Yamaha Virago XV250 2004 Owner'S Manual Download Page 55 | Manualshive

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-19

6

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.

EAU22092

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-

ver.

2. To increase the brake lever free

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

3. Tighten the locknut.

WARNING

EWA10630

●

After adjusting the brake lever
free play, check the free play
and make sure that the brake is
working properly.

●

A soft or spongy feeling in the
brake lever can 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.

1. Locknut

2. Brake lever free play adjusting screw
3. Brake lever free play

U2UJ1DE0.book Page 19 Thursday, May 13, 2004 11:59 PM

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Summary of Contents for Virago XV250 2004

Page 1: ...PRINTED IN JAPAN 2004 05 0 6 1 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD 2UJ 28199 1D LIT 11626 18 21 XV250T XV250TC OWNER S MANUAL ...

Page 2: ...EAU10041 U2UJ1DE0 book Page 1 Thursday May 13 2004 11 59 PM ...

Page 3: ...orcycle 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 ...

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 WA...

Page 5: ...AINED IN SAFE AND PROPER RIDING 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 U2UJ1DE0 book Page 2 Thursday May 13 2004 11 59 PM ...

Page 6: ...poration U S A 1st edition April 2004 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 18 21 AFFIX DEALER LABEL HERE U2UJ1DE0 book Page 3 Thursday May 13 2004 11 59 PM ...

Page 7: ...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 Adjusting the carburetor 6 14 Adjusting the throttle cable free play 6 15 Adjusting the valve clearance 6 15 Tires 6 15 Spoke wheels 6 17 Accessories and replacement parts 6 17 Adjusting the clutch lever free play 6 18 Adju...

Page 8: ...el 6 37 Troubleshooting 6 38 Troubleshooting chart 6 39 MOTORCYCLE CARE AND STORAGE 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 7 YAMAHA EXTENDED SERVICE Y E S 9 9 U2UJ1DE0 book Page 2 ...

Page 9: ...ts have been caused by an automobile driver who did not see the motorcycle Making yourself conspicuous ap pears to be very effective in reduc ing 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: ...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 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 engin...

Page 11: ... caution 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 s...

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 a...

Page 13: ...SAFETY INFORMATION 1 5 1 EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle U2UJ1DE0 book Page 5 Thursday May 13 2004 11 59 PM ...

Page 14: ...SAFETY INFORMATION 1 6 1 1 3 2 4 California only 5 California only U2UJ1DE0 book Page 6 Thursday May 13 2004 11 59 PM ...

Page 15: ...page 3 8 3 Fuel tank page 3 5 4 Battery page 6 29 5 Fuses page 6 31 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 U2UJ1DE0 book Page 1 Thursday May 13 2004 11 59 PM ...

Page 16: ...hts page 6 34 3 Rider 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 Owner s tool kit page 6 1 9 Shock absorber assembly spring preload adjusting ring page 3 9 U2UJ1DE0 book Page 2 Thursday May 13 2004 11 59 PM ...

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 cap page 3 5 U2UJ1DE0 book Page 3 Thursday May 13 2004 11 59 PM ...

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 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 or...

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 fuel This information will en able you to plan future fuel stops EAU12343 Handlebar switches Left Right 1 Odometer 2 Tripmeter 3 Tripmeter reset knob 4 Speedometer 1 Dimmer switch LIGHTS 2 Turn signa...

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 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 grip...

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 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 U2UJ1DE0 book Page 4 Thursday May 1...

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 closed before riding EAU13210 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 er...

Page 23: ...containing 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 EAU13580 Fuel cock This model is equipped with a negative pressure fuel cock The fuel cock sup plies fuel from the tank to the carb...

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 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 supplied...

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 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 In...

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 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 settin...

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 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 si...

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 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 a...

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 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 s...

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 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 w...

Page 31: ...ar Replace if necessary Check fluid level in reservoir If necessary add recommended brake fluid to specified level Check hydraulic system for leakage 6 19 6 21 6 22 Rear brake Check operation Check pedal free play Adjust if necessary 6 20 6 21 Clutch Check operation Lubricate cable if necessary Check lever free play Adjust if necessary 6 18 Throttle grip Make sure that operation is smooth Check ca...

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 27 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: ...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 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 Shif...

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 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 control...

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 w...

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 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 immediately...

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: ...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 U2UJ1DE0 book Page 2 Thursday May 13 2004 11 59 PM ...

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 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 Ex...

Page 40: ...y Check specific gravity 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 Replace brake pads if necessary 5 Rear brake Check operation Adjust cable and replace brake shoes if necessary 6 Brake hose Check for cracks or damage Replace Every 4 years 7 Wheels Check runout spoke tightness and for dam...

Page 41: ... 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 and clutch le ver pivot shafts Apply lithium soap based grease all purpose grease lightly 15 Brake and shift ped al pivot shafts Apply lithium soap based grease all purpose grease lightly 16 Sidestand pivot Check operation Apply lit...

Page 42: ...d for oil leak age Replace if necessary 20 Engine oil Change warm engine before draining 21 Engine oil filter ele ment Replace 22 Control and meter cables Apply Yamaha chain and cable lube or engine oil 10W 30 thor oughly 23 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 I...

Page 43: ...stem When disassembling the master 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 U2UJ1DE0 book Page 7 Thursday May 13 2004 11 59 PM ...

Page 44: ... panel and then push the rear of the panel in EAU19543 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 conditio...

Page 45: ...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 spark p...

Page 46: ...de 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 readin...

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 bolts 5 Remove and replace the oil filter element and O ring 1 Engine oil level check window 2 Maximum ...

Page 48: ...ality 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 oil level and correct it if necessary 1 Oil ...

Page 49: ...ly wet or dusty areas 1 Remove the bolts and loosen the air filter 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 joint clamp screw 2 Air filter case cover 3 Air filter case 1 Hose 2 Air filter case 1 Screw 1 W...

Page 50: ...p erated without the air filter ele ment installed otherwise the piston s and or cylinder s may become excessively worn 9 Install the air filter case cover by in stalling the screws 10 Connect the hoses to the air filter case 11 Install the air filter case onto the air filter joint and then tighten the air filter joint clamp screw 12 Install the bolts EAU21250 Adjusting the carburetor The carburet...

Page 51: ...rvals specified in the periodic maintenance and lubrication chart EAU32520 Tires To maximize the performance durabil ity and safe operation of your motor cycle note the following points regarding the specified tires Tire air pressure The tire air pressure should be checked and if necessary adjusted before each ride WARNING EWA10500 The tire air pressure must be checked and adjusted on cold tires i...

Page 52: ...glass fragments in it or if the sidewall is cracked con tact a Yamaha dealer immediately and have the tire replaced WARNING EWA10560 It is dangerous to ride with a worn out tire When a tire tread begins to show crosswise lines have a Yamaha dealer replace 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 nec...

Page 53: ...formance 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 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...

Page 54: ...ree 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...

Page 55: ...r free play turn the adjusting screw in di rection a To decrease the brake lever free play turn the adjusting screw in direction b 3 Tighten the locknut WARNING EWA10630 After adjusting the brake lever free play check the free play and make sure that the brake is working properly A soft or spongy feeling in the brake lever can indicate the presence of air in the hydraulic system If there is air in...

Page 56: ...11230 After adjusting the brake pedal posi tion the brake pedal free play must be adjusted Brake pedal free play The brake pedal free play should mea sure 20 0 30 0 mm 0 79 1 18 in at the brake pedal end Periodically check the 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 bra...

Page 57: ...ome on earlier turn the adjusting nut in direction a To make the brake light come on later turn the adjusting nut in direction b EAU22380 Checking the front brake pads and rear brake shoes The front brake pads and the rear brake shoes must be checked for wear at the intervals specified in the periodic main tenance and lubrication chart EAU22420 Front brake pads Each front brake pad is provided wit...

Page 58: ...e system leakage If the brake fluid level is low be sure to check the brake pads for wear and the brake system for leakage Observe these precautions When checking the fluid level make sure that the top of the mas ter cylinder is level by turning the handlebars Use only the recommended quality brake fluid otherwise the rubber seals may deteriorate causing leakage and poor braking perfor mance Refil...

Page 59: ...ars Brake hose Replace every four years EAU22760 Drive chain slack The drive chain slack should be checked before each ride and adjusted if necessary EAU22770 To check the drive chain slack 1 Place the motorcycle on a level surface and hold it in an upright po sition NOTE When checking and adjusting the drive chain slack the motorcycle should be positioned straight up and there should be no weight...

Page 60: ...b and then push the rear wheel forward NOTE 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 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 sl...

Page 61: ...ervals specified in the periodic maintenance and lubrica tion chart otherwise it will quickly wear out especially when riding in dusty or wet areas Service the drive chain as follows CAUTION ECA10581 The drive chain must be lubricated after washing the motorcycle and riding in the rain 1 Remove all dirt and mud from the drive chain with a brush or cloth NOTE For a thorough cleaning have a Yamaha d...

Page 62: ...les as soon as possible to prevent unsafe conditions EAU23110 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 or replaced at the intervals specified in the periodic maintenance chart EAU23131 Checking and lubricating the brake and shift pedals The operation of the brake and shift ...

Page 63: ...ivot and metal to metal contact surfaces should be lubricated if necessary WARNING EWA10730 If the sidestand does not move up and down smoothly have a Yamaha dealer check or repair it EAUM1650 Lubricating the swingarm pivots The swingarm pivots must be lubricat ed at the intervals specified in the peri odic maintenance and lubrication chart Recommended lubricant Lithium soap based grease all pur p...

Page 64: ...to check if the front fork compresses and rebounds smoothly CAUTION ECA10590 If any damage is found or the front fork does not operate smoothly have a Yamaha dealer check or re pair it EAU23280 Checking the steering Worn or loose steering bearings may cause danger Therefore the operation of the steering must be checked as fol lows at the intervals specified in the pe riodic maintenance and lubrica...

Page 65: ... and discharge quickly The electrolyte level battery lead connections and breather hose routing should be checked before each ride and at the in tervals specified in the periodic mainte nance and lubrication chart To check the electrolyte 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 ele...

Page 66: ...e Take care not to spill electrolyte on the drive chain as this may weaken it shorten chain life and possibly result in an accident KEEP THIS AND ALL BATTER IES OUT OF THE REACH OF CHILDREN CAUTION ECA10610 Use only distilled water as tap water contains minerals that are harmful to the battery 4 Check and if necessary tighten the battery lead connections and correct the breather hose routing To st...

Page 67: ...n replace it as follows 1 Turn the key to OFF and turn off the electrical circuit in question 2 Remove the blown fuse and then install a new fuse of the specified amperage CAUTION ECA10640 Do not use a fuse of a higher amper age rating than recommended to avoid causing extensive damage to the electrical system and possibly a fire 3 Turn the key to ON and turn on the electrical circuit in question ...

Page 68: ...ot There fore keep flammable products away from a lit headlight bulb and do not touch the bulb until it has cooled down 4 Place a new headlight bulb into po sition and then secure it with the bulb holder CAUTION ECA10660 Do not touch the 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 a...

Page 69: ...1 Remove the tail brake light lens by removing the screws 2 Remove the defective 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 CAUTION ECA10680 Do not overtighten the screws oth erwise the lens may break 1 Do not touch the glass part of the bulb 1 Screw 1 T...

Page 70: ...front and rear wheel or performing other maintenance requiring the motorcycle to stand up right Check that the motorcycle is in a stable 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 ava...

Page 71: ...he front wheel 2 Loosen the front wheel axle pinch bolt then the wheel axle 3 Lift the front wheel off the ground according to the procedure on page 6 34 4 Pull the wheel axle 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 EAU24931 To install the front wheel 1 Install t...

Page 72: ...l so that it is on the ground 5 Tighten the wheel axle to the spec ified torque 6 Tighten the front wheel axle pinch bolt to the specified torque 7 Push down hard on the handlebar several times to check for proper fork operation 8 Connect the speedometer cable 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 Tight...

Page 73: ...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 7 Push the wheel forward and then remove the drive chain from the rear sprocket NOTE The drive chain does not need to be disassembled in order to remove and install the rear wheel 8 Remove the a...

Page 74: ... 20 WARNING EWA10660 After adjusting the brake pedal free play check the operation of the brake light EAU25850 Troubleshooting Although Yamaha motorcycles receive a thorough inspection before shipment from the factory trouble may occur dur ing operation Any problem in the fuel compression or ignition systems for example can cause poor starting and loss of power The following troubleshooting chart ...

Page 75: ...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 good...

Page 76: ... dirt do not leave the cleaner on the af fected area any longer than in structed Also thoroughly rinse the area off with water immedi ately dry it and then apply a cor rosion protection spray Improper cleaning can damage windshields cowlings panels and other plastic parts Use only a soft clean cloth or sponge with mild detergent and water to clean plastic Do not use any harsh chemical products on ...

Page 77: ...uding chrome and nick el plated surfaces to prevent cor rosion After cleaning 1 Dry the motorcycle with a chamois or an absorbing cloth 2 Immediately dry the drive chain and lubricate it to prevent it from rusting 3 Use a chrome polish to shine chrome aluminum and stainless steel parts including the exhaust system Even the thermally in duced discoloring of stainless steel exhaust systems can be re...

Page 78: ... for sev eral months 1 Follow all the instructions in the Care section of this chapter 2 Turn the fuel cock lever to ON 3 Drain the carburetor float cham bers by loosening the drain bolts this will prevent fuel deposits from building up Pour the drained fuel into the fuel tank 4 Fill up the fuel tank and add fuel stabilizer if available to prevent the fuel tank from rusting and the fuel from deter...

Page 79: ...els are off the ground Alterna tively turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot 8 Cover the muffler outlets with plas tic bags to prevent moisture from entering them 9 Remove the battery and fully charge it Store it in a cool dry place and charge it once a month Do not store the battery in an ex cessively cold or warm place less than 0 C ...

Page 80: ...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 9 2 L 2 43 US gal 2 02 Imp gal CAL 9 5 L 2 51 US gal 2 09 Imp gal U49 Fuel reserve amount 2 6 L 0 69 US gal 0 57 Imp gal Carburetor Manufacturer MIKUNI Type x quantity BDS26 x 1 Spark plug s Manufacturer model NGK C6HS...

Page 81: ...6 kg 198 432 lb U49 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 shock absorb...

Page 82: ...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 indicator light 14 V 3 0 W 1 Fuses Main fuse 20 0 A Signaling system fuse 10 0 A U2UJ1DE0 book Page 3 Thursday May 13 2004 11 59 PM ...

Page 83: ...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 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 ma...

Page 84: ...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 Model label U2UJ1DE0 book Page 2 Thursday May 13 2004 11 59 PM ...

Page 85: ...stigation 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 either call the Auto Safety Hotline toll free at 1 800 424 9393 or 366 0123 in Washington D C area or write to NHTSA U S Department of Tra...

Page 86: ...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 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 Ex...

Page 87: ...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 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: ...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 U2UJ1DE0 book Page 6 Thursday May 13 2004 11 59 PM ...

Page 89: ...CONSUMER INFORMATION 9 7 9 EAU26661 YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY U2UJ1DE0 book Page 7 Thursday May 13 2004 11 59 PM ...

Page 90: ...CONSUMER INFORMATION 9 8 9 U2UJ1DE0 book Page 8 Thursday May 13 2004 11 59 PM ...

Page 91: ...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 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: ...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 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 U2UJ1DE0 book Page 10 Thursday May 13 2004 11 59 PM ...

Page 93: ...on 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 Model label 9 2 N Neutral indicator light 3 1 Noise regulation 9 4 P Panel removing and installing 6 8 Parking 5 4 Part locations 2 1 Pre operat...

Page 94: ...gnal switch 3 3 V Valve clearance adjusting 6 15 Vehicle identification number 9 1 W Warranty extended 9 9 Warranty limited 9 7 Wheel bearings checking 6 29 Wheel front 6 35 Wheel rear 6 37 Wheels 6 17 U2UJ1DE0 book Page 2 Thursday May 13 2004 11 59 PM ...

Page 95: ...PRINTED IN JAPAN 2004 05 0 6 1 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD 2UJ 28199 1D LIT 11626 18 21 XV250T XV250TC OWNER S MANUAL ...

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