2011 YAMAHA YZ125LC brake

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)

5-26
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)

5-33
SWINGARM
SWINGARM
REMOVING THE SWINGARM
Order Part name Q'ty Remarks
Hold the machine by placing the suitable stand
under the engine.Refer to "HANDLING NOTE".
Brake hose holder Refer to "FRONT BRAKE AND REAR
BRAKE" section.
Rear brake caliperRefer to "FRONT BRAKE AND REAR
BRAKE" section.
Bolt (brake pedal) Shift the brake pedal backward.
Drive chain
1 Drive chain support 1
2 Lower chain tensioner 1
3 Bolt (rear shock absorber-relay arm) 1 Hold the swingarm.
4 Bolt (connecting rod) 1
5 Pivot shaft 1
6 Swingarm 1

7-5
ENGINE
This should be taken simply for an example. It is necessary to set the carburetor while checking the operating conditions
of the engine and discoloration of spark plugs. Normally, carb uretor setting is made by means of the main jet, jet needle
clip position (including one with 0.5 difference), pilot jet and pilot air screw. If the result of setting is still unsatisfactory, it is
advisable to change the diameter of the straight portion the jet needle.
Lean mixture Lower jet needle clip position. (1 groove
down)
Clip position indicates the position of jet
needle groove, to which the clip is fitted.
The position is numbered from the top.
If a change in the clip position (1 groove) is
effective, try another jet needle that pro-
vides a difference of 0. 5 in the clip position.
Rich mixture Raise jet needle clip position. (1 groove up)
1/4–3/4 throttle
*Hard breathing
Lack of speed Lower jet needle clip position. (1 groove
down)
1/4–1/2 throttle Slow speed pick-up
White smoke
Poor acceleration Raise jet needle clip position. (1 groove up)
0–1/4 throttle *Hard breathing
Speed down Use jet needle having a smaller diameter. Number of turns-back
→Correct properly
Overflow from carburetor
0–1/4 throttle Poor acceleration
White smoke Use jet needle with a larger diameter.
Unstable at low speeds Pinking noise Lower jet needle clip position.
(1 groove down)
Turn in pilot air screw.
Poor response at extremely low
speed Reduce pilot jet calibration No.
Turn out pilot air screw.
If not effect, reverse the above procedures. Dragging brake
Overflow from carburetor
Poor response in the range of
low to intermediate speeds Raise jet needle clip position.
If no effect, reverse the above procedures.
Poor response when throttle is
opened quickly Check overall settings.
Use main jet having lower calibration no.
Raise jet needle clip position. (1 groove up)
If no effect, reverse the above procedures. Check air filter for fouling.
Poor engine operation Turn in pilot ai r screw. Check throttle valve operation.
* In case of hard breathing, check the air vent hose for clogging. Symptom Setting CheckingGroove 1
Groove 2
Groove 3
Groove 4
Groove 5
Clip
Jet needle
Leaner
(Standard)
Richer