Yamaha TZ125M1 Owner's Service Manual page 9

EC083000
MANUAL FORMAT
All of the procedures in this manual are organized in a sequential, step-by-step format. The infor-
mation has been complied to provide the mechanic with an easy to read, handy reference that con-
tains comprehensive 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.,
• 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
removal 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 unneces-
sary removal job.
6. For jobs requiring more information, the step-by-step format supplements 6 are given in addi-
tion to the exploded diagram and job instruction chart.
1
EC4A8100
CLUTCH HOUSING AND PUSH LEVER AXLE
2
50 Nm (5.0 mdkg, 36 ftdlb)
T
1 Clutch housing removal
Extend of removal:
4
Extend of removal Order Part name
CLUTCH HOUSING AND
PUSH LEVER AXLE
5 REMOVAL
1 Nut (clutch boss)
2 Lock washer
3 Clutch boss
4 Spacer 2
1
5 O-ring (small)
6 Clutch housing
7 O-ring (large)
8 Bearing
9 Spacer 1
10 Ball
11 Push rod
2
12 Bolt (seat plate)
13 Seat plate
14 Push lever axle
ENG
CLUTCH
11 Nm (1.1 mdkg, 8.0 ftdlb)
T
2 Push lever axle removal
Q'ty Remarks
1
Use special tool.
1
Refer to "REMOVAL POINTS".
1
1
1
1
1
1
1
1
1
1
1
1
4-25
3
ENG
CLUTCH
EC4A3000
REMOVAL POINTS
EC483211
Clutch boss
1. Remove:
• Nut 1
• Lock washer 2
• Clutch boss 3
NOTE:
Straighten the lock washer tab and use the
clutch holding tool 4, 5 to hold the clutch
B
boss.
Clutch holding tool:
YM-91042 . . . . . . . . . . . . . . . .4 4
90890-04086 . . . . . . . . . . . . .5 5
A For USA and CDN
B Except for USA and CDN
EC4A4000
INSPECTION
EC484100
Clutch housing and boss
1. Inspect:
• Clutch housing 1
Cracks/Wear/Damage ≥ Replace.
• Clutch boss 2
Scoring/Wear/Damage ≥ Replace.
EC4A4100
Clutch housing
1. Check:
• Circumferential play
Free play exists ≥ Replace.
• Gear teeth a
Wear/Damage ≥ Replace.
• O-ring 1
Damage ≥ Replace.
EC484400
Clutch spring
1. Measure:
• Clutch spring free length a
Out of specification ≥ Replace springs as
a set.
{
Clutch spring free length:
Standard <Limit>
36.0 mm (1.417 in) 35.0 mm (1.378 in)
4-26
6