Motorcycle Repair: 05 yz125ti clutch linkage, yamaha dirt bikes, clutch linkage


Question
got this bike in april 05 and have kept in in top shape. Don't have the vin with me, but it is a 05 yamaha yz 125ti. the 05 and 06 versions of this bike are having a problem with a bearing on the shift stop lever coming apart and often destroying transmissions...there on some good articles on this, (if you want to read, let me know)  but my problem is secondary to this.  My clutch started to slip and hang up...scorched the clutches just a bit, and I found too much metal in my trans oil. when I pulled my clutch push rod out, I found metal between it and what yamaha calls the "push lever assy" (the clutch cable is connected to other end of it).  I took the push rod and the push lever (to clarify, the push lever acts like a cars clutch fork, cable on one end, push rod on the other)  to my local yamaha dealer and confirmed there  was no wear or damage.  I flushed the trans many times and cleaned metal out with magnets. all the bearings are good. no visible tracking on gears. put it all back together. everything works great except- with my hand off the clutch (free play in cable) I can rev the bike three times and the push lever assy comes out (moves forward) until the case stops it (you have to have the plastic magneto cover off to see this). on the next clutch application the stop arm on the push lever assm gets bent, then moves forward out of contact with the push rod and my clutch lever hits the handlebar to stay...this is a different design than most Yamaha dirt bikes, and you may need to look at an oem parts diagram...the push stop lever is number 23 on the one I saw ( you are good if you don't) I can't find anything that holds it in place, other than its desire to line up with the cable. I can prevent it from coming out with my little finger.  It acts exactly like crank case pressure is pushing it out, but leaving the fill cap off doesn't affect it. I suspect this isn't your cup of tea, but I don't know where to turn. I posted this on thumpertalk a week ago and I'm the only one on there with zero replies.  Six dealer yamaha mechanics have no idea and they have led me to believe they have no tech support... hope you can point me in a direction...thanks in advance, sagers

Answer
Wow bro, that sounds tough.  I hate to say it, but without the bike I'm afraid I just can't help.  I would continue contacting yamaha mechs to see if any have delt directly with your issue.  I'm really sorry and good luck.

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