Yamaha YP125E 2003 Bedienungs- und Montageanleitung

SERVICE

INFORMATION

YP180E

YP125E

2003

5XL1-SE1

YP125E’03

YP180E’03

SERVICE INFORMATION

1st Edition, November 2002.

unauthorized use without the written

permission of Yamaha Motor España, S.A.

is expressly prohibited.

EB000000

EB001000

NOTICE

This manual was produced by the Yamaha Motor España, S.A., primarily for use by Yamaha/MBK

dealers and their qualified mechanics. It is not possible to include all the knowledge of a mecha-

nic in one manual, so it is assumed that anyone who uses this book to perform maintenance and

repairs on Yamaha/MBK scooter has a basic understanding of the mechanical ideas and the pro-

cedures of scooter repair. Repairs attempted by anyone without this knowledge are likely to render

the scooter unsafe and unfit for use.

Yamaha Motor España, S.A., is continually striving to improve all its models. Modifications and sig-

nificant changes in specifications or procedures will be forwarded to all authorized Yamaha/MBK

dealers and will appear in future editions of this manual where applicable.

NOTE:

Designs and specifications are subject to change without notice.

IMPORTANT INFORMATION

Particularly important information is distinguished in this manual by the following notations.

tThe Safety Alert Symbol means TTENTION! BECOME ALERT! YOUR

SAFETY IS INVOLVED!

ssWARNING Failure to follow WARNING instructions could result in severe injury or

death to the scooter operator, a bystander or a person inspecting or

repairing the scooter.

CAUTION: A CAUTION indicates special precautions that must be taken to avoid

damage to the scooter.

NOTE: A NOTE provides key information to make procedures easier or

clearer.

EB003000

ILLUSTRATED SYMBOLS

Illustrated symbols to are designed as

thumb tabs to indicate the chapeter’s number

and content.

 General information

 Specifications

 Periodic checks and adjustments

 Engine

 Cooling system

 Carburetion

 Chassis

 Electrical

 Troubleshooting

Illustrate symbols 10 to 17 are used to iden-

tify the specifications appearing in the text.

10 Possible to maintain with engine mounted

11 Filling fluid

12 Lubricant

13 Special tool

14 Tightening

15 Wear limit, clearance

16 Engine speed

17 Ω, V, A

Illustrated symbols 18 to 23 in the exploded

diagram indicate the types of lubricants and

lubrication points.

18 Apply engine oil

19 Apply gear oil

20 Aply molybdenium disulfide oil

21 Apply wheel bearing grease

22 Apply lightweight lithium-soap grease

23 Apply molybdenium disulfide grease

Illustrated symbols 24 to 25 in the exploded

diagram indicate the where to apply locking

agent 24 and where to install new parts 25 .

24 Apply locking agent (LOCTITE®)

25 Use new one

INSP

ADJ

COOL

CHAS

SPEC

ENG

CARB

ELEC

GEN

INFO











11

13

18

21









10

12

14

23

19

22

TRBL

SHTG

24 25

15 16 17

20

New

CONTENTS

GENERAL INFORMATION

SCOOTER IDENTIFICATION

FRAME SERIAL NUMBER......................................................................................................1

ENGINE SERIAL NUMBER.....................................................................................................1

MODEL LABEL .......................................................................................................................1

IMPORTANT INFORMATION.....................................................................................................2

PREPARATION FOR REMOVAL PROCEDURES....................................................................2

REPLACEMENT PARTS..........................................................................................................2

GASKETS, OIL SEALS, AND O-RINGS..................................................................................2

LOCK WASHERS/PLATES AND COTTER PINS ....................................................................3

BEARINGS AND OIL SEALS ..................................................................................................3

CIRCLIPS................................................................................................................................3

CHECKING OF CONNECTIONS ............................................................................................4

HOW TO USE THE CONVERSION TABLE.............................................................................5

SPECIAL TOOLS........................................................................................................................6

SPECIFICATIONS

GENERAL SPECIFICATIONS ....................................................................................................9

MAINTENANCE SPECIFICATIONS.........................................................................................12

ENGINE.................................................................................................................................12

LUBRICATION DIAGRAM .....................................................................................................15

TIGHTENING TORQUES (ENGINE) ......................................................................................17

CHASSIS...............................................................................................................................29

TIGHTENING TORQUES (CHASSIS)....................................................................................20

ELECTRICAL.........................................................................................................................21

GENERAL TORQUE SPECIFICATIONS..................................................................................23

CABLE ROUTING.....................................................................................................................24

PERIODIC INSPECTIONS AND ADJUSTMENTS

PERIODIC MAINTENANCE/LUBRICATION INTERVALS ......................................................27

WIRING DIAGRAM..................................................................................................................29

YP100000

GENERAL INFORMATION

SCOOTER IDENTIFICATION

YP100010

FRAME SERIAL NUMBER

The identification number is stamped onto the

frame.

YP100020

ENGINE SERIAL NUMBER

The engine serial number is stamped onto the

right side of the crankcase.

NOTE:

Design and specifications may change without

notice.

MODEL LABEL

The model reference label is affixed under the

seat. This information will be needed to order

sparre parts.

SCOOTER IDENTIFICATION

GEN

INFO



EB101000

IMPORTANT INFORMATION

PREPARATION FOR REMOVAL

PROCEDURES

1. Remove all dirt, mud, dust and foreign mate-

rial before removal and disassembly.

2. Use proper tools and cleaning equipment.

3. Refer to the “SPECIAL TOOLS” section.

4. When disassembling the machine, always

keep mated parts together. This includes

gears, cylinders, pistons and other parts that

have been “mated” through normal wear.

Mated parts must always be reused or repla-

ced as an assembly.

5. During machine disassembly, clean all parts

and place them in trays in the order o disas-

sembly. This will speed up assembly and

allow for the correct installation of all parts.

6. Keep all parts away from any source of fire.

EB101010

REPLACEMENT PARTS

1. Use only genuine Yamaha parts for all repla-

cements. Use oil and grease recommended

by Yamaha for all lubrication jobs. Other

brands may be similar in function and appea-

rance, but inferior in quality.

EB101020

GASKETS, OIL SEALS AND O-RINGS

1. Replace all gaskets, seals and O-rings when

overhauling the engine. All gasket surfaces, oil

seal lips and O-rings must be cleaned.

2. Properly oil all mating parts and bearings

during reassembly. Apply grease to the oil

seal lips.

IMPORTANT INFORMATION GEN

INFO

EB101030

LOCK WASHERS/PLATES AND COTTER PINS

1. Replace all lock washers/plates and cotter

pins after removal. Bend lock tabs along the

bolt or nut flats after the bolt or nut has been

tightened to specification.

EB101040

BEARINGS AND OIL SEALS

Install bearings and oil seals so that the manu-

facturer’s marks or numbers are visible. When

installing oil seals, apply a light coating of light-

weight lithium base grease to the seal lips. Oil

bearings liberally when installing, if appropriate.

Oil seal

CAUTION:

Do not use compressed air to spin the bea-

rings dry. This will damage the bearing surfa-

ces.

Bearing

EB101050

CIRCLIPS

1. Check all circlips carefully before reassembly.

Always replace piston pin clips after one use.

Replace distorted circlips. When installing a

circlip , make sure that the sharp-edged

corner is positioned opposite the thurst 

it receives. See sectional view.

Shaft

IMPORTANT INFORMATION GEN

INFO

EB801000

CHECKING OF CONNECTIONS

Dealing with stains, rust, moisture, etc. on the

connector.

1. Disconnect:

• Connector

2. Dry each terminal with an air blower.

3. Connect and disconnect the connector two or

three times.

4. Pull the lead to check that it will not come off.

5. If the terminal comes off, bend up the pin 

and reinsert the terminal into the connector.

6. Connect:

• Connector

NOTE:

The two connectors “click” together.

7. Check for continuity with a tester.

NOTE:

• If there is no continuity, clean the terminals.

• Be sure to perform the steps 1 to 7 listed

above when checking the wireharness.

• For a field remedy, use a contact revitalizer

available on the market.

• Use the tester on the connector as shown.

IMPORTANT INFORMATION GEN

INFO

EB201000

HOW TO USE THE CONVERSION TABLE

All specification data in this manual are listed in SI and METRIC UNITS.

Use this table to convert METRIC unit data to IMPERIAL unit data.

EX.

METRIC MULTIPLIER IMP

** mm x 0,03937 = **in

2 mm x 0,03937 = 0,08 in

TABLA DE CONVERSIÓN

METRIQUES EN ANGLAISES

Connu Multiplicateur Résultat

m•kg 7,233 ft•lb

Torque m•kg 86,794 in•lb

cm•kg 0,0723 ft•lb

cm•kg 0,8679 in•lb

Weight kg 2,205 lb

g 0,03527 oz

km/h 0,6214 mph

km 0,6214 mi

Distance m 3,281 ft

m 1,094 yd

cm 0,3937 in

mm 0,03937 in

cc (cm3) 0,03527 oz (IMP liq.)

Volume/ cc (cm3) 0,06102 cu•in

Capacity lit (litre) 0,08799 qt (IMP liq.)

lit (litre) 0,2199 gal (IMP liq.)

kg/mm 55,997 lb/in

Micescellaneous kg/cm214,2234 psi (lb/in2)

Centígrade 9/5 (°C) + 32 Fahrenheit (ºF)

IMPORTANT INFORMATION GEN

INFO

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