How to Fix a Clutch on a Yamaha ATVby Contributing Writer; Updated October 25, 2017
Items you will need
New clutch kit
Socket and ratchet set
Fixing a clutch on a Yamaha ATV is easy and can be done by the backyard mechanic. The procedures are the same as any ATV or motorcycle and can be done in a few hours. All ATVs will need a clutch repair or replacement eventually so knowing how to do it yourself will save you time and money.
Drain the oil from the ATV by unscrewing the drain plug under the engine. You might have a skid plate obstructing the plug. If so, remove it first.
Remove the clutch cover with a socket and ratchet. Inspect the gasket and replace if it is worn, cut or ripped.
Remove the pressure plate by loosening the bolts. Unscrew in a crisscross pattern so the pressure plate slides off smoothly and won't pinch. There are springs behind the bolts, so be careful not to lose them. When removing the pressure plate, pay attention to the lifter behind it. Don't lose it.
Remove the friction plates from inside the clutch compartment. Remove the jutter springs and pay attention to how they are positioned. Sometimes it can be confusing when reinstalling, so make a sketch or snap a photograph so you will remember.
Reverse the steps with new parts to reinstall. When installing the bolts on the pressure plate and the clutch cover, consult your service manual for the right torque pressure.
Ensure there is 2 to 4 mm of play in the clutch lever. This will avoid wear on the clutch plates. Replace the oil, fire up your ATV and hit the dirt.
Soaking the friction plates in oil overnight will make the job easier.
Don't over-torque the bolts on the friction and pressure plates. This can cause damage to your clutch.