2002 YAMAHA XVS125 lock

6-20
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU00696
Adjusting the brake lever
free play
Brake lever free play, adjusting
The brake lever free play should mea-
sure 5–8 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.
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
Brake pedal position and free play, adjusting
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 77 mm
above the top of the footrest as
shown. Periodically check the brake
pedal position and, if necessary,
adjust it as follows.
ba
2 1
c
1
a
1. Locknut
2. Adjusting bolt
c. Brake lever free play1. Footrest
a. Brake pedal position
5JX-28199-E2 honbun 10/11/01 2:14 PM Page 50

6-21
PERIODIC MAINTENANCE AND MINOR REPAIR
6 1. 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.
Brake pedal free play
The brake pedal free play should
measure 20–30 mm at the brake
pedal end. Periodically check the
brake pedal free play and, if neces-
sary, adjust it as follows.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
a 2
b
a
1
b a
1. Locknut
2. Brake pedal position adjusting bolta. Brake pedal free play 1. Brake pedal free play adjusting nut
5JX-28199-E2 honbun 10/11/01 2:14 PM Page 51

6-24
PERIODIC MAINTENANCE AND MINOR REPAIR
6Observe 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.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.
EAU03985
Changing the brake fluid
Brake fluid, changing
Have a Yamaha dealer change the
brake fluid at the intervals specified in
the NOTE after the periodic mainte-
nance and lubrication chart. In addi-
tion, have the oil seals of the brake
master cylinder and caliper as well as
the brake hose replaced at the inter-
vals listed below or whenever they
are damaged or leaking.
8Oil seals: Replace every two
years.
8Brake hose: Replace every four
years. Recommended brake fluid:
DOT 4
5JX-28199-E2 honbun 10/11/01 2:14 PM Page 54

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)
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6-36
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU03218
Replacing a turn signal light
bulb1. Remove the turn signal lens by
removing the screws.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.
2
1
1
1. Lens
2. Screw (×2)1. Bulb
6. Install the headlight unit by
installing the screws.
7. Have a Yamaha dealer adjust
the headlight beam if necessary.
5JX-28199-E2 honbun 10/11/01 2:14 PM Page 66

6-37
PERIODIC MAINTENANCE AND MINOR REPAIR
6 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.
EAU01579
Supporting the motorcycle
Supporting the motorcycle
Since this model is not equipped with
a centerstand, follow these precau-
tions when removing the front and
rear wheel or performing other main-
tenance requiring the motorcycle to
stand upright. Check that the motor-
cycle is in a stable and level position
before starting any maintenance. A
strong wooden box can be placed
under the engine for added stability.
To service the front wheel
1. Stabilize the rear of the motorcy-
cle by using a motorcycle stand
or, if an additional motorcycle
stand is not available, by placing
a jack under the frame in front of
the rear wheel.
2. Raise the front wheel off the
ground by using a motorcycle
stand.
1
1. Bulb
EAU01623
Replacing the tail/brake light
bulb
Tail/brake light bulb, replacing
1. Remove the tail/brake light lens
by removing the screws.
2
1
1. Lens
2 Screw (×2)
5JX-28199-E2 honbun 10/11/01 2:14 PM Page 67

6-40
PERIODIC MAINTENANCE AND MINOR REPAIR
62. 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.5. Loosen the locknut and the drive
chain adjusting nut on both ends
of the swingarm.
6. Remove the axle nut, and then
pull the wheel axle out.
7. Push the wheel forward, and
then remove the drive chain from
the rear sprocket.
NOTE:
The drive chain does not need to be
disassembled in order to remove and
install the wheel.8. Remove the wheel.
2
14
3
5
1
32
1. Brake torque rod nut
2. Brake torque rod
3. Brake pedal free play adjusting nut
4. Brake rod
5. Brake camshaft lever1. Locknut
2. Drive chain adjusting nut
3. Wheel axle
EAU03189
Rear wheel
Wheel (rear)
To remove the rear wheel
Removing
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
1. Axle nut
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