Yamaha Star XV250Z Owner'S Manual Download Page 71

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PERIODIC MAINTENANCE AND ADJUSTMENT

7-36

3. Lift the front wheel off the ground

according to the procedure on
page 7-35.

4. Pull the wheel axle out, and then

remove the wheel.

NOTICE:

not apply the brake after the
wheel has been removed to-
gether with the brake disc, oth-
erwise the brake pads will be
forced shut.

[ECA11071]

EAU24933

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.

TIP

Make sure that there is enough space
between the brake pads before insert-
ing the brake disc and that the slot in
the speedometer gear unit fits over the
retainer on the fork leg.

3. Insert the wheel axle.
4. Lower the front wheel so that it is

on the ground, and then put the
sidestand down.

5. Tighten the wheel axle to the spec-

ified torque.

6. Tighten the front wheel axle pinch

bolt to the specified torque.

1. Wheel axle
2. Front wheel axle pinch bolt

1. Speedometer gear unit

1. Speedometer gear unit
2. Retainer

3. Speedometer cable

Tightening torque:

Wheel axle:

59 Nm (5.9 m·kgf, 43 ft·lbf)

Tightening torque:

Front wheel axle pinch bolt:

20 Nm (2.0 m·kgf, 14 ft·lbf)

U46B11E0.book Page 36 Wednesday, May 13, 2009 8:55 AM

Summary of Contents for Star XV250Z

Page 1: ...DIC183 46B 28199 11 XV250Z C OWNER S MANUAL Read this manual carefully before operating this vehicle LIT 11626 23 21 ...

Page 2: ...EAU10042 Read this manual carefully before operating this vehicle This manual should stay with this vehicle if it is sold U46B11E0 book Page 1 Wednesday May 13 2009 8 55 AM ...

Page 3: ...ntain these high standards it is important that you and your Yamaha dealer pay close attention to the recommended maintenance schedules and operating instructions contained within this manual Yamaha continually seeks advancements in product design and quality Therefore while this manual contains the most cur rent product information available at the time of printing there may be minor discrepancie...

Page 4: ...ey all safety messages that follow this symbol to avoid possible injury or death A WARNING indicates a hazardous situation which if not avoided could result in death or serious injury A NOTICE indicates special precautions that must be taken to avoid damage to the vehicle or other property A TIP provides key information to make procedures easier or clearer WARNING NOTICE TIP U46B11E0 book Page 1 W...

Page 5: ...Motor Corporation U S A 1st edition April 2009 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 23 21 U46B11E0 book Page 2 Wednesday May 13 2009 8 55 AM ...

Page 6: ...art 7 4 Removing and installing the panel 7 8 Checking the spark plugs 7 8 Canister for California only 7 10 Engine oil and oil filter element 7 10 Cleaning the air filter element 7 13 Carburetor 7 15 Checking the engine idling speed 7 15 Checking the throttle cable free play 7 15 Valve clearance 7 16 Tires 7 16 Spoke wheels 7 18 Adjusting the clutch lever free play 7 18 Adjusting the brake lever ...

Page 7: ...eel 7 37 Troubleshooting 7 39 Troubleshooting chart 7 40 MOTORCYCLE CARE AND STORAGE 8 1 Matte color caution 8 1 Care 8 1 Storage 8 3 SPECIFICATIONS 9 1 CONSUMER INFORMATION 10 1 Identification numbers 10 1 Reporting safety defects 10 3 Motorcycle noise regulation 10 4 Maintenance record 10 5 YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY 10 7 YAMAHA EXTENDED SERVICE ...

Page 8: ...r vehicle They contain important information for safe and proper operation of your vehicle Never remove any labels from your vehicle If a label becomes difficult to read or comes off a replacement label is available from your Yamaha dealer U46B11E0 book Page 1 Wednesday May 13 2009 8 55 AM ...

Page 9: ...1 2 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 NOTICE 10D 2815N 00 U46B11E0 book Page 2 Wednesday May 13 2009 8 55 AM ...

Page 10: ...assenger The failure of motorists to detect and recognize motorcycles in traf fic is the predominating cause of automobile motorcycle accidents Many accidents have been caused by an automobile driver who did not see the motorcycle Making yourself conspicuous appears to be very effective in reducing the chance of this type of accident Therefore Wear a brightly colored jacket Use extra caution when ...

Page 11: ...d contribute to an impairment of vision that could delay seeing a hazard The use of a jacket heavy boots trousers gloves etc is effective in preventing or reducing abrasions or lacerations Never wear loose fitting clothes otherwise they could catch on the control levers footrests or wheels and cause injury or an accident Always wear protective clothing that covers your legs ankles and feet The eng...

Page 12: ...s evenly as possi ble on both sides of the motorcycle to minimize imbalance or instabili ty Shifting weights can create a sud den imbalance Make sure that ac cessories and cargo are securely attached to the motorcycle before riding Check accessory mounts and cargo restraints frequently Properly adjust the suspension for your load suspension ad justable models only and check the condition and pres ...

Page 13: ...ork area can create instability due to improper weight distribution or aerody namic changes If accessories are added to the handlebar or front fork area they must be as lightweight as possible and should be kept to a minimum Bulky or large accessories may seriously affect the stability of the motorcycle due to aerody namic effects Wind may at tempt to lift the motorcycle or the motorcycle may beco...

Page 14: ...page 4 8 3 Fuel tank page 4 5 4 Battery page 7 30 5 Fuses page 7 31 6 Helmet holder page 4 9 7 Shock absorber assembly spring preload adjusting ring page 4 10 8 Main switch page 4 1 9 Fuel cock page 4 7 10 Shift pedal page 4 4 U46B11E0 book Page 1 Wednesday May 13 2009 8 55 AM ...

Page 15: ...er seat page 4 9 4 Air filter element page 7 13 5 Front turn signal position lights page 7 34 6 Brake pedal page 4 4 7 Footrest 8 Rear brake light switch page 7 21 9 Owner s tool kit page 7 2 10 Shock absorber assembly spring preload adjusting ring page 4 10 U46B11E0 book Page 2 Wednesday May 13 2009 8 55 AM ...

Page 16: ...ver page 4 3 2 Left handlebar switches page 4 2 3 Speedometer unit page 4 2 4 Indicator lights page 4 1 5 Right handlebar switches page 4 2 6 Brake lever page 4 4 7 Throttle grip page 7 15 8 Fuel tank cap page 4 5 U46B11E0 book Page 3 Wednesday May 13 2009 8 55 AM ...

Page 17: ... loss of con trol or an accident EAU10810 P Parking The taillight and position lights are 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 NOTICE ECA11020 Do not use the parking position for an extended length of time other wise the battery may discharge EAU10981 Indicator lights EAU11040 Turn signal indicator ligh...

Page 18: ...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 fuel This information will en able you to plan future fuel stops EAU12348 Handlebar switches Left Right 1 Odometer 2 Tripmeter 3 Tripmeter reset knob 4 Speedometer 1 Dimmer switch LIGHTS 2 Turn signa...

Page 19: ...efore starting 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 EAU12691 Start switch START Push this switch to crank the engine with the starter See page 6 1 for start ing instructions prior to starting the en gine EAU12820 Clutch lever The clutch lever is located at the left handlebar grip To dise...

Page 20: ...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 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 U46B11E0 book Page 4 Wednesday May ...

Page 21: ...ing fuel Leaking fuel is a fire hazard EAU13212 Fuel Make sure there is sufficient gasoline in the tank WARNING EWA10881 Gasoline and gasoline vapors are extremely flammable To avoid fires and explosions and to reduce the risk of injury when refueling follow these instructions 1 Before refueling turn off the en gine and be sure that no one is sit ting on the vehicle Never refuel while smoking or w...

Page 22: ...ves and piston rings as well as to the exhaust system Your Yamaha engine has been de signed to use regular unleaded gaso line with a pump octane number R M 2 of 86 or higher or a research octane number of 91 or higher If knocking or pinging occurs use a gasoline of a different brand or premi um unleaded fuel Use of unleaded fuel will extend spark plug life and reduce maintenance costs Gasohol Ther...

Page 23: ...kly turn the fuel cock lever to this position if you run out of fuel while riding otherwise the engine may stall and will have to be primed see PRI After turning the fuel cock lever to RES refuel as soon as possible and be sure to turn the fuel cock lever back to ON PRI This indicates prime With the fuel cock lever in this position the engine can be primed Turn the fuel cock lever to this position...

Page 24: ...n the steering lock cover and then insert the key 3 Turn the key 1 8 turn counterclock wise push it in while turning the handlebar slightly to the left and then turn the key 1 8 turn clock wise 4 Check that the steering 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 counterclock...

Page 25: ...IP Make sure that the rider seat is properly secured before riding EAU14282 Helmet holder To open the helmet holder insert the key into the lock and then turn the key as shown To lock the helmet holder place it in the original position and then remove the key WARNING Never ride with a helmet attached to the helmet hold er since the helmet may hit objects causing loss of control and possibly an acc...

Page 26: ...shock absorber EAU15303 Sidestand The sidestand is located on the left side of the frame Raise the sidestand or lower it with your foot while holding the vehicle upright TIP The built in sidestand switch is part of the ignition circuit cut off system which cuts the ignition in certain situations See page 4 11 for an explanation of the ignition circuit cut off system WARNING EWA10240 The vehicle mu...

Page 27: ...ns mission is in gear and the side stand is up but 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 procedu...

Page 28: ...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 The neutral switch may not be working correctly The motorcycle should not be ridden until checked by a Yamaha dealer The sidestand switch may not be working correctly The motorcycle should not be ridden until checked by a Yamaha dealer The clutch swi...

Page 29: ...efore using this vehicle check the following points ITEM CHECKS PAGE Fuel Check fuel level in fuel tank Refuel if necessary Check fuel line for leakage 4 5 Engine oil Check oil level in engine If necessary add recommended oil to specified level Check vehicle for oil leakage 7 10 Front brake Check operation If soft or spongy have Yamaha dealer bleed hydraulic system Check lever free play Adjust if ...

Page 30: ...n and tread depth Check air pressure Correct if necessary 7 16 7 18 Brake and shift pedals Make sure that operation is smooth Lubricate pedal pivoting points if necessary 7 26 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 7 27 Sidestand Make sure that operation is smooth Lubricate pivot if necessary 7 28 Chassis fasteners Make sure that all...

Page 31: ...FOR YOUR SAFETY PRE OPERATION CHECKS 5 3 5 Battery Check fluid level Fill with distilled water if necessary 7 30 ITEM CHECKS PAGE U46B11E0 book Page 3 Wednesday May 13 2009 8 55 AM ...

Page 32: ...ha dealer to check the electrical circuit 4 Turn the starter choke on and completely close the throttle See page 4 8 5 Start the engine by pushing the start switch If the engine fails to start release the start switch wait a few sec onds and then try again Each starting attempt should be as short as possible to preserve the bat tery Do not crank the engine more than 10 seconds on any one at tempt ...

Page 33: ...not required when the engine is warm EAU16671 Shifting Shifting gears lets you control the amount of engine power available for starting off accelerating climbing hills etc The gear positions are shown in the il lustration TIP To shift the transmission into the neu tral position press the shift pedal down repeatedly until it reaches the end of its travel and then slightly raise it 1 Shift pedal 2 ...

Page 34: ...ear 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 TIP When shifting gears in normal operat ing conditions use the recommended shift points EAU16700 To decelerate 1 Apply both the front and the rear brakes to slow the motorcycle 2 Shift the trans...

Page 35: ...eration the engine oil must be changed and the oil filter car tridge or element replaced ECA11282 1000 1600 km 600 1000 mi Avoid prolonged operation above 1 2 throttle 1600 km 1000 mi and beyond The vehicle can now be operated nor mally NOTICE ECA10270 If any engine trouble should occur during the engine break in period immediately have a Yamaha dealer check the vehicle EAU17201 Parking When parki...

Page 36: ...unning engine has moving parts that can catch on body parts or clothing and electrical parts that can cause shocks or fires Running the engine while ser vicing can lead to eye injury burns fire or carbon monoxide poisoning possibly leading to death See page 2 1 for more in formation about carbon monox ide EAU17302 Emission controls not only function to ensure cleaner air but are also vital to prop...

Page 37: ...owner s tool kit are intended to assist you in the performance of preventive maintenance and minor repairs How ever additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly TIP If you do not have the tools or experi ence required for a particular job have a Yamaha dealer perform it for you 1 Owner s tool kit U46B11E0 book Page 2 Wednesday May 13 2009 ...

Page 38: ...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 Exh...

Page 39: ...nd 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 spok...

Page 40: ...ssemblies for looseness 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 lightly 16 Clutch lever pivot shaft Apply lithium soap based grease lightly No ITEM ...

Page 41: ...rm 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 thoroughly 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 No ITEM ROUTINE INITIAL ODOMETER READIN...

Page 42: ... cylinder or caliper cylinder always replace the brake fluid Check the brake 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 27 Lights signals and switches Check operation Adjust headlight beam No ITEM ROUTINE INITIAL ODOMETER READINGS 60...

Page 43: ...panel and then push the rear of the panel in EAU19545 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 condition...

Page 44: ...spark plug gap with a wire thickness gauge and if nec essary adjust the gap to specifica tion To install a spark plug 1 Clean the surface of the spark plug gasket and its mating surface and then wipe off any grime from the spark plug threads 2 Install the spark plug with the spark plug wrench and then tight en it to the specified torque TIP If a torque wrench is not available when installing a spa...

Page 45: ...ach 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 A slight tilt to the side can result in a false reading 2 Start the engine warm it up for several minutes and then turn it off 3 Wait ...

Page 46: ...oil filler cap and drain bolt to drain the oil from the crankcase TIP 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 6 Install the oil filter element cover by installing the screws then tighten ing them to the specified torque 1 Engine oil level check window 2 Maximum...

Page 47: ...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 check the ...

Page 48: ...g in unusually wet 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 f...

Page 49: ...ot 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 NOTICE Make sure that the air filter element is properly seated in the air filter case The engine should never be operat ed without the air filter element installed otherwise the pis ton s and or cylinder s may become excessively worn ECA10481 9 Insta...

Page 50: ...owledge and experience EAU44734 Checking the engine idling speed Check the engine idling speed and if necessary have it corrected by a Yamaha dealer EAU21382 Checking the throttle cable free play The throttle cable free play should mea sure 3 0 5 0 mm 0 12 0 20 in at the throttle grip Periodically check the throttle cable free play and if neces sary have a Yamaha dealer adjust it Engine idling spe...

Page 51: ...e se vere injury or death from loss of control The tire air pressure must be checked and adjusted on cold tires i e when the temperature of the tires equals the ambient temperature The 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 EWA10511 Never overload your vehicle Opera ...

Page 52: ...erience 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 equipped with spoke wheels and tube tires WARNING EWA10461 The front and rear tires should be of the same make and design other wise the handling characteristics of the vehicle may be differe...

Page 53: ...wheel must be replaced The wheel should be balanced whenever either the tire or wheel has been changed or replaced An unbalanced wheel can result in poor performance adverse han dling characteristics and a short ened tire life Ride at moderate speeds after changing a tire since the tire sur face must first be broken in for it to develop its optimal characteris tics EAU22043 Adjusting the clutch le...

Page 54: ...nut in direction b 7 Tighten the locknut at the crank case 8 Tighten the locknut at the clutch le ver and then slide the rubber cover to its original position EAU22093 Adjusting the brake lever free play The brake lever free play should mea sure 2 0 5 0 mm 0 08 0 20 in as shown Periodically check the brake le ver free play and if necessary adjust it as follows 1 Loosen the locknut at the brake le ...

Page 55: ... play WARNING EWA10670 It is advisable to have a Yamaha dealer make these adjustments Brake pedal position The top of the brake pedal should be positioned approximately 60 0 mm 2 36 in above the top of the footrest as shown Periodically check the brake pedal position and if necessary adjust it as follows 1 Loosen the locknut at the brake pedal 2 To raise the brake pedal turn the adjusting bolt in ...

Page 56: ...t be obtained as described have a Yamaha dealer make this ad justment After adjusting the brake pedal free play check the operation of the brake light EAU22272 Adjusting the rear brake light switch The rear brake light which is activated by the brake pedal should come on just before braking takes effect If neces sary adjust the rear brake light switch as follows Turn the rear brake light switch ad...

Page 57: ... brake To check the brake shoe wear check the position of the wear indicator while applying the brake If a brake shoe has worn to the point that the wear indicator reaches the wear limit line have a Yamaha dealer replace the brake shoes as a set EAU32344 Checking the brake fluid level Insufficient brake fluid may allow air to enter the brake system possibly caus ing it to become ineffective Before...

Page 58: ...ve a Yamaha dealer change the brake fluid at the intervals specified in the TIP after the periodic maintenance and lubrication chart In addition have the oil seals of the brake master cylin der and caliper as well as the brake hose replaced at the intervals listed be low or whenever they are damaged or leaking Oil seals Replace every two years Brake hose Replace every four years EAU22760 Drive cha...

Page 59: ...ll 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 with in the specified limits ECA10571 TIP Using the alignment marks on each side of the swingarm make sure that both chain pullers are in the same posi tion for proper wheel alignment 5 Tighten the locknuts and then tighten the axle nut to the specified tor...

Page 60: ...ce and lubrica tion chart otherwise it will quickly wear out especially when riding in dusty or wet areas Service the drive chain as follows NOTICE ECA10582 The drive chain must be lubricated after washing the motorcycle and riding in the rain or wet areas 1 Remove all dirt and mud from the drive chain with a brush or cloth TIP For a thorough cleaning have a Yamaha dealer remove the drive chain an...

Page 61: ...with cable movement Replace damaged cables as soon as possi ble to prevent unsafe conditions EWA10711 EAU23111 Checking and lubricating the throttle grip and cable The operation of the throttle grip should be checked before each ride In addi tion the cable should be lubricated at the intervals specified in the periodic maintenance chart EAU44271 Checking and lubricating the brake and shift pedals ...

Page 62: ...er 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 Recommended lubricants Brake lever Silicone grease Clutch lever Lithium soap based grease U46B11E0 book Page 27 Wednesday May 13 2009 8 55 AM ...

Page 63: ...c maintenance and lubrication chart EAU23272 Checking the front 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 Check the inner tubes for scratches damage and excessive oil leakage To check the operation 1 Place the vehicle on a level sur face and hold it in an upright...

Page 64: ...ff the ground See page 7 35 for more information WARNING To avoid injury securely support the vehicle so there is no danger of it falling over EWA10751 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 Yamaha dealer check or repair the steering EAU23291 Checking the wheel bearings The front and rear wheel bearings must be ch...

Page 65: ...attery ECA10611 WARNING EWA10770 Electrolyte is poisonous and dangerous since it contains sul furic acid which causes severe burns Avoid any contact with skin eyes or clothing and al ways shield your eyes when working near batteries In case of contact administer the fol lowing FIRST AID EXTERNAL Flush with plenty of water INTERNAL Drink large quan tities of water or milk and im mediately call a ph...

Page 66: ...e breather hose is properly routed in good condition and not obstructed NOTICE If the breather hose is positioned in such a way that the frame is ex posed to electrolyte or gas ex pelled from the battery the frame could suffer structural and external damages ECA10601 EAU23601 Replacing the fuses The main fuse and the signaling sys tem fuse holders are located under the rider seat See page 4 9 If a...

Page 67: ...t bulb to keep it free from oil otherwise the transpar ency of the glass the luminosity of the bulb and the bulb life will be adversely affected Thor oughly clean off any dirt and fin gerprints on the headlight bulb using a cloth moistened with al cohol or thinner Headlight lens Do not affix any type of tinted film or stickers to the headlight lens Do not use a headlight bulb of a wattage higher t...

Page 68: ...cover and then connect the coupler 6 Install the headlight unit by install ing the screws 7 Have a Yamaha dealer adjust the headlight beam if necessary EAU24133 Replacing the tail brake light bulb 1 Remove the tail brake light lens by removing the screws 2 Remove the burnt out bulb by pushing it in and turning it counter clockwise 1 Headlight coupler 2 Headlight bulb cover 1 Headlight bulb holder ...

Page 69: ... turn signal light bulb 1 Remove the turn signal lens by re moving the screws 2 Remove the burnt out bulb by pushing it in and turning it counter clockwise 3 Insert a new bulb into the socket push it in and then turn it clock wise until it stops 4 Install the lens by installing the screws NOTICE Do not over tighten the screws otherwise the lens may break ECA10681 1 Tail brake light bulb 1 Screw 1 ...

Page 70: ...ycle 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 To service the rear wheel Raise the rear wheel off the ground by using a motorcycle stand or if a motor cycle stand is not available by placing a jack either under each side of the frame in front of the rear wheel or under each side of the swi...

Page 71: ... Make sure that there is enough space between the brake pads before insert ing the brake disc and that the slot in the speedometer gear unit fits over the retainer on the fork leg 3 Insert the wheel axle 4 Lower the front wheel so that it is on the ground and then put the sidestand down 5 Tighten the wheel axle to the spec ified torque 6 Tighten the front wheel axle pinch bolt to the specified tor...

Page 72: ... nut on both ends of the swingarm 3 Loosen the axle nut and the brake torque rod nut at the brake shoe plate 4 Lift the rear wheel off the ground according to the procedure on page 7 35 5 Remove the brake pedal free play adjusting nut and then disconnect the brake rod at the brake cam shaft lever 6 Disconnect the brake torque rod from the brake shoe plate by re moving the nut and the bolt 1 Axle n...

Page 73: ... Install the axle nut 5 Lower the rear wheel so that it is on the ground and then put the sidestand down 6 Tighten the brake torque rod nut to the specified torque 7 Adjust the drive chain slack See page 7 23 8 Tighten the axle nut to the speci fied torque 9 Insert a new cotter pin into the axle nut and then bend its ends as shown WARNING Always use a new cotter pin for the axle nut EWA10701 TIP M...

Page 74: ...equire 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 replace ment parts Imitation parts may look like Yamaha parts but they are often inferi or have a shorter service life and can lead to expensive repair bills WARNING EWA15141 When checking the fuel system do not smoke and...

Page 75: ... 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 good Check the electrolyte and battery lead connections...

Page 76: ...utlets 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 axles Alway...

Page 77: ...nd a soft clean sponge and then rinse thoroughly with clean water Use a toothbrush or bottlebrush for 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 combinat...

Page 78: ...cess 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 TIP Consult a Yamaha dealer for ad vice on what products to use Washing rainy weather or humid climates can cause the headlight lens to fog Turning the headlight on for a short period of time will help remove the moisture ...

Page 79: ...ury from sparking make sure to ground the spark plug electrodes while turning the engine over EWA10951 e Remove the spark plug caps from the spark plugs and then install the spark plugs and the spark plug caps 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 80: ...acement 1 40 L 1 48 US qt 1 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 XV250Z 9 5 L 2 51 US gal 2 09 Imp gal XV250ZC 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 Type quantity BDS26 x 1 Spark plug s Manufacturer m...

Page 81: ... 198 432 lb XV250ZC 90 195 kg 198 430 lb Front 200 kPa 2 00 kgf cm 29 psi Rear 225 kPa 2 25 kgf cm 33 psi 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 for...

Page 82: ...n 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 U46B11E0 book Page 3 Wednesday May 13 2009 8 55 AM ...

Page 83: ...identification 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 TIP The vehicle identification number is used to identify your motorcycle and m...

Page 84: ...rdering spare parts from a Yamaha dealer EAU48061 Vehicle Emission Control Informa tion label The Vehicle Emission Control Informa tion label is affixed at the location in the illustration This label shows specifica tions related to exhaust emissions as required by federal law state law and Environment Canada 1 Model label 1 Vehicle Emission Control Information label 1 U46B11E0 book Page 2 Wednesd...

Page 85: ... 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 86: ...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 87: ...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 88: ...RMATION 10 6 10 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 U46B11E0 book Page 6 Wednesday May 13 2009 8 55 AM ...

Page 89: ...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 90: ...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 91: ...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 92: ...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 U46B11E0 book Page 10 Wednesday May 13 2009 8 55 AM ...

Page 93: ...s 10 1 Ignition circuit cut off system 4 11 Indicator lights 4 1 K Key identification number 10 1 L Labels location 1 1 M Main switch 4 1 Maintenance and lubrication periodic 7 4 Maintenance emission control system 7 3 Maintenance record 10 5 Matte color caution 8 1 Model label 10 2 N Neutral indicator light 4 1 Noise regulation 10 4 P Panel removing and installing 7 8 Parking 6 4 Part locations 3...

Page 94: ...lve clearance 7 16 Vehicle Emission Control Information label 10 2 Vehicle identification number 10 1 W Warranty extended 10 9 Warranty limited 10 7 Wheel bearings checking 7 29 Wheel front 7 35 Wheel rear 7 37 Wheels 7 18 U46B11E0 book Page 2 Wednesday May 13 2009 8 55 AM ...

Page 95: ...U46B11E0 book Page 3 Wednesday May 13 2009 8 55 AM ...

Page 96: ...PRINTED IN JAPAN 2009 05 0 6 1 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD DIC183 ...

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Yamaha Star XV250Z, Owner'S Manual

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