2004 YAMAHA XVS250 clutch

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

DESCRIPTION
2-3
2
EAU10430
Controls and instruments1. Clutch lever (page 3-5)
2. Left handlebar switches (page 3-4)
3. Speedometer unit (page 3-3)
4. Right handlebar switches (page 3-4)
5. Brake lever (page 3-6)
6. Throttle grip (page 6-12)
7. Fuel tank cap (page 3-6)5KRE2.book Page 3 Monday, June 23, 2003 3:32 PM

INSTRUMENT AND CONTROL FUNCTIONS
3-5
3
CAUTION:
ECA10050
See page 5-1 for starting instruc-tions prior to starting the engine.
EAU12820
Clutch lever The clutch lever is located at the left
handlebar grip. To disengage the
clutch, pull the lever toward the handle-
bar grip. To engage the clutch, release
the lever. The lever should be pulled
rapidly and released slowly for smooth
clutch operation.
The clutch lever is equipped with a
clutch switch, which is part of the igni-
tion circuit cut-off system. (See page
3-11.)
EAU12870
Shift pedal The shift pedal is located on the left
side of the engine and is used in com-
bination with the clutch lever when
shifting the gears of the 5-speed con-
stant-mesh transmission equipped on
this motorcycle.
1. Clutch lever
1. Shift pedal
5KRE2.book Page 5 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

PRE-OPERATION CHECKS
4-3
4
Drive chainCheck chain slack.
Adjust if necessary.
Check chain condition.
Lubricate if necessary.6-21, 6-22
Wheels and tiresCheck for damage.
Check tire condition and tread depth.
Check air pressure.
Correct if necessary.6-13, 6-15
Brake and shift pedalsMake sure that operation is smooth.
Lubricate pedal pivoting points if necessary.6-24
Brake and clutch leversMake sure that operation is smooth.
Lubricate lever pivoting points if necessary.6-24
SidestandMake sure that operation is smooth.
Lubricate pivot if necessary.6-24
Chassis fastenersMake sure that all nuts, bolts and screws are properly tightened.
Tighten if necessary.—
Instruments, lights, signals
and switchesCheck operation.
Correct if necessary.—
Sidestand switchCheck operation of ignition circuit cut-off system.
If system is defective, have Yamaha dealer check vehicle.3-10 ITEM CHECKS PAGE
5KRE2.book Page 3 Monday, June 23, 2003 3:32 PM

OPERATION AND IMPORTANT RIDING POINTS
5-1
5
EAU15950
WARNING
EWA10270


Become thoroughly familiar
with all operating controls and
their functions before riding.
Consult a Yamaha dealer re-
garding any control or function
that you do not thoroughly un-
derstand.


Never start the engine or oper-
ate it in a closed area for any
length of time. Exhaust fumes
are poisonous, and inhaling
them can cause loss of con-
sciousness and death within a
short time. Always make sure
that there is adequate ventila-
tion.


Before starting out, make sure
that the sidestand is up. If the
sidestand is not raised com-
pletely, it could contact the
ground and distract the opera-
tor, resulting in a possible lossof control.
EAU16400
Starting a cold engine In order for the ignition circuit cut-off
system to enable starting, one of the
following conditions must be met:

The transmission is in the neutral
position.


The transmission is in gear with
the clutch lever pulled and the sid-
estand up.WARNING
EWA10290


Before starting the engine,
check the function of the igni-
tion circuit cut-off system ac-
cording to the procedure
described on page 3-11.


Never ride with the sidestanddown.
1. Turn the fuel cock lever to “ON”.
2. Turn the key to “ON” and make
sure that the engine stop switch is
set to “”.
3. Shift the transmission into the neu-
tral position.
NOTE:When the transmission is in the neutral
position, the neutral indicator light
should be on, otherwise have a
Yamaha dealer check the electrical cir-cuit.
4. Turn the starter (choke) on and
completely close the throttle. (See
page 3-9.)
5. Start the engine by pushing the
start switch.NOTE:If the engine fails to start, release the
start switch, wait a few seconds, and
then try again. Each starting attempt
should be as short as possible to pre-
serve the battery. Do not crank the en-
gine more than 10 seconds on any oneattempt.CAUTION:
ECA11370
The engine trouble warning light
should come on when the key is
turned to “ON”, and then go off after
a few seconds. If the engine trouble
warning light comes on or flashes
5KRE2.book Page 1 Monday, June 23, 2003 3:32 PM