The Yamaha Road Star Warrior Forum

I posted a question day before yesterday and got some very helpful information from a couple of 4m members.  After their advice, I called my stealer and ordered (overnight) a stock "clutch kit" to fix my slipping problem prior to going on a long 3 day trip this weekend.  My stealer called me today and said my clutch kit was in.  I rushed over, picked it up, went home....opened the box and immediately thought "is that all there is?".  I decided to do some more 4m research and realized that my "clutch kit" is actually the clutch boss assembly (pn: 5PX-16370-10-00).  Is this all I need to repair my problem?  I would have thought that a kit would include all of the friction and steel plates.  Obviously I have never done this before but am willing to try it.  I consider myself mechanically capable (especially when compared to the jokers at my local stealer who argued that the warrior is carbeurated).  Any ideas???

I believe this free 2002 service manual covers the same clutch: http://www.paulmilner.com/yamaha/handbuch/warrior_service.pdf

I copied this from the 2007 data to match your bike, in case anything is different from the '02 manual above:

1	4WM-16111-00-00	GEAR, PRIMARY DRIVE		1
2	4WM-16193-00-00	KEY, FEATHER		1
3	4WM-16181-00-00	SPACER 1		1
4	90101-12011-00	BOLT		1
5	5PX-16340-00-00	PUSH LEVER ASSY		1
6	90508-16007-00	SPRING, TORSION		1
7	4WM-16382-00-00	AXLE, PUSH LEVER		1
8	92907-08600-00	WASHER, PLATE		1
9	99001-07600-00	CIRCLIP		1
10	93317-11020-00	BEARING		1
11	93102-15212-00	OIL SEAL		1
12	93315-31502-00	BEARING		1
13	91314-06020-00	BOLT		1
14	4WM-16150-00-00	PRIMARY DRIVEN GEAR COMP.		1
15	5VN-16154-00-00	PLATE, THRUST 1		1
16	5PX-16370-10-00	CLUTCH BOSS ASSY		1
17	26H-16385-00-00	RING, CLUTCH BOSS		1
18	26H-16384-00-00	PLATE, SEAT		1
19	1FK-16383-00-00	SPRING, CLUTCH BOSS		1
20	26H-16321-01-00	PLATE, FRICTION		1
21	26H-16324-00-00	PLATE, CLUTCH 1		1
22	26H-16307-01-00	PLATE, FRICTION 3		6
23	26H-16321-01-00	PLATE, FRICTION		2
24	26H-16324-00-00	PLATE, CLUTCH 1		7
25	1FK-16351-00-00	PLATE, PRESSURE 1		1
26	1FK-16334-10-00	SPRING, CLUTCH 2		1
27	1FK-16335-00-00	HOUSING, SPRING		1
28	5PX-16352-00-00	PLATE, PRESSURE 2		1
29	97007-06025-00	BOLT		6
30	93306-00304-00	BEARING		1
31	5PX-16383-00-00	SPRING, CLUTCH BOSS		2
32	4XV-16356-01-00	ROD, PUSH 1		1
33	90208-20001-00	WASHER, CONICAL SPRING		1
34	90179-20007-00	NUT		1
35	5PX-81673-00-00	ROTOR		1

Thanks AZ Warrior, the above information is where I realized that the "clutch kit" was not an all inclusive description as I thought it would be.  Will the part that I got repair my problem or do I need to order the corresponding clutch and friction plates as well.  I thought that when you order a clutch rebuild kit, all of the wearable parts are included.  I thought that I had made my situation clear to the dealer....but then that is why I ALWAYS consult this 4m first.  Just an idea, but it seems that someone could make a pretty good living by responding to posts like my original and then sending ALL of the correct parts needed to accomplish the stated task.  Just dreaming out loud.

Why did you wait till you got home to open the box?  Whenever I buy auto parts I always open the box at the store to make sure it's right.  I know you don't know exactly what you need, but somebody at the dealership might have possibly steered you in the right direction.

I do know better but I also should have pulled the above info prior to my ordering something so critical overnight.  Hopefully, one of my local dealers will actually stock the clutch and friction plates.  Am I just not remembering correctly, or aren't there clutch rebuild "packs" or kits that include all of the wearable parts of a clutch for other motorcycles.  I could have sworn that I was in a bike shop recently (can't remember which brand) and saw a "clutch kit" in a blister pack which seemed to include the friction / clutch plates.  Also, is the clutch boss assembly something that wears out often?

The Clutch Boss Assy with all its related parts will not solve your problem and shouldn't be req'd at such low miles. There isn't a "Clutch Kit" PN by Yamaha. You need to order the individual parts listed below!

• 6 - Item 22 PLATE, FRICTION 3 
• 2 - Item 23 PLATE, FRICTION 
• 7 - Item 24 PLATE,CLUTCH 1 
• 1 - Crankcase cover gasket 5VN-15451-00-00 

I would suggest a Barnett pressure plate conversion kit w/ std gold springs or a new Clutch Diamphram Spring (26) or a Speed* equivalent since you overheated the whole assy!

If you don't go with the Barnett you should inspect the existing pressure plate.

Edited: Here's a video by Redhorse:

http://img485.imageshack.us/slideshow/player.php?id=img485%2F5723%2F1149054461ef2.smil

Clutch plate replacement pointers:

• Recommended Reading: http://rswarrior.com/forums/p/107702/894063.aspx#894063
• Recommended Reading: http://www.motorcyclecruiser.com/tech/clutch_replacement/index.html  

Barnett Info by writer: http://rswarrior.com/forums/p/29213/392300.aspx#392300

http://rswarrior.com/forums/p/29213/429400.aspx#429400

Unbelievable help!!!!!!  Thank you so much AlanH.  Proof again that this is the best damn 4m!

As usual Alan is correct.