Yamaha xt 125 Owner'S Manual Download

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6-16

Clutch adjustment

1. Locknut

2. Adjuster

a. Free play

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.

Loosen the locknut at the handlebar.

Turn the adjuster in (A) or out (B) until proper lever free

play is obtained.

Tighten the locknut.

If the free play is still incorrect, make an adjustment at

the crankcase side.

NOTE:

If proper adjustment cannot be obtained or the clutch does

not work correctly, ask a Yamaha dealer to inspect the

internal clutch mechanism.

Clutch adjustment

1. Locknut

2. Adjuster

a. Free play

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.

Loosen the locknut at the handlebar.

Turn the adjuster in (A) or out (B) until proper lever free

play is obtained.

Tighten the locknut.

If the free play is still incorrect, make an adjustment at

the crankcase side.

NOTE:

If proper adjustment cannot be obtained or the clutch does

not work correctly, ask a Yamaha dealer to inspect the

internal clutch mechanism.

Summary of Contents for xt 125

Page 1: ......

Page 2: ...ing spare parts from a Yamaha dealer or reference in case the vehicle is stolen 2 ENGINE SERIAL NUMBER IDENTIFICATION NUMBERS RECORD 1 FRAME SERIAL NUMBER 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 2 ENGINE SERIAL NUMBER ...

Page 3: ... 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 XTZ 125K XTZ 125E ...

Page 4: ...u an understanding of the operation inspection and basic maintenance of this motorcycle If you have any questions about the operation or maintenance of your motorcycle please consult a Yamaha dealer YAMAHA MOTOR DA AMAZÕNIA LTDA 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 touri...

Page 5: ...NOTE provides key information to make procedures easier or clearer A CAUTION indicates special precautions that must be taken to avoid damage to the machine 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 CAUTION Particularly important information is distinguished in this manua...

Page 6: ...IDING SKILLS WILL ENSURE THAT YOU SAFELY ENJOY THE CAPABILITIES AND THE RELIABILITY OF THIS MOTORCYCLE 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 INS...

Page 7: ...void an accident b Only lend your machine to experienced operators 3 Many machine accidents have been caused by machine operator errors A typical error made by the operator is veering wide on a turn due to EXCESSIVE SPEED or undercornering insufficient lean angle for the speed Never travel faster than warranted by conditions 4 Ride cautiously in unfamiliar areas You may encounter hidden obstacles ...

Page 8: ... cause injury or accident 5 Never touch the engine or exhaust system during or after operation They become very hot and can cause burns Always wear protective clothing that covers your legs ankles and feet 6 Always use clear clothes to make your visualization easier 7 Items above must also be followed by pillion rider MODIFICATION Modifications made to the machine not approved by Yamaha or the rem...

Page 9: ...n or aerodynamic changes If accessories are added to the handlebar or front fork area they must be as lightweight as possible and should be kept to a minimum b Bulky or large accessories may seriously affect the stability of the machine due to aerodynamic effects Wind may attempt to lift the machine or the machine may become unstable in cross winds These accessories may also cause instability when...

Page 10: ... soft ground the machine may fall over c Do not park the machine near a flammable source e g a kerosene heater or near an open flame The machine could catch fire 4 When transporting the machine in another vehicle be sure it is kept upright and that the fuel cock is turned to ON or RES for vacuum type OFF for manual type If it should lean over gasoline may leak out of the carburetor or fuel tank 5 ...

Page 11: ... operation check 3 15 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 4 8 Switches 4 8 Wheels 4 8 Fuel 4 9 OPERATION AND IMPORTANT RIDING POINTS 5 1 Starting a cold engine 5 2 Starting a warm engine 5 5 Warming up the engine 5 5 Shifting 5 6 Tips for reducing fuel consumption 5 7 Engine Break in 5 7 Parking 5 8 PER...

Page 12: ...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 6 31 Wheel bearings 6 31 Battery 6 32 Replenishing the battery fluid 6 33 Storage the battery 6 34 Fuse replacement 6 34 Headlight bulb replacement 6 35 Front wheel removal 6 37 Front wheel installation 6 38 Rear wheel removal 6 3...

Page 13: ...r switches over right 14 Speedometer 15 Main switch 16 Front brake lever 17 Throttle grip 18 Handlebar switches over left 19 Fuel tank cap 01 Fuel cock 02 Starter lever 03 Battery 04 Fusible 05 Tool kit 06 Shift pedal 07 Shock absorber 08 Air filter 09 Kick starter DESCRIPTION XTZ 125K ...

Page 14: ...tches over right 13 Speedometer 14 Main switch 15 Front brake lever 16 Throttle grip 17 Handlebar switches over left 18 Fuel tank cap 01 Fuel cock 02 Starter lever 03 Battery 04 Fusible 05 Tool kit 06 Shift pedal 07 Shock absorber 08 Air filter 09 Dispstick DESCRIPTION XTZ 125E ...

Page 15: ...y 12th to 17th digits Record these numbers for reference in case of ordering parts from a Yamaha dealer A B MACHINE IDENTIFICATION The vehicle identification number is stamped into the steering head pipe Record this number in the space provided The engine serial number is stamped on right hand engine crankcase NOTE Vehicle identification number Engine serial number MACHINE IDENTIFICATION ...

Page 16: ...an 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 NOTE Always turn the main switch to OFF or LOCK and remove the key when the motorcycle is unattended CONTROL FUNCTIONS Main switch The main switch controls the ignition and the electrical system It s operation is described below ON Electric...

Page 17: ...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 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 ...

Page 18: ...tank of fuel This information will enable you to plan fuel stops in the future 1 Speedometer 2 Odometer 3 Trip meter 4 Adjusting knob 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 wi...

Page 19: ...m and to for the low beam TURN SIGNAL SWITCH To signal a right hand turn push the switch to to signal a left hand turn push the switch to Once the switch is released it will return to the center position To cancel the signal push the switch in after it has returned to the center position HORN SWITCH Press the switch to sound the horn Handlebar switches over left LIGHTS SWITCH Turning the light swi...

Page 20: ...itch to to stop the engine STARTER SWITCH The starter motor cranks the engine when pushing the starter switch CAUTION See starting instructions prior to starting the engine 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 th...

Page 21: ...pped with a constant mesh 5 speed transmission The shift pedal is located on the left side of the engine and is used in combination with the clutch when shifting Clutch lever Shift pedal 1 Clutch lever 1 Shift pedal 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...

Page 22: ...e The rear brake pedal is on the right side of the motorcycle Press down the brake pedal to apply the rear brake Front brake lever 1 Front brake lever 1 Rear brake pedal Rear brake pedal The front brake lever is located on the right handlebar Pull it toward the handlebar to apply the front brake Front brake lever ...

Page 23: ... 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 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 TO CLOSE Push the tank cap into position with the key inserted To remove the key turn it clockwise to the original positio...

Page 24: ...buretor Set the fuel cock to this position when starting the engine and while riding RES This indicates reserve If you run out of fuel while riding set the fuel cock to this position Fill the tank at the first opportunity Be sure to set fuel cock back to ON after refueling Fuel cock The fuel cock supplies fuel from the tank to the carburetor while filtering it also The fuel cock has three position...

Page 25: ... starter XTZ 125K 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 Kick starter Starting a cold engine requires a richer air fuel mixture A separate starter circuit supplies the mixture Pull the starter knob up to open the circuit for starting When t...

Page 26: ...move the key To release the lock turn the key to OFF WARNING Never turn the key to LOCK position when the motorcycle is moving Steering lock WARNING 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...

Page 27: ...nk then tighten the bolts Reinstall the side covers NOTE Make sure the seat is securely fitted Seat 1 Bolts 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 Seat ...

Page 28: ...o reinstall reverse the removal procedures Remove the screw and then pull the cover to release the pins To reinstall reverse the removal procedures 1 Lock the side cover 2 Pull A Pin A Side covers Insert the key and turn it 1 4 clockwise Pull the cover to release the pins To reinstall reverse the removal procedures A ...

Page 29: ...r proper adjustment procedures Rear shock absorber 1 Spring preload adjusting ring 2 Position indicator 1 2 3 4 5 6 7 Adjusting position Soft Standard Hard 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 Rear shock absorber ...

Page 30: ...CH TO TRANSMISSION IS IN GEAR PULL IN CLUTCH LEVER AND PUSH STARTER SWITCH ENGINE WILL START Clutch switch operation check CLUTCH SWITCH IS OK WARNING Obs XTZ 125E 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 Clutch switch operati...

Page 31: ...eck tire pressure wear damage and spoke tightness Check for smooth operation Lubricate if necessary 4 3 4 4 6 17 6 23 4 8 6 14 6 27 4 4 6 6 6 9 6 24 6 26 6 10 6 11 4 5 4 8 6 26 Check operation condition and free play Adjust if necessary Wheels Tires Clean and oil it frequently 4 8 6 16 Rear brake Check operation free play fluid level and fluid leakage Top up with DOT 4 or DOT 3 brake fluid if nece...

Page 32: ...otorcycle ITEM ROUTINE PAGE Sidestand Fittings Fasteners Check all chassi fittings and fasteners Tighten Adjust if necessary Check fuel level top up as required Fuel tank Lights signals and switches Battery Check electrolyte level Replenish with distilled water if necessary 6 27 4 8 6 5 4 8 6 35 6 36 6 32 6 34 6 28 4 9 Check for proper operation Front brake and clutch lever pivots Check for smooth...

Page 33: ...on in the brake system NOTE If DOT 4 is not available 3 can be used 3 Check the disc pads Refer to page 6 20 4 Check the brake shoes Refer to page 6 20 When a brake service is necessary consult a Yamaha dealer or other qualified mechanic NOTE 2 Brake fluid Check the brake fluid level Add fluid if necessary RECOMMENDED BRAKE FLUID DOT 4 WARNING Brakes See page 6 17 for details 1 Brake lever and bra...

Page 34: ...al 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 Engine oil See page 6 6 for details Make sure the engine oil is at the specified level Add oil as necessary Check the oil level in a daily manner and top it up if necessary CAUTION Brake fluid may deteriorate painted surfaces or plastic parts Never spill any fluid If spilled clean it up Brake fluid leak...

Page 35: ...G Basic weight With oil and without fuel XTZ 125K 113 Kg 249 lb XTZ 125E 114 Kg 251 lb Load is the total weght of cargo rider passenger and accessories Maximum load Cold tire pressure up to 90 Kg 198 lb load 90 Kg 198 lb maximum load 150 Kg 330 kg Front 1 5 kg cm2 22 PSI 147 kpa Rear 1 5 kg cm2 22 PSI 147Kpa 1 5 kg cm2 22 PSI 145 Kpa 2 0 kg cm2 28 PSI 200 Kpa Tires To ensure maximum performance lo...

Page 36: ...erating 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 the side wall is cracked contact a Yamaha dealer or other qualified mechanic and have the tire replaced 1 Tread depth 2 Side wall 3 wear indicator WARNING Proper loading of your motorcycle is important for the handling braking and other performance and safety chara...

Page 37: ...Patching a punctured tube is not recommended If it is absolutely necessary to do so use great care and replace the tube as soon as possible with a good quality replacement WARNING WARNING After extensive tests the tires listed below have been approved by Yamaha for this model The front and rear tires should always be by the same manufacturer and of the same design No guarantee concerning handling ...

Page 38: ... sure the lever operates properly If the free play is incorrect adjust it Throttle grip See page 6 14 for details Turn the throttle grip to see if it operates properly and check the free play Make sure the grip returns by spring force when released Ask a Yamaha dealer or other qualified mechanic to make any necessary adjustments Fitting Fasteners Alway check the tightness of chassis fittings and f...

Page 39: ... gasoline with a pump octane number R m 2 of 86 or higher or research octane number of 91 or higher If knocking or pinging occurs use a different brand of gasoline or premium unleaded fuel Unleaded fuel will give you longer spark plug life and reduced maintenance cost If unleaded gasoline is not available then leaded regular gasoline can be used Gasohol There are two types of gasohol gasohol conta...

Page 40: ...se loss of consciousness and death within a short time Always operate your machine in an area with adequate ventilation Before starting out always be sure the sidestand is up Failure to retract the sidestand completely can result in a serious accident when you try to turn a corner OPERATION AND IMPORTANT RIDING POINTS CAUTION 1 Be very careful if you are carrying object while riding the motorcycle...

Page 41: ...n into neutral 7 After warming up the engine turn back the starter CHOKE completely NOTE The engine is warm when it responds normally to the throttle with the starter turned off 4 Fully open the starter CHOKE and completely close the throttle grip 5 Kick the kick start to start the engine 6 After starting the engine turn back the starter to an intermediate position NOTE To obtain maximum engine li...

Page 42: ...e is warm when it responds normally to the throttle with the starter turned off 6 After starting the engine turn back the starter to an intermediate position NOTE To obtain maximum engine life and service do not ever thoroughly accelerate it while the engine is cold This motorcycle is equipped with a starting and an ignition circuit cut off switch NOTE 1 The engine can be started only under the fo...

Page 43: ...S IN NEUTRAL IF TRANSMISSION IS IN GEAR PULL IN CLUTCH LEVER AND PUSH STARTER SWITCH ENGINE WILL START PUT TRANSMISSION IN GEAR MOTORCYCLE CAN BE RIDDEN MOTORCYCLE CAN BE RIDDEN PUSH STARTER SWITCH ENGINE WILL START WARNING Obs XTZ 125E Before going through the following steps check the function of the clutch switch See page 3 15 TURN THE MAIN SWITCH TO ON AND WARNING ...

Page 44: ...closed and check to see if it responds normally CAUTION See the Break in section prior to operating the motorcycle for the first time CAUTION Starting a warm engine The starter lever is not required when the engine is warm 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 Warming up the engine For an extended engine life always war...

Page 45: ...3 6 To shift into NEUTRAL depress the shift pedal repeatedly until it reaches the end of its travel you will feel a stop when you are in first gear then raise the pedal slightly CAUTION 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 Inadequate lubric...

Page 46: ...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 Turn off the engine instead of letting it idle for an extended lenght of time i e in traffic jams at traffic lights or railroad crossings Tips for reducing fuel consumption Engine Break in There is never a more important...

Page 47: ...d consult a Yamaha dealer immediately The muffler and exhaust pipe are hot Park the motorcycle in a place where pedestrians or children are not likely to touch the motorcycle Do not park the motorcycle on a slope or soft ground the motorcycle may fall over WARNING 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 throttl...

Page 48: ... SHORTER INTERVALS TO MATCH THE ENVIRONMENT The most important points of motorcycle inspection adjustment and lubrication are explained in the following pages CAUTION If you are not familiar with motorcycle service this work should be done by a Yamaha dealer PERIODIC MAINTENANCE AND MINOR REPAIRS Perodic inspection adjustment and lubrication will keep your motorcycle in the safest and most efficie...

Page 49: ...r for service Modifications to this motorcycle not approved by Yamaha may cause loss of performance excessive emissions and render it unsafe for use Consult a Yamaha dealer before attempting any changes WARNING Tool kit The tools provided in the owner s tool kit are to assist you in the performance of periodic maintenance However some other tools such as a torque wrench are also necessary to perfo...

Page 50: ...ust Grease the brake cam Replace Check level Check loosenes Repack every 12 000 km or 12 month Check rear arm assembly for looseness Moderately repack EVERY 3 000KM OR ERERY 6 MONTHS Wheels and tires Check tire pressure runout and spoke tightness Spark plug Check condition and clean if necessary Replace if necessary every 12 000 Km 3 000KM PERIODIC MAINTENANCE LUBRICATION ITEM How it sounds Adjust...

Page 51: ... cylinder or caliper cylinder replace the brake fluid Normally check the brake fluid level and add fluid as required 2 On the inner parts of the master cylinder and caliper cylinder replace the oil seals every two years 3 Replace the brake hoses every four years or if cracked or damaged ITEM Front forks Sidestand Control cables throttle clutch front brake Rear shock absorber Drive chain Fittings f...

Page 52: ...eason A Nut 10 mm 12 mm 14 mm 17 mm 19 mm 22 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 specifications Torque Nm kgfm Item Nm 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...

Page 53: ...until the oil level settles before checking c remove the oil filler cap dispstick clean it with a dry cloth and check the oil level NOTE To check the oil level the oil filler cap dispstick can not be screwed just lightly seated in place d The oil level should be between the maximum and minimum marks If the level is low add oil to raise it to the indicated level check for oil leakage Engine oil 1 O...

Page 54: ...the specified torque 1 Dipstick 1 Engine oil drain plug 2 Engine oil and filter replacement Tightening torque Drain plug 20 N m 2 0 kgf m 14 5 lbf t a Warm up the engine for a few minutes b Stop the engine Place an oil pan under the engine and 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 torq...

Page 55: ... g Stop the engine and check the oil level CAUTION Be sure no foreign material enters the crankcase CAUTION Do not put in any chemical additives Engine oil also lubricates the clutch and additives could cause clutch slippage After replacing the engine oil be sure to check the oil pressure CAUTION e Fill engine with oil Install the oil filter cap and tighten Recommended oil YAMALUBE 4 Oil quantity ...

Page 56: ...r 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 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 de...

Page 57: ...lter case cover by removing the bolts 3 Remove the air filter from the case Air filter 1 Side cover 2 Bolts 1 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 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 cas...

Page 58: ... 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 6 Reinstall the air filter in its case 7 Install the air filter case cover and the right side cover Recommended oil 4 Remove the air filter element from the guide and clean it with solvent After cleaning remove the remaining solvent by s...

Page 59: ...s part of routine maintenance CAUTION The carburetor was set at Yamaha factory after many tests If the settings are changed poor engine performance and damage may result 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 p...

Page 60: ...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 NOTE A diagnostic tachometer must be used for this procedure Idle speed adjustment 1 Attach the tachometer Star...

Page 61: ...ble should have an specified free play in the turning direction at the grip flange If the free play is incorrect 1 Free play NOTE Before checking the throttle cable free play the engine idling speed should be adjusted Throttle cable adjustment The throttle cable should have an specified free play in the turning direction at the grip flange If the free play is incorrect ...

Page 62: ...he spark plug because heat and deposits will cause the spark plug to slowly break down and erode If electrode erosion becomes excessive or if carbon and other deposits are excessive you should replace the spark plug with the specified plug NOTE If a torque wrench is not available when you are installing a spark plug a good estimate of the correct torque is 1 4 to 1 2 turn past finger tight Have th...

Page 63: ... still incorrect make an adjustment at the crankcase side NOTE If proper adjustment cannot be obtained or the clutch does not work correctly ask a Yamaha dealer to inspect the internal clutch mechanism Clutch adjustment 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...

Page 64: ...lt in a loss of control and possibly an accident Inspect and if necessary bleed the brake system 1 Front lever 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 re...

Page 65: ...dal position so that its top end is approximatelly 2 mm 0 08 in below the footrest top end c Tighten the locknut Rear brake adjustment 1 Adjusting nut 2 locknut a Pedal height 2 mm 0 08 in 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 counterclo...

Page 66: ...ked whenever the chain is adjusted or the rear wheel is removed and then reinstalled If it is impossible to make proper adjustment consult a Yamaha dealer Check the operation of the brake light after adjusting the rear brake 1 Adjuster a Free play 20 30 mm 0 8 1 2 in WARNING WARNING ADVERTENCIA After adjusting the pedal height adjust brake pedal free play 2 Freeplay The rear brake pedal free play ...

Page 67: ...ake the brake light come on earlier Turn the adjusting nut in direction to make the brake light come on later Checking the front brake pads and rear brake shoes 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 Brake light switch adjustment Checking the front brake pads and rear brak...

Page 68: ...Rear 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 Front Brake 1 Wear limit line 2 Wear indicator 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 Front Brake ...

Page 69: ...ated quality brake fluid Otherwise the rubber seals may deteriorate causing leakage and poor brake performance Recommended brake fluid DOT 4 NOTE If DOT 4 is not available 3 can be used Inspecting the brake fluid level Insufficient brake fluid may let air enter the brake system possibly causing the brakes to become ineffective Before riding check that the brake fluid is above the lower level and r...

Page 70: ... or when they are damaged or leaking a Replace all rubber seals every two years b Replace all hoses every four years Brake fluid replacement 3 Refill with the same type of brake fluid Mixing fluids may result in a harmful reaction and lead to poor brake performance 4 Be careful that water does not enter the master cylinder when refilling Water will significantly lower the boiling point of the flui...

Page 71: ...n 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 Drive chain slack check a Free play 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 grou...

Page 72: ... rear brake adjuster 2 Loosen the axle nut 3 Turn both left and right chain puller the same amount Make sure that they are in the same position for proper wheel alignment Drive chain slack adjustment 1 Adjuster 2 Chain puller 3 Axle nut 4 After adjusting be sure to tighten the axle nut CAUTION Too little chain slack will overload the engine and other vital parts Keep the slack within the specified...

Page 73: ...mmediately lubricate the chain to prevent it from rusting 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 Lubricate the inner cable and the cable end If it does not operate smoothly ask a Yamaha dealer to replace them RECOMMENDED LUBRICANT Engine oil SAE 20W50 WARNING Ca...

Page 74: ...al surface of the grip assembly with a suitable all purpose grease Brake and shift pedals Lubricate the pivoting parts RECOMMENDED LUBRICANT Engine oil SAE 20W50 Brake and clutch levers Throttle cable and grip lubrication 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 After removing the s...

Page 75: ...W50 If the sidestand does not move smoothly consult a Yamaha dealer Lubricate the rear suspension through the nipple RECOMMENDED LUBRICANT Molybdenum dissulfide grease 1 Nipple 2 Rear suspension WARNING Rear suspension Sidestand Lubricate the pivoting parts Check to see that the sidestand moves up and down smoothly RECOMMENDED LUBRICANT Engine oil SAE 20W50 ...

Page 76: ... down hard several times and check if the fork rebounds smoothly If any damage or unsmooth movement is found with the front fork consult a Yamaha dealer CAUTION Securely support the motorcycle so there is no danger of it falling over WARNING Front fork inspection 1 Visual check Check for scratches or damage on the inner tube and excessive oil leakage from the front fork 2 Operation check CAUTION S...

Page 77: ...ar shock absorber adjustment The spring prelod of the rear shock absorber can be adjusted to suit rider s preference weight and course condition Turn the adjusting ring in direction to increase spring preload and in direction to decrease spring preload Make sure that the appropriate notch in the adjusting ring is aligned with the position indicator on the rear shock absorber 1 Spring preload adjus...

Page 78: ... 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 If any free play can be felt ask a Yamaha dealer to inspect and adjust the steering Inspection is easier if the front wheel is removed WARNING Wheel bearings If there is play in the front or rear wheel hu...

Page 79: ...use gas or electrolyte leakage it may cause structural or esthetic damages to the motorcycle 2 Take care not to spill battery fluid on the chain Battery fluid may weaken the chain causing shorter chain life and possibly result in an accident WARNING Battery BATTERY BREATHER HOSE ROUTING Check the level of the battery electrolyte and make sure that the terminals are tight Add distilled water if the...

Page 80: ... batteries KEEP OUT OF REACH OF CHILDREN Replenishing the battery fluid 1 Maximum marks 2 Minimum marks Normal tap water contains minerals which are harmful to a battery therefore refill only with distilled water A poorly maintained battery will corrode and discharge quickly The battery fluid should be checked at least once a month The level should be between the minimum and maximum marks Use only...

Page 81: ...tions and in good condition FUSE CAPACITY 10 A If a fuse is blown turn off the ignition switch and the switch of the circuit in question Install a new fuse of proper amperage Turn on the switches and see if the electrical device operates If the fuse immediately blows again consult a Yamaha dealer 1 Fuse 2 Reserve CAUTION Do not use fuses of higher amperage rating than those recommended Substitutio...

Page 82: ...lammable 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 WARNING 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 Keep flamm...

Page 83: ...h 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 If it is necessary to adjust the headlight beam please consult a Yamaha dealer 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 other...

Page 84: ...ise the fornt wheel off the ground 2 Remove the speedometer cable 3 Remove the axle nut and axle NOTE Do not depress the brake lever when the disc is off the caliper as the brake pads will be forced shut 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 r...

Page 85: ...ure 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 ft 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 respect...

Page 86: ...ar wheel by placing a stand under the engine 5 Remove the axle nut 6 Push the wheel forward and remove the drive chain NOTA There is no need of disassembling the drive chain to remove or reinstall the rear wheel 7 Pull out the axle and remove the wheel assembly by pulling backward CAUTION Rear wheel removal It is advisable to have a Yamaha dealer service the wheel Securely support the motorcycle s...

Page 87: ...e 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 See page 6 18 Check the operation of the brake light after adjusting the rear brake WARNING 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...

Page 88: ...nd know how to properly service your motorcycle Use only genuine Yamaha parts on your motorcycle Imitation parts may look like Yamaha parts but they are often inferior Consequently they have a shorter service life and can lead to expensive repair bills Troubleshooting Although Yamaha motorcycles receive a rigid inspection before shipment from the factory trouble may occur during operation Any prob...

Page 89: ...ition check Ask Yamaha dealer to inspect Wipe clean with dry cloth and correct spark plug gap or replace spark plugs Ask Yamaha dealer to inspect Battery good Check fluid recharge and check connections Go to compression check Engine doesn t start go to compression check Open the throttle hal way and start the engine Engine doesn t start ask Yamaha dealer to inspect Engine doesn t start go to batte...

Page 90: ... mild detergent type soap An old toothbrush or bottle brush is handy for hard to get at places 5 Rinse the motorcycle off immediately with clean water and dry all surfaces with a chamois clean towel or soft absorbent cloth 6 Dry the chain and lubricate it to prevent rust 7 Clean the seat with a vinyl upholstery cleaner to keep the cover pliable and glossy 8 Automotive type wax may be applied to al...

Page 91: ...alt air atmosphere coat all exposed metal surfaces with a light film of oil Do not apply oil to any rubber parts or the seat cover 8 Remove the battery and charge it Store it in a dry place and recharge it once a month Do not store the battery in an excessively warm or cold place less than 0ºC 30ºF or more than 30ºC 90ºF NOTE Make any necessary repairs before storing the machine B Storage Long ter...

Page 92: ...m 82 7 in XTZ 125K Air cooled 4 stroke gasoline SOHC Single cylinder 123 7 cm3 54 x 54 mm 2 13 x 2 13 in 10 0 1 Kick starter Wet sump 104 Kg 229 lb 114 Kg 251 lb 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 2 100 mm 82 7 in XTZ 125E Air cooled 4 stroke gasoline SOHC Single cylinder 123 7 cm3 54 x 54 mm 2 13 x 2 13 in 10 0 1 Electric starter Wet su...

Page 93: ...type SH Wet type element CR7HSA NGK or U22FSR U DENSO 0 7 mm 0 028 in Wet multi disc 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 1 0 l 0 220 Imp gal 0 264 US gal 1 2 l 0 264 Imp gal 0 317 US gal VM 20SS Mikuni MODEL XTZ 125E and XTZ 125K Engine oil Capacity Periódic oil change Total amount Type YAMALUBE 4 or SAE 20W50 type SH 1 0 l 0 220 Imp gal 0 264...

Page 94: ...ter angle Trail Tire Type Size Front Rear 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 Diamond 26 20 106 mm 4 2 in With tube 80 90 21 48T 110 80 18 58T MODEL XTZ 125E and XTZ 125K Transmission Primary reducion system Primary reduction rate Secondary reduction system Secondary reduction rate Transmission type Spur gear 68 20 Chain drive 4...

Page 95: ...TZ 125E and XTZ 125K Coil spring Oil damper Gas Coil spring Oil damper 180 mm 7 1 in 180 mm 7 1 in Telescopic fork Swingarm New monocross suspension C D I AC Magneto generator YB5L B 12V 5 0 Ah Single Disc brake Right hand operation Drum brake Right foot operation MODEL Brakes Front brake type Operation Rear brake type Operation XTZ 125E Single Disc brake Right hand operation Drum brake Right foot...

Page 96: ...dlight Flasher light Headlight type XTZ 125E and XTZ 125K 12V 35W 35W 1 Pc 12V 5W 21W 1 Pc 12V 10W 4 Pc 12V x 3 4W 1 Pc 12V x 1 7W 1 Pc 12V x 1 7W 1 Pc 12V x 1 7W 1 Pc Halogen bulb MODEL Bulb wattage x quantity Headlight tail Brake light Flasher light Headlight type XTZ 125E 12V 35W 35W 1 Pc 12V 5W 21W 1 Pc 12V 10W 4 Pc Halogen bulb ...

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Yamaha xt 125, Owner'S Manual

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