Yamaha YZ125N1 Manuals

Manuals and User Guides for Yamaha YZ125N1. We have 2 Yamaha YZ125N1 manuals available for free PDF download: Owner's Service Manual, Service Manual

YAMAHA YZ125N1 Owner's Service Manual

YAMAHA YZ125N1 Owner's Service Manual (559 pages)

YZ Series

Brand: YAMAHA | Category: Motorcycle | Size: 14.29 MB

Table of Contents

Important Notice
6
Safety Information
6
Wichtige Hinweise
7
F.I.M Machine Weights
10
Description
12
How to Use the Manual
12
Renseignements Generaux
13
- How to Read Descriptions
  14
- Manual Format
  14
- Illustrated Symbols
  16
- Table of Contents
  20
Description
26
- General Information
  26
- Vehicle Views
  26
- Informazioni Generali
  27
Chapter 1

28
- Machine Identification
  28
  - Frame Serial Number
    28
  - Engine Serial Number
    28
  - Model Label
    28
- Identification de la Machine
  29
- Preparation for Removal and Disassembly
  30
- Important Information
  30
- Informations Importantes
  31
- Wichtige Informationen
  31
  - Informazioni Importanti
    31
    
    All Replacement Parts
    32
    
    Gaskets, Oil Seals and O-Rings
    32
    
    Lock Washers/Plates and Cotter Pins
    32
    
    Bearings and Oil Seals
    32
    
    Circlips
    34
    
    Checklist of Connection
    36
- Vérification des Connexions
  37
- Controllo Dei Collegamenti
  37
- Special Tools
  38
- Outils Speciaux
  40
- Utensili Speciali
  44
- Control Functions
  46
  - "Engine Stop" Button
    46
  - Clutch Lever
    46
  - Shift Pedal, Kick Starter, Throttle Grip
    46
- Fonctions des Commandes
  47
  - Front Brake Lever
    48
  - Fuel Cock
    48
  - Rear Brake Pedal
    48
  - Funzioni Dei Comandi
    49
    
    Detachable Sidestand
    50
    
    Valve Joint
    50
- Fuel and Engine Mixing Oil
  52
- Essence Et Huile de Melange du Moteur
  53
- Starting and Break-In
  54
  - Starting a Cold Engine
    54
  - Starting a Warm Engine
    54
- Starten und Einfahren
  55
- Mise en Marche Et Rodage
  55
- Torque-Check Points
  60
- Points de Verification de Couple de Serrage
  61
- Cleaning and Storage
  64
- Nettoyage Et Rangement
  65
- Storage
  66
Chapter 2

68
- General Specifications
  68
- Maintenance Specifications
  70
- Electrical Specifications
  78
- General Torque Specifications
  79
- Definition of Units Table
  79
- Caracteristiques Generales
  80
- Caracteristiques D'entretien
  82
- Specifications Generales de Couple
  91
- Definition des Unites
  91
- Moteur
  91
- Technische Daten
  92
- Allgemeine Technische Daten
  92
- Wartungsdaten
  94
- Allgemeine Anzugsdaten
  103
- Definition der Einheiten
  103
  - Specifiche Generali
    104
  - Specifiche DI Manutenzione
    106
  - Specifiche Generali Relative Alla Coppia
    115
  - Definizione Delle Unità
    115
- Cable Routing Diagram
  116
  - Diagramma del Passaggio
    117
  - Dei Cavi
    117
    
    Kabelführungsübersichtplan
    117
    
    Cable Routing Diagram (Cont.)
    118
Chapter 3

122
- Maintenance Intervals
  122
  - Regular Inspection and Adjustments
    122
  - Intervalli DI Manutenzione
    131
  - Revisione Eregolazioni Regolari
    131
    
    Chassis
    134
    
    Engine
    134
    
    General Inspection and Maintenance Table
    134
    
    Pre-Operation Inspection and Maintenance
    134
  - Ispezione E Manutenzione Prima del Funzionamento
    137
    
    Coolant Level Inspection
    138
    
    Coolant Replacement
    138
    
    Engine Maintenance
    138
  - Motore
    139
    
    Handling Notes of Coolant
    142
    
    Cooling System Inspection
    144
    
    Radiator Cap Opening Pressure Inspection
    144
    
    Clutch Adjustment
    146
    
    Throttle Cable Adjustment
    148
    
    Throttle Lubrication
    148
    
    Air Filter Cleaning
    150
    
    Transmission Oil Level Check
    152
    
    Transmission Oil Replacement
    154
    
    Pilot Air Screw Adjustment
    156
    
    Idle Speed Adjustment/Muffler Inspection/Silencer Fiber Replacement
    158
    
    Silencer Fiber Replacement
    160
    
    Chassis/Brake System Air Bleeding
    162
    
    Partie Cycle
    163
  - Telaio
    163
    
    Front Brake Adjustment
    164
    
    Front Brake Pad Inspection and Replacement
    166
    
    Rear Brake Adjustment
    166
    
    Rear Brake Pad Inspection and Replacement
    170
    
    Brake Fluid Level Inspection
    174
    
    Rear Brake Pad Insulator Inspection
    174
    
    Drive Chain Inspection
    176
    
    Sprockets Inspection
    176
    
    Drive Chain Slack Adjustment
    178
    
    Front Fork Inspection
    180
    
    Front Fork Oil Seal and Dust Seal Cleaning
    182
    
    Front Fork Rebound Damping Adjustment
    182
    
    Front Fork Compression Damping Force Adjustment
    184
    
    Rear Shock Absorber Inspection
    186
    
    Rear Shock Absorber Spring Preload Adjustment
    188
    
    Rear Shock Absorber Rebound Damping Force Adjustment
    190
    
    Rear Shock Absorber Low Compression Damping Force Adjustment
    192
    
    Spokes Inspection and Tightening
    196
    
    Tire Pressure Check
    196
    
    Steering Head Inspection and Adjustment
    198
    
    Lubrication
    202
- Electrical
  204
  - Spark Plug Inspection
    204
  - Parte Elettrica
    205
- Moteur
  205
- Ignition Timing Check
  206
Chapter 4

210
- Seat, Fuel Tank and Side Covers
  210
- Side Cover Removal
  212
- Exhaust Pipe and Silencer
  214
- Tubo DI Scarico E Silenziatore
  215
- Radiator
  216
  - Radiator Handling Note
    218
  - Radiator Assembly and Installation
    220
- Carburetor and Reed Valve
  222
- Vergaser und Zungenventil
  223
  - Carburetor Disassembly
    224
  - Carburetor Inspection
    226
  - Needle Valve Inspection
    228
  - Throttle Valve Check
    228
  - Jet Needle Inspection
    228
  - Filter Inspection
    230
  - Fuel Level
    230
  - Float
    232
  - Reed Valve
    232
  - Carburetor Assembly and Installation
    232
- Cylinder Head, Cylinder and Piston
  242
  - Piston and Power Valve
    244
  - Push Rod Removal
    246
  - Piston and Piston Ring Removal
    246
  - Cylinder Head Inspection
    248
  - Cylinder Inspection
    248
  - Piston Inspection
    250
  - Piston Pin and Small End Bearing Inspection
    252
  - Piston Ring Inspection
    254
  - Piston Clearance Inspection
    254
  - Combination of Piston and Cylinder
    256
  - Power Valve Inspection
    258
  - Power Valve Hole on Cylinder
    258
  - Piston Ring and Piston Installation
    262
  - Cylinder Head and Cylinder Installation
    264
  - Clutch and Primary Driven Gear
    268
  - Clutch Plate and Friction Plate
    268
  - Primary Driven Gear View
    270
- Clutch and Primary Driven Gear
  270
  - Removal Point: Clutch Boss
    272
  - Clutch Housing and Boss Inspection
    272
  - Primary Driven Gear Inspection
    272
  - Clutch Spring Inspection
    272
  - Friction Plate Inspection
    274
  - Clutch Plate Inspection
    274
  - Push Lever and Push Rod Inspection
    274
  - Clutch Cover Inspection
    274
  - Clutch and Primary Gear Assembly and Installation
    276
  - Push Lever Installation
    280
- Kick Axle, Shift Shaft and Primary Drive Gear
  284
  - Primary Drive Gear View
    284
  - Kick Axle and Shift Shaft View
    286
  - Primary Drive Gear Removal
    288
  - Kick Axle Assembly Removal
    288
  - Shift Guide and Shift Lever Assembly Removal
    288
  - Kick Gear and Kick Idle Gear Inspection
    288
  - Kick Gear Clip Inspection
    290
  - Shift Shaft Inspection
    290
  - Shift Guide and Shift Lever Assembly
    290
  - Stopper Lever Assembly
    290
  - Kick Axle, Shift Shaft and Primary Drive Gear Assembly and Installation
    292
  - Shift Guide and Shift Lever Assembly Installation
    292
  - Shift Shaft Installation
    294
  - Kick Axle Assembly Installation
    294
  - Kick Idle Gear Installation
    296
  - Primary Drive Gear Installation
    296
- YPVS Governor
  300
- Regulateur Ypvs
  301
- Ypvs Regler
  301
- Regolatore Ypvs
  301
  - Governor Groove Inspection
    302
  - Governor Bearing Inspection
    302
  - Governor Assembly and Installation
    302
  - Water Pump View
    306
- Pompe a Eau
  307
  - Impeller Shaft Removal
    308
  - Oil Seal Removal
    308
  - Impeller Shaft Inspection
    308
  - Impeller Shaft Gear Inspection
    310
  - Water Pump Bearing Inspection
    310
  - Oil Seal Inspection
    310
  - Oil Seal Installation
    310
  - Impeller Shart Installation
    312
  - CDI Magneto View
    314
- Magneto CDI
  315
  - Rotor Removal
    316
  - CDI Magneto Inspection
    316
  - Woodruff Key Inspection
    316
  - CDI Magneto Assembly
    316
- Engine Removal
  322
- Depose du Moteur
  323
- Rimozione del Motore
  325
  - Drive Sprocket Removal
    326
  - Engine Removal Steps
    326
  - Engine Installation
    328
  - Brake Pedal Installation
    328
  - Crankcase and Crankshaft View
    332
- Carter Et Vilebrequin
  333
  - Segment Removal
    334
  - Crankcase Removal
    334
  - Crankshaft Removal
    336
  - Crankshaft Bearing Removal
    336
  - Crankcase Inspection
    336
  - Crankshaft Inspection
    338
  - Crankshaft Bearing Installation
    338
  - To Install the Oil Seal
    340
  - Crankshaft Installation
    340
- Transmission, Shift Cam and Shift Fork
  346
  - Main Axle and Drive Axle Removal
    348
  - Gears Inspection
    348
  - Shift Fork, Shift Cam and Segment Inspection
    350
  - Transmission Assembly and Installation
    350
  - Shift Cam and Shift Fork Installation
    354
  - Chassis
    356
Chapter 5

356
- Front Wheel and Rear Wheel
  356
- Front Wheel View
  356
- Partie Cycle
  357
- Motor
  357
- Fahrgestell
  357
  - Rear Wheel View
    358
  - Ruota Anteriore E Ruota Posteriore
    359
  - Rear Wheel Removal
    360
  - Rear Wheel Inspection
    360
  - Wheel Axle Inspection
    362
  - Brake Disc Inspection
    362
  - Front Wheel Assembly and Installation
    364
  - Rear Wheel Installation
    368
- Front Brake and Rear Brake
  374
- Front Brake View
  374
- Frein Avant Et Frein Arriere
  375
  - Rear Brake View
    376
  - Freno Posteriore
    377
  - Caliper Disassembly
    378
  - Master Cylinder Disassembly
    380
  - Caliper Piston Removal
    382
  - Piston Seal Removal
    384
  - Master Cylinder Inspection
    384
  - Caliper Inspection
    386
  - Brake Hose Inspection
    386
  - Brakes Assembly and Installation
    386
  - Front Caliper Installation
    388
  - Rear Caliper Installation
    390
  - Master Cylinder Kit Installation
    394
  - Front Master Cylinder Installation
    396
  - Rear Master Cylinder Installation
    398
  - Front Brake Hose Installation
    400
  - Rear Brake Hose Installation
    402
  - Brake Fluid Fill
    404
  - Front Fork View
    408
  - Fourche Avant
    409
  - Front Fork Disassembly
    410
- Forcella Anteriore
  411
  - Cap Bolt Removal
    412
  - Inner Tube Removal
    414
  - Oil Seal Removal Steps
    414
  - Damper Rod Inspection
    414
  - Base Valve Inspection
    416
  - Fork Spring Inspection
    416
  - Inner Tube Inspection
    416
  - Outer Tube Inspection
    416
  - Cap Bolt Inspection
    418
  - Front Fork Assembly
    418
  - Cushion Rubber Installation
    428
  - Push Rod Installation
    428
  - Fork Spring Installation
    428
  - Cap Bolt Installation
    428
  - Front Fork Installation
    430
  - Brake Hose Holder Installation
    432
  - Caliper Installation
    432
  - Handlebar View
    434
  - Throttle Disassembly
    436
  - Master Cylinder Removal
    438
  - Handlebar Inspection
    438
  - Throttle Assembly
    438
  - Handlebar Installation
    440
  - Throttle Cable Installation
    442
  - Master Cylinder Installation
    442
  - Steering View
    448
  - Ring Nut Removal
    450
  - Bearing (Lower) Removal
    450
  - Ball Race Removal
    450
  - Steering Shaft Inspection
    450
  - Bearing and Ball Race Inspection
    452
  - Under Bracket Installation
    452
- Swingarm
  458
- Bras Oscillant
  459
- Swingarm Disassembly
  460
- Forcellone Oscillante
  461
  - Bearing Removal
    462
  - Swingarm Inspection
    462
  - Relay Arm Inspection
    462
  - Connecting Rod Inspection
    462
  - Bearing and Oil Seal Installation
    464
  - Swingarm Installation
    466
  - Chain Tensioner Installation
    470
  - Chain Support Installation
    470
  - Rear Shock Absorber View
    472
- Et Couvercles Lateraux
  473
- Rear Shock Absorber - Handling Note
  474
- Ammortizzatore Posteriore
  475
Chapter 6

484
- Electrical Components and Wiring Diagram
  484
- Partie Electrique
  485
- Composants Electriques
  485
- Et Schema de Cablage
  485
  - Elektrische Einrichtungen
    485
  - Ignition System - Inspection Steps
    486
- Systeme D'allumage
  487
- Spezialwerkzeuge
  488
- Motor
  489
- Sistema DI Accensione
  489
  - Utensili Speciali
    489
    
    Spark Gap Test
    490
    
    Couplers and Leads Connection Inspection
    490
    
    "Engine Stop" Button Inspection
    490
    
    Ignition Coil Inspection
    492
    
    To Inspect the CDI Magneto
    494
    
    CDI Unit Inspection
    494
    
    Magneto CDI
    495
    
    CDI-Magnetzünder
    495
- Magnete CDI
  495
  - Setting
    496
  - Tuning (Engine)
    496
  - Carburetor Setting
    496
  - Atmospheric Conditions and Carburetor Setting
    496
- Messa a Punto
  497
- Motore
  497
- Chassis
  528
- Telaio
  529
  - Drive and Driven Sprockets Setting Parts
    530
  - Tire Pressure
    530
  - Front Fork Setting
    532
- Fourche Avant
  533
- Vorderradgabel
  533
  - Spring Preload Adjustment
    534
  - Setting of Spring after Replacement
    534
  - Use of Soft Spring
    534
  - Use of Stiff Spring
    536
  - Front Fork Setting Parts
    538
  - Rear Suspension Setting
    540
  - Choosing Set Length
    540
  - Rear Shock Absorber Setting Parts
    546
  - Suspension Setting
    548

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Yamaha YZ125N1 Service Manual

Yamaha YZ125N1 Service Manual (255 pages)

YZ series

Brand: Yamaha | Category: Motorcycle | Size: 9.18 MB

Table of Contents

Important Notice
6
Safety Information
6
F.I.M. Machine Weights
8
Finding the Required Page
9
How to Read Descriptions
10
Manual Format
10
Illustrated Symbols
11
Index
12
Table of Contents
13
CHAPTER 1 General Information

16
- Description
  16
- Machine Identification
  17
  - Vehicle Identification Number
    17
  - Frame Serial Number
    17
  - Engine Serial Number
    17
- Important Information
  18
  - Preparation for Removal and Disassembly
    18
  - All Replacement Parts
    19
  - Gaskets, Oil Seals and O-Rings
    19
  - Lock Washers/Plates and Cotter Pins
    19
  - Bearings and Oil Seals
    19
  - Circlips
    20
- Checking of Connection
  21
- Special Tools
  22
- Control Functions
  24
  - “Engine Stop” Button
    24
  - Clutch Lever
    24
  - Shift Pedal
    24
  - Front Brake Lever
    25
  - Rear Brake Pedal
    25
  - Fuel Cock
    25
  - Starter Knob (Choke)
    25
  - Valve Joint
    26
  - Detachable Sidestand
    26
- Fuel and Engine Mixing Oil
  27
- Starting and Break-In
  28
  - Starting a Cold Engine
    28
  - Starting a Warm Engine
    28
  - Break-In Procedures
    29
- Torque-Check Points
  31
- Cleaning and Storage
  32
- Storage
  33
- General Specifications
  34
- Maintenance Specifications
  36
- General Torque Specifications
  45
- Definition of Units
  45
- Cable Routing Diagram
  46
CHAPTER 3 Regular Inspection and Adjustments

49
- Maintenance Intervals
  49
- Pre-Operation Inspection and Maintenance
  51
- General Inspection and Maintenance
  51
- Engine
  52
  - Coolant Level Inspection
    52
  - Coolant Replacement
    52
  - Radiator Cap Inspection
    54
  - Radiator Cap Opening Pressure Inspection
    55
  - Cooling System Inspection
    55
  - Clutch Adjustment
    56
  - Throttle Cable Adjustment
    57
  - Throttle Lubrication
    57
  - Air Filter Cleaning
    58
  - Transmission Oil Level Check
    59
  - Transmission Oil Replacement
    60
  - Pilot Air Screw Adjustment
    61
  - Idle Speed Adjustment
    62
  - Muffler Inspection
    62
  - Silencer Fiber Replacement
    62
  - Silencer Fiber Replacement
    63
- Chassis
  64
- Electrical
  85
  - Spark Plug Inspection
    85
  - Ignition Timing Check
    86
Chapter 4

88
- Seat, Fuel Tank and Side Covers
  88
- Removal Points
  89
- Exhaust Pipe and Silencer
  90
- Radiator
  91
- Radiator Assembly and Installation
  93
- Carburetor and Reed Valve
  94
- Carburetor Disassembly
  95
- Cylinder Head, Cylinder and Piston
  104
  - Piston and Power Valve
    105
  - Push Rod
    106
  - Piston and Piston Ring
    106
  - Piston Pin and Small End Bearing
    109
  - Piston Ring
    110
  - Piston Clearance
    110
  - Combination of Piston and Cylinder
    111
  - Power Valve
    112
  - Power Valve Hole on Cylinder
    112
  - Piston Ring and Piston
    114
- Clutch and Primary Driven Gear
  117
  - Clutch Plate and Friction Plate
    117
  - Primary Driven Gear
    118
  - Clutch Boss
    119
  - Clutch Housing and Boss
    119
  - Clutch Spring
    119
  - Friction Plate
    120
  - Clutch Plate
    120
  - Clutch Cover
    120
  - Clutch
    121
  - Push Lever
    123
- Kick Axle, Shift Shaft and Primary Drive Gear
  125
  - Primary Drive Gear
    125
  - Kick Axle and Shift Shaft
    126
  - Kick Axle Assembly
    127
  - Shift Guide and Shift Lever Assembly
    127
  - Kick Axle and Kick Gear
    127
  - Kick Gear and Kick Idle Gear
    127
  - Kick Gear Clip
    128
  - Shift Shaft
    128
  - Stopper Lever
    128
  - Primary Drive Gear and Primary Driven Gear
    128
  - Kick Idle Gear
    131
- YPVS Governor
  133
  - Governor
    134
  - Governor Groove
    134
- Water Pump
  136
  - Impeller Shaft
    137
  - Oil Seal
    137
  - Impeller Shaft Gear
    138
- CDI Magneto
  140
  - Rotor
    141
  - Woodruff Key
    141
- Engine Removal
  144
  - Drive Sprocket
    146
  - Engine Installation
    147
  - Brake Pedal
    147
- Crankcase and Crankshaft
  149
  - Segment
    150
  - Crankcase
    150
  - Crankshaft
    151
  - Crankshaft Bearing
    151
- Transmission, Shift Cam and Shift Fork
  156
  - Transmission
    157
  - Gears
    157
  - Shift Fork, Shift Cam and Segment
    158
  - Shift Cam and Shift Fork
    160
Chapter 5

161
- Front Wheel and Rear Wheel
  161
  - Rear Wheel
    162
  - Wheel Bearing (if Necessary)
    163
  - Wheel Axle
    164
  - Brake Disc
    164
  - Front Brake Removal
    170
- Front Brake and Rear Brake
  170
  - Rear Brake
    171
  - Rear Brake Removal
    171
  - Caliper Disassembly
    172
  - Master Cylinder Disassembly
    173
  - Brake Fluid
    174
  - Caliper Piston
    174
  - Piston Seal Kit
    175
  - Master Cylinder
    175
  - Brake Hose
    176
  - Front Caliper
    177
  - Rear Caliper
    178
  - Master Cylinder Kit
    180
  - Front Master Cylinder
    181
  - Rear Master Cylinder
    182
  - Front Brake Hose
    183
  - Rear Brake Hose
    184
  - Front Fork Removal
    187
  - Front Fork Disassembly
    188
  - Cap Bolt
    189
  - Inner Tube
    190
  - Damper Rod
    190
  - Base Valve
    191
  - Fork Spring
    191
  - Outer Tube
    191
  - Front Fork Assembly
    192
- Front Fork
  195
  - Handlebar Removal
    200
  - Throttle Disassembly
    201
  - Grip
    202
  - Throttle Assembly
    202
  - Handlebar
    203
  - Steering Removal
    207
  - Ring Nut
    208
  - Ball Race
    208
  - Steering Shaft
    208
  - Bearing and Ball Race
    209
  - Under Bracket
    209
- Steering
  210
  - Swingarm Removal
    212
  - Swingarm Disassembly
    213
  - Relay Arm
    214
  - Connecting Rod
    214
  - Bearing and Oil Seal
    215
  - Swingarm
    216
  - Rear Shock Absorber Removal
    219
  - Rear Shock Absorber
    221
  - Spring (Rear Shock Absorber)
    222
Chapter 6

225
- Electrical Components and Wiring Diagram
  225
- Wiring Diagram
  225
- Ignition System
  226
  - Spark Gap Test
    227
  - Couplers and Leads Connection Inspection
    227
  - “Engine Stop” Button Inspection
    227
  - Ignition Coil Inspection
    228
  - CDI Magneto Inspection
    229
  - CDI Unit Inspection
    229
CHAPTER 7 Tuning

230
- Carburetor Setting
  230
- Engine
  230
- Chassis
  242
  - Drive and Driven Sprockets Setting Parts
    243
  - Tire Pressure
    243
  - Front Fork Setting
    244
  - Spring Preload Adjustment
    245
  - Setting of Spring after Replacement
    245
  - Front Fork Setting Parts
    247
  - Rear Suspension Setting
    248
  - Choosing Set Length
    248
  - Rear Shock Absorber Setting Parts
    251
  - Suspension Setting
    252

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