Hello All, My project is a 66’/67’ Yamaha YDS3. I bought it in 96’ and spent a lot of time stripping it down, polishing parts, and getting parts re-chromed. The bike was very complete, but very rusty and hadn't been run in a long time. Then I got married, changed jobs/locations, and had a couple of kids. Needless to say my progress stalled. As my kids are getting older I’ve been able to work on it here and there between coaching kids soccer. I wasn’t a fan of the two-tone paint scheme, therefore I decided to have all the body parts sprayed in metallic silver. Last summer was a big milestone as I got it together enough to ride it down the street a couple of times with no seat and temporary gas tank. The two issues I ran into were running lean and slipping clutch. On the clutch side I was wondering if anyone else has run into this issue. My bike had the original 4 plate design (4 friction plates, FP and 4 steel plates, SP) which were worn down below the service limit. Later bikes came with 5 plates. Since I could not locate new friction plates for the 4 plate design I purchased new Barnett friction plates for the 5 plate design. I’m having issues with the assembly stack height. Original 4 Plate Design (Going from inboard to outboard) FP(4.3mm)+SP(1.6mm)+FP(4.3mm)+SP(1.6mm)+FP(4.3mm)+SP(1.6mm)+FP(4.3mm)+SP(3.5mm) Total Stack Height = 25.5mm 5 Plate Design The Way I Interpret Parts Manual - Last thicker plate is 2.3mm per the parts manual - Measured friction plate thickness from Barnett is 3.68mm FP(3.68mm)+SP(1.6mm)+FP(3.68mm)+SP(1.6mm)+FP(3.68mm)+SP(1.6mm)+FP(3.68mm)+SP(2.3mm) Total Stack Height = 27.1mm So the stack height is different by 1.6mm. I checked the assembly and there is no way I can compress the plates enough to assemble the snap ring. One solution I have is to eliminate one of the 1.6mm steel plates. This would result in the same 25.5mm stack height but would mate two friction plates next to one another. Since they are not moving relative to one another I don’t see an issue. But I don’t think this is the way the design in intended. Any insight into this riddle is appreciated. Thanks, Scott
Hi Scott and welcome. Tidy bike you have there. I would try the clutch without the extra 1.6mm plate, as you said the friction plates will be both turning. Other way maybe to use one of your old thinner worn down plates?
