YAMAHA WR 125R 2009 Service Manual

PERIODIC MAINTENANCE AND ADJUSTMENT
6-5
6
19*Front forkCheck operation and for oil leak-
age.√√√√
20*Shock absorber as-
semblyCheck operation and shock ab-
sorber for oil leakage.√√√√
21*Rear suspension re-
lay arm and con-
necting arm
pivoting pointsCheck operation.√√√√
Lubricate with lithium-soap-based
grease.√√
22 Engine oilChange. (See page 3-3.)√When the oil change indicator flashes [2000 km (1200 mi) after
the initial 1000 km (600 mi) and every 3000 km (1800 mi) thereaf-
ter]
Check oil level and vehicle for oil
leakage.Every 3000 km (1800 mi)√
23Engine oil filter ele-
mentReplace.√√√√√
24*Cooling systemCheck coolant level and vehicle
for coolant leakage.√√√√√
Change. Every 3 years
25*Front and rear brake
switchesCheck operation.√√√√√√
26Moving parts and
cablesLubricate.√√√√√
27*Throttle grip hous-
ing and cableCheck operation and free play.
Adjust the throttle cable free play
if necessary.
Lubricate the throttle grip housing
and cable.√√√√√ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING
ANNUAL
CHECK 1000 km
(600 mi)6000 km
(3500 mi)12000 km
(7000 mi)18000 km
(10500 mi)24000 km
(14000 mi)
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-6
6
EAUM2070
TIP

The air filter needs more frequent service if you are riding in unusually wet or dusty areas.


Hydraulic brake service
Regularly check and, if necessary, correct the brake fluid level.
Every two years change the brake fluid.Replace the brake hoses every four years and if cracked or damaged.
28*Lights, signals and
switchesCheck operation.
Adjust headlight beam.√√√√√√ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING
ANNUAL
CHECK 1000 km
(600 mi)6000 km
(3500 mi)12000 km
(7000 mi)18000 km
(10500 mi)24000 km
(14000 mi)U22BE0E0.book Page 6 Wednesday, December 17, 2008 11:00 AM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-7
6
EAU18771
Removing and installing pan-
els The panels shown need to be removed
to perform some of the maintenance
jobs described in this chapter. Refer to
this section each time a panel needs to
be removed and installed.
EAU19210
Panel A
To remove the panelRemove the screws, and then take the
panel off.To install the panel
Place the panel in the original position,
and then install the screws.
EAU19210
Panel B
To remove the panelRemove the screws, and then take the
panel off.To install the panel
Place the panel in the original position,
and then install the screws.
1. Panel A
2. Panel B
1. Screw
2. Panel A
1. Screw
2. Panel B
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-8
6
EAU19603
Checking the spark plug The spark plug is an important engine
component, which is easy to check.
Since heat and deposits will cause any
spark plug to slowly erode, the spark
plug should be removed and checked
in accordance with the periodic mainte-
nance and lubrication chart. In addition,
the condition of the spark plug can re-
veal the condition of the engine.
To remove the spark plug
1. Remove the spark plug cap.
2. Remove the spark plug as shown,
with the spark plug wrench includ-
ed in the owner’s tool kit.To check the spark plug
1. Check that the porcelain insulator
around the center electrode of the
spark plug is a medium-to-light tan
(the ideal color when the vehicle is
ridden normally).
TIPIf the spark plug shows a distinctly dif-
ferent color, the engine could be oper-
ating improperly. Do not attempt to
diagnose such problems yourself. In-
stead, have a Yamaha dealer checkthe vehicle.2. Check the spark plug for electrode
erosion and excessive carbon or
other deposits, and replace it if
necessary.
To install the spark plug
1. Measure the spark plug gap with a
wire thickness gauge and, if nec-
essary, adjust the gap to specifica-
tion.
1. Spark plug cap
1. Spark plug wrench
Specified spark plug:
NGK/CR8E1. Spark plug gapSpark plug gap:
0.7–0.8 mm (0.028–0.031 in)
1
ZAUM0037
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-9
6 2. Clean the surface of the spark plug
gasket and its mating surface, and
then wipe off any grime from the
spark plug threads.
3. Install the spark plug with the
spark plug wrench, and then tight-
en it to the specified torque.
TIPIf a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4–1/2 turn
past finger tight. However, the spark
plug should be tightened to the speci-fied torque as soon as possible.
4. Install the spark plug cap.
EAUM2582
Engine oil and oil filter ele-
ment The engine oil level should be checked
before each ride. In addition, the oil
must be changed and the oil filter ele-
ment replaced at the intervals specified
in the periodic maintenance and lubri-
cation chart.
To check the engine oil level
1. Place the vehicle on a level sur-
face and hold it in an upright posi-
tion. A slight tilt to the side can
result in a false reading.
2. Start the engine, warm it up for
several minutes, and then turn it
off.
3. Wait a few minutes until the oil set-
tles, remove the oil filler cap, wipe
the dipstick clean, insert it back
into the oil filler hole (without
screwing it in), and then remove it
again to check the oil level.
NOTICE: Do not operate the ve-
hicle until you know that the en-
gine oil level is sufficient.
[ECA10011]
TIPThe engine oil should be between theminimum and maximum level marks.
Tightening torque:
Spark plug:
12.5 Nm (1.25 m·kgf, 9.0 ft·lbf)
1. Engine oil filler cap
1. Dipstick
2. Maximum level mark
3. Minimum level mark
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-10
64. If the engine oil is below the mini-
mum level mark, add sufficient oil
of the recommended type to raise
it to the correct level.
5. Install the oil filler cap.
To change the engine oil (with or
without oil filter element replace-
ment)
1. Start the engine, warm it up for
several minutes, and then turn it
off.
2. Place an oil pan under the engine
to collect the used oil.
3. Remove the engine oil filler cap
and the drain bolt along with the O-
ring, compression spring, and en-
gine oil strainer, to drain the oil
from the crankcase. NOTICE:
When removing the engine oil
drain bolt, the O-ring, compres-
sion spring, and oil strainer will
fall out. Take care not to lose
these parts.
[ECA11001]
4. Clean the engine oil strainer with
solvent.TIPSkip steps 5–7 if the oil filter element isnot being replaced.
5. Remove the oil filter element cover
by removing the bolts.6. Remove and replace the oil filter
element and O-ring.
7. Install the oil filter element cover by
installing the bolts, then tightening
them to the specified torque.1. Engine oil drain bolt
2. O-ring
3. Compression spring
4. Strainer
1. Bolt
2. Oil filter element cover
1. Oil filter element
2. O-ring
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-11
6
TIPMake sure that the O-ring is properlyseated.
8. Install the engine oil strainer, com-
pression spring, O-ring and the en-
gine oil drain bolt, and then tighten
it to the specified torque. NOTICE:
Before installing the engine oil
drain bolt, do not forget to in-
stall the O-ring, compression
spring, and oil strainer in posi-
tion.
[ECA10421]
9. Refill with the specified amount of
the recommended engine oil, and
then install and tighten the oil filler
cap.
NOTICE
ECA11620


In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives. Do
not use oils with a diesel speci-
fication of “CD” or oils of a high-
er quality than specified. In
addition, do not use oils labeled
“ENERGY CONSERVING II” or
higher.


Make sure that no foreign mate-rial enters the crankcase.
10. Start the engine, and then let it idle
for several minutes while checking
it for oil leakage. If oil is leaking, im-
mediately turn the engine off and
check for the cause.11. Turn the engine off, and then
check the oil level and correct it if
necessary.
Tightening torque:
Oil filter element cover bolt:
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Tightening torque:
Engine oil drain bolt:
32 Nm (3.2 m·kgf, 23 ft·lbf)
Recommended engine oil:
See page 8-1.
Oil quantity:
Without oil filter element replace-
ment:
0.95 L (1.00 US qt, 0.84 Imp.qt)
With oil filter element replacement:
1.00 L (1.06 US qt, 0.88 Imp.qt)
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-12
6
EAU20070
Coolant The coolant level should be checked
before each ride. In addition, the cool-
ant must be changed at the intervals
specified in the periodic maintenance
and lubrication chart.
EAUM2592
To check the coolant level
1. Place the vehicle on a level sur-
face and hold it in an upright posi-
tion.TIP

The coolant level must be checked
on a cold engine since the level
varies with engine temperature.


Make sure that the vehicle is posi-
tioned straight up when checking
the coolant level. A slight tilt to theside can result in a false reading.
2. Check the coolant level in the cool-
ant reservoir.
TIPThe coolant should be between theminimum and maximum level marks.3. If the coolant is at or below the
minimum level mark, remove the
seat (See page 3-10.), and then
open the coolant reservoir cap.4. Add coolant or distilled water to
raise the coolant to the specified
level, close the coolant reservoir
cap, and then install the seat.
WARNING! Remove only the
coolant reservoir cap. Never at-
tempt to remove the radiator
cap when the engine is hot.
[EWA15161]
NOTICE: If coolant is not
available, use distilled water or
soft tap water instead. Do not
use hard water or salt water
since it is harmful to the engine.
If water has been used instead
of coolant, replace it with cool-
ant as soon as possible, other-
wise the cooling system will not
be protected against frost and
corrosion. If water has been
added to the coolant, have a
Yamaha dealer check the anti-
freeze content of the coolant as
soon as possible, otherwise the
effectiveness of the coolant will
be reduced.
[ECA10472]
1. Coolant reservoir
2. Maximum level mark
3. Minimum level mark
1. Coolant reservoir cap
Coolant reservoir capacity:
0.25 L (0.26 US qt, 0.22 Imp.qt)
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-13
6
EAU33031
Changing the coolant
The coolant must be changed at the in-
tervals specified in the periodic mainte-
nance and lubrication chart. Have a
Yamaha dealer change the coolant.
WARNING! Never attempt to remove
the radiator cap when the engine is
hot.
[EWA10381]EAUM2390
Replacing the air filter element
and cleaning the check hose The air filter element should be re-
placed at the intervals specified in the
periodic maintenance and lubrication
chart. Have a Yamaha dealer replace
the air filter element more frequently if
you are riding in unusually wet or dusty
areas. In addition, the air filter check
hose must be frequently checked and
cleaned if necessary.
To clean the air filter check hose
1. Check the hose on the side of the
air filter case for accumulated dirt
or water.2. If dirt or water is visible, remove
the hose, clean it, and then install
it.1. Air filter check hose
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-14
6
EAUM1911
Adjusting the engine idling
speed The engine idling speed must be
checked and, if necessary, adjusted as
follows at the intervals specified in the
periodic maintenance and lubrication
chart.
The engine should be warm before
making this adjustment.TIPA diagnostic tachometer is needed tomake this adjustment.
1. Attach the tachometer to the spark
plug lead.
2. Check the engine idling speed
and, if necessary, adjust it to spec-
ification by turning the idle adjust-
ing screw. To increase the engine
idling speed, turn the screw in di-
rection (a). To decrease the en-
gine idling speed, turn the screw in
direction (b).
TIPIf the specified idling speed cannot be
obtained as described above, have aYamaha dealer make the adjustment.
EAU21370
Adjusting the throttle cable
free play The throttle cable free play should mea-
sure 3.0–5.0 mm (0.12–0.20 in) at the
throttle grip. Periodically check the
throttle cable free play and, if neces-
sary, adjust it as follows.TIPThe engine idling speed must be cor-
rectly adjusted before checking and ad-justing the throttle cable free play.
1. Loosen the locknut.
1. Idle adjusting screwEngine idling speed:
1400–1600 r/min
1. Throttle cable free play
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