2004 YAMAHA XVS125 clutch
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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
Page 6 of 78
TABLE OF CONTENTS
Checking and lubricating the
brake and clutch levers ......... 6-24
Checking and lubricating the
sidestand ............................... 6-25
Checking the front fork ............ 6-25
Checking the steering ............. 6-26
Checking the wheel
bearings ................................ 6-26
Battery ..................................... 6-27
Replacing the fuses ................. 6-28
Replacing the headlight bulb ... 6-29
Replacing the tail/brake light
bulb ....................................... 6-30
Replacing a turn signal light
bulb ....................................... 6-31
Supporting the motorcycle ...... 6-32
Front wheel ............................. 6-32
Rear wheel .............................. 6-34
Troubleshooting ...................... 6-36
Troubleshooting chart ............. 6-37
MOTORCYCLE CARE AND
STORAGE..................................... 7-1
Care .......................................... 7-1
Storage ...................................... 7-3
SPECIFICATIONS ....................... 8-1CONSUMER INFORMATION ...... 9-1
Identification numbers ............... 9-1
Page 13 of 78
DESCRIPTION
2-3
1
2
3
4
5
6
7
8
9
EAU10430
Controls and instruments
123
45
6 7
8
1. Clutch lever (page 3-4)
2. Left handlebar switches (page 3-3)
3. Speedometer unit (page 3-2)
4. Right handlebar switches (page 3-3)
5. Brake lever (page 3-5)
6. Throttle grip (page 6-12)
7. Fuel tank cap (page 3-6)
8. Starter (choke) lever (page 3-8)
Page 17 of 78
INSTRUMENT AND CONTROL FUNCTIONS
3-4
1
2
3
4
5
6
7
8
9Right
EAU12350
Pass switch “”
Press this switch to flash the headlight.
EAU12400
Dimmer switch “/”
Set this switch to “” for the high
beam and to “” for the low beam.
EAU12460
Turn signal switch “/”
To signal a right-hand turn, push this
switch to “”. To signal a left-hand
turn, push this switch to “”. When re-
leased, the switch returns to the center
position. To cancel the turn signallights, push the switch in after it has re-
turned to the center position.
EAU12500
Horn switch “”
Press this switch to sound the horn.
EAU12590
Light switch “//”
Set this switch to “” to turn on the
auxiliary light, meter lighting and tail-
light. Set the switch to “” to turn on
the headlight also. Set the switch to “”
to turn off all the lights.
EAU12660
Engine stop switch “/”
Set this switch to “” before starting
the engine. Set this switch to “” to
stop the engine in case of an emergen-
cy, such as when the vehicle overturns
or when the throttle cable is stuck.
EAU12710
Start switch “”
Push this switch to crank the engine
with the starter.
CAUTION:
ECA10050
See page 5-1 for starting instruc-
tions prior to starting the engine.
EAU12820
Clutch lever
The clutch lever is located at the left
handlebar grip. To disengage the
clutch, pull the lever toward the handle-
bar grip. To engage the clutch, release
the lever. The lever should be pulled
rapidly and released slowly for smooth
clutch operation.
The clutch lever is equipped with a
clutch switch, which is part of the igni-
tion circuit cut-off system. (See
page 3-10.)
1. Engine stop switch “/”
2. Light switch “//”
3. Start switch “”
1
2
3
1. Clutch lever
1
Page 18 of 78
INSTRUMENT AND CONTROL FUNCTIONS
3-5
2
34
5
6
7
8
9
EAU12870
Shift pedal
The shift pedal is located on the left
side of the engine and is used in com-
bination with the clutch lever when
shifting the gears of the 5-speed con-
stant-mesh transmission equipped on
this motorcycle.
EAU12890
Brake lever
The brake lever is located at the right
handlebar grip. To apply the front
brake, pull the lever toward the handle-
bar grip.
EAU12941
Brake pedal
The brake pedal is on the right side of
the motorcycle. To apply the rear
brake, press down on the brake pedal.
1. Shift pedal
1
1. Brake lever
1
1. Brake pedal
1
Page 23 of 78
INSTRUMENT AND CONTROL FUNCTIONS
3-10
1
2
3
4
5
6
7
8
9
EAU15300
Sidestand
The sidestand is located on the left side
of the frame. Raise the sidestand or
lower it with your foot while holding the
vehicle upright.
NOTE:
The built-in sidestand switch is part of
the ignition circuit cut-off system, which
cuts the ignition in certain situations.
(See further down for an explanation of
the ignition circuit cut-off system.)
WARNING
EWA10240
The vehicle must not be ridden with
the sidestand down, or if the side-
stand cannot be properly moved up
(or does not stay up), otherwise the
sidestand could contact the ground
and distract the operator, resulting
in a possible loss of control. Yama-
ha’s ignition circuit cut-off system
has been designed to assist the op-
erator in fulfilling the responsibility
of raising the sidestand before start-
ing off. Therefore, check this systemregularly as described below and
have a Yamaha dealer repair it if it
does not function properly.
EAU15311
Ignition circuit cut-off system
The ignition circuit cut-off system (com-
prising the sidestand switch, clutch
switch and neutral switch) has the fol-
lowing functions.
It prevents starting when the trans-
mission is in gear and the side-
stand is up, but the clutch lever is
not pulled.
It prevents starting when the trans-
mission is in gear and the clutch le-
ver is pulled, but the sidestand is
still down.
It cuts the running engine when the
transmission is in gear and the sid-
estand is moved down.
Periodically check the operation of the
ignition circuit cut-off system according
to the following procedure.
WARNING
EWA10250
If a malfunction is noted, have a
Yamaha dealer check the system be-
fore riding.
Page 24 of 78
INSTRUMENT AND CONTROL FUNCTIONS
3-11
2
34
5
6
7
8
9
With the engine turned off:
1. Move the sidestand down.
2. Make sure that the engine stop switch is turned on.
3. Turn the key on.
4. Shift the transmission into the neutral position.
5. Push the start switch.
Does the engine start?
With the engine still running:
6. Move the sidestand up.
7. Keep the clutch lever pulled.
8. Shift the transmission into gear.
9. Move the sidestand down.
Does the engine stall?
After the engine has stalled:
10. Move the sidestand up.
11. Keep the clutch lever pulled.
12. Push the start switch.
Does the engine start?
The system is OK. The motorcycle can be ridden.
This check is most reliable if performed with
a warmed-up engine.The neutral switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
The sidestand switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
The clutch switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
YES NO YES NO YES NONOTE:
Page 26 of 78
PRE-OPERATION CHECKS
4-2
2
3
45
6
7
8
9
EAU15601
Pre-operation check list
ITEM CHECKS PAGE
Fuel
Check fuel level in fuel tank.
Refuel if necessary.
Check fuel line for leakage.3-6
Engine oil
Check oil level in engine.
If necessary, add recommended oil to specified level.
Check vehicle for oil leakage.6-8
Front brake
Check operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check lever free play.
Adjust if necessary.
Check brake pads for wear.
Replace if necessary.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.6-19, 6-20
Rear brake
Check operation.
Check pedal free play.
Adjust if necessary.6-17
Clutch
Check operation.
Lubricate cable if necessary.
Check lever free play.
Adjust if necessary.6-16
Throttle grip
Make sure that operation is smooth.
Check cable free play.
If necessary, have Yamaha dealer adjust cable free play and lubricate cable
and grip housing.6-12, 6-24
Control cables
Make sure that operation is smooth.
Lubricate if necessary.6-23