Yamaha XT125, XT250 Repair Manual 1980-1984

The 1980-1984 Yamaha XT125, XT250 off-road bike repair manual by Clymer, covers the following models:

• Yamaha XT125, 1982-1983
• Yamaha XT200, 1980-1984
• Yamaha XT250, 1980-1984

Book Excerpt: 1980-1984 Yamaha XT125, XT250 Repair Manual CLUTCH AND TRANSMISSION

This chapter contains removal, inspection, overhaul and installation of the clutch, transmission and shift mechanism (external and internal). Table 1 (clutch specifications) and Table 2 (tightening torques) are at the end of the chapter.
CLUTCH The clutch used on all XT models is a wet multiplate type which operates immersed in the oil supply it shares with the transmission. The clutch boss is splined to the transmission main shaft. The clutch housing can rotate freely on the main shaft but is geared to the primary drive gear attached to the crankshaft. During disassembly pay particular attention to the location and positioning of spacers and washers to make assembly easier. The clutch can be removed with the engine in the frame. Refer to Figure 1 for the clutch assembly used on the various models.
TROUBLESHOOTING The XT clutch is relatively bulletproof. However, when clutch problems occur, they can be difficult to diagnose. The troubleshooting chart in Figure 2 lists typical clutch problems and their probable causes.
REMOVAL

1. Support the bike on the kickstand.
2. Drain the transmission oil as described in Chapter Three.
3. Remove the foot peg from the right-hand side (Figure 3). Then remove the brake lever assembly as described in Chapter Ten.

BRAKES

Both the front and rear brake are drum type. The brake system consists of a brake drum, camshaft, pivot post, brake shoes and linings. See Figure 1. Activating the brake hand lever or foot pedal pulls the cable or rod which in turn rotates the camshaft. This forces the brake shoes out into contact with the brake drum. Lever and pedal free play must be maintained on both brakes to minimize brake drag and premature brake wear and to compensate for brake lining wear. Refer to in Chapter Three for complete adjustment procedures. The front brake cable on all models must be inspected and replaced periodically as it stretches with use until it can no longer be properly adjusted. To increase cable life, it should be periodically lubricated as described in Chapter Three. Brake specifications are found in Table 1, located at the end of this chapter.

Subject: 1980, 1981, 1982, 1983, 1984 Yamaha XT125, XT250 service, maintenance, repair. ISBN-10: 0892873876 | ISBN-13: 9780892873876 | Clymer M417