maintenance YAMAHA XVS125 2004 Owners Manual

TABLE OF CONTENTS
SAFETY INFORMATION ............. 1-1
DESCRIPTION ............................. 2-1
Left view ..................................... 2-1
Right view................................... 2-2
Controls and instruments ........... 2-3
INSTRUMENT AND CONTROL
FUNCTIONS ................................ 3-1
Main switch/steering lock .......... 3-1
Indicator and warning lights ...... 3-2
Speedometer unit ...................... 3-2
Anti-theft alarm (optional) .......... 3-3
Handlebar switches ................... 3-3
Clutch lever ............................... 3-4
Shift pedal ................................. 3-5
Brake lever ................................ 3-5
Brake pedal ............................... 3-5
Fuel tank cap ............................. 3-6
Fuel ........................................... 3-6
Fuel cock ................................... 3-7
Starter (choke) lever “
1
” .......... 3-8
Helmet holder ............................ 3-9
Adjusting the shock absorber
assemblies .............................. 3-9
Sidestand ................................ 3-10
Ignition circuit cut-off system ... 3-10PRE-OPERATION CHECKS ........ 4-1
Pre-operation check list ............. 4-2
OPERATION AND IMPORTANT
RIDING POINTS .......................... 5-1
Starting a cold engine ............... 5-1
Starting a warm engine ............. 5-2
Shifting ...................................... 5-2
Tips for reducing fuel
consumption ............................ 5-3
Engine break-in ......................... 5-4
Parking ...................................... 5-4
PERIODIC MAINTENANCE AND
MINOR REPAIR ........................... 6-1
Owner’s tool kit ......................... 6-1
Periodic maintenance and
lubrication chart ....................... 6-2
Removing and installing
panels ..................................... 6-5
Checking the spark plugs .......... 6-6
Engine oil and oil filter
element ................................... 6-8
Cleaning the air filter
element ................................. 6-10
Adjusting the carburetor .......... 6-11
Adjusting the engine idling
speed .................................... 6-12Adjusting the throttle cable free
play ....................................... 6-12
Adjusting the valve
clearance .............................. 6-13
Tires ........................................ 6-13
Spoke wheels .......................... 6-15
Adjusting the clutch lever free
play ....................................... 6-16
Adjusting the brake lever free
play ....................................... 6-17
Adjusting the brake pedal
position and free play ............ 6-17
Adjusting the rear brake light
switch .................................... 6-19
Checking the front brake pads
and rear brake shoes ............ 6-19
Checking the brake fluid
level ....................................... 6-20
Changing the brake fluid ......... 6-21
Drive chain slack ..................... 6-21
Lubricating the drive chain ...... 6-23
Checking and lubricating the
cables .................................... 6-23
Checking and lubricating the
throttle grip and cable ........... 6-24
Checking and lubricating the
brake and shift pedals ........... 6-24

1-1
1
SAFETY INFORMATION
EAU10250
MOTORCYCLES ARE SINGLE
TRACK VEHICLES. THEIR SAFE
USE AND OPERATION ARE DEPEN-
DENT UPON THE USE OF PROPER
RIDING TECHNIQUES AS WELL AS
THE EXPERTISE OF THE OPERA-
TOR. EVERY OPERATOR SHOULD
KNOW THE FOLLOWING REQUIRE-
MENTS BEFORE RIDING THIS MO-
TORCYCLE.
HE OR SHE SHOULD:

OBTAIN THOROUGH INSTRUC-
TIONS FROM A COMPETENT
SOURCE ON ALL ASPECTS OF
MOTORCYCLE OPERATION.

OBSERVE THE WARNINGS
AND MAINTENANCE REQUIRE-
MENTS IN THE OWNER’S MAN-
UAL.

OBTAIN QUALIFIED TRAINING
IN SAFE AND PROPER RIDING
TECHNIQUES.

OBTAIN PROFESSIONAL TECH-
NICAL SERVICE AS INDICATED
BY THE OWNER’S MANUAL
AND/OR WHEN MADE NECES-SARY BY MECHANICAL CONDI-
TIONS.
Safe riding

Always make pre-operation
checks. Careful checks may help
prevent an accident.

This motorcycle is designed to car-
ry the operator and a passenger.

The failure of motorists to detect
and recognize motorcycles in traf-
fic is the predominating cause of
automobile/motorcycle accidents.
Many accidents have been caused
by an automobile driver who did
not see the motorcycle. Making
yourself conspicuous appears to
be very effective in reducing the
chance of this type of accident.

Therefore:

Wear a brightly colored jacket.

Use extra caution when ap-
proaching and passing through
intersections, since intersec-
tions are the most likely places
for motorcycle accidents to oc-
cur.

Ride where other motorists can
see you. Avoid riding in another
motorist’s blind spot.

Many motorcycle accidents in-
volve inexperienced operators. In
fact, many operators who have
been involved in accidents do not
even have a current motorcycle li-
cense.

Make sure that you are qualified
and that you only lend your mo-
torcycle to other qualified opera-
tors.

Know your skills and limits.
Staying within your limits may
help you to avoid an accident.

We recommend that you prac-
tice riding your motorcycle
where there is no traffic until you
have become thoroughly famil-
iar with the motorcycle and all of
its controls.

Many motorcycle accidents have
been caused by error of the motor-
cycle operator. A typical error
made by the operator is veering

INSTRUMENT AND CONTROL FUNCTIONS
3-7
2
34
5
6
7
8
9 fuel may deteriorate painted surfac-

es or plastic parts.
EAU13320
CAUTION:

ECA11400
Use only unleaded gasoline. The use
of leaded gasoline will cause severe
damage to internal engine parts,
such as the valves and piston rings,
as well as to the exhaust system.
Your Yamaha engine has been de-
signed to use regular unleaded gaso-
line with a research octane number of
91 or higher. If knocking (or pinging) oc-
curs, use a gasoline of a different brand
or premium unleaded fuel. Use of un-leaded fuel will extend spark plug life
and reduce maintenance costs.
EAU13580
Fuel cock
This model is equipped with a negative
pressure fuel cock. The fuel cock sup-
plies fuel from the tank to the carburetor
while also filtering it.
The fuel cock lever positions are ex-
plained as follows and shown in the il-
lustrations.
ON
With the fuel cock lever in this position,
fuel flows to the carburetor when the
engine is running. Turn the fuel cock le-
ver to this position when starting the en-
gine and riding. Recommended fuel:
REGULAR UNLEADED
GASOLINE ONLY
Fuel tank capacity:
11.0 L (2.91 US gal)
(2.42 Imp.gal)
Fuel reserve amount:
3.4 L (0.90 US gal)
(0.75 Imp.gal)
1. Arrow mark positioned over “ON”
1

PERIODIC MAINTENANCE AND MINOR REPAIR
6-1
2
3
4
5
67
8
9

EAU17240
Safety is an obligation of the owner. Pe-
riodic inspection, adjustment and lubri-
cation will keep your vehicle in the
safest and most efficient condition pos-
sible. The most important points of in-
spection, adjustment, and lubrication
are explained on the following pages.
The intervals given in the periodic
maintenance and lubrication chart
should be simply considered as a gen-
eral guide under normal riding condi-
tions. However, DEPENDING ON THE
WEATHER, TERRAIN, GEOGRAPHI-
CAL LOCATION, AND INDIVIDUAL
USE, THE MAINTENANCE INTER-
VALS MAY NEED TO BE SHORT-
ENED.
WARNING

EWA10320
If you are not familiar with mainte-
nance work, have a Yamaha dealer
do it for you.
EAU17340
Owner’s tool kit
The owner’s tool kit is located behind
panel B. (See page 6-5.)
The service information included in this
manual and the tools provided in the
owner’s tool kit are intended to assist
you in the performance of preventive
maintenance and minor repairs. How-
ever, additional tools such as a torque
wrench may be necessary to perform
certain maintenance work correctly.
NOTE:

If you do not have the tools or experi-
ence required for a particular job, have
a Yamaha dealer perform it for you.
WARNING

EWA10350
Modifications not approved by
Yamaha may cause loss of perfor-
mance and render the vehicle un-
safe for use. Consult a Yamaha
dealer before attempting any chang-
es.
1. Owner’s tool kit
1

PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
1
2
3
4
5
6
7
8
9

EAU17710
Periodic maintenance and lubrication chart
NOTE:


The annual checks must be performed every year, except if a kilometer-based maintenance is performed in-
stead.

From 30,000 km, repeat the maintenance intervals starting from 6,000 km.

Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical
skills.
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (
×
1,000 km)
ANNUAL
CHECK
1 6 12 18 24
1*
Fuel line


Check fuel hoses and vacuum hose for cracks or dam-
age.
√

√

√

√

√

2
Spark plugs


Check condition.

Clean and regap.
√

√


Replace.
√

√

3*
Valves


Check valve clearance.

Adjust.
√

√

√

√

4
Air filter element


Clean.
√

√



Replace.
√

√

5
Clutch


Check operation.

Adjust.
√

√

√

√

√

6*
Front brake


Check operation, fluid level and vehicle for fluid leak-
age. (See NOTE following this chart.)
√

√

√

√

√

√



Replace brake pads. Whenever worn to the limit
7*
Rear brake

Check operation and adjust brake pedal free play.
√

√

√

√

√

√



Replace brake shoes. Whenever worn to the limit
8*
Brake hose

Check for cracks or damage.
√

√

√

√

√



Replace. (See NOTE following this chart.) Every 4 years

PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
2
3
4
5
67
8
9

9*
Wheels

Check runout, spoke tightness and for damage.

Tighten spokes if necessary.
√

√

√

√


10

*
Tires

Check tread depth and for damage.

Replace if necessary.

Check air pressure.

Correct if necessary.
√

√

√

√

√


11

*
Wheel bearings

Check bearing for looseness or damage.
√

√

√

√


12

*
Swingarm

Check operation and for excessive play.
√

√

√

√



Lubricate with molybdenum disulfide grease. Every 24,000 km
13

Drive chain

Check chain slack.

Make sure that the rear wheel is properly aligned.

Clean and lubricate.Every 1,000 km and after washing the motorcycle or
riding in the rain
14

*
Steering bearings

Check bearing play and steering for roughness.
√

√

√

√

√



Lubricate with lithium-soap-based grease. Every 24,000 km
15

*
Chassis fasteners

Make sure that all nuts, bolts and screws are properly
tightened.
√

√

√

√

√


16

Sidestand

Check operation.

Lubricate.
√

√

√

√

√


17

*
Sidestand switch

Check operation.
√

√

√

√

√

√


18

*
Front fork

Check operation and for oil leakage.
√

√

√

√


19

*
Shock absorber assem-
blies

Check operation and shock absorbers for oil leakage.
√

√

√

√


20

*
Carburetor

Check starter (choke) operation.

Adjust engine idling speed.
√

√

√

√

√

√


21

Engine oil

Change.

Check oil level and vehicle for oil leakage.
√

√

√

√

√

√


22

Engine oil filter element

Replace.
√

√

√


23

*
Front and rear brake
switches

Check operation.
√

√

√
√ √ √ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1,000 km)
ANNUAL
CHECK
1 6 12 18 24

PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
1
2
3
4
5
6
7
8
9

EAU18660
NOTE:


The air filter needs more frequent service if you are riding in unusually wet or dusty areas.

Hydraulic brake service

Regularly check and, if necessary, correct the brake fluid level.

Every two years replace the internal components of the brake master cylinder and caliper, and change the brake fluid.

Replace the brake hoses every four years and if cracked or damaged.
24

Moving parts and cables

Lubricate.
√

√

√

√

√


25

*
Lights, signals and
switches

Check operation.

Adjust headlight beam.
√

√

√

√

√

√

NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (
×
1,000 km)
ANNUAL
CHECK
1 6 12 18 24

PERIODIC MAINTENANCE AND MINOR REPAIR
6-5
2
3
4
5
67
8
9

EAU18770
Removing and installing
panels
The panels shown above need to be re-
moved to perform some of the mainte-
nance jobs described in this chapter.Refer to this section each time a panel
needs to be removed and installed.
EAU32471
Panel A
To remove the panel
1. Remove the bolt.
2. Pull the rear of the panel out, and
then slide the panel forward to re-
lease it in the front.To install the panel
1. Secure the front of the panel, and
then push the rear of the panel in.
2. Install the bolt.
Panel B
To remove the panel1. Slide the panel lock cover open, in-
sert the key into the lock, and then
turn it 1/4 turn clockwise.

1. Panel A
1. Panel B
11

1. Bolt
1

PERIODIC MAINTENANCE AND MINOR REPAIR
6-6
1
2
3
4
5
6
7
8
9
2. Pull the rear of the panel out with
the key inserted in the lock, and
then slide the panel forward to re-
lease it in the front.
To install the panel
1. Secure the front of the panel, andthen push the rear of the panel in
with the key inserted in the lock.
2. Turn the key counterclockwise to
the original position, remove it, and
then close the panel lock cover.

EAU19543
Checking the spark plugs
The spark plugs are important engine
components, which are easy to check.
Since heat and deposits will cause any
spark plug to slowly erode, the spark
plugs should be removed and checked
in accordance with the periodic mainte-
nance and lubrication chart. In addition,
the condition of the spark plugs can re-
veal the condition of the engine.
To remove a spark plug
1. Remove the spark plug cap.
2. Remove the spark plug as shown,
with the spark plug wrench includ-
ed in the owner’s tool kit.
1. Lock cover
2. Unlock.
1
2

1. Spark plug cap
1

PERIODIC MAINTENANCE AND MINOR REPAIR
6-7
2
3
4
5
67
8
9 To check the spark plugs
1. Check that the porcelain insulator
around the center electrode on
each spark plug is a medi-
um-to-light tan (the ideal color
when the vehicle is ridden normal-
ly).
2. Check that all spark plugs installed
in the engine have the same color.
NOTE:

If any spark plug shows a distinctly dif-
ferent color, the engine could be defec-
tive. Do not attempt to diagnose such
problems yourself. Instead, have a
Yamaha dealer check the vehicle.
3. Check each spark plug for elec-trode erosion and excessive car-
bon or other deposits, and replace
it if necessary.
To install a spark plug
1. Measure the spark plug gap with a
wire thickness gauge and, if nec-
essary, adjust the gap to specifica-
tion.
2. Clean the surface of the spark pluggasket and its mating surface, and
then wipe off any grime from the
spark plug threads.
3. Install the spark plug with the
spark plug wrench, and then tight-
en it to the specified torque.
NOTE:

If a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4–1/2 turn
past finger tight. However, the spark
plug should be tightened to the speci-
fied torque as soon as possible.
4. Install the spark plug cap.
1. Spark plug wrench
1

Specified spark plug:
NGK/CR7HSA
DENSO/U22FSR-U
1. Spark plug gap
Spark plug gap:
0.6–0.7 mm (0.024–0.028 in)
1

Tightening torque:
Spark plug:
12.5 Nm (1.25 m·kgf, 9 ft·lbf)