Yamaha YP125E 2003 Operating and installation instructions

SERVICE
INFORMATION
YP180E
YP125E
2003
5XL1-SE1

YP125E’03
YP180E’03
SERVICE INFORMATION
© 2002 by Yamaha Motor España, S.A.
1st Edition, November 2002.
All rights reserved. Any reprinting or
unauthorized use without the written
permission of Yamaha Motor España, S.A.
is expressly prohibited.
EB000000

EB001000
NOTICE
This manual was produced by the Yamaha Motor España, S.A., primarily for use by Yamaha/MBK
dealers and their qualified mechanics. It is not possible to include all the knowledge of a mecha-
nic in one manual, so it is assumed that anyone who uses this book to perform maintenance and
repairs on Yamaha/MBK scooter has a basic understanding of the mechanical ideas and the pro-
cedures of scooter repair. Repairs attempted by anyone without this knowledge are likely to render
the scooter unsafe and unfit for use.
Yamaha Motor España, S.A., is continually striving to improve all its models. Modifications and sig-
nificant changes in specifications or procedures will be forwarded to all authorized Yamaha/MBK
dealers and will appear in future editions of this manual where applicable.
NOTE:
Designs and specifications are subject to change without notice.
IMPORTANT INFORMATION
Particularly important information is distinguished in this manual by the following notations.
tThe Safety Alert Symbol means TTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
ssWARNING Failure to follow WARNING instructions could result in severe injury or
death to the scooter operator, a bystander or a person inspecting or
repairing the scooter.
CAUTION: A CAUTION indicates special precautions that must be taken to avoid
damage to the scooter.
NOTE: A NOTE provides key information to make procedures easier or
clearer.

EB003000
ILLUSTRATED SYMBOLS
Illustrated symbols to are designed as
thumb tabs to indicate the chapeter’s number
and content.
 General information
 Specifications
 Periodic checks and adjustments
 Engine
 Cooling system
 Carburetion
 Chassis
 Electrical
 Troubleshooting
Illustrate symbols 10 to 17 are used to iden-
tify the specifications appearing in the text.
10 Possible to maintain with engine mounted
11 Filling fluid
12 Lubricant
13 Special tool
14 Tightening
15 Wear limit, clearance
16 Engine speed
17 Ω, V, A
Illustrated symbols 18 to 23 in the exploded
diagram indicate the types of lubricants and
lubrication points.
18 Apply engine oil
19 Apply gear oil
20 Aply molybdenium disulfide oil
21 Apply wheel bearing grease
22 Apply lightweight lithium-soap grease
23 Apply molybdenium disulfide grease
Illustrated symbols 24 to 25 in the exploded
diagram indicate the where to apply locking
agent 24 and where to install new parts 25 .
24 Apply locking agent (LOCTITE®)
25 Use new one
INSP
ADJ
COOL
CHAS
SPEC
ENG
CARB
ELEC
GEN
INFO





11
13
18
21




10
12
14
23
19
22
TRBL
SHTG
24 25
15 16 17
20
New

CONTENTS
GENERAL INFORMATION
SCOOTER IDENTIFICATION
FRAME SERIAL NUMBER......................................................................................................1
ENGINE SERIAL NUMBER.....................................................................................................1
MODEL LABEL .......................................................................................................................1
IMPORTANT INFORMATION.....................................................................................................2
PREPARATION FOR REMOVAL PROCEDURES....................................................................2
REPLACEMENT PARTS..........................................................................................................2
GASKETS, OIL SEALS, AND O-RINGS..................................................................................2
LOCK WASHERS/PLATES AND COTTER PINS ....................................................................3
BEARINGS AND OIL SEALS ..................................................................................................3
CIRCLIPS................................................................................................................................3
CHECKING OF CONNECTIONS ............................................................................................4
HOW TO USE THE CONVERSION TABLE.............................................................................5
SPECIAL TOOLS........................................................................................................................6
SPECIFICATIONS
GENERAL SPECIFICATIONS ....................................................................................................9
MAINTENANCE SPECIFICATIONS.........................................................................................12
ENGINE.................................................................................................................................12
LUBRICATION DIAGRAM .....................................................................................................15
TIGHTENING TORQUES (ENGINE) ......................................................................................17
CHASSIS...............................................................................................................................29
TIGHTENING TORQUES (CHASSIS)....................................................................................20
ELECTRICAL.........................................................................................................................21
GENERAL TORQUE SPECIFICATIONS..................................................................................23
CABLE ROUTING.....................................................................................................................24
PERIODIC INSPECTIONS AND ADJUSTMENTS
PERIODIC MAINTENANCE/LUBRICATION INTERVALS ......................................................27
WIRING DIAGRAM..................................................................................................................29

1
YP100000
GENERAL INFORMATION
SCOOTER IDENTIFICATION
YP100010
FRAME SERIAL NUMBER
The identification number is stamped onto the
frame.
YP100020
ENGINE SERIAL NUMBER
The engine serial number is stamped onto the
right side of the crankcase.
NOTE:
Design and specifications may change without
notice.
MODEL LABEL
The model reference label is affixed under the
seat. This information will be needed to order
sparre parts.
SCOOTER IDENTIFICATION
2
1
GEN
INFO


2
EB101000
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL
PROCEDURES
1. Remove all dirt, mud, dust and foreign mate-
rial before removal and disassembly.
2. Use proper tools and cleaning equipment.
3. Refer to the “SPECIAL TOOLS” section.
4. When disassembling the machine, always
keep mated parts together. This includes
gears, cylinders, pistons and other parts that
have been “mated” through normal wear.
Mated parts must always be reused or repla-
ced as an assembly.
5. During machine disassembly, clean all parts
and place them in trays in the order o disas-
sembly. This will speed up assembly and
allow for the correct installation of all parts.
6. Keep all parts away from any source of fire.
EB101010
REPLACEMENT PARTS
1. Use only genuine Yamaha parts for all repla-
cements. Use oil and grease recommended
by Yamaha for all lubrication jobs. Other
brands may be similar in function and appea-
rance, but inferior in quality.
EB101020
GASKETS, OIL SEALS AND O-RINGS
1. Replace all gaskets, seals and O-rings when
overhauling the engine. All gasket surfaces, oil
seal lips and O-rings must be cleaned.
2. Properly oil all mating parts and bearings
during reassembly. Apply grease to the oil
seal lips.
IMPORTANT INFORMATION GEN
INFO

3
EB101030
LOCK WASHERS/PLATES AND COTTER PINS
1. Replace all lock washers/plates and cotter
pins after removal. Bend lock tabs along the
bolt or nut flats after the bolt or nut has been
tightened to specification.
EB101040
BEARINGS AND OIL SEALS
Install bearings and oil seals so that the manu-
facturer’s marks or numbers are visible. When
installing oil seals, apply a light coating of light-
weight lithium base grease to the seal lips. Oil
bearings liberally when installing, if appropriate.
Oil seal
CAUTION:
Do not use compressed air to spin the bea-
rings dry. This will damage the bearing surfa-
ces.
Bearing
EB101050
CIRCLIPS
1. Check all circlips carefully before reassembly.
Always replace piston pin clips after one use.
Replace distorted circlips. When installing a
circlip , make sure that the sharp-edged
corner is positioned opposite the thurst 
it receives. See sectional view.
Shaft
IMPORTANT INFORMATION GEN
INFO

4
EB801000
CHECKING OF CONNECTIONS
Dealing with stains, rust, moisture, etc. on the
connector.
1. Disconnect:
• Connector
2. Dry each terminal with an air blower.
3. Connect and disconnect the connector two or
three times.
4. Pull the lead to check that it will not come off.
5. If the terminal comes off, bend up the pin 
and reinsert the terminal into the connector.
6. Connect:
• Connector
NOTE:
The two connectors “click” together.
7. Check for continuity with a tester.
NOTE:
• If there is no continuity, clean the terminals.
• Be sure to perform the steps 1 to 7 listed
above when checking the wireharness.
• For a field remedy, use a contact revitalizer
available on the market.
• Use the tester on the connector as shown.
IMPORTANT INFORMATION GEN
INFO

5
EB201000
HOW TO USE THE CONVERSION TABLE
All specification data in this manual are listed in SI and METRIC UNITS.
Use this table to convert METRIC unit data to IMPERIAL unit data.
EX.
METRIC MULTIPLIER IMP
** mm x 0,03937 = **in
2 mm x 0,03937 = 0,08 in
TABLA DE CONVERSIÓN
METRIQUES EN ANGLAISES
Connu Multiplicateur Résultat
m•kg 7,233 ft•lb
Torque m•kg 86,794 in•lb
cm•kg 0,0723 ft•lb
cm•kg 0,8679 in•lb
Weight kg 2,205 lb
g 0,03527 oz
km/h 0,6214 mph
km 0,6214 mi
Distance m 3,281 ft
m 1,094 yd
cm 0,3937 in
mm 0,03937 in
cc (cm3) 0,03527 oz (IMP liq.)
Volume/ cc (cm3) 0,06102 cu•in
Capacity lit (litre) 0,08799 qt (IMP liq.)
lit (litre) 0,2199 gal (IMP liq.)
kg/mm 55,997 lb/in
Micescellaneous kg/cm214,2234 psi (lb/in2)
Centígrade 9/5 (°C) + 32 Fahrenheit (ºF)
IMPORTANT INFORMATION GEN
INFO