Africa Twin XRV 650 RD03 - Clutch change

A DIY on how to change a clutch in a Africa Twin XRV 650 RD03 1989 . This is the 650 it has a little diference in the clutch cover for the XRV 750 but it's only that, this guide will work for any Africa Twin!  This will also work for XV650L Transalp!

I bought the material at Wemoto.com, good prices and great customer service!

Bought material:
Clutch Friction Plate Set: Wemoto
Clutch Steel Plates (only if they are blue they are not good so order new ones): Wemoto
Clutch Spring Set: Wemoto
Center Locking Nut for Clutch (a PITA to remove..): Wemoto
Clutch Cover Gasket: Wemoto
Clutch Arm Rod Oil Seal (i opted to put a new one): Wemoto

I chose heavy duty clutch and springs. Didn't notice any diference in pressure on the hand so no affect there. The steel plates were in good condition so no need for new ones. The Friction Plates should be left in an engine oil bath for a few hours, I left them overnight.

Clutch Friction Plate Set

I removed all the fairings and the gas tank, it's easier to work on.
NOTE: Wait for the tank reach reserver or you will need to pick up 20+ gas liters plus the tank.. It's heavy!

First we need to remove the header pipes in order to remove the clutch cover

Remove the clutch calbe and the screws, and this is spot where the RD03 is different you have an oil line with a screw in the right side of the cover (equal to XL650V Transalp). 

My cover was there for 24 years even after removing everything it stayed "glued" in place. After using the love hammer (rubber one) and after some beating I've managed to loose it. You can see the old gasket there and we need to remove it. Use something made of plastic ir order to avoid damage the metal and have leaks in the future, have patience.


Remove those four screws that hold the pressure plate, remove them in a cross in order to avoid pressure. You should always tight them in a cross pattern.  

Remove the screws and the springs. Now we need to remove the Center Locking Nut, it's a PAIN IN THE ASS. If you have an air impact tool use it. I didn't had one so a friend from our Portuguese forum www.africatwinpt.com made a tool in order to lock the motor from turning and with good leverage remove the nut!


The hand made tool attached by the four screws

With the nut removed, you have a spacer and another one behind the clutch basket

Remove the basket with the clutch on it, you can see the new one in the oil bath

It's easy to mount without getting it wrong, just mount it on the basket with the new Friction Plates and the old Steel plates, plate by plate it's a matter of "copy" the current layout 

Old friction plates 

Now put it back in place

This needs to be a new nut! Never use the old one. Side by side!

New nut in placet 

Use the tool this time to allow me to apply good torque on it

New heavy duty springs 

Pressure plate and the four screws, remember, cross pattern

New clutch cover gasket 

And in place, SPECIAL NOTE: Oil the gasket and in the next time ti will be easy to remove the cover and the gasket

Clutch cover in place 

Again try to use a cross pattern when tightening the screws
Now you just need to tighten the oil screw, put the headers pipes and exhaust, new oil and oil filter and it's done! It's easy and you will save money, and you know the job was well done!

Any doubts or suggestions are welcome!

Who am I and my motorcyles

Hello

I'm from Porto, Portugal! I love motorcycles, I've riding since 2009, and until today I had about 10 different models.

Currently my ride is an Africa Twin XRV 650 RD03 1989! The real one!! I bought it after selling my GSX-R 1000 K8, I sold it because I had a kid and needed to ride slower, take less chances! So I bought it with 15000km on the clock, seemed a bike that was stopped many years, at least that was the story from who sold me that he found it on a garage and received it as a pay for a job, when I opened the engine to change the clutch the few parts I could see looked new, so it may have only those kilometers, still somethings look strange, the HRC logo is the wrong one and my dashboard seems almost unique, has I have the sidestand light on the rev counter, and only five light on the light box... She has some rust on the frame, and soon I will restore everything, the frame will be powder coated, bolts and stuff zincked, basically a proper job! For this I will need another motorcycle as I only go to work by motorcycle, yes even in the winter with heavy rain I can stand be inside a car in traffic!

I'm in the look out for a new one, still deciding what to get I'm thinking on returning to fast bikes but this time SportTouring instead of SuperSport, I'm in love with the new Kawasaki ZZR 1400, or maybe a VFR 1200... But they are expensive and I need to think this through so currently I'm thinking on a budget dual sports as the winter is coming! :)

I always wanted a Suzuki DR 650 post 1996 maybe this is the time or I could get one Honda Dominator love them good solid bikes.