How to Replace a Clutch in a Dirt Bike
If it's determined that the clutch is smoked and replacement is certain, you should have no worries, as this is pretty simple, and can probably be wrapped up in 30 minutes or so barring any damage, or wear of other parts.
Most modern motocross bikes have what's known as a "Quick Change Cover" for accessing the clutch, and most clutch repairs, short of replacing the clutch basket can be performed through this access cover, although older dirt bikes frequently require removal of the RH engine side case.
While things are apart be sure to keep everything clean and organized and inspect all the clutch components as detailed below, then upon reassembly, be sure to consult a service manual specific to the motorcycle being serviced for torque specifications, and always use a new gasket or o-ring when reinstalling the cover.
Before beginning with replacement of the motorcycle's clutch, it's important to ensure the area around the clutch access cover, or RH engine cover is clean, and before opening up the motor cleaning is always a good idea.
1. With a clean motorcycle, turn off the gas, then lay the bike over so that the clutch cover is facing you.
(for those with a quick-change cover, you'll find that holding down the rear brake pedal and sticking a screwdriver in the swingarm pivot will provide adequate clearance for getting the cover off and for servicing the clutch, otherwise removal of the rear brake pedal may be necessary.)
2. With a screwdriver holding the brake pedal down, or the pedal removed, carefully remove the clutch access cover, or RH engine cover.
3. With the clutch cover removed, loosen the pressure plate bolts that will be facing you using a criss-cross and multiple step process, then remove the pressure plate.
4. Next, using a pick, remove all the clutch discs from the clutch basket and inner hub.
5. With all the clutch discs removed, inspect all the parts as detailed below, replacing parts which show wear, as will be obvious, or will be indicated by wear limits detailed within a factory service manual specific to the motorcycle being serviced.
How to Install New Clutch Plates
After all the clutch components have been inspected, (providing everything looks good), new clutch plates & springs can be installed and the clutch reassembled and adjusted.
Installation of the new clutch plates is simple, but there are a few steps you want to do to ensure a trouble free clutch.
During reassembly of the clutch, you'll need to soak the friction plates in a bath of clean oil and this is best accomplished (with the least amount of mess) by using a 1 gallon freezer ziploc bag and a sufficient quantity of new oil to cover the clutch discs.
Also, upon reassembly of the clutch, be absolutely certain that you begin, and end with a friction plate, then reassemble everything exactly as it was removed, or as outlined in a factory service manual specific to this motorcycle.
Lastly, If there are aluminium drive plates within the clutches, be sure to take into consideration the additional flywheel effect that can be gained by replacing these aluminium plates with steel.
With the clutch reassembled, be sure to adjust the clutch (if necessary).