2002 YAMAHA XVS250 maintenance

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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
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1
1-1
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1-
GIVE SAFETY THE RIGHT OF WAY
Motorcycles are fascinating vehicles, which can give you an unsurpassed feeling of power and
freedom. However, they also impose certain limits, which you must accept; even the best motorcycle
does not ignore the laws of physics.
Regular care and maintenance are essential for preserving value and operating condition of your
motorcycle. Moreover, what is true for the motorcycle is also true for the rider: good performance
depends on being in good shape. Riding under the influence of medication, drugs and alcohol is, of
course, out of the question. Motorcycle riders—more than car drivers—must always be at their mental
and physical best. Under the influence of even small amounts of alcohol, there is a tendency to take
dangerous risks.
Protective clothing is as essential for the motorcycle rider as seat belts are for car drivers and
passengers. Always wear a complete motorcycle suit (whether made of leather or tear-resistant
synthetic materials with protectors), sturdy boots, motorcycle gloves and a properly fitting helmet.
Optimum protective wear, however, should not encourage carelessness. Although full-coverage
helmets and suits, in particular, create an illusion of total safety and protection, motorcyclists will
always be vulnerable. Riders who lack critical self-control run the risk of going too fast and are apt to
take chances. This is even more dangerous in wet weather. The good motorcyclist rides safely,
predictably and defensively—avoiding all dangers, including those caused by others.
Enjoy your ride!
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INSTRUMENT AND CONTROL FUNCTIONS
3-8
3
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ECA00104
CAUTION:_ Use only unleaded gasoline. The
use of leaded gasoline will cause se-
vere damage to internal engine
parts, such as the valves and piston
rings, as well as to the exhaust sys-
tem. _Your Yamaha engine has been de-
signed to use regular unleaded gaso-
line with a research octane number of
91 or higher. If knocking (or pinging)
occurs, use a gasoline of a different
brand or premium unleaded fuel. Use
of unleaded fuel will extend spark plug
life and reduce maintenance costs.
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Fuel cock This motorcycle is equipped with a
negative pressure fuel cock. The fuel
cock supplies fuel from the tank to the
carburetor while also filtering it.
The fuel cock lever positions are ex-
plained as follows and shown in the il-
lustrations.
ON
With the fuel cock lever in this position,
fuel flows to the carburetor when the
engine is running. Turn the fuel cock le-
ver to this position when starting the
engine and riding.RES
This indicates reserve. With the fuel
cock lever in this position, the fuel re-
serve is made available. Quickly turn
the fuel cock lever to this position if you
run out of fuel while riding, otherwise
the engine may stall and will have to be
primed (see “PRI”). After turning the
fuel cock lever to “RES”, refuel as soon
as possible and be sure to turn the fuel
cock lever back to “ON”! Recommended fuel:
REGULAR UNLEADED
GASOLINE ONLY
Fuel tank capacity:
Total amount:
11 L
Reserve amount:
3.4 L1. Pointed end positioned over “ON”ON: Normal position
1. Pointed end positioned over “RES”RES: Reserve position
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6-1
6
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6-PERIODIC MAINTENANCE AND MINOR REPAIR
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Safety is an obligation of the owner.
Periodic inspection, adjustment and lu-
brication 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 main-
tenance and lubrication chart should be
simply considered as a general guide
under normal riding conditions. Howev-
er, DEPENDING ON THE WEATHER,
TERRAIN, GEOGRAPHICAL LOCA-
TION, AND INDIVIDUAL USE, THE
MAINTENANCE INTERVALS MAY
NEED TO BE SHORTENED.
EW000060
WARNING
_ If you are not familiar with motor-
cycle maintenance work, have a
Yamaha dealer do it for you. _
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Owner’s tool kit The owner’s tool kit is located behind
panel A. (See page 6-5 for panel re-
moval and installation procedures.)
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, have
a Yamaha dealer perform it for you. _
EW000063
WARNING
_ 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
changes. _
1. Owner’s tool kit
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
6
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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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PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
6
10
*WheelsCheck runout, spoke tightness and for damage.
Tighten spokes if necessary.√√√√
11*TiresCheck tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.√√√√ √
12*Wheel bearingsCheck bearing for looseness or damage.√√√√
13*SwingarmCheck operation and for excessive play.√√√√
Lubricate with lithium-soap-based grease. Every 50,000 km
14 Drive chainCheck chain slack.
Make sure that the rear wheel is properly aligned.
Clean and lubricate.Every 1,000 km and after washing
the motorcycle or riding in the rain
15*Steering bearingsCheck bearing play and steering for roughness.√√√√√
Lubricate with lithium-soap-based grease. Every 20,000 km
16*Chassis fastenersMake sure that all nuts, bolts and screws are properly tightened.√√√√ √
17 SidestandCheck operation.
Lubricate.√√√√ √
18*Sidestand switchCheck operation.√√√√√ √
19*Front forkCheck operation and for oil leakage.√√√√
20*Shock absorber
assembliesCheck operation and shock absorbers for oil leakage.√√√√
21*CarburetorCheck starter (choke) operation.
Adjust engine idling speed.√√√√√ √
22 Engine oilChange.
Check oil level and vehicle for oil leakage.√√√√√ √
23 Engine oil filter elementReplace.√√√
24*Engine oil strainerClean.√ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (×1,000 km)
ANNUAL
CHECK
1 10203040
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
6
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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.
_25
*Front and rear brake
switchesCheck operation.√√√√√ √
26 Moving parts and cablesLubricate.√√√√ √
27*Throttle grip housing
and cableCheck operation and free play.
Adjust the throttle cable free play if necessary.
Lubricate the throttle grip housing and cable.√√√√ √
28*Air induction systemCheck the air cut-off valve, read valve, and hose for
damage.
Replace the entire air induction system if necessary.√√√√ √
29*Lights, signals and
switchesCheck operation.
Adjust headlight beam.√√√√√ √ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (×1,000 km)
ANNUAL
CHECK
1 10203040
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-5
6
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Removing and installing
panels The panels shown above need to be
removed to perform some of the main-
tenance jobs described in this chapter.
Refer to this section each time a panel
needs to be removed and installed.
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Panel A
To remove the panel1. Slide the panel lock cover open,
insert the key into the lock, and
then turn it 1/4 turn clockwise.
1. Panel A
1. Panel B
1. Panel lock cover
2. Unlock.
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