Question about 1983 Yamaha XS 400 L Maxim

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Clutch cover bolts - 1983 Yamaha XS 400 L Maxim

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Posted on Oct 22, 2013

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I pull the clutch lever and it wont disengage. Before i ave done some work on it, pull out the front sprocket cover and took out the push rod (chain sprocket change), put back the cover in place than the...


Drain the oil and Pull the clutch cover off. That rod connects to the clutch push button. sounds like it fell out. Undo all the little clutch cover bolts. Carefully pull the cover off leaving all the clutch plates in a stack as some are different to others usually the first or last plate .Check the center of this plate as that is where the button usually is. Put it all back together and check clutch with cover off. You should see it move away as you pull the lever. Make sure you back off your clutch first. Hope this helps cheers

Oct 23, 2013 | 2004 Suzuki GSX-R 750

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2004 Hyundai Tiburon Clutch.


First you need to remove the Transaxle.

Manual Transaxle System REMOVAL

1. Remove the engine cover.
2. Remove the battery terminal.
3. Remove the air duct.
4. Remove the battery tray.
5. Remove the air cleaner.
(1) Upper
(2) Lower
6. Remove the back-up lamp switch.
7. After removing the CKP sensor, O2 sensor and oil pressure switch wiring bracket, separate the connectors.
8. Remove the brake fluid leveling sensor connector.
9. Remove the speedometer driven gear connector.
10. Remove the clutch release cylinder mounting bolt.
11. Remove the cotter pin of the shift cable (transaxle side).
12. Remove the cotter pin of the select cable. (transaxle side)
13. Remove the clip of the shift cable (transaxle side).
14. Remove the clip of the select cable (transaxle side).
15. Separate the steering column shaft joint.
16. Separate the power steering oil pump hose.
Be careful not to leak after separating.
17. Separate the hose after removing the clip of the power steering return hose.
18. Remove the upper connecting transaxle bolt.
19. Separate the start motor.
20. Install the engine support fixture.
21. After removing the tire, remove the caliper.
22. Remove the transaxle side cover.
23. Remove the transaxle side under cover.
24. Separate the tie rod end.
25. Remove the wheel speed sensor and the knuckle mounting bolt.
26. Drain the oil.
27. Remove the transaxle mounting bracket.
(1) Insulator bolt
(2) Body side mounting bolt (Upper)
(3) Body side mounting bolt (Side)
(4) Transaxle side mounting bolt.
28. Remove the front roll stopper.
(1) Insulator bolt
(2) Stopper bolt (Upper)
(3) Stopper bolt (Lower)
29. Remove the rear roll stopper.
(1) Insulator bolt
(2) Stopper bolt
30. Remove the drive shaft.
31. Remove the front muffler.
32. Remove the sub frame mounting bolt.
33. Install the transaxle jack.
34. Remove the transaxle lower mounting bolt to the engine.
35. Remove the transaxle assembly.

INSTALLATION
Installation is the reverse of the removal.

Then inspect and replace the clutch place and pressure plate.

INSTALLATION
1. Apply multipurpose grease to the release bearing contact surfaces and the release cylinder contact surface of the clutch release fork assembly.
When installing the clutch, apply grease to each part, but be careful not to apply excessive grease. It can cause clutch slippage and judder.
2. Apply multipurpose grease into the groove of the release bearing.
3. Apply multipurpose grease to the clutch release lever fulcrum contact surface of the clutch release fork assembly.
4. Clean the surfaces of the flywheel and pressure plate thoroughly with fine sandpaper or crocus cloth, and make certain that all oil or grease has been removed.
5. Apply a small amount of multipurpose grease to the clutch disc splines and input shaft splines.
Do not apply more grease than necessary. Too much grease could cause clutch slip or judder.
6. Using the special tool, install the clutch disc to the flywheel. When installing the clutch disc, be sure that the surface having the manufactures stamp is towards the pressure plate side.
7. Install the the clutch cover assembly onto the flywheel and install the six (6) bolts through the clutch cover into the flywheel.
8. Tighten the bolts by one or two turns at a time, in succession, to avoid bending the cover flange.
If a special tool is not available, tighten the bolt temporarily and then torque to specification in diagonal torquing sequence indicated below.
TIGHTENING TORQUE
Single mass flywheel:
15~22 N·m (150~220 kg·cm, 11~16 lb·ft)
Dual mass flywheel:
20~27 N·m (200~270 kg·cm, 14~19 lb·ft)
9. Remove the special tool.
10. Install the transaxle. (Refer to GROUP - Manual Transaxle Assembly)
11. Adjust the clutch pedal free-play. (See CH-6)
INSPECTION
1. Check the diaphragm spring end for wear and uneven height.
Replace if wear is evident or height difference exceeds the limit.
2. Check the pressure plate surface for wear, cracks and color change.
3. Check the rivets for looseness and replace the clutch cover assembly if necessary.
CLUTCH DISC
1. Check the clutch facing for loose rivets, uneven contact, deterioration due to seizure, adhesion of oil, or grease, and replace the clutch disc if defective.
2. Measure the rivet sink and replace the clutch disc if it is out of specification
3. Check for torsion spring play and damage and if defective, replace the clutch disc.
4. Clean the splines on the input shaft and install the clutch disc.
If the disc does not slide smoothly or if play is excessive, replace the clutch disc and/or the input shaft.
CLUTCH RELEASE BEARING
The release bearing is packed with grease. Do not use cleaning solvent or oil.
1. Check the bearing for seizure, damage or abnormal noise. Also check the diaphragm spring contacting points for wear.
2. Replace the bearing if the release fork contacting points are worn abnormally.
INSTALLATION
Installation is the reverse of the removal.
Then remove pressure plate and Clutch plate.

1. Insert the special tool (that came with your clutch kit) in the clutch disc to prevent the disc from falling.
2. Loosen the bolts that attach the clutch cover to the flywheel in a star pattern.
3. Loosen the bolts in succession, one or two turns at a time, to avoid bending the cover flange.

on Jan 13, 2010 | Hyundai Tiburon Cars & Trucks

1 Answer

Clutch installation


Genewrally speaking you need to remove the gear box. UNdo the bolts holding the clutch pressure plate on the flywheel. . Do this by undoing each bolt a few turns at a time. Remove pressure plate and clutch plate. Clean flywheel face. Remove bearing at center of crankshaft and replace as it will be dry and probably rusty. Fit new clutch plate taking care to observe the correct way the plate is fitted. Normally the raised hub section faces away from the flywheel. THis can be checked by pressing the plate against the flywheel and turning it and it it hits the crank bolts you have it in the wrong way round. Fit the pressure plate over the plate and insert the bolts. Some units have 2 or 4 bolts longer than the restand this is to allow the plate to be depressed a fraction to allow the other bolts to screw in. Place a clutch aligning tool through the clutch plate and into the bearing. Evenly retension the pressure plate bolts going alternately across the cover a bit at a time . When retensioned remove the clutch aligning tool. Remove and replace the throw out bearing on the clutch release forks. Ensure that the clutch kit is all new as mixing parts will not work. Refit the gear box. Basically that is the proceedure but to be exact get the manual for your vehicle to cover any extra steps needed for that vehicle.

Mar 07, 2013 | Ford Transit Connect Cars & Trucks

1 Answer

Same prob as a guy tht wrote a comment on here previous.. trajet gear box fully parted an ready to drop but the bugga wont come out. slave arm on box has been removed, but it will not release the box


says i laughing to myself ,yes they are easy to remove but you must lower the subframe ,although i have managed to change the clutch through a small gap by removing the engine mounts and moving the engine over a bit allowing the bell housing to swing back a bit so i can get to the clutch cover bolts ,then drop the disk which allows the cover to drop down WATCH YOU FINGERS .then refit the clutch leaving the cover bolts finger tight then the gearbox can be made to align up .then i drill a hole in the bell housing that aligns up with the clutch cover bolts which i then use a 1/4 socket set to tighten the clutch bolts through the hole .All clever stuff but this is a cowboy type job but at the end of the day it works

Nov 29, 2012 | 1999 Hyundai Sonata

2 Answers

Aprilia sx 50 torque setting


Hi Anonymous I am sorry you can't find the first and best tool you ever bought for your Aprilia but despair not for a mere $10 you can download another one. For more information about your issue, please visit the websites below. Good luck and have a nice day.
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Jan 15, 2012 | 2011 Aprilia SX 50

1 Answer

What is the clutch adjustment for 2003 HD Electric Glide Classic


To adjust the clutch, follow the clutch cable until you find the cable adjuster. Move the adjuster cover up or down to expose the adjuster. Loosen the lock nut and adjust the adjuster to get as much slack as possible.

Now, remove the derby cover. Loosen the locknut in center of the clutch assembly. Turn the center bolt inwards until you feel a resistance. Do not force the bolt, just turn it inward until you feel a resistance. Then back the bolt back out 1/2 turn and lock the locknut. Replace the derby cover.

Now, go back to the cable adjuster and adjust it back out until you have about 1/8" freeplay. Squeeze the clutch lever a few times and recheck the freeplay. Lock the locknut and replace the cover.

Good Luck
Steve

Jan 10, 2011 | Harley Davidson FLHTC Electra Glide...

1 Answer

How to adjust clutch


To adjust your clutch, follow the clutch cable down until you find a cable adjuster usually protected by a rubber bellows type cover. Move the cover up or down and loosen the lock nut. Adjust the cable adjuster inwards to make the cable as loose as possible.

Now, remove the derby cover. In the center of the clutch assembly you'll see an adjuster. Loosen the locknut and turn the center bolt inwards until you feel resistance. Do not force the bolt as you'll be disengaging the clutch. Turn it inwards until you feel the resistance, no more. Then, back the bolt back out 1/2 turn and lock the locknut. Replace the derby cover.

Then go back to the cable adjuster and adjust the adjuster outwards until you have about an 1/8" play at the lever. Lock the lock nut down and replace the cover.

BTW: If you have too much oil in your primary, it will make the clutch drag and you will be unable to find neutral with the engine running. Make sure the oil level is no higher than the lower point of the clutch spring with the bike standing straight up.

Good Luck
Steve

Sep 22, 2010 | 2008 Harley Davidson FLHX Street Glide

1 Answer

I have just replaced the clutch on a 1988 Hurricane 600. The final step before replacing the side cover, is to torque down the four bolts that pass through the clutch springs -- but the manual says only...


Those bolts should compress the springs, and seat in the clutch cover, if they do not seat and tighten up they will come loose. There may be a spacer that you have missed, or if an after market clutch kit was used maybe the spacers were not included with the kit, whichever one it is these bolts must seat and tighten up or the clutch will not work properly.

Mar 28, 2010 | 1988 Honda CBR 600 F Hurricane

2 Answers

How get to flywheel bolts


In the Toyota Pick-ups/Land Cruiser/4Runner 1989-1996 (free register) can find several graphics about this.

Driven Disc and Pressure Plate - REMOVAL & INSTALLATION

(see Figures 1 through 27).

cc66ac3.jpg


CAUTION The clutch driven disc may contain asbestos, which has been determined to be a cancer causing agent. Avoid inhaling any dust from any clutch surface! When cleaning clutch surfaces, use a commercially available brake cleaning fluid. Never clean clutch surfaces with compressed air.
  1. Remove the transmission.
  1. Matchmark the clutch cover (pressure plate) and flywheel, indicating their relationship.
  1. Loosen the clutch cover-to-flywheel retaining bolts one turn at a time in a crisscross pattern. The pressure on the clutch disc must be released GRADUALLY.
  1. Remove the clutch cover-to-flywheel bolts. Remove the clutch cover and the clutch disc.
  1. If the clutch throwout bearing is to be replaced, do so at this time as follows:
  1. Remove the bearing retaining clip(s) and remove the bearing and hub.
  2. Remove the release fork and the boot.
  3. The bearing is press fit to the hub. Turn the bearing by hand while placing it under some pressure; check for freedom of motion and lack of grinding or resistance. The bearing is permanently lubricated and cannot be disassembled or greased.
  4. Clean all parts; lightly grease the input shaft splines and all of the contact points.
  5. Install the bearing/hub assembly, fork, boot, and retaining clip(s) in their original locations.
  1. Inspect the flywheel surface for cracks, heat scoring (blue marks), and warpage. If oil is present on the flywheel surface, this indicates that either the engine rear oil seal or the transmission front oil seal is leaking. If necessary, replace the seal(s). If in doubt concerning the condition of the flywheel, consult an automotive machine shop.
  1. Before installing any new parts, make sure that they are clean. During installation, do not get grease or oil on any of the components, as this will shorten clutch life considerably. Grease or fingerprints may be cleaned with an evaporative cleaner such as the type used on brake linings.

To install:
  1. Position the clutch disc against the flywheel. The long side of the splined section faces the flywheel.
  2. Install the clutch cover over the disc and install the bolts loosely. Align the matchmarks made. If a new or rebuilt clutch cover assembly is installed, use the matchmark on the old cover assembly as a reference.

Whenever the clutch disc is replaced, replacement of the pressure plate (clutch cover) and release bearing is highly recommended.
  1. Align the clutch disc with the flywheel using a clutch aligning tool. These handy tools are available in many auto parts stores at a reasonable price. Do NOT attempt to align the clutch disc by eye; use an alignment tool.
  1. With the clutch aligning tool installed, tighten the clutch cover bolts gradually in a star pattern, as is done with lug nuts. Final tighten the bolts to 14 ft. lbs. (19 Nm).
  2. Apply molybdenum disulfide grease or multi-purpose grease to the release fork contact points, the pivot and the clutch disc splines. Install the boot, fork, and bearing on the transmission input shaft.
  3. Install the transmission.
Hope helped.

Mar 15, 2010 | Toyota Pickup Cars & Trucks

1 Answer

Chain brake band will not release to replace the clutch cover


Hi there
Sometimes that's not an easy job . I work for a Husqvarna dealer and I have that problem frequently . First try to get the clutch cover on place (do not use the bolts) and push in @ the top part of the clutch cover , then try to move the clutch lever backwards to release the band (better if done with two people) . If that does not work the only way is remove the clutch lever with the 2 bolts on each side and put the lever on the clutch cover (top metal piece that looks like a clover)to release the band (again with 2 people one holds the clutch cover and the other one the lever pulling the lever backwards) .
Hope this help
Hope this help

Sep 03, 2009 | Husqvarna "Chain Saw - 16" Bar, 3 Hp

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