2005-2011 Yamaha Xt125r Xt125x Service & Repair Manual

2006 XT125R(V) XT125X(V) SERVICE MANUAL 3D6-F8197-E0

XT125R(V)/XT125X(V) 2006 SERVICE MANUAL ©2005 by Yamaha Motor Europe N.V. First edition, 2006 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Europe N.V. is expressly prohibited.

WARNING This manual was written by Yamaha Motor Europe N.V. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to provide a mechanic with all necessary information with only one manual. For this reason, persons using this book to perform maintenance and repairs on Yamaha motorcycles should have a basic understanding of the mechanical concepts and procedures concerning motorcycle repair technology. Without such knowledge, attempted repairs or service to the motorcycle may render it unfit to use and/or unsafe. Yamaha Motor Europe N.V. is continuously striving to improve all models manufactured by Yamaha. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and, where applicable, they will appear in future editions of this manual. NOTE: _ Designs and specifications are subject to change without notice. PARTICULARLY IMPORTANT INFORMATION ABOUT THE MANUAL Particularly important information is shown with the following symbols. This symbol shows a danger and means CAUTION! DANGER! YOUR SAFETY IS INVOLVED! Failure to follow WARNING instructions could result in severe injury or death for the motorcycle operator, a bystander, or a person inspecting or repairing the motorcycle. The CAUTION symbol indicates special precautions that must be taken to avoid damage to the motorcycle. A NOTE provides key information to make procedures easier or clearer. WARNING CAUTION: NOTE:

HOW TO USE THIS MANUAL STRUCTURE OF THE MANUAL This manual is divided into chapters according to the main subject categories. See “EXPLANATORY SYMBOLS” 1 st title 1: This is the title of the chapter with its symbol on the upper right corner of each page. 2 nd title 2: This title indicates the section of each chapter and it is located in the upper left corner of the first page of each section. 3 rd title 3: This title indicates a sub-section that is followed by step-by-step procedures accompa- nied by illustrations. EXPLODED DIAGRAMS To help identify parts and clarify procedure steps, there are exploded diagrams at the beginning of each removal and disassembly section. 1. Each section is characterised by an exploded drawing (4) that can be easily understood and that facilitates assembly and disassembly operations. 2. The numeric references (5) in the exploded drawings show the order of the operations to be carried out. A number inside a circle shows a disassembly phase. 3. The symbols (6) supply precise information easy to be understood about the operations to be carried out with the relevant notes. 4. The exploded drawing is provided with an instruction box (7) that contains the description of the sequence of operations to be carried out, the name of the components, the notes, etc. 5. For operations that require further information, a supplement (8) with the description of step-by- step operations is supplied with the exploded drawings and the instruction box. 4 5 7 1 2 6 3 8

EXPLANATORY SYMBOLS The explanatory symbols from (1) to (8), shown in the side figure show the numbers and the content of the different chapters. (1) General information (2) Specifications (3) Periodic inspections and adjustments (4) Engine (5) Carburetor (6) Chassis (7) Electrical (8) Troubleshooting The explanatory symbols from (9) to (15) show some specifications that can be found in the text (9) Fill up (10) Lubricant (11) Special tool (12) Tighten with torque wrench (13) Wear limit, clearance (14) Engine speed (15) Multimeter Ω, V, A The explanatory symbols from (16) to (22), inserted in the exploded drawings show the type of sealant and/or lubricant and the appli- cation points (16) Apply sealant LOCTITE (17) Apply engine oil (18) Apply gear oil (19) Apply molybdenum disulfide oil (20) Apply bearing grease (21) Apply lithium-soap base grease (22) Apply molybdenum disulfide grease 1 2 3 4 5 6 7 8 9 0 A B C D E F G H I J K L GEN INFO SPEC INSP ADJ ENG CARB CHAS – + ELEC TRBL SHT T R . . LT E G M B LS M

INDEX GENERAL INFORMATION GEN INFO 1 SPECIFICATIONS SPEC 2 PERIODIC INSPECTION AND ADJUSTMENT INSP ADJ 3 ENGINE ENG 4 CARBURETOR CARB 5 CHASSIS CHAS 6 ELECTRICAL SYSTEM ELEC 7 TROUBLESHOOTING TRBL SHTG 8 – +

GEN INFO CHAPTER 1 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION .................................................................. 1-1 VEHICLE SERIAL NUMBER ..................................................................... 1-1 MODEL LABEL.......................................................................................... 1-1 IMPORTANT INFORMATION ......................................................................... 1-2 PREPARATION FOR REMOVAL AND DISASSEMBLY........................... 1-2 SPARE PARTS ......................................................................................... 1-3 GASKETS, SEALS AND O-RINGS ........................................................... 1-3 LOCK WASHERS, PLATES AND COTTER PINS .................................... 1-3 BEARINGS AND OIL SEALS .................................................................... 1-3 CIRCLIPS .................................................................................................. 1-4 SPECIAL TOOLS ............................................................................................ 1-5

1 - 1 GEN INFO GENERAL INFORMATION MOTORCYCLE IDENTIFICATION VEHICLE SERIAL NUMBER The vehicle serial number (1) is stamped on the right side of the steering sleeve tube. 1 The engine serial number (1) is stamped on the left side of the crankcase. NOTE: The first five figures of the number identify the engine Code; the other figures show the number of production of the unit. NOTE: Designs and specifications are subject to change without notice. 1 MODEL LABEL The model label (1) is applied to the rear mud- guard. This information is necessary for order- ing the spare parts. MOTORCYCLE IDENTIFICATION

1 - 2 GEN INFO IMPORTANT INFORMATION IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DISASSEMBLY 1. Remove all dirt, mud, dust, and foreign material before removing and disassembling. 2. Use proper tools and cleaning equipment. See “SPECIAL TOOLS”. 3. When disassembling the motorcycle, keep mated parts together. This includes gears, cylinders, pistons and other mated parts that wear out with each other. Mated parts must be reused as an assembly or replaced. 4. During motorcycle disassembly, clean all parts and place them in trays the order of disassembly. This will speed up assembly time and help assure that all parts are cor- rectly reinstalled. 5. Keep all components away from fire. DO NOT SMOKE

1 - 3 GEN INFO IMPORTANT INFORMATION SPARE PARTS 1. Use only genuine Yamaha parts for all replacements. Use oil and/or grease recom- mended by Yamaha for assembly and adjustment. Other brands may be similar in function and appearance, but inferior in quality. GASKETS, SEALS AND O-RINGS 1. All gaskets, seals and O-rings should be replaced when an engine is overhauled. All surfaces in contact with gaskets, oil seal lips and O-rings must be cleaned. 2. Properly oil all mating parts and bearings during reassembly. Apply grease to the oil seal lips. LOCK WASHERS, PLATES AND COTTER PINS 1. All lock washers, plates (1) and cotter pins must be replaced when they are removed. After proper tightening, lock tabs should be bent along the bolt or nut. BEARINGS AND OIL SEALS 1. Install the bearings and oil seals with their manufacturer’s marks or numbers facing outward. When installing oil seals, lubricate a light coating of lithium base grease to the seal lips. If necessary, lubricate the bearings. CAUTION: Do not use compressed air to dry the bearings. This may damage the bearing surfaces.

2005-2011 Yamaha Xt125r Xt125x Service & Repair Manual

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