Summary of SR125'99 3MW-AE3
Page 3: Foreword
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...
Page 4
Note: caution: 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 a...
Page 5: How To Use This Manual
1 2 6 7 6 4 3 8 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 indica...
Page 6: Gen
22 1 3 5 7 9 2 4 8 6 24 25 23 21 19 20 18 16 17 15 14 13 11 12 10 gen info spec eng carb elec chas cool insp adj trbl shtg eb003000 illustrated symbols illustrated symbols 1 to 9 are designed as thumb tabs to indicate the chapter’s number and content. 1 general information 2 specifications 3 periodi...
Page 7: Contents
Contents general specifications general specifications 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance specifications 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....
Page 9: Spec
–1– general specifications spec 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...
Page 10: Spec
–2– 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 chassis item standard limit steering system: steering b...
Page 11: Spec
–3– maintenance specifications spec note: tightening torques engine part to be tightened part name thread size q’ty tightening torque remarks g size y nm m s kg timing chain tensioner bolt timing drain tensioner cap bolt bolt bolt 2 1 10 10 0.1 0.1 chassis part to be tightened thread size tightening...
Page 12: Spec
–4– cable routing spec 12 wireharness 13 horn lead 14 headlight earth lead 15 auxilialy light lead 16 meter lead 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 wire- harness. C to auxiliary lig...
Page 13: Spec
–5– cable routing spec 13 clutch cable guide 14 right handlebar switch lead 15 front brake switch lead 16 clutch switch lead 17 clutch cable 18 rear stop switch 19 sidestand relay 20 battery breather hose a align the clamp to the white tape on the wireharness. B route the brake hose through the brak...
Page 14: Spec
–6– cable routing spec e clamp the clutch cable to the down tube of the frame. F cover the sack to the couplers..
Page 15: Spec
–7– 1 pick up coil lead 2 neutral switch lead 3 c.D.I unit 4 rear flasher lead (right) 5 rear flasher lead (left) 6 tail / brake light lead 7 clutch switch lead 8 wireharness 9 clamp 10 throttle cable 11 thermo switch lead 12 thermo switch a fasten the junction to the wire- harness with a band and c...
Page 16: Spec
–8– 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. Cable routing spec d route the leads inside the frame bracket. E clamp the starter relay lead rec- tifier / regulator lead and side- stand switch ...
Page 17: Insp
–9– checking and adjusting the steering head insp adj warning note: eb304130 checking and adjusting the steer- ing head 1. Stand the motorcycle on a level surface. Securely support the motorcycle so that there is no danger of it falling over. Place the motorcycle on a suitable stand so that the fron...
Page 18: Insp
–10– checking and adjusting the steering head insp adj note: warning note: 110 nm (11.0 m s kg) 26 nm (2.6 m s kg) 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 ...
Page 19: Eng
–11– cylinder head eng order job name / part name q’ty remarks 1 2 3 4 5 6 7 cylinder head removal timing chain tensioner assembly cam sprocket / timing chain ignition coil cylinder head dowel pins gasket cylinder head gasket 1 1 / 1 1 1 3 1 1 remove the parts in order. Reverse the removal procedure...
Page 20: Eng
–12– cylinder head eng note: new new 22 nm (2.2 m s kg) m8 (1 x 4) 20 nm (2.0 m s kg) m8 (5 x 6) note: eb401430 checking the timing chain tensioner 1. Check: s timing chain tensioner cracks / damage / rough movement re- place. A. Lightly press the timing chain tensioner rod into the timing chain ten...
Page 21: Eng
–13– cylinder head eng note: caution: 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” ma...
Page 22: Eng
–14– cylinder head eng warning 60 nm (6.0 m s kg) note: always use a new gasket. Timing chain tensioner bolt 10 nm (1.0 m s kg) 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 m s kg) 6. Tighten:...
Page 23: Chas
–15– steering chas order job name / part name q’ty remarks 1 2 3 4 5 6 7 8 9 under bracket removal front fork handlebar headlight unit meter assembly headlight stay handlebar crown lock washer upper ring nut rubber washer lower ring nut ball race cover 1 1 1 1 1 1 1 1 1 remove the parts in order. Re...
Page 24: Chas
–16– order job name / part name q’ty remarks 10 11 12 13 14 15 16 17 under bracket bearing inner race upper bearing bearing outer race lower bearing bearing inner race dust seal bearing outer race 1 1 1 1 1 1 1 1 reverse the removal procedure for installation. Refer to “steering removal/ installatio...
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Color code b black . . . . . Br brown . . . . Ch chocolate . . . Dg dark green . . . G green . . . . L blue . . . . . Or orange . . . . Sb sky blue . . . . P pink . . . . . R red . . . . . Y yellow . . . . . W white . . . . Br / l brown / blue . . Br / w brown / white . G / y green / yellow . . L/ b...