Table Of Contents - Yamaha YZ125 2009 Owner's Service Manual

Table of Contents

Important Manual Information4
Safety Information5
F.i.m. Machine Weights7
Weights Of Machines Without Fuel7
Finding The Required Page8
Manual Format8
General Information8
How To Read Descriptions9
Illustrated Symbols10
Table Of Contents11
Contents12
Location Of Important Labels15
Description16
Machine Identification17
Vehicle Identification Number17
Engine Serial Number17
Model Label17
Included Parts18
Detachable Sidestand18
Nipple Wrench18
Valve Joint18
Important Information19
Preparation For Removal And Disassembly19
All Replacement Parts19
Gaskets, Oil Seals And O-Rings19
Bearings And Oil Seals20
Checking Of Connection21
Special Tools22
Control Functions25
Engine Stop Switch25
Clutch Lever25
Shift Pedal25
Rear Brake Pedal26
Fuel Cock26
Starter Knob (Choke)26
Starting And Break-In27
Fuel27
Air Filter Maintenance27
Starting A Cold Engine27
Torque-Check Points29
Cleaning And Storage30
General Specifications31
Maintenance Specifications33
Tightening Torques39
General Torque Specifications43
Definition Of Units44
Cable Routing Diagram46
Regular Inspection And Adjustments54
Maintenance Intervals54
Pre-Operation Inspection And Maintenance58
General Inspection And Maintenance58
Engine59
Checking The Coolant Level59
Changing The Coolant59
Checking The Radiator Cap60
Checking The Radiator Cap Opening Pressure60
Checking The Cooling System60
Adjusting The Clutch Cable Free Play61
Adjusting The Throttle Cable Free Play62
Lubricating The Throttle62
Cleaning The Air Filter Element62
Checking The Transmission Oil Level64
Changing The Transmission Oil64
Adjusting The Pilot Air Screw65
Adjusting The Engine Idling Speed65
Checking The Exhaust Pipe65
Chassis66
Bleeding The Hydraulic Brake System66
Adjusting The Front Brake66
Adjusting The Rear Brake67
Checking And Replacing The Front Brake Pads67
Checking And Replacing The Rear Brake Pads69
Checking The Rear Brake Pad Insulator70
Checking The Brake Fluid Level70
Checking The Sprocket71
Checking The Drive Chain71
Specifications71
Adjusting The Drive Chain Slack72
Adjustments72
Checking The Front Fork73
Cleaning The Front Fork Oil Seal And Dust Seal73
Relieving The Front Fork Internal Pressure73
Adjusting The Front Fork Rebound Damping Force74
Adjusting The Front Fork Compression Damping Force74
Checking The Rear Shock Absorber74
Adjusting The Rear Shock Absorber Spring Preload75
Adjusting The Rear Shock Absorber Rebound Damping Force76
Adjusting The Rear Shock Absorber Low Compression Damping Force76
Adjusting The Rear Shock Absorber High Compression Damping Force77
Checking The Tire Pressure77
Checking And Tightening The Spokes78
Checking The Wheels78
Checking And Adjusting The Steering Head78
Lubrication81
Electrical82
Checking The Spark Plug82
Checking The Ignition Timing82
Seat, Fuel Tank And Side Covers85
Removing The Seat, Fuel Tank And Side Covers85
Removing The Side Cover86
Removing The Number Plate86
Exhaust Pipe And Silencer87
Removing The Exhaust Pipe And Silencer87
Changing The Silencer Fiber88
Removing The Radiator89
Checking The Radiator90
Installing The Radiator90
Carburetor And Reed Valve92
Removing The Carburetor And Reed Valve92
Disassembling The Carburetor93
Removing The Throttle Valve94
Checking The Carburetor94
Checking The Needle Valve95
Checking The Throttle Valve95
Checking The Jet Needle95
Checking The Filter95
Checking The Float96
Checking The Reed Valve96
Installing The Reed Valve96
Assembling The Carburetor97
Installing The Carburetor99
Cylinder Head, Cylinder And Piston100
Removing The Cylinder Head And Cylinder100
Removing The Piston And Power Valve101
Removing The Push Rod102
Removing The Piston And Piston Ring102
Checking The Cylinder Head102
Checking The Cylinder103
Checking The Piston104
Checking The Piston Pin And Small End Bearing104
Checking The Piston Ring105
Checking The Piston Clearance105
Checking The Power Valve106
Checking The Power Valve Hole On Cylinder106
Installing The Power Valve107
Installing The Piston Ring And Piston108
Installing The Cylinder Head And Cylinder109
Removing The Clutch111
Removing The Clutch Boss112
Checking The Clutch Housing And Boss113
Checking The Primary Driven Gear113
Checking The Clutch Springs113
Checking The Friction Plates113
Checking The Push Lever Shaft114
Checking The Push Rod114
Installing The Clutch114
Installing The Push Lever Shaft114
Kick Shaft And Shift Shaft117
Removing The Primary Drive Gear117
Removing The Kick Shaft And Shift Shaft118
Removing The Kick Shaft Assembly119
Removing The Shift Guide And Shift Lever Assembly119
Checking The Kick Gear Clip119
Checking The Kick Shaft And Kick Gear119
Checking The Shift Shaft120
Checking The Shift Guide And Shift Lever Assembly120
Checking The Stopper Lever120
Installing The Stopper Lever120
Installing The Shift Guide And Shift Lever Assembly121
Installing The Shift Shaft121
Installing The Kick Shaft Assembly122
Installing The Kick Idle Gear122
Installing The Primary Drive Gear123
Ypvs Governor125
Removing The Ypvs Governor125
Removing The Governor126
Checking The Governor Groove126
Checking The Bearing126
Installing The Governor126
Water Pump128
Disassembling The Water Pump128
Removing The Oil Seal129
Checking The Impeller Shaft129
Checking The Impeller Shaft Gear129
Checking The Oil Seal129
Installing The Impeller Shaft130
Removing The Cdi Magneto131
Removing The Rotor132
Checking The Cdi Magneto132
Checking The Woodruff Key132
Installing The Cdi Magneto132
Engine Removal134
Removing The Engine134
Removing The Drive Sprocket136
Installing The Engine136
Installing The Brake Pedal137
Installing The Drive Sprocket137
Removing The Crankshaft138
Crankcase And Crankshaft138
Removing The Segment140
Disassembling The Crankcase140
Removing The Crankcase Bearing140
Checking The Crankcase141
Checking The Crankshaft141
Installing The Crankcase Bearing142
Installing The Oil Seal142
Installing The Crankshaft142
Removing The Transmission, Shift Cam And Shift Fork145
Removing The Transmission146
Checking The Gears146
Checking The Shift Fork, Shift Cam And Segment146
Installing The Transmission147
Installing The Shift Cam And Shift Fork148
Removing The Front Wheel151
Front Wheel And Rear Wheel151
Removing The Rear Wheel152
Removing The Wheel Bearing153
Checking The Wheel153
Checking The Wheel Axle153
Checking The Brake Disc154
Installing The Front Wheel154
Installing The Rear Wheel156
Front Brake And Rear Brake158
Removing The Front Brake158
Removing The Rear Brake159
Disassembling The Brake Caliper160
Disassembling The Brake Master Cylinder161
Draining The Brake Fluid162
Removing The Brake Caliper Piston162
Removing The Brake Caliper Piston Seal Kit163
Checking The Brake Master Cylinder163
Checking The Brake Caliper164
Checking The Brake Hose164
Installing The Brake Caliper Piston164
Installing The Front Brake Caliper165
Installing The Rear Brake Caliper165
Installing The Brake Master Cylinder Kit166
Installing The Front Brake Master Cylinder167
Installing The Rear Brake Master Cylinder168
Installing The Front Brake Hose169
Installing The Rear Brake Hose170
Filling The Brake Fluid170
Removing The Front Fork172
Disassembling The Front Fork173
Removing The Damper Assembly174
Removing The Adjuster174
Removing The Inner Tube174
Removing The Base Valve175
Checking The Damper Assembly175
Checking The Base Valve175
Checking The Collar176
Checking The Fork Spring176
Checking The Inner Tube176
Checking The Outer Tube176
Assembling The Front Fork177
Installing The Front Fork183
Removing The Handlebar185
Disassembling The Throttle186
Removing The Brake Master Cylinder187
Removing The Grip187
Checking The Handlebar187
Assembling The Throttle187
Installing The Handlebar188
Removing The Steering192
Removing The Steering Ring Nut194
Removing The Lower Bearing194
Removing The Bearing Race194
Checking The Steering Stem194
Installing The Lower Bracket195
Removing The Swingarm197
Disassembling The Swingarm198
Removing The Cap199
Removing The Bearing199
Checking The Swingarm199
Checking The Relay Arm199
Installing The Bearing And Oil Seal200
Installing The Swingarm201
Removing The Rear Shock Absorber204
Installing The Bearing207
Installing The Spring (Rear Shock Absorber)208
Installing The Rear Shock Absorber208
Electrical Components And Wiring Diagram211
Ignition System213
Spark Gap Test214
Checking The Couplers And Leads Connection214
Checking The Engine Stop Switch214
Checking The Ignition Coil214
Checking The Spark Plug Cap215
Checking The Cdi Unit216
Tuning217
Carburetor Setting217
Atmospheric Conditions And Carburetor Settings217
Test Run217
Effect Of Setting Parts In Relation To Throttle Valve Opening218
Adjusting The Main Jet218
Adjusting The Pilot Jet218
Adjusting The Jet Needle Groove Position219
Adjusting The Jet Needle219
Relationship With Throttle Opening220
Carburetor Setting Parts221
Road Condition And Examples Of Carburetor Setting222
Specifications Of Jet Needle (For Usa And Cdn)222
Specifications Of Jet Needle (For Europe, Aus, Nz And Za)222
Examples Of Carburetor Setting Depending On Symptom223
Change Of The Heat Range Of Spark Plugs225
Selection Of The Secondary Reduction Ratio (Sprocket)226
Drive And Rear Wheel Sprockets Setting Parts226
Tire Pressure226
Front Fork Setting227
Change In Amount And Characteristics Of Fork Oil227
Setting Of Spring After Replacement227
Front Fork Setting Parts228
Rear Suspension Setting228
Choosing Set Length228
Rear Shock Absorber Setting230
Suspension Setting (Front Fork)231
Suspension Setting (Rear Shock Absorber)232