2002 YAMAHA YZ125LC bolt pattern

4-29
ENGCYLINDER HEAD, CYLINDER AND PISTON
7. Install:
9Cylinder head 1
9Copper washer 2
9Nut (cylinder head) 3
NOTE:
Tighten the nuts (cylinder head) in stage, using a
crisscross pattern.
8. Install:
9Engine bracket 1
9Bolt (engine bracket) 2
9CDI unit bracket 3
9Engine mounting bolt (upper) 4
9. Install:
9Spark plug 1
9Spark plug cap 2
9Radiator hose 2 3
28 Nm (2.8 m•kg, 20 ft•lb)
34 Nm (3.4 m•kg, 24 ft•lb)
34 Nm (3.4 m•kg, 24 ft•lb)
20 Nm (2.0 m•kg, 14 ft•lb)
5. Install:
9Gasket (power valve housing)
9Power valve housing 1
9Bolt (power valve housing) 2
6. Install:
9O-ring 1
NOTE:
Apply the lithium soap base grease on the O-
rings.
5 Nm (0.5 m•kg, 3.6 ft•lb)
1 Nm (0.1 m•kg, 0.7 ft•lb)
5NY-9-30-4B 5/23/01 8:48 PM Page 24

4-36
ENGCLUTCH AND PRIMARY DRIVEN GEAR
EC495121
Push lever
1. Install:
9Torsion spring 1
9Push lever 2
To push lever axle 3.
NOTE:
9Install the push lever with its 5mark a
downward.
9Temporarily install the torsion spring and push
lever at this point.
2. Check:
9Push lever position
NOTE:
When pushing the push lever forward, the front
line bshould be within the range a. If not, rein-
stall the push lever.
3. Adjust:
9Push lever position 10. Install:
9Clutch cover 1
9Bolt (clutch cover) 2
NOTE:
Tighten the bolts in stage, using a crisscross
pattern.
10 Nm (1.0 m•kg, 7.2 ft•lb)
Adjustment steps:
9Remove the push lever 1from the push
lever axle 2.
9Re-install the push lever so that the projec-
tion is positioned between alignment marks
when pushing the push lever forward.
9. Install:
9Gasket (clutch cover) 1
NOTE:
Position the rack aon the push rod backward.
5NY-9-30-4B 5/23/01 8:48 PM Page 38

4-45
ENG
KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE
GEAR
5. Install:
9Crankcase cover (right) 1
NOTE:
9Position the rack aon the push rod backward.
9Mesh 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:
Install the shift pedal so that the top of the shift
pedal outer diameter ais highest without ex-
ceeding the line bconnecting the center of the
shift shaft and the bottom of the screw
[crankcase cover (left)] 3.
9. Check:
9Push lever position
Refer to “CLUTCH AND PRIMARY DRI-
VEN GEAR” section.
10 Nm (1.0 m•kg, 7.2 ft•lb)
10 Nm (1.0 m•kg, 7.2 ft•lb)
10 Nm (1.0 m•kg, 7.2 ft•lb)
5NY-9-30-4C 5/23/01 8:56 PM Page 16

4-67
ENGCRANKCASE AND CRANKSHAFT
2. Check:
9Shifter operation
9Transmission operation
Unsmooth operation Repair.
3. Apply:
9Sealant
On the crankcase (right) 1
NOTE:
Clean the contacting surface of crankcase (left
and right) before applying the sealant.
4. Install:
9Dowel pin 1
9O-ring 2
9Crankcase (right) 3
To crankcase (left) 4.
NOTE:
9Fit the crankcase (right) onto the crankcase
(left). Tap lightly on the case with soft hammer.
9When installing the crankcase, the connecting
rod should be positioned at TDC (top dead
center).
5. Install:
9Clamp 1
9Bolt (crankcase) 2
NOTE:
Tighten the crankcase tightening bolts in stage,
using a crisscross pattern.
Quick gasket®:
ACC-QUICK-GS-KT
Yamaha bond No. 1215:
90890-85505
14 Nm (1.4 m•kg, 10 ft•lb)
5NY-9-30-4D 5/24/01 8:33 PM Page 22

5-5
CHASFRONT WHEEL AND REAR WHEEL
EC595000
ASSEMBLY AND INSTALLATION
EC595101
Front wheel
1. Install:
9Bearing (left) 1
9Spacer 2
9Bearing (right) 3
9Oil seal 4
NOTE:
9Apply the lithium soap base grease on the
bearing and oil seal lip when installing.
9Use a socket that matches the outside diam-
eter of the race of the bearing.
9Left side of bearing shall be installed first.
9Install the oil seal with its manufacture’s
marks or numbers facing outward.
cC
Do not strike the inner race of the bearing.
Contact should be made only with the out-
er race.
2. Install:
9Brake disc 1
9Bolt (brake disc) 2
NOTE:
Tighten the bolts in stage, using a crisscross
pattern.
3. Install:
9Collar 1
NOTE:
9Apply the lithium soap base grease on the oil
seal lip.
9Install the collars with their projections afac-
ing the wheel.
4. Install:
9Wheel
NOTE:
Install the brake disc 1between the brake pads
2correctly.
12 Nm (1.2 m•kg, 8.7 ft•lb)
5NY-9-30-5A 5/23/01 9:00 PM Page 10

5-7
CHASFRONT WHEEL AND REAR WHEEL
EC5251A0
Rear wheel
1. Install:
9Bearing (right) 1
9Circlip 2
9Spacer 3
9Bearing (left) 4
9Oil seal 5
NOTE:
9Apply the lithium soap base grease on the
bearing and oil seal lip when installing.
9Install the bearing with seal facing outward.
9Use a socket that matches the outside diam-
eter of the race of the bearing.
9Right side of bearing shall be installed first.
9Install the oil seal with its manufacture’s
marks or numbers facing outward.
cC
Do not strike the inner race of the bearing.
Contact should be made only with the out-
er race.
2. Install:
9Brake disc 1
9Bolt (brake disc) 2
NOTE:
Tighten the bolts in stage, using a crisscross
pattern.
9. Install:
9Hose cover 1
9Plain washer 2
9Bolt [hose cover (M8)] 3
9Bolt [hose cover (M6)] 4
16 Nm (1.6 m•kg, 11 ft•lb)
7 Nm (0.7 m•kg, 5.1 ft•lb)
14 Nm (1.4 m•kg, 1.0 ft•lb)
5NY-9-30-5A 5/23/01 9:00 PM Page 14