2009 – 2016 Yamaha YW125 Zuma 125 Scooter Service Manual

Description

This Official 2009 – 2016 Yamaha YW125 Zuma 125 Scooter Factory Service Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for 2009, 2010, 2011, 2012, 2013, 2014, 2015, 2016 Yamaha YW125 Zuma 125 Scooter models.

Some covers say 2009-2015 but does also cover 2016.

Table of Contents

General Information
Specifications
Periodic Checks And Adjustments
Chassis
Engine
Fuel Injection System
Electrical System
Troubleshooting

Index of Contents

Chapter 1 General Information
Scooter Identification
Vehicle Identification Number
Model Label
Features
Outline Of The Fi System
Fi System
02 Sensor
Important Information
Preparation For Removal And Disassembly
Replacement Parts
Gaskets, Oil Seals And O-rings
Lock Washers/plates And Cotter Pins
Bearings And Oil Seals
Circlips
Equipment Preparation
Checking The Connections
Special Tools

Chapter 2 Specifications
General Specifications
Engine Specifications
Chassis Specifications
Electrical Specifications
General Tightening Torque Specifications
Tightening Torques
Engine
Chassis
Lubrication Points And Lubricant Types
Engine
Chassis
Cable Routing

Chapter 3 Periodic Checks And Adjustments
Introduction
Periodic Maintenance And Adjustment
Periodic Maintenance Chart For The Emission Control System
Genela Maintenance And Lublication Chart
Cover And Panel
Seat And Trunk
Footrest Board
Leg Shield 1 Assembly And Leg Shield 2
Engine
Adjusting The Valve Clearance
Checking The Engine Idling Speed
Adjusting The Throttle Cable Free Play
Adjusting The Seat Spring Force
Checking The Spark Plug
Checking The Ignition Timing
Measuring The Compression Pressure
Checking The Engine Oil Level
Changing The Engine Oil
Changing The Transmission Oil
Measuring The Engine Oil Pressure
Replacing The Air Filter Element
Cleaning The V-belt Case Air Filter Element
Checking The Throttle Body Joint And Intake
Manifold
Checking The Fuel Hose
Checking The Breather Hoses
Checking The Exhaust System
Checking The Canister And Roll Over Valve
Chassis
Checking The Front Brake
Adjusting The Rear Brake
Checking The Brake Fluid Level
Checking The Front Brake Pads
Checking The Rear Brake Shoes
Checking The Front Brake Hose
Bleeding The Hydraulic Brake System
Checking And Adjusting The Steering Head
Checking The Front Fork
Checking The Tires
Checking The Wheels
Checking And Lubricating The Cables
Lubricating The Levers
Lubricating The Sidestand
Lubricating The Centerstand
Lubricating The Rear Suspension
Electrical System
Checking And Charging The Battery
Checking The Fuses
Replacing The Headlight Bulbs
Adjusting The Headlight Beams

Chapter 4 Chassis
Front Wheel And Brake Disc
Front Wheel
Removing The Front Wheel
Checking The Front Wheel
Checking The Brake Disc
Checking The Speedometer Gear Unit
Assembling The Front Wheel
Installing The Front Wheel
Adjusting The Front Wheel Static Balance
Rear Wheel And Rear Brake
Removing The Rear Wheel
Checking The Rear Wheel
Checking The Rear Wheel Drive Hub
Checking The Brake
Assembling The Brake Shoes
Installing The Rear Wheel
Adjusting The Rear Wheel Static Balance
Front Brake
Front Brake Pads
Replacing The Front Brake Pads
Front Brake Master Cylinder
Disassembling The Front Brake Master Cylinder
Checking The Front Brake Master Cylinder
Assembling And Installing The Front Brake Master
Cylinder
Front Brake Caliper
Disassembling The Front Brake Caliper
Checking The Front Brake Caliper
Assembling And Installing The Front Brake
Caliper
Front Fork
Removing The Front Fork Legs
Disassembling The Front Fork Legs
Checking The Front Fork Legs
Assembling The Front Fork Legs
Installing The Front Fork Legs
Handlebar
Removing The Handlebar
Checking The Handlebar
Installing The Handlebar
Steering Head
Handlebar Bracket And Front Bracket
Lower Bracket
Removing The Lower Bracket
Checking The Steering Head
Installing The Steering Head
Rear Shock Absorber Assemblies And Swingarm
Removing The Rear Shock Absorber Assemblies
Checking The Rear Shock Absorber Assembly
Installing The Rear Shock Absorber Assemblies
Removing The Swingarm
Checking The Swingarm
Installing The Swingarm

Chapter 5 Engine
Engine Removal
Leads And Hoses
Engine
Installing The Engine
Cylinder Head
Removing The Cylinder Head
Checking The Cylinder Head
Installing The Cylinder Head
The Rocker Arms And Camshaft
Removing The Rocker Arms And Camshaft
Checking The Camshaft
Checking The Rocker Arms And Rocker Arm
Shafts
Checking The Timing Chain, Camshaft Sprocket And
Timing Chain Guides
Checking The Timing Chain Tensioner
Installing The Camshaft And Rocker Arms
Valves And Valve Springs
Removing The Valves
Checking The Valves And Valve Guides
Checking The Valve Seats
Checking The Valve Springs
Installing The Valves
Cylinder And Piston
Removing The Cylinder And Piston
Checking The Cylinder And Piston
Checking The Piston Rings
Checking The Piston Pin
Checking The Timing Chain Guide (exhaust Side)
Installing The Piston And Cylinder
Belt Drive
V-belt Case
V-belt And Primary/secondary Sheave
Secondary Sheave
Removing The Primary Sheave
Removing The Secondary Sheave And V-belt
Disassembling The Secondary Sheave
Checking The Clutch Shoes
Checking The V-belt
Checking The Primary Sheave
Checking The Primary Sheave Weights
Checking The Slider
Checking The Secondary Sheave
Assembling The Primary Sheave
Assembling The Secondary Sheave
Installing The Secondary Sheave, V-belt And Primary
Sheave
Starter Clutch And Ac Magneto
Stator Coil Assembly
Starter Clutch
Removing The Ac Magneto
Checking The Starter Clutch
Installing The Ac Magneto
Oil Pump
Checking The Oil Pump
Assembling The Oil Pump
Installing The Oil Pump
Transmission
Checking The Transmission
Crankshaft
Crankshaft Assembly
Disassembling The Crankcase
Removing The Crankshaft Assembly
Checking The Crankshaft And Connecting Rod
Checking The Crankcase
Checking The Timing Chain And Timing Chain
Guide(intake Side)
Checking The Bearings And Oil Seals
Installing The Crankshaft Assembly
Assembling The Crankcase

Chapter 6 Fuel Injection System
Fuel Injection System
Wiring Diagram
Ecu’s Self-diagnostic Function
Checking For A Defective Engine Trouble Warning
Light Bulb
Self-diagnostic Fanction Table
Troubleshooting Chart
Diagnostic Mode
Troubleshooting Details
Throttle Body And Fuel Injector
Fuel Tank
Fuel Injector And Fuel Hose
Throttle Body
Removing The Fuel Tank
Removing The Fuel Pump
Checking The Fuel Injector
Checking The Throttle Body
Installing The Fuel Pump
Installing The Fuel Tank And Fuel Hose
Checking The Fuel Pump And Pressure Regulator Operation
Checking The Throttle Position Sensor
Checking The Isc (idle Speed Control) Valve

Chapter 7 Electrical System
Electrical Components
Wiring Diagram
Checking Switch Continuity
Checking The Switches
Checking The Bulbs And Bulb Sockets
Types Of Bulbs
Checking The Condition Of The Bulbs
Checking The Condition Of The Bulb Sockets
Ignition System
Circuit Diagram
Troubleshooting
Electric Starting System
Circuit Diagram
Starting Circuit Cut-off System Operation
Troubleshooting
Starter Motor
Checking The Starter Motor
Assembling The Starter Motor
Charging System
Circuit Diagram
Troubleshooting
Lighting System
Circuit Diagram
Troubleshooting
Checking The Lighting System
Signaling System
Circuit Diagram
Troubleshooting
Checking The Signaling System

Chapter 8 Troubleshooting
Starting Failure/hard Starting
Engine
Fuel System
Electrical Systems
Incorrect Engine Idling Speed
Engine
Fuel System
Electrical Systems
Poor Medium-and-high-speed Performance
Engine
Fuel System
Faulty Clutch
Engine Operates But Scooter Will Not Move
Clutch Slips
Poor Starting Performance
Poor Speed Performance
Overheating
Engine
Fuel System
Chassis
Electrical Systems
Poor Braking Performance
Faulty Front Fork Legs
Leaking Oil
Malfunction
Unstable Handling
Faulty Lighting Or Signaling System
Headlight Does Not Come On
Headlight Bulb Burnt Out
Tail/brake Light Does Not Come On
Tail/brake Light Bulb Burnt Out
Turn Signal Does Not Come On
Turn Signal Blinks Slowly
Turn Signal Remains Lit
Turn Signal Blinks Quickly
Horn Does Not Sound