wheel YAMAHA XV125S 2000 Owners Manual

Carburetor adjustment ..................................6-15
Idle speed adjustment ...................................6-15
Throttle cable free play adjustment..............6-16
Valve clearance adjustment ..........................6-16
Tires.................................................................6-17
Wheels ............................................................6-19
Clutch lever free play adjustment .................6-19
Front brake lever free play adjustment ........6-20
Rear brake pedal height and free play
adjustment ......................................................6-21
Brake light switch adjustment.......................6-22
Checking the front brake pads and rear brake
shoes ...............................................................6-22
Inspecting the brake fluid level .....................6-23
Brake fluid replacement.................................6-24
Drive chain slack check ..................................6-24
Drive chain slack adjustment ........................6-25
Drive chain lubrication...................................6-26
Cable inspection and lubrication ..................6-27
Throttle cable and grip lubrication ...............6-27
Brake and shift pedal lubrication ..................6-28
Brake and clutch lever lubrication ................6-28
Sidestand lubrication .....................................6-28
Front fork inspection ......................................6-29
Steering inspection ........................................6-29
Wheel bearings ..............................................6-30Battery .............................................................6-30
Fuse replacement ...........................................6-32
Headlight bulb replacement ..........................6-33
Turn signal light bulb replacement ..............6-34
Taillight bulb replacement ............................6-35
Supporting the motorcycle ...........................6-36
Front wheel removal ......................................6-36
Front wheel installation .................................6-37
Rear wheel removal .......................................6-38
Rear wheel installation ..................................6-39
Troubleshooting .............................................6-40
Troubleshooting chart ...................................6-41
MOTORCYCLE CARE AND STORAGE ..............7-1
Care ...................................................................7-1
Storage..............................................................7-4
SPECIFICATIONS................................................8-1
How to use the conversion table ....................8-5
CONSUMER INFORMATION .............................9-1
Identification number records.........................9-1
Key identification number ...............................9-1
Vehicle identification number .........................9-1
Model label .......................................................9-2
TABLE OF CONTENTS
1
2
3
4
5
6
7
8
9
7
8
9
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 6

EAU01114
PRE-OPERATION CHECKS
1
2
3
4
5
6
7
8
9
4-1
Owners are personally responsible for their vehicle’s condition. Your motorcycle’s vital functions can start to
deteriorate quickly and unexpectedly, even if it remains unused (for instance, if it is exposed to the elements).
Any damage, fluid leak or loss of tire pressure could have serious consequences. Therefore, it is very important
that, in addition to a thorough visual inspection, you check the following points before each ride.
EAU00340PRE-OPERATION CHECK LIST
ITEM CHECKS PAGE
Front brake9Check operation, free play, fluid level and vehicle for fluid leakage.
9Fill with DOT 4 (or DOT 3) brake fluid if necessary.
Rear brake9Check operation and free play.3-4 ~ 3-5, 6-20 ~ 6-24
9Adjust if necessary.
Clutch9Check operation and free play.
3-4, 6-19 ~ 6-20
9Adjust if necessary.
Throttle grip and housing9Check for smooth operation.
6-16, 6-27
9Lubricate.
Engine oil9Check oil level.
6-9 ~ 6-12
9Fill with oil if necessary.
Drive chain9Check chain slack and condition.
6-24 ~ 6-27
9Adjust if necessary.
Wheels and tires9Check tire pressure, wear, damage and spoke tightness.
6-17 ~ 6-19
9Tighten spokes if necessary.
Control and meter cable9Check for smooth operation.
6-27
9Lubricate if necessary.
Brake and shift pedal shafts9Check for smooth operation.
6-28
9Lubricate if necessary.
Brake and clutch lever pivots9Check for smooth operation.
6-28
9Lubricate if necessary.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 24

PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
5
6
7
8
9
6-3
EAU00473PERIODIC MAINTENANCE AND LUBRICATION
Every
Every
6,000 km 12,000 km
No. ITEM CHECKS AND MAINTENANCE JOBSINITIAL or or
1,000 km 6 months 12 months
(Whichever (Whichever
comes first) comes first)
1 * Fuel line 9Check fuel hoses and vacuum hose for cracks or damage.
ÖÖ
9Replace if necessary.
2 Spark plugs9Check condition.
ÖÖÖ
9Clean, regap or replace if necessary.
3 * Valves 9Check valve clearance.
ÖÖÖ
9Adjust if necessary.
4 Air filter9Clean or replace if necessary.ÖÖ
9Check electrolyte level and specific gravity.
5 * Battery9Correct or recharge if necessary.ÖÖ
9Make sure that the breather hose is properly routed.
6 Clutch9Check operation.
ÖÖÖ
9Adjust or replace cable.
9Check operation, fluid level and vehicle for fluid leakage.
7 * Front brake (See NOTE on page 6-5.)
ÖÖÖ
9Correct accordingly.
9Replace brake pads if necessary.
8 * Rear brake 9Check operation.
ÖÖÖ
9Adjust brake pedal freeplay and replace brake shoes if necessary.
9 * Wheels 9Check balance, runout, spoke tightness and for damage.
ÖÖ
9Tighten spokes and rebalance, replace if necessary.”
9Check tread depth and for damage.
10 * Tires9Replace if necessary.
ÖÖ
9Check air pressure.
9Correct if necessary.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 34

PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
5
6
7
8
9
6-4
Every
Every
6,000 km 12,000 km
No. ITEM CHECKS AND MAINTENANCE JOBSINITIAL or or
1,000 km 6 months 12 months
(Whichever (Whichever
comes first) comes first)
11 * Wheel bearings9Check bearing for looseness or damage.
ÖÖ
9Replace if necessary.
9Check swingarm pivoting point for play.
12 * Swingarm9Correct if necessary.
ÖÖ
9Lubricate with molybdenum disulfide grease every 24,000 km or
24 months (whichever comes first).
9Check chain slack.
Every 1,000 km and after washing
13 Drive chain9
Adjust if necessary. Make sure that the rear wheel is properly aligned.the motorcycle or riding in the rain9Clean and lubricate.
9Check bearing play and steering for roughness.
14 * Steering bearings9Correct accordingly.
ÖÖ
9Lubricate with lithium soap base grease every 24,000 km or
24 months (whichever comes first).
15 * Chassis fasteners9Make sure that all nuts, bolts and screws are properly tightened.
ÖÖ
9Tighten if necessary.
16 Sidestand9Check operation.
ÖÖ
9Lubricate and repair if necessary.
17 * Sidestand switch9Check operation.
ÖÖÖ
9Replace if necessary.
18 * Front fork9Check operation and for oil leakage.
ÖÖ
9Correct accordingly.
19 *Rear shock absorber 9Check operation and shock absorbers for oil leakage.
ÖÖ
assemblies9Replace shock absorber assembly if necessary.
20 * Carburetor9Check engine idling speed and starter operation.
ÖÖÖ
9Adjust if necessary.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 35

1
2
3
4
5
6
7
8
9
6-18
PERIODIC MAINTENANCE AND MINOR REPAIR
NOTE:
These limits may be different by
regulation from country to country.
If so, conform to the limits speci-
fied by the regulations of your own
country.
Tire inspection
Always check the tires before oper-
ating the motorcycle. If center
tread depth reaches the limit as
shown, if the tire has a nail or glass
fragments in it, or if the side wall is
cracked, contact a Yamaha dealer
immediately and have the tire
replaced.
1. Side wall
a. Tread depth
1a
Manufacturer Size Type
CHENG SHIN 3.00-18 47P C-916
Manufacturer Size Type
CHENG SHIN
130/90-15M/C 66PC-915
REAR
Minimum tire tread
depth (front and rear)1.6 mm
FRONTEAU00681
w
8Operating the motorcycle with
excessively worn tires
decrease riding stability and
can lead to loss of control.
Have excessively worn tires
replaced by a Yamaha dealer
immediately. Brakes, tires, and
related wheel parts replace-
ment should be left to a
Yamaha Service Technician.
8Patching 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.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 49

6-19
1
2
3
4
5
6
7
8
9
12b
a
c
EAU00694Clutch lever free play
adjustment
The clutch lever free play should
be adjusted to 10 ~ 15 mm.
1. Loosen the locknut at the
clutch lever.
2. Turn the adjusting bolt at the
clutch lever in direction ato
increase free play or in direc-
tion bto decrease free play.
3. Tighten the locknut at the
clutch lever.
If the specified free play cannot be
obtained, proceed with the follow-
ing steps.
1. Locknut
2. Adjusting bolt
c. Free play
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU00685Wheels
To ensure maximum performance,
long service, and safe operation,
note the following:
8Always 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 deal-
er. Do not attempt even small
repairs to the wheel. If a wheel
is deformed or cracked, it must
be replaced.
8Tires 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 characteris-
tics, and shortened tire life.8Ride at moderate speeds after
changing a tire since the tire
surface must first be broken in
for it to develop its optimal
characteristics.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 50

1
2
3
4
5
6
7
8
9
6-22
PERIODIC MAINTENANCE AND MINOR REPAIR
EW000106
w
8Brake pedal free play should
be checked whenever the
chain is adjusted or the rear
wheel is removed and then
reinstalled.
8Check the operation of the
brake light after adjusting the
rear brake.
8If it is impossible to make
proper adjustment, consult a
Yamaha dealer.
EAU00713Brake light switch
adjustment
The rear brake light switch is acti-
vated by the brake pedal and is
properly adjusted when the brake
light comes on just before braking
takes effect. To adjust the rear
brake light switch, hold the switch
body so it does not rotate while
turning the adjusting nut.
Turn the adjusting nut in direction
ato make the brake light come on
earlier.
Turn the adjusting nut in direction
bto make the brake light come on
later.
1. Brake light switch
2. Adjusting nut
1
2
a
b
EAU00720Checking the front brake
pads and rear brake shoes
EAU00725
Front brake
A wear indicator groove is provid-
ed on each brake pad. This indica-
tor allows checking of brake pad
wear without disassembling the
brake. Inspect the groove. If the
groove has almost disappeared,
ask a Yamaha dealer to replace the
pads.
1. Indicator groove
1
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 53

1
2
3
4
5
6
7
8
9
6-24
PERIODIC MAINTENANCE AND MINOR REPAIR
8Brake fluid may deteriorate
painted surfaces or plastic
parts. Always clean up spilled
fluid immediately.
8Have a Yamaha dealer check
the cause if the brake fluid
level goes down.EAU00742Brake fluid replacement
The brake fluid should be replaced
only by trained Yamaha service
personnel. Have the Yamaha deal-
er replace the following compo-
nents during periodic maintenance
or when they are damaged or leak-
ing:
8oil seals (every two years)
8brake hoses (every four years)
EAU00744Drive 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’s in this tightest
position.
To check the chain slack the motor-
cycle must be held straight up with
both wheels on the ground and
without rider. Check the slack at
the position shown in the illustra-
tion. Normal slack is approximately
30 ~ 40 mm. If the slack exceeds
40 mm, adjust.
a. Chain slack
a
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 55

6-25
1
2
3
4
5
6
7
8
9To tighten the chain, turn the
chain adjusting nuts in direc-
tion a. To loosen the chain,
turn the chain adjusting nuts in
direction band push the
wheel forward. Turn each
chain adjusting nut exactly the
same amount to maintain cor-
rect axle alignment. There are
marks on each side of the
swingarm. Use these marks to
align the rear wheel.
EC000096
cC
Too little chain slack will overload
the engine and other vital parts.
Keep the slack within the specified
limits.
5. After adjusting, be sure to
tighten each chain adjusting
locknut. Then tighten the axle
nut to the specified torque.
Tightening torque:
Axle nut:
105 Nm (10.5 m·kg)
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU00750Drive chain slack adjustment
1. Loosen the rear brake pedal
free play adjusting nut.
1. Rear brake pedal free play adjusting nut
2. Remove the cotter pin from
the axle nut.
3. Loosen the axle nut.
4. Loosen the chain adjusting
locknuts on each side of the
swingarm.
1. Cotter pin
2. Alignment marks
3. Locknut
4. Chain adjusting nut
5. Axle nut
1
1
2
5
b
a
43
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 56

6-29
1
2
3
4
5
6
7
8
9
EAU00794Steering inspection
Periodically inspect the condition
of the steering. Worn out or loose
steering bearings may be danger-
ous. Place a stand under the
engine to raise the front wheel off
the ground. Hold the lower end of
the front forks and try to move
them forward and backward. If any
free play can be felt, ask a Yamaha
dealer to inspect and adjust the
steering. Inspection is easier if the
front wheel is removed.
PERIODIC MAINTENANCE AND MINOR REPAIR
Operation check
1. Place the motorcycle on a level
place.
2. Hold the motorcycle in an
upright position and apply the
front brake.
3. Push down hard on the han-
dlebars several times and
check if the fork rebounds
smoothly.
EC000098
cC
If any damage or unsmooth move-
ment is found with the front fork,
consult a Yamaha dealer.
EAU02939Front fork inspection
Visual checkEW000115
w
Securely support the motorcycle
so there is no danger of it falling
over.
Check for scratches or damage on
the inner tube and excessive oil
leakage from the front fork.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 60