Clutch cable/pin

What to do here? Need help!

 

You'll need to take the clutch cover off, and most likely replace the little clip at the bottom of the throwout "axle" rod (the piece that is now sticking way out.)

Here is a page from the parts fiche for a 650 Maxim; the clutch mechanism is essentially the same on all of the shaft driven bikes, so yours will be similar: https://www.babbittsonline.com/oemparts/a/yam/5004202df8700209bc786d9c/clutch

The clip I am referring to is ref #25 in the diagram. The shaft that has escaped is part #22. That shaft has a little gear on it (ref #23) that operates the clutch pull-rod. Once everything is reassembled in the cover, you'll mesh the little gear up with part #3, which lifts the pressure plate to disengage the clutch, as you put the cover back on. Then then little actuating lever can be reinstalled in the correct position.

You will have to take it apart to get the shaft back in place, with the little gear on it and the washer and clip on the end to retain it. Since it has pulled out that far, the little gear has fallen off already. There is also a possibility that one or both of the bearings it rides in have been displaced, so DO NOT force it back in. I wouldn't pull it all the way out either, or everything on the shaft will fall off into the clutch housing. You'll need to be sure you have all the parts, or go fishing under the clutch with a magnet for anything that's gone missing.

 

I would advise to get a new clip. Spring steel is awesome, but once it slips out of place on its own (if that is what happened) it won't stay in place again.

 

I'd take it apart first; might need more than just the clip.

 

Definitely.

 

What I do not know so was reluctant to mention, is how likely it might be that some of the bits have made it to the sump? I don't know what the clutch "gallery" on the shaft drive bikes is like, how big and where is the opening to the sump?

 

Depends on what came apart/broke inside....

here’s what should be in there.....

 

Ok thanks guys! Appreciate it. I'll post pics n keep ya updated

 

The oil drain into the sump is about 30mm in diameter and right below the clutch basket, but it has a slightly raised lip to it and an anti-splash baffle along one side. The parts might have made it into the sump, but then again they might not have.

 

What happens if they made it into the sump. Worse case scenario... ?

 

Worst case, drop the sump, which I think you can do without pulling the motor. Probably could fish 'em out through the oil drain plug hole though; you'll need a small "extension" magnet. You're probably going to be looking for the clip, washer, and the gear; I doubt a bearing has been displaced, but you never know.

 

Let’s wait to see what he finds when he pulls the cover .... then we go from that point

 

Soooooo sorry it took so long but I haven't had time due to hockey season starting back up(I work for a team) but here it is. What ya guys thinking?!

 

That’s about as close being destroyed as you can get without being destroyed!!! Looks like you may get away with just a clutch rebuild and new bolts/springs...... assuming the end of the bolts can be unscrewed after the basket is pulled off