Assembling the Honda XR80 clutch plate is basically a matter of getting everything in the right order, and remembering to cover each clutch plate and friction disc with oil before adding it to the assembly. Use the same oil as the engine’s crankcase — but fresh. Otherwise, you could assemble the clutch, close up the engine, and find your clutch is locked up.

Instructions

1) Cover a friction disc with oil, then set it onto the raised side of the clutch center. The friction disk is basically round, but tabbed on the outside edge and round on the inside edge. The XR80 has three of them. The clutch center, has a splined hole in the center, with four holes around it in a square pattern.

2) Oil a clutch plate, and set it onto the friction disc you just installed on the clutch center. The clutch plate is round on the outside edge and tabbed on the inside edge. There are two.

3) Install another friction disc and the last clutch plate, then the last friction disc. Don’t forget the oil. The friction disc outer tabs should be lined up with each other.

4) Insert the pressure plate, a round plate with four cylinder-shaped posts, through the four holes in the clutch plate from the friction disc side. Set this assembly aside for now.

5) Slide the outer clutch housing onto the transmission shaft. It’s gear should mesh with the primary drive gear; the small gear on its right. The outer clutch housing is the biggest clutch part. Everything else will go inside it.

6) Install the thrust washer. It’s round on the outside and tabbed on the inside, so it can slip onto the splined transmission shaft and go up against the outer clutch housing.

7) Carefully pickup the parts assembled in steps 1 to 4, and install them onto the transmission shaft, pressure plate first. The friction disk tab’s will slide into the cut outs in the outer clutch housing.

8) Put the circlip on. There is a groove around the transmission shaft that it goes into. Make sure it is seated in this groove.

9) Place the four springs over the four cylinder-shaped posts inside the assembly. Put the lifter plate over the springs. It’s square shaped with a bearing in the middle and a hole in each of its four corners. Align the holes with the four cylinder-shaped posts. Install the four bolts with their washers to secure the lifter plate. Tighten the bolts little by little in a crisscross manner, not a circular manner.

10) Put the shaft end of the lifter rod through the bearing in the lifter plate.

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