2004 YAMAHA XVS250 brake

PERIODIC MAINTENANCE AND MINOR REPAIR
6-24
6
EAU23131
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.
EAU23140
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.
EAU23200
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.
WARNING
EWA10730
If the sidestand does not move up
and down smoothly, have a Yamahadealer check or repair it.
Recommended lubricant:
Lithium-soap-based grease (all-pur-
pose grease)
Recommended lubricant:
Lithium-soap-based grease (all-pur-
pose grease)
Recommended lubricant:
Lithium-soap-based grease (all-pur-
pose grease)
5KRE2.book Page 24 Monday, June 23, 2003 3:32 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-25
6
EAU23271
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
WARNING
EWA10750
Securely support the vehicle so thatthere 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 vehicle on a level sur-
face and hold it in an upright posi-
tion.
2. While applying the front brake,
push down hard on the handlebars
several times to check if the front
fork compresses and rebounds
smoothly.
CAUTION:
ECA10590
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or re-pair it.
EAU23280
Checking the steering Worn or loose steering bearings may
cause danger. Therefore, the operation
of the steering must be checked as fol-
lows at the intervals specified in the pe-
riodic maintenance and lubrication
chart.
1. Place a stand under the engine to
raise the front wheel off the
ground.
WARNING
EWA10750
Securely support the vehicle so thatthere is no danger of it falling over.
2. Hold the lower ends of the front
fork legs and try to move them for-
ward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the steering.
5KRE2.book Page 25 Monday, June 23, 2003 3:32 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-30
6
EAU24131
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.
CAUTION:
ECA10680
Do not overtighten the screws, oth-erwise the lens may break.
EAU24210
Replacing a turn signal light
bulb 1. Remove the turn signal lens by re-
moving the screws.
2. Remove the defective bulb by
pushing it in and turning it counter-
clockwise.
1. Screw
1. Tail/brake light bulb
1. Screw
5KRE2.book Page 30 Monday, June 23, 2003 3:32 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-32
6
EAU24360
Front wheel
EAU24660
To remove the front wheel
WARNING
EWA10820


It is advisable to have a Yamaha
dealer service the wheel.


Securely support the motor-
cycle so that there is no dangerof 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 6-31.
5. Pull the wheel axle out, and then
remove the wheel.
CAUTION:
ECA11070
Do not apply the brake after the
wheel has been removed together
with the brake disc, otherwise thebrake pads will be forced shut.
EAU24921
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 theretainer on the fork leg.
1. Speedometer cable
1. Front wheel axle pinch bolt
2. Rubber cap
3. Wheel axle
1. Speedometer gear unit
5KRE2.book Page 32 Monday, June 23, 2003 3:32 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-33
63. 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 handlebars
several times to check if the front
fork compresses and rebounds
smoothly.7. Connect the speedometer cable.
EAU25080
Rear wheel
EAU25430
To remove the rear wheel
WARNING
EWA10820


It is advisable to have a Yamaha
dealer service the wheel.


Securely support the motor-
cycle so that there is no dangerof it falling over.
1. Loosen the axle nut and the brake
torque rod nut at the brake shoe
plate.
1. Speedometer gear unit retainerTightening torques:
Wheel axle:
59 Nm (5.9 m·kgf, 43 ft·lbf)
Front wheel axle pinch bolt:
20 Nm (2.0 m·kgf, 14 ft·lbf)
1. Axle nut
2. Brake torque rod
3. Brake torque rod nut and bolt
4. Brake rod
5. Brake pedal free play adjusting nut
5KRE2.book Page 33 Monday, June 23, 2003 3:32 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-34
6 2. Lift the rear wheel off the ground
according to the procedure on
page 6-31.
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 andinstall the wheel.
8. Remove the wheel.
EAU25780
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 6-21.)
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 6-17.)
WARNING
EWA10660
After adjusting the brake pedal free
play, check the operation of thebrake light.
1. Wheel axle
2. Drive chain slack adjusting nut
3. Locknut
Tightening torque:
Brake torque rod nut:
23 Nm (2.3 m·kgf, 17 ft·lbf)
Tightening torque:
Axle nut:
104 Nm (10.4 m·kgf, 75 ft·lbf)
5KRE2.book Page 34 Monday, June 23, 2003 3:32 PM

MOTORCYCLE CARE AND STORAGE
7-1
7
EAU26040
Care While the open design of a motorcycle
reveals the attractiveness of the tech-
nology, it also makes it more vulnera-
ble. Rust and corrosion can develop
even if high-quality components are
used. A rusty exhaust pipe may go un-
noticed on a car, however, it detracts
from the overall appearance of a motor-
cycle. Frequent and proper care does
not only comply with the terms of the
warranty, but it will also keep your
motorcycle looking good, extend its life
and optimize its performance.
Before cleaning
1. Cover the muffler outlets with plas-
tic bags after the engine has
cooled down.
2. Make sure that all caps and covers
as well as all electrical couplers
and connectors, including the
spark plug caps, are tightly in-
stalled.
3. Remove extremely stubborn dirt,
like oil burnt onto the crankcase,
with a degreasing agent and a
brush, but never apply such prod-ucts onto seals, gaskets, sprock-
ets, the drive chain and wheel
axles. Always rinse the dirt and de-
greaser off with water.
Cleaning
CAUTION:
ECA10770


Avoid using strong acidic wheel
cleaners, especially on spoked
wheels. If such products are
used on hard-to-remove dirt, do
not leave the cleaner on the af-
fected area any longer than in-
structed. Also, thoroughly rinse
the area off with water, immedi-
ately dry it, and then apply a cor-
rosion protection spray.


Improper cleaning can damage
windshields, cowlings, panels
and other plastic parts. Use only
a soft, clean cloth or sponge
with mild detergent and water to
clean plastic.


Do not use any harsh chemical
products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
contact with strong or abrasivecleaning products, solvent or
thinner, fuel (gasoline), rust re-
movers or inhibitors, brake flu-
id, antifreeze or electrolyte.


Do not use high-pressure wash-
ers or steam-jet cleaners since
they cause water seepage and
deterioration in the following ar-
eas: seals (of wheel and swing-
arm bearings, fork and brakes),
electric components (couplers,
connectors, instruments,
switches and lights), breather
hoses and vents.


For motorcycles equipped with
a windshield: Do not use strong
cleaners or hard sponges as
they will cause dulling or
scratching. Some cleaning com-
pounds for plastic may leave
scratches on the windshield.
Test the product on a small hid-
den part of the windshield to
make sure that it does not leave
any marks. If the windshield is
scratched, use a quality plastic
polishing compound afterwashing.
5KRE2.book Page 1 Monday, June 23, 2003 3:32 PM

MOTORCYCLE CARE AND STORAGE
7-2
7 After normal use
Remove dirt with warm water, a mild
detergent, and a soft, clean sponge,
and then rinse thoroughly with clean
water. Use a toothbrush or bottlebrush
for hard-to-reach areas. Stubborn dirt
and insects will come off more easily if
the area is covered with a wet cloth for
a few minutes before cleaning.
After riding in the rain, near the sea oron salt-sprayed roadsSince sea salt or salt sprayed on roads
during winter are extremely corrosive in
combination with water, carry out the
following steps after each ride in the
rain, near the sea or on salt-sprayed
roads.NOTE:Salt sprayed on roads in the winter mayremain well into spring.
1. Clean the motorcycle with cold wa-
ter and a mild detergent, after the
engine has cooled down.
CAUTION:
ECA10790
Do not use warm water since it in-
creases the corrosive action of thesalt.
2. After drying the motorcycle, apply
a corrosion protection spray on all
metal, including chrome- and nick-
el-plated, surfaces to prevent cor-
rosion.
After cleaning
1. Dry the motorcycle with a chamois
or an absorbing cloth.
2. Immediately dry the drive chain
and lubricate it to prevent it from
rusting.
3. Use a chrome polish to shine
chrome, aluminum and stainless-
steel parts, including the exhaust
system. (Even the thermally in-
duced discoloring of stainless-
steel exhaust systems can be re-
moved through polishing.)4. To prevent corrosion, it is recom-
mended to apply a corrosion pro-
tection spray on all metal,
including chrome- and nickel-plat-
ed, surfaces.
5. Use spray oil as a universal clean-
er to remove any remaining dirt.
6. Touch up minor paint damage
caused by stones, etc.
7. Wax all painted surfaces.
8. Let the motorcycle dry completely
before storing or covering it.
WARNING
EWA10930


Make sure that there is no oil or
wax on the brakes or tires. If
necessary, clean the brake
discs and brake linings with a
regular brake disc cleaner or ac-
etone, and wash the tires with
warm water and a mild deter-
gent.


Before operating the motor-
cycle test its braking perfor-mance and cornering behavior.
5KRE2.book Page 2 Monday, June 23, 2003 3:32 PM