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?


Keenan:

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.
Some guys start it up in gear, get it rolling and then hold the clutch lever in and mash the brake until it frees up, easy but will surely get my hinder sued if I recommended it, so, pull off the clutch cover on the engine right where the lever moves with the clutch cable, watch the goo come out (oil), then remove the discs and plates, clean each one with brake cleaner and be sure you put them back in reverse order.
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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
quad ring
2. Remove the clamp and slide the rubber boot off the clutch in-line cable adjuster.
3. Loosen the adjuster locknut and turn the adjuster to provide maximum cable slack.
4. Make sure the clutch cable seats squarely in its perch at the handlebar.
5. At the clutch mechanism, loosen the clutch adjusting screw locknut and turn the adjusting screw clockwise until it is lightly seated.
6. Squeeze the clutch lever three times to verify the clutch balls are seated in the ramp release mechanism located behind the transmission side cover.
7. Back out the adjusting screw counterclockwise 1/2 to 1 turn. Then hold the adjusting screw and tighten the locknut to 72-120 in.-lb.(8-14 N•m).
8. Once again, squeeze the clutch lever to its maximum limit three times to set the clutch ball and ramp release mechanism.
9. Check the free play as follows:
a. At the in-line cable adjuster, turn the adjuster away from the locknut until slack is eliminated at the clutch hand lever.
b. Pull the clutch cable sheath away from the clutch lever, then turn the clutch cable adjuster to obtain the clearance gap
c. When the adjustment is correct, tighten the clutch in-line cable locknut and slide the rubber boot over the cable adjuster.
10. Install the clutch inspection cover quad ring onto the primary chain case cover.
11. Install the clutch inspection cover and tighten the screws to 84-108 in.-lb. (9.5-12 N•m).

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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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Yamaha YZ125N1 Service Manual
OEM parts for Yamaha
http://mybikemanuals.com/yamaha/yamaha-yz-owners-manuals

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Hi, Moto582 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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1 Answer

Replacing 91 suzuki gs500e clutch cable


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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How do you change clutch lever


Your clutch lever is held on by a simple nut and shoulder bolt. To take the lever off you first have to loosen the nut on the underside of the lever perch. Once the nut is taken off you just need to use the appropriate screw driver or spanner to remove the shoulder bolt from the top. Now loosen up the cable adjuster and pull the lever out of the slot spinning it backwards. Be careful not to lose the bushing in the lever. It is replaceable in case the lever gets sloppy in the perch. you should now be able to slide the ball end of the cable out of the lever slot.

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1 Answer

My 98 yz125 i cant get the clutch pin and the pin in the carriage basket to line up the pin comining out moves all over is it suppose to do that?


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.
http://216.37.204.203/Yamaha_OEM/YamahaDB.asp?Type=13&A=206&B=14

Now, the rod.push 1, reference #11 is supposed to float and have free play when installed under the pressure plate, #8. The key to getting the outer clutch cover installed is to point the teeth of the rod, push1 forward. Also, remove the push lever assembly #24 from the shaft before installing the cover. Once you engage the teeth of #11 to the teeth on #19, the axle, push lever, you rotate #19 to "pull the outer cover onto the clutch inner cover. At that point, install the screws to hold that cover on. Now, you want to twist #19 counter clock wise and install the push lever assembly in the correct position. Ultimately that correct position is where the push lever assembly and the clutch cable make a 90 degree angle. There should be a casting index on the case as well to show exactly where the push lever should be located. Just remember that when the cable is attached to the push lever, the cable and the push lever from a right angle.

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1 Answer

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In alot of cases after the clutch lever is removeds and reinstalled you will have to some minor adjustment. Start by setting the adjuster on the clutch lever to the center then start playing with the adjustment on the crankcase. once everything is in adjustment to where you like then lock everything down.

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