Yamaha 2003 Virago 250 Owners Manual

2015-03-13

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INTRODUCTION
IMPORTANT MANUAL INFORMATION
TABLE OF CONTENTS
SAFETY INFORMATION
DESCRIPTION
INSTRUMENT AND CONTROL FUNCTIONS
PRE-OPERATION CHECKS
OPERATION AND IMPORTANT RIDING POINTS
PERIODIC MAINTENANCE AND MINOR REPAIR
MOTORCYCLE CARE AND STORAGE
SPECIFICATIONS
CONSUMER INFORMATION

PRINTED IN JAPAN

2002.05-0.5×1 CR

(E)

PRINTED ON RECYCLED PAPER

YAMAHA MOTOR CO., LTD.

2UJ-28199-1BLIT-11626-16-21

XV250R

XV250RC

OWNER’S MANUAL

EAU03438

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 emis-

sions 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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EAU00003

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!

WARNING 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.

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.

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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 MOTOR-

CYCLE. DO NOT ATTEMPT TO OPERATE THIS MOTORCYCLE UNTIL YOU HAVE AT-

TAINED 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 RELI-

ABILITY OF THIS MOTORCYCLE.

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IMPORTANT MANUAL INFORMATION

AFFIX DEALER

LABEL HERE

EAU04247

XV250R/XV250RC

OWNER’S MANUAL

1st edition, April 2002

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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EAU00009 TABLE OF CONTENTS

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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1-1

SAFETY INFORMATION EAU03633

MOTORCYCLES ARE SINGLE TRACK VEHICLES. THEIR SAFE USE AND OPERATION ARE DE-

PENDENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EXPERTISE OF

THE OPERATOR. EVERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIREMENTS BE-

FORE 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 MANU-

AL.

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.

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SAFETY INFORMATION

1-2

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 opera-

tors.

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 (insuf-

ficient 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.

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SAFETY INFORMATION

1-3

Protective apparel

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 vi-

sion which could delay seeing a hazard.

3. The use of a jacket, heavy boots, trousers, gloves, etc., is effective in preventing or reducing abra-

sions 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 ac-

cessories to your motorcycle:

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SAFETY INFORMATION

1-4

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 imbal-

ance 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, in-

cluding 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 select-

ing and installing any accessories.

Keep the following guidelines in mind, as well as those provided under “Loading” when mounting acces-

sories.

1. Never install accessories or carry cargo that would impair the performance of your motorcycle. Care-

fully 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 ob-

scure lights or reflectors.

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SAFETY INFORMATION

1-5

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 ve-

hicles.

c. Certain accessories can displace the operator from his or her normal riding position. This improp-

er 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 poi-

sonous 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:

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SAFETY INFORMATION

1-6

a. The engine and exhaust system may be hot, therefore, park the motorcycle in a place where pe-

destrians 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.

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SAFETY INFORMATION

1-7

EAU02977

Location of important labels

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

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SAFETY INFORMATION

1-8

5 California only

4 California only

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2-1

EAU00026

DESCRIPTION

Left view

1. Headlight (page 6-32)

2. Steering lock (page 3-8)

3. Fuel tank (page 3-4)

4. Battery (page 6-29)

5. Fuses (page 6-31)

6. Helmet holder (page 3-9)

7. Shock absorber assembly spring

preload adjusting ring (page 3-10)

8. Main switch (page 3-1)

9. Fuel cock (page 3-6)

10. Shift pedal (page 3-3)

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DESCRIPTION

2-2

Right view

11. Tail/brake light

12. Rear turn signal light

13. Rider seat (page 3-8)

14. Air filter element (page 6-11)

15. Front turn signal/position light

16. Brake pedal (page 3-4)

17. Footrest

18. Owner’s tool kit (page 6-2)

19. Shock absorber assembly spring

preload adjusting ring (page 3-10)

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DESCRIPTION

2-3

Controls and instruments

1. Clutch lever (page 3-3)

2. Left handlebar switches (page 3-2)

3. Speedometer unit (page 3-2)

4. Indicator lights (page 3-1)

5. Right handlebar switches (page 3-3)

6. Brake lever (page 3-4)

7. Throttle grip (page 6-13)

8. Fuel tank cap (page 3-4)

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3-1

EAU00027

INSTRUMENT AND CONTROL FUNCTIONS

EAU00028

Main switch

The main switch controls the ignition

and lighting systems. The various main

switch positions are described below.

EAU00032

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.

EAU00038

OFF

All electrical systems are off. The key

can be removed.

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, other-

wise the battery may discharge.

@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.

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.

1. High beam indicator light “HIGH BEAM”

2. Neutral indicator light “NEUTRAL”

3. Turn signal indicator light “TURN”

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INSTRUMENT AND CONTROL FUNCTIONS

3-2

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 en-

able you to plan future fuel stops.

EAU00118

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-

ter position. To cancel the turn signal

lights, push the switch in after it has re-

turned to the center position.

EAU00130

Horn switch “HORN”

Press this switch to sound the horn.

1. Odometer

2. Tripmeter

3. Tripmeter reset knob

4. Speedometer

1. Dimmer switch “LIGHTS”

2. Turn signal switch “TURN”

3. Horn switch “HORN”

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INSTRUMENT AND CONTROL FUNCTIONS

3-3

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 emergen-

cy, such as when the motorcycle over-

turns or when the throttle cable is

stuck.

EAU00141

Start switch “START”

Push this switch to crank the engine

with the starter.

EC000005

CAUTION:

See page 5-2 for starting instruc-

tions prior to starting the engine.

EAU00152

Clutch lever

The clutch lever is located at the left

handlebar grip. To disengage the

clutch, pull the lever toward the handle-

bar grip. To engage the clutch, release

the lever. The lever should be pulled

rapidly and released slowly for smooth

clutch operation.

The clutch lever is equipped with a

clutch switch, which is part of the igni-

tion circuit cut-off system. (See page

3-11 for an explanation of the ignition

circuit cut-off system.)

EAU00157

Shift pedal

The shift pedal is located on the left

side of the engine and is used in com-

bination with the clutch lever when

shifting the gears of the 5-speed con-

stant-mesh transmission equipped on

this motorcycle.

1. Engine stop switch “ENGINE STOP”

2. Start switch “START”

1. Clutch lever 1. Shift pedal

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INSTRUMENT AND CONTROL FUNCTIONS

3-4

EAU00158

Brake lever

The brake lever is located at the right

handlebar grip. To apply the front

brake, pull the lever toward the handle-

bar grip.

EAU00162

Brake pedal

The brake pedal is on the right side of

the motorcycle. To apply the rear

brake, press down on the brake pedal.

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 re-

leased and the fuel tank cap can be

opened.

To close the fuel tank cap

1. Push the fuel tank cap into posi-

tion with the key inserted in the

lock.

2. Turn the key counterclockwise to

the original position, and then re-

move it.

1. Brake lever 1. Brake pedal 1. Fuel tank cap

2. Unlock.

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INSTRUMENT AND CONTROL FUNCTIONS

3-5

NOTE:

The fuel tank cap cannot be closed un-

less the key is in the lock. In addition,

the key cannot be removed if the cap is

not properly closed and locked.

EWA00025

WARNING

Make sure that the fuel tank cap is

properly closed before riding.

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, oth-

erwise it may overflow when the

fuel warms up and expands.

●Avoid spilling fuel on the hot

engine.

EAU00185

CAUTION:

Immediately wipe off spilled fuel

with a clean, dry, soft cloth, since

fuel may deteriorate painted surfac-

es or plastic parts.

EAU04265

1. Fuel tank filler tube

2. Fuel level

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

3-6

ECA00104

CAUTION:

Use only unleaded gasoline. The

use of leaded gasoline will cause se-

vere damage to internal engine

parts, such as the valves and piston

rings, as well as to the exhaust sys-

tem.

Your Yamaha engine has been de-

signed to use regular unleaded gaso-

line 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 premi-

um unleaded fuel. Use of unleaded fuel

will extend spark plug life and reduce

maintenance costs.

Gasohol

There are two types of gasohol: gaso-

hol containing ethanol and that contain-

ing methanol. Gasohol containing

ethanol can be used if the ethanol con-

tent does not exceed 10%. Gasohol

containing methanol is not recom-

mended by Yamaha because it can

cause damage to the fuel system or ve-

hicle performance problems.

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 ex-

plained as follows and shown in the il-

lustrations.

With the fuel cock lever in this position,

fuel flows to the carburetor when the

engine is running. Turn the fuel cock le-

ver to this position when starting the

engine and riding.

1. Arrow mark positioned over “ON”

ON: normal position

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INSTRUMENT AND CONTROL FUNCTIONS

3-7

RES

This indicates reserve. With the fuel

cock lever in this position, the fuel re-

serve 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).

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).

1. Arrow mark positioned over “RES”

RES: reserve position

1. Arrow mark positioned over “PRI”

PRI: priming position

1. Starter (choke) lever

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

INSTRUMENT AND CONTROL FUNCTIONS

3-8

EAU02934

Steering lock

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 counter-

clockwise, 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 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.

EAU01072

Rider seat

To remove the rider seat

Remove the bolts, and then pull the rid-

er seat off.

1. Steering lock 1. Bolt (× 2)

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

INSTRUMENT AND CONTROL FUNCTIONS

3-9

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 proper-

ly secured before riding.

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.

1. Projection

2. Seat holder

1. Helmet holder

2. Unlock.

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

INSTRUMENT AND CONTROL FUNCTIONS

3-10

EAU00300

Adjusting the shock absorber

assemblies

Each shock absorber assembly is

equipped with a spring preload adjust-

ing ring.

EC000015

CAUTION:

Never attempt to turn an adjusting

mechanism beyond the maximum

or minimum settings.

EW000040

WARNING

Always adjust both shock absorber

assemblies equally, otherwise poor

handling and loss of stability may

result.

Adjust the spring preload as follows.

To increase the spring preload and

thereby harden the suspension, turn

the adjusting ring on each shock ab-

sorber assembly in direction a. To de-

crease the spring preload and thereby

soften the suspension, turn the adjust-

ing ring on each shock absorber as-

sembly in direction b.

NOTE:

Align the appropriate notch in the ad-

justing ring with the position indicator

on the shock absorber.

CI-10E

EAU00330

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.

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.)

1. Spring preload adjusting ring

2. Position indicator

Setting

Minimum (soft) 1

Standard 2

Maximum (hard) 5

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

INSTRUMENT AND CONTROL FUNCTIONS

3-11

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), oth-

erwise the sidestand could contact

the ground and distract the opera-

tor, 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 side-

stand before starting off. Therefore,

check this system regularly as de-

scribed 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 (com-

prising the sidestand switch, clutch

switch and neutral switch) has the fol-

lowing functions.

●It prevents starting when the trans-

mission is in gear and the side-

stand is up, but the clutch lever is

not pulled.

●It prevents starting when the trans-

mission is in gear and the clutch

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.

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

INSTRUMENT AND CONTROL FUNCTIONS

3-12

CD-01E

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? The neutral 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?

After the engine has stalled:

10. Move the sidestand up.

11. Keep the clutch lever pulled.

12. Push the start switch.

Does the engine start?

The sidestand switch may be defective.

The motorcycle should not be ridden until

checked by a Yamaha dealer.

The clutch switch may be defective.

The motorcycle should not be ridden until

checked by a Yamaha dealer.

NOTE:

This check is most reliable if performed with

a warmed-up engine.

YES

YES NO

The system is OK. The motorcycle can be ridden.

YES NO

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

4-1

EAU01114

PRE-OPERATION CHECKS

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 inspec-

tion, to check the following points before each ride.

EAU03439

Pre-operation check list

CO-01E

ITEM CHECKS PAGE

Fuel

•Check fuel level in fuel tank.

•Refuel if necessary.

•Check fuel line for leakage.

3-5

Engine oil

•Check oil level in engine.

•If necessary, add recommended oil to specified level.

•Check vehicle for oil leakage.

6-8–6-9

Front brake

•Check operation.

•If soft or spongy, have Yamaha dealer bleed hydraulic system.

•Check lever free play.

•Adjust if necessary.

•Check fluid level in reservoir.

•If necessary, add recommended brake fluid to specified level.

•Check hydraulic system for leakage.

6-18, 6-20–6-22

Rear brake

•Check operation.

•Check pedal free play.

•Adjust if necessary.

6-18–6-21

Clutch

•Check operation.

•Lubricate cable if necessary.

•Check lever free play.

•Adjust if necessary.

6-17

Throttle grip

•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.

6-13

Control cables •Make sure that operation is smooth.

•Lubricate if necessary. 6-25

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

PRE-OPERATION CHECKS

4-2

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.

Drive chain

•Check chain slack.

•Adjust if necessary.

•Check chain condition.

•Lubricate if necessary.

6-22–6-23

Wheels and tires

•Check for damage.

•Check tire condition and tread depth.

•Check air pressure.

•Correct if necessary.

6-14–6-16

Brake and shift pedals •Make sure that operation is smooth.

•Lubricate pedal pivoting points if necessary. 6-26

Brake and clutch levers •Make sure that operation is smooth.

•Lubricate lever pivoting points if necessary. 6-26

Sidestand •Make sure that operation is smooth.

•Lubricate pivot if necessary. 6-27

Chassis fasteners •Make sure that all nuts, bolts and screws are properly tightened.

•Tighten if necessary. —

Instruments, lights, signals

and switches

•Check operation.

•Correct if necessary. —

Sidestand switch •Check operation of ignition circuit cut-off system.

•If system is defective, have Yamaha dealer check vehicle. 3-10–3-11

Battery •Check fluid level.

•Fill with distilled water if necessary. 6-29–6-30

ITEM CHECKS PAGE

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

5-1

EAU00372

OPERATION AND IMPORTANT RIDING POINTS

EAU00373

WARNING

●Become thoroughly familiar

with all operating controls and

their functions before riding.

Consult a Yamaha dealer re-

garding 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 poi-

sonous, and inhaling them can

cause loss of consciousness

and death within a short time. Al-

ways make sure that there is ad-

equate ventilation.

●Before starting out, make sure

that the sidestand is up. If the

sidestand is not raised com-

pletely, it could contact the

ground and distract the opera-

tor, resulting in a possible loss

of control.

EAU00376

CAUTION:

●Make sure not to store personal

items near the air cleaner in-

take, otherwise air intake will be

blocked and performance will

suffer.

●Make sure not to put anything

near the battery and its termi-

nals, otherwise electrical failure

and acid corrosion may result.

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

OPERATION AND IMPORTANT RIDING POINTS

5-2

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.

EW000054

WARNING

●Before starting the engine,

check the function of the igni-

tion circuit cut-off system ac-

cording to the procedure

described on page 3-12.

●Never ride with the sidestand

down.

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 neu-

tral position.

NOTE:

When the transmission is in the neutral

position, the neutral indicator light

should be on, otherwise have a

Yamaha dealer check the electrical cir-

cuit.

4. Turn the starter (choke) on and

completely close the throttle. (See

page 3-7 for starter (choke) opera-

tion.)

5. Start the engine by pushing the

start switch.

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 pre-

serve the battery. Do not crank the en-

gine more than 10 seconds on any one

attempt.

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

OPERATION AND IMPORTANT RIDING POINTS

5-3

6. After starting the engine, move the

starter (choke) back halfway.

ECA00055

CAUTION:

For maximum engine life, always

warm the engine up before starting

off. Never accelerate hard when the

engine is cold!

7. When the engine is warm, turn the

starter (choke) off.

NOTE:

The engine is warm when it responds

normally to the throttle with the starter

(choke) turned off. To avoid the possi-

bility of excessive exhaust emissions,

never leave the starter (choke) on long-

er than necessary. The time necessary

for starter (choke) use depends upon

the ambient temperature. Tempera-

tures above 10 °C (50 °F) require about

7 seconds of starter (choke) use and

temperatures below 10 °C (50 °F) re-

quire about 35 seconds with the starter

(choke) turned on, then about 2.5 min-

utes with the starter (choke) in the half-

way position.

EAU01258

Starting a warm engine

Follow the same procedure as for start-

ing a cold engine with the exception

that the starter (choke) is not required

when the engine is warm.

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

OPERATION AND IMPORTANT RIDING POINTS

5-4

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.

NOTE:

To shift the transmission into the neu-

tral position, press the shift pedal down

repeatedly until it reaches the end of its

travel, and then slightly raise it.

EC000048

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 dis-

tances. The transmission is

properly lubricated only when

the engine is running. Inade-

quate lubrication may damage

the transmission.

●Always use the clutch while

changing gears to avoid dam-

aging the engine, transmission,

and drive train, which are not

designed to withstand the

shock of forced shifting.

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 recommend-

ed shift points.

1. Shift pedal

N. Neutral position

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

OPERATION AND IMPORTANT RIDING POINTS

5-5

EAU00427

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 rough-

ly, pull the clutch lever in and use

the brakes to stop the motorcycle.

3. Shift the transmission into the neu-

tral position when the motorcycle

is almost completely stopped. The

neutral indicator light should come

on.

EAU02974

Recommended shift points

The recommended shift points during

acceleration and deceleration are

shown in the table below.

CF-04E

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 them-

selves to the correct operating clear-

ances. During this period, prolonged

full-throttle operation or any condition

that might result in engine overheating

must be avoided.

Acceleration

shift point

km/h (mi/h)

Deceleration

shift point

km/h (mi/h)

1st →2nd

2nd →3rd

3rd →4th

4th →5th

16 (9.9)

24 (14.9)

32 (19.9)

40 (24.9)

20 (12.5)

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

OPERATION AND IMPORTANT RIDING POINTS

5-6

EAU00452*

0–1,000 km (0–600 mi)

Avoid prolonged operation above

1/3 throttle.

1,000–1,600 km (600–1,000 mi)

Avoid prolonged operation above

1/2 throttle.

1,600 km and beyond

The vehicle can now be operated nor-

mally.

EC000059*

CAUTION:

●After 1,000 km (600 mi) of oper-

ation, the engine oil must be

changed, the oil filter element

replaced, and the oil strainer

cleaned.

●If any engine trouble should oc-

cur during the engine break-in

period, immediately have a

Yamaha dealer check the vehi-

cle.

EAU00460

Parking

When parking, stop the engine, and

then remove the key from the main

switch.

EW000058

WARNING

●Since the engine and exhaust

system can become very hot,

park in a place where pedestri-

ans or children are not likely to

touch them.

●Do not park on a slope or on

soft ground, otherwise the

motorcycle may overturn.

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

6-1

EAU00462

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU01790

Safety is an obligation of the owner.

Periodic inspection, adjustment and lu-

brication will keep your vehicle in the

safest and most efficient condition pos-

sible. The most important points of

motorcycle inspection, adjustment, and

lubrication are explained on the follow-

ing 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 motor-

cycle maintenance work, have a

Yamaha dealer do it for you.

EAU00467

PERIODIC MAINTENANCE

PROPER PERIODIC MAINTENANCE

OF YOUR MOTORCYCLE IS IMPOR-

TANT IN ORDER TO ENJOY LONG,

PLEASURABLE SERVICE. ESPE-

CIALLY IMPORTANT ARE THE

MAINTENANCE SERVICES RELAT-

ED 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 MAINTE-

NANCE CHARTS, THE SERVICES

RELATED TO EMISSIONS CON-

TROL ARE GROUPED SEPARATE-

LY. THESE SERVICES REQUIRE

SPECIALIZED DATA, KNOWLEDGE,

AND EQUIPMENT. YAMAHA DEAL-

ERS ARE TRAINED AND EQUIPPED

TO PERFORM THESE PARTICULAR

SERVICES.

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

PERIODIC MAINTENANCE AND MINOR REPAIR

6-2

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. How-

ever, 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 experi-

ence required for a particular job, have

a Yamaha dealer perform it for you.

EW000062

WARNING

Modifications not approved by

Yamaha may cause loss of perfor-

mance, excessive emissions, and

render the vehicle unsafe for use.

Consult a Yamaha dealer before at-

tempting any changes.

1. Owner’s tool kit

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

PERIODIC MAINTENANCE AND MINOR REPAIR

6-3

EAU00471

Periodic maintenance chart for the emission control system

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

No. ITEM ROUTINE

INITIAL ODOMETER READINGS

600 mi

(1,000km)

1 month

4,000 mi

(6,000km)

6 months

7,000 mi

(11,000km)

12 months

10,000 mi

(16,000km)

18 months

13,000 mi

(21,000km)

24 months

1*Valve clearance •Check and adjust valve clearance when engine is cold. √√√√√

2 Spark plugs

•Check condition.

•Adjust gap and clean.

•Replace every 7,000 mi (11,000 km) or 12 months .

√Replace. √Replace.

3*Crankcase ventilation

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

control system (for

California only)

•Check control system for damage.

•Replace if necessary. √√

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

PERIODIC MAINTENANCE AND MINOR REPAIR

6-4

EAU00472

General maintenance and lubrication chart

No. ITEM ROUTINE TYPE

INITIAL ODOMETER READINGS

600 mi

(1,000km)

1 month

4,000 mi

(6,000km)

6 months

7,000 mi

(11,000km)

12 months

10,000 mi

(16,000km)

18 months

13,000 mi

(21,000km)

24 months

1 Engine oil •Warm-up engine before

draining. See page 8-1. √√√√√

2*Engine oil filter

element •Replace. –√√√

3*Air filter element

•Wet type filter must be

washed and damped with

oil.

Engine oil √√√√

4*Brake system

•Adjust free play.

•Replace pads if necessary.

(front)

•Replace shoes if necessary.

(rear)

–√√√√√

5*Clutch •Adjust free play. –√√√√√

6 Drive chain

•Check chain condition.

•Adjust and lubricate chain

thoroughly.

SAE 30W-50W motor oil Every 300 mi (500 km)

7Control and meter

cable •Apply chain lube thoroughly.

Yamaha Chain and Cable Lube

or engine oil SAE 10W-30

(API SE)

√√√√√

8*Swingarm pivot shaft

•Check swingarm assembly

for looseness.

•Moderately repack.

Lithium-soap-based grease

(all-purpose grease) Check √√√√

9Brake and clutch lever

pivot shafts •Apply chain lube lightly. Lithium-soap-based grease

(all-purpose grease) √√√√

10 Brake and shift pedal

pivot shafts

•Lubricate.

•Apply chain lube lightly.

Lithium-soap-based grease

(all-purpose grease) √√√√

11 *Sidestand pivot

•Check operation and

lubricate.

•Apply chain lube lightly.

Lithium-soap-based grease

(all-purpose grease) √√√√

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

PERIODIC MAINTENANCE AND MINOR REPAIR

6-5

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

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.

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.

Lithium-soap-based grease

(all-purpose grease) √√

Repack. √

14 *Wheel bearings •Check bearings for smooth

operation. –√√√√

15 Battery

•Check specific gravity and

breather pipe for proper

operation.

–√√√√

16 *Sidestand switch •Check and clean or replace

if necessary. –√√√√√

No. ITEM ROUTINE TYPE

INITIAL ODOMETER READINGS

600 mi

(1,000km)

1 month

4,000 mi

(6,000km)

6 months

7,000 mi

(11,000km)

12 months

10,000 mi

(16,000km)

18 months

13,000 mi

(21,000km)

24 months

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

PERIODIC MAINTENANCE AND MINOR REPAIR

6-6

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 mainte-

nance and lubrication chart. In addition,

the condition of the spark plugs can re-

veal 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 includ-

ed 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-to-

light tan (the ideal color when the

motorcycle is ridden normally).

2. Check that all spark plugs installed

in the engine have the same color.

NOTE:

If any spark plug shows a distinctly dif-

ferent color, the engine could be defec-

tive. Do not attempt to diagnose such

problems yourself. Instead, have a

Yamaha dealer check the motorcycle.

3. Check each spark plug for elec-

trode erosion and excessive car-

bon or other deposits, and replace

it if necessary.

1. Spark plug cap 1. Spark plug wrench

Specified spark plug:

C6HSA (NGK) or

U20FS-U (DENSO)

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

PERIODIC MAINTENANCE AND MINOR REPAIR

6-7

To install a spark plug

1. Measure the spark plug gap with a

wire thickness gauge and, if neces-

sary, adjust the gap to specification.

2. Clean the surface of the spark

plug gasket and its mating sur-

face, and then wipe off any grime

from the spark plug threads.

3. Install the spark plug with the

spark plug wrench, and then tight-

en it to the specified torque.

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 speci-

fied torque as soon as possible.

4. Install the spark plug cap.

a. Spark plug gap

Spark plug gap:

0.6–0.7 mm (0.02–0.03 in)

Tightening torque:

Spark plug:

12.5 Nm (1.25 m·kgf, 9.0 ft·lbf)

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

PERIODIC MAINTENANCE AND MINOR REPAIR

6-8

EAU00499

Canister (for California only)

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 nec-

essary, clean it.

EAU04613

Engine oil and oil filter

element

The engine oil level should be checked

before each ride. In addition, the oil

must be changed and the oil filter ele-

ment replaced at the intervals specified

in the periodic maintenance and lubri-

cation chart.

To check the engine oil level

1. Place the motorcycle on a level

surface and hold it in an upright

position.

NOTE:

Make sure that the motorcycle is posi-

tioned straight up when checking the oil

level. A slight tilt to the side can result in

a false reading.

1. Canister cover

2. Canister breather

3. Canister

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

PERIODIC MAINTENANCE AND MINOR REPAIR

6-9

2. Start the engine, warm it up for

several minutes, and then turn it off.

3. Wait a few minutes until the oil set-

tles, and then check the oil level

through the check window located

at the bottom-right side of the

crankcase.

NOTE:

The engine oil should be between the

minimum and maximum level marks.

4. If the engine oil is below the mini-

mum level mark, add sufficient oil

of the recommended type to raise

it to the correct level.

To change the engine oil (with or

without oil filter element replace-

ment)

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.

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.

1. Engine oiil level check window

2. Maximum level mark

3. Minimum level mark

1. Engine oil filler cap 1. Engine oil drain bolt

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

PERIODIC MAINTENANCE AND MINOR REPAIR

6-10

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 tighten-

ing them to the specified torque.

NOTE:

Make sure that the O-ring is properly

seated.

7. Install the engine oil drain bolt, and

then tighten it to the specified

torque.

8. Add the specified amount of the

recommended engine oil, and

then install and tighten the oil filler

cap.

ECA00133

CAUTION:

●In order to prevent clutch slip-

page (since the engine oil also

lubricates the clutch), do not

mix any chemical additives. Do

not use oils with a diesel speci-

fication 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 mate-

rial enters the crankcase.

1. Bolt (× 3)

2. Oil filter element cover

Tightening torque:

Oil filter element cover bolt:

7 Nm (0.7 m·kgf, 5.1 ft·lbf)

1. Oil filter element

2. O-ring

Tightening torque:

Engine oil drain bolt:

34 Nm (3.4 m·kgf, 25 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)

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

PERIODIC MAINTENANCE AND MINOR REPAIR

6-11

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.

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 fre-

quently 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.

1. Bolt (× 2) 1. Clamp screw

2. Air filter case cover

3. Air filter case

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

PERIODIC MAINTENANCE AND MINOR REPAIR

6-12

2. Remove the air filter element cov-

er by removing the screws. 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 ex-

cess oil out.

NOTE:

The air filter element should be wet but

not dripping.

1. Screw (× 2) 1. Wing nut

2. Air filter case

1. Sponge material

2. Air filter element frame

Recommended oil:

Engine oil

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

PERIODIC MAINTENANCE AND MINOR REPAIR

6-13

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 ele-

ment is properly seated in the

air filter case.

●The engine should never be op-

erated without the air filter ele-

ment installed, otherwise the

pistons and/or cylinders may

become excessively worn.

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.

EAU01752

Adjusting the carburetor

The carburetor is an important part of

the engine and its emission control sys-

tem, which requires very sophisticated

adjustment. Therefore, carburetor ad-

justments should be left to Yamaha

dealer, who has the necessary profes-

sional knowledge and experience.

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 neces-

sary, have a Yamaha dealer adjust it.

a. Throttle cable free play

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

PERIODIC MAINTENANCE AND MINOR REPAIR

6-14

EAU00637

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.

EAU03360

Tires

To maximize the performance, durabil-

ity, and safe operation of your motor-

cycle, 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.

EW000082

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, car-

go, and accessories approved

for this model.

CE-22E

CE-07E

1. Sidewall

2. Tire wear indicator

a. Tire tread depth

Tire air pressure

(measured on cold tires)

Load* Front Rear

Up to 90 kg (198 lb)

175 kPa

(1.75 kgf/cm2,

25 psi)

200 kPa

(2.00 kgf/cm2,

29 psi)

90 kg (198 lb)–

maximum

200 kPa

(2.00 kgf/cm2,

29 psi)

225 kPa

(2.25 kgf/cm2,

33 psi)

Maximum load* XV250: 196 kg (432 lb)

XV250C: 195 kg (430 lb)

* Total weight of rider, passenger, cargo and

accessories

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

PERIODIC MAINTENANCE AND MINOR REPAIR

6-15

EW000083

WARNING

Proper loading of your motorcycle

is important for several characteris-

tics 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 dis-

tribute the weight evenly from side

to side. Properly adjust the suspen-

sion for your load, and check the

condition and pressure of your tires.

NEVER OVERLOAD YOUR MOTOR-

CYCLE. 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 over-

loaded 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, con-

tact a Yamaha dealer immediately and

have the tire replaced.

CE-10E

CE-23E

EAU00680

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 wheel-

and brake-related parts, includ-

ing the tires, should be left to a

Yamaha dealer, who has the

necessary professional knowl-

edge and experience.

●It is not recommended to patch

a punctured tube. If unavoid-

able, however, patch the tube

very carefully and replace it as

soon as possible with a high-

quality product.

FRONT

Manufacturer Size Model

CHENG SHIN 3.00-18 47P C-916

REAR

Manufacturer Size Model

CHENG SHIN 130/90-15M/C 66P C-915

Minimum tire tread depth

(front and rear) 1.0 mm (0.04 in)

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

PERIODIC MAINTENANCE AND MINOR REPAIR

6-16

EAU00685

Spoke wheels

To maximize the performance, durabil-

ity, and safe operation of your motor-

cycle, 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 dam-

age before each ride. If any dam-

age 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 han-

dling characteristics, and a short-

ened tire life.

●Ride at moderate speeds after

changing a tire since the tire sur-

face must first be “broken in” for it to

develop its optimal 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 replace-

ment parts you choose for your

motorcycle should be designed spe-

cifically for this model, and they

must be securely mounted to main-

tain the inherent stability of the orig-

inal design. Genuine Yamaha Parts

and Accessories are designed and

tested to be compatible with your

motorcycle. Please consider Genu-

ine 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 con-

trol the quality of accessories or

parts manufactured by other com-

panies, Yamaha cannot be held lia-

ble for any consequences caused

by the use of items which have not

been approved by Yamaha.

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

PERIODIC MAINTENANCE AND MINOR REPAIR

6-17

EAU00694

Adjusting the clutch lever free

play

The clutch lever free play should mea-

sure 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 di-

rection 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 de-

scribed 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 loos-

en the clutch cable.

5. Loosen the locknut at the

crankcase.

6. To increase the clutch lever free

play, turn the adjusting nut in di-

rection a. To decrease the clutch

lever free play, turn the adjusting

nut in direction b.

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

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

PERIODIC MAINTENANCE AND MINOR REPAIR

6-18

EAU00696

Adjusting the brake lever free

play

The brake lever free play should mea-

sure 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 di-

rection a. To decrease the brake

lever free play, turn the adjusting

bolt in direction b.

3. Tighten the locknut.

EW000099

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 hy-

draulic system, have a Yamaha

dealer bleed the system before

operating the motorcycle. Air in

the hydraulic system will dimin-

ish the braking performance,

which may result in loss of con-

trol and an accident.

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 po-

sitioned approximately 60 mm (2.4 in)

above the top of the footrest as shown.

Periodically check the brake pedal posi-

tion and, if necessary, adjust it as fol-

lows.

1. Locknut

2. Brake lever free play adjusting bolt

c. Brake lever free play

1. Footrest

a. Distance between brake pedal and footrest

b. Brake pedal free play

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

PERIODIC MAINTENANCE AND MINOR REPAIR

6-19

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 ad-

justing bolt in direction b.

3. Tighten the locknut.

EWA00044

WARNING

After adjusting the brake pedal posi-

tion, the brake pedal free play must

be adjusted.

Brake pedal free play

The brake pedal free play should mea-

sure 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.

EW000106

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 ad-

justment.

●After adjusting the brake pedal

free play, check the operation of

the brake light.

1. Locknut

2. Brake pedal position adjusting bolt

1. Brake pedal free play adjusting nut

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

PERIODIC MAINTENANCE AND MINOR REPAIR

6-20

EAU00713

Adjusting the rear brake light

switch

The rear brake light switch, which is ac-

tivated 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.

EAU00720

Checking the front brake pads

and rear brake shoes

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.

EAU00725

Front brake pads

Each front brake pad is provided with a

wear indicator groove, which allows

you to check the brake pad wear with-

out having to disassemble the brake.

To check the brake pad wear, check

the wear indicator groove. If a brake

pad has worn to the point that the wear

indicator groove has almost disap-

peared, have a Yamaha dealer replace

the brake pads as a set.

1. Rear brake light switch

2. Rear brake light switch adjusting nut

1. Brake pad wear indicator groove

Front

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

PERIODIC MAINTENANCE AND MINOR REPAIR

6-21

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 dis-

assemble 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.

EAU04856

Checking the brake fluid level

Insufficient brake fluid may allow air to

enter the brake system, possibly caus-

ing it to become ineffective.

Before riding, check that the brake fluid

is above the minimum level mark and

replenish if necessary. A low brake flu-

id 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.

Observe these precautions:

●When checking the fluid level,

make sure that the top of the brake

fluid reservoir is level.

●Use only the recommended quali-

ty brake fluid, otherwise the rubber

seals may deteriorate, causing

leakage and poor braking perfor-

mance.

●Refill with the same type of brake

fluid. Mixing fluids may result in a

harmful chemical reaction and

lead to poor braking performance.

●Be careful that water does not en-

ter the brake fluid reservoir when

refilling. Water will significantly

lower the boiling point of the fluid

and may result in vapor lock.

1. Brake shoe wear indicator

2. Brake shoe wear limit line

Rear

1. Minimum level mark

Recommended brake fluid: DOT 4

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

PERIODIC MAINTENANCE AND MINOR REPAIR

6-22

●Brake fluid may deteriorate paint-

ed surfaces or plastic parts. Al-

ways clean up spilled fluid

immediately.

●As the brake pads wear, it is nor-

mal for the brake fluid level to

gradually go down. However, if the

brake fluid level goes down sud-

denly, 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 mainte-

nance 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 dam-

aged or leaking.

●Oil seals: Replace every two

years.

●Brake hose: Replace every four

years.

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.

a. Drive chain slack

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

PERIODIC MAINTENANCE AND MINOR REPAIR

6-23

2. Shift the transmission into the neu-

tral position.

3. Move the rear wheel by pushing

the motorcycle to locate the tight-

est portion of the drive chain, and

then measure the drive chain

slack as shown.

4. If the drive chain slack is incorrect,

adjust it as follows.

EAU01076

To adjust the drive chain slack

1. Loosen the brake pedal free play

adjusting nut. 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 loos-

en the drive chain, turn the adjust-

ing nut at each end of the

swingarm in direction b, and then

push the rear wheel forward.

Drive chain slack:

30–40 mm (1.2–1.6 in) 1. Brake pedal free play adjusting nut 1. Axle nut

2. Cotter pin

3. Chain puller locknut

4. Drive chain slack adjusting nut

5. Alignment marks

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

PERIODIC MAINTENANCE AND MINOR REPAIR

6-24

NOTE:

Using the alignment marks on each

side of the swingarm, make sure that

both chain pullers are in the same posi-

tion for proper wheel alignment.

EC000096

CAUTION:

Improper drive chain slack will over-

load 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.

5. Tighten the locknuts, and then

tighten the axle nut to the specified

torque.

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 tight-

en the axle nut until they are.

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.)

EW000103

WARNING

After adjusting the brake pedal free

play, check the operation of the

brake light.

Tightening torque:

Axle nut:

104 Nm (10.4 m·kgf, 75 ft·lbf)

1. Cotter pin

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

PERIODIC MAINTENANCE AND MINOR REPAIR

6-25

EAU03006

Lubricating the drive chain

The drive chain must be cleaned and

lubricated at the intervals specified in

the periodic maintenance and lubrica-

tion chart, otherwise it will quickly wear

out, especially when riding in dusty or

wet areas. Service the drive chain as

follows.

EC000097

CAUTION:

The drive chain must be lubricated

after washing the motorcycle or

riding in the rain.

1. Clean the drive chain with kero-

sene and a small soft brush.

ECA00053

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.

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.

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 ca-

bles and cable ends should be lubricat-

ed if necessary. If a cable is damaged

or does not move smoothly, have a

Yamaha dealer check or replace it.

EW000111

WARNING

Damage to the outer housing of ca-

bles may result in internal rusting

and cause interference with cable

movement. Replace damaged ca-

bles as soon as possible to prevent

unsafe conditions.

Recommended lubricant:

Yamaha Chain and Cable Lube

or engine oil SAE 10W-30

(API SE)

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

PERIODIC MAINTENANCE AND MINOR REPAIR

6-26

EAU04034

Checking and lubricating the

throttle grip and cable

The operation of the throttle grip should

be checked before each ride. In addi-

tion, the cable should be lubricated or

replaced at the intervals specified in

the periodic maintenance chart.

EAU03370

Checking and lubricating the

brake and shift pedals

The operation of the brake and shift

pedals should be checked before each

ride, and the pedal pivots should be lu-

bricated if necessary.

EAU03164

Checking and lubricating the

brake and clutch levers

The operation of the brake and clutch

levers should be checked before each

ride, and the lever pivots should be lu-

bricated if necessary.

Recommended lubricant:

Lithium-soap-based grease

(all-purpose grease)

Recommended lubricant:

Lithium-soap-based grease

(all-purpose grease)

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

PERIODIC MAINTENANCE AND MINOR REPAIR

6-27

EAU03165

Checking and lubricating the

sidestand

The operation of the sidestand should

be checked before each ride, and the

sidestand pivot and metal-to-metal

contact surfaces should be lubricated if

necessary.

EW000113

WARNING

If the sidestand does not move up

and down smoothly, have a Yamaha

dealer check or repair it.

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 main-

tenance and lubrication chart.

To check the condition

EW000115

WARNING

Securely support the motorcycle so

that there is no danger of it falling

over.

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 handle-

bars several times to check if the

front fork compresses and re-

bounds smoothly.

EC000098

CAUTION:

If any damage is found or the front

fork does not operate smoothly,

have a Yamaha dealer check or re-

pair it.

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

6-28

EAU00794

Checking the steering

Worn or loose steering bearings may

cause danger. Therefore, the operation

of the steering must be checked as fol-

lows at the intervals specified in the pe-

riodic maintenance and lubrication

chart.

1. Place a stand under the engine to

raise the front wheel off the

ground.

EW000115

WARNING

Securely support the motorcycle so

that there is no danger of it falling

over.

2. Hold the lower ends of the front

fork legs and try to move them for-

ward and backward. If any free

play can be felt, have a Yamaha

dealer check or repair the steering.

EAU01144

Checking the wheel bearings

The front and rear wheel bearings must

be checked at the intervals specified in

the periodic maintenance and lubrica-

tion 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.

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

PERIODIC MAINTENANCE AND MINOR REPAIR

6-29

EAU01071

Battery

A poorly maintained battery will cor-

rode and discharge quickly. The elec-

trolyte level, battery lead connections

and breather hose routing should be

checked before each ride and at the in-

tervals specified in the periodic mainte-

nance and lubrication chart.

To check the electrolyte level

1. Place the motorcycle on a level

surface and hold it in an upright

position.

NOTE:

Make sure that the motorcycle is posi-

tioned 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.

3. If the electrolyte is at or below the

minimum level mark, add distilled

water to raise it to the maximum

level mark.

1. Battery

2. Battery breather hose

1. Maximum level mark

2. Minimum level mark

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

PERIODIC MAINTENANCE AND MINOR REPAIR

6-30

EW000117

WARNING

●Electrolyte is poisonous and

dangerous since it contains sul-

furic acid, which causes severe

burns. Avoid any contact with

skin, eyes or clothing and al-

ways shield your eyes when

working near batteries. In case

of contact, administer the fol-

lowing FIRST AID.

•EXTERNAL: Flush with plenty

of water.

•INTERNAL: Drink large quan-

tities of water or milk and im-

mediately call a physician.

•EYES: Flush with water for

15 minutes and seek prompt

medical attention.

●Batteries produce explosive hy-

drogen gas. Therefore, keep

sparks, flames, cigarettes, etc.,

away from the battery and pro-

vide sufficient ventilation when

charging it in an enclosed

space.

●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 BATTER-

IES OUT OF THE REACH OF

CHILDREN.

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.

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 con-

nected to the battery terminals and

that the breather hose is properly

routed, in good condition, and not

obstructed.

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

PERIODIC MAINTENANCE AND MINOR REPAIR

6-31

EC000099

CAUTION:

If the breather hose is positioned in

such a way that the frame is ex-

posed to electrolyte or gas expelled

from the battery, the frame could

suffer structural and external

damages.

EAU04201

Replacing the fuses

The main fuse and the signaling sys-

tem 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.

EC000103

CAUTION:

Do not use a fuse of a higher amper-

age rating than recommended to

avoid causing extensive damage to

the electrical system and possibly a

fire.

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.

1. Main fuse

2. Signaling system fuse

Specified fuses:

Main fuse: 20 A

Signaling system fuse: 10 A

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

PERIODIC MAINTENANCE AND MINOR REPAIR

6-32

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 re-

moving the screws.

2. Disconnect the headlight coupler,

and then remove the bulb cover.

3. Remove the headlight bulb holder

by turning it counterclockwise, and

then remove the defective bulb.

EW000119

WARNING

Headlight bulbs get very hot. There-

fore, 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.

1. Screw (× 2) 1. Headlight coupler

2. Headlight bulb cover

1. Headlight bulb holder

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

PERIODIC MAINTENANCE AND MINOR REPAIR

6-33

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 af-

fected. Thoroughly clean off any dirt

and fingerprints on the headlight

bulb using a cloth moistened with

alcohol or thinner.

5. Install the headlight bulb cover,

and then connect the coupler.

6. Install the headlight unit by install-

ing the screws.

7. Have a Yamaha dealer adjust the

headlight beam if necessary.

EAU01579

Supporting the motorcycle

Since this model is not equipped with a

centerstand, follow these precautions

when removing the front and rear

wheel or performing other mainte-

nance requiring the motorcycle to

stand upright. Check that the motor-

cycle is in a stable and level position

before starting any maintenance. A

strong wooden box can be placed un-

der the engine for added stability.

To service the front wheel

1. Stabilize the rear of the motorcycle

by using a motorcycle stand or, if

an additional motorcycle stand is

not available, by placing a jack un-

der the frame in front of the rear

wheel.

2. Raise the front wheel off the

ground by using a motorcycle

stand.

To service the rear wheel

Raise the rear wheel off the ground by

using a motorcycle stand or, if a motor-

cycle 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.

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

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

PERIODIC MAINTENANCE AND MINOR REPAIR

6-34

EAU03239

Front wheel

To remove the front wheel

EW000122

WARNING

●It is advisable to have a Yamaha

dealer service the wheel.

●Securely support the motor-

cycle so that there is no danger

of it falling over.

1. Disconnect the speedometer ca-

ble from the front wheel.

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.

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.

EAU04423

To install the front wheel

1. Install the speedometer gear unit

into the wheel hub so that the pro-

jections 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 insert-

ing 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.

1. Speedometer cable 1. Wheel axle

2. Front wheel axle pinch bolt

1. Speedometer gear unit

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

PERIODIC MAINTENANCE AND MINOR REPAIR

6-35

5. Tighten the wheel axle to the

specified torque.

6. Tighten the front wheel axle pinch

bolt to the specified torque.

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

Tightening torque:

Wheel axle:

59 Nm (5.9 m·kgf, 43 ft·lbf)

Tightening torque:

Front wheel axle pinch bolt:

20 Nm (2.0 m·kgf, 14 ft·lbf)

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

PERIODIC MAINTENANCE AND MINOR REPAIR

6-36

6EAU04850

Rear wheel

To remove the rear wheel

EW000122

WARNING

●It is advisable to have a Yamaha

dealer service the wheel.

●Securely support the motor-

cycle so that there is no danger

of it falling over.

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 cam-

shaft lever.

5. Disconnect the brake torque rod

from the brake shoe plate by re-

moving 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.

1. Brake torque rod

2. Brake torque rod cotter pin

3. Brake torque rod bolt and nut

4. Brake rod

5. Brake pedal free play adjusting nut

6. Brake cam shaft lever

1. Axle nut

2. Axle nut cotter pin

3. Chain puller locknut

4. Drive chain slack adjusting nut

5. Alignment marks

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

PERIODIC MAINTENANCE AND MINOR REPAIR

6-37

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 in-

stall the cotter pin.

EW000110

WARNING

Always use a new cotter pin for the

axle nut.

5. Adjust the drive chain slack. (See

page 6-23 for drive chain slack ad-

justment procedures.)

6. Tighten the axle nut to the speci-

fied torque, and then insert a new

cotter pin into the axle nut.

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.

EAU01008

Troubleshooting

Although Yamaha motorcycles receive

a thorough inspection before shipment

from the factory, trouble may occur dur-

ing operation. Any problem in the fuel,

compression, or ignition systems, for

example, can cause poor starting and

loss of power.

The following troubleshooting chart

represents a quick and easy procedure

for checking these vital systems your-

self. However, should your motorcycle

require any repair, take it to a Yamaha

dealer, whose skilled technicians have

the necessary tools, experience, and

know-how to service the motorcycle

properly.

Use only genuine Yamaha replace-

ment 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.

Tightening torque:

Brake torque rod bolt:

23 Nm (2.3 m·kgf, 17 ft·lbf)

Tightening torque:

Axle nut:

104 Nm (10.4 m·kgf, 75 ft·lbf)

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

PERIODIC MAINTENANCE AND MINOR REPAIR

6-38

EAU01562

Troubleshooting chart

EW000125

WARNING

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

Check the fuel level in

the fuel tank.

1. Fuel

There is enough fuel.

There is no fuel.

Check the compression.

Supply fuel.

Operate the electric starter.

2. Compression

There is compression.

There is no compression.

Check the ignition.

Have a Yamaha dealer

check the vehicle.

Remove the spark plugs

and check the electrodes.

3. Ignition Wet

Dry

Wipe off with a dry cloth and correct the

spark plug gaps, or replace the spark plugs.

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

Check the battery.

Open the throttle halfway and

operate the electric starter.

Operate the electric starter.

4. Battery The engine turns over

quickly.

The engine turns over

slowly.

The battery is good.

Check the electrolyte and battery

lead connections, and charge the

battery if necessary.

The engine does not start.

Have a Yamaha dealer

check the vehicle.

The engine does not start.

Check the compressoin.

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

7-1

EAU03430

MOTORCYCLE CARE AND STORAGE

Care

While the open design of a motorcycle

reveals the attractiveness of the tech-

nology, it also makes it more vulnera-

ble. Rust and corrosion can develop

even if high-quality components are

used. A rusty exhaust pipe may go un-

noticed 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.

Before cleaning

1. Cover the muffler outlets with plas-

tic 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 in-

stalled.

3. Remove extremely stubborn dirt,

like oil burnt onto the crankcase,

with a degreasing agent and a

brush, but never apply such prod-

ucts onto seals, gaskets, sprock-

ets, the drive chain and wheel

axles. Always rinse the dirt and

degreaser off with water.

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 af-

fected area any longer than in-

structed. Also, thoroughly rinse

the area off with water, immedi-

ately 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 1 Wednesday, May 29, 2002 1:56 PM

MOTORCYCLE CARE AND STORAGE

7-2

●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 re-

movers or inhibitors, brake flu-

id, antifreeze or electrolyte.

●Do not use high-pressure wash-

ers or steam-jet cleaners since

they cause water seepage and

deterioration in the following ar-

eas: seals (of wheel and swing-

arm bearings, fork and brakes),

electric components (couplers,

connectors, instruments, switch-

es 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 wind-

shield. Test the product on a

small hidden part of the wind-

shield to make sure that it does

not leave any marks. If the wind-

shield is scratched, use a quali-

ty plastic polishing compound

after washing.

After normal use

Remove dirt with warm water, a mild

detergent, and a soft, clean sponge,

and then rinse thoroughly with clean

water. Use a toothbrush or bottlebrush

for hard-to-reach areas. Stubborn dirt

and insects will come off more easily if

the area is covered with a wet cloth for

a few minutes before cleaning.

After riding in the rain, near the sea or

on salt-sprayed roads

Since sea salt or salt sprayed on roads

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

CAUTION:

Do not use warm water since it in-

creases the corrosive action of the

salt.

2. After drying the motorcycle, apply

a corrosion protection spray on all

metal, including chrome- and nick-

el-plated, surfaces to prevent

corrosion.

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

MOTORCYCLE CARE AND STORAGE

7-3

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 stainless-

steel parts, including the exhaust

system. (Even the thermally in-

duced discoloring of stainless-

steel exhaust systems can be re-

moved through polishing.)

4. To prevent corrosion, it is recom-

mended to apply a corrosion pro-

tection spray on all metal,

including chrome- and nickel-plat-

ed, surfaces.

5. Use spray oil as a universal clean-

er 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

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 ac-

etone, and wash the tires with

warm water and a mild deter-

gent.

●Before operating the motor-

cycle test its braking perfor-

mance and cornering behavior.

ECA00013

CAUTION:

●Apply spray oil and wax spar-

ingly 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.

NOTE:

Consult a Yamaha dealer for advice on

what products to use.

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

MOTORCYCLE CARE AND STORAGE

7-4

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 cover-

ing it with a tarp, while it is still

wet, will allow water and humid-

ity to seep in and cause rust.

●To prevent corrosion, avoid

damp cellars, stables (because

of the presence of ammonia)

and areas where strong chemi-

cals are stored.

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 cham-

bers 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 pro-

tect the cylinders, piston rings, etc.

from corrosion.

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 spark-

ing 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.

EWA00003

WARNING

To prevent damage or injury from

sparking, make sure to ground the

spark plug electrodes while turning

the engine over.

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

MOTORCYCLE CARE AND STORAGE

7-5

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. Alterna-

tively, 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 plas-

tic 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 ex-

cessively cold or warm place [(less

than 0 °C (30 °F) or more than

30 °C (60 °F)]. For more informa-

tion on storing the battery, see

page 6-30.

NOTE:

Make any necessary repairs before

storing the motorcycle.

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

8-1

EAU01038

SPECIFICATIONS

Specifications

CS-01E

Model XV250/XV250C

Dimensions

Overall length 2,190 mm (86.2 in)

Overall width 815 mm (32.1 in)

Overall height 1,140 mm (44.9 in)

Seat height 685 mm (27.0 in)

Wheelbase 1,490 mm (58.7 in)

Ground clearance 145 mm (5.7 in)

Minimum turning radius 2,800 mm (110.2 in)

Basic weight (with oil and full

fuel tank)

XV250 147 kg (324 lb)

XV250C 148 kg (326 lb)

Engine

Engine type Air-cooled 4-stroke, SOHC

Cylinder arrangement 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

Engine oil

Ty p e

Recommended engine oil

classification API Service SE, SF, SG or

higher

Quantity

Without oil filter element

replacement 1.4 L (1.2 Imp qt, 1.5 US qt)

With 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 Wet element

010 30 50 70 90 110 130 ˚F

YAMALUBE 4 (20W-40)

or SAE 20W-40

-20 -10 010 20 30 40 50 ˚C

YAMALUBE 4 (10W-30)

or SAE 10W-30

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 la-

beled “ENERGY CONSERVING II” or higher.

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

SPECIFICATIONS

8-2

Fuel

Type UNLEADED GASOLINE ONLY

Fuel tank capacity

XV250 9.5 L (2.1 Imp gal, 2.5 US gal)

XV250C 9.2 L (2.0 Imp gal, 2.4 US gal)

Fuel reserve amount 2.6 L (0.6 Imp gal, 0.7 US gal)

Carburetor

Manufacturer MIKUNI

Model × quantity BDS26 × 1

Spark plug

Model/manufacturer C6HSA / NGK or

U20FS-U / DENSO

Gap 0.6–0.7 mm (0.02–0.03 in)

Clutch type Wet, multiple-disc

Transmission

Primary reduction system Spur gear

Primary reduction ratio 3.130

Secondary reduction system Chain drive

Secondary reduction ratio 2.812

Number of drive chain

sprocket teeth (front/rear) 16/45

Transmission type Constant mesh 5-speed

Operation Left foot

Gear ratio

1st 2.643

2nd 1.684

3rd 1.261

4th 1.000

5th 0.821

Chassis

Frame type Double cradle

Caster angle 32°

Trail 120 mm (4.7 in)

Tires

Front

Type With tube

Size 3.00-18 47P

Manufacturer/

model CHENG SHIN / C-916

Rear

Type With tube

Size 130/90-15M/C 66P

Manufacturer/

model CHENG SHIN / C-915

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

SPECIFICATIONS

8-3

Maximum load*

XV250 196 kg (432 lb)

XV250C 195 kg (430 lb)

Tire air pressure (measured

on cold tires)

Up to 90 kg (198 lb)*

Front 175 kPa (1.75 kgf/cm2, 25 psi)

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

90 kg (198 lb)–maximum*

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

Rear 225 kPa (2.25 kgf/cm2, 33 psi)

* Total weight of rider, passenger, cargo and accessories

Wheels

Front

Type Spoke wheel

Size 18 × 1.60

Rear

Type Spoke wheel

Size 15M/C × MT 2.75

Brakes

Front

Type Single disc brake

Operation Right hand

Fluid DOT 4

Rear

Type Drum brake

Operation Right foot

Suspension

Front Telescopic fork

Rear Swingarm

Spring/shock absorbers

Front Coil spring / oil damper

Rear Coil spring / oil damper

Wheel travel

Front 140 mm (5.5 in)

Rear 100 mm (3.9 in)

Electrical system

Ignition system T.C.I. (digital)

Charging system

Type A.C. magneto

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

Battery

Model GM10-3A-2

Voltage, capacity 12 V, 10 Ah

Headlight type Quartz bulb (halogen)

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

SPECIFICATIONS

8-4

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

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

9-1

EAU01039

CONSUMER INFORMATION

EAU02944

Identification numbers

Record the key identification number,

vehicle identification number and mod-

el label information in the spaces pro-

vided below for assistance when

ordering spare parts from a Yamaha

dealer or for reference in case the vehi-

cle is stolen.

1. KEY IDENTIFICATION NUMBER:

CA-02E

2. VEHICLE IDENTIFICATION

NUMBER:

CA-02E

3. MODEL LABEL INFORMATION:

CA-01E

EAU01042

Key identification number

The key identification number is

stamped into the key. Record this num-

ber in the space provided and use it for

reference when ordering a new key.

EAU01043

Vehicle identification number

The vehicle identification number is

stamped into the steering head pipe.

Record this number in the space pro-

vided.

NOTE:

The vehicle identification number is

used to identify your motorcycle and

may be used to register your motor-

cycle with the licensing authority in

your area.

1. Key identification number 1. Vehicle identification number

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

CONSUMER INFORMATION

9-2

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 pro-

cedures.) Record the information on

this label in the space provided. This in-

formation will be needed when ordering

spare parts from a Yamaha dealer.

1. Model label

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

CONSUMER INFORMATION

9-3

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 immedi-

ately 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 informa-

tion about motor vehicle safety from the Hotline.

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

CONSUMER INFORMATION

9-4

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 ve-

hicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or (2) the use of

the vehicle after such device or element of design has been removed or rendered inoperative by any person.

“AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW”.

These acts include tampering with the following systems; i.e., modification, removal, etc.

CL-01E

Exhaust system

Muffler

Exhaust pipe

Silencer

Intake system

Air cleaner case

Air cleaner element

Intake duct

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

CONSUMER INFORMATION

9-5

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 Mileage Servicing dealer

name and address Remarks

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

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

CONSUMER INFORMATION

9-6

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

Maintenance

interval

Date of

service Mileage Servicing dealer

name and address Remarks

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

CONSUMER INFORMATION

9-7

EAU02918

YAMAHA MOTOR CORPORATION, U.S.A.

STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY

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

CONSUMER INFORMATION

9-8

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

CONSUMER INFORMATION

9-9

EAU01063

YAMAHA EXTENDED SERVICE (Y.E.S.)

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

CONSUMER INFORMATION

9-10

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

PRINTED IN JAPAN

2002.05-0.5×1 CR

(E)

PRINTED ON RECYCLED PAPER

YAMAHA MOTOR CO., LTD.

2UJ-28199-1BLIT-11626-16-21

XV250R

XV250RC

OWNER’S MANUAL

Yamaha 2003 Virago 250 Owners Manual

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