Question about 2003 Yamaha YZ 125

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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?

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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.
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.

Posted on Sep 25, 2009

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