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YAMAHA XG250 Owner's Manual

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OWNER'S MANUAL
XG250
4D6-28199-E0

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Troubleshooting

   Summary of Contents for YAMAHA XG250

  • Page 1

    OWNER’S MANUAL XG250 4D6-28199-E0...

  • Page 3

    Yamaha a reputation for dependability. Please take the time to read this manual thoroughly, so as to enjoy all advantages of your XG250. 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 oth- ers from trouble and injury.

  • Page 4: Important Manual Information

    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.

  • Page 5

    IMPORTANT MANUAL INFORMATION EAU10200 XG250 OWNER’S MANUAL ©2005 by Yamaha Motor Co., Ltd. 1st edition, March 2005 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan.

  • Page 6: Table Of Contents

    TABLE OF CONTENTS SAFETY INFORMATION ....1-1 OPERATION AND IMPORTANT Adjusting the brake lever free RIDING POINTS........5-1 play ..........6-16 DESCRIPTION ........2-1 Starting a cold engine ..... 5-1 Adjusting the rear brake light Left view ...........2-1 Starting a warm engine ....5-2 switch .........

  • Page 7: Table Of Contents

    TABLE OF CONTENTS Replacing a turn signal light bulb ..........6-29 Replacing the auxiliary light bulb ..........6-30 Supporting the motorcycle .....6-31 Front wheel ........6-31 Rear wheel ........6-33 Troubleshooting ......6-34 Troubleshooting chart ....6-35 MOTORCYCLE CARE AND STORAGE ...........7-1 Matte black caution ......7-1 Care ..........7-1 Storage ..........7-3 SPECIFICATIONS ......8-1...

  • Page 8: Safety Information

    SAFETY INFORMATION TIONS. Many accidents involve inexperi- EAU10311 Safe riding enced operators. In fact, many op- MOTORCYCLES SINGLE Always make pre-operation erators who have been involved in TRACK VEHICLES. THEIR SAFE checks. Careful checks may help accidents do not even have a cur- USE AND OPERATION ARE DEPEN- prevent an accident.

  • Page 9

    The majority of fatalities from motorcy- Modifications made to this motorcycle keep the following in mind: cle accidents are the result of head in- not approved by Yamaha, or the re- Cargo accessory weight juries. The use of a safety helmet is the...

  • Page 10

    Gasoline and exhaust gas this motorcycle. Since Yamaha cannot lightweight as possible and GASOLINE IS HIGHLY FLAMMA- test all other accessories that may be should be kept to a minimum.

  • Page 11

    SAFETY INFORMATION for any length of time in a closed cock(s) are turned to “ON” or area. The exhaust fumes are poi- “RES” (for vacuum type)/“OFF” sonous and may cause loss of (for manual type). If the motorcycle consciousness and death within a should lean over, gasoline may short time.

  • Page 12: Description, Left View

    DESCRIPTION EAU10410 Left view 1. Headlight (page 6-27) 2. Storage pouch (page 3-9) 3. Fuel cock (page 3-6) 4. Starter (choke) knob (page 3-7) 5. Air filter element (page 6-11) 6. Helmet holder (page 3-8) 7. Shift pedal (page 3-4)

  • Page 13: Right View

    DESCRIPTION EAU10420 Right view 1. Battery (page 6-25) 2. Fuse (page 6-27) 3. Owner’s tool kit (page 6-1) 4. Engine oil filter element (page 6-8) 5. Engine oil level check window (page 6-8) 6. Brake pedal (page 3-5)

  • Page 14: Controls And Instruments

    DESCRIPTION EAU10430 Controls and instruments 1. Clutch lever (page 3-4) 9. Fuel tank cap (page 3-5) 2. Left handlebar switches (page 3-3) 3. Speedometer unit (page 3-2) 4. Indicator lights (page 3-2) 5. Main switch/steering lock (page 3-1) 6. Right handlebar switches (page 3-3) 7.

  • Page 15: Instrument And Control Functions, Main Switch/steering Lock

    INSTRUMENT AND CONTROL FUNCTIONS To unlock the steering EAU10460 EAU10660 Main switch/steering lock All electrical systems are off. The key can be removed. EAU10690 LOCK The steering is locked, and all electrical systems are off. The key can be re- moved.

  • Page 16: Indicator Lights, Speedometer Unit

    INSTRUMENT AND CONTROL FUNCTIONS EAU10980 EAU11080 EAU11630 Indicator lights High beam indicator light “ ” Speedometer unit This indicator light comes on when the high beam of the headlight is switched 1. Reset knob 1. Turn signal indicator light “ ”...

  • Page 17: Handlebar Switches

    INSTRUMENT AND CONTROL FUNCTIONS Right EAU12343 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 “ ”...

  • Page 18: Clutch Lever, Shift Pedal, Brake Lever

    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.

  • Page 19: Brake Pedal, Fuel Tank Cap

    INSTRUMENT AND CONTROL FUNCTIONS EAU12941 EAUM1791 Brake pedal Fuel tank cap To remove the fuel tank cap 1. Open the fuel tank cap lock cover. 2. Insert the key into the lock and turn it 1/4 turn clockwise. The lock will be released and the fuel tank cap can be removed.

  • Page 20: Fuel, Fuel Cock

    Do not overfill the fuel tank, oth- not flow. Always return the lever to this erwise it may overflow when the Your Yamaha engine has been de- position when the engine is not running. fuel warms up and expands. signed to use regular unleaded gaso-...

  • Page 21: Starter (choke) Knob "1"

    INSTRUMENT AND CONTROL FUNCTIONS fuel while riding, move the lever to this EAU13600 Starter (choke) knob “ ” position. Fill the tank at the first oppor- tunity. Be sure to set the lever back to “ON” after refueling! (a) (b) 1.

  • Page 22: Seat, Helmet Holder

    INSTRUMENT AND CONTROL FUNCTIONS EAU13970 EAU14281 Seat Helmet holder To remove the seat Remove the bolts, and then pull the seat off. 1. Projection 2. Seat holder 1. Helmet holder 2. Place the seat in the original posi- 2. Open. tion, and then tighten the bolts.

  • Page 23: Storage Pouch, Shock Absorber, Sidestand

    Always have a Yamaha dealer sibility of raising the sidestand be- service the shock absorber. fore starting off. Therefore, check this system regularly as described below and have a Yamaha dealer re-...

  • Page 24: Ignition Circuit Cut-off System

    Periodically check the operation of the ignition circuit cut-off system according to the following procedure. EWA10250 WARNING If a malfunction is noted, have a Yamaha dealer check the system be- fore riding. 3-10...

  • Page 25

    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.

  • Page 26: Pre-operation Checks

    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.

  • Page 27: Pre-operation Check List

    Lubricate cable if necessary. Clutch 6-16 Check lever free play. Adjust if necessary. Make sure that operation is smooth. Check cable free play. Throttle grip 6-13, 6-21 If necessary, have Yamaha dealer adjust cable free play and lubricate cable and grip housing.

  • Page 28

    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 If system is defective, have Yamaha dealer check vehicle.

  • Page 29: Operation And Important Riding Points, Starting A Cold Engine

    OPERATION AND IMPORTANT RIDING POINTS should be on, otherwise have a EAU15950 EAU16060 Starting a cold engine Yamaha dealer check the electrical cir- EWA10270 In order for the ignition circuit cut-off cuit. WARNING system to enable starting, one of the 4.

  • Page 30: Starting A Warm Engine, Shifting

    OPERATION AND IMPORTANT RIDING POINTS EAU16640 EAU16671 NOTE: Starting a warm engine Shifting The engine is warm when it responds Follow the same procedure as for start- normally to the throttle with the starter ing a cold engine with the exception (choke) turned off.

  • Page 31: Tips For Reducing Fuel Consumption, Engine Break-in

    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).

  • Page 32: Parking

    If any engine trouble should occur system can become very hot, during the engine break-in period, park in a place where pedestri- immediately have a Yamaha dealer ans or children are not likely to check the vehicle. touch them. Do not park on a slope or on soft ground, otherwise the vehicle may overturn.

  • Page 33: Periodic Maintenance And Minor Repair, Owner's Tool Kit

    Yamaha dealer certain maintenance work correctly. do it for you. NOTE: If you do not have the tools or experi- ence required for a particular job, have a Yamaha dealer perform it for you.

  • Page 34: Periodic Maintenance And Lubrication Chart

    The annual checks must be performed every year, except if a kilometer-based maintenance is performed in- stead. From 50000 km, repeat the maintenance intervals starting from 10000 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 35

    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 36

    PERIODIC MAINTENANCE AND MINOR REPAIR ODOMETER READING (× 1000 km) ANNUAL ITEM CHECK OR MAINTENANCE JOB CHECK Front and rear brake √ √ √ √ √ √ 24 * Check operation. switches √ √ √ √ √ Moving parts and cables Lubricate.

  • Page 37: Removing And Installing Panels

    PERIODIC MAINTENANCE AND MINOR REPAIR EAU18771 Removing and installing panels The panels shown need to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time a panel needs to be removed and installed. 1.

  • Page 38: Checking The Spark Plug

    PERIODIC MAINTENANCE AND MINOR REPAIR first remove panel E. EAU19602 Checking the spark plug 2. Remove panel C or F by pulling it The spark plug is an important engine off as shown. component, which is easy to check. Since heat and deposits will cause any spark plug to slowly erode, the spark plug should be removed and checked in accordance with the periodic mainte-...

  • Page 39

    Do not attempt to diagnose such 0.6–0.7 mm (0.024–0.028 in) problems yourself. Instead, have a Yamaha dealer check the vehicle. 2. Clean the surface of the spark plug gasket and its mating surface, and 2. Check the spark plug for electrode...

  • Page 40: Engine Oil And Oil Filter Element

    PERIODIC MAINTENANCE AND MINOR REPAIR to collect the used oil. EAU37801 NOTE: Engine oil and oil filter 3. Remove the engine oil filler bolt The engine oil should be between the element and drain bolt to drain the oil from minimum and maximum level marks.

  • Page 41

    PERIODIC MAINTENANCE AND MINOR REPAIR bolt to drain the oil from the oil filter element. 1. Engine oil drain bolt 1. Bolt 2. Oil filter element cover NOTE: 1. Oil filter element drain bolt 6. Remove and replace the oil filter Check the washer for damage and re- element and O-rings.

  • Page 42

    PERIODIC MAINTENANCE AND MINOR REPAIR higher. Tightening torques: Make sure that no foreign mate- Engine oil drain bolt: rial enters the crankcase. 20 Nm (2.0 m·kgf, 14.5 ft·lbf) Oil filter element drain bolt: 11. Start the engine, and then let it idle 10 Nm (1.0 m·kgf, 7.2 ft·lbf) for several minutes while checking it for oil leakage.

  • Page 43: Replacing The Air Filter Element And Cleaning The Check Hose

    PERIODIC MAINTENANCE AND MINOR REPAIR 3. Pull the air filter element out. 6. Install the seat. EAU37870 Replacing the air filter element 4. Insert a new air filter element into To clean the air filter check hose and cleaning the check hose the air filter case as shown.

  • Page 44: Adjusting The Carburetor, Adjusting The Engine Idling Speed

    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.

  • Page 45: Checking The Throttle Cable Free Play, Valve Clearance, Tires

    To prevent this cle, note the following points regarding from occurring, the valve clearance the specified tires. must be adjusted by a Yamaha dealer Tire air pressure at the intervals specified in the periodic The tire air pressure should be checked maintenance and lubrication chart.

  • Page 46

    Do not carry along loosely cracked, have a Yamaha dealer re- 0–90 kg (0–198 lb): packed items, which can shift place the tire immediately. Front: during a ride.

  • Page 47: Spoke Wheels

    Manufacturer/model: the spokes for looseness or dam- BRIDGESTONE/TW202 age before each ride. If any dam- age is found, have a Yamaha EWA10570 WARNING dealer replace the wheel. Do not Have a Yamaha dealer replace attempt even the smallest repair to the wheel.

  • Page 48: Adjusting The Clutch Lever Free Play, Adjusting The Brake Lever Free Play

    PERIODIC MAINTENANCE AND MINOR REPAIR lever free play, turn the adjusting EAU22030 EAU22092 Adjusting the clutch lever free Adjusting the brake lever free bolt in direction (b). play play 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.

  • Page 49: Checking The Front And Rear Brake Pads

    EAU22420 Front brake pads 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 1. Rear brake light switch 2. Adjusting nut...

  • Page 50: Checking The Brake Fluid Level

    EAU22580 Checking the brake fluid level peared, have a Yamaha dealer replace Before riding, check that the brake fluid Front brake the brake pads as a set. is above the minimum level mark and replenish if necessary.

  • Page 51: Changing The Brake Fluid, Drive Chain Slack

    EAU22760 Changing the brake fluid Drive chain slack and may result in vapor lock. Have a Yamaha dealer change the The drive chain slack should be Brake fluid may deteriorate paint- brake fluid at the intervals specified in checked before each ride and adjusted ed surfaces or plastic parts.

  • Page 52

    PERIODIC MAINTENANCE AND MINOR REPAIR EAU23022 Cleaning and 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.

  • Page 53: Checking And Lubricating The Cables, Checking And Lubricating The Throttle Grip And Cable

    If a cable is damaged maintenance chart. or does not move smoothly, have a Yamaha dealer check or replace it. Recommended lubricant: Engine oil EWA10720 WARNING...

  • Page 54: Checking And Lubricating The Brake And Shift Pedals

    PERIODIC MAINTENANCE AND MINOR REPAIR EAU23131 EAU23140 Checking and lubricating the Checking and lubricating the Recommended lubricant: Lithium-soap-based grease brake and shift pedals brake and clutch levers (all-purpose grease) Brake lever Clutch lever The operation of the brake and shift pedals should be checked before each The operation of the brake and clutch ride, and the pedal pivots should be lu-...

  • Page 55: Checking And Lubricating The Sidestand, Lubricating The Rear Suspension

    Recommended lubricant: EWA10730 Molybdenum disulfide grease WARNING If the sidestand does not move up and down smoothly, have a Yamaha dealer check or repair it. Recommended lubricant: Lithium-soap-based grease (all-purpose grease) 6-23...

  • Page 56: Checking The Front Fork, Checking The Steering

    Securely support the vehicle so that To check the operation have a Yamaha dealer check or re- there is no danger of it falling over. 1. Place the vehicle on a level sur- pair it.

  • Page 57: Checking The Wheel Bearings, Battery

    To charge the battery 1. Have a Yamaha dealer charge the battery as soon as possible if it seems to have discharged. Keep in mind that the battery tends to...

  • Page 58

    IES OUT OF THE REACH OF sealed-type (MF) battery charg- trical accessories. CHILDREN. er, have a Yamaha dealer EWA10760 charge your battery. To store the battery WARNING 1. If the model will not be used for...

  • Page 59: Replacing The Fuse, Replacing The Headlight Bulb

    3. Turn the key to “ON” and turn on the electrical circuits to check if the devices operate. 4. If the fuse immediately blows again, have a Yamaha dealer 1. Fuse check the electrical system. 2. Spare fuse The fuse holder is located behind panel F.

  • Page 60

    8. Install the headlight rim by install- light bulb holder into its original ing the screws. position by turning it clockwise. 9. Have a Yamaha dealer adjust the ECA10660 headlight beam if necessary. CAUTION: Do not touch the glass part of the...

  • Page 61: Replacing The Tail/brake Light Bulb, Bulb

    PERIODIC MAINTENANCE AND MINOR REPAIR EAU24131 EAU24202 Replacing the tail/brake light Replacing a turn signal light bulb bulb 1. Remove the tail/brake light lens by 1. Remove the turn signal light lens removing the screws. by removing the screw. 1. Tail/brake light bulb 3.

  • Page 62: Replacing The Auxiliary Light Bulb

    PERIODIC MAINTENANCE AND MINOR REPAIR EAU37930 Replacing the auxiliary light bulb If the auxiliary light bulb burns out, re- place it as follows. 1. Remove the headlight rim by re- moving the screws. 1. Turn signal light bulb 1. Headlight unit 2.

  • Page 63: Supporting The Motorcycle, Front Wheel

    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 64

    PERIODIC MAINTENANCE AND MINOR REPAIR according to the procedure on 2. Lift the wheel up between the fork Tightening torque: page 6-31. legs. Axle nut: 4. Remove the axle nut, pull the NOTE: 85 Nm (8.5 m·kgf, 61.5 ft·lbf) wheel axle out, and then remove Make sure that there is enough space the wheel.

  • Page 65: Rear Wheel

    Rear wheel EAU37851 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 1. Axle nut 1. Chain adjusting plate it falling over.

  • Page 66: Troubleshooting

    However, should your motorcycle fore installing the wheel. 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.

  • Page 67: Troubleshooting Chart

    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.

  • Page 68: Motorcycle Care And Storage, Matte Black Caution, Care

    ECA10770 matte black finished parts. Be sure CAUTION: ble. Rust and corrosion can develop to consult a Yamaha dealer for ad- even if high-quality components are Avoid using strong acidic wheel vice on what products to use before used. A rusty exhaust pipe may go un- cleaners, especially on spoked cleaning the vehicle.

  • Page 69

    MOTORCYCLE CARE AND STORAGE movers or inhibitors, brake flu- detergent, and a soft, clean sponge, on all metal, including chrome- and id, antifreeze or electrolyte. and then rinse thoroughly with clean nickel-plated, surfaces to prevent Do not use high-pressure wash- water.

  • Page 70: Storage

    2. For motorcycles equipped with a compounds as they will wear fuel cock that has an “OFF” posi- away the paint. tion: Turn the fuel cock lever to “OFF”. NOTE: 3. Drain the carburetor float chamber Consult a Yamaha dealer for advice on...

  • Page 71

    MOTORCYCLE CARE AND STORAGE by loosening the drain bolt; this will formation on storing the battery, EWA10950 prevent fuel deposits from building WARNING see page 6-25. up. Pour the drained fuel into the To prevent damage or injury from NOTE: fuel tank.

  • Page 72: Specifications

    SPECIFICATIONS Engine oil: Carburetor: EAU2633D Dimensions: Type: Manufacturer: Overall length: SAE10W30 or SAE10W40 or SAE15W40 TEIKEI 2010 mm (79.1 in) Type × quantity: or SAE20W40 or SAE20W50 Overall width: MV33 x 1 -20 -10 10 20 30 40 50 ˚C 800 mm (31.5 in) Spark plug (s): Overall height:...

  • Page 73

    SPECIFICATIONS Tire air pressure (measured on cold Rear brake: 4th: 29/28 (1.035) tires): Type: 5th: Single disc brake Loading condition: 23/28 (0.821) Operation: 0–90 kg (0–198 lb) Chassis: Right foot operation Front: Frame type: Recommended fluid: 125 kPa (18 psi) (1.25 kgf/cm Semi double cradle DOT 4 Rear:...

  • Page 74

    SPECIFICATIONS Headlight: Bulb type: Halogen bulb Bulb voltage, wattage × quantity: Headlight: 12 V, 60 W/55.0 W × 1 Tail/brake light: 12 V, 5.0 W/21.0 W × 1 Front turn signal light: 12 V, 10.0 W × 2 Rear turn signal light: 12 V, 10.0 W ×...

  • Page 75: Consumer Information, 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. KEY IDENTIFICATION NUMBER: 1.

  • Page 76

    1. Model label The model label is affixed to the frame behind panel A. (See page 6-5.) Record the information on this label in the space provided. This information will be needed when ordering spare parts from a Yamaha dealer.

  • Page 77: Table Of Contents

    INDEX Front fork, checking......... 6-24 Fuel ............3-6 Air filter element and check hose, replacing Safety information ........1-1 Fuel cock ........... 3-6 and cleaning ..........6-11 Seat............3-8 Fuel consumption, tips for reducing ..5-3 Auxiliary light bulb, replacing ....6-30 Shifting ............

  • Page 78

    INDEX Wheel bearings, checking....... 6-25 Wheel (front) ........... 6-31 Wheel (rear) ..........6-33 Wheels ............ 6-15...

  • Page 80

    YAMAHA MOTOR CO., LTD. YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED ON RECYCLED PAPER PRINTED IN JAPAN PRINTED IN JAPAN 2005.3–1.3×1 ! 2005.3–1.3×1 !

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