2007 yz 125 clutch issues!!!!!!

sq2208

sq2208

PR Member
hey everyone i have a 2007 yz 125 and i just replaced the clutch because there was no adjustment left. well i got new plates fibers and springs and put it together and still little to no adjustment everything on my cable is fully out just to get the lever adjusted . i took it apart checked the push rod and ball bearing all good. i checked the linkage where the cable gos into on the left side of bike and it has a lot of play?? is this normal the linkage arm moves freely in till about half way up and the starts to disengage the clutch. it just doesn't make any since with new clutch to not have more adjustment. once the plates wear in a little i wont have any treads left on cable to adjust it. also i bought a new cable and perch with no difference??? please helllppppp


ps i am aware of the 2005-2006 push rod breaking issue but my push rod looks fine
 
What kind of shape is your pressure plate, basket and hub in, are they worn? Also, are you sure you have all the washers installed? s
Sometimes they stick to the parts you take out and therefore you don't reinstall them, I have done this before. Go to rocky mountain and look up the oem schematic.
 
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i have looked it up everything that is supposed to be there is and the bearings dont seeme worn all the internals seemed good just needed a light file so smooth out.
 
Are you using all OEM parts? We had trouble also. I would suggest to lay it on its side, pull everything out and reinstall. Make sure you install the springs like you would install lug nuts on a car. Its probably something simple.
 
Is the pressure plate fully engaged into the hub? It fits into the grooves in the end of the hub when it is lined up properly. Just a thought. I have seen that happen before. Also check that all of the large washers are in place one behind the hub and one behind the basket.
 
I know with mine the push rod would actually pop out and catch on a part of the case that was supposed to keep it from coming out. Just food for thought. We actually went through a ton of clutches before finding the issue. Nothing would break it would just pop out and my lever would flop around while my clutch slipped. Fried 3 clutches in a row trying to figure that one out. Mines an 05 but I think everything was the same
 
Is your clutch is behaving just as it did just as it did before installing the new parts? If it is then something else is out of spec. All of those parts from the actuator lever to the actual clutch on the other side of the cases have to work together. I had replaced everthing except the basket on my '06 (it had had all of the shift stopper/actuator rod problems). The basket was worn to where it looked like filing the fingers would make it right but other surfaces were worn as well. A new basket finally made it right. But again that was the last part I had replaced.
 
Your clutch hub and pressure plate are worn out. It has too much clearance and it causes the cable to run out of adjustment and puts pressure on the rod, pushing the actuator out of the case half and eventually breaking it. Replace those 2 items and you are good to ride! I have fixed 3 yz 125's with the same problem.
 
Thanks everyone I will let you know if any of the suggestions fix the issue. and hersey where the yz you fixed post 2006?
 
The hershey cure got my bike's clutch working but I couldn't adjust it properly without a new basket. Of course I had bearings from the shift stopper loose in there at one time. I even found part of bearing race mashed into the back side of the basket.
 
Spend some coin and get a wiseco kit. Lifetime warranty on basket!

Or just go full OEM replacement. Oem Yamaha parts are great.


Do you feather clutch a lot ? If you're hard on the clutch go with wiseco or Hinson.
 
sq2208 said:
Thanks everyone I will let you know if any of the suggestions fix the issue. and hersey where the yz you fixed post 2006?
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Yes, 2 - 2006 and 1 - 2005. Its the same clutch set up from then to the present. Like KO1, many people I have told this issue about have fixed theirs as well. I ended up going full Hinson in my 06 yz125.
 
thanks yea i haven't even been riding it yet... i bought it from drew szamia last winter and haven't been able to ride because i started a new job. so I put all new parts on it plastics bars chain sprockets and suspension from srs bearing and the engine was rebuilt. this is the last piece of the puzzle and drew is a pretty good rider so the clutch internals are prob pretty much ready to replace. i will make it threw indoors and i will have to do it all in spring ;( thanks again guys
 
sq2208
What was your fix ? we have a 2006 YZ125 that has new everything as far as clutch goes. There is nothing left to replace period, basket, hub, pressure plate, bearings, spacers, washers, actuator arm, fibers, steels, cable, it`s all new. Basket is Weisco, all other parts are OEM. Fibers and metals are Tusk. Still can`t get free play out, it`s like the cable is too long. Maybe the Tusk fibers and steels are junk but they measure within tolerance according to the manual.
 
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MarctheSharc said:
CE_3244_1.JPG
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It`s in there and also new, in this diagram I have replaced items, 9,8,20,19,18,17,15,21,22,23,5,11,4,12,13,and 14 along with new cable and has ASV lever and perch
interesting though that item 18 comes as a kit with bearing and 2 shim washers as picture shows but there is not enough room on item 17 to add shims and also item 19 and install the circlip item 20 and the current one I pulled out was same way. If you scroll down a few pages in the diagram it shows item 18 without shims.
I`m at the point where I think I have to long of cable even though it`s brand new and exactly the same length as one I removed or just got a junk set of fibers and metals even though they measure within spec. I`m at a loss and there is really nothing more to replace.
 
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