2003 YAMAHA TTR125 clutch

4 - 40
ENGCLUTCH AND PRIMARY DRIVEN GEAR
EC490000
CLUTCH AND PRIMARY DRIVEN GEAR
EC498000
CLUTCH PLATE AND FRICTION PLATE
Extent of removal:1 Clutch plate and friction plate removal
Extent of removal Order Part name Q’ty Remarks
CLUCTH PLATE AND FRIC-
TION PLATE REMOVAL
Preparation for removal Drain the engine oil. Refer to “ENGINE OIL REPLACEMENT”
section in the CHAPTER 3.
Engine skidplate Refer to “ENGINE REMOVAL” section.
Starter motor 1 Refer to “ELECTRIC STARTING SYS-
TEM” section in the CHAPTER 6.
1 Kickstarter crank 1
2 Right crankcase cover 1
3 Gasket 1
4 Dowel pin 2
5 Clutch spring 4
6 Pressure plate 1
7 Ball 1
8 Friction plate 5
9 Clutch plate 4
10 Nut/washer 1/1
11 Push rod 1 1
12 Push plate 1
1

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ENGCLUTCH AND PRIMARY DRIVEN GEAR
EC498100
PRIMARY DRIVEN GEAR
Extent of removal:1 Primary driven gear removal2 Primary drive gear removal
Extent of removal Order Part name Q’ty Remarks
PRIMARY DRIVEN GEAR
REMOVAL
1 Nut (clutch boss) 1
Use special tool.
Refer to “REMOVAL POINTS”. 2 Lock washer 1
3 Clutch boss 1
4 Thrust plate 1
5 Primary driven gear 1
6 Thrust plate 1
7 Conical spring washer 1
8 Nut (primary drive gear) 1
Refer to “REMOVAL POINTS”.
9 Primary drive gear 1
10Straight key
1
2
1

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ENGCLUTCH AND PRIMARY DRIVEN GEAR
PUSH LEVER
Extent of removal:1 Push lever removal
Extent of removal Order Part name Q’ty Remarks
PUSH LEVER REMOVAL
1 Clutch cable 1
2 Push lever 1
3 Spring 1
4 Circlip 1
5Oil seal
1
1

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ENGCLUTCH AND PRIMARY DRIVEN GEAR
EC493000
REMOVAL POINTS
Clutch boss
1. Remove:
Nut 1
Lock washer
Clutch boss 2
NOTE:
Straighten the lock washer tab and use the
clutch holding tool 3 to hold the clutch boss.
ÅFor USA and CDN
ıExcept for USA and CDN
Clutch holding tool:
YM-91042/90890-04086Å
ı
Primary drive gear
1. Remove:
Nut (primary drive gear) 1
Primary drive gear 2
NOTE:
Place a folded rag or aluminum plate
between the teeth of the primary drive gear
and primary driven gear.
Take care not to damage the gear teeth.
EC494000
INSPECTION
EC484100
Clutch housing and boss
1. Inspect:
Clutch housing 1
Cracks/wear/damage → Replace.
Clutch boss 2
Scoring/wear/damage → Replace.
EC484201
Primary driven gear
1. Check:
Circumferential play
Free play exists → Replace.
Gear teeth a
Wear/damage → Replace.

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ENGCLUTCH AND PRIMARY DRIVEN GEAR
EC484400
Clutch spring
1. Measure:
Clutch spring free length a
Out of specification → Replace springs
as a set.
Clutch spring free length:
33 mm (1.30 in)
: 31 mm (1.22 in)
EC484500
Friction plate
1. Measure:
Friction plate thickness
Out of specification → Replace friction
plate as a set.
Measure at all four points.
EC484600
Clutch plate
1. Measure:
Clutch plate warpage
Out of specification → Replace clutch
plate as a set.
Use a surface plate 1 and thickness
gauge 2.
Push lever
1. Inspect:
Push lever 1
Wear/damage → Replace.
Friction plate thickness:
2.92 ~ 3.08 mm
(0.115 ~ 0.121 in)
: 2.8 mm (0.110 in)
Warp limit:
0.2 mm (0.008 in)

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ENGCLUTCH AND PRIMARY DRIVEN GEAR
Push rod
1. Inspect:
Push rod 1 1
Ball 2
Wear/damage/bend → Replace.
Primary drive gear
1. Inspect:
Primary drive gear
Wear/damage → Replace.
EC495000
ASSEMBLY AND INSTALLATION
Push lever
1. Install:
Push lever 1
NOTE:
Apply the lithium soap base grease on the oil
seal lip.
Apply the engine oil on the push lever.
Primary drive gear
1. Install:
Straight key
Primary drive gear 1
Washer 2
Nut (primary drive gear) 3
Primary driven gear 4
NOTE:
Install the primary drive gear with the stamp
a facing out.
Place a folded rag or aluminum plate 5
between the teeth of the primary drive gear
and primary driven gear.
T R..70 Nm (7.0 m · kg, 50 ft · lb)

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ENGCLUTCH AND PRIMARY DRIVEN GEAR
Clutch
1. Install:
Conical spring washer 1
Thrust plate 2
Primary driven gear 3
Thrust plate 4
Clutch boss 5
2. Install:
Lock washer
Nut (clutch boss) 1
NOTE:
Use the clutch holding tool 2 to hold the clutch
boss.
ÅFor USA and CDN
ıExcept for USA and CDN
3. Bend:
Lock washer tab
Clutch holding tool:
YM-91042/90890-04086
New
T R..60 Nm (6.0 m · kg, 43 ft · lb)
Å
ı
4. Install:
Friction plate 1
Clutch plate 2
NOTE:
Install the clutch plates and friction plates
alternately on the clutch boss, starting with a
friction plate and ending with a friction plate.
Apply the engine oil on the friction plates and
clutch plates.
Be sure to install a clutch plate with projec-
tion a offset approximately 90˚ from previ-
ous plates projection. Continue this
procedure in a clockwise direction until all
clutch plates are installed.

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ENGCLUTCH AND PRIMARY DRIVEN GEAR
5. Install:
Ball
NOTE:
Apply the engine oil on the ball.
6. Install:
Push rod 1 1
Push plate 2
Washer 3
Nut (push rod 1) 4
7. Install:
Pressure plate 1
Clutch spring 2
Bolt (clutch spring) 3
NOTE:
Align the arrow mark a on the pressure
plate with the punched mark b on the clutch
boss.
Tighten the bolts in stage, using a crisscross
pattern.
T R..6 Nm (0.6 m · kg, 4.3 ft · lb)
8. Check:
Push lever position
Push the push lever assembly in the
arrow direction and make sure that the
mach mark are aligned → adjust.
aMatch mark on the push lever assembly
bMatch mark on the crankcase