The Royal Enfield Classic 350 is known for its iconic design and reliable performance, but like any motorcycle, the clutch will eventually wear out with time and usage. Replacing the clutch when necessary is vital to maintaining smooth gear shifts and optimal performance. This guide will walk you through the process of replacing the clutch in your Royal Enfield Classic 350, whether you’re experiencing slipping, difficulty in gear engagement, or other signs of clutch wear.
Signs Your Royal Enfield Classic 350 Clutch Needs Replacement
Before diving into the replacement, ensure that your clutch is indeed worn out or damaged. Some common signs that your Royal Enfield Classic 350 clutch needs replacement include:
- Slipping clutch: The engine revs increase, but the bike doesn’t accelerate as expected.
- Hard gear shifts: Difficulty shifting gears or gear slipping out of place.
- Excessive clutch lever play: A clutch lever that feels too loose or has excessive free play.
- Burning smell: A burnt smell coming from the clutch, indicating overheating or worn-out plates.
- Unresponsive acceleration: The bike feels sluggish and doesn’t respond to throttle input properly.
If you notice these symptoms, it’s likely time to replace the clutch.
Tools and Materials Needed
Before starting the clutch replacement, gather the following tools and materials:
- Socket wrench set
- Clutch holding tool (optional, but helpful)
- Screwdrivers (flat and Phillips)
- Torque wrench
- Drain pan
- New clutch plates (both friction and steel plates)
- New clutch springs (if needed)
- Engine oil
- Oil filter (optional)
- Gasket or gasket maker (for the clutch cover)
- Clutch cable (if necessary for replacement)
Step-by-Step Guide to Replacing the Clutch
Step 1: Prepare the Motorcycle
- Park the bike on a stable surface: Use the main stand or a paddock stand to ensure the bike is stable and level during the process.
- Disconnect the battery: This is an optional but recommended step to avoid any accidental electrical shorts.
- Drain the engine oil: Place a drain pan under the oil drain bolt and remove it to drain the oil. Let the engine oil fully drain before proceeding.
Step 2: Remove the Clutch Cover
- Remove the gear shifter: Use a socket wrench to unbolt the gear shifter and set it aside. This will give you access to the clutch cover.
- Remove the clutch cover bolts: Use the appropriate socket wrench to remove all the bolts holding the clutch cover. Be sure to note the location of each bolt, as some may be different lengths.
- Carefully remove the clutch cover: Once the bolts are out, gently tap the cover with a rubber mallet or use a flat-head screwdriver to pry it open. Be careful not to damage the gasket.
- Inspect the gasket: If the gasket is damaged or worn, you’ll need to replace it when reassembling the clutch cover.
Step 3: Remove the Old Clutch Plates
- Loosen the clutch springs: Use a socket wrench to loosen and remove the clutch spring bolts. Once removed, you can take out the clutch pressure plate.
- Remove the clutch plates: After the pressure plate is removed, you can slide out the old friction plates and steel plates one by one. Take note of the order in which the plates are stacked, as you’ll need to install the new ones in the same order.
- Inspect the clutch basket: Check the clutch basket for any signs of wear, such as notches or grooves. If the basket is heavily worn, it may need to be replaced.
Step 4: Install the New Clutch Plates
- Soak the new friction plates: Before installing the new friction plates, soak them in engine oil for about 15-20 minutes. This ensures that the plates are properly lubricated before operation.
- Install the clutch plates: Begin by installing the new friction and steel plates in the same order as they were removed. Typically, you’ll alternate between friction plates (coated) and steel plates (smooth).
- Install the pressure plate: Once all the plates are in place, re-install the pressure plate over the clutch pack.
- Tighten the clutch springs: Place the clutch springs back in position and use a torque wrench to tighten the spring bolts to the manufacturer’s specified torque.
Step 5: Reassemble the Clutch Cover
- Install a new gasket: If the original gasket is damaged, install a new one. Alternatively, use gasket maker to create a seal.
- Reinstall the clutch cover: Align the clutch cover with the engine and bolt it back in place. Tighten the bolts evenly and in a criss-cross pattern to ensure the cover is sealed properly.
- Reinstall the gear shifter: Bolt the gear shifter back into its original position.
Step 6: Replace the Engine Oil
- Install the oil drain bolt: After the oil has fully drained, reinstall the drain bolt and tighten it to the specified torque.
- Add fresh engine oil: Refill the engine with the recommended amount and type of oil for the Royal Enfield Classic 350. If needed, replace the oil filter at this stage.
Step 7: Adjust the Clutch Cable
- Check clutch lever play: After the new clutch is installed, you may need to adjust the clutch cable. Adjust the clutch lever free play by turning the adjuster on the clutch cable until there is about 2-3mm of free play at the lever.
- Test the clutch: Pull the clutch lever a few times to ensure the action is smooth and the clutch disengages properly.
Step 8: Test Ride
- Start the motorcycle: Once the oil is filled and the clutch cable is adjusted, start the engine and let it idle for a few minutes.
- Test the clutch: With the bike still on the stand, engage and disengage the clutch to ensure it’s working correctly.
- Take a test ride: Ride the bike around the block to make sure the clutch engages and disengages smoothly, and that the gear shifts are smooth and responsive.
Conclusion
Replacing the clutch in a Royal Enfield Classic 350 is a relatively straightforward process that can restore smooth shifting and optimal performance to your bike. By following the steps above, you can successfully replace worn clutch plates and springs, ensuring your motorcycle remains in peak condition. If you’re uncertain about any step, consult the Royal Enfield service manual or seek assistance from a professional mechanic to ensure the job is done correctly.