XTZ 125K XTZ 125E I OWNER'S MANUAL 5YM-F8199-E2 IDENTIFICATION NUMBERS RECORD Record the frame serial number and engine serial number in the spaces provided for assistance when ordering spare parts from a Yamaha dealer or reference in case the vehicle is stolen. 1. FRAME SERIAL NUMBER: 2. ENGINE SERIAL NUMBER: II XTZ 125K / XTZ 125E OWNER'S MANUAL © 2005 Yamaha Motor da Amazônia Ltda. 1st edition, November 2005 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor da Amazônia Ltda. is expressly prohibited. Printed in Brazil. III INTRODUCTION Congratulations on your purchase of the YAMAHA XTZ 125K / XTZ 125E. This model is the result of Yamaha's vast experience in the production of fine sporting, touring, and pacesetting racing machines. It represents the high degree of craftmanship and reliability that have made Yamaha a leader in these fields. This manual will give you an understanding of the operation, inspection, and basic maintenance of this motorcycle. If you have any questions about the operation or maintenance of your motorcycle, please consult a Yamaha dealer. YAMAHA MOTOR DA AMAZÕNIA LTDA. IV Particularly important information is distinguished in this manual by the following notations: NOTE: A NOTE provides key information to make procedures easier or clearer. CAUTION: A CAUTION indicates special precautions that must be taken to avoid damage to the machine. WARNING: Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander or a person inspecting or repairing the machine. NOTE: This manual should be considered a permanent part of this machine and should remain with it even if the machine is subsequently sold. Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most current product information available at the time of printing. There may be minor discrepancies between your machine and this manual. If there is any question concerning this manual, please consult your Yamaha dealer. V WARNING: PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MACHINE. DO NOT ATTEMPT TO OPERATE THIS MOTORCYCLE UNTIL YOU HAVE ATTAINED A SATISFACTORY KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES. REGULAR INSPECTIONS AND CAREFUL MAINTENANCE, ALONG WITH GOOD RIDING SKILLS WILL ENSURE THAT YOU SAFELY ENJOY THE CAPABILITIES AND THE RELIABILITY OF THIS MOTORCYCLE. VI 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. VII PROTECTIVE APPAREL The majority of fatalities from machine accidents are the result of head injuries. The use of a safety helmet is the single most critical factor in the prevention or reduction of head injuries. 1. 2. Always wear an approved helmet. Wear a face shield or goggles. Wind on your unprotected eyes could contribute to an impairment of vision which could delay seeing a hazard. 3. 4. 5. The use of heavy boots, jacket, trousers, gloves, etc. is effective in preventing or reducing abrasions or lacerations. Never wear loose fitting clothing. It could catch on the control levers, footrests, or wheels and cause injury or accident. Never touch the engine or exhaust system during or after operation. They become very hot and can cause burns. Always wear protective clothing that covers your legs, ankles and feet. 6. 7. Always use clear clothes to make your visualization easier. Items above must also be followed by pillion rider. MODIFICATION Modifications made to the machine not approved by Yamaha, or the removal of original equipment, may render your machine unsafe for use and may cause severe personal injury. Modifications may also make your machine illegal to use. VIII ACCESSORIES AND LOADING Adding accessories or cargo to your machine can adversely affect stability and handling if the weight distribution of the machine is changed. To avoid the possibility of an accident, extreme caution should be used if adding cargo or accessories to your machine. Use extra care if riding a machine which has added cargo or acessories. Genuine Yamaha accessories have been specifically designed for use on this machine. Since Yamaha cannot test all other accessories which may be available, you must personally be responsible for the proper selection, installation and use of non-Yamaha accessories. You should use extreme caution when selecting and installing any accessories. Keep in mind these guidelines for mounting accessories in addition to those provided under "LOADING". 1. Never install accessories or carry cargo that would impair the performance of your machine. Carefully inspect the accessory before using it to make sure it does not in any way reduce ground clearance or cornering clearance, limit suspension travel, steering travel or control operation, or obscure lights or reflectors. a. Accessories fitted to the handlebar or the front fork area can create instability due to improper weight distribution or aerodynamic changes. If accessories are added to the handlebar or front fork area, they must be as lightweight as possible and should be kept to a minimum. b. Bulky or large accessories may seriously affect the stability of the machine due to aerodynamic effects. Wind may attempt to lift the machine, or the machine may become unstable in cross winds. These accessories may also cause instability when being passed by or passing large vehicles. c. Certain accessories can displace the operator from his or her normal riding position. This improper position limits the freedom of movement of the operator and may limit control ability. Therefore such accessories are not recommended. 2. Caution must be used if adding electrical accessories. If these accessories exceed the capacity of the machine's electrical system, an electric failure could result, which could cause a dangerous loss of lights or engine power. IX GASOLINE AND EXHAUST GAS 1. GASOLINE IS HIGHLY FLAMMABLE: a. Always turn off the engine when refueling. b. Take care not to spill any gasoline on the engine or exhaust system when refueling. c. Never refuel while smoking or in the vicinity of an open flame. 2. Never start the engine or let it run for any length of time in a closed area. The exhaust fumes are poisonous and may cause loss of consciousness and death within a short time. Always operate your motorcycle in an area that has adequate ventilation. 3. Always turn off the engine before leaving the machine unattended and remove the ignition key. When parking the machine, note the following: a. The engine and exhaust system may be hot. Park the machine in a place where pedestrians or children are not likely to touch these hot areas. b. Do not park the machine on a slope or soft ground; the machine may fall over. c. Do not park the machine near a flammable source, e. g. a kerosene heater, or near an open flame. The machine could catch fire. 4. When transporting the machine in another vehicle, be sure it is kept upright and that the fuel cock is turned to "ON" or "RES" (for vacuum type) / "OFF" (for manual type). If it should lean over, gasoline may leak out of the carburetor or fuel tank. 5. If you should swallow any gasoline, inhale a lot of gasoline vapor, or allow gasoline to get in your eyes, see your doctor immediately. If any gasoline spills on your skin or clothing, immediately wash it off with soap and water and change your clothes. X 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 .................. 3-15 XI PRE-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 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 ..................................... ...