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Related Manuals for Yamaha XV250V
Summary of Contents for Yamaha XV250V
- Page 1 XV250V(C) ASSEMBLY MANUAL LIT-11666-19-23 2UJ-28107-11...
- Page 2 Since some external parts of the vehicle have been removed at the Yamaha factory for the convenience of packing, assembly by the Yamaha dealer is required. It should be noted that the assembled vehicle should be thoroughly cleaned, inspected, and adjusted pri- or to delivery to the customer.
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Page 3: Symbols Used In The Assembly Manual
EAA00008 SYMBOLS USED IN THE ASSEMBLY MANUAL In order to simplify descriptions in this assembly manual, the following symbols are used: (1): Coat with lithium-soap-based grease. (2): Tighten to 10 Nm. (10 Nm = 1.0 m · kg, 7.2 ft · lb) (3): Towards the front of the vehicle (4): Clearance required (5): Install so that the arrow mark faces... -
Page 4: Setup Procedures
EAA00100 SETUP PROCEDURES Perform the setup procedures in the order indicated by the numbers. Always follow the order as shown. –1–... -
Page 5: Front Fender
C: Tighten the bolts to specifica- EAA00109 1. FRONT FENDER tion. A: Fasten the brake hose with the Bolt speedometer cable guide. 16 Nm (1.6 m · kg, 11 ft · lb) B: Pass the speedometer cable through speedometer cable guide. CAUTION: Be careful not to scratch the WARNING... - Page 6 EAA00209 3. LEAD HOLDER A: Pass the wire harness through the lead holder. NOTE: Refer to “CABLE ROUTING”. Lead holder Flange bolt d = 6 (0.24), = 12 (0.47) EAA00014 D: Tighten the bolts to specifica- 4. HANDLEBAR tion. Before 2012 models Bolt A: Clean the right handlebar end.
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Page 7: Front Brake Master Cylinder
Proper cable and hose routing the brake lever. is essential to assure safe vehi- cle operation. Recommended lubricants Refer to “CABLE ROUTING”. Yamaha cable lube or motor B: Make sure that the “UP” mark holder is pointed upward. Front brake master cylinder... -
Page 8: Left Handlebar Switch
EAA00035 7. LEFT HANDLEBAR SWITCH Before 2012 models A: Align the slot on the left han- dlebar switch with the projec- tion on the clutch lever holder. B: Pass the starter cable through the cable guide. WARNING Proper cable routing is essen- tial to assure safe vehicle oper- ation. -
Page 9: Cable Ties
Recommended lubricants socket. Yamaha cable lube or motor NOTE: Check the clutch lever for smooth action. B: To install the clutch cable, be Refer to “ADJUSTMENTS AND sure to proceed as follows: PREDELIVERY SERVICE”. -
Page 10: Rear View Mirrors
C: Connect the front turn signal EAA00054 10. FRONT TURN SIGNAL light leads to the wire harness. LIGHTS The leads of identical colors should be connected. A: Install the turn signal light with a chocolate color lead on the NOTE: left side. -
Page 11: Shift Pedal
13. SHIFT PEDAL A: Align the punch mark with the slot. B: Tighten the bolt to specifica- tion. Bolt 10 Nm (1.0 m · kg, 7.2 ft · lb) Shift pedal Bolt d = 6 (0.24), = 20 (0.79) EAA00069 14. -
Page 12: License Plate Bracket
16. LICENSE PLATE BRACKET License plate bracket Flange bolt d = 6 (0.24), = 10 (0.39) Rear reflector d = 5 (0.20) AA00189 17. BATTERY A: Installing the battery. NOTE: Refer to “ADJUSTMENTS AND PREDELIVERY SERVICE”. B: First, connect the positive lead (red lead) to the positive termi- nal. -
Page 13: Cable Routing
EEAA00900 CABLE ROUTING WARNING Proper cable and lead routing are essential to insure safe vehi- cle operation. (1) Throttle cables (2) Front brake hose (3) Right handlebar switch lead (4) Front brake light switch lead (5) Left handlebar switch lead (6) Clutch switch lead (7) Starter cable (8) Clutch cable... - Page 14 (A) Pass the throttle cables through and to the front of the cable guide. (B) Fasten the right handlebar switch lead and front brake light switch lead with two plastic bands. (C) Fasten the left handlebar switch lead and clutch switch lead with two plastic bands.
- Page 15 (1) Negative battery lead (2) Main switch lead (3) Fuse holder (4) Right rear turn signal light connectors (5) Tail/brake light connectors (6) Left rear turn signal light connectors (7) Rectifier/regulator lead (8) Wire harness (9) Positive battery lead (10)Battery (11)Frame (12)Battery breather hose (13)Front brake hose...
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Page 16: Adjustments And Predelivery Service
EAA01100 ADJUSTMENTS AND PREDELIVERY SERVICE Perform the predelivery service in the order indicated by the letters. Always follow the order as shown. –13–... -
Page 17: Checking And Charging The Battery
Batteries also generate explosive EAA01003 A. CHECKING AND CHARGING hydrogen gas, therefore you should THE BATTERY always follow these preventive mea- sures: 1. Charge: Charge batteries in a well-ventilated The battery must be charged properly ● area. before using for the first time. This ini- Keep batteries away... -
Page 18: Draining The Fuel
EAA01005 B. DRAINING THE FUEL 1. Put a rag under the carburetor drain hose so fuel does not contact the crankcase. 2. Loosen the drain screw (1) and drain the standing fuel. WARNING FUEL IS HIGHLY FLAMMABLE: Always turn off the engine when ●... -
Page 19: Checking The Engine Oil Level
EAA01012 CAUTION: D. CHECKING THE ENGINE OIL Engine oil also lubricates the clutch ● LEVEL and the wrong oil types or additives 1. Stand the vehicle on a level surface. could cause clutch slippage. There- NOTE: fore, do not add any chemical addi- Place the vehicle on a suitable stand. -
Page 20: Adjusting The Front Brake
3. Measure: EAA01020 F. ADJUSTING THE ENGINE engine idling speed ● Out of specification → Adjust. IDLING SPEED NOTE: Engine idling speed Prior to adjusting the engine idling speed, 1,350 ~ 1,450 r/min the air filter should be clean, and the engine should have adequate compres- 4. -
Page 21: Adjusting The Rear Brake
EAA01029 Brake pedal free play H. ADJUSTING THE REAR BRAKE 1. Measure: Brake pedal position brake pedal free play (d) ● Out of specification → Adjust. 1. Measure: brake pedal position (a) ● Brake pedal free play (at the end of the (distance from the top of the rider foot- brake pedal) rest to the top of the brake pedal) -
Page 22: Checking The Brake Fluid Level
EAA01032 Refill with the same type of brake ● J. CHECKING THE BRAKE FLUID fluid that is already in the system. LEVEL Mixing brake fluids may result in a harmful chemical reaction, leading 1. Stand the vehicle on a level surface. to poor brake performance. -
Page 23: Adjusting The Clutch Cable Free Play
EAA01036 L. ADJUSTING THE CLUTCH CABLE FREE PLAY 1. Measure: clutch cable free play (a) ● Out of specification → Adjust. Clutch cable free play (at the end of the clutch lever) 10.0 ~ 15.0 mm (0.39 ~ 0.59 in) 2. -
Page 24: Adjusting The Headlight Beam
e. Turn both adjusting nuts (5) in direction EAA01059 N. ADJUSTING THE DRIVE CHAIN (b) or (c) until the specified drive chain SLACK slack is obtained. NOTE: Direction Drive chain is tightened. Measure the drive chain slack halfway between the drive axle and the rear axle. Direction Drive chain is loosened. -
Page 25: Service Data
EAA10000 APPENDICES SERVICE DATA Engine idling speed: 1,350 ~ 1,450 r/min Spark plug: Type (manufacturer) C6HSA (NGK) or U20FS-U (DENSO) 0.6 ~ 0.7 mm (0.024 ~ 0.028 in) Fuel: Recommended fuel Unleaded gasoline only Fuel tank capacity Total 9.5 L (2.09 Imp gal, 2.51 US gal) (U49) 9.2 L (2.02 Imp gal, 2.43 US gal) (CAL) Valve clearance (cold): 0.08 ~ 0.12 mm (0.003 ~ 0.005 in) -
Page 26: Owner's Tool Kit
EAA10200 OWNER’S TOOL KIT 1. Owner’s tool bag 1 pc. 2. Pliers 1 pc. 3. Wrench (8-10) 1 pc. 4. Wrench (10-12) 1 pc. 5. Wrench (14-17) 1 pc. 6. Wrench handle 1 pc. 7. Special wrench 1 pc. 8. Spark plug wrench (16-19) 1 pc. -
Page 27: Tightening Torques
EAA10300 TIGHTENING TORQUES Tightening torque Item Thread size m · kg ft · lb Engine: Spark plug Engine oil drain bolt Chassis: Upper bracket and steering stem Steering stem and nut See “NOTE”. Inner tube and lower bracket Front fork pinch bolt Front brake master cylinder and bracket Upper handlebar holder and lower handlebar holder Front turn signal light, cable guide and headlight... - Page 28 Tightening torque Item Thread size m · kg ft · lb Rear wheel axle and nut 10.5 Front brake caliper and front fork Front brake pad pin Front brake disc and wheel hub Rear wheel sprocket and clutch hub Rear brake camshaft and camshaft lever Bleed screw Front brake hose union bolt Drive chain puller locknut...
- Page 30 PRINTED IN U.S.A.