lock YAMAHA XVS250 2004 User Guide

PERIODIC MAINTENANCE AND MINOR REPAIR
6-17
6
WARNING
EWA10630


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 hy-
draulic system, have a Yamaha
dealer bleed the system before
operating the motorcycle. Air in
the hydraulic system will dimin-
ish the braking performance,
which may result in loss of con-trol and an accident.
EAU22201
Adjusting the brake pedal
position and free play
WARNING
EWA10670
It is advisable to have a Yamahadealer make these adjustments.
Brake pedal position
The top of the brake pedal should be
positioned approximately 76.6 mm
(3.02 in) above the top of the footrest as
shown. Periodically check the brake
pedal position and, if necessary, adjust
it as follows.1. Loosen the locknut at the brake
pedal.
2. To raise the brake pedal, turn the
adjusting bolt in direction (a). To
lower the brake pedal, turn the ad-
justing bolt in direction (b).
3. Tighten the locknut.
WARNING
EWA11230
After adjusting the brake pedal posi-
tion, the brake pedal free play mustbe adjusted.
1. Footrest
2. Distance between brake pedal and footrest
3. Brake pedal free play
1. Brake pedal position adjusting bolt
2. Locknut
5KRE2.book Page 17 Monday, June 23, 2003 3:32 PM

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 the
handlebars.


Use only the recommended quality
brake fluid, otherwise the rubber
seals may deteriorate, causing
leakage and poor braking perfor-
mance.


Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking performance.


Be careful that water does not en-
ter the master cylinder when refill-
ing. Water will significantly lower
the boiling point of the fluid and
may result in vapor lock.


Brake fluid may deteriorate paint-
ed surfaces or plastic parts. Al-
ways clean up spilled fluid
immediately.


As the brake pads wear, it is nor-
mal for the brake fluid level to grad-
ually go down. However, if thebrake fluid level goes down sud-
denly, have a Yamaha dealer
check the cause.
EAU22720
Changing the brake fluid Have a Yamaha dealer change the
brake fluid at the intervals specified in
the NOTE after the periodic mainte-
nance and lubrication chart. In addition,
have the oil seals of the brake master
cylinder and caliper as well as the
brake hose replaced at the intervals
listed below or whenever they are dam-
aged or leaking.

Oil seals: Replace every two
years.


Brake hose: Replace every four
years.
Recommended brake fluid:
DOT 4
5KRE2.book Page 20 Monday, June 23, 2003 3:32 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-21
6
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 po-
sition.NOTE:When checking and adjusting the drive
chain slack, the motorcycle should be
positioned straight up and there shouldbe no weight on it.
2. Shift the transmission into the neu-
tral position.
3. Move the rear wheel by pushing
the motorcycle to locate the tight-
est portion of the drive chain, and
then measure the drive chain slack
as shown.4. If the drive chain slack is incorrect,
adjust it as follows.
EAU22821
To adjust the drive chain slack
1. Loosen the brake pedal free play
adjusting nut, axle nut, and locknut
at each end of the swingarm.2. To tighten the drive chain, turn the
adjusting nut at each end of the
swingarm in direction (a). To loos-
en the drive chain, turn the adjust-
ing nut at each end of the
swingarm in direction (b), and then
push the rear wheel forward.
NOTE:Using the alignment marks on each
side of the swingarm, make sure that
both adjusting nuts are in the same po-sition for proper wheel alignment.
Drive chain slack:
30.0–40.0 mm (1.18–1.57 in)
1. Drive chain slack
1. Axle nut
2. Locknut
3. Brake pedal free play adjusting nut
5KRE2.book Page 21 Monday, June 23, 2003 3:32 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-22
6
CAUTION:
ECA10570
Improper drive chain slack will over-
load the engine as well as other vital
parts of the motorcycle and can lead
to chain slippage or breakage. To
prevent this from occurring, keep
the drive chain slack within thespecified limits.
3. Tighten both locknuts and the axle
nut to the specified torques.4. Adjust the brake pedal free play.
(See page 6-17.)
WARNING
EWA10660
After adjusting the brake pedal free
play, check the operation of thebrake light.
EAU23020
Lubricating the drive chain The drive chain must be cleaned and
lubricated at the intervals specified in
the periodic maintenance and lubrica-
tion chart, otherwise it will quickly wear
out, especially when riding in dusty or
wet areas. Service the drive chain as
follows.CAUTION:
ECA10580
The drive chain must be lubricated
after washing the motorcycle orriding in the rain.
1. Clean the drive chain with kero-
sene and a small soft brush.CAUTION:
ECA11120
To prevent damaging the O-rings, do
not clean the drive chain with steam
cleaners, high-pressure washers orinappropriate solvents.
2. Wipe the drive chain dry.
3. Thoroughly lubricate the drive
chain with a special O-ring chain
lubricant.
1. Alignment marks
2. Drive chain slack adjusting nut
3. Locknut
Tightening torques:
Locknut:
16 Nm (1.6 m·kgf, 12 ft·lbf)
Axle nut:
104 Nm (10.4 m·kgf, 75 ft·lbf)
5KRE2.book Page 22 Monday, June 23, 2003 3:32 PM

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 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.
EAU24210
Replacing a turn signal light
bulb 1. Remove the turn signal lens by re-
moving the screws.
2. Remove the defective bulb by
pushing it in and turning it counter-
clockwise.
1. Screw
1. Tail/brake light bulb
1. Screw
5KRE2.book Page 30 Monday, June 23, 2003 3:32 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-31
63. 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 Since this model is not equipped with a
centerstand, follow these precautions
when removing the front and rear
wheel or performing other maintenance
requiring the motorcycle to stand up-
right. Check that the motorcycle is in a
stable and level position before starting
any maintenance. A strong wooden
box can be placed under the engine for
added stability.
To service the front wheel
1. Stabilize the rear of the motorcycle
by using a motorcycle stand or, if
an additional motorcycle stand is
not available, by placing a jack un-
der the frame in front of the rear
wheel.
2. Raise the front wheel off the
ground by using a motorcycle
stand.
To service the rear wheel
Raise the rear wheel off the ground by
using a motorcycle stand or, if a motor-
cycle stand is not available, by placinga jack either under each side of the
frame in front of the rear wheel or under
each side of the swingarm.
1. Turn signal light bulb5KRE2.book Page 31 Monday, June 23, 2003 3:32 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-34
6 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 re-
moving the nut and the bolt.
4. Remove the brake pedal free play
adjusting nut, and then disconnect
the brake rod at the brake cam-
shaft lever.
5. Loosen the locknut and the drive
chain adjusting nut on both ends of
the swingarm.
6. Remove the axle nut, and then pull
the wheel axle out.7. Push the wheel forward, and then
remove the drive chain from the
rear sprocket.
NOTE:The drive chain does not need to be
disassembled in order to remove andinstall the wheel.
8. Remove the wheel.
EAU25780
To install the rear wheel
1. Insert the wheel axle from the left-
hand side, and then install the axle
nut.
2. Install the drive chain onto the rear
sprocket, and then adjust the drive
chain slack. (See page 6-21.)
3. Lower the rear wheel so that it is
on the ground.
4. Install the brake rod onto the brake
camshaft lever, and then install the
brake pedal free play adjusting nut
onto the brake rod.
5. Connect the brake torque rod to
the brake shoe plate by installing
the bolt and the nut, and then tight-
en the nut to the specified torque.6. Tighten the axle nut to the speci-
fied torque.
7. Adjust the brake pedal position
and free play. (See page 6-17.)
WARNING
EWA10660
After adjusting the brake pedal free
play, check the operation of thebrake light.
1. Wheel axle
2. Drive chain slack adjusting nut
3. Locknut
Tightening torque:
Brake torque rod nut:
23 Nm (2.3 m·kgf, 17 ft·lbf)
Tightening torque:
Axle nut:
104 Nm (10.4 m·kgf, 75 ft·lbf)
5KRE2.book Page 34 Monday, June 23, 2003 3:32 PM

INDEX
AAir filter element, cleaning .................... 6-10
Anti-theft alarm (optional) ....................... 3-3BBattery .................................................. 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 .................... 6-19
Brake lever ............................................. 3-6
Brake lever free play, adjusting ............ 6-16
Brake pads and shoes, checking.......... 6-19
Brake pedal ............................................ 3-6
Brake pedal position and free play,
adjusting ............................................. 6-17CCables, checking and lubricating .......... 6-23
Carburetor, adjusting ............................ 6-11
Care ........................................................ 7-1
Clutch lever............................................. 3-5
Clutch lever free play, adjusting ........... 6-15DDimmer switch ........................................ 3-4
Drive chain, lubricating ......................... 6-22
Drive chain slack .................................. 6-21EEngine break-in ...................................... 5-4
Engine idling speed .............................. 6-12
Engine oil and oil filter element............... 6-8
Engine, starting a warm .......................... 5-2
Engine stop switch.................................. 3-4
Engine trouble warning light ................... 3-2
FFront fork, checking...............................6-25
Fuel ......................................................... 3-7
Fuel cock ................................................. 3-8
Fuel consumption, tips for reducing ........ 5-3
Fuel tank cap........................................... 3-6
Fuses, replacing .................................... 6-28HHandlebar switches ................................. 3-4
Headlight bulb, replacing....................... 6-28
Helmet holder .......................................... 3-9
High beam indicator light......................... 3-2
Horn switch ............................................. 3-4IIdentification numbers ............................. 9-1
Ignition circuit cut-off system ................. 3-11
Indicator and warning lights .................... 3-2KKey identification number ........................ 9-1LLight switch ............................................. 3-4MMain switch/steering lock ........................ 3-1
Model label .............................................. 9-2NNeutral indicator light .............................. 3-2PPanels, removing and installing .............. 6-5
Parking ....................................................5-4
Part locations .......................................... 2-1
Pass switch ............................................. 3-4
Periodic maintenance and
lubrication chart.....................................6-2
Pre-operation check list........................... 4-2
RRear brake light switch, adjusting ......... 6-18SSafety information ................................... 1-1
Self-diagnosis device .............................. 3-3
Shifting .................................................... 5-2
Shift pedal ............................................... 3-5
Shock absorber assemblies,
adjusting ............................................. 3-10
Sidestand .............................................. 3-10
Sidestand, checking and lubricating ..... 6-24
Spark plugs, checking............................. 6-6
Specifications.......................................... 8-1
Speedometer unit ................................... 3-3
Starter (choke) lever ............................... 3-9
Starting a cold engine ............................. 5-1
Start switch ............................................. 3-4
Steering, checking ................................ 6-25
Storage ................................................... 7-3
Supporting the motorcycle .................... 6-31TTail/brake light bulb, replacing .............. 6-30
Throttle cable free play, adjusting ......... 6-12
Throttle grip and cable, checking
and lubricating .................................... 6-23
Tires ...................................................... 6-13
Tool kit .................................................... 6-1
Troubleshooting .................................... 6-35
Troubleshooting chart ........................... 6-36
Turn signal indicator light ........................ 3-2
Turn signal light bulb, replacing ............ 6-30
Turn signal switch ................................... 3-4VValve clearance, adjusting .................... 6-13
5KRE2.book Page 1 Monday, June 23, 2003 3:32 PM