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Yamaha 2011 XQ125, Service Manual

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XQ125

2001

XQ150

5HT1-AE2

SERVICE MANUAL

Summary of Contents for 2011 XQ125

Page 1: ...XQ125 2001 XQ150 5HT1 AE2 SERVICE MANUAL ...

Page 2: ...0000 XQ125 XQ150 SERVICE MANUAL 2001 by MBK Industrie 2nd edition April 2001 All rights reserved Any reproduction or unauthorized use without the written permission of MBK Industrie is expressly prohibited ...

Page 3: ...maha and MBK dealers and their qualified mechanics It is not possible to include all the knowledge of a mechanic in one manual Therefore anyone who uses this book to perform maintenance and repairs on Yamaha and MBK vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles Repair and maintenance work attempted by anyone without this knowledge is l...

Page 4: ...tially ENG ENG EASM0025 CYLINDER AND PISTON Removing the cylinder and piston Remove the parts in the order listed Cylinder head Refer to CYLINDER HEAD section 1 Cylinder bolt 2 2 Timing chain guide exhaust side 1 3 Cylinder 1 4 Dowel pin 2 5 Cylinder gasket 1 6 Piston pin clip 2 7 Piston pin 1 8 Piston 1 9 Piston ring top 1 10 Piston ring 2nd 1 11 Oil ring 1 For installation reverse the removal pr...

Page 5: ...ls 햻 to 헃 indicate the following 햻 Serviceable with engine mounted 햽 Filling fluid 햾 Lubricant 햿 Special tool 헀 Tightening torque 헁 Wear limit clearance 헂 Engine speed 헃 Electrical data Symbols 헄to쎻 23 intheexplodeddiagramsindicate the types of lubricants and lubrication points 헄 Engine oil 헅 Gear oil 헆 Molybdenum disulfide oil 쎻 21 Wheel bearing grease 쎻 22 Lithium soap base grease 쎻 23 Molybdenu...

Page 6: ...FICATIONS PERIODIC CHECKS AND ADJUSTMENTS ENGINE OVERHAUL COOLING SYSTEM CARBURETOR CHASSIS ELECTRICAL SYSTEM TROUBLESHOOTING 1 2 3 4 6 7 8 9 TRBL SHTG GEN INFO SPEC CHK ADJ ENG CARB ELEC CHAS 5 COOL EAS00010 TABLE OF CONTENTS ...

Page 7: ...1 GEN INFO ...

Page 8: ...ODOMETER TRIPMETER READING MODE 1 2 BATTERY VOLTAGE FUEL GAUGE 1 2 THE CLOCK 1 3 AUTO CHOKE SYSTEM 1 3 IMPORTANT INFORMATION 1 4 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 4 REPLACEMENT PARTS 1 4 GASKETS OIL SEALS AND O RINGS 1 4 LOCK WASHERS PLATES AND COTTER PINS 1 5 BEARINGS AND OIL SEALS 1 5 CIRCLIPS 1 5 CHECKING THE CONNECTIONS 1 6 SPECIAL TOOLS 1 7 ...

Page 9: ...OOTER IDENTIFICATION EASM0002 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 햲 is stamped into the frame EASM0003 MODEL LABEL The model label 햲 is affixed under the seat This information will be needed to order spare parts ZAUM0113 햲 ZAUM0114 햲 1 1 ...

Page 10: ...to the following procedure 1 Turn the key to ON 2 Press the TRIP button until the current mode appears in the dispaly CONT continental for kilometer mode and EnGL English for the mile mode 3 Press the TRIP button to switch mode 4 Press the TRIP button for two seconds to confirm the setting NOTE The odometer tripmeter reading mode can be changed any number of times while the odometer reading is bel...

Page 11: ... the second minute digit 8 Press the TRIP button for two seconds to set the clock AUTO CHOKE SYSTEM This system is the parallel connection of the ignitor unit circuit and the thermo switch as shown detecting the engine temperature and facilitates the restarting with the warm engine Circuit diagram Auto choke operation FEATURES Main switch Fuse Battery Thermo switch Auto choke Ignitor unit C P U Ig...

Page 12: ...in trays in the order of disassem bly This will speed up assembly and allow for the correct installation of all parts 5 Keep all parts away from any source of fire EAS00021 REPLACEMENT PARTS 1 Use only genuine Yamaha and MBK parts for all replacements Use oil and grease recom mended by Yamaha or MBK for all lubrication jobs Other brands may be similar in function and appearance but inferior in qua...

Page 13: ...are visible When installing oil seals lubricate the oil seal lips with a light coat of lithium soap base grease Oil bearings liberally when installing if appro priate 햳 Oil seal EAS00025 CIRCLIPS 1 Before reassembly check all circlips carefully and replace damaged or distorted circlips Always replace piston pin clips after one use When installing a circlip 햲 make sure the sharp edged corner 햳 is p...

Page 14: ...d disconnect sev eral times 3 Check all connections Loose connection Connect properly NOTE If the pin 햲 on the terminal is flattened bend it up 4 Connect lead coupler connector NOTE Make sure all connections are tight 5 Check continuity with the pocket tester Pocket tester 90890 03112 NOTE If there is no continuity clean the terminals Whencheckingthewireharness performsteps 1 to 3 As a quick remed...

Page 15: ...afts Rotor holding tool This tool is used to remove the flywheel magneto Ring nut wrench 햲 Steering nut wrench 햳 These tools are used to loosen and tighten the steering ring nuts Damper rod holder T handle These tools are used for disassembling or assembling the front fork Piston pin puller This tool is used to remove the piston pins Fuel level gauge This tool is used to measure the fuel level in ...

Page 16: ...able for checking the electrical system Engine tachometer This tool is needed for detecting the engine rpm Timing light This tool is needed for detecting ignition timing Valve spring compressor Attachment These tools are used when removing or installing the valve and the valve spring Valve guide remover This tool is used to remove the valve guide 90890 01367 90890 01368 90890 01701 90890 03111 908...

Page 17: ...nition checker This instrument is necessary for checking the ignition system components Yamaha bond No 1215 This sealant bond is used for crankcase mating surface etc Compression gauge This gauge is used to measure the engine compression 90890 04117 90890 04118 90890 06754 90890 85505 90890 03081 Tool No Tool name usage Illustration SPECIAL TOOLS 1 9 ...

Page 18: ...2 SPEC ...

Page 19: ...ELECTRICAL 2 10 CONVERSION TABLE 2 12 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 13 TIGHTENING TORQUES 2 14 TIGHTENING TORQUES ENGINE 2 14 TIGHTENING TORQUES CHASSIS 2 16 LUBRICATION POINTS AND LUBRICANT TYPES 2 17 ENGINE 2 17 CHASSIS 2 18 COOLING SYSTEM DIAGRAMS 2 19 LUBRICATION DIAGRAMS 2 21 CABLE ROUTING 2 23 ...

Page 20: ...l change Total amount Final gear case oil Total amount Coolant system Radiator capacity including all routes Coolant reservoir capacity from low to full level Air filter type Fuel Recommended fuel Fuel tank capacity 1 920 mm 750 mm 1 180 mm 824 mm 1 400 mm 118 mm 2 050 mm 130 kg 124 kg Liquid cooled 4 stroke SOHC Forward inclined single cylinder 124 cm3 152 cm3 53 7 x 54 8 mm 59 5 x 54 8 mm 11 1 1...

Page 21: ...to 90 kg load Front Rear 90 kg load Maximum load Front Rear Front wheel Wheel type Rim size Rear wheel Wheel type Rim size TK 5DS 1 TK 5KD 1 TEIKEI CR8E NGK 0 5 0 7 mm Dry centrifugal automatic Helical gear 40 15 2 666 Spur gear 44 12 3 666 42 14 3 V belt automatic Centrifugal automatic type Steel tube backbone 25 81 3 mm Tubeless 130 60 13 140 60 13 PIRELLI CHENG SHIN PIRELLI CHENG SHIN SL36 MAXX...

Page 22: ...ity Headlight Auxiliary light Brake taillight Turn signal light Meter light High beam indicator light Turn indicator light Coolant temperature warning light Amperage for fuses Main fuse Radiator fan fuse Single disc brake Right hand operation Single disc brake Left hand operation Telescopic fork Unit swing Coil spring oil damper Coil spring oil damper 103 mm 95 mm C D I Flywheel magneto CB7L B2 or...

Page 23: ...ide clearence IN EX Stem runout limit Valve seat width IN EX 0 03 mm 53 700 53 705 mm 59 500 59 505 mm 0 05 mm Chain drive left 30 811 30 911 mm 30 711 mm 25 145 25 245 mm 25 045 mm 5 666 m 30 811 30 911 mm 30 711 mm 25 152 25 252 mm 25 052 mm 5 659 m 0 03 mm 82 RH2005 94 12 000 12 018 mm 12 030mm 11 981 11 991 mm 11 950 mm 0 10 0 14 mm 0 16 0 20 mm A C B A B C Face width Seat width Item Standard ...

Page 24: ...c centrifugal clutch Clutch shoe thickness Clutch housing inside diameter Weight outside diameter Clutch in revolution Clutch stall revolution V Belt V belt width 41 94 mm 39 84 mm 37 5 mm 45 1 50 9 N 2 5 1 9 mm 0 025 0 035 mm 0 15 mm 53 670 53 687 mm 59 470 59 487mm 4 5 mm 15 002 15 013 mm 15 045 mm 14 991 15 000 mm 14 975 mm Barrel 0 15 0 25 mm 0 50 mm 0 03 0 07 mm 0 12 mm Taper 0 15 0 30 mm 0 6...

Page 25: ...otor clearence Radiator Type Width height thickness Radiator cap opening pressure Reservoir tank capacity Thermostatic valve Manufacturer Valve opening temperature Valve full open temperature TK 5DS TK 5KD 116 114 ø1 0 ø1 4 4E31 3 5 4E32 3 5 ø1 30 2 590 38 36 2 1 4 2 3 4 2 4 ø2 00 45 5 6 mm 1 600 1 800 rpm Trochoid 0 15 mm 0 15 mm 0 17 mm Cooling fin with electric fan 170 282 23 mm 100 120 kPa 0 3...

Page 26: ...ary drive gear oil seal Main axle bearing left Main axle bearing right Drive axle bearing left Drive axle bearing right Drive axle oil seal 22 x 32 x 7 19 x 30 x 8 Reinforced 19 x 30 x 8 Double lips 20 x 42 x 12 15 x 32 x 9 17 x 35 x 10 25 x 52 x 15 17 x 40 x 12 25 x 42 x 6 Double lips 15 x 25 x 12 Needle bearing 12 x 37 x 12 17 x 47 x 14 Sphere 22 x 50 x 14 Sphere 32 x 52 x 7 Item Size MAINTENANC...

Page 27: ...ion Minimum Standard Maximum Front wheel Type Rim size Rim material Rim runout limit Radial Lateral Rear wheel Type Rim size Rim material Rim runout limit Radial Lateral MAINTENANCE SPECIFICATIONS CHASSIS Item Standard Limit MAINTENANCE SPECIFICATIONS Ball bearing 103 mm 6 1 N mm 7 8 N mm 0 11 mm 11 87 mm 120 cm3 SAE20 33 mm No 95 mm 294 mm 8 N mm 12 N mm 18 N mm 0 70 mm 70 100 mm 100 130 mm 1 1 4...

Page 28: ...s Max deflection Pad thickness Master cylinder inside diameter Caliper cylinder outside diameter Brake fluid type Brake lever Brake lever free play front Brake lever free play rear Throttle cable free play Item Standard Limit MAINTENANCE SPECIFICATIONS Single disc brake 245 x 4 7 mm 4 2 mm 0 15 mm 4 mm 0 8 mm 13 mm 28 mm DOT 3 or DOT 4 Single disc brake 220 x 4 5 mm 4 0 mm 0 15 mm 4 mm 0 8 mm 12 m...

Page 29: ...r Operation voltage Output Armature coil resistance Brush overall length Brush quantity Spring force Commutator diameter Mica undercut depth Starter relay Model manufacturer Amperage rating Coil winding resistance MAINTENANCE SPECIFICATIONS ELECTRICAL MAINTENANCE SPECIFICATIONS Item Standard Limit 10 at 1 700 rpm 26 at 4 500 rpm Digital 248 372 Ω at 20 C 720 1080 Ω at 20 C MORIYAMA 0 5 mm 0 32 0 4...

Page 30: ...frequency Fuel gauge Model manufacturer Sender unit resistance full empty Circuit breaker Main Radiator fan fuse YF 12 NIKKO 3 A 800 TRANSVAL 01 2320 01 GUILERA 65 95 cycles min 70 90 cycles min 25 33 07 MAXIMA 4 10 Ω 90 100 Ω 20 A x 1 pcs 7 5 A x 1 pcs MAINTENANCE SPECIFICATIONS Item Standard Limit 2 11 ...

Page 31: ...c cm3 0 03527 oz IMP liq Volume Capacity cc cm3 0 06102 cu in L liter 0 8799 qt IMP liq L liter 0 2199 gal IMP liq kg mm 55 997 lb in Misc kg cm2 14 2234 psi lb in2 Centigrade C 9 5 32 Fahrenheit F CONVERSION TABLE AS00028 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 Ex METRIC MULTIPLIER IM...

Page 32: ...ti fastener assemblies in a crisscross pattern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque specifications require clean dry threads Components should be at room temperature A Width across flats B Thread diameter B A A B General tightening nut bolt torques Nm m kg 10 mm 6 mm 6 0 6 12 mm 8 mm 15 1 5 14 mm 10 mm 30 3 0 17 mm 12 ...

Page 33: ...alve cover Bolt M6 2 9 0 9 Oil pump Bolt M6 3 65 6 5 Engine drain plug M35 1 32 3 2 Inlet manifold on cylinder head Bolt M6 2 10 1 0 Air filter cover Bolt M6 4 6 5 0 65 V belt air filter cover Bolt M6 4 6 5 0 65 Crankcase left Bolt M6 8 9 0 9 Cover crankcase 1 Bolt M6 11 10 1 0 Cover crankcase 2 Bolt M6 6 10 1 0 Cover oil pump Bolt M6 3 6 5 0 65 Duct air Bolt M6 3 7 0 7 Cover magneto Bolt M6 3 7 0...

Page 34: ...ant drain bolt on cylinder Bolt M6 1 8 0 8 Starter motor Bolt M6 2 65 6 5 Rotor Nut M12 1 70 7 0 M16 1 225 22 5 M16 1 225 22 5 Stator Bolt M6 3 70 7 0 Item Fastener Thread size Q ty Tightening torque Nm m kg Remarks TIGHTENING TORQUES 2 15 ...

Page 35: ... 2 4 0 4 Box with seat rail Bolt M6 2 8 0 8 Fuel cock with tank 2 5 0 25 Handle seat with frame Bolt M6 4 4 0 4 Box with fuel tank Bolt M6 2 4 0 4 Screw tapping in plastic Bolt ø5 3 25 0 33 Screw tapping in clip Bolt ø5 2 25 0 23 Footrest board with frame Bolt M6 3 4 0 4 Fender on front fork Bolt M6 3 4 0 4 Cover handle with handle Bolt M5 2 4 5 0 45 Mainstand Nut M10 2 42 4 2 Front wheel axle Nut...

Page 36: ...ring groove Camshaft cam profile Valve stem IN EX Valve stem end IN EX Rocker shaft Valve rocker arm inner surface Shaft Shaft Oil pump assembly Gasket Oil pump assembly Holder Idle gear 1 thrust surfaces Shaft 1 Idle gear 2 thrust surfaces Idle gear 2 inner surface Main axle thrust surfaces Crankcase mating surfaces Yamaha bond No 1215 Crankcase breather plug Stator grommet Yamaha bond No 1215 Su...

Page 37: ... wheel oil seal lips left right Steering head pipe bearing upper lower Tube guide throttle grip inner surface Brake cable brake lever Brake lever and lever holder bolt sliding surface Sidestand sliding surface Centerstand sliding surface and mounting bolt Centerstand stopper pivot shaft 2 18 ...

Page 38: ...ank cap Coolant hose cylinder head outlet Frame Coolant tank Coolant tank breather hose Clip Drain bolt Thermo switch cover A B B A Clip Hose Coolant hose pump inlet Clamp A Keep the smaller diameter for fixing on the frame ø 22 B Keep the larger diameter for fixing the hose ø 24 2 19 ...

Page 39: ...Coolant lower level mark Coolant tank breather hose Battery box Drain bolt on water pump Under cover Thermo switch on radiator Radiator FRONT REAR l A B C Grommet Coolant hose pump inlet A Pass the hose under the seat rail fixation B Pass the hose under the frame down tube C Pass the hose through the under cover 2 20 ...

Page 40: ...SPEC LUBRICATION DIAGRAMS EAS00034 LUBRICATION DIAGRAMS 1 Lubrication of the cylinder head Cylinder head Cylinder Crankcase 2 Lubrication of the crankshaft Crankshaft 2 1 2 21 ...

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