Yamaha Star XV250X Owner'S Manual Download | Manualshive

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-19

6

EAU22041

Adjusting the clutch lever free
play

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

1. Loosen the locknut at the clutch le-

ver.

2. To increase the clutch lever free

play, turn the adjusting bolt in di-
rection (a). To decrease the clutch
lever free play, turn the adjusting
bolt in direction (b).

NOTE:

If the specified clutch lever free play
could be obtained as described above,
tighten the locknut and skip the rest of
the procedure, otherwise proceed as
follows.

3. Fully turn the adjusting bolt at the

clutch lever in direction (a) to 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, turn the adjusting nut
in direction (b).

6. Tighten the locknut at the clutch le-

ver and the crankcase.

1. Locknut

2. Clutch lever free play adjusting bolt
3. Clutch lever free play

1. Locknut

2. Clutch lever free play adjusting nut (crank-

case)

U2UJ1GE0.book Page 19 Friday, May 11, 2007 10:23 AM

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Summary of Contents for Star XV250X

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: ...cycle 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 emi...

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 OPER...

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 specification...

Page 6: ...ation 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...

Page 7: ...intenance 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...

Page 8: ...e 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 INFORMA...

Page 9: ...nts 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 br...

Page 10: ...ce 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 pre...

Page 11: ...tion 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 th...

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 motorcy...

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: ...TION 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...

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...

Page 16: ...der 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 Shoc...

Page 17: ...ver 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...

Page 18: ...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 l...

Page 19: ...istance 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...

Page 20: ...arting 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...

Page 21: ...ant 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 EAU1294...

Page 22: ...k 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 c...

Page 23: ...taining 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...

Page 24: ...ion 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 A...

Page 25: ...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 mov...

Page 26: ...hen 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 sho...

Page 27: ...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 explanat...

Page 28: ...he 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...

Page 29: ...er 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 relia...

Page 30: ...quences 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 use...

Page 31: ...ecessary 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 nece...

Page 32: ...at 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...

Page 33: ...eutral 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...

Page 34: ...arter 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...

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...

Page 36: ...ed 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 filt...

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...

Page 38: ...ARNING 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 U2U...

Page 39: ...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 clear...

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...

Page 41: ...eness 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 piv...

Page 42: ...er 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 o...

Page 43: ...luid 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...

Page 44: ...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 plu...

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...

Page 46: ...ide 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 veh...

Page 47: ...inutes 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...

Page 48: ...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 S...

Page 49: ...t 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 co...

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...

Page 51: ...ted 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...

Page 52: ...ire 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 yo...

Page 53: ...lace 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...

Page 54: ...rst 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 sideca...

Page 55: ...utch 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 dir...

Page 56: ...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 di...

Page 57: ...rake 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...

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...

Page 59: ...mful 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...

Page 60: ...ct 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 ch...

Page 61: ...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 Al...

Page 62: ...hain 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 C...

Page 63: ...ation 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 operati...

Page 64: ...nt 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 S...

Page 65: ...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 Sec...

Page 66: ...olyte 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 elect...

Page 67: ...he 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...

Page 68: ...mage 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 Yamah...

Page 69: ...lass 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...

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 Repla...

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 m...

Page 72: ...ut 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...

Page 73: ...peedometer 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 d...

Page 74: ...r 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 nu...

Page 75: ...nition 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...

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...

Page 77: ...uffler 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 s...

Page 78: ...r 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 spr...

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...

Page 80: ...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 eng...

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...

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...

Page 83: ...rn 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 indi...

Page 84: ...entification 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 num...

Page 85: ...el 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...

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 Yama...

Page 87: ...cle 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 o...

Page 88: ...inder 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...

Page 89: ...ORMATION 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 2...

Page 90: ...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...

Page 91: ...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 ca...

Page 92: ...d 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 incl...

Page 93: ...ed 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 hel...

Page 94: ...tion 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 Maintenan...

Page 95: ...eplacing 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...

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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