2002 YAMAHA XVS250 brake

PERIODIC MAINTENANCE AND MINOR REPAIR
6-26
6
EC000096
CAUTION:_ Improper drive chain slack will over-
load the engine as well as other vital
parts of the motorcycle and can lead
to chain slippage or breakage. To
prevent this from occurring, keep
the drive chain slack within the
specified limits. _3. Tighten both locknuts and the axle
nut to the specified torques.
4. Adjust the brake pedal free play.
(See page 6-21 for brake pedal
free play adjustment procedures.)
EW000103
WARNING
_ After adjusting the brake pedal free
play, check the operation of the
brake light. _
EAU03006
Lubricating the drive chain The drive chain must be cleaned and
lubricated at the intervals specified in
the periodic maintenance and lubrica-
tion chart, otherwise it will quickly wear
out, especially when riding in dusty or
wet areas. Service the drive chain as
follows.
EC000097
CAUTION:_ The drive chain must be lubricated
after washing the motorcycle or
riding in the rain. _1. Clean the drive chain with kero-
sene and a small soft brush.
ECA00053
CAUTION:_ To prevent damaging the O-rings,
do not clean the drive chain with
steam cleaners, high-pressure
washers or inappropriate solvents. _
2. Wipe the drive chain dry.
3. Thoroughly lubricate the drive
chain with a special O-ring chain
lubricant.
ECA00052
CAUTION:_ Do not use engine oil or any other
lubricants for the drive chain, as
they may contain substances that
could damage the O-rings. _
Tightening torques:
Locknut:
16 Nm (1.6 m·kgf)
Axle nut:
104 Nm (10.4 m·kgf)
E_5kr.book Page 26 Friday, December 14, 2001 11:33 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-28
6
EAU03370
Checking and lubricating the
brake and shift pedals The operation of the brake and shift
pedals should be checked before each
ride, and the pedal pivots should be lu-
bricated if necessary.
EAU03164
Checking and lubricating the
brake and clutch levers The operation of the brake and clutch
levers should be checked before each
ride, and the lever pivots should be lu-
bricated if necessary.
EAU03165
Checking and lubricating the
sidestand The operation of the sidestand should
be checked before each ride, and the
sidestand pivot and metal-to-metal
contact surfaces should be lubricated if
necessary.
EW000113
WARNING
_ If the sidestand does not move up
and down smoothly, have a Yamaha
dealer check or repair it. _
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
E_5kr.book Page 28 Friday, December 14, 2001 11:33 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-29
6
EAU02939
Checking the front fork The condition and operation of the front
fork must be checked as follows at the
intervals specified in the periodic main-
tenance and lubrication chart.
To check the condition
EW000115
WARNING
_ Securely support the motorcycle so
that there is no danger of it falling
over. _Check the inner tubes for scratches,
damage and excessive oil leakage.To check the operation
1. Place the motorcycle on a level
surface and hold it in an upright
position.
2. 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.
EC000098
CAUTION:_ If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or re-
pair it. _
E_5kr.book Page 29 Friday, December 14, 2001 11:33 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-35
6 6. Install the headlight unit by install-
ing the screws.
7. Have a Yamaha dealer adjust the
headlight beam if necessary.
EAU01623
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.
EC000108
CAUTION:_ Do not overtighten the screws, oth-
erwise the lens may break. _
1. Screw (× 2)
1. Tail/brake light bulb
E_5kr.book Page 35 Friday, December 14, 2001 11:33 AM

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