2004 YAMAHA XVS125 torque

PERIODIC MAINTENANCE AND MINOR REPAIR
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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

PERIODIC MAINTENANCE AND MINOR REPAIR
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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
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not being replaced.
4. Remove the oil filter element cover
by removing the bolts.
5. Remove and replace the oil filter
element and O-ring.6. Install the oil filter element cover by
installing the bolts, then tightening
them to the specified torque.
NOTE:

Make sure that the O-ring is properly
seated.
7. Install the engine oil drain bolt, and
then tighten it to the specified
torque.
8. Add the specified amount of the
recommended engine oil, and then
install and tighten the oil filler cap.
CAUTION:

ECA11620

In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives. Do
not use oils with a diesel speci-
fication of “CD” or oils of a high-
er quality than specified. In
addition, do not use oils labeled
“ENERGY CONSERVING II” or
higher.

Make sure that no foreign mate-
rial enters the crankcase.
9. Start the engine, and then let it idle
1. Bolt
1. Oil filter element
2. O-ring
1(×3)
2
1

Tightening torque:
Oil filter element cover bolt:
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Tightening torque:
Engine oil drain bolt:
34 Nm (3.4 m·kgf, 24.5 ft·lbf)
Recommended engine oil:
See page 8-1.
Oil quantity:
With oil filter element replace-
ment:
1.60 L (1.69 US qt)
(1.41 Imp.qt)
Without oil filter element re-
placement:
1.40 L (1.48 US qt)
(1.23 Imp.qt)

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
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3. Lift the front wheel off the ground
according to the procedure on
page 6-32.
4. Pull the wheel axle out, and then
remove the wheel.
CAUTION:

ECA11070
Do not apply the brake after the
wheel has been removed together
with the brake disc, otherwise the
brake pads will be forced shut.
EAU24931
To install the front wheel
1. Install the speedometer gear unit
into the wheel hub so that the pro-jections mesh with the slots.
2. Lift the wheel up between the fork
legs.
NOTE:

Make sure that there is enough space
between the brake pads before insert-
ing the brake disc and that the slot in
the speedometer gear unit fits over the
retainer on the fork leg.3. Insert the wheel axle.
4. Lower the front wheel so that it is
on the ground.
5. Tighten the wheel axle to the spec-
ified torque.
6. Tighten the front wheel axle pinch
bolt to the specified torque.
7. Push down hard on the handlebar
1. Front wheel axle pinch bolt
2. Wheel axle
1 2

1. Speedometer gear unit
1

1. Retainer
Tightening torque:
Wheel axle:
59 Nm (5.9 m·kgf, 42.7 ft·lbf)
Tightening torque:
Front wheel axle pinch bolt:
20 Nm (2.0 m·kgf, 14.5 ft·lbf)
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
2
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PERIODIC MAINTENANCE AND MINOR REPAIR
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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.
EAU25780
To install the rear wheel
1. Insert the wheel axle from the
left-hand side, and then install theaxle nut.
2. Install the drive chain onto the rear
sprocket, and then adjust the drive
chain slack. (See page 6-21.)
3. Lower the rear wheel so that it is
on the ground.
4. Install the brake rod onto the brake
camshaft lever, and then install the
brake pedal free play adjusting nut
onto the brake rod.
5. Connect the brake torque rod to
the brake shoe plate by installing
the bolt and the nut, and then tight-
en the nut to the specified torque.
6. Tighten the axle nut to the speci-
fied torque.
7. Adjust the brake pedal position
and free play. (See page 6-17.)
WARNING

EWA10660
After adjusting the brake pedal free
play, check the operation of the
brake light.
1. Locknut
2. Drive chain slack adjusting nut
3. Wheel axle
1
32

Tightening torque:
Brake torque rod nut:
23 Nm (2.3 m·kgf, 17 ft·lbf)
Tightening torque:
Axle nut:
104 Nm (10.4 m·kgf, 75 ft·lbf)