Topic Approved and moved to Help me Section.

Will you remove the entire clutch assembly, or only the clutch plates?
Kindly clarify what will you replace exactly, and also if is this due to a problem in the bike, or just for learning purpose only?

go to a good mechanic, if i am not wrong, clutch removal needs a special tool, and if you put clutch plates wrongly while re-assembling, you are gonna mess big time.

Removing clutch plates on an pulsar is a tedious task and requires proper tools.



The wet clutch plates are a set of elements and need to be properly adjusted while inserting. Hence, take it to a mechanic only.

Other than your normal set of tools you will require a tool to hold the clutch basket from spinning while you loosen the clutch nut. This can be had at your local tool shops and looks like this



Make sure you have the proper 6 point socket for the clutch nut to avoid damage to the nut, a 12 point socket sometimes tends to slip.

Its a straight forward task to change the plates, once you have the cover open, loosen the 6 bolts on the spring retaining steel plate. I would advise you to change the bolts & springs before reassembly.

Once you have the springs out of the way, have someone hold the basket with the tool shown above and with a socket wrench loosen the clutch nut. An impact wrench is the best tool for this job.

Then its just a matter of sliding the pressure plates and plates out. Just make a note of the order of the plates in the basket. While you have the plates out check the basket for any play between the gear and the basket and with the input shaft. Lubricate the friction plates with fresh engine oil before assembly & do not over tighten the bolts which hold the springs.

Here are some pictures for your reference https://picasaweb.google.com/suhirth...cClutchUpgrade

Not mine, picasa album of another guy.

Lets not try to discourage anyone from doing a bit of DIY. Clutch plate change out is a simple task if done with the correct tools & knowledge. Clutch plates require no 'adjustment', the only point one needs to be careful about is the order of the plates & the tightening torque on the clutch nut & spring bolts.