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Yamaha tdr125 clutch lever return spring

The clutch lever/cable return spring on the left crankcase has snapped and needs replacing. Is it just a case of releasing the cable from the arm and raising the acuator rod out and fitting new spring, tension it and refit cable. Thanks for any help

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  • Strech
    Strech Jan 04, 2014

    Hi Terry , I want to help you with your problem, but I need more information from you. Can you please add details in the comment box?

    What model year is it?

  • Terry
    Terry Jan 04, 2014

    Hi Strech,

  • Terry
    Terry Jan 04, 2014

    It's a 1991 with a 3XE engine

  • Terry
    Terry Jan 04, 2014

    It's full name is TDR125 Lightburner as it's the Italian Belgarda model, I believe the same engine is used in the TZR and DTR with different carbs, barrels etc..

  • Terry
    Terry Jan 04, 2014

    I have only just imported it from Switzerland and am giving it a tidy up and once over before venturing out on it.

  • Terry
    Terry Jan 04, 2014

    The clutch seemed to operate fine when I did have a run on it but I just noticed that the lever return spring is loose as one end has snapped and lost it's curled piece.

  • Terry
    Terry Jan 04, 2014

    Going to get some shut eye now as it's just after 3 am .... Any help appreciated.

  • Strech
    Strech Jan 04, 2014

    You STILL didn't give what YEAR it is, as parts change depending on year of the same models!

  • Terry
    Terry Jan 04, 2014

    I did say on my 2 comment to you,

  • Terry
    Terry Jan 04, 2014

    Add a Comment It's a 1991



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  • Yamaha Master
  • 1,190 Answers

If the lever cant be removed from the external clutch shaft then i doubt you will replace the spring unless you remove the sidecasing !

Posted on Jan 19, 2014


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SOURCE: just fitted new clutch friction plates. have

check the plate installation, one or more must be installed wrong, the last part, the pressure plate must fit in the teeth of the basket, check clutch tension before clutch cover goes on ,use motor cycle oil, car oils will make clutch slip

Posted on Apr 10, 2010

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SOURCE: hi i have a yamaha

It sits in the cutout
unhook the clutch cable and turn the arm back to hook up the spring, then refit the cable

Posted on Aug 12, 2011

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SOURCE: I have a 2006 Suzuki

Here is the service manual for the 2006 Suzuki DRZ400S:

Pages 120-142 involve the Clutch installation and removal, as well as the clutch cable removal and installation.

Posted on Aug 31, 2011

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SOURCE: 2005 yamaha r6 shift lever is limp

Do you have to drop the motor for this issue? I am kind of having the same issue with my 05 R6. Mine isnt limp but in order to up shift i have to press the lever down about an inch in order to shift up again or it wont shift at all. While down shifting it feels like i have to press a lil bit harder like its all tight down there. Any help on that would be much appreciated.

Posted on Feb 19, 2013

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I have a 1994 yz125, when I pull the clutch leaver in it won't spring back.I thought it might be the clutch cable so I got a new one but it still does the same thing. how do I fix this?


I'm not too familiar with the YZ125. If the clutch lever (where the lower end of the clutch cable connects) is on the outside of the transmission case, see if you can push the lever back and forth. Feel for resistance If the clutch lever moves both ways freely, the clutch return spring in the clutch is broken, or the clutch has failed. You'll have to drain the engine oil and remove the clutch cover. Then remove and disassemble the clutch to replace the return spring... or take it to a shop and have them do it.

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Ktm 85 egine noise,and just ad topend rebuild

    • 1 Take the motorcycle for at least a fifteen minute test drive. Use this time to determine if the clutch needs to "grab" more or less. For example, if you pull in the clutch lever and it is difficult to shift, it grabs too much. On the other hand, if when you let the clutch lever out the motorcycle is low on power, it is not grabbing enough.
    • 2 Set the motorcycle on its kickstand or, if like some dirt bikes, it does not have one, prop it against a solid object so that it will not fall over while being worked on.
    • 3 Loosen the clutch cable if the clutch needs to "grab" more, via the clutch cable adjuster bolts near the crankcase, until there is a small amount of play in the cable. You should be able to move the clutch lever just slightly with no change in the clutch's actuation.
    • 4 Tighten the clutch cable if you need the clutch to "grab" less. Tighten the cable until there is only a small amount of play left in the cable. Pulling the lever from now on will make a much larger difference in clutch actuation.
    • 5 Tighten the clutch cable adjusters near the crank case and take the motorcycle for a test ride in an open, private area. While riding, use your left hand to adjust the barrel adjuster where the cable housing meets the clutch lever to fine tune the adjustments made previously. When you feel the clutch is set up properly, return to your work area and tighten the barrel adjuster stop so that it will not loosen as you ride.

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My Nissan 95 sentra clutch had crunched and pedal would not spring back, found that clutch cable had snapped, replaced this and now my clutch pedal is still not 100% springing back, it springs back en

Check the spring to see if it has snapped anywhere within it's coil.

Remove the cable and check operation of the pedal and spring mechanism.
If all is well, then with a lever, check that the clutch release arm on the gearbox is operational. If that is also sticking, then you will have to remove the gearbox to investigate further.
If not sticking, then also remove the clutch cable outer sleeve, and replace.

Nov 10, 2012 | Cars & Trucks

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I just bought an 1987 Yamaha TT350 dirtbike. is it a 2 cycle and how do i change the kickstart shaft

Hi, a yamaha TT350 actually has a 4 stroke engine. To replace the kick starter shaft, You need to remove the crankcase cover on the kick starter side of the engine..
The clutch basket etc will then have to be removed. '
You then use a set of needle nose pliers to unhook the kickstarter return spring from its post in the crankcase.
Release the return spring and allow it to relax. Then rotate the kickstarter assembly counterclockwise by hand , and remove the shaft assembly from the crankcase. Reverse this process to refit.
You can buy cheap workshop manuals for the yamaha XT/TT 350 models. Clymer manuals make them, there are usually good second hand ones on ebay etc,
the XT/TT350 workshop manual number is
These workshop manuals are a "must have" when working on bikes or cars etc, and by following a manual, at least you'll know that the job has been done safely and 100% correctly.

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1 Answer

On a 06 yamaha vstar 650 i installed a new clutch but are the plates suppose to move when clutch is disengaged?? if so what is the gap suppose to be and how do u adjust it

Clutch drive plates (usu. has friction pads and tabs on outer rim) alternate with Clutch driven plates that are smooth with teeth on inner rim. These slot into clutch "basket" and clutch hub. (the basket is driven via the crank and the hub drives the gearshafts) They are bound by the springs and endcaps bolted to the pressure plate in the basket. The plate movement or spread is negligable, 10-15mm spread over 13 plates. This spread is goverened by the actuating step gear thruster which cannot be adjusted.
The lever adjustment is for the amount a free play and the crankcase adjustment governs take-up spot; where resting lever returns the thruster. this can effectively allow the clutch to drive whilst having slack at lever, or vice versa.
Hope this is helpfull, Cheers.

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The clutch cable actuates an axle with a gear at the other end. This gear bears against step gears on the thrust rod, which pushes against clutch. Make sure there is a circlip at BOTH ends of this axle. When replacing cover, ensure axle is returned fully with handlever out, and spring is in place on actuating fulcrum of the axle. Thrust rod must bear against roller bearing of the clutch pressure plate. Make sure step gears engage at first tooth when operating handlever. The above link provides an exploded view of the entire bike in appropriate sections as an aid.

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1 Answer

When i was riding yesterday my dt125r made a norise like a spring snapped then it stalled then i put the choke on road up the road abit and it clapped out again and never strated again am not to sure but i...

Your bike clapped out because of riding with choke on a warmed engine. If you have tension in clutch lever still the springs are fine (there are usually five springs). If you have no tension check actuation of cable lever on crankcase. Otherwise, drain oil and remove kickstart and clutch cover and see if clutch actuating lever is functioning and pushing outwards from clutch cover. Check tension of centre nut on clutch basket. This is as far as you should go without qualified assistance or a WORKSHOP manual pertinent to that model. Goodluck and Cheers.

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The clutch slips at high rpm's and when I barely touch the lever. Is there an adjustment on this hydraulic?

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When the problem is resolved and you're refilling the crankcase with oil, AVOID ANY OIL THAT SAYS ENERGY-CONSERVING (you'll see a seal on the bottle), that type of oil has a tendency to make the clutch slip.

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I have a 2006 yz125, I rode it once and the clutch give up on me. ive removed the casing and the lever inside the casing where the clutch cable attaches has become very loose and there is neither any...

It is an pretty easy fix. Remove the right case cover and then loosen or remove the bolts that are compressing the clutch springs. Now slide the push rod 1/4" into the engine from the left side. Remount the lever assembly into the casing and put the casing back on. Now re-tighten the springs and put the right case cover back on. Re-fill with oil. All fixed.

A “very helpful” rating for this answer? Thanks!

Jun 25, 2009 | 2004 Yamaha YZ 250 F

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