How do you replace the pressure plates in the clutch,i have a shop manual but its not very user friendly or informative.is there a scematic i can down load. also i need to replace the cam tentioner any addvice.

You can get a replacement clutch for about $146 that is a complete replacement of your clutch plates. It has the extra plates to replace that poor designed spring plate that comes standard on your Sporty
-or- you can buy, for about $190 that same clutch plate kit AND includes the clutch spring tool with it. Here is a link, if you are interested in seeing. Still should have the manual to take the case and clutch apart and put back together though. The kit works great! I have replaced several of them for my friends and never had a problem. Here is the link to where you can get them, but feel free to do some shopping around if you like. The link is just where I have found them at a reasonable price and the spring tool is one of the easiest to access the spring retaining ring too. Anyway, here is the link I use to order mine and my friends replacement kits.

Sportster and Buell Performance Extra Plate Kit

OBHighflyer (aka Scott)

I would suggest you get a cheap shop manual to guide you. The basic procedure is put it up on stands, discon battery, remove transmission (or if 4WD sometimes easier to pull engine) remove old clutch parts, resurface flywheel if needed, install new parts using clutch line up shaft, draw down pressure plate bolts in criss-cross pattern and tighten to specified torque (see, you do need a shop manual) and reassemble all. NOTE: clean flywheel and pressure plate suface with Brake-Clean or similar. Replace pilot bushing and throw out bearing too.

You put the spring plate on first (after putting on all the clutch disks) with it being held in the compressed state. Then you insert the snap ring into the grooves in the center of the clutch. Then you can re leave the pressure of the compressed spring plate. The snap ring is used to keep the spring plate under pressure at all times in normal operation.

SECTION 308-00: Manual Transmission/Transaxle and Clutch - General Information 1998 Contour/Mystique Workshop Manual DESCRIPTION AND OPERATION Manual Transaxle and Clutch Manual Transaxle and Clutch - General Information This section covers general procedures for diagnosis and testing the clutch system. For additional information, refer to Section 308-01 . For specified clutch system service procedures. For additional information, refer to Section 308-02 . For a complete description of the manual transaxle. For additional information, refer to Section 308-03 .
The clutch system includes:

• Flywheel.
• Clutch disc.
• Clutch pressure plate.
• Clutch master cylinder.
• Clutch slave cylinder.
• Clutch release fork.
• Clutch release hub and bearing.

The clutch master cylinder transmits fluid pressure to the slave cylinder, which in turn moves the clutch release fork and the clutch release hub and bearing.
The clutch master cylinder uses brake fluid and shares a common reservoir with the brake master cylinder
The clutch is a single plate, dry-friction disc with a diaphragm-style spring clutch pressure plate. The clutch disc has a hub which is splined to the input shaft. The clutch disc has friction material where it contacts the flywheel and the clutch pressure plate. Torsion springs on the clutch disc help absorb the engine torque pulses. The clutch pressure plate applies pressure to the clutch disc, holding it tightly against the surface of the flywheel.
In the engaged position, the diaphragm spring holds the clutch pressure plate against the clutch disc, so that engine torque is transmitted to the input shaft. When the clutch pedal is depressed, the clutch release hub and bearing pushes the diaphragm spring center toward the flywheel. The diaphragm spring pivots at the fulcrum, relieving the load on the clutch pressure plate. Steel spring straps riveted to the clutch pressure plate cover pull the clutch pressure plate from the clutch disc, disengaging the engine torque from the transaxle and enabling the gears to be changed.
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Inspection and Verification - MTX-75
The following checks should be carried out before repairing or replacing the transaxle:
Poor gear shifting

1. Check the operation of the clutch: Lay a block of wood approx. 25 mm thick under the clutch pedal and depress the clutch pedal as far as the stop. If 1st or 2nd gear can be selected with no problem with the engine running and the parking brake applied, the clutch is OK. If the gear cannot be selected, repair the clutch.

1. Check the selector mechanism:
   • The free play in the gearshift lever must be no more than 15 mm.
     • If the gearshift lever free play is too great, check the gearshift cables and replace them if necessary.
   • If the gearshift lever free play is OK, adjust the gearshift linkage. For additional information, refer to Section 308-06 .

1. Check the transaxle fluid level and top up with Automatic Transmission Fluid ESD-M2C186-A if necessary.

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Lets start with what was replaced : Clutch pressure plate, throwout bearing,pilot bearing,input shaft bearing, was flywheel cut or replaced,Clutch cable or slave cylinder (whatever is applicable,) Lets see what repair shop says. Depending on what they say they did or didn't do we will take it from there.
keep me posted

You want to know the procedure?

You will need tools and a jack and a really good strong friend.

Remove the drive shaft. Unbolt the trans from the engine and put it aside. Unbolt the pressure plate and remove. The clutch plate will fall on you. Remove the fly wheel for resurfacing.

Take everything to the auto parts place that has a machine shop.

Get the flywheel resurfaced. Purchase a new/rebuilt clutch plate and rebuilt pressure plate. Get a new throw out bearing. Also get a clutch plate alignment tool while you are there.

When you get all the stuff together, reassemble it.

Put the fly wheel back in ... becareful of the starter. Add the clutch plate and the pressure plate. Use the alignment tool. Bolt it all back to proper torque spece. You will have to ask at the auto parts place for the torque specs. Oh yea, you will need a torque wrench for this.

Put the trans back in. You should probably change the universal joints while you are at it, front and rear.


Or - you could have a shop do this for about $500.00 to $1,000.00 and save on the band aids.

Thanks for your question at FixYa.com

good luck on your project.

Replacing the clutch plate only sometimes doesn't help you should have replaced the clutch pressure plate too, best is to fit the clutch pro-kit (clutch plate, clutch pressure plate and release bearing).
I guess now you will have to just replace the clutch pressure plate and the release bearing.