Freebird Posted August 31, 2006 #1 Posted August 31, 2006 Clutch Hope this will explain all you will ever have to know about the clutch in your Venture, because sooner or later the tack will start going up faster then the speedometer when you punch it to pass. The one strange thing I have noticed about the Venture clutch is that you notice slippage in the higher gears not in first or second. The time it takes to inspect the clutch in your Venture before a long trip is well worth it. Things you will need before starting 5 mm Allen or hex socket, 6 new springs or diaphragm spring, a new clutch gasket, a 6 in ruler, a set of calipers or a 01 in micrometer. With the bike on the side stand the clutch cover can be removed with out loss of oil and if you start with a cold engine a novice should be able to complete the the inspection within two hours (one hr. at the Yamaha shop). After you have the cover off, remove the six bolts from the clutch and remove the driven plate (pressure plate), then remove the steel and fiber disks inspecting them for excessive wear and color. If the steel plates look blue or purple in spots or the knurling (diamond shaped indentations) are uneven replace them as they are warped. If they look good it might be a good idea to have them glass beaded or sand blasted to remove any glaze as they seem to cause slippage before the fiber plates are out of tolerance. You should now see the last metal plate held in with a long wire that goes all the way around the center of the clutch boss. This plate and the friction plate behind it need not be checked unless you intend to replace all of the metal plates. Have them de glazed if the clutch has been chattering, because they are, used as a damper. Now check the splines on the clutch boss for chafing where the plates run, as this can cause erratic operation. If the chafing (necks or grooves) are slight to moderate, you can carefully de-burr with a file or replace the boss. Now check all parts to see that they are within there ware limits listed. If the friction plates are ok it might be a good idea to de glaze them with a wire brush. I have listed the parts and there ware limits for both types of venture clutch. To reassemble start with one of the 6 friction plates that have the two round notches, alien the two notches with the two marks on the clutch housing, now place a metal plate on the clutch boss, repeat this until you have replaced the 6 plates then take the last plate with the large square notch and alien it with the two marks on the clutch housing . When you put the pressure plate on, alien the mark on the clutch boss with the hole or mark on the pressure plate then place the 6 springs or the diaphragm spring and retainer and tighten the 6 bolts evenly. replace the clutch cover and torque the 5 mm bolts to 8.7 ft-lb. most of the information in this article can be found in a Yamaha service manual that can be purchase through M.T.A. Remember to replace the hydraulic fluid with dot 3 once a year or if turns dark. Parts Standard clutch 1983-1985 6 springs #90501-24734-00 normal length 41.6 mm / 1.64 in minimum length 40.3 mm / 1.59 in replace if the springs are to short or you have over 30,000 miles on the clutch. 6 friction plates #26h-16307-00-00 1 friction plate #26h-16331-01-00 1 friction plate #26h-16321-00-00 thickness 2.9 to 3.1 mm / 0.1142 to 0.1220 minimum thickness 2.8 mm / 0.11 in 7 metal clutch plates #26h-16324-00-00 thickness 2.2 to 2.4 mm / 0.0866 to 0.0945 in no minimum listed warp limit 0.2 mm / 0.0079 in 1 clutch boss #26h-16371-00 1 gasket #26h-15462-00 1986-1991 venture / v-max diaphragm clutch 1 clutch spring #1fk-16334-00-00 6 friction plates #26h-16307-00-00* 1 friction plate #26h-16321-00-00* 1 friction plate #26h-16331-00-00* 7 metal clutch plates #26h-16324-00-00* 1 metal clutch plate #1fk-16352-00-00* 1 clutch boss #1fk-16371-00-00 1 gasket #26h-15462-00-00* *(parts are the same as 1983-85 clutch) Fred J. Vogt
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