Yamaha WR125X 2009 Manuals

Manuals and User Guides for Yamaha WR125X 2009. We have 1 Yamaha WR125X 2009 manual available for free PDF download: Service Manual

Yamaha WR125X 2009 Service Manual

Yamaha WR125X 2009 Service Manual (372 pages)

Brand: Yamaha | Category: Motorcycle | Size: 24.62 MB

Table of Contents

Table of Contents
7
General Information
9
- Identification
  10
- Vehicle Identification Number
  10
- Model Label
  10
- Features
  11
- Outline of the Fi System
  11
- Fi System
  12
- Instrument Functions
  13
- Important Information
  15
- Preparation for Removal and Disassembly
  15
- Replacement Parts
  15
- Gaskets, Oil Seals and O-Rings
  15
- Lock Washers/Plates and Cotter Pins
  15
- Bearings and Oil Seals
  16
- Circlips
  16
- Checking the Connections
  17
- Special Tools
  21
Specifications
25
- General Specifications
  26
- Engine Specifications
  27
- Chassis Specifications
  34
- Electrical Specifications
  37
- Tightening Torques
  40
- General Tightening Torque Specifications
  40
- Engine Tightening Torques
  41
- Chassis Tightening Torques
  44
- Lubrication Points and Lubricant Types
  48
- Engine
  48
- Chassis
  50
- Lubrication System Chart and Diagrams
  52
- Engine Oil Lubrication Chart
  52
- Lubrication Diagrams
  54
- Cooling System Diagrams
  58
- Cable Routing
  60
Periodic Checks and Adjustments
79
Chassis
98
- Adjusting the Rear Disc Brake
  98
- Checking the Brake Fluid Level
  98
- Checking the Front Brake Pads
  99
- Checking the Rear Brake Pads
  99
- Checking the Front Brake Hose
  99
- Checking the Rear Brake Hose
  100
- Bleeding the Hydraulic Brake System
  100
- Adjusting the Drive Chain Slack
  101
- Lubricating the Drive Chain
  102
- Checking and Adjusting the Steering Head
  102
- Checking the Front Fork
  103
- Adjusting the Rear Shock Absorber Assembly
  103
- Checking the Tires
  104
- Checking the Wheels
  106
- Checking and Tightening the Spokes
  106
- Checking and Lubricating the Cables
  107
- Lubricating the Clutch Lever
  107
- Lubricating the Brake Lever
  107
- Lubricating the Brake Pedal
  107
- Lubricating the Sidestand
  107
- Lubricating the Rear Suspension
  107
- General Chassis
  114
- Removing the Rear Side Covers
  118
- Installing the Air Filter Case
  118
- Front Wheel
  119
- Removing the Front Wheel (Disc)
  123
- Disassembling the Front Wheel
  123
- Checking the Front Wheel
  123
- Assembling the Front Wheel
  124
- Installing the Front Wheel (Disc)
  124
- Rear Wheel
  126
- Removing the Rear Wheel (Disc)
  130
- Disassembling the Rear Wheel
  130
- Checking the Rear Wheel
  130
- Checking and Replacing the Rear Wheel Sprocket
  130
- Assembling the Rear Wheel
  131
- Installing the Rear Wheel (Disc)
  131
- Front Brake
  132
- Introduction
  136
- Checking the Front Brake Disc
  136
- Replacing the Front Brake Pads
  137
- Removing the Front Brake Caliper
  138
- Disassembling the Front Brake Caliper
  138
- Checking the Front Brake Caliper
  138
- Assembling the Front Brake Caliper
  139
- Installing the Front Brake Caliper
  139
- Removing the Front Brake Master Cylinder
  140
- Checking the Front Brake Master Cylinder
  140
- Installing the Front Brake Master Cylinder
  140
- Rear Brake
  143
- Introduction
  149
- Checking the Rear Brake Disc
  149
- Replacing the Rear Brake Pads
  149
- Removing the Rear Brake Caliper
  150
- Disassembling the Rear Brake Caliper
  150
- Checking the Rear Brake Caliper
  151
- Assembling the Rear Brake Caliper
  151
- Installing the Rear Brake Caliper
  151
- Removing the Rear Brake Master Cylinder
  152
- Checking the Rear Brake Master Cylinder
  152
- Assembling the Rear Brake Master Cylinder
  153
- Installing the Rear Brake Master Cylinder
  153
- Handlebar
  156
- Removing the Handlebar
  156
- Checking the Handlebar
  156
- Installing the Handlebar
  156
- Front Fork
  159
- Removing the Front Fork Legs
  163
- Disassembling the Front Fork Legs
  163
- Checking the Front Fork Legs
  164
- Assembling the Front Fork Legs
  164
- Installing the Front Fork Legs
  167
- Steering Head
  168
- Removing the Lower Bracket
  171
- Checking the Steering Head
  171
- Installing the Steering Head
  171
- Rear Shock Absorber Assembly
  173
- Handling the Rear Shock Absorber Assembly (Wr125R)
  174
- Disposing of a Rear Shock Absorber Assembly (Wr125R)
  174
- Removing the Rear Shock Absorber Assembly
  174
- Checking the Rear Shock Absorber Assembly
  174
- Checking the Connecting Rod and Relay Arms
  174
- Installing the Relay Arms and Connecting Rod
  174
- Swingarm
  176
- Removing the Swingarm
  178
- Checking the Swingarm
  178
- Installing the Swingarm
  178
- Chain Drive
  180
- Removing the Drive Chain
  181
- Checking the Drive Chain
  181
- Checking the Drive Sprocket
  182
- Checking the Rear Wheel Sprocket
  182
- Installing the Drive Chain
  182
Engine
185
- Engine Removal
  188
- Removing the Engine
  192
- Installing the Engine
  192
- Installing the Rider Footrest/Brake Pedal Bracket Assembly
  192
- Installing the Shift Pedal
  193
- Installing the Muffler and Exhaust Pipe
  193
- Cylinder Head
  194
- Removing the Cylinder Head
  196
- Checking the Cylinder Head
  196
- Checking the Camshaft Sprocket and Timing Chain Guide
  197
- Checking the Timing Chain Tensioner
  197
- Checking the Decompression System
  198
- Installing the Cylinder Head
  198
- Camshaft
  201
- Checking the Camshaft
  202
- Checking the Rocker Arms and Rocker Arm Shafts
  202
- Installing the Camshaft and Rocker Arms
  203
- Valves and Valve Springs
  205
- Removing the Valves
  205
- Checking the Valves and Valve Guides
  205
- Checking the Valve Seats
  207
- Checking the Valve Springs
  208
- Installing the Valves
  209
- Cylinder and Piston
  211
- Removing the Piston
  212
- Checking the Cylinder and Piston
  212
- Checking the Piston Rings
  213
- Checking the Piston Pin
  214
- Installing the Piston and Cylinder
  214
- Generator and Starter Clutch
  216
- Removing the Generator
  218
- Removing the Starter Clutch
  218
- Checking the Starter Clutch
  219
- Installing the Starter Clutch
  219
- Installing the Generator
  219
- Electric Starter
  221
- Checking the Starter Motor
  223
- Assembling the Starter Motor
  224
- Clutch
  225
- Removing the Clutch
  229
- Checking the Friction Plates
  229
- Checking the Clutch Plates
  230
- Checking the Clutch Springs
  230
- Checking the Clutch Housing
  230
- Checking the Clutch Boss
  230
- Checking the Pressure Plate
  231
- Checking the Clutch Push Lever and Short Clutch Push Rod
  231
- Checking the Primary Drive Gear
  231
- Checking the Primary Driven Gear
  231
- Installing the Clutch
  231
- Oil Pump
  234
- Checking the Oil Pump
  236
- Assembling the Oil Pump
  236
- Installing the Oil Pump
  237
- Shift Shaft
  238
- Checking the Shift Shaft
  239
- Checking the Stopper Lever
  239
- Installing the Shift Shaft
  239
- Balancer Gears
  240
- Removing the Primary Drive Gear and Balancer Gears
  241
- Checking the Balancer Gears and Primary Drive Gear
  241
- Installing the Primary Drive Gear and Balancer Gears
  241
- Crankcase
  243
- Separating the Crankcase
  246
- Checking the Crankcase
  246
- Checking the Timing Chain and Timing Chain Guide
  246
- Checking the Oil Strainer
  246
- Checking the Bearings and Oil Seal
  246
- Installing the Bearing Retainer
  247
- Installing the Oil Seal
  247
- Assembling the Crankcase
  247
- Crankshaft
  249
- Removing the Crankshaft
  250
- Checking the Crankshaft
  250
- Installing the Crankshaft
  250
- Transmission
  252
- Checking the Shift Forks
  255
- Checking the Shift Drum Assembly
  255
- Checking the Transmission
  255
- Checking the Long Clutch Push Rod
  256
- Assembling the Main Axle and Drive Axle
  256
- Installing the Shift Forks and Shift Drum Assembly
  256
Cooling System
259
- Radiator
  260
- Checking the Radiator
  262
- Installing the Radiator
  262
- Thermostat
  263
- Checking the Thermostat
  264
- Installing the Thermostat
  264
- Water Pump
  265
- Disassembling the Water Pump
  267
- Checking the Water Pump
  267
- Assembling the Water Pump
  267
- Installing the Water Pump
  268
Fuel System
269
- Fuel Tank
  270
- Removing the Fuel Tank
  271
- Removing the Fuel Pump
  271
- Checking the Fuel Pump Body
  271
- Installing the Fuel Pump
  271
- Installing the Fuel Tank
  272
- Checking the Fuel Pressure
  272
- Throttle Body
  274
- Removing the Throttle Body
  276
- Checking the Fuel Injector
  276
- Checking the Throttle Body
  276
- Installing the Throttle Body
  276
- Air Induction System
  278
- Checking the Air Induction System
  281
Electrical System
283
- Ignition System
  286
- Circuit Diagram
  286
- Troubleshooting
  288
- Electric Starting System
  290
- Circuit Diagram
  290
- Starting Circuit Cut-Off System Operation
  292
- Troubleshooting
  293
- Charging System
  296
- Circuit Diagram
  296
- Troubleshooting
  298
- Lighting System
  300
- Circuit Diagram
  300
- Troubleshooting
  302
- Signaling System
  304
- Circuit Diagram
  304
- Troubleshooting
  306
- Cooling System
  310
- Circuit Diagram
  310
- Troubleshooting
  312
- Fuel Injection System
  314
- Circuit Diagram
  314
- Ecu Self-Diagnostic Function
  316
- Self-Diagnostic Function Table
  317
- Troubleshooting Method
  319
- Diagnostic Mode
  319
- Troubleshooting Details
  327
- Fuel Pump System
  340
- Circuit Diagram
  340
- Troubleshooting
  342
- Electrical Components
  344
- Checking the Switches
  346
- Checking the Bulbs and Bulb Sockets
  349
- Checking the Fuses
  350
- Checking and Charging the Battery
  350
- Checking the Relays
  352
- Checking the Turn Signal Relay
  353
- Checking the Diode
  354
- Checking the Spark Plug Cap
  354
- Checking the Ignition Coil
  355
- Checking the Ignition Spark Gap
  355
- Checking the Crankshaft Position Sensor
  356
- Checking the Lean Angle Sensor
  356
- Checking the Starter Motor Operation
  357
- Checking the Stator Coil
  357
- Checking the Rectifier/Regulator
  357
- Checking the Horn
  358
- Checking the Fuel Sender
  358
- Checking the Speed Sensor
  359
- Checking the Radiator Fan Motor
  359
- Checking the Coolant Temperature Sensor
  360
- Checking the Throttle Body Sensor Assembly
  360
- Checking the Fid (Fast Idle Solenoid)
  362
Troubleshooting
363
- Troubleshooting
  364
- General Information
  364
- Starting Failures
  364
- Incorrect Engine Idling Speed
  364
- Poor Medium-And-High-Speed Performance
  365
- Faulty Gear Shifting
  365
- Shift Pedal Does Not Move
  365
- Jumps out of Gear
  365
- Faulty Clutch
  365
- Overheating
  365
- Overcooling
  366
- Poor Braking Performance
  366
- Faulty Front Fork Legs
  366
- Unstable Handling
  366
- Faulty Lighting or Signaling System
  367

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