2001 YAMAHA XVS125 brake

1
2
3
4
56
7
8
9
6-24
PERIODIC MAINTENANCE AND MINOR REPAIR
Observe these precautions:
8When checking the fluid level,
make sure that the top of the
brake fluid reservoir is level.
8Use only the recommended qual-
ity brake fluid, otherwise the rub-
ber seals may deteriorate, caus-
ing leakage and poor braking
performance.
8Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking perfor-
mance.
8Be careful that water does not
enter the brake fluid reservoir
when refilling. Water will signifi-
cantly lower the boiling point of
the fluid and may result in vapor
lock. Recommended brake fluid:
DOT 4
8Brake fluid may deteriorate paint-
ed surfaces or plastic parts.
Always clean up spilled fluid
immediately.
8As the brake pads wear, it is nor-
mal for the brake fluid level to
gradually go down. However, if
the brake fluid level goes down
suddenly, have a Yamaha dealer
check the cause.
EAU03238
Changing the brake fluidHave a Yamaha dealer change the
brake fluid at the intervals specified in
the periodic maintenance and lubrica-
tion chart. In addition, have the oil
seals of the brake master cylinder
and caliper as well as the brake hose
replaced at the intervals listed below
or whenever they are damaged or
leaking.
8Oil seals: Replace every two
years.
8Brake hose: Replace every four
years.
5JX-9-E1 9/27/00 10:45 AM Page 53

6-25
1
2
3
4
56
7
8
9
PERIODIC MAINTENANCE AND MINOR REPAIR
2.Shift the transmission into the
neutral position.
3.Move the rear wheel by pushing
the motorcycle to locate the tight-
est portion of the drive chain,
and then measure the drive
chain slack as shown.
4.If the drive chain slack is incor-
rect, adjust it as follows. Drive chain slack:
30Ð40 mm
EAU03780
To adjust the drive chain slack
1.Loosen the brake pedal free play
adjusting nut, axle nut, and lock-
nut at each end of the swingarm.1.Brake pedal free play adjusting nut
2.Locknut
21
EAU00744
Drive chain slackThe drive chain slack should be
checked before each ride and adjust-
ed if necessary.
To check the drive chain slack
1.Place the motorcycle on a level
surface and hold it in an upright
position.NOTE:
When checking and adjusting the
drive chain slack, the motorcycle
should be positioned straight up and
there should be no weight on it.
a.Drive chain slack
a
5JX-9-E1 9/27/00 10:45 AM Page 54

1
2
3
4
56
7
8
9
6-26
PERIODIC MAINTENANCE AND MINOR REPAIR
1.Axle nut
1
2.To tighten the drive chain, turn
the adjusting nut at each end of
the swingarm in direction a. To
loosen the drive chain, turn the
adjusting nut at each end of the
swingarm in direction b, and
then push the rear wheel for-
ward.NOTE:
Using the alignment marks on each
side of the swingarm, make sure that
both adjusting nuts are in the same
position for proper wheel alignment.1.Drive chain adjusting nut
2.Alignment marks
3.Locknut
3
1
2
ba
EC000096
cCImproper drive chain slack will
overload the engine as well as
other vital parts of the motorcycle
and can lead to chain slippage or
breakage. To prevent this from
occurring, keep the drive chain
slack within the specified limits.3.Tighten both locknuts, and then
tighten the axle nut to the speci-
fied torque.
4.Adjust the brake pedal free play.
(See page 6-21 for brake pedal
free play adjustment proce-
dures.)
EW000103
wAfter adjusting the brake pedal
free play, check the operation of
the brake light.
Tightening torque:
Axle nut:
104 Nm (10.4 mákg)
5JX-9-E1 9/27/00 10:45 AM Page 55

1
2
3
4
56
7
8
9
6-28
PERIODIC MAINTENANCE AND MINOR REPAIR
EW000112
wDamage to the outer sheath may
interfere with proper cable opera-
tion and will cause the inner cable
to rust. Replace a damaged cable
as soon as possible to prevent
unsafe conditions.
EAU03370
Checking and lubricating the
brake and shift pedalsThe operation of the brake and shift
pedals should be checked before
each ride, and the pedal pivots
should be lubricated if necessary.
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
EAU03164
Checking and lubricating the
brake and clutch leversThe operation of the brake and clutch
levers should be checked before
each ride, and the lever pivots should
be lubricated if necessary.
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
5JX-9-E1 9/27/00 10:45 AM Page 57

6-29
1
2
3
4
56
7
8
9
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU02939
Checking the front forkThe 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.To 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.
EAU03165
Checking and lubricating the
sidestandThe 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.
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
5JX-9-E1 9/27/00 10:45 AM Page 58

1
2
3
4
56
7
8
9
6-36
PERIODIC MAINTENANCE AND MINOR REPAIR
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
5JX-9-E1 9/27/00 10:45 AM Page 65

1
2
3
4
56
7
8
9
6-38
PERIODIC MAINTENANCE AND MINOR REPAIR
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
5JX-9-E1 9/27/00 10:45 AM Page 67

6-39
6
PERIODIC MAINTENANCE AND MINOR REPAIR
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
2
14
3
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)
5JX-9-E1 9/27/00 10:45 AM Page 68