Yamaha Virago XV125 Utmutato

PRINTED ON RECYCLED PAPER PRINTED IN JAPAN

9960.1 1(E) !

OWNERS MANUAL

5AJ-28199-E3XV125SYAMAHA MOTOR CO., LTD.

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INTRODUCTION

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Welcome to the Yamaha world of motorcycling!

As the owner of a XV125S, you are benefiting from Yamahas vast experience in and newesttechnology for the design and the manufacture of high-quality products, which have earnedYamaha a reputation for dependability.

Please take the time to read this manual thoroughly, so as to enjoy all your XV125Ss advan-tages. The owners manual does not only instruct you in how to operate, inspect and maintainyour motorcycle, but also in how to safeguard yourself and others from trouble and injury.

In addition, the many tips given in this manual will help to keep your motorcycle in the bestpossible condition. If you have any further questions, do not hesitate to contact your Yamahadealer.

The Yamaha team wishes you many safe and pleasant rides. So, remember to put safety first!

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IMPORTANT MANUAL INFORMATION

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Particularly important information is distinguished in this manual by the following notations:

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY ISINVOLVED!

Failure to follow WARNING instructions could result in severe injury or death to themotorcycle operator, a bystander or a person inspecting or repairing the motorcycle.

A CAUTION indicates special precautions that must be taken to avoid damage tothe motorcycle.

A NOTE provides key information to make procedures easier or clearer.

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NOTE:

NOTE:8 This manual should be considered a permanent part of this motorcycle and should

remain with it even if the motorcycle is subsequently sold.8 Yamaha continually seeks advancements in product design and quality. Therefore,

while this manual contains the most current product information available at the timeof printing, there may be minor discrepancies between your motorcycle and this manu-al. If there is any question concerning this manual, please consult your Yamaha dealer.

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IMPORTANT MANUAL INFORMATION

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PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THISMOTORCYCLE.

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XV125SOWNERS MANUAL

1999 by Yamaha Motor Co., Ltd.1st Edition, June 1999

All rights reserved. Any reprinting orunauthorized use without the writtenpermission of Yamaha Motor Co., Ltd.

is expressly prohibited.Printed in Japan.

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TABLE OF CONTENTS

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GIVE SAFETY THE RIGHT OF WAY ..................1-1

DESCRIPTION.....................................................2-1Left view............................................................2-1Right view.........................................................2-2Controls/Instruments .......................................2-3

INSTRUMENT AND CONTROLFUNCTIONS........................................................3-1

Main switch ......................................................3-1Indicator lights..................................................3-1Speedometer ....................................................3-2Handlebar switches..........................................3-2Clutch lever.......................................................3-4Shift pedal.........................................................3-4Front brake lever ..............................................3-4Rear brake pedal ..............................................3-5Fuel tank cap.....................................................3-5Fuel....................................................................3-6Fuel cock ...........................................................3-7Starter (choke) 1.........................................3-8Steering lock.....................................................3-8Seat ...................................................................3-9Helmet holder...................................................3-9Rear shock absorber adjustment ..................3-10Sidestand........................................................3-10

Sidestand/clutch switch operation check.....3-11

PRE-OPERATION CHECKS.................................4-1Pre-operation check list ...................................4-1

OPERATION AND IMPORTANT RIDINGPOINTS................................................................5-1

Starting the engine ..........................................5-1Starting a warm engine...................................5-3Shifting..............................................................5-4Recommended shift point(for Switzerland only) ......................................5-4Tips for reducing fuel consumption ...............5-5Engine break-in ................................................5-5Parking ..............................................................5-6

PERIODIC MAINTENANCE AND MINORREPAIR ................................................................6-1

Tool kit ..............................................................6-1Periodic maintenance and lubrication............6-3Panel removal and installation .......................6-6Panel A..............................................................6-6Panel B ..............................................................6-7Spark plugs.......................................................6-8Engine oil ..........................................................6-9Air filter ...........................................................6-12

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Carburetor adjustment ..................................6-15Idle speed adjustment ...................................6-15Throttle cable free play adjustment..............6-16Valve clearance adjustment ..........................6-16Tires.................................................................6-17Wheels ............................................................6-19Clutch lever free play adjustment.................6-19Front brake lever free play adjustment ........6-20Rear brake pedal height and free playadjustment......................................................6-21Brake light switch adjustment.......................6-22Checking the front brake pads and rear brakeshoes...............................................................6-22Inspecting the brake fluid level .....................6-23Brake fluid replacement.................................6-24Drive chain slack check..................................6-24Drive chain slack adjustment ........................6-25Drive chain lubrication...................................6-26Cable inspection and lubrication ..................6-27Throttle cable and grip lubrication ...............6-27Brake and shift pedal lubrication..................6-28Brake and clutch lever lubrication ................6-28Sidestand lubrication.....................................6-28Front fork inspection......................................6-29Steering inspection........................................6-29Wheel bearings ..............................................6-30

Battery.............................................................6-30Fuse replacement...........................................6-32Headlight bulb replacement..........................6-33Turn signal light bulb replacement ..............6-34Taillight bulb replacement ............................6-35Supporting the motorcycle ...........................6-36Front wheel removal......................................6-36Front wheel installation.................................6-37Rear wheel removal .......................................6-38Rear wheel installation ..................................6-39Troubleshooting.............................................6-40Troubleshooting chart ...................................6-41

MOTORCYCLE CARE AND STORAGE..............7-1Care ...................................................................7-1Storage..............................................................7-4

SPECIFICATIONS................................................8-1How to use the conversion table ....................8-5

CONSUMER INFORMATION.............................9-1Identification number records.........................9-1Key identification number...............................9-1Vehicle identification number.........................9-1Model label .......................................................9-2

TABLE OF CONTENTS

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Q GIVE SAFETY THE RIGHT OF WAY

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Motorcycles are fascinating vehicles, which can give you an unsurpassed feeling of power andfreedom. However, they also impose certain limits, which you must accept; even the bestmotorcycle does not ignore the laws of physics.

Regular care and maintenance are essential for preserving your motorcycles value and operat-ing condition. Moreover, what is true for the motorcycle is also true for the rider: good perfor-mance depends on being in good shape. Riding under the influence of medication, drugs andalcohol is, of course, out of the question. Motorcycle riders - more than car drivers - mustalways be at their mental and physical best. Under the influence of even small amounts ofalcohol, there is a tendency to take dangerous risks.

Protective clothing is as essential for the motorcycle rider as seat belts are for car drivers andpassengers. Always wear a complete motorcycle suit (whether made of leather or tear-resistantsynthetic materials with protectors), sturdy boots, motorcycle gloves and a properly fitting hel-met. Optimum protective wear, however, should not encourage carelessness. Though full-cov-erage helmets and suits, in particular, create an illusion of total safety and protection, motorcy-clists will always be vulnerable. Riders who lack critical self-control run the risk of going toofast and are apt to take chances. This is even more dangerous in wet weather. The good motor-cyclist rides safely, predictably and defensively - avoiding all dangers, including those causedby others.

Enjoy your ride!

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DESCRIPTION

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2-1

1. Headlight (page 6-33)2. Steering lock (page 3-8)3. Fuel cock (page 3-7)4. Main switch (page 3-1)5. Fuses (page 6-32)

6. Helmet holder (page 3-9)7. Rear shock absorber spring preload

adjusting ring (page 3-10)8. Shift pedal (page 3-4)

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654Left view

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DESCRIPTION

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2-2

9. Battery (page 6-30)10. Air filter (page 6-12)11. Rear brake pedal (page 3-5, 6-21)12. Oil filter (page 6-9)13. Tool kit (page 6-1)

14. Rear shock absorber spring preloadadjusting ring (page 3-10)

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Right view

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DESCRIPTION

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2-3

15. Clutch lever (page 3-4, 6-19)16. Left handlebar switches (page 3-2)17. Speedometer (page 3-2)18. Right handlebar switches (page 3-3)19. Front brake lever (page 3-4, 6-20)

20. Throttle grip (page 6-16)21. Fuel tank cap (page 3-5)

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Controls/Instruments

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INSTRUMENT AND CONTROL FUNCTIONS

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Main switchThe main switch controls the igni-tion and lighting systems. Its oper-ation is described below.

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ONElectrical circuits are switched on.The engine can be started. The keycannot be removed in this position.

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OFFAll electrical circuits are switchedoff. The key can be removed in thisposition.

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P (Parking)The taillight and auxiliary lightcome on but all other circuits areoff. With the key at OFF, push itinto the main switch, turn it coun-terclockwise to P, and remove it.To cancel the parking, turn the keyclockwise.

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Indicator lightsEAU00063

High beam indicator light &This indicator comes on when theheadlight high beam is used.

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Neutral indicator light NThis indicator comes on when thetransmission is in neutral.

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Turn indicator light 5This indicator flashes when theturn switch is moved to the left orright.

1. High beam indicator light &2. Neutral indicator light N3. Turn indicator light 5

ONOFF

P 321

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SpeedometerThe speedometer shows ridingspeed. This speedometer isequipped with an odometer andtrip odometer. The trip odometercan be reset to 0 with the resetknob. Use the trip odometer toestimate how far you can ride on atank of fuel. This information willenable you to plan fuel stops in thefuture.

1. Odometer2. Trip odometer3. Reset knob

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Handlebar switches

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Pass switch &Press the switch to operate thepassing light.

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Dimmer switchTurn the switch to & for thehigh beam and to % for the lowbeam.

1. Pass switch &2. Dimmer switch3. Turn signal switch4. Horn switch *

NOTE:(for German model equipped withspeed limiter only)This motorcycle is equipped with aspeed limiter which prevents itfrom exceeding a top speed of 80km/h.

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3-3

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Turn signal switchTo signal a right-hand turn, pushthe switch to 6. To signal a left-hand turn, push the switch to4. Once the switch is releasedit will return to the center position.To cancel the signal, push theswitch in after it has returned tothe center position.

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Horn switch *Press the switch to sound the horn.

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Lights switchTurning the light switch to ',turns on the auxiliary light, meterlights and taillight. Turning thelight switch to : turns the head-light on also.

1. Engine stop switch2. Lights switch3. Start switch $

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Engine stop switchThe engine stop switch is a safetydevice for use in an emergencysuch as when the motorcycle over-turns or if trouble occurs in thethrottle system. Turn the switch to# to start the engine.In case of emergency, turn theswitch to $ to stop the engine.

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Start switch ,The starter motor cranks theengine when pushing the startswitch.

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See starting instructions prior tostarting the engine.

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Clutch leverThe clutch lever is located on theleft handlebar, and the ignition cir-cuit cut-off system is incorporatedin the clutch lever holder. Pull theclutch lever to the handlebar to dis-engage the clutch, and release thelever to engage the clutch. Thelever should be pulled rapidly andreleased slowly for smooth clutchoperation. (Refer to the enginestarting procedures for a descrip-tion of the ignition circuit cut-offsystem.)

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Shift pedalThis motorcycle is equipped with aconstant-mesh 5-speed transmis-sion.The shift pedal is located on theleft side of the engine and is usedin combination with the clutchwhen shifting.

N. Neutral1. Shift pedal

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Front brake leverThe front brake lever is located onthe right handlebar. Pull it towardthe handlebar to apply the frontbrake.

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Rear brake pedalThe rear brake pedal is on the rightside of the motorcycle. Press downon the brake pedal to apply therear brake.

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Fuel tank capTo openInsert the key and turn it 1/4 turnclockwise. The lock will be releasedand the cap can be opened.

To closePush the tank cap into positionwith the key inserted. To removethe key, turn it counterclockwise tothe original position.

1. Open

NOTE:This tank cap cannot be closedunless the key is in the lock. Thekey cannot be removed if the cap isnot locked properly.

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Be sure the cap is properlyinstalled and locked in placebefore riding the motorcycle.

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FuelMake sure there is sufficient fuel inthe tank. Fill the fuel tank to thebottom of the filler tube as shownin the illustration.

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Do not overfill the fuel tank. Avoidspilling fuel on the hot engine. Donot fill the fuel tank above the bot-tom of the filler tube or it mayoverflow when the fuel heats uplater and expands.

1. Filler tube2. Fuel level

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Always wipe off spilled fuel imme-diately with a dry and clean softcloth. Fuel may deteriorate paintedsurfaces or plastic parts.

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NOTE:If knocking or pinging occurs, use adifferent brand of gasoline or high-er octane grade.

1 2Recommended fuel:

Regular unleaded gasoline with a research octane number of 91 or higher.

Fuel tank capacity:Total:

9.5 LReserve:

2.6 L

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NOTE:The fuel cock operates on vacuumfrom the engine when set at ONor RES. If the line connecting thecock to the carburetor intake mani-fold is not connected or has a leak,the cock will not function properly.

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Fuel cockThe negative pressure fuel cocksupplies fuel from the tank to thecarburetor while filtering it also.The fuel cock has the followingthree positions:

ONWith the lever in this position, fuelflows if the engine is running, butstops if the engine is not running.

1. Arrow mark pointing to ON

RESThis indicates reserve. If you runout of fuel while riding, move thelever to PRI, start the engine,then move the lever to RES. FILLTHE TANK AT THE FIRST OPPOR-TUNITY. BE SURE TO MOVE THELEVER TO ON AFTER REFUEL-ING.

1. Arrow mark pointing to RES

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ON RES

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PRIThis indicates prime. With the leverin this position, fuel flows whetherthe engine is running or not. If thefuel tank is completely empty, refillthe tank and move the lever toPRI to prime the carburetor.Move the lever to ON after start-ing the engine.

1. Arrow mark pointing to PRI

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Starter (choke) 1Starting a cold engine requires aricher air-fuel mixture. A separatestarter circuit supplies this mixture.Move in direction a to turn on thestarter (choke).Move in direction b to turn off thestarter (choke).

1. Starter (choke) 1

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Steering lockTo lock the steeringTurn the handlebars all the way tothe right and open the steeringlock cover.Insert the key and turn it 1/8 turncounterclockwise. Then, push thekey in while turning the handlebarsslightly to the left and turn the key1/8 turn clockwise.Check that the steering is locked,remove the key and close the lockcover.To unlock the steeringInsert the key, push it in and turn it1/8 turn counterclockwise so that itmoves out. Then, release andremove the key.

1. Steering lock

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PRI

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SeatTo remove

1. Remove panels A and B. (Seepage 6-6 for panel removaland installation procedures.)

2. Remove the rider seat boltsand lift the seat upward.

1. Bolt ( 2)

To install1. Insert the projection on the

front of the rider seat into theseat holder, then tighten theseat bolts.

2. Install the panels.

NOTE:Make sure that the seat is securelyfitted.

1. Projection2. Seat holder

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Helmet holderTo open the helmet holder, insertthe key in the lock and turn it asshown. To lock the helmet holder,replace the holder in its originalposition.

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Never ride with a helmet in thehelmet holder. The helmet may hitobjects, causing loss of controland possibly an accident.

1. Helmet holder2. Open

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Rear shock absorber adjustmentEach shock absorber is equippedwith a spring preload adjustingring. Adjust spring preload as fol-lows.Turn the adjusting ring in directiona to increase spring preload andin direction b to decrease springpreload. Make sure that the appro-priate notch in the adjusting ring isaligned with the position indicatoron the rear shock absorber.

1. Position indicator

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Always adjust each shockabsorber to the same setting.Uneven adjustment can causepoor handling and loss of stability.

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SidestandThis model is equipped with anignition circuit cut-off system. Themotorcycle must not be riddenwhen the sidestand is down. Thesidestand is located on the left sideof the frame. (Refer to page 5-1 foran explanation of this system.)

Soft Stan- HarddardAdjusting

1 2 3 4 5position

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This motorcycle must not be oper-ated with the sidestand in thedown position. If the stand is notproperly retracted, it could contactthe ground and distract the opera-tor, resulting in a possible loss ofcontrol. Yamaha has designed intothis motorcycle a lockout systemto assist the operator in fulfillingthe responsibility of retracting thesidestand. Please check carefullythe operating instructions listedbelow and if there is any indicationof a malfunction, return the motor-cycle to a Yamaha dealer immedi-ately for repair.

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Sidestand/clutch switch operation checkCheck the operation of the side-stand switch and clutch switchagainst the information below.

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If improper operation is noted,consult a Yamaha dealer immedi-ately.

TURN THE MAIN SWITCH TO ON

AND THE ENGINE STOP SWITCH TO

#.

TRANSMISSION IS IN GEAR AND

SIDESTAND IS UP.

PULL IN CLUTCH LEVER AND

PUSH THE START SWITCH.

ENGINE WILL START.

CLUTCH SWITCH IS OK.

SIDESTAND IS DOWN.

ENGINE WILL STALL.

SIDESTAND SWITCH IS OK.

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PRE-OPERATION CHECKS

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Owners are personally responsible for their vehicles condition. Your motorcycles vital functions can start todeteriorate quickly and unexpectedly, even if it remains unused (for instance, if it is exposed to the elements).Any damage, fluid leak or loss of tire pressure could have serious consequences. Therefore, it is very importantthat, in addition to a thorough visual inspection, you check the following points before each ride.

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PRE-OPERATION CHECK LIST

ITEM CHECKS PAGE

Front brake 9 Check operation, free play, fluid level and vehicle for fluid leakage.9 Fill with DOT 4 (or DOT 3) brake fluid if necessary.

Rear brake 9 Check operation and free play.3-4 ~ 3-5, 6-20 ~ 6-24

9 Adjust if necessary.

Clutch 9 Check operation and free play. 3-4, 6-19 ~ 6-209 Adjust if necessary.

Throttle grip and housing 9 Check for smooth operation. 6-16, 6-279 Lubricate.

Engine oil 9 Check oil level. 6-9 ~ 6-129 Fill with oil if necessary.

Drive chain 9 Check chain slack and condition. 6-24 ~ 6-279 Adjust if necessary.

Wheels and tires 9 Check tire pressure, wear, damage and spoke tightness. 6-17 ~ 6-199 Tighten spokes if necessary.

Control and meter cable 9 Check for smooth operation. 6-279 Lubricate if necessary.

Brake and shift pedal shafts 9 Check for smooth operation. 6-289 Lubricate if necessary.

Brake and clutch lever pivots 9 Check for smooth operation. 6-289 Lubricate if necessary.

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PRE-OPERATION CHECKS

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ITEM CHECKS PAGE

Sidestand pivot 9 Check for smooth operation. 6-289 Lubricate if necessary.

Chassis fasteners 9 Make sure that all nuts, bolts, and screws are properly tightened. 9 Tighten if necessary.

Fuel tank 9 Check fuel level. 3-5 ~ 3-69 Fill with fuel if necessary.

Lights, signals and9 Check for proper operation. 6-33 ~ 6-35switches

Battery 9 Check fluid level. 6-30 ~ 6-329 Fill with distilled water if necessary.

NOTE:Pre-operation checks should be made each time the motorcycle is used. Such an inspection can be accom-plished in a very short time; and the added safety it assures is more than worth the time involved.

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If any item in the Pre-Operation Check is not working properly, have it inspected and repaired before operatingthe motorcycle.

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OPERATION AND IMPORTANT RIDING POINTS

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8 Before riding this motorcycle,become thoroughly familiarwith all operating controls andtheir functions. Consult aYamaha dealer regarding anycontrol or function that you donot thoroughly understand.

8 Never start your engine or letit run for any length of time ina closed area. The exhaustfumes are poisonous and cancause loss of consciousnessand death within a short time.Always operate your motorcy-cle in an area with adequateventilation.

8 Before starting out, always besure the sidestand is up.Failure to retract the sidestandcompletely can result in a seri-ous accident when you try toturn a corner.

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Starting the engine

NOTE:This motorcycle is equipped withan ignition circuit cut-off system.The engine can be started onlyunder one of the following condi-tions:8 The transmission is in neutral.8 The sidestand is up, the trans-

mission is in gear and theclutch is disengaged.

The motorcycle must not be riddenwhen the sidestand is down.

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Before going through the follow-ing steps, check the function of thesidestand switch and clutchswitch. (Refer to page 3-11.)

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IF THE TRANSMISSION IS IN NEUTRALAND THE SIDESTAND IS DOWN,

PUSH START SWITCH.THE ENGINE WILL START.

RETRACT THE SIDESTAND AND PUTTHE TRANSMISSION IN GEAR.

THE MOTORCYCLE CAN BE RIDDEN.THE MOTORCYCLE CAN BE RIDDEN.

IF THE TRANSMISSION IS IN GEARAND THE SIDESTAND IS UP,

PULL IN THE CLUTCH LEVER ANDPUSH THE START SWITCH.THE ENGINE WILL START.

TURN THE MAIN SWITCH TO ON ANDTHE ENGINE STOP SWITCH TO #.

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1. Turn the fuel cock to ON.2. Turn the main switch to ON

and the engine stop switch to#.

3. Shift the transmission intoneutral.

NOTE:When the transmission is in neu-tral, the neutral indicator lightshould be on. If the light does notcome on, ask a Yamaha dealer toinspect it.

4. Turn on the starter (choke) andcompletely close the throttlegrip.

5. Start the engine by pushingthe start switch.

NOTE:If the engine fails to start, releasethe start switch, wait a few sec-onds, then try again. Each attemptshould be as short as possible topreserve the battery. Do not crankthe engine more than 10 secondson any one attempt.

6. After starting the engine, movethe starter (choke) to thehalfway position.

NOTE:For maximum engine life, neveraccelerate hard with a cold engine!

7. After warming up the engine,turn off the starter (choke)completely.

NOTE:The engine is warm when itresponds normally to the throttlewith the starter (choke) turned off.

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Starting a warm engineThe starter (choke) is not requiredwhen the engine is warm.

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See the Engine break-in sectionprior to operating the motorcyclefor the first time.

1. Arrow mark pointing to ON

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ShiftingThe transmission lets you controlthe amount of power you haveavailable at a given speed for start-ing, accelerating, climbing hills,etc. The use of the shift pedal isshown in the illustration.To shift into neutral, depress theshift pedal repeatedly until it reach-es the end of its travel, then raisethe pedal slightly.

N. Neutral1. Shift pedal

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8 Do not coast for long periodswith the engine off, and donot tow the motorcycle a longdistance. Even with gears inneutral, the transmission isonly properly lubricated whenthe engine is running.Inadequate lubrication maydamage the transmission.

8 Always use the clutch whenchanging gears. The engine,transmission, and driveline arenot designed to withstand theshock of forced shifting andcan be damaged by shiftingwithout using the clutch.

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Recommended shift points(for Switzerland only)The recommended shift points areshown in the table below.

NOTE:When shifting two gears downfrom 4th to 2nd, bring your motor-cycle to a speed of 35 km/h.

Acceleration shift point(km/h)

1st fi 2nd 232nd fi 3rd 363rd fi 4th 504th fi 5th 60

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EAU00424

Tips for reducing fuel consumptionYour motorcycles fuel consump-tion depends to a large extent onyour riding style. The followingtips can help reduce fuel consump-tion:8 Warm up the engine before

riding.8 Turn off the starter (choke) as

soon as possible.8 Shift up swiftly and avoid high

engine speeds during accelera-tion.

8 Do not double-clutch or rev theengine while shifting downand avoid high engine speedswith no load on the engine.

8 Turn off the engine instead ofletting it idle for an extendedlength of time, i.e. in trafficjams, at traffic lights or rail-road crossings.

EAU00436

Engine break-inThere is never a more importantperiod in the life of your motorcy-cle than the period between zeroand 1,000 km. For this reason weask that you carefully read the fol-lowing material. Because theengine is brand new, you must notput an excessive load on it for thefirst 1,000 km. The various parts inthe engine wear and polish them-selves to the correct operatingclearances. During this period, pro-longed full throttle operation, orany condition which might result inexcessive heating of the engine,must be avoided.

EAU00443

0 ~ 150 km Avoid operation above 1/3 throttle.Stop the engine and let it cool for 5to 10 minutes after every hour ofoperation. Vary the speed of themotorcycle from time to time. Donot operate it at one set throttleposition.

150 ~ 500 km Avoid prolonged operation above1/2 throttle. Rev the motorcyclefreely through the gears, but donot use full throttle at any time.

500 ~ 1,000 km Avoid cruising speeds in excess of3/4 throttle.

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After 1,000 km of operation, besure to replace the engine oil andoil filter.

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1,000 km and beyondAvoid prolonged full throttle oper-ation. Vary speeds occasionally.

EC000049

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If any engine trouble should occurduring the break-in period, consulta Yamaha dealer immediately.

EAU00460

ParkingWhen parking the motorcycle, stopthe engine and remove the ignitionkey.

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The exhaust system is hot. Parkthe motorcycle in a place wherepedestrians or children are notlikely to touch the motorcycle. Donot park the motorcycle on a slopeor soft ground; the motorcyclemay overturn.

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EAU00462

PERIODIC MAINTENANCE AND MINOR REPAIR

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If you are not familiar with motor-cycle service, this work should bedone by a Yamaha dealer.

1

EAU01175

Tool kitThe tool kit is located behind panelA. (See page 6-6 for panel removaland installation procedures.) Thetools provided in the owners toolkit are to assist you in the perfor-mance of periodic maintenance.However, some other tools such asa torque wrench are also necessaryto perform the maintenance cor-rectly.The service information included inthis manual is intended to provideyou, the owner, with the necessaryinformation for completing someof your own preventive mainte-nance and minor repairs.

1. Tool kit

EAU00464

Periodic inspection, adjustmentand lubrication will keep yourmotorcycle in the safest and mostefficient condition possible. Safetyis an obligation of the motorcycleowner. The maintenance and lubri-cation schedule chart should beconsidered strictly as a guide togeneral maintenance and lubrica-tion intervals. YOU MUST TAKE INTO CONSID-ERATION THAT WEATHER, TER-RAIN, GEOGRAPHICAL LOCA-TIONS, AND A VARIETY OFINDIVIDUAL USES ALL TEND TODEMAND THAT EACH OWNERALTER THIS TIME SCHEDULE TOSHORTER INTERVALS TO MATCHTHE ENVIRONMENT. The mostimportant points of motorcycleinspection, adjustment, and lubri-cation are explained in the follow-ing pages.

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NOTE:If you do not have necessary toolsrequired during a service opera-tion, take your motorcycle to aYamaha dealer for service.

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Modifications to this motorcyclenot approved by Yamaha maycause loss of performance, andrender it unsafe for use. Consult aYamaha dealer before attemptingany changes.

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EAU00473

PERIODIC MAINTENANCE AND LUBRICATION

Every Every6,000 km 12,000 km

No. ITEM CHECKS AND MAINTENANCE JOBS INITIAL or or1,000 km 6 months 12 months(Whichever (Whichevercomes first) comes first)

1 * Fuel line 9 Check fuel hoses and vacuum hose for cracks or damage. 9 Replace if necessary.

2 Spark plugs 9 Check condition. 9 Clean, regap or replace if necessary.

3 * Valves 9 Check valve clearance. 9 Adjust if necessary.

4 Air filter 9 Clean or replace if necessary.

9 Check electrolyte level and specific gravity.5 * Battery 9 Correct or recharge if necessary.

9Make sure that the breather hose is properly routed.

6 Clutch 9 Check operation. 9 Adjust or replace cable.

9 Check operation, fluid level and vehicle for fluid leakage.

7 * Front brake (See NOTE on page 6-5.) 9 Correct accordingly.9 Replace brake pads if necessary.

8 * Rear brake 9 Check operation. 9 Adjust brake pedal freeplay and replace brake shoes if necessary.

9 * Wheels 9 Check balance, runout, spoke tightness and for damage. 9 Tighten spokes and rebalance, replace if necessary.

9 Check tread depth and for damage.

10 * Tires 9 Replace if necessary. 9 Check air pressure.9 Correct if necessary.

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11 * Wheel bearings 9 Check bearing for looseness or damage. 9 Replace if necessary.

9 Check swingarm pivoting point for play.

12 * Swingarm 9 Correct if necessary. 9 Lubricate with molybdenum disulfide grease every 24,000 km or

24 months (whichever comes first).

9 Check chain slack. Every 1,000 km and after washing13 Drive chain 9 Adjust if necessary. Make sure that the rear wheel is properly aligned. the motorcycle or riding in the rain9 Clean and lubricate.

9 Check bearing play and steering for roughness.

14 * Steering bearings 9 Correct accordingly. 9 Lubricate with lithium soap base grease every 24,000 km or

24 months (whichever comes first).

15 * Chassis fasteners 9Make sure that all nuts, bolts and screws are properly tightened. 9 Tighten if necessary.

16 Sidestand 9 Check operation. 9 Lubricate and repair if necessary.

17 * Sidestand switch 9 Check operation. 9 Replace if necessary.

18 * Front fork 9 Check operation and for oil leakage. 9 Correct accordingly.

19 * Rear shock absorber 9 Check operation and shock absorbers for oil leakage. assemblies 9 Replace shock absorber assembly if necessary.

20 * Carburetor 9 Check engine idling speed and starter operation. 9 Adjust if necessary.

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EAU02970

NOTE:8 The air filter needs more frequent service if you are riding in unusually wet or dusty areas.8 Hydraulic brake system8 When disassembling the master cylinder or caliper, always replace the brake fluid. Check the brake fluid

level regularly and fill as required.8 Replace the oil seals on the inner parts of the master cylinder and caliper every two years.8 Replace the brake hoses every four years or if cracked or damaged.

* Since these items require special tools, data and technical skills, they should be serviced by a Yamaha dealer.



9 Check oil level and vehicle for oil leakage. 21 Engine oil 9 Correct if necessary.

9 Change. (Warm engine before draining.)

22 Engine oil filter element 9 Replace.

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EAU01122

Panel removal and installationThe panels illustrated need to beremoved to perform some of themaintenance described in thischapter.Refer to this section each time apanel has to be removed or rein-stalled.

1. Panel A

1

1. Panel B

EAU01156

Panel ATo removePull outward on the rear of thepanel, then slide it forward tounhook it in the front.

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To installHook the front of the panel on theholders, then push inward on therear of the panel.

1. Holder ( 2)2. Bracket ( 2)3. Grommet4. Projection

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EAU01156

Panel BTo removePull outward on the rear of thepanel, then slide it forward tounhook it in the front.

4

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3

To installHook the front of the panel on theholders, then push inward on therear of the panel.

1. Holder ( 2)2. Grommet3. Projection4. Bracket ( 2)

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EAU03053

Spark plugsRemoval

1. Remove the spark plug caps.

1. Spark plug cap

1

2. Use the spark plug wrench inthe tool kit to remove the sparkplugs as shown.

1. Spark plug wrench

InspectionThe spark plug is an important enginecomponent and is easy to inspect.The condition of the spark plug canindicate the condition of the engine.Normally, all spark plugs from thesame engine should have the samecolor on the white insulator aroundthe center electrode. The ideal colorat this point is a medium-to-light tancolor for a motorcycle that is beingridden normally. If one spark plugshows a distinctly different color,there could be something wrong withthe engine.Do not attempt to diagnose suchproblems yourself. Instead, take themotorcycle to a Yamaha dealer. Youshould periodically remove andinspect the spark plugs because heatand deposits will cause any sparkplug to slowly break down and erode.If electrode erosion becomes exces-sive, or if carbon and other depositsare excessive, you should replace thespark plug with the specified plug.

Specified spark plug:CR6HSA (NGK) orU20FSR-U (DENSO)

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EAU01523

Engine oilOil level inspection

1. Place the motorcycle on a levelplace and hold it in an uprightposition. Warm up the enginefor several minutes.

NOTE:Be sure the motorcycle is posi-tioned straight up when checkingthe oil level. A slight tilt toward theside can result in false readings.

1. Oil level window2. Maximum level mark3. Minimum level mark

a

Installation1. Measure the electrode gap

with a wire thickness gaugeand, if necessary, adjust thegap to specification.

2. Clean the gasket surface. Wipeoff any grime from thethreads.

3. Install the spark plug and tight-en it to the specified torque.

a. Spark plug gap

NOTE:If a torque wrench is not availablewhen you are installing a sparkplug, a good estimate of the cor-rect torque is 1/4 to 1/2 turn pastfinger tight. Have the spark plugtightened to the specified torque assoon as possible.

4. Install the spark plug caps.

Spark plug gap:0.6 ~ 0.7 mm

Tightening torque:Spark plug:

12.5 Nm (1.25 m0kg)

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6-10

2. With the engine stopped,check the oil level through thelevel window located at thelower part of the right sidecrankcase cover.

NOTE:Wait a few minutes until the oillevel settles before checking.

3. The oil level should bebetween maximum level andminimum level marks. If thelevel is low, fill engine withsufficient oil to raise it to thespecified level.

1

Engine oil and oil filter elementreplacement

1. Warm up the engine for a fewminutes.

2. Stop the engine. Place an oilpan under the engine andremove the oil filler cap.

1. Oil filler cap

3. Remove the drain plug anddrain the oil.

1. Engine oil drain plug

1

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7. Install the new oil filter, new O-ring and the oil filter cover.Tighten the oil filter coverbolts to the specified torque.

NOTE:Make sure the O-ring is seatedproperly.

8. Fill the engine with oil. Installthe oil filler cap and tighten it.

Tightening torque:Oil filter cover bolt:

10 Nm (1.0 mkg)


4. Remove the oil filter coverbolts and the oil filter cover.

1. Oil filter cover bolt ( 3)

5. Remove the oil filter and O-ring.

6. Reinstall the drain plug andtighten it to the specifiedtorque.

1. Oil filter2. O-ring

1

21

Tightening torque:Drain plug:

32 Nm (3.2 mkg)

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EC000066

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8 Do not put in any chemicaladditives. Engine oil also lubri-cates the clutch and additivescould cause clutch slippage.

8 Be sure no foreign materialenters the crankcase.

9. Start the engine and warm upfor a few minutes. Whilewarming up, check for oil leak-age. If oil leakage is found,stop the engine immediatelyand check for the cause.

10. Stop the engine and check theoil level.

Recommended oil:See page 8-1.

Oil quantity:Total amount:

1.7 L Periodic oil change:

1.4 L With oil filter replacement:

1.6 L

EAU01174*

Air filterThe air filter should be cleaned atthe specified intervals. It should becleaned more frequently if you areriding in unusually wet or dustyareas.

1. Bolt2. Air filter cover3. Air filter case

1

3

2

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3. Remove the screws and the airfilter cover.

1. Screw ( 2)

1


1. Remove the bolts and the airfilter case.

1. Bolt ( 2)

2. Remove the hoses from the airfilter case.

1. Hose ( 2)

1 1

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4. Remove the wing nut and theair filter.

1. Wing nut2. Air filter

5. Remove the foam elementfrom its frame and clean itwith solvent. After cleaning,remove the remaining solventby squeezing it.

6. Apply recommended oil to theentire surface of the elementand squeeze out the excess oil.It should be wet but not drip-ping.

1. Foam element2. Frame

1 2 12

Recommended oil:Engine oil

7. Pull the element over itsframe, install the air filter inthe case and tighten the wingnut.

8. Install the air filter cover.9. Connect the hoses and install

the air filter case.

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8 Make sure the air filter is prop-erly seated in the air filtercase.

8 The engine should never berun without the air filterinstalled. Excessive pistonand/or cylinder wear mayresult.

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2. Set the idle to the specifiedengine speed by adjusting thethrottle stop screw. Turn thescrew in direction a toincrease engine speed and indirection b to decrease enginespeed.

NOTE:If the specified idle speed cannotbe obtained by performing theabove adjustment, consult aYamaha dealer.

1. Throttle stop screw

1

ab

Standard idle speed:1,300 ~ 1,400 r/min


EAU00629

Carburetor adjustmentThe carburetor is a vital part of theengine and requires very sophisti-cated adjustment. Most adjust-ments should be left to a Yamahadealer who has the professionalknowledge and experience to doso. However, the following may beserviced by the owner as part ofroutine maintenance.

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The carburetor was set at theYamaha factory after many tests. Ifthe settings are changed, poorengine performance and damagemay result.

EAU01168

Idle speed adjustment

NOTE:A diagnostic tachometer must beused for this procedure.

1. Attach the tachometer. Startthe engine and warm it up fora few minutes at approximate-ly 1,000 to 2,000 r/min.Occasionally rev the engine to4,000 to 5,000 r/min. Theengine is warm when it quicklyresponds to the throttle.

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EAU00634

Throttle cable free play adjustment

NOTE:Before checking the throttle cablefree play, the engine idling speedshould be adjusted.

Adjust the throttle cable by turningthe adjusting nut so that specifiedfree play at the throttle grip isobtained.

1. Adjusting nut2. Locknutc. Free play

1. Loosen the locknut.2. Turn the adjusting nut in direc-

tion a to increase free playand in direction b to decreasefree play.

3. Tighten the locknut.1 2a

bc

Free play:3 ~ 5 mm

EAU00637

Valve clearance adjustmentThe correct valve clearancechanges with use, resulting inimproper fuel/air supply or enginenoise. To prevent this, the valveclearance must be adjusted regu-larly. This adjustment however,should be left to a professionalYamaha service technician.

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Proper loading of your motorcycleis important for several character-istics of your motorcycle, such ashandling, braking, performanceand safety. Do not carry looselypacked items that can shift.Securely pack your heaviest itemsclose to the center of the motorcy-cle, and distribute the weightevenly from side to side. Properlyadjust the suspension for yourload, and check the condition andpressure of your tires. NEVEROVERLOAD YOUR MOTORCYCLE.Make sure the total weight of thecargo, rider, passenger, and acces-sories (fairing, saddlebags, etc. ifapproved for this model) does notexceed the maximum load of themotorcycle. Operation of an over-loaded motorcycle could cause tiredamage, an accident, or eveninjury.


EAU00647

TiresTo ensure maximum performance,long service, and safe operation,note the following:

Tire air pressureAlways check and adjust the tirepressure before operating themotorcycle.

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Tire inflation pressure should bechecked and adjusted when thetemperature of the tire equals theambient air temperature. Tire infla-tion pressure must be adjustedaccording to total weight of cargo,rider, passenger, and accessories(fairing, saddlebags, etc. ifapproved for this model), and vehi-cle speed.

* Load is the total weight of cargo, rider, passen-ger, and accessories.

Maximum load* 183 kg

Cold tire pressure Front Rear

175 kPa 200 kPaUp to 90 kg (1.75 kg/cm2, (2.0 kg/cm2,

1.75 bar) 2.00 bar)

90 kg load ~200 kPa 225 kPa

Maximum load*(2.0 kg/cm2, (2.25 kg/cm2,

2.00 bar) 2.25 bar)

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NOTE:These limits may be different byregulation from country to country.If so, conform to the limits speci-fied by the regulations of your owncountry.

Tire inspectionAlways check the tires before oper-ating the motorcycle. If centertread depth reaches the limit asshown, if the tire has a nail or glassfragments in it, or if the side wall iscracked, contact a Yamaha dealerimmediately and have the tirereplaced.

1. Side walla. Tread depth

1

aManufacturer Size Type

CHENG SHIN 3.00-18 47P C-916

Manufacturer Size Type

CHENG SHIN 130/90-15M/C 66P C-915

REAR

Minimum tire treaddepth (front and rear)

1.6 mm

FRONT EAU00681

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8 Operating the motorcycle withexcessively worn tiresdecrease riding stability andcan lead to loss of control.Have excessively worn tiresreplaced by a Yamaha dealerimmediately. Brakes, tires, andrelated wheel parts replace-ment should be left to aYamaha Service Technician.

8 Patching a punctured tube isnot recommended. If it isabsolutely necessary to do so,use great care and replace thetube as soon as possible witha good quality replacement.

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EAU00694

Clutch lever free play adjustmentThe clutch lever free play shouldbe adjusted to 10 ~ 15 mm.

1. Loosen the locknut at theclutch lever.

2. Turn the adjusting bolt at theclutch lever in direction a toincrease free play or in direc-tion b to decrease free play.

3. Tighten the locknut at theclutch lever.

If the specified free play cannot beobtained, proceed with the follow-ing steps.

1. Locknut2. Adjusting boltc. Free play


EAU00685

WheelsTo ensure maximum performance,long service, and safe operation,note the following:8 Always inspect the wheels

before a ride. Check for cracks,bends or warpage of thewheel. Be sure the spokes aretight and undamaged. If anyabnormal condition exists in awheel, consult a Yamaha deal-er. Do not attempt even smallrepairs to the wheel. If a wheelis deformed or cracked, it mustbe replaced.

8 Tires and wheels should bebalanced whenever either oneis changed or replaced. Failureto have a wheel balanced canresult in poor performance,adverse handling characteris-tics, and shortened tire life.

8 Ride at moderate speeds afterchanging a tire since the tiresurface must first be broken infor it to develop its optimalcharacteristics.

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1 2

a

b

4. Loosen the locknut at theclutch lever.

5. Turn the adjusting bolt at theclutch lever in direction a toloosen the cable.

6. Loosen the locknut at thecrankcase side.

7. Turn the adjusting nut at thecrankcase in direction a toincrease free play or in direc-tion b to decrease free play.

8. Tighten the locknut at thecrankcase and the clutch lever.

1. Locknut2. Adjusting nut

1 2a

b

c

EAU00696

Front brake lever free play adjustmentThe free play at the front brakelever should be 2 ~ 5 mm.

1. Loosen the locknut.2. Turn the adjusting bolt in

direction a to increase freeplay or in direction b todecrease free play.

3. After adjusting, tighten thelocknut.

1. Locknut2. Adjusting boltc. Free play

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8 Check the brake lever freeplay. Be sure the brake isworking properly.

8 A soft or spongy feeling in thebrake lever can indicate thepresence of air in the brakesystem. This air must beremoved by bleeding thebrake system before themotorcycle is operated. Air inthe system will cause greatlydiminished braking capabilityand can result in loss of con-trol and an accident. Have aYamaha dealer inspect andbleed the system if necessary.

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Free playThe rear brake pedal free playshould be adjusted to 20 ~ 30 mmat the brake pedal end. Turn theadjusting nut on the brake rod indirection a to increase free play orin direction b to decrease freeplay.

1. Adjusting nut

1

a

b


EAU01199

Rear brake pedal height and free play adjustment

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It is advisable to have a Yamahadealer make this adjustment.

Pedal heightThe brake pedal should be posi-tioned so that its top end isapproximately 60 mm above thetop of the footrest.

1. Footresta. Pedal height: 60 mmb. Free play 1. Loosen the locknut.

2. Turn the adjusting bolt indirection a to raise pedalheight or in direction b tolower pedal height.

3. Tighten the locknut.

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After adjusting the pedal height,adjust brake pedal free play.

1. Locknut2. Adjusting bolt

1 2

ba1

ab

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8 Brake pedal free play shouldbe checked whenever thechain is adjusted or the rearwheel is removed and thenreinstalled.

8 Check the operation of thebrake light after adjusting therear brake.

8 If it is impossible to makeproper adjustment, consult aYamaha dealer.

EAU00713

Brake light switch adjustmentThe rear brake light switch is acti-vated by the brake pedal and isproperly adjusted when the brakelight comes on just before brakingtakes effect. To adjust the rearbrake light switch, hold the switchbody so it does not rotate whileturning the adjusting nut.Turn the adjusting nut in directiona to make the brake light come onearlier.Turn the adjusting nut in directionb to make the brake light come onlater.

1. Brake light switch2. Adjusting nut

1

2a

b

EAU00720

Checking the front brake pads and rear brake shoes

EAU00725

Front brakeA wear indicator groove is provid-ed on each brake pad. This indica-tor allows checking of brake padwear without disassembling thebrake. Inspect the groove. If thegroove has almost disappeared,ask a Yamaha dealer to replace thepads.

1. Indicator groove

1

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8 Use only the designated quali-ty brake fluid. Otherwise, therubber seals may deteriorate,causing leakage and poorbrake performance.

NOTE:If DOT 4 is not available, DOT 3 canbe used.

8 Refill with the same type ofbrake fluid. Mixing fluids mayresult in a harmful chemicalreaction and lead to poorbrake performance.

8 Be careful that water does notenter the master cylinder whenrefilling. Water will significant-ly lower the boiling point ofthe fluid and may result invapor lock.

Recommended brake fluid: DOT 4


EAU00727

Rear brakeApply the brake and inspect thewear indicator.If the indicator reaches the wearlimit line, ask a Yamaha dealer toreplace the shoes.

1. Wear limit line2. Wear indicator

EAU00732

Inspecting the brake fluid levelInsufficient brake fluid may let airenter the brake system, possiblycausing the brakes to become inef-fective.Before riding, check that the brakefluid is above the minimum leveland fill when necessary.Observe these precautions:8 When checking the fluid level,

make sure the top of the mas-ter cylinder is level by turningthe handlebars.

1. Minimum level mark

1

2 1

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8 Brake fluid may deterioratepainted surfaces or plasticparts. Always clean up spilledfluid immediately.

8 Have a Yamaha dealer checkthe cause if the brake fluidlevel goes down.

EAU00742

Brake fluid replacementThe brake fluid should be replacedonly by trained Yamaha servicepersonnel. Have the Yamaha deal-er replace the following compo-nents during periodic maintenanceor when they are damaged or leak-ing:8 oil seals (every two years)8 brake hoses (every four years) EAU00744

Drive chain slack check

NOTE:Spin the wheel several times andfind the tightest position of thechain. Check and/or adjust thechain slack while its in this tightestposition.

To check the chain slack the motor-cycle must be held straight up withboth wheels on the ground andwithout rider. Check the slack atthe position shown in the illustra-tion. Normal slack is approximately30 ~ 40 mm. If the slack exceeds 40 mm, adjust.

a. Chain slack

a

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To tighten the chain, turn thechain adjusting nuts in direc-tion a. To loosen the chain,turn the chain adjusting nuts indirection b and push thewheel forward. Turn eachchain adjusting nut exactly thesame amount to maintain cor-rect axle alignment. There aremarks on each side of theswingarm. Use these marks toalign the rear wheel.

EC000096

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Too little chain slack will overloadthe engine and other vital parts.Keep the slack within the specifiedlimits.

5. After adjusting, be sure totighten each chain adjustinglocknut. Then tighten the axlenut to the specified torque.

Tightening torque:Axle nut:

105 Nm (10.5 mkg)


EAU00750

Drive chain slack adjustment1. Loosen the rear brake pedal

free play adjusting nut.

1. Rear brake pedal free play adjusting nut

2. Remove the cotter pin fromthe axle nut.

3. Loosen the axle nut.4. Loosen the chain adjusting

locknuts on each side of theswingarm.

1. Cotter pin2. Alignment marks3. Locknut4. Chain adjusting nut5. Axle nut

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7. Adjust the free play in thebrake pedal.

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Check the operation of the brakelight after adjusting the rear brake.

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6. Insert a new cotter pin into theaxle nut and bend the end ofthe cotter pin as shown. If thenotch in the axle nut and thecotter pin hole do not match,tighten the nut slightly to alignthem.

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Always use a new cotter pin onthe axle nut.

1. Cotter pin

EAU00769

Drive chain lubricationThe chain consists of many partswhich work with each other. If thechain is not maintained properly, itwill wear out quickly. Therefore,the chain must be serviced regular-ly. This service is especially neces-sary when riding in dusty areas.This motorcycle is equipped with asealed type chain. Steam cleaning,high-pressure washes, and sol-vents can damage chain so do notuse these for cleaning it. Use onlykerosene to clean the drive chain.Wipe it dry, and thoroughly lubri-cate it with SAE 30 ~ 50W motoroil. Do not use any other lubricantson the drive chain. They may con-tain solvents that could damagethe sealed chain.

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EAU00773

Throttle cable and grip lubricationThe throttle twist grip assemblyshould be greased at the time thatthe cable is lubricated, since thegrip must be removed to get at theend of the throttle cable. Afterremoving the screws, hold the endof the cable up in the air and put inseveral drops of lubricant. With thethrottle grip disassembled, coat themetal surface of the grip assemblywith a suitable all-purpose grease.


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Be sure to oil the chain after wash-ing the motorcycle or riding in therain.

EAU02962

Cable inspection and lubrication

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Damage to the outer housing ofcables may lead to internal rustingand interfere with the cable move-ment. Replace damaged cables assoon as possible to prevent unsafeconditions.

Lubricate the cables and cable ends.If a cable does not operate smooth-ly, ask a Yamaha dealer to replace it.

Recommended lubricant:Engine oil

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EAU02984

Brake and shift pedal lubricationLubricate the pivoting parts.

EAU02985

Brake and clutch lever lubricationLubricate the pivoting parts.



EAU02986

Sidestand lubricationLubricate the sidestand pivotingpoint and metal-to-metal contactsurfaces. Check that the sidestandmoves up and down smoothly.

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If the sidestand does not movesmoothly, consult a Yamaha deal-er.


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EAU00794

Steering inspectionPeriodically inspect the conditionof the steering. Worn out or loosesteering bearings may be danger-ous. Place a stand under theengine to raise the front wheel offthe ground. Hold the lower end ofthe front forks and try to movethem forward and backward. If anyfree play can be felt, ask a Yamahadealer to inspect and adjust thesteering. Inspection is easier if thefront wheel is removed.


Operation check1. Place the motorcycle on a level

place.2. Hold the motorcycle in an

upright position and apply thefront brake.

3. Push down hard on the han-dlebars several times andcheck if the fork reboundssmoothly.

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If any damage or unsmooth move-ment is found with the front fork,consult a Yamaha dealer.

EAU02939

Front fork inspectionVisual check

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Securely support the motorcycleso there is no danger of it fallingover.

Check for scratches or damage onthe inner tube and excessive oilleakage from the front fork.

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Securely support the motorcycleso there is no danger of it fallingover.

EAU01144

Wheel bearingsIf there is play in the front or rearwheel hub or if the wheel does notturn smoothly, have a Yamahadealer inspect the wheel bearings.

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2

EAU01071

BatteryCheck the level of the battery elec-trolyte and make sure that the ter-minals are tight.Fill with distilled water if the elec-trolyte level is low.

1. Battery2. Battery breather hose

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LOWER LEVEL

UPPER LEVEL

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Replenishing the battery fluidA poorly maintained battery willcorrode and discharge quickly. Thebattery fluid should be checked atleast once a month. The levelshould be between the minimumlevel and maximum level marks.Use only distilled water if refillingis necessary.

1. Maximum level mark2. Minimum level mark


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When inspecting the battery, besure the breather hose is routedcorrectly. If the breather hose ispositioned in such a way as tocause battery electrolyte or gas toexit onto the frame, structural andcosmetic damage to the motorcy-cle can occur.

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Battery electrolyte is poisonousand dangerous, causing severeburns, etc. It contains sulfuric acid.Avoid contact with skin, eyes orclothing.ANTIDOTE:8 EXTERNAL: Flush with water.8 INTERNAL: Drink large quanti-

ties of water or milk. Followwith milk of magnesia, beatenegg, or vegetable oil. Call aphysician immediately.

8 EYES: Flush with water for 15minutes and get prompt med-ical attention.

Batteries produce explosive gases.Keep sparks, flame, cigarettes etc.,away. Ventilate when charging orusing in an enclosed space.Always shield your eyes whenworking near batteries.KEEP OUT OF REACH OF CHIL-DREN.

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Normal tap water contains miner-als which are harmful to a battery;therefore, refill only with distilledwater.

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Take care not to spill battery fluidon the chain. Battery fluid mayweaken the chain causing shorterchain life and possibly result in anaccident.

Battery storage8 When the motorcycle will not

be used for a month or longer,remove the battery, fullycharge it and store it in a cool,dry place. Completely rechargethe battery before reinstalla-tion.

8 If the battery will be stored forlonger than two months, checkthe specific gravity of the fluidat least once a month and fullyrecharge the battery when it istoo low.

8 Always make sure the connec-tions are correct when puttingthe battery back in the motor-cycle. Make sure the breatherhose is properly connectedand is not damaged orobstructed.

EAU01073

Fuse replacementThe fuse cases are located underthe rider seat.If a fuse is blown, turn off the mainswitch and the switch of the circuitin question. Install a new fuse ofspecified amperage. Turn on theswitches and see if the electricaldevice operates. If the fuse imme-diately blows again, consult aYamaha dealer.

1. Main fuse2. Signaling system fuse

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2

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2. Remove the connectors, theheadlight unit and then thebulb cover.

1. Bulb cover2. Connector ( 2)

1 2


EAU00833

Headlight bulb replacementThis motorcycle is equipped with aquartz bulb headlight.If the headlight bulb burns out,replace the bulb as follows:

1. Remove the headlight unitscrews.

1. Screw ( 2)

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Do not use fuses of higher amper-age rating than those recommend-ed. Substitution of a fuse ofimproper rating can cause exten-sive electrical system damage andpossibly a fire.

1

Specified fuses:Main fuse: 20ASignaling system fuse: 10A

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3. Turn the bulb holder counter-clockwise to remove it andremove the defective bulb.

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Keep flammable products and yourhands away from a bulb while it ison, as it is hot. Do not touch a bulbuntil it cools down.

4. Put a new bulb into positionand secure it in place with thebulb holder.

1. Bulb holder

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Avoid touching the glass part of abulb. Keep it free from oil; other-wise, the transparency of theglass, life of the bulb, and lumi-nous flux will be adversely affect-ed. If oil gets on a bulb, thoroughlyclean it with a cloth moistenedwith alcohol or lacquer thinner.

5. Install the bulb cover, connec-tors and headlight unit.Ask a Yamaha dealer to adjustthe headlight beam if neces-sary.

1. Dont touch

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1

EAU03010

Turn signal light bulb replacement

1. Remove the screws and thelens.

1. Screw ( 2)

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2. Remove the defective bulb bypushing it inward and turningit counterclockwise.

3. Install a new bulb by pushingit inward and turning it clock-wise.

4. Install the lense and tightenthe screws.

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Do not over-tighten the screws asthe lens may break.

1. Bulb


1

2. Remove the defective bulb bypushing it inward and turningit counterclockwise.

3. Install a new bulb by pushingit inward and turning it clock-wise.

4. Install the lens and tighten thescrews.

1. Bulb

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EAU01623

Taillight bulb replacement1. Remove the screws and the

lense.

1. Screw ( 2)

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EAU00862

Supporting the motorcycleSince the Yamaha XV125S has nocenterstand, follow these precau-tions when removing the front andrear wheel or performing othermaintenance requiring the motor-cycle to stand upright.

Front wheel serviceTo stabilize the rear of the motor-cycle, either use a motorcyclestand or place a motorcycle jackunder the frame in front of the rearwheel to prevent it from movingfrom side to side. Then use amotorcycle stand to elevate thefront wheel off of the ground.

Rear wheel serviceUse a motorcycle stand or motor-cycle jack to elevate the motorcycleso the rear wheel is off the ground.Alternatively, two jacks can beplaced under the frame orswingarm.Check that the motorcycle is in astable and level position beforestarting any maintenance. A strongwooden box can be placed underthe engine for added stability.

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EAU00894

Front wheel removalEW000122

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8 It is advisable to have aYamaha dealer service thewheel.

8 Securely support the motorcy-cle so there is no danger of itfalling over.

1. Remove the speedometercable from the front wheelside.

1. Speedometer cable

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3. Make sure the slot in thespeedometer gear unit fitsover the stopper on the frontfork outer tube.

4. Install the wheel axle and letthe motorcycle down.


2. Loosen the pinch bolt andwheel axle.

3. Elevate the front wheel byplacing a suitable stand underthe engine.

4. Remove the wheel axle andthe front wheel.

NOTE:Do not depress the brake leverwhen the disc and caliper are sepa-rated.

1. Pinch bolt2. Wheel axle

EAU01547

Front wheel installation1. Install the speedometer gear

unit into the wheel hub. Makesure the wheel hub and thespeedometer gear unit hous-ing are installed with the pro-jections meshed into the slots.

2. Lift up the wheel between thefront fork legs and guide thebrake disc between the brakepads. Make sure there isenough gap between the brakepads before inserting the brakedisc.

2

1

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5. Push down hard on the han-dlebars several times to checkfor proper fork operation.

6. Tightening the wheel axle tothe specified torque.

7. Install the pinch bolts andtighten them to the specifiedtorque.

8. Install the speedometer cable.

EAU01550

Rear wheel removalEW000122

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8 It is advisable to have aYamaha dealer service thewheel.

8 Securely support the motorcy-cle so there is no danger of itfalling over.

1. Remove the axle nut cotter pinand brake torque rod cotterpin.

Tightening torque:Wheel axle:

59 Nm (5.9 mkg)Pinch bolt:

20 Nm (2.0 mkg)

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4 2

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2. Loosen the axle nut and braketorque nut.

3. Elevate the rear wheel by plac-ing a suitable stand under theengine.

4. Remove the brake torque rodnut and bolt from the brakeshoe plate.

1. Brake torque rod2. Brake torque rod cotter pin3. Brake torque rod nut4. Brake rod5. Rear brake pedal free play adjusting nut

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7. Adjust the rear brake pedalheight and free play. (See page6-21.)

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Check the operation of the brakelight after adjusting the rear brake.


EAU01696

Rear wheel installation1. Install the rear wheel and the

axle.2. Install the axle nut and let the

motorcycle down.3. Insert the brake rod into the

brake cam lever and install thebrake pedal free play adjustingnut.

4. Install the brake torque rodbolt and tighten to the speci-fied tightening torque. Theninstall a new cotter pin.

5. Adjust the drive chain freeplay. (See page 6-25.)

6. Tighten the axle nut to thespecified tightening torque.

Specified torque:Brake torque rod bolt:

23 Nm (2.3 mkg)

Specified torque:Axle nut:

105 Nm (10.5 mkg)

4 35

1 2

5. Remove the rear brake pedalfree play adjusting nut andbrake rod from the brake camlever.

6. Loosen the locknuts and chainadjusting nuts on each side.

7. Remove the axle nut.8. Pull out the wheel axle and

remove the wheel assembly.

1. Cotter pin2. Alignment marks3. Locknut4. Chain adjusting nut5. Axle nut

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EAU01008

TroubleshootingAlthough Yamaha motorcyclesreceive a rigid inspection beforeshipment from the factory, troublemay occur during operation.Any problem in the fuel, compres-sion, or ignition systems can causepoor starting and loss of power.The troubleshooting chartdescribes a quick, easy procedurefor making checks.If your motorcycle requires anyrepair, bring it to a Yamaha dealer.The skilled technicians at aYamaha dealership have the tools,experience, and know-how toproperly service your motorcycle.Use only genuine Yamaha parts onyour motorcycle. Imitation partsmay look like Yamaha parts, butthey are often inferior.Consequently, they have a shorterservice life and can lead to expen-sive repair bills.

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EAU01562

Troubleshooting chartEW000125

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Never check the fuel system while smoking or in the vicinity of an open flame.

1. Fuel

2. Compression

3. Ignition

4. Battery

Remove spark

There is compression. Go to ignition check.

No compression. Ask a Yamaha dealer to inspect.

Wet.

Dry.

Wipe clean with dry cloth and correct Open throttle half-way and start the

Ask a Yamaha dealer to inspect.

Engine turns over

Engine turns over

Battery good.

Check fluid, recharge,

Check if there is fuel

Enough fuel.

No fuel.

Go to compression check.

Supply fuel.

in the fuel tank

electrode.plugs and check

quickly.

slowly. check connections.

Engine doesnt start, go to batterycheck.

engine.plug gap or replace spark plugs.

Engine doesnt start, ask aYamaha dealer to inspect.

Engine doesnt start, go to compression check.

Use the electric starter.

Use the electric starter.

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EAU01517

MOTORCYCLE CARE AND STORAGE

7-1

CareThe exposure of its technologymakes a motorcycle charming butalso vulnerable. Although high-quality components are used, theyare not all rust-resistant. While arusty exhaust pipe may remainunnoticed on a car, it does lookunattractive on a motorcycle.Frequent and proper care, howev-er, will keep your motorcycle look-ing good, extend its life and main-tain its performance. Moreover, thewarranty states that the vehiclemust be properly taken care of. Forall these reasons, it is recommend-ed that you observe the followingcleaning and storing precautions.

Before cleaning1. Cover up the muffler outlets

with plastic bags.2. Make sure that all caps and

covers as well as all electricalcouplers and connectors,including the spark plug caps,are tightly installed.

3. Remove extremely stubborndirt, like oil burnt onto thecrankcase, with a degreasingagent and a brush, but neverapply such products ontoseals, gaskets, sprockets, thedrive chain and wheel axles.Always rinse the dirt anddegreaser off with water.

CleaningAfter normal useRemove dirt with warm water, aneutral detergent and a soft cleansponge, then rinse with plenty ofclean water. Use a tooth or bottlebrush for hard-to-reach parts.Tougher dirt and insects will comeoff more easily if the area is cov-ered with a wet cloth for a fewminutes before cleaning.

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8 Avoid using strong acidicwheel cleaners, especially onspoked wheels. If you do usesuch products for hard-to-remove dirt, do not leave it onany longer than instructed,then thoroughly rinse it offwith water, immediately drythe area and apply a corrosionprotection spray.

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8 Improper cleaning can damagewindshields, cowlings, panelsand other plastic parts. Useonly a soft, clean cloth orsponge with mild detergentand water to clean plastic.

8 Do not use any harsh chemicalproducts on plastic parts. Besure to avoid using cloths orsponges which have been incontact with strong or abra-sive cleaning products, solventor thinner, fuel (gasoline), rustremovers or inhibitors, brakefluid, antifreeze or electrolyte.

8 Do not use high-pressurewashers or steam-jet cleanerssince they cause water seep-age and deterioration in thefollowing areas: seals (ofwheel bearings, swingarmbearings, forks and brakes),electric components (couplers,connectors, instruments,switches and lights), breatherhoses and vents.

8 For motorcycles equippedwith a windshield: Do not usestrong cleaners or hardsponges as they will causedulling or scratching. Somecleaning compounds for plas-tic may leave scratches on thewindshield. Test the producton a small hidden part of thewindshield to make sure theydo not leave any marks. If thewindshield is scratched, use aquality plastic polishing com-pound after washing.

After riding in the rain, near thesea or on salt-sprayed roadsSince sea salt or salt sprayed onthe roads in the winter areextremely corrosive in combina-tion with water, carry out the fol-lowing steps after each ride in therain, near the sea or on salt-sprayed roads. (Salt sprayed in thewinter may remain on the roadswell into spring.)

1. Clean your motorcycle withcold water and soap after theengine has cooled down.

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Do not use warm water since itincreases the corrosive action ofthe salt.

2. Be sure to apply a corrosionprotection spray on all (evenchrome- and nickel-plated)metal surfaces to prevent cor-rosion.

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7-3

After cleaning1. Dry the motorcycle with a

chamois or an absorbing cloth.2. Immediately dry the drive

chain and lubricate it to pre-vent it from rusting.

3. Use a chrome polish to shinechrome, aluminum and stain-less-steel parts, including theexhaust system. (Even thethermally induced discoloringof stainless-steel exhaust sys-tems can be removed throughpolishing.)

4. To prevent corrosion, it is rec-ommended to apply a corro-sion protection spray on all(even chrome- and nickel-plat-ed) metal surfaces.

5. Use spray oil as a universalcleaner to remove any remain-ing dirt.

6. Touch up minor paint damagecaused by stones, etc.

7. Wax all painted surfaces.8. Let the motorcycle dry com-

pletely before storing it or cov-ering it.

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Make sure that there is no oil orwax on the brakes and tires. If nec-essary, clean the brake discs andlinings with a regular brake disccleaner or acetone, and wash thetires with warm water and mildsoap. Then, carefully test themotorcycle for its braking perfor-mance and cornering behavior.

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8 Apply spray oil and wax spar-ingly and wipe off any excess.

8 Never apply oil or wax on rub-ber and plastic parts, but treatthem with a suitable careproduct.

8 Avoid using abrasive polishingcompounds as they wearaway the paint.

NOTE:Consult a Yamaha dealer foradvice on what products to use.

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StorageShort-termAlways store your motorcycle in acool, dry place and, if necessary,protect it against dust with aporous cover.

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8 Storing the motorcycle in apoorly ventilated room or cov-ering it with a tarp while it isstill wet will allow water andhumidity to seep in and causerust.

8 To prevent corrosion, avoiddamp cellars, stables (becauseof the presence of ammonia)and areas where strong chem-icals are stored.

Long-termBefore storing your motorcycle forseveral months:

1. Follow all the instructions inthe Care section of thischapter.

2. Drain the carburetor floatchambers by loosening thedrain bolts; this will preventfuel deposits from building up.Pour the drained fuel into thefuel tank.

3. Only for motorcycles equippedwith a fuel cock which has anOFF position: Turn the fuelcock to OFF.

4. Fill up the fuel tank and addfuel stabilizer (if available) toprevent the fuel tank from rust-ing and the fuel from deterio-rating.

5. Perform the following steps toprotect the cylinders, pistonrings, etc. from corrosion.

a. Remove the spark plug capsand spark plugs.

b. Pour a teaspoonful of engineoil into each spark plug bore.

c. Install the spark plug caps ontothe spark plugs and place thespark plugs on the cylinderhead so that the electrodes aregrounded. (This will limitsparking during the next step.)

d. Turn the engine over severaltimes with the starter. (Thiswill coat the cylinder wallswith oil.)

e. Remove the spark plug capsfrom the spark plugs, installthe spark plugs and then thespark plug caps.

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When turning the engine over, besure to ground the spark plug elec-trodes to prevent damage or injuryfrom sparking.

6. Lubricate all control cables andthe pivoting points of all leversand pedals as well as of thesidestand/centerstand.

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7. Check and, if necessary, cor-rect the tire air pressure, thenraise the motorcycle so thatboth of its wheels are off theground. Alternatively, turn thewheels a little every month inorder to prevent the tires frombecoming degraded in onespot.

8. Cover up the muffler outletswith plastic bags to preventmoisture

Yamaha Virago XV125 Utmutato

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