2003 YAMAHA YZ125LC lock

5-32
CHASFRONT FORK
5. Install:
9Spring guide 1
9Locknut 2
To damper rod 3.
NOTE:
9Install the spring guide with its cut afacing up-
ward.
9With its thread bfacing upward, fully finger
tighten the locknut onto the damper rod.
6. Install:
9Dust seal 1
9Stopper ring 2
9Oil seal 3
9Plain washer 4
9Slide metal 5
To inner tube 6.
NOTE:
9Apply the fork oil on the inner tube.
9When installing the oil seal, use vinyl seat a
with fork oil applied to protect the oil seal lip.
9Install the oil seal with its manufacture's marks
or number facing the axle holder side.
7. Install:
9Piston metal 1
NOTE:
Install the piston metal onto the slot on inner
tube.
8. Install:
9Outer tube 1
To inner tube 2.

5-36
CHASFRONT FORK
23. Install:
9Cushion rubber 1
9Washer 2
9Spacer 3
To cap bolt 4.
NOTE:
Install the cushion rubber with its smaller dia.end
afacing the cap bolt.
21. Measure:
9Distance a
Out of specificationTurn into the locknut.
24. Install:
9Push rod 1
9Fork spring 2
NOTE:
9Install the fork spring with the damper rod 3
pulled up.
9Install the fork spring with its smaller pitch end
facing the cap bolt. (For EUROPE)
9After installing the fork spring , hold the damper
rod end so that it will not go down.
25. Install:
9Cap bolt 1
Fully tighten the cap bolt onto the damper
rod by hand. 22. Loosen:
9Rebound damping adjuster 1
NOTE:
9Loosen the rebound damping adjuster finger
tight.
9Record the set position of the adjuster (the
amount of turning out the fully turned in posi-
tion).
Distance a a
:
20 mm (0.79 in) or more
Between damper rod 1 1
top and
locknut 2 2
top.

5-37
CHASFRONT FORK
2. Tighten:
9Cap bolt 1
3. Adjust:
9Front fork top end a
30 Nm (3.0 m•kg, 22 ft•lb)
Front fork top end (standard) a a
:
5 mm (0.20 in)
26. Tighten:
9Cap bolt (locknut) 1
NOTE:
9While compressing the fork spring, set the thin
type spanners 2between the spacer 3and
spring guide 4.
9Hold the locknut 5and tighten the cap bolt
with specified torque.
27. Install:
9Cap bolt 1
To outer tube.
NOTE:
Temporarily tighten the cap bolt.
28. Install:
9Protector guide 1
EC5552A1
Installation
1. Install:
9Front fork 1
NOTE:
9Temporarily tighten the pinch bolts (under
bracket).
9Do not tighten the pinch bolts (handle crown)
yet.
29 Nm (2.9 m•kg, 21 ft•lb)

5-49
CHASSTEERING
4. Install:
9Plain washer 1
9Ring nut 2
Tighten the ring nut using the ring nut
wrench 3.
Refer to “STEERING HEAD INSPECTION
AND ADJUSTMENT” section in the CHAP-
TER 3.
5. Check the steering shaft by turning it lock to
lock. If there is any binding, remove the
steering shaft assembly and inspect the
steering bearings.
6. Install:
9Plain washer 1
7. Install:
9Front fork 1
9Handle crown 2
NOTE:
9Temporarily tighten the pinch bolts (under
bracket).
9Do not tighten the pinch bolts (handle crown) yet.
8. Install:
9Plain washer 1
9Steering shaft nut 2
7 Nm (0.7 m•kg, 5.1 ft•lb)
145 Nm (14.5 m•kg, 105 ft•lb)

5-59
CHASREAR SHOCK ABSORBER
Extent of removal Order Part name Q’ty Remarks
REAR SHOCK ABSORBER
REMOVAL
Preparation forHold the machine by placing the
removalsuitable stand under the engine.
SeatRefer to “SEAT, FUEL TANK AND
SIDE COVERS” section.
SilencerRefer to “EXHAUST PIPE AND
SILENCER” section.
1 Clamp (air cleaner joint) 1 Loosen the screw (air cleaner joint).
2 Rear frame 1
3
Bolt (rear shock absorber-relay arm)1 Hold the swingarm.
4 Bolt (rear shock absorber-frame) 1
5 Rear shock absorber 1
6 Locknut 1
7 Adjuster 1
8 Spring guide (lower) 1
9 Spring guide (upper) 1
10 Spring (rear shock absorber) 1
11 Bearing 2 Refer to “REMOVAL POINTS”.
2
w
Support the machine securely so there is no dan-
ger of it falling over.
Extent of removal:1Rear shock absorber removal 2Rear shock absorber disassembly
1
56 Nm (5.6 m•kg, 40 ft•lb)
53 Nm (5.3 m•kg, 38 ft•lb)
32 Nm (3.2 m•kg, 23 ft•lb)
EC580000
REAR SHOCK ABSORBER
29 Nm (2.9 m•kg, 21 ft•lb)

5-63
CHASREAR SHOCK ABSORBER
EC5852B5
Rear shock absorber
1. Install:
9Dust seal 1
9O-ring 2
9Collar 3
NOTE:
9Apply the molybdenum disulfide grease on the
bearing.
9Apply the lithium soap base grease on the dust
seals, O-rings and collars.
2. Install:
9Bush 1
9Collar 2
9Dust seal 3
NOTE:
9Apply the molybdenum disulfide grease on the
bearing.
9Apply the lithium soap base grease on the
bush, collars and dust seals.
9Install the dust seals with their lips facing out-
ward.
3. Adjust:
9Spring length (installed) a
*For EUROPE
NOTE:
The length of the spring (installed) changes 1.5
mm (0.06 in) per turn of the adjuster.
cC
Never attempt to turn the adjuster beyond
the maximum or minimum setting.
4. Tighten:
9Locknut 1
Spring length (installed) a
a
:
Standard
length
251 mm (9.88 in)
*262 mm (10.31 in)Extent of
adjustment
240.5~258.5 mm
(9.47~10.18 in)
*255.5~273.5 mm
(10.06~10.77 in)

6-3
ELEC
SYSTEME D’ALLUMAGE
ZÜNDANLAGE
SISTEMA DI ACCENSIONE
TEST DER ZÜNDFUNKENSTRECKE
1. Den Zündkerzenstecker von der
Zündkerze abtrennen.
2. Den dynamischen Zündfunken-
prüfer 1(Zündungs-Prüfgerät
2) gemäß Abbildung ansch-
ließen.
9Zündkerzenstecker 3
9Zündkerze 4
AFür USA und CDN
BAußer USA und CDN
3. Den Motor mit Hilfe des Kickstar-
ters durchdrehen.
4. Die Zündfunkenstrecke kontrollie-
ren.
5. Den Motor anlassen und die
Zündfunkenstrecke vergrößern,
bis es zu Fehlzündungen kommt.
(nur für USA und CDN)
INSPEKTION DES ANSCHLUSSES
DER KUPPLUNGEN UND KABEL
1. Kontrollieren:
9Anschluß deren Kupplungen
und Kabel
Rost/Staub/Lockerheit/Kurz-
schlußReparieren oder
erneuern.
INSPEKTION DES MOTORSTOPP-
KNOPFES „ENGINE STOP“
1. Prüfen:
9Kontakt des Motorstoppknop-
fes „ENGINE STOP“
Kein Stromdurchgang, wenn gedrückt
Erneuern.
Stromdurchgang, wenn freigelassen
Erneuern.ESSAI DE L’INTERVALLE
D’ETINCELLEMENT
D’ ALLUMAGE
1. Déconnecter le capuchon de bou-
gie de la bougie.
2. Connecter le testeur dynamique
d’étincelle 1(testeur d’allumage
2) comme indiqué.
9Capuchon de bougie 3
9Bougie 4
A Pour USA et CDN
BExcepté pour USA et CDN
3. Actionner la pédale de kick.
4. Contrôler l’écartement d’étincelle
d’allumage.
5. Démarrer le moteur et augmenter
l’intervalle d’étincellement jusqu’à
ce qu’un raté se produise. (unique-
ment USA et CDN)
VERIFICATION DE CONNEXION
DES COUPLEURS ET FILS
1. Contrôler:
9Connexion des coupleurs et fils
Rouille/poussière/desserré/court
-circuit→
Réparer ou changer.
VERIFICATION DU BOUTON
D’ARRET DU MOTEUR “ENGINE
STOP”.
1. Examiner:
9Conductibilité du bouton d’arrêt
du moteur “ENGINE STOP”
Pas de continuité lorsqu’enfoncé 
Changer.
Continuité lorsque relâché  Changer.
IC622001
TEST DELLA DISTANZA TRA
GLI ELETTRODI
1. Scollegare la calotta della candela
dalla candela.
2. Collegare il tester dinamico delle
scintille 1(apparecchio per il
controllo dell’accensione 2) come
illustrato.
9Calotta della candela 3
9Candela 4
APer USA e CDN
BTranne che per USA e CDN
3. Azionare la pedivella della messa
in moto.
4. Controllare la distanza tra gli elet-
trodi dell’accensione.
5. Avviare il motore e aumentare la
distanza tra gli elettrodi finché non
si verifica uno scatto a vuoto. (sol-
tanto per USA e CDN)
IC624000
ISPEZIONE DEL
COLLEGAMENTO DI
ACCOPPIATORI E CONDUTTORI
1. Controllare:
9Collegamento di accoppiatori e
conduttori
Ruggine/Polvere/Allentamen-
to/Cortocircuito Ripararli o
sostituirli.
IC625002
ISPEZIONE DEL PULSANTE
“ARRESTO MOTORE”
1. Ispezionare:
9Comportamento del pulsante
“ARRESTO MOTORE”
Assenza di continuità mentre è premuto
Sostituirlo.
Continuità mentre viene rilasciato 
Sostituirlo.B/W B
Posizione12del seletto
re del tester
PREM-
11UTO
RILAS-Ω× ×

1
CIATO
Conduttore (+) del tester 
Conduttore Nero/Bianco 1
Conduttore (–) del tester 
Conduttore Nero 2
Distanza minima tra gli
elettrodi:
6,0 mm (0,24 in)
Ecartement d’étincelle
minimum:
6,0 mm (0,24 in)
Fil (+) de testeur 
Fil noir/blanc 1
Fil (–) de testeur 
Fil noir 2
B/W BPosition de12sélecteur du
testeur
ENFO-
11NCE
RELA-Ω× ×

1
CHE
Min. Zündfunkenstrecke:
6,0 mm (0,24 in)
Positives (+) Kabel des Prüfgerätes
Schwarz/Weiß Kabel 1
Negatives (–) Kabel des Prüfgerätes
Schwarz Kabel 2
B/W BPosition des12Wahlschaltersam Prüfgerät
GEDR-11ÜCKT
FREIGE-Ω×
×

1
LASSEN

6-4
ELECIGNITION SYSTEM
EC626003
IGNITION COIL INSPECTION
1. Inspect:
9Primary coil resistance
Out of specification Replace.
2. Inspect:
9Secondary coil resistance
Out of specification Replace.
NOTE:
9Remove the spark plug cap by turning it coun-
terclockwise and inspect.
9Install the spark plug cap by turning it clock-
wise until it is tight.
Tester (+) leadOrange lead 1
Tester (–) lead
Black lead 2
Tester (+) leadSpark plug lead 1
Tester (–) lead
Orange lead 2
Primary coil Tester selector
resistance position
0.14~0.20Ωat
Ω× 1
20°C (68°F)
Secondary coil Tester selector
resistance position
6.7~10.1kΩat
kΩ× 1
20°C (68°F)