Yamaha XT250Z Owner'S Manual Download

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PERIODIC MAINTENANCE AND ADJUSTMENT

7-4

* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.

Air induction sys-
tem

●

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)

1 month

4000 mi

(6000 km)

6 months

7000 mi

(11000 km)

12 months

10000 mi

(16000 km)

18 months

13000 mi

(21000 km)

24 months

16000 mi

(26000 km)

30 months

Summary of Contents for XT250Z

Page 1: ...3C5 28199 12 XT250ZC OWNER S MANUAL Read this manual carefully before operating this vehicle LIT 11626 23 37 XT250Z ...

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 2009 by Yamaha Motor Corporation U S A 1st edition April 2009 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in Japan P N LIT 11626 23 37 ...

Page 6: ...l 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 18 Checking the throttle cable free play 7 18 Valve clear...

Page 7: ...torcycle 7 35 Front wheel 7 36 Rear wheel 7 37 Troubleshooting 7 38 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 ...

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: ...OTORCYCLE HELMET eye protection and protective clothing 5GK 2118K 00 2 CARB FROM FUEL TANK CANISTER TO ATMOSPHERE 1BF 21686 00 3C5 21668 00 Cold tire normal pressure should be set as follows Up to 90 kg 198 Ibs load FRONT 125 kPa 1 25 kgf cm2 18 psi REAR 150 kPa 1 50 kgf cm2 22 psi 90 kg 198 Ibs maximum load FRONT 150 kPa 1 50 kgf cm2 22 psi REAR 175 kPa 1 75 kgf cm2 25 psi ...

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: ...tect and recognize motorcycles in traf fic is the predominating cause of automobile motorcycle accidents Many accidents have been caused by an automobile driver who did not see the motorcycle Making yourself conspicuous appears to be very effective in reducing the chance of this type of accident Therefore Wear a brightly colored jacket Use extra caution when you are approaching and passing through...

Page 13: ... wear loose fitting clothes otherwise they could catch on the control levers footrests or wheels and cause injury or an accident Always wear protective clothing that covers your legs ankles and feet The 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 con...

Page 14: ...Check accessory 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...

Page 15: ...hey must be as lightweight as possible and should be kept to a minimum Bulky or large accessories may seriously affect the stability of the motorcycle due to aerody namic effects Wind may at tempt to lift the motorcycle or the motorcycle may 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...

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 32 4 Owner s tool kit page 7 2 5 Engine oil level check window page 7 13 6 Engine oil filler bolt page 7 13 ...

Page 18: ...3 5 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 Brake lever page 4 6 8 Throttle grip page 7 18 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: ...en the key is turned to ON all 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 betw...

Page 22: ...the SELECT button and then release it to start the clock EAU12348 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 th...

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 13 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: ...reload 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 Always tighten the locknut against the adjust ing ring and then tighten the locknut to the specified torque ECA10131 WARNING EWA10221 This shock absorbe...

Page 30: ...pright TIP The built in sidestand switch is part of the ignition circuit cut off system which cuts the ignition in certain situations See page 4 13 for an explanation of the ignition circuit cut off system WARNING EWA10240 The vehicle must not be ridden with the sidestand down or if the side stand cannot be properly moved up or does not stay up otherwise the sidestand could contact the ground and ...

Page 31: ...ssion is in gear and the side stand is up but the clutch lever is not pulled It prevents starting when the trans mission is in gear and the clutch le ver is pulled but the sidestand is still down It cuts the running engine when the transmission is in gear and the sid estand is moved down Periodically check the operation of the ignition circuit cut off system according to the following procedure TI...

Page 32: ...ll 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 b...

Page 33: ...g points ITEM CHECKS PAGE Fuel Check fuel level in fuel tank Refuel if necessary Check fuel line for leakage 4 7 Engine oil Check oil level in engine If necessary add recommended oil to specified level Check vehicle for oil leakage 7 13 Front brake Check operation If soft or spongy have Yamaha dealer bleed hydraulic system Check lever free play Adjust if necessary Check brake pads for wear Replace...

Page 34: ...eck for damage Check tire condition and tread depth Check air pressure Correct if necessary 7 19 7 21 Brake and shift pedals Make sure that operation is smooth Lubricate pedal pivoting points if necessary 7 27 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 Ch...

Page 35: ...If not ask 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 ...

Page 36: ... 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 ECA10260 Even with th...

Page 37: ... second gear Make sure not to shift the transmission into the neutral posi tion 6 Open the throttle part way and gradually release the clutch lever 7 Follow the same procedure when shifting to the next higher gear 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 ...

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: ...f 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 clearance when engine is cold 5 Crankcasebreather system Check breather hose for cracks or damage Replace if necessary 6 Idle speed Check and adjust engine idle speed...

Page 42: ...r perform the service 9 Air induction sys tem 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 11000km or 12 months 10000 mi 16000km or 18 months 13000 mi 21000km or 24 months 16000 mi 26000km or 30 months ...

Page 43: ...ace if necessary Replace 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 spokes if ne...

Page 44: ...Chassis fasteners Check all chassis fitting and fasteners 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 lightly 17 Sidestand pivot Check operation Apply lithium soap based gr...

Page 45: ...on Correct 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 housing and cable 27...

Page 46: ...nt needs to be replaced more frequently 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 bra...

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: ...gine 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: ...e 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 ...

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: ... 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 leaking im mediatel...

Page 54: ... 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 the air filter case The engine should never be operated with out the air filter element in stalled otherwi...

Page 55: ...NING EWA10980 Always let the exhaust system cool prior to touching exhaust components Do not start the engine when cleaning the exhaust system 1 Remove the tailpipe by removing the screw and then pulling it out of the muffler 2 Tap the tailpipe lightly and then use a wire brush to remove any carbon deposits from the spark ar rester portion of the tailpipe and in side of the tailpipe housing 3 Inse...

Page 56: ...as the necessary profes sional knowledge and experience EAU44734 Checking the engine idling speed Check the engine idling speed and if necessary have it corrected by a Yamaha dealer EAU21382 Checking the throttle cable free play The throttle cable free play should mea sure 3 0 5 0 mm 0 12 0 20 in at the throttle grip Periodically check the throttle cable free play and if neces sary have a Yamaha d...

Page 57: ...Operation of this vehicle with im proper tire pressure may cause se vere injury or death from loss of control The tire air pressure must be checked and adjusted on cold tires i e when the temperature of the tires equals the ambient temperature The tire air pressure must be ad justed in accordance with the riding speed and with the total weight of rider passenger car go and accessories approved for...

Page 58: ...fter extensive tests only the tires list ed below have been approved for this model by Yamaha Motor Co Ltd WARNING EWA10561 It is dangerous to ride with a worn out tire When a tire tread begins to show crosswise lines have a Yamaha dealer replace the tire immediately The replacement of all wheel and brake related parts includ ing the tires should be left to a Yamaha dealer who has the necessary pr...

Page 59: ...must be replaced The wheel should be balanced whenever either the tire or wheel has been changed or replaced An unbalanced wheel can result in poor performance adverse han dling characteristics and a short ened tire life Ride at moderate speeds after changing a tire since the tire sur face must first be broken in for it to develop its optimal characteris tics EAU22034 Adjusting the clutch lever fr...

Page 60: ...he brake lever free play The brake lever free play should mea sure 2 0 5 0 mm 0 08 0 20 in as shown Periodically check the brake le ver free play and if necessary adjust it as follows 1 Loosen the locknut at the brake le ver 2 To increase the brake lever free play turn the brake lever free play adjusting screw in direction a To decrease the brake lever free play turn the adjusting screw in directi...

Page 61: ... and lubrication chart EAU22420 Front brake pads Each front brake pad is provided with a wear indicator groove which allows you to check the brake pad wear with out having to disassemble the brake To check the brake pad wear check the wear indicator groove If a brake pad has worn to the point that the wear indicator groove has almost disap peared have a Yamaha dealer replace the brake pads as a se...

Page 62: ...d reservoir is level Use only the recommended quality brake fluid otherwise the rubber seals may deteriorate causing leakage and poor braking perfor mance Refill with the same type of brake fluid Mixing fluids may result in a harmful chemical reaction and lead to poor braking performance Be careful that water does not en ter the brake fluid reservoir when refilling Water will significantly lower t...

Page 63: ...tand TIP When checking and adjusting the drive chain slack there should be no weight on the motorcycle 2 Shift the transmission into the neu tral position 3 Move the rear wheel by pushing the motorcycle to locate the tight est portion of the drive chain and then measure the drive chain slack as shown 4 If the drive chain slack is incorrect adjust it as follows EAU22961 To adjust the drive chain sl...

Page 64: ...riding in dusty or wet areas Service the drive chain as follows NOTICE ECA10582 The drive chain must be lubricated after washing the motorcycle and riding in the rain or wet areas 1 Clean the drive chain with kero sene and a small soft brush NOTICE To prevent damaging the O rings do not clean the drive chain with steam cleaners high pressure washers or inap propriate solvents ECA11121 2 Wipe the d...

Page 65: ...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 addi tion the cable should be lubricated at the intervals specified in the periodic maintenance chart EAU44271 Checking and lubric...

Page 66: ...utch 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 bricated if necessary Recommended lubricant Lithium soap based grease Recommended lubricants Brake lever Silicone grease Clutch lever Lithium soap based grease ...

Page 67: ...ed at the intervals specified in the periodic maintenance and lubrication chart EAU23272 Checking the front fork The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic main tenance and lubrication chart To check the condition Check the inner tubes for scratches damage and excessive oil leakage To check the operation 1 Place the vehicle o...

Page 68: ... engine to raise the front wheel off the ground See page 7 35 for more information WARNING To avoid injury securely support the vehicle so there is no danger of it falling over EWA10751 2 Hold the lower ends of the front fork legs and try to move them for ward and backward If any free play can be felt have a Yamaha dealer check or repair the steering EAU23290 Checking the wheel bearings The front ...

Page 69: ... the battery and pro vide sufficient ventilation when charging it in an enclosed space KEEP THIS AND ALL BATTER IES OUT OF THE REACH OF CHILDREN To charge the battery Have a Yamaha dealer charge the bat tery as soon as possible if it seems to have discharged Keep in mind that the battery tends to discharge more quickly if the vehicle is equipped with optional electrical accessories NOTICE ECA16520...

Page 70: ...wn replace it as fol lows 1 Turn the key to OFF and turn off all electrical circuits 2 Remove the blown fuse and then install a new fuse of the specified amperage WARNING Do not use a fuse of a higher amperage rating than recommended to avoid causing extensive dam age to the electrical system and possibly a fire EWA15131 3 Turn the key to ON and turn on the electrical circuits to check if the devi...

Page 71: ...rsely af fected Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with al cohol or thinner 1 Remove cowling A See page 7 9 2 Remove the headlight unit by re moving the bolts 3 Disconnect the headlight coupler and then remove the headlight bulb cover 4 Remove the headlight bulb holder by turning it counterclockwise and then remove the burnt out bulb 5 Plac...

Page 72: ...if necessary EAU24133 Replacing the tail brake light bulb 1 Remove the tail brake light lens by removing the screws 2 Remove the burnt out bulb by pushing it in and turning it counter clockwise 3 Insert a new bulb into the socket push it in and then turn it clock wise until it stops 4 Install the lens by installing the screws NOTICE Do not over tighten the screws otherwise the lens may break ECA10...

Page 73: ...ont and rear wheel or performing other maintenance requiring the motorcycle to stand up right Check that the motorcycle is in a stable and level position before starting any maintenance A strong wooden box can be placed under the engine for added stability To service the front wheel 1 Stabilize the rear of the motorcycle by using a motorcycle stand or if an additional motorcycle stand is not avail...

Page 74: ... then remove the wheel NOTICE Do not apply the brake after the wheel has been removed together with the brake disc otherwise the brake pads will be forced shut ECA11071 EAUW0230 To install the front wheel 1 Lift the wheel up between the fork legs TIP Make sure that there is enough space between the brake pads before insert ing the brake disc into the caliper 2 Insert the wheel axle and then in sta...

Page 75: ...led in order to remove and install the wheel 5 Remove the axle nut and the drive chain adjusting plate from the left hand side 6 While supporting the brake caliper pull the wheel axle out together with the drive chain adjusting plate from the right hand side 7 Remove the wheel by pulling it to the back NOTICE Do not apply the brake after the wheel has been removed together with the brake disc othe...

Page 76: ...pment from the factory trouble may occur dur ing operation Any problem in the fuel compression or ignition systems for example can cause poor starting and loss of power The following troubleshooting chart represents a quick and easy procedure for checking these vital systems your self However should your motorcycle require any repair take it to a Yamaha dealer whose skilled technicians have the ne...

Page 77: ...PERIODIC MAINTENANCE AND ADJUSTMENT 7 39 2 3 4 5 6 7 8 9 heaters or furnaces Gasoline or gasoline vapors can ignite or ex plode causing severe injury or property damage ...

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: ...ore 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 ets the d...

Page 80: ...e Remove dirt with warm water a mild detergent and a soft clean sponge and then rinse thoroughly with clean water Use a toothbrush or bottlebrush for hard to reach areas Stubborn dirt and insects will come off more easily if the area is covered with a wet cloth for a few minutes before cleaning After riding in the rain near the sea or on salt sprayed roads Since sea salt or salt sprayed on roads d...

Page 81: ...ss Never apply oil or wax to any rubber and plastic parts but treat them with a suitable care product Avoid using abrasive polishing compounds as they will wear away the paint TIP Consult a Yamaha dealer for ad vice on what products to use Washing rainy weather or humid climates can cause the headlight lens to fog Turning the headlight on for a short period of time will help remove the moisture fr...

Page 82: ...ARNING 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 tire ...

Page 83: ...quantity Without oil filter element replacement 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 Carburet...

Page 84: ...ition 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 suspension ...

Page 85: ...y Headlight 12 V 60 W 55 W 1 Tail brake light 12 V 8 0 W 27 0 W 1 Front turn signal position light 12 V 27 W 8 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: ...ormation will be needed when ordering spare parts from a Yamaha dealer EAU48060 Vehicle Emission Control Informa tion label The Vehicle Emission Control Informa tion label is affixed at the location in the illustration This label shows specifica tions related to exhaust emissions as required by federal law state law and Environment Canada 1 Model label 1 1 Vehicle Emission Control Information labe...

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: ...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 months 19000 mi 3100...

Page 91: ...CONSUMER INFORMATION 10 6 2 3 4 5 6 7 8 9 10 28000 mi 46000 km or 54 months 31000 mi 51000 km or 60 months Maintenance interval Date of service Mileage Servicing dealer name and address Remarks ...

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: ...ght 4 2 Horn switch 4 5 I Identification numbers 10 1 Ignition circuit cut off system 4 13 Indicator lights 4 2 K Key identification number 10 1 L Labels location 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 light 4 ...

Page 97: ...rn signal switch 4 4 V Valve clearance 7 19 Vehicle Emission Control Information label 10 2 Vehicle identification number 10 1 W Warranty extended 10 10 Warranty limited 10 8 Wheel bearings checking 7 30 Wheel front 7 36 Wheel rear 7 37 Wheels 7 21 ...

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Page 100: ...PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2009 05 0 8 1 E ...

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Yamaha XT250Z, Owner'S Manual

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