Taking off and putting on a clutch cover

[Spot18]

Hello there,
Does anyone know how to put on a clutch cover on an 07' CBR600RR? i have put on a stator cover before with no problem but i know this requires a little more work. So if anyone knows hows to remove and put one back on please let me know. if you have pictures that would be great too.
Thanks,
Dustin

[pete13]

I've just done this to my CBR600RR 03. I'd recomend getting the manual and following it step by step....Alternatively

1. Drain the oil (Via sump plug) you'll need to replace the washer seal (silver crush type) when you put it back on. (change the oil filter behind the exhaust manifold...should be hand tight if not get a tool they're cheap)
2. remove the clutch lever cable (2 bolts)
3. Take the bolts out working at oppsite bolts around the casing (you'll need a torque wrench when putting them back in 12nm I think)
4. Pulling the lever on the casing will pop it off (2 washers may fall out...they go back on top right wavy one first)
5. You'll need to disconnect the electrics (this can be done either under the tank (nightmare to remove the tank first or much easier unscrew the two bolts on the inside of the cover
5. To replace use some proper gasket sealant (loads of different makes around)
6. There will be 3 guides to help put it on. Check there location and even try before applying the sealant.
7. Replace bolts again in criss cross fashion and torque them up once all in place
8. replace the oil (use full synthetic, the dealers will advise)
9. don't forget the plug and check the levels thro the small glass window on the side
10. swing you're leg over and your off.....
PS thats of the top of my head having only done it once but let me know how you get on.....

[maskale]

You dont need to drain the oil.

You will lose some when, take the cover off but it will be minimal, just replace what u lose with some fresh oil, if is even needed.

when you put the cover back on, tighten 4 of the bolts, check the function of your clutch by hand to be sure it functions, it if works tighten the rest of them up.

[Spot18]

thanks pete13 the clutch cover wont come in until thursday so hopefully i will be able to put it on then. I will reply once i get it done though. maskale thanks for the tip ill keep that in mind if i have to do this again. I had already drained the oil because it was time for an oil change anyway.

[cobes]

Don't freak out if your starter gears fall out, they usually do.  Easy to put back in just line up the teeth.  Make sure to put the washer back on in the correct order and put the crank positioning sensor on the same it came out.  That's the little thing inside if you do happen to unbolt if from the cover rather than unplug it.  It can fit in upside down or turned around but then the bike wont start.  Happened to a friend.....

[Nihon Newbie]

 

Was your friend's name Cobes?   

 

[cobes]

Names aren't important

[maskale]

Cobe has friends only he can see and hear.  A true friend no the less.

[Nihon Newbie]

Names aren't important

Of course, of course.......

[Jeff]

Following the manual will be the easiest way to do it, so go find one.  It gives you instructions on tightening the bolts as this is VERY key in getting it on right and not having any leaks.

When you're pulling it off, you may need to tap it with a mallet or piece of wood in order to pop it off.  BE GENTLE.

Putting it back on, it's easiest once you get things lined up to use the arm that disengages the clutch to "pull" the cover back on.  If you get things lined up right, you can twist that arm and it will pull the cover on straight and right.  It's a good way to tell if everything is lined up right.

Sorry, that's all I remember off the top of my head (oh yeah, you will need an 8MM socket, not a 12, and disconnect the electronics via the plug under the bodywork, don't pull the sensor...)

[Spot18]

thanks for all the help and advice. Ill let you know how it goes.

[maskale]

dont pry it off with a screwdriver,   I do, but im a professional.   

[Nihon Newbie]

Also,

http://www.cbrextreme.com/downloads/manuals/honda_cbr600rr_0708_repair_manual-60.html

I prefer to have a paper one also, but this is a start.   

[Spot18]

well thanks for all of ya'lls help i just finished puttin it on and suprisingly it wasnt as hard as i thought it would be. So after i got everything on and was ready to fire it up it started fine (with a jump start due to it sitting for a little while) sounded great no knocks or any unusual noises. I let it run for a couple minutes before i was gonna put the seat back on and ride it around the block to make sure everything was ok.well as soon as i took one of the jumper cables off..... it shut off..... my battery was shot so i gotta get one tom so i can ride again. but thanks again for the help!

[Nihon Newbie]

Glad it worked out OK!