Yamaha YP125R User manual

SERVICE MANUAL
2010
37P-F8197-E0
YP125R/YP250R

EAS20060
YP125R/YP250R 2010
SERVICE MANUAL
©2009 by Yamaha Motor España, S.A.
First edition, November 2009
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor España, S.A.
is expressly prohibited.

EAS20071
IMPORTANT
This manual was produced by Yamaha Motor España, S.A. primarily for use by Yamaha and MBK 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 and
MBK 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.
Yamaha Motor España, S.A. 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 and MBK
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.
1
7
2
3
4
5
6

EAS20101
SYMBOLS
The following symbols are used in this manual for easier understanding.
T
IP
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 (LOCTITE®).
Engine oil Replace the part with a new one.
G
M
BF
B
T
R
.
.
LS
M
S
LT
ENew

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 .........................................................................1-8
PREPARATION FOR REMOVAL AND DISASSEMBLY...........................1-8
REPLACEMENT PARTS...........................................................................1-8
GASKETS, OIL SEALS AND O-RINGS ....................................................1-8
LOCK WASHERS/PLATES AND COTTER PINS .....................................1-8
BEARINGS AND OIL SEALS....................................................................1-9
CIRCLIPS..................................................................................................1-9
CHECKING THE CONNECTIONS ................................................................1-10
SPECIAL TOOLS ..........................................................................................1-11

IDENTIFICATION
1-1
EAS20130
IDENTIFICATION
EAS20140
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number “1”is stamped
into the frame.
EAS20150
MODEL LABEL
The model label “1”is affixed to the location
shown. This information will be needed to order
spare parts.
1
1