2002 YAMAHA XVS125 wheel

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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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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6-3
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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6-17
PERIODIC MAINTENANCE AND MINOR REPAIR
6 Tire inspection
The tires must be checked before
each ride. If the center tread depth
reaches the specified limit, if the tire
has a nail or glass fragments in it, or
if the sidewall is cracked, have a
Yamaha dealer replace the tire imme-
diately.
NOTE:
The tire tread depth limits may differ
from country to country. Always com-
ply with the local regulations.
Tire information
This motorcycle is equipped with tube
tires.
EW000078
w8The front and rear tires should
be of the same make and
design, otherwise the handling
characteristics of the motorcy-
cle cannot be guaranteed.
8After extensive tests, only the
tires listed below have been
approved for this model by
Yamaha Motor Co., Ltd.
a
1
1. Side wall
a. Tire tread depthMinimum tire tread depth
(front and rear)1.6 mm
FRONT
Manufacturer Size Model
CHENG SHIN80/100-18 47P
C-916
80/100-18 M/C 47P
INOUE80/100-18 47P
MARBELLA NF27
80/100-18 M/C 47P
REAR
Manufacturer Size Model
CHENG SHIN 130/90-15 M/C 66P C-915
INOUE 130/90-15 M/C 66P
MARBELLA NR31
EAU00681
w8Have a Yamaha dealer replace
excessively worn tires.
Besides being illegal, operat-
ing the motorcycle with exces-
sively worn tires decreases
riding stability and can lead to
loss of control.
8The replacement of all wheel-
and brake-related parts,
including the tires, should be
left to a Yamaha dealer, who
has the necessary profession-
al knowledge and experience.
8It is not recommended to
patch a punctured tube. If
unavoidable, however, patch
the tube very carefully and
replace it as soon as possible
with a high-quality product.
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6-18
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU00685
Spoke wheels
Wheels
To maximize the performance, dura-
bility, and safe operation of your
motorcycle, note the following points
regarding the specified wheels.
8The wheel rims should be
checked for cracks, bends or
warpage, and the spokes for
looseness or damage before
each ride. If any damage is
found, have a Yamaha dealer
replace the wheel. Do not
attempt even the smallest repair
to the wheel. A deformed or
cracked wheel must be replaced.
8The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced.
An unbalanced wheel can result
in poor performance, adverse
handling characteristics, and a
shortened tire life.8Ride at moderate speeds after
changing a tire since the tire sur-
face must first be “broken in” for
it to develop its optimal charac-
teristics.
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6-22
PERIODIC MAINTENANCE AND MINOR REPAIR
6
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.
EAU00713
Adjusting the rear brake light
switch
Rear brake light switch, adjusting
The 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.
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.
12
b
a
1. Rear brake light switch
2. Adjusting nut
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6-25
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU00744
Drive chain slack
Drive chain slack
The drive chain slack should be
checked before each ride and adjust-
ed if necessary.
To check the drive chain slack
Checking
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.
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.
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.
a
21
a. Drive chain slack 1. Brake pedal free play adjusting nut
2. Locknut
Drive chain slack:
30–40 mm
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6-26
PERIODIC MAINTENANCE AND MINOR REPAIR
62. 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.
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.
1
3
1
2
ba
1. Axle nut 1. Drive chain adjusting nut
2. Alignment marks
3. Locknut
Tightening torque:
Axle nut:
104 Nm (10.4 m0kgf)
5JX-28199-E2 honbun 10/11/01 2:14 PM Page 56