YAMAHA XVS250 2004 Owner's Guide

OPERATION AND IMPORTANT RIDING POINTS
5-2
5 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.CAUTION:
ECA11040
For maximum engine life, never ac-
celerate hard when the engine iscold!
7. When the engine is warm, turn the
starter (choke) off.NOTE:The engine is warm when it responds
normally to the throttle with the starter(choke) turned off.
EAU16640
Starting a warm engine Follow the same procedure as for start-
ing a cold engine with the exception
that the starter (choke) is not required
when the engine is warm.
EAU16671
Shifting Shifting gears lets you control the
amount of engine power available for
starting off, accelerating, climbing hills,
etc.
The gear positions are shown in the il-
lustration.NOTE:To shift the transmission into the neu-
tral position, press the shift pedal down
repeatedly until it reaches the end of itstravel, and then slightly raise it.1. Shift pedal
2. Neutral position
5KRE2.book Page 2 Monday, June 23, 2003 3:32 PM

OPERATION AND IMPORTANT RIDING POINTS
5-3
5
CAUTION:
ECA10260


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 dis-
tances. The transmission is
properly lubricated only when
the engine is running. Inade-
quate lubrication may damage
the transmission.


Always use the clutch while
changing gears to avoid damag-
ing the engine, transmission,
and drive train, which are not
designed to withstand theshock of forced shifting.
EAU32810
Recommended shift points (for
Switzerland only)
The recommended shift points during
acceleration are shown in the table be-
low.
NOTE:When shifting down two gears at a
time, reduce the speed accordingly
[e.g., down to 35 km/h (22 mi/h) whenshifting from 4th to 2nd gear].
EAU16800
Tips for reducing fuel
consumption Fuel consumption depends largely on
your riding style. Consider the following
tips to reduce fuel consumption:

Turn the starter (choke) off as
soon as possible.


Shift up swiftly, and avoid high en-
gine speeds during acceleration.


Do not rev the engine while shifting
down, and avoid high engine
speeds with no load on the engine.


Turn the engine off instead of let-
ting it idle for an extended length of
time (e.g., in traffic jams, at traffic
lights or at railroad crossings).
Shift up points:
1st → 2nd: 23 km/h (14 mi/h)
2nd → 3rd: 36 km/h (22 mi/h)
3rd → 4th: 50 km/h (31 mi/h)
4th → 5th: 60 km/h (37 mi/h)
5KRE2.book Page 3 Monday, June 23, 2003 3:32 PM

OPERATION AND IMPORTANT RIDING POINTS
5-4
5
EAU16841
Engine break-in 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 follow-
ing material carefully.
Since the engine is brand new, do not
put an excessive load on it for the first
1600 km (1000 mi). The various parts in
the engine wear and polish themselves
to the correct operating clearances.
During this period, prolonged full-throt-
tle operation or any condition that might
result in engine overheating must be
avoided.
EAU17021
0–1000 km (0–600 mi)
Avoid prolonged operation above 1/3
throttle.
1000–1600 km (600–1000 mi)
Avoid prolonged operation above 1/2
throttle.
CAUTION:
ECA11281
After 1000 km (600 mi) of operation,
the engine oil must be changed, and
the oil filter cartridge or element re-placed.
1600 km (1000 mi) and beyond
The vehicle can now be operated nor-
mally.CAUTION:
ECA10270
If any engine trouble should occur
during the engine break-in period,
immediately have a Yamaha dealercheck the vehicle.
EAU17200
Parking When parking, stop the engine, and
then remove the key from the main
switch.
WARNING
EWA10310


Since the engine and exhaust
system can become very hot,
park in a place where pedestri-
ans or children are not likely to
touch them.


Do not park on a slope or on soft
ground, otherwise the vehiclemay overturn.
5KRE2.book Page 4 Monday, June 23, 2003 3:32 PM

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 the
safest and most efficient condition pos-
sible. The most important points of in-
spection, adjustment, and lubrication
are explained on the following pages.
The intervals given in the periodic
maintenance and lubrication chart
should be simply considered as a gen-
eral guide under normal riding condi-
tions. However, DEPENDING ON THE
WEATHER, TERRAIN, GEOGRAPHI-
CAL LOCATION, AND INDIVIDUAL
USE, THE MAINTENANCE INTER-
VALS MAY NEED TO BE SHORT-
ENED.
WARNING
EWA10320
If you are not familiar with mainte-
nance work, have a Yamaha dealerdo it for you.
EAU17340
Owner’s tool kit The owner’s tool kit is located behind
panel A. (See page 6-5.)
The service information included in this
manual and the tools provided in the
owner’s tool kit are intended to assist
you in the performance of preventive
maintenance and minor repairs. How-
ever, additional tools such as a torque
wrench may be necessary to perform
certain maintenance work correctly.NOTE:If you do not have the tools or experi-
ence required for a particular job, havea Yamaha dealer perform it for you.
WARNING
EWA10350
Modifications not approved by
Yamaha may cause loss of perfor-
mance and render the vehicle un-
safe for use. Consult a Yamaha
dealer before attempting any chang-es.
1. Owner’s tool kit
5KRE2.book Page 1 Monday, June 23, 2003 3:32 PM

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 marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technicalskills.
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1000 km)
ANNUAL
CHECK
1 10203040
1*Fuel lineCheck fuel and vacuum hoses for cracks or damage.√√√√ √
2 Spark plugsCheck condition.
Clean and regap.√ √
Replace.√ √
3*ValvesCheck valve clearance.
Adjust.√ √ √ √
4 Air filter elementClean.√ √
Replace.√ √
5ClutchCheck operation.
Adjust.√ √ √ √ √
6*Front brakeCheck operation, fluid level and vehicle for fluid leakage.√√√√√ √
Replace brake pads. Whenever worn to the limit
7*Rear brakeCheck operation and adjust brake pedal free play.√ √ √ √ √ √
Replace brake shoes. Whenever worn to the limit
8*Brake hoseCheck for cracks or damage.√√√√ √
Replace. Every 4 years
5KRE2.book Page 2 Monday, June 23, 2003 3:32 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
6
9*WheelsCheck runout, spoke tightness and for damage.
Tighten spokes if necessary.√ √ √ √
10*TiresCheck tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.√ √ √ √ √
11*Wheel bearingsCheck bearing for looseness or damage.√ √ √ √
12*SwingarmCheck operation and for excessive play.√√√√
Lubricate with lithium-soap-based grease. Every 50000 km
13 Drive chainCheck chain slack.
Make sure that the rear wheel is properly aligned.
Clean and lubricate.Every 1000 km and after washing the motorcycle or
riding in the rain
14*Steering bearingsCheck bearing play and steering for roughness.√√√√√
Lubricate with lithium-soap-based grease. Every 20000 km
15*Chassis fastenersMake sure that all nuts, bolts and screws are properly
tightened.√ √ √ √ √
16 SidestandCheck operation.
Lubricate.√ √ √ √ √
17*Sidestand switchCheck operation.√ √ √ √ √ √
18*Front forkCheck operation and for oil leakage.√ √ √ √
19*Shock absorber assem-
bliesCheck operation and shock absorbers for oil leakage.√ √ √ √
20*CarburetorCheck starter (choke) operation.
Adjust engine idling speed.√√√√√ √
21 Engine oilChange.
Check oil level and vehicle for oil leakage.√ √ √ √ √ √ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1000 km)
ANNUAL
CHECK
1 10203040
5KRE2.book Page 3 Monday, June 23, 2003 3:32 PM

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 the brake master cylinder and caliper, and change the brake fluid.Replace the brake hoses every four years and if cracked or damaged.
22 Engine oil filter elementReplace.√ √ √
23*Engine oil strainerClean.√
24*Front and rear brake
switchesCheck operation.√ √ √ √ √ √
25Moving parts and ca-
blesLubricate.√ √ √ √ √
26*Throttle grip housing
and cableCheck operation and free play.
Adjust the throttle cable free play if necessary.
Lubricate the throttle grip housing and cable.√ √ √ √ √
27*Air induction systemCheck the air cut-off valve, reed valve, and hose for dam-
age.
Replace the entire air induction system if necessary.√ √ √ √ √
28*Muffler and exhaust
pipeCheck the screw clamp for looseness.√
29*Lights, signals and
switchesCheck operation.
Adjust headlight beam.√ √ √ √ √ √ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1000 km)
ANNUAL
CHECK
1 10203040
5KRE2.book Page 4 Monday, June 23, 2003 3:32 PM

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 panel
needs to be removed and installed.
EAU19521
Panel A
To remove the panel1. Slide the panel lock cover open, in-
sert the key into the lock, and then
turn it 1/4 turn clockwise.
2. Pull the rear of the panel out with
the key inserted in the lock, 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
with the key inserted in the lock.
2. Turn the key counterclockwise to
the original position, remove it, and
then close the panel lock cover.
1. Panel A
1. Panel B
1. Panel lock cover
2. Unlock.
5KRE2.book Page 5 Monday, June 23, 2003 3:32 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-6
6
EAU19161
Panel B
To remove the panel1. 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. Install the bolt.
EAU19543
Checking the spark plugs The spark plugs are important engine
components, which are easy to check.
Since heat and deposits will cause any
spark plug to slowly erode, the spark
plugs should be removed and checked
in accordance with the periodic mainte-
nance and lubrication chart. In addition,
the condition of the spark plugs can re-
veal the condition of the engine.
To remove a spark plug
1. Remove the spark plug cap.
2. Remove the spark plug as shown,
with the spark plug wrench includ-
ed in the owner’s tool kit.
1. Bolt
1. Spark plug cap
5KRE2.book Page 6 Monday, June 23, 2003 3:32 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-7
6To check the spark plugs
1. Check that the porcelain insulator
around the center electrode on
each spark plug is a medium-to-
light tan (the ideal color when the
vehicle is ridden normally).
2. Check that all spark plugs installed
in the engine have the same color.
NOTE:If any spark plug shows a distinctly dif-
ferent color, the engine could be defec-
tive. Do not attempt to diagnose such
problems yourself. Instead, have aYamaha dealer check the vehicle.3. Check each spark plug for elec-
trode erosion and excessive car-
bon or other deposits, and replace
it if necessary.
To install a spark plug
1. Measure the spark plug gap with a
wire thickness gauge and, if nec-
essary, adjust the gap to specifica-
tion.2. Clean the surface of the spark plug
gasket and its mating surface, and
then wipe off any grime from the
spark plug threads.
3. Install the spark plug with the
spark plug wrench, and then tight-
en it to the specified torque.
NOTE:
If a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4–1/2 turn
past finger tight. However, the spark
plug should be tightened to the speci-fied torque as soon as possible.
4. Install the spark plug cap.
1. Spark plug wrench
Specified spark plug:
NGK/CR6HSA
DENSO/U20FSR-U1. Spark plug gapSpark plug gap:
0.6–0.7 mm (0.024–0.028 in)
Tightening torque:
Spark plug:
12.5 Nm (1.25 m·kgf, 9.0 ft·lbf)
5KRE2.book Page 7 Monday, June 23, 2003 3:32 PM