2005 YAMAHA YZ125LC radiator cap

3-4
PRE-OPERATION INSPECTION AND MAINTENANCE
INSP
ADJ
EC320000
PRE-OPERATION INSPECTION AND MAINTENANCE
Before riding for break-in operation, practice or a race, make sure the machine is in good operating
condition.
Before using this machine, check the following points.
EC321000
GENERAL INSPECTION AND MAINTENANCE
Item Routine Page
Coolant Check that coolant is filled up to the radiator filler cap.
Check the cooling system for leakage.P3-5~9
Fuel Check that a fresh mixture of oil and gasoline is filled in
the fuel tank. Check the fuel line for leakage.P1-12
Transmission oil Check that the oil level is correct. Check the crankcase
for leakage.P3-12~14
Gear shifter and clutch Check that gears can be shifted correctly in order and
that the clutch operates smoothly.P3-9
Throttle grip/Housing Check that the throttle grip operation and free play
are correctly adjusted. Lubricate the throttle grip and P3-10~11
housing, if necessary.
Brakes Check the play of front brake and effect of front and
rear brake.P3-17~23
Chain Check chain slack and alignment. Check that the chain
is lubricated properly.P3-24~26
Wheels Check for excessive wear and tire pressure. Check for
loose spokes and have no excessive play.P3-34~35
Steering Check that the handlebar can be turned smoothly and
have no excessive play.P3-35~36
Front forks and Check that they operate smoothly and there is no oil
rear shock absorber leakage.P3-26~33
Cables (wires) Check that the clutch and throttle cables move smooth-
ly. Check that they are not caught when the handlebars —
are turned or when the front forks travel up and down.
Muffler Check that the muffler is tightly mounted and has no
cracks.P3-15~16
Sprocket Check that the driven sprocket tightening bolt is
not loose.P3-24
Lubrication Check for smooth operation. Lubricate if necessary. P3-37
Bolts and nuts Check the chassis and engine for loose bolts and nuts. P1-16
Lead connectors Check that the CDI magneto, CDI unit, and ignition coil
are connected tightly.P1-6
Settings Is the machine set suitably for the condition of the
racing course and weather or by taking into account the
P7-1~23
results of test runs before racing? Are inspection and
maintenance completely done?
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3-5
INSP
ADJENGINE/COOLANT LEVEL INSPECTION/
COOLANT REPLACEMENT
EC350000
ENGINE
EC351011
COOLANT LEVEL INSPECTION
w
Do not remove the radiator cap 1 1
, drain
bolt and hoses when the engine and radia-
tor are hot. Scalding hot fluid and steam
may be blown out under pressure, which
could cause serious injury.
When the engine has cooled, place a thick
towel over the radiator cap, slowly rotate
the cap counterclockwise to the detent.
This procedure allows any residual pres-
sure to escape. When the hissing sound
has stopped, press down on the cap while
turning counterclockwise and remove it.
cC
Hard water or salt water is harmful to the
engine parts. You may use distilled water,
if you can’t get soft water.
1. Place the machine on a level place, and
hold it in an upright position.
2. Remove:
9Radiator cap
3. Check:
9Coolant level a
Coolant level low Add coolant.
1Radiator
EC353011
COOLANT REPLACEMENT
w
Do not remove the radiator cap when the
engine is hot.
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3-6
INSP
ADJ
COOLANT REPLACEMENT
cC
Take care so that coolant does not splash
on painted surfaces. If it splashes, wash it
away with water.
1. Place a container under the engine.
2. Remove:
9Coolant drain bolt 1
3. Remove:
9Radiator cap
Drain the coolant completely.
4. Clean:
9Cooling system
Thoroughly flush the cooling system with
clean tap water.
5. Install:
9Copper washer
9Coolant drain bolt
6. Fill:
9Radiator
9Engine
To specified level.
Recommended coolant:
High quality ethylene glycol
anti-freeze containing
anti-corrosion for
aluminum engine
Coolant 1 1
and water
(soft water) 2 2
mixing ratio:
50%/50%
Coolant capacity:
0.9 L (0.79 Imp qt, 0.95 US qt)
10 Nm (1.0 m•kg, 7.2 ft•lb)
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3-6
CHANGEMENT DU LIQUIDE DE REFROIDISSEMENT
ERNEUERUNG DES KÜHLMITTELS
SOSTITUZIONE DEL LIQUIDO REFRIGERANTE
INSP
ADJ
dD
Darauf achten, daß kein Kühlmittel
auf lackierte Flächen verspritzt
wird. Wird Kühlmittel verspritzt,
dieses sofort mit Wasser abwa-
schen.
1. Ein Auffanggefäß unter dem
Motor anordnen.
2. Ausbauen:
9Kühlmittelablaßschraube 1
3. Ausbauen:
9Kühlerdeckel
Das Kühlmittel vollständig
ablaufen lassen.
4. Reinigen:
9Kühlsystem
Das Kühlsystem gründlich mit
Leitungswasser spülen.
5. Einbauen:
9Kupferscheibe
9Kühlmittelablaßschraube
6. Füllen:
9Kühler
9Motor
Zum vorgeschriebenen Stand.
fF
Prendre garde à ne pas verser de
liquide de refroidissement sur les
surfaces peintes. Si cela était, l’élimi-
ner avec de l’eau.
1. Mettre un récipient sons le moteur.
2. Déposer:
9Boulon de vidange de refroidis-
sement 1
3. Déposer:
9Bouchon du radiateur
Vidanger le liquide de refroidis-
sement en totalité.
4. Nettoyer:
9Circuit de refroidissement
Bien rincer le circuit de refroi-
dissement avec de l’eau du robi-
net.
5. Monter:
9Rondelle en cuivre
9Boulon de vidange de refroidis-
sement
6. Remplir:
9Radiateur
9Moteur
Au niveau specifié.
iI
Fare attenzione che il liquido refrige-
rante non schizzi sulle superfici ver-
niciate. Se schizza, toglierlo con
acqua.
1. Collocare un contenitore sotto il
motore.
2. Togliere:
9Bullone di scarico del liquido
refrigerante 1
3. Togliere:
9Tappo del radiatore
Scaricare completamente il
liquido refrigerante.
4. Pulire:
9Impianto di raffreddamento
Lavare accuratamente l’impian-
to di raffreddamento con acqua
del rubinetto pulita.
5. Installare:
9Rondella di rame
9Bullone di scarico del liquido
refrigerante
6. Riempire:
9Radiatore
9Motore
Al livello specificato.
Empfohlenes Kühlmittel:
Hochqualitatives
Äthylenglykol-
Frostschutsmittel mit
Korrosionsschutzmittel
für Aluminium-Motoren
Mischungsverhältnis von
Kühlmittel 1 1
und Wasser
(Weiches Wasser) 2 2
:
50%/50%
Kühlerinhalt:
0,9 L (0,79 Imp qt,
0,95 US qt)Liquide de refroidissement
recommandé:
Antigel à l’ethyléne
glycol de haute qualité
contenant un agent
anticorrosion pour
moteurs en aluminium.
Taux du mélange liquide
de refroidissement 1 1
/eau
(eau douce) 2 2
:
50 %/50 %
Capacité de refroidisse-
ment:
0,9 L (0,79 Imp qt,
0,95 US qt)Liquido refrigerante
raccomandato:
Antigelo a base di
glicole etilenico di alta
qualità contenente
anticorrosivo per
motore in alluminio
Rapporto di miscelazione
di liquido refrigerante 1 1
e acqua (acqua dolce) 2 2
:
50%/50%
Capacità di liquido
refrigerante:
0,95 L (0,79 Imp qt,
0,95 US qt)
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)
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3-7
INSP
ADJ
RADIATOR CAP INSPECTION
cC
9Do not mix more than one type of ethyl-
ene glycol antifreeze containing corro-
sion inhibitors for aluminum engine.
9Do not use water containing impurities
or oil.
7. Install:
9Radiator cap
Start the engine and warm it up for a sev-
eral minutes.
8. Check:
9Coolant level
Coolant level low Add coolant.
EC355000
RADIATOR CAP INSPECTION
1. Inspect:
9Seal (radiator cap) 1
9Valve and valve seat 2
Crack/Damage Replace.
Exist fur deposits 3Clean or replace.
Handling notes of coolant:
The coolant is harmful so it should be handled
with special care.
w
9When coolant splashes to your eye.
Thoroughly wash your eye with water
and see your doctor.
9When coolant splashes to your clothes.
Quickly wash it away with water and then
with soap.
9When coolant is swallowed.
Quickly make him vomit and take him to
a doctor.
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3-8
INSP
ADJRADIATOR CAP OPENING PRESSURE INSPECTION/
COOLING SYSTEM INSPECTION
EC356002
RADIATOR CAP OPENING PRESSURE
INSPECTION
1. Attach:
9Radiator cap tester 1and adapter 2
NOTE:
Apply water on the radiator cap seal.
3Radiator cap
2. Apply the specified pressure.
3. Inspect:
9Pressure
Impossible to maintain the specified pres-
sure for 10 seconds Replace.
EC357003
COOLING SYSTEM INSPECTION
1. Inspect:
9Coolant level
2. Attach:
9Radiator cap tester 1and adapter 2
3. Apply the specified pressure.
Radiator cap tester:
YU-24460-01/90890-01325
Adapter:
YU-33984/90890-01352
Radiator cap tester:
YU-24460-01/90890-01325
Adapter:
YU-33984/90890-01352
Radiator cap opening pressure:
95~125 kPa (0.95~1.25 kg/cm
2,
13.5~17.8 psi)
Standard pressure:
180 kPa (1.8 kg/cm
2, 25.6 psi)
NOTE:
9Do not apply pressure more than specified
pressure.
9Radiator should be filled fully.
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3-9
INSP
ADJ
CLUTCH ADJUSTMENT
4. Inspect:
9Pressure
Impossible to maintain the specified pres-
sure for 10 seconds Repair.
9Radiator 1
9Radiator hose joint 2
Coolant leakage Repair or replace.
9Radiator hose 3
Swelling Replace.
2. Adjust:
9Clutch lever free play
EC359020
CLUTCH ADJUSTMENT
1. Check:
9Clutch lever free play a
Out of specification Adjust.
NOTE:
9Before adjustment, expose the adjuster by
moving the boot 3and cap 4away.
9Make minute adjustment on the lever side
using the adjuster 5.
9After adjustment, check proper operation of
clutch lever.
Clutch lever free play a a
:
8~13 mm (0.31~0.51 in)
Clutch lever free play adjustment steps:
9Loosen the locknut 1.
9Turn the adjuster 2until free play ais with-
in the specified limits.
9Tighten the locknut.
Locknut:
4 Nm (0.4 m•kg, 2.9 ft•lb)
3. Install:
9Cap 1
9Boot 2
NOTE:
Place the tip aof the cap in the boot.
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3-9
REGLAGE DE L’EMBRAYAGE
EINSTELLUNG DER KUPPLUNG
REGOLAZIONE DELLA FRIZIONE
INSP
ADJ
4. Prüfen:
9Druck
Der spezifizierte Druck kann
nicht für 10 Sekunden gehalten
werdenReparieren.
9Kühler 1
9Verbindung deren Kühler-
schläuche 2
Kühlmittel austrittReparieren
oder erneuern.
9Kühlerschlauche 3
Anschwellen Erneuern.
EINSTELLUNG DER KUPPLUNG
1. Kontrollieren:
9Spiel des Kupplungshebels a
Abweichung von Spezifikation
Einstellen.
2. Einstellen:
9Spiel des Kupplungshebels
HINWEIS:
9Vor der Einstellung den Einsteller
durch Verschieben der Schutzkappe
3und des Deckels 4freilegen.
9Feineinstellung mit Hilfe des Einstel-
lers 5an der Hebelseite verrichten.
9Nach der Einstellung, die richtige
Funktion des Kupplungshebels kon-
trollieren.
4. Examiner:
9Pression
Impossible de maintenir la pres-
sion spécifiée pendant 10
secondesRéparer.
9Radiateur 1
9Raccord des tuyaux du radiateur
2
Fuites du liquide de refroidisse-
mentRéparer ou changer.
9Tuyaux du radiateur 3
GonflementChanger.
REGLAGE DE L’EMBRAYAGE
1. Contrôler:
9Jeu du levier d’embrayage a
Hors spécificationRégler.
2. Régler:
9Jeu de levier d’embrayage
N.B.:
9Avant le réglage, exposer le dispositif
de réglage en retirant le soufflet 3et
le capuchon 4.
9Procéder à un léger réglage de côté du
levier à l’aide du dispositif de réglage
5.
9Après le réglage, contrôler de bon
fonctionnement du levier d’embraya-
ge.
4. Ispezionare:
9Pressione
Impossibile mantenere la pres-
sione specificata per 10 secondi
Ripararlo.
9Radiatore 1
9Giunto del manicotto flessibile
del radiatore 2
Perdita di liquido refrigerante
Ripararlo o sostituirlo.
9Manicotto flessibile del radiatore
3
RigonfiamentoSostituirlo.
IC359020
REGOLAZIONE DELLA
FRIZIONE
1. Controllare:
9Gioco libero della leva di
comando della frizione a
Fuori specificaRegolarlo.
2. Regolare:
9Gioco libero della leva di
comando della frizione
NOTA:
9Prima della regolazione, mettere a
nudo il dispositivo di regolazione spo-
stando il parapolvere 3e il coperchio
4.
9Eseguire una regolazione precisa sulla
leva laterale usando il regolatore 5.
9Dopo la regolazione, controllare il
corretto funzionamento della leva di
comando della frizione.
Jeu de levier d’embrayage
a a
:
8 ~ 13 mm
(0,31 ~ 0,51 in)
Procédure de réglage du jeu du
levier d’embrayage:
9Desserrer le contre-écrou 1.
9Tourner le dispositif de réglage 2
jusqu’à ce que le jeu asoit com-
pris dans les limites spécifiées.
9Serrer le contre-écrou.
Gioco libero della leva di
comando della frizione a a
:
8 ~ 13 mm
(0,31 ~ 0,51 in)
Spiel deskupplungshe-
bels a:
8~13 mm
(0,31~0,51 in)
Einstellschritte des Spiels des
Vorderrad-Bremshebels:
9Die Sicherungsmutter 1lösen.
9Den Einsteller 2drehen, bis das
Spiel ainnerhalb des vorge-
schriebenen Bereiches liegt.
9Die Sicherungsmutter festzie-
hen.Passi della regolazione del gioco
libero della leva di comando della
frizione:
9Allentare il controdado 1.
9Ruotare il regolatore 2finché il
gioco libero anon è compreso
nei limiti specificati.
9Serrare il controdado.
Contre écrou:
4 Nm (0,4 m•kg, 2,9 ft•lb)
Controdado:
4 Nm (0,4 m•kg, 2,9 ft•lb)Sichherungsmutter:
4 Nm (0,4 m•kg, 2,9 ft•lb)
3. Monter :
9Capuchon 1
9Soufflet 2
N.B.:
Placer l’embout adu capuchon dans le
soufflet.
3. Einbauen:
9Deckel 1
9Schuh 2
HINWEIS:
Die Spitze ades Deckels in den
Schuh einsetzen.
3. Installare
9Coperchio 1
9Parapolvere 2
NOTA:
Mettere la punta adel coperchio nel
parapolvere.
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