MT350 Clutch Replacement - Peak Riders

MT350 Clutch Replacement 

MOTOR CYCLE, GENERAL PURPOSE, 

HARLEY - DAVIDSON MT350 

TECHNICAL DESCRIPTION 

Rotax 348 Clutch Friction Plate 

Replacement & Maintenance 

This is intended as a walk through & Guide 

only to the Clutch Friction Plates 

replacement & Clutch Maintenance on a 

Rotax 348 engine. 

This is a guide only please refer to the relevant manuals 

for full details or ask professional advice if in doubt. 

This is the writer(s) interpretation of the required steps only and 

does not take any liability for the accuracy of the information 

supplied in this publication and it is supplied as is. 

File Location file: http://www.peakriders.org/files/mt350/tutorial/mt350clutch.pdf 

Joth Hill 14-Apr-2012 Rev DRAFT Page 1 of 12


Amendment Record 

Amendment 

No. 

Amendment 

By 

Date 

DRAFT N/A Joth 

16 April 2012 

1 

Minor Amendments and Note added on 

Page 4 Omitting Oil / Seal Changes. 

2 Various Enhancements and Amendments 

woodruff 

Bth2bth2 

Nickp500 

Bunker 

Wirralman 

17 April 2012 

18 April 2012 

3 Slide 50 Updated Joth 

27 April 2012 

Before carrying out the Procedure ensure you have the current amendment. 




General Tools 

13 MM Spanners X 2 

4,5,5.5, & 6 mm Allen Keys 

13mm socket 

24mm socket 

10mm spanner 

27mm Socket 

Torque Wrench 5 to 120Nm 

Fluids 

Engine Oil 

Lithium Grease (Lubricate Seals / O Rings) 

Loctite (Medium & Strong) 

Copper Slip (Apply where required) 

Specialist Tools 

TDC Locking Bolt M8 (P/N 241.965) 

Clutch Locking Tool 132mm Dia (P/N 276.825) 

M30x1.5 Extractor Lower Pulley (P/N 276.445) 

Top Pulley Puller 

Required Parts 

1x Clutch Cover Gasket (P/N 250-381) * 

8x 2.6mm Fibre Plate M41 132mm (P/N259.905) * 

1x Starter Gear Cover O ring (P/N 230-310) * 

1x Timing Belt (P/N 280-015) 

6x Clutch Springs (212-N)34.1mm (P/N 239.625) 

1x Clutch Cable (P/N297.530) 

1x Timing Pulley Oil Seals (P/N 930-715) 

1x kick Start Shaft Oil Seal (P/N 831-260) 

1x Oil Filter 

The parts marked * are the parts that you will need for this procedure. 

Other Parts were changed as general maintenance. 




General Torque Values 

Where Torque settings are not detailed the following are a guide. 

M5 

M6 

M8 

M10 

7-8 Nm 

11-14 Nm 

24-27 Nm 

51-54 Nm 

Minimum Procedure 

If you need to replace the clutch plates in an emergency or quickly you can omit the 

references to the oil / seal changes. You will need to remove the battery and lay the bike 

on its side. Protect the area just in case some oil spills out of the filler cap or engine. 

Omit Slides 2, 3, 4, 5, 6, 29, 30, 47, 48, 49, 50, 51, 52 & 53 




1. Remove Panniers Support Bar. 2. Drop the Right Foot Rest 

3. Remove the Oil Drain Plug and drain out the 

oil. (Hold a bucket up to the plug when removing 

as oil shoots out Horizontally. Then clean the 

magnet of metal filings. 

4. Remove the Sump Guard and the Sump drain 

plugs and drain out the oil. Also clean the 2nd 

magnet of metal filings. 

5. Remove the Oil Filter by removing the 3 bolts 

holding the Plastic Chain Guard on and then the 

3 oil filter cover screws and pull out the filter. 

6. The non return oil valve is located behind the 

oil filter. This can be replaced while the filter is 

out if the oil level is falling in the reservoir when 

the bike is stood. (Use Correct Size Screwdriver). 

7. Remove the 4 timing cover bolts with a 5mm 

Allen Key. (Note: Screws are Different Lengths) 

8. Remove the 4 bolts holding on the starter gear 

cover and remove the Cog & 2 washers. 




9. Remove the bolt circled above using a 6mm 

Allen Key . Locate the V in the fly wheel through 

the hole using a torch and screw in the crank 

locking bolt (the crank locking bolt is a M8 bolt 

with the end of the thread is tapered.) 

10. Mark the rotation of the Timing belt if you not 

replacing it. 

12. Remove the Timing Belt Tension bearing. 

11. Check the markings on the Pulleys and ensure 

they are all visible and Marked. Loosen the 

bolts marked with arrows. 

13. Remove the Timing Belt Runner Bearing. 

14. Remove the Bolt and washers on the top 

pulley, Remove the Belt then remove the pulley 

using the pulley removal tool. 

15. Remove the lower pulley nut and remove the 

pulley using the special removal tool. 




16. Remove timing belt cover stud. 17. Remove the Timing belt back plate. 

18. Remove the Gear Lever and Kick Start 

Lever by removing the 2 Allen Bolts. Then remove 

the Circlip and Washer. 

19. Remove the bolts around the casing. 

Make a note of which ones come from which 

hole as they are different lengths. 

20. Remove the Casing and disconnect the 

clutch cable. 

21. Remove the 6 Bolts holding the Clutch cover 

plate on. 

22. Remove the 6 Springs. 

(2 Shown in Place) 

23. Remove the nut in the Centre of the clutch 

basket using the basket spanner. Then pull out 

the basket assembly. 




8nr Friction Plates 2.6mm Thick 

7nr Plain Plates 1.25mm Thick 

1nr Plain Plate 1.5mm Thick 

24. Remove the Friction and steel Plates and 

keep them in order as one of the plain rings is a 

different thickness. Re assemble with the new 

Friction plates and plain rings as required. 

(Measure clutch plates pack - should be 31.5mm or within 3mm) 

25. Replace the Basket and plates on the bike, 

then put the Clutch Hub, lock washer and the 

bolt on with “Strong thread lock” and torque up 

to 120 Nm. 

120 Nm 

26. Bend back the Nut locking Washer, If bent 

more than twice then replace with a new 

washer. 

27. Replace the Springs. 

6 

1 

3 

5 

4 

2 

28. Replace the Clutch cover and tighten the 6 

Bolts holding the Clutch cover plate on. Tighten 

in a Alternate pattern 

29. While the cover is off I took the time to 

change the two seals. Pre grease the seals 

WARNING never insert seals / O Rings dry. 

30. Use a socket to push in the seals. 

31. Put on the casing gasket. 




32. Re connect the clutch cable and refit the 

casing, insert the bolts and tighten 

each bolt to 8 Nm (Read 33 First) 

8 Nm 

33. There are 2 washers and they go on the kick 

shaft before the case goes on. Circlip goes on 

after the case. 

See Manual for Full Instructions 

34. Refit the O Ring to the Gear Lever. 

Use tape around the splines to protect the O 

Ring from damage when sliding the O Ring over 

the splines. 

35. Adjust the clutch by screwing in the centre 

screw until it bites and then loosed 1/4 of a turn 

and tighten the lock nut. Check the clutch operation 

and then replace the cover. 

36 Refit the Starter Cog first by fitting the metal 

washer then cog then another washer. Fit the 

cover and tighten up the 4 bolts. 

37. Replace the lower pulley, lock washer and 

nut “Strong thread lock” on the 

thread and torque to 100 Nm. 

100 Nm 

38. Refit the Timing Back Plate. The back plate 

requires a bead of sealant between it and the 

casing. 

39. Install the two retaining bolts and replace 

the timing cover stud & Washer. 




40. Install the Timing Belt Runner 

Bearing “Medium thread lock” 

on the thread and torque to 20 Nm. 

20 Nm 

41. Refit the top Pulley and Spacers. 

Ensure the Two marks line up. 

42. Install the Large Washer, Lock Washer and 

Nut on the Top Pulley. Note : Put the Timing belt 

on temporarily to assist in Torquing 

the Bolt. 

20 Nm 

Note: See Slide 11 for realigning the Top Pulley. 

43. Install the Timing Belt Tension 

Bearing “Medium thread 

35 Nm 

lock” on the thread and torque to 

35 Nm. Ensure the belt can be twisted through 

90 Deg between the Top Pulley and the Tension 

Bearing. (See Manual for Detailed Settings.) 

44. Remove the Fly Wheel Locking Bolt and replace 

with the original bolt & Copper Washer. 

45. Re fit the Timing Belt cover and tighten the 4 

Allen bolts. 

46. Replace Kick Start. 

Replace Gear Lever. 

27 Nm 

8 Nm 


47. Replace the Drain Plug & Copper 

Compression Washer. Torque 20 Nm. 

20 Nm 



48. Insert a New Oil Filter. 49. Refit the Oil Filter Cover and Rataining 

Screws. 

50. Re Fit the Plastic Chain Guard. 51. Refit the Sump Plugs with new 

copper compression washers 20Nm. 

Then Refit the Metal Sump Guard. 

20 Nm 

52. Refit the Foot Rest and tighten 

the 2 bolts to 24 - 27 Nm. 

24-27 Nm 

53. Fill With Oil, Ensure you do not over fill. 

54. Pull in the Clutch Lever and Turn over the 

bike without starting to allow oil to coat the new 

Plates and Engine Parts. 

55. Run the Bike checking the oil level and fill to 

the correct level and replace the Filler Cap. 




END OF PROCEDURE

MT350 Clutch Replacement - Peak Riders

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