Yamaha MBK XMAX 2014 Service Manual Download | Manualshive

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GENERAL CHASSIS

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a. Push the footrest board downward to fit the

projection on the front lower portion of the
board into the hole in the leg shield, and then
fit the projection on the front upper portion of
the board under the leg shield.

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EAS1SD1048

HANDLING THE SEAT HINGE DAMPER

WARNING

EWA1SD1019

This seat hinge damper contains highly com-
pressed nitrogen gas. Before handling the
seat hinge damper, read and make sure you
understand the following information. The
manufacturer cannot be held responsible for
property damage or personal injury that may
result from improper handling of the seat
hinge damper.
• Do not tamper or attempt to open the seat

hinge damper.

• Do not subject the seat hinge damper to an

open flame or any other source of high
heat. High heat can cause an explosion due
to excessive gas pressure.

• Do not deform or damage the seat hinge

damper in any way.

EAS1SD1049

DISPOSING OF A SEAT HINGE DAMPER

1. Gas pressure must be released before dis-

posing of a seat hinge damper. To release
the gas pressure, drill a 2–3 mm (0.08–0.12

in) hole through the seat hinge damper at a
point 15–20 mm (0.59–0.79 in) from its end
as shown.

WARNING

EWA13760

Wear eye protection to prevent eye damage
from released gas or metal chips.

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Summary of Contents for MBK XMAX 2014

Page 1: ...2014 SERVICE MANUAL YP125R YP125RA 2DM F8197 E0 ...

Page 2: ...P125R YP125RA 2014 SERVICE MANUAL 2013 by MBK Industrie First edition October 2013 All rights reserved Any reproduction or unauthorized use without the written permission of MBK Industrie is expressly prohibited ...

Page 3: ...nd significant changes in specifications or procedures will be forwarded to all authorized Yamaha and MBK dealers and will appear in future editions of this manual where applicable TIP Designs and specifications are subject to change without notice EAS20081 IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following notations This is the safety ...

Page 4: ...Sub section titles appear in smaller print than the section title 2 To help identify parts and clarify procedure steps there are exploded diagrams at the start of each removal and disassembly section 3 Numbers are given in the order of the jobs in the exploded diagram A number indicates a disassembly step 4 Symbols indicate parts to be lubricated or replaced 5 Refer to SYMBOLS A job instruction ch...

Page 5: ...ITION Serviceable with engine mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque Lithium soap based grease Wear limit clearance Molybdenum disulfide grease Engine speed Silicone grease Electrical data Apply locking agent LOCTITE Engine oil Replace the part with a new one G M BF B T R LS M S LT E New ...

Page 6: ......

Page 7: ...EAS20110 TABLE OF CONTENTS GENERAL INFORMATION 1 SPECIFICATIONS 2 PERIODIC CHECKS AND ADJUSTMENTS 3 CHASSIS 4 ENGINE 5 COOLING SYSTEM 6 FUEL SYSTEM 7 ELECTRICAL SYSTEM 8 TROUBLESHOOTING 9 ...

Page 8: ......

Page 9: ... 8 ABS OPERATION 1 14 ABS WARNING LIGHT AND OPERATION 1 17 INSTRUMENT FUNCTIONS 1 18 IMPORTANT INFORMATION 1 24 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 24 REPLACEMENT PARTS 1 24 GASKETS OIL SEALS AND O RINGS 1 24 LOCK WASHERS PLATES AND COTTER PINS 1 24 BEARINGS AND OIL SEALS 1 25 CIRCLIPS 1 25 RUBBER PARTS 1 25 BASIC SERVICE INFORMATION 1 26 QUICK FASTENERS 1 26 ELECTRICAL SYSTEM 1 27 SPECIAL T...

Page 10: ...ICATION EAS20140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the frame EAS20150 MODEL LABEL The model label 1 is affixed to the location shown This information will be needed to order spare parts 1 1 ...

Page 11: ...ine to deliver more performance and cleaner exhaust gases increase it becomes necessary to control the air fuel ratio in a more precise and finely tuned manner To accom modate this need this model has adopted an electronically controlled fuel injection FI system in place of the conventional carburetor system This system can achieve an optimum air fuel ratio required by the engine at all times by u...

Page 12: ... position sensor coolant temperature sensor lean angle sensor crankshaft position sensor in take air pressure sensor intake air temperature sensor speed sensor for YP125R front wheel sensor for YP125RA and O2 sensor enable the ECU to determine the injection duration The injection timing is determined through the signals from the crankshaft position sensor As a result the volume of fuel that is req...

Page 13: ...perating the rear brake When wheel lock is detected during emergency braking hydraulic control is performed by the hydraulic system on the front and rear brakes independently Useful terms Wheel speed The rotation speed of the front and rear wheels Chassis speed The speed of the chassis When the brakes are applied wheel speed and chassis speed are reduced However the chassis travels forward by its ...

Page 14: ...force and vehicle stability When the brake pressure is increased wheel speed is reduced Slipping occurs between the tire and the road surface and brake force is generated The limit of this brake force is determined by the friction force between the tire and the road surface and is closely related to wheel slippage Wheel slippage is represented by the slip ratio Side force is also closely related t...

Page 15: ... the brake fluid pressure is reduced it increases the hydraulic pressure point B in the following figure The hydraulic pressure is initially increased quickly and then it is increased gradually ABS operation and vehicle control If the ABS starts operating there is a tendency of the wheel to lock and the vehicle is approaching the limit of control To make the rider aware of this condition the ABS h...

Page 16: ...dency of the wheel to lock caused by applying the brakes The ABS cannot prevent wheel lock on slippery surfaces such as ice when it is caused by engine braking even if the ABS is operating Electronic ABS features The Yamaha ABS anti lock brake system has been developed with the most advanced electronic technology The ABS control is processed with good response under various vehicle travel conditio...

Page 17: ...installed close to the wheel sensors As the sensor rotor rotates the hall element in the hall IC installed in the wheel sensor generates the voltage which is proportional to the magnetic flux density and the generated voltage is processed for waveform shaping in the hall IC to output The ABS ECU calculates the wheel rotation speed by detecting the frequency of this voltage 1 2 3 4 4 7 7 5 6 6 8 9 ...

Page 18: ...ning light will go off when the vehicle is ridden or pushed at a speed of 7 km h 4 mph or faster NOTICE ECA2DM1041 If the rear wheel is raced with the vehicle on a suitable stand the ABS warning light may flash or come on If this occurs turn the main switch to OFF then back to ON The ABS operation is normal if the ABS warning light goes off after the vehicle starts off If the fault codes are not d...

Page 19: ... is continuously variable the solenoid valve moves smoothly and the hydraulic pressure is adjusted linearly 1 When the brakes are operated normally the inlet solenoid valve 1 is open and the outlet solenoid valve 2 is closed The brake line between the brake master cylinder and brake caliper is open 2 When the ABS is activated the inlet solenoid valve 1 closes and the outlet solenoid valve 2 opens ...

Page 20: ... 1 11 Buffer chamber The buffer chamber accumulates the brake fluid that is depressurized while the ABS is operating 1 2 1 Buffer chamber pressurizing phase 2 Buffer chamber depressurizing phase 3 Raised piston ...

Page 21: ...alfunction is detected in the ABS a fault code is stored in the memory of the ABS ECU for easy problem identification and troubleshooting 14 7 4 5 6 2 3 1 9 10 11 12 13 17 15 24 20 22 23 21 26 27 18 19 16 25 8 1 Battery 2 AC magneto 3 Rectifier regulator 4 Main fuse 5 ABS motor fuse 6 ABS solenoid fuse 7 Main switch 8 ABS ECU fuse 9 Signaling system fuse 10 Rear brake light switch 11 Front brake l...

Page 22: ...witch was turned on During this test a clicking noise can be heard from front side and if the front brake lever or rear brake lever are even slightly applied a vibration can be felt at the levers but these do not indicate a malfunction 2 1 3 4 5 6 7 8 1 Software operation flow 2 Main switch ON 3 Initialize 4 Self diagnosis when static 5 Self diagnosis when riding 6 Receive signals 7 Control operat...

Page 23: ...he brake master cylinder increases and the brake fluid is sent to the brake caliper At this time the inlet and outlet check valves of the hydraulic pump are closed As a result of eliminating the orifice the brake master cylinder directly pressurizes the brake caliper during normal braking When the brake lever is released the brake fluid in the brake caliper returns to the brake master cylinder 12 ...

Page 24: ...outlet solenoid valve is open the brake fluid is sent to the buffer chamber As a result the hydraulic pressure in the brake caliper is reduced The brake fluid stored in the buffer chamber is pumped back to the brake master cylinder by the hy draulic pump linked to the ABS motor 12 13 7 6 11 3 4 5 9 8 10 1 Brake master cylinder 2 Brake light switch 3 ABS motor 4 Hydraulic pump 5 Buffer chamber 6 Ou...

Page 25: ...e As the inlet solenoid valve opens the brake line from the brake master cylinder opens allowing the brake fluid to be sent to the brake caliper 12 13 7 6 11 3 4 5 9 8 10 1 Brake master cylinder 2 Brake light switch 3 ABS motor 4 Hydraulic pump 5 Buffer chamber 6 Outlet solenoid valve 7 Inlet solenoid valve 8 Brake caliper 9 Wheel sensor 10 ABS ECU 11 ABS warning light 12 Brake fluid pressure 13 T...

Page 26: ...signed to shorten the braking distance or improve the cornering perfor mance Depending on the road conditions the braking distance may be longer compared to that of vehicles not equipped with ABS Therefore ride at a safe speed and keep a safe distance be tween yourself and other vehicles The braking of the vehicle even in the worst case is principally executed when the vehicle is advancing straigh...

Page 27: ...leage based units To switch between miles and kilometers hold the SELECT switch pushed turn the main switch to ON and keep the SELECT switch pushed for an additional 8 seconds For other countries traveling speed distance traveled and fuel consumption measurements are displayed in kilometer base units Speedometer The electric tachometer allows the rider to mon itor the engine speed and keep it with...

Page 28: ...e tripmeter Oil oil change tripmeter V Belt v belt replacement tripmeter Odo odometer When approximately 2 5 L 0 66 US gal 0 55 Imp gal of fuel remains in the fuel tank the dis play will automatically change to the fuel reserve tripmeter mode F Trip and start counting the distance traveled from that point In that case pushing the TRIP button switches the display between the various tripmeter and o...

Page 29: ...YSTEM on page 8 23 V belt replacement indicator V Belt This indicator flashes every 18000 km 10500 mi when the V belt needs to be replaced After changing the V belt reset the V belt re placement indicator To reset the V belt replacement indicator 1 Turn the key to ON 2 Push the TRIP button until V belt V belt replacement tripmeter is displayed in the odometer and trip meter display While V belt is...

Page 30: ...Air the battery voltage the average fuel consumption mode Ave Cons__ _ MPG the instantaneous fuel consumption mode Cons__ _MPG and the average speed Ave in the following order Ambient temperature display This display shows the ambient temperature from 10 C to 50 C in 1 C increments The icy road warning indicator will flash when the temperature is below 4 C The temperature displayed may vary from t...

Page 31: ...fuel consumption display can be set to either km L or L 100 km except for the UK For the UK only The instantaneous fuel consumption is dis played MPG When the display is set to km L the distance that can be traveled on 1 0 L of fuel under the current riding conditions is shown When the display is set to L 100 km the amount of fuel necessary to travel 100 km un der the current riding conditions is ...

Page 32: ...rouble warning light will come on and the display will indicate a fault code If the display indicates any fault codes note the code number and then check the vehicle Coolant temperature meter With the key in the ON position the coolant temperature meter indicates the temperature of the coolant The coolant temperature varies with changes in the weather and engine load If the top segment and coolant...

Page 33: ... correct installation of all parts 5 Keep all parts away from any source of fire EAS20200 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace ments Use oil and grease recommended by Yamaha for all lubrication jobs Other brands may be similar in function and appearance but inferior in quality EAS20210 GASKETS OIL SEALS AND O RINGS 1 When overhauling the engine replace all gaskets seals ...

Page 34: ...d air because this will damage the bearing surfac es EAS20240 CIRCLIPS Before reassembly check all circlips carefully and replace damaged or distorted circlips Al ways replace piston pin clips after one use When installing a circlip 1 make sure the sharp edged corner 2 is positioned opposite the thrust 3 that the circlip receives EAS2DM1132 RUBBER PARTS Check rubber parts for deterioration during ...

Page 35: ...stener push its pin so that it protrudes from the fastener head then insert the fastener into the part to be secured and push the pin in with a screwdriver Make sure that the pin is flush with the fastener s head Screw type 1 Remove Quick fastener TIP To remove the quick fastener loosen the screw with a screwdriver then pull the fastener out 2 Install Quick fastener TIP To install the quick fasten...

Page 36: ...f a battery lead is difficult to disconnect due to rust on the battery terminal remove the rust us ing hot water NOTICE ECA16760 Be sure to connect the battery leads to the correct battery terminals Reversing the bat tery lead connections could damage the electrical components NOTICE ECA16771 When connecting the battery leads to the battery be sure to connect the positive bat tery lead first then ...

Page 37: ... 5 seconds before turning the main switch back to ON Checking the electrical system TIP Before checking the electrical system make sure that the battery voltage is at least 12 V NOTICE ECA14371 Never insert the tester probes into the cou pler terminal slots Always insert the probes from the opposite end a of the coupler tak ing care not to loosen or damage the leads NOTICE ECA16640 For waterproof ...

Page 38: ...erefore be sure to check the type of cou pler lock before disconnecting the coupler NOTICE ECA16790 When disconnecting a connector do not pull the leads Hold both sections of the connec tor securely and then disconnect the con nector 2 Check Lead Coupler Connector Moisture Dry with an air blower Rust stains Connect and disconnect sev eral times 3 Connect Lead Coupler Connector TIP When connecting ...

Page 39: ...most part stores 5 Check Resistance TIP The resistance values shown were obtained at the standard measuring temperature of 20 C 68 F If the measuring temperature is not 20 C 68 F the specified measuring conditions will be shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C Pocket tester 90890 03112 Analog pocket tester YU 03112 C Intake air temperature sensor re sistance 5 40 6 60 kΩ a...

Page 40: ...y mistakes TIP For U S A and Canada use part numbers starting with YM YU or ACC For others use part numbers starting with 90890 Tool name Tool No Illustration Reference pages Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 30 8 133 8 134 8 135 8 139 8 140 8 141 8 142 8 143 8 144 8 145 8 146 8 147 8 148 8 149 8 150 Tappet adjusting tool 90890 01311 Six piece tappet set YM A5970 3 6 FI d...

Page 41: ... 90890 01326 T handle 3 8 drive 60 cm long YM 01326 4 76 4 78 Fork seal driver weight 90890 01367 Replacement hammer YM A9409 7 4 78 Fork seal driver attachment ø38 90890 01372 Replacement 38 mm YM A5142 1 4 78 Compression gauge 90890 03081 Engine compression tester YU 33223 5 1 Tool name Tool No Illustration Reference pages YM 01300 YM A9409 7 YM A5142 4 ...

Page 42: ... 24 Valve guide remover ø4 5 90890 04116 Valve guide remover 4 5 mm YM 04116 5 20 Valve guide installer ø4 5 90890 04117 Valve guide installer 4 5 mm YM 04117 5 20 Valve guide reamer ø4 5 90890 04118 Valve guide reamer 4 5 mm YM 04118 5 20 Piston pin puller set 90890 01304 Piston pin puller YU 01304 5 26 Rotor holding tool 90890 01235 Universal magneto and rotor holder YU 01235 5 33 Tool name Tool...

Page 43: ...85 5 34 5 37 Clutch spring holder arm 90890 01464 Compressor holder adapter YM 33285 6 5 34 5 37 Oil seal guide ø41 90890 01396 5 36 Sheave holder 90890 01701 Primary clutch holder YS 01880 A 5 37 5 38 5 41 5 42 5 43 Rotor holding tool 90890 01235 Universal magneto and rotor holder YU 01235 5 38 Flywheel puller 90890 01362 Heavy duty puller YU 33270 B 5 41 Tool name Tool No Illustration Reference ...

Page 44: ...ankcase separator YU 01135 B 5 56 Crankshaft installer pot 90890 01274 Installing pot YU 90058 5 58 5 59 Crankshaft installer bolt 90890 01275 Bolt YU 90060 5 58 5 59 Adapter M14 90890 01478 Adapter 6 YM 90066 5 58 5 59 Fork seal driver attachment 90890 01186 Replacement 27 mm YM A9409 1 5 58 Tool name Tool No Illustration Reference pages YU 90058 YU 90059 ...

Page 45: ... Pressure tester adapter YU 33984 6 2 Mechanical seal installer 90890 04145 6 7 Middle driven shaft bearing driver 90890 04058 Middle drive bearing installer 40 50 mm YM 04058 6 7 Pressure gauge 90890 03153 YU 03153 7 3 Fuel pressure adapter 90890 03181 YM 03181 7 3 Tool name Tool No Illustration Reference pages YU 24460 A YU 33984 ø10 ø30 ...

Page 46: ... 34487 8 143 Test harness lean angle sensor 6P 90890 03209 YU 03209 8 144 Test harness speed sensor 3P 90890 03208 YU 03208 8 146 Test harness TPS 5RU 3P 90890 03230 8 147 Test harness TPS 3P 90890 03204 YU 03204 8 148 Tool name Tool No Illustration Reference pages ...

Page 47: ...CAL SPECIFICATIONS 2 11 TIGHTENING TORQUES 2 14 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 14 ENGINE TIGHTENING TORQUES 2 15 CHASSIS TIGHTENING TORQUES 2 18 LUBRICATION POINTS AND LUBRICANT TYPES 2 22 ENGINE 2 22 CHASSIS 2 24 LUBRICATION SYSTEM DIAGRAMS 2 25 COOLING SYSTEM DIAGRAMS 2 27 CABLE ROUTING 2 29 ...

Page 48: ... Dimensions Overall length 2160 mm 85 0 in Overall width 790 mm 31 1 in Overall height 1385 mm 54 5 in Seat height 785 mm 30 9 in Wheelbase 1525 mm 60 0 in Ground clearance 125 mm 4 92 in Minimum turning radius 2500 mm 98 4 in Weight Curb weight YP125R 169 kg 373 lb YP125RA 173 kg 381 lb Maximum load YP125R 185 kg 408 lb YP125RA 181 kg 399 lb ...

Page 49: ...ecommended engine oil grade API service SG type or higher JASO standard MA Engine oil quantity Without oil filter element replacement 1 40 L 1 48 US qt 1 23 Imp qt With oil filter element replacement 1 50 L 1 59 US qt 1 32 Imp qt Final transmission oil Type YAMALUBE 10W 40 or SAE 10W 30 type SE motor oil Quantity 0 21 L 0 22 US qt 0 18 Imp qt Oil filter Oil filter type Paper Oil pump Oil pump type...

Page 50: ...on ratio 16 38 0 42 Spark plug s Manufacturer model NGK CPR9EA 9 Spark plug gap 0 8 0 9 mm 0 031 0 035 in Cylinder head Combustion chamber volume 9 90 10 50 cm 0 60 0 64 cu in Warpage limit 0 05 mm 0 0020 in Camshaft Drive system Chain drive left Camshaft lobe dimensions Intake A 30 225 30 325 mm 1 1900 1 1939 in Limit 30 125 mm 1 1860 in Intake B 25 064 25 164 mm 0 9868 0 9907 in Limit 24 964 mm ...

Page 51: ...0 0354 0 0433 in Limit 1 6 mm 0 06 in Valve stem diameter intake 4 475 4 490 mm 0 1762 0 1768 in Limit 4 445 mm 0 1750 in Valve stem diameter exhaust 4 460 4 475 mm 0 1756 0 1762 in Limit 4 430 mm 0 1744 in Valve guide inside diameter intake 4 500 4 512 mm 0 1772 0 1776 in Limit 4 550 mm 0 1791 in Valve guide inside diameter exhaust 4 500 4 512 mm 0 1772 0 1776 in Limit 4 550 mm 0 1791 in Valve st...

Page 52: ...Taper limit 0 050 mm 0 0020 in Out of round limit 0 005 mm 0 0002 in Warp limit 0 05 mm 0 0020 in Piston Piston to cylinder clearance 0 015 0 048 mm 0 0006 0 0019 in Diameter D 51 962 51 985 mm 2 0457 2 0466 in Height H 5 0 mm 0 20 in Offset 0 50 mm 0 0197 in Offset direction Intake side Piston pin bore inside diameter 14 002 14 013 mm 0 5513 0 5517 in Limit 14 043 mm 0 5529 in Piston pin outside ...

Page 53: ... centrifugal automatic Automatic centrifugal clutch Clutch shoe thickness 2 0 mm 0 08 in Limit 1 0 mm 0 04 in Clutch shoe spring free length 33 0 mm 1 30 in Clutch housing inside diameter 135 0 mm 5 31 in Limit 135 5 mm 5 33 in Compression spring free length 112 0 mm 4 41 in Limit 106 4 mm 4 19 in Weight outside diameter 20 0 mm 0 79 in Limit 19 5 mm 0 77 in Clutch in revolution 3500 4100 r min Cl...

Page 54: ...position sensor resistance 248 372 Ω Intake air pressure sensor output voltage 3 57 3 71 V Intake air temperature sensor resistance 2 21 2 69 kΩ Coolant temperature sensor resistance 2 32 2 59 kΩ at 20 C 68 F 310 326 Ω at 80 C 176 F Idling condition Fuel line pressure at idling 220 300 kPa 2 2 3 0 kgf cm 31 9 43 5 psi Regulated pressure 250 kPa 2 5 kgf cm 36 3 psi Engine idling speed 1600 1800 r m...

Page 55: ...it 0 5 mm 0 02 in Wheel axle bending limit 0 25 mm 0 01 in Front tire Type Tubeless Size 120 70 15 M C 56P METZELER 56S MICHELIN Manufacturer model METZELER FEELFREE Manufacturer model MICHELIN CITYGRIP Wear limit front 1 6 mm 0 06 in Rear tire Type Tubeless Size 140 70 14 M C 68P METZELER 68S MICHELIN Manufacturer model METZELER FEELFREE Manufacturer model MICHELIN CITYGRIP Wear limit rear 1 6 mm...

Page 56: ...thickness inner YP125R 4 3 mm 0 17 in YP125RA 5 3 mm 0 21 in Limit YP125R 0 5 mm 0 02 in YP125RA 0 8 mm 0 03 in Brake pad lining thickness outer YP125R 4 3 mm 0 17 in YP125RA 5 3 mm 0 21 in Limit YP125R 0 5 mm 0 02 in YP125RA 0 8 mm 0 03 in Master cylinder inside diameter 12 7 mm 0 50 in Caliper cylinder inside diameter YP125R 27 00 mm 2 1 06 in 2 YP125RA 22 00 mm 2 0 87 in 2 Specified brake fluid...

Page 57: ...avel 92 0 mm 3 62 in Spring free length 283 2 mm 11 15 in Spring installed length 248 2 mm 9 77 in Spring rate K1 7 00 N mm 0 71 kgf mm 39 97 lbf in Spring rate K2 13 50 N mm 1 38 kgf mm 77 09 lbf in Spring stroke K1 0 0 52 0 mm 0 00 2 05 in Spring stroke K2 52 0 78 0 mm 2 05 3 07 in Optional spring available No Spring preload adjusting positions Minimum 1 Standard 2 Maximum 5 Swingarm Swingarm en...

Page 58: ...ap Material Resin Resistance 10 0 kΩ AC magneto Standard output 14 0 V 245 W at 5000 r min Stator coil resistance 0 280 0 420 Ω Rectifier regulator Regulator type Semi conductor short circuit Regulated voltage DC 14 1 14 9 V Rectifier capacity 25 0 A Rectifier capacity DC 18 0 A Battery Model GT9B 4 Voltage capacity 12 V 8 0 Ah Specific gravity 1 33 Manufacturer GS Ten hour rate charging current 0...

Page 59: ...92 5 88 N 400 600 gf 14 11 21 17 oz Commutator diameter 17 6 mm 0 69 in Limit 16 6 mm 0 65 in Mica undercut depth 1 35 mm 0 05 in Starter relay Amperage 180 0 A Coil resistance 4 18 4 62 Ω Horn Horn type Plane Quantity 1 Maximum amperage 3 0 A Turn signal hazard relay Relay type Full transistor Built in self canceling device No Fuel sender unit Sender unit resistance full 10 0 12 0 Ω Sender unit r...

Page 60: ...0 A Radiator fan motor fuse 7 5 A ABS motor fuse YP125RA 30 0 A ABS solenoid fuse YP125RA 20 0 A ABS ECU fuse YP125RA 10 0 A Spare fuse 30 0 A Spare fuse 20 0 A Spare fuse 10 0 A Spare fuse 7 5 A Spare fuse YP125RA 30 0 A Spare fuse YP125RA 10 0 A ...

Page 61: ... To avoid warpage tight en multi fastener assemblies in a crisscross pat tern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque specifications re quire clean dry threads Components should be at room temperature A Distance between flats B Outside thread diameter A nut B bolt General tightening torques Nm m kgf ft lbf 10 mm 6 mm 6 0 ...

Page 62: ...5 1 ft lbf Valve clearance adjusting screw locknut M5 4 7 Nm 0 7 m kgf 5 1 ft lbf Coolant drain bolt cylinder M6 1 7 Nm 0 7 m kgf 5 1 ft lbf V belt case cover bolt M6 4 7 Nm 0 7 m kgf 5 1 ft lbf V belt case bolt M6 8 10 Nm 1 0 m kgf 7 2 ft lbf Primary sheave nut M12 1 55 Nm 5 5 m kgf 40 ft lbf Secondary sheave nut M14 1 60 Nm 6 0 m kgf 43 ft lbf Clutch carrier nut M36 1 90 Nm 9 0 m kgf 65 ft lbf T...

Page 63: ...bf Fuel injector assembly holder bolt M6 1 10 Nm 1 0 m kgf 7 2 ft lbf Intake air pressure sensor bolt M6 2 8 Nm 0 8 m kgf 5 8 ft lbf Intake air pressure sensor brack et bolt M6 1 10 Nm 1 0 m kgf 7 2 ft lbf Intake manifold bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Throttle position sensor screw M4 2 2 0 Nm 0 20 m kgf 1 4 ft lbf Throttle body clamp screw M4 1 3 0 Nm 0 30 m kgf 2 2 ft lbf Air filter case ...

Page 64: ...TIGHTENING TORQUES 2 17 Muffler tightening sequence 1 2 3 ...

Page 65: ... 10 Nm 1 0 m kgf 7 2 ft lbf Rear panel and frame bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Tail brake light assembly screw M5 2 2 3 Nm 0 23 m kgf 1 7 ft lbf Tail brake light assembly screw M5 1 2 3 Nm 0 23 m kgf 1 7 ft lbf Mudguard and frame bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Frame and mudguard bolt M6 2 4 0 Nm 0 40 m kgf 2 9 ft lbf License plate light nut M5 2 2 5 Nm 0 25 m kgf 1 8 ft lbf Rear refle...

Page 66: ... YP125RA M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Rear wheel sensor rotor bolt for YP125RA M5 5 8 Nm 0 8 m kgf 5 8 ft lbf Rear brake disc bolt M8 3 23 Nm 2 3 m kgf 17 ft lbf Front brake caliper bolt M10 2 40 Nm 4 0 m kgf 29 ft lbf Front brake hose union bolt brake caliper M10 1 23 Nm 2 3 m kgf 17 ft lbf Front brake hose union bolt master cylinder M10 1 23 Nm 2 3 m kgf 17 ft lbf Front brake hose lead holder ...

Page 67: ... kgf 8 7 ft lbf Throttle cable and handlebar switch screw M5 1 2 5 Nm 0 25 m kgf 1 8 ft lbf Throttle cable and throttle body screw M5 2 5 Nm 0 5 m kgf 3 6 ft lbf Steering stem nut M20 1 120 Nm 12 m kgf 87 ft lbf Upper ring nut M25 1 75 Nm 7 5 m kgf 54 ft lbf Lower ring nut M25 1 See TIP Lower bracket pinch bolt M8 4 23 Nm 2 3 m kgf 17 ft lbf Cap bolt M29 2 40 Nm 4 0 m kgf 29 ft lbf Damper rod bolt...

Page 68: ... the swingarm mounting bolt upper side 2 then the swingarm mounting bolt lower side 3 3 Tighten the rear wheel axle nut to 135 Nm 13 5 m kgf 98 ft lbf 4 Tighten the swingarm mounting bolt upper side then the swingarm mounting bolt lower side to 28 Nm 2 8 m kgf 20 ft lbf Swingarm tightening sequence Immobilizer screw M5 2 4 0 Nm 0 40 m kgf 2 9 ft lbf Battery terminal bolt M5 2 7 Nm 0 7 m kgf 5 1 ft...

Page 69: ...er surface Crankshaft end generator rotor side Camshaft lobes Valve stems intake and exhaust Valve stem ends intake and exhaust Rocker arm shafts Rocker arm inner surface Decompressor cam Oil pump driven gear shaft Oil pump rotors inner and outer Collar clutch housing Starter clutch idle gear thrust surface Starter clutch idle gear shaft surface Starter clutch gear thrust surface Starter clutch ge...

Page 70: ...lutch housing and secondary sheave BEL RAY assembly lube Crankcase mating surfaces Yamaha bond No 1215 Crankshaft position sensor stator assembly lead grommet Yamaha bond No 1215 Timing chain tensioner bolt Yamaha bond No 1215 Lubrication point Lubricant ...

Page 71: ...nd metal to metal moving parts Rear brake caliper retaining bolt Throttle cable end Throttle grip inner surface and throttle cables Handlebar grip inner surface Rubber adhesive Sidestand pivoting point and metal to metal moving parts Sidestand spring hook metal to metal moving parts Centerstand shaft pivoting point and metal to metal moving parts Centerstand spring hook metal to metal moving parts...

Page 72: ...LUBRICATION SYSTEM DIAGRAMS 2 25 EAS2DM1116 LUBRICATION SYSTEM DIAGRAMS 1 2 3 4 5 3 ...

Page 73: ...LUBRICATION SYSTEM DIAGRAMS 2 26 1 Camshaft 2 Crankshaft 3 Oil pump 4 Oil filter 5 Oil strainer ...

Page 74: ...COOLING SYSTEM DIAGRAMS 2 27 EAS20420 COOLING SYSTEM DIAGRAMS 1 2 3 4 5 6 7 8 9 9 10 11 12 5 3 1 2 6 7 13 8 9 12 10 ...

Page 75: ...voir hose 3 Coolant reservoir overflow hose 4 Coolant reservoir leveling hose 5 Radiator cap 6 Radiator filler hose 7 Radiator 8 Radiator inlet hose 9 Radiator pipes 10 Thermostat outlet hose 11 Thermostat inlet hose 12 Water pump inlet hose 13 Radiator outlet hose ...

Page 76: ...CABLE ROUTING 2 29 EAS20430 CABLE ROUTING Handlebar top and front view 1 1 1 1 2 6 3 3 3 3 4 4 5 2 5 A 5 2 4 5 4 6 2 6 6 ...

Page 77: ...4 Left handlebar switch lead 5 Right handlebar switch lead 6 Throttle cable accelerator cable A Install the brake light switch connectors so that the leads are routed outward as shown in the illustration This instruction applies to both the front brake light switch and rear brake light switch ...

Page 78: ...CABLE ROUTING 2 31 Steering head front view 1 2 3 4 5 6 8 8 A 7 7 ...

Page 79: ... Rear brake hose 3 Left front turn signal light lead 4 Seat lock cable 5 Fuel tank overflow hose 6 Wire harness 7 Speed sensor lead for YP125R 8 Front wheel sensor lead for YP125RA A Route the front brake hose in front of the rear brake hose ...

Page 80: ...CABLE ROUTING 2 33 Front brake left side view for YP125R 1 2 2 1 1 2 2 D E A B C ...

Page 81: ...e front brake hose with the holders Align the holders with the paint marks on the speed sensor lead B 25 mm 0 98 in C Fasten the speed sensor lead to the front brake hose with the holder Align the holder with the paint marks on the speed sensor lead and front brake hose D Right side E Left side ...

Page 82: ...CABLE ROUTING 2 35 Front brake left side view for YP125RA 2 1 1 2 1 2 2 A B D E C ...

Page 83: ...ake caliper with the holders Align the holders with the paint marks on the front wheel sensor lead B 20 25 mm 0 79 0 98 in C Fasten the front wheel sensor lead to the brake hose hydraulic unit to front brake caliper with the holder Align the holder with the paint marks on the front wheel sensor lead and brake hose hydraulic unit to front brake caliper D Right side E Left side ...

Page 84: ...CABLE ROUTING 2 37 Engine and rear brake left side and right side view for YP125R B 2 1 2 1 2 A A 3 3 C ...

Page 85: ... Cylinder head breather hose 3 Rear brake hose A Align each holder with the portion of the cylinder head breather hose where the hose begins to bend B Install the air filter case joint screw clamp with the clamp screw head pointing upward C 33 37 ...

Page 86: ...CABLE ROUTING 2 39 Engine and rear brake left side and right side view for YP125RA 1 2 1 2 2 A A B 3 4 3 4 4 ...

Page 87: ...ose 3 Brake hose hydraulic unit to rear brake caliper 4 Rear wheel sensor lead A Align each holder with the portion of the cylinder head breather hose where the hose begins to bend B Install the air filter case joint screw clamp with the clamp screw head pointing upward ...

Page 88: ...CABLE ROUTING 2 41 Steering head right side view for YP125R 13 14 A B C B C 4 2 9 10 1 9 9 B C 3 4 5 6 7 8 11 12 ...

Page 89: ...ay 7 Radiator fan motor relay 8 Turn signal hazard relay 9 Wire harness 10 Rear brake hose 11 Speed sensor lead coupler 12 Main switch 13 Right handlebar switch lead 14 Left handlebar switch leads A Route the handlebar switch leads to the inside of the meter cover and then fasten the leads with a plastic locking tie B Inside C Outside ...

Page 90: ...CABLE ROUTING 2 43 Steering head right side view for YP125RA 2 3 2 4 10 11 13 1 16 17 A B C B C 5 18 19 10 B C 10 15 14 12 5 6 7 8 9 ...

Page 91: ... hazard relay 10 Wire harness 11 Brake hose hydraulic unit to rear brake caliper 12 Front wheel sensor lead coupler 13 Brake hose hydraulic unit to front brake caliper 14 Main switch 15 Fuse boxes 16 Right handlebar switch lead 17 Left handlebar switch leads 18 Starting circuit cut off relay 2 19 Fuel pump relay A Route the handlebar switch leads to the inside of the meter cover and then fasten th...

Page 92: ...CABLE ROUTING 2 45 Frame right side view 3 2 4 1 2 3 A B 6 5 3 A B 3 3 2 3 3 A A B A B B 3 ...

Page 93: ...CABLE ROUTING 2 46 1 Rear brake hose 2 Radiator fan motor lead 3 Wire harness 4 Rectifier regulator 5 Radiator inlet hose 6 Radiator outlet hose A Inside B Outside ...

Page 94: ...CABLE ROUTING 2 47 Engine right side view 6 6 6 6 C D C D D C 10 B 9 5 6 1 2 8 3 4 5 6 7 A ...

Page 95: ...ad 3 Seat lock cable 4 Rear brake hose for YP125R 5 Ignition coil 6 Wire harness 7 O2 sensor 8 Right rear turn signal light lead 9 Rear wheel sensor lead for YP125RA 10 Brake hose hydraulic unit to rear brake caliper for YP125RA A For YP125R B For YP125RA C Inside D Outside ...

Page 96: ...CABLE ROUTING 2 49 Steering head left side view B C D C D E F C D 2 3 4 7 13 14 4 6 8 15 16 17 12 11 C D 7 A 2 3 4 6 7 8 9 10 1 11 1 5 6 ...

Page 97: ...s 8 Starter motor lead 9 Left front turn signal light lead 10 Headlight lead 11 Positive battery lead 12 Fuse box lead to ABS motor fuse and ABS solenoid fuse 13 Right handlebar switch lead 14 Front brake hose 15 Air temperature sensor 16 Ground lead 17 Negative battery lead A For YP125R B For YP125RA C Outside D Inside E Front side F Rear side ...

Page 98: ...CABLE ROUTING 2 51 Frame left side view C D C D 2 1 E 1 2 D C 6 1 4 5 3 2 1 7 3 2 1 A B ...

Page 99: ...estand switch lead 5 Rectifier regulator 6 Fuel tank overflow hose 7 Wire harness A Position the connector housing at the location shown between the frame tubes B Front side C Inside D Outside E Fasten the coolant reservoir overflow hose and starter motor lead with the plastic band ...

Page 100: ...CABLE ROUTING 2 53 Engine left side view 1 1 1 1 1 2 3 4 5 6 7 8 9 7 7 A B A B A B 1 ...

Page 101: ...2 54 1 Seat lock cable 2 Rear brake hose 3 Wire harness 4 Left tail brake light lead 5 Left rear turn signal light lead 6 License plate light lead 7 Starter motor lead 8 Fuel hose 9 Throttle cables A Outside B Inside ...

Page 102: ...CABLE ROUTING 2 55 Frame top view 7 8 9 10 11 12 13 13 17 19 19 A D B C 14 C B 1 2 3 4 5 6 14 15 16 18 19 ...

Page 103: ...9 Right handlebar switch lead 10 Rear brake hose 11 Fuel hose 12 Seat lock cable 13 Starter motor lead 14 Fuel pump lead 15 Rear brake hose 16 Left handlebar switch lead 17 Throttle cable 18 Left front turn signal light 19 Sidestand switch lead A Route the fuel pump lead and sidestand switch lead under the cross member B Front side C Rear side D Route the sidestand switch lead under the cross memb...

Page 104: ...CABLE ROUTING 2 57 Engine and frame top view 1 2 4 5 6 7 8 9 10 11 12 13 1 4 5 6 7 8 1 3 10 11 6 8 C 3 11 B A B A 3 ...

Page 105: ...rear turn signal light lead 5 Right tail brake light lead 6 License plate light lead 7 Left tail brake light lead 8 Left rear turn signal light lead 9 Seat lock cable 10 Intake air temperature sensor lead 11 Starter motor lead 12 Fuel hose 13 Throttle cables A Inside B Outside C Engine mounting bracket top side view ...

Page 106: ...CABLE ROUTING 2 59 Rear brake right side view 2 2 2 2 2 2 1 1 2 3 A B C 3 ...

Page 107: ... ROUTING 2 60 1 Rear wheel sensor lead for YP125RA 2 Rear brake hose 3 Brake hose hydraulic unit to rear brake caliper A Fasten the grommets on the rear brake hose with the holders B For YP125R C For YP125RA ...

Page 108: ...CABLE ROUTING 2 61 Hydraulic unit for YP125RA 3 2 1 2 3 3 2 2 3 2 2 2 3 3 3 4 4 1 1 4 2 6 B A A 5 1 5 1 5 ...

Page 109: ...ar brake master cylinder to hydraulic unit 4 Brake hose hydraulic unit to rear brake caliper 5 Hydraulic unit assembly 6 Throttle cables A Make sure to leave space between the brake hoses as shown in the illustration B Make sure that the crimped section of each brake hose contacts the hydraulic unit assembly bracket as shown in the illustration ...

Page 110: ...CABLE ROUTING 2 63 ...

Page 111: ...ECKING THE FRONT BRAKE HOSES 3 13 CHECKING THE REAR BRAKE HOSE 3 13 CHECKING THE WHEELS 3 13 CHECKING THE TIRES 3 13 CHECKING THE WHEEL BEARINGS 3 15 CHECKING AND ADJUSTING THE STEERING HEAD 3 15 CHECKING THE CHASSIS FASTENERS 3 16 LUBRICATING THE LEVERS 3 16 CHECKING THE SIDESTAND 3 17 LUBRICATING THE SIDESTAND 3 17 CHECKING THE CENTERSTAND 3 17 LUBRICATING THE CENTERSTAND 3 17 CHECKING THE SIDES...

Page 112: ...cks must be performed every year except if a kilometer based maintenance or for the UK a mileage based maintenance is performed instead From 30000 km 17500 mi repeat the maintenance intervals starting from 6000 km 3500 mi Items marked with an asterisk should be performed by a Yamaha and MBK dealer as they require special tools data and technical skills NO ITEM CHECK OR MAINTENANCE JOB ODOMETER REA...

Page 113: ...k operation and for oil leakage 18 Shock absorber assemblies Check operation and shock absorbers for oil leakage 19 Engine oil Change When the oil change indicator light flashes 5000 km 3000 mi after the initial 1000 km 600 mi and every 6000 km 3500 mi thereafter Check oil level and vehicle for oil leakage Every 3000 km 1800 mi 20 Engine oil filter el ement Replace 21 Cooling system Check coolant ...

Page 114: ... and the V belt air filter elements need to be ser viced more frequently when riding in unusually wet or dusty areas Hydraulic brake service After disassembling the brake master cylinders and calipers always change the fluid Regularly check the brake fluid levels and fill the reservoirs as required Every two years replace the internal components of the brake master cylinders and calipers and chang...

Page 115: ...e Incorrect Change 4 Check Electrode 1 Damage wear Replace the spark plug Insulator 2 Abnormal color Replace the spark plug Normal color is medium to light tan 5 Clean Spark plug with a spark plug cleaner or wire brush 6 Measure Spark plug gap a with a wire thickness gauge Out of specification Regap 7 Install Spark plug TIP Before installing the spark plug clean the spark plug and gasket surface 8...

Page 116: ...ead cover 2 4 Remove Timing mark accessing plug 1 5 Measure Valve clearance Out of specification Adjust a Turn the primary sheave nut on the left side of the crankshaft counterclockwise to turn the crankshaft b Align the I mark a on the generator rotor with the stationary pointer b on the genera tor cover c Check that the cam lobes are positioned as shown in the illustration d Measure the valve cl...

Page 117: ...asket Cylinder head cover Spark plug Spark plug cap 8 Install V belt case air filter element V belt case air duct V belt case air duct gasket V belt case cover 9 Install Storage box Refer to GENERAL CHASSIS on page 4 1 EAS21020 CHECKING THE THROTTLE BODY JOINT AND INTAKE MANIFOLD 1 Remove Storage box Refer to GENERAL CHASSIS on page 4 1 2 Check Throttle body joint 1 Intake manifold 2 Cracks damage...

Page 118: ...L CHASSIS on page 4 1 EAS2DM1021 CHECKING THE EXHAUST SYSTEM 1 Check Exhaust pipe 1 Muffler 2 Cracks damage Replace Exhaust system connection Exhaust gas leaks Replace the gaskets 3 2 Check Tightening torque EAS20600 ADJUSTING THE EXHAUST GAS VOLUME TIP Be sure to set the CO density level to standard and then adjust the exhaust gas volume 1 Remove Battery cover Refer to GENERAL CHASSIS on page 4 1...

Page 119: ...ngine idling speed appears on the LCD of the FI diagnostic tool To decrease the CO adjustment volume press the DOWN button To increase the CO adjustment volume press the UP button 11 Release the DOWN and UP buttons to ex ecute the selection 12 Set the main switch to OFF to cancel the mode 13 Disconnect FI diagnostic tool 14 Connect Self diagnosis signal coupler 15 Install Battery cover Refer to GE...

Page 120: ...belt case air filter element with solvent WARNING EWA2DM1004 Never use low flash point solvents such as gasoline to clean the V belt case air filter el ement Such solvents may cause a fire or an explosion TIP After cleaning gently squeeze the V belt case air filter element to remove the excess solvent NOTICE ECA2DM1025 Do not twist the V belt case air filter element when squeezing it 3 Check V bel...

Page 121: ...ed surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately EAS2DM1024 BLEEDING THE HYDRAULIC BRAKE SYSTEM for YP125R WARNING EWA1SD1002 Bleed the hydraulic brake system whenever the system is disassembled a brake hose is loosened disconnected or replaced the brake fluid level is very low the brake operation is faulty TIP Be careful not to spill any brake fluid or all...

Page 122: ...system in the following or der 1st step Front brake caliper 2nd step Rear brake caliper WARNING EWA2DM1005 Bleed the ABS whenever the system is disassembled a brake hose is loosened disconnected or replaced the brake fluid level is very low brake operation is faulty TIP Be careful not to spill any brake fluid or allow the brake master cylinder reservoir to overflow When bleeding the ABS make sure ...

Page 123: ...ke master cylinder res ervoir to the proper level with the specified brake fluid l Tighten the bleed screw to specification m Fill the brake master cylinder reservoir to the proper level with the specified brake fluid Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 10 WARNING EWA13110 After bleeding the hydraulic brake system check the brake operation EAS21250 CHECKING THE FRONT BRAKE PADS The f...

Page 124: ...leakage Replace the damaged hose Refer to FRONT BRAKE on page 4 31 EAS21290 CHECKING THE REAR BRAKE HOSE 1 Check Brake hose 1 Cracks damage wear Replace 2 Check Brake hose holder Loose Tighten the holder bolt 3 Hold the vehicle upright and apply the rear brake several times 4 Check Brake hose Brake fluid leakage Replace the damaged hose Refer to REAR BRAKE on page 4 44 EAS21670 CHECKING THE WHEELS...

Page 125: ...avoid tire fail ure and personal injury from sudden deflation When using a tube tire be sure to install the correct tube Always replace a new tube tire and a new tube as a set To avoid pinching the tube make sure the wheel rim band and tube are centered in the wheel groove Patching a punctured tube is not recom mended If it is absolutely necessary to do so use great care and replace the tube as so...

Page 126: ...rings 1 Check Wheel bearings Refer to CHECKING THE FRONT WHEEL on page 4 20 and CHECKING THE REAR WHEEL on page 4 29 EAS21520 CHECKING AND ADJUSTING THE STEERING HEAD 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over TIP Place the vehicle on a suitable stand so that the front wheel is elevated 2 Check Steering head Gr...

Page 127: ... the center ring nut until their slots are aligned h Install the lock washer 2 TIP Make sure the lock washer tabs a sit correctly in the ring nut slots b i Hold the lower and center ring nuts with a steering nut wrench and tighten the upper ring nut with a another steering nut wrench 5 Install Lower handlebar holder Refer to STEERING HEAD on page 4 81 EAS1SD1006 CHECKING THE CHASSIS FASTENERS Make...

Page 128: ...d check if the front fork rebounds smoothly Rough movement Repair Refer to FRONT FORK on page 4 74 EAS1SD1010 CHECKING THE REAR SUSPENSION 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over 2 Check Rear shock absorber assembly Oil leaks Replace the rear shock absorber assembly Refer to CHECKING THE REAR SHOCK ABSORBER ...

Page 129: ...proper level TIP Before checking the engine oil level wait a few minutes until the oil has settled Do not screw the dipstick in when inspecting the oil level NOTICE ECA2DM1028 Do not allow foreign materials to enter the crankcase 5 Start the engine warm it up for several min utes and then turn it off 6 Check the engine oil level again TIP Before checking the engine oil level wait a few minutes unt...

Page 130: ...g 3 c Install the new oil filter element and the oil fil ter element cover TIP Be sure to face the mark a on the oil filter element cover in the direction shown in the illus tration 6 If the oil strainer is also to be cleaned per form the following procedure a Remove the oil strainer cover 1 and oil strainer 2 b Install a new O ring 3 c Install the oil strainer cover 7 Install Engine oil drain bol...

Page 131: ...erstand Make sure the vehicle is upright 2 Remove Coolant reservoir cover Refer to GENERAL CHASSIS on page 4 1 3 Check Coolant level The coolant level should be between the min imum level mark a and maximum level mark b Below the minimum level mark Add the recommended coolant to the proper level NOTICE ECA13470 Adding water instead of coolant lowers the antifreeze content of the coolant If water i...

Page 132: ...r is under pressure Therefore do not remove the radiator cap when the en gine is hot Scalding hot fluid and steam may be blown out which could cause serious in jury When the engine has cooled open the radiator cap as follows Place a thick rag or a towel over the radiator cap and slowly turn the radiator cap counter clockwise toward the detent to allow any re sidual pressure to escape When the hiss...

Page 133: ...d If coolant comes into contact with painted surfaces immediately wash them with wa ter Do not mix different types of antifreeze 9 Tighten Coolant bleed bolt 10 Install Radiator cap 11 Fill Coolant reservoir with the recommended coolant to the maxi mum level mark a 12 Install Coolant reservoir cap 13 Start the engine warm it up for several min utes and then turn it off 14 Check Coolant level Refer...

Page 134: ...and second ary pulleys Refer to V BELT AUTOMATIC TRANSMIS SION on page 5 30 TIP Replace the V belt every 18000 km 10500 mi of operation 3 Install V belt case Refer to V BELT AUTOMATIC TRANSMIS SION on page 5 30 4 Reset V belt replacement indicator Refer to INSTRUMENT FUNCTIONS on page 1 18 EAS1SD1012 CHECKING THE BRAKE LIGHT SWITCHES 1 Check Front brake light switch operation Rear brake light swit...

Page 135: ...ght 3 Check Throttle grip free play a Out of specification Adjust 4 Adjust Throttle grip free play TIP Prior to adjusting the throttle grip free play the engine idling speed should be adjusted properly a Loosen the locknut 1 b Turn the adjusting nut 2 in direction a or b until the specified throttle grip free play is ob tained c Tighten the locknut WARNING EWA1SD1005 After adjusting the throttle g...

Page 136: ...adlight bulb WARNING EWA13320 Since the headlight bulb gets extremely hot keep flammable products and your hands away from the bulb until it has cooled down 5 Install Headlight bulb Secure the new headlight bulb with the head light bulb holder NOTICE ECA13690 Avoid touching the glass part of the head light bulb to keep it free from oil otherwise the transparency of the glass the life of the bulb a...

Page 137: ...LING THE FOOTREST BOARD 4 15 HANDLING THE SEAT HINGE DAMPER 4 16 DISPOSING OF A SEAT HINGE DAMPER 4 16 FRONT WHEEL 4 17 REMOVING THE FRONT WHEEL for YP125R 4 20 REMOVING THE FRONT WHEEL for YP125RA 4 20 DISASSEMBLING THE FRONT WHEEL 4 20 CHECKING THE FRONT WHEEL 4 20 MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR for YP125RA 4 21 ASSEMBLING THE FRONT WHEEL 4 22 ADJUSTING THE FRONT WHEEL ST...

Page 138: ...G THE REAR BRAKE CALIPER for YP125R 4 56 CHECKING THE REAR BRAKE CALIPER for YP125RA 4 56 ASSEMBLING THE REAR BRAKE CALIPER 4 57 INSTALLING THE REAR BRAKE CALIPER for YP125R 4 57 INSTALLING THE REAR BRAKE CALIPER for YP125RA 4 58 REMOVING THE REAR BRAKE MASTER CYLINDER 4 59 CHECKING THE REAR BRAKE MASTER CYLINDER 4 59 ASSEMBLING THE REAR BRAKE MASTER CYLINDER 4 59 INSTALLING THE REAR BRAKE MASTER ...

Page 139: ...STEERING HEAD 4 83 REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM 4 85 REMOVING THE REAR SHOCK ABSORBER ASSEMBLIES 4 87 REMOVING THE SWINGARM 4 87 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 4 87 CHECKING THE SWINGARM 4 87 MAINTENANCE OF THE REAR WHEEL SENSOR for YP125RA 4 87 INSTALLING THE SWINGARM 4 88 ...

Page 140: ...1 Disconnect from the left center inner panel 4 Left center panel 1 5 Left center inner panel 1 6 Right center panel 1 For installation reverse the removal proce dure 1 2 3 4 5 6 4 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R ...

Page 141: ...er 1 Disconnect 5 Rear turn signal light coupler 2 Disconnect 6 Tail brake light coupler 2 Disconnect 7 Tail brake light assembly 2 8 Mudguard 1 9 Rear lower cover 1 For installation reverse the removal proce dure 1 2 2 3 4 5 6 7 3 7 8 4 9 LT 23 Nm 2 3 m kgf 17 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 2 3 Nm 0 23 m kgf 1 7 ft Ibf T R...

Page 142: ...ight assembly coupler 1 Disconnect 7 Auxiliary light coupler 2 Disconnect 8 Front turn signal light coupler 2 Disconnect 9 Headlight assembly 1 10 Front turn signal light 2 11 Front cowling 2 For installation reverse the removal proce dure 5 6 2 2 6 3 4 2 2 2 3 2 2 7 7 8 6 11 2 2 2 10 8 0 4 Nm 0 04 m kgf 0 29 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 1 2 3 10 5 11 4 9 ...

Page 143: ...racket 1 2 Battery cover 1 3 Battery positive lead 1 Disconnect 4 Battery negative lead 1 Disconnect 5 Battery 1 6 Starter relay 1 7 Air temperature sensor 1 8 Windshield bracket 1 For installation reverse the removal proce dure 3 4 23 Nm 2 3 m kgf 17 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 7 5 2 1 2 8 6 7 Nm 0 7 m kgf 5 1 ft Ibf T R 2 3 Nm 0 23 m kgf 1 7 ft Ibf T R ...

Page 144: ...Main switch cover 1 5 Center handlebar cover 1 6 Upper handlebar cover 1 7 Lower handlebar cover 1 8 Meter assembly meter assembly cover 1 9 Meter assembly coupler 1 Disconnect 10 Meter assembly cover 1 11 Meter assembly 1 For installation reverse the removal proce dure 2 3 Nm 0 23 m kgf 1 7 ft Ibf T R 2 3 Nm 0 23 m kgf 1 7 ft Ibf T R 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 1 1 2 9 4 4 4 8 5 3 6 3 2 2 2 ...

Page 145: ...emoving the headlight assembly Front wheel Refer to FRONT WHEEL on page 4 17 Front fender Refer to FRONT FORK on page 4 74 1 Footrest board mat 2 2 Front lower panel 2 3 Relay holder 1 1 4 Radiator cover 1 For installation reverse the removal proce dure 1 1 4 2 2 2 2 2 2 3 4 LT LT 10 Nm 1 0 m kgf 7 2 ft Ibf T R ...

Page 146: ...meter assembly Front lower panel Refer to Removing the radiator cover 1 Bottom cover 1 2 Fuel tank filler lid 1 Open 3 Footrest board 1 4 Radiator filler neck 1 5 Fuse box 1 6 Relay holder 2 for YP125RA 1 7 Leg shield 1 8 Coolant level check hose 1 9 Coolant reservoir 1 For installation reverse the removal proce dure 10 Nm 1 0 m kgf 7 2 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 f...

Page 147: ...ter case cover 1 2 Air filter element 1 3 Intake air temperature sensor coupler 1 Disconnect 4 Intake air temperature sensor 1 5 Cylinder head breather hose 1 Disconnect 6 Air filter case joint screw clamp 1 7 Air filter case 1 For installation reverse the removal proce dure LT LT New 2 3 6 1 7 6 3 4 5 9 Nm 0 9 m kgf 6 5 ft Ibf T R 9 Nm 0 9 m kgf 6 5 ft Ibf T R ...

Page 148: ...rest board Refer to Removing the footrest board and leg shield 1 Bolt 2 2 Bushing 2 3 Seat hinge 1 4 Damper 1 5 Seat damper pivot 1 For installation reverse the removal proce dure LS LS 9 Nm 0 9 m kgf 6 5 ft Ibf T R 9 Nm 0 9 m kgf 6 5 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 4 5 2 2 1 1 3 ...

Page 149: ... 1 Remove Center panels a Pull the rear of the center panel outward to re move it from the grommet on the rear panel b Unhook the projections on the center panel from the footrest board and sliding it upward EAS1SD1017 INSTALLING THE CENTER PANELS The following procedure applies to both of the center panels 1 Install Center panels a Insert the projection on the center panel into the footrest board...

Page 150: ...jection on the rear upper cov er from the mudguard and sliding it back ward EAS1SD1015 INSTALLING THE REAR UPPER COVER 1 Install Rear upper cover a Install the rear upper cover by fitting the pro jection on the cover into the mudguard EAS1SD1018 REMOVING THE REAR PANELS The following procedure applies to both of the rear panels 1 Remove Rear panels a Slide the rear panel to outward and remove it ...

Page 151: ...e Front cowling cover Upper panel a Unhook the projections on the front cowling cover from the upper panel and radiator cov er b Pull the upper panel forward to remove the projections from the slots in the front cowling and the grommet in the headlight assembly EAS1SD1022 INSTALLING THE UPPER PANEL AND FRONT COWLING COVER 1 Install Upper panel Front cowling cover a Push the upper panel rearward to...

Page 152: ...r panel outward to unhook the 2 projections from the front cowling EAS1SD1041 INSTALLING THE FRONT UPPER PANEL 1 Install Front upper panel a Fit the 2 projections on the upper portion of the front upper panel into the holes in the front cowling EAS1SD1042 REMOVING THE FRONT COWLING 1 Remove Front cowling headlight assembly a Pull the upper portion of the front cowling out ward to unhook the projec...

Page 153: ...to the grommets in the windshield bracket b Fit the projection on the upper portion of the front cowling into the hole in the leg shield EAS1SD1044 REMOVING THE MAIN SWITCH COVER 1 Remove Coolant reservoir cover Fuse box cover Main switch cover a Pull the fuse box cover and coolant reservoir cover rearward to unhook the projections from the holes in the leg shield b Pull the main switch cover rear...

Page 154: ...s in the leg shield b Fit the projections on the fuse box cover and coolant reservoir cover into the holes in the leg shield EAS1SD1046 REMOVING THE FOOTREST BOARD 1 Remove Footrest board a Push the front lower portion of the footrest board downward and then pull the board rearward to unhook the projections from the leg shield EAS1SD1047 INSTALLING THE FOOTREST BOARD 1 Install Footrest board ...

Page 155: ...operty damage or personal injury that may result from improper handling of the seat hinge damper Do not tamper or attempt to open the seat hinge damper Do not subject the seat hinge damper to an open flame or any other source of high heat High heat can cause an explosion due to excessive gas pressure Do not deform or damage the seat hinge damper in any way EAS1SD1049 DISPOSING OF A SEAT HINGE DAMP...

Page 156: ...rake caliper bracket bolt 2 2 Speed sensor lead guide 1 3 Front brake caliper 1 4 Wheel axle pinch bolt 1 Loosen 5 Front wheel axle 1 6 Front wheel assembly 1 7 Speed sensor 1 8 Collar 1 9 Front brake disc 1 For installation reverse the removal proce dure LT LT LS LS 12 Nm 1 2 m kgf 8 7 ft Ibf T R 59 Nm 5 9 m kgf 43 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 2 4 1 1 LT 40 Nm 4 0 m kgf 29 ft Ibf T R ...

Page 157: ...Front brake caliper 1 4 Wheel axle pinch bolt 1 Loosen 5 Front wheel sensor 1 6 Front wheel axle 1 7 Front wheel assembly 1 8 Collar 2 9 Front brake disc 1 10 Front wheel sensor rotor 1 For installation reverse the removal proce dure 12 Nm 1 2 m kgf 8 7 ft Ibf T R 59 Nm 5 9 m kgf 43 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 2 5 4 1 1 LT LT 40 Nm 4 0 m kgf 29 ft Ibf T R 3 6 8 7 5 8 10 9 5 LT LT LS 7...

Page 158: ...FRONT WHEEL 4 19 Disassembling the front wheel Order Job Parts to remove Q ty Remarks 1 Oil seal 1 2 Wheel bearing 2 3 Spacer 1 For assembly reverse the disassembly pro cedure 2 1 2 3 New LS ...

Page 159: ...the front wheel sen sor rotor wipe it off immediately 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over 2 Remove Front brake caliper NOTICE ECA2DM1003 Be sure not to contact the sensor electrode to any metal part when removing the front wheel sensor from the outer tube Do not apply the brake lever when remov ing the b...

Page 160: ... ject them to shocks The front wheel sensor cannot be disas sembled Do not attempt to disassemble it If faulty replace with a new one Keep magnets including magnetic pick up tools magnetic screwdrivers etc away from the wheel sensor Do not drop or shock the wheel sensor or the wheel sensor rotor 1 Check Front wheel sensor 1 Cracks bends distortion Replace Iron powder dust Clean 2 Check Front wheel...

Page 161: ...es d If the deflection is still above specification re place the wheel sensor rotor TIP Install the wheel sensor rotor with the stamped mark a facing outward EAS21960 ASSEMBLING THE FRONT WHEEL NOTICE ECA2DM1042 For YP125RA Do not drop the wheel sensor rotor or sub ject it to shocks If any solvent gets on the wheel sensor ro tor wipe it off immediately 1 Install Wheel bearings a Install the new wh...

Page 162: ...n the front wheel b When the front wheel stops put an X1 mark at the bottom of the wheel c Turn the front wheel 90 so that the X1 mark is positioned as shown d Release the front wheel e When the wheel stops put an X2 mark at the bottom of the wheel f Repeat steps c through e several times until all the marks come to rest at the same spot g The spot where all the marks come to rest is the front whe...

Page 163: ...NG THE FRONT BRAKE DISC on page 4 37 3 Lubricate Oil seal lips Speed sensor oil seal lip 4 Install Collar Speed sensor Front wheel TIP Make sure that the projection a on the wheel hub do not contact the projections b on the speed sensor When installing the speed sensor make sure that the projection on the wheel hub does not damage the lip of the speed sensor oil seal Make sure that the slot c in t...

Page 164: ...nsor NOTICE ECA2DM1007 Make sure there are no foreign materials in the front wheel sensor rotor and front wheel sensor Foreign materials cause damage to the front wheel sensor rotor and front wheel sensor 7 Measure Distance between the front wheel sensor rotor 1 and front wheel sensor 2 Out of specification Check the wheel bear ing for looseness and the front wheel sensor and sensor rotor installa...

Page 165: ...otation of the front wheel Do not turn the front wheel while the thickness gauge is installed This may damage the front wheel sen sor rotor and the front wheel sensor Distance a between the front wheel sensor rotor and front wheel sensor 0 7 1 5 mm 0 028 0 059 in Thickness gauge 90890 03180 Feeler gauge set YU 26900 9 1 2 a 1 2 ...

Page 166: ...INE REMOVAL on page 5 2 Swingarm Refer to REAR SHOCK ABSORBER AS SEMBLIES AND SWINGARM on page 4 85 1 Air filter case mounting bolt 2 2 Rear fender 1 3 Rear wheel 1 4 Rear brake disc 1 For installation reverse the removal proce dure 2 1 1 4 3 3 LS LT LT LT 9 Nm 0 9 m kgf 6 5 ft Ibf T R 9 Nm 0 9 m kgf 6 5 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R ...

Page 167: ...o REAR SHOCK ABSORBER AS SEMBLIES AND SWINGARM on page 4 85 1 Air filter case mounting bolt 2 2 Rear fender 1 3 Rear wheel 1 4 Rear brake disc 1 5 Rear wheel sensor rotor 1 For installation reverse the removal proce dure 2 1 1 4 5 3 3 LT 5 LS LT LT 9 Nm 0 9 m kgf 6 5 ft Ibf T R 9 Nm 0 9 m kgf 6 5 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 8 Nm 0 8 m kgf 5 8 ft Ibf T R ...

Page 168: ...OTOR for YP125RA NOTICE ECA2DM1009 Handle the ABS components with care since they have been accurately adjusted Keep them away from dirt and do not sub ject them to shocks Keep magnets including magnetic pick up tools magnetic screwdrivers etc away from the wheel sensor rotor Do not drop or shock the wheel sensor ro tor 1 Check Rear wheel sensor rotor Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR...

Page 169: ... the wheel bear ings wheel sensor rotor or both were replaced Distance a between the wheel sensor rotor 1 and swingarm 2 edge of the wheel sensor in stallation hole b Out of specification Reinstall the bearing or replace the wheel sensor rotor T R Rear brake disc bolt 23 Nm 2 3 m kgf 17 ft lbf LOCTITE Rear wheel sensor rotor bolt for YP125RA 8 Nm 0 8 m kgf 5 8 ft lbf LOCTITE A For YP125R B For YP1...

Page 170: ...liper bolt 2 2 Sensor lead guide 1 3 Front brake caliper 1 4 Brake pad pin cap 1 5 Brake pad pin 1 6 Front brake pad 2 7 Brake pad spring 1 8 Brake pad support 1 For installation reverse the removal proce dure 2 1 1 6 8 7 6 2 5 Nm 0 25 m kgf 1 8 ft Ibf T R 18 Nm 1 8 m kgf 13 ft Ibf T R 40 Nm 4 0 m kgf 29 ft Ibf T R 3 4 5 LT ...

Page 171: ...ter cylinder reservoir cap 1 2 Brake master cylinder reservoir diaphragm hold er 1 3 Brake master cylinder reservoir diaphragm 1 4 Front brake lever 1 5 Front brake light switch connector 2 Disconnect 6 Brake hose union bolt 1 7 Copper washer 2 8 Front brake hose 1 9 Front brake master cylinder holder 1 10 Front brake master cylinder 1 S 7 6 8 1 2 3 10 11 9 4 5 New 7 Nm 0 7 m kgf 5 1 ft Ibf T R 10...

Page 172: ...val proce dure Removing the front brake master cylinder Order Job Parts to remove Q ty Remarks S 7 6 8 1 2 3 10 11 9 4 5 New 7 Nm 0 7 m kgf 5 1 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 1 2 Nm 0 12 m kgf 0 87 ft Ibf T R 1 8 Nm 0 18 m kgf 1 3 ft Ibf T R ...

Page 173: ...4 34 Disassembling the front brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder kit 1 2 Brake master cylinder body 1 For assembly reverse the disassembly pro cedure 1 2 New S S BF ...

Page 174: ...YP125R on page 3 10 and BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS for YP125RA on page 3 11 1 Brake hose union bolt 1 2 Copper washer 2 3 Front brake hose 1 4 Front brake caliper bolt 2 5 Sensor lead guide 1 6 Front brake caliper 1 For installation reverse the removal proce dure New 23 Nm 2 3 m kgf 17 ft Ibf T R 40 Nm 4 0 m kgf 29 ft Ibf T R 5 4 6 4 3 1 2 LT ...

Page 175: ...5 Brake pad support 1 6 Brake caliper bracket 1 7 Brake caliper piston 2 8 Brake caliper piston dust seal 2 9 Brake caliper piston seal 2 10 Bleed screw 1 11 Brake caliper body 1 For assembly reverse the disassembly pro cedure S 6 7 8 9 8 9 10 11 1 2 4 5 3 S S S BF BF New New New New 18 Nm 1 8 m kgf 13 ft Ibf T R 2 5 Nm 0 25 m kgf 1 8 ft Ibf T R 6 Nm 0 6 m kgf 4 3 ft Ibf T R ...

Page 176: ...1 Remove Front wheel Refer to FRONT WHEEL on page 4 17 2 Check Brake disc Damage galling Replace 3 Measure Brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc a Place the vehicle on a suitable stand so that the front wheel is elevated b Before measuring the front brake disc deflec tion turn the handlebar to the left or right to ensure that the fro...

Page 177: ...ew brake pad support as a set a Connect a clear plastic hose 1 tightly to the bleed screw 2 Put the other end of the hose into an open container b Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger c Tighten the bleed screw d Install new brake pad support new brake pad spring and new brake pads 3 Install Brake pad pin Brake pad pin cap Front brake cal...

Page 178: ...r the brake caliper piston with a rag Be careful not to get injured when the pis tons are expelled from the brake caliper Never try to pry out the brake caliper pis tons b Remove the brake caliper piston dust seals and brake caliper piston seals EAS22380 CHECKING THE FRONT BRAKE CALIPER 1 Check Brake caliper pistons 1 Rust scratches wear Replace the brake caliper pistons Brake caliper cylinders 2 ...

Page 179: ...stalling the brake hose onto the brake caliper make sure the brake pipe a touches the projection b on the brake cali per 2 Remove Front brake caliper 3 Install Brake pad support Brake pad spring Brake pads Brake pad pin Brake pad pin cap Front brake caliper Refer to REPLACING THE FRONT BRAKE PADS on page 4 38 4 Fill Brake master cylinder reservoir with the specified amount of the specified brake f...

Page 180: ...90 REMOVING THE FRONT BRAKE MASTER CYLINDER TIP Before removing the front brake master cylinder drain the brake fluid from the entire brake sys tem 1 Remove Brake hose union bolt 1 Copper washers 2 Front brake hose 3 TIP To collect any remaining brake fluid place a container under the master cylinder and the end of the brake hose EAS22500 CHECKING THE FRONT BRAKE MASTER CYLINDER 1 Check Brake mast...

Page 181: ...ed brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake master cylinder reser voir Water will significantly ...

Page 182: ... 6 Check Brake lever operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM for YP125R on page 3 10 and BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS for YP125RA on page 3 11 a ...

Page 183: ...ve Q ty Remarks 1 Rear brake caliper bolt 2 2 Rear brake caliper 1 3 Brake pad clip 1 4 Brake pad pin 1 5 Rear brake pad 2 6 Brake pad spring 1 For installation reverse the removal proce dure 1 3 4 5 5 6 2 New 7 Nm 0 7 m kgf 5 1 ft Ibf T R 14 Nm 1 4 m kgf 10 ft Ibf T R 28 Nm 2 8 m kgf 20 ft Ibf T R S ...

Page 184: ... ty Remarks 1 Rear brake caliper retaining bolt 2 2 Rear brake caliper 1 3 Rear brake pad 2 4 Brake pad shim 4 5 Brake pad support 2 For installation reverse the removal proce dure S 2 5 5 4 3 1 4 6 Nm 0 6 m kgf 4 3 ft Ibf T R 27 Nm 2 7 m kgf 19 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R ...

Page 185: ...r cylinder reservoir cap 1 2 Brake master cylinder reservoir diaphragm hold er 1 3 Brake master cylinder reservoir diaphragm 1 4 Rear brake lever 1 5 Rear brake light switch connector 2 Disconnect 6 Brake hose union bolt 1 7 Copper washer 2 8 Rear brake hose 1 9 Rear brake master cylinder holder 1 10 Rear brake master cylinder 1 5 4 11 3 7 9 8 10 2 1 New 7 6 New S 10 Nm 1 0 m kgf 7 2 ft Ibf T R 7 ...

Page 186: ...proce dure Removing the rear brake master cylinder Order Job Parts to remove Q ty Remarks 5 4 11 3 7 9 8 10 2 1 New 7 6 New S 10 Nm 1 0 m kgf 7 2 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 1 2 Nm 0 12 m kgf 0 87 ft Ibf T R 1 8 Nm 0 18 m kgf 1 3 ft Ibf T R ...

Page 187: ...4 48 Disassembling the rear brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder kit 1 2 Brake master cylinder body 1 For assembly reverse the disassembly pro cedure BF S S 1 2 New ...

Page 188: ...BLEEDING THE HYDRAULIC BRAKE SYSTEM for YP125R on page 3 10 1 Brake hose union bolt 1 2 Copper washer 2 3 Rear brake hose 1 4 Rear brake caliper bolt 2 5 Rear brake caliper 1 For installation reverse the removal proce dure 4 5 2 1 3 7 Nm 0 7 m kgf 5 1 ft Ibf T R 21 Nm 2 1 m kgf 15 ft Ibf T R 28 Nm 2 8 m kgf 20 ft Ibf T R New ...

Page 189: ... BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS for YP125RA on page 3 11 1 Brake hose union bolt 1 2 Copper washer 2 3 Rear brake hose hydraulic unit to rear brake caliper 1 4 Rear brake caliper bolt 3 5 Rear brake caliper 1 For installation reverse the removal proce dure 1 5 2 3 4 4 New 7 Nm 0 7 m kgf 5 1 ft Ibf T R 40 Nm 4 0 m kgf 29 ft Ibf T R 21 Nm 2 1 m kgf 15 ft Ibf T R ...

Page 190: ...liper for YP125R Order Job Parts to remove Q ty Remarks 1 Brake pad clip 1 2 Brake pad pin 1 3 Rear brake pad 2 4 Brake pad spring 1 5 Bleed screw cap 1 1 For assembly reverse the disassembly pro cedure New 1 2 3 4 5 14 Nm 1 4 m kgf 10 ft Ibf T R S ...

Page 191: ...liper bracket 1 3 Rear brake pad 2 4 Brake pad shim 4 5 Brake pad support 2 6 Brake caliper piston 2 7 Brake caliper piston dust seal 2 8 Brake caliper piston seal 2 9 Bleed screw 1 10 Brake caliper body 1 For assembly reverse the disassembly pro cedure 2 10 9 1 4 3 4 8 6 7 5 5 New New BF S S 6 Nm 0 6 m kgf 4 3 ft Ibf T R 27 Nm 2 7 m kgf 19 ft Ibf T R ...

Page 192: ...rake disc Damage galling Replace 3 Measure Brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc Refer to CHECKING THE FRONT BRAKE DISC on page 4 37 4 Measure Brake disc thickness Measure the brake disc thickness at a few dif ferent locations Out of specification Replace Refer to CHECKING THE FRONT BRAKE DISC on page 4 37 5 Adjust Brake disc deflect...

Page 193: ...d the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM for YP125R on page 3 10 EAS2DM1115 REPLACING THE REAR BRAKE PADS for YP125RA TIP When replacing the brake pads it is not neces sary to disconnect the brake hose or disassem ble the brake caliper 1 Measure Brake pad wear limit a Out of specification Replace the brake pads as a set 2 Install Brake pad supports Brake pad shims onto the ...

Page 194: ...feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS for YP125RA on page 3 11 EAS2DM1009 REMOVING THE REAR BRAKE CALIPER TIP Before removing the brake caliper drain the brake fluid from the entire brake system 1 Remove Brake hose union bolt 1 Copper washers 2 Rear brake hose 3 TIP Put the end of the brake hose into a container and pump out the brake fluid carefully EAS2...

Page 195: ...KING THE REAR BRAKE CALIPER for YP125RA 1 Check Brake caliper pistons 1 Rust scratches wear Replace the brake caliper pistons Brake caliper cylinders 2 Scratches wear Replace the brake caliper assembly Brake caliper body 3 Cracks damage Replace the brake caliper assembly Brake fluid delivery passages brake caliper body Obstruction Blow out with compressed air WARNING EWA2DM1001 Whenever a brake ca...

Page 196: ...he brake hose tighten the union bolt within the angle range shown in the illustration 2 Remove Rear brake caliper 3 Install Brake pad spring Brake pads Brake pad pin Brake pad clip Rear brake caliper Refer to REPLACING THE REAR BRAKE PADS for YP125R on page 4 53 4 Fill Brake master cylinder reservoir with the specified amount of the specified brake fluid WARNING EWA13540 Use only the designated br...

Page 197: ...safe vehicle operation Refer to CABLE ROUTING on page 2 29 NOTICE ECA14170 When installing the brake hose onto the brake caliper 1 make sure the brake pipe a touches the projection b on the brake caliper 2 Remove Rear brake caliper 3 Install Brake pad supports Brake pad shims Brake pads Rear brake caliper Refer to REPLACING THE REAR BRAKE PADS for YP125RA on page 4 54 4 Fill Brake master cylinder ...

Page 198: ...ing the rear brake master cylinder drain the brake fluid from the entire brake sys tem 1 Remove Brake hose union bolt 1 Copper washers 2 Brake hose 3 TIP To collect any remaining brake fluid place a container under the master cylinder and the end of the brake hose EAS22710 CHECKING THE REAR BRAKE MASTER CYLINDER 1 Check Brake master cylinder Damage scratches wear Replace Brake fluid delivery passa...

Page 199: ... brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake master cylinder reser voir Water will significantly lo...

Page 200: ... 6 Check Brake lever operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM for YP125R on page 3 10 and BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS for YP125RA on page 3 11 a ...

Page 201: ...r 1 Disconnect 3 Brake hose holder 1 4 Brake hose hydraulic unit to front brake caliper 1 Disconnect 5 Brake hose front brake master cylinder to hy draulic unit 1 Disconnect 6 Brake hose rear brake master cylinder to hy draulic unit 1 Disconnect 7 Brake hose hydraulic unit to rear brake caliper 1 Disconnect 8 Hydraulic unit assembly bracket 1 9 Hydraulic unit assembly 1 For installation reverse th...

Page 202: ...to the specified torque and bleed the brake system 1 Disconnect ABS ECU coupler 1 TIP Pull the lock lever a of the ABS ECU coupler in the direction of the arrow shown and then dis connect the coupler 2 Remove Brake hoses TIP Do not operate the brake levers while removing the brake hoses NOTICE ECA2DM1014 When removing the brake hoses cover the area around the hydraulic unit assembly to catch any s...

Page 203: ...the lock lever a of the coupler in the direction of the arrow shown Make sure that the ABS ECU coupler is con nected in the correct position as shown in illus tration A 5 Fill Brake master cylinder reservoir with the specified amount of the specified brake fluid WARNING EWA2DM1002 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and p...

Page 204: ...ated Brake line routing confirmation WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over TIP For the brake line routing confirmation use the diagnosis mode of the Yamaha diagnostic tool Before performing the brake line routing confir mation make sure that no malfunctions have been detected in the ABS ECU and that the wheels are not rotating 1 Place the vehic...

Page 205: ... the pulse is hardly felt in either the front brake lever or rear brake lever check that the brake hoses and brake pipes are con nected correctly to the hydraulic unit as sembly 10 If the operation of the hydraulic unit is normal delete all of the fault codes ABS reaction force confirmation WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over TIP For the ABS ...

Page 206: ...ating the hy draulic unit have not been met Off The front brake lever and rear brake lever are not being operated 9 A reaction force pulsating action is generated in the front brake lever 1 and continues for a few seconds TIP The reaction force pulsating action consists of quick pulses Be sure to continue operating the front brake lever and rear brake lever even after the pul sating action has sto...

Page 207: ... the brake hoses and brake pipes are connected correctly to the hydraulic unit assembly If the pulse is hardly felt in either the front brake lever or rear brake lever check that the brake hoses and brake pipes are con nected correctly to the hydraulic unit as sembly 12 Turn the main switch to OFF 13 Remove the Yamaha diagnostic tool coupler from the ABS test coupler and then install the protectiv...

Page 208: ... cable 2 Disconnect 7 Throttle grip 1 8 Rear brake light switch connector 2 Disconnect 9 Rear brake master cylinder holder 1 10 Rear brake master cylinder 1 11 Left handlebar switch 1 12 Handlebar grip 1 13 Upper handlebar holder 2 2 3 Nm 0 23 m kgf 1 7 ft Ibf T R 2 3 Nm 0 23 m kgf 1 7 ft Ibf T R 2 5 Nm 0 25 m kgf 1 8 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 23 Nm 2 3...

Page 209: ...to remove Q ty Remarks 2 3 Nm 0 23 m kgf 1 7 ft Ibf T R 2 3 Nm 0 23 m kgf 1 7 ft Ibf T R 2 5 Nm 0 25 m kgf 1 8 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R LS LS 1 1 3 4 2 5 5 6 6 7 9 8 10 11 12 14 13 ...

Page 210: ...bar Upper handlebar holders NOTICE ECA37P1031 First tighten the front bolt on each handle bar holder then the rear bolt TIP The upper handlebar holders should be installed with the arrow marks a facing forward A 3 Install Left handlebar switch 1 TIP Align the projection a on the left handlebar switch with the hole b in the handlebar 4 Install Handlebar grip 1 Left grip end 2 a Apply a thin coat of...

Page 211: ... with a thin coat of lith ium soap based grease Align the projection a on the right handlebar switch with the hole b in the handlebar Be sure to slide the throttle cable rubber cover to its original position 7 Install Right grip end 1 TIP There should be 3 5 mm 0 14 in of clearance a between the throttle grip 2 and the grip end 8 Install Front brake master cylinder 1 Front brake master cylinder ho...

Page 212: ...HANDLEBAR 4 73 9 Adjust Throttle grip free play Refer to CHECKING THE THROTTLE GRIP OPERATION on page 3 24 Throttle grip free play 3 0 5 0 mm 0 12 0 20 in b 1 a ...

Page 213: ... 1 Brake hose lead holder 1 Left side only 2 Sensor lead guide 1 Left side only 3 Front fender 1 4 Cap bolt 1 5 Lower bracket pinch bolt 2 Loosen 6 Front fork leg 1 For installation reverse the removal proce dure 1 2 3 4 5 5 6 New LT 10 Nm 1 0 m kgf 7 2 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 40 Nm 4 0 m kgf 29 ft Ibf T R 40 Nm 4 0 m kgf 29 ft Ibf T R 9 Nm 0 9 m kgf 6 5 ft Ibf T R 9 Nm 0 9 m kgf ...

Page 214: ...ies to both of the front fork legs 1 Fork spring 1 2 Dust seal 1 3 Oil seal clip 1 4 Damper rod bolt 1 5 Copper washer 1 6 Damper rod 1 7 Inner tube 1 8 Oil flow stopper 1 9 Oil seal 1 10 Outer tube 1 For assembly reverse the disassembly pro cedure 1 New New New New 7 2 3 9 10 5 4 8 6 30 Nm 3 0 m kgf 22 ft Ibf T R LT ...

Page 215: ...NING EWA37P1022 Before loosening the lower bracket pinch bolts support the front fork leg EAS22980 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Drain Fork oil TIP Stroke the inner tube several times while drain ing the fork oil 2 Remove Dust seal 1 Oil seal clip 2 with a flat head screwdriver NOTICE ECA14180 Do not scratch the inner tube 3 Remo...

Page 216: ... FORK LEGS The following procedure applies to both of the front fork legs WARNING EWA13660 Make sure the oil levels in both front fork legs are equal Uneven oil levels can result in poor han dling and a loss of stability TIP When assembling the front fork leg be sure to replace the following parts Oil seal Dust seal Clip Before assembling the front fork leg make sure all of the components are clea...

Page 217: ...ont fork leg with a plastic bag to protect the oil seal during installation 5 Install Oil seal clip 1 TIP Adjust the oil seal clip so that it fits into the outer tube s groove 6 Install Dust seal 1 with the fork seal driver weight 2 and fork seal driver attachment 3 Damper rod holder 90890 01294 Damping rod holder set YM 01300 T handle 90890 01326 T handle 3 8 drive 60 cm long YM 01326 Fork seal d...

Page 218: ...s settled and the air bubbles have dispersed TIP Be sure to bleed the front fork leg of any residual air 10 Measure Front fork leg oil level a from the top of the inner tube with the inner tube fully compressed and without the fork spring Out of specification Correct TIP While filling the front fork leg keep it upright After filling slowly pump the front fork leg up and down to distribute the fork...

Page 219: ...nstall Cap bolt along with the O ring TIP Before installing the cap bolt lubricate its O ring with grease If the cap bolt is difficult to install slightly loos en the lower bracket pinch bolts T R Lower bracket pinch bolt 23 Nm 2 3 m kgf 17 ft lbf 2 Lower bracket T R Cap bolt 40 Nm 4 0 m kgf 29 ft lbf 1 2 New ...

Page 220: ...FRONT FORK on page 4 74 1 Steering stem nut 1 2 Lower handlebar holder 1 3 Woodruff key 1 4 Upper ring nut 1 5 Lock washer 1 6 Center ring nut 1 7 Rubber washer 1 8 Lower ring nut 1 9 Lower bracket 1 10 Upper bearing cover 1 11 Upper bearing inner race 1 12 Upper bearing 1 3 4 5 6 7 8 10 11 12 17 18 2 1 9 14 15 13 16 LS LS 1st 38 Nm 3 8 m kgf 27 ft lbf 2nd 22 Nm 2 2 m kgf 16 ft lbf T R 75 Nm 7 5 m...

Page 221: ...r bearing outer race 1 18 Cover 1 For installation reverse the removal proce dure Removing the lower bracket Order Job Parts to remove Q ty Remarks 3 4 5 6 7 8 10 11 12 17 18 2 1 9 14 15 13 16 LS LS 1st 38 Nm 3 8 m kgf 27 ft lbf 2nd 22 Nm 2 2 m kgf 16 ft lbf T R 75 Nm 7 5 m kgf 54 ft Ibf T R 120 Nm 12 m kgf 87 ft lbf T R ...

Page 222: ...ace 3 Replace Bearings Bearing races a Remove the bearing races from the steering head pipe 1 with a long rod 2 and hammer b Remove the bearing race from the lower bracket 3 with a floor chisel 4 and ham mer c Install new bearing races NOTICE ECA14270 If the bearing race is not installed properly the steering head pipe could be damaged TIP Always replace the bearings and bearing races as a set 4 C...

Page 223: ... ring nut 4 Refer to CHECKING AND ADJUSTING THE STEERING HEAD on page 3 15 3 Install Woodruff key 1 Lower handlebar holder 2 Steering stem nut TIP Align the woodruff key with the groove a in the lower handlebar holder T R Steering stem nut 120 Nm 12 m kgf 87 ft lbf 2 a 1 ...

Page 224: ...el axle nut 1 2 Brake hose holder 1 3 Rear brake caliper 1 4 Rear shock absorber assembly 2 5 Swingarm 1 6 Spacer 1 7 Collar 1 8 Oil seal 2 9 Bearing 2 10 Spacer 1 For installation reverse the removal proce dure 4 7 3 2 8 5 9 10 8 6 1 New New 9 LS LS LS 28 Nm 2 8 m kgf 20 ft Ibf T R 28 Nm 2 8 m kgf 20 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 32 Nm 3 2 m kgf 23 ft Ibf ...

Page 225: ...1 5 Rear shock absorber assembly 2 6 Swingarm 1 7 Rear wheel sensor lead holder 1 8 Spacer 1 9 Collar 1 10 Oil seal 2 11 Bearing 2 12 Spacer 1 For installation reverse the removal proce dure 5 9 4 3 10 6 11 12 10 8 2 1 New New 11 LS LS LS 7 LT LT LT LT 28 Nm 2 8 m kgf 20 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 32 Nm 3 2 m kgf 23 ft Ibf T R 135 Nm 13 5 m kgf 98 ft lbf...

Page 226: ...0 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 1 Check Rear shock absorber rod Bends damage Replace the rear shock absorber assembly Rear shock absorber Oil leaks Replace the rear shock absorber assembly Spring Damage wear Replace the rear shock ab sorber assembly Bushings Damage wear Replace the rear shock ab sorber assembly Bolts Bends damage wear Replace EAS23370 CHECKING THE SWINGARM 1 Check Swin...

Page 227: ... for foreign materials 3 Install Swingarm 1 Rear wheel axle nut 2 temporarily tighten Swingarm mounting bolt upper side 3 temporarily tighten Swingarm mounting bolt lower side 4 temporarily tighten 4 Tighten Rear wheel axle nut 2 Swingarm mounting bolt upper side 3 Swingarm mounting bolt lower side 4 5 Install for YP125RA Rear wheel sensor NOTICE ECA2DM1022 Make sure there are no foreign materials...

Page 228: ...REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM 4 89 ...

Page 229: ... CAMSHAFT 5 15 CHECKING THE DECOMPRESSION SYSTEM 5 15 CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS 5 16 INSTALLING THE CAMSHAFT AND ROCKER ARMS 5 17 VALVES AND VALVE SPRINGS 5 18 REMOVING THE VALVES 5 19 CHECKING THE VALVES AND VALVE GUIDES 5 19 CHECKING THE VALVE SEATS 5 21 CHECKING THE VALVE SPRINGS 5 22 INSTALLING THE VALVES 5 23 CYLINDER AND PISTON 5 25 REMOVING THE PISTON 5 26 CHECKING THE ...

Page 230: ...R CLUTCH 5 41 CHECKING THE STARTER CLUTCH 5 41 INSTALLING THE STARTER CLUTCH 5 42 INSTALLING THE GENERATOR 5 42 ELECTRIC STARTER 5 44 CHECKING THE STARTER MOTOR 5 46 OIL PUMP 5 48 CHECKING THE OIL PUMP 5 49 ASSEMBLING THE OIL PUMP 5 49 INSTALLING THE OIL PUMP 5 50 TRANSMISSION 5 51 REMOVING THE TRANSMISSION 5 53 CHECKING THE TRANSMISSION 5 53 INSTALLING THE TRANSMISSION 5 53 CRANKSHAFT 5 54 DISASS...

Page 231: ......

Page 232: ...e stabilizes WARNING EWA12940 To prevent sparking ground all spark plug leads before cranking the engine c If the compression pressure is above the maximum specification check the cylinder head valve surfaces and piston crown for carbon deposits Carbon deposits Eliminate d If the compression pressure is below the min imum specification pour a teaspoonful of en gine oil into the spark plug bore and...

Page 233: ...e Order Job Parts to remove Q ty Remarks 1 O2 sensor coupler 1 Disconnect 2 Muffler 1 3 Gasket 1 4 Exhaust pipe 1 5 Gasket 1 For installation reverse the removal proce dure 1 2 3 4 5 New New 14 Nm 1 4 m kgf 10 ft Ibf T R 53 Nm 5 3 m kgf 38 ft Ibf T R 20 Nm 2 0 m kgf 14 ft Ibf T R ...

Page 234: ...assembly Throttle body Intake manifold Refer to THROTTLE BODY on page 7 4 1 Spark plug cap 1 Disconnect 2 Coolant temperature sensor coupler 1 Disconnect 3 Crankshaft position sensor stator assembly coupler 2 Disconnect 4 Thermostat outlet hose 1 Disconnect 5 Water pump inlet hose 1 Disconnect 6 Cylinder head breather hose 1 7 Starter motor lead 1 Disconnect 8 Ground lead 1 Disconnect For installa...

Page 235: ...r shock absorber 2 3 Engine mounting nut washer bolt 1 1 1 4 Spacer 1 5 Engine bracket rod nut washer bolt 2 2 2 6 Engine bracket rod 2 7 Engine 1 8 Engine bracket nut bolt 2 2 9 Engine bracket 1 For installation reverse the removal proce dure 8 9 5 5 8 2 1 7 4 3 5 8 5 6 6 3 LS 32 Nm 3 2 m kgf 23 ft Ibf T R 59 Nm 5 9 m kgf 43 ft Ibf T R 64 Nm 6 4 m kgf 46 ft Ibf T R 43 Nm 4 3 m kgf 31 ft Ibf T R 2...

Page 236: ...hock absorber assembly upper nuts Rear shock absorber assembly lower bolts 4 Install Gasket Exhaust pipe Exhaust pipe nuts temporarily tighten 5 Install Muffler Muffler mounting bolts temporarily tighten TIP Install the muffler mounting bolts in the proper in stalling sequence as shown 6 Tighten Muffler mounting bolts T R Engine bracket rod nut 64 Nm 6 4 m kgf 46 ft lbf Engine mounting nut 43 Nm 4...

Page 237: ...bolts in the proper tightening sequence as shown 7 Tighten Exhaust pipe nuts 8 Tighten Muffler joint bolt O2 sensor T R Exhaust pipe nut 20 Nm 2 0 m kgf 14 ft lbf T R Muffler joint bolt 14 Nm 1 4 m kgf 10 ft lbf O2 sensor 45 Nm 4 5 m kgf 33 ft lbf 1 2 3 ...

Page 238: ... element 1 7 Cylinder head cover 1 8 Cylinder head cover gasket 1 9 Timing chain tensioner 1 10 Timing chain tensioner gasket 1 11 Camshaft sprocket 1 12 Cylinder head 1 13 Cylinder head gasket 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 8 Nm 0 8 m kgf 5 8 ft Ibf T R 13 Nm 1 3 m kgf 9 4 f...

Page 239: ...ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 8 Nm 0 8 m kgf 5 8 ft Ibf T R 13 Nm 1 3 m kgf 9 4 ft Ibf T R 18 Nm 1 8 m kgf 13 ft Ibf T R 22 Nm 2 2 m kgf 16 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R 7 8 13 14 14 6 5 2 3 1 12 11 9 10 4 4 New New New New New New New New LS 4 4 E LS New ...

Page 240: ...t sprocket bolt 1 TIP While holding the primary sheave nut with a wrench remove the camshaft sprocket bolt 3 Remove Timing chain tensioner along with the gasket Camshaft sprocket bolt 1 Camshaft sprocket 2 TIP To prevent the timing chain from falling into the crankcase fasten it with a wire 3 4 Remove Cylinder head TIP Loosen the bolts and nuts in the proper se quence as shown Loosen each bolt and...

Page 241: ...face the cylinder head using a figure eight sanding pattern TIP To ensure an even surface rotate the cylinder head several times EAS2DM1034 CHECKING THE CAMSHAFT SPROCKET 1 Check Camshaft sprocket More than 1 4 tooth wear a Replace the camshaft sprocket timing chain and crank shaft as a set EAS24190 CHECKING THE TIMING CHAIN TENSIONER 1 Check Timing chain tensioner Cracks damage Replace a Remove t...

Page 242: ... the generator rotor with the stationary pointer b on the genera tor cover c Install the timing chain 1 onto the camshaft sprocket 2 then the camshaft sprocket onto the camshaft and then finger tighten the camshaft sprocket bolt TIP Fit the projections c on the camshaft into the holes d in the camshaft sprocket and fit the pin e on the decompression cam into the slot f in the decompression lever o...

Page 243: ...sket TIP Apply sealant to the threads of the timing chain tensioner bolts d Turn the timing chain tensioner rod counter clockwise with a thin screwdriver 1 make sure it releases and then install the timing chain tensioner plug 4 Turn Crankshaft turn the primary sheave nut on the left side of the crankshaft several turns counterclock wise 5 Check I mark a Make sure the I mark a on the generator rot...

Page 244: ... the camshaft sprocket bolt to the specified torque to avoid the possibil ity of the bolt coming loose and damaging the engine 7 Measure Valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEAR ANCE on page 3 4 T R Camshaft sprocket bolt 30 Nm 3 0 m kgf 22 ft lbf d c ...

Page 245: ...age 5 7 1 Locknut 4 2 Adjusting screw 4 3 Decompression cam 1 4 Camshaft retainer 1 5 Camshaft 1 6 Rocker arm shaft 2 7 Intake rocker arm 1 8 Exhaust rocker arm 1 For installation reverse the removal proce dure 1 2 1 2 7 3 4 5 6 6 2 1 2 1 8 M E M E E E E M LT LT 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R ...

Page 246: ...sprocket and the decompression cam installed to the camshaft b Check that the decompression lever 1 moves smoothly c Without operating the decompression lever check that the decompression cam 2 projects from the camshaft exhaust cam as shown in the illustration A d Move the decompression lever in the direc tion of the arrow shown and check that the decompression cam does not project from the camsh...

Page 247: ... Replace 4 Measure Rocker arm shaft outside diameter a Out of specification Replace 5 Calculate Rocker arm to rocker arm shaft clearance TIP Calculate the clearance by subtracting the rock er arm shaft outside diameter from the rocker arm inside diameter Out of specification Replace the defective part s 2 A 2 B 1 Rocker arm inside diameter 9 985 10 000 mm 0 3931 0 3937 in Limit 10 015 mm 0 3943 in...

Page 248: ...ocker arm shafts intake and exhaust are completely pushed into the cylin der head 4 Install Camshaft 1 TIP Make sure that the camshaft projections a and hole b are positioned as shown in the illustra tion 5 Install Camshaft retainer Recommended lubricant Camshaft Molybdenum disulfide grease Camshaft bearing Engine oil Recommended lubricant Rocker arm inner surface Molybdenum disulfide oil Rocker a...

Page 249: ...ER HEAD on page 5 7 Rocker arms Camshaft Refer to CAMSHAFT on page 5 14 1 Valve cotter 8 2 Upper spring seat 4 3 Valve spring 4 4 Intake valve 2 5 Exhaust valve 2 6 Valve stem seal 4 7 Lower spring seat 4 8 Valve guide 4 For installation reverse the removal proce dure M 6 6 6 6 1 1 2 2 3 3 7 7 8 5 8 5 8 4 8 4 1 2 3 7 1 2 3 7 New New New New New New New New M M M M M M M ...

Page 250: ...e cotters 1 TIP Remove the valve cotters by compressing the valve spring with the valve spring compressor and the valve spring compressor attachment 2 3 Remove Upper spring seat 1 Valve spring 2 Valve 3 Valve stem seal 4 Lower spring seat 5 TIP Identify the position of each part very carefully so that it can be reinstalled in its original place EAS2DM1041 CHECKING THE VALVES AND VALVE GUIDES The f...

Page 251: ...r valve stem to valve guide clearance TIP After replacing the valve guide reface the valve seat Valve stem to valve guide clear ance intake 0 010 0 037 mm 0 0004 0 0015 in Limit 0 080 mm 0 0032 in Valve stem to valve guide clear ance exhaust 0 025 0 052 mm 0 0010 0 0020 in Limit 0 100 mm 0 0039 in Valve guide position Intake 17 0 17 4 mm 0 670 0 685 in Exhaust 14 0 14 4 mm 0 551 0 567 in a Valve g...

Page 252: ...eplace the cylinder head 3 Measure Valve seat contact width a Out of specification Replace the cylinder head a Apply blue layout fluid b onto the valve face b Install the valve into the cylinder head c Press the valve through the valve guide and onto the valve seat to make a clear impres sion d Measure the valve seat contact width TIP Where the valve seat and valve face contacted one another the b...

Page 253: ...nstall the valve into the cylinder head i Press the valve through the valve guide and onto the valve seat to make a clear impres sion j Measure the valve seat contact width again If the valve seat contact width is out of speci fication reface and lap the valve seat EAS2DM1043 CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs 1 Measure Valve spring free length a...

Page 254: ...tem 1 Valve stem seal 2 with the recommended lubricant 3 Install Lower spring seat 1 Valve stem seal 2 Valve 3 Valve spring 4 Upper spring seat 5 into the cylinder head TIP Make sure each valve is installed in its original place Install the valve springs with the larger pitch a facing up 4 Install Valve cotters 1 b Installed length Spring tilt intake 2 5 1 8 mm 0 07 in Spring tilt exhaust 2 5 1 8 ...

Page 255: ...ompressor attachment 2 5 To secure the valve cotters onto the valve stem lightly tap the valve tip with a soft face hammer NOTICE ECA13800 Hitting the valve tip with excessive force could damage the valve Valve spring compressor 90890 04019 YM 04019 Valve spring compressor attach ment 90890 04108 Valve spring compressor adapt er 22 mm YM 04108 2 1 ...

Page 256: ...linder head Refer to CYLINDER HEAD on page 5 7 1 Timing chain guide exhaust side 1 2 Cylinder 1 3 Cylinder gasket 1 4 Dowel pin 2 5 Clip 2 6 Piston pin 1 7 Piston 1 8 Top ring 1 9 2nd ring 1 10 Oil ring 1 For installation reverse the removal proce dure 2 4 4 3 5 7 6 5 8 9 10 1 New New New New E E E 7 Nm 0 7 m kgf 5 1 ft Ibf T R ...

Page 257: ...open the end gap with your fingers and lift the other side of the ring over the piston crown EAS2DM1046 CHECKING THE CYLINDER AND PISTON 1 Check Piston wall Cylinder wall Vertical scratches Rebore or replace the cylinder and replace the piston and piston rings as a set 2 Measure Piston to cylinder clearance a Measure cylinder bore C with the cylinder bore gauge TIP Measure cylinder bore C by takin...

Page 258: ...eplace the piston and piston rings as a set TIP Before measuring the piston ring side clearance eliminate any carbon deposits from the piston ring grooves and piston rings 2 Install Piston ring into the cylinder TIP Level the piston ring into the cylinder with the piston crown b 5 mm 0 20 in from the bottom edge of the piston Piston Diameter D 51 962 51 985 mm 2 0457 2 0466 in Piston to cylinder c...

Page 259: ...CHAIN GUIDE 1 Check Timing chain guide exhaust side Damage wear Replace EAS2DM1050 INSTALLING THE PISTON AND CYLINDER 1 Install Top ring 1 2nd ring 2 Upper oil ring rail 3 Oil ring expander 4 Lower oil ring rail 5 TIP Be sure to install the piston rings so that the manufacturer marks or numbers face up Piston ring Top ring End gap installed 0 07 0 17 mm 0 0028 0 0067 in Limit 0 42 mm 0 0165 in 2nd...

Page 260: ...kcase 3 Lubricate Piston Piston rings Cylinder with the recommended lubricant 4 Offset Piston ring end gaps 5 Install Dowel pins Cylinder gasket Cylinder 1 TIP While compressing the piston rings with one hand install the cylinder with the other hand Pass the timing chain and timing chain guide intake side through the timing chain cavity Recommended lubricant Engine oil New 1 2 3 a New a Top ring b...

Page 261: ...r filter case Refer to GENERAL CHASSIS on page 4 1 1 V belt case cover 1 2 V belt case air duct 1 3 V belt case air filter element 1 4 V belt case 1 5 V belt case gasket 1 1 6 V belt case gasket 2 1 7 Dowel pin 1 8 Bearing 1 For installation reverse the removal proce dure New New 5 4 6 New 8 2 1 8 3 E 7 10 Nm 1 0 m kgf 7 2 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R ...

Page 262: ...1 2 Primary fixed sheave 1 3 Washer 1 4 Secondary sheave nut 1 5 Spacer 1 6 Clutch housing 1 7 Secondary sheave assembly 1 8 V belt 1 9 Primary sliding sheave 1 10 Oil seal 2 11 Spacer 1 12 Cam 1 13 Primary sheave weight 6 14 Slider 3 For installation reverse the removal proce dure 8 7 6 11 3 2 1 5 4 14 12 13 9 10 10 New New New 55 Nm 5 5 m kgf 40 ft Ibf T R 60 Nm 6 0 m kgf 43 ft Ibf T R ...

Page 263: ... Clutch carrier 1 3 Clip 3 4 Clutch carrier plate 1 5 Clutch shoe spring 3 6 Compression spring 1 7 Spring seat 1 8 Guide pin 3 9 Secondary sliding sheave 1 10 O ring 2 11 Oil seal 2 12 Oil seal 1 13 Secondary fixed sheave 1 For assembly reverse the disassembly pro cedure 12 7 6 3 4 5 2 1 13 8 8 8 9 11 11 New New New New New New 10 90 Nm 9 0 m kgf 65 ft Ibf T R ...

Page 264: ...ng 2 TIP While holding the clutch housing with the sheave holder 3 loosen the secondary sheave nut 2 Loosen Clutch carrier nut 1 NOTICE ECA13860 Do not remove the clutch carrier nut at this stage TIP While holding the clutch carrier with the sheave holder 2 loosen the clutch carrier nut one full turn with the locknut wrench 3 3 Remove Secondary sheave assembly 1 V belt 2 TIP Remove the V belt and ...

Page 265: ...e Damage wear Replace the clutch shoes and springs as a set Glazed areas Sand with coarse sandpa per TIP After sanding the glazed areas clean the clutch with a cloth 2 Measure Clutch shoe thickness a Out of specification Replace the clutch shoes and springs as a set EAS2DM1055 CHECKING THE V BELT 1 Check V belt 1 Cracks damage wear Replace Grease oil Clean the primary and second ary sheave 2 Measu...

Page 266: ...Primary sheave slider Cracks damage wear Replace EAS2DM1059 CHECKING THE SECONDARY SHEAVE 1 Check Secondary fixed sheave Secondary sliding sheave Cracks damage wear Replace the sec ondary fixed and sliding sheaves as a set 2 Check Torque cam groove 1 Damage wear Replace the secondary fixed and sliding sheaves as a set 3 Check Guide pin 2 Damage wear Replace the secondary fixed and sliding sheaves ...

Page 267: ...ndary sliding sheave inner surface 2 Oil seals Bearing with the recommended lubricant 2 Install Oil seal Secondary sliding sheave 1 TIP Install the secondary sliding sheave onto the secondary fixed sheave 2 with the oil seal guide 3 3 Install Guide pins 1 4 Lubricate Guide pin grooves 2 O rings 3 with the recommended lubricant 5 Install Spring seat Compression spring Clutch carrier 1 Clutch carrie...

Page 268: ...e 2 Tighten Clutch carrier nut 1 TIP While holding the clutch carrier with the sheave holder 2 tighten the clutch carrier nut with the locknut wrench 3 3 Install Clutch housing 1 Spacer Secondary sheave nut 2 TIP While holding the clutch housing with the sheave holder 3 tighten the secondary sheave nut Clutch spring holder 90890 01337 Universal clutch compressor holder YM 33285 Clutch spring holde...

Page 269: ...e to contact the primary sheave assembly 5 Tighten Primary sheave nut 1 TIP While holding the primary fixed sheave with the rotor holding tool 2 tighten the primary sheave nut 6 Install V belt case TIP Make sure that the V belt case gasket lip fits properly around the V belt case Tighten the V belt case bolts in stages and in a crisscross pattern Sheave holder 90890 01701 Primary clutch holder YS ...

Page 270: ...o ENGINE REMOVAL on page 5 2 1 Crankshaft position sensor coupler Stator as sembly coupler 1 1 Disconnect 2 Generator cover 1 3 Generator cover gasket 1 4 Dowel pin 2 5 Crankshaft position sensor 1 6 Stator coil 1 7 Oil seal 1 For installation reverse the removal proce dure 1 6 5 7 4 3 4 2 9 3 1 New New New LT LT LT LS LS 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kg...

Page 271: ...rks 1 Circlip 1 2 Washer 1 3 Starter clutch idle gear shaft 1 4 Starter clutch idle gear 1 5 Generator rotor 1 6 Woodruff key 1 7 Starter clutch gear 1 8 Starter clutch 1 For installation reverse the removal proce dure 4 6 8 7 5 3 3 2 1 New E E E M E LT LT E 13 Nm 1 3 m kgf 9 4 ft Ibf T R 80 Nm 8 0 m kgf 58 ft Ibf T R ...

Page 272: ...t place an appropriate sized socket between the fly wheel puller set center bolt and the crank shaft TIP Make sure the flywheel puller is centered over the generator rotor EAS2DM1064 REMOVING THE STARTER CLUTCH 1 Remove Starter clutch bolts 1 Starter clutch TIP While holding the generator rotor 2 with the sheave holder 3 remove the starter clutch bolts Do not allow the sheave holder to touch the p...

Page 273: ...erator rotor 2 with the sheave holder 3 tighten the starter clutch bolts Do not allow the sheave holder to touch the projection on the generator rotor EAS2DM1067 INSTALLING THE GENERATOR 1 Install Starter clutch gear Woodruff key Generator rotor Washer Generator rotor nut TIP Clean the tapered portion of the crankshaft and the generator rotor hub When installing the generator rotor make sure the w...

Page 274: ...Generator cover TIP Tighten the generator cover bolts in stages and in a crisscross pattern Sheave holder 90890 01701 Primary clutch holder YS 01880 A Yamaha bond No 1215 90890 85505 Three Bond No 1215 Oil seal installed depth 4 5 5 4 mm 0 18 0 21 in a Oil seal installed depth 1 2 3 New a 1 New T R Generator cover bolt 10 Nm 1 0 m kgf 7 2 ft lbf ...

Page 275: ...motor Order Job Parts to remove Q ty Remarks Storage box Air filter case Refer to GENERAL CHASSIS on page 4 1 1 Starter motor lead 1 Disconnect 2 Ground lead 1 Disconnect 3 Starter motor 1 For installation reverse the removal proce dure 2 1 3 7 Nm 0 7 m kgf 5 1 ft Ibf T R ...

Page 276: ...r Order Job Parts to remove Q ty Remarks 1 O ring 1 2 Starter motor yoke 1 3 O ring 1 4 Armature assembly 1 5 Shim 6 Brush 2 7 Spring 2 8 Front bracket brush holder set 1 For assembly reverse the disassembly pro cedure 1 7 3 5 4 2 8 6 7 6 New LS New New ...

Page 277: ...ut of specification Replace the starter motor a Measure the armature assembly resistances with the digital circuit tester b If any resistance is out of specification re place the starter motor 5 Measure Brush length a Out of specification Replace the brushes as a set 6 Measure Brush spring force Out of specification Replace the brush springs as a set Limit 16 6 mm 0 65 in Mica undercut depth 1 35 ...

Page 278: ...ELECTRIC STARTER 5 47 7 Check Gear teeth Damage wear Replace the gear 8 Check Bearing Oil seal Bushing Damage wear Replace the defective part s ...

Page 279: ...TCH AND GENER ATOR on page 5 39 1 Oil pump plate 1 2 Oil pump assembly 1 3 Oil pump housing cover 1 4 Pin 1 5 Oil pump driven gear 1 6 Oil pump inner rotor 1 7 Oil pump outer rotor 1 8 Oil pump housing 1 For installation reverse the removal proce dure 2 1 3 6 7 8 4 5 M LT E 4 Nm 0 4 m kgf 2 9 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R ...

Page 280: ...EAS2DM1070 ASSEMBLING THE OIL PUMP 1 Lubricate Inner rotor Outer rotor 2 Lubricate Oil pump shaft with the recommended lubricant 3 Install Oil pump driven gear Oil pump housing 1 Oil pump outer rotor 2 Oil pump inner rotor 3 Pin 4 Oil pump housing cover 1 Inner rotor 2 Outer rotor 3 Oil pump housing Inner rotor to outer rotor tip clearance Less than 0 150 mm 0 0059 in Limit 0 23 mm 0 0091 in Outer...

Page 281: ...ve a in the inner rotor 4 Check Oil pump operation Refer to CHECKING THE OIL PUMP on page 5 49 EAS2DM1071 INSTALLING THE OIL PUMP 1 Install Oil pump assembly NOTICE ECA2DM1036 After tightening the screws make sure the oil pump turns smoothly T R Oil pump assembly screw 4 0 Nm 0 40 m kgf 2 9 ft lbf 1 3 4 2 a ...

Page 282: ...ION OIL on page 3 22 Secondary sheave assembly Refer to V BELT AUTOMATIC TRANSMIS SION on page 5 30 1 Transmission case cover 1 2 Gasket 1 3 Dowel pin 2 4 Primary drive gear 1 5 Washer 1 6 Conical spring washer 1 7 1st wheel gear 1 8 Conical spring washer 1 9 Main axle primary driven gear 1 10 Washer 1 11 7 10 9 6 5 3 3 4 6 5 2 1 6 8 8 11 7 9 E E E E E E E New New New New LS A B A B LS 16 Nm 1 6 m...

Page 283: ...e 1 For installation reverse the removal proce dure Removing the transmission Order Job Parts to remove Q ty Remarks 11 7 10 9 6 5 3 3 4 6 5 2 1 6 8 8 11 7 9 E E E E E E E New New New New LS A B A B LS 16 Nm 1 6 m kgf 12 ft Ibf T R ...

Page 284: ...coloration pitting wear Replace the defective gear s Transmission gear dogs Cracks damage rounded edges Replace the defective gear s 2 Check Transmission gear engagement each pinion gear to its respective wheel gear Incorrect Reassemble the transmission axle assemblies 3 Check Transmission gear movement Rough movement Replace the defective part s EAS2DM1074 INSTALLING THE TRANSMISSION 1 Install Oi...

Page 285: ... on page 5 48 Transmission Refer to TRANSMISSION on page 5 51 1 Oil filter element cover 1 2 Oil filter element 1 3 Oil strainer cover 1 4 Spring 1 5 Oil strainer 1 6 Timing chain guide retaining bolt 1 7 Timing chain guide intake side 1 8 Left crankcase 1 9 Dowel pin 2 5 4 3 11 9 9 13 12 14 10 7 2 1 15 6 8 3 3 5 New New New New New New New LS LS LS LS E E E 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 ...

Page 286: ... the removal proce dure Removing the crankshaft Order Job Parts to remove Q ty Remarks 5 4 3 11 9 9 13 12 14 10 7 2 1 15 6 8 3 3 5 New New New New New New New LS LS LS LS E E E 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 20 Nm 2 0 m kgf 14 ft Ibf T R 20 Nm 2 0 m kgf 14 ft Ibf T R 32 Nm 3 2 m kgf 23 ft Ibf T R ...

Page 287: ...haft assembly with the crankcase separating tool 2 and M6 bolts 3 Make sure that the crankcase separating tool is centered over the crankshaft assembly NOTICE ECA2DM1038 To protect the end of the crankshaft place an appropriate sized socket 4 between the crankcase separating tool bolt and the crankshaft Do not tap on the crankshaft EAS2DM1077 CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDE 1 Chec...

Page 288: ...G THE CRANKCASE 1 Thoroughly wash the crankcase halves in a mild solvent 2 Thoroughly clean all the gasket surfaces and crankcase mating surfaces 3 Check Crankcase Cracks damage Replace Oil delivery passages Obstruction Blow out with compressed air EAS2DM1080 CHECKING THE BEARING AND OIL SEAL 1 Check Bearing Clean and lubricate the bearings and then rotate the inner race with your finger Rough mov...

Page 289: ...oil seal lips with lithium soap based grease and each bearing with engine oil TIP Hold the connecting rod at top dead center TDC with one hand while turning the nut of the crankshaft installer bolt with the other Turn the crankshaft installer bolt until the crankshaft as sembly bottoms against the bearing 5 Install Oil pump drive gear 1 TIP Install the oil pump drive gear with the crankshaft insta...

Page 290: ...ase bolts TIP Tighten the crankcase bolts in stages and in a crisscross pattern M6 110 mm 4 33 in bolts 1 M6 80 mm 3 15 in bolts 2 M6 70 mm 2 76 in bolts 3 5 Install Oil filter element cover 1 TIP Be sure to face the mark a on the oil filter element cover in the direction shown in the illus tration Crankshaft installer pot 90890 01274 Installing pot YU 90058 Crankshaft installer bolt 90890 01275 B...

Page 291: ...CRANKSHAFT 5 60 a 1 ...

Page 292: ...CRANKSHAFT 5 61 ...

Page 293: ...R 6 2 INSTALLING THE RADIATOR 6 2 THERMOSTAT 6 4 CHECKING THE THERMOSTAT 6 5 INSTALLING THE THERMOSTAT ASSEMBLY 6 5 WATER PUMP 6 6 DISASSEMBLING THE WATER PUMP 6 7 CHECKING THE WATER PUMP 6 7 ASSEMBLING THE WATER PUMP 6 7 INSTALLING THE WATER PUMP 6 8 ...

Page 294: ...NG THE COOLANT on page 3 21 1 Radiator filler hose 1 2 Coolant reservoir hose 1 3 Coolant reservoir 1 4 Radiator inlet hose 1 5 Radiator outlet hose 1 6 Radiator fan motor coupler 1 Disconnect 7 Radiator bracket 1 8 Radiator 1 9 Radiator fan 1 For installation reverse the removal proce dure 2 0 Nm 0 20 m kgf 1 4 ft Ibf T R 13 Nm 1 3 m kgf 9 4 ft Ibf T R 1 2 9 6 8 5 4 7 3 LT LT LT LT ...

Page 295: ...e 4 Check Radiator fan Damage Replace Malfunction Check and repair Refer to COOLING SYSTEM on page 8 33 EAS26400 INSTALLING THE RADIATOR 1 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 21 2 Check Cooling system Leaks Repair or replace any faulty part a Attach the radiator cap tester 1 to the radia tor b Apply 100 kPa 1 0 kg cm 14 ...

Page 296: ...RADIATOR 6 3 3 Measure Radiator cap opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE RADIATOR on page 6 2 ...

Page 297: ...s Storage box Refer to GENERAL CHASSIS on page 4 1 Coolant Drain Refer to CHANGING THE COOLANT on page 3 21 1 Thermostat outlet hose 1 Disconnect 2 Thermostat inlet hose 1 3 Thermostat cover 1 4 Thermostat 1 For installation reverse the removal proce dure New 3 2 4 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R ...

Page 298: ...verheating or overcooling 2 Check Thermostat cover Cracks damage Replace EAS26480 INSTALLING THE THERMOSTAT ASSEMBLY 1 Install Thermostat 1 Thermostat cover TIP Install the thermostat with its breather hole a in the position shown in the illustration 2 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 21 3 Check Cooling system Leaks R...

Page 299: ...pump housing cover 1 4 Water pump housing cover gasket 1 5 Cylinder head breather hose 1 Disconnect 6 Water pump housing 1 7 Water pump housing plate 1 1 8 Water pump housing plate 2 1 9 Water pump housing plate gasket 1 10 Impeller shaft 1 11 Water pump seal 1 12 Bearing 1 For installation reverse the removal proce dure 2 3 4 11 10 6 5 7 8 9 12 1 LT 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf ...

Page 300: ...ATER PUMP 1 Install Water pump seal 1 into the water pump housing 2 TIP Install the water pump seal with the special tools to the specified depth as shown in the illustra tion 2 Lubricate Water pump seal 3 Install Impeller shaft Water pump housing plate gasket 1 1 2 2 1 New Installed depth of water pump seal 0 0 5 mm 0 0 02 in Mechanical seal installer 90890 04145 Middle driven shaft bearing driv ...

Page 301: ...NG THE WATER PUMP 1 Install O rings Water pump assembly 1 TIP Lubricate the O rings with a thin coat of lithium soap based grease Align the projection a on the impeller shaft with the slot b in the camshaft sprocket bolt 2 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 21 3 Check Cooling system Leaks Repair or replace any faulty pa...

Page 302: ...WATER PUMP 6 9 ...

Page 303: ...TALLING THE FUEL TANK 7 2 CHECKING THE FUEL PRESSURE 7 3 THROTTLE BODY 7 4 REMOVING THE FUEL HOSE 7 6 CHECKING THE FUEL INJECTOR 7 6 CHECKING THE THROTTLE BODY 7 6 INSTALLING THE INTAKE MANIFOLD 7 6 INSTALLING THE FUEL HOSE 7 6 INSTALLING THE THROTTLE BODY 7 6 CHECKING THE THROTTLE POSITION SENSOR 7 7 CHECKING THE ISC IDLE SPEED CONTROL UNIT 7 7 ...

Page 304: ...r 1 Disconnect 4 Fuel hose connector cover 1 5 Fuel hose 1 Disconnect 6 Fuel pump bracket 1 7 Fuel pump 1 8 Rectifier regulator coupler 1 Disconnect 9 Rectifier regulator 1 10 Fuel tank bracket 1 11 Fuel tank 1 For installation reverse the removal proce dure 1 2 4 5 11 3 LT 13 Nm 1 3 m kgf 9 4 ft Ibf T R 14 Nm 1 4 m kgf 10 ft Ibf T R 14 Nm 1 4 m kgf 10 ft Ibf T R 6 6 7 8 10 9 4 10 Nm 1 0 m kgf 7 2...

Page 305: ...ank EAS26640 REMOVING THE FUEL PUMP 1 Remove Fuel pump NOTICE ECA14720 Do not drop the fuel pump or give it a strong shock Do not touch the base section of the fuel sender EAS26670 CHECKING THE FUEL PUMP BODY 1 Check Fuel pump body Obstruction Clean Cracks damage Replace fuel pump as sembly EAS26700 INSTALLING THE FUEL PUMP 1 Install Fuel pump TIP Do not damage the installation surfaces of the fue...

Page 306: ...ct the hose with tools Although the fuel has been removed from the fuel tank be careful when removing the fuel hose since there may be fuel remain ing in it Do not disconnect the fuel hose from the fuel hose connector Disconnect the con nector from the fuel pump TIP Before removing the hose place a few rags in the area under where it will be removed b Connect the pressure gauge 3 and fuel pressure...

Page 307: ... 1 Disconnect 7 Throttle position sensor 1 8 Throttle cable 2 Disconnect 9 Air filter case joint clamp screw 1 Loosen 10 Throttle body joint clamp screw 1 Loosen 11 Throttle body 1 12 Fuel injector coupler 1 Disconnect 13 Fuel hose connector cover 1 14 Fuel injector assembly 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 2 Nm 0 2 m kgf 1 4 ft Ibf T R...

Page 308: ...to remove Q ty Remarks 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 2 Nm 0 2 m kgf 1 4 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 1 5 Nm 0 15 m kgf 1 1 ft Ibf T R 3 Nm 0 3 m kgf 2 2 ft Ibf T R 5 Nm 0 5 m kgf 3 6 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R New 2 New New LS 3 1 4 16 15 13 12 14 5 11 7 6 10 9 8 LS E ...

Page 309: ...ith compressed air EAS2DM1090 INSTALLING THE INTAKE MANIFOLD 1 Install Intake manifold joint 1 Intake manifold 2 TIP Make sure that the projection a on the intake manifold joint is facing down EAS2DM1091 INSTALLING THE FUEL HOSE 1 Install Fuel hose Fuel hose connector cover NOTICE ECA2DM1039 When installing the fuel hose make sure that it is securely connected and that the fuel hose connector cove...

Page 310: ...N SENSOR 1 Check Throttle position sensor Refer to CHECKING THE THROTTLE PO SITION SENSOR on page 8 147 EAS2DM1094 CHECKING THE ISC IDLE SPEED CONTROL UNIT 1 Check ISC idle speed control unit Refer to CHECKING THE ISC IDLE SPEED CONTROL UNIT on page 8 150 a b ...

Page 311: ...ESHOOTING 8 17 LIGHTING SYSTEM 8 19 CIRCUIT DIAGRAM 8 19 TROUBLESHOOTING 8 21 SIGNALING SYSTEM 8 23 CIRCUIT DIAGRAM for YP125R 8 23 CIRCUIT DIAGRAM for YP125RA 8 25 TROUBLESHOOTING 8 27 COOLING SYSTEM 8 33 CIRCUIT DIAGRAM 8 33 TROUBLESHOOTING 8 35 FUEL INJECTION SYSTEM 8 37 CIRCUIT DIAGRAM for YP125R 8 37 CIRCUIT DIAGRAM for YP125RA 8 39 ECU SELF DIAGNOSTIC FUNCTION 8 41 TROUBLESHOOTING METHOD 8 4...

Page 312: ...1 FINAL CHECK 8 125 ELECTRICAL COMPONENTS 8 127 CHECKING THE SWITCHES 8 131 CHECKING THE BULBS AND BULB SOCKETS 8 134 CHECKING THE FUSES 8 135 CHECKING AND CHARGING THE BATTERY 8 136 CHECKING THE RELAYS 8 139 CHECKING THE TURN SIGNAL HAZARD RELAY 8 140 CHECKING THE DIODES 8 141 CHECKING THE SPARK PLUG CAP 8 142 CHECKING THE IGNITION COIL 8 142 CHECKING THE IGNITION SPARK GAP 8 143 CHECKING THE CRA...

Page 313: ......

Page 314: ... B B W Y G Br W R B G P G R B B Y L B L Y Y W Ch P W Dg B L G L R B Gy Y L R L Sb B W W W W W W W B L W R W R W R W W W W B R R L B B B B B B B R B B W Y L R L G L R W B R G Lg R L R B Sb B L Y W P W Ch Dg Y B Y L G L B Br L R B Br Ch Dg B B Y G Ch Br G Y Dg Br G Y B B B B Br G Y B Dg Ch Y G P Br W R Y L B L BW B R YR Y Br W Br R P Br B L R L G B R WR B Y L B W R L Y L B R L W B L W B L W W Y Dg B...

Page 315: ...EM 8 2 1 Crankshaft position sensor 5 Main switch 6 ECU fuse 9 Ignition fuse 12 Battery 13 Main fuse 17 Frame ground 18 Sidestand switch 33 Lean angle sensor 35 ECU engine control unit 36 Ignition coil 37 Spark plug ...

Page 316: ...Check the spark plug Refer to CHECKING THE SPARK PLUG on page 3 4 Re gap or replace the spark plug 4 Check the ignition spark gap Refer to CHECKING THE IGNI TION SPARK GAP on page 8 143 Ignition system is OK 5 Check the spark plug cap Refer to CHECKING THE SPARK PLUG CAP on page 8 142 Replace the spark plug cap 6 Check the ignition coil Refer to CHECKING THE IGNI TION COIL on page 8 142 Replace th...

Page 317: ...on page 8 131 Replace the sidestand switch 10 Check the lean angle sensor Refer to CHECKING THE LEAN ANGLE SENSOR on page 8 144 Replace the lean angle sensor 11 Check the entire ignition system wiring Refer to CIRCUIT DIAGRAM on page 8 1 Properly connect or replace the wire har ness Replace the ECU ...

Page 318: ...W W W Br B Y Gy G L B L O B Y L O P W B W W R L Y L W L R B R W B B Sb R G R B Lg G B B W Y G Br W R B G P G R W B L W R W R W R W W W W B R R L B B B B B B B R B B W Y L R L G L R W B R G Lg R L R B Sb B L Y W P W Ch Dg Y B Y L G L B Br L R B Br Ch Dg B B Y G Ch Br G Y Dg Br G Y B B B B Br G Y B Dg Ch Y G P Br W R Y L B L BW B R YR Y Br W Br R P Br B L R L G B R WR B Y L B W R L Y L B R L W B L W...

Page 319: ...on fuse 11 Signaling system fuse 12 Battery 13 Main fuse 14 Starter relay 15 Starter motor 16 Diode 1 17 Frame ground 18 Sidestand switch 21 Starting circuit cut off relay 22 Diode 2 24 Start switch 26 Front brake light switch 50 Rear brake light switch ...

Page 320: ...B R W B B Sb R G R B Lg G B B W Y G Br W R B G P G R Br B B R R B B B B B B B R R G Br Br G L Br W W Y W R Sb P B B Gy B Gy B W W W W W R B W B W R L G L G W G Y R L Sb Lg W R B B G W B B W B P B Br R B L R B R L R L Y L R G Y L Y L B B B W R W B R W L R B Y Dg B B B B B B B B Br G Y Br Ch R L Y W Y L B L B G L W R Sb R B B L P W L R B G B B W R W R B R Y Br R Br R Br L Br L Br W Br L Br L Br R R ...

Page 321: ...g system fuse 13 Battery 14 Main fuse 15 Starter relay 16 Starter motor 17 Frame ground 18 Diode 1 19 Sidestand switch 24 Starting circuit cut off relay 1 25 Diode 2 26 Starting circuit cut off relay 2 28 Start switch 30 Front brake light switch 60 Rear brake light switch ...

Page 322: ... is closed and the sidestand is up the sidestand switch is closed The starting circuit cut off relay prevents the starter motor from operating when neither of these condi tions has been met In this instance the starting circuit cut off relay is open so current cannot reach the starter motor When at least one of the above conditions has been met the starting circuit cut off relay is closed and the ...

Page 323: ...2 Main fuse 3 Main switch 4 Ignition fuse 5 Diode 2 6 Starting circuit cut off relay 7 Sidestand switch 8 Signaling system fuse 9 Front brake light switch 10 Rear brake light switch 11 Start switch 12 Diode 1 13 Starter relay 14 Starter motor ...

Page 324: ...the sidestand is up the sidestand switch is closed The starting circuit cut off relays 1 and 2 prevents the starter motor from operating when neither of these conditions has been met In this instance the starting circuit cut off relays 1 and 2 are open so current cannot reach the starter motor When at least one of the above conditions has been met the starting circuit cut off relays 1 and 2 are cl...

Page 325: ...switch 4 Ignition fuse 5 Signaling system fuse 6 Diode 2 7 Starting circuit cut off relay 1 8 Rear brake light switch 9 Front brake light switch 10 Starting circuit cut off relay 2 11 Sidestand switch 12 Start switch 13 Diode 1 14 Starter relay 15 Starter motor ...

Page 326: ...eration Refer to CHECKING THE START ER MOTOR OPERATION on page 8 144 Starter motor is OK Perform the electric starting system troubleshooting starting with step 5 4 Check the starter motor Refer to CHECKING THE START ER MOTOR on page 5 46 Repair or replace the starter motor 5 Check the starting circuit cut off re lay for YP125R Refer to CHECKING THE RE LAYS on page 8 139 Replace the starting circu...

Page 327: ... the sidestand switch Refer to CHECKING THE SWITCHES on page 8 131 Replace the sidestand switch 12 Check the brake light switches front and rear Refer to CHECKING THE SWITCHES on page 8 131 Replace the brake light switch es 13 Check the start switch Refer to CHECKING THE SWITCHES on page 8 131 The start switch is faulty Replace the right handlebar switch 14 Check the entire starting system wiring ...

Page 328: ...B B B B B B B B B R L B W Y L R L B W Y L Y L Y L R W L R B G B B L B R B Y L Lg R W R G B R L R B G L Y L B W B W W W W W W W B L W R W R W R W W W W B R R L B B B B B B B R B B W Y L R L G L R W B R G Lg L R L G B R WR B Y L B W Y L B R L W B B R Br LBr R R R Br R Br L Br L Br L R G R W Br R R B R Y Br 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 17 71 72 73 74 75 ...

Page 329: ...CHARGING SYSTEM 8 16 2 AC magneto 3 Rectifier regulator 12 Battery 13 Main fuse 17 Frame ground ...

Page 330: ...to CHECKING AND CHARGING THE BATTERY on page 8 136 Clean the battery terminals Recharge or replace the battery 3 Check the stator coil Refer to CHECKING THE STATOR COIL on page 8 145 Replace the crankshaft position sen sor stator assembly 4 Check the rectifier regulator Refer to CHECKING THE RECTI FIER REGULATOR on page 8 145 Replace the rectifier regulator 5 Check the entire charging system wirin...

Page 331: ...CHARGING SYSTEM 8 18 ...

Page 332: ... G L B L O B Y L O P W B W W R L Y L W L R B R W B B Sb R G R B Lg G B B W Y G Br W R B G P G R W B L W R W R W R W W W W B R R L B B B B B B B R B B W Y L R L G L R W B R G Lg R L R B Sb B L Y W P W Ch Dg Y B Y L G L B Br L R B Br Ch Dg B B Y G Ch Br G Y Dg Br G Y B B B B Br G Y B Dg Ch Y G P Br W R Y L B L BW B R YR Y Br W Br R P Br B L R L G B R WR B Y L B W R L Y L B R L W B L W B L W W Y Dg B...

Page 333: ...10 Headlight fuse 11 Signaling system fuse 12 Battery 13 Main fuse 17 Frame ground 35 ECU engine control unit 44 Headlight relay 46 Dimmer switch 47 Pass switch 52 Tail brake light 59 Auxiliary light 60 Headlight 61 License plate light 69 High beam indicator light ...

Page 334: ...ling system Refer to CHECKING THE FUS ES on page 8 135 Replace the fuse s 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 136 Clean the battery terminals Recharge or replace the battery 4 Check the main switch Refer to CHECKING THE SWITCHES on page 8 131 Replace the main switch immobilizer unit 5 Check the dimmer switch Refer to CHECKING THE SWITCHES on page 8 131 The dimm...

Page 335: ...ING SYSTEM 8 22 NG OK 8 Check the entire lighting system wiring Refer to CIRCUIT DIAGRAM on page 8 19 Properly connect or replace the wire har ness Replace the ECU meter assembly or tail brake light assembly ...

Page 336: ...r B Y Gy G L B L O B Y L O P W B W W R L Y L W L R B R W B B Sb R G R B Lg G B B W Y G Br W R B G P G R W B L W R W R W R W W W W B R R L B B B B B B B R B B W Y L R L G L R W B R G Lg R L R B Sb B L Y W P W Ch Dg Y B Y L G L B Br L R B Br Ch Dg B B Y G Ch Br G Y Dg Br G Y B B B B Br G Y B Dg Ch Y G P Br W R Y L B L BW B R YR Y Br W Br R P Br B L R L G B R WR B Y L B W R L Y L B R L W B L W B L W ...

Page 337: ...perature sensor 34 Speed sensor 35 ECU engine control unit 42 Horn 43 Turn signal hazard relay 48 Turn signal switch 49 Horn switch 50 Rear brake light switch 52 Tail brake light 53 Right rear turn signal light 55 Left rear turn signal light 56 Right front turn signal light 57 Left front turn signal light 63 Multi function meter 64 Fuel level indicator light 67 Left turn signal indicator light 68 ...

Page 338: ... R B R W B B Sb R G R B Lg G B B W Y G Br W R B G P G R R R B B B B B B B R R G Br Br G L Br W W Y W R Sb P B B Gy B Gy B W W W W W R B W B W R L G L G W G Y R L Sb Lg W R B B G W B B W B P B Br R B L R B R L R L Y L R G Y L Y L B B B W R W B R W L R B Y Dg B B B B B B B B Br G Y Br Ch R L Y W Y L B L B G L W R Sb R B B L P W L R B G B B W R W R B R Y Br R Br R Br L Br L Br W Br L Br L Br R R B R ...

Page 339: ...ne control unit 46 Front wheel sensor 48 Wheel sensor lead shield 49 ABS ECU electronic control unit 52 Horn 53 Turn signal hazard relay 58 Turn signal switch 59 Horn switch 60 Rear brake light switch 62 Tail brake light 63 Right rear turn signal light 65 Left rear turn signal light 66 Right front turn signal light 67 Left front turn signal light 73 Multi function meter 74 Fuel level indicator lig...

Page 340: ...1 Check the fuses Main signaling system ignition ECU turn signal hazard and ABS ECU fuse for YP125RA Refer to CHECKING THE FUS ES on page 8 135 Replace the fuse s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 136 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 131 Replace the main switch immobil...

Page 341: ...n 1 Check the front brake light switch Refer to CHECKING THE SWITCHES on page 8 131 Replace the front brake light switch 2 Check the rear brake light switch Refer to CHECKING THE SWITCHES on page 8 131 Replace the rear brake light switch 3 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM for YP125R on page 8 23 and CIR CUIT DIAGRAM for YP125RA on page 8 25 Properly connect or repl...

Page 342: ...he entire signaling system wiring Refer to CIRCUIT DIAGRAM for YP125R on page 8 23 and CIR CUIT DIAGRAM for YP125RA on page 8 25 Properly connect or replace the wire har ness Replace the meter assembly 1 Check the fuel sender Refer to CHECKING THE FUEL SENDER on page 8 145 Replace the fuel pump 2 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM for YP125R on page 8 23 and CIR CUIT...

Page 343: ...nnect or replace the wire har ness Replace the ECU or meter assembly 1 Check the speed sensor Refer to CHECKING THE SPEED SENSOR for YP125R on page 8 146 Replace the speed sensor 2 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM for YP125R on page 8 23 and CIR CUIT DIAGRAM for YP125RA on page 8 25 Properly connect or replace the wire har ness Replace the ECU or meter assembly 1 C...

Page 344: ...on page 8 23 and CIR CUIT DIAGRAM for YP125RA on page 8 25 Properly connect or replace the wire har ness Replace the ECU or meter assembly 1 Check the air temperature sensor Refer to CHECKING THE AIR TEMPERATURE SENSOR on page 8 149 Replace the air temperature sensor 2 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM for YP125R on page 8 23 and CIR CUIT DIAGRAM for YP125RA on page...

Page 345: ... indicator fails to come on NG OK 1 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM for YP125R on page 8 23 and CIR CUIT DIAGRAM for YP125RA on page 8 25 Properly connect or replace the wire har ness Replace the meter assembly ...

Page 346: ...G L B L O B Y L O P W B W W R L Y L W L R B R W B B Sb R G R B Lg G B B W Y G Br W R B G P G R W B L W R W R W R W W W W B R R L B B B B B B B R B B W Y L R L G L R W B R G Lg R L R B Sb B L Y W P W Ch Dg Y B Y L G L B Br L R B Br Ch Dg B B Y G Ch Br G Y Dg Br G Y B B B B Br G Y B Dg Ch Y G P Br W R Y L B L BW B R YR Y Br W Br R P Br B L R L G B R WR B Y L B W R L Y L B R L W B L W B L W W Y Dg Br...

Page 347: ... 34 5 Main switch 6 ECU fuse 7 Radiator fan motor fuse 9 Ignition fuse 12 Battery 13 Main fuse 17 Frame ground 30 Coolant temperature sensor 35 ECU engine control unit 71 Radiator fan motor 72 Radiator fan motor relay ...

Page 348: ...place the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 131 Replace the main switch immobilizer unit 4 Check the radiator fan motor Refer to CHECKING THE RADIA TOR FAN MOTOR on page 8 146 Replace the radiator fan motor 5 Check the radiator fan motor relay Refer to CHECKING THE RE LAYS on page 8 139 Replace the radiator fan motor relay 6 Check the coolant temperature sen ...

Page 349: ...COOLING SYSTEM 8 36 ...

Page 350: ...W W Br B Y Gy G L B L O B Y L O P W B W W R L Y L W L R B R W B B Sb R G R B Lg G B B W Y G Br W R B G P G R W B L W R W R W R W W W W B R R L B B B B B B B R B B W Y L R L G L R W B R G Lg R L R B Sb B L Y W P W Ch Dg Y B Y L G L B Br L R B Br Ch Dg B B Y G Ch Br G Y Dg Br G Y B B B B Br G Y B Dg Ch Y G P Br W R Y L B L BW B R YR Y Br W Br R P Br B L R L G B R WR B Y L B W R L Y L B R L W B L W B...

Page 351: ... Throttle position sensor 30 Coolant temperature sensor 31 Intake air pressure sensor 32 Intake air temperature sensor 33 Lean angle sensor 34 Speed sensor 35 ECU engine control unit 36 Ignition coil 37 Spark plug 38 Fuel injector 39 O2 sensor 40 ISC idle speed control unit 44 Headlight relay 63 Multi function meter 65 Engine trouble warning light 71 Radiator fan motor 72 Radiator fan motor relay ...

Page 352: ...W L R B R W B B Sb R G R B Lg G B B W Y G Br W R B G P G R R R B B B B B B B R R G Br Br G L Br W W Y W R Sb P B B Gy B Gy B W W W W W R B W B W R L G L G W G Y R L Sb Lg W R B B G W B B W B P B Br R B L R B R L R L Y L R G Y L Y L B B B W R W B R W L R B Y Dg B B B B B B B B Br G Y Br Ch R L Y W Y L B L B G L W R Sb R B B L P W L R B G B B W R W R B R Y Br R Br R Br L Br L Br W Br L Br L Br R R B...

Page 353: ...perature sensor 36 Throttle position sensor 37 Intake air pressure sensor 38 Intake air temperature sensor 39 Lean angle sensor 40 ECU engine control unit 41 Ignition coil 42 Spark plug 43 Fuel injector 44 O2 sensor 45 ISC idle speed control unit 46 Front wheel sensor 48 Wheel sensor lead shield 49 ABS ECU electronic control unit 54 Headlight relay 73 Multi function meter 75 Engine trouble warning...

Page 354: ...listed below is present and the start switch is pushed Checking for a defective engine trouble warning light The engine trouble warning light comes on for 2 0 seconds after the main switch has been set to ON and when the start switch is being pushed If the warning light does not come on under these conditions the warning light bulb may be defective ECU detects an abnormal signal from a sensor If t...

Page 355: ...LF DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TA BLE on page 9 5 Diagnostic code No 62 TIP Setting the main switch to OFF will not erase the malfunction history The engine operation is not normal but the engine trouble warning light does not come on 1 Check the operation of the following sensors and actuators in the Diagnostic mode Refer to TROUBLESHOOTING DETAILS on page 8 45 If a malfunction is det...

Page 356: ...r by pressing the UP and DOWN buttons TIP The diagnostic code number appears on the LCD 01 70 To decrease the selected diagnostic code number press the DOWN button Press the DOWN but ton for 1 second or longer to automatically decrease the diagnostic code numbers To increase the selected diagnostic code number press the UP button Press the UP button for 1 second or longer to automatically increase...

Page 357: ... TROUBLESHOOTING DETAILS Refer to TROUBLESHOOTING DETAILS on page 8 45 If a diagnostic code number does not have a corresponding fault code number the information is shown in DIAGNOSTIC CODE TABLE Refer to SELF DIAGNOSTIC FUNCTION AND DIAG NOSTIC CODE TABLE on page 9 5 10 Connect the wire harness coupler to the fuel pump ...

Page 358: ...er Check the locking condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler secure ly or replace the wire har ness Crank the engine Fault code number is not dis played Service is finished Fault code number is dis played Go to item 2 2 Connection of wire harness ECU coupler Check the loc...

Page 359: ...upler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler secure ly or replace the wire har ness Turn the main switch to ON Fault code number is not dis played Service is finished Fault code number is dis played Go to item 2 2 Connection of wire harness ECU coupler Check the locking condition of the coupler Disconnect the coupler ...

Page 360: ...a 600 0 mmHg 23 6 inHg 3000 m 9800 ft above sea level Approx 70 kPa 525 0 mmHg 20 7 inHg When engine is cranking Make sure that the indication value changes The value does not change when engine is cranking Check the intake air pressure sensor Replace if defective Refer to CHECKING THE INTAKE AIR PRESSURE SENSOR on page 8 148 Turn the main switch to ON Fault code number is not dis played Service i...

Page 361: ...3300 ft above sea level Approx 90 kPa 675 1 mmHg 26 6 inHg 2000 m 6700 ft above sea level Approx 80 kPa 600 0 mmHg 23 6 inHg 3000 m 9800 ft above sea level Approx 70 kPa 525 0 mmHg 20 7 inHg When engine is cranking Make sure that the indication value changes The value does not change when engine is cranking Check the intake air pressure sensor Replace if defective Refer to CHECKING THE INTAKE AIR ...

Page 362: ... dis played Service is finished Fault code number is dis played Go to item 3 3 Wire harness continuity Open or short circuit Re place the wire harness Between throttle position sensor coupler and ECU coupler black blue black blue yellow yellow blue blue Turn the main switch to ON Fault code number is not dis played Service is finished Fault code number is dis played Go to item 4 4 Installed condit...

Page 363: ... sensor is de tected Fail safe system Able to start engine Able to drive vehicle Diagnostic code No D01 FI diagnostic tool display Throttle position sensor signal 8 22 fully closed position 88 102 fully open position Procedure Check with throttle valve fully closed Check with throttle valve fully open Item Probable cause of mal function and check Maintenance job Confirmation of service completion ...

Page 364: ...n ECU Replace the ECU Fault code No 19 Item Sidestand switch a break or disconnection of the blue yellow lead of the ECU is detected Fail safe system Unable to start engine Unable to drive vehicle Diagnostic code No D20 FI diagnostic tool display Sidestand switch ON sidestand retracted OFF sidestand extended Procedure Extend and retract the sidestand Item Probable cause of mal function and check M...

Page 365: ... FI diagnostic tool display Displays the coolant temperature Procedure Compare the actually measured coolant temperature with the FI diagnostic tool display value Item Probable cause of mal function and check Maintenance job Confirmation of service completion 1 Connection of coolant tem perature sensor coupler Check the locking condition of the coupler Disconnect the coupler and check the pins ben...

Page 366: ...LANT TEMPERATURE SENSOR on page 8 147 Turn the main switch to ON Fault code number is not dis played Service is finished Fault code number is dis played Go to item 6 6 Malfunction in ECU Replace the ECU Fault code No 22 Item Intake air temperature sensor open or short circuit detected Fail safe system Able to start engine Able to drive vehicle Diagnostic code No D05 FI diagnostic tool display Disp...

Page 367: ...r is dis played Go to item 4 4 Installed condition of intake air temperature sensor Check for looseness or pinching Improperly installed sensor Reinstall or replace the sensor Turn the main switch to ON Fault code number is not dis played Service is finished Fault code number is dis played Go to item 5 5 Defective intake air tempera ture sensor Execute the diagnostic mode Code No D05 When engine i...

Page 368: ... dis played Service is finished Fault code number is dis played Go to item 3 3 Connection of wire harness ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler secure ly or replace the wire har ness Start the engine warm it up and then race it or execute t...

Page 369: ...on of service completion 1 The vehicle has overturned Raise the vehicle upright Turn the main switch to ON then to OFF and then back to ON Fault code number is not dis played Service is finished Fault code number is dis played Go to item 2 2 Installed condition of lean angle sensor Check the installed direction and condition of the sensor Turn the main switch to ON then to OFF and then back to ON ...

Page 370: ... and locking condition of the pins Improperly connected Connect the coupler secure ly or replace the wire har ness Start the engine and let it idle for approximately 5 seconds Fault code number is not dis played Service is finished Fault code number is dis played Go to item 3 3 Wire harness continuity Open or short circuit Re place the wire harness Between ignition coil coupler and ECU coupler ora...

Page 371: ...eed sensor sig nal For YP125R Check the speed sensor Execute the diagnostic mode Code No D07 Rotate the front wheel by hand and check that the indi cated value increases Value does not increase Go to fault code No 42 Start the engine and let it idle for approximately 10 sec onds Fault code number is not dis played Service is finished Fault code number is dis played Go to item 4 3 Incorrect front w...

Page 372: ... is not heard Fail safe system Able to start engine Able to drive vehicle Diagnostic code No D54 Actuation Actuates and fully closes the ISC valve then opens it to the stand by opening position when the engine is started This operation takes approximately 3 seconds until it is completed Procedure The ISC unit vibrates when the ISC valve operates Item Probable cause of mal function and check Mainte...

Page 373: ...he wire harness Between ISC idle speed control unit coupler and ECU coupler pink pink light green light green green green sky blue sky blue Execute the diagnostic mode Code No D54 ISC operating sound is heard Go to item 8 ISC operating sound is not heard Go to item 5 5 Installed condition of ISC idle speed control unit Check for looseness or pinching Improperly installed ISC idle speed control uni...

Page 374: ... ness Execute the diagnostic mode Code No D36 No operating sound Go to item 2 Operating sound Go to item 6 2 Defective injector Measure the injector resis tance Replace if out of specifica tion Refer to CHECKING THE FUEL INJECTOR on page 8 149 Execute the diagnostic mode Code No D36 No operating sound Go to item 3 Operating sound Go to item 6 3 Connection of wire harness ECU coupler Check the lock...

Page 375: ...t the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler secure ly or replace the wire har ness Turn the main switch to ON then to OFF and then back to ON Fault code number is not dis played Service is finished Fault code number is dis played Go to item 3 3 Wire harness continuity Open or short circuit Re place the wire h...

Page 376: ...e coupler secure ly or replace the wire har ness Turn the main switch to ON and then rotate the front wheel a few turns by hand Fault code number is not dis played Service is finished Fault code number is dis played Go to item 3 3 Wire harness continuity Open or short circuit Re place the wire harness Between speed sensor cou pler and ECU coupler white white blue blue black blue black blue Turn th...

Page 377: ...nd check that the indi cated value increases Value increases Go to item 7 and delete the fault code Value does not increase Go to item 2 2 Connection of ABS ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler secure ly or replace the wire har ness Execut...

Page 378: ... ABS ECU Replace the ABS ECU Go to item 7 and delete the fault code 7 Delete the fault code Turn the main switch to ON and then rotate the front wheel by hand Start the engine and input the vehicle speed signals by operating the vehicle at 20 to 30 km h 19 mph The fault code can also be deleted by activating the di agnostic mode and selecting diagnostic code number D63 Fault code No 43 Item Fuel s...

Page 379: ...s Fault code number is not dis played Service is finished Fault code number is dis played Go to item 3 3 Malfunction in ECU Replace the ECU Fault code No 44 Item EEPROM fault code number an error is detected while reading or writing on EEPROM Fail safe system Able to start engine Able to drive vehicle Diagnostic code No D60 FI diagnostic tool display EEPROM fault code display 00 no history 01 CO a...

Page 380: ...lues Turn the main switch to ON and then fully opens and closes the throttle valve Turn the main switch to OFF Turn the main switch to ON Fault code number is not dis played Service is finished Fault code number is dis played Repeat item 1 If the same number is indicat ed go to item 5 5 Malfunction in ECU Replace the ECU Fault code No 46 Item Charging voltage is abnormal Fail safe system Able to s...

Page 381: ...cedure Item Probable cause of mal function and check Maintenance job Confirmation of service completion 1 Connection of ISC idle speed control unit coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler secure ly or replace the wire har ness Turn the main switc...

Page 382: ...unction meter Fail safe system Able to start engine Able to drive vehicle Diagnostic code No FI diagnostic tool display Procedure Item Probable cause of mal function and check Maintenance job Confirmation of service completion 1 Connection of meter assem bly coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition ...

Page 383: ...n of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler secure ly or replace the wire har ness Turn the main switch to ON Fault code number is not dis played Service is finished Fault code number is dis played Go to item 2 2 Connection of wire harness ECU coupler Check the locking condition of t...

Page 384: ...t dis played Service is finished Fault code number is dis played Go to item 2 2 Connection of wire harness ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler secure ly or replace the wire har ness Turn the main switch to ON Fault code number is not dis ...

Page 385: ...shed Fault code number is dis played Go to item 2 2 Connection of wire harness ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler secure ly or replace the wire har ness Turn the main switch to ON Fault code number is not dis played Service is finished F...

Page 386: ...r B Y Gy G L B L O B Y L O P W B W W R L Y L W L R B R W B B Sb R G R B Lg G B B W Y G Br W R B G P G R W B L W R W R W R W W W W B R R L B B B B B B B R B B W Y L R L G L R W B R G Lg R L R B Sb B L Y W P W Ch Dg Y B Y L G L B Br L R B Br Ch Dg B B Y G Ch Br G Y Dg Br G Y B B B B Br G Y B Dg Ch Y G P Br W R Y L B L BW B R YR Y Br W Br R P Br B L R L G B R WR B Y L B W R L Y L B R L W B L W B L W ...

Page 387: ...FUEL PUMP SYSTEM 8 74 5 Main switch 6 ECU fuse 9 Ignition fuse 12 Battery 13 Main fuse 17 Frame ground 19 Fuel pump 35 ECU engine control unit ...

Page 388: ... R B R W B B Sb R G R B Lg G B B W Y G Br W R B G P G R R R B B B B B B B R R G Br Br G L Br W W Y W R Sb P B B Gy B Gy B W W W W W R B W B W R L G L G W G Y R L Sb Lg W R B B G W B B W B P B Br R B L R B R L R L Y L R G Y L Y L B B B W R W B R W L R B Y Dg B B B B B B B B Br G Y Br Ch R L Y W Y L B L B G L W R Sb R B B L P W L R B G B B W R W R B R Y Br R Br R Br L Br L Br W Br L Br L Br R R B R ...

Page 389: ...FUEL PUMP SYSTEM 8 76 5 Main switch 7 ECU fuse 10 Ignition fuse 13 Battery 14 Main fuse 17 Frame ground 20 Fuel pump 22 Fuel pump relay 23 Diode 3 40 ECU engine control unit ...

Page 390: ... the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 131 Replace the main switch immobilizer unit 4 Check the fuel pump relay for YP125RA Refer to CHECKING THE RE LAYS on page 8 139 Replace the fuel pump relay 5 Check the fuel pump operation Refer to CHECKING THE FUEL PRESSURE on page 7 3 Replace the fuel pump 6 Check the diode 3 for YP125RA Refer to CHECKING THE DI ODES o...

Page 391: ...FUEL PUMP SYSTEM 8 78 ...

Page 392: ... Gy G L B L O B Y L O P W B W W R L Y L W L R B R W B B Sb R G R B Lg G B B W Y G Br W R B G P G R W B L W R W R W R W W W W B R R L B B B B B B B R B B W Y L R L G L R W B R G Lg R L R B Sb B L Y W P W Ch Dg Y B Y L G L B Br L R B Br Ch Dg B B Y G Ch Br G Y Dg Br G Y B B B B Br G Y B Dg Ch Y G P Br W R Y L B L BW B R YR Y Br W Br R P Br B L R L G B R WR B Y L B W R L Y L B R L W B L W B L W W Y D...

Page 393: ...kup fuse 5 Main switch 6 ECU fuse 9 Ignition fuse 12 Battery 13 Main fuse 17 Frame ground 35 ECU engine control unit 63 Multi function meter 66 Immobilizer system indicator light 73 Self diagnosis signal coupler 74 Immobilizer unit ...

Page 394: ... is lost regis tering new codes in the standard keys is impossible The standard keys can still be used to start the vehicle However if code re registering is required e g if a new standard key is made or all keys are lost the entire immobilizer system must be replaced Therefore it is highly rec ommended to use either standard key for driving and to keep the code re registering key in a safe place ...

Page 395: ...tandby mode To enable the immobilizer system turn the ignition key to OFF 30 seconds later the indicator light will start flashing continuously in the standby flashing mode pattern for up to 24 hours After that time the indicator light will stop flashing but the immobilizer system is still enabled Parts to be replaced Key registration re quirement Main switch immo bilizer unit Standard key ECU Acc...

Page 396: ...tch then turn the key to ON within 5 seconds to activate the key registration mode TIP The existing standard key code is erased from the memory when the key registration mode is activated When the key registration mode is activated the immobilizer system indicator light flashes rapidly 4 While the indicator light is flashing turn the main switch to OFF remove the key and within 5 sec onds insert t...

Page 397: ... Main switch OFF c LED on d LED off e Less than 5 0 s f Code re registering key g First standard key h Second standard key i Registration mode A Registration of the second standard key is complete B Immobilizer system indicator light stops flashing when the registration of the second standard key is complete a Main switch ON b Main switch OFF c LED on d LED off e Less than 5 0 s f Code re register...

Page 398: ... 136 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 131 Replace the main switch immobilizer unit 4 Check the entire immobilizer sys tem wiring Refer to CIRCUIT DIAGRAM on page 8 79 Properly connect or replace the wire har ness Check the condition each of the im mobilizer system circuits Refer to SELF DIAGNOSIS FAULT CODE...

Page 399: ...nit mal function 4 ECU malfunction 1 Check the wire harness and connector 2 Replace the main switch im mobilizer unit 3 Replace the ECU 54 IMMOBILIZER UNIT Codes transmitted between the ECU and the immobilizer unit do not match Noise interference or disconnected lead ca ble 1 Interference due to radio wave noise 2 Disconnected com munication harness 3 Immobilizer unit mal function 4 ECU failure Th...

Page 400: ...IMMOBILIZER SYSTEM 8 87 a Light on b Light off ...

Page 401: ...IMMOBILIZER SYSTEM 8 88 ...

Page 402: ...B Y L O P W B W W R L Y L W L R B R W B B Sb R G R B Lg G B B W Y G Br W R B G P G R R R B B B B B B B R R G Br Br G L Br W W Y W R Sb P B B Gy B Gy B W W W W W R B W B W R L G L G W G Y R L Sb Lg W R B B G W B B W B P B Br R B L R B R L R L Y L R G Y L Y L B B B W R W B R W L R B Y Dg B B B B B B B B Br G Y Br Ch R L Y W Y L B L B G L W R Sb R B B L P W L R B G B B W R W R B R Y Br R Br R Br L Br...

Page 403: ...ttery 14 Main fuse 17 Frame ground 30 Front brake light switch 33 ABS motor fuse 34 ABS solenoid fuse 40 ECU engine control unit 46 Front wheel sensor 47 Rear wheel sensor 48 Wheel sensor lead shield 49 ABS ECU electronic control unit 50 ABS test coupler 60 Rear brake light switch 62 Tail brake light 73 Multi function meter 77 ABS warning light ...

Page 404: ...ABS COMPONENTS CHART 1 2 3 4 5 6 6 7 8 10 9 1 ABS motor fuse 2 ABS ECU fuse 3 ABS solenoid fuse 4 ABS test coupler 5 ABS warning light 6 Hydraulic unit assembly 7 Front wheel sensor 8 Front wheel sensor rotor 9 Rear wheel sensor 10 Rear wheel sensor rotor ...

Page 405: ...ABS ANTI LOCK BRAKE SYSTEM for YP125RA 8 92 ...

Page 406: ...OCK BRAKE SYSTEM for YP125RA 8 93 EAS27750 ABS COUPLER LOCATION CHART B W Gy W B W Gy W R B B B W P Sb W W W R G Y G L G WB W B W Br W W Y R L Lg W R B Sb Y Y W Ch P W W R Dg B L G L R B Gy Y L R L Sb B 1 2 3 5 4 ...

Page 407: ...ABS ANTI LOCK BRAKE SYSTEM for YP125RA 8 94 1 ABS test coupler 2 ABS ECU coupler 3 Meter assembly coupler 4 Front wheel sensor coupler 5 Rear wheel sensor coupler ...

Page 408: ... using the Yamaha diagnostic tool For information about using the Yamaha diagnostic tool refer to B 2 DIAG NOSIS USING THE FAULT CODES on page 8 99 For troubleshooting items other than the following items follow the normal service method WARNING EWA2DM1013 When maintenance or checks have been performed on components related to the ABS be sure to perform a final check before delivering the vehicle ...

Page 409: ...ecting them to shocks or pulling on them with too much force since the ABS components are precisely adjusted The ABS ECU and hydraulic unit are united assemblies and cannot be disassembled The malfunction history is stored in the memory of the ABS ECU Delete the fault codes when the ser vice is finished This is because the past fault codes will be displayed again if another malfunction occurs EAS2...

Page 410: ...pleted normally Finished Yes No A Turn the main switch to ON and check the ABS warning light Fails to come on Comes on The connection with the Yamaha diagnostic tool is defective The ABS ECU fuse is blown The ABS ECU coupler is disconnected The wire harness is defective The hydraulic unit assembly is defective Cannot communicate Can communicate B 1 Check for ABS fault codes in the screen for the Y...

Page 411: ...efective Replace the hydraulic unit assembly EAS2DM1124 A 2 THE ABS WARNING LIGHT AND ALL OTHER INDICATOR LIGHTS FAIL TO COME ON 1 Main switch Check the main switch for continuity Refer to CHECKING THE SWITCHES on page 8 131 If there is no continuity replace the main switch immobilizer unit 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 136 If the...

Page 412: ...e ABS ECU coupler and the ABS test coupler Check for continuity between the green white terminal of the ABS ECU coupler and the green white terminal of the ABS test coupler Check for continuity between the green blue terminal of the ABS ECU coupler and the green blue terminal of the ABS test coupler If there is no continuity the wire harness is defective Replace the wire harness 5 The hydraulic un...

Page 413: ...ANTI LOCK BRAKE SYSTEM for YP125RA 8 100 TIP When the Yamaha diagnostic tool is connected to the vehicle the operation of the multi function meter and indicators will be different from the normal operation ...

Page 414: ...t of the malfunction currently occurred are displayed 3 Code The following icons and the fault code numbers for the detected malfunctions are displayed 4 ECU The types of the control units are displayed e g FI ABS 5 Item The item names of the detected malfunction are displayed 2 3 1 4 5 6 7 8 Hydraulic unit assembly Rear wheel sensor Detected Recovered Power is not supplied to the ABS motor Rear w...

Page 415: ... received intermit tently while the vehicle is traveling Foreign material ad hered around the front wheel sensor Incorrect installation of the front wheel Defective sensor rotor or incorrect installation of the rotor Defective front wheel sensor or incorrect in stallation of the sensor 12 Rear wheel sensor inter mittent pulses or no puls es Rear wheel sensor signal is not received properly Pulses ...

Page 416: ...wheel sensor and the hydraulic unit assembly Defective front wheel sensor or hydraulic unit assembly 16 Rear wheel sensor open or short circuit Open or short circuit is de tected in the rear wheel sensor Defective coupler be tween the rear wheel sensor and the hydraulic unit assembly Open or short circuit in the wire harness be tween the rear wheel sensor and the hydraulic unit assembly Defective ...

Page 417: ...h circuit Defective signaling sys tem tail brake light or brake light switch Defective coupler be tween the signaling sys tem tail brake light or brake light switch and the hydraulic unit assem bly Open or short circuit in the wire harness be tween the signaling sys tem tail brake light or brake light switch and the hydraulic unit assem bly Defective hydraulic unit assembly 31 Hydraulic unit assem...

Page 418: ... the hydraulic pres sure Incorrect installation of the front wheel sensor Incorrect rotation of the front wheel Front brake dragging Defective hydraulic unit assembly 42 47 Rear wheel ABS intermit tent wheel speed pulses or incorrect depressuriza tion Pulses from the rear wheel sensor are re ceived intermittently while the vehicle is trav eling For fault code No 42 Rear wheel will not re cover fro...

Page 419: ...ected battery terminal Defective charging sys tem 53 Vehicle system power supply voltage of ABS ECU power supply is low Power voltage supplied to the ABS ECU in the hy draulic unit assembly is too low Defective battery Defective coupler be tween the battery and the hydraulic unit assem bly Open or short circuit in the wire harness be tween the battery and the hydraulic unit assem bly Defective cha...

Page 420: ...rear wheel sensor and the hydraulic unit assem bly Defective rear wheel sensor Defective hydraulic unit assembly Fault code No Item Symptom Check point Fault code No 11 25 Item Front wheel sensor intermittent pulses or no pulses Symptom Front wheel sensor signal is not received properly Pulses are not received or are received intermittently while the vehicle is traveling Order Item components and ...

Page 421: ... rotor and wheel sensor for foreign material such as metal particles Clean the sensor rotor and wheel sensor if neces sary 2 Incorrect installation of the rear wheel Check the components for looseness distortion and bends Refer to CHECKING THE REAR WHEEL on page 4 29 3 Defective sensor rotor or incorrect in stallation of the rotor Check the surface of the sensor rotor for damage Replace the sensor...

Page 422: ...rotor or incorrect in stallation of the rotor Check the surface of the sensor rotor for damage Replace the sensor rotor if there is visible damage Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR for YP125RA on page 4 21 4 Defective front wheel sensor or incor rect installation of the sensor Check the wheel sensor for damage and the in stalled condition of the sensor Repair or repla...

Page 423: ...pair or replace the wheel sensor if necessary Refer to MAINTENANCE OF THE REAR WHEEL SENSOR for YP125RA on page 4 87 Fault code No 15 Item Front wheel sensor open or short circuit Symptom Open or short circuit is detected in the front wheel sensor Order Item components and probable cause Check or maintenance job 1 Defective coupler between the front wheel sensor and the hydraulic unit assembly Che...

Page 424: ...cuit between the black white terminal 3 and the white terminal 4 and between the black white terminal 3 and the black terminal 5 If there is short circuit the wire harness is defec tive Replace the wire harness 6 ABS ECU 7 Wheel sensor 3 Defective front wheel sensor or hy draulic unit assembly If the above items were performed and no malfunc tions were found the wheel sensor or hydraulic unit asse...

Page 425: ... there is no continuity the wire harness is defec tive Replace the wire harness Check that there is no short circuit between the black terminal 1 and the white terminal 2 and between the black terminal 4 and the white ter minal 5 If there is continuity the wire harness is defective Replace the wire harness Check that there is no short circuit between the black white terminal 3 and the black termin...

Page 426: ...e 4 20 3 Defective sensor rotor or incorrect in stallation of the rotor Check the surface of the sensor rotor for damage Replace the sensor rotor if there is visible damage Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR for YP125RA on page 4 21 4 Defective front wheel sensor or incor rect installation of the sensor Check the wheel sensor for damage and the in stalled condition of ...

Page 427: ...pen or short circuited Order Item components and probable cause Check or maintenance job 1 Defective hydraulic unit assembly Replace the hydraulic unit assembly Refer to ABS ANTI LOCK BRAKE SYSTEM for YP125RA on page 4 62 Fault code No 24 Item Brake light switch or tail brake light Symptom Brake light signal is not received properly while the vehicle is traveling brake light circuit or front or re...

Page 428: ...If the ABS solenoid fuse is blown replace the fuse and check the wire harness Refer to CHECKING THE FUSES on page 8 135 2 Defective coupler between the battery and the hydraulic unit assembly Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler securely TIP Turn the main switch to OFF before disconnecting or connecting a coupler 3 Open or short cir...

Page 429: ...he ABS motor fuse If the ABS motor fuse is blown replace the fuse and check the wire har ness Refer to CHECKING THE FUSES on page 8 135 2 Defective coupler between the battery and the hydraulic unit assembly Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler securely TIP Turn the main switch t...

Page 430: ... ABS ECU to reduce the hydraulic pressure Order Item components and probable cause Check or maintenance job 1 Incorrect installation of the front wheel sensor Check the components for looseness distortion and bends Refer to CHECKING THE FRONT WHEEL on page 4 20 2 Incorrect rotation of the front wheel Check that there is no brake disc drag on the front wheel and make sure that it rotates smoothly R...

Page 431: ...gging Check that the brake fluid pressure is correctly transmitted to the brake caliper when the brake le ver is operated and that the pressure decreases when the lever is released Refer to CHECKING THE REAR BRAKE DISC on page 4 53 4 Defective hydraulic unit assembly If the above items were performed and no malfunc tions were found replace the hydraulic unit assem bly Refer to ABS ANTI LOCK BRAKE ...

Page 432: ...ear wheel sensor Check the surface of the sensor rotor and wheel sensor for foreign material such as metal particles Clean the sensor rotor and wheel sensor if neces sary 2 Incorrect installation of the rear wheel Check the components for looseness distortion and bends Refer to CHECKING THE REAR WHEEL on page 4 29 3 Defective sensor rotor or incorrect in stallation of the rotor Check the surface o...

Page 433: ...SYSTEM on page 8 15 Fault code No 53 Item Vehicle system power supply voltage of ABS ECU power sup ply is low Symptom Power voltage supplied to the ABS ECU in the hydraulic unit assembly is too low Order Item components and probable cause Check or maintenance job 1 Defective battery Recharge or replace the battery Refer to CHECKING AND CHARGING THE BAT TERY on page 8 136 2 Defective coupler betwee...

Page 434: ...disconnecting or connecting a coupler 3 Open or short circuit in the wire har ness between the battery and the hy draulic unit assembly Replace if there is an open or short circuit Between ABS ECU coupler and ABS motor fuse red blue red blue Between ABS ECU coupler and ABS solenoid fuse red red 4 Defective charging system Check the charging system Refer to CHARGING SYSTEM on page 8 15 5 Defective ...

Page 435: ... supply voltage of power supply is low Symptom Power voltage supplied from the ABS ECU to the front wheel sensor is too low Order Item components and probable cause Check or maintenance job 1 Short circuit in the wire harness be tween the front wheel sensor and the hydraulic unit assembly Check that there is no short circuit between the white terminal 1 and the black terminal 2 Check that there is...

Page 436: ...ABS ECU 4 Wheel sensor 3 Defective hydraulic unit assembly Replace the hydraulic unit assembly Refer to ABS ANTI LOCK BRAKE SYSTEM for YP125RA on page 4 62 Fault code No 63 Item Front wheel sensor power supply voltage of power supply is low Symptom Power voltage supplied from the ABS ECU to the front wheel sensor is too low Order Item components and probable cause Check or maintenance job W Gy B W...

Page 437: ...rt circuit between the black white terminal 3 and the white terminal 1 If there is a short circuit the wire harness is de fective Replace the wire harness 4 ABS ECU 5 Wheel sensor 2 Defective rear wheel sensor Check that there is no short circuit between the gray terminal 1 and the white terminal 2 If there is a short circuit the wheel sensor is de fective Repair or replace the wheel sensor 3 ABS ...

Page 438: ... Check the wheel sensors for proper installation Refer to INSTALLING THE FRONT WHEEL FRONT BRAKE DISCS for YP125RA on page 4 25 and INSTALLING THE REAR WHEEL REAR BRAKE DISC on page 4 29 3 Perform brake line routing confirmation If the reaction force is incorrect the brake hoses and brake pipes are not connected correctly Refer to HYDRAULIC UNIT OPERATION TESTS on page 4 65 4 Delete the fault code...

Page 439: ...ABS ANTI LOCK BRAKE SYSTEM for YP125RA 8 126 ...

Page 440: ...ELECTRICAL COMPONENTS 8 127 EAS27970 ELECTRICAL COMPONENTS YP125R 1 2 3 4 5 6 7 8 9 10 11 13 12 14 15 16 17 18 19 20 21 22 24 23 25 26 27 29 30 32 31 28 ...

Page 441: ...ttle position sensor 13 Intake air pressure sensor 14 ISC idle speed control unit 15 Crankshaft position sensor 16 Stator coil 17 Coolant temperature sensor 18 O2 sensor 19 Sidestand switch 20 Rectifier regulator 21 Lean angle sensor 22 Radiator fan motor 23 Horn 24 Diode 2 25 Speed sensor 26 Turn signal hazard relay 27 Radiator fan motor relay 28 Headlight relay 29 Starting circuit cut off relay ...

Page 442: ...ELECTRICAL COMPONENTS 8 129 YP125RA 1 2 3 4 5 6 7 8 9 10 11 12 15 16 17 18 19 20 21 22 24 23 25 26 28 29 30 34 33 31 32 27 13 14 ...

Page 443: ...take air pressure sensor 14 ISC idle speed control unit 15 Crankshaft position sensor 16 Stator coil 17 Coolant temperature sensor 18 O2 sensor 19 Sidestand switch 20 Rectifier regulator 21 Lean angle sensor 22 Radiator fan motor 23 Horn 24 Diode 2 25 Diode 3 26 Turn signal hazard relay 27 Radiator fan motor relay 28 Headlight relay 29 Starting circuit cut off relay 1 30 Starting circuit cut off r...

Page 444: ...ECKING THE SWITCHES 1 2 3 6 Br W Ch Dg P B B B B 12 7 9 8 10 11 4 5 ON R Br L Br R OFF OPEN LOCK P Br R R Br L G Y Br R Y L B B P Dg Y G Br W Ch L B G Y R Y Y Dg Ch Br W G Y Br L W W Y L W Dg W Y Br Br W Ch G Y Br G Y B P W Y W B P W Y W B B ...

Page 445: ... 132 1 Start switch 2 Hazard switch 3 Front brake light switch 4 Trip switch 5 Information switch 6 Main switch 7 Dimmer switch 8 Pass switch 9 Turn signal switch 10 Horn switch 11 Rear brake light switch 12 Sidestand switch ...

Page 446: ...en checking for continuity switch back and forth between the switch positions a few times The switches and their terminal connections are illustrated as in the following example of the main switch The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row The continuity i e a closed circuit between switch terminals at a given switch position is in...

Page 447: ...lbs 1 Remove Bulb WARNING EWA37P1018 Since headlight bulbs get extremely hot keep flammable products and your hands away from them until they have cooled down NOTICE ECA37P1039 Be sure to hold the socket firmly when re moving the bulb Never pull the lead other wise it may be pulled out of the terminal in the coupler Avoid touching the glass part of a headlight bulb to keep it free from oil otherwi...

Page 448: ...he pocket tester indicates replace the fuse 3 Replace Blown fuse a Turn the main switch to OFF b Install a new fuse of the correct amperage rating c Set on the switches to verify if the electrical circuit is operational d If the fuse immediately blows again check the electrical circuit WARNING EWA13310 Never use a fuse with an amperage rating other than that specified Improvising or us ing a fuse ...

Page 449: ...battery are different from those of conventional batteries The VRLA Valve Regulated Lead Acid battery should be charged according to the appropriate charging method If the battery is over charged the electrolyte level will drop con siderably Therefore take special care when charging the battery TIP Since VRLA Valve Regulated Lead Acid bat teries are sealed it is not possible to check the charge st...

Page 450: ...l contact with the battery terminal and that they are not shorted A corroded bat tery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks If the battery becomes hot to the touch at any time during the charging process dis connect the battery charger and let the bat tery cool before reconnecting it Hot batteries can explode As shown in the following illus...

Page 451: ...rior to charging TIP Voltage should be measured 30 minutes after the engine is stopped b Connect a charger and ammeter to the bat tery and start charging c Make sure that the current is higher than the standard charging current written on the bat tery TIP If the current is lower than the standard charging current written on the battery this type of battery charger cannot charge the VRLA Valve Regu...

Page 452: ... for YP125RA Starter relay Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe G Y W Y L W L Y 1 2 3 4 G W L W L G L Y 1 2 3 4 4 Negative tester probe Result Continuity between...

Page 453: ...3 and 4 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 R G R B L G B 1 2 3 4 R Y L B R Y W B 1 2 3 4 1 Positive battery terminal 2 Negative battery terminal 3 Positive tes...

Page 454: ... Replace TIP The pocket tester and the analog pocket tester readings are shown in the following table Turn signal hazard relay output voltage DC 12 V Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe brown white 1 Negative tester probe ground Br R Br R Pocket tester 90890 03112 Analog pocket tester YU 03112 C Continuity Positive tester probe blue white 1 for YP125R bl...

Page 455: ... a Remove the spark plug cap from the spark plug lead b Connect the pocket tester Ω 1k to the spark plug cap as shown c Measure the spark plug cap resistance EAS28090 CHECKING THE IGNITION COIL 1 Check Primary coil resistance Out of specification Replace a Disconnect the ignition coil connectors from the ignition coil terminals b Connect the pocket tester Ω 1 to the igni tion coil as shown Pocket ...

Page 456: ...ition checker 1 as shown c Turn the main switch to ON d Measure the ignition spark gap a e Crank the engine by pushing the start switch and gradually increase the spark gap un til a misfire occurs EAS28120 CHECKING THE CRANKSHAFT POSITION SENSOR 1 Disconnect Crankshaft position sensor coupler from the wire harness 2 Check Crankshaft position sensor resistance Out of specification Replace the crank...

Page 457: ...troubleshooting starting with step 4 Refer to TROUBLESHOOTING on page 8 13 a Connect the positive battery terminal 1 and starter motor lead 2 with a jumper lead 3 WARNING EWA13810 A wire that is used as a jumper lead must have at least the same capacity of the bat tery lead otherwise the jumper lead may burn This check is likely to produce sparks therefore make sure no flammable gas or fluid is in...

Page 458: ...e engine and let it run at approximate ly 5000 r min d Measure the charging voltage EAS28230 CHECKING THE FUEL SENDER 1 Remove Fuel pump from the fuel tank 2 Check Fuel sender resistance Out of specification Replace the fuel send er Stator coil resistance 0 280 0 420 Ω Digital circuit tester 90890 03174 Model 88 Multimeter with ta chometer YU A1927 Positive tester probe white 1 Negative tester pro...

Page 459: ...lack blue With each full rotation of the front wheel the voltage reading should cycle from 0 6 V to 4 8 V to 0 6 V to 4 8 V EAS28250 CHECKING THE RADIATOR FAN MOTOR 1 Check Radiator fan motor Faulty rough movement Replace a Disconnect the radiator fan motor coupler from the wire harness b Connect the battery DC 12 V as shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester...

Page 460: ...emperatures e Measure the coolant temperature sensor re sistances 3 Install Coolant temperature sensor EAS28300 CHECKING THE THROTTLE POSITION SENSOR 1 Check Throttle position sensor a Connect the test harness TPS 5RU 3P 1 to the throttle position sensor and wire har ness as shown b Connect the digital circuit tester DCV to the test harness TPS 5RU 3P c Measure the throttle position sensor voltage...

Page 461: ...ecial care Never subject the intake air temperature sensor to strong shocks If the intake air temperature sensor is dropped replace it 2 Check Intake air temperature sensor resistance Out of specification Replace a Connect the pocket tester Ω 1k to the in take air temperature sensor terminal as shown b Immerse the intake air temperature sensor 1 in a container filled with water 2 TIP Make sure tha...

Page 462: ... water 2 TIP Make sure that the air temperature sensor termi nals do not get wet c Place a thermometer 3 in the water d Heat the water or let it cool down to the spec ified temperatures e Measure the air temperature sensor resis tance EAS1SD1038 CHECKING THE FUEL INJECTOR 1 Check Fuel injector resistance Out of specification Replace the fuel injec tor a Disconnect the fuel injector coupler from wi...

Page 463: ...pler from the ISC unit b Connect the pocket tester Ω 10 to the ter minals of the ISC unit c Measure the ISC unit resistance Out of specification Replace the throttle body Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe pink 1 Negative tester probe light green 2 Positive tester probe green 3 Negative tester probe sky blue 4 Resistance 27 33 Ω Lg P Sb G 1 3 2 4 ...

Page 464: ...ELECTRICAL COMPONENTS 8 151 ...

Page 465: ...INCORRECT ENGINE IDLING SPEED 9 1 POOR MEDIUM AND HIGH SPEED PERFORMANCE 9 2 FAULTY CLUTCH 9 2 OVERHEATING 9 2 OVERCOOLING 9 3 POOR BRAKING PERFORMANCE 9 3 FAULTY FRONT FORK LEGS 9 3 UNSTABLE HANDLING 9 3 FAULTY LIGHTING OR SIGNALING SYSTEM 9 3 SELF DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE 9 5 ...

Page 466: ...hose 2 Fuel pump Faulty fuel pump Clogged fuel pump filter Faulty fuel pump relay for YP125RA 3 Throttle body Deteriorated or contaminated fuel Sucked in air Electrical system 1 Battery Discharged battery Faulty battery 2 Fuse s Blown damaged or incorrect fuse Improperly installed fuse 3 Spark plug Incorrect spark plug gap Incorrect spark plug heat range Fouled spark plug Worn or damaged electrode...

Page 467: ...d loose or worn clutch shoe spring 2 Clutch shoe s Damaged or worn clutch shoe 3 Primary sliding sheave Seized primary sliding sheave Poor starting performance 1 V belt Slipping V belt Oil or grease on the V belt 2 Primary sliding sheave Faulty operation 3 Clutch shoe s Bent damaged or worn clutch shoe Poor speed performance 1 V belt Slipping V belt Oil or grease on the V belt 2 Primary pulley wei...

Page 468: ... damaged outer tube bushing Bent or damaged damper rod Incorrect oil viscosity Incorrect oil level EAS28670 UNSTABLE HANDLING 1 Handlebar Bent or improperly installed handlebar 2 Steering head components Improperly installed lower handlebar holder Improperly installed lower bracket improperly tightened ring nut Bent steering stem Damaged ball bearing or bearing race 3 Front fork leg s Uneven oil l...

Page 469: ...rrect connection Damaged or faulty wire harness Improperly grounded circuit Faulty battery Blown damaged or incorrect fuse Turn signal flashes slowly Faulty turn signal hazard relay Faulty main switch Faulty turn signal switch Incorrect turn signal light bulb Turn signals remain lit Faulty turn signal hazard relay Burnt out turn signal light bulb Turn signal flashes quickly Incorrect turn signal l...

Page 470: ...il 8 57 37 Component other than ISC idle speed control unit is defective ISC operating sound is heard 8 58 Defective ISC idle speed control unit ISC operating sound is not heard 8 59 39 Injector open or short circuit detected 8 61 41 Lean angle sensor open or short circuit detected 8 62 42 for YP125R Speed sensor no normal signals are received from the speed sensor 8 62 42 for YP125RA Front wheel ...

Page 471: ...y 8 71 Er 4 ECU engine control unit internal malfunction input signal error non registered data has been received from the meter 8 72 Diagnostic code No Item Meter display Procedure D01 Throttle position sensor signal Fully closed position 8 22 Check with throttle valve fully closed Fully open position 88 102 Check with throttle valve fully open D03 Intake air pressure Displays the intake air pres...

Page 472: ...a sured battery voltage is low recharge the battery D20 Sidestand switch Extend and retract the sid estand Stand retracted ON Stand extended OFF D60 EEPROM fault code dis play No history 00 No malfunctions detect ed If the self diagnosis fault code 44 is indicat ed the ECU is defec tive History exists 01 Data error for CO ad justment value 03 Data error for immobi lizer code 04 Data error for ISC ...

Page 473: ...cond inter vals Illuminates the engine trouble warning light Check that injector is actu ated five times by listening for the operating sound D51 Radiator fan motor relay Actuates the radiator fan motor relay five times at five second intervals Illu minates the engine trouble warning light Check that the radiator fan motor relay is actuated five times by listening for the operating sound D52 Headl...

Page 474: ...52 Tail brake light 53 Right rear turn signal light 54 Left tail brake light assembly 55 Left rear turn signal light 56 Right front turn signal light 57 Left front turn signal light 58 Headlight assembly 59 Auxiliary light 60 Headlight 61 License plate light 62 Meter assembly 63 Multi function meter 64 Fuel level indicator light 65 Engine trouble warning light 66 Immobilizer system indicator light...

Page 475: ...urn signal switch 59 Horn switch 60 Rear brake light switch 61 Right tail brake light assembly 62 Tail brake light 63 Right rear turn signal light 64 Left tail brake light assembly 65 Left rear turn signal light 66 Right front turn signal light 67 Left front turn signal light 68 Headlight assembly 69 Auxiliary light 70 Headlight 71 License plate light 72 Meter assembly 73 Multi function meter 74 F...

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Page 477: ......

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Page 479: ... L R B R W B B Sb R G R B Lg G B B W Y G Br W R B G P G R B Y L B L Y Y W Ch P W Dg B L G L R B Gy Y L R L Sb B W W W W W W Br B B W B L W R W R W R W W W W B R R L B B B B B B B R B B W Y L R L G L R W B R G Lg R L R B Sb B L Y W P W Ch Dg Y B Y L G L B Br L R B Br Ch Dg B B Y G Ch Br G Y Dg Br G Y B B B B Br G Y B Dg Ch Y G P Br W R Y L B L BW B R YR Y Br W Br R P Br B L R L G B R WR B Y L B W R...

Page 480: ... YP125R 2014 DIAGRAMA ELÉCTRICO ON OFF OPEN LOCK P B B B B B Gy B B L B B B B B G B B B B B 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 ...

Page 481: ... L Y L R W L R B G B B B L B B R B Y L Lg R W R G B R L R B G L Y L B W B B B B B B B B B B B B B R R B B B B B B B R R G Br Br G L Br W W Y W R Sb P B B Gy B Gy B W W W W W R B W B W R L G L G W G Y R L Sb Lg W R B B G W B B W B P B Br R B L R B R L R L Y L R G Y L Y L B B B W R W B R W L R B Y Dg B B B B B B B B Br G Y Br Ch R L Y W Y L B L B G L W R Sb R B B L P W L R B G B B W R W R B R Y Br R...

Page 482: ...DIAGRAMA ELÉCTRICO ON OFF OPEN LOCK P B B B L B B B G B B B B B Gy B B B B B 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 ...

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