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Performing the"Double D"Clutch Spring Modificationfor the Gen IIMany old school first generation V-Max owners found that when you increased the horsepower of the engine, the clutch proved to be the next weak link that needed attention. Someone came up with the idea of double stacking the diaphragm type clutch springs and now we have the "Double D" mod. Bob Ward was the first I know of to attempt this on the Gen II V-Max.
Place the bike on the side stand for this modification. This tilts the bike allowing the oil to run to the opposite side. Remove the cover bolts making note of where the three short bolts are removed from.
Once the bolts are removed, you will find a tab on the cover plate (as illustrated in the photo) that you can use to pry off the cover plate. You may want to place a drip pan under the bike just in case, but I have had no problem with excess oil leaking out.
With the cover plate removed, take a 10mm socket and remove the six 6mm bolts that secure the clutch spring plate retainer.
I always remove the top bolt last and place it to the side like so.
At this point you may want to inspect your clutch plates and friction disk, but I will cover that on another page. Clutch Spring Part Number is 5YU-16334-00.
Take your new clutch spring, wipe it down and double stack the new spring atop the old spring.
Set your torque wrench to 8Nm or 5.8 ft-Lbs.
Clean your clutch spring retainer and re-install it. Finger tighten all the bolts. Using a 10mm socket and in a crisscross pattern, tighten the six bolts that secure the clutch spring retainer plate.
Here is a picture of the double stacked springs. Clean everything up and make sure no dirt or debris exist in the case or cover.
If you are installing a new gasket ( Part Number 2S3-15453-00-00), now would be the time to prepare the surfaces and install it. The picture was not in focus, but I also applied a very, very thin coat of "Form a Gasket" to the cover plate. To re-install the cover, find the two larger holes on the cover plate.
Locate the two guides on the crankcase. Line up the large holes with the guides and install the cover.
With the cover plate installed, the holes at 2, 5 and 7 o'clock require the short bolts.
Set your torque wrench to 12Nm or 8.7 ft-Lbs.
Tighten the cover Allen bolts in a crisscross pattern.
Clean it up and you are done. You will notice a slightly increased amount of effort is required to pull in the clutch lever, but it is not as bad as the Gen I in traffic.
Blog 8/10/09 I am back online!!!! But today is a work day for me. Esten is ordering an extra clutch spring plate to perform what is referred to as the "Double D" wherein you order a second clutch (diaphragm) spring and double stack two springs on the clutch basket to eliminate clutch slippage.
The part number for the clutch spring is 5YU-16334-00-00. List price at K&N is $36.90 Although I have re-used mine before but if you are a purest, you may want to order a gasket for the cover. The gasket part number is: 2S3-15453-00-00 and has a list of $8.34. I use the K&N website to find most of my parts and they offer a nice discount to VMOA members.
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