YAMAHA XVS125 2001 Repair Manual

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To charge the battery
Have a Yamaha dealer charge the
battery as soon as possible if it
seems to have discharged. Keep in
mind that the battery tends to dis-
charge more quickly if the motorcycle
is equipped with optional electrical
accessories.
EW000116
w8Electrolyte is poisonous and
dangerous since it contains
sulfuric acid, which causes
severe burns. Avoid any con-
tact with skin, eyes or clothing
and always shield your eyes
when working near batteries.
In case of contact, administer
the following FIRST AID.
9EXTERNAL: Flush with
plenty of water.
9INTERNAL: Drink large
quantities of water or milk
and immediately call a
physician.
9EYES: Flush with water for
15 minutes and seek
prompt medical attention.
8Batteries produce explosive
hydrogen gas. Therefore, keep
sparks, flames, cigarettes,
etc., away from the battery and
provide sufficient ventilation
when charging it in an
enclosed space.
8KEEP THIS AND ALL BATTER-
IES OUT OF THE REACH OF
CHILDREN.
EAU01271
BatteryThis motorcycle is equipped with a
sealed-type (MF) battery, which does
not require any maintenance. There
is no need to check the electrolyte or
to add distilled water.1.Battery
1
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PERIODIC MAINTENANCE AND MINOR REPAIR
To store the battery
1.If the motorcycle will not be used
for more than one month,
remove the battery, fully charge
it, and then place it in a cool, dry
place.
2.If the battery will be stored for
more than two months, check it
at least once a month and fully
charge it if necessary.
3.Fully charge the battery before
installation.
EC000102
cC8Always keep the battery
charged. Storing a discharged
battery can cause permanent
battery damage.
8To charge a sealed-type (MF)
battery, a special (constant-
voltage) battery charger is
required. Using a conventional
battery charger will damage
the battery. If you do not have
access to a sealed-type (MF)
battery charger, have a
Yamaha dealer charge your
battery.
EAU01749
Replacing the fusesThe fuse boxes are located behind
panel A. (See page 6-5 for panel
removal and installation procedures.)
If a fuse is blown, replace it as fol-
lows.
1.Turn the key to ÒOFFÓ and turn
off the electrical circuit in ques-
tion.1.Fuse box (´2)
1
1
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EC000103
cCDo not use a fuse of a higher
amperage rating than recommend-
ed to avoid causing extensive
damage to the electrical system
and possibly a fire.3.Turn the key to ÒONÓ and turn on
the electrical circuit in question to
check if the device operates.
4.If the fuse immediately blows
again, have a Yamaha dealer
check the electrical system.
EAU03188
Replacing the headlight bulbThis motorcycle is equipped with a
quartz bulb headlight. If the headlight
bulb burns out, replace it as follows.
1.Remove the headlight unit by
removing the screws.1.Headlight unit
2.Screw (´2)
1
2
2.Remove the blown fuse, and
then install a new fuse of the
specified amperage.1.Main fuse
2.Spare fuse
3.Headlight fuse
4.Ignition fuse
5.Signaling system fuse
6.Carburetor heater fuse
7.Spare fuse (´2)
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1Specified fuses:
Main fuse:30 A
Ignition fuse:10 A
Signaling system fuse:10 A
Headlight fuse:15 A
Carburetor heater fuse:10 A
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2.Disconnect the headlight cou-
pler, and then remove the head-
light unit and bulb cover.1.Headlight coupler
1
1.Bulb cover
1
1
3.Unhook the headlight bulb hold-
er, and then remove the defec-
tive bulb.
EW000119
wHeadlight bulbs get very hot.
Therefore, keep flammable prod-
ucts away from a lit headlight bulb,
and do not touch the bulb until it
has cooled down.4.Place a new bulb into position,
and then secure it with the bulb
holder.1.Bulb holder
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6.Install the headlight unit by
installing the screws.
7.Have a Yamaha dealer adjust
the headlight beam if necessary.
EAU03218
Replacing a turn signal light
bulb1.Remove the turn signal lens by
removing the screws.1.Lens
2.Screw (´2)
2
1
EC000105
cCDo not touch the glass part of the
headlight bulb to keep it free from
oil, otherwise the transparency of
the glass, the luminosity of the
bulb, and the bulb life will be
adversely affected. Thoroughly
clean off any dirt and fingerprints
on the headlight bulb using a cloth
moistened with alcohol or thinner.5.Install the bulb cover, and then
connect the coupler.a.Do not touch this area.
a
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2.Remove the defective bulb by
pushing it in and turning it coun-
terclockwise.
3.Insert a new bulb into the socket,
push it in, and then turn it clock-
wise until it stops.
4.Install the lens by installing the
screws.
EC000108
cCDo not overtighten the screws,
otherwise the lens may break.1.Bulb
1
2
1
EAU01623
Replacing the tail/brake light
bulb1.Remove the tail/brake light lens
by removing the screws.1.Lens
2Screw (´2)
1
2.Remove the defective bulb by
pushing it in and turning it coun-
terclockwise.
3.Insert a new bulb into the socket,
push it in, and then turn it clock-
wise until it stops.
4.Install the lens by installing the
screws.
EC000108
cCDo not overtighten the screws,
otherwise the lens may break.1.Bulb
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To service the rear wheel
Raise the rear wheel off the ground
by using a motorcycle stand or, if a
motorcycle stand is not available, by
placing a jack either under each side
of the frame in front of the rear wheel
or under each side of the swingarm.
EAU03239
Front wheelTo remove the front wheel
EW000122
w8It is advisable to have a
Yamaha dealer service the
wheel.
8Securely support the motorcy-
cle so that there is no danger
of it falling over.1.Disconnect the speedometer
cable from the front wheel.1.Speedometer cable
1
EAU01579
Supporting the motorcycleSince this model is not equipped with
a centerstand, follow these precau-
tions when removing the front and
rear wheel or performing other main-
tenance requiring the motorcycle to
stand upright. Check that the motor-
cycle is in a stable and level position
before starting any maintenance. A
strong wooden box can be placed
under the engine for added stability.
To service the front wheel
1.Stabilize the rear of the motorcy-
cle by using a motorcycle stand
or, if an additional motorcycle
stand is not available, by placing
a jack under the frame in front of
the rear wheel.
2.Raise the front wheel off the
ground by using a motorcycle
stand.
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2.Loosen the front wheel axle
pinch bolt, then the wheel axle.
3.Lift the front wheel off the ground
according to the procedure on
page 6-37.
4.Pull the wheel axle out, and then
remove the wheel.
ECA00048
cCDo not apply the brake after the
wheel has been removed together
with the brake disc, otherwise the
brake pads will be forced shut.1.Front wheel axle pinch bolt
2.Wheel axle
1 2
EAU03832
To install the front wheel
1.Install the speedometer gear unit
into the wheel hub so that the
projections mesh with the slots.
2.Lift the wheel up between the
fork legs.1.Speedometer gear unit
1
1
NOTE:
Make sure that there is enough
space between the brake pads
before inserting the brake disc and
that the slot in the speedometer gear
unit fits over the retainer on the fork
leg.3.Insert the wheel axle from the left
side.
4.Lower the front wheel so that it is
on the ground.1.Retainer
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EAU03189
Rear wheelTo remove the rear wheel
EW000122
w8It is advisable to have a
Yamaha dealer service the
wheel.
8Securely support the motorcy-
cle so that there is no danger
of it falling over.1.Loosen the axle nut and the
brake torque rod nut at the brake
shoe plate.1.Axle nut
1
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 nut
2.Brake torque rod
3.Brake pedal free play adjusting nut
4.Brake rod
5.Brake camshaft lever
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5
5.Tighten the wheel axle to the
specified torque.
6.Tighten the front wheel axle
pinch bolt to the specified torque.
7.Push down hard on the handle-
bar several times to check for
proper fork opertion.
8.Connect the speedometer cable. Tightening torque:
Wheel axle:
59 Nm (5.9 mákg)Tightening torque:
Front wheel axle pinch bolt:
20 Nm (2.0 mákg)
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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.Locknut
2.Drive chain adjusting nut
3.Wheel axle
1
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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 6-25 for drive chain
slack adjustment procedures.) Tightening torque:
Brake torque rod bolt:
23 Nm (2.3 mákg)
6.Tighten the axle nut to the speci-
fied torque.
7.Adjust the brake pedal position
and free play. (See page 6-20 for
brake pedal position and free
play adjustment procedures.)
EW000103
wAfter adjusting the brake pedal
free play, check the operation of
the brake light.
Tightening torque:
Axle nut:
104 Nm (10.4 mákg)
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