2000 YAMAHA XV125S lock

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EAU00694Clutch lever free play
adjustment
The clutch lever free play should
be adjusted to 10 ~ 15 mm.
1. Loosen the locknut at the
clutch lever.
2. Turn the adjusting bolt at the
clutch lever in direction ato
increase free play or in direc-
tion bto decrease free play.
3. Tighten the locknut at the
clutch lever.
If the specified free play cannot be
obtained, proceed with the follow-
ing steps.
1. Locknut
2. Adjusting bolt
c. Free play
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU00685Wheels
To ensure maximum performance,
long service, and safe operation,
note the following:
8Always inspect the wheels
before a ride. Check for cracks,
bends or warpage of the
wheel. Be sure the spokes are
tight and undamaged. If any
abnormal condition exists in a
wheel, consult a Yamaha deal-
er. Do not attempt even small
repairs to the wheel. If a wheel
is deformed or cracked, it must
be replaced.
8Tires and wheels should be
balanced whenever either one
is changed or replaced. Failure
to have a wheel balanced can
result in poor performance,
adverse handling characteris-
tics, and shortened tire life.8Ride at moderate speeds after
changing a tire since the tire
surface must first be broken in
for it to develop its optimal
characteristics.
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PERIODIC MAINTENANCE AND MINOR REPAIR
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a
b
4. Loosen the locknut at the
clutch lever.
5. Turn the adjusting bolt at the
clutch lever in direction ato
loosen the cable.
6. Loosen the locknut at the
crankcase side.
7. Turn the adjusting nut at the
crankcase in direction ato
increase free play or in direc-
tion bto decrease free play.
8. Tighten the locknut at the
crankcase and the clutch lever.
1. Locknut
2. Adjusting nut
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2
a
bc
EAU00696Front brake lever free play
adjustment
The free play at the front brake
lever should be 2 ~ 5 mm.
1. Loosen the locknut.
2. Turn the adjusting bolt in
direction ato increase free
play or in direction bto
decrease free play.
3. After adjusting, tighten the
locknut.
1. Locknut
2. Adjusting bolt
c. Free play
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8Check the brake lever free
play. Be sure the brake is
working properly.
8A soft or spongy feeling in the
brake lever can indicate the
presence of air in the brake
system. This air must be
removed by bleeding the
brake system before the
motorcycle is operated. Air in
the system will cause greatly
diminished braking capability
and can result in loss of con-
trol and an accident. Have a
Yamaha dealer inspect and
bleed the system if necessary.
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9Free play
The rear brake pedal free play
should be adjusted to 20 ~ 30 mm
at the brake pedal end. Turn the
adjusting nut on the brake rod in
direction ato increase free play or
in direction bto decrease free
play.
1. Adjusting nut
1
a
b
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU01199Rear brake pedal height and
free play adjustment
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It is advisable to have a Yamaha
dealer make this adjustment.
Pedal height
The brake pedal should be posi-
tioned so that its top end is
approximately 60 mm above the
top of the footrest.
1. Footrest
a. Pedal height: 60 mm
b. Free play
1. Loosen the locknut.
2. Turn the adjusting bolt in
direction ato raise pedal
height or in direction bto
lower pedal height.
3. Tighten the locknut.
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After adjusting the pedal height,
adjust brake pedal free play.
1. Locknut
2. Adjusting bolt
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2
ba1
ab
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98Use only the designated quali-
ty brake fluid. Otherwise, the
rubber seals may deteriorate,
causing leakage and poor
brake performance.
NOTE:
If DOT 4 is not available, DOT 3 can
be used.
8Refill with the same type of
brake fluid. Mixing fluids may
result in a harmful chemical
reaction and lead to poor
brake performance.
8Be careful that water does not
enter the master cylinder when
refilling. Water will significant-
ly lower the boiling point of
the fluid and may result in
vapor lock. Recommended brake fluid:
DOT 4
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU00727
Rear brake
Apply the brake and inspect the
wear indicator.
If the indicator reaches the wear
limit line, ask a Yamaha dealer to
replace the shoes.
1. Wear limit line
2. Wear indicator
EAU00732Inspecting the brake fluid
level
Insufficient brake fluid may let air
enter the brake system, possibly
causing the brakes to become inef-
fective.
Before riding, check that the brake
fluid is above the minimum level
and fill when necessary.
Observe these precautions:
8When checking the fluid level,
make sure the top of the mas-
ter cylinder is level by turning
the handlebars.
1. Minimum level mark
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2
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9To tighten the chain, turn the
chain adjusting nuts in direc-
tion a. To loosen the chain,
turn the chain adjusting nuts in
direction band push the
wheel forward. Turn each
chain adjusting nut exactly the
same amount to maintain cor-
rect axle alignment. There are
marks on each side of the
swingarm. Use these marks to
align the rear wheel.
EC000096
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Too little chain slack will overload
the engine and other vital parts.
Keep the slack within the specified
limits.
5. After adjusting, be sure to
tighten each chain adjusting
locknut. Then tighten the axle
nut to the specified torque.
Tightening torque:
Axle nut:
105 Nm (10.5 m·kg)
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU00750Drive chain slack adjustment
1. Loosen the rear brake pedal
free play adjusting nut.
1. Rear brake pedal free play adjusting nut
2. Remove the cotter pin from
the axle nut.
3. Loosen the axle nut.
4. Loosen the chain adjusting
locknuts on each side of the
swingarm.
1. Cotter pin
2. Alignment marks
3. Locknut
4. Chain adjusting nut
5. Axle nut
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6-34
PERIODIC MAINTENANCE AND MINOR REPAIR
3. Turn the bulb holder counter-
clockwise to remove it and
remove the defective bulb.
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Keep flammable products and your
hands away from a bulb while it is
on, as it is hot. Do not touch a bulb
until it cools down.
4. Put a new bulb into position
and secure it in place with the
bulb holder.
1. Bulb holder
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Avoid touching the glass part of a
bulb. Keep it free from oil; other-
wise, the transparency of the
glass, life of the bulb, and lumi-
nous flux will be adversely affect-
ed. If oil gets on a bulb, thoroughly
clean it with a cloth moistened
with alcohol or lacquer thinner.
5. Install the bulb cover, connec-
tors and headlight unit.
Ask a Yamaha dealer to adjust
the headlight beam if neces-
sary.
1. Don’t touch
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EAU03010Turn signal light bulb
replacement
1. Remove the screws and the
lens.
1. Screw (´2)
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2. Remove the defective bulb by
pushing it inward and turning
it counterclockwise.
3. Install a new bulb by pushing
it inward and turning it clock-
wise.
4. Install the lense and tighten
the screws.
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Do not over-tighten the screws as
the lens may break.
1. Bulb
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2. Remove the defective bulb by
pushing it inward and turning
it counterclockwise.
3. Install a new bulb by pushing
it inward and turning it clock-
wise.
4. Install the lens and tighten the
screws.
1. Bulb
1
EAU01623Taillight bulb replacement
1. Remove the screws and the
lense.
1. Screw (´2)
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97. Adjust the rear brake pedal
height and free play. (See page
6-21.)
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Check the operation of the brake
light after adjusting the rear brake.
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU01696Rear wheel installation
1. Install the rear wheel and the
axle.
2. Install the axle nut and let the
motorcycle down.
3. Insert the brake rod into the
brake cam lever and install the
brake pedal free play adjusting
nut.
4. Install the brake torque rod
bolt and tighten to the speci-
fied tightening torque. Then
install a new cotter pin.
5. Adjust the drive chain free
play. (See page 6-25.)
6. Tighten the axle nut to the
specified tightening torque. Specified torque:
Brake torque rod bolt:
23 Nm (2.3 m·kg)
Specified torque:
Axle nut:
105 Nm (10.5 m·kg)
435
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5. Remove the rear brake pedal
free play adjusting nut and
brake rod from the brake cam
lever.
6. Loosen the locknuts and chain
adjusting nuts on each side.
7. Remove the axle nut.
8. Pull out the wheel axle and
remove the wheel assembly.
1. Cotter pin
2. Alignment marks
3. Locknut
4. Chain adjusting nut
5. Axle nut
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