IDENTIFICATION NUMBERS RECORD Record the frame serial number and engine serial number in the spaces provided for assistance when ordering spare parts from a Yamaha dealer or reference in case the vehicle is stolen. 1. FRAME SERIAL NUMBER: 2. ENGINE SERIAL NUMBER: II IDENTIFICATION NUMBERS RECORD Record the frame serial number and engine serial number in the spaces provided for assistance when ordering spare parts from a Yamaha dealer or reference in case the vehicle is stolen. Downloaded from www.
XTZ 125K / XTZ 125E OWNER’S MANUAL © 2003 Yamaha Motor da Amazônia Ltda. 1st edition, April 2003 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor da Amazônia Ltda. is expressly prohibited. Printed in Brazil.
INTRODUCTION Congratulations on your purchase of the YAMAHA XTZ 125K / XTZ 125E. This model is the result of Yamaha’s vast experience in the production of fine sporting, touring, and pacesetting racing machines. It represents the high degree of craftmanship and reliability that have made Yamaha a leader in these fields. This manual will give you an understanding of the operation, inspection, and basic maintenance of this motorcycle.
Particularly important information is distinguished in this manual by the following notations: NOTE: A NOTE provides key information to make procedures easier or clearer. CAUTION: A CAUTION indicates special precautions that must be taken to avoid damage to the machine. WARNING: Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander or a person inspecting or repairing the machine.
WARNING: PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MACHINE. DO NOT ATTEMPT TO OPERATE THIS MOTORCYCLE UNTIL YOU HAVE ATTAINED A SATISFACTORY KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES. REGULAR INSPECTIONS AND CAREFUL MAINTENANCE, ALONG WITH GOOD RIDING SKILLS WILL ENSURE THAT YOU SAFELY ENJOY THE CAPABILITIES AND THE RELIABILITY OF THIS MOTORCYCLE.
SAFETY INFORMATION TWO-WHEELED Machines ARE SINGLE TRACK VEHICLES. THEIR SAFE USE AND OPERATION ARE DEPENDENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EXPERTISE OF THE OPERATOR. EVERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIREMENTS BEFORE RIDING. HE OR SHE SHOULD. 1. OBTAIN THOROUGH INSTRUCTIONS FORM A COMPETENT SOURCE ON ALL ASPECTS OF MACHINE OPERATION. 2. OBSERVE THE WARNINGS AND MAINTENANCE REQUIREMENTS IN THE OWNER’S MANUAL. 3.
PROTECTIVE APPAREL The majority of fatalities from machine accidents are the result of head injuries. The use of a safety helmet is the single most critical factor in the prevention or reduction of head injuries. 1. Always wear an approved helmet. 2. Wear a face shield or goggles. Wind on your unprotected eyes could contribute to an impairment of vision which could delay seeing a hazard. 3. The use of heavy boots, jacket, trousers, gloves, etc.
ACCESSORIES AND LOADING Adding accessories or cargo to your machine can adversely affect stability and handling if the weight distribution of the machine is changed. To avoid the possibility of an accident, extreme caution should be used if adding cargo or accessories to your machine. Use extra care if riding a machine which has added cargo or acessories. Genuine Yamaha accessories have been specifically designed for use on this machine.
GASOLINE AND EXHAUST GAS 1. GASOLINE IS HIGHLY FLAMMABLE: a. Always turn off the engine when refueling. b. Take care not to spill any gasoline on the engine or exhaust system when refueling. c. Never refuel while smoking or in the vicinity of an open flame. 2. Never start the engine or let it run for any length of time in a closed area. The exhaust fumes are poisonous and may cause loss of consciousness and death within a short time.
ÍNDICE PRE-OPERATION CHECKS ................................ 4-1 Brakes ....................................................... 4-3 Brake fluid leakage ................................... 4-4 Engine oil .................................................. 4-4 Tires .......................................................... 4-5 Clutch ........................................................ 4-8 Throttle grip ............................................... 4-8 Fitting/Fasteners .................................
Tool kit ...................................................... 6-2 Throttle cable and grip lubrication ............ 6-27 Brake and shift pedals .............................. 6-27 Brake and clutch levers ............................ 6-27 Rear suspension ....................................... 6-28 Sidestand .................................................. 6-28 Front fork inspection ................................. 6-29 Rear shock absorber adjustment .............. 6-30 Steering inspection .............
DESCRIPTION XTZ 125K 01. 02. 03. 04. 05. 06. 07. 08. 09. Fuel cock Starter lever Battery Fusible Tool kit Shift pedal Shock absorber Air filter Kick starter 1-1 DESCRIPTION XTZ 125K 10. 11. 12. 13. 14. 15. 16. 17. 18. 19.
DESCRIPTION XTZ 125E 01. 02. 03. 04. 05. 06. 07. 08. 09. Fuel cock Starter lever Battery Fusible Tool kit Shift pedal Shock absorber Air filter Dispstick 1-2 DESCRIPTION XTZ 125E 10. 11. 12. 13. 14. 15. 16. 17. 18.
MACHINE IDENTIFICATION Vehicle identification number 1. Frame number Engine serial number 2. Production year 1. Engine serial number The vehicle identification number is stamped into the steering head pipe.Record this number in the space provided. NOTE: A The engine serial number is stamped on right-hand engine crankcase. B Model code is indicated by 4th to 8th ) digits and serial number is indicated by 12th to 17th digits *.
CONTROL FUNCTIONS Main switch The main switch controls the ignition and the electrical system. It’s operation is described below. ON: Electrical circuits are switched on. Engine can be started. The key cannot be removed. OFF: All electrical circuits are switched off. The key can be removed. LOCK: The steering is locked and all electrical circuits are switched off. The key can be removed. Refer to page (3-11) “Steering lock” for instructions.
Indicator lights TURN INDICATOR LIGHTS " " The corresponding indicator fhashes when the turn switch is moved to the “ ç “ or “ è“. HIGH BEAM INDICATOR LIGHT " " This indicator comes on when the headlight high beam is used. NEUTRAL INDICATOR LIGHT " " This indicator comes on when the transmission is in neutral. 1. Turn indicator lights " 2. High beam indicator light " " 3.
Speedometer The speedometer shows riding speed. This speedometer is equipped with an odometer and a trip meter. The trip meter can be returned to zero by using the adjusting knob. Use the trip meter to estimate how for you can ride on a tank of fuel. This information will enable you to plan fuel stops in the future. 1. Speedometer 3. Trip meter 2. Odometer 4. Adjusting knob 3-3 Speedometer The speedometer shows riding speed. This speedometer is equipped with an odometer and a trip meter.
Handlebar switches over left: LIGHTS SWITCH Turning the light switch to “ “, turns on the meter lights and tail-lights. Turning the light switch to “ headlight on also. “, turns the PASS SWITCH " " Press the switch to operate the passing light. DIMMER SWITCH Turn the switch to " for the low beam. 1. Light switch 2. Pass switch 3. Dimmer switch 4. Turn signal switch 5.
Handlebar switches over right: “ENGINE STOP” SWITCH The engine stop switch is a safety device for use in an emergency such as when the motorcycle overturns or if trouble occurs in the throttle system. Turn the switch to “ ” to start the engine, and turn the switch to “ ” to stop the engine. STARTER SWITCH “ ” The starter motor cranks the engine when pushing the starter switch. 1. ENGINE STOP switch, shuts the engine off 2.
Clutch lever The clutch lever is located on the left handlebar, and the starting circuit cut off switch is incorporated in the clutch lever holder. Pull the clutch lever to the handlebar to disengage the clutch, and release the lever to engage the clutch. The lever should be pulled rapidly and released slowly for smooth clutch operation. 1. Clutch lever Shift pedal This motorcycle is equipped with a constant-mesh 5-speed transmission.
Front brake lever The front brake lever is located on the right handlebar. Pull it toward the handlebar to apply the front brake. 1. Front brake lever Rear brake pedal The rear brake pedal is on the right side of the motorcycle. Press down the brake pedal to apply the rear brake. 1.Rear brake pedal 3-7 Front brake lever The front brake lever is located on the right handlebar. Pull it toward the handlebar to apply the front brake.
TO OPEN: Insert the key and turn it 1/2 turn counterclockwise. The Fuel tank cap lock will be released and the cap can be opened. TO CLOSE: Push the tank cap into position with the key inserted. To remove the key, turn it clockwise to the original position. WARNING: Be sure the cap is properly installed and locked in place before riding the motorcycle. 3-8 Fuel tank cap TO OPEN: Insert the key and turn it 1/2 turn counterclockwise. The lock will be released and the cap can be opened.
Fuel cock The fuel cock supplies fuel from the tank to the carburetor while filtering it also. The fuel cock has three positions: OFF: With the fuel cock in this position, fuel will not flow. Always set the fuel cock to this position when the engine is not running. ON: With the fuel cock in this position, fuel flows to the carburetor. Set the fuel cock to this position when starting the engine and while riding. RES: This indicates reserve.
Starting a cold engine requires a richer air-fuel mixture. A separate starter circuit supplies the mixture. Starter lever Pull the starter knob up to open the circuit for starting. When the engine has warmed up, push the knob down to close the circuit. 1. Starter lever Kick starter Rotate the kick starter away from the engine. Push the starter down lighty with your foot until the gears engage, then kick smoothly and forcefully to start the engine. Shift to neutral before starting. 1.
Steering lock The steering is locked when the main switch is turned to “LOCK”. To lock the steering, turn the handlebars all the way to the left. With the key at “OFF” position, push it into the main switch and release it, turn it counterclockwise to “LOCK”, and remove the key. To release the lock, turn the key to “OFF”. WARNING: WARNING: Never turn the key to “LOCK” position when the motorcycle is moving. 1. Push 2. Release 3.
Seat To remove the seat, remove the bolts. To reinstall the seat, insert the lobes in to the receptacle on the frame and fuel tank, then tighten the bolts. Reinstall the side covers. NOTE: Make sure the seat is securely fitted. 1. Bolts 3-12 Seat To remove the seat, remove the bolts. To reinstall the seat, insert the lobes in to the receptacle on the frame and fuel tank, then tighten the bolts. Reinstall the side covers. NOTE: Make sure the seat is securely fitted.
Insert the key and turn it 1/4 clockwise. Pull the cover to release the pins. Side covers A To reinstall, reverse the removal procedures. 1. Lock the side cover 2. Pull A. Pin Remove the screw and then pull the cover to release the pins A To reinstall, reverse the removal procedures. 1. Screw 2. Pull 3. Pin 3-13 Side covers A Insert the key and turn it 1/4 clockwise. Pull the cover to release the pins. To reinstall, reverse the removal procedures.
The spring prelod can be adjusted to suit the motorcycle’s load (ex: optional accessories, etc.) and riding conditions. Rear shock absorber Refer to page 6-30 for proper adjustment procedures. 1. Spring preload adjusting ring 2.Position indicator Standard Soft Adjusting position 1 2 3 Hard 4 5 6 7 3-14 Rear shock absorber The spring prelod can be adjusted to suit the motorcycle’s load (ex: optional accessories, etc.) and riding conditions. Refer to page 6-30 for proper adjustment procedures.
* Clutch switch operation check WARNING: If improper operation is noted, consult a Yamaha dealer or other qualified mechanic immediately. Check the operation of the clutch switch against the information below. TURN MAIN SWITCH TO “ON” AND ENGINE STOP SWITCH TO “ ”. ↓ TRANSMISSION IS IN GEAR. ↓ PULL IN CLUTCH LEVER AND PUSH STARTER SWITCH. ↓ ENGINE WILL START ↓ CLUTCH SWITCH IS OK * Obs.
PRE-OPERATION CHECKS Before using this motorcycle, check the following points: ITEM Front brake Rear brake Clutch Throttle grip / cable ROUTINE Check operation, free play, fluid level and fluid leakage. Top-up with DOT #4 (or DOT #3) brake fluid if necessary. Check operation, condition and free play. Adjust if necessary Check operation, condition and free play. Adjust if necessary Check for smooth operation.
ROUTINE ITEM Rear brake and shift pedal Check for smooth operation. Lubricate if necessary shafts Front brake and clutch lever pivots Sidestand Fittings / Fasteners Fuel tank Check for smooth operation. Lubricate if necessary Check for smooth operation. Lubricate if necessary Check all chassi fittings and fasteners. Tighten / Adjust, if necessary Check fuel level / top up as required.
Brakes (See page 6-17 for details) 1. Brake lever and brake pedal Check for correct free play in the front brake lever and rear brake pedal and adjust if necessary. Make sure the brakes are working properly by checking at low speed shortly after starting out. 2. Brake fluid Check the brake fluid level. Add fluid if necessary. RECOMMENDED BRAKE FLUID: DOT #4 NOTE: If DOT #4 is not available, #3 can be used. WARNING: A soft, spongy feeling in the brake lever indicates a 3. Check the disc pads.
Brake fluid leakage Engine oil (See page 6-6 for details) Apply the brake for several seconds. Check to see if any Make sure the engine oil is at the specified level. Add oil as brake fluid leaks out from the pipe joints or the master cylinder. necessary. CAUTION: OIL QUANTITY: Brake fluid may deteriorate painted surfaces or plastic parts. Never spill any fluid. If spilled, clean it up immediately. Total amount: 1.2 L ( 0.264 Imp gal, 0.317 US gal) Periodic oil change: 1.0 L ( 0.220 Imp gal, 0.
Tires Basic weight: With oil and without fuel To ensure maximum performance, long service, and safe XTZ 125K 113 Kg ( 249 lb) XTZ 125E 114 Kg ( 251 lb) operation, note the following: Maximum load*: 1. Tire air pressure Always check and adjust the tire pressure before operating the machine. Cold tire pressure: 150 Kg ( 330 kg) Front Rear WARNING: Tire inflation pressure should be checked and adjusted when the temperature of the tire equals the ambient air temperature.
2. Tire inspection Always check the tires before operating the motorcycle. If a tire tread shows crosswise lines (minimum tread depth), if the tire has a nail or glass fragments in it, or if WARNING: Proper loading of your motorcycle is important for the handling, braking, and other performance and safety characteristics of your motorcyle. Do not carry loosely packed items that can shift.
WARNING: WARNING: After extensive tests, the tires listed below have been approved by Yamaha for this model. The front and rear 1. It is dangerous to ride with a worn-out tire. When the tire tread begin to show signs of wear, replace the tire immediately. Brakes, tires and related wheel parts should be left to a Yamaha dealer. 2. Patching a punctured tube is not recommended. If it is absolutely necessary to do so, use great care tires should always be by the same manufacturer and of the same design.
Clutch ( See page 6-16 for details) Wheels Check the free play in the clutch lever, and make sure the lever operates properly. If the free play is incorrect, adjust it. To ensure maximum performance, long service, and safe operation, note the following: 1. Always inspect the wheels before a ride. Check for cracks, bends, or warpage of the wheel; be sure the spokes are tight and undamaged.
Fuel CAUTION: Always wipe off spilled fuel immediately with a dry and clean soft cloth. Fuel may deteriorate painted surfaces or plastic parts. Recommended fuel: UNLEADED FUEL 1. Fuel level Fuel tank capacity: Total: 10.6 l ( 2.33 Imp gal, 2.80 US gal) Reserve: 1.0 l ( 0.220 Imp gal, 0.264 Us gal) 2. Filler tube Your Yamaha engine has been designed to use regular unleaded gasoline with a pump octane number ([R+m]/2) of 86 or higher, or research octane number of 91 or higher.
OPERATION AND IMPORTANT RIDING POINTS CAUTION: Before riding this motorcycle, become thoroughly familiar with all operating controls and their functions. Consult a Yamaha dealer regarding any control or function that you do not thoroughly understand. CAUTION: 1. Be very careful if you are carrying object while riding the motorcycle 2. Be vareful not to put any object near battery terminals. Never start your engine or let it run for any length of time in a closed area.
Starting a cold engine XTZ 125K 1. Turn the fuel cock to “ON”. 2. Turn the main switch to “ON” and the engine stop switch to “ “. 3. Shift transmission into neutral. NOTE: XTZ 125E 1. Turn the fuel cock to “ON”. 2. Turn the main switch to “ON” and the engine stop switch to “ “. 3. Shift transmission into neutral. NOTE: When the transmission is in neutral, the neutral indicator light should be on.
NOTE: 6. After starting the engine, turn back the starter to an intermediate position. This motorcycle is equipped with a starting and an ignition NOTE: circuit cut-off switch. 1. The engine can be started only under the following conditions: a. The transmission is in neutral. b. The transmission is in gear and the clutch is disengaged. To obtain maximum engine life and service, do not ever thoroughly accelerate it while the engine is cold. 7.
WARNING: Before going through the following steps, check the function of the clutch switch (See page 3-15) TURN THE MAIN SWITCH TO “ON” AND ENGINE STOP SWITCH TO “ ” IF TRANSMISSION IS IN NEUTRAL IF TRANSMISSION IS IN GEAR PUSH STARTER SWITCH; ENGINE WILL START PULL IN CLUTCH LEVER AND PUSH STARTER SWITCH; ENGINE WILL START PUT TRANSMISSION IN GEAR MOTORCYCLE CAN BE RIDDEN MOTORCYCLE CAN BE RIDDEN * Obs.
Starting a warm engine Warming up the engine The starter lever is not required when the engine is warm. For an extended engine life always warm the engine up never accelerate hard while the engine is cold. To check if engine temperature is normal, rev the engine with the choke closed and check to see if it responds normally. CAUTION: If the engine fail to start with the procedures above, try to start it again with the throttle grip opened 1/4 to 1/2.
Shifting CAUTION: The transmission lets you control the amount of power you have available at a given speed for starting, accelerating, 1. Do not coast for long periods with the engine off, and do not tow the motorcycle a long distance. Even with gears in neutral, the transmission is only properly lubricated when the engine is running. climbing hills, etc. The use of shift pedal is shown in the illustration (page 3-6).
Tips for reducing fuel consumption Your motorcycle’s fuel consumption depends to a large extent on your riding style. The following tips can help reduce fuel consumption. 1. Warm up the engine before riding. 2. Turn off the starter lever as soon as possible. Engine Break-in 3. Shift up swiftly and avoid high engine speeds during acceleration. 4. Do not double-clutch or rev the engine while shifting down and avoid high engine speeds with no load engine. 5.
2. 150 ~ 500 Km: Avoid prolonged operation above 1/2 throttle. Allow the machine to rev freely through the gears, but do not use full throttle at any time. Parking When parking the motorcycle, stop the engine and remove the ignition key. Turn the fuel cock to “OFF” whenever stopping the engine. WARNING: 3. 500 ~ 1,000 Km: Avoid cruising speeds in excess of 3/4 throttle. The muffler and exhaust pipe are hot.
PERIODIC MAINTENANCE AND MINOR REPAIRS Perodic inspection, adjustment, and lubrication will keep your motorcycle in the safest and most efficient condition possible. Safety is an OBLIGATION of the motorcycle owner. The maintenance and lubrication schedule chart should CAUTION: If you are not familiar with motorcycle service, this work should be done by a Yamaha dealer. be considered strictly as a guide to general maintenance and lubrication intervals.
The tools provided in the owner’s tool kit are to assist you in the performance of periodic maintenance. However, some Tool kit other tools such as a torque wrench are also necessary to perform the maintenance correctly. NOTE: If you do not have necessary tools required during a service operation, take your motorcycle to a Yamaha dealer for service. WARNING: Modifications to this motorcycle not approved by Yamaha may cause loss of performance, excessive emissions, and render it unsafe for use.
PERIODIC MAINTENANCE / LUBRICATION REMARKS ITEM Valves* How it sounds / Adjust if necessary. Spark plug Check condition and clean if necessary. Replace if necessary every 12,000 Km. Air filter Clean or replace if necessary. Fuel line Check fuel hose, for cracks or damage. Carburetor* Adjust Battery Check electrolyte level, routing breather pipe. Engine oil Replace / Check level Muffler Check damage, Retighten. Brakes* Check operation, adjust. Grease the brake cam.
ITEM 1,000KM REMARKS Front forks* Check operation / oil leakage. Rear shock absorber* Check operation / oil leakage. Drive chain Check chain slack / lubricate, adjust if necessary. Fittings / fasteners Check looseness. Sidestand Check operation, looseness. Control cables: throttle / clutch / front brake Adujst / Check operation Lubricate every 12,000 Km. Lights and flashers Check operation. Nuts and bolts Check tighten.
Use a torque wrench to tighten these items. It is recommended that these items be checked occasionally, specially before a long trip. Always check the tightness of Torque specifications these items whenever they are loosened for any reason. A (Nut) 10 12 14 17 19 22 mm mm mm mm mm mm B (Bolt) 6 mm 8 mm 10 mm 12 mm 14 mm 16 mm General torque especifications Nm 6 15 30 55 85 130 kgf.m 0,6 1,5 3,0 5,5 8,5 13,0 lbf. ft 4,3 11 22 40 61 94 Torque Item Nm Nm kgfm 12.5 1.25 9.
Engine oil 1. Oil level measurement a. Place the motorcycle on a level place and hold it in an upright position. Warm up the engine for several minutes. NOTE: Be sure the motorcycle is positioned straight up when checking the oil level. A slight tilt toward the side can result in false readings. b. With the engine stopped, with the engine stopped, unscrew the oil filler cap/ dispstick and rest it on the threads of the ok. 1.
a. Warm up the engine for a few minutes. b. Stop the engine. Place an oil pan under the engine and 2. Engine oil and filter replacement remove the dipstick. c. Remove the drain plug and drain the oil. d. Reinstall the drain plug, check if the gasket is damaged and lighten it to the specified torque. Tightening torque: Drain plug: 20 N.m (2.0 kgf.m, 14.5 lbf.t) 1.Dipstick 1. Engine oil drain plug 6-7 2. Engine oil and filter replacement a. Warm up the engine for a few minutes. b. Stop the engine.
e.Fill engine with oil. Install the oil filter cap and tighten. CAUTION: Do not put in any chemical additives. Engine oil also lubricates the clutch and additives could cause clutch slippage. Recommended oil: YAMALUBE 4 Oil quantity: Total amount: 1.2 L ( 0.264 Imp gal, 0.317 US gal) Periodic oil change: 1.0 L ( 0.220 Imp gal, 0.264 US gal) CAUTION: Be sure no foreign material enters the crankcase. f. Start the engine and warm up for a few minutes. While warming up, check for oil leakage.
Oil pressure 1. Remove the check bolt 1 in the cylinder head. 2. Start the engine and keep it idling until oil flows out of the bleed hole. If no oil comes out after one minute, turn off the engine immediately so it will not seize. In such a case go to the nearest Yamaha dealer or other qualified mechanic for repairs. 3. After checking, tighten the check bolt to the specified torque. Check bolt torque: 7 N.m (0.7 Kgf.m, 5.0 lbf.ft) 1. Check bolt 6-9 Oil pressure 1.
The air filter should be cleaned at the specified intervals. It should be cleaned more frequently if you are riding in unusually wet or dusty areas. 1. Remove the right side cover.(pag. 3-13) 2. Remove the air filter case cover by removing the bolts. 3. Remove the air filter from the case. Air filter 1. Side cover 2. Bolts 1. Air filter 6-10 Air filter The air filter should be cleaned at the specified intervals. It should be cleaned more frequently if you are riding in unusually wet or dusty areas.
4. Remove the air filter element from the guide and clean it with solvent. After cleaning, remove the remaining solvent by squeezing the air filter 5. Apply recommended oil to the entire surface of the filter and squeeze out the excess oil. The air filter should be wet but not dripping. Recommended oil: Engine oil 20W50 6. Reinstall the air filter in its case. 7. Install the air filter case cover and the right side cover. CAUTION: Make sure the element is properly seated in the air filter case.
Carburetor adjustment Valve clearance adjustment The correct valve clearance changes with use, resulting in improper fuel/air supply or engine noise. To prevent this, valve clearance must be adjusted regularly. This adjustment, however, should be left to a professional Yamaha service The carburetor is a vital part of the engine. Adjusting should be left to a Yamaha dealer who has the professional knowledge, specialized data, and equipment to do so properly.
NOTE: Idle speed adjustment A diagnostic tachometer must be used for this procedure. 1. Attach the tachometer. Start the engine and warm it up for a few minutes (normally, 1 or 2 minutes) at approximately 1,000 to 2,000 r/min. Occasionally rev the engine to 4,000 to 5,000 r/min. The engine is warm when it quickly responds to the throttle. 2. Set the idle to the specified engine speed by adjusting the throttle stop screw; turn the screw in to increase engine speed and out to decrease engine speed. 1.
NOTE: Throttle cable adjustment Before checking the throttle cable free play, the engine idling speed should be adjusted. The throttle cable should have an specified free play in the turning direction at the grip flange. If the free play is incorrect, 1. Free play Free play: 3 ~ 5 mm (0.12 ~ 0.19 in) 6-14 Throttle cable adjustment NOTE: Before checking the throttle cable free play, the engine idling speed should be adjusted.
Spark plug inspection Standard spark plug: CR7HSA (NGK) and U22FSR-U (DENSO) Before installing the spark plug, measure the electrode gap with a wire thickness gauge and adjust the gap to specification as necessary. Spark plug gap: 0.7 mm ( 0.028 in) When installing the plug, always clean the gasket surface and use a new gasket. Wipe off any grime from the threads, and torque the spark plug properly. 1.Spark plug gap The spark plug is an important engine component and is easy to inspect.
The clutch lever free play should be adjusted to 10 ~ 15 mm (0.4 ~ 0.6 in) at the clutch lever end. If the free play is incorrect, adjust as follows. 1. Loosen the locknut at the handlebar. 2. Turn the adjuster in (A) or out (B) until proper lever free play is obtained. Clutch adjustment 3. Tighten the locknut. 4. If the free play is still incorrect, make an adjustment at the crankcase side. 1. Locknut 2.
Front brake adjustment A soft or spongy feeling in the brake lever can indicate the presence of air in the brake system. This air must be removed by bleeding the brake system before the motorcycle is operated. Air in the brake system will considerably reduce braking performance and could result in a loss of control and possibly an accident. Inspect and if necessary, bleed the brake system. 1.
Rear brake adjustment WARNING: For brake pedal adjustment, be sure to proceed as follows (it is advisable to have a Yamaha dealer make this adjustment.) 1. Pedal height. a. Loosen the locknut. b. By turning the adjuster clockwise or counterclockwise adjust the brake pedal position so that its top end is approximatelly 2 mm (0.08 in) below the footrest top end. c. Tighten the locknut. 1. Adjusting nut 2. locknut a. Pedal height: 2 mm( 0.
ADVERTENCIA WARNING: After adjusting the pedal height adjust brake pedal free play. 2. Freeplay. The rear brake pedal free play should be adjusted to 20 ~ 30 mm (0.8 ~ 1.2 in) at the brake pedal end. Turn the adjuster on the brake rod clockwise to reduce play or counterclockwise to increase play. WARNING: ADVERTENCIA Brake pedal free play should be checked whenever the 1. Adjuster chain is adjusted or the rear wheel is removed and then reinstalled.
Checking the front brake pads and rear brake shoes Brake light switch adjustment A wear indicator is provided on each brake. This indicator allows checking of brake pad/shoe wear without disassembling the brake. = 1. Brake light switch 2. Adjusting nut The rear brake light switch is activated by the brake pedal and is properly adjusted when the brake light comes on just before braking takes effect.
Front Brake Apply the brake and inspect the wear indicator. If the wear indicator is almost in contact with the disc plate, ask a Yamaha dealer to replace the pads. 1. Wear indicator 2. Wear limit Apply the brake and inspect the wear indicator. If the indicator reaches the wear limit line, ask a Yamaha dealer to replace the shoes. Rear Brake 1. Wear limit line Front Brake 2. Wear indicator 6-21 Apply the brake and inspect the wear indicator.
Insufficient brake fluid may let air enter the brake system, Inspecting the brake fluid level possibly causing the brakes to become ineffective. Before riding, check that the brake fluid is above the lower level and replenish when necessary. Observe these precautions: 1. When checking the fluid level, make sure the top of the master cylinder is level by turning the handlebars. 2. Use only the designated quality brake fluid.
3. Refill with the same type of brake fluid. Mixing fluids may result in a harmful reaction and lead to poor brake Brake fluid replacement 1. Complete fluid replacement should be done only by performance. 4. Be careful that water does not enter the master cylinder when refilling. Water will significantly lower the boiling point of the fluid and may result in vapor lock. 5. Brake fluid may deteriorate painted surfaces or plastic trained service personnel. 2.
Drive chain slack check NOTE: Spin the wheel several times and find the tightest position of the chain. Check and/or adjust the chain slack while it is in this tightest position. To check the chain slack the motorcycle must be held straight up with both wheels on the ground and without rider. Check the slack at the position shown in the illustration. Normal slack is approximately 40 ~ 55 mm (1,6 ~ 2,2 in). If the slack exceeds 55 mm ( 2,2 in), adjust. a.
4. After adjusting, be sure to tighten the axle nut. Drive chain slack adjustment CAUTION: Too little chain slack will overload the engine and other vital parts. Keep the slack within the specified limits. Axle nut torque: 80 N.m (8.0 Kgf.m, 58 lbf.ft) 5. Adjust the free play in the brake pedal. 1. Adjuster 2. Chain puller 3. Axle nut CAUTION: 1. Loosen the rear brake adjuster. 2. Loosen the axle nut. 3. Turn both left and right chain puller the same amount.
Drive chain lubrication The chain consists of many parts which work with each other. If the chain is not maintained properly, it will wear out quickly. Therefore, the chain must be serviced regularly. This service is especially necessary when riding in dusty Cable inspection and lubrication WARNING: Damage to the outer housing of cables may allow internal rusting and cause interfere with cable movement. Replace damaged cables as soon as possible to prevent unsafe conditions. areas. 1.
Throttle cable and grip lubrication Brake and shift pedals Lubricate the pivoting parts. The throttle twist grip assembly should be greased at the time the cable is lubricated, since the grip must be removed to get at the end of the throttle cable. RECOMMENDED LUBRICANT: Engine oil SAE 20W50 After removing the screws, hold the end of the cable up in the air and put in several drops of lubricant.
Rear suspension Sidestand Lubricate the pivoting parts. Check to see that the sidestand moves up and down smoothly. RECOMMENDED LUBRICANT: Engine oil SAE 20W50 WARNING: If the sidestand does not move smoothly, consult a Yamaha dealer. 1.Nipple 2. Rear suspension Lubricate the rear suspension through the nipple. RECOMMENDED LUBRICANT: Molybdenum dissulfide grease 6-28 Rear suspension Sidestand Lubricate the pivoting parts. Check to see that the sidestand moves up and down smoothly.
Front fork inspection CAUTION: Securely support the motorcycle so there is no danger of it falling over. 1. Visual check Check for scratches or damage on the inner tube and excessive oil leakage from the front fork. 2. Operation check Place the motorcycle on a level place. a. Hold the motorcycle in an upright position and apply the front brake. b. Push down hard several times and check if the fork rebounds smoothly.
Rear shock absorber adjustment WARNING: This shock absorber contains highly pressurized nitrogen gas. Read and understand the following information before handling the shock absorber. The manufacturer cannot be held responsible for property damage or personal injury that may result from improper handling. 1. Spring preload adjusting ring 1. Do not tamper with or attempt to open the cylinder assembly. 2. Do not subject the shock absorber to an open flame or other high heat source.
Steering inspection Wheel bearings If there is play in the front or rear wheel hub or if the wheel does not turn smoothly, have a Yamaha dealer inspect the wheel bearings. The wheel bearings should be inspected according to the Maintenance Schedule. Periodically inspect the condition of the steering. Worn out or loose steering bearings may be dangerous. Place a stand under the engine to raise the front wheel off the ground. Hold the lower end of the front forks and try to move them forward and backward.
Battery Check the level of the battery electrolyte and make sure that the terminals are tight. Add distilled water if the electrolyte level is low. BATTERY BREATHER HOSE ROUTING WA R N I N G : 1. When inspecting the battery, make sure that the battery breather pipe routing is correct. If the breather pipe touches painted parts, or if its end is in such a position that may cause gas or electrolyte leakage, it may cause structural or esthetic damages to the motorcycle. 2.
Replenishing the battery fluid CAUTION: Battery electrolyte is poisonous and dangerous, causing severe burns, etc. It contains sulfuric acid. Avoid contact with skin, eyes or clothing. Antidote: EXTERNAL: Flush with water. INTERNAL: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable 1. Maximum marks oil. Call a physician immediately. EYES: Flush with water for 15 minutes and get prompt medical attention. Batteries produce explosive gases.
Fuse replacement Storage the battery 1. When the motorcycle is not used for a month or longer, remove the battery and store it in a cool, dark place. Completely recharge the battery before reinstallation. 2. If the baterry needs to be stored for a longer period than the period mentioned above, check the specific gravity at least once a month, and recharge it when the specific gravity is below normal. 3. Always make sure the connections are correct when reinstalling the battery.
Headlight bulb replacement This motocycle this equipped with halogen bulb on its headlight. If the headlight bulb burns out, replace the bulb as follows: 1. Remove the cowling by loosing its bolts. 2. Loosen the bulb connectors. ADVERTENCIA WARNING: Keep flammable products and your hands away from the bulb while it is on, as it is hot. Do not touch the bulb until it cools down 1. Screw 1. Bulb connectors 6-35 Headlight bulb replacement This motocycle this equipped with halogen bulb on its headlight.
3. Remove the rubber cover. 4. Remove the clip by pushing its tab dow. CAUTION: Avoid touching the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the life of the bulb and the luminous flux will be adversely affected. If the headlight bulb gets soiled, thoroughly clean it with a cloth moistened with alcohol or lacquer thinner. 5. Put a new bulb, install the socket and the bulb rubber cover. 6. Reconnect the connectors. 7. Reinstall the headlight assy.
Front wheel removal CAUTION: It is advisable to have a Yamaha dealer service the wheel. Securely support the motorcycle so there is no danger of it falling over. 1. Place a stand under the engine to raise the fornt wheel off the ground. 2. Remove the speedometer cable. 3. Remove the axle nut and axle. 1. Axle nut NOTE: Do not depress the brake lever when the disc is off the caliper as the brake pads will be forced shut. 2.
Front wheel installation When installing the front wheel, reverse the removal procedures. Pay attention to the following points: 1. Make sure that wheel boss and speedometer gear be installed with their projection fitted on their respective slits. 2. Make sure that front fork outer tub stopper is correctily placed on speedometer gear. 3. Make sure the axle nut is properly torqued. Axle nut torque: 80 N.m (8.0 Kgf.m, 58 lbf.
Rear wheel removal CAUTION: It is advisable to have a Yamaha dealer service the wheel. Securely support the motorcycle so there is no danger of it falling over. 1. Remove the brake adjuster. 1. Adjuster 3. Brake cam lever 2. Remove the brake rod from the brake cam lever. 3. Loosen the axle nut. 4. Elevate the rear wheel by placing a stand under the engine. 5. Remove the axle nut. 2. Brake rod 4. Axle nut 6. Push the wheel forward and remove the drive chain.
Rear wheel installation When installing the rear wheel, reverse the removal procedures. Pay attention to the following points: 1. Be sure the slot in the brake shoe plate is fit over the stopper on the rear arm. 2. Make sure the rear wheel axl is inserted from the righthand side and that the chain pullers are installed with the punched side outward. 3. Adjust the drive chain. 4. Make sure the axle nut is properly torqued. Axle nut torque: 80 N.m ( 8.0 Kgf.m, 58 lbf.ft) 5. Adjust the rear brake.
Troubleshooting Although Yamaha motorcycles receive a rigid inspection before shipment from the factory, trouble may occur during operation. Any problem in the fuel, compression, or ignition systems can cause poor starting and loss of power. The troubleshooting chart describes a quick, easy, procedure for making checks. If your motorcycle requires any repair, bring it to a Yamaha dealer.
Troubleshooting chart 1. Fuel ADVERTENC WARNING: Never check the fuel system while smoking or in the vicinity of an open flame. Enough fuel Go to compression check No fuel Supply fuel Check if there is fuel in the fuel tank Engine doesn’t start, go to compression check 2. Compression Use electric starter 3. Ignition Remove spark plug and check electrode 4.
CLEANING AND STORAGE A. Cleaning Frequent, thorough cleaning of your motorcycle will not only CAUTION: Excessive hose pressure may cause water seepage and deterioration of wheel bearings, front fork, brakes, transmission seals and electrical parts. Many expensive repair bills have resulted from enhance its appearance but will improve its general performance and extend the useful life of many components. 1. Before cleaning the motorcycle: a.
B. Storage Long term storage (30 days or more) of your machine will 7. If storing in a humid or salt-air atmosphere, coat all exposed metal surfaces with a light film of oil. Do not apply oil to any rubber parts or the require some preventive procedures to guard against deterioration. After thoroughly cleaning the machine, prepare for storage as follows: 1. Drain the fuel tank, fuel lines, and carburetor float bowl(s). seat cover. 8. Remove the battery and charge it.
SPECIFICATIONS XTZ 125E MODEL XTZ 125K Dimension: Overall length Overall width Overall height Seat height Wheet base Minimum ground clearance 2.090 mm (82.3 in) 810 mm (31.9 in) 1.125 mm (44.3 in) 840 mm (33.1 in) 1.340 mm (52.7 in) 265 mm (10.4 in) 2.090 mm (82.3 in) 810 mm (31.9 in) 1.125 mm (44.3 in) 840 mm (33.1 in) 1.340 mm (52.7 in) 265 mm (10.4 in) Basic weight: With oil and without fuel: 104 Kg (229 lb) 114 Kg (251 lb) 103 Kg (227 lb) 113 Kg (249 lb) Minimum turning radius: 2.100 mm (82.
MODEL XTZ 125E and XTZ 125K Engine oil: Type YAMALUBE 4 or SAE 20W50 type SH Capacity: Periódic oil change Total amount 1,0 l ( 0,220 Imp gal, 0.264 US gal) 1,2 l ( 0,264 Imp gal, 0.317 US gal) Air filter: Wet type element Fuel: Type Tank capacity Reserve amount Regular unleaded gasoline 10,6 l ( 2.33 Imp gal, 2.80 US gal) 1,0 l ( 0.220 Imp gal, 0.264 US gal) Carburetor: Type / manufacturer VM 20SS / Mikuni Spark plug: Type / manufacturer Gap CR7HSA / NGK or U22FSR-U / DENSO 0.7 mm (0.
MODEL XTZ 125E and XTZ 125K Transmission: Primary reducion system Primary reduction rate Secondary reduction system Secondary reduction rate Transmission type Operatíon Gear ratio 1st 2nd 3rd 4th 5th Spur gear 68 / 20 Chain drive 48 / 14 Constant mesh 5-speed Left foot operation 37 / 14 32 / 18 25 / 19 23 / 22 21 / 24 Chassis: Frame type Caster angle Trail Diamond 26° 20’ 106 mm (4,2 in) Tire: Type Size: With tube Front Rear 80 / 90-21 48T 110 / 80-18 58T 8-3 MODEL Transmission: Primary reducion s
XTZ 125E and XTZ 125K MODEL Brakes: Front brake type Operation Single, Disc brake Right hand operation Rear brake type Operation Drum brake Right foot operation Suspension: Front Rear Telescopic fork Swingarm (New monocross suspension) Shock absorber: Front Coil spring, Oil damper Rear Gas, Coil spring. Oil damper Wheel travel Front Rear 180 mm (7.1 in) 180 mm (7.1 in) Electrical: Ignition system Generator system Battery type / capacity C.D.I. AC Magneto generator YB5L-B/ 12V 5.
MODEL XTZ 125E and XTZ 125K Halogen bulb Headlight type: Bulb wattage x quantity Headlight tail / Brake light Flasher light 12V 35W/35W (1 Pc) 12V 5W/21W (1 Pc) 12V 10W (4 Pc) Indicator light wattage x quantity: Panel Neutral tamp Headlight Flasher light 12V x 3,4W (1 Pc) 12V x 1,7W (1 Pc) 12V x 1,7W (1 Pc) 12V x 1,7W (1 Pc) 8-5 MODEL Headlight type: Bulb wattage x quantity Headlight tail / Brake light Flasher light XTZ 125E Halogen bulb 12V 35W/35W (1 Pc) 12V 5W/21W (1 Pc) 12V 10W (4 Pc)