2004 YAMAHA XVS250 check engine

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

SAFETY INFORMATION
1-3
1Loading
The total weight of the operator, pas-
senger, accessories and cargo must
not exceed the maximum load limit of
180 kg (397 lb). When loading within
this weight limit, keep the following in
mind:

Cargo and accessory weight
should be kept as low and close to
the motorcycle as possible. Make
sure to distribute the weight as
evenly as possible on both sides of
the motorcycle to minimize imbal-
ance or instability.


Shifting weights can create a sud-
den imbalance. Make sure that ac-
cessories and cargo are securely
attached to the motorcycle before
riding. Check accessory mounts
and cargo restraints frequently.


Never attach any large or heavy
items to the handlebar, front fork,
or front fender. These items, in-
cluding such cargo as sleeping
bags, duffel bags, or tents, can
create unstable handling or slow
steering response.Accessories
Genuine Yamaha accessories have
been specifically designed for use on
this motorcycle. Since Yamaha cannot
test all other accessories that may be
available, you must personally be re-
sponsible for the proper selection, in-
stallation and use of non-Yamaha
accessories. Use extreme caution
when selecting and installing any ac-
cessories.
Keep the following guidelines in mind,
as well as those provided under “Load-
ing” when mounting accessories.

Never install accessories or carry
cargo that would impair the perfor-
mance of your motorcycle. Care-
fully inspect the accessory before
using it to make sure that it does
not in any way reduce ground
clearance or cornering clearance,
limit suspension travel, steering
travel or control operation, or ob-
scure lights or reflectors.
Accessories fitted to the handle-
bar or the front fork area can
create instability due to improper
weight distribution or aerody-
namic changes. If accessoriesare added to the handlebar or
front fork area, they must be as
lightweight as possible and
should be kept to a minimum.
Bulky or large accessories may
seriously affect the stability of
the motorcycle due to aerody-
namic effects. Wind may at-
tempt to lift the motorcycle, or
the motorcycle may become un-
stable in cross winds. These ac-
cessories may also cause
instability when passing or being
passed by large vehicles.
Certain accessories can dis-
place the operator from his or
her normal riding position. This
improper position limits the free-
dom of movement of the opera-
tor and may limit control ability,
therefore, such accessories are
not recommended.


Use caution when adding electri-
cal accessories. If electrical acces-
sories exceed the capacity of the
motorcycle’s electrical system, an
electric failure could result, which
could cause a dangerous loss of
lights or engine power.
5KRE2.book Page 3 Monday, June 23, 2003 3:32 PM

DESCRIPTION
2-2
2
EAU10420
Right view1. Owner’s tool kit (page 6-1)
2. Battery (page 6-26)
3. Air filter element (page 6-10)
4. Main switch/steering lock (page 3-1)
5. Brake pedal (page 3-6)
6. Engine oil filter element (page 6-8)
7. Engine oil level check window (page 6-8)
8. Shock absorber assembly spring preload adjusting ring (page 3-10)
5KRE2.book Page 2 Monday, June 23, 2003 3:32 PM

INSTRUMENT AND CONTROL FUNCTIONS
3-2
3
EAU10880
(Parking)
The steering is locked, and the taillight
and auxiliary light are on, but all other
electrical systems are off. The key can
be removed.
The steering must be locked before the
key can be turned to “”.
CAUTION:
ECA11020
Do not use the parking position for
an extended length of time, other-wise the battery may discharge.
EAU11001
Indicator and warning lights
EAU11020
Turn signal indicator light “”
This indicator light flashes when the
t u r n s i g n a l s w i t c h i s p u s h e d t o t h e l e f t o r
right.
EAU11060
Neutral indicator light “”
This indicator light comes on when the
transmission is in the neutral position.
EAU11080
High beam indicator light “”
This indicator light comes on when the
high beam of the headlight is switched
on.
EAU11500
Engine trouble warning light “”
This warning light comes on or flashes
when an electrical circuit monitoring the
engine is defective. When this occurs,
have a Yamaha dealer check the self-
diagnosis system.
The electrical circuit of the warning light
can be checked by turning the key to
“ON”. If the warning light does not come
on for a few seconds, then go off, have
a Yamaha dealer check the electrical
circuit.
1. High beam indicator light “”
2. Turn signal indicator light “”
3. Neutral indicator light “”
4. Engine trouble warning light “”
5KRE2.book Page 2 Monday, June 23, 2003 3:32 PM

INSTRUMENT AND CONTROL FUNCTIONS
3-3
3
EAU11630
Speedometer unit The speedometer unit is equipped with
a speedometer, an odometer and a
tripmeter. The speedometer shows
riding speed. The odometer shows the
total distance traveled. The tripmeter
shows the distance traveled since it
was last set to zero with the reset knob.
The tripmeter can be used to estimate
the distance that can be traveled with a
full tank of fuel. This information will en-
able you to plan future fuel stops.
EAU12090
Self-diagnosis device This model is equipped with a self-diag-
nosis device for various electrical cir-
cuits.
If any of those circuits are defective, the
engine trouble warning light will come
on or flash. If this occurs, have a
Yamaha dealer check the vehicle.CAUTION:
ECA11170
To prevent engine damage, be sure
to consult a Yamaha dealer as soonas possible if this occurs.
EAU12330
Anti-theft alarm (optional) This model can be equipped with an
optional anti-theft alarm by a Yamaha
dealer. Contact a Yamaha dealer for
more information.
1. Speedometer
2. Odometer
3. Tripmeter
4. Tripmeter reset knob
5KRE2.book Page 3 Monday, June 23, 2003 3:32 PM

INSTRUMENT AND CONTROL FUNCTIONS
3-11
3 below and have a Yamaha dealer re-
pair it if it does not function proper-
ly.
EAU15311
Ignition circuit cut-off system The ignition circuit cut-off system (com-
prising the sidestand switch, clutch
switch and neutral switch) has the fol-
lowing functions.

It prevents starting when the trans-
mission is in gear and the side-
stand is up, but the clutch lever is
not pulled.


It prevents starting when the trans-
mission is in gear and the clutch le-
ver is pulled, but the sidestand is
still down.


It cuts the running engine when the
transmission is in gear and the sid-
estand is moved down.
Periodically check the operation of the
ignition circuit cut-off system according
to the following procedure.WARNING
EWA10250
If a malfunction is noted, have a
Yamaha dealer check the system be-fore riding.
5KRE2.book Page 11 Monday, June 23, 2003 3:32 PM

INSTRUMENT AND CONTROL FUNCTIONS
3-12
3
With the engine turned off:
1. Move the sidestand down.
2. Make sure that the engine stop switch is turned on.
3. Turn the key on.
4. Shift the transmission into the neutral position.
5. Push the start switch.
Does the engine start?
With the engine still running:
6. Move the sidestand up.
7. Keep the clutch lever pulled.
8. Shift the transmission into gear.
9. Move the sidestand down.
Does the engine stall?
After the engine has stalled:
10. Move the sidestand up.
11. Keep the clutch lever pulled.
12. Push the start switch.
Does the engine start?
The system is OK. The motorcycle can be ridden.
This check is most reliable if performed with
a warmed-up engine.The neutral switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
The sidestand switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
The clutch switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
YES NO YES NO YES NONOTE:
5KRE2.book Page 12 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