Yamaha XT 125R 2005 Operating and installation instructions

IDM C144600300.fm
2005
XT 125R
XT 125X
SERVICE
INFORMATION

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IDM C144600300.fm
WARNING
This Manual has been written by Yamaha Motor and is addressed to Yamaha vendors and their qualified
engineers. This Manual cannot cover any aspect of mechanical knowledge; therefore, anyone who will refer to this
manual is expected to have a basic knowledge of the mechanical skills required for servicing and repairing Yamaha
motorcycles. Repairing performed by unskilled personnel may cause motorcycles to be unserviceable and
dangerous.
Yamaha Motor is constantly searching for enhancing all its motorcycle models. Authorized Yamaha distributors will
be informed of substantial changes and improvements made to specifications or mounting procedures; these ones
will be stated in the following issues of this Manual, when required.
NOTE: The motorcycle model and specifications are subject to changes without prior notice.
IMPORTANT INFORMATION
Particularly important information is highlighted as follows:
The symbol of danger means CAUTION! BEWARE! YOUR SAFETY DEPENDS ON THIS!
The non-observance of WARNINGS can cause serious injury or the death of the
motorcyclist, of the people standing near the motorcycle or the repairer of the motorcycle.
A CAUTION notice implies particular care to be taken not to damage the motorcycle.
A NOTE contains important information for a better comprehension of the described
procedures.
WARNING:
CAUTION:
NOTE:

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GRAPHIC SYMBOLS
Symbols to are drawn as tabs to indicate the
chapter number and its content.
General Information
Technical Specifications
Scheduled Servicing and Adjustment
Engine
Carburetion
Frame
Electrical System
Troubleshooting
Symbols to are used to identify technical
specifications stated in this Manual.
Repairing Possible with Engine in Place
Filling Up
Lubricant
Special Components
Tightening
Wear Limit, Distance
Engine RPM
Ω, V, A (to be measured with a tester)
Symbols to illustrated in the diagram indicate the
types of lubricant to be used and the greasing points.
Use Engine Oil
Use Oil for Spare Parts
Use Molybdenum-Bisulphide Oil
Use Grease for Bearings
Use Grease Made of Light Lithium Soap
Use Molybdenum-Bisulphide Grease
Symbols - illustrated in the diagram indicate where
to apply the high-resistance sealer and where to
install new Component Parts .
Apply High-Resistance Sealer (LOCTITE®)
Use a New Component Part
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INDEX
GENERAL INFORMATION ......................................................................................................6
IDENTIFICATION OF THE MOTORCYCLE .........................................................................6
SPECIAL COMPONENTS ....................................................................................................7
TECHNICAL SPECIFICATIONS ..............................................................................................9
GENERAL FEATURES ........................................................................................................9
SERVICING TECHNICAL DATA ...........................................................................................12
ENGINE ..............................................................................................................................12
LUBRICATION DIAGRAMS ................................................................................................15
ENGINE TIGHTENING TORQUES ....................................................................................17
FRAME ...............................................................................................................................18
FRAME TIGHTENING TORQUES .....................................................................................20
ELECTRICAL SYSTEM ......................................................................................................21
WIRING ...................................................................................................................................24
WIRING (1) .........................................................................................................................24
WIRING (2) ......................................................................................................................... 26
SCHEDULED SERVICING AND ADJUSTMENT ...................................................................28
SCHEDULED MAINTENANCE AND GREASING...............................................................28
WIRING DIAGRAM ................................................................................................................30

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GENERAL INFORMATION
GEN
INFO
GENERAL INFORMATION
IDENTIFICATION OF THE MOTORCYCLE
Serial Number of the Frame
The Serial Number of the frame is
marked on the metal tube of the
handlebar.
NOTE: The Serial Number of the
frame is used for the motorcycle
identification and registration.
Serial Number of the Engine
The Serial Number of the Engine is
marked on the right side of the
crankcase.
NOTE: The first three figures of this
Serial Number identify the
motorcycle model; the remaining
figures indicate the production
number of the unit.
NOTE: Technical specifications and
drawings can be changed without
prior notice.
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GENERAL INFORMATION
GEN
INFO
SPECIAL COMPONENTS
The special components listed below are required for a complete and accurate tuning and assembly of the
motorcycle. The use of proper special instruments prevents damages caused by improper instruments or made-
up techniques.
When ordering a special component, please refer to the list below to avoid any mistake.
Component N. Description Picture
90890-01312 Fuel Indicator
The fuel indicator is used to measure the fuel level in the
carburettor float chamber.
90890-06760 Rev Counter
The rev counter is used to measure the engine RPM.
90890-04086/09 All-purpose Clutch Support
This support is used to lock the clutch when assembling
or disassembling the clutch locking nut.
90890-01701 Pulley Lock
The pulley lock is used to lock the secondary pulley.
90890-01862 Flywheel Puller
This is used to pull out the flywheel.
90890-01304 Pin Puller
The pin puller is used to pull out the piston pin.
90890-01135 Tool for Drive Shaft Remover
This tool is used to remove the drive shaft or to separate
the crankcase.

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GENERAL INFORMATION
GEN
INFO
(*) Indications from Yamaha are required about the compatibility of the components above. If they are not compatible, ID codes and drawings
of new components are required. Otherwise, Yamaha should state which components are to be excluded from this Manual.
90890-01274 (1)
90890-01275 (2)
90890-01278 (3)
Tool for Drive Shaft Installation
Drive Shaft Pin
Adaptor (M12)
(*) 90890-01326 T-tool
The T-tool is used to hold the shock absorber rod when it
is removed or installed.
(*) 90890-01367
(*) 90890-01381
Fork Clamp
Fork Clamp Fitting
The fork clamp fitting is used to install the fork cross.
(*) 90890-01403 Nut Ring Wrench
This wrench is used to loosen and tighten the nut ring of
the handlebar.
90890-03112 Pocket Tester
The pocket tester is required to check the electrical
system.
Component N. Description Picture

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TECHNICAL SPECIFICATIONS SPEC
TECHNICAL SPECIFICATIONS
GENERAL FEATURES
Model XT 125R XT 125X
Dimensions:
Overall Length 2110 mm 2040 mm
Overall Width 860 mm 860 mm
Overall Height 1130 mm 1090 mm
Saddle Height 860 mm 830 mm
Pitch 1340 mm 1340 mm
Min. Distance from the Ground 300 mm 271 mm
Min. Turning Radius 2100 mm 2016 mm
Net Weight:
Oil and Fuel Included 120 kg 120 kg
Engine:
Type of Engine: 4-stroke, air-cooling
Feeding System Carburettor
Cylinder Arrangement Tilted forward, single-cylinder
Displacement 123.7 cm3
Diameter per Stroke 54.0x54.0
Compression Ratio 10:1 ±0.5
Max. Power 7.3 kW / 8500 RPM
Max. Torque 9.5 N*m / 5500 RPM
Min. Speed 1600~1800 RPM
Starting System Electrical and manual starter
Lubrication System Yamaha Autolube
Oil Type or Grade:
Motor Oil YAMALUBE 4, SAE 10W30/SH or equivalent
Total Quantity 1.2 L
Scheduled Oil Change 1.0 L
Air Filter: Humid-element type
Fuel:
Type Unleaded
Fuel Tank:
Capacity 10 L
Low Fuel 2.0 L

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TECHNICAL SPECIFICATIONS SPEC
Carburettor:
Type/Quantity VM20SS
Manufacturer MIKUNI
Spark Plugs:
Type CR7HSA
Manufacturer NGK
Distance between Electrodes 0.6 mm (0.0236 in)
Type of Clutch: Oil-bath, multiple disc
Gear:
Primary Step-down System Worm gear
Primary Step-down Ratio 68/20 (1/3,4)
Secondary Step-down Ratio Drive chain
Secondary Step-down Ratio 50/14 (3.5715) 48/14 (3.4286)
Type of Gear Continuous gear, 5-speed
Operation Left foot
Drive Ratio:
First Gear 14/37 (2.64)
Second Gear 18/32 (1.78)
Third Gear 19/25 (1.32)
Fourth Gear 22/23 (1.05)
Fifth Gear 24/21 (0.88)
Frame:
Type of Frame Semi double cradle Semi double cradle
Front Axle Angle 28° 26.7°
Angle Base 114.4 mm 78.33 mm
Tyres:
Type With inner tube With inner tube
Front 90/90-21 54S 100/80-17 52S
Rear 120/80-18 62S 130/70-17 62S
Pressure with Cold Wheels:
Front 0~90kg 1.8 bars (26.1 psi)
Rear 0~90kg 1.9 bars (27.6 psi)
Front 90~178kg 2.0 bars (29.0 psi)
Rear 90~178kg 2.1 bars (30.5 psi)
Model XT 125R XT 125X