Question about 2003 Yamaha YZ 125

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I HAVE TAKEN APART THE POWER VALVE ON MY 1988 YZ125 AND CAN'T FIGURE WHICH WAY TO LINE UP THE VALVE, OR HOW TO ASSEMBLE THE SIDE ROD. THE WAY IT LOOKS LIKE IT FITS DOESN'T ALLOW ANY MOVEMENT AT ALL.

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May have to lube them so they'll move properly The way their made on my '98 its made funny and they have to be lubed ALOT cant describe how to put the rod back tho

Posted on Nov 15, 2009

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  1. Disconnect the stop lamp switch wiring to prevent running the battery down.
  2. Support the master cylinder from the underside with a prop.
  3. Remove the master cylinder-to-booster retaining nuts.
  4. Loosen the clamp that secures the manifold vacuum hose to the booster check valve, and remove the hose. Remove the booster check valve.
  5. Pull the master cylinder off the booster and leave it supported by the prop, far enough away to allow removal of the booster assembly.
  6. From inside the cab on vehicles equipped with push rod mounted stop lamp switch, remove the retaining pin and slide the stop lamp switch, push rod, spacers and bushing off the brake pedal arm.
  7. From the engine compartment remove the bolts that attach the booster to the dash panel. To install:
  8. Mount the booster assembly on the engine side of the dash panel by sliding the bracket mounting bolts and valve operating rod in through the holes in the dash panel. NOTE: Make certain that the booster push rod is positioned on the correct side of the master cylinder to install onto the push pin prior to tightening the booster assembly to the dash.
  9. From inside the cab, install the booster mounting bracket-to-dash panel retaining nuts.
  10. Position the master cylinder on the booster assembly, install the retaining nuts, and remove the prop from underneath the master cylinder.
  11. Install the booster check valve. Connect the manifold vacuum hose to the booster check valve and secure with the clamp.
  12. From inside the cab on vehicles equipped with push rod mounted stop lamp switch, install the bushing and position the switch on the end of the push rod. Then install the switch and rod on the pedal arm, along with spacers on each side, and secure with the retaining pin.
  13. Connect the stop lamp switch wiring.
  14. Start the engine and check brake operation.
Fig. 1: Check the booster pushrod adjustment using a gauge with the shown dimensions

tecnovative_78.gif
Fig. 2: Exploded view of the typical power brake booster tecnovative_79.gif Fig. 3: Booster vacuum hose connections - 2.3L & 2.9L

tecnovative_80.gif
Fig. 4: Booster vacuum hose connections for the 4.0L

tecnovative_81.gif

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