YAMAHA YZ125 Workshop Repair Manual

OWNER’S SERVICE MANUAL MANUEL D’ATELIER DU PROPRIETAIRE FAHRER- UND WARTUNGSHANDBUCH MANUALE DI SERVIZIO DEL PROPRIETARIO YZ125 ( D ) 1SR-28199-31 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.

Q Read this manual carefully before operating this vehicle.This manual should stay with this vehicle if it is sold. Q Il convient de lire attentivement ce manuel avant la première utilisation du véhicule. Le manuel doit être remis avec le véhicule en cas de vente de ce dernier. Q Bitte lesen Sie diese Bedienungsanleitung sorgfältig durch, bevor Sie das Fahrzeug in Betrieb nehmen. Diese Bedienungsanleitung muss, wenn das Fahrzeug verkauft wird, beim Fahrzeug verbleiben. Q Leggere attentamente questo manuale prima di utilizzare il veicolo. Questo manuale dovrebbe accompagnare il veicolo se viene venduto.

YZ125(D) YZ125(D) 2013 2013 1SR-28199-31-E0 1SR-28199-31-E0 OWNER’S SERVICE MANUAL OWNER’S SERVICE MANUAL Read this manual carefully before operating this vehicle. Read this manual carefully before operating this vehicle.

YZ125 (D) OWNER'S SERVICE MANUAL ©2012 by Yamaha Motor Co., Ltd. 1st Edition, September 2012 All rights reserved.Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan

FOREWORD INTRODUCTION Congratulations on your purchase of a Yamaha YZ series. This model is the culmination of Yamaha's vast ex- perience in the production of paceset- ting racing machines. It represents the highest grade of craftsmanship and reliability that have made Yama- ha a leader. This manual explains operation, inspection, basic maintenance and tuning of your machine. If you have any questions about this manual or your machine, please contact your Yama- ha dealer. Yamaha continually seeks advance- ments in product design and quality. Therefore, while this manual contains the most current product information available at the time of printing, there may be minor discrepancies between your machine and this manual. If you have any questions concerning this manual, please consult your Yamaha dealer. PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MA- CHINE. DO NOT ATTEMPT TO OP- ERATE THIS MACHINE UNTIL YOU HAVE ATTAINED A SATISFACTO- RY KNOWLEDGE OF ITS CON- TROLS AND OPERATING FEATURES AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES. REGULAR INSPECTIONS AND CAREFUL MAINTENANCE, ALONG WITH GOOD RIDING SKILLS, WILL ENSURE THAT YOU SAFETY ENJOY THE CAPABILI- TIES AND THE RELIABILITY OF THIS MACHINE. IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following notations. This is the safety alert symbol. It is used to alert you to potential per- sonal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. A WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. A NOTICE indicates special pre- cautions that must be taken to avoid damage to the vehicle or oth- er property. A TIP provides key information to make procedures easier or clearer. SAFETY INFORMATION THIS MACHINE IS DESIGNED STRICTLY FOR COMPETITION USE, ONLY ON A CLOSED COURSE. It is illegal for this machine to be operated on any public street, road, or highway. Off-road use on public lands may also be illegal. Please check local regulations before riding. • THIS MACHINE IS TO BE OPER- ATED BY AN EXPERIENCED RID- ER ONLY. Do not attempt to operate this machine at maximum power until you are totally familiar with its character- istics. • THIS MACHINE IS DESIGNED TO BE RIDDEN BY THE OPERATOR ONLY. Do not carry passengers on this machine. • ALWAYS WEAR PROTECTIVE APPAREL. When operating this machine, always wear an approved helmet with goggles or a face shield. Also wear heavy boots, gloves, and protective clothing. Always wear proper fitting clothing that will not be caught in any of the moving parts or controls of the machine. • ALWAYS MAINTAIN YOUR MA- CHINE IN PROPER WORKING ORDER. For safety and reliability, the machine must be properly maintained. Always perform the pre-operation checks indicated in this manual. Correcting a mechanical problem before you ride may prevent an ac- cident. • GASOLINE IS HIGHLY FLAMMA- BLE. Always turn off the engine while re- fueling. Take care to not spill any gasoline on the engine or exhaust system. Never refuel in the vicinity of an open flame, or while smoking. • GASOLINE CAN CAUSE INJURY. If you should swallow some gasoline, inhale excess gasoline vapors, or allow any gasoline to get into your eyes, contact a doctor immediately. If any gasoline spills onto your skin or clothing, immediately wash skin areas with soap and water, and change your clothes. • ONLY OPERATE THE MACHINE IN AN AREA WITH ADEQUATE VENTILATION. Never start the engine or let it run for any length of time in an enclosed area. Exhaust fumes are poison- ous. These fumes contain carbon monoxide, which by itself is odor- less and colorless. Carbon monoxide is a dangerous gas which can cause unconsciousness or can be lethal. • PARK THE MACHINE CAREFUL- LY; TURN OFF THE ENGINE. Always turn off the engine if you are going to leave the machine. Do not park the machine on a slope or soft ground as it may fall over. • THE ENGINE, EXHAUST PIPE, MUFFLER, AND OIL TANK WILL BE VERY HOT AFTER THE EN- GINE HAS BEEN RUN. Be careful not to touch them or to allow any clothing item to contact them during inspection or repair. • PROPERLY SECURE THE MA- CHINE BEFORE TRANSPORTING IT. When transporting the machine in another vehicle, always be sure it is properly secured and in an upright position and that the fuel cock is in the "OFF" position. Otherwise, fuel may leak out of the carburetor or fuel tank.

HOW TO USE THIS MANUAL FINDING THE REQUIRED PAGE 1. This manual consists of seven chapters; "General Information", "Specifications", "Regular inspection and adjustments", "Engine", "Chassis", "Electrical" and "Tun- ing" 2. The table of contents is at the be- ginning of the manual. Look over the general layout of the book before finding then required chapter and item. Bend the book at its edge, as shown, to find the required fore edge symbol mark and go to a page for required item and description. MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step- by-step format. The information has been complied to provide the me- chanic with an easy to read, handy reference that contains comprehen- sive explanations of all disassembly, repair, assembly, and inspection op- erations. In this revised format, the condition of a faulty component will precede an arrow symbol and the course of ac- tion required will follow the symbol, e.g., • Bearings Pitting/damage → Replace.

HOW TO READ DESCRIPTIONS To help identify parts and clarify pro- cedure steps, there are exploded diagrams at the start of each removal and disassembly section. 1. An easy-to-see exploded diagram "1" is provided for removal and disassembly jobs. 2. Numbers "2" are given in the order of the jobs in the exploded diagram. A number that is enclosed by a circle indicates a disassembly step. 3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks "3". The meanings of the symbol marks are given on the next page. 4. A job instruction chart "4" accom- panies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc. 5. For jobs requiring more information, the step-by-step format sup- plements "5" are given in addition to the exploded diagram and job instruction chart. ILLUSTRATED SYMBOLS (Refer to the illustration) Illustrated symbols "1" to "7" are used to identify the specifications appear- ing in the text. 1. With engine mounted 2. Filling fluid 3. Lubricant 4. Special tool 5. Tightening 6. Specified value, Service limit 7. Resistance (Ω), Voltage (V), Electric current (A) Illustrated symbols "8" to "14" in the exploded diagrams indicate grade of lubricant and location of lubrication point. 8. Apply engine mixing oil 9. Apply transmission oil 10. Apply molybdenum disulfide oil 11. Apply brake fluid 12. Apply lightweight lithium-soap base grease 13. Apply molybdenum disulfide grease 14. Apply silicone grease Illustrated symbols "15" to "16" in the exploded diagrams indicate where to apply a locking agent and where to in- stall new parts. 15. Apply locking agent (LOC- TITE ® ) 16. Use new one 1 2 3 4 5

TABLE OF CONTENTS GENERAL INFORMATION 1 SPECIFICATIONS 2 REGULAR INSPECTION AND ADJUSTMENTS 3 ENGINE 4 CHASSIS 5 ELECTRICAL 6 TUNING 7

CONTENTS CHAPTER 1 GENERAL INFORMATION LOCATION OF IMPORTANT LABELS............................ 1-1 DESCRIPTION ................. 1-5 CONSUMER INFORMATION................. 1-6 INCLUDED PARTS .......... 1-6 IMPORTANT INFORMATION................. 1-6 CHECKING OF CONNECTION .................. 1-7 SPECIAL TOOLS ............. 1-8 CONTROL FUNCTIONS ................... 1-11 STARTING AND BREAK-IN ...................... 1-12 TORQUE-CHECK POINTS........................... 1-13 CLEANING AND STORAGE ...................... 1-14 CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS ............ 2-1 MAINTENANCE SPECIFICATIONS ............ 2-2 TIGHTENING TORQUES . 2-7 CABLE ROUTING DIAGRAM....................... 2-13 CHAPTER 3 REGULAR INSPEC- TION AND AD- JUSTMENTS MAINTENANCE INTERVALS ...................... 3-1 PRE-OPERATION INSPECTION AND MAINTENANCE................ 3-5 ENGINE ............................ 3-6 CHASSIS .......................... 3-9 ELECTRICAL ................. 3-19 CHAPTER 4 ENGINE SEAT, FUEL TANK AND SIDE COVERS.................. 4-1 EXHAUST PIPE AND SILENCER ........................ 4-3 RADIATOR ....................... 4-5 CARBURETOR AND REED VALVE ................... 4-7 CYLINDER HEAD, CYLIN- DER AND PISTON ......... 4-12 CLUTCH ......................... 4-19 KICK SHAFT AND SHIFT SHAFT ................. 4-23 YPVS GOVERNOR......... 4-28 WATER PUMP................ 4-30 CDI MAGNETO............... 4-33 ENGINE REMOVAL ....... 4-35 CRANKCASE AND CRANKSHAFT ............... 4-39 TRANSMISSION, SHIFT CAM AND SHIFT FORK. 4-44 CHAPTER 5 CHASSIS FRONT WHEEL AND REAR WHEEL ............................. 5-1 FRONT BRAKE AND REAR BRAKE .................. 5-6 FRONT FORK ................. 5-16 HANDLEBAR.................. 5-24 STEERING ...................... 5-29 SWINGARM .................... 5-33 REAR SHOCK ABSORBER .................... 5-38 CHAPTER 6 ELECTRICAL ELECTRICAL COMPO- NENTS AND WIRING DIA- GRAM ............................... 6-2 IGNITION SYSTEM........... 6-3 CHAPTER 7 TUNING ENGINE............................. 7-1 CHASSIS .......................... 7-6

YAMAHA YZ125 Workshop Repair Manual

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