Yamaha YZ125(V) Instruction Manual

1E1C3-100E1
2E1C3-100E1
()
YZ125V (1C35) U.S.A.,CANADA
YZ125 (1C36) EUROPE
YZ125 (1C37) JAPAN
YZ125V (1C38) OCEANIA
YZ125 (1C38) SOUTH AFRICA
2005-12-19NEWS NO. DATE COMMENT
PE0-MC-050191 Nov.,1,2005 COR:YZ125/V(1C35/6/7/8) FRONT FORK/LIST/ILLUSTRATION CORRECTION

A3
YZ125V/YZ125
PA RT S C ATA L O G U E
©2005 by Yamaha Motor Co., Ltd.
1st edition, June 2005
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Japan.

A4

A5
FOREWORD
This Parts Catalogue is related to the parts for the model(s) on the cover page. When you are
ordering replacement parts, please refer to this Parts Catalogue and quote both part numbers
and part names correctly.
1. Modifications or additions which have been made after the issue of the Parts Catalogue
will be announced in the Parts News.
It is advisable that you make the necessary corrections to the Parts Catalogue according
to the Parts News.
2. Abbreviations
The following abbreviations are used in this Parts Catalogue.
“UR” Use specified parts number.
“UN” Use as many as needed.
“AP” Alternate Parts
“LM” Locally Made (Parts need to be ordered locally)
“F#” Frame No. (Applicable machine No.)
“O/S” Over Size
3. The number of components for assembly
• Parts, which are to be supplied in an assembly, are listed with a dot (.) in front of the
part name as shown below.
• The numeral appearing to the right of each component part indicates the quantity of
parts for each assembly unit.
4. Applicable colours of graphics are represented in the “REMARKS” as shown below.
5. Note that the illustrations for reference in finding parts numbers are not to be used for
assembling. When assembling, please use the applicable service manual.
6. The asterisk (*) before a reference number indicates modified items after the first edition.
PART NO. DESCRIPTION Q’TY REMARKS
2F5–83310–60 FRONT FLASHER LIGHT ASSY 2
115–83311–60 .BULB (6V–18W) 1
PART NO. DESCRIPTION Q’TY REMARKS
2N4–24110–00–X5 FUEL TANK COMP. 2 MXR
3J1–24240–10 .GRAPHIC, FUEL TANK 1 FOR MXR

A6
FOREWORD
7. Applicable Serial No.
Engine Serial No. Frame Serial No.
8. Applicable Colour Code (The (*) mark shows Model colour.)
Abbreviation Colour Name Colour Code
DPBSE(*) DEEP PURPLISH BLUE SOLID E 0583

A7
MODEL LABEL
(1) A label called “Model Label” is affixed in the location as indicated in (3) below.
When using this parts catalogue, please be sure to cross–reference the “model code –
production code No.” in the catalogue with the “model code – production code No.” indi-
cated on the Model Label affixed onto the product concerned.
(2) “Model Label” Indication
(3) Model Label Affixing Location
(4) Colouring Information
Model Code Colouring
Type Code
Colour
Code Colour Name Abbrevia-
tion
1C35 A 0583 DEEP PURPLISH BLUE SOLID E DPBSE
1C36
A 0583 DEEP PURPLISH BLUE SOLID E DPBSE
1C37
A 0583 DEEP PURPLISH BLUE SOLID E DPBSE
1C38
A 0583 DEEP PURPLISH BLUE SOLID E DPBSE
(5) Model Code – Production Code Number of Model Listed in This Parts Catalogue
Model
Code
Production
Code No.
Country
(destination)
1C35 010 U.S.A.
020 CANADA
1C36 010 EUROPE
1C37 010 JAPAN
1C38 010 AUSTRALIA
NEW ZEALAND
030 SOUTH AFRICA
Model
Code
Production
Code No.
Country
(destination)

CONTENTS
ENGINE
CYLINDER HEAD ................................................................. B2
GOVERNOR ......................................................................... B4
CRANKSHAFT & PISTON .................................................... B5
WATER PUMP ...................................................................... B6
RADIATOR & HOSE ............................................................. B7
INTAKE ................................................................................. B8
CARBURETOR ..................................................................... B9
EXHAUST ............................................................................. B12
CRANKCASE ........................................................................ B14
CRANKCASE COVER 1 ....................................................... B15
STARTER .............................................................................. C2
CLUTCH ................................................................................ C3
TRANSMISSION ................................................................... C4
SHIFT CAM & FORK .............................................................C6
SHIFT SHAFT ....................................................................... C7
CHASSIS
FRAME .................................................................................. C8
FENDER ................................................................................ C10
SIDE COVER ........................................................................ C12
REAR ARM ........................................................................... C13
REAR SUSPENSION ............................................................ C15
STEERING ............................................................................ D3
FRONT FORK ....................................................................... D4
FUEL TANK ........................................................................... D7
SEAT ..................................................................................... D9
FRONT WHEEL .................................................................... D10
FRONT BRAKE CALIPER .................................................... D11
REAR WHEEL ....................................................................... D12
REAR BRAKE CALIPER ....................................................... D14
STEERING HANDLE & CABLE ............................................D15
FRONT MASTER CYLINDER ............................................... E2
STAND & FOOTREST .......................................................... E3
REAR MASTER CYLINDER .................................................E4
GENERATOR ........................................................................ E5
HANDLE SWITCH & LEVER ................................................E6
ELECTRICAL 1 ..................................................................... E7
ALTERNATE FOR CHASSIS ................................................ E8
OPTIONAL PARTS 1 ............................................................E9
INDEX
NUMERICAL INDEX ............................................................. M1

B2
FIG. 1 CYLINDER HEAD
REF.
NO. PART NO. DESCRIPTION
1C35 1C36 1C37 1C38
REMARKS
1 1C3–11111–10 HEAD, CYLINDER 1 1 1 1 1
2
90116–08394 BOLT, STUD 5 5 5 5
3
90176–08026 NUT, CROWN 5 5 5 5
4
90201–080L8 WASHER, PLATE 5 5 5 5
5
93210–63442 O-RING 1 1 1 1
6
93210–90785 O-RING 1 1 1 1
7
1C3–11311–01 CYLINDER 1 1 1 1 1
8
1C3–11351–00 GASKET, CYLINDER 1 1 1 1
9
90116–08318 BOLT, STUD 2 2 2 2
10
90116–08388 BOLT, STUD 2 2 2 2
11
99590–10114 PIN, DOWEL 2 2 2 2
12
90179–08299 NUT 4444
13
94702–00193 PLUG, SPARK (NGK BR9EVX) 1 1 1
94709–00193 PLUG, SPARK (NGK BR-9EVX) 1
14
1C3–1131D–00 VALVEASSY 1111
15
1C3–1132D–00 VALVE ASSY 2 1 1 1 1
16
91317–05012 BOLT 4444
17
5HD–1131V–00 SHAFT 1 1 1 1 1
18
4SS–11832–00 LEVER,LINK 1111
19
91317–04010 BOLT 1111
20
5UN–11395–00 HOLDER 1111
21
93104–08040 OIL SEAL 1 1 1 1
22
4SS–1131M–01 COVER 1 1 1 1
23
4JY–11166–00 PIPE, BREATHER 1 1 1 1 1
24
90467–13062 CLIP 1111
25
1C3–11354–00 GASKET 1 1 1 1
26
98907–05016 SCREW, BIND 4 4 4 4

B3
FIG. 1 CYLINDER HEAD
REF.
NO. PART NO. DESCRIPTION
1C35 1C36 1C37 1C38
REMARKS
27 90508–16134 SPRING, TORSION 2 2 2 2
28
90387–08785 COLLAR 2222
29
1C3–11992–00 HOUSING 2 1 1 1 1
30
1C3–11993–00 GASKET 1 1 1 1
31
97007–05016 BOLT 3333
32
92907–05600 WASHER, PLATE 3 3 3 3
33
1C3–11995–00 SEAL, HOUSING 1 1 1 1

B4
FIG. 2 GOVERNOR
REF.
NO. PART NO. DESCRIPTION
1C35 1C36 1C37 1C38
REMARKS
1 4JY–11915–10 PLATE, THRUST 1 1 1 1 1
2
98502–05012 SCREW, PAN HEAD 1 1 1 1
3
1C3–11990–10 PUSH ROD ASSY 1 1 1 1
4
90387–085E1 COLLAR 1111
5
90201–057H5 WASHER, PLATE 1 1 1 1
6
97007–05012 BOLT 1111
7
93104–08040 OIL SEAL 1 1 1 1
8
3JE–11922–01 FORK, GOVERNOR 1 1 1 1
9
91317–04006 BOLT 2222
10
93300–60801 BEARING 2 2 2 2 KOYO
11
5X4–11921–02 SHAFT, GOVERNOR 1 1 1 1
12
5NY–11953–00 GEAR, GOVERNOR 1 1 1 1
13
90501–300A0 SPRING, COMPRESSION 1 1 1 1
14
5CU–11952–00 PLATE 1 1 1 1
15
90201–150U6 WASHER, PLATE 3 3 3 3
16
90387–152F2 COLLAR 1111
17
93340–21505 BEARING 2 2 2 2
18
5CU–11912–00 RETAINER, WEIGHT 1 1 1 1
19
5CU–11911–00 RETAINER 1111
20
93507–16020 BALL 4444
21
93603–14240 PIN, DOWEL 1 1 1 1
22
90387–107T9 COLLAR 1111 AP

B5
FIG. 3 CRANKSHAFT & PISTON
REF.
NO. PART NO. DESCRIPTION
1C35 1C36 1C37 1C38
REMARKS
1 1C3–11400–00 CRANKSHAFT ASSY 1 1 1 1
2
1C3–11410–00 .CRANKSHAFT 1 1 1 1
3
1C3–11420–00 .CRANKSHAFT 1 1 1 1
4
1C3–11651–00 .ROD, CONNECTING 1 1 1 1
5
3JD–11681–10 .PIN, CRANK 1 1 1 1 1
6
90209–22326 .WASHER 2 2 2 2
7
93310–52238 .BEARING 1111
8
1C3–11631–01–A0 PISTON (STD) 1 1 1 1 UR RED
1C3–11631–01–B0 PISTON (STD) 1 1 1 1 UR ORANGE
1C3–11631–01–C0 PISTON (STD) 1 1 1 1 UR GREEN
1C3–11631–01–D0 PISTON (STD) 1 1 1 1 UR PURPLE
9
5NY–11611–00 RING, PISTON 1 1 1 1
10
1C3–11633–00 PIN, PISTON 1 1 1 1
11
93450–16068 CIRCLIP 2 2 2 2
12
93310–21510 BEARING 1 1 1 1
13
93306–37204 BEARING 2 2 2 2 KOYO
14
93102–20485 OIL SEAL 1 1 1 1
15
93102–22419 OIL SEAL 1 1 1 1
16
90280–03017 KEY,WOODRUFF 1111

B6
FIG. 4 WATER PUMP
REF.
NO. PART NO. DESCRIPTION
1C35 1C36 1C37 1C38
REMARKS
1 1C3–12450–00 IMPELLER SHAFT ASSY 1 1 1 1
2
1C3–12453–10 GEAR 1111
3
93603–12007 PIN, DOWEL 1 1 1 1
4
90201–08512 WASHER, PLATE 2 2 2 2
5
90387–08032 COLLAR 1111
6
93440–07182 CIRCLIP 1 1 1 1
7
93102–08004 OIL SEAL 1 1 1 1
8
93102–08307 OIL SEAL 1 1 1 1
9
93300–60801 BEARING 1 1 1 1 UR KOYO
93300–60814 BEARING 1 1 1 1 UR NMB
10
1C3–12422–00 COVER, HOUSING 1 1 1 1
11
90430–06014 GASKET 1 1 1 1
12
95027–06010 BOLT, FLANGE 1 1 1 1
13
1C3–12428–00 GASKET, HOUSING COVER 2 1 1 1 1
14
93604–10011 PIN, DOWEL 2 2 2 2
15
95027–06065 BOLT, FLANGE 1 1 1 1
16
95027–06025 BOLT, FLANGE 3 3 3 3

B7
FIG. 5 RADIATOR & HOSE
REF.
NO. PART NO. DESCRIPTION
1C35 1C36 1C37 1C38
REMARKS
1 1C3–1240A–00 RADIATOR ASSY 1 1 1 1
2
1C3–12465–00 DAMPER, RADIATOR 1 1 1 1
3
91A20–05065 TUBE, FLEXIBLE VINYL 1 1 1 1
4
90467–090A2 CLIP 1111
5
1C3–12461–00 RADIATOR ASSY 1 1 1 1
6
22W–12462–00 CAP, RADIATOR 1 1 1 1
7
1C3–12465–00 DAMPER, RADIATOR 1 1 1 1
8
1C3–12481–00 PIPE 1 1 1 1 1
9
1C3–12482–00 PIPE 2 1 1 1 1
10
1C3–12483–00 PIPE 3 1 1 1 1
11
1C3–12484–00 PIPE 4 1 1 1 1
12
90450–28001 HOSE CLAMP ASSY 2 2 2 2
13
90450–22001 HOSE CLAMP ASSY 4 4 4 4
14
90450–25001 HOSE CLAMP ASSY 2 2 2 2
15
90480–15528 GROMMET 6 6 6 6
16
90387–06065 COLLAR 6666
17
95027–06030 BOLT, FLANGE 6 6 6 6
18
90201–06571 WASHER, PLATE 6 6 6 6
19
95822–06010 BOLT, FLANGE 2 2 2 2

B8
FIG. 6 INTAKE
REF.
NO. PART NO. DESCRIPTION
1C35 1C36 1C37 1C38
REMARKS
1 1C3–13610–00 REED VALVE ASSY 1 1 1 1
2
5UN–13613–00 .REED, VALVE 2 2 2 2
3
5MV–13616–00 .STOPPER, REED VALVE 2 2 2 2
4
98507–03006 .SCREW, PAN HEAD 6 6 6 6
5
92907–03100 .WASHER, SPRING 6 6 6 6
6
1C3–13625–00 .SPACER, REED VALVE 1 1 1 1
7
1C3–13565–00 JOINT, CARBURETOR 1 1 1 1
8
95027–06020 BOLT, FLANGE 4 4 4 4
9
90450–54004 HOSE CLAMP ASSY 1 1 1 1
10
90450–70001 HOSE CLAMP ASSY 1 1 1 1
11
5NY–14401–01 AIR CLEANER CASE ASSY 1 1 1 1
12
1C3–14453–10 JOINT, AIR CLEANER 1 1 1 1 1
13
5NY–14459–00 HOLDER, GUIDE 1 1 1 1
14
5NY–14455–10 BAND 1111
15
5NY–14442–00 SPACER 1111
16
5NY–14417–00 COVER 1 1 1 1 1
17
90267–32070 RIVET, BLIND 3 3 3 3
18
90201–03313 WASHER, PLATE 6 6 6 6
19
4XM–14451–00 ELEMENT, AIR CLEANER 1 1 1 1
20
90209–06096 WASHER 1 1 1 1
21
90122–06005 BOLT,WING 1111
22
3JD–14458–01 GUIDE 1 1 1 1
23
90183–06023 NUT, SPRING 4 4 4 4
24
90109–067F4 BOLT 4444

B9
FIG. 7 CARBURETOR
REF.
NO. PART NO. DESCRIPTION
1C35 1C36 1C37 1C38
REMARKS
1 1C3–14101–30 CARBURETOR ASSY 1 1
1C3–14101–40 CARBURETOR ASSY 1 1
1C3–14101–50 CARBURETOR ASSY 1 1 1
2
5HD–14261–00 .HOLDER 1 1 1 1
3
4PE–14194–00 .RING 1 1 1 1
4
3MA–14159–00 .CLIP 1 1 1 1
5
3JE–14171–00 .PLUNGER, STARTER 1 1 1 1
6
5UN–14104–00 .AIR SCREW SET 1 1 1 1
7
1FN–14565–00 .SCREW 1 1 1 1
8
5ET–14261–01 .HOLDER 1 1 1 1
9
98507–04008 .SCREW, PAN HEAD 1 1 1 1
10
353–14186–00 .PIN, FLOAT 1 1 1 1
11
4PE–14107–38 .NEEDLE VALVE SET 1 1 1 1
12
98507–04014 .SCREW, PAN HEAD 2 2 2 2
13
4PE–14131–00 .SPRING, THROTTLE VALVE 1 1 1 1
14
4PE–14103–00 .THROTTLE SCREW SET 1 1 1 1
15
5ET–14197–00 .PIPE 2 2 2 2
16
10V–14196–00 .PIPE 1 1 1 1
17
5ET–14185–00 .FLOAT 1111
18
2K6–14147–00 .O-RING 1 1 1 1
19
5ET–14115–00 .PLUG, SCREW 1 1 1 1
20
284–14116–H4 .NEEDLE (6BFY42-74) 1 STD
284–14116–J4 .NEEDLE (6BFY43-74) 1 1 1 STD
284–14116–H2 .NEEDLE (6BFY42-72) 1 1 1 1 AP
284–14116–H3 .NEEDLE (6BFY42-73) 1 1 1 1 AP
284–14116–H4 .NEEDLE (6BFY42-74) 1 1 1 AP
284–14116–H5 .NEEDLE (6BFY42-75) 1 1 1 1 AP

B10
FIG. 7 CARBURETOR
REF.
NO. PART NO. DESCRIPTION
1C35 1C36 1C37 1C38
REMARKS
20 284–14116–H6 .NEEDLE (6BFY42-76) 1 1 1 1 AP
284–14116–J2 .NEEDLE (6BFY43-72) 1 1 1 1 AP
284–14116–J3 .NEEDLE (6BFY43-73) 1 1 1 1 AP
284–14116–J4 .NEEDLE (6BFY43-74) 1 AP
284–14116–J5 .NEEDLE (6BFY43-75) 1 1 1 1 AP
284–14116–J6 .NEEDLE (6BFY43-76) 1 1 1 1 AP
284–14116–K2 .NEEDLE (6BFY44-72) 1 1 1 1 AP
284–14116–K3 .NEEDLE (6BFY44-73) 1 1 1 1 AP
284–14116–K4 .NEEDLE (6BFY44-74) 1 1 1 1 AP
284–14116–K5 .NEEDLE (6BFY44-75) 1 1 1 1 AP
284–14116–K6 .NEEDLE (6BFY44-76) 1 1 1 1 AP
21
4KM–14142–40 .JET, PILOT (# 40) 1 1 1 STD
4KM–14142–45 .JET, PILOT (# 45) 1 STD
4KM–14142–30 .JET, PILOT (# 30) 1 1 1 1 AP
4KM–14142–32 .JET, PILOT (# 32.5) 1 1 1 1 AP
4KM–14142–35 .JET, PILOT (# 35) 1 1 1 1 AP
4KM–14142–37 .JET, PILOT (# 37.5) 1 1 1 1 AP
4KM–14142–40 .JET, PILOT (# 40) 1 AP
4KM–14142–42 .JET, PILOT (# 42.5) 1 1 1 1 AP
4KM–14142–45 .JET, PILOT (# 45) 1 1 1 AP
4KM–14142–47 .JET, PILOT (# 47.5) 1 1 1 1 AP
4KM–14142–50 .JET, PILOT (# 50) 1 1 1 1 AP
22
137–14143–82 .JET, MAIN (#410) 1 STD
137–14143–86 .JET, MAIN (#430) 1 1 1 STD
137–14143–80 .JET, MAIN (#400) 1 1 1 1 AP
137–14143–82 .JET, MAIN (#410) 1 1 1 AP
137–14143–84 .JET, MAIN (#420) 1 1 1 1 AP

B11
FIG. 7 CARBURETOR
REF.
NO. PART NO. DESCRIPTION
1C35 1C36 1C37 1C38
REMARKS
22 137–14143–86 .JET, MAIN (#430) 1 AP
137–14143–88 .JET, MAIN (#440) 1 1 1 1 AP
137–14143–90 .JET, MAIN (#450) 1 1 1 1 AP
137–14143–92 .JET, MAIN (#460) 1 1 1 1 AP
137–14143–94 .JET, MAIN (#470) 1 1 1 1 AP
23
1C3–14112–40 .VALVE, THROTTLE 1 (4.0) 1 1 1 1 STD
1C3–14112–42 .VALVE, THROTTLE 1 (4.25) 1 1 1 1 AP
24
5ET–1416A–00 .O-RING 1 1 1 1
25
5ET–14147–00 .O-RING 1 1 1 1
26
51R–14146–00 .PLATE 2222
27
98502–05014 .SCREW, PAN HEAD 3 3 3 3
28
2HH–14197–00 .PIPE 2 2 2 2
29
87M–14137–00 .CLIP 3 3 3 3
30
5MV–14194–00 .RING 1 1 1 1
31
5MV–24514–00 .NET, FILTER 1 1 1 1 1
32
5MV–14146–00 .PLATE 1111
33
5MV–14216–00 .SCREW 1 1 1 1
34
5MV–14261–00 .HOLDER 1 1 1 1
35
5NY–14181–00 .BODY, FLOAT CHAMBER 1 1 1 1 1

B12
FIG. 8 EXHAUST
REF.
NO. PART NO. DESCRIPTION
1C35 1C36 1C37 1C38
REMARKS
1 1C3–14610–00 EXHAUST PIPE ASSY 1 1 1 1 1
2
5MV–14642–00 SEAL, EXHAUST 2 2 2 2
3
90506–20018 SPRING, TENSION 2 2 2 2
4
565–14771–00 STAY, MUFFLER 1 1 1 1 1
5
95022–06012 BOLT, FLANGE 1 1 1 1
6
1C3–14763–00 SPACER 1111
7
90201–06077 WASHER, PLATE 1 1 1 1
8
95022–06025 BOLT, FLANGE 1 1 1 1
9
5CU–14771–01 STAY, MUFFLER 1 1 1 1 1
10
90480–16561 GROMMET 1 1 1 1
11
90387–063G3 COLLAR 1111
12
95022–06014 BOLT, FLANGE 1 1 1 1
13
90201–06078 WASHER, PLATE 1 1 1 1
14
90201–06033 WASHER, PLATE 1 1 1 1
15
95022–06025 BOLT, FLANGE 1 1 1 1
16
4JY–14615–00 JOINT, EXHAUST 1 1 1 1 1
17
5XE–14753–01 SILENCER, EXHAUST 1
1C3–14753–00 SILENCER, EXHAUST 1 1 1
18
5NY–1469A–00 .FIBER 1
1C3–1469A–00 .FIBER 1 1 1
19
92017–06010 .BOLT, BUTTON HEAD 2
92012–06010 .BOLT, BUTTON HEAD 4 4 4
20
95022–06030 BOLT, FLANGE 1 1 1 1
21
90201–06033 WASHER, PLATE 1
90201–060A3 WASHER, PLATE 1 1 1
22
90387–063G3 COLLAR 1
90387–06121 COLLAR 1 1 1

B13
FIG. 8 EXHAUST
REF.
NO. PART NO. DESCRIPTION
1C35 1C36 1C37 1C38
REMARKS
23 90480–16561 GROMMET 1
90480–17004 GROMMET 1 1 1
24
90387–06039 COLLAR 1111
25
90480–16404 GROMMET 1 1 1 1

B14
FIG. 9 CRANKCASE
REF.
NO. PART NO. DESCRIPTION
1C35 1C36 1C37 1C38
REMARKS
1 1C3–15111–00 CRANKCASE 1 1 1 1 1
2
1C3–15121–00 CRANKCASE 2 1 1 1 1
3
353–13115–01 CONNECTOR, SUCTION PIPE 1 1 1 1
4
90445–08605 HOSE 1111
5
99530–10116 PIN, DOWEL 2 2 2 2
6
95027–10016 BOLT, FLANGE 1 1 1 1
7
90430–10188 GASKET 1 1 1 1
8
91317–06045 BOLT 6666
9
91317–06055 BOLT 4444
10
91317–06065 BOLT 1111
11
91317–06075 BOLT 1111
12
90461–10136 CLAMP 1 1 1 1
13
4V4–15118–00 HOLDER 1111
14
90105–06556 BOLT, FLANGE 1 1 1 1
15
99590–17016 PIN, DOWEL 1 1 1 1
16
93210–16314 O-RING 1 1 1 1