ABS YAMAHA XTZ125 2003 Owners Manual

XI
XI
ÍNDICE
DESCRIPTION XTZ 125K ................................... 1-1
DESCRIPTION XTZ 125E ................................... 1-2
MACHINE IDENTIFICATION ................................ 2-1
Vehicle identification number.................... 2-1
Engine serial number................................ 2-1
CONTROL FUNCTIONS...................................... 3-1
Main switch............................................... 3-1
Indicator lights........................................... 3-2
Speedometer ............................................ 3-3
Handlebar switches over left .................... 3-4
Handlebar switches over right .................. 3-5
Clutch lever............................................... 3-6
Shift pedal................................................. 3-6
Front brake lever ....................................... 3-7
Rear brake pedal...................................... 3-7
Fuel tank cap ............................................ 3-8
Fuel cock .................................................. 3-9
Starter lever.............................................. 3-10
Kick Starter............................................... 3-10
Steering lock............................................. 3-11
Seat ........................................................... 3-12
Side covers............................................... 3-13
Rear shock absorber................................ 3-14
Clutch switch operation check .................. 3-15PRE-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
PERIODIC MAINTENANCE AND MINOR
REPAIRS .............................................................. 6-1
ÍNDICE
DESCRIPTION XTZ 125K ................................... 1-1
DESCRIPTION XTZ 125E ................................... 1-2
MACHINE IDENTIFICATION ................................ 2-1
Vehicle identification number.................... 2-1
Engine serial number................................ 2-1
CONTROL FUNCTIONS...................................... 3-1
Main switch............................................... 3-1
Indicator lights........................................... 3-2
Speedometer ............................................ 3-3
Handlebar switches over left .................... 3-4
Handlebar switches over right .................. 3-5
Clutch lever............................................... 3-6
Shift pedal................................................. 3-6
Front brake lever ....................................... 3-7
Rear brake pedal...................................... 3-7
Fuel tank cap ............................................ 3-8
Fuel cock .................................................. 3-9
Starter lever.............................................. 3-10
Kick Starter............................................... 3-10
Steering lock............................................. 3-11
Seat ........................................................... 3-12
Side covers............................................... 3-13
Rear shock absorber................................ 3-14
Clutch switch operation check .................. 3-15PRE-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
PERIODIC MAINTENANCE AND MINOR
REPAIRS .............................................................. 6-1

XII
XII
Tool kit ...................................................... 6-2
PERIODIC MAINTENANCE/LUBRICATION ........ 6-3
Torque specifications................................ 6-5
Engine oil .................................................. 6-6
Oil pressure .............................................. 6-9
Air filter...................................................... 6-10
Carburetor adjustment.............................. 6-12
Valve clearance adjustment...................... 6-12
Idle speed adjustment............................... 6-13
Throttle cable adjustment ......................... 6-14
Spark plug inspection............................... 6-15
Clutch adjustment..................................... 6-16
Front brake adjustment............................. 6-17
Rear brake adjustment ............................. 6-18
Brake light switch adjustment ...................6-20
Checking the front brake pads and rear brake
shoes ........................................................ 6-20
Front brake............................................... 6-21
Rear brake................................................ 6-21
Inspecting the brake fluid level ................. 6-22
Brake fluid replacement ............................ 6-23
Drive chain slack check ............................ 6-24
Drive chain slack adjustment .................... 6-25
Drive chain lubrication.............................. 6-26
Cable inspection and lubrication............... 6-26Throttle 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................................... 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.................................. 6-39
Rear wheel installation.............................. 6-40
Troubleshooting ........................................ 6-41
Troubleshooting chart ............................... 6-42
CLEANING AND STORAGE ................................ 7-1
Cleaning .................................................... 7-1
Storage ..................................................... 7-2
SPECIFICATIONS ................................................ 8-1
Tool kit ...................................................... 6-2
PERIODIC MAINTENANCE/LUBRICATION ........ 6-3
Torque specifications................................ 6-5
Engine oil .................................................. 6-6
Oil pressure .............................................. 6-9
Air filter...................................................... 6-10
Carburetor adjustment.............................. 6-12
Valve clearance adjustment...................... 6-12
Idle speed adjustment............................... 6-13
Throttle cable adjustment ......................... 6-14
Spark plug inspection............................... 6-15
Clutch adjustment..................................... 6-16
Front brake adjustment............................. 6-17
Rear brake adjustment ............................. 6-18
Brake light switch adjustment ...................6-20
Checking the front brake pads and rear brake
shoes ........................................................ 6-20
Front brake............................................... 6-21
Rear brake................................................ 6-21
Inspecting the brake fluid level ................. 6-22
Brake fluid replacement ............................ 6-23
Drive chain slack check ............................ 6-24
Drive chain slack adjustment .................... 6-25
Drive chain lubrication.............................. 6-26
Cable inspection and lubrication............... 6-26Throttle 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................................... 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.................................. 6-39
Rear wheel installation.............................. 6-40
Troubleshooting ........................................ 6-41
Troubleshooting chart ............................... 6-42
CLEANING AND STORAGE ................................ 7-1
Cleaning .................................................... 7-1
Storage ..................................................... 7-2
SPECIFICATIONS ................................................ 8-1

1-1
1-1
DESCRIPTION XTZ 125K
10. Dispstick
11. Rear brake pedal
12. Clutch lever
13. Handlebar 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
10. Dispstick
11. Rear brake pedal
12. Clutch lever
13. Handlebar 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

1-2
1-2
DESCRIPTION XTZ 125E
10. Rear brake pedal
11. Clutch lever
12. Handlebar switches 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
10. Rear brake pedal
11. Clutch lever
12. Handlebar switches 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

3-14
3-14
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


  
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1234
56
7 Adjusting
position
SoftStandard
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


  
#

 


1234
56
7 Adjusting
position
SoftStandard
Hard

4-7
4-7 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
characteristics can be given if a tire combination other
than one approved by Yamaha is used on this
motorcycle.
FRONT
REAR
Manufacturer
Minimum tire tread depth
(from and rear) !" #$% &'()'
*+,
#% &'()'
!+,1. It is dangerous to ride with a worn-out tire. When
the tire tread begin to show signs of wear, replace
the tire immediately. Brakes, tires and related wheel
parts should be left to a Yamaha dealer.
2. Patching a punctured tube is not recommended. If
it is absolutely necessary to do so, use great care
and replace the tube as soon as possible with a
good quality replacement.
WARNING:WARNING:
After extensive tests, the tires listed below have been
approved by Yamaha for this model. The front and rear
tires should always be by the same manufacturer and
of the same design. No guarantee concerning handling
characteristics can be given if a tire combination other
than one approved by Yamaha is used on this
motorcycle.
FRONT
REAR
Manufacturer
Minimum tire tread depth
(from and rear) !" #$% &'()'
*+,
#% &'()'
!+,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
and replace the tube as soon as possible with a
good quality replacement.
WARNING:WARNING:

6-4
6-4
* : It is recommended that these items be serviced by a Yamaha dealer.
** : Molybdenum disulfide grease.
*** : Lithium soap based grease.
NOTE: ______________________________________________________________________________________________Brake fluid replacement:
_______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
1. When disassembling the master 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 brakeRear shock absorber*
Drive chain
Fittings / fastenersCheck operation / oil leakage.
Check operation, looseness.
Adujst / Check operation
Lubricate every 12,000 Km. Check chain slack / lubricate, adjust if necessary.
Check looseness.REMARKS1,000KM
Lights and flashers
Nuts and bolts
Motorcycle AspectCheck operation.
Check tighten.
General Check
EVERY
3,000KM
OR EVERY
6 MONTHS3,000KM
Check operation / oil leakage.
Every 500 Km
* : It is recommended that these items be serviced by a Yamaha dealer.
** : Molybdenum disulfide grease.
*** : Lithium soap based grease.
NOTE: ______________________________________________________________________________________________Brake fluid replacement:
_______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
1. When disassembling the master 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 brakeRear shock absorber*
Drive chain
Fittings / fastenersCheck operation / oil leakage.
Check operation, looseness.
Adujst / Check operation
Lubricate every 12,000 Km. Check chain slack / lubricate, adjust if necessary.
Check looseness.REMARKS1,000KM
Lights and flashers
Nuts and bolts
Motorcycle AspectCheck operation.
Check tighten.
General Check
EVERY
3,000KM
OR EVERY
6 MONTHS3,000KM
Check operation / oil leakage.
Every 500 Km

6-30
6-30
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. 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. This may cause the unit
to explode due to excessive gas pressure.
3. Do not deform or damage the cylinder in any way.
Cylinder damage will result in poor damping
performance.
4. Take your shock absorber to a Yamaha dealer for
any service.
Rear 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.


&  '  
WARNING:
ADJUSTING
POSITIONSOFT STANDARD HARD
12 3 765 4
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. 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. This may cause the unit
to explode due to excessive gas pressure.
3. Do not deform or damage the cylinder in any way.
Cylinder damage will result in poor damping
performance.
4. Take your shock absorber to a Yamaha dealer for
any service.
Rear 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.


&  '  
WARNING:
ADJUSTING
POSITIONSOFT STANDARD HARD
12 3 765 4

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