Yamaha SR 125 `99 - Service Manual Supl

Yamaha SR 125 `99 - Service Manual Supl
FOREWORD
This Supplementary Service Manual has been prepared to introduce new service and data for the
SR125 ’99. For complete service information procedures it is necessary 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.
EB001000
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 motorcycles has a basic understanding of the mechanical ideas and the procedures of motorcycle repair.
Repairs attempted by anyone without this knowledge are likely to render the motorcycle 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.
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!
Failure to follow WARNING instructions could result in severe injury or death to
the scooter operator, a bystander or a person inspecting or repairing the scooter.
CAUTION:
NOTE:
A CAUTION indicates special precautions that must be taken to avoid damage
to the scooter.
A NOTE provides key information to make procedures easier or clearer.
YP002000
HOW TO USE THIS MANUAL
MANUAL ORGANIZATION
This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”)
1st title 1 :
This is the title of the chapter with its symbol on 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 heps identify parts and clarify procedure steps, there are exploded diagrams at start of each removal 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 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.
3
2
4
1
8
6
6
7
EB003000
1
ILLUSTRATED SYMBOLS
2
GEN
INFO
SPEC
3
4
INSP
ADJ
ENG
5
6
COOL
CARB
7
8
CHAS
Illustrated symbols 1 to 9 are designed as
thumb tabs to indicate the chapter’s number
and content.
1 General information
2 Specifications
3 Periodic inspection and adjustment
4 Engine
5 Cooling system
6 Carburetion
7 Chassis
8 Electrical
9 Troubleshooting
ELEC
Illustrated symbols 10 to 17 are used to identify the
specifications appearing in the text.
10
9
TRBL
SHTG
10 Possible to maintain with engine mounted
11 Filling fluid
12 Lubricant
11
12
13 Special tool
14 Tightening
15 Wear limit, clearance
13
15
16 Engine speed
14
16
17 Ω, V, A
17
Illustrated symbols 18 to 23 in the exploded diagrams indicate the types of lubricants and lubrication points.
18 Apply engine oil
19 Apply gear oil
18
19
20
20 Apply molybdenum disulfide oil
21 Apply wheel bearing grease
22 Apply lightweight lithium-soap base grease
21
22
23
23 Apply molybdenum disulfide grease
Illustrated symbols 24 to 25 in the exploded diagrams indicate the where to apply locking agent
24 and when to install new parts 25 .
24
25
24 Apply locking agent (LOCTITE)
25 Use new one
CONTENTS
GENERAL SPECIFICATIONS
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CABLE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
2
2
2
2
3
3
3
4
PERIODIC INSPECTIONS AND ADJUSTMENTS
CHECKING AND ADJUSTING THE STEERING HEAD . . . . . . . . . . . . . 9
CHECKING AND ADJUSTING THE STEERING HEAD . . . . . . . . . 9
ENGINE OVERHAUL
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE TIMING CHAIN TENSIONER . . . . . . . . . . . . . . . .
CYLINDER HEAD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
11
12
12
CHASSIS
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
UNDER BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
’99 SR125 WIRING DIAGRAM
GENERAL SPECIFICATIONS
SPECIFICATIONS
GENERAL SPECIFICATIONS
Model
SR125
Model code:
3MW8
Dimensions:
Overall height
1,100 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
–1–
SPEC
MAINTENANCE SPECIFICATIONS
SPEC
MAINTENANCE SPECIFICATIONS
ENGINE
Item
Standard
Limit
Cam chain:
Cam chain type/No. of links
Cam chain adjustment
DID 25SH/104 ENDLESS
Automatic
SSS
SSS
Carburetor:
Engine idle speed
1,300 – 1,400 rpm
SSS
Item
Standard
Limit
Steering system:
Steering 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
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/manufacturer
Flasher frequency
Full transistor type
FE246BH/DENSO
75 – 95 cycle/min
SSS
SSS
SSS
CHASSIS
ELECTRICAL
–2–
SPEC
MAINTENANCE SPECIFICATIONS
TIGHTENING TORQUES
ENGINE
g
Part to be tightened
Timing chain tensioner bolt
Timing drain tensioner cap bolt
Part name
Thread
Q’ty
y
size
Bolt
Bolt
2
1
Tightening
torque
Nm
mSkg
10
10
0.1
0.1
Remarks
CHASSIS
Thread size
Part to be tightened
g
Handle crown and front fork
Handle crown and steering shaft
Handlebar holder (under and upper)
Steering ring nut
M8
M22
M8
M25
Tightening
torque
Nm
mSkg
19
110
20
4
1.9
11.0
2.0
0.4
Remarks
Refer to NOTE
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 ring nut to specification.
–3–
CABLE ROUTING
SPEC
CABLE ROUTING
1
2
3
4
5
6
7
8
9
10
11
Speed meter cable
Handlebar switch lead (left)
Main switch lead
Front brake switch lead
Throttle cable
Brake hose
Handlebar switch lead (right)
Clutch cable
Clutch switch lead
Right flasher lead
Left flasher lead
12
13
14
15
16
Wireharness
Horn lead
Headlight earth lead
Auxilialy light lead
Meter lead
–4–
A Faster the handlebar switch lead
(left and right) front brake switch
lead clutch switch lead to the
handlebar with a band.
B Don’t contact the horn and wireharness.
C To auxiliary light.
D To headlight.
CABLE ROUTING
1
2
3
4
5
6
7
8
9
10
11
12
Flasher relay
Clamp
Wireharness
High tension cord
Collar
Ignition coil
Earth lead
Ignition coil lead
Throttle cable
Brake hose
Brake hose holder
Wire guide
13
14
15
16
17
18
19
20
Clutch cable guide
Right handlebar switch lead
Front brake switch lead
Clutch switch lead
Clutch cable
Rear stop switch
Sidestand relay
Battery breather hose
–5–
SPEC
A Align the clamp 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.
CABLE ROUTING
E Clamp the clutch cable to the
down tube of the frame.
F Cover the sack to the couplers.
–6–
SPEC
CABLE ROUTING
1
2
3
4
5
6
7
8
9
10
11
12
Pick up coil lead
Neutral switch lead
C.D.I unit
Rear flasher lead (right)
Rear flasher lead (left)
Tail/ Brake light lead
Clutch switch lead
Wireharness
Clamp
Throttle cable
Thermo switch lead
Thermo switch
13
14
15
16
17
18
19
20
21
22
23
24
25
26
Battery negative lead
Starter motor lead
Rectifier/ Regulator
Starter relay
Battery positive lead
Side stand switch lead
Side stand switch
Clutch cable
Wire guide
Brake hose
Brake hose holder
Wire holder
Speed meter cable
Handlebar switch lead
–7–
SPEC
A Fasten the junction to the wireharness with a band and cut the
end of band. (except 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 terminal.
CABLE ROUTING
D Route the leads inside the frame
bracket.
E Clamp the starter relay lead rectifier / regulator lead and sidestand switch lead.
F Clamp the rectifier / regulator
lead.
G Fasten the leads witin 40 m from
rectifire / regulator with a band.
H Route the brake hose through
the brake hose holder.
I Clamp the speed meter cable to
the under bracket and through
the wire holder of front fender.
–8–
SPEC
CHECKING AND ADJUSTING THE STEERING HEAD
INSP
ADJ
EB304130
CHECKING AND ADJUSTING THE STEERING HEAD
1. Stand the motorcycle on a level surface.
WARNING
Securely support the motorcycle so that
there is no danger of it falling over.
NOTE:
Place the motorcycle on a suitable stand so that
the front wheel is elevated.
2. Check:
S steering head
Grasp the bottom of the front fork legs and
gently rock the front fork.
Looseness/binding Adjust the steering
head.
3. Remove:
S handlebar 1
4. Loosen:
S upper bracket pinch bolts 1
5. Remove:
S steering stem nut 2
S washer 3
6. Remove:
S speed meter 1
S upper bracket 2
–9–
CHECKING AND ADJUSTING THE STEERING HEAD
INSP
ADJ
6.Adjust:
S steering head
a. Remove the lock washer 1 , the upper ring
nut 2 , and the rubber washer 3 .
b. Loosen the lower ring nut 4 and then tighten
it to specification with a ring nut wrench 5 .
NOTE:
Set the torque wrench at a right angle to the
steering nut wrench.
Steering nut wrench
90890-01268
Lower ring nut (initial tightening
torque)
38 Nm (3.8 mSkg)
c. Loosen the lower ring nut completely, then
tighten it to specification.
WARNING
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 the upper ring nut 2 , then
align the slots of both ring nuts. If necessary,
hold the lower ring nut and tighten the upper
ring nut until their slots are aligned.
h. Install the lock washer 1 .
NOTE:
Make sure that the lock washer tabs a sit correctly in the ring nut slots b .
7. Install:
S steering stem nut
110 Nm (11.0 mSkg)
S upper bracket pinch bolt
26 Nm (2.6 mSkg)
–10–
CYLINDER HEAD
ENG
CYLINDER HEAD
22 Nm (2.2 mSkg)
20 Nm (2.0 mSkg)
60 Nm (6.0 mSkg)
10 Nm (1.0 mSkg)
Order
1
2
3
4
5
6
7
Job name/Part name
Cylinder head removal
Timing chain tensioner assembly
Cam sprocket/Timing chain
Ignition coil
Cylinder head
Dowel pins
Gasket
Cylinder head gasket
Q’ty
Remarks
Remove the parts in order.
1
1/1
1
1
3
1
1
Refer to “CYLINDER HEAD
REMOVAL/INSTALLATION” section.
Refer to “CYLINDER HEAD
INSTALLATION” section.
Reverse the removal procedure for
installation.
–11–
CYLINDER HEAD
ENG
EB401430
CHECKING THE TIMING CHAIN TENSIONER
1. Check:
S timing chain tensioner
Cracks/damage/rough movement Replace.
a. Lightly press the timing chain tensioner rod
into the timing chain tensioner housing by
hand.
NOTE:
While pressing the timing chain 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 movement, replace the timing chain tensioner.
SR********
CYLINDER HEAD INSTALLATION
1. Install:
S dowel pins 1 New
S gasket 2
S gasket (cylinder head) 3 New
2. Install:
S cylinder head
M8 (1 X 4)
22 Nm (2.2 mSkg)
M8 (5 X 6)
20 Nm (2.0 mSkg)
NOTE:
S Apply engine oil onto the nut threads.
S Tighten the bolts starting with the lowest numbered one.
–12–
CYLINDER HEAD
ENG
3. Install:
S Cam sprocket
S Timing chain
Installing steps:
S Turn the crank shaft counterclockwise until the
slit 1 matches the stationary pointer 2 .
S Align the dowel pin 3 on the camshaft with the
stationary pointer 4 on the cylinder head.
S Align the “I” mark 5 on the cam sprocket with
the stationary pointer 6 on the cylinder head.
S Fit the timing chain 7 onto cam sprocket 8
and install the cam sprocket on the camshaft.
NOTE:
When installing the cam sprocket, keep the timing chain as tight as possible on the exhaust
side.
CAUTION:
Do not turn the crankshaft during installation of the camshaft. Damage or improper
valve timing will result.
S Remove the safety wire from the timing
chain.
4. Install:
S Plate washer
S Bolt (timing chain)
5. Install:
S timing chain tensioner
a. Lightly press the timing chain tensioner rod
into the timing chain tensioner housing by
hand.
b. While pressing the timing chain tensioner
rod, wind it clockwise with a thin screwdriver
1 until it stops.
c. With the screwdriver still inserted into the
timing chain tensioner, install the timing
chain tensioner 2 , gasket 3 onto the cylinder block. Then, tighten the timing chain tensioner bolts 4 to the specified torque.
–13–
CYLINDER HEAD
ENG
WARNING
Always use a new gasket.
Timing chain tensioner bolt
10 Nm (1.0 mSkg)
d. Remove the screwdriver, make sure that the
timing chain tensioner rod releases, and
tighten the cap bolt to the specified torque.
Cap bolt
10 Nm (1.0 mSkg)
6. Tighten:
S Bolt (timing chain)
60 Nm (6.0 mSkg)
NOTE:
Install the bolt while holding the magneto
mounting bolt with a wrench.
7. Turn:
S crankshaft
(several turns counterclockwise)
8. Check:
S Magneto rotor slit
Align the stationary pointer with the crankcase cover (left).
S Cam sprocket “I” mark
Align the stationary pointer with the cylinder
head.
Out of alignment Adjust.
9. Check:
S Valve clearance
Refer to “VALVE CLEARANCE ADJUSTMENT” section in CHAPTER 3.
–14–
STEERING
CHAS
STEERING
UNDER BRACKET
110 Nm (1.1 mSkg)
1st step:
38 Nm (3.8 mkg)
2nd step:
4m (0.4 mkg)
Order
Job name/Part name
Q’ty
Remarks
Remove the parts in order.
Refer to “FRONT FORK” section.
Refer to “HANDLEBAR” section.
1
2
3
4
5
6
7
Under bracket removal
Front fork
Handlebar
Headlight unit
Meter assembly
Headlight stay
Handlebar crown
Lock washer
Upper ring nut
Rubber washer
1
1
1
1
1
1
1
8
9
Lower ring nut
Ball race cover
1
1
–15–
NOTE:
Disconnect the connector.
Refer to “STEERING
REMOVAL/INSTALLATION” section.
STEERING
CHAS
110 Nm (1.1 mSkg)
1st step:
38 Nm (3.8 mkg)
2nd step:
4m (0.4 mkg)
Order
10
11
12
13
14
15
16
17
Job name/Part name
Q’ty
1
1
1
1
1
1
1
1
Under bracket
Bearing inner race
Upper bearing
Bearing outer race
Lower bearing
Bearing inner race
Dust seal
Bearing outer race
Remarks
Refer to “STEERING REMOVAL/
INSTALLATION” section.
Reverse the removal procedure for
installation.
–16–
’99 SR125 WIRING DIAGRAM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
COLOR CODE
B .....
Br . . . .
Ch . . .
Dg . . .
G ....
L .....
Or . . . .
Black
Brown
Chocolate
Dark green
Green
Blue
Orange
Sb . . . .
P .....
R.....
Y .....
W ....
Br / L . .
Br / W .
Sky blue
Pink
Red
Yellow
White
Brown/ Blue
Brown/ White
G/Y . .
L/ B . . .
L/ R . . .
L/ W . .
L/ Y . . .
R/ W . .
W/L . .
Green / Yellow
Blue/ Black
Blue/ Red
Blue/ White
Blue/ Yellow
Red/ White
White / Blue
W / R . . White / Red
C.D.I magneto
Rectifier / Regulator
Starter relay
Battery
Fuse
Main switch
Thermo switch
Heater unit
Handlebar switches (right)
Engine stop switch
Starter switch
C.D.I unit
Ignition coil
Spark plug
Clutch switch
Sidestand switch
Neutral relay
Speedometer
Neutral indicator light
Turn indicator light
Hi-beam indicator light
Meter light
Neutral switch
Rear turn signal lights
Tail/ Brake light
Front brake switch
Rear brake switch
Front turn signal lights
Auxilialy light
Flasher relay
Horn
Handlebar switches (left)
Light switch
Horn switch
Dimmer switch
Turn switch
Starting motor
Headlight
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