engine YAMAHA XVS125 2004 User Guide
[x] Cancel search | Manufacturer: YAMAHA, Model Year: 2004, Model line: XVS125, Model: YAMAHA XVS125 2004Pages: 78, PDF Size: 2.29 MB
Page 23 of 78
INSTRUMENT AND CONTROL FUNCTIONS
3-10
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9
EAU15300
Sidestand
The sidestand is located on the left side
of the frame. Raise the sidestand or
lower it with your foot while holding the
vehicle upright.
NOTE:
The built-in sidestand switch is part of
the ignition circuit cut-off system, which
cuts the ignition in certain situations.
(See further down for an explanation of
the ignition circuit cut-off system.)
WARNING
EWA10240
The vehicle must not be ridden with
the sidestand down, or if the side-
stand cannot be properly moved up
(or does not stay up), otherwise the
sidestand could contact the ground
and distract the operator, resulting
in a possible loss of control. Yama-
ha’s ignition circuit cut-off system
has been designed to assist the op-
erator in fulfilling the responsibility
of raising the sidestand before start-
ing off. Therefore, check this systemregularly as described below and
have a Yamaha dealer repair it if it
does not function properly.
EAU15311
Ignition circuit cut-off system
The ignition circuit cut-off system (com-
prising the sidestand switch, clutch
switch and neutral switch) has the fol-
lowing functions.
It prevents starting when the trans-
mission is in gear and the side-
stand is up, but the clutch lever is
not pulled.
It prevents starting when the trans-
mission is in gear and the clutch le-
ver is pulled, but the sidestand is
still down.
It cuts the running engine when the
transmission is in gear and the sid-
estand is moved down.
Periodically check the operation of the
ignition circuit cut-off system according
to the following procedure.
WARNING
EWA10250
If a malfunction is noted, have a
Yamaha dealer check the system be-
fore riding.
Page 24 of 78
INSTRUMENT AND CONTROL FUNCTIONS
3-11
2
34
5
6
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8
9
With the engine turned off:
1. Move the sidestand down.
2. Make sure that the engine stop switch is turned on.
3. Turn the key on.
4. Shift the transmission into the neutral position.
5. Push the start switch.
Does the engine start?
With the engine still running:
6. Move the sidestand up.
7. Keep the clutch lever pulled.
8. Shift the transmission into gear.
9. Move the sidestand down.
Does the engine stall?
After the engine has stalled:
10. Move the sidestand up.
11. Keep the clutch lever pulled.
12. Push the start switch.
Does the engine start?
The system is OK. The motorcycle can be ridden.
This check is most reliable if performed with
a warmed-up engine.The neutral switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
The sidestand switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
The clutch switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
YES NO YES NO YES NONOTE:
Page 26 of 78
PRE-OPERATION CHECKS
4-2
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3
45
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EAU15601
Pre-operation check list
ITEM CHECKS PAGE
Fuel
Check fuel level in fuel tank.
Refuel if necessary.
Check fuel line for leakage.3-6
Engine oil
Check oil level in engine.
If necessary, add recommended oil to specified level.
Check vehicle for oil leakage.6-8
Front brake
Check operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check lever free play.
Adjust if necessary.
Check brake pads for wear.
Replace if necessary.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.6-19, 6-20
Rear brake
Check operation.
Check pedal free play.
Adjust if necessary.6-17
Clutch
Check operation.
Lubricate cable if necessary.
Check lever free play.
Adjust if necessary.6-16
Throttle grip
Make sure that operation is smooth.
Check cable free play.
If necessary, have Yamaha dealer adjust cable free play and lubricate cable
and grip housing.6-12, 6-24
Control cables
Make sure that operation is smooth.
Lubricate if necessary.6-23
Page 28 of 78
OPERATION AND IMPORTANT RIDING POINTS
5-1
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EAU15950
WARNING
EWA10270
Become thoroughly familiar
with all operating controls and
their functions before riding.
Consult a Yamaha dealer re-
garding any control or function
that you do not thoroughly un-
derstand.
Never start the engine or oper-
ate it in a closed area for any
length of time. Exhaust fumes
are poisonous, and inhaling
them can cause loss of con-
sciousness and death within a
short time. Always make sure
that there is adequate ventila-
tion.
Before starting out, make sure
that the sidestand is up. If the
sidestand is not raised com-
pletely, it could contact the
ground and distract the opera-
tor, resulting in a possible loss
of control.
EAU16060
Starting a cold engine
In order for the ignition circuit cut-off
system to enable starting, one of the
following conditions must be met:
The transmission is in the neutral
position.
The transmission is in gear with
the clutch lever pulled and the sid-
estand up.
WARNING
EWA10290
Before starting the engine,
check the function of the igni-
tion circuit cut-off system ac-
cording to the procedure
described on page 3-10.
Never ride with the sidestand
down.
1. Turn the fuel cock lever to “ON”.
2. Turn the key to “ON” and make
sure that the engine stop switch is
set to “ ”.
3. Shift the transmission into the neu-
tral position.
NOTE:
When the transmission is in the neutral
position, the neutral indicator light
should be on, otherwise have a Yama-
ha dealer check the electrical circuit.
4. Turn the starter (choke) on and
completely close the throttle. (See
page 3-8.)
5. Start the engine by pushing the
start switch.
NOTE:
If the engine fails to start, release the
start switch, wait a few seconds, and
then try again. Each starting attempt
should be as short as possible to pre-
serve the battery. Do not crank the en-
gine more than 10 seconds on any one
attempt.
6. After starting the engine, move the
starter (choke) back halfway.
CAUTION:
ECA11040
For maximum engine life, never ac-
celerate hard when the engine is
cold!
Page 29 of 78
OPERATION AND IMPORTANT RIDING POINTS
5-2
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7. When the engine is warm, turn the
starter (choke) off.
NOTE:
The engine is warm when it responds
normally to the throttle with the starter
(choke) turned off.
EAU16640
Starting a warm engine
Follow the same procedure as for start-
ing a cold engine with the exception
that the starter (choke) is not required
when the engine is warm.
EAU16671
Shifting
Shifting gears lets you control the
amount of engine power available for
starting off, accelerating, climbing hills,
etc.
The gear positions are shown in the il-
lustration.
NOTE:
To shift the transmission into the neu-
tral position, press the shift pedal down
repeatedly until it reaches the end of its
travel, and then slightly raise it.
1. Shift pedal
2. Neutral position
1
1 N2 3 4 5
2
Page 30 of 78
OPERATION AND IMPORTANT RIDING POINTS
5-3
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56
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9
CAUTION:
ECA10260
Even with the transmission in
the neutral position, do not
coast for long periods of time
with the engine off, and do not
tow the motorcycle for long dis-
tances. The transmission is
properly lubricated only when
the engine is running. Inade-
quate lubrication may damage
the transmission.
Always use the clutch while
changing gears to avoid damag-
ing the engine, transmission,
and drive train, which are not
designed to withstand the
shock of forced shifting.
EAU16730
Recommended shift points (for
Switzerland only)
The recommended shift points during
acceleration are shown in the table be-
low.
NOTE:
When shifting down two gears at a
time, reduce the speed accordingly
(e.g., down to 35 km/h when shifting
from 4th to 2nd gear).
EAU16800
Tips for reducing fuel
consumption
Fuel consumption depends largely on
your riding style. Consider the following
tips to reduce fuel consumption:
Turn the starter (choke) off as
soon as possible.
Shift up swiftly, and avoid high en-
gine speeds during acceleration.
Do not rev the engine while shifting
down, and avoid high engine
speeds with no load on the engine.
Turn the engine off instead of let-
ting it idle for an extended length of
time (e.g., in traffic jams, at traffic
lights or at railroad crossings).
Shift up points:
1st
→
2nd: 23 km/h
2nd
→
3rd: 36 km/h
3rd
→
4th: 50 km/h
4th
→
5th: 60 km/h
Page 31 of 78
OPERATION AND IMPORTANT RIDING POINTS
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EAU16830
Engine break-in
There is never a more important period
in the life of your engine than the period
between 0 and 1,000 km (600 mi). For
this reason, you should read the follow-
ing material carefully.
Since the engine is brand new, do not
put an excessive load on it for the first
1,000 km (600 mi). The various parts in
the engine wear and polish themselves
to the correct operating clearances.
During this period, prolonged full-throt-
tle operation or any condition that might
result in engine overheating must be
avoided.
EAU17010
0–500 km (0–300 mi)
Avoid prolonged operation above 1/3
throttle.
500–1,000 km (300–600 mi)
Avoid prolonged operation above 1/2
throttle.
CAUTION:
ECA11150
After 1,000 km (600 mi) of operation,
the engine oil must be changed, and
the oil filter element replaced.
1,000 km (600 mi) and beyond
The vehicle can now be operated nor-
mally.
CAUTION:
ECA10270
If any engine trouble should occur
during the engine break-in period,
immediately have a Yamaha dealer
check the vehicle.
EAU17200
Parking
When parking, stop the engine, and
then remove the key from the main
switch.
WARNING
EWA10310
Since the engine and exhaust
system can become very hot,
park in a place where pedestri-
ans or children are not likely to
touch them.
Do not park on a slope or on soft
ground, otherwise the vehicle
may overturn.
Page 34 of 78
PERIODIC MAINTENANCE AND MINOR REPAIR
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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.
√
√
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16
Sidestand
Check operation.
Lubricate.
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17
*
Sidestand switch
Check operation.
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*
Front fork
Check operation and for oil leakage.
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*
Shock absorber assem-
blies
Check operation and shock absorbers for oil leakage.
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√
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*
Carburetor
Check starter (choke) operation.
Adjust engine idling speed.
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√
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21
Engine oil
Change.
Check oil level and vehicle for oil leakage.
√
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22
Engine oil filter element
Replace.
√
√
√
23
*
Front and rear brake
switches
Check operation.
√
√
√
√ √ √ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1,000 km)
ANNUAL
CHECK
1 6 12 18 24
Page 37 of 78
PERIODIC MAINTENANCE AND MINOR REPAIR
6-6
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2. Pull the rear of the panel out with
the key inserted in the lock, and
then slide the panel forward to re-
lease it in the front.
To install the panel
1. Secure the front of the panel, andthen push the rear of the panel in
with the key inserted in the lock.
2. Turn the key counterclockwise to
the original position, remove it, and
then close the panel lock cover.
EAU19543
Checking the spark plugs
The spark plugs are important engine
components, which are easy to check.
Since heat and deposits will cause any
spark plug to slowly erode, the spark
plugs should be removed and checked
in accordance with the periodic mainte-
nance and lubrication chart. In addition,
the condition of the spark plugs can re-
veal the condition of the engine.
To remove a spark plug
1. Remove the spark plug cap.
2. Remove the spark plug as shown,
with the spark plug wrench includ-
ed in the owner’s tool kit.
1. Lock cover
2. Unlock.
1
2
1. Spark plug cap
1
Page 38 of 78
PERIODIC MAINTENANCE AND MINOR REPAIR
6-7
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67
8
9 To check the spark plugs
1. Check that the porcelain insulator
around the center electrode on
each spark plug is a medi-
um-to-light tan (the ideal color
when the vehicle is ridden normal-
ly).
2. Check that all spark plugs installed
in the engine have the same color.
NOTE:
If any spark plug shows a distinctly dif-
ferent color, the engine could be defec-
tive. Do not attempt to diagnose such
problems yourself. Instead, have a
Yamaha dealer check the vehicle.
3. Check each spark plug for elec-trode erosion and excessive car-
bon or other deposits, and replace
it if necessary.
To install a spark plug
1. Measure the spark plug gap with a
wire thickness gauge and, if nec-
essary, adjust the gap to specifica-
tion.
2. Clean the surface of the spark pluggasket and its mating surface, and
then wipe off any grime from the
spark plug threads.
3. Install the spark plug with the
spark plug wrench, and then tight-
en it to the specified torque.
NOTE:
If a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4–1/2 turn
past finger tight. However, the spark
plug should be tightened to the speci-
fied torque as soon as possible.
4. Install the spark plug cap.
1. Spark plug wrench
1
Specified spark plug:
NGK/CR7HSA
DENSO/U22FSR-U
1. Spark plug gap
Spark plug gap:
0.6–0.7 mm (0.024–0.028 in)
1
Tightening torque:
Spark plug:
12.5 Nm (1.25 m·kgf, 9 ft·lbf)