How to Change a Honda CBR 900 Clutch

Written by jennifer simon
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Changing the clutch on your Honda CBR 900 can be simple, with the right tools and time. The steps for basic clutch change are similar, regardless of make or manufacturer, so if you've got some experience changing a clutch you're a step ahead. If you don't, however, you can save hundreds of dollars by doing it yourself with common hand tools and a new clutch kit.

Skill level:
Moderate

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Things you need

  • Socket set (metric)
  • Socket wrench
  • Oil
  • Container for small parts
  • Oil pan

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Instructions

  1. 1

    Drain the CBR 900's oil into the oil pan, and set it aside.

  2. 2

    Move the brake lever out of the way, or remove it completely.

  3. 3

    Use the socket wrench and socket set to remove the clutch cover. Observe and inspect all the O-rings and gaskets in the clutch assembly to make certain they are all intact. Replace worn, split or cut gaskets and O-rings if necessary.

  4. 4

    Loosen the bolts on the pressure plate with the socket wrench, alternating in a criss-cross pattern as you loosen and remove them. Pay close attention to the springs behind them so they do not fly off. Place the bolts and springs in the small container.

  5. 5

    Remove the pressure plate and the lifter behind it from the bike. Place the lifter in your small parts container.

  6. 6

    Remove the friction plates and jutter springs. Mark the installation positions for reinstallation, if your clutch kit doesn't include new springs.

  7. 7

    Install the new CBR 900 clutch, following the clutch kit's directions. The directions will vary slightly by aftermarket manufacturer.

  8. 8

    Replace the jutter springs, friction plates, pressure plate and lifter, springs and bolts and clutch cover, by reversing steps 2 through 6. Carefully adjust the torque required for pressure plate bolts, per the kit manufacturer's directions.

  9. 9

    Adjust the clutch lever, leaving 2 to 4mm of play to minimise clutch plate wear. Refill the CBR 900's oil. Give the bike a test drive.

Tips and warnings

  • Be sure not to over-torque pressure plate bolts. Tighten the pressure plate bolts in the manner you removed them, using a criss-cross pattern.
  • Placing the friction plates in oil overnight aids installation and lubricates the plates.

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