brake YAMAHA XVS250 2004 Owners Manual

TABLE OF CONTENTSSAFETY INFORMATION ..................1-1
DESCRIPTION ..................................2-1
Left view ..........................................2-1
Right view ........................................2-2
Controls and instruments.................2-3
INSTRUMENT AND CONTROL
FUNCTIONS.......................................3-1
Main switch/steering lock ................3-1
Indicator and warning lights ............3-2
Speedometer unit ...........................3-3
Self-diagnosis device ......................3-3
Anti-theft alarm (optional) ...............3-3
Handlebar switches ........................3-4
Clutch lever .....................................3-5
Shift pedal .......................................3-5
Brake lever .....................................3-6
Brake pedal ....................................3-6
Fuel tank cap ..................................3-6
Fuel .................................................3-7
Fuel cock ........................................3-8
Starter (choke) lever .......................3-9
Helmet holder .................................3-9
Adjusting the shock absorber
assemblies ................................3-10
Sidestand ......................................3-10
Ignition circuit cut-off system ........3-11
PRE-OPERATION CHECKS..............4-1
Pre-operation check list ..................4-2OPERATION AND IMPORTANT
RIDING POINTS................................. 5-1
Starting a cold engine .................... 5-1
Starting a warm engine .................. 5-2
Shifting ........................................... 5-2
Tips for reducing fuel
consumption ............................... 5-3
Engine break-in .............................. 5-4
Parking ........................................... 5-4
PERIODIC MAINTENANCE AND
MINOR REPAIR................................. 6-1
Owner’s tool kit ............................... 6-1
Periodic maintenance and
lubrication chart .......................... 6-2
Removing and installing panels ..... 6-5
Checking the spark plugs ............... 6-6
Engine oil and oil filter element ...... 6-8
Cleaning the air filter element ...... 6-10
Adjusting the carburetor ............... 6-11
Adjusting the engine idling
speed ........................................ 6-12
Adjusting the throttle cable
free play .................................... 6-12
Adjusting the valve clearance ...... 6-13
Tires ............................................. 6-13
Spoke wheels ............................... 6-15
Adjusting the clutch lever
free play .................................... 6-15
Adjusting the brake lever
free play .................................... 6-16Adjusting the brake pedal
position and free play ............... 6-17
Adjusting the rear brake
light switch ................................ 6-18
Checking the front brake pads
and rear brake shoes ............... 6-19
Checking the brake fluid level ...... 6-19
Changing the brake fluid .............. 6-20
Drive chain slack .......................... 6-21
Lubricating the drive chain ........... 6-22
Checking and lubricating the
cables ....................................... 6-23
Checking and lubricating the
throttle grip and cable ............... 6-23
Checking and lubricating the
brake and shift pedals .............. 6-24
Checking and lubricating the
brake and clutch levers ............ 6-24
Checking and lubricating the
sidestand .................................. 6-24
Checking the front fork ................. 6-25
Checking the steering .................. 6-25
Checking the wheel bearings ....... 6-26
Battery ......................................... 6-26
Replacing the fuses ..................... 6-28
Replacing the headlight bulb ....... 6-28
Replacing the tail/brake
light bulb ................................... 6-30
Replacing a turn signal
light bulb ................................... 6-30
Supporting the motorcycle ........... 6-315KRE2.book Page 1 Monday, June 23, 2003 3:32 PM

DESCRIPTION
2-2
2
EAU10420
Right view1. 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 spring preload adjusting ring (page 3-10)
5KRE2.book Page 2 Monday, June 23, 2003 3:32 PM

DESCRIPTION
2-3
2
EAU10430
Controls and instruments1. 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 23, 2003 3:32 PM

INSTRUMENT AND CONTROL FUNCTIONS
3-6
3
EAU12890
Brake lever The brake lever is located at the right
handlebar grip. To apply the front
brake, pull the lever toward the handle-
bar grip.
EAU12941
Brake pedal The brake pedal is on the right side of
the motorcycle. To apply the rear
brake, press down on the brake pedal.
EAU13000
Fuel tank cap To remove the fuel tank cap
Insert the key into the lock and turn it
1/4 turn clockwise. The lock will be re-
leased and the fuel tank cap can be re-
moved.
To install the fuel tank cap
1. Push the fuel tank cap into position
with the key inserted in the lock.
2. Turn the key counterclockwise to
the original position, and then re-
move it.
1. Brake lever
1. Brake pedal
1. Unlock.
5KRE2.book Page 6 Monday, June 23, 2003 3:32 PM

PRE-OPERATION CHECKS
4-2
4
EAU15601
Pre-operation check list
ITEM CHECKS PAGE
FuelCheck fuel level in fuel tank.
Refuel if necessary.
Check fuel line for leakage.3-7
Engine oilCheck oil level in engine.
If necessary, add recommended oil to specified level.
Check vehicle for oil leakage.6-8
Front brakeCheck operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check lever free play.
Adjust if necessary.
Check brake pads for wear.
Replace if necessary.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.6-16, 6-19, 6-19
Rear brakeCheck operation.
Check pedal free play.
Adjust if necessary.6-17, 6-19
ClutchCheck operation.
Lubricate cable if necessary.
Check lever free play.
Adjust if necessary.6-15
Throttle gripMake sure that operation is smooth.
Check cable free play.
If necessary, have Yamaha dealer adjust cable free play and lubricate cable and
grip housing.6-12, 6-23
Control cablesMake sure that operation is smooth.
Lubricate if necessary.6-23
5KRE2.book Page 2 Monday, June 23, 2003 3:32 PM

PRE-OPERATION CHECKS
4-3
4
Drive chainCheck chain slack.
Adjust if necessary.
Check chain condition.
Lubricate if necessary.6-21, 6-22
Wheels and tiresCheck for damage.
Check tire condition and tread depth.
Check air pressure.
Correct if necessary.6-13, 6-15
Brake and shift pedalsMake sure that operation is smooth.
Lubricate pedal pivoting points if necessary.6-24
Brake and clutch leversMake sure that operation is smooth.
Lubricate lever pivoting points if necessary.6-24
SidestandMake sure that operation is smooth.
Lubricate pivot if necessary.6-24
Chassis fastenersMake sure that all nuts, bolts and screws are properly tightened.
Tighten if necessary.—
Instruments, lights, signals
and switchesCheck operation.
Correct if necessary.—
Sidestand switchCheck operation of ignition circuit cut-off system.
If system is defective, have Yamaha dealer check vehicle.3-10 ITEM CHECKS PAGE
5KRE2.book Page 3 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
6-4
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
6-15
6
WARNING
EWA10570


Have a Yamaha dealer replace
excessively worn tires. Besides
being illegal, operating the
motorcycle with excessively
worn tires decreases riding sta-
bility and can lead to loss of
control.


The replacement of all wheel-
and brake-related parts, includ-
ing the tires, should be left to a
Yamaha dealer, who has the
necessary professional knowl-
edge and experience.


It is not recommended to patch
a punctured tube. If unavoid-
able, however, patch the tube
very carefully and replace it as
soon as possible with a high-quality product.
EAU21940
Spoke wheels To maximize the performance, durabil-
ity, and safe operation of your motor-
cycle, note the following points
regarding the specified wheels.

The wheel rims should be checked
for cracks, bends or warpage, and
the spokes for looseness or dam-
age before each ride. If any dam-
age is found, have a Yamaha
dealer replace the wheel. Do not
attempt even the smallest repair to
the wheel. A deformed or cracked
wheel must be replaced.


The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced. An
unbalanced wheel can result in
poor performance, adverse han-
dling characteristics, and a short-
ened tire life.


Ride at moderate speeds after
changing a tire since the tire sur-
face must first be “broken in” for it
to develop its optimal characteris-
tics.
EAU22040
Adjusting the clutch lever free
play The clutch lever free play should mea-
sure 5.0–10.0 mm (0.20–0.39 in) as
shown. Periodically check the clutch le-
ver free play and, if necessary, adjust it
as follows.
1. Loosen the locknut at the clutch le-
ver.
2. To increase the clutch lever free
play, turn the adjusting bolt in di-
rection (a). To decrease the clutch
lever free play, turn the adjusting
bolt in direction (b).1. Locknut
2. Clutch lever free play adjusting bolt
3. Clutch lever free play
5KRE2.book Page 15 Monday, June 23, 2003 3:32 PM

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 locknut
and 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 clutch cable.
5. Loosen the locknut at the crank-
case.
6. To increase the clutch lever free
play, turn the adjusting nut in direc-
tion (a). To decrease the clutch le-
ver free play, turn the adjusting nut
in direction (b).7. Tighten the locknut at the clutch le-
ver and the crankcase.
EAU22092
Adjusting the brake lever free
play The brake lever free play should mea-
sure 5.0–8.0 mm (0.20–0.31 in) as
shown. Periodically check the brake le-
ver free play and, if necessary, adjust it
as follows.
1. Loosen the locknut at the brake le-
ver.
2. To increase the brake lever free
play, turn the adjusting screw in di-
rection (a). To decrease the brake
lever free play, turn the adjusting
screw in direction (b).
3. Tighten the locknut.
1. Locknut
2. Clutch lever free play adjusting nut
(crankcase)
1. Locknut
2. Brake lever free play adjusting screw
3. Brake lever free play
5KRE2.book Page 16 Monday, June 23, 2003 3:32 PM