Yamaha XVS250 - Manuals

TABLE OF CONTENTS SAFETY INFORMATION ..................1-1 DESCRIPTION ..................................2-1 Left view ..........................................2-1Right view ........................................2-2Controls and instruments.................2-3 INSTRUMENT AND CONTROL FUNCTIONS .......

TABLE OF CONTENTS Front wheel ................................... 6-32Rear wheel ................................... 6-33Troubleshooting ............................ 6-35Troubleshooting chart ................... 6-36 MOTORCYCLE CARE AND STORAGE .......................................... 7-1 Care ......

1-1 1 SAFETY INFORMATION EAU10250 MOTORCYCLES ARE SINGLETRACK VEHICLES. THEIR SAFE USEAND OPERATION ARE DEPENDENTUPON THE USE OF PROPER RIDINGTECHNIQUES AS WELL AS THE EX-PERTISE OF THE OPERATOR. EV-ERY OPERATOR SHOULD KNOWTHE FOLLOWING REQUIREMENTSBEFORE RIDING THIS MOTOR-CYCLE.HE OR SHE SHOULD: ● ...

SAFETY INFORMATION 1-2 1 wide on a turn due to EXCESSIVESPEED or undercornering (insuffi-cient lean angle for the speed). • Always obey the speed limit and never travel faster than warrant-ed by road and traffic conditions. • Always signal before turning or changing lanes. Make sure thatother motori...

SAFETY INFORMATION 1-3 1 LoadingThe total weight of the operator, pas-senger, accessories and cargo mustnot exceed the maximum load limit of180 kg (397 lb). When loading withinthis weight limit, keep the following inmind: ● Cargo and accessory weightshould be kept as low and close tothe motorcycle a...

SAFETY INFORMATION 1-4 1 Gasoline and exhaust gas ● GASOLINE IS HIGHLY FLAMMA-BLE: • Always turn the engine off when refueling. • Take care not to spill any gaso- line on the engine or exhaustsystem when refueling. • Never refuel while smoking or in the vicinity of an open flame. ● Never start the e...

DESCRIPTION 2-1 2 EAU10410 Left view 1. Headlight (page 6-28)2. Fuel cock (page 3-8) 3. Fuses (page 6-28) 4. Helmet holder (page 3-9)5. Shock absorber assembly spring preload adjusting ring (page 3-10) 6. Shift pedal (page 3-5) 5KRE2.book Page 1 Monday, June 23, 2003 3:32 PM

DESCRIPTION 2-2 2 EAU10420 Right view 1. Owner’s tool kit (page 6-1)2. Battery (page 6-26) 3. Air filter element (page 6-10) 4. Main switch/steering lock (page 3-1)5. Brake pedal (page 3-6) 6. Engine oil filter element (page 6-8) 7. Engine oil level check window (page 6-8)8. Shock absorber assembly ...

DESCRIPTION 2-3 2 EAU10430 Controls and instruments 1. Clutch lever (page 3-5)2. Left handlebar switches (page 3-4) 3. Speedometer unit (page 3-3) 4. Right handlebar switches (page 3-4)5. Brake lever (page 3-6) 6. Throttle grip (page 6-12) 7. Fuel tank cap (page 3-6) 5KRE2.book Page 3 Monday, June 2...

INSTRUMENT AND CONTROL FUNCTIONS 3-1 3 EAU10460 Main switch/steering lock The main switch/steering lock controlsthe ignition and lighting systems, and isused to lock the steering. The variouspositions are described below. EAU10630 ON All electrical systems are supplied withpower, and the engine can ...

INSTRUMENT AND CONTROL FUNCTIONS 3-2 3 EAU10880 (Parking) The steering is locked, and the taillightand auxiliary light are on, but all otherelectrical systems are off. The key canbe removed.The steering must be locked before thekey can be turned to “ ”. CAUTION: ECA11020 Do not use the parking posit...

INSTRUMENT AND CONTROL FUNCTIONS 3-3 3 EAU11630 Speedometer unit The speedometer unit is equipped witha speedometer, an odometer and atripmeter. The speedometer showsriding speed. The odometer shows thetotal distance traveled. The tripmetershows the distance traveled since itwas last set to zero wit...

INSTRUMENT AND CONTROL FUNCTIONS 3-4 3 EAU12342 Handlebar switches Left Right EAU12350 Pass switch “ ” Press this switch to flash the headlight. EAU12400 Dimmer switch “ / ” Set this switch to “ ” for the high beam and to “ ” for the low beam. EAU12460 Turn signal switch “ / ” To signal a right-hand...

INSTRUMENT AND CONTROL FUNCTIONS 3-5 3 CAUTION: ECA10050 See page 5-1 for starting instruc-tions prior to starting the engine. EAU12820 Clutch lever The clutch lever is located at the lefthandlebar grip. To disengage theclutch, pull the lever toward the handle-bar grip. To engage the clutch, release...

INSTRUMENT AND CONTROL FUNCTIONS 3-6 3 EAU12890 Brake lever The brake lever is located at the righthandlebar grip. To apply the frontbrake, pull the lever toward the handle-bar grip. EAU12941 Brake pedal The brake pedal is on the right side ofthe motorcycle. To apply the rearbrake, press down on the...

INSTRUMENT AND CONTROL FUNCTIONS 3-7 3 NOTE: The fuel tank cap cannot be installedunless the key is in the lock. In addition,the key cannot be removed if the cap isnot properly installed and locked. WARNING EWA11140 Make sure that the fuel tank cap isproperly installed before riding. EAU13210 Fuel M...

INSTRUMENT AND CONTROL FUNCTIONS 3-8 3 or premium unleaded fuel. Use of un-leaded fuel will extend spark plug lifeand reduce maintenance costs. EAU13580 Fuel cock This model is equipped with a negativepressure fuel cock. The fuel cock sup-plies fuel from the tank to the carburetorwhile also filterin...

INSTRUMENT AND CONTROL FUNCTIONS 3-9 3 PRI This indicates prime. With the fuel cocklever in this position, the engine can be“primed”. Turn the fuel cock lever to thisposition when the engine has been al-lowed to run out of fuel. This sends fueldirectly to the carburetor, which willmake starting easi...

INSTRUMENT AND CONTROL FUNCTIONS 3-10 3 EAU14880 Adjusting the shock absorber assemblies Each shock absorber assembly isequipped with a spring preload adjust-ing ring. CAUTION: ECA10100 Never attempt to turn an adjustingmechanism beyond the maximum orminimum settings. WARNING EWA10210 Always adjust ...

INSTRUMENT AND CONTROL FUNCTIONS 3-11 3 below and have a Yamaha dealer re-pair it if it does not function proper-ly. EAU15311 Ignition circuit cut-off system The ignition circuit cut-off system (com-prising the sidestand switch, clutchswitch and neutral switch) has the fol-lowing functions. ● It pre...

INSTRUMENT AND CONTROL FUNCTIONS 3-12 3 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? With the engine still running:6...

PRE-OPERATION CHECKS 4-2 4 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...

OPERATION AND IMPORTANT RIDING POINTS 5-1 5 EAU15950 WARNING EWA10270 ● Become thoroughly familiarwith all operating controls andtheir functions before riding.Consult a Yamaha dealer re-garding any control or functionthat you do not thoroughly un-derstand. ● Never start the engine or oper-ate it in ...

OPERATION AND IMPORTANT RIDING POINTS 5-2 5 after starting, immediately stop theengine, and have a Yamaha dealercheck the self-diagnosis system. 6. After starting the engine, move the starter (choke) back halfway. CAUTION: ECA11040 For maximum engine life, never ac-celerate hard when the engine isco...

OPERATION AND IMPORTANT RIDING POINTS 5-4 5 EAU16841 Engine break-in There is never a more important periodin the life of your engine than the periodbetween 0 and 1600 km (1000 mi). Forthis reason, you should read the follow-ing material carefully.Since the engine is brand new, do notput an excessiv...

PERIODIC MAINTENANCE AND MINOR REPAIR 6-1 6 EAU17240 Safety is an obligation of the owner. Pe-riodic inspection, adjustment and lubri-cation will keep your vehicle in thesafest and most efficient condition pos-sible. The most important points of in-spection, adjustment, and lubricationare explained ...

PERIODIC MAINTENANCE AND MINOR REPAIR 6-2 6 EAU17701 Periodic maintenance and lubrication chart NOTE: ● The annual checks must be performed every year, except if a kilometer-based maintenance is performed in-stead. ● From 50000 km, repeat the maintenance intervals starting from 10000 km. ● Items mar...

PERIODIC MAINTENANCE AND MINOR REPAIR 6-4 6 EAU18660 NOTE: ● The air filter needs more frequent service if you are riding in unusually wet or dusty areas. ● Hydraulic brake service • Regularly check and, if necessary, correct the brake fluid level.• Every two years replace the internal components of...

PERIODIC MAINTENANCE AND MINOR REPAIR 6-5 6 EAU18770 Removing and installing panels The panels shown above need to be re-moved to perform some of the mainte-nance jobs described in this chapter.Refer to this section each time a panelneeds to be removed and installed. EAU19521 Panel A To remove the p...

PERIODIC MAINTENANCE AND MINOR REPAIR 6-6 6 EAU19161 Panel B To remove the panel 1. Remove the bolt. 2. Pull the rear of the panel out, and then slide the panel forward to re-lease it in the front. To install the panel 1. Secure the front of the panel, and then push the rear of the panel in. 2. Inst...

PERIODIC MAINTENANCE AND MINOR REPAIR 6-7 6 To check the spark plugs 1. Check that the porcelain insulator around the center electrode oneach spark plug is a medium-to-light tan (the ideal color when thevehicle is ridden normally). 2. Check that all spark plugs installed in the engine have the same ...

PERIODIC MAINTENANCE AND MINOR REPAIR 6-8 6 EAU19751 Engine oil and oil filter element The engine oil level should be checkedbefore each ride. In addition, the oilmust be changed and the oil filter ele-ment replaced at the intervals specifiedin the periodic maintenance and lubri-cation chart. To che...

PERIODIC MAINTENANCE AND MINOR REPAIR 6-9 6 5. Remove and replace the oil filter element and O-ring. 6. Install the oil filter element cover by installing the bolts, then tighteningthem to the specified torque. NOTE: Make sure that the O-ring is properlyseated. 7. Install the engine oil drain bolt, ...

PERIODIC MAINTENANCE AND MINOR REPAIR 6-10 6 EAU20660 Cleaning the air filter element The air filter element should be cleanedat the intervals specified in the periodicmaintenance and lubrication chart.Clean the air filter element more fre-quently if you are riding in unusuallywet or dusty areas. 1....

PERIODIC MAINTENANCE AND MINOR REPAIR 6-11 6 7. Install the plug into the check hose, and then install the clamp. CAUTION: ECA10480 ● Make sure that the air filter ele-ment is properly seated in theair filter case. ● The engine should never be op-erated without the air filter ele-ment installed, oth...

PERIODIC MAINTENANCE AND MINOR REPAIR 6-12 6 EAU21340 Adjusting the engine idling speed The engine idling speed must bechecked and, if necessary, adjusted asfollows at the intervals specified in theperiodic maintenance and lubricationchart.The engine should be warm beforemaking this adjustment. NOTE...

PERIODIC MAINTENANCE AND MINOR REPAIR 6-13 6 EAU21400 Adjusting the valve clearance The valve clearance changes with use,resulting in improper air-fuel mixtureand/or engine noise. To prevent thisfrom occurring, the valve clearancemust be adjusted by a Yamaha dealerat the intervals specified in the p...

PERIODIC MAINTENANCE AND MINOR REPAIR 6-14 6 passenger, cargo, and accesso-ries does not exceed the speci-fied maximum load for thevehicle. ● Do not carry along looselypacked items, which can shiftduring a ride. ● Securely pack the heaviestitems close to the center of themotorcycle and distribute th...

PERIODIC MAINTENANCE AND MINOR REPAIR 6-15 6 WARNING EWA10570 ● Have a Yamaha dealer replaceexcessively worn tires. Besidesbeing illegal, operating themotorcycle with excessivelyworn tires decreases riding sta-bility and can lead to loss ofcontrol. ● The replacement of all wheel-and brake-related pa...

PERIODIC MAINTENANCE AND MINOR REPAIR 6-16 6 3. If the specified clutch lever free play could be obtained as de-scribed above, tighten the locknutand skip the rest of the procedure,otherwise proceed as follows. 4. Fully turn the adjusting bolt at the clutch lever in direction (a) to loos-en the clut...

PERIODIC MAINTENANCE AND MINOR REPAIR 6-17 6 WARNING EWA10630 ● After adjusting the brake leverfree play, check the free playand make sure that the brake isworking properly. ● A soft or spongy feeling in thebrake lever can indicate thepresence of air in the hydraulicsystem. If there is air in the hy...

PERIODIC MAINTENANCE AND MINOR REPAIR 6-18 6 Brake pedal free play The brake pedal free play should mea-sure 20.0–30.0 mm (0.79–1.18 in) atthe brake pedal end. Periodically checkthe brake pedal free play and, if neces-sary, adjust it as follows.To increase the brake pedal free play,turn the adjustin...

PERIODIC MAINTENANCE AND MINOR REPAIR 6-19 6 EAU22380 Checking the front brake pads and rear brake shoes The front brake pads and the rear brakeshoes must be checked for wear at theintervals specified in the periodic main-tenance and lubrication chart. EAU22420 Front brake pads Each front brake pad ...

PERIODIC MAINTENANCE AND MINOR REPAIR 6-20 6 ● When checking the fluid level,make sure that the top of the mas-ter cylinder is level by turning thehandlebars. ● Use only the recommended qualitybrake fluid, otherwise the rubberseals may deteriorate, causingleakage and poor braking perfor-mance. ● Ref...

PERIODIC MAINTENANCE AND MINOR REPAIR 6-21 6 EAU22760 Drive chain slack The drive chain slack should bechecked before each ride and adjustedif necessary. EAU22770 To check the drive chain slack 1. Place the motorcycle on a level surface and hold it in an upright po-sition. NOTE: When checking and ad...

PERIODIC MAINTENANCE AND MINOR REPAIR 6-22 6 CAUTION: ECA10570 Improper drive chain slack will over-load the engine as well as other vitalparts of the motorcycle and can leadto chain slippage or breakage. Toprevent this from occurring, keepthe drive chain slack within thespecified limits. 3. Tighten...

PERIODIC MAINTENANCE AND MINOR REPAIR 6-23 6 CAUTION: ECA11110 Do not use engine oil or any other lu-bricants for the drive chain, as theymay contain substances that coulddamage the O-rings. EAU23100 Checking and lubricating the cables The operation of all control cables andthe condition of the cabl...

PERIODIC MAINTENANCE AND MINOR REPAIR 6-25 6 EAU23271 Checking the front fork The condition and operation of the frontfork must be checked as follows at theintervals specified in the periodic main-tenance and lubrication chart. To check the condition WARNING EWA10750 Securely support the vehicle so ...

PERIODIC MAINTENANCE AND MINOR REPAIR 6-26 6 EAU23290 Checking the wheel bearings The front and rear wheel bearings mustbe checked at the intervals specified inthe periodic maintenance and lubrica-tion chart. If there is play in the wheelhub or if the wheel does not turnsmoothly, have a Yamaha deale...

PERIODIC MAINTENANCE AND MINOR REPAIR 6-27 6 WARNING EWA10760 ● Electrolyte is poisonous anddangerous since it contains sul-furic acid, which causes severeburns. Avoid any contact withskin, eyes or clothing and al-ways shield your eyes whenworking near batteries. In caseof contact, administer the fo...

PERIODIC MAINTENANCE AND MINOR REPAIR 6-28 6 EAU23550 Replacing the fuses The main fuse and the fuse box, whichcontains the fuses for the individual cir-cuits, are located behind panel B. (Seepage 6-5.) If a fuse is blown, replace it as follows. 1. Turn the key to “OFF” and turn off the electrical c...

PERIODIC MAINTENANCE AND MINOR REPAIR 6-29 6 3. Unhook the headlight bulb holder, and then remove the defectivebulb. WARNING EWA10790 Headlight bulbs get very hot. There-fore, keep flammable products awayfrom a lit headlight bulb, and do nottouch the bulb until it has cooleddown. 4. Place a new head...

PERIODIC MAINTENANCE AND MINOR REPAIR 6-30 6 EAU24131 Replacing the tail/brake light bulb 1. Remove the tail/brake light lens by removing the screws. 2. Remove the defective bulb by pushing it in and turning it counter-clockwise. 3. Insert a new bulb into the socket, push it in, and then turn it clo...

PERIODIC MAINTENANCE AND MINOR REPAIR 6-31 6 3. Insert a new bulb into the socket, push it in, and then turn it clock-wise until it stops. 4. Install the lens by installing the screws. CAUTION: ECA10680 Do not overtighten the screws, oth-erwise the lens may break. EAU24350 Supporting the motorcycle ...

PERIODIC MAINTENANCE AND MINOR REPAIR 6-32 6 EAU24360 Front wheel EAU24660 To remove the front wheel WARNING EWA10820 ● It is advisable to have a Yamahadealer service the wheel. ● Securely support the motor-cycle so that there is no dangerof it falling over. 1. Disconnect the speedometer ca- ble fro...

PERIODIC MAINTENANCE AND MINOR REPAIR 6-33 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 speci-fied torques, and then install therubber cap. 6. While applying the front brake, push down hard on the ha...

PERIODIC MAINTENANCE AND MINOR REPAIR 6-34 6 2. Lift the rear wheel off the ground according to the procedure onpage 6-31. 3. Disconnect the brake torque rod from the brake shoe plate by re-moving the nut and the bolt. 4. Remove the brake pedal free play adjusting nut, and then disconnectthe brake r...

PERIODIC MAINTENANCE AND MINOR REPAIR 6-35 6 EAU25850 Troubleshooting Although Yamaha motorcycles receivea thorough inspection before shipmentfrom the factory, trouble may occur dur-ing operation. Any problem in the fuel,compression, or ignition systems, forexample, can cause poor starting andloss o...

PERIODIC MAINTENANCE AND MINOR REPAIR 6-36 6 EAU25891 Troubleshooting chart WARNING EWA10840 Keep away open flames and do not smoke while checking or working on the fuel system. Check the fuel level inthe fuel tank. 1. Fuel There is enough fuel. There is no fuel. Check the compression. Supply fuel. ...

MOTORCYCLE CARE AND STORAGE 7-1 7 EAU26040 Care While the open design of a motorcyclereveals the attractiveness of the tech-nology, it also makes it more vulnera-ble. Rust and corrosion can developeven if high-quality components areused. A rusty exhaust pipe may go un-noticed on a car, however, it d...

MOTORCYCLE CARE AND STORAGE 7-2 7 After normal useRemove dirt with warm water, a milddetergent, and a soft, clean sponge,and then rinse thoroughly with cleanwater. Use a toothbrush or bottlebrushfor hard-to-reach areas. Stubborn dirtand insects will come off more easily ifthe area is covered with a ...

MOTORCYCLE CARE AND STORAGE 7-3 7 CAUTION: ECA10800 ● Apply spray oil and wax spar-ingly and make sure to wipe offany excess. ● Never apply oil or wax to anyrubber and plastic parts, buttreat them with a suitable careproduct. ● Avoid using abrasive polishingcompounds as they will wearaway the paint....

MOTORCYCLE CARE AND STORAGE 7-4 7 WARNING EWA10950 To prevent damage or injury fromsparking, make sure to ground thespark plug electrodes while turningthe engine over. 6. Lubricate all control cables and the pivoting points of all levers andpedals as well as of the side-stand/centerstand. 7. Check a...

CONSUMER INFORMATION 9-1 9 EAU26351 Identification numbers Record the key identification number,vehicle identification number and mod-el label information in the spaces pro-vided below for assistance whenordering spare parts from a Yamahadealer or for reference in case the vehi-cle is stolen.KEY IDE...

CONSUMER INFORMATION 9-2 9 EAU26460 Model label The model label is affixed to the loca-tion shown. Record the information onthis label in the space provided. This in-formation will be needed when orderingspare parts from a Yamaha dealer. 1. Model label 5KRE2.book Page 2 Monday, June 23, 2003 3:32 PM

INDEX A Air filter element, cleaning .................... 6-10Anti-theft alarm (optional) ....................... 3-3 B Battery .................................................. 6-26Brake and clutch levers, checking and lubricating .................................... 6-24 Brake and shift pedals, c...