i have to change the clutch in my 03 636 and have never done it before....how hard is it?
should i buy a complete clutch basket off a used bike os buy the barnett clutch kit...


thanks in advance

 

you dont have to replace the basket. And dont buy barnett clutches. they sucks ***. Buy OEM. fibers, plates, and springs is all you need.

 

Get a new set of Fibers and steels... (some people dont replace steels, but they are cheap, if you can afford them, get em or at least get a few of them and replace any steels that are discolored)

Another option is to get the clutch plates (or whole basket) out of a crashed bike, if that is an option for you...

Either way, its not hard to replace as long as you have basic tools and some mechanical knowledge...

Drain oil (or lean bike to left)
take clutch cover off after removing cable
loosen 5-6 bolts (i dunno cause i have yet to do a 636 clutch) that hold down the springs
remove pressure plate
remove plates
reinstall new plates in same order
replace everything making sure it all fits together like it did before... done...

 

oh yeah, springs are cheap and a good idea too unless you bike has really low miles and your clutch is only burnt from you slippin clutch...

after a while, springs get sacked out, so they dont have as much pushing power to hold the plates together... that's why i say if your bike has low miles they prolly arent necessary... but are cheap if you can afford them...

 

wow that was fast
yea i am goin to start looking for a whole basket out of crashed bike. if not then ill order all the parts from the dealer....
thanks guys

 

yea the bike only has 5100 miles but my buddy was borrowing it and tried a rolling burnout on the new conti sport attack tires...and they dont spin very easy when warm, but if i order everything from the dealer ill replace everything

 

Glad we could help... good luck with it

 

I woulndt take my chances with a used complete basket, I bought one on Ebay only to get a clutch that was burnt up worse then mine was...I was able to use some of the plates but it wasnt the deal I was looking for.....Splurge and get a new OEM set, it will last the longest possilbe because everything is fresh and it will feel so nice and snappy! Just make sure you soak the fibers in oil overnight before intslling them and that you break it in nicely before you start beatin it.

 

I agree!

And WOW DEFAINTELY soak the fibers in oil... cant believe i left that out... it's automatic with me so i forget to even mention it... thanks for being on top of that Johnny.

 

hey thanks man yea im calling dealer in a few min and ordering everything,
do i need any special spring tool to get them off
im not really a motorcycle mechanic but im a damn good parts changer

 

nah no special tools needed...

Only thing i can think of is a pick with a little 90 degree hook on the end to get the plates that are really far in there makes removing the plates easier!

 

ok thanks..yea i got a pic set

i just called the dealer and they told me they need to measure my plates because there are a couple diffrent options 1.4 mm 1.6 and 2.1 mm or something so im gonna take mine apart and bring them up
thanks for the fast responses and all your guys help

 

No special tools just the 4mm HEX for the fairing, 12mm open end wrench for the clutch cable, 8mm socket for the clutch cover bolts, and a 6mm HEX for the clutch springs...

Do you have the service manual? If you dont just remember that the last friction plate you put in needs to be rotated and goes in a different slot in the basket then the others.......Look at the clutch plate stack before you take the plates out and you'll see what I mean, the last one is in a differnt slot then the others....

You can download the 03/04 service manual here for free
http://xfer.gofastvideo.com/gallery/...ice_Manual.pdf

 

JohnnyP - you ever hear of this??? i never heard of different thickness plates for the same bike... ?!?!?!


03-04 636 plates should all be the same...

 

wow definitly more details then i was expecting
i think with the help from you guys the oil changers at walmart could change the clutch
thanks
alot
ill let you guys know what happens next week when the parts come in

 

The standard steels are all 1.6 mm, you want all 1.6mm if your going to be buyin a complete set of new steel and friction plates. The thicker and thinner ones are to get a used clutch within the spec, which is 37.7mm-38.3mm for the complete 636 clutch stack......

You can add a thicker plate to a worn clutch to bring it back to spec but I never do that, I just replace everything as a set....

 

Yes there are actually 3 sizes available from Kawi

13089-1126 1.4mm
13089-013 STANDARD 1.6mm plates that come OEM
13089-1073 2.0mm

 

Oh 1 more thing......9 times out of 10 the clutch cover gasket sticks to the cover and comes off nicley without ripping and can be reused, but you might want to order a new one just in case...

 

WOW that's just retarted... talk about putting a really big bandaid on a small problem... frictions are worn... replace them... dont replace with thicker metals to fill up space! LOL Sometimes the Big 4 are RETARDED!!!


Oh and +1 on the gasket, between it usually sticking to the cover or motor and a litlte RTV (i use rtv anyway cause i like the extra seal it gives) u are usually fine, but having a new gasket is always nice!!! nothing worse than having a project almost done and not being able to button up and finish for a small cheap part like a gasket...

 

honda bond, yamabond, best stuff in the world, now sold at CHECKERS auto parts stores.