oil YAMAHA YZ125LC 2005 Service Manual

4-33
EMBRAYAGE ET PIGNON MENE PRIMAIRE
KUPPLUNG UND PRIMÄRABTRIEBSZAHNRAD
FRIZIONE E INGRANAGGIO CONDOTTO PRIMARIOENG
Schubstange
1. Prüfen:
9Schubstange 1 1
9Lager 2
9Beilegescheibe 3
9Schubstange 2 4
9Kugel 5
Abnutzung/Beschädigung/
Biegung Erneuern.IC484810Asta di spinta
1. Ispezionare:
9Asta di spinta 1 1
9Cuscinetto 2
9Rosetta 3
9Asta di spinta 2 4
9Sfera 5
Usura/Danni/CurvaturaSosti-
tuirli.
MONTAGE UND EINBAU
Schubhebelachse
1. Einbauen:
9Schubhebelachse 1
HINWEIS:
Lithiumfett auf die Öldichtungslippe
und Schubhebelachse auftragen.
IC495000
MONTAGGIO E
INSTALLAZIONE
IC485120
Asse leva di spinta
1. Installare:
9Asse leva di spinta 1
NOTA:
Applicare il grasso a base di sapone al
litio sul bordo del paraolio e spingere
l’asse della leva di spinta.
Reibscheibe
1. Messen:
9Reibscheibendicke
Abweichung von Spezifikation
Die Reibscheiben als Satz
erneuern.
Die Reibscheiben an vier Stel-
len messen.
Kuplungsscheibe
1. Messen:
9Verzug der Kupplungsschei-
ben
Abweichung von Spezifikation
Kupplungsscheiben als Satz
erneuern.
Eine Richtplatte 1und eine
Fühlerlehre 2verwenden.
Schubhebelachse
1. Prüfen:
9Schubhebelachse 1
Abnutzung/Beschädigung
Erneuern.Disque de friction
1. Mesurer:
9Epaisseur de disque de friction
Hors-spécificationChanger
tous les disques de friction.
Mesurer chaque disque en
quatre endroits.
Disque d’embrayage
1. Mesurer:
9Voile de disque d’embrayage
Hors-spécificationChanger
tous les disques d’embrayage.
Utiliser une plaque à surfacer 1
et une jauge d’épaisseur 2.
Axe de levier de poussée
1. Examiner:
9Axe de levier de poussée 1
Usure/endommagementChan-
ger.
Tige de poussée
1. Examiner:
9Tige de poussée 1 1
9Roulement 2
9Rondelle ordinaire 3
9Tige de poussée 2 4
9Bille 5
Usure/endommagement/défor-
mationChanger.
REMONTAGE ET
MONTAGE
Axe de levier de poussée
1. Monter:
9Axe de levier de poussée 1
N.B.:
Appliquer de la graisse à base de sapo-
nification de lithium sur le joint à lèvre
et l’axe de levier de poussoir.
IC484500Disco di innesto
1. Misurare:
9Spessore del disco di innesto
Fuori specificaSostituire il
disco di innesto come set.
Misurare su tutti e quattro i
punti.
IC484600
Disco della frizione
1. Misurare:
9Svergolamento del disco della
frizione
Fuori specificaSostituire il
disco della frizione come set.
Usare un piano di riscontro 1e
uno spessimetro 2.
IC484700
Asse della leva di spinta
1. Ispezionare:
9Asse della leva di spinta 1
Usura/DanniSostituirlo.
Standard
2,9~3,1 mm 2,8 mm
(0,114~0,122 in) (0,110 in)
Reibscheibendicke:
Verzungsgrenze:
0,2 mm (0,008 in)
Valore normale
2,9~3,1 mm 2,8 mm
(0,114~0,122 in) (0,110 in)
Spessore del disco di inne-
sto:
Limite di svergolamento:
0,2 mm (0,008 in)
Limite de déformation:
0,2 mm (0,008 in)
Standard
2,9~3,1 mm 2,8 mm
(0,114~0,122 in) (0,110 in)
Epaisseur de disque de
friction:
1C3-9-30-4B 25/5/04 7:20 PM Page 33

4-34
CLUTCH AND PRIMARY DRIVEN GEARENG
EC495230
Clutch
1. Install:
9Plain washer [D=ø 34 mm (1.34 in)] 1
9Spacer 2
9Bearing 3
9Primary driven gear 4
NOTE:
Apply the transmission oil on the bearing, spacer
and primary driven gear inner circumference.
2. Install:
9Plain washer [D=ø 34 mm (1.34 in)] 1
9Clutch boss 2
3. Install:
9Lock washer 1
9Nut (clutch boss) 2
NOTE:
Use the clutch holding tool 3, 4to hold the
clutch boss.
åFor USA and CDN
∫Except for USA and CDN
4. Bend the lock washer 1tab.
80 Nm (8.0 m•kg, 58 ft•lb)
Clutch holding tool:
YM-91042 ..............................3 3
90890-04086 ..........................4 4
å
∫
1C3-9-30-4B 1/7/04 8:07 PM Page 34

4-35
CLUTCH AND PRIMARY DRIVEN GEARENG
5. Install:
9Friction plate 1
9Clutch plate 2
NOTE:
9Install the clutch plates and friction plates alter-
nately on the clutch boss, starting with a friction
plate and ending with a friction plate.
9Apply the transmission oil on the friction plates
and clutch plates.
6. Install:
9Bearing 1
9Plain washer 2
9Circlip 3
To push rod 1 4.
NOTE:
Apply the lithium soap base grease on the bear-
ing and plain washer.
7. Install:
9Push rod 2 1
9Ball 2
9Push rod 1 3
NOTE:
Apply the transmission oil the push rod 1, 2 and
ball.
8. Install:
9Pressure plate 1
9. Install:
9Clutch spring 1
9Screw (clutch spring) 2
NOTE:
Tighten the screws in stage, using a crisscross
pattern.
10 Nm (1.0 m•kg, 7.2 ft•lb)
1C3-9-30-4B 25/5/04 7:20 PM Page 36

4-37
ENG
KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE
GEAR
Extent of removal Order Part name Q’ty Remarks
RPIMARY DRIVE GEAR REMOVAL
Preparation for Drain the transmission oil.Refer to “TRANSMISSION OIL REPLACE-
removalMENT“ section in the CHAPTER 3.
Clutch cable Disconnect at engine side.
Bolt (brake pedal) Shift the brake pedal downward.
Radiator hose 4 Disconnect at water pump side.
Bolt (push rod)
Refer to “CYLINDER HEAD, CYLINDER
AND PISTON” section.
1 Kick starter 1
2 Crankcase cover (right) 1
3 Bolt (Primary drive gear) 1 Only loosening
Refer to “REMOVAL POINTS”.
4 Primary driven gear 1 Refer to “CLUTCH AND PRIMARY
DRIVEN GEAR”section.
5 Primary drive gear 1
EC4C0000
KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE GEAREC4C8000PRIMARY DRIVE GEAR
1
Extent of removal:1Primary drive gear removal
10 Nm (1.0 m•kg, 7.2 ft•lb)
10 Nm (1.0 m•kg, 7.2 ft•lb)
48 Nm (4.8 m•kg, 35 ft•lb)
1C3-9-30-4C 25/5/04 7:17 PM Page 2

4-41
ENG
KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE
GEAR
EC4C5000
ASSEMBLY AND INSTALLATION
EC4C5120
Stopper lever
1. Install:
9Torsion spring 1
9Stopper lever 2
9Bolt (stopper lever) 3
NOTE:
9Align the stopper lever roller with the slot on
segment.
9When installing the stopper lever, make sure
that the torsion spring is in the position as
shown.
EC4C5202
Shift guide and shift lever assembly
1. Install:
9Spring 1
9Pawl pin 2
9Pawl 3
To shift lever 4.
2. Install:
9Shift lever assembly 1
To shift guide 2.
3. Install:
9Shift lever assembly 1
9Shift guide 2
NOTE:
9The shift lever assembly is installed at the
same time as the shift guide.
9Apply the transmission oil on the bolt (seg-
ment) shaft.
10 Nm (1.0 m•kg, 7.2 ft•lb)
1C3-9-30-4C 25/5/04 7:17 PM Page 10

4-42
ENG
KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE
GEAR
4. Install:
9Bolt (shift guide) 1
EC4C5301
Shift shaft
1. Install:
9Roller 1
9Shift shaft 2
NOTE:
Apply the transmission oil on the roller and shift
shaft.
EC4B5302
Kick axle assembly
1. Install:
9Kick gear 1
9Plain washer 2
9Torsion spring 3
To kick axle 4.
NOTE:
Make sure the stopper aof the torsion spring
fits into the hole bon the kick axle.
2. Install:
9Spring guide 1
NOTE:
Slide the spring guide into the kick axle, make
sure the groove ain the spring guide fits on the
stopper of the torsion spring.
3. Install:
9Kick axle assembly 1
NOTE:
9Apply the transmission oil on the kick axle.
9Slide the kick axle assembly into the
crankcase, make sure the clip 2and kick axle
stopper afit into their home positions b, c.
10 Nm (1.0 m•kg, 7.2 ft•lb)
1C3-9-30-4C 25/5/04 7:17 PM Page 12

4-43
ENG
KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE
GEAR
4. Hook:
9Torsion spring 1
NOTE:
Turn the torsion spring clockwise and hook into
the proper hole ain the crankcase.
EC4C5402
Kick idle gear
1. Install:
9Kick idle gear 1
9Plain washer 2
9Circlip 3
NOTE:
Apply the transmission oil on the kick idle gear
inner circumference.
EC4C5503
Primary drive gear
1. Install:
9Spacer 1
9Primary drive gear 2
9Bolt 3
NOTE:
Install the primary drive gear with its depressed
side toward you.
2. Install:
9Primary driven gear
Refer to “CLUTCH AND PRIMARY DRI-
VEN GEAR” section.
3. Tighten:
9Bolt (primary drive gear) 1
NOTE:
Place an aluminum plate abetween the teeth of
the primary drive gear 2and driven gear 3.
4. Install:
9Dowel pin 1
9Gasket [crankcase cover (right)] 2
48 Nm (4.8 m•kg, 35 ft•lb)
1C3-9-30-4C 25/5/04 7:17 PM Page 14

4-47
ENGYPVS GOVERNOR
2. Install:
9Ball 1
9Retainer 2
To governor shaft 3.
NOTE:
Apply the transmission oil on the retainer and
ball.
3. Install:
9Dowel pin 1
NOTE:
9While compressing the spring, install the dowel
pin.
9Make sure the dowel pin fits into the groove a
in the retainer.
4. Install:
9Governor assembly 1
NOTE:
Align the groove ain the governor with the fork
band set the governor in the crankcase cover.
1C3-9-30-4C 25/5/04 7:17 PM Page 22

4-48
ENGWATER PUMP
Extent of removal Order Part name Q’ty Remarks
WATER PUMP DISASSEMBLY
Preparation for Crankcase cover (right)
Refer to “KICK AXLE, SHIFT SHAFT AND
removalPRIMARY DRIVE GEAR” section.
1 Water pump housing cover 1
2 Impeller shaft gear 1
3 Dowel pin 1Refer to “REMOVAL POINTS”.
4 Plain washer 1
5 Impeller shaft assembly 1
6 Bearing 1
Refer to “REMOVAL POINTS”.
7 Oil seal 2
EC4G0000
WATER PUMP
1
2
Extent of removal:1Impeller shaft removal2Oil seal removal








10 Nm (1.0 m•kg, 7.2 ft•lb)
10 Nm (1.0 m•kg, 7.2 ft•lb)
1C3-9-30-4C 25/5/04 7:17 PM Page 24

4-49
ENGWATER PUMP
EC4G3000
REMOVAL POINTS
EC4G3210
Oil seal
NOTE:
9Replace the oil seal when transmission oil or
coolant leaks out from the water pump housing
hole at the bottom.
9Do not reuse the removed bearing and oil seal.
1. Remove:
9Bearing 1
2. Remove:
9Oil seal (outside) 1
9Oil seal (inside) 2
EC4G4000
INSPECTIONEC444200
Impeller shaft assembly
1. Inspect:
9Impeller shaft assembly1
Bend/Wear/Damage Replace.
Fur deposits Clean.
1C3-9-30-4C 25/5/04 7:17 PM Page 26