Yamaha XMAX YP125R - Service manual > V-belt automatic transmission (YP250R)

Removing the V-belt case cover

Removing the V-belt, primary sheave and secondary sheave

Removing the V-belt, primary sheave and secondary sheave

* Apply Shell BT grease 3 (Yamaha grease G 90793-40016).

Yamaha grease G 90793-40016

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 145.0 mm (5.71 in)

Limit 145.5 mm (5.73 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 3.3 mm (0.13 in)

Wear limit 2.0 mm (0.08 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 23.0 mm (0.91 in)

Limit 21.0 mm (0.83 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 102.4 mm (4.03 in)

Limit 90.0 mm (3.54 in)

Assembling the primary sheave

1. Clean:

• Primary fixed sheave
• Primary sliding sheave
• Spacer
• Primary sheave weights
• Cam

2. Install:

• Primary sheave weights "1"
• Spacer "2"

TIP

Before installing the primary sheave weights, lubricate the inside and outside of each weight with Shell BT grease 3.

Recommended lubricant Shell BT grease 3

Assembling the secondary sheave

1. Lubricate:

• Secondary fixed sheave's inner surface "1"
• Secondary sliding sheave's inner surface "2"
• Oil seals
• Bearing (with the recommended lubricant)

Recommended lubricant BEL-RAY assembly lube

2. Install:

• Oil seals
• 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
• Spacer
• 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"

NOTICE

Do not allow grease to contact the primary sheave assembly.

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.

5. Tighten:

• Primary sheave nut "1"

Primary sheave nut 80 Nm (8.0 m*kgf, 58 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: