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The
Kevlar Clutch Installation:
The following is the steps
that will be needed to replace the clutch plates in a 3rd
generation Magna:
Step# 1---Drain the oil from the crank case so
that when you remove the right side engine case you do not end up
with oil all over the place.
Step# 2---Remove the brake pedal pivot bolt so
that the brake linkage is hanging loose from the peg assembly.
Step# 3---Remove the two peg bracket bolts that
secure the foot pegs to the frame under the engine case. Remove
this entire assembly from the bike to allow the removal of the
engine case cover.
Step# 4---Remove the two bolts that hold the
exhaust heat shield in place and pull the heat shield off to
allow clearance for the engine case cover removal.
Step# 5---Remove the crankcase bolts that hold
the side cover in place taking note that the furthest front bolt
and the bolt just below the oil dipstick have dowel pins in them
to aid in lining up the cover. These two bolts are longer than the rest and
must go back into the same holes.
Step# 6---Take an extension for your sockets
and place a small socket on the extension. You will need to
gently tap the tabs on the cover from between the front frame
tubes to break the gasket seal. Remember, do this gently!! Be
careful at this point since the pin that the starter gears ride
on may come out with the side cover. If this happens do not
panic, re-installing this pin is not to difficult. (see Starter Pin Install)
Step# 7---Cover the internal clutch and starter
assemblies with a shop rag and remove any gasket from the engine
case. Take your time and remember you are working with a soft
metal and do not want to gouge the sealing surface.
Step# 8---Remove any gasket that may have been
left on the side cover itself. Again be cautious since you do not
want to damage the sealing surface.
Step# 9---Remove the five clutch spring bolts
that hold the springs into place. The springs should be easily
removed at this point. If you are using Dave Dodges kit you can
discard these springs now.
Step# 10---Remove the clutch pressure plate. You
may need to get a finger nail or a small flat tip screwdriver
under the plate to get it out since it sits inside the clutch
basket slightly. The clutch pressure plate bearing will come out
with the pressure plate,note not to turn it down or the bearing
itself will fall out of the plate.
Step# 11---Remove all the old clutch plates and
discard them if you are installing new plates.
Step# 12---Take the new clutch plates and place
them in a bowl upside down of the way that they were delivered to
you. You will then need to cover them completely in oil and allow
them to soak for a minimum
of 5 minutes. This will
allow them to seat better once the bike is back together and
running.
Step# 13---Install the new plates starting with
the thinnest plate first and the the thicker plates after that.
This part is a little confusing, but the thinner plate has a
smaller disc surface than the rest of the plates. As long as you
install them in the in the order that they came in the kit from
Dave Dodge with the thinner plate in first you cannot go wrong.
You will notice that the plates have a RED mark on the on the outer edges, this is for people that
want to install the plates with all the marks lined up for
inspection purposes but is not necessary.
Step# 14---Install the pressure plate in the
reverse order of removal. Put you new clutch springs in the holes
and the place replace the bolts. These clutch spring bolts get
torqued to a value of 9 ft lbs. In a crisscross pattern.
SPECIAL NOTE:
STARTER PIN INSTALL---If
by chance the starter reduction gear pin came out with the side
cover during removal you probably had a washer fall out of the
engine case and are wondering where it goes. This small flat
washer is placed between the starter reduction gear and the
engine case. You will need to remove the pin from the side cover
and carefully slide the washer up behind the gear and then
sliding the pin thru the gear and the washer. If the gear came
out also upon removal of the side cover you will need to realign
it with the smaller starter sprocket in the front and the larger
starter clutch assembly sprocket in the middle.
Step# 15---Place your gasket on engine case
using the dowel guide pins to hold it in place and place side
cover back on the engine.
Step# 16---Reinstall the crankcase cover bolts
making sure that you place the longer bolts in the same holes as
the dowel guide pins. Torque bolts to a value of 9 ft lbs.
Step# 17---Reinstall the peg assembly and brake
linkage in the reverse order of removal.
Step# 18---Reinstall the heat shield for the
lower header pipe in reverse order of removal.
Step# 19---Refill the oil to operating level and
start bike and inspect for leaks.
Step# 20---Take the bike for a short spin and
make sure that the new clutch is in proper adjustment.
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