Installing The Clutch - Yamaha XV19SX(C) Service Manual

1
EAS25260

INSTALLING THE CLUTCH

1. Install:
• Clutch housing
• Thrust washer
NOTE:
• Lubricate the clutch housing bearings with en-
gine oil.
• Make sure that the primary driven gear teeth
and primary drive gear teeth mesh correctly.
• Make sure that the primary driven gear teeth
and oil pump driven gear teeth mesh correctly.
2. Install:
• Clutch boss assembly "1"
NOTE:
• Install the clutch damper spring "2" with the
"OUTSIDE" mark facing out.
• If the wire circlip "3" has been removed, care-
fully install a new one.
2
New
3. Install:
• Clutch boss "1"
2
4
3
1
3
• Washer
• Conical spring washer "2"
• Clutch boss nut "3"
Clutch boss nut
105 Nm (10.5 m·kg, 75 ft·lb)
NOTE:
• Lubricate the clutch boss nut threads and con-
ical spring washer mating surfaces 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 a cutout "b" in
the main axle.
Universal clutch holder
90890-04086
YM-91042
4
3
4. Lubricate:
• Friction plates
• Clutch plates
(with the recommended lubricant)
Recommended lubricant
Engine oil
5. Install:
• Friction plates 2 "1"
• Clutch plates
• Friction plate 1 "2"
NOTE:
• First, install a friction plate and then alternate
between a clutch plate and a friction plate.
• Align a projection on each friction plate 2 "1"
with the " " mark "a" on the clutch housing
and align a projection on friction plate 1 "2" with
the punch mark "b" on the housing.
5-69
CLUTCH
1
2
a
b