2004 YAMAHA YZ125LC transmission oil

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)
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4-42
ENG
KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE
GEAR
EC4C5000
ASSEMBLY AND INSTALLATION
EC4C5120
Stopper lever
1. Install:
9Torsion spring 1
9Stopper lever 2
9Spacer 3
9Bolt (stopper lever) 4
NOTE:
9Align the stopper lever roller with the slot on
segment.
9When installing the stopper lever, make sure
that the torsion spring is in the position as
shown.
EC4C5202
Shift guide and shift lever assembly
1. Install:
9Spring 1
9Pawl pin 2
9Pawl 3
To shift lever 4.
2. Install:
9Shift lever assembly 1
To shift guide 2.
3. Install:
9Shift lever assembly 1
9Shift guide 2
NOTE:
9The shift lever assembly is installed at the
same time as the shift guide.
9Apply the transmission oil on the bolt (seg-
ment) shaft.
10 Nm (1.0 m•kg, 7.2 ft•lb)
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4-43
ENG
KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE
GEAR
4. Install:
9Bolt (shift guide) 1
EC4C5301
Shift shaft
1. Install:
9Roller 1
9Shift shaft 2
NOTE:
Apply the transmission oil on the roller and shift
shaft.
EC4B5302
Kick axle assembly
1. Install:
9Kick gear 1
9Plain washer 2
9Torsion spring 3
To kick axle 4.
NOTE:
Make sure the stopper aof the torsion spring
fits into the hole bon the kick axle.
2. Install:
9Spring guide 1
NOTE:
Slide the spring guide into the kick axle, make
sure the groove ain the spring guide fits on the
stopper of the torsion spring.
3. Install:
9Kick axle assembly 1
NOTE:
9Apply the transmission oil on the kick axle.
9Slide the kick axle assembly into the
crankcase, make sure the clip 2and kick axle
stopper afit into their home positions b, c.
10 Nm (1.0 m•kg, 7.2 ft•lb)
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4-44
ENG
KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE
GEAR
4. Hook:
9Torsion spring 1
NOTE:
Turn the torsion spring clockwise and hook into
the proper hole ain the crankcase.
EC4C5402
Kick idle gear
1. Install:
9Circlip 1
9Kick idle gear 2
9Plain washer 3
NOTE:
9Apply the transmission oil on the kick idle gear
inner circumference.
9Install the kick idle gear with its depressed side
atoward you.
EC4C5503
Primary drive gear
1. Install:
9Spacer 1
9Primary drive gear 2
9Bolt 3
NOTE:
Temporarily tighten the bolt at this point.
2. Install:
9Primary driven gear
Refer to “CLUTCH AND PRIMARY DRI-
VEN GEAR” section.
3. Tighten:
9Bolt (primary drive gear) 1
NOTE:
Place an aluminum plate abetween the teeth of
the primary drive gear 2and driven gear 3.
4. Install:
9Dowel pin 1
9Gasket [crankcase cover (right)] 2
55 Nm (5.5 m•kg, 40 ft•lb)
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4-48
ENGYPVS GOVERNOR
2. Install:
9Ball 1
9Retainer 2
To governor shaft 3.
NOTE:
Apply the transmission oil on the retainer and
ball.
3. Install:
9Dowel pin 1
NOTE:
9While compressing the spring, install the dowel
pin.
9Make sure the dowel pin fits into the groove a
in the retainer.
4. Install:
9Governor assembly 1
NOTE:
Align the groove ain the governor with the fork
band set the governor in the crankcase cover.
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4-50
ENGWATER PUMP
EC4G3000
REMOVAL POINTS
EC4G3110
Impeller shaft
1. Remove:
9Impeller 1
9Plain washer 2
9Impeller shaft 3
NOTE:
Hold the impeller shaft on its width across the
flats awith spanners, etc. and remove the im-
peller.
EC4G3210
Oil seal
NOTE:
It is not necessary to disassemble the water
pump, unless there is an abnormality such as
excessive change in coolant level, discoloration
of coolant, or milky transmission oil.
1. Remove:
9Bearing 1
2. Remove:
9Oil seal 1
EC4G4000
INSPECTIONEC444200
Impeller shaft
1. Inspect:
9Impeller shaft 1
Bend/Wear/Damage Replace.
Fur deposits Clean.
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4-68
ENGCRANKCASE AND CRANKSHAFT
6. Install:
9Holder 1
9Bolt (holder) 2
7. Install:
9Segment 1
9Bolt (segment) 2
NOTE:
9When installing the segment onto the shift cam
3, align the punch mark awith the dowel pin
b.
9Turn the segment clockwise until it stops and
tighten the bolt.
8. Remove:
9Sealant
Forced out on the cylinder mating surface.
9. Apply:
9Engine oil
To the crank pin, bearing, oil delivery hole
and connecting rod big end washer.
10. Check:
9Crankshaft and transmission operation
Unsmooth operation Repair.
30 Nm (3.0 m•kg, 22 ft•lb)
10 Nm (1.0 m•kg, 7.2 ft•lb)
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4-71
ENGTRANSMISSION, SHIFT CAM AND SHIFT FORK
EC4H4801
Shift fork, shift cam and segment
1. Inspect:
9Shift fork 1
Wear/Damage/Scratches Replace.
2. Inspect:
9Shift cam 1
9Segment 2
9Guide bar 3
Bend/Wear/Damage Replace.
3. Check:
9Shift fork movement
On its guide bar.
Unsmooth operation Replace shift fork
and/or guide bar.
NOTE:
For a malfunctioning shift fork, replace not only
the shift fork itself but the two gears each adja-
cent to the shift fork.
EC4H5000
ASSEMBLY AND INSTALLATION
EC4H5213
Transmission
1. Install:
95th pinion gear (23T) 1
93rd pinion gear (19T) 2
94th pinion gear (19T) 3
92nd pinion gear (15T) 4
To main axle 5.
NOTE:
9Apply the molybdenum disulfide oil on the 4th
and 5th pinion gears inner circumference and
on the end surface.
9Apply the molybdenum disulfide oil on the 2nd
and 3rd pinion gears inner circumference.
5XE-9-30-4D 3/24/03 11:14 PM Page 30