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Yamaha TZR125 1987-1993 Full Service Repair Manual

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🏷️ Basic Information Identification Make: Yamaha Model: TZR125 Generation: 2TR/3ET Model Years Covered: 1987, 1988, 1989, 1990, 1991, 1992, 1993 Codes Chassis Codes: 2RM, 2RN, 2RW, 2RX, 3ET, 3KC 👋 Introduction Market Position Segment: Lightweight Sportbike / Supersport (125cc class) Competitive Analysis Key Rivals: Honda NSR125R, Suzuki RG125 Gamma, Aprilia RS125, Cagiva Mito 125. Key Features Technological Highlights: YPVS (Yamaha Power Valve System) for improved power delivery, liquid cooling, advanced chassis design for its class, aggressive styling. Target Audience Intended Users: Yamaha TZR125 owners, mechanics, restorers, hobbyists requiring detailed service and repair information. 📋 Manual Details Coverage Areas Manual Scope: Full Service Repair Page Count Estimated Pages: Comprehensive (Specific page count not provided, typical for this era of sportbike manuals would be 300-500+ pages) Manual Type Type: Factory Service Manual (FSM) Equivalent / Professional Repair Manual Language Language: English Format File Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, disassembly, inspection, tuning, lubrication, cooling system, fuel system (carburetor, ignition), exhaust system. Chassis And Suspension: Frame, front fork (telescopic, damping, seals), rear suspension (monoshock, linkage, adjustments), steering system, wheels, tires, brakes (front and rear disc, hydraulic system, calipers, master cylinders). Electrical System: Wiring diagrams, ignition system, lighting, charging system (stator, regulator/rectifier, battery), starter motor, indicators, horn, fuses, troubleshooting. Bodywork And Trim: Fairings, seat, fuel tank, fenders, graphics, fasteners, removal and installation procedures. Procedures Included Maintenance: Scheduled maintenance, fluid changes (oil, coolant, brake fluid), filter replacements, chain adjustment, spark plug replacement, valve clearance check (if applicable to 2-stroke tuning), general inspection. Repair And Rebuild: Complete engine rebuilds, carburetor overhaul, brake system repairs, suspension component replacement, electrical component diagnosis and repair, bodywork repair. Troubleshooting: Diagnostic procedures for common and uncommon faults, problem identification, step-by-step troubleshooting guides for electrical and mechanical issues. Technical Depth Depth: Comprehensive, covering everything from basic maintenance to complete engine and chassis overhauls. Designed for both professional technicians and experienced DIY enthusiasts. 📊 Manual Specifications File Format Digital Format: PDF Print Quality Printability: Full Printable Binding Type Delivery Method: Instant Download (No physical binding, digital delivery) Paper Type Digital Medium: Digital file (for display on screen or print on demand) Software Requirements Reader Software: Adobe PDF Reader Extraction Software: WinRAR (or compatible archive utility) Compatibility Operating Systems: All versions of Windows and Mac OS ⚙️ Engine Specifications Primary Engine Type: 2-Stroke, Liquid-Cooled, Single-Cylinder Displacement: 124.7 cc Bore X Stroke: 56.4 mm x 50.0 mm (typical, may vary slightly by sub-model) Compression Ratio: 7.2:1 (typical, for unleaded fuel) Performance Horsepower: Approx. 20-30 PS (14.7-22 kW) at 10,000-11,000 RPM (depending on market regulations and specific model variant) Torque: Approx. 15-18 Nm at 9,500-10,500 RPM (depending on market regulations and specific model variant) Fuel System Carburetor: Mikuni VM28SS (or similar 28mm slide carburetors) Fuel Type: Unleaded gasoline (minimum 91 RON) Lubrication System: Premix or Autolube (Yamaha Hand-o-Matic oil injection system) Ignition Type: CDI (Capacitor Discharge Ignition) Cooling System: Liquid-cooled Coolant Type: Yamaha Hi-Performance All-Season Motorcycle Coolant or equivalent (50/50 mix of ethylene glycol and distilled water) 🔧 Transmission Standard Type: 6-Speed Constant Mesh Features Clutch: Wet, Multi-plate Final Drive: Chain Drive Transmission Oil Type: Yamalube 2R or SAE 10W-40 API SE (or higher) API SF/SG lubricant (refer to manual for precise specification) 📐 Dimensions Exterior Length: Approx. 1,970 mm Width: Approx. 725 mm Height: Approx. 1,105 mm Weights Dry Weight: Approx. 126 kg Wet Weight: Approx. 136 kg (with fluids) Fuel Capacity Tank Capacity: 14 Liters (including reserve) Wheelbase Wheelbase: Approx. 1,335 mm 🛡️ Safety Features Ratings Braking System: Front: Hydraulic Disc (270mm), Rear: Hydraulic Disc (210mm) Active Features Tires Front: 100/80-17 M/C 52S (tubeless) Tires Rear: 120/80-17 M/C 61S (tubeless) Passive Features Lighting: Halogen Headlight, LED Tail Light (depending on sub-model variant) 💡 Technology Features Infotainment Instrument Cluster: Analog speedometer, tachometer, coolant temperature gauge, neutral indicator, turn signal indicators, high beam indicator. Driver Assistance Ypvs System: Yamaha Power Valve System (YPVS) controlled by a servo motor to optimize exhaust port timing for improved torque and power across the RPM range. Connectivity Diagnostic Ports: Not applicable for this era; diagnosis relies on visual inspection, physical checks, and interpretation of symptoms. 🔧 Maintenance Service Intervals Oil Change: Every 3,000 km or 6 months (refer to manual for specific gearbox oil) Spark Plug Inspection: Every 2,000 km Air Filter Cleaning: Every 3,000 km Chain Lubrication Adjustment: Every 1,000 km or after riding in wet conditions Fluid Specifications Brake Fluid: DOT 3 or DOT 4 (refer to manual for specific recommendation) 2-Stroke Oil: Yamalube 2R or equivalent high-quality 2-stroke oil (specifically for premix or autolube system) Known Issues Common Problems: Carburetor tuning sensitivity, wear on YPVS mechanism, aging electrical components (e.g., regulator/rectifier), front fork seal leaks, exhaust port blockages due to 2-stroke residue. 📚 Vehicle History Brand Heritage Legacy: Yamaha's long history of producing performance-oriented motorcycles, particularly in the sportbike and racing...
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Yamaha TZR125 1987-1993 Full Service Repair Manual
🏷️ Basic Information
Identification
Make:
Yamaha
Model:
TZR125
Generation:
2TR/3ET
Model Years Covered:
1987, 1988, 1989, 1990, 1991, 1992, 1993
Codes
Chassis Codes:
2RM, 2RN, 2RW, 2RX, 3ET, 3KC
👋 Introduction
Market Position
Segment:
Lightweight Sportbike / Supersport (125cc class)
Competitive Analysis
Key Rivals:
Honda NSR125R, Suzuki RG125 Gamma, Aprilia RS125, Cagiva Mito 125.
Key Features
Technological Highlights:
YPVS (Yamaha Power Valve System) for improved power delivery, liquid cooling, advanced chassis design for its class, aggressive styling.
Target Audience
Intended Users:
Yamaha TZR125 owners, mechanics, restorers, hobbyists requiring detailed service and repair information.
📋 Manual Details
Coverage Areas
Manual Scope:
Full Service Repair
Page Count
Estimated Pages:
Comprehensive (Specific page count not provided, typical for this era of sportbike manuals would be 300-500+ pages)
Manual Type
Type:
Factory Service Manual (FSM) Equivalent / Professional Repair Manual
Language
Language:
English
Format
File Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, disassembly, inspection, tuning, lubrication, cooling system, fuel system (carburetor, ignition), exhaust system.
Chassis And Suspension:
Frame, front fork (telescopic, damping, seals), rear suspension (monoshock, linkage, adjustments), steering system, wheels, tires, brakes (front and rear disc, hydraulic system, calipers, master cylinders).
Electrical System:
Wiring diagrams, ignition system, lighting, charging system (stator, regulator/rectifier, battery), starter motor, indicators, horn, fuses, troubleshooting.
Bodywork And Trim:
Fairings, seat, fuel tank, fenders, graphics, fasteners, removal and installation procedures.
Procedures Included
Maintenance:
Scheduled maintenance, fluid changes (oil, coolant, brake fluid), filter replacements, chain adjustment, spark plug replacement, valve clearance check (if applicable to 2-stroke tuning), general inspection.
Repair And Rebuild:
Complete engine rebuilds, carburetor overhaul, brake system repairs, suspension component replacement, electrical component diagnosis and repair, bodywork repair.
Troubleshooting:
Diagnostic procedures for common and uncommon faults, problem identification, step-by-step troubleshooting guides for electrical and mechanical issues.
Technical Depth
Depth:
Comprehensive, covering everything from basic maintenance to complete engine and chassis overhauls. Designed for both professional technicians and experienced DIY enthusiasts.
📊 Manual Specifications
File Format
Digital Format:
PDF
Print Quality
Printability:
Full Printable
Binding Type
Delivery Method:
Instant Download (No physical binding, digital delivery)
Paper Type
Digital Medium:
Digital file (for display on screen or print on demand)
Software Requirements
Reader Software:
Adobe PDF Reader
Extraction Software:
WinRAR (or compatible archive utility)
Compatibility
Operating Systems:
All versions of Windows and Mac OS
⚙️ Engine Specifications
Primary Engine
Type:
2-Stroke, Liquid-Cooled, Single-Cylinder
Displacement:
124.7 cc
Bore X Stroke:
56.4 mm x 50.0 mm (typical, may vary slightly by sub-model)
Compression Ratio:
7.2:1 (typical, for unleaded fuel)
Performance
Horsepower:
Approx. 20-30 PS (14.7-22 kW) at 10,000-11,000 RPM (depending on market regulations and specific model variant)
Torque:
Approx. 15-18 Nm at 9,500-10,500 RPM (depending on market regulations and specific model variant)
Fuel System
Carburetor:
Mikuni VM28SS (or similar 28mm slide carburetors)
Fuel Type:
Unleaded gasoline (minimum 91 RON)
Lubrication
System:
Premix or Autolube (Yamaha Hand-o-Matic oil injection system)
Ignition
Type:
CDI (Capacitor Discharge Ignition)
Cooling
System:
Liquid-cooled
Coolant Type:
Yamaha Hi-Performance All-Season Motorcycle Coolant or equivalent (50/50 mix of ethylene glycol and distilled water)
🔧 Transmission
Standard
Type:
6-Speed Constant Mesh
Features
Clutch:
Wet, Multi-plate
Final Drive:
Chain Drive
Transmission Oil Type:
Yamalube 2R or SAE 10W-40 API SE (or higher) API SF/SG lubricant (refer to manual for precise specification)
📐 Dimensions
Exterior
Length:
Approx. 1,970 mm
Width:
Approx. 725 mm
Height:
Approx. 1,105 mm
Weights
Dry Weight:
Approx. 126 kg
Wet Weight:
Approx. 136 kg (with fluids)
Fuel Capacity
Tank Capacity:
14 Liters (including reserve)
Wheelbase
Wheelbase:
Approx. 1,335 mm
🛡️ Safety Features
Ratings
Braking System:
Front: Hydraulic Disc (270mm), Rear: Hydraulic Disc (210mm)
Active Features
Tires Front:
100/80-17 M/C 52S (tubeless)
Tires Rear:
120/80-17 M/C 61S (tubeless)
Passive Features
Lighting:
Halogen Headlight, LED Tail Light (depending on sub-model variant)
💡 Technology Features
Infotainment
Instrument Cluster:
Analog speedometer, tachometer, coolant temperature gauge, neutral indicator, turn signal indicators, high beam indicator.
Driver Assistance
Ypvs System:
Yamaha Power Valve System (YPVS) controlled by a servo motor to optimize exhaust port timing for improved torque and power across the RPM range.
Connectivity
Diagnostic Ports:
Not applicable for this era; diagnosis relies on visual inspection, physical checks, and interpretation of symptoms.
🔧 Maintenance
Service Intervals
Oil Change:
Every 3,000 km or 6 months (refer to manual for specific gearbox oil)
Spark Plug Inspection:
Every 2,000 km
Air Filter Cleaning:
Every 3,000 km
Chain Lubrication Adjustment:
Every 1,000 km or after riding in wet conditions
Fluid Specifications
Brake Fluid:
DOT 3 or DOT 4 (refer to manual for specific recommendation)
2-Stroke Oil:
Yamalube 2R or equivalent high-quality 2-stroke oil (specifically for premix or autolube system)
Known Issues
Common Problems:
Carburetor tuning sensitivity, wear on YPVS mechanism, aging electrical components (e.g., regulator/rectifier), front fork seal leaks, exhaust port blockages due to 2-stroke residue.
📚 Vehicle History
Brand Heritage
Legacy:
Yamaha's long history of producing performance-oriented motorcycles, particularly in the sportbike and racing segments.
Model Evolution
Tzr Lineage:
Part of Yamaha's renowned TZR series, known for its 2-stroke performance and Grand Prix inspired styling, following earlier models like the TZR250.
Production
Manufacturing Era:
Popular in the late 1980s and early 1990s, representing Yamaha's entry into the competitive 125cc supersport class.
🏆 Awards & Recognition
Recognitions
Market Reception:
Highly regarded in its class for its performance, handling, and styling, making it a popular choice for aspiring sportbike riders and club racing.
Certifications
Emissions:
Compliant with market-specific emissions regulations of its production era. Manual provides details on emissions control systems.
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