2006 YAMAHA XTZ125 torque

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

4-8
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.

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:

6-5
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

6-7
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)

6-9
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)




6-15
6-15Before installing the spark plug, measure the electrode gap
with a wire thickness gauge and adjust the gap to
specification as necessary.
Standard spark plug:
CR7HSA (NGK) and U22FSR-U (DENSO)


Spark plug gap:
0.7 mm ( 0.028 in) Spark plug inspection
The spark plug is an important engine component and is
easy to inspect. The condition of the spark plug can indicate
the condition of the engine.
The ideal color on the white porcelain insulator around the
center electrode is a medium to light tan color for a
motorcycle that is being ridden normally. Do not attempt to
diagnose any problems yourself. Instead, take the
motorcycle to a Yamaha dealer. You should periodically
remove and inspect the spark plug because heat and
deposits will cause the spark plug to slowly break down
and erode.
If electrode erosion becomes excessive, or if carbon and
other deposits are excessive, you should replace the spark
plug with the specified plug.NOTE:
If a torque wrench is not available when you are installing a
spark plug, a good estimate of the correct torque is 1/4 to
1/2 turn past finger tight. Have the spark plug torqued to
the correct value as soon as possible with a torque wrench.
When installing the plug, always clean the gasket surface
and use a new gasket. Wipe off any grime from the threads,
and torque the spark plug properly.
Spark plug torque:
12.5 N.m (1.25 Kgf.m, 9 lbf.ft)
Before installing the spark plug, measure the electrode gap
with a wire thickness gauge and adjust the gap to
specification as necessary.
Standard spark plug:
CR7HSA (NGK) and U22FSR-U (DENSO)


Spark plug gap:
0.7 mm ( 0.028 in) Spark plug inspection
The spark plug is an important engine component and is
easy to inspect. The condition of the spark plug can indicate
the condition of the engine.
The ideal color on the white porcelain insulator around the
center electrode is a medium to light tan color for a
motorcycle that is being ridden normally. Do not attempt to
diagnose any problems yourself. Instead, take the
motorcycle to a Yamaha dealer. You should periodically
remove and inspect the spark plug because heat and
deposits will cause the spark plug to slowly break down
and erode.
If electrode erosion becomes excessive, or if carbon and
other deposits are excessive, you should replace the spark
plug with the specified plug.NOTE:
If a torque wrench is not available when you are installing a
spark plug, a good estimate of the correct torque is 1/4 to
1/2 turn past finger tight. Have the spark plug torqued to
the correct value as soon as possible with a torque wrench.
When installing the plug, always clean the gasket surface
and use a new gasket. Wipe off any grime from the threads,
and torque the spark plug properly.
Spark plug torque:
12.5 N.m (1.25 Kgf.m, 9 lbf.ft)

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.