Yamaha YZF-R125 Service Manual: Installing the clutch

Yamaha YZF-R125 Service Manual / Engine / Clutch / Installing the clutch

1. Install:

  • Conical spring washer "1"

NOTE:

Install the conical spring washer as shown in the illustration.

Installing the clutch


2. Install:

  • Clutch housing
  • Thrust washer "1"

NOTE:

Be sure to install the thrust washer so that its sharp edge "a" is facing away from the clutch boss.

Installing the clutch


3. Install:

  • Clutch boss "1"
  • Lock washer "2"

  • Clutch boss nut

NOTE:

  • Lubricate the clutch boss nut threads and lock washer mating surfaces with engine oil.
  • Align the notch "a" in the lock washer with a rib "b" on the clutch boss.

Installing the clutch


4. Tighten:

  • Clutch boss nut "1"

NOTE:

While holding the clutch boss "2" with the universal clutch holder "3", tighten the clutch boss nut.


Installing the clutch


5. Bend the lock washer tab along a flat side of the nut.

6. Lubricate:

  • Friction plates
  • Clutch plates (with the recommended lubricant)

7. Install:

  • Clutch damper spring seat "1"
  • Clutch damper spring "2"
  • Friction plate 2
  • Clutch plates
  • Friction plates 3
  • Friction plate 1

NOTE:

  • Install the clutch damper spring seat and clutch damper spring as shown in the illustration.
  • First, install a friction plate and then alternate between a clutch plate and a friction plate.

Installing the clutch


8. Install:

  • Pressure plate
  • Clutch springs
  • Clutch spring bolts "1"

NOTE:

Tighten the clutch spring bolts in stages and in a crisscross pattern.

Installing the clutch


9. Adjust:

  • Clutch mechanism free play

a. Check that projection "a" on the clutch push lever "1" aligns with mark "b" shown on the crankcase in the illustration by pushing the clutch push lever manually in direction "c" until it stops.

Installing the clutch


b. If projection "a" is not aligned with mark "b", align them as follows:

  • Loosen the locknut "2".
  • With the clutch push lever fully pushed in direction "c", turn the short clutch push rod "3" in or out until projection "a" aligns with mark "b".
  • Hold the short clutch push rod to prevent it from moving and then tighten the locknut to specification.

Installing the clutch


10.Install:

  • Oil seal "1"

Installing the clutch


11.Install:

  • Clutch cover

NOTE:

Tighten the clutch cover bolts in the proper tightening sequence as shown.

Installing the clutch


12.Adjust:

  • Clutch cable free play Refer to "ADJUSTING THE CLUTCH CABLE FREE PLAY" on page 3-12.
    Checking the primary driven gear
    1. Check: Primary driven gear "1" Damage/wear Replace the primary drive gear and clutch housing as a set. Excessive noise during operation  Replace the primary drive gear and ...

    Oil pump
    ...

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    Checking the shift shaft
    1. Check: Shift shaft Bends/damage/wear Replace. Shift shaft spring Damage/wear Replace. Checking the stopper lever 1. Check: Stopper lever Bends/damage Replace. Roller turns roughly Replace the stopper lever. Stopper lever spring Damage/wear Replace. ...

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    1. Air induction system hose (air filter case to reed valve assembly) 2. Air induction system reed valve assembly 3. Air induction system hose (reed valve assembly to exhaust pipe) Checking the air induction system Air injection The air induction system burns unburned exhaust gases b ...

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