Removed clutch cover

[Thee_oddball]

Hey Oddball,

It's kinda late, but if you'll look in the MODS section, the extra steel plate tech tip, you'll see some better photos on the clutch removal and reinstallation process, including info on those washers. Also, the washers are 2 different sizes, one inside the clutch basket, one behind the basket next to the engine, you want the smaller diameter one for the one behind the basket, otherwise it can block the oil flow thru that bearing....ask Tod/Trbig!
T.C.

thnx topcat, i am am embarrassed to admit this but i cannot find the MODS section you are talking about..

[DiverRay]

i cannot find the MODS section you are talking about..

Just scroll to the VERY TOP of the page, click on the XS11 INFO button, and start looking. We all call it different things, but it's the resting place of the best information about the bikes.

[trbig]

I know a couple of people have told you to put the bike on the center stand, but if you just use the sidestand, you won't have to drain your oil to do this job you're doing. You can stick a broom handle through the back spokes on the front side of the wheel, then roll the bike backwards in neutral until the broomstick is snug against the frame and wheel spoke.. then poke it back into gear and loosen that nut.

When you take the clutch apart, you'll remove the whole basket at once. There will be a brass collar/spacer that goes inside the clutch boss. There should also be a washer between the clutch basket and the bearing/housing unless that's the washer that's missing. If you turn the clutch basket upside down so the back gear is facing up, then lift the clutch basket off of the discs, the other washer should be on top of the discs there or stuck to the bottom of the basket in your hand. If you set the clutch basket aside and remove all the fiber and steel discs from the clutch boss, there will be one more steel disc that is wired onto the clutch boss. DO NOT MESS WITH THIS WIRE! Don't even act like that steel plate is there... count the others and disregard that one in all measurements and such. TC goes over this warning in the mod section he talked about. but this was worth mentioning again.

Tod

[Thee_oddball]

thnx again guys, does anyone know the size of the "clutch nut washer" i have to replace? I ask because i cant walk away from the bike once i start.

[TopCatGr58]

The clutch nut washer..if you're talking about the special LOCK washer that secures the main clutch shaft/nut before you put the star plate on, is a special lock washer with fitting tabs, you'll need to get that one from Yamaha!

The tech tips are also just from scrolling down from the MAIN FORUM PAGE, there are 5 sections, Maintanence, Repairs, Mods, and Misc. and Riding.
This is explained in the STICKY THREAD at the top of this forum, but for some reason folks don't seem to see or read it?
T.C.

[Thee_oddball]

The clutch nut washer..if you're talking about the special LOCK washer that secures the main clutch shaft/nut before you put the star plate on, is a special lock washer with fitting tabs, you'll need to get that one from Yamaha!

The tech tips are also just from scrolling down from the MAIN FORUM PAGE, there are 5 sections, Maintanence, Repairs, Mods, and Misc. and Riding.
This is explained in the STICKY THREAD at the top of this forum, but for some reason folks don't seem to see or read it?
T.C.

I did go there TC, and found info on removing the clutch under "1st and 2nd gear Dremmel Fix Part 1, 2, and 3" thread I also saw the Clutch Reassembly Warning,Correct Procedure for Adjusting Clutch,Clutch Cleaning and Refurb...etc If it is mentioned in there that i have to go to yamaha to get the new washer than i missed it , thnx for the info

[trbig]

a special lock washer with fitting tabs, you'll need to get that one from Yamaha!

Or bend the sides back up when you're done and re-use it over and over like most folks do..


Tod

[CatatonicBug]

Or bend the sides back up when you're done and re-use it over and over like most folks do..


Tod

Yeah, you can probably get at least 2-4 rebuilds out of that washer, depending on how mangled it gets.

[Thee_oddball]

thnx guys...this is my first time doing this so im a little nervous and the manual put in bold print to "use new one" i just didn't want Tobe popping a wheelie at 90mph and hear the clutch disintegrate because i didn't replace a $2 washer between the tech tips the manual and you guys i think this is going to proceed nicely...now that ive said that ill probably be back in here Friday cussing up a storm

[CatatonicBug]

Nah. You'll be back here asking more questions because you had so much fun doing this, that you want to fix something else too! That's what I did anyway.. I just keep thinking up more things that give me an excuse to work on the bike. It's so much fun!

[DGXSER]

If the tabs to hold the nut in place crack or break when you bend them back up, its time to replace it, until then, its all good. JMHO

[trbig]

If the tabs to hold the nut in place crack or break when you bend them back up

The tabs that hold the nut in place don't get bent up. You are simply folding one side of a washer up against the nut to hold it. If that side splits or breaks, you can simply use another portion of the washer to bend up to hold the nut. I've re-used them MUCH MUCH more than the 2-4 times posted.


Tod

[CatatonicBug]

The tabs that hold the nut in place don't get bent up. You are simply folding one side of a washer up against the nut to hold it. If that side splits or breaks, you can simply use another portion of the washer to bend up to hold the nut. I've re-used them MUCH MUCH more than the 2-4 times posted.


Tod

You're probably right. I just guessed because of the appearance of mine after 3 disassemblies. I guess it depends on where the crease is made, and how mangled it gets. Like any metal though, the more it gets bent, the weaker it gets.

[trbig]

If it gets too mangled, use a ball-peen hammer and tap it back flat on a vice or something. Yes, this may make the metal a touch weaker, but honestly, that nut should never loosen up.. and if it does.. it won't take a very stout piece of metal to lay against, and keep a loose nut from turning.


Tod

[DGXSER]

The tabs that hold the nut in place don't get bent up. You are simply folding one side of a washer up against the nut to hold it.

Tod,
I thought that was what I said, tab being the same as "side of the washer" since there are cutouts to make the side easy to fold. sorry for the confusion. And I agree there are multiple sides and only one is needed. Mine certainly shows no signs of weakening and I would not expect it to happen.