Yp125r Service Manual

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Aug 25, 2012 - To download your manual please click on the blue links below. Good luck and have a wonderful day. Yamaha YP125R Service Manual.

. Read this manual carefully before operating this vehicle. OWNER’S MANUAL YP125R YP125RA YP125R Sports YP125RA Business Edition 2AB-F8199-E2.

Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold. YAMAHA MOTOR ELECTRONICS CO., LTD. 1450-6, Mori, Mori-machi, Shuchi-gun, Shizuoka-ken, 437-0292 Japan DECLARATION of CONFORMITY Company: YAMAHA MOTOR ELECTRONICS CO., LTD. Address: 1450-6, Mori, Mori-Machi, Shuchi-gun, Shizuoka-Ken, 437-0292 Japan Hereby declare that the product: Kind of equipment: IMMOBILIZER. Yamaha a reputation for dependability. Please take the time to read this manual thoroughly, so as to enjoy all advantages of your YP125R/YP125RA.

The Owner’s Manual does not only instruct you in how to operate, inspect and maintain your scooter, but also in how to safeguard yourself and others from trouble and injury. IMPORTANT MANUAL INFORMATION EAU10133 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 personal injury hazards.

Obey all safety messages that follow this symbol to avoid possible injury or death. IMPORTANT MANUAL INFORMATION EAUM1011 YP125R/YP125RA OWNER’S MANUAL ©2012 by MBK INDUSTRIE 1st edition, August 2012 All rights reserved Any reprinting or unauthorized use without the written permission of MBK INDUSTRIE is expressly prohibited. Printed in France.

TABLE OF CONTENTS SAFETY INFORMATION.1-1 Sidestand.3-21 Air filter and V-belt case air filter Further safe-riding points.1-5 Ignition circuit cut-off system.3-21 elements.6-16 Auxiliary DC jack.3-23 Adjusting the throttle grip free DESCRIPTION.2-1 play. TABLE OF CONTENTS License plate light.6-33 Replacing an auxiliary light bulb.6-33 Troubleshooting.6-33 Troubleshooting charts.6-35 SCOOTER CARE AND STORAGE.7-1 Matte color caution.7-1 Care.7-1 Storage.7-3 SPECIFICATIONS.8-1 CONSUMER INFORMATION.9-1 Identification numbers.9-1. SAFETY INFORMATION ● EAU1026A Never operate a scooter without spicuous appears to be very effec- proper training or instruction. Take tive in reducing the chance of this training course. Beginners type of accident. Be a Responsible Owner should receive training from a cer- Therefore: As the vehicle’s owner, you are respon- tified instructor.

SAFETY INFORMATION ● Many accidents involve inexperi-. Always signal before turning or Protective Apparel enced operators. In fact, many op- changing lanes.

Make sure that The majority of fatalities from scooter erators who have been involved in other motorists can see you. Accidents are the result of head inju- accidents do not even have a cur- ●.

Maximum load: idly reach dangerous levels. Fork, or front fender. Such items YP125R 180 kg (398 lb) ● Do not run engine in poorly venti- can create unstable handling or YP125RA 172 kg (379 lb) lated or partially enclosed areas a slow steering response. Yamaha accessories, which are avail- characteristics can put you and others effects. Wind may attempt to lift able only from a Yamaha dealer, have at greater risk of serious injury or death. The scooter, or the scooter may been designed, tested, and approved. SAFETY INFORMATION Aftermarket Tires and Rims straps carefully so the straps will EAU10373 Further safe-riding points The tires and rims that came with your not rub against painted surfaces ● Be sure to signal clearly when scooter were designed to match the during transport.

SAFETY INFORMATION ● Always wear a helmet, gloves, trousers (tapered around the cuff and ankle so they do not flap), and a bright colored jacket. ● Do not carry too much luggage on the scooter. An overloaded scoot- er is unstable. Use a strong cord to secure any luggage to the carrier (if equipped). DESCRIPTION EAU32220 Left view YP125R/YP125RA 1. Headlight (page 6-30) 8. Engine oil drain bolt (page 6-10) 2.

Fuel tank cap (page 3-14) 9. Centerstand (page 6-25) 3. Owner’s tool kit (page 6-2) 10.Sidestand (page 3-21) 4. V-belt case air filter element (page 6-16) 5. DESCRIPTION YP125RA Business Edition / YP125R Sports 1. Headlight (page 6-30) 10.Sidestand (page 3-21) 2. Fuel tank cap (page 3-14) 3.

Owner’s tool kit (page 6-2) 4. V-belt case air filter element (page 6-16) 5. Rear storage compartment (page 3-18) 6.

DESCRIPTION EAU32230 Right view YP125R/YP125RA 1. Grab bar (page 5-2) 8. Engine oil filler cap (page 6-10) 2. Seat (page 3-17) 9. Rear brake pads (page 6-21) 3. Coolant reservoir cap (page 6-14) 10.Shock absorber assembly spring preload adjusting ring (page 3-20) 4. DESCRIPTION YP125RA Business Edition / YP125R Sports 1.

Grab bar (page 5-2) 10.Shock absorber assembly spring preload adjusting ring (page 3-20) 2. Seat (page 3-17) 3. Coolant reservoir cap (page 6-14) 4.

Battery (page 6-27) 5. Fuses (page 6-29) 6. Front brake pads (page 6-21) 7. DESCRIPTION EAU10430 Controls and instruments 1. Rear brake lever (page 3-13) 9. Main switch/steering lock (page 3-2) 2. Left handlebar switches (page 3-11) 10.Front storage compartment (page 3-18) 3.

Speedometer (page 3-5) 4. Multi-function display (page 3-6) 5. Tachometer (page 3-6) 6.

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● the vehicle along with all three keys to Do not expose any key to exces- a Yamaha dealer to have them re-reg- sively high temperatures. Do not use the key with the red ● Do not place any key close to bow for driving.

INSTRUMENT AND CONTROL FUNCTIONS ● Keep other immobilizer system EAU10472 EAU34121 Main switch/steering lock keys away from the main switch All electrical circuits are supplied with as they may cause signal inter- power; the meter lighting, taillight, li- ference. Cense plate light and auxiliary lights come on, and the engine can be start- ed. INSTRUMENT AND CONTROL FUNCTIONS EAU10684 To unlock the steering ECA11020 LOCK NOTICE The steering is locked, and all electrical Do not use the parking position for systems are off. The key can be re- an extended length of time, other- moved. Engine trouble warning light “ ” not work correctly.

Yp125r Service Manual

If this occurs, This warning light comes on if an elec- have a Yamaha dealer check the trical circuit monitoring the engine is not electrical circuit. Working correctly.

If this occurs, have a. If the indicator light does not come on initially when the key is turned to “ON”, or if the indicator light remains on, have a Yamaha dealer check the electrical circuit.

When the key is turned to “OFF” and 30 seconds have passed, the indicator 1. INSTRUMENT AND CONTROL FUNCTIONS When the key is turned to “ON”, the EAU11872 EAUS1682 Tachometer Multi-function display speedometer needle will sweep once EWA12312 across the speed range and then return WARNING to zero in order to test the electrical cir- Be sure to stop the vehicle before cuit. INSTRUMENT AND CONTROL FUNCTIONS ● an ambient temperature display ● an oil change indicator ● a V-belt replacement indicator ● Be sure to turn the key to “ON” be- fore using the “SELECT” and “RE- SET” buttons. ● When the key is turned to “ON”, all of the display segments of the 1. INSTRUMENT AND CONTROL FUNCTIONS self automatically and the display will ture warning indicator flash, stop the return to the prior mode after refueling vehicle and let the engine cool. (See and traveling 5 km (3 mi).

Page 6-36.) The display cannot be changed back to “Trip F”. If the indicator does not come on, If the multi-function display indicates have a Yamaha dealer check the such an error code, note the code num- electrical circuit. Ber, and then have a Yamaha dealer check the vehicle. V-belt replacement indicator “V- ECA11790 NOTICE BELT”.

If the multi-function display indicates any error codes, note the code number, ● If the ambient temperature falls be- and then have a Yamaha dealer check low –10 °C, a lower temperature the vehicle. Than –10 °C will not be displayed. INSTRUMENT AND CONTROL FUNCTIONS EAU12331 EAU1234B Anti-theft alarm (optional) Handlebar switches This model can be equipped with an Left optional anti-theft alarm by a Yamaha dealer. Contact a Yamaha dealer for more information. Pass switch “ ” 2. Dimmer switch “ ”.

INSTRUMENT AND CONTROL FUNCTIONS EAU12350 EAU44711 EAU12901 Front brake lever Pass switch “ ” The engine trouble warning light and Press this switch to flash the headlight. ABS warning light (ABS model only) may come on when the key is turned to EAU12400 “ON”.

Rear brake lever ABS (for ABS models) ● The ABS performs a self-diagno- The Yamaha ABS (Anti-lock Brake sis test for a few seconds each System) features a dual electronic con- time the vehicle first starts off after trol system, which acts on the front and the key was turned to “ON”. INSTRUMENT AND CONTROL FUNCTIONS front and rear wheel hubs, otherwise EAUS1661 Fuel tank cap the magnetic rotors equipped in the wheel hubs may be damaged, result- To open the fuel tank cap ing in improper performance of the 1.

Open the fuel tank cap cover by ABS system. INSTRUMENT AND CONTROL FUNCTIONS 3. Close the fuel tank cover. EAU13221 Fuel EWA11091 Make sure there is sufficient gasoline in WARNING the tank. Make sure that the fuel tank cap is EWA10881 properly closed after filling fuel. WARNING Leaking fuel is a fire hazard. Gasoline and gasoline vapors are extremely flammable.

Do not allow the engine to idle as well as to the exhaust system. More than a few minutes. Long idling can cause a build-up of Your Yamaha engine has been de- heat. Signed to use premium unleaded gaso- line with a research octane number of 95 or higher. INSTRUMENT AND CONTROL FUNCTIONS ECA10701 EAUT1040 EAU13932 Securing bracket Seat NOTICE Use only unleaded gasoline. The use To open the seat of leaded gasoline will cause unre- 1.

Place the scooter on the center- pairable damage to the catalytic stand. INSTRUMENT AND CONTROL FUNCTIONS EAUS1623 Storage compartments Front storage compartment To open the storage compartment when it is locked, insert the key in the lock, turn it counterclockwise, and then grasp the lock while pushing the button To open the storage compartment 1. (2 lb) ● Do not exceed the maximum when using the storage compart- ● Rear storage compartment: 5 kg load of YP125R 180 kg (398 lb) ment. (11 lb) YP125RA 172 kg (379 lb) for the ● Since the storage compartment ●. INSTRUMENT AND CONTROL FUNCTIONS ● For information on how to operate the EAU14892 Align the appropriate notch in the Adjusting the shock absorber travel trunk, refer to the supplementary adjusting ring with the position in- assemblies instruction leaflet that came with your dicator on the shock absorber. Periodically check the operation of the this system regularly and have a lower it with your foot while holding the ignition circuit cut-off system according Yamaha dealer repair it if it does not vehicle upright.

To the following procedure. Function properly. Make sure that the engine stop switch is turned on. Stand during this inspection. Turn the key on. If a malfunction is noted, have a Yamaha 4.

Keep the front or rear brake applied. Dealer check the system before riding.

Push the start switch. INSTRUMENT AND CONTROL FUNCTIONS EAUM2850 3. Remove the auxiliary DC jack cap. Auxiliary DC jack EWA14360 WARNING To prevent electrical shock or short- circuiting, make sure that the cap is installed when the auxiliary DC jack is not being used. ECA15431 NOTICE The accessory connected to the. If necessary, add recommended coolant to specified level.

6-14. Check cooling system for leakage. Check operation. If soft or spongy, have Yamaha dealer bleed hydraulic system. Check brake pads for wear.

Front brake. Replace if necessary. Make sure that operation is smooth. Check throttle grip free play. Throttle grip 6-17, 6-24. If necessary, have Yamaha dealer adjust throttle grip free play and lubricate cable and grip housing. Check for damage.

Check tire condition and tread depth. See page 5-4 for engine break-in in- gle sensor to stop the engine in case of understand, ask your Yamaha dealer. Structions prior to operating the ve- a turnover. In this case, the multi-func- EWA10271 hicle for the first time. OPERATION AND IMPORTANT RIDING POINTS ECA15024 tery. Do not crank the engine more EAU45091 Starting off NOTICE than 10 seconds on any one at- 1. While pulling the rear brake lever tempt.

If a warning light, indicator light or with your left hand and holding the indicator does not go off, see pages ECA11042 grab bar with your right hand, push. OPERATION AND IMPORTANT RIDING POINTS EAU16780 EAU16793 Front Acceleration and deceleration Braking EWA10300 WARNING ● Avoid braking hard or suddenly (especially when leaning over to one side), otherwise the scooter may skid or overturn. ● Railroad crossings, streetcar rails, iron plates on road con- struction sites, and manhole Rear covers become extremely slip.

● Turn the engine off instead of let- Yamaha dealer check the vehi- to the correct operating clearances. Ting it idle for an extended length of cle. During this period, prolonged full-throt- time (e.g., in traffic jams, at traffic.

OPERATION AND IMPORTANT RIDING POINTS EAU17213 Parking When parking, stop the engine, and then remove the key from the main switch. EWA10311 WARNING ● Since the engine and exhaust system can become very hot, park in a place where pedestri- ans or children are not likely to touch them and be burned. If replaced more frequently, otherwise you are not familiar with vehicle ser- rapid engine wear may result. Con- vice, have a Yamaha dealer perform sult a Yamaha dealer for proper service.

Maintenance intervals. If you do not have the tools or experi- ence required for a particular job, have a Yamaha dealer perform it for you. ● From 30000 km (17500 mi), repeat the maintenance intervals starting from 6000 km (3500 mi). ● Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. EAU46920 Periodic maintenance chart for the emission control system.

PERIODIC MAINTENANCE AND ADJUSTMENT EAU17718 General maintenance and lubrication chart ODOMETER READING ANNUAL ITEM CHECK OR MAINTENANCE JOB 1000 km 6000 km 12000 km 18000 km 24000 km CHECK (600 mi) (3500 mi) (7000 mi) (10500 mi) (14000 mi) √ √. PERIODIC MAINTENANCE AND ADJUSTMENT ODOMETER READING ANNUAL ITEM CHECK OR MAINTENANCE JOB 1000 km 6000 km 12000 km 18000 km 24000 km CHECK (600 mi) (3500 mi) (7000 mi) (10500 mi) (14000 mi). Check bearing play and steering √ √. PERIODIC MAINTENANCE AND ADJUSTMENT ODOMETER READING ANNUAL ITEM CHECK OR MAINTENANCE JOB 1000 km 6000 km 12000 km 18000 km 24000 km CHECK (600 mi) (3500 mi) (7000 mi) (10500 mi) (14000 mi). Check coolant level and vehicle √ √.

PERIODIC MAINTENANCE AND ADJUSTMENT ● Hydraulic brake service. After disassembling the brake master cylinders and calipers, always change the fluid. Regularly check the brake fluid levels and fill the reservoirs as required.

Every two years replace the internal components of the brake master cylinders and calipers, and change the brake fluid. PERIODIC MAINTENANCE AND ADJUSTMENT EAU18741 2. Remove the screws, and then pull Removing and installing the the cowling off as shown. Cowling and panel The cowling and panel shown need to be removed to perform some of the maintenance jobs described in this chapter. Do not attempt to diagnose such problems yourself. Instead, have a Yamaha dealer check the vehicle. If the spark plug shows signs of elec- trode erosion and excessive carbon or other deposits, it should be replaced.

PERIODIC MAINTENANCE AND ADJUSTMENT Before installing a spark plug, the spark EAUS1703 Engine oil plug gap should be measured with a If a torque wrench is not available when The engine oil level should be checked wire thickness gauge and, if necessary, installing a spark plug, a good estimate before each ride. PERIODIC MAINTENANCE AND ADJUSTMENT 3.

Remove the engine oil filler cap and the engine oil drain bolt to Skip steps 5–9 if the oil filter element is drain the oil from the crankcase. Not being replaced. Remove the oil filter element cover by removing the bolts. PERIODIC MAINTENANCE AND ADJUSTMENT 10. Install the washer and the engine ECA11670 NOTICE oil drain bolt, and then tighten the drain bolt to the specified torque. ● Do not use oils with a diesel specification of “CD” or oils of a Tightening torque: higher quality than specified. To reset the oil change ride.

If any leakage is found, have a indicator before the periodic oil change Yamaha dealer check and repair the interval has been reached, follow the scooter. In addition, the final transmis.

PERIODIC MAINTENANCE AND ADJUSTMENT 6. Install the final transmission oil EAU20070 Coolant drain bolt and its new gasket, and The coolant level should be checked then tighten the bolt to the speci- before each ride. In addition, the cool- fied torque. Ant must be changed at the intervals specified in the periodic maintenance Tightening torque. If water has been ward to secure it.

Added to the coolant, have a Yamaha dealer check the anti- EAU33031 freeze content of the coolant as Changing the coolant soon as possible, otherwise the. PERIODIC MAINTENANCE AND ADJUSTMENT EAUM2242 3. Pull the air filter element out. Air filter and V-belt case air fil- 4.

Insert a new air filter element into ter elements the air filter case. The air filter element should be re- 5. PERIODIC MAINTENANCE AND ADJUSTMENT 4.

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Install the air filter element with the EAU48432 3. To increase the throttle grip free Adjusting the throttle grip free colored side facing outward. Play, turn the adjusting nut in direc- play 5. Install the V-belt case air filter cov- tion (a).

Therefore, it control. Must be adjusted by a Yamaha dealer is essential to maintain the tires in good ● The tire air pressure must be. Rear: ally. Cracking of the tread and sidewall 220 kPa (2.20 kgf/cm², 32 psi) rubber, sometimes accompanied by YP125R 90–180 kg (198–398 lb) carcass deformation, is an evidence of YP125RA 90–172 kg (198–379 lb): Front: ageing. Old and aged tires shall be 210 kPa (2.10 kgf/cm², 30 psi). METZELER / FEELFREE er damage before each ride.

If any Rear tire: damage is found, have a Yamaha Size: 140/70-14 M/C 68P(PIRELLI- dealer replace the wheel. Do not METZELER)-68S(MICHELIN) attempt even the smallest repair to Manufacturer/model: the wheel. The front and rear brake pads must be ver free play and, if necessary, have a Front checked for wear at the intervals spec- Yamaha dealer check the brake sys- ified in the periodic maintenance and tem. Lubrication chart. YP125R If the lining thickness is less than 0.8 mm (0.03 in), have a Yamaha dealer replace the brake pads as a set.

Minimum level mark 1. Brake pad wear indicator groove 1. ● Rear brake Use only the specified brake flu- fluid level goes down suddenly, have a id; otherwise, the rubber seals Yamaha dealer check the cause before may deteriorate, causing leak- further riding. ● Refill with the same type of brake fluid. EAU23095 EAU23114 Changing the brake fluid Checking and lubricating the Checking and lubricating the Have a Yamaha dealer change the cables throttle grip and cable brake fluid at the intervals specified in The operation of all control cables and The operation of the throttle grip should. PERIODIC MAINTENANCE AND ADJUSTMENT EAU23172 EAU23213 Recommended lubricant: Lubricating the front and rear Checking and lubricating the Silicone grease brake levers centerstand and sidestand Front brake lever 1. Sidestand Rear brake lever 1.

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Centerstand The pivoting points of the front and rear brake levers must be lubricated at the intervals specified in the periodic main- tenance and lubrication chart. Check the inner tubes for scratches, not move up and down smoothly, damage and excessive oil leakage.

Have a Yamaha dealer check or re- pair it. Otherwise, the centerstand or sidestand could contact the ground and distract the operator, resulting in a possible loss of control. If any free A.

(See page 6-8.) hub or if the wheel does not turn play can be felt, have a Yamaha This model is equipped with a VRLA smoothly, have a Yamaha dealer check dealer check or repair the steering. To charge the battery once a month and fully charge it if Have a Yamaha dealer charge the bat- necessary.

Tery as soon as possible if it seems to 3. Fully charge the battery before in- have discharged. (See page 6-8.) The main fuse, which is in a different and hard-to-reach location, must be re- placed by a Yamaha dealer. If a fuse for the individual circuits is 1. Radiator fan fuse blown, replace it as follows. Main fuse: This model is equipped with halogen 30.0 A bulb headlights.

If a headlight bulb Ignition fuse: burns out, have a Yamaha dealer re- 10.0 A Signaling system fuse: place it and, if necessary, adjust the 10.0 A headlight beam. PERIODIC MAINTENANCE AND ADJUSTMENT EAU43051 EAUM2860 Replacing a front turn signal Replacing a tail/brake light This model can be equipped with two light bulb bulb or a rear turn signal light different types of tail/brake and rear 1. Place the scooter on the center- bulb turn signal units. PERIODIC MAINTENANCE AND ADJUSTMENT 6. Install the panel.

Install the panel. Close the seat. Tail/brake light unit type B 1. Remove the socket (together with the bulb) by turning it counter- clockwise. Turn signal light bulb 2.

Tail/brake light bulb 2. However, should your scooter re- quire any repair, take it to a Yamaha dealer, whose skilled technicians have the necessary tools, experience, and know-how to service the scooter prop- erly. PERIODIC MAINTENANCE AND ADJUSTMENT heaters or furnaces. Gasoline or gasoline vapors can ignite or ex- plode, causing severe injury or property damage. Remove the spark plug and check the electrodes. The engine does not start.

Have a Yamaha dealer check the vehicle. Check the compression.

Compression The engine does not start. There is compression. Start the engine. If the engine overheats again, have a The coolant level Yamaha dealer check and repair the cooling system.

If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommended coolant as soon as possible. Cleaning Rust and corrosion can develop even if matte colored finished parts.

Be ECA10783 sure to consult a Yamaha dealer for high-quality components are used. A NOTICE advice on what products to use be- rusty exhaust pipe may go unnoticed ●. SCOOTER CARE AND STORAGE off any detergent residue using Test the product on a small hid- plenty of water, as it is harmful den part of the windshield to Salt sprayed on roads in the winter may to plastic parts. Make sure that it does not leave remain well into spring.

WARNING with a tarp, while it is still wet, ● Contaminants on the brakes or tires Consult a Yamaha dealer for ad- will allow water and humidity to can cause loss of control. Vice on what products to use. Seep in and cause rust.

SCOOTER CARE AND STORAGE 2. Fill up the fuel tank and add fuel 4. Lubricate all control cables and the stabilizer (if available) to prevent pivoting points of all levers and the fuel tank from rusting and the pedals as well as of the side- fuel from deteriorating.

. Louis has taken great care in compiling the specifications and associated products. They apply to the model of the selected vehicle that is sold in Germany.

The specifications of models sold in other countries may differ. Louis does not accept any responsibility for the accuracy of the information provided. Prior to installation, you should consult your motorcycle's handbook and/or seek information from the manufacturer. Data or products for your motorcycle missing from the database?

Found an error? Please let us know. Specifications.: Engine size: 124 Cylinders: 1 hp/kW: 12/8.5 Valve clearance (intake): KALT 0,10-0,14 MM Valve clearance (exhaust): KALT 0,16-0,20 MM Engine idle speed: 1800 ± 100 U/MIN Tyre pressure (front): 1,9 BAR Tyre pressure (rear): 2,2 (2,4) BAR Spark plug 1: NGK CR8E Spark plug 2: NGK CR8EIX Electrode gap: 0,7 MM Chain/Final drive: KEILRIEMEN Capacities.: Fork oil per rod: 130 ML SAE 20W Engine oil w/o filter: 1,3 L SAE 10W-40 Engine oil with filter: 1,4 L MIN. API SE Brake fluid: DOT 4 Final drive oil: 130 ML SAE 10W-40 Fuel: 10,5 LITER Coolant: 1,1 LITER. Specifications, spare parts and accessories for YAMAHA YP 125 R MAJESTY (SE068) Are you planning to maintain and service your own YAMAHA YP 125 R MAJESTY (SE068)? If so, Louis will provide you with all the information you need. What type of engine oil and which brake fluid should you use?

Which are the right spark plugs? What are the correct tyre pressures and valve clearances? We give you the answers to all the important questions about your motorcycle. In addition, we offer a carefully compiled list of all the wearing parts, add-ons and accessories available in our range specifically for your YAMAHA YP 125 R MAJESTY (SE068). So we are a one-stop shop where you can get all the information you need and the right product quickly and easily.

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