User Guide

2A-32
Chapter 2 Part A Engine, clutch and transmission (XV535 models)
16.5a Take off the pressure plate ...
16.5b ... together with the push piece (A)
and short pushrod (B)
16.5c The friction plates and metal plates
can be removed as a set
16.6a Pull out the steel ball with
a magnet...
16.6b ... then pull out the long pushrod 16.7a Bend back the lockwasher
16.7b You'll need a tool to keep the clutch hub from turning; this
is the Yamaha special tool...
1) Clutch boss nut 2) Holding tool
16.7c ... or you can make your own tool from steel strap
5 Remove the pressure plate, then take off the friction plates and
metal plates as a set (see illustrations).
6 Remove the steel ball and the long pushrod (see illustration).
7 Bend back the lockwasher on the clutch boss nut (see
illustration). Loosen the nut, using a special holding tool (Yamaha tool
no. YM-91402, part no. 90890-04086 or equivalent) to prevent the
clutch housing from turning (see illustration). An alternative to this tool
can be fabricated from some steel strap, bent at the ends and bolted
together in the middle (see illustration). You can also make a holding
tool by drilling through a steel plate and friction plate and bolting them
together (see illustration). Slip the bolted plates into their normal
installed position to lock the clutch housing artd clutch boss together.
To keep the engine from turning, wedge a rag between the teeth of the
primary drive gear and the driven gear on the clutch housing. Once the
nut is loose, remove it (see illustration).