2004 YAMAHA XVS250 brake pads

TABLE OF CONTENTSSAFETY INFORMATION ..................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 ......................................3-10
Ignition circuit cut-off system ........3-11
PRE-OPERATION CHECKS..............4-1
Pre-operation check list ..................4-2OPERATION AND IMPORTANT
RIDING POINTS................................. 5-1
Starting a cold engine .................... 5-1
Starting a warm engine .................. 5-2
Shifting ........................................... 5-2
Tips for reducing fuel
consumption ............................... 5-3
Engine break-in .............................. 5-4
Parking ........................................... 5-4
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 ............... 6-6
Engine oil and oil filter element ...... 6-8
Cleaning the air filter element ...... 6-10
Adjusting the carburetor ............... 6-11
Adjusting the engine idling
speed ........................................ 6-12
Adjusting the throttle cable
free play .................................... 6-12
Adjusting the valve clearance ...... 6-13
Tires ............................................. 6-13
Spoke wheels ............................... 6-15
Adjusting the clutch lever
free play .................................... 6-15
Adjusting the brake lever
free play .................................... 6-16Adjusting the brake pedal
position and free play ............... 6-17
Adjusting the rear brake
light switch ................................ 6-18
Checking the front brake pads
and rear brake shoes ............... 6-19
Checking the brake fluid level ...... 6-19
Changing the brake fluid .............. 6-20
Drive chain slack .......................... 6-21
Lubricating the drive chain ........... 6-22
Checking and lubricating the
cables ....................................... 6-23
Checking and lubricating the
throttle grip and cable ............... 6-23
Checking and lubricating the
brake and shift pedals .............. 6-24
Checking and lubricating the
brake and clutch levers ............ 6-24
Checking and lubricating the
sidestand .................................. 6-24
Checking the front fork ................. 6-25
Checking the steering .................. 6-25
Checking the wheel bearings ....... 6-26
Battery ......................................... 6-26
Replacing the fuses ..................... 6-28
Replacing the headlight bulb ....... 6-28
Replacing the tail/brake
light bulb ................................... 6-30
Replacing a turn signal
light bulb ................................... 6-30
Supporting the motorcycle ........... 6-315KRE2.book Page 1 Monday, June 23, 2003 3:32 PM

PRE-OPERATION CHECKS
4-2
4
EAU15601
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.6-8
Front brakeCheck operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check lever free play.
Adjust if necessary.
Check brake pads for wear.
Replace if necessary.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.6-16, 6-19, 6-19
Rear brakeCheck operation.
Check pedal free play.
Adjust if necessary.6-17, 6-19
ClutchCheck operation.
Lubricate cable if necessary.
Check lever free play.
Adjust if necessary.6-15
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.6-12, 6-23
Control cablesMake sure that operation is smooth.
Lubricate if necessary.6-23
5KRE2.book Page 2 Monday, June 23, 2003 3:32 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
6
EAU17701
Periodic maintenance and lubrication chart NOTE:

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


From 50000 km, repeat the maintenance intervals starting from 10000 km.


Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technicalskills.
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1000 km)
ANNUAL
CHECK
1 10203040
1*Fuel lineCheck fuel and vacuum hoses for cracks or damage.√√√√ √
2 Spark plugsCheck condition.
Clean and regap.√ √
Replace.√ √
3*ValvesCheck valve clearance.
Adjust.√ √ √ √
4 Air filter elementClean.√ √
Replace.√ √
5ClutchCheck operation.
Adjust.√ √ √ √ √
6*Front brakeCheck operation, fluid level and vehicle for fluid leakage.√√√√√ √
Replace brake pads. Whenever worn to the limit
7*Rear brakeCheck operation and adjust brake pedal free play.√ √ √ √ √ √
Replace brake shoes. Whenever worn to the limit
8*Brake hoseCheck for cracks or damage.√√√√ √
Replace. Every 4 years
5KRE2.book Page 2 Monday, June 23, 2003 3:32 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-19
6
EAU22380
Checking the front brake pads
and rear brake shoes The front brake pads and the rear brake
shoes must be checked for wear at the
intervals specified in the periodic main-
tenance and lubrication chart.
EAU22420
Front brake pads
Each front brake pad is provided with a
wear indicator groove, which allows
you to check the brake pad wear with-
out having to disassemble the brake.
To check the brake pad wear, check
the wear indicator groove. If a brake
pad has worn to the point that the wearindicator groove has almost disap-
peared, have a Yamaha dealer replace
the brake pads as a set.
EAU22540
Rear brake shoes
The rear brake is provided with a wear
indicator, which allows you to check the
brake shoe wear without having to dis-
assemble the brake. To check the
brake shoe wear, check the position of
the wear indicator while applying the
brake. If a brake shoe has worn to the
point that the wear indicator reaches
the wear limit line, have a Yamaha
dealer replace the brake shoes as a
set.
EAU32341
Checking the brake fluid level Front brake
Insufficient brake fluid may allow air to
enter the brake system, possibly caus-
ing it to become ineffective.
Before riding, check that the brake fluid
is above the minimum level mark and
replenish if necessary. A low brake fluid
level may indicate worn brake pads
and/or brake system leakage. If the
brake fluid level is low, be sure to check
the brake pads for wear and the brake
system for leakage.
Observe these precautions:
1. Brake pad wear indicator groove
1. Brake shoe wear limit line
2. Brake shoe wear indicator
1. Minimum level mark
5KRE2.book Page 19 Monday, June 23, 2003 3:32 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-20
6


When checking the fluid level,
make sure that the top of the mas-
ter cylinder is level by turning the
handlebars.


Use only the recommended quality
brake fluid, otherwise the rubber
seals may deteriorate, causing
leakage and poor braking perfor-
mance.


Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking performance.


Be careful that water does not en-
ter the master cylinder when refill-
ing. Water will significantly lower
the boiling point of the fluid and
may result in vapor lock.


Brake fluid may deteriorate paint-
ed surfaces or plastic parts. Al-
ways clean up spilled fluid
immediately.


As the brake pads wear, it is nor-
mal for the brake fluid level to grad-
ually go down. However, if thebrake fluid level goes down sud-
denly, have a Yamaha dealer
check the cause.
EAU22720
Changing the brake fluid Have a Yamaha dealer change the
brake fluid at the intervals specified in
the NOTE after the periodic mainte-
nance and lubrication chart. In addition,
have the oil seals of the brake master
cylinder and caliper as well as the
brake hose replaced at the intervals
listed below or whenever they are dam-
aged or leaking.

Oil seals: Replace every two
years.


Brake hose: Replace every four
years.
Recommended brake fluid:
DOT 4
5KRE2.book Page 20 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

INDEX
AAir filter element, cleaning .................... 6-10
Anti-theft alarm (optional) ....................... 3-3BBattery .................................................. 6-26
Brake and clutch levers, checking
and lubricating .................................... 6-24
Brake and shift pedals, checking
and lubricating .................................... 6-24
Brake fluid, changing ............................ 6-20
Brake fluid level, checking .................... 6-19
Brake lever ............................................. 3-6
Brake lever free play, adjusting ............ 6-16
Brake pads and shoes, checking.......... 6-19
Brake pedal ............................................ 3-6
Brake pedal position and free play,
adjusting ............................................. 6-17CCables, checking and lubricating .......... 6-23
Carburetor, adjusting ............................ 6-11
Care ........................................................ 7-1
Clutch lever............................................. 3-5
Clutch lever free play, adjusting ........... 6-15DDimmer switch ........................................ 3-4
Drive chain, lubricating ......................... 6-22
Drive chain slack .................................. 6-21EEngine break-in ...................................... 5-4
Engine idling speed .............................. 6-12
Engine oil and oil filter element............... 6-8
Engine, starting a warm .......................... 5-2
Engine stop switch.................................. 3-4
Engine trouble warning light ................... 3-2
FFront fork, checking...............................6-25
Fuel ......................................................... 3-7
Fuel cock ................................................. 3-8
Fuel consumption, tips for reducing ........ 5-3
Fuel tank cap........................................... 3-6
Fuses, replacing .................................... 6-28HHandlebar switches ................................. 3-4
Headlight bulb, replacing....................... 6-28
Helmet holder .......................................... 3-9
High beam indicator light......................... 3-2
Horn switch ............................................. 3-4IIdentification numbers ............................. 9-1
Ignition circuit cut-off system ................. 3-11
Indicator and warning lights .................... 3-2KKey identification number ........................ 9-1LLight switch ............................................. 3-4MMain switch/steering lock ........................ 3-1
Model label .............................................. 9-2NNeutral indicator light .............................. 3-2PPanels, removing and installing .............. 6-5
Parking ....................................................5-4
Part locations .......................................... 2-1
Pass switch ............................................. 3-4
Periodic maintenance and
lubrication chart.....................................6-2
Pre-operation check list........................... 4-2
RRear brake light switch, adjusting ......... 6-18SSafety information ................................... 1-1
Self-diagnosis device .............................. 3-3
Shifting .................................................... 5-2
Shift pedal ............................................... 3-5
Shock absorber assemblies,
adjusting ............................................. 3-10
Sidestand .............................................. 3-10
Sidestand, checking and lubricating ..... 6-24
Spark plugs, checking............................. 6-6
Specifications.......................................... 8-1
Speedometer unit ................................... 3-3
Starter (choke) lever ............................... 3-9
Starting a cold engine ............................. 5-1
Start switch ............................................. 3-4
Steering, checking ................................ 6-25
Storage ................................................... 7-3
Supporting the motorcycle .................... 6-31TTail/brake light bulb, replacing .............. 6-30
Throttle cable free play, adjusting ......... 6-12
Throttle grip and cable, checking
and lubricating .................................... 6-23
Tires ...................................................... 6-13
Tool kit .................................................... 6-1
Troubleshooting .................................... 6-35
Troubleshooting chart ........................... 6-36
Turn signal indicator light ........................ 3-2
Turn signal light bulb, replacing ............ 6-30
Turn signal switch ................................... 3-4VValve clearance, adjusting .................... 6-13
5KRE2.book Page 1 Monday, June 23, 2003 3:32 PM