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   Summary of Contents for YAMAHA Drag Star XVS250

  • Page 1 OWNER’S MANUAL XVS250 5KR-28199-E2...
  • Page 3 Yamaha a reputation for dependability. Please take the time to read this manual thoroughly, so as 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.
  • Page 4: Important Manual Information

    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.
  • Page 5 IMPORTANT MANUAL INFORMATION EAU10200 XVS250 OWNER’S MANUAL ©2003 by Yamaha Motor Co., Ltd. 1st edition, May 2003 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan.
  • Page 6: Table Of Contents

    TABLE OF CONTENTS SAFETY INFORMATION ....1-1 OPERATION AND IMPORTANT Adjusting the brake pedal RIDING POINTS......... 5-1 position and free play ....6-17 DESCRIPTION ........2-1 Starting a cold engine ....5-1 Adjusting the rear brake Left view ..........2-1 Starting a warm engine ....5-2 light switch ........
  • Page 7 TABLE OF CONTENTS Front 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...
  • Page 8: Safety Information

    SAFETY INFORMATION EAU10250 AND/OR WHEN MADE NECES- • Ride where other motorists can SARY BY MECHANICAL CONDI- see you. Avoid riding in another MOTORCYCLES SINGLE TIONS. motorist’s blind spot. TRACK VEHICLES. THEIR SAFE USE Many motorcycle accidents in- AND OPERATION ARE DEPENDENT Safe riding volve inexperienced operators.
  • Page 9 Modifications made to this motorcycle other motorists can see you. the single most critical factor in the pre- not approved by Yamaha, or the re- The posture of the operator and vention or reduction of head injuries. moval of original equipment, may ren- passenger is important for proper Always wear an approved helmet.
  • Page 10 Since Yamaha cannot should be kept to a minimum. 180 kg (397 lb). When loading within test all other accessories that may be •...
  • Page 11 SAFETY INFORMATION Gasoline and exhaust gas • Do not park the motorcycle on a GASOLINE IS HIGHLY FLAMMA- slope or soft ground, otherwise it BLE: may fall over. • Always turn the engine off when • Do not park the motorcycle near refueling.
  • Page 12: Description

    DESCRIPTION EAU10410 Left view 1. Headlight (page 6-28) 2. Fuel cock (page 3-8) 3. Fuses (page 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)
  • Page 13: Right View

    DESCRIPTION EAU10420 Right view 1. Owner’s tool kit (page 6-1) 2. Battery (page 6-26) 3. Air filter element (page 6-10) 4. Main switch/steering lock (page 3-1) 5. Brake pedal (page 3-6) 6. Engine oil filter element (page 6-8) 7. Engine oil level check window (page 6-8) 8.
  • Page 14: Controls And Instruments

    DESCRIPTION EAU10430 Controls and instruments 1. Clutch lever (page 3-5) 2. Left handlebar switches (page 3-4) 3. Speedometer unit (page 3-3) 4. Right handlebar switches (page 3-4) 5. Brake lever (page 3-6) 6. Throttle grip (page 6-12) 7. Fuel tank cap (page 3-6)
  • Page 15: Instrument And Control Functions

    INSTRUMENT AND CONTROL FUNCTIONS EAU10460 EAU10680 To unlock the steering Main switch/steering lock LOCK The steering is locked, and all electrical systems are off. The key can be re- moved. To lock the steering 1. Push. 2. Turn. The main switch/steering lock controls the ignition and lighting systems, and is Push the key in, and then turn it to used to lock the steering.
  • Page 16: Indicator And Warning Lights

    CAUTION: engine is defective. When this occurs, Do not use the parking position for have a Yamaha dealer check the self- an extended length of time, other- diagnosis system. 1. High beam indicator light “...
  • Page 17: Speedometer Unit

    Yamaha dealer check the vehicle. ECA11170 CAUTION: To prevent engine damage, be sure 1. Speedometer to consult a Yamaha dealer as soon 2. Odometer as possible if this occurs. 3. Tripmeter 4. Tripmeter reset knob The speedometer unit is equipped with a speedometer, an odometer and a tripmeter.
  • Page 18: Handlebar Switches

    INSTRUMENT AND CONTROL FUNCTIONS EAU12342 Right position. To cancel the turn signal Handlebar switches lights, push the switch in after it has re- turned to the center position. Left EAU12500 Horn switch “ ” Press this switch to sound the horn. EAU12590 Light switch “...
  • Page 19: Clutch Lever

    INSTRUMENT AND CONTROL FUNCTIONS ECA10050 EAU12820 EAU12870 Clutch lever Shift pedal CAUTION: See page 5-1 for starting instruc- tions prior to starting the engine. 1. Clutch lever 1. Shift pedal The clutch lever is located at the left The shift pedal is located on the left handlebar grip.
  • Page 20: Brake Lever

    INSTRUMENT AND CONTROL FUNCTIONS EAU12890 EAU12941 EAU13000 Brake lever Brake pedal Fuel tank cap 1. Brake lever 1. Brake pedal 1. Unlock. The brake lever is located at the right The brake pedal is on the right side of To remove the fuel tank cap handlebar grip.
  • Page 21: Fuel

    Your Yamaha engine has been de- signed to use regular unleaded gaso- line with a research octane number of 91 or higher. If knocking (or pinging) oc-...
  • Page 22: Fuel Cock

    INSTRUMENT AND CONTROL FUNCTIONS or premium unleaded fuel. Use of un- EAU13580 Fuel cock leaded fuel will extend spark plug life This model is equipped with a negative and reduce maintenance costs. pressure fuel cock. The fuel cock sup- plies fuel from the tank to the carburetor while also filtering it.
  • Page 23: Starter (choke) Lever

    INSTRUMENT AND CONTROL FUNCTIONS EAU13590 EAU14281 Starter (choke) lever “ ” Helmet holder 1. Pointed end positioned over “PRI” 1. Starter (choke) lever “ ” 1. Helmet holder This indicates prime. With the fuel cock 2. Unlock. Starting a cold engine requires a richer lever in this position, the engine can be To open the helmet holder, insert the air-fuel mixture, which is supplied by...
  • Page 24: Adjusting The Shock Absorber Assemblies

    Spring preload setting: minimum settings. Yamaha’s ignition circuit cut-off Minimum (soft): system has been designed to assist the operator in fulfilling the respon- Standard:...
  • Page 25: Ignition Circuit Cut-off System

    INSTRUMENT AND CONTROL FUNCTIONS below and have a Yamaha dealer re- EAU15311 Ignition circuit cut-off system pair it if it does not function proper- The ignition circuit cut-off system (com- prising the sidestand switch, clutch switch and neutral switch) has the fol- lowing functions.
  • Page 26 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.
  • Page 27: Pre-operation Checks

    PRE-OPERATION CHECKS EAU15591 The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly, even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss of tire air pressure could have serious consequences.
  • Page 28: Pre-operation Check List

    • Make sure that operation is smooth. • Check cable free play. Throttle grip 6-12, 6-23 • If necessary, have Yamaha dealer adjust cable free play and lubricate cable and grip housing. • Make sure that operation is smooth. Control cables 6-23 •...
  • Page 29 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.
  • Page 30: Operation And Important Riding Points

    Become thoroughly familiar following conditions must be met: Yamaha dealer check the electrical cir- The transmission is in the neutral with all operating controls and cuit. position. their functions before riding.
  • Page 31: Starting A Warm Engine

    EAU16640 EAU16671 Starting a warm engine Shifting engine, and have a Yamaha dealer Follow the same procedure as for start- check the self-diagnosis system. ing a cold engine with the exception 6. After starting the engine, move the that the starter (choke) is not required starter (choke) back halfway.
  • Page 32: Tips For Reducing Fuel Consumption

    OPERATION AND IMPORTANT RIDING POINTS ECA10260 EAU16800 Shift up points: Tips for reducing fuel CAUTION: 1st → 2nd: 23 km/h (14 mi/h) consumption 2nd → 3rd: 36 km/h (22 mi/h) Even with the transmission in 3rd → 4th: 50 km/h (31 mi/h) Fuel consumption depends largely on the neutral position, do not 4th →...
  • Page 33: Engine Break-in

    Do not park on a slope or on soft during the engine break-in period, tle operation or any condition that might ground, otherwise the vehicle immediately have a Yamaha dealer result in engine overheating must be may overturn. check the vehicle.
  • Page 34: Periodic Maintenance And Minor Repair

    If you are not familiar with mainte- certain maintenance work correctly. nance work, have a Yamaha dealer do it for you. NOTE: If you do not have the tools or experi- ence required for a particular job, have a Yamaha dealer perform it for you.
  • Page 35: Periodic Maintenance And Lubrication Chart

    The annual checks must be performed every year, except if a kilometer-based maintenance is performed in- stead. From 50000 km, repeat the maintenance intervals starting from 10000 km. Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. ODOMETER READING (× 1000 km)
  • Page 36 PERIODIC MAINTENANCE AND MINOR REPAIR ODOMETER READING (× 1000 km) ANNUAL ITEM CHECK OR MAINTENANCE JOB CHECK • Check runout, spoke tightness and for damage. √ √ √ √ 9 * Wheels • Tighten spokes if necessary. • Check tread depth and for damage. •...
  • Page 37 PERIODIC MAINTENANCE AND MINOR REPAIR ODOMETER READING (× 1000 km) ANNUAL ITEM CHECK OR MAINTENANCE JOB CHECK √ √ √ Engine oil filter element • Replace. √ 23 * Engine oil strainer • Clean. Front and rear brake √ √ √...
  • Page 38: Removing And Installing Panels

    PERIODIC MAINTENANCE AND MINOR REPAIR EAU18770 The panels shown above need to be re- Removing and installing moved to perform some of the mainte- panels nance jobs described in this chapter. Refer to this section each time a panel needs to be removed and installed. EAU19521 Panel A To remove the panel...
  • Page 39: Checking The Spark Plugs

    PERIODIC MAINTENANCE AND MINOR REPAIR EAU19161 To install the panel EAU19543 Panel B Checking the spark plugs 1. Secure the front of the panel, and The spark plugs are important engine then push the rear of the panel in. To remove the panel components, which are easy to check.
  • Page 40 If any spark plug shows a distinctly dif- ferent color, the engine could be defec- tive. Do not attempt to diagnose such 1. Spark plug gap problems yourself. Instead, have a Yamaha dealer check the vehicle. Spark plug gap: 0.6–0.7 mm (0.024–0.028 in)
  • Page 41: Engine Oil And Oil Filter Element

    PERIODIC MAINTENANCE AND MINOR REPAIR EAU19751 2. Place an oil pan under the engine Engine oil and oil filter NOTE: to collect the used oil. The engine oil should be between the element 3. Remove the engine oil filler cap minimum and maximum level marks.
  • Page 42 PERIODIC MAINTENANCE AND MINOR REPAIR ECA11620 Tightening torque: CAUTION: Oil filter element cover bolt: In order to prevent clutch slip- 10 Nm (1.0 m·kgf, 7.2 ft·lbf) page (since the engine oil also lubricates the clutch), do not NOTE: mix any chemical additives. Do Make sure that the O-ring is properly not use oils with a diesel speci- seated.
  • Page 43: Cleaning The Air Filter Element

    PERIODIC MAINTENANCE AND MINOR REPAIR EAU20660 out with compressed air as shown. Cleaning the air filter element If the air filter element is damaged, The air filter element should be cleaned replace it. at the intervals specified in the periodic maintenance and lubrication chart.
  • Page 44: Adjusting The Carburetor

    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- 1.
  • Page 45: Adjusting The Engine Idling Speed

    Yamaha dealer make the adjustment. sary, have a Yamaha dealer adjust it. 2. Check the engine idling speed and, if necessary, adjust it to spec- ification by turning the throttle stop screw.
  • Page 46: Adjusting The Valve Clearance

    175 kPa (25 psi) (1.75 kgf/cm²) Rear: from occurring, the valve clearance regarding the specified tires. 200 kPa (29 psi) (2.00 kgf/cm²) must be adjusted by a Yamaha dealer 90–180 kg (198–397 lb): at the intervals specified in the periodic Tire air pressure Front: maintenance and lubrication chart.
  • Page 47 Front tire: glass fragments in it, or if the sidewall is Size: cracked, have a Yamaha dealer re- 80/100-18M/C 47P place the tire immediately. Manufacturer/model: CHENG SHIN/C-916...
  • Page 48: Spoke Wheels

    If any dam- The replacement of all wheel- age is found, have a Yamaha and brake-related parts, includ- dealer replace the wheel. Do not ing the tires, should be left to a...
  • Page 49: Adjusting The Brake Lever Free Play

    PERIODIC MAINTENANCE AND MINOR REPAIR 3. If the specified clutch lever free 7. Tighten the locknut at the clutch le- EAU22092 Adjusting the brake lever free play could be obtained as de- ver and the crankcase. play scribed above, tighten the locknut and skip the rest of the procedure, otherwise proceed as follows.
  • Page 50: Adjusting The Brake Pedal Position And Free Play

    1. Brake pedal position adjusting bolt EWA10670 trol and an accident. WARNING 2. Locknut It is advisable to have a Yamaha 3. Tighten the locknut. dealer make these adjustments. EWA11230 WARNING After adjusting the brake pedal posi-...
  • Page 51: Adjusting The Rear Brake Light Switch

    The brake pedal free play should mea- obtained as described, have a switch sure 20.0–30.0 mm (0.79–1.18 in) at Yamaha dealer make this ad- the brake pedal end. Periodically check justment. the brake pedal free play and, if neces- After adjusting the brake pedal sary, adjust it as follows.
  • Page 52: Checking The Front Brake Pads And Rear Brake Shoes

    Observe these precautions: the wear indicator groove. If a brake the wear limit line, have a Yamaha pad has worn to the point that the wear dealer replace the brake shoes as a set.
  • Page 53: Changing The Brake Fluid

    Changing the brake fluid make sure that the top of the mas- denly, have a Yamaha dealer Have a Yamaha dealer change the ter cylinder is level by turning the check the cause. brake fluid at the intervals specified in handlebars.
  • Page 54: Drive Chain Slack

    PERIODIC MAINTENANCE AND MINOR REPAIR EAU22760 Drive chain slack The drive chain slack should be checked before each ride and adjusted if necessary. EAU22770 To check the drive chain slack 1. Place the motorcycle on a level surface and hold it in an upright po- sition.
  • Page 55: Lubricating The Drive Chain

    PERIODIC MAINTENANCE AND MINOR REPAIR EAU23020 Tightening torques: Lubricating the drive chain Locknut: The drive chain must be cleaned and 16 Nm (1.6 m·kgf, 12 ft·lbf) lubricated at the intervals specified in Axle nut: the periodic maintenance and lubrica- 104 Nm (10.4 m·kgf, 75 ft·lbf) tion chart, otherwise it will quickly wear 4.
  • Page 56: Checking And Lubricating The Cables

    If a cable is damaged periodic maintenance chart. or does not move smoothly, have a Yamaha dealer check or replace it. Recommended lubricant: Engine oil EWA10720 WARNING...
  • Page 57: Checking And Lubricating The Brake And Shift Pedals

    Recommended lubricant: EWA10730 Lithium-soap-based grease (all-pur- Lithium-soap-based grease (all-pur- WARNING pose grease) pose grease) If the sidestand does not move up and down smoothly, have a Yamaha dealer check or repair it. Recommended lubricant: Lithium-soap-based grease (all-pur- pose grease) 6-24...
  • Page 58: Checking The Front Fork

    Securely support the vehicle so that fork does not operate smoothly, damage and excessive oil leakage. there is no danger of it falling over. have a Yamaha dealer check or re- pair it. To check the operation 2. Hold the lower ends of the front 1.
  • Page 59: Checking The Wheel Bearings

    If there is play in the wheel hub or if the wheel does not turn smoothly, have a Yamaha dealer check the wheel bearings. 1. Battery The battery is located behind panel A.
  • Page 60 To charge the battery burns. Avoid any contact with battery damage. Have a Yamaha dealer charge the bat- skin, eyes or clothing and al- To charge a sealed-type (MF) tery as soon as possible if it seems to...
  • Page 61: Replacing The Fuses

    7. Spare fuse 4. If the fuse immediately blows If a fuse is blown, replace it as follows. again, have a Yamaha dealer 1. Turn the key to “OFF” and turn off check the electrical system. the electrical circuit in question.
  • Page 62 6. Install the headlight unit by install- 4. Place a new headlight bulb into po- ing the screws. sition, and then secure it with the 7. Have a Yamaha dealer adjust the 1. Headlight bulb cover headlight beam if necessary. bulb holder.
  • Page 63: Replacing The Tail/brake Light Bulb

    PERIODIC MAINTENANCE AND MINOR REPAIR EAU24131 EAU24210 Replacing the tail/brake light Replacing a turn signal light bulb bulb 1. Remove the tail/brake light lens by 1. Remove the turn signal lens by re- removing the screws. moving the screws. 1. Tail/brake light bulb 3.
  • Page 64: Supporting The Motorcycle

    PERIODIC MAINTENANCE AND MINOR REPAIR EAU24350 a jack either under each side of the Supporting the motorcycle frame in front of the rear wheel or under Since this model is not equipped with a each side of the swingarm. centerstand, follow these precautions when removing the front and rear wheel or performing other maintenance requiring the motorcycle to stand up-...
  • Page 65: Front Wheel

    To remove the front wheel jections mesh with the slots. EWA10820 WARNING It is advisable to have a Yamaha dealer service the wheel. Securely support the motor- cycle so that there is no danger 1. Front wheel axle pinch bolt of it falling over.
  • Page 66: Rear Wheel

    Rear wheel EAU25430 To remove the rear wheel EWA10820 WARNING It is advisable to have a Yamaha dealer service the wheel. Securely support the motor- cycle so that there is no danger 1. Speedometer gear unit retainer of it falling over.
  • Page 67 PERIODIC MAINTENANCE AND MINOR REPAIR 2. Lift the rear wheel off the ground 7. Push the wheel forward, and then Tightening torque: according to the procedure on remove the drive chain from the Brake torque rod nut: page 6-31. rear sprocket. 23 Nm (2.3 m·kgf, 17 ft·lbf) 3.
  • Page 68: Troubleshooting

    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.
  • Page 69: Troubleshooting Chart

    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.
  • Page 70: Motorcycle Care And Storage

    MOTORCYCLE CARE AND STORAGE EAU26040 ucts onto seals, gaskets, sprock- cleaning products, solvent or Care ets, the drive chain and wheel thinner, fuel (gasoline), rust re- While the open design of a motorcycle axles. Always rinse the dirt and de- movers or inhibitors, brake flu- reveals the attractiveness of the tech- greaser off with water.
  • Page 71 MOTORCYCLE CARE AND STORAGE After normal use ECA10790 4. To prevent corrosion, it is recom- CAUTION: Remove dirt with warm water, a mild mended to apply a corrosion pro- detergent, and a soft, clean sponge, tection spray metal, Do not use warm water since it in- and then rinse thoroughly with clean including chrome- and nickel-plat- creases the corrosive action of the...
  • Page 72: Storage

    NOTE: and spark plugs. To prevent corrosion, avoid Consult a Yamaha dealer for advice on b. Pour a teaspoonful of engine oil damp cellars, stables (because what products to use. into each spark plug bore.
  • Page 73 MOTORCYCLE CARE AND STORAGE EWA10950 than 30 °C (90 °F)]. For more in- WARNING formation on storing the battery, To prevent damage or injury from see page 6-26. sparking, make sure to ground the NOTE: spark plug electrodes while turning Make any necessary repairs before the engine over.
  • Page 74: Specifications

    SPECIFICATIONS Dimensions: Engine oil: Carburetor: Overall length: Type: Manufacturer: 2320 mm (91.3 in) SAE10W30 or SAE10W40 or SAE15W40 MIKUNI Overall width: or SAE20W40 or SAE20W50 Type x quantity: 910 mm (35.8 in) BDS26 x 1 Overall height: Spark plug(s): -20 -10 10 20 30 40 50 ˚C 1075 mm (42.3 in) Manufacturer/model:...
  • Page 75 SPECIFICATIONS 3rd: (Total weight of rider, passenger, cargo and Rear brake: 29/23 (1.261) accessories) Type: 4th: Tire air pressure (measured on cold Drum brake 26/26 (1.000) tires): Operation: 5th: Right foot operation Loading condition: 23/28 (0.821) Front suspension: 0–90 kg (0–198 lb) Chassis: Front: Type:...
  • Page 76 SPECIFICATIONS Bulb voltage, wattage x quantity: Headlight: 12 V, 60 W/55.0 W × 1 Tail/brake light: 12 V, 5 W/21.0 W × 1 Front turn signal light: 12 V, 21.0 W × 2 Rear turn signal light: 12 V, 21.0 W × 2 Auxiliary light: 12 V, 4.0 W ×...
  • Page 77: Consumer Information

    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. KEY IDENTIFICATION NUMBER: 1.
  • Page 78 EAU26460 Model label 1. Model label The model label is affixed to the loca- tion shown. Record the information on this label in the space provided. This in- formation will be needed when ordering spare parts from a Yamaha dealer.
  • Page 79 INDEX Air filter element, cleaning ....6-10 Front fork, checking.......6-25 Rear brake light switch, adjusting ..6-18 Anti-theft alarm (optional) ....... 3-3 Fuel ............3-7 Fuel cock..........3-8 Safety information........1-1 Fuel consumption, tips for reducing ..5-3 Battery ..........6-26 Self-diagnosis device......3-3 Fuel tank cap...........3-6 Brake and clutch levers, checking Shifting............
  • Page 80 INDEX Vehicle identification number ....9-1 Wheel bearings, checking..... 6-26 Wheel (front) ......... 6-32 Wheel (rear) .......... 6-33 Wheels ..........6-15...

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  • Glenn Letchworth Jan 19, 2016 06:21:
    Love this website. Very helpful