Yamaha XTZ 125K Page 89 Owner'S Manual Download

Page: 89 / 97

6-42

Troubleshooting chart

ADVERTENC

Never check the fuel system while smoking or in the

vicinity of an open flame.

WARNING:

Check if there is
fuel in the fuel tank

Use electric
starter

Remove spark plug
and check
electrode

Use electric starter

1. Fuel

2. Compression

3. Ignition

4. Battery *

Enough fuel

No fuel

There is compression

No compression

Wet

Dry

Engine turns
over quickly

Engine turns
over slowly

Supply fuel

Go to ignition 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 battery check

* Obs.: XTZ 125E

Troubleshooting chart

ADVERTENC

Never check the fuel system while smoking or in the

vicinity of an open flame.

WARNING:

Check if there is
fuel in the fuel tank

Use electric
starter

Remove spark plug
and check
electrode

Use electric starter

1. Fuel

2. Compression

3. Ignition

4. Battery *

Enough fuel

No fuel

There is compression

No compression

Wet

Dry

Engine turns
over quickly

Engine turns
over slowly

Supply fuel

Go to ignition 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 battery check

* Obs.: XTZ 125E

Summary of Contents for XTZ 125K

Page 1: ......

Page 2: ...ng 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 seri...

Page 3: ...2003 Yamaha Motor da Amaz nia Ltda 1st edition April 2003 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor da Amaz nia Ltda is expressly prohibited...

Page 4: ...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 YA...

Page 5: ...OTE 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...

Page 6: ...DING 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 ATTE...

Page 7: ...oid 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 du...

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...

Page 9: ...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...

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 anot...

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...

Page 12: ...nd 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 Batter...

Page 13: ...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 ki...

Page 14: ...ches 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...

Page 15: ...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 pi...

Page 16: ...n 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 o...

Page 17: ...ed to the or 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...

Page 18: ...ank 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...

Page 19: ...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 positi...

Page 20: ...tch 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 righ...

Page 21: ...ped 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...

Page 22: ...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 brak...

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...

Page 24: ...uretor 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 t...

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...

Page 26: ...ove 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 turne...

Page 27: ...k 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 receptac...

Page 28: ...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 Inse...

Page 29: ...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...

Page 30: ...H 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 consul...

Page 31: ...ck 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 conditio...

Page 32: ...torcycle 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 Ba...

Page 33: ...n 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 Yamah...

Page 34: ...l 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 necessa...

Page 35: ...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 l...

Page 36: ...rating 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 qualifie...

Page 37: ...atching 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 extensi...

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...

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 fue...

Page 40: ...e 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 sid...

Page 41: ...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 starte...

Page 42: ...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 serv...

Page 43: ...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 ENG...

Page 44: ...losed 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 wh...

Page 45: ...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...

Page 46: ...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 i...

Page 47: ...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...

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 motor...

Page 49: ...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 change...

Page 50: ...st 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 C...

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 sea...

Page 52: ...ason 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 Tor...

Page 53: ...ntil 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 s...

Page 54: ...he 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 en...

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 coul...

Page 56: ...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 t...

Page 57: ...ter 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...

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...

Page 59: ...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...

Page 60: ...00 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...

Page 61: ...le 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 sh...

Page 62: ...e 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...

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...

Page 64: ...t 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 presen...

Page 65: ...al 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...

Page 66: ...ed 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 a...

Page 67: ...ke 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 bra...

Page 68: ...ear 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 ind...

Page 69: ...ted 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...

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...

Page 71: ...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...

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...

Page 73: ...mediately 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 poss...

Page 74: ...l 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...

Page 75: ...50 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 WARNIN...

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...

Page 77: ...r 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...

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 an...

Page 79: ...se 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...

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 dist...

Page 81: ...ions 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 s...

Page 82: ...ammable 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 thi...

Page 83: ...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 head...

Page 84: ...se 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 sh...

Page 85: ...re 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 inst...

Page 86: ...r 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...

Page 87: ...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 re...

Page 88: ...d 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...

Page 89: ...tion 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...

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...

Page 91: ...lt 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 recharg...

Page 92: ...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 m...

Page 93: ...ype 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...

Page 94: ...er 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 11...

Page 95: ...Z 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...

Page 96: ...light 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...

Page 97: ......

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Yamaha XTZ 125K, Owner'S Manual

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