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ASSEMBLY INSTRUCTIONS CYLINDER KIT YAMAHA DOHC 125
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PRELIMINARY INSTRUCTIONS AND DISASSEMBLY:
Wash the vehicle and the engine thoroughly. In sequence remove: Saddle, fairing, tank, exhaust silencer, exhaust manifold and
thermal unit fixing plates. After having emptied the cooling liquid, remove the head water pipe, the valve lid vent pipe, the spark
plug and the throttle body or carburettor.
Remove the water pump, the valves lid and the cap of the inspection hole and align the mark on the positioned on the fly wheel with
reference positioned on the ignition sump, by turning the shaft anti-clockwise "Δ" (fig.2). Make sure that the piston is at the top
dead centre (TDC). Check that the reference line present on the distribution notched wheel is aligned with the "Δ" mark of the shaft
support with cams "Δ" (fig.3). Remove the chain-tensioner and the notched distribution wheel of the cam shaft. Do not drop the
bolts and washers. Loosen the cylinder heads bolts cross-wise and remove (to prevent deformation of the cylinder head, loosen
the nuts by about ¼ turn a time); remove the gasket and the centring pins, slide the cylinder out and cover the sump vent to prevent
impurities from entering. Remove the base gasket and the piston.
Check the following components: ROD: check that it is in good working order, CYLINDER HEAD: clean the top panel of the head
from any deposits, INTAKE-EXHAUST VALVES: check the sealing and play, following the vehicle use and maintenance manual.
The reliability of your engine is also guaranteed by the good conditions of these components.
ASSEMBLING INSTRUCTIONS:
Thoroughly clean the original components that will be re-used and all new components of the Athena thermal unit, paying particu-
lar attention that there are no impurities inside the various channels of the cylinder and in the piston.
Install the piston rings, avoiding damage to the piston, paying attention that the upper ring has the mark facing upwards. Therefore,
position the piston rings as indicated in fig.1.
Cover the opening of the sump with paper. Install the piston positioning the arrow mark upwards towards the exhaust side.
After having lubricated the pin, insert it in the piston, making it advance by pressing it manually. After having inserted the pin
retainer rings, make sure that the same are well-organised in their seats.
Install the new base-cylinder gasket supplied in the Athena kit and the centring pins onto the sump.
Grease the cylinder rod, the piston and the piston rings using clean engine oil and install the cylinder by pressing the piston
rings.
N.B. Do not force the cylinder beyond the necessary because it could lead to breakage of the piston rings.
Install the distribution chain guide, aligning its tabs with the cylinder groove.
Install the centring pins and the new cylinder head gasket supplied in the Athena kit.
Install the cylinder head with relative washers and tighten the nuts following the cross layout in two or three phases, at the torque
specified: 22 N•m (2.2 kgf•m).
Tighten the M6 assembly bolts of the head at the torque specified: 9.8 N•m (1.0 Kgf•m).
Check that the cam shaft moves without problems.
Use a thickness gauge to control the valve play: intake 0.10-0.15 mm; exhaust 0.15-0.17 mm.
Install the distribution notched wheel onto the cam shaft.
Turn the motor shaft clockwise and align the mark, positioned on the fly wheel with the reference on the ignition sump "Δ" (fig.2).
Make sure that the piston is at the top dead centre (TDC) of the run. Check that the reference line on the cam shaft gear is aligned
with the mark "Δ" of the cam shaft support (fig.3).
Now it is possible to block the gear onto the cam shaft using the central screw, applying Loctite for safety and tighten to the spe-
cified torque: 24 N•m (2.4 Kgf•m).
Install the distribution chain tensioner and loosen the automatic internal tensioner, successively tighten the sealing bolt with the
washer.
Check whether the cylinder valve gasket is damaged or deteriorated and replace it with a new one if necessary.
Install the water pump and the relative seal, controlling that it is not damaged, tighten the screws to the torque specified: 10 N•m (1.0 Kgf•m).
Install the valves lid and tighten the bolts to the torque specified: 10 N•m (1.0 Kgf•m).
Install the spark plug, the spark plug hood and the valves lid vent pipe.
Install the engine support plates, the washers, the bolts and the nuts.
N.B. Every engine attachment plate has an identification mark: "L" for the left side and "R" for the right side.
Tighten the engine support plate nut to the specified torque: 30 N•m (3.0 Kgf•m).
Install and tighten the ignition side inspection cap to the torque specified: 10 N•m (1 Kgf•m).
Install the throttle body or carburettor and fix the relative strap. Connect the various electric plant connectors.
For motors equipped with the electronic injection, it is necessary to follow the instructions for the additional Athena control unit step-by-step, selecting one of the two maps
available according to necessity.
N.B. If your vehicle has a carburettor, adapt the carburetion to the requirements of the new Athena kit.
On completion of installation it is possible to continue with the assembly of the filter casing with sleeve, tightening the relative strap and the oil vent pipe.
Connect the cooling liquid circuit sleeves.
Install the exhaust manifold with the new gasket, the silencer and tighten the relative bolts and the joint strap.
Install the protections of the engine and the tank.
Fill the cooling circuit with the liquid up to the neck of the filling hole.
Fill the engine sump with oil (SAE 10 W-40) up to the upper level mark.
Clean and, if necessary, replace the air filter.
Install all fairings and protections.
RUNNING IN, USE AND MAINTENANCE:
For running-in and maintenance, scrupulously follow the "VEHICLE USE AND MAINTENANCE MANUAL". Do not use benzene with less than 96 octanes. Do not force the engine
for the first 2-3 hours of use, as there would be a risk of damaging the thermal unit. Moreover, maximum performance is obtained after good running-in. It is good practice to
replace the piston at the first sign of fatigue of the kit in order not to compromise the roundness of the cylinder rod. Piston service limit: replacement is recommended after 20
hours work.
We remind you that it is not the single part but all the parts as a whole that give your engine the best performance.
Only qualified technicians must make the assembling of the articles included in this kit. In case a wrong assembling causes any faults and/or problems, we will not be responsible for any
damage or technical or economical request which are claimed to us. The descriptions contained in this leaflet are not binding. Athena reserves the right to make any changes, if necessary. We
are not responsible for any printing errors.
All ATHENA products, which are manufactured with higher displacement and power than those permitted by law of the country where the end user lives, are intended solely for compe-
tition-sports usage. Use on public roads as well as in aeronautics and marine is prohibited. ATHENA is not responsible for any different usage.
The customer takes full responsibility that the distribution of the articles purchased from Athena is in line with the current regulations of his country and therefore frees Athena from
whatever responsibility in this matter.
FIM/G049
ATHENA SPA - Via delle Albere, 13 - 36045 Alonte (VI) - Italy - Tel. +39-0444-727258 - Fax +39-0444-727222
www.athena-ad.com - e-mail: sales@athena-ad.com
BORE SIZE
STROKE
DISPLACEMENT
63 mm
58,6 mm
182,6 cc
COMPRESSION RATIO
11,4:1
1
2
3
GB
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