Yamaha XT250 2008 Owner'S Manual Download Page 66

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PERIODIC MAINTENANCE AND ADJUSTMENT

7-28

EAU44271

Checking and lubricating the
brake and shift pedals

The operation of the brake and shift
pedals should be checked before each
ride, and the pedal pivots should be lu-
bricated if necessary.

EAU23142

Checking and lubricating the
brake and clutch levers

Brake lever

Clutch lever

The operation of the brake and clutch
levers should be checked before each
ride, and the lever pivots should be lu-

Recommended lubricant:

Lithium-soap-based grease

Summary of Contents for XT250 2008

Page 1: ...3C5 28199 11 XT250YC OWNER S MANUAL Read this manual carefully before operating this vehicle LIT 11626 22 25 XT250Y ...

Page 2: ...EAU10042 Read this manual carefully before operating this vehicle This manual should stay with this vehicle if it is sold Q ...

Page 3: ...tion of the motorcycle To maintain 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 th...

Page 4: ...personal injury hazards Obey 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 ...

Page 5: ...WNER S MANUAL 2008 by Yamaha Motor Corporation U S A 1st edition April 2008 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 22 25 ...

Page 6: ...ral maintenance and lubrication chart 7 5 Removing and installing the cowling and panels 7 9 Checking the spark plug 7 11 Canister for California only 7 13 Engine oil and oil filter element 7 13 Replacing the air filter element and cleaning the check hose 7 16 Cleaning the spark arrester 7 17 Carburetor 7 18 Checking the engine idling speed 7 19 Checking the throttle cable free play 7 19 Valve cle...

Page 7: ... Front wheel 7 37 Rear wheel 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...

Page 8: ...l of the labels on your 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 2 1 3 ...

Page 9: ...B FROM FUEL TANK CANISTER TO ATMOSPHERE 4YN 21686 00 1 California only WARNING BEFORE YOU OPERATE THIS VEHICLE READ THE OWNER S MANUAL AND ALL LABELS ALWAYS WEAR AN APPROVED MOTORCYCLE HELMET eye protection and protective clothing 5GK 2118K 00 2 3TT 21668 00 ...

Page 10: ...LOCATION OF IMPORTANT LABELS 1 3 1 2 3 4 5 6 7 8 9 1 2 ...

Page 11: ...LOCATION OF IMPORTANT LABELS 1 4 1 2 3 4 5 6 7 8 9 2 1 ...

Page 12: ...d 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 you are approaching and passing through inters...

Page 13: ...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 engine or exhaust sys tem become very hot during or af ter operation and can cause burns A passenger should also observe the above precautions Avoid Carbon Monoxide Poisoning All engine exhaust contains ...

Page 14: ...ccessory mounts and cargo restraints frequently Properly adjust the suspension for your load and check the con dition and pressure of your tires Never attach any large or heavy items to the handlebar front fork or front fender These items including such cargo as sleeping bags duffel bags or tents can create unstable han dling or a slow steering re sponse This vehicle is not designed to pull a trai...

Page 15: ...st 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 become un stable in cross winds These ac cessories may also cause instability when passing or being passed by large vehicles Certain accessories can dis place the o...

Page 16: ...3 1 1 2 3 4 5 6 7 8 9 DESCRIPTION EAU10410 Left view 1 2 4 3 1 Fuel cock page 4 8 2 Starter choke knob page 4 9 3 Air filter element page 7 16 4 Helmet holder page 4 10 ...

Page 17: ... 2 3 4 5 6 7 8 9 EAU10420 Right view 2 3 4 5 6 1 1 Spark arrester page 7 17 2 Battery page 7 31 3 Fuse page 7 33 4 Owner s tool kit page 7 2 5 Engine oil level check window page 7 13 6 Engine oil filler cap page 7 13 ...

Page 18: ... 7 9 4 1 Clutch lever page 4 5 2 Left handlebar switches page 4 4 3 Indicator lights page 4 2 4 Main switch steering lock page 4 1 5 Multi function display page 4 3 6 Right handlebar switches page 4 4 7 Front brake lever page 4 6 8 Throttle grip page 7 19 9 Fuel tank cap page 4 6 ...

Page 19: ...cally when the engine is started and stays on until the key is turned to OFF even if the engine stalls EAU10661 OFF All electrical systems are off The key can be removed WARNING EWA10061 Never turn the key to OFF or LOCK while the vehicle is moving Otherwise the electrical systems will be switched off which may result in loss of control or an accident EAU10691 LOCK The steering is locked and all e...

Page 20: ...This indicator light flashes when the turn signal switch is pushed to the left or right EAU11060 Neutral indicator light This indicator light comes on when the transmission is in the neutral position EAU11080 High beam indicator light This indicator light comes on when the high beam of the headlight is switched on 1 Push 2 Turn 1 2 1 High beam indicator light 2 Turn signal indicator light 3 Neutra...

Page 21: ...ll of the display segments of the multi function display will appear one after the other and then disap pear in order to test the electrical circuit To switch the speedometer and odometer tripmeter displays be tween miles and kilometers press the SELECT button for at least two seconds Odometer clock and tripmeter modes Pushing the SELECT button switches the display between the odometer mode ODO an...

Page 22: ...elease it to start the clock EAU12347 Handlebar switches Left Right EAU12400 Dimmer switch Set this switch to for the high beam and to for the low beam EAU12460 Turn signal switch To signal a right hand turn push this switch to To signal a left hand turn push this switch to When re leased the switch returns to the center position To cancel the turn signal lights push the switch in after it has re ...

Page 23: ... the en gine EAU12820 Clutch lever The clutch lever is located at the left handlebar grip To disengage the clutch pull the lever toward the handle bar grip To engage the clutch release the lever The lever should be pulled rapidly and released slowly for smooth clutch operation The clutch lever is equipped with a clutch switch which is part of the igni tion circuit cut off system See page 4 12 EAU1...

Page 24: ...ess down on the brake pedal EAUM1793 Fuel tank cap To remove the fuel tank cap 1 Open the fuel tank cap lock cover 2 Insert the key into the lock and turn it 1 4 turn clockwise The lock will be released and the fuel tank cap can be removed To install the fuel tank cap 1 Push and install the fuel tank cap into position with the key inserted in the lock 2 Turn the key counterclockwise to the origina...

Page 25: ...vehicle Never refuel while smoking or while in the vi cinity of sparks open flames or other sources of ignition such as the pilot lights of water heaters and clothes dryers 2 Do not overfill the fuel tank Stop filling when the fuel reaches the bottom of the filler tube Because fuel expands when it heats up heat from the engine or the sun can cause fuel to spill out of the fuel tank 3 Wipe up any s...

Page 26: ...nleaded fuel will extend spark plug life and reduce maintenance costs Gasohol There are two types of gasohol gaso hol containing ethanol and that contain ing methanol Gasohol containing ethanol can be used if the ethanol con tent does not exceed 10 E10 Gas ohol containing methanol is not recommended by Yamaha because it can cause damage to the fuel system or vehicle performance problems EAU13561 F...

Page 27: ... to this position Fill the tank at the first oppor tunity Be sure to set the lever back to ON after refueling EAU13600 Starter choke knob Starting a cold engine requires a richer air fuel mixture which is supplied by the starter choke Move the knob in direction a to turn on the starter choke Move the knob in direction b to turn off the starter choke 1 Pointed end positioned over ON 1 Pointed end p...

Page 28: ...n the bolts TIP Make sure that the seat is properly se cured 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 possibl...

Page 29: ...djusting ring in direction a To decrease the spring pre load and thereby soften the sus pension turn the adjusting ring in direction b The spring preload setting is deter mined by measuring distance A shown in the illustration The short er the distance A is the higher the spring preload the longer distance A is the lower the spring preload 3 Tighten the locknut to the specified torque NOTICE Alway...

Page 30: ...en designed to assist the operator in fulfilling the respon sibility of raising the sidestand be fore starting off Therefore check this system regularly as described below and have a Yamaha dealer re pair it if it does not function proper ly EAU15313 Ignition circuit cut off system The ignition circuit cut off system com prising the sidestand switch clutch switch and neutral switch has the fol low...

Page 31: ...all After the engine has stalled 10 Move the sidestand up 11 Keep the clutch lever pulled 12 Push the start switch Does the engine start The 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 ...

Page 32: ... procedures and schedules described in the Owner s Manual WARNING EWA11151 Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equipment damage Do not operate the vehicle if you find any problem If a problem cannot be corrected by the procedures provided in this manual have the vehicle inspected by a Yamaha dealer Before using this vehicle check the foll...

Page 33: ...cessary Check fluid level in reservoir If necessary add recommended brake fluid to specified level Check hydraulic system for leakage 7 22 7 23 7 24 Rear brake Check operation If soft or spongy have Yamaha dealer bleed hydraulic system Check brake pads for wear Replace if necessary Check fluid level in reservoir If necessary add recommended brake fluid to specified level Check hydraulic system for...

Page 34: ...hat operation is smooth Lubricate pedal pivoting points if necessary 7 28 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 7 28 Sidestand Make sure that operation is smooth Lubricate pivot if necessary 7 29 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened Tighten if necessary Instruments lights signals and swit...

Page 35: ...a Yamaha dealer to check the electrical circuit 4 Turn the starter choke on and completely close the throttle See page 4 9 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 ...

Page 36: ...is 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 NOTICE ECA102...

Page 37: ...nd 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 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 t...

Page 38: ...0 km 600 mi of operation 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 EAU17171 P...

Page 39: ...e unless otherwise specified A running 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 cleane...

Page 40: ...al and the tools provided in the 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 1 ...

Page 41: ...if necessary 2 Spark plug Check condition Adjust gap and clean Replace at 7000 mi 11000 km or 12 months and thereafter every 6000 mi 10000 km or 12 months Replace Replace 3 Spark arrester Clean 4 Valve clearance Check and adjust valve clear ance when engine is cold 5 Crankcase breather system Check breather hose for cracks or damage Replace if necessary 6 Idle speed Check and adjust engine idle sp...

Page 42: ...perform the service 9 Air induction system Check the air cut off valve reed valve and hose for damage Replace any damaged parts No ITEM ROUTINE INITIAL ODOMETER READINGS 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 ...

Page 43: ...ssary Replace Every 12000 mi 19000 km 2 Clutch Check operation Adjust or replace cable 3 Front brake Check operation fluid level and for fluid leakage Replace brake pads if necessary 4 Rear brake Check operation fluid level and for fluid leakage Replace brake pads if necessary 5 Brake hose Check for cracks or damage Replace Every 4 years 6 Wheels Check runout spoke tightness and for damage Tighten...

Page 44: ...eness Moderately repack with lith ium soap based grease Repack 12 Chassis fasteners Check all chassis fitting and fas teners Correct if necessary 13 Brake lever pivot shaft Apply silicone grease lightly 14 Brake pedal pivot shaft Apply lithium soap based grease lightly 15 Clutch lever pivot shaft Apply lithium soap based grease lightly 16 Shift pedal pivot shaft Apply lithium soap based grease lig...

Page 45: ...if necessary 22 Engine oil Change warm engine before draining 23 Engine oil filter ele ment Replace 24 Front and rear brake switches Check operation 25 Control 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 hous ing and cable No ITEM ROUT...

Page 46: ...quently when riding in unusually wet or dusty areas Hydraulic brake service After disassembling the brake master cylinders and calipers always change the fluid Regularly check the brake fluid levels and fill the reservoirs as required Every two years replace the internal components of the brake master cylinders and calipers and change the brake fluid Replace the brake hoses every four years and if...

Page 47: ...r a panel needs to be re moved and installed EAU44841 Cowling A To remove the cowling 1 Remove the bolts 2 Unhook both projections at the bottom of the cowling by pulling it downward and then pull the cowl ing forward as shown To install the cowling 1 Place the cowling in the original position 2 Install the bolts EAU44850 Panels A and B To remove one of the panels 1 Remove the screw and collar 1 C...

Page 48: ...e the panel by pulling it forward as shown To install the panel Place the collar and panel in their origi nal position and then install the screw Panel C To remove the panel 1 Remove the seat See page 4 10 1 Screw 2 Collar 3 Panel A 1 Screw 2 Collar 3 Panel B 1 2 3 1 2 3 1 Panel A 1 Panel B 1 1 1 Panel A 1 Panel B 1 1 ...

Page 49: ...ine component which is easy to check Since heat and deposits will cause any spark plug to slowly erode the spark plug should be removed and checked in accordance with the periodic mainte nance and lubrication chart In addition the condition of the spark plug can re veal the condition of the engine To remove the spark plug 1 Remove the spark plug cap 2 Remove the spark plug as shown with the spark ...

Page 50: ... spark plug 1 Measure the spark plug gap with a wire thickness gauge and if nec essary adjust the gap to specifica tion 2 Clean the surface of the spark plug gasket and its mating surface and then wipe off any grime from the spark plug threads 3 Install the spark plug with the spark plug wrench and then tight en it to the specified torque TIP If a torque wrench is not available when installing a s...

Page 51: ... 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 a few minutes until the oil set tles and then check the oil level through the check window located at the bottom right side of the crankcase TIP The engine oil should be between the minimum and maximum...

Page 52: ...ary 5 Remove the oil filter element drain bolt to drain the oil from the oil filter element TIP Skip steps 6 8 if the oil filter element is not being replaced 6 Remove the oil filter element cover by removing the bolts 1 Engine oil filler bolt 1 Engine oil drain bolt 1 1 1 Engine oil drain bolt 2 Washer 2 1 1 Oil filter element drain bolt 1 Oil filter element cover bolt 2 Oil filter element cover ...

Page 53: ...e engine oil also lubricates the clutch do not mix any chemical additives Do not use oils with a diesel speci fication of CD or oils of a high er quality than specified In addition do not use oils labeled ENERGY CONSERVING II or higher Make sure that no foreign mate rial enters the crankcase 12 Start the engine and then let it idle for several minutes while checking it for oil leakage If oil is le...

Page 54: ... or dusty areas In addition the air filter check hose must be fre quently checked and cleaned if neces sary To replace the air filter element 1 Remove the seat See page 4 10 2 Remove the air filter case cover by removing the screws 3 Pull the air filter element out 4 Insert a new air filter element into the air filter case as shown NOTICE Make sure that the air filter element is properly seated in...

Page 55: ...ng the spark arrester The spark arrester should be cleaned at the intervals specified in the periodic maintenance and lubrication chart WARNING EWA10980 Always let the exhaust system cool prior to touching exhaust components Do not start the engine when cleaning the exhaust system TIP Make sure to select a well ventilated area free of combustible materials to clean the spark arrester 1 Remove the ...

Page 56: ...lpipe into the muffler and then install and tighten the screw TIP Make sure to align the screw hole when inserting the tailpipe EAU21251 Carburetor The carburetor is an important part of the engine and its emission control sys tem which requires very sophisticated adjustment Therefore carburetor ad justments should be left to Yamaha dealer who has the necessary profes sional knowledge and experien...

Page 57: ...n it quickly re sponds to the throttle EAU21382 Checking the throttle cable free play The throttle cable free play should mea sure 3 0 5 0 mm 0 12 0 20 in at the throttle grip Periodically check the throttle cable free play and if neces sary have a Yamaha dealer adjust it EAU21401 Valve clearance The valve clearance changes with use resulting in improper air fuel mixture and or engine noise To pre...

Page 58: ...ger car go and accessories approved for this model WARNING EWA10511 Never overload your vehicle Opera tion of an overloaded vehicle could cause an accident Tire inspection The tires must be checked before each ride If the tire shows crosswise lines minimum tread depth if the tire has a nail or glass fragments in it or if the sidewall is cracked have a Yamaha dealer replace the tire immediately TIP...

Page 59: ...id able however patch the tube very carefully and replace it as soon as possible with a high quality product EAU21940 Spoke wheels To maximize the performance durabil ity and safe operation of your motorcy cle note the following points regarding the specified wheels The wheel rims should be checked for cracks bends or warpage and the spokes for looseness or dam age before each ride If any dam age ...

Page 60: ... a to loosen the clutch ca ble 5 Loosen the locknut further down the clutch cable 6 To increase the clutch lever free play turn the clutch lever free play adjusting nut in direction a To decrease the clutch lever free play turn the adjusting nut in direction b 7 Tighten both locknuts 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 s...

Page 61: ...ke light comes on just before braking takes effect If necessary adjust the brake light switch as follows Turn the rear brake light switch adjust ing nut while holding the rear brake light switch in place To make the brake light come on earlier turn the adjusting nut in direction a To make the brake light come on later turn the adjusting nut in direction b EAU22390 Checking the front and rear brake...

Page 62: ... ing it to become ineffective Before riding check that the brake fluid is above the minimum level mark and replenish if necessary A low brake fluid level may indicate worn brake pads and or brake 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 t...

Page 63: ...brication chart In addition have the oil seals of the master cylinders and calipers as well as the brake hoses re placed at the intervals listed below or whenever they are damaged or leak ing Oil seals Replace every two years Brake hoses Replace every four years EAU22760 Drive chain slack The drive chain slack should be checked before each ride and adjusted if necessary EAU22773 To check the drive...

Page 64: ...ighten the axle nut to the speci fied torque EAU23023 Cleaning and lubricating the drive chain The drive chain must be cleaned and lubricated at the intervals 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 NOTICE ECA10581 The drive chain must be lubricated after washing ...

Page 65: ...ot move smoothly have a Yamaha dealer check or replace it WARNING Damage to the outer housing of cables may result in in ternal rusting and cause interfer ence with cable movement Replace damaged cables as soon as possi ble to prevent unsafe condi tions EWA10711 EAU23111 Checking and lubricating the throttle grip and cable The operation of the throttle grip should be checked before each ride In ad...

Page 66: ...shift pedals should be checked before each ride and the pedal pivots should be lu bricated if necessary EAU23142 Checking and lubricating the brake and clutch levers Brake lever Clutch lever The operation of the brake and clutch levers should be checked before each ride and the lever pivots should be lu Recommended lubricant Lithium soap based grease ...

Page 67: ...and down smoothly have a Yamaha dealer check or repair it Otherwise the sidestand could contact the ground and distract the operator re sulting in a possible loss of control EAU23250 Lubricating the rear suspension The pivoting points of the rear suspen sion must be lubricated at the intervals specified in the periodic maintenance and lubrication chart Recommended lubricants Brake lever Silicone g...

Page 68: ...s several times to check if the front fork compresses and rebounds smoothly NOTICE ECA10590 If any damage is found or the front fork does not operate smoothly have a Yamaha dealer check or re pair it EAU23282 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 maintena...

Page 69: ...ck the wheel bearings EAU23392 Battery The battery is located behind panel C See page 7 9 This model is equipped with a VRLA Valve Regulated Lead Acid battery There is no need to check the electro lyte or to add distilled water However the battery lead connections need to be checked and if necessary tightened To charge the battery Have a Yamaha dealer charge the bat tery as soon as possible if it ...

Page 70: ...n enclosed space KEEP THIS AND ALL BATTER IES OUT OF THE REACH OF CHILDREN To store the battery 1 If the model will not be used for more than one month remove the battery fully charge it and then place it in a cool dry place NOTICE When removing the battery be sure the key is turned to OFF before discon necting the coupler ECA16322 2 If the battery will be stored for more than two months check it ...

Page 71: ...e electrical circuits to check if the devices operate 4 If the fuse immediately blows again have a Yamaha dealer check the electrical system EAU23814 Replacing the headlight bulb This model is equipped with a quartz bulb headlight If the headlight bulb burns out replace it as follows NOTICE ECA10660 Do not touch the glass part of the headlight bulb to keep it free from oil otherwise the transparen...

Page 72: ...turning it counterclockwise and then remove the burnt out bulb 5 Place a new bulb into position and then secure it with the bulb holder 6 Install the bulb cover and then connect the coupler 7 Place the headlight unit in the orig inal position and then install the bolts 8 Install the cowling 9 Have a Yamaha dealer adjust the headlight beam if necessary 1 Bolt 1 1 Headlight coupler 2 Headlight bulb ...

Page 73: ... 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 EAU24204 Replacing a turn signal light bulb 1 Remove the turn signal light lens by removing the screw 2 Remove the burnt out bulb by pushing it in and turning it counter clockwise 1 Tail brake light lens 2 Screw 1 ...

Page 74: ... 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 available by placing a jack un der the frame in front of the rear wheel 2 Raise the front wheel off the groun...

Page 75: ...IP Make sure that there is enough space between the brake pads before insert ing the brake disc into the caliper 2 Insert the wheel axle and then in stall the axle nut 3 Lower the front wheel so that it is on the ground 4 Tighten the axle nut to the speci fied torque 5 Push down hard on the handlebar several times to check for proper fork operation EAU25080 Rear wheel EAU37852 To remove the rear w...

Page 76: ...l 1 Install the drive chain adjusting plates the wheel and the brake cal iper bracket by inserting the wheel axle from the right hand side TIP Make sure that the drive chain ad justing plates are installed with the punched sides facing to the out side and that the retainer on the swingarm is inserted into the slot in the brake caliper bracket Make sure that there is enough space between the brake ...

Page 77: ...ever should your motorcycle require any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools experience and know how to service the motorcycle properly Use only genuine Yamaha 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...

Page 78: ...aha dealer check the vehicle Remove the spark plug and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gap or replace the spark plug Have a Yamaha dealer check the vehicle The engine does not start Have a Yamaha dealer check the vehicle The engine does not start Check the battery Operate the electric starter 4 Battery The engine turns over quickly The engine tu...

Page 79: ...ance Before cleaning 1 Cover the muffler outlet with a plastic bag 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 cap 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 e...

Page 80: ...ily if the area is covered with a wet cloth for a few minutes before cleaning After riding in the rain near the sea or on salt sprayed roads Since sea salt or salt sprayed on roads during winter are extremely corrosive in combination with water carry out the following steps after each ride in the rain near the sea or on salt sprayed roads TIP Salt sprayed on roads in the winter may remain well int...

Page 81: ...y 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 advice on what products to use EAU26151 Storage Short term Always store your motorcycle in a cool dry place and if necessary protect it against dust with a porous cover NOTICE ECA10810 Storing the motorcycle in a poorly ven...

Page 82: ... WARNING To prevent dam age or injury from sparking make sure to ground the spark plug electrodes while turning the engine over EWA10951 e Remove the spark plug cap from the spark plug and then install the spark plug and the spark plug cap 6 Lubricate all control cables and the pivoting points of all levers and pedals as well as of the sidestand centerstand 7 Check and if necessary correct the tir...

Page 83: ...lacement 1 20 L 1 27 US qt 1 06 Imp qt With oil filter element replacement 1 30 L 1 37 US qt 1 14 Imp qt Air filter Air filter element Oil coated paper element Fuel Recommended fuel Regular unleaded gasoline only Fuel tank capacity 9 1 L 2 40 US gal 2 00 Imp gal CAL 9 8 L 2 59 US gal 2 16 Imp gal U49 Fuel reserve amount 1 9 L 0 50 US gal 0 42 Imp gal Carburetor Manufacturer TEIKEI Type quantity MV...

Page 84: ...ng condition 90 160 kg 198 353 lb Front 150 kPa 1 50 kgf cm2 22 psi Rear 175 kPa 1 75 kgf cm2 25 psi Front wheel Wheel type Spoke wheel Rim size 21x1 60 Rear wheel Wheel type Spoke wheel Rim size 18M C x MT2 15 Front brake Type Single disc brake Operation Right hand operation Recommended fluid DOT 4 Rear brake Type Single disc brake Operation Right foot operation Recommended fluid DOT 4 Front susp...

Page 85: ...wattage quantity Headlight 12 V 60 W 55 0 W 1 Tail brake light 12 V 8 0 W 27 0 W 1 Front turn signal position light 12 V 27 W 5 0 W 2 Rear turn signal light 12 V 27 0 W 2 Neutral indicator light LED High beam indicator light LED Turn signal indicator light LED Fuse Main fuse 20 0 A ...

Page 86: ... LABEL INFORMATION EAU26381 Key identification number The key identification number is stamped into the key tag Record this number 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 use...

Page 87: ...0 EAU36980 Model label The model label is affixed to the frame behind panel A See page 7 9 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 1 ...

Page 88: ...aints it may open an investigation 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 wri...

Page 89: ...ign incorporated into any new ve hicle 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 syst...

Page 90: ...s warranty The chart below is printed only as a reminder 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 month...

Page 91: ...FORMATION 10 6 2 3 4 5 6 7 8 9 10 25000 mi 41000 km or 48 months 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 ...

Page 92: ...hine be inspected and registered for 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 s...

Page 93: ...f sale and upon your request at any 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 SE...

Page 94: ...n t have to pay anything for covered 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 replaceme...

Page 95: ...ing you ll have strong factory backed 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 ...

Page 96: ... 2 Horn switch 4 5 I Identification numbers 10 1 Ignition circuit cut off system 4 12 Indicator lights 4 2 K Key identification number 10 1 L Location of important labels 1 1 M Main switch steering lock 4 1 Maintenance and lubrication periodic 7 5 Maintenance emission control system 7 3 Maintenance record 10 5 Matte color caution 8 1 Model label 10 2 Multi function display 4 3 N Neutral indicator ...

Page 97: ...Turn signal light bulb replacing 7 35 Turn signal switch 4 4 V Valve clearance 7 19 Vehicle identification number 10 1 W Warranty extended 10 9 Warranty limited 10 7 Wheel bearings checking 7 31 Wheel front 7 37 Wheel rear 7 37 Wheels 7 21 ...

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Page 100: ...PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2008 4 1 2 1 E ...

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Yamaha XT250 2008, Owner'S Manual

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Summary of Contents for XT250 2008

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