Yamaha 2001 Drag Star XV250N Owner'S Manual Download | Manualshive

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-21

6

1. Loosen the locknut at the brake

pedal.

2. To raise the brake pedal, turn the

adjusting bolt in direction

a

. To

lower the brake pedal, turn the ad-
justing bolt in direction

b

.

3. Tighten the locknut.

EWA00044

WARNING

_

After adjusting the brake pedal posi-
tion, the brake pedal free play must
be adjusted.

_

Brake pedal free play
The brake pedal free play should mea-
sure 20–30 mm at the brake pedal end.
Periodically check the brake pedal free
play and, if necessary, adjust it as
follows.
To increase the brake pedal free play,
turn the adjusting nut at the brake rod
in direction

a

. To decrease the brake

pedal free play, turn the adjusting nut in
direction

b

.

EW000106

WARNING

_

●

After adjusting the drive chain
slack or removing and installing
the rear wheel, always check
the brake pedal free play.

●

If proper adjustment cannot be
obtained as described, have a
Yamaha dealer make this ad-
justment.

●

After adjusting the brake pedal
free play, check the operation of
the brake light.

_

1. Brake pedal position adjusting bolt
2. Locknut

1. Brake pedal free play adjusting nut

E_5kr.book Page 21 Wednesday, October 4, 2000 6:02 PM

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Summary of Contents for 2001 Drag Star XV250N

Page 1: ...PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2000 9 0 3 1 CR E 5KR 28199 20 XVS250N OWNER S MANUAL ...

Page 2: ...H_5KS_Toc0 fm Page 2 Monday August 21 2000 11 11 AM ...

Page 3: ... machines It represents the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields This manual will give you an understanding of the operation inspection and basic maintenance of this motorcycle If you have any questions concerning the operation or maintenance of your motorcycle please consult a Yamaha dealer E_5kr book Page 1 Wednesday October 4 2000 6 02 PM ...

Page 4: ...e taken to avoid damage to the motorcycle NOTE A NOTE provides key information to make procedures easier or clearer NOTE _ This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold Yamaha continually seeks advancements in product design and quality Therefore while this manual contains the most current product informat...

Page 5: ...IMPORTANT MANUAL INFORMATION EW000002 WARNING _ PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE _ E_5kr book Page 2 Wednesday October 4 2000 6 02 PM ...

Page 6: ...UAL 2000 by Yamaha Motor Co Ltd 1st Edition September 2000 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan E_5kr book Page 3 Wednesday October 4 2000 6 02 PM ...

Page 7: ...ng the shock absorber assemblies 3 9 Sidestand 3 10 Ignition circuit cut off system 3 10 PRE OPERATION CHECKS 4 1 Pre operation check list 4 1 OPERATION AND IMPORTANT RIDING POINTS 5 1 Starting and warming up a cold engine 5 1 Starting a warm engine 5 2 Shifting 5 3 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...

Page 8: ...ers 6 28 Checking and lubricating the sidestand 6 28 Checking the front fork 6 28 Checking the steering 6 29 Checking the wheel bearings 6 30 Battery 6 30 Replacing the fuses 6 32 Replacing the headlight bulb 6 33 Replacing the tail brake light bulb 6 35 Replacing a turn signal light bulb 6 36 Supporting the motorcycle 6 36 Front wheel 6 37 Rear wheel 6 39 Troubleshooting 6 40 Troubleshooting char...

Page 9: ... MECHANICAL CONDITIONS Safe riding 1 Always make pre operation checks Careful checks may help prevent an accident 2 This motorcycle is designed to carry the operator and a passenger 3 The failure of motorists to detect and recognize motorcycles in traffic is the predominating cause of automobile motorcycle accidents Many accidents have been caused by an automobile driver who did not see the motorc...

Page 10: ...undercornering insuf ficient lean angle for the speed a Always obey the speed limit and never travel faster than warranted by road and traffic conditions b Always signal before turning or changing lanes Make sure that other motorists can see you 6 The posture of the operator and passenger is important for proper control a The operator should keep both hands on the handlebar and both feet on the op...

Page 11: ... They become very hot and can cause burns Always wear protective clothing that covers your legs ankles and feet 6 Passengers should also observe the precautions mentioned above Modifications Modifications made to this motorcycle not approved by Yamaha or the removal of original equipment may render the motorcycle unsafe for use and may cause severe personal injury Modifications may also make your ...

Page 12: ...ng 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 responsible for the proper selection installation and use of non Yamaha accessories Use extreme caution...

Page 13: ...ion limits the freedom of movement of the operator and may limit control ability therefore such accessories are not recommended 2 Use caution when adding electrical accessories If electrical accessories 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 Gasoline and exhaust gas 1 GASOLINE IS HIGHLY...

Page 14: ... a flammable source e g a kerosene heater or near an open flame otherwise it could catch fire 4 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 gasoline may leak out of the carburetor or fuel tank 5 If you should swallow any gasoline inhale a lot of gasolin...

Page 15: ...SAFETY INFORMATION 1 1 7 EAU01277 Location of important labels Please read the following important label carefully before operating this motorcycle 1 E_5kr book Page 7 Wednesday October 4 2000 6 02 PM ...

Page 16: ...ft view 1 Headlight page 6 33 2 Fuel cock page 3 7 3 Fuses page 6 32 4 Helmet holder page 3 8 5 Shock absorber assembly spring preload adjusting ring page 3 9 6 Shift pedal page 3 4 E_5kr book Page 1 Wednesday October 4 2000 6 02 PM ...

Page 17: ... Battery page 6 30 9 Air filter element page 6 12 10 Main switch steering lock page 3 1 11 Brake pedal page 3 5 12 Oil filter element page 6 10 13 Shock absorber assembly spring preload adjusting ring page 3 9 E_5kr book Page 2 Wednesday October 4 2000 6 02 PM ...

Page 18: ... Clutch lever page 3 4 2 Left handlebar switches page 3 3 3 Speedometer unit page 3 2 4 Right handlebar switches page 3 4 5 Brake lever page 3 5 6 Throttle grip page 6 15 7 Fuel tank cap page 3 6 E_5kr book Page 3 Wednesday October 4 2000 6 02 PM ...

Page 19: ... LOCK The steering is locked and all electrical systems are off The key can be removed To lock the steering 1 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 EW000016 WARNING _ Never turn the key to OFF or LOCK w...

Page 20: ...lf diagnosis system NOTE _ This warning light comes on for a few seconds and then flashes when the key is turned to ON but this does not indicate a malfunction _ EAU00095 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...

Page 21: ...EAU00118 Handlebar switches EAU00119 Pass switch Press this switch to flash the headlight EAU00121 Dimmer switch Set this switch to for the high beam and to for the low beam EAU00127 Turn signal switch To signal a right hand turn push this switch to To signal a left hand turn push this switch to When released the switch returns to the cen ter position To cancel the turn signal lights push the swit...

Page 22: ...l 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 ignition circuit cut off system See page 3 10 for an explanation of the ignition circuit cut off system EAU00157 Shift pedal The shift pedal is located on the left side...

Page 23: ...right handlebar grip To apply the front brake pull the lever toward the handle bar grip EAU00162 Brake pedal The brake pedal is on the right side of the motorcycle To apply the rear brake press down on the brake pedal 1 Brake lever 1 Brake pedal E_5kr book Page 5 Wednesday October 4 2000 6 02 PM ...

Page 24: ...tank cap cannot be installed unless the key is in the lock In addition the key cannot be removed if the cap is not properly installed and locked _ EWA00032 WARNING _ Make sure that the fuel tank cap is properly installed before riding _ EAU03753 Fuel Make sure that there is sufficient fuel in the tank Fill the fuel tank to the bottom of the filler tube as shown EW000130 WARNING _ Do not overfill t...

Page 25: ...unning Turn the fuel cock le ver to this position when starting the engine and riding RES This indicates reserve With the fuel cock lever in this position the fuel re serve is made available Quickly turn the fuel cock lever to this position if you run out of fuel while riding otherwise the engine may stall and will have to be primed see PRI After turning the fuel cock lever to RES refuel as soon a...

Page 26: ...fuel mixture which is supplied by the starter choke Move the lever in direction a to turn on the starter choke Move the lever in direction b to turn off the starter choke EAU00260 Helmet holder To open the helmet holder insert the key into the lock and then turn the key as shown To lock the helmet holder place it in the original position and then remove the key EW000030 WARNING _ Never ride with a...

Page 27: ...y result _ Adjust the spring preload as follows To increase the spring preload and thereby harden the suspension turn the adjusting ring on each shock ab sorber assembly in direction a To de crease the spring preload and thereby soften the suspension turn the adjust ing ring on each shock absorber as sembly in direction b NOTE _ Align the appropriate notch in the ad justing ring with the position ...

Page 28: ...filling the responsibility of raising the side stand before starting off Therefore check this system regularly as de scribed below and have a Yamaha dealer repair it if it does not function properly _ EAU03720 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 t...

Page 29: ...e 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 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 shoul...

Page 30: ...7 Engine oil Check oil level in engine If necessary add recommended oil to specified level Check vehicle for oil leakage 6 10 Front brake Check operation If soft or spongy have Yamaha dealer bleed hydraulic system Check lever free play Adjust if necessary Check fluid level in reservoir If necessary add recommended brake fluid to specified level Check hydraulic system for leakage 6 20 6 22 6 24 Rea...

Page 31: ...dal pivoting points if necessary 6 27 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 28 Sidestand Make sure that operation is smooth Lubricate pivot if necessary 6 28 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened Tighten if necessary Instruments lights signals and switches Check operation Correct if nece...

Page 32: ...tion can be accomplished in a very short time and the added safety it assures is more than worth the time involved _ EWA00033 WARNING _ If any item in the Pre operation check list is not working properly have it inspected and repaired before operating the motorcycle _ E_5kr book Page 3 Wednesday October 4 2000 6 02 PM ...

Page 33: ...f control _ EAU03812 Starting and warming up 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 sidestand up EW000054 WARNING _ Before starting the engine check the function of the igni tion circuit cut off system ac...

Page 34: ...en gine more than 10 seconds on any one attempt _ 6 After starting the engine move the starter choke lever back halfway ECA00045 CAUTION _ For maximum engine life never ac celerate hard when the engine is cold _ 7 When the engine is warm turn the starter choke off NOTE _ The engine is warm when it responds normally to the throttle with the starter choke turned off _ EAU01258 Starting a warm engine...

Page 35: ...g Inade quate lubrication may damage the transmission Always use the clutch while changing gears to avoid dam aging the engine transmission and drive train which are not designed to withstand the shock of forced shifting _ EAU00424 Tips for reducing fuel consumption Fuel consumption depends largely on your riding style Consider the following tips to reduce fuel consumption Thoroughly warm up the e...

Page 36: ...ove 1 3 throttle 1 000 1 600 km Avoid prolonged operation above 1 2 throttle ECA00058 CAUTION _ After 1 000 km of operation the en gine oil must be changed and the oil filter element replaced _ 1 600 km and beyond The vehicle can now be operated normally EC000049 CAUTION _ If any engine trouble should occur during the engine break in period immediately have a Yamaha dealer check the vehicle _ EAU0...

Page 37: ...r cycle maintenance work have a Yamaha dealer do it for you _ EAU01175 Owner s tool kit The owner s tool kit is located behind panel A See page 6 5 for panel re moval and installation procedures The service information included in this manual and the tools provided in the owner s tool kit are intended to assist you in the performance of preventive maintenance and minor repairs How ever additional ...

Page 38: ...ECK OR MAINTENANCE JOB ODOMETER READING 1 000 km ANNUAL CHECK 1 10 20 30 40 1 Fuel line Check fuel hoses and vacuum hose for cracks or damage 2 Fuel filter Check condition 3 Spark plugs Check condition Clean and regap Replace 4 Valves Check valve clearance Adjust 5 Air filter element Clean Replace 6 Clutch Check operation Adjust 7 Front brake Check operation fluid level and vehicle for fluid leaka...

Page 39: ...rly aligned Clean and lubricate Every 1 000 km and after washing the motorcycle or riding in the rain 15 Steering bearings Check bearing play and steering for roughness Lubricate with lithium soap based grease Every 20 000 km 16 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 17 Sidestand Check operation Lubricate 18 Sidestand switch Check operation 19 Front fork ...

Page 40: ... the brake fluid Replace the brake hoses every four years and if cracked or damaged _ 23 Engine oil filter element Replace 24 Front and rear brake switches Check operation 25 Moving parts and cables Lubricate 26 Air induction system Check the air cut valve and reed valve for damage Replace the entire air induction system if necessary 27 Lights signals and switches Check operation Adjust headlight ...

Page 41: ...e main tenance jobs described in this chapter Refer to this section each time a panel needs to be removed and installed EAU03184 Panel A To remove the panel 1 Slide the lock cover open insert the key into the lock and then turn it 1 4 turn clockwise 1 Panel A 1 Panel B 1 Panel lock cover 2 Unlock E_5kr book Page 5 Wednesday October 4 2000 6 02 PM ...

Page 42: ...se it in the front To install the panel 1 Secure the front of the panel and then push the rear of the panel in with the key inserted in the lock 2 Turn the key counterclockwise to the original position remove it and then close the lock cover EAU03185 Panel B To remove the panel 1 Remove the bolt 1 Bolt E_5kr book Page 6 Wednesday October 4 2000 6 02 PM ...

Page 43: ...l the rear of the panel out and then slide the panel forward to re lease it in the front To install the panel 1 Secure the front of the panel and then push the rear of the panel in 2 Install the bolt E_5kr book Page 7 Wednesday October 4 2000 6 02 PM ...

Page 44: ...d in the owner s tool kit To check the spark plugs 1 Check that the porcelain insulator around the center electrode on each spark plug is a medium to light tan the ideal color when the motorcycle is ridden normally 2 Check that all spark plugs installed in the engine have the same color NOTE _ If any spark plug shows a distinctly dif ferent color the engine could be defec tive Do not attempt to di...

Page 45: ... 3 Install the spark plug with the spark plug wrench and then tight en it to the specified torque NOTE _ If a torque wrench is not available when installing a spark plug a good estimate of the correct torque is 1 4 1 2 turn past finger tight However the spark plug should be tightened to the speci fied torque as soon as possible _ 4 Install the spark plug cap a Spark plug gap Spark plug gap 0 6 0 7...

Page 46: ... warm it up for several minutes and then turn it off 3 Wait a few minutes until the oil set tles and then check the oil level through the check window located at the bottom right side of the crankcase NOTE _ The engine oil should be between the minimum and maximum level marks _ 4 If the engine oil is below the mini mum level mark add sufficient oil of the recommended type to raise it to the correc...

Page 47: ...t cover by removing the bolts 5 Remove and replace the oil filter element and O ring 6 Install the oil filter element cover by installing the bolts then tighten ing them to the specified torque NOTE _ Make sure that the O ring is properly seated _ 1 Engine oil drain bolt 2 Oil pan 1 Bolt 3 1 Oil filter element 2 O ring Tightening torque Oil filter element cover bolt 10 Nm 1 0 m kg E_5kr book Page ...

Page 48: ...oil leakage If oil is leaking immediately turn the engine off and check for the cause 10 Turn the engine off and then check the oil level and correct it if necessary EAU03735 Cleaning the air filter element The air filter element should be cleaned at the intervals specified in the periodic maintenance and lubrication chart Clean the air filter element more fre quently if you are riding in unusuall...

Page 49: ...ilter element to remove most of the dust and dirt and then blow the remaining dirt out with compressed air as shown If the air filter element is damaged replace it 5 Install the air filter element by in serting it into the air filter case then installing the screws 1 Air filter case cover 2 Screw 4 1 Air filter element 2 Screw 3 E_5kr book Page 13 Wednesday October 4 2000 6 02 PM ...

Page 50: ...clamp screw EAU00629 Adjusting the carburetor The carburetor is an important part of the engine and requires very sophisti cated adjustment Therefore most car buretor adjustments should be left to a Yamaha dealer who has the neces sary professional knowledge and expe rience The adjustment described in the following section however may be serviced by the owner as part of routine maintenance EC00009...

Page 51: ...to the throttle _ 3 Check the engine idling speed and if necessary adjust it to spec ification by turning the throttle stop screw To increase the engine idling speed turn the screw in di rection a To decrease the engine idling speed turn the screw in di rection b NOTE _ If the specified idling speed cannot be obtained as described above have a Yamaha dealer make the adjustment _ EAU00635 Adjusting...

Page 52: ...sure should be checked and if necessary adjusted before each ride EW000082 WARNING _ The tire air pressure must be checked and adjusted on cold tires i e when the temperature of the tires equals the ambient temperature The tire air pressure must be adjusted in accordance with the riding speed and with the total weight of rider passenger car go and accessories approved for this model _ CE 21E CE 07...

Page 53: ...ge an acci dent or even injury _ Tire inspection Always check the tires before operating the motorcycle If a tire tread shows crosswise lines minimum tread depth if the tire has a nail or glass fragments in it or if the sidewall is cracked con tact a Yamaha dealer immediately and have the tire replaced CE 20E NOTE _ The tire tread depth limits may differ from country to country Always comply with ...

Page 54: ...th a high quality product _ EAU00685 Spoke wheels To maximize the performance durabil ity and safe operation of your motor cycle note the following points regarding the specified wheels The wheel rims should be checked for cracks bends or warpage and the spokes for looseness or dam age before each ride If any dam age is found have a Yamaha dealer replace the wheel Do not attempt even the smallest ...

Page 55: ...lever free play could be obtained as de scribed above tighten the locknut and skip the rest of the procedure otherwise proceed as follows 4 Fully turn the adjusting bolt at the clutch lever in direction a to loos en the clutch cable 5 Loosen the locknut at the crankcase 6 To increase the clutch lever free play turn the adjusting nut in di rection a To decrease the clutch lever free play turn the a...

Page 56: ...e the presence of air in the hydraulic system If there is air in the hy draulic system have a Yamaha dealer bleed the system before operating the motorcycle Air in the hydraulic system will dimin ish the braking performance which may result in loss of con trol and an accident _ EAU03778 Adjusting the brake pedal position and free play EW000104 WARNING _ It is advisable to have a Yamaha dealer make...

Page 57: ...al free play and if necessary adjust it as follows To increase the brake pedal free play turn the adjusting nut at the brake rod in direction a To decrease the brake pedal free play turn the adjusting nut in direction b EW000106 WARNING _ After adjusting the drive chain slack or removing and installing the rear wheel always check the brake pedal free play If proper adjustment cannot be obtained as...

Page 58: ...cking 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 maintenance and lubrication chart EAU00725 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 ch...

Page 59: ...brake flu id level may indicate worn brake pads and or brake system leakage If the brake level is low be sure to check the brake pads for wear and the brake sys tem for leakage Observe these precautions When checking the fluid level make sure that the top of the brake fluid reservoir is level Use only the recommended quali ty brake fluid otherwise the rubber seals may deteriorate causing leakage a...

Page 60: ... tion 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 damaged or leaking Oil seals Replace every two years Brake hose Replace every four years EAU00744 Drive chain slack The drive chain slack should be checked before each ride and adjusted if necessary To check the drive chain slack ...

Page 61: ...f the swingarm 2 To tighten the drive chain turn the adjusting nut at each end of the swingarm in direction a To loos en the drive chain turn the adjust ing nut at each end of the swingarm in direction b and then push the rear wheel forward NOTE _ Using the alignment marks on each side of the swingarm make sure that both adjusting nuts are in the same po sition for proper wheel alignment _ a Drive...

Page 62: ...t the intervals specified in the periodic maintenance and lubrica tion chart otherwise it will quickly wear out especially when riding in dusty or wet areas Service the drive chain as follows EC000097 CAUTION _ The drive chain must be lubricated after washing the motorcycle or riding in the rain _ 1 Clean the drive chain with kero sene and a small soft brush ECA00053 CAUTION _ To prevent damaging ...

Page 63: ...EW000112 WARNING _ Damage to the outer sheath may in terfere with proper cable operation and will cause the inner cable to rust Replace a damaged cable as soon as possible to prevent unsafe conditions _ EAU03370 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 R...

Page 64: ...ARNING _ If the sidestand does not move up and down smoothly have a Yamaha dealer check or repair it _ EAU02939 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 EW000115 WARNING _ Securely support the motorcycle so that there is no danger of it fallin...

Page 65: ... EAU00794 Checking the steering Worn or loose steering bearings may cause danger Therefore the operation of the steering must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart 1 Place a stand under the engine to raise the front wheel off the ground EW000115 WARNING _ Securely support the motorcycle so that there is no danger of it falling over _ 2 H...

Page 66: ...ck the wheel bearings EAU01271 Battery This motorcycle is equipped with a sealed type MF battery which does not require any maintenance There is no need to check the electrolyte or to add distilled water To charge the battery Have a Yamaha dealer charge the bat tery as soon as possible if it seems to have discharged Keep in mind that the battery tends to discharge more quickly if the motorcycle is...

Page 67: ...tion when charging it in an enclosed space KEEP THIS AND ALL BATTER IES OUT OF THE REACH OF CHILDREN _ To store the battery 1 If the motorcycle will not be used for more than one month remove the battery fully charge it and then place it in a cool dry place 2 If the battery will be stored for more than two months check it at least once a month and fully charge it if necessary 3 Fully charge the ba...

Page 68: ...mper age rating than recommended to avoid causing extensive damage to the electrical system and possibly a fire _ 3 Turn the key to ON and turn on the electrical circuit in question to check if the device operates 4 If the fuse immediately blows again have a Yamaha dealer check the electrical system 1 Fuse box 2 1 Main fuse 2 Spare main fuse 3 Headlight fuse 4 Ignition fuse 5 Signaling system fuse...

Page 69: ...a quartz bulb headlight If the headlight bulb burns out replace it as follows 1 Remove the headlight unit by removing the screws 2 Disconnect the headlight coupler and then remove the headlight unit and bulb cover 1 Screw 2 1 Headlight coupler 1 Headlight bulb cover E_5kr book Page 33 Wednesday October 4 2000 6 02 PM ...

Page 70: ...o not touch the glass part of the headlight bulb to keep it free from oil otherwise the transparency of the glass the luminosity of the bulb and the bulb life will be adversely af fected Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with alcohol or thinner _ 5 Install the bulb cover and then connect the coupler 6 Install the headlight unit by install ...

Page 71: ...efective 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 EC000108 CAUTION _ Do not overtighten the screws oth erwise the lens may break _ 1 Screw 2 1 Tail brake light bulb E_5kr book Page 35 Wednesday October 4 2000 6 02 PM ...

Page 72: ... equipped with a centerstand follow these precautions when removing the front and rear wheel or performing other mainte nance requiring the motorcycle to stand upright Check that the motor cycle is in a stable and level position before starting any maintenance A strong wooden box can be placed un der the engine for added stability To service the front wheel 1 Stabilize the rear of the motorcycle b...

Page 73: ...pport the motor cycle so that there is no danger of 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 36 5 Pull the wheel axle out and then remove the wheel ECA00048 CAUTION _ Do not apply the brake after...

Page 74: ... fits over the retainer on the fork leg _ 3 Insert the wheel axle 4 Lower the front wheel so that it is on the ground 5 Push down hard on the handlebar several times to check for proper fork operation 6 Tighten the wheel axle to the specified torque and then install the rubber cap 7 Tighten the front wheel axle pinch bolt to the specified torque 8 Connect the speedometer cable 1 Speedometer gear u...

Page 75: ... 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 disassem...

Page 76: ...EW000103 WARNING _ After adjusting the brake pedal free play check the operation of the brake light _ EAU01008 Troubleshooting Although Yamaha motorcycles receive a thorough inspection before shipment from the factory trouble may occur dur ing operation Any problem in the fuel compression or ignition systems for example can cause poor starting and loss of power The following troubleshooting chart ...

Page 77: ...gnition Have a Yamaha dealer check the vehicle Remove the spark plugs and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gaps or replace the spark plugs Have a Yamaha dealer check the vehicle The engine does not start Have a Yamaha dealer check the vehicle The engine does not start Check the battery Operate the electric starter 4 Battery The engine turns over ...

Page 78: ...ctrical couplers and connectors including the spark plug caps are tightly installed 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 degreaser off with water Cleaning ECA00010 CAUTION _ Avoid using strong acidic wheel cleaners ...

Page 79: ...eld is scratched use a quali ty plastic polishing compound after washing _ 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 i...

Page 80: ...damage caused by stones etc 7 Wax all painted surfaces 8 Let the motorcycle dry completely before storing or covering it EWA00001 WARNING _ 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 b...

Page 81: ... Pour the drained fuel into the fuel tank 4 Fill up the fuel tank and add fuel stabilizer if available to prevent the fuel tank from rusting and the fuel from deteriorating 5 Perform the following steps to pro tect the cylinders piston rings etc from corrosion a Remove the spark plug caps and spark plugs b Pour a teaspoonful of engine oil into each spark plug bore c Install the spark plug caps ont...

Page 82: ...ery month in order to prevent the tires from becoming degraded in one spot 8 Cover the muffler outlets with plas tic bags to prevent moisture from entering them 9 Remove the battery and fully charge it Store it in a cool dry place and charge it once a month Do not store the battery in an ex cessively cold or warm place less than 0 C or more than 30 C For more information on storing the battery see...

Page 83: ...rter Lubrication system Wet sump Engine oil Type Recommended engine oil classification API Service SE SF SG or higher Quantity Without oil filter element replacement 1 4 L With oil filter element replacement 1 6 L Total amount dry engine 1 75 L 20 10 0 10 20 30 40 50 C SAE 10W 30 SAE 15W 40 SAE 20W 40 SAE 20W 50 SAE 10W 40 CAUTION Be sure to use motor oils that do not contain anti fric tion modifi...

Page 84: ...uction ratio 3 130 Secondary reduction system Chain drive Secondary reduction ratio 2 800 Number of drive chain sprocket teeth front rear 20 56 Transmission type Constant mesh 5 speed Operation Left foot Gear ratio 1st 2 643 2nd 1 684 3rd 1 261 4th 1 000 5th 0 821 Chassis Frame type Double cradle Caster angle 35 Trail 135 mm Tires Front Type Tube tire Size 80 100 18 47P Manufacturer model CHENG SH...

Page 85: ...Spoke wheel Size 15 M C MT 3 00 Brakes Front Type Single disc brake Operation Right hand Fluid DOT 4 Rear Type Drum brake Operation Right foot Suspension Front Telescopic fork Rear Swingarm Spring shock absorber Front Coil spring oil damper Rear Coil spring oil damper Wheel travel Front 140 mm Rear 100 mm Electrical system Ignition system T C I digital Charging system Type A C magneto Standard out...

Page 86: ...ighting 12 V 1 7 W 1 Neutral indicator light 12 V 1 7 W 1 High beam indicator light 12 V 1 7 W 1 Turn signal indicator light 12 V 1 7 W 1 Engine trouble warning light 12 V 1 7 W 1 Fuses Main fuse 30 A Headlight fuse 15 A Signaling system fuse 10 A Ignition fuse 10 A Carburetor heater fuse 10 A E_5kr book Page 4 Wednesday October 4 2000 6 02 PM ...

Page 87: ...etric unit Multiplier Imperial unit Torque m kg m kg cm kg cm kg 7 233 86 794 0 0723 0 8679 ft lb in lb ft lb in lb Weight kg g 2 205 0 03527 lb oz Speed km h 0 6214 mi h Distance km m m cm mm 0 6214 3 281 1 094 0 3937 0 03937 mi ft yd in in Volume Capacity cc cm3 cc cm3 L liter L liter 0 03527 0 06102 0 8799 0 2199 oz IMP liq cu in qt IMP liq gal IMP liq Miscellaneous kg mm kg cm2 Centigrade C 55...

Page 88: ... EAU01041 Key identification number The key identification number is stamped into the key tag Record this number in the space provided and use it for reference when ordering a new key EAU01043 Vehicle identification number The vehicle identification number is stamped into the steering head pipe Record this number in the space provided NOTE _ The vehicle identification number is used to identify yo...

Page 89: ...TED Owners are warned that the law may prohibit a The removal or rendering inopera tive by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the pur pose of noise control prior to its sale or delivery to the ultimate pur chaser or while it is in use and b The use of the vehicle after such device or eleme...

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Page 91: ...H_5KS_Toc0 fm Page 2 Monday August 21 2000 11 11 AM ...

Page 92: ...PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2000 9 0 3 1 CR E 5KR 28199 20 XVS250N OWNER S MANUAL ...

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