Friday, 13 June 2014

Yamaha YBR 125 , Yamaha FI diagnostics Tool Scanner Machine








Yamaha FI diagnostics machine , it just arrived this mourning , only had it 2 hours and not used it to its full extent but ran through a few live tests .
and its excellent i have to admit its probably not needed as most of the tests can be done without it
but wheres the fun in that !!

for the price i cannot fault it ! .

Yamaha YBR 125 , Yamaha FI diagnostics




the manual is not very clear on how to connect and use this so it was a bit trial and error .





How to connect the FI diagnostics to Yamaha YBR 125


this is how i did it anyway correct me if i make any mistakes in comments 

-first turn key to off positon 
Yamaha YBR 125 , Yamaha FI diagnostics

-disconnect the fuel injection pump wiring connector block 
Yamaha YBR 125 , Yamaha FI diagnostics


-remove side panel and split the light green Ecu-Diagnostics connector block
Yamaha YBR 125 , Yamaha FI diagnostics
-connect yamaha FI unit to wire and the battery leads to + and - terminals 
-press and hold mode button down 
-turn key to on position
-display on Yamaha FI unit should now read Diag .




your now connected flick through the modes and do some tests .

this is as far as i have gone so far , i gone through and done all individual test all of which ill write below .

as i learn more ill update this post so keep tuned !! .

Fuel System diagnostic codes tests 

D01- throttle angle fully closed 14~20   fully open 97-107
move throttle from open to closed and check reading



D03- Intake air pressure - crank engine and check for reading change 

D05 - Intake air temperature , check by measurement 

D06 - coolant temp -not needed on YBR 125 

D07- speed sensor - turn wheel i did not check this not sure if this is needed ?? ill check next time

D08- Tip sensor voltage check , upright voltage 0.4to 1.2 

D09-Voltage supply - 12v 

D20- side stand switch check 

D21- neutral switch check 

D30 - check operation of coil Press MODE , and it will fire 5 times sparks

D36 -  fuel injector , press mode will pulse the injector 5 times

D51 - cooling fan relay , checks operation of fan

D52 - headlight relay , checks operation of the relay , it should click and light headlamp 5 times

D54 - fast idle solenoid , checks operation of solenoid , you should hear its operation and see engine light 5 times

D60 - EEPROM 01-00 when no fault

D61 - fault code history 12-50 00 when no fault

D62 - fault code history 00 - 16








Monday, 9 June 2014

Yamaha YBR 125 Oil Pump Test < warning - oil pump failure engine seizure








I am having a lot of engines in seized and i am not sure why , maybe bad oil maybe old thin oil .

maybe running oil to low for pump to circulate , maybe i do not know !! .

or maybe its just coincidence .

here is a test to see if oil is circulating to the top of engine , do it regular and check oil levels 
regular as well , and change oils as per manual .

you need a 10mm spanner , that is it ! .








Sunday, 8 June 2014

Yamaha YBR 125 Fuel Injection System , FI diagnostics .










Yamaha YBR 125 Fuel Injection System , FI diagnostics




This post will be about the fuel injection system on the Yamaha YBR 125 , common faults , test procedures repair and diagnosis .

by the way i just bought the Yamaha FI diagnostics machine , probably not necessary , but who cares it looks interesting to me , i know nothing about it tbh what its capable of or how to use it so should be fun to learn .

The Yamaha YBR 125 has a built in engine management system , where a series of flashes on the clocks  , engine management light gives out a fault code.

Yamaha YBR 125 Fuel Injection System Components

the main components are shown below , ecu , fuel pump (£270) and fuel pipe ( £98) and the fuel injector / throttle position sensor assembly all photoed below .

there are other components obviously like crank position sensor and flywheel ,idle control  , wiring loom differences etc etc . 
a lot of people ask me if a Yamaha YBR 125 carb engine will fit into an injection model frame but it will not
not unless you change the flywheel-stator  at least  , it might then be possible but im not sure yet , i will eventually try but have not had time to attempt yet , may be other differences as well .

yamaha ybr 125 fuel pump injector pump and level sender unit

yamaha ybr 125 fuel pump injector pump and level sender unit

buy fuel pumps from ebay uk here  or Amazon uk here ( be quick they go fast )



Yamaha YBR 125 Fuel Injection System , FI diagnostics
or cheaper still the internal pump unit on Ebay UK


testing the fuel pump it easy , i usually just provide 12v power to terminals and listen to motor if its off the bike ,  this tell you it operates but does not tell you if its proving enough system pressure , i do this with my
tool i made for 2 stroke injection engine bikes i used to work on , ill add a photo later , its basically just a pressure gauge fitted on a T and in the middle of a spare fuel hose i had ( these fuel pipes cost £90ea from Yamaha so your brave to cut them up lol . )  , anyway fuel pressure should be 35 psi at idle .

Yamaha YBR 125 Fuel Injection System , FI diagnostics


                             


you should hear the fuel pump prime the circuit on initial turn of the key ,
running the fuel pump - tank out of fuel can cause damage to the pump .

and testing the resistance values of the fuel level sensor is easy also see below link for expected values
at the empty and full positions .

You can see all the electrical test procedures for the fuel pump and the fuel level sender unit here .      =================================================================




ECU , cannot really be tested unless fitted to a known working bike or swapping it out with a know functioning ECU.
The ECU is located on the frame underneath the tank and is easily removed and refitted to bike .

Yamaha YBR 125 Fuel Injection System , FI diagnostics

18 pin fuel injection ecu


Brown - 12Volts
Black/White - 12 Volts
Black - Ground

Red - Magneto Sensor 

Blue - Throttle Body Sensor
Pink/White - Throttle Body Sensor
Black/Blue - Throttle Body Sensor
Brown/White - Throttle Body Sensor

Yellow/Blue - Throttle opening (Variable)

Green/Red - Engine Temperature Sensor
Yellow/Green - Lean Angle Sensor
Orange - Ignition Coil
Yellow/Red - Fast Idle Solenoid
Orange/Black - Fuel Injector
Yellow - Fuel Pump
Blue/Yellow - Rev Counter Pulse
Light Green - Engine Diagnostic Indicator (Amber Light on Instrument Panel)

White/Black - Head Light


================================================

fuel injector , inlet air pressure sensor and throttle position sensor all can be tested via the
Yamaha Fi diagnostics .

check out the posts on how to test these parts below 



Yamaha YBR 125 Fuel Injection System , FI diagnostics

Yamaha YBR 125 Fuel Injection System , FI diagnostics
        the Throttle body sensor combines TPS , Inlet pressure and
                                     Temperature sensors
Yamaha YBR 125 Fuel Injection System , FI diagnostics




=================================================


Yamaha YBR 125 EFI electronic fuel injection videos , excellent information .



                             






see more Yamaha YBR 125 blog posts



Saturday, 7 June 2014

Yamaha YBR 125 service maintenance specs .










Yamaha YBR 125 XT 125 servicing maintenance specifications

YBR 125 Engine Specs 

Spark plug - NGK CR7HSA
Spark plug gap - 0.6mm
Idle speed - 1400-1500rpm
Valve clearance - Cold 
intake - 0.10mm
exhaust - 0.12mm

YBR 125 Chassis Specs

Brake pad min - 1.0mm
Cable / lever free play - 
Clutch - 10mm
Throttle - 5mm
Front brake lever - 4mm 
Rear brake lever - 25mm
Chain slack - 25mm





Yamaha YBR 125 Clutch - rebuild









Motorcycle clutches are very good these days , i have no reason to think Yamaha are any different .

not had any problems yet but im bored and thought id start another post off , ill list common problems
with clutches and there remedies .

here is a little photo pictorial of a clutch rebuild i did today , not much i know ..

see this post here for Yamaha YBR 125 common clutch problems



Yamaha YBR 125 Clutch - rebuild

Yamaha YBR 125 Clutch - rebuild

Yamaha YBR 125 Clutch - rebuild

Yamaha YBR 125 Clutch - rebuild


Yamaha YBR 125 Clutch - rebuild


Yamaha YBR 125 Clutch - rebuild


Yamaha YBR 125 Clutch - rebuild


                             



Yamaha YBR 125 Engine Rebuild Information




Ill use this post to gather all information i can on rebuilding the engine on the Yamaha YBR 125 .

so far i have only done a top end rebuild , new piston and rings after having barrel honed 
the bottom end so far seems bullet proof but i am sure ill do one eventually  , i have stripped one out
and documented it , see the links below for all these posts and videos 

if you have any advice on engine rebuild for the Yamaha YBR 125 , and would like to help out
let me know and ill upload it .


other posts of interest


Yamaha YBR 125 Clutch - rebuild


Yamaha YBR 125 Engine rebuild


Four stroke single
123.7cc
54mm bore
54mm stroke
10 to 1 comp
170 psi compression
Air cooled


All service settings for valves ,  head , piston , rings clutch etc are in the Haynes workshop manual id get one if you attempting to rebuild your engine it will be invaluable BUY HERE on Ebay UK 


Check out complete engines for YBR 125 on Ebay UK here
 

Yamaha YBR 125 Engine Rebuild Information

Yamaha YBR 125 Engine Rebuild Information

Yamaha YBR 125 Engine Rebuild Information

yamaha YBR 125 engine rebuild
Yamaha YBR 125 engine rebuild 

yamaha YBR 125 engine rebuild
Yamaha YBR 125 engine rebuild 

yamaha YBR 125 engine rebuild
yamaha YBR 125 engine rebuild 

yamaha YBR 125 engine rebuild
Yamaha YBR 125 engine rebuild

Yamaha YBR 125 Engine Rebuild Information


Starter clutch / flywheel rebuild just done this today took some photos .

made them into video easier to upload - ill do engine rebuild one soon .


compression testing
                              

Top end rebuild and removal




Gearbox 

                          

engine refit and removal 

                                                                                      

timing chain gear 

                            


Friday, 6 June 2014

Yamaha YBR 125 electrical system , wiring diagrams and components .







ive studied the internet and many books to find this info , but still i cannot get anywhere near close
to the level of information in the Haynes workshop manual , buy one here on Amazon UK .

if you know nothing about electrics like i did not when i first started out , read this book from Amazon UK 
this will save you £100s in repair bills and has easy to follow instructions , and some excellent
tips and advice , literally makes electrical fault diagnosis simple .

Yamaha YBR 125 electrical system














Yamaha YBR 125 wiring and electrical post .

battery - 12v 6ah

bulbs
headlight bulb - 35/35w
sidelight bulb - 5w
brake light bulb - 21/5w
plate light bulb - 5w
indicator bulb - 10w
clocks bulbs - 1.7w

15a fuse

Yamaha YBR 125 charging system resistance figures

stator coil - 0.6~0.95(05~06) 2007-on (0.45~0.67)
regulated volts - 13.7~14.7
0.1ma max volt leakage

Yamaha YBR 125 fuel level sender unit resistance figures

full - 4~10 ohms
empty - 90~100 ohms

injection system resistance figures

crank position sensor  - 248 ~ 372 ohms @ 20 degrees C
engine temp sensor - @ 20 degree C~2.5-2.8 ohms - @ 100 degrees C~210-221 ohms
fast idle solenoid - 31.5~38.5 : 25 degrees C
intake air pressure sensor  output voltage - 3.75~4.25V
intake air temp sensor resistance - 2007-2009 2.4 to 2.9 k-ohms 2010 on 5.7 to 6.3 k-ohms
throttle position sensor input voltage 5v  output throttle closed 0.63-0.73v
tip over sensor voltage output - upright 0.4-1.4 ~ 65degree angle 3.7-4.4v


other electrical posts

Yamaha YBR 125 Generator , Alternator Stator  testing 

Yamaha YBR 125 Not sparking no spark diagnostics


yamaha ybr 125 wiring diagram
yamaha ybr 125  wiring diagram

yamaha ybr 125  wiring diagram
yamaha ybr 125 2007 wiring diagram 

see this diagram larger here

and see below key to above diagram larger here


Yamaha YBR 125 electrical system , wiring diagrams and components




some photos off my latest Yamaha YBR 125 - ill update soon with id of parts and wires .

Yamaha YBR 125 electrical system , wiring diagrams and components

regulator 

Yamaha YBR 125 electrical system , wiring diagrams and components

cdi unit 3d900 

Yamaha YBR 125 electrical system , wiring diagrams and components

On the left hand side under battery cover you have the solonoid ( brass ) with fuse , if you have a failure to turn bike over it could be this , flasher unit ( black ) , and headlamp relay ( white )

Yamaha YBR 125 electrical system , wiring diagrams and components

Yamaha YBR 125 electrical system , wiring diagrams and components

Yamaha YBR 125 electrical system , wiring diagrams and components


Yamaha YBR 125 electrical system , wiring diagrams and components

Yamaha YBR 125 electrical system , wiring diagrams and components



                                   front headlamp loom

=================================================

Test battery at the negative and positive terminals 

Yamaha YBR 125 electrical system , wiring diagrams and components


If you have a voltage meter you can do some basic tests.
When the engine has been off for at least 1-2 hours with ignition key turned off,
100% Charged 12.60 to 12.8v
75% Charged 12.4v
50% Charged 12.1v
25% Charged 11.9v
0% Charged less than 11.8v

========================================================================



            Heres some excellent motorcycle electrical test videos .

                                    Charging system testing

                                     No spark situation testing




Must have electrical tool

Yamaha YBR 125 electrical system , wiring diagrams and components

12v circuit tester mines snap on but hard to find in UK click here for any on Ebay UK  now.






Yamaha YBR 125 electrical system , wiring diagrams and components
Kewtech multimeter , there are better and worse .this has always done everything ive asked of it and would recommend them , you can get a lot cheaper . see here on Ebay UK



Yamaha YBR 125 electrical system , wiring diagrams and components

Power Probe , dont use that often but an excellent tool when needed mine is a cheaper version this one here in ebay UK 



you can get Snap On Powerprobe which is excellent if you can afford it it see them here on ebay UK 



Yamaha YBR 125 electrical system , wiring diagrams and components

My S.W.A ratchet electrical connector crimps , i paid a lot of money for these when i  worked as an electrician but still paying for themselves
now 10 yrs later

cant find this model but heres some on ebay UK  a lot cheaper these days




thats about it for interesting electrical tools i own , got any recommendations send a comment below .