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Yamaha 2002 Virago 250 Owner's Manual

1. 3 7 Steering lOCk enin wise aie 3 8 Rider Seat 3 8 Helmet holder 3 9 Adjusting the shock absorber assemblies 3 10 Sidestand 3 10 Ignition circuit cut off system 3 11 PRE OPERATION CHECKS 4 1 Pre operation check list 4 1 OPERATION AND IMPORTANT RIDING POINTS reiten rere et 5 1 Starting and warming up a cold engine 5 2 Starting a warm engine 10 3 Shifting si neret et dis 5 4 Engine break in ete RR 5 5 Parking aH nere menter 5 6 PERIODIC MAINTENANCE AND MINOR REPAIR iere tee ted e eee EE 6 1 PERIODIC MAINTENANCE 6 1 Owner s tool 6 2 Periodic maintenance chart for the emission control system sssseeeee 6 3 General maintenance and lubrication chart 6 4 Checking the spark plugs Canister for California only Engine oil and oil filter element 6 8 Cleaning the air filter element 6 11 Adjusting the carburetor 6 13 TABLE OF CONTENTS Adjusting the throttle cable free play 6 13 Adjusting the valve clearance Spoke wheels
2. Accessories and replacement parts 6 16 Adjusting the clutch lever free play Adjusting the brake lever free play Adjusting the brake pedal position and free play EUREN 6 18 Adjusting the rear brake light switch 6 20 Checking the front brake pads and rear brake eee 6 20 Checking the brake fluid level 6 21 Changing the brake fluid 6 22 Drive chain slack 6 22 Lubricating the drive chain 6 25 Checking and lubricating the cables 6 25 Checking and lubricating the throttle grip and cable 3 rente oett 6 26 Checking and lubricating the brake and shift pedals rre ap eerte rens 6 26 Checking and lubricating the brake and clutch cg Checking and lubricating the sidestand Checking the front fork Checking the steering Checking the wheel bearings race ntes Replacing the fuses 6 32 Replacing the headlight bulb 6 32 Supporting the motorcycle Front wheel Rear wheel rte ter tete Troubleshooting Troubleshooting chart MOTORCYCLE CARE
3. Operate the electric starter Have a Yamaha dealer check the vehicle L There is no compression 3 Ignition gt Wet Wipe off with a dry cloth and correct the Open the throttle halfway and Spark plug gaps or replace the spark plugs operate the electric starter Remove the spark plugs i and check the electrodes The engine does not start Check the battery Dry Have a Yamaha dealer check the vehicle 4 Battery Ab The engine turns over a battery is good QUIC y The engine does not start Operate the electric starter Have a Yamaha dealer Fi Check the electrolyte and battery check the vehicle Nisi e turns over lead connections and charge the battery if necessary 6 39 MOTORCYCLE CARE AND STORAGE Care While the open design of a motorcycle reveals the attractiveness of the tech nology it also makes it more vulnera ble Rust and corrosion can develop even if high quality components are used A rusty exhaust pipe may go un noticed on a car however it detracts from the overall appearance of a motorcycle Frequent and proper care does not only comply with the terms of the warranty but it will also keep your motorcycle looking good extend its life and optimize its performance Before cleaning 1 Cover the muffler outlets with plas tic b
4. Press this switch to sound the horn INSTRUMENT AND CONTROL FUNCTIONS 1 Engine stop switch ENGINE STOP 2 Start switch START EAU00137 Engine stop switch ENGINE STOP Set this switch to OFF to stop the en gine in case of an emergency such as when the motorcycle overturns or when the throttle cable is stuck EAU00141 Start switch START Push this switch to crank the engine with the starter EC000005 CAUTION See page 5 2 for starting instruc tions prior to starting the engine 1 Clutch lever EAU00152 Clutch lever The clutch lever is located at the left handlebar grip To disengage the clutch pull the lever toward the handle bar grip To engage the clutch release the lever The lever should be pulled rapidly and released slowly for smooth clutch operation The clutch lever is equipped with a clutch switch which is part of the igni tion circuit cut off system See page 3 11 for an explanation of the ignition circuit cut off system 3 3 1 Shift pedal EAU00157 Shift pedal The shift pedal is located on the left side of the engine and is used in com bination with the clutch lever when shifting the gears of the 5 speed con stant mesh transmission equipped on this motorcycle INSTRUMENT AND CONTROL FUNCTIONS 1 Brake lever 1 Brake pedal 1 Fuel tank cap 2 Unlock Brake lever Brake pedal 756 EAU00158 EAU00162 The bra
5. from the brake shoe plate by re moving the nut and the bolt Remove the brake pedal free play adjusting nut and then disconnect the brake rod at the brake cam shaft lever PERIODIC MAINTENANCE AND MINOR REPAIR EAU01696 To install the rear wheel 1 Insert the wheel axle from the right hand side and then install the drive chain onto the rear sprocket 2 Install the axle nut and then lower the rear wheel so that it is on the ground 1 Axle nut 3 Install the brake rod onto the brake a quads cotter pin camshaft lever and then install Locknu 4 Drive chain slack adjusting nut the brake pedal free play adjusting 5 Alignment marks nut onto the brake rod 4 Install the brake torque rod bolt at the swingarm tighten it to the Specified torque and then install the cotter pin 6 Loosen the locknut and the drive chain slack adjusting nut on both ends of the swingarm 7 Remove the axle nut 8 Pull the wheel axle out and then remove the wheel Tightening torque Brake torque rod bolt 23 Nm 2 3 m kgf 17 ft lb EW000110 Always use a new cotter pin for the axle nut 5 Adjust the drive chain slack See page 6 22 for drive chain slack ad justment procedures 6 Tighten the axle nut to the speci fied torque Tightening torque Axle nut 104 Nm 10 4 m kgf 75 ft lb 7 Adjust the brake pedal position and free play See page 6 18 for brake pedal position a
6. Add the specified amount of the the oil or use oils of a higher Oil filter element cover bolt recommended engine oil and grade than 6D In addition do 7 Nm 0 7 m kgf 5 1 ftlb then install and tighten the oil filler not use oils labeled ENERGY ee cap CONSERVING II or higher NOTE e Make sure that no foreign mate Make sure that the O ring is properly rial enters the crankcase seated 9 Startthe engine and then let it idle for several minutes while checking it for oil leakage If oil is leaking immediately turn the engine off and check for the cause 10 Turn the engine off and then check the oil level and correct it if necessary 77 PERIODIC MAINTENANCE AND MINOR REPAIR 1 Bolt x 2 EAUO04182 Cleaning the air filter element The air filter element should be cleaned at the intervals specified in the periodic maintenance lubrication chart Clean the air filter element more fre quently if you are riding in unusually wet or dusty areas 1 Remove the air filter case cover by removing the bolts and loosening the clamp screw 1 Clamp screw 2 Air filter case cover 3 Air filter case PERIODIC MAINTENANCE AND MINOR REPAIR 1 Screw x 2 1 Wing nut 1 Sponge material 2 Air filter case 2 Air filter element frame 2 Remove the air filter element cov er by removing the screws 3 Remove the air filter element by 4 Remove the sponge material from removi
7. ing the brake disc and that the slot in the speedometer gear unit fits over the retainer on the fork leg 3 Insert the wheel axle 4 Lower the front wheel so that it is on the ground 6 35 PERIODIC MAINTENANCE AND MINOR REPAIR 1 Speedometer gear unit 2 Retainer 3 Speedometer cable 5 Push down hard on the handlebar several times to check for proper fork operation 6 Tighten the wheel axle to the specified torque Tightening torque Wheel axle 59 Nm 5 9 m kgf 43 ft lb 7 Tighten the front wheel axle pinch bolt to the specified torque PERIODIC MAINTENANCE AND MINOR REPAIR Tightening torque Front wheel axle pinch bolt 20 Nm 2 0 m kgf 14 ft lb 8 Connect the speedometer cable Brake torque rod Brake torque rod cotter pin Brake torque rod bolt Brake rod Brake pedal free play adjusting nut Brake cam shaft lever EAU01550 Rear wheel To remove the rear wheel e Itis advisable to have a Yamaha dealer service the wheel Securely support the motor cycle so that there is no danger ot it falling over EW000122 Remove the axle nut cotter pin and the brake torque rod cotter pin Loosen the axle nut and the brake torque rod nut at the brake shoe plate Lift the rear wheel off the ground according to the procedure on page 6 34 Disconnect the brake torque rod
8. The remainder of the existing warranty can be transferred upon request The unit has to be inspected and re registered by an authorized Yamaha Motorcycle dealer for the policy to remain effective CONSUMER INFORMATION CUSTOMER SERVICE If your machine requires warranty service you must take it to any authorized Yamaha Motorcycle dealer within the continental United States Be sure to bring your warranty registration card or other valid proof of the original date of purchase If a question or problem arises regarding warranty first con tact the owner of the dealership Since all warranty matters are handled at the dealer level this person is in the best position to help you If you are still not satisfied and require additional assistance please write YAMAHA MOTOR CORPORATION U S A CUSTOMER RELATIONS DEPARTMENT P O Box 6555 Cypress California 90630 When contacting Yamaha Motor Corporation U S A don t forget to include any important information such as names addresses model V I N frame number dates and receipts CHANGE OF ADDRESS The federal government requires each manufacturer of a motor vehicle to maintain a complete up to date list of all first purchasers against the possibility of a safety related defect and recall This list is compiled from the purchase registrations sent to Yamaha Motor Corporation U S A by the selling dealer at the time of your purchase If you should move after you have purchased your
9. amp YAMAHA EAUO03438 AWARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm YAMAHA LIT CALIF 65 01 EAUO00002 INTRODUCTION Congratulations on your purchase of the Yamaha XV250 XV250C This model is the result of Yamaha s vast experience in the production of fine sporting touring and pacesetting racing machines It represents the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields This manual will give you an understanding of the operation inspection and basic maintenance of this motorcycle If you have any questions concerning the operation or maintenance of your motorcycle please consult a Yamaha dealer The design and manufacture of this Yamaha motorcycle fully comply with the emis sions standards for clean air applicable at the date of manufacture Yamaha has met these standards without reducing the performance or economy of operation of the motorcycle To maintain these high standards it is important that you and your Yamaha dealer pay close attention to the recommended maintenance schedules and operating instructions contained within this manual MEORTANT MANUALINFORMA TON S Ll _ _ Particularly important information is distinguished in this manual by the following notations A The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOL
10. become involved in individual problems between you your dealer or Yamaha Motor Corporation U S A To contact NHTSA you may either call the Auto Safety Hotline toll free at 1 800 424 9393 or 366 0123 in Washington D C area or write to NHTSA U S Department of Transportation Washington D C 20590 You can also obtain other informa tion about motor vehicle safety from the Hotline 9 3 CONSUMER INFORMATION EAUO01053 MOTORCYCLE NOISE REGULATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the following acts or the causing thereof 1 The removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new ve hicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW These acts include tampering with the following systems i e modification removal etc Muffler Exhaust system Exhaust pipe Silencer Air cleaner case Intake system Air cleaner element Intake duct 9 4 CONSUMER INFORMATION EAU03052 Maintenance record Copies of work orders and or receipts for parts purchased and installed on your motorcycle will be required to
11. cable free play v v v N Evaporative emission 7 control system for system for damage California only Since these items require special tools data and technical skills have a Yamaha dealer perform the service 6 3 PERIODIC MAINTENANCE AND MINOR REPAIR General maintenance and lubrication chart EAU00472 6 4 INITIAL ODOMETER READINGS 600 mi 4 000 mi 7 000 mi 10 000 mi 13 000 mi ITEM ROUTINE TYPE 1 000km 6 000km 11 000km 16 000km 21 000km or or or or or 1 month 6 months 12 months 18 months 24 months Warm up engine before Engine oil draining See page 8 1 Ei 4 Ei Oil filter element Replace Ei Wet type filter must be Pee Yamalube 4 10W 30 or SAE Air filter element washed and damped with g ies P 4 Ei oil 10W 30 type SE motor oil Adjust free play Replace pads if necessary Brake system front EI N N Replace shoes if necessary rear Clutch Adjust free play N Check chain condition Drive chain Adjust and lubricate chain SAE 30W 50W motor oil Every 300 mi 500 km thoroughly Control and meter Yamaha Chain and Cable Lube cable Apply chain lube thoroughly S engine oil SAE 10W 30 v y N Y Y Check swingarm assembly Lithium soap based grease Swingarm pivot shaft or looseness Y Check N Moderat
12. cargo and accessories EW000083 Proper loading of your motorcycle is important for several characteris tics of your motorcycle such as handling braking performance and safety Do not carry loosely packed items that can shift Securely pack your heaviest items close to the center of the motorcycle and dis tribute the weight evenly from side to side Properly adjust the suspen sion for your load and check the condition and pressure of your tires NEVER OVERLOAD YOUR MOTOR CYCLE Make sure the total weight of the cargo rider passenger and accessories cowling saddlebags etc if approved for this model does not exceed the maximum load of the motorcycle Operation of an over loaded motorcycle could cause tire damage an accident or even injury PERIODIC MAINTENANCE AND MINOR REPAIR Tire inspection EAU00680 Always check the tires before operating the motorcycle If a tire tread shows crosswise lines minimum tread depth if the tire has a nail or glass fragments in it or if the sidewall is cracked con tact a Yamaha dealer immediately and have the tire replaced FRONT Manufacturer Size Model CHENG SHIN 3 00 18 47P C 916 REAR Manufacturer Size Model CHENG SHIN 130 90 15 66 C 915 Minimum tire tread depth 1 0 mm 0 04 in front and rear e It is dangerous to ride with a worn out tire When a tire tread begins to show crosswise lines have a Yamaha dealer replac
13. check the condition Securely support the motorcycle so that there is no danger of it falling over EW000115 Check the inner tubes for scratches damage and excessive oil leakage To check the operation 1 Place the motorcycle on a level surface and hold it in an upright position 2 While applying the front brake push down hard on the handle bars several times to check if the front fork compresses and re bounds smoothly EC000098 CAUTION If any damage is found or the front fork does not operate smoothly have a Yamaha dealer check or re pair it EAU00794 Checking the steering Worn or loose steering bearings may cause danger Therefore the operation of the steering must be checked as fol lows at the intervals specified in the pe riodic maintenance and lubrication chart 1 Place a stand under the engine to raise the front wheel off the ground Securely support the motorcycle so that there is no danger of it falling over EW000115 PERIODIC MAINTENANCE AND MINOR REPAIR EAU01144 Checking the wheel bearings The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrica tion chart If there is play in the wheel hub or if the wheel does not turn smoothly have a Yamaha dealer check the wheel bearings P 2 Hold the lower ends of the front fork legs and try to move them for ward and backward If any free play can be felt have a Yam
14. document that maintenance has been completed in accordance with the emissions warranty The chart below is printed only as a reminder that maintenance work is required It is not acceptable proof of maintenance work Maintenance Date of Mileage Servicing dealer interval service name and address 600 mi 1 000 km or 1 month 4 000 mi 6 000 km or 6 months 7 000 mi 11 000 km or 12 months 10 000 mi 16 000 km or 18 months 13 000 mi 21 000 km or 24 months 16 000 mi 26 000 km or 30 months 19 000 mi 31 000 km or 36 months Remarks CONSUMER INFORMATION Maintenance Date of Servicing dealer Mileage Remarks interval service 9 name and address 22 000 mi 36 000 km or 42 months 25 000 mi 41 000 km or 48 months 28 000 mi 46 000 km or 54 months 31 000 mi 51 000 km or 60 months CONSUMER INFORMATION YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY Yamaha Motor Corporation U S A hereby warrants each new model Yamaha motorcycle will be free from defects in material and workmanship for the period of time stated herein subject to certain stated limitations THE PERIOD OF WARRANTY for Yamaha motorcycles originally equipped with headlight stoplight and turn signals shall be one 1 year from the date of purchase with no mileage limitation MODELS EXCLUDED FROM WARRANTY inc
15. engine off before leaving the motorcycle unattended and remove the key from the main switch When parking the motorcycle note the following 1 5 A SAFETY INFORMATION 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 b Do not park the motorcycle on a slope or soft ground otherwise it may fall over c Do not park the motorcycle near a flammable source e g a kerosene heater or near an open flame otherwise it could catch fire 4 When transporting the motorcycle in another vehicle make sure that it is kept upright and that the fuel cock is turned to ON or RES for vacuum type OFF for manual type If it should lean over gasoline may leak out of the carburetor or fuel tank 5 If you should swallow any gasoline inhale a lot of gasoline vapor or allow gasoline to get into your eyes see your doctor immediately If any gasoline spills on your skin or clothing immediately wash the affected area with soap and water and change your clothes A SAFETY INFORMATION EAUO02977 Location of important labels EJ Please read the following important labels carefully before operating this motorcycle 1 7 A SAFETY INFORMATION TIRE INFORMATION Cold tire normal pressure should be set as follows Up to 90 kg 198 Ibs load A WARNING BEFORE YOU OPERATE THIS VEHICLE READ THE OWNER S MANUAL A
16. following Check each hose connection Check each hose and canister for cracks or damage Replace if damaged e Make sure that the canister breather is not blocked and if nec essary clean it 1 Canister cover 2 Canister breather 3 Canister 6 8 EAUO01523 Engine oil and oil filter element The engine oil level should be checked before each ride In addition the oil must be changed and the oil filter ele ment replaced at the intervals specified in the periodic maintenance and lubri cation chart To check the engine oil level 1 Place the motorcycle on a level surface and hold it in an upright position NOTE Make sure that the motorcycle is posi tioned straight up when checking the oil level A slight tilt to the side can result in a false reading PERIODIC MAINTENANCE AND MINOR REPAIR Us 1 Engine oiil level check window 1 Engine oil filler cap 1 Engine oil drain bolt 2 Maximum level mark 2 ah gs 3 Minimum level mark To change the engine oil with or Remove the engine oil filler cap without oil filter element replace and drain bolt to drain the oil from 2 Start the engine warm it up for several minutes and then turn it off 3 Wait a few minutes until the oil set tles and then check the oil level through the check window located at the bottom right side of the crankcase ment the crankcase 1 Start the engi
17. height Seat height Wheelbase Ground clearance Minimum turning radius Basic weight with oil and full fuel tank XV250 XV250C Engine Engine type Cylinder arrangement Displacement Bore x Stroke Compression ratio Starting system Lubrication system XV250 XV250C 2 190 mm 86 2 in 815 mm 32 1 in 1 140 mm 44 9 in 685 mm 27 0 in 1 490 mm 58 7 in 145 mm 5 7 in 2 800 mm 110 2 in 147 kg 324 Ib 148 kg 326 Ib Air cooled 4 stroke SOHC V type 2 cylinder 249 cm 49 x 66 mm 1 93 x 2 60 in 10 1 Electric starter Wet sump Engine oil Type Recommended engine oil classification CAUTION SPECIFICATIONS 0 10 30 50 70 90 110 130 F I de ers d V dere e i00 IYAMALUBE 4 10W 30 ior SAE 10W 30 i YAMALUBE 4 2011 40 i or SAE 20W 40 20 10 0 10 20 30 40 50 C API Service SE SF SG or higher Be sure to use motor oils that do not contain anti friction modifiers car motor oils often labeled ENERGY CONSERVING II contain anti friction additives which will cause clutch and or starter clutch slippage result ing in reduced component life and poor engine performance Quantity Without oil filter element replacement With oil filter element replacement Total amount dry engine Air filter 1 4L 1 2 Imp qt 1 5 US at 1 6 L 1 4 Imp qt 1 7 US qt 1 8 L 1 6 Imp qt 1 9 US qt Wet type element SPECIFICATIONS Fuel Type Fuel
18. new motorcycle please advise us of your new address by sending a postcard listing your motorcycle model name V I N frame number dealer number or dealer s name as it is shown on your warranty card your name and new mailing address Mail to YAMAHA MOTOR CORPORATION U S A P O Box 6555 Cypress California 90630 Attention Warranty Department This will ensure that Yamaha Motor Corporation U S A has an up to date registration record in accordance with federal law CONSUMER INFORMATION YAMAHA EXTENDED SERVICE Y E S Keep your Yamaha protected even after your warranty expires with genuine Yamaha Extended Service Y E S e Y E S is designed and administered by Yamaha Motor Corporation to provide maximum owner satisfaction You get uninterrupted factory backed coverage for extra peace of mind Y E S is flexible You choose the plan that s right for you 12 months 24 months or 36 months beyond your warranty period Y E S is designed and administered by the same Yamaha people who handle your warranty and it shows in the comprehensive coverage benefits There are no mileage limitations Coverage isn t limited to moving parts or the drive train like many other plans And Y E S covers manufacturing defects just like the warranty See the sample contract at your Yamaha dealer to see how comforting uninterrupted factory backed protection can be You don t have to pay anything for covered repairs There s n
19. 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 Bulky or large accessories may seriously affect the stability of the motorcycle due to aerodynamic effects Wind may attempt to lift the motorcycle or the motorcycle may become unstable in cross winds These accessories may also cause instability when passing or being passed by large ve hicles c Certain accessories can displace the operator from his or her normal riding position This improp er position limits the freedom of movement of the operator and may limit control ability therefore Such accessories are not recommended Use caution when adding electrical accessories If electrical accessories exceed the capacity of the motorcycle s electrical system an electric failure could result which could cause a dangerous loss of lights or engine power Gasoline and exhaust gas 1 GASOLINE IS HIGHLY FLAMMABLE a Always turn the engine off when refueling b Take care not to spill any gasoline on the engine or exhaust system when refueling c Never refuel while smoking or in the vicinity of an open flame Never start the engine or let it run for any length of time in a closed area The exhaust fumes are poi sonous and may cause loss of consciousness and death within a short time Always operate your motorcycle in an area that has adequate ventilation Always turn the
20. tank capacity XV250 XV250C Fuel reserve amount Carburetor Manufacturer Model x quantity Spark plug Model manufacturer Gap Clutch type Transmission Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Number of drive chain sprocket teeth front rear Transmission type Operation UNLEADED FUEL ONLY 9 5 L 2 1 Imp gal 2 5 US gal 9 2 L 2 0 Imp gal 2 4 US gal 2 6 L 0 6 Imp gal 0 7 US gal MIKUNI BDS26 x 1 C6HSA NGK or U20FS U DENSO 0 6 0 7 mm 0 02 0 03 in Wet multiple disc Spur gear 3 130 Chain drive 2 812 16 45 Constant mesh 5 speed Left foot Gear ratio 1st 2nd 3rd 4th 5th Chassis Frame type Caster angle Trail Tires Front Type Size Manufacturer model Rear Type Size Manufacturer model 2 643 1 684 1 261 1 000 0 821 Double cradle 32 120 mm 4 7 in With tube 3 00 18 47P CHENG SHIN C 916 With tube 130 90 15M C 66P CHENG SHIN C 915 Maximum load XV250 XV250C Tire air pressure measured on cold tires Up to 90 kg 198 Ib Front Rear 90 kg 198 Ib maximum Front Rear 196 kg 432 Ib 195 kg 430 Ib 175 kPa 1 75 kgf cm 25 psi 200 kPa 2 00 kgf cm 29 psi 200 kPa 2 00 kgf cm 29 psi 225 kPa 2 25 kgf cm 33 psi Total weight of rider passenger cargo and accessories Wheels Front Type Size Rear Type Size Brakes Front Type Operation Fluid Spoke
21. to electrolyte or gas expelled from the battery the frame could suffer structural and external damages PERIODIC MAINTENANCE AND MINOR REPAIR Specified fuses Main fuse 20A Signaling system fuse 10 EC000103 CAUTION Do not use a fuse of a higher amper age rating than recommended to avoid causing extensive damage to 1 Main fuse x h 2 Signaling system fuse the electrical system and possibly a a EAU03003 eoo fire Replacing the headlight bulb 3 Turn the key to ON and turn on This motorcycle is equipped with a the electrical circuit in question to quartz bulb headlight If the headlight Replacing the fuses The main fuse and the signaling sys tem fuse holders are located under the A check if the device operates bulb burns out replace it as follows rider seat See page 3 8 for rider seat If the fuse immediately blows 1 Remove the headlight unit by re removal and installation procedures again have a Yamaha dealer moving the screws If a fuse is blown replace it as follows 1 Turn the key to OFF and turn off the electrical circuit in question 2 Remove the blown fuse and then install a new fuse of the specified amperage check the electrical system PERIODIC MAINTENANCE AND MINOR REPAIR 1 Headlight coupler 2 Headlight bulb cover 2 Disconnect the headlight coupler and then remove the headlight unit and bulb cover 1 Headlight bulb holde
22. 10 DESCRIPTION Controls and instruments 1 Clutch lever 2 Left handlebar switches 3 Speedometer unit 4 Indicator lights page 3 3 page 3 2 page 3 2 page 3 1 2 3 5 Right handlebar switches 6 Brake lever 7 Throttle grip 8 Fuel tank cap page 3 3 page 3 4 page 6 13 page 3 4 EAU00027 EAU00028 Main switch The main switch controls the ignition and lighting systems The various main switch positions are described below EAU00032 ON All electrical systems are supplied with power the headlight meter lighting taillight and front position lights come on and the engine can be started The key cannot be removed EAU00038 OFF All electrical systems are off The key can be removed INSTRUMENT AND CONTROL FUNCTIONS EAU00050 P Parking The taillight and position lights are on but all other electrical systems are off The key can be removed The key must be pushed in from the OFF position to be turned to P ECA00043 CAUTION Do not use the parking position for an extended length of time other wise the battery may discharge 3 1 Or S 1 High beam indicator light HIGH BEAM 2 Neutral indicator light NEUTRAL 3 Turn signal indicator light TURN EAU00056 Indicator lights High beam indicator light HIGH BEAM This indicator light comes on when the high beam of the headlight
23. 2 4 in above the top of the footrest as shown 2 To increase the brake lever free play turn the adjusting bolt in di rection To decrease the brake lever free play turn the adjusting Periodically check the brake pedal posi bolt in direction tion and if necessary adjust it as fol 3 Tighten the locknut lows 1 Locknut 2 Adjusting bolt 1 Loosen the locknut at the brake pedal 2 To raise the brake pedal turn the adjusting bolt in direction 8 To lower the brake pedal turn the ad justing bolt in direction 3 Tighten the locknut After adjusting the brake pedal posi tion the brake pedal free play must be adjusted EWA00044 1 Brake pedal free play adjusting nut Brake pedal free play The brake pedal free play should mea sure 20 30 mm 0 8 1 2 in at the brake pedal end Periodically check the brake pedal free play and if necessary adjust it as follows To increase the brake pedal free play turn the adjusting nut at the brake rod in direction To decrease the brake pedal free play turn the adjusting nut in direction PERIODIC MAINTENANCE AND MINOR REPAIR EW000106 e After adjusting the drive chain slack or removing and installing the rear wheel always check the brake pedal free play If proper adjustment cannot be obtained as described have a Yamaha dealer make this ad justment e After adjusting the brake pedal free play check the operation of the br
24. 4 At the recommended shift points shown in the table on page 5 5 close the throttle and at the same time quickly pull the clutch lever in 5 Shift the transmission into second gear Make sure not to shift the transmission into the neutral position 6 Open the throttle part way and gradually release the clutch lever 7 Follow the same procedure when shifting to the next higher gear NOTE Always shift gears at the recommend ed shift points EAU00427 To decelerate 1 Apply both the front and the rear brakes to slow the motorcycle 2 Shift the transmission into first gear when the motorcycle reaches 20 km h 12 5 mi h If the engine is about to stall or runs very rough ly pull the clutch lever in and use the brakes to stop the motorcycle 3 Shiftthe transmission into the neu tral position when the motorcycle is almost completely stopped The neutral indicator light should come on OPERATION AND IMPORTANT RIDING POINTS EAU02974 Recommended shift points The recommended shift points during acceleration and deceleration are shown in the table below Acceleration Deceleration shift point shift point km h mi h km h mi h 1st 2nd 16 9 9 20 12 5 2nd 3rd 24 14 9 20 12 5 4th 32 19 9 20 12 5 4th 5th 40 24 9 20 12 5 5 5 EAUO1128 Engine break in There is never a more important period in the life of your engine than the peri
25. AND STORAGE 7 1 Caro 15 bce iate ie o beef Gest Storage SPECIFICATIONS sse 8 1 Specifications 8 1 CONSUMER 9 1 Identification numbers Key identification number Vehicle identification number 9 1 Model label cn ette intet Reporting safety defects Motorcycle noise regulation Maintenance record Street and enduro motorcycle limited deseen ette tiat haad 9 7 Yamaha extended service Y E S 9 9 _ SAFETY INFORMATION 7 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 2 8 4 OBTAIN THOROUGH INSTRUCTIONS FROM A COMPETENT SOURCE ON ALL ASPECTS OF MOTORCYCLE OPERATION OBSERVE THE WARNINGS AND MAINTENANCE REQUIREMENTS IN THE OWNER S MANU AL OBTAIN QUALIFIED TRAINING IN SAFE AND PROPER RIDING TECHNIQUES OBTAIN PROFESSIONAL TECHNICAL SERVICE AS INDICATED BY THE OWNER S MANUAL AND OR WHEN MADE NECESSARY BY MECHANICAL CONDITIONS Safe riding Always make pre operation checks Careful checks may help pre
26. FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS AND TIME LIMITS STATED IN THIS WARRANTY ARE HEREBY DISCLAIMED BY YAMAHA MOTOR COR PORATION U S A AND EXCLUDED FROM THIS WARRANTY SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU ALSO EXCLUDED FROM THIS WARRANTY ARE ANY IN CIDENTAL OR CONSEQUENTIAL DAMAGES INCLUD ING LOSS OF USE SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES SO THE ABOVE EXCLUSION MAY NOT APPLY TO YOU THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE YAMAHA MOTOR CORPORATION U S A P O Box 6555 Cypress California 90630 EAU02918 gt gt o po WARRANTY QUESTIONS AND ANSWERS What costs are my responsibility during the warranty period The customer s responsibility includes all costs of normal maintenance services non warranty repairs accident and collision damages and oil oil filters air filters spark plugs and brake shoes What are some examples of abnormal strain neglect or abuse These terms are general and overlap each other in areas Specific examples include Running the machine out of oil sustained high rpm full throttle operating the machine with a broken or damaged part which causes another part to fail damage or failure due to improper or careless transportation and
27. IX DEALER LABEL HERE EAU03336 XV250P XV250PC OWNER S MANUAL 2001 by Yamaha Motor Corporation U S A 1st Edition March 2001 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in Japan P N LIT 11626 15 02 EAU00009 TABLE OF CONTENTS SAFETY INFORMATION 1 1 Safe riding ort eerie etre 1 1 Protective apparel Modifications recie GAA aed Loading and accessories Gasoline and exhaust gas Location of important labels DESCRIPTION 2 eene efle 2 1 Left Ee cir gene 2 1 Right view c scccseesseessecssesseessessseessessnsesesssesaneess 2 2 Controls and instruments 2 3 INSTRUMENT AND CONTROL FUNCTIONS 3 1 Main switch 3 1 Indicator lights 3 1 Speedometer unit 3 2 Handlebar switches 3 2 nere treten 3 3 Shift pedal 3 3 Brake lever 3 4 Brake pedal 3 4 Fuel TANK CAP nennt eene 3 4 F lle eS IAS 3 5 F el Gock iid RE di 3 6 Starter choke lever
28. L FUNCTIONS 1 Steering lock EAU02934 Steering lock To lock the steering 1 Turn the handlebar all the way to right 2 Open the steering lock cover and then insert the key 3 Turn the key 1 8 turn counter clockwise push it in while turning the handlebar slightly to the left and then turn the key 1 8 turn clockwise 4 Check that the steering is locked remove the key and then close the lock cover To unlock the steering 1 Open the steering lock cover and then insert the key 2 Push the key in turn it 1 8 turn counterclockwise so that it moves out and then release it 3 Remove the key and then close the lock cover 3 8 C IN EAU01072 1 Bolt x 2 Rider seat To remove the rider seat Remove the bolts and then pull the rid er seat off INSTRUMENT AND CONTROL FUNCTIONS 1 Projection 2 Seat holder To install the rider seat 1 Insert the projection on the front of the rider seat into the seat holder as shown 2 Place the rider seat in the original position and then tighten the bolts NOTE Make sure that the rider seat is proper ly secured before riding 1 Helmet holder 2 Unlock EAU00260 Helmet holder To open the helmet holder insert the key into the lock and then turn the key as shown To lock the helmet holder place it in the original position and then remove the key Never ride with a helmet attached to the he
29. ND ALL LABELS ALWAYS WEAR AN APPROVED MOTORCYCLE HELMET eye protection and protective clothing FRONT 175 kPa 1 75 kgf cm 25 psi REAR 200 kPa 2 00 kgf cm 29 psi 90 kg 198 Ibs maximum load FRONT 200 kPa 2 00 kgf cm 29 psi REAR 225 kPa 2 25 kgf cm 33 psi 3CK 21668 A0 3MX 2118K A0 4 California only EMISSION HOSE ROUTING CAUTION Read owner s manual before servicing battery Electrolyte will damage metal parts or paint If electrolyte spills wash area with fresh water immediately Be sure to connect breather hose after installing battery FROM FUEL TANK 3JL 28177 A0 CANISTER TO ATMOSPHERE 4YN 21686 00 1 8 EAU00026 DESCRIPTION Left view 1 Headlight 2 Fuel tank 3 Battery 4 Fuses 5 Helmet holder 4 V C 2 1 GY ERF TAAN SS Fre D Q 6 Shock absorber assembly spring preload adjusting ring 7 Main switch 8 Fuel cock 9 Shift pedal page 3 10 page 3 1 page 3 6 page 3 3 DESCRIPTION Right view 10 11 12 Op has 27 ay 17 10 Tail brake light 14 Front turn signal position light 11 Rear turn signal light 15 Brake pedal page 3 4 12 Rider seat page 3 8 16 Footrest 13 Air filter element page 6 11 17 Shock absorber assembly spring preload adjusting ring page 3
30. VED A WARNING Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator a bystander or a person inspecting or repairing the motorcycle CAUTION A CAUTION indicates special precautions that must be taken to avoid damage to the motorcycle NOTE A NOTE provides key information to make procedures easier or clearer NOTE This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold e 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 If you have any questions concerning this manual please consult your Yamaha dealer IMPORTANT MANUAL INFORMATION EW000000 PLEASE READ THIS MANUAL AND THE YOU AND YOUR MOTORCYCLE RIDING TIPS BOOKLET CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTOR CYCLE DO NOT ATTEMPT TO OPERATE THIS MOTORCYCLE UNTIL YOU HAVE AT TAINED ADEQUATE KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES REGULAR INSPECTIONS AND CAREFUL MAINTENANCE ALONG WITH GOOD RIDING SKILLS WILL ENSURE THAT YOU SAFELY ENJOY THE CAPABILITIES AND THE RELI ABILITY OF THIS MOTORCYCLE IMPORTANT MANUAL INFORMATION AFF
31. ags after the engine has cooled down 2 Make sure that all caps and covers as well as all electrical couplers and connectors including the spark plug caps are tightly in stalled 3 Remove extremely stubborn dirt like oil burnt onto the crankcase with a degreasing agent and a brush but never apply such prod ucts onto seals gaskets sprock ets the drive chain and wheel axles Always rinse the dirt and degreaser off with water 7 1 EAUO03430 Cleaning ECA00010 CAUTION Avoid using strong acidic wheel cleaners especially on spoked wheels If such products are used on hard to remove dirt do not leave the cleaner on the af fected area any longer than in structed Also thoroughly rinse the area off with water immedi ately dry it and then apply a corrosion protection spray e Improper cleaning can damage windshields cowlings panels and other plastic parts Use only a soft clean cloth or sponge with mild detergent and water to clean plastic Do not use any harsh chemical products on plastic parts Be sure to avoid using cloths or sponges which have been in contact with strong or abrasive cleaning products solvent or thinner fuel gasoline rust re movers or inhibitors brake flu id antifreeze or electrolyte Do not use high pressure wash ers or steam jet cleaners since they cause water seepage and deterioration in the following ar eas seals of wheel and swing arm bearings f
32. aha dealer check or repair the steering PERIODIC MAINTENANCE AND MINOR REPAIR 1 Battery 2 Battery breather hose EAUO1071 Battery A poorly maintained battery will cor rode and discharge quickly The elec trolyte level battery lead connections and breather hose routing should be checked before each ride and at the in tervals specified in the periodic mainte nance and lubrication chart To check the electrolyte level 1 Place the motorcycle on a level surface and hold it in an upright position NOTE Make sure that the motorcycle is posi tioned straight up when checking the electrolyte level 2 Check the electrolyte level in the battery NOTE The electrolyte should be between the minimum and maximum level marks 3 If the electrolyte is at or below the minimum level mark add distilled water to raise it to the maximum level mark Electrolyte is poisonous and dangerous since it contains sul furic acid which causes severe burns Avoid any contact with skin eyes or clothing and al ways shield your eyes when working near batteries In case of contact administer the fol lowing FIRST AID EW000117 EXTERNAL Flush with plenty of water INTERNAL Drink large quan tities of water or milk and im mediately call a physician EYES Flush with water for 15 minutes and seek prompt medical attention Batteries produce explosive hy drogen gas Therefore k
33. ake light PERIODIC MAINTENANCE AND MINOR REPAIR N LY LA amp 2 E 6 1 Rear brake light switch 2 Rear brake light switch adjusting nut EAU00713 Adjusting the rear brake light switch The rear brake light switch which is ac tivated by the brake pedal is properly adjusted when the brake light comes on just before braking takes effect If necessary adjust the brake light switch as follows Turn the adjusting nut while holding the rear brake light switch in place To make the brake light come on earlier turn the adjusting nut in direction To make the brake light come on later turn the adjusting nut in direction EAUO00720 Checking the front brake pads and rear brake shoes The front brake pads and the rear brake shoes must be checked for wear at the intervals specified in the periodic maintenance and lubrication chart 1 Brake pad wear indicator groove EAU00725 Front brake pads Each front brake pad is provided with a wear indicator groove which allows you to check the brake pad wear with out having to disassemble the brake To check the brake pad wear check the wear indicator groove If a brake pad has worn to the point that the wear indicator groove has almost disap peared have a Yamaha dealer replace the brake pads as a set 1 Brake shoe wear indicator 2 Brake shoe wear limit line EAU00727 Rear brake shoes The rear brake is provided with a wear indic
34. and then place the spark plugs on the cylinder head So that the electrodes are ground ed This will limit sparking during the next step Turn the engine over several times with the starter This will coat the cylinder walls with oil Remove the spark plug caps from the spark plugs and then install the spark plugs and the spark plug caps EWA00003 To prevent damage or injury from sparking make sure to ground the spark plug electrodes while turning the engine over the pivoting points of all levers and pedals as well as of the sidestand centerstand Check and if necessary correct the tire air pressure and then lift the motorcycle so that both of its wheels are off the ground Alterna tively turn the wheels a little every month in order to prevent the tires MOTORCYCLE CARE AND STORAGE 6 Lubricate all control cables and 9 Remove the battery and fully charge it Store it in a cool dry place and charge it once a month Do not store the battery in an ex cessively cold or warm place less than 0 30 F or more than 30 C 60 F For more informa tion on storing the battery see page 6 31 NOTE Make any necessary repairs before storing the motorcycle from becoming degraded in one spot Cover the muffler outlets with plas tic bags to prevent moisture from entering them 7 5 EAU01038 Specifications Model Dimensions Overall length Overall width Overall
35. ater will significantly lower the boiling point of the fluid and may result in vapor lock PERIODIC MAINTENANCE AND MINOR REPAIR e Brake fluid may deteriorate paint ed surfaces or plastic parts Al ways clean up spilled fluid immediately As the brake pads wear it is nor mal for the brake fluid level to gradually go down However if the brake fluid level goes down sud denly have a Yamaha dealer check the cause EAU03985 Changing the brake fluid Have a Yamaha dealer change the brake fluid at the intervals specified in the NOTE after the periodic mainte nance and lubrication chart In addition have the oil seals of the brake master cylinder and caliper as well as the brake hose replaced at the intervals listed below or whenever they are dam aged or leaking Oil seals Replace every two years Brake hose Replace every four years a Drive chain slack EAU00744 Drive chain slack The drive chain slack should be checked before each ride and adjusted if necessary To check the drive chain slack 1 Place the motorcycle on a level surface and hold it in an upright position NOTE When checking and adjusting the drive chain slack the motorcycle should be positioned straight up and there should be no weight on it 2 3 Shift the transmission into the neu tral position Move the rear wheel by pushing the motorcycle to locate the tight est portion of the drive chain and
36. ator which allows you to check the brake shoe wear without having to dis assemble the brake To check the brake shoe wear check the position of the wear indicator while applying the brake If a brake shoe has worn to the point that the wear indicator reaches the wear limit line have a Yamaha dealer replace the brake shoes as a set 1 Minimum level mark EAU00732 Checking the brake fluid level Insufficient brake fluid may allow air to enter the brake system possibly caus ing it to become ineffective Before riding check that the brake fluid is above the minimum level mark and replenish if necessary A low brake flu id level may indicate worn brake pads and or brake system leakage If the brake level is low be sure to check the brake pads for wear and the brake sys tem for leakage PERIODIC MAINTENANCE AND MINOR REPAIR Observe these precautions e When checking the fluid level make sure that the top of the mas ter cylinder is level by turning the handlebars Use only the recommended quali ty brake fluid otherwise the rubber seals may deteriorate causing leakage and poor braking performance Recommended brake fluid DOT 4 NOTE If DOT 4 is not available DOT 3 can be used e Refill with the same type of brake fluid Mixing fluids may result in a harmful chemical reaction and lead to poor braking performance Be careful that water does not en ter the master cylinder when refill ing W
37. ch ride ITEM Pre operation check list CHECKS EAUO03439 PAGE Fuel Check fuel level in fuel tank Refuel if necessary Check fuel line for leakage 3 5 Engine oil Check oil level in engine If necessary add recommended oil to specified level Check vehicle for oil leakage 6 8 6 9 Front brake Check operation If soft or spongy have Yamaha dealer bleed hydraulic system Check lever free play Adjust if necessary Check fluid level in reservoir If necessary add recommended brake fluid to specified level Check hydraulic system for leakage 6 18 6 20 6 22 Rear brake Check operation Check pedal free play Adjust if necessary 6 18 6 21 Clutch Check operation Lubricate cable if necessary Check lever free play Adjust if necessary Throttle grip Make sure that operation is smooth Lubricate throttle grip housing and cables if necessary Check free play If necessary have Yamaha dealer make adjustment 6 13 Control cables Make sure that operation is smooth Lubricate if necessary 6 26 PRE OPERATION CHECKS ITEM CHECKS PAGE Check chain slack i Adjust if necessary Drive chain Check chain condition Gree bed Lubricate if necessary Check for damage Check tire condition and tread depth Whee
38. crews 9 Install the air filter case cover by installing the bolts 10 Tighten the clamp screw PERIODIC MAINTENANCE AND MINOR REPAIR EAU00637 Adjusting the valve clearance The valve clearance changes with use resulting in improper air fuel mixture and or engine noise To prevent this from occurring the valve clearance must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart 1 Sidewall 2 Tire wear indicator a Tire tread depth EAU03360 Tires To maximize the performance durabil ity and safe operation of your motor cycle note the following points regarding the specified tires Tire air pressure The tire air pressure should be checked and if necessary adjusted before each ride EW000082 e The tire air pressure must be checked and adjusted on cold tires i e when the temperature of the tires equals the ambient temperature e The tire air pressure must be adjusted in accordance with the riding speed and with the total weight of rider passenger car go and accessories approved for this model Tire air pressure measured on cold tires Load Front Rear 175 kPa 200 kPa Up to 90 kg 198 16 1 75 kgf cm 2 00 kgf cm 25 psi 29 psi 200 kPa 225 kPa x ae I 2 00 kgf cm 2 25 kgf cm Sms 29 psi 33 psi XV250 196 kg 432 Ib Maximum load XV250C 195 kg 430 Ib Total weight of rider passenger
39. days after you buy your Yamaha See your dealer today A special note YAMAHA EXTENDED SERVICE If visiting your dealer isn t convenient contact Yamaha with your Primary ID number your frame number We ll be happy to help you get the Y E S coverage you need Yamaha Service Marketing P O Box 6555 Cypress CA 90630 9 10 See your Authorized YAMAHA Dealer for a Genuine YAMAHA Service Manual PRINTED IN JAPAN 2001 3 1 0x1 CR E
40. e the tire immediately The replacement of all wheel and brake related parts includ ing the tires should be left to a Yamaha dealer who has the necessary professional knowl edge and experience It is not recommended to patch a punctured tube If unavoid able however patch the tube very carefully and replace it as Soon as possible with a high quality product PERIODIC MAINTENANCE AND MINOR REPAIR EAU00685 Spoke wheels To maximize the performance durabil ity and safe operation of your motor cycle note the following points regarding the specified wheels The wheel rims should be checked for cracks bends or warpage and the spokes for looseness or dam age before each ride If any dam age is found have a Yamaha dealer replace the wheel Do not attempt even the smallest repair to the wheel A deformed or cracked wheel must be replaced The wheel should be balanced whenever either the tire or wheel has been changed or replaced An unbalanced wheel can result in poor performance adverse han dling characteristics and a short ened tire life Ride at moderate speeds after changing a tire since the tire sur face must first be broken in for it to develop its optimal characteristics EAU00691 Accessories and replacement parts This motorcycle is not designed to pull a trailer or to be attached to a sidecar The accessories or replace ment parts you choose for your motorcycle should b
41. e designed spe cifically for this model and they must be securely mounted to main tain the inherent stability of the orig inal design Genuine Yamaha Parts and Accessories are designed and tested to be compatible with your motorcycle Please consider Genu ine Yamaha Parts and Accessories before making a purchase Use of non Yamaha approved accessories or replacement parts may cause loss of handling stability and riding safety Since Yamaha cannot con trol the quality of accessories or parts manufactured by other com panies Yamaha cannot be held lia EW000098 6 16 ble for any consequences caused by the use of items which have not been approved by Yamaha PERIODIC MAINTENANCE AND MINOR REPAIR 7 Tighten the locknut at the clutch lever and the crankcase 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 play could be obtained as de play Scribed above tighten the locknut and skip the rest of the procedure The clutch lever free play should mea otherwise proceed as follows sure 10 15 mm 0 4 0 6 in as shown Fully turn the adjusting bolt at the Periodically check the clutch lever free clutch lever in direction to loos play and if necessary adjust it as en the clutch cable EAU00694 Adjusting the clutch lever free Eu 5 Loosen the locknut at the Loosen
42. e grip by installing the screws Recommended lubricant Throttle cable Yamaha Chain and Cable Lube or engine oil SAE 10W 30 Throttle grip housing and grip Lithium soap based grease all purpose grease EAU03370 Checking and lubricating the brake and shift pedals The operation of the brake and shift pedals should be checked before each ride and the pedal pivots should be lu bricated if necessary Recommended lubricant Lithium soap based grease all purpose grease EAU03164 Checking and lubricating the brake and clutch levers The operation of the brake and clutch levers should be checked before each ride and the lever pivots should be lu bricated if necessary Recommended lubricant Lithium soap based grease all purpose grease PERIODIC MAINTENANCE AND MINOR REPAIR EAU03165 Checking and lubricating the sidestand The operation of the sidestand should be checked before each ride and the sidestand pivot and metal to metal contact surfaces should be lubricated if necessary If the sidestand does not move up and down smoothly have a Yamaha dealer check or repair it EW000113 Recommended lubricant Lithium soap based grease all purpose grease PERIODIC MAINTENANCE AND MINOR REPAIR EAU02939 Checking the front fork The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic main tenance and lubrication chart To
43. eat them with a suitable care product Avoid using abrasive polishing compounds as they will wear away the paint 7 3 NOTE Consult a Yamaha dealer for advice on what products to use Storage Short term Always store your motorcycle in a cool dry place and if necessary protect it against dust with a porous cover 00014 CAUTION Storing the motorcycle in a poorly ventilated room or cover ing it with a tarp while it is still wet will allow water and humid ity to seep in and cause rust To prevent corrosion avoid damp cellars stables because of the presence of ammonia and areas where strong chemi cals are stored MOTORCYCLE CARE AND STORAGE Long term Before storing your motorcycle for Several months 1 Follow all the instructions in the Care section of this chapter 2 Turn the fuel cock lever to ON 3 Drain the carburetor float cham bers by loosening the drain bolts this will prevent fuel deposits from building up Pour the drained fuel into the fuel tank Fill up the fuel tank and add fuel stabilizer if available to prevent the fuel tank from rusting and the fuel from deteriorating Perform the following steps to pro tect the cylinders piston rings etc from corrosion 7 4 a b Remove the spark plug caps and spark plugs Pour a teaspoonful of engine oil into each spark plug bore Install the spark plug caps onto the spark plugs
44. eep sparks flames cigarettes etc away from the battery and pro vide sufficient ventilation when charging it in an enclosed space Take care not to spill electrolyte on the drive chain as this may weaken it shorten chain life and possibly result in an accident KEEP THIS AND ALL BATTER IES OUT OF THE REACH OF CHILDREN 000100 CAUTION Use only distilled water as tap water contains minerals that are harmful to the battery 4 Check and if necessary tighten the battery lead connections and correct the breather hose routing PERIODIC MAINTENANCE AND MINOR REPAIR TOOT eh tte urren eveL LOWER LEVEL 1 Maximum level mark 2 Minimum level mark To store the battery 1 If the motorcycle will not be used for more than one month remove the battery fully charge it and then place it in a cool dry place If the battery will be stored for more than two months check the specific gravity of the electrolyte at least once a month and fully charge the battery whenever necessary Fully charge the battery before installation 4 After installation make sure that the battery leads are properly con nected to the battery terminals and that the breather hose is properly routed in good condition and not obstructed 000099 CAUTION If the breather hose is positioned in such a way that the frame is ex posed
45. ely repack all purpose grease Brake and clutch lever i Lithium soap based grease pivot shaft Apply chain lube lightly all purpose grease V V V Brake and shift pedal Lubricate Lithium soap based grease 4 d 4 shaft Apply chain lube lightly all purpose grease Check operation and fes Lithium soap based grease Sidestand pivot ubricate ja guess dreasa Ei E Apply chain lube lightly Check operation and _ Front fork leakage J PERIODIC MAINTENANCE AND MINOR REPAIR INITIAL ODOMETER READINGS 600 mi 4 000 mi 7 000 mi 10 000 mi 13 000 mi No ITEM ROUTINE TYPE 1 000km 6 000km 11 000km 16 000km 21 000km or or or or or 1 month 6 months 12 months 18 months 24 months Check bearings assembly for looseness PN i Lithium soap based grease 13 Steering bearings Moderately repack every 4 Repack 10 000 mi 16 000 or grease 18 months Check bearings for smooth 14 Wheel bearings rotation 4 y Check specific gravity and 15 Battery breather pipe for proper 4 Ei operation SP Check and clean or replace 16 Sidestand switch if necessary 4 Since these items require special tools data and technical skills have a Yamaha dealer perform the service EAU03906 NOTE B From 16 000 mi 26 000 km or 30 months repeat the maintenance intervals
46. ength of time Exhaust fumes are poi sonous and inhaling them can cause loss of consciousness and death within a short time Al ways make sure that there is ad equate ventilation Before starting out make sure that the sidestand is up If the sidestand is not raised com pletely it could contact the ground and distract the opera tor resulting in a possible loss of control OPERATION AND IMPORTANT RIDING POINTS EAU00376 CAUTION e Make sure not to store personal items near the air cleaner in take otherwise air intake will be blocked and performance will suffer Make sure not to put anything near the battery and its termi nals otherwise electrical failure and acid corrosion may result 5 1 OPERATION AND IMPORTANT RIDING POINTS EAUO1751 Starting and warming up a cold engine In order for the ignition circuit cut off System to enable starting one of the following conditions must be met e The transmission is in the neutral position e The transmission is in gear with the clutch lever pulled and the sidestand up Before starting the engine check the function of the igni tion circuit cut off system ac cording to the procedure described on page 3 12 Never ride with the sidestand down EW000054 1 Turn the fuel cock lever to ON 2 Turn the key to ON and make 4 Turn the starter choke on and completely close the throttle See sure that the engine stop s
47. fuel cock lever in this position fuel flows to the carburetor when the engine is running Turn the fuel cock le ver to this position when starting the engine and riding 3 6 1 Arrow mark positioned over RES RES This indicates reserve With the fuel cock lever in this position the fuel re serve is made available Quickly turn the fuel cock lever to this position if you run out of fuel while riding otherwise the engine may stall and will have to be primed see PRI After turning the fuel cock lever to RES refuel as soon as possible and be sure to turn the fuel cock lever back to ON PRI priming position INSTRUMENT AND CONTROL FUNCTIONS 1 Arrow mark positioned over PRI PRI This indicates prime With the fuel cock lever in this position the engine can be primed Turn the fuel cock lever to this position when the engine has been allowed to run out of fuel This sends fuel directly to the carburetor which will make starting easier After the engine has started be sure to turn the lever to ON or RES if you have not refueled yet 1 Starter choke lever EAUO0211 Starter choke lever Starting a cold engine requires a richer air fuel mixture which is supplied by the starter choke Move the lever in direction 8 to turn on the starter choke Move the lever in direction to turn off the starter choke 3 7 INSTRUMENT AND CONTRO
48. g insuf ficient lean angle for the speed a Always obey the speed limit and never travel faster than warranted by road and traffic conditions b Always signal before turning or changing lanes Make sure that other motorists can see you The posture of the operator and passenger is important for proper control a The operator should keep both hands on the handlebar and both feet on the operator footrests during operation to maintain control of the motorcycle b The passenger should always hold onto the operator seat strap or grab bar if equipped with both hands and keep both feet on the passenger footrests C Never carry a passenger unless he or she can firmly place both feet on the passenger footrests Never ride under the influence of alcohol or other drugs This motorcycle is designed for on road use only therefore it is not suitable for off road use A SAFETY INFORMATION Protective apparel The majority of fatalities from motorcycle accidents are the result of head injuries The use of a safety helmet is the single most critical factor in the prevention or reduction of head injuries 1 Always wear an approved helmet 2 Wear a face shield or goggles Wind in your unprotected eyes could contribute to an impairment of vi sion which could delay seeing a hazard 3 The use of a jacket heavy boots trousers gloves etc is effective in preventing or reducing abra sions or lacerations 4 Never wear loose fittin
49. g clothes otherwise they could catch on the control levers footrests or wheels and cause injury or an accident 5 Never touch the engine or exhaust system during or after operation They become very hot and can cause burns Always wear protective clothing that covers your legs ankles and feet 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 Loading and accessories Adding accessories or cargo to your motorcycle can adversely affect stability and handling if the weight distribution of the motorcycle is changed To avoid the possibility of an accident use extreme caution when adding cargo or accessories to your motorcycle Use extra care when riding a motorcycle that has added cargo or accessories Here are some general guidelines to follow if loading cargo or adding ac cessories to your motorcycle 1 3 A SAFETY INFORMATION Loading The total weight of the operator passenger accessories and cargo must not exceed the maximum load limit of XV250 432 Ib 196 kg XV250C 430 Ib 195 kg When loading within this weight limit keep the following in mind 1 Cargo and accessory weight should be kept as low and close to the motorcycle as possible Make sure to dist
50. gf 75 ft lb 1 Cotter pin 6 Insert a new cotter pin into the axle nut and then bend its ends as shown NOTE Make sure that two notches in the axle nut are aligned with the hole through the wheel axle otherwise further tight en the axle nut until they are Always use a new cotter pin for the axle nut EW000110 7 Adjust the brake pedal free play See page 6 18 for brake pedal free play adjustment procedures 6 24 EW000103 After adjusting the brake pedal free play check the operation of the brake light EAU03006 Lubricating the drive chain The drive chain must be cleaned and lubricated at the intervals specified in the periodic maintenance and lubrica tion chart otherwise it will quickly wear out especially when riding in dusty or wet areas Service the drive chain as follows 000097 CAUTION The drive chain must be lubricated after washing the motorcycle or riding in the rain 1 Clean the drive chain with kero sene and a small soft brush ECA00053 CAUTION To prevent damaging the O rings do not clean the drive chain with steam cleaners high pressure washers or inappropriate solvents 2 Wipe the drive chain dry 3 Thoroughly lubricate the drive chain with a special O ring chain lubricant PERIODIC MAINTENANCE AND MINOR REPAIR ECA00052 CAUTION Do not use engine oil or any other lubricants for the drive chain as they may contain substances that cou
51. hoke in the half way position 5 3 EAUO01258 Starting a warm engine Follow the same procedure as for start ing a cold engine with the exception that the starter choke is not required when the engine is warm OPERATION AND IMPORTANT RIDING POINTS Shift pedal N Neutral position EAU00423 Shifting Shifting gears lets you control the amount of engine power available for starting off accelerating climbing hills etc The gear positions are shown in the illustration NOTE To shift the transmission into the neu tral position press the shift pedal down repeatedly until it reaches the end of its travel and then slightly raise it 000048 CAUTION Even with the transmission in the neutral position do not coast for long periods of time with the engine off and do not tow the motorcycle for long dis tances The transmission is properly lubricated only when the engine is running Inade quate lubrication may damage the transmission Always use the clutch while changing gears to avoid dam aging the engine transmission and drive train which are not designed to withstand the shock of forced shifting 5 4 EAU02988 To start out and accelerate 1 Pull the clutch lever to disengage the clutch 2 Shift the transmission into first gear The neutral indicator light should go out 3 Open the throttle gradually and at the same time release the clutch lever slowly
52. ill keep your vehicle in the safest and most efficient condition pos sible The most important points of motorcycle inspection adjustment and lubrication are explained on the follow ing pages Maintenance replacement or repair of the emission control devices and systems may be performed by any repair establishment or individual that is certified if applicable If you are not familiar with motor cycle maintenance work have a Yamaha dealer do it for you EW000060 PERIODIC MAINTENANCE AND MINOR REPAIR EAU00467 PERIODIC MAINTENANCE PROPER PERIODIC MAINTENANCE OF YOUR MOTORCYCLE IS IMPOR TANT IN ORDER TO ENJOY LONG PLEASURABLE SERVICE ESPE CIALLY IMPORTANT ARE THE MAINTENANCE SERVICES RELAT ED TO EMISSIONS CONTROL THESE CONTROLS NOT ONLY FUNCTION TO ENSURE CLEANER AIR BUT ARE ALSO VITAL TO PROPER ENGINE OPERATION AND MAXIMUM PERFORMANCE IN THE FOLLOWING PERIODIC MAINTE NANCE CHARTS THE SERVICES RELATED TO EMISSIONS CON TROL ARE GROUPED SEPARATE LY THESE SERVICES REQUIRE SPECIALIZED DATA KNOWLEDGE AND EQUIPMENT YAMAHA DEAL ERS ARE TRAINED AND EQUIPPED TO PERFORM THESE PARTICULAR SERVICES 6 1 PERIODIC MAINTENANCE AND MINOR REPAIR EW000062 Modifications not approved by Yamaha may cause loss of perfor mance excessive emissions and render the vehicle unsafe for use Consult a Yamaha dealer before at tempting any changes 1 Owner s tool kit EAU00468 Owner
53. is switched on EAU00062 Neutral indicator light NEUTRAL This indicator light comes on when the transmission is in the neutral position EAUO00059 Turn signal indicator light TURN This indicator light flashes when the turn signal switch is pushed to the left or right INSTRUMENT AND CONTROL FUNCTIONS 1 Odometer 2 Tripmeter 3 Reset knob 4 Speedometer EAU00095 Speedometer unit The speedometer unit is equipped with a speedometer an odometer and a tripmeter The speedometer shows riding speed The odometer shows the total distance traveled The tripmeter shows the distance traveled since it was last set to zero with the reset knob The tripmeter can be used to estimate the distance that can be traveled with a full tank of fuel This information will en able you to plan future fuel stops 1 Dimmer switch LIGHTS 2 Turn signal switch TURN 3 Horn switch HORN EAU00118 Handlebar switches EAU00122 Dimmer switch LIGHTS Set the switch to HI for the high beam and to LO for the low beam EAU00125 Turn signal switch TURN To signal a right hand turn push this switch to the right To signal a left hand turn push this switch to the left When released the switch returns to the cen 3 2 ter position To cancel the turn signal lights push the switch in after it has re turned to the center position EAUO00130 Horn switch HORN
54. it cut off system EW000044 The motorcycle must not be ridden with the sidestand down or if the sidestand cannot be properly moved up or does not stay up oth erwise the sidestand could contact the ground and distract the opera tor resulting in a possible loss of control Yamaha s ignition circuit cut off system has been designed to assist the operator in fulfilling the responsibility of raising the side stand before starting off Therefore check this system regularly as de scribed below and have a Yamaha dealer repair it if it does not function properly INSTRUMENT AND CONTROL FUNCTIONS EAU03720 Ignition circuit cut off system The ignition circuit cut off system com prising the sidestand switch clutch switch and neutral switch has the fol lowing functions t prevents starting when the trans mission is in gear and the side stand is up but the clutch lever is not pulled Itprevents starting when the trans mission is in gear and the clutch lever is pulled but the sidestand is still down It cuts the running engine when the transmission is in gear and the sidestand is moved down Periodically check the operation of the ignition circuit cut off system according to the following procedure If a malfunction is noted have a Yamaha dealer check the system before riding EWO000045 INSTRUMENT AND CONTROL FUNCTIONS NOTE With the engine turned off F 1 1 Move the
55. ke lever is located at the right The brake pedal is on the right side of Fuel tank cap 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 remove the fuel tank cap bar grip Insert the key into the lock and turn it 1 4 turn clockwise The lock will be re leased and the fuel tank cap can be re moved To install the fuel tank cap 1 Push the fuel tank cap into posi tion with the key inserted in the lock 2 Turn the key counterclockwise to the original position and then re move it 3 4 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 Make sure that the fuel tank cap is properly installed before riding EWA00032 INSTRUMENT AND CONTROL FUNCTIONS 1 Fuel tank filler tube 2 Fuel level EAU03753 Fuel Make sure that there is sufficient fuel in the tank Fill the fuel tank to the bottom of the filler tube as shown Do not overfill the fuel tank oth erwise it may overflow when the fuel warms up and expands Avoid spilling fuel on the hot engine EW000130 3 5 EAUO00185 CAUTION _ o ZO SSS Immediately wipe off spilled fuel with a clean dry soft cloth since fuel may deteriorate painted surfac es or plastic parts EAU04194 Recommended fuel UNLEADED FUEL ONLY Fuel
56. l motorcycle stand is not available by placing a jack un der the frame in front of the rear wheel 2 Raise the front wheel off the ground by using a motorcycle stand To service the rear wheel Raise the rear wheel off the ground by using a motorcycle stand or if a motor cycle stand is not available by placing a jack either under each side of the frame in front of the rear wheel or under each side of the swingarm 1 Speedometer cable EAUO03239 Front wheel To remove the front wheel e Itis advisable to have a Yamaha dealer service the wheel Securely support the motor cycle so that there is no danger of it falling over EW000122 1 Disconnect the speedometer ca ble from the front wheel 1 Wheel axle 2 Front wheel axle pinch bolt 2 Loosen the front wheel axle pinch bolt then the wheel axle 3 Lift the front wheel off the ground according to the procedure on page 6 34 4 Pull the wheel axle out and then remove the wheel ECA00048 CAUTION Do not apply the brake after the wheel has been removed together with the brake disc otherwise the brake pads will be forced shut 1 Speedometer gear unit EAU04183 To install the front wheel 1 Install the speedometer gear unit into the wheel hub so that the pro jections mesh with the slots 2 Lift the wheel up between the fork legs NOTE Make sure that there is enough space between the brake pads before insert
57. ld damage the O rings EAU03297 Checking and lubricating the cables The operation of all control cables and the condition of the cables should be checked before each ride and the ca bles and cable ends should be lubricat ed if necessary If a cable is damaged or does not move smoothly have a Yamaha dealer check or replace it Recommended lubricant Yamaha Chain and Cable Lube or engine oil SAE 10W 30 API SE EW000111 Damage to the outer housing of ca bles may result in internal rusting and cause interference with cable movement Replace damaged ca bles as soon as possible to prevent unsafe conditions PERIODIC MAINTENANCE AND MINOR REPAIR EAU03364 Checking and lubricating the throttle grip and cable The operation of the throttle grip and the condition of the throttle cable should be checked before each ride and the cable should be lubricated or replaced if necessary NOTE Since the throttle grip must be removed to access the throttle cable end the throttle grip and the cable should al ways be lubricated at the same time 1 Remove the throttle grip by remov ing the screws 2 Disconnect the throttle cable hold it up and then apply several drops of oil to the cable end allowing it to trickle into the sheath 3 Connect the throttle cable and then grease the inside of the throt tle grip housing 4 Grease the metal to metal contact surface of the throttle grip and then install th
58. lmet holder since the helmet may hit objects causing loss of control and possibly an accident EWO000030 3 9 INSTRUMENT AND CONTROL FUNCTIONS T 1 Spring preload adjusting ring 2 Position indicator EAU00300 Adjusting the shock absorber assemblies Each shock absorber assembly is equipped with a spring preload adjust ing ring EC000015 CAUTION Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings EW000040 Always adjust both shock absorber assemblies equally otherwise poor handling and loss of stability may result Adjust the spring preload as follows To increase the spring preload and thereby harden the suspension turn the adjusting ring on each shock ab sorber assembly in direction To de crease the spring preload and thereby soften the suspension turn the adjust ing ring on each shock absorber as sembly in direction NOTE Align the appropriate notch in the ad justing ring with the position indicator on the shock absorber Setting Minimum soft 1 Standard 2 Maximum hard 5 EAUO00330 Sidestand The sidestand is located on the left side of the frame Raise the sidestand or lower it with your foot while holding the motorcycle upright NOTE The built in sidestand switch is part of the ignition circuit cut off system which cuts the ignition in certain situations See further down for an explanation of the ignition circu
59. ls and tires Check air pressure 6 14 6 16 Correct if necessary sure that operation is smooth Brake and shift pedals Lubricate pedal pivoting points if necessary 56 Make sure that operation is smooth 7 Drake and clutch levers Lubricate lever pivoting points if necessary m sure that operation is smooth Sidestand Lubricate pivot if necessary 6227 Make sure that all nuts bolts and screws are properly tightened Chassis tesiencts Tighten if necessary Instruments lights signals Check operation _ and switches Correct if necessary Sidestand switch Check operation of ignition circuit cut off system 3 10 3 11 If system is defective have Yamaha dealer check vehicle Check fluid level Battery Fill with distilled water if necessary 6 90 6 31 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 If any item in the Pre operation check list is not working properly have it inspected and repaired before operating the motorcycle EAU00372 EAU00373 e Become thoroughly familiar with all operating controls and their functions before riding Consult a Yamaha dealer re garding any control or function that you do not thoroughly understand Never start the engine or operate it in a closed area for any l
60. lude those used for non Yamaha authorized renting leas ing or other commercial purposes and TZ models DURING THE PERIOD OF WARRANTY any authorized Yamaha motorcycle dealer will free of charge repair or replace any part adjudged defective by Yamaha due to faulty workmanship or material from the factory Parts used in warranty repairs will be warranted for the balance of the product s warranty period All parts replaced under warranty become property of Yamaha Motor Corp U S A GENERAL EXCLUSIONS from this warranty shall include any failures caused by a Competition or racing use b Installation of parts or accessories that are not qualitatively equivalent to genuine Yamaha parts Abnormal strain neglect or abuse Lack of proper maintenance Accident or collision damage Modification to original parts SPECIFIC EXCLUSIONS from this warranty shall include parts replaced due to normal wear or routine maintenance THE CUSTOMER S RESPONSIBILITY under this war ranty shall be to 1 Operate and maintain the motorcycle as specified in the appropriate Owner s Manual and 2 Give notice to an authorized Yamaha motorcycle dealer of any and all apparent defects within ten 10 days after discovery and make the machine available at that time for inspection and repairs at such dealer s place of business WARRANTY TRANSFER To transfer the warranty from the original purchaser to any subsequent pur chaser it is impe
61. nd free play adjustment procedures After adjusting the brake pedal free play check the operation of the brake light EW000103 PERIODIC MAINTENANCE AND MINOR REPAIR EAU01008 Troubleshooting Although Yamaha motorcycles receive a thorough inspection before shipment from the factory trouble may occur dur ing operation Any problem in the fuel compression or ignition systems for example can cause poor starting and loss of power The following troubleshooting chart represents a quick and easy procedure for checking these vital systems your self 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 Use only genuine Yamaha replace ment parts Imitation parts may look like Yamaha parts but they are often inferior have a shorter service life and can lead to expensive repair bills PERIODIC MAINTENANCE AND MINOR REPAIR EAU01562 Troubleshooting chart WARNING Keep away open flames and do not smoke while checking or working on the fuel system EW000125 1 Fuel r gt There is enough fuel Check the compression Check the fuel level in I ael the fuel tank i There is no fuel gt Supply fuel The engine does not start Check the compressoin 2 Compression gt There is compression Check the ignition
62. ne warm it up for several minutes and then turn it off 2 Place an oil pan under the engine to collect the used oil NOTE Skip steps 4 6 if the oil filter element is not being replaced NOTE The engine oil should be between the minimum and maximum level marks 4 If the engine oil is below the mini mum level mark add sufficient oil of the recommended type to raise it to the correct level 6 9 PERIODIC MAINTENANCE AND MINOR REPAIR Recommended engine oil See page 8 1 Oil quantity c1 With oil filter element replacement 1 6 L 1 4 Imp qt 1 7 US qt Without oil filter element SN Y fs g gt 1 Bolt x 3 1 Oil filter element 1 4 L 1 2 Imp qt 1 5 US qt 2 Oil filter element cover 2 O ring Total amount dry engine 4 Remove the oil filter element cover 7 Install the engine oil drain bolt and 1 8 L 1 6 Imp qt 1 9 US qt by removing the bolts then tighten it to the specified m 5 Remove and replace the oil filter torque CAUTION element and O ring fo prevent cluich slip 6 Install the oil filter element cover Tightening torque aded er hee pud by installing the bolts then tighten Engine oil drain bolt ach d ad ing th h ified t e 34 Nm 3 4 m kgf 25 ft lb Ha ing them to the specified torqu 3 mix any chemical additives with Tightening torque 8
63. ng the wing nut the air filter element frame clean it with solvent and then squeeze the remaining solvent out 5 Apply oil of the recommended type to the entire surface of the sponge material and then squeeze the ex cess oil out NOTE The air filter element should be wet but not dripping Recommended oil Engine oil 6 12 PERIODIC MAINTENANCE AND MINOR REPAIR 6 Pull the sponge material over the r EAQUE air filter element frame Adjusting the carburetor 7 Insert the element into the air filter The carburetor is an important part of case and then tighten the wing the engine and its emission control sys nut tem which requires very sophisticated ecoooosz adjustment Therefore carburetor ad CAUTION justments should be left to Yamaha e Make sure that the air filter ele dealer who has the necessary profes ment is properly seated in the sional knowledge and experience air filter case The engine should never be op erated without the air filter ele a Throttle cable free play EAUO00635 Adjusting the throttle cable ment installed otherwise the free play pistons and or cylinders may The throttle cable free play should become excessively worn measure 3 5 mm 0 12 0 20 in at the B throttle grip Periodically check the throttle cable free play and if neces sary have a Yamaha dealer adjust it 8 Install the air filter element cover by installing the s
64. o deductible to pay and repairs aren t pro rated You don t have any out of pocket expenses for covered repairs 9 9 e In addition Travel and Recreation Interruption Protection TRIP is included at no extra cost TRIP gives you up to 150 reimbursement per occurrence for any reasonable expenses you incur because your Yamaha needs covered service replacement vehicle rental emergency towing phone calls even food and lodging when you are away from home This superb coverage goes into effect when you purchase Y E S so it applies to any warranty repairs as well as covered repairs during your entire Y E S plan period e Y E S coverage is honored at any authorized Yamaha dealer nationwide e Y E S coverage is transferable to a new owner if you sell or trade in That can make your Yamaha much more valuable This excellent Y E S plan coverage is only available to Yamaha owners like you and only while your Yamaha is still within the Yamaha Limited Warranty period So visit your authorized Yamaha dealer to get all the facts He can show you how easy it is to protect your investment with Yamaha Extended Service EAUO01063 CONSUMER INFORMATION We urge you to act now You ll get the excellent benefits of TRIP coverage right away and you ll rest easy knowing you ll have strong factory backed protection even after your Yamaha Limited Warranty expires You can also save money Y E S costs less within the first 90
65. od between 0 and 1 600 km 1 000 mi For this reason you should read the following material carefully Since the engine is brand new do not put an excessive load on it for the first 1 600 km 1 000 mi The various parts in the engine wear and polish them Selves to the correct operating clear ances During this period prolonged full throttle operation or any condition that might result in engine overheating must be avoided OPERATION AND IMPORTANT RIDING POINTS EAUO0452 0 1 000 km 0 600 mi Avoid prolonged operation above 1 3 throttle 1 000 1 600 km 600 1 000 mi Avoid prolonged operation above 1 2 throttle 1 600 km and beyond The vehicle can now be operated nor mally EC000059 CAUTION After 1 000 km 600 mi of oper ation the engine oil must be changed the oil filter element replaced and the oil strainer cleaned e If any engine trouble should oc cur during the engine break in period immediately have a Yamaha dealer check the vehi cle EAU00460 Parking When parking stop the engine and then remove the key from the main switch e Since the engine and exhaust system can become very hot park in a place where pedestri ans or children are not likely to touch them Do not park on a slope or on soft ground otherwise the motorcycle may overturn EW000058 5 6 EAU00462 EAU01790 Safety is an obligation of the owner Periodic inspection adjustment and lu brication w
66. or tie down If you have any specific questions on operation or maintenance please contact your dealer for advice Does the warranty cover incidental costs such as towing or transportation due to a failure No The warranty is limited to repair of the machine itself May perform any or all of the recommended maintenance shown in the Owner s Manual instead of having the dealer do them Yes if you are a qualified mechanic and follow the procedures specified in the Owner s and Service Manual We do recommend however that items requiring special tools or equipment be done by Yamaha Motorcycle dealer Will the warranty be void or cancelled if do not operate or maintain my new motor cycle exactly as specified in the Owner s Manual No The warranty on a new motorcycle cannot be voided or cancelled However if a particular failure is caused by operation or maintenance other than as shown in the Owner s Manual that failure may not be covered under warranty What responsibility does my dealer have under this warranty Each Yamaha Motorcycle dealer is expected to 1 Completely set up every new machine before sale 2 Explain the operation maintenance and warranty requirements to your satis faction at the time of sale and upon your request at any later date 3 Each Yamaha Motorcycle dealer is held responsible for his setup service and warranty repair work Is the warranty transferable to second owners Yes
67. ork and brakes electric components couplers connectors instruments switch es and lights breather hoses and vents MOTORCYCLE CARE AND STORAGE e For motorcycles equipped with a windshield Do not use strong cleaners or hard sponges as they will cause dulling or scratching Some cleaning compounds for plastic may leave scratches on the wind shield Test the product on a small hidden part of the wind shield to make sure that it does not leave any marks If the wind shield is scratched use a quali ty plastic polishing compound after washing After normal use Remove dirt with warm water a mild detergent and a soft clean sponge and then rinse thoroughly with clean water Use a toothbrush or bottlebrush for hard to reach areas Stubborn dirt and insects will come off more easily if the area is covered with a wet cloth for a few minutes before cleaning 7 2 After riding in the rain near the sea or on salt sprayed roads Since sea salt or salt sprayed on roads during winter are extremely corrosive in combination with water carry out the following steps after each ride in the rain near the sea or on salt sprayed roads NOTE Salt sprayed on roads in the winter may remain well into spring 1 Clean the motorcycle with cold water and a mild detergent after the engine has cooled down ECA00012 CAUTION Do not use warm water since it in creases the corrosive action of the salt 2 After d
68. r 3 Remove the headlight bulb holder by turning it counterclockwise and then remove the defective bulb Headlight bulbs get very hot There fore keep flammable products away from a lit headlight bulb and do not touch the bulb until it has cooled down EWO000119 4 Place anew bulb into position and then secure it with the bulb holder 1 Do not touch this area EC000105 CAUTION Do not touch the glass part of the headlight bulb to keep it free from oil otherwise the transparency of the glass the luminosity of the bulb and the bulb life will be adversely af fected Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with alcohol or thinner 5 Install the bulb cover and then connect the coupler 6 Install the headlight unit by install ing the screws 7 Have a Yamaha dealer adjust the headlight beam if necessary 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 before starting any maintenance A strong wooden box can be placed un der the engine for added stability To service the front wheel 1 Stabilize the rear of the motorcycle by using a motorcycle stand or if an additiona
69. rative that the machine be inspected and registered for warranty by an authorized Yamaha motorcycle dealer In order for this warranty to remain in effect this inspection and registration must take place within ten 10 days after transfer An inspection and registration fee will be charged for this service EMISSIONS CONTROL SYSTEM WARRANTY Yamaha Motor Corporation U S A also warrants to the ultimate purchaser and each subsequent purchaser of each Yamaha motorcycle covered by this warranty with a displacement of 50cc or greater that the vehi cle is designed built and equipped so as to conform at the time of sale with all U S emissions standards applicable at the time of manufacture and that it is free from defects in materials and workmanship which would cause it not to meet these standards within the periods listed immediately below Failure other than those resulting from defects in material or workman ship which arise solely as a result of owner abuse and or lack of proper maintenance are not covered by this warranty ENGINE DISPLACEMENT 50cc to 169cc PERIOD 12 000 km 7 465 miles or five years whichever occurs first 170cc to 279cc 18 000 km 11 185 miles or five years whichever occurs first 280cc or over 30 000 km 18 641 miles or five years whichever occurs first YAMAHA MOTOR CORPORATION U S A MAKES NO OTHER WARRANTY OF ANY KIND EXPRESSED OR IMPLIED ALL IMPLIED WARRANTIES OF MER CHANTABILITY AND FITNESS
70. ribute the weight as evenly as possible on both sides of the motorcycle to minimize imbal ance or instability 2 Shifting weights can create a sudden imbalance Make sure that accessories and cargo are securely attached to the motorcycle before riding Check accessory mounts and cargo restraints frequently 3 Never attach any large or heavy items to the handlebar front fork or front fender These items in cluding such cargo as sleeping bags duffel bags or tents can create unstable handling or slow Steering response Accessories 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 Keep the following guidelines in mind as well as those provided under Loading when mounting acces sories 1 Never install accessories or carry cargo that would impair the performance of your motorcycle Care fully inspect the accessory before using it to make sure that it does not in any way reduce ground clearance or cornering clearance limit suspension travel steering travel or control operation or ob scure lights or reflectors A SAFETY INFORMATION a Accessories fitted to the handlebar or the front fork area can create instability due to improper weight distribution
71. rying the motorcycle apply a corrosion protection spray on all metal including chrome and nick el plated surfaces to prevent corrosion MOTORCYCLE CARE AND STORAGE After cleaning Dry the motorcycle with a chamois 1 or an absorbing cloth Immediately dry the drive chain and lubricate it to prevent it from rusting Use a chrome polish to shine chrome aluminum and stainless Steel parts including the exhaust System Even the thermally in duced discoloring of stainless steel exhaust systems can be re moved through polishing To prevent corrosion it is recom mended to apply a corrosion pro tection spray on metal including chrome and nickel plat ed surfaces Use spray oil as a universal clean er to remove any remaining dirt Touch up minor paint damage caused by stones etc Wax all painted surfaces Let the motorcycle dry completely before storing or covering it EWA00001 e Make sure that there is no oil or wax on the brakes or tires If necessary clean the brake discs and brake linings with a regular brake disc cleaner or ac etone and wash the tires with warm water and a mild deter gent Before operating the motor cycle test its braking perfor mance and cornering behavior ECA00013 CAUTION Apply spray oil and wax spar ingly and make sure to wipe off any excess Never apply oil or wax to any rubber and plastic parts but tr
72. s tool kit The service information included in this manual and the tools provided in the owner s tool kit are intended to assist you in the performance of preventive maintenance and minor repairs How ever additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly NOTE If you do not have the tools or experi ence required for a particular job have a Yamaha dealer perform it for you 6 2 PERIODIC MAINTENANCE AND MINOR REPAIR EAU00471 Periodic maintenance chart for the emission control system INITIAL ODOMETER READINGS 600 mi 4 000 mi 7 000 mi 10 000 mi 13 000 mi No ITEM ROUTINE 1 000km 6 000km 11 000km 16 000km 21 000km or or or or or 1 month 6 months 12 months 18 months 24 months 1 Valve clearance Check and adjust valve clearance when engine is cold Check condition 2 Spark plugs Adjust gap and clean E Replace Replace Replace every 7 000 mi 11 000 km or 12 months Crankcase ventilation Check ventilation hose for cracks damage system Replace if necessary V V E Check fuel hose and vacuum hose for cracks or damage Fuel line Replace if necessary V V Check for leakage 5 Exhaust system Retighten if necessary Replace gasket s if necessary A Check and adjust engine idle speed 6 Idle speed Adjust
73. sidestand down This check is most reliable if performed with 2 Make sure that the engine stop switch is set to RUN a warmed up engine 3 Turn the key to ON 4 Shift the transmission into the neutral position 5 Push the start switch Does the engine start g 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 8 Shift the transmission into gear 9 Move the sidestand down Does the engine stall The sidestand switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer After the engine has stalled 10 Move the sidestand up 11 Keep the clutch lever pulled 12 Push the start switch Does the engine start The clutch switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer The system is OK The motorcycle can be ridden EAUO1114 LLL PRE OPERATION CHECKS 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 Therefore it is very important in addition to a thorough visual inspec tion to check the following points before ea
74. starting from 4 000 mi 6 000 km or 6 months EAU03057 NOTE e The air filter needs more frequent service if you are riding in unusually wet or dusty areas e Hydraulic brake system When disassembling the master cylinder or caliper cylinder always replace the brake fluid Check the brake fluid level regularly and fill as required Replace the oil seals on the inner parts of the master cylinder and caliper cylinder every two years Replace the brake hoses every four years or if cracked or damaged PERIODIC MAINTENANCE AND MINOR REPAIR SS 1 Spark plug cap EAU03329 Checking the spark plugs The spark plugs are important engine components which are easy to check Since heat and deposits will cause any spark plug to slowly erode the spark plugs should be removed and checked in accordance with the periodic mainte nance and lubrication chart In addition the condition of the spark plugs can re veal the condition of the engine To remove a spark plug 1 Remove the spark plug cap 1 Spark plug wrench 2 Remove the spark plug as shown with the spark plug wrench includ ed in the owner s tool kit To check the spark plugs 1 Check that the porcelain insulator around the center electrode on each spark plug is a medium to light tan the ideal color when the motorcycle is ridden normally 2 Check that all spark plugs installed in the engine have the same color 6 6 NOTE If any spark pl
75. tank capacity Total amount XV250 9 5L 2 1 Imp gal 2 5 US gal XV250C 9 2L 2 0 Imp gal 2 4 US gal Reserve amount 2 6 L 0 6 Imp gal 0 7 US gal ECA00102 CAUTION Use only unleaded gasoline The use of leaded gasoline will cause se vere damage to the engine internal parts such as valves piston rings exhaust system etc INSTRUMENT AND CONTROL FUNCTIONS Your Yamaha engine has been de signed to use regular unleaded gaso line with a pump octane number R M 2 of 86 or higher or a research octane number of 91 or higher If knocking or pinging occurs use a gasoline of a different brand or premi um unleaded fuel Use of unleaded fuel will extend spark plug life and reduce maintenance costs Gasohol There are two types of gasohol gaso hol containing ethanol and that contain ing methanol Gasohol containing ethanol can be used if the ethanol con tent does not exceed 1096 Gasohol containing methanol is not recom mended by Yamaha because it can cause damage to the fuel system or ve hicle performance problems ON normal position RES reserve position 1 Arrow mark positioned over ON EAU03236 Fuel cock This motorcycle is equipped with a negative pressure fuel cock The fuel cock supplies fuel from the tank to the carburetors while also filtering it The fuel cock lever positions are ex plained as follows and shown in the il lustrations ON With the
76. the locknut at the clutc crankcase lever 6 To increase the clutch lever free 2 To increase the clutch lever free play turn the adjusting bolt in di rection To decrease the clutch lever free play turn the adjusting bolt in direction play turn the adjusting nut in di rection 3 To decrease the clutch lever free play turn the adjusting nut in direction 6 17 PERIODIC MAINTENANCE AND MINOR REPAIR EW000099 e After adjusting the brake lever free play check the free play and make sure that the brake is working properly A soft or spongy feeling in the brake lever can indicate the presence of air in the hydraulic 5 EM TENE free play adjusting bolt system If there is air in the hy between brake pedal footrest c Brake lever free play draulic system have a Yamaha p Brake pedal free play dealer bleed the system before Bits Adjusting the brake lever free operating the motorcycle Air in Adjusting the brake pedal The brake lever free play should mea ish the braking performance EW000104 sure 2 5 mm 0 08 0 20 in as shown which may result in loss of con Periodically check the brake lever free trol and an accident It is advisable to have a Yamaha play and if necessary adjust it as dealer make these adjustments follows 1 Loosen the locknut at the brake Ix iver Brake pedal position The top of the brake pedal should be po sitioned approximately 60 mm
77. then measure the drive chain slack as shown Drive chain slack 30 40 mm 1 2 1 6 in 4 If the drive chain slack is incorrect adjust it as follows PERIODIC MAINTENANCE AND MINOR REPAIR 1 Brake pedal free play adjusting nut To adjust the drive chain slack 1 Loosen the brake pedal free play adjusting nut NN v Axle nut Cotter pin Chain puller locknut Drive chain slack adjusting nut Alignment marks 2 Remove the cotter pin from the axle nut and then loosen the axle nut Loosen the chain puller locknut at each end of the swingarm To tighten the drive chain turn the adjusting nut at each end of the swingarm in direction To loos en the drive chain turn the adjust ing nut at each end of the swingarm in direction and then push the rear wheel forward PERIODIC MAINTENANCE AND MINOR REPAIR NOTE Using the alignment marks on each side of the swingarm make sure that both chain pullers are in the same posi tion for proper wheel alignment EC000096 CAUTION Improper drive chain slack will over load the engine as well as other vital parts of the motorcycle and can lead to chain slippage or breakage To prevent this from occurring keep the drive chain slack within the specified limits 5 Tighten the locknuts and then tighten the axle nut to the specified torque Tightening torque Axle nut 104 Nm 10 4 m k
78. ug shows a distinctly dif ferent color the engine could be defec tive Do not attempt to diagnose such problems yourself Instead have a Yamaha dealer check the motorcycle 3 Check each spark plug for elec trode erosion and excessive car bon or other deposits and replace it if necessary Specified spark plug C6HSA NGK or U20FS U DENSO PERIODIC MAINTENANCE AND MINOR REPAIR Tightening torque Spark plug 12 5 Nm 1 25 m kgf 9 0 ft lb NOTE a 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 a Spark plug gap past finger tight However the spark plug should be tightened to the speci fied torque as soon as possible To install a spark plug 1 Measure the spark plug gap with a wire thickness gauge and if neces 4 Install the spark plug cap sary adjust the gap to specification Spark plug gap 0 6 0 7 mm 0 02 0 03 in 2 Clean the surface of the spark plug gasket and its mating sur face and then wipe off any grime from the spark plug threads 3 Install the spark plug with the spark plug wrench and then tight en it to the specified torque 6 7 PERIODIC MAINTENANCE AND MINOR REPAIR EAU00499 Canister for California only This model is equipped with a canister to prevent the discharging of fuel vapor into the atmosphere Before operating this motorcycle make sure to check the
79. vent an accident This motorcycle is designed to carry the operator and a passenger The failure of motorists to detect and recognize motorcycles in traffic is the predominating cause of automobile motorcycle accidents Many accidents have been caused by an automobile driver who did not see the motorcycle Making yourself conspicuous appears to be very effective in reducing the chance of this type of accident Therefore a Wear a brightly colored jacket b Use extra caution when approaching and passing through intersections since intersections are the most likely places for motorcycle accidents to occur c Ride where other motorists can see you Avoid riding in another motorist s blind spot 1 1 A SAFETY INFORMATION 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 b Know your skills and limits Staying within your limits may help you to avoid an accident c We recommend that you practice riding your motorcycle where there is no traffic until you have become thoroughly familiar with the motorcycle and all of its controls Many motorcycle accidents have been caused by error of the motorcycle operator A typical error made by the operator is veering wide on a turn due to EXCESSIVE SPEED or undercornerin
80. wheel 18 x 1 60 Spoke wheel 15M C x MT 2 75 Single disc brake Right hand DOT 4 or DOT 3 Rear Type Operation Suspension Front Rear Spring shock absorbers Front Rear Wheel travel Front Rear Electrical system Ignition system Charging system Type Standard output Battery Model Voltage capacity Headlight type SPECIFICATIONS Drum brake Right foot Telescopic fork Swingarm Coil spring oil damper Coil spring oil damper 140 mm 5 5 in 100 mm 3 9 in T C I digital A C magneto 14 V 25 A 5 000 r min GM10 3A 2 12 V 10 Ah Quartz bulb halogen SPECIFICATIONS Bulb voltage wattage x quantity Headlight Tail brake light Front turn signal position light Rear turn signal light Meter lighting Neutral indicator light High beam indicator light Turn signal indicator light Fuses Main fuse Signaling system fuse 12 V 60 55 W x 1 12 V 8 27 W x 1 12 V 27 86 W x2 12V 27Wx2 14V 38Wx1 14V 3Wx1 12V 1 7W x1 14V 8W x1 20A 10A CONSUMER INFORMATION EAU02944 Identification numbers 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 Ld 2 VEHICLE IDENTIFICATION NUMBER LE 3 MODEL LABEL INFORMATION 1 Ke
81. witch is page 3 7 for starter choke set to RUN operation 3 Shiftthe transmission into the neu 5 Start the engine by pushing the tral position start switch NOTE NOTE When the transmission is in the neutral position the neutral indicator light should be on otherwise have a Yamaha dealer check the electrical circuit If the engine fails to start release the start switch wait a few seconds and then try again Each starting attempt should be as short as possible to pre serve the battery Do not crank the en gine more than 10 seconds on any one attempt 5 2 6 After starting the engine move the starter choke lever back halfway ECAO00055 CAUTION For maximum engine life always warm the engine up before starting off Never accelerate hard when the engine is cold 7 When the engine is warm turn the starter choke off NOTE The engine is warm when it responds normally to the throttle with the starter choke turned off To avoid the possi bility of excessive exhaust emissions never leave the starter choke on long er than necessary The time necessary for starter choke use depends upon the ambient temperature Tempera tures above 10 C 50 F require about 7 seconds of starter choke use and temperatures below 10 C 50 F re quire about 35 seconds with the starter OPERATION AND IMPORTANT RIDING POINTS choke turned on then about 2 5 min utes with the starter c
82. y identification number EAU01042 Key identification number The key identification number is stamped into the key Record this num ber in the space provided and use it for reference when ordering a new key 9 1 EAUO01039 1 Vehicle identification number EAUO1043 Vehicle identification number The vehicle identification number is stamped into the steering head pipe Record this number in the space pro vided NOTE The vehicle identification number is used to identify your motorcycle and may be used to register your motor cycle with the licensing authority in your area 1 Model label EAU01804 Model label The model label is affixed to the frame under the rider seat See page 3 8 for rider seat removal and installation pro cedures Record the information on this label in the space provided This in formation will be needed when ordering spare parts from a Yamaha dealer 9 2 CONSUMER INFORMATION CONSUMER INFORMATION EAU01051 REPORTING SAFETY DEFECTS If you believe that your vehicle has a defect which could cause a crash or could cause injury or death you should immedi ately inform the National Highway Traffic Safety Administration NHTSA in addition to notifying Yamaha Motor Corporation U S A If NHTSA receives similar complaints it may open an investigation and if it finds that a safety defect exists in group of vehicles it may order a recall and remedy campaign However NHTSA cannot

Yamaha 2002 Virago 250 Owner's Manual

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