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Yamaha YFM125S Owner's Manual

Other manuals for YFM125S: Service Manual

Summary of YFM125S

  • Page 1

    Owner’s manual read this manual carefully! It contains important safety information. W lit-11626-19-05 1c5-28199-12 this atv should not be ridden by anyone under 16 years of age. Yfm125gv 1c5-9-12 hyoshi 3/11/05 9:59 am page 1.

  • Page 2

    1c5-9-12 hyoshi 3/11/05 9:59 am page 2.

  • Page 3: Introduction

    Ebu13290 introduction congratulations on your purchase of the yamaha yfm125g. It represents the result of many years of yamaha experience in the production of fine sporting, touring, and pace-setting racing machines. With the purchase of this yamaha, you can now appreciate the high degree of craftsm...

  • Page 4: Important Manual Information

    Ebu00801 important manual information failure to follow the warnings contained in this manual can result in seri- ous injury or death. Particularly important information is distinguished in this manual by the following notations: q the safety alert symbol means attention! Become alert! Your safety i...

  • Page 5: Important Notice

    Ebu15000 important notice this atv is designed and manufactured for off-road use only. It is illegal and unsafe to operate this atv on any public street, road or highway. This atv complies with all applicable off-road noise level and spark arrester laws and regulations in effect at the time of manuf...

  • Page 6: Contents

    Location of the warning and specification labels .......................1-1 safety information .........................2-1 description and machine identification.....................................3-1 identification number records ...............3-2 key identification number .....................3...

  • Page 7

    Pre-operation checks ...................5-1 front and rear brakes ...........................5-2 fuel ......................................................5-3 engine and transmission oil .................5-5 chain ....................................................5-6 throttle lever .................

  • Page 8

    Periodic maintenance and adjustment .........................................8-1 owner’s manual and tool kit .................8-1 periodic maintenance/lubrication ........8-3 engine oil..............................................8-5 final transmission oil ............................8-7 spark plug...

  • Page 9

    Specifications .................................10-1 noise regulation............................11-1 maintenance record ....................12-1 atv limited warranty ...................13-1 yamaha extended service (y.E.S.)...................................................14-1 10 11 12 13 14 1c5-9-...

  • Page 10: Location of The Warning and

    1-1 ebu00464 location of the warning and specification labels 1 5 4 6 8 7 8 2 3 1c5-9-12-1 3/11/05 10:01 am page 8.

  • Page 11: Warning

    1-2 read and understand all of the labels on your machine. They contain important information for safe and proper operation of your atv. Never remove any labels from your atv. If a label becomes difficult to read or comes off, a replacement label is available from your yamaha dealer. 1 2 1 5fe-21697...

  • Page 12

    1-3 4 5 5yt-2151e-30 drive select lever 8 read owner’s manual carefully before operating. 8 when shifting the drive select lever, always be sure to stop the atv and apply the rear brake. 5fe-21568-01 6 7 5kg 11lbs 3ld-24877-a0 10kg 22lbs 1c5-24877-a0 8 sit here. Never 3mx-24875-a0 1c5-9-12-1 3/11/05...

  • Page 13: Safety Information

    2-1 ebu13360 an atv is not a toy and can be hazardous to operate. An atv handles differently from other vehicles including motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers such as turning and riding on hills or over obstacles, if you fail to take proper ...

  • Page 14

    2-2 8 always avoid operating an atv on any paved surfaces, including sidewalks, driveways, parking lots and streets. 8 never operate an atv on any public street, road or highway, even a dirt or gravel one. 8 never operate an atv without wearing an approved motorcycle helmet that fits properly. You s...

  • Page 15

    2-3 8 never operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary to control the atv on such terrain. Always be especially cautious on these kinds of terrain. 8 always follow proper procedures for turning as described in this manual. Practi...

  • Page 16

    2-4 8 always use proper procedures if you stall or roll backwards when climbing a hill. To avoid stalling, maintain a steady speed when climbing a hill. If you stall or roll backwards, follow the special proce- dure for braking described in this manual. Dismount on the uphill side or to a side if po...

  • Page 17

    2-5 8 never exceed the stated load capacity for an atv. Cargo should be properly distributed and securely attached. Reduce speed and follow instructions in this manual for carrying cargo. Allow greater distance for braking. For more information about atv safety, call the consumer products safety com...

  • Page 18: Qwarning

    Potential hazard improper handling of gasoline. What can happen gasoline can catch fire and you could be burned. How to avoid the hazard always turn off the engine when refueling. Do not refuel right after the engine has been running and is still very hot. Do not spill gasoline on the engine or exha...

  • Page 19: Qwarning

    Potential hazard starting or running the engine in a closed area. What can happen exhaust fumes are poisonous and may cause loss of consciousness and death within a short time. How to avoid the hazard always operate your atv in an area with adequate ventilation. Qwarning 2-7 1c5-9-12-1 3/11/05 10:01...

  • Page 20

    3-1 1. Seat 11. Footboard 2. Drive select lever 12. Rear brake lever 3. Front cover 13. Parking brake 4. Headlight 14. Reverse indicator light 5. Front carrier 15. Neutral indicator light 6. Starter (choke) 16. Front brake lever 7. Fuel cock 17. Throttle lever 8. Tail/brake light 18. Main switch 9. ...

  • Page 21

    Ebu00600 identification number records record the key identification number, vehicle identification number and model label informa- tion in the spaces provided for assistance when ordering spare parts from a yamaha dealer or for reference in case the vehicle is stolen. 1. Key identification number: ...

  • Page 22

    Ebu00036 vehicle identification number the vehicle identification number is stamped into the frame. Note: the vehicle identification number is used to identify your machine. Ebu00787 model label the model label is affixed to the location in the illustration. Record the information on this label in t...

  • Page 23: Control Functions

    Ebu00039 control functions w indicates a potential hazard that could result in serious injury or death. Ebu09420 main switch functions of the respective switch positions are as follows: on: the engine can be started only at this position and the headlights and taillight come on when the light switch...

  • Page 24

    Ebu00043 indicator lights ebu12500 reverse indicator light “r” this indicator light comes on when the drive select lever is in the “r” position. Ebu09720 neutral indicator light “n” this indicator light comes on when the drive select lever is in the “n” position. Ebu00053 handlebar switches ebu11580...

  • Page 25

    Ebu00056 start switch “start” the starter motor cranks the engine when this switch is pushed. C c see starting instructions prior to starting engine (see page 6-1 for details). Note: if the starter switch is pushed with the main switch “on” and the engine stop switch “off”, the starter motor will be...

  • Page 26: Qwarning

    Ebu00062 throttle lever once the engine is running, movement of the throttle lever will increase the engine speed. Regulate the speed of the machine by varying the throttle position. Because the throttle is spring-loaded, the machine will decelerate, and the engine will return to an idle any time th...

  • Page 27: Qwarning

    Ebu11590 speed limiter the speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum. Turning in the adjusting screw limits the maximum engine power available and decreases the maximum speed of the atv. 4-5 a q w potential hazard improper adjustment o...

  • Page 28

    Ebu00070 front brake lever the front brake lever is located on the right han- dlebar. Pull it toward the handlebar to apply the front brake. Ebu00072 rear brake lever the rear brake lever is located on the left han- dlebar. Pull it toward the handlebar to apply the rear brake. 4-6 q q 1. Front brake...

  • Page 29: Qwarning

    Ebu00074 parking brake use the parking brake when you have to start the engine or park the machine, especially on a slope. Apply the rear brake lever and push down the lock plate to apply the parking brake. Squeeze the rear brake lever to release the parking brake. 4-7 q potential hazard improper us...

  • Page 30

    4-8 ebu11060 drive select lever the drive select lever is used to shift your machine into the forward, neutral and reverse positions. (refer to page 6-4 for the drive select lever operation.) ebu00092 fuel tank cap remove the fuel tank cap by turning it counter- clockwise. 1 2 3 a 1 a. Drive select ...

  • Page 31

    4-9 res off on ebu00093 fuel cock the fuel cock supplies fuel from the fuel tank to the carburetor. The fuel cock has three positions. Off: with the lever in this position fuel will not flow. Always turn the lever to this position when the engine is not running. On: with the lever in this position, ...

  • Page 32

    Ebu00094 starter (choke) starting a cold engine requires a richer air-fuel mixture. A separate starter circuit supplies this mixture. Move in direction a to turn on the starter (choke). Move in direction b to turn off the starter (choke). Refer to “starting a cold engine” for proper oper- ation. (se...

  • Page 33

    To install the seat, insert the projections on the front of the seat into the seat holders and push down on the seat at the rear. Note: make sure that the seat is securely fitted. 4-11 ebu05820 front carrier ebu05830 rear carrier ebu00112 w indicates a potential hazard that could result in serious i...

  • Page 34: Pre-Operation Checks

    5-1 pre-operation checks before using this machine, check the following points: item routine page brakes • check operation, condition and free play. 5-2–5-3, 8-20–8-26 • adjust if necessary. Fuel • check fuel level. • fill with fuel if necessary. 5-3–5-4 engine oil and • check oil level. 5-5, 8-5–8-...

  • Page 35: Qwarning

    5-2 ebu04721 front and rear brakes 8 brake levers check for correct free play in the brake levers. If the free play is incorrect, adjust it. (see pages 8-21–8-26.) 8 check operation of the levers. They should move smoothly and there should be a firm feeling when the brake is applied. If not, have th...

  • Page 36: Qwarning

    Ebu13410 fuel make sure there is sufficient gasoline in the tank. 5-3 potential hazard riding with improperly operating brakes. What can happen you could lose braking ability, which could lead to an accident. How to avoid the hazard always check the brakes at the start of every ride. Do not ride the...

  • Page 37: Qwarning

    C c use only unleaded gasoline. The use of lead- ed gasoline will cause severe damage to inter- nal engine parts, such as the valves and pis- ton rings, as well as to the exhaust system. Your yamaha engine has been designed to use regular unleaded gasoline with a pump octane number ([r+m]/2) of 86 o...

  • Page 38

    5-5 ebu11163 engine and final transmission oil make sure the engine and final transmission oil is at the specified level. Add oil as necessary. (see page 8-5.) c c 8 do not use oils with a diesel specification of “cd” or oils of a higher quality than specified. In addition, do not use oils labeled “...

  • Page 39: Qwarning

    Ebu01083 throttle lever check to see that the throttle lever operates cor- rectly. It must open smoothly and spring back to the idle position when released. Have a yamaha dealer repair as necessary for proper operation. Ebu00157 tires 5-6 potential hazard operating this atv with improper tires, or w...

  • Page 40

    5-7 4. Use no more than the following pres- sures when seating the tire beads. Front 250 kpa (2.5 kgf/cm 2 , 36 psi) rear 250 kpa (2.5 kgf/cm 2 , 36 psi) higher pressures may cause the tire to burst. Inflate the tires very slowly and carefully. Fast inflation could cause the tire to burst. 2. The ti...

  • Page 41

    5-8 set pressure with tires cold. Set tire pressures to the following specifications: ebu00160 tire wear limit when the tire groove decreases to 3 mm (0.12 in) due to wear, replace the tire. Q 20 kpa (0.20 kgf/cm 2 , 2.9 psi) 17 kpa (0.17 kgf/cm 2 , 2.5 psi) 23 kpa (0.23 kgf/cm 2 , 3.2 psi) 25 kpa (...

  • Page 42

    Ebu01162 fittings and fasteners always check the tightness of chassis fittings and fasteners before a ride. Take the machine to a yamaha dealer or refer to the service manual for correct tightening torque. Ebu00499 battery check fluid level and fill if necessary. Use only distilled water if refillin...

  • Page 43: Operation

    Ebu00161 operation w indicates a potential hazard that could result in serious injury or death. Ebu00509 starting a cold engine 1. Set the parking brake. 2. Turn the fuel cock to “on”. 3. Turn the main switch to “on” and the engine stop switch to “run”. 4. Shift the drive select lever to neutral. 6-...

  • Page 44

    Note: 8 the engine can be started only when the drive select lever is in neutral. 8 when the drive select lever is in neutral, the neutral indicator light should come on. If the light does not come on, ask a yamaha dealer to inspect it. 5. Use the starter (choke) in reference to the figure: position...

  • Page 45

    Note: if the engine fails to start, release the start switch, then push the start switch again. Pause a few seconds before the next attempt. Each cranking should be as short as possible to pre- serve battery energy. Do not crank the engine more than 10 seconds on each attempt. 7. If the engine is st...

  • Page 46

    Ebu15190 drive select lever operation and reverse dri- ving c c before shifting, you must stop the machine and return the throttle lever to its closed position. Otherwise, the transmission may be damaged. Shifting: forward 1. Bring the machine to a complete stop and return the throttle lever to the ...

  • Page 47: Qwarning

    Note: when in reverse, the reverse indicator light should be on. If the light does not come on, ask a yamaha dealer to inspect the atv. 4. Check behind for people or obstacles, then release the rear brake. 5. Open the throttle lever gradually and contin- ue to watch to the rear while backing. Note: ...

  • Page 48

    Ebu02092 engine break-in there is never a more important period in the life of your machine than the period between zero and 20 hours. For this reason, we ask that you carefully read the following material. Because the engine is brand new, you must not put an excessive load on it for the first sever...

  • Page 49

    Ebu15690 parking when parking, stop the engine and shift into the forward position. Turn the fuel cock to “off” and apply the parking brake. 6-7 1 1. Locked position 10–20 hours: avoid prolonged operation above 3/4 throttle. Rev the machine freely through the gears but do not use full throttle at an...

  • Page 50: Qwarning

    Ebu00215 parking on a slope 1. Bring the machine to a stop by applying the brakes. 2. Stop the engine. 3. With the rear brake applied, apply the park- ing brake. 6-8 potential hazard parking on a hill or other incline. What can happen the atv could roll out of control, increas- ing the chance of an ...

  • Page 51

    Ebu00221 accessories and loading ebu00222 accessories accessories can affect the handling and control of your atv. Keep the following in mind when considering an accessory or operating an atv which has accessories. 8 choose only accessories designed for your atv. Your yamaha dealer has a variety of ...

  • Page 52

    Ebu14781 loading as originally equipped, this atv is not designed to carry cargo or tow a trailer. If you choose to add accessories so that you can carry cargo or tow a trailer, you must use common sense and good judgment. Keep the following points in mind: 8 never exceed the weight limits shown. An...

  • Page 53: Qwarning

    6-11 potential hazard overloading this atv or carrying or tow- ing cargo improperly. What can happen could cause changes in vehicle handling which could lead to an accident. How to avoid the hazard never exceed the stated load capacity for this atv. Cargo should be properly distributed and securely ...

  • Page 54

    6-12 ebu14870 w indicates a potential hazard that could result in serious injury or death. 1c5-9-12-1 3/11/05 10:01 am page 6-12.

  • Page 55: Riding

    7 7-1 riding your atv 1c5-9-12-2 3/2/05 7:03 pm page 7-1.

  • Page 56

    This owner’s manual completely and understand the operation of the controls. Pay particular attention to the safety information on pages 2-1–2-7. Please also read all caution and warn- ing labels on your atv. W indicates a potential hazard that could result in serious injury or death. Getting to kno...

  • Page 57: Qwarning

    7-4 ride with care and good judgement get training if you are inexperienced. Beginners should get training from a certified instructor. Become familiar with this atv at slow speeds first, even if you are an experienced operator. Do not attempt to operate at maximum perfor- mance until you are totall...

  • Page 58: Qwarning

    7-5 not recommended for children under 16 years of age. Potential hazard failure to follow the age recommendations for this atv. What can happen use by children of atvs that are not rec- ommended for their age can lead to severe injury or death of the child. How to avoid the hazard a child under 16 ...

  • Page 59: Qwarning

    7-6 this atv is designed to carry operator and cargo only - passengers prohibited. Potential hazard carrying a passenger on this atv. What can happen greatly reduces your ability to balance and control this atv. Could cause an acci- dent, resulting in harm to you and/or your passenger. How to avoid ...

  • Page 60: Qwarning

    Apparel potential hazard operating this atv without wearing an approved motorcycle helmet, eye protec- tion and protective clothing. What can happen operating without an approved motorcy- cle helmet increases your chances of a severe head injury or death in the event of an accident. Operating withou...

  • Page 61: Qwarning

    7-8 do not operate after consuming alcohol or drugs. Operator’s performance capability is reduced by the influence of alcohol or drugs. Potential hazard operating this atv after consuming alco- hol or drugs. What can happen could seriously affect your judgment. Could cause you to react more slowly. ...

  • Page 62: Qwarning

    7-9 pre-operation checks always perform the pre-operation checks listed on page 5-1 before riding for safety and proper care of the atv. Potential hazard failure to inspect the atv before operat- ing. Failure to properly maintain the atv. What can happen increases the possibility of an accident or e...

  • Page 63: Qwarning

    W indicates a potential hazard that could result in serious injury or death. Do not operate at speeds too fast for your skills or the conditions speed limiter for riders inexperienced with this model, this model is equipped with a speed limiter in the throttle lever housing. The speed limiter limits...

  • Page 64: Qwarning

    7-11 loading and accessories use extra caution when riding the atv with additional loads, such as accessories or cargo. The atv’s handling may be adversely affected. Reduce your speed when adding additional loads. Maximum loading limit 8 vehicle loading limit (total weight of cargo, rider and access...

  • Page 65: Qwarning

    7-12 during operation always keep your feet on the footboards during operation. Otherwise your feet may contact the rear wheels. Potential hazard removing hands from handlebars or feet from footboards during operation. What can happen removing even one hand or foot can reduce your ability to control...

  • Page 66: Qwarning

    7-13 avoid wheelies and jumping. You may lose con- trol of the atv or overturn. Potential hazard attempting wheelies, jumps, and other stunts. What can happen increases the chance of an accident, including an overturn. How to avoid the hazard never attempt stunts, such as wheelies or jumps. Don’t tr...

  • Page 67: Qwarning

    7-14 modifications potential hazard operating this atv with improper modifi- cations. What can happen improper installation of accessories or modification of this vehicle may cause changes in handling which in some situa- tions could lead to an accident. How to avoid the hazard never modify this atv...

  • Page 68: Qwarning

    Exhaust system the exhaust system on the atv is very hot dur- ing and following operation. To prevent burns, avoid touching the exhaust system. Park the atv in a place where pedestrians or children are not likely to touch it. 7-15 potential hazard hot exhaust system. What can happen dry grass or bru...

  • Page 69: Qwarning

    Be careful where you ride this atv is designed for off-road use only. Riding on paved surfaces can cause loss of con- trol. Potential hazard operating this atv on paved surfaces. What can happen atvs are designed for off-road use only. Paved surfaces may seriously affect han- dling and control of th...

  • Page 70: Qwarning

    7-17 do not ride on any public road, street, or high- way. Riding on public roads can result in collisions with other vehicles. Potential hazard operating this atv on public streets, roads or highways. What can happen you can collide with another vehicle. How to avoid the hazard never operate this a...

  • Page 71: Qwarning

    Know the terrain where you ride. Ride cautiously in unfamiliar areas. Stay alert for holes, rocks, or roots in the terrain, and other hidden haz- ards which may cause the atv to upset. 7-18 potential hazard failure to use extra care when operating this atv on unfamiliar terrain. What can happen you ...

  • Page 72: Qwarning

    7-19 potential hazard failure to use extra care when operating on excessively rough, slippery or loose terrain. What can happen could cause loss of traction or vehicle control, which could result in an accident, including an overturn. How to avoid the hazard do not operate on excessively rough, slip...

  • Page 73: Qwarning

    7-20 when riding in an area where you might not easily be seen, such as desert terrain, mount a caution flag on the atv. Do not use the flag pole bracket as a trailer hitch. Do not ride in areas posted “no trespassing”. Do not ride on private property without getting per- mission. Potential hazard o...

  • Page 74

    Select a large, flat area off-road to become familiar with your atv. Make sure that this area is free of obstacles and other riders. You should practice control of the throttle, brakes, shifting procedures, and turning techniques in this area before trying more difficult terrain. Always avoid riding...

  • Page 75: Qwarning

    7-22 turning your atv to achieve maximum traction while riding off- road, the two rear wheels are mounted solidly on one axle and turn together at the same speed. Therefore, unless the wheel on the inside of the turn is allowed to slip or lose some traction, the atv will resist turning. A special tu...

  • Page 76

    This procedure should be practiced at slow speed many times in a large off-road area with no obstacles. If an incorrect technique is used, your atv may continue to go straight. If the atv doesn’t turn, come to a stop and then practice the procedure again. If the riding surface is slip- pery or loose...

  • Page 77: Qwarning

    7-24 climbing uphill use proper riding techniques to avoid vehicle overturns on hills. Be sure that you can maneu- ver your atv well on flat ground before attempt- ing any incline and then practice riding first on gentle slopes. Try more difficult climbs only after you have developed your skill. In ...

  • Page 78: Qwarning

    7-25 7-25 potential hazard climbing hills improperly. What can happen could cause loss of control or cause the atv to overturn. How to avoid the hazard always follow proper procedures for climbing hills as described in this owner’s manual. Always check the terrain carefully before you start up any h...

  • Page 79: Qwarning

    7-26 7-26 if you are climbing a hill and you find that you have not properly judged your ability to make it to the top, you should turn the atv around while you still have forward motion (provided you have the room to do so) and go down the hill. Potential hazard improperly crossing hills or turning...

  • Page 80: Qwarning

    7-28 if your atv has stalled or stopped and you believe you can continue up the hill, restart care- fully to make sure you do not lift the front wheels which could cause you to lose control. If you are unable to continue up the hill, dismount the atv on the uphill side. Physically turn the atv aroun...

  • Page 81

    7-29 when fully stopped, apply the rear brake as well, and then lock the parking brake. Dismount on uphill side or to a side if pointed straight uphill. Turn the atv around and remount, following the proce- dure described in the owner’s manual. 1c5-9-12-2 3/2/05 7:03 pm page 7-29.

  • Page 82: Qwarning

    7-30 7-30 riding downhill when riding your atv downhill, shift your weight as far to the rear and uphill side of the atv as possible. Move back on the seat and sit with your arms straight. Improper braking may cause a loss of traction. Use caution while descending a hill with loose or slippery surfa...

  • Page 83

    7-31 7-31 1c5-9-12-2 3/2/05 7:03 pm page 7-31.

  • Page 84: Qwarning

    7-32 7-32 crossing a slope traversing a sloping surface on your atv requires you to properly position your weight to maintain proper balance. Be sure that you have learned the basic riding skills on flat ground before attempting to cross a sloping surface. Avoid slopes with slippery surfaces or roug...

  • Page 85

    7-33 7-33 shift your weight to the uphill side of the atv. 1c5-9-12-2 3/2/05 7:03 pm page 7-33.

  • Page 86: Qwarning

    7-34 7-34 crossing through shallow water the atv can be used to cross slow moving, shallow water of up to a maximum of 20 cm (7.9 inches) in depth. Before entering the water, choose your path carefully. Enter where there is no sharp drop off, and avoid rocks or other obstacles which may be slippery ...

  • Page 87

    Test your brakes after leaving the water. Do not continue to ride your atv without verifying that you have regained proper braking ability. C c after riding your atv in water, be sure to drain the trapped water by removing the check hose at the bottom of the air filter case. Wash the atv in fresh wa...

  • Page 88: Qwarning

    7-36 7-36 riding over rough terrain riding over rough terrain should be done with caution. Look out for obstacles which could cause damage to the atv or could lead to an upset or accident. Be sure to keep your feet firmly mounted on the footboards at all times. Avoid jumping the atv as loss of contr...

  • Page 89

    7-38 7-38 sliding and skidding care should be used when riding on loose or slippery surfaces since the atv may slide. If unexpected and uncorrected, sliding could lead to an accident. To reduce the tendency for the front wheels to slide in loose or slippery conditions, positioning your weight over t...

  • Page 90: Qwarning

    7-39 7-39 with practice, over a period of time, skill at con- trolled sliding can be developed. The terrain should be chosen carefully before attempting such maneuvers, since both stability and control are reduced. Bear in mind that sliding maneu- vers should always be avoided on extremely slippery ...

  • Page 91

    7-40 7-40 what to do if ... This section is designed to be a reference guide only. Be sure to read each section on riding techniques completely. What to do ... 8 if your atv doesn’t turn when you want it to: bring the atv to a stop and practice the turn- ing maneuvers again. Be sure you are putting ...

  • Page 92

    8 if your atv is traversing a sloping surface: be sure to ride with your weight positioned towards the uphill side of the atv to maintain proper balance. If the atv starts to tip, steer down the hill (if there are no obstacles in your way) to regain balance. If you discover that the atv is going to ...

  • Page 93: Periodic Maintenance and

    Ebu00515 periodic maintenance and adjustment periodic inspection, adjustment and lubrication will keep your machine in the safest and most efficient condition possible. Safety is an obliga- tion of the machine owner. The most important points of machine inspection, adjustment and lubrication are exp...

  • Page 94: Qwarning

    The service information included in this manual is intended to provide you, the owner, with the necessary information for completing your own preventive maintenance and minor repairs. The tools provided in the owner’s tool kit are suffi- cient for this purpose, except that a torque wrench is also ne...

  • Page 95

    8-3 ebu02611 periodic maintenance/lubrication note: 8 for atvs not equipped with an odometer or an hour meter, follow the month maintenance intervals. 8 for atvs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance intervals. However, keep in mind that if the atv isn’t...

  • Page 96

    8-4 * since these items require special tools, data and technical skills, have a yamaha dealer perform the service. W indicates a potential hazard that could result in serious injury or death. Initial every month 1 3 6 6 12 item routine whichever km 320 1200 2400 2400 4800 comes first (mi) (200) (75...

  • Page 97

    8-5 ebu08963 engine oil the engine oil level should be checked before each ride. In addition, the oil must be changed at the intervals specified in the periodic mainte- nance and lubrication chart. Engine oil level measurement 1. Place the machine on a level surface. 2. Warm up the engine for severa...

  • Page 98

    8-6 4. Remove the dipstick and drain bolt to drain the oil. C c when removing the drain bolt, the compres- sion spring, oil strainer and o-ring will fall out. Take care not to lose these parts. 5. Clean the oil strainer with solvent. 6. Inspect the o-ring and replace it if dam- aged. 7. Install the ...

  • Page 99

    8-7 ebu14892 final transmission oil the final transmission case must be checked for oil leakage before each ride. If any leakage is found, have a yamaha dealer check and repair the machine. In addition, the final transmission oil must be changed at the intervals specified in the periodic maintenance...

  • Page 100

    8-8 3. Install the screw and oil filler bolt, and then tighten them to their specified torques. Final transmission oil replacement 1. Place the machine on a level surface. 2. Place a container under the engine. 3. Remove the oil filler bolt and drain bolt to drain the oil from the final transmission...

  • Page 101

    8-9 ebu11820 spark plug inspection the spark plug is an important engine compo- nent and is easy to inspect. The condition of the spark plug can indicate the condition of the engine. For example, a very white center electrode porcelain color could indicate an intake air leak or carburetion problem f...

  • Page 102

    8-10 before installing the spark plug, measure the electrode gap with a wire thickness gauge and adjust it to specification. When installing the spark plug, always clean the gasket surface and its mating surface. Wipe off any grime from the threads and tighten it to the specified torque. A spark plu...

  • Page 103

    8-11 ebu14830 engine air filter element and v-belt case air filter element cleaning both air filter elements should be cleaned at the specified intervals in the periodic maintenance chart. Engine air filter element note: there is a check hose at the bottom of the air fil- ter case. If dust or water ...

  • Page 104: Qwarning

    8-12 4. Remove the air filter element, and separate it from the frame. 5. Wash the air filter element gently but thor- oughly in solvent. 6. Squeeze the excess solvent out of the air fil- ter element and let it dry. C c do not twist the air filter element when squeezing it. Potential hazard using lo...

  • Page 105

    7. Inspect the air filter element. If damaged, replace it. 8. Apply yamaha foam air filter oil or other quality foam air filter oil to the air filter ele- ment. Note: the air filter element should be wet but not drip- ping. 9. Install the air filter element on the frame. 10. Install the air filter e...

  • Page 106

    8-14 note: the air filter element should be cleaned every 20-40 hours. It should be cleaned and lubricated more often if the machine is operated in extremely dusty areas. Each time air filter ele- ment maintenance is performed, check the air inlet to the air filter case for obstructions. Check the a...

  • Page 107

    8-15 3. Remove the v-belt air filter element cover by removing the screw. 4. Pull out the air filter element. 5. Tap the air filter element lightly to remove most of the dust and dirt. Blow out the remaining dirt with compressed air. If the air filter element is damaged, replace it. Note: be sure th...

  • Page 108

    8-16 ebu13600 spark arrester cleaning be sure the exhaust pipe and muffler are cool before cleaning the spark arrester. 1. Remove the screws. 2. Remove the tailpipe by pulling it out of the muffler. 3. Tap the tailpipe lightly, then use a wire brush to remove any carbon deposits from the spark arres...

  • Page 109: Qwarning

    8-17 ebu13020 idle speed adjustment note: a diagnostic tachometer must be used for this procedure. 1. Start the engine and warm it up for a few minutes at approximately 1,000 to 2,000 r/min. Occasionally rev the engine to 4,000 to 5,000 r/min. The engine is warm when it quickly responds to the throt...

  • Page 110

    2. Connect the tachometer to the spark plug lead, and then set the idle to the specified idling speed by adjusting the throttle stop screw. Turn the screw in direction a to increase the engine speed, and in direction b to decrease the engine speed. Ebu00303 valve clearance adjustment the correct val...

  • Page 111

    8-19 ebu00307 throttle lever adjustment note: adjust the engine idling speed before adjusting the throttle lever free play. 1. Loosen the locknut. 2. Turn the adjusting bolt until the throttle lever free play is 3–5 mm (0.12–0.20 in). 3. Tighten the locknut. A q w 1. Locknut 2. Adjusting bolt a. Fre...

  • Page 112

    8-20 ebu00308 front and rear brake shoe inspection a wear indicator is provided on each brake. The indicators allows checking of brake shoe wear without disassembling the brake. Apply the brake and check the position of the indicator. If the indicator reaches the wear limit line, ask a yamaha dealer...

  • Page 113

    8-21 ebu14822 front brake lever free play adjustment note: before adjusting the brake lever free play, inspect the front brake shoes. The front brake lever free play should be adjusted to 5–8 mm (0.2–0.3 in) at the brake lever pivot. If the free play is incorrect, adjust it as follows. 1. Remove the...

  • Page 114

    8-22 3. Remove the v-belt air filter element cover by removing the screw. 4. Loosen the locknut and fully turn in the adjusting bolt at the front brake lever. 1. Locknut 2. Adjusting bolt q w 1 2 1. Front cover 2. Coupler w q 1. V-belt air filter element cover 2. Screw 1c5-9-12-3 3/11/05 10:02 am pa...

  • Page 115

    8-23 5. Make sure the brake cable joint in the equal- izer is straight when the brake is applied. If not, loosen the locknut, and then turn the adjusting nuts at the front brake cables until the cable joint becomes straight. 6. Tighten the locknut of each brake cable. Q w q w 1. Locknut ( × 2) 2. Ad...

  • Page 116: Qwarning

    7. Turn the adjusting bolt at the brake lever until the specified free play is obtained. 8. Tighten the locknut at the brake lever. 9. Install the air filter element cover by installing the screw. 10. Connect the coupler, and then install the front cover by installing the quick fasteners. 11. Instal...

  • Page 117

    8-25 ebu00965 rear brake adjustment brake lever free play should be 5–8 mm (0.2–0.3 in) at the brake lever pivot. If the free play is incorrect, adjust as follows: turn the adjusting nut on the brake hub in direc- tion a to decrease play, and in direction b to increase play. A a. Free play a b q 1. ...

  • Page 118: Qwarning

    8-26 ebu01144 drive chain slack check note: move the atv back and forth and find the tight- est position of the drive chain. Check and/or adjust the chain slack while it is in this tightest position. To check the drive chain slack, all tires must be touching the ground and there should be no weight ...

  • Page 119

    8-27 ebu01146 drive chain slack adjustment 1. Loosen the hub stopper bolt locknut and then the hub stopper bolt. 2. Loosen the upper and lower axle holding bolts. 3. Loosen the locknut. To tighten the drive chain, turn the adjusting bolt in direction a. To loosen the drive chain, turn the adjusting ...

  • Page 120

    8-28 4. After adjusting, be sure to tighten the lock- nut and the axle holding bolts. 5. Finger tighten the hub stopper bolt and tight- en the hub stopper bolt locknut. C c if measurement a a of the drive chain adjust- ing bolt is less than 27 mm (1.06 in), ask a yamaha dealer to replace the drive c...

  • Page 121

    8-29 2. Wipe the drive chain dry. 3. Thoroughly lubricate the drive chain with a special o-ring chain lubricant. C c do not use engine oil or any other lubricants for the drive chain, as they may contain sub- stances that could damage the o-rings. Ebu00805 lubricating the drive chain the drive chain...

  • Page 122: Qwarning

    8-30 ebu00355 draining the v-belt compartment if water leaks into the v-belt compartment such as when the machine is driven in water, remove the drain screw on the bottom of compartment and drain the water. Be sure to drive slowly until the v-belt becomes dry. If slipping is noticed, ask a yamaha de...

  • Page 123

    8-31 ebu00725 brake lever lubrication lubricate the pivoting parts of the brake levers. Ebu00728 knuckle shaft, lower arms and steering shaft lubrication lubricate the pivot points using a grease gun. Recommended lubricant: lithium-soap-based grease (all-purpose grease) 1 1 1 1 recommended lubricant...

  • Page 124

    Ebu01112 wheel removal 1. Loosen the wheel nuts. 2. Elevate the atv and place a suitable stand under the frame. 3. Remove the nuts from the wheel. 4. Remove the wheel. Ebu01150 wheel installation 1. Install the wheel and the nuts. Note: tapered wheel nuts are used for both front and rear wheels. Ins...

  • Page 125

    8-33 ebu00378 battery check the level of the battery fluid and see if the terminals are tight. Add distilled water if the fluid level is low. C c do not leave or store the battery on its side. When inspecting the battery, be sure the breather hose is routed correctly. If it touch- es the frame or ex...

  • Page 126: Qwarning

    8-34 potential hazard failure to handle batteries or battery elec- trolyte carefully. What can happen you could be poisoned. You could be severely burned by the sulfuric acid in bat- tery electrolyte. Batteries produce explosive gases. How to avoid the hazard avoid contact with skin, eyes or clothin...

  • Page 127

    8-35 ebu11950 replenishing the battery fluid a poorly maintained battery will corrode and dis- charge quickly. The battery fluid should be checked at least once a month. 1. The level should be between the maximum and minimum level marks. Use only distilled water if refilling is necessary. 2. Disconn...

  • Page 128: Qwarning

    Ebu00388 fuse replacement 1. The fuse case is located on the right side of the machine. 2. If the fuse is blown, turn off the main switch and install a new fuse of the specified amperage. Then turn on the switches, if the fuse immediately blows again, consult a yamaha dealer. C c to prevent accident...

  • Page 129

    8-37 ebu14802 replacing a headlight bulb if a headlight bulb burns out, replace it as fol- lows. 1. Remove the cover at the rear of the head- light by pulling it off. 2. Remove the bulb holder cover by pulling it off. 3. Remove the bulb holder by pushing it inward and turning it counterclockwise. 4....

  • Page 130: Qwarning

    8-38 5. Install a new headlight bulb into position. 6. Install the bulb holder by pushing it inward and turning it clockwise. 7. Install the bulb holder cover. 8. Install the cover at the rear of the headlight. Potential hazard a headlight bulb is hot when it is on and immediately after it is turned...

  • Page 131

    8-39 ebu00861 tail/brake light bulb replacement 1. Remove the bulb holder (together with the bulb) by turning it counterclockwise. 2. Remove the defective bulb from the bulb holder by pushing it inward and turning it counterclockwise. 3. Install a new bulb in the bulb holder by push- ing it inward a...

  • Page 132

    8-40 ebu10890 headlight beam adjustment c c it is advisable to have a yamaha dealer make this adjustment. To raise the beam, turn the adjusting screw in direction a. To lower the beam, turn the adjusting screw in direction b. A b 1 1. Adjusting screw 1c5-9-12-3 3/11/05 10:02 am page 8-41.

  • Page 133: Qwarning

    8-41 ebu00412 troubleshooting although yamaha machines receive a rigid inspection before shipment from the factory, trouble may occur during operation. Any prob- lem in the fuel, compression, or ignition systems can cause poor starting and loss of power. The troubleshooting chart describes a quick, ...

  • Page 134

    8-42 ebu00440 troubleshooting chart 1. Fuel check if there is fuel in the fuel tank. 2. Compression use electric starter to see if there is compression. 3. Ignition remove plug and check electrodes. Wet wipe clean with dry cloth. Dry attach plug cap and ground to chassis. Use electric starter. Spark...

  • Page 135: Cleaning and Storage

    Ebu00417 cleaning and storage a. Cleaning frequent, thorough cleaning of your machine will not only enhance its appearance but will improve its general performance and extend the useful life of many components. 1. Before cleaning the machine: a. Block off the end of the exhaust pipe to prevent water...

  • Page 136: Qwarning

    7. Clean the seat with a vinyl upholstery clean- er to keep the cover pliable and glossy. 8. Automotive type wax may be applied to all painted and chrome plated surfaces. Avoid combination cleaner-waxes. Many contain abrasives which may mar the paint or pro- tective finish. When finished, start the ...

  • Page 137

    Ebu00525 b. Storage long term storage (60 days or more) of your machine will require some preventive proce- dures to guard against deterioration. After thor- oughly cleaning the machine, prepare for stor- age as follows: 1. Fill the fuel tank with fresh fuel and add the specified amount of yamaha fu...

  • Page 138: Specifications

    Ebu00428 specifications model yfm125g dimension: overall length 1,710 mm ( 67.3 in) overall width 990 mm ( 39.0 in) overall height 980 mm ( 38.6 in) seat height 705 mm ( 27.8 in) wheel base 1,080 mm ( 42.5 in) ground clearance 145 mm ( 5.71 in) minimum turning radius 2,900 mm (114.2 in) basic weight...

  • Page 139

    Model yfm125g engine oil/final transmission oil: type recommended engine oil/final transmission api service se, sf, sg type or higher oil classification: quantity engine oil: periodic oil change 1.25 l (1.10 lmp qt, 1.32 us qt) final transmission oil: 0.6 l (0.53 lmp qt, 0.63 us qt) c c 8 do not use...

  • Page 140

    Model yfm125g air filter: for engine wet type element for v-belt case dry type element fuel: type unleaded gasoline only tank capacity 7.6 l (1.67 imp gal, 2.01 us gal) reserve amount 1.3 l (0.29 imp gal, 0.34 us gal) carburetor: type/manufacturer vm18sh/mikuni spark plug: type/manufacturer cr7hsa/n...

  • Page 141

    Model yfm125g chassis: frame type steel tube caster angle 6° trail 15 mm (0.59 in) tire: type tubeless size: front at20 × 7 - 8 rear at22 × 10 - 8 manufacturer/type: front dunlop/kt536a rear dunlop/kt537a brake: front brake type drum brake operation right hand operation rear brake type drum brake op...

  • Page 142

    Model yfm125g wheel travel: front 70 mm (2.8 in) rear 80 mm (3.2 in) electrical: ignition system dc. C.D.I. Charging system a.C. Magneto battery type/voltage, capacity 12n12c-4a-2/12v, 12ah headlight type: bulb bulb voltage, wattage × quantity: headlight 12v, 30 w/30 w × 2 tail/brake light 12v, 5 w/...

  • Page 143: Noise Regulation

    Ebu13640 noise regulation tampering with noise control system prohibited: federal law prohibits the following acts or the causing thereof: (1) the removal or rendering inopera- tive by any person other than for purposes of maintenance, repair, or replacement of any device or element of design incorp...

  • Page 144: Maintenance Record

    Ebu13653 maintenance record copies of work orders and/or receipts for parts you purchase and install will be required to document maintenance done in accordance with the warranty. The chart below is printed only as a reminder to you that the maintenance work is required. It is not acceptable proof o...

  • Page 145

    13-1 ebu00432 1c5-9-12-3 3/11/05 10:02 am page 13-2.

  • Page 146

    13-2 13 1c5-9-12-3 3/11/05 10:02 am page 13-3.

  • Page 147

    14-1 ebu00435 1c5-9-12-3 3/11/05 10:02 am page 14-2.

  • Page 148

    14-2 14 1c5-9-12-3 3/11/05 10:02 am page 14-3.

  • Page 149

    14-3 ebu00436 w indicates a potential hazard that could result in serious injury or death. 1c5-9-12-3 3/11/05 10:02 am page 14-4.

  • Page 150: Protect Your Investment

    Ebu00437 protect your investment 1c5-9-12-3 3/11/05 10:02 am page 14-6.

  • Page 151: Warning

    Printed in japan 2005.3-1.1x1 ! (e) improper atv use can result in severe injury or death. Q warning always use an approved helmet and protective gear never use on public roads never carry passengers never use with drugs or alcohol never operate: 9 without proper training or instruction. 9 at speeds...

  • Page 152: Read    Carefull

    Dear new yamaha atv owner: congratulations on the purchase of your new yamaha atv. You have purchased a quality yamaha product that, with proper use and care, will provide hours of riding pleasure. Before you operate your new atv, yamaha recommends these important points: 8 read your owner’s manual ...

  • Page 153

    No postage necessary if mailed in the united states first class permit no. 4 cypress, ca postage will be paid by addressee yamaha motor corporation u.S.A. P.O. Box 6555 cypress, california 90630-9989 attn: sales administration atv card for us 4/2/03 9:06 am page 2.