OWNER’S MANUAL XV250S XV250SC YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2003.06-0.
UJ1C.
2UJ1C.book Page 1 Monday, June 2, 2003 1:04 PM INTRODUCTION EAU10080 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.
2UJ1C.book Page 1 Monday, June 2, 2003 1:04 PM IMPORTANT MANUAL INFORMATION EAU10130 Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! WARNING Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator, a bystander or a person inspecting or repairing the motorcycle.
2UJ1C.book Page 2 Monday, June 2, 2003 1:04 PM IMPORTANT MANUAL INFORMATION EAU10192 AFFIX DEALER LABEL HERE XV250S/XV250SC OWNER’S MANUAL ©2003 by Yamaha Motor Corporation, U.S.A. 1st edition, May 2003 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.
2UJ1C.book Page 1 Monday, June 2, 2003 1:04 PM TABLE OF CONTENTS SAFETY INFORMATION ..................1-1 Location of important labels ............1-5 DESCRIPTION ..................................2-1 Left view ..........................................2-1 Right view ........................................2-2 Controls and instruments.................2-3 INSTRUMENT AND CONTROL FUNCTIONS .......................................3-1 Main switch .....................................3-1 Indicator lights ........
2UJ1C.book Page 2 Monday, June 2, 2003 1:04 PM TABLE OF CONTENTS Front wheel ...................................6-33 Rear wheel ...................................6-34 Troubleshooting ............................6-36 Troubleshooting chart ...................6-37 MOTORCYCLE CARE AND STORAGE ..........................................7-1 Care ................................................7-1 Storage ...........................................7-3 SPECIFICATIONS .............................
2UJ1C.book Page 1 Monday, June 2, 2003 1:04 PM SAFETY INFORMATION EAU10250 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: ● OBTAIN THOROUGH INSTRUCTIONS FROM A COMPETENT SOURCE ON ALL ASPECTS OF MOTORCYCLE OPERATION.
2UJ1C.book Page 2 Monday, June 2, 2003 1:04 PM SAFETY INFORMATION ● ● wide on a turn due to EXCESSIVE SPEED or undercornering (insufficient lean angle for the speed). • Always obey the speed limit and never travel faster than warranted by road and traffic conditions. • Always signal before turning or changing lanes. Make sure that other motorists can see you. The posture of the operator and passenger is important for proper control.
2UJ1C.book Page 3 Monday, June 2, 2003 1:04 PM SAFETY INFORMATION 1 Loading The total weight of the operator, passenger, accessories and cargo must not exceed the maximum load limit of 195 kg (430 lb) (CAL) / 196 kg (432 lb) (U49). When loading within this weight limit, keep the following in mind: ● Cargo and accessory weight should be kept as low and close to the motorcycle as possible.
2UJ1C.book Page 4 Monday, June 2, 2003 1:04 PM SAFETY INFORMATION Gasoline and exhaust gas ● GASOLINE IS HIGHLY FLAMMABLE: • Always turn the engine off when refueling. • Take care not to spill any gasoline on the engine or exhaust system when refueling. • 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.
2UJ1C.book Page 5 Monday, June 2, 2003 1:04 PM SAFETY INFORMATION EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle.
2UJ1C.
2UJ1C.book Page 1 Monday, June 2, 2003 1:04 PM DESCRIPTION EAU10410 Left view 2 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
2UJ1C.book Page 2 Monday, June 2, 2003 1:04 PM DESCRIPTION EAU10420 Right view 2 1. 2. 3. 4. 5. 6. 7. 8. 9.
2UJ1C.book Page 3 Monday, June 2, 2003 1:04 PM DESCRIPTION EAU10430 Controls and instruments 2 1. 2. 3. 4. 5. 6. 7. 8.
2UJ1C.book Page 1 Monday, June 2, 2003 1:04 PM INSTRUMENT AND CONTROL FUNCTIONS EAU10450 Main switch EAU10810 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”. EAU10980 Indicator lights ECA11020 CAUTION: 3 Do not use the parking position for an extended length of time, otherwise the battery may discharge.
2UJ1C.book Page 2 Monday, June 2, 2003 1:04 PM INSTRUMENT AND CONTROL FUNCTIONS EAU11090 High beam indicator light “HIGH BEAM” This indicator light comes on when the high beam of the headlight is switched on. EAU11630 Speedometer unit EAU12341 Handlebar switches Left 3 1. 2. 3. 4. Odometer Tripmeter Tripmeter reset knob Speedometer The speedometer unit is equipped with a speedometer, an odometer and a tripmeter. The speedometer shows riding speed. The odometer shows the total distance traveled.
2UJ1C.book Page 3 Monday, June 2, 2003 1:04 PM INSTRUMENT AND CONTROL FUNCTIONS EAU12410 Dimmer switch “LIGHTS” Set the switch to “HI” for the high beam and to “LO” for the low beam. ECA10050 EAU12820 Clutch lever CAUTION: See page 5-1 for starting instructions prior to starting the engine. EAU12440 Turn signal switch “TURN” To signal a right-hand turn, push this switch to the right. To signal a left-hand turn, push this switch to the left. When released, the switch returns to the center position.
2UJ1C.book Page 4 Monday, June 2, 2003 1:04 PM INSTRUMENT AND CONTROL FUNCTIONS EAU12870 EAU12890 EAU12941 Shift pedal Brake lever Brake pedal 1. Shift pedal 1. Brake lever 1. Brake pedal The shift pedal is located on the left side of the engine and is used in combination with the clutch lever when shifting the gears of the 5-speed constant-mesh transmission equipped on this motorcycle. The brake lever is located at the right handlebar grip.
2UJ1C.book Page 5 Monday, June 2, 2003 1:04 PM INSTRUMENT AND CONTROL FUNCTIONS EAU13040 Fuel tank cap EAU13210 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. Fuel EWA11090 WARNING 3 Make sure that the fuel tank cap is properly closed before riding. 1. Fuel tank cap 2. Unlock. 1. Fuel tank filler tube 2. Fuel level Make sure that there is sufficient fuel in the tank.
2UJ1C.book Page 6 Monday, June 2, 2003 1:04 PM INSTRUMENT AND CONTROL FUNCTIONS ECA10070 CAUTION: Immediately wipe off spilled fuel with a clean, dry, soft cloth, since fuel may deteriorate painted surfaces or plastic parts. EAU13300 3 Recommended fuel: UNLEADED GASOLINE ONLY Fuel tank capacity: 9.2 L (2.43 US gal) (2.02 Imp.gal) (CAL) 9.5 L (2.51 US gal) (2.09 Imp.gal) (U49) Fuel reserve amount: 2.6 L (0.69 US gal) (0.57 Imp.gal) [(R+M)/2] of 86 or higher, or a research octane number of 91 or higher.
2UJ1C.book Page 7 Monday, June 2, 2003 1:04 PM INSTRUMENT AND CONTROL FUNCTIONS RES PRI EAU13630 Starter (choke) lever 3 1. Arrow mark positioned over “RES” 1. Arrow mark positioned over “PRI” 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”).
2UJ1C.book Page 8 Monday, June 2, 2003 1:04 PM INSTRUMENT AND CONTROL FUNCTIONS EAU13730 Steering lock 3 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. EAU14220 Rider seat To remove the rider seat Remove the bolts, and then pull the rider seat off. 1. Steering lock To lock the steering 1.
2UJ1C.book Page 9 Monday, June 2, 2003 1:04 PM INSTRUMENT AND CONTROL FUNCTIONS EAU14280 Helmet holder EAU14880 Adjusting the shock absorber assemblies 3 1. Projection 2. Seat holder 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. To open the helmet holder, insert the key into the lock, and then turn the key as shown.
2UJ1C.book Page 10 Monday, June 2, 2003 1:04 PM INSTRUMENT AND CONTROL FUNCTIONS EWA10210 WARNING 3 EAU15300 Sidestand Always adjust both shock absorber assemblies equally, otherwise poor handling and loss of stability may result. The sidestand is located on the left side of the frame. Raise the sidestand or lower it with your foot while holding the vehicle upright. Adjust the spring preload as follows.
2UJ1C.book Page 11 Monday, June 2, 2003 1:04 PM INSTRUMENT AND CONTROL FUNCTIONS EAU15311 Ignition circuit cut-off system The ignition circuit cut-off system (comprising the sidestand switch, clutch switch and neutral switch) has the following functions. ● It prevents starting when the transmission is in gear and the sidestand is up, but the clutch lever is not pulled. ● It prevents starting when the transmission is in gear and the clutch lever is pulled, but the sidestand is still down.
2UJ1C.book Page 12 Monday, June 2, 2003 1:04 PM INSTRUMENT AND CONTROL FUNCTIONS With the engine turned off: 1. Move the sidestand down. 2. Make sure that the engine stop switch is turned on. 3. Turn the key on. 4. Shift the transmission into the neutral position. 5. Push the start switch. Does the engine start? NOTE: This check is most reliable if performed with a warmed-up engine. 3 YES NO The neutral switch may be defective. The motorcycle should not be ridden until checked by a Yamaha dealer.
2UJ1C.book Page 1 Monday, June 2, 2003 1:04 PM PRE-OPERATION CHECKS EAU15591 The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly, even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thorough visual inspection, to check the following points before each ride.
2UJ1C.book Page 2 Monday, June 2, 2003 1:04 PM PRE-OPERATION CHECKS EAU15601 Pre-operation check list ITEM CHECKS PAGE Fuel • Check fuel level in fuel tank. • Refuel if necessary. • Check fuel line for leakage. 3-5 Engine oil • Check oil level in engine. • If necessary, add recommended oil to specified level. • Check vehicle for oil leakage. 6-10 Front brake • • • • • • • • • Rear brake • Check operation. • Check pedal free play. • Adjust if necessary.
2UJ1C.book Page 3 Monday, June 2, 2003 1:04 PM PRE-OPERATION CHECKS ITEM CHECKS PAGE Drive chain • • • • Check chain slack. Adjust if necessary. Check chain condition. Lubricate if necessary. 6-22, 6-24 Wheels and tires • • • • Check for damage. Check tire condition and tread depth. Check air pressure. Correct if necessary. 6-15, 6-16 Brake and shift pedals • Make sure that operation is smooth. • Lubricate pedal pivoting points if necessary.
2UJ1C.book Page 1 Monday, June 2, 2003 1:04 PM OPERATION AND IMPORTANT RIDING POINTS EAU15950 EWA10270 WARNING ● ● 5 ● 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. Exhaust fumes are poisonous, and inhaling them can cause loss of consciousness and death within a short time.
2UJ1C.book Page 2 Monday, June 2, 2003 1:04 PM OPERATION AND IMPORTANT RIDING POINTS ECA11130 EAU16640 CAUTION: Starting a warm engine For maximum engine life, always warm the engine up before starting off. Never accelerate hard when the engine is cold! Follow the same procedure as for starting a cold engine with the exception that the starter (choke) is not required when the engine is warm. EAU16671 Shifting 7. When the engine is warm, turn the starter (choke) off.
2UJ1C.book Page 3 Monday, June 2, 2003 1:04 PM OPERATION AND IMPORTANT RIDING POINTS ECA10260 CAUTION: ● 5 ● 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. The transmission is properly lubricated only when the engine is running. Inadequate lubrication may damage the transmission.
2UJ1C.book Page 4 Monday, June 2, 2003 1:04 PM OPERATION AND IMPORTANT RIDING POINTS EAU16841 ECA11281 EAU17200 Engine break-in CAUTION: Parking There is never a more important period in the life of your engine than the period between 0 and 1600 km (1000 mi). For this reason, you should read the following material carefully. Since the engine is brand new, do not put an excessive load on it for the first 1600 km (1000 mi).
2UJ1C.book Page 1 Monday, June 2, 2003 1:04 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU17231 EAU17300 PERIODIC MAINTENANCE 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.
2UJ1C.book Page 2 Monday, June 2, 2003 1:04 PM PERIODIC MAINTENANCE AND MINOR REPAIR EWA10340 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.
2UJ1C.book Page 3 Monday, June 2, 2003 1:04 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU17580 Periodic maintenance chart for the emission control system INITIAL No. ITEM ROUTINE 600 mi (1000 km) or 1 month ODOMETER READINGS 4000 mi (6000 km) or 6 months 7000 mi 10000 mi 13000 mi 16000 mi (11000 km) (16000 km) (21000 km) (26000 km) or or or or 12 months 18 months 24 months 30 months Fuel line • Check fuel and vacuum hoses for cracks or damage. • Replace if necessary.
2UJ1C.book Page 4 Monday, June 2, 2003 1:04 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU32161 General maintenance and lubrication chart INITIAL No. ITEM ROUTINE 600 mi (1000 km) or 1 month ODOMETER READINGS 4000 mi (6000 km) or 6 months 7000 mi 10000 mi 13000 mi 16000 mi (11000 km) (16000 km) (21000 km) (26000 km) or or or or 12 months 18 months 24 months 30 months 1 * Air filter element • Clean with solvent. • Replace if necessary.
2UJ1C.book Page 5 Monday, June 2, 2003 1:04 PM PERIODIC MAINTENANCE AND MINOR REPAIR INITIAL No. ITEM ROUTINE 9 * Wheel bearings • Check bearings for smooth operation. • Replace if necessary. 10 * Swingarm pivot bearings • Check bearing assemblies for looseness. • Moderately repack with lithiumsoap-based grease. Drive chain • Check chain slack/alignment and condition. • Adjust and lubricate chain with a special O-ring chain lubricant thoroughly.
2UJ1C.book Page 6 Monday, June 2, 2003 1:04 PM PERIODIC MAINTENANCE AND MINOR REPAIR INITIAL No. ITEM ROUTINE ODOMETER READINGS 600 mi (1000 km) or 1 month 4000 mi (6000 km) or 6 months √ √ √ √ √ √ 7000 mi 10000 mi 13000 mi 16000 mi (11000 km) (16000 km) (21000 km) (26000 km) or or or or 12 months 18 months 24 months 30 months 17 * Sidestand switch • Check operation and replace if necessary. 18 * Front fork • Check operation and for oil leakage. • Replace if necessary.
2UJ1C.book Page 7 Monday, June 2, 2003 1:04 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU17620 NOTE: ● The air filter needs more frequent service if you are riding in unusually wet or dusty areas. ● Hydraulic brake system • When disassembling the master cylinder or caliper cylinder, always replace the brake fluid. Check the brake fluid level regularly and fill as required. • Replace the oil seals on the inner parts of the master cylinder and caliper cylinder every two years.
2UJ1C.book Page 8 Monday, June 2, 2003 1:04 PM PERIODIC MAINTENANCE AND MINOR REPAIR 3. Check each spark plug for electrode erosion and excessive carbon or other deposits, and replace it if necessary. EAU19543 Checking the spark plugs The spark plugs are important engine components, which are easy to check. Since heat and deposits will cause any spark plug to slowly erode, the spark plugs should be removed and checked in accordance with the periodic maintenance and lubrication chart.
2UJ1C.book Page 9 Monday, June 2, 2003 1:04 PM PERIODIC MAINTENANCE AND MINOR REPAIR 2. Clean the surface of the spark plug gasket and its mating surface, and then wipe off any grime from the spark plug threads. 3. Install the spark plug with the spark plug wrench, and then tighten it to the specified torque. EAU19680 Canister (for California only) Tightening torque: Spark plug: 12.5 Nm (1.25 m·kgf, 9.
2UJ1C.book Page 10 Monday, June 2, 2003 1:04 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU19751 Engine oil and oil filter element The engine oil level should be checked before each ride. In addition, the oil must be changed and the oil filter element replaced at the intervals specified in the periodic maintenance and lubrication chart. To check the engine oil level 1. Place the vehicle on a level surface and hold it in an upright position.
2UJ1C.book Page 11 Monday, June 2, 2003 1:04 PM PERIODIC MAINTENANCE AND MINOR REPAIR Tightening torque: Engine oil drain bolt: 34 Nm (3.4 m·kgf, 25 ft·lbf) NOTE: Skip steps 4–6 if the oil filter element is not being replaced. 8. Add the specified amount of the recommended engine oil, and then install and tighten the oil filler cap. 4. Remove the oil filter element cover by removing the bolts. 1. Oil filter element 2. O-ring 6.
2UJ1C.book Page 12 Monday, June 2, 2003 1:04 PM PERIODIC MAINTENANCE AND MINOR REPAIR ● Make sure that no foreign material enters the crankcase. 9. Start the engine, and then let it idle for several minutes while checking it for oil leakage. If oil is leaking, immediately turn the engine off and check for the cause. 10. Turn the engine off, and then check the oil level and correct it if necessary.
2UJ1C.book Page 13 Monday, June 2, 2003 1:04 PM PERIODIC MAINTENANCE AND MINOR REPAIR 3. Remove the air filter case cover by removing the screws. 5. Remove the sponge material from the air filter element frame, clean it with solvent, and then squeeze the remaining solvent out. 7. Pull the sponge material over the air filter element frame. 8. Insert the element into the air filter case, and then tighten the wing nut. ECA10480 CAUTION: ● ● 1. Screw 4.
2UJ1C.book Page 14 Monday, June 2, 2003 1:04 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU21250 Adjusting the carburetor The carburetor is an important part of the engine and its emission control system, which requires very sophisticated adjustment. Therefore, carburetor adjustments should be left to Yamaha dealer, who has the necessary professional knowledge and experience.
2UJ1C.book Page 15 Monday, June 2, 2003 1:04 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU32520 Tires To maximize the performance, durability, and safe operation of your motorcycle, note the following points regarding the specified tires. Tire air pressure The tire air pressure should be checked and, if necessary, adjusted before each ride. EWA10500 WARNING ● 6 ● The tire air pressure must be checked and adjusted on cold tires (i.e., when the temperature of the tires equals the ambient temperature).
2UJ1C.book Page 16 Monday, June 2, 2003 1:04 PM PERIODIC MAINTENANCE AND MINOR REPAIR if the tire has a nail or glass fragments in it, or if the sidewall is cracked, contact a Yamaha dealer immediately and have the tire replaced. Tire information This motorcycle is equipped with spoke wheels and tube tires. EWA10460 WARNING Minimum tire tread depth (front and rear): 1.0 mm (0.04 in) ● EWA10560 WARNING ● ● ● It is dangerous to ride with a worn-out tire.
2UJ1C.book Page 17 Monday, June 2, 2003 1:04 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU22010 Accessories and replacement parts any consequences caused by the use of items which have not been approved by Yamaha. EAU22040 Adjusting the clutch lever free play EWA10620 WARNING 6 This motorcycle is not designed to pull a trailer or to be attached to a sidecar.
2UJ1C.book Page 18 Monday, June 2, 2003 1:04 PM PERIODIC MAINTENANCE AND MINOR REPAIR 3. If the specified clutch lever free play could be obtained as described above, tighten the locknut and skip the rest of the procedure, otherwise proceed as follows. 4. Fully turn the adjusting bolt at the clutch lever in direction (a) to loosen the clutch cable. 5. Loosen the locknut at the crankcase. 7. Tighten the locknut at the clutch lever and the crankcase. EAU22091 Adjusting the brake lever free play 1.
2UJ1C.book Page 19 Monday, June 2, 2003 1:04 PM PERIODIC MAINTENANCE AND MINOR REPAIR EWA10630 WARNING ● ● 6 After adjusting the brake lever free play, check the free play and make sure that the brake is working properly. A soft or spongy feeling in the brake lever can indicate the presence of air in the hydraulic system. If there is air in the hydraulic system, have a Yamaha dealer bleed the system before operating the motorcycle.
2UJ1C.book Page 20 Monday, June 2, 2003 1:04 PM PERIODIC MAINTENANCE AND MINOR REPAIR Brake pedal free play The brake pedal free play should measure 20.0–30.0 mm (0.79–1.18 in) at the brake pedal end. Periodically check the brake pedal free play and, if necessary, adjust it as follows. To increase the brake pedal free play, turn the adjusting nut at the brake rod in direction (a). To decrease the brake pedal free play, turn the adjusting nut in direction (b).
2UJ1C.book Page 21 Monday, June 2, 2003 1:04 PM PERIODIC MAINTENANCE AND MINOR REPAIR Checking the front brake pads and rear brake shoes indicator groove has almost disappeared, have a Yamaha dealer replace the brake pads as a set. 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. Rear brake shoes EAU22380 EAU22580 Checking the brake fluid level Front brake EAU22540 EAU22420 Front brake pads 1.
2UJ1C.book Page 22 Monday, June 2, 2003 1:04 PM PERIODIC MAINTENANCE AND MINOR REPAIR ● Use only the recommended quality brake fluid, otherwise the rubber seals may deteriorate, causing leakage and poor braking performance. Recommended brake fluid: DOT 4 ● ● ● ● Refill with the same type of brake fluid. Mixing fluids may result in a harmful chemical reaction and lead to poor braking performance. Be careful that water does not enter the brake fluid reservoir when refilling.
2UJ1C.book Page 23 Monday, June 2, 2003 1:04 PM PERIODIC MAINTENANCE AND MINOR REPAIR 1. Drive chain slack 4. If the drive chain slack is incorrect, adjust it as follows. EAU22860 6 To adjust the drive chain slack 1. Loosen the brake pedal free play adjusting nut. 2. Remove the cotter pin from the axle nut, and then loosen the axle nut. 3. Loosen the chain puller locknut at each end of the swingarm. 4. To tighten the drive chain, turn the adjusting nut at each end of the swingarm in direction (a).
2UJ1C.book Page 24 Monday, June 2, 2003 1:04 PM PERIODIC MAINTENANCE AND MINOR REPAIR Tightening torque: Axle nut: 104 Nm (10.4 m·kgf, 75 ft·lbf) 6. Insert a new cotter pin into the axle nut, and then bend its ends as shown. 7. Adjust the brake pedal free play. (See page 6-19.) EWA10660 WARNING After adjusting the brake pedal free play, check the operation of the brake light.
2UJ1C.book Page 25 Monday, June 2, 2003 1:04 PM PERIODIC MAINTENANCE AND MINOR REPAIR ECA11110 CAUTION: Do not use engine oil or any other lubricants for the drive chain, as they may contain substances that could damage the O-rings. EAU23090 Checking and lubricating the throttle grip and cable The operation of all control cables and the condition of the cables should be checked before each ride, and the cables and cable ends should be lubricated if necessary.
2UJ1C.book Page 26 Monday, June 2, 2003 1:04 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23131 EAU23140 EAU23200 Checking and lubricating the brake and shift pedals Checking and lubricating the brake and clutch levers Checking and lubricating the sidestand The operation of the brake and shift pedals should be checked before each ride, and the pedal pivots should be lubricated if necessary.
2UJ1C.book Page 27 Monday, June 2, 2003 1:04 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23271 EAU23280 Checking the front fork Checking the steering The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart. 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.
2UJ1C.book Page 28 Monday, June 2, 2003 1:04 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23290 EAU23310 Checking the wheel bearings Battery The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart. If there is play in the wheel hub or if the wheel does not turn smoothly, have a Yamaha dealer check the wheel bearings. A poorly maintained battery will corrode and discharge quickly.
2UJ1C.book Page 29 Monday, June 2, 2003 1:04 PM PERIODIC MAINTENANCE AND MINOR REPAIR ● 1. Maximum level mark 2. Minimum level mark 6 3. If the electrolyte is at or below the minimum level mark, add distilled water to raise it to the maximum level mark. ● EWA10770 WARNING ● Electrolyte is poisonous and dangerous since it contains sulfuric acid, which causes severe burns. Avoid any contact with skin, eyes or clothing and always shield your eyes when working near batteries.
2UJ1C.book Page 30 Monday, June 2, 2003 1:04 PM PERIODIC MAINTENANCE AND MINOR REPAIR that the breather hose is properly routed, in good condition, and not obstructed. EAU23600 Replacing the fuses ECA10640 CAUTION: Do not use a fuse of a higher amperage rating than recommended to avoid causing extensive damage to the electrical system and possibly a fire.
2UJ1C.book Page 31 Monday, June 2, 2003 1:04 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23780 EWA10790 Replacing the headlight bulb WARNING This model 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. Headlight bulbs get very hot. Therefore, keep flammable products away from a lit headlight bulb, and do not touch the bulb until it has cooled down. 1. Headlight coupler 2. Headlight bulb cover 3.
2UJ1C.book Page 32 Monday, June 2, 2003 1:04 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU24350 Supporting the motorcycle 1. Do not touch the glass part of the bulb. 5. Install the headlight bulb cover, and then connect the coupler. 6. Install the headlight unit by installing the screws. 7. Have a Yamaha dealer adjust the headlight beam if necessary.
2UJ1C.book Page 33 Monday, June 2, 2003 1:04 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU24360 Front wheel EAU24600 To remove the front wheel EWA10820 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. 6 1. Wheel axle 2. Front wheel axle pinch bolt 1. Speedometer gear unit 3.
2UJ1C.book Page 34 Monday, June 2, 2003 1:04 PM PERIODIC MAINTENANCE AND MINOR REPAIR 7. Push down hard on the handlebar several times to check for proper fork operation. 8. Connect the speedometer cable. EAU25080 Rear wheel EAU32750 To remove the rear wheel EWA10820 WARNING ● ● 1. Speedometer gear unit 2. Retainer 3. Speedometer cable 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.
2UJ1C.book Page 35 Monday, June 2, 2003 1:04 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU32760 1. 2. 3. 4. 5. 6 Axle nut Axle nut cotter pin Chain puller locknut Drive chain slack adjusting nut Alignment marks 3. Loosen the axle nut and the brake torque rod nut at the brake shoe plate. 4. Lift the rear wheel off the ground according to the procedure on page 6-32. 5. Remove the brake pedal free play adjusting nut, and then disconnect the brake rod at the brake camshaft lever. 6.
2UJ1C.book Page 36 Monday, June 2, 2003 1:04 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU25850 Tightening torque: Axle nut: 104 Nm (10.4 m·kgf, 75 ft·lbf) EWA10700 WARNING Always use a new cotter pin for the axle nut. 7. Adjust the brake pedal position and free play. (See page 6-19.) EWA10660 WARNING After adjusting the brake pedal free play, check the operation of the brake light.
2UJ1C.book Page 37 Monday, June 2, 2003 1:04 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU25931 Troubleshooting chart EWA10840 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. Check the fuel level in the fuel tank. The engine does not start. Check the compressoin. 2. Compression There is compression. Check the ignition. There is no compression.
2UJ1C.book Page 1 Monday, June 2, 2003 1:04 PM MOTORCYCLE CARE AND STORAGE ucts onto seals, gaskets, sprockets, the drive chain and wheel axles. Always rinse the dirt and degreaser off with water. EAU26040 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.
2UJ1C.book Page 2 Monday, June 2, 2003 1:04 PM MOTORCYCLE CARE AND STORAGE After normal use Remove dirt with warm water, a mild detergent, and a soft, clean sponge, and then rinse thoroughly with clean water. Use a toothbrush or bottlebrush for hard-to-reach areas. Stubborn dirt and insects will come off more easily if the area is covered with a wet cloth for a few minutes before cleaning.
2UJ1C.book Page 3 Monday, June 2, 2003 1:04 PM MOTORCYCLE CARE AND STORAGE ECA10800 CAUTION: ● ● ● Apply spray oil and wax sparingly and make sure to wipe off any excess. Never apply oil or wax to any rubber and plastic parts, but treat them with a suitable care product. Avoid using abrasive polishing compounds as they will wear away the paint. NOTE: Consult a Yamaha dealer for advice on what products to use.
2UJ1C.book Page 4 Monday, June 2, 2003 1:04 PM MOTORCYCLE CARE AND STORAGE EWA10950 WARNING To prevent damage or injury from sparking, make sure to ground the spark plug electrodes while turning the engine over. 7 °C (90 °F)]. For more information on storing the battery, see page 6-28. NOTE: Make any necessary repairs before storing the motorcycle. 6. Lubricate all control cables and the pivoting points of all levers and pedals as well as of the sidestand/centerstand. 7.
2UJ1C.book Page 1 Monday, June 2, 2003 1:04 PM SPECIFICATIONS Dimensions: Overall length: 2190 mm (86.2 in) Overall width: 815 mm (32.1 in) Overall height: 1140 mm (44.9 in) Seat height: 685 mm (27.0 in) Wheelbase: 1490 mm (58.7 in) Ground clearance: 145 mm (5.71 in) Minimum turning radius: 2800 mm (110.2 in) Weight: With oil and fuel: 147.0 kg (324 lb) (U49) 148.0 kg (326 lb) (CAL) Engine: Engine type: Air cooled 4-stroke, SOHC Cylinder arrangement: V-type 2-cylinder Displacement: 249.0 cm³ (15.19 cu.
2UJ1C.book Page 2 Monday, June 2, 2003 1:04 PM SPECIFICATIONS Gear ratio: 1st: 37/14 (2.643) 2nd: 32/19 (1.684) 3rd: 29/23 (1.261) 4th: 26/26 (1.000) 5th: 23/28 (0.821) Chassis: Frame type: Double cradle Caster angle: 32.0 ° Trail: 120.0 mm (4.72 in) Front tire: 8 Type: With tube Size: 3.
2UJ1C.book Page 3 Monday, June 2, 2003 1:04 PM SPECIFICATIONS Headlight: Bulb type: Halogen bulb Bulb voltage, wattage x quantity: Headlight: 12 V, 60 W/55.0 W × 1 Tail/brake light: 12 V, 8 W/27.0 W × 1 Front turn signal/position light: 12 V, 27 W/8.0 W × 2 Rear turn signal light: 12 V, 27.0 W × 2 Meter lighting: 14 V, 3.0 W × 1 Neutral indicator light: 14 V, 3.0 W × 1 High beam indicator light: 12 V, 1.7 W × 1 Turn signal indicator light: 14 V, 3.0 W × 1 Fuses: Main fuse: 20.
2UJ1C.book Page 1 Monday, June 2, 2003 1:04 PM CONSUMER INFORMATION EAU26351 Identification numbers EAU26390 EAU26400 Key identification number Vehicle identification number 1. Key identification number 1. Vehicle identification number The key identification number is stamped into the key. Record this number in the space provided and use it for reference when ordering a new key. The vehicle identification number is stamped into the steering head pipe. Record this number in the space provided.
2UJ1C.book Page 2 Monday, June 2, 2003 1:04 PM CONSUMER INFORMATION EAU26470 Model label 1. Model label The model label is affixed to the frame under the rider seat. (See page 3-8.) Record the information on this label in the space provided. This information will be needed when ordering spare parts from a Yamaha dealer.
2UJ1C.book Page 3 Monday, June 2, 2003 1:04 PM CONSUMER INFORMATION EAU26550 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.
2UJ1C.
2UJ1C.book Page 5 Monday, June 2, 2003 1:04 PM CONSUMER INFORMATION EAU26611 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.
2UJ1C.
2UJ1C.book Page 7 Monday, June 2, 2003 1:04 PM CONSUMER INFORMATION EAU26661 YAMAHA MOTOR CORPORATION, U.S.A.
2UJ1C.
2UJ1C.book Page 9 Monday, June 2, 2003 1:04 PM CONSUMER INFORMATION EAU26750 YAMAHA EXTENDED SERVICE (Y.E.S.) Keep your Yamaha protected even after your warranty expires with genuine Yamaha Extended Service (Y.E.S.). In addition, Travel and Recreation Interruption Protection (TRIP) is included at no extra cost.
2UJ1C.book Page 10 Monday, June 2, 2003 1:04 PM CONSUMER INFORMATION We urge you to act now. You’ll get the excellent benefits of TRIP coverage right away, and you’ll rest easy knowing you’ll have strong factory-backed protection even after your Yamaha Limited Warranty expires. A special note: If visiting your dealer isn’t convenient, contact Yamaha with your Primary ID number (your frame number). We’ll be happy to help you get the Y.E.S. coverage you need. Yamaha Service Marketing P.O.
2UJ1C.book Page 1 Monday, June 2, 2003 1:04 PM INDEX A F Accessories and replacement parts...... 6-17 Air filter element, cleaning..................... 6-12 B Battery................................................... 6-28 Brake and clutch levers, checking and lubricating ........................................... 6-26 Brake and shift pedals, checking and lubricating ........................................... 6-26 Brake fluid, changing ............................ 6-22 Brake fluid level, checking ....
2UJ1C.book Page 2 Monday, June 2, 2003 1:04 PM INDEX Vehicle identification number.................. 9-1 W Warranty, extended ................................ 9-9 Warranty, limited..................................... 9-7 Wheel bearings, checking .................... 6-28 Wheel (front) ......................................... 6-33 Wheel (rear).......................................... 6-34 Wheels..................................................
OWNER’S MANUAL XV250S XV250SC YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2003.06-0.
