lock YAMAHA YZ125LC 2007 Owner's Guide

4-13
ENGCARBURETOR AND REED VALVE
2. Install:
9Reed valve assembly 1
9Reed valve spacer 2
3. Install:
9Carburetor joint 1
9Bolt (carburetor joint) 2
EC4652C2
Carburetor
1. Install:
9Throttle stop screw 1
9Locknut 2
9Pilot air screw 3
Pilot air screw:
2-1/4 turns out
Note the following installation points:
9Screw in the pilot air screw until it is lightly
seated.
9Back out it by the specified number of turns.
10 Nm (1.0 m•kg, 7.2 ft•lb)
2. Install:
9Starter plunger 1
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4-15
ENGCARBURETOR AND REED VALVE
7. Install:
9Throttle cable 1
9Locknut 2
9Mixing chamber top 3
9Spring (throttle valve) 4
9Ring 5
9Throttle valve 6
NOTE:
9While compressing the spring, connect the
throttle cable.
9Align the projection aon the ring with the
groove bin the needle holder 7.
8. Install:
9Mixing chamber top 1
9Screw (mixing chamber top) 2
To carburetor 3.
NOTE:
After installing, check the throttle grip for smooth
movement.
9. Install:
9Air vent hose 1
9Overflow hose 2
9Clamp 3
NOTE:
Pass the air vent hose at the rear (on the air
cleaner side) of the throttle cable 4.
EC465352
Carburetor installation
1. Install:
9Carburetor 1
NOTE:
Install the projection between the carburetor joint
slots.
4 Nm (0.4 m•kg, 2.9 ft•lb)
1C3-9-32-4A 4/6/06 2:07 PM Page 30

4-17
ENG
CULASSE, CYLINDRE ET PISTON
ZYLINDERKOPF, ZYLINDER UND KOLBEN
TESTA CILINDRO, CILINDRO E PISTONE
Etendue de dépose Ordre Nom de pièce Q’té Remarques
DEPOSE DE LA CULASSE ET DU
CYLINDRE
Selle et réservoir à essence Se reporter à la section “SELLE, RESERVOIR A
ESSENCE ET COUVERCLES LATERAUX”.
Tuyau d’échappement et silencier Se reporter à la section “TUYAU
D’ECHAPPEMENT ET SILENCIEUX”
Radiateur Se reporter à la section “RADIATEUR”.
1 Bougie 1
2 Support du moteur 2
3 Ecrou (culasse) 5 Desserrer chaque écrou d’un quart de tour puis
pousser à la suivante.
4 Culasse 1
5 Boîtier de chapet de puissance 1
6 Champignon de débrayage 1 Se reporter à “POINTS DE DEPOSE”.
7 Ecrou (cylindre) 4
8 Cylindre 1
AusbauumfangReihen-
TeilenameStück-
Bemerkungen
folgezahl
AUSBAU DES ZYLINDERKOPFS UND
ZYLINDERS
Sitz und Kraftstofftank Siehe Abschnitt „SITZ, KRAFTSTOFFTANK UND
SEITENDECKEL“.
Auspuffrohr und Schalldämpfer Siehe Abschnitt „AUSPUFFROHR UND
SCHALLDÄMPFER“.
Kühler Siehe Abschnitt „KÜHLER“.
1 Zündkerze 1
2 Motorhalterung 2
3 Mutter (Zylinderkopf) 5 Dabei jede Mutter nur jeweils 1/4 Drehung
lösen, bis alle Muttern locker sind.
4 Zylinderkopf 1
5 Leistungsventilgehäuse 1
6 Schubstange 1 Siehe unter „AUSBAUPUNKTE“.
7 Mutter (Zylinder) 4
8 Zylinder 1
ZYLINDERKOPF, ZYLINDER UND KOLBEN
ZYLINDERKOPF UND ZYLINDER
Ausbauumfang:1Ausbau des Zylinderkopfes2Ausbau des Zylinders
IC470000
TESTA CILINDRO, CILINDRO E PISTONE
IC478000
TESTA CILINDRO E CILINDRO
Ampiezza della rimozione:1Rimozione della testa cilindro2Rimozione del cilindro
Ampiezza della rimozione Ordine Particolare Quantità Osservazioni
RIMOZIONE DELLA TESTA
CILINDRO E DEL CILINDRO
Sella e serbatoio del carburante Consultare la sezione “SELLA, SERBATOIO DEL
CARBURANTE E COPERTURE LATERALI”.
Tubo di scarico e silenziatore Consultare la sezione “TUBO DI SCARICO E
SILENZIATORE”.
Radiatore Consultare la sezione “RADIATORE”
1 Candela 1
2 Staffa del motore 2
3 Dado (testa cilindro) 5 Allentare ciascun dado di 1/4 di giro
e toglierli dopo avere allentato tutti i dadi.
4 Testa cilindro 1
5 Carcassa della valvola di potenza 1
6 Asta di spinta 1 Consultare “PUNTI DI RIMOZIONE”.
7 Dado (cilindro) 4
8 Cilindro 1
Preparazione per
la rimozione
Vorbereitung für den Ausbau
1
2
1
2
1
2
CULASSE, CYLINDRE ET PISTON
CULASSE ET CYLINDRE
Etendue de dépose:1Dépose de la culasse2Dépose du cylindre
Préparation
pour la dépose
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4-28
ENG
CULASSE, CYLINDER ET PISTON
ZYLINDERKOPF, ZYLINDER UND KOLBEN
TESTA CILINDRO, CILINDRO E PISTONE
3. Einbauen:
9Mutter (Zylinder) 1
HINWEIS:
Die Muttern über Kreuz in mehreren
Schritten festziehen.
4. Einbauen:
9Hülse 1
9Schubstange 2
9Unterlegscheibe 3
9Schraube (Schubstange) 4
HINWEIS:
9Die im Werkzeugsatz enthaltene
Hülse 5einsetzen, um die Schrau-
be (Schubstange) einzubauen.
9Danach nicht vergessen, die Hülse
zu entfernen.
3. Installare:
9Dado (cilindro) 1
NOTA:
Serrare i dadi in sequenza, usando uno
schema incrociato.
4. Installare:
9Piattello 1
9Asta di spinta 2
9Rosetta 3
9Bullone (asta di spinta) 4
NOTA:
9Per installare il bullone (asta di spin-
ta), collocare il piattello 5incluso nel
kit di utensili del proprietario.
9Non dimenticare di togliere il piattel-
lo.
Zylinderkopf und Zylinder
1. Auftragen:
9Motoröl
Auf Kolben 1, Kolbenring 2
und Zylinderfläche.
2. Einbauen:
9Zylinder 1
dD
Darauf achten, dass der Kolbenring
richtig positioniert ist.
Zylinderblock mit einer Hand
anbringen, während der Kolbenring
mit der anderen Hand zusammen-
gedrückt wird.
HINWEIS:
Nachdem das Leistungsventil einge-
baut wurde, dieses auf glatte Bewe-
gung prüfen.
Culasse et cylindre
1. Appliquer:
9Huile du moteur
Sur le piston 1, le segment 2
et la surface de cylindre.
2. Monter:
9Cylindre 1
fF
Veiller à positionner le segment cor-
rectement.
Mettre d’une main, le cylindre en
place tout en comprimant le segment
de l’autre.
N.B.:
Après avoir monter, contrôler si elle se
déplace régulièrement.
3. Monter:
9Ecrou (cylindre) 1
N.B.:
Serrer les écrous par étapes en utilisant
un modèle déntre croisement.
4. Monter:
9Collerette 1
9Champignon de débrayage 2
9Rondelle plain 3
9Boulon (champignon de débra-
yage) 4
N.B.:
9Poser le collet 5fourni dans la trous-
se d’outils pour mettre le boulon en
place (champignon de débrayage).
9Ne pas oublier d’enlever le collet.
IC4753A2Testa cilindro e cilindro
1. Applicare:
9Olio per motori
Sul pistone 1, sulla fascia ela-
stica 2e sulla superficie del
cilindro.
2. Installare:
9Cilindro 1
iI
Assicurarsi che la fascia elastica sia
posizionata correttamente. Installare
il cilindro con una mano comprimen-
do allo stesso tempo la fascia elastica
con l’altra mano.
NOTA:
Dopo l’installazione, controllare che il
pistone si muova senza difficoltà.
30 Nm (3,0 m•kg, 22 ft•lb)
5 Nm (0,5 m•kg, 3,6 ft•lb)
30 Nm (3,0 m•kg, 22 ft•lb)
5 Nm (0,5 m•kg, 3,6 ft•lb)
30 Nm (3,0 m•kg, 22 ft•lb)
5 Nm (0,5 m•kg, 3,6 ft•lb)
1C3-9-32-4B 4/6/06 2:10 PM Page 23

4-31
CLUTCH AND PRIMARY DRIVEN GEARENG
Extent of removal Order Part name Q’ty Remarks
PRIMARY DRIVEN GEAR, PUSH
ROD AND PUSH LEVER AXLE
REMOVAL
1 Push rod 1 1
2 Circlip 1
3 Plain washer 1
4
Bearing 1
5 Ball 1
6 Push rod 2 1
7 Nut (clutch boss) 1
Use special tool.
8
Lock washer1
Refer to “REMOVAL POINTS”.
9 Clutch boss 1
10
Plain washer [D=ø34mm (1.34 in)]1
11 Primary driven gear 1
12 Bearing 1
13
Plain washer [D=ø34mm (1.34 in)]1
14 Push lever axle 1
EC498200
PRIMARY DRIVEN GEAR, PUSH ROD AND PUSH LEVER AXLE
Extent of removal:1Push rod and push lever axle removal2Push rod 1 disassembly
3Primary driven gear removal
2
3
1
1
1





3
80 Nm (8.0 m•kg, 58 ft•lb)
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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
40.1 mm 38.1 mm
(1.579 in) (1.500 in)
å
∫å
1C3-9-32-4B 4/6/06 2:11 PM Page 30

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
∫
1C3-9-32-4B 4/6/06 2:11 PM Page 34

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)
1C3-9-32-4C 4/6/06 2:12 PM Page 14

4-44
ENG
KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE
GEAR
5. Install:
9Crankcase cover (right) 1
NOTE:
Mesh the governor gear 2, and impeller shaft
gear 3with primary drive gear 4.
6. Install:
9Bolt [crankcase cover (right)] 1
NOTE:
Tighten the bolts in stage, using a crisscross
pattern.
7. Install:
9Kick starter 1
9Plain washer 2
9Bolt (kick starter) 3
NOTE:
Install the kick starter closest to but not contact-
ing the pillar tube 4.
8. Install:
9Shift pedal 1
9Bolt (shift pedal) 2
NOTE:
Align the upper line aof the shift pedal with the
center bof the crankcase projection and rotate
the shift pedal counterclockwise until it first
engages. Then install the shift pedal.
12 Nm (1.2 m•kg, 8.7 ft•lb)
10 Nm (1.0 m•kg, 7.2 ft•lb)
10 Nm (1.0 m•kg, 7.2 ft•lb)
1C3-9-32-4C 4/6/06 2:12 PM Page 16

4-53
ENGCDI MAGNETO
EC4L3000
REMOVAL POINTS
EC4L3102
Rotor
1. Remove:
9Nut (rotor) 1
9Plain washer 2
Use the rotor holding tool 3.
2. Remove:
9Rotor 1
Use the flywheel puller 2.
NOTE:
When installing the flywheel puller, turn it coun-
terclockwise.
EC4L4000
INSPECTION
EC4L4101
CDI magneto
1. Inspect:
9Rotor inner surface a
9Stator outer surface b
Damage Inspect the crankshaft runout
and crankshaft bearing.
If necessary, replace CDI magneto and/or
stator.
EC4L4200
Woodruff key
1. Inspect:
9Woodruff key 1
Damage Replace.
EC4L5000
ASSEMBLY AND INSTALLATION
EC4L5172
CDI magneto
1. Install:
9Stator 1
9Screw (stator) 2
NOTE:
Temporarily tighten the screw (stator) at this
point.
Rotor holding tool:
YU-1235/90890-01235
Flywheel puller:
YM-1189/90890-01189
1C3-9-32-4C 4/6/06 2:13 PM Page 34