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I NTRODUCTION EAU00000 Congratulations on your purchase of the Yamaha XVS250. This model is the result of Yamaha’s vast experience in the production of fine sporting, touring, and paceset- ting racing machines. It represents the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields.
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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 information available at the time of printing, there may be minor discrepancies between your motorcycle and this manual.
TABLE OF CONTENTS EAU00009 SAFETY INFORMATION ........1-1 Adjusting the shock absorber assemblies ..3-9 Safe riding ............1-1 Sidestand ............3-10 Protective apparel ..........1-3 Ignition circuit cut-off system ......3-10 Modifications ............1-3 Loading and accessories ........1-3 PRE-OPERATION CHECKS .......4-1 Gasoline and exhaust gas........1-5 Pre-operation check list ........4-1 Location of important labels ......1-7 OPERATION AND IMPORTANT RIDING DESCRIPTION ...........2-1...
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TABLE OF CONTENTS Tires ..............6-16 Front wheel .............6-37 Spoke wheels ..........6-18 Rear wheel ............6-39 Adjusting the clutch lever free play ....6-19 Troubleshooting ..........6-40 Adjusting the brake lever free play ....6-20 Troubleshooting chart ........6-41 Adjusting the brake pedal position and free play ............
EAU03633 SAFETY INFORMATION MOTORCYCLES ARE SINGLE TRACK VEHICLES. THEIR SAFE USE AND OPERATION ARE DE- PENDENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EXPERTISE OF THE OPERATOR. EVERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIREMENTS BE- FORE RIDING THIS MOTORCYCLE. HE OR SHE SHOULD: 1.
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SAFETY INFORMATION 4. Many motorcycle accidents involve inexperienced operators. In fact, many operators who have been involved in accidents do not even have a current motorcycle license. a. Make sure that you are qualified and that you only lend your motorcycle to other qualified opera- tors.
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 motorcycle illegal to use.
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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 when select- ing and installing any accessories.
SAFETY INFORMATION a. Accessories fitted to the handlebar or the front fork area can create instability due to improper weight distribution or aerodynamic changes. If accessories are added to the handlebar or front fork area, they must be as lightweight as possible and should be kept to a minimum. b.
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SAFETY INFORMATION 3. Always turn the engine off before leaving the motorcycle unattended and remove the key from the main switch. When parking the motorcycle, note the following: a. The engine and exhaust system may be hot, therefore, park the motorcycle in a place where pe- destrians or children are not likely to touch these hot areas.
EAU00027 I NSTRUMENT AND CONTROL FUNCTIONS 1. Push. 2. Turn. EAU00029 EAU00040 Main switch/steering lock LOCK EW000016 The steering is locked, and all electrical WARNING The main switch/steering lock controls systems are off. The key can be the ignition and lighting systems, and is Never turn the key to “OFF”...
When this oc- 1. High beam indicator light “ ” 1. Speedometer curs, have the Yamaha dealer check 2. Turn signal indicator light “ ” 2. Odometer the self-diagnosis system. 3. Neutral indicator light “...
3. Turn signal switch To prevent engine damage, be sure 4. Horn switch “ ” Press this switch to sound the horn. to consult a Yamaha dealer as soon EAU00118 as possible if this occurs. Handlebar switches EAU00119 Pass switch “...
INSTRUMENT AND CONTROL FUNCTIONS 1. Engine stop switch 1. Clutch lever 1. Shift pedal 2. Start switch “ ” EAU00152 EAU00157 Clutch lever Shift pedal EAU00138 Engine stop switch The clutch lever is located at the left The shift pedal is located on the left Set this switch to “...
INSTRUMENT AND CONTROL FUNCTIONS 1. Brake lever 1. Brake pedal EAU00158 EAU00162 Brake lever Brake pedal The brake lever is located at the right The brake pedal is on the right side of handlebar grip. To apply the front the motorcycle. To apply the rear brake, pull the lever toward the handle- brake, press down on the brake pedal.
INSTRUMENT AND CONTROL FUNCTIONS NOTE: The fuel 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.
INSTRUMENT AND CONTROL FUNCTIONS EAU00185 ON: normal position RES: reserve position CAUTION: Immediately wipe off spilled fuel with a clean, dry, soft cloth, since fuel may deteriorate painted surfac- es or plastic parts. EAU00192 Recommended fuel: 1. Arrow mark positioned over “ON” 1.
INSTRUMENT AND CONTROL FUNCTIONS PRI: priming position 1. Arrow mark positioned over “PRI” 1. Starter (choke) lever “ ” 1. Helmet holder 2. Unlock. EAU03839 Starter (choke) lever “ ” EAU00260 This indicates prime. With the fuel cock Helmet holder Starting a cold engine requires a richer lever in this position, the engine can be To open the helmet holder, insert the...
INSTRUMENT AND CONTROL FUNCTIONS EAU00300 CI-10E Setting Adjusting the shock absorber Minimum (soft) assemblies Standard Each shock absorber assembly is Maximum (hard) equipped with a spring preload adjust- ing ring. EC000015 CAUTION: Never attempt to turn an adjusting 1. Spring preload adjusting ring mechanism beyond the maximum 2.
It cuts the running engine when check this system regularly as de- the transmission is in gear and the scribed below and have a Yamaha sidestand is moved down. dealer repair it if it does not function Periodically check the operation of the properly.
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5. Push the start switch. Does the engine start? The neutral switch may be defective. The motorcycle should not be ridden until checked by a Yamaha dealer. With the engine still running: 6. Move the sidestand up. 7. Keep the clutch lever pulled.
• If necessary, add recommended oil to specified level. 6-10 • Check vehicle for oil leakage. • Check operation. • If soft or spongy, have Yamaha dealer bleed hydraulic system. • Check lever free play. Front brake • Adjust if necessary.
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Chassis fasteners — • Tighten if necessary. Instruments, lights, signals • Check operation. — and switches • Correct if necessary. • Check operation of ignition circuit cut-off system. Sidestand switch 3-10 • If system is defective, have Yamaha dealer check vehicle.
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PRE-OPERATION CHECKS NOTE: Pre-operation checks should be made each time the motorcycle 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. EWA00033 WARNING If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operating the motorcycle.
Consult a Yamaha dealer re- The transmission is in the neutral garding any control or function position. that you do not thoroughly The transmission is in gear with understand.
OPERATION AND IMPORTANT RIDING POINTS 4. Turn the starter (choke) on and ECA00045 EAU01258 Starting a warm engine CAUTION: completely close the throttle. (See Follow the same procedure as for start- For maximum engine life, never ac- page 3-8 for starter (choke) ing a cold engine with the exception celerate hard when the engine is operation.)
OPERATION AND IMPORTANT RIDING POINTS EC000048 EAU00424 Tips for reducing fuel CAUTION: consumption Even with the transmission in Fuel consumption depends largely on the neutral position, do not your riding style. Consider the following coast for long periods of time tips to reduce fuel consumption: with the engine off, and do not Thoroughly warm up the engine.
1,600 km and beyond motorcycle may overturn. 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.
Periodic inspection, adjustment and lu- ence required for a particular job, have brication will keep your vehicle in the a Yamaha dealer perform it for you. safest and most efficient condition pos- EW000063 sible. The most important points of in-...
The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead. From 50,000 km, repeat the maintenance intervals starting from 10,000 km. Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and techni- cal skills.
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PERIODIC MAINTENANCE AND MINOR REPAIR ODOMETER READING (× 1,000 km) ANNUAL ITEM CHECK OR MAINTENANCE JOB CHECK √ √ √ √ √ • Check for cracks or damage. Brake hose • Replace. (See NOTE on page 6-4.) Every 4 years •...
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PERIODIC MAINTENANCE AND MINOR REPAIR ODOMETER READING (× 1,000 km) ANNUAL ITEM CHECK OR MAINTENANCE JOB CHECK √ √ √ Engine oil filter element • Replace. Front and rear brake √ √ √ √ √ √ • Check operation. switches √...
PERIODIC MAINTENANCE AND MINOR REPAIR 1. Panel A 1. Panel B 1. Panel lock cover 2. Unlock. EAU01122 Removing and installing EAU03184 Panel A panels To remove the panel The panels shown above need to be 1. Slide the lock cover open, insert removed to perform some of the main- the key into the lock, and then turn tenance jobs described in this chapter.
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PERIODIC MAINTENANCE AND MINOR REPAIR 1. Bolt 2. Pull the rear of the panel out with To install the panel EAU03185 Panel B the key inserted in the lock, and 1. Secure the front of the panel, and To remove the panel then slide the panel forward to re- then push the rear of the panel in 1.
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PERIODIC MAINTENANCE AND MINOR REPAIR 2. Pull the rear of the panel out, and To install the panel then slide the panel forward to re- 1. Secure the front of the panel, and lease it in the front. then push the rear of the panel in. 2.
Instead, have a Since heat and deposits will cause any Yamaha dealer check the motorcycle. spark plug to slowly erode, the spark 3. Check each spark plug for elec- plugs should be removed and checked...
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PERIODIC MAINTENANCE AND MINOR REPAIR Tightening torque: Spark plug: 12.5 Nm (1.25 m·kg) 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 a.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU01523 To change the engine oil (with or with- Right side Engine oil and oil filter out oil filter element replacement) element 1. Start the engine, warm it up for The engine oil level should be checked several minutes, and then turn it before each ride.
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PERIODIC MAINTENANCE AND MINOR REPAIR 1. Engine oil drain bolt 1. Bolt (× 3) 1. Oil filter element 2. Oil pan 2. O-ring 4. Remove the oil filter element cover 3. Remove the engine oil filler cap 5. Remove and replace the oil filter by removing the bolts.
PERIODIC MAINTENANCE AND MINOR REPAIR 7. Install the engine oil drain bolt, and EC000072 CAUTION: then tighten it to the specified In order to prevent clutch slip- torque. page (since the engine oil also lubricates the clutch), do not Tightening torque: mix any chemical additives Engine oil drain bolt: with the oil or use oils of a...
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PERIODIC MAINTENANCE AND MINOR REPAIR 1. Air filter case cover 1. Air filter element 2. Screw (× 4) 2. Screw (× 3) 4. Lightly tap the air filter element to 2. Remove the air filter case cover by 3. Remove the air filter element by remove most of the dust and dirt, removing the screws.
Therefore, most car- air filter case. buretor adjustments should be left to a The engine should never be op- Yamaha dealer, who has the neces- erated without the air filter ele- sary professional knowledge and expe- ment installed, otherwise the rience.
4,000–5,000 r/min. NOTE: Engine idling speed: The engine is warm when it quickly re- 1,200–1,400 r/min sponds to the throttle. NOTE: If the specified idling speed cannot be obtained as described above, have a Yamaha dealer make the adjustment. 6-15...
1.75 bar) 2.00 bar) from occurring, the valve clearance regarding the specified tires. 225 kPa 225 kPa must be adjusted by a Yamaha dealer 90 kg–maximum (2.25 kgf/cm (2.25 kgf/cm 2.25 bar) 2.25 bar) at the intervals specified in the periodic...
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(cowling, sad- tact a Yamaha dealer immediately and dlebags, etc. if approved for this have the tire replaced. model) does not exceed the maxi- CE-20E mum load of the motorcycle.
If any dam- cycle cannot be guaranteed. ing the tires, should be left to a age is found, have a Yamaha After extensive tests, only the Yamaha dealer, who has the dealer replace the wheel. Do not...
PERIODIC MAINTENANCE AND MINOR REPAIR 1. Locknut 1. Locknut 2. Clutch lever free play adjusting bolt 2. Clutch lever free play adjusting nut c. Clutch lever free play 3. If the specified clutch lever free EAU00694 play could be obtained as de- Adjusting the clutch lever free scribed above, tighten the locknut play...
WARNING sure 5–8 mm as shown. Periodically trol and an accident. It is advisable to have a Yamaha check the brake lever free play and, if dealer make these adjustments. necessary, adjust it as follows.
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If proper adjustment cannot be obtained as described, have a Yamaha dealer make this ad- 1. Brake pedal position adjusting bolt 1. Brake pedal free play adjusting nut justment. 2. Locknut...
Yamaha dealer replace Turn the adjusting nut while holding the the brake pads as a set. rear brake light switch in place. To make the brake light come on earlier, turn the adjusting nut in direction a.
EAU00744 Changing the brake fluid Drive chain slack ed surfaces or plastic parts. Have a Yamaha dealer change the The drive chain slack should be Always clean up spilled fluid im- brake fluid at the intervals specified in checked before each ride and adjusted mediately.
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PERIODIC MAINTENANCE AND MINOR REPAIR a. Drive chain slack 1. Axle nut 1. Alignment marks 2. Drive chain puller locknut 2. Drive chain slack adjusting nut 2. Shift the transmission into the neu- 3. Brake pedal free play adjusting nut 3.
PERIODIC MAINTENANCE AND MINOR REPAIR EC000096 EAU03006 2. Wipe the drive chain dry. Lubricating the drive chain CAUTION: 3. Thoroughly lubricate the drive The drive chain must be cleaned and Improper drive chain slack will over- chain with a special O-ring chain lubricated at the intervals specified in load the engine as well as other vital lubricant.
If a cable is damaged or does not move smoothly, have a Recommended lubricant: Yamaha dealer check or replace it. Lithium-soap-based grease (all-purpose grease) Recommended lubricant: Engine oil...
EW000113 Recommended lubricant: WARNING Lithium-soap-based grease If the sidestand does not move up (all-purpose grease) and down smoothly, have a Yamaha dealer check or repair it. Recommended lubricant: Lithium-soap-based grease (all-purpose grease) 6-28...
If any free Securely support the motorcycle so position. play can be felt, have a Yamaha that there is no danger of it falling 2. While applying the front brake, dealer...
PERIODIC MAINTENANCE AND MINOR REPAIR EAU01144 To charge the battery Checking the wheel bearings Have a Yamaha dealer charge the bat- The front and rear wheel bearings must tery as soon as possible if it seems to be checked at the intervals specified in have discharged.
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(MF) bat- charge it if necessary. • INTERNAL: Drink large quan- tery charger, have a Yamaha 3. Fully charge the battery before tities of water or milk and im- dealer charge your battery. installation.
EAU01749 3. Headlight fuse Replacing the fuses 4. If the fuse immediately blows 4. Ignition fuse again, have a Yamaha dealer The fuse boxes are located behind 5. Signaling system fuse check the electrical system. 6. Carburetor heater fuse panel B. (See page 6-6 for panel re- 7.
PERIODIC MAINTENANCE AND MINOR REPAIR 1. Screw (× 2) 1. Headlight coupler 1. Headlight bulb cover 2. Disconnect the headlight coupler, EAU03188 Replacing the headlight bulb and then remove the headlight unit This motorcycle is equipped with a and bulb cover. quartz bulb headlight.
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PERIODIC MAINTENANCE AND MINOR REPAIR 6. Install the headlight unit by install- ing the screws. 7. Have a Yamaha dealer adjust the headlight beam if necessary. 1. Headlight bulb holder 1. Do not touch this area. 3. Unhook the headlight bulb holder,...
PERIODIC MAINTENANCE AND MINOR REPAIR 1. Screw (× 2) 1. Tail/brake light bulb 2. Remove the defective bulb by EAU01623 Replacing the tail/brake light pushing it in and turning it counter- bulb clockwise. 1. Remove the tail/brake light lens by 3.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU01579 Supporting the motorcycle Since this model is not 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 1.
3. Remove the rubber cap, and then EW000122 loosen the wheel axle. WARNING 4. Lift the front wheel off the ground It is advisable to have a Yamaha according to the procedure on dealer service the wheel. page 6-36. Securely support the motor- 5.
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PERIODIC MAINTENANCE AND MINOR REPAIR 6. Tighten the wheel axle to the specified torque, and then install the rubber cap. Tightening torque: Wheel axle: 59 Nm (5.9 m·kg) 7. Tighten the front wheel axle pinch 1. Speedometer gear unit 1. Retainer bolt to the specified torque.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU03189 Rear wheel To remove the rear wheel EW000122 WARNING It is advisable to have a Yamaha dealer service the wheel. Securely support the motor- cycle so that there is no danger 1. Axle nut 1. Wheel axle 2.
However, should your motorcycle the brake shoe plate by installing After adjusting the brake pedal free require any repair, take it to a Yamaha the bolt and the nut, and then tight- play, check the operation of the dealer, whose skilled technicians have en the bolt to the specified torque.
Remove the spark plugs and check the electrodes. The engine does not start. Have a Yamaha dealer check the vehicle. Check the battery. 4. Battery The engine turns over The battery is good.
M OTORCYCLE CARE AND STORAGE EAU03430 Care Before cleaning Cleaning 1. Cover the muffler outlets with plas- ECA00010 While the open design of a motorcycle CAUTION: tic bags after the engine has reveals the attractiveness of the tech- Avoid using strong acidic wheel cooled down.
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MOTORCYCLE CARE AND STORAGE Do not use any harsh chemical For motorcycles equipped with After riding in the rain, near the sea or products on plastic parts. Be a windshield: Do not use strong on salt-sprayed roads sure to avoid using cloths or cleaners or hard sponges as Since sea salt or salt sprayed on roads sponges which have been in...
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NOTE: 4. To prevent corrosion, it is recom- Consult a Yamaha dealer for advice on mended to apply a corrosion pro- what products to use. tection spray...
MOTORCYCLE CARE AND STORAGE Storage Long-term a. Remove the spark plug caps and Before storing your motorcycle for spark plugs. several months: b. Pour a teaspoonful of engine oil Short-term 1. Follow all the instructions in the into each spark plug bore. Always store your motorcycle in a cool, “Care”...
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MOTORCYCLE CARE AND STORAGE 6. Lubricate all control cables and NOTE: Make any necessary repairs before the pivoting points of all levers and storing the motorcycle. pedals as well as of the sidestand/ centerstand. 7. Check and, if necessary, correct the tire air pressure, and then lift the motorcycle so that both of its wheels are off the ground.
SPECIFICATIONS Air filter Dry type element Gear ratio Fuel 2.643 Type Regular gasoline 1.684 Unleaded fuel only (for Australia) 1.261 Fuel tank capacity 11 L 1.000 Fuel reserve amount 3.4 L 0.821 Carburetor Chassis Manufacturer MIKUNI Frame type Double cradle Model ×...
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SPECIFICATIONS Maximum load* 180 kg Rear Tire air pressure (measured Type Drum brake on cold tires) Operation Right foot Up to 90 kg* Suspension Front 175 kPa (1.75 kgf/cm , 1.75 bar) Front Telescopic fork Rear 200 kPa (2.00 kgf/cm , 2.00 bar) Rear Swingarm...
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SPECIFICATIONS Bulb voltage, wattage × quantity 12 V, 60/55 W × 1 Headlight 12 V, 5/21 W × 1 Tail/brake light 12 V, 21 W × 4 Turn signal light 12 V, 1.7 W × 1 Meter lighting 12 V, 1.7 W × 1 Neutral indicator light 12 V, 1.7 W ×...
SPECIFICATIONS EAU01064 Conversion table CS-02E Conversion table All specification data in this manual are listed in SI and METRIC TO IMPERIAL METRIC UNITS. Metric unit Multiplier Imperial unit Use this table to convert METRIC unit data to IMPERIAL m·kg 7.233 ft·lb m·kg 86.794...
Record the key identification number, vehicle identification number and mod- el label information in the spaces pro- vided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehi- cle is stolen. 1. Key identification number 1.