brake YAMAHA XVS125 2002 Owner's Manual

6-29
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU03164
Checking and lubricating the
brake and clutch levers
Brake and clutch levers, checking and lubricating
The operation of the brake and clutch
levers should be checked before
each ride, and the lever pivots should
be lubricated if necessary.
EAU03165
Checking and lubricating the
sidestand
Sidestand, checking and lubricating
The operation of the sidestand
should be checked before each ride,
and the sidestand pivot and metal-to-
metal contact surfaces should be
lubricated if necessary.
EW000113
wIf the sidestand does not move up
and down smoothly, have a
Yamaha dealer check or repair it.
EAU02939
Checking the front fork
Front fork, checking
The condition and operation of the
front fork must be checked as follows
at the intervals specified in the peri-
odic maintenance and lubrication
chart.
To check the condition
EW000115
wSecurely support the motorcycle
so that there is no danger of it
falling over.Check the inner tubes for scratches,
damage and excessive oil leakage.
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
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6-30
PERIODIC MAINTENANCE AND MINOR REPAIR
6To check the operation
1. Place the motorcycle on a level
surface and hold it in an upright
position.
2. While applying the front brake,
push down hard on the handle-
bars several times to check if the
front fork compresses and
rebounds smoothly.
EC000098
cCIf any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or
repair it.
EAU00794
Checking the steering
Steering, checking
Worn or loose steering bearings may
cause danger. Therefore, the opera-
tion of the steering must be checked
as follows at the intervals specified in
the periodic maintenance and lubrica-
tion chart.
1. Place a stand under the engine
to raise the front wheel off the
ground.
EW000115
wSecurely support the motorcycle
so that there is no danger of it
falling over.
2. Hold the lower ends of the front
fork legs and try to move them
forward and backward. If any
free play can be felt, have a
Yamaha dealer check or repair
the steering.
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6-37
PERIODIC MAINTENANCE AND MINOR REPAIR
6 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.
EAU01579
Supporting the motorcycle
Supporting the motorcycle
Since 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.
1
1. Bulb
EAU01623
Replacing the tail/brake light
bulb
Tail/brake light bulb, replacing
1. Remove the tail/brake light lens
by removing the screws.
2
1
1. Lens
2 Screw (×2)
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6-38
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU03239
Front wheel
Front wheel
To remove the front wheel
Removing
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.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
1 2
1. Speedometer cable 1. Front wheel axle pinch bolt
2. Wheel axle
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.
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6-39
PERIODIC MAINTENANCE AND MINOR REPAIR
6
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.
4. Lower the front wheel so that it is
on the ground.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 operation.
8. Connect the speedometer cable.
1
1. Retainer
EAU04423
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
1. Speedometer gear unit
Tightening torque:
Wheel axle:
59 Nm (5.9 m0kgf)Tightening torque:
Front wheel axle pinch bolt:
20 Nm (2.0 m0kgf)
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6-40
PERIODIC MAINTENANCE AND MINOR REPAIR
62. 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.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.
2
14
3
5
1
32
1. Brake torque rod nut
2. Brake torque rod
3. Brake pedal free play adjusting nut
4. Brake rod
5. Brake camshaft lever1. Locknut
2. Drive chain adjusting nut
3. Wheel axle
EAU03189
Rear wheel
Wheel (rear)
To remove the rear wheel
Removing
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
1. Axle nut
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6-41
PERIODIC MAINTENANCE AND MINOR REPAIR
6 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.
EAU01008
Troubleshooting
Troubleshooting
Although Yamaha motorcycles
receive a thorough inspection before
shipment from the factory, trouble
may occur during operation. Any
problem in the fuel, compression, or
ignition systems, for example, can
cause poor starting and loss of
power.
The following troubleshooting chart
represents a quick and easy proce-
dure for checking these vital systems
yourself. However, should your
motorcycle require any repair, take it
to a Yamaha dealer, whose skilled
technicians have the necessary tools,
experience, and know-how to service
the motorcycle properly.
Use only genuine Yamaha replace-
ment parts. Imitation parts may look
like Yamaha parts, but they are often
inferior, have a shorter service life
and can lead to expensive repair
bills. Tightening torque:
Axle nut:
104 Nm (10.4 m0kgf)
EAU03190
To install the rear wheel
Installing
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 m0kgf)
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7-2
MOTORCYCLE CARE AND STORAGE
78Do not use any harsh chemical
products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
contact with strong or abra-
sive cleaning products, sol-
vent or thinner, fuel (gasoline),
rust removers or inhibitors,
brake fluid, antifreeze or elec-
trolyte.
8Do not use high-pressure
washers or steam-jet cleaners
since they cause water seep-
age and deterioration in the
following areas: seals (of
wheel and swingarm bearings,
fork and brakes), electric com-
ponents (couplers, connec-
tors, instruments, switches
and lights), breather hoses
and vents.8For motorcycles equipped
with a windshield: Do not use
strong cleaners or hard
sponges as they will cause
dulling or scratching. Some
cleaning compounds for plas-
tic may leave scratches on the
windshield. Test the product
on a small hidden part of the
windshield to make sure that it
does not leave any marks. If
the windshield is scratched,
use a quality plastic polishing
compound after washing.
After normal useRemove dirt with warm water, a mild
detergent, and a soft, clean sponge,
and then rinse thoroughly with clean
water. Use a toothbrush or bottle-
brush for hard-to-reach areas.
Stubborn dirt and insects will come
off more easily if the area is covered
with a wet cloth for a few minutes
before cleaning.After riding in the rain, near the sea
or on salt-sprayed roadsSince sea salt or salt sprayed on
roads during winter are extremely
corrosive in combination with water,
carry out the following steps after
each ride in the rain, near the sea or
on salt-sprayed roads.NOTE:
Salt sprayed on roads in the winter
may remain well into spring.1. Clean the motorcycle with cold
water and a mild detergent, after
the engine has cooled down.
ECA00012
cCDo not use warm water since it
increases the corrosive action of
the salt.2. After drying the motorcycle,
apply a corrosion protection
spray on all metal, including
chrome- and nickel-plated, sur-
faces to prevent corrosion.
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7-3
MOTORCYCLE CARE AND STORAGE
7 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
w8Make 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
cC8Apply 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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8-3
SPECIFICATIONS
8
Maximum load* 183 kg
Air pressure (cold tire)
up to 90 kg load*
Front
175 kPa (1.75 kgf/cm
2, 1.75 bar)
Rear
200 kPa (2.00 kgf/cm
2, 2.00 bar)
90 kg load–maximum
load*
Front
175 kPa (1.75 kgf/cm
2, 1.75 bar)
Rear
200 kPa (2.00 kgf/cm
2, 2.00 bar)
*Total weight of rider, passenger, cargo and accessories
Wheels
Front
Type Spoke wheel
Size 18 ×1.60
Rear
Type Spoke wheel
Size 15 M/C ×MT 3.00
Brakes
Front
Type Single disc brake
Operation Right hand
Fluid DOT 4Rear
Type Drum brake
Operation Right foot
Suspension
Front
Type Telescopic fork
Rear
Type Swingarm
Spring/shock absorber
Front
Type Coil spring/oil damper
Rear
Type Coil spring/oil damper
Wheel travel
Front 140 mm
Rear 100 mm
Electrical system
Ignition system Transistorized coil ignition
(digital)
Charging system
Type A.C. magneto
Standard output 14 V, 23 A @ 5,000 r/min
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