Motorcycle Clutch Replacement - Part 1 - Seized Clutch - Project Yamaha TDM900

[@PJGajewski]

Be careful while fitting bolts with springs back. They can snap all of sudden - very brittle!

[@TheGarage2018]

Thank you for your comment! Every 10 minute job is one broken bolt away from a two day ordeal :D. Whenever possible I try to torque down bolts with a torque wrench anyway, that significantly reduces the risk of snapping;)

[@PJGajewski]

@@TheGarage2018 Funny thing with TDM900 clutch is, that if you will go with the manual specification its good if you have new bolts. Old ones properly torqued will give you that jumpy feeling on the clutch - they need to be tightened a little bit more than specified. Trust me, I was there! Good luck!

[@TheGarage2018]

Thank you for the tip PJ! I might as well order new bolts then.

[@TheGarage2018]

I got lucky, none of the old bolts have snapped:). I’ll post the video soon

[@PJGajewski]

@@TheGarage2018 👍👍👍 Did you buy a new set of springs?

[@turoksilvares]

Man, your videos help me a lot. I have a 2006 model. I have to say. Thankyou for share🤝🏼

[@Fortemagno]

A bike born to ride and go for many miles! a lot of "real" quality made in Japan! If the engine is treated well and with the right oil, it can last a long time! I use shell advance as an oil and for now I feel good.

[@TheGarage2018]

Fortemagno what grade oil are you using in your TDM?

[@Fortemagno]

@@TheGarage2018 :shell advance 10w40 - 100% synthetic with shell pure plus technology

[@travelsw]

Great tutorial and very helpful for people who don't have big mechanic skills ( like me ) 🤣 👍👏👏✌

[@TheGarage2018]

Glad it helped

[@TigersharkPL]

Hi. Quick, short question. Before open a clutch case , should I remove oil from engine?

[@TheGarage2018]

Yes absolutely!

[@panagoskakatosis5314]

i take out today the disc ..i not take out the oil engine is no problem inde is dry can make this jop easy.. alll is yamaha my model xtz 750

[@yanou9742]

hello, do you have to change the oil before disassembly?

[@TheGarage2018]

You don’t necessarily need to change the oil although you need to drain the oil before disassembly otherwise it will leak all over your floor lol :)

[@yanou9742]

@@TheGarage2018 I wanted to be part of it, thank you very much for the information

[@TheGarage2018]

Glad I could help

[@thatmaddude6047]

I’m curious to see what caused your clutch to seize. Great vid btw 👍

[@TheGarage2018]

Yes, me too. The failure analysis video will be out soon. There are some quite interesting findings

[@DaBuzz92]

I thought that there is no replace kit for tdm900 clutch, because it's indestructable. (140kkm my clutch has).

[@TheGarage2018]

Yes, I thought the same and yet.... I don’t know what happened to my clutch to be honest, I have measured the old clutch plates and everything and it’s within spec. Watch part 2 of the video if you haven’t already. Thanks for your comment!

[@DaBuzz92]

@@TheGarage2018 Just watch part 2. Imo, there is no need to do anything with this clutch. That's the dry clutch, so I think the only thing which is impprtant is to prevent it from SLIDING. If clutch SPRINGS are not worn out (looks like their dimenssions are ok), and if clutch mechanizm is working smoothly, there is only one thing to checkn. Pay attetion to clutch cord tension. There must be few milimeters (2-3) of free space in clutch handle. What I discover in some bikes: after hard stress drive, the cord tension Can change (probably because of fiction plates expand in high temperaturers), so in this case clutch cord tension can increase and that's the reason why cord must have few mm free. I think in your case there was something like "micro-slide" of the clutch which is hard to be observed and it causes the clutch temperature increase. After last ride, your bike spend some time in Garage, cools down, humidity inside clutch chamber changed into water and clutch have coroded (it happens even in WET clutches). I think everything will be fine, just take care of clutch cord and take your baby for long rides :) regards :)

[@TheGarage2018]

My clutch cable tension was alright. I decided to change the clutch purely for my own piece of mind. I don’t ride it on a daily basis and whenever I want to take it for a ride I want to avoid the clutch sticking together again and having to fuck around with unsticking the clutch, I want to hop on and go. Anyway, I really appreciate your input ;)

[@simboklice1094]

my clutch broke at 120.000 , the bearing on the clutch disengager broke and the bike stoped disengaging... You will feel it as the clutch lever will get lose everyday and you will tighten it by the nut on the lever and the clutch after 3-4 days will get lose again..

[@Dobbo2958]

Appreciate your video's thank you...

[@TheGarage2018]

Thank you!

[@ahmedmouhcine3468]

Nice bro

[@TheGarage2018]

Thanks!

[@ahmedmouhcine3468]

Wellcom

[@Knockelhead]

Normal on a 900 you only change the springs

[@TheGarage2018]

Interesting. I’ve never done a clutch on a 900 so I don’t really know. Why do you change the springs only? I have measured the friction plates and clutch plates and they’re all within spec so I don’t know why it got stuck... I’ll change the clutch plates anyway for my own piece of mind :D

[@fathisaidi309]

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