How to do the double D clutch mod

How to do the "Double D" Clutch Mod

Compliments of Bert......

I highly recommend a spring retainer, which was previously manufactured by Don Smith to keep the
plates in-line and on top of each other. Saves a chewed-up clutch basket and metal shavings in the oil
(own experience). Hope that PCW will add this retainer ring to the kit.

1. Place the bike on the SIDE STAND. You do not need to drain oil.

2. Remove clutch cover and gasket. Catch dripping oil with a small pan.

3. Remove diaphragm spring by removing the six 6mm hex bolts with a 10mm socket. Now remove
the aluminum pressure plate.

4. Remove the clutch plates one at a time, using a 90 deg pick or coat hanger. Inspect the friction
plates for wear and the steel plates for over-heating (blue discoloration). Keep the plates in order for assy.

5. Look inside the hub and you'll find the ends of a retaining wire that holds the clutch damper plate
in place. Remove the wire by pushing the ends back through the holes in the inner hub.

6. With the wire removed you can pull the full sized steel plate out. Now you can see the narrow f
riction disc, small wave washer and thin steel plate under the wave washer. Discard the friction disc,
wave washer and thin steel plate, as they will be
of no further use.

7. Get a new friction disc (Yamaha P/N 26H-16307-00) and put a small amount of
engine oil on the new plate. Slide it in where the small wave washer used to be. Install the large steel
plate and forget about the wire. You don't need that either.

8.Install the clutch plates in the order that you removed them, pressure plate and diaphragm spring.

9. Install the second diaphragm spring.

10. Torque the six 6mm bolts to 5.8 ft-lbs or 70 in-lbs (that's very little torque).

11. Install the new clutch cover gasket (P/N 26H-15462-00-00) and cover. Don't over tighten the cover.
Make sure to start your Max and check for leaks.

Compliments of Mike......

One more thing I'd like to add to this.

When reinstalling the steel plates, make sure they are all facing the same direction. If you look closely at them,
you will see all the edges on one side are slightly rounded, while the other side is sharp, as a result of the die
cutting process.

Mixing directions will result in increased clutch drag when disengaged, and possibly reduce holding power as well.

Additional comment by Kelly....

Don told me that's too much torque, and I'm here to say, HE'S RIGHT. One of my bolts snapped before they got
to spec torque. DON'T TORQUE THEM! Put on some loctite, and make them snug. Believe me on this. If you don't,
and try torquing them anyway, I'll give advice on how to fix the broken bolt inside the basket.

Back to FAQ'S
Back to Tips Page