Question about 2003 Yamaha YZ 125

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Clutch bolts and springs snapped threw clutch cover

Hi m8 i was on my bike when it started missing gears. Then it locked up and trough me off , when i picked it up under the clutch cover there was two clutch bolts ann springs in the oil . the springs and bolts where bent and scuffed , .Have the clutch bolts been torqued properly?,. cheers

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  • Yamaha Master
  • 43,091 Answers

Hi, Mark for this situation I would call my local dealer or reputable shop's service/parts department and inquire about any possible quick fix, answers, or parts inquiry. If necessary, transport your bike to the dealer or shop and have a professional technician take it for a test drive, if it is in running condition, and give you a written estimate of repairs and answer any specific questions you may have about your problem. For more information about your issue and valuable "FREE" downloads that you will need please click on the links below. Good luck and have a nice day.
YAMAHA YZ125 Owner Service Manual
OEM parts for Suzuki
http://mybikemanuals.com/yamaha/yamaha-yz-owners-manuals
Yamaha XV 250 Virago 95 96
Yamaha YZ 125 02
yz 125 tips and tricks YouTube

Posted on Jul 17, 2016

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6ya6ya
  • 2 Answers

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Posted on Jan 02, 2017

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flh1
  • 36 Answers

SOURCE: clutch pulling

Your clutch is not fully disengaging.Adjust the cable at the lever until you have plenty of free play.Then adjust the cable at the motor until you have full engagement then readjust lever to 3/8 in play.Fine tune at the motor.It may take a few trys but you can get it.

Posted on Feb 12, 2009

goofduck
  • 490 Answers

SOURCE: '95 Yamaha YZ 125 clutch - stays in gear when clutch is pulled in

the plates will stick to each other because of oil
check the clutch lever at the motor and make sure it is moving the arm that pushes the pressure plate and make sure it is moving

Posted on Apr 15, 2009

  • 10 Answers

SOURCE: yam tdm850 oil leak from strange place under carbs

dont try to crank it the carbs float are stuck and will fill crank case with gas drain the oil turn the gas off tap the carbs with a small object then turn the gas back on try cranking it then

Posted on May 07, 2009

  • 1565 Answers

SOURCE: bike starts in neutral but

Check your kickstand switch. It will not allow the engine to run in gear when you release the clutch lever. It may be gummed up.

Posted on Aug 09, 2010

  • 2 Answers

SOURCE: Start the bike in neutral,

Kick stand switch broken or kick stand down my bike is the same way.

Posted on Jun 27, 2012

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1 Answer

Clutch locked up on my 82 Suzuki dr250 I am at a loss what should I do.


your clutch is simply a stack of friction disks and metal plates. The friction disks are splined into the outer hub ring and alternate, one friction disk / one plate / one friction disk / one plate etc. It's very simple to free this up if it's locked up. remove clutch cover. If you are unsure which is your clutch cover, follow the clutch lever cable to the actuator arm. remove the cable from arm and all bolts holding the cover. as you pull out the cover, you will see the arm rotate that's because it's geared into an arm that is connected to the front plate of the clutch basket assembly. You'll see it as soon as you pull it off. now you'll be looking at a round plate with 6 bolts with springs underneath. when you arent pulling the lever, these springs are extended and push the friction disks and metal plates together, thereby locking the inner hub to the outer hub. The inner hub is connected to the crank, and the outer hub is connected to the transmission input gear. So, if pressed together by the springs, your engine running causes your bike to move. Pulling the clutch lever in pulls the spring tension off the plates and allows them to separate. This allows your engine to be disconnected from the transmission. If your plates are locked together you will remove them one by one if you can and lubricate between each plate and disk and reinstalling. Pay close attention to how it came apart. Reinstall bolts and springs reinstall cover, aligning the lever gear teeth with the front of the clutches teeth correctly. put it all together and see if you are okay now.

Nov 23, 2010 | 1988 Suzuki Rg 250

1 Answer

Moves when cranking,can't seem to find right adjustment spot with cable nut, how do you check any fluids involved.


First off, you shouldn't be starting your bike with it in gear. You should start it in neutral.

Now the reason it is moving is because the clutch is not adjusted correctly. Follow the clutch cable down to where the cable adjuster is in the middle of the cable. Loosen the locknut and turn the adjuster inwards as far as it will go getting as much slack in the cable as possible.

Now, remove the derby cover from the outer primary cover. In the middle, you'll see a bolt and a locknut. Loosen the locknut and turn the bolt inwards until you feel a resistance. DO NOT FORCE THE BOLT AS YOU'LL BE DISENGAGING THE CLUTCH. Turn it inwards until you feel the resistance. Then, back the adjuster back out 1/2 turn and lock the lock nut down.

Check the oil level in the primary. Stand the bike straight up and down and the oil level should be no higher than the lowest point on the clutch spring. If it's too high, it will cause the clutch to drag. Put the derby cover back on.

Now, at the cable adjuster, adjust the cable adjuster back out until you get approximately 1/8" freeplay. Lock the locknut

good luck
Steve

Oct 18, 2010 | Harley Davidson XLH Sportster 883...

2 Answers

Hi, I just want to know how to loosen the bolts th...


You can simply jam the primary drive gear with a penny or other soft metal.

May 16, 2010 | Motorcycles

1 Answer

All gears from 1 to 5 are slipping. each gear


does the clutch lever release "sharply" and snap back after engagement? then lean bike over drain about a quart of oil, take off access cover to clutch and check to see if you have any broken clutch springs. if thats looks o.k. you"ll probably need new clutch plates. a real quick check when you ride the bike smell the oil, does it smell burnt? if it does, the plates are probably no good.

Apr 02, 2010 | 1996 Suzuki VS 800 Intruder

1 Answer

Bike wont go into gear, just had a new clutch put on and the level was low, bike had been sitting for 4 months without being ridden. What could be the causes? it's a 1990 Ultra Classic with Big Bore Kit


With bike not running, rock the bike backwards and forwards and shift through all the gears. If it shifts all the way to fifth gear and back down, then the problem is not in the transmission. If you can't shift the transmission into any gear with the bike not running, just rocking it backwards and forwards, then you've got a problem with the transmission or the shift lever mechanism.

If it does shift but you still can't get it into gear something is strange. I've seen a clutch that the plates were locked together from sitting up, but it still would shift into gear. Of course, when it did shift into first gear, the bike would lurch forward and kill the engine. In this case, we had to disassemble the clutch pack and free the plates up. If you've had a new clutch put in the bike, it could simply need an adjustment. But, usually a new clutch will have a tendency to wear in and start to slip rather than drag. When a clutch causes the bike to lurch when put into gear or become difficult to find neutral with the engine running, it's dragging. I'd check the entire clutch adjustment to start with.

Slide the rubber boot on the clutch cable up, break the lock nut loose and turn the adjuster to make the cable as short as possible. Take the derby cover off the primary to gain access to the clutch release adjuster bolt. Break the large locknut loose, adjust the center bolt inward until you feel resistance. Back the screw back out and back in until you feel resistance again several times. You want to just take the slack out of the adjustment, not start to open the clutch up. Once you've turned the bolt in and feel the resistance, back the bolt back out 1/2 to 1 complete turn. Hold the bolt in this position and lock the lock nut again. Now, adjust the clutch cable back out until you get a freeplay of about an 1/8 inch at the lever. The clutch should be adjusted well enough to release at this point. If it doesn't, the clutch plates are probably stuck.

If the clutch plates are stuck, rock the bike back and forth and shift the bike into fourth or fifth gear. Now, while holding the clutch lever in, push the bike backwards and forwards far enough to "bump" the clutch. This may break the bond between the plates and free it up. If not, you'll have to disassemble the clutch in order to free it up. Good Luck.

Nov 08, 2009 | 2000 Harley Davidson FLHTCUI Electra Glide...

2 Answers

1987 kx125 clutch wont engage


push rod bent ? too short ?

Aug 06, 2009 | 2003 kawasaki KX 125

2 Answers

Yamaha Enduro Clutch not engaging


i actuall have a yamaha enduro 100 and had this same problem.
First thing is take the clutch apart take all the rings out and clean them good with momry cloth assemble the clutch compleatly as it came out and when tighting the springs tight them all one turn at a time and after everytime you go around try to move youre clutch with youre bike in gear. if it trys to move it is engageing just keep turning the screws untill they stop. also recomend putting threadlocker on the drive gear bolt and the clutch bolt that holds the clutch on. if you have and questions just e-mail me at Jvossbrink@comcast.net just make shure to tell me that i responded to youre fixya question about youre bike and i will walk you threw it.

ps just rember to put the clutch pushrod back in

Aug 02, 2009 | 1974 Yamaha DT 360

1 Answer

Yz 125 2001 stays in gear with clutch pulled in


hi m8,,this might sound stupid,, but in winter dayz and salty conditions ,cables corrode in side,,so i can start some where to help,, 1st take the cable off the handle bar,, and the clutch casin,,get a little bit of oil in a jam jar or any thing like that,,dip one end of the cable in the oil ,and keep pullin and pushing the inner cable as if u were trying to draw oil up threw the inside of the cable ,, turn cable the other end and repeat,, try that 1st m8,, still have probs come bk, and il go threw the next step,,

Apr 19, 2009 | 2003 Yamaha YZ 125

1 Answer

How do i replace my clutch kit. i burned it out


ello mate,,first drain the oil out,remove the right side lower fairing,,then remove the wot looks like a large circular engine casing,then remove the bolts with springs holding the clutch plates in,,take off the cover then u will see the plates and metal lookin clutch plates,, now take out the clutch plates one at a time,,,ie take one out then place on the bench,take a metal plate out and place that on top of the 1st plate u took out,and so on,, when u have the new fibre plates,,replace back in the bike as u took the old ones out,,ie, new fibre plate 1st then put a metal friction plate back in from your bench,,then a new fibre plate and so on,,each time u replace the new plate ,chuck away the old one,,wen u have done that ,on the clutch plate cover look at the face of the cover u will see a small arrow head or a dot stamped on the face of it,, that dot should line up with a dot thats stamped on the housing where the clutch plates are,put the plate casing on so that the dots line up ,,put the springs and bolts back on and do them up tight,,then replace the engine casing,,,put your oil back in,,if u have a hydrolic clutch u will have to remove the 3 screws and the clutch piston b4 taking the casing off ,,,to read this it will sound complicated m8,, but wen u start the job itl be quite easy,, take your time tho,,any probs m8 ,shout and il anserw u,, ok,, cheers now

Mar 30, 2009 | 2007 Suzuki GSX-R 600

2 Answers

Tough start


The clutch slave can be difficult to bleed. It sounds like you have air in there. I'd bleed it, and zip tie the lever to the grip overnight. That will allow air to return to the master. Another issue could be sticky plates in the clutch pack. Does the bike get ridden infrequently?

Nov 10, 2008 | 1994 Yamaha XJ 600 Diversion S

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