2010 YAMAHA YZ125LC Owners Manual

5-23
FRONT FORK
4. Tighten:
• Pinch bolt (upper bracket) "1"
• Pinch bolt (lower bracket) "2"
Tighten the lower bracket to speci-
fied torque. If torqued too much, it
may cause the front fork to mal-
function.
5. Install:
• Protector "1"
• Bolt (protector) "2"
6. Adjust:
• Rebound damping force
Turn in the damping adjuster "1" fin-
ger-tight and then turn out to the orig-
inally set position.
7. Adjust:
• Compression damping force
Turn in the damping adjuster "1" fin-
ger-tight and then turn out to the orig-
inally set position.
Pinch bolt (upper brack-
et):
21 Nm (2.1 m•kg, 15
ft•lb)
Pinch bolt (lower brack-
et):
21 Nm (2.1 m•kg, 15
ft•lb)
Bolt (protector):
5 Nm (0.5 m•kg, 3.6
ft•lb)

5-24
HANDLEBAR
HANDLEBAR
REMOVING THE HANDLEBAR
Order Part name Q'ty Remarks
Number plate Remove the band only.
1 Clutch cable 1 Disconnect at the lever side.
2 Clutch lever holder 1
3 Engine stop switch 1
4 Brake master cylinder 1 Refer to removal section.
5 Throttle cable cap 1 Turn over the cap cover.
6 Throttle cable 1 Disconnect at the throttle side.
7 Throttle 1 Loosen the bolts.
8 Cap cover 1
9 Collar 1
10 Left grip 1 Refer to removal section.
11 Handlebar upper holder 2
12 Handlebar 1
13 Handlebar lower holder 2
1 Nm (0.1 m kg, 0.7 ft lb)
4 Nm (0.4 m kg, 2.9 ft lb)
4 Nm (0.4 m kg, 2.9 ft lb)
4 Nm (0.4 m kg, 2.9 ft lb)
9 Nm (0.9 m kg, 6.5 ft lb)
28 Nm (2.8 m kg, 20 ft lb)
40 Nm (4.0 m kg, 29 ft lb)

5-25
HANDLEBAR
DISASSEMBLING THE THROTTLE
Order Part name Q'ty Remarks
1 Grip cap (lower) 1
2 Grip cap (upper) 1
3 Grip assembly 1
4 Grip (right) 1 Refer to removal section.
5 Tube guide 1

5-26
HANDLEBAR
REMOVING THE BRAKE MASTER
CYLINDER
1. Remove:
• Brake master cylinder bracket "1"
• Brake master cylinder "2"
• Do not let the brake master cylin-
der hang on the brake hose.
• Keep the brake master cylinder
cap side horizontal to prevent air
from coming in.
REMOVING THE GRIP
1. Remove:
•Grip "1"
Blow in air between the handlebar or
tube guide and the grip. Then remove
the grip which has become loose.
CHECKING THE HANDLEBAR
1. Inspect:
• Handlebar "1"
Bends/cracks/damage→Re-
place.
Do not attempt to straighten a bent
handlebar as this may dangerous-
ly weaken the handlebar.
ASSEMBLING THE THROTTLE
1. Remove:
• Grip (right) "1"
Apply the adhesive on the tube
guide "2".
• Before applying the adhesive, wipe
off grease or oil on the tube guide
surface "a" with a lacquer thinner.
• Align the mating mark "b" on the
grip (right) with the slot "c" in the
tube guide.
2. Install:
• Grip cap (upper) "1"
• Grip cap (lower) "2"
• Bolt (grip cap) "3"
Temporarily tighten the bolts (grip
cap).
INSTALLING THE HANDLEBAR
1. Install:
• Handlebar lower holder "1"
• Washer "2"
• Nut (handlebar lower holder) "3"
• Install the handlebar lower holder
with its side having the greater dis-
tance "a" from the mounting bolt
center facing forward.
• Apply the lithium soap base grease
on the thread of the handlebar low-
er holder.
• Installing the handlebar lower hold-
er in the reverse direction allows the
front-to-rear offset amount of the
handlebar position to be changed.
• Do not tighten the nut yet.
2. Install:
• Handlebar "1"
• Handlebar upper holder "2"
• Bolt (handlebar upper holder) "3"
• The handlebar upper holder should
be installed with the punched mark
"a" forward.
• Install the handlebar so that the
marks "b" are in place on both
sides.
• Install the handlebar so that the pro-
jection "c" of the handlebar upper
holder is positioned at the mark on
the handlebar as shown.
• First tighten the bolts on the front
side of the handlebar upper holder,
and then tighten the bolts on the
rear side.
Bolt (handlebar upper
holder):
28 Nm (2.8 m•kg, 20
ft•lb)

5-27
HANDLEBAR
3. Tighten:
• Nut (handlebar lower holder) "1"
4. Install:
• Left grip "1"
Apply the adhesive to the handle-
bar "2".
• Before applying the adhesive, wipe
off grease or oil on the handlebar
surface "a" with a lacquer thinner.
• Install the left grip to the handlebar
so that the line "b" between the two
arrow marks faces straight upward.
5. Install:
•Collar "1"
• Grip cap cover "2"
• Throttle grip "3"
• Apply the lithium soap base grease
on the throttle grip sliding surface.
• Tighten the grip cap bolts temporar-
ily without the throttle being fixed to
the handlebar.
6. Install:
• Throttle cables "1"
To tube guide "2".
Apply the lithium soap base grease
on the throttle cable end and tube
guide cable winding portion.
7. Install:
• Roller "1"
• Collar "2"
• Apply the lithium soap base grease
on the roller sliding surface and ca-
ble guide.
• Install the roller so that the "UP-
PER" mark "a" faces upward.
• Pass the throttle cable in the groove
"b" in the roller.
8. Install:
• Throttle cable cap "1"
• Screw (throttle cable cap) "2"9. Adjust:
• Throttle grip free play
Refer to "ADJUSTING THE
THROTTLE CABLE FREE PLAY"
section in the CHAPTER 3.
10. Install:
• Cap cover "1"
11. Install:
• Brake master cylinder "1"
• Brake master cylinder bracket "2"
• Bolt (brake master cylinder brack-
et) "3"
• Install the bracket so that the arrow
mark "a" faces upward.
• First tighten the bolt on the upper
side of the brake master cylinder
bracket, and then tighten the bolt on
the lower side.
12. Install:
• Bolt (grip cap) "1" Nut (handlebar lower
holder):
40 Nm (4.0 m•kg, 29
ft•lb)
Screw (throttle cable
cap):
1 Nm (0.1 m•kg, 0.7
ft•lb)
Bolt (brake master cylin-
der bracket):
9 Nm (0.9 m•kg, 6.5
ft•lb)
Bolt (grip cap):
4 Nm (0.4 m•kg, 2.9
ft•lb)

5-28
HANDLEBAR
After tightening the bolts, check
that the throttle grip "2" moves
smoothly. If it does not, retighten
the bolts for adjustment.
13. Install:
• Engine stop switch "1"
• Clutch lever holder "2"
• Bolt (clutch lever holder) "3"
• Clamp "4"
• The engine stop switch, clutch lever
holder and clamp should be in-
stalled according to the dimensions
shown.
• Pass the engine stop switch lead in
the middle of the clutch lever hold-
er.
14. Install:
• Clutch cable "1"
Apply the lithium soap base grease
on the clutch cable end.
15. Adjust:
• Clutch lever free play
Refer to "ADJUSTING THE
CLUTCH CABLE FREE PLAY"
section in the CHAPTER 3.
Bolt (clutch lever holder):
4 Nm (0.4 m•kg, 2.9
ft•lb)
(0.55 in)

5-29
STEERING
STEERING
REMOVING THE STEERING
Order Part name Q'ty Remarks
TIGHTENING STEPS:
• Tighten ring nut. 38 Nm (3.8 m•kg, 27 ft•lb)
• Loosen it one turn.
• Retighten it. 7 Nm (0.7 m•kg, 5.1 ft•lb)
Hold the machine by placing the suitable stand
under the engine.Refer to "HANDLING NOTE".
Number plateRefer to "SEAT, FUEL TANK AND SIDE
COVERS" section in the CHAPTER 4.
Handlebar Refer to "HANDLEBAR" section.
Front fender
1 Steering stem nut 1
2 Front fork 2 Refer to "FRONT FORK" section.
3 Upper bracket 1
4 Steering ring nut 1 Refer to removal section.
5 Lower bracket 1
6 Bearing race cover 1
7 Upper bearing 1
8 Lower bearing 1 Refer to removal section.

5-30
STEERING
9 Bearing race 2 Refer to removal section. Order Part name Q'ty Remarks