engine YAMAHA YZ125LC 2005 Notices Demploi (in French)

1-16
GEN
INFO
TORQUE-CHECK POINTS
EC1A0013
TORQUE-CHECK POINTS
Frame construction Frame to rear frame
Combined seat and tank Fuel tank to frame
Engine mounting Frame to engine
Engine bracket to engine
Engine bracket to frame
Steering Steering shaft to Steering shaft to frame
handlebar Steering shaft to handle crown
Handle crown to handlebar
Suspension Front Steering shaft to Front fork to handle crown
front fork Front fork to under bracket
Rear For link type Assembly of links
Link to frame
Link to shock absorber
Link to swingarm
Rear Installation of shock Shock absorber to frame
absorber
Rear Installation of swingarm Tightening of pivot shaft
Wheel Installation of wheel Front Tightening of front axle
Tightening of axle holder
Rear Tightening of rear axle
Wheel to sprocket
Brake Front Caliper to front fork
Brake disc to wheel
Tightening of union bolt
Master cylinder to handlebar
Tightening of air bleeder
Tightening of brake hose holder
Rear Brake pedal to frame
Brake disc to wheel
Tighening of union bolt
Master cylinder to frame
Tightening of air bleeder
Tightening of brake hose holder
Fuel system Fuel tank to fuel cock
NOTE:
Concerning the tightening torque, refer to “
MAINTENANCE SPECIFICATIONS” section in
the CHAPTER 2.
1C3-9-30-1B 14/5/04 5:03 PM Page 10

1-17
GEN
INFO
CLEANING AND STORAGE
EC1B0000
CLEANING AND STORAGE
EC1B1000
CLEANING
Frequent cleaning of your machine will enhance
its appearance, maintain good overall perfor-
mance, and extend the life of many components.
1. Before washing the machine, block off the
end of the exhaust pipe to prevent water
from entering. A plastic bag secured with a
rubber band may be used for this purpose.
2. If the engine is excessively greasy, apply
some degreaser to it with a paint brush. Do
not apply degreaser to the chain, sprockets,
or wheel axles.
3. Rinse the dirt and degreaser off with a gar-
den hose; use only enough pressure to do
the job.
cC
Excessive hose pressure may cause water
seepage and contamination of wheel bear-
ings, front forks, brakes and transmission
seals. Many expensive repair bills have re-
sulted from improper high pressure deter-
gent applications such as those available
in coin-operated car washers.
4. After the majority of the dirt has been hosed
off, wash all surfaces with warm water and a
mild detergent. Use an old toothbrush to
clean hard-to-reach places.
5. Rinse the machine off immediately with
clean water, and dry all surfaces with a soft
towel or cloth.
6. Immediately after washing, remove excess
water from the chain with a paper towel and
lubricate the chain to prevent rust.
7. Clean the seat with a vinyl upholstery clean-
er to keep the cover pliable and glossy.
8. Automotive wax may be applied to all paint-
ed or chromed surfaces. Avoid combination
cleaner-waxes, as they may contain abra-
sives.
9. After completing the above, start the engine
and allow it to idle for several minutes.
1C3-9-30-1B 14/5/04 5:03 PM Page 14

1-18
GEN
INFO
CLEANING AND STORAGE
EC1B2001
STORAGE
If your machine is to be stored for 60 days or
more, some preventive measures must be taken
to avoid deterioration. After cleaning the ma-
chine thoroughly, prepare it for storage as fol-
lows:
1. Drain the fuel tank, fuel lines, and the carbu-
retor float bowl.
2. Remove the spark plug, pour a tablespoon
of SAE 10W-30 motor oil in the spark plug
hole, and reinstall the plug. With the engine
stop switch pushed in, kick the engine over
several times to coat the cylinder walls with
oil.
3. Remove the drive chain, clean it thoroughly
with solvent, and lubricate it. Reinstall the
chain or store it in a plastic bag tied to the
frame.
4. Lubricate all control cables.
5. Block the frame up to raise the wheels off
the ground.
6. Tie a plastic bag over the exhaust pipe out-
let to prevent moisture from entering.
7. If the machine is to be stored in a humid or
salt-air environment, coat all exposed metal
surfaces with a film of light oil. Do not apply
oil to rubber parts or the seat cover.
NOTE:
Make any necessary repairs before the machine
is stored.
1C3-9-30-1B 14/5/04 5:03 PM Page 16

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
1C3-9-30-2A 25/5/04 7:13 PM Page 2

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

2-10
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 64 6.4 46
Engine and frame (lower) M10 ×1.25 1 64 6.4 46
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 5 0.5 3.6
Cable guide and frame M 5 ×0.8 2 4 0.4 2.9
Fuel tank mounting boss and frame M10 ×1.25 2 20 2.0 14
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 and fuel tank M 6 ×1.0 4 7 0.7 5.1
Air scoop and panel M 6 ×1.0 2 6 0.6 4.3
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 12 1.2 8.7
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.


 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
1C3-9-30-2A 25/5/04 7:13 PM Page 11

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

2-13
SPECCABLE ROUTING DIAGRAM
EC240000
CABLE ROUTING DIAGRAM
1Ground lead
2High tension cord
3Grommet
4Air vent hose
5Crankcase breather hose
6Y.P.V.S. breather hose
7Throttle cable
8Clutch cable
9Engine bracket (right)
0Engine bracket (left)
qAir vent hose (left)
wAir vent hose (right)
e“ENGINE STOP” button leadAPass the clutch cable on the
outside of the throttle cable and
“ENGINE STOP” button lead.
BInsert the tip of the fuel tank
breather hose into the hole in
the steering shaft cap.
CAlign the throttle cable locating
tape with the cable guide.
DPass through the cable guide
the throttle cable, “ENGINE
STOP” button lead and clutch
cable.
EPass the throttle cable and
clutch cable above the radiator
hose, and pass the “ENGINE
STOP” button lead below the
radiator hose.FInstall the ignition coil, side
core and ground lead together
to the frame.
GClamp the clutch cable to the
left engine bracket. Clamp the
clutch cable below the position-
ing grommet.
HPass the air vent hose back of
the throttle cable.
IPass the air vent hose, over-
flow hose and crankcase
breather hose between the
frame and connecting rod.
1C3-9-30-2B 27/5/04 4:18 PM Page 26

2-13
SPEC
SCHEMA DE CHEMINEMENT DES CABLES
KABELFÜHRUNGSÜBERSICHTPLAN
DIAGRAMMA DEL PASSAGGIO DEI CAVI
KABELFÜHRUNGSÜBER-
SICHTPLAN
1Erdungskabel
2Hochspannungskabel
3Gummitülle
4Belüftungsschlauch
5Kurbelgehäuse-Entlüftungsschlauch
6Y.P.V.S.-Entlüftungsschlauch
7Gaszug
8Kupplungszug
9Motorhalterung (rechts)
0Motorhalterung (links)
qBelüftungsschlauch (links)
wBelüftungsschlauch (rechts)
e„ENGINE STOP“-Schalterkabel
ADen Kupplungszug außen am Gaszug
und am „ENGINE STOP“-Schalterkabel
entlangführen.
BDie Spitze des Kraftstofftank-Belüf-
tungsschlauches in die Öffnung des
Lenkwellendeckels einsetzen.
CDas Gaszug-Lokalisierungsband an der
Kabelführung ausrichten.
DDen Gaszug, das „ENGINE STOP“-
Schalterkabel und den Kupplungszug
durch die Kabelführung führen.
EDen Gaszug und den Kupplungszug
über dem Kühlerschlauch entlang-
führen, und das „ENGINE STOP“-
Schalterkabel unter dem Kühler-
schlauch entlangführen.
FDie Zündspule, den Seitenkern und das
Erdungskabel zusammen am Rahmen
installieren.
GDen Kupplungszug an der linken Motor-
halterung festklammern. Den Kupp-
lungszug unter der Positionierungsgum-
mitülle festklammern.
HDen Belüftungsschlauch an der Rück-
seite des Gaszugs entlangführen.
IDen Belüftungsschlauch, den Überlauf-
schlauch und den Kurbelgehäuse-Ent-
lüftungsschlauch zwischen dem Rah-
men und der Verbindungsstange ent-
langführen.
SCHEMA DE
CHEMINEMENT DES
CABLES
1Fil de masse
2Câble haute tension
3Œillet en caoutchouc
4Durit de ventilation
5Durit de mise à l’air du carter moteur
6Durit de mise à l’air Y.P.V.S.
7Câble des gaz.
8Câble d'embrayage
9Support du moteur (droit)
0Support du moteur (gauche)
qDurit de ventilation (gauche)
wDurit de ventilation (droite)
eFil du bouton “ENGINE STOP”
åFaire passer le câble d’embrayage à
l’extérieur du câble des gaz et du fil du
bouton “ENGINE STOP”.
∫Insérer l’extrémité de la durit de mise à
l’air du réservoir de carburant dans l’ori-
fice du bouchon d’axe de direction.
çAligner la bande de positionnement du
câble des gaz sur le guide du câble.
∂Faire passer dans guide de câble le câble
des gaz, le fil du bouton “ENGINE
STOP” et le câble d’embrayage.
´Faire passer le câble des gaz et le câble
d’embrayage au-dessus de la durit du
radiateur, et faire passer le fil du bouton
“ENGINE STOP” sous la durit du radia-
teur.
ƒInstaller la bobine d’allumage, le fais-
ceau latéral et le fil de masse ensemble
sur le cadre.
©Brider le câble d’embrayage sur le sup-
port gauche du moteur. Brider le câble
d’embrayage sous l’œillet en caoutchouc
de positionnement.
˙Refaire passer la durit de ventilation
depuis le câble des gaz.
ˆFaire passer la durit de ventilation, la
durit de trop-plein et la durit de mise à
l’air du carter moteur entre le cadre et la
bielle.
IC240000
DIAGRAMMA DEL
PASSAGGIO DEI CAVI
1Conduttore di terra
2Cavo alta tensione
3Boccola isolante
4Flessibile di sfiato aria
5Tubo di sfiato del carter
6Tubo di sfiato Y.P.V.S.
7Cavo acceleratore
8Cavo frizione
9Staffa motore (destra)
0Staffa motore (sinistra)
qFlessibile di sfiato aria (sinistro)
wFlessibile di sfiato aria (destro)
eConduttore del pulsante “ARRESTO
MOTORE”
åFar passare il cavo della frizione dal lato
esterno del cavo dell’acceleratore e del
conduttore del pulsante “ARRESTO
MOTORE”.
∫Inserire la punta del flessibile di sfiato
del serbatoio carburante nel foro del
coperchio dell’albero dello sterzo.
çAllineare il nastro di posizione del cavo
acceleratore con la guida per cavi.
∂Far passare attraverso la guida per cavi il
cavo acceleratore, il conduttore del pul-
sante “ARRESTO MOTORE” e il cavo
frizione.
´Far passare il cavo acceleratore e il cavo
frizione sopra il flessibile radiatore, e far
passare il conduttore del pulsante
“ARRESTO MOTORE” sotto il flessibi-
le del radiatore.
ƒInstallare la bobina di accensione, il
nucleo laterale e il conduttore di terra
insieme nel telaio.
©Agganciare il cavo frizione alla staffa
sinistra del motore. Agganciare il cavo
frizione sotto la boccola isolante di posi-
zionamento.
˙Passare il flessibile di sfiato aria al dorso
del cavo acceleratore.
ˆFar passare il flessibile di sfiato aria, il
flessibile di troppopieno carburante e il
flessibile di sfiato del carter tra il telaio e
la biella.
1C3-9-30-2B 27/5/04 4:18 PM Page 27

2-14
SPECCABLE ROUTING DIAGRAM
JPass the radiator breather hose
and Y.P.V.S. breather hose
from the outside of the engine
bracket to the inside of the
downtube.
KClamp the C.D.I. magneto lead,
radiator breather hose and
Y.P.V.S. breather hose.
LClamp to the frame the C.D.I.
magneto lead and radiator
breather hose.
MPass the air vent hose, over-
flow hose and crankcase
breather hose so that they do
not contact the rear shock
absorber.
1C3-9-30-2B 27/5/04 4:18 PM Page 28