Yamaha 2003 Virago 250 Owners Manual

2015-03-13

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OWNER’S MANUAL

XV250R
XV250RC

YAMAHA MOTOR CO., LTD.

PRINTED ON RECYCLED PAPER

PRINTED IN JAPAN
2002.05-0.5×1 CR
(E)

LIT-11626-16-21

2UJ-28199-1B

EAU03438

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EAU00002

INTRODUCTION

Congratulations on your purchase of the Yamaha XV250/XV250C. This model is the
result of Yamaha’s vast experience in the production of fine sporting, touring, and
pacesetting racing machines. It represents the high degree of craftsmanship and
reliability that have made Yamaha a leader in these fields.
This manual will give you an understanding of the operation, inspection, and basic
maintenance of this motorcycle. If you have any questions concerning the operation
or maintenance of your motorcycle, please consult a Yamaha dealer.
The design and manufacture of this Yamaha motorcycle fully comply with the emissions standards for clean air applicable at the date of manufacture. Yamaha has met
these standards without reducing the performance or economy of operation 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.

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IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following notations:
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!
Failure to follow WARNING instructions could result in severe injury or death to the
motorcycle operator, a bystander or a person inspecting or repairing the motorcycle.

WARNING

CAUTION:

A CAUTION indicates special precautions that must be taken to avoid damage to the
motorcycle.

NOTE:

A NOTE provides key information to make procedures easier or clearer.

NOTE:
● This manual should be considered a permanent part of this motorcycle and should remain
with it even if the motorcycle is subsequently sold.
● Yamaha continually seeks advancements in product design and quality. Therefore, while
this manual contains the most current product information available at the time of printing,
there may be minor discrepancies between your motorcycle and this manual. If you have
any questions concerning this manual, please consult your Yamaha dealer.
@

EAU00003

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IMPORTANT MANUAL INFORMATION
EW000000

WARNING
PLEASE READ THIS MANUAL AND THE “YOU AND YOUR MOTORCYCLE: RIDING
TIPS” BOOKLET CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE. DO NOT ATTEMPT TO OPERATE THIS MOTORCYCLE UNTIL YOU HAVE ATTAINED ADEQUATE KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES
AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES.
REGULAR INSPECTIONS AND CAREFUL MAINTENANCE, ALONG WITH GOOD RIDING
SKILLS, WILL ENSURE THAT YOU SAFELY ENJOY THE CAPABILITIES AND THE RELIABILITY OF THIS MOTORCYCLE.
@

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IMPORTANT MANUAL INFORMATION

AFFIX DEALER
LABEL HERE

EAU04247

XV250R/XV250RC
OWNER’S MANUAL
©2002 by Yamaha Motor Corporation, U.S.A.
1st edition, April 2002
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-11626-16-21

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TABLE OF CONTENTS

EAU00009

SAFETY INFORMATION ....................................1-1
Safe riding ..........................................................1-1
Protective apparel ..............................................1-3
Modifications ......................................................1-3
Loading and accessories ...................................1-3
Gasoline and exhaust gas..................................1-5
Location of important labels ..............................1-7

DESCRIPTION ...................................................2-1
Left view ............................................................2-1
Right view ..........................................................2-2
Controls and instruments ..................................2-3

INSTRUMENT AND CONTROL FUNCTIONS ...3-1
Main switch .......................................................3-1
Indicator lights ...................................................3-1
Speedometer unit ..............................................3-2
Handlebar switches ...........................................3-2
Clutch lever .......................................................3-3
Shift pedal .........................................................3-3
Brake lever ........................................................3-4
Brake pedal .......................................................3-4
Fuel tank cap .....................................................3-4
Fuel ...................................................................3-5
Fuel cock ...........................................................3-6
Starter (choke) lever ..........................................3-7
Steering lock .....................................................3-8
Rider seat ..........................................................3-8

Helmet holder ....................................................3-9
Adjusting the shock absorber assemblies .......3-10
Sidestand ........................................................3-10
Ignition circuit cut-off system ...........................3-11

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 .............5-2
Starting a warm engine .....................................5-3
Shifting ..............................................................5-4
Engine break-in .................................................5-5
Parking ..............................................................5-6

PERIODIC MAINTENANCE AND MINOR
REPAIR................................................................6-1
Periodic maintenance ........................................6-1
Owner’s tool kit ..................................................6-2
Periodic maintenance chart for the emission
control system ...............................................6-3
General maintenance and lubrication chart ......6-4
Checking the spark plugs ..................................6-6
Canister (for California only) .............................6-8
Engine oil and oil filter element .........................6-8
Cleaning the air filter element .........................6-11
Adjusting the carburetor ..................................6-13

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TABLE OF CONTENTS
Adjusting the throttle cable free play ............... 6-13
Adjusting the valve clearance ......................... 6-14
Tires ................................................................ 6-14
Spoke wheels .................................................. 6-16
Accessories and replacement parts ................ 6-16
Adjusting the clutch lever free play ................. 6-17
Adjusting the brake lever free play .................. 6-18
Adjusting the brake pedal position and free
play .............................................................. 6-18
Adjusting the rear brake light switch ............... 6-20
Checking the front brake pads and rear brake
shoes ........................................................... 6-20
Checking the brake fluid level ......................... 6-21
Changing the brake fluid ................................. 6-22
Drive chain slack ............................................. 6-22
Lubricating the drive chain .............................. 6-25
Checking and lubricating the cables ............... 6-25
Checking and lubricating the throttle grip and
cable ............................................................ 6-26
Checking and lubricating the brake and
shift pedals .................................................. 6-26
Checking and lubricating the brake and
clutch levers ................................................ 6-26
Checking and lubricating the sidestand .......... 6-27
Checking the front fork .................................... 6-27
Checking the steering ..................................... 6-28
Checking the wheel bearings .......................... 6-28
Battery ............................................................. 6-29

Replacing the fuses ........................................6-31
Replacing the headlight bulb ...........................6-32
Supporting the motorcycle .............................. 6-33
Front wheel .....................................................6-34
Rear wheel ......................................................6-36
Troubleshooting ..............................................6-37
Troubleshooting chart .....................................6-38

MOTORCYCLE CARE AND STORAGE ............. 7-1
Care .................................................................. 7-1
Storage ............................................................. 7-4

SPECIFICATIONS............................................... 8-1
Specifications .................................................... 8-1

CONSUMER INFORMATION.............................. 9-1
Identification numbers ....................................... 9-1
Key identification number .................................. 9-1
Vehicle identification number ............................ 9-1
Model label ........................................................ 9-2
REPORTING SAFETY DEFECTS .................... 9-3
MOTORCYCLE NOISE REGULATION ............ 9-4
Maintenance record .......................................... 9-5
Street and enduro motorcycle limited
warranty.......................................................... 9-7
Yamaha extended service (Y.E.S.) ................... 9-9

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SAFETY INFORMATION

EAU03633

MOTORCYCLES ARE SINGLE TRACK VEHICLES. THEIR SAFE USE AND OPERATION ARE DEPENDENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EXPERTISE OF
THE OPERATOR. EVERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIREMENTS BEFORE RIDING THIS MOTORCYCLE.
HE OR SHE SHOULD:
1. OBTAIN THOROUGH INSTRUCTIONS FROM A COMPETENT SOURCE ON ALL ASPECTS OF
MOTORCYCLE OPERATION.
2. OBSERVE THE WARNINGS AND MAINTENANCE REQUIREMENTS IN THE OWNER’S MANUAL.
3. OBTAIN QUALIFIED TRAINING IN SAFE AND PROPER RIDING TECHNIQUES.
4. OBTAIN PROFESSIONAL TECHNICAL SERVICE AS INDICATED BY THE OWNER’S MANUAL
AND/OR WHEN MADE NECESSARY 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 motorcycle. Making yourself conspicuous appears to be very effective in reducing the
chance of this type of accident.
Therefore:
a. Wear a brightly colored jacket.
b. Use extra caution when approaching and passing through intersections, since intersections are
the most likely places for motorcycle accidents to occur.
c. Ride where other motorists can see you. Avoid riding in another motorist’s blind spot.

1-1

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SAFETY INFORMATION
4. Many motorcycle accidents involve inexperienced operators. In fact, many operators who have been
involved in accidents do not even have a current motorcycle license.
a. Make sure that you are qualified and that you only lend your motorcycle to other qualified operators.
b. Know your skills and limits. Staying within your limits may help you to avoid an accident.
c. We recommend that you practice riding your motorcycle where there is no traffic until you have
become thoroughly familiar with the motorcycle and all of its controls.
5. Many motorcycle accidents have been caused by error of the motorcycle operator. A typical error
made by the operator is veering 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 conditions.
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 hands on the handlebar and both feet on the operator footrests
during operation to maintain control of the motorcycle.
b. The passenger should always hold onto the operator, seat strap, or grab bar, if equipped, with
both hands and keep both feet on the passenger footrests.
c. Never carry a passenger unless he or she can firmly place both feet on the passenger footrests.
7. Never ride under the influence of alcohol or other drugs.
8. This motorcycle is designed for on-road use only, therefore, it is not suitable for off-road use.

1-2

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SAFETY INFORMATION
Protective apparel
1

The majority of fatalities from motorcycle accidents are the result of head injuries. The use of a safety
helmet is the single most critical factor in the prevention or reduction of head injuries.
1. Always wear an approved helmet.
2. Wear a face shield or goggles. Wind in your unprotected eyes could contribute to an impairment of vision which could delay seeing a hazard.
3. The use of a jacket, heavy boots, trousers, gloves, etc., is effective in preventing or reducing abrasions or lacerations.
4. Never wear loose-fitting clothes, otherwise they could catch on the control levers, footrests, or wheels
and cause injury or an accident.
5. Never touch the engine or exhaust system during or after operation. 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 your motorcycle illegal to use.

Loading and accessories
Adding accessories or cargo to your motorcycle can adversely affect stability and handling if the weight
distribution of the motorcycle is changed. To avoid the possibility of an accident, use extreme caution
when adding cargo or accessories to your motorcycle. Use extra care when riding a motorcycle that has
added cargo or accessories. Here are some general guidelines to follow if loading cargo or adding accessories to your motorcycle:
1-3

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SAFETY INFORMATION
Loading
The total weight of the operator, passenger, accessories and cargo must not exceed the maximum load
limit of XV250: 432 lb (196 kg) / XV250C: 430 lb (195 kg). When loading within this weight limit, keep the
following in mind:
1. Cargo and accessory weight should be kept as low and close to the motorcycle as possible. Make
sure to distribute the weight as evenly as possible on both sides of the motorcycle to minimize imbalance or instability.
2. Shifting weights can create a sudden imbalance. Make sure that accessories and cargo are securely
attached to the motorcycle before riding. Check accessory mounts and cargo restraints frequently.
3. 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 handling or slow
steering response.
Accessories
Genuine Yamaha accessories have been specifically designed for use on this motorcycle. Since
Yamaha cannot test all other accessories that may be available, you must personally be responsible for
the proper selection, installation and use of non-Yamaha accessories. Use extreme caution when selecting and installing any accessories.
Keep the following guidelines in mind, as well as those provided under “Loading” when mounting accessories.
1. Never install accessories or carry cargo that would impair the performance of your motorcycle. Carefully inspect the accessory before using it to make sure that it does not in any way reduce ground
clearance or cornering clearance, limit suspension travel, steering travel or control operation, or obscure lights or reflectors.

1-4

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SAFETY INFORMATION

a. Accessories fitted to the handlebar or the front fork area can create instability due to improper
weight distribution or aerodynamic changes. If accessories are added to the handlebar or front
fork area, they must be as lightweight as possible and should be kept to a minimum.
b. Bulky or large accessories may seriously affect the stability of the motorcycle due to aerodynamic
effects. Wind may attempt to lift the motorcycle, or the motorcycle may become unstable in cross
winds. These accessories may also cause instability when passing or being passed by large vehicles.
c. Certain accessories can displace the operator from his or her normal riding position. This improper position limits the freedom of movement of the operator and may limit control 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 to spill any gasoline on the engine or exhaust system when refueling.
c. Never refuel while smoking or in the vicinity of an open flame.
2. Never start the engine or let it run for any length of time in a closed area. The exhaust fumes are poisonous and may cause loss of consciousness and death within a short time. Always operate your
motorcycle in an area that has adequate ventilation.
3. Always turn the engine off before leaving the motorcycle unattended and remove the key from the
main switch. When parking the motorcycle, note the following:

1-5

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SAFETY INFORMATION
a. The engine and exhaust system may be hot, therefore, park the motorcycle in a place where pedestrians or children are not likely to touch these hot areas.
b. Do not park the motorcycle on a slope or soft ground, otherwise it may fall over.
c. Do not park the motorcycle near a flammable source (e.g. a kerosene heater, or near an open
flame), otherwise it could catch fire.
4. When transporting the motorcycle in another vehicle, make sure that it is kept upright and that the fuel
cock is turned to “ON” or “RES” (for vacuum type) / “OFF” (for manual type). If it should lean over,
gasoline may leak out of the carburetor or fuel tank.
5. If you should swallow any gasoline, inhale a lot of gasoline vapor, or allow gasoline to get into your
eyes, see your doctor immediately. If any gasoline spills on your skin or clothing, immediately wash
the affected area with soap and water and change your clothes.

1-6

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SAFETY INFORMATION
EAU02977

Location of important labels
1

Please read the following important labels carefully before operating this motorcycle.

1-7

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SAFETY INFORMATION
1

California only
1

1-8

California only

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DESCRIPTION

EAU00026

Left view

1. Headlight
2. Steering lock
3. Fuel tank
4. Battery
5. Fuses
6. Helmet holder

7. Shock absorber assembly spring
preload adjusting ring
8. Main switch
9. Fuel cock
10. Shift pedal

(page 6-32)
(page 3-8)
(page 3-4)
(page 6-29)
(page 6-31)
(page 3-9)

2-1

(page 3-10)
(page 3-1)
(page 3-6)
(page 3-3)

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DESCRIPTION
Right view

11. Tail/brake light
12. Rear turn signal light
13. Rider seat
14. Air filter element

15. Front turn signal/position light
16. Brake pedal
17. Footrest
18. Owner’s tool kit
19. Shock absorber assembly spring
preload adjusting ring

(page 3-8)
(page 6-11)

2-2

(page 3-4)
(page 6-2)
(page 3-10)

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DESCRIPTION
Controls and instruments

1. Clutch lever
2. Left handlebar switches
3. Speedometer unit
4. Indicator lights

5. Right handlebar switches
6. Brake lever
7. Throttle grip
8. Fuel tank cap

(page 3-3)
(page 3-2)
(page 3-2)
(page 3-1)

2-3

(page 3-3)
(page 3-4)
(page 6-13)
(page 3-4)

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INSTRUMENT AND CONTROL FUNCTIONS

EAU00027

EAU00050

P (Parking)
The taillight and position lights are on,
but all other electrical systems are off.
The key can be removed.
The key must be pushed in from the
“OFF” position to be turned to “P”.
ECA00043

CAUTION:
Do not use the parking position for
an extended length of time, otherwise the battery may discharge.

EAU00028

Main switch
The main switch controls the ignition
and lighting systems. The various main
switch positions are described below.

1. High beam indicator light “HIGH BEAM”
2. Neutral indicator light “NEUTRAL”
3. Turn signal indicator light “TURN”
EAU00056

Indicator lights
EAU00064

High beam indicator light
“HIGH BEAM”
This indicator light comes on when the
high beam of the headlight is switched
on.

EAU00032

ON
All electrical systems are supplied with
power, the headlight, meter lighting,
taillight and front position lights come
on, and the engine can be started. The
key cannot be removed.

EAU00062

Neutral indicator light “NEUTRAL”
This indicator light comes on when the
transmission is in the neutral position.
EAU00059

Turn signal indicator light “TURN”
This indicator light flashes when the
turn signal switch is pushed to the left
or right.

EAU00038

OFF
All electrical systems are off. The key
can be removed.
3-1

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INSTRUMENT AND CONTROL FUNCTIONS
ter position. To cancel the turn signal
lights, push the switch in after it has returned to the center position.
EAU00130

Horn switch “HORN”
Press this switch to sound the horn.
3
1.
2.
3.
4.

Odometer
Tripmeter
Tripmeter reset knob
Speedometer

1. Dimmer switch “LIGHTS”
2. Turn signal switch “TURN”
3. Horn switch “HORN”
EAU00118
EAU00095

Speedometer unit
The speedometer unit is equipped with
a speedometer, an odometer and a
tripmeter. The speedometer 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.

Handlebar switches
EAU00122

Dimmer switch “LIGHTS”
Set the switch to “HI” for the high beam
and to “LO” for the low beam.
EAU00125

Turn signal switch “TURN”
To signal a right-hand turn, push this
switch to the right. To signal a left-hand
turn, push this switch to the left. When
released, the switch returns to the cen-

3-2

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INSTRUMENT AND CONTROL FUNCTIONS

3
1. Engine stop switch “ENGINE STOP”
2. Start switch “START”

1. Clutch lever

1. Shift pedal
EAU00152

EAU04822

Engine stop switch “ENGINE STOP”
Set this switch to “RUN” before starting
the engine. Set this switch to “OFF” to
stop the engine in case of an emergency, such as when the motorcycle overturns or when the throttle cable is
stuck.
EAU00141

Start switch “START”
Push this switch to crank the engine
with the starter.
EC000005

EAU00157

Clutch lever

Shift pedal

The clutch lever is located at the left
handlebar grip. To disengage the
clutch, pull the lever toward the handlebar 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 ignition circuit cut-off system. (See page
3-11 for an explanation of the ignition
circuit cut-off system.)

The shift pedal is located on the left
side of the engine and is used in combination with the clutch lever when
shifting the gears of the 5-speed constant-mesh transmission equipped on
this motorcycle.

CAUTION:
See page 5-2 for starting instructions prior to starting the engine.
@

3-3

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INSTRUMENT AND CONTROL FUNCTIONS

3
1. Brake lever

1. Brake pedal
EAU00158

EAU00162

Brake lever

Brake pedal

The brake lever is located at the right
handlebar grip. To apply the front
brake, pull the lever toward the handlebar grip.

The brake pedal is on the right side of
the motorcycle. To apply the rear
brake, press down on the brake pedal.

1. Fuel tank cap
2. Unlock.
EAU03712

Fuel tank cap
To open the fuel tank cap
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
opened.
To close the fuel tank cap
1. Push the fuel tank cap into position with the key inserted in the
lock.
2. Turn the key counterclockwise to
the original position, and then remove it.

3-4

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INSTRUMENT AND CONTROL FUNCTIONS
EAU00185

NOTE:
The fuel tank cap cannot be closed unless the key is in the lock. In addition,
the key cannot be removed if the cap is
not properly closed and locked.
_

CAUTION:
Immediately wipe off spilled fuel
with a clean, dry, soft cloth, since
fuel may deteriorate painted surfaces or plastic parts.
@

EWA00025

WARNING
Make sure that the fuel tank cap is
properly closed before riding.

EAU04265

1. Fuel tank filler tube
2. Fuel level
EAU03753

Fuel
Make sure that there is sufficient fuel in
the tank. Fill the fuel tank to the bottom
of the filler tube as shown.
EW000130

WARNING
● Do not overfill the fuel tank, otherwise it may overflow when the
fuel warms up and expands.
● Avoid spilling fuel on the hot
engine.

3-5

Recommended fuel:
UNLEADED GASOLINE ONLY
Fuel tank capacity:
Total amount:
XV250
9.5 L
(2.1 Imp gal, 2.5 US gal)
XV250C
9.2 L
(2.0 lmp gal, 2.4 US gal)
Reserve amount:
2.6 L (0.6 Imp gal, 0.7 US gal)

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INSTRUMENT AND CONTROL FUNCTIONS
ECA00104

CAUTION:
Use only unleaded gasoline. The
use of leaded gasoline will cause severe damage to internal engine
parts, such as the valves and piston
rings, as well as to the exhaust system.
_

Your Yamaha engine has been designed to use regular unleaded gasoline with a pump octane number
[(R+M)/2] of 86 or higher, or a research
octane number of 91 or higher. If
knocking (or pinging) occurs, use a
gasoline of a different brand or premium unleaded fuel. Use of unleaded fuel
will extend spark plug life and reduce
maintenance costs.

Gasohol
There are two types of gasohol: gasohol containing ethanol and that containing methanol. Gasohol containing
ethanol can be used if the ethanol content does not exceed 10%. Gasohol
containing methanol is not recommended by Yamaha because it can
cause damage to the fuel system or vehicle performance problems.

ON: normal position

1. Arrow mark positioned over “ON”
EAU04484

Fuel cock
This motorcycle is equipped with a
negative pressure fuel cock. The fuel
cock supplies fuel from the tank to the
carburetor while also filtering it.
The fuel cock lever positions are explained as follows and shown in the illustrations.
ON
With the fuel cock lever in this position,
fuel flows to the carburetor when the
engine is running. Turn the fuel cock lever to this position when starting the
engine and riding.
3-6

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INSTRUMENT AND CONTROL FUNCTIONS
RES: reserve position

PRI: priming position

3
1. Arrow mark positioned over “RES”

1. Arrow mark positioned over “PRI”

RES
This indicates reserve. With the fuel
cock lever in this position, the fuel reserve is made available. Quickly turn
the fuel cock lever to this position if you
run out of fuel while riding, otherwise
the engine may stall and will have to be
primed (see “PRI”). After turning the
fuel cock lever to “RES”, refuel as soon
as possible and be sure to turn the fuel
cock lever back to “ON”!

PRI
This indicates prime. With the fuel cock
lever in this position, the engine can be
“primed”. Turn the fuel cock lever to
this position when the engine has been
allowed to run out of fuel. This sends
fuel directly to the carburetor, which will
make starting easier. After the engine
has started, be sure to turn the lever to
“ON” (or “RES” if you have not refueled
yet).

3-7

1. Starter (choke) lever
EAU00211

Starter (choke) lever
Starting a cold engine requires a richer
air-fuel mixture, which is supplied by
the starter (choke).
Move the lever in direction a to turn on
the starter (choke).
Move the lever in direction b to turn off
the starter (choke).

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INSTRUMENT AND CONTROL FUNCTIONS
To unlock the steering
1. Open the steering lock cover, and
then insert the key.
2. Push the key in, turn it 1/8 turn
counterclockwise so that it moves
out, and then release it.
3. Remove the key, and then close
the lock cover.

3
1. Steering lock

1. Bolt (× 2)
EAU02934

EAU01072

Steering lock

Rider seat

To lock the steering
1. Turn the handlebar all the way to
right.
2. Open the steering lock cover, and
then insert the key.
3. Turn the key 1/8 turn counterclockwise, push it in while turning
the handlebar slightly to the left,
and then turn the key 1/8 turn
clockwise.
4. Check that the steering is locked,
remove the key, and then close
the lock cover.

To remove the rider seat
Remove the bolts, and then pull the rider seat off.

3-8

E_U2UJ1B.book Page 9 Wednesday, May 29, 2002 1:56 PM

INSTRUMENT AND CONTROL FUNCTIONS

3
1. Projection
2. Seat holder

To install the rider seat
1. Insert the projection on the front of
the rider seat into the seat holder
as shown.
2. Place the rider seat in the original
position, and then tighten the
bolts.
NOTE:
Make sure that the rider seat is properly secured before riding.

1. Helmet holder
2. Unlock.
EAU00260

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.
EW000030

WARNING
Never ride with a helmet attached to
the helmet holder, since the helmet
may hit objects, causing loss of
control and possibly an accident.
@

3-9

E_U2UJ1B.book Page 10 Wednesday, May 29, 2002 1:56 PM

INSTRUMENT AND CONTROL FUNCTIONS
EAU00330

EW000040

WARNING
Always adjust both shock absorber
assemblies equally, otherwise poor
handling and loss of stability may
result.
@

Sidestand
The sidestand is located on the left side
of the frame. Raise the sidestand or
lower it with your foot while holding the
motorcycle upright.

3
1. Spring preload adjusting ring
2. Position indicator
EAU00300

Adjusting the shock absorber
assemblies
Each shock absorber assembly is
equipped with a spring preload adjusting ring.
EC000015

CAUTION:
Never attempt to turn an adjusting
mechanism beyond the maximum
or minimum settings.
@

Adjust the spring preload as follows.
To increase the spring preload and
thereby harden the suspension, turn
the adjusting ring on each shock absorber assembly in direction a. To decrease the spring preload and thereby
soften the suspension, turn the adjusting ring on each shock absorber assembly in direction b.
NOTE:
Align the appropriate notch in the adjusting ring with the position indicator
on the shock absorber.
@

CI-10E

Setting

Minimum (soft)

Standard

Maximum (hard)

3-10

NOTE:
The built-in sidestand switch is part of
the ignition circuit cut-off system, which
cuts the ignition in certain situations.
(See further down for an explanation of
the ignition circuit cut-off system.)
@

E_U2UJ1B.book Page 11 Wednesday, May 29, 2002 1:56 PM

INSTRUMENT AND CONTROL FUNCTIONS
EW000044

WARNING
The motorcycle must not be ridden
with the sidestand down, or if the
sidestand cannot be properly
moved up (or does not stay up), otherwise the sidestand could contact
the ground and distract the operator, resulting in a possible loss of
control. Yamaha’s ignition circuit
cut-off system has been designed to
assist the operator in fulfilling the
responsibility of raising the sidestand before starting off. Therefore,
check this system regularly as described below and have a Yamaha
dealer repair it if it does not function
properly.
@

EAU03720

Ignition circuit cut-off system
The ignition circuit cut-off system (comprising the sidestand switch, clutch
switch and neutral switch) has the following functions.
● It prevents starting when the transmission is in gear and the sidestand is up, but the clutch lever is
not pulled.
● It prevents starting when the transmission is in gear and the clutch
lever is pulled, but the sidestand is
still down.
● 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

WARNING
If a malfunction is noted, have a
Yamaha dealer check the system
before riding.
_

3-11

E_U2UJ1B.book Page 12 Wednesday, May 29, 2002 1:56 PM

INSTRUMENT AND CONTROL FUNCTIONS
CD-01E

NOTE:
This check is most reliable if performed with
a warmed-up engine.

With the engine turned off:
1. Move the sidestand down.
2. Make sure that the engine stop switch is set to “RUN”.
3. Turn the key to “ON”.
4. Shift the transmission into the neutral position.
5. Push the start switch.
Does the engine start?

YES

The neutral switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.

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 should not be ridden until
checked by a Yamaha dealer.

With the engine still running:
6. Move the sidestand up.
7. Keep the clutch lever pulled.
8. Shift the transmission into gear.
9. Move the sidestand down.
Does the engine stall?

YES
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?

YES

The system is OK. The motorcycle can be ridden.

3-12

E_U2UJ1B.book Page 1 Wednesday, May 29, 2002 1:56 PM

PRE-OPERATION CHECKS

EAU01114

The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly,
even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss
of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thorough visual inspection, to check the following points before each ride.
EAU03439

Pre-operation check list
CO-01E

ITEM
Fuel

Engine oil

Front brake

Rear brake

Clutch

Throttle grip

Control cables

CHECKS
Check fuel level in fuel tank.
Refuel if necessary.
Check fuel line for leakage.
Check oil level in engine.
If necessary, add recommended oil to specified level.
Check vehicle for oil leakage.
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 recommended brake fluid to specified level.
Check hydraulic system for leakage.
Check operation.
Check pedal free play.
Adjust if necessary.
Check operation.
Lubricate cable if necessary.
Check lever free play.
Adjust if necessary.
Make sure that operation is smooth.
Check cable free play.
If necessary, have Yamaha dealer adjust cable free play and lubricate cable and
grip housing.
• Make sure that operation is smooth.
• Lubricate if necessary.

•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•

4-1

PAGE
3-5

4
6-8–6-9

6-18, 6-20–6-22

6-18–6-21

6-17

6-13

6-25

E_U2UJ1B.book Page 2 Wednesday, May 29, 2002 1:56 PM

PRE-OPERATION CHECKS
ITEM
Drive chain

Wheels and tires

Brake and shift pedals
Brake and clutch levers

Sidestand
Chassis fasteners
Instruments, lights, signals
and switches
Sidestand switch
Battery

•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•

CHECKS
Check chain slack.
Adjust if necessary.
Check chain condition.
Lubricate if necessary.
Check for damage.
Check tire condition and tread depth.
Check air pressure.
Correct if necessary.
Make sure that operation is smooth.
Lubricate pedal pivoting points if necessary.
Make sure that operation is smooth.
Lubricate lever pivoting points if necessary.
Make sure that operation is smooth.
Lubricate pivot if necessary.
Make sure that all nuts, bolts and screws are properly tightened.
Tighten if necessary.
Check operation.
Correct if necessary.
Check operation of ignition circuit cut-off system.
If system is defective, have Yamaha dealer check vehicle.
Check fluid level.
Fill with distilled water if necessary.

PAGE
6-22–6-23

6-14–6-16

6-26
6-26
6-27
—
—
3-10–3-11
6-29–6-30

NOTE:
Pre-operation checks should be made each time the motorcycle is used. Such an inspection can be accomplished in a very
short time; and the added safety it assures is more than worth the time involved.
_

EWA00033

WARNING
If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operating
the motorcycle.
_

4-2

E_U2UJ1B.book Page 1 Wednesday, May 29, 2002 1:56 PM

EAU00372
5-

OPERATION AND IMPORTANT RIDING POINTS

EAU00373

EAU00376

WARNING
● Become thoroughly familiar
with all operating controls and
their functions before riding.
Consult a Yamaha dealer regarding any control or function
that you do not thoroughly
understand.
● Never start the engine or operate
it in a closed area for any length
of time. Exhaust fumes are poisonous, and inhaling them can
cause loss of consciousness
and death within a short time. Always make sure that there is adequate ventilation.
● Before starting out, make sure
that the sidestand is up. If the
sidestand is not raised completely, it could contact the
ground and distract the operator, resulting in a possible loss
of control.

CAUTION:
● Make sure not to store personal
items near the air cleaner intake, otherwise air intake will be
blocked and performance will
suffer.
● Make sure not to put anything
near the battery and its terminals, otherwise electrical failure
and acid corrosion may result.

5-1

E_U2UJ1B.book Page 2 Wednesday, May 29, 2002 1:56 PM

OPERATION AND IMPORTANT RIDING POINTS
EAU04683

Starting and warming up a
cold engine
In order for the ignition circuit cut-off
system to enable starting, one of the
following conditions must be met:
● The transmission is in the neutral
position.
● The transmission is in gear with
the clutch lever pulled and the
sidestand up.

1. Turn the fuel cock lever to “ON”.
2. Turn the key to “ON” and make
sure that the engine stop switch is
set to “RUN”.
3. Shift the transmission into the neutral position.

4. Turn the starter (choke) on and
completely close the throttle. (See
page 3-7 for starter (choke) operation.)
5. Start the engine by pushing the
start switch.

NOTE:
When the transmission is in the neutral
position, the neutral indicator light
should be on, otherwise have a
Yamaha dealer check the electrical circuit.

NOTE:
If the engine fails to start, release the
start switch, wait a few seconds, and
then try again. Each starting attempt
should be as short as possible to preserve the battery. Do not crank the engine more than 10 seconds on any one
attempt.

EW000054

5
_

WARNING
Before starting the engine,
check the function of the ignition circuit cut-off system according to the procedure
described on page 3-12.
● Never ride with the sidestand
down.
●

5-2

E_U2UJ1B.book Page 3 Wednesday, May 29, 2002 1:56 PM

OPERATION AND IMPORTANT RIDING POINTS
6. After starting the engine, move the
starter (choke) back halfway.
ECA00055

utes with the starter (choke) in the halfway position.
_

CAUTION:
For maximum engine life, always
warm the engine up before starting
off. Never accelerate hard when the
engine is cold!
_

EAU01258

Starting a warm engine
Follow the same procedure as for starting a cold engine with the exception
that the starter (choke) is not required
when the engine is warm.

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. To avoid the possibility of excessive exhaust emissions,
never leave the starter (choke) on longer than necessary. The time necessary
for starter (choke) use depends upon
the ambient temperature. Temperatures above 10 °C (50 °F) require about
7 seconds of starter (choke) use and
temperatures below 10 °C (50 °F) require about 35 seconds with the starter
(choke) turned on, then about 2.5 min-

5-3

E_U2UJ1B.book Page 4 Wednesday, May 29, 2002 1:56 PM

OPERATION AND IMPORTANT RIDING POINTS
EC000048

1. Shift pedal
N. Neutral position
EAU00423

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
illustration.

CAUTION:
● Even with the transmission in
the neutral position, do not
coast for long periods of time
with the engine off, and do not
tow the motorcycle for long distances. The transmission is
properly lubricated only when
the engine is running. Inadequate lubrication may damage
the transmission.
● Always use the clutch while
changing gears to avoid damaging the engine, transmission,
and drive train, which are not
designed to withstand the
shock of forced shifting.

NOTE:
To shift the transmission into the neutral position, press the shift pedal down
repeatedly until it reaches the end of its
travel, and then slightly raise it.
@

EAU02988

To start out and accelerate
1. Pull the clutch lever to disengage
the clutch.
2. Shift the transmission into first
gear. The neutral indicator light
should go out.
3. Open the throttle gradually, and at
the same time, release the clutch
lever slowly.
4. At the recommended shift points
shown in the table on page 5-5,
close the throttle, and at the same
time, quickly pull the clutch lever
in.
5. Shift the transmission into second
gear. (Make sure not to shift the
transmission into the neutral
position.)
6. Open the throttle part way and
gradually release the clutch lever.
7. Follow the same procedure when
shifting to the next higher gear.
NOTE:
Always shift gears at the recommended shift points.
@

5-4

E_U2UJ1B.book Page 5 Wednesday, May 29, 2002 1:56 PM

OPERATION AND IMPORTANT RIDING POINTS
EAU00427

EAU02974

To decelerate
1. Apply both the front and the rear
brakes to slow the motorcycle.
2. Shift the transmission into first
gear when the motorcycle reaches
20 km/h (12.5 mi/h). If the engine
is about to stall or runs very roughly, pull the clutch lever in and use
the brakes to stop the motorcycle.
3. Shift the transmission into the neutral position when the motorcycle
is almost completely stopped. The
neutral indicator light should come
on.

Recommended shift points
The recommended shift points during
acceleration and deceleration are
shown in the table below.
CF-04E

1st
2nd
3rd
4th

→
→
→
→

2nd
3rd
4th
5th

Acceleration
shift point
km/h (mi/h)

Deceleration
shift point
km/h (mi/h)

16 (9.9)
24 (14.9)
32 (19.9)
40 (24.9)

20 (12.5)
20 (12.5)
20 (12.5)
20 (12.5)

5-5

EAU01128

Engine break-in
There is never a more important period
in the life of your engine than the period
between 0 and 1,600 km (1,000 mi).
For this reason, you should read the
following material carefully.
Since the engine is brand new, do not
put an excessive load on it for the first
1,600 km (1,000 mi). The various parts
in the engine wear and polish themselves to the correct operating clearances. During this period, prolonged
full-throttle operation or any condition
that might result in engine overheating
must be avoided.

E_U2UJ1B.book Page 6 Wednesday, May 29, 2002 1:56 PM

OPERATION AND IMPORTANT RIDING POINTS
EAU00452*

0–1,000 km (0–600 mi)
Avoid prolonged operation
1/3 throttle.

EAU00460

Parking
above

When parking, stop the engine, and
then remove the key from the main
switch.

1,000–1,600 km (600–1,000 mi)
Avoid prolonged operation above
1/2 throttle.

EW000058

1,600 km and beyond
The vehicle can now be operated normally.
5

EC000059*

CAUTION:
● After 1,000 km (600 mi) of operation, the engine oil must be
changed, the oil filter element
replaced, and the oil strainer
cleaned.
● If any engine trouble should occur during the engine break-in
period, immediately have a
Yamaha dealer check the vehicle.

WARNING
Since the engine and exhaust
system can become very hot,
park in a place where pedestrians or children are not likely to
touch them.
● Do not park on a slope or on
soft ground, otherwise the
motorcycle may overturn.
●

5-6

E_U2UJ1B.book Page 1 Wednesday, May 29, 2002 1:56 PM

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU00462

EAU01790

Safety is an obligation of the owner.
Periodic inspection, adjustment and lubrication will keep your vehicle in the
safest and most efficient condition possible. The most important points of
motorcycle inspection, adjustment, and
lubrication are explained on the following pages.
Maintenance, replacement, or repair
of the emission control devices and
systems may be performed by any
repair establishment or individual
that is certified (if applicable).
EW000060

WARNING
If you are not familiar with motorcycle maintenance work, have a
Yamaha dealer do it for you.
@

EAU00467

PERIODIC MAINTENANCE
PROPER PERIODIC MAINTENANCE
OF YOUR MOTORCYCLE IS IMPORTANT IN ORDER TO ENJOY LONG,
PLEASURABLE SERVICE. ESPECIALLY IMPORTANT ARE THE
MAINTENANCE SERVICES RELATED TO EMISSIONS CONTROL.
THESE CONTROLS NOT ONLY
FUNCTION TO ENSURE CLEANER
AIR, BUT ARE ALSO VITAL TO
PROPER ENGINE OPERATION AND
MAXIMUM PERFORMANCE. IN THE
FOLLOWING PERIODIC MAINTENANCE CHARTS, THE SERVICES
RELATED TO EMISSIONS CONTROL ARE GROUPED SEPARATELY. THESE SERVICES REQUIRE
SPECIALIZED DATA, KNOWLEDGE,
AND EQUIPMENT. YAMAHA DEALERS ARE TRAINED AND EQUIPPED
TO PERFORM THESE PARTICULAR
SERVICES.

6-1

E_U2UJ1B.book Page 2 Wednesday, May 29, 2002 1:56 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
EW000062

WARNING
Modifications not approved by
Yamaha may cause loss of performance, excessive emissions, and
render the vehicle unsafe for use.
Consult a Yamaha dealer before attempting any changes.
@

1. Owner’s tool kit
EAU00468

Owner’s tool kit

The service information included in this
manual and the tools provided in the
owner’s tool kit are intended to assist
you in the performance of preventive
maintenance and minor repairs. However, additional tools such as a torque
wrench may be necessary to perform
certain maintenance work correctly.
NOTE:
If you do not have the tools or experience required for a particular job, have
a Yamaha dealer perform it for you.
@

6-2

E_U2UJ1B.book Page 3 Wednesday, May 29, 2002 1:56 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
EAU00471

Periodic maintenance chart for the emission control system
No.

ITEM

ROUTINE

INITIAL
600 mi
(1,000km)
or
1 month

4,000 mi
(6,000km)
or
6 months

√

ODOMETER READINGS
7,000 mi
10,000 mi
(11,000km)
(16,000km)
or
or
12 months
18 months

13,000 mi
(21,000km)
or
24 months

1 * Valve clearance

• Check and adjust valve clearance when engine is cold.

√

• Check condition.
• Adjust gap and clean.
• Replace every 7,000 mi (11,000 km) or 12 months .

√

Replace.

√

Replace.

Crankcase ventilation
3 *
system

• Check ventilation hose for cracks or damage.
• Replace if necessary.

√

4 * Fuel line

• Check fuel hose and vacuum hose for cracks or damage.
• Replace if necessary.

√

5 * Exhaust system

• Check for leakage.
• Tighten if necessary.
• Replace gasket(s) if necessary.

√

6 * Idle speed

• Check and adjust engine idle speed.
• Adjust cable free play.

√

Evaporative emission
7 * control system (for
California only)

• Check control system for damage.
• Replace if necessary.

Spark plugs

√

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

6-3

√

E_U2UJ1B.book Page 4 Wednesday, May 29, 2002 1:56 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
EAU00472

General maintenance and lubrication chart
No.

ITEM

Engine oil

ROUTINE

• Warm-up engine before
draining.

TYPE

See page 8-1.

Engine oil filter
2 *
element

• Replace.

3 * Air filter element

• Wet type filter must be
washed and damped with
oil.

4 * Brake system

• Adjust free play.
• Replace pads if necessary.
(front)
• Replace shoes if necessary.
(rear)

–

5 * Clutch

• Adjust free play.

–

Drive chain

• Check chain condition.
• Adjust and lubricate chain
thoroughly.

Control and meter
cable

Yamaha Chain and Cable Lube
• Apply chain lube thoroughly. or engine oil SAE 10W-30
(API SE)

8 * Swingarm pivot shaft

• Check swingarm assembly
for looseness.
• Moderately repack.

INITIAL
600 mi
(1,000km)
or
1 month

4,000 mi
(6,000km)
or
6 months

√

–

√

13,000 mi
(21,000km)
or
24 months

√
√

√

Engine oil

Every 300 mi (500 km)

SAE 30W-50W motor oil

Lithium-soap-based grease
(all-purpose grease)

ODOMETER READINGS
7,000 mi
10,000 mi
(11,000km)
(16,000km)
or
or
12 months
18 months

√

Check

√

Brake and clutch lever
• Apply chain lube lightly.
pivot shafts

Lithium-soap-based grease
(all-purpose grease)

√

Brake and shift pedal
pivot shafts

• Lubricate.
• Apply chain lube lightly.

Lithium-soap-based grease
(all-purpose grease)

√

• Check operation and
lubricate.
• Apply chain lube lightly.

Lithium-soap-based grease
(all-purpose grease)

√

11 * Sidestand pivot

6-4

E_U2UJ1B.book Page 5 Wednesday, May 29, 2002 1:56 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
No.

ITEM

ROUTINE

TYPE

12 * Front fork

• Check operation and
leakage.

13 * Steering bearings

• Check bearings assembly
for looseness.
• Moderately repack every
10,000 mi (16,000 km) or
18 months.

14 * Wheel bearings

• Check bearings for smooth
operation.

• Check specific gravity and
breather pipe for proper
operation.
• Check and clean or replace
if necessary.

–

Battery

16 * Sidestand switch

INITIAL
600 mi
(1,000km)
or
1 month

4,000 mi
(6,000km)
or
6 months

ODOMETER READINGS
7,000 mi
10,000 mi
(11,000km)
(16,000km)
or
or
12 months
18 months

13,000 mi
(21,000km)
or
24 months

√

Repack.

√

–

√

–

√

–

Lithium-soap-based grease
(all-purpose grease)

√

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

6
EAU03906

NOTE:
From 16,000 mi (26,000 km) or 30 months, repeat the maintenance intervals starting from 4,000 mi (6,000 km) or 6 months.
_

EAU03057

NOTE:
● The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
● Hydraulic brake system
• When disassembling the master cylinder or caliper cylinder, always replace the brake fluid. Check the brake fluid level
regularly and fill as required.
• Replace the oil seals on the inner parts of the master cylinder and caliper cylinder every two years.
• Replace the brake hoses every four years or if cracked or damaged.
@

6-5

E_U2UJ1B.book Page 6 Wednesday, May 29, 2002 1:56 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
NOTE:
If any spark plug shows a distinctly different color, the engine could be defective. Do not attempt to diagnose such
problems yourself. Instead, have a
Yamaha dealer check the motorcycle.
@

1. Spark plug cap

1. Spark plug wrench
EAU03329

Checking the spark plugs

The spark plugs are important engine
components, which are easy to check.
Since heat and deposits will cause any
spark plug to slowly erode, the spark
plugs should be removed and checked
in accordance with the periodic maintenance and lubrication chart. In addition,
the condition of the spark plugs can reveal the condition of the engine.
To remove a spark plug
1. Remove the spark plug cap.

2. Remove the spark plug as shown,
with the spark plug wrench included in the owner’s tool kit.
To check the spark plugs
1. Check that the porcelain insulator
around the center electrode on
each spark plug is a medium-tolight tan (the ideal color when the
motorcycle is ridden normally).
2. Check that all spark plugs installed
in the engine have the same color.

6-6

3. Check each spark plug for electrode erosion and excessive carbon or other deposits, and replace
it if necessary.
Specified spark plug:
C6HSA (NGK) or
U20FS-U (DENSO)

E_U2UJ1B.book Page 7 Wednesday, May 29, 2002 1:56 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
Tightening torque:
Spark plug:
12.5 Nm (1.25 m·kgf, 9.0 ft·lbf)
NOTE:
If a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4–1/2 turn
past finger tight. However, the spark
plug should be tightened to the specified torque as soon as possible.
@

a. Spark plug gap

To install a spark plug
1. Measure the spark plug gap with a
wire thickness gauge and, if necessary, adjust the gap to specification.

4. Install the spark plug cap.
6

Spark plug gap:
0.6–0.7 mm (0.02–0.03 in)
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 tighten it to the specified torque.

6-7

E_U2UJ1B.book Page 8 Wednesday, May 29, 2002 1:56 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
EAU00499

EAU04613

Canister (for California only)

Engine oil and oil filter
element

This model is equipped with a canister
to prevent the discharging of fuel vapor
into the atmosphere. Before operating
this motorcycle, make sure to check
the following:
● Check each hose connection.
● Check each hose and canister for
cracks or damage. Replace if
damaged.
● Make sure that the canister
breather is not blocked, and if necessary, clean it.
6

The engine oil level should be checked
before each ride. In addition, the oil
must be changed and the oil filter element replaced at the intervals specified
in the periodic maintenance and lubrication chart.
To check the engine oil level
1. Place the motorcycle on a level
surface and hold it in an upright
position.

1. Canister cover
2. Canister breather
3. Canister

NOTE:
Make sure that the motorcycle is positioned straight up when checking the oil
level. A slight tilt to the side can result in
a false reading.
_

6-8

E_U2UJ1B.book Page 9 Wednesday, May 29, 2002 1:56 PM

PERIODIC MAINTENANCE AND MINOR REPAIR

1. Engine oiil level check window
2. Maximum level mark
3. Minimum level mark

2. Start the engine, warm it up for
several minutes, and then turn it off.
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
crankcase.

1. Engine oil filler cap

1. Engine oil drain bolt

To change the engine oil (with or
without oil filter element replacement)
1. Start the engine, warm it up for
several minutes, and then turn it
off.
2. Place an oil pan under the engine
to collect the used oil.

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 sufficient oil
of the recommended type to raise
it to the correct level.
6-9

3. Remove the engine oil filler cap
and drain bolt to drain the oil from
the crankcase.
NOTE:
Skip steps 4–6 if the oil filter element is
not being replaced.
_

E_U2UJ1B.book Page 10 Wednesday, May 29, 2002 1:56 PM

PERIODIC MAINTENANCE AND MINOR REPAIR

1. Bolt (× 3)
2. Oil filter element cover

4. Remove the oil filter element cover
by removing the bolts.
5. Remove and replace the oil filter
element and O-ring.
6. Install the oil filter element cover
by installing the bolts, then tightening them to the specified torque.

Tightening torque:
Oil filter element cover bolt:
7 Nm (0.7 m·kgf, 5.1 ft·lbf)

Recommended engine oil:
See page 8-1.
Oil quantity:
With oil filter element
replacement:
1.6 L (1.4 Imp qt, 1.7 US qt)
Without oil filter element
replacement:
1.4 L (1.2 Imp qt, 1.5 US qt)
Total amount (dry engine):
1.8 L (1.6 Imp qt, 1.9 US qt)

1. Oil filter element
2. O-ring

7. Install the engine oil drain bolt, and
then tighten it to the specified
torque.

ECA00133

Tightening torque:
Engine oil drain bolt:
34 Nm (3.4 m·kgf, 25 ft·lbf)
8. Add the specified amount of the
recommended engine oil, and
then install and tighten the oil filler
cap.

NOTE:
Make sure that the O-ring is properly
seated.
_

6-10

CAUTION:
● In order to prevent clutch slippage (since the engine oil also
lubricates the clutch), do not
mix any chemical additives. Do
not use oils with a diesel specification of “CD” or oils of a
higher quality than specified. In
addition, do not use oils labeled
“ENERGY CONSERVING II” or
higher.
● Make sure that no foreign material enters the crankcase.

E_U2UJ1B.book Page 11 Wednesday, May 29, 2002 1:56 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
9. Start the engine, and then let it idle
for several minutes while checking
it for oil leakage. If oil is leaking,
immediately turn the engine off
and check for the cause.
10. Turn the engine off, and then
check the oil level and correct it if
necessary.
1. Bolt (× 2)
EAU04182*

Cleaning the air filter element
The air filter element should be cleaned
at the intervals specified in the periodic
maintenance and lubrication chart.
Clean the air filter element more frequently if you are riding in unusually
wet or dusty areas.
1. Remove the air filter case cover by
removing the bolts and loosening
the clamp screw.

6-11

1. Clamp screw
2. Air filter case cover
3. Air filter case

E_U2UJ1B.book Page 12 Wednesday, May 29, 2002 1:56 PM

PERIODIC MAINTENANCE AND MINOR REPAIR

1. Screw (× 2)

2. Remove the air filter element cover by removing the screws.

1. Wing nut
2. Air filter case

1. Sponge material
2. Air filter element frame

3. Remove the air filter element by
removing the wing nut.

4. Remove the sponge material from
the air filter element frame, clean it
with solvent, and then squeeze the
remaining solvent out.
5. Apply oil of the recommended type
to the entire surface of the sponge
material, and then squeeze the excess oil out.

NOTE:
The air filter element should be wet but
not dripping.
_

Recommended oil:
Engine oil
6-12

E_U2UJ1B.book Page 13 Wednesday, May 29, 2002 1:56 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6. Pull the sponge material over the
air filter element frame.
7. Insert the element into the air filter
case, and then tighten the wing
nut.
EC000082*

CAUTION:
● Make sure that the air filter element is properly seated in the
air filter case.
● The engine should never be operated without the air filter element installed, otherwise the
pistons and/or cylinders may
become excessively worn.

EAU01752

Adjusting the carburetor
The carburetor is an important part of
the engine and its emission control system, which requires very sophisticated
adjustment. Therefore, carburetor adjustments should be left to Yamaha
dealer, who has the necessary professional knowledge and experience.
a. Throttle cable free play
EAU00635

Adjusting the throttle cable
free play
The throttle cable free play should
measure 3–5 mm (0.12–0.20 in) at the
throttle grip. Periodically check the
throttle cable free play and, if necessary, have a Yamaha dealer adjust it.

8. Install the air filter element cover
by installing the screws.
9. Install the air filter case cover by
installing the bolts.
10. Tighten the clamp screw.

6-13

E_U2UJ1B.book Page 14 Wednesday, May 29, 2002 1:56 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
EAU00637

EW000082

Adjusting the valve clearance
@

The valve clearance changes with use,
resulting in improper air-fuel mixture
and/or engine noise. To prevent this
from occurring, the valve clearance
must be adjusted by a Yamaha dealer
at the intervals specified in the periodic
maintenance and lubrication chart.
1. Sidewall
2. Tire wear indicator
a. Tire tread depth
EAU03360

Tires
6

To maximize the performance, durability, and safe operation of your motorcycle, note the following points
regarding the specified tires.
Tire air pressure
The tire air pressure should be
checked and, if necessary, adjusted
before each ride.

WARNING
● 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
adjusted in accordance with the
riding speed and with the total
weight of rider, passenger, cargo, and accessories approved
for this model.

CE-22E

Tire air pressure
(measured on cold tires)
Load*

Front

Rear

Up to 90 kg (198 lb)

175 kPa
200 kPa
(1.75 kgf/cm2, (2.00 kgf/cm2,
25 psi)
29 psi)

90 kg (198 lb)–
maximum

200 kPa
225 kPa
(2.00 kgf/cm2, (2.25 kgf/cm2,
29 psi)
33 psi)

CE-07E

Maximum load*

XV250: 196 kg (432 lb)
XV250C: 195 kg (430 lb)

* Total weight of rider, passenger, cargo and
accessories

6-14

E_U2UJ1B.book Page 15 Wednesday, May 29, 2002 1:56 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
EW000083

WARNING
Proper loading of your motorcycle
is important for several characteristics of your motorcycle, such as
handling, braking, performance and
safety. Do not carry loosely packed
items that can shift. Securely pack
your heaviest items close to the
center of the motorcycle, and distribute the weight evenly from side
to side. Properly adjust the suspension for your load, and check the
condition and pressure of your tires.
NEVER OVERLOAD YOUR MOTORCYCLE. Make sure the total weight
of the cargo, rider, passenger, and
accessories (cowling, saddlebags,
etc. if approved for this model) does
not exceed the maximum load of the
motorcycle. Operation of an overloaded motorcycle could cause tire
damage, an accident, or even injury.
@

Tire inspection
Always check the tires before operating
the motorcycle. If a tire tread shows
crosswise lines (minimum tread depth),
if the tire has a nail or glass fragments
in it, or if the sidewall is cracked, contact a Yamaha dealer immediately and
have the tire replaced.

EAU00680

CE-10E

FRONT
Manufacturer

Size

Model

CHENG SHIN

3.00-18 47P

C-916

Size

Model

REAR
Manufacturer

CHENG SHIN 130/90-15M/C 66P

C-915

CE-23E

Minimum tire tread depth
(front and rear)

1.0 mm (0.04 in)

6-15

WARNING
● 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 wheeland brake-related parts, including the tires, should be left to a
Yamaha dealer, who has the
necessary professional knowledge and experience.
● It is not recommended to patch
a punctured tube. If unavoidable, however, patch the tube
very carefully and replace it as
soon as possible with a highquality product.

E_U2UJ1B.book Page 16 Wednesday, May 29, 2002 1:56 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
EAU00685

Spoke wheels

To maximize the performance, durability, and safe operation of your motorcycle, note the following points
regarding the specified wheels.
● The wheel rims should be checked
for cracks, bends or warpage, and
the spokes for looseness or 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.
● 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 characteristics, and a shortened tire life.
● Ride at moderate speeds after
changing a tire since the tire surface must first be “broken in” for it to
develop its optimal characteristics.

EAU00691

Accessories and replacement
parts
EW000098

WARNING
This motorcycle is not designed to
pull a trailer or to be attached to a
sidecar. The accessories or replacement parts you choose for your
motorcycle should be designed specifically for this model, and they
must be securely mounted to maintain the inherent stability of the original design. Genuine Yamaha Parts
and Accessories are designed and
tested to be compatible with your
motorcycle. Please consider Genuine Yamaha Parts and Accessories
before making a purchase. Use of
non-Yamaha-approved accessories
or replacement parts may cause
loss of handling stability and riding
safety. Since Yamaha cannot control the quality of accessories or
parts manufactured by other companies, Yamaha cannot be held lia@

6-16

ble for any consequences caused
by the use of items which have not
been approved by Yamaha.
@

E_U2UJ1B.book Page 17 Wednesday, May 29, 2002 1:56 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
7. Tighten the locknut at the clutch
lever and the crankcase.

1. Locknut
2. Clutch lever free play adjusting bolt
c. Clutch lever free play

1. Locknut
2. Clutch lever free play adjusting nut
EAU00694

Adjusting the clutch lever free
play
The clutch lever free play should measure 10–15 mm (0.4–0.6 in) as shown.
Periodically check the clutch lever free
play and, if necessary, adjust it as
follows.
1. Loosen the locknut at the clutch
lever.
2. To increase the clutch lever free
play, turn the adjusting bolt in direction a. To decrease the clutch
lever free play, turn the adjusting
bolt in direction 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 at the
clutch lever in direction a to loosen the clutch cable.
5. Loosen the locknut at the
crankcase.
6. To increase the clutch lever free
play, turn the adjusting nut in direction a. To decrease the clutch
lever free play, turn the adjusting
nut in direction b.
6-17

E_U2UJ1B.book Page 18 Wednesday, May 29, 2002 1:56 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
EW000099

1. Locknut
2. Brake lever free play adjusting bolt
c. Brake lever free play
EAU00696

Adjusting the brake lever free
play
The brake lever free play should measure 2–5 mm (0.08–0.20 in) as shown.
Periodically check the brake lever free
play and, if necessary, adjust it as
follows.
1. Loosen the locknut at the brake
lever.
2. To increase the brake lever free
play, turn the adjusting bolt in direction a. To decrease the brake
lever free play, turn the adjusting
bolt in direction b.
3. Tighten the locknut.

WARNING
● After adjusting the brake lever
free play, check the free play
and make sure that the brake is
working properly.
● A soft or spongy feeling in the
brake lever can 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. Footrest
a. Distance between brake pedal and footrest
b. Brake pedal free play
EAU03778

Adjusting the brake pedal
position and free play
EW000104

WARNING
It is advisable to have a Yamaha
dealer make these adjustments.
_

Brake pedal position
The top of the brake pedal should be positioned approximately 60 mm (2.4 in)
above the top of the footrest as shown.
Periodically check the brake pedal position and, if necessary, adjust it as follows.
6-18

E_U2UJ1B.book Page 19 Wednesday, May 29, 2002 1:56 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
EW000106

1. Locknut
2. Brake pedal position adjusting bolt

1. Brake pedal free play adjusting nut

1. Loosen the locknut at the brake
pedal.
2. To raise the brake pedal, turn the
adjusting bolt in direction a. To
lower the brake pedal, turn the adjusting bolt in direction b.
3. Tighten the locknut.
EWA00044

WARNING
After adjusting the brake pedal position, the brake pedal free play must
be adjusted.
_

Brake pedal free play
The brake pedal free play should measure 20–30 mm (0.8–1.2 in) at the
brake pedal end. Periodically check the
brake pedal free play and, if necessary,
adjust it as follows.
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, turn the adjusting nut in
direction b.

6-19

WARNING
● After adjusting the drive chain
slack or removing and installing
the rear wheel, always check
the brake pedal free play.
● If proper adjustment cannot be
obtained as described, have a
Yamaha dealer make this adjustment.
● After adjusting the brake pedal
free play, check the operation of
the brake light.

E_U2UJ1B.book Page 20 Wednesday, May 29, 2002 1:56 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
EAU00720

Checking the front brake pads
and rear brake shoes

Front

The front brake pads and the rear
brake shoes must be checked for wear
at the intervals specified in the periodic
maintenance and lubrication chart.

1. Rear brake light switch
2. Rear brake light switch adjusting nut

1. Brake pad wear indicator groove
EAU00725

Front brake pads
Each front brake pad is provided with a
wear indicator groove, which allows
you to check the brake pad wear without 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 disappeared, have a Yamaha dealer replace
the brake pads as a set.

EAU00713

Adjusting the rear brake light
switch
6

The rear brake light switch, which is activated by the brake pedal, is properly
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 earlier,
turn the adjusting nut in direction a. To
make the brake light come on later,
turn the adjusting nut in direction b.
6-20

E_U2UJ1B.book Page 21 Wednesday, May 29, 2002 1:56 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
Observe these precautions:
● When checking the fluid level,
make sure that the top of the brake
fluid reservoir is level.
● Use only the recommended quality brake fluid, otherwise the rubber
seals may deteriorate, causing
leakage and poor braking performance.

Rear

1. Brake shoe wear indicator
2. Brake shoe wear limit line

1. Minimum level mark
EAU04856
EAU04502

Rear brake shoes
The rear brake is provided with a wear
indicator, which allows you to check the
brake shoe wear without having to disassemble the brake. To check the
brake shoe wear, check the position of
the wear indicator while applying the
brake. If a brake shoe has worn to the
point that the wear indicator reaches
the wear limit line, have a Yamaha
dealer replace the brake shoes as a
set.

Checking the brake fluid level
Insufficient brake fluid may allow air to
enter the brake system, possibly causing it to become ineffective.
Before riding, check that the brake fluid
is above the minimum level mark and
replenish if necessary. A low brake fluid level may indicate worn brake pads
and/or brake system leakage. If the
brake fluid level is low, be sure to check
the brake pads for wear and the brake
system for leakage.

6-21

Recommended brake fluid: DOT 4
●

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 enter the brake fluid reservoir when
refilling. Water will significantly
lower the boiling point of the fluid
and may result in vapor lock.

E_U2UJ1B.book Page 22 Wednesday, May 29, 2002 1:56 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
●

Brake fluid may deteriorate painted surfaces or plastic parts. Always clean up spilled fluid
immediately.
● As the brake pads wear, it is normal for the brake fluid level to
gradually go down. However, if the
brake fluid level goes down suddenly, have a Yamaha dealer
check the cause.

EAU03985

Changing the brake fluid
Have a Yamaha dealer change the
brake fluid at the intervals specified in
the NOTE after the periodic maintenance and lubrication 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 leaking.
● Oil seals: Replace every two
years.
● Brake hose: Replace every four
years.

a. Drive chain slack
EAU00744

Drive chain slack
The drive chain slack should be
checked before each ride and adjusted
if necessary.
To check the drive chain slack
1. Place the motorcycle on a level
surface and hold it in an upright
position.
NOTE:
When checking and adjusting the drive
chain slack, the motorcycle should be
positioned straight up and there should
be no weight on it.
@

6-22

E_U2UJ1B.book Page 23 Wednesday, May 29, 2002 1:56 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
2. Shift the transmission into the neutral position.
3. Move the rear wheel by pushing
the motorcycle to locate the tightest portion of the drive chain, and
then measure the drive chain
slack as shown.
Drive chain slack:
30–40 mm (1.2–1.6 in)

1. Brake pedal free play adjusting nut
EAU01076

4. If the drive chain slack is incorrect,
adjust it as follows.

To adjust the drive chain slack
1. Loosen the brake pedal free play
adjusting nut.

6-23

1.
2.
3.
4.
5.

Axle nut
Cotter pin
Chain puller locknut
Drive chain slack adjusting nut
Alignment marks

2. Remove the cotter pin from the
axle nut, and then loosen the axle
nut.
3. Loosen the chain puller locknut at
each end of the swingarm.
4. To tighten the drive chain, turn the
adjusting nut at each end of the
swingarm in direction a. To loosen the drive chain, turn the adjusting nut at each end of the
swingarm in direction b, and then
push the rear wheel forward.

E_U2UJ1B.book Page 24 Wednesday, May 29, 2002 1:56 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
EW000103

NOTE:
Using the alignment marks on each
side of the swingarm, make sure that
both chain pullers are in the same position for proper wheel alignment.

WARNING
After adjusting the brake pedal free
play, check the operation of the
brake light.

EC000096

CAUTION:
Improper drive chain slack will overload the engine as well as other vital
parts of the motorcycle and can lead
to chain slippage or breakage. To
prevent this from occurring, keep
the drive chain slack within the
specified limits.
@

1. Cotter pin

6. 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 further tighten the axle nut until they are.
@

5. Tighten the locknuts, and then
tighten the axle nut to the specified
torque.

Tightening torque:
Axle nut:
104 Nm (10.4 m·kgf, 75 ft·lbf)

EW000110

WARNING
Always use a new cotter pin for the
axle nut.
@

7. Adjust the brake pedal free play.
(See page 6-19 for brake pedal
free play adjustment procedures.)
6-24

E_U2UJ1B.book Page 25 Wednesday, May 29, 2002 1:56 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
EAU03006

Lubricating the drive chain
The drive chain must be cleaned and
lubricated at the intervals specified in
the periodic maintenance and lubrication chart, otherwise it will quickly wear
out, especially when riding in dusty or
wet areas. Service the drive chain as
follows.

ECA00052

CAUTION:
Do not use engine oil or any other
lubricants for the drive chain, as
they may contain substances that
could damage the O-rings.
@

EC000097

CAUTION:
The drive chain must be lubricated
after washing the motorcycle or
riding in the rain.

EAU03297

Checking and lubricating the
cables
The operation of all control cables and
the condition of the cables should be
checked before each ride, and the cables and cable ends should be lubricated if necessary. If a cable is damaged
or does not move smoothly, have a
Yamaha dealer check or replace it.

Recommended lubricant:
Yamaha Chain and Cable Lube
or engine oil SAE 10W-30
(API SE)

1. Clean the drive chain with kerosene and a small soft brush.

EW000111

ECA00053

WARNING
Damage to the outer housing of cables may result in internal rusting
and cause interference with cable
movement. Replace damaged cables as soon as possible to prevent
unsafe conditions.

CAUTION:
To prevent damaging the O-rings,
do not clean the drive chain with
steam
cleaners,
high-pressure
washers or inappropriate solvents.

2. Wipe the drive chain dry.
3. Thoroughly lubricate the drive
chain with a special O-ring chain
lubricant.

6-25

E_U2UJ1B.book Page 26 Wednesday, May 29, 2002 1:56 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
EAU04034

EAU03370

EAU03164

Checking and lubricating the
throttle grip and cable

Checking and lubricating the
brake and shift pedals

Checking and lubricating the
brake and clutch levers

The operation of the throttle grip should
be checked before each ride. In addition, the cable should be lubricated or
replaced at the intervals specified in
the periodic maintenance chart.

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

The operation of the brake and clutch
levers should be checked before each
ride, and the lever pivots should be lubricated if necessary.

Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)

6-26

Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)

E_U2UJ1B.book Page 27 Wednesday, May 29, 2002 1:56 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
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.

EAU02939

Checking the front fork
The condition and operation of the front
fork must be checked as follows at the
intervals specified in the periodic maintenance and lubrication chart.
To check the condition

EW000113

EW000115

WARNING
If the sidestand does not move up
and down smoothly, have a Yamaha
dealer check or repair it.

WARNING
Securely support the motorcycle so
that there is no danger of it falling
over.

@
@

Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)

Check the inner tubes for scratches,
damage and excessive oil leakage.

To check the operation
1. Place the motorcycle on a level
surface and hold it in an upright
position.
2. While applying the front brake,
push down hard on the handlebars several times to check if the
front fork compresses and rebounds smoothly.
EC000098

CAUTION:
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or repair it.
@

6-27

E_U2UJ1B.book Page 28 Wednesday, May 29, 2002 1:56 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
EAU00794

Checking the wheel bearings

Worn or loose steering bearings may
cause danger. Therefore, the operation
of the steering must be checked as follows at the intervals specified in the periodic maintenance and lubrication
chart.
1. Place a stand under the engine to
raise the front wheel off the
ground.

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 wheel does not turn
smoothly, have a Yamaha dealer
check the wheel bearings.

EW000115

WARNING
Securely support the motorcycle so
that there is no danger of it falling
over.
@

EAU01144

Checking the steering

2. Hold the lower ends of the front
fork legs and try to move them forward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the steering.

6-28

E_U2UJ1B.book Page 29 Wednesday, May 29, 2002 1:56 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
NOTE:
Make sure that the motorcycle is positioned straight up when checking the
electrolyte level.
@

2. Check the electrolyte level in the
battery.
NOTE:
The electrolyte should be between the
minimum and maximum level marks.
@

1. Battery
2. Battery breather hose

1. Maximum level mark
2. Minimum level mark

3. If the electrolyte is at or below the
minimum level mark, add distilled
water to raise it to the maximum
level mark.

EAU01071

Battery
A poorly maintained battery will corrode and discharge quickly. The electrolyte level, battery lead connections
and breather hose routing should be
checked before each ride and at the intervals specified in the periodic maintenance and lubrication chart.
To check the electrolyte level
1. Place the motorcycle on a level
surface and hold it in an upright
position.

6-29

E_U2UJ1B.book Page 30 Wednesday, May 29, 2002 1:56 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
●

Take care not to spill electrolyte
on the drive chain, as this may
weaken it, shorten chain life and
possibly result in an accident.
● KEEP THIS AND ALL BATTERIES OUT OF THE REACH OF
CHILDREN.

EW000117

WARNING
● Electrolyte is poisonous and
dangerous since it contains sulfuric acid, which causes severe
burns. Avoid any contact with
skin, eyes or clothing and always shield your eyes when
working near batteries. In case
of contact, administer the following FIRST AID.
• EXTERNAL: Flush with plenty
of water.
• INTERNAL: Drink large quantities of water or milk and immediately call a physician.
• EYES: Flush with water for
15 minutes and seek prompt
medical attention.
● Batteries produce explosive hydrogen gas. Therefore, keep
sparks, flames, cigarettes, etc.,
away from the battery and provide sufficient ventilation when
charging it in an enclosed
space.

EC000100

CAUTION:
Use only distilled water, as tap water
contains minerals that are harmful
to the battery.
@

4. Check and, if necessary, tighten
the battery lead connections and
correct the breather hose routing.

6-30

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 the
specific gravity of the electrolyte at
least once a month and fully
charge the battery whenever
necessary.
3. Fully charge the battery before
installation.
4. After installation, make sure that
the battery leads are properly connected to the battery terminals and
that the breather hose is properly
routed, in good condition, and not
obstructed.

E_U2UJ1B.book Page 31 Wednesday, May 29, 2002 1:56 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
EC000099

Specified fuses:
Main fuse:
Signaling system fuse:

CAUTION:
If the breather hose is positioned in
such a way that the frame is exposed to electrolyte or gas expelled
from the battery, the frame could
suffer structural and external
damages.
@

20 A
10 A
EC000103

CAUTION:
Do not use a fuse of a higher amperage rating than recommended to
avoid causing extensive damage to
the electrical system and possibly a
fire.
_

1. Main fuse
2. Signaling system fuse
EAU04201

Replacing the fuses
The main fuse and the signaling system fuse holders are located under the
rider seat. (See page 3-8 for rider seat
removal and installation procedures.)
If a fuse is blown, replace it as follows.
1. Turn the key to “OFF” and turn off
the electrical circuit in question.
2. Remove the blown fuse, and then
install a new fuse of the specified
amperage.

6-31

3. Turn the key to “ON” and turn on
the electrical circuit in question to
check if the device operates.
4. If the fuse immediately blows
again, have a Yamaha dealer
check the electrical system.

E_U2UJ1B.book Page 32 Wednesday, May 29, 2002 1:56 PM

PERIODIC MAINTENANCE AND MINOR REPAIR

1. Screw (× 2)
EAU04187

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 the headlight unit by removing the screws.

1. Headlight coupler
2. Headlight bulb cover

1. Headlight bulb holder

3. Remove the headlight bulb holder
by turning it counterclockwise, and
then remove the defective bulb.

2. Disconnect the headlight coupler,
and then remove the bulb cover.

EW000119

WARNING
Headlight bulbs get very hot. Therefore, keep flammable products away
from a lit headlight bulb, and do not
touch the bulb until it has cooled
down.
_

4. Place a new headlight bulb into
position, and then secure it with
the bulb holder.

6-32

E_U2UJ1B.book Page 33 Wednesday, May 29, 2002 1:56 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
EAU01579

Supporting the motorcycle

1. Do not touch the glass part of the bulb.
EC000105

CAUTION:
Do not touch the glass part of the
headlight bulb to keep it free from
oil, otherwise the transparency of
the glass, the luminosity of the bulb,
and the bulb life will be adversely affected. Thoroughly clean off any dirt
and fingerprints on the headlight
bulb using a cloth moistened with
alcohol or thinner.

Since this model is not equipped with a
centerstand, follow these precautions
when removing the front and rear
wheel or performing other maintenance requiring the motorcycle to
stand upright. Check that the motorcycle is in a stable and level position
before starting any maintenance. A
strong wooden box can be placed under the engine for added stability.

To service the rear wheel
Raise the rear wheel off the ground by
using a motorcycle stand or, if a motorcycle stand is not available, by placing
a jack either under each side of the
frame in front of the rear wheel or under
each side of the swingarm.

5. Install the headlight bulb cover,
and then connect the coupler.
6. Install the headlight unit by installing the screws.
7. Have a Yamaha dealer adjust the
headlight beam if necessary.

To service the front wheel
1. Stabilize the rear of the motorcycle
by using a motorcycle stand or, if
an additional motorcycle stand is
not available, by placing a jack under the frame in front of the rear
wheel.
2. Raise the front wheel off the
ground by using a motorcycle
stand.

6-33

E_U2UJ1B.book Page 34 Wednesday, May 29, 2002 1:56 PM

PERIODIC MAINTENANCE AND MINOR REPAIR

1. Speedometer cable
EAU03239

1. Wheel axle
2. Front wheel axle pinch bolt

Front wheel

EW000122

WARNING
● It is advisable to have a Yamaha
dealer service the wheel.
● Securely support the motorcycle so that there is no danger
of it falling over.

1. Disconnect the speedometer cable from the front wheel.

EAU04423

2. Loosen the front wheel axle pinch
bolt, then the wheel axle.
3. Lift the front wheel off the ground
according to the procedure on
page 6-33.
4. Pull the wheel axle out, and then
remove the wheel.

To remove the front wheel
6

1. Speedometer gear unit

ECA00048

CAUTION:
Do not apply the brake after the
wheel has been removed together
with the brake disc, otherwise the
brake pads will be forced shut.
@

To install the front wheel
1. Install the speedometer gear unit
into the wheel hub so that the projections mesh with the slots.
2. Lift the wheel up between the fork
legs.
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.
4. Lower the front wheel so that it is
on the ground.

6-34

E_U2UJ1B.book Page 35 Wednesday, May 29, 2002 1:56 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
Tightening torque:
Front wheel axle pinch bolt:
20 Nm (2.0 m·kgf, 14 ft·lbf)
7. Push down hard on the handlebar
several times to check for proper
fork operation.
8. Connect the speedometer cable.
1. Speedometer gear unit
2. Retainer
3. Speedometer cable

5. Tighten the wheel axle to the
specified torque.
6

Tightening torque:
Wheel axle:
59 Nm (5.9 m·kgf, 43 ft·lbf)
6. Tighten the front wheel axle pinch
bolt to the specified torque.

6-35

E_U2UJ1B.book Page 36 Wednesday, May 29, 2002 1:56 PM

PERIODIC MAINTENANCE AND MINOR REPAIR

1.
2.
3.
4.
5.
6.

Brake torque rod
Brake torque rod cotter pin
Brake torque rod bolt and nut
Brake rod
Brake pedal free play adjusting nut
Brake cam shaft lever

1.
2.
3.
4.
5.
EAU04850

Rear wheel
To remove the rear wheel
EW000122

WARNING
It is advisable to have a Yamaha
dealer service the wheel.
● Securely support the motorcycle so that there is no danger
of it falling over.
●

Axle nut
Axle nut cotter pin
Chain puller locknut
Drive chain slack adjusting nut
Alignment marks

1. Remove the axle nut cotter pin
and the brake torque rod cotter
pin.
2. Loosen the chain puller locknut
and the drive chain slack adjusting
nut on both ends of the swingarm.
3. Loosen the axle nut and the brake
torque rod nut at the brake shoe
plate.
4. Remove the brake pedal free play
adjusting nut, and then disconnect
the brake rod at the brake camshaft lever.
6-36

5. Disconnect the brake torque rod
from the brake shoe plate by removing the nut and the bolt.
6. Lift the rear wheel off the ground
according to the procedure on
page 6-33.
7. Remove the axle nut.
8. Pull the wheel axle out, and then
remove the wheel.

E_U2UJ1B.book Page 37 Wednesday, May 29, 2002 1:56 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
5. Adjust the drive chain slack. (See
page 6-23 for drive chain slack adjustment procedures.)
6. Tighten the axle nut to the specified torque, and then insert a new
cotter pin into the axle nut.

EAU04851

To install the rear wheel
1. Insert the wheel axle from the
right-hand side, and then install
the drive chain onto the rear
sprocket.
2. Install the axle nut, and then lower
the rear wheel so that it is on the
ground.
3. Install the brake rod onto the brake
camshaft lever, and then install
the brake pedal free play adjusting
nut onto the brake rod.
4. Install the brake torque rod bolt at
the brake shoe plate, tighten it to
the specified torque, and then install the cotter pin.

Tightening torque:
Axle nut:
104 Nm (10.4 m·kgf, 75 ft·lbf)
7. Adjust the brake pedal position
and free play. (See page 6-18 for
brake pedal position and free play
adjustment procedures.)
EW000103

WARNING
After adjusting the brake pedal free
play, check the operation of the
brake light.
_

Tightening torque:
Brake torque rod bolt:
23 Nm (2.3 m·kgf, 17 ft·lbf)

EW000110

WARNING
Always use a new cotter pin for the
axle nut.
_

6-37

EAU01008

Troubleshooting
Although Yamaha motorcycles receive
a thorough inspection before shipment
from the factory, trouble may occur during 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 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 replacement parts. Imitation parts may look
like Yamaha parts, but they are often
inferior, have a shorter service life and
can lead to expensive repair bills.

E_U2UJ1B.book Page 38 Wednesday, May 29, 2002 1:56 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
EAU01562

Troubleshooting chart
EW000125

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

1. Fuel
There is enough fuel.

Check the compression.

There is no fuel.

Supply fuel.

There is compression.

Check the ignition.

There is no compression.

Have a Yamaha dealer
check the vehicle.

Check the fuel level in
the fuel tank.

The engine does not start.
Check the compressoin.

2. Compression
Operate the electric starter.

6
3. Ignition

Wet

Wipe off with a dry cloth and correct the
spark plug gaps, or replace the spark plugs.

Open the throttle halfway and
operate the electric starter.

Dry

Have a Yamaha dealer check the vehicle.

The engine does not start.
Check the battery.

Remove the spark plugs
and check the electrodes.

4. Battery

The engine turns over
quickly.

The battery is good.

Operate the electric starter.
The engine turns over
slowly.

Check the electrolyte and battery
lead connections, and charge the
battery if necessary.

6-38

The engine does not start.
Have a Yamaha dealer
check the vehicle.

E_U2UJ1B.book Page 1 Wednesday, May 29, 2002 1:56 PM

EAU03430
7-

Care
While the open design of a motorcycle
reveals the attractiveness of the technology, it also makes it more vulnerable. Rust and corrosion can develop
even if high-quality components are
used. A rusty exhaust pipe may go unnoticed on a car, however, it detracts
from the overall appearance of a
motorcycle. Frequent and proper care
does not only comply with the terms of
the warranty, but it will also keep your
motorcycle looking good, extend its life
and optimize its performance.

MOTORCYCLE CARE AND STORAGE

Before cleaning
1. Cover the muffler outlets with plastic bags 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 caps, 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.

7-1

Cleaning
ECA00010

CAUTION:
● Avoid using strong acidic wheel
cleaners, especially on spoked
wheels. If such products are
used on hard-to-remove dirt, do
not leave the cleaner on the affected area any longer than instructed. Also, thoroughly rinse
the area off with water, immediately dry it, and then apply a
corrosion protection spray.
● Improper cleaning can damage
windshields, cowlings, panels
and other plastic parts. Use
only a soft, clean cloth or
sponge with mild detergent and
water to clean plastic.

E_U2UJ1B.book Page 2 Wednesday, May 29, 2002 1:56 PM

MOTORCYCLE CARE AND STORAGE
●

Do not use any harsh chemical
products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
contact with strong or abrasive
cleaning products, solvent or
thinner, fuel (gasoline), rust removers or inhibitors, brake fluid, antifreeze or electrolyte.
● Do not use high-pressure washers or steam-jet cleaners since
they cause water seepage and
deterioration in the following areas: seals (of wheel and swingarm bearings, fork and brakes),
electric components (couplers,
connectors, instruments, switches and lights), breather hoses
and vents.

●

For motorcycles equipped with
a windshield: Do not use strong
cleaners or hard sponges as
they will cause dulling or
scratching. Some cleaning
compounds for plastic may
leave scratches on the windshield. Test the product on a
small hidden part of the windshield to make sure that it does
not leave any marks. If the windshield is scratched, use a quality plastic polishing compound
after washing.

After riding in the rain, near the sea or
on salt-sprayed roads
Since sea salt or salt sprayed on roads
during winter are extremely corrosive in
combination with water, carry out the
following steps after each ride in the
rain, near the sea or on salt-sprayed
roads.
NOTE:
Salt sprayed on roads in the winter may
remain well into spring.
@

1. Clean the motorcycle with cold
water and a mild detergent, after
the engine has cooled down.

ECA00012

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 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.

7-2

CAUTION:
Do not use warm water since it increases the corrosive action of the
salt.
@

2. After drying the motorcycle, apply
a corrosion protection spray on all
metal, including chrome- and nickel-plated, surfaces to prevent
corrosion.

E_U2UJ1B.book Page 3 Wednesday, May 29, 2002 1:56 PM

MOTORCYCLE CARE AND STORAGE
After cleaning
1. Dry the motorcycle with a chamois
or an absorbing cloth.
2. Immediately dry the drive chain
and lubricate it to prevent it from
rusting.
3. Use a chrome polish to shine
chrome, aluminum and stainlesssteel parts, including the exhaust
system. (Even the thermally induced discoloring of stainlesssteel exhaust systems can be removed through polishing.)
4. To prevent corrosion, it is recommended to apply a corrosion protection spray on all metal,
including chrome- and nickel-plated, surfaces.
5. Use spray oil as a universal cleaner to remove any remaining dirt.
6. Touch up minor paint damage
caused by stones, etc.
7. Wax all painted surfaces.
8. Let the motorcycle dry completely
before storing or covering it.

EWA00001

NOTE:
Consult a Yamaha dealer for advice on
what products to use.
@

WARNING
● 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.
● Before operating the motorcycle test its braking performance and cornering behavior.

ECA00013

CAUTION:
● Apply spray oil and wax sparingly and make sure to wipe off
any excess.
● 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.

7-3

E_U2UJ1B.book Page 4 Wednesday, May 29, 2002 1:56 PM

MOTORCYCLE CARE AND STORAGE
Storage
Short-term
Always store your motorcycle in a cool,
dry place and, if necessary, protect it
against dust with a porous cover.
ECA00014

CAUTION:
● Storing the motorcycle in a
poorly ventilated room or covering it with a tarp, while it is still
wet, will allow water and humidity to seep in and cause rust.
● To prevent corrosion, avoid
damp cellars, stables (because
of the presence of ammonia)
and areas where strong chemicals are stored.

a. Remove the spark plug caps
and spark plugs.
b. Pour a teaspoonful of engine
oil into each spark plug bore.
c. Install the spark plug caps onto
the spark plugs, and then place
the spark plugs on the cylinder
head so that the electrodes are
grounded. (This will limit sparking during the next step.)
d. Turn the engine over several
times with the starter. (This will
coat the cylinder walls with oil.)
e. Remove the spark plug caps
from the spark plugs, and then
install the spark plugs and the
spark plug caps.

Long-term
Before storing your motorcycle for
several months:
1. Follow all the instructions in the
“Care” section of this chapter.
2. Turn the fuel cock lever to “ON”.
3. Drain the carburetor float chambers by loosening the drain bolts;
this will prevent fuel deposits from
building up. Pour the drained 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 cylinders, piston rings, etc.
from corrosion.

EWA00003

WARNING
To prevent damage or injury from
sparking, make sure to ground the
spark plug electrodes while turning
the engine over.

7-4

E_U2UJ1B.book Page 5 Wednesday, May 29, 2002 1:56 PM

MOTORCYCLE CARE AND STORAGE
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 air pressure, and then lift
the motorcycle so that both of its
wheels are off the ground. Alternatively, turn the wheels a little every
month in order to prevent the tires
from becoming degraded in one
spot.
8. Cover the muffler outlets with plastic bags to prevent moisture from
entering them.

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 (30 °F) or more than
30 °C (60 °F)]. For more information on storing the battery, see
page 6-30.
NOTE:
Make any necessary repairs before
storing the motorcycle.
@

7-5

E_U2UJ1B.book Page 1 Wednesday, May 29, 2002 1:56 PM

SPECIFICATIONS

EAU01038

Specifications
CS-01E

Model

XV250/XV250C

Engine oil
Type

Dimensions
Overall length
Overall width
Overall height

685 mm (27.0 in)
1,490 mm (58.7 in)

XV250C

-20 -10

145 mm (5.7 in)
Recommended engine oil
classification

2,800 mm (110.2 in)

110 130 ˚F

Air-cooled 4-stroke, SOHC
V-type 2-cylinder

Displacement

249 cm3

Bore × Stroke

49 × 66 mm (1.93 × 2.60 in)

Compression ratio

10:1

Starting system

Electric starter

Lubrication system

Wet sump

50 ˚C

API Service SE, SF, SG or
higher

In order to prevent clutch slippage (since the engine oil also
lubricates the clutch), do not mix any chemical additives. Do
not use oils with a diesel specification of “CD” or oils of a
higher quality than specified. In addition, do not use oils labeled “ENERGY CONSERVING II” or higher.

148 kg (326 lb)

Cylinder arrangement

CAUTION:

147 kg (324 lb)

Engine
Engine type

YAMALUBE 4 (20W-40)
or SAE 20W-40

Basic weight (with oil and full
fuel tank)
XV250

1,140 mm (44.9 in)

Wheelbase

Minimum turning radius

YAMALUBE 4 (10W-30)
or SAE 10W-30

815 mm (32.1 in)

Seat height

Ground clearance

2,190 mm (86.2 in)

Quantity
Without oil filter element
replacement

1.6 L (1.4 Imp qt, 1.7 US qt)

Total amount (dry engine)

1.8 L (1.6 Imp qt, 1.9 US qt)

Air filter

8-1

1.4 L (1.2 Imp qt, 1.5 US qt)

With oil filter element
replacement

Wet element

E_U2UJ1B.book Page 2 Wednesday, May 29, 2002 1:56 PM

SPECIFICATIONS
Fuel

Gear ratio

Type

UNLEADED GASOLINE ONLY

Fuel tank capacity

1st

2.643

2nd

1.684

XV250

9.5 L (2.1 Imp gal, 2.5 US gal)

3rd

1.261

XV250C

9.2 L (2.0 Imp gal, 2.4 US gal)

4th

1.000

5th

0.821

Fuel reserve amount

2.6 L (0.6 Imp gal, 0.7 US gal)

Carburetor

Chassis

Manufacturer

MIKUNI

Frame type

Double cradle

Model × quantity

BDS26 × 1

Caster angle

32°

Trail

120 mm (4.7 in)

Spark plug
Model/manufacturer

C6HSA / NGK or
U20FS-U / DENSO

Gap

0.6–0.7 mm (0.02–0.03 in)

Tires
Front
Type

With tube

Wet, multiple-disc

Size

3.00-18 47P

Primary reduction system

Spur gear

Manufacturer/
model

CHENG SHIN / C-916

Primary reduction ratio

3.130

Secondary reduction system

Chain drive

Type

With tube

Secondary reduction ratio

2.812

Size

130/90-15M/C 66P

Number of drive chain
sprocket teeth (front/rear)

16/45

Manufacturer/
model

CHENG SHIN / C-915

Clutch type
Transmission

Transmission type

Constant mesh 5-speed

Operation

Left foot

Rear

8-2

E_U2UJ1B.book Page 3 Wednesday, May 29, 2002 1:56 PM

SPECIFICATIONS
Maximum load*

Rear

XV250

196 kg (432 lb)

Type

Drum brake

XV250C

195 kg (430 lb)

Operation

Right foot

Tire air pressure (measured
on cold tires)

Suspension

Up to 90 kg (198 lb)*
Front

175 kPa (1.75 kgf/cm2, 25 psi)

Rear

200 kPa (2.00 kgf/cm2, 29 psi)
200 kPa (2.00 kgf/cm2, 29 psi)

Rear

225 kPa (2.25 kgf/cm2, 33 psi)

Telescopic fork

Rear

Swingarm

Spring/shock absorbers

90 kg (198 lb)–maximum*
Front

Front

Coil spring / oil damper

Rear

Coil spring / oil damper

Wheel travel

* Total weight of rider, passenger, cargo and accessories
Wheels

Front

140 mm (5.5 in)

Rear

100 mm (3.9 in)

Electrical system

Front

Ignition system
Type

Spoke wheel

Size

18 × 1.60

Rear

Type

Spoke wheel

Size

15M/C × MT 2.75

Type

A.C. magneto

Standard output

14 V, 25 A @ 5,000 r/min

Model

GM10-3A-2

Voltage, capacity

12 V, 10 Ah

Battery

Brakes
Front

Headlight type
Type

Single disc brake

Operation

Right hand

Fluid

DOT 4

T.C.I. (digital)

Charging system

8-3

Quartz bulb (halogen)

E_U2UJ1B.book Page 4 Wednesday, May 29, 2002 1:56 PM

SPECIFICATIONS
Bulb voltage, wattage × quantity
Headlight

12 V, 60/55 W × 1

Tail/brake light

12 V, 8/27 W × 1

Front turn signal /
position light

12 V, 27/8 W × 2

Rear turn signal light

12 V, 27 W × 2

Meter lighting

14 V, 3 W × 1

Neutral indicator light

14 V, 3 W × 1

High beam indicator light

12 V, 1.7 W × 1

Turn signal indicator light

14 V, 3 W × 1

Fuses
Main fuse

20 A

Signaling system fuse

10 A

8-4

E_U2UJ1B.book Page 1 Wednesday, May 29, 2002 1:56 PM

CONSUMER INFORMATION

EAU01039

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 from a Yamaha
dealer or for reference in case the vehicle is stolen.
1. Key identification number

1. KEY IDENTIFICATION NUMBER:
CA-02E

2. VEHICLE IDENTIFICATION
NUMBER:

EAU01043

EAU01042

Key identification number

Vehicle identification number

The key identification number is
stamped into the key. Record this number in the space provided and use it for
reference when ordering a new key.

The vehicle identification number is
stamped into the steering head pipe.
Record this number in the space provided.
NOTE:
The vehicle identification number is
used to identify your motorcycle and
may be used to register your motorcycle with the licensing authority in
your area.

CA-02E

1. Vehicle identification number

3. MODEL LABEL INFORMATION:
CA-01E

9-1

E_U2UJ1B.book Page 2 Wednesday, May 29, 2002 1:56 PM

CONSUMER INFORMATION

1. Model label
EAU01804

Model label
The model label is affixed to the frame
under the rider seat. (See page 3-8 for
rider seat removal and installation procedures.) Record the information on
this label in the space provided. This information will be needed when ordering
spare parts from a Yamaha dealer.

9-2

E_U2UJ1B.book Page 3 Wednesday, May 29, 2002 1:56 PM

CONSUMER INFORMATION
EAU01051

REPORTING SAFETY DEFECTS
If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Yamaha Motor Corporation,
U.S.A. If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in 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 either call the Auto Safety Hotline toll-free at 1-800-424-9393 (or 366-0123 in Washington, D.C.
area) or write to: NHTSA, U.S. Department of Transportation, Washington, D.C. 20590. You can also obtain other information about motor vehicle safety from the Hotline.

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CONSUMER INFORMATION
EAU01053

MOTORCYCLE NOISE REGULATION
TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED:
Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other
than for purposes of maintenance, repair, or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use 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 systems; i.e., modification, removal, etc.
CL-01E

Muffler
Exhaust pipe
Silencer

Exhaust system

Air cleaner case
Air cleaner element
Intake duct

Intake system

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CONSUMER INFORMATION
EAU03052

Maintenance record
Copies of work orders and/or receipts for parts purchased and installed on your motorcycle will be required to document that
maintenance has been completed in accordance with the emissions warranty. The chart below is printed only as a reminder
that maintenance work is required. It is not acceptable proof of maintenance work.
CL-06E

Maintenance
interval

Date of
service

Servicing dealer
name and address

Mileage

600 mi
(1,000 km) or
1 month
4,000 mi
(6,000 km) or
6 months
7,000 mi
(11,000 km) or
12 months
10,000 mi
(16,000 km) or
18 months
13,000 mi
(21,000 km) or
24 months

16,000 mi
(26,000 km) or
30 months
19,000 mi
(31,000 km) or
36 months
9-5

Remarks

E_U2UJ1B.book Page 6 Wednesday, May 29, 2002 1:56 PM

CONSUMER INFORMATION
Maintenance
interval

Date of
service

Servicing dealer
name and address

Mileage

Remarks

22,000 mi
(36,000 km) or
42 months
25,000 mi
(41,000 km) or
48 months
28,000 mi
(46,000 km) or
54 months
31,000 mi
(51,000 km) or
60 months

9-6

E_U2UJ1B.book Page 7 Wednesday, May 29, 2002 1:56 PM

CONSUMER INFORMATION
EAU02918

YAMAHA MOTOR CORPORATION, U.S.A.
STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY

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CONSUMER INFORMATION

9-8

E_U2UJ1B.book Page 9 Wednesday, May 29, 2002 1:56 PM

CONSUMER INFORMATION
EAU01063

YAMAHA EXTENDED SERVICE (Y.E.S.)

9-9

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CONSUMER INFORMATION

9-10

OWNER’S MANUAL

XV250R
XV250RC

YAMAHA MOTOR CO., LTD.

PRINTED ON RECYCLED PAPER

PRINTED IN JAPAN
2002.05-0.5×1 CR
(E)

LIT-11626-16-21

2UJ-28199-1B

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Metadata Date                   : 2003:04:16 12:31:12-07:00
Creator                         : YMC Ltd
Title                           : Virago

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Yamaha 2003 Virago 250 Owners Manual

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