Yamaha Raptor 125 (YFM125RA), 2011 ATV Service Manual (P/N LIT-11616-24-36)

Yamaha’s 2011 service manual covers the Raptor 125 YFM125RA, including USA, Canadian, Australian, and New Zealand configurations. The original cover identifies this publication as P/N LIT-11616-24-36 / 2PA-28197-10.

Text Search, Bookmarks, and Wiring Sheets

Search and diagram detail: The manual’s text is searchable, and embedded bookmarks link to chapters and major assemblies. Wiring-diagram labels are not searchable. Small circuit markings, connector identifiers, and wire-color codes need zooming for comfortable reading.

The download contains one printable English PDF with 300 pages, including the front and back covers, six blank pages, and two final wiring-diagram sheets.

Engine Overhaul, Chassis Service, and Electrical Fault Tracing

The following selected contents outline the main workshop coverage. Other topics include speed-limiter adjustment and headlight-beam adjustment.

• Periodic maintenance: Emissions and lubrication schedules, valve-clearance and idle adjustment, air-filter and spark-arrester cleaning, engine-oil service, and control-cable adjustment.

• Engine repair: Removal and installation, cylinder-head and camshaft service, valve and piston inspection, crankcase separation, crankshaft and balancer checks, and oil-pump service.

• Clutch and transmission: Wet multi-disc clutch repair, shift-shaft service, transmission disassembly and assembly, and inspection of shift forks, the shift drum, and gearsets.

• Brakes and chassis: Wheel-hub bearings, rear-axle removal and installation, hydraulic brake repair and bleeding, steering joints, front arms, swingarm service, and drive-chain inspection.

• Fuel system: Fuel-tank and fuel-cock service, BSR29 carburetor disassembly, inspection and assembly, installation, and fuel-level measurement and adjustment.

• Electrical diagnosis: Circuit diagrams and troubleshooting charts for ignition, electric starting, starter cut-off operation, charging, lighting, signaling, and carburetor heating.

• Workshop references: Component torque tables, lubrication charts, cable-routing views, capacities, wear limits, clearances, electrical test data, exploded job-order diagrams, and complete wiring diagrams.

Yamaha produced this manual primarily for its dealers and qualified mechanics, and it assumes a working knowledge of basic ATV mechanics and repair techniques.

Scheduled Service and Internal Engine Repair

The maintenance chapter distinguishes emissions-related work from general maintenance and lubrication. It also addresses starter enrichment operation, crankcase-breather and exhaust checks, parking-brake setup, hub-bearing checks, suspension-pivot lubrication, and toe-in adjustment.

Internal engine coverage includes step-by-step procedures for valve-guide replacement, valve-seat lapping, piston and ring inspection, and timing-chain tensioner installation. Camshaft and rocker-gear checks use component dimensions and wear limits. Exploded views and job-order tables identify replacement points, lubrication requirements, special tools, and tightening data.

Bottom-end sections cover crankshaft and connecting-rod measurements, balancer alignment, crankcase bearings, and oil passages. The wet-sump lubrication material includes trochoid oil-pump clearance checks and rotary-filter inspection. Clutch inspection extends to friction plates, steel plates, springs, the housing, boss, pressure plate, and push mechanism; transmission checks address shaft runout, gear dogs, and gear engagement.

The cylinder-head section flags crankshaft movement during camshaft-sprocket installation as a cause of damage or incorrect valve timing.

Brake, Steering, and Suspension Work

Brake coverage reaches pad replacement, disc measurement, and caliper and master-cylinder disassembly, inspection, and assembly. Chassis procedures add wheel-hub bearing installation, rear-axle checks, steering-stem bushings, tie-rods, steering knuckles, front-arm ball joints, and swingarm bearing inspection.

Shock sections cover removal, inspection, replacement, and spring-preload adjustment; the nitrogen-charged rear unit must not be opened. Hydraulic brake work and rear-shock handling require the specified precautions, proper support, protective equipment, and workshop-level competence.

The chain-drive section explains how high-pressure cleaning and unsuitable solvents can damage the chain’s O-rings.

Regional Carburetor Details

The specification tables distinguish carburetor ID mark 2PA1 00 for USA/Canada from 2PA1 10 for Australia/New Zealand, with different jet-needle specifications and regional pilot-screw data. These distinctions help match carburetor components and adjustment information to the correct market version.

Inspection covers the float and needle valve, piston-valve diaphragm, coasting enricher, jets, starter plunger, carburetor joint, and intake manifold. Canadian reflector and license-bracket hardware is identified separately in the chassis removal tables.

Electrical Tests and Diagnostic References

Electrical fault-isolation charts connect symptoms with component tests, helping distinguish relay, switch, wiring, and starter-motor faults before replacement decisions. Component procedures include diode, ignition-coil, pickup-coil, stator, rectifier/regulator, thermo-switch, carburetor-warmer, and battery checks. Starter-motor disassembly and inspection are also included.

Named visual references include the engine-oil lubrication chart, cable-routing views, ignition circuit diagram, starting circuit cut-off operation diagram, carburetor-heating circuit diagram, and complete YFM125RA wiring diagram in black-and-white and color.

A separate troubleshooting chapter addresses starting failure, incorrect idle, poor medium- and high-speed performance, shifting and clutch faults, overheating, weak braking, unstable handling, and lighting or signaling failures.

Special-Tool Cross-References

The tool index pairs international 90890 numbers with USA/Canada tool numbers. Examples include crankcase separator 90890-01135 / YU-01135-B, flywheel puller 90890-01362 / YU-33270-B, 46 mm rear-axle nut wrench 90890-01498 / YM-37134, and fuel-level gauge 90890-01312 / YM-01312-A.

A Preview of Valve and Fuel-Level Settings

For cold-engine valve-clearance checks, the manual specifies 0.08–0.12 mm for intake valves and 0.10–0.14 mm for exhaust valves. These settings accompany the valve-adjustment procedure and timing-mark illustrations.

Carburetor fuel level is specified as 4.0–5.0 mm above the float-chamber mating surface. The fuel-system chapter pairs that reference with gauge-based measurement and adjustment instructions.