Yamaha TZR 125 1987-1992 Full Service Repair Manual

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Taper: Motorcycle

Distributeur:

UGS: 67736

Mots clés: 1987 1988 1989 1990 1991 1992 Motorcycle Motorcycles TZR 125 TZR Models Yamaha

Variantes de produits

Description

This manual covers the TZR125, a lightweight sportbike produced for the global market between 1987 and 1992. Known for its performance-oriented 125cc two-stroke engine and aggressive styling, the TZR125 was a competitive offering in its class, often compared to models from Honda, Suzuki, and Aprilia. Its engineering emphasizes a sporty riding experience, featuring a steel Deltabox frame and a liquid-cooled, reed valve inducted engine that delivers approximately 28-32 horsepower. This model represents a heritage in creating engaging and capable motorcycles. This comprehensive service repair manual provides detailed information for the maintenance, repair, and troubleshooting of the TZR125. It covers all major systems, including the engine, fuel system, cooling system, transmission, suspension, brakes, and electrical systems. The manual includes step-by-step repair instructions, diagnostic procedures, and technical specifications, making it an essential resource for owners, mechanics, and technicians. It also features wiring diagrams and guidance on common issues and performance tuning, ensuring the vehicle can be kept in optimal condition.

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

TZR125

Model Code:

4FN / 3FN (varies by region and specific year)

Production Years Covered By Manual:

1987, 1988, 1989, 1990, 1991, 1992

👋 Introduction

Market Position

Category:

Lightweight Sportbike / Commuter

Competitive Analysis

Competitors:

Honda NSR125, Suzuki RG125, Aprilia AF1 125, Cagiva Mito 125

Key Features

Design Philosophy:

Performance-oriented 125cc two-stroke motorcycle, often featuring aggressive styling inspired by larger Yamaha R-series bikes.

📋 Manual Details

Coverage Areas

Primary Market:

Global (specific regional variations may exist)

Page Count

Estimated Page Count:

Approximately 300-500 pages (typical for a comprehensive service manual)

Manual Type

Type:

Full Service Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Comprehensive engine disassembly, assembly, tuning, and troubleshooting.

Fuel System:

Carburetor specifications, adjustment, cleaning, and fuel pump operation.

Cooling System:

Radiator, water pump, thermostat, and coolant flow diagnostics.

Exhaust System:

Exhaust pipe, muffler, and catalytic converter (if applicable) maintenance.

Transmission:

Clutch operation, gearbox disassembly/assembly, shift mechanism, and lubrication.

Suspension:

Front fork (telescopic, inverted depending on sub-model) service, rear shock absorber adjustments and replacement.

Brakes:

Front and rear brake system overhaul, hydraulic fluid bleeding, pad/shoe replacement, caliper service.

Wheels And Tires:

Wheel bearing service, tire pressure recommendations, wheel balancing.

Electrical System:

Ignition system, lighting, charging system, battery maintenance, starter motor, and wiring diagrams.

Frame And Bodywork:

Frame inspection, body panel removal/installation, fairing repair, seat maintenance.

Procedures Included

Maintenance:

Regular service checks, lubrication points, filter replacement, chain adjustment.

Troubleshooting:

Detailed diagnostic procedures for common starting, running, and electrical issues.

Repair:

Step-by-step instructions for component replacement and repair.

Rebuilding:

Complete engine rebuild procedures, including piston, ring, and cylinder head service.

Refurbishment:

Guidance on restoring worn or damaged components.

Restoration:

Information applicable to bringing older models back to original specifications.

Wiring Diagrams:

Detailed, often color-coded, wiring schematics for electrical system diagnosis.

Diagnostics:

Systematic diagnostic approaches for identifying faults.

Technical Depth

Depth:

Professional-level, covering everything from basic maintenance to complete engine and gearbox overhauls.

📊 Manual Specifications

File Format

File Format:

Print Quality

Printability:

Full Printable

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

Software Requirements

Required Software:

Adobe PDF Reader, WinRAR (for potential ZIP archives)

Compatibility

Operating Systems:

All versions of Windows & Mac

Delivery Method

Delivery:

Instant Download

⚙️ Engine Specifications

Primary Engine

Engine Type:

2-stroke, liquid-cooled, reed valve inducted

Displacement:

124.7 cc

Bore X Stroke:

56.4 mm x 50.7 mm (typical)

Compression Ratio:

7.2:1 (typical, may vary)

Power Output:

Approx. 28-32 HP at 10,500 RPM (depending on market and tuning)

Torque:

Approx. 18-20 Nm at 9,000 RPM (depending on market and tuning)

Performance

Top Speed:

Capable of exceeding 140 km/h (87 mph)

Fuel System

Carburetor Model:

Mikuni VM28SS or similar 28mm constant velocity carburetor

Fuel Type:

Unleaded gasoline (min. 95 RON recommended)

Oil Mixing:

Autolube system (pre-mix ratio specified in manual if manual mixing is required)

🔧 Transmission

Standard

Type:

6-speed constant mesh sequential gearbox

Optional

Optional Gearbox:

Features

Clutch Type:

Wet, multi-plate, cable-actuated

Final Drive:

Chain drive

📐 Dimensions

Exterior

Length:

Approx. 1970 mm (varies by sub-model)

Width:

Approx. 710 mm (varies by sub-model)

Height:

Approx. 1060 mm (varies by sub-model)

Wheelbase:

Approx. 1340 mm (varies by sub-model)

Weights

Dry Weight:

Approx. 126 kg (varies by sub-model)

Wet Weight:

Approx. 135 kg (with fluids)

Fuel Tank Capacity:

Approx. 16 liters

🛡️ Safety Features

Ratings

Safety Ratings:

N/A (Motorcycle safety is typically assessed by accident statistics and manufacturer-provided information, not standardized crash ratings like cars)

Active Features

Braking System:

Front: Hydraulic disc brake, Rear: Hydraulic disc brake

Lighting:

Halogen headlight, LED or incandescent taillight/turn signals.

Passive Features

Frame Construction:

Steel Deltabox frame (typical for TZR series)

💡 Technology Features

Infotainment

Infotainment System:

N/A (Basic motorcycle instrumentation)

Driver Assistance

Driver Assistance Features:

Connectivity

Connectivity Features:

Instrumentation

Dashboard Features:

Speedometer, tachometer, odometer, trip meter, neutral indicator, turn signal indicators, high beam indicator, oil level warning light (autolube).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000 - 5,000 km or annually (refer to manual for specific recommendations)

Spark Plug Replacement:

Every 6,000 - 10,000 km (depending on plug type and condition)

Air Filter Cleaning:

Every 3,000 - 5,000 km (more frequently in dusty conditions)

Chain Maintenance:

Lubrication and adjustment every 500-1000 km, and inspection of wear

Fluid Specifications

Engine Oil Type:

2-stroke specific engine oil (e.g., Yamalube 2R, Castrol TTS) meeting API TC or JASO FD standards.

Coolant Type:

Ethylene glycol-based antifreeze/coolant (typically 50/50 mix with distilled water)

Brake Fluid Type:

DOT 3 or DOT 4 hydraulic brake fluid (refer to manual for specific recommendation)

Known Issues

Common Issues:

Carburetor jetting sensitivity to altitude and temperature, potential for carbon buildup in the exhaust port, clutch wear, aging electrical components, fork seal leaks.

Performance Tuning:

Common upgrades include aftermarket exhaust systems, performance air filters, and rejetting the carburetor for improved power delivery.

📚 Vehicle History

Brand Heritage

Yamaha Heritage:

Yamaha has a long-standing history in motorcycle racing and performance-oriented road bikes, known for innovation in engine technology and chassis design.

Model Evolution

Tzr Lineage:

The TZR series is Yamaha's line of sporty 125cc two-stroke motorcycles, often designed to mimic the styling and performance of their larger RZ and YZR racing machines. The TZR125 was a popular entry-level sportbike in many global markets.

Production

Manufacturing Location:

Japan (primarily)

🏆 Awards & Recognition

Recognitions

Motorcycle Awards:

While specific 'awards' for individual models of this era are rare, the TZR125 was generally well-regarded in its class for performance and styling, contributing to Yamaha's strong reputation in the 125cc segment.