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Yamaha YZ 125 1994 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Yamaha Model: YZ125 Year: 1994 Codes Chassis Code: 4JY 👋 Introduction Market Position Category: Motocross Competition Motorcycle Target User: Motocross Racers, Off-Road Enthusiasts, Mechanics Competitive...
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Type: Motorcycle
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Sku: 488811
Yamaha YZ 125 1994 Service Repair Workshop Manual
🏷️ Basic Information
Identification
Make:
Yamaha
Model:
YZ125
Year:
1994
Codes
Chassis Code:
4JY
👋 Introduction
Market Position
Category:
Motocross Competition Motorcycle
Target User:
Motocross Racers, Off-Road Enthusiasts, Mechanics
Competitive Analysis
Competitors 125Cc Class:
KTM 125 EXC, Honda CR125R, Suzuki RM125, Kawasaki KX125
Key Features Vehicle
Engine Type:
Liquid-Cooled, 2-Stroke, Reed Valve
Suspension Front:
Upside-down (USD) Cartridge Forks
Suspension Rear:
Monocross Suspension with Linkage
Braking Front:
Hydraulic Disc Brake
Braking Rear:
Drum Brake
📋 Manual Details
Coverage Areas
Primary Focus:
Service and Repair
Page Count
Estimated Pages:
300-400
Manual Type
Type:
Workshop Manual / Service Manual
Language
Language:
English
Format
Format:
Digital Download (PDF)
📖 Manual Coverage
Systems Covered
Engine Systems:
Top End (Cylinder, Piston, Rings, Head), Bottom End (Crankshaft, Connecting Rod, Crankcases), Cooling System (Radiators, Hoses), Lubrication System (Oil Pump, Passages), Fuel System (Carburetor, Intake), Ignition System (CDI, Spark Plug), Exhaust System
Drivetrain Systems:
Transmission (Gearbox Internals, Shifting Mechanism), Clutch (Wet Multi-Plate, Operation, Adjustment), Drive Chain and Sprockets
Chassis Systems:
Frame, Suspension (Front Forks - Damping, Rebuild; Rear Shock - Rebuild, Linkage), Steering (Headstock Bearings), Wheels and Tires (Spoke Tension, Rim Truing), Brakes (Hydraulic Front Disc, Rear Drum - Pad Replacement, Fluid Flush)
Electrical Systems:
Wiring Harness, Lighting (Headlight, Taillight, Brake Light), Ignition Switch, Kill Switch, CDI Unit, Coil, Voltage Regulator (if applicable)
Procedures Included
Maintenance Procedures:
Routine Inspections, Oil Changes, Air Filter Cleaning/Replacement, Spark Plug Replacement, Chain Lubrication and Adjustment, Brake Bleeding, Cable Adjustments
Repair Procedures:
Engine Top-End Rebuild (Piston, Rings), Engine Bottom-End Overhaul (Bearings, Seals), Carburetor Cleaning and Re-jetting, Suspension Fork Service and Seal Replacement, Rear Shock Rebuild, Brake System Overhaul, Clutch Rebuild, Wheel Bearing Replacement, Steering Head Bearing Service
Troubleshooting Guides:
Diagnostic flowcharts for common running issues, electrical faults, and performance problems.
Technical Depth
Depth:
Comprehensive, covering everything from basic adjustments to full engine and suspension rebuilds. Includes specifications for torque values, clearances, and fluid types.
📊 Manual Specifications
File Format
File Type:
PDF
Print Quality
Resolution:
High-resolution scans of original manual pages, ensuring clarity of diagrams and text.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Quality:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-Cooled, 2-Stroke, Reed Valve Induction
Displacement:
123.8 cc
Bore X Stroke:
56.0 mm x 50.7 mm
Compression Ratio:
8.5:1 (for normal fuel)
Carburetor:
Keihin PWK38 (38mm) Single
Performance
Horsepower:
Approx. 35-40 HP (at crankshaft, estimated for the era)
Torque:
Not commonly specified in public domain for this model, focus is on peak power.
Fuel System
Fuel Type:
Unleaded gasoline with 2-stroke oil mix (typically 20:1 or 32:1 ratio)
Fuel Tank Capacity:
8.0 Liters (2.1 US gal)
🔧 Transmission
Standard
Type:
6-speed constant mesh
Clutch Type:
Wet, multi-plate
Final Drive:
Chain Drive
Features
Gear Ratios:
Specific ratios will be detailed in the manual for each gear.
Transmission Oil Type:
Yamalube 10W-30 or API SE/SF/SG classification, SAE 10W-30 API SE or SF or SG, specific grades like SAE 80 or 90 may also be listed for gearbox. Check manual for precise Yamaha recommendation.
📐 Dimensions
Exterior
Overall Length:
Approx. 2,130 mm (83.9 in)
Overall Width:
Approx. 800 mm (31.5 in)
Overall Height:
Approx. 1,250 mm (49.2 in)
Wheelbase:
Approx. 1,455 mm (57.3 in)
Ground Clearance:
Approx. 350 mm (13.8 in)
Weights
Dry Weight:
Approx. 94 kg (207.3 lbs)
Wet Weight:
Approx. 99 kg (218.3 lbs) (with fluids, estimate)
Seat Height:
Approx. 950 mm (37.4 in)
🛡️ Safety Features
Ratings
Safety Classification:
Off-Road Competition Vehicle - Not intended for public road use. No traditional safety ratings apply.
Active Features
Braking System:
Front Hydraulic Disc, Rear Drum for stopping power.
Suspension Performance:
Advanced suspension systems designed for control and handling on rough terrain.
Passive Features
Chassis Design:
Robust steel frame designed to withstand impacts and stresses of motocross.
💡 Technology Features
Infotainment
Features:
N/A - This is a competition motocross bike; no infotainment features.
Driver Assistance
Features:
N/A - No electronic driver assistance features.
Connectivity
Features:
N/A - No connectivity features.
🔧 Maintenance
Service Intervals
Oil Change Frequency:
Recommended every 10-15 hours of riding or annually, whichever comes first. Check manual for precise guidance based on usage.
Air Filter Cleaning:
Clean after every few rides, especially in dusty conditions. Inspect for damage.
Spark Plug Replacement:
Inspect every 10-15 hours, replace as needed. Specific plug type detailed in manual.
Chain Adjustment:
Check and adjust tension before every ride, and lubricate regularly.
Fluid Specifications
Engine Oil Type:
Yamalube 2-stroke oil or equivalent JASO FD/FC, ISO-L-EGD certified 2-stroke engine oil.
Coolant Type:
Permanent Antifreeze (Ethylene Glycol based) with distilled water, typically a 50:50 mix. Refer to manual for specific Yamaha coolant or equivalent.
Brake Fluid Type:
DOT 4 hydraulic brake fluid.
Transmission Oil Specification:
Yamaha 4-stroke motorcycle gear oil or SAE 80W API GL-4.
Known Issues
Common Wear Items:
Piston rings, clutch plates, wheel bearings, steering head bearings, fork seals, exhaust packing.
Carburetor Tuning:
Can be sensitive to altitude and temperature changes, requiring occasional re-jetting.
Power Valve Operation:
Can accumulate carbon and require cleaning for optimal performance.
📚 Vehicle History
Brand Heritage
Manufacturer Founding:
1887 (Musical Instruments), 1955 (Motorcycles)
Motocross Legacy:
Yamaha has a long and storied history in professional motocross, with numerous championships and innovations in the sport.
Model Evolution
Yz Series Introduction:
The YZ line has been a cornerstone of Yamaha's off-road offerings for decades, continuously evolving in technology and performance.
1990S Yz125 Focus:
The 1990s saw significant advancements, including the move to larger front forks (upside-down), improved power delivery, and refined chassis dynamics.
Production
Production Region:
Japan (primarily)
🏆 Awards & Recognition
Recognitions
Motocross Performance:
The YZ125 has historically been a competitive platform in the 125cc motocross class, with many amateur and professional riders achieving success on this model and its predecessors/successors.
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