Disclaimer: Consult your Yamaha dealer concerning warranty issues before performing this modification.

Required Parts: (Note: factory parts list and diagram for Clutch Assembly is included for reference at the end of this document)

Primary Sliding Sheave Part No. 5KM-17620-00-00

Recommended Optional Parts:

New oil seals for the Sheave Part No. 93101-35001-00 (Qty 2: One each side)
Note the ones on your original Sheave can be used if they are carefully removed

Before attempting this mod, understand that I am not a Yamaha mechanic and I do not have nor will I recommend any torque specs, if after reading the instructions you still want to try this, please be careful.

Step 1

Remove seats and engine housing to access crank (clutch) case cover (Denoted by RED Arrow). Next remove bolt holding hose clamp (Denoted by YELLOW arrow). Push hose down and out of the way in order to be able to remove clutch case housing through framed opening.

(Larger View of Hose Clamp noted in Step 1)

Step 2

Remove housing to expose clutch assembly. Next remove (4) four bolts holding the bearing housing. Bolts are located at each of the four corners of the the part denoted by RED arrow. Note or label location of each bolt when removed given that bolt lengths vary.

Step 3

In order to remove tension from the “V-Belt”, it is necessary to install (2) two metric bolts labeled by RED arrows into the Secondary Fixed Sheave shown in photo above. It is not necessary to over insert these bolts since it does not take much to remove tension from the V-Belt.

Step 4

Bearing Housing removed and tension off the belt, using an impact wrench remove the 22 mm nut holding the Primary Sliding Sheave Assembly in place. This 22 mm nut is denoted by a GREEN arrow.  With nut and washer removed the Sheave Assembly should slide right off.

Photo below shows clutch assembly with Primary Sliding Sheave Assembly removed.

Step 5

Remove the (8) Eight Phillips head screws and Washers holding the “Stopper Plate” in place. Stopper plate is noted by the YELLOW arrow.

Step 6

With Stopper Plate Removed, you will need to carefully remove the O-Ring seal for re-use on new sheave. O-Ring seal is noted with a YELLOW arrow. Next, remove Cam (noted by RED arrow) from the sheave. The Cam should simply pull straight out of the sheave. Be careful not to lose your sliders (qty 4) or spacers (qty 4) at each corner of the Cam. Pay careful attention as to how these sliders and spacers are installed for re-assembly.

Step 7

With Cam set aside, you can now remove the weights from the sheave. There are (8) eight weights total, as noted by the YELLOW arrow. At this point, if you have not purchased new Oil Seals for the Sheave, you will need to remove your old ones very carefully using a flat headed screw driver. Do not damage these seals! Seals are noted by GREEN arrow. There are (2) two (one on each side).

This is a close up of the inside of the Sheave Assembly showing the weights.

Step 8
Before reinstalling parts into your new sheave you will need to apply grease (I used a good quality synthetic) to all areas that come in contact with moving parts.

Step 9
Insert the oil seals into your new sheave (these should be easily pushed in with your fingers) be sure to remember both sides, next reinstall the weights, the cam, the o-ring for the stopper, the stopper and the eight Phillips screws and washers.

Step 10
With the primary sliding sheave reassemble you can now put it back on the Rhino, be careful when doing this, if the cam is allowed to open the weights can fall out of place and you will have to take the assembly apart again.

Step 11
Before the 22mm nut and washer go back on, make sure the cam has fit into the splines on the clutch shaft (this is important), once done you can reinstall the washer and nut, double check that the washer is centered or over the splines before tightening with your impact wrench. As you are tightening this nut you should turn the belt a little at a time to keep it from becoming pinched or binding between the pulleys.
 

Step 12
Reinstall the bearing housing, make sure to use the proper length bolts in each corner
 

Step 13
Remove the bolts from the secondary fixed sheave that were used to release the belt tension, once removed, turn the secondary sheave several times until the belt is tight again.
 

Step 14
Now you can start your machine, and in neutral with the parking brake on, rev the engine making sure the belt and pulleys are operating properly. If everything appears to work, reinstall the clutch cover, the hose strap, engine cover and seats, and go have fun.

Disclaimer: Do not perform this modification to your machine.

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