YFM125S
YFM125S
3FA-AE2
SUPPLEMENTARY
SERVICE MANUAL
FOREWORD
This Supplementary Service Manual has been prepared to introduce new service and data for the
YFM125S. For complete service information procedures it is necessary to use this Supplementary
Service Manual together with the following manual.
YFA1W SERVICE MANUAL: 3FA-ME1
YFA1(P) 2002 SUPPLEMENTARY SERVICE MANUAL: 3FA-AE1
YFM125S
SUPPLEMENTARY
SERVICE MANUAL
©2004 by Yamaha Motor Co., Ltd.
First edition, January 2004
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
EBS00002
NOTICE
This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one
manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on
Yamaha machine has a basic understanding of the mechanical ideas and the procedures of
machine repair. Repairs attempted by anyone without this knowledge are likely to render the
machine unsafe and unfit for use.
Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers
and will appear in future editions of this manual where applicable.
NOTE:
Designs and specifications are subject to change without notice.
_
EBS00003
IMPORTANT INFORMATION
Particularly important information is distinguished in this manual by the following notations.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
WARNING
CAUTION:
NOTE:
Failure to follow WARNING instructions could result in severe injury or death
to the machine operator, a bystander or a person checking 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.
EBS00004
HOW TO USE THIS MANUAL
MANUAL ORGANIZATION
This manual consists of chapters for the main categories of subjects. (See “symbols”)
1st title 1: This is the title of the chapter with its symbol in the upper right corner of each page.
2nd title 2: This title indicates the section of the chapter and only appears on the first page of each
section. It is located in the upper left corner of the page.
3rd title 3: This title indicates a sub-section that is followed by step-by-step procedures accompanied by corresponding illustrations.
EXPLODED DIAGRAMS
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 4 is provided for removal and disassembly jobs.
2. Numbers 5 are given in the order 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
6. The meanings of the symbol marks are given on the next page.
4. A job instruction chart 7 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 8 are given in addition
to the exploded diagram and the job instruction chart.
1
EB003000
2
GEN
INFO
ILLUSTRATED SYMBOLS
Illustrated symbols 1 to 8 are printed on the
top right of each page and indicate the subject
of each chapter.
SPEC
3
4
CHK
ADJ
1 General information
2 Specifications
3 Periodic checks and adjustments
4 Engine
5 Carburetion
6 Chassis
7 Electrical
8 Troubleshooting
ENG
5
6
CHAS
CARB
7
8
ELEC
–
TRBL
SHTG
+
0
Illustrated symbols 9 to E are used to identify
the specifications appearing in the text.
A
B
9 Filling fluid
0 Lubricant
A Special tool
B Torque
C Wear limit, clearance
D Engine speed
E Ω, V, A
C
D
9
T.
R.
E
F
G
G
E
I
J
B
M
K
L
M
LS
M
Illustrated symbols F to L in the exploded
diagrams indicate the types of lubricants and
lubrication points.
H
S
N
LT
New
F Apply engine oil
G Apply gear oil
H Apply molybdenum disulfide oil
I Apply wheel bearing grease
J Apply lightweight lithium soap base grease
K Apply molybdenum disulfide grease
L Apply silicon grease
Illustrated symbols M to N in the exploded
diagrams indicate where to apply a locking
agent M and when to install a new part N.
M Apply the locking agent (LOCTITE®)
N Replace
CONTENTS
SPECIFICATIONS ............................................................................................1
GENERAL SPECIFICATIONS ..................................................................1
MAINTENANCE SPECIFICATIONS .........................................................2
ENGINE ................................................................................................2
CHASSIS ..............................................................................................2
ELECTRICAL ........................................................................................3
CABLE ROUTING .....................................................................................4
PERIODIC CHECKS AND ADJUSTMENTS ..................................................17
SEAT, CARRIERS AND FENDERS ........................................................17
SEAT, FRONT CARRIER, FRONT BUMPER AND CENTER COVER ....17
FRONT GRILL ASSEMBLY AND FRONT FENDER ..........................19
REAR CARRIER AND REAR FENDER ..............................................20
ELECTRICAL ..........................................................................................22
ADJUSTING THE HEADLIGHT BEAMS ............................................22
REPLACING A HEADLIGHT BULB ....................................................22
ELECTRICAL .................................................................................................24
IGNITION SYSTEM .................................................................................24
CIRCUIT DIAGRAM ............................................................................24
CHARGING SYSTEM .............................................................................25
CIRCUIT DIAGRAM ............................................................................25
LIGHTING SYSTEM ................................................................................26
CIRCUIT DIAGRAM ............................................................................26
TROUBLESHOOTING ........................................................................27
SIGNAL SYSTEM ...................................................................................29
CIRCUIT DIAGRAM ............................................................................29
CHECKING THE SIGNALING SYSTEM .............................................30
YFM125S WIRING DIAGRAM
GENERAL SPECIFICATIONS
SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
Model
Model code number
Dimensions
Overall length
Overall width
Overall height
Seat height
Wheelbase
Minimum ground clearance
Basic weight
Wet (with oil and a full fuel tank)
Dry (without oil and fuel)
Maximum load (except vehicle)
Fuel
Type
Fuel tank capacity
Reserve amount
Spark plug
Type/manufacturer
Spark plug gap
Electrical
Ignition system
Generator system
Battery capacity
Battery type
Headlight type
Headlight bulb type
Bulb wattage (quantity)
Headlight
Tail/brake light
Neutral indicator light
Reverse indicator light
YFM125S
1C51: (for Oceania)
1C53: (for CDN)
1C54: (for Europe)
1,710 mm (67.3 in)
990 mm (39.0 in)
980 mm (38.6 in)
705 mm (27.8 in)
1,080 mm (42.5 in)
145 mm (5.7 in)
152 kg (335 lb)
144 kg (317 lb)
100 kg (220 lb)
Regular unleaded gasoline only (for CDN and
Europe)
Unleaded gasoline only (for Oceania)
7.6 L (1.67 Imp gal, 2.01 US gal)
1.3 L (0.28 Imp gal, 0.34 US gal)
CR7HS/NGK
0.6 ~ 0.7 mm (0.024 ~ 0.028 in)
DC C.D.I.
A.C. magneto generator
12V 12Ah
12N12C-4A-2
Bulb type
Krypton
12 V 30 W/30 W (2 pc.)
12 V 5 W/21 W (1 pc.)
12 V 1.7 W (1 pc.)
12 V 1.7 W (1 pc.)
–1–
MAINTENANCE SPECIFICATIONS
SPEC
MAINTENANCE SPECIFICATIONS
ENGINE
Model
Carburetor
I.D. mark
Main jet
Main air jet
Jet needle
Needle jet
Cutaway
Pilot air jet
Pilot outlet
Pilot jet
Bypass 1
Pilot screw
Valve seat size
Starter jet
Fuel level
Engine idling speed
Intake vacuum
YFM125S
(M.J)
(M.A.J)
(J.N)
(N.J)
(C.A)
(P.A.J)
(P.O)
(P.J)
(B.P.1)
(P.S)
(V.S)
(G.S)
(F.L)
5VJ2 10
# 77.5
ø 1.3
4HPY46-1
O-1M
2.5
# 130
ø 0.7
# 12.5
1.1
2 and 1/2 turns out (for Europe and Oceania)
1.8
# 45
3.5 ~ 4.5 mm (0.14 ~ 0.18 in)
With special tool
1,650 ~ 1,750 r/min
26.7 kPa (200 mmHg, 7.88 inHg)
CHASSIS
Tightening torques
Part to be tightened
Thread size
Footrest board and footrest bracket
Footrest and footrest bracket
Front fender and frame
Front carrier and front grill
Fuel tank
M5
M6
M6
M6
M6
–2–
Tightening torque
Nm m · kg ft · lb
7
10
7
7
10
0.7
1.0
0.7
0.7
1.0
5.1
7.2
5.1
5.1
7.2
Remarks
MAINTENANCE SPECIFICATIONS
SPEC
ELECTRICAL
Model
C.D.I.
Magneto model/manufacturer
Pickup coil resistance
(lead color)
C.D.I. unit model/manufacturer
Charging system
Type
Magneto model/manufacturer
Charging coil resistance
(lead color)
Charging current
Standard output
Rectifier/regulator
Model/manufacturer
Regulator type
No load regulated voltage (DC)
Rectifier capacity
Withstand voltage
Electric starting system
Type
Starter motor
Model/manufacturer
Output
Armature coil resistance
Overall length (brush)
<Limit>
Brush spring pressure
Commutator diameter
<Wear limit>
Mica undercut
Starter relay
Model/manufacturer
Amperage rating
Coil resistance
Starting circuit cut off relay
Model/manufacturer
Coil resistance
Diode
Circuit breaker
Type
Amperage for individual circuit
Main
YFM125S
F1C5/YAMAHA
248 ~ 372 Ω at 20 °C (68 °F)
(white-red)
3FA/YAMAHA
(Minimum)
(Maximum)
A.C. magneto generator
F1C5/YAMAHA
0.8 ~ 1.2 Ω at 20 °C (68 °F)
(white-white)
6.2 A at 1,500 r/min
13 A at 5,000 r/min
14 V 150 W at 5,000 r/min
SH640E-11/SHINDENGEN
Semi conductor short circuit type
14.0 ~ 15.0 V
14.0 A
200 V
Constant mesh
3FA/YAMAHA
0.4 kW
0.019 ~ 0.023 Ω at 20 °C (68 °F)
10.0 mm (0.39 in)
<3.5 mm (0.14 in)>
552 ~ 828 g
22.0 mm (0.87 in)
<21.0 mm (0.83 in)>
1.5 mm (0.06 in)
MS5E-661/JIDECO
100 A
4.18 ~ 4.62 Ω at 20 °C (68 °F)
ACA12115-1/MATSUSHITA
72 ~ 88 Ω at 20 °C (68 °F)
No
Fuse
15 A
–3–
CABLE ROUTING
SPEC
CABLE ROUTING
1 Rear brake switch lead
2 Rear brake cable
3 Front brake cable
4 Front brake switch lead
5 Throttle cable
6 Fuel tank breather hose
7 Horn switch lead (for Europe)
8 Horn switch (for Europe)
9 Headlight lead (left)
0 Headlight lead (right)
A Neutral/reverse indicator light lead
B Main switch lead
C Coupler cover
D Steering shaft
For CDN and Oceania
1 2
3
4
HI
LO
HTS
LIG
0FF
P
TO
G.S N
EN RU
OFF
É
6
È
For Europe
5
9
0
1 2
A
B
HI
LIG
HTS
LO
0FF
P
TO
G.S N
EN RU
OFF
7
Ê
8
Ë
Í
DC Ì
–4–
CABLE ROUTING
È Fasten the front brake switch lead with two plastic bands.
É Fasten the rear brake switch lead and handlebar
switch lead with two plastic bands.
Ê Fasten the rear brake switch lead, handlebar
switch lead, and horn switch lead with two plastic bands. (for Europe)
Ë Do not pull the wire harness after fastening it.
Ì When installing the front fender, do not pinch the
coupler cover.
SPEC
Í Pass the leads and wire harness through the
guides on the front fender as shown.
For CDN and Oceania
1 2
3
4
HI
LO
HTS
LIG
0FF
P
TO
G.S N
EN RU
OFF
É
6
È
For Europe
5
9
0
1 2
A
B
HI
LIG
HTS
LO
0FF
P
TO
G.S N
EN RU
OFF
7
Ê
8
Ë
Í
DC Ì
–5–
CABLE ROUTING
1 Front brake cable
2 Throttle cable
3 Rear brake cable
4 Rear brake switch lead
5 Handlebar switch lead
6 Horn switch lead (for Europe)
7 Wire harness
8 Front brake switch lead
SPEC
È Pass the front brake cable and rear brake cable
through the cable guide. (for CDN and Oceania)
Pass the front brake cable, rear brake cable, and
horn switch lead through the cable guide. (for
Europe)
É Route the rear brake cable to the inside of the
front fender bracket.
Ê Pass the air duct inlet and outlet hoses between
the brake cables.
1 2
3
8
4
5
6
Î
Í
Ì
È
7
É
Ê
Ë
–6–
CABLE ROUTING
SPEC
Ë Cross the front brake cables behind the steering
shaft. Route the right front brake cable in front of
the left front brake cable.
Ì Put the cover on the couplers, and then fasten a
plastic band around the middle of the cover.
Í Route the rear brake switch lead and the handlebar switch lead behind the throttle cable and the
rear brake cable.
Î Route the horn switch lead behind the coupler
cover, throttle cable, front brake cable, and rear
brake cable. (for Europe)
1 2
3
8
4
5
6
Î
Í
Ì
È
7
É
Ê
Ë
–7–
CABLE ROUTING
1 Transmission case breather hose
2 Throttle cable
3 Front brake cable
4 Main switch lead
5 Wire harness
6 Rectifier/regulator
7 Horn lead (for Europe)
8 Horn (for Europe)
9 Starter motor lead
0 A.C. magneto lead
A Starter motor
SPEC
È Fasten the wire harness, starter motor lead, and
transmission case breather hose to the frame
with a plastic band.
É Route the wire harness, starter motor lead, and
the transmission case breather hose under the
frame cross member.
7
Ô
7
A
B-B
3
4
1È
É Ê
2
Ë
5
6
Ì
Í
7
8
B
B
A
Î
Ï
Ò
Ó
Ò
A0 Ñ 9
–8–
Ð
CABLE ROUTING
Ê Fasten the wire harness, starter motor lead, and
transmission case breather hose to the frame
with a plastic band. Be sure not to pinch the
transmission case breather hose. The end of the
plastic band should be toward the front of the
vehicle, facing inward.
Ë Pass the main switch lead and wire harness
through the hole in the front fender. Do not leave
any slack in the main switch lead and wire harness under the front fender.
SPEC
Ì Face the end of the transmission case breather
hose down.
Í Fasten the wire harness, starter motor lead, and
rectifier/regulator lead to the frame with a plastic
band. (for CDN and Oceania)
Fasten the wire harness, starter motor lead, rectifier/regulator lead, and horn lead to the frame
with a plastic band. (for Europe)
Î Fasten the horn lead to the front fender bracket
with a plastic band just above the horn bracket.
(for Europe)
7
Ô
7
A
B-B
3
4
1È
É Ê
2
Ë
5
6
Ì
Í
7
8
B
B
A
Î
Ï
Ò
Ó
Ò
A0 Ñ 9
–9–
Ð
CABLE ROUTING
Ï 80 mm (3.15 in)
Ð Fasten the starter motor lead and A.C. magneto
lead to the frame with a plastic band. The end of
the plastic band should be toward the rear of the
vehicle, facing inward.
Ñ Fasten the starter motor lead and A.C. magneto
lead with a plastic locking tie.
Ò Fasten the A.C. magneto lead with the holders.
Ó Route the A.C. magneto lead on top of the
crankcase.
SPEC
Ô Face the end of the plastic band inward. (for
Europe)
7
Ô
7
A
B-B
3
4
1È
É Ê
2
Ë
5
6
Ì
Í
7
8
B
B
A
Î
Ï
Ò
Ó
Ò
A0 Ñ 9
– 10 –
Ð
CABLE ROUTING
1 Tail/brake light
2 Tail/brake light lead
3 Reverse relay
4 Starting circuit cut-off relay
5 Starter relay
6 Positive battery lead
7 Negative battery lead
8 Transmission case breather hose
9 Reverse switch
0 Neutral switch lead
A Reverse switch lead
1
2
B Starter motor lead
C Battery breather hose
D Fuse holder
3
È
4
5
É
6
Ê
Ë
Ô
7
A 0
SPEC
7
Ì
8
A
D
C
B
Ó
Ñ
Ò
Ñ
Ð
Ï Î A 0 9 Í
Õ
A
– 11 –
CABLE ROUTING
Î Install both the holder and the negative battery
lead terminal to the crankcase with the screw so
that the holder is in front of the terminal. Fasten
the neutral switch lead and reverse switch lead
with the holder.
Ï Pass the fuel overflow hose between the swingarm and crankcase.
Ð The end of battery breather hose should be
lower than the frame.
È Fasten the tail/brake light lead to the rear carrier
with a plastic band.
É Pass the positive battery lead through the rear
hole in the rear fender.
Ê Pass the negative battery leads through the front
hole in the rear fender.
Ë Fasten the wire harness with the holder.
Ì Align the white tape of the wire harness with the
front end of the frame support as shown.
Í Route the fuel overflow hose in front of the transmission case breather hose.
1
2
3
È
4
5
É
6
Ê
Ë
Ô
7
A 0
SPEC
7
Ì
8
A
D
C
B
Ó
Ñ
Ò
Ñ
Ð
Ï Î A 0 9 Í
Õ
A
– 12 –
CABLE ROUTING
Õ Do not straighten the negative battery lead terminal. The negative battery lead should be bent
as shown.
Ñ Pass the battery breather hose through the
guide.
Ò Route the battery breather hose so that there is
no slack.
Ó Fasten the negative battery lead, neutral switch
lead, reverse switch lead, and starter motor lead
to the frame with a plastic band. The end of the
plastic band should be toward the rear of the
vehicle, facing inward.
Ô 60 mm (2.36 in)
1
2
3
È
4
5
É
6
Ê
Ë
Ô
7
A 0
SPEC
7
Ì
8
A
D
C
B
Ó
Ñ
Ò
Ñ
Ð
Ï Î A 0 9 Í
Õ
A
– 13 –
CABLE ROUTING
1 C.D.I. unit
2 Air duct inlet hose
3 Air duct outlet hose
4 Fuel tank breather hose
5 Fuel hose
6 Crankcase breather hose
7 Fuel overflow hose
8 Rear brake cable
9 Front brake cable (left)
0 Front brake cable (right)
A C.D.I. unit holder
SPEC
È Route the rear brake cable to the outside of the
frame.
É Place the end of the fuel tank breather hose in
the rubber fuel overflow tray.
Ê Pass the fuel tank breather hose through the
hole in the handlebar cover.
Ë Route the fuel overflow hose to the outside of
the engine bracket. Keep the hose as far away
as possible from the exhaust pipe.
Ì Pass the rear brake cable through the swingarm.
Í Pass the rear brake cable through the guide.
Ê
4
É
5
3
2
È
1
6
Ë
RES
OFF
FUEL
A
0
9 Í
8
Í
1
A
A
– 14 –
7
Ì
CABLE ROUTING
1 C.D.I. unit
2 Throttle cable
3 Starter motor lead
4 Wire harness
5 Transmission case breather hose
6 Ignition coil
7 Negative battery leads
8 Positive battery lead
9 Air vent hose
0 Crankcase breather hose
A Starter cable
4
B
SPEC
B Starting circuit cut-off relay
C Reverse relay
D Fuse holder
1
È
C
2
ÎA
D
3
4
5
A
6
Í0
Ì9
Ë
É
A
7
8Ê
– 15 –
CABLE ROUTING
È Route the C.D.I. unit lead over the front shock
absorber bracket.
É Route the negative battery leads under the
frame.
Ê Route the positive battery lead over the frame.
Ë Pass the air vent hose through the hole in the
fuel tank from the top. The end of the air vent
hose should extend 15 ~ 20 mm (0.59 ~ 0.79 in)
from the hole.
Ì Do not kink the air vent hose.
4
B
SPEC
Í Pass the crankcase breather hose between the
starter cable and throttle cable.
Î Route the starter cable over the crankcase
breather hose and under the throttle cable.
1
È
C
2
ÎA
D
3
4
5
A
6
Í0
Ì9
Ë
É
A
7
8Ê
– 16 –
SEAT, CARRIERS AND FENDERS
CHK
ADJ
PERIODIC CHECKS AND ADJUSTMENTS
SEAT, CARRIERS AND FENDERS
SEAT, FRONT CARRIER, FRONT BUMPER AND CENTER COVER
5
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
6
7
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
1
T.
R.
23 Nm (2.3 m • kg, 17 ft • Ib)
(4)
2
3
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
23 Nm (2.3 m • kg, 17 ft • Ib)
4
T.
R.
Order
23 Nm (2.3 m • kg, 17 ft • Ib)
1
Job/Part
Removing the seat, front carrier,
front bumper and center cover
Seat
Q’ty
2
3
4
5
6
Handlebar cover
Front carrier
Front bumper
Neutral/reverse indicator light coupler
Front fender panel
1
1
1
1
1
1
– 17 –
Remarks
Remove the parts in the order listed.
NOTE:
Pull the seat lock lever backward, then
pull up the seat at the rear.
Disconnect.
SEAT, CARRIERS AND FENDERS
5
CHK
ADJ
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
6
7
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
1
T.
R.
23 Nm (2.3 m • kg, 17 ft • Ib)
(4)
2
3
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
23 Nm (2.3 m • kg, 17 ft • Ib)
4
T.
R.
Order
7
23 Nm (2.3 m • kg, 17 ft • Ib)
Job/Part
Center cover
Q’ty
Remarks
1
NOTE:
Install the fuel tank cap after removing
the center cover to prevent dust, mud,
etc., from entering the fuel tank.
For installation, reverse the removal procedure.
– 18 –
SEAT, CARRIERS AND FENDERS
CHK
ADJ
FRONT GRILL ASSEMBLY AND FRONT FENDER
T.
R.
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
1
7 Nm (0.7 m • kg, 5.1 ft • Ib)
3
7
(6)
4
2
5
2
(6)
6
Order
1
2
3
4
5
6
7
Job/Part
Removing the front grill assembly
and front fender
Seat/center cover
Main switch coupler
Headlight coupler
Air filter cover
Front grill assembly
Air duct outlet hose
Air duct inlet hose
Front fender
Q’ty
1
2
1
1
1
1
1
Remarks
Remove the parts in the order listed.
Refer to “SEAT, FRONT CARRIER,
FRONT BUMPER AND CENTER
COVER”.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
For installation, reverse the removal procedure.
– 19 –
SEAT, CARRIERS AND FENDERS
CHK
ADJ
REAR CARRIER AND REAR FENDER
3
T.
R.
23 Nm (2.3 m • kg, 17 ft • Ib)
5
2
1
7 6
9
(4)
4
T.
(4)
R.
(4)
Order
8
Job/Part
Removing the rear carrier and rear
fender
Seat/center cover
Q’ty
Front grill assembly/front fender
1
2
3
4
Tail/brake light connector
Tail/brake light
Rear carrier
Battery lead
23 Nm (2.3 m • kg, 17 ft • Ib)
3
1
1
2
Remarks
Remove the parts in the order listed.
Refer to “SEAT, FRONT CARRIER,
FRONT BUMPER AND CENTER
COVER”.
Refer to “FRONT GRILL ASSEMBLY
AND FRONT FENDER”.
Disconnect.
Disconnect.
CAUTION:
First disconnect the negative lead,
then disconnect the positive lead.
– 20 –
SEAT, CARRIERS AND FENDERS
CHK
ADJ
3
T.
R.
23 Nm (2.3 m • kg, 17 ft • Ib)
5
2
1
7 6
9
(4)
4
T.
(4)
R.
(4)
Order
5
6
7
8
9
Job/Part
Battery
Carburetor joint clamp screw
Crankcase breather hose
Air filter case
Rear fender
23 Nm (2.3 m • kg, 17 ft • Ib)
8
Q’ty
Remarks
1
1
Loosen.
1
Disconnect.
1
1
For installation, reverse the removal procedure.
– 21 –
ADJUSTING THE HEADLIGHT BEAMS/
REPLACING A HEADLIGHT BULB
CHK
ADJ
ELECTRICAL
EBS00122
ADJUSTING THE HEADLIGHT BEAMS
1. Adjust:
• headlight beam (vertically)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a
b
a. Turn the adjusting screw 1 in direction a
or b.
1
Direction a
Headlight beam is
raised.
Direction b
Headlight beam is
lowered.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EBS00124
1
REPLACING A HEADLIGHT BULB
1. Remove:
• headlight unit cover 1
2. Remove:
• headlight bulb holder cover 1
1
– 22 –
REPLACING A HEADLIGHT BULB
CHK
ADJ
3. Remove:
• bulb holder 1
• bulb
1
NOTE:
Push the headlight bulb holder inward, turn it
counterclockwise and remove the defective
bulb.
_
WARNING
_
Keep flammable products and your hands
away from the bulb while it is on, since it
will be hot. Do not touch the bulb until it
cools down.
4. Install:
• bulb New
CAUTION:
_
Avoid touching the glass part of the bulb.
Keep it free from oil; otherwise, the transparency of the glass, life of the bulb, and
luminous flux will be adversely affected. If
oil gets on the bulb, thoroughly clean it
with a cloth moistened with alcohol or lacquer thinner.
– 23 –
È
W
W
R
W
W
– 24 –
Br
B
B
B
G
B
B
Y
G
L
Y
R/B
J
B
2
OFF
ON
B
B
Br
B
Y
Y
Br
Br
B
Y
5
R
6
R
L
B
Y
G
G
Y
N
B
G
OFF
ON
L
ON
OFF
R
R
B
Y
G
R/B
Y
N
B
G
OFF
PUSH
M
(GRAY)
Br
(GRAY)
G
R/W
B
B
B
B
R
Y
B
Br
B
H
7
B
B
R
Br
L/W
Y
I
B
L
Y
Y
B
Br G/Y
R/W
R/W
R/W
L/W
L/W
L/W Sb
8
B
Br R/B
Sb L/W
Y
G/L
(RED)
Br
G/W B
(GRAY)
B
G/Y Br
(GRAY)
Y
Br G/Y
G
R/B Br
F
G/L Br
B G/W
E
B
G/W
B
9
D
L
L
L
Sb R/W
G/L R/W
B
Br Sb
O
R
Br G/L
O
O G/Y
W G/W
R/B B
Br
A
Sb
G/L
C B
Br
0
ELEC
P
P
Br
G
OFF
LO
HI
1 A.C. magneto
3 Main switch
4 Fuse
5 Battery
9 C.D.I. unit
0 Ignition coil
A Spark plug
E Reverse switch
G Brake lever switch
L Engine stop switch
O
Br
3
R
W
R
G/Y
G/W
W
4
R
R/B
R
W
W
W
K
R
W W W
1
Br R/W
R/B
W
R/W Br
L
(BLACK)
R
W
W
W
B
W
W
P
W
(BLACK) (BLACK)
R
IGNITION SYSTEM
–
+
EBS00503
ELECTRICAL
IGNITION SYSTEM
CIRCUIT DIAGRAM
È
W
W
R
W
W
W
– 25 –
B
B
Y
OFF
LO
HI
K
R
W
L
Br
Y
G
OFF
ON
L
ON
OFF
3
R
Br
Br
R
R/B
R/W
4
OFF
PUSH
M
(GRAY)
Br
(GRAY)
R
R
B
5
B
B
B
R
R
7
B
B
Y
B
Br
B
H
6
R
R
Y
Br
Y
Br G/Y
R/W
R/W
R/W
L/W
L/W
L/W
B
G/W
–
1 A.C. magneto
2 Rectifier/regulator
4 Fuse
5 Battery
G/Y Br
(GRAY)
Y
Br R/B
Sb L/W
8
Br G/Y
G
R/B Br
L/W Sb
W
G/Y
R
R/B
R
W
W
W
ELEC
G
G
L
Y
R/B
J
B
2
W W W
Br R/W
R/B
W
1
R/W Br
L
(BLACK)
W
W
W
R
B
W
W
(BLACK) (BLACK)
R
CHARGING SYSTEM
+
EBS00516
CHARGING SYSTEM
CIRCUIT DIAGRAM
È
W
W
– 26 –
W
W
W
W
OFF
ON
W
R
W
Br
B
Y
Br
B
B
B
B
G
B
L
G
Br
B
Y
Br R/W
R/B
J
B
2
W
W
G
OFF
LO
HI
B
Y
L
Br
B
Y
Y
G
G
Y
N
B
G
OFF
ON
L
ON
OFF
3
R
Br
Br
R
B
Y
G
R/B
Y
N
B
G
OFF
PUSH
M
(GRAY)
Br
(GRAY)
R
R
G
R/W
4
B
B
Y
5
B
B
B
R
R
7
B
B
Y
B
Br
B
H
6
R
R
Y
Br
I
B
L
Y
Y
B
Br G/Y
R/W
R/W
R/W
L/W
L/W
L/W
B
Y
G/L
(RED)
Br
G/W B
(GRAY)
B
G/Y Br
(GRAY)
Y
Br R/B
Sb L/W
8
Br G/Y
G
R/B Br
L/W Sb
F
B G/W
G/L Br
G/W
G/Y
R
R/B
R
W
K
R
W W W
1
W
W
E
B
G/W
B
9
D
L
L
L
O
Br G/L
B
G/L R/W
Sb R/W
R
Br Sb
O
O G/Y
W G/W
R/B B
Br
A
Sb
G/L
C B
Br
0
ELEC
P
P
R/B
W
R/W Br
L
(BLACK)
W
B
P
W
3 Main switch
4 Fuse
5 Battery
I Tail/brake light
K Light switch
N Headlight
O
R
(BLACK) (BLACK)
R
LIGHTING SYSTEM
–
+
EBS00518
LIGHTING SYSTEM
CIRCUIT DIAGRAM
LIGHTING SYSTEM
EBS01067
–
ELEC
+
EBS01044
TROUBLESHOOTING
2. Battery
Any of the following fail to light: headlight or tail/brake light.
• Check the condition of the battery.
Refer to “BATTERY INSPECTION” in
chapter 3 (Manual No.: 3FA-ME1).
Check:
1. fuse
2. battery
3. main switch
4. light switch
5. wiring connections
(of the entire lighting system)
Minimum open-circuit voltage
12.8 V or more at 20 °C (68 °F)
• Is the battery OK?
NO
YES
NOTE:
• Before troubleshooting, remove the following
part(s):
1. seat
2. front carrier
3. front fender panel
• Troubleshoot with the following special
tool(s).
• Clean the battery
terminals.
• Recharge or
replace the battery.
_
EBS01041
3. Main switch
• Check the main switch for continuity.
Refer to “CHECKING THE SWITCH”
(Manual No.: 3FA-AE1).
• Is the main switch OK?
Pocket tester
YM-03112-C, 90890-03112
EBS01043
NO
YES
1. Fuse
• Check the fuse for continuity.
Refer to “CHECKING THE SWITCH”
(Manual No.: 3FA-AE1).
• Is the fuse OK?
YES
NO
Replace
switch.
the
main
EBS01068
4. Light switch
• Check the light switch for continuity.
Refer to “CHECKING THE SWITCH”
(Manual No.: 3FA-AE1).
• Is the light switch OK?
Replace the fuse.
YES
NO
The light switch is
faulty. Replace the
left handlebar switch.
– 27 –
LIGHTING SYSTEM
EBS01069
5. Wiring
• Check the entire lighting system’s wiring.
Refer to “WIRING DIAGRAM”.
• Is the lighting system’s wiring properly
connected and without defects?
YES
Check the condition
of each of the lighting
system’s circuits.
Refer to “LIGHTING
SYSTEM” in chapter
7 (Manual No.: 3FAME1).
NO
Properly connect or
repair the lighting
system’s wiring.
– 28 –
ELEC
–
+
È For Europe
– 29 –
W
OFF
ON
O
È
W
W
R
W
B
Br
B
B
B
B
Br
B
Y
W
G
OFF
LO
HI
K
R
B
Y
Br
Y
3
R
Br
R
Br
4
B
Y
5
R
6
R
L
B
Y
G
G
Y
N
B
G
OFF
ON
L
ON
OFF
R
R
B
Y
G
R/B
Y
N
B
G
OFF
PUSH
M
(GRAY)
Br
(GRAY)
G
R/W
B
B
B
B
R
Y
B
Br
B
H
7
B
B
R
Br
L/W
Y
I
B
L
Y
Y
B
Br G/Y
R/W
R/W
R/W
L/W
L/W
L/W Sb
8
B
Br R/B
Sb L/W
Y
G/L
(RED)
Br
G/W B
(GRAY)
B
G/Y Br
(GRAY)
Y
Br G/Y
G
R/B Br
F
G/L Br
B G/W
G/W
G/Y
R
R/B
R
W
W
W
W
E
B
G/W
B
9
D
L
L
L
O
Br G/L
B
G/L R/W
Sb R/W
R
Br Sb
O
O G/Y
W G/W
R/B B
Br
A
Sb
G/L
C B
Br
0
ELEC
P
P
Br
B
G
G
L
Y
R/B
J
B
2
W W W
Br R/W
R/B
W
R/W Br
L
(BLACK)
R
W
W
W
B
W
W
P
W
1
3 Main switch
4 Fuse
5 Battery
G Brake lever switch
H Front brake light switch
I Tail/brake light
O Horn switch
P Horn
(BLACK) (BLACK)
R
SIGNAL SYSTEM
–
+
EB806000
SIGNAL SYSTEM
CIRCUIT DIAGRAM
SIGNAL SYSTEM
CHECKING THE SIGNALING SYSTEM
1. The horn fails to sound. (for Europe)
ELEC
–
3. Horn
• Disconnect the black connector at the horn
terminal.
• Connect a jumper lead 1 to the horn terminal and ground the jumper lead.
• Set the main switch to “ON”.
• Push the horn switch.
• Does the horn sound?
1. Horn switch
• Check the horn switch for continuity.
Refer to “CHECKING THE SWITCH”
(Manual No.: 3FA-AE1).
• Is the horn switch OK?
NO
YES
Replace
switch.
the
horn
2. Voltage
• Connect the pocket tester (DC 20 V) to the
horn connector at the horn terminal as
shown.
YES
Positive tester probe → pink 1
Negative tester probe → ground
The horn is OK.
• Set the main switch to “ON”.
• Push the horn switch.
• Measure the voltage (DC 12 V) of pink at
the horn terminal.
• Is the voltage within specification?
YES
+
NO
The wiring circuit
from the main switch
to the horn connector
is faulty and must be
repaired.
– 30 –
NO
Replace the horn.
YAMAHA MOTOR CO., LTD.
2500 SHINGAI IWATA SHIZUOKA JAPAN
YFM125S WIRING DIAGRAM
R
W
W
R
(BLACK) (BLACK)
1
W
W
W
W
W
W
W
R
R
W
R/B
W
G/Y
W
G/W
4
W
9
O
R/B B
O G/Y
R
W G/W
0
O
A
B
R
B
R
3
W W W
ON
OFF
B
R
W
W
R
R
R
5
R
2
W
R
Br
L/W
L/W Sb
6
L/W
L/W
R/W
R/W
8
B
(GRAY)
R/W
B
B
Br
R/B Br
(BLACK)
Br
B
R
B
Sb L/W
7
(GRAY)
Br R/B
R
B
1 A.C. magneto
2 Rectifier/regulator
3 Main switch
4 Fuse
5 Battery
6 Starter relay
7 Starter motor
8 Starting circuit cut-off relay
9 C.D.I. unit
0 Ignition coil
A Spark plug
B Reverse indicator light
C Neutral indicator light
D Neutral switch
E Reverse switch
F Reverse relay
G Brake lever switch
H Front brake light switch
I Tail/brake light
J Handlebar switch (left)
K Light switch
L Engine stop switch
M Start switch
N Headlight
O Horn switch
P Horn
È For Europe
È
J
Br
R/B
G/W
R/W
Br
L
R/B
R/B
R/W Br
Y
L
Br R/W
G
G
B
Y
K
L
OFF
LO
HI
M
OFF
ON
H
OFF
PUSH
G
E
Br G/Y
B
Br
Br
Br G/Y
Br Sb
Sb R/W
Br G/L
G/L R/W
B
Y
C B
Sb
B
G/L
(GRAY)
B
Y
L
Y
B
G
Y
Y
B
G/Y Br
Br
B
Y
B
G/L Br
(GRAY)
L
Br
O
Br
OFF
ON
B
B
L
Br
Y
G/W B
Br
Y
G
Y
P
N
B
B
P
B
P
G
Y
G
Y
B
B
F
L
L
B G/W
N
Y
B
G/L
(RED)
G
G
B
G
Y
I
D
B
B
B
COLOR CODE
B ............Black
Br ...........Brown
G............Green
L.............Blue
O............Orange
P ............Pink
R............ Red
Sb.......... Sky blue
W........... White
Y............ Yellow
G/L ........ Green/Blue
G/W ....... Green/White
G/Y ........Green/Yellow
L/W ........Blue/White
R/B.........Red/Black
R/W........Red/White
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