lock YAMAHA YZ125LC 2004 Service Manual

5-9
CHASFRONT WHEEL AND REAR WHEEL
8. Install:
9Chain puller (right) 1
9Plain washer 2
9Nut (wheel axle) 3
NOTE:
Temporarily tighten the nut (wheel axle) at this
point.
9. Adjust:
9Drive chain slack a
Refer to “DRIVE CHAIN SLACK ADJUSTMENT”
section in the CHAPTER 3.
10. Tighten:
9Nut (wheel axle) 1
9Locknut 2
125 Nm (12.5 m•kg, 90 ft•lb)
Drive chain slack :
40~50 mm (1.6~2.0 in)
16 Nm (1.6 m•kg, 11 ft•lb)
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5-14
CHASFRONT BRAKE AND REAR BRAKE
EC5A3000
REMOVAL POINTS
EC5A3101
Brake fluid
1. Remove:
[Front]
9Master cylinder cap 1
[Rear]
9Master cylinder cap 1
9Protector
NOTE:
Do not remove the diaphragm.
AFront
BRear
2. Connect the transparent hose 1to the
bleed screw 2and place a suitable contain-
er under its end.
AFront
BRear
3. Loosen the bleed screw and drain the brake
fluid while pulling the lever in or pushing
down on the pedal.
cC
9Do not reuse the drained brake fluid.
9Brake fluid may erode painted surfaces or
plastic parts. Always clean up spilled fluid
immediately.
EC533301
Caliper piston
1. Remove:
9Caliper piston
Use compressed air and proceed carefully.
w
9Cover piston with rag and use extreme cau-
tion when expelling piston from cylinder.
9Never attempt to pry out piston.
AFront
BRear
Caliper piston removal steps:
9Insert a piece of rag into the caliper to lock
one caliper.
9Carefully force the piston out of the caliper
cylinder with compressed air.
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5-24
CHASFRONT BRAKE AND REAR BRAKE
2. Install:
9Brake hose holder 1
9Screw (brake hose holder) 2
cC
After installing the brake hose holders,
make sure the brake hose does not contact
the spring (rear shock absorber). If it does,
correct its twist.
EC5A5620
Brake fluid
1. Fill:
9Brake fluid
Until the fluid level reaches “LOWER” level
line a.
w
9Use only the designated quality brake fluid:
otherwise, the rubber seals may deterio-
rate, causing leakage and poor brake per-
formance.
9Refill with the same type of brake fluid;
mixing fluids may result in a harmful chemi-
cal reaction and lead to poor performance.
9Be careful that water does not enter the
master cylinder when refilling. Water will
significantly lower the boiling point of the
fluid and may result in vapor lock.
cC
Brake fluid may erode painted surfaces or
plastic parts. Always clean up spilled fluid
immediately.
AFront
BRear
Recommended brake fluid:
DOT #4
1 Nm (0.1 m•kg, 0.7 ft•lb)
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5-24
CHAS
FREIN AVANT ET FREIN ARRIERE
VORDERRADBREMSE UND HINTERRADBREMSE
FRENO ANTERIORE E FRENO POSTERIORE
2. Einbauen:
9Bremsschlauchhalter 1
9Schraube (Bremsschlauchhal-
ter) 2
dD
Nachdem die Bremsschlauchhalter
eingebaut wurden, darauf achten,
daß der Bremsschlauch die Feder
(Hinterrad-Stoßdämpfer) nicht
berührt. Anderenfalls die Verdre-
hung berichtigen.
Bremsflüssigkeit
1. Füllen:
9Bremsflüssigkeit
Bis der Flüssigkeitsstand die
Standlinie „LOWER“ a
erreicht.
W
9Nur bezeichnete Qualitätsbrems-
flüssigkeit verwenden; anderen-
falls können die Gummidichtun-
gen angegriffen werden, wodurch
Undichtheiten und schlechte
Bremswirkung entstehen können.
9Zum Nachfüllen dieselbe Brems-
flüssigkeit verwenden; das
Mischen von Bremsflüssigkeiten
kann schädliche chemische Vor-
gänge hervorrufen und zu
schlechter Bremsleistung führen.
9Man achte darauf, daß beim Nach-
füllen kein Wasser in den Steuer-
zylinder gelangt. Wasser setzt den
Siedepunkt erheblich herab und
kann Dampfblasenbildung verur-
sachen.
dD
Bremsflüssigkeit kann lackierte
Flächen oder Plastikteile angreifen.
Deshalb ist vergossene Bremsflüs-
sigkeit sofort abzuwischen.
AVorne
BHinten
2. Monter:
9Support de tuyau de frein 1
9
Vis (support de tuyau de frein) 2
fF
Après avoir installé les supports de
tuyau de frein, s’assurer que le tuyau
de frein ne touche pos le ressort
(amortisseur arrière) S’il le touche,
corriger le coude.
Liquide de frein
1. Remplir:
9Liquide de frein
Jusqu’à ce que le liquide
atteigne le niveau “LOWER”
a.
XG
9La qualité du liquide de frein utilisé
doit être conforme aux normes spé-
cifiées, sinon les joints en caout-
chouc risquent de se détériorer, ce
qui causera des fuites et un mauvais
fonctionnement du frein.
9Toujours utiliser la même marque
de liquide de frein. Le mélange de
liquides de marques différentes
risque de provoquer une réaction
chimique nuisible au fonctionne-
ment du frein.
9Lorsqu’on ajoute du liquide, faire
attention de ne pas laisser pénétrer
de l’eau dans le maître-cylindre.
L’eau risque d’abaisser fortement
le point d’ébullition et de provoquer
le phénomène appelé “VAPOR
LOCK”.
fF
Le liquide de frein attaque les sur-
faces peintes et le plastique. Si on en
renverse, il faut l’essuyer immédiate-
ment.
AAvant
BArrière2. Installare:
9Supporto del tubo flessibile del
freno 1
9Vite (supporto del tubo flessibi-
le del freno) 2
iI
Dopo avere installato i supporti del
tubo flessibile del freno, assicurarsi
che il tubo flessibile del freno non
tocchi la molla (ammortizzatore
posteriore). Se lo fa, correggerne la
torsione.
IC5A5620
Liquido per freni
1. Riempire:
9Liquido per freni
Finché il livello del liquido rag-
giunge la linea di livello
“LOWER” a.
T
9Usare soltanto il liquido per freni
della qualità indicata: altrimenti, le
tenute in gomma possono deterio-
rarsi, provocando perdite e uno
scarso rendimento frenante.
9Rabboccare con lo stesso tipo di
liquido per freni; miscelare liquidi
diversi può portare a una reazione
chimica nociva e comporta uno
scarso rendimento.
9Fare attenzione che, durante il rab-
bocco, non entri acqua nel cilindro
principale. L'acqua abbasserà note-
volmente il punto di ebollizione del
liquido e può comportare un tam-
pone di vapore.
iI
Il liquido per freni può erodere le
superfici verniciate o le parti in pla-
stica. Ripulire sempre immediata-
mente il liquido versato.
AAnteriore
BPosteriore
Liquide de frein recom-
mandé:
DOT #4Empfohlene Bremsflüs-
sigkeit:
DOT Nr. 4Liquido per freni racco-
mandato:
DOT No. 4
1 Nm (0,1 m•kg, 0,7ft•lb)
1 Nm (0,1 m•kg, 0,7 ft•lb)
1 Nm (0,1 m•kg, 0,7 ft•lb)
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5-28
CHASFRONT FORK
EC556000
HANDLING NOTE
NOTE:
The front fork requires careful attention. So it is
recommended that the front fork be maintained
at the dealers.
cC
To prevent an accidental explosion of air,
the following instructions should be ob-
served:
9The front fork with a built-in piston rod
has a very sophisticated internal con-
struction and is particularly sensitive to
foreign material.
Use enough care not to allow any foreign
material to come in when the oil is re-
placed or when the front fork is disassem-
bled and reassembled.
9Before removing the cap bolts or front
forks, be sure to extract the air from the air
chamber completely.
EC553000
REMOVAL POINTSEC553160
Cap bolt
1. Remove:
9Cap bolt 1
From the outer tube.
NOTE:
Before removing the front fork from the machine,
loosen the cap bolt.
2. Remove:
9Cap bolt 1
NOTE:
Hold the locknut 2and remove the cap bolt.
5XE-9-30-5B 4/30/03 9:41 AM Page 6

5-29
CHASFRONT FORK
EC553201
Inner tube
1. Remove:
9Dust seal 1
9Stopper ring 2
Using slotted-head screwdriver.
cC
Take care not to scratch the inner tube.
2. Remove:
9Inner tube 1
EC553311
Damper rod
1. Remove:
9Base valve 1
9Damper rod 2
NOTE:
Use a damper rod holder 3to lock the
damper rod.
EC554000
INSPECTIONEC554100
Damper rod
1. Inspect:
9Damper rod 1
Bend/DamageReplace damper rod.
cC
The front fork with a built-in piston rod has
a very sophisticated internal construction
and is particularly sensitive to foreign ma-
terial.
Use enough care not to allow any foreign
material to come in when the oil is re-
placed or when the front fork is disassem-
bled and reassembled.
Oil seal removal steps:
9Push in slowly athe inner tube just be-
fore it bottoms out and then pull it back
quickly b.
9Repeat this step until the inner tube can
be pulled out from the outer tube.
Damper rod holder:
YM-01494/90890-01494
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5-30
CHASFRONT FORK
EC554200
Base valve
1. Inspect:
9Valve assembly 1
Wear/DamageReplace.
9O-ring 2
DamageReplace.
EC554400
Fork spring
1. Measure:
9Fork spring free length a
Out of specificationReplace.
EC554502
Inner tube
1. Inspect:
9Inner tube surface a
Score marksRepair or replace.
Use #1,000 grit wet sandpaper.
Damaged oil lock pieceReplace.
9Inner tube bends
Out of specificationReplace.
Use the dial gauge 1.
NOTE:
The bending value is shown by one half of the
dial gauge reading.
w
Do not attempt to straighten a bent inner
tube as this may dangerously weaken the
tube.
EC554600
Outer tube
1. Inspect:
9Outer tube 1
Score marks/Wear/DamageReplace.
Standard
479 mm 474 mm
(18.9 in) (18.7 in)Fork spring free length:
Inner tube bending limit:
0.2 mm (0.008 in)
5XE-9-30-5B 4/30/03 9:41 AM Page 10

5-31
CHASFRONT FORK
EC554700
Cap bolt
1. Inspect:
9Cap bolt 1
9O-ring 2
9Air bleed screw 3
Wear/DamageReplace.
EC555000
ASSEMBLY AND INSTALLATIONEC5551D0
Front fork assembly
1. Wash the all parts in a clean solvent.
2. Install:
9Damper rod 1
To inner tube 2.
cC
To install the damper rod into the inner
tube, hold the inner tube aslant. If the inner
tube is held vertically, the damper rod may
fall into it, damaging the valve inside.
3. Install:
9Copper washer 1
9O-ring 2
9Base valve 3
To inner tube 4.
4. Tighten:
9Base valve 1
NOTE:
9Use a damper rod holder 2to lock the damper
rod 3.
9Apply the LOCTITE
®on the base valve thread.
Damper rod holder:
YM-01494/90890-01494
55 Nm (5.5 m•kg, 40 ft•lb)
5XE-9-30-5B 4/30/03 9:41 AM Page 12

5-32
CHASFRONT FORK
5. Install:
9Spring guide 1
9Locknut 2
To damper rod 3.
NOTE:
9Install the spring guide with its smaller dia. end
afacing downward.
9With its thread bfacing upward, fully finger
tighten the locknut onto the damper rod.
6. Install:
9Dust seal 1
9Stopper ring 2
9Oil seal 3
9Oil seal washer 4
9Slide metal 5
To inner tube 6.
NOTE:
9Apply the fork oil on the inner tube.
9When installing the oil seal, use vinyl seat a
with fork oil applied to protect the oil seal lip.
9Install the oil seal with its manufacture's marks
or number facing the axle holder side.
9Install the oil seal washer with its projections b
facing upward.
7. Install:
9Piston metal 1
NOTE:
Install the piston metal onto the slot on inner
tube.
8. Install:
9Outer tube 1
To inner tube 2.
5XE-9-30-5B 4/30/03 9:41 AM Page 14

5-36
CHASFRONT FORK
21. Measure:
9Distance a
Out of specificationTurn into the locknut.
23. Install:
9Push rod 1
9Fork spring 2
NOTE:
9Install the fork spring with the damper rod 3
pulled up.
9After installing the fork spring , hold the damper
rod end so that it will not go down.
24. Install:
9Spring seat 1
9Cap bolt 2
NOTE:
Fully finger tighten the cap bolt onto the damper
rod.
25. Tighten:
9Cap bolt (locknut) 1
NOTE:
Hold the locknut 2and tighten the cap bolt with
specified torque.
22. Loosen:
9Rebound damping adjuster 1
NOTE:
9Loosen the rebound damping adjuster finger
tight.
9Record the set position of the adjuster (the
amount of turning out the fully turned in posi-
tion).
Distance a a
:
19 mm (0.75 in) or more
Between damper rod 1 1
top and
locknut 2 2
top.
29 Nm (2.9 m•kg, 21 ft•lb)
5XE-9-30-5B 4/30/03 9:42 AM Page 22