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Yamaha 1998 Virago 250 Owner's Manual

1. 2 If any item in the PRE OPERATION CHECK is not working properly have it inspected and repaired before operating the motorcycle 6 2 EAE 13302 Brakes 1 Brake lever and brake pedal Check for correct free play in the front brake lever and rear brake pedal and adjust if necessary Make sure the brakes are working properly by check ing at low speed shortly after starting out see page 8 17 for details EUU62300 WARNING A soft spongy feeling in the brake lever in dicates a failure in the brake system Do not operate the motorcycle until the fail ure in the brake system is corrected Ask a Yamaha dealer for immediate repairs A soft spongy feeling could indicate a haz ardous condition in the brake system 6 3 2 Brake fluid Check the brake fluid level Fill the master cylinder with brake fluid if nec essary Recommended brake fluid DOT 4 EUU13100 NOTE 2 ee lf DOT 4 is not available DOT 3 can be used 3 Check the disc pads Refer to page 8 21 4 Check the brake shoes Refer to page 8 21 EUU02201 NOTE ee When this brake service is necessary con sult a Yamaha dealer EAE11302 Brake fluid leakage Front Apply the brake for a few minutes Check to see if any brake fluid leaks out from the pipe joints or the master cylinder EUU37801 Brake fluid may deteriorate painted sur faces or plastic parts Never spill any fluid If spilled clean it up immediately EUU62500
2. 1 Model label EABO00000 CONTROL FUNCTIONS EAB00100 Main switch The main switch controls the ignition and lighting systems Its operation is described below 5 1 EAB0O4800 ON All electrical circuits are switched on and the headlight meter light taillight and front position lights come on The engine can be started The key cannot be removed in this position EABO0600 OFF All electrical circuits are switched off The key can be removed in this position EABO1602 P Parking The taillight and front position light come on but all other circuits are off With the key at OFF push it into the main switch turn it counterclockwise to P and re move it To cancel the parking turn the key clockwise EUU08800 NOTE uM Always turn the main switch to OFF and remove the key when the motorcycle is un attended EAB10000 Indicator lights 1 Turn indicator light TURN 2 Neutral indicator light NEUTRAL 3 High beam indicator light HIGH BEAM EAB12403 Turn indicator light TURN This indicator flashes when the turn switch is moved to the left or right EAB10201 Neutral indicator light NEUTRAL This indicator comes on when the trans mission is in neutral EAB10301 High beam indicator light HIGH BEAM This indicator comes on when the head light high beam is used EAB40005 Speedometer _ The speedometer shows riding s
3. Dear Yamaha ATV Owner Please Review this IMPORTANT SAFETY CARD before operating your ATV If card is not attached call 1 800 344 6418 Dear New Yamaha ATV Owner CONGRATULATIONS ON THE PURCHASE OF YOUR NEW YAMAHA ATV You have purchased a quality Yamaha product that with proper use and care will provide hours of riding pleasure BEFORE YOU OPERATE YOUR NEW ATV Yamaha recommends these important points READ YOUR OWNER S MANUAL A CHILD UNDER 12 YEARS OLD SHOULD NOT OPERATE AN ATV WITH ENGINE SIZE 70CC OR GREATER A CHILD UNDER 16 YEARS OLD SHOULD NOT OPERATE AN ATV WITH ENGINE SIZE GREATER THAN 90CC TAKE THE FREE HANDS ON TRAINING COURSE OFFERED BY YAMAHA ASK YOUR DEALER FOR DETAILS OR CALL 1 800 887 2887 If you have any questions about these points or if you purchased your ATV from an authorized Yamaha dealership and were not informed of the age recommendation for your ATV by the dealership please fill out the information below and mail this card to Yamaha today Name 7 ATV Model Purchase Date READ CAREFULLY BUSINESS REPLY MAIL FIRST CLASS PERMIT NO 4 CYPRESS CA POSTAGE WILL BE PAID BY ADDRESSEE YAMAHA MOTOR CORPORATION U S A P O BOX 6555 CYPRESS CALIFORNIA 90630 9989 ATTN SALES ADMINISTRATION NO POSTAGE NECESSARY IF MAILED IN THE UNITED STATES AFFIX DEALER LABEL HERE EAA00000 XV250K XV250KC OWNER S MANUAL 1997 by Yamaha Motor Corporation U S A 1st Edition Ma
4. b Installation of parts or accessories that are not qualitatively equivalent to genuine Yamaha parts Abnormal strain neglect or abuse Lack of proper maintenance Accident or collision damage Modification to original parts Damage due to improper transportation pado SPECIFIC EXCLUSIONS from this warranty shall include parts replaced due to normal wear or routine maintenance THE CUSTOMER S RESPONSIBILITY under this war ranty shall be to 1 Operate and maintain the motorcycle as specified in the appropriate Owner s Manual and 2 Give notice to an authorized Yamaha motorcycle dealer of any and all apparent defects within ten 10 days after discovery and make the machine available at that time for inspection and repairs at such dealer s place of business WARRANTY TRANSFER To transfer the warranty from the original purchaser to any subsequent pur chaser it is imperative that the machine be inspected and registered for warranty by an authorized Yamaha motorcycle dealer In order for this warranty to remain in effect this inspection and registration must take place within ten 10 days after transfer An inspec tion and registration fee will be charged for this service EMISSIONS CONTROL SYSTEM WARRANTY Yamaha Motor Corporation U S A also warrants to the ultimate purchaser and each subsequent purchaser of each Yamaha motorcycle covered by this warranty with a displacement of 50cc or greater that the vehi
5. Be careful not to shift into neutral Open the throttle part way and gradu ally release the clutch lever Follow the same procedure when shifting to the next higher gear Al ways shift gears at the recommended shift points EAF20302 To decelerate 1 Apply both the front and the rear brakes at the same time to slow the motorcycle 2 When the motorcycle reaches 20 km h 12 5 mi h shift into first gear Any time the engine is about to stall or runs very roughly pull tn the clutch and use the brakes to stop 3 When the motorcycle is almost com pletely stopped shift into neutral The neutral indicator light should come on EAF20500 Recommended shift point Acceleration Deceleration shift point shift point km h mi h km h mi h 1st 2nd 16 9 9 20 12 5 2nd gt 3rd 24 14 9 20 12 5 3rd Ath 32 19 9 20 12 5 4th 5th 40 24 9 20 12 5 7 7 EAF30000 Engine break in There is never a more important period in the life of your motorcycle than the period between zero and 1 000 km 600 mi For this reason we ask that you carefully read the following material Because the engine is brand new you must not put an exces sive load on it for the first 1 000 km 600 mi The various parts in the engine wear and polish themselves to the correct oper ating clearances During this period pro longed full throttle operation or any condition which might result in excessive heating of the engi
6. EUU04801 NOTE 7 7 P CTT Spin the wheel several times and find the tightest position of the chain Check and or adjust the chain slack while it s in this tightest position To check the chain slack the motorcycle must be held straight up with both wheels on the ground and without rider Check the slack at the position shown in the illustra tion Normal slack is approximately 30 40 mm 1 2 1 6 in If the slack exceeds 40 mm 1 6 in adjust a 30 40 mm 1 2 1 6 in EAI40103 Drive chain slack adjustment 1 Loosen the rear brake pedal free play adjusting nut 1 Adjusting nut 2 Remove the cotter pin from the axle nut 1 Axle nut 3 Locknut 2 Cotter pin 4 Chain adjusting nut 5 Alignment marks 3 4 Loosen the axle nut Loosen the chain adjuster locknuts on each side of the swingarm To tighten the chain turn the chain adjusting nuts on each side of the swingarm in direction To loosen the chain turn each chain adjusting nut in direction and push the wheel forward Turn each chain adjusting nut exactly the same amount to maintain correct axle alignment There are marks on each 8 26 side of the swingarm and a match mark on each chain adjusting nut Use these marks to align the rear wheel EUU33301 Too little chain slack will overload the en gine and other vital parts Keep the slack within the specified limits 5 After adjusting be sure to tighten each cha
7. To avoid the possibility of an accident extreme caution should be used if adding cargo or accessories to your motor cycle Use extra care if riding a motorcycle which has added cargo or accessories Here are some general guidelines to follow if loading cargo or adding accessories to your mo torcycle The total weight of the operator passenger accessories and cargo must not exceed the maximum load limit of XV250 431 Ib 196 kg XV250C 429 Ib 195 kg When loading within these weight limits keep the following in mind 1 Cargo and accessory weight should be kept as low and close to the motorcycle as possible Be sure to distribute the weight as evenly as possible on both sides of the machine to minimize imbalance or instability 2 Shifting weights can create a sudden imbalance Make sure that accessories and car go are securely attached to the motorcycle before riding Recheck accessory mounts and cargo restraints frequently 3 Never attach any large or heavy items to the handlebars front forks or front fender These items including such cargo as sleeping bags duffle bags or tents can create unstable handling or slow steering response ACCESSORIES Genuine Yamaha accessories have been specifically designed for use on this motorcy cle Since Yamaha cannot test all other accessories which may be available you must personally be responsible for the proper selection installation and use of non Yamaha accessories You should use
8. Travel and Recreation Interruption Protection expires with genuine Yamaha Extended Service Y E S TRIP is included at no extra cost TRIP gives you up to 150 reimbursement per occurrence for any reasonable e Y E S is designed and administered by Yamaha Motor expenses you incur because your Yamaha needs Corporation to provide maximum owner satisfaction You get uninterrupted factory backed coverage for extra peace of mind Y E S is flexible You choose the plan that s right for you 12 months 24 months or 36 months beyond your warranty period Y E S is designed and administered by the same Yamaha people who handle your warranty and it shows in the comprehensive coverage benefits There are no mileage limitations Coverage isn t limited to moving parts or the drive train like many other plans And Y E S covers manufacturing defects just like the warranty See the sample contract at your Yamaha dealer to see how comforting uninterrupted factory backed protection can be You don t have to pay anything for covered repairs There s no deductible to pay and repairs aren t pro rated You don t have any out of pocket expenses for covered repairs covered service replacement vehicle rental emergency towing phone calls even food and lodging when you are away from home This superb coverage goes into effect when you purchase Y E S so it applies to any warranty repairs as well as covered repairs
9. is low fill the engine with oil Wait a few minutes until the oil level set tles before checking 2 Engine oil and oil filter element re placement a Warm up the engine for a few min utes b Stop the engine Place an oil pan un der the engine and remove the oil filler cap 1 Oil filler cap c Remove the drain plug and drain the oil 1 Drain plug d Remove the oil filter cover bolts and oil filter p ey O A ses Sy IL cone A p g 12 1 Oil filter bolt x 3 e Reinstall the drain plug and tighten it to the specified torque Tightening torque Drain plug 34 Nm 3 4 m kg 25 ft lb f Install the new oil filter new O ring and the filter cover Tighten the oil fil ter cover bolts to the specified torque Tightening torque Oil filter cover bolt 7 Nm 0 7 m kg 5 1 ft lb EUU04101 NOTE nI Make sure the O ring is seated properly 8 13 1 Oil filter 2 O ring g Fill the engine with oil Install the oil filler cap and tighten EUU32301 Recommended oil 30 F 40 F 50 F 60 F i aa F YAMALUBE 4 20W40 or Do not put in any chemical additives En SAE 20W40 type SE motor oil gine oil also lubricates the clutch and addi YAMALUBE 4 10W30 or i ole sic 10 C iec SAE 10W30 type SE motor oil tives could cause clutch slippage EUU32400 Recommended engine oil classification API Service SE SF type or z EE enn ae equivalent Be
10. 5 Brake adjusting nut 3 Remove the rear brake pedal free play adjusting nut and brake rod from the brake cam lever 3 Locknut 2 Cotter pin 4 Chain adjusting nut 5 Alignment marks 1 Axle nut 4 Loosen the locknuts and chain adjust ing nuts on each side 5 Remove the axle nut cotter pin and the axle nut 6 Pull out the wheel axle and remove the wheel assembly EUU05600 NOTE You do not have to disassemble the chain in order to remove or install the rear wheel 8 39 EAJ34003 Rear wheel installation When installing the rear wheel reverse the removal procedure Pay attention to the following points 1 Adjust the drive chain 2 Tighten the following parts to the specified torque and make sure a new cotter pin is installed Tightening torque Axle nut 105 Nm 10 5 m kg 76 ft lb Tension bar bolt 23 Nm 2 3 m kg 17 ft lb EUU78000 44 WARNING Always use a new cotter pin 3 Adjust the rear brake pedal height and free play see page 8 19 EUU64500 A WARNING Check the operation of the brake light af ter adjusting the rear brake 8 40 EAJ50002 Troubleshooting Although Yamaha motorcycles receive a rigid inspection before shipment from the factory trouble may occur during opera tion Any problem in the fuel compression or ignition systems can cause poor starting and loss of power The troubleshooting chart describes a quick easy procedure for making checks l
11. Check for cracks warpage of the wheel be sure the spokes are tight and undamaged If any abnormal condition exists in a wheel consult a Yamaha dealer Do not attempt even small repairs to the wheel If a wheel is deformed or cracked it must be replaced 2 Tires and wheels should be balanced whenever either one is changed or re placed Failure to have a wheel bal anced can result in poor performance adverse handling characteristics and shortened tire life bends or 6 8 3 After installing a tire ride conserva tively to allow the tire to seat itself on the rim properly Failure to allow prop er seating may cause tire failure re sulting in damage to the motorcycle and injury to the rider EAE93900 Accessories or replacement parts EUU69700 4 WARNING This motorcycle is not designed to pull a trailer or to be attached to a sidecar The accessories or replacement parts you choose for your motorcycle should be de signed specifically for it and they must be securely mounted to maintain the inher ent stability of the original design Genu ine Yamaha Parts and Accessories are designed and tested to be compatible with your motorcycle Please consider Genuine Yamaha Parts and Accessories before making an accessory purchase Use of non Yamaha approved parts or acces sories may cause loss of handling stability and riding safety Since Yamaha cannot control the quality of parts or accessories manufacture
12. 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 you are qualified Also only lend your motorcycle to experienced op erators 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 your motorcycle and all of its con trols 1 2 Many motorcycle accidents have been caused by motorcycle operator errors A typ ical error made by the operator is veering wide on a turn due to EXCESSIVE SPEED or undercornering insufficient lean angle for the speed a Always obey the speed limits and never travel faster than warranted by road and traffic conditions b Always signal before turning or changing lanes Make sure other motorists see you The operator s and passenger s posture are important for proper control a The operator should keep both hands on the handlebars and both feet on the op erator footrests during operation to maintain control of the motorcycle b The passenger should always hold on to the operator or the seat strap or grab bar if the motorcycle is so 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 passen ger footrests Never
13. SE motor oil oil e Adjust free play Replace pads if a Brake necessary system front Replace shoes if necessary _ rear sjefen mre fT Oo Oo fT o play 8 7 Unit km mi INITIAL ODOMETER READINGS 4 2 3 ROUTINE 1 000 6 000 11 000 16 000 21 000 600 or 3 800 or 6 900 or 10 000 or 13 100 or 1 month 7 months 13 months 19 months 25 months e Check chain condition SAE 30W 50W motor e Adjust and oil Every 500 300 lubricate chain thoroughly Control Apply chain Yamaha chain and and meter lube cable lube or SAE cable thoroughly 10W30 motor oil e Check swingarm Swingarm assembly for Lithium soap base pivot shaft looseness grease e Moderately repack Yamaha chain and cable lube or SAE 10W30 motor oil Brake Clutch lever pivot shaft Brake pedal and shift pedal shaft Apply chain lube lightly Lubricate Yamaha chain and Apply chain cable lube or SAE lube lightly 10W30 motor oil e Check operation and Yamaha chain and lubricate cable lube or SAE e Apply chain 10W30 motor oil lube lightly Sidestand operation and leakage Unit km mi INITIAL ODOMETER READINGS ED 3 1 _ e Check 1 000 6 000 11 000 16 000 21 000 600 or 3 800 or 6 900 or 10 000 or 13 100 or 1 month 7 months 13 months 19 months 25 months bearings Steering ee
14. WARNING If brake fluid leakage is found ask a Yamaha dealer for immediate repairs Such leakage could indicate a hazardous condition 6 4 EAE20001 Clutch Check the free play in the clutch lever and make sure the clutch operates properly If the free play is incorrect adjust it See page 8 23 for details EAE30101 Throttle grip Turn the throttle grip to see if it operates properly and check the throttle cable free play See page 8 28 for details Make sure the grip returns by spring force when re leased Ask a Yamaha dealer to make any necessary adjustments EAE40003 Engine oil Make sure the engine oil is at the specified level Fill with oil as necessary See page 8 11 for details Recommended oll 30 F 40 F 50 F 60 F YAMALUBE 4 20W40 or SAE 20W40 type SE motor oil YAMALUBE 4 10W30 or SAE 10W30 type SE motor oil 0 C 5 C 10 C 15 C Recommended engine oil classification API Service SE SF type or equivalent e g SF SE SF SE CC SF SE SD etc Oil quantity Total amount 1 8L 1 6 Imp qt 1 9 US qt Periodic oil change 1 4 L 1 2 Imp qt 1 5 US at With oil filter replacement 1 6 L 1 4 Imp qt 1 7 US at 6 5 EAE50001 Chain Check the general condition of the chain and the chain slack before every ride Lu bricate and adjust the chain as necessary See page 8 24 for details EAE90102 Tires To ensure m
15. dealer EUU34400 Do not use fuses of higher amperage rat ing than those recommended Substitu tion of a fuse of improper rating can cause extensive electrical system damage and possibly a fire Specified fuse Main 20A Signal 10A EAI83501 Replacing the headlight bulb If the headlight bulb burns out replace the bulb as follows 1 Remove the headlight unit assembly 2 Disconnect the headlight leads and remove the cover 8 34 EUU66001 WARNING Keep flammable products and your hands away from the bulb while it is on as it is hot Do not touch the bulb until it cools down 4 Put a new bulb into position and se cure it in place with the bulb holder 5 Install the cover 1 Cover 2 Connedor 6 Reconnect the headlight leads 3 Turn the bulb holder counterclockwise 7 Install the headlight unit assembly If and remove the defective bulb the headlight beam adjustment is nec essary ask a Yamaha dealer to make adjustment 1 Bulb holder 8 35 EAJ24403 Front wheel removal EUU66202 WARNING e It is advisable to have a Yamaha dealer service the wheel Securely support the motorcycle so there is no danger of it falling over 1 Remove the speedometer cable from the front wheel side 1 Speedometer cable 2 Loosen the pinch bolt and wheel axle 8 36 1 Pinch bolt 2 Wheel axle 3 Elevate the front wheel by placing a suitable stand under th
16. during your entire Y E S plan period e Y E S coverage is honored at any authorized Yamaha dealer nationwide e Y E S coverage is transferrable to a new owner if you sell or trade in That can make your Yamaha much more valuable This excellent Y E S plan coverage is only available to Yamaha owners like you and only while your Yamaha is still within the Yamaha Limited Warranty period So visit your authorized Yamaha dealer to get all the facts He can show you how easy it is to protect your investment with Yamaha Extended Service We urge you to act now You ll get the excellent benefits of TRIP coverage right away and you ll rest easy knowing you ll have strong factory backed protection even after your Yamaha Limited Warranty expires You can also save money Y E S costs less within the first 90 days after you buy your Yamaha See your dealer today A special note If visiting your dealer isn t convenient contact Yamaha with your Primary ID number your engine number We ll be happy to help you get the Y E S coverage you need Yamaha Service Marketing P O Box 6555 Cypress CA 90630 714 761 7631 v YAMAHA EXTENDED SERVICE
17. extreme caution when selecting and installing any acces sories Keep in mind these guidelines for mounting accessories in addition to those provided under LOADING 1 6 1 Never install accessories or carry cargo that would impair the performance of your motorcycle Carefully inspect the accessory before using it to make sure it does not in any way reduce ground clearance or cornering clearance limit suspension travel steering travel or control operation or obscure lights or reflectors Accessories fitted to the handlebar or the front fork area can create 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 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 motorcy cle may become unstable in cross winds These accessories may also cause insta bility when being passed by or passing large vehicle Certain accessories can displace the operator from his or her normal riding posi tion This improper position limits the freedom of movement of the operator and may limit control ability Therefore such accessories are not recommended Caution must be used if adding electrical accessories If these accessories exceed the capacity of the motorcycle s electrical system an electric
18. 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 off the engine when refueling b Take care not to spill any gasoline on the engine or exhaust pipe s muffler s 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 poisonous and may cause loss of consciousness and death within a short time Always operate your motorcycle in an area that has adequate ventilation Always turn off the engine before leaving the motorcycle unattended and remove the ignition key When parking the motorcycle note the following a The engine and exhaust pipe s muffler s may be hot Park the motorcycle in a place where pedestrians or children are not likely to touch these hot areas b Do not park the motorcycle on a slope or soft ground the motorcycle may fall over c Do not park the motorcycle near a flammable source e g a kerosene heater or near an open flame The motorcycle could catch fire 1 8 4 When transporting the motorcycle in another vehicle be sure it is kept upright and that the fuel cock s is turned to ON or RES for vacuum type OFF for manual type If it should lean over gasoline may leak out of the carburetor or fuel tank 5 If you should swallow any gasolin
19. sure no foreign material enters the e g SF SE SF SE CC crankcase SF SE SD etc Se ge ee ens eee Oil quantity h Start the engine and warm up for a Total amount few minutes While warming up 1 8 L 1 6 Imp at 1 9 US qt check for oil leakage If oil leakage is Periodic oil change found stop the engine immediately 1 4 L 1 2 Imp at 1 5 US at and check for the cause With oil filter replacement 1 6 L 1 4 Imp qt 1 7 US qt 8 14 EAH69001 Air filter The air filter should be cleaned at the spec ified intervals It should be cleaned more frequently if you are riding in unusually wet or dusty areas 1 Remove the air filter case assembly 8 15 3 Remove the air filter from its case and clean it with solvent After cleaning remove the remaining solvent by squeezing the air filter roe m 4 CH Ane y t a ERINE EI A ema EAE KERA EREN ETNE Se AN E A EAA e ds WAS ss Shae Neier me bebat ESE Pen Ly SAA AAE K Bae AES y pear PES Se 1 Air filter 2 Element guide 4 Apply recommended oil to the entire surface of the air filter and squeeze out the excess oil It should be wet but not 1 Wing nut dripping 2 Recommended oil Yamalube 4 10W30 or SAE 10W30 type SE motor oil 5 Install the air filter in its case and rein stall the air filter case assembly 8 16 EUU35702 Make sure the air filter is properly seated in the filter case EUU
20. system A C magneto Battery type GM10 3A 2 Battery voltage capacity 12 V 10 AH Bulb voltage wattage x quantity Headlight 12 V 65 W 60W x 1 Tail brake light 12V8W 27Wx1 Front flasher position light 12V27W 8Wx2 Rear flasher light 12V27Wx2 Meter light 12V3Wx 1 Neutral indicator light 12V3Wx 1 High beam indicator light 12V1 7W x 1 Turn indicator light 12V3Wx1 CONSUMER INFORMATION EALO00900 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 immediately inform the National Highway Traffic Safety Administra tion NHTSA in addition to notifying YAMAHA MOTOR CORP 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 CORP 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 Transpor tation Washington D C 20590 You can also obtain other information about motor vehicle safety from the Hotline 11 1 EAL00300 Motorcycle noise regulation TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the following acts or the causing thereof 1 The removal or render ing inoperati
21. the outer housing of cables may allow internal rusting and cause in terference with cable movement Replace damaged cables as soon as possible to prevent unsafe conditions Lubricate the inner cable and the cable end If it does not operate smoothly ask a Yamaha dealer to replace them Recommended lubricant Yamaha Chain and Cable Lube or SAE 10W30 motor oil 8 28 EAI10201 Throttle cable and grip lubrication The throttle twist grip assembly should be greased at the time that the cable is lubri cated since the grip must be removed to get at the end of the throttle cable After re moving the screws hold the end of the ca ble up in the air and put in several drops of lubricant With the throttle grip disassem bled coat the metal surface of the grip as sembly with a suitable all purpose grease EAI30202 Brake and shift pedal lubrication Lubricate the pivoting parts Recommended lubricant Yamaha Chain and Cable Lube or SAE 10W30 motor oil EAI30301 Brake and clutch lever lubrication Lubricate the pivoting parts Recommended lubricant Yamaha Chain and Cable Lube or SAE 10W30 motor oil EAI31202 Sidestand lubrication Lubricate the sidestand pivoting and mat ing parts Check to see that the sidestand moves up and down smoothly Recommended lubricant Yamaha Chain and Cable Lube or SAE 10W30 motor oil EUU70401 4 amp 4 WARNING If the sidestand does not move smoothly cons
22. 01 Checking the front brake pads and rear brake shoes A wear indicator is provided on each brake This indicator allows checking of brake pad shoe wear without disassem bling the brake 8 21 EAH87401 FRONT Apply the brake and inspect the wear indi cator If the brake pads are worn to the wear limit have a Yamaha dealer replace the pads j j j g Z Z Z g Z 1 Wear limit 0 8 mm 0 031 in 2 Wear indicator EAH82601 REAR Apply the brake and inspect the wear indi cator If the indicator reaches the wear limit line ask a Yamaha dealer to replace the shoes 2 Wear limit 1 Wear indicator EAH88203 Inspecting the brake fluid level Insufficient brake fluid may let air enter the brake system possibly causing the brakes to become ineffective Before riding check that the brake fluid is above the minimum level and fill when necessary Observe these precautions 1 When checking the fluid level make sure the top of the master cylinder is level by turning the handlebars 8 22 2 Use only the designated quality brake fluid Otherwise the rubber seals may deteriorate causing leakage and poor brake performance Recommended brake fluid DOT 4 EUU13100 NOTE gt lf DOT 4 is not available DOT 3 can be used 3 Refill with the same type of brake flu id Mixing fluids may result in a harm ful chemical reaction and lead to poor brake performance Be careful that wa
23. 02 Starting a warm engine The starter CHOKE is not required when the engine is warm EUU31401 See the Engine break in section prior to operating the motorcycle for the first time EAF20003 Shifting The transmission lets you control the amount of power you have available at a given speed for starting accelerating climbing hills etc The use of the shift ped al is shown in the illustration Page 5 5 To shift into neutral depress the shift ped al repeatedly until it reaches the end of its travel then raise the pedal slightly EUU31501 2 Donot coast for long periods with the engine off and do not tow the motor cycle a long distance Even with gears in neutral the transmission is only properly lubricated when the engine is running Inadequate lubrication may damage the transmission Always use the clutch when changing gears The engine transmission and driveline are not designed to with stand the shock of forced shifting and can be damaged by shifting without using the clutch 7 6 EAF20101 To start out and accelerate 1 Pull the clutch lever to disengage the clutch Shift into first gear The neutral indica tor light should go out Open the throttle gradually and at the same time release the clutch lever slowly At the recommended shift point in the table below close the throttle and at the same time quickly pull in the clutch lever Shift into second gear
24. 3 Clutch lever free play adjustment 8 23 Drive chain slack Check cs0s000 8 24 Drive chain slack adjustment 8 25 Drive chain lubrication ccsseee 8 27 Cable inspection and lubrication 8 28 Throttle cable and grip lubrication 8 28 Brake and shift pedal lubrication 8 28 Brake and clutch lever lubrication 8 29 Sidestand lubrication ccceesseeeees 8 29 Front fork INSPECTION cccceseeeeeeeeeees 8 29 Steering INSPECTION c0csecceesessseeeees 8 30 Wheel De aringS scccccesessssesssseeeees 8 31 SAUCONY or 8 31 Fuse replacement ccccssseceesseneees 8 33 Replacing the headlight bulb 8 34 Front wheel removal cseeeeeeeeees 8 36 Front wheel installation 0 000 8 37 Rear wheel removal cccececcecereeceees 8 38 Rear wheel installation 0 cc000 8 39 Troubleshooting scceeeeeeeeeeeeenees 8 40 Troubleshooting chart ccccceeeeeeee 8 41 CLEANING AND STORAGE cseeeee 9 1 A Cleaning sscsceeeees iede ai 9 1 SLO AGC aeea 9 2 SPECIFICATIONS assioni 10 1 CONSUMER INFORMATION 006 11 1 Reporting safety defects 000 11 1 Motorcycle noise regulation 11 2 Maintenance record ceeeeeeeee 11 3 Street and enduro motorcycle limited Warranty ccccsssccessesseeeeeees 11 5 Yamaha extended Service 00005 11 7 EUU
25. 31100 1 Be careful where you store personal items on the motorcycle Avoid block ing the air cleaner intake or perfor mance will suffer Be careful not to put anything near the battery and its terminals Electrical failure and acid corrosion may result EAF18702 Starting and warming up a cold engine EUU02801 NOTE This motorcycle is equipped with an igni tion circuit cut off system 1 The engine can be started only under the following conditions a The transmission is in neutral b The sidestand is up the transmission is in gear and the clutch is disengaged 2 The motorcycle must not be ridden when the sidestand is down 7 2 EUU69200 A WARNING Before going through the following steps check the function of the sidestand switch and clutch switch Refer to page 5 12 TURN THE MAIN SWITCH TO ON AND THE ENGINE STOP SWITCH TO RUN IF TRANSMISSION IS IN NEUTRAL AND IF TRANSMISSION IS IN GEAR AND SIDESTAND IS DOWN SIDESTAND IS UP PUSH THE START SWITCH PULL IN THE CLUTCH LEVER AND PUSH ENGINE WILL START THE START SWITCH ENGINE WILL START RETRACT SIDESTAND AND PUT TRANSMISSION IN GEAR MOTORCYCLE CAN BE RIDDEN MOTORCYCLE CAN BE RIDDEN 1 Turn the main switch to ON and the engine stop switch to RUN 2 Shift the transmission into neutral EUU03001 NOTE When the transmission is in neutral the neutral indicator light should be on If the light d
26. 42401 The engine should never be run without the air filter installed Excessive piston and or cylinder wear may result EAH90201 Carburetor adjustment The carburetor is a vital part of the engine and its emission control system Adjusting should be left to a Yamaha dealer with the professional knowledge specialized data and equipment to do so properly 8 17 EAH90801 Valve clearance adjustment The correct valve clearance changes with use resulting in improper fuel air supply or engine noise To prevent this the valve clearance must be adjusted regularly This adjustment however should be left to a professional Yamaha service technician EAH80103 Front brake lever free play adjustment The free play at the front brake lever should be 2 5 mm 0 08 0 2 in 1 Loosen the locknut 2 Turn the adjusting bolt so that the brake lever movement is 2 5 mm 0 08 0 2 in before the bolt contacts the master cylinder piston 3 After adjusting tighten the locknut EUU81500 WARNING Check the brake lever free play Be sure the brake is working properly e A soft or spongy feeling in the brake lever can indicate the presence of air in the brake system This air must be removed by bleeding the brake sys tem before the motorcycle is operat ed Air in the system will cause 1 Locknut 2 Adjusting bolt a 2 5 mm 0 08 0 2 in greatly diminished braking capability and can result in loss of control and an
27. 75301 SAFETY INFORMATION TWO WHEELED 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 HE OR SHE SHOULD 1 OBTAIN THOROUGH INSTRUCTIONS FROM A COMPETENT SOURCE ON ALL AS PECTS OF MOTORCYCLE OPERATION 2 OBSERVE THE WARNINGS AND MAINTENANCE REQUIREMENTS IN THE OWNER S MANUAL 3 OBTAIN QUALIFIED TRAINING IN SAFE AND PROPER RIDING TECHNIQUES 4 OBTAIN PROFESSIONAL TECHNICAL SERVICE AS INDICATED BY THE OWNER S MANUAL AND OR WHEN MADE NECESSARY BY MECHANICAL CONDITIONS 1 Always make pre operation checks Careful checks may help prevent an accident 2 This motorcycle is designed to carry the operator and a passenger 3 The failure of motorists to detect and recognize motorcycles in traffic is the predom inating 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 acci dent Therefore a Wear a brightly colored jacket b Use extra caution when you approach and pass through intersections since inter sections are the most likely places for motorcycle accidents c Ride where other motorists can see you Avoid riding in another motorist s blind spot 4
28. E 4 10W30 or SAE10W30 type SE motor oil If temperature does not go above 15 C 60 F 1 4 L 1 2 Imp qt 1 5 US qt 1 6 L 1 4 Imp qt 1 7 US qt 1 8 L 1 6 Imp qt 1 9 US qt Wet type element Unleaded fuel XV250 9 5L 2 1 Imp gal 2 XV250C 9 2L 2 0 Imp gal 2 2 6 L 0 6 Imp gal 0 7 US gal BDS26 1 MIKUNI Spark plug Type Manufacturer Spark plug gap Clutch type Transmission Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Transmission type Operation Gear ratio Chassis Frame type Caster angle Trail C6HSA U20FS U NGK DENSO 0 6 0 7 mm 0 024 0 028 in Wet multiple disc 10 3 Spur gear 72 23 3 130 Chain drive 45 16 2 813 Constant mesh 5 speed Left foot operation 37 14 2 643 32 19 1 684 29 23 1 261 26 26 1 000 23 28 0 821 Double cradle 32 120 mm 4 7 In Ma a XV250 XV250C With tube front 3 00 18 47P rear 130 90 15M C 66P Brake Front brake type Single disc brake operation Right hand operation Rear brake type Drum brake operation Right foot operation Suspension Front suspension Telescopic fork Rear suspension Swingarm Shock absorber Front shock absorber Coil spring Oil damper Rear shock absorber Coil spring Oil damper Wheel travel Front wheel travel 140 mm 5 5 in Rear wheel travel 100 mm 3 9 in 10 4 XV250 XV250C Electrical Ignition system T C I Digital Generator
29. ING instructions could result in severe injury or death to the motorcycle operator a bystander or a person inspect ing or repairing the motorcycle 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 clear er EUU00001 NOTE e a ee er This manual should be considered a permanent part of this motorcycle and should re main 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 there is any question concerning this manual please consult your Yamaha dealer EUU60001 4 WARNING PLEASE READ THIS MANUAL AND THE YOU AND YOUR MOTORCYCLE RIDING TIPS BOOKLET CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE DO NOT ATTEMPT TO OPERATE THIS MOTORCYCLE UNTIL YOU HAVE ATTAINED A SATIS FACTORY KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES REGULAR IN SPECTIONS AND CAREFUL MAINTENANCE ALONG WITH GOOD RIDING SKILLS WILL ENSURE THAT YOU SAFELY ENJOY THE CAPABILITIES AND THE RELIABILITY OF THIS MOTORCYCLE CONTENTS SAFETY INFORMATION osais 1 1 SPL DOC AN lonon 5 5 Front brake
30. Lithium soap base bearings 3 grease e Moderately repack every 15 000 9 000 Wheel bearings bearings for smooth rotation Check specific gravity and breather pipe for proper operation Check and clean or replace if necessary Sidestand switch 1 If ambient temperature does not go below 5 C 40 F 2 If ambient temperature does not go above 15 C 60 F Items marked with an asterisk require special tools data and technical skills for servicing Take the motorcycle to a Yamaha Dealer or refer to the Service Manual when servicing these items NOTE a eee For farther odometer reading repeat the above maintenance at the period established 1 Every 5 000 km 3 100 mi 2 Every 10 000 km 6 200 mi and 3 Every 15 000 km 9 000 mi intervals 8 10 EAH44703 Engine oil 1 Oil level inspection a Place the motorcycle on a level place and hold it in an upright position Warm up the engine for several min utes EUU03901 INO a a Be sure the motorcycle is positioned straight up when checking the oil level A i 1 Level window 2 Maximum mark slight tilt toward the side can result in false BC Minana readings EUU04000 NOTE b With the engine stopped check the oil level through the level window locat ed at the lower part of the right side Se ee crankcase cover c The oil level should be between maxi mum and minimum marks If the level
31. NING Never ride with a helmet in the helmet holder The helmet may hit objects caus ing loss of control and possibly an acci dent EUU01700 NOTE oo Make sure that the seat is securely fitted EAD30101 Sidestand This model is equipped with an ignition circuit cut off system The motorcycle must not be ridden when the sidestand is down The sidestand is located on the left side of the frame Refer to page 7 2 for an explanation of this system EUU68901 4 WARNING This motorcycle must not be operated with the sidestand in the down position If the stand is not properly retracted it could contact the ground and distract the opera tor resulting in a possible loss of control Yamaha has designed into this motorcycle a lockout system to assist the operator in fulfilling the responsibility of retracting the sidestand Please check carefully the operating instructions listed below and if there is any indication of a malfunction re turn the motorcycle to a Yamaha dealer immediately for repair EAD30802 Sidestand clutch switch operation check CLUTCH SWITCH IS OK Check the operation of the sidestand switch and clutch switch against the infor mation below SIDESTAND IS DOWN TURN THE MAIN SWITCH TO ON AND THE ENGINE STOP SWITCH TO RUN ENGINE WILL STALL TRANSMISSION IS IN GEAR AND SIDESTAND SWITCH IS OK SIDESTAND IS UP EUU69100 4 WARNING PULL IN CLUTCH LEVER AND If improper operati
32. RRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE YAMAHA MOTOR CORPORATION U S A P O Box 6555 Cypress California 90630 gt o gt o WARRANTY QUESTIONS AND ANSWERS What costs are my responsibility during the warranty period The customer s responsibility includes all costs of normal maintenance services non warranty repairs accident and collision damage and oil oil filters air filters spark plugs and brake shoes or pads What are some examples of abnormal strain neglect or abuse These terms are general and overlap each other in areas Specific examples include Running the machine out of oil sustained high rpm full throttle use operating the machine with a broken or damaged part which causes another part to fail damage or failure due to improper or careless transporation and or tie down and so on If you have any specific questions on operation or maintenance please contact your dealer for advice Does the warranty cover incidental costs such as towing or transportation due to a failure No The warranty is limited to repair of the machine itself May I perform any or all of the recommended maintenance shown in the Owner s Manual instead of having the dealer do them Yes if you are a qualified mechanic and follow the procedures specified in the Owner s and Service Manual We do recommend however that items requiring special tools or equipment be
33. accident Have a Yamaha dealer in spect and bleed the system if neces sary 8 18 EAH87 105 Rear brake pedal height and free play ad justment EUU64301 WARNING It is advisable to have a Yamaha dealer make this adjustment 1 Pedal height a Loosen the locknut b Turn the adjusting bolt so that the top of the brake pedal is approximately 60 mm 2 4 in above the top of the foot rest c Tighten the locknut 1 Footrest 2 Pedal height 60 mm 2 4 in 3 Free play 20 30 mm 0 8 1 2 in 1 Locknut 2 Adjusting bolt for pedal height 8 19 EUU64400 EUU69800 A WARNING A WARNING After adjusting the pedal height adjust 1 The rear brake pedal adjustment must brake pedal free play be checked whenever the chain is ad 2 Free play justed or the rear wheel is removed Turn the adjusting nut so that the free and then reinstalled play at the end of the brake pedal is 2 Check the operation of the brake light approximately 20 30 mm 0 8 1 2 after adjusting the rear brake in EAH83301 Brake light switch adjustment The brake light switch is operated by movement of the brake pedal To adjust hold the main body of the switch so it does not rotate and turn the adjusting nut Prop 7 er adjustment is achieved when the brake Saaana paaa aa iff light comes on just before the brake be Mie 7 gins to take effect 1 Adjusting nut 8 20 1 Main body 2 Adjusting nut EAH814
34. ance its appear ance but will improve its general performance and extend the useful life of many components 1 Before cleaning the motorcycle a Block off the end of the exhaust pipes to prevent water entry a plastic bag and strong rubber band may be used b Make sure the spark plugs and all filler caps are properly installed 2 If the engine case is excessively greasy apply degreaser with a paint brush Do not apply degreaser to the chain sprockets or wheel axles 3 Rinse the dirt and degreaser off with a garden hose Use only enough pres sure to do the job 9 1 EUU34602 Excessive hose pressure may cause water seepage and deterioration of wheel bear ings front fork brakes transmission seals and electrical parts Many expensive repair bills have resulted from improper high pressure detergent applications such as those available in coin operated car washers 4 Once the majority of the dirt has been hosed off wash all surfaces with warm water and mild detergent type soap An old toothbrush or bottle brush is handy for hard to get at plac es 5 Rinse the motorcycle off immediately with clean water and dry all surfaces with a chamois clean towel or soft absorbent cloth 6 Dry the chain and lubricate it to pre vent rust 7 Clean the seat with a vinyl upholstery cleaner to keep the cover pliable and glossy 8 Automotive type wax may be applied to all painted and chrome plated sur faces Avo
35. aximum performance long service and safe operation note the fol lowing 1 Tire air pressure Always check and adjust the tire pres sure before operating the motorcycle EUU67500 WARNING Tire inflation pressure should be checked and adjusted when the temperature of the tire equals the ambient air temperature Tire inflation pressure must be adjusted according to total weight of cargo rider passenger and accessories fairing sad dlebags etc if approved for this model and vehicle speed Basic weight 147 kg 324 Ib XV250 With oil and full fuel tank 148 kg 326 Ib XV250C 196 kg 431 Ib XV250 195 kg 429 Ib XV250C Maximum load Cold tire pressure 175 kPa 200 kPa Up to 90 kg 198 Ib load 1 75 kgf cm 2 0 kgf cm 25 psi 29 psi 200 kPa 225 kPa So A 2 0 kgf cm2 2 25 kgf cm2 Maximum load 29 psi 33 psi Load is the total weight of cargo rider passenger and accessories 6 6 EUU67701 WARNING Proper loading of your motorcycle is im portant for several characteristics of your motorcycle such as handling braking performance and safety Do not carry loosely packed items that can shift Se curely pack your heaviest items close to the center of the motorcycle and distrib ute the weight evenly from side to side Properly adjust the suspension for your load and check the condition and pres sure of your tires NEVER OVERLOAD YOUR MOTORCYCLE Make su
36. cenentemtenaseseenre 6 5 Periodic maintenance eseeseeeeee 8 1 WV ICONS sesira 6 8 TOOW Ki Coremans a 8 2 Accessories or replacement parts 6 8 Periodic maintenance emission Chassis fasteners cccceeeeeeeeeeeeeeeeeeeees 6 9 CONLEON SYSTE Mhirsa 8 3 Lights signals and switches 6 9 Spark plug inspection ccees 8 4 BAUS Menaio eects 6 9 Canister for California only 8 5 Fel ecrecec seca secndni tate ecatessaasauiaestemeeeecnce 6 10 General maintenance lubrication 8 7 ENGINE Ol cccisscapaduasienigess eee 8 11 OPERATION AND IMPORTANT Alr TCO P ariana thames nectaaae 8 15 RIDING POINTS tisinitesecscvtinsencesernsanaesstendes 7 1 Carburetor adjustment seeceeeee 8 17 Starting and warming up a cold Valve clearance adjustment 8 17 eNO Esai tees 7 2 Front brake lever free play Starting a warm engine eeeeeeeeeee ee 7 5 AC OSUMONE aninion as 8 17 SANO ucgan aa 7 5 Rear brake pedal height and free To start out and accelerate 4 7 6 play adjustment sssssssssssserssrssnssnns 8 19 TO d celeral Cossin 7 7 Brake light switch adjustment 8 20 Recommended shift point 7 7 Checking the front brake pads Engine reak iN ivcsvenisensanteeiedeetccctsstiantes 7 7 and rear brake shoes ssassn 8 21 Parkin ae 7 8 Inspecting the brake fluid level 8 22 Brake fluid replacement 2s000 8 2
37. cle is designed built and equipped so as to conform at the time of sale with all U S emissions standards applicable at the time of manufacture and that it is free from defects in materials and workmanship which would cause it not to meet these standards within the periods listed immediately below Failure other than those resulting from defects in material or workman ship which arise solely as a result of owner abuse and or lack of proper maintenance are not covered by this warranty ENGINE DISPLACEMENT 50cc to 169cc PERIOD 12 000 km 7 465 miles or five years whichever occurs first 170cc to 279cc 18 000 km 11 185 miles or five years whichever occurs first 280cc or over 30 000 km 18 641 miles or five years whichever occurs first YAMAHA MOTOR CORPORATION U S A MAKES NO OTHER WARRANTY OF ANY KIND EXPRESSED OR IMPLIED ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS AND TIME LIMITS STATED IN THIS WARRANTY ARE HEREBY DISCLAIMED BY YAMAHA MOTOR CORPORATION U S A AND EXCLUDED FROM THIS WARRANTY SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU ALSO EXCLUDED FROM THIS WARRANTY ARE ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF USE SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES SO THE ABOVE EXCLUSION MAY NOT APPLY TO YOU THIS WA
38. d should be checked at least once a month The level should be between the minimum level and maximum level marks Use only distilled water if refilling is necessary UPPER LEVEL LOWER LEVEL 1 Maximum level 2 Minimum level EUU33800 Normal tap water contains minerals which are harmful to a battery therefore refill only with distilled water EUU65901 WARNING Take care not to spill battery fluid on the chain Battery fluid may weaken the chain causing shorter chain life and possibly re sult in an accident Storage 1 When the motorcycle will not be used for a month or longer remove the bat tery and store it in a cool dark place Completely recharge the battery be fore reinstallation If the battery will be stored for longer than two months check the specific gravity of the fluid at least once a month and recharge the battery when it is too low 8 33 Always make sure the connections are correct when putting the battery back in the motorcycle Make sure the breather pipe is properly connected and is not damaged or obstructed EAI93402 Fuse replacement 1 The fuse cases are located under the rider seat 1 Main fuse 2 Signal fuse 2 If a fuse is blown turn off the main switch and the switch of the circuit in question Install a new fuse of speci fied amperage Turn on the switches and see if the electrical device oper ates If the fuse immediately blows again consult a Yamaha
39. d by other companies Yamaha cannot be held liable for any con sequences caused by the use of items which have not been approved by Yamaha EAE85101 Chassis fasteners Always check the tightness of all chassis nuts bolts and screws before a ride Take the motorcycle to a Yamaha dealer or refer to the Service Manual for correct tighten ing torque 6 9 EAE71500 Lights signals and switches Check all the lights meter lights and indi cator lights to make sure they are in work ing condition Check the operation of the handlebar switches and main switch EAE70501 Battery Check the fluid level and fill if necessary Use only distilled water if refilling is neces sary see page 8 31 for details EAE80000 Fuel Make sure there is sufficient fuel in the tank EUU61000 A WARNING Do not overfill the fuel tank Avoid spilling fuel on the hot engine Do not fill the fuel tank above the bottom of the filler tube as shown in the illustration or it may over flow when the fuel heats up later and ex pands 2 Fuel level 1 Filler tube 6 10 EUU39302 Always wipe off spilled fuel immediately with a dry and clean soft cloth Fuel may deteriorate painted surfaces or plastic parts EAE81701 Recommended fuel UNLEADED FUEL Fuel tank capacity Total XV250 9 5 L 2 1 Imp gal 2 5 US gal XV250C 9 2 L 2 0 Imp gal 2 4 US gal Reserve 2 6 L 0 6 Imp gal 0 7 US gal Your Yamaha engi
40. done by a Yamaha motorcycle dealer Will the warranty be void or cancelled if do not operate or maintain my new motorcycle exactly as specified in the Owner s Manual No The warranty on a new motorcycle cannot be voided or cancelled However if a particular failure is caused by operation or maintenance other than as shown in the Owner s Manual that failure may not be covered under warranty What responsibility does my dealer have under this warranty Each Yamaha motorcycle dealer is expected to 1 Completely set up every new machine before sale 2 Explain the operation maintenance and warranty requirements to your satisfa tion at the time of sale and upon your request at any later date In addition each Yamaha motorcycle dealer is held responsible for his setup service and warranty repair work Is the warranty transferable to second owners Yes The remainder of the existing warranty can be transferred upon request The unit has to be inspected and re registered by an authorized Yamaha motorcycle dealer for the warranty coverage to remain effective CUSTOMER SERVICE If your machine requires warranty service you must take it to any authorized Yamaha motorcycle dealer within the continental United States Be sure to bring your warranty registration identification or other valid proof of the original date of purchase If a question or problem arises regarding warranty first contact the owner of the dealership S
41. e inhale a lot of gasoline vapor or allow gasoline to get in your eye s see your doctor immediately If any gasoline spills on your skin or clothing immediately wash it off with soap and water and change your clothes EAA40000 LOCATION OF THE IMPORTANT LABELS Please read the following labels carefully before operating this motorcycle 2 2 1 D A WARNING BEFORE YOU OPERATE THIS VEHICLE READ THE OWNER S MANUAL AND ALL LABELS ALWAYS WEAR AN APPROVED MOTORCYCLE HELMET eye protection and protective clothing 3MX 2118K 00 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 Be sure to connect breather hose after installing battery YAMAHA 3JL 28177 00 TIRE INFORMATION Cold tire normal pressure should be set as follows Up to 90 kg 198 Ibs load 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 cm2 29 psi REAR 225 kPa 2 25 kgf cm 33 psi 3CK 21668 00 EAA50000 DESCRIPTION SIS x a A CA A ea Se AE Lae CR A Pe P E e NN YY O a rf Cio CD 15 16 16 18 1 Tail Brake light 11 Rear wheel 2 Rear flasher light 12 Main switch C 3 Seat 13 Shift pedal DAN LR 4 Air filter 14 Front wheel 2 INY O M N 5 Front flashe
42. e engine Remove the wheel axle and the front wheel Make sure the motorcycle is properly supported EUU05401 NOTE S Do not depress the brake lever when the disc and caliper are separated 4 EAJ83201 Front wheel installation 3 Make sure the slot in the soeedometer When installing the front wheel reverse gear unit fits over the stopper on the the removal procedure Pay attention to front fork outer tube the following points 1 Make sure the wheel hub and the speedometer gear unit are installed with the projections meshed into the slots 4 Tighten the wheel axle to the specified torque Tightening torque Wheel axle 59 Nm 5 9 m kg 43 ft lb 2 Make sure there is enough gap be tween the brake pads before inserting the brake disc 8 37 Before tightening the pinch bolt push down hard on the handlebars several times to check for proper fork opera tion Tighten the pinch bolt to the specified Elevate the rear wheel by placing a suitable stand under the engine Remove the cotter pin nut and ten sion bar bolt from the brake shoe plate torque Tightening torque Pinch bolt 20 Nm 2 0 m kg 14 ft lb EAJ31204 Rear wheel removal EUU66202 A WARNING It is advisable to have a Yamaha dealer service the wheel e Securely support the motorcycle so there is no danger of it falling over 2 Cotter pin 4 Brake rod 1 Tension bar 3 Nut tension bar bot
43. er air fuel mixture A separate starter circuit sup plies this mixture Move in direction to turn on the starter Move in direction to turn off the starter 1 Starter CHOKE EAC30201 Steering lock To lock the steering turn the handlebars all the way to the right Open the steering lock cover turn the key 1 8 counterclock wise then push the key in and turn it 1 8 turn clockwise After checking to see that the steering is locked remove the key from the lock and close the cover To release the lock reverse the above procedure 5 8 EAC41502 Seat To remove the rider seat remove the bolts EAI50902 Rear shock absorber adjustment Each shock absorber is equipped with a spring preload adjuster Adjust spring preload as follows Turn adjuster in direction to increase spring preload and in direction to de crease spring preload SA Standard position a Harder b Softer EUU65200 44 WARNING Always adjust each shock absorber to the same setting Uneven adjustment can cause poor handling and loss of stability EUU20700 NOTE o Ask a Yamaha dealer to make this adjust ment EAC50001 When reinstalling the rider seat insert the Helmet holder lobe on the seat front under the frame To open the helmet holder insert the key then tighten the bolts in the lock and turn it as shown To lock the helmet holder replace the holder in its Original position EUU72900 WAR
44. et surface and use a new gasket Wipe off any grime from the threads and tighten the spark plug to the specified torque Tightening torque Spark plug 12 5 Nm 1 25 m kg 9 0 ft lb EUU03802 NOTE if a torque wrench is not available when you are installing a spark plug a good esti mate of the correct torque is 1 4 to 1 2 turn past finger tight Have the spark plug tight ened to the specified torque as soon as possible 8 5 EAH92600 Canister for California only This model is equipped with a canister to prevent the discharging of fuel vapor into the atmosphere Before using this motor cycle be sure to check the following 1 Check each hose connection 2 Check each hose and canister for cracks or damage Replace if dam aged 3 Make sure the canister breather is not blocked Clean it if necessary Canister 2 cover Canister Canister breather GENERAL MAINTENANCE LUBRICATION Unit km mi ITEM ROUTINE TYPE 1 000 6 000 11 000 16 000 21 000 600 or 3 800 or 6 900 or 10 000 or 13 100 or 1 month 7 months 13 months 19 months 25 months 1 Yamalube 4 20W40 or SAE 20W40 type Warm up SE motor oil engine before 2 Yamalube 4 draining 10W30 or SAE 10W30 type SE motor oil fef ontiner Replace OT OT d o Wet type filter must be Yamalube 4 10W30 Air filter washed and or SAE 10W30 type damped with
45. f your motorcycle requires any repair bring it to a Yamaha dealer The skilled technicians at a Yamaha dealership have the tools experience and know how to properly service your motorcycle Use only genuine Yamaha parts on your mo torcycle Imitation parts may look like Yamaha parts but they are often inferior Consequently they have a shorter service life and can lead to expensive repair bills EAJ50200 Troubleshooting chart EUU66300 A WARNING Never check the fuel system while smoking or in the vicinity Have tank cap of an open flame breather inspected for california only Check canister hoses for bend kink pinch clog etc 1 Fuel Start Fuel check Turn cock to PRI Open tank cap Add f A uel to check internal Normal fuel OK pressure No start Go to compression check 2 Compression Compression No start Turn over Go to ignition check check fuel OK engine Unusually light or ee Have engine inspected Ignition check Fuel OK Replace spark Go to battery check Engine turns fast 4 Battery battery is good Fuel OK Have engine Battery check Compression OK No start Use electric starter inspected if applicable Engine turns slowly Have battery charged electrical problem and system inspected Ignition OK 8 41 EAK00000 CLEANING AND STORAGE EAK02001 A CLEANING Frequent thorough cleaning of your mo torcycle will not only enh
46. id combination cleaner waxes Many contain abrasives which may mar the paint or protective finish When finished start the engine and let it idle for several minutes EAK02500 B STORAGE Long term storage 60 days or more of your motorcycle will require some preven tive procedures to guard against deteriora tion After thoroughly cleaning the motorcycle prepare for storage as follows 1 Drain the fuel tank fuel lines and car buretor float bowl 9 2 2 Remove the empty fuel tank pour a cup of SAE 10W30 or 20W40 motor oil in the tank shake the tank to coat the inner surfaces thoroughly and drain off the excess oil Reinstall the tank 3 Remove the spark plugs pour about one tablespoon of SAE 10W30 or 20W40 motor oil in the spark plug holes and reinstall the spark plugs Turn the engine over several times ground spark plug leads to coat the cylinder walls with oil EUU66400 4 WARNING When using the starter motor to crank the engine remove the spark plug wires and ground them to prevent sparking 4 Remove the drive chain Thoroughly clean the chain with solvent and lubri cate it Reinstall the chain or store it in a plastic bag tied to frame for safe keeping 5 Lubricate all control cables 6 Block up the frame to raise both wheels off the ground 7 Tie a plastic bag over the exhaust pipe outlet to prevent moisture from enter Ing 8 If storing in a humid or salt air atmo sphere coa
47. in adjuster locknut Then tighten the axle nut to the specified torque Tightening torque Axle nut 105 Nm 10 5 m kg 76 ft lb 6 Insert a new cotter pin into the axle nut and bend the end of the cotter pin as shown If the notch in the axle nut and the cotter pin hole do not match tighten the nut slightly to align them 1 Cotter pin EUU64700 WARNING Always use a new cotter pin on the axle nut 7 Adjust the free play in the brake pedal EUU64500 A WARNING Check the operation of the brake light af ter adjusting the rear brake 8 27 EAl40201 Drive chain lubrication The chain consists of many parts which work with each other If the chain is not maintained properly it will wear out quick ly Therefore the chain must be serviced regularly This service is especially neces sary when riding in dusty areas 1 Use Yamaha Chain and Cable Lube or any brands of spray type chain lubri cant First remove all dirt and mud from the chain with a brush or cloth then spray lubricant between both rows of side plates and on all center rollers The chain should be lubricated every 500 km 300 mi To clean the chain remove it from the motorcycle dip it in solvent and clean out as much dirt as possible Take the chain out of the solvent and dry it Im mediately lubricate the chain to pre vent it from rusting EAI10101 Cable inspection and lubrication EUU64601 WARNING Damage to
48. ince all warranty matters are handled at the dealer level this person is in the best position to help you If you are still not satisfied and require additional assistance please write YAMAHA MOTOR CORPORATION U S A CUSTOMER RELATIONS DEPARTMENT P O Box 6555 Cypress California 90630 When contacting Yamaha Motor Corporation U S A don t forget to include any important information such as names addresses model engine serial number dates and receipts CHANGE OF ADDRESS The federal government requires each manufacturer of a motor vehicle to maintain a complete up to date list of all first purchasers against the possibility of a safety related defect and recall This list is compiled from the purchase registrations sent to Yamaha Motor Corporation U S A by the selling dealer at the time of your purchase If you should move after you have purchased your new motorcycle please advise us of your new address by sending a postcard listing your motorcycle model name engine serial number dealer number or dealer s name as it is shown on your warranty identification your name and new mailing address Mail to YAMAHA MOTOR CORPORATION U S A WARRANTY DEPARTMENT P O Box 6555 Cypress California 90630 This will ensure that Yamaha Motor Corporation U S A has an up to date registration record in accordance with federal law YAMAHA EXTENDED SERVICE Y E S Keep your Yamaha protected even after your warranty In addition
49. lever ccccccccccssesseeeeeeess 5 5 LOCATION OF THE IMPORTANT Rear brake pedal 5 5 LABELS arsin 2 1 Fuel tank Cap seannsasssssnnnnnnennnnnnnnnenoonnon 5 5 UCU COCK oen accaieacenseecnes 5 6 DESCRIPTION caian 3 1 Starter CHOKE sesersedeiiiscomvisaticscatcowe 5 7 Steering LOCK ccecceesesseeeeeeeeeeesereeenes 5 8 MOTORCYCLE IDENTIFICATION 4 1 Seal erenn 5 8 Identification numbers record 4 1 Helmet holder asnnnsnssnssennsnnnnrsnsnnnenennn 5 9 Key identification NUMDET ssaessseessseene 4 1 Rear shock absorber adjustment 5 10 Vehicle identification number 4 2 Sidestand csceceeees A EE AEE 5 11 Model ADC I scsitastecestc ct wate crdeusssaneateieiends 4 2 Sidestand clutch switch operation CHECK checsacuadedancenduisscunesnctedesshomecncaies 5 12 CONTROL FUNCTIONS 008 coments 5 1 Main SWITCH sicciccsseterasiceciccunsevetasswerveons 5 1 PRE OPERATION CHECKS ccceeee 6 1 Indicator lights seccetescictcsticesnatedarsiaentietins 5 2 DEAK CS aoccrinnanan as 6 3 SDE CCOMIELE LE osisssa 5 3 Brake fluid leakage Front 6 4 Handlebar switches ccccesssseseesseaes 5 3 CITC Wigatesndeissaed tuba E E 6 4 CIUTCH JOVEN ninnaa 5 4 TR PORIG ON ID cronniconorinna 6 4 Engine Ollessaan 6 4 PERIODIC MAINTENANCE AND Chaiheeser esehtvessatornetiiesscensaeneentantecaes 6 5 MINOR REPAIR ccccesseeeesseseeesesseeeeees 8 1 Tre S oere ncbee
50. ne must be avoided EAF32101 1 0 150 km 0 100 mi Avoid operation above 1 3 throttle Stop the engine and let it cool for 5 to 10 minutes after every hour of opera tion Vary the speed of the motorcycle from time to time Do not operate it at one set throttle position EUU32200 2 150 500 km 100 300 mi Avoid prolonged operation above 1 2 throttle Rev the motorcycle freely through the gears but do not use full throttle at any time 3 500 1 000 km 300 600 mi If any engine trouble should occur during the break in period consult a Yamaha dealer immediately Avoid cruising speeds in excess of 3 4 EAF40000 throttle Parking EUU32001 When parking the motorcycle stop the en SEALT gine and remove the ignition key EUU63000 After 1 000 km 600 mi of operation be A WARNING sure to replace the engine oil and oil filter a 4 1 000 km 600 mi and beyond The muffler and exhaust pipe are hot Park the motorcycle in a place where pedestri ans or children are not likely to touch the motorcycle Do not park the motorcycle on a slope or soft ground the motorcycle may overturn Avoid prolonged full throttle opera tion Vary speeds occasionally 7 8 EAHO0000 PERIODIC MAINTENANCE AND MINOR REPAIR EAHO0101 Periodic inspection adjustment and lubri cation will keep your motorcycle in the saf est and most efficient condition possible Safety is an obligation of the motorcycle owne
51. ne has been designed to use regular unleaded gasoline with a pump octane number R M 2 of 86 or higher or research octane number of 91 or higher If knocking or pinging occurs use a different brand of gasoline or premium un leaded fuel Unleaded fuel will give you longer spark plug life and reduced mainte nance cost If unleaded gasoline is not available then leaded regular gasoline can be used Gasohol There are two types of gasohol gasohol containing ethanol and that containing methanol Gasohol containing ethanol can be used if ethanol content does not exceed 10 Gasohol containing methanol is not recommended by Yamaha because it can cause fuel system damage or vehicle per formance problems 6 11 EAF00000 OPERATION AND IMPORTANT RIDING POINTS EUU67201 A WARNING 1 Before riding this motorcycle become thoroughly familiar with all operating controls and their functions Consult a Yamaha dealer regarding any control or function that you do not thorough ly understand Never start your engine or let it run for any length of time in a closed area The exhaust fumes are poisonous and can cause loss of consciousness and death within a short time Always op erate your motorcycle in an area with adequate ventilation 7 1 3 Before starting out always be sure the sidestand is up Failure to retract the sidestand completely can result in a serious accident when you try to turn a corner EUU
52. nia type only Exhaust system NOTE For farther odometer reading repeat the above maintenance at the period established 1 Every 5 000 km 3 100 mi and 2 Every 10 000 km 6 200 mi intervals 8 3 EAH20102 Spark plug inspection The spark plug is an important engine component and is easy to inspect The condition of the spark plug can indicate the condition of the engine Normally all spark plugs from the same engine should have the same color on the white insulator around the center elec trode The ideal color at this point is a me dium to light tan color for a motorcycle that is being ridden normally If one spark plug shows a distinctly different color there could be something wrong with the engine Do not attempt to diagnose such problems yourself Instead take the motorcycle to a Yamaha dealer You should periodically remove and inspect the spark plugs be cause heat and deposits will cause any spark plug to slowly break down and erode If electrode erosion becomes exces 8 4 sive or if carbon and other deposits are ex cessive you should replace the spark plug with the specified plug Specified spark plug C6HSA NGK or U20FS U DENSO Before installing any spark plug measure the electrode gap with a wire thickness gauge Adjust the gap to specification Ur 1 Spark plug gap Spark plug gap 0 6 0 7 mm 0 024 0 028 in When installing the spark plug always clean the gask
53. oes not come on ask a Yamaha dealer to inspect it 3 Turn on the starter CHOKE completely close the throttle grip 4 Start the engine by pushing the start switch and 7 4 EUU02501 NOTE n o uaaa If the engine fails to start release the start switch wait a few seconds then try again Each attempt should be as short as possi ble to preserve the battery Do not crank the engine more than 10 seconds on any one attempt 5 After starting the engine move the starter CHOKE back to the half way position EUU02600 NOTE u For maximum engine life always warm up the engine before starting off Never accel erate hard with a cold engine 6 After warming up the engine turn off the starter CHOKE completely EUU03100 NOTE a ee The engine is warm when it responds nor mally to the throttle with the starter turned off To avoid the possibility of excessive exhaust emissions never leave the starter circuit on longer than necessary The length of time the starter is needed de pends upon the ambient temperature Warm ambient temperatures above 10 C 50 F require about 25 seconds of starter use Cold ambient temperatures below 10 C 50 F require about 35 sec onds with the starter fully open then about 2 5 minutes with the starter in the half open position For maximum engine life always warm up the engine before starting off Never accelerate hard with a cold en gine 7 5 EAF 108
54. on is noted consult a PUSH THE START SWITCH Yamaha dealer immediately ENGINE WILL START 5 12 PRE OPERATION CHECKS Before using this motorcycle check the following points ITEM ROUTINE e Check operation free play fluid level and fluid leakage Fill with DOT 4 or DOT 3 brake fluid if necessary Rear brake Check operation condition and free play Adjust if necessary e Check operation condition and free play cutee e Adjust if necessary ot esa oe RE 6 4 6 5 e Check engine oil level fill with oil if necessary 8 11 8 14 e Check chain slack and condition Drive chain e Adjust if necessary O AET RAI 6 3 6 4 8 17 8 23 e Check for smooth operation e Adjust if necessary 6 4 8 28 e Check fluid level fill with distilled water if necessary 6 9 8 31 8 33 Lights signals and er 6 5 6 8 Wheels Tires e Check tire pressure wear damage and spoke tightness 8 36 8 40 Chassie tastene Cc Check all chassis fittings and fasteners e Adjust if necessary I a a Pre operation checks should be made each time the motorcycle is used Such an inspection can be thoroughly accomplished in a very short time and the added safety it assures is more than worth the time involved A WARNING 1 The engine exhaust pipe s and muffler s will be very hot after the engine has been run Be careful not to touch them or to allow any clothing item to contact them during inspection or repair
55. peed This speedometer is equipped with an odometer and trip odometer The trip odometer can be reset to 0 with the re set knob Use the trip odometer to esti mate how far you can ride on a tank of fuel This information will enable you to plan fuel stops in the future 60 60 A N A 100 Q10101010 Q 245 10 0100 km h FN NX 2 Trip odometer Y D X 1 Odometer 3 Reset knob EAB60000 Handlebar switches 1 Dimmer switch 4 Engine stop switch LIGHTS ENGINE STOP 2 Turn signal switch 5 Start switch START TURN 3 Horn switch HORN EAB60101 Dimmer switch LIGHTS Turn the switch to HI for the high beam and to LO for the low beam EAB62102 Turn signal switch TURN To signal a right hand turn push the switch to the right To signal a left hand turn push the switch to the left Once the switch is released it will return to the cen ter position To cancel the signal push the switch in after it has returned to the center position EAB60201 Horn switch HORN Press the switch to sound the horn EAB60902 Engine stop switch ENGINE STOP The engine stop switch is a safety device for use in an emergency such as when the motorcycle overturns or if trouble occurs in the throttle system Turn the switch to RUN to start the engine In case of emer gency turn the switch to OFF to stop the engine 5 4 EAB60703 Start
56. r The most important points of mo torcycle inspection adjustment and lubri cation are explained in the following pages Maintenance replacement or repair of the emission control devices and systems may be performed by any repair establish ment or individual using any part which is certified if applicable EUU63200 WARNING If you are not familiar with motorcycle ser vice this work should be done by a Yamaha dealer 8 1 EAH00300 PERIODIC MAINTENANCE PROPER PERIODIC MAINTENANCE OF YOUR MOTORCYCLE IS IMPORTANT IN ORDER TO ENJOY LONG PLEASURABLE SERVICE ESPECIALLY IMPORTANT ARE THE MAINTENANCE SERVICES RELATED TO EMISSIONS CONTROL THESE CON TROLS NOT ONLY FUNCTION TO EN SURE CLEANER AIR BUT ARE ALSO VITAL TO PROPER ENGINE OPERATION AND MAXIMUM PERFORMANCE IN THE FOL LOWING TABLES OF PERIODIC MAINTE NANCE THE SERVICES RELATED TO EMISSIONS CONTROL ARE GROUPED SEPARATELY THESE SERVICES REQUIRE SPECIALIZED DATA KNOWLEDGE AND EQUIPMENT YAMAHA DEALERS ARE TRAINED AND EQUIPPED TO PERFORM THESE PARTICULAR SERVICES EAH10102 Tool kit The service information included in this manual is intended to provide you the owner with the necessary information for completing some of your own preventive maintenance and minor repairs The tools provided in the owner s tool kit are to as sist you in the performance of periodic maintenance However some other tools such as a torque wrench are also neces
57. r position 15 Clutch lever vig AND IA ENS K light 16 Handlebar switches LARGE Wake I NG 6 Brake pedal 17 Speedometer Q SALLY 7 Footrest 18 Brake lever A 8 Headlight 19 Throttle grip 7 9 Fuel tank l 10 Helmet holder 3 1 EAA60000 MOTORCYCLE IDENTIFICATION EAA61800 Identification numbers record Record the key identification number ve hicle identification number and model la bel information in the spaces provided for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen 1 KEY IDENTIFICATION NUMBER O 2 VEHICLE IDENTIFICATION NUMBER E 3 MODEL LABEL INFORMATION 4 1 EAA61400 Key identification number The key identification number is stamped on the key Record this number in the space provided and use it for reference when obtaining a new key 1 Key identification number EAA80000 Vehicle identification number The vehicle identification number stamped into the steering head pipe is 1 Vehicle identification number EUU00400 NOTE n The vehicle identification number is used to identify your motorcycle and may be used to register your motorcycle with the licensing authority in your state 4 2 EAA61601 Model label The model label is affixed to the frame Record the information on this label in the space provided This information will be needed to order spare parts from your Yamaha dealer
58. re the total weight of the cargo rider passenger and accessories fairing saddlebags etc if ap proved for this model does not exceed the maximum load of the motorcycle Op eration of an overloaded motorcycle could cause tire damage an accident or even in jury 2 Tire inspection FRONT Always check the tires before operat Manufacturer Type ing the motorcycle If a tire tread Cheng shin 3 00 18 47P C 916 shows crosswise lines minimum REAR tread depth if the tire has a nail or Type glass fragments in it or if the side wall Cheng shin 130 90 15M C 66P C 915 is cracked contact a Yamaha dealer Minimum tire tread depth 1 0 mm 0 04 in immediately and have the tire re front and rear placed m C am N WARNING 1 Operating the motorcycle with exces sively worn tires decrease riding sta bility and can lead to loss of control Have excessively worn tires replaced by a Yamaha dealer immediately Brakes tires and related wheel parts replacement should be left to a Yamaha Service Technician 2 Patching a punctured tube is not rec 1 Tread depth 2 Side wall ommended If it is absolutely neces 3 Wear indicator sary to do so use great care and replace the tube as soon as possible with a good quality replacement 6 7 EAE93400 Wheels To ensure maximum performance long service and safe operation note the fol lowing 1 Always inspect the wheels before a ride
59. ride under the influence of alcohol or drugs This motorcycle is designed for on road use only It is not suitable for off road use 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 on your unprotected eyes could contribute to an impairment of vision which could delay seeing a hazard 3 The use of heavy boots jacket trousers gloves etc is effective in preventing or re ducing abrasions or lacerations 4 Never wear loose fitting clothing It could catch on the control levers footrests or wheels and cause injury or accident 5 Never touch the engine or exhaust system during or after operation They become very hot and can cause burns Always wear protective clothing that covers your legs ankles and feet 6 A passenger should also observe the above precautions 1 4 MODIFICATION Modifications made to the motorcycle not approved by Yamaha or the removal of orig inal equipment may render your motorcycle unsafe for use and may cause severe per sonal 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 han dling if the weight distribution of the machine is changed
60. s 31 000 km or 19 200 mi or 37 mos 36 000 km or 22 300 mi or 43 mos 41 000 km or 25 400 mi or 49 mos 46 000 km or 28 500 mi or 55 mos 51 000 km or 31 600 mi or 61 mos YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY Yamaha Motor Corporation U S A hereby warrants each new street or enduro model Yamaha motorcycle purchased from an authorized Yamaha motorcycle dealer in the continental United States will be free from defects in material and workmanship for the period of time stated herein subject to certain stated limitations THE PERIOD OF WARRANTY for Yamaha motorcycles originally equipped with headlight stoplight and turn signals shall be one 1 year from the date of purchase with no mileage limitation MODELS EXCLUDED FROM WARRANTY include those used for non Yamaha authorized renting leas ing or other commercial purposes and TZ models DURING THE PERIOD OF WARRANTY any authorized Yamaha motorcycle dealer will free of charge repair or replace at Yamaha s option any part adjudged defective by Yamaha due to faulty workmanship or material from the factory Parts used in warranty repairs will be warranted for the balance of the pro duct s warranty period All parts replaced under war ranty become property of Yamaha Motor Corporation U S A GENERAL EXCLUSIONS from this warranty shall include any failures caused by a Competition or racing use
61. sary to perform the maintenance correctly 1 Tool kit 8 2 EUU18500 IN a gs yo If you do not have necessary tools re quired during a service operation take your motorcycle to a Yamaha dealer for service EUU63301 WARNING Modifications to this motorcycle not ap proved by Yamaha may cause loss of per formance excessive emissions and render it unsafe for use Consult a Yamaha dealer before attempting any changes PERIODIC MAINTENANCE EMISSION CONTROL SYSTEM Unit km mi INITIAL ODOMETER READINGS ITEM ROUTINE 1 000 6 000 11 000 16 000 21 000 600 or 3 800 or 6 900 or 10 000 or 13 100 or 7 months 13 months 19 months 25 months xX a e Check condition e Adjust gap and clean Spark plug e Replace at 11 000 or 13 months and thereafter every 10 000 or 12 months Crankcase Jaron ventilation Check ventilation hose for cracks or damage system e Replace if necessary e Check fuel hose and vacuum pipe for cracks or damage e Replace if necessary e Check for leakage e Retighten if necessary e Replace gasket s if necessary e Check and adjust engine idle speed idle speed e Adjust cable free play Evaporative 7 emission control I E for damage system p Y Items marked with an asterisk require special tools data and technical skills for servicing Take the motorcycle to a Yamaha Dealer or refer to the Service Manual when servicing these items Califor
62. switch START The starter motor cranks the engine when pushing the start switch EUU30700 See starting instructions prior to starting the engine EAB70003 Clutch lever The clutch lever is located on the left han dlebar and the ignition circuit cut off sys tem is incorporated in the clutch lever holder Pull the clutch lever to the handle bar to disengage the clutch and release the lever to engage the clutch The lever should be pulled rapidly and released slowly for smooth clutch operation Refer to the engine starting procedures for a de scription of the ignition circuit cut off sys tem EAB80001 Shift pedal This motorcycle is equipped with a con stant mesh 5 speed transmission The shift pedal is located on the left side of the engine and is used in combination with the clutch when shifting 1 Shift pedal N Neutral EAB90001 Front brake lever The front brake lever is located on the right handlebar Pull it toward the handlebar to apply the front brake 5 5 EAB90101 Rear brake pedal The rear brake pedal is on the right side of the motorcycle Press down on the brake pedal to apply the rear brake EAC00101 Fuel tank cap TO OPEN Insert the key and turn it 1 4 turn clockwise The lock will be released and the cap can N 1 Open TO CLOSE Push the tank cap into position with the key inserted To remove the key turn it counterclockwise to the original posi
63. t all exposed metal surfac es with a light film of oil Do not apply oil to any rubber parts or the seat cov er 9 Remove the battery and charge it Store it in a dry place and recharge it once a month Do not store the battery in an excessively warm or cold place less than 0 C 30 F or more than 30 C 90 F EUU05800 NOTE Make any necessary repairs before storing the motorcycle 9 3 SPECIFICATIONS a Dimensions Overall length 2 190 mm 86 2 in Overall width 815 mm 32 1 in Overall height 1 140 mm 44 9 in Seat height 685 mm 27 0 in Wheelbase 1 490 mm 58 7 in 145mm _ 5 7 tn 2 800 mm 110 2 in Minimum ground clearance Minimum turning radius Basic weight With oil and full fuel tank XV250 147 kg 324 Ib XV250C 148 kg 326 Ib Engine Engine type Cylinder arrangement Air cooled 4 stroke SOHC V type 2 cylinder Displacement 249 cm Bore x stroke 49 x 66 mm 1 93 x 2 60 in Compression ratio 10 1 Starting system Electric starter Lubrication system Wet sump Oil type or grade Engine oil Oil capacity Engine oil Periodic oil change With oil filter replacement Total amount Air filter Fuel Type Fuel tank capacity Fuel reserve amount Carburetor Type quantity Manufacturer YAMALUBE 4 20W40 or SAE20W40 type SE motor oil If temperature does not go below 5 C 40 F YAMALUB
64. ter does not enter the master cylinder when refilling Water will significantly lower the boil ing point of the fluid and may result in vapor lock Brake fluid may deteriorate painted surfaces or plastic parts Always clean up spilled fluid immediately 6 Have a Yamaha dealer check the cause if the brake fluid leve goes down 1 Minimum level EAH83501 Brake fluid replacement 1 Complete fluid replacement should be done only by trained Yamaha service personnel 8 23 2 Have a Yamaha dealer replace the fol lowing components during periodic maintenance or when they are dam aged or leaking a Replace all rubber seals every two years b Replace all hoses every four years EAIO0504 Clutch lever free play adjustment The clutch lever free play should be adjust ed to 10 15 mm 0 39 0 59 in If the free play is incorrect adjust as follows Free play 10 15 mm 0 39 0 59 in 1 Loosen the locknut at the handlebar 2 Turn the adjusting bolt in or out until specified lever free play is obtained 3 Tighten the locknut 4 If the free play is still incorrect make an adjustment at the crankcase side EUU17800 NOTE If proper adjustment cannot be obtained or the clutch does not work correctly ask a Yamaha dealer to inspect the internal clutch mechanism 1 Locknut a 10 15 mm 0 39 0 59 in 2 Adjusting bolt 8 24 1 Locknut 2 Adjusting nut EAI40801 Drive chain slack check
65. tion EUU01200 NOTE CFC TT This tank cap cannot be closed unless the key is in the lock The key cannot be re moved if the cap is not locked properly EUU61100 a WARNING Be sure the cap is properly installed and locked in place before riding the motorcy cle 5 6 EAC10300 Fuel cock The negative pressure fuel cock supplies fuel from the tank to the carburetor while filtering it also The fuel cock has the following three posi tions ON With the lever in this position fuel flows if the engine is running but stops if the engine is not running This indicates reserve If you run out of fuel while riding move the lever to PRI start the engine then move the lever to RES FILL THE TANK AT THE FIRST OPPORTUNITY BE SURE TO MOVE THE LEVER TO ON AFTER REFUELING EUU01400 NOTE ee ee The fuel cock operates on vacuum from the engine when set at ON or RES If the line connecting the cock to the carbure tor intake manifold is not connected or has a leak the cock will not function properly RES PRI This indicates prime With the lever in this position fuel flows whether the engine is running or not If the fuel tank is completely empty refill the tank and move the lever to PRI to prime the carburetor Move the le ver to ON after starting the engine 5 7 EAC20502 Starter CHOKE Starting a cold engine requires a rich
66. ult a Yamaha dealer 8 29 EAI20502 Front fork inspection EUU65700 WARNING Securely support the motorcycle so there is no danger of it falling over 1 Visual check Check for scratches or damage on the inner tube and excessive oil leakage from the front fork Operation check Place the motorcycle on a level place Hold the motorcycle in an upright po sition and apply the front brake Push down hard on the handlebars several times and check if the fork re bounds smoothly If any damage or unsmooth movement is found with the front fork consult a Yamaha dealer 8 30 EAI60301 Steering inspection 3 Periodically inspect the condition of the steering Worn out or loose steering bear ings may be dangerous Place a stand un der the engine to raise the front wheel off the ground Hold the lower end of the front forks and try to move them forward and backward If any free play can be felt ask a Yamaha dealer to inspect and adjust the steering Inspection is easier if the front wheel is removed EUU65700 WARNING Securely support the motorcycle so there is no danger of it falling over EAI60103 Wheel bearings lf there is play in the front or rear wheel hub or if the wheel does not turn smooth ly have a Yamaha dealer inspect the wheel bearings The wheel bearings should be inspected according to the Gen eral Maintenance Schedule EAI70003 Battery Check the level of the batter
67. ve by any person other than for purposes of maintenance repair or replace ment of any device or element of design incorporated into any new vehicle 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 ren dered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LIST ED 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 11 2 EAL00400 Maintenance record Copies of work orders and or receipts for parts you purchase and install will be required to document that maintenance has been completed in accordance with the emission warran ty The chart below is printed only as a reminder to you that the maintenance work is re quired It is not acceptable proof of maintenance work MAINTENANCE DATE OF SERVICING DEALER INTERVAL SERVICE MILEAGE NAME AND ADDRESS REMARKS 1 000 km or 600 mi or 1mo 6 000 km or 3 800 mi or 7 mos 11 000 km or 6 900 mi or 13 mos 16 000 km or 10 000 mi or 19 mos 21 000 km or 13 100 mi or 25 mos 11 3 MAINTENANCE DATE OF SERVICING DEALER INTERVAL SERVICE eats NAME AND ADDRESS BEMARES 26 000 km or 16 100 mi or 31 mo
68. y 1997 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 11 08 EAA20201 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 main tenance of this motorcycle If you have any questions about the operation or maintenance of your motorcycle please consult a Yamaha dealer The design and manufacture of this Yamaha motorcycle fully comply with the emissions standards for clean air applicable at the date of manufacture Yamaha has met these stan dards without reducing the motorcycle s performance or economy of operation To main tain these high standards it is important that you and your dealer pay close attention to the recommended maintenance schedules and operating instructions contained within this manual EAA10700 IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following nota tions A The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED A WARNING Failure to follow WARN
69. y electrolyte and make sure that the terminals are tight Fill with distilled water if the electrolyte level is low 8 31 Batte ry Battery breather pipe EUU33601 Cr onn nnt O E OOE a E G OO E ak ae ae E a et aE SE OO we O ie rote ee ono en ee GO O OOO amp ono ove oD Fae E R roar cree els e ore 8 8 5 ors o o arero ose aro o o ere orere 8 8 a ee oe t O EEEE E E O eb ee 8 we 8 hw ee Cee OO Te RE When inspecting the battery be sure the breather pipe is routed correctly If the breather pipe is positioned in such a way as to cause battery electrolyte or gas to exit onto the frame structural and cos metic damage to the motorcycle can oc cur EUU65800 A WARNING Battery electrolyte is poisonous and dan gerous causing severe burns etc It con tains sulfuric acid Avoid contact with skin eyes or clothing Antidote EXTERNAL Flush with water INTERNAL Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call a physi cian immediately EYES Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Always shield your eyes when working near batteries KEEP OUT OF REACH OF CHILDREN 8 32 Replenishing the battery fluid A poorly maintained battery will corrode and discharge quickly The battery flui

Yamaha 1998 Virago 250 Owner's Manual

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