Putting "power spring" in a Yamaha G1

[chuddly]

As promised here is pictures of putting the torque spring in a yamaha G1. First off i had my front clutch off because i was changing out my crank seal so thats why it looks like there is a TON of room.

step 1. remove the cotter pin and nut on the out side of the rear clutch
step 2. using a puller (i made my own or you can buy them) pull the outter clutch plate off and remove the belt (mine was already off in the pictures).
SAM_0209.jpg
step 3. push the inner clutch plate back and hold it back some way (i used a pair of vice grips on the clutch shaft but others have said use a ratchet strap) You do this so you can remove the half moon key in the key way.
step 4. Remove the half moon key and slide the inner clutch plate off
SAM_0210.jpg
step 5. Remove the helix and the snap ring behind it
SAM_0211.jpg
step 6. Replace the snap ring with the supplied splined collar (you DO NOT reinstall the snap ring)with the splines part of the collar facing away from the axle housing.
SAM_0212.jpg
step 7. Reinstall the helix,then the new spring then the inner clutch plate just as normal. You may want to grease the clutch shaft to make them work better over time.
step 8. DO NOT put the plastic washer between the inner and outter clutch plates.
step 9. push the inner plate back again (this will be harder due to the stiffer spring) and hold it back again (i used vice grips but you can do what you like).
step 10. Reinstall the half moon key in the keyway
step 11. Reinstall the belt and the outter clutch plate along with the nut and cotter pin.

You should be ready to go now...have fun and enjoy the new torque

[kcnaz]

Thanks for the info....love pictures......

[nitro1]

Thanks chuddly iv been wanting to do this with my g-16 but wanted more of an idea on how hard it is to do...i also love pictures

[chuddly]

no problem guys...hope it helps out. It only took me about 30-40 min so its not too bad to do.

[sqhunter57]

somebody told me you had to load the clutch when you put it back together. Fixing to do mene just wondering. Thanks

[kcnaz]

step 9. push the inner plate back again (this will be harder due to the stiffer spring) and hold it back again (i used vice grips but you can do what you like).

I used a rachet strap. Either way "yes" you have to collapse the spring to get the clutch back together.
Don't forget the grease......and clean up your parts while you have them out. CLEAN IS COOL!!

[sqhunter57]

They told me you had to turn them so many time to load them I didn't know. Thanks for the information.

[Frank32159]

Hi: I would like to know what size bolts you need that screw in to the fixed pulley on the driven clutch to make the puller. I have a G1 but it's a hundred miles from my house and I'd like to bring the bolts with me when I go to remove the clutch to replace the spring. Thanks: Frank

[xd675x]

6mm bolts.

[selli8910]

Why dont you replace the plastic washer between the two clutch plates?