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

Removing the V-belt case cover
Removing the V-belt case cover

Removing the V-belt, primary sheave and secondary sheave
Removing the V-belt, primary sheave and secondary sheave

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
Disassembling the secondary sheave

* Apply BEL-RAY assembly lube.

Removing the primary sheave

1. Remove:

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:

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 primary sheave

Removing the secondary sheave

1. Remove:

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

Removing the secondary sheave

2. Loosen:

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

Removing the secondary sheave

3. Remove:

TIP

Remove the V-belt and secondary sheave assembly from the primary sheave side.

Removing the secondary sheave

Disassembling the secondary sheave

1. Remove:

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

Disassembling the secondary sheave

Checking the clutch housing

1. Check:

Damage/wear → Replace.

2. Measure:

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 housing

Checking the clutch shoes

The following procedure applies to all of the clutch shoes.

1. Check:

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:

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 clutch shoes

Checking the v-belt

1. Check:

Cracks/damage/wear → Replace.

Grease/oil → Clean the primary and secondary sheave.

2. Measure:

Out of specification → Replace.

V-belt width 23.0 mm (0.91 in)

Limit 21.0 mm (0.83 in)

Checking the v-belt

Checking the primary sheave

1. Check:

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:

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 weights

Checking the primary sheave sliders

1. Check:

Cracks/damage/wear → Replace.

Checking the secondary sheave

1. Check:

Cracks/damage/wear → Replace the secondary fixed and sliding sheaves as a set.

2. Check:

Damage/wear → Replace the secondary fixed and sliding sheaves as a set.

3. Check:

Damage/wear → Replace the secondary fixed and sliding sheaves as a set.

Checking the secondary sheave

4. Check:

Out of specification → Replace the spring.

Compression spring free length 102.4 mm (4.03 in)

Limit 90.0 mm (3.54 in)

Checking the secondary sheave

Assembling the primary sheave

1. Clean:

2. Install:

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 primary sheave

Assembling the secondary sheave

1. Lubricate:

Recommended lubricant BEL-RAY assembly lube

Assembling the secondary sheave

2. Install:

TIP

Install the secondary sliding sheave onto the secondary fixed sheave "2" with the oil seal guide "3".

Oil seal guide (ø41) 90890-01396

Assembling the secondary sheave

3. Install:

4. Lubricate:

Recommended lubricant BEL-RAY assembly lube

Assembling the secondary sheave

5. Install:

TIP

Clutch spring holder 90890-01337

Clutch spring holder arm 90890-01464

Assembling the secondary sheave

Installing the v-belt

1. Install:

NOTICE

Do not allow grease to come in contact with the V-belt or secondary sheave assembly.

TIP

Installing the v-belt

2. Tighten:

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

Installing the v-belt

3. Install:

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

Installing the v-belt

4. Install:

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.

Installing the v-belt

5. Tighten:

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

Installing the v-belt

6. Install:

TIP

See also:

 Yamaha XMAX YP125R - Service manual > Cylinder and piston (YP250R)

Removing the cylinder and piston Removing the piston

 Yamaha XMAX YP125R - Service manual > Starter clutch and generator (YP250R)

Removing the generator cover and stator coil Removing the generator rotor and starter clutch

Maxi Scooters: