2004 YAMAHA XVS125 maintenance
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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 7 of 78
1-1
1
SAFETY INFORMATION
EAU10250
MOTORCYCLES ARE SINGLE
TRACK VEHICLES. THEIR SAFE
USE AND OPERATION ARE DEPEN-
DENT UPON THE USE OF PROPER
RIDING TECHNIQUES AS WELL AS
THE EXPERTISE OF THE OPERA-
TOR. EVERY OPERATOR SHOULD
KNOW THE FOLLOWING REQUIRE-
MENTS BEFORE RIDING THIS MO-
TORCYCLE.
HE OR SHE SHOULD:
OBTAIN THOROUGH INSTRUC-
TIONS FROM A COMPETENT
SOURCE ON ALL ASPECTS OF
MOTORCYCLE OPERATION.
OBSERVE THE WARNINGS
AND MAINTENANCE REQUIRE-
MENTS IN THE OWNER’S MAN-
UAL.
OBTAIN QUALIFIED TRAINING
IN SAFE AND PROPER RIDING
TECHNIQUES.
OBTAIN PROFESSIONAL TECH-
NICAL SERVICE AS INDICATED
BY THE OWNER’S MANUAL
AND/OR WHEN MADE NECES-SARY BY MECHANICAL CONDI-
TIONS.
Safe riding
Always make pre-operation
checks. Careful checks may help
prevent an accident.
This motorcycle is designed to car-
ry the operator and a passenger.
The failure of motorists to detect
and recognize motorcycles in traf-
fic is the predominating cause of
automobile/motorcycle accidents.
Many accidents have been caused
by an automobile driver who did
not see the motorcycle. Making
yourself conspicuous appears to
be very effective in reducing the
chance of this type of accident.
Therefore:
Wear a brightly colored jacket.
Use extra caution when ap-
proaching and passing through
intersections, since intersec-
tions are the most likely places
for motorcycle accidents to oc-
cur.
Ride where other motorists can
see you. Avoid riding in another
motorist’s blind spot.
Many motorcycle accidents in-
volve inexperienced operators. In
fact, many operators who have
been involved in accidents do not
even have a current motorcycle li-
cense.
Make sure that you are qualified
and that you only lend your mo-
torcycle to other qualified opera-
tors.
Know your skills and limits.
Staying within your limits may
help you to avoid an accident.
We recommend that you prac-
tice riding your motorcycle
where there is no traffic until you
have become thoroughly famil-
iar with the motorcycle and all of
its controls.
Many motorcycle accidents have
been caused by error of the motor-
cycle operator. A typical error
made by the operator is veering
Page 20 of 78
INSTRUMENT AND CONTROL FUNCTIONS
3-7
2
34
5
6
7
8
9 fuel may deteriorate painted surfac-
es or plastic parts.
EAU13320
CAUTION:
ECA11400
Use only unleaded gasoline. The use
of leaded gasoline will cause severe
damage to internal engine parts,
such as the valves and piston rings,
as well as to the exhaust system.
Your Yamaha engine has been de-
signed to use regular unleaded gaso-
line with a research octane number of
91 or higher. If knocking (or pinging) oc-
curs, use a gasoline of a different brand
or premium unleaded fuel. Use of un-leaded fuel will extend spark plug life
and reduce maintenance costs.
EAU13580
Fuel cock
This model is equipped with a negative
pressure fuel cock. The fuel cock sup-
plies fuel from the tank to the carburetor
while also filtering it.
The fuel cock lever positions are ex-
plained as follows and shown in the il-
lustrations.
ON
With the fuel cock lever in this position,
fuel flows to the carburetor when the
engine is running. Turn the fuel cock le-
ver to this position when starting the en-
gine and riding. Recommended fuel:
REGULAR UNLEADED
GASOLINE ONLY
Fuel tank capacity:
11.0 L (2.91 US gal)
(2.42 Imp.gal)
Fuel reserve amount:
3.4 L (0.90 US gal)
(0.75 Imp.gal)
1. Arrow mark positioned over “ON”
1
Page 32 of 78
PERIODIC MAINTENANCE AND MINOR REPAIR
6-1
2
3
4
5
67
8
9
EAU17240
Safety is an obligation of the owner. Pe-
riodic inspection, adjustment and lubri-
cation will keep your vehicle in the
safest and most efficient condition pos-
sible. The most important points of in-
spection, adjustment, and lubrication
are explained on the following pages.
The intervals given in the periodic
maintenance and lubrication chart
should be simply considered as a gen-
eral guide under normal riding condi-
tions. However, DEPENDING ON THE
WEATHER, TERRAIN, GEOGRAPHI-
CAL LOCATION, AND INDIVIDUAL
USE, THE MAINTENANCE INTER-
VALS MAY NEED TO BE SHORT-
ENED.
WARNING
EWA10320
If you are not familiar with mainte-
nance work, have a Yamaha dealer
do it for you.
EAU17340
Owner’s tool kit
The owner’s tool kit is located behind
panel B. (See page 6-5.)
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 preventive
maintenance and minor repairs. How-
ever, additional tools such as a torque
wrench may be necessary to perform
certain maintenance 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.
WARNING
EWA10350
Modifications not approved by
Yamaha may cause loss of perfor-
mance and render the vehicle un-
safe for use. Consult a Yamaha
dealer before attempting any chang-
es.
1. Owner’s tool kit
1
Page 33 of 78
PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
1
2
3
4
5
6
7
8
9
EAU17710
Periodic maintenance and lubrication chart
NOTE:
The annual checks must be performed every year, except if a kilometer-based maintenance is performed in-
stead.
From 30,000 km, repeat the maintenance intervals starting from 6,000 km.
Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical
skills.
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (
×
1,000 km)
ANNUAL
CHECK
1 6 12 18 24
1*
Fuel line
Check fuel hoses and vacuum hose for cracks or dam-
age.
√
√
√
√
√
2
Spark plugs
Check condition.
Clean and regap.
√
√
Replace.
√
√
3*
Valves
Check valve clearance.
Adjust.
√
√
√
√
4
Air filter element
Clean.
√
√
Replace.
√
√
5
Clutch
Check operation.
Adjust.
√
√
√
√
√
6*
Front brake
Check operation, fluid level and vehicle for fluid leak-
age. (See NOTE following this chart.)
√
√
√
√
√
√
Replace brake pads. Whenever worn to the limit
7*
Rear brake
Check operation and adjust brake pedal free play.
√
√
√
√
√
√
Replace brake shoes. Whenever worn to the limit
8*
Brake hose
Check for cracks or damage.
√
√
√
√
√
Replace. (See NOTE following this chart.) Every 4 years
Page 34 of 78
PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
2
3
4
5
67
8
9
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.
√
√
√
√
19
*
Shock absorber assem-
blies
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.
√
√
√
√ √ √ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1,000 km)
ANNUAL
CHECK
1 6 12 18 24
Page 35 of 78
PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
1
2
3
4
5
6
7
8
9
EAU18660
NOTE:
The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
Hydraulic brake service
Regularly check and, if necessary, correct the brake fluid level.
Every two years replace the internal components of the brake master cylinder and caliper, and change the brake fluid.
Replace the brake hoses every four years and if cracked or damaged.
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
Page 36 of 78
PERIODIC MAINTENANCE AND MINOR REPAIR
6-5
2
3
4
5
67
8
9
EAU18770
Removing and installing
panels
The panels shown above need to be re-
moved to perform some of the mainte-
nance jobs described in this chapter.Refer to this section each time a panel
needs to be removed and installed.
EAU32471
Panel A
To remove the panel
1. Remove the bolt.
2. Pull the rear of the panel out, and
then slide the panel forward to re-
lease it in the front.To install the panel
1. Secure the front of the panel, and
then push the rear of the panel in.
2. Install the bolt.
Panel B
To remove the panel1. Slide the panel lock cover open, in-
sert the key into the lock, and then
turn it 1/4 turn clockwise.
1. Panel A
1. Panel B
11
1. Bolt
1