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Summary of Contents for Yamaha XQ125
- Page 1 XQ125 2001 5HT1-AE2 XQ150 SERVICE MANUAL...
- Page 2 EASM0000 XQ125 / XQ150 SERVICE MANUAL © 2001 by MBK Industrie 2nd edition, April 2001 All rights reserved. Any reproduction or unauthorized use without the written permission of MBK Industrie is expressly prohibited.
- Page 3 EASM0001 NOTICE This manual was produced by the MBK Industrie primarily for use by Yamaha and MBK dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha and MBK vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
- Page 4 EAS00007 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. The manual is divided into chapters.
- Page 5 EAS00008 SYMBOLS The following symbols are not relevant to every SPEC INFO vehicle. Symbols indicate the subject of each chapter. General information Specifications Periodic checks and adjustments Engine Cooling system Carburetor COOL CARB Chassis Electrical system Troubleshooting CHAS ELEC Symbols indicate the following.
- Page 6 EAS00010 TABLE OF CONTENTS GENERAL INFORMATION INFO SPECIFICATIONS SPEC PERIODIC CHECKS AND ADJUSTMENTS ENGINE OVERHAUL COOLING SYSTEM COOL CARBURETOR CARB CHASSIS CHAS ELECTRICAL SYSTEM ELEC TROUBLESHOOTING TRBL SHTG...
- Page 7 INFO...
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Page 8: Table Of Contents
INFO CHAPTER 1. GENERAL INFORMATION SCOOTER IDENTIFICATION ................ 1-1 VEHICLE IDENTIFICATION NUMBER ............ 1-1 MODEL LABEL ..................1-1 FEATURES ....................1-2 OIL INDICATOR LIGHT ................1-2 ODOMETER/TRIPMETER READING MODE ......... 1-2 BATTERY VOLTAGE/FUEL GAUGE ............1-2 THE CLOCK ..................... 1-3 AUTO-CHOKE SYSTEM ................. -
Page 9: Chapter 1. General Information
INFO SCOOTER IDENTIFICATION EAS00015 GENERAL INFORMATION SCOOTER IDENTIFICATION EASM0002 VEHICLE IDENTIFICATION NUMBER The vehicle identification number is stamped into the frame. ZAUM0113 EASM0003 MODEL LABEL The model label is affixed under the seat. This information will be needed to order spare parts. -
Page 10: Features
INFO FEATURES EASM0004 FEATURES OIL INDICATOR LIGHT • FUNCTION Pulses (travel distance signals) from the speedometer are counted and cause the oil indicator light to come on at 500 km for the first time and thereafter every 3,000 km. In this way, the light indicates the time for oil change. -
Page 11: The Clock
INFO FEATURES THE CLOCK • Setting the clock To set the clock: 1) Make sure that the key is turned to “OFF”. 2) Press the “TRIP” button for two seconds and the hour display will flash. 3) Press the “TRIP” button to set the hours. 4) Press the “TRIP”... -
Page 12: Important Information
5.Keep all parts away from any source of fire. EAS00021 REPLACEMENT PARTS 1.Use only genuine Yamaha and MBK parts for all replacements. Use oil and grease recom- mended by Yamaha or MBK for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality. -
Page 13: Lock Washers/Plates And Cotter Pins
INFO IMPORTANT INFORMATION EAS00023 LOCK WASHERS / PLATES AND COTTER PINS 1.After removal, replace all lock washers / plates and cotter pins. After the bolt or nut has been tightened to specification, bend the lock tabs along a flat of the bolt or nut. EAS00024 BEARINGS AND OIL SEALS 1.Install bearings and oil seals so that the manu-... -
Page 14: Checking The Connections
INFO CHECKING THE CONNECTIONS EAS00026 CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1.Disconnect: • lead • coupler • connector 2.Check: • lead • coupler • connector Moisture → Dry with an air blower. Rust/stains →... -
Page 15: Special Tools
INFO SPECIAL TOOLS EAS00027 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country. - Page 16 INFO SPECIAL TOOLS Tool No. Tool name/usage Illustration 90890-01367 Fork seal driver weight 90890-01368 Frok seal driver attachment These tools are used when installing the fork seal. 90890-01701 Sheave holder This tool is used to hold the secondary sheave when removing or installing the nut.
- Page 17 This tool is used to rebore the valve guide. 90890-06754 Ignition checker This instrument is necessary for checking the ignition system components. 90890-85505 Yamaha bond No. 1215 This sealant (bond) is used for crankcase mating surface, etc. 90890-03081 Compression gauge This gauge is used to measure the engine...
- Page 18 SPEC...
- Page 19 SPEC CHAPTER 2. SPECIFICATIONS GENERAL SPECIFICATIONS ..............2-1 MAINTENANCE SPECIFICATIONS ............. 2-4 ENGINE ....................2-4 CHASSIS ....................2-8 ELECTRICAL ..................2-10 CONVERSION TABLE ................2-12 GENERAL TIGHTENING TORQUE SPECIFICATIONS ......2-13 TIGHTENING TORQUES ................2-14 TIGHTENING TORQUES (ENGINE) ............. 2-14 TIGHTENING TORQUES (CHASSIS) ........... 2-16 LUBRICATION POINTS AND LUBRICANT TYPES ........
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Page 20: Specifications
SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item XQ125 [XQ150] Dimensions Overall length 1.920 mm Overall width 750 mm Overall height 1.180 mm Seat height 824 mm Wheelbase 1.400 mm Minimum ground clearance 118 mm Minimum turning radius 2.050 mm Weight... -
Page 21: General Specifications
SPEC GENERAL SPECIFICATIONS Item XQ125 [XQ150] Carburetor Type/quantity TK 5DS/1 [TK 5KD/1] TEIKEI Manufacturer Spark plug Type CR8E Manufacturer Spark plug gap 0.5~0.7 mm Clutch type Dry, centrifugal automatic Transmission Helical gear Primary reduction system Primary reduction ratio 40/15 (2.666) - Page 22 SPEC GENERAL SPECIFICATIONS Item XQ125 [XQ150] Brake Front brake type Single disc brake Front brake operation Right hand operation Rear brake type Single disc brake Rear brake operation Left hand operation Suspension Front suspension Telescopic fork Rear suspension Unit swing...
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Page 23: Maintenance Specifications
SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS * [XQ 150] ENGINE Item Standard Limit Cylinder head Warp limit ••• 0.03 mm Cylinder Bore size 53.700~53.705 mm [59.500~59.505 mm]* ••• Out of round limit ••• 0.05 mm Camshaft Drive system Chain drive (left) •••... - Page 24 SPEC MAINTENANCE SPECIFICATIONS * [XQ 150] Item Standard Limit Valve spring Free length IN/EX 41.94 mm 39.84 mm Set length (valve closed) IN/EX 37.5 mm ••• Compressed pressure IN/EX 45.1 ~ 50.9 N ••• Tilt limit IN/EX 2.5° / 1.9 mm •••...
- Page 25 SPEC MAINTENANCE SPECIFICATIONS * [XQ 150] Item Standard Limit Carburetor Type TK 5DS [TK 5KD]* I.D mark ••• Main jet (M.J) #116 [#114] ••• Main air jet (M.A.J) ø1.0 [ø1.4] ••• Jet needle (J.N) 4E31 (3/5) [4E32 (3/5)]* ••• Pilot air jet (P.A.J.1) ø1.30 •••...
- Page 26 SPEC MAINTENANCE SPECIFICATIONS Item Size Crankshaft oil seal (left) 22 x 32 x 7 Crankshaft oil seal (right) 19 x 30 x 8 (Reinforced) Crankshaft oil seal (right) 19 x 30 x 8 (Double lips) Camshaft bearing (left) 20 x 42 x 12 Camshaft bearing (right) 15 x 32 x 9 Starter clutch bearing...
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Page 27: Chassis
SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS CHASSIS Item Standard Limit Steering system Steering bearing type Ball bearing ••• Front suspension Front fork travel 103 mm ••• Spring rate (K1) 6.1 N/mm ••• (K2) 7.8 N/mm ••• Stroke (K1) 0 ~ 11 mm •••... - Page 28 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Front disc brake Type Single disc brake ••• Disc outside diameter x thickness 245 x 4.7 mm ••• Min. thickness ••• 4.2 mm Max deflection ••• 0.15 mm Pad thickness 4 mm 0.8 mm Master cylinder inside diameter 13 mm •••...
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Page 29: Electrical
SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ELECTRICAL Item Standard Limit Ignition timing Ignition timing (B.T.D.C) 10° at 1.700 rpm ••• Advanced timing (B.T.D.C) 26° at 4.500 rpm ••• Advancer type Digital ••• Ignition system 248 ~ 372 Ω at 20°C Pickup coil resistance •••... - Page 30 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Horn Model/manufacturer YF-12 / NIKKO ••• Maximum amperage ••• Turn signal relay Model/Manufacturer 800 TRANSVAL / 01.2320.01 GUILERA ••• Turn signal blinking frequency 65 ~ 95 cycles/min. / 70 ~ 90 cycles/min. ••• Fuel gauge Model/manufacturer 25.33.07 / MAXIMA •••...
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Page 31: Conversion Table
SPEC CONVERSION TABLE AS00028 CONVERSION TABLE All specification data in this manual are listed in SI and METRIC UNITS. Use this table to convert METRIC unit data to IMPERIAL unit data. METRIC MULTIPLIER IMPERERIAL ** mm 0.03937 ** in 2 mm 0.03937 0.08 in CONVERSION TABLE... -
Page 32: General Tightening Torque Specifications
SPEC GENERAL TIGHTENING TORQUE SPECIFICATIONS EAS00029 GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch. Tightening torque specifications for special components or assemblies are provided for each chapter of this manual. To avoid warpage, tighten multi-fastener assemblies in a crisscross pattern and progressive stages until the specified tightening torque is reached. -
Page 33: Tightening Torques
SPEC TIGHTENING TORQUES TIGHTENING TORQUES ENGINE Tightening Thread torque Item Fastener Q'ty Remarks size m•kg Oil check bolt Bolt Spark plug Cylinder, water drain bolt Bolt Cylinder head and cylinder Cylinder head and cylinder Bolt Cylinder and crankcase Bolt Camshaft bearing stopper Bolt Camchain guide Bolt... - Page 34 SPEC TIGHTENING TORQUES Tightening Thread torque Item Fastener Q'ty Remarks size m•kg Thermo unit Pt 1/8 Coolant drain bolt on cylinder Bolt Starter motor Bolt Rotor 22.5 22.5 Stator Bolt 2-15...
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Page 35: Tightening Torques Chassis
SPEC TIGHTENING TORQUES TIGHTENING TORQUES CHASSIS Tightening Thread torque Item Fastener Q'ty Remarks size m•kg Frame with engine bracket Bolt Engine bracket 2 with 3 Bolt E/G bracket with E/G (with main stand) Bolt Exhaust pipe stud bolt on cylinder Muffler on rear arm Bolt Rear arm on crankcase... -
Page 36: Lubrication Points And Lubricant Types
Idle gear 1 thrust surfaces Shaft 1 Idle gear 2 thrust surfaces Idle gear 2 inner surface Main axle thrust surfaces Crankcase mating surfaces Yamaha bond No. 1215 Crankcase breather plug Stator grommet Yamaha bond No. 1215 Suction pipe 2-17... -
Page 37: Chassis
SPEC LUBRICATION POINTS AND LUBRICANT TYPES EAS00032 CHASSIS Lubrication Point Symbol Front wheel oil seal lips (left/right) Steering head pipe bearing (upper/lower) Tube guide (throttle grip) inner surface Brake cable (brake lever) Brake lever and lever holder bolt sliding surface Sidestand sliding surface Centerstand sliding surface and mounting bolt Centerstand stopper pivot shaft... -
Page 38: Cooling System Diagrams
SPEC COOLING SYSTEM DIAGRAMS EAS00033 COOLING SYSTEM DIAGRAMS Radiator cap Clip Coolant tank cap Hose Coolant hose (cylinder head outlet) Coolant hose (pump inlet) Frame Clamp Coolant tank Coolant tank breather hose A Keep the smaller diameter for fixing on the Clip frame (ø... - Page 39 SPEC COOLING SYSTEM DIAGRAMS EAS00033(bis) COOLING SYSTEM DIAGRAMS Grommet Radiator cap Coolant tank Coolant hose (pump inlet) Coolant upper level mark A Pass the hose under the seat rail fixation. Coolant lower level mark B Pass the hose under the frame down tube. Coolant tank breather hose C Pass the hose through the under cover.
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Page 40: Lubrication Diagrams
SPEC LUBRICATION DIAGRAMS EAS00034 LUBRICATION DIAGRAMS 1 Lubrication of the cylinder head Cylinder head Cylinder Crankcase 2 Lubrication of the crankshaft Crankshaft 2-21...