🏷️ Basic Information Identification Make: Yamaha Model: TZ125 Model Codes: TZ125G, TZ125G1, TZM Vehicle Type: Competition Motorcycle (2-stroke) Production Years Covered: 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005 Manual Product Name: Yamaha TZ125 Factory Repair Manual 1990-2005 Download PDF 👋 Introduction Market Position Target Audience: Do-it-yourself enthusiasts and experienced mechanics. Value Proposition: Inexpensive alternative to dealer servicing, comprehensive repair and maintenance resource. Competitive Analysis Alternatives: Dealer service manuals (often more expensive and less accessible), aftermarket repair guides (may lack factory detail). Key Features Completeness: COMPLETE factory service workshop repair manual. Accessibility: Instant download, no shipping or waiting required. Instructional Style: Numbered instructions, bold figure numbers for quick illustration matching. 📋 Manual Details Coverage Areas Manual Type: Factory Service Workshop Repair Manual Page Count: 300 pages (printable) Language: English (assumed, typical for factory manuals) Format: PDF Download Coverage Scope: All styles covered within the specified production years 📖 Manual Coverage Systems Covered Engine: Complete disassembly, assembly, tuning, and troubleshooting of the 125cc 2-stroke engine. Transmission: Gearbox inspection, repair, and adjustment procedures. Clutch: Wet multi-plate clutch service, adjustment, and component replacement. Cooling System: Liquid cooling system maintenance, radiator service, and coolant specifications. Fuel System: Carburetor (likely Mikuni VM series) tuning, overhaul, and jetting specifications. Fuel tank and line service. Ignition System: CDI ignition system, spark plug selection, timing checks, and troubleshooting. Electrical System: Comprehensive wiring diagrams, lighting system, charging system (stator/generator), and troubleshooting for electrical faults. Exhaust System: Expansion chamber maintenance, exhaust port cleaning, and tuning considerations. Suspension Front: Front fork (likely upside-down) disassembly, oil change, seal replacement, and damping adjustments. Suspension Rear: Monoshock rear suspension service, linkage maintenance, and shock absorber adjustment. Brakes Front: Hydraulic disc brake system service, caliper overhaul, pad replacement, and bleeding procedures. Brakes Rear: Hydraulic disc brake system service, caliper overhaul, pad replacement, and bleeding procedures. Wheels And Tires: Wheel bearing service, tire mounting and balancing, rim specifications. Frame And Bodywork: Frame inspection, fairing removal and installation, seat, and tank components. Controls: Throttle, clutch, and brake lever adjustment and replacement. Procedures Included Routine Maintenance: Oil changes, filter replacements, chain adjustment, spark plug service, general inspection. Engine Rebuild: Top-end rebuild (piston, rings, cylinder), bottom-end rebuild (crankshaft, bearings), complete engine overhaul. Troubleshooting: Step-by-step diagnostic procedures for common and uncommon problems across all systems. Electrical Diagnostics: Detailed guidance for diagnosing and repairing electrical issues using wiring diagrams. Suspension Tuning: Instructions for adjusting damping, spring preload, and fork oil levels for optimal performance. Carburetor Tuning: Jetting charts, idle speed adjustment, mixture control, and float level settings. Brake System Overhaul: Caliper seal replacement, piston servicing, master cylinder repair, and fluid bleeding. Component Replacement: Detailed instructions for replacing all major and minor components. Technical Depth Depth: Comprehensive (from basic maintenance to complete engine and chassis rebuilds). Detail Level: Detailed substeps, critical notes, cautions, and warnings. Illustrations: Hundreds of photos and detailed illustrations, drawings, and enlarged insets. Troubleshooting Aid: Dedicated troubleshooting sections and integrated electrical system diagnostics. 📊 Manual Specifications File Format File Type: PDF Compatibility: Windows and Mac operating systems Searchability: Likely searchable text within the PDF (standard for factory manuals). Print Quality Printability: All pages are printable, allowing for selective or full manual printing. Output Options: Print to paper, print to CD-ROM. Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download, user printable on desired paper) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 2-stroke, reed valve induction Displacement: 124 cc (approximate, specific variations may exist across years) Bore X Stroke: Typically around 56.0 mm x 50.0 mm (exact specifications in manual) Compression Ratio: Variable by year and tuning, generally high for competition use (e.g., 8.5:1 to 10.5:1 or higher for racing tunes). Performance Horsepower: Speculative, but typically in the 30-40 HP range for a well-tuned TZ125 of this era, higher for race-prepped models. Torque: Speculative, but proportional to horsepower. Fuel System Carburetor Type: Single Mikuni VM series (e.g., VM28 or VM30, specific to year and model variant). Fuel Type: Unleaded gasoline mixed with 2-stroke oil (pre-mix or Autolube system, depending on variant). Octane rating as per Yamaha recommendation, likely premium. Lubrication Lubrication Type: Premix or Autolube (oil injection system). 🔧 Transmission Standard Transmission Type: 6-speed constant mesh Clutch Type: Wet, multi-plate Features Gear Ratios: Specific ratios provided in the manual, crucial for racing setup. Final Drive: Chain drive 📐 Dimensions Exterior Wheelbase: Varies by year and specific race configuration, typically around 1350-1400 mm. Overall Length: Varies by year and specific race configuration. Weights Dry Weight: Typically around 90-100 kg, depending on year and specific race components. Wet Weight: Weight with all fluids, higher than dry weight. 🛡️ Safety Features Ratings Safety Rating: N/A (Competition motorcycle, not subject to road vehicle safety ratings like NHTSA or Euro NCAP). Active Features Braking System: Powerful hydraulic disc brakes front and rear, designed...