Yamaha XT250N 2000 Owner'S Manual Download Page 81

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6-41

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU01397

Troubleshooting chart

EW000125

Keep away open flames and do not smoke while checking or working on the fuel system.

1. Fuel

2. Compression

3. Ignition

4. Battery

Use the electric starter.

Remove spark

There is compression.

Go to ignition check.

No compression.

Ask a Yamaha dealer to inspect.

Wet.

Dry.

Wipe clean with dry cloth and correct

Ask a Yamaha dealer to inspect.

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.

electrodes.

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 replace spark plug.

Engine doesn’t start, ask a Yamaha

dealer to inspect.

Engine doesn’t start, go to

compression check.

4FD-9-28-6~11 7/25/00 3:51 PM Page 42

ProCarManuals.com

Summary of Contents for XT250N 2000

Page 1: ...PRINTED IN JAPAN 2000 8 0 2 1 E OWNER S MANUAL 4FD 28199 28 XT250N PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD ProCarManuals com ...

Page 2: ...cing 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 maintenance of this motorcycle If you have any questions concerning the operation or maintenance of your motorcy cle please consult a Yamaha dealer 4FD 9 28 1 5 7 25 00 3 50 PM Page 1 ProCarManua...

Page 3: ...en 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 info...

Page 4: ...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 28 1 5 7 25 00 3 50 PM Page 3 ProCarManuals com ...

Page 5: ...maha Motor Co Ltd 1st Edition July 2000 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan EAU03337 4FD 9 28 1 5 7 25 00 3 50 PM Page 4 ProCarManuals com ...

Page 6: ... knob 1 3 7 Seat 3 7 Helmet holder 3 8 Adjusting the shock absorber assembly 3 9 Sidestand 3 11 Ignition circuit cut off system 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 2 Shifting 5 3 Tips for reducing fuel consumption 5 3 Engine break in 5 4 Parking 5 5 PERIODIC MAINTENAN...

Page 7: ...g and lubricating the brake and clutch levers 6 28 Checking and lubricating the sidestand 6 28 Lubricating the rear suspension 6 28 Checking the front fork 6 29 Checking the steering 6 29 Checking the wheel bearings 6 30 Battery 6 30 Replacing the fuse 6 32 Replacing the headlight bulb 6 32 Replacing a turn signal light bulb 6 34 Replacing the tail brake light bulb 6 35 Supporting the motorcycle 6...

Page 8: ...4FD 9 28 1 5 7 25 00 3 50 PM Page 7 ProCarManuals com ...

Page 9: ...ARY 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 automobile driver who did not see the ...

Page 10: ...g wide on a turn due to EXCESSIVE SPEED or undercornering insufficient lean angle for the speed a Always obey the speed limit and never travel faster than warranted by road and traffic condi tions b Always signal before turning or changing lanes Make sure that other motorists can see you 6 The posture of the operator and passenger is important for proper control a The operator should keep both han...

Page 11: ...ration They become very hot and can cause burns Always wear protective clothing that covers your legs ankles and feet 6 Passengers should also observe the precautions mentioned above Modifications Modifications made to this motorcycle not approved by Yamaha or the removal of original equipment may render the motorcycle unsafe for use and may cause severe personal injury Modifications may also make...

Page 12: ...including such cargo as sleeping bags duffel bags or tents can create unstable handling or a slow steering response Accessories Genuine Yamaha accessories have been specifically designed for use on this motorcycle Since Yamaha cannot test all other accessories that may be available you must personally be responsible for the proper selection installation and use of non Yamaha accessories Use extrem...

Page 13: ... ability therefore such accessories are not recommended 2 Use caution when adding electrical accessories If electrical 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 the engine off when refueling b Take care not t...

Page 14: ...ld catch fire 4 When transporting the motorcycle in another vehicle make sure that it is kept upright and that the fuel cock s are turned to ON or RES for vacuum type OFF for manual type If the motor cycle 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 into your eyes see your doctor ...

Page 15: ... INFORMATION 1 2 3 4 5 6 7 8 9 1 2 EAU02977 Location of important labels Please read the following important labels carefully before operating this motorcycle 4FD 9 28 1 5 7 25 00 3 50 PM Page 14 ProCarManuals com ...

Page 16: ...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 4FD 9 28 1 5 7 25 00 3 50 PM Page 15 ProCarManuals com ...

Page 17: ... 6 4 Air filter element page 6 11 5 Helmet holder page 3 8 6 Owner s tool kit page 6 1 7 Rear shock absorber spring preload adjusting nut page 3 9 8 Rear shock absorber rebound damping adjusting dial page 3 10 9 Shift pedal page 3 4 1 2 3 4 6 7 8 9 5 Left view 4FD 9 28 1 5 7 25 00 3 50 PM Page 16 ProCarManuals com ...

Page 18: ...IPTION 1 2 3 4 5 6 7 8 9 2 2 10 Battery page 6 30 11 Fuse page 6 32 12 Oil filter element page 6 10 13 Brake pedal page 3 4 6 19 10 13 11 12 Right view 4FD 9 28 1 5 7 25 00 3 50 PM Page 17 ProCarManuals com ...

Page 19: ... page 3 2 3 Speedometer unit page 3 2 4 Main switch steering lock page 3 1 5 Right handlebar switches page 3 3 6 Brake lever page 3 4 6 19 7 Throttle grip page 6 14 6 27 8 Fuel tank cap page 3 5 1 2 3 4 5 6 7 8 Controls and instruments 4FD 9 28 1 5 7 25 00 3 50 PM Page 18 ProCarManuals com ...

Page 20: ...lock con trols the ignition and lighting systems and is used to lock the steering The various positions are described below EAU00030 ON All electrical systems are supplied with power the headlight meter light ing and taillight come on and the engine can be started The key can not be removed EAU00038 OFF All electrical systems are off The key can be removed a b EW000016 w Never turn the key to OFF ...

Page 21: ...edometer shows riding speed The odometer shows the total distance 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 enable you to plan future fuel stops 1 2 3 4 1 Speedometer 2 Odometer 3 Tripmeter 4 Reset knob EAU00118 Handlebar ...

Page 22: ... equipped with a clutch switch which is part of the igni tion circuit cut off system See page 3 12 for an explanation of the ignition circuit cut off system 1 Clutch lever EAU00138 Engine stop switch Set this switch to to stop the engine in case of an emergency such as when the motorcycle over turns or when the throttle cable is stuck EAU00141 Start switch START Push this switch to crank the engin...

Page 23: ... the 6 speed constant mesh transmission equipped on this motorcycle 1 1 Brake pedal EAU00162 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 1 Brake lever EAU00158 Brake lever The brake lever is located at the right handlebar grip To apply the front brake pull the lever toward the han dlebar grip 4FD 9 28 1 5 7 25 00 3 50 P...

Page 24: ...1 Fuel tank cap a Unlock b Open NOTE The fuel tank cap cannot be installed unless the key is in the lock In addi tion the key cannot be removed if the cap is not properly installed and locked EW000023 w Make sure that the fuel tank cap is properly closed and locked before riding 1 2 EAU01183 Fuel Make sure that there is sufficient fuel in the tank Fill the fuel tank to the bottom of the filler tub...

Page 25: ...uel cock supplies fuel from the tank to the carburetor while filtering 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 positioned over OFF 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 ...

Page 26: ...ned over RES RES Reserve position 1 a b 1 Starter choke knob 1 EAU03032 Starter choke knob 1 Starting a cold engine requires a rich er 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 EAU02949 Seat To remove the seat 1 Remove panels A and B See page 6 5 for panel removal and ...

Page 27: ... Install the panels NOTE Make sure that the seat is properly secured before riding 1 a 1 Helmet holder a Unlock EAU00261 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 turn the key to the original position and then remove it EW000030 w Never ride with a helmet attached to the helmet holder since the hel met may hit obje...

Page 28: ...uring dis tance A shown in the illustration The longer distance A is the higher the spring preload the shorter distance A is the lower the spring preload a Distance A 1 2 a b EAU03673 Adjusting the shock absorber assembly This shock absorber assembly is equipped with a spring preload adjusting nut and a rebound damping force adjusting dial EC000015 cC Never attempt to turn an adjusting mechanism b...

Page 29: ...mall dif ferences in production the actual number of clicks always represents the entire adjusting range To obtain a precise adjustment it would be advisable to check the number of clicks of the damping force adjusting mechanism and to modify the specifi cations as necessary Tightening torque Locknut 54 Nm 5 4 m0kg 3 Tighten the locknut to the speci fied torque ECA00076 cC Always tighten the lockn...

Page 30: ...sidestand is located on the left side of the frame Raise the side stand or lower it with your foot while holding the motorcycle upright NOTE The built in sidestand switch is part of the ignition circuit cut off system which cuts the ignition in certain situ ations See further down for an explanation of the ignition circuit cut off system EW000044 w The motorcycle must not be ridden with the sidest...

Page 31: ... up but the clutch lever is not pulled 8 It prevents starting when the transmission is in gear and the clutch lever is pulled but the sidestand is still down 8 It cuts the running engine when the transmission is in gear and the sidestand is moved down Periodically check the operation of the ignition circuit cut off system according to the following procedure EW000045 w If a malfunction is noted ha...

Page 32: ... the clutch lever pulled 8 Shift the transmission into gear 9 Move the sidestand down Does the engine stall 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 sidestand switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer The clutch switch may be defective The motorcycle sh...

Page 33: ... Check fuel level in fuel tank Refuel if necessary Check fuel line for leakage 3 5 3 6 Engine oil Check oil level in engine If necessary add recommended oil to specified level Check vehicle for oil leakage 6 8 6 11 Front brake Check operation If soft or spongy have Yamaha dealer bleed hydraulic system Check lever free play Adjust if necessary Check fluid level in reservoir If necessary add recomme...

Page 34: ...Brake and shift pedals Make sure that operation is smooth Lubricate pedal pivoting points if necessary 6 27 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 28 Sidestand Make sure that operation is smooth Lubricate pivot if necessary 6 28 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened Tighten if necessary I...

Page 35: ... an inspection can be accomplished in a very short time and the added safety it assures is more than worth the time involved EWA00033 w If any item in the Pre operation check list is not working properly have it inspected and repaired before operat ing the motorcycle 4FD 9 28 1 5 7 25 00 3 50 PM Page 34 ProCarManuals com ...

Page 36: ...r for the ignition circuit cut off system to enable starting one of the following conditions must be met 8 The transmission is in the neutral position 8 The transmission is in gear with the clutch lever pulled and the sidestand up EW000054 w 8 Before starting the engine check the function of the igni tion circuit cut off system according to the procedure described on page 3 13 8 Never ride with th...

Page 37: ... Do not crank the engine more than 10 seconds on any one attempt 6 After starting the engine move the starter choke knob back halfway ECA00045 cC For maximum engine life never accelerate hard when the engine is cold 7 When the engine is warm turn the starter choke off NOTE The engine is warm when it responds normally to the throttle with the starter choke turned off EAU01258 Starting a warm engine...

Page 38: ...uate lubrication may damage the transmission 8 Always use the clutch while changing gears to avoid dam aging the engine transmis sion and drive train which are not designed to withstand the shock of forced shifting 1 5 4 3 2 1 N 6 1 Shift pedal N Neutral EAU00424 Tips for reducing fuel consumption Fuel consumption depends largely on your riding style Consider the follow ing tips to reduce fuel con...

Page 39: ...ve 1 3 throttle 8 After every hour of operation stop the engine and then let it cool for five to ten minutes 8 Vary the engine speed from time to time Do not operate the engine at one set throttle posi tion 150 500 km 8 Avoid prolonged operation above 1 2 throttle 8 Rev the engine freely through the gears but do not use full throttle at any time 500 1 000 km Avoid prolonged operation above 3 4 thr...

Page 40: ...ain switch and then turn the fuel cock lever to OFF EW000058 w 8 Since the engine and exhaust system can become very hot park in a place where pedestri ans or children are not likely to touch them 8 Do not park on a slope or on soft ground otherwise the motorcycle may overturn 4FD 9 28 1 5 7 25 00 3 50 PM Page 39 ProCarManuals com ...

Page 41: ...on the fol lowing pages The intervals given in the periodic maintenance and lubrication chart should be simply considered as a general guide under normal riding conditions However DEPENDING ON THE WEATHER TERRAIN GEOGRAPHICAL LOCATION AND INDIVIDUAL USE THE MAINTE NANCE INTERVALS MAY NEED TO BE SHORTENED EW000060 w If you are not familiar with motor cycle maintenance work have a Yamaha dealer do i...

Page 42: ... CHECK 1 6 12 18 24 1 Fuel line Check fuel hoses for cracks or damage 2 Spark plug Check condition Clean and regap Replace 3 Valves Check valve clearance Adjust 4 Air filter element Clean Replace 5 Clutch Check operation Adjust 6 Front brake Check operation fluid level and vehicle for fluid leakage See NOTE on page 6 4 Replace brake pads Whenever worn to the limit 7 Rear brake Check operation and ...

Page 43: ...play and steering for roughness Lubricate with lithium soap based grease Every 24 000km 15 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 16 Sidestand Check operation Lubricate 17 Sidestand switch Check operation 18 Front fork Check operation and for oil leakage 19 Rear shock absorber assembly Check operation and shock absorber for oil leakage 20 Rear suspension ...

Page 44: ...NANCE JOB ODOMETER READING 1 000 km ANNUAL CHECK 1 6 12 18 24 EAU03541 NOTE 8 The air filter needs more frequent service if you are riding in unusually wet or dusty areas 8 Hydraulic brake service 9 Regularly check and if necessary correct the brake fluid level 9 Every two years replace the internal components of the brake master cylinder and caliper and change the brake fluid 9 Replace the brake ...

Page 45: ...cowling or a panel needs to be removed and installed 1 EAU01145 Cowling A To remove the cowling Remove the screw and then pull the cowling off as shown To install the cowling Place the cowling in the original posi tion and then install the screw 1 Screw 1 Panel A 2 Screw EAU00488 Panel A To remove the panel Remove the screw and then pull the panel off as shown To install the panel Place the panel ...

Page 46: ...ne 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 maintenance and lubrication chart In addition the condition of the spark plug can reveal the condition of the engine To remove the spark plug 1 Remove the spark plug cap 1 Spark plug wrench 2 Remove the spark plug as show...

Page 47: ...e such problems yourself Instead have a Yamaha dealer check the motorcycle 2 Check the spark plug for elec trode erosion and excessive car bon or other deposits and replace it if necessary 1 2 3 4 5 6 7 8 9 6 7 PERIODIC MAINTENANCE AND MINOR REPAIR 6 Specified spark plug DR8EA NGK or X24ESR U DENSO To install the spark plug 1 Measure the spark plug gap with a wire thickness gauge and if necessary ...

Page 48: ...everal minutes and then turn it off 2 3 1 1 Level window 2 Maximum level mark 3 Minimum level mark 3 Wait a few minutes until the oil settles and then check the oil level through the check window located at the bottom right side of the engine guard NOTE The engine oil should be between the minimum and maximum level marks 4 If the engine oil is below the minimum level mark add suffi cient oil of th...

Page 49: ...l filter element cover 3 Screw 2 6 Remove the oil filter element drain bolt to drain the oil from the oil filter element 7 Remove the oil filter element cover by removing the screws 1 1 Engine oil filler cap 4 Remove the engine oil filler cap and drain bolt along with the O ring compression spring and oil strainer to drain the oil from the crankcase ECA00039 cC When removing the oil drain bolt the...

Page 50: ... age and replace it if necessary 11 Install the oil filter element cover by installing the screws and drain bolt then tightening them to the specified torques Tightening torques Oil filter element cover screw 7 Nm 0 7 m kg Oil filter element drain bolt 10 Nm 1 0 m kg Tightening torque Engine oil drain bolt 43 Nm 4 3 m0kg 13 Add the specified amount of the recommended engine oil and then install an...

Page 51: ...t EAU03675 Cleaning the air filter element The air filter element should be cleaned at the intervals specified in the periodic maintenance and lubrica tion chart Clean the air filter element more frequently if you are riding in unusually wet or dusty areas 1 Remove panel A See page 6 5 for removal and installation pro cedures 2 Remove the air filter case cover by removing the screws 2 1 1 Air filt...

Page 52: ...r filter case NOTE Install the air filter element so that the gray side is facing forward and with the UP mark pointing as shown 5 Clean the sponge material with solvent and then squeeze the remaining solvent out 6 Apply oil of the recommended type to the entire surface of the sponge material and then squeeze the excess oil out NOTE The sponge material should be wet but not dripping 1 2 3 4 Recomm...

Page 53: ...cribed in the following section however may be serviced by the owner as part of routine mainte nance EC000094 cC The carburetor has been set and extensively tested at the Yamaha factory Changing these settings without sufficient technical knowl edge may result in poor perfor mance of or damage to the engine EAU01168 Adjusting the engine idling speed The engine idling speed must be checked and if n...

Page 54: ...ling speed 1 350 1 450 r min EAU00634 Adjusting the throttle cable free play The throttle cable free play should measure 3 5 mm at the throttle grip Periodically check the throttle cable free play and if necessary adjust it as follows NOTE The engine idling speed must be cor rectly adjusted before checking and adjusting the throttle cable free play 1 Loosen the locknut 1 Locknut 2 Adjusting nut 1 ...

Page 55: ...he tire air pressure should be checked and if necessary adjusted before each ride EW000082 w 8 The tire air pressure must be checked and adjusted on cold tires i e when the tempera ture of the tires equals the ambient temperature 8 The tire air pressure must be adjusted in accordance with the riding speed and with the total weight of rider passen ger cargo and accessories approved for this model T...

Page 56: ...gard to the load 8 Check the tire condition and air pressure before each ride 1 2 a 1 Side wall 2 Wear indicator a Tread depth 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 imme diately NOTE The tire tread depth limit...

Page 57: ...bends or warpage and the spokes for looseness or damage before each ride If any damage is found have a Yamaha dealer replace the wheel Do not attempt even the smallest repair to the wheel A deformed or cracked wheel must be replaced 8 The wheel should be balanced whenever either the tire or wheel has been changed or replaced An unbalanced wheel can result in poor performance adverse handling chara...

Page 58: ... direction a To decrease the clutch lever free play turn the adjusting bolt in direction b 1 Locknut Clutch lever 2 Adjusting bolt c Free play 1 2 a b 3 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 4 Fully turn the adjusting bolt in direction a to loosen the clutch cable 5 Loosen the...

Page 59: ...an indicate the presence of air in the hydraulic system If there is air in the hydraulic system have a Yamaha dealer bleed the system before operating the motorcycle Air in the hydraulic system will diminish the braking performance which may result in loss of control and an accident 1 2 c a b EAU00696 Adjusting the brake lever free play The brake lever free play should measure 2 5 mm as shown Peri...

Page 60: ...free play must be adjusted a b 1 2 1 Adjusting bolt 2 Locknut Brake pedal free play The brake pedal free play should measure 20 30 mm as shown Periodically check the brake pedal free play and if necessary adjust it as follows a 1 b 1 Brake pedal free play adjusting nut To increase the brake pedal free play turn the adjusting nut at the brake rod in direction a To decrease the brake pedal free play...

Page 61: ...al is prop erly adjusted when the brake light comes on just before braking takes effect If necessary adjust the brake light switch as follows Turn the adjusting nut while holding the rear brake light switch in place To make the brake light come on ear lier turn the adjusting nut in direction a To make the brake light come on later turn the adjusting nut in direc tion b 1 2 a b 1 Rear brake light s...

Page 62: ...ctive 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 level is low be sure to check the brake pads for wear and the brake system for leak age 1 Minimum level mark EAU00727 Rear brake shoes The rear brake is provided with a wear indicator which allows you...

Page 63: ...int of the fluid and may result in vapor lock Recommended brake fluid DOT 4 EAU03238 Changing the brake fluid Have a Yamaha dealer change the brake fluid at the intervals specified in the periodic maintenance and lubrica tion chart In addition have the oil seals of the brake master cylinder and caliper as well as the brake hose replaced at the intervals listed below or whenever they are damaged or...

Page 64: ...e the cotter pin from the axle nut and then loosen the axle nut 3 To tighten the drive chain turn the adjusting plate on each side of the swingarm in direction a To loosen the drive chain turn the adjusting plate on each side of the swingarm in direction b and then push the rear wheel for ward 1 3 a b 4 2 1 Rear brake pedal free play adjusting nut 2 Cotter pin 3 Axle nut 4 Chain adjusting plate 2 ...

Page 65: ...nut to the speci fied torque Tightening torque Axle nut 85 Nm 8 5 m0kg 5 Insert a new cotter pin into the axle nut and then bend its ends as shown NOTE Make sure that two notches in the axle nut are aligned with the hole through the wheel axle otherwise fur ther tighten the axle nut until they are EW000110 w Always use a new cotter pin for the axle nut 1 1 Cotter pin 6 Adjust the brake pedal free ...

Page 66: ...lvents 2 Wipe the drive chain dry 3 Thoroughly lubricate the drive chain with a special O ring chain lubricant ECA00052 cC Do not use engine oil or any other lubricants for the drive chain as they may contain substances that could damage the O rings EAU02962 Checking and lubricating the cables The operation of all control cables and the condition of the cables should be checked before each ride an...

Page 67: ... up and then apply several drops of oil to the cable end allowing it to trickle into the sheath 3 Connect the throttle cable and then grease the inside of the throttle grip housing EAU03370 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 lubricated if necessary Recommended lubricant Li...

Page 68: ...nsion must be lubricated at the intervals specified in the periodic maintenance and lubrication chart 1 1 Grease nipple 3 EAU03165 Checking and lubricating the sidestand The operation of the sidestand should be checked before each ride and the sidestand pivot and metal to metal contact surfaces should be lubricated if necessary EW000113 w If the sidestand does not move up and down smoothly have a ...

Page 69: ...ht position 2 While applying the front brake push down hard on the handle bars several times to check if the front fork compresses and rebounds smoothly EC000098 cC If any damage is found or the front fork does not operate smoothly have a Yamaha dealer check or repair it EAU00794 Checking the steering Worn or loose steering bearings may cause danger Therefore the opera tion of the steering must be...

Page 70: ...ny maintenance There is no need to check the electrolyte or to add distilled water EC000101 cC Never attempt to remove the bat tery cell seals as this would per manently damage the battery EAU01144 Checking the wheel bearings The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart If there is play in the wheel hub or if the whe...

Page 71: ... as soon as possible if it seems to have discharged Keep in mind that the battery tends to dis charge more quickly if the motorcycle is equipped with optional electrical accessories To store the battery 1 If the motorcycle will not be used for more than one month remove the battery fully charge it and then place it in a cool dry place 2 If the battery will be stored for more than two months check ...

Page 72: ... EAU01235 Replacing the headlight bulb This motorcycle is equipped with a quartz bulb headlight If the headlight bulb burns out replace it as follows 1 Remove cowling A See page 6 5 for cowling removal and installation procedures EC000103 cC Do not use a fuse of a higher amperage rating than recommend ed to avoid causing extensive damage to the electrical system and possibly a fire 3 Turn the key ...

Page 73: ... Headlight bulb cover 4 Remove the headlight bulb hold er by turning it counterclockwise and then remove the defective bulb EW000119 w Headlight bulbs get very hot Therefore keep flammable prod ucts away from a lit headlight bulb and do not touch the bulb until it has cooled down 5 Place a new bulb into position and then secure it with the bulb holder 1 1 Headlight bulb holder 4FD 9 28 6 11 7 25 0...

Page 74: ...t the coupler 7 Install the headlight unit by installing the bolts 8 Install the cowling 9 Have a Yamaha dealer adjust the headlight beam if necessary 2 1 1 1 Lens 2 Screw 1 Bulb EAU03497 Replacing a turn signal light bulb 1 Remove the turn signal light lens by removing the screw 2 Remove the defective bulb by pushing it in and turning it coun terclockwise 3 Insert a new bulb into the socket push ...

Page 75: ...he motorcycle Since this model is not equipped with a centerstand follow these precau tions when removing the front and rear wheel or performing other main tenance requiring the motorcycle to stand upright Check that the motor cycle 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 S...

Page 76: ...ecurely support the motorcy cle so that there is no danger of it falling over 1 Remove the engine guard by removing the bolt 1 Brake disc cover 2 Screw 2 3 Speedometer cable holder 4 Speedometer cable 5 Cotter pin 5 Axle nut 2 Remove the brake disc cover by removing the screws 3 Remove the speedometer cable holder by removing the screw 4 Disconnect the speedometer cable from the front wheel 5 Remo...

Page 77: ...n removed together with the brake disc otherwise the brake pads will be forced shut NOTE Make sure that there is enough space between the brake pads before inserting the brake disc and that the slot in the speedometer gear unit fits over the retainer on the fork leg 3 Insert the wheel axle and then install the axle nut 4 Lower the front wheel so that it is on the ground 5 Tighten the axle nut to t...

Page 78: ... pin 5 Chain adjusting plate 6 Axle nut 2 Remove the brake pedal free play adjusting nut and then dis connect the brake rod from the brake camshaft lever 3 Remove the cotter pin and then loosen the axle nut 4 Turn the drive chain adjusting plate on each side of the swingarm fully in direction a 5 Lift the rear wheel off the ground according to the procedure on page 6 35 6 Remove the axle nut EAU03...

Page 79: ...e fits over the retainer on the swingarm 2 Install the drive chain onto the rear sprocket and then adjust the drive chain slack See page 6 24 for drive chain slack adjust ment procedures 1 1 Retainer 3 Install the axle nut and then lower the rear wheel so that it is on the ground 4 Tighten the axle nut to the speci fied torque and then install the cotter pin EW000124 w Always use a new cotter pin ...

Page 80: ... systems for example can cause poor starting and loss of power The following troubleshooting chart represents a quick and easy proce dure for checking these vital systems yourself However 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 m...

Page 81: ...ean 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 electrodes 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...

Page 82: ... all electrical cou plers and 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 ECA00010 cC 8 Avoid using strong acidic wheel cleaners...

Page 83: ...leave any marks If the windshield is scratched use a quality plastic polishing compound after washing After normal use Remove dirt with warm water a mild detergent and a soft clean sponge and then rinse thoroughly with clean water Use a toothbrush or bottle brush for hard to reach areas Stubborn dirt and insects will come off more easily if the area is covered with a wet cloth for a few minutes be...

Page 84: ...nor paint damage caused by stones etc 7 Wax all painted surfaces 8 Let the motorcycle dry complete ly before storing or covering it EWA00001 w 8 Make sure that there is no oil or wax on the brakes or tires If necessary clean the brake discs and brake linings with a regular brake disc cleaner or acetone and wash the tires with warm water and a mild detergent 8 Before operating the motorcy cle test ...

Page 85: ...ained 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 deteriorating 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 plug a...

Page 86: ...ing degraded in one spot 8 Cover the muffler outlet with a plastic bag to prevent moisture from entering it 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 excessively cold or warm place less than 0 C or more than 30 C For more information on storing the battery see page 6 31 NOTE Make any necessary repairs before stor...

Page 87: ...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 component life and poor eng...

Page 88: ... 3 318 Secondary reduction system Chain drive Secondary reduction ratio 3 000 Number of drive chain sprocket teeth rear front 45 15 Transmission type Constant mesh 6 speed Operation Left foot 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 Tires Type With tube Front Size 2 75 21 45P Manufacturer model BRIDGESTONE TRAI...

Page 89: ...ear Type Spoke Size 2 15 18 Brakes Front Type Single disc brake Operation Right hand Fluid DOT 4 Rear Type Drum brake Operation Right foot Suspension Front Type Telescopic fork Rear Type Swingarm link suspension Spring 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 ...

Page 90: ... Tail brake light 12V 5 21W 1 Front turn signal light 12V 21W 2 Rear turn signal light 12V 21W 2 Meter lighting 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 15A 4FD 9 28 6 11 7 25 00 3 51 PM Page 51 ProCarManuals com ...

Page 91: ...ltiplier 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 L liter 0 8799 qt IMP liq L liter 0 2199 gal IMP liq kg mm 55 997 lb in Misc kg cm2 14 2234 psi lb in2 Centi...

Page 92: ...ntification number is used to identify your motorcycle and may be used to register your motor cycle with the licensing authority in your area 1 Key identification number 1 Vehicle identification number EAU02944 Identification numbers Record the key identification number vehicle identification number and model label information in the spaces provided below for assistance when ordering spare parts f...

Page 93: ...stralia TAMPERING WITH NOISE CON TROL SYSTEM PROHIBITED Owners are warned that the law may prohibit a The removal or rendering inoper ative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehi cle for the purpose of noise con trol prior to its sale or delivery to the ultimate purchaser or while it is in use and...

Page 94: ...PRINTED IN JAPAN 2000 8 0 2 1 E OWNER S MANUAL 4FD 28199 28 XT250N PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD ProCarManuals com ...

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