Jak w tytule.
OWNER’S MANUAL
XC125E
4P7-F8199-E0
Preface
Thanks for your kind selection of our YAMAHA motorcycle series.
With the most up-to-date design of YAMAHA-motor (Japan) Co., Ltd., the YAMAHA motorcycle series we produced are
the most modern vehicles which represent the most advanced technology in the new century.
With the advanced one-cylinder four-stroke air-cooled engine, you will be satisfied with the novel design of our motorcycle series. The installation of every parts and components can meet the requirement of easy riding and comfortable
seating; also our products integrate the excellent durability with reliability perfectly. The motorcycles we produced are
powerful and fascinating vehicles as you wish.
This operation manual will show you the correct operation, the basic inspection, repair and installation messages. This
booklet illustrates the various functions of our YAMAHA motorcycles thoroughly, we are pretty sure that ride our
motorcycle series can make you feel comfortable and joyful.
If you have any questions about the operation, repair and installation, please feel free to contact with the technicians in
our specified maintenance stations which locate in different cities. Our tenet is " Best quality, Best reputation and
Consumer first " , we can satisfy your various requirements.
Please keep this operation manual as a basic part of your YAMAHA motorcycle, and take it with the motorcycle at any
time. If you wish to resell your motorcycle, take this manual also.
You will see different symbols for the particularly important information in this booklet as below:
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
!
WARNING
CAUTION:
NOTE:
Failure to follow WARNING instructions could result in severe injury or death to the motorcycle
operator, a bystander or a person inspecting or repairing the motorcycle.
A CAUTION indicates special precautions that must be taken to avoid damage to the motorcycle.
A NOTE provides key information to make procedures easier or clearer.
NOTE:
The operation manual is one of the permanent parts of the motorcycle, even in situations of reselling.
NOTE:
We enhance the design and quality of our YAMAHA motorcycles continually, the manual contains the latest information till printing, and there maybe have differences with 09 manual.
If you have any questions about this manual, please feel free to contact with your agency.
WARNING
PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY
BEFORE OPERATING THE MOTORCYCLE.
CONTENTS
1
SAFE-RIDING AND SAFETY POINTS
1
2
MOTORCYCLE INFORMATION
2
3
PARTS LIST AND OPERATION
3
4
PARTS CONTROL
4
5
RUNNING AND OPERATION
5
6
PRE-OPERATION CHECKS
6
7
MAINTENANCE
7
8
TROUBLE SHOOTING
8
9
SPECIFICATIONS
9
SAFE-RIDING AND SAFETY POINTS
1
Safe-riding
1-1
2
Safety points
1-2
SAFE-RIDING AND SAFETY POINTS
Motorcycles are convenient vehicles; you should always keep the motorcycle in the perfect conditions to make sure
that you can ride it safely. What's more, the rider must always be at their best mental and physical status. Riding under
the influence of medication, drugs and alcohol is, of course, prohibited. (Under the influence of even a small amount of
alcohol, the rider is more likely to put him/herself in extremely dangerous conditions.)
Protective clothing is as essential to the motorcycle riders as seat belts to car drivers and passengers. Always wearing
a proper motorcycle suit, gloves and helmet will protect rider from being hurt. Note: Some riders with protective clothing
may have illusions of total safety and protection, and they will run the risk of going too fast and are apt to take chances,
facing even greater dangers in wet weather. Good motorcyclists will always have his/her wits about this situation
besides the traffic rules.
Enjoy your ride!
1-1
SAFE-RIDING AND SAFETY POINTS
1.Be sure to signal clearly in the following situations:
Turn right
Turn left
2.Braking can be extremely difficult on
a wet road. Avoid hard braking, since
the motorcycle may slide. Apply the
brakes slowly when stopping on a wet
surface.
3.Slow down when approaching a corner or turn, and accelerate slowly once
the turn has been completed.
4.Be careful when passing parked cars.
The driver might have not seen you and
open the door in a sudden.
5.Railroad crossings, streetcar rails, iron
plates on road construction sites, and
manhole covers will become extremely
slippery when wet. Slow down and cross
them with caution. Keep the motorcycle
upright, otherwise you may fall from the
motorcycle.
6.The brake pads could get wet when
1-2
you wash the motorcycle. After washing the motorcycle, check the brakes
before riding.
7.Always wear a helmet, gloves, trousers (tapered around the cuff and ankle
so they would not flap), and a bright
color jacket.
8.Do not carry too much luggage on
the motorcycle. Overloaded motorcycles are unstable. Please secure the
luggage to the rear rack with a firm
rope. Unfastened luggage will affect
the stability of the motorcycle and divert your attention from the road
condition.
9.When riding the motorcycle in the
littoral, since the salinity in the air is
higher, this will speedup the corrosion
of the iron parts, you should wash the
motorcycle more frequently.
MOTORCYCLE INFORMATION
1
Engine models and serial number
2-1
2
Identification code
2-1
3
Name plate
2-1
4
Engine running-in
2-2
MOTORCYCLE INFORMATION
Identification code
Engine models and serial number
■ Engine models and serial
number
The model and serial number will be
engraved in the left part of the gear
box.
Name plate
■ Identification code
■ Name plate
The identification code will be stamped
in the lower place of the front storage
compartment.
The name plate will be stuck to the
right side of frame under the foot board
by rivet.
NOTE:
Always remember the engine model
and serial number of your motorcycle,
so that, when ordering parts from our
specified maintenance stations, you
will get your parts sooner.
2-1
MOTORCYCLE INFORMATIONS
■ Engine running-in
The distance between 0 and 1,000 km
is most important to your engine.
Keeping this fact in mind, please read
the following material carefully and
carry out as per instructions.
Since the engine is brand new, various parts of the engine will wear and
polish themselves to the proper operating clearances. At the same time,
overloading the throttle or any other
conditions that might result in engine
overheating must be avoided in 0 1,000 km.
1. 0 - 150 km
Avoid prolonged operation above 1/3
throttle. After operating for an hour,
stop the engine and let it cool for five
to ten minutes. Vary the engine speed
from time to time and do no operate
the engine at full throttle.
2. 150 - 500 km
Avoid prolonged operation above 1/2
throttle.
3. 500 - 1,000 km
Avoid prolonged operation above 3/4
throttle.
CAUTION:
After 500 km of operation, replace
the engine oil and gear oil, and clean
the oil filter (bottom part). Replace
the engine oil every 1,500 km.
4. 1,000 km and beyond
Avoid prolonged full-throttle operation.
Vary the engine speed from time to
time.
2-2
PARTS LIST AND OPERATION
1
Parts list
3-1
2
Panel
3-2
3
Switch operation
3-3
4
Handlebar switches
3-4
5
Fuel tank cap
3-5
6
Front storage compartment
3-5
7
Storage compartment
3-5
PARTS LIST AND OPERATION
Parts list of ZY125T-3 motorcycle
rearview mirror
handlebar switch
front turn signal
storage
compartment
taillight
odometer
rear brake lever
main switch
front brake lever
front headlight
front vibration
damper
exhaust pipe
rear wheel
rear light/stoplight
front storage compartment
rear vibration damper
air filter
kick-starter
crankcase filter
front wheel
accumulator
fuse
dish brake
3-1
rear luggage carrier
side-stand
center-stand
PARTS LIST AND OPERATION
■ Panel
12
3
41
1 Turn signal indicator light (Green)
This indicator light comes on when the
from " F " (full) to " E " (empty) as the fuel
level decreases. When the needle
reaches the refuel line (E line), please
refuel as soon as possible.
NOTE:
Refuel the fuel tank before emptying.
In case that the main switch is " ON " ,
the needle shows the quantity left;
when the main switch is " OFF " , the
needle locates under " E " line.
turn signals are being used.
2 High beam indicator light (Blue)
This indicator light comes on when the
high beam of the headlight is being on.
3 Odometer:
The meter shows the distance the motorcycle ran.
4 Fuel gauge
The fuel gauge indicates the amount of
fuel left in the fuel tank. The needles move
3-2
PARTS LIST AND OPERATION
■ Switch operation
3.Open the rider seat
1.Turn on electric door lock
ON
1.Turn the switch to
position " ON " , the
electric system will
be powered and the
engine can be
started.
2.The key can not be
removed.
2.Turn off electric door lock
OFF
1.Turn the switch to
position " OFF " ,
power off the electric system and the
engine will be
stopped.
2.The key can be
removed.
NOTE:
When you do not operate the
motorcycle, you should turn the key
to position " OFF " or " LOCK " , and remove the key.
OPEN
1. P o w e r o f f t h e
engine, and turn the
key counterclockwise
to position " OPEN " ,
unlock the seat lock ;
2.When the steering
system and the center-stand are
locked, turn the key
counterclockwise to
position " OPEN " ,
unlock the seat lock;
3.The key can not
be removed.
4.Lock the steering system and center-stand
LOCK
1.Push the key inward
and turn counterclockwise to position " LOCK " ,
lock the steering system
and center-stand ;
2.If the center-stand is
not in position, you
cannot lock it. Once the
center-stand is in
position, it will be
locked automatically.
3.The key can be
removed.
3-3
If you do not ride the motorcycle, you can
turn the handlebar to left till the end of
travel, and lock the handlebar as per
following instructions to prevent your
motorcycle from being stolen:
(1.)
(2.)
1.Turn the handlebar, push the key inward and turn to position LOCK
2.Remove the key
NOTE:
When you lock the handlebar, you
should lock it when turning, do not push
the key inward to lock the handlebar
by force, it will cause inner core
broken.
When operating motorcycle, you
should not turn the key to position
LOCK.
PARTS LIST AND OPERATION
■ Handlebar switches
■ Left handlebar switches
Turn the switch to right (R/
■ Right handlebar switches
2 Turn signal switch
left handlebar
switches
1
2
) means
turn right, and turn it to left (L/
)
right handlebar switches
1
means turn left. When you release the
switch, it will move back to center
position. To cancel the signal, just
2
push the switch inward when it's in
3
1 Dimmer switch
When the light switch in the right
handlebar is positioned to
center position.
1 Light switch
3 Horn switch
Press this switch to sound the horn.
Headlight off.
Position light, rear light, instrument light on.
Position light, headlight, rear
light, instrument light on.
High beam lights
Low beam lights
2 Start switch
To start the engine, press this switch
while holding the front or rear brake
lever.
3-4
PARTS LIST AND OPERATION
2
1
Fuel tank cap
■ Fuel tank cap
The fuel tank cap locates under the
rider seat, open the seat and you can
see the cap.
1. If you wish to remove the fuel tank
cap, turn it counterclockwise.
2. If you wish to fasten the fuel tank
cap, table the flange in the cap to the
groove in the fuel tank, and turn
clockwise.
3. Gasoline
Make sure that there is enough fuel in
the tank; fill the tank till the fuel reaches
the bottom of filler tube as per
illustration.
Fuel tank capacity: 5.4L
■ Front storage compartment
WARNING
Do not exceed the load limit of 3 kg
for the front storage compartment.
3-5
■ Storage compartment
The storage compartment locates
under seat, which can hold a full-covered helmet. When storing helmet,
place it upright, and the front side
should face the motorcycle head
(shown in the drawing above).
PARTS CONTROL
1
Front brake lever
4-1
2
Rear brake lever
4-1
PARTS CONTROL
WARNING
Do not exceed the load limit of the
storage compartment.
Load limit: 5 kg
CAUTION:
Keep the following points in mind when
using the storage compartment.
1. Since the storage compartment accumulates heat when exposed to the
sun, do not store anything susceptible
to heat.
2. Do not store costly or fragile articles
in the storage compartment.
3. Since the storage compartment may
become wet when raining or washing
the motorcycles, pack the articles in the
storage compartment by plastic bags.
4. Pack the wet articles by plastic bags
before placing them into the storage
compartment.
1
1
1. Front brake lever
1. Rear brake lever
■ Front brake lever
■ Rear brake lever
The front brake lever is located on the
right handlebar. To brake the front
wheels, pull this lever toward the
handlebar.
The rear brake lever is located on the
left handlebar. To brake the left wheels,
pull this lever toward the handlebar.
NOTE:
Place suitable safety helmet into the
storage compartment.
Do not leave your motorcycle unattended with the seat open.
4-1
RUNNING AND OPERATION
1
Start the engine
5-1
2
Shut-down the engine and park the motorcycle
5-2
3
Engine exhaust
5-3
RUNNING AND OPERATION
■ Start the engine
NOTE:
· Check the engine before starting.
· Check the fuel level.
· The motorcycle should be supported
by center-stand.
· The side-stand should be in horizontal position.
· Operate on the left side of the
motorcycle.
3.Before starting off, allow the engine
to warm up for 1-3 minutes, which will
maximize the engine's service life.
Never accelerate the motorcycle rapidly when the engine is still cold,
otherwise, the accelerating ability will
be reduced.
1/4
1/8
ON
1.Turn the key of main switch to position ON.
2.Release the throttle grip, press the
start switch to start the engine while
holding the front or rear brake lever.
5-1
NOTE:
If the engine fails to start, release the
start switch, wait for a few seconds,
then try again. Do not crank the engine for more than 5 seconds on any
single attempt preserve battery charge.
If the engine cannot be started by starting motor, try tramping on the kickstarter.
If the engine still fails to start after the
start switch has be pressed for 4-5
times, turn the throttle grip for 1/8-1/4
of a circle and then press the start
switch again.
RUNNING AND OPERATION
WARNING
1.Never start the engine in a closed
environment. The exhaust fumes are
poisonous which may cause loss of
consciousness and death within a
short time. Operate the motorcycle
always with adequate ventilation.
2.Make sure that the side-stand has
been back to its original position before riding; otherwise, serious accident may occur when turning.
3.After warming the engine, hold the
fixed bracket by right hand and push
the motorcycle off the center-stand.
6.Turn the throttle grip on the right
handlebar slowly to take off, switch
off the turn signal.
■ Shut-down the engine and
park the motorcycle
When stopping, turn the main switch
to position OFF.
WARNING
Since the exhaust pipe of muffle
may become extremely hot, you
should park the motorcycle in a
place where pedestrians or children
are unlikely to come in contact with
the vehicle. Do not park on a slope
or soft ground, otherwise the motorcycle may overturn.
4.Sit astride the seat and adjust the
rear view mirrors.
5.Check the oncoming traffic; switch
on the turn signal before starting off.
5-2
OPERATION AND IMPORTANT RIDING POINTS
CAUTION:
. Only use unleaded fuels (#93 unleaded petrol). The leaded petrol will
cause the catalyzing device become contaminated and rendered
useless.
When riding, do not turn off the
main switch. Otherwise, it will produce massive incomplete combusted gases.
If the ignition or fuel system is
out of condition, the agent catalyzing device will overheat.
Be careful when the motorcycle
rides for a period of time, the outside of exhaust pipe will be very hot.
Do not splash or overfill the fuel
to the exhaust pipe when re-fueling.
It may burn when the petrol dripped
to hot exhaust pipe.
.
■ Engine exhaust
We take the environmental protection
into consideration maturely, our motorcycles are equipped with AIS system and agent catalyzing device in the
exhaust pipe, and can meet the requirement of Europe II emission
standard.
Massive incomplete combusted gas
mixture will re-combust when flowing
into the hot agent catalyzing device,
thus causes exhaust pipe overheating and shortens the service life of
catalyzing device. To prevent this kind
of situation and other damages,
please read the following list carefully.
.
.
.
5-3
WARNING
Do not ride or park your motorcycle
over inflammable material (like
mow or something else) to avoid
fire hazard.
PRE-OPERATION CHECKS
1
Pre-operation checks
6-1
2
Brake lever free travel
6-2
3
Brake fluid
6-2
4
Engine oil level
6-2
5
Petrol level
6-3
6
Throttle grip
6-3
7
Tyre
6-3
8
Lights and signal light
6-3
9
Switches
6-3
PRE-OPERATION CHECKS
■ Pre-operation checks
Before riding the motorcycle, you should check the following items:
Item
Description
Front brake (disk brake)
(drum brake)
Action, free gap, brake fluid level and leakage, refuel if necessary
Rear brake
Action, free gap, adjust if necessary
Throttle grip
Operation, lubricate and adjust if necessary
Engine oil
Oil level, refuel if necessary
Tires and tyre casing
Tyre pressure, wear and deflection
The steel wires
Action, lubricate if necessary
Brake lever pivot
Action, lubricate if necessary
Center/side stand shaft
Action, lubricate if necessary
Tightness
Check the tightness of the bolts and nuts which connect the parts, tighten if necessary
Fuel tank
Oil level, refuel if necessary
Lights and signal lights
Action, repair if necessary
Action, free gap, adjust if necessary
NOTE:
Carry out the pre-operation checks every time you ride the motorcycle. It takes only a little of time to inspect the items
listed above, but the value of consequent safety is much more than the time cost.
WARNING
If you find any of the items listed above is not qualified or can not run well, clean up hazards before riding. Seek
help from your YAMAHA agency if necessary.
6-1
PRE-OPERATION CHECKS
■ Brake lever free travel
■ Brake fluid (disk brake)
front brake lever
If the oil level is below the LOWER
signal, take your motorcycle to the
agency for refueling.
front (right)
Travel
disk brake
drum brake
Rear brake
10-20mm
rear brake lever
rear (left)
drum brake
Front disk brake
(idle motion)
10-20mm
Front drum brake
10-20mm
WARNING
If the brake lever fails, do not ride
the motorcycle before
troubleshooting, and ask your
YAHAMA agency to repair the brake.
Soft brake means troubles in the
brake system.
Hold the brake lever for a few minutes
to check leakage in the brake pipe joint
or main cylinder. If leakages detected,
ask your agency to repair it
immediately. The leakage of brake
fluid means troubles in brake system.
■ Engine oil level
1.Uphold the motorcycle by center-stand.
NOTE:
When checking the engine oil level,
the motorcycle must be upright. Even
a small incline will cause fault result
of inspection.
This inspection should be took when
you buying the vehicle or every
1,000 km mileage.
2.Start the engine and warm the vehicle for a few minutes, then shut off
the engine.
3.Wait a few minutes, so that the engine oil flows back, take the oil dip rod
out of the crankcase, clean the rod,
put it back to the dipstick hole (do not
turn around), take it out again to check
the oil level.
Oil replaced periodically
Oil replaced periodically
(including the oil needed for
replacing filter element)
12
1.upper limit
2.lower limit
6-2
1.0L
1.2L
Special engine oil used YAHAMA Four-stroke
for four-stroke motor- YAMALUBE engine oil,
cycle
SAE 20W-40 combustion
engine oil (API) , Spec. SF
PRE-OPERATION CHECKS
■ Petrol level
■ Tyre
Make sure that there is sufficient petrol
in the fuel tank.
1.Tyre pressure:
Adjust the tyre pressure to value
specified before riding.
Specified Only with unleaded petrol (#93 unleaded
fuel
fuel recommended)
Capacity 5.4L totally
WARNING
Do not splash or overfill the gasoline to the exhaust pipe when
fueling. There are agents equipped
in the exhaust pipe. The surface
temperature is very high, and it may
burn when the gasoline is spilled.
■ Throttle grip
Place the throttle grip to check the
operation and free gaps. Make sure
that the grip will return to the original
position by spring force when releasing.
Ask the agency to adjust if necessary.
Tyre pressure
1 person
2 persons
front tyre:
rear tyre:
front tyre:
rear tyre:
175Kpa
200Kpa
175Kpa
225Kpa
2. Tyre casing
Check the situation of the tyre before
riding. If the tyre casing is over worn,
or there are pins or broken glasses, or
the tyre casing has crackles, ask the
agency to repair it, replace if
necessary.
foreign material (pin,gallet)
NOTE:
Check the tyre pressure when the tyre
is cooled.
WARNING
Never overload at any time,
otherwise, it may cause hazard
because of tyre bursting.
alligatoring, broke
wear limit indicator
■ Lights and signal light
Check the front headlight, position light,
turn signal, rear light, stoplight, instrument light and all the other indicator
lights, and make sure that they run
well.
■ Switches
3-5mn
Check the operation of the switches
for front headlight, position light, turn
signal, stoplight, horn and starter, main
switch.
6-3
MAINTENANCE
1
Periodical maintenance
7-1
2
Tool kits
7-3
3
Replace engine oil
7-3
4
Gear oil
7-5
5
Air filter
7-5
6
Crankcase filter
7-6
7
Adjust mixing ratio
7-6
8
Adjust idle speed
7-7
MAINTENANCE
9
Adjust throttle grip
7-7
10 Check ignition plug
7-7
11 Check front/rear brake
7-8
12 Check front fork
7-9
13 Check steering system
7-9
14 Replace fuse
7-9
15 Accumulator
7-10
MAINTENANCE
I Periodical maintenance
See detailed description and time requirement for the general periodical maintenance of motorcycle and exhaust gas
control system in the " Consumer Manual " .
The information supplied in this chapter is some kind of easy maintenance which can be finished by consumer him/
herself. If you are not familiar with the repair and maintenance procedure, ask the agency to finish it.
Periodical maintenance/lubrication table
Items
At the first
Every
Running-in
1,500km or 2 months 1,500km or 2 months
500km
Description
Air drain*
Check the clearance, adjust if necessary.
Ignition plug
Check the working condition, clean or replace if necessary.
Air filter
Clean every 1,000km, replace if necessary.
Carburetor*
Check idle speed/start operation, adjust if necessary.
Fuel line*
Check the fuel tube (or vacuum tube) for crackles or damages, replace if necessary.
Engine oil
Replace (warming engine before exhausting)
Engine oil filter*
Clean, replace if necessary.
Crankcase filter*
Clean every 1,000km, replace if necessary.
Gear oil*
Check leakage, replace every 3,000km.
Front brake*(dish brake) Check action/brake fluid leakage, see " Note " . Replace if necessary.
Front brake(drum brake) Check action, replace if necessary.
Rear brake
Check action, replace if necessary.
Front shaft
Lubricate a little. **
Wheel
Check wearing and damage. Repair if necessary.
Wheel bearing*
Check the fastening/damages of the bearing assembly, replace when there are damages.
7-1
MAINTENANCE
Items
Running-in
500km
Description
Steering bearing*
Check action/leakage, repair if necessary.
Rear shock absorber *
Check action/leakage, repair if necessary.
V belt
Every
1,500km or 2 months
Check the fastening degree of bearing assembly, modify and re-lubricate if necessary.**
Front fork*
At the first
1,500km or 2 months
Check the wear and damages, replace if necessary.
Accessory/Fastener* Check the accessories and fasteners in the chassis. Modify if necessary.
Center/side stand* Check action, repair if necessary.
*: Recommended to be finished by a YAMAHA specified maintenance station.
**: Use lithium grease.
CAUTION:
Replace brake fluid:
1.Replace brake fluid when disassembling the main cylinder or cartridge style cylinder. Check the liquid level
in normal condition, re-fuel if necessary.
2.It's recommended that you should replace the oil seals in the main cylinder and cartridge style cylinder
every 2 years.
3.It's recommended to change brake tube every 4 years, or replace it when found crackles.
7-2
MAINTENANCE
2
1
3
4
1
1. tool kits
■ Tool kits
■ Replace engine oil
Service information included in this
manual and the tool kits provided will
help you perform the maintenance and
minor repairs. However, additional
tools such as a torque wrench to fasten the nuts or screws may be necessary for correctly performing certain
maintenance work.
1.Start the engine and warm the
vehicle for a few minutes, then shut
off the engine.
2.Place an oil pan under the engine
to collect the engine oil used.
3.Remove the drain bolt.
WARNING
Modification without approval of
our company may affect the function of the motorcycle, and render
hazards.
7-3
1.fuel drain plug 2.spring
3.filter screen 4.O-ring
CAUTION:
When removing the drain plug, the
spring, the filter screen and O-ring
will fall out, do not lose any of the
components.
MAINTENANCE
4.Clean the filter screen.
5.Inspect the O-ring for damages, replace if necessary.
6.Tight the drain bolt and drain plug
according to the torque specification.
Locking torque of drain bolt: 2.0kg.m
Locking torque of drain plug: 3.2kg.m
CAUTION:
Before installing the drain plug,
make sure that the O-ring, spring
and filter screen is in position.
Oil replaced periodically
7.Re-install the engine oil cap.
8.Start the engine, warm the vehicle
for a few minutes, and check for
leakage. While the engine oil leaking,
shut off the engine and inspect the
parts leaking.
9.Shut off the engine, check the oil
level. Re-install the oil cap.
1.2L
Special engine oil used
for four-stroke motorcycle
When re-fueling, make sure that no
foreign materials fall into the oil
tank.
1.0L
Oil replaced periodically
(including the oil needed
for replacing filter element)
CAUTION:
YAHAMA Four-stroke
YAMALUBE engine oil,
SAE 10W-30 combustion engine oil (API) ,
Spec. SF
7-4
MAINTENANCE
refuel plug
WARNING
Make sure that no foreign material
falls into gear box when refueling
or discharging gear oil. Prevent the
gear oil from adhering to the tyre.
drain bolt
4.Reinstall the refuel plug and check
the leakage of gear oil.
■ Gear oil
■ Air filter
1.Park the vehicle on a flat place, remove refuel plug and drain bolt to discharge the gear oil.
2.Tight the drain bolt to 2.3kgm.
3.Refuel gear oil.
1.Loose the screws and remove the air
filter cover.
Total capacity of gear oil 150cc
While exchanging 130cc
Gear oil type
YAHAMA special gear oil
YAHAMA special four-stroke engine oil
2.Take out the filter element, clean or
replace if necessary.
7-5
3.Reinstall the air filter cover and tight
the screws to prevent the un-filtered
air flowing into the engine.
MAINTENANCE
■ Crankcase filter
1. Remove the crankcase cover.
■ Adjust mixing ratio
WARNING
Use the specified solvent to clean
the parts, never use petrol or solvent with low flash point which will
cause fire or explosion.
CAUTION:
1.Open the rubber cover which locates
under seat.
mixing ratio
adjustment
screw
Do not twist the filter element to
avoid of damages.
2. Take out the filter to clean.
3. Apply suitable engine oil (SAE 10W30) to the filter element after drying.
4.Install the filter element, crankcase
cover and kick-starter back.
CAUTION:
To avoid fast wearing of the parts
in belt chamber, you should maintain the filter element in the belt
chamber as per time and mileage
listed in the Consumer Manual.
7-6
2.Adjust the screw.
NOTE:
The mixing ratio pre-set should be
operated by local agency.
MAINTENANCE
■ Adjust idle speed
Turn clockwise
NOTE:
Warm the engine before adjusting the
idle speed.
1.Remove the small lid which locates
under the seat.
vehicle idling adjustment
position
Speed up
Turn counterclockwise
Speed down
Idle speed
specification
1700rpm 50rpm
CAUTION:
Before the motorcycle leaving factory,
we have already set the carburetor to
the standard position. Change the setting at random will affect the engine
performance and increase the discharge of exhaust gas.
■ Adjust throttle grip
2.Turn the idle speed adjusting screw.
idle speed
adjusting
screw
NOTE:
Adjust idle speed before adjusting the
free gap of throttle grip.
1.Loose the fixing nut.
2.Turn the adjustor till the clearance
meets specification.
3.Fasten the fixing nut and recheck
the clearance whether meets the standard clearance.
Clearance specified: 3 - 5mm
7-7
3-5mm
Adjusting direction of throttle grip clearance
1. Remove the ignition plug to check
the clearance and model.
■ Check ignition plug
Clearance: 0.7mm - 0.8mm
Model: C7ER
MAINTENANCE
■ Check front/rear brake
Front brake (dish brake)
Hold the front brake lever, if the wear
indicator of brake block touches the
brake disc, ask your agency to replace
the brake block.
wear indicator
brake disc
WARNING
1.Use the specified brake fluid,
otherwise, the rubber seal ring will
distort and cause leakage, thus render brake failure.
2.Refuel the same model of brake
fluid. Mix different brake fluid will
cause hazard chemical reaction
and render brake failure.
3.Avoid water going into the main
cylinder when refueling, it will decrease the boiling point of the brake
fluid and arise air bind.
4.The brake fluid will erode the
varnish surface and plastic
components, clean the fluid immediately if splashed.
5.If you cannot refuel the brake fluid
to the standard level, seek assistance from your agency.
Brake fluid: YAHAMA brake fluid
DOT #3 or DOT #4.
Front brake (drum brake)
1.Hold the brake lever, check whether
the wear indicator 1 reaches wear
margin 2.
2.If the indicator points to the wear
margin, ask your agency to replace the
brake block.
1
2
7-8
Rear brake
1.Hold the brake lever, check whether
the wear indicator reaches wear margin.
1
2
1. wear indicator
2. wear margin
2.If the indicator points to the wear
margin, ask your agency to replace the
brake block.
MAINTENANCE
■ Check front fork
WARNING
The motorcycle shall be securely
supported when being checked, so
that it would not fall over.
1.Visual examination
Check the inner tubes for scratches,
damages or oil leakage.
2.Action examination
Pull the motorcycle to a flat place.
a.Hold the handlebar and keep the
motorcycle upright, grasp the front and
rear brake lever to avoid slipping when
checking.
b.Actuate the handlebar up and right
for several times to check the action
of front fork.
CAUTION:
If you find any damage, oil leakage
or malfunction, ask your agency to
check it.
■ Check steering system
Worn or loose steering bearings may
cause danger. Place a stand under the
engine to raise the front wheel off
ground. Hold the lower ends of the
front fork and move them forward and
backward. If any free play can be felt,
ask your agency to check it.
WARNING
Make sure that the motorcycle
stands steadily when checking the
steering system to avoid hazard.
7-9
■ Replace fuse
1.Remove the cover of accumulator.
2.Remove the negative terminal (-) and
positive terminal (+), then you can
take out the fuse.
3.Replace the blown fuse.
Fuse specification: 15A
CAUTION:
Do not use fuses of a higher amperage rating than recommended to
avoid extensive damages to the electrical system, which may result in
fire.
MAINTENANCE
■ Accumulator
· Disassembly of the accumulator
1.Remove the battery cover.
specified for the accumulator,
otherwise, it will shorten the service
lift of accumulator.
2.Before using the battery for the
first time, you should charge it for
about 1-2 hours to extend the service life.
accumulator
2.Remove the negative terminal (-) and
positive terminal (+), and you can take
off the battery.
3.Clean the connector.
Use steel brush to clean the rust and
dirt on the connector, after coating thin
grease to the connector, assemble the
parts reversely.
CAUTION:
1.The accumulator equipped is free
of maintenance (do not need to add
water), you have to use the sealed
charger (constant voltage/current
value or constant voltage value)
connector
CAUTION:
1 Never attempt to remove the covers on the accumulator.
2 If the motorcycle will not be used
for more than 15 days, you should
charge the battery before riding.
3 If the motorcycle is always serviced in low speed and short
distance, and will be started
frequently, you should check the
battery regularly and charge it if
necessary.
7-10
WARNING
Electrolyte is poisonous and dangerous and will cause severe burn
injury. It contains strong acid;
avoid any contact with skin, eyes
or clothing. In case of contact, the
procedure is as per following:
External: Flush with water. Internal:
Drink large amount of boiled water
or milk, and drink milk of magnesia,
eggs mixture or vegetable oil, and
promptly consult for medical attention immediately.
Eyes: Flush with water for 15 minutes and seek prompt medical
attention. Batteries may produce
explosive gases. Therefore, keep
fire source (sparks, flames,
cigarettes, etc.) away from batteries and provide sufficient ventilation when charging or using the
battery in an enclosed space. Take
care of your eyes while working
around the battery.
Anyway, keep children away from
battery.
TROUBLE SHOOTING
1
Engine cannot start
8-1
2
Shut-down suddenly while running
8-1
3
Lights failure
8-1
TROUBLE SHOOTING
■ Engine cannot start
1.Whether the main switch locates on
position ON?
2.Is fuel enough? Whether the needle
points within the fuel range (above E
line)?
3.While pressing start switch, do you
hold rear brake lever?
4.While pressing start switch, do you
turn throttle grip? (See references listed
in page 10)
If you have already confirmed the 1-4
procedures, and the motorcycle still
cannot start:
5.Locate the main switch on position
ON, press horn switch, the horn does
not operate means there is possible
fuse failure.
6.If the fuse is good, use kick-starter
to start the engine and seek help from
your agency.
■ Shut-down suddenly while
running
Check the oil level.
Refuel as soon as possible if the fuel
is not enough.
■ Lights failure
Check as per following:
1.Whether the main switch locates on
position ON?
2.After starting the engine, check
whether the front headlight and rear
light is on?
3.Can the switches operate well?
4.Press horn switch, does the horn
operate?
The horn operates well means bulb
failure; the horn does not operate
means that there is possible fuse
failure.
8-1
The troubles other than listed
above or if you have any
questions, please consult your
agency.
SPECIFICATION
1
Specification
9-1
SPECIFICATION
■ Specification
Item
Dimension and weight
Overall length
Overall width
Overall height
Maximum load
Wheel base
Minimum ground clearance
Basic weight
Specification
Item
Specification
Fuel
1,860mm
Tank capacity
670mm
Electrical devices
Ignition spark model C7ER
Accumulator capacity 12V, 6AH
Accumulator model GTX7A-BS/YTX7A-BS
1,045mm
153 ± 7kg
1,250mm ± 30mm
95mm ± 20mm
5.4L
Transmission device
105kg ± 7kg
Primary reduction
Reduction ratio(idem)
Second reduction
Reduction ratio(idem)
Clutch
Engine
Model
4-stroke SOHC
Cylinder arrangement Single cylinder, Forward inclined
125cc
Air displacement
51.5mm × 60mm
Bore x Stroke
9.5:1
Compression ratio
electrical/kick-start
Starting system
Forced lubrication
Lubrication
E/G lubrication oil capacity 1.2L
Helical gear
40/15
Spur gear
38/13
Dry, centrifugal
Variable speed ratio
Model
V-belt infinite variable speed
Shift type
Infinite variable speed
Variable speed ratio 0.852 - 2.572
9-1
SPECIFICATION
Specification
Front
Item
3.5-10 51J
Specification
Front
Coil spring/oil damper
Rear
Coil spring/oil damper
Front
90mm
Rear
Tyre
specification
75mm
Rear
Shock absorber
Type
3.5-10 51J
Front Hand operated mechanical
drum/hydraulic dish brake
Cushion stroke
Model
Rear Hand operated mechanical
drum brake
Lights and illumination
Suspension gear
Break system
Running gear
Item
Front Expanding sleeve
Model
Rear Telescopic
9-2
Front headlight
Position light
Front turn signal
Rear turn signal
Taillight/stoplight
Instrument light
12V
12V
12V
12V
12V
12V
35W/35W
5W
10W
16W
5W/21W
1.7W
x1
x1
x2
x2
x1
x3