2002 YAMAHA XVS125 check oil

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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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4-1
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PRE-OPERATION CHECKS
4 The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpect-
edly, even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leak-
age or loss of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thor-
ough visual inspection, to check the following points before each ride.
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Pre-operation check list
Pre-operation check list
ITEM CHECKS PAGE
Fuel•Check fuel level in fuel tank.
•Refuel if necessary.
•Check fuel line for leakage.3-6–3-7
Engine oil•Check oil level in engine.
•If necessary, add recommended oil to specified level.
•Check vehicle for oil leakage.6-9–6-12
Front brake•Check operation.
•If soft or spongy, have Yamaha dealer bleed hydraulic system.
•Check lever free play.
•Adjust if necessary.
•Check fluid level in reservoir.
•If necessary, add recommended brake fluid to specified level.
•Check hydraulic system for leakage.3-5, 6-20,
6-22–6-24
Rear brake•Check operation.
•Check pedal free play.
•Adjust if necessary.3-6, 6-20–6-23
Clutch•Check operation.
•Lubricate cable if necessary.
•Check lever free play.
•Adjust if necessary.3-5, 6-19
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5-4
OPERATION AND IMPORTANT RIDING POINTS
5
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Tips for reducing fuel
consumption
Fuel consumption, tips for reducing
Fuel consumption depends largely on
your riding style. Consider the follow-
ing tips to reduce fuel consumption:
8Thoroughly warm up the engine.
8Turn the starter (choke) off as
soon as possible.
8Shift up swiftly, and avoid high
engine speeds during accelera-
tion.
8Do not rev the engine while shift-
ing down, and avoid high engine
speeds with no load on the
engine.
8Turn the engine off instead of let-
ting it idle for an extended length
of time (e.g., in traffic jams, at
traffic lights or at railroad cross-
ings).
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Engine break-in
Engine break-in
There is never a more important peri-
od in the life of your engine than the
period between 0 and 1,000 km. For
this reason, you should read the fol-
lowing material carefully.
Since the engine is brand new, do
not put an excessive load on it for the
first 1,000 km. The various parts in
the engine wear and polish them-
selves to the correct operating clear-
ances. During this period, prolonged
full-throttle operation or any condition
that might result in engine overheat-
ing must be avoided.
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0–500 km
Avoid prolonged operation above 1/3
throttle.
500–1,000 km
Avoid prolonged operation above 1/2
throttle.
ECA00058
cCAfter 1,000 km of operation, the
engine oil must be changed, and
the oil filter element replaced.1,000 km and beyond
The vehicle can now be operated
normally.
EC000049
cCIf any engine trouble should occur
during the engine break-in period,
immediately have a Yamaha dealer
check the vehicle.
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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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6-4
PERIODIC MAINTENANCE AND MINOR REPAIR
6
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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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6-9
PERIODIC MAINTENANCE AND MINOR REPAIR
6
NOTE:
If a torque wrench is not available
when installing a spark plug, a good
estimate of the correct torque is
1/4–1/2 turn past finger tight.
However, the spark plug should be
tightened to the specified torque as
soon as possible.4. Install the spark plug cap.
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Engine oil and oil filter
element
Engine oil and oil filter element
The engine oil level should be
checked before each ride. In addition,
the oil must be changed and the oil
filter element replaced at the intervals
specified in the periodic maintenance
and lubrication chart.
To check the engine oil level
1. Place the motorcycle on a level
surface and hold it in an upright
position.NOTE:
Make sure that the motorcycle is
positioned straight up when checking
the oil level. A slight tilt to the side
can result in a false reading.2. Start the engine, warm it up for
several minutes, and then turn it
off.3. Wait a few minutes until the oil
settles, and then check the oil
level through the check window
located at the bottom-right side
of the crankcase.
NOTE:
The engine oil should be between the
minimum and maximum level marks.4. If the engine oil is below the min-
imum level mark, add sufficient
oil of the recommended type to
raise it to the correct level.
2
1
3
1. Oil level check window
2. Maximum level mark
3. Minimum level mark
Tightening torque:
Spark plug:
12.5 Nm (1.25 m0kgf)
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6-12
PERIODIC MAINTENANCE AND MINOR REPAIR
69. Start the engine, and then let it
idle for several minutes while
checking it for oil leakage. If oil is
leaking, immediately turn the
engine off and check for the
cause.
10. Turn the engine off, and then
check the oil level and correct it if
necessary.
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Cleaning the air filter
elementThe air filter element should be
cleaned at the intervals specified in
the periodic maintenance and lubrica-
tion chart. Clean the air filter element
more frequently if you are riding in
unusually wet or dusty areas.
1. Remove the air filter case by
removing the bolts and loosening
the clamp screw.2. Remove the air filter case cover
by removing the screws.
1
2
1
1
1. Bolt (×2)
2. Clamp screw1. Screw (×5)
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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.
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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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