Yamaha DragStar XVS250 (2003) manual

PRINTED ON RECYCLED PAPER Y AMAHA MO T OR CO . , L TD . PRINTED IN JAPAN 2003.07-0.3 × 1 CR (E) 5KR-28199-E2 XVS250 OWNER’S MANUAL[...]

5KRE2.book Page 2 Mo nday, June 23, 2003 3:3 2 PM[...]

INTRODUCTION EAU10100 Welcom e to the Yamaha world of moto rcycling! As the owne r of the XV S250, you ar e benefi ting from Yamah a’s vast experi ence and new est techno logy regard ing the des ign and m anufactu re of high -quality product s, which have earne d Yamaha a reputat ion for dep endability. Please take the time to read this manual th[...]

IMPORTANT MANUAL INFORMATION EAU1015 0 Parti cular ly impo rtant in for mation is disti nguis hed in this manua l by the foll owi ng nota tions: N O TE: ● This ma nual sho uld be co nsid ered a pe rmanent part of this motorc ycle and should remain w ith it e ven if the mot orc ycle is subs equently so ld. ● Yama ha continua lly seeks a dvanceme[...]

IMPORTANT MANU AL INFORMATION EAU10200 XVS25 0 OW N E R ’ S MANU AL ©2003 by Y amaha Motor C o., Ltd. 1st edit ion, May 2003 All right s reser ved. Any reprinting or una uthorized use without the written permissi on of Y amaha Motor Co., Ltd. is expressl y prohibited. Prin ted in Ja pan. 5KRE2.book Page 2 Mo nday, June 23, 2003 3:3 2 PM[...]

TABLE OF CONTENTS SAFETY INFORMATION ... ...............1-1 DESCRIPTION .. ................. ...............2-1 Left view ................ ...................... ....2-1 Right view .............. ...................... ....2-2 Controls an d instruments............. .... 2-3 INSTRUMENT AND CONTROL FUN CTIO NS ............. ...................... ...[...]

TABLE OF CONTENTS Front wheel ..................... .............. 6-32 Rear wheel ............... ................. ... 6-33 Troubles hooting ... ........... .............. 6-35 Troubles hooting c hart ................... 6-36 MOTORCYCLE CARE AND STORAGE ............... ................. .......... 7-1 Care .......... ............................ [...]

1-1 1 SAFETY INFORMATION EAU10250 MOTORCYC LES ARE SINGLE TRACK VEH ICLES. THEIR SAFE USE AND OPERATI ON ARE DEPENDENT UPON THE USE OF PROPE R RIDING TECHNIQUES AS WELL AS THE EX- PERTISE OF THE OPERATOR. EV- ERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIREMENTS BEFORE RIDING THI S MOTOR- CYCLE. HE OR SH E SHO ULD: ● OBTAIN THOROUGH INSTRUC- TIONS [...]

SAFETY INFORMATION 1-2 1 wide on a t urn du e to E XCESS IVE SPEED or unde rcor nerin g (insu ffi- cient lean angl e fo r the spee d). • Always obe y the s peed l imit a nd neve r travel fas ter than warrant- ed by road and traffic co nditio ns. • Alway s sign al befor e turni ng or changin g lane s. Make su re that other mo torists can se e yo[...]

SAFETY INFORMATION 1-3 1 Load ing The tota l weight of th e oper ator, pa s- seng er, acc esso ries an d car go mus t not e xceed t he maxim um load limi t of 180 kg (397 lb) . When loa ding with in this w eight lim it, keep the f ollowi ng in mind: ● Cargo a nd accesso ry weight shoul d be ke pt as l ow an d close t o the moto rcycle as possibl [...]

SAFETY INFORMATION 1-4 1 Gasoline and exhaust gas ● GASO LINE IS HIGHLY FLAMMA - BLE : • Always turn t he en gine of f when refueling. • Take care no t to spi ll any gaso- line on the engine or exh aust system when refueling. • Never refu el w hile s moki ng or in the v icinity of an open flam e. ● Neve r sta rt the en gine o r let it r u[...]

DESC RIPTION 2-1 2 EAU1041 0 Left view 1. Headlight (page 6-28) 2. Fuel cock (page 3-8) 3. Fuses (pa ge 6-28) 4. Helmet holder (page 3-9) 5. Shock absorber assembly spring preload adjusting ring (page 3-10) 6. Shift pedal (page 3-5) 5KRE2.book Page 1 Mo nday, June 23, 2003 3:3 2 PM[...]

DESCRIPTI O N 2-2 2 EAU10420 Right view 1. Owner ’ s tool k it (page 6-1) 2. Battery (page 6-26) 3. Air filt er element (page 6-10) 4. Main s witch/steer ing lock (page 3-1) 5. Brak e pedal (page 3-6) 6. Engine oil fi lter element (page 6-8) 7. Engine oil le vel chec k window (page 6-8) 8. Shoc k absorber assembly spring pr eload adjusting ring ([...]

DESC RIPTION 2-3 2 EAU1043 0 Controls and instruments 1. Clutch le ver (page 3-5) 2. Left handlebar s witches (page 3-4) 3. Speedometer unit (page 3-3) 4. Right handlebar switches (page 3-4) 5. Brake le ver (page 3-6) 6. Throttle grip (page 6-12) 7. Fuel tank cap (page 3-6) 5KRE2.book Page 3 Mo nday, June 23, 2003 3:3 2 PM[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-1 3 EAU10460 Main switch/steer ing lock The main switch/st eering lo ck controls the igniti on an d ligh ting syst ems, and is used t o lock t he st eering. The variou s posi tions ar e descr ibed be low. EAU10630 ON All e lectr ical syst ems ar e su pplied with power, and the eng ine can b e started. The key ca n[...]

INSTRUMENT A ND CONTROL FUNCTIONS 3-2 3 EAU10880 (Parki ng) The s teeri ng is lock ed, and th e tai llig ht and aux iliar y ligh t are on, but all other electr ical system s are off. The key can be rem oved. The st eering mus t be locke d bef ore th e key can be turned to “” . CAUTION: ECA11020 Do not use the parking p osition for an extended l[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-3 3 EAU11630 Speedometer unit The sp eedome ter u nit is equi pped w ith a speed ometer, a n odom eter and a trip meter. The spee dome ter s hows riding spe ed. T he odom eter shows the total d istanc e trav eled. Th e tripmete r shows the dis tance trav eled s ince i t was last set to z ero with the reset kno b. [...]

INSTRUMENT A ND CONTROL FUNCTIONS 3-4 3 EAU12342 Handlebar swi tches Left Right EAU12350 Pass s witch “” Pres s this switc h to flash the head light. EAU12400 Dimmer switch “ / ” Set th is swit ch to “” for th e high beam an d to “” for the low beam. EAU12460 Turn signal switch “ / ” To sign al a ri ght-ha nd turn , push th is s[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-5 3 CAUTION: ECA10050 See page 5-1 for start ing instr uc- tions prior to starting the engine . EAU12820 Clutch leve r The clut ch lever is locate d at the le ft handle bar grip. To disengage t he clutch, pull the le ver toward the handl e- bar g rip. T o enga ge the clut ch, r elease the le ver. T he lever shou l[...]

INSTRUMENT A ND CONTROL FUNCTIONS 3-6 3 EAU12890 Brake lev er The br ake lev er is lo cate d at the rig ht handle bar grip. To appl y the fro nt brak e, pul l the le ver tow ard the ha ndle- bar gri p. EAU12941 Brake pe dal The brake pedal is on the righ t si de of the moto rcycl e. To ap ply the rear brak e, press down on the bra ke pedal. EAU1300[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-7 3 NOTE: The f uel ta nk cap canno t be in sta lled unless the key is in th e lock. In additio n, the key canno t be removed if the cap is not prope rly inst alle d an d lock ed. W ARNING EWA11140 Make sure that the fuel tank cap is properly in stalled before riding. EAU13210 Fuel Make su re th at there is suffic[...]

INSTRUMENT A ND CONTROL FUNCTIONS 3-8 3 or premi um un lead ed fuel . Use of un- leaded fuel will extend spa rk pl ug li fe and re duce m ain tenanc e cos ts. EAU13580 Fuel cock This mo del i s equi pped wi th a n egativ e pres sure fuel cock. The fuel cock sup - plies fuel f rom the tank to the car bure tor while also filteri n g it. The fuel coc [...]

INSTRUMENT AND CONTROL FUNCTIONS 3-9 3 PRI This indica tes pri me. W ith the f uel coc k leve r in this p osition , the en gine ca n be “ pri med ” . Turn the fuel cock lever to this posi tion wh en th e eng ine ha s be en al- lowed to run out of fuel. This se nds fuel directly to the carb uretor, whic h will make star ting e asi er. Af ter the[...]

INSTRUMENT A ND CONTROL FUNCTIONS 3-10 3 EAU14880 Adjusti ng the shock ab sorbe r assem bli es Each shock a b sorber a ssembly is equipp ed wit h a spr ing pre load adj ust- ing rin g. CAUTION: ECA10100 Never a ttempt to tur n an adj usting mechanism beyond the maximum or minimum settings. W ARNING EWA10210 Always adjust both shock absorber assembl[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-11 3 below and h ave a Yamaha dealer re- pair it if it does not function proper- ly. EAU15311 Ignition circuit cut-off system The igni tion circ uit cut -off s ystem (com- prising th e sidestand switch, clutch switch and neutr a l switc h) has the fol- lowi ng fu nctions . ● It pr events starti ng whe n the tr a[...]

INSTRUMENT A ND CONTROL FUNCTIONS 3-12 3 With the engine turned off: 1. Mov e the sidestand down. 2. Make sure that the engine stop s witch is tur ned on. 3. T ur n the key on. 4. Shift the transmission into the neutral position. 5. Push the star t switch. Does the engine start? With the engine still running: 6. Mov e the sidestand up. 7. K eep the[...]

PRE-OPERATION CHE CKS 4-1 4 EAU15591 The c onditi on of a ve hicle is the ow ner ’ s res ponsi bility . Vital comp onents can star t to de teriora te qui ckly an d unexpe cted ly, even i f the veh icl e rema ins unu sed (for exa mple , as a re sult of e xposu re to the elem ents) . Any da mage , fluid l eakag e or los s of tir e air press ure c o[...]

PRE-OPERATION CH ECKS 4-2 4 EAU15601 Pre-opera tion check list ITEM CHECKS P A GE Fuel • Check fuel l evel in fuel tank. • Refuel if necessary . • Check fuel l ine for leakage. 3-7 Engin e oil • Check oil lev el in engine. • If necessar y , add recommended oil t o specified lev e l. • Check v ehicle for oil leak age. 6-8 Fr ont bra ke ?[...]

PRE-OPERATION CHE CKS 4-3 4 Drive chain • Check chain slack. • Adjust if necessar y . • Check chain condition. • Lubricate if necessar y . 6-21, 6-22 Wheels and tires • Check for damage. • Check tire condition and tread depth. • Check air pressure. • Correct if neces sary . 6-13, 6-15 Brake and shift pedals • Make sure that operat[...]

OPERATION AND IM PORTANT RIDING POINTS 5-1 5 EAU15950 W ARNING EWA10270 ● Become thoroughly familiar with all operating c ontrols 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 clo sed ar ea for any length of ti[...]

OPERATION AND IMPORTANT RIDING P OINTS 5-2 5 after startin g, im mediat ely st op the engine, and have a Yamaha dealer check the s elf-diagnosis syste m. 6. Aft er starting th e engine, mov e the start er (choke) back half way. CAUTION: ECA11040 For maximum engine life, ne ver ac- cel erate ha rd when the en gine is cold! 7. Wh en the eng ine is wa[...]

OPERATION AND IM PORTANT RIDING POINTS 5-3 5 CAUTION: ECA10260 ● Even with the transmission in the neutral position, d o not coast for long periods of time with the engin e off, and do not tow the motorcycle for long dis- tances. The transmissi on is properly lubricated on ly when the engine is running. Ina de- quate lubrication may damage the tr[...]

OPERATION AND IMPORTANT RIDING P OINTS 5-4 5 EAU16841 Engine break-in There is never a mo re im portan t peri od in the l ife of you r engine th an the per iod betw een 0 and 1600 km (100 0 mi). For this re ason, y ou sho uld read th e follo w- ing mate rial caref ully. Sinc e the eng ine is brand n ew, do not put an exce ssive loa d on it for th e[...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-1 6 EAU17240 Safety is an obli gation of th e owne r. Pe- riod ic ins pecti on, ad justmen t and lubri- cation will kee p your veh icle in t he safes t and mos t effic ient co ndit ion po s- sibl e. The mo st importan t point s of in - spec tion, a d just ment, and lubri cation are e xplaine d on the follo[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-2 6 EAU17701 Periodic maintenance and lubrication chart NOTE: ● The annual checks mus t be per formed every year, except i f a kilo meter-based mainte nance is pe rformed in- stead. ● From 50000 km , repe at the ma intena nce in terva ls star ting fr om 1000 0 km. ● Items mark ed with a n ast erisk s [...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-3 6 9 * Wheels • Check runout, spoke t ightness and f or damage. • Tighten spokes if necessary . √ √ √ √ 10 * Ti res • Check tread depth and for damage . • Replace if necessary . • Check air pressure. • Correct if necessar y . √ √ √ √ √ 11 * Wheel beari ngs • Check bearing f[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-4 6 EAU18660 NOTE: ● The air f ilter need s mor e freq uent servi ce if you are r iding in u nusual ly we t or du sty area s. ● Hydrauli c brake service • Regularly check a nd, if necessary, correct the bra ke fluid leve l. • Every two year s rep lace the inte rnal com ponen ts of the brak e maste r[...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-5 6 EAU18770 Removing and installing panels The pane ls show n abov e need to be re- moved to perfor m some of the main te- nance j obs des cribe d in this chapt er. Refer to this sec tion ea ch time a pane l need s to be re move d and i nst alle d. EAU19521 Panel A To r emove the panel 1. Sli de the pane [...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-6 6 EAU19161 Panel B To rem ove th e pa nel 1. Rem ove th e bo lt. 2. Pu ll the rea r of the pane l out, a nd then slide th e panel f orwar d to re- lease it in the fro nt. To instal l the panel 1. Secu re the fro nt of t he pane l, and then pu sh th e rea r of the pa nel in . 2. In stall t he bo lt. EAU195[...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-7 6 To ch eck the spar k pl ugs 1. Che ck that th e porce lain insul ator arou nd the ce nter electr ode on each sp ark pl ug is a m e dium- to- ligh t tan (the i deal colo r when the vehic le is ridd en nor mally) . 2. Ch eck th at all spa rk plugs in stalle d in the engi ne ha ve th e same col or. NOTE: [...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-8 6 EAU19751 Engine oil and oil filter element The engi ne oil level should b e checke d bef ore each ride. In ad dition , the oil must be changed an d the oil filter ele- men t replace d at the in terva ls sp ecifi ed in the pe riodic main tenance an d lubr i- cation chart. To check the engine oil level 1.[...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-9 6 5. Rem ove and re place th e oil filt er elem ent and O-ri ng. 6. Inst all the oil filt er elemen t cover by install ing the bolts, then tig hteni ng them to the speci fied torqu e. N O TE: Make su re th at the O -ring is pro perly seated . 7. Inst all the engine oil dra in bolt , and then ti ghte n it[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-10 6 EAU20660 Cleaning the a ir filter element The ai r filt er e lement should be cl eaned at th e inte rvals s pecified in the period ic main ten ance and lubr icati on ch art. Clea n the a ir filt er el ement more fre- quent ly if yo u are ridi ng in unusu ally wet or dus ty areas . 1. Rem ove th e ai r [...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-11 6 7. Ins tall th e plug i nto th e check hose, a nd then in stall th e clamp. CAUTION: ECA10480 ● Make sure th at the a ir filt er ele- ment is properly seated in the air fi lter case. ● The engine should never be op- erated without the air filter ele- ment installe d, otherwise the piston(s) and/or[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-12 6 EAU21340 Adjusting the engine idling speed The en gine idl ing speed must be checked a nd, if ne cessary, adjuste d as follow s at t he interv als specifi ed in t he peri odic ma inte nanc e and lubr icati on chart. The en gine sh ould be warm be fore maki ng th is ad just ment . N O TE: ● The en gin[...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-13 6 EAU21400 Adjusti ng the val ve clear ance The v alve c learance changes wit h use, resul ting in improp er air -fue l mixt ure and/or engine nois e. To p reven t this from oc cur ring, t he va lve c leara nce must be adjust ed by a Y amaha d ealer at the inte rval s spec ifie d in the per iodi c maint[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-14 6 passe nger, car go, and access o- ries does not exceed the spe ci- fied maximu m load for the vehicl e. ● Do not carr y along loosely pack ed it ems, wh ich can sh ift during a ride. ● Secu rel y pack th e heav iest items clo se to the ce nter of the motorcycle and distribute the weight evenly on b[...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-15 6 W ARNING EWA10570 ● Have a Yam aha d eal er re place exces sivel y worn tire s. Be sides being illega l, operating the moto rcycl e with ex cess ively worn tires decr ease s ri ding sta- bility and c an lead to loss o f control. ● The replacement of all whe el- and brake-related parts, includ- ing[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-16 6 3. If th e speci fied cl utc h lever free play cou ld be o btaine d as de - scribe d abo ve, tigh ten the loc knu t and ski p the res t of the p roced ure, othe rwise procee d as follo w s. 4. Ful ly turn t he adj ust ing bol t at the clutch lever in dir ection (a) to loos- en the c lutc h cabl e. 5. L[...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-17 6 W ARNING EWA10630 ● After adjustin g the bra ke lever free play, che ck th e free pla y and ma ke sur e that the bra ke is working properly. ● A soft or spongy feeling in the brak e lever can in dicat e the presence of air in the hydraulic syst em. I f th ere is air in the h y- draul ic syst em, h[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-18 6 Brak e pedal free play The b rake pedal free pla y should mea- sure 20. 0 – 30. 0 mm (0.79 – 1.18 in) at the br ake peda l end. Per iodically che ck the brake peda l fre e play an d, if nec es- sary, adj ust it as foll ows. To i ncreas e the brake pedal free p lay, turn the ad justing nut at the br[...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-19 6 EAU22380 Checking the front brake pads and rear brake shoes The f ront brake pads an d the rea r brake shoes must be checked for wea r at t he interv als spec ified in t he period ic main - tenanc e an d lubr ication cha rt. EAU22420 Front brake pads Each f ront brak e pad is provided with a wear i nd[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-20 6 ● Wh en che cki ng t he flui d le vel, make sur e that the top of th e mas- ter c ylinder is level by turning th e handle bars. ● Use on ly the re comme nded qu ality brake fluid, o therwi se the r ubber seals may dete riorat e, ca usi ng leakag e and poor b rakin g per for- mance. ● Refill with [...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-21 6 EAU22760 Drive c hain slack The dri ve chain slack sho uld be checke d befo re eac h ride and a djuste d if necessa ry. EAU22770 To ch eck the driv e chai n s lack 1. Place the moto rcycl e on a level surfac e and hold it in an upri ght po - sition. NOTE: When checki ng and adju stin g the d rive chai[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-22 6 CAUTION: ECA10570 Improp er drive ch ain slack will over- load the engine as well as other vital parts of the motorcycle and can lead to chain slip page or brea kage. To prevent this from occurring, keep the dr ive ch ain slac k withi n the specif ied limit s. 3. Ti ghten bo th locknu ts and the axl e [...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-23 6 CAUTION: ECA11110 Do not use engine oil or any other lu- bric ants for the d rive ch ain, as they may contain substances that could damage the O-rings. EAU23100 Checki ng and lubricat ing the cables The o peratio n of al l contr ol cable s and the co nditio n of t he cabl es shoul d be checked before [...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-24 6 EAU23131 Checking and lubricating the brake and shift pedals The op erati on of th e brak e and sh ift pedals sh ould be che cked bef ore each ride , and t he pe dal p ivots sh oul d be lu - bricat ed if ne cessary. EAU23140 Checking and lubricating the brake and cl utch levers The o perati on of th e [...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-25 6 EAU23271 Checking the front fork The c onditi on an d oper atio n of t he fro nt fork mus t be checke d as follo ws at the interv als spec ified in t he period ic main - tenanc e an d lubr ication cha rt. To check the conditio n W ARNING EWA10750 Secu rely sup port the veh icle so t hat there is no da[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-26 6 EAU23290 Checking th e wheel bearings The fro nt and rea r wheel beari ngs mu st be checke d at th e inter vals spe cified in the pe riodi c mai ntena nce an d lubr ica- tion c hart. I f there i s play i n the w heel hub or if the whe el does not turn smoot hly, h ave a Yamaha deal er chec k the wheel [...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-27 6 W ARNING EWA10760 ● Electrolyte is pois onous and dangerous since it contains sul- furic ac id, whic h cau ses sever e burns. Avoid any contact with skin, eyes or clothing and al- ways shield yo ur e yes when working near batter ies. In case of contact, admini ster the fol- lowing FIRST AI D. • EX[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-28 6 EAU23550 Replaci ng the fuses The m ain fuse a nd th e fuse box, wh ich contai ns the fuses for the individ u al c ir- cuits , are l ocate d behi nd pa nel B. ( See page 6- 5.) If a fuse is blown, replace i t as follo w s. 1. Turn th e key to “ OFF ” and t urn of f the electric al ci rcuit in qu es[...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-29 6 3. Un hook th e hea dlight bulb hold er, and th en rem ove the de fectiv e bulb. W ARNING EWA10790 Headlight bulbs get very hot. There- fore, keep flammable products away from a lit head light bulb, a nd do not touch the bulb until it has cooled down. 4. Place a new headlig ht bulb into po - sition, a[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-30 6 EAU24131 Replacing the ta il/brake light bulb 1. Re move th e tail/ brake li ght lens by removi ng the screws . 2. Rem ove the defe ctiv e bu lb by pushi ng it in and t u rnin g it counte r- clock wis e. 3. Insert a new bulb into the socke t, push i t in, and then turn i t clock - wise un til it stop s[...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-31 6 3. Ins ert a n ew bu lb into the s ocke t, push it in, and t hen tu rn it clock - wise unt il it stops. 4. Install the lens by i nstal ling th e screws. CAUTION: ECA10680 Do not overtighten the screws, oth- erwi se the l ens may bre ak. EAU24350 Supporting the motorcycle Sinc e this model is not eq ui[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-32 6 EAU24360 Front wheel EAU24660 To remove the front wheel W ARNING EWA10820 ● It is advi sable t o have a Yamah a deal er serv ice the whe el. ● Securely support the motor- cycle so that t here is no danger of it falli ng over. 1. Dis connect th e speed o meter ca- ble from the front whe el. 2. Loos [...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-33 6 3. Inse rt the wh eel axle. 4. L ower th e fron t whee l so that it is on the g round. 5. Ti ghten th e whee l ax le and fr ont wheel axle pinch bolt to th e sp eci- fied t orques , and th en i nstall th e rubber cap. 6. Whi le appl ying th e front br ake, push do wn hard on the hand leba rs several t[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-34 6 2. Lift the rea r wh eel of f the ground accord ing to the proc edu re on page 6-3 1. 3. Disc onn ect the br ake tor que rod from th e brak e shoe plate b y re- movin g the nut and t he bo lt. 4. Rem ove the brake peda l free play adju sting nu t, and th en dis conne ct the b rake ro d at th e brake ca[...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-35 6 EAU25850 Troubleshooting Altho ugh Yama ha moto rcycles re ceive a thor ough inspe ction before ship ment fro m the fact ory, tr ouble ma y occur dur - ing o peration. Any pr oblem in the f uel, compre ssion, or ignitio n systems, for exam ple, ca n cause po or sta rting and loss of po wer. The f ollo[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-36 6 EAU25891 Troubleshooting chart W ARNING EWA10840 Keep away open flames and do not smoke while checking or wor king on the fuel system. Check the fuel level in the fuel tank. 1. Fuel There is enough fuel. There is no fuel. Check the compression. Supply fuel. The engine does not start. Check the compress[...]

MOTORCYCLE CARE A ND ST ORAGE 7-1 7 EAU26040 Care While the op en de sign of a moto rcycle reveal s the a ttrac tivene ss of the t ech- nology , it al so makes it m ore vul n era- ble. Rust and cor rosion can d evel op even if high-q uality co mponents are used. A rusty ex haust pipe m a y go un- notic ed on a car, howe ver, i t de tract s fro m th[...]

MOTORCYCLE CAR E AND STORAGE 7-2 7 After normal use Remov e dirt wi th warm wa ter, a mild det ergent , and a soft, cl ean s ponge , and th en rinse th oroughly with cl ean wate r. Use a toot hbr ush or bott lebr ush for h ard-t o-reac h areas. Stub born dirt and inse cts will com e off more e a sily if the ar ea is co vered with a w et clot h for [...]

MOTORCYCLE CARE A ND ST ORAGE 7-3 7 CAUTION: ECA10800 ● Apply spray oil an d wax spar- ingly and make sure to wipe off any ex cess. ● Never apply oil or wax to any rubber and plastic parts , but treat them with a suit able care product. ● Avoid using abrasive polishing compounds as they will wear away the p aint. NOTE: Consul t a Yama ha de a[...]

MOTORCYCLE CAR E AND STORAGE 7-4 7 W ARNING EWA10950 To prevent damage or injury from sparking, make sure to g round the spark plug electrodes while turning the engine over. 6. Lu bricate all c ontrol cabl es and the pivoting poi nts of all l evers a nd pedals as we ll a s of th e si de- stan d/cent ersta nd. 7. Check and, if nece ssary, correct th[...]

SPECI FI CAT IONS 8-1 8 Dimensions: Overa ll length: 2320 mm (91.3 in) Overa ll width: 910 mm (35.8 in ) Overa ll height: 1075 mm (42.3 in) Seat hei ght: 670 mm (26.4 in ) Wheel bas e: 1530 mm (60.2 in) Gro und clear ance: 150 mm (5.91 in ) Minimu m turni ng radius : 2900 mm (114 .2 in) Weight: With oil a nd fuel: 159. 0 kg (3 51 lb ) Engine: Engin[...]

SPECIFICATIONS 8-2 8 3rd: 29/2 3 (1 .261 ) 4th: 26/2 6 (1 .000 ) 5th: 23/2 8 (0 .821 ) Chassis: Frame type: Double cr adle Caste r angle : 35.0 ° Trail: 135.0 mm (5.31 in) Front tire: Type: With tube Size: 80/100- 18M/C 47P Manuf acturer/ model: CHENG SHIN/C-916 Manuf acturer/ model: IRC/MARBE LLA NF27 Rea r tir e: Type: With tube Size: 130/90- 15[...]

SPECI FI CAT IONS 8-3 8 Bulb voltage, wattage x quantity: Headlig ht: 12 V, 60 W/55.0 W × 1 Tail/br ake light: 12 V, 5 W/21 .0 W × 1 Fron t turn sig nal li ght: 12 V, 21.0 W × 2 Rear tur n signal lig ht: 12 V, 21.0 W × 2 Auxi liar y light: 12 V, 4.0 W × 1 Met er lightin g: 12 V, 1.7 W × 1 Neutr al indi cator ligh t: 12 V, 1.7 W × 1 High beam[...]

CONSUMER INFORMATI ON 9-1 9 EAU26351 Identification numbers Recor d the key iden tificatio n number, vehic le ide ntifica tion number and mo d- el labe l informa tion in the s p aces pro- vided bel ow for a ssistan ce when order ing spar e par ts from a Y amaha deal er or f or re feren ce in ca se the vehi - cle is stole n. KEY IDENTIFICATION NUMBE[...]

CONSUMER INFORMA T ION 9-2 9 EAU26460 Model label The mode l la bel is affi xed to the l oca- tion s hown . Record the i nform atio n on this la bel i n the sp ace pr ovided . Thi s in- for mation will be needed when ord ering spar e parts fr om a Ya maha dea ler. 1. Model label 5KRE2.book Page 2 Mo nday, June 23, 2003 3:3 2 PM[...]

INDEX A Air filter element, cleaning .................... 6- 10 Anti -th ef t alar m (op tion al) ...... .... .... ... .... .. 3-3 B Batter y ....... ........ ...... ......... ...... .... ....... ... 6-26 Brake and clutch levers, chec king and lubricating .......................... .......... 6- 24 Brake and shift pedals, checking and lubricating .[...]

INDEX Vehicle identification number .................. 9-1 W Wheel bearings, chec king ..................... 6-26 Wheel (front) ......................................... 6-32 Wheel (rear) .......................................... 6-33 Wheels .................... ............................ .. 6-15 5KRE2.book Page 2 Mo nday, June 23, 2003 3:3 2 PM[...]

5KRE2.book Page 3 Mo nday, June 23, 2003 3:3 2 PM[...]

PRINTED ON RECYCLED PAPER Y AMAHA MO T OR CO . , L TD . PRINTED IN JAPAN 2003.07-0.3 × 1 CR (E) 5KR-28199-E2 XVS250 OWNER’S MANUAL[...]