2008 YAMAHA XTZ125 chain

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

4-1
4-1
PRE-OPERATION CHECKS
Before using this motorcycle, check the following points:
ITEM ROUTINE PAGE
Front brake
Check operation, condition and free play.
Adjust if necessary
Clutch
Throttle grip / cableCheck for smooth operation.
Lubricate / Adjust if necessary
Check oil level / add oil as necessary
Engine oil
Drive chainCheck chain slack and condition. Lubricate if necessary
Adjust if necessary.
Air filter
Control and meter cableCheck tire pressure, wear, damage and spoke tightness
Check for smooth operation.
Lubricate if necessary4-3 ~ 4-4
6-17 ~ 6-23
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 Check operation, condition and free play.
Adjust if necessary
Wheels / Tires
Clean and oil it frequently.4-8 , 6-16 Rear brakeCheck operation, free play, fluid level and fluid leakage.
Top-up with DOT #4 (or DOT #3) brake fluid if necessary.
PRE-OPERATION CHECKS
Before using this motorcycle, check the following points:
ITEM ROUTINE PAGE
Front brake
Check operation, condition and free play.
Adjust if necessary
Clutch
Throttle grip / cableCheck for smooth operation.
Lubricate / Adjust if necessary
Check oil level / add oil as necessary
Engine oil
Drive chainCheck chain slack and condition. Lubricate if necessary
Adjust if necessary.
Air filter
Control and meter cableCheck tire pressure, wear, damage and spoke tightness
Check for smooth operation.
Lubricate if necessary4-3 ~ 4-4
6-17 ~ 6-23
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 Check operation, condition and free play.
Adjust if necessary
Wheels / Tires
Clean and oil it frequently.4-8 , 6-16 Rear brakeCheck operation, free play, fluid level and fluid leakage.
Top-up with DOT #4 (or DOT #3) brake fluid if necessary.

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

6-19
6-19
ADVERTENCIA
After adjusting the pedal height adjust brake pedal free
play.
2. Freeplay. The rear brake pedal free play should be adjusted to
20 ~ 30 mm (0.8 ~ 1.2 in) at the brake pedal end. Turn
the adjuster on the brake rod clockwise to reduce play
or counterclockwise to increase play.
ADVERTENCIA
Brake pedal free play should be checked whenever the
chain is adjusted or the rear wheel is removed and then
reinstalled.
If it is impossible to make proper adjustment, consult
a Yamaha dealer.
Check the operation of the brake light after adjusting
the rear brake.
1. Adjuster
a.Free play: 20 ~ 30 mm ( 0.8 ~ 1.2 in)
WARNING:
WARNING:
ADVERTENCIA
After adjusting the pedal height adjust brake pedal free
play.
2. Freeplay. The rear brake pedal free play should be adjusted to
20 ~ 30 mm (0.8 ~ 1.2 in) at the brake pedal end. Turn
the adjuster on the brake rod clockwise to reduce play
or counterclockwise to increase play.
ADVERTENCIA
Brake pedal free play should be checked whenever the
chain is adjusted or the rear wheel is removed and then
reinstalled.
If it is impossible to make proper adjustment, consult
a Yamaha dealer.
Check the operation of the brake light after adjusting
the rear brake.
1. Adjuster
a.Free play: 20 ~ 30 mm ( 0.8 ~ 1.2 in)
WARNING:
WARNING:

6-24
6-24
NOTE:
Spin the wheel several times and find the tightest position
of the chain. Check and/or adjust the chain slack while it is
in this tightest position.
To check the chain slack the motorcycle must be held
straight up with both wheels on the ground and without rider.
Check the slack at the position shown in the illustration.
Normal slack is approximately 40 ~ 55 mm (1,6 ~ 2,2 in). If
the slack exceeds 55 mm ( 2,2 in), adjust.Drive chain slack check
#

$
NOTE:
Spin the wheel several times and find the tightest position
of the chain. Check and/or adjust the chain slack while it is
in this tightest position.
To check the chain slack the motorcycle must be held
straight up with both wheels on the ground and without rider.
Check the slack at the position shown in the illustration.
Normal slack is approximately 40 ~ 55 mm (1,6 ~ 2,2 in). If
the slack exceeds 55 mm ( 2,2 in), adjust.Drive chain slack check
#

$

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.

6-26
6-26Cable inspection and lubrication Drive chain lubrication
The chain consists of many parts which work with each
other. If the chain is not maintained properly, it will wear out
quickly. Therefore, the chain must be serviced regularly.
This service is especially necessary when riding in dusty
areas.
1. Use Yamaha Chain and Cable Lube or any brands of
spray-type chain lubricant. First, remove all dirt and mud
from the chain with a brush or cloth, then spray lubricant
between both rows of side plates and on all center
rollers. The chain should be lubricated every 500 km
(300 mi).
2. To clean the chain, remove it from the machine, dip it
in solvent, and clean out as much dirt as possible. Take
the chain out of the solvent and dry it. Immediately
lubricate the chain to prevent it from rusting.Damage to the outer housing of cables may allow
internal rusting and cause interfere with cable
movement. Replace damaged cables as soon as
possible to prevent unsafe conditions.
Lubricate the inner cable and the cable end. If it does not
operate smoothly, ask a Yamaha dealer to replace them.
RECOMMENDED LUBRICANT:
Engine oil SAE 20W50
WARNING:
Cable inspection and lubrication Drive chain lubrication
The chain consists of many parts which work with each
other. If the chain is not maintained properly, it will wear out
quickly. Therefore, the chain must be serviced regularly.
This service is especially necessary when riding in dusty
areas.
1. Use Yamaha Chain and Cable Lube or any brands of
spray-type chain lubricant. First, remove all dirt and mud
from the chain with a brush or cloth, then spray lubricant
between both rows of side plates and on all center
rollers. The chain should be lubricated every 500 km
(300 mi).
2. To clean the chain, remove it from the machine, dip it
in solvent, and clean out as much dirt as possible. Take
the chain out of the solvent and dry it. Immediately
lubricate the chain to prevent it from rusting.Damage to the outer housing of cables may allow
internal rusting and cause interfere with cable
movement. Replace damaged cables as soon as
possible to prevent unsafe conditions.
Lubricate the inner cable and the cable end. If it does not
operate smoothly, ask a Yamaha dealer to replace them.
RECOMMENDED LUBRICANT:
Engine oil SAE 20W50
WARNING:

6-32
6-32
Battery
BATTERY BREATHER HOSE ROUTING
YAMAHA 5RM-F8179-00Check the level of the battery electrolyte and make sure
that the terminals are tight. Add distilled water if the
electrolyte level is low.
1. When inspecting the battery, make sure that the
battery breather pipe routing is correct. If the
breather pipe touches painted parts, or if its end is
in such a position that may cause gas or electrolyte
leakage, it may cause structural or esthetic damages
to the motorcycle.
2. Take care not to spill battery fluid on the chain.
Battery fluid may weaken the chain causing shorter
chain life and possibly result in an accident.
WARNING:
Battery
BATTERY BREATHER HOSE ROUTING
YAMAHA 5RM-F8179-00Check the level of the battery electrolyte and make sure
that the terminals are tight. Add distilled water if the
electrolyte level is low.
1. When inspecting the battery, make sure that the
battery breather pipe routing is correct. If the
breather pipe touches painted parts, or if its end is
in such a position that may cause gas or electrolyte
leakage, it may cause structural or esthetic damages
to the motorcycle.
2. Take care not to spill battery fluid on the chain.
Battery fluid may weaken the chain causing shorter
chain life and possibly result in an accident.
WARNING: