brake YAMAHA XVS250 2002 Owner's Manual

PERIODIC MAINTENANCE AND MINOR REPAIR
6-37
6 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 placing
a jack either under each side of the
frame in front of the rear wheel or under
each side of the swingarm.
EAU03737
Front wheel To remove the front wheel
EW000122
WARNING
_

It is advisable to have a Yamaha
dealer service the wheel.


Securely support the motor-
cycle so that there is no danger
of it falling over.
_1. Disconnect the speedometer ca-
ble from the front wheel.2. Loosen the front wheel axle pinch
bolt.
3. Remove the rubber cap, and then
loosen the wheel axle.
4. Lift the front wheel off the ground
according to the procedure on
page 6-36.
5. Pull the wheel axle out, and then
remove the wheel.
ECA00048
CAUTION:_ Do not apply the brake after the
wheel has been removed together
with the brake disc, otherwise the
brake pads will be forced shut. _
1. Speedometer cable
1. Front wheel axle pinch bolt
2. Rubber cap
3. Wheel axle
E_5kr.book Page 37 Friday, December 14, 2001 11:33 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-38
6
EAU04352
To install the front wheel
1. Install the speedometer gear unit
into the wheel hub so that the pro-
jections mesh with the slots.
2. Lift the wheel up between the fork
legs.
NOTE:_ Make sure that there is enough space
between the brake pads before insert-
ing the brake disc and that the slot in
the speedometer gear unit fits over the
retainer on the fork leg. _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 the
rubber cap.6. While applying the front brake,
push down hard on the handle-
bars several times to check if the
front fork compresses and re-
bounds smoothly.
7. Connect the speedometer cable.1. Speedometer gear unit retainer
Tightening torques:
Wheel axle:
59 Nm (5.9 m·kgf)
Front wheel axle pinch bolt:
20 Nm (2.0 m·kgf)
E_5kr.book Page 38 Friday, December 14, 2001 11:33 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-39
6
EAU03189
Rear wheel To remove the rear wheel
EW000122
WARNING
_

It is advisable to have a Yamaha
dealer service the wheel.


Securely support the motor-
cycle so that there is no danger
of it falling over.
_1. Loosen the axle nut and the brake
torque rod nut at the brake shoe
plate.2. Lift the rear wheel off the ground
according to the procedure on
page 6-37.
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 and
install the wheel. _8. Remove the wheel.
1. Axle nut
2. Brake torque rod
3. Brake torque rod nut and bolt
4. Brake rod
5. Brake pedal free play adjusting nut
1. Wheel axle
2. Drive chain slack adjusting nut
3. Locknut
E_5kr.book Page 39 Friday, December 14, 2001 11:33 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-40
6
EAU04487
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 6-25 for
drive chain slack adjustment pro-
cedures.)
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 6-20 for
brake pedal position and free play
adjustment procedures.)
EW000103
WARNING
_ After adjusting the brake pedal free
play, check the operation of the
brake light. _
EAU01008
Troubleshooting Although Yamaha motorcycles receive
a thorough inspection before shipment
from the factory, trouble may occur dur-
ing 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 your-
self. However, should your motorcycle
require any repair, take it to a Yamaha
dealer, whose skilled technicians have
the necessary tools, experience, and
know-how to service the motorcycle
properly.
Use only genuine Yamaha replace-
ment parts. Imitation parts may look
like Yamaha parts, but they are often
inferior, have a shorter service life and
can lead to expensive repair bills. Tightening torque:
Brake torque rod nut:
23 Nm (2.3 m·kgf)
Tightening torque:
Axle nut:
104 Nm (10.4 m·kgf)
E_5kr.book Page 40 Friday, December 14, 2001 11:33 AM

MOTORCYCLE CARE AND STORAGE
7-2
7


Do not use any harsh chemical
products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
contact with strong or abrasive
cleaning products, solvent or
thinner, fuel (gasoline), rust re-
movers or inhibitors, brake flu-
id, antifreeze or electrolyte.


Do not use high-pressure wash-
ers or steam-jet cleaners since
they cause water seepage and
deterioration in the following ar-
eas: seals (of wheel and swing-
arm bearings, fork and brakes),
electric components (couplers,
connectors, instruments, switch-
es and lights), breather hoses
and vents.


For motorcycles equipped with
a windshield: Do not use strong
cleaners or hard sponges as
they will cause dulling or
scratching. Some cleaning
compounds for plastic may
leave scratches on the wind-
shield. Test the product on a
small hidden part of the wind-
shield to make sure that it does
not leave any marks. If the wind-
shield is scratched, use a quali-
ty plastic polishing compound
after washing.
_After normal useRemove 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.After riding in the rain, near the sea or
on salt-sprayed roadsSince sea salt or salt sprayed on roads
during winter are extremely corrosive in
combination with water, carry out the
following steps after each ride in the
rain, near the sea or on salt-sprayed
roads.NOTE:_ Salt sprayed on roads in the winter may
remain well into spring. _1. Clean the motorcycle with cold
water and a mild detergent, after
the engine has cooled down.
ECA00012
CAUTION:_ Do not use warm water since it in-
creases the corrosive action of the
salt. _2. After drying the motorcycle, apply
a corrosion protection spray on all
metal, including chrome- and nick-
el-plated, surfaces to prevent
corrosion.
E_5kr.book Page 2 Friday, December 14, 2001 11:33 AM

MOTORCYCLE CARE AND STORAGE
7-3
7After 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 in-
duced discoloring of stainless-
steel exhaust systems can be re-
moved through polishing.)
4. To prevent corrosion, it is recom-
mended to apply a corrosion pro-
tection spray on all metal,
including chrome- and nickel-plat-
ed, surfaces.
5. Use spray oil as a universal clean-
er to remove any remaining dirt.
6. Touch up minor paint damage
caused by stones, etc.
7. Wax all painted surfaces.
8. Let the motorcycle dry completely
before storing or covering it.
EWA00001
WARNING
_

Make sure that there is no oil or
wax on the brakes or tires. If
necessary, clean the brake
discs and brake linings with a
regular brake disc cleaner or ac-
etone, and wash the tires with
warm water and a mild deter-
gent.


Before operating the motor-
cycle test its braking perfor-
mance and cornering behavior.
_
ECA00013
CAUTION:_

Apply spray oil and wax spar-
ingly 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. _
E_5kr.book Page 3 Friday, December 14, 2001 11:33 AM

SPECIFICATIONS
8-3
8
Maximum load* 180 kg
Tire air pressure (measured
on cold tires)
Up to 90 kg*
Front 175 kPa (1.75 kgf/cm
2, 1.75 bar)
Rear 200 kPa (2.00 kgf/cm2, 2.00 bar)
90 kg–maximum*
Front 225 kPa (2.25 kgf/cm2, 2.25 bar)
Rear 225 kPa (2.25 kgf/cm2, 2.25 bar)
* Total weight of rider, passenger, cargo and accessories
Wheels
Fron t
Type Spoke wheel
Size 18 × 1.60
Rear
Type Spoke wheel
Size 15 M/C × MT 3.00
Brakes
Front
Type Single disc brake
Operation Right hand
Fluid DOT 4Rear
Type Drum brake
Operation Right foot
Suspension
Front Telescopic fork
Rear Swingarm
Spring/shock absorber
Front Coil spring / oil damper
Rear Coil spring / oil damper
Wheel travel
Front 140 mm
Rear 100 mm
Electrical system
Ignition system T.C.I (digital)
Charging system
Type A.C. magneto
Standard output 14 V, 23 A @ 5,000 r/min
Battery
Model GT6B-3
Voltage, capacity 12 V, 6 Ah
Headlight typeQuartz bulb (halogen)
E_5kr.book Page 3 Friday, December 14, 2001 11:33 AM

SPECIFICATIONS
8-4
8
Bulb voltage, wattage × quantity
Headlight 12 V, 60/55 W × 1
Tail/brake light 12 V, 5/21 W × 1
Turn signal light 12 V, 21 W × 4
Auxiliary light 12 V, 4 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, 1.7 W × 1
Fuses
Main fuse 30 A
Headlight fuse 15 A
Signaling system fuse 10 A
Ignition fuse 10 A
Carburetor heater fuse 10 A
E_5kr.book Page 4 Friday, December 14, 2001 11:33 AM