JAVIK Starter Clutch Kit and Flywheel Puller Installation Manual

1. Product Overview

This manual provides detailed instructions for the installation and maintenance of the JAVIK Starter Clutch Kit and Flywheel Puller. This kit is designed as a replacement for specific Yamaha ATV models.

1.1 Package Contents

• Starter One-Way Assembly x 1
• Idler Gear 67T x 1
• Screw x 6
• Gasket x 1
• Flywheel Puller x 1

Image 1.1: Complete JAVIK Starter Clutch Kit including the one-way assembly, idler gear, screws, gasket, and flywheel puller.

1.2 Compatibility

This kit is compatible with the following Yamaha ATV models:

• Yamaha Rhino 660 YXR66F (2004-2007)
• Yamaha Grizzly 660 YFM660F (2003-2008)

Refer to the OEM part numbers for cross-reference:

• Original OEM#: 5KM-15590-00-00, 5KM-15517-10-00, 5KM-15451-00-00
• Replacement OEM#: 5GH-15517-10-00, 1UY-15590-01-00, 1UY-15590-00-00

2. Safety Information

Always prioritize safety when working on any vehicle. Improper installation can lead to serious injury or damage to the vehicle. If you are unsure about any step, consult a qualified mechanic.

• Wear appropriate personal protective equipment (PPE), including safety glasses and gloves.
• Ensure the vehicle is stable and securely supported before beginning work. Disconnect the battery to prevent accidental starting.
• Use the correct tools for each task.
• Keep the work area clean and well-lit.
• Dispose of old parts and fluids responsibly.

3. Setup and Installation Guide

This section outlines the general steps for installing the starter clutch kit. Specific procedures may vary slightly depending on your vehicle's exact configuration. It is highly recommended to consult your vehicle's service manual for detailed torque specifications and removal/installation sequences.

3.1 Required Tools (Not Included)

• Socket set and wrenches
• Torque wrench
• Gasket scraper
• Oil drain pan
• New engine oil (if draining)
• Cleaning supplies (e.g., brake cleaner, rags)

3.2 Installation Steps

1. Preparation: Park the ATV on a level surface. Ensure the engine is cool. Disconnect the negative battery terminal. Drain the engine oil if necessary, depending on the access required for the starter clutch.
2. Remove Side Cover: Carefully remove the engine side cover that provides access to the starter clutch and flywheel. Be prepared for residual oil to drain.
3. Remove Old Gasket: Thoroughly clean the mating surfaces, removing all traces of the old gasket material. Ensure surfaces are smooth and free of debris.
4. Flywheel Removal: Use the provided flywheel puller to safely remove the flywheel. Follow the instructions for the puller to avoid damage to the crankshaft or flywheel.
   

   Image 3.1: The included flywheel puller, essential for safe flywheel removal.

5. Starter Clutch and Idler Gear Removal: Once the flywheel is off, remove the old starter one-way assembly and idler gear. Note their orientation for correct reinstallation.
   

   Image 3.2: The new 67T idler gear, part of the replacement kit.

   

   Image 3.3: The JAVIK Starter One-Way Assembly, showing the bearing and housing.

6. Install New Components: Install the new JAVIK Starter One-Way Assembly and Idler Gear in the correct orientation. Ensure all components fit smoothly without force.
7. Reinstall Flywheel: Carefully reinstall the flywheel. Ensure it seats correctly. Torque the flywheel nut to the manufacturer's specifications using a torque wrench.
8. Install New Gasket: Place the new gasket onto the clean mating surface of the engine case. Ensure it is properly aligned.
   

   Image 3.4: The replacement engine gasket, crucial for a proper seal.

   Important Gasket Note: The gasket should be fixed with appropriate tension – neither too tight nor too loose. Incorrect tension can compromise the gasket's sealing efficiency and lead to leaks.

9. Reinstall Side Cover: Carefully place the side cover back onto the engine, aligning it with the gasket and mounting holes. Install the six new screws provided in the kit. Tighten the screws evenly and to the manufacturer's specified torque.
10. Refill Oil and Reconnect Battery: If engine oil was drained, refill it to the correct level with the recommended type of oil. Reconnect the negative battery terminal.

4. Post-Installation Checks

After completing the installation, perform the following checks before operating the vehicle:

• Fluid Levels: Verify engine oil level is correct. Check for any leaks around the newly installed gasket and side cover.
• Battery Connection: Ensure battery terminals are securely connected.
• Initial Start: Start the engine and listen for any unusual noises. Allow the engine to idle for a few minutes, checking for proper operation and any warning lights.
• Test Ride: Perform a short, controlled test ride in a safe area to confirm proper starting and engine function.

5. Maintenance

Proper maintenance extends the life of your starter clutch and related components:

• Regular Oil Changes: Ensure engine oil is changed according to the vehicle manufacturer's recommendations. Clean, fresh oil is vital for the proper lubrication and function of the starter clutch.
• Battery Health: Maintain a healthy battery. A weak battery can put excessive strain on the starter motor and clutch.
• Inspect for Leaks: Periodically check the engine side cover area for any oil leaks, which could indicate a gasket issue.

6. Troubleshooting

If you encounter issues after installation, consider the following common problems and solutions:

• Engine Cranks but Does Not Start:
  • Check fuel supply and ignition system.
  • Ensure battery is fully charged and connections are secure.
• Starter Motor Spins but Engine Does Not Crank (Freewheeling):
  • This often indicates a problem with the starter one-way clutch. Re-check installation of the one-way assembly.
  • Verify the idler gear is correctly engaged.
• Oil Leak from Side Cover:
  • The gasket may be improperly seated or damaged. Ensure the mating surfaces were clean before installation.
  • Check that the side cover screws are torqued correctly and evenly.
• Unusual Noises During Starting:
  • Could indicate improper gear mesh or a loose component. Re-inspect the installation of the idler gear and starter clutch assembly.

For persistent issues, it is recommended to seek professional assistance.

7. Specifications

8. Warranty and Support

JAVIK offers a 1-year warranty on this product. For any questions, concerns, or assistance with installation or troubleshooting, please contact JAVIK customer service. They provide 24-hour customer support.

You can typically find contact information through the retailer where the product was purchased or by visiting the official JAVIK store page on Amazon: JAVIK Store