I Was trying to locate some good technical info for the clutch on the Yamaha XV750 the 93-19 YAMAHA YZ250 Friction and Steels are the Same the springs are different.
Clutch Exploded Diagram form the Yamaha Virago XV750 Service Manual You will notice that the 10 then goes to 11 there are unlisted parts…
The Diagram form Japan motorcycle parts diagram web site list the proper parts. parts 24-26 are missing in the commonly found online manual.
Here is an Archive of the Haynes Yamaha 535 to 1100 Virago Manual
Here is an Archive oof the Clymer Manual
The Clutches China and KG Clutch Factory.
Friction 22U-16321-00 X 8 EBC CK2274
Steel 4X7-16325-00-00 X 7
Steel 4X7-16324-00-00 X 1 (This is a 3MM Plate for Adjusting stack Height)
Hinson
Friction FP196-8-001
Steel SP073-7-001
Springs EBC CSK14
Barnett
Friction 301-90-10040 X 8
Steel 401-90-063041 X 7
Springs 501-50-06042 x 6
KG Clutch Factory
KGK-5004Y
China Clutches
Caltric
Friction plate thickness
Standard 2.9 to 3.1 mm (0.116 to 0.124 inch) Most are 2.98mm to 3.00mm
Minimum 2.8 mm (0.11 inch)
Steel plate thickness 1.5 to 1.7 mm (0.059 to 0.067 inch) Most are 1.59 to 1.6mm
Steel plate warpage limit 0.1 mm (0.004 inch)
Pushrod bend limit 0.5 mm (0.02 inch)
Spring length (Stock Springs)
Standard 41.2 mm (1.622 inch)
Minimum 40.2 mm (1.582 inch)
OEM Stack Height
Max 36.7mm
Standard 35.2mm
Min 32.9MM
July 19th 2025 I’ll be using the KG Clutch Factory Clutch. (35.8mm stack height) if i use the caltrick steel plates its 35.25mm which is perfect.
I also found this site it is awesome for parts lists. https://en.impex-jp.com/catalogs/moto/yamaha/xv750/xv750f-1994-usa-10155.html
May 2026 Revisiting the Clutch… I have Noticed the Bike is Missing the Clutch Boss Ring ( “piano wire”) 4X7-16385-00-00
The Seat Plate 4X7-16384-00-00 and Clutch Boss Cushion Spring 4X7-16383-01-00 seem to be good.
The 1St Plate 4X7-16324-00 Retained by that ring is very worn and maybe also the wrong thickness?
I Have Ordered the Parts… I am going to assume this is the reason why its not working correctly!
05/07/2026 The proper Plate 1 and Boss Ring Arrived. T
05/28/2026
I need a holder to be able to torq down the nut so I printed this clutch boss hub holding tool.
Torq to 50ft Lbs.
Install the Clutch Plates I have a Choice dimpled or smooth plates? Ill go with the dimpled Smooth is 35.25mm prob regret it the Smooth Plates Slightly thicker stack height 35.42mm. All within the tolerances?
Installing the clutch pack! There is debate on the stamping rounded edge some say out some say in? I put it in that the way the manual says. I dont like the look of the lock washer not supposed to reuse them but nothing local so f-it! Deed it done!
Pressure Plate Bolts Torq 8-10NM depending on revision of the factory or other manuals?
Virago Clutch Cover Bolts.. 7NM Torque
- 91314-06040-00 → M6 × 40mm hex socket head bolt X 2
- 91314-06025-00 → M6 × 25mm hex socket head bolt X 8
- 91314-06030-00 → M6 × 30mm hex socket head bolt X 1
Pressure Plate back on.
Assembled and Leak Check.. No Drips!!
Need to Drain the Fuel Tank and the Carb. The fuel is bad! Petcock dont look Original.
Need to do the Fork Seals… ??
Last Updated on June 7, 2026 by Steven Rhine