Yamaha VIRAGO XV250VC, VIRAGO, VIRAGO XV250V User Manual

Download

OWNER’S MANUAL

XV250V

XV250VC

LIT-11626-19-23

2UJ-28199-1E

EAU10041

INTRODUCTION

EAU10080

Congratulations on your purchase of the Yamaha XV250V/XV250VC. This model is the result of Yamaha’s vast experience in the production of fine sporting, touring, and pacesetting racing machines. It represents the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields. This manual will give you an understanding of the operation, inspection, and basic maintenance of this motorcycle. If you have any questions concerning the operation or maintenance of your motorcycle, please consult a Yamaha dealer. The design and manufacture of this Yamaha motorcycle fully comply with the emissions standards for clean air applicable at the date of manufacture. Yamaha has met these standards without reducing the performance or economy of operation of the motorcycle. To maintain these high standards, it is important that you and your Yamaha dealer pay close attention to the recommended maintenance schedules and operating instructions contained within this manual.

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!

EAU10130

WARNING

Failure to follow WARNING instructions could result in severe injury or death motorcycle operator, a bystander or a person inspecting or repairing the motor-

to the

cycle.

CAUTION:

NOTE:

A CAUTION indicates special precautions that must be taken to avoid damage to the motorcycle.

A NOTE provides key information to make procedures easier or clearer.

NOTE:

● This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle

is subsequently sold.

● Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most

current product information available at the time of printing, there may be minor discrepancies between your motorcycle and this manual. If you have any questions concerning this manual, please consult your Yamaha dealer.

EWA10010

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

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.

IMPORTANT MANUAL INFORMATION

AFFIX DEALER

LABEL HERE

XV250V/XV250VC

OWNER’S MANUAL

1st edition, May 2005

Any reprinting or unauthorized use

without the written permission of

Yamaha Motor Corporation, U.S.A.

is expressly prohibited.

Printed in Japan.

P/N LIT-11626-19-23

EAU10192

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 ................................3-1

Speedometer unit ...........................3-2

Handlebar switches ........................3-2

Clutch lever ....................................3-3

Shift pedal ......................................3-4

Brake lever .....................................3-4

Brake pedal ....................................3-4

Fuel tank cap ..................................3-5

Fuel ................................................3-5

Fuel cock ........................................3-6

Starter (choke) lever .......................3-7

Steering lock ...................................3-8

Rider seat .......................................3-8

Helmet holder .................................3-9

Adjusting the shock absorber

assemblies ..................................3-9

Sidestand .....................................3-10

Ignition circuit cut-off system ........3-11

PRE-OPERATION CHECKS ............. 4-1

Pre-operation check list ................. 4-2

OPERATION AND IMPORTANT

RIDING POINTS ................................ 5-1

Starting and warming up a

cold engine ................................. 5-1

Starting a warm engine .................. 5-2

Shifting ........................................... 5-2

Engine break-in .............................. 5-4

Parking ........................................... 5-4

PERIODIC MAINTENANCE AND

MINOR REPAIR................................. 6-1

PERIODIC MAINTENANCE .......... 6-1

Owner’s tool kit .............................. 6-1

Periodic maintenance chart for the

emission control system ............. 6-3

General maintenance and

lubrication chart .......................... 6-4

Removing and installing the

panel ........................................... 6-8

Checking the spark plugs .............. 6-8

Canister (for California only) ........ 6-10

Engine oil and oil filter element .... 6-10

Cleaning the air filter element ...... 6-13

Carburetor .................................... 6-14

Checking the throttle cable free

play ........................................... 6-15

Valve clearance ........................... 6-15

Tires ............................................. 6-15

Spoke wheels ...............................6-17

Accessories and replacement

parts ..........................................6-17

Adjusting the clutch lever free

play ...........................................6-18

Adjusting the brake lever free

play ...........................................6-19

Adjusting the brake pedal position

and free play .............................6-20

Adjusting the rear brake light

switch ........................................6-21

Checking the front brake pads

and rear brake shoes ................6-21

Checking the front brake fluid

level ..........................................6-22

Changing the brake fluid .............. 6-23

Drive chain slack ..........................6-23

Cleaning and lubricating the

drive chain ................................6-25

Checking and lubricating the

cables .......................................6-26

Checking and lubricating the

throttle grip and cable ...............6-26

Checking and lubricating the

brake and shift pedals ............... 6-27

Checking and lubricating the

brake and clutch levers .............6-27

Checking and lubricating the

sidestand ..................................6-27

Lubricating the swingarm pivots ... 6-28

Checking the front fork .................6-28

TABLE OF CONTENTS

Checking the steering ...................6-29

Checking the wheel bearings .......6-29

Battery ..........................................6-30

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 ............6-35

Front wheel ...................................6-35

Rear wheel ...................................6-37

Troubleshooting ............................6-39

Troubleshooting chart ...................6-40

MOTORCYCLE CARE AND

STORAGE ..........................................7-1

Care ................................................7-1

Storage ...........................................7-3

SPECIFICATIONS .............................8-1

CONSUMER INFORMATION.............9-1

Identification numbers ....................9-1

Reporting safety defects .................9-3

Motorcycle noise regulation ............9-4

Maintenance record ........................9-5

YAMAHA MOTOR CORPORATION,

U.S.A. STREET AND ENDURO

MOTORCYCLE LIMITED

WARRANTY ................................9-7

YAMAHA EXTENDED SERVICE

(Y.E.S.) .......................................9-9

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 INSTRUC-

TIONS FROM A COMPETENT SOURCE ON ALL ASPECTS OF MOTORCYCLE OPERATION.

● OBSERVE THE WARNINGS AND

MAINTENANCE REQUIREMENTS IN THE OWNER’S MANUAL.

● OBTAIN QUALIFIED TRAINING

IN SAFE AND PROPER RIDING TECHNIQUES.

● OBTAIN PROFESSIONAL TECH-

NICAL SERVICE AS INDICATED BY THE OWNER’S MANUAL

AND/OR WHEN MADE NECESSARY BY MECHANICAL CONDITIONS.

Safe riding

● Always make pre-operation

checks. Careful checks may help prevent an accident.

● This motorcycle is designed to car-

ry the operator and a passenger.

● The failure of motorists to detect

and recognize motorcycles in traffic is the predominating cause of automobile/motorcycle accidents. Many accidents have been caused by an automobile driver who did not see the motorcycle. Making yourself conspicuous appears to be very effective in reducing the chance of this type of accident.

Therefore:

• Wear a brightly colored jacket.

• Use extra caution when ap-

proaching and passing through intersections, since intersections are the most likely places for motorcycle accidents to occur.

• Ride where other motorists can see you. Avoid riding in another motorist’s blind spot.

● Many motorcycle accidents in-

volve inexperienced operators. In fact, many operators who have been involved in accidents do not even have a current motorcycle license.

• Make sure that you are qualified and that you only lend your motorcycle to other qualified operators.

• Know your skills and limits. Staying within your limits may help you to avoid an accident.

• We recommend that you practice riding your motorcycle where there is no traffic until you have become thoroughly familiar with the motorcycle and all of its controls.

● Many motorcycle accidents have

been caused by error of the motorcycle operator. A typical error made by the operator is veering

1-1

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.

• The operator should keep both hands on the handlebar and both feet on the operator footrests during operation to maintain control of the motorcycle.

• The passenger should always hold onto the operator, seat strap, or grab bar, if equipped, with both hands and keep both feet on the passenger footrests.

• Never carry a passenger unless he or she can firmly place both feet on the passenger footrests.

● Never ride under the influence of

alcohol or other drugs.

● This motorcycle is designed for on-

road use only, therefore, it is not suitable for off-road use.

Protective apparel

The majority of fatalities from motorcycle accidents are the result of head injuries. The use of a safety helmet is the single most critical factor in the prevention or reduction of head injuries.

● Always wear an approved helmet.

● Wear a face shield or goggles.

Wind in your unprotected eyes could contribute to an impairment of vision which could delay seeing a hazard.

● The use of a jacket, heavy boots,

trousers, gloves, etc., is effective in preventing or reducing abrasions or lacerations.

● Never wear loose-fitting clothes,

otherwise they could catch on the control levers, footrests, or wheels and cause injury or an accident.

● Never touch the engine or exhaust

system during or after operation. They become very hot and can

cause burns. Always wear protective clothing that covers your legs, ankles, and feet.

● Passengers should also observe

the precautions mentioned above.

Modifications

Modifications made to this motorcycle not approved by Yamaha, or the removal of original equipment, may render the motorcycle unsafe for use and may cause severe personal injury. Modifications may also make your motorcycle illegal to use.

Loading and accessories

Adding accessories or cargo to your motorcycle can adversely affect stability and handling if the weight distribution of the motorcycle is changed. To avoid the possibility of an accident, use extreme caution when adding cargo or accessories to your motorcycle. Use extra care when riding a motorcycle that has added cargo or accessories. Here are some general guidelines to follow if loading cargo or adding accessories to your motorcycle:

1-2

SAFETY INFORMATION

Loading The total weight of the operator, passenger, accessories and cargo must not exceed the maximum load limit.

Maximum load:

XV250V 196 kg (432 lb) XV250VC 195 kg (430 lb)

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. Make sure to distribute the weight as evenly as possible on both sides of the motorcycle to minimize imbalance or instability.

● Shifting weights can create a sud-

den imbalance. Make sure that accessories and cargo are securely attached to the motorcycle before riding. Check accessory mounts and cargo restraints frequently.

● Never attach any large or heavy

items to the handlebar, front fork, or front fender. These items, including such cargo as sleeping

bags, duffel bags, or tents, can create unstable handling or slow

steering response. Accessories Genuine Yamaha accessories have been specifically designed for use on this motorcycle. Since Yamaha cannot test all other accessories that may be available, you must personally be responsible for the proper selection, installation and use of non-Yamaha accessories. Use extreme caution when selecting and installing any accessories. Keep the following guidelines in mind, as well as those provided under “Load- ing” when mounting accessories.

● Never install accessories or carry

cargo that would impair the perfor-

mance of your motorcycle. Care-

fully inspect the accessory before

using it to make sure that it does

not in any way reduce ground

clearance or cornering clearance,

limit suspension travel, steering travel or control operation, or obscure lights or reflectors.

• Accessories fitted to the handlebar or the front fork area can create instability due to improper weight distribution or aerodynamic changes. If accessories are added to the handlebar or front fork area, they must be as lightweight as possible and should be kept to a minimum.

• Bulky or large accessories may seriously affect the stability of the motorcycle due to aerodynamic effects. Wind may attempt to lift the motorcycle, or the motorcycle may become unstable in cross winds. These accessories may also cause instability when passing or being passed by large vehicles.

• Certain accessories can displace the operator from his or her normal riding position. This improper position limits the freedom of movement of the opera-

1-3

SAFETY INFORMATION

tor and may limit control ability, therefore, such accessories are not recommended.

● Use caution when adding electri-

cal 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 FLAMMA-

BLE:

• 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. Always operate your motorcycle in an area that has adequate ventilation.

● Always turn the engine off before

leaving the motorcycle unattended and remove the key from the main switch. When parking the motorcycle, note the following:

• 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.

• Do not park the motorcycle on a slope or soft ground, otherwise it may fall over.

• Do not park the motorcycle near a flammable source (e.g. a kerosene heater, or near an open flame), otherwise it could catch fire.

● When transporting the motorcycle

in another vehicle, make sure that it is kept upright and that the fuel cock is turned to “ON” or “RES” (for vacuum type) / “OFF” (for manual type). If it should lean over, gasoline may leak out of the carburetor or fuel tank.

● If you should swallow any gaso-

line, inhale a lot of gasoline vapor, or allow gasoline to get into your

1-4

eyes, see your doctor immediately. If any gasoline spills on your skin or clothing, immediately wash the affected area with soap and water and change your clothes.

Location of important labels

Please read the following important labels carefully before operating this vehicle.

SAFETY INFORMATION

EAU10381

1-5

SAFETY INFORMATION

4 California only

5 California only

Cold tire normal pressure should be set as follows.

3CK-21668-A1

1-6

Left view

DESCRIPTION

EAU10410

1. Headlight (page 6-32)

2. Steering lock (page 3-8)

3. Fuel tank (page 3-5)

4. Battery (page 6-30)

5. Fuses (page 6-31)

6. Helmet holder (page 3-9)

7. Shock absorber assembly spring preload adjusting ring (page 3-9)

8. Main switch (page 3-1)

9. Fuel cock (page 3-6)

10.Shift pedal (page 3-4)

2-1

DESCRIPTION

Right view

1. Tail/brake light (page 6-33)

2. Rear turn signal lights (page 6-34)

3. Rider seat (page 3-8)

4. Air filter element (page 6-13)

5. Front turn signal/position lights (page 6-34)

6. Brake pedal (page 3-4)

7. Footrest

8. Owner’s tool kit (page 6-1)

9. Shock absorber assembly spring preload adjusting ring (page 3-9)

EAU10420

2-2

Controls and instruments

1. Clutch lever (page 3-3)

2. Left handlebar switches (page 3-2)

3. Speedometer unit (page 3-2)

4. Indicator lights (page 3-1)

5. Right handlebar switches (page 3-2)

6. Brake lever (page 3-4)

7. Throttle grip (page 6-15)

8. Fuel tank cap (page 3-5)

DESCRIPTION

EAU10430

2-3

INSTRUMENT AND CONTROL FUNCTIONS

Main switch

The main switch controls the ignition and lighting systems. The various main switch positions are described below.

All electrical systems are supplied with power, and the headlight, meter lighting, taillight and position lights come on, and the engine can be started. The key cannot be removed.

OFF

All electrical systems are off. The key can be removed.

EAU10450

EAU10510

EAU10660

P (Parking)

EAU10810

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”.

ECA11020

CAUTION:

Do not use the parking position for an extended length of time, otherwise the battery may discharge.

EAU10980

Indicator lights

1. High beam indicator light “HIGH BEAM”

2. Neutral indicator light “NEUTRAL”

3. Turn signal indicator light “TURN”

EAU11040

Turn signal indicator light “TURN”

This indicator light flashes when the turn signal switch is pushed to the left or right.

EAU11070

Neutral indicator light “NEUTRAL”

This indicator light comes on when the transmission is in the neutral position.

3-1

INSTRUMENT AND CONTROL FUNCTIONS

High beam indicator light “HIGH

EAU11090

BEAM”

This indicator light comes on when the high beam of the headlight is switched on.

EAU11630

Speedometer unit

1. Odometer

2. Tripmeter

3. Tripmeter reset knob

4. 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. The tripmeter shows the distance traveled since it was last set to zero with the reset knob. The tripmeter can be used to estimate the distance that can be traveled with a full tank of fuel. This information will enable you to plan future fuel stops.

EAU12343

Handlebar switches

Left

1. Dimmer switch “LIGHTS”

2. Turn signal switch “TURN”

3. Horn switch “HORN”

Right

1. Engine stop switch “ENGINE STOP”

2. Start switch “START”

3-2

INSTRUMENT AND CONTROL FUNCTIONS

Dimmer switch “LIGHTS”

Set the switch to “HI” for the high beam and to “LO” for the low beam.

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. To cancel the turn signal lights, push the switch in after it has returned to the center position.

Horn switch “HORN”

Press this switch to sound the horn.

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 vehicle overturns or when the throttle cable is stuck.

EAU12410

EAU12440

EAU12510

EAU12650

ECA10050

CAUTION:

See page 5-1 for starting instructions prior to starting the engine.

EAU12820

Clutch lever

1. Clutch lever

The clutch lever is located at the left handlebar grip. To disengage the clutch, pull the lever toward the handlebar grip. To engage the clutch, release the lever. The lever should be pulled rapidly and released slowly for smooth clutch operation. The clutch lever is equipped with a clutch switch, which is part of the ignition circuit cut-off system. (See page 3-11.)

Start switch “START”

EAU12690

Push this switch to crank the engine with the starter.

3-3

INSTRUMENT AND CONTROL FUNCTIONS

EAU12870

Shift 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 con-

Brake lever

The brake lever is located at the right handlebar grip. To apply the front brake, pull the lever toward the handlebar grip.

EAU12890

Brake pedal

The brake pedal is on the right side of the motorcycle. To apply the rear brake, press down on the brake pedal.

stant-mesh transmission equipped on this motorcycle.

EAU12941

3-4

INSTRUMENT AND CONTROL FUNCTIONS

Fuel tank cap

1. Fuel tank cap

2. Unlock.

To open the fuel tank cap

Insert the key into the lock and turn it 1/4 turn clockwise. The lock will be released and the fuel tank cap can be opened.

To close the fuel tank cap

1. Push the fuel tank cap into position with the key inserted in the lock.

2. Turn the key counterclockwise to the original position, and then remove it.

EAU13040

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.

EWA11090

WARNING

Make sure that the fuel tank cap is properly closed before riding.

EAU13210

Fuel

1. Fuel tank filler tube

2. Fuel level

Make sure that there is sufficient fuel in the tank. Fill the fuel tank to the bottom of the filler tube as shown.

EWA10880

WARNING

● Do not overfill the fuel tank, oth-

erwise it may overflow when the fuel warms up and expands.

● Avoid spilling fuel on the hot en-

gine.

3-5

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:

XV250V 9.5 L (2.51 US gal) (2.09 Imp.gal) XV250VC 9.2 L (2.43 US gal) (2.02 Imp.gal)

Fuel reserve amount:

2.6 L (0.69 US gal) (0.57 Imp.gal)

ECA11400

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.

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. If knocking (or pinging) occurs, use a gasoline of a different brand or premium unleaded fuel. Use of unleaded fuel will extend spark plug life and reduce maintenance costs.

Gasohol

There are two types of gasohol: gasohol containing ethanol and that containing methanol. Gasohol containing ethanol can be used if the ethanol content does not exceed 10%. Gasohol containing methanol is not recommended by Yamaha because it can cause damage to the fuel system or vehicle performance problems.

3-6

EAU13580

Fuel cock

This model is equipped with a negative pressure fuel cock. The fuel cock supplies fuel from the tank to the carburetor while also filtering it. The fuel cock lever positions are explained as follows and shown in the illustrations.

1. Arrow mark positioned over “ON”

With the fuel cock lever in this position, fuel flows to the carburetor when the engine is running. Turn the fuel cock lever to this position when starting the engine and riding.

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”). After turning the fuel cock lever to “RES”, refuel as soon as possible and be sure to turn the fuel cock lever back to “ON”!

This indicates prime. With the fuel cock lever in this position, the engine can be “primed”. Turn the fuel cock lever to this position when the engine has been allowed to run out of fuel. This sends fuel directly to the carburetor, which will make starting easier. After the engine has started, be sure to turn the lever to “ON” (or “RES” if you have not refueled yet).

EAU13630

Starter (choke) lever

1. Starter (choke) lever

Starting a cold engine requires a richer air-fuel mixture, which is supplied by the starter (choke). Move the lever in direction (a) to turn on the starter (choke). Move the lever in direction (b) to turn off the starter (choke).

3-7

INSTRUMENT AND CONTROL FUNCTIONS

EAU13730

Steering lock

1. Steering lock

To lock the steering

1. Turn the handlebar all the way to the right.

2. Open the steering lock cover, and then insert the key.

3. Turn the key 1/8 turn counterclockwise, push it in while turning the handlebar slightly to the left, and then turn the key 1/8 turn clockwise.

4. Check that the steering is locked, remove the key, and then close the lock cover.

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. Bolt

To install the rider seat

1. Insert the projection on the front of the rider seat into the seat holder as shown.

3-8

INSTRUMENT AND CONTROL FUNCTIONS

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.

EAU14281

Helmet holder

1. Helmet holder

2. Unlock.

To open the helmet holder, insert the key into the lock, and then turn the key as shown. To lock the helmet holder, place it in the original position, and then remove the key.

EWA10160

WARNING

Never ride with a helmet attached to the helmet holder, since the helmet may hit objects, causing loss of control and possibly an accident.

EAU14880

Adjusting the shock absorber assemblies

1. Spring preload adjusting ring

2. Position indicator

Each shock absorber assembly is equipped with a spring preload adjusting ring.

ECA10100

CAUTION:

Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings.

3-9

INSTRUMENT AND CONTROL FUNCTIONS

EWA10210

WARNING

Always adjust both shock absorber assemblies equally, otherwise poor handling and loss of stability may result.

Adjust the spring preload as follows. To increase the spring preload and thereby harden the suspension, turn the adjusting ring on each shock absorber assembly in direction (a). To decrease the spring preload and thereby soften the suspension, turn the adjusting ring on each shock absorber assembly in direction (b).

NOTE:

Align the appropriate notch in the adjusting ring with the position indicator on the shock absorber.

Spring preload setting:

Minimum (soft):

Standard:

Maximum (hard):

EAU15301

Sidestand

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.

NOTE:

The built-in sidestand switch is part of the ignition circuit cut-off system, which cuts the ignition in certain situations. (See further down for an explanation of the ignition circuit cut-off system.)

EWA10240

WARNING

The vehicle 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. Yamaha’s ignition circuit cut-off system has been designed to assist the operator in fulfilling the responsibility of raising the sidestand before starting off. Therefore, check this system regularly as described

below and have a Yamaha dealer repair it if it does not function properly.

3-10

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 trans-

mission is in gear and the side-

stand is up, but the clutch lever is not pulled.

● It prevents starting when the trans-

mission is in gear and the clutch lever is pulled, but the sidestand is still down.

● It cuts the running engine when the

transmission is in gear and the sidestand is moved down.

Periodically check the operation of the ignition circuit cut-off system according to the following procedure.

EWA10250

WARNING

If a malfunction is noted, have a Yamaha dealer check the system before riding.

3-11

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 NO

With the engine still running:

6. Move the sidestand up.

7. Keep the clutch lever pulled.

8. Shift the transmission into gear.

9. Move the sidestand down.

Does the engine stall?

YES NO

After the engine has stalled:

10. Move the sidestand up.

11. Keep the clutch lever pulled.

12. Push the start switch.

Does the engine start?

YES NO

The system is OK. The motorcycle can be ridden.

NOTE:

This check is most reliable if performed with a warmed-up engine.

The neutral switch may be defective. The motorcycle should not be ridden until checked by a Yamaha dealer.

The sidestand switch may be defective. The motorcycle should not be ridden until checked by a Yamaha dealer.

The clutch switch may be defective. The motorcycle should not be ridden until checked by a Yamaha dealer.

3-12

PRE-OPERATION CHECKS

The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly, even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thorough visual inspection, to check the following points before each ride.

NOTE:

Pre-operation checks should be made each time the vehicle is used. Such an inspection can be accomplished in a very short time; and the added safety it assures is more than worth the time involved.

WARNING

If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operating the vehicle.

EAU15591

EWA11150

4-1

Pre-operation check list

ITEM CHECKS PAGE

Fuel

Engine oil

Front brake

Rear brake

Clutch

Throttle grip

Control cables

• Check fuel level in fuel tank.

• Refuel if necessary.

• Check fuel line for leakage.

• Check oil level in engine.

• If necessary, add recommended oil to specified level.

• Check vehicle for oil leakage.

• Check operation.

• If soft or spongy, have Yamaha dealer bleed hydraulic system.

• Check lever free play.

• Adjust if necessary.

• Check brake pads for wear.

• Replace if necessary.

• Check fluid level in reservoir.

• If necessary, add recommended brake fluid to specified level.

• Check hydraulic system for leakage.

• Check operation.

• Check pedal free play.

• Adjust if necessary.

• Check operation.

• Lubricate cable if necessary.

• Check lever free play.

• Adjust if necessary.

• Make sure that operation is smooth.

• Check cable free play.

• If necessary, have Yamaha dealer adjust cable free play and lubricate cable and

• Make sure that operation is smooth.

• Lubricate if necessary.

PRE-OPERATION CHECKS

EAU15603

3-5

6-10

6-19, 6-21, 6-22

6-20, 6-21

6-18

6-15, 6-26

grip housing.

6-26

4-2

PRE-OPERATION CHECKS

ITEM CHECKS PAGE

• Check chain slack.

Drive chain

Wheels and tires

Brake and shift pedals

Brake and clutch levers

Sidestand

Chassis fasteners

Instruments, lights, signals and switches

Sidestand switch

Battery

• Adjust if necessary.

• Check chain condition.

• Lubricate if necessary.

• Check for damage.

• Check tire condition and tread depth.

• Check air pressure.

• Correct if necessary.

• Make sure that operation is smooth.

• Lubricate pedal pivoting points if necessary.

• Make sure that operation is smooth.

• Lubricate lever pivoting points if necessary.

• Make sure that operation is smooth.

• Lubricate pivot if necessary.

• Make sure that all nuts, bolts and screws are properly tightened.

• Tighten if necessary.

• Check operation.

• Correct if necessary.

• Check operation of ignition circuit cut-off system.

• If system is defective, have Yamaha dealer check vehicle.

• Check fluid level.

• Fill with distilled water if necessary.

6-23, 6-25

6-15, 6-17

6-27

—

3-10

6-30

4-3

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 oper-

ate 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. Always make sure that there is adequate ventilation.

● Before starting out, make sure

that the sidestand is up. If the sidestand is not raised completely, it could contact the ground and distract the operator, resulting in a possible loss of control.

EAU32620

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.

EWA10290

WARNING

● Before starting the engine,

check the function of the ignition circuit cut-off system according to the procedure described on page 3-11.

● Never ride with the sidestand

down.

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. Shift the transmission into the neutral position.

NOTE:

When the transmission is in the neutral position, the neutral indicator light should be on, otherwise have a Yamaha dealer check the electrical circuit.

4. Turn the starter (choke) on and completely close the throttle. (See page 3-7.)

5. Start the engine by pushing the start switch.

NOTE:

If the engine fails to start, release the start switch, wait a few seconds, and then try again. Each starting attempt should be as short as possible to preserve the battery. Do not crank the engine more than 10 seconds on any one attempt.

6. After starting the engine, move the starter (choke) back halfway.

5-1

OPERATION AND IMPORTANT RIDING POINTS

CAUTION:

For maximum engine life, always warm the engine up before starting off. Never accelerate hard when the engine is cold!

7. When the engine is warm, turn the starter (choke) off.

NOTE:

The engine is warm when it responds normally to the throttle with the starter (choke) turned off. To avoid the possi-

bility of excessive exhaust emissions, never leave the starter (choke) on longer than necessary. The time necessary for starter (choke) use depends upon the ambient temperature. Temperatures above 10 °C (50 °F) require about 7 seconds of starter (choke) use and temperatures below 10 °C (50 °F) require about 35 seconds with the starter (choke) turned on, then about 2.5 minutes with the starter (choke) in the halfway position.

ECA11130

EAU16640

Starting a warm engine

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

1. Shift pedal

2. Neutral position

Shifting gears lets you control the amount of engine power available for starting off, accelerating, climbing hills, etc. The gear positions are shown in the illustration.

NOTE:

To shift the transmission into the neutral position, press the shift pedal down repeatedly until it reaches the end of its travel, and then slightly raise it.

5-2

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.

● Always use the clutch while

changing gears to avoid damaging the engine, transmission, and drive train, which are not designed to withstand the shock of forced shifting.

EAU16680

To start out and accelerate

1. Pull the clutch lever to disengage the clutch.

2. Shift the transmission into first gear. The neutral indicator light should go out.

3. Open the throttle gradually, and at the same time, release the clutch lever slowly.

4. At the recommended shift points shown in the following table, close the throttle, and at the same time, quickly pull the clutch lever in.

5. Shift the transmission into second gear. (Make sure not to shift the transmission into the neutral position.)

6. Open the throttle part way and gradually release the clutch lever.

7. Follow the same procedure when shifting to the next higher gear.

NOTE:

Always shift gears at the recommended shift points.

EAU16700

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.

5-3

3. Shift the transmission into the neutral position when the motorcycle is almost completely stopped. The neutral indicator light should come on.

EAU16720

Recommended shift points

The recommended shift points during acceleration and deceleration are shown in the table below.

Shift up points:

1st → 2nd: 16 km/h (9.9 mi/h) 2nd → 3rd: 24 km/h (14.9 mi/h) 3rd → 4th: 32 km/h (19.9 mi/h) 4th → 5th: 40 km/h (24.9 mi/h)

Shift down points:

5th → 4th: 20 km/h (12.5 mi/h) 4th → 3rd: 20 km/h (12.5 mi/h) 3rd → 2nd: 20 km/h (12.5 mi/h) 2nd → 1st: 20 km/h (12.5 mi/h)

OPERATION AND IMPORTANT RIDING POINTS

Engine break-in

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). The various parts in the engine wear and polish themselves to the correct operating clearances. During this period, prolonged full-throt-

tle operation or any condition that might result in engine overheating must be avoided.

0–1000 km (0–600 mi)

Avoid prolonged operation above 1/3 throttle.

1000–1600 km (600–1000 mi)

Avoid prolonged operation above 1/2 throttle.

EAU16841

EAU17021

ECA11281

CAUTION:

After 1000 km (600 mi) of operation, the engine oil must be changed, and the oil filter cartridge or element replaced.

1600 km (1000 mi) and beyond

The vehicle can now be operated normally.

ECA10270

CAUTION:

If any engine trouble should occur during the engine break-in period, immediately have a Yamaha dealer check the vehicle.

EAU17200

Parking

When parking, stop the engine, and then remove the key from the main switch.

EWA10310

WARNING

● Since the engine and exhaust

system can become very hot, park in a place where pedestrians or children are not likely to touch them.

● Do not park on a slope or on soft

ground, otherwise the vehicle may overturn.

5-4

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU17231

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.

Maintenance, replacement, or repair of the emission control devices and systems may be performed by any repair establishment or individual that is certified (if applicable).

EWA10320

WARNING

If you are not familiar with maintenance work, have a Yamaha dealer do it for you.

EAU17301

PERIODIC MAINTENANCE

PROPER PERIODIC MAINTENANCE OF YOUR VEHICLE IS IMPORTANT IN ORDER TO ENJOY LONG, PLEASURABLE SERVICE. ESPECIALLY IMPORTANT ARE THE MAINTENANCE SERVICES RELATED TO EMISSIONS CONTROL. THESE CONTROLS NOT ONLY FUNCTION TO ENSURE CLEANER AIR, BUT ARE ALSO VITAL TO PROPER ENGINE OPERATION AND MAXIMUM PERFORMANCE. IN THE FOLLOWING PERIODIC MAINTENANCE CHARTS, THE SERVICES RELATED TO EMISSIONS CONTROL ARE GROUPED SEPARATELY. THESE SERVICES REQUIRE SPECIALIZED DATA, KNOWLEDGE, AND EQUIPMENT. YAMAHA DEALERS ARE TRAINED AND EQUIPPED TO PERFORM THESE PARTICULAR SERVICES.

EAU17330

Owner’s tool kit

1. Owner’s tool kit

The owner’s tool kit is located behind panel A. (See page 6-8.) The service information included in this manual and the tools provided in the owner’s tool kit are intended to assist you in the performance of preventive maintenance and minor repairs. However, additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly.

NOTE:

If you do not have the tools or experience required for a particular job, have a Yamaha dealer perform it for you.

6-1

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.

6-2

PERIODIC MAINTENANCE AND MINOR REPAIR

Periodic maintenance chart for the emission control system

INITIAL ODOMETER READINGS

No. ITEM ROUTINE

1 * Fuel line

2 Spark plugs

3 * Valve clearance

Crankcase breather

4 *

system

5 * Idle speed

6 * Exhaust system

Evaporative emis-

7 *

sion control system (For California only)

* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.

• Check fuel and vacuum hoses for cracks or damage.

• Replace if necessary.

• Check condition.

• Adjust gap and clean.

• Replace every 7000 mi (11000

km) or 12 months.

• Check and adjust valve clearance when engine is cold.

• Check breather hose for cracks or damage.

• Replace if necessary.

• Check and adjust engine idle

speed.

• Check for leakage.

• Tighten if necessary.

• Replace gasket(s) if necessary.

• Check control system for dam-

age.

• Replace if necessary.

600 mi

(1000 km)

1 month

√√√√√√

4000 mi

(6000 km)

6 months

√√√√√

√ Replace. √ Replace. √

√√√

√√√√√

7000 mi

(11000 km)

12 months

√√

10000 mi

(16000 km)

18 months

13000 mi

(21000 km)

24 months

EAU17580

16000 mi

(26000 km)

30 months

6-3

PERIODIC MAINTENANCE AND MINOR REPAIR

General maintenance and lubrication chart

INITIAL ODOMETER READINGS

No. ITEM ROUTINE

1 * Air filter element

2 * Battery

3 * Clutch

4 * Front brake

5 * Rear brake

6 * Brake hose

7 * Wheels

8 * Tires

• Clean with solvent.

• Replace if necessary.

• Check specific gravity and breath-

er hose for proper operation.

• Check operation.

• Adjust or replace cable.

• Check operation, fluid level, and

for fluid leakage.

• Replace brake pads if necessary.

• Check operation.

• Adjust cable and replace brake

shoes if necessary.

• Check for cracks or damage. √√√√√

• Replace. Every 4 years

• Check runout, spoke tightness

and for damage.

• Tighten spokes if necessary.

• Check tread depth and for dam-

age.

• Replace if necessary.

• Check air pressure.

• Correct if necessary.

600 mi

(1000 km)

1 month

√√√√√√

4000 mi

(6000 km)

6 months

EAU32161

7000 mi

(11000 km)

12 months

√√√√√

10000 mi

(16000 km)

18 months

13000 mi

(21000 km)

24 months

16000 mi

(26000 km)

30 months

6-4

PERIODIC MAINTENANCE AND MINOR REPAIR

No. ITEM ROUTINE

9 * Wheel bearings

Swingarm pivot

10 *

bearings

11 Drive chain

12 * Steering bearings

13 * Chassis fasteners

Brake and clutch le-

ver pivot shafts

Brake and shift ped-

al pivot shafts

16 Sidestand pivot

• Check bearings for smooth operation.

• Replace if necessary.

• Check bearing assemblies for

looseness.

• Moderately repack with lithiumsoap-based grease.

• Check chain slack, alignment and condition.

• Adjust and thoroughly lubricate chain with Yamaha chain and cable lube.

• Check bearing assembly for looseness.

• Moderately repack with lithiumsoap-based grease every 10000 mi (16000 km) or 18 months.

• Check all chassis fitting and fasteners.

• Correct if necessary.

• Apply lithium-soap-based grease

(all-purpose grease) lightly.

• Apply lithium-soap-based grease (all-purpose grease) lightly.

• Check operation.

• Apply lithium-soap-based grease

(all-purpose grease) lightly.

INITIAL ODOMETER READINGS

600 mi

(1000 km)

1 month

Check. √√√√√

Every 300 mi (500 km) and after washing the motorcycle or riding in the rain

√√√Repack. √√

4000 mi

(6000 km)

6 months

√√√√√

7000 mi

(11000 km)

12 months

10000 mi

(16000 km)

18 months

13000 mi

(21000 km)

24 months

16000 mi

(26000 km)

30 months

6-5

PERIODIC MAINTENANCE AND MINOR REPAIR

INITIAL ODOMETER READINGS

No. ITEM ROUTINE

17 * Sidestand switch

18 * Front fork

Shock absorber as-

19 *

semblies

20 Engine oil

Engine oil filter ele-

ment

Front and rear brake

22 *

switches

Control and meter

23 *

cables

Throttle grip hous-

24 *

ing and cable

Lights, signals and

25 *

switches

* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.

• Check operation and replace if necessary.

• Check operation and for oil leakage.

• Replace if necessary.

• Check operation and for oil leak-

age.

• Replace if necessary.

• Change (warm engine before

draining).

• Replace. √√√

• Check operation. √√√√√√

• Apply Yamaha chain and cable

lube or engine oil 10W-30 thoroughly.

• Check operation and free play.

• Adjust the throttle cable free play

if necessary.

• Lubricate the throttle grip housing and cable.

• Check operation.

• Adjust headlight beam.

600 mi

(1000 km)

1 month

√√√√√√

4000 mi

(6000 km)

6 months

√√√√√

7000 mi

(11000 km)

12 months

10000 mi

(16000 km)

18 months

13000 mi

(21000 km)

24 months

16000 mi

(26000 km)

30 months

6-6

PERIODIC MAINTENANCE AND MINOR REPAIR

NOTE:

From 19000 mi (31000 km) or 36 months, repeat the maintenance intervals starting from 7000 mi (11000 km) or 12 months.

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.

• Replace the brake hoses every four years or if cracked or damaged.

6-7

PERIODIC MAINTENANCE AND MINOR REPAIR

Removing and installing the panel

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.

1. Panel A

Panel A

To remove the panel Pull the rear of the panel out, and then slide the panel forward to release it in the front.

EAU18751

EAU19510

To install the panel Secure the front of the panel, and then push the rear of the panel in.

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. In addition, the condition of the spark plugs can reveal the condition of the engine.

To remove a spark plug

1. Remove the spark plug cap.

1. Spark plug cap

2. Remove the spark plug as shown, with the spark plug wrench included in the owner’s tool kit.

6-8

PERIODIC MAINTENANCE AND MINOR REPAIR

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. Check that all spark plugs installed in the engine have the same color.

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 vehicle.

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

To install a spark plug

1. Measure the spark plug gap with a wire thickness gauge and, if necessary, adjust the gap to specification.

1. Spark plug gap

Spark plug gap:

0.6–0.7 mm (0.024–0.028 in)

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.

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.

4. Install the spark plug cap.

6-9

PERIODIC MAINTENANCE AND MINOR REPAIR

Canister (for California only)

1. Canister cover

2. Canister breather

3. Canister

This model is equipped with a canister to prevent the discharging of fuel vapor into the atmosphere. Before operating this vehicle, make sure to check the following:

● Check each hose connection.

● Check each hose and canister for

cracks or damage. Replace if damaged.

EAU19681

● Make sure that the canister breath-

er 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. Place the vehicle on a level surface and hold it in an upright position.

NOTE:

Make sure that the vehicle is positioned straight up when checking the oil level. A slight tilt to the side can result in a false reading.

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.

6-10

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

4. If the engine oil is below the minimum level mark, add sufficient oil of the recommended type to raise it to the correct level.

To change the engine oil (with or without oil filter element replacement)

1. Start the engine, warm it up for several minutes, and then turn it off.

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.

1. Engine oil filler cap

1. Engine oil drain bolt

NOTE:

Skip steps 4–6 if the oil filter element is not being replaced.

4. Remove the oil filter element cover by removing the bolts.

1. Bolt

2. Oil filter element cover

5. Remove and replace the oil filter element and O-ring.

6-11

PERIODIC MAINTENANCE AND MINOR REPAIR

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.

Tightening torque:

Oil filter element cover bolt:

7.0 Nm (0.7 m·kgf, 5.1 ft·lbf)

NOTE:

Make sure that the O-ring is properly seated.

7. Install the engine oil drain bolt, and then tighten it to the specified torque.

Tightening torque:

Engine oil drain bolt:

34 Nm (3.4 m·kgf, 24 ft·lbf)

8. Add the specified amount of the recommended engine oil, and then install and tighten the oil filler cap.

Recommended engine oil:

See page 8-1.

Oil quantity:

With oil filter element replacement:

1.60 L (1.69 US qt) (1.41 Imp.qt) Without oil filter element replacement:

1.40 L (1.48 US qt) (1.23 Imp.qt)

ECA11620

CAUTION:

● In order to prevent clutch slip-

page (since the engine oil also lubricates the clutch), do not mix any chemical additives. Do not use oils with a diesel specification of “CD” or oils of a higher quality than specified. In addition, do not use oils labeled “ENERGY CONSERVING II” or higher.

● Make sure that no foreign mate-

rial enters the crankcase.

9. Start the engine, and then let it idle for several minutes while checking it for oil leakage. If oil is leaking, immediately turn the engine off and check for the cause.

10. Turn the engine off, and then check the oil level and correct it if necessary.

6-12

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU32732

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 case joint clamp screw.

1. Bolt

1. Air filter joint clamp screw

2. Air filter case cover

3. Air filter case

2. Disconnect the hoses from the air filter case, and then remove the air filter case.

3. Remove the air filter case cover by removing the screws.

1. Screw

4. Remove the air filter element by removing the wing nut.

1. Hose

2. Air filter case

1. Wing nut

2. Air filter element

6-13

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.

1. Sponge material

2. Air filter element frame

6. Apply oil of the recommended type to the entire surface of the sponge material, and then squeeze the excess oil out.

NOTE:

The air filter element should be wet but not dripping.

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:

● Make sure that the air filter ele-

ment is properly seated in the air filter case.

● The engine should never be op-

erated without the air filter element installed, otherwise the piston(s) and/or cylinder(s) may become excessively worn.

9. Install the air filter case cover by installing the screws.

10. Connect the hoses to the air filter case.

11. Push the air filter case onto the air filter case joint, and then tighten the clamp screw.

12. Install the air filter case bolts.

EAU21251

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.

Recommended oil:

Yamaha foam air filter oil or other quality air filter oil

6-14

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU21381

Checking the throttle cable free play

1. Throttle cable free play

The throttle cable free play should measure 3.0–5.0 mm (0.12–0.20 in) at the throttle grip. Periodically check the throttle cable free play and, if necessary, have a Yamaha dealer adjust it.

EAU21401

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.

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

● The tire air pressure must be

checked and adjusted on cold tires (i.e., when the temperature of the tires equals the ambient temperature).

● The tire air pressure must be ad-

justed in accordance with the riding speed and with the total weight of rider, passenger, cargo, and accessories approved for this model.

6-15

PERIODIC MAINTENANCE AND MINOR REPAIR

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)

XV250V 90–196 kg (198–432 lb) XV250VC 90–195 kg (198–430 lb):

Front:

200 kPa (29 psi) (2.00 kgf/cm²)

Rear:

225 kPa (33 psi) (2.25 kgf/cm²)

Maximum load*:

XV250V 196 kg (432 lb) XV250VC 195 kg (430 lb)

* Total weight of rider, passenger, car-

go and accessories

WARNING

Proper loading of your vehicle is important for several characteristics of your vehicle, 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 vehicle, and distribute the weight evenly from side to side. Properly adjust the suspension for your load,

EWA10510

and check the condition and pressure of your tires. NEVER OVERLOAD YOUR VEHICLE. Make sure that the total weight of the cargo, rider, passenger, and accessories (cowling, saddlebags, etc. if approved for this model) does not exceed the maximum load of the vehicle. Operation of an overloaded vehicle could cause tire damage, an accident, or even injury.

Tire inspection

1. Tire sidewall

2. Tire wear indicator

3. Tire tread depth

Always check the tires before operating the motorcycle. If a tire tread shows crosswise lines (minimum tread depth),

6-16

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.

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. When a tire tread begins to show crosswise lines, have a Yamaha dealer replace the tire immediately.

● The replacement of all wheel-

and brake-related parts, including the tires, should be left to a Yamaha dealer, who has the necessary professional knowledge and experience.

● It is not recommended to patch

a punctured tube. If unavoidable, however, patch the tube very carefully and replace it as soon as possible with a highquality product.

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:

3.00-18 47P

Manufacturer/model:

CHENG SHIN/C-916

Rear tire:

Size:

130/90-15M/C 66P

Manufacturer/model:

CHENG SHIN/C-915

EAU21940

Spoke wheels

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. A deformed or cracked wheel must be replaced.

● The wheel should be balanced

whenever either the tire or wheel has been changed or replaced. An unbalanced wheel can result in poor performance, adverse handling characteristics, and a shortened tire life.

● Ride at moderate speeds after

changing a tire since the tire surface must first be “broken in” for it to develop its optimal characteristics.

EAU22011

Accessories and replacement parts

EWA10621

WARNING

This vehicle is not designed to pull a trailer or to be attached to a sidecar. The accessories or replacement parts you choose for your vehicle should be designed specifically for this model, and they must be securely mounted to maintain the inherent stability of the original design. Genuine Yamaha Parts and Accessories are designed and tested to be compatible with your vehicle. Please consider Genuine Yamaha Parts and Accessories before making a purchase. Use of nonYamaha-approved accessories or replacement parts may cause loss of handling stability and riding safety. Since Yamaha cannot control the quality of accessories or parts manufactured by other companies, Yamaha cannot be held liable for

6-17

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

1. Locknut

2. Clutch lever free play adjusting bolt

3. Clutch lever free play

The clutch lever free play should measure 10.0–15.0 mm (0.39–0.59 in) as shown. Periodically check the clutch lever free play and, if necessary, adjust it as follows.

1. Loosen the locknut at the clutch lever.

2. To increase the clutch lever free play, turn the adjusting bolt in direction (a). To decrease the clutch lever free play, turn the adjusting bolt in direction (b).

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. Loosen the locknut at the crankcase.

1. Locknut

2. Clutch lever free play adjusting nut (crankcase)

6-18

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

1. Locknut

2. Brake lever free play adjusting screw

3. Brake lever free play

The brake lever free play should measure 2.0–5.0 mm (0.08–0.20 in) as shown. Periodically check the brake lever free play and, if necessary, adjust it as follows.

1. Loosen the locknut at the brake lever.

2. To increase the brake lever free play, turn the adjusting screw in direction (a). To decrease the brake lever free play, turn the adjusting screw in direction (b).

3. Tighten the locknut.

EWA10630

WARNING

● 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. Air in the hydraulic system will diminish the braking performance, which may result in loss of control and an accident.

6-19

PERIODIC MAINTENANCE AND MINOR REPAIR

Adjusting the brake pedal position and free play

1. Footrest

2. Distance between brake pedal and footrest

3. Brake pedal free play

WARNING

It is advisable to have a Yamaha dealer make these adjustments.

Brake pedal position

The top of the brake pedal should be positioned approximately 60.0 mm (2.36 in) above the top of the footrest as shown. Periodically check the brake pedal position and, if necessary, adjust it as follows.

EAU22201

EWA10670

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).

1. Locknut

2. Brake pedal position adjusting bolt

3. Tighten the locknut.

EWA11230

WARNING

After adjusting the brake pedal position, the brake pedal free play must be adjusted.

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).

1. Brake pedal free play adjusting nut

EWA10680

WARNING

● After adjusting the drive chain

slack or removing and installing the rear wheel, always check the brake pedal free play.

6-20

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.

EAU22270

Adjusting the rear brake light switch

1. Rear brake light switch

2. Rear brake light switch adjusting nut

The rear brake light switch, which is activated by the brake pedal, is properly adjusted when the brake light comes on just before braking takes effect. If necessary, adjust the brake light switch as follows. Turn the adjusting nut while holding the rear brake light switch in place. To make the brake light come on earlier, turn the adjusting nut in direction (a). To make the brake light come on later, turn the adjusting nut in direction (b).

EAU22380

Checking the front brake pads and rear brake shoes

The front brake pads and the rear brake shoes must be checked for wear at the intervals specified in the periodic maintenance and lubrication chart.

EAU22420

Front brake pads

1. Brake pad wear indicator groove

Each front brake pad is provided with a wear indicator groove, which allows you to check the brake pad wear without having to disassemble the brake. To check the brake pad wear, check the wear indicator groove. If a brake pad has worn to the point that the wear

6-21

PERIODIC MAINTENANCE AND MINOR REPAIR

indicator groove has almost disappeared, have a Yamaha dealer replace the brake pads as a set.

Rear brake shoes

1. Brake shoe wear indicator

2. Brake shoe wear limit line

The rear brake is provided with a wear indicator, which allows you to check the brake shoe wear without having to disassemble the brake. To check the brake shoe wear, check the position of the wear indicator while applying the brake. If a brake shoe has worn to the point that the wear indicator reaches the wear limit line, have a Yamaha dealer replace the brake shoes as a set.

EAU22540

EAU32343

Checking the front brake fluid level

1. Minimum level mark

Insufficient brake fluid may allow air to enter the brake system, possibly causing it to become ineffective. Before riding, check that the brake fluid is above the minimum level mark and replenish if necessary. A low brake fluid level may indicate worn brake pads and/or brake system leakage. If the brake fluid level is low, be sure to check the brake pads for wear and the brake system for leakage. Observe these precautions:

● When checking the fluid level,

make sure that the top of the master cylinder is level by turning the handlebars.

● 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 en-

ter the master cylinder when refilling. Water will significantly lower the boiling point of the fluid and may result in vapor lock.

● Brake fluid may deteriorate paint-

ed surfaces or plastic parts. Always clean up spilled fluid immediately.

● As the brake pads wear, it is nor-

mal for the brake fluid level to gradually go down. However, if the

6-22

PERIODIC MAINTENANCE AND MINOR REPAIR

brake fluid level goes down suddenly, have a Yamaha dealer check the cause.

EAU22720

Changing the brake fluid

Have a Yamaha dealer change the brake fluid at the intervals specified in the NOTE after the periodic maintenance and lubrication chart. In addition, have the oil seals of the brake master cylinder and caliper as well as the brake hose replaced at the intervals listed below or whenever they are damaged or leaking.

● Oil seals: Replace every two

years.

● Brake hose: Replace every four

years.

EAU22760

Drive chain slack

The drive chain slack should be checked before each ride and adjusted if necessary.

EAU22771

To check the drive chain slack

1. Place the motorcycle on the sidestand.

NOTE:

When checking and adjusting the drive chain slack, there should be no weight on the motorcycle.

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:

30.0–40.0 mm (1.18–1.57 in)

6-23

PERIODIC MAINTENANCE AND MINOR REPAIR

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). To loosen the drive chain, turn the adjust-

1. Drive chain slack

4. If the drive chain slack is incorrect, adjust it as follows.

To adjust the drive chain slack

1. Loosen the brake pedal free play adjusting nut.

EAU22860

ing nut at each end of the swingarm in direction (b), and then push the rear wheel forward.

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.

1. Axle nut

2. Cotter pin

3. Chain puller locknut

4. Drive chain slack adjusting nut

5. Alignment marks

ECA10570

CAUTION:

Improper drive chain slack will overload the engine as well as other vital parts of the motorcycle and can lead to chain slippage or breakage. To prevent this from occurring, keep the drive chain slack within the specified limits.

1. Brake pedal free play adjusting nut

5. Tighten the locknuts, and then tighten the axle nut to the specified torque.

6-24

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.

1. Cotter pin

NOTE:

Make sure that two notches in the axle nut are aligned with the hole through the wheel axle, otherwise further tighten the axle nut until they are.

EWA10700

WARNING

Always use a new cotter pin for the axle nut.

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.

EAU23013

Cleaning and 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.

ECA10581

CAUTION:

The drive chain must be lubricated after washing the motorcycle and riding in the rain.

1. Remove all dirt and mud from the drive chain with a brush or cloth.

NOTE:

For a thorough cleaning, have a Yamaha dealer remove the drive chain and soak it in solvent.

2. Spray Yamaha Chain and Cable Lube or a high-quality spray-type drive chain lubricant on both sides and on the middle of the chain,

6-25

PERIODIC MAINTENANCE AND MINOR REPAIR

making sure that all side plates and rollers have been sufficiently oiled.

EAU23090

Checking and lubricating the cables

The operation of all control cables and the condition of the cables should be checked before each ride, and the cables and cable ends should be lubricated if necessary. If a cable is damaged

Checking and lubricating the throttle grip and cable

The operation of the throttle grip should be checked before each ride. In addition, the cable should be lubricated at the intervals specified in the periodic maintenance chart.

EAU23111

or does not move smoothly, have a Yamaha dealer check or replace it.

Recommended lubricant:

Yamaha Chain and Cable Lube or engine oil SAE 10W-30 (API SE)

EWA10710

WARNING

Damage to the outer housing of cables may result in internal rusting and cause interference with cable movement. Replace damaged cables as soon as possible to prevent unsafe conditions.

6-26

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU23131

Checking and lubricating the brake and shift pedals

The operation of the brake and shift pedals should be checked before each ride, and the pedal pivots should be lubricated if necessary.

Recommended lubricant:

Lithium-soap-based grease (all-purpose grease)

EAU23140

Checking and lubricating the brake and clutch levers

The operation of the brake and clutch levers should be checked before each ride, and the lever pivots should be lubricated if necessary.

Recommended lubricant:

Lithium-soap-based grease (all-purpose grease)

EAU23200

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.

EWA10730

WARNING

If the sidestand does not move up and down smoothly, have a Yamaha dealer check or repair it.

Recommended lubricant:

Lithium-soap-based grease (all-purpose grease)

6-27

PERIODIC MAINTENANCE AND MINOR REPAIR

Lubricating the swingarm pivots

The swingarm pivots must be lubricated at the intervals specified in the periodic maintenance and lubrication chart.

Recommended lubricant:

Lithium-soap-based grease

EAUM1650

EAU23271

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.

To check the condition

EWA10750

WARNING

Securely support the vehicle so that there is no danger of it falling over.

Check the inner tubes for scratches, damage and excessive oil leakage.

To check the operation

1. Place the vehicle on a level surface and hold it in an upright position.

2. While applying the front brake, push down hard on the handlebars several times to check if the front fork compresses and rebounds smoothly.

ECA10590

CAUTION:

If any damage is found or the front fork does not operate smoothly, have a Yamaha dealer check or repair it.

6-28

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU23280

Checking the steering

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.

EWA10750

WARNING

Securely support the vehicle so that there is no danger of it falling over.

2. Hold the lower ends of the front fork legs and try to move them forward and backward. If any free play can be felt, have a Yamaha dealer check or repair the steering.

EAU23290

Checking the wheel bearings

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.

6-29

PERIODIC MAINTENANCE AND MINOR REPAIR

Battery

A poorly maintained battery will corrode and discharge quickly. The electrolyte level, battery lead connections and breather hose routing should be checked before each ride and at the intervals specified in the periodic maintenance and lubrication chart.

To check the electrolyte level

1. Place the vehicle on a level surface and hold it in an upright position.

NOTE:

Make sure that the vehicle 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.

EAU23310

1. Maximum level mark

2. Minimum level mark

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. In case of contact, administer the following FIRST AID.

• EXTERNAL: Flush with plenty

of water.

6-30

• INTERNAL: Drink large quantities of water or milk and immediately call a physician.

• EYES: Flush with water for 15 minutes and seek prompt medical attention.

● Batteries produce explosive hy-

drogen gas. Therefore, keep sparks, flames, cigarettes, etc., away from the battery and provide sufficient ventilation when charging it in an enclosed space.

● 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 BATTER-

IES OUT OF THE REACH OF CHILDREN.

ECA10610

CAUTION:

Use only distilled water, as tap water contains minerals that are harmful to the battery.

4. Check and, if necessary, tighten the battery lead connections and correct the breather hose routing.

PERIODIC MAINTENANCE AND MINOR REPAIR

1. Battery

2. Battery breather hose

To store the battery

1. If the motorcycle will not be used for more than one month, remove the battery, fully charge it, and then place it in a cool, dry place.

2. If the battery will be stored for more than two months, check the specific gravity of the electrolyte at least once a month and fully charge the battery whenever necessary.

3. Fully charge the battery before installation.

4. After installation, make sure that the battery leads are properly connected to the battery terminals and

that the breather hose is properly routed, in good condition, and not obstructed.

ECA10600

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.

EAU23600

Replacing the fuses

1. Main fuse

2. Signaling system fuse

The main fuse and the signaling system fuse holders are located under the rider seat. (See page 3-8.) If a fuse is blown, replace it as follows.

1. Turn the key to “OFF” and turn off the electrical circuit in question.

2. Remove the blown fuse, and then install a new fuse of the specified amperage.

Specified fuses:

Main fuse:

20.0 A

Signaling system fuse:

10.0 A

6-31

PERIODIC MAINTENANCE AND MINOR REPAIR

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.

3. Turn the key to “ON” and turn on the electrical circuit in question to check if the device operates.

4. If the fuse immediately blows again, have a Yamaha dealer check the electrical system.

ECA10640

EAU23780

Replacing the headlight bulb

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.

1. Headlight coupler

2. Headlight bulb cover

3. Remove the headlight bulb holder by turning it counterclockwise, and then remove the defective bulb.

1. Screw

2. Disconnect the headlight coupler, and then remove the bulb cover.

6-32

1. Headlight bulb holder

PERIODIC MAINTENANCE AND MINOR REPAIR

EWA10790

WARNING

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.

4. Place a new headlight bulb into position, and then secure it with the bulb holder.

ECA10660

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.

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.

EAU24131

Replacing the tail/brake light bulb

1. Remove the tail/brake light lens by removing the screws.

1. Screw

2. Remove the defective bulb by pushing it in and turning it counterclockwise.

6-33

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU24210

Replacing a turn signal light bulb

1. Remove the turn signal lens by removing the screws.

1. Tail/brake light bulb

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.

CAUTION:

Do not overtighten the screws, otherwise the lens may break.

ECA10680

1. Screw

2. Remove the defective bulb by pushing it in and turning it counterclockwise.

6-34

1. Turn signal light bulb

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.

ECA10680

CAUTION:

Do not overtighten the screws, otherwise the lens may break.

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU24350

Supporting the motorcycle

Since this model is not equipped with a centerstand, follow these precautions when removing the front and rear wheel or performing other maintenance requiring the motorcycle to stand upright. Check that the motorcycle is in a stable and level position before starting any maintenance. A strong wooden box can be placed under the engine for added stability.

To service the front wheel

1. Stabilize the rear of the motorcycle by using a motorcycle stand or, if an additional motorcycle stand is not available, by placing a jack under the frame in front of the rear wheel.

2. Raise the front wheel off the ground by using a motorcycle stand.

To service the rear wheel

Raise the rear wheel off the ground by using a motorcycle stand or, if a motorcycle stand is not available, by placing

a jack either under each side of the frame in front of the rear wheel or under each side of the swingarm.

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 motor-

cycle so that there is no danger of it falling over.

1. Disconnect the speedometer cable from the front wheel.

1. Speedometer cable

2. Loosen the front wheel axle pinch bolt, then the wheel axle.

6-35

PERIODIC MAINTENANCE AND MINOR REPAIR

1. Wheel axle

2. Front wheel axle pinch bolt

3. Lift the front wheel off the ground according to the procedure on page 6-35.

4. Pull the wheel axle out, and then

remove the wheel.

CAUTION:

Do not apply the brake after the wheel has been removed together with the brake disc, otherwise the brake pads will be forced shut.

To install the front wheel

1. Install the speedometer gear unit into the wheel hub so that the projections mesh with the slots.

ECA11070

EAU24932

1. Speedometer gear unit 1. Speedometer gear unit

2. Lift the wheel up between the fork

2. Retainer

3. Speedometer cable

legs.

NOTE:

Make sure that there is enough space between the brake pads before inserting the brake disc and that the slot in

3. Insert the wheel axle.

4. Lower the front wheel so that it is on the ground.

5. Tighten the wheel axle to the specified torque.

the speedometer gear unit fits over the retainer on the fork leg.

Tightening torque:

Wheel axle:

59 Nm (5.9 m·kgf, 43 ft·lbf)

6. Tighten the front wheel axle pinch bolt to the specified torque.

Tightening torque:

Front wheel axle pinch bolt:

20 Nm (2.0 m·kgf, 14 ft·lbf)

6-36

PERIODIC MAINTENANCE AND MINOR REPAIR

7. While applying the front brake, push down hard on the handlebars several times to check if the front fork compresses and rebounds smoothly.

8. Connect the speedometer cable.

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 motor-

cycle 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. Axle nut

2. Axle nut cotter pin

3. Chain puller locknut

4. Drive chain slack adjusting nut

5. 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 6-35.

5. Remove the brake pedal free play adjusting nut, and then disconnect the brake rod at the brake camshaft lever.

6. Disconnect the brake torque rod from the brake shoe plate by removing the nut and the bolt.

6-37

PERIODIC MAINTENANCE AND MINOR REPAIR

1. Brake torque rod

2. Brake torque rod bolt and nut

3. Brake rod

4. Brake pedal free play adjusting nut

5. Brake camshaft lever

7. Push the wheel forward, and then

remove the drive chain from the rear sprocket.

NOTE:

The drive chain does not need to be disassembled in order to remove and install the rear wheel.

8. Remove the axle nut.

9. Pull the wheel axle out, and then remove the wheel.

To install the rear wheel

EAU32760

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. Connect the brake torque rod to the brake shoe plate by installing the bolt and nut, and then tighten the bolt to the specified torque.

Tightening torque:

Brake torque rod bolt:

23 Nm (2.3 m·kgf, 17 ft·lbf)

4. Adjust the drive chain slack. (See page 6-23.)

5. Install the axle nut, and then lower the rear wheel so that it is on the ground.

6. Tighten the axle nut to the specified torque, and then insert a new cotter pin into the axle nut.

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 6-20.)

EWA10660

WARNING

After adjusting the brake pedal free play, check the operation of the brake light.

6-38

EAU25850

Troubleshooting

Although Yamaha motorcycles receive a thorough inspection before shipment from the factory, trouble may occur during operation. Any problem in the fuel, compression, or ignition systems, for example, can cause poor starting and loss of power. The following troubleshooting chart represents a quick and easy procedure for checking these vital systems yourself. However, should your motorcycle require any repair, take it to a Yamaha dealer, whose skilled technicians have the necessary tools, experience, and know-how to service the motorcycle properly. Use only genuine Yamaha replacement parts. Imitation parts may look like Yamaha parts, but they are often inferior, have a shorter service life and can lead to expensive repair bills.

PERIODIC MAINTENANCE AND MINOR REPAIR

6-39

PERIODIC MAINTENANCE AND MINOR REPAIR

Troubleshooting chart

WARNING

Keep away open flames and do not smoke while checking or working on the fuel system.

EAU25931

EWA10840

1. Fuel

Check the fuel level in

There is enough fuel.

the fuel tank.

There is no fuel.

Check the compression.

Supply fuel.

The engine does not start. Check the compressoin.

2. Compression

There is compression.

Operate the electric starter.

There is no compression.

Check the ignition.

Have a Yamaha dealer check the vehicle.

3. Ignition

Remove the spark plugs and check the electrodes.

4. Battery

Operate the electric starter.

Wet

Dry

The engine turns over quickly.

The engine turns over slowly.

Wipe off with a dry cloth and correct the spark plug gaps, or replace the spark plugs.

Have a Yamaha dealer check the vehicle.

The battery is good.

Check the electrolyte and battery lead connections, and charge the battery if necessary.

6-40

Open the throttle halfway and operate the electric starter.

The engine does not start. Check the battery.

The engine does not start. Have a Yamaha dealer check the vehicle.

MOTORCYCLE CARE AND STORAGE

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. A rusty exhaust pipe may go unnoticed on a car, however, it detracts from the overall appearance of a motorcycle. Frequent and proper care does not only comply with the terms of the warranty, but it will also keep your motorcycle looking good, extend its life and optimize its performance.

Before cleaning

1. Cover the muffler outlets with plastic bags after the engine has cooled down.

2. Make sure that all caps and covers as well as all electrical couplers and connectors, including the spark plug caps, are tightly installed.

3. Remove extremely stubborn dirt, like oil burnt onto the crankcase, with a degreasing agent and a brush, but never apply such prod-

ucts onto seals, gaskets, sprockets, the drive chain and wheel axles. Always rinse the dirt and degreaser off with water.

Cleaning

ECA10770

CAUTION:

● Avoid using strong acidic wheel

cleaners, especially on spoked wheels. If such products are used on hard-to-remove dirt, do not leave the cleaner on the affected area any longer than instructed. Also, thoroughly rinse the area off with water, immediately dry it, and then apply a corrosion protection spray.

● Improper cleaning can damage

windshields, cowlings, panels and other plastic parts. Use only a soft, clean cloth or sponge with mild detergent and water to clean plastic.

● Do not use any harsh chemical

products on plastic parts. Be sure to avoid using cloths or sponges which have been in contact with strong or abrasive

7-1

cleaning products, solvent or thinner, fuel (gasoline), rust removers or inhibitors, brake fluid, antifreeze or electrolyte.

● Do not use high-pressure wash-

ers or steam-jet cleaners since they cause water seepage and deterioration in the following areas: seals (of wheel and swingarm bearings, fork and brakes), electric components (couplers, connectors, instruments, switches and lights), breather hoses and vents.

● For motorcycles equipped with

a windshield: Do not use strong cleaners or hard sponges as they will cause dulling or scratching. Some cleaning compounds for plastic may leave scratches on the windshield. Test the product on a small hidden part of the windshield to make sure that it does not leave any marks. If the windshield is scratched, use a quality plastic polishing compound after washing.

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.

After riding in the rain, near the sea or on salt-sprayed roads Since sea salt or salt sprayed on roads during winter are extremely corrosive in combination with water, carry out the following steps after each ride in the rain, near the sea or on salt-sprayed roads.

NOTE:

Salt sprayed on roads in the winter may remain well into spring.

1. Clean the motorcycle with cold water and a mild detergent, after the engine has cooled down.

ECA10790

CAUTION:

Do not use warm water since it increases the corrosive action of the salt.

2. After drying the motorcycle, apply a corrosion protection spray on all metal, including chrome- and nickel-plated, surfaces to prevent corrosion.

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. To prevent corrosion, it is recommended to apply a corrosion protection spray on all metal, including chrome- and nickel-plated, surfaces.

5. Use spray oil as a universal cleaner to remove any remaining dirt.

6. Touch up minor paint damage caused by stones, etc.

7. Wax all painted surfaces.

8. Let the motorcycle dry completely before storing or covering it.

EWA10930

WARNING

● Make sure that there is no oil or

wax on the brakes or tires. If necessary, clean the brake discs and brake linings with a regular brake disc cleaner or acetone, and wash the tires with warm water and a mild detergent.

● Before operating the motor-

cycle test its braking performance and cornering behavior.

7-2

MOTORCYCLE CARE AND STORAGE

ECA10800

CAUTION:

● Apply spray oil and wax spar-

ingly and make sure to wipe off any excess.

● Never apply oil or wax to any

rubber and plastic parts, but treat them with a suitable care product.

● Avoid using abrasive polishing

compounds as they will wear away the paint.

NOTE:

Consult a Yamaha dealer for advice on what products to use.

EAU32640

Storage

Short-term

Always store your motorcycle in a cool, dry place and, if necessary, protect it against dust with a porous cover.

ECA10810

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.

● To prevent corrosion, avoid

damp cellars, stables (because of the presence of ammonia) and areas where strong chemicals are stored.

Long-term

Before storing your motorcycle for several months:

1. Follow all the instructions in the “Care” section of this chapter.

2. Turn the fuel cock lever to “ON”.

7-3

3. Drain the carburetor float chambers by loosening the drain bolts; this will prevent fuel deposits from building up. Pour the drained fuel into the fuel tank.

4. Fill up the fuel tank and add fuel stabilizer (if available) to prevent the fuel tank from rusting and the fuel from deteriorating.

5. Perform the following steps to protect the cylinders, piston rings, etc. from corrosion. a. Remove the spark plug caps

and spark plugs.

b. Pour a teaspoonful of engine oil

into each spark plug bore.

c. Install the spark plug caps onto

the spark plugs, and then place the spark plugs on the cylinder head so that the electrodes are grounded. (This will limit sparking during the next step.)

d. Turn the engine over several

times with the starter. (This will coat the cylinder walls with oil.)

e. Remove the spark plug caps

from the spark plugs, and then install the spark plugs and the spark plug caps.

MOTORCYCLE CARE AND STORAGE

WARNING

To prevent damage or injury from sparking, make sure to ground the spark plug electrodes while turning the engine over.

6. Lubricate all control cables and the pivoting points of all levers and pedals as well as of the sidestand/centerstand.

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. Cover the muffler outlets with plastic bags to prevent moisture from entering them.

9. Remove the battery and fully charge it. Store it in a cool, dry place and charge it once a month. Do not store the battery in an excessively cold or warm place [less than 0 °C (30 °F) or more than 30

EWA10950

°C (90 °F)]. For more information on storing the battery, see page 6-30.

NOTE:

Make any necessary repairs before storing the motorcycle.

7-4

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:

XV250V 147.0 kg (324 lb) XV250VC 148.0 kg (326 lb)

Engine:

Engine type:

Air cooled 4-stroke, SOHC

Cylinder arrangement:

V-type 2-cylinder

Displacement:

249.0 cm³ (15.19 cu.in)

Bore × stroke:

49.0 × 66.0 mm (1.93 × 2.60 in)

Compression ratio:

10.00 :1

Starting system:

Electric starter

Lubrication system:

Wet sump

Engine oil:

Type:

YAMALUBE 4, SAE10W30 or SAE20W40

0°

10° 30° 50° 70° 90°

YAMALUBE 4 (10W30)

or SAE 10W30

YAMALUBE 4 (20W40) or SAE 20W40

–20°

–10° 0° 10° 20° 30°

110°

40°

Recommended engine oil grade:

API service SE, SF, SG type or higher

Engine oil quantity:

Without oil filter element replacement:

1.40 L (1.48 US qt) (1.23 Imp.qt)

With oil filter element replacement:

1.60 L (1.69 US qt) (1.41 Imp.qt)

Air filter:

Air filter element:

Wet element

Fuel:

Recommended fuel:

Unleaded gasoline only

Fuel tank capacity:

XV250V 9.5 L (2.51 US gal) (2.09 Imp.gal) XV250VC 9.2 L (2.43 US gal) (2.02 Imp.gal)

Fuel reserve amount:

2.6 L (0.69 US gal) (0.57 Imp.gal)

130°F

50°C

Carburetor:

Manufacturer:

MIKUNI

Type × quantity:

BDS26 x 1

Spark plug (s):

Manufacturer/model:

NGK/C6HSA

Manufacturer/model:

DENSO/U20FS-U

Spark plug gap:

0.6–0.7 mm (0.024–0.028 in)

Clutch:

Clutch type:

Wet, multiple-disc

Transmission:

Primary reduction system:

Spur gear

Primary reduction ratio:

72/23 (3.130)

Secondary reduction system:

Chain drive

Secondary reduction ratio:

45/16 (2.812)

Transmission type:

Constant mesh 5-speed

Operation:

Left foot operation

Gear ratio:

1st:

37/14 (2.643)

2nd:

32/19 (1.684)

8-1

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:

3.00-18 47P

Manufacturer/model:

CHENG SHIN/C-916

Rear tire:

Type:

With tube

Size:

130/90-15M/C 66P

Manufacturer/model:

CHENG SHIN/C-915

Loading:

Maximum load:

XV250V 196 kg (432 lb) XV250VC 195 kg (430 lb) (Total weight of ride r, passenger, cargo and accessories)

Tire air pressure (measured on cold tires):

Loading condition:

0–90 kg (0–198 lb) Front:

175 kPa (25 psi) (1.75 kgf/cm²)

Rear:

200 kPa (29 psi) (2.00 kgf/cm²)

Loading condition:

XV250V 90–196 kg (198–432 lb) XV250VC 90–195 kg (198–430 lb) Front:

200 kPa (29 psi) (2.00 kgf/cm²)

Rear:

225 kPa (33 psi) (2.25 kgf/cm²)

Front wheel:

Wheel type:

Spoke wheel

Rim size:

18x1.60

Rear wheel:

Wheel type:

Spoke wheel

Rim size:

15M/C x MT2.75

Front brake:

Type:

Single disc brake

Operation:

Right hand operation

Recommended fluid:

DOT 4

Rear brake:

Type:

Drum brake

Operation:

Right foot operation

Front suspension:

Type:

Telescopic fork

Spring/shock absorber type:

Coil spring/oil damper

Wheel travel:

140.0 mm (5.51 in)

Rear suspension:

Type:

Swingarm

Spring/shock absorber type:

Coil spring/oil damper

Wheel travel:

100.0 mm (3.94 in)

Electrical system:

Ignition system:

Transistorized coil ignition (digital)

Charging system:

AC magneto

Battery:

Model:

YB10L-A

Voltage, capacity:

12 V, 10.0 Ah

Headlight:

Bulb type:

Halogen bulb

8-2

Bulb voltage, wattage × quantity:

Headlight:

12 V, 60 W/55.0 W × 1

Tail/brake light:

12 V, 8.0 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:

20.0 A

Signaling system fuse:

10.0 A

SPECIFICATIONS

8-3

CONSUMER INFORMATION

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. KEY IDENTIFICATION NUMBER:

VEHICLE IDENTIFICATION NUMBER:

MODEL LABEL INFORMATION:

EAU26351

Key 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.

EAU26390

Vehicle identification number

The vehicle identification number is stamped into the steering head pipe. Record this number in the space provided.

NOTE:

The vehicle identification number is used to identify your motorcycle and may be used to register your motorcycle with the licensing authority in your area.

EAU26400

9-1

CONSUMER INFORMATION

Model label

EAU26470

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.

9-2

CONSUMER INFORMATION

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. If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in individual problems between you, your dealer, or Yamaha Motor Corporation, U.S.A. To contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1-800-424-9393 (or 366-0123 in Washington, D.C. area) or write to: NHTSA, U.S. Department of Transportation, Washington, D.C. 20590. You can also obtain other information about motor vehicle safety from the Hotline.

EAU26550

9-3

CONSUMER INFORMATION

EAU26560

Motorcycle noise regulation

TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED:

Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. “AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW”. These acts include tampering with the following systems; i.e., modification, removal, etc.

Exhaust system

• Muffler

• Exhaust pipe

• Silencer

Intake system

• Air cleaner case

• Air cleaner element

• Intake duct

9-4

CONSUMER INFORMATION

Maintenance record

Copies of work orders and/or receipts for parts purchased and installed on your motorcycle will be required to document that maintenance has been completed in accordance with the emissions warranty. The chart below is printed only as a reminder that maintenance work is required. It is not acceptable proof of maintenance work.

Maintenance

interval

600 mi

(1000 km) or

1 month 4000 mi

(6000 km) or

6 months

7000 mi

(11000 km) or

12 months

10000 mi

(16000 km) or

18 months

13000 mi

(21000 km) or

24 months

16000 mi

(26000 km) or

30 months

19000 mi

(31000 km) or

36 months

22000 mi

(36000 km) or

42 months

25000 mi

(41000 km) or

48 months

Date of service

Mileage

Servicing dealer

name and address

Remarks

EAU26611

9-5

CONSUMER INFORMATION

Maintenance

interval

28000 mi

(46000 km) or

54 months

31000 mi

(51000 km) or

60 months

Date of service

Mileage

Servicing dealer

name and address

Remarks

9-6

CONSUMER INFORMATION

YAMAHA MOTOR CORPORATION, U.S.A. STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY

EAU26661

9-7

CONSUMER INFORMATION

9-8

CONSUMER INFORMATION

YAMAHA EXTENDED SERVICE (Y.E.S.)

EAU26750

Keep your Yamaha protected even after your warranty expires with genuine Yamaha Extended Service (Y.E.S.).

Y.E.S. is designed and administered by Yamaha Motor Corporation to provide maximum owner satisfaction. You get uninterrupted factory-backed coverage for extra peace of mind.

Y.E.S. is flexible. You choose the plan that’s right for you: 12 months, 24 months, 36 months or, on certain models, even 48 months beyond your warranty period.

Y.E.S. is designed and administered by the same Yamaha people who handle your warranty – and it shows in the comprehensive coverage benefits. There are no mileage limitations. Coverage isn’t limited to “moving parts” or the “drive train” like many other plans. And Y.E.S. covers manufacturing defects just like the warranty. See the sample contract at your Yamaha dealer to see how comforting uninterrupted factorybacked protection can be.

You don’t have to pay anything for covered repairs. There’s no deductible to pay, and repairs aren’t “pro-rated.” You don’t have any “out-of-pocket” expenses for covered repairs.

In addition, Travel and Recreation Interruption Protection (TRIP) is included at no extra cost. TRIP gives you up to $150 reimbursement per occurrence for any reasonable expenses you incur because your Yamaha needs covered service: replacement vehicle rental, emergency towing, phone calls, even food and lodging when you are away from home. This superb coverage goes into effect when you purchase Y.E.S., so it applies to any warranty repairs as well as covered repairs during your entire Y.E.S. plan period.

Y.E.S. coverage is honored at any authorized Yamaha dealer nationwide.

Y.E.S. coverage is transferable to a new owner if you sell or trade-in. That can make your Yamaha much more valuable!

This excellent Y.E.S. plan coverage is only available to Yamaha owners like you, and only while your Yamaha is still within the Yamaha Limited Warranty period. So visit your authorized Yamaha dealer to get all the facts. He can show you how easy it is to protect your investment with Yamaha Extended Service.

9-9

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. Box 6555 Cypress, CA 90630 1-(866)-YES-EXTD (1-866-937-3983)

CONSUMER INFORMATION

9-10

INDEX

Accessories and replacement parts ...... 6-17

Air filter element, cleaning..................... 6-13

Battery...................................................6-30

Brake and clutch levers,

checking and lubricating ..................... 6-27

Brake and shift pedals,

checking and lubricating ..................... 6-27

Brake fluid, changing ............................6-23

Brake fluid level, checking .................... 6-22

Brake lever..............................................3-4

Brake lever free play, adjusting............. 6-19

Brake pads and shoes, checking ..........6-21

Brake pedal.............................................3-4

Brake pedal position and free play,

adjusting .............................................6-20

Cables, checking and lubricating ..........6-26

Canister (for California only) .................6-10

Carburetor.............................................6-14

Care ........................................................7-1

Clutch lever.............................................3-3

Clutch lever free play, adjusting............ 6-18

Dimmer switch ........................................3-3

Drive chain, cleaning and

lubricating ...........................................6-25

Drive chain slack...................................6-23

Engine break-in.......................................5-4

Engine oil and oil filter element.............6-10

Engine, starting a warm .......................... 5-2

Engine stop switch..................................3-3

Front fork, checking.............................. 6-28

Fuel......................................................... 3-5

Fuel cock ................................................ 3-6

Fuel tank cap.......................................... 3-5

Fuses, replacing ................................... 6-31

Handlebar switches ................................ 3-2

Headlight bulb, replacing ...................... 6-32

Helmet holder ......................................... 3-9

High beam indicator light ........................ 3-2

Horn switch............................................. 3-3

Identification numbers ............................ 9-1

Ignition circuit cut-off system ................ 3-11

Indicator lights ........................................ 3-1

Key identification number ....................... 9-1

Labels, location of................................... 1-5

Main switch............................................. 3-1

Maintenance and lubrication,

periodic................................................. 6-4

Maintenance, emission control

system.................................................. 6-3

Maintenance, periodic ............................ 6-1

Maintenance record................................ 9-5

Model label ............................................. 9-2

Neutral indicator light.............................. 3-1

Noise regulation...................................... 9-4

Panel, removing and installing................ 6-8

Parking....................................................5-4

Part locations ..........................................2-1

Pre-operation check list...........................4-2

Rear brake light switch, adjusting .........6-21

Rider seat................................................3-8

Safety defects, reporting .........................9-3

Safety information...................................1-1

Shifting ....................................................5-2

Shift pedal ............................................... 3-4

Shock absorber assemblies, adjusting....3-9

Sidestand ..............................................3-10

Sidestand, checking and lubricating...... 6-27

Spark plugs, checking .............................6-8

Specifications..........................................8-1

Speedometer unit.................................... 3-2

Starter (choke) lever................................3-7

Starting and warming up a cold

engine ...................................................5-1

Start switch..............................................3-3

Steering, checking.................................6-29

Steering lock ...........................................3-8

Storage....................................................7-3

Supporting the motorcycle ....................6-35

Swingarm pivots, lubricating .................6-28

Tail/brake light bulb, replacing ..............6-33

Throttle cable free play, checking .........6-15

Throttle grip and cable,

checking and lubricating .....................6-26

Tires ......................................................6-15

Tool kit.....................................................6-1

Troubleshooting ....................................6-39

Troubleshooting chart........................... 6-40

Turn signal indicator light........................ 3-1

Turn signal light bulb, replacing............ 6-34

Turn signal switch................................... 3-3

Valve clearance.................................... 6-15

Vehicle identification number.................. 9-1

Warranty, extended ................................ 9-9

Warranty, limited..................................... 9-7

Wheel bearings, checking .................... 6-29

Wheel (front)......................................... 6-35

Wheel (rear).......................................... 6-37

Wheels.................................................. 6-17

INDEX

PRINTED ON RECYCLED PAPER

YAMAHA MOTOR CO., LTD.

PRINTED IN JAPAN

2005.05-0.3×1 CR

(E)

Yamaha VIRAGO XV250VC, VIRAGO, VIRAGO XV250V User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

INTRODUCTION

TABLE OF CONTENTS

SAFETY INFORMATION

Location of important labels

Controls and instruments

INSTRUMENT AND CONTROL FUNCTIONS

Main switch

Indicator lights

Handlebar switches

Shift pedal

Brake lever

Brake pedal

Fuel

Starter (choke) lever

Adjusting the shock absorber assemblies

PRE-OPERATION CHECKS

Pre-operation check list

Shifting

To start out and accelerate

To decelerate

Engine break-in

PERIODIC MAINTENANCE AND MINOR REPAIR

Periodic maintenance chart for the emission control system

General maintenance and lubrication chart

Checking the spark plugs

Engine oil and oil filter element

Checking the throttle cable free play

Tires

Adjusting the clutch lever free play

Adjusting the brake lever free play

Checking the front brake pads and rear brake shoes

Drive chain slack

Checking and lubricating the cables

Checking the front fork

Checking the steering

Battery

Replacing the fuses

Replacing the headlight bulb

Front wheel

Rear wheel

Troubleshooting

MOTORCYCLE CARE AND STORAGE

Care

Storage

SPECIFICATIONS

CONSUMER INFORMATION

Identification numbers

Maintenance record

YAMAHA EXTENDED SERVICE (Y.E.S.)

INDEX