maintenance YAMAHA XVS250 2004 Owner's Guide
[x] Cancel search | Manufacturer: YAMAHA, Model Year: 2004, Model line: XVS250, Model: YAMAHA XVS250 2004Pages: 82, PDF Size: 4.64 MB
Page 61 of 82
PERIODIC MAINTENANCE AND MINOR REPAIR
6-28
6
EAU23550
Replacing the fuses The main fuse and the fuse box, which
contains the fuses for the individual cir-
cuits, are located behind panel B. (See
page 6-5.)
If a fuse is blown, replace it as follows.
1. Turn the key to “OFF” and turn off
the electrical circuit in question.
2. Remove the blown fuse, and then
install a new fuse of the specified
amperage.
CAUTION:
ECA10640
Do not use a fuse of a higher amper-
age rating than recommended to
avoid causing extensive damage to
the electrical system and possibly afire.
3. Turn the key to “ON” and turn on
the electrical circuit in question to
check if the device operates.
4. If the fuse immediately blows
again, have a Yamaha dealer
check the electrical system.
EAU23791
Replacing the headlight bulb This model is equipped with a quartz
bulb headlight. If the headlight bulb
burns out, replace it as follows.
1. Remove the headlight unit by re-
moving the screws.
2. Disconnect the headlight coupler,
and then remove the bulb cover.
1. Main fuse
2. Spare main fuse
3. Headlight fuse
4. Ignition fuse
5. Signaling system fuse
6. Carburetor heater fuse
7. Spare fuse
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
1. Screw
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PERIODIC MAINTENANCE AND MINOR REPAIR
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6
3. Unhook the headlight bulb holder,
and then remove the defective
bulb.
WARNING
EWA10790
Headlight bulbs get very hot. There-
fore, keep flammable products away
from a lit headlight bulb, and do not
touch the bulb until it has cooleddown.
4. Place a new headlight bulb into po-
sition, and then secure it with the
bulb holder.CAUTION:
ECA10660
Do not touch the glass part of the
headlight bulb to keep it free from
oil, otherwise the transparency of
the glass, the luminosity of the bulb,
and the bulb life will be adversely af-fected. Thoroughly clean off any dirt
and fingerprints on the headlight
bulb using a cloth moistened with al-
cohol or thinner.
5. Install the headlight bulb cover,
and then connect the coupler.
6. Install the headlight unit by install-
ing the screws.
7. Have a Yamaha dealer adjust the
headlight beam if necessary.
1. Headlight coupler
1. Headlight bulb cover
1. Headlight bulb holder
1. Do not touch the glass part of the bulb.
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Page 63 of 82
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
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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
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PERIODIC MAINTENANCE AND MINOR REPAIR
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6
EAU24360
Front wheel
EAU24660
To remove the front wheel
WARNING
EWA10820
It is advisable to have a Yamaha
dealer service the wheel.
Securely support the motor-
cycle so that there is no dangerof 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 6-31.
5. Pull the wheel axle out, and then
remove the wheel.
CAUTION:
ECA11070
Do not apply the brake after the
wheel has been removed together
with the brake disc, otherwise thebrake pads will be forced shut.
EAU24921
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 theretainer on the fork leg.
1. Speedometer cable
1. Front wheel axle pinch bolt
2. Rubber cap
3. Wheel axle
1. Speedometer gear unit
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-33
63. 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 handlebars
several times to check if the front
fork compresses and rebounds
smoothly.7. Connect the speedometer cable.
EAU25080
Rear wheel
EAU25430
To remove the rear wheel
WARNING
EWA10820
It is advisable to have a Yamaha
dealer service the wheel.
Securely support the motor-
cycle so that there is no dangerof it falling over.
1. Loosen the axle nut and the brake
torque rod nut at the brake shoe
plate.
1. Speedometer gear unit retainerTightening torques:
Wheel axle:
59 Nm (5.9 m·kgf, 43 ft·lbf)
Front wheel axle pinch bolt:
20 Nm (2.0 m·kgf, 14 ft·lbf)
1. Axle nut
2. Brake torque rod
3. Brake torque rod nut and bolt
4. Brake rod
5. Brake pedal free play adjusting nut
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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)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-35
6
EAU25850
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 inferi-
or, have a shorter service life and can
lead to expensive repair bills.5KRE2.book Page 35 Monday, June 23, 2003 3:32 PM
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PERIODIC MAINTENANCE AND MINOR REPAIR
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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 in
the fuel tank.1. Fuel
There is enough fuel.
There is no fuel.
Check the compression.
Supply fuel.
The engine does not start.
Check the compression.
Operate the electric starter.2. Compression
There is compression.
There is no compression.
Check the ignition.
Have a Yamaha dealer
check the vehicle.
Remove the spark plugs
and check the electrodes.3. Ignition
Wipe off with a dry cloth and correct the
spark plug gaps, or replace the spark plugs.
Have a Yamaha dealer check the vehicle.
The engine does not start.
Have a Yamaha dealer
check the vehicle.
The engine does not start.
Check the battery.
Operate the electric starter.4. Battery
The engine turns over
quickly.
The engine turns over
slowly.
The battery is good.Check the battery lead connections,
and charge the battery if necessary.
DryWet
Open the throttle halfway and operate
the electric starter.
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Page 79 of 82
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
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