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2005
XT 125R
XT 125X
SERVICE
INFORMATION

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Table of Contents

   Summary of Contents for Yamaha XT 125R 2005

  • Page 1 2005 XT 125R XT 125X SERVICE INFORMATION...
  • Page 3: Important Information

    This Manual cannot cover any aspect of mechanical knowledge; therefore, anyone who will refer to this manual is expected to have a basic knowledge of the mechanical skills required for servicing and repairing Yamaha motorcycles. Repairing performed by unskilled personnel may cause motorcycles to be unserviceable and dangerous.
  • Page 4 GRAPHIC SYMBOLS Symbols are drawn as tabs to indicate the chapter number and its content. General Information Technical Specifications Scheduled Servicing and Adjustment Engine Carburetion Frame Electrical System Troubleshooting Symbols are used to identify technical specifications stated in this Manual. Repairing Possible with Engine in Place Filling Up Lubricant...
  • Page 5: Table Of Contents

    INDEX GENERAL INFORMATION ......................6 IDENTIFICATION OF THE MOTORCYCLE .................6 SPECIAL COMPONENTS ....................7 TECHNICAL SPECIFICATIONS ....................9 GENERAL FEATURES ......................9 SERVICING TECHNICAL DATA ...................12 ENGINE ..........................12 LUBRICATION DIAGRAMS ....................15 ENGINE TIGHTENING TORQUES ..................17 FRAME ..........................18 FRAME TIGHTENING TORQUES ..................20 ELECTRICAL SYSTEM ......................21 WIRING ...........................24 WIRING (1) .........................24 WIRING (2) .........................
  • Page 6: General Information

    INFO GENERAL INFORMATION GENERAL INFORMATION IDENTIFICATION OF THE MOTORCYCLE Serial Number of the Frame The Serial Number of the frame marked on the metal tube of the handlebar. NOTE: The Serial Number of the frame is used for the motorcycle identification and registration.
  • Page 7: Special Components

    INFO GENERAL INFORMATION SPECIAL COMPONENTS The special components listed below are required for a complete and accurate tuning and assembly of the motorcycle. The use of proper special instruments prevents damages caused by improper instruments or made- up techniques. When ordering a special component, please refer to the list below to avoid any mistake. Component N.
  • Page 8 (*) Indications from Yamaha are required about the compatibility of the components above. If they are not compatible, ID codes and drawings of new components are required. Otherwise, Yamaha should state which components are to be excluded from this Manual.
  • Page 9: Technical Specifications

    9.5 N * m / 5500 RPM Min. Speed 1600~1800 RPM Starting System Electrical and manual starter Lubrication System Yamaha Autolube Oil Type or Grade: Motor Oil YAMALUBE 4, SAE 10W30/SH or equivalent Total Quantity 1.2 L Scheduled Oil Change 1.0 L...
  • Page 10 SPEC TECHNICAL SPECIFICATIONS Model XT 125R XT 125X Carburettor: Type/Quantity VM20SS Manufacturer MIKUNI Spark Plugs: Type CR7HSA Manufacturer Distance between Electrodes 0.6 mm (0.0236 in) Type of Clutch: Oil-bath, multiple disc Gear: Primary Step-down System Worm gear Primary Step-down Ratio 68/20 (1/3,4) Secondary Step-down Ratio Drive chain...
  • Page 11 SPEC TECHNICAL SPECIFICATIONS Model XT 125R XT 125X Brakes: Type of Front Brake Disc brake with hydraulic drive Front Brake Operation Right hand Type of Rear Brake Disc brake with hydraulic drive Rear Brake Operation Right foot Suspensions: Front Hydraulic fork Rear Swinging arm with hydraulic shock absorber Shock Absorbing System:...
  • Page 12: Servicing Technical Data

    SPEC SERVICING TECHNICAL DATA SERVICING TECHNICAL DATA ENGINE Picture Description Standard Limit Cylinder Head: The lines indicate the Planarity Error points for the planarity 0.03 mm measures. Cylinder: Hole size 54.00~54.020 mm Cylinder: Hole size 54.00~54.020 mm Piston: Piston Diameter (D) 53.977~53.996 mm Measure Point (H) 4.5 mm...
  • Page 13 SPEC SERVICING TECHNICAL DATA Picture Description Standard Limit Exhaust Valve Width (B) 1.7~2.8 mm Valve Housing Width (C) 0.9~1.1 mm 1.6 mm Inlet Valve Thickness (D) 0.4~0.8 mm Exhaust Valve Thickness (D) 0.8~1.2 mm Diameter of Inlet Valve Stem 4.975~4.990 mm 4.950 mm Diameter of Exhaust Valve Stem 4.960~4.975 mm...
  • Page 14 SPEC SERVICING TECHNICAL DATA Picture Description Standard Limit Clutch: Clutch Disc Thickness (conductors) 2.92~3.08 mm 2.80 mm Quantity 5 pcs Clutch Disc Thickness (conduced) 1.05~1.35 mm 0.05 mm Quantity 4 pcs Clutch Spring Free Length 31 mm Quantity 4 pcs Min.
  • Page 15: Lubrication Diagrams

    SPEC SERVICING TECHNICAL DATA LUBRICATION DIAGRAMS Compensator Arm Cam Shaft (Exhaust) Compensator Arm Compensator (Suction) Shaft Clutch Lever Crankcase (right) Centrifugal Filter Motor Axis Main Axis Oil Pump Oil Suction Motor Oil in Filter Crankcase Do not damage the crankcase surface to avoid oil leakage. CAUTION: IDM-44600300900.tif...
  • Page 16 SPEC SERVICING TECHNICAL DATA Cam Shaft Cylinder Head Cylinder Cover (Left) Centrifugal Filter Crankcase Main Axis Chain Guard (Right) Clutch Cover (Right) Chain Guard (Left) Motor Axis CAUTION: To enhance performance, always use “Yamalube” oil. IDM-44600301000.tif...
  • Page 17: Engine Tightening Torques

    SPEC SERVICING TECHNICAL DATA ENGINE TIGHTENING TORQUES Tightening Torque Components To Be Tightened Type Q.ty Thread Notes Kg * m N * m Screw Cylinder Head Oil check Screw Plug 1.25 12.5 Cylinder Head Side Guard Screw Valve Cap 1.75 17.5 Magnet Rotor Screw...
  • Page 18: Frame

    SPEC SERVICING TECHNICAL DATA FRAME Standard Limit Detail XT 125R XT 125X XT 125R XT 125X Front Wheel: Type Spoked wheel Spoked wheel Rim Dimensions 21x1.85 17x2.50 Rim Material Aluminium Aluminium Stroke 170 mm (6.69’’) 170 mm (6.69’’) Max. Radial Clearance 1 mm 1 mm Max.
  • Page 19 SPEC SERVICING TECHNICAL DATA Standard Limit Detail XT 125R XT 125X XT 125R XT 125X Front Suspension: Fork Free Length 575 mm Spring Stiffness K1 4.8 N/mm Spring Stroke K1 (Packed Spring) 250 mm Available Optional Spring Recommended Oil SAE10 Quantity 285 cc/Rod Level...
  • Page 20: Frame Tightening Torques

    SPEC SERVICING TECHNICAL DATA FRAME TIGHTENING TORQUES Tightening Torque Components To Be Tightened Type Q.ty Thread Notes kg * m N * m Front Wheel Pin Screw M14x1.5 Front Wheel Pin Locking Screw M8x25 Front Brake Pliers Screw Muffler Side Connection Screw Engine Rear Connection Screw...
  • Page 21: Electrical System

    SPEC SERVICING TECHNICAL DATA ELECTRICAL SYSTEM Model XT 125R XT 125X System Voltage Starting System: Type of Starting System C.D.I. Spark Lead (B.T.D.C.) 0° at 1400 RPM Type of Ignition Electric Ignition C.D.I. Control Unit: Magnet Flywheel/Manufacturer 3D6-MORIYAMA Pick-up Winding Resistance (Ohm) 240±20% at 20°C (68°F) (Blue/Yellow-Green) CDI Control Unit, Model/Manufacturer 5HH-DENSO...
  • Page 22 SPEC SERVICING TECHNICAL DATA Model XT 125R XT 125X Limit Engine Starting System: Type of Starting System Electrical Starter and Foot Lever Starting Motor: Model/Manufacturer 3MB/Moric Output Power 0.2 kW Winding Resistance 0.0315~0.0385<Ohm> 20°C Brush Dimensions 5x7x7mm 3.5 mm Brush Spring Strength 4.9 N ±20% 3.92 N Selector Diameter...
  • Page 24: Wiring

    SPEC WIRING (1) WIRING (1) 1) Clutch wire 2) Carburettor starter wire 3) Front left indicator wires 4) Front right indicator wires 5) Wires for headlight on full beam, on low beam 6) Parking light wires 7) Clutch switch wire 8) Front brake switch wire 9) Front brake drive 10) Mileometer wire...
  • Page 25 SPEC WIRING (1)
  • Page 26: Wiring (2)

    SPEC WIRING (2) WIRING (2) 1) Gas control wire 2) Carburettor starter wire 3) Clutch wire 4) Starter motor wire 5) AIS valve hose - exhaust manifold 6) Plug wire 7) AIS valve vacuum pipe 8) Air AIS valve 9) Coil 10) Coil feeding wire 11) Fuel probe connector 12) Tank cock vacuum pipe...
  • Page 27 SPEC WIRING (2)
  • Page 28: Scheduled Servicing And Adjustment

    Check serviceability and tightening. Control Wires: Adjust/check serviceability. Grease Gas Feeding/Clutch/ every 12,000 km Front Brake Lights and Indicators Check operation. Bolts and Nuts Check tightening. Motorcycle Appearance Check. * Address to a Yamaha Dealer. ** Molybdenum-bisulphide grease. *** Lithium soap grease.
  • Page 30: Wiring Diagram

    WIRING DIAGRAM 1) Battery (12V) Colours 2) Control unit Orange 3) Fuse (10A) Light blue 4) Starting relay AZ-B Light Blue-White 5) Rear brake switch White 6) Starter motor White-Black 7) Front left indicator B-MA White-Brown 8) Rear light/brake White-Red 9) Plate light B-VL White-Purple...
  • Page 31 WIRING DIAGRAM (*) Available...

This manual is also suitable for:

Xt125 2005Xt 125x 2005

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