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Yamaha Tech Originally the Yamaha XT600 Tech Forum, due to demand it now includes all Yamaha's technical / mechanical / repair / preparation questions.
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  #1  
Old 9 Dec 2007
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87 Tenere 1-VJ user manual & How to replace clutch

Hello all,

More learning to be done.

Firstly does anyone have access to a user manual or service manual for the 1-VJ it appears to be strangely low key

I have had a great deal of fun so far with my bike but want to get it running a bit smoother. Hence the request for a user manual.

My clutch takes at the very extent of the travel available, so I want to replace the plates (and springs) but before I go nuts:

How easy is it to do this with basic tools?
Any specific tools needed?
What is the time frame?
What parts are needed? - Clutch plates, springs and gasket, anything else?
Oh and Any tips? - Will some vital, highly strung spring jump out and run away from me?

Thats about it: except for the manual request. Please please please

The way I figure it, is to remove battery and tank, lie bike on side and then attack with spanners, heat gun and 3in1 penetrating spray. Alternate order and try again (remembering to apply heat before spray.)



My bike has the fittings in place for an automatic kick start decompressor on the cylinder head, but no attachment to the kickstart lever: another thread
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  #2  
Old 9 Dec 2007
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Join Date: Jan 2001
Location: Stockholm
Posts: 651
Easy job

Quote:
Originally Posted by photographicsafaris View Post
Hello all,

More learning to be done.

Firstly does anyone have access to a user manual or service manual for the 1-VJ it appears to be strangely low key

** Somebody else? But, the engine is the same as the later 3AJ model, except for the oil pump and technical data.

I have had a great deal of fun so far with my bike but want to get it running a bit smoother. Hence the request for a user manual.

My clutch takes at the very extent of the travel available, so I want to replace the plates (and springs) but before I go nuts:

How easy is it to do this with basic tools?
Any specific tools needed?

** Nothing special needed.

What is the time frame?

** Depends; As a novice, take your time, work cleanly, check and check again, 1 day?

What parts are needed? - Clutch plates, springs and gasket, anything else?

** That's it. Probably no need to replace the steel clutch plates.

Oh and Any tips? - Will some vital, highly strung spring jump out and run away from me?

** No nasty springs running away. Be sure to liberally lubricate the clutch plates in engine oil before installation.
As I remember, there are two narrower clutch plates. They should go at the positions as per manual.
The allen bolts holding the clutch cover are of differents lengths. Make a carton with holes to keep them in the correct location. This saves a lot of time and possible damage to threads in your precious engine.

Thats about it: except for the manual request. Please please please

The way I figure it, is to remove battery and tank, lie bike on side and then attack with spanners, heat gun and 3in1 penetrating spray. Alternate order and try again (remembering to apply heat before spray.)



My bike has the fittings in place for an automatic kick start decompressor on the cylinder head, but no attachment to the kickstart lever: another thread
Good luck!
Auke
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http://aukemarieke.blogspot.com
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  #3  
Old 10 Dec 2007
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Join Date: Dec 2007
Location: Christchurch,New Zealand
Posts: 95
We just did my clutch recently.
Taking it all apart is very easy,even a monkey could do it
I'd probably replace your steel plates as well,just piece of mind really.
To give you an idea of what I paid for my bits in New Zealand....The whole lot,fibre plates,steel plates and new springs cost me around $216NZD!

Only problem was the amount of gasket sealer on the engine and casing,took a bit to get it cleaned properly!
Only real major thing is getting the alignment done properly.I'm pretty sure you need to remove the starter motor to see the mark on the casing.
Also,make sure you have some 6mm helicoils at hand! I'd imagine just about every man and his dog has pulled your engine apart in the last 20 odd years.I know mine has been pulled apart numerous times by the fact every bolt hole the right side of the engine has a helicoil in it!

As for a manual,I managed to find an ex-Yamaha workshop supplimental manual locally,which pretty much covers the extra bits the Tenere has over the normal XT - Starter motor etc.I'm also sure the clutch is different as the plate sizes I found on some of the downloadable manuals were different to what this book listed.
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