RS Warrior Forum banner

1 - 8 of 8 Posts

·
Registered
Joined
·
71 Posts
Discussion Starter #1
I posted a question day before yesterday and got some very helpful information from a couple of 4m members. After their advice, I called my stealer and ordered (overnight) a stock "clutch kit" to fix my slipping problem prior to going on a long 3 day trip this weekend. My stealer called me today and said my clutch kit was in. I rushed over, picked it up, went home....opened the box and immediately thought "is that all there is?". I decided to do some more 4m research and realized that my "clutch kit" is actually the clutch boss assembly (pn: 5PX-16370-10-00). Is this all I need to repair my problem? I would have thought that a kit would include all of the friction and steel plates. Obviously I have never done this before but am willing to try it. I consider myself mechanically capable (especially when compared to the jokers at my local stealer who argued that the warrior is carbeurated). Any ideas???
 

·
Administrator
Joined
·
29,923 Posts
I believe this free 2002 service manualcovers the same clutch: http://www.paulmilner.com/yamaha/handbuch/warrior_service.pdf


I copied this from the 2007 data to match your bike, in case anything is different from the '02 manual above:







1
4WM-16111-00-00
GEAR, PRIMARY DRIVE

1


2
4WM-16193-00-00
KEY, FEATHER

1


3
4WM-16181-00-00
SPACER 1

1


4
90101-12011-00
BOLT

1


5
5PX-16340-00-00
PUSH LEVER ASSY

1


6
90508-16007-00
SPRING, TORSION

1


7
4WM-16382-00-00
AXLE, PUSH LEVER

1


8
92907-08600-00
WASHER, PLATE

1


9
99001-07600-00
CIRCLIP

1


10
93317-11020-00
BEARING

1


11
93102-15212-00
OIL SEAL

1


12
93315-31502-00
BEARING

1


13
91314-06020-00
BOLT

1


14
4WM-16150-00-00
PRIMARY DRIVEN GEAR COMP.

1


15
5VN-16154-00-00
PLATE, THRUST 1

1


16
5PX-16370-10-00
CLUTCH BOSS ASSY

1


17
26H-16385-00-00
RING, CLUTCH BOSS

1


18
26H-16384-00-00
PLATE, SEAT

1


19
1FK-16383-00-00
SPRING, CLUTCH BOSS

1


20
26H-16321-01-00
PLATE, FRICTION

1


21
26H-16324-00-00
PLATE, CLUTCH 1

1


22
26H-16307-01-00
PLATE, FRICTION 3

6


23
26H-16321-01-00
PLATE, FRICTION

2


24
26H-16324-00-00
PLATE, CLUTCH 1

7


25
1FK-16351-00-00
PLATE, PRESSURE 1

1


26
1FK-16334-10-00
SPRING, CLUTCH 2

1


27
1FK-16335-00-00
HOUSING, SPRING

1


28
5PX-16352-00-00
PLATE, PRESSURE 2

1


29
97007-06025-00
BOLT

6


30
93306-00304-00
BEARING

1


31
5PX-16383-00-00
SPRING, CLUTCH BOSS

2


32
4XV-16356-01-00
ROD, PUSH 1

1


33
90208-20001-00
WASHER, CONICAL SPRING

1


34
90179-20007-00
NUT

1


35
5PX-81673-00-00
ROTOR

1
 

·
Registered
Joined
·
71 Posts
Discussion Starter #3
Thanks AZ Warrior, the above informationis where I realized that the "clutch kit" was not an all inclusive description as I thought it would be. Will the part that I got repair my problem or do I need to order the corresponding clutch and friction plates as well. I thought that when you order a clutch rebuild kit, all of the wearable parts are included. I thought that I had made my situation clear to the dealer....but then that is why I ALWAYS consult this 4m first. Just an idea, but it seems that someone could make a pretty good living by responding to posts like my original and then sending ALL of the correct parts needed to accomplish the stated task. Just dreaming out loud.
 

·
Registered
Joined
·
670 Posts
Why did you wait till you got home to open the box? Whenever I buy auto parts I always open the box at the store to make sure it's right. I know you don't know exactly what you need, but somebody at the dealership might have possibly steered you in the right direction.
 

·
Registered
Joined
·
71 Posts
Discussion Starter #5
I do know better but I also should have pulled the above info prior to my ordering something so critical overnight. Hopefully, one of my local dealers will actually stock the clutch and friction plates. Am I just not remembering correctly, or aren't there clutch rebuild "packs" or kits that include all of the wearable parts of a clutch for other motorcycles. I could have sworn that I was in a bike shop recently (can't remember which brand) and saw a "clutch kit" in a blister pack which seemed to include the friction / clutch plates. Also, is the clutch boss assembly something that wears out often?
 

·
Premium Member
Joined
·
8,918 Posts
The Clutch Boss Assy with all its related parts will not solve your problem and shouldn't be req'd at such low miles. There isn't a "Clutch Kit" PN by Yamaha. You need to order the individual parts listed below!
  • 6 - Item 22 PLATE, FRICTION 3
  • 2 - Item 23 PLATE, FRICTION
  • 7 - Item 24 PLATE,CLUTCH 1
  • 1 - Crankcase cover gasket 5VN-15451-00-00
I would suggest a Barnett pressure plate conversion kit w/ std gold springs or a new Clutch Diamphram Spring (26) or a Speed* equivalent since you overheated the whole assy!

If you don't go with the Barnett you should inspect the existing pressure plate.

Edited: Here's a video by Redhorse: ImageShack(TM) slideshow

Clutch plate replacement pointers:
Barnett Info by writer:
 

·
Registered
Joined
·
71 Posts
Discussion Starter #7
Unbelievable help!!!!!! Thank you so much AlanH. Proof again that this is the best **** 4m!
 
1 - 8 of 8 Posts
Top