Virago 250

93
4TN-28199-E2 XV250P OWNER’S MANUAL

Transcript of Virago 250

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PRINTED IN JAPAN2003.02-0.3×1 CR

(E)

PRINTED ON RECYCLED PAPERYAMAHA MOTOR CO., LTD.

4TN-28199-E2

XV250P

OWNER’S MANUAL

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ODUCTION

n your purchase of the This model is the result ofperience in the productionuring, and pacesetting rac-presents the high degree of reliability that have made

in these fields.ive you an understanding ofpection, and basic mainte-torcycle. If you have anye operation or maintenance, please consult a Yamaha

EAA00100 EAA20301

INTR

Congratulations oYamaha XV250P.Yamaha’s vast exof fine sporting, toing machines. It recraftsmanship andYamaha a leader This manual will gthe operation, insnance of this moquestions about thof your motorcycledealer.

XV250POWNER’S MANUAL

©2003 by Yamaha Motor Co., Ltd.1st Edition, January 2003

All rights reserved. Any reprinting orunauthorized use without the written

permission of Yamaha Motor Co., Ltd.is expressly prohibited.

Printed in Japan

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EAA10603

cates special precautionsn to avoid damage to the

key information to makeor clearer.

specting or repairing the motorcycle.

IMPORTANT MANUAL INFORMATION

Particularly important information is distin-guished in this manual by the following nota-tions:

The Safety Alert Symbol means ATTENTION!BECOME ALERT! YOUR SAFETY IS IN-VOLVED!

WARNINGFailure to follow WARNING instructions couldresult in severe injury or death to the motor-cycle operator, a bystander or a person in-

CAUTION:A CAUTION indithat must be takemotorcycle.

NOTE:A NOTE providesprocedures easier

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HIS MANUAL CAREFUL-TELY BEFORE OPERAT-CYCLE.

EUU00001

NOTE:� This manual should be considered a per-

manent part of this motorcycle andshould remain with it even if the motor-cycle is subsequently sold.

� Yamaha continually seeks advance-ments in product design and quality.Therefore, while this manual contains themost current product information avail-able at the time of printing, there may beminor discrepancies between yourmotorcycle and this manual. If there isany question concerning this manual,please consult your Yamaha dealer.

EUU60100

WARNINGPLEASE READ TLY AND COMPLEING THIS MOTOR

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GIVE

DES

MOTIdeKeFraMo

CONMaIndSpHaCluShFroReFu

....................................... 4-8” .................................... 4-9

..................................... 4-10

..................................... 4-10orber adjustment......... 4-11..................................... 4-11ut-off system................ 4-13

CHECKS .................... 5-1....................................... 5-3 leakage ....................... 5-3

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

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

....................................... 5-5

....................................... 5-5

....................................... 5-6

....................................... 5-9rs................................... 5-9nd switches ................ 5-10

..................................... 5-10

EAA30001

CONTENTS

SAFETY THE RIGHT OF WAY .......1-1

CRIPTION ..........................................2-1

ORCYCLE IDENTIFICATION ...........3-1ntification numbers ............................3-1y identification number .......................3-1me serial number ..............................3-2del label .............................................3-2

TROL FUNCTIONS...........................4-1in switch .............................................4-1icator lights.........................................4-2eedometer ..........................................4-2ndlebar switches ................................4-3tch lever.............................................4-6ift pedal...............................................4-6nt brake lever.....................................4-6ar brake pedal ....................................4-6el tank cap ..........................................4-7

Fuel cock.........Starter “CHOKESteering lock ...Seat .................Rear shock absSidestand ........Ignition circuit c

PRE-OPERATIONBrakes .............Front brake fluidClutch ..............Throttle grip .....Engine oil.........Chain ...............Tires ................Cast wheels.....Chassis fasteneLights, signals aBattery .............

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er free play ...................................... 7-15justment......................... 7-16tch adjustment .............. 7-18ront brake pads and oes............................... 7-18

brake fluid level ............ 7-20lacement ....................... 7-21ent ................................ 7-21ck check ....................... 7-22ck adjustment ............... 7-23rication.......................... 7-25n and lubrication.......... 7-25

and grip lubrication........ 7-26t pedals ......................... 7-26ch levers........................ 7-26...................................... 7-26on.................................. 7-26ection ............................ 7-27ction .............................. 7-28s .................................... 7-28...................................... 7-28

1-2

Fuel.......................................................5-10

OPERATION AND IMPORTANT RIDING POINTS........................................6-1

Starting and warming up a cold engine..................................................6-1

Starting a warm engine ..........................6-3Shifting....................................................6-3Engine break-in ......................................6-4Parking....................................................6-5

PERIODIC MAINTENANCE ANDMINOR REPAIR ........................................7-1

Tool kit ....................................................7-1Periodic maintenance/lubrication ...........7-3Engine oil ................................................7-6Air filter....................................................7-9Carburetor adjustment..........................7-12Idle speed adjustment ..........................7-12Throttle cable free play inspection........7-13Valve clearance adjustment .................7-14Spark plug inspection ...........................7-14

Front brake levadjustment ..

Rear brake adBrake light swiChecking the f

rear brake shInspecting the Brake fluid repClutch adjustmDrive chain slaDrive chain slaDrive chain lubCable inspectioThrottle cable Brake and shifBrake and clutSidestand .......Rear suspensiFront fork inspSteering inspeWheel bearingBattery............

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1-3

Replenishing the battery fluid ...............7-30Fuse replacement.................................7-31Headlight bulb replacement..................7-31Front wheel removal .............................7-33Front wheel installation.........................7-34Rear wheel removal..............................7-35Rear wheel installation .........................7-37Troubleshooting....................................7-38Troubleshooting chart...........................7-39

CLEANING AND STORAGE.....................8-1A. Cleaning .............................................8-1B. Storage...............................................8-2

SPECIFICATIONS.....................................9-1Conversion table.....................................9-5

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1-1

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GIVE SAFETY THE RIGHT OF WAYEUU75901

Motorcycles are fascinating vehicles, which can give you an unsurpassed feeling ofpower and freedom. However, they also impose certain limits, which you must accept;even the best motorcycle does not ignore the laws of physics.Regular care and maintenance are essential for preserving your motorcycle’s value andoperating condition. Moreover, what is true for the motorcycle is also true for the rider:good performance depends on being in good shape. Riding under the influence of med-ication, drugs and alcohol is, of course, out of the question. Motorcycle riders – morethan car drivers – must always be at their mental and physical best. Under the influenceof even small amounts of alcohol, there is a tendency to take dangerous risks.Protective clothing is as essential for the motorcycle rider as seat belts are for car driv-ers and passengers. Always wear a complete motorcycle suit (whether made of leatheror tear-resistant synthetic materials with protectors), sturdy boots, motorcycle glovesand a properly fitting helmet. Optimum protective wear, however, should not encouragecarelessness. Though full-coverage helmets and suits, in particular, create an illusionof total safety and protection, motorcyclists will always be vulnerable. Riders who lackcritical self-control run the risk of going too fast and are apt to take chances. This is evenmore dangerous in wet weather. The good motorcyclist rides safely, predictably and de-fensively – avoiding all dangers, including those caused by others.Enjoy your ride!

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EA

ht11. Rear wheel12. Main switch13. Shift pedal14. Steering lock15. Front wheel16. Clutch lever17. Handlebar switches18. Speedometer19. Brake lever20. Throttle grip

2-1

4. Seat5. Air filter6. Front turn signal light7. Brake pedal8. Footrest9. Headlight

10. Fuel tank

A50000

DE

SCRIPTION

1. Tail/brake light2. Rear turn signal lig3. Tool kit

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numbertion number is stamped onis number in the space pro-r reference when obtaining

ber

3-1

EAA60000

MOTORCYCLEIDENTIFICATION

EAA62000

Identification numbersRecord the key identification number, frameserial number and model label information inthe spaces provided for assistance when or-dering spare parts from a Yamaha dealer orfor reference in case the vehicle is stolen.1. KEY IDENTIFICATION NUMBER:

2. FRAME SERIAL NUMBER:

3. MODEL LABEL INFORMATION:

EAA61400

Key identificationThe key identificathe key. Record thvided and use it foa new key.

1. Key identification num

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EAA60201 EAA62200

affixed to the frame under 4-10 for seat removal pro-

he information on this labeled. This information will be spare parts from your

3-2

Frame serial numberThe frame serial number is stamped into thesteering head pipe.

1. Frame serial number

Model labelThe model label isthe seat. (See pagecedures.) Record tin the space providneeded to orderYamaha dealer.

1. Model label

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ts are switched off. The key this position.

uxiliary light come on but alloff. With the key at “OFF”,ain switch, turn it counter-nd remove it. To cancel theey clockwise.

ain switch to “OFF” and re-en the motorcycle is unat-

4-1

EAB00000

CONTROL FUNCTIONS

EAB00100

Main switchThe main switch controls the ignition and light-ing systems. Its operation is described below.

EAB00500

ON:Electrical circuits are switched on. The enginecan be started. The key cannot be removed inthis position.

EAB00600

OFF:All electrical circuican be removed in

EAB02002

P (Parking)The taillight and aother circuits are push it into the mclockwise to “P”, aparking, turn the kEUU08800

NOTE:Always turn the mmove the key whtended.

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EAB10000 EAB13200

tor light “ ”es on when the headlight.

shows riding speed. Thisuipped with an odometer

The trip odometer can bee reset knob. Use the tripte how far you can ride on

information will enable you the future.

rip odometer 3. Reset knob

4-2

Indicator lights

1. Turn indicator light “ ”2. Neutral indicator light “ ”3. High beam indicator light “ ”

EAB10102

Turn indicator light “ ”This indicator flashes when the turn signalswitch is moved to the left or right.

EAB13100

Neutral indicator light “ ”This indicator comes on when the transmis-sion is in neutral.

High beam indicaThis indicator comhigh beam is usedEAB40005

SpeedometerThe speedometer speedometer is eqand trip odometer.reset to “0” with thodometer to estimaa tank of fuel. Thisto plan fuel stops in

1. Odometer 2. T

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LIGHTS” “HI” for the high beam and beam.

h “TURN”and turn, push the switch tol a left-hand turn, push thence the switch is released

center position. To cancelhe switch in after it has re-r position.

RN”o sound the horn.

HTS” to “PO” turns on the auxil-nd meter lights. Turning to

adlight on also.

4-3

EAB60000

Handlebar switches

1. PASS switch “PASS” 6. Engine stop switch2. Dimmer switch “ENGINE STOP”

“LIGHTS” 7. Siren switch “SIREN”3. Turn signal switch 8. Microphone switch “MIC”

“TURN” 9. Patrol switch4. Horn switch “HORN” 10.Start switch “START”5. Light switch “LIGHTS” 11.Hazard switch “HAZARD”

EAB63201

Pass switch “PASS”Press the switch to operate the passing light.

EAB60101

Dimmer switch “Turn the switch toto “LO” for the low

EAB62102

Turn signal switcTo signal a right-hthe right. To signaswitch to the left. Oit will return to thethe signal, push tturned to the cente

EAB60201

Horn switch “HOPress the switch t

EAB61202

Light switch “LIGTurning this switchiary light, taillight a“ON”, turns the he

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EAB60902 EAB62802

AZARD” should be turned on underardous conditions. All turnlash simultaneously when on with the main switch in

ischarge from extendeddifficult to operate the

switch to warn other driv-cle must be stopped where hazard.

4-4

Engine stop switch “ENGINE STOP”The engine stop switch is a safety device foruse in an emergency such as when the motor-cycle overturns or if trouble occurs in the throt-tle system. Turn the switch to “RUN” to startthe engine. In case of emergency, turn theswitch to “OFF” to stop the engine.

EAB60702

Start switch “START”The starter motor cranks the engine whenpushing the starter switch.EUU30700

CAUTION:See starting instructions prior to startingthe engine.

Hazard switch “HThe hazard switchemergency or hazsignal lights will fthis switch is turnedthe “ON” position.EUU46100

CAUTION:The battery can duse, making it starter.

EUU01101

NOTE:Turn on the hazarders if your motorcyit might be a traffic

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Position

FF P M S

4-5

Siren switch “SIREN”The siren (if equipped) sounds intermittentlywhen this switch is set to “SIREN”. The sirencan only be used with the main switch in the“ON” position.

Microphone switch “MIC”The microphone (if equipped) can be usedwhen this switch is set to “MIC” with the mainswitch in the “ON” position. This switch canalso be used when the patrol switch is in anyposition except “OFF” with the main switch inthe “ON” position.

Patrol switchThis switch can only be used with the mainswitch in the “ON” position. The following ta-ble indicates which accessories are enabledwhen the patrol switch is set to “P”, “M”, or “S”.

Accessory O

Patrol light

Turn signal light

Microphone

Siren

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EAB70003

N. Neutral

ver is located on the rightward the handlebar to ap-

al is on the right side of thedown on the brake pedal toe.

4-6

Clutch leverThe clutch lever is located on the left handle-bar, and the ignition circuit cut-off system is in-corporated in the clutch lever holder. Pull theclutch lever to the handlebar to disengage theclutch, and release the lever to engage theclutch. The lever should be pulled rapidly andreleased slowly for smooth clutch operation.(Refer to the engine starting procedures for adescription of the ignition circuit cut-off sys-tem.)

EAB80001

Shift pedalThis motorcycle is equipped with a constant-mesh 5-speed transmission.The shift pedal is located on the left side of theengine and is used in combination with theclutch when shifting.

1. Shift pedal

EAB90001

Front brake leverThe front brake lehandlebar. Pull it toply the front brake.

EAB90101

Rear brake pedalThe rear brake pedmotorcycle. Press apply the rear brak

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ot be closed unless the key key cannot be removed ifed properly.

is properly installed andbefore riding the motor-

4-7

EAC00101

Fuel tank capTO OPEN:Insert the key and turn it 1/4 turn clockwise.The lock will be released and the cap can beopened.

1. Unlock.

TO CLOSE:Push the tank cap into position with the key in-serted. To remove the key, turn it counter-clockwise to the original position.

EUU01200

NOTE:This tank cap cannis in the lock. Thethe cap is not lock

EUU61100

WARNINGBe sure the caplocked in place cycle.

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EAC10205

for “reserve”. If you are run-el while riding with the fuel

“ON” position, quickly turnhis position. Otherwise the die and will have to be “PRI” below). After turning“RES”, fill the tank at the

nity and be sure to set theck to “ON”!

4-8

Fuel cockThe fuel cock supplies fuel from the tank tothe carburetors while also filtering it.The fuel cock has three positions, whichshould be set as illustrated.ON: With the fuel cock in this position, fuel

flows to the carburetors when the en-gine is running. Set the fuel cock to thisposition when starting the engine andfor riding.

RES: This stands ning out of fucock in the the lever to tengine mayprimed (seethe lever to first opportufuel cock ba

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ine requires a richer air-fuele starter circuit supplies this

a to turn on the starter.b to turn off the starter.

4-9

PRI: This stands for “prime”. If the enginehas been allowed to run out of fuel, turnthe lever to the “PRI” position to sendfuel directly to the carburetors. This willmake starting easier. However, be sureto turn the lever to the “ON” position (or“RES” if you have not refuelled yet) af-ter the engine has started.

EAC20502

Starter “CHOKE”Starting a cold engmixture. A separatmixture.Move in direction Move in direction

1. Starter “CHOKE”

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EAC30201 EAC41503

r seat, remove the bolts.

seat, insert the projectionseat into the holder on then the bolts.

seat is securely fitted.

4-10

Steering lockTo lock the steering, turn the handlebars allthe way to the right. Open the steering lockcover, turn the key 1/8 counterclockwise thenpush the key in and turn it 1/8 turn clockwise.After checking to see that the steering islocked, remove the key from the lock andclose the cover. To release the lock, reversethe above procedure.

1. Steering lock

SeatTo remove the ride

To install the rideron the front of the frame. Then tighteEUU01700

NOTE:Make sure that the

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ipped with an ignition circuite motorcycle must not be

idestand is down. The side-n the left side of the frame.1 for an explanation of this

Right

4-11

EAI57804

Rear shock absorber adjustmentThis shock absorber is equipped with a springpreload adjuster. Adjust spring preload as fol-lows. Turn the adjusting ring in direction a toincrease spring preload and in direction b todecrease spring preload.COPY CI-18ECI-18E

EAD30101

SidestandThis model is equcut-off system. Thridden when the sstand is located o(Refer to page 6-system.)

Hard Standard Soft

Adjusting position

5 4 3 2 1

Left

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EUU68901 EAU03720

t-off system cut-off system (comprisingch, clutch switch and neu- following functions.arting when the transmis-r and the sidestand is up,lever is not pulled.arting when the transmis-r and the clutch lever is

sidestand is still down.ing engine when the trans-gear and the sidestand is

the operation of the ignitionm according to the follow-

s noted, have a Yamahasystem before riding.

4-12

WARNINGThis motorcycle must not be operated withthe sidestand in the down position. If thestand is not properly retracted, it couldcontact the ground and distract the opera-tor, resulting in a possible loss of control.Yamaha has designed into this motorcyclea lockout system to assist the operator infulfilling the responsibility of retracting thesidestand. Please check carefully the op-erating instructions listed below and ifthere is any indication of a malfunction, re-turn the motorcycle to a Yamaha dealerimmediately for repair.

Ignition circuit cuThe ignition circuitthe sidestand swittral switch) has the

� It prevents stsion is in geabut the clutch

� It prevents stsion is in geapulled, but the

� It cuts the runnmission is in moved down.

Periodically check circuit cut-off systeing procedure.EW000045

WARNINGIf a malfunction idealer check the

CD-01E

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switch may be defective.ycle should not be ridden until a Yamaha dealer.

d switch may be defective.ycle should not be ridden until a Yamaha dealer.

witch may be defective.ycle should not be ridden until a Yamaha dealer.

most reliable if performed with engine.

4-13

With the engine turned off:1. Move the sidestand down.2. Make sure that the engine stop switch is set to “ ”.3. Turn the key to “ON”. 4. Shift the transmission into the neutral position.5. Push the start switch.Does the engine start?

The neutral The motorcchecked by

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?

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?

The sidestanThe motorcchecked by

The clutch sThe motorcchecked by

NO

NOTE:This check isa warmed-up

YES

YES NO

The system is OK. The motorcycle can be ridden.

YES NO

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Page

age.ry. 5-3 ~ 5-4,

7-15 ~ 7-21

5-4, 7-21 ~ 7-22

5-4, 7-13, 7-26

5-5, 7-6 ~ 7-9

5-5, 7-22 ~ 7-25

5-6 ~ 5-9, 7-33 ~ 7-37

7-25

7-26

7-26

7-26

5-1

PRE-OPERATION CHECKS

Before using this motorcycle, check the following points:

Item Routine

Front brake • Check operation, free play, fluid level and fluid leak• Top-up with DOT4 (or DOT 3) brake fluid if necessa

Rear brake • Check operation, condition and free play.• Adjust if necessary.

Clutch • Check operation, condition and free play.• Adjust if necessary.

Throttle grip/Housing • Check for smooth operation. • Lubricate/Adjust if necessary.

Engine oil • Check oil level/add oil as required.

Drive chain • Check chain slack and condition. • Adjust if necessary.

Wheels/Tires • Check tire pressure, wear, damage.

Control/Meter cables • Check for smooth operation. • Lubricate if necessary.

Brake and shift pedal shafts

• Check for smooth operation. • Lubricate if necessary.

Brake and clutch lever pivots

• Check for smooth operation. • Lubricate if necessary.

Sidestand pivot • Check for smooth operation. • Lubricate if necessary.

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used. Such an inspection canafety it assures is more than

erly, have it inspected and

5-9

5-10 ~ 5-11

5-10, 7-31 ~ 7-33

ssary. 5-10, 7-28 ~ 7-30

Page

5-2

NOTE:Pre-operation checks should be made each time the motorcycle is be thoroughly accomplished in a very short time; and the added sworth the time involved.

WARNINGIf any item in the PRE-OPERATION CHECK is not working proprepaired before operating the motorcycle.

Chassis fasteners • Check all chassis fittings and fasteners.• Tighten/Adjust if necessary.

Fuel tank • Check fuel level/top-up as required.

Lights, signals and switches • Check for proper operation.

Battery • Check fluid level, top-up with distilled water if nece

Item Routine

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EAE13303

ilable, DOT 3 can be used.

c pads. 7-18.ke shoes. 7-18.

rvice is necessary, consult

leakager a few minutes. Check toid leaks out from the pipe

r cylinder.

rake fluid: DOT 4

5-3

Brakes1. Brake lever and brake pedal

Check for correct free play in the frontbrake lever and rear brake pedal and ad-just if necessary. (See page 7-15 for de-tails.) Make sure the brakes are workingproperly by checking at low speed shortlyafter starting out.

EUU62300

WARNINGA soft, spongy feeling in the brake lever in-dicates a failure in the brake system. Donot operate the motorcycle until the failurein the brake system is corrected. Ask aYamaha dealer for immediate repairs. Asoft, spongy feeling could indicate a haz-ardous condition in the brake system.

2. Brake fluidCheck the brake fluid level. Fill the mas-ter cylinder with brake fluid if necessary.(See page 7-20 for details.)

EUU13100

NOTE:If DOT 4 is not ava

3. Check the disRefer to page

4. Check the braRefer to page

EUU02201

NOTE:When this brake sea Yamaha dealer.

EAE11303

Front brake fluid Apply the brake fosee if any brake flujoints or the maste

Recommended b

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lay in the clutch lever andtch operates properly. If thect, adjust it. (See page 7-21

rip to see if it operates prop-the grip returns by springed. There should be a freet the throttle grip. If the freeask a Yamaha dealer to

ent.

5-4

EUU37801

CAUTION:Brake fluid may deteriorate painted surfac-es or plastic parts. Never spill any fluid. Ifspilled, clean it up immediately.

EUU62500

WARNINGIf brake fluid leakage is found, ask aYamaha dealer for immediate repairs.Such leakage could indicate a hazardouscondition.

EAE20002

ClutchCheck the free pmake sure the clufree play is incorrefor details.)

EAE30104

Throttle gripTurn the throttle gerly. Make sure force when releasplay of 3 ~ 5 mm aplay is incorrect, make this adjustm

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EAE40105 EUU32303

chemical additives. Also,e oils labeled “ENERGYor higher. Engine oil alsotch and additives couldage.

-22 for details) condition of the chain andfore every ride. Lubricate

in as necessary.

5-5

Engine oilMake sure the engine oil is at the specifiedlevel. Fill with oil as necessary. (See page 7-6for details.)

CAUTION:Do not put in any be sure not to usCONSERVING II” lubricates the clucause clutch slipp

EAE50001

Chain (See page 7Check the generalthe chain slack beand adjust the cha

-10° 0° 10° 20° 30° 40°-20°

SAE 10W/30

SAE 20W/50

SAE 20W/40

SAE 10W/40

50°CRecommended oil:

Recommended engine oil classification:API Service “SE”, “SF” type or equivalent(e.g. “SF-SE”, “SF-SE-CC”, “SF-SE-SD” etc.)

Oil quantity:Total amount: 1.8 LPeriodic oil change: 1.4 LWith oil filter replacement: 1.6 L

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2E180 kg

Front Rear

175 kPa(1.75 kgf/cm2,

1.75 bar)

200 kPa(2.0 kgf/cm2,

2.0 bar)

200 kPa(2.0 kgf/cm2,

2.0 bar)

225 kPa(2.25 kgf/cm2,

2.25 bar)

t of cargo, rider and accessories.

5-6

EAE97900

TiresTo ensure maximum performance, long ser-vice and safe operation, note the following:1. Tire air pressure

Always check and adjust the tire pres-sure before operating the motorcycle.

EUU67500

WARNINGTire inflation pressure should be checkedand adjusted when the temperature of thetire equals the ambient air temperature.Tire inflation pressure must be adjustedaccording to total weight of cargo, riderand accessories (fairing, saddlebags, etc.if approved for this model), and vehiclespeed.

COPY CE-32ECE-3Maximum load*:

Cold tire pressure:

Up to 90 kg

90 kg load ~Maximum load*

* Load is the total weigh

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EUU67701

the tires before operatingle. If a tire tread showss (minimum tread depth), ifail or glass fragments in it,wall is cracked, contact aer immediately and haved.

5-7

WARNINGProper loading of your motorcycle is im-portant for several characteristics of yourmotorcycle, such as handling, braking,performance and safety. Do not carryloosely packed items that can shift. Se-curely pack your heaviest items close tothe center of the motorcycle, and distrib-ute the weight evenly from side to side.Properly adjust the suspension for yourload, and check the condition and pres-sure of your tires. NEVER OVERLOADYOUR MOTORCYCLE. Make sure the totalweight of the cargo, rider and accessories(fairing, saddlebags, etc. if approved forthis model) does not exceed the maximumload of the motorcycle. Operation of anoverloaded motorcycle could cause tiredamage, an accident, or even injury.

2. Tire inspectionAlways checkthe motorcyccrosswise linethe tire has a nor if the side Yamaha dealthe tire replace

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be different by regulationuntry. If so, conform to the

the regulations of your own

us to ride with a worn-out tire tread begins to showa Yamaha dealer replacediately. Brakes, tires, andeel parts replacementbe left to a Yamaha deal-

unctured tube is not rec-If it is absolutely neces-so, use great care and

tube as soon as possiblequality replacement.

5-8

1. Tread depth 2. Side wall 3. Wear indicator

COPY CE-10ECE-10E

COPY CE-16ECE-16E

EUU12600

NOTE:These limits mayfrom country to colimits specified bycountry.

EUU68402

WARNING1. It is dangero

tire. When alines, have the tire immerelated whshould also er.

2. Patching a pommended. sary to do replace the with a good

FRONT:

Manufacturer Size Type

CHENG SHIN 3.00-18 47P C916

REAR:

Manufacturer Size Type

CHENG SHIN 130/90-15 M/C 66P C915

Minimum tire tread depth (front and rear)

1.0 mm

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EAE93600

a tire, ride conservativelyre to seat itself on the rimre to allow proper seatinge failure, resulting in dam-torcycle and injury to the

ightness of all chassis nuts, before a ride. Take themaha dealer or refer to the correct tightening torque.

5-9

Cast wheelsEUU71200

WARNINGThe wheels on this model are not designedfor use with tubeless tires. Do not attemptto use tubeless tires on this model.

To ensure maximum performance, long ser-vice, and safe operation, note the following:1. Always inspect the wheels before a ride.

Check for cracks, bends, or warpage ofthe wheels. If any abnormal condition ex-ists in a wheel, consult a Yamaha dealer.Do not attempt even small repairs to thewheel. If a wheel is deformed or cracked,it must be replaced.

2. Tires and wheels should be balancedwhenever either one is changed or re-placed. Failure to have a wheel balancedcan result in poor performance, adversehandling characteristics, and shortenedtire life.

3. After installingto allow the tiproperly. Failumay cause tirage to the morider.

EAE85101

Chassis fastenersAlways check the tbolts and screwsmotorcycle to a YaService Manual for

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sufficient fuel in the tank.

e fuel tank. Avoid spillingngine. Do not fill the fuelottom of the filler tube astration or it may overflow

ats up later and expands.

2. Fuel level

5-10

EAE71500

Lights, signals and switchesCheck all the lights, meter lights and indicatorlights to make sure they are in working condi-tion.Check the operation of the handlebar switch-es and main switch.

EAE70502

BatteryCheck the fluid level and fill if necessary. Useonly distilled water if refilling is necessary.(See page 7-28 for details.)

EAE80000

FuelMake sure there isEUU61000

WARNINGDo not overfill thfuel on the hot etank above the bshown in the illuswhen the fuel he

1. Filler tube

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EUU39302

5-11

CAUTION:Always wipe off spilled fuel immediatelywith a dry and clean soft cloth. Fuel maydeteriorate painted surfaces or plasticparts.

EAE80300

Recommended fuel:Regular unleaded gasoline

Fuel tank capacity:Total:

9.5 LReserve:

2.6 L

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ing out, always be sured is up. Failure to retractd completely can result inccident when you try tor.

ming up a cold engine

equipped with an ignitionm. an explanation of this sys-

6-1

EAF00000

OPERATION ANDIMPORTANT RIDING

POINTS

EUU67201

WARNING1. Before riding this motorcycle, become

thoroughly familiar with all operatingcontrols and their functions. Consulta Yamaha dealer regarding any con-trol or function that you do not thor-oughly understand.

2. Never start your engine or let it run forany length of time in a closed area.The exhaust fumes are poisonous andcan cause loss of consciousness anddeath within a short time. Always op-erate your motorcycle in an area withadequate ventilation.

3. Before startthe sidestanthe sidestana serious aturn a corne

EAF19800

Starting and warEUU07401

NOTE:This motorcycle iscircuit cut-off systeSee page 4-12 fortem.

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he engine, move the starter position.

ne life, always warm up therting off. Never accelerategine.

up the engine, turn off thetely.

when it responds normal-with the starter “CHOKE”

6-2

1. Turn the fuel cock to “ON”.2. Turn the main switch to “ON” and the en-

gine stop switch to “RUN”.3. Shift transmission into neutral.

EUU03001

NOTE:When the transmission is in neutral, the neu-tral indicator light should be on. If the lightdoes not come on, ask a Yamaha dealer to in-spect it.

4. Turn on the starter “CHOKE” and com-pletely close the throttle grip.

5. Start the engine by pushing the startswitch.

EUU02501

NOTE:If the engine fails to start, release the startswitch, wait a few seconds, then try again.Each attempt should be as short as possibleto preserve the battery. Do not crank the en-gine more than 10 seconds on any one at-tempt.

6. After starting tto the halfway

EUU02600

NOTE:For maximum engiengine before stahard with a cold en

7. After warmingstarter comple

EUU02701

NOTE:The engine is warmly to the throttle turned off.

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t for long periods with thend do not tow the motor-distance. Even with gearshe transmission is onlyicated when the engine isdequate lubrication maytransmission.the clutch when changingngine, transmission, and not designed to with-

ock of forced shifting andaged by shifting withouttch.

6-3

EAF10802

Starting a warm engineThe starter “CHOKE” is not required when theengine is warm.EUU31401

CAUTION:See the “Engine break-in” section prior tooperating the motorcycle for the first time.

EAF20003

ShiftingThe transmission lets you control the amountof power you have available at a given speedfor starting, accelerating, climbing hills, etc.The use of the shift pedal is shown in the illus-tration. (Page 4-6)To shift into neutral, depress the shift pedalrepeatedly until it reaches the end of its travel,then raise the pedal slightly.

EUU31501

CAUTION:1. Do not coas

engine off, acycle a long in neutral, tproperly lubrrunning. Inadamage the

2. Always use gears. The edriveline arestand the shcan be damusing the clu

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EAF30000

:ed operation above 1/2

the motorcycle freelyears, but do not use fulltime.m: speeds in excess of 3/4

operation, be sure to re-oil and oil filter.

beyond:ed full throttle operation.ccasionally.

ble should occur duringiod, consult a Yamahaly.

6-4

Engine break-inThere is never a more important period in thelife of your motorcycle than the period be-tween zero and 1,000 km. For this reason weask that you carefully read the following mate-rial. Because the engine is brand new, youmust not put an excessive load on it for thefirst 1,000 km. The various parts in the enginewear and polish themselves to the correct op-erating clearances. During this period, pro-longed full throttle operation, or any conditionwhich might result in excessive heating of theengine, must be avoided.EAF32101

1. 0 ~ 150 km:Avoid operation above 1/3 throttle. Stopthe engine and let it cool for 5 to 10 min-utes after every hour of operation. Varythe speed of the motorcycle from time totime. Do not operate it at one set throttleposition.

2. 150 ~ 500 kmAvoid prolongthrottle. Revthrough the gthrottle at any

3. 500 ~ 1,000 kAvoid cruisingthrottle.

EUU32001

CAUTION:After 1,000 km ofplace the engine

4. 1,000 km andAvoid prolongVary speeds o

EUU32200

CAUTION:If any engine trouthe break-in perdealer immediate

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6-5

EAF40001

ParkingWhen parking the motorcycle, stop the engineand remove the key.EUU63001

WARNINGThe exhaust system is hot. Park the motor-cycle in a place where pedestrians or chil-dren are not likely to touch the motorcycle.Do not park the motorcycle on a slope orsoft ground; the motorcycle may overturn.

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iliar with motorcycle ser- should be done by a

ation included in this man-rovide you, the owner, withformation for completingn preventive maintenance. The tools provided in the to assist you in the perfor-

ic maintenance. However,uch as a torque wrench are perform the maintenance

7-1

EAH00000

PERIODICMAINTENANCE AND

MINOR REPAIR

EAH00400

Periodic inspection, adjustment and lubrica-tion will keep your motorcycle in the safestand most efficient condition possible. Safety isan obligation of the motorcycle owner. Themaintenance and lubrication schedule chartshould be considered strictly as a guide togeneral maintenance and lubrication inter-vals. YOU MUST TAKE INTO CONSIDER-ATION THAT WEATHER, TERRAIN,GEOGRAPHICAL LOCATIONS, AND A VA-RIETY OF INDIVIDUAL USES ALL TEND TODEMAND THAT EACH OWNER ALTERTHIS TIME SCHEDULE TO SHORTER IN-TERVALS TO MATCH THE ENVIRON-MENT. The most important points ofmotorcycle inspection, adjustment, and lubri-cation are explained in the following pages.

EUU63200

WARNINGIf you are not famvice, this workYamaha dealer.

EAH10300

Tool kitThe service informual is intended to pthe necessary insome of your owand minor repairsowner’s tool kit aremance of periodsome other tools salso necessary tocorrectly.

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EUU67100

this motorcycle not ap-a may cause loss of per-nder it unsafe for use.a dealer before attempt-

7-2

1. Tool kit

EUU18500

NOTE:If you do not have necessary tools requiredduring a service operation, take your motor-cycle to a Yamaha dealer for service.

WARNINGModifications to proved by Yamahformance, and reConsult a Yamahing any changes.

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BREAK-IN1,000 km

EVERY

6,000 km or

6 months

12,000 km or

12 months

7-3

PERIODIC MAINTENANCE/LUBRICATION

ITEM ROUTINE

Valve(s)* • Check valve clearance. • Adjust if necessary.

Spark plug(s) • Check condition. • Clean or replace if necessary.

Air filter • Clean. • Replace if necessary.

Carburetor* • Check idle speed/starter operation.• Adjust if necessary.

Fuel line*• Check fuel hose and vacuum pipe for cracks or

damage. • Replace if necessary.

Fuel filter* • Check condition. • Replace if necessary.

Engine oil • Replace (Warm engine before draining).

Engine oil filter* • Replace.

Front brake*• Check operation/fluid leakage/See NOTE

(page 7-5).• Correct if necessary.

Rear brake • Check operation. • Adjust if necessary.

Clutch • Check operation. • Adjust if necessary.

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EVERY 500 km

REAK-IN1,000 km

EVERY

6,000 km or

6 months

12,000 km or

12 months

7-4

Rear arm pivot*

• Check rear arm assembly for looseness.• Correct if necessary.• Moderately repack every 24,000 km or

24 months.**

Wheels* • Check balance/damage/runout/spoke tightness.• Replace if necessary.

Wheel bearings* • Check bearings assembly for looseness/damage.• Replace if damaged.

Steering bearing*

• Check bearings assembly for looseness.• Correct if necessary.• Moderately repack every 24,000 km or

24 months.**

Front fork* • Check operation/oil leakage. • Repair if necessary.

Rear shock absorber* • Check operation/oil leakage. • Repair if necessary.

Drive chain• Check chain slack/alignment. • Adjust if necessary.• Clean if necessary.

Chassis fasteners* • Check all chassis fittings and fasteners.• Correct if necessary.

Sidestand* • Check operation. • Repair if necessary.

Sidestand switch* • Check operation. • Clean or replace if necessary.

ITEM ROUTINE B

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lace the brake fluid. Normally as required.eplace the oil seals every two

aged.

BREAK-IN1,000 km

EVERY

6,000 km or

6 months

12,000 km or

12 months

7-5

* : It is recommended that these items be serviced by a Yamaha dealer.** : Lithium soap base grease

NOTE:Brake fluid replacement:1. When disassembling the master cylinder or caliper cylinder, rep

check the brake fluid level and fill the master cylinder with fluid2. On the inner parts of the master cylinder and caliper cylinder, r

years.3. Replace the brake/hoses every four years, or if cracked or dam

Battery*• Check specific gravity.• Check breather pipe for proper operation.• Correct if necessary.

ITEM ROUTINE

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EAH44705

2. Maximum level mark

s until the oil level settles

should be between maxi-imum marks. If the level is the specified level.

7-6

Engine oil1. Oil level inspectiona. Place the motorcycle on a level place

and hold it in an upright position. Warmup the engine for several minutes.

EUU03901

NOTE:Be sure the motorcycle is positioned straightup when checking the oil level. A slight tilt to-ward the side can result in false readings.

b. With the engine stopped, check the oillevel through the level window located atthe lower part of the right side crankcasecover.

1. Level window3. Minimum level mark

EUU04000

NOTE:Wait a few minutebefore checking.

c. The oil level mum and minlow, add oil to

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oil filter cover bolts, oil filter

3)

7-7

2. Engine oil and oil filter element replace-ment

a. Warm up the engine for a few minutes.b. Stop the engine. Place an oil pan under

the engine and remove the oil filler cap.

1. Oil filler cap

c. Remove the drain plug and drain the oil.

1. Drain plug

d. Remove the and O-ring.

1. Oil filter cover bolt (×

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ng is seated properly.

ngine with the specifiedommended oil. Install thed tighten.

e: bolt:·kgf)

il:

ange:

placement:

7-8

e. Reinstall the drain plug and tighten it tothe specified torque.

f. Install the new oil filter, new O-ring andthe filter cover. Tighten the oil filter coverbolts to the specified torque.

1. Oil filter element 2. O-ring

EUU04101

NOTE:Make sure the O-ri

g. Fill up the eamount of recoil filler cap an

Tightening torque:Drain plug:

34 Nm (3.4 m·kgf)

Tightening torquOil filter cover

7 Nm (0.7 m

Recommended oSee page 5-5

Oil quantity:Total amount:

1.8 LPeriodic oil ch

1.4 LWith oil filter re

1.6 L

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ld be cleaned at the speci-ould be cleaned more fre- riding in unusually wet or

amp.

olts.

7-9

EUU32401

CAUTION:� Do not put in any chemical additives.

Engine oil also lubricates the clutchand additives could cause clutch slip-page.

� Be sure no foreign material enters thecrankcase.

h. Start the engine and warm up for a fewminutes. While warming up, check for oilleakage. If oil leakage is found, stop theengine immediately and check for thecause.

EAH600A0

Air filterThe element shoufied intervals. It shquently if you aredusty areas.1. Loosen the cl

1. Screw

2. Remove the b

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ir filter case cover.

ing bolt.

7-10

1. Bolt (× 2)

3. Remove the hoses and the air filter case.

1. Hose (× 2)

4. Remove the a

1. Screw (× 2)

5. Remove the w

1. Wing bolt

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ersing the removal proce-

ement is properly seated

7-11

6. Pull out the element.7. Remove the element from its guide and

clean it with solvent. After cleaning, re-move the remaining solvent by squeez-ing the element.

1. Air filter element 2. Guide

8. Apply recommended oil to the entire sur-face of the filter and squeeze out the ex-cess oil. The element should be wet butnot dripping.

9. Install by revdures.

EUU35701

CAUTION:Make sure the elin the filter case.

Recommended oil:SAE 10W30 type SE motor oil

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EUU42400 EUU47100

were set at the Yamahaany tests. If they arengine performance andlt.

ment

meter must be used for this

hometer. Start the enginep for a few minutes at ap-,000 to 2,000 r/min. Occa-the engine to 4,000 tohe engine is warm when itds to the throttle.the specified engine speede throttle stop screw. Turnirection a to increase en-nd in direction b to de- speed.

7-12

CAUTION:The engine should never be run withoutthe air filter element installed; excessivepiston and/or cylinder wear may result.

EAH93100

Carburetor adjustmentThe carburetors are important parts of the en-gine and requires very sophisticated adjust-ment. Most adjustments should be left to aYamaha dealer who has the professionalknowledge and experience to do so. Howev-er, the following may be serviced by the own-er as part of routine maintenance.EUU13700

NOTE:A diagnostic tachometer must be used for thisprocedure.

CAUTION:The carburetors factory after mchanged, poor edamage may resu

EAH92002

Idle speed adjustEUU13700

NOTE:A diagnostic tachoprocedure.

1. Attach the tacand warm it uproximately 1sionally rev 5,000 r/min. Tquickly respon

2. Set the idle to by adjusting ththe screw in dgine speed acrease engine

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e play inspection free play of 3 ~ 5 mm at the free play is incorrect, ask a make this adjustment.

7-13

1. Throttle stop screw

EUU04500

NOTE:If the specified idle speed cannot be obtainedby performing the above adjustment, consulta Yamaha dealer.

EAH92202

Throttle cable freThere should be athrottle grip. If theYamaha dealer to

a. Free play

Standard idle speed:1,250 ~ 1,350 r/min

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EAH90801

diagnose such problemstake the motorcycle to aou should periodically re- the spark plugs becauseill cause any spark plug to

n and erode. If electrodexcessive, or if carbon and

excessive, you should re-g with the specified plug.

y spark plug, measure the a wire thickness gauge.pecification.

lug:K) orENSO)

7-14

Valve clearance adjustmentThe correct valve clearance changes withuse, resulting in improper fuel/air supply orengine noise. To prevent this, the valve clear-ance must be adjusted regularly. This adjust-ment however, should be left to a professionalYamaha service technician.

EAH20102

Spark plug inspectionThe spark plug is an important engine compo-nent and is easy to inspect. The condition ofthe spark plug can indicate the condition ofthe engine.Normally, all spark plugs from the same en-gine should have the same color on the whiteinsulator around the center electrode. Theideal color at this point is a medium-to-lighttan color for a motorcycle that is being riddennormally. If one spark plug shows a distinctlydifferent color, there could be somethingwrong with the engine.

Do not attempt toyourself. Instead, Yamaha dealer. Ymove and inspectheat and deposits wslowly break dowerosion becomes eother deposits areplace the spark plu

Before installing anelectrode gap withAdjust the gap to s

Specified spark pCR6HSA (NGU20FSR-U (D

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is not available when yourk plug, a good estimate of

is 1/4 to 1/2 turn past fingerpark plug tightened to thes soon as possible.

free play adjustmenthe front brake lever should

cknut.sting bolt in direction a to

play or in direction b to de-lay.g, tighten the locknut.

7-15

1. Spark plug gap

When installing the spark plug, always cleanthe gasket surface and use a new gasket.Wipe off any grime from the threads and tight-en the spark plug to the specified torque.

EUU03802

NOTE:If a torque wrenchare installing a spathe correct torquetight. Have the sspecified torque a

EAH80104

Front brake leverThe free play at tbe 2 ~ 5 mm.1. Loosen the lo2. Turn the adju

increase freecrease free p

3. After adjustin

Spark plug gap:0.6 ~ 0.7 mm

Tightening torque:Spark plug:

12.5 Nm (1.25 m·kgf)

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of control and an acci- Yamaha dealer inspect system if necessary.

ment

have a Yamaha dealerent.

knut.e adjuster clockwise orise, adjust the brake pedalat its top end is approxi-

m above the top of the foot-

locknut.

7-16

in the brake system. This air must beremoved by bleeding the brake sys-tem before the motorcycle is operat-ed. Air in the system will cause greatlydiminished braking capability and can

mately 50 mrest.

c. Tighten the

1. Locknut 2. Adjusting bolt 3. Free play

EUU81500

WARNING� Check the brake lever free play. Be

sure the brake is working properly.� A soft or spongy feeling in the brake

lever can indicate the presence of air

result in lossdent. Have aand bleed the

EAH87103

Rear brake adjustEUU64301

WARNINGIt is advisable tomake this adjustm

1. Pedal heighta. Loosen the locb. By turning th

counterclockwposition so th

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the pedal height adjustplay.

e pedal free play should be ~ 30 mm at the brake ped-

he adjuster on the brake rodeduce free play or counter-ncrease free play.

y)

7-17

1. Footrest2. Pedal height3. Free play

1. Locknut 2. Adjuster (for pedal height)

EUU64400

WARNINGAfter adjusting brake pedal free

2. Free playThe rear brakadjusted to 20al end. Turn tclockwise to rclockwise to i

1. Adjuster (for free pla

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EUU69800

2. Adjusting nut

nt brake pads and rear

provided on each brake.lows checking of brakeithout disassembling the

7-18

WARNING1. The rear brake pedal adjustment must

be checked whenever the chain is ad-justed or the rear wheel is removedand then reinstalled.

2. Check the operation of the brake lightafter adjusting the rear brake.

EAH83301

Brake light switch adjustmentThe brake light switch is operated by move-ment of the brake pedal. To adjust, hold themain body of the switch so it does not rotateand turn the adjusting nut. Proper adjustmentis achieved when the brake light comes onjust before the brake begins to take effect.

1. Main body

EAH81401

Checking the frobrake shoesA wear indicator isThis indicator alpad/shoe wear wbrake.

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nd inspect the wear indica-

ches the wear limit line, askto replace the shoes.

2. Wear limit line

7-19

EAH87401

FRONTApply the brake and inspect the wear indica-tor. If the brake pads are worn to the wear lim-it, have a Yamaha dealer replace the pads.

1. Wear indicator a. Wear limit 0.8 mm

EAH82601

REARApply the brake ator.If the indicator reaa Yamaha dealer

1. Wear indicator

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EAH88202*

same type of brake fluid.may result in a harmful

tion and lead to poor brake

t water does not enter ther when refilling. Water willwer the boiling point of theresult in vapor lock.ay deteriorate painted sur-tic parts. Always clean upmediately.ha dealer check the causeid level goes down.

7-20

Inspecting the brake fluid levelInsufficient brake fluid may let air enter thebrake system, possibly causing the brakes tobecome ineffective.Before riding, check that the brake fluid isabove the lower level and replenish whennecessary.Observe these precautions:1. When checking the fluid level, make sure

the top of the master cylinder is level byturning the handlebars.

2. Use only the designated quality brake flu-id. Otherwise, the rubber seals may dete-riorate, causing leakage and poor brakeperformance.

EUU13100

NOTE:If DOT 4 is not available, DOT 3 can be used.

3. Refill with theMixing fluids chemical reacperformance.

4. Be careful thamaster cylindesignificantly lofluid and may

5. Brake fluid mfaces or plasspilled fluid im

6. Have a Yamaif the brake flu

Recommended brake fluids: DOT 4

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ntee play should be adjusted the clutch lever. If the freedjust as follows.

Adjuster a. Free play

7-21

1. Lower level

EAH83501

Brake fluid replacement1. Complete fluid replacement should be

done only by trained Yamaha servicepersonnel.

2. Have a Yamaha dealer replace the fol-lowing components during periodic main-tenance or when they are damaged orleaking.

a. Replace all rubber seals every two years.b. Replace all hoses every four years.

EAI00501

Clutch adjustmeThe clutch lever frto 10 ~ 15 mm atplay is incorrect, a

1. Locknut 2.

Free play:10 ~ 15 mm

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EAI40801

check

everal times and find thef the chain. Check and/orck while it’s in this tightest

slack the motorcycle mustp with both wheels on thet rider. Check the slack at in the illustration. Normal

ately 30 ~ 40 mm. If them, adjust.

7-22

1. Loosen the locknut at the handlebar.2. Turn the adjuster in or out until proper le-

ver free play is obtained.3. Tighten the locknut.4. If the free play is still incorrect, make an

adjustment at the crankcase side.

1. Locknut 2. Adjuster

EUU17800

NOTE:If proper adjustment cannot be obtained orthe clutch does not work correctly, ask aYamaha dealer to inspect the internal clutchmechanism.

Drive chain slackEUU04801

NOTE:Spin the wheel stightest position oadjust the chain slaposition.

To check the chainbe held straight uground and withouthe position shownslack is approximslack exceeds 40 m

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tter pin from the axle nut.

tter pin 3. Locknutnment marks

e nut.hain adjuster locknut one swingarm. To tighten the chain adjuster on each

ngarm clockwise. To loos-urn each adjuster counter- push the wheel forward.juster exactly the sameintain correct axle align-re marks on each side of

7-23

a. Drive chain slackEAI40102

Drive chain slack adjustment1. Loosen the rear brake adjuster.

1. Adjuster

2. Remove the co

1. Axle nut 2. Co4. Adjuster 5. Alig

3. Loosen the axl4. Loosen the c

each side of thchain, turn theside of the swien the chain, tclockwise andTurn each adamount to mament. There a

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shown. If the notch in the axle nut and the

w cotter pin on the axle

play in the brake pedal.EUU64500

on of the brake light after brake.

7-24

cotter pin hole do not match, tighten thenut slightly to align them.

WARNINGCheck the operatiadjusting the rear

the swingarm and a match mark on eachchain adjuster. Use these marks to alignthe rear wheel.

EUU33301

CAUTION:Too little chain slack will overload the en-gine and other vital parts. Keep the slackwithin the specified limits.

5. After adjusting, be sure to tighten eachchain adjuster locknut and the axle nut.

6. Insert a new cotter pin into the axle nutand bend the end of the cotter pin as

Axle nut torque:105 Nm (10.5 m·kgf)

1. Cotter pin

EUU64700

WARNINGAlways use a nenut.

7. Adjust the free

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and lubrication

outer housing of cablesl rusting and cause inter-ble movement. Replace as soon as possible toonditions.

r cable and the cable end. Ife smoothly, ask a Yamahahem.

lubricant:motor oil

7-25

EAI40701

Drive chain lubricationThe chain consists of many parts which workwith each other. If the chain is not maintainedproperly, it will wear out quickly, Therefore,the chain must be serviced regularly. This ser-vice is especially necessary when riding industy areas. This motorcycle is equipped witha sealed type chain. Steam cleaning, high-pressure washes, and solvents can damagechain so do not use these for cleaning it. Useonly kerosene to clean the drive chain. Wipe itdry, and thoroughly lubricate it with SAE 30 ~50W motor oil. Do not use any other lubri-cants on the drive chain. They may containsolvents that could damage the sealed chain.

EAI10701

Cable inspectionEUU64601

WARNINGDamage to the may allow internaference with cadamaged cablesprevent unsafe c

Lubricate the inneit does not operatdealer to replace t

Recommended SAE 10W30

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EAI10201 EAI31101

ing parts. Check to see thates up and down smoothly.

oes not move smoothly, dealer.

ing parts.

ubricant:otor oil

ubricant:ase grease

7-26

Throttle cable and grip lubricationThe throttle twist grip assembly should begreased at the time that the cable is lubricat-ed, since the grip must be removed to get atthe end of the throttle cable. After removingthe screws, hold the end of the cable up in theair and put in several drops of lubricant. Withthe throttle grip disassembled, coat the metalsurface of the grip assembly with a suitableall-purpose grease.EAI30601

Brake and shift pedalsLubricate the pivoting parts.

EAI30700

Brake and clutch leversLubricate the pivoting parts.

SidestandLubricate the pivotthe sidestand mov

EUU70401

WARNINGIf the sidestand dconsult a Yamaha

EAI31300

Rear suspensionLubricate the pivot

Recommended lubricant:SAE 10W30 motor oil

Recommended lubricant:SAE 10W30 motor oil

Recommended lSAE 10W30 m

Recommended lLithium soap b

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7-27

EAI20502

Front fork inspectionEUU65700

WARNINGSecurely support the motorcycle so thereis no danger of it falling over.

1. Visual checkCheck for scratches or damage on the in-ner tube and excessive oil leakage fromthe front fork.

2. Operation checkPlace the motorcycle on a level place.

a. Hold the motorcycle in an upright positionand apply the front brake.

b. Push down hard on the handlebars seve-ral times and check if the fork reboundssmoothly.

EUU42500

CAUTION:If any damage or unsmooth movement isfound with the front fork, consult aYamaha dealer.

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EAI60301 EUU65700

the motorcycle so therefalling over.

e front or rear wheel hub ornot turn smoothly, have aspect the wheel bearings.s should be inspected ac-tenance Schedule.

the battery electrolyte ande terminals are tight. Add electrolyte level is low.

7-28

Steering inspectionPeriodically inspect the condition of the steer-ing. Worn out or loose steering bearings maybe dangerous. Place a stand under the en-gine to raise the front wheel off the ground.Hold the lower end of the front forks and try tomove them forward and backward. If any freeplay can be felt, ask a Yamaha dealer to in-spect and adjust the steering. Inspection iseasier if the front wheel is removed.

WARNINGSecurely supportis no danger of it

EAI60201

Wheel bearingsIf there is play in thif the wheel does Yamaha dealer inThe wheel bearingcording to the Main

EAI70001

BatteryCheck the level ofmake sure that thdistilled water if the

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te is poisonous and dan-severe burns, etc. It con-cid. Avoid contact withhing.

h with water. large quantities of waterwith milk of magnesia,

egetable oil. Call a physi-. water for 15 minutes andical attention. Batteries

ve gases. Keep sparks,s etc., away. Ventilateor using in an enclosedshield your eyes whenteries.EACH OF CHILDREN.

7-29

EUU33601

CAUTION:When inspecting the battery, be sure thebreather pipe is routed correctly. If thebreather pipe is positioned in such a wayas to cause battery electrolyte or gas toexit onto the frame, structural and cosmet-ic damage to the motorcycle can occur.

EUU65800

WARNINGBattery electrolygerous, causing tains sulfuric askin, eyes or clotAntidote:EXTERNAL: FlusINTERNAL: Drinkor milk. Follow beaten egg, or vcian immediatelyEYES: Flush withget prompt medproduce explosiflame, cigarettewhen charging space. Always working near batKEEP OUT OF R

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EAI70401 EUU65901

spill battery fluid on theid may weaken the chainhain life and possibly re-t.

orcycle will not be used fornger, remove the battery a cool, dark place. Com-

ge the battery before reus-

will be stored for a longere above, check the specificfluid at least once a month the battery when it is too

sure the connections areputting the battery back ine. Make sure the breatherrly connected and is notbstructed.

7-30

Replenishing the battery fluidA poorly maintained battery will corrode anddischarge quickly. The battery fluid should bechecked at least once a month.1. The level should be between the upper

and lower level marks. Use only distilledwater if refilling is necessary.

1. “UPPER LEVEL” 2. “LOWER LEVEL”

EUU33800

CAUTION:Normal tap water contains minerals whichare harmful to a battery; therefore, refillonly with distilled water.

WARNINGTake care not to chain. Battery flucausing shorter csult in an acciden

2. When the mota month or loand store it inpletely recharing.

3. If the battery period than thgravity of the and rechargelow.

4. Always makecorrect when the motorcyclpipe is propedamaged or o

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of higher amperage rat-recommended. Substitu-mproper rating can causecal system damage and

placementis equipped with a quartzhe headlight bulb burns out,s follows:crews holding the light unit

20 A10 A5 A5 A

7-31

EAI91801

Fuse replacement1. The fuse case is located under the seat.

1. Main fuse 2. Signal fuse3. Patrol fuse 4. Siren fuse

2. If a fuse is blown, turn off the ignitionswitch and the switch of the circuit inquestion. Install a new fuse of proper am-perage. Turn on the switches and see ifthe electrical device operates. If the fuseimmediately blows again, consult aYamaha dealer.

EUU34400

CAUTION:Do not use fusesing than those tion of a fuse of iextensive electripossibly a fire.

EAI88300

Headlight bulb reThis motorcycle bulb headlight. If treplace the bulb a1. Remove the s

assembly.

Specified fuse:Main:Signal:Patrol:Siren:

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holder counterclockwise to remove the defective bulb.

roducts and your handslb while it is on, as it is

h the bulb until it cools

7-32

1. Light unit assembly 2. Screw (× 2)

2. Disconnect the headlight coupler, removethe light unit assembly and then the cover.

1. Headlight coupler 2. Cover

3. Turn the bulb remove it and

1. Bulb holder

EUU66001

WARNINGKeep flammable paway from the buhot. Do not toucdown.

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val

o have a Yamaha dealerl.

t the motorcycle so there falling over.

peedometer cable from thede.

7-33

4. Put a new bulb into position and secure itin place with the bulb holder.

EUU34100

CAUTION:Avoid touching the glass part of the bulb.Keep it free from oil; otherwise, the trans-parency of the glass, life of the bulb, and il-luminous flux will be adversely affected. Ifoil gets on the bulb, thoroughly clean itwith a cloth moistened with alcohol or lac-quer thinner.

5. Install the cover.6. Connect headlight coupler.7. Install the light unit assembly.

If the headlight beam adjustment is nec-essary, ask a Yamaha dealer to makeadjustment.

EAJ24402

Front wheel remoEUU66201

WARNINGIt is advisable tservice the wheeEUU65700

WARNINGSecurely supporis no danger of it

1. Remove the sfront wheel si

1. Speedometer cable

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EAJ28400

llatione front wheel, reverse the. Pay attention to the fol-

wheel hub and the speed-unit are installed with theshed into the slots.

re is enough gap betweens before inserting the brake

7-34

2. Loosen the pinch bolt and wheel axle.

1. Pinch bolt 2. Wheel axle

3. Elevate the front wheel by placing a suit-able stand under the engine.

4. Remove the wheel axle and the frontwheel. Make sure the motorcycle is prop-erly supported.

EUU05400

NOTE:Do not depress the brake lever when the discis off the caliper as the brake pads will beforced shut.

Front wheel instaWhen installing thremoval procedurelowing points:1. Make sure the

ometer gear projections me

2. Make sure thethe brake paddisc.

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the pinch bolt, push downeveral times to check forration.

al

have a Yamaha dealer

the motorcycle so therealling over.

r wheel by placing a suit-er the engine.otter pin, nut and tensione brake shoe plate.

7-35

3. Make sure the slot in the speedometergear unit fits over the stopper on the frontfork outer tube.

4. Make sure the wheel axle is properlytorqued.

5. Tighten the pinch bolt.

6. After tighteningthe front fork sproper fork ope

EAJ31202

Rear wheel removEUU66201

WARNINGIt is advisable toservice the wheel.

EUU65700

WARNINGSecurely support is no danger of it f

1. Elevate the reaable stand und

2. Remove the cbar bolt from th

Tightening torque:Wheel axle:

59 Nm (5.9 m·kgf)

Pinch bolt torque:20 Nm (2.0 m·kgf)

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r pin 3. Locknutment marks

xle nut cotter pin and the

heel axle and remove thely.

disassemble the chain in install the rear wheel.

7-36

1. Tension bar 2. Cotter pin3. Nut (tension bar bolt) 4. Brake rod5. Brake adjuster

3. Remove the brake adjuster and brakerod from the brake cam lever.

4. Loosen the locknuts and chain adjusterson each side.

1. Axle nut 2. Cotte4. Adjuster 5. Align

5. Remove the aaxle nut.

6. Pull out the wwheel assemb

EUU05600

NOTE:You do not have toorder to remove or

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ion of the brake light afterr brake.

7-37

EAJ34001

Rear wheel installationWhen installing the rear wheel, reverse the re-moval procedure. Pay attention to the follow-ing points:1. Adjust the drive chain.2. Make sure the following parts are proper-

ly torqued, and a new cotter pin is in-stalled.

EUU78000

WARNINGAlways use a new cotter pin.

3. Adjust the rear brake. (See page 7-16)

EUU64500

WARNINGCheck the operatadjusting the rea

Tightening torque:Axle nut:

105 Nm (10.5 m·kgf)Tension bar bolt:

23 Nm (2.3 m·kgf)

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EAJ50002

7-38

TroubleshootingAlthough Yamaha motorcycles receive a rigidinspection before shipment from the factory,trouble may occur during operation.Any problem in the fuel, compression, or igni-tion systems can cause poor starting and lossof power. The troubleshooting chart describesa quick, easy procedure for making checks.If your motorcycle requires any repair, bring itto a Yamaha dealer. The skilled technicians ata Yamaha dealership have the tools, experi-ence, and know-how to properly service yourmotorcycle. Use only genuine Yamaha partson your motorcycle. Imitation parts may looklike Yamaha parts, but they are often inferior.Consequently, they have a shorter service lifeand can lead to expensive repair bills.

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7-39

D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-7.fmR

Check the fuel level inthe fuel tank.

1. FuelThere is enough fuel.

There is no fuel.

Check the compression.

Supply fuel.

Operate the electric starter.

2. CompressionThere is compression.

There is no compression.

Check the ignition.

Have a Yamaha dealercheck the vehicle.

spark plugse electrodes.

nWet

Dry

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 engine does not start.Check the battery.

Open the throttle halfway and operatethe electric starter.

electric starter.

ry The engine turns over quickly.

The engine turns over slowly.

The battery is good.

Check the electrolyte and batterylead connections, and charge thebattery if necessary.

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

The engine does not start. Check the compressoin.

EAJ51800

Troubleshooting chartEUU66300

WARNINGNever check the fuel system while smoking or in the vicinity of an open flame.

Remove theand check th

3. Ignitio

Operate the

4. Batte

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EAK00000 EUU34602

ressure may cause watererioration of wheel bear-, brakes, transmissional parts.repair bills have resultedh pressure detergent ap-

s those available in coin-hers.

jority of the dirt has beensh all surfaces with warmd, detergent-type soap. An or bottle brush is handy for places.otorcycle off immediatelyer and dry all surfaces withan towel, or soft absorbent

and lubricate it to prevent

8-1

CLEANING ANDSTORAGE

EAK02000

A. CLEANINGFrequent, thorough cleaning of your motor-cycle will not only enhance its appearance butwill improve its general performance and ex-tend the useful life of many components.1. Before cleaning the motorcycle:a. Block off the end of the exhaust pipe to

prevent water entry; a plastic bag andstrong rubber band may be used.

b. Make sure the spark plugs and all fillercaps are properly installed.

2. If the engine case is excessively greasy,apply degreaser with a paint brush. Donot apply degreaser to the chain, sprock-ets, or wheel axles.

3. Rinse the dirt and degreaser off with agarden hose. Use only enough pressureto do the job.

CAUTION:Excessive hose pseepage and detings, front forkseals and electricMany expensive from improper higplications such aoperated car was

4. Once the mahosed off, wawater and milold toothbrushhard-to-get-at

5. Rinse the mwith clean wata chamois, clecloth.

6. Dry the chainrust.

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empty fuel tank, pour a cup0 or 20W40 motor oil in thee tank to coat the inner sur-hly and drain off the excesshe tank. spark plug, pour about onef SAE 10W30 or 20W40ach spark plug hole and re-ark plugs. Turn the enginetimes (ground spark plug the cylinder walls with oil.

starter motor to crank thehe spark plug wires, andrevent sparking.

ain and lubricate it (refer toubrication”).ontrol cables.frame to raise both wheels.

8-2

7. Clean the seat with a vinyl upholsterycleaner to keep the cover pliable andglossy.

8. Automotive type wax may be applied toall painted and chrome-plated surfaces.Avoid combination cleaner-waxes. Manycontain abrasives which may mar thepaint or protective finish. When finished,start the engine and let it idle for severalminutes.

EAK02101

B. STORAGELong term storage (60 days or more) of yourmotorcycle will require some preventive pro-cedures to guard against deterioration. Afterthoroughly cleaning the motorcycle, preparefor storage as follows:1. Drain the fuel tank, fuel lines and carbu-

retor float bowls.

2. Remove the of SAE 10W3tank, shake thfaces thorougoil. Reinstall t

3. Remove eachtablespoon omotor oil in einstall the spover several leads) to coat

EUU66400

WARNINGWhen using the engine, remove tground them to p

4. Clean the ch“Drive chain l

5. Lubricate all c6. Block up the

off the ground

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8-3

7. Tie a plastic bag over the exhaust pipeoutlet to prevent moisture from entering.

8. If storing in a humid or salt-air atmo-sphere, coat all exposed metal surfaceswith a light film of oil. Do not apply oil toany rubber parts or the seat cover.

9. Remove the battery and charge it. Storeit in a dry place and recharge it once amonth. Do not store the battery in an ex-cessively warm or cold place (less than0°C or more than 30°C).

EUU05800

NOTE:Make any necessary repairs before storingthe motorcycle.

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XV250P

gasoline, SOHC

9-1

SPECIFICATIONS

Model

Dimension:Overall lengthOverall widthOverall heightSeat heightWheel baseMinimum ground clearance

2,215 mm770 mm

1,150 mm695 mm

1,495 mm150 mm

Basic weight:With oil and full fuel tank 150 kg

Minimum turning radius: 2,800 mm

Engine:TypeCylinder arrangementDisplacementBore × StrokeCompression ratioStarting system

Air cooled 4-stroke,V-2 cylinder248 cm3

49 × 66 mm10 : 1Electric starter

Lubrication system: Wet sump

Engine oil (4-cycle)TypeCapacity

Periodic oil changeWith oil filter replacementTotal amount

See page 5-5.

1.4 L1.6 L1.8 L

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soline

0FSR-U/DENSO

eed

XV250P

9-2

Air filter: Wet type element

Fuel:TypeTank capacityReserve amount

Regular unleaded ga9.5 L2.6 L

Carburetor:Type/Manufacturer BDS26/MIKUNI

Spark plug:Type/ManufacturerGap

CR6HSA/NGK or U20.6 ~ 0.7 mm

Clutch type: Wet, multi-disc

Transmission:Primary reduction systemPrimary reduction ratioSecondary reduction systemSecondary reduction ratioTransmission typeOperationGear ratio: 1st

2nd3rd4th5th

Spur gear72/23 (3.130)Chain drive45/16 (2.813)Constant mesh 5-spLeft foot operation37/14 (2.643)32/19 (1.684)29/23 (1.261)26/26 (1.000)23/28 (0.821)

Model

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n

perper

torAH

XV250P

9-3

Chassis:Frame typeCaster angleTrail

Double cradle32.0°119 mm

Tire:TypeSize : Front

Rear

With tube3.00-18 47P130/90-15 M/C 66P

Brake:Front brake typeOperationRear brake typeOperation

Single, disc brakeRight hand operatioDrum brakeRight foot operation

Suspension:FrontRear

Telescopic forkSwingarm

Shock absorber:FrontRear

Coil spring, oil damCoil spring, oil dam

Wheel travel:FrontRear

140 mm100 mm

Electrical:Ignition systemGenerator systemBattery type/Capacity

TCI (Digital)AC magneto generaGM10-3A-2/12V 10

Model

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XV250P

9-4

Headlight type: Halogen bulb

Bulb wattage × Quantity:HeadlightTail/brake lightTurn signal lightMeter lightAuxiliary light

12V 60W/55W × 112V 5W/21W × 112V 21W × 412V 1.7W × 112V 3.4W × 1

Indicator light wattage × Quantity:Neutral indicator lightHigh beam indicator lightTurn indicator light

12V 1.7W × 112V 1.7W × 112V 3W × 1

Model

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version tableEM TO IMPERIAL SYSTEM

nit Conversion fac-tor Imperial unit

× 7.233× 86.794× 0.0723× 0.8679

ft·lbfin·lbfft·lbfin·lbf

× 2.205× 0.03527

lboz

× 0.6214 mi/h

× 0.6214× 3.281× 1.094× 0.3937× 0.03937

miftydinin

× 0.03527× 0.06102× 0.8799× 0.2199

oz (IMP liq.)cu·inqt (IMP liq.)gal (IMP liq.)

× 55.997× 14.2234× 1.8 + 32

lb/inpsi (lbf/in2)°F

EAU04

CS-04E

All sin S

Useto I

Exa

MET

9-5

513

Conversion table

pecification data in this manual are listedI and METRIC UNITS.

this table to convert METRIC unit valuesMPERIAL unit values.

mple:

RIC VALUE CONVERSION FACTOR

IMPERIAL VALUE

2 mm × 0.03937 = 0.08 in

ConMETRIC SYST

Metric u

Torque

m·kgfm·kgfcm·kgfcm·kgf

Weight kgg

Speed km/h

Distance

kmmmcmmm

Volume,Capacity

cc (cm3)cc (cm3)L (liter)L (liter)

Miscellaneouskg/mmkgf/cm2

°C

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PRINTED IN JAPAN2003.02-0.3×1 CR

(E)

PRINTED ON RECYCLED PAPERYAMAHA MOTOR CO., LTD.

4TN-28199-E2

XV250P

OWNER’S MANUAL

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WIRING DIAGRAM

COLOR CODE

B .........L .........G .........Y .........R .........

BlackBlueGreenYellowRed

P .........Or .......Br ........Ch .......Gy .......

PinkOrangeBrownChocolateGray

Sb .......Dg .......G/Y .....G/W.....Y/B ......

Sky blueDark greenGreen/YellowGreen/WhiteYellow/Black

Y/R ......R/B ......R/G .....R/Y ...... R/W .....

Yellow/RedRed/BlackRed/GreenRed/YellowRed/White

Br/W ....W/B .....W .........B/Y ......B/R ......

Brown/WhiteWhite/BlackWhiteBlack/YellowBlack/Red

L/Y ......L/R ......L/W .....

Blue/YellowBlue/RedBlue/White

Neutral switchA.C. magnetoRectifier/regulatorFrame earthMain switchMain fuseWire plus leadBatteryWire minus leadStarter relayStarter motorClutch switchRelaySidestand switchIgnitor unitIgnition coilHandlebar switch (R)Front brake switchMicrophone switchSiren switchPatrol switchEngine stop switch

1.2.3.4.5.6.7.8.9.

10.11.12.13.14.15.16.17.18.19.20.21.22.

Start switchHazard switchThermo switch (option)Patrol fuseRear patrol lightCarburetor heaterDiodeSignal fuseSiren fuse MicrophoneSirenPatrol relayCord flasher relayFlasher relayFront patrol lightWire earth leadHornFlasher relaySpeedometerNeutral indicator lightHigh beam indicator lightTurn indicator lightMeter lightRear brake switchTail/brake lightHandlebar switch (L)Light switchDimmer switchPass switchHorn switchTurn signal switchAuxiliary lightHeadlightFront turn signal lightRear turn signal lightMeter light (option)Fuel gauge (option)Fuel sender (option)

23.24.25.26.27.28.29.30.31.32.33.34.35.36.37.38.39.40.41.42.43.44.45.46.47.48.49.50.51.52.53.54.55.56.57.58.59.60.

q

q

B

U

R/WGy

Gy

A

A

F1

W W

W

W W

W

L/Y

G/W

Sb

G/W

L/Y

L

W

Sb

W

W

W

W

W

2

RR3

B

WB

W WR

OFF

ON

P

5

R

L

Br

L/R

R

L

Br

L/R

Br L

R

8

9

6 7

L/W

0

A

R

R/B

C

B/YSb

L/W GB/R W/B

L/WR/B

L/YL/W

L/Y

B/YB

B

L/W B/Y

B/Y L/Y

BB

B

B

L/Y

L/Y

L/Y

B

D

GyOr R/B

B

L/YL/YG/W

B

E

R/B

L/YG/W

R/W

Or

Or

A

A

F

Or

R/WR/W

Gy

R/WR/W

OrGy

A

MAIN HARNESS ING. COIL

L/Y

4

B

Br/W

Ch

Dg

Ch

Br/W

Dg

Y/B

G

R/B R/Y

B/R

Br

R/Y

Y/BB/R

GBr

R/B

B

R/WY/B

R/B

Y/BR/W

BR/W

(RED)(RED)

ON

OFF

Dg

Br/W

Ch

NP

S

M

OFF

ON

OFF

ON

OFF

RUN

OFF

ON

OFF

B

R/BR/W

GBr B R/Y Y/BR/B

Y/B

G

I J L

K

M

L/W

G/Y

L/WBr

B

BrL/W

G/YB

(BLACK)(BLACK)

G/Y

Br

B

B

H

P

Br L/R

Br

S

T

Q

R/BR/G

BBr

Br R/B

BR/B R/G

Br X

B

B

Y

Br

f

LY

g

Y

B

V

Y

Z

Br/W

Br B

\[

PO

ON

OFF

LO

HI

N

L

R

ON

OFF

ON

OFFP

Y

B R/Y

L

G

R/Y

PL

YG

B

DgCh

Y/RBr/WG

P ChDgB

ChDg

Br/W

(BROWN) (BROWN)

h

i j k

l m

B

G Y

Y B

G

on

B

B

B/YB/Y

O RR

B/Y

Br

Br/W

Br

Br/W

]^

Br/W

p

B

p

Sb

B

Br/W Br

L

Br

Sb

BL

Br/W

Br

Y

Sb

L

Br/W

b

c

d

e

(BLACK)

(BLACK)

r

Br

L

G

LBr

B

BrL

GB

BG

GB

t

G/W

L/Y

L/R

R

Sb

R/W

Gy

R/W

Or

R/W

Gy

R/W

Or

a

B

(BLACK)(BLACK)

G/Y

Br

L/R

Br

Br

Br Br

Br

Br

Br

R

R/Y

B

W

R GY/B

B

R/B

R/B B

P

Br

sBG

G

B

B

B

B

Dg

Ch

Ch

Dg

B

YLR/YL/R

(BLACK)

(BLACK)

(BLUE) (BLUE)

Br

(BLACK)(BLACK)

(BLACK)(BLACK)

+V

#2

#1

SS

GND