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EAU00000 INTRODUCTION Congratulations on your purchase of the Yamaha XT250. 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.
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8 This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold. 8 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.
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IMPORTANT MANUAL INFORMATION EW000002 PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE.
EAU00009 TABLE OF CONTENTS SAFETY INFORMATION........1-1 Helmet holder.............3-8 Safe riding............1-1 Adjusting the shock absorber assembly ....3-9 Protective apparel ..........1-3 Sidestand ............3-11 Modifications ............1-3 Ignition circuit cut-off system......3-12 Loading and accessories ........1-3 PRE-OPERATION CHECKS .......4-1 Gasoline and exhaust gas .........1-5 Location of important labels .......1-7 Pre-operation check list ........4-1 DESCRIPTION ............2-1 OPERATION AND IMPORTANT RIDING...
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TABLE OF CONTENTS Adjusting the engine idling speed ....6-13 Checking the wheel bearings......6-30 Adjusting the throttle cable free play....6-14 Battery..............6-30 Adjusting the valve clearance ......6-15 Replacing the fuse ...........6-32 Tires ..............6-15 Replacing the headlight bulb ......6-32 Spoke wheels ..........6-17 Replacing a turn signal light bulb .....6-34 Adjusting the clutch lever free play ....6-18 Replacing the tail/brake light bulb ....6-35 Adjusting the brake lever free play....6-19...
EAU00017 Q SAFETY INFORMATION MOTORCYCLES ARE SINGLE TRACK VEHICLES. THEIR SAFE USE AND OPERATION ARE DEPENDENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EXPER- TISE OF THE OPERATOR. EVERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIRE- MENTS BEFORE RIDING THIS MOTORCYCLE. HE OR SHE SHOULD: 1.
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Q SAFETY INFORMATION 4. Many 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 oper- ators.
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.
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Genuine Yamaha accessories have been specifically designed for use on this motorcycle. Since Yamaha cannot test all other accessories that may be available, you must personally be responsible for the proper selection, installation and use of non-Yamaha accessories. Use extreme caution when selecting and installing any accessories.
Q SAFETY INFORMATION a. Accessories fitted to the handlebar or the front fork area can create instability due to improper weight distribution or aerodynamic changes. If accessories are added to the handlebar or front fork area, they must be as lightweight as possible and should be kept to a minimum. b.
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Q SAFETY INFORMATION a. The engine and exhaust system may be hot, therefore, park the motorcycle in a place where pedestrians or children are not likely to touch these hot areas. b. Do not park the motorcycle on a slope or soft ground, otherwise it may fall over. c.
EAU00027 INSTRUMENT AND CONTROL FUNCTIONS EW000016 Never turn the key to “OFF” or “LOCK” while the motorcycle is moving, otherwise the electrical systems will be switched off, which may result in loss of control LOCK or an accident. Make sure that the motorcycle is stopped before turn- a.
INSTRUMENT AND CONTROL FUNCTIONS EAU00129 Horn switch “*” Press this switch to sound the horn. 1. Clutch lever 1. Engine stop switch 2. Start switch “START” EAU00152 EAU00138 Clutch lever Engine stop switch The clutch lever is located at the left Set this switch to “$”...
INSTRUMENT AND CONTROL FUNCTIONS 1. Shift pedal 1. Brake lever 1. Brake pedal EAU00157 EAU00158 EAU00162 Shift pedal Brake lever Brake pedal The shift pedal is located on the left The brake lever is located at the right The brake pedal is on the right side side of the engine and is used in handlebar grip.
INSTRUMENT AND CONTROL FUNCTIONS NOTE: The fuel tank cap cannot be installed unless the key is in the lock. In addi- tion, the key cannot be removed if the cap is not properly installed and locked. EW000023 1. Fuel tank cap 1.
INSTRUMENT AND CONTROL FUNCTIONS EAU00185 OFF: Closed position ON: Normal position Immediately wipe off spilled fuel with a clean, dry, soft cloth, since fuel may deteriorate painted sur- faces or plastic parts. EAU00192* Recommended fuel: 1. Arrow mark positioned over “OFF” 1.
INSTRUMENT AND CONTROL FUNCTIONS EAU02949 RES: Reserve position Seat To remove the seat 1. Remove panels A and B. (See page 6-5 for panel removal and installation procedures.) 1. Arrow mark positioned over “RES” 1. Starter(choke) knob “1” EAU03032 Starter (choke) knob “1” This indicates reserve.
INSTRUMENT AND CONTROL FUNCTIONS 1. Bolt (×2) 1. Projection 1. Helmet holder 2. Seat holder a. Unlock. 2. Remove the bolts and pull the EAU00261 To install the seat Helmet holder seat off. 1. Insert the projection on the front To open the helmet holder, insert the of the seat into the seat holder key into the lock, and then turn the...
INSTRUMENT AND CONTROL FUNCTIONS EAU03673 Adjusting the shock absorber assembly This shock absorber assembly is equipped with spring preload adjusting nut and a rebound damping force adjusting dial. EC000015 Never attempt to turn an adjusting 1. Spring preload adjusting nut a.
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INSTRUMENT AND CONTROL FUNCTIONS 3. Tighten the locknut to the speci- NOTE: fied torque. Although the total number of clicks of the damping force adjusting mecha- Tightening torque: nism may not exactly match the Locknut: above specifications due to small dif- 54 Nm (5.4 m0kg) ferences in production, the actual number of clicks always represents...
Therefore, check this system absorber to an open flame or regularly as described below and other high heat sources, other- have a Yamaha dealer repair it if it wise it may explode due to does not function properly. excessive gas pressure.
Periodically check the operation of the ignition circuit cut-off system according to the following procedure. EW000045 If a malfunction is noted, have a Yamaha dealer check the system before riding. 3-12...
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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.
• If necessary, add recommended oil to specified level. 6-8–6-11 • Check vehicle for oil leakage. • Check operation. • If soft or spongy, have Yamaha dealer bleed hydraulic system. • Check lever free play. 3-4, 6-19, Front brake • Adjust if necessary.
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— • Tighten if necessary. Instruments, lights, • Check operation. 3-1–3-3, 6-32–6-35 signals and switches • Correct if necessary. • Check operation of ignition circuit cut-off system. Sidestand switch 3-12–3-13 • If system is defective, have Yamaha dealer check vehicle.
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PRE-OPERATION CHECKS 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 If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operat- ing the motorcycle.
If the should be on, otherwise have a sidestand is not raised com- Yamaha dealer check the electrical pletely, it could contact the circuit. ground and distract the opera- tor, resulting in a possible loss of control.
EAU00372 OPERATION AND IMPORTANT RIDING POINTS EAU01258 4. Turn the starter (choke) on and 7. When the engine is warm, turn Starting a warm engine completely close the throttle. the starter (choke) off. Follow the same procedure as for (See page 3-7 for starter (choke) starting a cold engine with the excep- NOTE: operation.)
OPERATION AND IMPORTANT RIDING POINTS EC000048 EAU00424 Tips for reducing fuel consumption 8 Even with the transmission in Fuel consumption depends largely on the neutral position, do not your riding style. Consider the follow- coast for long periods of time ing tips to reduce fuel consumption: with the engine off, and do not 8 Thoroughly warm up the engine.
1/2 throttle. immediately have a Yamaha dealer 8 Rev the engine freely through ing must be avoided. check the vehicle. the gears, but do not use full throttle at any time.
OPERATION AND IMPORTANT RIDING POINTS EAU00457 Parking When parking, stop the engine, remove the key from the main switch, and then turn the fuel cock lever to “OFF”. EW000058 8 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.
If you do not have the tools or experi- Periodic inspection, adjustment and ence required for a particular job, lubrication will keep your vehicle in have a Yamaha dealer perform it for the safest and most efficient condi- you. tion possible. The most important...
8 The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead. 8 From 30,000 km, repeat the maintenance intervals starting from 6,000 km. 8 Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
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PERIODIC MAINTENANCE AND MINOR REPAIR ODOMETER READING (×1,000 km) ANNUAL ITEM CHECK OR MAINTENANCE JOB CHECK • Check tread depth and for damage. • Replace if necessary. √ √ √ √ Tires • Check air pressure. • Correct if necessary. √...
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PERIODIC MAINTENANCE AND MINOR REPAIR ODOMETER READING (×1,000 km) ANNUAL ITEM CHECK OR MAINTENANCE JOB CHECK √ √ √ Engine oil filter element • Clean. √ √ √ Engine oil strainer • Clean. Front and rear brake √ √ √ √...
PERIODIC MAINTENANCE AND MINOR REPAIR 1. Cowling A 1. Screw 1. Panel A 2. Panel A 2. Screw EAU01145 3. Panel B EAU00488 Cowling A EAU03516 Panel A Removing and installing the To remove the cowling To remove the panel cowling and panels Remove the screw, and then pull the Remove the screw, and then pull the...
PERIODIC MAINTENANCE AND MINOR REPAIR 1. Panel B 1. Spark plug cap 1. Spark plug wrench 2. Screw EAU01833 2. Remove spark plug EAU00488 Checking the spark plug shown, with the spark plug Panel B The spark plug is an important wrench included in the owner’s To remove the panel engine component, which is easy to...
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Instead, 1. Measure the spark plug gap with soon as possible. have a Yamaha dealer check the a wire thickness gauge and, if motorcycle. necessary, adjust the gap to 4. Install the spark plug cap. specification. 2. Check the spark plug for elec-...
PERIODIC MAINTENANCE AND MINOR REPAIR EAU03674 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 element cleaned at the intervals specified in the General maintenance and lubrication chart.
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PERIODIC MAINTENANCE AND MINOR REPAIR 4 3 2 1 1. Engine oil filler cap 1. Engine oil drain bolt 1. Oil filter element drain bolt 2. O-ring 2. Oil filter element cover 4. Remove the engine oil filler cap 3. Compression spring 3.
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PERIODIC MAINTENANCE AND MINOR REPAIR 13. Add the specified amount of the Tightening torques: recommended engine oil, and Oil filter element cover screw: then install and tighten the oil 7 Nm (0.7 m.kg) filler cap. Oil filter element drain bolt: 10 Nm (1.0 m.kg) Recommended oil: See page 8-1.
PERIODIC MAINTENANCE AND MINOR REPAIR 14. 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. 15. Turn the engine off, and then check the oil level and correct it if necessary.
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PERIODIC MAINTENANCE AND MINOR REPAIR 1. Sponge material 1. “UP” mark 2. Air filter element frame 5. Clean the sponge material with 7. Install the sponge material onto 4. Remove the sponge material solvent, and then squeeze the the air filter element frame, and from the air filter element frame.
8 The engine should never be to a Yamaha dealer, who has the the periodic maintenance and lubrica- operated without the air filter necessary professional knowledge tion chart.
The engine idling speed must be cor- rectly adjusted before checking and NOTE: adjusting the throttle cable free play. If the specified idling speed cannot be obtained as described above, 1. Loosen the locknut. have a Yamaha dealer make the adjustment. 6-14...
1.50 kgf/cm 1.75 kgf/cm maximum 1.50 bar 1.75 bar ance must be adjusted by a Yamaha Tire air pressure dealer at the intervals specified in the The tire air pressure should be Maximum load* 183 kg...
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PERIODIC MAINTENANCE AND MINOR REPAIR EWA00012 EW000079 Because loading has an enormous 8 Have a Yamaha dealer replace impact on the handling, braking, excessively worn tires. performance and safety character- Besides being illegal, operat- istics of your motorcycle, you ing the motorcycle with exces-...
If any damage is including the tires, should be 8 After extensive tests, only the found, have a Yamaha dealer left to a Yamaha dealer, who tires listed below have been replace wheel. has the necessary profession-...
PERIODIC MAINTENANCE AND MINOR REPAIR 8 Ride at moderate speeds after changing a tire since the tire sur- face must first be “broken in” for it to develop its optimal charac- teristics. 1. Locknut (Clutch lever) 1. Locknut 2. Adjusting bolt 2.
Adjusting the brake lever system before operating the EW000104 free play motorcycle. The brake lever free play should hydraulic system will diminish It is advisable to have a Yamaha measure 2–5 shown. braking performance, dealer make these adjustments. Periodically check the brake lever...
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PERIODIC MAINTENANCE AND MINOR REPAIR 1. Adjusting bolt a. Brake pedal free play 1. Brake pedal free play adjusting nut 2. Locknut Brake pedal free play To increase the brake pedal free 1. Loosen the locknut at the brake The brake pedal free play should play, turn the adjusting nut at the pedal.
8 If proper adjustment cannot be obtained as described, have a 1. Rear brake light switch Yamaha dealer make this 2. Adjusting nut adjustment. EAU00713 8 After adjusting the brake pedal...
Changing the brake fluid 8 When checking the fluid level, ed surfaces or plastic parts. Have a Yamaha dealer change the Always clean up spilled fluid make sure that the top of the brake fluid at the intervals specified in master cylinder or brake fluid immediately.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU00744 Drive chain slack The drive chain slack should be checked before each ride and adjust- ed if necessary. To check the drive chain slack 1. Place the motorcycle on a level surface and hold it in an upright position.
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PERIODIC MAINTENANCE AND MINOR REPAIR 6. Adjust the brake pedal free play. NOTE: (See page 6-20 for brake pedal Make sure that both adjusting plates free play adjustment proce- are in the same position for proper dures.) wheel alignment. EW000103 EC000096 After adjusting the brake pedal free play, check the operation of...
If they may contain substances that chain as follows. a cable is damaged or does not move could damage the O-rings. smoothly, have a Yamaha dealer EC000097 check or replace it. The drive chain must be lubricated Recommended lubricant:...
PERIODIC MAINTENANCE AND MINOR REPAIR EAU03209 4. Grease the metal-to-metal con- Checking and lubricating the tact surface of the throttle grip, throttle grip and cable and then install the grip by The operation of the throttle grip and installing the screws. the condition of the throttle cable should be checked before each ride, Recommended lubricant:...
Yamaha dealer check or repair it. The operation of the brake and clutch The pivoting points of the rear sus- levers should be checked before pension must be lubricated at the Recommended lubricant:...
If there is play is no need to check the electrolyte or in the wheel hub or if the wheel does to add distilled water. not turn smoothly, have a Yamaha EC000101 dealer check the wheel bearings. Never attempt to remove the bat- tery cell seals, as this would per- 2.
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PERIODIC MAINTENANCE AND MINOR REPAIR EW000116 EC000102 To charge the battery Have a Yamaha dealer charge the 8 Electrolyte is poisonous and 8 Always keep battery battery as soon as possible if it dangerous since it contains charged. Storing a discharged seems to have discharged.
2. Spare fuse the devices operate. EAU01307 Replacing the fuse 4. If the fuse immediately blows again, have a Yamaha dealer The fuse holder is located behind check the electrical system. panel B. (See page 6-6 for panel removal and installation procedures.) If the fuse is blown, replace it as fol- lows.
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PERIODIC MAINTENANCE AND MINOR REPAIR 1. Headlight unit 1. Coupler 1. Headlight bulb holder 2. Bolt (×2) 2. Headlight bulb cover 4. Remove the headlight bulb hold- 2. Remove the headlight unit by 3. Disconnect the headlight cou- er by turning it counterclockwise, removing the bolts.
4. Install the lens by installing the 8. Install the cowling. screw. 9. Have a Yamaha dealer adjust the headlight beam if necessary. ECA00065 Do not overtighten the screw, oth- erwise the lens may break.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU01579 Supporting the motorcycle Since this model is not equipped with a centerstand, follow these precau- tions when removing the front and rear wheel or performing other main- tenance requiring the motorcycle to stand upright. Check that the motor- cycle is in a stable and level position before starting any maintenance.
EW000122 2. Remove the brake disc cover by removing the screws. 8 It is advisable to have a 3. Remove the speedometer cable Yamaha dealer service the holder by removing the screw. wheel. 4. Disconnect speedometer 8 Securely support the motorcy- cable from the front wheel.
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PERIODIC MAINTENANCE AND MINOR REPAIR ECA00048 Do not apply the brake after the wheel has been removed together with the brake disc, otherwise the brake pads will be forced shut. 1. Speedometer gear unit 1. Retainer EAU03700 NOTE: To install the front wheel Make sure that there is enough 1.
8 It is advisable to have a EW000110 connect the brake rod from the Yamaha dealer service the brake camshaft lever. Always use a new cotter pin for the wheel. 3. Remove the cotter pin, and then 8 Securely support the motorcy- axle nut.
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PERIODIC MAINTENANCE AND MINOR REPAIR 3. Install the axle nut, and then lower the rear wheel so that it is on the ground. 4. Tighten the axle nut to the speci- fied torque, and then install the cotter pin. EW000124 Always use a new cotter pin.
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. 6-40...
2. Compression There is compression. Go to ignition check. Use the electric starter. No compression. Ask a Yamaha dealer to inspect. 3. Ignition Wipe clean with dry cloth and correct Open throttle half-way and start Wet. Remove spark spark gap or replace spark plug.
EAU03521 MOTORCYCLE CARE AND STORAGE Before cleaning Cleaning Care 1. Cover the muffler outlet with a ECA00010 While the open design of a motorcy- plastic bag after the engine has cle reveals the attractiveness of the 8 Avoid using strong acidic cooled down.
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MOTORCYCLE CARE AND STORAGE 8 Do not use any harsh chemical 8 For motorcycles equipped After riding in the rain, near the sea products on plastic parts. Be with a windshield: Do not use or on salt-sprayed roads Since sea salt or salt sprayed on sure to avoid using cloths or strong cleaners...
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NOTE: 4. To prevent corrosion, it is recom- Consult a Yamaha dealer for advice mended to apply a corrosion pro- on what products to use. tection spray on all metal, includ- ing chrome- and nickel-plated, surfaces.
MOTORCYCLE CARE AND STORAGE Long-term c. Install the spark plug cap onto Storage Before storing your motorcycle for the spark plug, and then place Short-term several months: the spark plug on the cylinder Always store your motorcycle in a 1. Follow all the instructions in the head so that the electrodes cool, dry place and, if necessary, pro- “Care”...
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MOTORCYCLE CARE AND STORAGE 7. Check and, if necessary, correct the tire air pressure, and then lift the motorcycle so that both of its wheels ground. Alternatively, turn the wheels a little every month in order to pre- vent the tires from becoming degraded in one spot.
SPECIFICATIONS Air filter Wet type element Gear ratio 3.090 Fuel 2.000 Type Unleaded fuel only 1.428 Fuel tank capacity 8.8 L 1.125 Reserve amount 2.0 L 0.925 Carburetor 0.793 Manufacturer MIKUNI Chassis Model × quantity BST34 × 1 Frame type Diamond Spark plug Caster angle...
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SPECIFICATIONS Maximum load* 183 kg Rear Tire air pressure (measured on cold tires) Type Drum brake Up to 90 kg load* Operation Right foot Front 125 kPa (1.25 kgf/cm , 1.25 bar) Suspension Rear 150 kPa (1.50 kgf/cm , 1.50 bar) Front 90 kg load–maximum load* Type...
SPECIFICATIONS EAU01064 Conversion table CONVERSION TABLE All specification data in this manual are listed in SI and METRIC TO IMPERIAL METRIC UNITS. Metric unit Multiplier Imperial unit Use this table to convert METRIC unit data to m • kg 7.233 ft•...
Record the key identification number, vehicle identification number and model label information in the spaces provided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen. 1. KEY IDENTIFICATION 1. Key identification number 1.
This is in use; and information will be needed when (b) The use of the vehicle after such ordering spare parts from a Yamaha device or element of design has dealer. been removed or rendered inop-...
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YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2000·8–0.2×1(E)
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