Yamaha 1999 SR125, Service Manual

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Page 3: ...ecessary to use this Supplementary Service Manual together with the following manual SR125 SERVICE MANUAL 3MW AE1 SR125 SUPPLEMENTARY SERVICE MANUAL 3MW AE2 SR125 99 SUPPLEMENTARY SERVICE MANUAL 1998 by Yamaha Motor Co Ltd First Edition October 1998 Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited ...

Page 4: ...ve all its models Modifications and signifi cant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable Designs and specifications are subject to change without notice IMPORTANT INFORMATION Particularly important information is distinguished in this manual by the following notations The Safety Al...

Page 5: ...To heps identify parts and clarify procedure steps there are exploded diagrams at start of each remov al and disassembly section 1 An easy to see exploded diagram 4 is provided for disassembly and assembly jobs 2 Numbers 5 are given in the order of 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 e...

Page 6: ...pecifications appearing in the text 10 Possible to maintain with engine mounted 11 Filling fluid 12 Lubricant 13 Special tool 14 Tightening 15 Wear limit clearance 16 Engine speed 17 Ω V A Illustrated symbols 18 to 23 in the exploded dia grams indicate the types of lubricants and lu brication points 18 Apply engine oil 19 Apply gear oil 20 Apply molybdenum disulfide oil 21 Apply wheel bearing grea...

Page 7: ...3 ENGINE 3 CHASSIS 3 CABLE ROUTING 4 PERIODIC INSPECTIONS AND ADJUSTMENTS CHECKING AND ADJUSTING THE STEERING HEAD 9 CHECKING AND ADJUSTING THE STEERING HEAD 9 ENGINE OVERHAUL CYLINDER HEAD 11 CYLINDER HEAD 11 CHECKING THE TIMING CHAIN TENSIONER 12 CYLINDER HEAD INSTALLATION 12 CHASSIS STEERING 15 UNDER BRACKET 15 99 SR125 WIRING DIAGRAM ...

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Page 9: ... mm Chassis Caster angle Trail 26 75 90 mm Wheel travel Rear wheel travel 76 mm Bulb wattage quantity Headlight Auxiliary light Tail brake light Flasher light Meter light High beam indicator Neutral indicator Turn indicator 12 V 60 W 55 W 1 12 V 4 W 1 12 V 5 W 21 W 1 12 V 21 W 4 14 V 3 W 1 12 V 1 7 W 1 12 V 1 7 W 1 12 V 1 7 W 1 ...

Page 10: ...ng bearing type Angular bearing SSS Front suspension Fork spring free length Fitting length Oil capacity Oil level Oil grade 353 4 mm 338 4 mm 0 187 L 187 cm3 138 mm Fork oil 10 W or equivalent 321 mm SSS SSS SSS SSS ELECTRICAL Item Standard Limit Ignition coil Primary winding resistance Secondary winding resistance 0 184 0 276 Ω at 20_C 6 32 9 48 kΩ at 20_C SSS SSS Flasher relay Type Model manufa...

Page 11: ...olt 2 1 10 10 0 1 0 1 CHASSIS Part to be tightened Thread size Tightening torque Remarks g Nm mSkg Handle crown and front fork Handle crown and steering shaft Handlebar holder under and upper Steering ring nut M8 M22 M8 M25 19 110 20 4 1 9 11 0 2 0 0 4 Refer to NOTE 1 First tighten the ring nut to approximately 38 Nm 3 8mSkg with a torque wrench then loosen the ring nut completely 2 Retighten the ...

Page 12: ...ch lead clutch switch lead to the handlebar with a band B Don t contact the horn and wire harness C To auxiliary light D To headlight CABLE ROUTING 1 Speed meter cable 2 Handlebar switch lead left 3 Main switch lead 4 Front brake switch lead 5 Throttle cable 6 Brake hose 7 Handlebar switch lead right 8 Clutch cable 9 Clutch switch lead 10 Right flasher lead 11 Left flasher lead ...

Page 13: ...p to the white tape on the wireharness B Route the brake hose through the brake hose holder C Route the clutch cable through the clutch cable guide D Route the throttle cable front brake switch lead handlebar switch lead through the guide 1 Flasher relay 2 Clamp 3 Wireharness 4 High tension cord 5 Collar 6 Ignition coil 7 Earth lead 8 Ignition coil lead 9 Throttle cable 10 Brake hose 11 Brake hose...

Page 14: ... 6 CABLE ROUTING SPEC E Clamp the clutch cable to the down tube of the frame F Cover the sack to the couplers ...

Page 15: ...for ignition coil lead and earth lead B Clamp the sidestand switch lead battery negative lead and cut the end C Route the battery positive lead between air filter case and mud guard set the battery positive ter minal CABLE ROUTING SPEC 13 Battery negative lead 14 Starter motor lead 15 Rectifier Regulator 16 Starter relay 17 Battery positive lead 18 Side stand switch lead 19 Side stand switch 20 Cl...

Page 16: ...bracket and through the wire holder of front fender CABLE ROUTING SPEC D Route the leads inside the frame bracket E Clamp the starter relay lead rec tifier regulator lead and side stand switch lead F Clamp the rectifier regulator lead G Fasten the leads witin 40 m from rectifire regulator with a band ...

Page 17: ...hat there is no danger of it falling over Place the motorcycle on a suitable stand so that the front wheel is elevated 2 Check Ssteering head Grasp the bottom of the front fork legs and gently rock the front fork Looseness binding Adjust the steering head 3 Remove Shandlebar 1 4 Loosen Supper bracket pinch bolts 1 5 Remove Ssteering stem nut 2 Swasher 3 6 Remove Sspeed meter 1 Supper bracket 2 ...

Page 18: ... Do not overtighten the lower ring nut Lower ring nut final tightening torque 4 Nm 0 4 mSkg d Check the steering head for looseness or binding by turning the front fork all the way in both directions If any binding is felt remove the lower bracket and check the upper and lower bearings Refer to STEERING HEAD in chapter 6 e Install the rubber washer 3 f Install the upper ring nut 2 g Finger tighten...

Page 19: ...t Timing chain Ignition coil Cylinder head Dowel pins Gasket Cylinder head gasket 1 1 1 1 1 3 1 1 Remove the parts in order Reverse the removal procedure for installation Refer to CYLINDER HEAD INSTALLATION section Refer to CYLINDER HEAD REMOVAL INSTALLATION section 22 Nm 2 2 mSkg 20 Nm 2 0 mSkg 60 Nm 6 0 mSkg 10 Nm 1 0 mSkg CYLINDER HEAD ...

Page 20: ...in tensioner rod wind it clockwise with a thin screwdriver 1 until it stops b Remove the screwdriver and slowly release the timing chain tensioner rod c Make sure that the timing chain tensioner rod comes out of the timing chain tensioner housing smoothly If there is rough move ment replace the timing chain tensioner SR CYLINDER HEAD INSTALLATION 1 Install Sdowel pins 1 Sgasket 2 Sgasket cylinder ...

Page 21: ...ing chain as tight as possible on the exhaust side Do not turn the crankshaft during installa tion of the camshaft Damage or improper valve timing will result SRemove the safety wire from the timing chain 4 Install SPlate washer SBolt timing chain 5 Install Stiming chain tensioner a Lightly press the timing chain tensioner rod into the timing chain tensioner housing by hand b While pressing the ti...

Page 22: ...ue Cap bolt 10 Nm 1 0 mSkg 6 Tighten SBolt timing chain Install the bolt while holding the magneto mounting bolt with a wrench 7 Turn Scrankshaft several turns counterclockwise 8 Check SMagneto rotor slit Align the stationary pointer with the crank case cover left SCam sprocket I mark Align the stationary pointer with the cylinder head Out of alignment Adjust 9 Check SValve clearance Refer to VALV...

Page 23: ...ght stay Handlebar crown Lock washer Upper ring nut Rubber washer Lower ring nut Ball race cover 1 1 1 1 1 1 1 1 1 Remove the parts in order Refer to FRONT FORK section Refer to HANDLEBAR section Disconnect the connector Refer to STEERING REMOVAL INSTALLATION section NOTE 110 Nm 1 1 mSkg 1st step 38 Nm 3 8 mkg 2nd step 4m 0 4 mkg STEERING UNDER BRACKET ...

Page 24: ... inner race Upper bearing Bearing outer race Lower bearing Bearing inner race Dust seal Bearing outer race 1 1 1 1 1 1 1 1 Reverse the removal procedure for installation Refer to STEERING REMOVAL INSTALLATION section 110 Nm 1 1 mSkg 1st step 38 Nm 3 8 mkg 2nd step 4m 0 4 mkg STEERING CHAS ...

Page 25: ...ndlebar switches right 10 Engine stop switch 11 Starter switch 12 C D I unit 13 Ignition coil 14 Spark plug 15 Clutch switch 16 Sidestand switch 17 Neutral relay 18 Speedometer 19 Neutral indicator light 20 Turn indicator light 21 Hi beam indicator light 22 Meter light 23 Neutral switch 24 Rear turn signal lights 25 Tail Brake light 26 Front brake switch 27 Rear brake switch 28 Front turn signal l...