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YJ125S Service Manual - 49ccscoot.com

YJ125 SSERVICE MANUALLIT-11616-17-435YR-28197-10 EAS00000YJ125S 2003 Service Manual 2003 by yamaha Motor Taiwan Co., edition, November 2003 All rights reproduction or unauthorized usewithout the written permission ofYamaha Motor Taiwan Co., expressly in Manual was produced by the yamaha Motor Taiwan Company, Ltd. primarily for use by Yamahadealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic inone Manual . Therefore, anyone who uses this book to perform maintenance and repairs on Yamahavehicles should have a basic understanding of mechanics and the techniques to repair these typesof vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely torender the vehicle unsafe and unfit for Motor Taiwan Company, Ltd.

EAS00002 NOTICE This manual was produced by the Yamaha Motor Taiwan Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics.

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Transcription of YJ125S Service Manual - 49ccscoot.com

1 YJ125 SSERVICE MANUALLIT-11616-17-435YR-28197-10 EAS00000YJ125S 2003 Service Manual 2003 by yamaha Motor Taiwan Co., edition, November 2003 All rights reproduction or unauthorized usewithout the written permission ofYamaha Motor Taiwan Co., expressly in Manual was produced by the yamaha Motor Taiwan Company, Ltd. primarily for use by Yamahadealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic inone Manual . Therefore, anyone who uses this book to perform maintenance and repairs on Yamahavehicles should have a basic understanding of mechanics and the techniques to repair these typesof vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely torender the vehicle unsafe and unfit for Motor Taiwan Company, Ltd.

2 Is continually striving to improve all of its models. Modificationsand significant changes in specifications or procedures will be forwarded to all authorized Yamahadealers and will appear in future editions of this Manual where :Designs and specifications are subject to change without Manual INFORMATIONP articularly important information is distinguished in this Manual by the Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!The Safety Alert Symbol means ATTENTION] BECOME ALERT! YOURSAFETY IS INVOLVED!Failure to follow WARNING instructions could result in severe injury or deathto the scooter operator, a bystander or a person inspecting or repairing CAUTION indicates special precautions that must be taken to avoid dam-age to the NOTE provides key information to make procedures easier or :wcCQHOW TO USE THIS MANUALThis Manual is intended as a handy, easy-to-read reference book for the mechanic.

3 Comprehensiveexplanations of all installation, removal, disassembly, assembly, repair and check procedures arelaid out with the individual steps in sequential Manual is divided into chapters. An abbreviation and symbol in the upper right corner ofeach page indicate the current to SYMBOLS .2 Each chapter is divided into sections. The current section title is shown at the top of each page,except in Chapter 3 ( PERIODIC CHECKS AND ADJUSTMENTS ), where the sub-section title(s) titles appear in smaller print than the section help identify parts and clarify procedure steps, there are exploded diagrams at the start ofeach removal and disassembly are given in the order of the jobs in the exploded diagram. A circled number indicatesa disassembly indicate parts to be lubricated or to SYMBOLS.

4 7A job instruction chart accompanies the exploded diagram, providing the order of jobs, namesof parts, notes in jobs, requiring more information (such as special tools and technical data) are described ty1234567891011121314 EAS00251 CYLINDER AND PISTONR emoving the cylinder and pistonCylinder headClampPipeTiming chain guide (exhaust side)CylinderO-ringDowel pinCylinder gasketPiston pin clipPiston pinPistonTop ring2nd ringOil ringExpanderRemove the parts in the order to CYLINDER HEAD .Refer to INSTALLING THE PISTONAND CYLINDER Refer to REMOVING THE CYLINDERAND PISTON Refer to INSTALLING THE PISTONAND CYLINDER For installation, reverse the removal AND PISTON121098813141312117512Nm( kg, ft lb)463444 ENG5-29 EAS00253 REMOVING THE CYLINDER AND PISTON1.

5 Remove:8piston pin clip 18piston pin 28piston 3cCDo not use a hammer to drive the piston :8 Before removing the piston pin clip, coverthe crankcase opening with a clean rag toprevent the piston pin clip from falling intothe removing the piston pin, deburr thepiston pin clip s groove and the piston s pinbore Remove:8top ring82nd ring8oil ringNOTE:When removing a piston ring, open the end gapwith your fingers and lift the other side of thering over the piston AND PISTON32184571326 GENINFOSPECCHKADJENGTRBLSHTGCARBCHAS-+EL ECEMBLSNewMGCOOL1234567890qweriopasdfgEA S00008 SYMBOLSThe following symbols are not relevant to 1 to 9 indicate the subject of information2 Specifications3 Periodic checks and adjustments4 Chassis5 Engine6 Cooling system7 Carburetor(s)

6 8 Electrical system9 TroubleshootingSymbols 0 to u indicate the with engine mountedqFilling fluidwLubricanteSpecial toolrTightening torquetWear limit, clearanceyEngine speeduElectrical dataSymbols i to d in the exploded diagrams indi-cate the types of lubricants and oiloGear oilpMolybdenum-disulfide oilaWheel-bearing greasesLithium-soap- based greasedMolybdenum-disulfide greaseSymbols f to g in the exploded diagrams indi-cate the locking agent (LOCTITE )gReplace the partT y uLTEAS00011 TABLE OF CONTENTSGENERAL INFORMATIONSPECIFICATIONSPERIODIC CHECKS ANDADJUSTMENTSCHASSISENGINECARBURETORELE CTRICAL SYSTEMTROUBLESHOOTING-+GEN INFOSPECCHKADJCHASENGCARBELECTRBLSHTG123 456781-8 GENINFOCHAPTER 1 GENERAL INFORMATIONSCOOTER 1-1 VEHICLE IDENTIFICATION 1-1 MODEL 1-1 IMPORTANT 1-2 PREPARATION FOR REMOVAL AND DISASSEMBLY.

7 1-2 REPLACEMENT 1-2 GASKETS, OIL SEALS AND O-RINGS .. 1-2 LOCK WASHERS/PLATES AND COTTER 1-3 BEARINGS AND OIL SEALS .. 1-3 CHECKING THE 1-4 SPECIAL 1-51-1 GENINFOEAS00015 GENERAL INFORMATIONSCOOTER IDENTIFICATIONEAS00017 VEHICLE IDENTIFICATION NUMBERThe vehicle identification number 1 is stampedinto the steering head LABELThe model label 1 is affixed to the seat. Thisinformation will be needed to order spare IDENTIFICATION111-2 GENINFOEAS00020 IMPORTANT INFORMATIONPREPARATION FOR REMOVAL AND DISAS-SEMBLY1. Before removal and disassembly, removeall dirt, mud, dust and foreign Use only the proper tools and to the SPECIAL TOOLS .3. When disassembling, always keep matedparts together.

8 This includes gears, cylin-ders, pistons and other parts that have been mated through normal wear. Mated partsmust always be reused or replaced as During disassembly, clean all of the partsand place them in trays in the order of dis-assembly. This will speed up assembly andallow for the correct installation of all Keep all parts away from any source of PARTSUse only genuine yamaha parts for all replace-ments. Use oil and grease recommended byYamaha for all lubrication jobs. Other brands maybe similar in function and appearance, but infe-rior in , OIL SEALS AND O-RINGS1. When overhauling the engine, replace allgaskets, seals and O-rings. All gasket sur-faces, oil seal lips and O-rings must During reassembly, properly oil all matingparts and bearings and lubricate the oil seallips with INFORMATION1-3 GENINFOEAS00023 LOCK WASHERS/PLATES AND COTTERPINSA fter removal, replace all lock washers/plates1 and cotter pins.

9 After the bolt or nut has beentightened to specification, bend the lock tabsalong a flat of the bolt or AND OIL SEALSI nstall bearings and oil seals so that themanufacturer s marks or numbers are installing oil seals, lubricate the oil seallips with a light coat of lithium-soap-basedgrease. Oil bearings liberally when installing, sealcCDo not spin the bearing with compressedair because this will damage the reassembly, check all circlips carefullyand replace damaged or distorted circlips. Al-ways replace piston pin clips after one use. Wheninstalling a circlip 1, make sure the sharp-edgedcorner 2 is positioned opposite the thrust 3that the circlip INFORMATION1-4 GENINFOEAS00026 CHECKING THE CONNECTIONSC heck the leads, couplers, and connectors forstains, rust, moisture, Disconnect:8lead8coupler8connector2.

10 Check:8lead8coupler8connectorMoisture J Dry with an air J Connect and disconnectseveral Check:8all connectionsLoose connection J Connect :If the pin 1 on the terminal is flattened, bend Connect:8lead8coupler8connectorNOTE:Make sure all connections are Check:8continuity(with the pocket tester)Pocket tester90890-03132 (YU-03112-C)NOTE:8If there is no continuity, clean the checking the wire harness, performsteps (1) to (3).8As a quick remedy, use a contact revitalizeravailable at most part THE CONNECTIONS1-5 GENINFOEAS00027 SPECIAL TOOLSThe following special tools are necessary for complete and accurate tune-up and assembly. Useonly the appropriate special tools as this will help prevent damage caused by the use of inappropri-ate tools or improvised techniques.


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