2002 YAMAHA XVS125 service

6-1
EAU00462
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU00464
Safety is an obligation of the owner.
Periodic inspection, adjustment and
lubrication will keep your vehicle in
the safest and most efficient condi-
tion possible. The most important
points of inspection, adjustment, and
lubrication are explained on the fol-
lowing pages.
The intervals given in the periodic
maintenance and lubrication chart
should be simply considered as a
general guide under normal riding
conditions. However, DEPENDING
ON THE WEATHER, TERRAIN,
GEOGRAPHICAL LOCATION, AND
INDIVIDUAL USE, THE MAINTE-
NANCE INTERVALS MAY NEED TO
BE SHORTENED.
EW000060
wIf you are not familiar with motor-
cycle maintenance work, have a
Yamaha dealer do it for you.
EAU01175
Owner’s tool kit
Tool kit
The owner’s tool kit is located behind
panel B. (See page 6-6 for panel
removal and installation procedures.)
The service information included in
this manual and the tools provided in
the owner’s tool kit are intended to
assist you in the performance of pre-
ventive maintenance and minor
repairs. However, additional tools
such as a torque wrench may be nec-
essary to perform certain mainte-
nance work correctly.
NOTE:
If you do not have the tools or experi-
ence required for a particular job,
have a Yamaha dealer perform it for
you.
EW000063
wModifications not approved by
Yamaha may cause loss of perfor-
mance and render the vehicle
unsafe for use. Consult a Yamaha
dealer before attempting any
changes.
1
1. Owner’s tool kit
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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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6-14
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU00629
Adjusting the carburetor
Carburetor, adjusting
The carburetor is an important part of
the engine and requires very sophisti-
cated adjustment. Therefore, most
carburetor adjustments should be left
to a Yamaha dealer, who has the
necessary professional knowledge
and experience. The adjustment
described in the following section,
however, may be serviced by the
owner as part of routine mainte-
nance.
EC000094
cCThe carburetor has been set and
extensively tested at the Yamaha
factory. Changing these settings
without sufficient technical knowl-
edge may result in poor perfor-
mance of or damage to the engine.
EAU01168
Adjusting the engine idling
speed
Engine idling speed
The engine idling speed must be
checked and, if necessary, adjusted
as follows at the intervals specified in
the periodic maintenance and lubrica-
tion chart.NOTE:
A diagnostic tachometer is needed to
make this adjustment.1. Attach the tachometer to the
spark plug lead.
2. Start the engine and warm it up
for several minutes at 1,000–
2,000 r/min while occasionally
revving it to 4,000–5,000 r/min.NOTE:
The engine is warm when it quickly
responds to the throttle.
3. Check the engine idling speed
and, if necessary, adjust it to
specification by turning the throt-
tle stop screw. To increase the
engine idling speed, turn the
screw in direction a. To
decrease the engine idling speed,
turn the screw in direction b.NOTE:
If the specified idling speed cannot
be obtained as described above,
have a Yamaha dealer make the
adjustment.
1b
a
1. Throttle stop screw
Engine idling speed:
1,250–1,450 r/min
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6-27
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU03006
Lubricating the drive chain
Drive chain, lubricating
The drive chain must be cleaned and
lubricated at the intervals specified in
the periodic maintenance and lubrica-
tion chart, otherwise it will quickly
wear out, especially when riding in
dusty or wet areas. Service the drive
chain as follows.
EC000097
cCThe drive chain must be lubricated
after washing the motorcycle or
riding in the rain.1. Clean the drive chain with
kerosene and a small soft brush.
ECA00053
cCTo prevent damaging the O-rings,
do not clean the drive chain with
steam cleaners, high-pressure
washers or inappropriate solvents.
2. Wipe the drive chain dry.
3. Thoroughly lubricate the drive
chain with a special O-ring chain
lubricant.
ECA00052
cCDo not use engine oil or any other
lubricants for the drive chain, as
they may contain substances that
could damage the O-rings.
EAU02962
Checking and lubricating the
cables
Cables, checking and lubricating
The operation of all control cables
and the condition of the cables
should be checked before each ride,
and the cables and cable ends
should be lubricated if necessary. If
a cable is damaged or does not move
smoothly, have a Yamaha dealer
check or replace it.
Recommended lubricant:
Engine oil
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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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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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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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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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