brake YAMAHA XTZ125 2003 Owner's Manual

6-27
6-27Brake and clutch levers
Lubricate the pivoting parts.
RECOMMENDED LUBRICANT:
Engine oil SAE 20W50 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 screws, hold the end of the cable up in
the air and put in several drops of lubricant. With the throttle
grip disassembled, coat the metal 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
Lubricate the pivoting parts.
RECOMMENDED LUBRICANT:
Engine oil SAE 20W50 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 screws, hold the end of the cable up in
the air and put in several drops of lubricant. With the throttle
grip disassembled, coat the metal 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

6-29
6-29 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
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.
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
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.
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:

6-37
6-37
Front wheel removal

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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.
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 raise 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.

6-39
6-39
Rear wheel removal

!&
  

. 


 2!

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.
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.
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

!&
  

. 


 2!

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.
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.
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:

6-40
6-40
Rear wheel installationWhen 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 right-
hand 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.(See page 6-18)
Check the operation of the brake light after adjusting
the rear brake
WARNING:
Rear wheel installationWhen 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 right-
hand 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.(See page 6-18)
Check the operation of the brake light after adjusting
the rear brake
WARNING:

7-1
7-1 A. Cleaning
Frequent, thorough cleaning of your motorcycle will not only
enhance its appearance but will improve its general
performance and extend the useful life of many components.
1. Before cleaning the motorcycle:
a. Block off the end of the exhaust pipe to prevent water
entry; a plastic bag and strong rubber band may be
used.
b. Make sure the spark plug and all filler caps are properly
installed.
2. If the engine case is excessively greasy, apply
degreaser with a paint brush. Do not apply degreaser
to the chain, sprockets, or wheel axles.
3. Rinse the dirt and degreaser off with a garden hose,
Use only enough pressure to do the job.
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
improper high pressure detergent applications such as
those available in coin-operated car washers.
4. Once the majority of the dirt has been hosed off, wash
all surfaces with warm water and 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 all painted and
chrome-plated surfaces. Avoid combination cleaner-
waxes. Many contain abrasives which may mar the paint
or protective finish. When finished, start the engine and
let it idle for several minutes.
CLEANING AND STORAGE
A. Cleaning
Frequent, thorough cleaning of your motorcycle will not only
enhance its appearance but will improve its general
performance and extend the useful life of many components.
1. Before cleaning the motorcycle:
a. Block off the end of the exhaust pipe to prevent water
entry; a plastic bag and strong rubber band may be
used.
b. Make sure the spark plug and all filler caps are properly
installed.
2. If the engine case is excessively greasy, apply
degreaser with a paint brush. Do not apply degreaser
to the chain, sprockets, or wheel axles.
3. Rinse the dirt and degreaser off with a garden hose,
Use only enough pressure to do the job.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
improper high pressure detergent applications such as
those available in coin-operated car washers.
4. Once the majority of the dirt has been hosed off, wash
all surfaces with warm water and 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 all painted and
chrome-plated surfaces. Avoid combination cleaner-
waxes. Many contain abrasives which may mar the paint
or protective finish. When finished, start the engine and
let it idle for several minutes.
CLEANING AND STORAGE

8-4
8-4
MODEL
Brakes:
Front brake type
Operation
Rear brake type
Operation
Shock absorber:
Front
Rear
Wheel travel
Front
Rear Suspension:
Front
Rear
Electrical:
Ignition system
Generator system
Battery type / capacity
XTZ 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
Shock absorber:
Front
Rear
Wheel travel
Front
Rear Suspension:
Front
Rear
Electrical:
Ignition system
Generator system
Battery type / capacity
XTZ 125E
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

8-5
8-5
MODEL
Bulb wattage x quantity
Headlight
tail / Brake light
Flasher light
Indicator light wattage x quantity:
Panel
Neutral tamp
Headlight
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
Indicator light wattage x quantity:
Panel
Neutral tamp
Headlight
Flasher light
Headlight type:XTZ 125E
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