2005 YAMAHA YZ125LC oil

5-43
CHASHANDLEBAR
EC5B3000
REMOVAL POINTS
EC5B3100Master cylinder
1. Remove:
9Master cylinder bracket 1
9Master cylinder 2
cC
9Do not let the master cylinder hang on the
brake hose.
9Keep the master cylinder cap side horizontal
to prevent air from coming in.
EC5B3200
Grip
1. Remove:
9Grip 1
NOTE:
Blow in air between the handlebar or tube guide
and the grip. Then remove the grip which has
become loose.
EC5B4000
INSPECTION
EC5B4100
Handlebar
1. Inspect:
9Handlebar 1
Bends/Cracks /DamageReplace.
w
Do not attempt to straighten a bent handlebar
as this may dangerously weaken the handlebar.
EC5B5000
ASSEMBLY AND INSTALLATION
EC5B5100
Throttle assembly
1. Install
9Grip (right) 1
Apply the adhesive on the tube guide 2.
NOTE:
9Before applying the adhesive, wipe off grease
or oil on the tube guide surface awith a lac-
quer thinner.
9Align the mating mark bon the grip (right) with
the slot cin the tube guide.
1C3-9-30-5C 25/5/04 7:29 PM Page 6

5-44
CHASHANDLEBAR
2. Install:
9Grip cap (upper) 1
9Grip cap (lower) 2
9Bolt (grip cap) 3
NOTE:
Temporarily tighten the bolts (grip cap).
EC5B5210
Handlebar
1. Install:
9Handlebar 1
9Handlebar holder 2
9Bolt (handlebar holder) 3
NOTE:
9The upper handlebar holder should be installed
with the punched mark aforward.
9Install the handlebar so that the marks bare in
place on both sides.
9First tighten the bolts on the front side of the
handlebar holder, and then tighten the bolts on
the rear side.
2. Install:
9Grip (left) 1
Apply the adhesive to the handlebar 2.
NOTE:
9Before applying the adhesive, wipe off grease
or oil on the handlebar surface awith a lac-
quer thinner.
9Install the grip (left) to the handlebar so that the
line bbetween the two arrow marks faces
straight upward.
28 Nm (2.8 m•kg, 20 ft•lb)
1C3-9-30-5C 25/5/04 7:29 PM Page 8

5-54
CHASSWINGARM
Extent of removal Order Part name Q’ty Remarks
SWINGARM DISASSEMBLY
1Cap 2 Refer to “REMOVAL POINTS”.
2Relay arm 1
3Connecting rod 1
4Collar 2
5Oil seal 2
6Thrust bearing 2
7Bush 2
8Oil seal 8
9Bearing 10 Refer to “REMOVAL POINTS”.
EC578000
SWINGARM DISASSEMBLY
Extent of removal:1Swingarm disassembly 2Connecting rod removal and disassembly
3Relay arm removal and disassembly
1
2
3
23
80 Nm (8.0 m•kg, 58 ft•lb)
5 Nm (0.5 m•kg, 3.6 ft•lb)
80 Nm (8.0 m•kg, 58 ft•lb)
2 Nm (0.2 m•kg, 1.4 ft•lb)
1C3-9-30-5D 25/5/04 7:27 PM Page 4

5-55
CHASSWINGARM
EC573201
Bearing
1. Remove:
9Bearing 1
NOTE:
Remove the bearing by pressing its outer race.
EC574010
INSPECTION
Wash the bearings, bushes, collars, and covers in
a solvent.
EC574111
Swingarm
1. Inspect:
9Bearing 1
9Bush 2
Free play exists/Unsmooth revolution/Rust 
Replace bearing and bush as a set.
2. Inspect:
9Oil seal 3
Damage Replace.
EC574211
Relay arm
1. Inspect:
9Bearing 1
9Collar 2
Free play exists/Unsmooth revolution/Rust 
Replace bearing and collar as a set.
2. Inspect:
9Oil seal 3
Damage Replace.
EC573000
REMOVAL POINTS
Cap
1. Remove:
9Cap (left) 1
NOTE:
Remove with a slotted-head screwdriver insert-
ed under the mark aon the cap (left).
1C3-9-30-5D 25/5/04 7:27 PM Page 6

5-56
CHASSWINGARM
EC575000
ASSEMBLY AND INSTALLATION
EC575202
Bearing and oil seal
1. Install:
9Bearing 1
9Oil seal 2
To swingarm.
NOTE:
9Apply the molybdenum disulfide grease on the
bearing when installing.
9Install the bearing by pressing it on the side hav-
ing the manufacture's marks or numbers.
9First install the outer and then the inner bear-
ings to a specified depth from inside.
Installed depth of bearings:
Outer a a
: Zero mm (Zero in)
Inner b b
: 8.5 mm (0.33 in)
EC574311
Connecting rod
1. Inspect:
9Bearing 1
9Collar 2
Free play exists/Unsmooth revolution/Rust 
Replace bearing and collar as a set.
2. Inspect:
9Oil seal 3
Damage Replace.
2. Install:
9Bearing 1
9Plain washer 2
9Oil seal 3
To relay arm.
NOTE:
9Apply the molybdenum disulfide grease on the
bearing when installing.
9Install the bearing by pressing it on the side hav-
ing the manufacture's marks or numbers.
9Apply the molybdenum disulfide grease on the
plain washer.
Installed depth of bearings a a
:
Zero mm (Zero in)
1C3-9-30-5D 25/5/04 7:27 PM Page 8

5-57
CHASSWINGARM
EC5751B3
Swingarm
1. Install:
9Bush 1
9Thrust bearing 2
9Oil seal 3
9Collar 4
To swingarm 5.
NOTE:
Apply the molybdenum disulfide grease on the
bushes, thrust bearings, oil seal lips and contact
surfaces of the collar and thrust bearing.
2. Install:
9Collar 1
9Washer 2
To relay arm 3.
NOTE:
Apply the molybdenum disulfide grease on the
collars and oil seal lips.
3. Install:
9Bearing 1
9Oil seal 2
To connecting rod.
NOTE:
9Apply the molybdenum disulfide grease on the
bearing when installing.
9Install the bearing by pressing it on the side hav-
ing the manufacture's marks or numbers.
Installed depth of bearings a a
:
5 mm (0.20 in)
3. Install:
9Collar 1
To connecting rod 2.
NOTE:
Apply the molybdenum disulfide grease on the
collar and oil seal lips.
1C3-9-30-5D 25/5/04 7:27 PM Page 10

5-62
CHASREAR SHOCK ABSORBER
EC586000
HANDLING NOTE
w
This shock absorber is provided with a
separate type tank filled with high-pressure
nitrogen gas. To prevent the danger of ex-
plosion, read and understand the following
information before handling the shock ab-
sorber.
The manufacturer can not be held respon-
sible for property damage or personal in-
jury that may result from improper han-
dling.
1. Never tamper or attempt to disassemble
the cylinder or the tank.
2. Never throw the shock absorber into an
open flame or other high heat. The shock
absorber may explode as a result of ni-
trogen gas expansion and/or damage to
the hose.
3. Be careful not to damage any part of the
gas tank. A damaged gas tank will impair
the damping performance or cause a
malfunction.
4. Take care not to scratch the contact sur-
face of the piston rod with the cylinder;
or oil could leak out.
5. Never attempt to remove the plug at the
bottom of the nitrogen gas tank. It is very
dangerous to remove the plug.
6. When scrapping the shock absorber, fol-
low the instructions on disposal.
EC587000
NOTES ON DISPOSAL (YAMAHA DEAL-
ERS ONLY)
Before disposing the shock absorber, be sure to
extract the nitrogen gas from valve 1. Wear eye
protection to prevent eye damage from escaping
gas and/or metal chips.
w
To dispose of a damaged or worn-out
shock absorber, take the unit to your
Yamaha dealer for this disposal procedure.
1C3-9-30-5D 25/5/04 7:27 PM Page 20

5-63
CHASREAR SHOCK ABSORBER
EC583000
REMOVAL POINTS
EC583320
Bearing
1. Remove:
9Stopper ring (upper bearing) 1
NOTE:
Press in the bearing while pressing its outer race
and remove the stopper ring.
2. Remove:
9Upper bearing 1
NOTE:
Remove the bearing by pressing its outer race.
EC584000
INSPECTION
EC584110
Rear shock absorber
1. Inspect:
9Damper rod 1
Bends/Damage Replace absorber
assembly.
9Shock absorber 2
Oil leaks Replace absorber assembly.
Gas leaks Replace absorber assembly.
9Spring 3
Damage Replace spring.
Fatigue Replace spring.
Move spring up and down.
9Spring guide 4
Wear/Damage Replace spring guide.
9Bearing 5
Free play exists/Unsmooth revolution/
Rust Replace. 3. Remove:
9Lower bearing 1
NOTE:
Remove the bearing by pressing its outer race.
1C3-9-30-5D 25/5/04 7:27 PM Page 22