Motorcycle Repair: Yamaha Maxim Clutch Assembly, friction discs, clutch work

Question
Hi Mike,

I am having a problem with my '81 Yamaha 550 Maxim.  I removed the old clutch and installed new friction discs and pressure plate springs.  My problem is that I installed the clutch boss spring after the third friction disc which is the way it looked in picture in my service manual.  After I put all the discs in place there was a noticeable gap between the third and fourth discs.  I thought this was normal.  When putting the clutch cover back on it was difficult to get the clutch arm to mate up with the clutch pull rod.  Once assembled the clutch lever was very hard to pull and when I tried to start the bike and put it in gear, I had to hold the brake to stop it.  My question is, did I put the clutch boss spring in the right spot and if I did why didn't it go in place better? Also could I leave it out and would the clutch work properly?  Any help and advice about installing a clutch would be greatly appreciated.

Gary

Answer
Hi Gary,

Sounds as if you have the clutch plates assembled correctly. I suspect the problem is with the clutch arm and pull rod (rack & pinion).

Ensure that the fiber disk adjacent with the clutch boss is the proper fiber disk. It's inside diameter is a bit larger than the other fiber disks.

Have to have the clutch boss in place with that application.

I can send you tech files on clutches. I'll need your email addy as requested and explained in my instructions. The files may help.

Respectfully,
Mark Shively