Forum Donations
Search
VTF Google Search
 Click Here

Clutch Replacement

Virago Help Tech and user submitted articles.
  • Advertisement

Topic locked

Clutch Replacement

PostAuthor: mark75 » Fri Apr 20, 2007 4:36 am

Has your clutch been slipping or grabbing? Don't panic, and you don't have leave your bike at the dealer for a week (or more). Change the plates yourself. You only need a few basic tools and the necessary parts.
Most of us don't give the clutch much thought until it starts to go wonky, grabbing or slipping. The usual problem is the clutch plates, and maybe the springs, both are an easy switch out. The whole thing can be done in just an hour or two.
I did this on my '86-700, but it would be pretty much the same for most all motorcycles, but particularly the Yamaha V-twins.

1. Get your stuff together. Tools, parts, oil and filter.

Tools:
10mm, 14mm, 17mm sockets, ratchet, &/or wrenches(spanners), I prefer open/box combination.
5mm allen wrench,
torque wrench,
large plain screwdriver,
paint scrapper, or similar device to remove old gasket material.

Parts:
clutch plates - fiber ~$80,
- steel ~$35,
springs(6) - ~$18,
new gasket - ~$12,
3 quarts oil,
oil filter,
manual,
clean rags,
Yamabond, or equivalent (because I hate leaks and take no chances)

As long as you're going into your bike, you might as well make the best of it and replace all the clutch pieces. If $$ are really tight, you can probably get by with just the fiber plates, but the springs are the least expensive part so do them, too. Fiber plates and springs are most subject to wear.

2. On center stand, Drain the oil.

3. Remove: Engine guards/crash bars(if equipped).

4. Unhook rear brake light spring.

5. remove the rear brake pedal (take note of alignment marks on pedal & spindle to simplify replacement --- Mark with a "Sharpie", etc.)

6. remove right foot peg bracket.

7. with 5mm allen wrench loosen clutch cover bolts(in crisscross pattern)
To help keep up with them, draw an outline of the cover on a piece of cardboard and stick each one in the corresponding spot on the cardboard from where they came.

8. remove the oil filter cover, and to the side of it, at the juncture of clutch cover and the case you will see the notch (see pic, the yellow arrow).
This is where you can delicately pry the cases apart. Careful! the cases are soft.

9. You're in.

10. using a 10mm socket remove the 6 pressure plate bolts and springs.
Take note of any alignment marks that may need to be matched for reassembly, or you can make your own with a marker.

11. When you remove the pressure plate(the top plate) you will notice the throw-out bearings on the center shaft. Be careful when you remove the PP as these may stick to the back of the plate and fall out, so place a rag underneath to catch them, in case.

12. Remove the clutch plates, and stack them in the exact order as they came out. Incorrect stacking can cause premature clutch failure.
Note: the clutch fiber plates have alignment notches, a single notch on one "tab" edge and 3 on the opposite side "tab"(see pic).

13. pre-soak your new fiber plates in oil.

14. reassemble clutch pack(usually the first and last are fiber plates)
you will notice the metal plates are stamped steel, and one side has an edge and the other is rounded somewhat. There is debate on whether the edge should face in or out. Either way, they have to all face the same way or excessive hub wear will result.

15. Put the pressure plate over the clutch pack and install the springs, tighten in a crisscross pattern and torque to 5.8 ft/lbs

16. make sure all the old gasket is removed, apply gasket sealer, following mfg instructions. It should hold gasket in position along with the dowel pins in case.

17. reinstall cover and tighten bolt in crisscross pattern, and torque to 5.8 ft/lbs.

18. reassemble in reverse order, adjust clutch as outlined in your manual, add oil, and your done.

for a little more in depth article, see http://www.motorcyclecruiser.com/tech/c ... eplacement
You do not have the required permissions to view the files attached to this post.
"Over the Mountains of the Moon,
Down the Valley of the Shadow,
Ride, boldly ride" ... E.A. Poe


Time flies >>> whether you're having fun __ :bike: or not :fan: ---

Any day above ground is a good day.
so Laissez les bon temps roulez. just roll safely --- Semper Vigilans...always watchful

"I hear and I forget, I see and I remember, I do and I understand." ... Confucius*

If you don't read the news you are not informed.
If you read the news you are misinformed.
... Mark Twain


-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
The views, opinions, and experiences expressed in this post are mine and may not necessarily represent views and opinions of other VTF members, so feel free to agree, disagree, or ignore them.
-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
User avatar
mark75
Mod
Mod
 
Posts: 15747
Images: 15
Joined: Sun Apr 02, 2006 3:57 am
Location: Republic of Texas Flag
Bike year & model: 1982 - XV750
2013 - FXDC Super Glide Custom
*
Sex: Male

Re: Clutch Replacement

PostAuthor: yamaguzzi » Fri Apr 20, 2007 5:48 am

way to go mark, thanks for the trouble of explaining the process. saves a lot of money.

yamaguzzi
Mod
Mod
 
Posts: 2484
Images: 1
Joined: Sat Dec 09, 2006 10:35 am
Location: Paducah, Ky Flag
Bike year & model: 2000 HD Heritage Softail Classic
Sex: Male

PostAuthor: ante705 » Fri Apr 20, 2007 9:25 pm

is the clutch for a 85 700, the same as a 86 700? my clutch is worn, and i can get a used 85 clutch and basket assy. cheap. anyone know if it will fit? its alot cheaper to get me by until i can afford to buy new parts to replace it.
1986 xv700

ante705
Junior Membership
Junior Membership
 
Posts: 37
Joined: Sun Apr 15, 2007 6:44 pm
Location: Flint, MI Flag

PostAuthor: mark75 » Fri Apr 20, 2007 10:09 pm

'85 & '86 700s have same part #s, so they are the same.
Sure, a used one will get you by. Hopefully it will be in better shape than the the one it replaces.
If you search the parts places you can probably find new fiber plates for about the price of a used clutch, that's probably all you will need for a better fix(and a new gasket).
"Over the Mountains of the Moon,
Down the Valley of the Shadow,
Ride, boldly ride" ... E.A. Poe


Time flies >>> whether you're having fun __ :bike: or not :fan: ---

Any day above ground is a good day.
so Laissez les bon temps roulez. just roll safely --- Semper Vigilans...always watchful

"I hear and I forget, I see and I remember, I do and I understand." ... Confucius*

If you don't read the news you are not informed.
If you read the news you are misinformed.
... Mark Twain


-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
The views, opinions, and experiences expressed in this post are mine and may not necessarily represent views and opinions of other VTF members, so feel free to agree, disagree, or ignore them.
-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
User avatar
mark75
Mod
Mod
 
Posts: 15747
Images: 15
Joined: Sun Apr 02, 2006 3:57 am
Location: Republic of Texas Flag
Bike year & model: 1982 - XV750
2013 - FXDC Super Glide Custom
*
Sex: Male

PostAuthor: ante705 » Fri Apr 20, 2007 10:16 pm

good to know, i also bought an 84 700 motor in case i have to replace my motor. by chance do you know if an 84 is also compatable?
1986 xv700

ante705
Junior Membership
Junior Membership
 
Posts: 37
Joined: Sun Apr 15, 2007 6:44 pm
Location: Flint, MI Flag

PostAuthor: mark75 » Fri Apr 20, 2007 10:34 pm

yep, looks like '84-'86 all have same #s.
"Over the Mountains of the Moon,
Down the Valley of the Shadow,
Ride, boldly ride" ... E.A. Poe


Time flies >>> whether you're having fun __ :bike: or not :fan: ---

Any day above ground is a good day.
so Laissez les bon temps roulez. just roll safely --- Semper Vigilans...always watchful

"I hear and I forget, I see and I remember, I do and I understand." ... Confucius*

If you don't read the news you are not informed.
If you read the news you are misinformed.
... Mark Twain


-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
The views, opinions, and experiences expressed in this post are mine and may not necessarily represent views and opinions of other VTF members, so feel free to agree, disagree, or ignore them.
-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
User avatar
mark75
Mod
Mod
 
Posts: 15747
Images: 15
Joined: Sun Apr 02, 2006 3:57 am
Location: Republic of Texas Flag
Bike year & model: 1982 - XV750
2013 - FXDC Super Glide Custom
*
Sex: Male

PostAuthor: ante705 » Fri Apr 20, 2007 10:43 pm

great!! thanks!! man you guys are great! you always have the answers!!
1986 xv700

ante705
Junior Membership
Junior Membership
 
Posts: 37
Joined: Sun Apr 15, 2007 6:44 pm
Location: Flint, MI Flag

PostAuthor: mark75 » Mon Aug 02, 2010 8:31 pm

EDIT
guess I need to up-date this for something I forgot to mention.
the clutch adjuster.

When re-assembling (putting the left-side case on) be careful that the adjuster stays in place.
the adjuster is the disk shown here.
Behind it is a bearing gizmo with 3 balls in it, and each one fits into a corresponding dimple.
If the balls aren't seated correctly the clutch will not disengage.

[I use grease on them to help hold them in place while putting the case back on] the grease will later dissolve in the oil
You do not have the required permissions to view the files attached to this post.
User avatar
mark75
Mod
Mod
 
Posts: 15747
Images: 15
Joined: Sun Apr 02, 2006 3:57 am
Location: Republic of Texas Flag
Bike year & model: 1982 - XV750
2013 - FXDC Super Glide Custom
*
Sex: Male

PostAuthor: grazingazer » Mon Aug 02, 2010 9:36 pm

it's also a good idea to put a little vaseline on the inner crankshaft seal on the right side cover to keep from damaging it when re-installing the cover [vaseline will dissolve in oil while most grease doesn't and remains suspended]
if you're asking for help please include the year and model of the bike in your signature
then turn your signature on

my bike is a modified 1981 virago xv75012927the rockabilly rat
User avatar
grazingazer
Mod
Mod
 
Posts: 16725
Images: 19
Joined: Sun Jan 07, 2007 1:07 pm
Location: georgia Flag
Bike year & model: modified 1981 xv750 virago...1975 650 xsb
Sex: Male

PostAuthor: Jake » Fri Mar 04, 2011 10:00 pm

Mark, why don't you rewrite with the clutch adjuster segment included and submit it to the KB ?

Ooops ! Already there ! :doh:
_______________________________________________________________________
“It ain’t what you don’t know that gets you in trouble.
It’s what you know for sure that just ain’t so.”

~Mark Twain


There is an old Chinese proverb - "Man with one watch knows the time. Man with two, not sure."
User avatar
Jake
Mod
Mod
 
Posts: 12548
Images: 108
Joined: Wed Jun 06, 2007 3:18 pm
Location: Penn's Forestland otherwise known as Pennsylvania Flag
Bike year & model: 1996 XV750
Sex: Male

Re: Clutch Replacement

PostAuthor: bulpup » Sat Jul 21, 2012 1:44 pm

Okay so I am looking here

http://www.bikebandit.com/houseofmotorcycles/1996-yamaha-virago-1100-special-xv1100sh/o/m146248#sch605441

I can't really tell which plates are fibre or steel and it looks like Ineed about 8 of each, is this correct?
Dave

1996 XV1100/S
User avatar
bulpup
Junior Membership
Junior Membership
 
Posts: 54
Joined: Wed Dec 14, 2011 5:32 pm
  Flag
Bike year & model: 1996 XV1100/S
Sex: Male

Re: Clutch Replacement

PostAuthor: mark75 » Sat Jul 21, 2012 2:40 pm

the ones with the "teeth" or cogs to the outside are fiber-coated "friction" plates, the ones with "teeth" to inside are steel.

8 friction plates; &
8 steel plates* - one with 1100 p/n [1TA-16325-00-00]
- 7 with "xv" p/n [4X7-16324-00-00]
*for xv1100 - per star microfiche.

:con: steel all looked the same to me, but that one plate does have a different p/n. :con:
this is on all xv models - 1st plate has p/n *-16325-*, & 7 p/n *-16324-*

the fiber ones due most of the "wearing", but steel ones may warp.
"Over the Mountains of the Moon,
Down the Valley of the Shadow,
Ride, boldly ride" ... E.A. Poe


Time flies >>> whether you're having fun __ :bike: or not :fan: ---

Any day above ground is a good day.
so Laissez les bon temps roulez. just roll safely --- Semper Vigilans...always watchful

"I hear and I forget, I see and I remember, I do and I understand." ... Confucius*

If you don't read the news you are not informed.
If you read the news you are misinformed.
... Mark Twain


-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
The views, opinions, and experiences expressed in this post are mine and may not necessarily represent views and opinions of other VTF members, so feel free to agree, disagree, or ignore them.
-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
User avatar
mark75
Mod
Mod
 
Posts: 15747
Images: 15
Joined: Sun Apr 02, 2006 3:57 am
Location: Republic of Texas Flag
Bike year & model: 1982 - XV750
2013 - FXDC Super Glide Custom
*
Sex: Male

Re: Clutch Replacement

PostAuthor: bulpup » Sat Jul 21, 2012 2:52 pm

cool thanks. I also noticed the spring for my bike is $80 sheesh!
Dave

1996 XV1100/S
User avatar
bulpup
Junior Membership
Junior Membership
 
Posts: 54
Joined: Wed Dec 14, 2011 5:32 pm
  Flag
Bike year & model: 1996 XV1100/S
Sex: Male

Re: Clutch Replacement

PostAuthor: mark75 » Sat Jul 21, 2012 5:52 pm

"Over the Mountains of the Moon,
Down the Valley of the Shadow,
Ride, boldly ride" ... E.A. Poe


Time flies >>> whether you're having fun __ :bike: or not :fan: ---

Any day above ground is a good day.
so Laissez les bon temps roulez. just roll safely --- Semper Vigilans...always watchful

"I hear and I forget, I see and I remember, I do and I understand." ... Confucius*

If you don't read the news you are not informed.
If you read the news you are misinformed.
... Mark Twain


-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
The views, opinions, and experiences expressed in this post are mine and may not necessarily represent views and opinions of other VTF members, so feel free to agree, disagree, or ignore them.
-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
User avatar
mark75
Mod
Mod
 
Posts: 15747
Images: 15
Joined: Sun Apr 02, 2006 3:57 am
Location: Republic of Texas Flag
Bike year & model: 1982 - XV750
2013 - FXDC Super Glide Custom
*
Sex: Male

Re: Clutch Replacement

PostAuthor: bulpup » Thu Jul 26, 2012 11:51 pm

Ordered. The $20 in savings for the spring alone more than offsets the silly rip-off shipping charge.
Dave

1996 XV1100/S
User avatar
bulpup
Junior Membership
Junior Membership
 
Posts: 54
Joined: Wed Dec 14, 2011 5:32 pm
  Flag
Bike year & model: 1996 XV1100/S
Sex: Male

Re: Clutch Replacement

PostAuthor: bones1918 » Fri Jul 27, 2012 6:51 am

don't forget to order your gasket too!
User avatar
bones1918
Silver Membership
Silver Membership
 
Posts: 648
Images: 2
Joined: Thu Aug 24, 2006 4:17 am
Location: Arlington, VA Flag
Bike year & model: 94 xv750



Topic locked


  • Advertisement

Return to Virago Help - Tech Articles

Who is online

Registered users: No registered users