Yamaha YZ 125 1996-2006 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Yamaha Model: YZ125 Model Variant: Two-Stroke Motocross Engine Type: Two-Stroke, Reed Valve Cooling System: Liquid-Cooled Codes Manual Product Code: YZ125-WSM-PDF-1996-2006 👋 Introduction Market Position Market...

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Type: Motorcycle

Vendor:

Sku: 451096

Tags: 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 Motorcycle Motorcycles Yamaha YZ 125 YZ Models

Product variants

Description

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

YZ125

Model Variant:

Two-Stroke Motocross

Engine Type:

Two-Stroke, Reed Valve

Cooling System:

Liquid-Cooled

Codes

Manual Product Code:

YZ125-WSM-PDF-1996-2006

👋 Introduction

Market Position

Market Segment:

Performance motocross motorcycle, competitive in its class for off-road racing and recreational use.

Competitive Analysis

Competitors:

KTM 125 SX, Honda CR125R, Suzuki RM125, Kawasaki KX125 during the same production era.

Key Features

Yz125 Characteristics:

Renowned for its sharp handling, potent two-stroke powerband, and reliable performance, making it a popular choice for aspiring and experienced riders.

📋 Manual Details

Coverage Areas

Covered Years:

1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006

Page Count

Page Count:

Manual Type

Manual Type:

Workshop Service Repair Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine:

Complete engine disassembly, assembly, inspection, and repair of all internal components including piston, rings, cylinder, crankshaft, connecting rod, and crankcase seals.

Cooling System:

Radiator, hoses, water pump, thermostat (if applicable), coolant type, capacities, and bleeding procedures.

Fuel System:

Carburetor (Mikuni VM series typical) disassembly, cleaning, adjustment, jetting, and fuel filter replacement. Fuel tank and petcock inspection.

Ignition System:

CDI unit, spark plug specifications, ignition timing, stator, and flywheel inspection.

Transmission:

Clutch operation, disassembly, inspection, and replacement of plates. Gearbox disassembly, inspection, and lubrication. Shift drum and fork alignment.

Suspension Front:

Front fork (Kayaba or similar) disassembly, service, oil type, level, compression, rebound, and preload adjustments. Seal replacement.

Suspension Rear:

Monocross rear suspension system, shock absorber service, linkage maintenance, bearings inspection, and adjustment procedures.

Brakes Front:

Hydraulic disc brake system, caliper disassembly, piston replacement, brake pad specifications, fluid type (DOT 4 typical), bleeding procedure, and rotor inspection.

Brakes Rear:

Hydraulic disc brake system, caliper disassembly, piston replacement, brake pad specifications, fluid type (DOT 4 typical), bleeding procedure, and rotor inspection.

Electrical System:

Wiring diagrams, lighting system (if applicable), kill switch, and basic troubleshooting of electrical faults.

Frame And Bodywork:

Chassis inspection, swingarm pivot bearings, steering head bearings, seat, fenders, and fuel tank removal/installation.

Procedures Included

Maintenance:

Routine maintenance checks, lubrication points, chain adjustment, air filter cleaning, and bolt torque specifications.

Troubleshooting:

Systematic diagnostic procedures for common running issues, starting problems, and performance anomalies.

Repair Overhaul:

Detailed step-by-step instructions for complete disassembly, repair, and reassembly of all major vehicle components.

Diagnostics:

Troubleshooting guides based on symptoms, identification of potential causes, and recommended corrective actions.

Technical Data:

Comprehensive torque specifications, clearances, fluid capacities, and component measurements for accurate assembly and repair.

Technical Depth

Depth Level:

Comprehensive workshop-level detail covering everything from basic maintenance to full engine and transmission rebuilds.

📊 Manual Specifications

File Format

File Format:

Print Quality

Print Quality:

High-resolution scans suitable for printing with clear diagrams and text.

Binding Type

Binding Type:

N/A (Digital PDF)

Paper Type

Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Displacement:

124cc (approx.)

Bore X Stroke:

Specifications vary slightly by year but typically around 54.0 mm x 54.5 mm

Compression Ratio:

Varies by year, typically in the range of 9.5:1 to 10.5:1 (unconfirmed, check manual)

Engine Layout:

Single-cylinder, two-stroke

Performance

Horsepower:

Approx. 30-35 HP (estimates, exact figures vary by year and dyno)

Torque:

Specifications vary by year (estimates, consult manual for precise figures)

Fuel System

Carburetor Model:

Mikuni VM Series (e.g., VM28 or VM30 typical)

Fuel Type:

Unleaded gasoline with appropriate two-stroke oil pre-mix (e.g., 50:1 ratio typical, check manual)

Oil Type Premix:

High-quality JASO FD or ISO-L-EGD rated two-stroke engine oil

🔧 Transmission

Standard

Transmission Type:

Constant-mesh, 6-speed

Clutch Type:

Wet, multi-plate

Features

Gearbox Lubricant:

Yamalube 2R or equivalent 2-stroke racing oil mixed with gasoline.

Final Drive:

Chain drive

📐 Dimensions

Exterior

Overall Length:

Approx. 2135 mm (varies slightly by year)

Overall Width:

Approx. 800 mm (varies slightly by year)

Overall Height:

Approx. 1270 mm (varies slightly by year)

Weights

Dry Weight:

Approx. 92 kg (varies slightly by year)

Fuel Capacity:

Approx. 7.0 Liters (1.85 Gallons)

🛡️ Safety Features

Ratings

Safety Certification:

Not applicable for off-road competition use. Rider safety relies on protective gear and safe riding practices.

Active Features

Braking System:

Hydraulic front and rear disc brakes for reliable stopping power.

Passive Features

Frame Construction:

Strong steel perimeter frame designed for rigidity and rider feedback.

💡 Technology Features

Infotainment

Infotainment System:

N/A (Pure Motocross Motorcycle)

Driver Assistance

Driver Assistance Features:

N/A (Pure Motocross Motorcycle)

Connectivity

Connectivity Features:

N/A (Pure Motocross Motorcycle)

🔧 Maintenance

Service Intervals

Oil Change Frequency:

Refer to manual: Engine oil and gearbox oil checks should be performed before every ride. Gearbox oil change intervals depend on usage but typically every 10-20 hours of operation.

Air Filter Cleaning:

Clean after every few rides or more frequently in dusty conditions.

Spark Plug Replacement:

Replace as needed or per manual recommendations, typically every 15-30 hours of use depending on riding style.

Fluid Specifications

Fork Oil Type:

Yamaha Genuine Fork Oil (e.g., G-10 or G-15) or equivalent with similar viscosity (e.g., Showa SS-01 or Motul Factory Line).

Fork Oil Level:

Specified in manual, typically around 100-120 mm from the top of the inner tube with the fork compressed.

Brake Fluid Type:

DOT 4

Known Issues

Common Wear Items:

Clutch plates, piston rings, brake pads, wheel bearings, steering head bearings, suspension seals.

Performance Tips:

Proper jetting, maintaining the exhaust power valve, and correct two-stroke oil mix are crucial for optimal performance and engine longevity.

📚 Vehicle History

Brand Heritage

Yamaha Motorcycles:

Yamaha Motor Company, founded in 1955, has a long and successful history in motorcycle racing, particularly in motocross, with legendary riders and championship-winning machines.

Model Evolution

Yz125 Lineage:

The YZ125 is a continuously developed model, known for its consistent performance and updates to suspension, engine tuning, and chassis geometry throughout its production run.

Production

Manufacturing Location:

Japan (primarily)

🏆 Awards & Recognition

Recognitions

Motocross Awards:

While specific awards may not be documented, the YZ125 has consistently been a highly regarded and competitive machine in its class throughout its production years, earning praise in industry reviews and rider feedback.