Diy Clutch Cover Oil Squirter Upgrade

[jeepman380]

First off this is my first "How To" post so bear with me. So if you feel that I left a step out or something let me know. We used a Bridgeport mill to do this modification for your reference.

To start off drain the oil and coolant and take off the clutch cover. You won't have to strip the clutch cover completely down, just take off all the covers (clutch insert, oil filter, water pump cover), remove the 2 dowels if they came off with the cover, and remove the water pump. Just use a open end wrench to hold the back side of the water pump and a 12mm socket on an impact and take the impellar off the shaft. It comes off counterclockwise or lefty loosey FYI. Now tape off the water pump bearing and make sure there are no other dowels on the clutch cover so it can sit flat. Make sure you have it sitting flat on the milling surface inside facing up and tighten it down.

This is going to be what you will be milling down. The circle must be milled down 3.5mm or .1378".


Start off by coming from the side and mill across one pass then by the two little peices that come down you will have to make a circular pass. Don't take off anything more than the circle. The two little peices that hang down hold the squirter from spinning.

This is what it should look like when you finish milling it down.


Next step is to drill the hole for the squirter to fit in. I used a 5/16" drill bit for this. You will want to drill it down 1/2". It is important that you mill it down first then drill your hole so you get the right depth. After we finished drilling the hole we chamfered the hole just a bit to allow the o-ring to slide in easier so you won't pinch it.


Next you need to drill a hole into the oil pressure passage. We used a 7/32" drill bit but you could use smaller one if needed. When you are drilling be sure to watch through the banjo bolt hole and make sure you don't go to far through just enough to make a passage to the squirter.




Now blow air through all the oil passage ways and make sure it's all clear of shavings. Before you insert the oil squirter, put a bit of grease on the o-ring so it will slide in easier. It fits a little tighter than the stock '07 cover which I like better and it doesn't rock back and forth like the stock one. I think the '07 one has a bit to much clearance than it needs.


You can use the OEM Yamaha o-ring for the squirter and like I said it fits a bit tight but it isn't a problem as long as you have a good chamfer on the hole so you dont' pinch the o-ring. I ended up pinching the o-ring and taking a chunk out of it from taking it in and out of the hole so much test fitting it so I ended up using a tiny bit smaller o-ring I got from one of those bulk o-ring kits you can get from harbor freight or hardware store. You can also get the o-ring seperatly from your local hardware store too. Here is a pic to show the difference.


Don't forget you need the new style oil pump as well. To get to it you will need to take off the clutch basket and everything. The clutch basket nut is a 30mm FYI. Now for the final step when putting the clutch cover back on, you may have to cut out a spot on the clutch cover gasket to clear the squirter but if you got a new gasket it most likely has the cut out already.

Hope this was helpful and showed people how to do the squirter upgrade themselves and save some money.

[sidewinder]

Good writeup, thanks for posting!

[j1o2e3]

thanks alot jeepman! this is VERY helpful. i will be tearing mine down this weekend!

[j1o2e3]

is this similar to the pinned up oil mod post? but using the squirter instead?

[sidewinder]

It does the same thing but it goes about it a different way. Think of this as upgrading your case similar to the '07 and later versions.

[jeepman380]

It's the same thing as the '07 squirter upgrade but instead of buying a whole new cover you are just modding your existing cover to use the squirter. Saves you almost $150 or whatever the '07 covers cost.

[bigal90]

Great write-up I've been wanting to do this for a while. Thanks

[Terse]

Excellent write up.

I'm pinning this in the tips and tricks section FYI.

[bmf454]

Does J&T do this mod anymore and is this a better mod than the others? Can't I just buy a side cover from a 07 and an 07 oil pump? I really want to do this but I am really confused as to which way to go any advise would be appreciated.

[j1o2e3]

QUOTE (BMF454 @ Mar 19 2009, 09:16 PM)

Does J&T do this mod anymore and is this a better mod than the others? Can't I just buy a side cover from a 07 and an 07 oil pump? I really want to do this but I am really confused as to which way to go any advise would be appreciated.[/b]

yes J&T still does the mod. this is the same thing that J&T will do but your machining the case and installing the squiter yourself. J&T machines your case for the squirter, installs the squirter and then sends you your case with the squirter installed and the 07 oil pump that you have to install yourself.

this mod is very effective. and yes you can just buy the 07 cover and 07 oil pump and install it and it should work. but youll be spending way more money that way.

[bmf454]

does the 3.5mm have to be exactly machined down or is this something I can do with a die grinder or something simular? I can easily drill the holes but dont have a local machinist.

[j1o2e3]

QUOTE (BMF454 @ Mar 19 2009, 11:25 PM)

does the 3.5mm have to be exactly machined down or is this something I can do with a die grinder or something simular? I can easily drill the holes but dont have a local machinist.[/b]

exactly 3.5mm if you dont have the right machine take it to a machine shop and make sure they mill the circle only and not the two tabs that hang down. those tabs hold the squirter in place and also ask them to put a chamfer on the hole. it shouldnt cost that much. i work at a machine shop im a journeyman machinist and i could mill that down within a half hour.

[jeepman380]

QUOTE (BMF454 @ Mar 19 2009, 11:25 PM)

does the 3.5mm have to be exactly machined down or is this something I can do with a die grinder or something simular? I can easily drill the holes but dont have a local machinist.[/b]

Yes it has to be exactly 3.5mm. You could possibly use a die grinder but you would have to be PRECISE on how much you remove and make sure that it's level. I wouldn't recommend to do it that way but you could try I guess.

[amstall]

correct me if i'm wrong, but the only new parts you need are the O-Ring, Oil Squirter, and Oil Pump and possibly the gasket. With the squirter and pump being specifically an 07. Anybody got part numbers for those 2?

[amstall]

bump.

[daddio]

5D3-15155-00-00 NOZZLE 3
93210-05098-00 O-RING
5D3-13300-00-00 OIL PUMP ASSY

[amstall]

thanks bud.

[yfz450_0569]

QUOTE (ballsdeep450 @ Mar 18 2009, 02:00 AM)

is this similar to the pinned up oil mod post? but using the squirter instead?[/b]

Another oil mod? Where this be at? I'm curious cuz the local atv shop here quoted me $65 for the oil mod and I thought that was basically just drilling something while this includes the squirter...

[maddmatt02]

QUOTE (yfz450_0569 @ Apr 30 2009, 05:09 PM)

Another oil mod? Where this be at? I'm curious cuz the local atv shop here quoted me $65 for the oil mod and I thought that was basically just drilling something while this includes the squirter...[/b]

over in the engine section, that one is drilling a hole in the case half and installing a jet, and then on the other side installing an o ring, and drilling a hole behind the oil filter to feed the jet.

what holds the squirter in? I can see why it doesnt spin, but what stops the oil pressure from blowing it right out? when you install the outer cover, does any part of the nozzle hit something on the case half to keep it in?

[amstall]

ya. when you do it the other way you install a jet right next to the slot in the right case half. with this you install the squirter in the right case cover, then when you put the cover on the squirter goes into the hole and butts up against the sides of it, preventing it from coming out.