YAMAHA XTZ125 2008 Workshop Manual

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

6-5
6-5
Spark plug12.5 1.25 9.0
Engine oil drain plug20 2.0 14.5
Oil check bolt 7 0.7 5.0
Front wheel axle nut 80 8.0 58
Rear wheel axle nut 80 8.0 58
Use a torque wrench to tighten these items. It is
recommended that these items be checked occasionally,
specially before a long trip. Always check the tightness of
these items whenever they are loosened for any reason.
A
(Nut)
10 mm
12 mm
14 mm
17 mm
19 mm
22 mmB
(Bolt)
6 mm
8 mm
10 mm
12 mm
14 mm
16 mmGeneral torque especifications
Nm
6
15
30
55
85
130kgf.m
0,6
1,5
3,0
5,5
8,5
13,0lbf. ft
4,3
11
22
40
61
94 Torque specifications
Torque
Nm
kgfm Item
Nm
Spark plug12.5 1.25 9.0
Engine oil drain plug20 2.0 14.5
Oil check bolt 7 0.7 5.0
Front wheel axle nut 80 8.0 58
Rear wheel axle nut 80 8.0 58
Use a torque wrench to tighten these items. It is
recommended that these items be checked occasionally,
specially before a long trip. Always check the tightness of
these items whenever they are loosened for any reason.
A
(Nut)
10 mm
12 mm
14 mm
17 mm
19 mm
22 mmB
(Bolt)
6 mm
8 mm
10 mm
12 mm
14 mm
16 mmGeneral torque especifications
Nm
6
15
30
55
85
130kgf.m
0,6
1,5
3,0
5,5
8,5
13,0lbf. ft
4,3
11
22
40
61
94 Torque specifications
Torque
Nm
kgfm Item
Nm

6-6
6-6






 
1. Oil level measurement
a. Place the motorcycle on a level place and hold it in an
upright position. Warm up the engine for several
minutes.
NOTE:
Be sure the motorcycle is positioned straight up when
checking the oil level. A slight tilt toward the side can result
in false readings.
b. With the engine stopped, with the engine stopped,
unscrew the oil filler cap/ dispstick and rest it on the
threads of the ok.
NOTE:
Wait a few minutes until the oil level settles before checking.
c. remove the oil filler cap/ dispstick, clean it with a dry
cloth and check the oil level.
NOTE:
To check the oil level the oil filler cap/ dispstick can not be
screwed, just lightly seated in place.
d. The oil level should be between the maximum and
minimum marks. If the level is low, add oil to raise it to
the indicated level, check for oil leakage. Engine oil






 
1. Oil level measurement
a. Place the motorcycle on a level place and hold it in an
upright position. Warm up the engine for several
minutes.
NOTE:
Be sure the motorcycle is positioned straight up when
checking the oil level. A slight tilt toward the side can result
in false readings.
b. With the engine stopped, with the engine stopped,
unscrew the oil filler cap/ dispstick and rest it on the
threads of the ok.
NOTE:
Wait a few minutes until the oil level settles before checking.
c. remove the oil filler cap/ dispstick, clean it with a dry
cloth and check the oil level.
NOTE:
To check the oil level the oil filler cap/ dispstick can not be
screwed, just lightly seated in place.
d. The oil level should be between the maximum and
minimum marks. If the level is low, add oil to raise it to
the indicated level, check for oil leakage. Engine oil

6-7
6-7
a. Warm up the engine for a few minutes.
b. Stop the engine. Place an oil pan under the engine and
remove the dipstick.
c. Remove the drain plug and drain the oil.
d. Reinstall the drain plug, check if the gasket is damaged
and lighten it to the specified torque.

 




2. Engine oil and filter replacement
Tightening torque:
Drain plug:
20 N.m (2.0 kgf.m, 14.5 lbf.t)
a. Warm up the engine for a few minutes.
b. Stop the engine. Place an oil pan under the engine and
remove the dipstick.
c. Remove the drain plug and drain the oil.
d. Reinstall the drain plug, check if the gasket is damaged
and lighten it to the specified torque.

 




2. Engine oil and filter replacement
Tightening torque:
Drain plug:
20 N.m (2.0 kgf.m, 14.5 lbf.t)

6-8
6-8 e.Fill engine with oil. Install the oil filter cap and tighten.
NOTE:
Recommended engine oil classification; API Service “SH”
type or equivalent
Recommended oil:
YAMALUBE 4
Oil quantity:
Total amount:
1.2 L ( 0.264 Imp gal, 0.317 US gal)
Periodic oil change:
1.0 L ( 0.220 Imp gal, 0.264 US gal)
f. Start the engine and warm up for a few minutes. While
warming up, check for oil leakage. If oil leakage is found,
stop the engine immediately, and check for the cause.
g. Stop the engine and check the oil level.
CAUTION:
Be sure no foreign material enters the crankcase.
CAUTION:
Do not put in any chemical additives. Engine oil also
lubricates the clutch and additives could cause clutch
slippage.
After replacing the engine oil, be sure to check the oil
pressure.
CAUTION:
e.Fill engine with oil. Install the oil filter cap and tighten.
NOTE:
Recommended engine oil classification; API Service “SH”
type or equivalent
Recommended oil:
YAMALUBE 4
Oil quantity:
Total amount:
1.2 L ( 0.264 Imp gal, 0.317 US gal)
Periodic oil change:
1.0 L ( 0.220 Imp gal, 0.264 US gal)
f. Start the engine and warm up for a few minutes. While
warming up, check for oil leakage. If oil leakage is found,
stop the engine immediately, and check for the cause.
g. Stop the engine and check the oil level.
CAUTION:
Be sure no foreign material enters the crankcase.
CAUTION:
Do not put in any chemical additives. Engine oil also
lubricates the clutch and additives could cause clutch
slippage.
After replacing the engine oil, be sure to check the oil
pressure.
CAUTION:

6-9
6-9
Oil pressure1. Remove the check bolt 1 in the cylinder head.
2. Start the engine and keep it idling until oil flows out of
the bleed hole. If no oil comes out after one minute,
turn off the engine immediately so it will not seize. In
such a case go to the nearest Yamaha dealer or other
qualified mechanic for repairs.
3. After checking, tighten the check bolt to the specified
torque.
Check bolt torque:
7 N.m (0.7 Kgf.m, 5.0 lbf.ft)



Oil pressure1. Remove the check bolt 1 in the cylinder head.
2. Start the engine and keep it idling until oil flows out of
the bleed hole. If no oil comes out after one minute,
turn off the engine immediately so it will not seize. In
such a case go to the nearest Yamaha dealer or other
qualified mechanic for repairs.
3. After checking, tighten the check bolt to the specified
torque.
Check bolt torque:
7 N.m (0.7 Kgf.m, 5.0 lbf.ft)




6-10
6-10
The air filter should be cleaned at the specified intervals.
It should be cleaned more frequently if you are riding in
unusually wet or dusty areas.
1. Remove the right side cover.(pag. 3-13)
2. Remove the air filter case cover by removing the bolts.
3. Remove the air filter from the case.Air filter



   

!

The air filter should be cleaned at the specified intervals.
It should be cleaned more frequently if you are riding in
unusually wet or dusty areas.
1. Remove the right side cover.(pag. 3-13)
2. Remove the air filter case cover by removing the bolts.
3. Remove the air filter from the case.Air filter



   

!


6-11
6-11
CAUTION:
Make sure the element is properly seated in the air filter
case.
CAUTION:
The engine should never be run without the air filter
element installed; excessive piston and/or cylinder wear
may result.
Recommended oil:
Engine oil 20W50 4. Remove the air filter element from the guide and clean
it with solvent. After cleaning, remove the remaining
solvent by squeezing the air filter
5. Apply recommended oil to the entire surface of the filter
and squeeze out the excess oil. The air filter should be
wet but not dripping.
6. Reinstall the air filter in its case.
7. Install the air filter case cover and the right side cover.
CAUTION:
Make sure the element is properly seated in the air filter
case.
CAUTION:
The engine should never be run without the air filter
element installed; excessive piston and/or cylinder wear
may result.
Recommended oil:
Engine oil 20W50 4. Remove the air filter element from the guide and clean
it with solvent. After cleaning, remove the remaining
solvent by squeezing the air filter
5. Apply recommended oil to the entire surface of the filter
and squeeze out the excess oil. The air filter should be
wet but not dripping.
6. Reinstall the air filter in its case.
7. Install the air filter case cover and the right side cover.

6-12
6-12Valve clearance adjustment
The correct valve clearance changes with use, resulting in
improper fuel/air supply or engine noise. To prevent this,
valve clearance must be adjusted regularly. This adjustment,
however, should be left to a professional Yamaha service
technician. Carburetor adjustment
The carburetor is a vital part of the engine. Adjusting should
be left to a Yamaha dealer who has the professional
knowledge, specialized data, and equipment to do so
properly. However, the following may be serviced by the
owner as part of routine maintenance.
CAUTION:
The carburetor was set at Yamaha factory after many
tests. If the settings are changed, poor engine
performance and damage may result.
Valve clearance adjustment
The correct valve clearance changes with use, resulting in
improper fuel/air supply or engine noise. To prevent this,
valve clearance must be adjusted regularly. This adjustment,
however, should be left to a professional Yamaha service
technician. Carburetor adjustment
The carburetor is a vital part of the engine. Adjusting should
be left to a Yamaha dealer who has the professional
knowledge, specialized data, and equipment to do so
properly. However, the following may be serviced by the
owner as part of routine maintenance.
CAUTION:
The carburetor was set at Yamaha factory after many
tests. If the settings are changed, poor engine
performance and damage may result.

6-13
6-13
1
NOTE:
A diagnostic tachometer must be used for this
procedure.
Standard idle speed:1400
± 100 rpm NOTE:
If the specified idle speed cannot be obtained by performing
the above adjustment, consult a Yamaha dealer.
1. Throttle stop screw
Idle speed adjustment
1. Attach the tachometer. Start the engine and warm it upfor a few minutes (normally, 1 or 2 minutes) at
approximately 1,000 to 2,000 r/min. Occasionally rev
the engine to 4,000 to 5,000 r/min. The engine is warm
when it quickly responds to the throttle.
2. Set the idle to the specified engine speed by adjusting the throttle stop screw; turn the screw in to increase
engine speed and out to decrease engine speed.
1
NOTE:
A diagnostic tachometer must be used for this
procedure.
Standard idle speed: 1400
± 100 rpm NOTE:
If the specified idle speed cannot be obtained by performing
the above adjustment, consult a Yamaha dealer.
1. Throttle stop screw
Idle speed adjustment
1. Attach the tachometer. Start the engine and warm it upfor a few minutes (normally, 1 or 2 minutes) at
approximately 1,000 to 2,000 r/min. Occasionally rev
the engine to 4,000 to 5,000 r/min. The engine is warm
when it quickly responds to the throttle.
2. Set the idle to the specified engine speed by adjusting the throttle stop screw; turn the screw in to increase
engine speed and out to decrease engine speed.