1. Gather Tools:
Before starting, make sure you have the necessary tools, including:
- Complete Clutch Kit (friction plates, steel plates, clutch springs)
- Clutch Hub Puller
- Clutch Basket Holder
- Torque Wrench
- Metric Wrench Set
- Phillips/Flat Head Screwdriver
- Gasket Sealant
- Safety Glasses and Gloves
2. Prepare the Bike:
- Place the Banshee on a level surface and secure it using a motorcycle stand or jack.
- Shift the transmission into neutral.
- Remove the spark plug wire to prevent the engine from starting accidentally.
- Drain the oil from the engine completely.
3. Remove the Clutch Cover:
- Locate the clutch cover on the right side of the engine.
- Remove any bolts, nuts, or screws holding the clutch cover.
- Carefully pry open the clutch cover and inspect the clutch components.
4. Remove the Pressure Plate:
- Using a clutch hub puller, remove the pressure plate bolts in a criss-cross pattern to release spring tension.
- Carefully lift the pressure plate, paying attention to the position of the friction and steel plates.
5. Inspect Clutch Components:
- Check the friction plates for wear, grooves, or cracks. Replace if necessary.
- Inspect the steel plates for any significant bending or warping. Replace if needed.
- Replace clutch springs if they are worn or compressed too much.
6. Install New Clutch Components:
- Stack the new clutch plates in the correct sequence (friction plate, steel plate, repeat) ensuring they align properly.
- Lubricate the clutch plates lightly with engine oil.
- Place the pressure plate back on, aligning the tab on the pressure plate with the notch in the clutch basket.
- Reinstall the pressure plate bolts and tighten them in a criss-cross pattern to evenly distribute the pressure.
- Tighten the pressure plate bolts to the specified torque mentioned in the Banshee's service manual.
7. Reinstall Clutch Cover:
- Clean and inspect the clutch cover gasket surface. Apply a thin layer of gasket sealant if needed.
- Carefully place the clutch cover back onto the engine, ensuring proper alignment.
- Replace and tighten the clutch cover bolts.
8. Refill Engine Oil:
- Refill the engine with the recommended amount and type of oil as per the Banshee's manual.
9. Final Checks:
- Check all the bolts, nuts, and screws to ensure they are tightened properly.
- Reconnect the spark plug wire.
- Start the engine and let it idle for a few minutes. Listen for any unusual noises.
- Test the clutch operation by engaging and disengaging the clutch lever and shifting through the gears.
10. Test Ride:
- Take the Banshee for a test ride to ensure that the clutch is working properly.
11. Adjust the Clutch:
- If necessary, adjust the clutch cable to ensure proper clutch engagement and disengagement.
Remember, if you are unsure about any step or encounter difficulties during the installation, consult the Yamaha Banshee service manual or seek assistance from a qualified mechanic.
