yamaha yz125 full service repair manual 2007
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yamaha yz125 full service repair manual 2007January 31, 2021 What Kind of Limos Are There. January 30, 2021 Your Personal Finance Guide to Car Loans January 29, 2021 Getting Back in Shape: What Is Frame Straightening. January 29, 2021 What Is Classed as a Commercial Vehicle. January 28, 2021 The Revolution Will Drive Itself: The Dawning of the Age of Vehicular Automation January 28, 2021 Having Trouble Driving at Night. Here Is How You Can Stay Focused. January 27, 2021 Search Motor Era. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan. This model is the culmination of Yamaha’s vast experience in the production of pacesetting racing machines. It represents the highest grade of craftsmanship and reliability that have made Yamaha a leader. Dieses Modell entspricht fort-. Off-road use on public lands may also be illegal. Please check local regulations before riding. Take care to not spill any gasoline on the engine or exhaust system. Never refuel in the vicinity of an open flame, or while smoking. 6. GASOLINE CAN CAUSE INJURY. If you should swallow some gasoline, inhale excess gasoline vapors, or allow any gasoline to get into your eyes, con-. Immer den Motor abstellen, TE INFIAMMABILE. Dar- Spegnere sempre il motore faisant le plein.If there is any question you have regarding this manual or your machine, please consult your Yamaha deal- EC070001 F.I.M. MACHINE WEIGHTS: Weights of machines without fuel. The information has been complied to provide the mechanic with an easy to read, handy reference that contains com- prehensive explanations of all disassembly, repair, assembly, and inspection operations. In this revised format, the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol, e.g., 9 Bearings.http://www.vvk-wiedermann.at/userfiles/dma-q800-manual.xml
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General information INSP Specifications Regular inspection and adjustments Engine Chassis Electrical Tuning CHAS ELEC Illustrated symbols 8 to r are used to identify the specifications appearing in the text. When washing the machine with high pres- sured water, cover the parts as follows. 9 Silencer exhaust port 9 Side cover air intake port 9 Crankcase cover hole at the bottom. EC133000 GASKETS, OIL SEALS AND O-RINGS 1. All gaskets, oil seals, and O-rings should be replaced when an engine is overhauled. Bauteile zu verwenden.Always replace piston pin clips after one use. Replace distorted cir- clips. When installing a circlip 1, make sure that the sharp-edged corner 2 is positioned opposite to the thrust 3 it receives. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised tech- niques. The shape and part number used for the special tool differ by country, so two types are provid- ed. La forma e il numero categorico usati per l’utensile speciale sono diversi a seconda del paese, quindi vengono forniti due tipi. Continue pushing the “ENGINE STOP” button till the engine comes to a stop. EC152000 CLUTCH LEVER The clutch lever 1 is located on the left handle- bar;. Pull it toward the handlebar to acti- vate the front brake. EC157000 REAR BRAKE PEDAL The rear brake pedal 1 is located on the right side of the machine. EC15F000 VALVE JOINT This valve joint 1 prevents fuel from flowing out and is installed to the fuel tank breather hose. Always use fresh, name-brand gasoline, and mix the oil and gas the day of the race. Do not use premix that is more than a few hours old. Never start or run the engine in a closed area. The exhaust fumes are poisonous; they can cause loss of consciousness and death in a very short time. Mixing oil: Mixing ratio: Yamalube “2-R” 15:1 2. Perform the pre-operation checks on the machine. 3. Start and warm up the engine.http://finatwork.com/userfiles/dma-q800-user-manual.xml Check the idle speed, and check the operation of the controls and the “ENGINE STOP”. Tighten all such fasteners as required. 9 When any of the following parts have been replaced, they must be broken in. After cleaning the ma- chine thoroughly, prepare it for storage as fol- lows: 1. To avoid warpage, tighten multi-faste- ner assemblies in a crisscross fashion, in pro- gressive stages, until full torque is reached. Wenn Teile mit mehreren Befestigungselementen festgezogen werden, die Schrauben und Muttern kreuzweise und in meh- reren Schritten. Clamp the 3 Clutch cable “ENGINE STOP”. K Clamp to the frame the CDI magneto lead and radiator breather hose. Take care to clamp them above the projec- tion on the frame. B Pass the brake hose into the brake hose hold- ers. B Pass the “ENGINE STOP” button lead in the 4 “ENGINE STOP”. Before using this machine, check the following points. EC321000 GENERAL INSPECTION AND MAINTENANCE Item Routine Page. Prima di usare questo veicolo, controllare i punti che seguono. IC321000 ISPEZIONE E MANUTENZIONE GENERALI Voce. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury. If it splashes, wash it away with water. 1. Place a container under the engine. 2. Remove: 9 Coolant drain bolt 1 3. Remove: 9 Radiator cap Drain the coolant completely. Handling notes of coolant: The coolant is harmful so it should be handled with special care. Never run the engine without the air filter element in place;. NOTE: Squeeze out the excess oil. Element should be wet but not dripping. 5. Install: 9 Filter guide 1 NOTE: Align the projection a on filter guide with the. NOTE: Be sure the machine is positioned straight up when inspecting the oil level. Never attempt to remove the oil check bolt just after high speed operation. A dangerous loss of braking performance may occur if the brake system is not properly bled. Repeat the bleeding procedure when the tiny bubbles in the system have disappeared. j. Add brake fluid to the level line on the reservoir. Brake pedal height a a: Zero mm (Zero in) NOTE: The brake pedal height is the vertical distance from the inside top end of the footrest. NOTE: Replace the drive, driven sprockets and drive chain as a set.EC36U070 STEERING HEAD INSPECTION AND ADJUSTMENT 1. Elevate the front wheel by placing a suitable stand under the engine. 2. Check: 9 Steering shaft Grasp the bottom of the forks and gently rock the fork assembly back and forth. Avoid over-tightening.Scalding hot fluid and steam may be blown out under pressure, which could cause serious in- jury. When the engine has cooled, open the ra- diator cap by the following procedure: Place a thick rag, like a towel, over the radi- ator cap, slowly rotate the cap counter-. Needle holder Jet needle Float chamber Needle jet cover. EC463000 REMOVAL POINTS EC463110 Throttle valve 1. Remove: 9 Throttle valve 1 9 Ring 2 9 Spring (throttle valve) 3 9 Mixing chamber top 4. NOTE: 9 Use a petroleum based solvent for cleaning. Blow out all passages and jets with com- pressed air. 9 Never use a wire. NOTE: Inspect the filter as it is assembled to the carbu- retor. Do not remove the filter except when replacing it.EC473402 Piston and piston ring 1. Do not use a sharp instrument. Avoid scratching the aluminum. 2. NOTE: Measure the cylinder bore “C”. Piston pin outside diameter: Standard. Ring end gap (installed): Standard. In Zylinder. Nel cilindro. Pousser le segment avec la Den Kolbenring mit dem Kol- Spingere la fascia con la corona calotte du piston. Install the cylinder with one hand while compressing the piston ring with the other hand. Measure at all four points.EC4C5402 Kick idle gear 1. Install: 9 Kick idle gear 1 9 Plain washer 2 9 Circlip 3 NOTE:. EC4K4200 Bearing 1. EC4H4600 Bearing 1. Inspect: 9 Bearing 1 Rotate inner race with a finger.If the segment gets an impact, it may be damaged. Take care not to give an impact to the segment when removing the bolt.http://ladylordwest.com/images/competent-communication-pdf-manual.pdf Do not use a hammer to drive out the crankshaft. Note the position of each part. Use the dial gauge 1. Wheel axle bending limit: 0.5 mm (0.020 in) NOTE: The bending value is shown by one half of the dial gauge reading. A Front B Rear 2. Connect the transparent hose 2 to the bleed screw 1 and place a suitable contain- er under its end. Never attempt to pry out piston seals and dust seals. Install the brake hose so that its pipe por- tion a a directs as shown and lightly touch- es the projection b b on the master cylinder. Refer to “REAR BRAKE ADJUSTMENT” section in the CHAPTER 3. EC5A5911 Front brake hose 1. Install the brake hose so that its pipe por- tion a a directs as shown and lightly touch- es the projection b b on the master cylinder. If it does, correct its twist. Refer to “BRAKE FLUID LEVEL INSPEC- TION”. So it is recommended that the front fork be maintained at the dealers. To prevent an accidental explosion of air, the following instructions should be ob- served: 9 The front fork with a built-in piston rod has a very sophisticated internal con- struction and is particularly sensitive to. Use the dial gauge 1. Inner tube bending limit: 0.2 mm (0.008 in) NOTE: The bending value is shown by one half of the. Recommended oil: Suspension oil “S1” Oil capacity: 195cm (6.86 Imp oz, 6.59 US oz) Install: 9 Oil seal 1 NOTE: Press the oil seal into the outer tube with fork seal driver 2. Vers la fente de tube externe. Uneven adjustment can cause poor handling and loss of stability. 9 Be sure to use recommended fork oil. If other oils are used, they may have an ex- cessively adverse effect on the front fork performance. Tube guide 5-43. EC5B3200 Grip 1. EC563300 Bearing (lower) 1. Remove: 9 Bearing (lower) 1 Use the floor chisel 2. Install the bearing in the bearing races. Spin the bearings by hand. After tightening the nut, check the steering for smooth movement. If not, adjust the steering by loosening the ring nut little by little. 11. Adjust: 9 Front fork top end a Front fork top end (standard) a a: 5 mm (0.20 in) 12. Nach dem Festziehen der Mutter, si le mouvement de la direction est die Lenkung auf glatte Bewegung 10. EC574010 INSPECTION Wash the bearings, bushes and collars in a sol-. EC575000 ASSEMBLY AND INSTALLATION EC575202 Bearing and oil seal 1. NOTE: 9 Apply the molybdenum disulfide grease on the bearing when installing. 9 Install the bearing by pressing it on the side hav- ing the manufacture’s marks or numbers. Installed depth of bearings a a: Zero mm (Zero in) EC5751B3. To dispose of a damaged or worn-out shock absorber, take the unit to your Yamaha dealer for this disposal procedure. 5-64. Do not apply the grease on the bearing outer race because it will wear the rear shock absorber surface on which the bear- ing is press fitted. Accordingly, if a mixture of air and fuel is too lean, abnormal combustion will occur, and engine seizure may result. If the mixture is too rich or too lean at intermediate speed operation, irregular engine operation and poor acceleration will result. Therefore, carburetor setting requires the change of the jet needle. 1. The jet needle setting parts, having the same taper angle, are available in different straight portion diameters and in different taper starting positions. Pertanto, la registrazione del carburatore richiede il cambiamento dell’ago a getto. 1. Therefore, carburetor setting requires the change of the jet needle. 1. Pertanto, la registrazione del carburatore richiede il cambiamento dell’ago a getto. 1. White smoke Unstable at low speeds Lower jet needle clip position. The front fork setting includes the following three factors: 1. Setting of air spring characteristics 9 Change the fork oil amount. Something went wrong. Get what you love for less.User Agreement, Privacy, Cookies and AdChoice Norton Secured - powered by Verisign. If you continue browsing the site, you agree to the use of cookies on this website. See our User Agreement and Privacy Policy.If you continue browsing the site, you agree to the use of cookies on this website. See our Privacy Policy and User Agreement for details.You can change your ad preferences anytime. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable. Using this repair manual is an inexpensive way to keep your vehicle working properly. All rights reserved. Any reprinting orPrinted in JapanIt representsThis manual explains operation, in-Yamaha continually seeks advance-Therefore, while this manual containsA CAUTION indicates special pre-A NOTE provides key information toNever refuel in the vicinity ofIf any gasoline spills ontoIf you haveThis manual should be considered aYamaha dealer.The minimum weights for motocrossIn modifying your machine (e.g., forBend the book at its edge, asIn this revised format, the condition ofILLUSTRATED SYMBOLS (Refer toElectric current (A)In this installation, make sure theCOLLAR (tool for YPVS)Silencer exhaust port. Side cover air intake port. Crankcase cover hole at the bot-Water pump housing hole at theEnd of each hoseThey include gears, cylinders,This will speed up assembly timeDo not use compressed air to spinUsing the correct special tool willThe shape and part number used forRefer to the list provided to avoid errors when placing an order. Crankcase separating toolFlywheel pullerRotor holding toolDial gauge and standCrankshaft installing tool. Crankshaft installing potPiston pin puller setRadiator cap testerFlywheel pullerSteering nut wrenchCap bolt wrenchCap bolt ring wrenchPocket testerClutch holding toolDynamic spark testerYAMAHA Bond No. 1215 (ThreeB-. No. 1215)Continue push-For accelera-Normal ridingIf knocking or pinging occurs, use aNever mix two types of oil in theRecommended fuel. Premium unleadedFuel tank capacity:US gal)Never start or run the engine in aAlways oper-Do not warm up the engine for ex-Observe the following break-inCheck the idle speed, and checkFull throttleCheck the spark plug condition.Stop and check the spark plugObserve theMixing oil. Recommended oil:Mixing ratio: 30:1. If unavailable, use anMixing oil. Mixing ratio:Combined seat and fuel tank Fuel tank to frame. Exhaust system Silencer to rear frame. Engine mounting Frame to engine. Engine bracket to engine. Engine bracket to frame. Steering Steering stem to handlebar Steering stem to frame. Steering stem to upper bracket. Upper bracket to handlebar. Suspension Front Steering stem to front fork Front fork to upper bracket. Front fork to lower bracket. Rear For link type Assembly of links. Link to frame. Link to rear shock absorber. Link to swingarm. Installation of rear shock absorber Rear shock absorber to frame. Installation of swingarm Tightening of pivot shaft. Wheel Installation of wheel Front Tightening of wheel axle. Tightening of axle holder. Rear Tightening of wheel axle. Wheel to rear wheel sprocket. Brake Front Brake caliper to front fork. Brake disc to wheel. Tightening of union bolt. Brake master cylinder to handlebar. Tightening of bleed screw. Tightening of brake hose holder. Rear Brake pedal to frame. Brake disc to wheel. Tightening of union bolt. Brake master cylinder to frame. Tightening of bleed screw. Tightening of brake hose holder. Fuel system Fuel tank to fuel cockDo not applyExcessive hose pressure mayDo not applyMake any necessary repairs beforeOverall length 2,135 mm (84.1 in) 2,139 mm (84.2 in). Overall width 827 mm (32.6 in) Operation Left foot operation. Gear ratio. Chassis: USA, ZA, AUS, NZ EUROPE, CDN. Frame type Semi double cradle Piston:Piston pin:Piston ring:Crankshaft:Item Standard LimitClutch spring free length 40.1 mm (1.579 in) 38.1 mmClutch release method Inner push, cam push ----. Transmission. Main axle deflection limit ---- 0.01 mmDrive axle deflection limit ---- 0.01 mmShifter. Guide bar bending limit ---- 0.05 mmKick starter type: Kick and mesh type ----. Air filter oil grade (oiled filter): Foam-air-filter oil or equivalent oil ----. Carburetor: USA, CDN EUROPE AUS, NZ, ZAType Single-suction centrifugal pump ----. Item Standard Limit. Steering system. Front suspension: USA, CDN, ZA, AUS,Rim runout limit. Radial ---- 2.0 mm (0.08Lateral ---- 2.0 mm (0.08Drive chain. Chain length (15 links) ---- 242.9 mmFront disc brake. Disc outside dia.?Thickness 250 ? 3.0 mm (9.84 ? 0.12 in) 250 ? 2.5 mmPad thickness 4.4 mm (0.17 in) 1.0 mm (0.04Master cylinder inside dia. 9.52 mm (0.375 in) ----. Caliper cylinder inside dia. 22.65 mm (0.892 in) ? 2 ----. Rear disc brake. Disc outside dia.?Thickness 245 ? 4.0 mm (9.65 ? 0.16 in) 245 ? 3.5 mmDeflection limit ---- 0.15 mmPad thickness 6.4 mm (0.25 in) 1.0 mm (0.04Master cylinder inside dia. 11.0 mm (0.433 in) ----. Caliper cylinder inside dia. 25.4 mm (1.000 in) ? 1 ----. Brake lever and brake pedal. Brake lever position 95 mm (3.74 in) ----. Brake pedal height (vertical height above footrestZero mm (Zero in) ----. Item Standard Limit. Item Standard Limit. Ignition system. Ignition timing (B.T.D.C.) 0.48 mm (0.019 in) ----Minimum spark gap 6 mm (0.24 in) ----. Spark plug cap. Item Standard Limit. Part to be tightened Thread size Q'ty. Tightening torque. Spark plug M14S ? 1.25 1 20 2.0 14. Cylinder head (nut) M8 ? 1.25 5 28 2.8 20. Cylinder head (stud) M8 ? 1.25 5 13 1.3 9.4. Cylinder (nut) M8 ? 1.25 4 30 3.0 22. Cylinder (stud) M10 ? 1.25 4 13 1.3 9.4. Power valve. Cover M5 ? 0.8 4 5 0.5 3.6. Link lever M4 ? 0.7 1 4 0.4 2.9. Holder (power valve) M5 ? 0.8 4 8 0.8 5.8. Push rod M5 ? 0.8 1 5 0.5 3.6. Thrust plate M5 ? 0.8 1 4 0.4 2.9. Governor fork M4 ? 0.7 2 5 0.5 3.6. Housing M5 ? 0.8 3 4 0.4 2.9. Water pump housing cover M6 ? 1.0 4 10 1.0 7.2. Coolant drain bolt M6 ? 1.0 1 10 1.0 7.2. Radiator M6 ? 1.0 6 10 1.0 7.2. Radiator panel M6 ? 1.0 2 10 1.0 7.2. Radiator hose clamp M6 ? 1.0 8 2 0.2 1.4. Air filter element M6 ? 1.0 1 2 0.2 1.4. Carburetor joint M6 ? 1.0 4 10 1.0 7.2. Carburetor joint clamp M4 ? 0.7 1 2 0.2 1.4. Air filter joint clamp M4 ? 0.7 1 2 0.2 1.4Air filter guide clamp M5 ? 0.8 1 4 0.4 2.9. Reed valve M3 ? 0.5 6 1 0.1 0.7Throttle cable adjust bolt and locknut M8 ? 1.25 1 7 0.7 5.1. Throttle cable M6 ? 0.75 1 4 0.4 2.9. Crankcase M6 ? 1.0 12 14 1.4 10. Right crankcase cover M6 ? 1.0 8 10 1.0 7.2. Left crankcase cover M6 ? 1.0 4 5 0.5 3.6. Drive chain sprocket cover M6 ? 1.0 2 5 0.5 3.6. Bearing plate cover M6 ? 1.0 4 10 1.0 7.2. Holder M6 ? 1.0 1 10 1.0 7.2. Oil check bolt M6 ? 1.0 1 10 1.0 7.2. Oil drain bolt M10 ? 1.25 1 20 2.0 14. Kickstarter crank M6 ? 1.0 1 10 1.0 7.2. Clutch cover M6 ? 1.0 6 10 1.0 7.2. Primary drive gear M8 ? 1.25 1 48 4.8 35. Clutch boss M16 ? 1.0 1 80 8.0 58. Clutch spring M6 ? 1.0 5 10 1.0 7.2. Clutch cable adjust bolt and locknut M6 ? 0.75 1 4 0.4 2.9. Drive sprocket M18 ? 1.0 1 75 7.5 54. Shift pedal M6 ? 1.0 1 12 1.2 8.7. Bearing plate cover (shift cam) M6 ? 1.0 2 10 1.0 7.2. Shift guide M6 ? 1.0 2 10 1.0 7.2. Stopper lever M6 ? 1.0 1 10 1.0 7.2. Segment M8 ? 1.25 1 30 3.0 22Silencer:Fiber (Except for EUROPE) M6 ? 1.0 2 10 1.0 7.2. Fiber (For EUROPE) M6 ? 1.0 4 10 1.0 7.2. Part to be tightened Thread size Q'ty. Tightening torque. Part to be tightened Thread size Q'ty. Tightening torqueFront fork and damper assembly M51 ? 1.5 2 30 3.0 22. Front fork and adjuster M22 ? 1.25 2 55 5.5 40. Damper assembly and base valve M42 ? 1.5 2 29 2.9 21. Adjuster and damper assembly M12 ? 1.25 2 29 2.9 21Throttle cable cap M4 ? 0.7 2 1 0.1 0.7Brake lever mounting bolt M6 ? 1.0 1 6 0.6 4.3. Brake lever mounting nut M6 ? 1.0 1 6 0.6 4.3. Brake lever position locknut M6 ? 1.0 1 5 0.5 3.6. Clutch lever mounting nut M6 ? 1.0 1 4 0.4 2.9. Clutch lever holder M5 ? 0.8 2 4 0.4 2.9. Front brake master cylinder cap M4 ? 0.7 2 2 0.2 1.4Grip cap upper and lower M6 ? 1.0 2 4 0.4 2.9. Brake caliper (front and rear) and pad pin plug M10 ? 1.0 2 3 0.3 2.2Footrest bracket and frame M10 ? 1.25 4 55 5.5 40Rear brake master cylinder cap M4 ? 0.7 2 2 0.2 1.4Drive chain puller adjust bolt and locknut M8 ? 1.25 2 19 1.9 13. Engine:Part to be tightened Thread size Q'ty. Tightening torquePlease Click Here. Then Get More. 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