OWNER’S MANUAL XV250R XV250RC YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2002.05-0.
EAU03438
E_U2UJ1B.book Page 1 Wednesday, May 29, 2002 1:56 PM EAU00002 INTRODUCTION Congratulations on your purchase of the Yamaha XV250/XV250C. This model is the result of Yamaha’s vast experience in the production of fine sporting, touring, and pacesetting racing machines. It represents the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields. This manual will give you an understanding of the operation, inspection, and basic maintenance of this motorcycle.
E_U2UJ1B.book Page 1 Wednesday, May 29, 2002 1:56 PM IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator, a bystander or a person inspecting or repairing the motorcycle.
E_U2UJ1B.book Page 2 Wednesday, May 29, 2002 1:56 PM IMPORTANT MANUAL INFORMATION EW000000 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 ADEQUATE KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES.
E_U2UJ1B.book Page 3 Wednesday, May 29, 2002 1:56 PM IMPORTANT MANUAL INFORMATION AFFIX DEALER LABEL HERE EAU04247 XV250R/XV250RC OWNER’S MANUAL ©2002 by Yamaha Motor Corporation, U.S.A. 1st edition, April 2002 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.
E_U2UJ1B.book Page 1 Wednesday, May 29, 2002 1:56 PM TABLE OF CONTENTS EAU00009 1 SAFETY INFORMATION ....................................1-1 Safe riding ..........................................................1-1 Protective apparel ..............................................1-3 Modifications ......................................................1-3 Loading and accessories ...................................1-3 Gasoline and exhaust gas..................................
E_U2UJ1B.book Page 2 Wednesday, May 29, 2002 1:56 PM TABLE OF CONTENTS Adjusting the throttle cable free play ............... 6-13 Adjusting the valve clearance ......................... 6-14 Tires ................................................................ 6-14 Spoke wheels .................................................. 6-16 Accessories and replacement parts ................ 6-16 Adjusting the clutch lever free play ................. 6-17 Adjusting the brake lever free play ..................
E_U2UJ1B.book Page 1 Wednesday, May 29, 2002 1:56 PM SAFETY INFORMATION EAU03633 1- 1 MOTORCYCLES ARE SINGLE TRACK VEHICLES. THEIR SAFE USE AND OPERATION ARE DEPENDENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EXPERTISE OF THE OPERATOR. EVERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIREMENTS BEFORE RIDING THIS MOTORCYCLE. HE OR SHE SHOULD: 1. OBTAIN THOROUGH INSTRUCTIONS FROM A COMPETENT SOURCE ON ALL ASPECTS OF MOTORCYCLE OPERATION. 2.
E_U2UJ1B.book Page 2 Wednesday, May 29, 2002 1:56 PM SAFETY INFORMATION 4. Many motorcycle accidents involve inexperienced operators. In fact, many operators who have been involved in accidents do not even have a current motorcycle license. a. Make sure that you are qualified and that you only lend your motorcycle to other qualified operators. b. Know your skills and limits. Staying within your limits may help you to avoid an accident. c.
E_U2UJ1B.book Page 3 Wednesday, May 29, 2002 1:56 PM SAFETY INFORMATION Protective apparel 1 The majority of fatalities from motorcycle accidents are the result of head injuries. The use of a safety helmet is the single most critical factor in the prevention or reduction of head injuries. 1. Always wear an approved helmet. 2. Wear a face shield or goggles. Wind in your unprotected eyes could contribute to an impairment of vision which could delay seeing a hazard. 3.
E_U2UJ1B.book Page 4 Wednesday, May 29, 2002 1:56 PM SAFETY INFORMATION Loading The total weight of the operator, passenger, accessories and cargo must not exceed the maximum load limit of XV250: 432 lb (196 kg) / XV250C: 430 lb (195 kg). When loading within this weight limit, keep the following in mind: 1. Cargo and accessory weight should be kept as low and close to the motorcycle as possible.
E_U2UJ1B.book Page 5 Wednesday, May 29, 2002 1:56 PM SAFETY INFORMATION 1 a. 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. b. Bulky or large accessories may seriously affect the stability of the motorcycle due to aerodynamic effects.
E_U2UJ1B.book Page 6 Wednesday, May 29, 2002 1:56 PM SAFETY INFORMATION a. The engine and exhaust system may be hot, therefore, 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, otherwise it may fall over. c. Do not park the motorcycle near a flammable source (e.g. a kerosene heater, or near an open flame), otherwise it could catch fire. 4.
E_U2UJ1B.book Page 7 Wednesday, May 29, 2002 1:56 PM SAFETY INFORMATION EAU02977 Location of important labels 1 Please read the following important labels carefully before operating this motorcycle.
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E_U2UJ1B.book Page 1 Wednesday, May 29, 2002 1:56 PM DESCRIPTION EAU00026 2- Left view 2 1. Headlight 2. Steering lock 3. Fuel tank 4. Battery 5. Fuses 6. Helmet holder 7. Shock absorber assembly spring preload adjusting ring 8. Main switch 9. Fuel cock 10.
E_U2UJ1B.book Page 2 Wednesday, May 29, 2002 1:56 PM DESCRIPTION Right view 2 11. Tail/brake light 12. Rear turn signal light 13. Rider seat 14. Air filter element 15. Front turn signal/position light 16. Brake pedal 17. Footrest 18. Owner’s tool kit 19.
E_U2UJ1B.book Page 3 Wednesday, May 29, 2002 1:56 PM DESCRIPTION Controls and instruments 2 1. Clutch lever 2. Left handlebar switches 3. Speedometer unit 4. Indicator lights 5. Right handlebar switches 6. Brake lever 7. Throttle grip 8.
E_U2UJ1B.book Page 1 Wednesday, May 29, 2002 1:56 PM INSTRUMENT AND CONTROL FUNCTIONS EAU00027 3- EAU00050 P (Parking) The taillight and position lights are on, but all other electrical systems are off. The key can be removed. The key must be pushed in from the “OFF” position to be turned to “P”. ECA00043 CAUTION: Do not use the parking position for an extended length of time, otherwise the battery may discharge. 3 @ EAU00028 Main switch The main switch controls the ignition and lighting systems.
E_U2UJ1B.book Page 2 Wednesday, May 29, 2002 1:56 PM INSTRUMENT AND CONTROL FUNCTIONS ter position. To cancel the turn signal lights, push the switch in after it has returned to the center position. EAU00130 Horn switch “HORN” Press this switch to sound the horn. 3 1. 2. 3. 4. Odometer Tripmeter Tripmeter reset knob Speedometer 1. Dimmer switch “LIGHTS” 2. Turn signal switch “TURN” 3.
E_U2UJ1B.book Page 3 Wednesday, May 29, 2002 1:56 PM INSTRUMENT AND CONTROL FUNCTIONS 3 1. Engine stop switch “ENGINE STOP” 2. Start switch “START” 1. Clutch lever 1. Shift pedal EAU00152 EAU04822 Engine stop switch “ENGINE STOP” Set this switch to “RUN” before starting the engine. Set this switch to “OFF” to stop the engine in case of an emergency, such as when the motorcycle overturns or when the throttle cable is stuck.
E_U2UJ1B.book Page 4 Wednesday, May 29, 2002 1:56 PM INSTRUMENT AND CONTROL FUNCTIONS 3 1. Brake lever 1. Brake pedal EAU00158 EAU00162 Brake lever Brake pedal The brake lever is located at the right handlebar grip. To apply the front brake, pull the lever toward the handlebar grip. The brake pedal is on the right side of the motorcycle. To apply the rear brake, press down on the brake pedal. 1. Fuel tank cap 2. Unlock.
E_U2UJ1B.book Page 5 Wednesday, May 29, 2002 1:56 PM INSTRUMENT AND CONTROL FUNCTIONS EAU00185 NOTE: The fuel tank cap cannot be closed unless the key is in the lock. In addition, the key cannot be removed if the cap is not properly closed and locked. _ CAUTION: Immediately wipe off spilled fuel with a clean, dry, soft cloth, since fuel may deteriorate painted surfaces or plastic parts. @ _ EWA00025 @ WARNING Make sure that the fuel tank cap is properly closed before riding. EAU04265 _ _ 1.
E_U2UJ1B.book Page 6 Wednesday, May 29, 2002 1:56 PM INSTRUMENT AND CONTROL FUNCTIONS ECA00104 CAUTION: Use only unleaded gasoline. The use of leaded gasoline will cause severe damage to internal engine parts, such as the valves and piston rings, as well as to the exhaust system. _ 3 _ Your Yamaha engine has been designed to use regular unleaded gasoline with a pump octane number [(R+M)/2] of 86 or higher, or a research octane number of 91 or higher.
E_U2UJ1B.book Page 7 Wednesday, May 29, 2002 1:56 PM INSTRUMENT AND CONTROL FUNCTIONS RES: reserve position PRI: priming position 3 1. Arrow mark positioned over “RES” 1. Arrow mark positioned over “PRI” RES This indicates reserve. With the fuel cock lever in this position, the fuel reserve is made available. Quickly turn the fuel cock lever to this position if you run out of fuel while riding, otherwise the engine may stall and will have to be primed (see “PRI”).
E_U2UJ1B.book Page 8 Wednesday, May 29, 2002 1:56 PM INSTRUMENT AND CONTROL FUNCTIONS To unlock the steering 1. Open the steering lock cover, and then insert the key. 2. Push the key in, turn it 1/8 turn counterclockwise so that it moves out, and then release it. 3. Remove the key, and then close the lock cover. 3 1. Steering lock 1. Bolt (× 2) EAU02934 EAU01072 Steering lock Rider seat To lock the steering 1. Turn the handlebar all the way to right. 2.
E_U2UJ1B.book Page 9 Wednesday, May 29, 2002 1:56 PM INSTRUMENT AND CONTROL FUNCTIONS 3 1. Projection 2. Seat holder To install the rider seat 1. Insert the projection on the front of the rider seat into the seat holder as shown. 2. Place the rider seat in the original position, and then tighten the bolts. NOTE: Make sure that the rider seat is properly secured before riding. 1. Helmet holder 2. Unlock.
E_U2UJ1B.book Page 10 Wednesday, May 29, 2002 1:56 PM INSTRUMENT AND CONTROL FUNCTIONS EAU00330 EW000040 WARNING Always adjust both shock absorber assemblies equally, otherwise poor handling and loss of stability may result. @ Sidestand The sidestand is located on the left side of the frame. Raise the sidestand or lower it with your foot while holding the motorcycle upright. @ 3 1. Spring preload adjusting ring 2.
E_U2UJ1B.book Page 11 Wednesday, May 29, 2002 1:56 PM INSTRUMENT AND CONTROL FUNCTIONS EW000044 WARNING The motorcycle must not be ridden with the sidestand down, or if the sidestand cannot be properly moved up (or does not stay up), otherwise the sidestand could contact the ground and distract the operator, resulting in a possible loss of control.
E_U2UJ1B.book Page 12 Wednesday, May 29, 2002 1:56 PM INSTRUMENT AND CONTROL FUNCTIONS CD-01E NOTE: This check is most reliable if performed with a warmed-up engine. With the engine turned off: 1. Move the sidestand down. 2. Make sure that the engine stop switch is set to “RUN”. 3. Turn the key to “ON”. 4. Shift the transmission into the neutral position. 5. Push the start switch. Does the engine start? 3 YES NO The neutral switch may be defective.
E_U2UJ1B.book Page 1 Wednesday, May 29, 2002 1:56 PM PRE-OPERATION CHECKS EAU01114 4- The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly, even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss of tire air pressure could have serious consequences.
E_U2UJ1B.book Page 2 Wednesday, May 29, 2002 1:56 PM PRE-OPERATION CHECKS ITEM Drive chain Wheels and tires Brake and shift pedals Brake and clutch levers 4 Sidestand Chassis fasteners Instruments, lights, signals and switches Sidestand switch Battery • • • • • • • • • • • • • • • • • • • • • • CHECKS Check chain slack. Adjust if necessary. Check chain condition. Lubricate if necessary. Check for damage. Check tire condition and tread depth. Check air pressure. Correct if necessary.
E_U2UJ1B.book Page 1 Wednesday, May 29, 2002 1:56 PM EAU00372 5- @ OPERATION AND IMPORTANT RIDING POINTS EAU00373 EAU00376 WARNING ● Become thoroughly familiar with all operating controls and their functions before riding. Consult a Yamaha dealer regarding any control or function that you do not thoroughly understand. ● Never start the engine or operate it in a closed area for any length of time.
E_U2UJ1B.book Page 2 Wednesday, May 29, 2002 1:56 PM OPERATION AND IMPORTANT RIDING POINTS EAU04683 Starting and warming up a cold engine In order for the ignition circuit cut-off system to enable starting, one of the following conditions must be met: ● The transmission is in the neutral position. ● The transmission is in gear with the clutch lever pulled and the sidestand up. 1. Turn the fuel cock lever to “ON”. 2. Turn the key to “ON” and make sure that the engine stop switch is set to “RUN”. 3.
E_U2UJ1B.book Page 3 Wednesday, May 29, 2002 1:56 PM OPERATION AND IMPORTANT RIDING POINTS 6. After starting the engine, move the starter (choke) back halfway. ECA00055 utes with the starter (choke) in the halfway position. _ CAUTION: For maximum engine life, always warm the engine up before starting off.
E_U2UJ1B.book Page 4 Wednesday, May 29, 2002 1:56 PM OPERATION AND IMPORTANT RIDING POINTS EC000048 @ 1. Shift pedal N. Neutral position EAU00423 5 Shifting Shifting gears lets you control the amount of engine power available for starting off, accelerating, climbing hills, etc. The gear positions are shown in the illustration. CAUTION: ● Even with the transmission in the neutral position, do not coast for long periods of time with the engine off, and do not tow the motorcycle for long distances.
E_U2UJ1B.book Page 5 Wednesday, May 29, 2002 1:56 PM OPERATION AND IMPORTANT RIDING POINTS EAU00427 EAU02974 To decelerate 1. Apply both the front and the rear brakes to slow the motorcycle. 2. Shift the transmission into first gear when the motorcycle reaches 20 km/h (12.5 mi/h). If the engine is about to stall or runs very roughly, pull the clutch lever in and use the brakes to stop the motorcycle. 3. Shift the transmission into the neutral position when the motorcycle is almost completely stopped.
E_U2UJ1B.book Page 6 Wednesday, May 29, 2002 1:56 PM OPERATION AND IMPORTANT RIDING POINTS EAU00452* 0–1,000 km (0–600 mi) Avoid prolonged operation 1/3 throttle. EAU00460 Parking above When parking, stop the engine, and then remove the key from the main switch. 1,000–1,600 km (600–1,000 mi) Avoid prolonged operation above 1/2 throttle. EW000058 @ 1,600 km and beyond The vehicle can now be operated normally.
E_U2UJ1B.book Page 1 Wednesday, May 29, 2002 1:56 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU00462 6- EAU01790 Safety is an obligation of the owner. Periodic inspection, adjustment and lubrication will keep your vehicle in the safest and most efficient condition possible. The most important points of motorcycle inspection, adjustment, and lubrication are explained on the following pages.
E_U2UJ1B.book Page 2 Wednesday, May 29, 2002 1:56 PM PERIODIC MAINTENANCE AND MINOR REPAIR EW000062 WARNING Modifications not approved by Yamaha may cause loss of performance, excessive emissions, and render the vehicle unsafe for use. Consult a Yamaha dealer before attempting any changes. @ @ 1.
E_U2UJ1B.book Page 3 Wednesday, May 29, 2002 1:56 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU00471 Periodic maintenance chart for the emission control system No. ITEM ROUTINE INITIAL 600 mi (1,000km) or 1 month 4,000 mi (6,000km) or 6 months √ ODOMETER READINGS 7,000 mi 10,000 mi (11,000km) (16,000km) or or 12 months 18 months 13,000 mi (21,000km) or 24 months 1 * Valve clearance • Check and adjust valve clearance when engine is cold. √ √ √ √ 2 • Check condition. • Adjust gap and clean.
E_U2UJ1B.book Page 4 Wednesday, May 29, 2002 1:56 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU00472 General maintenance and lubrication chart No. 1 6 ITEM Engine oil ROUTINE • Warm-up engine before draining. TYPE See page 8-1. Engine oil filter 2 * element • Replace. 3 * Air filter element • Wet type filter must be washed and damped with oil. 4 * Brake system • Adjust free play. • Replace pads if necessary. (front) • Replace shoes if necessary. (rear) – 5 * Clutch • Adjust free play.
E_U2UJ1B.book Page 5 Wednesday, May 29, 2002 1:56 PM PERIODIC MAINTENANCE AND MINOR REPAIR No. ITEM ROUTINE TYPE 12 * Front fork • Check operation and leakage. 13 * Steering bearings • Check bearings assembly for looseness. • Moderately repack every 10,000 mi (16,000 km) or 18 months. 14 * Wheel bearings • Check bearings for smooth operation. 15 • Check specific gravity and breather pipe for proper operation. • Check and clean or replace if necessary.
E_U2UJ1B.book Page 6 Wednesday, May 29, 2002 1:56 PM PERIODIC MAINTENANCE AND MINOR REPAIR NOTE: If any spark plug shows a distinctly different color, the engine could be defective. Do not attempt to diagnose such problems yourself. Instead, have a Yamaha dealer check the motorcycle. @ @ 1. Spark plug cap 1. Spark plug wrench EAU03329 Checking the spark plugs 6 The spark plugs are important engine components, which are easy to check.
E_U2UJ1B.book Page 7 Wednesday, May 29, 2002 1:56 PM PERIODIC MAINTENANCE AND MINOR REPAIR Tightening torque: Spark plug: 12.5 Nm (1.25 m·kgf, 9.0 ft·lbf) NOTE: If a torque wrench is not available when installing a spark plug, a good estimate of the correct torque is 1/4–1/2 turn past finger tight. However, the spark plug should be tightened to the specified torque as soon as possible. @ a. Spark plug gap To install a spark plug 1.
E_U2UJ1B.book Page 8 Wednesday, May 29, 2002 1:56 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU00499 EAU04613 Canister (for California only) Engine oil and oil filter element This model is equipped with a canister to prevent the discharging of fuel vapor into the atmosphere. Before operating this motorcycle, make sure to check the following: ● Check each hose connection. ● Check each hose and canister for cracks or damage. Replace if damaged.
E_U2UJ1B.book Page 9 Wednesday, May 29, 2002 1:56 PM PERIODIC MAINTENANCE AND MINOR REPAIR 1. Engine oiil level check window 2. Maximum level mark 3. Minimum level mark 2. Start the engine, warm it up for several minutes, and then turn it off. 3. Wait a few minutes until the oil settles, and then check the oil level through the check window located at the bottom-right side of the crankcase. 1. Engine oil filler cap 1.
E_U2UJ1B.book Page 10 Wednesday, May 29, 2002 1:56 PM PERIODIC MAINTENANCE AND MINOR REPAIR 1. Bolt (× 3) 2. Oil filter element cover 4. Remove the oil filter element cover by removing the bolts. 5. Remove and replace the oil filter element and O-ring. 6. Install the oil filter element cover by installing the bolts, then tightening them to the specified torque. 6 Tightening torque: Oil filter element cover bolt: 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Recommended engine oil: See page 8-1.
E_U2UJ1B.book Page 11 Wednesday, May 29, 2002 1:56 PM PERIODIC MAINTENANCE AND MINOR REPAIR 9. Start the engine, and then let it idle for several minutes while checking it for oil leakage. If oil is leaking, immediately turn the engine off and check for the cause. 10. Turn the engine off, and then check the oil level and correct it if necessary. 1.
E_U2UJ1B.book Page 12 Wednesday, May 29, 2002 1:56 PM PERIODIC MAINTENANCE AND MINOR REPAIR 1. Screw (× 2) 2. Remove the air filter element cover by removing the screws. 1. Wing nut 2. Air filter case 1. Sponge material 2. Air filter element frame 3. Remove the air filter element by removing the wing nut. 4. Remove the sponge material from the air filter element frame, clean it with solvent, and then squeeze the remaining solvent out. 5.
E_U2UJ1B.book Page 13 Wednesday, May 29, 2002 1:56 PM PERIODIC MAINTENANCE AND MINOR REPAIR 6. Pull the sponge material over the air filter element frame. 7. Insert the element into the air filter case, and then tighten the wing nut. EC000082* _ CAUTION: ● Make sure that the air filter element is properly seated in the air filter case. ● The engine should never be operated without the air filter element installed, otherwise the pistons and/or cylinders may become excessively worn.
E_U2UJ1B.book Page 14 Wednesday, May 29, 2002 1:56 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU00637 EW000082 Adjusting the valve clearance @ The valve clearance changes with use, resulting in improper air-fuel mixture and/or engine noise. To prevent this from occurring, the valve clearance must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart. 1. Sidewall 2. Tire wear indicator a.
E_U2UJ1B.book Page 15 Wednesday, May 29, 2002 1:56 PM PERIODIC MAINTENANCE AND MINOR REPAIR EW000083 WARNING Proper loading of your motorcycle is important for several characteristics of your motorcycle, such as handling, braking, performance and safety. Do not carry loosely packed items that can shift. Securely pack your heaviest items close to the center of the motorcycle, and distribute the weight evenly from side to side.
E_U2UJ1B.book Page 16 Wednesday, May 29, 2002 1:56 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU00685 Spoke wheels 6 To maximize the performance, durability, and safe operation of your motorcycle, note the following points regarding the specified wheels. ● The wheel rims should be checked for cracks, bends or warpage, and the spokes for looseness or damage before each ride. If any damage is found, have a Yamaha dealer replace the wheel. Do not attempt even the smallest repair to the wheel.
E_U2UJ1B.book Page 17 Wednesday, May 29, 2002 1:56 PM PERIODIC MAINTENANCE AND MINOR REPAIR 7. Tighten the locknut at the clutch lever and the crankcase. 1. Locknut 2. Clutch lever free play adjusting bolt c. Clutch lever free play 1. Locknut 2. Clutch lever free play adjusting nut EAU00694 Adjusting the clutch lever free play The clutch lever free play should measure 10–15 mm (0.4–0.6 in) as shown. Periodically check the clutch lever free play and, if necessary, adjust it as follows. 1.
E_U2UJ1B.book Page 18 Wednesday, May 29, 2002 1:56 PM PERIODIC MAINTENANCE AND MINOR REPAIR EW000099 @ 1. Locknut 2. Brake lever free play adjusting bolt c. Brake lever free play EAU00696 6 Adjusting the brake lever free play The brake lever free play should measure 2–5 mm (0.08–0.20 in) as shown. Periodically check the brake lever free play and, if necessary, adjust it as follows. 1. Loosen the locknut at the brake lever. 2.
E_U2UJ1B.book Page 19 Wednesday, May 29, 2002 1:56 PM PERIODIC MAINTENANCE AND MINOR REPAIR EW000106 _ 1. Locknut 2. Brake pedal position adjusting bolt 1. Brake pedal free play adjusting nut 1. Loosen the locknut at the brake pedal. 2. To raise the brake pedal, turn the adjusting bolt in direction a. To lower the brake pedal, turn the adjusting bolt in direction b. 3. Tighten the locknut. EWA00044 WARNING After adjusting the brake pedal position, the brake pedal free play must be adjusted.
E_U2UJ1B.book Page 20 Wednesday, May 29, 2002 1:56 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU00720 Checking the front brake pads and rear brake shoes Front The front brake pads and the rear brake shoes must be checked for wear at the intervals specified in the periodic maintenance and lubrication chart. 1. Rear brake light switch 2. Rear brake light switch adjusting nut 1.
E_U2UJ1B.book Page 21 Wednesday, May 29, 2002 1:56 PM PERIODIC MAINTENANCE AND MINOR REPAIR Observe these precautions: ● When checking the fluid level, make sure that the top of the brake fluid reservoir is level. ● Use only the recommended quality brake fluid, otherwise the rubber seals may deteriorate, causing leakage and poor braking performance. Rear 1. Brake shoe wear indicator 2. Brake shoe wear limit line 1.
E_U2UJ1B.book Page 22 Wednesday, May 29, 2002 1:56 PM PERIODIC MAINTENANCE AND MINOR REPAIR ● Brake fluid may deteriorate painted surfaces or plastic parts. Always clean up spilled fluid immediately. ● As the brake pads wear, it is normal for the brake fluid level to gradually go down. However, if the brake fluid level goes down suddenly, have a Yamaha dealer check the cause.
E_U2UJ1B.book Page 23 Wednesday, May 29, 2002 1:56 PM PERIODIC MAINTENANCE AND MINOR REPAIR 2. Shift the transmission into the neutral position. 3. Move the rear wheel by pushing the motorcycle to locate the tightest portion of the drive chain, and then measure the drive chain slack as shown. Drive chain slack: 30–40 mm (1.2–1.6 in) 1. Brake pedal free play adjusting nut EAU01076 4. If the drive chain slack is incorrect, adjust it as follows. To adjust the drive chain slack 1.
E_U2UJ1B.book Page 24 Wednesday, May 29, 2002 1:56 PM PERIODIC MAINTENANCE AND MINOR REPAIR EW000103 NOTE: Using the alignment marks on each side of the swingarm, make sure that both chain pullers are in the same position for proper wheel alignment. WARNING After adjusting the brake pedal free play, check the operation of the brake light.
E_U2UJ1B.book Page 25 Wednesday, May 29, 2002 1:56 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU03006 Lubricating the drive chain The drive chain must be cleaned and lubricated at the intervals specified in the periodic maintenance and lubrication chart, otherwise it will quickly wear out, especially when riding in dusty or wet areas. Service the drive chain as follows.
E_U2UJ1B.book Page 26 Wednesday, May 29, 2002 1:56 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU04034 EAU03370 EAU03164 Checking and lubricating the throttle grip and cable Checking and lubricating the brake and shift pedals Checking and lubricating the brake and clutch levers The operation of the throttle grip should be checked before each ride. In addition, the cable should be lubricated or replaced at the intervals specified in the periodic maintenance chart.
E_U2UJ1B.book Page 27 Wednesday, May 29, 2002 1:56 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU03165 Checking and lubricating the sidestand The operation of the sidestand should be checked before each ride, and the sidestand pivot and metal-to-metal contact surfaces should be lubricated if necessary. EAU02939 Checking the front fork The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart.
E_U2UJ1B.book Page 28 Wednesday, May 29, 2002 1:56 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU00794 Checking the wheel bearings Worn or loose steering bearings may cause danger. Therefore, the operation of the steering must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart. 1. Place a stand under the engine to raise the front wheel off the ground.
E_U2UJ1B.book Page 29 Wednesday, May 29, 2002 1:56 PM PERIODIC MAINTENANCE AND MINOR REPAIR NOTE: Make sure that the motorcycle is positioned straight up when checking the electrolyte level. @ @ 2. Check the electrolyte level in the battery. NOTE: The electrolyte should be between the minimum and maximum level marks. @ 1. Battery 2. Battery breather hose @ 1. Maximum level mark 2. Minimum level mark 3.
E_U2UJ1B.book Page 30 Wednesday, May 29, 2002 1:56 PM PERIODIC MAINTENANCE AND MINOR REPAIR ● Take care not to spill electrolyte on the drive chain, as this may weaken it, shorten chain life and possibly result in an accident. ● KEEP THIS AND ALL BATTERIES OUT OF THE REACH OF CHILDREN. EW000117 @ 6 WARNING ● Electrolyte is poisonous and dangerous since it contains sulfuric acid, which causes severe burns.
E_U2UJ1B.book Page 31 Wednesday, May 29, 2002 1:56 PM PERIODIC MAINTENANCE AND MINOR REPAIR EC000099 Specified fuses: Main fuse: Signaling system fuse: CAUTION: If the breather hose is positioned in such a way that the frame is exposed to electrolyte or gas expelled from the battery, the frame could suffer structural and external damages.
E_U2UJ1B.book Page 32 Wednesday, May 29, 2002 1:56 PM PERIODIC MAINTENANCE AND MINOR REPAIR 1. Screw (× 2) EAU04187 Replacing the headlight bulb 6 This motorcycle is equipped with a quartz bulb headlight. If the headlight bulb burns out, replace it as follows. 1. Remove the headlight unit by removing the screws. 1. Headlight coupler 2. Headlight bulb cover 1. Headlight bulb holder 3. Remove the headlight bulb holder by turning it counterclockwise, and then remove the defective bulb. 2.
E_U2UJ1B.book Page 33 Wednesday, May 29, 2002 1:56 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU01579 Supporting the motorcycle 1. Do not touch the glass part of the bulb. EC000105 CAUTION: Do not touch the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the luminosity of the bulb, and the bulb life will be adversely affected. Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with alcohol or thinner.
E_U2UJ1B.book Page 34 Wednesday, May 29, 2002 1:56 PM PERIODIC MAINTENANCE AND MINOR REPAIR 1. Speedometer cable EAU03239 1. Wheel axle 2. Front wheel axle pinch bolt Front wheel EW000122 @ WARNING ● It is advisable to have a Yamaha dealer service the wheel. ● Securely support the motorcycle so that there is no danger of it falling over. @ 1. Disconnect the speedometer cable from the front wheel. EAU04423 2. Loosen the front wheel axle pinch bolt, then the wheel axle. 3.
E_U2UJ1B.book Page 35 Wednesday, May 29, 2002 1:56 PM PERIODIC MAINTENANCE AND MINOR REPAIR Tightening torque: Front wheel axle pinch bolt: 20 Nm (2.0 m·kgf, 14 ft·lbf) 7. Push down hard on the handlebar several times to check for proper fork operation. 8. Connect the speedometer cable. 1. Speedometer gear unit 2. Retainer 3. Speedometer cable 5. Tighten the wheel axle to the specified torque. 6 Tightening torque: Wheel axle: 59 Nm (5.9 m·kgf, 43 ft·lbf) 6.
E_U2UJ1B.book Page 36 Wednesday, May 29, 2002 1:56 PM PERIODIC MAINTENANCE AND MINOR REPAIR 1. 2. 3. 4. 5. 6. 6 Brake torque rod Brake torque rod cotter pin Brake torque rod bolt and nut Brake rod Brake pedal free play adjusting nut Brake cam shaft lever 1. 2. 3. 4. 5. EAU04850 Rear wheel To remove the rear wheel EW000122 _ WARNING It is advisable to have a Yamaha dealer service the wheel. ● Securely support the motorcycle so that there is no danger of it falling over.
E_U2UJ1B.book Page 37 Wednesday, May 29, 2002 1:56 PM PERIODIC MAINTENANCE AND MINOR REPAIR 5. Adjust the drive chain slack. (See page 6-23 for drive chain slack adjustment procedures.) 6. Tighten the axle nut to the specified torque, and then insert a new cotter pin into the axle nut. EAU04851 To install the rear wheel 1. Insert the wheel axle from the right-hand side, and then install the drive chain onto the rear sprocket. 2.
E_U2UJ1B.book Page 38 Wednesday, May 29, 2002 1:56 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU01562 Troubleshooting chart EW000125 WARNING Keep away open flames and do not smoke while checking or working on the fuel system. @ @ 1. Fuel There is enough fuel. Check the compression. There is no fuel. Supply fuel. There is compression. Check the ignition. There is no compression. Have a Yamaha dealer check the vehicle. Check the fuel level in the fuel tank. The engine does not start.
E_U2UJ1B.book Page 1 Wednesday, May 29, 2002 1:56 PM EAU03430 7- Care While the open design of a motorcycle reveals the attractiveness of the technology, it also makes it more vulnerable. Rust and corrosion can develop even if high-quality components are used. A rusty exhaust pipe may go unnoticed on a car, however, it detracts from the overall appearance of a motorcycle.
E_U2UJ1B.book Page 2 Wednesday, May 29, 2002 1:56 PM MOTORCYCLE CARE AND STORAGE ● 7 Do not use any harsh chemical products on plastic parts. Be sure to avoid using cloths or sponges which have been in contact with strong or abrasive cleaning products, solvent or thinner, fuel (gasoline), rust removers or inhibitors, brake fluid, antifreeze or electrolyte.
E_U2UJ1B.book Page 3 Wednesday, May 29, 2002 1:56 PM MOTORCYCLE CARE AND STORAGE After cleaning 1. Dry the motorcycle with a chamois or an absorbing cloth. 2. Immediately dry the drive chain and lubricate it to prevent it from rusting. 3. Use a chrome polish to shine chrome, aluminum and stainlesssteel parts, including the exhaust system. (Even the thermally induced discoloring of stainlesssteel exhaust systems can be removed through polishing.) 4.
E_U2UJ1B.book Page 4 Wednesday, May 29, 2002 1:56 PM MOTORCYCLE CARE AND STORAGE Storage Short-term Always store your motorcycle in a cool, dry place and, if necessary, protect it against dust with a porous cover. ECA00014 @ 7 CAUTION: ● Storing the motorcycle in a poorly ventilated room or covering it with a tarp, while it is still wet, will allow water and humidity to seep in and cause rust.
E_U2UJ1B.book Page 5 Wednesday, May 29, 2002 1:56 PM MOTORCYCLE CARE AND STORAGE 6. Lubricate all control cables and the pivoting points of all levers and pedals as well as of the sidestand/ centerstand. 7. Check and, if necessary, correct the tire air pressure, and then lift the motorcycle so that both of its wheels are off the ground. Alternatively, turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot. 8.
E_U2UJ1B.book Page 1 Wednesday, May 29, 2002 1:56 PM SPECIFICATIONS EAU01038 8- Specifications CS-01E Model XV250/XV250C Engine oil Type Dimensions Overall length Overall width Overall height 685 mm (27.0 in) 1,490 mm (58.7 in) XV250C -20 -10 145 mm (5.7 in) Recommended engine oil classification 2,800 mm (110.2 in) 8 70 90 110 130 ˚F Air-cooled 4-stroke, SOHC V-type 2-cylinder Displacement 249 cm3 Bore × Stroke 49 × 66 mm (1.93 × 2.
E_U2UJ1B.book Page 2 Wednesday, May 29, 2002 1:56 PM SPECIFICATIONS Fuel Gear ratio Type UNLEADED GASOLINE ONLY Fuel tank capacity 1st 2.643 2nd 1.684 XV250 9.5 L (2.1 Imp gal, 2.5 US gal) 3rd 1.261 XV250C 9.2 L (2.0 Imp gal, 2.4 US gal) 4th 1.000 5th 0.821 Fuel reserve amount 2.6 L (0.6 Imp gal, 0.7 US gal) Carburetor Chassis Manufacturer MIKUNI Frame type Double cradle Model × quantity BDS26 × 1 Caster angle 32° Trail 120 mm (4.
E_U2UJ1B.book Page 3 Wednesday, May 29, 2002 1:56 PM SPECIFICATIONS Maximum load* Rear XV250 196 kg (432 lb) Type Drum brake XV250C 195 kg (430 lb) Operation Right foot Tire air pressure (measured on cold tires) Suspension Up to 90 kg (198 lb)* Front 175 kPa (1.75 kgf/cm2, 25 psi) Rear 200 kPa (2.00 kgf/cm2, 29 psi) 200 kPa (2.00 kgf/cm2, 29 psi) Rear 225 kPa (2.
E_U2UJ1B.book Page 4 Wednesday, May 29, 2002 1:56 PM SPECIFICATIONS Bulb voltage, wattage × quantity Headlight 12 V, 60/55 W × 1 Tail/brake light 12 V, 8/27 W × 1 Front turn signal / position light 12 V, 27/8 W × 2 Rear turn signal light 12 V, 27 W × 2 Meter lighting 14 V, 3 W × 1 Neutral indicator light 14 V, 3 W × 1 High beam indicator light 12 V, 1.
E_U2UJ1B.book Page 1 Wednesday, May 29, 2002 1:56 PM CONSUMER INFORMATION EAU01039 9- EAU02944 Identification numbers Record the key identification number, vehicle identification number and model label information in the spaces provided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen. 1. Key identification number 1. KEY IDENTIFICATION NUMBER: CA-02E 2.
E_U2UJ1B.book Page 2 Wednesday, May 29, 2002 1:56 PM CONSUMER INFORMATION 1. Model label EAU01804 Model label The model label is affixed to the frame under the rider seat. (See page 3-8 for rider seat removal and installation procedures.) Record the information on this label in the space provided. This information will be needed when ordering spare parts from a Yamaha dealer.
E_U2UJ1B.book Page 3 Wednesday, May 29, 2002 1:56 PM CONSUMER INFORMATION EAU01051 REPORTING SAFETY DEFECTS If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Yamaha Motor Corporation, U.S.A.
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E_U2UJ1B.book Page 5 Wednesday, May 29, 2002 1:56 PM CONSUMER INFORMATION EAU03052 Maintenance record Copies of work orders and/or receipts for parts purchased and installed on your motorcycle will be required to document that maintenance has been completed in accordance with the emissions warranty. The chart below is printed only as a reminder that maintenance work is required. It is not acceptable proof of maintenance work.
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E_U2UJ1B.book Page 7 Wednesday, May 29, 2002 1:56 PM CONSUMER INFORMATION EAU02918 YAMAHA MOTOR CORPORATION, U.S.A.
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E_U2UJ1B.book Page 9 Wednesday, May 29, 2002 1:56 PM CONSUMER INFORMATION EAU01063 YAMAHA EXTENDED SERVICE (Y.E.S.
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OWNER’S MANUAL XV250R XV250RC YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2002.05-0.
