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Yamaha YZ125 2015 Owner's Service Manual

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2015
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.
OWNER'S SERVICE MANUAL
MANUEL D'ATELIER DU
PROPRIETAIRE
FAHRER- UND
WARTUNGSHANDBUCH
MANUALE DI SERVIZIO DEL
PROPRIETARIO
YZ125
YZ125F2
1SR-28199-33

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Summary of Contents for Yamaha YZ125 2015

  • Page 1 2015 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. OWNER’S SERVICE MANUAL MANUEL D’ATELIER DU PROPRIETAIRE...
  • Page 2 Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold. 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. Bitte lesen Sie diese Bedienungsanleitung sorgfältig durch, bevor Sie das Fahrzeug in Betrieb nehmen.
  • Page 3 2015 2015 Read this manual carefully before operating this vehicle. Read this manual carefully before operating this vehicle. OWNER’S SERVICE MANUAL OWNER’S SERVICE MANUAL YZ125 YZ125 YZ125F2 YZ125F2 1SR-28199-33-E0 1SR-28199-33-E0...
  • Page 5 YZ125 YZ125F2 OWNER'S SERVICE MANUAL ©2014 by Yamaha Motor Co., Ltd. 1st Edition, June 2014 All rights reserved.Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan...
  • Page 6 Always turn off the engine while re- Congratulations on your purchase of could result in death or serious in- fueling. Take care to not spill any a Yamaha YZ series. This model is jury. gasoline on the engine or exhaust the culmination of Yamaha's vast ex- system.
  • Page 7 HOW TO USE THIS MANUAL FINDING THE REQUIRED PAGE 1. This manual consists of seven chapters; "General Information", "Specifications", "Regular inspec- tion 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 be- fore finding then required chapter and item.
  • Page 8 2. Numbers "2" are given in the or- 4. A job instruction chart "4" accom- HOW TO READ DESCRIPTIONS der of the jobs in the exploded di- panies the exploded diagram, To help identify parts and clarify pro- agram. A number that is enclosed providing the order of jobs, names cedure steps, there are exploded dia- by a circle indicates a disassem-...

  • Page 9: Table Of Contents

    TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS REGULAR INSPECTION AND ADJUSTMENTS ENGINE CHASSIS ELECTRICAL TUNING...

  • Page 10: General Information

    CONTENTS CHAPTER 1 CHAPTER 3 CHAPTER 5 GENERAL REGULAR CHASSIS INFORMATION INSPECTION AND ADJUSTMENTS FRONT WHEEL AND REAR WHEEL ....5-1 LOCATION OF FRONT BRAKE AND IMPORTANT LABELS ..1-1 MAINTENANCE REAR BRAKE ....5-6 DESCRIPTION ....1-5 INTERVALS...... 3-1 FRONT FORK....5-16 CONSUMER PRE-OPERATION HANDLEBAR....5-24...
  • Page 11 LOCATION OF IMPORTANT LABELS GENERAL INFORMATION LOCATION OF IMPORTANT LABELS Please read the following important labels carefully before operating this vehicle. CANADA...
  • Page 12 LOCATION OF IMPORTANT LABELS EUROPE...
  • Page 13 LOCATION OF IMPORTANT LABELS AUS, NZ, ZA...
  • Page 14 LOCATION OF IMPORTANT LABELS Familiarize yourself with the following pictograms and read the explanatory text. Read Owner's service manual. This unit contains high-pressure nitrogen gas. Mishandling can cause explosion. Do not incinerate, puncture or open. Turn off the main switch after riding to avoid draining the battery. Use unleaded gasoline only.
  • Page 15 DESCRIPTION DESCRIPTION Clutch lever 14. Fuel cock Engine stop switch 15. Air filter Front brake lever 16. Drive chain Throttle grip 17. Shift pedal Radiator cap 18. Starter knob Fuel tank cap 19. Front fork Kickstarter lever Fuel tank Radiator 10.
  • Page 16 There are two significant reasons for knowing the serial number of your machine: 1. When ordering parts, you can give the number to your Yamaha dealer for positive identification of the model you own. VALVE JOINT 2. If your machine is stolen, the au- This valve joint "1"...
  • Page 17 CHECKING OF CONNECTION ALL REPLACEMENT PARTS 6. Connect: 1. We recommend to use Yamaha • Connector genuine parts for all replace- ments. Use oil and/or grease rec- The two connectors "click" together. ommended by Yamaha for 7. Check for continuity with a tester.
  • Page 18 SPECIAL TOOLS SPECIAL TOOLS The proper special tools are necessary for complete and accurate tune-up and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised techniques. The shape and part number used for the special tool differ by country, so two types are provided.
  • Page 19 SPECIAL TOOLS Tool name/Part number How to use Illustration Fuel level gauge "1" This gauge is used to measure the YM-01312-A, 90890-01312 fuel level in the float chamber. Fuel level gauge adaptor "2" YM-01470, 90890-01470 Radiator cap tester These tools are used for checking YU-24460-A, 90890-01325 the cooling system.
  • Page 20 Dynamic spark tester This instrument is necessary for YM-34487 checking the ignition system compo- Ignition checker nents. 90890-06754 Yamaha bond No. 1215 This sealant (Bond) is used for 90890-85505 crankcase mating surface, etc. (Three bond No. 1215®) 1-10...
  • Page 21 CONTROL FUNCTIONS CONTROL FUNCTIONS ENGINE STOP SWITCH The engine stop switch "1" is located on the left handlebar. Continue push- ing the engine stop switch till the en- gine comes to a stop. THROTTLE GRIP STARTER KNOB (CHOKE) The throttle grip "1" is located on the When cold, the engine requires a right handlebar;...
  • Page 22 STARTING AND BREAK-IN STARTING A WARM ENGINE 9. Restart the engine and check the Mixing oil: Do not operate the starter knob operation of the machine through- Recommended oil: (CHOKE). Open the throttle slightly out its entire operating range. YAMALUBE "2-R" and start the engine by kicking the Stop and check the spark plug (YAMALUBE racing 2-...
  • Page 23 TORQUE-CHECK POINTS TORQUE-CHECK POINTS Frame construction Frame to rear frame Combined seat and fuel tank Fuel tank to frame Exhaust system Silencer to rear frame Engine mounting Frame to engine Engine bracket to engine Engine bracket to frame Steering Steering stem to handlebar Steering stem to frame Steering stem to upper bracket Upper bracket to handlebar...
  • Page 24 MAINTENANCE AFTER BREAK-IN MAINTENANCE AFTER • Cable 4. After the majority of the dirt has Grease and adjust cables. been hosed off, wash all surfaces BREAK-IN • Drive chain with warm water and a mild deter- After a break-in, perform careful Lubricate the drive chain and ad- gent.

  • Page 25: Specifications

    GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Model name: YZ125F2 (USA, CDN, AUS, NZ) YZ125 (EUROPE, ZA) Model code number: 1SRD (USA, CDN) 1SRE (EUROPE) 1SRG (AUS, NZ, ZA) Dimensions: Overall length 2,137 mm (84.1 in) Overall width 827 mm (32.6 in) Overall height 1,295 mm (51.0 in) Seat height...
  • Page 26 GENERAL SPECIFICATIONS Transmission: Primary reduction system Gear Primary reduction ratio 3.368 (64/19) Final drive Chain Secondary reduction ratio 3.692 (48/13) Transmission type Constant mesh, 6-speed Operation Left foot operation Gear ratio: 2.385 (31/13) 1.933 (29/15) 1.588 (27/17) 1.353 (23/17) 1.200 (24/20) 1.095 (23/21) Chassis: Frame type...
  • Page 27 MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Item Standard Limit Cylinder head: Combustion chamber volume 8.40–8.60 cm (0.51–0.52 cu.in) ---- Warp limit ---- 0.03 mm (0.0012 in) Cylinder: Bore size 54.000–54.014 mm (2.1260–2.1265 in) 54.100 mm (2.1299 in) Taper limit ---- 0.050 mm (0.0020 in) Out of round limit ----...
  • Page 28 MAINTENANCE SPECIFICATIONS Item Standard Limit Crankshaft: Crank width "A" 55.90–55.95 mm (2.201–2.203 in) ---- Runout limit "C" 0.030 mm (0.0012 in) 0.050 mm (0.0020 in) Connecting rod big end side clearance "D" 0.060–0.640 mm (0.0024–0.0252 in) ---- Small end free play "F" 0.80–1.00 mm (0.03–0.04 in) 2.0 mm (0.08 Clutch:...
  • Page 29 MAINTENANCE SPECIFICATIONS Item Standard Limit Carburetor: USA, CDN EUROPE AUS, NZ, ZA ← ← Type/Manufacturer TMXχ38SS/ MIKUNI ← I.D. mark 1C37 51 1C36 41 ---- ← ← Main jet (M.J.) #430 ---- ← ← Jet needle-clip position (J.N.) 6BFY43-74-3 ---- ←...
  • Page 30 MAINTENANCE SPECIFICATIONS CHASSIS Item Standard Limit Steering system: Steering bearing type Taper roller bearing ---- Front suspension: Front fork travel 300.0 mm (11.81 in) ---- Fork spring free length 454.0 mm (17.87 in) 449.0 mm (17.68 in) Spring rate, STD K=4.10 N/mm (0.42 kg/mm, 23.41 lb/in) ---- Optional spring...
  • Page 31 Green/Blue) 248.0–372.0 Ωat 20 °C (68 °F) (White/ Pickup coil resistance (color) ---- Blue-White/Red) CDI unit-model/manufacturer 1C3-10/YAMAHA (USA, CDN) ---- 1SR-00/YAMAHA (EUROPE, AUS, ZA, Ignition coil: Model/manufacturer 1C3-00/YAMAHA ---- Minimum spark gap 6.0 mm (0.24 in) ---- 0.24–0.36 Ωat 20 °C (68 °F)
  • Page 32 TIGHTENING TORQUES TIGHTENING TORQUES ENGINE △ - marked portion shall be checked for torque tightening after break-in or before each race. Thread Item Q'ty Tightening torque Remarks size Spark plug M14S 20 Nm (2.0 m•kg, 14 ft•lb) Copper Cylinder head (nut) 28 Nm (2.8 m•kg, 20 ft•lb) washer Cylinder head (stud)
  • Page 33 TIGHTENING TORQUES Thread Item Q'ty Tightening torque Remarks size Primary drive gear 48 Nm (4.8 m•kg, 35 ft•lb) Clutch boss 80 Nm (8.0 m•kg, 58 ft•lb) Lock washer Clutch spring 10 Nm (1.0 m•kg, 7.2 ft•lb) Clutch cable adjust bolt and locknut 4 Nm (0.4 m•kg, 2.9 ft•lb) Drive sprocket 75 Nm (7.5 m•kg, 54 ft•lb)
  • Page 34 TIGHTENING TORQUES CHASSIS △ - marked portion shall be checked for torque tightening after break-in or before each race. Thread Item Q'ty Tightening torque Remarks size △ Upper bracket and outer tube 21 Nm (2.1 m•kg, 15 ft•lb) △ Lower bracket and outer tube 21 Nm (2.1 m•kg, 15 ft•lb) △...
  • Page 35 TIGHTENING TORQUES Thread Item Q'ty Tightening torque Remarks size TORX Footrest bracket and frame 55 Nm (5.5 m•kg, 40 ft•lb) △ Brake pedal mounting 26 Nm (2.6 m•kg, 19 ft•lb) △ Rear brake master cylinder and frame 10 Nm (1.0 m•kg, 7.2 ft•lb) Rear brake master cylinder cap 2 Nm (0.2 m•kg, 1.4 ft•lb) △...
  • Page 36 TIGHTENING TORQUES Thread Item Q'ty Tightening torque Remarks size △ Rear fender (rear) 12 Nm (1.2 m•kg, 8.7 ft•lb) △ Mud flap — 1 Nm (0.1 m•kg, 0.7 ft•lb) △ Side cover 7 Nm (0.7 m•kg, 5.1 ft•lb) △ Seat 19 Nm (1.9 m•kg, 13 ft•lb) △...
  • Page 37 TIGHTENING TORQUES GENERAL TORQUE TORQUE SPECIFI- SPECIFICATIONS CATION This chart specifies torque for stan- (Nut) (Bolt) dard fasteners with standard I.S.O. m•kg ft•lb pitch threads. Torque specifications 6 mm for special components or assem- blies are included in the applicable sections of this book.
  • Page 38 CABLE ROUTING DIAGRAM CABLE ROUTING DIAGRAM Engine stop switch lead 10. YPVS breather hose Pass the clutch cable on the out- Throttle cable 11. Engine bracket (right) side of the throttle cable and en- Clutch cable 12. Engine bracket (left) gine stop switch lead.
  • Page 39 CABLE ROUTING DIAGRAM Install the ignition coil, side core and ground lead together to the frame. Take care to fasten the ground lead so that its terminal is within the indicated range. Clamp the throttle cable and high tension cord to the frame. Clamp the clutch cable to the left engine bracket.
  • Page 40 CABLE ROUTING DIAGRAM High tension cord 12. CDI unit stay Clamp to the frame the throttle Engine stop switch lead Pass the high tension cord to the cable, clutch cable, ignition coil Ignition coil lead left of the radiator hose. lead and engine stop switch Clamp Using a plastic locking tie, clamp...
  • Page 41 CABLE ROUTING DIAGRAM Pass the CDI magneto lead and radiator breather hose between the frame and the radiator (right). Clamp the CDI magneto lead to the frame at its locating tape. Bring the connector cover into contact with the coupler. Locate the clamp ends in the ar- rowed range.
  • Page 42 CABLE ROUTING DIAGRAM Master cylinder Install the brake hose so that its Install the brake hose so that its Brake hose holder pipe portion directs as shown pipe portion directs as shown Brake hose and lightly touches the projec- and lightly touches the projec- tion on the caliper.
  • Page 43 CABLE ROUTING DIAGRAM Brake hose Install the brake hose so that its Pass the brake hose in front of Master cylinder pipe portion directs as shown the number plate and through Engine stop switch lead and lightly touches the projec- the cable guide.

  • Page 44: Regular Inspection And Adjustments

    If you are a doubt as to what intervals to follow in maintaining and lubricating your machine, consult your Yamaha dealer. • Periodic inspection is essential in making full use of the machine performance. The service life of the parts varies sub- stantially according to the environment in which the machine runs (e.g., rain, dirt, etc.).
  • Page 45 MAINTENANCE INTERVALS Every Every Every race third fifth After As re- Item (about (about (about Remarks break-in quired 12.5 hours) hours) hours) ROTOR NUT ● ● Retighten MUFFLER ● ● Inspect ● Clean ● ● Retighten ● * Replace fiber * When the exhaust sound be- comes louder or when a per- formance drop is felt.
  • Page 46 MAINTENANCE INTERVALS Every Every Every race third fifth After As re- Item (about (about (about Remarks break-in quired 12.5 hours) hours) hours) BRAKES ● ● Adjust lever position and pedal height ● ● Lubricate pivot point ● ● Check brake disc surface ●...
  • Page 47 ● ● Retighten sprocket bolt ● Inspect bearings ● Replace bearings ● Lubricate Lithium base grease THROTTLE, CONTROL CA- ● ● Check routing and connec- tion ● ● Lubricate Yamaha cable lube or SAE 10W-40 motor oil...
  • Page 48 PRE-OPERATION INSPECTION AND MAINTENANCE PRE-OPERATION INSPECTION AND MAINTENANCE Before riding for break-in operation, practice or a race, make sure the machine is in good operating condition. Before using this machine, check the following points. GENERAL INSPECTION AND MAINTENANCE Item Routine Page Check that coolant is filled up to the radiator cap.

  • Page 49: Engine

    ENGINE ENGINE 2. Remove: • Coolant drain bolt "1" CHECKING THE COOLANT LEVEL • When coolant splashes to your eye. Thoroughly wash your eye with Do not remove the radiator cap water and see your doctor. "1", drain bolt and hoses when the •...
  • Page 50 ENGINE 2. Apply the specified pressure. ADJUSTING THE CLUTCH LEVER POSITION If the clutch lever free play cannot be Radiator cap opening 1. Adjust: obtained on the handlebar side, use pressure: • Clutch lever position the adjuster on the clutch cable side. 95.0–125.0 kPa (0.95–...
  • Page 51 ENGINE Prior to adjusting throttle grip free Never run the engine without the play, the engine idling speed should air filter element in place; this be adjusted. would allow dirt and dust to enter the engine and cause rapid wear and possible engine damage.
  • Page 52 ENGINE ADJUSTING THE ENGINE IDLING SPEED Never attempt to remove the oil 1. Start the engine and thoroughly check bolt just after high speed warm it up. operation. The heated oil could 2. Adjust: spout out, causing danger. Wait • Engine idling speed until the oil cools down.

  • Page 53: Chassis

    CHASSIS CHASSIS h. Tighten the bleed screw when the lever or pedal limit has been BLEEDING THE HYDRAULIC reached; then release the lever or BRAKE SYSTEM pedal. Bleed screw: Bleed the brake system if: 6 Nm (0.6 m•kg, 4.3 • The system has been disassem- ft•lb) bled.
  • Page 54 CHASSIS d. Remove the pad pin and brake pads "4". Install the pad pin plug "10". Pad pin plug: e. Connect the transparent hose "5" 3 Nm (0.3 m•kg, 2.2 to the bleed screw "6" and place ft•lb) the suitable container under its end.
  • Page 55 CHASSIS 2. Inspect: • Rear brake pad insulator "1" Damage → Replace. b. Loosen the pad pin "3". Install the brake caliper "12" and c. Remove the rear wheel "4" and rear wheel "13". brake caliper "5". Refer to "FRONT WHEEL AND Refer to "FRONT WHEEL AND REAR WHEEL"...
  • Page 56 CHASSIS 4. Check: • Drive chain stiffness "a" Before checking and/or adjusting, ro- Clean and oil the drive chain and tate the rear wheel through several hold as illustrated. revolutions and check the slack sev- Stiff → Replace the drive chain. eral times to find the tightest point.
  • Page 57 CHASSIS d. Tighten the axle nut while pushing 2. Clean: down the drive chain. • Dust seal "a" • Oil seal "b" Axle nut: 125 Nm (12.5 m•kg, 90 • Clean the dust seal and oil seal af- ft•lb) ter every run. e.
  • Page 58 CHASSIS Do not force the adjuster past the Never attempt to turn the adjuster minimum or maximum extent of beyond the maximum or minimum adjustment. The adjuster may be setting. damaged. e. Tighten the locknut. Locknut: 30 Nm (3.0 m•kg, 22 Always adjust each front fork to ft•lb) the same setting.
  • Page 59 CHASSIS CHECKING THE TIRE PRESSURE 1. Measure: Do not force the adjuster past the • Tire pressure minimum or maximum extent of Out of specification → Adjust. adjustment. The adjuster may be Standard tire pressure: damaged. 100 kPa (1.00 kgf/cm 15 psi) ADJUSTING THE REAR SHOCK ABSORBER HIGH COMPRESSION...
  • Page 60 CHASSIS 3. Check: f. Retighten the steering ring nut us- • Steering smooth action ing the steering nut wrench. Turn the handlebar lock to lock. Unsmooth action → Adjust steer- Avoid over-tightening. ing ring nut. Steering ring nut (final tightening): 7 Nm (0.7 m•kg, 5.1 Spoke nipple wrench: ft•lb)
  • Page 61 CHASSIS 3-18...
  • Page 62 CHASSIS LUBRICATION To ensure smooth operation of all Use Yamaha cable lube or components, lubricate your machine equivalent on these areas. during setup, after break-in, and after Use SAE 10W-40 motor oil or every race. suitable chain lubricants. All control cable...

  • Page 63: Electrical

    ELECTRICAL CHECKING THE IGNITION TIMING 7. Adjust: ELECTRICAL 1. Remove: • Ignition timing CHECKING THE SPARK PLUG • Fuel tank 1. Remove: Refer to "SEAT, FUEL TANK Adjustment steps: • Spark plug AND SIDE COVERS" section in a. Loosen the screws (stator) "1". 2.
  • Page 64 SEAT, FUEL TANK AND SIDE COVERS ENGINE This section is intended for those who have basic knowledge and skill concerning the servicing of Yamaha motorcycles (e.g., Yamaha dealers, service engineers, etc.). Those who have little knowledge and skill concerning servicing are request- ed not to undertake inspection, adjustment, disassembly, or reassembly only by reference to this manual.
  • Page 65 SEAT, FUEL TANK AND SIDE COVERS REMOVING THE SIDE COVER 1. Remove: • Bolt (side cover) • Side cover (left and right) "1" Draw the side cover backward to re- move it because its claws "a" are in- serted in the air filter case. REMOVING THE NUMBER PLATE 1.
  • Page 66 EXHAUST PIPE AND SILENCER EXHAUST PIPE AND SILENCER REMOVING THE EXHAUST PIPE AND SILENCER 12 Nm (1.2 m kg, 8.7 ft lb) 12 Nm (1.2 m kg, 8.7 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) 12 Nm (1.2 m kg, 8.7 ft lb) 12 Nm (1.2 m kg, 8.7 ft lb) Order Part name...
  • Page 67 • Fiber "2" 4. Install: • Inner pipe ® Fully apply Quick gasket (Yamaha bond No.1215) or equivalent as shown. Yamaha bond No.1215: 90890-85505 (Three bond No.1215®) 5. Install: • Bolt (fiber) "1" Bolt (fiber): 10 Nm (1.0 m•kg, 7.2 ft•lb) •...
  • Page 68 RADIATOR RADIATOR REMOVING THE RADIATOR 2 Nm (0.2 m kg, 1.4 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) 2 Nm (0.2 m kg, 1.4 ft lb) Order Part name Q'ty...
  • Page 69 RADIATOR HANDLING NOTE 2. Install: 5. Install: • Right radiator "1" • Radiator guard "1" • Washer "2" • Bolt (radiator guard) "2" Do not remove the radiator cap • Bolt (right radiator) "3" Bolt (radiator guard): when the engine and radiator are Bolt (right radiator): 10 Nm (1.0 m•kg, 7.2 hot.
  • Page 70 CARBURETOR AND REED VALVE CARBURETOR AND REED VALVE REMOVING THE CARBURETOR AND REED VALVE 2 Nm (0.2 m kg, 1.4 ft lb) 2 Nm (0.2 m kg, 1.4 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) 1 Nm (0.1 m kg, 0.7 ft lb) Order Part name Q'ty...
  • Page 71 CARBURETOR AND REED VALVE DISASSEMBLING THE CARBURETOR 4 Nm (0.4 m kg, 2.9 ft lb) Order Part name Q'ty Remarks Mixing chamber top Refer to removal section. Throttle valve Needle holder Jet needle Float chamber Needle jet cover Float pin Float Valve seat Main jet...
  • Page 72 CARBURETOR AND REED VALVE HANDLING NOTE CHECKING THE JET NEEDLE 1. Inspect: • Jet needle "1" Do not disassemble the venturi Bends/wear → Replace. block "1" and main nozzle "2" be- • Clip groove cause it will cause a drop in carbu- Free play exists/wear →...
  • Page 73 CARBURETOR AND REED VALVE d. Measure the fuel level with the 2. Measure: fuel level gauge. • Valve stopper height "a" Out of specification → Adjust stop- per/Replace valve stopper. Keep the carburetor and fuel level gauge vertically when measuring the Valve stopper height "a": fuel level.
  • Page 74 CARBURETOR AND REED VALVE 4. Install: • Needle valve "1" • Float "2" • Float pin "3" • Screw (float pin) "4" • Needle jet cover "5" • After installing the needle valve to 2. Tighten: the float, install them to the carbure- •...
  • Page 75 CYLINDER HEAD, CYLINDER AND PISTON CYLINDER HEAD, CYLINDER AND PISTON REMOVING THE CYLINDER HEAD AND CYLINDER 20 Nm (2.0 m kg, 14 ft lb) 28 Nm (2.8 m kg, 20 ft lb) 34 Nm (3.4 m kg, 24 ft lb) 13 Nm (1.3 m kg, 9.4 ft lb) 30 Nm (3.0 m kg, 22 ft lb) 4 Nm (0.4 m kg, 2.9 ft lb)
  • Page 76 CYLINDER HEAD, CYLINDER AND PISTON REMOVING THE PISTON AND POWER VALVE 4 Nm (0.4 m kg, 2.9 ft lb) 8 Nm (0.8 m kg, 5.8 ft lb) 4 Nm (0.4 m kg, 2.9 ft lb) 5 Nm (0.5 m kg, 3.6 ft lb) Order Part name Q'ty...
  • Page 77 CYLINDER HEAD, CYLINDER AND PISTON REMOVING THE PUSH ROD 3. Remove: 1. Remove: • Piston ring "1" • Bolt (push rod) "1" • Push rod "2" Take care not to scratch the piston or damage the piston ring by expanding Set the collar "3"...
  • Page 78 CYLINDER HEAD, CYLINDER AND PISTON 5. Check: • Free play Standard Wear limit There should be no noticeable free play. 54.000– Free play exists → Inspect the Cylin- 54.100 54.014 mm der bore connecting rod for wear/Replace (2.1260– "C" (2.1299 in) the pin and/or connecting rod as 2.1265 in) required.
  • Page 79 CYLINDER HEAD, CYLINDER AND PISTON 2. Check: CHECKING THE POWER VALVE • Piston mark "a" HOLE ON CYLINDER 1. Remove: Piston mark "a" Piston size • Carbon deposits (color) From power valve hole surface 53.957–53.960 "a". A (red) mm (2.1243– 2.1244 in) Do not use a sharp instrument.
  • Page 80 CYLINDER HEAD, CYLINDER AND PISTON • Install the spring to the link lever, • The arrow "a" on the piston dome and then to the cylinder. must point to exhaust side. • Install the spring with its stopper • Apply the engine oil on the piston portion "a"...
  • Page 81 CYLINDER HEAD, CYLINDER AND PISTON 5. Install: 8. Install: • Gasket (power valve housing) • Engine bracket "1" • Bolt (engine bracket) "2" • Power valve housing "1" Bolt (engine bracket): • Bolt (power valve housing) "2" 34 Nm (3.4 m•kg, 24 Bolt (power valve hous- ft•lb) ing):...
  • Page 82 CLUTCH CLUTCH REMOVING THE CLUTCH 10 Nm (1.0 m kg, 7.2 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) Order Part name Q'ty Remarks Refer to "CHANGING THE TRANSMISSION Drain the transmission oil. OIL" section in the CHAPTER 3. Bolt (brake pedal) Shift the brake pedal downward.
  • Page 83 CLUTCH REMOVING THE CLUTCH BOSS 80 Nm (8.0 m kg, 58 ft lb) Order Part name Q'ty Remarks Push rod 1 Circlip Washer Bearing Ball Push rod 2 Nut (clutch boss) Refer to removal section. Lock washer Refer to removal section. Clutch boss Refer to removal section.
  • Page 84 CLUTCH REMOVING THE CLUTCH BOSS CHECKING THE CLUTCH CHECKING THE PUSH LEVER 1. Remove: SPRINGS SHAFT • Nut "1" 1. Measure: 1. Inspect: • Lock washer "2" • Clutch spring free length "a" • Push lever shaft "1" Out of specification → Replace Wear/Damage →...
  • Page 85 CLUTCH 5. Install: 9. Install: • Friction plate "1" • Clutch spring "1" • Clutch plate "2" • Bolt (clutch spring) "2" Bolt (clutch spring): • Install the clutch plates and friction 10 Nm (1.0 m•kg, 7.2 plates alternately on the clutch ft•lb) boss, starting with a friction plate and ending with a friction plate.
  • Page 86 KICK SHAFT AND SHIFT SHAFT KICK SHAFT AND SHIFT SHAFT REMOVING THE PRIMARY DRIVE GEAR Order Part name Q'ty Remarks Refer to "CHANGING THE TRANSMISSION Drain the transmission oil. OIL" section in the CHAPTER 3. Clutch cable Disconnect at engine side. Bolt (brake pedal) Shift the brake pedal downward.
  • Page 87 KICK SHAFT AND SHIFT SHAFT REMOVING THE KICK SHAFT AND SHIFT SHAFT Order Part name Q'ty Remarks Kick idle gear Kick shaft assembly Refer to removal section. Shift pedal Shift shaft Roller Shift guide Refer to removal section. Shift lever assembly Refer to removal section.
  • Page 88 KICK SHAFT AND SHIFT SHAFT REMOVING THE PRIMARY DRIVE CHECKING THE SHIFT SHAFT GEAR 1. Inspect: If the segment gets an impact, the 1. Loosen: • Shift shaft "1" stopper lever may be damaged. Bend/damage → Replace. • Bolt (primary drive gear) "1" Take care not to give an impact to •...
  • Page 89 KICK SHAFT AND SHIFT SHAFT INSTALLING THE SEGMENT INSTALLING THE SHIFT GUIDE INSTALLING THE SHIFT SHAFT 1. Install: AND SHIFT LEVER ASSEMBLY 1. Install: • Segment "1" 1. Install: • Roller "1" • Bolt (segment) • Spring "1" • Shift shaft "2" •...
  • Page 90 KICK SHAFT AND SHIFT SHAFT 3. Install: • Kick shaft assembly "1" Tighten the bolts in stage, using a crisscross pattern. • Apply the transmission oil on the kick shaft. • Slide the kick shaft assembly into the crankcase, make sure the clip "2"...
  • Page 91 YPVS GOVERNOR YPVS GOVERNOR REMOVING THE YPVS GOVERNOR Order Part name Q'ty Remarks Refer to "KICK SHAFT AND SHIFT SHAFT" Right crankcase cover section. Governor assembly Dowel pin Refer to removal section. Retainer Ball Retainer weight Plain washer Thrust bearing Collar Plate Compression spring...
  • Page 92 YPVS GOVERNOR REMOVING THE GOVERNOR 1. Remove: • Dowel pin "1" While compressing the spring, re- move the dowel pin. CHECKING THE GOVERNOR GROOVE 2. Install: 1. Inspect: • Ball "1" • Washer "1" • Retainer "2" • Collar "2" To governor shaft "3".
  • Page 93 WATER PUMP WATER PUMP DISASSEMBLING THE WATER PUMP Order Part name Q'ty Remarks Refer to "KICK SHAFT AND SHIFT SHAFT" Crankcase cover (right) section. Water pump housing cover Impeller shaft gear Dowel pin Plain washer Impeller shaft assembly Bearing Refer to removal section. Oil seal Refer to removal section.
  • Page 94 WATER PUMP REMOVING THE OIL SEAL CHECKING THE BEARING INSTALLING THE IMPELLER 1. Inspect: SHAFT • Bearing "1" 1. Install: • Replace the oil seal when transmis- Rotate inner race with a finger. • Impeller shaft "1" sion oil or coolant leaks out from the Rough spot/seizure →...
  • Page 95 WATER PUMP 4. Install: • Water pump housing cover "1" • Bolt (water pump housing cover) "2" Bolt (water pump hous- ing cover): 10 Nm (1.0 m•kg, 7.2 ft•lb) • Copper washer (coolant drain bolt) "3" • Coolant drain bolt "4" Coolant drain bolt: 10 Nm (1.0 m•kg, 7.2 ft•lb)
  • Page 96 CDI MAGNETO CDI MAGNETO REMOVING THE CDI MAGNETO Order Part name Q'ty Remarks Refer to "SEAT, FUEL TANK AND SIDE Seat and fuel tank COVERS" section. Bolt (Radiator) Refer to "RADIATOR" section. Disconnect the CDI magneto lead. Left crankcase cover Nut (rotor) Refer to removal section.
  • Page 97 CDI MAGNETO REMOVING THE ROTOR INSTALLING THE CDI MAGNETO 4. Adjust: 1. Remove: 1. Install: • Ignition timing • Nut (rotor) "1" • Stator "1" Refer to "CHECKING THE IGNI- • Washer "2" • Screw (stator) "2" TION TIMING" section in the Use the rotor holding tool "3".
  • Page 98 ENGINE REMOVAL ENGINE REMOVAL REMOVING THE ENGINE 26 Nm (2.6 m kg, 19 ft lb) 34 Nm (3.4 m kg, 24 ft lb) 5 Nm (0.5 m kg, 3.6 ft lb) 64 Nm (6.4 m kg, 46 ft lb) 64 Nm (6.4 m kg, 46 ft lb) 85 Nm (8.5 m kg, 61 ft lb) 75 Nm (7.5 m kg, 54 ft lb) Order...
  • Page 99 ENGINE REMOVAL 26 Nm (2.6 m kg, 19 ft lb) 34 Nm (3.4 m kg, 24 ft lb) 5 Nm (0.5 m kg, 3.6 ft lb) 64 Nm (6.4 m kg, 46 ft lb) 64 Nm (6.4 m kg, 46 ft lb) 85 Nm (8.5 m kg, 61 ft lb) 75 Nm (7.5 m kg, 54 ft lb) Order...
  • Page 100 ENGINE REMOVAL HANDLING NOTE 2. Remove: • Engine "1" From right side. Support the machine securely so there is no danger of it falling over. Make sure that the couplers, hoses and cables are disconnected. REMOVING THE DRIVE SPROCKET 1. Remove: •...
  • Page 101 ENGINE REMOVAL 2. Install: • Lock washer "1" • Nut (drive sprocket) "2" Nut (drive sprocket): 75 Nm (7.5 m•kg, 54 ft•lb) Tighten the nut while applying the rear brake. 3. Bend the lock washer tab to lock the nut. 4.
  • Page 102 CRANKCASE AND CRANKSHAFT CRANKCASE AND CRANKSHAFT REMOVING THE CRANKSHAFT 30 Nm (3.0 m kg, 22 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) 14 Nm (1.4 m kg, 10 ft lb) 20 Nm (2.0 m kg, 14 ft lb) Order Part name Q'ty...
  • Page 103 CRANKCASE AND CRANKSHAFT 30 Nm (3.0 m kg, 22 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) 14 Nm (1.4 m kg, 10 ft lb) 20 Nm (2.0 m kg, 14 ft lb) Order Part name Q'ty Remarks Crankshaft Refer to removal section.
  • Page 104 CRANKCASE AND CRANKSHAFT REMOVING THE SEGMENT 1. Remove: • Bolt (segment) "1" • Segment "2" Turn the segment counterclockwise until it stops and loosen the bolt. REMOVING THE CRANKSHAFT CHECKING THE CRANKCASE 1. Remove: 1. Inspect: If the segment gets an impact, the •...
  • Page 105 — (0.0024– • Sealant ance: Crankshaft installing pot 0.0252 in) On the right crankcase "1". "2": 55.90–55.95 YU-90058/90890-01274 Yamaha bond No.1215: Crack mm (2.201– — Crankshaft installing bolt 90890-85505 width: 2.203 in) "3": (Three bond No.1215®) YU-90060/90890-01275 Adapter "4":...
  • Page 106 "a" where the crank- Unsmooth operation → Repair. shaft and bearing come in contact. Bolt (holder): • Use two plain washers (Yamaha 10 Nm (1.0 m•kg, 7.2 genuine: 90201-243K3) "5" or the If the crankshaft will not turn smooth- ft•lb)
  • Page 107 TRANSMISSION, SHIFT CAM AND SHIFT FORK TRANSMISSION, SHIFT CAM AND SHIFT FORK REMOVING THE TRANSMISSION, SHIFT CAM AND SHIFT FORK 10 Nm (1.0 m kg, 7.2 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) Order Part name Q'ty Remarks Engine Refer to "ENGINE REMOVAL"...
  • Page 108 TRANSMISSION, SHIFT CAM AND SHIFT FORK REMOVING THE TRANSMISSION CHECKING THE SHIFT FORK, 1. Remove: SHIFT CAM AND SEGMENT • Main axle "1" 1. Inspect: • Drive axle "2" • Shift fork "1" Wear/damage/scratches → Re- place. • Tap lightly on the transmission drive axle with a soft hammer to remove.
  • Page 109 TRANSMISSION, SHIFT CAM AND SHIFT FORK 4. Check: • Shifter operation • Transmission operation Unsmooth operation → Repair. 4. Install: 2. Install: • Collar "1" • Shift cam "1" • Apply the lithium soap base grease • Apply the transmission oil on the on the oil seal lip.
  • Page 110 FRONT WHEEL AND REAR WHEEL CHASSIS This section is intended for those who have basic knowledge and skill concerning the servicing of Yamaha motorcycles (e.g., Yamaha dealers, service engineers, etc.). Those who have little knowledge and skill concerning servicing are request- ed not to undertake inspection, adjustment, disassembly, or reassembly only by reference to this manual.
  • Page 111 FRONT WHEEL AND REAR WHEEL REMOVING THE REAR WHEEL Order Part name Q'ty Remarks Hold the machine by placing the suitable stand Refer to "HANDLING NOTE". under the engine. Nut (rear wheel axle) Rear wheel axle Drive chain puller Rear wheel Refer to removal section.
  • Page 112 FRONT WHEEL AND REAR WHEEL HANDLING NOTE Support the machine securely so there is no danger of it falling over. REMOVING THE REAR WHEEL 1. Remove: • Wheel "1" CHECKING THE WHEEL AXLE 1. Measure: Push the wheel forward and remove •...
  • Page 113 FRONT WHEEL AND REAR WHEEL 2. Install: 6. Install: • Brake disc "1" • Nut (wheel axle) "1" Do not strike the inner race of the • Bolt (brake disc) "2" Nut (wheel axle): bearing. Contact should be made Bolt (brake disc): 105 Nm (10.5 m•kg, 75 only with the outer race.
  • Page 114 FRONT WHEEL AND REAR WHEEL 4. Install: 8. Install: • Collar "1" • Right drive chain puller "1" • Washer "2" • Nut (wheel axle) "3" Apply the lithium soap base grease on the oil seal lip. Temporarily tighten the nut (wheel axle) at this point.
  • Page 115 FRONT BRAKE AND REAR BRAKE FRONT BRAKE AND REAR BRAKE REMOVING THE FRONT BRAKE Order Part name Q'ty Remarks Hold the machine by placing the suitable stand Refer to "HANDLING NOTE". under the engine. Drain the brake fluid. Refer to removal section. Brake hose holder (protector) Union bolt Brake hose...
  • Page 116 FRONT BRAKE AND REAR BRAKE REMOVING THE REAR BRAKE Order Part name Q'ty Remarks Hold the machine by placing the suitable stand Refer to "HANDLING NOTE". under the engine. Refer to "FRONT WHEEL AND REAR Rear wheel WHEEL" section. Drain the brake fluid. Refer to removal section.
  • Page 117 FRONT BRAKE AND REAR BRAKE DISASSEMBLING THE BRAKE CALIPER Order Part name Q'ty Remarks Front Rear Pad pin Brake pad Pad support Brake caliper piston Refer to removal section. Brake caliper piston dust seal Refer to removal section. Brake caliper piston seal Refer to removal section.
  • Page 118 FRONT BRAKE AND REAR BRAKE DISASSEMBLING THE BRAKE MASTER CYLINDER Order Part name Q'ty Remarks Front Rear Brake master cylinder cap Diaphragm Reservoir float Push rod (Front) Brake master cylinder boot Circlip Use a long nose circlip pliers. Washer Push rod (Rear) Brake master cylinder kit...
  • Page 119 FRONT BRAKE AND REAR BRAKE HANDLING NOTE REMOVING THE BRAKE CALIPER PISTON 1. Remove: Support the machine securely so • Brake caliper piston there is no danger of it falling over. Use compressed air and proceed carefully. DRAINING THE BRAKE FLUID 1.
  • Page 120 FRONT BRAKE AND REAR BRAKE 3. Inspect: (front brake only) CHECKING THE BRAKE HOSE • Reservoir float "1" 1. Inspect: Damage → Replace. • Brake hose "1" Crack/damage → Replace. A. Front B. Rear 3. Install: 4. Inspect: • Brake caliper piston "1" •...
  • Page 121 FRONT BRAKE AND REAR BRAKE 2. Install: 3. Install: • Brake caliper "1" • Brake caliper "1" • Bolt (brake caliper) "2" • Rear wheel "2" Refer to "FRONT WHEEL AND Bolt (brake caliper): REAR WHEEL" section. 28 Nm (2.8 m•kg, 20 4.
  • Page 122 FRONT BRAKE AND REAR BRAKE INSTALLING THE FRONT BRAKE MASTER CYLINDER Always use new copper washers. 1. Install: • Brake master cylinder "1" • Brake master cylinder bracket "2" • Bolt (brake master cylinder brack- et) "3" Bolt (brake master cylin- 4.
  • Page 123 FRONT BRAKE AND REAR BRAKE 2. Install: INSTALLING THE REAR BRAKE • Brake hose holder "1" HOSE • Bolt (brake hose holder) "2" 1. Install: • Copper washer "1" Bolt (brake hose holder): • Brake hose "2" 8 Nm (0.8 m•kg, 5.8 •...
  • Page 124 FRONT BRAKE AND REAR BRAKE 2. Air bleed: 5. Install: (rear brake only) • Brake system • Protector "1" Refer to "BLEEDING THE HY- • Bolt (protector) "2" DRAULIC BRAKE SYSTEM" sec- Bolt (protector): tion in the CHAPTER 3. 7 Nm (0.7 m•kg, 5.1 3.
  • Page 125 FRONT FORK FRONT FORK REMOVING THE FRONT FORK Order Part name Q'ty Remarks Hold the machine by placing the suitable stand Refer to "HANDLING NOTE". under the engine. Refer to "FRONT WHEEL AND REAR Front wheel WHEEL" section. Refer to "FRONT BRAKE AND REAR Front brake caliper BRAKE"...
  • Page 126 FRONT FORK DISASSEMBLING THE FRONT FORK 30 Nm (3.0 m kg, 22 ft lb) 29 Nm (2.9 m kg, 21 ft lb) 1 Nm (0.1 m kg, 0.7 ft lb) 29 Nm (2.9 m kg, 21 ft lb) 55 Nm (5.5 m kg, 40 ft lb) Order Part name Q'ty...
  • Page 127 FRONT FORK HANDLING NOTE 3. Remove: REMOVING THE BASE VALVE • Adjuster "1" 1. Remove: • Base valve "1" Support the machine securely so From damper assembly "2". • While compressing the inner tube there is no danger of it falling over. "2", set the cap bolt ring wrench "4"...
  • Page 128 FRONT FORK CHECKING THE BASE VALVE Inner tube bending limit: 1. Inspect: • Be sure to use recommended 0.2 mm (0.01 in) • Base valve "1" fork oil. If other oils are used, Wear/damage → Replace. they may have an excessively ad- Contamination →...
  • Page 129 FRONT FORK 6. Tighten: 14. Check: • Locknut "1" • Damper assembly smooth move- Hold the damper assembly with the ment cap bolt ring wrench "2" and use the Tightness/binding/rough spots → Fully finger tighten the locknut onto cap bolt wrench "3" to tighten the Repeat the steps 2 to 13.
  • Page 130 FRONT FORK 17. Install: • Outer tube "1" To inner tube "2". 21. Install: 25. Install: • Dust seal "1" • Damper assembly "1" To inner tube "2". 18. Install: Apply the lithium soap base grease • Slide metal "1" on the inner tube.
  • Page 131 FRONT FORK 31. Fill: 33. Install: • Front fork oil "1" • Protector guide "1" From outer tube top. Recommended oil: Suspension oil "S1" Standard oil amount: 315 cm (11.1 Imp oz, 10.7 US oz) 28. Inspect: Extent of adjustment: •...
  • Page 132 FRONT FORK 4. Tighten: 7. Adjust: • Pinch bolt (upper bracket) "1" • Compression damping force Pinch bolt (upper brack- Turn in the damping adjuster "1" fin- et): ger-tight and then turn out to the orig- 21 Nm (2.1 m•kg, 15 inally set position.
  • Page 133 HANDLEBAR HANDLEBAR REMOVING THE HANDLEBAR 0.5 Nm (0.05 m kg, 0.36 ft lb) 9 Nm (0.9 m kg, 6.5 ft lb) 28 Nm (2.8 m kg, 20 ft lb) 5 Nm (0.5 m kg, 3.6 ft lb) 4 Nm (0.4 m kg, 2.9 ft lb) 0.5 Nm (0.05 m kg, 0.36 ft lb) 40 Nm (4.0 m kg, 29 ft lb) 4 Nm (0.4 m kg, 2.9 ft lb)
  • Page 134 HANDLEBAR DISASSEMBLING THE THROTTLE Order Part name Q'ty Remarks Grip cap (lower) Grip cap (upper) Grip assembly Grip (right) Refer to removal section. Tube guide 5-25...
  • Page 135 HANDLEBAR REMOVING THE BRAKE MASTER ASSEMBLING THE THROTTLE CYLINDER 1. Remove: 1. Remove: • Grip (right) "1" • Brake master cylinder bracket "1" Apply the adhesive on the tube • Brake master cylinder "2" guide "2". • Before applying the adhesive, wipe •...
  • Page 136 HANDLEBAR 9. Adjust: • Throttle grip free play Refer to "ADJUSTING THE THROTTLE GRIP FREE PLAY" section in the CHAPTER 3. 10. Install: • Cap cover "1" 6. Install: • Throttle cables "1" To tube guide "2". Apply the lithium soap base grease on the throttle cable end and tube guide cable winding portion.
  • Page 137 HANDLEBAR 15. Adjust: • Clutch lever free play Refer to "ADJUSTING THE CLUTCH LEVER FREE PLAY" section in the CHAPTER 3. 13. Install: • Engine stop switch "1" Engine stop switch: 0.5 Nm (0.05 m•kg, 0.36 ft•lb) • Clutch lever holder "2" •...
  • Page 138 STEERING STEERING REMOVING THE STEERING Order Part name Q'ty Remarks TIGHTENING STEPS: • Tighten ring nut. 38 Nm (3.8 m•kg, 27 ft•lb) • Loosen it one turn. • Retighten it. 7 Nm (0.7 m•kg, 5.1 ft•lb) Hold the machine by placing the suitable stand Refer to "HANDLING NOTE".
  • Page 139 STEERING HANDLING NOTE CHECKING THE STEERING STEM 1. Inspect: • Steering stem "1" Support the machine securely so Bend/damage → Replace. there is no danger of it falling over. REMOVING THE STEERING RING 1. Remove: 3. Install: • Steering ring nut "1" •...
  • Page 140 STEERING 6. Install: 11. Tighten: • Washer "1" • Pinch bolt (upper bracket) "1" Pinch bolt (upper brack- et): 21 Nm (2.1 m•kg, 15 ft•lb) • Pinch bolt (lower bracket) "2" Pinch bolt (lower brack- et): 7. Install: 21 Nm (2.1 m•kg, 15 •...
  • Page 141 SWINGARM SWINGARM REMOVING THE SWINGARM Order Part name Q'ty Remarks Hold the machine by placing the suitable stand Refer to "HANDLING NOTE". under the engine. Refer to "FRONT BRAKE AND REAR Brake hose holder BRAKE" section. Refer to "FRONT BRAKE AND REAR Rear brake caliper BRAKE"...
  • Page 142 SWINGARM DISASSEMBLING THE SWINGARM 70 Nm (7.0 m kg, 50 ft lb) 2 Nm (0.2 m kg, 1.4 ft lb) 6 Nm (0.6 m kg, 4.3 ft lb) 80 Nm (8.0 m kg, 58 ft lb) Order Part name Q'ty Remarks Refer to removal section.
  • Page 143 SWINGARM HANDLING NOTE 2. Inspect: • Oil seal "3" Damage → Replace. Support the machine securely so there is no danger of it falling over. REMOVING THE CAP 1. Remove: • Left cap "1" 2. Install: • Bearing "1" Remove with a slotted-head screw- •...
  • Page 144 SWINGARM 4. Install: 7. Check: • Connecting rod "1" • Swingarm side play "a" Free play exists → Replace thrust • Bolt (connecting rod) "2" • Washer "3" bearing. • Nut (connecting rod) "4" • Swingarm up and down move- ment "b"...
  • Page 145 SWINGARM 10. Tighten: 14. Install: • Nut (connecting rod) "1" • Drive chain support "1" • Drive chain support cover "2" Nut (connecting rod): • Bolt {drive chain support [L = 50 80 Nm (8.0 m•kg, 58 mm (1.97 in)]} "3" ft•lb) •...
  • Page 146 REAR SHOCK ABSORBER REAR SHOCK ABSORBER REMOVING THE REAR SHOCK ABSORBER 56 Nm (5.6 m kg, 40 ft lb) 2 Nm (0.2 m kg, 1.4 ft lb) 32 Nm (3.2 m kg, 23 ft lb) 29 Nm (2.9 m kg, 21 ft lb) 53 Nm (5.3 m kg, 38 ft lb) Order Part name...
  • Page 147 CHECKING THE REAR SHOCK To dispose of a damaged or worn- ABSORBER out rear shock absorber, take the 1. Inspect: unit to your Yamaha dealer for this • Damper rod "1" disposal procedure. Bends/damage → Replace rear shock absorber assembly.
  • Page 148 REAR SHOCK ABSORBER 2. Install: 3. Adjust: Nut (rear shock absorb- • Stopper ring (upper bearing) "1" • Spring length (installed) er-frame): Refer to "ADJUSTING THE 56 Nm (5.6 m•kg, 40 REAR SHOCK ABSORBER ft•lb) SPRING PRELOAD" section in After installing the stopper ring, push the CHAPTER 3.
  • Page 149 REAR SHOCK ABSORBER 7. Tighten: • Bolt (air filter joint) "1" Bolt (air filter joint): 2 Nm (0.2 m•kg, 1.4 ft•lb) 5-40...
  • Page 150 ELECTRICAL COMPONENTS AND WIRING DIAGRAM ELECTRICAL This section is intended for those who have basic knowledge and skill concerning the servicing of Yamaha motorcycles (e.g., Yamaha dealers, service engineers, etc.). Those who have little knowledge and skill concerning servicing are request- ed not to undertake inspection, adjustment, disassembly, or reassembly only by reference to this manual.
  • Page 151 IGNITION SYSTEM IGNITION SYSTEM INSPECTION STEPS Use the following steps for checking the possibility of the malfunctioning engine being attributable to ignition system failure and for checking the spark plug which will not spark. Spark → Spark gap test *Clean or replace spark plug. No spark ↓...
  • Page 152 IGNITION SYSTEM Not conductive while it is pushed → SPARK GAP TEST 1. Disconnect the spark plug cap Replace. Conductive while it is freed → Re- from spark plug. 2. Connect the dynamic spark tester place. "1" (ignition checker "2") as shown.
  • Page 153 IGNITION SYSTEM 2. Inspect: • Charging coil 1 resistance Out of specification → Replace. Tester (+) lead → Black/Red lead "1" Tester (-) lead→Green/White lead "2" Charging Tester se- coil 1 resis- lector posi- tance tion 720.0– 1,080.0 Ω Ω × 100 at 20 °C (68 °F) 3.

  • Page 154: Tuning

    ENGINE TUNING • Higher humidity reduces the amount of oxygen in the air by so ENGINE much of the water vapor in the CARBURETOR SETTING same air. • The role of fuel is to cool the engine, • Lower atmospheric pressure (at a and in the case of a 2-stroke en- high altitude) reduces the density of gine, to lubricate the engine in addi-...
  • Page 155 ENGINE ADJUSTING THE PILOT JET ADJUSTING THE JET NEEDLE RELATIONSHIP WITH THROTTLE The richness of air-fuel mixture with On the carburetors used in the OPENING the throttle fully closed to 1/2 open YZ125, the main nozzle is a non dis- The flow of the fuel through the car- can be set by changing the pilot jet assembly type, so it can not be re-...
  • Page 156 ENGINE CARBURETOR SETTING PARTS Part Jet nee- Main jet Part number Size number Size dle "4" "1" (-14143-) (-14116-) Rich #470 137-94 Rich 6BFY44-72 284-K2 #460 137-92 6BFY44-73 284-K3 #450 137-90 6BFY44-74 284-K4 #440 137-88 6BFY44-75 284-K5 (STD) #430 137-86 Lean 6BFY44-76 284-K6 #420...
  • Page 157 ENGINE ROAD CONDITION AND EXAMPLES OF CARBURETOR SETTING General condition Sandy condition Under 10°C 15–25°C Over 30°C Under 10°C 15–25°C Over 30°C (50°F) (59–77°F) (86°F) (50°F) (59–77°F) (86°F) (Winter) (Spring, Au- (Summer) (Winter) (Spring, Au- (Summer) tumn) tumn) Main jet #440 #430 #420...
  • Page 158 ENGINE EXAMPLES OF CARBURETOR SETTING DEPENDING ON SYMPTOM Symptom Setting Checking Discoloration of spark plug → If tan color, it At full throttle Increase main jet calibration no. (Gradual- Stall at high speeds is in good condition. *Hard breathing If cannot be corrected: Shearing noise Clogged float valve seat Whitish spark plug...
  • Page 159 CHASSIS CHANGE OF THE HEAT RANGE CHASSIS DRIVE AND REAR WHEEL OF SPARK PLUGS SPROCKETS SETTING PARTS SELECTION OF THE SECONDARY Judging from the discoloration of REDUCTION RATIO (SPROCKET) Part name Size Part number spark plugs, if they are found improp- er, it can be corrected by the following Secondary reduction ratio = Drive...
  • Page 160 CHASSIS FRONT FORK SETTING FRONT FORK SETTING PARTS The front fork setting should be made • Front fork spring "1" depending on the rider's feeling of an SPRING SPRI I.D. actual run and the circuit conditions. PART TYPE MARK The front fork setting includes the fol- NUMBER RATE (slits)
  • Page 161 CHASSIS CHOOSING SET LENGTH SETTING OF SPRING AFTER REAR SHOCK ABSORBER 1. Place a stand or block under the REPLACEMENT SETTING PARTS engine to put the rear wheel After replacement, be sure to adjust • Rear shock spring "1" above the floor, and measure the the spring to the set length [sunken [Equal-pitch steel spring] length "a"...
  • Page 162 CHASSIS • Extent of adjustment (spring pre- load) SPRING PART Maximum Minimum NUMBER (-22212-) 5UN-00 5UN-10 5UN-20 5UN-30 Position Position 5UN-40 in which in which 5UN-50 the spring the spring 5UN-60 is turned is turned 5UN-70 in 18 mm in 1.5 mm 5UN-A0 (0.71 in) (0.06 in)
  • Page 163 CHASSIS SUSPENSION SETTING (FRONT FORK) • If any of the following symptoms is experienced with the standard position as the base, make resetting by reference to the adjustment procedure given in the same chart. • Before any change, set the rear shock absorber sunken length to the standard figure 90–100 mm (3.5–3.9 in). Section Medi- Symptom...
  • Page 164 CHASSIS SUSPENSION SETTING (REAR SHOCK ABSORBER) • If any of the following symptoms is experienced with the standard position as the base, make resetting by reference to the adjustment procedure given in the same chart. • Adjust the rebound damping in 2-click increments or decrements. •...
  • Page 166 PRINTED ON RECYCLED PAPER PRINTED IN JAPAN...

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