JETPRIME KF 002 User manual

INSTALLATION MANUAL
KF 002 - RACING SUPERLIGHT CLUTCH KIT
Issue n°00 - 20/09/2022
YAMAHA T-MAX 500/530 2001/2019

2
INSTALLATION MANUAL (Issue n°00 - 20/09/2022) Ref. KF 002 - Yamaha T-MAX 500/530 2001/2019
Product components list
• Aluminum clutch bell
• Aluminum spacer (thickness 12mm, Ø 29.5)
• Lower disk (for screws and springs)
• Upper disk
• Sieger
• Springs and screws (6 pcs)
• 2 mixed discs (cork / smooth)*
• 4 steel discs*
• 5 cork discs*
Motorbike Preparation
Remove the crankcase and the clutch cover following the original
motorbike instruction manual.
All pictures shown are for illustration purpose only. Actual product may slightly vary due to its enhancement or di󰀨erent colour of the material used for its assembly.
The motorcycle shown may be slightly di󰀨erent due to a di󰀨erent color, version or conguration, with also other Jetprime components assembled on it.
WARNING: All Jetprime products are meant for racing use only and should be installed by an expert and
skilled mechanic in order to not jeopardize any component or the motorbike operation.
Jetprime is not responsable for any issue or damage done by an incorrect assembly, installation or any improper
use of its products.
Components List and Motorbike Preparation
(*) original t-max components

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INSTALLATION MANUAL (Issue n°00 - 20/09/2022) Ref. KF 002 - Yamaha T-MAX 500/530 2001/2019
Assembly Instructions
1) Hub preparation
Remove water and oil from the engine and remove the left crankcase.
Unscrew the central retaining nut and remove the original clutch unit.
Remove the central hub with the gear from the original clutch unit, then unscrew
the central sealing nut with the appropriate wrench and extract the hub from the
gear.
2) Clutch plates sequence
The disc pack consists of 2 mixed discs (cork inserts on one side and smooth
on the other), 5 friction discs and 4 smooth steel discs.
As shown in the picture below, the disk assembly sequence is as follows:
Mixed|Friction|Smooth|Friction|Smooth|Friction|Smooth|Friction|Smooth|Fri-
ction|Mixed
taking care to start from our spring holder disc, against which the friction side
(with cork inserts) of the rst mixed disc must be positioned.
Please note: the gauge measurement of the correctly
coupled disc pack is approximately 24,5 mm.
WARNING - FOR T-MAX 530/560 ONLY, NOT FOR T-MAX 500
Removed the hub, you need to machine its side (the full one) and lowering it of
0,5 mm (see picture below).
Once the part has been machined, rotate the hub of 180° and couple it with the
gear again, then tighten the nut with a torque of 90 Nm.

4
INSTALLATION MANUAL (Issue n°00 - 20/09/2022) Ref. KF 002 - Yamaha T-MAX 500/530 2001/2019
Assembly Instructions
3) Discs coupling
For easier assembly, we recommend to prepare the disc pack by mounting
them directly on the hub (but you can also do it in reverse, inside the aluminum
bell).
Before coupling the outer bell, remember to put the spacer that was inside the
orginal clutch (part not supplied by Jetprime) in the same position, between its
internal side and the hub’s retaining bolt.
4) Clutch unit closure
Insert the springs in the appropriate screws as well as close the clutch unit with
the upper locking disc and the seiger.
Assemble the complete clutch unit on the engine again, placing our aluminum
spacer on the clutch pivot, outside the bell, before tighten the retaining nut with
65 Nm (following Yamaha manual) and lock the new clutch unit.
Fill the water and oil engine tanks again.
WARNING:
The clutch needs a little running-in, so we recommend doing about 10/15 km
without forcing too much when starting to avoid overheat the discs too much.

All Jetprime products are completely designed and made in Italy.
Thank you for choosing our products.
Jetprime S.r.l. ( Single Shareholder Company )
Via Eugenio Montale, 1 – 41016 Novi di Modena – Fraz. Rovereto (MO) – Italy
Phone: [phone] – Email: [email protected]
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