OWNER’S MANUAL XV125S YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 99·6– 0.
5AJ-9-E3 (XV125S)<3.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 1 INTRODUCTION EAU00001 Welcome to the Yamaha world of motorcycling! 1 As the owner of a XV125S, you are benefiting from Yamaha’s vast experience in and newest technology for the design and the manufacture of high-quality products, which have earned Yamaha a reputation for dependability. 2 Please take the time to read this manual thoroughly, so as to enjoy all your XV125S’s advantages.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 2 IMPORTANT MANUAL INFORMATION EAU00005 Particularly important information is distinguished in this manual by the following notations: 1 The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Q 2 3 4 w Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator, a bystander or a person inspecting or repairing the motorcycle.
AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 3 IMPORTANT MANUAL INFORMATION w EW000002 PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 4 1 2 3 4 5 6 7 8 9 EAU00008 XV125S OWNER’S MANUAL ©1999 by Yamaha Motor Co., Ltd. 1st Edition, June 1999 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 5 EAU00009 1 2 3 TABLE OF CONTENTS GIVE SAFETY THE RIGHT OF WAY ..................1-1 DESCRIPTION .....................................................2-1 Left view............................................................2-1 Right view .........................................................2-2 Controls/Instruments .......................................2-3 INSTRUMENT AND CONTROL FUNCTIONS........................................................
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 6 TABLE OF CONTENTS 1 2 3 4 5 6 7 8 9 Carburetor adjustment ..................................6-15 Idle speed adjustment ...................................6-15 Throttle cable free play adjustment..............6-16 Valve clearance adjustment ..........................6-16 Tires.................................................................6-17 Wheels ............................................................6-19 Clutch lever free play adjustment.............
5AJ-9-E3 (XV125S)<3.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 8 Q GIVE SAFETY THE RIGHT OF WAY 1 2 3 4 5 6 7 8 EAU00021 Motorcycles are fascinating vehicles, which can give you an unsurpassed feeling of power and freedom. However, they also impose certain limits, which you must accept; even the best motorcycle does not ignore the laws of physics. Regular care and maintenance are essential for preserving your motorcycle’s value and operating condition.
5AJ-9-E3 (XV125S)<3.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 10 EAU00026 DESCRIPTION Left view 1 2 4 3 5 6 1 2 3 4 5 6 7 8 9 8 1. 2. 3. 4. 5. Headlight Steering lock Fuel cock Main switch Fuses 7 (page 6-33) (page 3-8) (page 3-7) (page 3-1) (page 6-32) 6. Helmet holder (page 3-9) 7. Rear shock absorber spring preload adjusting ring (page 3-10) 8.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 11 DESCRIPTION Right view 9 10 1 2 3 4 5 6 7 14 9. 10. 11. 12. 13. Battery Air filter Rear brake pedal Oil filter Tool kit 12 13 (page 6-30) (page 6-12) (page 3-5, 6-21) (page 6-9) (page 6-1) 11 14.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 12 DESCRIPTION Controls/Instruments 15 1 16 17 18 19 2 3 4 5 6 7 21 8 9 15. 16. 17. 18. 19. Clutch lever Left handlebar switches Speedometer Right handlebar switches Front brake lever (page 3-4, 6-19) (page 3-2) (page 3-2) (page 3-3) (page 3-4, 6-20) 20. Throttle grip 21.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 13 EAU00027 INSTRUMENT AND CONTROL FUNCTIONS EAU00054 P (Parking) The taillight and auxiliary light come on but all other circuits are off. With the key at “OFF”, push it into the main switch, turn it counterclockwise to “P”, and remove it. To cancel the parking, turn the key clockwise. ON OFF P 1 2 1 2 3 3 1. High beam indicator light “&” 2. Neutral indicator light “N” 3.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 14 INSTRUMENT AND CONTROL FUNCTIONS 3 1 1 2 2 NOTE: (for German model equipped with speed limiter only) This motorcycle is equipped with a speed limiter which prevents it from exceeding a top speed of 80 km/h. 1 2 3 4 3 4 1. Odometer 2. Trip odometer 3. Reset knob 5 Speedometer 6 7 8 9 1. 2. 3. 4. EAU01087 Pass switch “&” Dimmer switch Turn signal switch Horn switch “*” EAU00118 Handlebar switches The speedometer shows riding speed.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 15 INSTRUMENT AND CONTROL FUNCTIONS EAU00127 EAU00138 Turn signal switch To signal a right-hand turn, push the switch to “6”. To signal a lefthand turn, push the switch to “4”. Once the switch is released it will return to the center position. To cancel the signal, push the switch in after it has returned to the center position.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 16 INSTRUMENT AND CONTROL FUNCTIONS 5 4 3 2 N 1 1 2 1 3 4 EAU00152 Clutch lever 5 6 7 8 9 The clutch lever is located on the left handlebar, and the ignition circuit cut-off system is incorporated in the clutch lever holder. Pull the clutch lever to the handlebar to disengage the clutch, and release the lever to engage the clutch. The lever should be pulled rapidly and released slowly for smooth clutch operation.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 17 INSTRUMENT AND CONTROL FUNCTIONS NOTE: This tank cap cannot be closed unless the key is in the lock. The key cannot be removed if the cap is not locked properly. 1 w 1. Open EAU00162 EAU00167 Rear brake pedal Fuel tank cap The rear brake pedal is on the right side of the motorcycle. Press down on the brake pedal to apply the rear brake. To open Insert the key and turn it 1/4 turn clockwise. The lock will be released and the cap can be opened.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 18 INSTRUMENT AND CONTROL FUNCTIONS 1 EAU00185 cC 2 Always wipe off spilled fuel immediately with a dry and clean soft cloth. Fuel may deteriorate painted surfaces or plastic parts. 1 2 3 4 1. Filler tube 2. Fuel level EAU00191 Recommended fuel: Regular unleaded gasoline with a research octane number of 91 or higher. Fuel tank capacity: Total: 9.5 L Reserve: 2.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 19 INSTRUMENT AND CONTROL FUNCTIONS ON RES 1 1 NOTE: The fuel cock operates on vacuum from the engine when set at “ON” or “RES”. If the line connecting the cock to the carburetor intake manifold is not connected or has a leak, the cock will not function properly. 1 2 3 1. Arrow mark pointing to “ON” 1. Arrow mark pointing to “RES” EAU00208 Fuel cock The negative pressure fuel cock supplies fuel from the tank to the carburetor while filtering it also.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 20 INSTRUMENT AND CONTROL FUNCTIONS PRI 1 2 1 a 1 4 5 6 7 8 1 b 3 1. Arrow mark pointing to “PRI” PRI This indicates prime. With the lever in this position, fuel flows whether the engine is running or not. If the fuel tank is completely empty, refill the tank and move the lever to “PRI” to prime the carburetor. Move the lever to “ON” after starting the engine. 1. Starter (choke) “1” 1.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 21 INSTRUMENT AND CONTROL FUNCTIONS 1 1 2 2 1 2 1 3 1. Bolt (×2) EAU03020 Seat To remove 1. Remove panels A and B. (See page 6-6 for panel removal and installation procedures.) 2. Remove the rider seat bolts and lift the seat upward. 1. Projection 2. Seat holder 1. Helmet holder 2. Open To install 1. Insert the projection on the front of the rider seat into the seat holder, then tighten the seat bolts. 2. Install the panels.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 22 INSTRUMENT AND CONTROL FUNCTIONS 1 2 3 4 5 b 1 a 2 1 5 6 7 8 9 Standard 1 2 EAU00330 Hard 3 4 Sidestand 5 EW000040 w Always adjust each shock absorber to the same setting. Uneven adjustment can cause poor handling and loss of stability. 3 4 Adjusting position Soft 1. Position indicator EAU00300 Rear shock absorber adjustment Each shock absorber is equipped with a spring preload adjusting ring. Adjust spring preload as follows.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 23 INSTRUMENT AND CONTROL FUNCTIONS w EW000044 This motorcycle must not be operated with the sidestand in the down position. If the stand is not properly retracted, it could contact the ground and distract the operator, resulting in a possible loss of control. Yamaha has designed into this motorcycle a lockout system to assist the operator in fulfilling the responsibility of retracting the sidestand.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 24 EAU01114 PRE-OPERATION CHECKS 1 Owners are personally responsible for their vehicle’s condition. Your motorcycle’s vital functions can start to deteriorate 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.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 25 PRE-OPERATION CHECKS ITEM Sidestand pivot Chassis fasteners Fuel tank 9 9 9 9 9 9 CHECKS Check for smooth operation. Lubricate if necessary. Make sure that all nuts, bolts, and screws are properly tightened. Tighten if necessary. Check fuel level. Fill with fuel if necessary. PAGE 6-28 — 3-5 ~ 3-6 Lights, signals and switches 9 Check for proper operation. 6-33 ~ 6-35 Battery 9 Check fluid level. 9 Fill with distilled water if necessary.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 26 OPERATION AND IMPORTANT RIDING POINTS w 1 2 3 4 5 6 7 8 9 EAU00373 8 Before riding this motorcycle, become thoroughly familiar with all operating controls and their functions. Consult a Yamaha dealer regarding any control or function that you do not thoroughly understand. 8 Never start your engine or let it run for any length of time in a closed area. The exhaust fumes are poisonous and can cause loss of consciousness and death within a short time.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 27 OPERATION AND IMPORTANT RIDING POINTS TURN THE MAIN SWITCH TO “ON” AND THE ENGINE STOP SWITCH TO “#”. 1 IF THE TRANSMISSION IS IN NEUTRAL AND THE SIDESTAND IS DOWN, IF THE TRANSMISSION IS IN GEAR AND THE SIDESTAND IS UP, PUSH START SWITCH. THE ENGINE WILL START. PULL IN THE CLUTCH LEVER AND PUSH THE START SWITCH. THE ENGINE WILL START. RETRACT THE SIDESTAND AND PUT THE TRANSMISSION IN GEAR. 2 3 4 5 THE MOTORCYCLE CAN BE RIDDEN.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 28 OPERATION AND IMPORTANT RIDING POINTS 1 2 1 3 4 5 6 7 8 9 NOTE: If the engine fails to start, release the start switch, wait a few seconds, then try again. Each attempt should be as short as possible to preserve the battery. Do not crank the engine more than 10 seconds on any one attempt. 1. Arrow mark pointing to “ON” 1. Turn the fuel cock to “ON”. 2. Turn the main switch to “ON” and the engine stop switch to “#”. 3. Shift the transmission into neutral.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 29 OPERATION AND IMPORTANT RIDING POINTS EC000048 cC 5 4 3 2 N 1 1 N. Neutral 1. Shift pedal EAU00423 Shifting The transmission lets you control the amount of power you have available at a given speed for starting, accelerating, climbing hills, etc. The use of the shift pedal is shown in the illustration. To shift into neutral, depress the shift pedal repeatedly until it reaches the end of its travel, then raise the pedal slightly.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 30 OPERATION AND IMPORTANT RIDING POINTS EAU00424 Tips for reducing fuel consumption 1 2 3 4 5 6 7 8 9 Your motorcycle’s fuel consumption depends to a large extent on your riding style. The following tips can help reduce fuel consumption: 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 acceleration.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 31 OPERATION AND IMPORTANT RIDING POINTS 1,000 km and beyond Avoid prolonged full throttle operation. Vary speeds occasionally. cC EC000049 If any engine trouble should occur during the break-in period, consult a Yamaha dealer immediately. EAU00460 Parking When parking the motorcycle, stop the engine and remove the ignition key. EW000058 w The exhaust system is hot.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 32 EAU00462 PERIODIC MAINTENANCE AND MINOR REPAIR EAU00464 1 2 3 4 5 6 7 8 9 Periodic inspection, adjustment and lubrication will keep your motorcycle in the safest and most efficient condition possible. Safety is an obligation of the motorcycle owner. The maintenance and lubrication schedule chart should be considered strictly as a guide to general maintenance and lubrication intervals.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 33 PERIODIC MAINTENANCE AND MINOR REPAIR NOTE: If you do not have necessary tools required during a service operation, take your motorcycle to a Yamaha dealer for service. w 1 2 EW000063 3 Modifications to this motorcycle not approved by Yamaha may cause loss of performance, and render it unsafe for use. Consult a Yamaha dealer before attempting any changes.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 34 PERIODIC MAINTENANCE AND MINOR REPAIR EAU00473 PERIODIC MAINTENANCE AND LUBRICATION 1 No. ITEM CHECKS AND MAINTENANCE JOBS INITIAL 1,000 km 2 3 4 8 9 √ √ 9 Check fuel hoses and vacuum hose for cracks or damage. 9 Replace if necessary. 2 9 Check condition. 9 Clean, regap or replace if necessary. √ √ √ 9 Check valve clearance. 9 Adjust if necessary. √ √ √ 9 Clean or replace if necessary.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 35 PERIODIC MAINTENANCE AND MINOR REPAIR No. ITEM CHECKS AND MAINTENANCE JOBS INITIAL 1,000 km Every 6,000 km or 6 months (Whichever comes first) Every 12,000 km or 12 months (Whichever comes first) 11 * Wheel bearings 9 Check bearing for looseness or damage. 9 Replace if necessary. √ √ 12 * Swingarm 9 Check swingarm pivoting point for play. 9 Correct if necessary.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 36 PERIODIC MAINTENANCE AND MINOR REPAIR No. ITEM CHECKS AND MAINTENANCE JOBS INITIAL 1,000 km Every 6,000 km or 6 months (Whichever comes first) Every 12,000 km or 12 months (Whichever comes first) √ √ √ 1 2 9 Check oil level and vehicle for oil leakage. 9 Correct if necessary. 9 Change. (Warm engine before draining.) 21 Engine oil 22 Engine oil filter element 9 Replace.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 37 PERIODIC MAINTENANCE AND MINOR REPAIR 1 1 1 2 3 1. Panel A 1. Panel B EAU01122 EAU01156 Panel removal and installation 4 Panel A To remove Pull outward on the rear of the panel, then slide it forward to unhook it in the front. The panels illustrated need to be removed to perform some of the maintenance described in this chapter. Refer to this section each time a panel has to be removed or reinstalled.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 38 PERIODIC MAINTENANCE AND MINOR REPAIR 1 1 2 1 2 3 5 6 3 4 3 4 4 2 1. 2. 3. 4. Holder (×2) Bracket (×2) Grommet Projection To install Hook the front of the panel on the holders, then push inward on the rear of the panel. EAU01156 Panel B To remove Pull outward on the rear of the panel, then slide it forward to unhook it in the front. 7 8 9 6-7 1. 2. 3. 4.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 39 PERIODIC MAINTENANCE AND MINOR REPAIR 1 1 1. Spark plug cap 1. Spark plug wrench EAU03053 Spark plugs Removal 1. Remove the spark plug caps. 2. Use the spark plug wrench in the tool kit to remove the spark plugs as shown. Inspection The spark plug is an important engine component and is easy to inspect. The condition of the spark plug can indicate the condition of the engine.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 40 PERIODIC MAINTENANCE AND MINOR REPAIR 1 2 a 3 4 5 6 7 8 9 NOTE: If a torque wrench is not available when you are installing a spark plug, a good estimate of the correct torque is 1/4 to 1/2 turn past finger tight. Have the spark plug tightened to the specified torque as soon as possible. a. Spark plug gap Installation 1. Measure the electrode gap with a wire thickness gauge and, if necessary, adjust the gap to specification. 4.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 41 PERIODIC MAINTENANCE AND MINOR REPAIR 2. With the engine stopped, check the oil level through the level window located at the lower part of the right side crankcase cover. 1 2 NOTE: Wait a few minutes until the oil level settles before checking. 1 1 1. Oil filler cap 3. The oil level should be between maximum level and minimum level marks. If the level is low, fill engine with sufficient oil to raise it to the specified level. 1.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 42 PERIODIC MAINTENANCE AND MINOR REPAIR 2 1 1 7. Install the new oil filter, new Oring and the oil filter cover. Tighten the oil filter cover bolts to the specified torque. 1 2 Tightening torque: Oil filter cover bolt: 10 Nm (1.0 m·kg) 3 4 5 6 7 8 1. Oil filter cover bolt (×3) 4. Remove the oil filter cover bolts and the oil filter cover. 1. Oil filter 2. O-ring 5. Remove the oil filter and Oring. 6.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 43 PERIODIC MAINTENANCE AND MINOR REPAIR 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 cC 9. Start the engine and warm up for a few minutes. While warming up, check for oil leakage. If oil leakage is found, stop the engine immediately and check for the cause. 10. Stop the engine and check the oil level. 3 1 2 2 1 3 1. Bolt 2. Air filter cover 3.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 44 PERIODIC MAINTENANCE AND MINOR REPAIR 1 1 1 1 2 3 4 5 1. Bolt (×2) 1. Remove the bolts and the air filter case. 1. Hose (×2) 1. Screw (×2) 2. Remove the hoses from the air filter case. 6 7 8 9 6-13 3. Remove the screws and the air filter cover.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 45 PERIODIC MAINTENANCE AND MINOR REPAIR 1 2 1 2 7. Pull the element over its frame, install the air filter in the case and tighten the wing nut. 8. Install the air filter cover. 9. Connect the hoses and install the air filter case. 1 2 3 1. Wing nut 2. Air filter 4. Remove the wing nut and the air filter. cC 1. Foam element 2. Frame 5. Remove the foam element from its frame and clean it with solvent.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 46 PERIODIC MAINTENANCE AND MINOR REPAIR EAU00629 Carburetor adjustment 4 The carburetor is a vital part of the engine and requires very sophisticated adjustment. Most adjustments should be left to a Yamaha dealer who has the professional knowledge and experience to do so. However, the following may be serviced by the owner as part of routine maintenance.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 47 PERIODIC MAINTENANCE AND MINOR REPAIR EAU00637 Free play: 3 ~ 5 mm b a Valve clearance adjustment 1. Loosen the locknut. 2. Turn the adjusting nut in direction a to increase free play and in direction b to decrease free play. 3. Tighten the locknut. c 1 2 1. Adjusting nut 2. Locknut c. Free play The correct valve clearance changes with use, resulting in improper fuel/air supply or engine noise.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 48 PERIODIC MAINTENANCE AND MINOR REPAIR EAU00647 Tires 1 2 3 4 5 6 7 8 9 To ensure maximum performance, long service, and safe operation, note the following: Tire air pressure Always check and adjust the tire pressure before operating the motorcycle. w Maximum load* Cold tire pressure 183 kg Front Rear Up to 90 kg 175 kPa 200 kPa (1.75 kg/cm2, (2.0 kg/cm2, 1.75 bar) 2.00 bar) 90 kg load ~ Maximum load* 200 kPa 225 kPa (2.0 kg/cm2, (2.25 kg/cm2, 2.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 49 PERIODIC MAINTENANCE AND MINOR REPAIR FRONT a Manufacturer CHENG SHIN Size Type 3.00-18 47P C-916 REAR 1 Manufacturer CHENG SHIN Size Type 130/90-15M/C 66P C-915 Minimum tire tread depth (front and rear) 1. Side wall a. Tread depth Tire inspection Always check the tires before operating the motorcycle.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 50 PERIODIC MAINTENANCE AND MINOR REPAIR EAU00685 Wheels 1 2 3 4 5 6 7 8 9 To 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 the wheel. Be sure the spokes are tight and undamaged. If any abnormal condition exists in a wheel, consult a Yamaha dealer. Do not attempt even small repairs to the wheel.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 51 PERIODIC MAINTENANCE AND MINOR REPAIR 1 a 1 2 2 c a b b 1. Locknut 2. Adjusting nut 4. Loosen the locknut at the clutch lever. 5. Turn the adjusting bolt at the clutch lever in direction a to loosen the cable. 6. Loosen the locknut at the crankcase side. 7. Turn the adjusting nut at the crankcase in direction a to increase free play or in direction b to decrease free play. 8. Tighten the locknut at the crankcase and the clutch lever. 1. Locknut 2.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 52 PERIODIC MAINTENANCE AND MINOR REPAIR 1 1 2 a 2 1 b a 1 a b b 3 4 5 6 7 1. Footrest a. Pedal height: 60 mm b. Free play 1. Locknut 2. Adjusting bolt EAU01199 Rear brake pedal height and free play adjustment w EW000104 It is advisable to have a Yamaha dealer make this adjustment. 8 9 Pedal height The brake pedal should be positioned so that its top end is approximately 60 mm above the top of the footrest. 1. Adjusting nut 1.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 53 PERIODIC MAINTENANCE AND MINOR REPAIR w EW000106 8 Brake pedal free play should be checked whenever the chain is adjusted or the rear wheel is removed and then reinstalled. 8 Check the operation of the brake light after adjusting the rear brake. 8 If it is impossible to make proper adjustment, consult a Yamaha dealer. 1 1 1 a b 2 2 3 1. Brake light switch 2. Adjusting nut 1.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 54 PERIODIC MAINTENANCE AND MINOR REPAIR 8 Use only the designated quality brake fluid. Otherwise, the rubber seals may deteriorate, causing leakage and poor brake performance. 1 2 1 1 2 Recommended brake fluid: DOT 4 3 4 1. Wear limit line 2. Wear indicator 1. Minimum level mark EAU00732 EAU00727 5 6 7 8 9 Rear brake Apply the brake and inspect the wear indicator. If the indicator reaches the wear limit line, ask a Yamaha dealer to replace the shoes.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 55 PERIODIC MAINTENANCE AND MINOR REPAIR 8 Brake fluid may deteriorate painted surfaces or plastic parts. Always clean up spilled fluid immediately. 8 Have a Yamaha dealer check the cause if the brake fluid level goes down. EAU00742 Brake fluid replacement The brake fluid should be replaced only by trained Yamaha service personnel.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 56 PERIODIC MAINTENANCE AND MINOR REPAIR 1 2 1 b 2 a 1 5 4 3 3 4 1. Rear brake pedal free play adjusting nut EAU00750 Drive chain slack adjustment 5 6 7 8 1. Loosen the rear brake pedal free play adjusting nut. 1. 2. 3. 4. 5. Cotter pin Alignment marks Locknut Chain adjusting nut Axle nut 2. Remove the cotter pin from the axle nut. 3. Loosen the axle nut. 4. Loosen the chain adjusting locknuts on each side of the swingarm.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 57 PERIODIC MAINTENANCE AND MINOR REPAIR 7. Adjust the free play in the brake pedal. EW000103 w Check the operation of the brake light after adjusting the rear brake. 1 1. Cotter pin 6. Insert a new cotter pin into the axle nut and bend the end of the cotter pin as shown. If the notch in the axle nut and the cotter pin hole do not match, tighten the nut slightly to align them. w EW000110 Always use a new cotter pin on the axle nut.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 58 PERIODIC MAINTENANCE AND MINOR REPAIR cC 1 EC000097 EAU00773 Throttle cable and grip lubrication Be sure to oil the chain after washing the motorcycle or riding in the rain. 2 3 4 5 6 7 8 EAU02962 Cable inspection and lubrication EW000112 w Damage to the outer housing of cables may lead to internal rusting and interfere with the cable movement. Replace damaged cables as soon as possible to prevent unsafe conditions.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 59 PERIODIC MAINTENANCE AND MINOR REPAIR 1 2 3 EAU02984 EAU02985 Brake and shift pedal lubrication Brake and clutch lever lubrication Lubricate the pivoting parts. Lubricate the pivoting parts. Recommended lubricant: Engine oil Recommended lubricant: Engine oil EAU02986 Sidestand lubrication Lubricate the sidestand pivoting point and metal-to-metal contact surfaces. Check that the sidestand moves up and down smoothly.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 60 PERIODIC MAINTENANCE AND MINOR REPAIR EAU02939 Front fork inspection Visual check 1 2 3 4 5 6 7 8 9 w EW000115 Securely support the motorcycle so there is no danger of it falling over. Check for scratches or damage on the inner tube and excessive oil leakage from the front fork. Operation check 1. Place the motorcycle on a level place. 2. Hold the motorcycle in an upright position and apply the front brake. 3.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 61 PERIODIC MAINTENANCE AND MINOR REPAIR w EW000115 Securely support the motorcycle so there is no danger of it falling over. EAU01144 1 Wheel bearings If there is play in the front or rear wheel hub or if the wheel does not turn smoothly, have a Yamaha dealer inspect the wheel bearings. 1 2 2 3 1. Battery 2. Battery breather hose 4 EAU01071 Battery Check the level of the battery electrolyte and make sure that the terminals are tight.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 62 PERIODIC MAINTENANCE AND MINOR REPAIR cC 1 2 3 4 5 6 7 8 9 EC000099 When inspecting the battery, be sure the breather hose is routed correctly. If the breather hose is positioned in such a way as to cause battery electrolyte or gas to exit onto the frame, structural and cosmetic damage to the motorcycle can occur. EW000116 w Battery electrolyte is poisonous and dangerous, causing severe burns, etc. It contains sulfuric acid.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 63 PERIODIC MAINTENANCE AND MINOR REPAIR cC EC000100 Normal tap water contains minerals which are harmful to a battery; therefore, refill only with distilled water. w EW000117 Take care not to spill battery fluid on the chain. Battery fluid may weaken the chain causing shorter chain life and possibly result in an accident.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 64 PERIODIC MAINTENANCE AND MINOR REPAIR cC 1 2 3 4 5 6 7 EC000103 Do not use fuses of higher amperage rating than those recommended. Substitution of a fuse of improper rating can cause extensive electrical system damage and possibly a fire. 1 1 1. Screw (×2) Specified fuses: Main fuse: 20A Signaling system fuse: 10A 2 EAU00833 Headlight bulb replacement This motorcycle is equipped with a quartz bulb headlight.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 65 PERIODIC MAINTENANCE AND MINOR REPAIR 1 1 1 1 3 1. Bulb holder 1. Don’t touch 3. Turn the bulb holder counterclockwise to remove it and remove the defective bulb. w 2 EW000119 Keep flammable products and your hands away from a bulb while it is on, as it is hot. Do not touch a bulb until it cools down. 1. Screw (×2) EC000105 cC Avoid touching the glass part of a bulb.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 66 PERIODIC MAINTENANCE AND MINOR REPAIR 1 1 1 2 1 3 4 5 6 7 1. Bulb 2. Remove the defective bulb by pushing it inward and turning it counterclockwise. 3. Install a new bulb by pushing it inward and turning it clockwise. 4. Install the lens and tighten the screws. 1. Screw (×2) 1. Bulb EAU01623 Taillight bulb replacement 1. Remove the screws and the lense. 8 2. Remove the defective bulb by pushing it inward and turning it counterclockwise. 3.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 67 PERIODIC MAINTENANCE AND MINOR REPAIR EAU00862 Supporting the motorcycle Since the Yamaha XV125S has no centerstand, follow these precautions when removing the front and rear wheel or performing other maintenance requiring the motorcycle to stand upright. Front wheel service To stabilize the rear of the motorcycle, either use a motorcycle stand or place a motorcycle jack under the frame in front of the rear wheel to prevent it from moving from side to side.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 68 PERIODIC MAINTENANCE AND MINOR REPAIR 1 2 2 1 3 4 5 6 7 8 9 1. Pinch bolt 2. Wheel axle 2. Loosen the pinch bolt and wheel axle. 3. Elevate the front wheel by placing a suitable stand under the engine. 4. Remove the wheel axle and the front wheel. NOTE: Do not depress the brake lever when the disc and caliper are separated. EAU01547 Front wheel installation 1. Install the speedometer gear unit into the wheel hub.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 69 PERIODIC MAINTENANCE AND MINOR REPAIR 5. Push down hard on the handlebars several times to check for proper fork operation. 6. Tightening the wheel axle to the specified torque. 7. Install the pinch bolts and tighten them to the specified torque. Tightening torque: Wheel axle: 59 Nm (5.9 m·kg) Pinch bolt: 20 Nm (2.0 m·kg) EAU01550 Rear wheel removal EW000122 w 5 8 It is advisable to have a Yamaha dealer service the wheel.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 70 PERIODIC MAINTENANCE AND MINOR REPAIR EAU01696 1 Rear wheel installation 2 1 2 5 4 3 3 4 5 6 7 8 9 1. 2. 3. 4. 5. Cotter pin Alignment marks Locknut Chain adjusting nut Axle nut 5. Remove the rear brake pedal free play adjusting nut and brake rod from the brake cam lever. 6. Loosen the locknuts and chain adjusting nuts on each side. 7. Remove the axle nut. 8. Pull out the wheel axle and remove the wheel assembly. 1.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 71 PERIODIC MAINTENANCE AND MINOR REPAIR EAU01008 Troubleshooting Although Yamaha motorcycles receive a rigid inspection before shipment from the factory, trouble may occur during operation. Any problem in the fuel, compression, or ignition systems can cause poor starting and loss of power. The troubleshooting chart describes a quick, easy procedure for making checks. If your motorcycle requires any repair, bring it to a Yamaha dealer.
5AJ-9-E3 (XV125S)<3.1E> 4/14/00 12:23 PM Page 72 PERIODIC MAINTENANCE AND MINOR REPAIR EAU01562 Troubleshooting chart 1 EW000125 w Never check the fuel system while smoking or in the vicinity of an open flame. 2 3 1. Fuel Supply fuel. Engine doesn’t start, go to compression check. There is compression. Go to ignition check. No compression. Ask a Yamaha dealer to inspect. Use the electric starter. 3. Ignition Remove spark plugs and check electrode. 8 9 No fuel. 2.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 73 EAU01517 Care The exposure of its technology makes a motorcycle charming but also vulnerable. Although highquality components are used, they are not all rust-resistant. While a rusty exhaust pipe may remain unnoticed on a car, it does look unattractive on a motorcycle. Frequent and proper care, however, will keep your motorcycle looking good, extend its life and maintain its performance.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 74 MOTORCYCLE CARE AND STORAGE 1 2 3 4 5 6 7 8 9 8 Improper cleaning can damage windshields, cowlings, panels and other plastic parts. Use only a soft, clean cloth or sponge with mild detergent and water to clean plastic. 8 Do not use any harsh chemical products on plastic parts.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 75 MOTORCYCLE CARE AND STORAGE After cleaning 1. Dry the motorcycle with a chamois or an absorbing cloth. 2. Immediately dry the drive chain and lubricate it to prevent it from rusting. 3. Use a chrome polish to shine chrome, aluminum and stainless-steel parts, including the exhaust system. (Even the thermally induced discoloring of stainless-steel exhaust systems can be removed through polishing.) 4.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 76 MOTORCYCLE CARE AND STORAGE Storage 2 Short-term Always store your motorcycle in a cool, dry place and, if necessary, protect it against dust with a porous cover. 3 cC 1 4 5 6 7 8 9 ECA00014 8 Storing the motorcycle in a poorly ventilated room or covering it with a tarp while it is still wet will allow water and humidity to seep in and cause rust.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 77 MOTORCYCLE CARE AND STORAGE 7. Check and, if necessary, correct the tire air pressure, then raise the motorcycle so that both of its wheels are off the ground. Alternatively, turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot. 8. Cover up the muffler outlets with plastic bags to prevent moisture from entering. 9. Remove the battery and fully charge it. Store it in a cool, dry place and recharge it once a month.
5AJ-9-E3 (XV125S)<3.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 79 SPECIFICATIONS Fuel 1st 2.643 Regular unleaded gasoline 2nd 1.684 Fuel tank capacity 9.5 L 3rd 1.261 Reserve amount 2.6 L 4th 1.000 5th 0.821 Type Gear ratio Carburetor Type/quantity BDS26/1 Manufacturer MIKUNI Gap Clutch type NGK / CR6HSA or DENSO / U20FSR-U Frame type Double cradle Caster angle 32° Trail 120 mm Type Wet, multiple-disc Primary reduction ratio 3.400 With tube Front Transmission Spur gear 3 4 5 Tire 0.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 80 SPECIFICATIONS 1 Maximum load* 183 kg Rear Air pressure (cold tire) up to 90 kg load* 2 3 175 kPa (1.75 kg/cm2, 1.75 bar) Rear 200 kPa (2.00 kg/cm2, 2.00 bar) Front 200 kPa (2.00 kg/cm2, 2.00 bar) Rear 225 kPa (2.25 kg/cm2, 2.25 bar) 7 Size 18 × 1.6 9 Type Spoke wheel Size 15 M/C × MT 2.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 81 SPECIFICATIONS Bulb voltage, wattage × quantity Headlight 1 12 V, 60 W/55 W × 1 Tail/brake light 12 V, 5 W/21 W × 1 Flasher light 12 V, 21 W × 4 Auxiliary light 12 V, 4 W × 1 (except for GB) 12 V , 3.4 W × 1 (for GB) Meter light 12 V, 1.7 W × 1 Neutral indicator light 12 V, 1.7 W × 1 High beam indicator light 12 V, 1.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 82 SPECIFICATIONS EAU01064 HOW TO USE THE CONVERSION TABLE 2 All specification data in this manual are listed in SI and METRIC UNITS. Use this table to convert METRIC unit data to IMPERIAL unit data. 3 Ex. 1 CONVERSION TABLE METRIC TO IMPERIAL Metric unit Multiplier Imperial unit Torque m • kg m • kg cm • kg cm • kg 7.233 86.794 0.0723 0.8679 ft • lb in• lb ft • lb in • lb Weight kg g 2.205 0.03527 lb oz Speed km/hr 0.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 83 EAU01039 CONSUMER INFORMATION EAU02944 Identification number records Record the key identification number, vehicle identification number and model label information in the spaces provided for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen. 1. KEY IDENTIFICATION NUMBER: 2. VEHICLE IDENTIFICATION NUMBER: 1 1 1 2 3 1. Key identification number 1.
5AJ-9-E3 (XV125S)<3.1E> 4/5/0 5:01 PM Page 84 CONSUMER INFORMATION 1 1 2 3 4 1. Model label EAU01050 Model label 5 6 7 8 The model label is affixed to the frame under the seat. (See page 3-9 for seat removal procedures.) Record the information on this label in the space provided. This information will be needed to order spare parts from your Yamaha dealer.
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OWNER’S MANUAL XV125S YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 99·6– 0.
