Here we go:
Step 1.
Unplug the signal generator wire, from the bottom right corner of the left hand radiator.
Bring it around to the clutch side so that it doesn't get in the way.
Step 2.
Drain the coolant from the bottom of the right radiator by removing the jubilee clip and sliding the hose off
Then slacken off the jubilee clips shown and remove all the pipes from the water pump, and tuck the hoses away to make it easier to remove and replace the clutch cover.
Like so.
Step 3.
Remove the 3 water pump cover bolts shown. leaving the fourth in place, at this point i also stood the bike up to drain the last of the water out of the water pump.
Step 4.
slacken all the bolts on the clutch cover.
Then use the prying locations on the cover to pry it off, and leave you with this.
From here you can have a good looky in the sump. and can see the oil, noting that it does not need to be drained to remove the clutch cover
Step 5.
Loosen the 5 clutch spring bolts, in a criss cross patten evenly doing each one a little at a time. you should end up with this.
once you've removed the bolts and springs the clutch top plate will just slide off, hopefully you aren't greeted with anything like I was. a clutch post with some serious welding.
Step 6.
Remove the clutch pack by using something to poke in the holes honda has left in the back of the clutch basket
I used 2 small allen keys
This should leave you with this, inside you can see the marks the clutch frictions and steels have made, aswell as the anti judder spring, leave this in place.
Step 7.
Insert the new or old clutch plates. starting with a friction, then a steel, then a friction, and so on and so forth, placing the last plate, which should be a friction plate, rotated differently to all the other plates, as shown in the picture. I don't know what purpose this serves but is stated in the hanyes book of lies.
Step 8.
Reassemble, which is the reverse of dissasembly, replace the clutch top plate, fit you're new or old springs, with the bolts and do them up in a alternating opposite pattern until all are done up. replace the clutch cover. fitting a new gasker if needed. followed by doing up all the clutch cover bolts and the 3 in the water pump.
Then reconnect all hoses, and fill the coolant back up from the right radiator neck until full, then fill the coolant reservoir up to the max line. last but most important REMEBER TO RECONNECT THE SIGNAL GENERATOR WIRE. otherwise you might be stood there turning the bike over for 10 minutes, wondering why it won't start.
