16803 Antihopping clutch kit R1 2007 - mounting instructions

This clutch should be installed by an experienced Yamaha mechanic.

1. Read these instructions with photos befor you start. Make sure the kit includes all parts.
2. Remove the old clutch ( according to Yamaha workshop manual ), clean the thread on the shaft of old glue perfectly. Clean this part with brake cleaner.
3. Make sure the original spacer under clutch drum is in it´s position ( pic.a). DON´T install the kit thick shim ( pic. b ).
4. Make sure the steel balls are in their pockets. Use one or two clutch springs and upper retainers to hold both parts of clutch drum together. Position of both drums´s parts should be as delivered.
5. Install the clutch unit to gearbox shaft ( pic.c).
6. The kit includes small parts for mounting. They are packed in the position as how to mount them. Mount the shim at first (pic.d), then the spider spring (pic.e) and the nut (pic.f ). Nut torque moment 110 Nm, use glue Loctite No. 620 (red) to secure it ( pic.g)
7. Remove the springs with caps (from step 4) .
8. Install clutch plates. We suggest mounting a full width friction plate first, followed by a thin friction plate with the judder springs 9if used) then mount all remaining plates to position as usual (pic.h,i).
9. Secure the nut into gearbox shaft ( pic.j).
10. Mount the pressure plate with pull-rod. Install clutch springs with kit retainers. (pic.k).
11. Check the clearance between pressure plate and clutch hub via the small holes in the pressure plates. The correct clearance is about 1.0 mm, minimal clearance is 0.5mm. When the clutch wears to this dimension, install all new friction plates.
12. If you use aftermarket friction plates, you can reach correct clearance by using a

suitable combination of following steel plates:

Order No. Thickness

5VY-16325-00 2.0

4B1-16325-00 2.3

13. Install clutch cover according Yamaha workshop manual, adjust clutch cable and go back to track.

LIST OF PARTS

1 pc. clutch drum lower side

1 pc. clutch drum upper side

1 pc. presure plate

6 pcs. steel ball

1 pc. curved washer

1 pc. spider springs

1 pc. nut

6 pcs. spring retainer