Installing The Clutch - Yamaha XT1200Z 2010 Service Manual

Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys
Excessive noise during operation → Replace
the clutch housing and crankshaft as a set.
EAS25250

INSTALLING THE CLUTCH

1. Install:
• Thrust plate "1"
• Spacer
• Clutch housing
TIP
Install the thrust plate "1" with the paint mark "a"
facing out.
1
2. Install:
• Clutch boss assembly "1"
TIP
• If the wire circlip "2" has been removed, care-
fully install a new one.
• Install the clutch damper spring "3" with the
"OUTSIDE" mark facing out.
3
New
3. Install:
• Clutch boss assembly "1"
• Conical spring washer "2"
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1
a
1
2
• Clutch boss nut "3"
Clutch boss nut
125 Nm (12.5 m·kgf, 90 ft·lbf)
TIP
• Lubricate the conical spring washer and clutch
boss nut threads with engine oil.
• Install the conical spring washer "2" with the
"OUT" mark "a" facing out.
• While holding the clutch boss with the univer-
sal clutch holder "4", tighten the clutch boss
nut.
• Stake the clutch boss nut "3" at cutouts "b" in
the main axle.
Universal clutch holder
90890-04086
YM-91042
4
b
3
4. Lubricate:
• Friction plates
• Clutch plates
(with the recommended lubricant)
Recommended lubricant
Engine oil
5. Install:
• Friction plates
• Clutch plates
TIP
• First, install a friction plate and then alternate
between a clutch plate and a friction plate.
• Friction plate 1 "1", which has an identification
mark made before removal, must be installed
last.
• Offset friction plate 1 "1" from the other friction
plates "2", making sure to align a projection on
friction plate 1 with the punch mark "a" on the
clutch housing.
5-63
CLUTCH
New
1
2
New
a