2004 YAMAHA YZ125LC Fork

3-29
REAR SHOCK ABSORBER INSPECTION
INSP
ADJ
9STANDARD POSITION:
This is the position which is back by the spe-
cific number of clicks from the fully turned-in
position.
cC
Do not force the adjuster past the minimum
or maximum extent of adjustment. The ad-
juster may be damaged.
w
Always adjust each front fork to the same
setting. Uneven adjustment can cause
poor handling and loss of stability.
3. Install:
9Rubber cap
EC36K000
REAR SHOCK ABSORBER INSPECTION
1. Inspect:
9Swingarm smooth action
Abnormal noise/Unsmooth action 
Grease the pivoting points or repair the
pivoting points.
Damage/Oil leakage Replace.
Minimum
20 clicks out
(from maximum
position)
Extent of adjustment:
Maximum
Fully turned in
position
Standard position:
12 clicks out
*13 clicks out
*For EUROPE
5XE-9-30-3B 4/16/03 10:24 AM Page 22

3-35
STEERING HEAD INSPECTION AND ADJUSTMENT
INSP
ADJ
2. Inspect:
9Bearing free play
Exist play Replace.
EC36U070
STEERING HEAD INSPECTION AND
ADJUSTMENT
1. Elevate the front wheel by placing a suitable
stand under the engine.
2. Check:
9Steering shaft
Grasp the bottom of the forks and gently
rock the fork assembly back and forth.
Free play Adjust steering head.
3. Check:
9Steering smooth action
Turn the handlebar lock to lock.
Unsmooth action Adjust steering ring
nut.
4. Adjust:
9Steering ring nut
Steering ring nut adjustment steps:
9Remove the number plate.
9Remove the handlebar and handle crown.
9Loosen the ring nut 1using the ring nut
wrench 2.
9Tighten the ring nut 3using ring nut wrench
4.
NOTE:
9Apply the lithium soap base grease on the
thread of the steering shaft.
9Set the torque wrench to the ring nut wrench
so that they form a right angle.
Ring nut wrench:
YU-33975/90890-01403
5XE-9-30-3B 4/16/03 10:24 AM Page 34

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.
5XE-9-30-4C 4/16/03 10:32 AM Page 22

4-69
ENGTRANSMISSION, SHIFT CAM AND SHIFT FORK
Extent of removal Order Part name Q’ty Remarks
TRANSMISSION, SHIFT CAM AND
SHIFT FORK REMOVAL
Preparation for EngineRefer to “ENGINE REMOVAL” section.
removal Separate the crankcase. Refer to“CRANKCASE AND CRANK
SHAFT
” section.
1 Guide bar (long) 1
2 Guide bar (short) 1
3 Shift cam 1
4 Shift fork 3 1
5 Shift fork 1 1
6 Shift fork 2 1
7 Main axle 1
8 Drive axle 1Refer to “REMOVAL POINTS”.
9 Spacer 1
EC4H0000
TRANSMISSION, SHIFT CAM AND SHIFT FORK
Extent of removal:1Shift cam and shift fork removal2Main axle and drive axle removal
1
2



10 Nm (1.0 m•kg, 7.2 ft•lb)
10 Nm (1.0 m•kg, 7.2 ft•lb)
5XE-9-30-4D 3/24/03 11:14 PM Page 26

4-70
ENGTRANSMISSION, SHIFT CAM AND SHIFT FORK
EC4H3000
REMOVAL POINTS
EC4H3200
Transmission
1. Remove:
9Main axle 1
9Drive axle 2
NOTE:
9Tap lightly on the transmission drive axle with a
soft hammer to remove.
9Remove assembly carefully. Note the position
of each part. Pay particular attention to the lo-
cation and direction of shift forks.
EC4H4000
INSPECTION
EC4H4200
Gears
1. Inspect:
9Matching dog a
9Gear teeth b
9Shift fork groove c
Wear/Damage Replace.
2. Check:
9Gears movement
Unsmooth movement 
Repair or replace.
EC4H4600
Bearing
1. Inspect:
9Bearing 1
Rotate inner race with a finger.
Rough spot/Seizure Replace.
5XE-9-30-4D 3/24/03 11:14 PM Page 28

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

4-72
ENGTRANSMISSION, SHIFT CAM AND SHIFT FORK
2. Install:
93rd wheel gear (29T) 1
94th wheel gear (24T) 2
92nd wheel gear (28T) 3
95th wheel gear (25T) 4
91st wheel gear (30T) 5
To drive axle 6.
NOTE:
9Apply the molybdenum disulfide oil on the 1st,
2nd and 3rd wheel gears inner circumference
and on the end surface.
9Apply the molybdenum disulfide oil on the 4th
and 5th wheel gears inner circumference.
3. Install:
9Plain washer 1
9Circlip 2
NOTE:
9Be sure the circlip sharp-edged corner ais po-
sitioned opposite side to the plain washer and
gear b.
9Be sure the circlip end cis positioned at axle
spline groove d.
4. Install:
9Spacer 1
NOTE:
9Apply the lithium soap base grease on the oil
seal lip.
9When installing the spacer into the crankcase,
pay careful attention to the crankcase oil seal
lip.
5XE-9-30-4D 3/24/03 11:14 PM Page 32

4-73
ENGTRANSMISSION, SHIFT CAM AND SHIFT FORK
EC4H5312
Shift cam and shift fork
1. Install:
9Shift fork 1 (L) 1
9Shift fork 2 (C) 2
9Shift fork 3 (R) 3
NOTE:
9Mesh the shift fork #1 (L) with the 4th wheel
gear 4and #3 (R) with the 5th wheel gear 6
on the drive axle.
9Mesh the shift fork #2 (C) with the 3rd pinion
gear 5on the main axle.
2. Install:
9Shift cam 1
NOTE:
9Apply the transmission oil on the shift cam.
9Install the shift cam while holding up the 4th
wheel gear 2and keeping the shift fork #1 3
moved in the direction of the arrow.
3. Install:
9Guide bar (short) 1
9Guide bar (long) 2
NOTE:
9Apply the transmission oil on the guide bars.
9Be sure the long bar is inserted into the shift
forks #1 and #3 and the short one into #2.
5. Install:
9Main axle 1
9Drive axle 2
NOTE:
Apply the transmission oil on the crankcase
bearings.
5XE-9-30-4D 3/24/03 11:14 PM Page 34