steering YAMAHA YZ125LC 2005 User Guide

3-36
STEERING HEAD INSPECTION AND ADJUSTMENT
INSP
ADJ
9Loosen the ring nut one turn.
9Retighten the ring nut using the ring nut
wrench.
w
Avoid over-tightening.
9Check the steering shaft by turning it lock to
lock. If there is any binding, remove the
steering shaft assembly and inspect the
steering bearings.
9Install the plain washer 5, handle crown 6,
plain washer 7, steering shaft nut 8, steer-
ing shaft cap 9, handlebar 0, handlebar
holder q and number plate w.
NOTE:
9The upper handlebar holder should be
installed with the punched mark aforward.
9Install the handlebar so that the marks b
are in place on both sides.
9Insert the end of the fuel breather hose e
into the hole in the steering shaft cap.
cC
First tighten the bolts on the front side of
the handlebar holder, and then tighten the
bolts on the rear side.
Ring nut wrench:
YU-33975/90890-01403
Ring nut (initial tightening):
38 Nm (3.8 m•kg, 27ft•lb)
Steering shaft nut:
145 Nm (14.5 m•kg, 105 t•lb)
Handlebar upper holder:
28 Nm (2.8 m•kg, 20 ft•lb)
Pinch bolt (handle crown):
23 Nm (2.3 m•kg, 17 ft•lb)
Number plate:
7 Nm (0.7 m•kg, 5.1 ft•lb)
Ring nut (final tightening):
7 Nm (0.7 m•kg, 5.1 ft•lb)
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5-47
CHASHANDLEBAR
14. Clamp the clamp portion aof the number
plate to the handlebar.
15. Insert the end of the fuel breather hose 1
into the hole in the steering shaft cap 2.
12. Install:
9Clutch cable 1
NOTE:
Apply the lithium soap base grease on the clutch
cable end.
13. Adjust:
9Clutch lever free play
Refer to “CLUTCH ADJUSTMENT” section in
the CHAPTER 3.
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5-48
CHASSTEERING
Extent of removal Order Part name Q’ty Remarks
STEERING REMOVAL
Preparation for
Hold the machine by placing the
removalsuitable stand under the engine.
Number plate
Handlebar Refer to “HANDLEBAR” section.
Front fender
1 Steering shaft cap 1
2 Steering shaft nut 1
3 Front fork 2 Refer to “FRONT FORK” section.
4 Handle crown 1
5 Ring nut 1 Use special tool.
Refer to “REMOVAL POINTS”.
6 Under bracket 1
7 Bearing race cover 1
8 Bearing (upper) 1
9 Bearing (lower) 1 Refer to “REMOVAL POINTS”.
10 Bearing race 2 Refer to “REMOVAL POINTS”. Extent of removal:1Under bracket removal 2Bearing removal
2
1
w
Support the machine securely so there is no dan-
ger of it falling over.
EC560000
STEERING
145 Nm (14.5 m•kg, 105 ft•lb)
23 Nm (2.3 m•kg, 17 ft•lb)
9Tighten ring nut.
38 Nm (3.8 m•kg, 27 ft•lb)
9Loosen it one turn.
9Retighten it.
7 Nm (0.7 m•kg, 5.1 ft•lb)
TIGHTENING STEPS:
20 Nm (2.0 m•kg, 14 ft•lb)
4Nm (0.4 m•kg, 2.9 ft•lb)
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5-49
CHASSTEERING
EC563000
REMOVAL POINTS
EC563202
Ring nut
1. Remove:
9Ring nut 1
Use the ring nut wrench 2.
w
Support the steering shaft so that it may
not fall down.
EC563300
Bearing (lower)
1. Remove:
9Bearing (lower) 1
Use the floor chisel 2.
cC
Take care not to damage the steering shaft
thread.
EC563400
Bearing race
1. Remove:
9Bearing race 1
Remove the bearing race using long rod 2
and the hammer.
EC564000
INSPECTION
EC564200
Steering shaft
1. Inspect:
9Steering shaft 1
Bend/Damage Replace.
Ring nut wrench:
YU-33975/90890-01403
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5-50
CHASSTEERING
EC564101
Bearing and bearing race
1. Wash the bearings and bearing races with a
solvent.
2. Inspect:
9Bearing 1
9Bearing race
Pitting/Damage Replace bearings and
bearing races as a set.
Install the bearing in the bearingraces. Spin
the bearings by hand. If the bearings hang up
or are not smooth in their operation in the
bearingraces, replace bearings and bearing
races as a set.
EC565000
ASSEMBLY AND INSTALLATION
EC5651A0
Under bracket
1. Install:
9Bearing (lower) 1
NOTE:
Apply the lithium soap base grease on the dust
seal lip and bearing inner circumference.
2. Install:
9Bearing race
9Bearing (upper) 1
9Bearing race cover 2
NOTE:
Apply the lithium soap base grease on the bear-
ing and bearing race cover lip.
3. Install:
9Under bracket 1
NOTE:
Apply the lithium soap base grease on the bear-
ing, the portion aand thread of the steering
shaft.
1 a
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5-51
CHASSTEERING
4. Install:
9Ring nut 1
Tighten the ring nut using the ring nut
wrench 2.
Refer to “STEERING HEAD INSPECTION
AND ADJUSTMENT” section in the CHAP-
TER 3.
5. Check the steering shaft by turning it lock to
lock. If there is any binding, remove the
steering shaft assembly and inspect the
steering bearings.
6. Install:
9Plain washer 1
7. Install:
9Front fork 1
9Handle crown 2
NOTE:
9Temporarily tighten the pinch bolts (under
bracket).
9Do not tighten the pinch bolts (handle crown)
yet.
8. Install:
9Plain washer 1
9Steering shaft nut 2
7 Nm (0.7 m•kg, 5.1 ft•lb)
145 Nm (14.5 m•kg, 105 ft•lb)
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5-52
CHASSTEERING
11. Adjust:
9Front fork top end a
12. Tighten:
9Pinch bolt (handle crown) 1
9Pinch bolt (under bracket) 2
cC
Tighten the under bracket to specified
torque. If torqued too much, it may cause
the front fork to malfunction.
Front fork top end (standard) a a
:
5 mm (0.20 in)
23 Nm (2.3 m•kg, 17 ft•lb)
20 Nm (2.0 m•kg, 14 ft•lb)
9. Install:
9Steering shaft cap 1
10. After tightening the nut, check the steering for
smooth movement. If not, adjust the steering
by loosening the ring nut little by little.
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