2004 YAMAHA XVS125 lock

PERIODIC MAINTENANCE AND MINOR REPAIR
6-17
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EAU22091
Adjusting the brake lever free
play
The brake lever free play should mea-
sure 5.0–8.0 mm (0.20–0.31 in) as
shown. Periodically check the brake le-
ver free play and, if necessary, adjust it
as follows.
1. Loosen the locknut at the brake le-
ver.
2. To increase the brake lever free
play, turn the adjusting bolt in di-
rection (a). To decrease the brake
lever free play, turn the adjusting
bolt in direction (b).3. Tighten the locknut.
WARNING

EWA10630

After adjusting the brake lever
free play, check the free play
and make sure that the brake is
working properly.

A soft or spongy feeling in the
brake lever can indicate the
presence of air in the hydraulic
system. If there is air in the hy-
draulic system, have a Yamaha
dealer bleed the system before
operating the motorcycle. Air in
the hydraulic system will dimin-
ish the braking performance,
which may result in loss of con-
trol and an accident.
EAU22201
Adjusting the brake pedal
position and free play
WARNING

EWA10670
It is advisable to have a Yamaha
dealer make these adjustments.
Brake pedal position
The top of the brake pedal should be
positioned approximately 76.6 mm
(3.02 in) above the top of the footrest as
shown. Periodically check the brake
pedal position and, if necessary, adjust
it as follows.
1. Loosen the locknut at the brake
1. Locknut
2. Adjusting bolt
3. Brake lever free play
2 1
3
(b)
(a)

1. Footrest
2. Brake pedal position
1
2

PERIODIC MAINTENANCE AND MINOR REPAIR
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pedal.
2. To raise the brake pedal, turn the
adjusting bolt in direction (a). To
lower the brake pedal, turn the ad-
justing bolt in direction (b).
3. Tighten the locknut.
WARNING

EWA11230
After adjusting the brake pedal posi-
tion, the brake pedal free play must
be adjusted.
Brake pedal free play
The brake pedal free play should mea-
sure 20.0–30.0 mm (0.79–1.18 in) at
the brake pedal end. Periodically checkthe 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).
WARNING

EWA10680

After adjusting the drive chain
slack or removing and installing
the rear wheel, always check the
brake pedal free play.

If proper adjustment cannot be
obtained as described, have a
Yamaha dealer make this ad-
justment.

After adjusting the brake pedal
free play, check the operation of
the brake light.
1. Locknut
2. Brake pedal position adjusting bolt
(b)1
2
(a)

1. Brake pedal free play
1

1. Brake pedal free play adjusting nut
1
(a)
(b)

PERIODIC MAINTENANCE AND MINOR REPAIR
6-20
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EAU32341
Checking the brake fluid level
Front brake
Insufficient brake fluid may allow air to
enter the brake system, possibly caus-
ing 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 fluid level is low, be sure to check
the brake pads for wear and the brake
system for leakage.
Observe these precautions:

When checking the fluid level,
make sure that the top of the mas-ter cylinder is level by turning the
handlebars.

Use only the recommended quality
brake fluid, otherwise the rubber
seals may deteriorate, causing
leakage and poor braking perfor-
mance.

Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking performance.

Be careful that water does not en-
ter the master cylinder when refill-
ing. Water will significantly lower
the boiling point of the fluid and
may result in vapor lock.

Brake fluid may deteriorate paint-
ed surfaces or plastic parts. Al-
ways clean up spilled fluid
immediately.

As the brake pads wear, it is nor-
mal for the brake fluid level to grad-
ually go down. However, if thebrake fluid level goes down sud-
denly, have a Yamaha dealer
check the cause.
1. Minimum level mark
1

Recommended brake fluid:
DOT 4

PERIODIC MAINTENANCE AND MINOR REPAIR
6-21
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EAU22720
Changing the brake fluid
Have a Yamaha dealer change the
brake fluid at the intervals specified in
the NOTE after the periodic mainte-
nance and lubrication chart. In addition,
have the oil seals of the brake master
cylinder and caliper as well as the
brake hose replaced at the intervals
listed below or whenever they are dam-
aged or leaking.

Oil seals: Replace every two
years.

Brake hose: Replace every four
years.
EAU22760
Drive chain slack
The drive chain slack should be
checked before each ride and adjusted
if necessary.
EAU22770
To check the drive chain slack
1. Place the motorcycle on a level
surface and hold it in an upright po-
sition.
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 neu-
tral 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 incorrect,
adjust it as follows.
EAU22821
To adjust the drive chain slack
1. Loosen the brake pedal free play
adjusting nut, axle nut, and locknut
at each end of the swingarm.
Drive chain slack:
30.0–40.0 mm (1.18–1.57 in)
1. Drive chain slack
1

PERIODIC MAINTENANCE AND MINOR REPAIR
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2. To tighten the drive chain, turn the
adjusting nut at each end of the
swingarm in direction (a). To loos-
en the drive chain, turn the adjust-
ing nut at each end of theswingarm in direction (b), and then
push the rear wheel forward.
NOTE:

Using the alignment marks on each
side of the swingarm, make sure that
both adjusting nuts are in the same po-
sition for proper wheel alignment.
CAUTION:

ECA10570
Improper drive chain slack will over-
load the engine as well as other vital
parts of the motorcycle and can lead
to chain slippage or breakage. To
prevent this from occurring, keepthe drive chain slack within the
specified limits.
3. Tighten both locknuts and the axle
nut to the specified torques.
4. Adjust the brake pedal free play.
(See page 6-17.)
WARNING

EWA10660
After adjusting the brake pedal free
play, check the operation of the
brake light.
1. Brake pedal free play adjusting nut
2. Locknut
1. Axle nut
21
1

1. Drive chain slack adjusting nut
2. Alignment marks
3. Locknut
3
1
2
(a) (b)

Tightening torques:
Locknut:
16 Nm (1.6 m·kgf, 11.6 ft·lbf)
Axle nut:
104 Nm (10.4 m·kgf, 75 ft·lbf)

PERIODIC MAINTENANCE AND MINOR REPAIR
6-30
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WARNING

EWA10790
Headlight bulbs get very hot. There-
fore, keep flammable products away
from a lit headlight bulb, and do not
touch the bulb until it has cooled
down.
4. Place a new headlight bulb into po-
sition, and then secure it with the
bulb holder.
CAUTION:

ECA10660
Do not touch the glass part of the
headlight bulb to keep it free from
oil, otherwise the transparency of
the glass, the luminosity of the bulb,and the bulb life will be adversely af-
fected. Thoroughly clean off any dirt
and fingerprints on the headlight
bulb using a cloth moistened with al-
cohol or thinner.
5. Install the headlight bulb cover,
and then connect the coupler.
6. Install the headlight unit by install-
ing the screws.
7. Have a Yamaha dealer adjust the
headlight beam if necessary.
EAU24131
Replacing the tail/brake light
bulb
1. Remove the tail/brake light lens by
removing the screws.
2. Remove the defective bulb by
pushing it in and turning it counter-
clockwise.
1. Headlight bulb holder
1

1. Do not touch the glass part of the bulb.
1

1. Tail/brake light lens
2. Screw
2(×2)
1

PERIODIC MAINTENANCE AND MINOR REPAIR
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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.
CAUTION:

ECA10680
Do not overtighten the screws, oth-
erwise the lens may break.
EAU24210
Replacing a turn signal light
bulb
1. Remove the turn signal lens by re-
moving the screws.
2. Remove the defective bulb by
pushing it in and turning it counter-
clockwise.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.
CAUTION:

ECA10680
Do not overtighten the screws, oth-
erwise the lens may break.
1. Tail/brake light bulb
1

1. Turn signal light lens
2. Screw
2(×2)
1

1. Turn signal light bulb
1

PERIODIC MAINTENANCE AND MINOR REPAIR
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several times to check for proper
fork operation.
8. Connect the speedometer cable.

EAU25080
Rear wheel
EAU25430
To remove the rear wheel
WARNING

EWA10820

It is advisable to have a Yamaha
dealer service the wheel.

Securely 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.
2. Lift the rear wheel off the ground
according to the procedure on
page 6-32.3. Disconnect the brake torque rod
from the brake shoe plate by re-
moving the nut and the bolt.
4. Remove the brake pedal free play
adjusting nut, and then disconnect
the brake rod at the brake cam-
shaft lever.
5. Loosen the locknut and the drive
chain adjusting nut on both ends of
the swingarm.
1. Axle nut
1

1. Brake torque rod bolt and nut
2. Brake torque rod
3. Brake pedal free play adjusting nut
4. Brake rod
5. Brake camshaft lever
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