2004 YAMAHA XVS125 check engine light

TABLE OF CONTENTS
SAFETY INFORMATION ............. 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 ............................... 3-4
Shift pedal ................................. 3-5
Brake lever ................................ 3-5
Brake pedal ............................... 3-5
Fuel tank cap ............................. 3-6
Fuel ........................................... 3-6
Fuel cock ................................... 3-7
Starter (choke) lever “
1
” .......... 3-8
Helmet holder ............................ 3-9
Adjusting the shock absorber
assemblies .............................. 3-9
Sidestand ................................ 3-10
Ignition circuit cut-off system ... 3-10PRE-OPERATION CHECKS ........ 4-1
Pre-operation check list ............. 4-2
OPERATION AND IMPORTANT
RIDING POINTS .......................... 5-1
Starting a cold engine ............... 5-1
Starting a warm engine ............. 5-2
Shifting ...................................... 5-2
Tips for reducing fuel
consumption ............................ 5-3
Engine break-in ......................... 5-4
Parking ...................................... 5-4
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 .......... 6-6
Engine oil and oil filter
element ................................... 6-8
Cleaning the air filter
element ................................. 6-10
Adjusting the carburetor .......... 6-11
Adjusting the engine idling
speed .................................... 6-12Adjusting the throttle cable free
play ....................................... 6-12
Adjusting the valve
clearance .............................. 6-13
Tires ........................................ 6-13
Spoke wheels .......................... 6-15
Adjusting the clutch lever free
play ....................................... 6-16
Adjusting the brake lever free
play ....................................... 6-17
Adjusting the brake pedal
position and free play ............ 6-17
Adjusting the rear brake light
switch .................................... 6-19
Checking the front brake pads
and rear brake shoes ............ 6-19
Checking the brake fluid
level ....................................... 6-20
Changing the brake fluid ......... 6-21
Drive chain slack ..................... 6-21
Lubricating the drive chain ...... 6-23
Checking and lubricating the
cables .................................... 6-23
Checking and lubricating the
throttle grip and cable ........... 6-24
Checking and lubricating the
brake and shift pedals ........... 6-24

INSTRUMENT AND CONTROL FUNCTIONS
3-2
1
2
3
4
5
6
7
8
9

EAU11001
Indicator and warning lights
EAU11020
Turn signal indicator light “”
This indicator light flashes when the
turn signal switch is pushed to the left or
right.
EAU11060
Neutral indicator light “”
This indicator light comes on when the
transmission is in the neutral position.
EAU11080
High beam indicator light “”
This indicator light comes on when the
high beam of the headlight is switched
on.
EAU11490
Engine trouble warning light “”
This warning light comes on or flashes
when an electrical circuit monitoring the
engine is defective. When this occurs,
have a Yamaha dealer check the
self-diagnosis system.
NOTE:

This warning light comes on for a few
seconds when the key is turned to
“ON”, but this does not indicate a mal-
function.
EAU11640
Speedometer unit
The speedometer unit is equipped with
a speedometer, an odometer and a
tripmeter. The speedometer shows
riding speed. The odometer shows the
total distance traveled. The tripmeter
shows the distance traveled since it
was last set to zero with the reset knob.
The tripmeter can be used to estimate
the distance that can be traveled with a
full tank of fuel. This information will en-
able you to plan future fuel stops.
1. High beam indicator light “”
2. Turn signal indicator light “”
3. Neutral indicator light “”
4. Engine trouble warning light “”
12 34
km/h

1. Speedometer
2. Odometer
3. Tripmeter
4. Reset knob
2040600
km/h80
100
120140160
1
23
4

OPERATION AND IMPORTANT RIDING POINTS
5-1
2
3
4
56
7
8
9

EAU15950
WARNING

EWA10270

Become thoroughly familiar
with all operating controls and
their functions before riding.
Consult a Yamaha dealer re-
garding any control or function
that you do not thoroughly un-
derstand.

Never start the engine or oper-
ate it in a closed area for any
length of time. Exhaust fumes
are poisonous, and inhaling
them can cause loss of con-
sciousness and death within a
short time. Always make sure
that there is adequate ventila-
tion.

Before starting out, make sure
that the sidestand is up. If the
sidestand is not raised com-
pletely, it could contact the
ground and distract the opera-
tor, resulting in a possible loss
of control.
EAU16060
Starting a cold engine
In order for the ignition circuit cut-off
system to enable starting, one of the
following conditions must be met:

The transmission is in the neutral
position.

The transmission is in gear with
the clutch lever pulled and the sid-
estand up.
WARNING

EWA10290

Before starting the engine,
check the function of the igni-
tion circuit cut-off system ac-
cording to the procedure
described on page 3-10.

Never ride with the sidestand
down.
1. Turn the fuel cock lever to “ON”.
2. Turn the key to “ON” and make
sure that the engine stop switch is
set to “ ”.
3. Shift the transmission into the neu-
tral position.
NOTE:

When the transmission is in the neutral
position, the neutral indicator light
should be on, otherwise have a Yama-
ha dealer check the electrical circuit.
4. Turn the starter (choke) on and
completely close the throttle. (See
page 3-8.)
5. Start the engine by pushing the
start switch.
NOTE:

If the engine fails to start, release the
start switch, wait a few seconds, and
then try again. Each starting attempt
should be as short as possible to pre-
serve the battery. Do not crank the en-
gine more than 10 seconds on any one
attempt.
6. After starting the engine, move the
starter (choke) back halfway.
CAUTION:

ECA11040
For maximum engine life, never ac-
celerate hard when the engine is
cold!

PERIODIC MAINTENANCE AND MINOR REPAIR
6-7
2
3
4
5
67
8
9 To check the spark plugs
1. Check that the porcelain insulator
around the center electrode on
each spark plug is a medi-
um-to-light tan (the ideal color
when the vehicle is ridden normal-
ly).
2. Check that all spark plugs installed
in the engine have the same color.
NOTE:

If any spark plug shows a distinctly dif-
ferent color, the engine could be defec-
tive. Do not attempt to diagnose such
problems yourself. Instead, have a
Yamaha dealer check the vehicle.
3. Check each spark plug for elec-trode erosion and excessive car-
bon or other deposits, and replace
it if necessary.
To install a spark plug
1. Measure the spark plug gap with a
wire thickness gauge and, if nec-
essary, adjust the gap to specifica-
tion.
2. Clean the surface of the spark pluggasket and its mating surface, and
then wipe off any grime from the
spark plug threads.
3. Install the spark plug with the
spark plug wrench, and then tight-
en it to the specified torque.
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 speci-
fied torque as soon as possible.
4. Install the spark plug cap.
1. Spark plug wrench
1

Specified spark plug:
NGK/CR7HSA
DENSO/U22FSR-U
1. Spark plug gap
Spark plug gap:
0.6–0.7 mm (0.024–0.028 in)
1

Tightening torque:
Spark plug:
12.5 Nm (1.25 m·kgf, 9 ft·lbf)

PERIODIC MAINTENANCE AND MINOR REPAIR
6-8
1
2
3
4
5
6
7
8
9

EAU19751
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 ele-
ment replaced at the intervals specified
in the periodic maintenance and lubri-
cation chart.
To check the engine oil level
1. Place the vehicle on a level sur-
face and hold it in an upright posi-
tion.
NOTE:

Make sure that the vehicle 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 set-
tles, 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 mini-
mum level mark, add sufficient oil
of the recommended type to raise
it to the correct level.
To change the engine oil (with or
without oil filter element replace-
ment)
1. Start the engine, warm it up for
several minutes, and then turn it
off.
2. Place an oil pan under the engineto collect the used oil.
3. Remove the engine oil filler cap
and drain bolt to drain the oil from
the crankcase.
NOTE:

Skip steps 4–6 if the oil filter element is
1. Engine oil level check window
2. Maximum level mark
3. Minimum level mark
2
1
3

1. Engine oil filler cap
1. Engine oil drain bolt
11

PERIODIC MAINTENANCE AND MINOR REPAIR
6-10
1
2
3
4
5
6
7
8
9
for several minutes while checking
it for oil leakage. If oil is leaking, im-
mediately 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.

EAU32401
Cleaning the air filter element
The air filter element should be cleaned
at the intervals specified in the periodic
maintenance and lubrication chart.
Clean the air filter element more fre-
quently if you are riding in unusually
wet or dusty areas.
1. Remove the air filter case by re-
moving the bolts and loosening the
clamp screw.
2. Remove the air filter case cover by
removing the screws.3. Remove the air filter element by
removing the screws.
4. Lightly tap the air filter element to
remove most of the dust and dirt,
and then blow the remaining dirt
1. Bolt
2. Clamp screw
1
2

1. Screw
1. Air filter element
2. Screw
1
1
1
2(×2)

PERIODIC MAINTENANCE AND MINOR REPAIR
6-22
1
2
3
4
5
6
7
8
9
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)