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CLUTCH
5-43
EAS25110
CHECKING THE CLUTCH PLATES
The following procedure applies to all of the
clutch plates.
1. Check:
• Clutch plate
Damage
→
Replace the clutch plates as a
set.
2. Measure:
• Clutch plate warpage
(with a surface plate and thickness gauge “1”)
Out of specification
→
Replace the clutch
plates as a set.
EAS25140
CHECKING THE CLUTCH SPRINGS
The following procedure applies to all of the
clutch springs.
1. Check:
• Clutch spring
Damage
→
Replace the clutch springs as a
set.
2. Measure:
• Clutch spring free length “a”
Out of specification
→
Replace the clutch
springs as a set.
EAS25150
CHECKING THE CLUTCH HOUSING
1. Check:
• Clutch housing dogs “1”
Damage/pitting/wear
→
Deburr the clutch
housing dogs or replace the clutch housing.
TIP
Pitting on the clutch housing dogs will cause er-
ratic clutch operation.
2. Check:
• Bearing
Damage/wear
→
Replace the bearing and
clutch housing.
EAS25160
CHECKING THE CLUTCH BOSS
1. Check:
• Clutch boss splines
Damage/pitting/wear
→
Replace the clutch
boss.
TIP
Pitting on the clutch boss splines will cause er-
ratic clutch operation.
Thickness gauge
90890-03180
Feeler gauge set
YU-26900-9
Clutch plate thickness
1.45–1.75 mm (0.057–0.069 in)
Warpage limit
0.20 mm (0.0079 in)
Clutch spring free length
38.71 mm (1.52 in)
Minimum length
36.77 mm (1.45 in)
Summary of Contents for WR125R 2009
Page 1: ...2009 SERVICE MANUAL WR125R WR125X 22B F8197 E0 ...
Page 6: ......
Page 8: ......
Page 24: ...SPECIAL TOOLS 1 15 ...
Page 51: ...LUBRICATION POINTS AND LUBRICANT TYPES 2 26 ...
Page 54: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 29 EAS20410 LUBRICATION DIAGRAMS A 1 4 5 6 7 2 3 ...
Page 56: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 31 1 3 2 4 ...
Page 57: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 32 1 Camshaft 2 Crankshaft 3 Main axle 4 Drive axle ...
Page 58: ...COOLING SYSTEM DIAGRAMS 2 33 EAS20420 COOLING SYSTEM DIAGRAMS 9 1 2 6 7 8 3 5 4 ...
Page 66: ...CABLE ROUTING 2 41 A A B B C C A A B B A B C E D 1 2 3 4 5 6 7 8 9 12 10 11 14 13 ...
Page 68: ...CABLE ROUTING 2 43 B B C C A A A B B C C A A B C C 1 2 3 4 3 4 5 6 7 8 9 10 11 ...
Page 78: ...CABLE ROUTING 2 53 ...
Page 81: ......
Page 109: ...ELECTRICAL SYSTEM 3 28 1 a b ...
Page 110: ...ELECTRICAL SYSTEM 3 29 ...
Page 113: ......
Page 142: ...FRONT BRAKE 4 29 Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 19 ...
Page 184: ...CHAIN DRIVE 4 71 ...
Page 248: ...CRANKCASE 5 61 A Left crankcase B Right crankcase A 1 7 11 12 3 14 2 13 4 5 6 8 9 10 16 15 B ...
Page 258: ...TRANSMISSION 5 71 ...
Page 277: ...THROTTLE BODY 7 8 ...
Page 278: ...AIR INDUCTION SYSTEM 7 9 EAS27040 AIR INDUCTION SYSTEM 2 1 3 ...
Page 282: ...AIR INDUCTION SYSTEM 7 13 ...
Page 285: ......
Page 295: ...ELECTRIC STARTING SYSTEM 8 10 ...
Page 297: ...CHARGING SYSTEM 8 12 2 AC magneto 4 Rectifier regulator 5 Main fuse 6 Battery ...
Page 299: ...CHARGING SYSTEM 8 14 ...
Page 313: ...COOLING SYSTEM 8 28 ...
Page 343: ...FUEL PUMP SYSTEM 8 58 ...
Page 369: ......
Page 370: ......