Yamaha XVS250 2001 User manual

EB000000
XVS250
SERVICE MANUAL
2000 by Yamaha Motor Co.,Ltd.
First edition, September 2000
All rights reserved. Any reproduction or
unauthorized use without the written
permission of Yamaha Motor Co., Ltd.
is expressly prohibited.

NOTE:
CAUTION:
EB001000 NOTICE
This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and
their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual,
so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha mo-
torcycleshasabasicunderstandingofthemechanicalideasandtheproceduresofmotorcyclerepair.
Repairs attempted by anyone without this knowledge are likely to render the motorcycle unsafe and
unfit for use.
YamahaMotorCompany,Ltd.iscontinuallystrivingtoimproveallitsmodels.Modificationsandsignifi-
cant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and
will appear in future editions of this manual where applicable.
Designs and specifications are subject to change without notice.
IMPORTANT INFORMATION
Particularly important information is distinguished in this manual by the following notations.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
Failuretofollow WARNINGinstructions couldresultin severeinjuryor deathto
the motorcycle operator, a bystander or a person inspecting or repairing the
motorcycle.
ACAUTIONindicatesspecialprecautionsthatmust be taken to avoid damage
to the motorcycle.
NOTE: A NOTE provides key information to make procedures easier or clearer.

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26
4
5
7
3
8
EAS00007 HOW TO USE THIS MANUAL
This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive
explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid
out with the individual steps in sequential order.
1The manual is divided into chapters. An abbreviation and symbol in the upper right corner of each
page indicate the current chapter. Refer to “SYMBOLS” on the following page.
2Each chapter is divided into sections. The current section title is shown at the top of each page,
except in Chapter 3 (“Periodic checks and Adjustments”), where the sub-section title(-s) appears.
(InChapter3,“PeriodicchecksandAdjustments”,thesub-sectiontitleappearsatthetopofeachpage,
instead of the section title.)
3Sub-section titles appear in smaller print than the section title.
4To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each
removal and disassembly section.
5Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a
disassembly step.
6Symbols indicate parts to be lubricated or replaced (see “SYMBOLS”).
7A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc.
8Jobs requiring more information (such as special tools and technical data) are described sequen-
tially.

21
1
3
5
7
9
2
4
8
6
24 25
2220
18 1917
15
1413
11 12
10
GEN
INFO SPEC
ENG CARB
ELEC
CHAS
CHK
ADJ
TRBL
SHTG
16
23
EAS00009
SYMBOLS
The following symbols are not relevant to every
vehicle.
Symbols 1to 8indicate the subject of each
chapter.
1General information
2Specifications
3Periodic checks and adjustments
4Chassis
5Engine
6Carburetor(-s)
7Electrical system
8Troubleshooting
Symbols 9to 16 indicate the following.
9Serviceable with engine mounted
10 Filling fluid
11 Lubricant
12 Special tool
13 Tightening torque
14 Wear limit, clearance
15 Engine speed
16 Electrical data
Symbols 17 to 22 intheexplodeddiagramsindi-
cate the types of lubricants and lubrication
points.
17 Engine oil
18 Gear oil
19 Molybdenum disulfide oil
20 Wheel bearing grease
21 Lithium soap base grease
22 Molybdenum disulfide grease
23 Silicon grease
Symbols 24 to 25 intheexplodeddiagramsindi-
cate the following:
24 Apply locking agent (LOCTITE)
25 Replace the part

CHK
ADJ
GENERAL INFORMATION
SPECIFICATIONS
PERIODIC CHECKS AND
ADJUSTMENTS
CHASSIS
ENGINE
CARBURETOR
ELECTRICAL SYSTEM
TROUBLESHOOTING
GEN
INFO 1
SPEC 2
3
CHAS 4
ENG 5
CARB 6
ELEC 7
TRBL
SHTG 8
EAS00011 INDEX

GEN
INFO
CHAPTER 1.
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VEHICLE IDENTIFICATION NUMBER 1-1. . . . . . . . . . . . . . . . . . . . . . . . .
MODEL CODE 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IMPORTANT INFORMATION 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PREPARATION FOR REMOVAL PROCEDURES 1-2. . . . . . . . . . . . . . .
REPLACEMENT PARTS 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GASKETS, OIL SEALS AND O-RINGS 1-2. . . . . . . . . . . . . . . . . . . . . . . .
LOCK WASHER/PLATE AND COTTER PINS 1-3. . . . . . . . . . . . . . . . . . .
BEARINGS AND OIL SEALS 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCLIPS 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CONNECTIONS 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS 1-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GEN
INFO

1-1
MOTORCYCLE IDENTIFICATION GEN
INFO
EB100000
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
EB10010
VEHICLE IDENTIFICATION NUMBER
Thevehicleidentificationnumber 1isstamped
into the right side of the steering head.
MODEL CODE
The model code label 1is affixed to the frame.
This information will be needed to order spare
parts.

1-2
IMPORTANT INFORMATION GEN
INFO
EB101000
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL PROCE-
DURES
1. Remove all dirt, mud, dust and foreign mate-
rial before removal and disassembly.
2. Use proper tools and cleaning equipment.
Refer to the “SPECIAL TOOLS” section.
3. When disassembling the machine, always
keep mated parts together. This includes
gears,cylinders, pistons and otherparts that
have been ”mated” through normal wear.
Mated parts must always be reused or re-
placed as an assembly.
4. Duringmachinedisassembly, clean all of the
parts and place them in trays in the order of
disassembly. This will speed up assembly
and allow for the correct installation of all
parts.
5. Keep all parts away from any source of fire.
EB101010
REPLACEMENT PARTS
1. Use only genuine Yamaha parts for all re-
placements. Use oil and grease recom-
mended by Yamaha for all lubrication jobs.
Other brands may be similar in function and
appearance, but inferior in quality.
EB101020
GASKETS, OIL SEALS AND O-RINGS
1. Replaceallgaskets,seals and O-rings when
overhauling the engine. All gasket surfaces,
oil seal lips and O-rings must be cleaned.
2. Properly oil all mating parts and bearings
during reassembly. Apply grease to the oil
seal lips.

1-3
OR
IMPORTANT INFORMATION GEN
INFO
CAUTION:
EB101030
LOCK WASHERS/PLATES AND COTTER
PINS
1. Replace all lock washers/plates 1and cot-
ter pins after removal. Bend lock tabs along
the bolt or nut flats after the bolt or nut has
been tightened to specification.
EB101040
BEARINGS AND OIL SEALS
1. Install bearings and oil seals so that the
manufacturer’s marks or numbers are vis-
ible. When installing oil seals, apply a light
coating of lightweight lithium base grease to
the seal lips. Oil bearings liberally when
installing, if appropriate.
1Oil seal
Do not use compressed air to spin the bear-
ings dry. This will damage the bearing sur-
faces.
1Bearing
EB101050
CIRCLIPS
1. Check all circlips carefully before reassemb-
ly. Always replace piston pin clips after one
use. Replace distorted circlips. When instal-
ling a circlip 1, make sure that the sharp-
edged corner 2is positioned opposite the
thrust 3it receives See sectional view.
4Shaft

1-4
CHECKING THE CONNECTIONS GEN
INFO
NOTE:
NOTE:
NOTE:
EB103000
CHECKING THE CONNECTIONS
Check the leads, couplers, and connectors for
stains, rust, moisture, etc.
1. Disconnect:
lead
coupler
connector
2. Check:
lead
coupler
connector
Moisture Dry with an air blower.
Rust/stains Connect and disconnect sev-
eral times.
3. Check:
all connections
Loose connection Connect properly.
If the pin 1on the terminal is flattened, bend it
up.
4. Connect:
lead
coupler
connector
Make sure that all connections are tight.
5. Check:
continuity
(with the pocket tester)
Pocket tester
90890-03112
If there is no continuity, clean the terminals.
When checking the wire harness, perform
steps (1) to (3).
As a quick remedy, use a contact revitalizer
available at most part stores.

1-5
SPECIAL TOOLS GEN
INFO
EB102001
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use only
theappropriate specialtools;thiswill helppreventdamage causedbytheuse ofinappropriatetools or
improvised techniques. Special tools may differ by shape and part number from country to country. In
such a case, two types are provided.
When placing an order, refer to the list provided below to avoid any mistakes.
Tool No. Tool name /How to use Illustration
Bolt
90890-01085
Weight
90890-01084
Slide hammer bolt/Weight
These tools are used to remove the rocker
arm shaft.
Valve adjusting
tool
90890-01311
Tappet adjusting tool
This tool is used to adjust the valve
CLEARANCE.
T-handle
90890-01326
Damper rod
holder
90890-01365
T-handle/Damper rod holder (22 mm)
These tools are needed to loosen and
tighten the damper rod holding bolt.
90890-01304
Piston pin puller set
This tool is used to remove the piston pin.
90890-01312
Fuel level gauge
Thisgauge is usedtomeasure the fuellevelin
the float chamber.
Flywheel puller
90890-01362
Flywheel puller
These tools are needed to remove the rotor.
90890-01403
Ring nut wrench
This tool is used to loosen and tighten the
steering stem ring nut.
Weight
90890-01367
Adapter
90890-01369
Front fork seal driver weight/
Adapter (33 mm)
These tools are needed when installing the
slide metal, oil seal and dust seal into the fork.

1-6
SPECIAL TOOLS GEN
INFO
Tool No. Tool name/ How to use Illustration
90890-01701
Sheave holder
This tool is needed to hold the rotor, when
removing or installing the rotor bolt.
90890-04086
Clutch holding tool
This tool is heed to hold the clutch when
removing or installing the clutch boss nut.
90890-04019
Valve spring compressor
This tool is needed to remove and install the
valve assemblies.
90890-04097
Valve guide remover (5.0 mm)
This tool is needed to remove the valve guide.
90890-04098
Valve guide installer (5.0 mm)
This tool is needed to install the valve guides
properly.
90890-04099
Valve guide reamer (5.0 mm)
This tool is needed to rebore the new valve
guide.
90890-03141
Timing light
This tool is necessary for checloing ignition
timing.
90890-03112
Pocket toster
This instrument is needed for checking the
electrical system.
90890-03113
Engine tachometer
Thistoolisneededforobservingenginer/min.

1-7
SPECIAL TOOLS GEN
INFO
Tool No. Tool name/ How to use Illustration
90890-06754
Ignition checker
This instrument is necessary for checking the
ignition system components.
90890-03081
Compression gauge set
These tools are needed to measure engine
compression.
90890-85505
Yamaha bond No.1215
Thissealant(bond)isusedforcrankcasemat-
ing surfaces, etc.