battery YAMAHA XTZ125 2004 Owners Manual

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

4-2
4-2 NOTE:
Pre-operation checks should be made each time the motorcycle is used. Such an inspection can be thoroughly accomplished
in a very short time; and the added safety it assures is more than worth the time involved. If any maintenance service or
adjustment is needed, consult the chart above to refer to the pages in which the service or adjustment is described.
1. The engine, exhaust pipe, and muffler will be very hot after the engine has been run.
Be careful not to touch them or to allow any clothing item to contact them during inspection or repair.
2. If any item is not working properly, have it inspected and repaired before operating the motorcycle.
ITEMROUTINE
PAGE
Sidestand
Fittings / FastenersCheck all chassi fittings and fasteners.
Tighten / Adjust, if necessary
Check fuel level / top up as required.
Fuel tank
Lights, signals and switches
BatteryCheck electrolyte level.
Replenish with “distilled water” if necessary.6-27
4-8 , 6-5
4-8 , 6-35 ~ 6-36
6-32 ~ 6-346-28
4-9
Check for proper operation
Front brake and clutch
lever pivotsCheck for smooth operation.
Lubricate if necessary
Check for smooth operation.
Lubricate if necessary
6-27 Check for smooth operation.
Lubricate if necessary Rear brake and shift pedal
shafts
WARNING:
NOTE:
Pre-operation checks should be made each time the motorcycle is used. Such an inspection can be thoroughly accomplished
in a very short time; and the added safety it assures is more than worth the time involved. If any maintenance service or
adjustment is needed, consult the chart above to refer to the pages in which the service or adjustment is described.
1. The engine, exhaust pipe, and muffler will be very hot after the engine has been run.
Be careful not to touch them or to allow any clothing item to contact them during inspection or repair.
2. If any item is not working properly, have it inspected and repaired before operating the motorcycle.
ITEMROUTINE
PAGE
Sidestand
Fittings / FastenersCheck all chassi fittings and fasteners.
Tighten / Adjust, if necessary
Check fuel level / top up as required.
Fuel tank
Lights, signals and switches
BatteryCheck electrolyte level.
Replenish with “distilled water” if necessary.6-27
4-8 , 6-5
4-8 , 6-35 ~ 6-36
6-32 ~ 6-346-28
4-9
Check for proper operation
Front brake and clutch
lever pivotsCheck for smooth operation.
Lubricate if necessary
Check for smooth operation.
Lubricate if necessary
6-27 Check for smooth operation.
Lubricate if necessary Rear brake and shift pedal
shafts
WARNING:

5-1
5-1
OPERATION AND IMPORTANT RIDING POINTS
CAUTION:
1. Be very careful if you are carrying object while riding
the motorcycle
2. Be vareful not to put any object near battery
terminals.
Electrical failure or acid corrosion may occur.
CAUTION:
Before riding this motorcycle, become thoroughly
familiar with all operating controls and their functions.
Consult a Yamaha dealer regarding any control or
function that you do not thoroughly understand.
Never start your engine or let it run for any
length of time in a closed area.
The exhaust fumes are poisonous and can cause 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
2. Be vareful not to put any object near battery
terminals.
Electrical failure or acid corrosion may occur.
CAUTION:
Before riding this motorcycle, become thoroughly
familiar with all operating controls and their functions.
Consult a Yamaha dealer regarding any control or
function that you do not thoroughly understand.
Never start your engine or let it run for any
length of time in a closed area.
The exhaust fumes are poisonous and can cause 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.

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.

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

6-32
6-32
Battery
BATTERY BREATHER HOSE ROUTING
YAMAHA 5RM-F8179-00Check the level of the battery electrolyte and make sure
that the terminals are tight. Add distilled water if the
electrolyte level is low.
1. When inspecting the battery, make sure that the
battery breather pipe routing is correct. If the
breather pipe touches painted parts, or if its end is
in such a position that may cause 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
YAMAHA 5RM-F8179-00Check the level of the battery electrolyte and make sure
that the terminals are tight. Add distilled water if the
electrolyte level is low.
1. When inspecting the battery, make sure that the
battery breather pipe routing is correct. If the
breather pipe touches painted parts, or if its end is
in such a position that may cause 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:

6-33
6-33
CAUTION:
Battery electrolyte is poisonous and dangerous,
causing severe burns, etc. It contains sulfuric acid.
Avoid contact with skin, eyes or clothing.
Antidote:
EXTERNAL: Flush with water.
INTERNAL: Drink large quantities of water or milk.
Follow with milk of magnesia, beaten egg, or vegetable
oil. Call a physician immediately.
EYES: Flush with water for 15 minutes and get prompt
medical attention.
Batteries produce explosive gases. Keep sparks, flame,
cigarrettes, etc., away. Ventilate when charging or using
it in an enclosed space. Always shield your eyes when
working near batteries.
KEEP OUT OF REACH OF CHILDREN.
Replenishing the battery fluid

 
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 “distilled water” if refilling is necessary.
WARNING:
CAUTION:
Battery electrolyte is poisonous and dangerous,
causing severe burns, etc. It contains sulfuric acid.
Avoid contact with skin, eyes or clothing.
Antidote:
EXTERNAL: Flush with water.
INTERNAL: Drink large quantities of water or milk.
Follow with milk of magnesia, beaten egg, or vegetable
oil. Call a physician immediately.
EYES: Flush with water for 15 minutes and get prompt
medical attention.
Batteries produce explosive gases. Keep sparks, flame,
cigarrettes, etc., away. Ventilate when charging or using
it in an enclosed space. Always shield your eyes when
working near batteries.
KEEP OUT OF REACH OF CHILDREN.
Replenishing the battery fluid

 
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 “distilled water” if refilling is necessary.
WARNING:

6-34
6-34
Storage the battery
1. When the motorcycle is not used for a month or longer,
remove the battery and store it in a cool, dark place.
Completely recharge the battery before reinstallation.
2. If the baterry needs to be stored for a longer period
than the period mentioned above, check the specific
gravity at least once a month, and recharge it when the
specific gravity is below normal.
3. Always make sure the connections are correct when
reinstalling the battery. The red (positive) lead is for the
+ terminal and the black (negative) lead is for the -
terminal. Always connect the red (positive) lead first,
then connect the black (negative) lead. Make sure that
the battery breather pipe is correctly routed, free of
obstructions, 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


CAUTION:
Do not use fuses of higher amperage rating than those
recommended. Substitution of a fuse of improper rating
can cause extensive electrical system damage and
possibly a fire. Fuse replacement
Storage the battery
1. When the motorcycle is not used for a month or longer,
remove the battery and store it in a cool, dark place.
Completely recharge the battery before reinstallation.
2. If the baterry needs to be stored for a longer period
than the period mentioned above, check the specific
gravity at least once a month, and recharge it when the
specific gravity is below normal.
3. Always make sure the connections are correct when
reinstalling the battery. The red (positive) lead is for the
+ terminal and the black (negative) lead is for the -
terminal. Always connect the red (positive) lead first,
then connect the black (negative) lead. Make sure that
the battery breather pipe is correctly routed, free of
obstructions, 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


CAUTION:
Do not use fuses of higher amperage rating than those
recommended. Substitution of a fuse of improper rating
can cause extensive electrical system damage and
possibly a fire. Fuse replacement