Billet Dry Clutch Pressure Plate & Clutch Cover Installation Guide

I know this has probably been done before, but the subject pops up reasonably regularly, so here it goes:

1. Remove RHS Fairing panel. Owners of unfaired bikes can skip this step!
2. Remove O/E clutch cover using a 5mm Allen key.  Remove the rubber gasket also. The gasket has some little collets in 4 of the holes, one or more may be stuck to the inner mating face of the O/E cover. Replace them into the gasket.
3. Inside of the O/E cover will be coated in clutch dust. This is normal.
4. Remove spring retaining bolts with a 4mm Allen key. These bolts are often quite hard to shift and they are made of stale cheddar, so don't go at it too hard. A bit of gentle, sustained pressure on the key will probably suffice. If you try to whack them off, you will probably round the head. If you really cant shift a bolt, use some WD40 or similar & let it soak in. Do not get it on the clutch plates!
5. Note the slotted post and the triangle mark on the pressure plate. This will come in useful later
6. The push rod may well be stuck in the clutch control pin, which in turn will be stuck in the old pressure plate.
7. Drift the control pin & push rod out of the old pressure plate. Put something soft under the workmate (or whatever) so that the rod doesn't get damaged when it drops out. You don't need to whack it. A few firm taps will do the job.
8. Insert the control pin/push rod into the back of the new pressure plate.
9. Put new pressure plate into place. The rod just slides right back where it came from. Note the marking on the new plate. Align this mark with the slotted post.
10. Put some oil on the threads of your new stainless spring retaining bolts. DO NOT LOCTITE THEM!  3 in 1 oil will work perfect.
11. Put the 1st spring/cap/bolt assembly into place, just tighten it enough to locate it at this stage.
12. Put the 2nd assembly in opposite the 1st. Continue in this fashion till all 6 are loosely in place.
13. Tighten the bolts up, do it in a similar order to how you inserted them, ie tighten opposite pairs. If you have a small enough torque wrench, then the setting is 5nm. If you dont, just nip them up a touch when the bolt is fully inserted, about an 8th of a turn.
14. Put some Loctite on the cover retaining bolts as you use them.
15. Insert these 2 bolts first. They are long ones. Your cover should have larger diameter holes for these, they don't actually hold the cover on.
16. Again if you have a small enough torque wrench, tighten to 10nm. If not, just nip them up nice & tight
17. Put cover into place & insert remaining bolts. The short ones go in at 3 o'clock & 6 o'clock. Tighten to 10nm or just a good nip up.

To Learn More About Us Please Visit

DESMOPORSCHE