Diy Clutch Cover Oil Squirter Upgrade

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.