Removing Clutch

[flyp3]

I have an 07 that seems to have the more and more common sticking clutch plate issue. It has the classic issues of clunky shifts, difficulty putting into gear, and bike continuing to move with clutch lever pulled in. It is much worse if the bike has been sitting for awhile and now requires a long duration pull on the clutch to get into first gear without a severe clunk. It has been to the dealer around the 600 mile initial service and the dealer purged the clutch fluid for air and told me that sticking clutch plates would not cause this problem nor had they ever heard of this type of problem. Overall, I was not impressed with the dealer's desire to investigate or attempt to fix the problem. The latest attempt with the dealer was that they would try to get to it in their spare time because they were very busy. I now have over 3000 miles on the bike and the problem is getting worse. My experience with the dealer seems to be not uncommon and until Yamaha comes out with a recall, dealerships are going to be less than willing to devote the time to fix the problem.

I've read numerous threads where folks have just gotten tired of fighting the dealerships and fixed it themselves, even with the bike still on warranty. I'm wondering if it would just be easier to fix it myself than attempting to fight the dealer or get into a drawn-out effort to get Yamaha to work on the problem.

For those folks that have preformed this fix, are there any special tools required or lessons learned that might make this job a little easier for the first timer with a clutch repair? I have the service manual and have reviewed the previous discussions on this subject. Most of those discussions make the job sound straight forward and relatively simple. After reviewing the service manual, it seems anything but simple, but that could just be the manual.

Recommendations welcome.

 

[SkooterG]

This is a simple task. Since you are just soaking plates and not removing the clutch basket it is relatively straight forward. Just don't forget to get a new gasket beforehand.

Did you read the thread on my clutch saga where I opened up a motorcycle clutch for the first time?

Clicky HERE for SkooterG clutch saga

Good pics are on page 3.

 

[flyp3]

SkooterG- Thanks much for the info. Just what I was looking for.

 

[Pressman111]

Hi,

I have a 07 fjr and had the same problem with the clutch that you are experiencing. I had to fight Yamaha in order to have them fix it. You have to tell them that you almost got hurt because of the problem. All their calls are recorded and once you say that they have to do something about it. They didn't want to help me until I told them I was stuck in traffic and I whent to stop and the bike and the bike kept pulling me into the car in front of me. Once I said that they changed their attitude and offered to fix it. My clutch now is silky smooth and so is the shifting. Call Yamaha in California, the number is with your paper work for the bike.

Good luck to you,

Brian

 

[dcarver]

Good job SkooterG..

Imagine that, SkooterG, master maintenance mechanic of the flippermobile!

 

[murf]

Hi,I have a 07 fjr and had the same problem with the clutch that you are experiencing. I had to fight Yamaha in order to have them fix it. You have to tell them that you almost got hurt because of the problem. All their calls are recorded and once you say that they have to do something about it. They didn't want to help me until I told them I was stuck in traffic and I whent to stop and the bike and the bike kept pulling me into the car in front of me. Once I said that they changed their attitude and offered to fix it. My clutch now is silky smooth and so is the shifting. Call Yamaha in California, the number is with your paper work for the bike.

Good luck to you,

Brian

This is were having a knowledgeable service dept at a dealership is great. I had the same problem with a sticking clutch on my 07. Took it back to the selling dealership. They kept it a week and said nothing is wrong. Took it to another dealership and their service manager knew right away what the problem was. They disassembled the clutch, soaked the friction plates in oil overnight and put it back together. Zero problems with the clutch since then.

 

[jocflier]

I just did mine 08 and here are some tips.

1. You can do this with the bike on the side stand. No need to drain the oil.

2. The hardest part for me was removing the side panel. There is a self taping screwing holding the evaporation canister facing forward from the inside (back side) of the lower scoop. It is a bitch to get to, and line up when putting it back together.

3. Just remember that the # 9 and #12 fiber plates are different from the rest. #9 One is the first fiber plate to come off and the #12 is the last fiber plate to come off. Reverse when putting it back together.

4. Remember to make sure when putting the everything back together, that the Pressure plate is on and in its groves on the clutch housing. You can check after you put it together. If you can not squeeze the clutch lever, or it has a hard squeeze, then more than likely the pressure plate is not on correctly. Check this before you button up the cover.

5. There are two pins that help with holding the clutch cover on. Be careful not to drop on down in the crankcase.

6. Put all of your fiber plates in a zip lock bag with a quart of oil and let soak over night.

7. Remember to torx everything down. Take your time. It make a world of difference in my bike.

Joc