Removing the Clutch Assembly

Start by removing the rear horn from the left-side of the engine. This is located just aft (rearward) of the clutch case.

Remove the clutch assembly. I will not go in to the details of clutch removal in this article. It is covered adequately in other documents. Refer to the How to install the Barnett Clutch with new Oil Pump Gear article in this website for details.

Tip: I do have a few suggestions, however. Rather than purchase a one-time-use tool like the Yamaha clutch basket wrench, I wrapped a nylon webbing hold-down strap around the basket. I tied one end to the frame. The other end I just wrapped around the basket, overlapping itself at least one revolution. The webbing does stretch. But as long as you wrap it in the right direction (see picts below), it will tighten on itself nicely.

Better yet, if you have access to an impact wrench, use it instead.

Tip: As you remove the oil pump driven gear, be sure to completely pull out the oil delivery pipe located under one of the driven gear bracket bolts. The oil pipe is held in place with an O-ring seal.

Tip: Put the following in a labeled sandwich bag:

• Oil pump driven gear
• Oil delivery pipe and three O-rings. One of the O-rings may get caught inside the engine case as you remove the oil pipe. It is easily extracted with forceps or tweezers, but if you are splitting your crankcases you can retrieve the O-ring once you have separated the crankcase halves.
• Oil pump driven gear bracket and bolts