Yamaha RAPTOR YFM125RA User manual

SERVICE MANUAL
YFM125RA
2011
2PA-28197-10LIT-11616-24-36

EAS20050
YFM125RA
SERVICE MANUAL
©2010 by Yamaha Motor Corporation, U.S.A.
First edition, May 2010
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
Printed in U.S.A.
P/N LIT-11616-24-36

EAS20071
IMPORTANT
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha deal-
ers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one
manual. Therefore, anyone 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 maintenance work attempted by anyone without this knowledge is likely to
render the vehicle unsafe and unfit for use.
This model has been designed and manufactured to perform within certain specifications in regard
to performance and emissions. Proper service with the correct tools is necessary to ensure that the
vehicle will operate as designed. If there is any question about a service procedure, it is imperative
that you contact a Yamaha dealer for any service information changes that apply to this model. This
policy is intended to provide the customer with the most satisfaction from his vehicle and to conform
to federal environmental quality objectives.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and
significant changes in specifications or procedures will be forwarded to all authorized Yamaha deal-
ers and will appear in future editions of this manual where applicable.
TIP
• This Service Manual contains information regarding periodic maintenance to the emission control
system. Please read this material carefully.
• 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 per-
sonal 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

EAS20091
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 dis-
assembly 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
sequentially.

EAS30370
SYMBOLS
The following symbols are used in this manual for easier understanding.
TIP
The following symbols are not relevant to every vehicle.
SYMBOL DEFINITION SYMBOL DEFINITION
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 (LOC-
TITE®).
Engine oil Replace the part with a new
one.
G
M
BF
B
T
R
.
.
LS
M
S
LT
E
New

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

1
GENERAL INFORMATION
IDENTIFICATION ..........................................................................................1-1
VEHICLE IDENTIFICATION NUMBER...................................................1-1
MODEL LABEL .......................................................................................1-1
IMPORTANT INFORMATION .......................................................................1-2
PREPARATION FOR REMOVAL AND DISASSEMBLY..........................1-2
REPLACEMENT PARTS.........................................................................1-2
GASKETS, OIL SEALS AND O-RINGS..................................................1-2
LOCK WASHERS/PLATES AND COTTER PINS ...................................1-2
BEARINGS AND OIL SEALS .................................................................1-3
CIRCLIPS ...............................................................................................1-3
BASIC SERVICE INFORMATION.................................................................1-4
QUICK FASTENERS ..............................................................................1-4
ELECTRICAL SYSTEM ..........................................................................1-5
SPECIAL TOOLS..........................................................................................1-9

IDENTIFICATION
1-1
EAS20130
IDENTIFICATION
EAS20140
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number “1” is
stamped into the left side of the frame.
EAS20150
MODEL LABEL
The model label “1” is affixed to the air filter
case cover. This information will be needed to
order spare parts.

IMPORTANT INFORMATION
1-2
EAS20180
IMPORTANT INFORMATION
EAS20190
PREPARATION FOR REMOVAL AND DISAS-
SEMBLY
1. Before removal and disassembly, remove
all dirt, mud, dust and foreign material.
2. Use only the proper tools and cleaning
equipment.
Refer to “SPECIAL TOOLS” on page 1-9.
3. When disassembling, always keep mated
parts together. This includes gears, cylin-
ders, pistons and other parts that have
been “mated” through normal wear. Mated
parts must always be reused or replaced
as an assembly.
4. During disassembly, clean all of the parts
and place them in trays in the order of dis-
assembly. This will speed up assembly and
allow for the 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 and O-rings. All gasket sur-
faces, oil seal lips and O-rings must be
cleaned.
2. During reassembly, properly oil all mating
parts and bearings and lubricate the oil
seal lips with grease.
EAS20220
LOCK WASHERS/PLATES AND COTTER
PINS
After removal, replace all lock washers/plates
“1” and cotter pins. After the bolt or nut has
been tightened to specification, bend the lock
tabs along a flat of the bolt or nut.
1. Oil
2. Lip
3. Spring
4. Grease

IMPORTANT INFORMATION
1-3
EAS20231
BEARINGS AND OIL SEALS
Install bearings “1” and oil seals “2” so that the
manufacturer marks or numbers are visible.
When installing oil seals, lubricate the oil seal
lips with a light coat of lithium-soap-based
grease. Oil bearings liberally when installing, if
appropriate.
ECA13300
Do not spin the bearing with compressed
air because this will damage the bearing
surfaces.
EAS20240
CIRCLIPS
Before reassembly, check all circlips carefully
and replace damaged or distorted circlips.
Always 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.

BASIC SERVICE INFORMATION
1-4
EAS30380
BASIC SERVICE INFORMATION
EAS30390
QUICK FASTENERS
Rivet type
1. Remove:
• Quick fastener
TIP
To remove the quick fastener, push its pin with
a screwdriver, then pull the fastener out.
2. Install:
• Quick fastener
TIP
To install the quick fastener, 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 “a” 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 fastener, insert the fastener
into the part to be secured and tighten the
screw “a”.

BASIC SERVICE INFORMATION
1-5
EAS30402
ELECTRICAL SYSTEM
Electrical parts handling
ECA16600
Never disconnect a battery lead while the
engine is running; otherwise, the electrical
components could be damaged.
ECA16751
When disconnecting the battery leads from
the battery, be sure to disconnect the nega-
tive battery lead first, then the positive bat-
tery lead. If the positive battery lead is
disconnected first and a tool or similar item
contacts the vehicle, a spark could be gen-
erated, which is extremely dangerous.
TIP
If a battery lead is difficult to disconnect due to
rust on the battery terminal, remove the rust
using hot water.
ECA16760
Be sure to connect the battery leads to the
correct battery terminals. Reversing the
battery lead connections could damage the
electrical components.
ECA16771
When connecting the battery leads to the
battery, be sure to connect the positive bat-
tery lead first, then the negative battery
lead. If the negative battery lead is con-
nected first and a tool or similar item con-
tacts the vehicle while the positive battery
lead is being connected, a spark could be
generated, which is extremely dangerous.
ECA16610
Turn the main switch to “OFF” before dis-
connecting or connecting an electrical
component.

BASIC SERVICE INFORMATION
1-6
ECA16620
Handle electrical components with special
care, and do not subject them to strong
shocks.
ECA16630
Electrical components are very sensitive to
and can be damaged by static electricity.
Therefore, never touch the terminals and be
sure to keep the contacts clean.
TIP
When resetting the CDI Unit by turning the
main switch to “OFF”, be sure to wait approxi-
mately 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.
ECA14371
Never insert the tester probes into the cou-
pler terminal slots. Always insert the
probes from the opposite end “a” of the
coupler, taking care not to loosen or dam-
age the leads.
ECA16640
For waterproof couplers, never insert the
tester probes directly into the coupler.
When performing any checks using a
waterproof coupler, use the specified test
harness or a suitable commercially avail-
able test harness.
a

BASIC SERVICE INFORMATION
1-7
Checking the connections
Check the leads, couplers, and connectors for
stains, rust, moisture, etc.
1. Disconnect:
• Lead
• Coupler
• Connector
ECA16780
• When disconnecting a coupler, release
the coupler lock, hold both sections of
the coupler securely, and then disconnect
the coupler.
• There are many types of coupler locks;
therefore, be sure to check the type of
coupler lock before disconnecting the
coupler.
ECA16790
When disconnecting a connector, do not
pull the leads. Hold both sections of the
connector securely, and then disconnect
the connector.
2. Check:
• Lead
• Coupler
• Connector
Moisture →Dry with an air blower.
Rust/stains →Connect and disconnect
several times.
3. Check:
• All connections
Loose connection →Connect properly.
TIP
• If the pin “1” on the terminal is flattened,
bend it up.
• After disassembling and assembling a cou-
pler, pull on the leads to make sure that they
are installed securely.
4. Connect:
• Lead
• Coupler
• Connector
TIP
• When connecting a coupler or connector,
push both sections of the coupler or connec-
tor together until they are connected
securely.
• Make sure all connections are tight.
1

BASIC SERVICE INFORMATION
1-8
5. Check:
•Continuity
(with the pocket tester)
TIP
• If there is no continuity, clean the terminals.
• When checking the wire harness, perform
steps (1) to (3).
• As a quick remedy, use a contact revitalizer
available at most part stores.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C

SPECIAL TOOLS
1-9
EAS20260
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use
only the appropriate special tools as this will help prevent damage caused by the use of inappropri-
ate tools or improvised techniques. Special tools, part numbers or both may differ depending on the
country.
When placing an order, refer to the list provided below to avoid any mistakes.
TIP
• For U.S.A. and Canada, use part number starting with “YM-”, “YU-”, or “ACC-”.
• For others, use part number starting with “90890-”.
Tool name/Tool No. Illustration Reference
pages
Slide hammer bolt
90890-01083
Slide hammer bolt 6 mm
YU-01083-1
5-14, 5-16
Weight
90890-01084
YU-01083-3
5-14
Crankcase separating tool
90890-01135
Crankcase separator
YU-01135-B
5-64
Ring nut wrench
90890-01268
Spanner wrench
YU-01268
3-18

SPECIAL TOOLS
1-10
Crankshaft installer pot
90890-01274
Installing pot
YU-90058
5-65
Crankshaft installer bolt
90890-01275
Bolt
YU-90060
5-65
Adapter (M12)
90890-01278
Adapter #3
YU-90063
5-65
Spacer (crankshaft installer)
90890-04081
Pot spacer
YM-91044
5-65
Piston pin puller set
90890-01304
Piston pin puller
YU-01304
5-27
Tool name/Tool No. Illustration Reference
pages
YM-91044

SPECIAL TOOLS
1-11
Tappet adjusting tool
90890-01311
Six piece tappet set
YM-A5970
3-6
Flywheel puller
90890-01362
Heavy duty puller
YU-33270-B
5-50
Sheave holder
90890-01701
Primary clutch holder
YS-01880-A
5-50, 5-51, 5-52
Thickness gauge
90890-03180
Feeler gauge set
YU-26900-9
3-5, 5-36
Digital circuit tester
90890-03174
Model 88 Multimeter with tachometer
YU-A1927
5-56
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
1-8, 7-31, 7-32,
7-33, 7-37, 7-
38, 7-39, 7-40,
7-41, 7-42
Carburetor angle driver
90890-03158
3-7
Tool name/Tool No. Illustration Reference
pages