fuel cap YAMAHA YZ125LC 2003 Betriebsanleitungen (in German)

1-1
GEN
INFO
DESCRIPTION
EC100000
GENERAL INFORMATION
EC110000
DESCRIPTION
1Clutch lever
2“ENGINE STOP” button
3Front brake lever
4Throttle grip
5Radiator cap
6Fuel tank cap
7Kick starter
8Fuel tank
9Radiator
0Coolant drain bolt
qCheck bolt (Transmission oil level)
wRear brake pedal
eValve joint
rFuel cock
tAir cleaner
yDrive chain
uShift pedal
iStarter knob
oFront fork
NOTE:
9The machine you have purchased may differ
slightly from those shown in the following.
9Designs and specifications are subject to
change without notice.

1-12
GEN
INFO
FUEL AND ENGINE MIXING OIL
EC160051
FUEL AND ENGINE MIXING OIL
Mix oil with the gas at the ratio specified below.
Always use fresh, name-brand gasoline, and mix
the oil and gas the day of the race. Do not use
premix that is more than a few hours old.
NOTE:
If knocking or pinging occurs, use a different
brand of gasoline or higher octane grade.
cC
Never mix two types of oil in the same
batch; clotting of the oil could result. If you
wish to change oil types, be sure to drain
the fuel tank and the carburetor float bowl
of old premix prior to filling with the new
type.
Fuel tank capacity:
8.0 L (1.76 Imp gal, 2.11 US gal)
Mixing oil
Recommended oil:
Yamalube “2-R”
(Yamalube racing 2-cycle oil)
Mixing ratio: 30 : 1
If unavailable, use an equivalent
type of oil.
Recommended fuel:
Except for ZA:
Premium unleaded gasoline
only with a research octane
number of 95 or higher.
For ZA:
Premium gasoline

2-1
SPECGENERAL SPECIFICATIONS
Model name: YZ125LC (EUROPE)
YZ125R (USA)
YZ125(R) (CDN, AUS, NZ, ZA)
Model code number: 5UN1 (USA, CDN, ZA)
5UN2 (EUROPE)
5UN4 (AUS, NZ)
Dimensions:USA, ZAAUS, NZ EUROPE CDN
Overall length 2,134 mm←2,130 mm←
(84.0 in) (83.9 in)
Overall width 827 mm←←←
(32.6 in)
Overall height 1,318 mm 1,315 mm 1,311 mm 1,315 mm
(51.9 in) (51.8 in) (51.6 in) (51.8 in)
Seat height 993 mm←992 mm←
(39.1 in) (39.1 in)
Wheelbase 1,438 mm←←←
(56.6 in)
Minimum ground clearance 400 mm←398 mm←
(15.7 in) (15.7 in)
Basic weight:
With oil and full fuel tank 94.5 kg (208.3 lb)
Engine:
Engine type Liquid cooled 2-stroke, gasoline
Cylinder arrangement Single cylinder, forward inclined
Displacement 124 cm
3(4.36 lmp oz, 4.19 US oz)
Bore ×Stroke 54 ×54.5 mm (2.126 ×2.146 in)
Compression ratio 8.7~11.0 : 1
Starting system Kick starter
Lubrication system: Premix (30 : 1)(Yamalube 2-R)
Oil type or grade (2-Cycle):
Transmission oil Yamalube 4 (10W-30) or SAE 10W-30 type SE
motor oil
Periodic oil change 0.65 L (0.57 Imp qt, 0.69 US qt)
Total amount 0.70 L (0.62 Imp qt, 0.74 US qt)
Coolant capacity (including all routes): 0.95 L (0.84 Imp qt, 1.00 US qt)
Air filter: Wet type element
Fuel:
Type Except for ZA: Premium unleaded gasoline
only with a research octane
number of 95 or higher
For ZA: Premium gasoline
Tank capacity 8.0 L (1.76 Imp gal, 2.11 US gal)
EC200000
SPECIFICATIONSEC211000
GENERAL SPECIFICATIONS

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 equivalent oil…
Carburetor: USA, CDN, ZA
EUROPE
AUS, NZ
Type/Manufacturer TMXχ
38SS←
/MIKUNI
I.D. mark 5UN1 00 5UN2 10…
Main jet (M.J.) #410←…
Jet needle-clip position (J.N.) 6CHY6-82-3 6CHY6-82-4…
Cutaway (C.A.) 4.0←…
Pilot jet (P.J.) #40←…
Pilot air screw (P.A.S.) 2 1-1/2…
Valve seat size (V.S.)
ø3.8 mm (0.15 in)←…
Starter jet (G.S.) #80←…
Fuel level (F.L.) 9.5~10.5 mm ←
(0.37~0.41 in)
Reed valve:
Thickness* 0.47 mm (0.019 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 107.8 mm (4.24 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…

2-10
SPECMAINTENANCE SPECIFICATIONS
Part to be tightened Thread size Q'tyT ightening torqueNm m•kg ft•lb
Rear brake master cylinder and frame M 6 ×1.0 2 10 1.0 7.2
Rear brake master cylinder cap M 4 ×0.7 2 2 0.2 1.4
Rear brake hose union bolt (caliper) M10 ×1.25 1 30 3.0 22
Rear brake hose union bolt (master cylinder) M10 ×1.25 1 30 3.0 22
Rear wheel axle and nut M20 ×1.5 1 125 12.5 90
Nipple (spoke) – 72 3 0.3 2.2
Driven sprocket and wheel hub M 8 ×1.25 6 42 4.2 30
Disc cover and rear brake caliper M 6 ×1.0 2 7 0.7 5.1
Protector and rear brake caliper M 6 ×1.0 2 7 0.7 5.1
Chain puller adjust bolt and locknut M 8 ×1.25 2 16 1.6 11
Engine mounting:
Engine and frame (front) M10 ×1.25 1 69 6.9 50
Engine and frame (lower) M10 ×1.25 1 69 6.9 50
Engine bracket and frame M 8 ×1.25 2 34 3.4 24
Engine bracket and engine M 8 ×1.25 1 34 3.4 24
Pivot shaft and nut M16 ×1.5 1 85 8.5 61
Relay arm and swingarm M14 ×1.5 1 80 8.0 58
Relay arm and connecting rod M14 ×1.5 1 80 8.0 58
Connecting rod and frame M14 ×1.5 1 80 8.0 58
Rear shock absorber and frame M10 ×1.25 1 56 5.6 40
Rear shock absorber and relay arm M10 ×1.25 1 53 5.3 38
Rear frame and frame (upper) M 8 ×1.25 1 32 3.2 23
Rear frame and frame (lower) M 8 ×1.25 2 29 2.9 21
Swingarm and brake hose holder M 5 ×0.8 4 1 0.1 0.7
Swingarm and patch M 4 ×0.7 4 2 0.2 1.4
Chain tensioner mounting M 8 ×1.25 2 19 1.9 13
Chain support and swingarm M 6 ×1.0 3 7 0.7 5.1
Seal guard and swingarm M 5 ×0.8 4 6 0.6 4.3
Fuel tank mounting M 6 ×1.0 2 10 1.0 7.2
Fuel tank and fuel cock M 6 ×1.0 2 7 0.7 5.1
Fuel tank and seat set bracket M 6 ×1.0 1 7 0.7 5.1
Fuel tank and hooking screw (fitting band) M 6 ×1.0 1 7 0.7 5.1
Fuel tank and fuel tank bracket M 6 ×1.0 4 7 0.7 5.1
Air scoop mounting M 6 ×1.0 6 4 0.4 2.9
Front fender mounting M 6 ×1.0 4 7 0.7 5.1
Rear fender mounting (front) M 6 ×1.0 2 7 0.7 5.1
Rear fender mounting (rear) M 6 ×1.0 2 11 1.1 8.0
Side cover mounting M 6 ×1.0 2 7 0.7 5.1
Seat mounting M 8 ×1.25 2 19 1.9 13
Number plate M 6 ×1.0 1 7 0.7 5.1
NOTE:

- marked portion shall be checked for torque tightening after break-in or before each race.


 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

3-2
MAINTENANCE INTERVALS
INSP
ADJ
Item Remarks
COOLING SYSTEM
Check coolant level and leakage
Check radiator cap operation
Replace coolantEvery two years
Inspect hoses
OUTSIDE NUTS AND BOLTS Refer to “STARTING
RetightenAND BREAK-IN” section
in the CHAPTER 1.
AIR FILTER
Clean and lubricateUse foam air-filter oil or
Replaceequivalent oil
FRAME
Clean and inspect
FUEL TANK, COCK
Clean and inspect
BRAKES
Adjust lever position and pedal height
Lubricate pivot point
Check brake disc surface
Check fluid level and leakage
Retighten brake disc bolts, caliper bolts,

master cylinder bolts and union bolts
Replace pads
Replace brake fluidEvery one year
FRONT FORKS
Inspect and adjust
Replace oilSuspension oil “01”
Replace oil seal
FRONT FORK OIL SEAL AND DUST SEAL
Clean and lubeLithium base grease
REAR SHOCK ABSORBER
(After
Inspect and adjustrain ride)
Lube Molybdenum disulfide grease
Retighten
CHAIN GUARD AND ROLLERS
Inspect
SWINGARM
Inspect, lube and retightenMolybdenum disulfide grease
RELAY ARM, CONNECTING ROD
Inspect, lube and retightenMolybdenum disulfide grease
STEERING HEAD
Inspect free play and retighten
Clean and lubeLithium base grease
Replace bearing
TIRE, WHEELS
Inspect air pressure, wheel run-out,

tire wear and spoke looseness
Retighten sprocket bolt
Inspect bearings
Replace bearings
LubricateLithium base grease
THROTTLE, CONTROL CABLE
Check routing and connectionYamaha cable lube or
LubricateSAE 10W-30 motor oil
After
break-
inEvery
raceEvery
thirdEvery
fifthAs re-
quired
3

3-4
PRE-OPERATION INSPECTION AND MAINTENANCE
INSP
ADJ
EC320000
PRE-OPERATION INSPECTION AND MAINTENANCE
Before riding for break-in operation, practice or a race, make sure the machine is in good operating
condition.
Before using this machine, check the following points.
EC321000
GENERAL INSPECTION AND MAINTENANCE
Item Routine Page
Coolant Check that coolant is filled up to the radiator filler cap.
Check the cooling system for leakage.P3-5~9
Fuel Check that a fresh mixture of oil and gasoline is filled in
the fuel tank. Check the fuel line for leakage.P1-12
Transmission oil Check that the oil level is correct. Check the crankcase
for leakage.P3-12~14
Gear shifter and clutch Check that gears can be shifted correctly in order and
that the clutch operates smoothly.P3-9
Throttle grip/Housing Check that the throttle grip operation and free play
are correctly adjusted. Lubricate the throttle grip and P3-10~11
housing, if necessary.
Brakes Check the play of front brake and effect of front and
rear brake.P3-17~23
Chain Check chain slack and alignment. Check that the chain
is lubricated properly.P3-24~26
Wheels Check for excessive wear and tire pressure. Check for
loose spokes and have no excessive play.P3-34~35
Steering Check that the handlebar can be turned smoothly and
have no excessive play.P3-35~36
Front forks and Check that they operate smoothly and there is no oil
rear shock absorber leakage.P3-26~33
Cables (wires) Check that the clutch and throttle cables move smooth-
ly. Check that they are not caught when the handlebars —
are turned or when the front forks travel up and down.
Muffler Check that the muffler is tightly mounted and has no
cracks.P3-15~16
Sprocket Check that the driven sprocket tightening bolt is
not loose.P3-24
Lubrication Check for smooth operation. Lubricate if necessary. P3-37
Bolts and nuts Check the chassis and engine for loose bolts and nuts. P1-16
Lead connectors Check that the CDI magneto, CDI unit, and ignition coil
are connected tightly.P1-6
Settings Is the machine set suitably for the condition of the
racing course and weather or by taking into account the
P7-1~25
results of test runs before racing? Are inspection and
maintenance completely done?

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
ENGINE REMOVAL
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)
65 Nm (6.5 m•kg, 47 ft•lb)
5 Nm (0.5 m•kg, 3.6 ft•lb)

6-2
ELECIGNITION SYSTEM
EC620000
IGNITION SYSTEM
EC621003
INSPECTION STEPS
Use the following steps for checking the possibility of the malfunctioning engine being attributable to
ignition system failure and for checking the spark plug which will not spark.
*Clean or replace
spark plug.
Primary coil
Secondary coil
Repair or replace.
Spark
Check entire ignition
system for connection.
Spark gap test
No good
No good
No good
No good
No good
No good No Spark
Check “ENGINE STOP”
button.
Pick-up coil
Source coil
Check ignition coil.
Check CDI magneto.
Replace CDI unit.
Replace.
Replace.
Replace.
Replace.
Replace.
*marked: Only when the ignition checker is used.
NOTE:
9Remove the following parts before inspection.
1) Seat
2) Fuel tank
9Use the following special tools in this inspection.
Dynamic spark tester:
YM-34487
Ignition checker:
90890-06754Pocket tester:
YU-3112-C/90890-03112
OK
OK
OK
OKReplace.
Check spark plug cap.No good
OK