Page 3 - FOREWORD
FOREWORD This Supplementary Service Manual has been prepared to introduce new service and data for theSR125 ’99. For complete service information procedures it is necessary to use this SupplementaryService Manual together with the following manual. SR125 SERVICE MANUAL: 3MW-AE1 SR125 SUPPLEMENTARY S...
Page 4 - NOTICE; IMPORTANT INFORMATION
NOTE: CAUTION: EB001000 NOTICE This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers andtheir qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual,so it is assumed that anyone who uses this book to perform maintenance and...
Page 5 - HOW TO USE THIS MANUAL
1 2 6 7 6 4 3 8 YP002000 HOW TO USE THIS MANUAL MANUAL ORGANIZATIONThis manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”) 1st title 1 : This is the title of the chapter with its symbol on the upper right corner of each page. 2nd title 2 : This title indicat...
Page 6 - ILLUSTRATED SYMBOLS
22 1 3 5 7 9 2 4 8 6 24 25 23 21 19 20 18 16 17 15 14 13 11 12 10 GEN INFO SPEC ENG CARB ELEC CHAS COOL INSP ADJ TRBL SHTG EB003000 ILLUSTRATED SYMBOLS Illustrated symbols 1 to 9 are designed as thumb tabs to indicate the chapter’s numberand content. 1 General information 2 Specifications 3 Periodic...
Page 7 - CONTENTS; PERIODIC INSPECTIONS AND ADJUSTMENTS
CONTENTS GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE SPECIFICATIONS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....
Page 9 - SPEC
–1– GENERAL SPECIFICATIONS SPEC SPECIFICATIONS GENERAL SPECIFICATIONS Model SR125 Model code: 3MW8 Dimensions: Overall height 1,100 mm Chassis: Caster angleTrail 26.75 90 mm Wheel travel: Rear wheel travel 76 mm Bulb wattage quantity: HeadlightAuxiliary lightTail / brake lightFlasher lightMeter ligh...
Page 10 - MAINTENANCE SPECIFICATIONS; ENGINE
–2– MAINTENANCE SPECIFICATIONS SPEC MAINTENANCE SPECIFICATIONS ENGINE Item Standard Limit Cam chain: Cam chain type / No. of linksCam chain adjustment DID 25SH / 104 ENDLESSAutomatic SSS SSS Carburetor: Engine idle speed 1,300 – 1,400 rpm SSS CHASSIS Item Standard Limit Steering system: Steering bea...
Page 11 - CHASSIS
–3– MAINTENANCE SPECIFICATIONS SPEC NOTE: TIGHTENING TORQUESENGINE Part to be tightened Part name Thread size Q’ty Tightening torque Remarks g size y Nm m S kg Timing chain tensioner boltTiming drain tensioner cap bolt BoltBolt 21 1010 0.10.1 CHASSIS Part to be tightened Thread size Tightening torqu...
Page 12 - CABLE ROUTING
–4– CABLE ROUTING SPEC 12 Wireharness 13 Horn lead 14 Headlight earth lead 15 Auxilialy light lead 16 Meter lead A Faster the handlebar switch lead (left and right) front brake switch lead clutch switch lead to the handlebar with a band. B Don’t contact the horn and wire- harness. C To auxiliary lig...
Page 17 - CHECKING AND ADJUSTING THE STEERING HEAD; INSP; WARNING
–9– CHECKING AND ADJUSTING THE STEERING HEAD INSP ADJ WARNING NOTE: EB304130 CHECKING AND ADJUSTING THE STEER-ING HEAD1. Stand the motorcycle on a level surface. Securely support the motorcycle so thatthere is no danger of it falling over. Place the motorcycle on a suitable stand so thatthe front wh...
Page 18 - Steering nut wrench
–10– CHECKING AND ADJUSTING THE STEERING HEAD INSP ADJ NOTE: WARNING NOTE: 110 Nm (11.0 m S kg) 26 Nm (2.6 m S kg) 6.Adjust: S steering head a. Remove the lock washer 1 , the upper ring nut 2 , and the rubber washer 3 . b. Loosen the lower ring nut 4 and then tighten it to specification with a ring ...
Page 19 - ENG; CYLINDER HEAD
–11– CYLINDER HEAD ENG Order Job name / Part name Q’ty Remarks 1234567 Cylinder head removalTiming chain tensioner assemblyCam sprocket / Timing chainIgnition coilCylinder headDowel pinsGasketCylinder head gasket 1 1 / 1 11311 Remove the parts in order. Reverse the removal procedure forinstallation....
Page 22 - Always use a new gasket.; Cap bolt
–14– CYLINDER HEAD ENG WARNING 60 Nm (6.0 m S kg) NOTE: Always use a new gasket. Timing chain tensioner bolt 10 Nm (1.0 m S kg) d. Remove the screwdriver, make sure that the timing chain tensioner rod releases, andtighten the cap bolt to the specified torque. Cap bolt 10 Nm (1.0 m S kg) 6. Tighten: ...
Page 23 - CHAS; STEERING
–15– STEERING CHAS Order Job name / Part name Q’ty Remarks 1234567 89 Under bracket removalFront forkHandlebarHeadlight unitMeter assemblyHeadlight stayHandlebar crownLock washerUpper ring nutRubber washer Lower ring nutBall race cover 1111111 11 Remove the parts in order.Refer to “FRONT FORK” secti...
Page 25 - COLOR CODE
COLOR CODE B Black . . . . . Br Brown . . . . Ch Chocolate . . . Dg Dark green . . . G Green . . . . L Blue . . . . . Or Orange . . . . Sb Sky blue . . . . P Pink . . . . . R Red . . . . . Y Yellow . . . . . W White . . . . Br / L Brown / Blue . . Br / W Brown / White . G / Y Green / Yellow . . L / ...
