2011 YAMAHA YZ125LC ignition

3-19
ELECTRICAL
ELECTRICAL
CHECKING THE SPARK PLUG
1. Remove:
• Spark plug
2. Inspect:
• Electrode "1"
Wear/damage→Replace.
• Insulator color "2"
Normal condition is a medium to
light tan color.
Distinctly different color→Check
the engine condition.
When the engine runs for many hours
at low speeds, the spark plug insula-
tor will become sooty, even if the en-
gine and carburetor are in good
operating condition.
3. Measure:
• Plug gap "a"
Use a wire gauge or thickness
gauge.
Out of specification→Regap.
4. Clean the plug with a spark plug
cleaner if necessary.
5. Tighten:
• Spark plug
• Before installing a spark plug, clean
the gasket surface and plug sur-
face.
• Finger-tighten "a" the spark plug
before torquing to specification "b".
CHECKING THE IGNITION TIMING
1. Remove:
•Fuel tank
Refer to "SEAT, FUEL TANK
AND SIDE COVERS" section in
the CHAPTER 4.
• Spark plug
• Crankcase cover (left)
2. Attach:
• Dial gauge "1"
• Spark plug hole dial stand "2"
3. Rotate the magneto rotor "1" until
the piston reaches top dead cen-
ter (TDC). When this happens,
the needle on the dial gauge will
stop and reverse directions even
though the rotor is being turned in
the same direction.
4. Set the dial gauge to zero at TDC.
5. From TDC, rotate the rotor clock-
wise until the dial gauge indicates
that the piston is at a specified
distance from TDC.
6. Check:
• Ignition timing
Punch mark "a" on rotor should be
aligned with punch mark "b" on
stator.
Not aligned→Adjust.7. Adjust:
• Ignition timing
Adjustment steps:
a. Loosen the screws (stator) "1".
b. Align the punch mark on the rotor
with punch mark on the stator "2"
by moving the stator.
c. Tighten the screws (stator).
Spark plug gap:
0.6–0.7 mm (0.024–
0.028 in)
Standard spark plug:
BR9EVX/NGK (resistance type)
Spark plug:
20 Nm (2.0 m•kg, 14
ft•lb)
Dial gauge:
YU-3097/90890-01252
Spark plug hole dial
stand:
YU-1256
Ignition timing (B.T.D.C.):
0.48 mm (0.019 in)
Screw (stator):
7 Nm (0.7 m•kg, 5.1
ft•lb)

4-34
CDI MAGNETO
REMOVING THE ROTOR
1. Remove:
• Nut (rotor) "1"
• Washer "2"
Use the rotor holding tool "3".
2. Remove:
• Rotor "1"
Use the flywheel puller "2".
When installing the flywheel puller,
turn it counterclockwise.
CHECKING THE CDI MAGNETO
1. Inspect:
• Rotor inner surface "a"
• Stator outer surface "b"
Damage→Inspect the crankshaft
runout and crankshaft bearing.
If necessary, replace CDI magne-
to and/or stator.
CHECKING THE WOODRUFF KEY
1. Inspect:
• Woodruff key "1"
Damage→Replace.INSTALLING THE CDI MAGNETO
1. Install:
• Stator "1"
• Screw (stator) "2"
Temporarily tighten the screw (stator)
at this point.
2. Install:
• Woodruff key "1"
• Rotor "2"
• Clean the tapered portions of the
crankshaft and rotor.
• When installing the woodruff key,
make sure that its flat surface "a" is
in parallel with the crankshaft center
line "b".
• When installing the rotor, align the
keyway "c" of the rotor with the
woodruff key.
3. Install:
• Washer "1"
• Nut (rotor) "2"
Use the rotor holding tool "3".4. Adjust:
• Ignition timing
Refer to "CHECKING THE IGNI-
TION TIMING" section in the
CHAPTER 3.
5. Tighten:
• Screw (stator) "1"
6. Check:
• Ignition timing
Re-check the ignition timing.
7. Connect:
• CDI magneto lead "1"
Refer to "CABLE ROUTING DIA-
GRAM" section in the CHAPTER
2.
8. Install:
• Gasket [crankcase cover (left)]
• Crankcase cover (left) "1"
• Screw [crankcase cover (left)] "2"
Tighten the screws in stage, using a
crisscross pattern.
Rotor holding tool:
YU-1235/90890-01235
Flywheel puller:
YM-1189/90890-01189
Nut (rotor):
56 Nm (5.6 m•kg, 40
ft•lb)
Rotor holding tool:
YU-1235/90890-01235
Ignition timing (B.T.D.C):
0.48 mm (0.019 in)
Screw (stator):
7 Nm (0.7 m•kg, 5.1
ft•lb)
Screw [crankcase cover
(left)]:
5 Nm (0.5 m•kg, 3.6
ft•lb)

6-2
ELECTRICAL COMPONENTS AND WIRING DIAGRAM
ELECTRICAL
COMPONENTS AND
WIRING DIAGRAM
ELECTRICAL COMPONENTS
1. Engine stop switch
2. CDI unit3. Ignition coil
4. CDI magneto5. Spark plug
WIRING DIAGRAM
1. Engine stop switch
2. CDI unit
3. Ignition coil
4. CDI magneto
5. Spark plugCOLOR CODE
BBlack
O Orange
YYellow
B/R Black/Red
B/W Black/White
G/L Green/Blue
G/W Green/White
W/L White/Blue
W/R White/Red

6-3
IGNITION SYSTEM
IGNITION SYSTEM
INSPECTION STEPS
Use the following steps for checking the possibility of the malfunctioning engine being attributable to ignition system failure
and for checking the spark plug which will not spark.
*marked: Only when the ignition checker is used.
• Remove the following parts before inspection.
1. Seat
2. Fuel tank
• Use the following special tools in this inspection.
Spark gap test Spark→*Clean or replace spark plug.
No spark↓
Check entire ignition system for connection. No good→Repair or replace.
OK↓
Check engine stop switch. No good→Replace.
OK↓
Check ignition coil. (primary coil and secondary
coil)No good→
Replace.
OK↓
Check spark plug cap. No good→Replace.
OK↓
Check CDI magneto. (pickup coil and charging
coil)No good→
Replace.
OK↓
Replace CDI unit.
Dynamic spark tester:
YM-34487
Ignition checker:
90890-06754
Pocket tester:
YU-3112-C/90890-03112

6-4
IGNITION SYSTEM
SPARK GAP TEST
1. Disconnect the spark plug cap
from spark plug.
2. Connect the dynamic spark tester
"1" (ignition checker "2") as
shown.
• Ignition coil "3"
• Spark plug "4"
A. For USA and CDN
B. Except for USA and CDN
3. Kick the kickstarter crank.
4. Check the ignition spark gap.
5. Start engine, and increase spark
gap until misfire occurs. (for USA
and CDN only)
CHECKING THE COUPLERS,
LEADS AND IGNITION COIL
CONNECTION
1. Check:
• Couplers and leads connection
Rust/dust/looseness/short-circuit
→Repair or replace.CHECKING THE ENGINE STOP
SWITCH
1. Inspect:
• Engine stop switch conduction
Not conductive while it is pushed→
Replace.
Conductive while it is freed→Re-
place.
Set the tester selection position to "Ω
× 1".
CHECKING THE IGNITION COIL
1. Inspect:
• Primary coil resistance
Out of specification→Replace.
2. Inspect:
• Secondary coil resistance
Out of specification→Replace.
• Remove the spark plug cap by turn-
ing it counterclockwise and inspect.
• Install the spark plug cap by turning
it clockwise until it is tight.
CHECKING THE SPARK PLUG
CAP
1. Inspect:
• Spark plug cap
Loose connection→Tighten.
Deteriorated/damaged→Re-
place.
• Spark plug cap resistance
Out of specification→Replace.
Minimum spark gap:
6.0 mm (0.24 in)
Tester (+) lead→Black/White lead
"1"
Tester (-) lead→Black lead "2"
Result
Conductive (while the
engine stop switch is
pushed)
Tester (+) lead→Yellow lead "1"
Tester (-) lead→Black lead "2"
Primary
coil resis-
tanceTester se-
lector posi-
tion
0.24–0.36 Ω at 20 °C
(68 °F) Ω × 1
Tester (+) lead→Spark plug lead
"1"
Tester (-) lead→Yellow lead "2"
Secondary
coil resis-
tanceTester se-
lector posi-
tion
5.7–8.5 kΩat 20 °C
(68 °F) kΩ × 1
Tester (+) lead→Spark plug lead
terminal "1"
Tester (-) lead→Spark plug termi-
nal "2"
Spark plug
cap resis-
tanceTester se-
lector posi-
tion
4–6 kΩ at
20 °C (68
°F) kΩ × 1

6-5
IGNITION SYSTEM
CHECKING THE CDI MAGNETO
1. Inspect:
• Pickup coil resistance
Out of specification→Replace.
2. Inspect:
• Charging coil 1 resistance
Out of specification→Replace.3. Inspect:
• Charging coil 2 resistance
Out of specification→Replace.
CHECKING THE CDI UNIT
Check all electrical components. If no
fault is found, replace the CDI unit.
Then check the electrical compo-
nents again. Tester (+) lead→White/Red lead
"1"
Tester (-) lead→White/Blue lead
"2"
Pickup coil
resistanceTester se-
lector posi-
tion
248–372 Ω
at 20 °C (68
°F)Ω × 100
Tester (+) lead→Black/Red lead
"1"
Tester (-) lead→Green/White lead
"2"
Charging
coil 1 resis-
tanceTester se-
lector posi-
tion
720–1,080
Ω at 20 °C
(68 °F)Ω × 100
Tester (+) lead→Green/Blue lead
"1"
Tester (-) lead→Black lead "2"
Charging
coil 2 resis-
tanceTester se-
lector posi-
tion
44–66 Ω at
20 °C (68
°F)Ω × 10