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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Other materials:

Chassis tightening torques
NOTE: First, tighten the lower ring nut to approximately 48 Nm (4.8 m.kg, 35 ft.lb) with a torque wrench, then loosen the lower ring nut completely. Retighten the lower ring nut to 13 Nm (1.3 m.kg, 9.4 ft.lb) with a torque wrench. ...

Checking the condition of the bulbs
The following procedure applies to all of the bulbs. 1. Remove: Bulb WARNINGSince the headlight bulbs get extremely hot, keep flammable products and your hands away from them until they have cooled down. CAUTION: Be sure to hold the socket firmly when re ...

Special tools
The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the ...