Yamaha Star XV250C Owner'S Manual Download Page 61

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-25

CAUTION:

ECA10570

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

5. Tighten the locknuts, and then

tighten the axle nut to the specified
torque.

6. Insert a new cotter pin into the axle

nut, and then bend its ends as
shown.

NOTE:

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

WARNING

EWA10700

Always use a new cotter pin for the
axle nut.

7. Adjust the brake pedal free play.

(See page 6-20.)

WARNING

EWA10660

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

1. Axle nut
2. Axle nut cotter pin

3. Chain puller locknut

4. Drive chain slack adjusting nut
5. Alignment marks

Tightening torque:

Axle nut:

104 Nm (10.4 m·kgf, 75 ft·lbf)

1. Cotter pin

U2UJ1GE0.book Page 25 Friday, May 11, 2007 10:23 AM

Summary of Contents for Star XV250C

Page 1: ...2UJ 28199 1G XV250X C OWNER S MANUAL LIT 11626 21 25 ...

Page 2: ...EAU10041 U2UJ1GE0 book Page 1 Friday May 11 2007 10 23 AM ...

Page 3: ...rcycle If you have any questions concerning the operation or maintenance of your motorcycle please consult a Yamaha dealer The design and manufacture of this Yamaha motorcycle fully comply with the emissions standards for clean air applicable at the date of manufacture Yamaha has met these standards without reducing the performance or economy of operation of the motorcycle To maintain these high s...

Page 4: ... consult your Yamaha dealer WARNING EWA10010 PLEASE READ THIS MANUAL AND THE YOU AND YOUR MOTORCYCLE RIDING TIPS BOOKLET CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE DO NOT ATTEMPT TO OPERATE THIS MOTOR CYCLE UNTIL YOU HAVE ATTAINED ADEQUATE KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED Failure to follow W...

Page 5: ... TECHNIQUES REGULAR INSPECTIONS AND CAREFUL MAINTENANCE ALONG WITH GOOD RIDING SKILLS WILL ENSURE THAT YOU SAFELY ENJOY THE CAPABILITIES AND THE RELIABILITY OF THIS MOTORCYCLE Product and specifications are subject to change without notice U2UJ1GE0 book Page 2 Friday May 11 2007 10 23 AM ...

Page 6: ...ration U S A 1st edition April 2007 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in Japan P N LIT 11626 21 25 AFFIX DEALER LABEL HERE U2UJ1GE0 book Page 3 Friday May 11 2007 10 23 AM ...

Page 7: ...aintenance and lubrication chart 6 4 Removing and installing the panel 6 8 Checking the spark plugs 6 8 Canister for California only 6 10 Engine oil and oil filter element 6 10 Cleaning the air filter element 6 13 Carburetor 6 15 Checking the engine idling speed 6 15 Checking the throttle cable free play 6 15 Valve clearance 6 16 Tires 6 16 Spoke wheels 6 18 Accessories and replacement parts 6 18 ...

Page 8: ...le 6 35 Front wheel 6 36 Rear wheel 6 37 Troubleshooting 6 39 Troubleshooting chart 6 40 MOTORCYCLE CARE AND STORAGE 7 1 Matte color caution 7 1 Care 7 1 Storage 7 3 SPECIFICATIONS 8 1 CONSUMER INFORMATION 9 1 Identification numbers 9 1 Reporting safety defects 9 3 Motorcycle noise regulation 9 4 Maintenance record 9 5 YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY 9 ...

Page 9: ...ents have been caused by an automobile driver who did not see the motorcycle Making yourself conspicuous appears to be very effective in reducing the chance of this type of accident Therefore Wear a brightly colored jacket Use extra caution when ap proaching and passing through intersections since intersec tions are the most likely places for motorcycle accidents to oc cur Ride where other motoris...

Page 10: ...ace shield or goggles Wind in your unprotected eyes could contribute to an impairment of vision which could delay seeing a hazard The use of a jacket heavy boots trousers gloves etc is effective in preventing or reducing abrasions or lacerations Never wear loose fitting clothes otherwise they could catch on the control levers footrests or wheels and cause injury or an accident Never touch the engi...

Page 11: ...ution when selecting and installing any ac cessories Keep the following guidelines in mind as well as those provided under Load ing when mounting accessories Never install accessories or carry cargo that would impair the perfor mance of your motorcycle Care fully inspect the accessory before using it to make sure that it does not in any way reduce ground clearance or cornering clearance limit susp...

Page 12: ... off before leaving the motorcycle unattended and remove the key from the main switch When parking the motor cycle note the following The engine and exhaust system may be hot therefore park the motorcycle in a place where pe destrians or children are not like ly 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 ...

Page 13: ...SAFETY INFORMATION 1 5 1 EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle U2UJ1GE0 book Page 5 Friday May 11 2007 10 23 AM ...

Page 14: ...ATION 1 6 1 1 3 2 4 California only 5 California only Cold tire normal pressure should be set as follows 225 2 25 33 200 2 00 29 200 2 00 29 175 1 75 25 3CK 21668 A1 U2UJ1GE0 book Page 6 Friday May 11 2007 10 23 AM ...

Page 15: ... page 3 8 3 Fuel tank page 3 5 4 Battery page 6 30 5 Fuses page 6 32 6 Helmet holder page 3 9 7 Shock absorber assembly spring preload adjusting ring page 3 9 8 Main switch page 3 1 9 Fuel cock page 3 6 10 Shift pedal page 3 4 U2UJ1GE0 book Page 1 Friday May 11 2007 10 23 AM ...

Page 16: ...ider seat page 3 8 4 Air filter element page 6 13 5 Front turn signal position lights page 6 34 6 Brake pedal page 3 4 7 Footrest 8 Rear brake light switch page 6 22 9 Owner s tool kit page 6 1 10 Shock absorber assembly spring preload adjusting ring page 3 9 U2UJ1GE0 book Page 2 Friday May 11 2007 10 23 AM ...

Page 17: ...ever page 3 3 2 Left handlebar switches page 3 2 3 Speedometer unit page 3 2 4 Indicator lights page 3 1 5 Right handlebar switches page 3 2 6 Brake lever page 3 4 7 Throttle grip page 6 15 8 Fuel tank cap page 3 5 U2UJ1GE0 book Page 3 Friday May 11 2007 10 23 AM ...

Page 18: ...e on but all other electrical systems are off The key can be removed The key must be pushed in from the OFF position to be turned to P CAUTION ECA11020 Do not use the parking position for an extended length of time other wise the battery may discharge EAU10980 Indicator lights EAU11040 Turn signal indicator light TURN This indicator light flashes when the turn signal switch is pushed to the left o...

Page 19: ...distance traveled The tripmeter shows the distance traveled since it was last set to zero with the reset knob The tripmeter can be used to estimate the distance that can be traveled with a full tank of fuel This information will en able you to plan future fuel stops EAU12347 Handlebar switches Left Right 1 Odometer 2 Tripmeter 3 Tripmeter reset knob 4 Speedometer 1 Dimmer switch LIGHTS 2 Turn sign...

Page 20: ...tarting the engine Set this switch to OFF to stop the engine in case of an emergen cy such as when the vehicle overturns or when the throttle cable is stuck EAU12690 Start switch START Push this switch to crank the engine with the starter CAUTION ECA10050 See page 5 1 for starting instruc tions prior to starting the engine EAU12820 Clutch lever The clutch lever is located at the left handlebar gri...

Page 21: ...tant mesh transmission equipped on this motorcycle EAU12890 Brake lever The brake lever is located at the right handlebar grip To apply the front brake pull the lever toward the handle bar grip EAU12941 Brake pedal The brake pedal is on the right side of the motorcycle To apply the rear brake press down on the brake pedal 1 Shift pedal 1 Brake lever 1 Brake pedal U2UJ1GE0 book Page 4 Friday May 11...

Page 22: ...nk cap cannot be closed un less the key is in the lock In addition the key cannot be removed if the cap is not properly closed and locked WARNING EWA11090 Make sure that the fuel tank cap is properly closed before riding EAU13211 Fuel Make sure that there is sufficient fuel in the tank Fill the fuel tank to the bottom of the filler tube as shown WARNING EWA10880 Do not overfill the fuel tank oth e...

Page 23: ...ntaining ethanol and that contain ing methanol Gasohol containing ethanol can be used if the ethanol con tent does not exceed 10 Gasohol containing methanol is not recom mended by Yamaha because it can cause damage to the fuel system or ve hicle performance problems EAU13581 Fuel cock This model is equipped with a negative pressure fuel cock The fuel cock sup plies fuel from the tank to the carbur...

Page 24: ...tion the engine can be primed Turn the fuel cock lever to this position when the engine has been al lowed to run out of fuel This sends fuel directly to the carburetor which will make starting easier After the engine has started be sure to turn the lever to ON or RES if you have not refueled yet EAU13630 Starter choke lever Starting a cold engine requires a richer air fuel mixture which is supplie...

Page 25: ...g is locked remove the key and then close the lock cover To unlock the steering 1 Open the steering lock cover and then insert the key 2 Push the key in turn it 1 8 turn counterclockwise so that it moves out and then release it 3 Remove the key and then close the lock cover EAU14220 Rider seat To remove the rider seat Remove the bolts and then pull the rid er seat off To install the rider seat 1 I...

Page 26: ...then remove the key WARNING EWA10160 Never ride with a helmet attached to the helmet holder since the helmet may hit objects causing loss of con trol and possibly an accident EAU14880 Adjusting the shock absorber assemblies Each shock absorber assembly is equipped with a spring preload adjust ing ring CAUTION ECA10100 Never attempt to turn an adjusting mechanism beyond the maximum or minimum setti...

Page 27: ...r foot while holding the vehicle upright NOTE The built in sidestand switch is part of the ignition circuit cut off system which cuts the ignition in certain situations See further down for an explanation of the ignition circuit cut off system WARNING EWA10240 The vehicle must not be ridden with the sidestand down or if the side stand cannot be properly moved up or does not stay up otherwise the s...

Page 28: ...the clutch lever is not pulled It prevents starting when the trans mission is in gear and the clutch le ver is pulled but the sidestand is still down It cuts the running engine when the transmission is in gear and the sid estand is moved down Periodically check the operation of the ignition circuit cut off system according to the following procedure WARNING EWA10250 If a malfunction is noted have ...

Page 29: ...ter 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 system is OK The motorcycle can be ridden This check is most reliable if performed with a warmed up engine The neutral switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer The sidestand switch may be defective The motorcycle ...

Page 30: ...equences Therefore it is very important in addition to a thorough visual inspec tion to check the following points before each ride NOTE Pre operation checks should be made each time the vehicle is used Such an inspection can be accomplished in a very short time and the added safety it assures is more than worth the time involved WARNING EWA11150 If any item in the Pre operation check list is not ...

Page 31: ...necessary Check fluid level in reservoir If necessary add recommended brake fluid to specified level Check hydraulic system for leakage 6 20 6 22 6 23 Rear brake Check operation Lubricate cable if necessary Check pedal free play Adjust if necessary 6 20 6 22 Clutch Check operation Lubricate cable if necessary Check lever free play Adjust if necessary 6 19 Throttle grip Make sure that operation is ...

Page 32: ...hat operation is smooth Lubricate lever pivoting points if necessary 6 27 Sidestand Make sure that operation is smooth Lubricate pivot if necessary 6 28 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened Tighten if necessary Instruments lights signals and switches Check operation Correct if necessary Sidestand switch Check operation of ignition circuit cut off system...

Page 33: ...neutral position The transmission is in gear with the clutch lever pulled and the sid estand up WARNING EWA10290 Before starting the engine check the function of the igni tion circuit cut off system ac cording to the procedure described on page 3 11 Never ride with the sidestand down 1 Turn the fuel cock lever to ON 2 Turn the key to ON and make sure that the engine stop switch is set to RUN 3 Shi...

Page 34: ...tarter choke use and temperatures below 10 C 50 F re quire about 35 seconds with the starter choke turned on then about 2 5 min utes with the starter choke in the half way position EAU16640 Starting a warm engine Follow the same procedure as for start ing a cold engine with the exception that the starter choke is not required when the engine is warm EAU16671 Shifting Shifting gears lets you contro...

Page 35: ... second gear Make sure not to shift the transmission into the neutral posi tion 6 Open the throttle part way and gradually release the clutch lever 7 Follow the same procedure when shifting to the next higher gear NOTE Always shift gears at the recommended shift points EAU16700 To decelerate 1 Apply both the front and the rear brakes to slow the motorcycle 2 Shift the transmission into first gear ...

Page 36: ...ged operation above 1 3 throttle 1000 1600 km 600 1000 mi Avoid prolonged operation above 1 2 throttle CAUTION ECA11281 After 1000 km 600 mi of operation the engine oil must be changed and the oil filter cartridge or element re placed 1600 km 1000 mi and beyond The vehicle can now be operated nor mally CAUTION ECA10270 If any engine trouble should occur during the engine break in period immediatel...

Page 37: ... RELATED TO EMISSIONS CONTROL THESE CONTROLS NOT ONLY FUNCTION TO ENSURE CLEANER AIR BUT ARE ALSO VITAL TO PROPER EN GINE OPERATION AND MAXIMUM PERFORMANCE IN THE FOLLOW ING PERIODIC MAINTENANCE CHARTS THE SERVICES RELATED TO EMISSIONS CONTROL ARE GROUPED SEPARATELY THESE SERVICES REQUIRE SPECIALIZED DATA KNOWLEDGE AND EQUIP MENT YAMAHA DEALERS ARE TRAINED AND EQUIPPED TO PER FORM THESE PARTICULAR...

Page 38: ...WARNING EWA10340 Modifications not approved by Yamaha may cause loss of perfor mance excessive emissions and render the vehicle unsafe for use Consult a Yamaha dealer before at tempting any changes U2UJ1GE0 book Page 2 Friday May 11 2007 10 23 AM ...

Page 39: ...l line Check fuel and vacuum hoses for cracks or damage Replace if necessary 2 Spark plugs Check condition Adjust gap and clean Replace every 7000 mi 11000 km or 12 months Replace Replace 3 Valve clearance Check and adjust valve clearance when engine is cold 4 Crankcase breather system Check breather hose for cracks or damage Replace if necessary 5 Idle speed Check and adjust engine idle speed 6 E...

Page 40: ... and breath er hose for proper operation 3 Clutch Check operation Adjust or replace cable 4 Front brake Check operation fluid level and for fluid leakage Adjust brake lever free play and replace brake pads if necessary 5 Rear brake Check operation Adjust brake pedal free play and replace brake shoes if necessary 6 Brake hose Check for cracks or damage Replace Every 4 years 7 Wheels Check runout sp...

Page 41: ...seness Moderately repack with lithium soap based grease every 10000 mi 16000 km or 18 months Repack 13 Chassis fasteners Check all chassis fitting and fas teners Correct if necessary 14 Brake lever pivot shaft Apply silicone grease lightly 15 Brake pedal pivot shaft Apply lithium soap based grease all purpose grease lightly 16 Clutch lever pivot shaft Apply lithium soap based grease all purpose gr...

Page 42: ...ber as semblies Check operation and for oil leak age Replace if necessary 22 Engine oil Change warm engine before draining 23 Engine oil filter ele ment Replace 24 Front and rear brake switches Check operation 25 Control and meter cables Apply Yamaha chain and cable lube or engine oil 10W 30 thor oughly No ITEM ROUTINE INITIAL ODOMETER READINGS 600 mi 1000 km or 1 month 4000 mi 6000 km or 6 months...

Page 43: ...fluid level regularly and fill as required Replace the oil seals on the inner parts of the master cylinder and caliper cylinder every two years Replace the brake hoses every four years or if cracked or damaged 26 Throttle grip hous ing and cable Check operation and free play Adjust the throttle cable free play if necessary Lubricate the throttle grip housing and cable 27 Lights signals and switche...

Page 44: ...e panel and then push the rear of the panel in EAU19544 Checking the spark plugs The spark plugs are important engine components which are easy to check Since heat and deposits will cause any spark plug to slowly erode the spark plugs should be removed and checked in accordance with the periodic mainte nance and lubrication chart In addition the condition of the spark plugs can re veal the conditi...

Page 45: ... spark plug 1 Measure the spark plug gap with a wire thickness gauge and if nec essary adjust the gap to specifica tion 2 Clean the surface of the spark plug gasket and its mating surface and then wipe off any grime from the spark plug threads 3 Install the spark plug with the spark plug wrench and then tight en it to the specified torque NOTE If a torque wrench is not available when installing a ...

Page 46: ...ride In addition the oil must be changed and the oil filter ele ment replaced at the intervals specified in the periodic maintenance and lubri cation chart To check the engine oil level 1 Place the vehicle on a level sur face and hold it in an upright posi tion NOTE Make sure that the vehicle is positioned straight up when checking the oil level A slight tilt to the side can result in a false read...

Page 47: ...minutes and then turn it off 2 Place an oil pan under the engine to collect the used oil 3 Remove the engine oil filler cap and drain bolt to drain the oil from the crankcase NOTE Skip steps 4 6 if the oil filter element is not being replaced 4 Remove the oil filter element cover by removing the screws 5 Remove and replace the oil filter element and O ring 1 Engine oil level check window 2 Maximum...

Page 48: ...a diesel speci fication of CD or oils of a high er quality than specified In addition do not use oils labeled ENERGY CONSERVING II or higher Make sure that no foreign mate rial enters the crankcase 9 Start the engine and then let it idle for several minutes while checking it for oil leakage If oil is leaking im mediately turn the engine off and check for the cause 10 Turn the engine off and then c...

Page 49: ...et or dusty areas 1 Remove the bolts and loosen the air filter case joint clamp screw 2 Disconnect the hoses from the air filter case and then remove the air filter case 3 Remove the air filter case cover by removing the screws 4 Remove the air filter element by removing the wing nut 1 Bolt 1 Air filter case joint clamp screw 2 Air filter case cover 3 Air filter case 1 Hose 2 Air filter case 1 Scr...

Page 50: ... not dripping 7 Pull the sponge material over the air filter element frame 8 Insert the element into the air filter case and then tighten the wing nut CAUTION ECA10480 Make sure that the air filter ele ment is properly seated in the air filter case The engine should never be op erated without the air filter ele ment installed otherwise the piston s and or cylinder s may become excessively worn 9 I...

Page 51: ...sted by a Yamaha dealer at the in tervals specified in the periodic mainte nance and lubrication chart Start the engine and warm it up for sev eral minutes at 1000 2000 r min while occasionally revving it to 4000 5000 r min NOTE The engine is warm when it quickly re sponds to the throttle EAU21382 Checking the throttle cable free play The throttle cable free play should mea sure 3 0 5 0 mm 0 12 0 ...

Page 52: ...tire air pressure must be ad justed in accordance with the riding speed and with the total weight of rider passenger car go and accessories approved for this model WARNING EWA10510 Proper loading of your vehicle is im portant for several characteristics of your vehicle such as handling braking performance and safety Do not carry loosely packed items that can shift Securely pack your heavi est item...

Page 53: ...place the tire immediately The replacement of all wheel and brake related parts includ ing the tires should be left to a Yamaha dealer who has the necessary professional knowl edge and experience It is not recommended to patch a punctured tube If unavoid able however patch the tube very carefully and replace it as soon as possible with a high quality product Tire information This motorcycle is equ...

Page 54: ...irst be broken in for it to develop its optimal characteris tics EAU22011 Accessories and replacement parts WARNING EWA10621 This vehicle is not designed to pull a trailer or to be attached to a sidecar The accessories or replacement parts you choose for your vehicle should be designed specifically for this model and they must be se curely mounted to maintain the in herent stability of the origina...

Page 55: ...lutch lever free play could be obtained as described above tighten the locknut and skip the rest of the procedure otherwise proceed as follows 3 Fully turn the adjusting bolt at the clutch lever in direction a to loos en the clutch cable 4 Loosen the locknut at the crank case 5 To increase the clutch lever free play turn the adjusting nut in direc tion a To decrease the clutch le ver free play tur...

Page 56: ...n indicate the presence of air in the hydraulic system If there is air in the hy draulic system have a Yamaha dealer bleed the system before operating the motorcycle Air in the hydraulic system will dimin ish the braking performance which may result in loss of con trol and an accident EAU22201 Adjusting the brake pedal po sition and free play WARNING EWA10670 It is advisable to have a Yamaha deale...

Page 57: ...brake pedal free play and if neces sary adjust it as follows To increase the brake pedal free play turn the adjusting nut at the brake rod in direction a To decrease the brake pedal free play turn the adjusting nut in direction b WARNING EWA10680 After adjusting the drive chain slack or removing and installing the rear wheel always check the brake pedal free play If proper adjustment cannot be obt...

Page 58: ... Each front brake pad is provided with a wear indicator groove which allows you to check the brake pad wear with out having to disassemble the brake To check the brake pad wear check the wear indicator groove If a brake pad has worn to the point that the wear indicator groove has almost disap peared have a Yamaha dealer replace the brake pads as a set EAU22540 Rear brake shoes The rear brake is pr...

Page 59: ...rmful chemical reaction and lead to poor braking performance Be careful that water does not en ter the master cylinder when refill ing Water will significantly lower the boiling point of the fluid and may result in vapor lock Brake fluid may deteriorate paint ed surfaces or plastic parts Al ways clean up spilled fluid immediately As the brake pads wear it is nor mal for the brake fluid level to gr...

Page 60: ...ect adjust it as follows EAU22860 To adjust the drive chain slack 1 Loosen the brake pedal free play adjusting nut 2 Remove the cotter pin from the axle nut and then loosen the axle nut 3 Loosen the chain puller locknut at each end of the swingarm 4 To tighten the drive chain turn the adjusting nut at each end of the swingarm in direction a To loos en the drive chain turn the adjust ing nut at eac...

Page 61: ...d then bend its ends as shown NOTE Make sure that two notches in the axle nut are aligned with the hole through the wheel axle otherwise further tight en the axle nut until they are WARNING EWA10700 Always use a new cotter pin for the axle nut 7 Adjust the brake pedal free play See page 6 20 WARNING EWA10660 After adjusting the brake pedal free play check the operation of the brake light 1 Axle nu...

Page 62: ...Chain and Cable Lube or a high quality spray type drive chain lubricant on both sides and on the middle of the chain making sure that all side plates and rollers have been sufficiently oiled EAU23091 Checking and lubricating the cables The operation of all control cables and the condition of the cables should be checked before each ride and the ca bles and cable ends should be lubricat ed if neces...

Page 63: ...ration of the brake and shift pedals should be checked before each ride and the pedal pivots should be lu bricated if necessary EAU23141 Checking and lubricating the brake and clutch levers The operation of the brake and clutch levers should be checked before each ride and the lever pivots should be lu bricated if necessary Recommended lubricant Lithium soap based grease all pur pose grease Recomm...

Page 64: ...ont fork The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic main tenance and lubrication chart To check the condition WARNING EWA10750 Securely support the vehicle so that there is no danger of it falling over Check the inner tubes for scratches damage and excessive oil leakage To check the operation 1 Place the vehicle on a level su...

Page 65: ...g must be checked as fol lows at the intervals specified in the pe riodic maintenance and lubrication chart 1 Place a stand under the engine to raise the front wheel off the ground WARNING EWA10750 Securely support the vehicle so that there is no danger of it falling over 2 Hold the lower ends of the front fork legs and try to move them for ward and backward If any free play can be felt have a Yam...

Page 66: ...rolyte level 1 Place the vehicle on a level sur face and hold it in an upright posi tion NOTE Make sure that the vehicle is positioned straight up when checking the electro lyte level 2 Check the electrolyte level in the battery NOTE The electrolyte should be between the minimum and maximum level marks 3 If the electrolyte is at or below the minimum level mark add distilled water to raise it to th...

Page 67: ...the battery lead connections and correct the breather hose routing To store the battery 1 If the motorcycle will not be used for more than one month remove the battery fully charge it and then place it in a cool dry place 2 If the battery will be stored for more than two months check the specif ic gravity of the electrolyte at least once a month and fully charge the battery whenever necessary 3 Fu...

Page 68: ...amage to the electrical system and possibly a fire 3 Turn the key to ON and turn on the electrical circuit in question to check if the device operates 4 If the fuse immediately blows again have a Yamaha dealer check the electrical system EAU23780 Replacing the headlight bulb This model is equipped with a quartz bulb headlight If the headlight bulb burns out replace it as follows 1 Remove the headl...

Page 69: ...glass part of the headlight bulb to keep it free from oil otherwise the transparency of the glass the luminosity of the bulb and the bulb life will be adversely af fected Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with al cohol or thinner 5 Install the headlight bulb cover and then connect the coupler 6 Install the headlight unit by install ing the...

Page 70: ... the socket push it in and then turn it clock wise until it stops 4 Install the lens by installing the screws CAUTION ECA10680 Do not overtighten the screws oth erwise the lens may break EAU24210 Replacing a turn signal light bulb 1 Remove the turn signal lens by re moving the screws 2 Remove the defective bulb by pushing it in and turning it counter clockwise 1 Screw 1 Tail brake light bulb 1 Scr...

Page 71: ... and level position before starting any maintenance A strong wooden box can be placed under the engine for added stability To service the front wheel 1 Stabilize the rear of the motorcycle by using a motorcycle stand or if an additional motorcycle stand is not available by placing a jack un der the frame in front of the rear wheel 2 Raise the front wheel off the ground by using a motorcycle stand ...

Page 72: ...out and then remove the wheel CAUTION ECA11070 Do not apply the brake after the wheel has been removed together with the brake disc otherwise the brake pads will be forced shut EAU24932 To install the front wheel 1 Install the speedometer gear unit into the wheel hub so that the pro jections mesh with the slots 2 Lift the wheel up between the fork legs NOTE Make sure that there is enough space bet...

Page 73: ...speedometer cable EAU25080 Rear wheel EAU32750 To remove the rear wheel WARNING EWA10820 It is advisable to have a Yamaha dealer service the wheel Securely support the motor cycle so that there is no danger of it falling over 1 Remove the axle nut cotter pin 2 Loosen the chain puller locknut and the drive chain slack adjusting nut on both ends of the swingarm 1 Speedometer gear unit 2 Retainer 3 S...

Page 74: ...ar sprocket and then install the wheel by inserting the wheel axle from the right hand side 2 Install the brake rod onto the brake camshaft lever and then install the brake pedal free play adjusting nut onto the brake rod 3 Connect the brake torque rod to the brake shoe plate by installing the bolt and nut and then tighten the bolt to the specified torque 4 Adjust the drive chain slack See page 6 ...

Page 75: ...gnition systems for example can cause poor starting and loss of power The following troubleshooting chart represents a quick and easy procedure for checking these vital systems your self However should your motorcycle require any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools experience and know how to service the motorcycle properly Use only genuine Yamaha re...

Page 76: ... spark plugs and check the electrodes 3 Ignition Wet 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 operate the electric starter Operate the electric starter 4 Battery The engine turns over quickly The engine turns over slowly The battery is goo...

Page 77: ...muffler outlets with plas tic bags after the engine has cooled down 2 Make sure that all caps and covers as well as all electrical couplers and connectors including the spark plug caps are tightly in stalled 3 Remove extremely stubborn dirt like oil burnt onto the crankcase with a degreasing agent and a brush but never apply such prod ucts onto seals gaskets sprock ets the drive chain and wheel ax...

Page 78: ...or hard to reach areas Stubborn dirt and insects will come off more easily if the area is covered with a wet cloth for a few minutes before cleaning After riding in the rain near the sea or on salt sprayed roads Since sea salt or salt sprayed on roads during winter are extremely corrosive in combination with water carry out the following steps after each ride in the rain near the sea or on salt sp...

Page 79: ... oil and wax spar ingly and make sure to wipe off any excess Never apply oil or wax to any rubber and plastic parts but treat them with a suitable care product Avoid using abrasive polishing compounds as they will wear away the paint NOTE Consult a Yamaha dealer for advice on what products to use EAU32640 Storage Short term Always store your motorcycle in a cool dry place and if necessary protect ...

Page 80: ...m the spark plugs and then install the spark plugs and the spark plug caps WARNING EWA10950 To prevent damage or injury from sparking make sure to ground the spark plug electrodes while turning the engine over 6 Lubricate all control cables and the pivoting points of all levers and pedals as well as of the side stand centerstand 7 Check and if necessary correct the tire air pressure and then lift ...

Page 81: ... 23 Imp qt With oil filter element replacement 1 60 L 1 69 US qt 1 41 Imp qt Air filter Air filter element Wet element Fuel Recommended fuel Unleaded gasoline only Fuel tank capacity XV250X 9 5 L 2 51 US gal 2 09 Imp gal XV250XC 9 2 L 2 43 US gal 2 02 Imp gal Fuel reserve amount 2 6 L 0 69 US gal 0 57 Imp gal Carburetor Manufacturer MIKUNI Type quantity BDS26 x 1 Spark plug s Manufacturer model NG...

Page 82: ... XV250XC 90 195 kg 198 430 lb Front 200 kPa 29 psi 2 00 kgf cm Rear 225 kPa 33 psi 2 25 kgf cm Front wheel Wheel type Spoke wheel Rim size 18x1 60 Rear wheel Wheel type Spoke wheel Rim size 15M C x MT2 75 Front brake Type Single disc brake Operation Right hand operation Recommended fluid DOT 4 Rear brake Type Drum brake Operation Right foot operation Front suspension Type Telescopic fork Spring sh...

Page 83: ...urn signal position light 12 V 27 W 8 0 W 2 Rear turn signal light 12 V 27 0 W 2 Meter lighting 14 V 3 0 W 1 Neutral indicator light 14 V 3 0 W 1 High beam indicator light 12 V 1 7 W 1 Turn signal indicator light 14 V 3 0 W 1 Fuses Main fuse 20 0 A Signaling system fuse 10 0 A U2UJ1GE0 book Page 3 Friday May 11 2007 10 23 AM ...

Page 84: ...dentification number The key identification number is stamped into the key Record this num ber in the space provided and use it for reference when ordering a new key EAU26400 Vehicle identification number The vehicle identification number is stamped into the steering head pipe Record this number in the space pro vided NOTE The vehicle identification number is used to identify your motorcycle and m...

Page 85: ...bel is affixed to the frame under the rider seat See page 3 8 Record the information on this label in the space provided This information will be needed when ordering spare parts from a Yamaha dealer 1 Model label U2UJ1GE0 book Page 2 Friday May 11 2007 10 23 AM ...

Page 86: ... and if it finds that a safety defect exists in a group of vehicles it may order a recall and remedy campaign However NHTSA cannot become involved in individual problems between you your dealer or Yamaha Motor Corporation U S A To contact NHTSA you may call the Vehicle Safety Hotline toll free at 1 888 327 4236 TTY 1 800 424 9153 go to http www safercar gov or write to Administrator NHTSA 400 Seve...

Page 87: ...icle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW These acts include tampering with the following systems i e modification removal etc E...

Page 88: ...minder that maintenance work is required It is not acceptable proof of maintenance work Maintenance interval Date of service Mileage Servicing dealer name and address Remarks 600 mi 1000 km or 1 month 4000 mi 6000 km or 6 months 7000 mi 11000 km or 12 months 10000 mi 16000 km or 18 months 13000 mi 21000 km or 24 months 16000 mi 26000 km or 30 months 19000 mi 31000 km or 36 months 22000 mi 36000 km...

Page 89: ...FORMATION 9 6 9 28000 mi 46000 km or 54 months 31000 mi 51000 km or 60 months Maintenance interval Date of service Mileage Servicing dealer name and address Remarks U2UJ1GE0 book Page 6 Friday May 11 2007 10 23 AM ...

Page 90: ...r warranty by an authorized Yamaha motorcycle dealer In order for this warranty to remain in effect this inspection and registration must take place within ten 10 days after transfer An inspection and registration fee will be charged for this service EMISSION CONTROL SYSTEM WARRANTY Yamaha Motor Corporation U S A also warrants to the ultimate purchaser and each subsequent purchaser of each Yamaha ...

Page 91: ...y later date Each Yamaha motorcycle dealer is held responsible for his setup service and warranty repair work Is the warranty transferable to second owners Yes The remainder of the existing warranty can be transferred upon request The unit has to be inspected and re registered by an authorized Yamaha motorcycle dealer for the policy to remain effective CUSTOMER SERVICE If your machine requires war...

Page 92: ...ed repairs There s no deductible to pay and repairs aren t pro rated You don t have any out of pocket expenses for covered repairs In addition Travel and Recreation Interruption Protection TRIP is included at no extra cost TRIP gives you up to 150 reimbursement per occurrence for any reasonable expenses you incur because your Yamaha needs covered service replacement vehicle rental emergency towing...

Page 93: ...ked protection even after your Yamaha Limited Warranty expires A special note If visiting your dealer isn t convenient contact Yamaha with your Primary ID number your frame number We ll be happy to help you get the Y E S coverage you need Yamaha Service Marketing P O Box 6555 Cypress CA 90630 1 866 YES EXTD 1 866 937 3983 U2UJ1GE0 book Page 10 Friday May 11 2007 10 23 AM ...

Page 94: ...ation numbers 9 1 Ignition circuit cut off system 3 11 Indicator lights 3 1 K Key identification number 9 1 L Labels location of 1 5 M Main switch 3 1 Maintenance and lubrication periodic 6 4 Maintenance emission control system 6 3 Maintenance periodic 6 1 Maintenance record 9 5 Matte color caution 7 1 Model label 9 2 N Neutral indicator light 3 1 Noise regulation 9 4 P Panel removing and installi...

Page 95: ...replacing 6 34 Turn signal switch 3 3 V Valve clearance 6 16 Vehicle identification number 9 1 W Warranty extended 9 9 Warranty limited 9 7 Wheel bearings checking 6 30 Wheel front 6 36 Wheel rear 6 37 Wheels 6 18 U2UJ1GE0 book Page 2 Friday May 11 2007 10 23 AM ...

Page 96: ...A5 yoko_Blank fm Page 1 Tuesday April 8 2003 11 43 AM ...

Page 97: ...A5 yoko_Blank fm Page 1 Tuesday April 8 2003 11 43 AM ...

Page 98: ...PRINTED IN JAPAN 2007 05 0 7 1 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD ...

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Yamaha Star XV250C, Owner'S Manual

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