Yamaha YZ125(W)/W1 Owner's Service Manual page 14

EC083000
MANUAL FORMAT
All of the procedures in this manual are organized in a sequential, step-by-step format. The information
has been complied to provide the mechanic with an easy to read, handy reference that contains com-
prehensive explanations of all disassembly, repair, assembly, and inspection operations.
In this revised format, the condition of a faulty component will precede an arrow symbol and the course
of action required will follow the symbol, e.g.,
9 Bearings
Pitting/Damage¡ Replace.
EC084002
HOW TO READ DESCRIPTIONS
To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each re-
moval and disassembly section.
1. An easy-to-see exploded diagram 1 is provided for removal and disassembly jobs.
2. Numbers 2 are given in the order of the jobs in the exploded diagram. A number that is enclosed
by a circle indicates a disassembly step.
3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks
3. The meanings of the symbol marks are given on the next page.
4. A job instruction chart 4 accompanies the exploded diagram, providing the order of jobs, names
of parts, notes in jobs, etc.
5. Extent of removal 5 is provided in the job instruction chart to save the trouble of an unnecessary
removal job.
6. For jobs requiring more information, the step-by-step format supplements 6 are given in addition
to the exploded diagram and job instruction chart.
1
CLUTCH AND PRIMARY DRIVEN GEAR
EC490000
CLUTCH AND PRIMARY DRIVEN GEAR
EC498000
CLUTCH PLATE AND FRICTION PLATE
10 Nm (1.0 m•kg, 7.2 ft•lb)
1 Clutch plate and friction plate removal
Extent of removal:
4
Extent of removal Order Part name
CLUTCH PLATE AND
FRICTION PLATE REMOVAL
Preparation for Drain the transmission oil.
removal
Bolt (brake pedal)
Clutch cable
1 Clutch cover
5
2 Screw (clutch spring)
3 Clutch spring
4 Pressure plate
1
5 Push rod
6 Plain washer
7 Bearing
8 Friction plate
9 Clutch plate
ENG
10 Nm (1.0 m•kg, 7.2 ft•lb)
Q'ty Remarks
Refer to "TRANSMISSION OIL REPLACE-
MENT" section in the CHAPTER 3.
Shift the brake pedal downward.
Disconnect at engine side.
1
5
5
1
1
2
1
8
7
4-30
CLUTCH AND PRIMARY DRIVEN GEAR
å å
2
∫
3
ENG
EC493000
REMOVAL POINTS
EC483211
Clutch boss
1. Remove:
9
Nut 1
9
Lock washer 2
9
Clutch boss 3
NOTE:
Straighten the lock washer tab and use the
clutch holding tool 4, 5 to hold the clutch boss.
Clutch holding tool:
YM-91042................................ 4 4
90890-04086............................5 5
å For USA and CDN
∫ Except for USA and CDN
EC494000
INSPECTION
EC484100
Clutch housing and boss
1. Inspect:
9
Clutch housing 1
Cracks/Wear/Damage ¡ Replace.
9
Clutch boss 2
Scoring/Wear/Damage ¡ Replace.
EC484201
Primary driven gear
1. Check:
9
Circumferential play
Free play exists ¡ Replace.
9
Gear teeth a
Wear/ Damage ¡ Replace.
EC484400
Clutch spring
1. Measure:
9
Clutch spring free length a
Out of specification ¡ Replace springs as
a set.
Clutch spring free length:
Standard <Limit>
40.1 mm 38.1 mm
(1.579 in) (1.500 in)
4-32
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