Yamaha V Star XVS250S Owner'S Manual Download

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SPECIFICATIONS

8-2

3rd:

29/23 (1.261)

4th:

26/26 (1.000)

5th:

23/28 (0.821)

Chassis:

Frame type:

Double cradle

Caster angle:

35.0 °

Trail:

135.0 mm (5.31 in)

Front tire:

Type:

With tube

Size:

80/100-18M/C 47P

Manufacturer/model:

CHENG SHIN/C-916

Manufacturer/model:

IRC/MARBELLA NF27

Rear tire:

Type:

With tube

Size:

130/90-15M/C 66P

Manufacturer/model:

CHENG SHIN/C-915

Manufacturer/model:

IRC/MARBELLA NR31

Loading:

Maximum load:

180 kg (397 lb)

(Total weight of rider, passenger, cargo and
accessories)

Tire air pressure (measured on cold
tires):

Loading condition:

0–90 kg (0–198 lb)
Front:

175 kPa (25 psi) (1.75 kgf/cm²)

Rear:

200 kPa (29 psi) (2.00 kgf/cm²)

Loading condition:

90–180 kg (198–397 lb)
Front:

225 kPa (33 psi) (2.25 kgf/cm²)

Rear:

225 kPa (33 psi) (2.25 kgf/cm²)

Front wheel:

Wheel type:

Spoke wheel

Rim size:

18x1.60

Rear wheel:

Wheel type:

Spoke wheel

Rim size:

15M/C x MT3.00

Front brake:

Type:

Single disc brake

Operation:

Right hand operation

Recommended fluid:

Dot 4

Rear brake:

Type:

Drum brake

Operation:

Right foot operation

Front suspension:

Type:

Telescopic fork

Spring/shock absorber type:

Coil spring/oil damper

Wheel travel:

140.0 mm (5.51 in)

Rear suspension:

Type:

Swingarm

Spring/shock absorber type:

Coil spring/oil damper

Wheel travel:

100.0 mm (3.94 in)

Electrical system:

Ignition system:

Transistorized coil ignition (digital)

Charging system:

A.C. magneto

Battery:

Model:

GT6B-3

Voltage, capacity:

12 V, 6.0 Ah

Headlight:

Bulb type:

Halogen bulb

5KR23.book Page 2 Tuesday, June 24, 2003 1:47 PM

Summary of Contents for V Star XVS250S

Page 1: ...PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2003 07 0 3 1 CR E 5KR 28199 23 XVS250S OWNER S MANUAL ...

Page 2: ...5KR23 book Page 2 Tuesday June 24 2003 1 47 PM ...

Page 3: ...s to enjoy all advantages of your XVS250 The owner s manual does not only instruct you in how to operate inspect and maintain your motorcycle but also in how to safeguard yourself and others from trouble and injury In addition the many tips given in this manual will help keep your motorcycle in the best possible con dition If you have any further questions do not hesitate to contact your Yamaha de...

Page 4: ...n your motorcycle and this manual If you have any questions concerning this manual please consult your Yamaha dealer WARNING EWA10030 PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED Failure to follow WARNING instructions could result in severe injury or death to the motor cycle operator a...

Page 5: ... MANUAL 2003 by Yamaha Motor Co Ltd 1st edition June 2003 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan 5KR23 book Page 2 Tuesday June 24 2003 1 47 PM ...

Page 6: ... 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 16 Adjusting the brake pedal posit...

Page 7: ...nt wheel 6 32 Rear wheel 6 33 Troubleshooting 6 35 Troubleshooting chart 6 36 MOTORCYCLE CARE AND STORAGE 7 1 Care 7 1 Storage 7 3 SPECIFICATIONS 8 1 CONSUMER INFORMATION 9 1 Identification numbers 9 1 Motorcycle noise regulation for Australia 9 2 5KR23 book Page 2 Tuesday June 24 2003 1 47 PM ...

Page 8: ...dents have been caused by an automobile driver who did not see the motorcycle Making yourself conspicuous appears to be very effective in reducing the chance of this type of accident Therefore Wear a brightly colored jacket Use extra caution when ap proaching and passing through intersections since intersec tions are the most likely places for motorcycle accidents to oc cur Ride where other motori...

Page 9: ...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 eng...

Page 10: ... 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...

Page 11: ...ust 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 su...

Page 12: ...SAFETY INFORMATION 1 5 1 EAU10390 Location of important label Please read the following important label carefully before operating this vehicle 1 5KR23 book Page 5 Tuesday June 24 2003 1 47 PM ...

Page 13: ...eft view 1 Headlight page 6 28 2 Fuel cock page 3 7 3 Fuses page 6 28 4 Helmet holder page 3 8 5 Shock absorber assembly spring preload adjusting ring page 3 9 6 Shift pedal page 3 4 5KR23 book Page 1 Tuesday June 24 2003 1 47 PM ...

Page 14: ... 26 3 Air filter element page 6 10 4 Main switch steering lock page 3 1 5 Brake pedal page 3 5 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 9 5KR23 book Page 2 Tuesday June 24 2003 1 47 PM ...

Page 15: ...ents 1 Clutch lever page 3 4 2 Left handlebar switches page 3 3 3 Speedometer unit page 3 2 4 Right handlebar switches page 3 3 5 Brake lever page 3 5 6 Throttle grip page 6 12 7 Fuel tank cap page 3 5 5KR23 book Page 3 Tuesday June 24 2003 1 47 PM ...

Page 16: ...e removed EAU10680 LOCK The steering is locked and all electrical systems are off The key can be re moved 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 WARNING EWA10060 Never turn the key...

Page 17: ...ical 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 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 ...

Page 18: ...his switch to for the high beam and to for the low beam EAU12460 Turn signal switch To signal a right hand turn push this switch to To signal a left hand turn push this switch to When re leased the switch returns to the center position To cancel the turn signal lights push the switch in after it has re turned to the center position EAU12500 Horn switch Press this switch to sound the horn EAU12660 ...

Page 19: ...ip 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 10 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 t...

Page 20: ...r brake press down on the brake pedal EAU13000 Fuel tank cap To remove the fuel tank cap Insert the key into the lock and turn it 1 4 turn clockwise The lock will be re leased and the fuel tank cap can be re moved To install the fuel tank cap 1 Push the fuel tank cap into position with the key inserted in the lock 2 Turn the key counterclockwise to the original position and then re move it 1 Brake...

Page 21: ...gine CAUTION ECA10070 Immediately wipe off spilled fuel with a clean dry soft cloth since fuel may deteriorate painted surfac es or plastic parts EAU13330 CAUTION ECA11400 Use only unleaded gasoline The use of leaded gasoline will cause severe damage to internal engine parts such as the valves and piston rings as well as to the exhaust system Your Yamaha engine has been de signed to use regular un...

Page 22: ...sition fuel flows to the carburetor when the engine is running Turn the fuel cock le ver to this position when starting the en gine 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 ...

Page 23: ... a richer air 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 EAU14281 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 WARNING EWA10160 Never...

Page 24: ...ock absorber EAU15300 Sidestand The sidestand is located on the left side of the frame Raise the sidestand or lower it with your foot while holding the vehicle upright NOTE The built in sidestand switch is part of the ignition circuit cut off system which cuts the ignition in certain situations See further down for an explanation of the ignition circuit cut off system WARNING EWA10240 The vehicle ...

Page 25: ...s 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 E...

Page 26: ...fter 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...

Page 27: ...sequences Therefore it is very important in addition to a thorough visual inspec tion to check the following points before each ride NOTE Pre operation checks should be made each time the vehicle is used Such an inspection can be accomplished in a very short time and the added safety it assures is more than worth the time involved WARNING EWA11150 If any item in the Pre operation check list is not...

Page 28: ...ear 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 brake Check operation Check pedal free play Adjust if necessary 6 17 6 19 Clutch Check operation Lubricate cable if necessary Check lever free play Adjust if necessary 6 15 Throttle grip Make sure that operation is smooth Check c...

Page 29: ...4 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 24 Sidestand Make sure that operation is smooth Lubricate pivot if necessary 6 24 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 necessary Sidestand switch Check operati...

Page 30: ...ch 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 10 Never ride with the sidestand down 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 t...

Page 31: ...o the throttle with the starter choke turned off EAU16640 Starting a warm engine Follow the same procedure as for start ing a cold engine with the exception that the starter choke is not required when the engine is warm EAU16671 Shifting Shifting gears lets you control the amount of engine power available for starting off accelerating climbing hills etc The gear positions are shown in the il lustr...

Page 32: ...g acceleration Do not rev the engine while shifting down and avoid high engine speeds with no load on the engine Turn the engine off instead of let ting it idle for an extended length of time e g in traffic jams at traffic lights or at railroad crossings EAU16841 Engine break in There is never a more important period in the life of your engine than the period between 0 and 1600 km 1000 mi For this...

Page 33: ...gine trouble should occur during the engine break in period immediately have a Yamaha dealer check the vehicle EAU17200 Parking When parking stop the engine and then remove the key from the main switch WARNING EWA10310 Since the engine and exhaust system can become very hot park in a place where pedestri ans or children are not likely to touch them Do not park on a slope or on soft ground otherwis...

Page 34: ... you are not familiar with mainte nance work have a Yamaha dealer do it for you EAU17340 Owner s tool kit The owner s tool kit is located behind panel A See page 6 5 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 tools such as a torque wrench...

Page 35: ...MAINTENANCE JOB ODOMETER READING 1000 km ANNUAL CHECK 1 10 20 30 40 1 Fuel line Check fuel and vacuum hoses for cracks or damage 2 Spark plugs Check condition Clean and regap Replace 3 Valves Check valve clearance Adjust 4 Air filter element Clean Replace 5 Clutch Check operation Adjust 6 Front brake Check operation fluid level and vehicle for fluid leakage Replace brake pads Whenever worn to the ...

Page 36: ...ing the motorcycle or riding in the rain 14 Steering bearings Check bearing play and steering for roughness Lubricate with lithium soap based grease Every 20000 km 15 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 16 Sidestand Check operation Lubricate 17 Sidestand switch Check operation 18 Front fork Check operation and for oil leakage 19 Shock absorber assem bl...

Page 37: ... oil strainer Clean 24 Front and rear brake switches Check operation 25 Moving parts and ca bles Lubricate 26 Throttle grip housing and cable Check operation and free play Adjust the throttle cable free play if necessary Lubricate the throttle grip housing and cable 27 Air induction system Check the air cut off valve reed valve and hose for dam age Replace the entire air induction system if necess...

Page 38: ... cover open in sert the key into the lock and then turn it 1 4 turn clockwise 2 Pull the rear of the panel out with the key inserted in the lock 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 with the key inserted in the lock 2 Turn the key counterclockwise to the original position remove it a...

Page 39: ...ark plugs are important engine components which are easy to check Since heat and deposits will cause any spark plug to slowly erode the spark plugs should be removed and checked in accordance with the periodic mainte nance and lubrication chart In addition the condition of the spark plugs can re veal the condition of the engine To remove a spark plug 1 Remove the spark plug cap 2 Remove the spark ...

Page 40: ... plug 1 Measure the spark plug gap with a wire thickness gauge and if nec essary adjust the gap to specifica tion 2 Clean the surface of the spark plug gasket and its mating surface and then wipe off any grime from the spark plug threads 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 ...

Page 41: ... 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 correct level To change the engine oil with or without oil filter element replace ment 1 Start the engine warm it up for several ...

Page 42: ...D or oils of a high er quality than specified In addition do not use oils labeled ENERGY CONSERVING II or higher Make sure that no foreign mate rial enters the crankcase 9 Start the engine and then let it idle for several minutes while checking it for oil leakage If oil is leaking im mediately turn the engine off and check for the cause 10 Turn the engine off and then check the oil level and corre...

Page 43: ...cover by removing the screws 3 Remove the air filter element by removing the screws 4 Lightly tap the air filter 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 6 Remove the clamp from the...

Page 44: ... the clamp screw EAU21280 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 ser viced by the owner as part of routine maintenance C...

Page 45: ...ed 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 en gine idling speed turn the screw in direction b NOTE If the specified idling speed cannot be obtained as described above have a Yamaha dealer make the adjustment EAU21380 Adjusting the throttle cable free play The throttle cable fr...

Page 46: ...ture The tire air pressure must be ad justed in accordance with the riding speed and with the total weight of rider passenger car go and accessories approved for this model WARNING EWA10510 Proper loading of your vehicle is im portant for several characteristics of your vehicle such as handling braking performance and safety Do not carry loosely packed items that can shift Securely pack your heavi...

Page 47: ...orn tires Besides being illegal operating the vehi cle with excessively worn tires decreases riding stability and can lead to loss of control The replacement of all wheel and brake related parts includ ing the tires should be left to a Yamaha dealer who has the necessary professional knowl edge and experience Tire information This motorcycle is equipped with tube tires WARNING EWA10460 The front a...

Page 48: ... age is found have a Yamaha dealer replace the wheel Do not attempt even the smallest repair to the wheel A deformed or cracked wheel must be replaced The wheel should be balanced whenever either the tire or wheel has been changed or replaced An unbalanced wheel can result in poor performance adverse han dling characteristics and a short ened tire life Ride at moderate speeds after changing a tire...

Page 49: ...ut in direction b 7 Tighten the locknut at the clutch le ver and the crankcase EAU22092 Adjusting the brake lever free play The brake lever free play should mea sure 5 0 8 0 mm 0 20 0 31 in as shown Periodically check the brake le ver free play and if necessary adjust it as follows 1 Loosen the locknut at the brake le ver 2 To increase the brake lever free play turn the adjusting screw in di recti...

Page 50: ...RNING EWA10670 It is advisable to have a Yamaha dealer make these adjustments Brake pedal position The top of the brake pedal should be positioned approximately 76 6 mm 3 02 in above the top of the footrest as shown Periodically check the brake pedal position and if necessary adjust it as follows 1 Loosen the locknut at the brake pedal 2 To raise the brake pedal turn the adjusting bolt in directio...

Page 51: ... 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 EAU22270 Adjusting the rear brake light switch The rear brake light switch which is ac tivated by the brake pedal is properly adjusted when the brake light comes on just before braking takes effect If necessary adjust the brake light switch as follows T...

Page 52: ...k 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 ente...

Page 53: ...r 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 the brake 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 ...

Page 54: ...re the drive chain slack as shown 4 If the drive chain slack is incorrect adjust it as follows EAU22821 To adjust the drive chain slack 1 Loosen the brake pedal free play adjusting nut axle nut and locknut at each end of 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 s...

Page 55: ...tervals 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 CAUTION ECA10580 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 CAUTION ECA11120 To prevent damaging the O rings do...

Page 56: ...able is damaged or does not move smoothly have a Yamaha dealer check or replace it WARNING EWA10720 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 EAU23110 Checking and lubricating the throttle grip and cable The operation of the throttle grip should be checked bef...

Page 57: ... should be lu bricated if necessary EAU23200 Checking and lubricating the sidestand The operation of the sidestand should be checked before each ride and the sidestand pivot and metal to metal contact surfaces should be lubricated if necessary WARNING EWA10730 If the sidestand does not move up and down smoothly have a Yamaha dealer check or repair it Recommended lubricant Lithium soap based grease...

Page 58: ...s to check if the front fork compresses and rebounds smoothly CAUTION ECA10590 If any damage is found or the front fork does not operate smoothly have a Yamaha dealer check or re pair it EAU23280 Checking the steering Worn or loose steering bearings may cause danger Therefore the operation of the steering must be checked as fol lows at the intervals specified in the pe riodic maintenance and lubri...

Page 59: ...es not turn smoothly have a Yamaha dealer check the wheel bearings EAU23380 Battery The battery is located behind panel A See page 6 5 This model is equipped with a sealed type MF battery which does not re quire any maintenance There is no need to check the electrolyte or to add distilled water CAUTION ECA10620 Never attempt to remove the battery cell seals as this would permanent ly damage the ba...

Page 60: ... soon as possible if it seems to have discharged Keep in mind that the battery tends to discharge more quickly if the vehicle is equipped with optional electrical accessories To store the battery 1 If the vehicle 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 leas...

Page 61: ...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 EAU23791 Replacing the headlight bulb This model is equipped with a quartz bulb headlight If the headlight bulb burns out replace it as follows 1 Remove the headlight unit by re moving the screws 2 Disconnect the headlig...

Page 62: ...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 al cohol or thinner 5 Install the headlight bulb cover and then connect the coupler 6 Install the headlight unit by install ing the screws 7 Have...

Page 63: ...o the socket push it in and then turn it clock wise until it stops 4 Install the lens by installing the screws CAUTION ECA10680 Do not overtighten the screws oth erwise the lens may break EAU24210 Replacing a turn signal light bulb 1 Remove the turn signal lens by re moving the screws 2 Remove the defective bulb by pushing it in and turning it counter clockwise 1 Screw 1 Tail brake light bulb 1 Sc...

Page 64: ...e and level position before starting any maintenance A strong wooden box can be placed under the engine for added stability To service the front wheel 1 Stabilize the rear of the motorcycle by using a motorcycle stand or if an additional motorcycle stand is not available by placing a jack un der the frame in front of the rear wheel 2 Raise the front wheel off the ground by using a motorcycle stand...

Page 65: ... 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 the brake 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 enou...

Page 66: ...meter cable EAU25080 Rear wheel EAU25430 To remove the rear wheel WARNING EWA10820 It is advisable to have a Yamaha dealer service the wheel Securely support the motor cycle so that there is no danger of it falling over 1 Loosen the axle nut and the brake torque rod nut at the brake shoe plate 1 Speedometer gear unit retainer Tightening torques Wheel axle 59 Nm 5 9 m kgf 43 ft lbf Front wheel axle...

Page 67: ...l axle from the left hand side and then install the axle nut 2 Install the drive chain onto the rear sprocket and then adjust the drive chain slack See page 6 21 3 Lower the rear wheel so that it is on the ground 4 Install the brake rod onto the brake camshaft lever and then install the brake pedal free play adjusting nut onto the brake rod 5 Connect the brake torque rod to the brake shoe plate by...

Page 68: ...g troubleshooting chart represents a quick and easy procedure for checking these vital systems your self However should your motorcycle require any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools experience and know how to service the motorcycle properly Use only genuine Yamaha replace ment parts Imitation parts may look like Yamaha parts but they are often inf...

Page 69: ...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 70: ...ve dirt do not leave the cleaner on the af fected area any longer than in structed Also thoroughly rinse the area off with water immedi ately dry it and then apply a cor rosion protection spray Improper cleaning can damage windshields cowlings panels and other plastic parts Use only a soft clean cloth or sponge with mild detergent and water to clean plastic Do not use any harsh chemical products o...

Page 71: ...cluding chrome and nick el plated surfaces to prevent cor rosion After cleaning 1 Dry the motorcycle with a chamois or an absorbing cloth 2 Immediately dry the drive chain and lubricate it to prevent it from rusting 3 Use a chrome polish to shine chrome aluminum and stainless steel parts including the exhaust system Even the thermally in duced discoloring of stainless steel exhaust systems can be ...

Page 72: ...le for sev eral months 1 Follow all the instructions in the Care section of this chapter 2 Turn the fuel cock lever to ON 3 Drain the carburetor float cham bers by loosening the drain bolts this will prevent fuel deposits from building up 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 det...

Page 73: ...heels are off the ground Alterna tively turn the wheels a little every 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 ...

Page 74: ...ent replacement 1 40 L 1 48 US qt 1 23 Imp qt With oil filter element replacement 1 60 L 1 69 US qt 1 41 Imp qt Air filter Air filter element Dry element Fuel Recommended fuel Unleaded gasoline only Fuel tank capacity 11 0 L 2 91 US gal 2 42 Imp gal Fuel reserve amount 3 4 L 0 90 US gal 0 75 Imp gal Carburetor Manufacturer MIKUNI Type x quantity BDS26 x 1 Spark plug s Manufacturer model NGK CR6HSA...

Page 75: ...oading condition 90 180 kg 198 397 lb Front 225 kPa 33 psi 2 25 kgf cm Rear 225 kPa 33 psi 2 25 kgf cm Front wheel Wheel type Spoke wheel Rim size 18x1 60 Rear wheel Wheel type Spoke wheel Rim size 15M C x MT3 00 Front brake Type Single disc brake Operation Right hand operation Recommended fluid Dot 4 Rear brake Type Drum brake Operation Right foot operation Front suspension Type Telescopic fork S...

Page 76: ...ght 12 V 21 0 W 2 Meter lighting 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 0 A Headlight fuse 15 0 A Signaling system fuse 10 0 A Ignition fuse 10 0 A Carburetor heater fuse 10 0 A 5KR23 book Page 3 Tuesday June 24 2003 1 47 PM ...

Page 77: ...dentification 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 EAU26400 Vehicle identification number The vehicle identification number is stamped into the steering head pipe Record this number in the space pro vided NOTE The vehicle identification number is used to identify your motorcycle an...

Page 78: ...BITED 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 ele...

Page 79: ...fication numbers 9 1 Ignition circuit cut off system 3 10 Important label location of 1 5 Indicator and warning lights 3 2 K Key identification number 9 1 M Main switch steering lock 3 1 Model label 9 2 N Neutral indicator light 3 2 Noise regulation for Australia 9 2 P Panels removing and installing 6 5 Parking 5 4 Part locations 2 1 Pass switch 3 3 Periodic maintenance and lubrication chart 6 2 P...

Page 80: ...INDEX V Valve clearance adjusting 6 13 Vehicle identification number 9 1 W Wheel bearings checking 6 26 Wheel front 6 32 Wheel rear 6 33 Wheels 6 15 5KR23 book Page 2 Tuesday June 24 2003 1 47 PM ...

Page 81: ...5KR23 book Page 3 Tuesday June 24 2003 1 47 PM ...

Page 82: ...PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2003 07 0 3 1 CR E 5KR 28199 23 XVS250S OWNER S MANUAL ...

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