Clutch

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Clutch Basket

Install the clutch housing, check for any broken "fingers" and heavy wear

Install the Toothed washer, Yamaha calls this "thrust plate 1"

Clutch boss and Clutch pack

Install the Clutch boss as shown then install the clutch in this fashion or in the picture below starting from right to left. Oil the fiber friction plates when installing them.

1. Friction plate (regular)
2. Clutch plate (metal)
3. Friction Plate 2 (#5 below, inner diameter is bigger)
4. Clutch Boss Spring (fits inside Friction plate 2, step 3)
5. Clutch Plate (metal)
6. Frinction plate (fiber)
7. Clutch Plate (metal)
8. Friction plate (fiber)
9. Clutch Plate (metal)
10. Friction plate (fiber)
11. Clutch plate (metal
12. Friction plate (fiber)
13. Clutch plate (metal)
14. Friction plate (fiber)
15. Clutch plate (metal)
16. Friction plate 2 (#5 on the left below, inner diammeter larger

 

Part Number 8 in the above picture actually goes inside the clutch fiber plate to its right - part number 5.

Install a new Lock washer thingy and tighten the clutch boss nut on it.

Clutch Boss nut torque 90Nm or 65Ft lb.
Lock Washer P/N 90215-20231-00 (#18 on alba's clutch fiche)

Pressure Plate

1. Install the "Push Rod" (similar in action to a "throw out bearing on a manual tranny car) into the Pressure plate, make sure it has its washer and bearing still - the bearing goes on the push rod first
2. Install the pressure plate (in the picture to the left) align the arrow and the dot as shown.

Pressure Plate install..

1. Install all 5 bolts and nuts
2. Tighten them in criss cross or start fashion as you would a cars wheel. Tighten them all a few turns at a time until snug.

Now Torque them to 8Nm or 5.8ft pounds

Right Side Case

Inspect/clean gasket mating surfaces one last time on both the case half and the clutch cover.

Install the gasket, I use a tacky spray to keep everything in place. I do not use gasket sealer because it looks like crap and I have had no luck with it. Make sure you have the dowels in, mine fell out when I first dissasembled the motor. One in the front and one in the rear (rear pictured)

This can be a little tricky...

1. Point the cogs on the push rod toward the back lower end of the motor, this will help it align with the right side clutch cover
2. Take the circlip off the clutch lever on the clutch cover so you can turn it. The idea is to pull the clutch push rod up into the cover using the clutch rod which has the mating gear on it for the push rod.
3. Make a couple alignment checks and go ahead and install the cover, turn the clutch rod and manuever the cover to align properly. This is another reason to not use gasket sealer as it would be all over the place during this step.