OWNER’S MANUAL XV250T XV250TC YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2004.05-0.
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U2UJ1DE0.book Page 1 Thursday, May 13, 2004 11:59 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.
U2UJ1DE0.book Page 1 Thursday, May 13, 2004 11:59 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.
U2UJ1DE0.book Page 2 Thursday, May 13, 2004 11:59 PM IMPORTANT MANUAL INFORMATION AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES. REGULAR INSPECTIONS AND CAREFUL MAINTENANCE, ALONG WITH GOOD RIDING SKILLS, WILL ENSURE THAT YOU SAFELY ENJOY THE CAPABILITIES AND THE RELIABILITY OF THIS MOTORCYCLE.
U2UJ1DE0.book Page 3 Thursday, May 13, 2004 11:59 PM IMPORTANT MANUAL INFORMATION EAU10192 AFFIX DEALER LABEL HERE XV250T/XV250TC OWNER’S MANUAL ©2004 by Yamaha Motor Corporation, U.S.A. 1st edition, April 2004 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.
U2UJ1DE0.book Page 1 Thursday, May 13, 2004 11:59 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 ...
U2UJ1DE0.book Page 2 Thursday, May 13, 2004 11:59 PM TABLE OF CONTENTS Battery ..........................................6-29 Replacing the fuses ......................6-31 Replacing the headlight bulb ........6-32 Replacing the tail/brake light bulb ....................................6-33 Replacing a turn signal light bulb ...........................................6-34 Supporting the motorcycle ............6-34 Front wheel ...................................6-35 Rear wheel ..............................
U2UJ1DE0.book Page 1 Thursday, May 13, 2004 11:59 PM SAFETY INFORMATION EAU10251 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.
U2UJ1DE0.book Page 2 Thursday, May 13, 2004 11:59 PM SAFETY INFORMATION 1 ● ● 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.
U2UJ1DE0.book Page 3 Thursday, May 13, 2004 11:59 PM SAFETY INFORMATION Loading The total weight of the operator, passenger, accessories and cargo must not exceed the maximum load limit. Maximum load: 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.
U2UJ1DE0.book Page 4 Thursday, May 13, 2004 11:59 PM SAFETY INFORMATION 1 ● tor and may limit control ability, therefore, such accessories are not recommended. Use caution when adding electrical accessories. If electrical accessories exceed the capacity of the motorcycle’s electrical system, an electric failure could result, which could cause a dangerous loss of lights or engine power. Gasoline and exhaust gas ● GASOLINE IS HIGHLY FLAMMABLE: • Always turn the engine off when refueling.
U2UJ1DE0.book Page 5 Thursday, May 13, 2004 11:59 PM SAFETY INFORMATION EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle.
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U2UJ1DE0.book Page 1 Thursday, May 13, 2004 11:59 PM DESCRIPTION EAU10410 Left view 2 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
U2UJ1DE0.book Page 2 Thursday, May 13, 2004 11:59 PM DESCRIPTION EAU10420 Right view 2 1. 2. 3. 4. 5. 6. 7. 8. 9.
U2UJ1DE0.book Page 3 Thursday, May 13, 2004 11:59 PM DESCRIPTION EAU10430 Controls and instruments 2 1. 2. 3. 4. 5. 6. 7. 8.
U2UJ1DE0.book Page 1 Thursday, May 13, 2004 11:59 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.
U2UJ1DE0.book Page 2 Thursday, May 13, 2004 11:59 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 EAU12343 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.
U2UJ1DE0.book Page 3 Thursday, May 13, 2004 11:59 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 3 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.
U2UJ1DE0.book Page 4 Thursday, May 13, 2004 11:59 PM INSTRUMENT AND CONTROL FUNCTIONS EAU12870 Shift pedal EAU12890 Brake lever EAU12941 Brake pedal 3 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.
U2UJ1DE0.book Page 5 Thursday, May 13, 2004 11:59 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.
U2UJ1DE0.book Page 6 Thursday, May 13, 2004 11:59 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 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.
U2UJ1DE0.book Page 7 Thursday, May 13, 2004 11:59 PM INSTRUMENT AND CONTROL FUNCTIONS RES PRI 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”).
U2UJ1DE0.book Page 8 Thursday, May 13, 2004 11:59 PM INSTRUMENT AND CONTROL FUNCTIONS EAU13730 Steering lock 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. 3 1. Steering lock To lock the steering 1.
U2UJ1DE0.book Page 9 Thursday, May 13, 2004 11:59 PM INSTRUMENT AND CONTROL FUNCTIONS EAU14281 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.
U2UJ1DE0.book Page 10 Thursday, May 13, 2004 11:59 PM INSTRUMENT AND CONTROL FUNCTIONS EWA10210 WARNING 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.
U2UJ1DE0.book Page 11 Thursday, May 13, 2004 11:59 PM INSTRUMENT AND CONTROL FUNCTIONS EAU15311 Ignition circuit cut-off system 3 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.
U2UJ1DE0.book Page 12 Thursday, May 13, 2004 11:59 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? YES NOTE: This check is most reliable if performed with a warmed-up engine. NO The neutral switch may be defective. The motorcycle should not be ridden until checked by a Yamaha dealer.
U2UJ1DE0.book Page 1 Thursday, May 13, 2004 11:59 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.
U2UJ1DE0.book Page 2 Thursday, May 13, 2004 11:59 PM PRE-OPERATION CHECKS EAU15603 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.
U2UJ1DE0.book Page 3 Thursday, May 13, 2004 11:59 PM PRE-OPERATION CHECKS ITEM CHECKS PAGE Drive chain • • • • Check chain slack. Adjust if necessary. Check chain condition. Lubricate if necessary. 6-23, 6-25 Wheels and tires • • • • Check for damage. Check tire condition and tread depth. Check air pressure. Correct if necessary. 6-15, 6-17 Brake and shift pedals • Make sure that operation is smooth. • Lubricate pedal pivoting points if necessary.
U2UJ1DE0.book Page 1 Thursday, May 13, 2004 11:59 PM OPERATION AND IMPORTANT RIDING POINTS EAU15950 EWA10270 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. Exhaust fumes are poisonous, and inhaling them can cause loss of consciousness and death within a short time.
U2UJ1DE0.book Page 2 Thursday, May 13, 2004 11:59 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.
U2UJ1DE0.book Page 3 Thursday, May 13, 2004 11:59 PM OPERATION AND IMPORTANT RIDING POINTS ECA10260 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. The transmission is properly lubricated only when the engine is running. Inadequate lubrication may damage the transmission.
U2UJ1DE0.book Page 4 Thursday, May 13, 2004 11:59 PM OPERATION AND IMPORTANT RIDING POINTS EAU16841 5 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).
U2UJ1DE0.book Page 1 Thursday, May 13, 2004 11:59 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU17231 EAU17301 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.
U2UJ1DE0.book Page 2 Thursday, May 13, 2004 11:59 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.
U2UJ1DE0.book Page 3 Thursday, May 13, 2004 11:59 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.
U2UJ1DE0.book Page 4 Thursday, May 13, 2004 11:59 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.
U2UJ1DE0.book Page 5 Thursday, May 13, 2004 11:59 PM PERIODIC MAINTENANCE AND MINOR REPAIR 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 9 * Wheel bearings • Check bearings for smooth operation. • Replace if necessary. 10 * Swingarm pivot bearings • Check bearing assemblies for looseness.
U2UJ1DE0.book Page 6 Thursday, May 13, 2004 11:59 PM PERIODIC MAINTENANCE AND MINOR REPAIR INITIAL No. 6 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.
U2UJ1DE0.book Page 7 Thursday, May 13, 2004 11:59 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.
U2UJ1DE0.book Page 8 Thursday, May 13, 2004 11:59 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU18751 EAU19543 Removing and installing the panel Checking the spark plugs The panel shown needs to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time the panel needs to be removed and installed. To install the panel Secure the front of the panel, and then push the rear of the panel in.
U2UJ1DE0.book Page 9 Thursday, May 13, 2004 11:59 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. Specified spark plug: NGK/C6HSA DENSO/U20FS-U 1. Spark plug wrench To check the spark plugs 1. Check that the porcelain insulator around the center electrode on each spark plug is a medium-tolight tan (the ideal color when the vehicle is ridden normally). 2.
U2UJ1DE0.book Page 10 Thursday, May 13, 2004 11:59 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU19681 Canister (for California only) ● Make sure that the canister breather is not blocked, and if necessary, clean it. 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.
U2UJ1DE0.book Page 11 Thursday, May 13, 2004 11:59 PM PERIODIC MAINTENANCE AND MINOR REPAIR NOTE: The engine oil should be between the minimum and maximum level marks. 1. Engine oil level check window 2. Maximum level mark 3. Minimum level mark 2. Place an oil pan under the engine to collect the used oil. 3. Remove the engine oil filler cap and drain bolt to drain the oil from the crankcase. 4. Remove the oil filter element cover by removing the bolts. 1. Engine oil filler cap 1. Bolt 2.
U2UJ1DE0.book Page 12 Thursday, May 13, 2004 11:59 PM PERIODIC MAINTENANCE AND MINOR REPAIR ● Tightening torque: Engine oil drain bolt: 34 Nm (3.4 m·kgf, 25 ft·lbf) 8. Add the specified amount of the recommended engine oil, and then install and tighten the oil filler cap. 1. Oil filter element 2. O-ring 6. Install the oil filter element cover by installing the bolts, then tightening them to the specified torque. Recommended engine oil: See page 8-1.
U2UJ1DE0.book Page 13 Thursday, May 13, 2004 11:59 PM PERIODIC MAINTENANCE AND MINOR REPAIR 3. Remove the air filter case cover by removing the screws. EAU32730 Cleaning the air filter element The air filter element should be cleaned at the intervals specified in the periodic maintenance and lubrication chart. Clean the air filter element more frequently if you are riding in unusually wet or dusty areas. 1. Remove the bolts and loosen the air filter joint clamp screw. 1. Air filter joint clamp screw 2.
U2UJ1DE0.book Page 14 Thursday, May 13, 2004 11:59 PM PERIODIC MAINTENANCE AND MINOR REPAIR 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: ● ● 6 1. Sponge material 2. Air filter element frame 6.
U2UJ1DE0.book Page 15 Thursday, May 13, 2004 11:59 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU21380 Adjusting the throttle cable free play EAU21400 EAU32520 Adjusting the valve clearance Tires 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.
U2UJ1DE0.book Page 16 Thursday, May 13, 2004 11:59 PM PERIODIC MAINTENANCE AND MINOR REPAIR 6 Tire air pressure (measured on cold tires): 0–90 kg (0–198 lb): Front: 175 kPa (25 psi) (1.75 kgf/cm²) Rear: 200 kPa (29 psi) (2.00 kgf/cm²) 90–195 kg (198–430 lb) (CAL) 90–196 kg (198–432 lb) (U49): Front: 200 kPa (29 psi) (2.00 kgf/cm²) Rear: 225 kPa (33 psi) (2.
U2UJ1DE0.book Page 17 Thursday, May 13, 2004 11:59 PM PERIODIC MAINTENANCE AND MINOR REPAIR Tire information This motorcycle is equipped with spoke wheels and tube tires. EWA10460 WARNING ● ● The front and rear tires should be of the same make and design, otherwise the handling characteristics of the vehicle cannot be guaranteed. After extensive tests, only the tires listed below have been approved for this model by Yamaha Motor Co., Ltd. Front tire: Size: 3.
U2UJ1DE0.book Page 18 Thursday, May 13, 2004 11:59 PM PERIODIC MAINTENANCE AND MINOR REPAIR any consequences caused by the use of items which have not been approved by Yamaha. EAU22041 Adjusting the clutch lever free play NOTE: 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. 3. Fully turn the adjusting bolt at the clutch lever in direction (a) to loosen the clutch cable. 4.
U2UJ1DE0.book Page 19 Thursday, May 13, 2004 11:59 PM PERIODIC MAINTENANCE AND MINOR REPAIR 5. To increase the clutch lever free play, turn the adjusting nut in direction (a). To decrease the clutch lever free play, turn the adjusting nut in direction (b). 6. Tighten the locknut at the clutch lever and the crankcase. EAU22092 Adjusting the brake lever free play EWA10630 WARNING ● ● 1. Locknut 2. Brake lever free play adjusting screw 3.
U2UJ1DE0.book Page 20 Thursday, May 13, 2004 11:59 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU22201 Adjusting the brake pedal position and free play 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). 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.
U2UJ1DE0.book Page 21 Thursday, May 13, 2004 11:59 PM PERIODIC MAINTENANCE AND MINOR REPAIR ● ● If proper adjustment cannot be obtained as described, have a Yamaha dealer make this adjustment. After adjusting the brake pedal free play, check the operation of the brake light.
U2UJ1DE0.book Page 22 Thursday, May 13, 2004 11:59 PM PERIODIC MAINTENANCE AND MINOR REPAIR indicator groove has almost disappeared, have a Yamaha dealer replace the brake pads as a set. EAU32343 Checking the front brake fluid level ● ● EAU22540 Rear brake shoes When checking the fluid level, make sure that the top of the master cylinder is level by turning the handlebars.
U2UJ1DE0.book Page 23 Thursday, May 13, 2004 11:59 PM PERIODIC MAINTENANCE AND MINOR REPAIR brake fluid level goes down suddenly, have a Yamaha dealer check the cause. EAU22720 EAU22760 Changing the brake fluid Drive chain slack Have a Yamaha dealer change the brake fluid at the intervals specified in the NOTE after the periodic maintenance and lubrication chart.
U2UJ1DE0.book Page 24 Thursday, May 13, 2004 11:59 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.
U2UJ1DE0.book Page 25 Thursday, May 13, 2004 11:59 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 6-20.) EWA10660 WARNING After adjusting the brake pedal free play, check the operation of the brake light.
U2UJ1DE0.book Page 26 Thursday, May 13, 2004 11:59 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23090 EAU23110 Checking and lubricating the throttle grip and cable Checking and lubricating the brake and shift pedals 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. If a cable is damaged or does not move smoothly, have a Yamaha dealer check or replace it.
U2UJ1DE0.book Page 27 Thursday, May 13, 2004 11:59 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23140 EAU23200 EAUM1650 Checking and lubricating the brake and clutch levers Checking and lubricating the sidestand Lubricating the swingarm pivots The operation of the brake and clutch levers should be checked before each ride, and the lever pivots should be lubricated if necessary.
U2UJ1DE0.book Page 28 Thursday, May 13, 2004 11:59 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.
U2UJ1DE0.book Page 29 Thursday, May 13, 2004 11:59 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.
U2UJ1DE0.book Page 30 Thursday, May 13, 2004 11:59 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.
U2UJ1DE0.book Page 31 Thursday, May 13, 2004 11:59 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.
U2UJ1DE0.book Page 32 Thursday, May 13, 2004 11:59 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.
U2UJ1DE0.book Page 33 Thursday, May 13, 2004 11:59 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU24131 Replacing the tail/brake light bulb 1. Remove the tail/brake light lens by removing the screws. 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. 1. Tail/brake light bulb 3.
U2UJ1DE0.book Page 34 Thursday, May 13, 2004 11:59 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU24210 EAU24350 Replacing a turn signal light bulb Supporting the motorcycle 1. Remove the turn signal lens by removing the screws. 1. Turn signal light bulb 6 1. Screw 2. Remove the defective bulb by pushing it in and turning it counterclockwise. 3. Insert a new bulb into the socket, push it in, and then turn it clockwise until it stops. 4. Install the lens by installing the screws.
U2UJ1DE0.book Page 35 Thursday, May 13, 2004 11:59 PM PERIODIC MAINTENANCE AND MINOR REPAIR a jack either under each side of the frame in front of the rear wheel or under each side of the swingarm. 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. 1. Wheel axle 2.
U2UJ1DE0.book Page 36 Thursday, May 13, 2004 11:59 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. 1. Speedometer gear unit 2. Lift the wheel up between the fork legs. 6 NOTE: Make sure that there is enough space between the brake pads before inserting the brake disc and that the slot in the speedometer gear unit fits over the retainer on the fork leg. 1. Speedometer gear unit 2. Retainer 3.
U2UJ1DE0.book Page 37 Thursday, May 13, 2004 11:59 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU25080 Rear wheel EAU32750 To remove the rear 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. Remove the axle nut cotter pin. 2. Loosen the chain puller locknut and the drive chain slack adjusting nut on both ends of the swingarm. 1. 2. 3. 4. 5.
U2UJ1DE0.book Page 38 Thursday, May 13, 2004 11:59 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU32760 To install the rear wheel 1. Install the drive chain onto the rear sprocket, and then install the wheel by inserting the wheel axle from the right-hand side. 2. Install the brake rod onto the brake camshaft lever, and then install the brake pedal free play adjusting nut onto the brake rod. 3.
U2UJ1DE0.book Page 39 Thursday, May 13, 2004 11:59 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.
U2UJ1DE0.book Page 1 Thursday, May 13, 2004 11:59 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.
U2UJ1DE0.book Page 2 Thursday, May 13, 2004 11:59 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.
U2UJ1DE0.book Page 3 Thursday, May 13, 2004 11:59 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.
U2UJ1DE0.book Page 4 Thursday, May 13, 2004 11:59 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. °C (90 °F)]. For more information on storing the battery, see page 6-29. 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.
U2UJ1DE0.book Page 1 Thursday, May 13, 2004 11:59 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: 8 Engine type: Air cooled 4-stroke, SOHC Cylinder arrangement: V-type 2-cylinder Displacement: 249.
U2UJ1DE0.book Page 2 Thursday, May 13, 2004 11:59 PM SPECIFICATIONS 3rd: 29/23 (1.261) 4th: 26/26 (1.000) 5th: 23/28 (0.821) Chassis: Frame type: Double cradle Caster angle: 32.00 ° Trail: 120.0 mm (4.72 in) Front tire: Type: With tube Size: 3.
U2UJ1DE0.book Page 3 Thursday, May 13, 2004 11:59 PM SPECIFICATIONS Bulb voltage, wattage x quantity: Headlight: 12 V, 60 W/55.0 W × 1 Tail/brake light: 12 V, 8.0/27.0 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: 20.0 A Signaling system fuse: 10.
U2UJ1DE0.book Page 1 Thursday, May 13, 2004 11:59 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.
U2UJ1DE0.book Page 2 Thursday, May 13, 2004 11:59 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.
U2UJ1DE0.book Page 3 Thursday, May 13, 2004 11:59 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.
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U2UJ1DE0.book Page 5 Thursday, May 13, 2004 11:59 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.
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U2UJ1DE0.book Page 7 Thursday, May 13, 2004 11:59 PM CONSUMER INFORMATION EAU26661 YAMAHA MOTOR CORPORATION, U.S.A.
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U2UJ1DE0.book Page 9 Thursday, May 13, 2004 11:59 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.
U2UJ1DE0.book Page 10 Thursday, May 13, 2004 11:59 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.
U2UJ1DE0.book Page 1 Thursday, May 13, 2004 11:59 PM INDEX A F Accessories and replacement parts ..... 6-17 Air filter element, cleaning .................... 6-13 B Battery .................................................. 6-29 Brake and clutch levers, checking and lubricating..................... 6-27 Brake and shift pedals, checking and lubricating..................... 6-26 Brake fluid, changing ............................ 6-23 Brake fluid level, checking .................... 6-22 Brake lever ......
U2UJ1DE0.book Page 2 Thursday, May 13, 2004 11:59 PM INDEX Turn signal light bulb, replacing ............ 6-34 Turn signal switch ................................... 3-3 V Valve clearance, adjusting .................... 6-15 Vehicle identification number .................. 9-1 W Warranty, extended................................. 9-9 Warranty, limited ..................................... 9-7 Wheel bearings, checking..................... 6-29 Wheel (front) .........................................
OWNER’S MANUAL XV250T XV250TC YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2004.05-0.
