engine YAMAHA XTZ125 2003 Owner's Manual

5-3
5-3 NOTE:
If the engine fails to start, release the starter switch, wait a
few seconds, then try again. Each attempt should be as
short as possible to preseve the battery. Do not crank the
engine more than 10 seconds on any one attempt.
This motorcycle is equipped with a starting and an ignition
circuit cut-off switch. NOTE:
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.
2. The motorcycle must not be ridden when the sidestand
is down.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.
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.
NOTE:
If the engine fails to start, release the starter switch, wait a
few seconds, then try again. Each attempt should be as
short as possible to preseve the battery. Do not crank the
engine more than 10 seconds on any one attempt.
This motorcycle is equipped with a starting and an ignition
circuit cut-off switch. NOTE:
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.
2. The motorcycle must not be ridden when the sidestand
is down.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.
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.

5-4
5-4 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 NEUTRALIF TRANSMISSION IS IN GEAR
PULL IN CLUTCH LEVER
AND PUSH STARTER SWITCH; ENGINE WILL
START
PUT TRANSMISSION IN GEAR
MOTORCYCLE CAN BE RIDDENMOTORCYCLE 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
ENGINE STOP SWITCH TO “ ”
IF TRANSMISSION IS IN NEUTRALIF TRANSMISSION IS IN GEAR
PULL IN CLUTCH LEVER
AND PUSH STARTER SWITCH; ENGINE WILL
START
PUT TRANSMISSION IN GEAR
MOTORCYCLE CAN BE RIDDENMOTORCYCLE CAN BE RIDDEN
PUSH STARTER SWITCH; ENGINE WILL
START
WARNING:
* Obs.: XTZ 125E

5-5
5-5 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 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:
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 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:
See the “Break-in section” prior to operating the
motorcycle for the first time.
CAUTION:

5-6
5-6
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 lubrication may damage the
transmission.
2. Always use the clutch when changing gears. The
engine, transmission, and driveline are not
designed to withstand the shock of forced shifting
and can be damaged by shifting without using the
clutch.
Shifting
The transmission lets you control the amount of power you
have available at a given speed for starting, accelerating,
climbing hills, etc. The use of shift pedal is shown in the
illustration (page 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 lubrication may damage the
transmission.
2. Always use the clutch when changing gears. The
engine, transmission, and driveline are not
designed to withstand the shock of forced shifting
and can be damaged by shifting without using the
clutch.
Shifting
The transmission lets you control the amount of power you
have available at a given speed for starting, accelerating,
climbing hills, etc. The use of shift pedal is shown in the
illustration (page 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.

5-7
5-7Engine Break-in
There is never a more important period in the life of your
motorcycle than the period 1.000Km. For this reason we
ask that you carefully read the following material. Because
the engine is brand new, you must not put an excessive
load on it for the first several hours of running.
During this period, prolonged full throttle operation, or any
condition which might result in excessive heating of the
engine must be avoided.
1. 0 ~ 150 Km:
Avoid operation above 1/3 throttle. Stop the engine and
let it cool for 5 to 10 minutes after every hour of
operation. Vary the speed of the motorcycle from time
to time. Do not operate it at one set throttle position. 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.
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 period in the life of your
motorcycle than the period 1.000Km. For this reason we
ask that you carefully read the following material. Because
the engine is brand new, you must not put an excessive
load on it for the first several hours of running.
During this period, prolonged full throttle operation, or any
condition which might result in excessive heating of the
engine must be avoided.
1. 0 ~ 150 Km:
Avoid operation above 1/3 throttle. Stop the engine and
let it cool for 5 to 10 minutes after every hour of
operation. Vary the speed of the motorcycle from time
to time. Do not operate it at one set throttle position. 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.
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

5-8
5-8 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.
3. 500 ~ 1,000 Km:
Avoid cruising speeds in excess of 3/4 throttle.
CAUTION:
After 1,000Km of operation, be sure to replace the
engine oil.
4. After 1,000 Km:
Avoid prolonged full throttle operation. Vary speeds
occasionally.Parking
When parking the motorcycle, stop the engine and remove
the ignition key. Turn the fuel cock to “OFF” whenever
stopping the engine.
CAUTION:
If any engine trouble should occur during the break-in
period, 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 throttle at any time.
3. 500 ~ 1,000 Km:
Avoid cruising speeds in excess of 3/4 throttle.
CAUTION:
After 1,000Km of operation, be sure to replace the
engine oil.
4. After 1,000 Km:
Avoid prolonged full throttle operation. Vary speeds
occasionally.Parking
When parking the motorcycle, stop the engine and remove
the ignition key. Turn the fuel cock to “OFF” whenever
stopping the engine.
CAUTION:
If any engine trouble should occur during the break-in
period, 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:

6-3
6-3 PERIODIC MAINTENANCE / LUBRICATION
Wheel bearings* Battery
Check looseness and damage. Check electrolyte level, routing breather pipe.
ITEM
How it sounds
/ Adjust if necessary.
REMARKS1,000KM
Fuel line Air filter
Carburetor*Valves*
Muffler
Brakes* Engine oil
Steering bearings* Rear arm pivot*Check fuel hose, for cracks or damage.Clean or replace if necessary.
Adjust
Check damage, Retighten.
Check operation, adjust.
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 plugCheck condition and clean if necessary.
Replace if necessary every 12,000 Km.
3,000KM
PERIODIC MAINTENANCE / LUBRICATION
Wheel bearings* Battery
Check looseness and damage. Check electrolyte level, routing breather pipe.
ITEM
How it sounds
/ Adjust if necessary.
REMARKS1,000KM
Fuel line Air filter
Carburetor*Valves*
Muffler
Brakes* Engine oil
Steering bearings* Rear arm pivot*Check fuel hose, for cracks or damage.Clean or replace if necessary.
Adjust
Check damage, Retighten.
Check operation, adjust.
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 plugCheck condition and clean if necessary.
Replace if necessary every 12,000 Km.
3,000KM

6-5
6-5
Spark plug12.5 1.25 9.0
Engine oil drain plug20 2.0 14.5
Oil check bolt 7 0.7 5.0
Front wheel axle nut 80 8.0 58
Rear wheel axle nut 80 8.0 58
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
these items whenever they are loosened for any reason.
A
(Nut)
10 mm
12 mm
14 mm
17 mm
19 mm
22 mmB
(Bolt)
6 mm
8 mm
10 mm
12 mm
14 mm
16 mmGeneral torque especifications
Nm
6
15
30
55
85
130kgf.m
0,6
1,5
3,0
5,5
8,5
13,0lbf. ft
4,3
11
22
40
61
94 Torque specifications
Torque
Nm
kgfm Item
Nm
Spark plug12.5 1.25 9.0
Engine oil drain plug20 2.0 14.5
Oil check bolt 7 0.7 5.0
Front wheel axle nut 80 8.0 58
Rear wheel axle nut 80 8.0 58
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
these items whenever they are loosened for any reason.
A
(Nut)
10 mm
12 mm
14 mm
17 mm
19 mm
22 mmB
(Bolt)
6 mm
8 mm
10 mm
12 mm
14 mm
16 mmGeneral torque especifications
Nm
6
15
30
55
85
130kgf.m
0,6
1,5
3,0
5,5
8,5
13,0lbf. ft
4,3
11
22
40
61
94 Torque specifications
Torque
Nm
kgfm Item
Nm

6-6
6-6






 
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.
NOTE:
Wait a few minutes 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. 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.
NOTE:
Wait a few minutes 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

6-7
6-7
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 torque.

 




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 torque.

 




2. Engine oil and filter replacement
Tightening torque:
Drain plug:
20 N.m (2.0 kgf.m, 14.5 lbf.t)