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Kevlar clutch installation

The following are the steps that will be needed to replace the clutch plates in a 3rd generation Magna:

1. Drain the oil from the crank case so that when you remove the right side engine case you do not end up with oil all over the place.
2. Remove the brake pedal pivot bolt so that the brake linkage is hanging loose from the peg assembly.
3. Remove the two peg bracket bolts that secure the foot pegs to the frame under the engine case. Remove this entire assembly from the bike to allow the removal of the engine case cover.
4. Remove the two bolts that hold the exhaust heat shield in place and pull the heat shield off to allow clearance for the engine case cover removal.
5. Remove the crankcase bolts that hold the side cover in place taking note that the furthest front bolt and the bolt just below the oil dipstick have dowel pins in them to aid in lining up the cover. These two bolts are longer than the rest and must go back into the same holes.
6. Take an extension for your sockets and place a small socket on the extension. You will need to gently tap the tabs on the cover from between the front frame tubes to break the gasket seal. Remember, do this gently!! Be careful at this point since the pin that the starter gears ride on may come out with the side cover. If this happens do not panic, re-installing this pin is not too difficult. (see Starter Pin Install)
7. Cover the internal clutch and starter assemblies with a shop rag and remove any gasket from the engine case. Take your time and remember you are working with a soft metal and do not want to gouge the sealing surface.
8. Remove any gasket that may have been left on the side cover itself. Again be cautious since you do not want to damage the sealing surface.
9. Remove the five clutch spring bolts that hold the springs into place. The springs should be easily removed at this point. If you are using Dave Dodge's kit you can discard these springs now.
10. Remove the clutch pressure plate. You may need to get a finger nail or a small flat tip screwdriver under the plate to get it out since it sits inside the clutch basket slightly. The clutches pressure plate bearing will come out with the pressure plate, note not to turn it down or the bearing itself will fall out of the plate.
11. Remove all the old clutch plates and discard if you are installing new plates.
12. Take the new clutch plates and place them in a bowl upside down of the way that they were delivered to you. You will then need to cover them completely in engine oil and allow them to soak for a minimum of 5 minutes. This will allow them to seat better once the bike is back together and running.
13. Install the new plates starting with the thinnest plate first and the the thicker plates after that. This part is a little confusing, but the thinner plate has a smaller disc surface than the rest of the plates. As long as you install them in the in the order that they came in the kit from Dave Dodge with the thinner plate in first you cannot go wrong. You will notice that the plates have a RED mark on the outer edges, this is for people that want to install the plates with all the marks lined up for inspection purposes but is not necessary.
14. Install the pressure plate in the reverse order of removal. Put you new clutch springs in the holes and replace the bolts. These clutch spring bolts get torqued to a value of 9 ft lbs. in a crisscross pattern.

SPECIAL NOTE: STARTER PIN INSTALL - If by chance the starter reduction gear pin came out with the side cover during removal you probably had a washer fall out of the engine case and are wondering where it goes. This small flat washer is placed between the starter reduction gear and the engine case. You will need to remove the pin from the side cover and carefully slide the washer up behind the gear and then sliding the pin thru the gear and the washer. If the gear came out also upon removal of the side cover you will need to re-align it with the smaller starter sprocket in the front and the larger starter clutch assembly sprocket in the middle.

15. Place your gasket on engine case using the dowel guide pins to hold it in place and place side cover back on the engine.
16. Re-install the crankcase cover bolts making sure that you place the longer bolts in the same holes as the dowel guide pins. Torque bolts to a value of 9 ft lbs.
17. Re-install the peg assembly and brake linkage in the reverse order of removal.
18. Re-install the heat shield for the lower header pipe in reverse order of removal.
19. Re-fill the oil to operating level and start bike and inspect for leaks.
20. Take the bike for a short spin and make sure that the new clutch is in proper adjustment.

Kevin Reinhold (MRA #270)

"Dragun Slayer"