Yamaha XVS250(N) 2001 Service Manual – DragStar 250 / V Star 250 (P/N 5KR2-AE1)

This Yamaha factory service manual covers the 2001 XVS250(N), model code 5KR2. It is the first edition from September 2000 (P/N 5KR2-AE1).

PDF Search, Bookmarks, and Printing

Finding procedures and wiring details. The workshop text is searchable, and bookmarks open all eight chapters and both regional wiring diagrams. The cover, chapter dividers, and some labels inside diagrams are outside text search. Zoom in to read the smallest connector labels and wire codes.

The ZIP contains one printable English-language PDF with 332 pages, including the original cover, eight chapter dividers, eight blank pages, five pages with chapter headers only, and both wiring sheets.

From Valve Service to Electrical Diagnosis

The selected procedures below show the range of service and repair work covered. Other topics include speedometer drive inspection and battery-charging charts for different charger types.

• Routine maintenance: Mileage-based and annual checks cover fuel lines, valve clearance, engine oil and filter service, and lubrication points.

• Engine overhaul: Engine removal, cylinder-head disassembly, valve-guide replacement, camshaft timing, piston and ring inspection, crankcase separation, and oil-pump service.

• Clutch and transmission: Wet-clutch overhaul, starter-clutch inspection, and internal transmission disassembly, inspection, and reassembly.

• Fuel and air induction: MIKUNI BDS26 carburetor disassembly, float-chamber fuel-level adjustment, fuel-pump testing, and air-induction system inspection.

• Brakes and chassis: Front disc and rear drum brake service, hydraulic bleeding, front-fork rebuilding, and steering-head and swingarm inspection.

• Electrical troubleshooting: TCI ignition, electric starting, charging, lighting, and signaling tests, with separate EUR and OCE wiring diagrams.

Yamaha wrote this manual primarily for its dealers and qualified mechanics and assumes a working knowledge of motorcycle repair.

Engine and Drivetrain Repair

On the air-cooled SOHC V-twin, the front and rear camshafts have distinct timing references. Top-end procedures include valve-seat inspection and lapping, rocker-arm and shaft checks, and piston-to-cylinder clearance measurements.

Compression readings taken with and without oil in the cylinder help narrow down the cause of low pressure before teardown. The ignition-timing procedure is a check only.

Bottom-end checks cover crankshaft runout and connecting-rod big-end side clearance. Transmission procedures cover gear dogs, shift forks, guide bars, shift-drum grooves, and shift operation after assembly. Clutch inspection covers friction-plate wear, clutch-plate warpage, and push-lever adjustment.

Exploded views and job charts show the order of disassembly and assembly. Reassembly references include cylinder-head tightening sequences and clutch-boss nut torque. The Engine Oil Flow Diagrams trace lubrication through the engine and transmission.

Carburetor and Air Induction

Carburetor inspection covers the vacuum piston and diaphragm, float needle valve, jets, and starter plunger. Throttle position sensor (TPS) procedures cover resistance checks with the sensor installed and removed, plus sensor-angle adjustment.

Fuel-pump checks cover fuel delivery and the condition of the diaphragm and gaskets. The Air Induction System Diagrams trace fresh air, vacuum pulses, and exhaust flow for reed-valve and air-cutoff-valve inspection.

Yamaha’s tool references identify the valve spring compressor (90890-04019), universal clutch holder (90890-04086), and fuel-level gauge (90890-01312) used in the corresponding procedures.

Wiring and Fault Tracing

The Electric Starting System Circuit Diagram pairs with tests for the cutoff relay and the neutral, clutch, and sidestand switches. These checks help distinguish an interlock fault from a starter-motor fault. Starter-motor repair covers the brushes, commutator, and armature.

The EUR wiring diagram shows a light switch, while the OCE diagram shows a headlight relay. The Carburetor Heater System Circuit Diagram accompanies thermoswitch and heater-resistance tests. Cable-routing drawings show harness, hose, and control-cable paths and clamp locations. Electrical tables include battery and halogen headlight ratings.

A separate troubleshooting chapter covers symptoms such as hard shifting, clutch slip or drag, poor running, and unstable handling.

Brakes, Wheels, and Suspension

Wheel procedures cover bearing inspection, rim runout, static balancing, and rear-hub dampers. Final-drive checks cover chain wear and sprocket condition. Front brake repair includes master-cylinder and caliper rebuilding. Solvents can swell and distort the caliper piston seals.

Fork service covers damper rods, bushings, seals, and oil-level setting. Bottoming the inner tube during disassembly can damage the oil-flow stopper. Rear-shock procedures are limited to removal, inspection, replacement, and spring-preload adjustment.

Consult a qualified technician if you’re unsure about a major engine, brake, or suspension procedure.

Selected Valve, Fuel-Level, and Oil Specs

For cold valve adjustment, intake clearance is 0.08–0.12 mm and exhaust clearance is 0.10–0.14 mm.

The BDS26 fuel-level check specifies 3–4 mm above the line on the float chamber, with the motorcycle upright on a level surface.

Engine oil capacity is 1.75 L total. For an oil change, the manual specifies 1.4 L without filter replacement or 1.6 L with a new filter.