Yamaha YZ125 X1 2008 Owner's manual

2008

OWNER’S SERVICE MANUAL

MANUEL D’ATELIER DU

PROPRIETAIRE

FAHRER- UND

WARTUNGSHANDBUCH

MANUALE DI SERVIZIO DEL

PROPRIETARI

YZ125(X)/X1

1C3-28199-33

YZ125(X)/X1

1C3-28199-33-E0

2008

OWNER’S SERVICE MANUAL

YZ125 (X)/X1

OWNER'S SERVICE MANUAL

permission of Yamaha Motor Co., Ltd.

is expressly prohibited.

Printed in Japan

FOREWORD

INTRODUCTION

Congratulations on your purchase of a Yamaha YZ series. 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. This manual explains operation, inspection, basic maintenance and tuning of your machine. If you have any questions about this manual or your machine, please contact your Yamaha dealer.

Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most current product information available at the time of printing, there may be minor discrepancies between your machine and this manual. If you have any questions concerning this manual, please consult your Yamaha dealer.

PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MACHINE. DO NOT ATTEMPT TO OPERATE THIS MACHINE UNTIL YOU HAVE ATTAINED A SATISFACTORY KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES. REGULAR INSPECTIONS AND CAREFUL MAINTENANCE, ALONG WITH GOOD RIDING SKILLS, WILL ENSURE THAT YOU SAFETY ENJOY THE CAPABILITIES AND THE RELIABILITY OF THIS MACHINE.

PARTICULARLY IMPORTANT INFORMATION

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander, or a person inspecting or repairing the machine.

A CAUTION indicates special precautions that must be taken to avoid damage to the machine.

A NOTE provides key information to make procedures easier or clearer.

IMPORTANT NOTICE

THIS MACHINE IS DESIGNED STRICTLY FOR COMPETITION USE, ONLY ON A CLOSED COURSE. It is illegal for this machine to be operated on any public street, road, or highway. Off-road use on public lands may be illegal. Please check local regulations before riding.

1. THIS MACHINE IS TO BE OPERATED BY AN EXPERIENCED RIDER ONLY. Do not attempt to operate this machine at maximum power until you are totally familiar with its characteristics.

2. THIS MACHINE IS DESIGNED TO BE RIDDEN BY THE OPERATOR ONLY. Do not carry passengers on this machine.

3. ALWAYS WEAR PROTECTIVE APPAREL. When operating this machine, always wear an approved helmet with goggles or a face shield. Also wear heavy boots, gloves, and protective clothing. Always wear proper fitting clothing that will not be caught in any of the moving parts or controls of the machine.

4. ALWAYS MAINTAIN YOUR MACHINE IN PROPER WORKING ORDER. For safety and reliability, the machine must be properly maintained. Always perform the pre-operation checks indicated in this manual. Correcting a mechanical problem before you ride may prevent an accident.

5. GASOLINE IS HIGHLY FLAMMABLE. Always turn off the engine while refueling. 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, contact a doctor immediately. If any gasoline spills onto your skin or clothing, immediately wash skin areas with soap and water, and change your clothes.

7. ONLY OPERATE THE MACHINE IN AN AREA WITH ADEQUATE VENTILATION. Never start the engine or let it run for any length of time in an enclosed area. Exhaust fumes are poisonous. These fumes contain carbon monoxide, which by itself is odorless and colorless. Carbon monoxide is a dangerous gas which can cause unconsciousness or can be lethal.

8. PARK THE MACHINE CAREFULLY; TURN OFF THE ENGINE. Always turn off the engine if you are going to leave the machine. Do not park the machine on a slope or soft ground as it may fall over.

9. PROPERLY SECURE THE MACHINE BEFORE TRANSPORTING IT. When transporting the machine in another vehicle, always be sure it is properly secured and in an upright position and that the fuel cock is in the "OFF" position. Otherwise, fuel may leak out of the carburetor or fuel tank.

TO THE NEW OWNER

This manual will provide you with a good basic understanding of features, operation, and basic maintenance and inspection items of this machine. Please read this manual carefully and completely before operating your new machine. If you have any questions regarding the operation or maintenance of your machine, please consult your Yamaha dealer.

This manual should be considered a permanent part of this machine and should remain with it even if the machine is subsequently sold.

NOTICE

Some data in this manual may become outdated due to improvements made to this model in the future. If there is any question you have regarding this manual or your machine, please consult your Yamaha dealer.

F.I.M. MACHINE WEIGHTS

Weights of machines without fuel

The minimum weights for motocross machines are:

for the class 125 cc: minimum 88 kg (194 lb)

for the class 250 cc: minimum 98 kg (216 lb)

for the class 500 cc: minimum 102 kg (225 lb)

In modifying your machine (e.g., for weight reduction), take note of the above limits of weight.

HOW TO USE THIS MANUAL

FINDING THE REQUIRED PAGE

1. This manual consists of seven chapters; "General Information", "Specifications", "Regular inspection and adjustments", "Engine", "Chassis", "Electrical" and "Tuning"

2. The table of contents is at the beginning of the manual. Look over the general layout of the book before finding then required chapter and item. Bend the book at its edge, as shown, to find the required fore edge symbol mark and go to a page for required item and description.

MANUAL FORMAT

All of the procedures in this manual are organized in a sequential, stepby-step format. The information has been complied to provide the mechanic with an easy to read, handy reference that contains comprehensive 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.,

• Bearings Pitting/damage

→ Replace.

HOW TO READ DESCRIPTIONS

To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section.

1. An easy-to-see exploded diagram "1" is provided for removal and disassembly jobs.

2. Numbers "2" are given in the or-

der of the jobs in the exploded diagram. A number that is enclosed by a circle indicates a disassembly step.

3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks "3". The meanings of the symbol marks are given on the next page.

4. A job instruction chart "4" accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc.

5. For jobs requiring more information, the step-by-step format supplements "5" are given in addition to the exploded diagram and job instruction chart.

ILLUSTRATED SYMBOLS (Refer to the illustration)

Illustrated symbols "1" to "7" are used to identify the specifications appearing in the text.

1. With engine mounted

2. Filling fluid

3. Lubricant

4. Special tool

5. Tightening

6. Specified value, Service limit

7. Resistance ( Electric current (A)

Illustrated symbols "8" to "14" in the exploded diagrams indicate grade of lubricant and location of lubrication point.

8. Apply engine mixing oil

9. Apply transmission oil

10. Apply molybdenum disulfide oil

11. Apply brake fluid

12. Apply lightweight lithium-soap base grease

13. Apply molybdenum disulfide grease

14. Apply silicone grease

Ω), Voltage (V),

Illustrated symbols "15" to "16" in the exploded diagrams indicate where to apply a locking agent and where to install new parts.

15. Apply locking agent (LOC-

16. Use new one

TITE

)

TABLE OF CONTENTS

GENERAL INFORMATION

SPECIFICATIONS

REGULAR INSPECTION AND ADJUSTMENTS

ENGINE

CHASSIS

ELECTRICAL

TUNING

CONTENTS

CHAPTER 1

GENERAL INFOR-

MATION

DESCRIPTION ................. 1-1

MACHINE

IDENTIFICATION ............. 1-2

INCLUDED PARTS .......... 1-2

IMPORTANT

INFORMATION................. 1-2

CHECKING OF CONNEC-

TION ................................. 1-3

SPECIAL TOOLS............. 1-4

CONTROL FUNCTIONS .. 1-7 STARTING AND

BREAK-IN ........................ 1-7

TORQUE-CHECK

POINTS............................. 1-9

CLEANING AND

STORAGE ...................... 1-10

CHAPTER 2

SPECIFICATIONS

GENERAL SPECIFICA-

TIONS ............................... 2-1

MAINTENANCE SPECIFICA-

TIONS ............................... 2-2

TIGHTENING TORQUES.2-7 CABLE ROUTING

DIAGRAM....................... 2-12

CHAPTER 3

REGULAR INSPEC-

TION AND AD-

JUSTMENTS

MAINTENANCE

INTERVALS...................... 3-1

PRE-OPERATION INSPECTION AND MAINTE-

NANCE ............................. 3-3

ENGINE ............................3-5

CHASSIS ..........................3-8

ELECTRICAL ................. 3-18

CHAPTER 4

ENGINE

SEAT, FUEL TANK AND

SIDE COVERS..................4-1

EXHAUST PIPE AND SI-

LENCER ...........................4-3

RADIATOR .......................4-5

CARBURETOR AND REED

VALVE ..............................4-7

CYLINDER HEAD, CYLIN-

DER AND PISTON .........4-12

CLUTCH .........................4-19

KICK SHAFT AND SHIFT

SHAFT ............................4-23

YPVS GOVERNOR.........4-28

WATER PUMP................4-30

CDI MAGNETO............... 4-33

ENGINE REMOVAL ....... 4-35

CRANKCASE AND CRANK-

SHAFT ............................4-39

TRANSMISSION, SHIFT CAM AND SHIFT FORK.4-44

CHAPTER 5

CHASSIS

FRONT WHEEL AND REAR

WHEEL .............................5-1

FRONT BRAKE AND REAR

BRAKE .............................5-6

FRONT FORK................. 5-16

HANDLEBAR .................5-24

STEERING......................5-29

SWINGARM....................5-33

REAR SHOCK

ABSORBER.................... 5-38

CHAPTER 6

ELECTRICAL

ELECTRICAL COMPONENTS AND WIRING DIA-

GRAM ...............................6-1

IGNITION SYSTEM...........6-2

CHAPTER 7

TUNING

ENGINE.............................7-1

CHASSIS ..........................7-6

GENERAL INFORMATION

DESCRIPTION

1. Clutch lever

2. Engine stop switch

3. Front brake lever

4. Throttle grip

5. Radiator cap

6. Fuel tank cap

7. Kickstarter crank

8. Fuel tank

9. Radiator

10. Coolant drain bolt

11. Check bolt (Transmission oil level)

12. Rear brake pedal

13. Valve joint

• The machine you have purchased may differ slightly from those shown in the following.

• Designs and specifications are subject to change without notice.

14. Fuel cock

15. Air filter

16. Drive chain

17. Shift pedal

18. Starter knob

19. Front fork

1-1

MACHINE IDENTIFICATION

There are two significant reasons for knowing the serial number of your machine:

1. When ordering parts, you can give the number to your Yamaha dealer for positive identification of the model you own.

2. If your machine is stolen, the authorities will need the number to search for and identify your machine.

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number "1" is stamped on the right of the steering head pipe.

ENGINE SERIAL NUMBER

The engine serial number "1" is stamped into the elevated part of the right-side of the engine.

MODEL LABEL

The model label "1" is affixed to the frame under the rider's seat. This information will be needed to order spare parts.

VALVE JOINT

This valve joint "1" prevents fuel from flowing out and is installed to the fuel tank breather hose.

In this installation, make sure the arrow faces the fuel tank and also downward.

COLLAR (tool for YPVS)

This collar "1" is used to remove and install the push rod of the engine.

NIPPLE WRENCH

This nipple wrench "1" is used to tighten the spoke.

End of each hose

2. Use proper tools and cleaning equipment. Refer to "SPECIAL TOOLS" section.

3. When disassembling the machine, keep mated parts together. They include gears, cylinders, pistons, and other mated parts that have been "mated" through normal wear. Mated parts must be reused as an assembly or replaced.

INCLUDED PARTS

DETACHABLE SIDESTAND

This sidestand "1" is used to support only the machine when standing or transporting it.

• Never apply additional force to the sidestand.

• Remove this sidestand before starting out.

IMPORTANT INFORMATION

PREPARATION FOR REMOVAL AND DISASSEMBLY

1. Remove all dirt, mud, dust, and foreign material before removal and disassembly.

• When washing the machine with high pressured water, cover the parts follows. Silencer exhaust port Side cover air intake port Crankcase cover hole at the bottom Water pump housing hole at the bottom

1-2

4. During the machine disassembly, clean all parts and place them in trays in the order of disassembly. This will speed up assembly time and help assure that all parts are correctly reinstalled.

5. Keep away from fire.

ALL REPLACEMENT PARTS

1. We recommend to use Yamaha genuine parts for all replacements. Use oil and/or grease rec-

CHECKING OF CONNECTION

ommended by Yamaha for assembly and adjustment.

GASKETS, OIL SEALS AND ORINGS

1. All gaskets, oil seals, and O-rings should be replaced when an engine is overhauled. All gasket surfaces, oil seal lips, and O-rings must be cleaned.

2. Properly oil all mating parts and bearings during reassembly. Apply grease to the oil seal lips.

LOCK WASHERS/PLATES AND COTTER PINS

1. All lock washers/plates "1" and cotter pins must be replaced when they are removed. Lock tab(s) should be bent along the bolt or nut flat(s) after the bolt or nut has been properly tightened.

carefully before reassembly. Always replace piston pin clips after one use. Replace distorted circlips. When installing a circlip "1", make sure that the sharp-edged corner "2" is positioned opposite to the thrust "3" it receives. See the sectional view.

CHECKING OF CONNECTION

Dealing with stains, rust, moisture, etc. on the connector.

1. Disconnect:

• Connector

2. Dry each terminal with an air blower.

shown.

BEARINGS AND OIL SEALS

1. Install the bearing(s) "1" and oil seal(s) "2" with their manufacturer's marks or numbers facing outward. (In other words, the stamped letters must be on the side exposed to view.) When installing oil seal(s), apply a light coating of lightweight lithium base grease to the seal lip(s). Oil the bearings liberally when installing.

Do not use compressed air to spin the bearings dry. This causes damage to the bearing surfaces.

CIRCLIPS

1. All circlips should be inspected

3. Connect and disconnect the connector two or three times.

4. Pull the lead to check that it will not come off.

5. If the terminal comes off, bend up the pin "1" and reinsert the terminal into the connector.

6. Connect:

• Connector

The two connectors "click" together.

7. Check for continuity with a tester.

• If there in no continuity, clean the

terminals.

• Be sure to perform the steps 1 to 7

listed above when checking the wire harness.

• For a field remedy, use a contact re-

vitalizer available on the market.

• Use the tester on the connector as

1-3

SPECIAL TOOLS

The proper special tools are necessary for complete and accurate tune-up and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised techniques. The shape and part number used for the special tool differ by country, so two types are provided. Refer to the list provided to avoid errors when placing an order.

• For U.S.A. and Canada, use part number starting with "YM-", "YU-" or "ACC-".

• For others, use part number starting with "90890-".

Tool name/Part number How to use Illustration

Crankcase separating tool YU-1135-A, 90890-01135

These tool is used to remove the crankshaft from either case.

Flywheel puller YM-1189, 90890-01189

Rotor holding tool YU-1235, 90890-01235

Dial gauge and stand YU-3097, 90890-01252 Stand YU-1256

Crankshaft installing tool Crankshaft installing pot YU-90050, 90890-01274 Crankshaft installing bolt YU-90050, 90890-01275 Adapter YU-90063, 90890-01278 Adapter YU-01499, 90890-01499

This tool is used to remove the flywheel magneto.

This tool is used when loosening or tightening the flywheel magneto securing nut.

These tools are used to check each part for runout or bent.

These tools are used to install the crankshaft.

Piston pin puller set YU-1304, 90890-01304

This tool is used to remove the piston pin.

1-4

SPECIAL TOOLS

Tool name/Part number How to use Illustration

Fuel level gauge "1" YM-1312-A, 90890-01312 Fuel level gauge adaptor "2" YM-01470, 90890-01470

This gauge is used to measure the fuel level in the float chamber.

Radiator cap tester YU-24460-01, 90890-01325 Radiator cap tester adapter YU-33984, 90890-01352

Flywheel puller YU-33270-B, 90890-01362

Steering nut wrench YU-33975, 90890-01403

These tools are used for checking the cooling system.

These tool is used to split the crankcase.

This tool is used when tighten the steering ring nut to specification.

Cap bolt wrench YM-01500, 90890-01500

Cap bolt ring wrench YM-01501, 90890-01501

This tool is used to loosen or tighten the base valve.

This tool is used to loosen or tighten the damper assembly.

1-5

SPECIAL TOOLS

Tool name/Part number How to use Illustration

Fork seal driver YM-A0948, 90890-01502

This tool is used when install the fork oil seal.

Pocket tester YU-3112-C, 90890-03112

Clutch holding tool YM-91042, 90890-04086

Dynamic spark tester YM-34487 Ignition checker 90890-06754

Use this tool to inspect the coil resistance, output voltage and amperage.

This tool is used to hold the clutch when removing or installing the clutch boss securing nut.

This instrument is necessary for checking the ignition system components.

YAMAHA Bond No. 1215 (ThreeB-

No. 1215)

ond 90890-85505

This sealant (Bond) is used for crankcase mating surface, etc.

1-6

CONTROL FUNCTIONS

ENGINE STOP SWITCH

The engine stop switch "1" is located on the left handlebar. Continue pushing the engine stop switch till the engine comes to a stop.

CONTROL FUNCTIONS

CLUTCH LEVER

The clutch lever "1" is located on the left handlebar; it disengages or engages the clutch. Pull the clutch lever to the handlebar to disengage the clutch, and release the lever to engage the clutch. The lever should be pulled rapidly and released slowly for smooth starts.

SHIFT PEDAL

The gear ratios of the constant-mesh 6 speed transmission are ideally spaced. The gears can be shifted by using the shift pedal "1" on the left side of the engine.

THROTTLE GRIP

The throttle grip "1" is located on the right handlebar; it accelerates or decelerates the engine. For acceleration, turn the grip toward you; for deceleration, turn it away from you.

FRONT BRAKE LEVER

The front brake lever "1" is located on the right handlebar. Pull it toward the handlebar to activate the front brake.

REAR BRAKE PEDAL

The rear brake pedal "1" is located on the right side of the machine. Press down on the brake pedal to activate the rear brake.

STARTER KNOB (CHOKE)

When cold, the engine requires a richer air-fuel mixture for starting. A separate starter circuit, which is controlled by the starter knob "1", supplies this mixture. Pull the starter knob out to open the circuit for starting. When the engine has warmed up, push it in to close the circuit.

STARTING AND BREAK-IN

FUEL

Mix oil with the gas at the ratio specified below. Always use fresh, namebrand gasoline, and mix the oil and gas the day of the race. Do not use premix that is more than a few hours old.

Recommended fuel:

Premium unleaded gasoline only with a research octane number of 95 or higher.

KICKSTARTER CRANK

Rotate the kickstarter crank "1" away from the engine. Push the starter down lightly with your foot until the gears engage, then kick smoothly and forcefully to start the engine. This model has a primary kickstarter crank so the engine can be started in any gear if the clutch is disengaged. In normal practices, however, shift to neutral before starting.

FUEL COCK

The fuel cock supplies fuel from the tank to carburetor and also filters the fuel. The fuel cock has the two positions: OFF: With the lever in this position, fuel will not flow. Always return the lever to this position when the engine is not running. ON: With the lever in this position, fuel flows to the carburetor. Normal riding is done with the lever in this position.

1-7

If knocking or pinging occurs, use a different brand of gasoline or higher octane grade.

Never mix two types of oil in the same batch; clotting of the oil could result. If you wish to change oil types, be sure to drain the fuel tank and the carburetor float bowl of old premix prior to filling with the new type.

Fuel tank capacity:

8.0 L (1.76 Imp gal, 2.11 US gal)

STARTING AND BREAK-IN

Mixing oil:

Recommended oil:

Yamalube "2-R" (Yamalube racing 2cycle oil)

Mixing ratio: 30:1 If unavailable, use an equivalent type of oil.

HANDLING NOTE

Before starting the machine, perform the checks in the pre-operation check list.

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. Always operate the machine in a well-ventilated area.

STARTING A COLD ENGINE

1. Shift the transmission into neutral.

2. Turn the fuel cock to "ON" and full open the starter knob (CHOKE).

3. With the throttle completely closed start the engine by kicking the kick starter forcefully with firm stroke.

4. Run the engine at idle or slightly higher until it warms up: this usually takes about one or two minutes.

5. The engine is warmed up when it responds normally to the throttle with the starter knob (CHOKE) turned off.

Do not warm up the engine for extended periods of time.

STARTING A WARM ENGINE

Do not operate the starter knob (CHOKE). Open the throttle slightly and start the engine by kicking the kick starter forcefully with firm stroke.

Observe the following break-in procedures during initial operation to ensure optimum performance

and avoid engine damage.

BREAK-IN PROCEDURES

1. Before starting the engine, fill the fuel tank with a break-in oil-fuel mixture as follows.

Mixing oil:

Yamalube "2-R"

Mixing ratio:

15:1

2. Perform the pre-operation checks on the machine.

3. Start and warm up the engine. Check the idle speed, and check the operation of the controls and the "ENGINE STOP" button.

4. Operate the machine in the lower gears at moderate throttle openings for five to eight minutes. Stop and check the spark plug condition; it will show a rich condition during break-in.

5. Allow the engine to cool. Restart the engine and operate the machine as in the step above for five minutes. Then, very briefly shift to the higher gears and check fullthrottle response. Stop and check the spark plug.

6. After again allowing the engine to cool, restart and run the machine for five more minutes. Full throttle and the higher gears may be used, but sustained full-throttle operation should be avoided. Check the spark plug condition.

7. Allow the engine to cool, remove the top end, and inspect the piston and cylinder. Remove any high spots on the piston with #600 grit wet sandpaper. Clean all components and carefully reassemble the top end.

8. Drain the break-in oil-fuel mixture from the fuel tank and refill with the specified mix.

9. Restart the engine and check the operation of the machine throughout its entire operating range. Stop and check the spark plug condition. Restart the machine and operate it for about 10 to 15 more minutes. The machine will now be ready to race.

• After the break-in or before each

race, you must check the entire machine for loose fittings and fasteners as per "TORQUECHECK POINTS". Tighten all such fasteners as required.

• When any of the following parts have been replaced, they must be broken in. CYLINDER AND CRANKSHAFT: About one hour of break-in operation is necessary. PISTON, RING AND GEARS: These parts require about 30 minutes of break-in operation at half-throttle or less. Observe the condition of the engine carefully during operation.

1-8

TORQUE-CHECK POINTS

Frame construction Frame to rear frame

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 cock

Concerning the tightening torque, refer to "TIGHTENING TORQUES" section in the CHAPTER 2.

1-9

CLEANING AND STORAGE

CLEANING

Frequent cleaning of your machine will enhance its appearance, maintain good overall performance, and extend the life of many components.

1. Before washing the machine, block off the end of the exhaust pipe to prevent water from entering. A plastic bag secured with a rubber band may be used for this purpose.

2. If the engine is excessively greasy, apply some degreaser to it with a paint brush. Do not apply degreaser to the chain, sprockets, or wheel axles.

3. Rinse the dirt and degreaser off with a garden hose; use only enough pressure to do the job.

Excessive hose pressure may cause water seepage and contamination of wheel bearings, front forks, brakes and transmission seals. Many expensive repair bills have resulted from improper high pressure detergent applications such as those available in coin-operated car washers.

the carburetor float bowl.

2. Remove the spark plug, pour a tablespoon of SAE 10W-30 motor oil in the spark plug hole, and reinstall the plug. With the engine stop switch pushed in, kick the engine over several times to coat the cylinder walls with oil.

3. Remove the drive chain, clean it thoroughly with solvent, and lubricate it. Reinstall the chain or store it in a plastic bag tied to the frame.

4. Lubricate all control cables.

5. Block the frame up to raise the wheels off the ground.

6. Tie a plastic bag over the exhaust pipe outlet to prevent moisture from entering.

7. If the machine is to be stored in a humid or salt-air environment, coat all exposed metal surfaces with a film of light oil. Do not apply oil to rubber parts or the seat cover.

Make any necessary repairs before the machine is stored.

4. After the majority of the dirt has been hosed off, wash all surfaces with warm water and a mild detergent. Use an old toothbrush to clean hard-to-reach places.

5. Rinse the machine off immediately with clean water, and dry all surfaces with a soft towel or cloth.

6. Immediately after washing, remove excess water from the chain with a paper towel and lubricate the chain to prevent rust.

7. Clean the seat with a vinyl upholstery cleaner to keep the cover pliable and glossy.

8. Automotive wax may be applied to all painted or chromed surfaces. Avoid combination cleanerwaxes, as they may contain abrasives.

9. After completing the above, start the engine and allow it to idle for several minutes.

STORAGE

If your machine is to be stored for 60 days or more, some preventive measures must be taken to avoid deterioration. After cleaning the machine thoroughly, prepare it for storage as follows:

1. Drain the fuel tank, fuel lines, and

1-10

GENERAL SPECIFICATIONS

SPECIFICATIONS

GENERAL SPECIFICATIONS

Model name: YZ125X1 (USA, CDN)

YZ125 (EUROPE, ZA) YZ125X (AUS, NZ)

Model code number: 1C3D (USA, CDN)

1C3E (EUROPE) 1C3G (AUS, NZ, ZA)

Dimensions: USA, AUS, NZ, ZA EUROPE, CDN

Overall length 2,135 mm (84.1 in) 2,139 mm (84.2 in) Overall width 827 mm (32.6 in) Overall height 1,315 mm (51.8 in) 1,318 mm (51.9 in) Seat height 997 mm (39.3in) 998 mm (39.3 in) Wheelbase 1,443 mm (56.8 in) Minimum ground clearance 386 mm (15.2 in) 388 mm (15.3 in)

Dry weight:

Without oil and fuel 86.0kg (189.6 lb)

Engine:

Engine type Liquid cooled 2-stroke, gasoline Cylinder arrangement Single cylinder, forward inclined

Displacement 124 cm Bore × stroke 54 × 54.5 mm (2.126 × 2.146 in) Compression ratio 8.6–10.7 : 1

Starting system Kick starter Lubrication system: Premix (30 : 1)(Yamalube 2-R) Oil type or grade (2-stroke):

Transmission oil Yamalube 4 (10W-30) or SAE 10W-30 type SE motor oil

Periodic oil change 0.66 L (0.58 Imp qt, 0.69 US qt)

Total amount 0.70 L (0.62 Imp qt, 0.74 US qt) Coolant capacity (including all routes): 0.9 L (0.79 Imp qt, 0.95 US qt) Air filter: Wet type element Fuel:

Type Premium unleaded gasoline only with a research octane

number of 95 or higher.

Tank capacity 8.0 L (1.76 Imp gal, 2.11 US gal) Carburetor:

Type/Manufacturer TMX Spark plug:

Type/Manufacturer BR9EVX/NGK (resistance type)

Gap 0.6–0.7 mm (0.024–0.028 in) Clutch type: Wet, multiple-disc Transmission:

Primary reduction system Gear

Primary reduction ratio 64/19 (3.368)

Secondary reduction system Chain drive

Secondary reduction ratio 48/13 (3.692)

(4.36 Imp oz, 4.19 US oz)

χ38SS/MIKUNI

←

2-1

MAINTENANCE SPECIFICATIONS

Transmission type Constant mesh, 6-speed

Operation Left foot operation

Gear ratio:

1st 31/13 (2.385) 2nd 29/15 (1.933) 3rd 27/17 (1.588) 4th 23/17 (1.353) 5th 24/20 (1.200) 6th 23/21 (1.095)

Chassis: USA, ZA, AUS, NZ EUROPE, CDN

Frame type Semi double cradle

Caster angle 25.5 ° 25.6 °

Trail 105 mm (4.13 in) 107 mm (4.21 in) Tire:

Type With tube

Size (front) 80/100-21 51M

Size (rear) 100/90-19 57M

Tire pressure (front and rear) 100 kPa (1.0 kgf/cm Brake:

Front brake type Single disc brake

Operation Right hand operation

Rear brake type Single disc brake

Operation Right foot operation Suspension:

Front suspension Telescopic fork

Rear suspension Swingarm (link type monocross suspension) Shock absorber:

Front shock absorber Coil spring/oil damper

Rear shock absorber Coil spring/gas, oil damper Wheel travel:

Front wheel travel 300 mm (11.8 in)

Rear wheel travel 315 mm (12.4 in) Electrical:

Ignition system CDI magneto

, 15 psi)

MAINTENANCE SPECIFICATIONS

ENGINE

←

Item Standard Limit

Cylinder head:

Combustion chamber capacity 8.4 cm

Warp limit ---- 0.03 mm

Cylinder:

Bore size 54.000–54.014 mm (2.1260–2.1265 in) 54.1 mm

Taper limit ---- 0.05 mm

(0.296 Imp oz, 0.284 US oz) ----

(0.0012 in)

(2.130 in)

(0.0020 in)

2-2

MAINTENANCE SPECIFICATIONS

Item Standard Limit

Out of round limit ---- 0.01 mm

(0.0004 in)

Piston:

Piston size/ 53.957–53.972 mm (2.1243–2.1249 in) ----

Measuring point "H" 17.5 mm (0.69 in) ----

Piston clearance 0.040–0.045 mmm (0.0016–0.0018 in) 0.1 mm (0.004

in)

Piston offset 0.5 mm (0.019 in)/EX-side ---Piston pin:

Piston pin outside diameter 14.995–15.000 mm (0.5904–0.5906 in) 14.975 mm

(0.5896 in)

Piston ring:

Sectional sketch Plain ----

B=1.0 mm (0.039 in) ---T=2.35 mm (0.093 in) ----

End gap (installed) 0.5–0.7 mm (0.020–0.028 in) 1.2 mm (0.047

in)

Side clearance (installed) 0.035–0.070 mm (0.0014~0.0028 in) 0.1 mm (0.004

in)

Crankshaft:

Crank width "A" 55.90–55.95 mm (2.201–2.203 in) ----

Runout limit "C" 0.03 mm (0.0012 in) 0.05 mm

(0.0020 in) Connecting rod big end side clearance "D" 0.06–0.64 mm (0.002–0.025 in) ---Small end free play "F" 0.8–1.0 mm (0.031–0.039 in) 2.0 mm (0.08

in)

----

Clutch:

Friction plate thickness 2.9–3.1 mm (0.114–0.122 in) 2.8 mm (0.110

in)

Quantity 8 ----

Clutch plate thickness 1.5–1.7 mm (0.059–0.067 in) ----

Quantity 7 ----

2-3

MAINTENANCE SPECIFICATIONS

Item Standard Limit

Warp limit ---- 0.2 mm (0.008

in) Clutch spring free length 40.1 mm (1.579 in) 38.1 mm

(1.500 in)

Quantity 5 ---Clutch housing thrust clearance 0.15–0.26 mm (0.006–0.010 in) ---Clutch housing radial clearance 0.014–0.046 mm (0.0006–0.0018 in) ---Clutch release method Inner push, cam push ----

Transmission:

Main axle deflection limit ---- 0.01 mm

(0.0004 in)

Drive axle deflection limit ---- 0.01 mm

(0.0004 in)

Shifter:

Shifting type Cam drum and guide bar ---Guide bar bending limit ---- 0.05 mm

(0.0020 in)

Kick starter type: Kick and mesh type ----

Kick clip friction force P=0.8–1.2 kg (1.8–2.6 lb) ----

Air filter oil grade (oiled filter): Foam-air-filter oil or equivalent oil ---Carburetor: USA, CDN EUROPE AUS, NZ, ZA

Type/Manufacturer TMX

I.D. mark 1C35 30 1C36 40 1C37 50 ---Main jet (M.J.) #410 #430 Jet needle-clip position (J.N.) 6BFY42-74-3 6BFY43-74-3 Cutaway (C.A.) 4.0 Pilot jet (P.J.) #40 #45 #40 ---Pilot air screw (P.A.S.) 2-1/4 Valve seat size (V.S.) ø3.8 mm (0.15

Starter jet (G.S.) #80 Fuel level (F.L.) 9.5–10.5 mm

Reed valve:

Thickness 0.47 mm (0.019 in) ---Valve stopper height 8.2–8.6 mm (0.323–0.339 in) ---Valve bending limit ---- 0.2 mm (0.008

Cooling:

Radiator core size: ----

Width 107.8 mm (4.24 in) ----

Height (left) 240 mm (9.45 in) ----

Height (right) 220 mm (8.66 in) ----

Thickness 32 mm (1.26 in) ---Radiator cap opening pressure 95–125 kPa (0.95–1.25 kg/cm Radiator capacity (total) 0.56 L (0.49 Imp qt, 0.59 US qt) ----

χ38SS/

MIKUNI

in)

(0.37–0.41 in)

←←

← ---← ----

←←----

←←---←←----

in)

, 13.5–17.8 psi) ----

2-4

MAINTENANCE SPECIFICATIONS

Item Standard Limit

Water pump:

Type Single-suction centrifugal pump ----

CHASSIS

Item Standard Limit

Steering system:

Steering bearing type Taper roller bearing ----

Front suspension: USA, CDN, ZA, AUS,

NZ Front fork travel 300 mm (11.8 in) Fork spring free length 454 mm (17.9 in)

Spring rate, STD K=4.1 N/mm (0.418 kg/

mm, 23.4 lb/in)

Optional spring Yes

Oil capacity 524 cm

17.7 US oz)

Oil grade Suspension oil "S1" ← ---Inner tube outer diameter 48 mm (1.89 in) Front fork top end 5 mm (0.2 in)

Rear suspension: USA, CDN, ZA, AUS,

Shock absorber travel 131.5 mm (5.18 in) Spring free length Approx.265 mm (10.43

in)

Fitting length ----

One I.D. mark 258 mm (10.16 in) 252 mm (9.92 in) ---Two I.D. marks 264 mm (10.39 in) 258 mm (10.16 in) ---Three I.D. marks 255.5 mm (10.06 in) 249.5 mm (9.82 in) ----

<Min.–Max.>

One I.D. mark 245.5–263.5 mm (9.67–

10.37 in)

Two I.D. marks 251.5–269.5 mm (9.90–

10.61 in)

Three I.D. marks 243.0–261.0 mm (9.57–

10.28 in)

Spring rate, STD K=46.0 N/mm (4.70 kg/

mm, 263.2 lb/in) Optional spring Yes Enclosed gas pressure 1,000 kPa (10 kg/cm

142 psi)

Swingarm:

Swingarm free play limit

End ---- 1.0 mm (0.04

Side clearance ---- 0.2–0.9 mm

(18.4 Imp oz,

EUROPE

← ---← 449 mm (17.7

in)

← ----

526 cm3 (18.5 Imp oz,

17.8 US oz)

----

← ---← ----

EUROPE

← ---← ----

← ----

← ---← ----

in)

(0.008–0.035 in)

2-5

MAINTENANCE SPECIFICATIONS

Item Standard Limit

Wheel:

Front wheel type Spoke wheel ---Rear wheel type Spoke wheel ---Front rim size/material 21 × 1.60/Aluminum ---Rear rim size/material 19 × 1.85/Aluminum ---Rim runout limit:

Radial ---- 2.0 mm (0.08

in)

Lateral ---- 2.0 mm (0.08

in)

Drive chain:

Type/manufacturer DID520DMA2 SDH/DAIDO ---Number of links 111 links + joint ---Chain slack 48–58 mm (1.9–2.3 in) ---Chain length (15 links) ---- 242.9 mm

(9.563 in)

Front disc brake:

Disc outside dia.×Thickness 250 × 3.0 mm (9.84 × 0.12 in) 250 × 2.5 mm

(9.84 × 0.10 in)

Pad thickness 4.4 mm (0.17 in) 1.0 mm (0.04

in) Master cylinder inside dia. 9.52 mm (0.375 in) ---Caliper cylinder inside dia. 22.65 mm (0.892 in) × 2 ---Brake fluid type DOT #4 ----

Rear disc brake:

Disc outside dia.×Thickness 245 × 4.0 mm (9.65 × 0.16 in) 245 × 3.5 mm

(9.65 × 0.14 in) Deflection limit ---- 0.15 mm

(0.006 in) Pad thickness 6.4 mm (0.25 in) 1.0 mm (0.04

in) Master cylinder inside dia. 11.0 mm (0.433 in) ---Caliper cylinder inside dia. 25.4 mm (1.000 in) × 1 ---Brake fluid type DOT #4 ----

Brake lever and brake pedal:

Brake lever position 95 mm (3.74 in) ---Brake pedal height (vertical height above footrest

top) Clutch lever free play (lever end) 8–13 mm (0.31–0.51 in) ---Throttle grip free play 3–5 mm (0.12–0.20 in) ----

ELECTRICAL

Zero mm (Zero in) ----

Item Standard Limit

Ignition system:

Ignition timing (B.T.D.C.) 0.48 mm (0.019 in) ---Advancer type Electrical ----

CDI:

Magneto-model (stator)/Manufacturer 1C3-10/YAMAHA ----

2-6

TIGHTENING TORQUES

Item Standard Limit

Charging coil 1 resistance (color) 720–1,080 Ωat 20 °C (68 °F) (Green/

White-Black/Red)

Charging coil 2 resistance (color) 44–66

Pickup coil resistance (color) 248–372

CDI unit-model/manufacturer 1C3-10/YAMAHA ----

Ignition coil:

Model/manufacturer 1C3-00/YAMAHA ---Minimum spark gap 6 mm (0.24 in) ---Primary winding resistance 0.24–0.36 Secondary winding resistance 5.7–8.5 k

Spark plug cap:

Resistance 4–6 k

TIGHTENING TORQUES

ENGINE

Ωat 20 °C (68 °F) (Black-Green/

Blue)

Ωat 20 °C (68 °F) (White/Blue-

White/Red)

Ωat 20 °C (68 °F) ----

----

△ - marked portion shall be checked for torque tightening after break-in or before each race.

Part to be tightened Thread size Q'ty

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 1.4

Tightening torque

Nm m•kg ft•lb

△ Air filter case M6 × 1.0 4 8 0.8 5.8

Air filter guide clamp M5 × 0.8 1 4 0.4 2.9 Reed valve M3 × 0.5 6 1 0.1 0.7

2-7

TIGHTENING TORQUES

Part to be tightened Thread size Q'ty

Throttle 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 22

Tightening torque

Nm m•kg ft•lb

△ Exhaust pipe M6 × 1.0 2 12 1.2 8.7 △ Exhaust pipe stay (front) M6 × 1.0 1 12 1.2 8.7 △ Exhaust pipe stay (rear) M6 × 1.0 1 12 1.2 8.7

Silencer:

△ Silencer and frame M6 × 1.0 2 12 1.2 8.7

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

CHASSIS

△ - marked portion shall be checked for torque tightening after break-in or before each race.

Part to be tightened Thread size Q'ty

Tightening torque

Nm m•kg ft•lb

△ Upper bracket and outer tube M8 × 1.25 4 21 2.1 15 △ Lower bracket and outer tube M8 × 1.25 4 21 2.1 15 △ Upper bracket and steering stem M24 × 1.0 1 145 14.5 105 △ Handlebar upper holder M8 × 1.25 4 28 2.8 20 △ Handlebar lower holder M12 × 1.25 2 40 4.0 29 △ Steering ring nut M28 × 1.0 1 Refer to NOTE.

Front 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 21

2-8

TIGHTENING TORQUES

Part to be tightened Thread size Q'ty

Bleed screw (front fork) and base valve M5 × 0.8 2 1 0.1 0.7

Tightening torque

Nm m•kg ft•lb

△ Front fork and front fork protector M6 × 1.0 6 5 0.5 3.6 △ Cable guide (front brake hose) and lower bracket M6 × 1.0 1 4 0.4 2.9 △ Front fork protector and brake hose holder M6 × 1.0 2 7 0.7 5.1

Throttle cable cap M4 × 0.7 2 1 0.1 0.7

△ Front brake master cylinder and bracket M6 × 1.0 2 9 0.9 6.5

Brake 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 1.4

△ Front brake hose union bolt (brake master cylinder) M10 × 1.25 1 30 3.0 22 △ Front brake hose union bolt (caliper) M10 × 1.25 1 30 3.0 22 △ Front brake caliper and front fork M8 × 1.25 2 28 2.8 20

Grip 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 2.2

△ Brake caliper (front and rear) and pad pin M10 × 1.0 2 18 1.8 13 △ Brake caliper (front and rear) and bleed screw M8 × 1.25 2 6 0.6 4.3 △ Front wheel axle and axle nut M16 × 1.5 1 105 10.5 75 △ Front wheel axle holder M8 × 1.25 4 21 2.1 15 △ Front brake disc and wheel hub M6 × 1.0 6 12 1.2 8.7 △ Rear brake disc and wheel hub M6 × 1.0 6 14 1.4 10

Footrest bracket and frame M10 × 1.25 4 55 5.5 40

△ Brake pedal mounting M8 × 1.25 1 26 2.6 19 △ Rear brake master cylinder and frame M6 × 1.0 2 10 1.0 7.2

Rear brake master cylinder cap M4 × 0.7 2 2 0.2 1.4

△ Rear brake hose union bolt (caliper) M10 × 1.25 1 30 3.0 22 △ Rear brake hose union bolt (master cylinder) M10 × 1.25 1 30 3.0 22 △ Rear wheel axle and axle nut M20 × 1.5 1 125 12.5 90 △ Nipple (spoke) — 72 3 0.3 2.2 △ Driven sprocket and wheel hub M8 × 1.25 6 42 4.2 30 △ Disc cover and rear brake caliper M6 × 1.0 2 10 1.0 7.2 △ Protector and rear brake caliper M6 × 1.0 2 7 0.7 5.1

Drive chain puller adjust bolt and locknut M8 × 1.25 2 19 1.9 13 Engine :

△ Engine and frame (front) M10 × 1.25 1 64 6.4 46 △ Engine and frame (lower) M10 × 1.25 1 64 6.4 46 △ Engine bracket and frame M8 × 1.25 2 34 3.4 24 △ Engine bracket and engine M8 × 1.25 1 34 3.4 24 △ Pivot shaft and nut M16 × 1.5 1 85 8.5 61 △ Relay arm and swingarm M14 × 1.5 1 70 7.0 50 △ Relay arm and connecting rod M14 × 1.5 1 80 8.0 58 △ Connecting rod and frame M14 × 1.5 1 80 8.0 58

2-9

TIGHTENING TORQUES

Part to be tightened Thread size Q'ty

Tightening torque

Nm m•kg ft•lb

△ Rear shock absorber and frame M10 × 1.25 1 56 5.6 40 △ Rear shock absorber and relay arm M10 × 1.25 1 53 5.3 38 △ Rear frame and frame (upper) M8 × 1.25 1 32 3.2 23 △ Rear frame and frame (lower) M8 × 1.25 2 29 2.9 21 △ Swingarm and brake hose holder M5 × 0.8 4 2 0.2 1.4

Swingarm and patch M4 × 0.7 4 2 0.2 1.4 Drive chain tensioner M8 × 1.25 2 16 1.6 11 Drive chain support and swingarm M6 × 1.0 3 7 0.7 5.1 Seal guard and swingarm M5 × 0.8 4 6 0.6 4.3 Cable guide and frame M5 × 0.8 2 4 0.4 2.9

△ Fuel tank boss and frame M10 × 1.25 2 20 2.0 14 △ Fuel tank M6 × 1.0 2 10 1.0 7.2 △ Fuel tank and fuel cock M6 × 1.0 2 4 0.4 2.9

Fuel tank and seat set bracket M6 × 1.0 1 7 0.7 5.1 Fuel tank and hooking screw (fitting band) M6 × 1.0 1 7 0.7 5.1 Fuel tank and fuel tank bracket M6 × 1.0 4 7 0.7 5.1

△ Air scoop and fuel tank M6 × 1.0 4 7 0.7 5.1 △ Air scoop and radiator guard (lower) M6 × 1.0 2 6 0.6 4.3 △ Front fender M6 × 1.0 4 7 0.7 5.1 △ Rear fender (front) M6 × 1.0 2 7 0.7 5.1 △ Rear fender (rear) M6 × 1.0 2 12 1.2 8.7 △ Side cover M6 × 1.0 2 7 0.7 5.1

Seat M8 × 1.25 2 19 1.9 13

△ Number plate M6 × 1.0 1 7 0.7 5.1

1. First, tighten the steering ring nut approximately 38 Nm (3.8 m•kg, 27 ft•lb) by using the steering nut wrench, then loosen the steering ring nut one turn.

2. Retighten the steering ring nut 7 Nm (0.7 m•kg, 5.1 ft•lb).

ELECTRICAL

Part to be tightened Thread size Q'ty

Stator M6 × 1.0 3 7 0.7 5.1 Rotor M12 × 1.25 1 56 5.6 40 Ignition coil M6 × 1.0 2 7 0.7 5.1

Tightening torque

Nm m•kg ft•lb

2-10

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