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Yamaha YZ125(D) User Manual

Yamaha YZ125(D)
168 pages
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OWNER’S SERVICE MANUAL
MANUEL D’ATELIER DU
PROPRIETAIRE
FAHRER- UND
WARTUNGSHANDBUCH
MANUALE DI SERVIZIO DEL
PROPRIETARI
O
YZ125
(
D
)
1SR-28199-31
PRINTED IN JAPAN
2012.08—0.8 × 1
!
(E, F, G, H)
PRINTED ON RECYCLED PAPER
2013
YZ125
(
D
)
2013
q Read this manual carefully before operating this vehicle.
q Il convient de lire attentivement ce manuel avant la première utilisation du véhicule.
q
Bitte lesen Sie diese Bedienungsanleitung sorgfältig durch, bevor Sie das Fahrzeug in Betrieb nehmen.
q Leggere attentamente questo manuale prima di utilizzare questo veicolo.
1SR-9-31_cover.indd 1 2012/09/15 15:56:32
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Yamaha YZ125(D) Specifications

General IconGeneral
BrandYamaha
ModelYZ125(D)
CategoryMotorcycle
LanguageEnglish

Summary

Foreword and Important Manual Information

Introduction

Introduces the Yamaha YZ series and the purpose of the manual.

Safety Information

Details critical safety precautions for operating the competition-use machine.

Using the Manual and Reading Descriptions

How to Use This Manual

Explains how to navigate the manual using its structure and edge symbols.

Manual Format

Describes the sequential, step-by-step format and notation used in the manual.

How to Read Descriptions

Explains the meaning of symbols used in exploded diagrams and text.

General Information and Description

Location of Important Labels

Identifies and explains important labels on the vehicle for safe operation.

Vehicle Description

Provides an illustrated overview of the vehicle's main components.

Consumer and Special Tool Information

Consumer Information

Details reasons for knowing serial numbers and identifies included parts.

Important Information for Preparation

Provides crucial preparation steps before removal and disassembly.

Special Tools

Lists special tools required for tune-up and assembly with their part numbers and uses.

Control Functions and Starting Procedures

Control Functions Overview

Explains operation of clutch, throttle, brakes, engine stop, and starter.

Starting and Break-In Procedures

Details fuel requirements, starting procedures, and break-in guidelines.

Specifications and Maintenance Intervals

General Specifications

Lists general specifications like model, dimensions, weight, and engine details.

Maintenance Specifications Overview

Details transmission ratios, chassis type, caster angle, and brake specifications.

Engine and Crankshaft Specifications

Provides specifications for cylinder bore, piston, and crankshaft measurements.

Clutch, Transmission, and Carburetor Specifications

Lists specifications for clutch, transmission, shifter, and carburetor settings.

Cooling, Steering, and Suspension Specifications

Provides specifications for cooling system, steering, and suspension components.

Swingarm, Wheel, Brake, and Drive Chain Specifications

Details specifications for swingarm, wheels, brakes, and drive chain.

Maintenance Intervals Overview

Details inspection and replacement intervals for key engine and chassis components.

Torque Specifications and Cable Routing

Electrical and Engine Torque Specifications

Lists torque specifications for electrical and engine components.

Chassis Torque Specifications

Lists torque specifications for chassis components like steering and front fork.

General Torque Specifications and Unit Definitions

Specifies general torque values and defines common measurement units.

Cable Routing Diagram

Illustrates the correct routing of various cables and hoses on the motorcycle.

Engine Component Service

Coolant Level Check and Changing

Provides steps to check and change the engine coolant.

Radiator Cap Inspection

Explains how to inspect the radiator cap for damage and wear.

Clutch and Throttle Adjustments

Details how to adjust clutch lever and throttle grip free play.

Cooling System Check

Explains how to check the cooling system for leaks and pressure.

Throttle Lubrication and Air Filter Cleaning

Provides instructions for throttle lubrication and air filter cleaning.

Transmission Oil Level Check

Explains how to check the transmission oil level.

Chassis Component Service

Brake System Bleeding

Outlines the procedure for bleeding the hydraulic brake system.

Transmission Oil Change

Provides steps for draining and refilling transmission oil.

Carburetor Adjustments

Explains pilot air screw and engine idling speed adjustments.

Front and Rear Brake Adjustments

Details how to adjust front brake lever and rear brake pedal height.

Brake Pad Replacement

Outlines how to inspect and replace front and rear brake pads.

Brake Fluid Level and Drive Chain Inspection

Explains brake fluid checks and drive chain inspection.

Drive Chain Slack Adjustment

Provides steps for adjusting the drive chain slack.

Front Fork Inspection

Details how to inspect the front fork's smooth action and oil leakage.

Front Fork Seal and Valve Maintenance

Explains how to clean front fork seals and relieve pressure.

Front Fork Damping Adjustments

Details how to adjust front fork rebound and compression damping.

Rear Shock Absorber Inspection and Adjustment

Outlines inspection and adjustment of rear shock absorber preload and damping.

Wheel and Spoke Inspection

Explains how to inspect wheels for runout and tighten spokes.

Steering Head Inspection and Adjustment

Provides steps to check and adjust the steering head for play and smooth action.

Disassembly and Service Procedures

Seat, Fuel Tank and Side Covers Removal

Outlines the procedure and torque values for removing body panels.

Exhaust Pipe and Silencer Removal

Details the procedure and torque values for removing the exhaust system.

Radiator Removal

Outlines the steps and torque values for removing the radiator.

Carburetor and Reed Valve Removal

Details the procedure for removing the carburetor and reed valve assembly.

Carburetor Disassembly

Illustrates the components of the carburetor and their disassembly.

Throttle Valve and Carburetor Inspection

Explains inspection of throttle valve, needle valve, and carburetor body.

Jet Needle and Filter Inspection

Details inspection of jet needle and carburetor filter.

Fuel Level Measurement and Adjustment

Provides steps for measuring and adjusting the fuel level in the float chamber.

Cylinder Head, Cylinder, and Piston Removal

Details the procedure and torque values for removing the cylinder head and cylinder.

Piston and Power Valve Removal

Outlines the procedure for removing the piston and power valve assembly.

Push Rod and Piston Removal

Explains how to remove the push rod and piston/piston rings.

Cylinder Head and Cylinder Inspection

Outlines procedures for cleaning and checking cylinder head and cylinder.

Clutch Removal and Inspection

Details the procedure for removing and inspecting clutch components.

Clutch Boss Removal

Outlines the procedure and torque values for removing the clutch boss.

Clutch Housing, Gear, and Spring Inspection

Explains inspection of clutch housing, gear, springs, and plates.

Push Rod and Shaft Inspection

Details inspection of push rod, shaft, and related components.

Clutch Assembly

Provides steps for installing clutch components.

Kick Shaft and Shift Shaft System Removal

Illustrates the components of the kick and shift shaft systems and their removal.

Gear and Shaft Inspections

Explains inspection of kick shaft, gears, shift shaft, guide, lever, stopper, and primary gears.

YPVS Governor Removal

Illustrates the components of the YPVS governor assembly and their removal.

Water Pump Disassembly

Details the parts and procedure for disassembling the water pump.

CDI Magneto Removal

Illustrates the CDI magneto components and their removal.

Engine Removal Procedure

Outlines the steps and torque values for removing the engine from the frame.

Crankshaft Removal

Details the procedure and torque values for removing the crankshaft.

Segment and Crankcase Disassembly

Explains how to remove the segment and disassemble the crankcase halves.

Crankshaft and Bearing Removal

Details how to remove the crankshaft and crankcase bearings.

Crankcase and Crankshaft Inspection

Outlines inspection of crankcase, bearings, and crankshaft measurements.

Transmission Assembly Removal

Illustrates the transmission components and their removal.

Gear and Shaft Inspections

Explains inspection of gears, bearings, shift forks, cam, and segment.

Wheel and Brake System Service

Front Wheel Removal

Outlines the procedure and torque values for removing the front wheel.

Rear Wheel Removal

Details the procedure and torque values for removing the rear wheel.

Wheel and Brake Disc Inspection

Explains inspection of wheel axle, brake discs, and wheels.

Front Brake System Removal

Outlines the procedure and torque values for removing the front brake system.

Rear Brake System Removal

Details the procedure and torque values for removing the rear brake system.

Brake Caliper Disassembly

Illustrates the components of the brake caliper and their disassembly.

Brake Master Cylinder Disassembly

Details the components of the brake master cylinder and their disassembly.

Brake Fluid Drain and Caliper Piston Removal

Explains how to drain brake fluid and remove caliper pistons.

Brake Master Cylinder Inspection

Outlines how to inspect the brake master cylinder and diaphragm.

Rear Brake Caliper and Master Cylinder Installation

Provides steps for installing rear brake caliper and master cylinder kit.

Front Brake Master Cylinder Installation

Explains how to install the front brake master cylinder and bracket.

Rear Brake Master Cylinder and Front Brake Hose Installation

Details how to install rear master cylinder and front brake hose.

Rear Brake Hose and Brake Fluid Filling

Explains how to install rear brake hose and fill brake fluid.

Front Fork Service

Front Fork Removal

Outlines the procedure and torque values for removing the front fork assembly.

Front Fork Disassembly

Illustrates the components of the front fork and their disassembly.

Damper Assembly and Base Valve Removal

Explains how to remove damper assembly and base valve.

Adjuster and Inner Tube Removal

Details how to remove the adjuster and inner tube.

Damper Assembly Inspection

Outlines how to inspect the damper assembly and O-ring for damage.

Base Valve Inspection

Explains how to inspect the base valve, O-ring, piston metal, spring, and bleed screw.

Collar and Fork Spring Inspection

Details inspection of collar and fork spring.

Inner and Outer Tube Inspection

Explains how to inspect inner and outer tubes for wear.

Adjuster Inspection

Outlines how to inspect the adjuster and O-ring for wear.

Front Fork Assembly

Provides steps for washing parts, stretching damper, and filling with oil.

Handlebar and Steering Service

Handlebar Removal

Outlines the procedure and torque values for removing the handlebar.

Throttle Disassembly

Illustrates the components of the throttle assembly and their disassembly.

Brake Master Cylinder and Grip Removal

Details how to remove brake master cylinder and grip.

Handlebar Inspection

Outlines how to inspect the handlebar for bends and damage.

Throttle and Handlebar Installation

Provides steps for assembling throttle and installing handlebar.

Steering Removal

Outlines the procedure and torque values for removing the steering assembly.

Steering Ring Nut and Bearing Removal

Explains how to remove steering ring nut and lower bearing.

Bearing Race and Stem Inspection

Details inspection of steering bearings, races, and stem.

Lower Bracket Installation

Provides steps for installing the lower steering bracket and bearings.

Swingarm and Rear Shock Absorber Service

Swingarm Removal

Outlines the procedure and torque values for removing the swingarm.

Swingarm Disassembly

Illustrates the components of the swingarm and their disassembly.

Cap, Bearing and Oil Seal Removal

Explains how to remove swingarm cap, bearings, and oil seals.

Swingarm, Relay Arm and Connecting Rod Inspection

Outlines inspection of swingarm, relay arm, and connecting rod.

Bearing and Oil Seal Installation

Provides steps for installing bearings and oil seals into the swingarm.

Rear Shock Absorber Removal

Outlines the procedure and torque values for removing the rear shock absorber.

Bearing Removal and Inspection

Explains how to remove and inspect shock absorber bearings.

Rear Shock Absorber Inspection

Details how to inspect damper rod, shock absorber, and spring.

Bearing Installation

Provides steps for installing bearings into the rear shock absorber.

Spring Installation

Details how to install the spring, spring guides, and spring seat.

Rear Shock Absorber Installation

Provides steps for installing dust seal, O-ring, collar, bushing, and shock absorber.

Electrical System Service

Electrical System Introduction

Introduction to the electrical system servicing section.

Electrical Components and Wiring Diagram

Identifies electrical components and presents the wiring diagram.

Ignition System Inspection Steps

Outlines steps for diagnosing ignition system malfunctions and spark plug issues.

Spark Gap Test and Coupler Inspection

Details spark gap testing and coupler/lead connection checks.

Engine Stop Switch and Ignition Coil Inspection

Explains inspection of engine stop switch and ignition coil resistance.

Spark Plug Cap Inspection

Outlines inspection of spark plug cap for connection and resistance.

CDI Magneto and CDI Unit Inspection

Details inspection of CDI magneto coil resistances and CDI unit.

Engine Tuning

Carburetor Setting Fundamentals

Explains the role of fuel mixture and factors affecting carburetor settings.

Engine Test Run and Spark Plug Analysis

Outlines engine test runs and interpreting spark plug discoloration.

Main Jet and Pilot Air Screw Adjustments

Explains how to adjust main jet and pilot air screw for fuel mixture.

Pilot Jet and Jet Needle Adjustments

Details pilot jet changes and jet needle clip position adjustments.

Jet Needle Settings and Throttle Relationship

Explains how jet needle settings affect fuel mixture and performance.

Carburetor Setting Parts

Lists carburetor parts like jets, valves, and needles with part numbers.

Chassis Tuning and Settings

Spark Plug Heat Range and Sprocket Selection

Discusses spark plug selection and secondary gear ratio for racing.

Tire Pressure and Front Fork Settings

Advises adjusting tire pressure and front fork settings for optimal performance.

Front Fork Suspension Setting

Provides a chart for adjusting front fork settings based on symptoms.

Rear Shock Absorber Spring Settings

Lists rear shock absorber springs with part numbers and ID marks.

Front Fork Suspension Setting Guide

Provides a chart for adjusting front fork settings based on symptoms.

Rear Shock Absorber Suspension Setting Guide

Provides a chart for adjusting rear shock absorber settings based on symptoms.

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