User manual YAMAHA XTZ125-2006

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 ................................................ 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 ............... 6-26 XII Throttle 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 DESCRIPTION XTZ 125K 16 19 01. 02. 03. 04. 05. 06. 07. 08. 09. Fuel cock Starter lever Battery Fusible Tool kit Shift pedal Shock absorber Air filter Kick starter 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. Dispstick Rear brake pedal Clutch lever Handlebar switches over right Speedometer Main switch Front brake lever Throttle grip Handlebar switches over left Fuel tank cap 1-1 DESCRIPTION XTZ 125E 16 19 01. 02. 03. 04. 05. 06. 07. 08. 09. Fuel cock Starter lever Battery Fusible Tool kit Shift pedal Shock absorber Air filter Kick starter 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. Dispstick Rear brake pedal Clutch lever Handlebar switches over right Speedometer Main switch Front brake lever Throttle grip Handlebar switches over left Fuel tank cap 1-2 MACHINE IDENTIFICATION Vehicle identification number Engine serial number 1. Frame number 2. Production year 1. Engine serial number The vehicle identification number is stamped into the steering head pipe.Record this number in the space provided. NOTE: The engine serial number is stamped on right-hand engine crankcase. A B Model code is indicated by 4th to 8th A digits and serial number is indicated by 12th to 17th digits B. Record these numbers for reference in case of ordering parts from a Yamaha dealer. 2-1 CONTROL FUNCTIONS Main switch The main switch controls the ignition and the electrical system. It's operation is described below. ON: Electrical circuits are switched on. Engine can be started. The key cannot be removed. OFF: All electrical circuits are switched off. The key can be removed. LOCK: The steering is locked and all electrical circuits are switched off. The key can be removed. Refer to page (3-11) "Steering lock" for instructions. NOTE: Always turn the main switch to "OFF" or "LOCK" and remove the key when the motorcycle is unattended. 3-1 Indicator lights TURN INDICATOR LIGHTS " " The corresponding indicator fhashes when the turn switch is moved to the " ç " or " è". HIGH BEAM INDICATOR LIGHT " " This indicator comes on when the headlight high beam is used. NEUTRAL INDICATOR LIGHT " " This indicator comes on when the transmission is in neutral. 1. Turn indicator lights " 2. High beam indicator light " " 3. Neutral indicator light "N" " 3-2 Speedometer The speedometer shows riding speed. This speedometer is equipped with an odometer and a trip meter. The trip meter can be returned to zero by using the adjusting knob. Use the trip meter to estimate how for you can ride on a tank of fuel. This information will enable you to plan fuel stops in the future. 1. Speedometer 3. Trip meter 2. Odometer 4. Adjusting knob 3-3 Handlebar switches over left: LIGHTS SWITCH Turning the light switch to " headlight and tail-lights. ", turns on the meter lights, PASS SWITCH " " Press the switch to operate the passing light. DIMMER SWITCH Turn the switch to " for the low beam. " for the high beam and to " " 1. Light switch 2. Pass switch 3. Dimmer switch 4. Turn signal switch 5. Horn switch TURN SIGNAL SWITCH " " To signal a right-hand turn, push the switch to " " ; to signal a left-hand turn, push the switch to " ". Once the switch is released it will return to the center position. To cancel the signal, push the switch in after it has returned to the center position. HORN SWITCH " " Press the switch to sound the horn. 3-4 Handlebar switches over right: "ENGINE STOP" SWITCH The engine stop switch is a safety device for use in an emergency such as when the motorcycle overturns or if trouble occurs in the throttle system. Turn the switch to " " to start the engine, and turn the switch to " " to stop the engine. STARTER SWITCH " " The starter motor cranks the engine when pushing the starter switch. 1. ENGINE STOP switch, shuts the engine off 2. Starter switch (XTZ 125E) CAUTION: See starting instructions prior to starting the engine. 3-5 Clutch lever The clutch lever is located on the left handlebar, and the starting circuit cut off switch is incorporated in the clutch lever holder. Pull the clutch lever to the handlebar to disengage the clutch, and release the lever to engage the clutch. The lever should be pulled rapidly and released slowly for smooth clutch operation. 1. Clutch lever Shift pedal This motorcycle is equipped with a constant-mesh 5-speed transmission. The shift pedal is located on the left side of the engine and is used in combination with the clutch when shifting. 1. Shift pedal 3-6 Front brake lever The front brake lever is located on the right handlebar. Pull it toward the handlebar to apply the front brake. 1. Front brake lever Rear brake pedal The rear brake pedal is on the right side of the motorcycle. Press down the brake pedal to apply the rear brake. 1.Rear brake pedal 3-7 Fuel tank cap TO OPEN: Insert the key and turn it 1/2 turn counterclockwise. The lock will be released and the cap can be opened. TO CLOSE: Push the tank cap into position with the key inserted. To remove the key, turn it clockwise to the original position. WARNING: Be sure the cap is properly installed and locked in place before riding the motorcycle. 3-8 Fuel cock The fuel cock supplies fuel from the tank to the carburetor while filtering it also. The fuel cock has three positions: OFF: With the fuel cock in this position, fuel will not flow. Always set the fuel cock to this position when the engine is not running. ON: With the fuel cock in this position, fuel flows to the carburetor. Set the fuel cock to this position when starting the engine and while riding. RES: This indicates reserve. If you run out of fuel while riding, set the fuel cock to this position. Fill the tank at the first opportunity. Be sure to set fuel cock back to "ON" after refueling! 3-9 Starter lever Starting a cold engine requires a richer air-fuel mixture. A separate starter circuit supplies the mixture. Pull the starter knob up to open the circuit for starting. When the engine has warmed up, push the knob down to close the circuit. 1 1. Starter lever Kick starter Rotate the kick starter away from the engine. Push the starter down lighty with your foot until the gears engage, then kick smoothly and forcefully to start the engine. Shift to neutral before starting. 1. Kick starter 3-10 Steering lock The steering is locked when the main switch is turned to "LOCK". To lock the steering, turn the handlebars all the way to the left. With the key at "OFF" position, push it into the main switch and release it, turn it counterclockwise to "LOCK", and remove the key. To release the lock, turn the key to "OFF". WARNING: WARNING: Never turn the key to "LOCK" position when the motorcycle is moving. 1. Push 2. Release 3. Turn 3-11 Seat To remove the seat, remove the bolts. To reinstall the seat, insert the lobes in to the receptacle on the frame and fuel tank, then tighten the bolts. Reinstall the side covers. NOTE: Make sure the seat is securely fitted. 1. Bolts 3-12 Side covers A Insert the key and turn it 1/4 clockwise. Pull the cover to release the pins. To reinstall, reverse the removal procedures. 1. Lock the side cover 2. Pull A. Pin A Remove the screw and then pull the cover to release the pins To reinstall, reverse the removal procedures. 1. Screw 2. Pull 3. Pin 3-13 Rear shock absorber The spring prelod can be adjusted to suit the motorcycle's load (ex: optional accessories, etc.) and riding conditions. Refer to page 6-30 for proper adjustment procedures. 1. Spring preload adjusting ring 2.Position indicator Soft Adjusting position 1 2 Standard 3 4 Hard 5 3-14 * Clutch switch operation check WARNING: If improper operation is noted, consult a Yamaha dealer or other qualified mechanic immediately. Check the operation of the clutch switch against the information below. TURN MAIN SWITCH TO "ON" AND ENGINE STOP SWITCH TO " ". TRANSMISSION IS IN GEAR. PULL IN CLUTCH LEVER AND PUSH STARTER SWITCH. ENGINE WILL START CLUTCH SWITCH IS OK * Obs.: XTZ 125E 3-15 PRE-OPERATION CHECKS Before using this motorcycle, check the following points: ITEM Front brake ROUTINE Check operation, free play, fluid level and fluid leakage. Top-up with DOT #4 (or DOT #3) brake fluid if necessary. Check operation, condition and free play. Adjust if necessary Check operation, condition and free play. Adjust if necessary Check for smooth operation. Lubricate / Adjust if necessary Check oil level / add oil as necessary Check chain slack and condition. Lubricate if necessary Adjust if necessary. Clean and oil it frequently. Check tire pressure, wear, damage and spoke tightness Check for smooth operation. Lubricate if necessary 4-1 PAGE 4-3 ~ 4-4 6-17 ~ 6-23 Rear brake Clutch Throttle grip / cable Engine oil Drive chain Air filter Wheels / Tires Control and meter cable 4-8 , 6-16 4-8 , 6-14 , 6-27 4-4 , 6-6 , 6-9 6-24 ~ 6-26 6-10 ~ 6-11 4-5 ~ 4-8 6-26 ITEM ROUTINE PAGE 6-27 6-27 6-28 4-8 , 6-5 4-9 4-8 , 6-35 ~ 6-36 6-32 ~ 6-34 Rear brake and shift pedal Check for smooth operation. Lubricate if necessary shafts Front brake and clutch lever pivots Sidestand Fittings / Fasteners Fuel tank Check for smooth operation. Lubricate if necessary Check for smooth operation. Lubricate if necessary Check all chassi fittings and fasteners. Tighten / Adjust, if necessary Check fuel level / top up as required. Lights, signals and switches Check for proper operation Battery NOTE: Check electrolyte level. Replenish with "distilled water" if necessary. 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. WARNING: 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. 4-2 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. 2. Brake fluid Check the brake fluid level. Add fluid if necessary. RECOMMENDED BRAKE FLUID: DOT #4 NOTE: WARNING: 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. 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 NOTE: When a brake service is necessary, consult a Yamaha dealer or other qualified mechanic. 4-3 Brake fluid leakage Apply the brake for several seconds. Check to see if any brake fluid leaks out from the pipe joints or the master cylinder. CAUTION: Brake fluid may deteriorate painted surfaces or plastic parts. Never spill any fluid. If spilled, clean it up immediately. WARNING: If brake fluid leakage is found, ask a Yamaha dealer or other qualified mechanic for immediate repairs. Such leakage could indicate a hazardous condition. Engine oil (See page 6-6 for details) Make sure the engine oil is at the specified level. Add oil as necessary. 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) CAUTION: Check the oil level in a daily manner and top it up if necessary. 4-4 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. WARNING: 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. Basic weight: With oil and without fuel XTZ 125K 113 Kg ( 249 lb) XTZ 125E 114 Kg ( 251 lb) Maximum load*: Cold tire pressure: 150 Kg ( 330 kg) Front Rear 1.5 kg/cm2 22 PSI / 147Kpa up to 90 Kg (198 lb) load*: 90 Kg (198 lb) ~ maximum load*: 1.5 kg/cm2 22 PSI / 147 kpa 1.5 kg/cm2 22 PSI / 145 Kpa 2.0 kg/cm2 28 PSI / 200 Kpa * Load is the total weght of cargo, rider, passenger and accessories. 4-5 WARNING: Proper loading of your motorcycle is important for the handling, braking, and other performance and safety characteristics of your motorcyle. Do not carry loosely packed items that can shift. Securely pack your heaviest items close to the center of the motorcycle, and distribute the weight evenly from side to side. Properly adjust the suspension for your load, and check the condition and pressure of your tires. NEVER OVERLOAD YOUR MOTORCYCLE. Make sure the total weight of the cargo, rider, passenger, and accessories (fairing, saddlebags, etc. if approved for this model) does not exceed the maximum load of the motorcycle. Operation of an overloaded motorcycle could cause tire damage, an accident, or even injury. 2. Tire inspection Always check the tires before operating the motorcycle. If a tire tread shows crosswise lines (minimum tread depth), if the tire has a nail or glass fragments in it, or if the side wall is cracked, contact a Yamaha dealer or other qualified mechanic and have the tire replaced. 1.Tread depth 2. Side wall 3. wear indicator 4-6 WARNING: After extensive tests, the tires listed below have been approved by Yamaha for this model. The front and rear tires should always be by the same manufacturer and of the same design. No guarantee concerning handling characteristics can be given if a tire combination other than one approved by Yamaha is used on this motorcycle. WARNING: 1. It is dangerous to ride with a worn-out tire. When the tire tread begin to show signs of wear, replace the tire immediately. Brakes, tires and related wheel parts should be left to a Yamaha dealer. 2. Patching a punctured tube is not recommended. If it is absolutely necessary to do so, use great care and replace the tube as soon as possible with a good quality replacement. Manufacturer FRONT REAR PIRELLI PIRELLI Size 80/90 - 21 110/80 - 18 Type 48T MT 60 58T MT 60 Minimum tire tread depth (from and rear) 0,8 mm (0.0315 in) 4-7 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. 4-8 Fuel CAUTION: Always wipe off spilled fuel immediately with a dry and clean soft cloth. Fuel may deteriorate painted surfaces or plastic parts. Recommended fuel: UNLEADED FUEL Fuel tank capacity: Total: 10.6 l ( 2.33 Imp gal, 2.80 US gal) Reserve: 1.0 l ( 0.220 Imp gal, 0.264 Us gal) Your Yamaha engine has been designed to use regular unleaded gasoline with a pump octane number ([R+m]/2) of 86 or higher, or research octane number of 91 or higher. If knocking or pinging occurs, use a different brand of gasoline or premium unleaded fuel. Unleaded fuel will give you longer spark plug life and reduced maintenance cost. If unleaded gasoline is not available, then leaded regular gasoline can be used. Gasohol There are two types of gasohol; gasohol containing ethanol and that containing methanol. Gasohol containing ethanol can be used if ethanol content does not exceed 10%. Gasohol containing methanol is not recommended by Yamaha because it can cause fuel system damage or vehicle performance problems. 4-9 1. Fuel level 2. Filler tube Make sure there is sufficient fuel in the tank. WARNING: Do not overfill the fuel tank. Avoid spilling fuel on the hot engine. Do not fill the fuel tank above the bottom of the filler tube as shown in the illustration or it may overflow when the fuel heats up later and expands. OPERATION AND IMPORTANT RIDING POINTS 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. 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. 5-1 Starting a cold engine 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. Kick the kick start to start the engine. 6. After warming up the engine, turn back the starter (CHOKE) completely. 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. 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. 5-2 NOTE: This motorcycle is equipped with a starting and an ignition circuit cut-off switch. 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. 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. 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. 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. 5-3 WARNING: Before going through the following steps, check the function of the clutch switch (See page 3-15) TURN THE MAIN SWITCH TO "ON" AND ENGINE STOP SWITCH TO " " IF TRANSMISSION IS IN NEUTRAL IF TRANSMISSION IS IN GEAR PUSH STARTER SWITCH; ENGINE WILL START PULL IN CLUTCH LEVER AND PUSH STARTER SWITCH; ENGINE WILL START PUT TRANSMISSION IN GEAR MOTORCYCLE CAN BE RIDDEN * Obs.: XTZ 125E MOTORCYCLE CAN BE RIDDEN 5-4 Starting a warm engine The starter lever is not required when the engine is warm. CAUTION: If the engine fail to start with the procedures above, try to start it again with the throttle grip opened 1/4 to 1/2. Warming up the engine For an extended engine life always warm the engine up never accelerate hard while the engine is cold. To check if engine temperature is normal, rev the engine with the choke closed and check to see if it responds normally. CAUTION: See the "Break-in section" prior to operating the motorcycle for the first time. 5-5 Shifting The transmission lets you control the amount of power you have available at a given speed for starting, accelerating, climbing hills, etc. The use of shift pedal is shown in the illustration (page 3-6). To shift into NEUTRAL, depress the shift pedal repeatedly until it reaches the end of its travel (you will feel a stop when you are in first gear), then raise the pedal slightly. CAUTION: 1. Do not coast for long periods with the engine off, and do not tow the motorcycle a long distance. Even with gears in neutral, the transmission is only properly lubricated when the engine is running. Inadequate lubrication may damage the transmission. 2. Always use the clutch when changing gears. The engine, transmission, and driveline are not designed to withstand the shock of forced shifting and can be damaged by shifting without using the clutch. 5-6 Tips for reducing fuel consumption Your motorcycle's fuel consumption depends to a large extent on your riding style. The following tips can help reduce fuel consumption. 1. Warm up the engine before riding. 2. Turn off the starter lever as soon as possible. 3. Shift up swiftly and avoid high engine speeds during acceleration. 4. Do not double-clutch or rev the engine while shifting down and avoid high engine speeds with no load engine. 5. Turn off the engine instead of letting it idle for an extended lenght of time, i.e. in traffic jams, at traffic lights or railroad crossings. Engine Break-in There is never a more important period in the life of your motorcycle than the period 1.000Km. For this reason we ask that you carefully read the following material. Because the engine is brand new, you must not put an excessive load on it for the first several hours of running. During this period, prolonged full throttle operation, or any condition which might result in excessive heating of the engine must be avoided. 1. 0 ~ 150 Km: Avoid operation above 1/3 throttle. Stop the engine and let it cool for 5 to 10 minutes after every hour of operation. Vary the speed of the motorcycle from time to time. Do not operate it at one set throttle position. 5-7 2. 150 ~ 500 Km: Avoid prolonged operation above 1/2 throttle. Allow the machine to rev freely through the gears, but do not use full throttle at any time. 3. 500 ~ 1,000 Km: Avoid cruising speeds in excess of 3/4 throttle. Parking When parking the motorcycle, stop the engine and remove the ignition key. Turn the fuel cock to "OFF" whenever stopping the engine. WARNING: The muffler and exhaust pipe are hot. Park the motorcycle in a place where pedestrians or children are not likely to touch the motorcycle. Do not park the motorcycle on a slope or soft ground; the motorcycle may fall over. CAUTION: After 1,000Km of operation, be sure to replace the engine oil. 4. After 1,000 Km: Avoid prolonged full throttle operation. Vary speeds occasionally. CAUTION: If any engine trouble should occur during the break-in period, consult a Yamaha dealer immediately. 5-8 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. 6-1 Tool kit The 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. 1. Tool kit WARNING: 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. 6-2 PERIODIC MAINTENANCE / LUBRICATION REMARKS How it sounds / Adjust if necessary. Check condition and clean if necessary. Replace if necessary every 12,000 Km. Clean or replace if necessary. Check fuel hose, for cracks or damage. Adjust Check electrolyte level, routing breather pipe. Replace / Check level Check damage, Retighten. Check operation, adjust. Grease the brake cam. Check rear arm assembly for looseness. Moderately repack.*** Check tire pressure, runout and spoke tightness. Check looseness and damage. Check loosenes. Repack every 12,000 km or 12 month.** 1,000KM 3,000KM EVERY 3,000KM OR ERERY 6 MONTHS ITEM Valves* Spark plug Air filter Fuel line Carburetor* Battery Engine oil Muffler Brakes* Rear arm pivot* Wheels and tires Wheel bearings* Steering bearings* 6-3