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Yamaha YJ125 2003-2010 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Yamaha Model: YJ125 Codes Internal Model Code: YJ125 (Model variations may exist depending on region) 👋 Introduction Market Position Vehicle Segment: Lightweight scooter, utility/commuter segment Competitive Analysis Competitors: Honda Lead 125, Suzuki Address 125, Kymco Agility 125, SYM Jet 125 (depending on specific market) Key Features Design Purpose: Designed for urban commuting, providing a balance of fuel efficiency, maneuverability, and reliability. Manual Purpose: Essential resource for all maintenance, repair, and diagnostic needs for the Yamaha YJ125, ensuring longevity and optimal performance. 📋 Manual Details Coverage Areas Years Covered: 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010 Page Count Estimated Pages: Hundreds (exact count varies, but substantial) Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Systems: Engine disassembly, assembly, inspection, tuning, lubrication, cooling, fuel, ignition, exhaust, starting, charging Transmission Drivetrain: Transmission operation, inspection, repair, final drive, clutch Chassis Suspension: Frame, front fork, rear shock absorber, swingarm, wheel bearings, steering Braking System: Brake system maintenance, inspection, repair, bleeding, component replacement (discs, pads, calipers, master cylinders) Electrical System: Wiring diagrams, battery, charging system (alternator/stator, rectifier/regulator), ignition system, lighting, instrumentation, starter motor Fuel System: Carburetor disassembly, cleaning, adjustment, fuel pump, fuel tank, fuel lines Body And Trim: Body panel removal/installation, seat, fairings, fenders, trim pieces Procedures Included Maintenance Procedures: Routine maintenance, oil changes, filter replacements, spark plug service, chain adjustment, brake pad inspection/replacement, tire pressure checks Troubleshooting Guides: Systematic diagnostics for common and uncommon issues, fault finding charts Repair Procedures: Step-by-step instructions for component disassembly, repair, and reassembly Overhaul Procedures: Detailed instructions for engine and transmission overhauls Wiring Diagrams: Comprehensive electrical schematics for all systems Technical Depth Depth Level: Comprehensive factory-level detail, suitable for professional technicians and experienced DIY enthusiasts 📊 Manual Specifications File Format File Type: Portable Document Format (PDF) Print Quality Quality: High-resolution scans of original factory documentation, ensuring clarity of text and diagrams Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, air-cooled, SOHC Displacement: Approximately 125cc (Specific bore and stroke figures detailed in manual) Bore X Stroke: Refer to manual for precise dimensions Compression Ratio: Refer to manual for specific ratio Performance Horsepower: Typically in the 8-10 HP range (exact figures vary by market and tuning) Torque: Torque figures available in manual for optimal tuning Fuel System Carburetor Type: CV (Constant Velocity) carburetor, specific model detailed in manual (e.g., Mikuni VM series) Fuel Type: Unleaded gasoline Fuel Capacity: Approximately 5-6 Liters (specific capacity detailed in manual) 🔧 Transmission Standard Transmission Type: Automatic CVT (Continuously Variable Transmission) Drive Type: Belt drive to rear wheel Features Clutch Type: Automatic centrifugal clutch 📐 Dimensions Exterior Overall Length: Refer to manual for exact dimensions Overall Width: Refer to manual for exact dimensions Overall Height: Refer to manual for exact dimensions Weights Dry Weight: Approx. 100-110 kg (Specific figures in manual) Curb Weight: Refer to manual for precise curb weight 🛡️ Safety Features Ratings Safety Standards: Complies with applicable safety regulations for its class in various markets. Specific certifications not typically detailed in service manuals but implicit in design. Active Features Braking System: Disc front brake, drum rear brake (common configuration; check manual for variations). ABS typically not present on this model. Passive Features Lighting: Headlight, taillight, brake light, turn signals for visibility. 💡 Technology Features Infotainment Instrument Cluster: Analog speedometer, fuel gauge, odometer, trip meter, indicator lights (turn signals, oil, high beam). Specific cluster design may vary. Driver Assistance ABS: Anti-lock Braking System (ABS) is typically not a feature on this model. Connectivity Charging Ports: 12V accessory socket (optional or standard depending on market/trim) for charging devices is possible, but not standard on all models. Manual may show wiring for this. 🔧 Maintenance Service Intervals Oil Change Interval: Refer to manual for specific mileage/time interval (e.g., every 3,000-5,000 km or annually). Air Filter Cleaning Replacement: Refer to manual for specific interval. Spark Plug Replacement: Refer to manual for specific interval. Fluid Specifications Engine Oil Type: Yamalube (or equivalent) SAE 10W-30 or 20W-40 API SG or higher, JASO MA recommended. Specific viscosity based on ambient temperature is detailed in the manual. Engine Oil Capacity: Refer to manual for exact capacity (e.g., ~0.8-1.0 liters). Brake Fluid Type: DOT 3 or DOT 4 (refer to manual for specific recommendation and replacement intervals). Gear Oil Type: Refer to manual for specific gear oil specification and capacity (typically API GL-3 or GL-4). Known Issues Common Wear Items: Tires, brake pads, drive belt, spark plugs, air filter, battery. Manual provides wear limits and replacement procedures. Carburetor Issues: Can be prone to gumming if fuel sits; requires periodic cleaning and adjustment. Manual details proper cleaning procedures. 📚 Vehicle History Brand Heritage Yamaha History: Yamaha Motor Company, established in 1955, has a rich history...
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Yamaha YJ125 2003-2010 Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
Yamaha
Model:
YJ125
Codes
Internal Model Code:
YJ125 (Model variations may exist depending on region)
👋 Introduction
Market Position
Vehicle Segment:
Lightweight scooter, utility/commuter segment
Competitive Analysis
Competitors:
Honda Lead 125, Suzuki Address 125, Kymco Agility 125, SYM Jet 125 (depending on specific market)
Key Features
Design Purpose:
Designed for urban commuting, providing a balance of fuel efficiency, maneuverability, and reliability.
Manual Purpose:
Essential resource for all maintenance, repair, and diagnostic needs for the Yamaha YJ125, ensuring longevity and optimal performance.
📋 Manual Details
Coverage Areas
Years Covered:
2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010
Page Count
Estimated Pages:
Hundreds (exact count varies, but substantial)
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine disassembly, assembly, inspection, tuning, lubrication, cooling, fuel, ignition, exhaust, starting, charging
Transmission Drivetrain:
Transmission operation, inspection, repair, final drive, clutch
Chassis Suspension:
Frame, front fork, rear shock absorber, swingarm, wheel bearings, steering
Braking System:
Brake system maintenance, inspection, repair, bleeding, component replacement (discs, pads, calipers, master cylinders)
Electrical System:
Wiring diagrams, battery, charging system (alternator/stator, rectifier/regulator), ignition system, lighting, instrumentation, starter motor
Fuel System:
Carburetor disassembly, cleaning, adjustment, fuel pump, fuel tank, fuel lines
Body And Trim:
Body panel removal/installation, seat, fairings, fenders, trim pieces
Procedures Included
Maintenance Procedures:
Routine maintenance, oil changes, filter replacements, spark plug service, chain adjustment, brake pad inspection/replacement, tire pressure checks
Troubleshooting Guides:
Systematic diagnostics for common and uncommon issues, fault finding charts
Repair Procedures:
Step-by-step instructions for component disassembly, repair, and reassembly
Overhaul Procedures:
Detailed instructions for engine and transmission overhauls
Wiring Diagrams:
Comprehensive electrical schematics for all systems
Technical Depth
Depth Level:
Comprehensive factory-level detail, suitable for professional technicians and experienced DIY enthusiasts
📊 Manual Specifications
File Format
File Type:
Portable Document Format (PDF)
Print Quality
Quality:
High-resolution scans of original factory documentation, ensuring clarity of text and diagrams
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Four-stroke, air-cooled, SOHC
Displacement:
Approximately 125cc (Specific bore and stroke figures detailed in manual)
Bore X Stroke:
Refer to manual for precise dimensions
Compression Ratio:
Refer to manual for specific ratio
Performance
Horsepower:
Typically in the 8-10 HP range (exact figures vary by market and tuning)
Torque:
Torque figures available in manual for optimal tuning
Fuel System
Carburetor Type:
CV (Constant Velocity) carburetor, specific model detailed in manual (e.g., Mikuni VM series)
Fuel Type:
Unleaded gasoline
Fuel Capacity:
Approximately 5-6 Liters (specific capacity detailed in manual)
🔧 Transmission
Standard
Transmission Type:
Automatic CVT (Continuously Variable Transmission)
Drive Type:
Belt drive to rear wheel
Features
Clutch Type:
Automatic centrifugal clutch
📐 Dimensions
Exterior
Overall Length:
Refer to manual for exact dimensions
Overall Width:
Refer to manual for exact dimensions
Overall Height:
Refer to manual for exact dimensions
Weights
Dry Weight:
Approx. 100-110 kg (Specific figures in manual)
Curb Weight:
Refer to manual for precise curb weight
🛡️ Safety Features
Ratings
Safety Standards:
Complies with applicable safety regulations for its class in various markets. Specific certifications not typically detailed in service manuals but implicit in design.
Active Features
Braking System:
Disc front brake, drum rear brake (common configuration; check manual for variations). ABS typically not present on this model.
Passive Features
Lighting:
Headlight, taillight, brake light, turn signals for visibility.
💡 Technology Features
Infotainment
Instrument Cluster:
Analog speedometer, fuel gauge, odometer, trip meter, indicator lights (turn signals, oil, high beam). Specific cluster design may vary.
Driver Assistance
ABS:
Anti-lock Braking System (ABS) is typically not a feature on this model.
Connectivity
Charging Ports:
12V accessory socket (optional or standard depending on market/trim) for charging devices is possible, but not standard on all models. Manual may show wiring for this.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Refer to manual for specific mileage/time interval (e.g., every 3,000-5,000 km or annually).
Air Filter Cleaning Replacement:
Refer to manual for specific interval.
Spark Plug Replacement:
Refer to manual for specific interval.
Fluid Specifications
Engine Oil Type:
Yamalube (or equivalent) SAE 10W-30 or 20W-40 API SG or higher, JASO MA recommended. Specific viscosity based on ambient temperature is detailed in the manual.
Engine Oil Capacity:
Refer to manual for exact capacity (e.g., ~0.8-1.0 liters).
Brake Fluid Type:
DOT 3 or DOT 4 (refer to manual for specific recommendation and replacement intervals).
Gear Oil Type:
Refer to manual for specific gear oil specification and capacity (typically API GL-3 or GL-4).
Known Issues
Common Wear Items:
Tires, brake pads, drive belt, spark plugs, air filter, battery. Manual provides wear limits and replacement procedures.
Carburetor Issues:
Can be prone to gumming if fuel sits; requires periodic cleaning and adjustment. Manual details proper cleaning procedures.
📚 Vehicle History
Brand Heritage
Yamaha History:
Yamaha Motor Company, established in 1955, has a rich history in manufacturing motorcycles, scooters, and marine products, known for innovation and performance.
Model Evolution
Yj125 Lineage:
The YJ125 is part of Yamaha's scooter lineup, evolving from earlier models to meet commuter demands. Specific evolution details are not typically in a single service manual but implied by the model generation.
Production
Manufacturing Location:
Typically manufactured in Asia (specific country may vary by market, e.g., Indonesia, Taiwan, China).
🏆 Awards & Recognition
Recognitions
Model Awards:
Specific industry awards for the YJ125 are not widely documented as a mass-market commuter scooter; its success is measured in utility and sales figures.
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