Engine, clutch and transmission 2»29
16.6 Remove the clutch plates as a pack
16.7a Bend back the lockwasher tabs
16.7b Slackening the clutch nut using the
holding tool described
lockwasher from the mainshaft, noting how it fits.
Discard the lockwasher as a new one must be used
on installation.
8 R
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v
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t
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c
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ntre and the outer thrust plate from the shaft
(see
illustrations 16.26a and 16.25).
9
Support the clutch housing and remove the
large sleeve from its centre
(see illustration).
To
get a grip on the sleeve, grasp the housing and
wiggle it out and in - it should draw the sleeve out
far enough to grip it. If difficulty is experienced,
screw a 6 mm bolt (a clutch cover bolt is the
correct size) into one or both of the threaded
holes and pull the sleeve from the housing.
10 Remove the caged needle roller bearing
from the housing if it didn't come away with the
sleeve, and then remove the housing from the
engine
(see illustrations 16. 24a and 16.23).
11
Remove the inner thrust plate
(see
illustration 16.22b)
and,
with
the
EEHJ
TSP
WWIV-
A clutch centre
holding tool can
easily be made
using two strips of steel with the
ends bent over,
and bolted together in the middle
exception of 1989 to 1991 XTZ models, the
thrust washer from the shaft
(see illustration
16.22a).
12
On 1989 XTZ models, the clutch centre
anti-judder assembly can be left intact unless
the clutch has been chattering (juddering)
excessively. If it is necessary to remove it,
remove the wire retainer ring, plain plate, anti-
judder spring and spring seat.
Inspection
13
After an extended period of service the
clutch friction plates will wear and promote
clutch slip. Measure the thickness of each
friction plate using a vernier caliper (see
illustration).
If any plate has worn to or
beyond the service limit given in the
Staned by Stalker
remove them as a pack
(see illustration).
Unless the plates are being renewed, keep them
in their original order. On 1991 to 1995 TDM
models and 1990-on XTZ models, note the inner
plate fitted in the clutch centre - if you remove it,
keep it separate as it must be installed first
(see
illustration 16.27).
7
Bend back the tabs on the clutch nut
lockwasher
(see illustration).
To remove the
clutch nut the transmission input shaft must be
locked. This can be done in several ways. If the
engine is in the frame, engage 1st gear and have
an assistant hold the rear brake on hard with the
rear tyre in firm contact with the ground.
Alternatively, the Yamaha service tool (pt. no.
90890-04086), or a similar homemade tool made
from two strips of steel bent at the ends and
bolted together in the middle (see
Tool tip),
can
be used to hold the clutch centre whilst the nut is
slackened
(see illustration).
Unscrew the nut
and remove the
J.5IN APPROX.
Of CLUTCH CENTRE SPLINES
16.9 Remove the inner sleeve ;
described
16.13 Measuring clutch friction plate
thickness
