Assembling The Clutch Release Cylinder; Installing The Clutch Release Cylinder - Yamaha VMAX 2009 Service Manual

1. Check:
• Clutch release cylinder body
Cracks/damage → Replace the clutch re-
lease cylinder.
2. Check:
• Clutch release cylinder
• Clutch release cylinder piston
Rust/scratches/wear → Replace the clutch
release cylinder and clutch release cylinder
piston as a set.
EAS25340
ASSEMBLING THE CLUTCH RELEASE
CYLINDER
EWA2S31011
WARNING
• Before installation, all internal clutch com-
ponents must be cleaned and lubricated
with clean or new clutch fluid.
• Never use solvents on internal clutch com-
ponents as they will cause the piston seal
to swell and distort.
• Whenever a clutch release cylinder is dis-
assembled, replace the piston seal.
Recommended fluid
DOT 4
EAS25350
INSTALLING THE CLUTCH RELEASE
CYLINDER
1. Install:
• Clutch release cylinder "1"
• Clutch release cylinder plate "2"
• Dowel pins "3"
TIP
Push the plate onto the clutch release cylinder
piston, and then turn the plate so that the clasps
"a" hooks onto the clutch release cylinder. Then
install the dowel pins.
1
2. Install:
• Clutch hose gasket "1"
• Clutch hose "2"
3
a
2
a
3
New
• Clutch hose union bolt "3"
Clutch hose union bolt
30 Nm (3.0 m·kgf, 22 ft·lbf)
ECA2S31042
NOTICE
When installing the clutch hose onto the
clutch release cylinder, make sure the pipe
"a" touches the projection "b" on the clutch
release cylinder body.
a
New
1
3. Fill:
• Clutch master cylinder reservoir
(with the specified amount of the recom-
mended clutch fluid)
Recommended fluid
DOT 4
EWA13370
WARNING
• Use only the designated clutch fluid. Other
clutch fluids may cause the rubber seals to
deteriorate, causing leakage and poor
clutch performance.
• Refill with the same type of clutch fluid that
is already in the system. Mixing clutch flu-
ids may result in a harmful chemical reac-
tion, leading to poor clutch performance.
• When refilling, be careful that water does
not enter the clutch fluid reservoir. Water
will significantly lower the boiling point of
the clutch fluid and could cause vapor lock.
ECA13420
NOTICE
Clutch fluid may damage painted surfaces or
plastic parts. Therefore, always clean up any
spilt clutch fluid immediately.
TIP
In order to ensure a correct reading of the clutch
fluid level, make sure that the top of the reservoir
is horizontal.
5-63
CLUTCH
2
b
3