Yamaha DT400 Clutch Question

east high · 06-20-2011, 09:56 AM

My buddy is replacing the clutch plates on his DT400 and he's stuck at the torquing down part. His books says to torque the clutch bolt down to 55 ft/lbs. The schematics refer to the six bolts in the pic as clutch bolts, but the torque specifications says clutch bolt (singular).

My google-fu found a tute for replacing the clutch plates on a DT400, but he didn't torque anything down nor did his clutch basket have the center adjuster nut.

Anyone know anything about this clutch setup?

anotherguy · 06-20-2011, 12:33 PM

DON'T DO IT!!!! The 55 ft-lbs figure is for the nut that attaches the hub to the mainshaft!! The spring screws are 7 ft-lbs. Honestly they'll be fine if you run them in 'til they bottom and snug them up gently. As far as the adjuster lock nut just snug it up while holding the screw from moving with a screwdriver.

east high · 06-20-2011, 01:29 PM

Sweet. Thanks for the help.

JeffS77 · 06-20-2011, 06:15 PM

glad somebody stopped him,,, 55 ft lbs would snap the aluminum under the spring screws

beaton172 · 04-03-2012, 11:24 AM

I was wondering if someone could help me with how to reattach the clutch cable on a DT400. The cable was removed about 6 months ago to rebuild the engine and I can't figure it out. The bottom end of the cable has a flat metal plate with a hole in it but the engine case does not have a hole in it that lines up. Any help or pics would be great.

Kai Ju · 04-03-2012, 12:10 PM

Is that hole D shaped ?
If so it'll line up a matching shaft, nut and washer under the sprocket cover where the throw out mechanism resides.
Purely a guess, btw.

Kai Ju · 04-03-2012, 12:14 PM

Quote:

Originally Posted by anotherguy

DON'T DO IT!!!! The 55 ft-lbs figure is for the nut that attaches the hub to the mainshaft!! The spring screws are 7 ft-lbs. Honestly they'll be fine if you run them in 'til they bottom and snug them up gently. As far as the adjuster lock nut just snug it up while holding the screw from moving with a screwdriver.

You might want to add that the adjuster screw needs to be run in until it touches, lightly, than back it off a quarter turn. Hold the screw and tighten the lock nut. All of that is done with the cable adjuster at the handlebar all the way in.

beaton172 · 04-03-2012, 12:54 PM

OK, so the metal plate goes vertical and the hex bolt that holds the sprocket cover also holds the clutch cable?
I will give that a try tonight. The clutch plates are also stuck together and need to be removed this weekend. The fun doesn't stop.

Kai Ju · 04-04-2012, 12:26 PM

Quote:

Originally Posted by beaton172

OK, so the metal plate goes vertical and the hex bolt that holds the sprocket cover also holds the clutch cable?
I will give that a try tonight. The clutch plates are also stuck together and need to be removed this weekend. The fun doesn't stop.

It's been a while since I've had my hands on one, pics would help.

anotherguy · 04-08-2012, 06:40 PM

You need to host the images online and link from there. I use Photobucket for mine.

beaton172 · 04-09-2012, 04:14 AM

http://s1162.photobucket.com/albums/...t=DT400001.jpg

Here is a pic of the clutch lever. Does anyone know, or have a pic of how to connect the bracket?
Thanks

SEJO · 04-15-2013, 05:22 AM

I'm having the same problem...I have no idea how that cable mounts. Please Help!!

Scootern29 · 04-15-2013, 08:09 AM

There should be a bolt hole on the underside of the cylinder that holds the bracket I believe.

SEJO · 04-15-2013, 03:25 PM

I looked but didn't see any bolt holes....

Scootern29 · 04-15-2013, 03:58 PM

If the clutch actuation arm is on top of the motor, like a 1977 there will be a bolt hole in the bottom of the cylinder. It shows it on the parts fiche. The 76 may have hooked up like the YZ's which was under the motor.

06-20-2011, 09:56 AM	#1
east high ^OP Studly Adventurer Joined: Oct 2009 Location: Portland, Oregon Oddometer: 749	Yamaha DT400 Clutch Question My buddy is replacing the clutch plates on his DT400 and he's stuck at the torquing down part. His books says to torque the clutch bolt down to 55 ft/lbs. The schematics refer to the six bolts in the pic as clutch bolts, but the torque specifications says clutch bolt (singular). My google-fu found a tute for replacing the clutch plates on a DT400, but he didn't torque anything down nor did his clutch basket have the center adjuster nut. Anyone know anything about this clutch setup? __________________ '71 r75/5

06-20-2011, 12:33 PM	#2
anotherguy Beastly Adventurer Joined: Jun 2009 Location: in the foothills now.... Oddometer: 4,315	DON'T DO IT!!!! The 55 ft-lbs figure is for the nut that attaches the hub to the mainshaft!! The spring screws are 7 ft-lbs. Honestly they'll be fine if you run them in 'til they bottom and snug them up gently. As far as the adjuster lock nut just snug it up while holding the screw from moving with a screwdriver. __________________ When injustice becomes law,resistance becomes duty. Thomas Jefferson

06-20-2011, 01:29 PM	#3
east high ^OP Studly Adventurer Joined: Oct 2009 Location: Portland, Oregon Oddometer: 749	Sweet. Thanks for the help. __________________ '71 r75/5

06-20-2011, 06:15 PM	#4
JeffS77 cheap bastard Joined: Apr 2006 Location: Riverside , CA Oddometer: 2,999	glad somebody stopped him,,, 55 ft lbs would snap the aluminum under the spring screws __________________ A n00b Races Hell on Wheels Vintage Scrambles A n00b Races Elsinore Grand Prix For a Cause A n00b Goes Flat Track Racing

04-03-2012, 11:24 AM	#5
beaton172 n00b Joined: Oct 2011 Oddometer: 4	Dt400 I was wondering if someone could help me with how to reattach the clutch cable on a DT400. The cable was removed about 6 months ago to rebuild the engine and I can't figure it out. The bottom end of the cable has a flat metal plate with a hole in it but the engine case does not have a hole in it that lines up. Any help or pics would be great.

04-03-2012, 12:10 PM	#6
Kai Ju Beastly Adventurer Joined: Jul 2009 Location: So Cal Oddometer: 1,025	Is that hole D shaped ? If so it'll line up a matching shaft, nut and washer under the sprocket cover where the throw out mechanism resides. Purely a guess, btw.

04-03-2012, 12:54 PM	#8
beaton172 n00b Joined: Oct 2011 Oddometer: 4	OK, so the metal plate goes vertical and the hex bolt that holds the sprocket cover also holds the clutch cable? I will give that a try tonight. The clutch plates are also stuck together and need to be removed this weekend. The fun doesn't stop.

04-08-2012, 06:40 PM	#10
anotherguy Beastly Adventurer Joined: Jun 2009 Location: in the foothills now.... Oddometer: 4,315	You need to host the images online and link from there. I use Photobucket for mine. __________________ When injustice becomes law,resistance becomes duty. Thomas Jefferson

04-09-2012, 04:14 AM	#11
beaton172 n00b Joined: Oct 2011 Oddometer: 4	http://s1162.photobucket.com/albums/...t=DT400001.jpg Here is a pic of the clutch lever. Does anyone know, or have a pic of how to connect the bracket? Thanks beaton172 screwed with this post 04-10-2012 at 09:48 AM

04-15-2013, 05:22 AM	#12
SEJO n00b Joined: Apr 2013 Oddometer: 6	I'm having the same problem...I have no idea how that cable mounts. Please Help!!

04-15-2013, 08:09 AM	#13
Scootern29 Gnarly Adventurer Joined: Sep 2012 Location: In the hot, hot, dezert Oddometer: 234	There should be a bolt hole on the underside of the cylinder that holds the bracket I believe.

04-15-2013, 03:25 PM	#14
SEJO n00b Joined: Apr 2013 Oddometer: 6	I looked but didn't see any bolt holes....

04-15-2013, 03:58 PM	#15
Scootern29 Gnarly Adventurer Joined: Sep 2012 Location: In the hot, hot, dezert Oddometer: 234	If the clutch actuation arm is on top of the motor, like a 1977 there will be a bolt hole in the bottom of the cylinder. It shows it on the parts fiche. The 76 may have hooked up like the YZ's which was under the motor.

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