length YAMAHA YZ125LC 2005 Betriebsanleitungen (in German)

5. GASOLINE IS HIGHLY FLAMMABLE.
Always turn off the engine while refuel-
ing. Take care to not spill any gasoline
on the engine or exhaust system.
Never refuel in the vicinity of an open
flame, or while smoking.
6. GASOLINE CAN CAUSE INJURY.
If you should swallow some gasoline,
inhale excess gasoline vapors, or allow
any gasoline to get into your eyes, con-
tact a doctor immediately. If any gaso-
line spills onto your skin or clothing,
immediately wash skin areas with soap
and water, and change your clothes.
7. ONLY OPERATE THE MACHINE IN AN
AREA WITH ADEQUATE VENTILATION.
Never start the engine or let it run for
any length of time in an enclosed area.
Exhaust fumes are poisonous. These
fumes contain carbon monoxide, which
by itself is odorless and colorless.
Carbon monoxide is a dangerous gas
which can cause unconsciousness or
can be lethal.
8. PARK THE MACHINE CAREFULLY;
TURN OFF THE ENGINE.
Always turn off the engine if you are
going to leave the machine. Do not
park the machine on a slope or soft
ground as it may fall over.
9. PROPERLY SECURE THE MACHINE
BEFORE TRANSPORTING IT.
When transporting the machine in an-
other vehicle, always be sure it is prop-
erly secured and in an upright position
and that the fuel cock is in the “OFF”
position. Otherwise, fuel may leak out
of the carburetor or fuel tank.
1C3-9-30-0 25/5/04 7:14 PM Page 6

2-1
SPECGENERAL SPECIFICATIONS
Model name: YZ125T1 (USA, CDN)
YZ125 (EUROPE, ZA)
YZ125T (AUS, NZ)
Model code number: 1C31 (USA, CDN, ZA)
1C32 (EUROPE)
1C34 (AUS, NZ)
Dimensions:USA, ZAAUS, NZ EUROPE, CDN
Overall length 2,134 mm←2,139 mm
(84.0 in) (84.2 in)
Overall width 827 mm←←
(32.6 in)
Overall height 1,316 mm←1,318 mm
(51.8 in) (51.9 in)
Seat height 992 mm←994 mm
(39.1 in) (39.1 in)
Wheelbase 1,443 mm←←
(56.8 in)
Minimum ground clearance 387 mm 388 mm 389 mm
(15.2 in) (15.3 in) (15.3 in)
Dry weight:
Without oil and fuel 86.0 kg (189.6 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 8.6~10.7 : 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 0.66 L (0.58 Imp qt, 0.69 US qt)
Total amount 0.70 L (0.62 Imp qt, 0.74 US qt)
Coolant capacity (including all routes): 0.9 L (0.79 Imp qt, 0.95 US qt)
Air filter: Wet type element
Fuel:
Type Premium unleaded gasoline
only with a research octane
number of 95 or higher
Tank capacity 8.0 L (1.76 Imp gal, 2.11 US gal)
EC200000
SPECIFICATIONSEC211000
GENERAL SPECIFICATIONS
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2-3
SPECMAINTENANCE SPECIFICATIONS
Item Standard Limit
Cylinder head:
Combustion chamber capacity 8.5 cm
3…
(0.299 Imp oz, 0.287 US oz)
Warp limit…
0.03 mm (0.0012 in)
Cylinder:
Bore size 54.000~54.014 mm 54.1 mm (2.130 in)
(2.1260~2.1265 in)
Taper limit…
0.05 mm (0.0020 in)
Out of round limit…
0.01 mm (0.0004 in)
Piston:
Piston size/ 53.957~53.972 mm…
(2.1243~2.1249 in)
Measuring point* 17.5 mm (0.69 in)…
Piston clearance 0.040~0.045 mm 0.1 mm (0.004 in)
(0.0016~0.0018 in)
Piston offset 0.5 mm (0.019 in)/EX-side…
Piston pin:
Piston pin outside diameter 14.995~15.000 mm 14.975 mm
(0.5904~0.5906 in) (0.5896 in)
Piston ring:
Sectional sketch Plain…
B=1.0 mm (0.039 in)…
T=2.35 mm (0.093 in)…
End gap (installed) 0.5~0.7 mm (0.020~0.028 in) 1.2 mm (0.047 in)
Side clearance (installed) 0.035~0.070 mm 0.1 mm (0.004 in)
(0.0014~0.0028 in)
Crankshaft:
Crank width “A” 55.90~55.95 mm …
(2.201~2.203 in)
Runout limit “C” 0.03 mm (0.0012 in) 0.05 mm (0.0020 in)
Connecting rod big end
side clearance “D” 0.06~0.64 mm (0.002~0.025 in)…
Small end free play “F” 0.8~1.0 mm (0.031~0.039 in) 2.0 mm (0.08 in)
Clutch:
Friction plate thickness 2.9~3.1 mm (0.114~0.122 in) 2.8 mm (0.110 in)
Quantity 8 …
Clutch plate thickness 1.5~1.7 mm (0.059~0.067 in) …
Quantity 7 …
Warp limit … 0.2 mm (0.008 in)
Clutch spring free length 41.2 mm (1.622 in) 39.2 mm (1.543 in)
Quantity 5 …
Clutch housing thrust clearance 0.15~0.26 mm (0.006~0.010 in) …
Clutch housing radial clearance 0.014~0.046 mm …
(0.0006~0.0018 in)
Clutch release method Inner push, cam push …
EC212000
MAINTENANCE SPECIFICATIONSEC212100
ENGINE
1C3-9-30-2A 25/5/04 7:13 PM Page 4

2-7
SPECMAINTENANCE SPECIFICATIONS
EC212201
CHASSIS
Item Standard Limit
Steering system:
Steering bearing type Taper roller bearing…
Front suspension: USA, CDN, ZA,
EUROPE
AUS, NZ
Front fork travel
300 mm (11.8 in)←…
Fork spring free length
465 mm (18.3 in)←460 mm (18.1 in)
Spring rate, STD K=4.1 N/mm K=4.0 N/mm…
(0.418 kg/mm, (0.408 kg/mm,
23.4 lb/in) 22.8 lb/in)
Optional spring/Spacer Yes←…
Oil capacity 430 cm
3435 cm3…
(15.1 Imp oz, (15.3 Imp oz,
14.5 US oz) 14.7 US oz)
Oil grade Suspension oil ←…
“S1”
Inner tube outer diameter 48 mm (1.89 in)←…
Front fork top end 5 mm (0.2 in)←…
Rear suspension: USA, CDN, ZA,
EUROPE
AUS, NZ
Shock absorber travel
132 mm (5.20 in)←…
Spring free length
260 mm (10.24 in)←…
Fitting length
252 mm (9.92 in)248 mm (9.76 in)…

240.5~258.5 mm←…
(9.47~10.18 in)
Spring rate, STD K=46.0 N/mm ←…
(4.70 kg/mm,
263.2 lb/in)
Optional spring Yes←…
Enclosed gas pressure 1,000 kPa ←…
(10 kg/cm
2,
142 psi)
Swingarm:
Swingarm free play limit
End…
1.0 mm (0.04 in)
Side clearance…
0.2~0.9 mm
(0.008~0.035 in)
1C3-9-30-2A 25/5/04 7:13 PM Page 8

2-8
SPECMAINTENANCE SPECIFICATIONS
Item Standard Limit
Wheel:
Front wheel type Spoke wheel…
Rear wheel type Spoke wheel…
Front rim size/Material 21 ×1.60/Aluminum…
Rear rim size/Material 19 ×1.85/Aluminum…
Rim runout limit:
Radial…
2.0 mm (0.08 in)
Lateral … 2.0 mm (0.08 in)
Drive chain:
Type/Manufacturer DID520DMA2 SDH/DAIDO …
Number of links 111 links+joint …
Chain slack 48~58 mm (1.9~2.3 in) …
Chain length (15 links) … 242.9 mm (9.563 in)
Front disc brake:
Disc outside dia. ×Thickness 250 ×3.0 mm 250 ×2.5 mm
(9.84 ×0.12 in) (9.84 ×0.10 in)
Pad thickness 4.4 mm (0.17 in) 1.0 mm (0.04 in)
Master cylinder inside dia. 11.0 mm (0.433 in)…
Caliper cylinder inside dia. 27.0 mm (1.063 in) ×2…
Brake fluid type DOT #4…
Rear disc brake:
Disc outside dia. ×Thickness 245 ×4.0 mm 245 ×3.5 mm
(9.65 ×0.16 in) (9.65 ×0.14 in)
Deflection limit…
0.15 mm (0.006 in)
Pad thickness 6.4 mm (0.25 in) 1.0 mm (0.04 in)
Master cylinder inside dia. 11.0 mm (0.433 in)…
Caliper cylinder insdie dia. 25.4 mm (1.000 in)…
Brake fluid type DOT #4…
Brake lever & brake pedal:
Brake lever position 95 mm (3.74 in)…
Brake pedal height Zero mm (Zero in)…
(vertical height above footrest top)
Clutch lever free play (lever end) 8~13 mm (0.31~0.51 in)…
Throttle grip free play 3~5 mm (0.12~0.20 in)…
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2-12
SPEC
GENERAL TORQUE SPECIFICATIONS/
DEFINITION OF UNITS
This chart specifies torque for standard faste-
ners with standard I.S.O. pitch threads. Torque
specifications for special components or assem-
blies are included in the applicable sections of
this book. To avoid warpage, tighten multi-faste-
ner assemblies in a crisscross fashion, in pro-
gressive stages, until full torque is reached.
Unless otherwise specified, torque specifications
call for clean, dry threads. Components should
be at room temperature.
A: Distance across flats
B: Outside thread diameter
EC230000
DEFINITION OF UNITS
EC220001
GENERAL TORQUE SPECIFICATIONS
A B TORQUE SPECIFICATION
(Nut) (Bolt)
Nm m•kg ft•lb
10 mm 6 mm 6 0.6 4.3
12 mm 8 mm 15 1.5 11
14 mm 10 mm 30 3.0 22
17 mm 12 mm 55 5.5 40
19 mm 14 mm 85 8.5 61
22 mm 16 mm 130 13 94
Unit Read Definition Measure
mm milimeter 10-
3meter Length
cm centimeter 10-2meter Length
kg kilogram 103gram Weight
N Newton 1 kg ×m/sec2Force
Nm Newton meter N ×m Torque
m•kg Meter kilogrma m ×kg Torque
Pa Pascal N/m2Pressure
N/mm Newton per millimeter N/mm Spring rate
L Liter — Volume or capacity
cm3Cubic centimeter — Volume or capacity
r/min Revolution per minute — Engine speed
1C3-9-30-2A 25/5/04 7:13 PM Page 13

3-24
SPROCKETS INSPECTION/DRIVE CHAIN INSPECTION
INSP
ADJ
EC368000
SPROCKETS INSPECTION
1. Inspect:
9Sprocket teeth a
Excessive wear Replace.
NOTE:
Replace the drive, driven sprockets and drive
chain as a set.
NOTE:
9While measuring the drive chain length push
down on the drive chain to increase its tension.
9Measure the length between drive chain roller
1and y as shown.
9Perform this measurement at two or three dif-
ferent places.
2. Remove:
9Master link clip
9Joint 1
9Drive chain 2
3. Clean:
9Drive chain
Place it in kerosene, and brush off as much
dirt as possible. Then remove the chain
from the kerosene and dry the chain.
EC369002
DRIVE CHAIN INSPECTION
1. Measure:
9Drive chain length (15 links) a
Out of specificationReplace.
Drive chain length (15 links):
Limit: 242.9 mm (9.563 in)
1C3-9-30-3B 17/5/04 1:21 PM Page 12

3-30
REAR SHOCK ABSORBER SPRING PRELOAD
ADJUSTMENTINSP
ADJ
EC36M014
REAR SHOCK ABSORBER SPRING
PRELOAD ADJUSTMENT
1. Elevate the rear wheel by placing the suit-
able stand under the engine.
2. Remove:
9Rear frame
3. Loosen:
9Locknut 1
4. Adjust:
9Spring preload
By turning the adjuster 2.
NOTE:
9Be sure to remove all dirt and mud from around
the locknut and adjuster before
adjustment.
9The length of the spring (installed) changes 1.5
mm (0.06 in) per turn of the adjuster.
cC
Never attempt to turn the adjuster beyond
the maximum or minimum setting.
5. Tighten:
9Locknut
6. Install:
9Rear frame (upper)
9Rear frame (lower)
Stiffer Increase the spring preload.
(Turn the adjuster 2 2
in.)
Softer Decrease the spring pre-
load. (Turn the adjuster 2 2
out.)
Extent of adjustment
240.5~258.5 mm
(9.47~10.18 in)
Spring length (installed) a a
:
Standard length
252 mm (9.92 in)
*248 mm (9.76 in)
*For EUROPE
32 Nm (3.2 m•kg, 23 ft•lb)
29 Nm (2.9 m•kg, 21 ft•lb)
1C3-9-30-3B 17/5/04 1:21 PM Page 24

4-32
CLUTCH AND PRIMARY DRIVEN GEARENG
EC493000
REMOVAL POINTS
EC483211
Clutch boss
1. Remove:
9Nut 1
9Lock washer 2
9Clutch boss 3
NOTE:
Straighten the lock washer tab and use the
clutch holding tool 4, 5to hold the clutch boss.
åFor USA and CDN
∫Except for USA and CDN
EC494000
INSPECTION
EC484100
Clutch housing and boss
1. Inspect:
9Clutch housing 1
Cracks/Wear/Damage  Replace.
9Clutch boss 2
Scoring/Wear/Damage Replace.
EC484201
Primary driven gear
1. Check:
9Circumferential play
Free play exists Replace.
9Gear teeth a
Wear/ Damage Replace.
EC484400
Clutch spring
1. Measure:
9Clutch spring free length a
Out of specification Replace springs as
a set.
Clutch holding tool:
YM-91042................................
4 4
90890-04086............................5 5
Clutch spring free length:
Standard
41.2 mm 39.2 mm
(1.622 in) (1.543 in)
å
∫å
1C3-9-30-4B 25/5/04 7:20 PM Page 30

5-31
CHASFRONT FORK
Base valve
1. Inspect:
9Base valve 1
Wear/DamageReplace.
ContaminationClean.
9O-ring 2
Wear/DamageReplace.
9Bush 3
Wear/DamageReplace base valve.
9Spring 4
Damage/FatigueReplace base valve.
9Air bleed screw 5
Wear/DamageReplace base valve.
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.
Standard
465 mm 460 mm
(18.3 in) (18.1 in)Fork spring free length:
Inner tube bending limit:
0.2 mm (0.008 in)
1C3-9-30-5B 28/5/04 9:07 AM Page 12