Question about 2004 Yamaha YZ 250 F

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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 resistence neither does it spring back up, can this be repaired easily?

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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.

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I have a 2006 yz125, I rode it once and the clutch - 8ab325e.gif

Posted on Jun 25, 2009


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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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My Vulcan Classic has not been rode in a while, the battery went down and I bought a new one, it starts fine, but when I take it out of neutral to go to first gear it jumps and cuts off, I just cant...

Did I just answer this one? If not what I said just before is, yes the clutch can get gooey and bound up after sitting.
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How to adjust clutch inside primary case?

Because the clutch cable adjuster clearance increases with engine temperature, adjust
the clutch when the engine is cold. If the clutch is adjusted when the engine is hot, insufficient pushrod clearance can cause the clutch to slip.
1. Remove the clutch mechanism inspection cover and
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3. Loosen the adjuster locknut and turn the adjuster to provide maximum cable slack.
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Hi, Anonymous for this scenario you will need your service/owners manual if you can't find the first and best tool you ever bought for your Yamaha, despair not, for a mere $0 you can download another one. 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.
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Hi, if you are ok doing this type of job, then its quite easy to fit a cable, remove the seat, undo the 2 bolts securing the fuel tank and prop up the back end of the fuel tank, remove the gear change lever by removing the 10mm bolt, remove all the screws holding the sprocket caseing, next comes the cable with the case still on the engine undo the locking nut on the clutch cable, (12 mm), next get the new cable and lay it along side the whole length of the old cable and fasten it to the frame where ness, screw in the addjuster all the way at the clutch lever and align the slot for cable removal from the lever now remove the sprocket cover and old cable with it, undo the cable adduster all the way until it is removed from the case, push the cable wire back to remove it from the clutch control arm inside the case, try not to remove the arm as it will fit back in more than 1 position, retaining the original position is important, you can then refit the new cable into the arm a small amount of grease on the cable nipple will help, replace the case back onto the engine it should fit flush with no effort, replace all the screws, it important they are fitted in accordance, so place them loosly in the holes they should all protude around the same amount, if any are shorter or longer move them around untill correct. Once happy tighten them up, connect the cable at the control lever on the handlebar and then remove all the slack from the cable at both ends untill you have around 5mm free play at the handlebar end, replace gear change lever, and all other fixings.

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Here is a diagram of the parts of the clutch. For ease of explanation, I am going to refer to the reference numbers in the picture so you will know which component I am talking about.

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