2002 YAMAHA XVS250 torque

6-1
6
EAU00462
6-PERIODIC MAINTENANCE AND MINOR REPAIR
EAU00464
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. _
EAU01175
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
6-9
6 To install a spark plug
1. Measure the spark plug gap with a
wire thickness gauge and, if nec-
essary, adjust the gap to
specification.
2. Clean the surface of the spark
plug gasket and its mating sur-
face, and then wipe off any grime
from the spark plug threads.
3. Install the spark plug with the
spark plug wrench, and then tight-
en it to the specified torque.
NOTE:_ If a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4–1/2 turn
past finger tight. However, the spark
plug should be tightened to the speci-
fied torque as soon as possible. _4. Install the spark plug cap.
a. Spark plug gap
Spark plug gap:
0.6–0.7 mm
Tightening torque:
Spark plug:
12.5 Nm (1.25 m·kgf)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-11
6 3. Remove the engine oil filler cap
and drain bolt to drain the oil from
the crankcase.
NOTE:_ Skip steps 4–6 if the oil filter element is
not being replaced. _
4. Remove the oil filter element cover
by removing the bolts.5. Remove and replace the oil filter
element and O-ring.
6. Install the oil filter element cover
by installing the bolts, then tighten-
ing them to the specified torque.
NOTE:_ Make sure that the O-ring is properly
seated. _
1. Engine oil drain bolt
2. Oil panLeft side
1. Bolt (× 3)
1. Oil filter element
2. O-ringTightening torque:
Oil filter element cover bolt:
10 Nm (1.0 m·kgf)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-12
67. Install the engine oil drain bolt, and
then tighten it to the specified
torque.
8. Add the specified amount of the
recommended engine oil, and
then install and tighten the oil filler
cap.
ECA00105
CAUTION:_

In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives with
the oil or use oils of grade “CD”
or higher. In addition, do not
use oils labeled “ENERGY CON-
SERVING II” or higher.


Make sure that no foreign mate-
rial enters the crankcase.
_9. Start the engine, and then let it idle
for several minutes while checking
it for oil leakage. If oil is leaking,
immediately turn the engine off
and check for the cause.
10. Turn the engine off, and then
check the oil level and correct it if
necessary.
EAU04485*
Cleaning the air filter element The air filter element should be cleaned
at the intervals specified in the periodic
maintenance and lubrication chart.
Clean the air filter element more fre-
quently if you are riding in unusually
wet or dusty areas.
1. Remove the air filter case by re-
moving the bolts, loosening the
clamp screw, then disconnecting
the hose. Tightening torque:
Engine oil drain bolt:
34 Nm (3.4 m·kgf)
Recommended engine oil:
See page 8-1.
Oil quantity:
With oil filter element
replacement:
1.6 L
Without oil filter element
replacement:
1.4 L
Total amount (dry engine):
1.75 L1. Bolt (× 2)
2. Clamp screw
3. Hose
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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)
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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)
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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
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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