water pump YAMAHA YZ125LC 2001 Betriebsanleitungen (in German)

CHAPTER 4
ENGINE
SEAT, FUEL TANK AND SIDE
COVERS.....................................................4-1
EXHAUST PIPE AND SILENCER..............4-3
RADIATOR..................................................4-4
CARBURETOR AND REED VALVE...........4-7
CYLINDER HEAD , CYLINDER AND
PISTON.....................................................4-17
CLUTCH AND PRIMARY DRIVEN
GEAR.......................................................4-30
KICK AXLE, SHIFT SHAFT AND
PRIMARY DRIVE GEAR...........................4-38
YPVS GOVERNOR...................................4-46
WATER PUMP..........................................4-49
CDI MAGNETO.........................................4-53
ENGINE REMOVAL..................................4-57
CRANKCASE AND CRANKSHAFT.........4-62
TRANSMISSION, SHIFT CAM AND
SHIFT FORK.............................................4-69
CHAPTER 5
CAHSSIS
FRONT WHEEL AND REAR WHEEL........5-1
FRONT BRAKE AND REAR BRAKE.......5-10
FRONT FORK...........................................5-27
HANDLEBAR............................................5-40
STEERING................................................5-47
SWINGARM..............................................5-52
REAR SHOCK ABSORBER.....................5-59
5MV-9-30-0 6/19/00 2:05 PM Page 20

1-3
GEN
INFO
IMPORTANT INFORMATION
EC130000
IMPORTANT INFORMATION
EC131010
PREPARATION FOR REMOVAL AND
DISASSEMBLY
1. Remove all dirt, mud, dust, and foreign ma-
terial before removal and disassembly.
When washing the machine with high pres-
sured water, cover the parts as follows.
9Silencer end
9Air filter intake slit
9Crankcase cover hole at the bottom
9Water pump housing hole at the bottom
2. Use proper tools and cleaning equipment.
Refer to “SPECIAL TOOLS” section.
3. When disassembling the machine, keep
mated parts together. They include gears,
cylinders, pistons, and other mated parts
that have been “mated” through normal
wear. Mated parts must be reused as an as-
sembly or replaced.
4. During the machine disassembly, clean all
parts and place them in trays in the order of
disassembly. This will speed up assembly
time and help assure that all parts are cor-
rectly reinstalled.
5. Keep away from fire.
5MV-9-30-1A 6/19/00 1:11 PM Page 6

2-4
SPECMAINTENANCE SPECIFICATIONS
Item Standard Limit
Transmission:
Main axle deflection limit…
0.01 mm (0.0004 in)
Drive axle deflection limit…
0.01 mm (0.0004 in)
Shifter:
Shifting type Cam drum and guide bar…
Guide bar bending limit…
0.05 mm (0.0020 in)
Kick starter type: Kick and mesh type…
Kick clip friction force P=0.8~1.2 kg (1.8~2.6 lb)…
Air filter oil grade (oiled filter):Foam-air-filter oil or engine mixing oil…
Carburetor: USA, CDN, ZA
EUROPE
AUS, NZ
Type/Manufacturer TMXø
38SS¬
/MIKUNI
I.D. mark 5MV1 00 5MV2 10…
Main jet (M.J.) #460 #450…
Jet needle-clip position (J.N.) 6BGK9-75-3 6BHY1-75-3…
Cutaway (C.A.) 5.75¬…
Pilot jet (P.J.) #25 #30…
Pilot air screw (P.A.S.) 1-1/4 1-1/2…
Valve seat size (V.S.)
ø3.8 mm (0.15 in)¬…
Starter jet (G.S.) #80¬…
Fuel level (F.L.) 13.5~14.5 mm ¬
(0.53~0.57 in)
Reed valve:
Thickness* 0.42 mm (0.017 in)…
Valve stopper height 8.2~8.6 mm (0.323~0.339 in)…
Valve bending limit…
0.2 mm (0.008 in)
Cooling:
Radiator core size:
Width 110 mm (4.33 in)…
Height (left) 240 mm (9.45 in)…
(right) 220 mm (8.66 in)…
Thickness 32 mm (1.26 in)…
Radiator cap opening pressure 95~125 kPa…
(0.95~1.25 kg/cm
2, 13.5~17.8 psi)
Radiator capacity (total) 0.63 L (0.55 Imp qt, 0.67 US qt)…
Water pump:
Type Single-suction centrifugal pump…
5MV-9-30-2A 6/19/00 1:15 PM Page 5

2-5
SPECMAINTENANCE SPECIFICATIONS
Part to be tightened Thread size Q'tyT ightening torqueNm m•kg ft•lb
Spark plug M14 ´1.25 1 20 2.0 14
Cylinder head (nut) M 8 ´1.25 5 28 2.8 20
(stud) M 8 ´1.25 5 13 1.3 9.4
Cylinder (nut) M 8 ´1.25 4 30 3.0 22
(stud) M10 ´1.25 4 13 1.3 9.4
Power valve:
Cover M 5 ´0.8 4 4 0.4 2.9
Link lever M 4 ´0.7 1 4 0.4 2.9
Holder (power valve) M 5 ´0.8 4 8 0.8 5.8
Push rod M 5 ´0.8 1 5 0.5 3.6
Thrust plate M 5 ´0.8 1 4 0.4 2.9
Governor fork M 4 ´0.7 2 5 0.5 3.6
Housing M 5 ´0.8 4 5 0.5 3.6
Impeller M 8 ´1.25 1 14 1.4 10
Water pump housing cover M 6 ´1.0 4 10 1.0 7.2
Coolant drain bolt M 6 ´1.0 1 10 1.0 7.2
Radiator hose clamp M 6 ´1.0 8 1 0.1 0.7
Air filter element M 6 ´1.0 1 2 0.2 1.4
Carburetor joint M 6 ´1.0 4 10 1.0 7.2
Air filter case M 6 ´1.0 2 4 0.4 2.9
Air filter joint M 5 ´0.8 5 1 0.1 0.7
Read valve M 3 ´0.5 6 1 0.1 0.7
Crankcase M 6 ´1.0 12 14 1.4 10
Crankcase cover (right) M 6 ´1.0 8 10 1.0 7.2
Crankcase cover (left) M 6 ´1.0 5 5 0.5 3.6
Chain cover M 6 ´1.0 2 5 0.5 3.6
Bearing plate cover M 6 ´1.0 3 10 1.0 7.2
Holder M 6 ´1.0 1 10 1.0 7.2
Oil check bolt M 6 ´1.0 1 10 1.0 7.2
Oil drain bolt M12 ´1.5 1 20 2.0 14
Kick starter M 6 ´1.0 1 10 1.0 7.2
Cluch cover M 6 ´1.0 6 10 1.0 7.2
Primary drive gear M10 ´1.25 1 55 5.5 40
Clutch boss M16 ´1.0 1 80 8.0 58
Clutch spring M 6 ´1.0 5 10 1.0 7.2
Push lever axle M 6 ´1.0 1 7 0.7 5.1
Drive sprocket M16 ´1.0 1 60 6.0 43
Shift pedal M 6 ´1.0 1 10 1.0 7.2
Bearing plate cover (shift cam) M 6 ´1.0 2 10 1.0 7.2
Shift guide M 6 ´1.0 2 10 1.0 7.2
Stopper lever M 6 ´1.0 1 10 1.0 7.2
Segment M 8 ´1.25 1 30 3.0 22
5MV-9-30-2A 6/19/00 1:15 PM Page 6

4-38
ENG
KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE
GEAR
Extent of removal Order Part name Q’ty Remarks
RPIMARY DRIVE GEAR REMOVAL
Preparation for Drain the transmission oil.Refer to “TRANSMISSION OIL REPLACE-
removalMENT“ section in the CHAPTER 3.
Clutch cable Disconnect at engine side.
Bolt (brake pedal) Shift the brake pedal downward.
Radiator hose 4 Disconnect at water pump side.
Bolt (push rod)
Refer to “CYLINDER HEAD, CYLINDER
AND PISTON” section.
1 Kick starter 1
2 Crankcase cover (right) 1
3 Bolt (Primary drive gear) 1 Only loosening
Refer to “REMOVAL POINTS”.
4 Primary driven gear 1 Refer to “CLUTCH AND PRIMARY
DRIVEN GEAR”section.
5 Primary drive gear 1
EC4C0000
KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE GEAREC4C8000PRIMARY DRIVE GEAR
1
Extent of removal:1Primary drive gear removal
10 Nm (1.0 m•kg, 7.2 ft•lb)
10 Nm (1.0 m•kg, 7.2 ft•lb)
55 Nm (5.5 m•kg, 40 ft•lb)
5MV-9-30-4C 6/19/00 1:41 PM Page 2

4-49
ENGWATER PUMP
Extent of removal Order Part name Q’ty Remarks
WATER PUMP DISASSEMBLY
Preparation for Crankcase cover (right)
Refer to “KICK AXLE, SHIFT SHAFT AND
removalPRIMARY DRIVE GEAR” section.
1 Water pump housing cover 1
2 Impeller 1
3 Plain washer 1 Refer to “REMOVAL POINTS”.
4 Impeller shaft 1
5 Bearing 1
6 Oil seal 2Refer to “REMOVAL POINTS”.
EC4G0000
WATER PUMP
1
2
Extent of removal:1Impeller shaft removal2Oil seal removal
ü
ï
ý
ï
þ
ü
ý
þ
14 Nm (1.4 m•kg, 10 ft•lb)
10 Nm (1.0 m•kg, 7.2 ft•lb)
10 Nm (1.0 m•kg, 7.2 ft•lb)
5MV-9-30-4C 6/19/00 1:42 PM Page 24

4-50
ENGWATER PUMP
EC4G3000
REMOVAL POINTS
EC4G3110
Impeller shaft
1. Remove:
9Impeller 1
9Plain washer 2
9Impeller shaft 3
NOTE:
Hold the impeller shaft on its width across the
flats awith spanners, etc. and remove the im-
peller.
EC4G3210
Oil seal
NOTE:
It is not necessary to disassemble the water
pump, unless there is an abnormality such as
excessive change in coolant level, discoloration
of coolant, or milky transmission oil.
1. Remove:
9Bearing 1
2. Remove:
9Oil seal 1
EC4G4000
INSPECTIONEC444200
Impeller shaft
1. Inspect:
9Impeller shaft 1
Bend/Wear/Damage ÕReplace.
Fur deposits ÕClean.
5MV-9-30-4C 6/19/00 1:42 PM Page 26

4-51
ENGWATER PUMP
EC444300
Impeller shaft gear
1. Inspect:
9Gear teeth a
Wear/Damage ÕReplace.
EC4H4600
Bearing
1. Inspect:
9Bearing 1
Rotate inner race with a finger.
Rough spot/Seizure ÕReplace.
EC444400
Oil seal
1. Inspect:
9Oil seal 1
Wear/Damage ÕReplace.
EC4G5000
ASSEMBLY AND INSTALLATION
EC4G5111
Oil seal
1. Install:
9Oil seal 1
NOTE:
9Apply the lithium soap base grease on the oil
seal lip.
9Install the oil seal with its manufacture's marks
or numbers facing the crankcase cover (right)
2.
2. Install:
9Bearing 1
NOTE:
Install the bearing by pressing its outer race par-
allel.
5MV-9-30-4C 6/19/00 1:42 PM Page 28

4-52
ENGWATER PUMP
EC4G5220
Impeller shaft
1. Install:
9Impeller shaft 1
NOTE:
9Take care so that the oil seal lip is not dam-
aged or the spring does not slip off its position.
9When installing the impeller shaft, apply the
lithium soap base grease on the oil seal lip and
impeller shaft. And install the shaft while turn-
ing it.
2. Install:
9Plain washer 1
9Impeller 2
NOTE:
Hold the impeller shaft on its width across the
flats awith spanners, etc. and install the im-
peller.
3. Install:
9Dowel pin 1
9Gasket (water pump housing cover) 2
4. Install:
9Water pump housing cover 1
9Bolt (water pump housing cover) 2
9Copper washer (coolant drain bolt) 3
9Coolant drain bolt 4
10 Nm (1.0 m•kg, 7.2 ft•lb)
10 Nm (1.0 m•kg, 7.2 ft•lb)
14 Nm (1.4 m•kg, 10 ft•lb)
5MV-9-30-4C 6/19/00 1:42 PM Page 30

4-57
ENGENGINE REMOVAL
Extent of removal Order Part name Q’ty Remarks
ENGINE REMOVAL
Preparation for
Hold the machine by placing the
removalsuitable stand under the engine.
Seat and fuel tankRefer to “SEAT, FUEL TANK AND
SIDE COVERS” section.
Carburetor Refer to “CARBURETOR AND REED
VALVE” section.
Exhaust pipe and silencer Refer to “EXHAUST PIPE AND
SILENCER” section.
Clutch cable Disconnect at engine side.
Radiator hose 2 Disconnect at cylinder head side.
Radiator hose 4 Disconnect at water pump side.
Bolt (radiator) Refer to “RADIATOR” section.
Radiator hose 3 Disconnect at right side radiator,
then shift the radiators forward.
Spark plug cap
Disconnect the CDI magneto lead.
EC4M0000
w
Support the machine securely so there is no dan-
ger of it falling over.
26 Nm (2.6 m•kg, 19 ft•lb)
34 Nm (3.4 m•kg, 24 ft•lb)
69 Nm (6.9 m•kg, 50 ft•lb)
69 Nm (6.9 m•kg, 50 ft•lb)
85 Nm (8.5 m•kg, 61 ft•lb)
60 Nm (6.0 m•kg, 43 ft•lb)
5 Nm (0.5 m•kg, 3.6 ft•lb)
5MV-9-30-4D 6/19/00 1:39 PM Page 2