brake YAMAHA XVS125 2002 Owners Manual

EAU00009
TABLE OF CONTENTS
GIVE SAFETY THE RIGHT OF WAY ................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 ......................................................3-5
Shift pedal ........................................................3-5
Brake lever .......................................................3-5
Brake pedal ......................................................3-6
Fuel tank cap ...................................................3-6
Fuel ..................................................................3-7
Fuel cock .........................................................3-8
Starter (choke) lever ........................................3-9
Helmet holder ..................................................3-9
Adjusting the shock absorber assemblies .......3-9
Sidestand .......................................................3-10
Ignition circuit cut-off system ........................3-11PRE-OPERATION CHECKS .............................4-1
Pre-operation check list ...................................4-1
OPERATION AND IMPORTANT RIDING
POINTS ..............................................................5-1
Starting the engine ...........................................5-1
Starting a warm engine ....................................5-2
Shifting .............................................................5-3
Recommended shift points
(for Switzerland only) .....................................5-3
Tips for reducing fuel consumption .................5-4
Engine break-in ................................................5-4
Parking .............................................................5-5
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 ................................6-7
Engine oil and oil filter element .......................6-9
Cleaning the air filter element .......................6-12
Adjusting the carburetor .................................6-14
Adjusting the engine idling speed ..................6-14
Adjusting the throttle cable free play ..............6-15
Adjusting the valve clearance .......................6-15
123
456
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Tires ...............................................................6-15
Spoke wheels ................................................6-18
Adjusting the clutch lever free play ................6-19
Adjusting the brake lever free play ................6-20
Adjusting the brake pedal position and free
play ..............................................................6-20
Adjusting the rear brake light switch ..............6-22
Checking the front brake pads and rear
brake shoes .................................................6-22
Checking the brake fluid level ........................6-23
Changing the brake fluid ................................6-24
Drive chain slack ............................................6-25
Lubricating the drive chain .............................6-27
Checking and lubricating the cables ..............6-27
Checking and lubricating the throttle grip
and cable .....................................................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 .......................................6-33Replacing the headlight bulb .........................6-34
Replacing a turn signal light bulb ...................6-36
Replacing the tail/brake light bulb ..................6-37
Supporting the motorcycle .............................6-37
Front wheel ....................................................6-38
Rear wheel .....................................................6-40
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
789
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2-2
DESCRIPTION
2
7. Owner’s tool kit (page 6-1)
8. Battery (page 6-31)
9. Air filter element (page 6-12)
10. Main switch/steering lock (page 3-1)11. Brake pedal (page 3-6, 6-20)
12. Engine oil filter element (page 6-9)
78 9
10
11
12
Right view
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2-3
DESCRIPTION
2
1. Clutch lever (page 3-5, 6-19)
2. Left handlebar switches (page 3-3)
3. Speedometer unit (page 3-2)
4. Right handlebar switches (page 3-4)5. Brake lever (page 3-5, 6-20)
6. Throttle grip (page 6-15, 6-28)
7. Fuel tank cap (page 3-6)
8. Starter (choke) lever (page 3-9)
123
45
6 7
8
Controls and instruments
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3-5
INSTRUMENT AND CONTROL FUNCTIONS
3
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Clutch lever
Clutch lever
The clutch lever is located at the left
handlebar grip. To disengage the
clutch, pull the lever toward the han-
dlebar grip. To engage the clutch,
release the lever. The lever should
be pulled rapidly and released slowly
for smooth clutch operation.
The clutch lever is equipped with a
clutch switch, which is part of the igni-
tion circuit cut-off system. (See page
3-11 for an explanation of the ignition
circuit cut-off system.)
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Shift pedal
Shift pedal
The shift pedal is located on the left
side of the engine and is used in
combination with the clutch lever
when shifting the gears of the
5-speed constant-mesh transmission
equipped on this motorcycle.
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Brake lever
Brake lever
The brake lever is located at the right
handlebar grip. To apply the front
brake, pull the lever toward the han-
dlebar grip.
1
1
1
1. Clutch lever 1. Shift pedal 1. Brake lever
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3-6
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Brake pedal
Brake pedal
The brake pedal is on the right side
of the motorcycle. To apply the rear
brake, press down on the brake
pedal.
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Fuel tank cap
Fuel tank cap
To remove the fuel tank cap
Insert the key into the lock and turn it
1/4 turn clockwise. The lock will be
released and the fuel tank cap can be
removed.
To install the fuel tank cap
1. Push the fuel tank cap into posi-
tion with the key inserted in the
lock.
2. Turn the key counterclockwise to
the original position, and then
remove it.
NOTE:
The fuel tank cap cannot be installed
unless the key is in the lock. In addi-
tion, the key cannot be removed if the
cap is not properly installed and
locked.
EWA00032
wMake sure that the fuel tank cap is
properly installed before riding.
INSTRUMENT AND CONTROL FUNCTIONS
3
1
a
1. Brake pedal a. Unlock.
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4-1
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PRE-OPERATION CHECKS
4 The condition of a vehicle is the owner’s 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.
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Pre-operation check list
Pre-operation check list
ITEM CHECKS PAGE
Fuel•Check fuel level in fuel tank.
•Refuel if necessary.
•Check fuel line for leakage.3-6–3-7
Engine oil•Check oil level in engine.
•If necessary, add recommended oil to specified level.
•Check vehicle for oil leakage.6-9–6-12
Front brake•Check operation.
•If soft or spongy, have Yamaha dealer bleed hydraulic system.
•Check lever free play.
•Adjust if necessary.
•Check fluid level in reservoir.
•If necessary, add recommended brake fluid to specified level.
•Check hydraulic system for leakage.3-5, 6-20,
6-22–6-24
Rear brake•Check operation.
•Check pedal free play.
•Adjust if necessary.3-6, 6-20–6-23
Clutch•Check operation.
•Lubricate cable if necessary.
•Check lever free play.
•Adjust if necessary.3-5, 6-19
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4-2
PRE-OPERATION CHECKS
4
Throttle grip•Make sure that operation is smooth.
•Check free play.
•If necessary, have Yamaha dealer make adjustment or lubricate.6-15, 6-28
Control cables•Make sure that operation is smooth.
•Lubricate if necessary.6-27–6-28
Drive chain•Check chain slack.
•Adjust if necessary.
•Check chain condition.
•Lubricate if necessary.6-25–6-27
Wheels and tires•Check for damage.
•Check tire condition and tread depth.
•Check air pressure.
•Correct if necessary.6-15–6-18
Brake and shift pedals•Make sure that operation is smooth.
•Lubricate pedal pivoting points if necessary.6-28
Brake and clutch levers•Make sure that operation is smooth.
•Lubricate lever pivoting points if necessary.6-29
Sidestand•Make sure that operation is smooth.
•Lubricate pivot if necessary.6-29
Chassis fasteners•Make sure that all nuts, bolts and screws are properly tightened.
•Tighten if necessary.—
Instruments, lights, signals
and switches•Check operation.
•Correct if necessary.3-2–3-4, 6-34–6-37
Sidestand switch•Check operation of ignition circuit cut-off system.
•If system is defective, have Yamaha dealer check vehicle.3-11–3-12 ITEM CHECKS PAGE
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6-2
PERIODIC MAINTENANCE AND MINOR REPAIR
6
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Periodic maintenance and lubrication chart
Periodic maintenance and lubrication chart
NOTE:
8
The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.
8From 30,000 km, repeat the maintenance intervals starting from 6,000 km.
8Items 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 damage.√√√√ √
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 leakage.
(See NOTE on page 6-4.)√√√√√ √
•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
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6-3
PERIODIC MAINTENANCE AND MINOR REPAIR
6
8
*Brake hose•Check for cracks or damage.√√√√ √
•Replace. (See NOTE on page 6-4.)Every 4 years
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.√√√√ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1,000 km)
ANNUAL
CHECK
1 6 12 18 24
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