maintenance YAMAHA YZ125LC 2011 Owners Manual

FOREWORD
INTRODUCTION
Congratulations on your purchase of
a Yamaha YZ series. This model is
the culmination of Yamaha's vast ex-
perience in the production of paceset-
ting racing machines. It represents
the highest grade of craftsmanship
and reliability that have made Yama-
ha a leader.
This manual explains operation, in-
spection, basic maintenance and tun-
ing of your machine. If you have any
questions about this manual or your
machine, please contact your Yama-
ha dealer.
Yamaha continually seeks advance-
ments in product design and quality.
Therefore, while this manual contains
the most current product information
available at the time of printing, there
may be minor discrepancies between
your machine and this manual. If you
have any questions concerning this
manual, please consult your Yamaha
dealer.
PLEASE READ THIS MANUAL
CAREFULLY AND COMPLETELY
BEFORE OPERATING THIS MA-
CHINE. DO NOT ATTEMPT TO OP-
ERATE THIS MACHINE UNTIL YOU
HAVE ATTAINED A SATISFACTO-
RY KNOWLEDGE OF ITS CON-
TROLS AND OPERATING
FEATURES AND UNTIL YOU HAVE
BEEN TRAINED IN SAFE AND
PROPER RIDING TECHNIQUES.
REGULAR INSPECTIONS AND
CAREFUL MAINTENANCE,
ALONG WITH GOOD RIDING
SKILLS, WILL ENSURE THAT YOU
SAFETY ENJOY THE CAPABILI-
TIES AND THE RELIABILITY OF
THIS MACHINE.
IMPORTANT MANUAL
INFORMATION
Particularly important information is
distinguished in this manual by the
following notations.
This is the safety alert symbol. It is
used to alert you to potential per-
sonal injury hazards. Obey all safe-
ty messages that follow this
symbol to avoid possible injury or
death.
A WARNING indicates a hazardous
situation which, if not avoided,
could result in death or serious in-
jury.
A NOTICE indicates special pre-
cautions that must be taken to
avoid damage to the vehicle or oth-
er property.
A TIP provides key information to
make procedures easier or clearer.
SAFETY INFORMATION
THIS MACHINE IS DESIGNED
STRICTLY FOR COMPETITION
USE, ONLY ON A CLOSED
COURSE. It is illegal for this machine
to be operated on any public street,
road, or highway. Off-road use on
public lands may also be illegal.
Please check local regulations before
riding.
• THIS MACHINE IS TO BE OPER-
ATED BY AN EXPERIENCED RID-
ER ONLY.
Do not attempt to operate this ma-
chine at maximum power until you
are totally familiar with its character-
istics.
• THIS MACHINE IS DESIGNED TO
BE RIDDEN BY THE OPERATOR
ONLY.
Do not carry passengers on this
machine.
• ALWAYS WEAR PROTECTIVE
APPAREL.
When operating this machine, al-
ways wear an approved helmet with
goggles or a face shield. Also wear
heavy boots, gloves, and protective
clothing. Always wear proper fitting
clothing that will not be caught in
any of the moving parts or controls
of the machine.• ALWAYS MAINTAIN YOUR MA-
CHINE IN PROPER WORKING
ORDER.
For safety and reliability, the ma-
chine must be properly maintained.
Always perform the pre-operation
checks indicated in this manual.
Correcting a mechanical problem
before you ride may prevent an ac-
cident.
• GASOLINE IS HIGHLY FLAMMA-
BLE.
Always turn off the engine while re-
fueling. 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.
• GASOLINE CAN CAUSE INJURY.
If you should swallow some gaso-
line, inhale excess gasoline vapors,
or allow any gasoline to get into
your eyes, contact a doctor immedi-
ately. If any gasoline spills onto
your skin or clothing, immediately
wash skin areas with soap and wa-
ter, and change your clothes.
• 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 poison-
ous. These fumes contain carbon
monoxide, which by itself is odor-
less and colorless. Carbon monox-
ide is a dangerous gas which can
cause unconsciousness or can be
lethal.
• PARK THE MACHINE CAREFUL-
LY; 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.
• THE ENGINE, EXHAUST PIPE,
MUFFLER, AND OIL TANK WILL
BE VERY HOT AFTER THE EN-
GINE HAS BEEN RUN.
Be careful not to touch them or to
allow any clothing item to contact
them during inspection or repair.
• PROPERLY SECURE THE MA-
CHINE BEFORE TRANSPORTING
IT.
When transporting the machine in
another vehicle, always be sure it is
properly 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.

CONTENTS
CHAPTER 1
GENERAL INFOR-
MATION
LOCATION OF IMPORTANT
LABELS............................ 1-1
DESCRIPTION ................. 1-5
CONSUMER
INFORMATION................. 1-6
INCLUDED PARTS .......... 1-6
IMPORTANT
INFORMATION................. 1-6
CHECKING OF
CONNECTION .................. 1-7
SPECIAL TOOLS ............. 1-8
CONTROL
FUNCTIONS ................... 1-11
STARTING AND
BREAK-IN ...................... 1-12
TORQUE-CHECK
POINTS........................... 1-13
CLEANING AND
STORAGE ...................... 1-14
CHAPTER 2
SPECIFICATIONS
GENERAL
SPECIFICATIONS ............ 2-1
MAINTENANCE
SPECIFICATIONS ............ 2-2
TIGHTENING TORQUES . 2-7
CABLE ROUTING
DIAGRAM ....................... 2-12
CHAPTER 3
REGULAR INSPEC-
TION AND AD-
JUSTMENTS
MAINTENANCE
INTERVALS ...................... 3-1
PRE-OPERATION
INSPECTION AND
MAINTENANCE................ 3-5
ENGINE ............................ 3-6
CHASSIS .......................... 3-9
ELECTRICAL ................. 3-19
CHAPTER 4
ENGINE
SEAT, FUEL TANK AND
SIDE COVERS.................. 4-1
EXHAUST PIPE AND
SILENCER ........................ 4-3
RADIATOR ....................... 4-5
CARBURETOR AND
REED VALVE ................... 4-7
CYLINDER HEAD, CYLIN-
DER AND PISTON ......... 4-12
CLUTCH ......................... 4-19
KICK SHAFT AND
SHIFT SHAFT ................. 4-23
YPVS GOVERNOR......... 4-28
WATER PUMP................ 4-30
CDI MAGNETO............... 4-33
ENGINE REMOVAL ....... 4-35
CRANKCASE AND
CRANKSHAFT ............... 4-39
TRANSMISSION, SHIFT
CAM AND SHIFT
FORK .............................. 4-44
CHAPTER 5
CHASSIS
FRONT WHEEL AND
REAR WHEEL ..................5-1
FRONT BRAKE AND
REAR BRAKE ..................5-6
FRONT FORK .................5-16
HANDLEBAR..................5-24
STEERING ......................5-29
SWINGARM ....................5-33
REAR SHOCK
ABSORBER ....................5-38
CHAPTER 6
ELECTRICAL
ELECTRICAL
COMPONENTS AND
WIRING DIAGRAM ...........6-2
IGNITION SYSTEM...........6-3
CHAPTER 7
TUNING
ENGINE.............................7-1
CHASSIS ..........................7-6

1-12
STARTING AND BREAK-IN
STARTING AND BREAK-IN
FUEL
Mix oil with the gas at the ratio speci-
fied below. Always use fresh, name-
brand gasoline, and mix the oil and gas
the day of the race. Do not use premix
that is more than a few hours old.
If knocking or pinging occurs, use a
different brand of gasoline or higher
octane grade.
Never mix two types of oil in the
same batch; clotting of the oil
could result. If you wish to change
oil types, be sure to drain the fuel
tank and the carburetor float bowl
of old premix prior to filling with
the new type.
HANDLING NOTE
Before starting the machine, per-
form the checks in the pre-opera-
tion check list.
Never start or run the engine in a
closed area. The exhaust fumes are
poisonous; they can cause loss of
consciousness and death in a very
short time. Always operate the ma-
chine in a well-ventilated area.
AIR FILTER MAINTENANCE
According to "CLEANING THE AIR
FILTER ELEMENT" section in the
CHAPTER 3, apply the foam-air-filter
oil or its equivalent to the element.
(Excess oil in the element may ad-
versely affect engine starting.)
STARTING A COLD ENGINE
1. Shift the transmission into neutral.
2. Turn the fuel cock to "ON" and full
open the starter knob (CHOKE).
3. With the throttle completely
closed start the engine by kicking
the kick starter forcefully with firm
stroke.
4. Run the engine at idle or slightly
higher until it warms up: this usu-
ally takes about one or two min-
utes.
5. The engine is warmed up when it
responds normally to the throttle
with the starter knob (CHOKE)
turned off.
Do not warm up the engine for ex-
tended periods of time.
STARTING A WARM ENGINE
Do not operate the starter knob
(CHOKE). Open the throttle slightly
and start the engine by kicking the
kick starter forcefully with firm stroke.
Observe the following break-in
procedures during initial operation
to ensure optimum performance
and avoid engine damage.
BREAK-IN PROCEDURES
1. Before starting the engine, fill the
fuel tank with a break-in oil-fuel
mixture as follows.
2. Perform the pre-operation checks
on the machine.
3. Start and warm up the engine.
Check the idle speed, and check
the operation of the controls and
the "ENGINE STOP" button.
4. Operate the machine in the lower
gears at moderate throttle open-
ings for five to eight minutes. Stop
and check the spark plug condi-
tion; it will show a rich condition
during break-in.5. Allow the engine to cool. Restart
the engine and operate the ma-
chine as in the step above for five
minutes. Then, very briefly shift to
the higher gears and check full-
throttle response. Stop and check
the spark plug.
6. After again allowing the engine to
cool, restart and run the machine
for five more minutes. Full throttle
and the higher gears may be
used, but sustained full-throttle
operation should be avoided.
Check the spark plug condition.
7. Allow the engine to cool, remove
the top end, and inspect the pis-
ton and cylinder. Remove any
high spots on the piston with #600
grit wet sandpaper. Clean all
components and carefully reas-
semble the top end.
8. Drain the break-in oil-fuel mixture
from the fuel tank and refill with
the specified mix.
9. Restart the engine and check the
operation of the machine through-
out its entire operating range.
Stop and check the spark plug
condition. Restart the machine
and operate it for about 10 to 15
more minutes. The machine will
now be ready to race.
• After the break-in or before each
race, you must check the entire
machine for loose fittings and
fasteners as per "TORQUE-
CHECK POINTS". Tighten all
such fasteners as required.
• When any of the following parts
have been replaced, they must
be broken in.
CYLINDER AND CRANKSHAFT:
About one hour of break-in oper-
ation is necessary.
PISTON, RING AND GEARS:
These parts require about 30
minutes of break-in operation at
half-throttle or less. Observe the
condition of the engine carefully
during operation.
Recommended fuel:
Premium unleaded
gasoline only with a re-
search octane number
of 95 or higher.
Fuel tank capacity:
8.0 L (1.76 Imp gal, 2.11
US gal)
Mixing oil:
Recommended oil:
Yamalube "2-R"
(Yamalube racing 2-
cycle oil)
Mixing ratio: 30:1
If unavailable, use an
equivalent type of oil.
Mixing oil:
Yamalube "2-R"
Mixing ratio:
15:1

2-2
MAINTENANCE SPECIFICATIONS
MAINTENANCE SPECIFICATIONS
ENGINETransmission:
Primary reduction system Gear
Primary reduction ratio 64/19 (3.368)
Secondary reduction system Chain drive
Secondary reduction ratio 48/13 (3.692)
Transmission type Constant mesh, 6-speed
Operation Left foot operation
Gear ratio:
1st 31/13 (2.385)
2nd 29/15 (1.933)
3rd 27/17 (1.588)
4th 23/17 (1.353)
5th 24/20 (1.200)
6th 23/21 (1.095)
Chassis: USA, ZA, AUS, NZ EUROPE, CDN
Frame type Semi double cradle←
Caster angle 25.5 ° 25.6 °
Trail 105 mm (4.13 in) 107 mm (4.21 in)
Tire:
Type With tube
Size (front) 80/100-21 51M
Size (rear) 100/90-19 57M
Tire pressure (front and rear) 100 kPa (1.0 kgf/cm
2, 15 psi)
Brake:
Front brake type Single disc brake
Operation Right hand operation
Rear brake type Single disc brake
Operation Right foot operation
Suspension:
Front suspension Telescopic fork
Rear suspension Swingarm (link type monocross suspension)
Shock absorber:
Front shock absorber Coil spring/oil damper
Rear shock absorber Coil spring/gas, oil damper
Wheel travel:
Front wheel travel 300 mm (11.8 in)
Rear wheel travel 315 mm (12.4 in)
Electrical:
Ignition system CDI magneto
Item Standard Limit
Cylinder head:
Combustion chamber capacity 8.4 cm
3 (0.296 Imp oz, 0.284 US oz) ----
Warp limit ---- 0.03 mm
(0.0012 in)

2-3
MAINTENANCE SPECIFICATIONS
Cylinder:
Bore size 54.000–54.014 mm (2.1260–2.1265 in) 54.1 mm
(2.130 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 "H" 17.5 mm (0.69 in) ----
Piston clearance 0.040–0.045 mmm (0.0016–0.0018 in) 0.1 mm (0.004
in)
Piston offset 0.5 mm (0.019 in)/EX-side ----
Piston pin:
Piston pin outside diameter 14.995–15.000 mm (0.5904–0.5906 in) 14.975 mm
(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 (0.0014~0.0028 in) 0.1 mm (0.004
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) Item Standard Limit

2-4
MAINTENANCE SPECIFICATIONS
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 40.1 mm (1.579 in) 38.1 mm (1.500 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 ----
Transmission: Main axle deflec tion limit ---- 0.01 mm
(0.0004 in)
Drive axle deflection limit ---- 0.01 mm (0.0004 in)
Shifter: Shifting type Cam drum and guide bar ----
Guide bar bending limit ---- 0.05 mm (0.0020 in)
Kick starter type: Kick and mesh type ---- Kick clip friction force P=0 .8–1.2 kg (1.8–2.6 lb) ----
Air filter oil grade (oiled filter): Foam-air-filter oil or equivalent oil ----
Carburetor: USA, CDN EUROPE AUS, NZ, ZA Type/Manufacturer TMX χ38SS/
MIKUNI ←←
I.D. mark 1C37 50 1C36 40 ←----
Main jet (M.J.) #430 ←←----
Jet needle-clip position (J.N.) 6BFY43-74-3 ←←----
Cutaway (C.A.) 4.0 ←←----
Pilot jet (P.J.) #40 #45 ←----
Pilot air screw (P.A.S.) 2-1/4 ←←----
Valve seat size (V.S.) ø3.8 mm (0.15 in)←←
----
Starter jet (G.S.) #80 ←←----
Fuel level (F.L.) 9.5–10.5 mm (0.37–0.41 in)←←
----
Reed valve: Thickness 0.47 mm (0.019 in) ----
Valve stopper height 8.2–8.6 mm (0.323–0.339 in) ----
Valve bending limi t ---- 0.2 mm (0.008
in)
Item Standard Limit

2-5
MAINTENANCE SPECIFICATIONS
CHASSISCooling:
Radiator core size:
Width 107.8 mm (4.24 in) ----
Height (left) 240 mm (9.45 in) ----
Height (right) 220 mm (8.66 in) ----
Thickness 32 mm (1.26 in) ----
Radiator cap opening pressure 95–125 kPa (0.95–1.25 kg/cm
2, 13.5–17.8 psi) ----
Radiator capacity (total) 0.56 L (0.49 Imp qt, 0.59 US qt) ----
Water pump:
Type Single-suction centrifugal pump ----
Item Standard Limit
Steering system:
Steering bearing typeTaper roller bearing ----
Front suspension: USA, CDN, ZA, AUS,
NZEUROPE
Front fork travel 300 mm (11.8 in)←----
Fork spring free length 454 mm (17.9 in)←449 mm (17.7
in)
Spring rate, STD K=4.1 N/mm (0.418 kg/
mm, 23.4 lb/in)←----
Optional spring Yes←----
Oil capacity 524 cm
3 (18.4 Imp oz,
17.7 US oz)526 cm3 (18.5 Imp oz,
17.8 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, AUS,
NZEUROPE
Shock absorber travel 131.5 mm (5.18 in)←----
Spring free length Approx.265 mm (10.43
in)←----
Fitting length*----
I.D. mark (Red/1) 258 mm (10.16 in) 252 mm (9.92 in) ----
I.D. mark (Red/2) 264 mm (10.39 in) 258 mm (10.16 in) ----
I.D. mark (Red/3) 255.5 mm (10.06 in) 249.5 mm (9.82 in) ----
Preload length
1.5–18 mm (0.06–0.71
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)←----
* Spring specification varies according to the differ-
ence in the production lot.Item Standard Limit

2-6
MAINTENANCE SPECIFICATIONS
Swingarm:
Swingarm free play limit
End ---- 1.0 mm (0.04
in)
Side clearance ---- 0.2–0.9 mm
(0.008–0.035
in)
Wheel:
Front wheel type Spoke wheel ----
Rear wheel typeSpoke 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 G&B/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 (9.84 × 0.12 in) 250 × 2.5 mm
(9.84 × 0.10 in)
Pad thickness 4.4 mm (0.17 in) 1.0 mm (0.04
in)
Master cylinder inside dia. 9.52 mm (0.375 in) ----
Caliper cylinder inside dia. 22.65 mm (0.892 in) × 2 ----
Brake fluid type DOT #4 ----
Rear disc brake:
Disc outside dia.×Thickness 245 × 4.0 mm (9.65 × 0.16 in) 245 × 3.5 mm
(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 inside dia. 25.4 mm (1.000 in) × 1 ----
Brake fluid type DOT #4 ----
Brake lever and brake pedal:
Brake lever position 95 mm (3.74 in) ----
Brake pedal height (vertical height above footrest
top)Zero mm (Zero in) ----
Clutch lever free play (lever end) 8–13 mm (0.31–0.51 in) ----
Throttle grip free play3–5 mm (0.12–0.20 in) ---- Item Standard Limit

3-1
MAINTENANCE INTERVALS
REGULAR INSPECTION AND ADJUSTMENTS
MAINTENANCE INTERVALS
• The following schedule is intended as a general guide to maintenance and lubrication. Bear in mind that such factors as
weather, terrain, geographical location, and individual usage will alter the required maintenance and lubrication intervals.
If you are a doubt as to what intervals to follow in maintaining and lubricating your machine, consult your Yamaha dealer.
• Periodic inspection is essential in making full use of the machine performance. The service life of the parts varies sub-
stantially according to the environment in which the machine runs (e.g., rain, dirt, etc.). Therefore, earlier inspection is
required by reference to the list below.
ItemAfter
break-in
Every
race
(about
2.5
hours)Every
third
(about
7.5
hours)Every
fifth
(about
12.5
hours)
As re-
quiredRemarks
PISTON
Inspect and clean●●Inspect crack.
Replace●●Inspect carbon deposits and
eliminate them.
PISTON RING
Inspect●●Check ring end gap.
Replace●●
PISTON PIN, SMALL END
BEARING
Inspect●
Replace●
CYLINDER HEAD Inspect carbon deposits and
eliminate them.
Inspect and clean●●Check gasket.
Retighten●●
CYLINDER
Inspect and clean●●Inspect score marks.
Replace●Inspect wear.
YPVS
Inspect and clean●●Inspect carbon deposits and
eliminate them.
CLUTCH
Inspect and adjust●●Inspect housing, friction plate,
clutch plate and spring.
Replace●
TRANSMISSION
Replace oil●●Recommended brand: YA-
MALUBE
SAE10W-40
API service SG type or higher
JASO standard MA
Inspect●
Replace bearing●
SHIFT FORK, SHIFT CAM,
GUIDE BAR
Inspect●Inspect wear

3-2
MAINTENANCE INTERVALS
ROTOR NUT
Retighten●●
MUFFLER
Inspect●●
Clean●
Retighten●●
Replace fiber●** When the exhaust sound be-
comes louder or when a per-
formance drop is felt
CRANK
Inspect and clean●●
CARBURETOR
Inspect, adjust and clean●●
SPARK PLUG
Inspect and clean●●
Replace●
DRIVE CHAINUse chain lube.
Lubricate, slack, alignment●●Chain slack: 48–58 mm (1.9–
2.3 in)
Replace●
COOLING SYSTEM
Check coolant level and
leakage●●
Check radiator cap opera-
tion●
Replace coolant●Every two years
Inspect hoses●
OUTSIDE NUTS AND
BOLTS
Retighten●●Refer to "STARTING AND
BREAK-IN" section in the
CHAPTER 1.
AIR FILTER
Clean and lubricate●●Use foam air-filter oil or equiv-
alent oil.
Replace●
FRAME
Clean and inspect●●
FUEL TANK, COCK
Clean and inspect●● ItemAfter
break-in
Every
race
(about
2.5
hours)Every
third
(about
7.5
hours)Every
fifth
(about
12.5
hours)
As re-
quiredRemarks
3