OWNER’S MANUAL XVS250 YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2003.07-0.
5KRE2.
5KRE2.book Page 1 Monday, June 23, 2003 3:32 PM INTRODUCTION EAU10100 Welcome to the Yamaha world of motorcycling! As the owner of the XVS250, you are benefiting from Yamaha’s vast experience and newest technology regarding the design and manufacture of high-quality products, which have earned Yamaha a reputation for dependability. Please take the time to read this manual thoroughly, so as to enjoy all advantages of your XVS250.
5KRE2.book Page 1 Monday, June 23, 2003 3:32 PM IMPORTANT MANUAL INFORMATION EAU10150 Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! WARNING 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.
KRE2.book Page 2 Monday, June 23, 2003 3:32 PM IMPORTANT MANUAL INFORMATION EAU10200 XVS250 OWNER’S MANUAL ©2003 by Yamaha Motor Co., Ltd. 1st edition, May 2003 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan.
5KRE2.book Page 1 Monday, June 23, 2003 3:32 PM TABLE OF CONTENTS SAFETY INFORMATION ..................1-1 DESCRIPTION ..................................2-1 Left view ..........................................2-1 Right view ........................................2-2 Controls and instruments.................2-3 INSTRUMENT AND CONTROL FUNCTIONS .......................................3-1 Main switch/steering lock ................3-1 Indicator and warning lights ............3-2 Speedometer unit ..............
5KRE2.book Page 2 Monday, June 23, 2003 3:32 PM TABLE OF CONTENTS Front wheel ...................................6-32 Rear wheel ...................................6-33 Troubleshooting ............................6-35 Troubleshooting chart ...................6-36 MOTORCYCLE CARE AND STORAGE ..........................................7-1 Care ................................................7-1 Storage ...........................................7-3 SPECIFICATIONS .............................
5KRE2.book Page 1 Monday, June 23, 2003 3:32 PM SAFETY INFORMATION EAU10250 1 MOTORCYCLES ARE SINGLE TRACK VEHICLES. THEIR SAFE USE AND OPERATION ARE DEPENDENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EXPERTISE OF THE OPERATOR. EVERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIREMENTS BEFORE RIDING THIS MOTORCYCLE. HE OR SHE SHOULD: ● OBTAIN THOROUGH INSTRUCTIONS FROM A COMPETENT SOURCE ON ALL ASPECTS OF MOTORCYCLE OPERATION.
5KRE2.book Page 2 Monday, June 23, 2003 3:32 PM SAFETY INFORMATION ● ● wide on a turn due to EXCESSIVE SPEED or undercornering (insufficient lean angle for the speed). • Always obey the speed limit and never travel faster than warranted by road and traffic conditions. • Always signal before turning or changing lanes. Make sure that other motorists can see you. The posture of the operator and passenger is important for proper control.
5KRE2.book Page 3 Monday, June 23, 2003 3:32 PM SAFETY INFORMATION 1 Loading The total weight of the operator, passenger, accessories and cargo must not exceed the maximum load limit of 180 kg (397 lb). When loading within this weight limit, keep the following in mind: ● Cargo and accessory weight should be kept as low and close to the motorcycle as possible. Make sure to distribute the weight as evenly as possible on both sides of the motorcycle to minimize imbalance or instability.
5KRE2.book Page 4 Monday, June 23, 2003 3:32 PM SAFETY INFORMATION Gasoline and exhaust gas ● GASOLINE IS HIGHLY FLAMMABLE: • Always turn the engine off when refueling. • Take care not to spill any gasoline on the engine or exhaust system when refueling. • Never refuel while smoking or in the vicinity of an open flame. ● Never start the engine or let it run for any length of time in a closed area. The exhaust fumes are poisonous and may cause loss of consciousness and death within a short time.
5KRE2.book Page 1 Monday, June 23, 2003 3:32 PM DESCRIPTION EAU10410 Left view 2 1. 2. 3. 4. 5. 6.
5KRE2.book Page 2 Monday, June 23, 2003 3:32 PM DESCRIPTION EAU10420 Right view 2 1. 2. 3. 4. 5. 6. 7. 8.
5KRE2.book Page 3 Monday, June 23, 2003 3:32 PM DESCRIPTION EAU10430 Controls and instruments 2 1. 2. 3. 4. 5. 6. 7.
5KRE2.book Page 1 Monday, June 23, 2003 3:32 PM INSTRUMENT AND CONTROL FUNCTIONS EAU10460 Main switch/steering lock EAU10680 LOCK The steering is locked, and all electrical systems are off. The key can be removed. To unlock the steering To lock the steering 3 1. Push. 2. Turn. The main switch/steering lock controls the ignition and lighting systems, and is used to lock the steering. The various positions are described below.
5KRE2.book Page 2 Monday, June 23, 2003 3:32 PM INSTRUMENT AND CONTROL FUNCTIONS EAU10880 (Parking) The steering is locked, and the taillight and auxiliary light are on, but all other electrical systems are off. The key can be removed. The steering must be locked before the key can be turned to “ ”. 3 EAU11001 Indicator and warning lights EAU11500 ECA11020 CAUTION: Do not use the parking position for an extended length of time, otherwise the battery may discharge.
5KRE2.book Page 3 Monday, June 23, 2003 3:32 PM INSTRUMENT AND CONTROL FUNCTIONS EAU11630 Speedometer unit EAU12090 Anti-theft alarm (optional) This model is equipped with a self-diagnosis device for various electrical circuits. If any of those circuits are defective, the engine trouble warning light will come on or flash. If this occurs, have a Yamaha dealer check the vehicle. This model can be equipped with an optional anti-theft alarm by a Yamaha dealer.
5KRE2.book Page 4 Monday, June 23, 2003 3:32 PM INSTRUMENT AND CONTROL FUNCTIONS EAU12342 Handlebar switches position. To cancel the turn signal lights, push the switch in after it has returned to the center position. Right Left EAU12500 Horn switch “ ” Press this switch to sound the horn. EAU12590 3 1. 2. 3. 4. Pass switch “ ” Dimmer switch “ / ” Turn signal switch “ / ” Horn switch “ ” 1. Engine stop switch “ 2. Light switch “ / 3.
5KRE2.book Page 5 Monday, June 23, 2003 3:32 PM INSTRUMENT AND CONTROL FUNCTIONS ECA10050 CAUTION: EAU12820 Clutch lever EAU12870 Shift pedal See page 5-1 for starting instructions prior to starting the engine. 3 1. Clutch lever 1. Shift pedal The clutch lever is located at the left handlebar grip. To disengage the clutch, pull the lever toward the handlebar grip. To engage the clutch, release the lever. The lever should be pulled rapidly and released slowly for smooth clutch operation.
5KRE2.book Page 6 Monday, June 23, 2003 3:32 PM INSTRUMENT AND CONTROL FUNCTIONS EAU12890 EAU12941 EAU13000 Brake lever Brake pedal Fuel tank cap 1. Brake lever 1. Brake pedal 1. Unlock. The brake lever is located at the right handlebar grip. To apply the front brake, pull the lever toward the handlebar grip. The brake pedal is on the right side of the motorcycle. To apply the rear brake, press down on the brake pedal.
5KRE2.book Page 7 Monday, June 23, 2003 3:32 PM INSTRUMENT AND CONTROL FUNCTIONS EAU13210 NOTE: The fuel tank cap cannot be installed unless the key is in the lock. In addition, the key cannot be removed if the cap is not properly installed and locked. Fuel ECA10070 CAUTION: Immediately wipe off spilled fuel with a clean, dry, soft cloth, since fuel may deteriorate painted surfaces or plastic parts. EWA11140 WARNING EAU13320 Make sure that the fuel tank cap is properly installed before riding. 1.
5KRE2.book Page 8 Monday, June 23, 2003 3:32 PM INSTRUMENT AND CONTROL FUNCTIONS or premium unleaded fuel. Use of unleaded fuel will extend spark plug life and reduce maintenance costs. 3 EAU13580 Fuel cock RES This model is equipped with a negative pressure fuel cock. The fuel cock supplies fuel from the tank to the carburetor while also filtering it. The fuel cock lever positions are explained as follows and shown in the illustrations. ON 1. Pointed end positioned over “RES” 1.
5KRE2.book Page 9 Monday, June 23, 2003 3:32 PM INSTRUMENT AND CONTROL FUNCTIONS PRI EAU13590 Starter (choke) lever “ ” EAU14281 Helmet holder 3 1. Pointed end positioned over “PRI” 1. Starter (choke) lever “ This indicates prime. With the fuel cock lever in this position, the engine can be “primed”. Turn the fuel cock lever to this position when the engine has been allowed to run out of fuel. This sends fuel directly to the carburetor, which will make starting easier.
5KRE2.book Page 10 Monday, June 23, 2003 3:32 PM INSTRUMENT AND CONTROL FUNCTIONS EAU14880 Adjusting the shock absorber assemblies 3 1. Spring preload adjusting ring 2. Position indicator Each shock absorber assembly is equipped with a spring preload adjusting ring. ECA10100 CAUTION: Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings.
5KRE2.book Page 11 Monday, June 23, 2003 3:32 PM INSTRUMENT AND CONTROL FUNCTIONS below and have a Yamaha dealer repair it if it does not function properly. EAU15311 Ignition circuit cut-off system The ignition circuit cut-off system (comprising the sidestand switch, clutch switch and neutral switch) has the following functions. ● It prevents starting when the transmission is in gear and the sidestand is up, but the clutch lever is not pulled.
5KRE2.book Page 12 Monday, June 23, 2003 3:32 PM INSTRUMENT AND CONTROL FUNCTIONS With the engine turned off: 1. Move the sidestand down. 2. Make sure that the engine stop switch is turned on. 3. Turn the key on. 4. Shift the transmission into the neutral position. 5. Push the start switch. Does the engine start? NOTE: This check is most reliable if performed with a warmed-up engine. 3 YES NO The neutral switch may be defective. The motorcycle should not be ridden until checked by a Yamaha dealer.
5KRE2.book Page 1 Monday, June 23, 2003 3:32 PM PRE-OPERATION CHECKS EAU15591 The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly, even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thorough visual inspection, to check the following points before each ride.
5KRE2.book Page 2 Monday, June 23, 2003 3:32 PM PRE-OPERATION CHECKS EAU15601 Pre-operation check list ITEM CHECKS PAGE Fuel • Check fuel level in fuel tank. • Refuel if necessary. • Check fuel line for leakage. 3-7 Engine oil • Check oil level in engine. • If necessary, add recommended oil to specified level. • Check vehicle for oil leakage. 6-8 Front brake • • • • • • • • • Rear brake • Check operation. • Check pedal free play. • Adjust if necessary.
5KRE2.book Page 3 Monday, June 23, 2003 3:32 PM PRE-OPERATION CHECKS ITEM CHECKS PAGE Drive chain • • • • Check chain slack. Adjust if necessary. Check chain condition. Lubricate if necessary. 6-21, 6-22 Wheels and tires • • • • Check for damage. Check tire condition and tread depth. Check air pressure. Correct if necessary. 6-13, 6-15 Brake and shift pedals • Make sure that operation is smooth. • Lubricate pedal pivoting points if necessary.
5KRE2.book Page 1 Monday, June 23, 2003 3:32 PM OPERATION AND IMPORTANT RIDING POINTS EAU15950 EAU16400 Starting a cold engine EWA10270 WARNING ● ● 5 ● Become thoroughly familiar with all operating controls and their functions before riding. Consult a Yamaha dealer regarding any control or function that you do not thoroughly understand. Never start the engine or operate it in a closed area for any length of time.
5KRE2.book Page 2 Monday, June 23, 2003 3:32 PM OPERATION AND IMPORTANT RIDING POINTS after starting, immediately stop the engine, and have a Yamaha dealer check the self-diagnosis system. 6. After starting the engine, move the starter (choke) back halfway. EAU16640 Starting a warm engine EAU16671 Shifting Follow the same procedure as for starting a cold engine with the exception that the starter (choke) is not required when the engine is warm.
5KRE2.book Page 3 Monday, June 23, 2003 3:32 PM OPERATION AND IMPORTANT RIDING POINTS ECA10260 CAUTION: ● 5 ● Even with the transmission in the neutral position, do not coast for long periods of time with the engine off, and do not tow the motorcycle for long distances. The transmission is properly lubricated only when the engine is running. Inadequate lubrication may damage the transmission.
5KRE2.book Page 4 Monday, June 23, 2003 3:32 PM OPERATION AND IMPORTANT RIDING POINTS EAU16841 ECA11281 EAU17200 Engine break-in CAUTION: Parking There is never a more important period in the life of your engine than the period between 0 and 1600 km (1000 mi). For this reason, you should read the following material carefully. Since the engine is brand new, do not put an excessive load on it for the first 1600 km (1000 mi).
5KRE2.book Page 1 Monday, June 23, 2003 3:32 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU17240 EAU17340 Owner’s tool kit 6 Safety is an obligation of the owner. Periodic inspection, adjustment and lubrication will keep your vehicle in the safest and most efficient condition possible. The most important points of inspection, adjustment, and lubrication are explained on the following pages.
5KRE2.book Page 2 Monday, June 23, 2003 3:32 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU17701 Periodic maintenance and lubrication chart NOTE: ● The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead. ● From 50000 km, repeat the maintenance intervals starting from 10000 km. ● Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. ODOMETER READING (× 1000 km) NO.
5KRE2.book Page 3 Monday, June 23, 2003 3:32 PM PERIODIC MAINTENANCE AND MINOR REPAIR ODOMETER READING (× 1000 km) NO. ITEM CHECK OR MAINTENANCE JOB 1 20 30 40 9 * Wheels • Check runout, spoke tightness and for damage. • Tighten spokes if necessary. √ √ √ √ 10 * Tires • • • • √ √ √ √ • Check bearing for looseness or damage. √ √ √ √ • Check operation and for excessive play.
5KRE2.book Page 4 Monday, June 23, 2003 3:32 PM PERIODIC MAINTENANCE AND MINOR REPAIR ODOMETER READING (× 1000 km) NO. ITEM CHECK OR MAINTENANCE JOB 1 22 Engine oil filter element 23 * Engine oil strainer • Replace. √ • Clean. √ √ 24 * Front and rear brake switches • Check operation. 25 Moving parts and cables 26 * Throttle grip housing and cable 27 * Air induction system 10 20 30 √ 40 ANNUAL CHECK √ √ √ √ √ √ • Lubricate. √ √ √ √ √ • Check operation and free play.
5KRE2.book Page 5 Monday, June 23, 2003 3:32 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU18770 Removing and installing panels The panels shown above need to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time a panel needs to be removed and installed. EAU19521 Panel A 1. Panel A To remove the panel 1. Slide the panel lock cover open, insert the key into the lock, and then turn it 1/4 turn clockwise. To install the panel 1.
5KRE2.book Page 6 Monday, June 23, 2003 3:32 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU19161 Panel B To remove the panel 1. Remove the bolt. To install the panel 1. Secure the front of the panel, and then push the rear of the panel in. 2. Install the bolt. EAU19543 Checking the spark plugs The spark plugs are important engine components, which are easy to check.
5KRE2.book Page 7 Monday, June 23, 2003 3:32 PM PERIODIC MAINTENANCE AND MINOR REPAIR 3. Check each spark plug for electrode erosion and excessive carbon or other deposits, and replace it if necessary. Specified spark plug: NGK/CR6HSA DENSO/U20FSR-U 1. Spark plug wrench 6 To check the spark plugs 1. Check that the porcelain insulator around the center electrode on each spark plug is a medium-tolight tan (the ideal color when the vehicle is ridden normally). 2.
5KRE2.book Page 8 Monday, June 23, 2003 3:32 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU19751 Engine oil and oil filter element The engine oil level should be checked before each ride. In addition, the oil must be changed and the oil filter element replaced at the intervals specified in the periodic maintenance and lubrication chart. To check the engine oil level 1. Place the vehicle on a level surface and hold it in an upright position.
5KRE2.book Page 9 Monday, June 23, 2003 3:32 PM PERIODIC MAINTENANCE AND MINOR REPAIR ECA11620 Tightening torque: Oil filter element cover bolt: 10 Nm (1.0 m·kgf, 7.2 ft·lbf) CAUTION: ● NOTE: Make sure that the O-ring is properly seated. 1. Bolt 5. Remove and replace the oil filter element and O-ring. 6 7. Install the engine oil drain bolt, and then tighten it to the specified torque. Tightening torque: Engine oil drain bolt: 34 Nm (3.4 m·kgf, 25 ft·lbf) 8.
5KRE2.book Page 10 Monday, June 23, 2003 3:32 PM PERIODIC MAINTENANCE AND MINOR REPAIR out with compressed air as shown. If the air filter element is damaged, replace it. EAU20660 Cleaning the air filter element The air filter element should be cleaned at the intervals specified in the periodic maintenance and lubrication chart. Clean the air filter element more frequently if you are riding in unusually wet or dusty areas. 1.
5KRE2.book Page 11 Monday, June 23, 2003 3:32 PM PERIODIC MAINTENANCE AND MINOR REPAIR 10. Install the air filter case by inserting the projection into the grommet, installing the bolts, then tightening the clamp screw. 1. Air filter check hose plug 2. Clamp 3. Air filter check hose ECA10480 CAUTION: ● ● The carburetor is an important part of the engine and requires very sophisticated adjustment.
5KRE2.book Page 12 Monday, June 23, 2003 3:32 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU21340 EAU21380 Adjusting the engine idling speed The engine idling speed must be checked and, if necessary, adjusted as follows at the intervals specified in the periodic maintenance and lubrication chart. The engine should be warm before making this adjustment. NOTE: ● The engine is warm when it quickly responds to the throttle. ● A diagnostic tachometer is needed to make this adjustment. 1.
5KRE2.book Page 13 Monday, June 23, 2003 3:32 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU21400 EAU21540 Adjusting the valve clearance Tires The valve clearance changes with use, resulting in improper air-fuel mixture and/or engine noise. To prevent this from occurring, the valve clearance must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart.
5KRE2.book Page 14 Monday, June 23, 2003 3:32 PM PERIODIC MAINTENANCE AND MINOR REPAIR ● ● ● ● passenger, cargo, and accessories does not exceed the specified maximum load for the vehicle. Do not carry along loosely packed items, which can shift during a ride. Securely pack the heaviest items close to the center of the motorcycle and distribute the weight evenly on both sides. Adjust the suspension and tire air pressure with regard to the load.
5KRE2.book Page 15 Monday, June 23, 2003 3:32 PM PERIODIC MAINTENANCE AND MINOR REPAIR EWA10570 ● ● 6 ● EAU21940 WARNING Spoke wheels Have a Yamaha dealer replace excessively worn tires. Besides being illegal, operating the motorcycle with excessively worn tires decreases riding stability and can lead to loss of control. The replacement of all wheeland brake-related parts, including the tires, should be left to a Yamaha dealer, who has the necessary professional knowledge and experience.
5KRE2.book Page 16 Monday, June 23, 2003 3:32 PM PERIODIC MAINTENANCE AND MINOR REPAIR 3. If the specified clutch lever free play could be obtained as described above, tighten the locknut and skip the rest of the procedure, otherwise proceed as follows. 4. Fully turn the adjusting bolt at the clutch lever in direction (a) to loosen the clutch cable. 5. Loosen the locknut at the crankcase. 7. Tighten the locknut at the clutch lever and the crankcase. EAU22092 Adjusting the brake lever free play 1.
5KRE2.book Page 17 Monday, June 23, 2003 3:32 PM PERIODIC MAINTENANCE AND MINOR REPAIR EWA10630 WARNING ● ● 6 After adjusting the brake lever free play, check the free play and make sure that the brake is working properly. A soft or spongy feeling in the brake lever can indicate the presence of air in the hydraulic system. If there is air in the hydraulic system, have a Yamaha dealer bleed the system before operating the motorcycle.
5KRE2.book Page 18 Monday, June 23, 2003 3:32 PM PERIODIC MAINTENANCE AND MINOR REPAIR Brake pedal free play The brake pedal free play should measure 20.0–30.0 mm (0.79–1.18 in) at the brake pedal end. Periodically check the brake pedal free play and, if necessary, adjust it as follows. To increase the brake pedal free play, turn the adjusting nut at the brake rod in direction (a). To decrease the brake pedal free play, turn the adjusting nut in direction (b).
5KRE2.book Page 19 Monday, June 23, 2003 3:32 PM PERIODIC MAINTENANCE AND MINOR REPAIR Checking the front brake pads and rear brake shoes indicator groove has almost disappeared, have a Yamaha dealer replace the brake pads as a set. The front brake pads and the rear brake shoes must be checked for wear at the intervals specified in the periodic maintenance and lubrication chart. Rear brake shoes EAU22380 EAU32341 Checking the brake fluid level Front brake EAU22540 EAU22420 Front brake pads 1.
5KRE2.book Page 20 Monday, June 23, 2003 3:32 PM PERIODIC MAINTENANCE AND MINOR REPAIR ● ● When checking the fluid level, make sure that the top of the master cylinder is level by turning the handlebars. Use only the recommended quality brake fluid, otherwise the rubber seals may deteriorate, causing leakage and poor braking performance. brake fluid level goes down suddenly, have a Yamaha dealer check the cause. Recommended brake fluid: DOT 4 ● ● ● ● Refill with the same type of brake fluid.
5KRE2.book Page 21 Monday, June 23, 2003 3:32 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU22760 Drive chain slack The drive chain slack should be checked before each ride and adjusted if necessary. EAU22770 To check the drive chain slack 1. Place the motorcycle on a level surface and hold it in an upright position. 6 NOTE: When checking and adjusting the drive chain slack, the motorcycle should be positioned straight up and there should be no weight on it. 2.
5KRE2.book Page 22 Monday, June 23, 2003 3:32 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23020 Tightening torques: Locknut: 16 Nm (1.6 m·kgf, 12 ft·lbf) Axle nut: 104 Nm (10.4 m·kgf, 75 ft·lbf) 4. Adjust the brake pedal free play. (See page 6-17.) EWA10660 WARNING 1. Alignment marks 2. Drive chain slack adjusting nut 3.
5KRE2.book Page 23 Monday, June 23, 2003 3:32 PM PERIODIC MAINTENANCE AND MINOR REPAIR ECA11110 CAUTION: Do not use engine oil or any other lubricants for the drive chain, as they may contain substances that could damage the O-rings. EAU23100 Checking and lubricating the throttle grip and cable The operation of all control cables and the condition of the cables should be checked before each ride, and the cables and cable ends should be lubricated if necessary.
5KRE2.book Page 24 Monday, June 23, 2003 3:32 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23131 EAU23140 EAU23200 Checking and lubricating the brake and shift pedals Checking and lubricating the brake and clutch levers Checking and lubricating the sidestand The operation of the brake and shift pedals should be checked before each ride, and the pedal pivots should be lubricated if necessary.
5KRE2.book Page 25 Monday, June 23, 2003 3:32 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23271 EAU23280 Checking the front fork Checking the steering The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart. Worn or loose steering bearings may cause danger. Therefore, the operation of the steering must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart. 1.
5KRE2.book Page 26 Monday, June 23, 2003 3:32 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23290 Checking the wheel bearings EAU23380 Battery The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart. If there is play in the wheel hub or if the wheel does not turn smoothly, have a Yamaha dealer check the wheel bearings. 1. Battery The battery is located behind panel A. (See page 6-5.
5KRE2.book Page 27 Monday, June 23, 2003 3:32 PM PERIODIC MAINTENANCE AND MINOR REPAIR EWA10760 WARNING ● 6 ● Electrolyte is poisonous and dangerous since it contains sulfuric acid, which causes severe burns. Avoid any contact with skin, eyes or clothing and always shield your eyes when working near batteries. In case of contact, administer the following FIRST AID. • EXTERNAL: Flush with plenty of water. • INTERNAL: Drink large quantities of water or milk and immediately call a physician.
5KRE2.book Page 28 Monday, June 23, 2003 3:32 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23550 Replacing the fuses The main fuse and the fuse box, which contains the fuses for the individual circuits, are located behind panel B. (See page 6-5.) EAU23791 Specified fuses: Main fuse: 30.0 A Ignition fuse: 10.0 A Signaling system fuse: 10.0 A Headlight fuse: 15.0 A Carburetor heater fuse: 10.0 A Replacing the headlight bulb This model is equipped with a quartz bulb headlight.
5KRE2.book Page 29 Monday, June 23, 2003 3:32 PM PERIODIC MAINTENANCE AND MINOR REPAIR fected. Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with alcohol or thinner. 1. Headlight coupler 1. Headlight bulb holder EWA10790 WARNING Headlight bulbs get very hot. Therefore, keep flammable products away from a lit headlight bulb, and do not touch the bulb until it has cooled down. 6 1. Headlight bulb cover 3.
5KRE2.book Page 30 Monday, June 23, 2003 3:32 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU24131 EAU24210 Replacing the tail/brake light bulb Replacing a turn signal light bulb 1. Remove the tail/brake light lens by removing the screws. 1. Remove the turn signal lens by removing the screws. 1. Tail/brake light bulb 1. Screw 2. Remove the defective bulb by pushing it in and turning it counterclockwise. 3. Insert a new bulb into the socket, push it in, and then turn it clockwise until it stops. 4.
5KRE2.book Page 31 Monday, June 23, 2003 3:32 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU24350 Supporting the motorcycle 1. Turn signal light bulb 6 3. Insert a new bulb into the socket, push it in, and then turn it clockwise until it stops. 4. Install the lens by installing the screws. ECA10680 CAUTION: Do not overtighten the screws, otherwise the lens may break.
5KRE2.book Page 32 Monday, June 23, 2003 3:32 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU24360 EAU24921 Front wheel To install the front wheel 1. Install the speedometer gear unit into the wheel hub so that the projections mesh with the slots. EAU24660 To remove the front wheel EWA10820 WARNING ● ● It is advisable to have a Yamaha dealer service the wheel. Securely support the motorcycle so that there is no danger of it falling over. 1. Disconnect the speedometer cable from the front wheel. 1.
5KRE2.book Page 33 Monday, June 23, 2003 3:32 PM PERIODIC MAINTENANCE AND MINOR REPAIR 7. Connect the speedometer cable. EAU25080 Rear wheel EAU25430 To remove the rear wheel EWA10820 WARNING ● ● 1. Speedometer gear unit retainer 6 3. Insert the wheel axle. 4. Lower the front wheel so that it is on the ground. 5. Tighten the wheel axle and front wheel axle pinch bolt to the specified torques, and then install the rubber cap. It is advisable to have a Yamaha dealer service the wheel.
5KRE2.book Page 34 Monday, June 23, 2003 3:32 PM PERIODIC MAINTENANCE AND MINOR REPAIR 2. Lift the rear wheel off the ground according to the procedure on page 6-31. 3. Disconnect the brake torque rod from the brake shoe plate by removing the nut and the bolt. 4. Remove the brake pedal free play adjusting nut, and then disconnect the brake rod at the brake camshaft lever. 7. Push the wheel forward, and then remove the drive chain from the rear sprocket.
5KRE2.book Page 35 Monday, June 23, 2003 3:32 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU25850 Troubleshooting 6 Although Yamaha motorcycles receive a thorough inspection before shipment from the factory, trouble may occur during operation. Any problem in the fuel, compression, or ignition systems, for example, can cause poor starting and loss of power. The following troubleshooting chart represents a quick and easy procedure for checking these vital systems yourself.
5KRE2.book Page 36 Monday, June 23, 2003 3:32 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU25891 Troubleshooting chart EWA10840 WARNING Keep away open flames and do not smoke while checking or working on the fuel system. 1. Fuel There is enough fuel. Check the compression. There is no fuel. Supply fuel. There is compression. Check the ignition. There is no compression. Have a Yamaha dealer check the vehicle. Check the fuel level in the fuel tank. The engine does not start. Check the compression.
5KRE2.book Page 1 Monday, June 23, 2003 3:32 PM MOTORCYCLE CARE AND STORAGE ucts onto seals, gaskets, sprockets, the drive chain and wheel axles. Always rinse the dirt and degreaser off with water. EAU26040 Care While the open design of a motorcycle reveals the attractiveness of the technology, it also makes it more vulnerable. Rust and corrosion can develop even if high-quality components are used.
5KRE2.book Page 2 Monday, June 23, 2003 3:32 PM MOTORCYCLE CARE AND STORAGE After normal use Remove dirt with warm water, a mild detergent, and a soft, clean sponge, and then rinse thoroughly with clean water. Use a toothbrush or bottlebrush for hard-to-reach areas. Stubborn dirt and insects will come off more easily if the area is covered with a wet cloth for a few minutes before cleaning.
5KRE2.book Page 3 Monday, June 23, 2003 3:32 PM MOTORCYCLE CARE AND STORAGE ECA10800 CAUTION: ● ● ● Apply spray oil and wax sparingly and make sure to wipe off any excess. Never apply oil or wax to any rubber and plastic parts, but treat them with a suitable care product. Avoid using abrasive polishing compounds as they will wear away the paint. NOTE: Consult a Yamaha dealer for advice on what products to use.
5KRE2.book Page 4 Monday, June 23, 2003 3:32 PM MOTORCYCLE CARE AND STORAGE EWA10950 WARNING To prevent damage or injury from sparking, make sure to ground the spark plug electrodes while turning the engine over. than 30 °C (90 °F)]. For more information on storing the battery, see page 6-26. NOTE: Make any necessary repairs before storing the motorcycle. 6. Lubricate all control cables and the pivoting points of all levers and pedals as well as of the sidestand/centerstand. 7.
5KRE2.book Page 1 Monday, June 23, 2003 3:32 PM SPECIFICATIONS Dimensions: Overall length: 2320 mm (91.3 in) Overall width: 910 mm (35.8 in) Overall height: 1075 mm (42.3 in) Seat height: 670 mm (26.4 in) Wheelbase: 1530 mm (60.2 in) Ground clearance: 150 mm (5.91 in) Minimum turning radius: 2900 mm (114.2 in) Weight: With oil and fuel: 159.0 kg (351 lb) Engine: 8 Engine type: Air cooled 4-stroke, SOHC Cylinder arrangement: V-type 2-cylinder Displacement: 249.0 cm³ (15.19 cu.in) Bore × stroke: 49.
5KRE2.book Page 2 Monday, June 23, 2003 3:32 PM SPECIFICATIONS 3rd: 29/23 (1.261) 4th: 26/26 (1.000) 5th: 23/28 (0.821) Chassis: Frame type: Double cradle Caster angle: 35.0 ° Trail: 135.0 mm (5.
5KRE2.book Page 3 Monday, June 23, 2003 3:32 PM SPECIFICATIONS Bulb voltage, wattage x quantity: Headlight: 12 V, 60 W/55.0 W × 1 Tail/brake light: 12 V, 5 W/21.0 W × 1 Front turn signal light: 12 V, 21.0 W × 2 Rear turn signal light: 12 V, 21.0 W × 2 Auxiliary light: 12 V, 4.0 W × 1 Meter lighting: 12 V, 1.7 W × 1 Neutral indicator light: 12 V, 1.7 W × 1 High beam indicator light: 12 V, 1.7 W × 1 Turn signal indicator light: 12 V, 1.7 W × 1 Engine trouble warning light: 12 V, 1.
5KRE2.book Page 1 Monday, June 23, 2003 3:32 PM CONSUMER INFORMATION EAU26351 Identification numbers EAU26381 EAU26400 Key identification number Vehicle identification number 1. Key identification number 1. Vehicle identification number The key identification number is stamped into the key tag. Record this number in the space provided and use it for reference when ordering a new key. The vehicle identification number is stamped into the steering head pipe. Record this number in the space provided.
5KRE2.book Page 2 Monday, June 23, 2003 3:32 PM CONSUMER INFORMATION EAU26460 Model label 1. Model label The model label is affixed to the location shown. Record the information on this label in the space provided. This information will be needed when ordering spare parts from a Yamaha dealer.
5KRE2.book Page 1 Monday, June 23, 2003 3:32 PM INDEX A F Air filter element, cleaning .................... 6-10 Anti-theft alarm (optional) ....................... 3-3 B Battery .................................................. 6-26 Brake and clutch levers, checking and lubricating .................................... 6-24 Brake and shift pedals, checking and lubricating .................................... 6-24 Brake fluid, changing ............................ 6-20 Brake fluid level, checking ......
5KRE2.book Page 2 Monday, June 23, 2003 3:32 PM INDEX Vehicle identification number .................. 9-1 W Wheel bearings, checking..................... 6-26 Wheel (front) ......................................... 6-32 Wheel (rear) .......................................... 6-33 Wheels ..................................................
5KRE2.
OWNER’S MANUAL XVS250 YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2003.07-0.
