Yamaha YSR-50 Racing Clutch Kit PDF Installation Instruction

Installation Instructions:
First you must remove the lower fairing from the bike, and drain all of the transmission oil, via the drain plug on the bottom of the engine, into a pan. Next, remove the kick starter lever. Then you can remove all of the Phillips screws holding the clutch cover on, with a #3 Phillips screwdriver. Position the drain pan under the clutch cover, as some residual oil will flow out as this cover is removed. You may have to lightly tap the cover with a soft hammer to loosen it.

Be careful to not rip or otherwise damage the clutch cover gasket. (If in doubt as to the status of the gasket, throw it away and use a new one) Once the cover is off, you will see 4 bolts on the clutch hub. Remove these 4 bolts and pull off the outer pressure plate. Now you can remove the 2 old friction plates and the 1 steel plate (If the steel plate is warped or blue, replace it too). Also, be sure to remove the rubber o-rings from the inner clutch hub as they are not needed in the racing clutch. Apply some fresh transmission oil to the new friction plates, (both sides) then place one new friction plate in the clutch, then the steel plate, then the other friction plate. Replace the outer pressure plate and, with the new springs, replace the 4 bolts.

Be very careful in tightening these bolts as the aluminum bosses they thread into are very soft and stripping is very likely. If in doubt as to the quality of the threads, have them repaired using “HELI-COILS”. Replace the drain oil bolt, (preferably with one of our Magnetic Drain Plugs, Part No. 15-4037) Replace the cover (using a new gasket, if yours was damaged) tighten all the cover bolts evenly and in a criss-cross pattern. Replace the kick starter, and refill the transmission with 600cc of good oil, like Castrol 20/50 GTX To adjust the new clutch, remove the ignition cover on the left side, (If your screw heads are buggerd, we have a nice Allen Bolt Kit that replaces every bolt on both engine covers for only $12.95 Part No. 50-3000). You will notice the clutch release mechanism to the rear of the ignition rotor. Just above the release mechanism is the clutch cable adjuster.

Loosen this adjuster all the way. Now, loosen the 10mm nut in the center of the clutch release mechanism, and back out the center screw a couple of turns. Now screw it back in paying close attention to the feel of it coming into contact with the clutch push rod inside the engine. Turn it in a little to take all play out of the system. The object here is to take all play out of the system with out having any pressure on the clutch push rod in the engine. Once you feel you are at that point, back out the screw about a quarter turn and lock down the 10mm nut that surrounds the screw.

If you can, hold the screw with the screwdriver and tighten the nut with a box wrench so you will be sure the adjustment has not changed by tightening the 10mm nut. You should now have a little play in the system. If not, you WILL burn-up the clutch right away! Now you can adjust the lever play with the cable adjuster. 3/8 to 1/2 inch is what you are looking for at the lever tip. Replace the ignition cover and the fairing and you are ready to go!