Yamaha XMAX YP125R - Service manual > V-belt automatic transmission (YP125R)
Removing the V-belt case cover
Removing the V-belt, primary sheave and secondary sheave
* Apply BEL-RAY assembly lube.
Disassembling the secondary sheave
* Apply BEL-RAY assembly lube.
Removing the primary sheave
1. Remove:
- V-belt case
TIP
Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them.
2. Remove:
- Primary sheave nut "1"
- Washer
- Primary fixed sheave "2"
TIP
While holding the primary fixed sheave with the rotor holding tool "3", loosen the primary sheave nut.
Rotor holding tool
90890-01235
Universal magneto & rotor holder YU-01235
Removing the secondary sheave
1. Remove:
- Secondary sheave nut "1"
- Spacer
- Clutch housing "2"
TIP
While holding the clutch housing with the sheave holder "3", loosen the secondary sheave nut.
Sheave holder
90890-01701
Primary clutch holder YS-01880-A
2. Loosen:
- Clutch carrier nut "1"
NOTICE
Do not remove the clutch carrier nut at this stage.
TIP
While holding the clutch carrier with the sheave holder "2", loosen the clutch carrier nut one full turn with the locknut wrench "3".
Sheave holder
90890-01701
Primary clutch holder YS-01880-A
Locknut wrench 90890-01348 YM-01348
3. Remove:
- Secondary sheave assembly "1"
- V-belt "2"
TIP
Remove the V-belt and secondary sheave assembly from the primary sheave side.
Disassembling the secondary sheave
1. Remove:
- Clutch carrier nut "1"
TIP
While compressing the compression spring with the clutch spring holder "2" and clutch spring holder arm "3", remove the clutch carrier nut.
Clutch spring holder
90890-01337
Clutch spring holder arm 90890-01464
Checking the clutch housing
1. Check:
- Clutch housing
Damage/wear → Replace.
2. Measure:
- Clutch housing inside diameter "a"
Out of specification → Replace the clutch housing.
Clutch housing inside
diameter
135.0 mm (5.31 in)
Limit 135.5 mm (5.33 in)
Checking the clutch shoes
The following procedure applies to all of the clutch shoes.
1. Check:
- Clutch shoe
Damage/wear → Replace the clutch shoes and springs as a set.
Glazed areas → Sand with coarse sandpaper.
TIP
After sanding the glazed areas, clean the clutch with a cloth.
2. Measure:
- Clutch shoe thickness "a"
Out of specification → Replace the clutch shoes and springs as a set.
Clutch shoe thickness
2.0 mm (0.08 in)
Wear limit 1.0 mm (0.04 in)
Checking the v-belt
1. Check:
- V-belt "1"
Cracks/damage/wear → Replace.
Grease/oil → Clean the primary and secondary sheave.
2. Measure:
- V-belt width "2"
Out of specification → Replace.
V-belt width
22.0 mm (0.87 in)
Limit 19.8 mm (0.78 in)
Checking the primary sheave
1. Check:
- Primary sliding sheave
- Primary fixed sheave
- Spacer
Cracks/damage/wear → Replace the primary sliding sheave and primary fixed sheave as a set.
Checking the primary sheave weights
The following procedure applies to all of the primary sheave weights.
1. Check:
- Primary sheave weight
Cracks/damage/wear → Replace.
2. Measure:
- Primary sheave weight outside diameter
Out of specification → Replace.
Weight outside diameter
20.0 mm (0.79 in)
Limit 19.5 mm (0.77 in)
Checking the primary sheave sliders
1. Check:
- Primary sheave slider
Cracks/damage/wear → Replace.
Checking the secondary sheave
1. Check:
- Secondary fixed sheave
- Secondary sliding sheave
Cracks/damage/wear → Replace the secondary fixed and sliding sheaves as a set.
2. Check:
- Torque cam groove "1"
Damage/wear → Replace the secondary fixed and sliding sheaves as a set.
3. Check:
- Guide pin "2"
Damage/wear → Replace the secondary fixed and sliding sheaves as a set.
4. Check:
- Spring free length
Out of specification → Replace the spring.
Compression spring free
length
112.0 mm (4.41 in)
Limit 106.4 mm (4.19 in)
Assembling the primary sheave
1. Clean:
- Primary fixed sheave
- Primary sliding sheave
- Spacer
- Primary sheave weights
- Cam
2. Lubricate:
- Oil seal
- Primary sliding sheave
- Spacer
Recommended lubricant
BEL-RAY assembly lube
TIP
Fill the notches of the primary sliding sheave with grease. Apply grease to the inner surface of the primary sliding sheave as shown.
NOTICE
Do not get any grease on the surfaces of the sheaves. If any grease gets on the sheaves, be sure to wipe it off with alcohol, etc.
Assembling the secondary sheave
1. Lubricate:
- Secondary fixed sheave inner surface "1"
- Secondary sliding sheave inner surface "2"
- Oil seals
- Bearing (with the recommended lubricant)
Recommended lubricant
BEL-RAY assembly lube
2. Install:
- Oil seal
- Secondary sliding sheave "1"
TIP
Install the secondary sliding sheave onto the secondary fixed sheave "2" with the oil seal guide "3".
Oil seal guide (ø41)
90890-01396
3. Install:
- Guide pins "1"
4. Lubricate:
- Guide pin grooves "2"
- O-rings "3"
(with the
recommended lubricant)
Recommended lubricant
BEL-RAY assembly lube
5. Install:
- Spring seat
- Compression spring
- Clutch carrier "1"
- Clutch carrier nut "2"
TIP
- While compressing the compression spring with the clutch spring holder "3" and clutch spring holder arm "4", install the clutch carrier nut.
- Install the clutch carrier nut "2" with its tapered side "a" facing the clutch carrier.
Clutch spring holder
90890-01337
Clutch spring holder arm 90890-01464
Installing the v-belt
1. Install:
- V-belt "1"
- Secondary sheave assembly "2"
NOTICE
Do not allow grease to come in contact with the V-belt or secondary sheave assembly.
TIP
- Install the V-belt with the printed arrow mark on the V-belt facing in the direction shown in the illustration.
- Install the V-belt onto the primary sheave side.
2. Tighten:
- Clutch carrier nut "1"
Clutch carrier nut
90 Nm (9.0 m*kgf, 65 ft*lbf)
TIP
While holding the clutch carrier with the sheave holder "2", tighten the clutch carrier nut with the locknut wrench "3".
Sheave holder
90890-01701
Primary clutch holder YS-01880-A
Locknut wrench 90890-01348 YM-01348
3. Install:
- Clutch housing "1"
- Spacer
- Secondary sheave nut "2"
Secondary sheave nut
60 Nm (6.0 m*kgf, 43 ft*lbf)
TIP
While holding the clutch housing with the sheave holder "3", tighten the secondary sheave nut.
Sheave holder
90890-01701
Primary clutch holder YS-01880-A
4. Install:
- V-belt "1"
- Primary fixed sheave "2"
- Washer
- Primary sheave nut "3"
TIP
Install the V-belt in the primary sheave (when the pulley is at its widest position) and in the secondary sheave (when the pulley is at its narrowest position), and make sure the V-belt is tight.
NOTICE
Do not allow grease to contact the primary sheave assembly.
5. Tighten:
- Primary sheave nut "1"
Primary sheave nut
55 Nm (5.5 m*kgf, 40 ft*lbf)
TIP
While holding the primary fixed sheave with the rotor holding tool "2", tighten the primary sheave nut.
Rotor holding tool
90890-01235
Universal magneto & rotor holder YU-01235
6. Install:
- V-belt case
TIP
- Make sure that the V-belt case gasket lip fits properly around the V-belt case.
- Tighten the V-belt case bolts in stages and in a crisscross pattern.
See also:
Yamaha XMAX YP125R - Service manual > Checking the piston pin
1. Check: Piston pin Blue discoloration/grooves → Replace the piston pin, and then check the lubrication system. 2. Measure: Piston pin outside diameter "a"
Yamaha XMAX YP125R - Service manual > Starter clutch and generator (YP125R)
Removing the generator cover and stator coil Removing the generator rotor and starter clutch
