08-25-2009, 02:23 PM #1
I have some pics at home I will upload later.
Before You Start print and read pages 5-42 through 5-51 of the service manual and keep it close.
Part numbers Needed:
Its really not too bad. First thing download a service manual
turn to page 5-42. You will need to order some parts from yamaha: all of the parts on this page that say "not reusable" you will need that means you need: 4 of #10 (part # 90430-10007-00), 4 of #15 (part # 93210-21631-00), and 1 of #16 (part # 6s5-13563-00-00). If you do not replace these parts the engine will not hold oil. (ask me how I know...)
now turn to 5-44. You will need 1 # 16 (part # 6s5-15657-00-00).
Very important!! don't mix up the bolts. I had every part I took off in a zip lock bag labeled. I would recommend that you do this there will be alot of parts laying around.
Now it is easy.
1.) Drain the oil
2.) remove the air filter
3.) remove supercharger mark which bolt comes from which hole. they are different. you cant remove the gears for the super until you remove the oil pump.
4.) put some rags in the bottom of the hull. oil is about to be dumped.
4a.)open beer at this point. next three steps are a B!tch!!
5.) remove oil pump. follow the diagram on pg. 5-42. Yes there are 12 Allen head bolts on the oil pump. one is particularly hard to find (hint its down in a hole). but they are all there. don't lose the 2 alignment pins.
6.) remove supercharger gear (slide out) and put your special tool through the supercharger hole and hold the gears (I really wish I would have had this tool).
7.) remove the bolt on the end of the shaft. you may want to put a rag or something soft behind the tool so you dont indent the aluminium. The bolt takes alot of force to break lose.
7a.)open second beer (that bolt was the worst but I had to pull the ecu to get to the intermediate housing R&D will let you skip all that with that special tool.)
8.) Slide the gear assembly out.
9.) disassemble the gear assembly. you will need some pliers for the c-clips.
10.) change the clutch.
11.) reassemble clutch
12.) slide gear assembly back on.
13.) install bolt to hold gear assembly (torque to 59ftlbs) (use r&d tool) Be Very Cautious here to use correct torque. Most Torque wrenches are less accurate with left hand threads! There have been reports of breaking this bolt due to over torquing
14.) reinstall oil pump. You need to fill it with oil first! turn to pg 5-51 for instructions.
14a.)open beer 3 and relax before trying to put the bolts back.
15.) put back the 12 allen bolts (I was cussing yami like crazy for this. you will see what a pain in the a$$ this is.)
16.) Reinstall Super
17.) reinstall airbox
18.) go finish your night with vodka!
dont think that I forgot anything but??
dealer wanted over 600 to do this repair. He had already done it twice and messed it up twice!
First pic is a pic with everything removed.
second pic is the coupler in the back that I had to hold
third is the clutch and the gear assembly with the new clutch
Last edited by allstar71; 06-03-2011 at 07:40 AM.
08-25-2009, 03:05 PM #2
Good info David, thanks for sharing. Looking forward to your pics.
08-25-2009, 03:14 PM #3
08-25-2009, 06:33 PM #4
Don't need it yet but I'm sure I will.
Thanks for taking the time to do this thread.
08-25-2009, 08:32 PM #5
- Join Date
- Oct 2007
- Brisbane, Australia
08-25-2009, 09:51 PM #6
- Join Date
- Apr 2008
- Gold Coast Australia
Great post, do you have the Yamaha parts numbers of the items required?
08-26-2009, 07:28 AM #7
08-26-2009, 07:52 AM #8
- Join Date
- Sep 2007
- Northeast, Georgia
If my supercharger clutch goes out, I'll be down there at your place with my SHO and a bottle Vodka.
Thanks for the info.
08-26-2009, 08:38 AM #9
- Join Date
- Oct 2005
08-26-2009, 11:02 AM #10
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