First time replacing the clutch on my 2008 Rebel 250 - Honda Rebel Forum
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post #1 of 13 Old 10-06-2012, 04:38 PM Thread Starter
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First time replacing the clutch on my 2008 Rebel 250

Hello, you all!

This is my first post and I am thrilled to be online. Recently, I noticed my clutch on m 2008 Rebel with just over 9k miles has been slipping. I have experience with cars and I am good a handy man and mechanic, but I honestly know little about motorcycle clutches.

I looked up the parts online and found I need to replace the clutch discs, steel discs, and springs. Are all of these necessary? How much money will I spend overall and what tools will I need? What brand parts should I buy?

Please feel free to provide any insight if you have experience with these kinds of jobs.


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post #2 of 13 Old 10-06-2012, 05:08 PM
 
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1.5 quarts of oil, gasket or gasket maker and a honda clutch spanner tool, tool is aroun 8-15$ on ebay

1985 Rebel 250 near mint
2003 yz250 completely rebuilt <- 2 stroke love
2004 kx100 <- My girlfriends/soon to be wife
2006 crf50<- Full custom race bike 6yrold sons
1994 pw50 <- My first bike now my 5yr old sons
2005 pw50 <- Rockin the train wheels till my 4 yr old son can touch
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post #3 of 13 Old 10-08-2012, 07:53 AM
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this is what you need but to suit your year rebel EBC CK Clutch Plates Honda CMX 250 Rebel 1985-1987 you don't have to replace the steel plates just clean them up with 320 wet n dry sand paper ,plus replace the springs as well



2000 rebel 250 Aussie My Baby.
2012 honda PSX 150cc scooter [in Thailand]
1986 rebel Silver 450 Elvis

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post #4 of 13 Old 10-08-2012, 10:48 AM
 
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I didn't do anything with the steel plates, but I am told you do want to replace the springs, I replaced mine. You will want a gasket, mine was held up a week until it came in. You also might want a replacement nut for the one that special spanner is for. I got one but then didn't use it, but it was only $ 4. I got aftermarket clutch parts and saved a bunch. Those low torque values are very important too, so you need a good torque wrench. In case I sound like I know what I am talking about, I had a Harley mechanic come over and help. He had a super good torque wrench.

2004 Rebel 250, 2010 Kawasaki VN 900 LT, 2007 Searay 185, 9 kids, 1 wife
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post #5 of 13 Old 10-08-2012, 01:15 PM
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You only need to replace the spring if they are out of spec so a lot of the time you don't need to. I replaced mine anyway with springs that were the same brand as the new clutch plates. I bought KG Clutch Factory Kevlar plates and +10% springs. I have been happy with the feel and performance of them. I don't remember exactly what I paid but it was very reasonable when compared to other kits I priced. It wasn't the cheapest but by far wasn't the most expensive.

1985 Rebel 250
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post #6 of 13 Old 02-26-2015, 11:34 PM
 
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Replacing the clutch on Rebel

I, garage chick, have found a very easy process to replacing your clutch. The locking nut on the basket is hard to loosen because the clutch basket keeps turning. Someone suggested making a tool that you drill holes in it to hold the basket assembly still. Well, I broke 2 baskets by using this method so I decided to find my own way and it worked perfectly!!

1-if you pull the clutch plates forward you will see 4 holes placed at 12:00, 3:00, 6:00 and 9:00
2-pull the plates forward so you can see the holes.
3-place a small screw driver in the top hole to prevent the basket from turning
4-THAT'S IT!! Now remove or tighten the center nut.

I banged my head so many times on this job
Until I stopped banging my head and started to think....
Now I am very happy with the process and it is sooo easy a caveman can do it!!

I can't figure out how to post pics...

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post #7 of 13 Old 02-26-2015, 11:42 PM
 
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4 holes in what?

2004 Rebel 250, 2003 BMW K1200GT (roadburner), 2004 BMW R1200GS(all purpose),
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post #8 of 13 Old 02-27-2015, 12:15 AM
 
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Oops sorry I will edit my post tomorrow. 4 holes in the basket that holds the played. In the back of the basket you will see them.

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post #9 of 13 Old 02-27-2015, 12:18 AM
 
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PLATES! Not played

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post #10 of 13 Old 02-27-2015, 04:00 PM
 
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there are many ways to go about changing the clutch plates and holding the clutch basket but once you have used the EBC clutch removal tool which holds the clutch basket you will never try it any other way for it does not put the load on the 4 bosses of the basket where the springs go but rather on the inside of the basket where the load belongs. Changing the clutch is one of the easiest things to do if you have the proper tools but yet one of the hardest things to do with out the proper tools.



I used Barnett Kevlar plates bought them as a kit with springs. As for as I know Barnett is the finest on the market.


Parts needed for clutch replacement 250. Each particular situation may be different, for instants if the clutch cover gasket does not tear it may not need to be replaced or if the clutch springs are within allowable specifications they may not need to be replaced.

6 friction plates –--------------Honda part # 22201-KBG-900
6 steel plates –-----------------Honda part # 22321-KE8- 000
4 clutch springs –--------------Honda part # 22401-KT0-000
1 lock nut 16mm--------------Honda part # 90231-KB5-720
1 clutch cover gasket----------Honda part # 11393-KBG-772
1 spanner socket----------------Motion Pro part # 08-0015
1 EBC clutch removal tool -----EBC part # CTO12SP
1 torque wrench
2 quarts of engine oil

I used Barnett Kevlar plates

Parts needed for clutch replacement 250. Each particular situation may be different, for instants if the clutch cover gasket does not tear it may not need to be replaced or if the clutch springs are within allowable specifications they may not need to be replaced.

6 friction plates –--------------Honda part # 22201-KBG-900
6 steel plates –-----------------Honda part # 22321-KE8- 000
4 clutch springs –--------------Honda part # 22401-KT0-000
1 lock nut 16mm--------------Honda part # 90231-KB5-720
1 clutch cover gasket----------Honda part # 11393-KBG-772
1 spanner socket----------------Motion Pro part # 08-0015
1 EBC clutch removal tool -----EBC part # CTO12SP or
1 strap wrench-----------------(clutch removal tool recommended)
1 torque wrench
2 quarts of engine oil

1986 Honda Rebel 450 28,000 miles
1987 Honda Rebel 450 5,000 miles
2009 Honda Rebel 250 8,000 miles
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