Yamaha XT 125R 2005, Service Information

Page 1: ...IDM C144600300 fm 2005 XT 125R XT 125X SERVICE INFORMATION ...

Page 2: ......

Page 3: ...e informed of substantial changes and improvements made to specifications or mounting procedures these ones will be stated in the following issues of this Manual when required NOTE The motorcycle model and specifications are subject to changes without prior notice IMPORTANT INFORMATION Particularly important information is highlighted as follows The symbol of danger means CAUTION BEWARE YOUR SAFET...

Page 4: ... to illustrated in the diagram indicate the types of lubricant to be used and the greasing points Use Engine Oil Use Oil for Spare Parts Use Molybdenum Bisulphide Oil Use Grease for Bearings Use Grease Made of Light Lithium Soap Use Molybdenum Bisulphide Grease Symbols illustrated in the diagram indicate where to apply the high resistance sealer and where to install new Component Parts Apply High ...

Page 5: ...L SPECIFICATIONS 9 GENERAL FEATURES 9 SERVICING TECHNICAL DATA 12 ENGINE 12 LUBRICATION DIAGRAMS 15 ENGINE TIGHTENING TORQUES 17 FRAME 18 FRAME TIGHTENING TORQUES 20 ELECTRICAL SYSTEM 21 WIRING 24 WIRING 1 24 WIRING 2 26 SCHEDULED SERVICING AND ADJUSTMENT 28 SCHEDULED MAINTENANCE AND GREASING 28 WIRING DIAGRAM 30 ...

Page 6: ...me is used for the motorcycle identification and registration Serial Number of the Engine The Serial Number of the Engine is marked on the right side of the crankcase NOTE The first three figures of this Serial Number identify the motorcycle model the remaining figures indicate the production number of the unit NOTE Technical specifications and drawings can be changed without prior notice 1 1 IDM ...

Page 7: ...ator The fuel indicator is used to measure the fuel level in the carburettor float chamber 90890 06760 Rev Counter The rev counter is used to measure the engine RPM 90890 04086 09 All purpose Clutch Support This support is used to lock the clutch when assembling or disassembling the clutch locking nut 90890 01701 Pulley Lock The pulley lock is used to lock the secondary pulley 90890 01862 Flywheel...

Page 8: ...0 01275 2 90890 01278 3 Tool for Drive Shaft Installation Drive Shaft Pin Adaptor M12 90890 01326 T tool The T tool is used to hold the shock absorber rod when it is removed or installed 90890 01367 90890 01381 Fork Clamp Fork Clamp Fitting The fork clamp fitting is used to install the fork cross 90890 01403 Nut Ring Wrench This wrench is used to loosen and tighten the nut ring of the handlebar 90...

Page 9: ... 120 kg 120 kg Engine Type of Engine 4 stroke air cooling Feeding System Carburettor Cylinder Arrangement Tilted forward single cylinder Displacement 123 7 cm3 Diameter per Stroke 54 0x54 0 Compression Ratio 10 1 0 5 Max Power 7 3 kW 8500 RPM Max Torque 9 5 N m 5500 RPM Min Speed 1600 1800 RPM Starting System Electrical and manual starter Lubrication System Yamaha Autolube Oil Type or Grade Motor ...

Page 10: ...14 3 4286 Type of Gear Continuous gear 5 speed Operation Left foot Drive Ratio First Gear 14 37 2 64 Second Gear 18 32 1 78 Third Gear 19 25 1 32 Fourth Gear 22 23 1 05 Fifth Gear 24 21 0 88 Frame Type of Frame Semi double cradle Semi double cradle Front Axle Angle 28 26 7 Angle Base 114 4 mm 78 33 mm Tyres Type With inner tube With inner tube Front 90 90 21 54S 100 80 17 52S Rear 120 80 18 62S 13...

Page 11: ...l damper Rear Coil spring Oil damper Wheel Stroke Front Wheel Stroke 170 mm 6 69 in 170 mm 6 69 in Rear Wheel Stroke 190 mm 7 48 in 190 mm 7 48 in Electrical System Starting System CDI Generator System Magnetic AC Battery Capacity 12V 6 5Ah Headlight Bulb Headlight Power Headlight 12V 35 35W Rear Light Stop Light 12V P21 5W Front Rear Indicators 12V 10Wx4 Plate Light 12V 5W Dashboard Warning Light...

Page 12: ...ain drive Timing Cams Inlet Cam Height A 25 881 25 981 mm 25 851 mm Exhaust Cam Height A 25 841 25 941 mm 25 811 mm Inlet Cam Width B 21 195 21 295 mm 21 165 mm Exhaust Cam Width B 21 05 21 15 mm 21 02 mm Inlet Cam Height C 4 391 mm Timing Shaft Eccentricity 0 03 mm Compensators Bearing Inner Diameter 10 000 10 015 mm 10 03 mm Bearing Outer Diameter 9 981 9 991 mm 9 95 mm Timing Chain Type Bush ch...

Page 13: ...m 37 0 mm Spring Length when the Valve is Closed 25 6 mm Compression 13 2 15 5 kgf 132 155 N Winding Direction from top Clockwise Upper Piston Ring Type Barrel Dimensions BxT 1 0x2 1 mm Distance between Ends when installed 0 15 0 30 mm 0 4 mm Side Clearance 0 03 0 07 mm 0 12 mm Intermediate Piston Ring Type Taper Dimensions BxT 1 0x2 1 mm Distance between Ends when installed 0 15 0 30 mm 0 4 mm Si...

Page 14: ...ty 4 pcs Clutch Spring Free Length 31 mm Quantity 4 pcs Min Free Length 29 mm Carburettor ID Mark 3D6 Main Jet 105 Main Air Jet 1 2 Jet Pin 5EJ9 2 Jet Needle N 7M 913 Min Output f1 05 Min Jet 12 5 Bypass 1 6 Adjusting Screw Rev 1 Valve Housing Dimensions 1 8 Starter Jet 22 5 Jet Power 60 Fuel Level 7 5 mm Float Height 18 9 mm Min Speed 1600 1800 RPM Picture Description Standard Limit ...

Page 15: ... 44600300900 tif Compensator Arm Suction Compensator Arm Exhaust Compensator Shaft Cam Shaft Crankcase right Clutch Lever Oil Suction Filter Oil Pump Centrifugal Filter Motor Oil in Crankcase Motor Axis Main Axis Do not damage the crankcase surface to avoid oil leakage CAUTION ...

Page 16: ...ICAL DATA SPEC IDM 44600301000 tif Cam Shaft Centrifugal Filter Crankcase Main Axis Clutch Cover Right Chain Guard Right Cover Left Motor Axis Chain Guard Left To enhance performance always use Yamalube oil CAUTION Cylinder Head Cylinder ...

Page 17: ...mp Screw 1 M4 0 2 2 Carburettor Air Filter Clamp Screw 1 M4 0 2 2 Silencer Screw 2 M6 1 0 10 Oil Sump Torque Screw Screw Screw 2 7 1 M6 M6 M6 1 0 1 0 1 0 10 10 10 Flywheel Side Cap Screw Screw Screw 4 2 1 M6 M6 M6 1 0 1 0 1 0 10 10 10 Clutch Side Cap Screw Screw Screw 6 2 1 M6 M6 M6 1 0 1 0 1 0 10 10 10 Plate Screw 1 M6 0 7 7 Ignition Stage Control Plug Screw 1 M14 0 7 7 Main Plug Screw 1 M32 0 7 ...

Page 18: ...48 Max Radial Clearance 1 mm 0 04 1 mm 0 04 Max Side Clearance 0 5 mm 0 02 0 5 mm 0 02 Front Disc Brake Disc Dimensions 245 0x3 5 mm 260 0x3 5 mm Inside Pad Lining Thickness 3 mm 3 mm 0 8 mm 0 8 mm Inside Pad Lining Thickness 3 mm 3 mm 0 8 mm 0 8 mm Pump Piston Diameter 11 mm 11 mm Piston Pliers Diameter 32 mm 25 mm Recommended Fluid DOT 4 DOT 4 Rear Disk Brake Disc Dimensions 218x3 5 mm Inside Pa...

Page 19: ...nging Arm Rear Shock Absorber Compression 45 mm Spring Free Length 163 mm Spring Length when Installed 158 mm Spring Preload Hard Soft 5 mm Spring Stiffness K 17 7 daN mm Spring Stroke 55 mm Available Optional Spring YES Gas Air Pressure Included 12 5 3 bars Drive Chain Type Manufacturer 428H G G DID 428H G G DID Articulated Joint N 128 126 Front Brake Lever Rear Brake Pedal Front Brake Lever Clea...

Page 20: ...M8 3 0 30 Muffler Side Connection Screw 3 M6 0 8 8 Engine Rear Connection Screw 2 M8 2 3 23 Fork Pin Screw 1 M14x1 5 6 0 60 Engine Front Connection Screw 2 M8 2 3 23 Front Pump Clamp Screw 2 M6 0 6 6 Rear Wheel Screw 1 M14x1 5 8 5 85 Command Clamp Screw 2 M6 0 3 3 Rear Shock Absorber Screw 2 M10 4 5 45 Upper Cross Screw 2 M8 1 95 19 5 Handlebar U bolt Screw 4 M8 2 15 21 5 Steering System Nut 1 M25...

Page 21: ... Ohm 0 3 10 at 20 C 68 F Secondary Winding Resistance kOhm 3 16 10 at 20 C 68 F Recharge System Type Magnet Flywheel Model Manufacturer 3D6 MORIYAMA Charge Voltage 14V Rated Power 1 0A 3000 RPM 2 0A 8000 RPM Recharge Winding Resistance Ohm 0 64 20 at 20 C 68 F White Black Lighting Min Voltage 12V 3000 RPM Max Voltage 15V 8000 RPM Winding Resistance Ohm 0 49 20 at 20 C 68 F Yellow Black Regulator T...

Page 22: ...5 0 0385 Ohm 20 C Brush Dimensions 5x7x7mm 3 5 mm Brush Spring Strength 4 9 N 20 3 92 N Selector Diameter 17 6 mm 16 6 mm Mica Recess Depth 1 35 mm Starting Relay Model Manufacturer NAIS Amperage 70A Winding Resistance 90 100 Ohm Horn Type of Horn Flat Quantity 1 Model Manufacturer K70H LEB Max Amperage 3A Performance 105 118db A Indicator Relay Type Electronic Model Manufacturer Cablologica CBL F...

Page 23: ...23 IDM C144600300 fm ...

Page 24: ...lywheel connectors 21 Idling warning light wire 22 Tank cock vacuum pipe 23 Fuel feeding pipe 24 Air AIS valve 25 Regulator 26 Starting relay 27 Intermittence 28 Thermal sensor 29 Regulator ground lug 30 Carburettor PTC heater 31 Starting selector switch What To Do 1 Insert device A after connecting connector 14 and lock the rubber clamp B 2 Bring wires inside frame C and lock them with clamps D 3...

Page 25: ...25 IDM C144600300 fm WIRING 1 SPEC 29 25 28 22 17 24 19 16 H 13 27 26 18 G B A 2 1 7 12 31 9 11 8 15 F E C 10 21 20 M D 3 6 4 5 IDM 44600300500 tif L 23 30 N 14 ...

Page 26: ...Rear pliers oil drive 18 Battery 19 Fuse 10A 20 CDI control unit 21 Rear right indicator wires 22 Rear left indicator wires 23 Rear light brake wires 24 Plate light wires 25 Ground lug 26 Battery positive wire red 27 Battery negative wire black 28 Rear brake switch What To Do 1 Fasten wire 4 to the motorcycle frame with three clamps A bring it inside plate B and cable gland H 2 Insert clutch wire ...

Page 27: ...27 IDM C144600300 fm WIRING 2 SPEC 25 22 8 5 7 4 24 23 21 26 19 27 18 20 10 16 9 25 D A B 17 15 3 6 A A A H 11 13 12 14 1 2 F E G IDM 44600300700 tif 28 C ...

Page 28: ... X Brakes Check operation adjust lever stroke Check pad thickness X X X Rear Arm Pin Check arm tightening Do not exaggerate greasing X X Wheels and Tyres Check tyre pressure wear and tightening X X X Wheel Bearings Check tightening check to see if damaged X X Steering System Bearings Check tightening Grease every 12 000 km or every 12 months X X X Front Forks Check operation oil leakage X X X Rear...

Page 29: ...29 IDM C144600300 fm ...

Page 30: ... command 25 Indicator command 26 Horn command 27 Left command unit 28 Rear left indicator 29 Headlight on full beam on low beam 30 Parking light 31 Rear right indicator 32 Dashboard 33 Key selector switch 34 Right command unit 35 Starting command 36 Front brake switch Colours AR Orange AZ Light blue AZ B Light Blue White B White B N White Black B MA White Brown B R White Red B VL White Purple B VR...

Page 31: ...31 IDM C144600300 fm WIRING DIAGRAM Available 5 2 1 15 16 17 18 22 3 4 6 7 8 9 10 11 12 13 14 19 20 21 33 34 36 35 32 31 30 29 28 27 23 24 25 26 ...

Page 32: ......