2002 YAMAHA YZ125LC brake

5-21
CHASFRONT BRAKE AND REAR BRAKE
4. Install:
[Front]
9Master cylinder kit 1
9Plain washer 2
9Circlip 3
9Master cylinder boot 4
To master cylinder 5.
[Rear]
9Master cylinder kit 1
9Push rod 2
9Circlip 3
9Master cylinder boot 4
To master cylinder 5.
NOTE:
9Apply the brake fluid on the master cylinder
kit.
9Apply the lithium soap base grease on the
tip of the push rod.
9When installing the circlip, use a long nose
circlip pliers.
AFront
BRear
EC5A5310
Front master cylinder
1. Install:
9Master cylinder 1
9Master cylinder bracket 2
9Bolt (master cylinder bracket) 3
NOTE:
9Install the bracket so that the arrow mark a
face upward.
9First tighten the bolts on the upper side of
the master cylinder bracket, and then tighten
the bolts on the lower side.
9 Nm (0.9 m•kg, 6.5 ft•lb)
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3. 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-ring and brake pedal bracket.
9Install the clip with its stopper portion afac-
ing inward.
5-22
CHASFRONT BRAKE AND REAR BRAKE
2. Install:
9Brake lever 1
9Bolt (brake lever) 2
9Nut (brake lever) 3
NOTE:
Apply the lithium soap base grease on the
brake lever sliding surface, bolt and contacting
surface of the master cylinder piston.
EC5A5400
Rear master cylinder
1. Install:
9Reservoir hose 1
9Reservoir tank 2
NOTE:
Pass the reservoir hose into the hose guide.
2. Install:
9Master cylinder 1
9Bolt (master cylinder) 2
6 Nm (0.6 m•kg, 4.3 ft•lb)
6 Nm (0.6 m•kg, 4.3 ft•lb)
10 Nm (1.0 m•kg, 7.2 ft•lb)
26 Nm (2.6 m•kg, 19 ft•lb)
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5-23
CHASFRONT BRAKE AND REAR BRAKE
EC5A5911
Front brake hose
1. Install:
9Brake hose 1
To brake hose holder 2.
NOTE:
Before tightening the bolt (brake hose holder),
align the top aof the brake hose neck with the
brake hose holder bottom b. Then pass the
brake hose in front of the axle boss cand fit it
into the hose groove dso that the brake hose
does not contact the nut (wheel axle).
2. Install:
9Hose cover 1
9Plain washer 2
9Bolt [hose cover (M8)] 3
9Bolt [hose cover (M6)] 4
10 Nm (1.0 m•kg, 7.2 ft•lb)
16 Nm (1.6 m•kg, 11 ft•lb)
7 Nm (0.7 m•kg, 5.1 ft•lb)
4. Install:
9Pin 1
9Plain washer 2
9Cotter pin 3
NOTE:
After installing, check the brake pedal height.
Refer to “REAR BRAKE ADJUSTMENT” section
in the CHAPTER 3.
3. Pass the brake hose through the cable
guide 1, then through the guide aon the
protector 2.
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5-24
CHASFRONT BRAKE AND REAR BRAKE
EC5A5501
Rear brake hose
1. Install:
9Copper washer 1
9Brake hose 2
9Union bolt 3
w
Always use new copper washers.
cC
Install the brake hose so that its pipe por-
tion
a adirects as show and lightly touches
the projection
b bon the master cylinder.
30 Nm (3.0 m•kg, 22 ft•lb)
4. Install:
9Copper washer 1
9Brake hose 2
9Union bolt 3
w
Always use new copper washers.
cC
Install the brake hose so that its pipe por-
tion a a
directs as show and lightly touches
the projection b b
on the master cylinder.
30 Nm (3.0 m•kg, 22 ft•lb)
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5-25
CHASFRONT BRAKE AND REAR BRAKE
2. Install:
9Brake hose holder 1
9Screw (brake hose holder) 2
cC
After installing the brake hose holders,
make sure the brake hose does not contact
the spring (rear shock absorber). If it does,
correct its twist.
EC5A5600
Brake fluid
1. Fill:
9Brake fluid
Until the fluid level reaches “LOWER” level
line a.
w
9Use only the designated quality brake fluid:
otherwise, the rubber seals may deterio-
rate, causing leakage and poor brake per-
formance.
9Refill with the same type of brake fluid;
mixing fluids may result in a harmful chemi-
cal reaction and lead to poor performance.
9Be careful that water does not enter the
master cylinder when refilling. Water will
significantly lower the boiling point of the
fluid and may result in vapor lock.
cC
Brake fluid may erode painted surfaces or
plastic parts. Always clean up spilled fluid
immediately.
AFront
BRear
Recommended brake fluid:
DOT #4
2 Nm (0.2 m•kg, 1.4 ft•lb)
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5-26
CHASFRONT BRAKE AND REAR BRAKE
2. Air bleed:
9Brake system
Refer to “BRAKE SYSTEM AIR BLEED-
ING” section in the CHAPTER 3.
3. Inspect:
9Brake fluid level
Fluid at lower levelFill up.
Refer to “BRAKE FLUID LEVEL INSPEC-
TION” section in the CHAPTER 3.
4. Install:
[Front]
9Diaphragm
9Master cylinder cap 1
9Screw (master cylinder cap) 2
[Rear]
9Diaphragm
9Reservoir tank cap 1
9Bolt (reservoir tank) 2
cC
After installation, while pulling the lever in
or pushing down on the pedal, check
whether there is any brake fluid leaking
where the union bolts are installed respec-
tively at the master cylinder and caliper.
AFront
BRear
5. Install: (rear brake only)
9Protector 1
9Bolt (protector) 2
7 Nm (0.7 m•kg, 5.1 ft•lb)
2 Nm (0.2 m•kg, 1.4 ft•lb)
7 Nm (0.7 m•kg, 5.1 ft•lb)
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5-27
CHASFRONT FORK
Extent of removal Order Part name Q’ty Remarks
FRONT FORK REMOVAL
Preparation for
Hold the machine by placing the
removalsuitable stand under the engine.
Front wheel Refer to “FRONT WHEEL AND
REAR WHEEL”section.
Front caliper Refer to “FRONT BRAKE AND
REAR BRAKE”section.
Number plate
1 Protector 1
2 Brake hose holder 2
3 Pinch bolt (handle crown) 2 Only loosening.
4 Cap bolt 1
Loosen when disassembling the front fork.
5 Pinch bolt (under bracket) 2 Only loosening.
6 Front fork 1
1
w
Support the machine securely so there is no dan-
ger of it falling over.
Extent of removal:1Front fork removal
4 Nm (0.4 m•kg, 2.9 ft•lb)
20 Nm (2.0 m•kg, 14 ft•lb)
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)
23 Nm (2.3 m•kg, 17 ft•lb)
EC550000
FRONT FORK
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5-39
CHASFRONT FORK
7. Adjust:
9Rebound damping force
NOTE:
Turn in the damping adjuster 1finger-tight and
then turn out to the originally set position.
4. Tighten:
9Pinch bolt (handle crown) 1
9Pinch bolt (under bracket) 2
cC
Tighten the under bracket to specified
torque. If torqued too much, it may cause
the front fork to malfunction.
5. Install:
9Brake hose holder 1
9Caliper 2
9Bolt (caliper) 3
NOTE:
Fit the brake hose holder cut aover the projec-
tion bon the front fork and clamp the brake
hose.
6. Install:
9Brake hose holder 1
9Bolt (brake hose holder) 2
9Protector 3
9Bolt (protector) 4
NOTE:
When installing the brake hose holder, align the
top aof the brake hose neck with the brake
hose holder bottom b. Then pass the brake
hose 5in front of the axle boss cand fit it into
the hose groove dso that the brake hose does
not contact the nut (wheel axle).
23 Nm (2.3 m•kg, 17 ft•lb)
20 Nm (2.0 m•kg, 14 ft•lb)
23 Nm (2.3 m•kg, 17 ft•lb)
10 Nm (1.0 m•kg, 7.2 ft•lb)
10 Nm (1.0 m•kg, 7.2 ft•lb)
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