Yamaha YZ125(D) Owner's Service Manual page 83

REMOVING THE CLUTCH BOSS
1. Remove:
• Nut "1"
• Lock washer "2"
• Clutch boss "3"
Straighten the lock washer tab and
use the clutch holding tool "4" to hold
the clutch boss.
Clutch holding tool:
YM-91042/90890-04086
A. For USA and CDN
B. Except for USA and CDN
CHECKING THE CLUTCH
HOUSING AND BOSS
1. Inspect:
• Clutch housing "1"
Cracks/wear/damage → Replace.
• Clutch boss "2"
Scoring/wear/damage → Re-
place.
CHECKING THE PRIMARY DRIVEN
GEAR
1. Check:
• Circumferential play
Free play exists → Replace.
• Gear teeth "a"
Wear/damage → Replace.
CHECKING THE CLUTCH
SPRINGS
1. Measure:
• Clutch spring free length "a"
Out of specification → Replace
springs as a set.
Clutch spring free length
"a":
40.1 mm (1.579 in)
<Limit>: 38.1 mm
(1.500 in)
CHECKING THE FRICTION
PLATES
1. Measure:
• Friction plate thickness
Out of specification → Replace
friction plate as a set.
Measure at all four points.
Friction plate thickness:
2.9–3.1 mm (0.114–
0.122 in)
<Limit>: 2.8 mm (0.110
in)
CHECKING THE CLUTCH PLATES
1. Measure:
• Clutch plate warpage
Out of specification → Replace
clutch plate as a set.
Use a surface plate "1" and thick-
ness gauge "2".
Warp limit:
0.2 mm (0.008 in)
4-21
CLUTCH
CHECKING THE PUSH LEVER
SHAFT
1. Inspect:
• Push lever shaft "1"
Wear/Damage → Replace.
CHECKING THE PUSH ROD
1. Inspect:
• Push rod 1 "1"
• Bearing "2"
• Washer "3"
• Push rod 2 "4"
• Ball "5"
Wear/damage/bend → Replace.
INSTALLING THE PUSH LEVER
SHAFT
1. Install:
• Push lever shaft "1"
Apply the lithium soap base grease
on the oil seal lip and push lever
shaft.
INSTALLING THE CLUTCH
1. Install:
• Thrust washer [D=ø34 mm (1.34
in)] "1"
• Spacer "2"
• Bearing "3"
• Primary driven gear "4"
Apply the transmission oil on the
bearing, spacer and primary driven
gear inner circumference.