2008 Honda CBR1000RR Clutch Inner Installation PROCEDURE

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Filed Under (Honda) by admin on 23-04-2011

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Refer to the 2008 CBR1000RR Service Manual for specific removal instructions. While completing this procedure, be careful not to damage the covers, cowls, or any other components. 1. Remove the air intake cover (page 3-8). 2. Remove the upper inner cover (page 3-9). 3. Remove the lower cowl (page 3-9). 4. Remove the right middle cowl (page 3-10). 5. Remove the right crankcase cover (page 10-5). Clutch Removal (page 10-7) 6. Remove the starter idle gear and shaft. 7. Remove the snap ring and stopper ring. 8. Remove the clutch lifter piece and plate. 9. Unstake the clutch center lock nut. Be careful not to damage the mainshaft threads. 10. Hold the pressure plate with the special tool. You must use the special tool (Clutch Holder, T/N 070MB-MFLA100) when removing the lock nut. Using an impact wrench will damage the main shaft threads. Clutch Holder: 070MB-MFLA100 (autoshipped in May 2008) 11. Remove the clutch center lock nut and washer and discard the lock nut as shown on top of page 3 12. Remove the clutch spring holder, spring seat, and two clutch springs. 13. Remove the spring seat. 14. Remove the following: • Pressure plate
• Spring seat • Judder spring • Clutch disc A • Clutch plate A • Seven clutch discs B • Clutch disc C  Clutch center NOTE: Do not remove the clutch outer. New Clutch Installation (page 10-20) NOTE: The new clutch disc assembly has a dif- ferent order of plates than the illustration shown in the Service Manual. Keep note of this when repairing updated units.
15. Install the new clutch disc assembly with- out removing the setting bolts. Rotate the main shaft to align the clutch disc assem- bly with the main shaft spline. 16. Slightly loosen the setting bolts. 17. Rotate clutch disc C to align its tabs into clutch outer shallow slots, then fully install the clutch disc assembly. 18. Remove and discard the setting bolts. 19. Install the spring seat

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Kawasaki Ninja 650R, How to Replace Clutch Springs

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Filed Under (Kawasaki) by admin on 25-10-2010

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(Refer to Fig. 1) Take your 4mm Allen wrench and remove the four bolts holding the lower fairing and frame cover in place. Using the flat head screwdriver, remove the three plastic clips from the bottom and front of the lower fairing. Remove the lower fairing by pulling towards you, then down. Remove the frame cover by pulling the bottom towards you to pop the bottom two retaining clips, and then pulling up to pop the remaining top clip. Drain all the oil from the engine, but leave the oil filter in place (unless you plan on replacing it also). Fig. 1 (Refer to Fig. 2 & 3) Remove the throttle adjustment cable from its mount. It just slides right out. Place it out of the way, but do not let it slide behind the engine, as it is a pain to fish out. Removing the clutch cable was quite a job, for me at least. Here’s how I did it: I removed the clutch lever assembly from the handlebars, turned the unit upside down, and removed the cable from the lever. Place the clutch lever assembly to the side. Much of the tension on the clutch release lever should now be gone. Take your pliers and get a good grip on the clutch cable right in front of the clutch release lever. You’re going to have to push the clutch release lever towards the front of the bike as hard as you can; at the same time, you will also have to push the cable away from you and out of the mounting bracket. It took me quite awhile to get it done, but it is do-able this way

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