YAMAHA SR125 2000 Workshop Manual

PERIODIC MAINTENANCE AND MINOR REPAIR
6-21
6
EAU00746
Drive chain slack checkNOTE:@ 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. @The chain slack should be checked
through the inspection window in the
chain case by the following procedure.
1. Place the motorcycle on the cen-
terstand.
2. Put the transmission in neutral.
3. While looking in the inspection
window, rotate the rear wheel.4. Chain slack is correct if the full end
of the chain link can be seen in the
usable range as shown in illustra-
tion.
5. If any portion of the top or bottom
of the chain link end is hidden, ad-
just the chain.1. Inspection window
1. USABLE RANGE
2. Too tight
3. Too loose
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-22
6
EAU01533
Drive chain slack adjustment1. Loosen the rear brake adjusting
nut.
2. Loosen the wheel axle nut.3. To tighten the chain, turn the chain
adjusting plates in direction
a.
To loosen the chain, turn the chain
adjusting plates in direction
b and
push the wheel forward. Turn each
chain adjusting plate to exactly the
same position to maintain correct
axle alignment.
EC000096
CAUTION:@ Too little chain slack will overload
the engine and other vital parts.
Keep the slack within the specified
limits. @
4. Tighten the wheel axle nut to the
specified torque.
5. Adjust the brake pedal free play.
EW000103
WARNING
@ Check the operation of the brake
light after adjusting the rear brake. @
1. Adjusting nut
1. Axle nut
2. Chain adjusting plate
Tightening torque:
Wheel axle nut:
65 Nm (6.5 m·kg)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-23
6
EAU01106*
Drive chain lubricationThe 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 es-
pecially necessary when riding in dusty
areas.
The drive chain should be lubricated
every 500 km. First, remove all dirt and
mud from the chain with a brush or
cloth. Then, spray any of the many
brands of spray-type chain lubricant
between both rows of side plates and
on all center rollers.
To clean the chain thoroughly, remove
it from the motorcycle, dip it in solvent,
and clean out as much dirt as possible.
Then, take the chain out of the solvent
to dry it, and immediately lubricate it to
prevent it from rusting.
EAU02962
Cable inspection and
lubrication
EW000112
WARNING
@ Damage to the outer housing of ca-
bles may lead to internal rusting and
interfere with the cable movement.
Replace damaged cables as soon as
possible to prevent unsafe condi-
tions. @Lubricate the cables and cable ends. If
a cable does not operate smoothly, ask
a Yamaha dealer to replace it.
EAU00773
Throttle cable and grip
lubricationThe throttle twist grip assembly should
be greased at the time that the cable is
lubricated, since the grip must be re-
moved to get at the end of the throttle
cable. After removing the screws, hold
the end of the cable up in the air and
put in several drops of lubricant. With
the throttle grip disassembled, coat the
metal surface of the grip assembly with
a suitable all-purpose grease.
Recommended lubricant:
Engine oil
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-24
6
EAU02984
Brake and shift pedal
lubricationLubricate the pivoting parts.
EAU02985
Brake and clutch lever
lubricationLubricate the pivoting parts.
EAU02965
Center and sidestand
lubricationLubricate the pivoting and mating
joints.
Check to see that the center and side-
stand move up and down smoothly. Recommended lubricant:
Engine oil
Recommended lubricant:
Engine oil
Recommended lubricant:
Engine oil
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-25
6
EW000114
WARNING
@ If the center and/or sidestand does
not move smoothly, consult a
Yamaha dealer. @
EAU02939
Front fork inspectionVisual check
EW000115
WARNING
@ 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.
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 handle-
bars several times and check if the
fork rebounds smoothly.
EC000098
CAUTION:@ If any damage or unsmooth move-
ment is found with the front fork,
consult a Yamaha dealer. @
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-26
6
EAU00794
Steering inspectionPeriodically inspect the condition of the
steering. Worn out or loose steering
bearings may be dangerous. 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 steer-
ing. Inspection is easier if the front
wheel is removed.
EW000115
WARNING
@ Securely support the motorcycle so
there is no danger of it falling over. @
EAU01144
Wheel bearingsIf there is play in the front or rear wheel
hub or if the wheel does not turn
smoothly, have a Yamaha dealer in-
spect the wheel bearings.
EAU01647
BatteryRemove panel A. (See page 6-5 for re-
moval and installation procedures.)
Check the level of the battery electro-
lyte and make sure that the terminals
are tight. Fill with distilled water if the
electrolyte level is low.1. Maximum level mark
2. Minimum level mark
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-27
6
EC000099
CAUTION:@ When inspecting the battery, be
sure the breather hose is routed cor-
rectly. If the breather hose is posi-
tioned in such a way as to cause
battery electrolyte or gas to exit
onto the frame, structural and cos-
metic damage to the motorcycle can
occur. @
EW000116
WARNING
@ Battery electrolyte is poisonous and
dangerous, causing severe burns,
etc. It contains sulfuric acid. Avoid
contact with skin, eyes or clothing.
ANTIDOTE:l
EXTERNAL: Flush with water.
l
INTERNAL: Drink large quanti-
ties of water or milk. Follow with
milk of magnesia, beaten egg,
or vegetable oil. Call a physi-
cian immediately.
l
EYES: Flush with water for
15 minutes and get prompt
medical attention.
Batteries produce explosive gases.
Keep sparks, flame, cigarettes etc.,
away. Ventilate when charging or
using in an enclosed space. Always
shield your eyes when working near
batteries.
KEEP OUT OF REACH OF CHIL-
DREN.
@
Replenishing the battery fluid
A poorly maintained battery will cor-
rode and discharge quickly. The bat-
tery fluid should be checked at least
once a month. The level should be be-
tween the minimum level and maxi-
mum level marks. Use only distilled
water if refilling is necessary.
EC000100
CAUTION:@ Normal tap water contains minerals
which are harmful to a battery;
therefore, refill only with distilled
water. @
EW000117
WARNING
@ 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. @
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-28
6Battery storage
l
When the motorcycle will not be
used for a month or longer, re-
move the battery, fully charge it
and store it in a cool, dry place.
Completely recharge the battery
before reinstallation.
l
If the battery will be stored for
longer than two months, check the
specific gravity of the fluid at least
once a month and fully recharge
the battery when it is too low.
l
Always make sure the connec-
tions are correct when putting the
battery back in the motorcycle.
Make sure the breather hose is
properly connected and is not
damaged or obstructed.
EAU01307
Fuse replacementThe fuse is located behind panel B.
(See page 6-5 for panel removal and
installation procedures.) If the fuse is
blown, turn off the main switch and the
switch of the circuit in question. Install a
new fuse of proper amperage. Turn on
the switches and see if the electrical
device operates. If the fuse immediate-
ly blows again, consult a Yamaha deal-
er.
EC000103
CAUTION:@ Do not use fuses of higher amper-
age rating than those recommend-
ed. Substitution of a fuse of
improper rating can cause extensive
electrical system damage and pos-
sibly a fire. @
1. Fuse box
Specified fuse: 20 A
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-29
6
EAU03003
Headlight bulb replacementThis motorcycle is equipped with a
quartz bulb headlight.
If the headlight bulb burns out, replace
the bulb as follows:
1. Remove the headlight unit screws.
2. Remove the connector, the head-
light unit and then the bulb holder
cover.3. Turn the bulb holder counterclock-
wise to remove it and remove the
defective bulb.
EWA00023
WARNING
@ Keep flammable products and your
hands away from the bulb while it is
on, as it is hot. Do not touch the bulb
until it cools down. @4. Put a new bulb into position and
secure it in place with the bulb
holder.
ECA00040
CAUTION:@ Avoid touching the glass part of the
bulb. Keep it free from oil; other-
wise, the transparency of the glass,
life of the bulb, and luminous flux
will be adversely affected. If oil gets
on the bulb, thoroughly clean it with
a cloth moistened with alcohol or
lacquer thinner. @5. Install the bulb holder cover, con-
nector and headlight unit.
Ask a Yamaha dealer to adjust the
headlight beam if that adjustment
is necessary.
1. Screw (´ 2)
2. Bulb holder cover
1. Bulb holder
1. Don’t touch
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-30
6
EAU00855*
Turn signal and tail/brake light
bulb replacement1. Remove the screws and the lens.
2. Push the bulb inward and turn it
counterclockwise.3. Place a new bulb in the socket.
Push the bulb inward and turn it
clockwise until it engages into the
socket.
4. Install the lens and the screws.
EC000108
CAUTION:@ Do not over-tighten the screws as
the lens may break. @
EAU00866
Front wheel removal
EW000122
WARNING
@ l
It is advisable to have a Yamaha
dealer service the wheel.
l
Securely support the motor-
cycle so there is no danger of it
falling over.
@1. Place the motorcycle on the cen-
terstand.
2. Remove the speedometer cable
from the front wheel side.
1. Screw (´ 2)
1. Screw
1. Speedometer cable
E_3mw.book Page 30 Monday, February 5, 2001 9:54 AM