2001 YAMAHA XVS125 Owners Manual

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PERIODIC MAINTENANCE AND MINOR REPAIR
EAU00694
Adjusting the clutch lever
free playThe clutch lever free play should
measure 5Ð10 mm as shown.
Periodically check the clutch lever
free play and, if necessary, adjust it
as follows.
1.Loosen the locknut at the clutch
lever.
2.To increase the clutch lever free
play, turn the adjusting bolt in
direction a. To decrease the
clutch lever free play, turn the
adjusting bolt in direction b.1.Locknut (Clutch lever)
2.Adjusting bolt
c.Clutch lever free play
12
b
a
c
3.If the specified clutch lever free
play could be obtained as
described above, tighten the
locknut and skip the rest of the
procedure, otherwise proceed as
follows.
4.Fully turn the adjusting bolt at the
clutch lever in direction ato
loosen the clutch cable.
5.Loosen the locknut at the
crankcase.
6.To increase the clutch lever free
play, turn the adjusting nut in
direction a. To decrease the
clutch lever free play, turn the
adjusting nut in direction b.1.Locknut (Crank case)
2.Clutch lever free play adjusting nut
2
1
a
b
7.Tighten the locknut at the clutch
lever and the crankcase.
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6-20
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU00696
Adjusting the brake lever
free playThe brake lever free play should
measure 5Ð8 mm as shown.
Periodically check the brake lever
free play and, if necessary, adjust it
as follows.
1.Loosen the locknut at the brake
lever.
2.To increase the brake lever free
play, turn the adjusting bolt in
direction a. To decrease the
brake lever free play, turn the
adjusting bolt in direction b.
3.Tighten the locknut.1.Locknut
2.Adjusting bolt
c.Brake lever free play
ba
2 1
c
EW000099
w8After adjusting the brake lever
free play, check the free play
and make sure that the brake
is working properly.
8A soft or spongy feeling in the
brake lever can indicate the
presence of air in the
hydraulic system. If there is air
in the hydraulic system, have
a Yamaha dealer bleed the
system before operating the
motorcycle. Air in the
hydraulic system will diminish
the braking performance,
which may result in loss of
control and an accident.
EAU03778
Adjusting the brake pedal
position and free play
EW000104
wIt is advisable to have a Yamaha
dealer make these adjustments.Brake pedal position
The top of the brake pedal should be
positioned approximately 76.6 mm
above the top of the footrest as
shown. Periodically check the brake
pedal position and, if necessary,
adjust it as follows.
1
a
1.Footrest
a.Brake pedal position
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6-21
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PERIODIC MAINTENANCE AND MINOR REPAIR1.Loosen the locknut at the brake
pedal.
2.To raise the brake pedal, turn the
adjusting bolt in direction a. To
lower the brake pedal, turn the
adjusting bolt in direction b.
3.Tighten the locknut.
EWA00044
wAfter adjusting the brake pedal
position, the brake pedal free play
must be adjusted.
1
a 2
b
1.Locknut
2.Brake pedal position adjusting bolt
Brake pedal free play
The brake pedal free play should
measure 20Ð30 mm at the brake
pedal end. Periodically check the
brake pedal free play and, if neces-
sary, adjust it as follows.a.Brake pedal free play
a
To increase the brake pedal free
play, turn the adjusting nut at the
brake rod in direction a. To
decrease the brake pedal free play,
turn the adjusting nut in direction b.1.Brake pedal free play adjusting nut
1
b a
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PERIODIC MAINTENANCE AND MINOR REPAIR
EAU00713
Adjusting the rear brake light
switchThe rear brake light switch, which is
activated by the brake pedal, is prop-
erly adjusted when the brake light
comes on just before braking takes
effect. If necessary, adjust the brake
light switch as follows.
Turn the adjusting nut while holding
the rear brake light switch in place.
To make the brake light come on ear-
lier, turn the adjusting nut in direction
a. To make the brake light come on
later, turn the adjusting nut in direc-
tion b.1.Rear brake light switch
2.Adjusting nut
12
b
a
EAU00720
Checking the front brake
pads and rear brake shoesThe front brake pads and the rear
brake shoes must be checked for
wear at the intervals specified in the
periodic maintenance and lubrication
chart.
EW000106
w8After adjusting the drive chain
slack or removing and
installing the rear wheel,
always check the brake pedal
free play.
8If proper adjustment cannot be
obtained as described, have a
Yamaha dealer make this
adjustment.
8After adjusting the brake pedal
free play, check the operation
of the brake light.
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PERIODIC MAINTENANCE AND MINOR REPAIR
EAU00727
Rear brake shoes
The rear brake is provided with a
wear indicator, which allows you to
check the brake shoe wear without
having to disassemble the brake. To
check the brake shoe wear, check
the position of the wear indicator
while applying the brake. If a brake
shoe has worn to the point that the
wear indicator reaches the wear limit
line, have a Yamaha dealer replace
the brake shoes as a set.1.Wear limit line
2.Wear indicator
1
2
EAU03776
Checking the brake fluid
levelInsufficient brake fluid may allow air
to enter the brake system, possibly
causing it to become ineffective.
Before riding, check that the brake
fluid is above the minimum level mark
and replenish if necessary. A low
brake fluid level may indicate worn
brake pads and/or brake system
leakage. If the brake level is low, be
sure to check the brake pads for
wear and the brake system for leak-
age.1.Mimimum level mark1
EAU00725
Front brake pads
Each front brake pad is provided with
a wear indicator groove, which allows
you to check the brake pad wear
without having to disassemble the
brake. To check the brake pad wear,
check the wear indicator groove. If a
brake pad has worn to the point that
the wear indicator groove has almost
disappeared, have a Yamaha dealer
replace the brake pads as a set.1.Wear indicator groove
1
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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.
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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
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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)
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