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Old 01-05-2010, 06:26 PM   #1
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Location: Connectict
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Default Removal and install of Secondary Clutch kit

Installing a new Proformance clutch spring kit
this can be a simple project with 2 people, but can be done by yourself
tools needed
Clutch puller ( a must have or you will bend the fixed pulley)
17mm Socket (impact with air tool prefered)
Snap ring pliers
a good spring compressor

remove rear drivers wheel
remove 17mm nut from secondary clutch
attach puller tight and tighten center nut until fixed plate comes off
remove belt and woodruff key and plastic spacer
then remove sliding plate, spring and inner drive hub
then remove the snap ring from the shaft
(you will not use the snap ring or the plastic washer again)

inspect all parts well, you will want to replace the ramps on the hub if not replace the entire hub if there is wear on the metal.

installing

install the new spacer (there is a spline only on half the spacer, YOU MUST FACE the spline side out from the shaft, slide on the hub.
slide on the spring and then the sliding plate, MAKE SURE TO GREASE BUSHING AND SHAFT
attach a spring compressor to the hub and the outer of the sliding plate and compress till you can see the entire slot for the woodruff key.

install the wooduff key, then attach the fix plate then put on washer and nut and make sure you tighted well (use a torch wrench if you have one)

now release the compressor and re-assemble..

put on belt, (pay the money and use a new one)


now if you don't have a compressor that will work for you
here is a way you can do it, if you can push the sliding plate on yourself far enough to see the woodruff key, then you can have somone else put the key, fix plate and nut for you, but this is not easy with the new heavy spring kit..

if your alone, you can use a 2x4 to get leverage and push it on, but you will need to remove the rear body, this works well but still need a person to install the fixed plate and nut.

this is by far the hardest thing i have done to date on a Yamaha cart.
so if you not sure you can handle it, it might be worth paying a shop to do it, with the right tools, this can be a 1/2 hour job, hope this helps somone..
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Old 01-05-2010, 06:51 PM   #2
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Default Re: Removal and install of Secondary Clutch kit

great post! if anyone has other questions about this install there is a sticky (by Spriddle) in the yamaha section with detailed instuctions also.
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Old 01-06-2010, 06:48 AM   #3
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Default Re: Removal and install of Secondary Clutch kit

Thanks RR, good post!

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Old 01-06-2010, 10:45 PM   #4
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Default Re: Removal and install of Secondary Clutch kit

notice how high the belt rides now,
inside plate is machined and had the new
heavy spring and notice the spacer on the inside

machined sliding plate
heavy spring
new belt
MEANS LOT OF LOW END TORQUE
Attached Images
File Type: jpg in progress build.jpg (80.9 KB, 103 views)
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Old 01-12-2010, 01:01 PM   #5
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Default Re: Removal and install of Secondary Clutch kit

this picture shows you why the heavy spring and the new machined pulleys make more torque (gives you a lower gearing for pulling)

notice that the belt is only down a couple inches when at full RPM's this gives you more power for pulling up hills.. and makes up some of the power lost with larger wheels and tire...
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File Type: jpg Sec clutch running.JPG (39.0 KB, 77 views)
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