2002 YAMAHA XVS250 brake

EAU00009
TABLE OF CONTENTS
GIVE SAFETY THE RIGHT OF WAY .................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 ........................................................ 3-11
Ignition circuit cut-off system ........................... 3-11PRE-OPERATION CHECKS ...............................4-1
Pre-operation check list .....................................4-1
OPERATION AND IMPORTANT RIDING
POINTS................................................................5-1
Starting the engine ............................................5-1
Starting a warm engine .....................................5-2
Shifting ..............................................................5-3
Recommended shift points
(for Switzerland only) .....................................5-3
Tips for reducing fuel consumption ...................5-4
Engine break-in .................................................5-4
Parking ..............................................................5-5
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 ..................................6-8
Engine oil and oil filter element .......................6-10
Cleaning the air filter element .........................6-12
Adjusting the carburetor ..................................6-15
Adjusting the engine idling speed ...................6-15
Adjusting the throttle cable free play ...............6-16
Adjusting the valve clearance .........................6-16
Tires ................................................................6-16
Spoke wheels ..................................................6-19
123
456
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TABLE OF CONTENTS
Adjusting the clutch lever free play ................. 6-19
Adjusting the brake lever free play .................. 6-20
Adjusting the brake pedal position and
free play ....................................................... 6-20
Adjusting the rear brake light switch ............... 6-22
Checking the front brake pads and rear
brake shoes ................................................. 6-22
Checking the brake fluid level ......................... 6-23
Changing the brake fluid ................................. 6-24
Drive chain slack ............................................. 6-24
Lubricating the drive chain .............................. 6-26
Checking and lubricating the cables ............... 6-27
Checking and lubricating the throttle grip
and cable ..................................................... 6-27
Checking and lubricating the brake and
shift pedals .................................................. 6-28
Checking and lubricating the brake and
clutch levers ................................................ 6-28
Checking and lubricating the sidestand .......... 6-28
Checking the front fork .................................... 6-29
Checking the steering ..................................... 6-30
Checking the wheel bearings .......................... 6-30
Battery ............................................................. 6-31
Replacing the fuses ........................................ 6-32
Replacing the headlight bulb ........................... 6-33
Replacing the tail/brake light bulb ................... 6-35
Replacing a turn signal light bulb .................... 6-36
Supporting the motorcycle .............................. 6-36Front wheel ..................................................... 6-37
Rear wheel ...................................................... 6-39
Troubleshooting .............................................. 6-40
Troubleshooting chart ..................................... 6-41
MOTORCYCLE CARE AND STORAGE ............. 7-1
Care .................................................................. 7-1
Storage ............................................................. 7-4
SPECIFICATIONS ............................................... 8-1
Specifications .................................................... 8-1
Conversion table ............................................... 8-5
CONSUMER INFORMATION.............................. 9-1
Identification numbers ....................................... 9-1
Key identification number .................................. 9-1
Vehicle identification number ............................ 9-1
Model label ........................................................ 9-2
789
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DESCRIPTION
2-2
2
Right view7. Owner’s tool kit (page 6-1)
8. Battery (page 6-31)
9. Air filter element (page 6-12)
10. Main switch/steering lock (page 3-1)11. Brake pedal (page 3-6)
12. Oil filter element (page 6-10)
13. Engine oil level check window (page 6-10)
14. Shock absorber assembly spring
preload adjusting ring (page 3-10)
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DESCRIPTION
2-3
2
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 6-16)
7. Fuel tank cap (page 3-6)
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INSTRUMENT AND CONTROL FUNCTIONS
3-6
3
EAU00158
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.
EAU00162
Brake pedal The brake pedal is on the right side of
the motorcycle. To apply the rear
brake, press down on the brake pedal.
EAU03756
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 released
and the fuel tank cap can be removed.
To install the fuel tank cap
1. Push the fuel tank cap into posi-
tion 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.
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4-1
4
EAU01114
4-PRE-OPERATION CHECKS
The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly,
even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss
of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thorough visual inspec-
tion, to check the following points before each ride.
EAU03439
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.6-10
Front brakeCheck operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check lever free play.
Adjust if necessary.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.6-20, 6-22–6-24
Rear brakeCheck operation.
Check pedal free play.
Adjust if necessary.6-20–6-24
ClutchCheck operation.
Lubricate cable if necessary.
Check lever free play.
Adjust if necessary.6-19, 6-28
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.6-16, 6-27
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PRE-OPERATION CHECKS
4-2
4
Control cablesMake sure that operation is smooth.
Lubricate if necessary.6-27
Drive chainCheck chain slack.
Adjust if necessary.
Check chain condition.
Lubricate if necessary.6-24–6-25
Wheels and tiresCheck for damage.
Check tire condition and tread depth.
Check air pressure.
Correct if necessary.6-16–6-18
Brake and shift pedalsMake sure that operation is smooth.
Lubricate pedal pivoting points if necessary.6-28
Brake and clutch leversMake sure that operation is smooth.
Lubricate lever pivoting points if necessary.6-28
SidestandMake sure that operation is smooth.
Lubricate pivot if necessary.6-28
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.3-11 ITEM CHECKS PAGE
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
6
EAU03685
Periodic maintenance and lubrication chart
NOTE:_

The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.


From 50,000 km, repeat the maintenance intervals starting from 10,000 km.


Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and techni-
cal skills.
_CP-03ENO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (×1,000 km)
ANNUAL
CHECK
1 10203040
1
*Fuel lineCheck fuel hoses and vacuum hose for cracks or damage.√√√√ √
2*Fuel filterCheck condition.√√
3 Spark plugsCheck condition.
Clean and regap.√√
Replace.√√
4*ValvesCheck valve clearance.
Adjust.√√√√
5 Air filter elementClean.√√
Replace.√√
6ClutchCheck operation.
Adjust.√√√√√
7*Front brakeCheck operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)√√ √ √ √ √
Replace brake pads. Whenever worn to the limit
8*Rear brakeCheck operation and adjust brake pedal free play.√√√√√ √
Replace brake shoes. Whenever worn to the limit
9*Brake hoseCheck for cracks or damage.√√√√ √
Replace. (See NOTE on page 6-4.) Every 4 years
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