Checking The Long Clutch Push Rod; Assembling The Main Axle And Drive Axle; Installing The Shift Forks And Shift Drum Assembly - Yamaha WR125R 2009 Service Manual

3. Check:
• Transmission gears
Blue discoloration/pitting/wear → Replace
the defective gear(s).
• Transmission gear dogs
Cracks/damage/rounded edges → Replace
the defective gear(s).
4. Check:
• Transmission gear engagement
(each pinion gear to its respective wheel
gear)
Incorrect → Reassemble the transmission
axle assemblies.
5. Check:
• Transmission gear movement
Rough movement → Replace the defective
part(s).
EAS22B1030

CHECKING THE LONG CLUTCH PUSH ROD

1. Check:
• Long clutch push rod
Cracks/damage/wear → Replace the long
clutch push rod.
2. Measure:
• Long clutch push rod bending limit
Out of specification → Replace the long
clutch push rod.
Long clutch push rod bending
limit
0.500 mm (0.0197 in)
EAS29020
ASSEMBLING THE MAIN AXLE AND DRIVE
AXLE
1. Install:
• Toothed washer "1"
• Circlip "2" New
TIP
• Be sure to install the circlip so that its sharp
edge "a" is facing away from the toothed wash-
er and gear.
• Be sure the circlip ends "b" are positioned at
the axle spline groove "c".
New 2
a
2. Install:
• 2nd pinion gear "1"
TIP
Press the 2nd pinion gear into the main axle "2",
as shown in the illustration.
Installed depth "a"
106.85–107.05 mm (4.207–4.215
in)
1
EAS26320
INSTALLING THE SHIFT FORKS AND SHIFT
DRUM ASSEMBLY
1. Install:
• Shift fork-L "1"
• Shift fork-C "2"
• Shift fork-R "3"
• Shift drum assembly "4"
• Springs
• Shift fork guide bar "5"
5-69
TRANSMISSION
b
1
c
a
2