Yamaha WR125R 2009 User manual

2009
SERVICE MANUAL
WR125R
WR125X
22B-F8197-E0

EAS20060
WR125R/WR125X 2009
SERVICE MANUAL
©2008 by MBK Industrie
First edition, December 2008
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
MBK Industrie
is expressly prohibited.

EAS20071
IMPORTANT
This manual was produced by MBK Industrie primarily for use by Yamaha dealers and their qualified
mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, any-
one who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic
understanding of mechanics and the techniques to repair these types of vehicles. Repair and mainte-
nance work attempted by anyone without this knowledge is likely to render the vehicle unsafe and unfit
for use.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and sig-
nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and
will appear in future editions of this manual where applicable.
T
IP
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 alert symbol. It is used to alert you to potential person-
al injury hazards. Obey all safety messages that follow this symbol to
avoid possible injury or death.
A WARNING indicates a hazardous situation which, if not avoided, could
result in death or serious injury.
A NOTICE indicates special precautions that must be taken to avoid
damage to the vehicle or other property.
A TIP provides key information to make procedures easier or clearer.
WARNING
NOTICE
TIP

EAS20090
HOW TO USE THIS MANUAL
This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive
explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid
out with the individual steps in sequential order.
• The manual is divided into chapters and each chapter is divided into sections. The current section title
“1” is shown at the top of each page.
• Sub-section titles “2” appear in smaller print than the section title.
• To help identify parts and clarify procedure steps, there are exploded diagrams “3” at the start of each
removal and disassembly section.
• Numbers “4” are given in the order of the jobs in the exploded diagram. A number indicates a disas-
sembly step.
• Symbols “5” indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.
• A job instruction chart “6” accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc.
• Jobs “7” requiring more information (such as special tools and technical data) are described sequen-
tially.
12
7
3
5
4
6

EAS20100
SYMBOLS
The following symbols are used in this manual
for easier understanding.
T
IP
The following symbols are not relevant to every
vehicle.
G
M
E
BLS
M
910
11 12
13 14
15 16
17 18
LT New
BF
S
T
R
.
.
123
456
78
1. Serviceable with engine mounted
2. Filling fluid
3. Lubricant
4. Special tool
5. Tightening torque
6. Wear limit, clearance
7. Engine speed
8. Electrical data
9. Engine oil
10.Gear oil
11. Molybdenum disulfide oil
12. Brake fluid
13.Wheel bearing grease
14. Lithium-soap-based grease
15. Molybdenum disulfide grease
16.Silicone grease
17. Locking agent (LOCTITE®)
18. Replace the part with a new one.

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

1
GENERAL INFORMATION
IDENTIFICATION ............................................................................................1-1
VEHICLE IDENTIFICATION NUMBER .....................................................1-1
MODEL LABEL..........................................................................................1-1
FEATURES......................................................................................................1-2
OUTLINE OF THE FI SYSTEM................................................................. 1-2
FI SYSTEM................................................................................................1-3
INSTRUMENT FUNCTIONS .....................................................................1-4
IMPORTANT INFORMATION .........................................................................1-6
PREPARATION FOR REMOVAL AND DISASSEMBLY........................... 1-6
REPLACEMENT PARTS...........................................................................1-6
GASKETS, OIL SEALS AND O-RINGS ....................................................1-6
LOCK WASHERS/PLATES AND COTTER PINS .....................................1-6
BEARINGS AND OIL SEALS ....................................................................1-7
CIRCLIPS ..................................................................................................1-7
CHECKING THE CONNECTIONS ..................................................................1-8
SPECIAL TOOLS ............................................................................................1-9

IDENTIFICATION
1-1
EAS20130
IDENTIFICATION
EAS20140
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number “1”is stamped
into the right side of the steering head pipe.
EAS20150
MODEL LABEL
The model label “1”is affixed to the frame under
the seat. This information will be needed to order
spare parts.
1
1