Yamaha XT250 M 2000 Owner's manual
OWNER’S MANUAL
XT250M
4FD-28199-27
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INTRODUCTION
Congratulations on your purchase of the Yamaha XT250. 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 about the operation or maintenance of
your motorcycle, please consult a Yamaha dealer
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IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following notations:
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NOTE:
NOTE:
8 This manual should be considered a permanent part of this motorcycle and should
8 Yamaha continually seeks advancements in product design and quality. Therefore,
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!
Failure to follow WARNING instructions could result in severe injury or death to
the motorcycle operator, a bystander or a person inspecting or repairing the
motorcycle.
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.
remain with it even if the motorcycle is subsequently sold.
while this manual contains the most current product information available at the time
of printing, there may be minor discrepancies between your motorcycle and this manual. If there is any question concerning this manual, please consult your Yamaha dealer.
IMPORTANT MANUAL INFORMATION
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PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS
MOTORCYCLE.
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XT250M
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OWNER’S MANUAL
©1999 by Yamaha Motor Co., Ltd.
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1st Edition, June 1999
All rights reserved. Any reprinting or
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unauthorized use without the written
permission of Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Japan.
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TABLE OF CONTENTS
SAFETY INFORMATION ....................................1-1
1
Safe riding ........................................................1-1
Protective apparel ............................................1-3
Modification......................................................1-3
Loading and accessories .................................1-3
Gasoline and exhaust gas ...............................1-5
Location of the important labels.....................1-7
DESCRIPTION .....................................................2-1
2
Left view............................................................2-1
Right view.........................................................2-2
Controls/Instruments .......................................2-3
INSTRUMENT AND CONTROL FUNCTIONS ...3-1
3
Main switch/Steering lock ...............................3-1
Indicator lights..................................................3-2
Speedometer....................................................3-2
Handlebar switches..........................................3-3
Clutch lever.......................................................3-4
Shift pedal.........................................................3-4
Front brake lever ..............................................3-5
Rear brake pedal ..............................................3-5
Fuel tank cap.....................................................3-5
Fuel....................................................................3-6
Fuel cock ...........................................................3-7
Starter(choke) “1”..........................................3-8
Seat ...................................................................3-8
Helmet holder...................................................3-9
Rear shock absorber adjustment..................3-10
Sidestand........................................................3-12
Sidestand/clutch switch operation check.....3-12
PRE-OPERATION CHECKS.................................4-1
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Pre-operation check list ...................................4-1
OPERATION AND IMPORTANT RIDING
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POINTS................................................................5-1
Starting and warming up a cold engine.........5-1
Starting a warm engine...................................5-4
Shifting..............................................................5-4
Tips for reducing fuel consumption ...............5-5
Engine break-in ................................................5-5
Parking ..............................................................5-6
PERIODIC MAINTENANCE AND MINOR
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REPAIR ................................................................6-1
Tool kit ..............................................................6-1
Periodic maintenance and lubrication............6-3
Cowling A .........................................................6-6
Panel A and B ...................................................6-6
Spark plug.........................................................6-7
Engine oil..........................................................6-8
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TABLE OF CONTENTS
Air filter ...........................................................6-11
Carburetor adjustment ..................................6-13
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Idle speed adjustment ...................................6-13
Throttle cable free play adjustment..............6-14
Valve clearance adjustment ..........................6-14
Tires.................................................................6-15
Wheels ............................................................6-16
Clutch lever free play adjustment.................6-17
Front brake lever free play adjustment ........6-18
Rear brake pedal height and free play
adjustment......................................................6-18
Brake light switch adjustment.......................6-20
Checking the front brake pads and rear brake
shoes...............................................................6-20
Inspecting the brake fluid level.....................6-21
Brake fluid replacement.................................6-22
Drive chain slack check..................................6-22
Drive chain slack adjustment ........................6-22
Drive chain lubrication...................................6-24
Cable inspection and lubrication ..................6-24
Throttle cable and grip lubrication ...............6-25
Brake and shift pedal lubrication..................6-25
Brake and clutch lever lubrication ................6-25
Sidestand lubrication.....................................6-26
Rear suspension lubrication..........................6-26
Front fork inspection......................................6-26
Steering inspection........................................6-27
Wheel bearings ..............................................6-28
Battery.............................................................6-28
Fuse replacement...........................................6-29
Headlight bulb replacement..........................6-29
Turn signal light bulb replacement ..............6-31
Taillight bulb replacement ............................6-32
Supporting the motorcycle ...........................6-32
Front wheel removal......................................6-33
Front wheel installation.................................6-34
Rear wheel removal.......................................6-35
Rear wheel installation ..................................6-35
Troubleshooting.............................................6-36
Troubleshooting chart ...................................6-37
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MOTORCYCLE CARE AND STORAGE ..............7-1
Care ...................................................................7-1
Storage..............................................................7-4
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SPECIFICATIONS................................................8-1
Specifications ...................................................8-1
How to use the conversion table ....................8-5
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CONSUMER INFORMATION .............................9-1
Identification number records.........................9-1
Key identification number ...............................9-1
Vehicle identification number .........................9-1
Model label.......................................................9-2
Noise regulation (For Australia)......................9-2
Q SAFETY INFORMATION
TWO-WHEELED MOTORCYCLES ARE SINGLE TRACK VEHICLES. THEIR SAFE USE AND OPERATION ARE DEPENDENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE
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EXPERTISE OF THE OPERATOR. EVERY OPERATOR SHOULD KNOW THE FOLLOWING
REQUIREMENTS BEFORE RIDING.
HE OR SHE SHOULD:
1. OBTAIN THOROUGH INSTRUCTIONS FROM A COMPETENT SOURCE ON ALL ASPECTS
OF MOTORCYCLE OPERATION.
2. OBSERVE THE WARNINGS AND MAINTENANCE REQUIREMENTS IN THE OWNER’S MANUAL.
3. OBTAIN QUALIFIED TRAINING IN SAFE AND PROPER RIDING TECHNIQUES.
4. OBTAIN PROFESSIONAL TECHNICAL SERVICE AS INDICATED BY THE OWNER’S MANUAL AND/OR WHEN MADE NECESSARY BY MECHANICAL CONDITIONS.
Safe riding
1. Always make pre-operation checks. Careful checks may help prevent an accident.
2. This motorcycle is designed to carry the operator and a passenger.
3. The failure of motorists to detect and recognize motorcycles in traffic is the 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:
a. Wear a brightly colored jacket.
b. Use extra caution when you approach and pass through intersections, since intersec-
tions are the most likely places for motorcycle accidents.
c. Ride where other motorists can see you. Avoid riding in another motorist’s “blind spot”.
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Q SAFETY INFORMATION
4. Many accidents involve inexperienced operators. In fact, many operators who have been
involved in accidents do not even have a current motorcycle license.
a. Make sure you are qualified. Also, only lend your motorcycle to experienced operators.
b. Know your skills and limits. Staying within your limits may help you to avoid an acci-
dent.
c. We recommend that you practice riding your motorcycle where there is no traffic until
you have become thoroughly familiar with your motorcycle and all of its controls.
5. Many motorcycle accidents have been caused by motorcycle operator errors. A typical
error made by the operator is veering wide on a turn due to EXCESSIVE SPEED or undercornering (insufficient lean angle for the speed).
a. Always obey the speed limits and never travel faster than warranted by road and traffic
conditions.
b. Always signal before turning or changing lanes. Make sure other motorists see you.
6. The operator’s and passenger’s posture are important for proper control.
a. The operator should keep both hands on the handlebars and both feet on the operator
footrests during operation to maintain control of the motorcycle.
b. The passenger should always hold on to the operator, or the seat strap or grab bar if the
motorcycle is so equipped with both hands and keep both feet on the passenger
footrests.
c. Never carry a passenger unless he or she can firmly place both feet on the passenger
footrests.
7. Never ride under the influence of alcohol or drugs.
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Q SAFETY INFORMATION
Protective apparel
The majority of fatalities from motorcycle accidents are the result of head injuries.
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The use of a safety helmet is the single most critical factor in the prevention or reduction of
head injuries.
1. Always wear an approved helmet.
2. Wear a face shield or goggles. Wind on your unprotected eyes could contribute to an
impairment of vision which could delay seeing a hazard.
3. The use of heavy boots, jacket, trousers, gloves, etc. is effective in preventing or reducing
abrasions or lacerations.
4. Never wear loose fitting clothing. It could catch on the control levers, footrests, or wheels
and cause injury or accident.
5. Never touch the engine or exhaust system during or after operation. They become very hot
and can cause burns. Always wear protective clothing that covers your legs, ankles, and
feet.
6. A passenger should also observe the above precautions.
Modification
Modifications made to the motorcycle not approved by Yamaha, or the removal of original
equipment, may render your 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 machine is changed. To avoid the possibility of an accident,
extreme caution should be used if adding cargo or accessories to your motorcycle. Use extra
care if riding a motorcycle which has added cargo or accessories. Here are some general
guidelines to follow if loading cargo or adding accessories to your motorcycle:
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Loading
The total weight of the operator, passenger, accessories and cargo must not exceed the maximum load limit of 183 kg
When loading within these weight limits, keep the following in mind:
1. Cargo and accessory weight should be kept as low and close to the motorcycle as possible.
Be sure to distribute the weight as evenly as possible on both sides of the machine to minimize imbalance or instability.
2. Shifting weights can create a sudden imbalance. Make sure that accessories and cargo are
securely attached to the motorcycle before riding. Recheck accessory mounts and cargo
restraints frequently.
3. Never attach any large or heavy items to the handlebars, front forks, or front fender. These
items, including such cargo as sleeping bags, duffle bags, or tents, can create unstable
handling or slow steering response.
Accessories
Genuine Yamaha accessories have been specifically designed for use on this motorcycle. Since
Yamaha cannot test all other accessories which may be available, you must personally be
responsible for the proper selection, installation and use of non-Yamaha accessories. You
should use extreme caution when selecting and installing any accessories.
Keep in mind these guidelines for mounting accessories in addition to those provided under
“LOADING”.
1. Never install accessories or carry cargo that would impair the performance of your motorcycle. Carefully inspect the accessory before using it to make sure it does not in any way
reduce ground clearance or cornering clearance, limit suspension travel, steering travel or
control operation, or obscure lights or reflectors.
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Q SAFETY INFORMATION
a. Accessories fitted to the handlebar or the front fork area can create instability due to
improper weight distribution or aerodynamic changes. If accessories are added to the
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Gasoline and exhaust gas
handlebar or front fork area, they must be as lightweight as possible and should be kept
to a minimum.
b. Bulky or large accessories may seriously affect the stability of the motorcycle due to
aerodynamic effects. Wind may attempt to lift the motorcycle, or the motorcycle may
become unstable in cross winds. These accessories may also cause instability when
being passed by or passing large vehicles.
c. Certain accessories can displace the operator from his or her normal riding position.
This improper position limits the freedom of movement of the operator and may limit
control ability. Therefore such accessories are not recommended.
2. Caution must be used if adding electrical accessories. If these 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.
1. GASOLINE IS HIGHLY FLAMMABLE:
a. Always turn off the engine when refueling.
b. Take care not to spill any gasoline on the engine or exhaust system when refueling.
c. Never refuel while smoking or in the vicinity of an open flame.
2. 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.
3. Always turn off the engine before leaving the motorcycle unattended and remove the ignition key. When parking the motorcycle, note the following:
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Q SAFETY INFORMATION
a. The engine and exhaust system may be hot. Park the motorcycle in a place where
pedestrians or children are not likely to touch these hot areas.
b. Do not park the motorcycle on a slope or soft ground; the motorcycle may fall over.
c. Do not park the motorcycle near a flammable source, e.g. a kerosene heater, or near an
open flame. The motorcycle could catch fire.
4. When transporting the motorcycle in another vehicle, be sure it is kept upright and that the
fuel cock(s) is turned to “ON” or “RES” (for vacuum type)/“OFF” (for manual type). If it
should lean over, gasoline may leak out of the carburetor or fuel tank.
5. If you should swallow any gasoline, inhale a lot of gasoline vapor, or allow gasoline to get
in your eyes, see your doctor immediately. If any gasoline spills on your skin or clothing,
immediately wash it off with soap and water and change your clothes.
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Location of the important labels
Please read the following labels carefully before operating this motorcycle.
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WARNING
Before you operate this vehicle,
read the owner’s manual.
English
3HP-21568-00
4AA-22259-40
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DESCRIPTION
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Left view
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1. Front wheel (page 6-33)
2. Front turn signal light
3. Fuel cock (page 3-7)
4. Seat (page 3-8)
5. Panel B (page 6-6)
6. Helmet holder (page 3-9)
7. Tool box (page 6-1)
8. Rear wheel (page 6-35)
9. Shift pedal (page 3-4, 5-4)
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Right view
DESCRIPTION
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10. Tail/brake light (page 6-32)
11. Rear turn signal light (page 6-31)
12. Panel A (page 6-6)
13. Headlight (page 6-29)
14. Rear brake pedal (page 3-5)
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2-2
DESCRIPTION
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Controls/Instruments
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15. Clutch lever (page 3-4, 6-17)
16. Left handlebar switches (page 3-3)
17. Speedometer (page 3-2)
18. Main switch (page 3-1)
19. Right handlebar switches (page 3-3)
20. Front brake lever (page 3-5, 6-18)
21. Throttle grip (page 6-25)
22. Fuel tank cap (page 3-5)
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OFF (Push)
LOCK
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ON
OFF
LOCK
INSTRUMENT AND CONTROL FUNCTIONS
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OFF
All electrical circuits are switched
off. The key can be removed in this
position.
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Main switch/Steering lock
The main switch controls the ignition and lighting systems. Its operation is described below.
ON
Electrical circuits are switched on,
and the headlight, meter light, and
taillight come on. The engine can
be started. The key cannot be
removed in this position
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LOCK
The steering is locked in this position and all electrical circuits are
switched off. The key can be
removed in this position.
To lock the steering, turn the handlebars all the way to the left.
While pushing the key into the
main switch, turn it from “OFF” to
“LOCK” and remove it.
To release the lock, turn the key to
“OFF” while pushing.
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INSTRUMENT AND CONTROL FUNCTIONS
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1. Push
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2. Turn
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Never turn the key to “OFF” or
“LOCK” when the motorcycle is
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moving. The electrical circuits will
be switched off which may result
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in loss of control or an accident. Be
sure the motorcycle is stopped
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before turning the key to “OFF” or
“LOCK”.
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1. Turn indicator light “TURN”
2. High beam indicator light “HIGH BEAM”
3. Neutral indicator light “NEUTRAL”
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Indicator lights
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Turn indicator light “TURN”
This indicator flashes when the
turn switch is moved to the left or
right.
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High beam indicator light “HIGH
BEAM”
This indicator comes on when the
headlight high beam is used.
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Neutral indicator light “NEUTRAL”
This indicator comes on when the
transmission is in neutral.
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1. Speedometer
2. Odometer
3. Trip odometer
4. Reset knob
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Speedometer
The speedometer shows riding
speed. This speedometer is
equipped with an odometer and
trip odometer. The trip odometer
can be reset to “0” with the reset
knob. Use the trip odometer to
estimate how far you can ride on a
tank of fuel. This information will
enable you to plan fuel stops in the
future.
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1. Dimmer switch
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2. Turn signal switch
3. Horn switch “*”
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Handlebar switches
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Dimmer switch
Turn the switch to “&” for the
high beam and to “%” for the low
beam.
INSTRUMENT AND CONTROL FUNCTIONS
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Turn signal switch
To signal a right-hand turn, push
the switch to “6”. To signal a lefthand turn, push the switch to
“4”. Once the switch is released
it will return to the center position.
To cancel the signal, push the
switch in after it has returned to
the center position.
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Horn switch “*”
Press the switch to sound the horn.
1. Engine stop switch
2. Start switch “START”
Engine stop switch
The engine stop switch is a safety
device for use in an emergency
such as when the motorcycle overturns or if trouble occurs in the
throttle system. Turn the switch to
“#” to start the engine.
In case of emergency, turn the
switch to “$” to stop the engine.
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INSTRUMENT AND CONTROL FUNCTIONS
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Start switch “START”
The starter motor cranks the
engine when pushing the start
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switch.
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See starting instructions prior to
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starting the engine.
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1. Clutch lever
Clutch lever
The clutch lever is located on the
left handlebar, and the ignition circuit cut-off system is incorporated
in the clutch lever holder. Pull the
clutch lever to the handlebar to disengage the clutch, and release the
lever to engage the clutch. The
lever should be pulled rapidly and
released slowly for smooth clutch
operation. (Refer to the engine
starting procedures for a description of the ignition circuit cut-off
system.)
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1. Shift pedal
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Shift pedal
This motorcycle is equipped with a
constant-mesh 6-speed transmission.
The shift pedal is located on the
left side of the engine and is used
in combination with the clutch
when shifting.
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INSTRUMENT AND CONTROL FUNCTIONS
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1. Front brake lever
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Front brake lever
The front brake lever is located on
the right handlebar. Pull it toward
the handlebar to apply the front
brake.
1. Rear brake pedal
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Rear brake pedal
The rear brake pedal is on the right
side of the motorcycle. Press down
on the brake pedal to apply the
rear brake.
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1. Unlock
2. Open
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Fuel tank cap
To open
Insert the key and turn it 1/4 turn
counterclockwise. Turn the cap 1/3
turn counterclockwise and remove
it from the tank.
To close
Put the cap in the filler neck and
turn it 1/3 turn clockwise. Lock the
cap by turning the key 1/4 turn
clockwise, and remove the key.
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INSTRUMENT AND CONTROL FUNCTIONS
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NOTE:
The tank cap cannot be reinstalled
unless it is unlocked. The key must
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remain in the cap until the cap is
properly installed and locked onto
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the fuel tank.
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Be sure the cap is properly
installed and locked in place
before riding the motorcycle.
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Always wipe off spilled fuel immediately with a dry and clean soft
cloth. Fuel may deteriorate painted
surfaces or plastic parts.
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1. Fuel level
2. Filler tube
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Fuel
Make sure there is sufficient fuel in
the tank. Fill the fuel tank to the
bottom of the filler tube as shown
in the illustration.
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Do not overfill the fuel tank. Avoid
spilling fuel on the hot engine. Do
not fill the fuel tank above the bottom of the filler tube or it may
overflow when the fuel heats up
later and expands.
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INSTRUMENT AND CONTROL FUNCTIONS
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Recommended fuel:
Regular gasoline
For Australia:
Unleaded fuel only
Fuel tank capacity:
Total:
8.8 L
Reserve:
2.0 L
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Closed position
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FUEL
1. Arrow mark over “OFF”
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Fuel cock
The fuel cock supplies fuel from
the tank to the carburetor while filtering it also.
The fuel cock has three positions:
OFF
With the lever in this position, fuel
will not flow. Always return the
lever to this position when the
engine is not running.
Normal position
FU
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FUEL
1. Arrow mark over “ON”
ON
With the lever in this position, fuel
flows to the carburetor. Normal
riding is done with the lever in this
position.
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INSTRUMENT AND CONTROL FUNCTIONS
FUEL
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1
a
b
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Reserve position
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FU
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1. Arrow mark over “RES”
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RES
This indicates reserve. If you run
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out of fuel while riding, move the
lever to this position. Fill the tank
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at the first opportunity. Be sure to
set the lever back to “ON” after
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refueling!
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1. Starter(choke) “1”
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Starter (choke) “1”
Starting a cold engine requires a
richer air-fuel mixture. A separate
starter circuit supplies this mixture.
Move in direction a to turn on the
1. Panel A
2. Panel B
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Seat
To remove
1. Remove panels A and B. (See
page 6-6 for panel removal
and installation procedures.)
starter (choke).
Move in direction b to turn off the
starter (choke).
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