2002 YAMAHA XVS125 brake pads

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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6-2
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU03686
Periodic maintenance and lubrication chart
Periodic maintenance and lubrication chart
NOTE:
8
The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.
8From 30,000 km, repeat the maintenance intervals starting from 6,000 km.
8Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and
technical skills.NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1,000 km)
ANNUAL
CHECK
1 6 12 18 24
1
*Fuel line•Check fuel hoses and vacuum hose for cracks or damage.√√√√ √
2 Spark plugs•Check condition.
•Clean and regap.√√
•Replace.√√
3*Valves•Check valve clearance.
•Adjust.√√√√
4 Air filter element•Clean.√√
•Replace.√√
5 Clutch•Check operation.
•Adjust.√√√√√
6*Front brake•Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)√√√√√ √
•Replace brake pads.Whenever worn to the limit
7*Rear brake•Check operation and adjust brake pedal free play.√√√√√ √
•Replace brake shoes.Whenever worn to the limit
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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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6-23
PERIODIC MAINTENANCE AND MINOR REPAIR
6
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.
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.
EAU03294
Checking the brake fluid
level
Brake fluid level, checking
Insufficient 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
1
2
1
1. Wear indicator groove 1. Wear limit line
2. Wear indicator1. Mimimum level markFront
Rear
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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
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PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU03239
Front wheel
Front wheel
To remove the front 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. Disconnect the speedometer
cable from the front wheel.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
1 2
1. Speedometer cable 1. Front wheel axle pinch bolt
2. Wheel axle
To service the rear wheel
Raise the rear wheel off the ground
by using a motorcycle stand or, if a
motorcycle stand is not available, by
placing a jack either under each side
of the frame in front of the rear wheel
or under each side of the swingarm.
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PERIODIC MAINTENANCE AND MINOR REPAIR
6
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.
4. Lower the front wheel so that it is
on the ground.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 operation.
8. Connect the speedometer cable.
1
1. Retainer
EAU04423
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
1. Speedometer gear unit
Tightening torque:
Wheel axle:
59 Nm (5.9 m0kgf)Tightening torque:
Front wheel axle pinch bolt:
20 Nm (2.0 m0kgf)
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