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Yamaha 2001 Virago 250 Owner's Manual

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3. EAU03438 AWARNING The engine exhaust fr
4. XV250C 148 kg 326 Ib Be sure to use motor oils that do not contain anti friction modifiers Passenger car motor oils often labeled Engine Energy Conserving contain anti friction additives which Engine type Air cooled 4 stroke SOHC will cause clutch and or starter clutch slippage resulting in reduced component life and poor engine performance Cylinder arrangement V type 2 cylinder eens serene re acude Displacement 249 cm Quantity mn Ore HONE ao oem Without oil filter element Compression ratio 10 1 replacement 1 4L 1 2 Imp qt 1 5 US qt With oil filter element replacement Starting system Electric starter 1 6 L 1 4 Imp qt 1 7 US qt 1 8L 1 6 Imp qt 1 9 US qt Air filter Wet type element Lubrication system Wet sump Total amount dry engine 8 1 SPECIFICATIONS Fuel Type Fuel tank capacity XV250 XV250C 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 rear front Transmission type Operation UNLEADED FUEL 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 2 813 45 16 Constant m
5. 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 MOTORCYCLE CARE AND STORAGE 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 O C 30 F or more than 30 60 F For more informa tion on storing the battery see page 6 31 month in order to prevent the tires from becoming degraded in one spot NOTE Make any necessary repairs before storing the motorcycle Coverthe muffler outlets with plas tic bags to prevent moisture from entering them EAUO1038 SPECIFICATIONS Specifications Model XV250 XV250C Engine oil Dimensions Type 10 30 50 70 90 110 130 F Overall length Overall width Overall height Seat height 2 190 mm 86 2 in 815 mm 32 1 in 1 140 mm 44 9 in E YAMALUBE 4 10W 30 ior SAE 10W 30 i YAMALUBE 4 20W 40 685 mm 27 0 in t or SAE 20W 40 1 490 mm 58 7 in 145 mm 5 7 in Recommended engine oil 2800mm 110 21 classification API Service SE SF SG type or Basic weight with oil and full higher fuel tank Wheelbase 20 10 0 10 20 30 40 50 C Ground clearance Minimum turning radius XV250 147 kg 324 Ib CAUTION
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7. Use the electric starter Engine turns over slowly Y Ask a Yamaha dealer to inspect Engine doesn t start go to battery check Battery good Engine doesn t start ask a Yamaha dealer to inspect Check fluid recharge check connections 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 bags after the engine has cooled down Make sure that all caps and covers as well as all electrical couplers and connectors including the spark plug caps are tightly in stalled 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 EAU03430 Cleaning ECA00010 CAUTION e Avoid using strong acidic wheel cleaners especially
8. 3 Shift the transmission into the neu tral position 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 4 Turn the starter choke on and completely close the throttle See page 3 7 for starter choke operation 5 Start the engine by pushing the start switch NOTE 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 6 After starting the engine move the starter choke knob lever back halfway ECA00055 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 SSS 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 c
9. EWOO00083 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 EAUOO0680 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 side wall is cracked con tact a Yamaha dealer immediately and have the tire replaced FRONT Manufacturer Size Type CHENG SHIN 3 00 18 47P C 916 REAR CHENG SHIN 130 90 15M C 66P C 915 Minimum tire tread depth 1 0 mm 0 04 in front and rear 6 15 e It is dangerous to ride with a worn out tire When a tire tread begins to show crosswise lines have a Yamaha dealer replace the tire immediately e The replacement of all wheel
10. 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 EAUOO685 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 e Hide 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 be designed spe cifically for this model and they must be sec
11. 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 EWO000117 6 30 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 keep 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 c
12. 26 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 EAUO3165 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 EWO000113 Recommended lubricant Lithium soap based grease all purpose grease 6 27 PERIODIC MAINTENANCE AND MINOR REPAIR EAUO2939 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 check the condition EWO000115 Securely support the motorcycle so that there is no danger of it falling over Check the inner tubes for scratches damage and excessive oil leakage To check the o
13. 3 Speedometer cable 5 6 Push down hard on the handlebar several times to check for proper fork operation Tighten the wheel axle to the specified torque Tightening torque 7 Wheel axle 59 Nm 5 9 m kg 43 16 Install the front wheel axle pinch bolt and then tighten it to the specified torque PERIODIC MAINTENANCE AND MINOR REPAIR Tightening torque Front wheel axle pinch bolt 20 Nm 2 0 m kg 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 1 2 3 4 5 6 Rear wheel EAU01550 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 of it falling over EWo000122 6 36 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 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 EAUOISSS 5 Adjust the drive chain slack See page 6 22 for drive chai
14. 5 US qt Total amount dry engine 1 8 L 1 6 Imp qt 1 9 US qt 000072 CAUTION e In order to prevent clutch slip page since the engine oil also lubricates the clutch do not mix any chemical additives with the oil or use oils of a higher grade than CD In addition do not use oils labeled ENERGY CONSERVING II or higher Make sure that no foreign mate rial enters the crankcase 9 Start the 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 Tum the engine off and then check the oil level and correct it if necessary PERIODIC MAINTENANCE AND MINOR REPAIR 1 Bolt x 2 EAUO1103 Cleaning the air filter element The air filter element should be cleaned at the intervals specified in the periodic maintenance and 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 loosing the screw clamp by removing the Screw 6 11 1 Screw clamp 2 Air filter case cover 3 Air filter case PERIODIC MAINTENANCE AND MINOR REPAIR 1 Screw x 2 1 Wing nut 1 Foam element 5 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 r
15. AND CONTROL FUNCTIONS EAU00331 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 It 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 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 EW000045 INSTRUMENT AND CONTROL FUNCTIONS With the engine turned off NOTE Soa fs i a DENEN HT 1 Move the 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 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
16. 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 CONSUMER INFORMATION EAU03052 Maintenance record Copies of work orders and or receipts for parts purchased and installed on your motorcycle will be required to 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 Servicing dealer Mileage Remarks 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 81 000 km or 36 months 9 5 CONSUMER INFORMATION Maintenance Date of Servicing dealer Mileage Remarks interval service name and addre
17. install ing the screws and bolts 6 13 PERIODIC MAINTENANCE AND MINOR REPAIR EAUO0637 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 Side wall 2 Wear indicator 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 6 14 Ewooo0s2 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 _ forthismode this model Tire air pressure measured on cold tires Load Front Rea 175 kPa 200 ELM 1 75 kgf cm 2 00 kgf cm 25 psi 29 psi 200 kPa 225 kPa 2 00 kgf cm 2 25 kgf cm 29 psi 33 psi Up to 90 kg 198 Ib 90 kg 198 Ib maximum XV250 196 kg 432 Ib XV250C 195 kg 430 Ib cargo and Maximum load Total weight of rider accessories passenger
18. is veering wide on a turn due to EXCESSIVE SPEED or undercornering insufficient 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 re
19. mi For this reason you should read the follow ing material carefully Since the engine is brand new do not put an excessive load on it for the first 1 000 km 600 mi The various parts in the engine wear and polish themselves to the correct operating clearances During this period prolonged full throt tle operation or any condition that might result in engine overheating must be avoided OPERATION AND IMPORTANT RIDING POINTS EMIT CAUTION EAU00445 0 150 km 0 90 mi Avoid prolonged operation above 1 3 throttle After every hour of operation stop the engine and then let it cool for five to ten minutes e Vary the engine speed from time to time Do not operate the engine at one set throttle position 150 500 km 90 300 mi Avoid prolonged operation above 1 2 throttle e Rev the engine freely through the gears but do not use full throttle at any time 500 1 000 km 300 600 mi Avoid prolonged operation above 3 4 throttle 1 000 km 600 mi and beyond Avoid prolonged full throttle operation Vary the engine speed occasionally ECO00059 After 1 000 km 600 mi of oper ation the engine oil must be changed the oil filter tridge 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 EAUO0460 Parking When parking stop the engine and then remove th
20. 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 fork and brakes electric components couplers connectors instruments switch es and lights breather hoses and vents MOTORCYCLE CARE AND STORAGE 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 wa
21. polishing To prevent corrosion it is recom mended to apply a corrosion pro tection spray on all 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 EWAOO0001 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 ingly and make sure to wipe off any excess Never apply oil or wax to any rubber and plastic parts but treat them with a suitable care product Avoid using abrasive polishing compounds as they will wear away the paint 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 ECA00014 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 ammon
22. 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 6 34 1 Speedometer cable EAU03239 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 EWO000122 1 Disconnect the speedometer ca ble from the front wheel 1 Front 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 PERIODIC MAINTENANCE AND MINOR REPAIR EAU01394 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 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 1 Speedometer gear unit 2 Retainer
23. than 13 100 mi 21 000 km or 25 months follow the maintenance require ments listed in the maintenance chart under the 3 800 mi 6 000 km or 7 month interval NOTE EAU03057 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 6 5 PERIODIC MAINTENANCE AND MINOR REPAIR 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 or U20FS U DENSO 1 Spark plug cap 1 Spark plug wrench w99 To check the spark plugs Checking the spark plugs 1 Check that the porcelain insulator The spark plugs are important engine around the center electrode on components which are easy to check each spark plug is a medium to Since heat and deposits will cause any light tan the ideal color when the spark plug to slowly erode the spark motorcycle is ridden normally plugs should be removed and checked 5 Check that all spark plugs installed in accordance with the periodic mainte in the engine have the same color nance and lubricat
24. the electrical system and possibly a fire ECO000103 3 Turn the key to and turn on 1 Main fuse the electrical circuit in question to Screw 2 2 Signaling system fuse check if the device operates EAUO3003 ew 4 If the fuse immediately blows Replacing the headlight bulb Replacing the fuses again have a Yamaha dealer This motorcycle is equipped with a The fuse boxes are located under the check the electrical system quartz bulb headlight If the headlight rider seat See page 3 8 for rider seat bulb burns out replace it as follows removal and installation procedures 1 Remove the headlight unit by re If a fuse is blown replace it as follows moving the screws 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 Specified fuses Main fuse 20A Signaling system fuse 10A 6 32 PERIODIC MAINTENANCE AND MINOR REPAIR 1 Headlight coupler 1 Headlight bulb holder 1 Do not touch this area 2 Bulb cover 3 Remove the headlight bulb holder 29090108 2 Disconnect the headlight coupler by turning it counterclockwise and CAUTION and then remove the headlight unit then remove the defective bulb Do not touch the glass part of the and bulb cover Ewooott headlight bulb to keep it free from A WARNING oil otherwise the transparency of Headlight bulbs get very hot There
25. tire normal pressure should be set as ALWAYS WEAR AN APPROVED MOTORCYCLE follows HELMET eye protection and protective clothing Up to 90 kg 198 Ibs load SMUCZVISKCAD 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 225kPa 2 25 kgf cm 33 psi 3CK 21668 A0 4 California only EMISSION HOSE ROUTING 2 CAUTION Read owner s manual before servicing battery Electrolyte will damage metal parts or paint If electrolyte spills wash area with fresh water immediately 9 Be sure to connect breather hose after installing battery FROM FUEL TANK 3JL 28177 A0 CANISTER TO ATMOSPHERE 4YN 21686 00 DESCRIPTION Left view 1 Headlight 2 Fuel tank 3 Helmet holder 4 Rear wheel page 6 32 page 3 5 page 3 9 page 6 36 2 1 5 Main switch 6 Fuel cock 7 Shift pedal 8 Front wheel EAUO0026 page 3 1 page 3 6 page 3 3 page 6 34 DESCRIPTION Right view 13 Front turn signal position light 14 Brake pedal 15 Footrest 9 Tail brake light page 3 4 10 Rear turn signal light 11 Rider seat 12 Air filter page 3 8 page 6 11 2 2 DESCRIPTION Controls and instruments 1 2 34 o 8 7 1 Clutch lever page 3 3 5 Right handlebar switches page 3 3 2 L
26. 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 PERIODIC MAINTENANCE AND MINOR REPAIR S J D 1 Oil filter element 2 O ring 1 Oil filter cover screw x 3 2 Oil filter cover 4 Remove the oil filter element cover by removing the bolts 5 Remove and replace the oil filter g element and O ring 6 Install the oil filter element cover by installing the bolts then tighten ing them to the specified torque 7 Install the engine oil drain bolt and then tighten it to the specified torque Tightening torque Engine oil drain bolt 34 Nm 3 4 m kg 25 ft lb 8 Add the specified amount of the recommended engine oil and then install and tighten the oil filler cap Tightening torque Oil filter element cover bolt 7 Nm 0 7 m kg 5 1 ft lb NOTE Make sure that the O ring is properly seated 6 10 Recommended engine oil See page 8 1 Oil quantity With oil filter element replacement 1 6 L 1 4 Imp qt 1 7 US qt Without oil filter element replacement 1 4 L 1 2 Imp qt 1
27. 1 Brake light switch 2 Adjusting nut EAUO0713 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 8 To make the brake light come on later turn the adjusting nut in direction EAUO0720 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 6 20 1 Wear indicator groove EAUO0725 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 Wear indicator 2 Wear limit line EAU00727 Rear brake shoes The rear brake is provided with a wear indicator 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 indica
28. 30 motor oil ry 300 mi 500 Swingarm pivot shaft Brake clutch lever pivot shaft Brake pedal and shift pedal shaft Sidestand pivot Check swingarm assembly for looseness Moderately repack Apply chain lube lightly Lubricate Apply chain lube lightly Check operation and lubricate Apply chain lube lightly Lithium soap based grease Yamaha chain and cable lube or SAE 10W 30 motor oil Yamaha chain and cable lube or SAE 10W 30 motor oil Yamaha chain and cable lube or SAE 10W 30 motor oil Front fork Check operation and leakage PERIODIC MAINTENANCE AND MINOR REPAIR ROUTINE INITIAL ODOMETER READINGS 600 mi 1 000km or 1 month 4 000 mi 6 000km or 6 months 7 000 mi 11 000km or 12 months 10 000 mi 13 000 mi 16 000km 21 000km or or 18 months 24 months Steering bearings Check bearings assembly for looseness Moderately repack every 10 000 mi 16 000 km or 18 months Lithium soap based grease Repack Wheel bearings Check bearings for smooth rotation Battery hel Sidestand switch Check specific gravity and breather pipe for proper operation Check and clean or replace if necessary Since these items require special tools data and technical skills have a Yamaha dealer perform the service NOTE EAUO0475 For odometer readings or time periods higher
29. Axle nut 2 Cotter pin 3 Chain puller locknut 4 Adjusting nut adjust it as follows 1 Loosen the brake pedal free play 5 alignment marks adjusting nut EAUO1076 4 If the drive chain slack is incorrect adjust the drive chain slack 2 Remove the cotter pin from the axle nut and then loosen the axle nut 3 Loosen the chain puller locknut at each end of the swingarm 4 To tighten the drive chain turn the adjusting nut at each end of the swingarm in direction 8 To loos en the drive chain turn the adjust ing nut at each end of the swingarm in direction D and then push the rear wheel forward 6 23 PERIODIC MAINTENANCE AND MINOR REPAIR NOTE gt 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 105 Nm 10 5 m kg 76 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 t
30. Brake fluid may deteriorate paint ed surfaces or plastic parts Al ways clean up spiled 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 EAU03238 Changing the brake fluid Have a Yamaha dealer change the brake fluid at the intervals specified in the periodic maintenance and lubrica tion 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 damaged or leaking Oil seals Replace every two years e Brake hose Replace every four years 6 22 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 PERIODIC MAINTENANCE AND MINOR REPAIR 2 Shiftthe transmission into the neu tral position 3 Move the rear wheel by pushing the motorcycle to locate the tight est portion of the drive chain and then measure the drive chain slack as shown Drive chain slack 30 40 mm 1 2 1 6 in 1 Adjusting nut 1
31. HA DEAL ERS ARE TRAINED AND EQUIPPED TO PERFORM THESE PARTICULAR SERVICES PERIODIC MAINTENANCE AND MINOR REPAIR 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 Ewooo062 1 Tool kit EAUO0468 Owner 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 PERIODIC MAINTENANCE AND MINOR REPAIR EAUO0471 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 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 aje Valve clearance Check and adjust valve clearance when engine is cold 4 4 NI Nl Check condition Adjust gap and clean Replace at 7 000 mi 11 000 km or 12 months and thereafter every 7 000 mi 11 000 km or 12 months Crankcase ventilation Check ventilation hose for cracks or damage system Replace if n
32. ICAL CONDITIONS Safe riding Always make pre operation checks Careful checks may help prevent 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 A SAFETY INFORMATION Many 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 operators 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 accidents have been caused by error of the motorcycle operator A typical error made by the operator
33. OTORCYCLE CARE AND STORAGE 7 1 CAPS 7 1 Slorage oru ti eie RH REOR 7 4 SPECIFICATIONS 8 1 Specifications 8 1 CONSUMER 9 1 Identification numbers 9 1 Key identification number 9 1 Vehicle identification number 9 1 Model label ener 9 2 Reporting safety defects 9 3 Motorcycle noise regulation 9 4 Maintenance record 9 5 Street and enduro motorcycle limited warranty 9 7 Yamaha extended service Y E S 9 9 _Q SAFETYINFORMATION 7 MOTORCYCLES ARE SINGLE TRACK VEHICLES THEIR SAFE USE AND OPERATION ARE DEPENDENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EXPERTISE OF THE OPERATOR EVERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIREMENTS BEFORE RIDING THIS MOTORCYCLE HE OR SHE SHOULD 1 2 3 4 OBTAIN THOROUGH INSTRUCTIONS FROM A COMPETENT SOURCE ON ALL ASPECTS OF MOTORCYCLE OPERATION OBSERVE THE WARNINGS AND MAINTENANCE REQUIREMENTS IN THE OWNER S MANUAL 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 MECHAN
34. SWIICh 3 1 Parkin 5 6 Indicator 1195 3 1 Speedometer unit 3 2 g PERIODIC MAINTENANCE AND MINOR Handlebar switches ee 3 2 REPAIR Pt 6 1 Clutch lever 3 3 PERIODIC MAINTENANCE 6 1 Shift pedal inei 3 3 Owner s tool kit eeeenmnne 6 2 Brake lev r 3 4 Periodic maintenance chart for the emission Brake pedal 3 4 control SySlem 6 3 Fuel tank 3 4 General maintenance and lubrication chart 6 4 FUG ENTE 3 5 Checking the spark plugs PLN DS TUER RENE ets 6 6 Fuel cock E ctecieied aee 3 6 Canister for California only 6 8 Starter choke lever 3 7 Engine oil and oil filter element 6 8 Steering lock 3 8 Cleaning the air filter element 6 11 Rider seati aa ai Haaren 3 8 Adjusting the carburetor 6 13 TABLE OF CONTENTS Adjusting the throttle cable free play 6 13 Adjusting the valve clearance 6 14 TMCS oim eU ERR ERE ERREUR IIS 6 14 Spoke wheels 6 16 Accessories and replacement parts 6 16 Adjusting the clutch lever free play 6 17 Adj
35. 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 3 12 LLL BRE 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 each ride EAUO3328 Pre operation check list ITEM CHECKS PAGE Front brake Rear brake Clutch Engine oil Drive chain Throttle grip and housing Battery Lights signals and Switches Wheels and tires Chassis fasteners Check operation free play fluid level and fluid leakage Fill with DOT 4 or DOT 3 brake fluid if necessary Check operation condition and free play Adjust if necessary Check operation condition and free play Adjust if necessary Check oil level Fill with oil if necessary Check chain slack and condition Adjust if necessary Check smooth ope
36. amaha Motor Corporation U S A 1st Edition May 2000 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 14 19 LLL TABLE OF CONTENTS 1 SAFETY INFORMATION 1 1 Helmetiholder eye te 3 9 Safe riding teme 1 1 Adjusting the shock absorber assemblies 3 10 Protective 1 3 Sidestand wees ee eere reete 3 10 Modifications eene 1 3 Ignition circuit cut off system 3 11 Loading and accessories 1 3 Gasoline and exhaust gas 1 5 PRE OPERATION 4 1 Location of important labels 1 7 Pre ti heck list 4 1 re operation check list PR DESCRIPTION eennmm 2 1 OPERATION AND IMPORTANT RIDING Left VIEW ctii DPI Up SUO PUN DER UE 2 1 POINTS A et rd e RUN 5 1 Right MOM 2 2 Starting and warming upa cold engine 5 5 2 Controls and instruments 2 3 Starting a warm engine 5 3 Shifting tenons 5 4 INSTRUMENT AND CONTROL FUNCTIONS 3 1 Engine break in esee 5 5 M in
37. 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 EWO00111 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 SSS 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 the 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 6
38. ck cover and then insert the key Push the key in turn it 1 8 turn counterclockwise so that it moves out and then release it Remove the key and then close the lock cover 1 Rider seat 2 Bolt x 2 EAUO1072 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 Open EAUO0260 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 helmet holder since the helmet may hit objects causing loss of control and possibly an accident EW000030 INSTRUMENT AND CONTROL FUNCTIONS 1 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 Ewoo0040 Always adjust both shock absorber assemblies equally otherw
39. ducing abra sions or lacerations 4 Never wear loose fitting 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 bums 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 accessories to your motorcycle A SAFETY INFORMATION Loading The total weight of the operator passenger accessories and cargo must not exceed the maximum load limit of XV250 432 Ibs 196 kg XV250C 430 Ibs 195 kg When loading within this weight limit keep the following in mind 1 Cargo and accessory weight should be kept as low and c
40. e key from the main switch 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 e Do not park on a slope or on soft ground otherwise the motorcycle may overturn Ewooo0ss EAUO0462 EAUO1790 Safety is an obligation of the owner Periodic inspection adjustment and lu brication will 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 EWO00060 A WARNING If you are not familiar with motor cycle maintenance work have a Yamaha dealer do it for you 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 YAMA
41. ea that has adequate ventilation Always turn the engine off before leaving the motorcycle unattended and remove the key from the main switch When parking the motorcycle note the following A 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 either to ON or to RES for vacuum fuel cocks or OFF for manual fuel cocks If it should lean over gasoline may leak out of the carburetor or fuel tank 5 f 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 2 7 EAUO2977 Location of important labels Please read the following important labels carefully before operating this motorcycle 1 7 A SAFETY INFORMATION TIRE INFORMATION BEFORE YOU OPERATE THIS VEHICLE READ THE OWNER S MANUAL AND ALL LABELS Cold
42. eate instability due to improper weight distribution or aerodynamic changes If accessories are added to the handlebar or front fork area they must be as lightweight as possible and should be kept to a minimum b 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 vehicles 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 ar
43. ecessary Fuel line Check fuel hose and vacuum pipe for cracks or damage Replace if necessary Check for leakage Exhaust system Retighten if necessary Replace gasket s if necessary Check and adjust engine idle speed idle speed Adjust cable free play Evaporative emission Check control system for damage control system Replace if necessary Spark plugs Replace Replace Since these items require special tools data and technical skills have a Yamaha dealer perform the service California only 6 3 PERIODIC MAINTENANCE AND MINOR REPAIR n Engine oil General maintenance and lubrication chart ROUTINE Warm up engine before draining Replace Wet type filter must be washed and damped with oil EAUO0472 INITIAL ODOMETER READINGS 600 mi 1 000km or 1 month See page 8 1 Yamalube 4 10W 30 or SAE 10W 30 type SE motor oil 4 000 mi 6 000km or 6 months 7 000 mi 11 000km or 12 months 10 000 mi 16 000km or 18 months 13 000 mi 21 000km or 24 months Clutch Adjust free play Replace pads if necessary front Replace shoes if necessary rear Adjust free play EI Drive chain Control and meter cable Check chain condition Adjust and lubricate chain thoroughly Apply chain lube thoroughly SAE 30W 50W motor oil Yamaha chain and cable lube or SAE 10W
44. eft handlebar switches page 3 2 6 Brake lever page 3 4 3 Speedometer page 3 2 7 Throttle grip page 6 13 4 Indicator lights page 3 1 8 Fuel tank cap page 3 4 2 3 EAUOD0027 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 EAUOO0050 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 SC ll 5 E Ji es Do not use the parking position for an extended length of time other wise the battery may discharge 1 High beam indicator light HIGH BEAM 2 Neutral indicator light NEUTRAL 3 Turn signal indicator light TURN EAUO0056 Indicator lights High beam indicator light HIGH BEAM This indicator light comes on when the high beam of the headlight is switched on EAUO0062 Neutral indicator light NEUTRAL This indicator light comes on when the transmission is in the neutral position EAUO0059 Turn signal indicator l
45. emoving 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 EAUO TIS air filter element frame Adjusting the carburetor 7 Insert the element into the air filter 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 Ecos 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 EAU00635 Adjusting the throttle cable ment installed otherwise the free play piston s and or cylinder s may The throttle cable free play should become excessively worn measure 3 5 mm 0 12 0 20 in at the 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 and air filter case cover by
46. esh 5 speed Left foot operation 8 2 Gear ratio 1st 2nd 3rd 4th 5th Chassis Frame type Caster angle Trail Tire 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 915 SPECIFICATIONS Maximum load Rear XV250 196 kg 432 Ib Type Drum brake XV250C 195 kg 430 Ib Operation Right foot operation Tire air pressure measured Suspension on cold tires Front Up to 90 kg 198 Ib Type Telescopic fork Front 175 kPa 1 75 kgf cm 25 psi Bad Rear 200 kPa 2 00 kgt cm 29 psi Swingarm 90 kg 198 Ib maximum Shock absorbers Front 200 kPa 2 00 kgf cm 29 psi Front Coil spring oil damper Rear 225 kPa 2 25 kgf cm 33 psi Rear Coil spring oil damper Total weight of rider passenger cargo and accessories Wheel travel Wheels Front 140 mm 5 5 in Front Rear 100 mm 3 9 in Type Spoke wheel Electrical system Size 18 x 1 60 Ignition system Transistorized coil ignition digital Rear Charging system Type Spoke wheel Type A C magneto Size 15M C x MT 2 75 Standard output 14 V 25 A 5 000 r min Brakes Battery Front Type GM10 3A 2 Type Single disc brake Voltage capacity 12 V 10 Ah Operation Right hand operation Headlight type Quartz bulb halogen Fluid DOT 4 or DOT 3 8 3 SPECIFICATIONS Bulb voltage watta
47. ge 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 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 8 W x2 12V 27Wx2 14V 3Wx1 14V 3W x1 12V 1 7W x 1 14V 8Wx1 20A 10A 8 4 CONSUMER INFORMATION EAUO2944 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 2 VEHICLE IDENTIFICATION NUMBER 3 MODEL LABEL INFORMATION 1 Key identification number EAUO1042 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 EAUO1039 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 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 EAUO1050 Model label The model labe
48. gine 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 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 EAU00211 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 to turn on the starter choke Move the lever in direction to turn off the starter choke INSTRUMENT AND CONTROL FUNCTIONS 1 Steering lock EAU02934 Steering lock To lock the steering 1 2 3 Turn the handlebar all the way to right Open the steering lock cover and then insert the key 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 Check that the steering is locked remove the key and then close the lock cover To unlock the steering 1 Open the steering lo
49. hain 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 ECo00100 CAUTION S 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 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 2 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 3 Fully charge the battery before installation PERIODIC MAINTENANCE AND MINOR REPAIR 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 00099 CAUTION _______ If the breather hose is positioned in such a way that the frame is ex posed to electrolyte or gas expelled from the battery the frame could suffer structural external damages PERIODIC MAINTENANCE AND MINOR REPAIR co 2 MEME Do not use a fuse of a higher amper age rating than recommended to avoid causing extensive damage to
50. he wheel axle otherwise further tight en the axle nut until they are Always use a new cotter pin for the axle nut EWO00110 7 Adjust the brake pedal free play See page 6 18 for brake pedal free play adjustment procedures 6 24 EWO000103 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 97 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 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 _ _ _ _ Do not use engine oil or any other lubricants for the drive chain as they may contain substances that could damage the O rings 6 25 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
51. hoke turned on then about 2 5 min utes with the starter choke in the half way position EAU01258 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 1 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 48 EMIT 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 e 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 EAUO2988 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 gradua
52. ia and areas where strong chemi cals are stored MOTORCYCLE CARE AND STORAGE Long term Before storing your motorcycle for several months 1 2 3 Follow all the instructions in the Care section of this chapter Turn the fuel cock lever to ON 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 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 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 Tum 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 EWAO00003 To prevent damage or injury from sparking make sure to ground the spark plug electrodes while turning the engine over 6 Lubricate all control cables and the pivoting points of all levers and pedals as well as of the sidestand centerstand
53. ight 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 EAUO0095 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 ter position To cancel the turn signal lights push the switch in after it has re turned to the center position EAUO0130 Horn switch HORN Press this switch to sound the horn 1 Engine stop switch ENGINE STOP 2 Start switch START EAUO0137 Engine stop switch ENGINE STOP Set this switch to OFF to stop the en gine in case of an e
54. ion chart In addition the condition of the spark plugs can re NOTE veal the condition of the engine If any spark plug shows a distinctly dif ferent color the engine could be defec To remove a spark plug tive Do not attempt to diagnose such 1 Remove the spark plug cap problems yourself Instead have a 2 Remove the spark plug as shown Yamaha dealer check the motorcycle with the spark plug wrench includ ed in the owner s tool kit PERIODIC MAINTENANCE AND MINOR REPAIR Tightening torque Spark plug 12 5 Nm 1 25 m kg 9 0 ft lb NOTE If a torque wrench is not available when 4 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 ifneces 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 PERIODIC MAINTENANCE AND MINOR REPAIR 1 Canister cover 2 Canister breather 3 Canister EAUO0499 Canister for California only This model is equipped with a can
55. ise 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 3 10 EAUO0330 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 circuit cut off system EWO00044 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
56. ister to prevent the discharging of fuel vapor into the atmosphere Before operating this motorcycle make sure to check the 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 EAUO1523 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 1 Engine oiil level window 1 Engine oil filler cap 1 Engine oil drain bolt 2 Maximum level mark i ics 3 Minimum level mark To change the engine oil with or 3 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 engine
57. l is affixed to the frame under the seat See page 3 8 for seat removal and installation procedures Record the information on this label in the space provided This information will be needed when ordering spare parts from a Yamaha dealer CONSUMER INFORMATION CONSUMER INFORMATION EAUO1051 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 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 CONSUMER INFORMATION EAUO1053 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
58. leaded 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 If unleaded gaso line is not available then leaded regu lar gasoline can be used 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 10 Gasohol containing methanol is not recom mended by Yamaha because it can cause damage to the fuel system or ve hicle performance problems 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 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 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 en
59. lly and at the same time release the clutch lever slowly 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 a Always shift gears at the recommend ed shift points EAUO0427 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 EAUO2974 Recommended shift points The recommended shift points during acceleration and deceleration shown in the table below Deceleration shift point km h mi h 20 12 5 Acceleration shift point km h mi h 16 9 9 24 14 9 32 19 9 40 24 9 EAUO0436 Engine break in There is never a more important period in the life of your engine than the period between and 1 000 km 600
60. lose to the motorcycle as possible Make sure to distribute 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 selecting and installing any accessories Keep the following guidelines in mind as well as those provided under Loading when mounting accessories 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 cr
61. mergency such as when the motorcycle overturns when the throttle cable is stuck EAUO0141 Start switch START Push this switch to crank the engine with the starter EC000005 See page 5 2 for starting instruc tions prior to starting the engine INSTRUMENT AND CONTROL FUNCTIONS 1 Clutch lever EAUO0152 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 1 Shift pedal EAUO0157 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 Front brake lever EAUO0158 Brake lever The brake lever is located at the right handlebar grip To apply the front brake pull the lever toward the handle bar grip 1 Rear brake pedal EAU00162 Brake pedal The brake pedal is on the right side of the motorcycle To apply the rear brake press down on the brake pedal 1 Fuel tank cap 2 Open EAU03327 Fuel tank ca
62. n slack ad justment procedures 6 Tighten the axle nut to the speci fied torque 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 Tightening torque ground Axle nut 105 Nm 10 5 m kg 76 ft l 1 Axle nut 3 Install the brake rod onto the brake OS NM GTI arin coker pin camshaft lever and then install 7 Adjust the brake pedal position u H 4 Drive chain adjusting nut the brake pedal free play adjusting and free play See page 6 18 for se Alignment marke nut onto the brake rod brake pedal position and free play 6 Loosen the locknut and the drive lt Install the brake torque rod bolt at adjustment procedures chain adjusting nut on both ends the swingarm tighten it to the Ewo00103 of the swingarm specified torque and then install WARNING 7 Remove the axle nut the cotter pin After adjusting the brake pedal free 8 Pull the wheel axle out and then play check the operation of the remove the wheel Tightening torque brake light Brake torque rod bolt 23 Nm 2 3 m kg 17 ft lb EWO000110 Always use a new cotter pin for the axle nut 6 37 PERIODIC MAINTENANCE AND MINOR REPAIR EAUO1008 Troubleshooting Although Yamaha motorcycles receive a thorough inspection before shipment from the factory trouble may occ
63. ng 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 length 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 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 OPERATION AND IMPORTANT RIDING POINTS EAU01751 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 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 11 Never ride with the sidestand down Ewoo0054 1 Turn the fuel cock lever to ON 2 Turn the key to ON and make sure that the engine stop switch is set to RUN
64. om this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm YAMAHA LIT CALIF 65 01 EAUO0002 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 INEORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following notations A The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED A WARNING Failure to follow WARNING instructions could result in severe injur
65. p To remove the fuel tank cap 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 opened 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 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 closed and locked Make sure that the fuel tank cap is properly installed before riding EWAO00032 INSTRUMENT AND CONTROL FUNCTIONS 1 Filler tube 2 Fuel level EAUO1183 Fuel Make sure that there is sufficient fuel in the tank Fill the fuel tank to the bottom of the filler tube as shown in the illustra tion 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 EWO000130 EAUO0185 CAUTION Immediately wipe off spilled fuel with a clean dry soft cloth since fuel may deteriorate painted surfac es or plastic parts EAUO0189 Recommended fuel UNLEADED FUEL Fuel 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 INSTRUMENT AND CONTROL FUNCTIONS WW Your Yamaha engine has been de signed to use regular un
66. peration 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 ECO000098 a _ If any damage is found or the front fork does not operate smoothly have a Yamaha dealer check or re pair it 6 28 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 Ewooo115 PERIODIC MAINTENANCE AND MINOR REPAIR EAUO1144 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 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 Yamaha dealer check or repair the steering 6 29 PERIODIC MAINTENANCE AND MINOR REPAIR 1 Battery 2 Battery breather hose EAUO1071 Battery A poorly maintained battery will cor
67. ration Lubricate if necessary Check fluid level Fill with distilled water if necessary Check proper operation Check tire pressure wear damage and spoke tightness Tighten spokes if necessary Make sure that all nuts bolts and screws are properly tightened Adjust if necessary 4 1 6 18 6 22 6 22 6 25 6 30 6 31 6 32 6 33 PRE OPERATIO N CHECKS CHECKS PASE Control and meter cables Brake and shift pedal shafts Brake and clutch lever pivots Sidestand pivot NOTE ee 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 Check smooth operation Lubricate if necessary Check smooth operation Lubricate if necessary Check smooth operation Lubricate if necessary Check smooth operation Lubricate if necessary Check fuel level Fill with fuel if necessary 6 25 6 26 6 27 6 27 3 5 EWA00033 If any item in the Pre operation check list is not working properly have it inspected and repaired before operating the motorcycle 4 2 Z OPERATION AND IMPOR TANT RIDING POINTS EAUO0373 EAU00376 CAUTIC N CAUTION a c LZ e Make sure not to store personal Become thoroughly familiar with all operating controls and their functions before ridi
68. shing 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 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 drying 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 Ad WARNING 1 2 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
69. ss 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 9 6 CONSUMER INFORMATION EAUO2918 YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY 9 7 9 8 CONSUMER INFORMATION CONSUMER INFORMATION YAMAHA EXTENDED SERVICE Y E S 9 9 CONSUMER INFORMATION ee your Authorized YAMAHA Dealer for a Genuine YAMAHA Service Manual PRINTED IN JAPAN 2000 5 0 3x1 CR
70. the glass luminosity of the bulb fore keep flammable products away and the bulb life will be adversely af from a lit headlight bulb and do not fected Thoroughly clean off any dirt touch the bulb until it has cooled and fingerprints on the headlight down bulb using a cloth moistened with alcohol or thinner 4 Place a new bulb into position and then secure it with the bulb holder 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 6 33 PERIODIC MAINTENANCE AND MINOR REPAIR EAUO1579 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 additional 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
71. tor 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 6 21 PERIODIC MAINTENANCE AND MINOR REPAIR Observe these precautions 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 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 lead to poor braking performance e Be careful that water does not en ter the master cylinder when refill ing Water will significantly lower the boiling point of the fluid and may result in vapor lock PERIODIC MAINTENANCE AND MINOR REPAIR e
72. ur 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 6 38 PERIODIC MAINTENANCE AND MINOR REPAIR Troubleshooting chart EAU01562 EW000125 Keep away open flames and do not smoke while checking or working on the fuel system 1 Fuel Enough fuel EL Check if there is fuel Go to compression check in the fuel tank No fuel 2 Compression There is compression Use the electric starter No compression Supply fuel Engine doesn t start go to compression check Go to ignition check Ask a Yamaha dealer to inspect Wipe clean with dry cloth and correct spark gap or replace spark plugs Open throttle half way and start the engine 3 Ignition Wet Remove spark plugs and check electrode Dry 4 Battery Engine turns over quickly
73. urely 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 Ewooooss 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 Adjusting bolt 2 Adjusting nut c Free play 3 If the specified clutch lever free play could be obtained as de scribed above tighten the locknut and skip the rest of the procedure The clutch lever free play should mea otherwise proceed as follows SAS 10 15 mm 0 4 0 6 in as shown 4 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 eres 5 Loosen the locknut at the Loosen the locknut at the clutc crankcase lever 6 To increase the clutch lever free 2 To increase the clutch lever free play t
74. urn the adjusting bolt in di rection 3 To decrease the clutch lever free play turn the adjusting bolt in direction b play turn the adjusting nut in di rection To decrease the clutch lever free play turn the adjusting nut in direction 6 17 PERIODIC MAINTENANCE AND MINOR REPAIR 1 Locknut 2 Adjusting bolt c Free play EAUO0696 Adjusting the brake lever free play The brake lever free play should mea sure 2 5 mm 0 08 0 20 in as shown Periodically check the brake lever free play and if necessary adjust it as follows 1 Loosen the locknut at the brake lever 2 To increase the brake lever free play turn the adjusting bolt in di rection 3 To decrease the brake lever free play turn the adjusting bolt in direction b 3 Tighten the locknut EW000099 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 system If there is air in the hy draulic system have a Yamaha dealer bleed the system before operating the motorcycle Air in the hydraulic system will dimin ish the braking performance which may result in loss of con trol and an accident 6 18 fo SERT 1 Footrest Pedal height b Free play EAUO1199 Adjusting the brake pedal position and free play It is advisable to ha
75. usting the brake lever free play 6 18 Adjusting the brake pedal position and free play rennen eite nnn 6 18 Adjusting the rear brake light switch 6 20 Checking the front brake pads and rear brake shoes 6 20 Checking the brake fluid level 6 21 Changing the brake fluid 6 22 Drive chain slack seeeeene 6 22 Lubricating the drive chain 6 25 Checking and lubricating the cables 6 25 Checking and lubricating the throttle grip and cable nct tii tenens 6 26 Checking and lubricating the brake and shift pedals esses 6 26 Checking and lubricating the brake and clutch levers enirn 6 27 Checking and lubricating the sidestand 6 27 Checking the front 6 28 Checking the steering 6 28 Checking the wheel bearings 6 29 Battery iuuenis bg 6 30 Replacing the fuses 6 32 Replacing the headlight bulb 6 32 Supporting the motorcycle 6 34 Front wheel tete ri ee ts 6 34 Rear wheel eese 6 36 Troubleshooting 6 38 Troubleshooting chart 6 39 M
76. ve a Yamaha dealer make these adjustments EWO000104 Brake pedal position The top of the brake pedal should be positioned approximately 60 mm 2 4 in above the top of the footrest as shown Periodically check the brake pedal position and if necessary adjust it as follows 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 height the brake pedal free play must be adjusted EWO000105 72 4 1 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 6 19 PERIODIC MAINTENANCE AND MINOR REPAIR EWO00106 e After adjusting the drive chain slack or removing and installing the rear wheel always check the brake pedal free play e If proper adjustment cannot be obtained as described have a Yamaha dealer this adjustment e After adjusting the brake pedal free play check the operation of the brake light PERIODIC MAINTENANCE AND MINOR REPAIR
77. y or death to the motorcycle operator a bystander or a person inspecting or repairing the motorcycle CAUTIO 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 e 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 EWO00000 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 AFFIX DEALER LABEL HERE EAU03336 XV250N XV250NC OWNER S MANUAL 2000 by Y

Yamaha 2001 Virago 250 Owner's Manual

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