2002 YAMAHA XVS125 brake light

EAU00009
TABLE OF CONTENTS
GIVE SAFETY THE RIGHT OF WAY ................1-1
DESCRIPTION ..................................................2-1
Left view ...........................................................2-1
Right view ........................................................2-2
Controls and instruments .................................2-3
INSTRUMENT AND CONTROL
FUNCTIONS ......................................................3-1
Main switch/steering lock .................................3-1
Indicator and warning lights .............................3-2
Speedometer unit ...........................................3-2
Anti-theft alarm (optional) ................................3-3
Handlebar switches .........................................3-3
Clutch lever ......................................................3-5
Shift pedal ........................................................3-5
Brake lever .......................................................3-5
Brake pedal ......................................................3-6
Fuel tank cap ...................................................3-6
Fuel ..................................................................3-7
Fuel cock .........................................................3-8
Starter (choke) lever ........................................3-9
Helmet holder ..................................................3-9
Adjusting the shock absorber assemblies .......3-9
Sidestand .......................................................3-10
Ignition circuit cut-off system ........................3-11PRE-OPERATION CHECKS .............................4-1
Pre-operation check list ...................................4-1
OPERATION AND IMPORTANT RIDING
POINTS ..............................................................5-1
Starting the engine ...........................................5-1
Starting a warm engine ....................................5-2
Shifting .............................................................5-3
Recommended shift points
(for Switzerland only) .....................................5-3
Tips for reducing fuel consumption .................5-4
Engine break-in ................................................5-4
Parking .............................................................5-5
PERIODIC MAINTENANCE AND
MINOR REPAIR .................................................6-1
Owner’s tool kit ................................................6-1
Periodic maintenance and lubrication chart .....6-2
Removing and installing panels .......................6-5
Checking the spark plugs ................................6-7
Engine oil and oil filter element .......................6-9
Cleaning the air filter element .......................6-12
Adjusting the carburetor .................................6-14
Adjusting the engine idling speed ..................6-14
Adjusting the throttle cable free play ..............6-15
Adjusting the valve clearance .......................6-15
123
456
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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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6-4
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU03541
NOTE:
8The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
8Hydraulic brake service
9Regularly check and, if necessary, correct the brake fluid level.
9Every two years replace the internal components of the brake master cylinder and caliper, and change the brake
fluid.
9Replace the brake hoses every four years and if cracked or damaged.19
*Shock absorber
assemblies•Check operation and shock absorbers for oil leakage.√√√√
20*Carburetor•Check starter (choke) operation.
•Adjust engine idling speed.√√√√√ √
21 Engine oil•Change.
•Check oil level and vehicle for oil leakage.√√√√√ √
22 Engine oil filter element•Replace.√√√
23*Front and rear brake
switches•Check operation.√√√√√ √
24 Moving parts and cables•Lubricate.√√√√ √
25*Lights, signals and
switches•Check operation.
•Adjust headlight beam.√√√√√ √ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1,000 km)
ANNUAL
CHECK
1 6 12 18 24
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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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6-26
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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6-37
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)
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6-41
PERIODIC MAINTENANCE AND MINOR REPAIR
6 6. Tighten the axle nut to the speci-
fied torque.
7. Adjust the brake pedal position
and free play. (See page 6-20 for
brake pedal position and free
play adjustment procedures.)
EW000103
wAfter adjusting the brake pedal
free play, check the operation of
the brake light.
EAU01008
Troubleshooting
Troubleshooting
Although Yamaha motorcycles
receive a thorough inspection before
shipment from the factory, trouble
may occur during operation. Any
problem in the fuel, compression, or
ignition systems, for example, can
cause poor starting and loss of
power.
The following troubleshooting chart
represents a quick and easy proce-
dure for checking these vital systems
yourself. However, should your
motorcycle require any repair, take it
to a Yamaha dealer, whose skilled
technicians have the necessary tools,
experience, and know-how to service
the motorcycle properly.
Use only genuine Yamaha replace-
ment parts. Imitation parts may look
like Yamaha parts, but they are often
inferior, have a shorter service life
and can lead to expensive repair
bills. Tightening torque:
Axle nut:
104 Nm (10.4 m0kgf)
EAU03190
To install the rear wheel
Installing
1. Insert the wheel axle from the
left-hand side, and then install
the drive chain onto the rear
sprocket.
2. Install the axle nut, and then
lower the rear wheel so that it is
on the ground.
3. Install the brake rod onto the
brake camshaft lever, and then
install the brake pedal free play
adjusting nut onto the brake rod.
4. Connect the brake torque rod to
the brake shoe plate by installing
the bolt and the nut, and then
tighten the bolt to the specified
torque.
5. Adjust the drive chain slack.
(See page 6-25 for drive chain
slack adjustment procedures.) Tightening torque:
Brake torque rod bolt:
23 Nm (2.3 m0kgf)
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