Yamaha TZR 125 Service Manual

a

FOREWORD

This

Service

For complete

manuals.

lnformation

information

has been

service

on

TZR125'93

prepared

procedures,

SERVICE

to introduce new service and new data

necessary

it is

MANUAL:

to use this

4FL-MEl

together

for

the TZR125'93.

with following

T2R125',93

01993 by Yamaha Motor Co., Ltd.

lst Edition,

rights reserved.

All

unauthorized use without

permission

of

is expressly

Printed in Japan

March 1993

Any reprinting or

Yamaha

prohibited.

the

Motor Co., Ltd.

:

+?

written

NOTICE

This manual

qualified

their

it is assumed

so

cycle have a repair technology.

it unfit

Yamaha Motor Company,

Modifications and rized Yamaha dealers

was written by the

mechanics.

that

basic understanding

Without

to use andlor

significant

persons

unsafe.

and

PARTICULARLY

material is distinguished

This

Yamaha Motor Company

lt is not

such

Ltd.

possible

this book

using

of the

knowledge,

is

continually

changes in specifications

mechanical concepts

will, where applicable,

HOW

TO USE

IMPORTANT

the following

by

primarily

put

to

perform

to

an entire

attempted

striving

appear

THIS

to improve

mechanic's education

maintenance

and

repairs or service

procedures

or

future editions

in

MANUAL

INFORMATION

notation.

for use by Yamaha dealers and

into one manual,

repairs on Yamaha motor-

and

procedures

all models

will be forwarded

inherent

to this

manufactured

this manual.

of

in motorcycle

model may render

to all

by Yamaha.

Autho-

The

SAFETY

WARNING

Failure to follow

to the motorcycle operator, the motorcycle.

A

CAUTION indicates special

lo

the

NOTE:

A NOTE

MANUAL FORMAT

All

of

tion has been

comprehensive explanations

ln this

of action

.

Bearings Pitting

procedures

the

compiled

revised

format,

required will follow the symbol,

Damage-- Replace.

/

in this manual are

provide

to

the

condition

Safety

Alert Symbol

IS INVOLVED!

motorcycle.

provides

the mechanic

disassembly,

of all

of a

means

WARNING

key information

organized

faulty component

e.9.,

instructions

a bystander,

precautions

in a sequential,

an easy

with

repair,

ATTENTION!

could

or a

that must

to make

read, handy

to

assembly,

precede

will

BECOME

in severe

result person

be taken

procedures

step-by-step

reference

inspection

and

an arrow

ALERT!

injury or

inspecting

to avoid damage

easier or

format.

operations.

symbol

and

YOUR

death

repairing

or

clearer.

The informa-

that contains

the course

EXPLODED DIAGRAM

Each chapter

provides

rect disassembly and assembly

exploded

diagrams before procedures.

each

disassembly

section

for ease

in identifying

cor-

e

@

ILLUSTRATED SYMBOLS

(Refer

the illustrationl

to

@

H#@

@

cooll

If

@

cnnsl

o

TRBL

SHT,

@

dtvo

,)

sPEcl

@

ENG

@

cnnal

@

ELEC I

F?

l4.t

t

l-

lllustrated symbols

thumb tabs content.

General Specifications Periodic inspection

Engine

Cooling system Carburetion

Chassis Electrical

Troubleshooting

to indicate the chapter's

information

to

C

and adjustment

are designed as

@

number and

=

@

a

@

lllustrated

the specifications appearing in the text.

Filling

Lubricant Special tool Tightening

Wear limit,

Engine speed

O,V,A

symbols

fluid

clearance

@

to

are used to identify

@

@ @

I

o

@ @ @

t@-=--

@

t&-=-- t&---

@

I

6

@

1

@

lllustrated

gram

lubrication

Apply Apply

Apply molybdenum disulfide

Apply wheel Apply lightweight

Apply molybdenum disulfide Apply locking

Use new one

symbols

indicate

point.

engine oil

gear

grade

oil

bearing

agent

@to@

of

lithium-soap base

in the exploded

lubricant

oil

grease

(LOCTITE@)

and

location

grease

i:-

dia-

of

CONTENTS

GENERAL

MOTORCYCLE IDENTIFICATION

INFORMATION

.......1

.....1

SPECIFTCATTONS .........2

GENERAL SPECIFICATIONS ,,,,,,,,,2

MAINTENANCE SPECIFICATIONS.... ......5

ENGTNE .......5

CHASSTS ....10

ELECTRICAL.... ...14

EXCLUSIVE

GENERAL

LUBRICATION POINTS AND LUBRICANT TYPE , , ,., , , ,20

COOLANT

SPECIFICATIONS

TOROUE

FLOW

SPECIFICATIONS

CHART

CABLEROUTING

PERIODIC INSPECTION AND ADJUSTMENT.. ..,,28

INTRODUCTION . ,.....28

PERIODIC MAINTENANCE/LUBRICATION ........28

EXPLODED DIAGRAM .........30

AUTOLUBE

POWER

CRANKSHAFT/BALANCER WEIGHT ....,..32

TRANSMISSION . ......33

PUMP .....30

VALVE

SHIFTER

CRANKCASE MAGNETO

SHIFT SHAFT .........37

BALANCER PISTON,

WATER PUMP

... .......35

ROTOR AND

GEAR,

CYLINDER HEAD AND CYLINDER . .....39

STARTER

CLUTCH AND PRIMARY DRIVE

DRIVE

GEAR

RADTATOR

THERMOSTATIC

VALVE ,,,,,.42

........,17

......19

.....22

.....,23

........31

...,,...34

.......36

.....38

.........40

......41

CARBURETOR... ......43

REED VALVE

FRONT

REAR WHEEL

FRONT AND REAR BRAKE ......

FRONT FORK ..,,49

STEERING

HANDLEBAR .... ......51

REAR DRIVE

ELECTRICAL COMPONENTS

TZR125 WIRING

WHEEL ........45

HEAD ......50

SHOCK

CHAIN

ABSORBER AND

AND

SPROCKETS

DIAGRAM

SWINGARM

,,,,4

.. ,46

"..47

,..,,52

....54

........55

-1-

MOTORCYCLE

I DENTI

FICATION

GENERAL

INFORMATION

MOTORCYCLE

FRAME SERIAL The frame serial right side

of steering

Starting

4FL-000101

4HW-000101

4Hx-oool

4JB-ooo101

NOTE:

The first

model

the unit

three digits

identifications;

production

NUMBER

number

serial

(F)

01

I DENTI FICATION

(1)

is stamped into the

head.

number:

(GB)

(CH) (A)

(B) (G)

(SF)

(P)

of these numbers are

the remaining

number.

digits

for

are

serial

NUMBER

number

number:

(F)

ENGINE SERIAL

The engine

left side

the engine.

Starting

4FL-000101

4HW-000101

4Hx-oool01

4JB-000101

NOTE:

oThe

first three

(CH) (A) (SF)

(B)(G)(P)

digits of these numbers are

model identifications;

the unit

oDesigns

change

production

specifications are subject

and

without notice.

is stamped

@

(GB)

the remaining digits are

number.

into the

for

to

-2-

ERAL SPECI

GEN

SPECIFICATIONS

EN ERAL

G

SPECI

Modelcode: 4JB1

Engine starting number: Frame

Dimensions:

starting

Overall length

Overallwidth

Overall height Seat height Wheelbase

Minimum

ground

Minimum turning radius

Basic weight:

With

oil and

fullfuel tank

FICATIONS

Model

number:

clearance

4JB-0001 01 4JB-0001 0 1

2,015 mm

730 mm

1,105 mm

770 mm

1,370 mm

160 mm

3,100 mm

136 ks

(3001b)

FICATIONS

(79.3

in)

(28.7

in)

(43.5

in)

(30.3

in)

(53.9

in)

(6.30

in)

1122.0inl

TZR125

sPEc

F7

I

Engine:

Engine type

lnduction system

Cylinder Displacement BoreXstroke Compression ratio Starting system

Lubrication

Oiltype

Engine

Transmission

Oil capacity:

Oiltank

Transmission oil

Periodic Total

Radiator capacity

arrangement

system:

grade:

or

oil

(engine

oil change

amount

Air filter:

oil:

oil)

(including

all

routes):

Liquid-cooled

valve

Reed

Forward-inclined single cylinder

125

cm3

56.0x50.7

2-stroke

(2.20x2.00

mm

in)

6.2:1

Electric

Separate

Yamaha

SAE10W30 type SE motor oil

1.7 L

0.75 L

0.8

0.9 L

Wet

starter

lubrication

2T

oil

(1.5

lmp

(0.7

lmp

(0.7

L

lmp

(0.79

lmp

type element

(Yamaha

air-cooled

qt,

1.8 US

qt,0.8

qt,

US

0.95 US

2-stroke engine oil

qt)

US

qt)

Autolube)

Fuel:

Type

Fuel tank capacity

reserve

Fuel

Carburetor:

Type/quantity

Manufacturer

amount

Regular

15 L

2.5 L

TM28SS/1

MIKUNI

unleaded

(3.30

(0.55

lmp

gasoline

gal,

3.96 US

9a1,0,66

US

gal)

-3-

Model

plug:

Spark

Type

Manufacturer

plug

Spark

Clutch type:

Transmission:

Primary reduction Primary reduction Secondary reduction system Secondary reduction Transmission type Operation

Gear

gap

system ratio

ratio

ratio 1st

2nd

3rd 4th 5th 6th

G EN

ERAL

SPECI FICATIONS

BR9ECM

NGK

0.7-0.8 mm

Wet, multiple-disc

Helicalgear

71/2213.2271 Chain drive

46/16{.2.875]|

Constant mesh 6-speed

Left foot operation

(2.833)

34/12

(1.813)

29/16

(1.368)

26/19 24/21(1.1431

(1.000)

23/23

(0.917)

22/24

TZR125

(0.028-0.031

sPEc

in)

F?

I

Chassis:

Frame Caster

Trail

Tire:

Type

type

angle

Size

Manufacturer front

Type

pressure

Tire

Maximum load-except motorcycle

Loading condition A

Loading condition B

(cold

tire):

*

f ront

rear

front

rear

front

rear

front

rear

Pressed

24'

87 mm

Tubeless

110/70-17

140/70-17 DUNLOP/INOUE DUNLOP/INOUE

D13OF/R532OF D13OA/RS32OR

170 ks

0-e0 ks

175 kPa

200 kPa

90-170 kg

175 kPa

225 kPa

*Load

passenger

backbone

(3.a3

in)

545 665

(375

lb)

(0-1981b)

(1.75

kg/cm2,25

(2kg/cm2,28 psi)

(198-37s

(1.75

kg/cm2,25

kg/ cm2, 32

12.25

is the total weight

and accessories.

psi)

lb)

psi) psi)

of cargo,

rider,

-4-

Brake:

Front brake

Rear brake

Suspension:

Front suspension

Rear suspension

Shock absorber:

Front shock absorber

Rear shock absorber

Wheeltravel:

Front wheel travel

Rear wheel travel

Electrical:

lgnition system

Generator system

Battery type Battery

capacity

Model

EN ERAL SPECI

G

type

operation

type

operation

FICATIONS

Single disc brake

Right hand Single disc brake

Bight

Telescopic

Swingarm

Coilspring/Oil damper

Coil spring/Gas-oil

130 mm

110 mm

c.D.t.

A.C. magneto

GM6-48

12V 6 AH

operation

foot operation

fork

(monocross)

(5.1

in)

(a.3

in)

generator

damper

TZR125

sPEc

F?

I

Headlight type:

Bulb wattageXquantity:

Headlight

Auxiliary light Tail/brake light

Flasher light

Meter light lndicator light

NEUTRAL HIGH BEAM OIL LEVEL TURN

Bulb type

12V 60 W/55 Wx1

12V 4Wx2

12V

5W/21WX1

12V 21Wx4

12V 1.7 Wx4

12V 3.4

12V 3.4 12V 3.4 Wx1 12V 3.4

WX1 WX1

WX1

-5-

MAI NTENANCE

ENGINE

Cylinder head:

Warp limit

Cylinder:

Bore

size

Taper

limit

Out of round limit

Piston:

Piston to

cylinder clearance

(Limit)

Piston

size

"D"

SPECI

Model

MAI NTENANCE

FICATIONS

SPECI FICATIONS

0.03 mm

:icLines

56.00-56.02

0.05 mm

0.01 mm

0.035-0.040 mm

{0.1

55.96- 55.98 mm

(0.0012

indicate

(0.002

(0.0004

(0.0039

mm

in)

straightedge measurement.

(2.2A47-2.2055

mm

in)

(0.0014-0.0016

in)>

(2.203

TZR125

-2.204

sPEc

in)

inl

F?

I

Measuring Piston Piston Piston Piston

Piston

Top ring:

2nd

off-set off-set direction

pin pin

rings:

Type Dimensions

gap (installed)

End

Side clearance

ring:

Type Dimensions

gap (installed)

End

Side

clearance

point "H"

bore inside diameter outside diameter

(Bxr)

(installed)

(BXT)

-17,

L-T---;

[-r*l

I

-T

H

mm

side

(0.591

in)

(0.02

in)

16.023 mm

6.000 mm

(0.047X0.094

mm

(0.012-0.018

mm

(0.001-0.002

(0.047X0.075

mm

(0.012-0.018

(0.6300-0.6308 (0.6280-0.6299

in)

in) in)

in)

(0.001-0.003

in) in)

in)

15

0.5 mm

lN

16.002-

1 5.950-1

Keystone

1.2x2.4

0.30-0.45

0.02-0.06 mm

Plain

1.2x1.9

0.30-0.45 mm

0.035-0.070 mm

-6-

Crankshaft:

Balancer:

Balancer drive method

Clutch:

Friction

plate

thickness

Ouantity

limit

Wear

plate

Clutch

thickness

Ouantity Warp limit

Clutch spring

free length Ouantity Minimum

Clutch

Push rod bending limit

length

release method

MAI NTENANCE SPECI

Model

width

Crank

Round limit

end side clearance

Big Big end

"A"

"C"

radial clearance

"D"

"E"

FICATIONS

57.90- 57.95 mm

0.02 mm

0.2-0.7 mm

0.026-0.040

Gear

2.9-3.1

pcs

7

2.7 mm

1.05-1.35 mm

pcs

6

0.05 mm

34.5 mm

pcs

5

32 mm

lnner

0.15 mm

(0.0008

mm

(0.11

(0.002 (1.36

(1.26

push,

(0.006

(0.008-0.028

mm

(0.1

in)

(0.041-0.053

in)

cam

TZR125

(2.280

in)

(0.0010-0.0016

14-0.122

in)

push

in)

2.281 inl

-

in)

inl

sPEc

in)

F7

I

Transmission:

Main axle deflection Drive axle deflection

Shifter:

Shifter

Air filter oil

type

grade: Foam-air-filter oil

limit

mm

(0.003 (0.003

0.08 mm

0.08

Cam drum and

in)

guide

bar

or SAE10W30

type SE motor oil

-7-

Carburetor:

l.D.

mark

jet

Main

jet

Air

Jet needle

Needle

Cutaway

Pilot

Bypass

Air

Valve Starter Power

Float Fuel level

Engine

jet

outlet

jet

screw

seat size

jet

height

idle speed

in)

sPEc

edge

F?

I

MAI

NTENANCE

Model

(M.J)

(A.J) (J.N) (N.J)

(c.A)

(P.o)

(P.J)

1

(8.P.1) (A.S)

(V.S)

(G.s.1) (PW.J)

(F.H) (F.L)

SPECI FICATIONS

4FL

OO

#210

0.6

5H38-2/5

P-2

1.0

0.6

# 17.5

1.6

1-1/2

2.8

#25 #110

15.5-16.5

1.5-2.5 mm

Below 1,250-1,450

the

(0.61-0.65

mm

(0.06-0.10

carburetor body

rlmin

TZR125

Reed valve:

Thickness Valve

stopper

Upper Lower

Valve bending

Lubrication

Autolube

Plunger

Minimum Maximum

Pulley

Cooling

Radiator

adjusting

system:

core

width

Height

Thickness Radiator Reservoir

(From

Water

Type

Reduction

cap

low

pump

height

limit

system:

pump:

diameter

stroke

size

opening

tank

capacity

to full

ratio

mark

pressure

level)

mm mm

(0.02

(0.37 (0.30 (0.02

(0.138

0.4 mm

9.5

7.5

0.5 mm

3.5 mm

0.20-0.24

2.78-2.92 At full

throttle

315 mm

160 mm 16 110

0.28 L

<0.15

Single 30/22

(0.63

mm

(1.1k9/cm2,

kPa

(0.25

L

suction centrifugal

(1.364)

in)

in) in) in)

in)

(0.008-0.010

mm

(0.109-0.1

mm

(2.ainl

(6.30

in)

qt,

lmp

(0.13|mp

15.65

0.30

US

qt,0.16

in)

15 in)

psi)

qt)

US

pump

qt))

-8-

Tightening

Spark

torque

Parts

to be tightened

plug Cylinder head Cylinder Cylinder

Power valve

holder Power valve Power Pulley

valve

cover

pulley

(power Pulley housing

Balancer weight

gear

Thermostatic valve Water

Water

pump

housing

housing Radiator Radiator Radiator cap

(carburetor

Hose

Autolube

(autolube

Stay Carburetor

Air filter

Cylinder

Exhaust Exhaust Exhaust

stopper

warmer)

pump

pump)

joint

case

(exhaust pipe)

pipe (exhaust pipe

(exhaust pipe-frame)

pipe

(silencer-silencer

Silencer bracket

Crankcase Crankcase

Transmission

Crankcase cover

Front

Crankcase Oil

seal

Baffle

Bearing retainer Plate

(left/ri ght)

(left/right)

oil

drain bolt

(left)

drive sprocket

(right)

cover

retainer

(crankshaft)

plate

(starter

idle

gear)

Starter clutch Primary

drive

gear

Clutch boss

Pressure

Bearing

Drive

Stopper lever

plate

stopper

sprocket

plate (main

(shift

valve)

cover

cover drain

pipe

pipe-cylinder)

bracket)

protector

wheel

bearing)

axle

cam)

MAI NTENANCE

Part name

nut

Cap

Stud bolt

Nut Bolt Bolt Bolt Bolt Bolt Nut

Screw Screw

bolt

gear)

Bolt Bolt Bolt

Cap nut

Bolt

bolt

Union

Screw Screw

Bolt with washer Bolt with washer

Stud bolt

Nut Bolt Bolt Bolt

Stud bolt

Screw

Bolt

Screw Screw Screw Screw Screw Screw

with washer

Screw

Bolt

Nut Nut

Bolt with washer

Screw

Nut

Bolt

SPECI FICATIONS

Thread

size

M14

M8 M8 M8 M5 M5 M6 M5 M5

M12

M6 M6 M6 M6 M6 M6

M5

M6 M5 M6 M6 M6 M8 M8 M8 M6 M6 M8 M6 M8 M6 M6 M6 M8 M6 M6 M6 M6

M12 M12

M5

M6

M16

M6

Tightening torque

O'ty

Nm m'kg ft.tb

1

20

5

22

5

13

4

28

2

7

1

10

2

7

2

7

1

55

3

I

2

8

1

10

1

8

2

6

1

6

1

5

2

8

2

5

1

8

4

8

2

6

2

13

2

20

1

18

1

10

1

10

4

13

I

1

15

5

8

2

8

6

8

1

16

2

8

3

8

2

8

3

14

1

80

1

60

5

6

2

10

1

60

1

14

2.0

2.2

1.3

2.8

0.7

1.0

0.7

5.5

0.8

1.0

0.8

0.6

0.5

0.8

0.5

0.8

0.6

1.3

2.0

1.8

1.0

1.3

0.8

1.5

0.8

1.6

0.8

1.4

8.0

6.0

0.6

1.0

6.0

1.4

sPEc

14

16

9.4 20

5.1

See NOTE

7.2

5.1

40

Use lock washer

5.8

7.2

5.8

4.3

3.6

5.8

3.6

5.8

4.3

9.4

14 13

7.2

9.4

5.8

11

5.8

11

5.8

10

s,";@

58

Use

43

Use lock

4.3

7.2

43

Use lock washer

10

F?

I

Remarks

-(I

-,@

lock washer

washer

-,@

-9-

Parts

pedal

Shift

pedal

Shift

pedal

Shift Thermo

CDI magneto

unit

Magneto base

Starter

motor

Neutralswitch

NOTE:

First, tighten

tighten the

MAI NTENANCE

to be tightened Part name

Bolt adjuster adjuster

the

power

(front)

(rear)

assembly

power

valve

valve bolt 1/8 turn.

bolt

6 Nm

Nut Nut

Nut

Bolt

Screw

(0.6

SPECI

Thread

size

O'ty

M6 M6 M6

M12

M6 M6

M10

m. kg, 4.3 ft. lb)

FICATIONS

Tightening

Nm m'kg ft.lb

1

10

1

80

2

1

8 8

15

8

4

1.0

0.8

1.5

8.0

0.8

8

0.8

0.4

SPEC

torque

7.2

5.8

11

58

5.8

2.9

F7

Remarks

Left-hand thread

Use water resistant sealan

by using the torque wrench, and then

-

10-

CHASSIS

Steering

Front

Fork

system:

suspension:

fork

spring free length

{Limit}

Spring

rate

Stroke

Optionalspring Oilcapacity Oillevel

Oilgrade

bearing

travel

type

Model

MAI

NTENANCE

(K1) (K2) (K1) (K2)

SPECI FICATIONS

Taper roller

130

mm

376 mm

<372

4.0 N/mm

6.5 N/mm

0-58

58-130

No

372 cm3

124

mm

From top damper rod fully

Fork

oil 5

bearing

(5.12

in)

(1a.8

in)

(14.6

mm

(13.1 (4.88

in))

(0.4

kg/mm 22.4\blinl

(0.65

kg/mm

(0.00-2.28

(2.28-5.12

lmp

o2,12.6 US oz)

in)

of outer tube with inner

compressed without

WT

or equivalent

rzR125

36.4|blin)

in)

sPEc

tube and

F?

I

fork spring

Rear

suspension: Shock Spring

absorber travel

free length

{Limit}

Fitting

Spring

length

rate

Stroke

Optionalspring

Enclosed

Swingarm:

play

Free

Front wheel:

Type

Rim

size

Rim

material

Rim

runout

gas/air pressure

(STD)

limit

limit radial

(K1) (K2) (K1) (K2)

end

side

lateral

39 mm

174

<172

163

120.0

152.0

(1.54

mm

N/mm N/mm

(6.85

(6.42

0-14 mm

14-39

No

1,500 kPa

1 mm

0.6 mm

Cast wheel

MT3.00x17 Aluminum

1 mm

0.5 mm

mm

(0.04

(0.02

(0.04

(0.02

in)

(6.77

in))

in)

(12

kg/mm 672.0lblinl

(15.2

kg/mm 851.2|blin)

(0.00-0.55

(0.55-1.54

(15

kg/cm2, 213

in)

psi)

Rear wheel:

Type

Rim

size

Rim

material

Rim

runout limit

radial lateral

Cast wheel

MT3.50X17

Aluminum

(0.04

1 mm

0.5 mm

(0.02

in)

-11-

Model

Drive chain:

Type/manufacturer

No.

Chain free

Front

Type

Disc

Pad thickness

(Limit)

Master cylinder inside diameter Caliper cylinder inside diameter Caliper cylinder inside diameter

Brake'fluid type

links

of

play

disc brake:

outside diameterXthickness

i(

MAI NTENANCE SPECI

428V2/DA|DO

140

30-40 mm

Single

282x4 mm

5.5 mm

(0.5

12.7 mm

33.9 mm 27 mm

DOT #3

(0.22in\

mm

(1.06

FICATIONS

(1.2-1.6

(11.1x0.16

(0.02

in)>

(0.50

in)

(1.33

in)

or DOT

#4

rzR125

in)

sPEc

F?

I

Rear disc brake:

Type

Disc

outside diameterXthickness

Master

Caliper cylinder inside

Brake fluid

Brake

Brake lever free

Clutch lever

cylinder inside diameter

type

lever & brake

play

play (at

free

pedal:

(at

diameter

lever

lever end)

pivot)

Single

210x5 mm

5.5 mm

(0.5

12.7 mm

38.1 mm

DOT #4

2-5 mm

(0.22in1

mm

(0.50 (1.50

(0.08-0.20

10-15 mm

(8.3X0.20

(0.02

in)>

in) in)

(0.4-0.6

in)

in) in)

-12-

Tightening

Upper bracket Upper Handlebar Handlebar Steering Main

switch and upper

Outer tube Front master

Brake hose Brake hose

Upper cowling Upper cowling

torque

Parts to

and outer tube

bracket

and steering shaft

and outer tube and upper

shaft

and

lower

and

cylinder

and brake and master cylinder

and screen and side cowling

Front flasher light

Upper cowling

panel

Inner Front

master

Engine Engine mount

mount

Main frame

Frame

Pivot

Flear

Rear

Mirror

Fuel Fuel

Side

Rear flasher

and down tube

shaft shock absorber shock absorber

stay and frame

tank

cock and fuel

cover

Sidestand Sidestand

Footrest

Rear

footrest

Rear master Rear brake Brake hose Brake

hose

Sidestand

Footrest Front

wheel

Rear

wheel

Front

caliper

Rear

caliper

Brake

disc

Rear

wheel

and inner

and

side cowling

cylinder and cap

(front-lower)

(upper)

and rear frame

nut

and

and frame

rear

and

light bolt and bolt

and lock nut

bracket

and frame

cylinder

reservoir

and brake caliper and master cylinder

bracket

axle

axle and nut

and front fork

and caliper bracket

and wheel hub

sprocket

MA! NTENANCE

be tightened Thread

MB

M22

M8

bracket

ring

nut

bracket bracket and bracket

caliper

(front)

M6

M25

M6

MB

M6

M10 M10

M5 M5

and cowling

panel

stay

M12x 1.25

M5 M5 M5

M10

MB

M8 M8

M16

and swingarm

frame

and

M12 M12

M6 M6

tank

frame

and rear fender

sidestand

frame

and

M6

MG

M12x 1.25

M 10 x 1.25

M10

M8 M8

and bracket

tank

and frame

plate

and

frame

and

(rear)

(front

and

clutch hub

rear)

M8 M6

M10 M10 M10

M6

M16 M14 M10 M10

MB

M10

SPECI FICATIONS

Tightening

size

Nm nr.kg

x

x x x x

x x

x x x

x x x x x x x x x x x

x x

1.25

1.0

1.25

1.0

1.25

0.8

1.25

1.5

1.25

1.0

1.25

1.0

1.25

1.0

1.5

1.25

1.0

1.25

23

110

28

13

7

I

20

9 26 26

0.7

4

0.7

0.7 2

65 40 35 23

104

74 74

I

7 7 7

4

45

40

30 30 30

4 26 26 56

9 75

144

40

4A

23 40

2.3

1 1.0

2.8

1.3

0.7

0.9

2.0

0.9

2.6

0.07

4.4

0.07

0.2

6.5

4.0

3.5

2.3

10.4

7.4

0.9

0.7

0.4

4.5

4.0

3.0

0.4

2.6

5.6

0.9

1.5

10.4

4.4

4.0

2.3

4.0

torque

ft.lb

17

80

20

9.4

5.1

6.5 14

6.5 19 19

0.51

2.9

0.51

1.4

47

29 25

17

l5

53 53

6.5

5.1

2.9

32

29 22 22 22

2.9 19 19

40

6.5

54

75

29 29

17

29

sPEc

Remarks

NOTE

See

_JaLorl

_zt9}t

_JlLJrl

d{

-a-{

a,d

F?

I

-

13-

NTENANCE SPECI FICATIONS

MAI

Tightening torque

Parts to be tightened

Bleed

screw and

Caliper bracket and syvingarm

brake caliper

(front

and

rear)

Thread

M8

M10

x x

size

1.25

Nm

52

m'kg

6

0.6

5.2

1. First,tightentheringnutapproximately45Nm(4.5m.kg,32ft.lb)

loosen the ring nut one

then

2. Retighten the

ring nut to specification.

turn.

sPEc

F'

I

Remarks

ft. lb

4.3 37

byusingthetorquewrench,

-14-

ELECTRICAL

Voltage:

lgnition

Advancer

lgnition

system:

o,

C

c

F-.:.

c(J O-i

c'

-"9

timing

type

Model

(B.T.D.C.)

30

20

-

10

MAI NTENANCE

/\ \

I

\

J

SPECI

12V

I

17"

at 1,500

|

Electrical type

I

t t

L

J

FICATIONS

TZR125

r/min

\

sPEc

F?

I

c.D.t.:

Magneto model/manufactu

p

Picku

Source coil resistance/color

C.D.l. unit model/manufacturer

lgnition coil:

Model/manufactu rer

Minimum

Pri mary winding resistance

Secondary winding resistance

plug

Spark

Type

Resistance

resistance/color

coil

gap

spark

cap:

246810

rer

Engine Speed

F4FLlYAMAHA

280-420

White/Red-White/Blue

496-744 Q Black/Red-G reen/White

4JBIYAMAHA

2JN/YAMAHA

6 mm

0.56-0.84 Q

5.68-8.52 kQ at 20"C

Noise-suppressor type

5kQ

(x103

(0.24

r/min)

A

at 20'C

at

in)

20'C

at

20"C

(68'F)

(68"F)

\