Yamaha YP125E 2003 Service Information
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Yamaha YP125E 2003 Service Information

Yamaha YP125E 2003 Service Information

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YP125E
2003
5XL1-SE1
YP180E
SERVICE
INFORMATION

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Summary of Contents for Yamaha YP125E 2003

  • Page 1 YP125E 2003 5XL1-SE1 YP180E SERVICE INFORMATION...
  • Page 2 EB000000 YP125E’03 YP180E’03 SERVICE INFORMATION © 2002 by Yamaha Motor España, S.A. 1st Edition, November 2002. All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor España, S.A. is expressly prohibited.
  • Page 3 EB001000 NOTICE This manual was produced by the Yamaha Motor España, S.A., primarily for use by Yamaha/MBK dealers and their qualified mechanics. It is not possible to include all the knowledge of a mecha- nic in one manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha/MBK scooter has a basic understanding of the mechanical ideas and the pro- cedures of scooter repair.
  • Page 4 EB003000 ILLUSTRATED SYMBOLS SPEC INFO Illustrated symbols are designed as thumb tabs to indicate the chapeter’s number and content. INSP General information Specifications Periodic checks and adjustments Engine Cooling system Carburetion COOL CARB Chassis Electrical Troubleshooting CHAS ELEC Illustrate symbols are used to iden- tify the specifications appearing in the text.

  • Page 5: Table Of Contents

    CONTENTS GENERAL INFORMATION SCOOTER IDENTIFICATION FRAME SERIAL NUMBER ......................1 ENGINE SERIAL NUMBER .....................1 MODEL LABEL ........................1 IMPORTANT INFORMATION.....................2 PREPARATION FOR REMOVAL PROCEDURES ..............2 REPLACEMENT PARTS......................2 GASKETS, OIL SEALS, AND O-RINGS..................2 LOCK WASHERS/PLATES AND COTTER PINS ..............3 BEARINGS AND OIL SEALS ....................3 CIRCLIPS..........................3 CHECKING OF CONNECTIONS ....................4 HOW TO USE THE CONVERSION TABLE ................5...

  • Page 6: General Information

    SCOOTER IDENTIFICATION INFO YP100000 GENERAL INFORMATION SCOOTER IDENTIFICATION YP100010 FRAME SERIAL NUMBER The identification number is stamped onto the frame. YP100020 ENGINE SERIAL NUMBER The engine serial number is stamped onto the right side of the crankcase. NOTE: Design and specifications may change without notice.

  • Page 7: Important Information

    6. Keep all parts away from any source of fire. EB101010 REPLACEMENT PARTS 1. Use only genuine Yamaha parts for all repla- cements. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appea- rance, but inferior in quality.

  • Page 8: Lock Washers/Plates And Cotter Pins

    IMPORTANT INFORMATION INFO EB101030 LOCK WASHERS/PLATES AND COTTER PINS 1. Replace all lock washers/plates and cotter pins after removal. Bend lock tabs along the bolt or nut flats after the bolt or nut has been tightened to specification. EB101040 BEARINGS AND OIL SEALS Install bearings and oil seals so that the manu- facturer’s marks or numbers are visible.

  • Page 9: Checking Of Connections

    IMPORTANT INFORMATION INFO EB801000 CHECKING OF CONNECTIONS Dealing with stains, rust, moisture, etc. on the connector. 1. Disconnect: • Connector 2. Dry each terminal with an air blower. 3. Connect and disconnect the connector two or three times. 4. Pull the lead to check that it will not come off. 5.

  • Page 10: How To Use The Conversion Table

    IMPORTANT INFORMATION INFO EB201000 HOW TO USE THE 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 ** mm 0,03937 **in 2 mm 0,03937...

  • Page 11: Special Tools

    SPECIAL TOOLS INFO EB102000 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools; this will help prevent damage caused by the use of inap- propriate tools or improvised techniques. When placing an order, refer to the list provided below to avoid any mistakes.
  • Page 12 SPECIAL TOOLS INFO Tool No. Tool name/Usage Illustration 90890-01337 Clutch spring compressor -01464 These tools are used for removing the nut with holding the compression spring 90890-01348 Locknut wrench This tool is used when removing or installing the secondary sheave nut. 90890-01367 Fork seal driver weight -01368...
  • Page 13 90890-04116 Valve guide puller 90890-04117 Valve guide installer 90890-04118 Valve guide reamer 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.

  • Page 14: Specifications General Specifications

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Model YP125E YP180E Model code Dimensions: Overall lenght 2,030 mm Overall width 745 mm Overall height 1,285 mm Seatheight 774 mm Wheelbase 1,480 mm Minimum ground clearance 102 mm Basic weight: With oil and full fuel tank 141 kg Engine: Engine type...
  • Page 15 SPEC GENERAL SPECIFICATIONS Model YP125E YP180E Carburetor: Type/quantity Y28V-1K/1 Y28V-1L/1 Manufacturer TEIKEI Spark plug: Type CR8E Manufacturer Spark plug gap 0,7 ~ 0,8 mm Clutch type: Dry, centrigual automatic Transmission: Primary reduction system Helical gear Primary reduction ratio 40/15(2.666) Secondary reduction system Sper gear Secondary reduction ratio 44/12 (3.666)
  • Page 16 SPEC GENERAL SPECIFICATIONS Model YP125E YP180E Brake: Front brake type Single disc brake operation Right hand operation Rear brake type Single disc brake operation Left hand operation Suspension: Front suspension Telescopic fork Rear suspension Unit swing Shock absorber: Front shock absorber Coil spring/oil damper Rear shock absorber Coil spring/oil damper...

  • Page 17: Maintenance Specifications

    SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Item Standard Limit YP125E YP180E Cylinder head: Warp limit ••• 0,03 mm Cylinder: Bore size 53,700 ~ 53,715 62,200 ~ 62,215 ••• Out of round limit ••• 0,03 mm Camshaft: Cam dimensions Intake “A” 30,811 ~ 30,911 mm 30,711 mm “B”...
  • Page 18 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit YP125E YP180E Valve spring: Free length IN/EX 41,94 mm 39,8 mm Set length (valve closed) IN/EX 37,5 mm ••• Compressed pressure IN/EX 45,1 - 50,9 kg ••• Tilt IN/EX ••• 2,5 º / 1,9 mm Piston: Piston to cylinder clearance 0,013 ~ 0,045 mm...
  • Page 19 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit YP125E YP180E Automatic centrigual clutch: Clutch shoe tickness 2,0 mm 2,75 mm 1/1,75 mm Clutch shoe spring free length 28,5 mm 32 mm ••• Clutch - in revolution 3800±250 r/min 3400±250 r/min ••• Cluth - stall revolution 5800±500 r/min 5300±500 r/min •••...

  • Page 20: Lubrication Diagram

    SPEC MAINTENANCE SPECIFICATIONS LUBRICATION DIAGRAM Cylinder head lubrication Crankshaft lubrication...
  • Page 21 SPEC MAINTENANCE SPECIFICATIONS LUBRICATION DIAGRAM Oil routing A Pressure circuit Lubrication chart B Oil overflow circuit A ––––––––––––––––––––– B – – – – – – – – – – – – –...

  • Page 22: Tightening Torques (Engine)

    SPEC MAINTENANCE SPECIFICATIONS TIGHTENING TORQUES ENGINE Tightening Thread torque Part to be tightened Part name size Q’ty m•kg Remarks Oil check bolt — Exhaust pipe stud bolt — Spark plug — 12,5 1,25 Cylinder head and cylinder Cylinder head and cylinder Bolt (Cam chain side) Rotor...
  • Page 23 SPEC MAINTENANCE SPECIFICATIONS Tightening Thread torque Part to be tightened Part name size Q’ty m•kg Remarks Cylinder Bolt Cylinder Screw 12,5 1,25 Cluth boss Cluth shoes Primary pulley Cluth housing Stator –– Pick up coil –– Starter motor Bolt 0,65 Thermo switch ––...

  • Page 24: Chassis

    SPEC MAINTENANCE SPECIFICATIONS CHASSIS Item Standard Limit YP125E YP180E Steering system: Steering bearing type Ball bearing ••• Front suspension: Front fork travel 90 mm ••• Fork spring free length 287,4 mm 281,7 mm Spring rate (K1) 5,4 N/mm (0,54 kg/mm) •••...

  • Page 25: Tightening Torques (Chassis)

    SPEC MAINTENANCE SPECIFICATIONS TIGHTENING TORQUES CHASSIS Tightening torque Part to be tightened Thread size m•kg Remarks Frame and engine swingarm M10 x 1,25 Swingarm and engine bracket M10 x 1,25 Engine and engine bracket M10 x 1,25 Sidestand (bolt and frame) M10 x 1,25 Sidestand (bolt and nut) M10 x 1,25...

  • Page 26: Electrical

    SPEC MAINTENANCE SPECIFICATIONS ELECTRICAL Item Standard Limit YP125E YP180E Igntion timing: Igntion timing (B.T.D.C.) 10º at 1800 r/min ••• Advanced timing (B.T.D.C.) 26º at 8000 r/min ••• Advanced type Electrical type ••• CDI: 248 ~ 372 Ω at 20 ºC/ Pickup coil resistance/color •••...
  • Page 27 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit YP125E YP180E Starter relay: Model/manufacturer 3 MW/JIDECO ••• Amperage rating 100 A ••• 4,2 ~ 4,6 Ω at 20 ºC Coil winding resistance ••• Horn: Model/manufacturer K80N/LEB ••• Maximum amperage ••• Flasher relay: Type Electronic •••...

  • Page 28: General Torque Specifications

    SPEC GENERAL TORQUE SPECIFICATIONS GENERAL TORQUE General torque SPECIFICATIONS (Nut) (Bolt) specifications This chart specifies torque for standard faste- ners with standard I.S.O. pitch threads. Torque m• kg specifications for special components or 10 mm 6 mm assemblies are included in the applicable sec- 12 mm 8 mm tions of this book.

  • Page 29: Cable Routing

    SPEC CABLE ROUTING CABLE ROUTING CDI flywheel Fuel sender CDI unit Fan thermoswitch Ignition coil Spark plug Anti-theft connections Main switch Fuel cock Battery Seat lock cable Regulator/rectifier A Place the wire harness as shown to prevent it from getting pinched by the helmet box Horn carrier.
  • Page 30 SPEC CABLE ROUTING Starter relay Vacuum hose for the cock Starter motor Radiator overflow pipe Autochoke A Tighten together the ground cable and the ignition coil. Sidestand switch B Clamp the main harness and the sidestand switch cable to the frame. Thermoswitch (temperature) C Pass pipe 1 through the clamp.
  • Page 31 SPEC CABLE ROUTING Right handlebar switch Left handlebar switch Front brake switch Rear brake switch Throttle cable Rear brake hose Front brake cable...

  • Page 32: Periodic Maintenance/Lubrication Intervals

    • The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead. • From 30,000 km, repeat the maintenance intervals starting from 6,000 km. • Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. ODOMETER READING ANUAL ( x 1.000 km)
  • Page 33 PERIODIC MAINTENANCE/ INSP LUBRICATION INTERVALS ODOMETER READING ANUAL ( x 1.000 km) CHECK ITEM CHECK OR MAINTENANCE JOB 14 * Steering • Check bearing play and steering √ √ √ √ √ for roughness bearings • Lubricate with lithium-soap-based Every 24,000 km grease 15 * Chassis...
  • Page 35 COMPONENTS COLOR CODE 1. FLYWHEEL CDI B .....Balck 2. CDI Br....Brown 3. IGNITION COIL Ch....Chocolate 4. SPARK PLUG Dg....Dark green 5. MAIN SWITCH G.....Green 6. FUSE (MAIN) L .....Blue 7. BATTERY O.....Orange 8. RECTIFIER/REGULATOR P .....Pink 9. STARTER RELAY R .....Red 10.
  • Page 36 Aiguaders, 10-16 • Pol. Ind. Riera de Caldes 08184 Palau-Solità i Plegamans • Barcelona • Spain IMPRESO EN ESPAÑA CENTRO TELEMÀTIC EDITORIAL, 02.11 (E)

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