Shop manual xe máy Yamaha Virago XV 250P

Yamaha Virago XV 250P owner

@ YAMAHA

XV250P OWNER’S MANUAL

©2003 by Yamaha Motor Co., Ltd

1st Edition, January 2003

All rights reserved Any reprinting or

unauthorized use without the written

is expressly prohibited

Printed in Japan permission of Yamaha Motor Co., Ltd

INTRODUCTION Congratulations on your purchase of the Yamaha XV250P This model is the result of Yamaha’s vast experience in the production

of fine sporting, touring, and pacesetting rac- ing 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 mainte- nance of this motorcycle If you have any questions about the operation or maintenance

of your motorcycle, please consult a Yamaha dealer

IMPORTANT MANUAL

INFORMATION

Particularly important information is distin-

guished in this manual by the following nota-

tions:

AN

The Safety Alert Symbol means ATTENTION!

BECOME ALERT! YOUR SAFETY IS IN-

VOLVED!

A WARNING

Failure to follow WARNING instructions could

result in severe injury or death to the motor-

cycle operator, a bystander or a person in-

specting 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: Á WARNING

e This manual should be considered a per-

manent part of this motorcycle and PLEASE READ THIS MANUAL CAREFUL-

LY AND COMPLETELY BEFORE OPERAT-

should remain with it even if the motor-

cycle is subsequently sold ING THIS MOTORCYCLE

ments in product design and quality

Therefore, while this manual contains the

most current product information avail-

able at the time of printing, there may be

motorcycle and this manual If there is

any question concerning this manual,

please consult your Yamaha dealer

CONTENTS

GIVE SAFETY THE RIGHT OF WAY 1-1 Fuel cock - -<-+s++x++seseesrz 4-8

Starter “CHOKE” - s55 4-9 DESCRIPTION - - 2-1 S†eering lock . -«~«-<s 4-10

MOTORCYCLE IDENTIFICATION 3-1 Rear shock absorber adjustment 4-11 ldentification numbers 3-1 Sidestand - se seesses 4-11 Key identification number 3-1 Ignition circuit cut-off system 4-13 Frame serial number - 3-2

Model label - - -~~<+ 3-2 PRE-OPEHATION CHECKS 5-1

CONTROL FUNCTIONS 4-1 Front brake fluid leakage 5-3 Main SWITCH .ccccccecceceeceeeeeeeeeessenseneeees 4-1 Clutch -.- -<<<<<<<s<x xs.x se se 5-4 Indicator lighs - - -=<==ss+ 4-2 Throttle grip - -<~<-« 5-4 Speedometer .ccsecseeceeeessssseeeeeeeees 4-2 Engine oi -cscsssssseseexreeeres 5-5 Handlebar switches - 4-3 Chain - - - 225225 sree 5-5 Clutch lever - -<<<<<<<<s 4-6 THOS 5-6 ShiÍt pedal - - - -+-<-<ccscssxxxxs 4-6 Cast wheels cccScSSse+xxexez 5-9 Front brake leVer - -====+ 4-6 Chassis fasteners - - 5-9 Hear brake pedal - - se: 4-6 Lights, signals and switches 5-10 Fuel tank cap .- - -=e+ 4-7 s00 5-10

OPERATION AND IMPORTANT

ldle speed adjustmertt 7-12

Throttle cable free play inspection 7-13

Valve clearance adjustment 7-14

Spark plug inspection - 7-14

Front brake lever free play ACJUSIMEN .ceeeeeeeeceeeeeteeeeeeeees 7-15 HRear brake adjustmeritt 7-16 Brake light switch adjustment 7-18 Checking the front brake pads and

rear brake shoes - - 7-18

Inspecting the brake fluid level 7-20 Brake fluid replacement 7-21

Clutch adjustment 7-21

Drive chain slack check 7-22 Drive chain slack adjustment 7-23 Drive chain lubrication - - 7-25 Cable inspection and lubrication 7-25 Throttle cable and grip lubrication 7-26 Brake and shift pedals 7-26 Brake and clutch levers 7-26 Sle- s0 7-26 HRear suspension - 7-26 Front fork inspection . 7-27 Steering inspection .- 7-28 Wheel bearings - - 7-28

Replenishing the battery fluid 7-30 Fuse replacemert -ss: 7-31 Headlight bulb replacement 7-31 Front wheel removal - - 7-33 Front wheel installation - 7-34 Hear wheel removal - - - 7-35 Hear wheel installation 7-37 Troubleshooting - - 7-38 Troubleshooting chart 7-39

CLEANING AND STORAGE 8-1

A Cleaning -c-++seeeeeres 8-1

B StOraQe .ccceeeecesscceeeeeesseeeeeeeeeeeseees 8-2

SPECIFICATIONS - 9-1

Conversion table cccceccceccceceeeeees 9-5

Á GIVE SAFETY THE RIGHT OF WAY

Motorcycles are fascinating vehicles, which can give you an unsurpassed feeling of power and freedom However, they also impose certain limits, which you must accept; even the best motorcycle does not ignore the laws of physics

Regular care and maintenance are essential for preserving your motorcycle’s value and operating condition Moreover, what is true for the motorcycle is also true for the rider: good performance depends on being in good shape Riding under the influence of med- ication, drugs and alcohol is, of course, out of the question Motorcycle riders — more than car drivers — must always be at their mental and physical best Under the influence

of even small amounts of alcohol, there is a tendency to take dangerous risks

Protective clothing is as essential for the motorcycle rider as seat belts are for car driv- ers and passengers Always wear a complete motorcycle suit (whether made of leather

or tear-resistant synthetic materials with protectors), sturdy boots, motorcycle gloves and a properly fitting helmet Optimum protective wear, however, should not encourage carelessness Though full-coverage helmets and suits, in particular, create an illusion

of total safety and protection, motorcyclists will always be vulnerable Riders who lack critical self-control run the risk of going too fast and are apt to take chances This is even more dangerous in wet weather The good motorcyclist rides safely, predictably and de- fensively — avoiding all dangers, including those caused by others

Enjoy your ride!

1-1

Seat Air filter Front turn signal light

Brake pedal

Footrest Headlight Fuel tank

Shift pedal Steering lock

Front wheel Clutch lever Handlebar switches

Speedometer

Brake lever

Throttle grip

MOTORCYCLE

IDENTIFICATION

EAA62000

Identification numbers

Record the key identification number, frame

serial number and model label information in

the spaces provided for assistance when or-

dering spare parts from a Yamaha dealer or

for reference in case the vehicle is stolen

1 KEY IDENTIFICATION NUMBER:

Frame serial number

The frame serial number is stamped into the

steering head pipe

in the space provided This information will be needed to order spare parts from your Yamaha dealer

1 Model label

CONTROL FUNCTIONS

EAB00100

Main switch

The main switch controls the ignition and light-

ing systems Its operation is described below

Electrical circuits are switched on The engine

can be started The key cannot be removed in

this position

4-1

OFF:

All electrical circuits are switched off The key

can be removed in this position

EAB02002

P (Parking) The taillight and auxiliary light come on but all

other circuits are off With the key at “OFF”,

push it into the main switch, turn it counter- clockwise to “P”, and remove it To cancel the parking, turn the key clockwise

EUU08800

NOTE:

Always turn the main switch to “OFF” and re-

move the key when the motorcycle is unat- tended

1 Turn indicator light “<a >”

2 Neutral indicator light “N”

3 High beam indicator light “ZO”

EAB10102

Turn indicator light “< >”

This indicator flashes when the turn signal

switch is moved to the left or right

EAB13100

Neutral indicator light “N ”

This indicator comes on when the transmis-

sion Is in neutral

4-2

High beam indicator light “20”

This indicator comes on when the headlight high beam is used

EAB40005

Speedometer The speedometer shows riding speed This speedometer is equipped with an odometer and trip odometer The trip odometer can be reset to “O” with the reset knob Use the trip odometer to estimate how far you can ride on

a tank of fuel This information will enable you

to plan fuel stops in the future

1 PASS switch “PASS” 6 Engine stop switch

2 Dimmer switch “ENGINE STOP”

“LIGHTS” 7 Siren switch “SIREN”

3 Turn signal switch 8 Microphone switch “MIC”

“TURN” 9 Patrol switch

4 Horn switch “HORN” 10 Start switch “START”

5 Light switch “LIGHTS” 11.Hazard switch “HAZARD”

EAB63201

Pass switch “PASS”

Press the switch to operate the passing light

4-3

Dimmer switch “LIGHTS”

Turn the switch to “HI” for the high beam and

to “LO” for the low beam

EAB62102

Turn signal switch “TURN”

To signal a right-hand turn, push the switch to

the right To signal a left-hand turn, push the

switch to the left Once the switch is released

it will return to the center position To cancel the signal, push the switch in after it has re- turned to the center position

EAB60201

Horn switch “HORN”

Press the switch to sound the horn

EAB61202

Light switch “LIGHTS”

Turning this switch to “PO” turns on the auxil-

lary light, taillignt and meter lights Turning to

“ON”, turns the headlight on also.

Engine stop switch “ENGINE STOP”

The engine stop switch is a safety device for

use in an emergency such as when the motor-

cycle overturns or if trouble occurs in the throt-

tle system Turn the switch to “RUN” to start

the engine In case of emergency, turn the

switch to “OFF” to stop the engine

EAB60702

Start switch “START”

The starter motor cranks the engine when

pushing the starter switch

Hazard switch “HAZARD”

The hazard switch should be turned on under emergency or hazardous conditions All turn signal lights will flash simultaneously when this switch is turned on with the main switch in the “ON” position

EUU46100

CAUTION:

The battery can discharge from extended use, making it difficult to operate the starter

Siren switch “SIREN”

The siren (if equipped) sounds intermittently

when this switch is set to “SIREN” The siren

can only be used with the main switch in the

“ON” position

Microphone switch “MIC”

The microphone (if equipped) can be used

when this switch is set to “MIC” with the main

switch in the “ON” position This switch can

also be used when the patrol switch is in any

position except “OFF” with the main switch in

the “ON” position

Patrol switch

This switch can only be used with the main

switch in the “ON” position The following ta-

ble indicates which accessories are enabled

when the patrol switch is set to “P”, “M”, or “S”

4-5

Position

Clutch lever

The clutch lever is located on the left handle-

bar, and the ignition circuit cut-off system is in-

corporated in the clutch lever holder Pull the

clutch lever to the handlebar to disengage the

clutch, and release the lever to engage the

clutch The lever should be pulled rapidly and

released slowly for smooth clutch operation

(Refer to the engine starting procedures for a

description of the ignition circuit cut-off sys-

tem.)

EAB80001

Shift pedal

This motorcycle is equipped with a constant-

mesh 5-speed transmission

The shift pedal is located on the left side of the

engine and is used in combination with the

clutch when shifting

4-6

EAB90101

Rear brake pedal The rear brake pedal is on the right side of the motorcycle Press down on the brake pedal to apply the rear brake

Fuel tank cap NOTE:

Insert the key and turn it 1/4 turn clockwise is in the lock The key cannot be removed if

The lock will be released and the cap can be the cap is not locked properly

Push the tank cap into position with the key in-

serted To remove the key, turn it counter-

clockwise to the original position

4-7

Fuel cock

The fuel cock supplies fuel from the tank to

the carburetors while also filtering it

The fuel cock has three positions, which

should be set as illustrated

ON: With the fuel cock in this position, fuel

flows to the carburetors when the en-

gine is running Set the fuel cock to this

position when starting the engine and

cock in the “ON” position, quickly turn

the lever to this position Otherwise the engine may die and will have to be primed (see “PRI” below) After turning the lever to “RES”, fill the tank at the first opportunity and be sure to set the

fuel cock back to “ON”!

PRI: This stands for “prime” If the engine

has been allowed to run out of fuel, turn

the lever to the “PRI” position to send

fuel directly to the carburetors This will

make starting easier However, be sure

to turn the lever to the “ON” position (or

“RES” if you have not refuelled yet) af-

ter the engine has started

Move in direction @ to turn on the starter Move in direction © to turn off the starter

1 Starter “CHOKE”

Steering lock

To lock the steering, turn the handlebars all

the way to the right Open the steering lock

cover, turn the key 1/8 counterclockwise then

push the key in and turn it 1/8 turn clockwise

After checking to see that the steering is

locked, remove the key from the lock and

close the cover To release the lock, reverse

the above procedure

To install the rider seat, insert the projection

on the front of the seat into the holder on the frame Then tighten the bolts

EUU01700

NOTE:

Make sure that the seat is securely fitted

EAI57804

Rear shock absorber adjustment

This shock absorber is equipped with a spring

preload adjuster Adjust spring preload as fol-

lows Turn the adjusting ring in direction @ to

increase spring preload and in direction © to

decrease spring preload

Áà WARNING

This motorcycle must not be operated with

the sidestand in the down position If the

stand is not properly retracted, it could

contact the ground and distract the opera-

tor, resulting in a possible loss of control

Yamaha has designed into this motorcycle

a lockout system to assist the operator in

fulfilling the responsibility of retracting the

sidestand Please check carefully the op-

erating instructions listed below and if

there is any indication of a malfunction, re-

turn the motorcycle to a Yamaha dealer

immediately for repair

Ignition circuit cut-off system The ignition circuit cut-off system (comprising

the sidestand switch, clutch switch and neu-

tral switch) has the following functions

e It prevents starting when the transmis- sion is in gear and the sidestand is up, but the clutch lever is not pulled

It prevents starting when the transmis- sion is in gear and the clutch lever is pulled, but the sidestand is still down

It cuts the running engine when the trans- mission is in gear and the sidestand is

moved down

Periodically check the operation of the ignition circuit cut-off system according to the follow- ing procedure

With the engine turned off:

1 Move the sidestand down

2 Make sure that the engine stop switch is set to “7”

3 Turn the key to “ON”

4 Shift the transmission into the neutral position

5 Push the start switch

The neutral switch may be defective

»| The motorcycle should not be ridden until

Ỷ

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

After the engine has stalled:

10 Move the sidestand up

11 Keep the clutch lever pulled

12 Push the start switch

PRE-OPERATION CHECKS

Before using this motorcycle, check the following points:

Front brake ¢ Check operation, free play, fluid level and fluid leakage

¢ Top-up with DOT4 (or DOT 3) brake fluid if necessary 5-3 ~ 5-4,

¢ Adjust if necessary

¢ Check for smooth operation

Brake and shift pedal ¢ Check for smooth operation

¢ Lubricate if necessary

5-1

; ¢ Check all chassis fittings and fasteners

Lights, signals and

Pre-operation checks should be made each time the motorcycle is used Such an inspection can

be thoroughly accomplished in a very short time; and the added safety it assures is more than worth the time involved

Brakes

1 Brake lever and brake pedal

Check for correct free play in the front

brake lever and rear brake pedal and ad-

just if necessary (See page 7-15 for de-

tails.) Make sure the brakes are working

properly by checking at low speed shortly

after starting out

EUU62300

A WARNING

A soft, spongy feeling in the brake lever in-

dicates a failure in the brake system Do

not operate the motorcycle until the failure

in the brake system is corrected Ask a

Yamaha dealer for immediate repairs A

soft, spongy feeling could indicate a haz-

ardous condition in the brake system

2 Brake fluid

Check the brake fluid level Fill the mas-

ter cylinder with brake fluid if necessary

(See page 7-20 for details.)

5-3

Recommended brake fluid: DOT 4

EUU13100 NOTE:

If DOT 4 is not available, DOT 3 can be used

CAUTION:

Brake fluid may deteriorate painted surfac-

es or plastic parts Never spill any fluid If

spilled, clean it up immediately

EUU62500

A WARNING

If brake fluid leakage is found, ask a

Yamaha dealer for immediate repairs

Such leakage could indicate a hazardous

EAE30104 Throttle grip Turn the throttle grip to see if it operates prop- erly Make sure the grip returns by spring

force when released There should be a free

play of 3 ~ 5 mmat the throttle grip If the free play is incorrect, ask a Yamaha dealer to make this adjustment

Engine oil

Make sure the engine oil is at the specified

level Fill with oil as necessary (See page 7-6

Recommended engine oil classification:

API Service “SE”, “SF” type or

With oil filter replacement: 1.6L

5-5

CAUTION:

Do not put in any chemical additives Also,

be sure not to use oils labeled “ENERGY CONSERVING II’ or higher Engine oil also lubricates the clutch and additives could cause clutch slippage

EAE50001 Chain (See page 7-22 for details) Check the general condition of the chain and the chain slack before every ride Lubricate and adjust the chain as necessary

Tires

To ensure maximum performance, long ser-

vice and safe operation, note the following:

1 Tire air pressure

Always check and adjust the tire pres-

sure before operating the motorcycle

EUU67500

A WARNING

Tire inflation pressure should be checked

and adjusted when the temperature of the

tire equals the ambient air temperature

Tire inflation pressure must be adjusted

according to total weight of cargo, rider

and accessories (fairing, saddlebags, etc

if approved for this model), and vehicle

A WARNING

Proper loading of your motorcycle is im-

portant for several characteristics of your

motorcycle, such as handling, braking,

performance and safety Do not carry

loosely packed items that can shift Se-

curely pack your heaviest items close to

the center of the motorcycle, and distrib-

ute the weight evenly from side to side

Properly adjust the suspension for your

load, and check the condition and pres-

sure of your tires NEVER OVERLOAD

YOUR MOTORCYCLE Make sure the total

weight of the cargo, rider and accessories

(fairing, saddlebags, etc if approved for

this model) does not exceed the maximum

load of the motorcycle Operation of an

overloaded motorcycle could cause tire

damage, an accident, or even injury

5-7

2 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 side wall is cracked, contact a Yamaha dealer immediately and have the tire replaced

These limits may be different by regulation

from country to country If so, conform to the

limits specified by the regulations of your own

country

EUU68402

er

Patching a punctured tube is not rec- ommended If it is absolutely neces- sary to do so, use great care and replace the tube as soon as possible with a good quality replacement

Cast wheels

EUU71200

A WARNING

The wheels on this model are not designed

for use with tubeless tires Do not attempt

to use tubeless tires on this model

To ensure maximum performance, long ser-

vice, and safe operation, note the following:

1 Always inspect the wheels before a ride

Check for cracks, bends, or warpage of

the wheels If any abnormal condition ex-

ists in a wheel, consult a Yamaha dealer

Do not attempt even small repairs to the

wheel If a wheel is deformed or cracked,

it must be replaced

Tires and wheels should be balanced

whenever either one is changed or re-

placed Failure to have a wheel balanced

can result in poor performance, adverse

handling characteristics, and shortened

tire life

5-9

3 After installing a tire, ride conservatively

to allow the tire to seat itself on the rim properly Failure to allow proper seating may cause tire failure, resulting in dam- age to the motorcycle and injury to the rider

EAE85101 Chassis fasteners

Always check the tightness of all chassis nuts, bolts and screws before a ride Take the motorcycle to a Yamaha dealer or refer to the Service Manual for correct tightening torque

Lights, signals and switches

Check all the lights, meter lights and indicator

lights to make sure they are in working condi-

tion

Check the operation of the handlebar switch-

es and main switch

EAE70502

Battery

Check the fluid level and fill if necessary Use

only distilled water if refilling is necessary

(See page 7-28 for details.)

5-10

Fuel Make sure there is sufficient fuel in the tank

EUU61000

A WARNING

Do not overfill the fuel tank Avoid spilling

fuel on the hot engine Do not fill the fuel

tank above the bottom of the filler tube as shown in the illustration or it may overflow when the fuel heats up later and expands

CAUTION:

Always wipe off spilled fuel immediately with a dry and clean soft cloth Fuel may deteriorate painted surfaces or plastic

Regular unleaded gasoline

Fuel tank capacity:

OPERATION AND

IMPORTANT RIDING

POINTS EUU67201

Áà WARNING

1

Before riding this motorcycle, become

thoroughly familiar with all operating

controls and their functions Consult

a Yamaha dealer regarding any con-

trol or function that you do not thor-

oughly understand

Never start your engine or let it run for

any length of time in a closed area

The exhaust fumes are poisonous and

can cause loss of consciousness and

death within a short time Always op-

erate your motorcycle in an area with

adequate ventilation

6-1

3 Before starting out, always be sure the sidestand is up Failure to retract the sidestand completely can result in

a serious accident when you try to

turn a corner

EAF19800 Starting and warming up a cold engine

Turn the fuel cock to “ON”

Turn the main switch to “ON” and the en-

gine stop switch to “RUN”

3 Shift transmission into neutral

EUU03001

NOTE:

When the transmission is in neutral, the neu-

tral indicator light should be on If the light

does not come on, ask a Yamaha dealer to in-

4 Turn on the starter “CHOKE” and com-

pletely close the throttle grip

5 Start the engine by pushing the start

switch

EUU02501

NOTE:

If the engine fails to start, release the start

switch, wait a few seconds, then try again

Each attempt should be as short as possible

to preserve the battery Do not crank the en-

gine more than 10 seconds on any one at-

tempt

6-2

6 After starting the engine, move the starter

to the halfway position

EUU02600 NOTE:

For maximum engine life, always warm up the engine before starting off Never accelerate hard with a cold engine

The engine is warm when it responds normal-

ly to the throttle with the starter “CHOKE” turned off

Starting a warm engine

The starter “CHOKE?” is not required when the

engine is warm

EUU31401

CAUTION:

See the “Engine break-in” section prior to

operating the motorcycle for the first time

EAF20003

Shifting

The transmission lets you control the amount

of power you have available at a given speed

for starting, accelerating, climbing hills, etc

The use of the shift pedal is shown in the illus-

tration (Page 4-6)

To shift into neutral, depress the shift pedal

repeatedly until it reaches the end of its travel,

then raise the pedal slightly

in neutral, the transmission is only properly lubricated when the engine is running Inadequate lubrication may damage the transmission

Always use the clutch when changing gears The engine, transmission, and driveline are not designed to with- stand the shock of forced shifting and can be damaged by shifting without using the clutch

Engine break-in

There is never a more important period in the

life of your motorcycle than the period be-

tween zero and 1,000 km For this reason we

ask that you carefully read the following mate-

rial Because the engine is brand new, you

must not put an excessive load on it for the

first 1,000 km The various parts in the engine

wear and polish themselves to the correct op-

erating clearances During this period, pro-

longed full throttle operation, or any condition

which might result in excessive heating of the

engine, must be avoided

EAF32101

1 O~ 150 km:

Avoid operation above 1/3 throttle Stop

the engine and let it cool for 5 to 10 min-

utes after every hour of operation Vary

the speed of the motorcycle from time to

time Do not operate it at one set throttle

position

6-4

2 150 ~ 500 km:

Avoid prolonged operation above 1/2

through the gears, but do not use full throttle at any time