How To Replace a Slipping Clutch Plates in a Yamaha Moto4 YFM200DX ATV

  / wrekkedoffroad      / @vermontlife   https://www.buyjimmyabeer.com/

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This is a one beer job (or can be if you have your gasket or RVT ready ahead of time). Otherwise...

We have had this 1986 Yamaha Moto4 YFM200DX for more than 15 years. After I bought my first quad we bought this one for Anne Marie rom a fella who had just rebuilt it. Anne has put it through a lot of mud and creek beds over the year and I've never done any clutch work on it. Frankly, I haven't done much work to this one at all. It's just that bullet proof. It's now time to swap out the friction plates and springs.

Torque Specs from Clymer manual for YFM200
Clutch Cover Screws: 5.1ft-lbs
Primary Clutch Nut: 56ft-lbs
Clutch Spring Screw: 4.3ft-lbs
Clutch Boss Nut: 36ft-lbs
Shift Cam Segment Screw: 8.7ft-lbs
Clutch Adjuster Nut: 11ft-lbs

Primary Clutch Wear Limits:
YFM200 Shoe Thickness 1.5mm

Secondary Clutch Limits:
Friction Plate: 2.8mm
Clutch Plate Warp Limit: .2mm
Clutch Spring Free Length: 32.9mm


In this video:
In the intro enjoy some beautiful drone footage through low hanging fog and witness a daring frog escape from our Labradoodle Chloe.
Learn how to swap clutch and spring plates without needing to drain and change the oil on a Moto4.
Then see me decide to change the oil and filter anyway... Parts links and how to included.

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Parts used in this video: (Thanks in advance if you purchase from these links as I get a small commission.)
Vesrah Friction Plates: https://amzn.to/3SJjfgS
Vesrah Clutch Springs: https://amzn.to/3w0IGkc
Clutch Case Gasket: https://amzn.to/3w2D0q5
Locking Washer: Had to hunt Ebay for 'YAMAHA Clutch Lock Washer 1983-1998 YFM200'
YamaLube 10w40 Wet Clutch Oil: https://amzn.to/3C6p2am


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#moto4
#ATVRepair