Xmotos XZ 250R V4 Owner'S Manual Download

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OPERATING INSTRUCTION MANUAL

2011 - 2012

XZ 250R

OWNER’S MANUAL

XZ 250R V4

MOTOCROSS

DIRT BIKE

MOTARD

XZ 250RM

VER.2 10/2011

Summary of Contents for XZ 250R V4

Page 1: ...1 OPERATING INSTRUCTION MANUAL 2011 2012 XZ 250R OWNER S MANUAL XZ 250R V4 LC ZS MOTOCROSS DIRT BIKE MOTARD XZ 250RM VER 2 10 2011...

Page 2: ...ld remain if it is resold This manual contains the latest product information available before printing XGroup Corporation reserves the right to make changes at any time without notice and without inc...

Page 3: ...motos dealer for information IMPORTANT PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE GOING ON YOUR FIRST RIDE IT CONTAINS A GREAT DEAL OF INFORMATION AND ADVICE WHICH WILL HELP YOU USE AND H...

Page 4: ...ranty service Without limiting the above this warranty is Voided with respect to any product that has been used for rental or commercial purposes or that sustained the following damage Bent or broken...

Page 5: ...M ENGINE IDLE SPEED CLUTCH SYSTEM SPARK PLUG BRAKING SYSTEM BRAKE LEVER ADJUSTMENT BRAKE FLUID CHECK ADDING BRAKE FLUID BRAKE PADS BRAKE SYSTEM BLEEDING SUSPENSION SYSTEM FRONT SUSPENSION INSPECTION F...

Page 6: ...before you begin riding In this manual you will find safety information facts instructions helpful tips and illustrations To make it easy to use the manual contains a table of contents at the beginnin...

Page 7: ...use your own good judgment Safety information will come in a variety of different forms including Safety Labels on the Motorcycle Safety Messages preceded by a safety symbol and one of these signal wo...

Page 8: ...ignals horn and other features required to drive a motorcycle on public roads The tires are not designed for pavement and will make the motorcycle unstable if it is ridden on pavement If you have to c...

Page 9: ...ld think through problems and come to logical conclusions Does your child obey your rules when they ride their bicycle If your child makes bad judgments takes un warranted risks and or does not obey y...

Page 10: ...some labels warn you of potential hazards Others will provide important safety and maintenance information Please read them carefully and do not remove them If your label wears off from riding or bec...

Page 11: ...hat some labels warn you of potential hazards Others will provide important safety and maintenance information Please read them carefully and do not remove them If your label wears off from riding or...

Page 12: ...cation and operation of all the basic controls of your motorcycle COMPONENT LOCATIONS Engine Stop Switch Engine Start Switch Front Master Cylinder Reservoir Front Brake Lever Throttle Clutch Cable Clu...

Page 13: ...em Please read this section carefully before you ride your motorcycle This section of the manual will show the location and operation of all the basic controls of your motorcycle COMPONENT LOCATIONS R...

Page 14: ...14 COMPONENT LOCATIONS OFF ROAD Rear Brake Pedal Spark Plug Oil Filter Kick Starter Battery Drive Chain Fuel Valve Air Filter Shift Lever Engine Number Chassis Number Side Stand CDI Box...

Page 15: ...15 COMPONENT LOCATIONS ON ROAD Rear Brake Pedal Oil Filter Kick Starter Battery Drive Chain Fuel Valve Air Filter Shift Lever Engine Number Chassis Number CDI Box Spark Plug Ignition Coil...

Page 16: ...of frame 3 Steering head tube Write this number in the VIN box on page 3 Engine Model Serial Number The engine model number and serial number is stamped on the left side of the engine under the count...

Page 17: ...bar The adjusting screw can be used to change the basic position of the brake lever Stop Switch The stop switch turns off the engine When this button is pressed the ignition circuit is turned off Star...

Page 18: ...n Headlight Dimmer Switch In position the headlight low beam and tail light turn on In position the headlight high beam and tail light turn on The high beam indicator light also turn on Turn Signal Li...

Page 19: ...LOCK position Fuel Tap OFF In this position the fuel tap is closed No fuel can flow to the carburetor ON In this position the fuel tap in open This means fuel can flow to the carburetor With the lever...

Page 20: ...er is closed again Shift Lever LC ZS The shift lever is on the left side of the engine The gear positions are shown in the illustration on page 28 Foot Brake Lever LC ZS The brake lever is located on...

Page 21: ...he rear brake to slow or stop the motorcycle Kick Start Lever V4 RM The kick start lever is mounted on the right side of the engine It is used to start the engine in case the electrical starter system...

Page 22: ...ator Light The green indicator light will come on when the transmission is in neutral The light will go out when you shift into any gear other than neutral High Beam Indicator Light This blue indicato...

Page 23: ...otection is not possible wearing the proper gear can reduce the chance of and severity of injuries when you ride Helmets Eye Protection Your helmet is your most important piece of riding gear because...

Page 24: ...his manual Brake Hoses Inspect the brake hoses for leaks and replace if needed Nuts Bolts Inspect all accessible nuts and bolts Tighten then if it is needed Spark Plug Cap Check the spark plug for loo...

Page 25: ...some stress on the engine components during break in you must be careful not to load the engine too much Before riding this motorcycle be sure you have read this entire manual up to this point includi...

Page 26: ...eps 1 2 3 6 7 and 8 in section Starting when the engine is cold Starting When the Engine Is Cold 1 Turn the key switch to the ON position 2 Make sure the transmission is in the neutral position 3 Turn...

Page 27: ...nd push the engine stop switch on the left side of the handle bar For your safety avoid starting or operating the motorcycle in an enclosed area with poor ventilation such as a garage The motorcycle s...

Page 28: ...ever smoothly Learning when to shift gears will come with riding experience Up shift into a higher gear when you hear the engine speed rpm get too high When the engine rpm gets too high in a gear you...

Page 29: ...e brake controls and steer straight ahead until you regain control of the motorcycle Once you have control reapply the brakes with less force Generally reduce your speed and complete your braking befo...

Page 30: ...Hot Motorcycle Parts Let the engine and exhaust system cool off before you touch them 3 Injury From Moving Parts Do not run the engine unless instructed to do so Read all instructions before you begin...

Page 31: ...our nearest Xmotos dealer If you decide to do your own maintenance use only genuine replacement parts that you have purchased from an Xmotos dealer or parts purchased directly from Xmotos This will en...

Page 32: ...ks and proper operation Clean air filter and filter box Check cables for damage and kink less arrangement Check headlamp adjustment Check all electrical system for function Check brake fluid level bra...

Page 33: ...leaks Drain fuel bowl chamber Check all controls for smooth operation Check brake performance Treat exposed metal components except brake and exhaust system with wax based anti corrosion agents Treat...

Page 34: ...g Use of unleaded fuel is recommended because it produces fewer engine deposits and extends the life of the engine and exhaust components Never use stale or contaminated gasoline Never use gasoline th...

Page 35: ...u notice the level is low Inspect the coolant level before each ride Coolant loss through the overflow tube is normal But if loss is more than normal inspect the cooling system Cooling System Inspecti...

Page 36: ...r the right or left 4 Remove the oil filler cap wipe it clean and insert it back in to its place but DO NOT screw it back in 5 Check that the oil level is within the 1 2 hash marks on the dip stick as...

Page 37: ...check the oil level through the sight glass 10 Repeat steps 1 through 5 11 Reinstall the dipstick and check for any leaks 12 The V4 RM model do not have a dipstick please make sure the oil level is a...

Page 38: ...Remove the filter from the filter cover 12 Remove the spring in the filter 13 Check and see if the cover O ring is in good condition 14 After the oil is drained out of the filter chamber install a new...

Page 39: ...ng at either end 9 Once the filter is removed wash it clean with a non flammable cleaning solvent Then wash in hot soapy water rinse well Then allow the filter to dry well 10 If the filter is damaged...

Page 40: ...the direction will increase free play 5 Operate the throttle to ensure that it is functioning smoothly and when released it returns completely from fully open to fully closed in all steering positions...

Page 41: ...ff 2 Connect a tachometer to the engine 3 Make sure the transmission is in neutral gear 4 Keep the motorcycle in an upright position 5 Adjust the idle speed with the stop screw 6 To increase the idle...

Page 42: ...t covers loosen the lock nut and turn the internal cable adjuster to adjust free play 4 Once you are satisfied with the adjustment tighten the lock nut 5 If the adjuster is threaded out near its limit...

Page 43: ...tch lever in and shift into gear Make sure the engine does not stall and the motorcycle does not creep forward 5 Gradually release the clutch lever and open the throttle The motorcycle should move smo...

Page 44: ...rts store The spark plug gap should be 02 03 in 0 6 0 7mm Always check the gap of a new spark plug before you install it 8 Be sure all dirt has been cleaned from the threads Install the spark plug by...

Page 45: ...the specification is reached 1 Loosen the nut and turn the adjuster to either direction for the desired height 2 The height of the lever should approximately be level with the height of the foot rest...

Page 46: ...st from the master cylinder cap 2 Remove the cap screws with a Phillips head screwdriver 3 Remove the cap Be careful not to damage the diaphragm gasket that is seated under the cap 4 Add the required...

Page 47: ...r motorcycle for servicing Because the brake system utilizes fluid any air bubbles inside the brake system will cause you to lose braking efficiency Air generally enters the brake system when the moto...

Page 48: ...clicker 2 It will have the writing S H meaning Soft Hard or the marks or This is the Compression Adjuster 3 If you turn the screw toward the H the downward action of the fork will harden Alternatively...

Page 49: ...ether or not replacement parts or service is required Your motorcycle is new Break it in for about 2 hours with the original settings before attempting adjustments 1 Move the motorcycle by bouncing it...

Page 50: ...t clockwise or counter clockwise to make changes This affects how quickly or how slowly the shock works during compression over small rough bumpy terrain 4 Softening the nut can help make the bike rid...

Page 51: ...djuster clockwise until it will no longer turn DO NOT FORCE This is the full hard setting 4 Turn the adjuster counter clockwise 6 to 9 clicks Slow setting 1 The rebound damping adjuster is located at...

Page 52: ...Generally speaking underinflated tires will wear unevenly and adversely affect handling Underinflated tires are also more likely to fail from being overheated and can cause wheel damage on rocky terra...

Page 53: ...d could fail while riding For more information on a temporary repair see the section titled Resolving the Unexpected Always use replacement tubes that are the same size as the original We recommend th...

Page 54: ...step 1 along several points of the drive chain The slack should remain constant through out If it is not some links may be kinked and binding Lubricating the chain will often stop this 3 Inspect the...

Page 55: ...er has been worn down beyond the two points marked in Fig 1 then the roller s must be replaced 4 If you cannot or do not know how take the motorcycle to a Xmotos dealer for service Fig 1 THE USE OF A...

Page 56: ...it must be replaced Fig 1 1 Check the guide slider for wear Fig 2 2 Replace the guide slider if it is worn to the bottom of the wear limit Fig 3 Fig 2 Fig 3 THE SLIDERS MUST BE REPLACED IF WORN DOWN T...

Page 57: ...of the adjusting plate with the same reference marks on both sides of the swing arm 5 Tighten the axle nut to 85ft lbs 115 Nm 6 Re check chain slack and readjust if necessary Fig 1 Commercially prepa...

Page 58: ...er link is the most critical element of drive chain security Master links are reusable as long as they are in excellent condition We recommend installing a new master link when you install a new drive...

Page 59: ...stop switch Loose or corroded wires and or connectors always clean bad electrical connections Yes SEE STEP 4 4 Cylinder Compression Test Perform a simple compression test by kick starting the engine s...

Page 60: ...the engine speed increase No Clogged air filter Restricted or clogged fuel line and or fuel filter Clogged muffler spark arrester Choke valve is closed Clogged fuel tank breather hose Yes SEE STEP 5...

Page 61: ...ion See your local Xmotos dealer or motorcycle repair shop to have the ignition timing and engine lubrication system inspected Only attempt these procedures if you are qualified and have the proper to...

Page 62: ...the ignition timing normal Timing is non adjustable No Faulty CDI ignition box Faulty ignition pulse generator Yes See your Xmotos dealer to have your motorcycle serviced 1 Examine the Fuel Line Disco...

Page 63: ...earing play Bent Rim Improperly installed wheel hub Damaged swing arm Bent frame Loose or broken spokes Old tires with dry rot The motorcycle pulls to one side Front and rear wheels out of alignment F...

Page 64: ...le 3 Do not continue riding if you are hurt or if your motorcycle is not in safe riding condition Recommendations for specific problems follow If the engine was not making unusual noises before it qui...

Page 65: ...tightness of critical nuts and bolts such as the handle bars control levers brakes and wheels If there is minor damage or you are not sure about possible damage but decide to ride back to your base r...

Page 66: ...66 TORQUE SPECIFICATIONS Q G C D F E A H L J K M S U T R V Z Q Y A B N O W X P AD A C AF A E AL A K AJ AH A Q A P A M AN A O A R AS A T AU A V A W A X A B A A G D A Y A 1 K...

Page 67: ...6 7 5 3 AU Connecting rod rear 60 7 45 2 AV Shock mount lower 48 6 36 1 AW Kick stand bolt 40 5 30 3 AX Connecting rod front 60 7 45 2 AY Linkage connection 64 8 48 2 Name Torque Notes N m ft lbs A S...

Page 68: ...B Oil drain cap 17 5 13 1 C Engine mount lower 40 5 30 2 D Sprocket bolts 16 2 12 3 E Swing arm nut 81 60 3 F Engine mount upper 54 40 2 G Engine mount top 51 38 3 H Brake lever pivot bolt 29 7 22 3...

Page 69: ...13 1 C Engine mount lower 40 5 30 2 D Sprocket bolts 16 2 12 3 E Swing arm nut 81 60 3 F Engine mount upper 54 40 2 G Engine mount top 51 38 3 H Brake lever pivot bolt 29 7 22 3 4 J Kick starter bolt...

Page 70: ...ne mount upper 40 5 30 3 D Sprocket cover bolts 16 2 12 E Sprocket bolt 48 6 36 3 F Engine mount lower 40 5 30 2 G Oil filter screen 13 5 10 H Oil drain bolt 17 5 13 1 J Swing arm nut 81 60 3 K Kick s...

Page 71: ...r 91 Octane or Higher 91 Octane or Higher Required Oil 15w40 10w50 1 3 1 5L Capacity Ignition Timing 11 BTDC 2000 Rpm 15 BTDC 2000 Rpm 8 BTDC 2000 Rpm Ignition Type Contactless DC CDI Ignition Spark P...

Page 72: ...100 21 off road 110 70 17 on road Air Pressure 15 18 Psi 104 124 kPa off road 27 30 Psi 186 206 kPa on road Rear Tire 110 100 18 off road 130 70 17 on road Air Pressure 15 18 Psi 104 124 kPa off road...

Page 73: ...73 WIRING SCHEMATIC OFF ROAD LC ZS V4...

Page 74: ...74 WIRING SCHEMATIC ON ROAD RM...

Page 75: ...75 WIRING SCHEMATIC ON ROAD RM Model XZ250RM Revised 03 2011...

Page 76: ...aler Stamp Date Signature Odometer or Hour Reading km hr Dealer Stamp Date Signature Odometer or Hour Reading km hr Dealer Stamp Date Signature Odometer or Hour Reading km hr Dealer Stamp Date Signatu...

Page 77: ...77 NOTES...

Page 78: ...78 NOTES...

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