2002 YAMAHA YZ125LC brake

4-30
ENGCLUTCH AND PRIMARY DRIVEN GEAR
Extent of removal Order Part name Q’ty Remarks
CLUTCH PLATE AND
FRICTION PLATE REMOVAL
Preparation for Drain the transmission oil.
Refer to “TRANSMISSION OIL REPLACE-
removalMENT“ section in the CHAPTER 3.
Bolt (brake pedal) Shift the brake pedal downward.
Clutch cable Disconnect at engine side.
1 Clutch cover 1
2 Screw (clutch spring) 5
3 Clutch spring 5
4 Pressure plate 1
5 Push rod 1
6 Plain washer 2
7 Bearing 1
8 Friction plate 8
9 Clutch plate 7
Extent of removal:1Clutch plate and friction plate removal
EC490000
CLUTCH AND PRIMARY DRIVEN GEAREC498000
CLUTCH PLATE AND FRICTION PLATE
1
10 Nm (1.0 m•kg, 7.2 ft•lb)
10 Nm (1.0 m•kg, 7.2 ft•lb)
5NY-9-30-4B 5/23/01 8:48 PM Page 26

4-38
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)
55 Nm (5.5 m•kg, 40 ft•lb)
5NY-9-30-4C 5/23/01 8:56 PM Page 2

4-58
ENGENGINE REMOVAL
Extent of removal:1Engine removal
Extent of removal Order Part name Q’ty Remarks
1 Chain cover 1
2 Nut (drive sprocket) 1
3 Lock washer 1 Refer to “REMOVAL POINTS”.
4 Drive sprocket 1
5 Clip 1
6 Bolt (brake pedal) 1
7 Brake pedal 1
8 Engine bracket 2
9 Engine mounting bolt 3
10 Pivot shaft 1
Refer to “REMOVAL POINTS”.
11 Engine 1
1







26 Nm (2.6 m•kg, 19 ft•lb)
34 Nm (3.4 m•kg, 24 ft•lb)
69 Nm (6.9 m•kg, 50 ft•lb)
69 Nm (6.9 m•kg, 50 ft•lb)
85 Nm (8.5 m•kg, 61 ft•lb)
60 Nm (6.0 m•kg, 43 ft•lb)
5 Nm (0.5 m•kg, 3.6 ft•lb)
5NY-9-30-4D 5/24/01 8:33 PM Page 4

4-59
ENGENGINE REMOVAL
EC4M3000
REMOVAL POINTS
EC4F3100
Drive sprocket
1. Remove:
9Nut (drive sprocket) 1
9Lock washer 2
NOTE:
9Straighten the lock washer tab.
9Loosen the nut while applying the rear brake.
2. Remove:
9Drive sprocket 1
9Drive chain 2
NOTE:
Remove the drive sprocket together with the dri-
ve chain.
EC4M3301
Engine removal
1. Remove:
9Pivot shaft 1
NOTE:
If the pivot shaft is pulled all the way out, the
swingarm will come loose. If possible, insert a
shaft of similar diameter into the other side of
the swingarm to support it.
2. Remove:
9Engine 1
From right side.
NOTE:
Make sure that the couplers, hoses and cables
are disconnected.
5NY-9-30-4D 5/24/01 8:33 PM Page 6

4-60
ENGENGINE REMOVAL
EC4M5000
ASSEMBLY AND INSTALLATION
EC4M5171
Engine installation
1. Install:
9Engine 1
Install the engine from right side.
9Pivot shaft 2
9Engine mounting bolt (lower) 3
9Engine mounting bolt (front) 4
9Engine bracket 5
9Bolt (engine bracket) 6
9CDI unit bracket 7
9Engine mounting bolt (upper) 8
NOTE:
Apply the molybdenum disulfide grease on the
pivot shaft.
EC4M5211
Brake pedal
1. Install:
9Spring 1
9Brake pedal 2
9O-ring 3
9Bolt (brake pedal) 4
9Clip 5
NOTE:
9Apply the lithium soap base grease on the bolt,
O-rings and brake pedal bracket.
9Install the clip with its stopper portion afacing
inward.
EC4M5311
Drive sprocket
1. Install:
9Drive sprocket 1
9Drive chain 2
NOTE:
Install the drive sprocket together with the drive
chain.
85 Nm (8.5 m•kg, 61 ft•lb)
69 Nm (6.9 m•kg, 50 ft•lb)
69 Nm (6.9 m•kg, 50 ft•lb)
34 Nm (3.4 m•kg, 24 ft•lb)
34 Nm (3.4 m•kg, 24 ft•lb)
26 Nm (2.6 m•kg, 19 ft•lb)
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4-61
ENGENGINE REMOVAL
2. Install:
9Lock washer 1
9Nut (drive sprocket) 2
NOTE:
Tighten the nut while applying the rear brake.
3. Bend the lock washer tab to lock the nut.
4. Install:
9Chain cover 1
9Screw (chain cover) 2
5 Nm (0.5 m•kg, 3.6 ft•lb)
60 Nm (6.0 m•kg, 43 ft•lb)
5NY-9-30-4D 5/24/01 8:33 PM Page 10

5-1
CHASFRONT WHEEL AND REAR WHEEL
Extent of removal Order Part name Q’ty Remarks
FRONT WHEEL REMOVAL
Preparation for
Hold the machine by placing the
removalsuitable stand under the engine.
1 Hose cover 1
2 Bolt (brake hose holder) 2 Only loosening.
3 Bolt (axle holder) 4 Only loosening.
4 Nut (front wheel axle) 1
5 Front wheel axle 1
6 Front wheel 1
7 Collar 2
8 Oil seal 2
9 Bearing 2 Refer to “REMOVAL POINTS”.
10 Brake disk 1
EC500000
CHASSISEC590000
FRONT WHEEL AND REAR WHEELEC598000
FRONT WHEEL
2
13
3
Extent of removal:1Front wheel removal2Wheel bearing removal3Brake disc removal
w
Support the machine securely so there is no dan-
ger of it falling over.
5
23 Nm (2.3 m•kg, 17 ft•lb)
23 Nm (2.3 m•kg, 17 ft•lb)
105 Nm (10.5 m•kg, 75 ft•lb)
16 Nm (1.6 m•kg, 11 ft•lb)
7 Nm (0.7 m•kg, 5.1 ft•lb)12 Nm (1.2 m•kg, 8.7 ft•lb)
10 Nm (1.0 m•kg, 7.2 ft•lb)
5NY-9-30-5A 5/23/01 9:00 PM Page 2

5-2
CHASFRONT WHEEL AND REAR WHEEL
EC598100
REAR WHEEL
Extent of removal:1Rear wheel removal2Wheel bearing removal3Brake disc removal
Extent of removal Order Part name Q’ty Remarks
REAR WHEEL REMOVAL
Preparation for
Hold the machine by placing the
removalsuitable stand under the engine.
1 Nut (rear wheel axle) 1
2 Rear wheel axle 1
3 Chain puller 2
4 Rear wheel 1 Refer to “REMOVAL POINTS”.
5 Collar 2
6 Driven sprocket 1
7 Oil seal 2
8 Circlip 1
9 Bearing 2 Refer to “REMOVAL POINTS”.
10 Brake disk 1
2
13
3
w
Support the machine securely so there is no dan-
ger of it falling over.
125 Nm (12.5 m•kg, 90 ft•lb)
14 Nm (1.4 m•kg, 10 ft•lb)
42 Nm (4.2 m•kg, 30 ft•lb)
5NY-9-30-5A 5/23/01 9:00 PM Page 4