Go Back   Horizons Unlimited - The HUBB > Technical, Bike forums > Yamaha Tech
Torque problems while reassembling my clutch Torque problems while reassembling my clutch
Register FAQ Calendar Today's Posts
Yamaha Tech Originally the Yamaha XT600 Tech Forum, due to demand it now includes all Yamaha's technical / mechanical / repair / preparation questions.
Photo by Ellen Delis, Lagunas Ojos del Campo, Antofalla, Catamarca

I haven't been everywhere...
but it's on my list!


Photo by Ellen Delis,
Lagunas Ojos del Campo,
Antofalla, Catamarca



Reply
 
LinkBack Thread Tools Display Modes
  #1  
Old 30 Apr 2008
Registered Users
New on the HUBB
  
Join Date: Dec 2007
Location: Vermillion, SD
Posts: 9
Torque problems while reassembling my clutch
I was having shifting problems with my '89 XT600, so I removed the clutch for routine maintenance, and when doing that I noticed that the clutch boss nut came off without a wrench. Other things were loose too, but not as bad, so I figured that this looseness was the reason for the shifting problems.

Anyway, as I'm reassembling it, I tighten the clutch boss nut to the torque specified in my manual, 51 ft lbs, and I notice that the clutch boss and the primary drive are bound, essentially rendering the clutch useless. Taking the clutch boss nut off cures the problem, so I finger-tighten the nut. If I tighten it so that it doesn't spin freely (about 2ft lbs), the clutch boss spins freely. If I tighten it as tight as I can with my fingers (maybe 3-4 ft lbs, I don't know), it binds up. It will still spin if I really grab onto it, but there's very noticeable resistance.

Is there something wrong with the clutch, or might something be out of spec? If so, what could it be? Or should I just give up and finger-tighten the clutch boss nut and count on the lock washer tabs to hold it in place?

Any help is appreciated, thanks.
Reply With Quote
  #2  
Old 30 Apr 2008
Registered Users
Veteran HUBBer
  
Join Date: Jan 2001
Location: Stockholm
Posts: 651
Washer?
There is supposed to be a washer (approx. 2 mm thickness, with splines on the inside) between the two clutch parts. Are you sure this is installed - if not this would explain the problem.
Normally, the clutch nut should be tightened, 70 Nm as I remember.

So, what your bike has is not what it should be.

If you like, can send you exploded view of the clutch showing the parts. PM me.

Auke
__________________
Auke
http://aukemarieke.blogspot.com
Reply With Quote
  #3  
Old 30 Apr 2008
Registered Users
Veteran HUBBer
  
Join Date: Apr 2003
Location: Manchester UK
Posts: 235
Quote:
Originally Posted by aukeboss View Post
There is supposed to be a washer (approx. 2 mm thickness, with splines on the inside) between the two clutch parts. Are you sure this is installed - if not this would explain the problem.
Normally, the clutch nut should be tightened, 70 Nm as I remember.

So, what your bike has is not what it should be.

If you like, can send you exploded view of the clutch showing the parts. PM me.

Auke
Ditto, and it's a right miserable b"£$ER% to loosen or tighten too. I broke a basket when the torque wrench slipped off £$%^&*!
Reply With Quote
  #4  
Old 30 Apr 2008
bacardi23's Avatar
Registered Users
Veteran HUBBer
  
Join Date: Sep 2007
Location: XXX<-Portugal->Azores->Santa Maria (island)
Posts: 1,544
Use a airgun to take that nut on and off...I broke to studs trying to take the nut out and had to buy a new part(the one that has the holes for the clutch springs)

As said, there should be a washer between both clutch hub and boss... it is about 3mm thick..

When I toke my clutch apart to put the the idle gear for the kickstart I forgot to put that washer back in between both clutch parts and it was happening the same thing that's happening to you...

Oh and get the other washer that helps the nut not vibrate loose!very important!

Vando
Reply With Quote
  #5  
Old 30 Apr 2008
Registered Users
Veteran HUBBer
  
Join Date: Jan 2001
Location: Stockholm
Posts: 651
Trick
To block the clutch to do / undo the nut ....

1. Put in 2nd gear
2. Fix tie-down strap, the sturdy type, around the wheel with tyre, two or three times around does it. Other end goes to a sturdy point on the frame (footrest or whatever)
3. Get out your wrench and undo / do the nut

Obviously, only works with the engine in the frame and the chain installed ... :-)

Auke
__________________
Auke
http://aukemarieke.blogspot.com
Reply With Quote
  #6  
Old 30 Apr 2008
Registered Users
New on the HUBB
  
Join Date: Dec 2007
Location: Vermillion, SD
Posts: 9
I have a tool specifically for holding the clutch boss, it looks like a Vice-Grip with big L-shaped jaws. It works pretty well. I broke one of the studs off of my original clutch boss, thinking I could get by without the tool. So I bought a new clutch boss, and the appropriate tool to put it on.

The washer that goes in between the two pieces is there, although it seems to be stuck in place and I can't get it off. It does not rotate indepentently of the primary gear, and seems to be what the clutch boss is tightening against when I tighten the nut. All the parts appear to be normal, but I can't torque them properly.

I have a new (well, once used) lock washer for the nut, but I'd like to know why I can't tighten the clutch nut as much as I'm supposed to.

Thanks for all the help so far guys!
Reply With Quote
Reply

« Previous Thread | Next Thread »

Currently Active Users Viewing This Thread: 1 (0 Registered Users and/or Members and 1 guests)
 

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts
BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

Similar Threads
Thread Thread Starter Forum Replies Last Post
clutch problems???????????? klunk yed Honda Tech 2 4 Apr 2008 21:29
Vstrom 1000 Clutch Problems in Peru Laser Jock Suzuki Tech 5 21 Feb 2008 23:26
Clutch problems or what? rowey007 Suzuki Tech 5 20 Sep 2005 10:37
BHP per Tonne vs Torque Jabbawocky Equipping the Overland Vehicle 23 11 Mar 2005 00:38
clutch problems martync Honda Tech 4 17 Feb 2004 03:43

 
 

Announcements

Thinking about traveling? Not sure about the whole thing? Watch the HU Achievable Dream Video Trailers and then get ALL the information you need to get inspired and learn how to travel anywhere in the world!

Have YOU ever wondered who has ridden around the world? We did too - and now here's the list of Circumnavigators!
Check it out now, and add your information if we didn't find you.

Next HU Eventscalendar

HU Event and other updates on the HUBB Forum "Traveller's Advisories" thread.
ALL Dates subject to change.

2024:

Add yourself to the Updates List for each event!

Questions about an event? Ask here

HUBBUK: info

See all event details

 
World's most listened to Adventure Motorbike Show!
Check the RAW segments; Grant, your HU host is on every month!
Episodes below to listen to while you, err, pretend to do something or other...

2020 Edition of Chris Scott's Adventure Motorcycling Handbook.

2020 Edition of Chris Scott's Adventure Motorcycling Handbook.

"Ultimate global guide for red-blooded bikers planning overseas exploration. Covers choice & preparation of best bike, shipping overseas, baggage design, riding techniques, travel health, visas, documentation, safety and useful addresses." Recommended. (Grant)



Ripcord Rescue Travel Insurance.

Ripcord Rescue Travel Insurance™ combines into a single integrated program the best evacuation and rescue with the premier travel insurance coverages designed for adventurers.

Led by special operations veterans, Stanford Medicine affiliated physicians, paramedics and other travel experts, Ripcord is perfect for adventure seekers, climbers, skiers, sports enthusiasts, hunters, international travelers, humanitarian efforts, expeditions and more.

Ripcord travel protection is now available for ALL nationalities, and travel is covered on motorcycles of all sizes!


 

What others say about HU...

"This site is the BIBLE for international bike travelers." Greg, Australia

"Thank you! The web site, The travels, The insight, The inspiration, Everything, just thanks." Colin, UK

"My friend and I are planning a trip from Singapore to England... We found (the HU) site invaluable as an aid to planning and have based a lot of our purchases (bikes, riding gear, etc.) on what we have learned from this site." Phil, Australia

"I for one always had an adventurous spirit, but you and Susan lit the fire for my trip and I'll be forever grateful for what you two do to inspire others to just do it." Brent, USA

"Your website is a mecca of valuable information and the (video) series is informative, entertaining, and inspiring!" Jennifer, Canada

"Your worldwide organisation and events are the Go To places to for all serious touring and aspiring touring bikers." Trevor, South Africa

"This is the answer to all my questions." Haydn, Australia

"Keep going the excellent work you are doing for Horizons Unlimited - I love it!" Thomas, Germany

Lots more comments here!



Five books by Graham Field!

Diaries of a compulsive traveller
by Graham Field
Book, eBook, Audiobook

"A compelling, honest, inspiring and entertaining writing style with a built-in feel-good factor" Get them NOW from the authors' website and Amazon.com, Amazon.ca, Amazon.co.uk.



Back Road Map Books and Backroad GPS Maps for all of Canada - a must have!

Your ad could be here, on EVERY page of the HUBB, or the whole website, or as many as you like!

New to Horizons Unlimited?

New to motorcycle travelling? New to the HU site? Confused? Too many options? It's really very simple - just 4 easy steps!

Horizons Unlimited was founded in 1997 by Grant and Susan Johnson following their journey around the world on a BMW R80G/S.

Susan and Grant Johnson Read more about Grant & Susan's story

Membership - help keep us going!

Horizons Unlimited is not a big multi-national company, just two people who love motorcycle travel and have grown what started as a hobby in 1997 into a full time job (usually 8-10 hours per day and 7 days a week) and a labour of love. To keep it going and a roof over our heads, we run events all over the world with the help of volunteers; we sell inspirational and informative DVDs; we have a few selected advertisers; and we make a small amount from memberships.

You don't have to be a Member to come to an HU meeting, access the website, or ask questions on the HUBB. What you get for your membership contribution is our sincere gratitude, good karma and knowing that you're helping to keep the motorcycle travel dream alive. Contributing Members and Gold Members do get additional features on the HUBB. Here's a list of all the Member benefits on the HUBB.



All times are GMT +1. The time now is 03:56.

Contact Us - Horizons Unlimited Motorcycle Travellers Website - Archive - Privacy Statement - Top