alright im in the middle of doing mods to my DS.... The main ones (where the problems are)
are the Intake, and the clutch.
The intake was a PAIN to get out.... i got it back from MR.HP yesterday, and went to install it. The problem is, is that when i tried to tighten the bolt back into the head, it started new threads.... so now when i go at it with nothing in the way to screw it in to check the threads, it goes in only about two turns, and then gets really hard to turn. (which is what makes me believe the threads are off...)

i also checked the same bolt in the other holes, and it threads in very easily....

What should i do? I was going to be taking my DS into my Yamaha shop, because i have an inside link with a guy who was going to check my valve clearances for me.... Do i need to retap the hole? I really dont want to do anything else with it because i dont want to do anything that is going to cost me big bucks if i screw it up....

The second problem is my clutch.... im more worried about my intake than this right now..but it is still eating away at me. (mainly because we are leaving in 9 days [next friday] for the dunes)
I installed 60% Rwr Clutch springs. I took the case off, drained the coolant, installed the clutch springs (i tightened them down till they bottomed, then snugged them up a bit) I made sure that output shaft with the splined teeth was so it would line up with the shaft. (that matches up with the clutch cable up on top of the case) I assumed there was only One way for that shaft to go. (is this assumption correct? or can that shaft be off a just a little?) I put the case back on, loosened the cable up on the lever, pulled the slack out of the cable and put the little clamp back on. After adjusting the cable at the bars (tigthening it a bit) it makes the clutch seem to not be working properly. It dosnt move when the clutch is disengaged when its in gear (which obviously is good) but then when i go to pull the cable in, the tires barely want to move... it dosnt free it up and roll as if it were in neutral. What would cause this? i have tried adjusting the cable all over the place, but everything yields the same results....

Also a question about the springs.... can i stagger the springs? as in run 2 or 4 stock springs with 4 or 6 of the 60% springs? im thinking that would make it a bit less stiff for those really long rides.

Sorry for the long post... im just worried im not gonna get everything done in time for Silver lake, which would obviously SUCK!

Any help would be greatly appreciated.

 

On your clutch take the connector that you cable attaches to off at the side case and rotate it out one or two teeth. It sounds like when you put the case back on ,, you didnt compensate enough for the Pull of the clutch, and you dont have quite enough adjustment in your cable to make up the difference. NO biggie really. You can alternate if you like.


On you intake, it does sound like you got your threads boogered up, So take a tap that threads into on eof you good hole easily, and then tap out the boogered up one. Its probably just a small damage on one thread, so it should fix its self pretty easy. Remeber to use a Allen wrench with a BALL point end. this way you dont put the bolt in at a wierd angle,and repeat your troubles.


Good Luck,


Bigger.

 

Ditto to what bigger said, and I have heard some people stagger the springs. Just remember that if you replace too many stiff ones you will end up without enough pressure and the clutch will slip again.

Be careful when you pull the little clutch arm off down at the cases. I took the bolt out and pried against the case and ruined the e-clip inside. Only 30 cents, but you have to pull the side cover back off to fix it. I ended up using a little gear puller designed to take off the posts on batteries and it worked great.

Good luck.

Justin

 

Actually its perfectly normal for it to be harder to push - in gear - with the clutch pulled in compared to nutural. More so when the oil is cold. It was that way before you changed your springs, in fact its that way on any bike or quad with a multi-plate wet clutch. It will not have any effect when you ride it.
If you ended up with a small amount of lever free-play and the lever pulls freely to the bars, your clutch cable and linkage are assembled correctly, no problem there.
Rookie mistake on the screw though[img]i/expressions/face-icon-small-frown.gif[/img] (jk). Rule-of- thumb: If the screw is hard to turn, its most likely cross treaded and you better not force it. As bigger mentioned, the only way to install (or remove) the upper intake manifold screw is by using a Ball-End Allen wrench. Its just too tight an area and the angle is too extreme for anything else. I hope you get it fixed and your dune trip is a fun, trouble-free event.