2004 YAMAHA XVS250 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
1-2
1 wide on a turn due to EXCESSIVE
SPEED or undercornering (insuffi-
cient lean angle for the speed).
Always obey the speed limit and
never travel faster than warrant-
ed by road and traffic conditions.
Always signal before turning or
changing lanes. Make sure that
other motorists can see you.


The posture of the operator and
passenger is important for proper
control.
The operator should keep both
hands on the handlebar and
both feet on the operator foot-
rests during operation to main-
tain control of the motorcycle.
The passenger should always
hold onto the operator, seat
strap, or grab bar, if equipped,
with both hands and keep both
feet on the passenger footrests.
Never carry a passenger unless
he or she can firmly place both
feet on the passenger footrests.


Never ride under the influence of
alcohol or other drugs.


This motorcycle is designed for on-
road use only, therefore, it is not
suitable for off-road use.
Protective apparel
The majority of fatalities from motor-
cycle accidents are the result of head
injuries. The use of a safety helmet is
the single most critical factor in the pre-
vention or reduction of head injuries.


Always wear an approved helmet.


Wear a face shield or goggles.
Wind in your unprotected eyes
could contribute to an impairment
of vision which could delay seeing
a hazard.


The use of a jacket, heavy boots,
trousers, gloves, etc., is effective in
preventing or reducing abrasions
or lacerations.


Never wear loose-fitting clothes,
otherwise they could catch on the
control levers, footrests, or wheels
and cause injury or an accident.


Never touch the engine or exhaust
system during or after operation.
They become very hot and cancause burns. Always wear protec-
tive clothing that covers your legs,
ankles, and feet.


Passengers should also observe
the precautions mentioned above.
Modifications
Modifications made to this motorcycle
not approved by Yamaha, or the re-
moval of original equipment, may ren-
der the motorcycle unsafe for use and
may cause severe personal injury.
Modifications may also make your
motorcycle illegal to use.
Loading and accessories
Adding accessories or cargo to your
motorcycle can adversely affect stabili-
ty and handling if the weight distribution
of the motorcycle is changed. To avoid
the possibility of an accident, use ex-
treme caution when adding cargo or
accessories to your motorcycle. Use
extra care when riding a motorcycle
that has added cargo or accessories.
Here are some general guidelines to
follow if loading cargo or adding acces-
sories to your motorcycle:
5KRE2.book Page 2 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

SAFETY INFORMATION
1-4
1 Gasoline and exhaust gas


GASOLINE IS HIGHLY FLAMMA-
BLE:
Always turn the engine off when
refueling.
Take care not to spill any gaso-
line on the engine or exhaust
system when refueling.
Never refuel while smoking or in
the vicinity of an open flame.


Never start the engine or let it run
for any length of time in a closed
area. The exhaust fumes are poi-
sonous and may cause loss of
consciousness and death within a
short time. Always operate your
motorcycle in an area that has ad-
equate ventilation.


Always turn the engine off before
leaving the motorcycle unattended
and remove the key from the main
switch. When parking the motor-
cycle, note the following:
The engine and exhaust system
may be hot, therefore, park the
motorcycle in a place where pe-
destrians or children are not like-
ly to touch these hot areas.Do not park the motorcycle on a
slope or soft ground, otherwise it
may fall over.
Do not park the motorcycle near
a flammable source (e.g. a kero-
sene heater, or near an open
flame), otherwise it could catch
fire.


When transporting the motorcycle
in another vehicle, make sure that
it is kept upright and that the fuel
cock is turned to “ON” or “RES” (for
vacuum type) / “OFF” (for manual
type). If it should lean over, gaso-
line may leak out of the carburetor
or fuel tank.


If you should swallow any gaso-
line, inhale a lot of gasoline vapor,
or allow gasoline to get into your
eyes, see your doctor immediately.
If any gasoline spills on your skin
or clothing, immediately wash the
affected area with soap and water
and change your clothes.
5KRE2.book Page 4 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
3-1
3
EAU10460
Main switch/steering lock The main switch/steering lock controls
the ignition and lighting systems, and is
used to lock the steering. The various
positions are described below.
EAU10630
ON
All electrical systems are supplied with
power, and the engine can be started.
The key cannot be removed.
EAU10660
OFF
All electrical systems are off. The key
can be removed.
EAU10680
LOCK
The steering is locked, and all electrical
systems are off. The key can be re-
moved.
To lock the steering1. Turn the handlebars all the way to
the left.
2. Push the key in from the “OFF” po-
sition, and then turn it to “LOCK”
while still pushing it.
3. Remove the key.To unlock the steering
Push the key in, and then turn it to
“OFF” while still pushing it.
WARNING
EWA10060
Never turn the key to “OFF” or
“LOCK” while the vehicle is moving,
otherwise the electrical systems will
be switched off, which may result in
loss of control or an accident. Make
sure that the vehicle is stopped be-
fore turning the key to “OFF” or“LOCK”.
1. Push.
2. Turn.
1. Push.
2. Turn.
5KRE2.book Page 1 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