Clymer Yamaha YZ125 1994-2001 Motorcycle Repair Manual

Description

This Clymer Yamaha YZ125 1994-2001 Repair Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for 1994-2001 Yamaha YZ125 motocross motorcycles.

1994 1995 1996 1997 1998 1999
2000 2001

Includes everything you need to know to perform tune-up and routine maintenance on the engine, clutch and transmission, fuel and exhaust, ignition system, steering and suspension, wheels, brakes and tires, electrical system, frame and body. Features complete wiring diagrams and 450 illustrated pages.

QUICK REFERENCE DATA

CHAPTER ONE, GENERAL INFORMATION
Manual organization, Notes, cautions and warnings, Safety first, Cleaning parts, Handling gasoline safely, Service hints, Serial numbers, Warning labels, Torque specifications, Fasteners, Lubricants, Sealant, cements and cleaners, Threadlocking compound, Basic hand tools, Precision measuring tools, Test equipment, Special tools, Mechanic’s tips, Ball bearing replacement, Seals

CHAPTER TWO, TROUBLESHOOTING
Operating requirements, Starting the engine, Starting difficulties, Engine performance, Engine, Engine noises, Two-stroke leak down test, Fuel system, Electrical troubleshooting, Test equipment, Ignition system, Clutch, External shift mechanism and transmission, Kickstarter, Drive train noise, Front suspension and steering, Rear suspension, Frame noise, Brakes

CHAPTER THREE, LUBRICATION, MAINTENANCE AND TUNE-UP
Service intervals, Tune-up, Pre-ride inspection, Engine lubrication, Transmission oil, Air filter, Engine compression check, Ignition timing, Spark plug, Carburetor, Exhaust system, Cooling system, Control cable lubrication, Throttle cable adjustment, Clutch, Engine top end inspection, Kickstarter pedal and shift pedal, Brakes, Drive chain and sprockets, Tires and wheels, Wheel bearings, Steering, Front fork, Rear swing arm and linkage, General lubrication, Nuts, bolts and other fasteners, Storage

CHAPTER FOUR, ENGINE TOP END
Engine operating principles, Cleanliness, Exhaust system, Cylinder head, Cylinder, Exhaust valve, Exhaust valve service (1994-1995), Exhaust valve service (1996-on), Exhaust valve cleaning and decarbonizing (all years), Piston, piston rings, piston pin and connecting rod, Reed valve assembly, Engine break-in

CHAPTER FIVE, ENGINE BOTTOM END
Servicing engine in frame, Engine, Countershaft seal replacement, Left side main bearing seal replacement, Crankcase and crankshaft

CHAPTER SIX, CLUTCH
Clutch cover, Clutch release lever, Right crankcase cover, Exhaust valve governor, Clutch, Clutch service, Primary drive gear, Kickstarter and idle gear, External shift mechanism, Clutch cable replacement

CHAPTER SEVEN, TRANSMISSION AND INTERNAL SHIFT MECHANISM
Transmission operation, Transmission troubleshooting, Transmission, Transmission overhaul, Transmission inspection, Internal shift mechanism

CHAPTER EIGHT, FUEL SYSTEM
Carburetor, Carburetor (1994 model), Carburetor (1995-1998 models), Carburetor (since 1999), Carburetor cleaning and inspection (all model years), Flat level adjustment (1994-1996 models), Carburetor rejetting, Fuel tank, Fuel valve, Throttle cable replacement

CHAPTER NINE, IGNITION SYSTEM
Component testing, Capacitor discharge ignition, Flywheel, Stator coils, CDI unit, Ignition coil, Engine stop switch, Ignition timing, Wiring diagrams

CHAPTER TEN, LIQUID COOLING SYSTEM
Safety precautions, Hoses and hose clamps, Cooling system inspection, Radiator, Water pump (1994-1997), Water pump (1998 and later)

CHAPTER ELEVEN, WHEELS, TIRES AND DRIVE CHAIN
Front wheel, Rear wheel, Front and rear hubs, Rim and spoke service, Tire changing, Drive chain, Sprocket replacement

CHAPTER TWELVE, FRONT SUSPENSION AND STEERING
Handlebar, Steering head, Front fork oil change and oil level adjustment, Front fork, Fork tools (all models), Front fork service (1994-1997), Front fork (1998-on), Inspection (all models), Fork oil refilling (all models), Front fork adjustment (1994-1997), Front fork adjustment (1998 and later)

CHAPTER THIRTEEN, REAR SUSPENSION
Rear suspension system, Shock absorber (all models), Shock linkage (1994-1995), Rear swing arm (1994-1995), Shock linkage (1996-on), Rear swing arm (1996-on), Rear swing arm service (all models), Connecting rod and relay arm (all models), Rear suspension adjustment

CHAPTER FOURTEEN, BRAKES
Disc brake, Front brake pads, Brake caliper, Front master cylinder, Rear brake pads, Rear brake caliper, Rear master cylinder, Brake hose replacement, Brake disc, Draining brake fluid, Brake bleeding, Rear brake pedal

CHAPTER FIFTEEN, BODY
Seat, Side covers, Radiator covers, Subframe

SUPPLEMENT, 2000-2001 SERVICE INFORMATION
Service intervals (2001), Carburetor (2000-2001), Clutch (2000-2001), Brakes, Exhaust system (2000-2001), Cylinder head, Exhaust valve service (2001), Piston, piston rings, piston pin and connecting rods (2001), Clutch release lever (2001), Clutch service (2000-2001), Carburetor (2001), Carburetor fuel level adjustment (2000-2001), Flywheel (2001), Steering head (2001), Rear shock absorber (2001), Rear swing arm (2000-2001), Rear suspension adjustment (2000-2001), Front master cylinder (2001), Brake disc (2001), Rear brake pedal (2000-2001), Subframe (2001)

INDEX

WIRING DIAGRAMS