Yamaha XT250 X 2008 Owner's manual

OWNER’S MANUAL
XT250X
3C5-28199-20

INTRODUCTION

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Welcome to the Yamaha world of motorcycling! As the owner of the XT250X, you are benefiting from Yamaha’s vast experience and newest technology regarding the design and manufacture of high-quality products, which have earned Yamaha a reputation for dependability. Please take the time to read this manual thoroughly, so as to enjoy all advantages of your XT250X. The owner’s manual does not only instruct you in how to operate, inspect and maintain your motorcycle, but also in how to safeguard yourself and others from trouble and injury. In addition, the many tips given in this manual will help keep your motorcycle in the best possible condition. If you have any further questions, do not hesitate to contact your Yamaha dealer. The Yamaha team wishes you many safe and pleasant rides. So, remember to put safety first!

IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following notations:
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
Failure to follow WARNING instructions could result in severe injury or death to the
WARNING
motorcycle operator, a bystander, or a person inspecting or repairing the motorcy­cle.
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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.
WARNING
PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE.
*Product and specifications are subject to change without notice.
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IMPORTANT MANUAL INFORMATION
EAU10200
XT250X
OWNER’S MANUAL
©2007 by Yamaha Motor Co., Ltd.
1st edition, September 2007
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd. is expressly prohibited.
Printed in Japan.

TABLE OF CONTENTS

SAFETY INFORMATION
Location of important labels .............1-5
DESCRIPTION
Left view ...........................................2-1
Right view .........................................2-2
Controls and instruments..................2-3
INSTRUMENT AND CONTROL FUNCTIONS
Main switch/steering lock .................3-1
Indicator lights .................................3-2
Multi-function display .......................3-2
Handlebar switches .........................3-4
Clutch lever ......................................3-5
Shift pedal ........................................3-5
Brake lever ......................................3-5
Brake pedal .....................................3-6
Fuel tank cap ...................................3-6
Fuel ..................................................3-7
Fuel cock .........................................3-7
Starter (choke) knob “1” .................3-8
Seat .................................................3-9
Helmet holder ..................................3-9
Adjusting the shock absorber
assembly ....................................3-10
Sidestand .......................................3-11
Ignition circuit cut-off system .........3-12
PRE-OPERATION CHECKS
Pre-operation check list ...................4-2
...................................2-1
........................................3-1
...................1-1
...............4-1
OPERATION AND IMPORTANT RIDING POINTS
PERIODIC MAINTENANCE AND MINOR REPAIR
............................................... 5-1
Starting and warming up a cold
engine .......................................... 5-1
Starting a warm engine ...................5-2
Shifting ............................................ 5-2
Tips for reducing fuel
consumption ................................ 5-3
Engine break-in ...............................5-3
Parking ............................................ 5-4
............................................... 6-1
Owner’s tool kit ................................ 6-1
Periodic maintenance and lubrication
chart ............................................. 6-2
Removing and installing the cowling
and panels ...................................6-6
Checking the spark plug .................. 6-8
Engine oil and oil filter element .....6-10
Replacing the air filter element and
cleaning the check hose ............6-13
Adjusting the carburetor ................6-14
Adjusting the engine idling
speed ......................................... 6-14
Checking the throttle cable free
play ............................................ 6-15
Valve clearance ............................. 6-15
Tires .............................................. 6-15
Spoke wheels ................................ 6-17
Adjusting the clutch lever free
play ............................................ 6-18
Adjusting the brake lever free
play ............................................ 6-18
Adjusting the rear brake light
switch ......................................... 6-19
Checking the front and rear brake
pads ........................................... 6-19
Checking the brake fluid level ....... 6-20
Changing the brake fluid ............... 6-21
Drive chain slack ........................... 6-21
Cleaning and lubricating the drive
chain .......................................... 6-22
Checking and lubricating the
cables ........................................ 6-23
Checking and lubricating the throttle
grip and cable ............................ 6-23
Checking and lubricating the brake
and shift pedals ......................... 6-24
Checking and lubricating the brake
and clutch levers ........................ 6-24
Checking and lubricating the
sidestand ................................... 6-25
Lubricating the rear
suspension ................................ 6-25
Checking the front fork .................. 6-26
Checking the steering ................... 6-26
Checking the wheel bearings ........ 6-27
Battery ........................................... 6-27
Replacing the fuse ........................ 6-29
Replacing the headlight bulb ........ 6-29
Replacing the tail/brake light
bulb ............................................6-31
Replacing a turn signal light bulb ..6-31
Supporting the motorcycle ............. 6-32
Front wheel .................................... 6-33
Rear wheel ....................................6-34
Troubleshooting .............................6-35
Troubleshooting chart .................... 6-36
MOTORCYCLE CARE AND STORAGE
Matte color caution ..........................7-1
Care .................................................7-1
Storage ............................................7-3
...........................................7-1
TABLE OF CONTENTS
SPECIFICATIONS
CONSUMER INFORMATION
Identification numbers .....................9-1
Motorcycle noise regulation
(for Australia) ................................9-2
..............................8-1
..............9-1

SAFETY INFORMATION

MOTORCYCLES ARE SINGLE TRACK VEHICLES. THEIR SAFE USE AND OPERATION ARE DEPEN-
1
DENT 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 REQUIRE-
MENTS IN THE OWNER’S MAN-
UAL.
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 NECES-
SARY BY MECHANICAL CONDI-
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TIONS.
Safe riding
Always make pre-operation checks. Careful checks may help prevent an accident.
This motorcycle is designed to car­ry 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 ap­proaching 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
1-1
motorist’s blind spot.
Many accidents involve 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 accidents have been caused by error of the motorcycle opera­tor. 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).
Always obey the speed limit and never travel faster than warrant-
SAFETY INFORMATION
ed 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, the 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.
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 preven-
tion 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 that 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 ren-
der the motorcycle unsafe for use and may cause severe personal injury. Modifications may also make your mo­torcycle illegal to use.
1
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:
Loading The total weight of the operator, pas­senger, accessories and cargo must not exceed the maximum load limit.
Maximum load:
160 kg (353 lb)
When loading within this weight limit, keep the following in mind:
1-2
SAFETY INFORMATION
Cargo and accessory weight
should be kept as low and close to
the motorcycle as possible. Make
sure to distribute the weight as
1
evenly as possible on both sides of
the motorcycle to minimize imbal-
ance or instability.
Shifting weights can create a sud-
den imbalance. Make sure that ac-
cessories 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, in-
cluding such cargo as sleeping
bags, duffel bags, or tents, can
create unstable handling or a 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, in-
stallation 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 “Load­ing” when mounting accessories.
Never install accessories or carry cargo that would impair the perfor­mance of your motorcycle. Care­fully 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 opera­tor and may limit control ability, therefore, such accessories are not recommended.
Use caution when adding electri­cal accessories. If electrical acces­sories exceed the capacity of the motorcycle’s electrical system, an electric failure could result, which could cause a dangerous loss of lights or engine power.
Gasoline and exhaust gas
GASOLINE IS HIGHLY FLAMMA­BLE:
Always turn the engine off when
1-3
SAFETY INFORMATION
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(s) are turned to “ON” or “RES” (for vacuum type)/“OFF” (for manual type). If the motorcycle should lean over, gasoline may leak out of the carburetor or fuel tank.
If you should swallow any gaso­line, inhale a lot of gasoline vapor, or allow gasoline to get into your 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.
1
1-4
SAFETY INFORMATION
Location of important labels
Please read the following important labels carefully before operating this vehicle.
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1
1 2
1-5
SAFETY INFORMATION
1
Before you operate this vehicle, read the owners manual.
Prima di usare il veicolo, leggete il manuale di istruzioni. Lire le manuel du propriétaire avant dutiliser ce véhicule. Lesen Sie die Bedienungsanleitung bevor Sie dieses Fahrzeug fahren. Antes de conducir este vehículo, lea el Manual del Propietario.
5RU-21568-00
1
2
3TT-21668-00
1-6
SAFETY INFORMATION
2
1
1
1-7
SAFETY INFORMATION
1
1
2
4AA-22259-40
1-8

DESCRIPTION

Left view
1
2
3
4
5
6
7
8
1. Fuel cock (page 3-7)
2. Starter (choke) knob (page 3-8)
9
3. Air lter element (page 6-13)
4. Helmet holder (page 3-9)
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1 2 43
2-1
Right view
DESCRIPTION
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12 3
2
3
4
5
6
7
1. Battery (page 6-27)
2. Fuse (page 6-29)
3. Owner’s tool kit (page 6-1)
4. Engine oil level check window (page 6-10)
5. Engine oil ller cap (page 6-10)
5
2-2
4
8
9
DESCRIPTION
Controls and instruments
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1
2
3
4
5
6
7
8
1. Clutch lever (page 3-5)
2. Left handlebar switch (page 3-4)
9
3. Indicator lights (page 3-2)
4. Main switch/steering lock (page 3-1)
5. Multi-function display (page 3-2)
6. Right handlebar switches (page 3-4)
7. Front brake lever (page 3-5)
8. Throttle grip (page 6-15)
12 6 83 5 7
4
9
9. Fuel tank cap (page 3-6)
2-3

INSTRUMENT AND CONTROL FUNCTIONS

1
2
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Main switch/steering lock
The main switch/steering lock controls the ignition and lighting systems, and is used to lock the steering. The various positions are described below.
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ON
All electrical circuits are supplied with power, and the meter lighting and tail­light come on, and the engine can be started. The key cannot be removed.
NOTE:
The headlight comes on automatically when the engine is started and stays on until the key is turned to OFF, even if the engine stalls.
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OFF
All electrical systems are off. The key can be removed.
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LOCK
The steering is locked, and all electrical systems are off. The key can be re­moved.
To lock the steering
1
2
1. Push.
2. Turn.
1. Turn the handlebars all the way to the left or right.
2. Push the key in from the OFF po­sition, and then turn it to LOCK while still pushing it.
3-1
3. Remove the key.
To unlock the steering
1. Push.
2. Turn.
Push the key into the main switch, and then turn it to OFF while still pushing it.
EWA10060
WARNING
Never turn the key to OFF or LOCK while the vehicle is moving, otherwise the electrical systems will be switched off, which may result in loss of control or an accident. Make sure that the vehicle is stopped be­fore turning the key to OFF or LOCK.
2
3
4
5
6
7
8
9
INSTRUMENT AND CONTROL FUNCTIONS
1
2
3
4
Indicator lights
1 2
1
2
3
4
1. High beam indicator light “”
2. Turn signal indicator light “”
5
3. Neutral indicator light “”
6
Turn signal indicator light “”
This indicator light flashes when the
7
turn signal switch is pushed to the left or right.
8
Neutral indicator light “”
9
This indicator light comes on when the transmission is in the neutral position.
3
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High beam indicator light “”
This indicator light comes on when the high beam of the headlight is switched on.
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Multi-function display
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WARNING
Be sure to stop the vehicle before making any setting changes to the multi-function display.
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1. SELECT” button
2. RESET” button
3. Clock
4. Speedometer
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3-2
INSTRUMENT AND CONTROL FUNCTIONS
1
1. Odometer/tripmeter (bottom)
2. Tripmeter (top)
2
The multi-function display is equipped with the following:
a speedometer (which shows the riding speed)
an odometer (which shows the to­tal distance traveled)
two tripmeters (which show the distance traveled since they were last set to zero)
a clock
NOTE:
Be sure to turn the key to ON be-
fore using the SELECT and RE­SET buttons. When the key is turned to ON, all
of the display segments of the
multi-function display will appear one after the other and then disap­pear, in order to test the electrical circuit.
Odometer, clock and tripmeter modes
Pushing the SELECT button switches the display between the odometer mode ODO and the tripmeter modes TRIP in the following order: ODO → TRIP (top) → TRIP (bottom)
ODO To reset a tripmeter, select it by push­ing the SELECT button until TRIP begins flashing (TRIP will only flash for five seconds). While TRIP is flash­ing, push the RESET button for at least one second.
Clock mode
To set the clock:
1. Push the SELECT button and RESET button together for at least two seconds.
2. When the hour digits start flashing, push the RESET button to set the hours.
3. Push the SELECT button, and the minute digits will start flashing.
4. Push the RESET button to set the minutes.
5. Push the SELECT button and then release it to start the clock.
2
3
4
5
6
7
8
9
3-3
INSTRUMENT AND CONTROL FUNCTIONS
Handlebar switches
Left
1
2
3
4
5
1. Dimmer switch /
2. Turn signal switch /
6
3. Horn switch “”
7
8
9
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Right
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Horn switch “”
Press this switch to sound the horn.
1
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Engine stop switch /
1
2
2 3
1. Engine stop switch /
2. Start switch “”
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Dimmer switch /
Set this switch to “” for the high beam and to “” for the low beam.
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Turn signal switch /
To signal a right-hand turn, push this switch to “”. To signal a left-hand turn, push this switch to “”. When re- leased, 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.
Set this switch to “” before starting the engine. Set this switch to “” to stop the engine in case of an emergen­cy, such as when the vehicle overturns or when the throttle cable is stuck.
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Start switch “”
Push this switch to crank the engine with the starter.
ECA10050
CAUTION:
See page 5-1 for starting instruc­tions prior to starting the engine.
3-4
INSTRUMENT AND CONTROL FUNCTIONS
1
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Clutch lever
1
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 3-12.)
EAU12870
Shift pedal
1
1. Shift pedal
The shift pedal is located on the left side of the engine and is used in com­bination with the clutch lever when shifting the gears of the 5-speed con­stant-mesh transmission equipped on this motorcycle.
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Brake lever
1. Brake lever
The brake lever is located at the right handlebar grip. To apply the front brake, pull the lever toward the handle­bar grip.
2
3
4
5
6
7
8
9
3-5
INSTRUMENT AND CONTROL FUNCTIONS
Brake pedal
1
2
3
4
1. Brake pedal
The brake pedal is on the right side of
5
the motorcycle. To apply the rear brake, press down on the brake pedal.
6
7
8
9
1
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Fuel tank cap
To remove the fuel tank cap
1. Open the fuel tank cap lock cover.
2. 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 removed.
2
1
1. Fuel tank cap lock cover
2. Unlock.
To install the fuel tank cap
1. Push and install 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.
EAUM1792
NOTE:
The fuel tank cap cannot be installed unless the key is in the lock. In addition, the key cannot be removed if the cap is not properly installed and locked.
3. Close the lock cover.
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WARNING
Make sure that the fuel tank cap is properly installed before riding.
3-6
INSTRUMENT AND CONTROL FUNCTIONS
1
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Fuel
2
1
1. Fuel level
2. Fuel tank ller tube
Make sure that there is sufficient fuel in the tank. Fill the fuel tank to the bottom of the filler tube as shown.
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.
CAUTION:
Immediately wipe off spilled fuel with a clean, dry, soft cloth, since
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ECA10070
fuel may deteriorate painted surfac­es or plastic parts.
EAU13332
Recommended fuel:
UNLEADED GASOLINE ONLY
Fuel tank capacity:
9.8 L (2.59 US gal) (2.16 Imp.gal)
Fuel reserve amount:
1.9 L (0.50 US gal) (0.42 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 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.
EAU13561
Fuel cock
The fuel cock supplies fuel from the tank to the carburetor while filtering it al­so. The fuel cock has three positions:
OFF
1. Pointed end positioned under OFF
With the lever in this position, fuel will not flow. Always return the lever to this position when the engine is not running.
2
3
4
5
6
7
8
9
3-7
INSTRUMENT AND CONTROL FUNCTIONS
1
(a)
(b)
ON
1
2
3
4
With the lever in this position, fuel flows to the carburetor. Normal riding is done
5
with the lever in this position.
6
RES
7
8
9
1
1. Pointed end positioned over ON
1
This indicates reserve. If you run out of fuel while riding, move the lever to this position. Fill the tank at the first oppor­tunity. Be sure to set the lever back to ON after refueling!
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Starter (choke) knob “”
1. Starter (choke) knob “”
Starting a cold engine requires a richer air-fuel mixture, which is supplied by the starter (choke). Move the knob in direction (a) to turn on the starter (choke). Move the knob in direction (b) to turn off the starter (choke).
1. Pointed end positioned over RES
3-8
INSTRUMENT AND CONTROL FUNCTIONS
1
2
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Seat
To remove the seat
Remove the bolts, and then pull the seat off.
1
1. Bolt
To install the seat
1. Insert the projection on the front of the seat into the seat holder as shown.
2
1
1. Projection
2. Seat holder
2. Place the seat in the original posi­tion, and then tighten the bolts.
NOTE:
Make sure that the seat is properly se­cured before riding.
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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.
2
3
4
5
6
7
8
9
3-9
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