Yamaha DT400 Clutch Question

Discussion in '2 smokers' started by east high, Jun 20, 2011.

  1. east high

    east high Been here awhile

    Joined:
    Oct 13, 2009
    Oddometer:
    955
    Location:
    Portland, Oregon
    [​IMG]

    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?
    #1
  2. anotherguy

    anotherguy Long timer

    Joined:
    Jun 18, 2009
    Oddometer:
    6,630
    Location:
    the hills
    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.
    #2
  3. east high

    east high Been here awhile

    Joined:
    Oct 13, 2009
    Oddometer:
    955
    Location:
    Portland, Oregon
    Sweet. Thanks for the help. :freaky
    #3
  4. JeffS77

    JeffS77 cheap bastard

    Joined:
    Apr 23, 2006
    Oddometer:
    3,377
    Location:
    Riverside , CA
    glad somebody stopped him,,, 55 ft lbs would snap the aluminum under the spring screws
    #4
  5. beaton172

    beaton172 n00b

    Joined:
    Oct 27, 2011
    Oddometer:
    4
    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.
    #5
  6. Kai Ju

    Kai Ju Long timer

    Joined:
    Jul 29, 2009
    Oddometer:
    1,924
    Location:
    So Cal
    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.
    #6
  7. Kai Ju

    Kai Ju Long timer

    Joined:
    Jul 29, 2009
    Oddometer:
    1,924
    Location:
    So Cal
    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.
    #7
  8. beaton172

    beaton172 n00b

    Joined:
    Oct 27, 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.
    #8
  9. Kai Ju

    Kai Ju Long timer

    Joined:
    Jul 29, 2009
    Oddometer:
    1,924
    Location:
    So Cal

    It's been a while since I've had my hands on one, pics would help.
    #9
  10. anotherguy

    anotherguy Long timer

    Joined:
    Jun 18, 2009
    Oddometer:
    6,630
    Location:
    the hills
    You need to host the images online and link from there. I use Photobucket for mine.
    #10
  11. beaton172

    beaton172 n00b

    Joined:
    Oct 27, 2011
    Oddometer:
    4
    #11
  12. SEJO

    SEJO n00b

    Joined:
    Apr 14, 2013
    Oddometer:
    6
    I'm having the same problem...I have no idea how that cable mounts. Please Help!!
    #12
  13. Scootern29

    Scootern29 Been here awhile

    Joined:
    Sep 4, 2012
    Oddometer:
    540
    Location:
    In the hot, hot, dezert
    There should be a bolt hole on the underside of the cylinder that holds the bracket I believe.
    #13
  14. SEJO

    SEJO n00b

    Joined:
    Apr 14, 2013
    Oddometer:
    6
    I looked but didn't see any bolt holes....
    #14
  15. Scootern29

    Scootern29 Been here awhile

    Joined:
    Sep 4, 2012
    Oddometer:
    540
    Location:
    In the hot, hot, dezert
    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.
    #15
  16. SEJO

    SEJO n00b

    Joined:
    Apr 14, 2013
    Oddometer:
    6
    Its a 1978...
    #16
  17. Scootern29

    Scootern29 Been here awhile

    Joined:
    Sep 4, 2012
    Oddometer:
    540
    Location:
    In the hot, hot, dezert
    It is the same as a 1977. It is under the cylinder. They are hard to see.
    #17
  18. SEJO

    SEJO n00b

    Joined:
    Apr 14, 2013
    Oddometer:
    6
    Hmmm I stared at that thing for like 2 hours and couldn't figure it out. Maybe I'm making it to difficult than what it is.
    #18
  19. JeffS77

    JeffS77 cheap bastard

    Joined:
    Apr 23, 2006
    Oddometer:
    3,377
    Location:
    Riverside , CA
    Yes go on bike bandit or something of that sorts n look up the schematics of the motor you will see it bolt underneath the cylinder.

    See it in this pic ?

    [​IMG]
    #19
  20. SEJO

    SEJO n00b

    Joined:
    Apr 14, 2013
    Oddometer:
    6
    I'll have to take a closer look tonight.
    #20