brake light YAMAHA XTZ125 2004 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

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:

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

6-19
6-19ADVERTENCIA
After adjusting the pedal height adjust brake pedal free
play.
2. Freeplay.
The rear brake pedal free play should be adjusted to
20 ~ 30 mm (0.8 ~ 1.2 in) at the brake pedal end. Turn
the adjuster on the brake rod clockwise to reduce play
or counterclockwise to increase play.
ADVERTENCIA
Brake pedal free play should be checked 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 adjusting
the rear brake.

!&

#

$(*-.*)*+-
,
WARNING:
WARNING:
ADVERTENCIA
After adjusting the pedal height adjust brake pedal free
play.
2. Freeplay.
The rear brake pedal free play should be adjusted to
20 ~ 30 mm (0.8 ~ 1.2 in) at the brake pedal end. Turn
the adjuster on the brake rod clockwise to reduce play
or counterclockwise to increase play.
ADVERTENCIA
Brake pedal free play should be checked 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 adjusting
the rear brake.

!&

#

$(*-.*)*+-
,
WARNING:
WARNING:

6-20
6-20
Brake light switch adjustment
The rear brake light switch is activated by the brake pedal
and is properly adjusted when the brake light comes on
just before braking takes effect. To adjust the rear brake
light switch, hold the switchbody so it does not rotate while
turning the adjusting nut.
Turn the adjusting nut in direction
to make 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 brake. This indicator
allows checking of brake pad/shoe wear without
disassembling the brake.

 
 "  !& 


Brake light switch adjustment
The rear brake light switch is activated by the brake pedal
and is properly adjusted when the brake light comes on
just before braking takes effect. To adjust the rear brake
light switch, hold the switchbody so it does not rotate while
turning the adjusting nut.
Turn the adjusting nut in direction
to make 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 brake. This indicator
allows checking of brake pad/shoe wear without
disassembling the brake.

 
 "  !& 

6-25
6-25
CAUTION:
Too little chain slack will overload the engine and other
vital parts. Keep the slack within the specified limits.
Axle nut torque:
80 N.m (8.0 Kgf.m, 58 lbf.ft)
5. Adjust the free play in the brake pedal.
CAUTION:
Check the operation of the brake light after adjusting
the rear brake.1. Loosen the 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

!&
 
 .!

4. After adjusting, be sure to tighten the axle nut.
CAUTION:
Too little chain slack will overload the engine and other
vital parts. Keep the slack within the specified limits.
Axle nut torque:
80 N.m (8.0 Kgf.m, 58 lbf.ft)
5. Adjust the free play in the brake pedal.
CAUTION:
Check the operation of the brake light after adjusting
the rear brake.1. Loosen the 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

!&
 
 .!

4. After adjusting, be sure to tighten the axle nut.

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:

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