). Carefully take out the disks as a set if possible. Notice how the disks alternate between friction disks and pressure plates. Your new clutch kit will tell you which one is which, just remember to install the new ones in the same order.
5). Clean any gunk, grease, or built up dirt from inside the clutch basket. Notice if there are any shims left in the clutch basket. These will be thin metal rings placed behind the series of clutch disks.

1). Replace any shims that you pulled out of the clutch basket. Make sure everything is clean and dirt free.
2). Start installing the clutch plates in the same manner that the old ones came out.
3). Once all the new disks are in, replace the side cover and screw in the new clutch springs one at a time, tightening the screws just until they seat.
4). Tighten the spring screws with your hex wrench one at a time, in a criss-cross pattern to ensure even tightening and prevent warping of the components. Tighten each one a little at a time until they are as tight as they were when you removed them.
5). Reinstall the side cover, again, tightening the bolts evenly around the perimeter. Refill the engine with the proper amount of oil.