service YAMAHA XTZ125 2005 Owners Manual

VII
VII
SAFETY INFORMATION
TWO-WHEELED Machines ARE SINGLE TRACK VEHICLES. THEIR SAFE USE AND OPERATION ARE DEPENDENT
UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EXPERTISE OF THE OPERATOR.
EVERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIREMENTS BEFORE RIDING. HE OR SHE SHOULD.
1. OBTAIN THOROUGH INSTRUCTIONS FORM A COMPETENT SOURCE ON ALL ASPECTS OF MACHINE
OPERATION.
2. OBSERVE THE WARNINGS AND MAINTENANCE REQUIREMENTS IN THE OWNER’S MANUAL.
3. OBTAIN QUALIFIED TRAINING IN SAFE AND PROPER RIDING TECHNIQUES.
4. OBTAIN PROFESSIONAL TECHNICAL SERVICE AS INDICATED BY THE OWNER’S MANUAL AND/OR WHEN
MADE NECESSARY BY MECHANICAL CONDITIONS.
SAFE RIDING
1. Always make pre-operation checks. Careful checks may help prevent an accident.
2. Many accidents involve inexperienced operators.
a. Know your skills and limits. Staying within your limits may help you to avoid an accident.
b. Only lend your machine to experienced operators.
3. Many machine accidents have been caused by machine operator errors. A typical error made by the operator is
veering wide on a turn due to EXCESSIVE SPEED or undercornering (insufficient lean angle for the speed). Never
travel faster than warranted by conditions.
4. Ride cautiously in unfamiliar areas. You may encounter hidden obstacles which could cause an accident.
5. The operator’s posture is important for proper control. The operator should keep both hands on the handlebars and
both feet on the operator footrests during operation to maintain control of the machine.
6. Never ride under the influence of alcohol or drugs.
SAFETY INFORMATION
TWO-WHEELED Machines ARE SINGLE TRACK VEHICLES. THEIR SAFE USE AND OPERATION ARE DEPENDENT
UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EXPERTISE OF THE OPERATOR.
EVERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIREMENTS BEFORE RIDING. HE OR SHE SHOULD.
1. OBTAIN THOROUGH INSTRUCTIONS FORM A COMPETENT SOURCE ON ALL ASPECTS OF MACHINE
OPERATION.
2. OBSERVE THE WARNINGS AND MAINTENANCE REQUIREMENTS IN THE OWNER’S MANUAL.
3. OBTAIN QUALIFIED TRAINING IN SAFE AND PROPER RIDING TECHNIQUES.
4. OBTAIN PROFESSIONAL TECHNICAL SERVICE AS INDICATED BY THE OWNER’S MANUAL AND/OR WHEN
MADE NECESSARY BY MECHANICAL CONDITIONS.
SAFE RIDING
1. Always make pre-operation checks. Careful checks may help prevent an accident.
2. Many accidents involve inexperienced operators.
a. Know your skills and limits. Staying within your limits may help you to avoid an accident.
b. Only lend your machine to experienced operators.
3. Many machine accidents have been caused by machine operator errors. A typical error made by the operator is
veering wide on a turn due to EXCESSIVE SPEED or undercornering (insufficient lean angle for the speed). Never
travel faster than warranted by conditions.
4. Ride cautiously in unfamiliar areas. You may encounter hidden obstacles which could cause an accident.
5. The operator’s posture is important for proper control. The operator should keep both hands on the handlebars and
both feet on the operator footrests during operation to maintain control of the machine.
6. Never ride under the influence of alcohol or drugs.

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:

4-3
4-3 Brakes (See page 6-17 for details)
1. Brake lever and brake pedal
Check for correct free play in the front brake lever and
rear brake pedal and adjust if necessary. Make sure
the brakes are working properly by checking at low
speed shortly after starting out.
A soft, spongy feeling in the brake lever indicates a
failure in the brake system. Do not operate the
motorcycle until the failure in the brake system is
corrected. Ask a Yamaha dealer or other qualified
mechanic for immediate repairs. A soft, spongy feeling
could indicate a hazardous condition in the brake
system.
NOTE:
If DOT #4 is not available, #3 can be used.
3. Check the disc pads.
Refer to page 6-20
4. Check the brake shoes.
Refer to page 6-20
When a brake service is necessary, consult a Yamaha
dealer or other qualified mechanic.
NOTE:
2. Brake fluid
Check the brake fluid level. Add fluid if necessary.
RECOMMENDED BRAKE FLUID: DOT #4
WARNING:
Brakes (See page 6-17 for details)
1. Brake lever and brake pedal
Check for correct free play in the front brake lever and
rear brake pedal and adjust if necessary. Make sure
the brakes are working properly by checking at low
speed shortly after starting out.
A soft, spongy feeling in the brake lever indicates a
failure in the brake system. Do not operate the
motorcycle until the failure in the brake system is
corrected. Ask a Yamaha dealer or other qualified
mechanic for immediate repairs. A soft, spongy feeling
could indicate a hazardous condition in the brake
system.
NOTE:
If DOT #4 is not available, #3 can be used.
3. Check the disc pads.
Refer to page 6-20
4. Check the brake shoes.
Refer to page 6-20
When a brake service is necessary, consult a Yamaha
dealer or other qualified mechanic.
NOTE:
2. Brake fluid
Check the brake fluid level. Add fluid if necessary.
RECOMMENDED BRAKE FLUID: DOT #4
WARNING:

4-5
4-5 Tires
To ensure maximum performance, long service, and safe
operation, note the following:
1. Tire air pressure
Always check and adjust the tire pressure before
operating the machine.
Tire inflation pressure should be checked and adjusted
when the temperature of the tire equals the ambient air
temperature.
Tire inflation pressure must be adjusted according to
total weight of cargo, rider, passenger and accessories
(fairing, saddlebags, etc. if approved for this model),
and vehicle speed.
WARNING:
Basic weight:
With oil and without fuelXTZ 125K 113 Kg ( 249 lb)
XTZ 125E 114 Kg ( 251 lb)


  


Maximum load*:
Cold tire pressure:
up to 90 Kg (198 lb)
load*:
90 Kg (198 lb) ~
maximum load*:150 Kg ( 330 kg)
Front
1.5 kg/cm222 PSI / 147 kpa
Rear
1.5 kg/cm222 PSI / 147Kpa
1.5 kg/cm
222 PSI / 145 Kpa2.0 kg/cm228 PSI / 200 Kpa
Tires
To ensure maximum performance, long service, and safe
operation, note the following:
1. Tire air pressure
Always check and adjust the tire pressure before
operating the machine.
Tire inflation pressure should be checked and adjusted
when the temperature of the tire equals the ambient air
temperature.
Tire inflation pressure must be adjusted according to
total weight of cargo, rider, passenger and accessories
(fairing, saddlebags, etc. if approved for this model),
and vehicle speed.
WARNING:
Basic weight:
With oil and without fuelXTZ 125K 113 Kg ( 249 lb)
XTZ 125E 114 Kg ( 251 lb)


  


Maximum load*:
Cold tire pressure:
up to 90 Kg (198 lb)
load*:
90 Kg (198 lb) ~
maximum load*:150 Kg ( 330 kg)
Front
1.5 kg/cm222 PSI / 147 kpa
Rear
1.5 kg/cm222 PSI / 147Kpa
1.5 kg/cm
222 PSI / 145 Kpa2.0 kg/cm228 PSI / 200 Kpa

4-8
4-8Wheels
To ensure maximum performance, long service, and safe
operation, note the following:
1. Always inspect the wheels before a ride. Check for
cracks, bends, or warpage of the wheel; be sure the
spokes are tight and undamaged. If any abnormal
condition exists in a wheel, consult a Yamaha dealer or
other qualified mechanic. Do not attempt even small
repairs to the wheel. If a wheel is deformed or cracked,
it must be replaced.
2. Tires and wheels should be balanced whenever either
one is changed or replaced. Failure to have a wheel
balanced can result in poor performance, adverse
handling characteristics, and shortened tire life.
3. After installing a tire, ride conservatively to allow the
tire to seat itself on the rim properly. Failure to allow
proper seating may cause tire failure, resulting in
damage to the motorcycle and injury to the rider. Clutch ( See page 6-16 for details)
Check the free play in the clutch lever, and make sure the
lever operates properly. If the free play is incorrect, adjust
it.
Throttle grip (See page 6-14 for details)
Turn the throttle grip to see if it operates properly, and check
the free play.
Make sure the grip returns by spring force when released.
Ask a Yamaha dealer or other qualified mechanic to make
any necessary adjustments.
Fitting/Fasteners
Alway check the tightness of chassis fittings and fasteners
before a ride. Use the chart on page 6-5 to find the correct
torque.
Switches
Check the operation of the starter switch, main switch,
“Engine Stop” switch.
Wheels
To ensure maximum performance, long service, and safe
operation, note the following:
1. Always inspect the wheels before a ride. Check for
cracks, bends, or warpage of the wheel; be sure the
spokes are tight and undamaged. If any abnormal
condition exists in a wheel, consult a Yamaha dealer or
other qualified mechanic. Do not attempt even small
repairs to the wheel. If a wheel is deformed or cracked,
it must be replaced.
2. Tires and wheels should be balanced whenever either
one is changed or replaced. Failure to have a wheel
balanced can result in poor performance, adverse
handling characteristics, and shortened tire life.
3. After installing a tire, ride conservatively to allow the
tire to seat itself on the rim properly. Failure to allow
proper seating may cause tire failure, resulting in
damage to the motorcycle and injury to the rider. Clutch ( See page 6-16 for details)
Check the free play in the clutch lever, and make sure the
lever operates properly. If the free play is incorrect, adjust
it.
Throttle grip (See page 6-14 for details)
Turn the throttle grip to see if it operates properly, and check
the free play.
Make sure the grip returns by spring force when released.
Ask a Yamaha dealer or other qualified mechanic to make
any necessary adjustments.
Fitting/Fasteners
Alway check the tightness of chassis fittings and fasteners
before a ride. Use the chart on page 6-5 to find the correct
torque.
Switches
Check the operation of the starter switch, main switch,
“Engine Stop” switch.

5-2
5-2 Starting a cold engine
NOTE:
When the transmission is in neutral, the neutral indicator
light should be on. If the light does not come on, ask a
Yamaha dealer to inspect it.
XTZ 125K
1. Turn the fuel cock to “ON”.
2. Turn the main switch to “ON” and the engine stop switch
to “ “.
3. Shift transmission into neutral.
NOTE:
When the transmission is in neutral, the neutral indicator
light should be on. If the light does not come on, ask a
Yamaha dealer to inspect it.
4. Fully open the starter (CHOKE) and completely close
the throttle grip.
5. Start the engine by pushing the starter switch.
XTZ 125E
1. Turn the fuel cock to “ON”.
2. Turn the main switch to “ON” and the engine stop switch
to “ “.
3. Shift transmission into neutral.
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.
4. Fully open the starter (CHOKE) and completely close
the throttle grip.
5. Kick the kick start to start the engine.
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.
Starting a cold engine
NOTE:
When the transmission is in neutral, the neutral indicator
light should be on. If the light does not come on, ask a
Yamaha dealer to inspect it.
XTZ 125K
1. Turn the fuel cock to “ON”.
2. Turn the main switch to “ON” and the engine stop switch
to “ “.
3. Shift transmission into neutral.
NOTE:
When the transmission is in neutral, the neutral indicator
light should be on. If the light does not come on, ask a
Yamaha dealer to inspect it.
4. Fully open the starter (CHOKE) and completely close
the throttle grip.
5. Start the engine by pushing the starter switch.
XTZ 125E
1. Turn the fuel cock to “ON”.
2. Turn the main switch to “ON” and the engine stop switch
to “ “.
3. Shift transmission into neutral.
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.
4. Fully open the starter (CHOKE) and completely close
the throttle grip.
5. Kick the kick start to start the engine.
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.

5-3
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.

6-1
6-1
PERIODIC MAINTENANCE AND MINOR REPAIRS
Perodic inspection, adjustment, and lubrication will keep
your motorcycle in the safest and most efficient condition
possible. Safety is an OBLIGATION of the motorcycle
owner.
The maintenance and lubrication schedule chart should
be considered strictly as a guide to general maintenance
and lubrication intervals. YOU MUST TAKE INTO
CONSIDERATION THAT WEATHER, TERRAIN,
GEOGRAPHICAL LOCATIONS, AND A VARIETY OF
INDIVIDUAL USES ALL TEND TO DEMAND THAT EACH
OWNER ALTER THIS TIME SCHEDULE TO SHORTER
INTERVALS TO MATCH THE ENVIRONMENT.
The most important points of motorcycle inspection,
adjustment, and lubrication are explained in the following
pages.CAUTION:
If you are not familiar with motorcycle service, this work
should be done by a Yamaha dealer.
PERIODIC MAINTENANCE AND MINOR REPAIRS
Perodic inspection, adjustment, and lubrication will keep
your motorcycle in the safest and most efficient condition
possible. Safety is an OBLIGATION of the motorcycle
owner.
The maintenance and lubrication schedule chart should
be considered strictly as a guide to general maintenance
and lubrication intervals. YOU MUST TAKE INTO
CONSIDERATION THAT WEATHER, TERRAIN,
GEOGRAPHICAL LOCATIONS, AND A VARIETY OF
INDIVIDUAL USES ALL TEND TO DEMAND THAT EACH
OWNER ALTER THIS TIME SCHEDULE TO SHORTER
INTERVALS TO MATCH THE ENVIRONMENT.
The most important points of motorcycle inspection,
adjustment, and lubrication are explained in the following
pages.CAUTION:
If you are not familiar with motorcycle service, this work
should be done by a Yamaha dealer.

6-2
6-2
Tool kitThe tools provided in the owner’s tool kit are to assist you
in the performance of periodic maintenance. However, some
other tools such as a torque wrench are also necessary to
perform the maintenance correctly.


NOTE:
If you do not have necessary tools required during a service
operation, take your motorcycle to a Yamaha dealer for
service.
Modifications to this motorcycle not approved by
Yamaha may cause loss of performance, excessive
emissions, and render it unsafe for use. Consult a
Yamaha dealer before attempting any changes.
WARNING:
Tool kitThe tools provided in the owner’s tool kit are to assist you
in the performance of periodic maintenance. However, some
other tools such as a torque wrench are also necessary to
perform the maintenance correctly.


NOTE:
If you do not have necessary tools required during a service
operation, take your motorcycle to a Yamaha dealer for
service.
Modifications to this motorcycle not approved by
Yamaha may cause loss of performance, excessive
emissions, and render it unsafe for use. Consult a
Yamaha dealer before attempting any changes.
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