Page 3
Yamaha a reputation for dependability. Please take the time to read this manual thoroughly, so as to enjoy all advantages of your XT250W. The owner’s manual does not only instruct you in how to operate, inspect and maintain your motorcycle, but also in how to safeguard yourself and others from trouble and injury.
Page 4
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.
TABLE OF CONTENTS SAFETY INFORMATION ....1-1 OPERATION AND IMPORTANT Adjusting the brake lever free Location of important labels .....1-5 RIDING POINTS........5-1 play ..........6-17 Starting and warming up a cold Adjusting the brake pedal position DESCRIPTION ........2-1 engine .......... 5-1 and free play ......
Page 7
TABLE OF CONTENTS Replacing the tail/brake light bulb ..........6-30 Replacing a turn signal light bulb ..6-31 Supporting the motorcycle .....6-32 Front wheel ........6-32 Rear wheel ........6-34 Troubleshooting ......6-36 Troubleshooting chart ....6-37 MOTORCYCLE CARE AND STORAGE ...........7-1 Care ..........7-1 Storage ..........7-3 SPECIFICATIONS ......8-1 CONSUMER INFORMATION....9-1 Identification numbers .....9-1...
SAFETY INFORMATION EAU10311 TIONS. motorist’s blind spot. Many accidents involve inexperi- MOTORCYCLES SINGLE Safe riding enced operators. In fact, many op- TRACK VEHICLES. THEIR SAFE Always make pre-operation erators who have been involved in USE AND OPERATION ARE DEPEN- checks. Careful checks may help accidents do not even have a cur- DENT UPON THE USE OF PROPER prevent an accident.
Page 9
Modifications made to this motorcycle juries. The use of a safety helmet is the not approved by Yamaha, or the re- When loading within this weight limit, single most critical factor in the preven-...
Page 10
SAFETY INFORMATION Cargo accessory weight stallation and use of non-Yamaha the motorcycle due to aerody- should be kept as low and close to accessories. Use extreme caution namic effects. Wind may at- the motorcycle as possible. Make when selecting and installing any ac-...
Page 11
SAFETY INFORMATION refueling. a flammable source (e.g., a ker- Take care not to spill any gaso- osene heater, or near an open line on the engine or exhaust flame), otherwise it could catch system when refueling. fire. Never refuel while smoking or in When transporting the motorcycle the vicinity of an open flame.
SAFETY INFORMATION EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle.
Page 13
SAFETY INFORMATION Before you operate this vehicle, read the owner’s manual. Prima di usare il veicolo, leggete il manuale di istruzioni. Lire le manuel du propri étaire avant d ’utiliser ce v éhicule. Lesen Sie die Bedienungsanleitung bevor Sie dieses Fahrzeug fahren. Antes de conducir este vehículo, lea el Manual del Propietario.
INSTRUMENT AND CONTROL FUNCTIONS EAU10460 EAU10680 To unlock the steering Main switch/steering lock LOCK Push the key in, and then turn it to The steering is locked, and all electrical “OFF” while still pushing it. systems are off. The key can be re- EWA10060 moved.
INSTRUMENT AND CONTROL FUNCTIONS EAU10980 EAU11080 EAU11630 Indicator lights Speedometer unit High beam indicator light “ ” This indicator light comes on when the high beam of the headlight is switched 1. Speedometer 1. High beam indicator light “ ” 2.
INSTRUMENT AND CONTROL FUNCTIONS EAU12346 Right EAU12500 Handlebar switches Horn switch “ ” Press this switch to sound the horn. Left EAU12660 Engine stop switch “ ” Set this switch to “ ” before starting the engine. Set this switch to “ ”...
INSTRUMENT AND CONTROL FUNCTIONS EAU12820 EAU12870 EAU12890 Clutch lever Shift pedal Brake lever 1. Clutch lever 1. Shift pedal 1. Brake lever The clutch lever is located at the left The shift pedal is located on the left The brake lever is located at the right handlebar grip.
INSTRUMENT AND CONTROL FUNCTIONS EAU12941 EAU32280 NOTE: Brake pedal Fuel tank cap The fuel tank cap cannot be installed unless the key is in the lock. In addition, the key cannot be removed if the cap is not properly installed and locked. EWA10120 WARNING Make sure that the fuel tank cap is...
WARNING Do not overfill the fuel tank, oth- With the lever in this position, fuel will Your Yamaha engine has been de- erwise it may overflow when the not flow. Always return the lever to this signed to use regular unleaded gaso- fuel warms up and expands.
INSTRUMENT AND CONTROL FUNCTIONS This indicates reserve. If you run out of EAU13600 Starter (choke) knob “ ” fuel while riding, move the lever to this position. Fill the tank at the first oppor- tunity. Be sure to set the lever back to “ON”...
INSTRUMENT AND CONTROL FUNCTIONS EAU13981 EAU14290 Seat Helmet holder To remove the seat 1. Remove panels A and B. (See page 6-5.) 2. Remove the bolts and pull the seat off. 1. Projection 2. Seat holder 1. Helmet holder 2. Place the seat in the original posi- 2.
INSTRUMENT AND CONTROL FUNCTIONS EAU14930 thereby harden the suspension, preload. Adjusting the shock absorber turn the adjusting nut in direction assembly (a). To decrease the spring pre- Spring preload: This shock absorber assembly is load and thereby soften the sus- Minimum (soft): Distance A = 36.5 mm (1.4 in) equipped with a spring preload adjust-...
Page 26
Always have a Yamaha dealer (a). To decrease the rebound damping clicks always represents the entire ad- service the shock absorber.
Yamaha dealer check the system be- the operator in fulfilling the respon- fore riding. sibility of raising the sidestand be- fore starting off. Therefore, check this system regularly as described below and have a Yamaha dealer re- 3-11...
Page 28
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.
PRE-OPERATION CHECKS EAU15591 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.
Adjust if necessary. Make sure that operation is smooth. Check cable free play. Throttle grip 6-13, 6-24 If necessary, have Yamaha dealer adjust cable free play and lubricate cable and grip housing. Make sure that operation is smooth. Control cables 6-24...
Page 31
Make sure that all nuts, bolts and screws are properly tightened. Chassis fasteners — Tighten if necessary. Instruments, lights, signals Check operation. — and switches Correct if necessary. Check operation of ignition circuit cut-off system. Sidestand switch 3-11 If system is defective, have Yamaha dealer check vehicle.
EAU15950 EAU16070 position, the neutral indicator light Starting and warming up a should be on, otherwise have a EWA10270 cold engine Yamaha dealer check the electrical cir- WARNING In order for the ignition circuit cut-off cuit. Become thoroughly familiar system to enable starting, one of the 4.
OPERATION AND IMPORTANT RIDING POINTS starter (choke) off. EAU16640 EAU16671 Starting a warm engine Shifting NOTE: Follow the same procedure as for start- The engine is warm when it responds ing a cold engine with the exception normally to the throttle with the starter that the starter (choke) is not required (choke) turned off.
OPERATION AND IMPORTANT RIDING POINTS the neutral position, do not EAU16800 EAU16841 Tips for reducing fuel Engine break-in coast for long periods of time consumption There is never a more important period with the engine off, and do not in the life of your engine than the period tow the motorcycle for long dis- Fuel consumption depends largely on between 0 and 1600 km (1000 mi).
Yamaha dealer check the vehi- ans or children are not likely to cle. touch them. Do not park on a slope or on soft ground, otherwise the vehicle may overturn.
If you are not familiar with mainte- NOTE: nance work, have a Yamaha dealer If you do not have the tools or experi- do it for you. ence required for a particular job, have a Yamaha dealer perform it for you. EWA10350 WARNING Modifications approved...
The annual checks must be performed every year, except if a kilometer-based maintenance is performed in- stead. From 30000 km, repeat the maintenance intervals starting from 6000 km. Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. ODOMETER READING (× 1000 km)
Page 38
PERIODIC MAINTENANCE AND MINOR REPAIR ODOMETER READING (× 1000 km) ANNUAL ITEM CHECK OR MAINTENANCE JOB CHECK Check tread depth and for damage. Replace if necessary. √ √ √ √ √ 10 * Tires Check air pressure. Correct if necessary. √...
Page 39
PERIODIC MAINTENANCE AND MINOR REPAIR ODOMETER READING (× 1000 km) ANNUAL ITEM CHECK OR MAINTENANCE JOB CHECK Front and rear brake √ √ √ √ √ √ 25 * Check operation. switches √ √ √ √ √ Moving parts and cables Lubricate.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU18721 To install the cowling Removing and installing the Place the cowling in the original posi- cowling and panels tion, and then install the screw. The cowling and panels shown need to be removed to perform some of the EAU19292 Panels A and B maintenance jobs described in this...
If the spark plug shows a distinctly dif- ferent color, the engine could be oper- ating improperly. Do not attempt to diagnose such problems yourself. In- stead, have a Yamaha dealer check the vehicle. 1. Spark plug cap 2. Remove the spark plug as shown, 2.
Page 42
PERIODIC MAINTENANCE AND MINOR REPAIR necessary. 3. Install the spark plug with the EAU19812 Engine oil and oil filter spark plug wrench, and then tight- Specified spark plug: element en it to the specified torque. NGK/DR8EA The engine oil level should be checked DENSO/X24ESR-U Tightening torque: before each ride.
Page 43
PERIODIC MAINTENANCE AND MINOR REPAIR to collect the used oil. NOTE: 3. Remove the engine guard by re- The engine oil should be between the moving the bolt. minimum and maximum level marks. 1. Engine oil filler cap ECA11000 CAUTION: 1.
Page 44
PERIODIC MAINTENANCE AND MINOR REPAIR bolt to drain the oil from the oil filter replace them if necessary. element. 10. Clean the oil filter element with sol- vent, and then install it. 4 3 2 1 NOTE: Check the oil filter element for damage and replace it if necessary.
PERIODIC MAINTENANCE AND MINOR REPAIR O-ring, compression spring, and oil higher. EAU20851 Cleaning the air filter element strainer in position. Make sure that no foreign mate- The air filter element should be cleaned rial enters the crankcase. at the intervals specified in the periodic Tightening torque: 14.
Page 46
PERIODIC MAINTENANCE AND MINOR REPAIR mark pointing as shown. 6. Apply oil of the recommended type 1. Air filter element to the entire surface of the sponge 4. Remove the sponge material from 1. “UP” mark material, and then squeeze the ex- the air filter element frame.
Therefore, most car- checked and, if necessary, adjusted as buretor adjustments should be left to a follows at the intervals specified in the Yamaha dealer, who has the neces- periodic maintenance and lubrication sary professional knowledge and expe- chart.
(b). resulting in improper air-fuel mixture and/or engine noise. To prevent this from occurring, the valve clearance must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart. 1. Locknut 1.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU21630 passenger, cargo, and accesso- Tires Tire air pressure (measured on cold ries does not exceed the speci- tires): To maximize the performance, durabil- fied maximum load for the 0–90 kg (0–198 lb): ity, and safe operation of your motorcy- vehicle.
Page 50
Front tire: sidewall is cracked, have a Yamaha high-quality product. Size: dealer replace the tire immediately. 2.75-21 45P Manufacturer/model: Minimum tire tread depth (front and...
(a) to loos- age before each ride. If any dam- en the clutch cable. age is found, have a Yamaha 4. Loosen the locknut at the crank- dealer replace the wheel. Do not case.
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 1. Locknut operating the motorcycle. Air in 2.
Periodically check the brake EWA10670 2. Locknut WARNING pedal free play and, if necessary, adjust It is advisable to have a Yamaha 3. Tighten the locknut. it as follows. dealer make these adjustments. EWA11230 To increase the brake pedal free play,...
If proper adjustment cannot be on just before braking takes effect. If obtained as described, have a necessary, adjust the brake light switch Yamaha dealer make this ad- 1. Wear indicator groove justment. as follows. Each front brake pad is provided with a...
If a brake shoe has worn to the system for leakage. point that the wear indicator reaches Observe these precautions: the wear limit line, have a Yamaha When checking the fluid level, dealer replace the brake shoes as a make sure that the top of the mas-...
EAU22720 Changing the brake fluid handlebars. Have a Yamaha dealer change the Use only the recommended quality brake fluid at the intervals specified in brake fluid, otherwise the rubber the NOTE after the periodic mainte- seals may deteriorate, causing nance and lubrication chart.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU22760 Drive chain slack The drive chain slack should be checked before each ride and adjusted if necessary. EAU22771 To check the drive chain slack 1. Place the motorcycle on the side- stand. NOTE: 1. Drive chain slack 1.
PERIODIC MAINTENANCE AND MINOR REPAIR load the engine as well as other vital EAU23022 ECA11110 Cleaning and lubricating the parts of the motorcycle and can lead CAUTION: drive chain to chain slippage or breakage. To Do not use engine oil or any other lu- prevent this from occurring, keep The drive chain must be cleaned and bricants for the drive chain, as they...
If a cable is damaged maintenance chart. or does not move smoothly, have a Yamaha dealer check or replace it. Recommended lubricant: Engine oil The operation of the brake and shift...
EWA10730 WARNING If the sidestand does not move up and down smoothly, have a Yamaha dealer check or repair it. The operation of the brake and clutch 1. Grease nipple levers should be checked before each...
Check the inner tubes for scratches, fork does not operate smoothly, Securely support the vehicle so that damage and excessive oil leakage. have a Yamaha dealer check or re- there is no danger of it falling over. pair it. To check the operation 2.
If there is play in the wheel no need to check the electrolyte or to hub or if the wheel does not turn add distilled water. smoothly, have a Yamaha dealer check ECA10620 CAUTION: the wheel bearings. Never attempt to remove the battery cell seals, as this would permanent- ly damage the battery.
B. (See page 6-5.) To charge the battery battery, a special (constant-volt- If the fuse is blown, replace it as fol- Have a Yamaha dealer charge the bat- age) battery charger is required. lows. tery as soon as possible if it seems to Using a conventional battery 1.
1. Headlight coupler 4. If the fuse immediately blows 2. Headlight bulb cover again, have a Yamaha dealer 4. Remove the headlight bulb holder check the electrical system. by turning it counterclockwise, and then remove the defective bulb.
5. Place a new bulb into position, and 8. Install the cowling. clockwise. then secure it with the bulb holder. 9. Have a Yamaha dealer adjust the ECA10660 headlight beam if necessary. CAUTION: Do not touch the glass part of the...
PERIODIC MAINTENANCE AND MINOR REPAIR EAU24202 Replacing a turn signal light bulb 1. Remove the turn signal light lens by removing the screw. 1. Tail/brake light bulb 1. Turn signal light bulb 3. Insert a new bulb into the socket, 3.
EWA10820 wheel or performing other maintenance WARNING requiring the motorcycle to stand up- It is advisable to have a Yamaha right. Check that the motorcycle is in a dealer service the wheel. stable and level position before starting Securely support the motorcy- any maintenance.
Page 68
PERIODIC MAINTENANCE AND MINOR REPAIR 3. Remove the speedometer cable with the brake disc, otherwise the holder by removing the screw. brake pads will be forced shut. 4. Disconnect the speedometer ca- ble from the front wheel. EAU25011 5. Remove the axle nut. To install the front wheel 1.
EAU25470 To remove the rear wheel EWA10820 WARNING It is advisable to have a Yamaha dealer service the wheel. Securely support the motorcy- cle so that there is no danger of it falling over. 1. Brake pedal free play adjusting nut 1.
Page 70
PERIODIC MAINTENANCE AND MINOR REPAIR Tightening torque: Axle nut: 85 Nm (8.5 m·kgf, 62 ft·lbf) 5. Install the brake rod onto the brake camshaft lever, and then install the brake pedal free play adjusting nut onto the brake rod. 6. Adjust the brake pedal free play. (See page 6-18.) 1.
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.
Remove the spark plug and check the electrodes. The engine does not start. Have a Yamaha dealer check the vehicle. Check the battery. 4. Battery The engine turns over The battery is good.
MOTORCYCLE CARE AND STORAGE EAU26001 ucts onto seals, gaskets, sprock- cleaning products, solvent or Care ets, the drive chain and wheel thinner, fuel (gasoline), rust re- While the open design of a motorcycle axles. Always rinse the dirt and de- movers or inhibitors, brake flu- reveals the attractiveness of the tech- greaser off with water.
Page 74
MOTORCYCLE CARE AND STORAGE After normal use salt. 7. Wax all painted surfaces. Remove dirt with warm water, a mild 8. Let the motorcycle dry completely 2. Apply a corrosion protection spray detergent, and a soft, clean sponge, before storing or covering it. on all metal, including chrome- and and then rinse thoroughly with clean EWA11130...
EAU26150 “OFF”. Storage NOTE: 3. Drain the carburetor float chamber Consult a Yamaha dealer for advice on by loosening the drain bolt; this will what products to use. Short-term prevent fuel deposits from building Always store your motorcycle in a cool, up.
Page 76
MOTORCYCLE CARE AND STORAGE install the spark plug and the [less than 0 °C (30 °F) or more spark plug cap. than 30 °C (90 °F)]. For more in- EWA10950 formation on storing the battery, WARNING see page 6-27. To prevent damage or injury from NOTE: sparking, make sure to ground the Make any necessary repairs before...
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. KEY IDENTIFICATION NUMBER: 1.
The use of the vehicle after such space provided. This information will be device or element of design has needed when ordering spare parts from been removed or rendered inoper- a Yamaha dealer. ative by any person.
Page 82
INDEX Air filter element, cleaning....... 6-10 Front fork, checking .........6-26 Rear brake light switch, adjusting.... 6-19 Fuel............3-6 Rear suspension, lubricating ....6-25 Fuel cock ...........3-6 Battery............. 6-27 Fuel consumption, tips for reducing...5-3 Brake and clutch levers, checking and Safety information ........1-1 Fuel tank cap ..........3-5 lubricating ..........
Page 86
YAMAHA MOTOR CO., LTD. YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED ON RECYCLED PAPER PRINTED IN JAPAN PRINTED IN JAPAN 2006.6–0.1×1 ! 2006.6–0.1×1 !