Chain YAMAHA XVS125 2000 Owners Manual

Tires .................................................................6-16
Spoke wheels ..................................................6-19
Adjusting the clutch lever free play ..................6-19
Adjusting the brake lever free play...................6-20
Adjusting the brake pedal position and
free play .........................................................6-21
Adjusting the rear brake light switch ................6-22
Checking the front brake pads and
rear brake shoes ............................................6-23
Checking the brake fluid level ..........................6-24
Changing the brake fluid ..................................6-25
Drive chain slack ..............................................6-25
Lubricating the drive chain ...............................6-27
Checking and lubricating the cables ................6-28
Checking and lubricating the brake and
shift pedals.....................................................6-28
Checking and lubricating the brake and
clutch levers ...................................................6-29
Checking and lubricating the sidestand ...........6-29
Checking the front fork .....................................6-29
Checking the steering ......................................6-30
Checking the wheel bearings ...........................6-31
Battery..............................................................6-31
Replacing the fuses .........................................6-33
Replacing the headlight bulb ...........................6-34
Replacing a turn signal light bulb .....................6-36Replacing the tail/brake light bulb ....................6-36
Supporting the motorcycle ...............................6-37
Front wheel ......................................................6-38
Rear wheel .......................................................6-39
Troubleshooting ...............................................6-41
Troubleshooting chart ......................................6-42
MOTORCYCLE CARE AND STORAGE .............7-1
Care ...................................................................7-1
Storage ..............................................................7-4
SPECIFICATIONS ...............................................8-1
Specifications .....................................................8-1
Conversion table ................................................8-5
CONSUMER INFORMATION ..............................9-1
Identification numbers ........................................9-1
Key identification number...................................9-1
Vehicle identification number .............................9-1
Model label.........................................................9-2
TABLE OF CONTENTS
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EAU01114
PRE-OPERATION CHECKS
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4-1
The condition of a vehicle is the ownerís responsibility. Vital components can start to deteriorate quickly and unexpect-
edly, even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leak-
age or loss of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thor-
ough visual inspection, to check the following points before each ride.
EAU00340*
Pre-operation check list
ITEM CHECKS PAGE
Front brake9Check operation, free play, fluid level and vehicle for fluid leakage.
3-5, 6-20–6-21, 6-23–6-25
9Add DOT 4 brake fluid if necessary.
Rear brake9Check operation and free play.
3-6, 6-21–6-23
9Adjust if necessary.
Clutch9Check operation and free play.
3-5, 6-19–6-20
9Adjust if necessary.
Throttle grip and housing9Check smooth operation.
6-15
9Lubricate.
Engine oil9Check oil level.
6-9–6-10
9Add oil if necessary.
Drive chain9Check chain slack and condition.
6-25–6-27
9Adjust if necessary.
Wheels and tires9Check tire pressure, wear, damage and spoke tightness.
6-16–6-19
9Tighten spokes if necessary.
Control and meter cable9Check smooth operation.
6-28
9Lubricate if necessary.
Brake and shift pedal shafts9Check smooth operation.
6-28
9Lubricate if necessary.
Brake and clutch lever pivots9Check smooth operation.
6-29
9Lubricate if necessary.
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PERIODIC MAINTENANCE AND MINOR REPAIR
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6-3
13 Drive chain¥ Check chain slack.
¥ Adjust if necessary. 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.
¥ Correct accordingly.
¥ Lubricate with lithium-soap-based grease every 24.000 km or 24
months (whichever comes first)ÖÖ
15
*Chassis fasteners¥ Make sure that all nuts, bolts and screws are properly tightened.
¥ Tighten if necessary.ÖÖ
16 Sidestand¥ Check operation.
¥ Lubricate and repair if necessary.ÖÖ
17
*Sidestand switch¥ Check operation.
¥ Replace if necessary.ÖÖ Ö
18
*Front fork¥ Check operation and for oil leakage.
¥ Correct accordingly.Ö
19
*Rear shock absorber
assemblies¥ Check operation and shock absorbers for oil leakage.
¥ Replace shock absorber assembly if necessary.Ö
20
*Carburetor¥ Check engine idling speed and starter operation.
¥ Adjust if necessary.ÖÖ Ö
21 Engine oil¥ Check oil level and vehicle for oil leakage.
¥ Correct accordingly.
¥ Change. (Warm engine before draining.)ÖÖ Ö
22 Engine oil filter element¥ Replace.ÖÖ
23
*Front and rear brake
switches¥ Check operation.
¥ Correct accordingly.ÖÖ Ö
24
*Moving parts and cables¥ Lubricate if necessary.ÖÖ No. ITEM CHECKS AND MAINTENANCE JOBSInitial
1,000 kmEvery
6,000 kmEvery
12,000 kmAnnual
check
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6-22
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PERIODIC MAINTENANCE AND MINOR REPAIR
Brake pedal free play
The brake pedal free play should
measure 20–30 mm at the brake
pedal end. Periodically check the
brake pedal free play and, if neces-
sary, adjust it as follows.
To increase the brake pedal free
play, turn the adjusting nut at the
brake rod in direction a. To
decrease the brake pedal free play,
turn the adjusting nut in direction b.
1. Brake pedal free play adjusting nut
1
b a
EW000106
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8After adjusting the drive chain
slack or removing and
installing the rear wheel,
always check the brake pedal
free play.
8If proper adjustment cannot be
obtained as described, have a
Yamaha dealer make this
adjustment.
8After adjusting the brake pedal
free play, check the operation
of the brake light.
EAU00713
Adjusting the rear brake light
switch
The rear brake light switch, which is
activated by the brake pedal, is prop-
erly adjusted when the brake light
comes on just before braking takes
effect. If necessary, adjust the brake
light switch as follows.
Turn the adjusting nut while holding
the rear brake light switch in place.
To make the brake light come on ear-
lier, turn the adjusting nut in direction
a. To make the brake light come on
later, turn the adjusting nut in direc-
tion b.
1. Rear brake light switch
2. Adjusting nut
1
2
b
a
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6-25
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU03238
Changing the brake fluid
Have a Yamaha dealer change the
brake fluid at the intervals specified in
the periodic maintenance and lubrica-
tion chart. In addition, have the oil
seals of the brake master cylinder
and caliper as well as the brake hose
replaced at the intervals listed below
or whenever it is damaged or leaking.
8Oil seals: Replace every two
years.
8Brake hose: Replace every four
years.2. Shift the transmission into the
neutral position.
3. Move the rear wheel by pushing
the motorcycle to locate the tight-
est portion of the drive chain,
and then measure the drive
chain slack as shown.
4. If the drive chain slack is incor-
rect, adjust it as follows.
EAU00744
Drive chain slack
The drive chain slack should be
checked before each ride and adjust-
ed if necessary.
To check the drive chain slack
1. Place the motorcycle on a level
surface and hold it in an upright
position.
NOTE:
When checking and adjusting the
drive chain slack, the motorcycle
should be positioned straight up and
there should be no weight on it.
a. Drive chain slack
a
Drive chain slack:
30–40 mm
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6-26
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PERIODIC MAINTENANCE AND MINOR REPAIR
EAU03187
To adjust the drive chain slack
1. Loosen the brake pedal free play
adjusting nut, the axle nut, and
the chain puller locknut at each
end of the swingarm.
1. Brake pedal free play adjusting nut
2. Drive chain puller locknut
2
1
1. Axle nut
1
2. To tighten the drive chain, turn
the adjusting nut at each end of
the swingarm in direction a. To
loosen the drive chain, turn the
adjusting nut at each end of the
swingarm in direction b, and
then push the rear wheel for-
ward.
NOTE:
Using the alignment marks on each
side of the swingarm, make sure that
both adjusting nuts are in the same
position for proper wheel alignment.
1. Alignment marks
2. Drive chain adjusting nut
3. Locknut
312
b
a
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6-27
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU03006
Lubricating the drive chain
The drive chain must be cleaned and
lubricated at the intervals specified in
the periodic maintenance and lubrica-
tion chart, otherwise it will quickly
wear out, especially when riding in
dusty or wet areas. Service the drive
chain as follows.
EC000097
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The drive chain must be lubricated
after washing the motorcycle or
riding in the rain.
1. Clean the drive chain with
kerosene and a small soft brush.
ECA00053
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To prevent damaging the O-rings,
do not clean the drive chain with
steam cleaners, high-pressure
washers or inappropriate solvents.
EC000096
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Improper drive chain slack will
overload the engine as well as
other vital parts of the motorcycle
and can lead to chain slippage or
breakage. To prevent this from
occurring, keep the drive chain
slack within the specified limits.
3. Tighten both locknuts, and then
tighten the axle nut to the speci-
fied torque.
4. Adjust the brake pedal free play.
(See page 6-22 for brake pedal
free play adjustment proce-
dures.)
EW000103
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After adjusting the brake pedal
free play, check the operation of
the brake light.
Tightening torque:
Axle nut:
104 Nm (10.4 m·kg)
2. Wipe the drive chain dry.
3. Thoroughly lubricate the drive
chain with a special O-ring chain
lubricant.
ECA00052
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Do not use engine oil or any other
lubricants for the drive chain, as
they may contain substances that
could damage the O-rings.
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6-40
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PERIODIC MAINTENANCE AND MINOR REPAIR
2. Lift the rear wheel off the ground
according to the procedure on
page 6-37.
3. Disconnect the brake torque rod
from the brake shoe plate by
removing the nut and the bolt.
4. Remove the brake pedal free
play adjusting nut, and then dis-
connect the brake rod at the
brake camshaft lever.
1. Brake torque rod
2. Brake torque rod nut
3. Brake rod
4. Brake pedal free play adjusting nut
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2
34
5. Loosen the locknut and the drive
chain adjusting nut on both ends
of the swingarm.
6. Remove the axle nut, and then
pull the wheel axle out.
7. Push the wheel forward, and
then remove the drive chain from
the rear sprocket.
NOTE:
The drive chain does not need to be
disassembled in order to remove and
install the wheel.
8. Remove the wheel.
1. Wheel axle
2. Drive chain adjusting nut
3. Locknut
312
EAU03190
To install the rear wheel
1. Insert the wheel axle from the
left-hand side, and then install
the drive chain onto the rear
sprocket.
2. Install the axle nut, and then
lower the rear wheel so that it is
on the ground.
3. Install the brake rod onto the
brake camshaft lever, and then
install the brake pedal free play
adjusting nut onto the brake rod.
4. Connect the brake torque rod to
the brake shoe plate by installing
the bolt and the nut, and then
tighten the bolt to the specified
torque.
5. Adjust the drive chain slack.
(See page 6-26 for drive chain
slack adjustment procedures.) Tightening torque:
Brake torque rod bolt:
23 Nm (2.3 m·kg)
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EAU03224*
MOTORCYCLE CARE AND STORAGE
Care
While the open design of a motorcy-
cle reveals the attractiveness of the
technology, it also makes it more vul-
nerable. Rust and corrosion can
develop even if high-quality compo-
nents are used. A rusty exhaust pipe
may go unnoticed on a car, however,
it detracts from the overall appear-
ance of a motorcycle. Frequent and
proper care does not only comply
with the terms of the warranty, but it
will also keep your motorcycle looking
good, extend its life and optimize its
performance.Before cleaning
1. Cover the muffler outlets with
plastic bags after the engine has
cooled down.
2. Make sure that all caps and cov-
ers as well as all electrical cou-
plers and connectors, including
the spark plug caps, are tightly
installed.
3. Remove extremely stubborn dirt,
like oil burnt onto the crankcase,
with a degreasing agent and a
brush, but never apply such
products onto seals, gaskets,
sprockets, the drive chain and
wheel axles. Always rinse the dirt
and degreaser off with water.CleaningECA00010
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8Avoid using strong acidic
wheel cleaners, especially on
spoked wheels. If such prod-
ucts are used on hard-to-
remove dirt, do not leave the
cleaner on the affected area
any longer than instructed.
Also, thoroughly rinse the area
off with water, immediately dry
it, and then apply a corrosion
protection spray.
8Improper cleaning can damage
windshields, cowlings, panels
and other plastic parts. Use
only a soft, clean cloth or
sponge with mild detergent
and water to clean plastic.
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MOTORCYCLE CARE AND STORAGE
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After cleaning
1. Dry the motorcycle with a
chamois or an absorbing cloth.
2. Immediately dry the drive chain
and lubricate it to prevent it from
rusting.
3. Use a chrome polish to shine
chrome, aluminum and stainless-
steel parts, including the exhaust
system. (Even the thermally
induced discoloring of stainless-
steel exhaust systems can be
removed through polishing.)
4. To prevent corrosion, it is recom-
mended to apply a corrosion pro-
tection spray on all metal, includ-
ing chrome- and nickel-plated,
surfaces.
5. Use spray oil as a universal
cleaner to remove any remaining
dirt.
6. Touch up minor paint damage
caused by stones, etc.7. Wax all painted surfaces.
8. Let the motorcycle dry complete-
ly before storing or covering it.
EWA00001
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8Make sure that there is no oil
or wax on the brakes or tires.
If necessary, clean the brake
discs and brake linings with a
regular brake disc cleaner or
acetone, and wash the tires
with warm water and a mild
detergent.
8Before operating the motorcy-
cle test its braking perfor-
mance and cornering behav-
ior.
ECA00013
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8Apply spray oil and wax spar-
ingly and make sure to wipe
off any excess.
8Never apply oil or wax to any
rubber and plastic parts, but
treat them with a suitable care
product.
8Avoid using abrasive polish-
ing compounds as they will
wear away the paint.
NOTE:
Consult a Yamaha dealer for advice
on what products to use.
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