Yamaha YZ125 2021 Manuals

Yamaha YZ125 2021 Manuals

Manuals and User Guides for Yamaha YZ125 2021. We have 1 Yamaha YZ125 2021 manual available for free PDF download: Owner's Service Manual

Yamaha YZ125 2021 Owner's Service Manual

Yamaha YZ125 2021 Owner's Service Manual (268 pages)

Brand: Yamaha | Category: Motorcycle | Size: 8.74 MB

Table of Contents

Table of Contents

9
- Safety Information
  13
- For Safety, be Sure to Obey the Following
  13
- Location of Important Labels
  16
- Description
  17
- Identification
  18
- Vehicle Identification Number
  18
- Engine Serial Number
  18
- COLLAR (Tool for YPVS)
  19
- Valve Joint
  19
- Nipple Wrench
  19
- Sidestand
  19
- Included Parts
  19
- Important Information
  20
- Preparation for Removal and Disassembly
  20
- Replacement Parts
  20
- Gaskets, Oil Seals and O-Rings
  20
- Lock Washers/Plates and Cotter Pins
  21
- Bearings and Oil Seals
  21
- Circlips
  21
- Basic Service Information
  22
- Electrical System
  22
- Special Tools
  24
- Instrument and Control Functions
  28
- Engine Stop Switch
  28
- Shift Pedal
  28
- Kickstarter Lever
  28
- Front Brake Lever
  28
- Rear Brake Pedal
  28
- Fuel Cock
  28
- Starter Knob (Choke)
  29
- Starting and Break-In
  30
- Fuel and Engine Mixing Oil
  30
- Starting a Cold Engine
  30
- Starting a Warm Engine
  30
- Break-In Procedures
  30
- Maintenance after Break-In
  32
- Major Maintenance
  32
- Air Filter Maintenance
  32
- Torque-Check Points
  33
- Motorcycle Care and Storage
  35
- Care
  35
- Storage
  36
Specifications

39
- General Specifications
  40
- Engine Specifications
  41
- Chassis Specifications
  46
- Electrical Specifications
  47
- General Tightening Torque Specifications
  48
- Tightening Torques
  48
- Engine Tightening Torques
  49
- Chassis Tightening Torques
  50
- Cable Routing Diagram
  54
Periodic Checks and Adjustments

63
Chassis

91
- General Chassis
  94
- Removing the Number Plate
  94
- Removing the Side Cover
  94
- Front Wheel
  95
- Assembling the Front Wheel
  96
- Checking the Front Wheel
  96
- Disassembling the Front Wheel
  96
- Removing the Front Wheel
  96
- Installing the Front Wheel
  97
- Checking and Replacing the Rear Wheel Sprocket
  100
- Checking the Rear Wheel
  100
- Disassembling the Rear Wheel
  100
- Rear Wheel
  100
- Removing the Rear Wheel
  100
- Assembling the Rear Wheel
  101
- Installing the Rear Wheel
  101
- Front Brake
  103
- Checking the Front Brake Disc
  107
- Introduction
  107
- Replacing the Front Brake Pads
  107
- Assembling the Front Brake Caliper
  109
- Checking the Front Brake Caliper
  109
- Disassembling the Front Brake Caliper
  109
- Removing the Front Brake Caliper
  109
- Installing the Front Brake Caliper
  110
- Assembling the Front Brake Master Cylinder
  111
- Checking the Front Brake Master Cylinder
  111
- Removing the Front Brake Master Cylinder
  111
- Installing the Front Brake Master Cylinder
  112
- Rear Brake
  114
- Checking the Rear Brake Disc
  118
- Introduction
  118
- Replacing the Rear Brake Pads
  118
- Assembling the Rear Brake Caliper
  120
- Checking the Rear Brake Caliper
  120
- Disassembling the Rear Brake Caliper
  120
- Removing the Rear Brake Caliper
  120
- Installing the Rear Brake Caliper
  121
- Removing the Rear Brake Master Cylinder
  121
- Assembling the Rear Brake Master Cylinder
  122
- Checking the Rear Brake Master Cylinder
  122
- Installing the Rear Brake Master Cylinder
  123
- Checking the Handlebar
  125
- Handlebar
  125
- Installing the Handlebar
  125
- Removing the Handlebar
  125
- Disassembling the Front Fork Legs
  132
- Removing the Front Fork Legs
  132
- Checking the Front Fork Legs
  133
- Assembling the Front Fork Legs
  134
- Installing the Front Fork Legs
  140
- Steering Head
  142
- Checking the Steering Head
  143
- Installing the Steering Head
  143
- Removing the Lower Bracket
  143
- Rear Shock Absorber Assembly
  146
- Checking the Connecting Arm and Relay Arm
  148
- Checking the Rear Shock Absorber Assembly
  148
- Disposing of a Rear Shock Absorber
  148
- Handling the Rear Shock Absorber
  148
- Removing the Rear Shock Absorber Assembly
  148
- Installing the Rear Shock Absorber Assembly
  149
- Installing the Relay Arm
  149
- Swingarm
  151
- Checking the Swingarm
  152
- Installing the Swingarm
  152
- Removing the Swingarm
  152
- Chain Drive
  154
- Checking the Drive Chain
  155
- Removing the Drive Chain
  155
- Checking the Drive Sprocket
  156
- Checking the Rear Wheel Sprocket
  156
- Installing the Drive Chain
  156
Engine

159
- Engine Removal
  161
- Installing the Engine
  164
- Removing the Engine
  164
- Cylinder Head, Cylinder and Piston
  165
- Removing the Cylinder Head
  167
- Removing the Piston
  167
- Removing the Push Rod
  167
- Checking the Cylinder and Piston
  168
- Checking the Cylinder Head
  168
- Combination of Piston and Cylinder
  169
- Checking the Piston Pin
  170
- Checking the Piston Ring
  170
- Assembling the Power Valve
  171
- Checking the Power Valve
  171
- Checking the Power Valve Hole on Cylinder
  171
- Checking the Small End Bearing
  171
- Installing the Piston and Cylinder
  172
- Installing the Cylinder Head
  174
- CDI Magneto
  175
- Checking the CDI Magneto
  176
- Checking the Woodruff Key
  176
- Installing the CDI Magneto
  176
- Removing the Rotor
  176
- Kickstarter
  178
- Checking the Kick Gear and Kick Idle Gear
  180
- Installing the Kick Shaft Assembly
  180
- Removing the Kick Shaft Assembly
  180
- Removing the Primary Drive Gear
  180
- Installing the Kick Idle Gear
  181
- Installing the Primary Drive Gear
  181
- Installing the Kickstarter Lever
  182
- Ypvs Governor
  183
- Checking the Bearing
  184
- Checking the Governor Groove
  184
- Installing the Governor
  184
- Removing the Governor
  184
- Clutch
  186
- Checking the Clutch Boss
  188
- Checking the Clutch Housing
  188
- Checking the Clutch Plates
  188
- Checking the Clutch Springs
  188
- Checking the Friction Plates
  188
- Removing the Clutch
  188
- Checking the Pressure Plate
  189
- Checking the Primary Drive Gear
  189
- Checking the Primary Driven Gear
  189
- Checking the Push Lever Shaft
  189
- Checking the Push Rods
  189
- Installing the Clutch
  189
- Shift Shaft
  192
- Checking the Shift Shaft
  193
- Checking the Stopper Lever
  193
- Installing the Shift Shaft
  193
- Removing the Segment
  193
- Crankcase
  196
- Assembling the Crankcase
  197
- Checking the Crankcase
  197
- Disassembling the Crankcase
  197
- Crankshaft
  200
- Checking the Crankshaft
  201
- Installing the Crankshaft
  201
- Removing the Crankshaft
  201
- Transmission
  203
- Checking the Shift Drum Assembly
  204
- Checking the Shift Forks
  204
- Checking the Transmission
  204
- Removing the Transmission
  204
- Installing the Transmission
  205
Cooling System

207
- Cooling System Diagrams
  208
- Radiator
  209
- Checking the Radiator
  210
- Installing the Radiator
  210
- Assembling the Water Pump
  213
- Checking the Water Pump
  213
- Disassembling the Water Pump
  213
Fuel System

215
- Fuel Tank
  218
- Carburetor
  219
- Checking the Carburetor
  220
- Handling Note
  220
- Checking the Reed Valve
  221
- Assembling the Carburetor
  222
- Installing the Reed Valve
  222
- Installing the Carburetor
  224
- Measuring and Adjusting the Fuel Level
  225
Electrical System

227
- Color Code
  228
- Wiring Diagram
  228
- Ignition System
  229
- Troubleshooting
  229
- Electrical Components
  230
- Checking the Switches
  231
- Checking the Ignition Coil
  233
- Checking the Ignition Spark Gap
  233
- Checking the Spark Plug Cap
  233
- Checking the Pickup Coil
  234
- Checking the Source Coil
  234
Troubleshooting

237
- Troubleshooting
  238
- Troubleshooting of Engine
  238
- Troubleshooting of Clutch
  243
- Troubleshooting of Transmission
  244
- Troubleshooting of Cooling System
  245
- Troubleshooting of Brake
  246
- Troubleshooting of Suspension
  246
- Troubleshooting of Steering/Handling
  248
Tuning

251
- Atmospheric Conditions and Carburetor Settings
  252
- Engine
  252
- Test Run
  252
- Effects of the Setting Parts on the Throttle Valve Opening
  253
- Main Jet Adjustment
  253
- Pilot Air Screw Adjustment
  253
- Pilot Jet Adjustment
  253
- Jet Needle Adjustment
  254
- Jet Needle Groove Position Adjustment
  254
- Relationship with Throttle Opening
  254
- Carburetor Setting Parts
  255
- Road Condition and Examples of Carburetor Setting
  256
- Symptom
  256
- Change of the Heat Range of Spark Plugs
  258
- Chassis
  259
- Drive and Rear Wheel Sprockets Setting Parts
  259
- Selection of the Secondary Reduction Ratio (Sprocket)
  259
- Tire Pressure
  259
- Change in Amount and Characteristics of Fork Oil
  260
- Front Fork Setting
  260
- Setting of Spring after Replacement
  260
- Choosing Set Length
  261
- Front Fork Setting Parts
  261
- Rear Suspension Setting
  261
- Rear Shock Absorber Setting Parts
  262
- Setting of Spring after Replacement
  262
- Suspension Setting (Front Fork)
  264
- Suspension Setting (Rear Shock Absorber)
  265

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