Yamaha XT250M 1999 Owner'S Manual Download Page 74

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6-33

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU00902

Front wheel removal

EW000122

It is advisable to have a
Yamaha dealer service the
wheel.

Securely support the motorcy-
cle so there is no danger of it
falling over.

1. Remove the engine guard.

Disc cover

Speedometer cable

Holder

Axle nut

Cotter pin

2. Remove the disc cover, holder

and speedometer cable.

3. Remove the cotter pin and axle

nut.

4. Elevate the front wheel by

placing a suitable stand under
the engine.

5. Remove the axle and the front

wheel. Make sure the motorcy-
cle is properly supported.

NOTE:

Do not depress the brake lever
when the disc and caliper are sepa-
rated.

Rear wheel service

Use a motorcycle stand or motor-
cycle jack to elevate the motorcycle
so the rear wheel is off the ground.
Alternatively, two jacks can be
placed under the frame or
swingarm.

4FD-9-27-6~11 4/19/0 10:31 AM Page 34

ProCarManuals.com

Summary of Contents for XT250M 1999

Page 1: ...OWNER S MANUAL 4FD 28199 27 XT250M XT250 OCE ï éÜ4FD 27 4 19 0 10 59 AM Page 1 2 1 Magenta plate ProCarManuals com ...

Page 2: ...siro page 4 6 0 3 58 AM Page 1 ProCarManuals com ...

Page 3: ... racing machines It represents the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields This manual will give you an understanding of the operation inspection and basic mainte nance of this motorcycle If you have any questions about the operation or maintenance of your motorcycle please consult a Yamaha dealer 4FD 9 27 1 5 4 19 0 10 28 AM Page 1 ProCarManuals...

Page 4: ...ken to avoid damage to the motorcycle A NOTE provides key information to make procedures easier or clearer Q w cC NOTE NOTE 8 This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold 8 Yamaha continually seeks advancements in product design and quality Therefore while this manual contains the most current product inf...

Page 5: ...IMPORTANT MANUAL INFORMATION 1 2 4 5 6 7 8 9 EW000002 w PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE 4FD 9 27 1 5 4 19 0 10 28 AM Page 3 ProCarManuals com ...

Page 6: ...maha Motor Co Ltd 1st Edition June 1999 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan EAU00008 4FD 9 27 1 5 4 19 0 10 28 AM Page 4 ProCarManuals com ...

Page 7: ...r brake pedal 3 5 Fuel tank cap 3 5 Fuel 3 6 Fuel cock 3 7 Starter choke 1 3 8 Seat 3 8 Helmet holder 3 9 Rear shock absorber adjustment 3 10 Sidestand 3 12 Sidestand clutch switch operation check 3 12 PRE OPERATION CHECKS 4 1 Pre operation check list 4 1 OPERATION AND IMPORTANT RIDING POINTS 5 1 Starting and warming up a cold engine 5 1 Starting a warm engine 5 4 Shifting 5 4 Tips for reducing fu...

Page 8: ...lutch lever lubrication 6 25 Sidestand lubrication 6 26 Rear suspension lubrication 6 26 Front fork inspection 6 26 Steering inspection 6 27 Wheel bearings 6 28 Battery 6 28 Fuse replacement 6 29 Headlight bulb replacement 6 29 Turn signal light bulb replacement 6 31 Taillight bulb replacement 6 32 Supporting the motorcycle 6 32 Front wheel removal 6 33 Front wheel installation 6 34 Rear wheel rem...

Page 9: ...4FD 9 27 1 5 4 19 0 10 28 AM Page 7 ProCarManuals com ...

Page 10: ...ESSARY BY MECHANICAL CONDITIONS Safe riding 1 Always make pre operation checks Careful checks may help prevent an accident 2 This motorcycle is designed to carry the operator and a passenger 3 The failure of motorists to detect and recognize motorcycles in traffic is the predominating cause of automobile motorcycle accidents Many accidents have been caused by an auto mobile driver who did not see ...

Page 11: ...a turn due to EXCESSIVE SPEED or under cornering insufficient lean angle for the speed a Always obey the speed limits and never travel faster than warranted by road and traffic conditions b Always signal before turning or changing lanes Make sure other motorists see you 6 The operator s and passenger s posture are important for proper control a The operator should keep both hands on the handlebars...

Page 12: ...on They become very hot and can cause burns Always wear protective clothing that covers your legs ankles and feet 6 A passenger should also observe the above precautions Modification Modifications made to the motorcycle not approved by Yamaha or the removal of original equipment may render your motorcycle unsafe for use and may cause severe personal injury Modifications may also make your motorcyc...

Page 13: ...s including such cargo as sleeping bags duffle bags or tents can create unstable handling or slow steering response Accessories Genuine Yamaha accessories have been specifically designed for use on this motorcycle Since Yamaha cannot test all other accessories which may be available you must personally be responsible for the proper selection installation and use of non Yamaha accessories You shoul...

Page 14: ...ntrol ability Therefore such accessories are not recommended 2 Caution must be used if adding electrical accessories If these accessories exceed the capacity of the motorcycle s electrical system an electric failure could result which could cause a dangerous loss of lights or engine power Gasoline and exhaust gas 1 GASOLINE IS HIGHLY FLAMMABLE a Always turn off the engine when refueling b Take car...

Page 15: ... motorcycle could catch fire 4 When transporting the motorcycle in another vehicle be sure it is kept upright and that the fuel cock s is turned to ON or RES for vacuum type OFF for manual type If it should lean over gasoline may leak out of the carburetor or fuel tank 5 If you should swallow any gasoline inhale a lot of gasoline vapor or allow gasoline to get in your eyes see your doctor immediat...

Page 16: ...FETY INFORMATION 1 2 3 4 5 6 7 8 9 1 2 EAU02977 Location of the important labels Please read the following labels carefully before operating this motorcycle 4FD 9 27 1 5 4 21 0 4 54 AM Page 14 ProCarManuals com ...

Page 17: ...Q SAFETY INFORMATION 1 8 WARNING Before you operate this vehicle read the owner s manual English 3HP 21568 00 4AA 22259 40 1 2 1 4FD 9 27 1 5 4 21 0 7 01 PM Page 15 ProCarManuals com ...

Page 18: ...6 33 2 Front turn signal light 3 Fuel cock page 3 7 4 Seat page 3 8 5 Panel B page 6 6 6 Helmet holder page 3 9 7 Tool box page 6 1 8 Rear wheel page 6 35 9 Shift pedal page 3 4 5 4 1 2 3 4 6 7 8 9 5 Left view 4FD 9 27 1 5 4 19 0 10 28 AM Page 16 ProCarManuals com ...

Page 19: ... 8 9 2 2 10 Tail brake light page 6 32 11 Rear turn signal light page 6 31 12 Panel A page 6 6 13 Headlight page 6 29 14 Rear brake pedal page 3 5 10 11 12 13 14 Right view 4FD 9 27 1 5 4 19 0 10 28 AM Page 17 ProCarManuals com ...

Page 20: ...tches page 3 3 17 Speedometer page 3 2 18 Main switch page 3 1 19 Right handlebar switches page 3 3 20 Front brake lever page 3 5 6 18 21 Throttle grip page 6 25 22 Fuel tank cap page 3 5 15 16 17 18 19 20 21 22 Controls Instruments 4FD 9 27 1 5 4 19 0 10 28 AM Page 18 ProCarManuals com ...

Page 21: ...y into the main switch turn it from OFF to LOCK and remove it To release the lock turn the key to OFF while pushing EAU00027 INSTRUMENT AND CONTROL FUNCTIONS 1 2 3 4 5 6 7 8 9 ON OFF LOCK EAU00029 Main switch Steering lock The main switch controls the igni tion and lighting systems Its oper ation is described below EAU00030 ON Electrical circuits are switched on and the headlight meter light and t...

Page 22: ...BEAM This indicator comes on when the headlight high beam is used EAU00062 Neutral indicator light NEUTRAL This indicator comes on when the transmission is in neutral 1 Turn indicator light TURN 2 High beam indicator light HIGH BEAM 3 Neutral indicator light NEUTRAL EAU00095 Speedometer The speedometer shows riding speed This speedometer is equipped with an odometer and trip odometer The trip odom...

Page 23: ...el the signal push the switch in after it has returned to the center position EAU00129 Horn switch Press the switch to sound the horn 1 2 3 1 Dimmer switch 2 Turn signal switch 3 Horn switch EAU00138 Engine stop switch The engine stop switch is a safety device for use in an emergency such as when the motorcycle over turns or if trouble occurs in the throttle system Turn the switch to to start the ...

Page 24: ...ll the clutch lever to the handlebar to dis engage the clutch and release the lever to engage the clutch The lever should be pulled rapidly and released slowly for smooth clutch operation Refer to the engine starting procedures for a descrip tion of the ignition circuit cut off system 1 Clutch lever 1 1 Shift pedal EAU00157 Shift pedal This motorcycle is equipped with a constant mesh 6 speed trans...

Page 25: ...ront brake lever is located on the right handlebar Pull it toward the handlebar to apply the front brake 2 1 EAU00177 Fuel tank cap To open Insert the key and turn it 1 4 turn counterclockwise Turn the cap 1 3 turn counterclockwise and remove it from the tank To close Put the cap in the filler neck and turn it 1 3 turn clockwise Lock the cap by turning the key 1 4 turn clockwise and remove the key...

Page 26: ...there is sufficient fuel in the tank Fill the fuel tank to the bottom of the filler tube as shown in the illustration EW000130 w Do not overfill the fuel tank Avoid spilling fuel on the hot engine Do not fill the fuel tank above the bot tom of the filler tube or it may overflow when the fuel heats up later and expands 1 Fuel level 2 Filler tube EAU00185 cC Always wipe off spilled fuel imme diately...

Page 27: ...arburetor while fil tering it also The fuel cock has three positions OFF With the lever in this position fuel will not flow Always return the lever to this position when the engine is not running 1 Arrow mark over OFF Closed position F U E L F U E 1 ON With the lever in this position fuel flows to the carburetor Normal riding is done with the lever in this position 1 Arrow mark over ON Normal posi...

Page 28: ...rk over RES Reserve position 1 a b 1 Starter choke 1 EAU02976 Starter choke 1 Starting a cold engine requires a richer air fuel mixture A separate starter circuit supplies this mixture Move in direction a to turn on the starter choke Move in direction b to turn off the starter choke 1 2 1 Panel A 2 Panel B EAU01648 Seat To remove 1 Remove panels A and B See page 6 6 for panel removal and installat...

Page 29: ...e panels NOTE Make sure that the seat is securely fitted 2 1 1 Helmet holder 2 Unlock EAU00261 Helmet holder To open the helmet holder insert the key in the lock and turn it as shown To lock the helmet holder turn the key to its original position EW000030 w Never ride with a helmet in the helmet holder The helmet may hit objects causing loss of control and possibly an accident 4FD 9 27 1 5 4 19 0 ...

Page 30: ...easurement A Minimum length soft 36 5 mm Standard length 43 5 mm Maximum length hard 48 0 mm Tightening torque Locknut 54 Nm 5 4 m0kg 1 2 a b EAU00303 Rear shock absorber adjustment This shock absorber is equipped with a spring preload and damping adjuster 1 Adjust spring preload as fol lows a Loosen the locknut b Turn adjusting nut in direction a to increase spring preload and in direction b to d...

Page 31: ...5 w This shock absorber contains high ly pressurized nitrogen gas Read and understand the following information before handling the shock absorber The manufacturer cannot be held responsible for property damage or personal injury that may result from improper handling 8 Do not tamper with or attempt to open the cylinder assembly 8 Do not subject the shock absorber to an open flame or other high he...

Page 32: ...oss of control Yamaha has designed into this motorcycle a lockout system to assist the operator in fulfilling the responsibility of retracting the sidestand Please check carefully the operating instructions listed below and if there is any indication of a malfunction return the motor cycle to a Yamaha dealer immedi ately for repair EAU00331 Sidestand clutch switch operation check Check the operati...

Page 33: ...TROL FUNCTIONS 1 2 3 4 5 6 7 8 9 EW000045 w If improper operation is noted consult a Yamaha dealer immedi ately ENGINE WILL STALL SIDESTAND SWITCH IS OK SIDESTAND IS DOWN 4FD 9 27 1 5 4 19 0 10 28 AM Page 31 ProCarManuals com ...

Page 34: ... operation free play fluid level and fluid leakage 6 18 6 22 9 Fill with DOT 4 or DOT 3 brake fluid if necessary Rear brake 9 Check operation condition and free play 6 18 6 20 9 Adjust if necessary Clutch 9 Check operation condition and free play 6 17 9 Adjust if necessary Throttle grip and housing 9 Check for smooth operation 6 25 9 Lubricate if necessary Engine oil 9 Check oil level 6 8 6 11 9 F...

Page 35: ... motorcycle ITEM ROUTINE PAGE Brake and shift pedal 9 Check for smooth operation 6 25 9 Lubricate if necessary Brake and clutch lever pivot 9 Check for smooth operation 6 25 9 Lubricate if necessary Sidestand pivot 9 Check for smooth operation 6 26 9 Lubricate if necessary Chassis fasteners 9 Make sure that all nuts bolts and screws are properly tightened 9 Tighten if necessary Fuel tank 9 Check f...

Page 36: ...ilation 8 Before starting out always be sure the sidestand is up Failure to retract the sidestand completely can result in a seri ous accident when you try to turn a corner EAU01860 Starting and warming up a cold engine NOTE This motorcycle is equipped with an ignition circuit cut off system The engine can be started only under one of the following condi tions 8 The transmission is in neutral 8 Th...

Page 37: ...NGINE WILL START RETRACT SIDESTAND AND PUT TRANSMISSION IN GEAR MOTORCYCLE CAN BE RIDDEN MOTORCYCLE CAN BE RIDDEN IF TRANSMISSION IS IN GEAR AND SIDESTAND IS UP PULL IN CLUTCH LEVER AND PUSH START SWITCH ENGINE WILL START TURN THE MAIN SWITCH TO ON AND THE ENGINE STOP SWITCH TO 4FD 9 27 1 5 4 19 0 10 28 AM Page 35 ProCarManuals com ...

Page 38: ...pushing the start switch NOTE If the engine fails to start release the start switch wait a few sec onds then try again Each attempt should be as short as possible to preserve the battery Do not crank the engine more than 10 seconds on any one attempt 6 After starting the engine move the starter choke to the halfway position NOTE For maximum engine life never accelerate hard with a cold engine 7 Af...

Page 39: ...nto neutral depress the shift pedal repeatedly until it reach es the end of its travel then raise the pedal slightly EC000048 cC 8 Do not coast for long periods with the engine off and do not tow the motorcycle a long distance Even with gears in neutral the transmission is only properly lubricated when the engine is running Inadequate lubrication may damage the transmission 8 Always use the clutch...

Page 40: ...w you must not put an excessive load on it for the first 1 000 km The various parts in the engine wear and polish them selves to the correct operating clearances During this period pro longed full throttle operation or any condition which might result in excessive heating of the engine must be avoided EAU00424 Tips for reducing fuel consumption Your motorcycle s fuel consump tion depends to a larg...

Page 41: ...torcycle stop the engine and remove the ignition key Turn the fuel cock to OFF whenever stopping the engine EW000058 w The exhaust system is hot Park the motorcycle in a place where pedestrians or children are not likely to touch the motorcycle Do not park the motorcycle on a slope or soft ground the motorcycle may overturn OPERATION AND IMPORTANT RIDING POINTS 1 2 3 4 5 6 7 8 9 4FD 9 27 1 5 4 19 ...

Page 42: ...DULE TO SHORTER INTERVALS TO MATCH THE ENVIRONMENT The most important points of motorcycle inspection adjustment and lubri cation are explained in the follow ing pages EW000060 w If you are not familiar with motor cycle service this work should be done by a Yamaha dealer EAU00469 Tool kit The service information included in this manual is intended to provide you the owner with the necessary inform...

Page 43: ...ring a service opera tion take your motorcycle to a Yamaha dealer for service EW000063 w Modifications to this motorcycle not approved by Yamaha may cause loss of performance and render it unsafe for use Consult a Yamaha dealer before attempting any changes 4FD 9 27 6 11 4 19 0 10 31 AM Page 3 ProCarManuals com ...

Page 44: ...n or replace if necessary 5 Clutch 9 Check operation 9 Adjust or replace cable 9 Check operation fluid level and vehicle for fluid leakage 6 Front brake See NOTE on page 6 5 9 Correct accordingly 9 Replace brake pads if necessary 7 Rear brake 9 Check operation 9 Adjust cable and replace brake shoes if necessary 8 Wheels 9 Check balance runout spoke tightness and for damage 9 Tighten spokes and reb...

Page 45: ...dingly 9 Lubricate with lithium soap base grease every 24 000 km or 24 months whichever comes first 14 Chassis fasteners 9 Make sure that all nuts bolts and screws are properly tightened 9 Tighten if necessary 15 Sidestand 9 Check operation 9 Lubricate and repair if necessary 16 Sidestand switch 9 Check operation 9 Replace if necessary 17 Front fork 9 Check operation and for oil leakage 9 Correct ...

Page 46: ...if necessary EAU02970 NOTE 8 The air filter needs more frequent service if you are riding in unusually wet or dusty areas 8 Hydraulic brake system 8 When disassembling the master cylinder or caliper cylinder always replace the brake fluid Check the brake fluid level regularly and fill as required 8 Replace the oil seals on the inner parts of the master cylinder and caliper cylinder every two years...

Page 47: ...areas shown To install Place in the original position and install the screw 1 Screw 2 Pull 1 Panel B 2 Screw 1 Panel A 2 Screw EAU00488 Panel A and B To remove Remove the screw and pull out ward on the areas shown To install Place the panel in the original posi tion and install the screw 1 2 4FD 9 27 6 11 4 19 0 10 31 AM Page 7 ProCarManuals com ...

Page 48: ...an color for a motorcycle that is being ridden normally Do not attempt to diagnose such problems yourself Instead take the motorcycle to a Yamaha deal er You should periodically remove and inspect the spark plug because heat and deposits will cause any spark plug to slowly break down and erode If electrode erosion becomes excessive or if carbon and other deposits are excessive you should replace t...

Page 49: ...17 5 Nm 1 75 m0kg Spark plug gap 0 6 0 7 mm EAU03002 Engine oil Oil level inspection 1 Place the motorcycle on a level place and hold it in an upright position Warm up the engine for several minutes NOTE Be sure the motorcycle is posi tioned straight up when checking the oil level A slight tilt toward the side can result in false readings 2 With the engine stopped check the oil level through the l...

Page 50: ...oving the oil drain bolt the O ring compression spring and oil strainer will fall out Take care not to lose these parts 1 1 Engine oil filler cap 3 Stop the engine Place an oil pan under the engine and remove the oil filler cap Engine oil replacement and oil filter element cleaning 1 Remove the engine guard 2 Warm up the engine for a few minutes 4FD 9 27 6 11 4 19 0 10 31 AM Page 10 ProCarManuals ...

Page 51: ...g compression spring and oil strainer in position 9 Fill the engine with oil Install the oil filler cap and tighten it 1 2 1 Oil filter element 2 O ring 2 6 Clean the oil filter and strainer with solvent Replace if neces sary 7 Check the O ring If damaged replace 8 Install the drain bolt and oil fil ter cover Tighten the oil filter cover bolts to the specified torque NOTE Make sure the O ring is s...

Page 52: ... ing in unusually wet or dusty areas 1 Remove panel A See page 6 6 for removal and installa tion procedures 2 Remove the air filter case fit ting screws and the filter case cover 2 1 1 Air filter case fitting screw 3 2 Air filter case cover EC000066 cC 8 Do not put in any chemical additives Engine oil also lubri cates the clutch and additives could cause clutch slippage 8 Be sure no foreign materi...

Page 53: ...rface of the element and squeeze out the excess oil It should be wet but not drip ping 6 Insert the air filter guide into the air filter and install it in the case 7 Install the air filter case cover and panel 1 2 3 4 Recommended oil Engine oil EC000082 cC 8 Make sure the air filter is prop erly seated in the air filter case 8 The engine should never be run without the air filter installed Excessi...

Page 54: ...ection b to decrease engine speed EAU00629 Carburetor adjustment The carburetor is a vital part of the engine and requires very sophisti cated adjustment Most adjust ments should be left to a Yamaha dealer who has the professional knowledge and experience to do so However the following may be serviced by the owner as part of routine maintenance EC000094 cC The carburetor was set at the Yamaha fact...

Page 55: ...sting nut 1 2 a b 1 Loosen the locknut 2 Turn the adjusting nut in direc tion a to increase free play and in direction b to decrease free play 3 Tighten the locknut c Free play c Free play 3 5 mm EAU00637 Valve clearance adjustment The correct valve clearance changes with use resulting in improper fuel air supply or engine noise To prevent this the valve clearance must be adjusted regu larly This ...

Page 56: ...ion for your load and check the condition and pressure of your tires NEVER OVERLOAD YOUR MOTORCYCLE Make sure the total weight of the cargo rider passenger and acces sories fairing saddlebags etc if approved for this model does not exceed the maximum load of the motorcycle Operation of an over loaded motorcycle could cause tire damage an accident or even injury Load is the total weight of cargo ri...

Page 57: ... quality replacement Manufacturer Size Type BRIDGESTONE 2 75 21 4PR TRAIL WING 27 CHENG SHIN 2 75 21 4PR C 6006 Minimum tire tread 1 0 mm depth front and rear FRONT Manufacturer Size Type BRIDGESTONE 120 80 18 62P TRAIL WING 30 CHENG SHIN 120 80 18 62P C 6006 REAR EAU00685 Wheels To ensure maximum performance long service and safe operation note the following 8 Always inspect the wheels before a r...

Page 58: ...h the follow ing steps 1 Locknut 2 Adjusting bolt c Free play 1 2 a b 4 Loosen the locknut at the clutch lever 5 Turn the adjusting bolt at the clutch lever in direction a to loosen the cable 6 Loosen the locknut at the crankcase side 7 Turn the adjusting nut at the crankcase in direction a to increase free play or in direc tion b to decrease free play 8 Tighten the locknut at the crankcase and th...

Page 59: ...ng in the brake lever can indicate the presence of air in the brake system This air must be removed by bleeding the brake system before the motorcycle is operated Air in the system will cause greatly diminished braking capability and can result in loss of con trol and an accident Have a Yamaha dealer inspect and bleed the system if necessary EAU00707 Rear brake pedal height and free play adjustmen...

Page 60: ... should be checked whenever the chain is adjusted or the rear wheel is removed and then reinstalled 8 Check the operation of the brake light after adjusting the rear brake 8 If it is impossible to make proper adjustment consult a Yamaha dealer 1 Loosen the locknut 2 Turn the adjusting bolt in direction a to raise pedal height or in direction b to lower pedal height 3 Tighten the locknut EW000105 w...

Page 61: ... on earlier Turn the adjusting nut in direction b to make the brake light come on later 1 2 a b 1 Brake light switch 2 Adjusting nut EAU00720 Checking the front brake pads and rear brake shoes EAU00723 Front brake Apply the brake and inspect the wear indicator If the wear indicator is ALMOST in contact with the disc plate ask a Yamaha dealer to replace the pads 1 1 Wear indicator EAU00727 Rear bra...

Page 62: ...fluid Otherwise the rubber seals may deteriorate causing leakage and poor brake performance NOTE If DOT 4 is not available DOT 3 can be used 8 Refill with the same type of brake fluid Mixing fluids may result in a harmful chemical reaction and lead to poor brake performance 8 Be careful that water does not enter the master cylinder when refilling Water will significant ly lower the boiling point o...

Page 63: ...otor cycle must be held straight up with both wheels on the ground and without rider Check the slack at the position shown in the illustra tion Normal slack is approximately 35 45 mm If the slack exceeds 45 mm adjust a a Chain slack EAU01502 Drive chain slack adjustment 1 Loosen the rear brake pedal free play adjusting nut 2 Remove the cotter pin from the axle nut 3 Loosen the axle nut 4 Turn both...

Page 64: ...in into the axle nut and bend the end of the cotter pin as shown in the illustration If the notch in the nut and cotter pin hole do not match tighten the nut slightly to align them EW000110 w Always use a new cotter pin on the axle nut 7 Adjust the free play in the brake pedal See page 6 19 1 1 Cotter pin Tightening torque Axle nut 85 Nm 8 5 m0kg EW000103 w Check the operation of the brake light a...

Page 65: ...l vents can damage the drive chain so do not use these for cleaning it Use only kerosene to clean the drive chain Wipe it dry and thor oughly lubricate it with SAE 30 50W motor oil Do not use any other lubricants on the drive chain They may contain solvents that could damage the sealed chain EAU02962 Cable inspection and lubrication EW000112 w Damage to the outer housing of cables may lead to inte...

Page 66: ...emoving the screws hold the end of the cable up in the air and put in several drops of lubricant With the throttle grip disassembled coat the metal surface of the grip assembly with a suitable all purpose grease EAU02984 Brake and shift pedal lubrication Lubricate the pivoting parts EAU02985 Brake and clutch lever lubrication Lubricate the pivoting parts Recommended lubricant Engine oil Recommende...

Page 67: ... smoothly consult a Yamaha deal er EAU00790 Rear suspension lubrication Lubricate the pivoting parts Recommended lubricant Molybdenum disulfide grease Recommended lubricant Engine oil EAU02939 Front fork inspection Visual check EW000115 w Securely support the motorcycle so there is no danger of it falling over Check for scratches or damage on the inner tube and excessive oil leakage from the front...

Page 68: ...e steering Worn out or loose steering bearings may be danger ous Place a stand under the engine to raise the front wheel off the ground Hold the lower end of the front forks and try to move them forward and backward If any free play can be felt ask a Yamaha dealer to inspect and adjust the steering Inspection is easier if the front wheel is removed EW000115 w Securely support the motorcycle so the...

Page 69: ...er or milk Follow with milk of magnesia beaten egg or vegetable oil Call a physician immediately 8 EYES Flush with water for 15 minutes and get prompt med ical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Always shield your eyes when working near batteries KEEP OUT OF REACH OF CHIL DREN Battery storage When ...

Page 70: ...maha dealer 1 2 1 Main fuse 2 Spare fuse EC000103 cC Do not use fuses of higher amper age rating than those recommend ed Substitution of a fuse of improper rating can cause exten sive electrical system damage and possibly a fire Specified fuse 15 A EAU01146 Headlight bulb replacement This motorcycle is equipped with a quartz bulb headlight If the head light bulb burns out replace it as follows 1 R...

Page 71: ...over 4 Turn the bulb holder counter clockwise to remove it and remove the defective bulb EW000119 w Keep flammable products and your hands away from a bulb while it is on as it is hot Do not touch a bulb until it cools down 5 Put a new bulb into position and secure it in place with the bulb holder 1 1 Bulb holder 4FD 9 27 6 11 4 19 0 10 31 AM Page 31 ProCarManuals com ...

Page 72: ...ENANCE AND MINOR REPAIR 6 EC000105 cC Avoid touching the glass part of a bulb Keep it free from oil other wise the transparency of the glass life of the bulb and lumi nous flux will be adversely affect ed If oil gets on a bulb thoroughly clean it with a cloth moistened with alcohol or lacquer thinner 6 Install the bulb holder cover connector and headlight unit 7 Install the cowling 8 If the headli...

Page 73: ...maha XT250 has no centerstand follow these precau tions when removing the front and rear wheel or performing other maintenance requiring the motor cycle to stand upright 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 Front wheel service To stabilize the rear of the motor cycle either...

Page 74: ...isc cover holder and speedometer cable 3 Remove the cotter pin and axle nut 4 Elevate the front wheel by placing a suitable stand under the engine 5 Remove the axle and the front wheel Make sure the motorcy cle is properly supported NOTE Do not depress the brake lever when the disc and caliper are sepa rated Rear wheel service Use a motorcycle stand or motor cycle jack to elevate the motorcycle so...

Page 75: ...ds before inserting the brake disc and that the slot in the speedometer gear unit housing fits over the stopper on the front fork outer tube 3 Install the wheel axle and axle nut Then let the motorcycle down 4 Tighten the axle nut to the specified torque Tightening torque Axle nut 85 Nm 8 5 m0kg EAU01449 Front wheel installation 1 Install the speedometer gear unit housing into the wheel hub Make s...

Page 76: ...el assembly and insert the axle from the left hand side Be sure that the chain adjusting plates are installed with the punched side outward and the slot in the brake shoe plate is fit over the stopper on the swingarm 2 Install and adjust the drive chain See page 6 22 for details about adjusting the drive chain slack 1 2 3 4 5 1 Brake pedal free play adjusting nut 2 Chain adjusting plate 3 Axle nut...

Page 77: ...service your motorcycle Use only genuine Yamaha parts on your motorcycle Imitation parts may look like Yamaha parts but they are often inferior Consequently they have a shorter service life and can lead to expen sive repair bills 3 Install the axle nut and let the motorcycle down 4 Tighten the axle nut to the specified torque and install the axle nut cotter pin EW000110 w Always use a new cotter p...

Page 78: ... with dry cloth and correct Ask a Yamaha dealer to inspect Engine turns over Engine turns over Battery good Check connections Use the electric starter Check if there is fuel Enough fuel No fuel Go to compression check Supply fuel in the fuel tank electrode plug and check quickly slowly or recharge Open throttle half way and start Engine doesn t start go to battery check the engine spark gap or rep...

Page 79: ...connectors including the spark plug cap are tightly installed 3 Remove extremely stubborn dirt like oil burnt onto the crankcase with a degreasing agent and a brush but never apply such products onto seals gaskets sprockets the drive chain and wheel axles Always rinse the dirt and degreaser off with water Cleaning After normal use Remove dirt with warm water a neutral detergent and a soft clean sp...

Page 80: ...ot use strong cleaners or hard sponges as they will cause dulling or scratching Some cleaning compounds for plas tic may leave scratches on the windshield Test the product on a small hidden part of the windshield to make sure they do not leave any marks If the windshield is scratched use a quality plastic polishing com pound after washing After riding in the rain near the sea or on salt sprayed ro...

Page 81: ...rt 6 Touch up minor paint damage caused by stones etc 7 Wax all painted surfaces 8 Let the motorcycle dry com pletely before storing it or cov ering it EWA00001 w Make sure that there is no oil or wax on the brakes and tires If nec essary clean the brake discs and linings with a regular brake disc cleaner or acetone and wash the tires with warm water and mild soap Then carefully test the motorcycl...

Page 82: ...osition Turn the fuel cock to OFF 4 Fill up the fuel tank and add fuel stabilizer if available to prevent the fuel tank from rust ing and the fuel from deterio rating 5 Perform the following steps to protect the cylinder piston rings etc from corrosion a Remove the spark plug cap and spark plug b Pour a teaspoonful of engine oil into the spark plug bore c Install the spark plug cap onto the spark ...

Page 83: ...ot 8 Cover up the muffler outlet with a plastic bag to prevent moisture from entering 9 Remove the battery and fully charge it Store it in a cool dry place and recharge it once a month Do not store the bat tery in an excessively cold or warm place less than 0 C or more than 30 C For more information see Battery stor age in the chapter PERIODIC MAINTENANCE AND MINOR REPAIRS NOTE Make any necessary ...

Page 84: ... 1 Starting system Electric starter Lubrication system Wet sump Engine oil Type Recommended engine oil API Service SE SF SG type classification or higher cC Be sure to use motor oils that do not contain anti friction modifiers Passenger car motor oils often labeled Energy Conserving contain anti friction additives which will cause clutch and or starter clutch slippage resulting in reduced componen...

Page 85: ... ratio 3 318 Secondary reduction system Chain drive Secondary reduction ratio 3 000 Number of sprocket feeth Rear Front 45 15 Transmission type Constant mesh 6 speed Operation Left foot operation Gear ratio 1st 3 090 2nd 2 000 3rd 1 428 4th 1 125 5th 0 925 6th 0 793 Chassis Frame type Diamond Caster angle 26 5 Trail 102 mm Tire Type With tube Front Size 2 75 21 4PR Manufacturer model BRIDGESTONE T...

Page 86: ...akes Front Type Single disc brake Operation Right hand operation Fluid DOT 4 or DOT 3 Rear Type Drum brake Operation Right foot operation Suspension Front Type Telescopic fork Rear Type Swingarm link suspension Shock absorber Front Coil spring oil damper Rear Coil gas spring oil damper Wheel travel Front 225 mm Rear 190 mm Electrical system Ignition system C D I Charging system Type C D I magneto ...

Page 87: ...ht 12V 35W 35W 1 Tail brake light 12V 5W 21W 1 Turn signal light 12V 21W 4 Meter light 12V 3 4W 1 Neutral indicator light 12V 3 4W 1 High beam indicator light 12V 3 4W 1 Turn indicator light 12V 3 4W 1 Fuse Main fuse 15A 4FD 9 27 6 11 4 19 0 10 31 AM Page 47 ProCarManuals com ...

Page 88: ...t Multiplier Imperial unit m kg 7 233 ft lb Torque m kg 86 794 in lb cm kg 0 0723 ft lb cm kg 0 8679 in lb Weight kg 2 205 lb g 0 03527 oz Speed km hr 0 6214 mph km 0 6214 mi m 3 281 ft Distance m 1 094 yd cm 0 3937 in mm 0 03937 in cc cm3 0 03527 oz IMP liq Volume cc cm3 0 06102 cu in Capacity lt liter 0 8799 qt IMP liq lt liter 0 2199 gal IMP liq kg mm 55 997 lb in Misc kg cm2 14 2234 psi lb in2...

Page 89: ...fication number is used to identify your motorcycle and may be used to register your motorcycle with the licensing authority in your state 1 Key identification number 1 Vehicle identification number EAU02944 Identification number records Record the key identification num ber vehicle identification number and model label information in the spaces provided for assistance when ordering spare parts fr...

Page 90: ...ING WITH NOISE CON TROL SYSTEM PROHIBITED Owners are warned that the law may prohibit a The removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporat ed into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use and b The use of th...

Page 91: ...siro page 4 6 0 3 58 AM Page 1 ProCarManuals com ...

Page 92: ...PRINTED IN JAPAN 99 6 0 2 1 E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD XT250 OCE ï éÜ4FD 27 4 19 0 10 59 AM Page 1 1 1 Magenta plate ProCarManuals com ...

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Yamaha XT250M 1999, Owner'S Manual

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