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Yamaha XN125 2000 User Manual

Yamaha XN125 2000
259 pages
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XN125
2000
XN150
5MF1-AE2
SERVICE MANUAL

Table of Contents

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Yamaha XN125 2000 Specifications

General IconGeneral
BrandYamaha
ModelXN125 2000
CategoryMotorcycle
LanguageEnglish

Summary

Chapter 1. General Information

Scooter Identification

Identifies the scooter's VIN and model label for parts ordering.

Features

Describes key features like the oil indicator light, odometer/tripmeter modes, clock, and auto-choke system.

Important Information

Provides crucial guidelines for removal, disassembly, and safe handling of parts and materials.

Checking the Connections

Details procedures for inspecting electrical leads, couplers, and connectors for stains or corrosion.

Special Tools

Lists necessary special tools with part numbers and illustrations for tune-up and assembly.

Chapter 2. Specifications

General Specifications

Lists key dimensions, weights, engine details, oil/coolant capacities, and fuel tank capacity.

Maintenance Specifications

Details standard and limit values for engine, chassis, and electrical components for servicing.

Conversion Table

Provides metric to imperial unit conversion factors for various measurements like torque, weight, and volume.

General Tightening Torque Specifications

Specifies general tightening torques for standard fasteners based on thread pitch and size.

Tightening Torques

Lists specific engine and chassis tightening torques for various bolts and nuts.

Lubrication Points and Lubricant Types

Identifies lubrication points and corresponding lubricant symbols for engine and chassis components.

Cooling System Diagrams

Illustrates the routing and components of the scooter's cooling system with numbered parts.

Lubrication Diagrams

Shows oil flow paths within the engine for lubricating critical components like the cylinder and crankshaft.

Cable Routing

Illustrates the correct routing of electrical wires, cables, and hoses for proper assembly and function.

Chapter 3. Periodic Checks and Adjustments

Periodic Maintenance and Lubrication Intervals

Outlines the recommended maintenance schedule based on odometer readings and annual checks.

Cover and Panel

Details procedures for removing and installing side covers, seat, front cover, and inner panels.

Engine

Covers recommended adjustments and checks for valve clearance, idling speed, and spark plug condition.

Chassis

Details checks and adjustments for front/rear brakes, steering head, tires, wheels, and suspension.

Electrical System

Covers checks for battery condition, fuses, bulb replacement, and basic electrical system troubleshooting.

Chapter 4. Overhauling the Engine

Engine

Covers engine-related wiring, cables, hoses, air filter, and mounting bolts removal and installation.

Camshaft

Details removal, checking, and installation procedures for the camshaft, rocker arms, and timing components.

Cylinder Head

Covers removal, checking for warpage, and installation of the cylinder head assembly.

Valves and Valve Springs

Details removal, checking, and installation procedures for valves, springs, seats, and guides.

Cylinder and Piston

Covers removal, checking, and installation of the cylinder, piston, piston rings, and piston pin.

Clutch

Details removal, disassembly, checking, and assembly of the clutch, V-belt, and sheave components.

Starter Clutch and Generator

Covers removal, checking, and installation of starter clutch, generator, magneto cover, and stator coil.

Oil Pump

Details removal and checking procedures for the engine's oil pump components like gears and housing.

Crankcase and Crankshaft

Covers disassembly, checking, and assembly of the crankcase halves and crankshaft assembly.

Transmission

Details removal and installation of transmission components including gears, axles, and covers.

Chapter 5. Cooling System

Radiator

Covers removal, checking for damage, and installation of the radiator and its associated hoses and fan.

Thermostat

Details checking the thermostat's operation by temperature and its installation procedure.

Water Pump

Covers removal, checking for damage, and installation procedures for the water pump assembly.

Chapter 6. Carburetor

Carburetor

Details removal, disassembly, checking of components, and assembly of the carburetor.

Chapter 7. Chassis

Front Wheel and Brake Disc

Covers removal, checking, and installation of the front wheel, brake disc, caliper, and axle.

Rear Wheel and Brake

Details checking and adjustment of the rear wheel, brake shoes, drum, and camshaft.

Front Brake

Covers replacement of brake pads, master cylinder service, and caliper disassembly and checking.

Front Fork

Details disassembly, checking, and assembly of the front fork legs, including oil replacement.

Handlebar

Covers checking and installation procedures for the handlebar, grips, levers, and switches.

Steering Head

Details removal, checking, and installation procedures for the steering head bearings and components.

Rear Shock Absorber and Exhaust Pipe

Covers removal and checking procedures for the rear shock absorber assembly and exhaust pipe.

Chapter 8. Electrical

Electrical Components

Provides an overview and illustration of the scooter's electrical components and their connections.

Switches

Details checking switch continuity using a pocket tester and identifying switch positions and wire colors.

Checking the Bulbs and Bulb Sockets

Explains how to check bulb types, condition, socket continuity, and recommended replacement schedule.

Ignition System

Provides a circuit diagram and troubleshooting guide for the ignition system, including spark plug and coil checks.

Electric Starting System

Includes a circuit diagram and troubleshooting steps for the starter motor, relay, and battery system.

Starter Motor

Details removal, disassembly, checking of components, and assembly of the starter motor.

Charging System

Provides a circuit diagram and troubleshooting for charging system issues like battery not charging or stator coil resistance.

Lighting System

Includes circuit diagrams and troubleshooting for headlights, signals, brake lights, meter lights, and related switches.

Signaling System

Provides circuit diagrams and troubleshooting for turn signals, brake lights, horn, and indicator lights.

Cooling System

Includes circuit diagrams and troubleshooting for the radiator fan motor, thermo switch, and temperature warning light.

Carburetor Heating System

Provides a circuit diagram and troubleshooting for the carburetor heating system, including thermo switch and heater element.

Chapter 9. Troubleshooting

Starting Failure/ Hard Starting

Lists common causes for engine starting failures, categorized by system (engine, fuel, electrical).

Incorrect Engine Idling Speed

Identifies engine, fuel system, carburetor, and electrical causes for incorrect idling speed.

Poor Medium-and-High-Speed Performance

Details potential issues in engine, fuel system, and carburetor affecting performance at higher speeds.

Faulty Clutch

Lists common causes for clutch malfunction, including V-belt, pulley, spring, and gear issues.

Over Heating

Identifies engine, cooling system, fuel system, chassis, and electrical causes of engine overheating.

Overcooling

Lists cooling system causes for engine overcooling, primarily related to thermostat operation.

Poor Braking

Details common causes for poor braking performance in both disc and drum brake systems.

Faulty Front Fork Legs

Lists causes for front fork leg malfunction, including oil leaks, bent components, and incorrect oil levels.

Malfunction

Lists general malfunctions related to front fork legs such as bent parts, damaged springs, or incorrect oil viscosity.

Unstable Handling

Covers issues related to handlebar, steering head, front forks, swingarm, tires, wheels, and frame affecting stability.

Faulty Lighting or Signaling System

Lists common problems with headlights, turn signals, brake lights, horn, and other signaling system components.

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