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Read this manual carefully before operating this vehicle. OWNER’S MANUAL XV250Z(C) LIT-11626-23-21 46B-28199-11...
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EAU10042 Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold.
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Yamaha has met these standards without reducing the performance or economy of operation of the motorcycle. To maintain these high standards, it is important that you and your Yamaha dealer pay close attention to the recommended maintenance schedules and operating instructions contained within this manual.
IMPORTANT MANUAL INFORMATION EAU10132 Particularly important information is distinguished in this manual by the following notations: This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.
TABLE OF CONTENTS LOCATION OF IMPORTANT FOR YOUR SAFETY – Tires ..........7-16 LABELS ..........1-1 PRE-OPERATION CHECKS ..... 5-1 Spoke wheels ......7-18 Adjusting the clutch lever SAFETY INFORMATION ....2-1 OPERATION AND IMPORTANT free play ........7-18 RIDING POINTS......... 6-1 Adjusting the brake lever DESCRIPTION ........3-1 Starting and warming up...
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U.S.A. STREET AND Replacing the headlight bulb ..7-32 ENDURO MOTORCYCLE Replacing the tail/brake light LIMITED WARRANTY ....10-7 bulb ...........7-33 YAMAHA EXTENDED SERVICE Replacing a turn signal light (Y.E.S.) ........10-9 bulb ...........7-34 Supporting the motorcycle ....7-35 Front wheel ........7-35 Rear wheel ........7-37...
Read and understand all of the labels on your vehicle. They contain important information for safe and proper operation of your vehicle. Never remove any labels from your vehicle. If a label becomes difficult to read or comes off, a replacement label is available from your Yamaha dealer.
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LOCATION OF IMPORTANT LABELS California only NOTICE California only 10D-2815N-00 Cold tire normal pressure should be set as follows. 1.75 2.00 2.00 2.25 3CK-21668-A1...
SAFETY INFORMATION EAU10283 Safe Riding • Ride where other motorists can Perform the pre-operation checks each see you. Avoid riding in another time you use the vehicle to make sure it motorist’s blind spot. Be a Responsible Owner is in safe operating condition. Failure to Many accidents involve inexperi- As the vehicle’s owner, you are respon- inspect or maintain the vehicle properly...
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SAFETY INFORMATION due to excessive speed or under- This motorcycle is designed for on- A passenger should also observe cornering (insufficient lean angle road use only. It is not suitable for the above precautions. for the speed). off-road use. • Always obey the speed limit and Avoid Carbon Monoxide Poisoning never travel faster than warrant- Protective apparel...
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Yamaha accessories, which are avail- Shifting weights can create a sud- accessories to your motorcycle. Use able only from a Yamaha dealer, have den imbalance. Make sure that ac- extra care when riding a motorcycle been designed, tested, and approved cessories and cargo are securely that has added cargo or accessories.
SAFETY INFORMATION modifications not specifically recom- clearance or cornering clearance, tor and may limit control ability, mended by Yamaha, even if sold and limit suspension travel, steering therefore, such accessories are installed by a Yamaha dealer. travel or control operation, or ob- not recommended.
INSTRUMENT AND CONTROL FUNCTIONS EAU10450 EWA10072 EAU10981 Main switch Indicator lights WARNING Never turn the key to “OFF” while the vehicle is moving, otherwise the electrical systems will be switched off, which may result in loss of con- trol or an accident. EAU10810 P (Parking) The taillight and position lights are on,...
INSTRUMENT AND CONTROL FUNCTIONS EAU11090 EAU11630 EAU12348 Speedometer unit Handlebar switches High beam indicator light “HIGH BEAM” Left This indicator light comes on when the high beam of the headlight is switched 1. Odometer 2. Tripmeter 1. Dimmer switch “LIGHTS” 3.
INSTRUMENT AND CONTROL FUNCTIONS EAU12410 EAU12691 EAU12820 Clutch lever Dimmer switch “LIGHTS” Start switch “START” Set the switch to “HI” for the high beam Push this switch to crank the engine and to “LO” for the low beam. with the starter. See page 6-1 for start- ing instructions prior to starting the en- gine.
INSTRUMENT AND CONTROL FUNCTIONS EAU12870 EAU12890 EAU12941 Shift pedal Brake lever Brake pedal 1. Shift pedal 1. Brake lever 1. 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 of side of the engine and is used in com- handlebar grip.
INSTRUMENT AND CONTROL FUNCTIONS EAU13041 EAU13212 Fuel tank cap Fuel The fuel tank cap cannot be closed un- Make sure there is sufficient gasoline in less the key is in the lock. In addition, the tank. the key cannot be removed if the cap is EWA10881 WARNING not properly closed and locked.
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Gasoline is poisonous and can as well as to the exhaust system. cause injury or death. Handle gaso- Your Yamaha engine has been de- line with care. Never siphon gaso- signed to use regular unleaded gaso- line by mouth. If you should swallow...
INSTRUMENT AND CONTROL FUNCTIONS EAU13581 Fuel cock This model is equipped with a negative pressure fuel cock. The fuel cock sup- plies fuel from the tank to the carburetor while also filtering it. The fuel cock lever positions are ex- plained as follows and shown in the il- lustrations.
INSTRUMENT AND CONTROL FUNCTIONS EAU13630 EAU13730 To unlock the steering Starter (choke) lever Steering lock 1. Open the steering lock cover, and then insert the key. 2. Push the key in, turn it 1/8 turn counterclockwise so that it moves out, and then release it.
INSTRUMENT AND CONTROL FUNCTIONS EAU14220 EAU14282 Rider seat Helmet holder To remove the rider seat Remove the bolts, and then pull the rid- er seat off. 1. Projection 2. Seat holder 1. Helmet holder 2. Place the rider seat in the original 2.
INSTRUMENT AND CONTROL FUNCTIONS below and have a Yamaha dealer re- EAU48240 Ignition circuit cut-off system pair it if it does not function proper- The ignition circuit cut-off system (com- prising the sidestand switch, clutch switch and neutral switch) has the fol- lowing functions.
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WARNING With the engine turned off: 1. Move the sidestand down. If a malfunction is noted, have a Yamaha 2. Make sure that the engine stop switch is set to “RUN”. dealer check the system before riding. 3. Turn the key on.
• If necessary, add recommended oil to specified level. 7-10 • Check vehicle for oil leakage. • Check operation. • If soft or spongy, have Yamaha dealer bleed hydraulic system. • Check lever free play. • Adjust if necessary. Front brake •...
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• Make sure that operation is smooth. • Check cable free play. Throttle grip 7-15, 7-26 • If necessary, have Yamaha dealer adjust cable free play and lubricate cable and grip housing. • Make sure that operation is smooth. Control cables 7-26 •...
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FOR YOUR SAFETY – PRE-OPERATION CHECKS ITEM CHECKS PAGE • Check fluid level. Battery 7-30 • Fill with distilled water if necessary.
(choke) turned off. To avoid the possi- neutral indicator light should come bility of excessive exhaust emissions, on. If not, ask a Yamaha dealer to never leave the starter (choke) on long- check the electrical circuit. er than necessary. The time necessary 4.
OPERATION AND IMPORTANT RIDING POINTS (choke) turned on, then about 2.5 min- EAU16640 EAU16671 Starting a warm engine Shifting utes with the starter (choke) in the half- Follow the same procedure as for start- way position. ing a cold engine with the exception that the starter (choke) is not required when the engine is warm.
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OPERATION AND IMPORTANT RIDING POINTS ECA10260 4. At the recommended shift points 3. Shift the transmission into the neu- NOTICE shown in the following table, close tral position when the motorcycle the throttle, and at the same time, is almost completely stopped. The Even with the transmission in quickly pull the clutch lever in.
Since the engine is brand new, do not Since the engine and exhaust immediately have a Yamaha dealer put an excessive load on it for the first system can become very hot, check the vehicle.
• Replace gasket(s) if necessary. Evaporative emis- • Check control system for dam- √ √ sion control system age. (for California only) • Replace if necessary. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.
PERIODIC MAINTENANCE AND ADJUSTMENT EAU32164 General maintenance and lubrication chart INITIAL ODOMETER READINGS 600 mi 4000 mi 7000 mi 10000 mi 13000 mi 16000 mi ITEM ROUTINE (1000 km) (6000 km) (11000 km) (16000 km) (21000 km) (26000 km) 1 month 6 months 12 months 18 months...
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• Check chain slack, alignment and condition. Drive chain • Adjust and thoroughly lubricate Every 300 mi (500 km) and after washing the motorcycle or riding in the rain chain with Yamaha chain and ca- ble lube. • Check bearing assemblies for looseness. √...
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√ √ √ √ √ √ 24 * • Check operation. switches Control and meter • Apply Yamaha chain and cable √ √ √ √ √ √ 25 * cables lube or engine oil thoroughly. • Check operation and free play.
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• Adjust headlight beam. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. From 19000 mi (31000 km) or 36 months, repeat the maintenance intervals starting from 7000 mi (11000 km) or 12 months.
PERIODIC MAINTENANCE AND ADJUSTMENT EAU18751 EAU19545 Removing and installing the Checking the spark plugs panel The spark plugs are important engine components, which are easy to check. The panel shown needs to be removed Since heat and deposits will cause any to perform some of the maintenance spark plug to slowly erode, the spark jobs described in this chapter.
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If any spark plug shows a distinctly dif- 1. Spark plug gap ferent color, the engine could be oper- ating improperly. Do not attempt to Spark plug gap: diagnose such problems yourself. In- 0.6–0.7 mm (0.024–0.028 in) stead, have a Yamaha dealer check the vehicle.
PERIODIC MAINTENANCE AND ADJUSTMENT EAU19681 Make sure that the canister breath- EAU42103 Canister (for California only) Engine oil and oil filter ele- er is not blocked, and if necessary, ment clean it. The engine oil level should be checked before each ride. In addition, the oil must be changed and the oil filter ele- ment replaced at the intervals specified in the periodic maintenance and lubri-...
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PERIODIC MAINTENANCE AND ADJUSTMENT 1. Engine oil level check window 1. Engine oil filler cap 1. Screw 2. Maximum level mark 2. Oil filter element cover 3. Minimum level mark 5. Remove and replace the oil filter 4. If the engine oil is below the mini- element and O-ring.
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PERIODIC MAINTENANCE AND ADJUSTMENT 9. Start the engine, and then let it idle Tightening torque: Recommended engine oil: for several minutes while checking Oil filter element cover screw: See page 9-1. it for oil leakage. If oil is leaking, im- 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Oil quantity: With oil filter element replacement:...
PERIODIC MAINTENANCE AND ADJUSTMENT EAU32738 3. Remove the air filter case cover by Cleaning the air filter element removing the screws. The air filter element should be cleaned or replaced at the intervals specified in the periodic maintenance and lubrica- tion chart.
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12. Install the air filter case bolts. The air filter element should be wet but not dripping. Recommended oil: Yamaha foam air filter oil or other quality foam air filter oil 7. Pull the sponge material over the 1. Sponge material air filter element frame.
1. Throttle cable free play The throttle cable free play should mea- sure 3.0–5.0 mm (0.12–0.20 in) at the throttle grip. Periodically check the throttle cable free play and, if neces- sary, have a Yamaha dealer adjust it. 7-15...
Rear: from occurring, the valve clearance the specified tires. 200 kPa (2.00 kgf/cm², 29 psi) must be adjusted by a Yamaha dealer XV250Z 90–196 kg (198–432 lb) at the intervals specified in the periodic Tire air pressure XV250ZC 90–195 kg (198–430 lb): maintenance and lubrication chart.
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After extensive tests, only the tires list- and brake-related parts, includ- ed below have been approved for this ing the tires, should be left to a model by Yamaha Motor Co., Ltd. Yamaha dealer, who has the 1. Tire sidewall necessary professional knowl- 2.
4. Rubber cover age before each ride. If any dam- age is found, have a Yamaha The clutch lever free play should mea- dealer replace the wheel. Do not sure 10.0–15.0 mm (0.39–0.59 in) as attempt even the smallest repair to shown.
PERIODIC MAINTENANCE AND ADJUSTMENT 3. To increase the clutch lever free 6. To increase the clutch lever free EAU22093 Adjusting the brake lever free play, turn the adjusting bolt in di- play, turn the adjusting nut in direc- play rection (a). To decrease the clutch tion (a).
1. Locknut EWA10670 which may result in loss of con- WARNING 2. Brake pedal position adjusting bolt trol and an accident. It is advisable to have a Yamaha 3. Tighten the locknut. dealer make these adjustments. EWA11230 WARNING Brake pedal position...
The brake pedal free play should mea- obtained as described, have a switch sure 20.0–30.0 mm (0.79–1.18 in) at Yamaha dealer make this ad- the brake pedal end. Periodically check justment. the brake pedal free play and, if neces- After adjusting the brake pedal sary, adjust it as follows.
When checking the fluid level, the wear indicator groove. If a brake the wear limit line, have a Yamaha make sure that the top of the mas- pad has worn to the point that the wear...
EAU22760 Changing the brake fluid Drive chain slack brake fluid, otherwise the rubber Have a Yamaha dealer change the The drive chain slack should be seals may deteriorate, causing brake fluid at the intervals specified in checked before each ride and adjusted...
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PERIODIC MAINTENANCE AND ADJUSTMENT 2. Remove the cotter pin from the axle nut, and then loosen the axle nut. 3. Loosen the chain puller locknut at each end of the swingarm. 4. To tighten the drive chain, turn the drive chain slack adjusting nut at each end of the swingarm in direc- tion (a).
(See page 7-20.) EWA10660 For a thorough cleaning, have a WARNING Yamaha dealer remove the drive chain After adjusting the brake pedal free and soak it in solvent. play, check the operation of the 2. Spray Yamaha Chain and Cable brake light.
If a cable is damaged maintenance chart. or does not move smoothly, have a Yamaha dealer check or replace it. WARNING! Damage to the outer housing of cables may result in in- ternal rusting and cause interfer- ence with cable movement.
PERIODIC MAINTENANCE AND ADJUSTMENT EAU23142 Recommended lubricant: Recommended lubricants: Checking and lubricating the Lithium-soap-based grease Brake lever: brake and clutch levers Silicone grease Clutch lever: Brake lever Lithium-soap-based grease Clutch lever The operation of the brake and clutch levers should be checked before each ride, and the lever pivots should be lu- bricated if necessary.
WARNING push down hard on the handlebars If the sidestand does not move up several times to check if the front and down smoothly, have a Yamaha fork compresses and rebounds dealer check or repair it. Otherwise, smoothly. the sidestand could contact the ground and distract the operator, re- sulting in a possible loss of control.
PERIODIC MAINTENANCE AND ADJUSTMENT EAU23312 working near batteries. In case Battery of contact, administer the fol- A poorly maintained battery will corrode lowing FIRST AID. and discharge quickly. The electrolyte • EXTERNAL: Flush with plenty level, battery lead connections and of water.
PERIODIC MAINTENANCE AND ADJUSTMENT 3. Fully charge the battery before in- EAU23601 Replacing the fuses stallation. 4. After installation, make sure that the battery leads are properly con- nected to the battery terminals and that the breather hose is properly routed, in good condition, and not obstructed.
4. If the fuse immediately blows Headlight bulb 1. Do not touch the glass part of the bulb. again, have a Yamaha dealer Do not touch the glass part of check the electrical system. the headlight bulb to keep it free 1.
6. Install the headlight unit by install- 1. Remove the tail/brake light lens by ing the screws. removing the screws. 7. Have a Yamaha dealer adjust the headlight beam if necessary. 1. Headlight coupler 2. Headlight bulb cover 3. Remove the headlight bulb holder by turning it counterclockwise, and then remove the burnt-out bulb.
PERIODIC MAINTENANCE AND ADJUSTMENT EAU24212 Replacing a turn signal light bulb 1. Remove the turn signal lens by re- moving the screws. 1. Tail/brake light bulb 1. Turn signal light bulb 3. Insert a new bulb into the socket, 3. Insert a new bulb into the socket, push it in, and then turn it clock- push it in, and then turn it clock- wise until it stops.
PERIODIC MAINTENANCE AND ADJUSTMENT EAU24350 a jack either under each side of the EAU24360 Supporting the motorcycle Front wheel frame in front of the rear wheel or under Since this model is not equipped with a each side of the swingarm. centerstand, follow these precautions EAU24601 To remove the front wheel...
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PERIODIC MAINTENANCE AND ADJUSTMENT 1. Wheel axle 1. Speedometer gear unit 1. Speedometer gear unit 2. Front wheel axle pinch bolt 2. Retainer 2. Lift the wheel up between the fork 3. Speedometer cable 3. Lift the front wheel off the ground legs.
PERIODIC MAINTENANCE AND ADJUSTMENT 7. While applying the front brake, EAU25080 3. Loosen the axle nut and the brake Rear wheel push down hard on the handlebars torque rod nut at the brake shoe several times to check if the front plate.
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PERIODIC MAINTENANCE AND ADJUSTMENT 7. Push the wheel forward, and then 6. Tighten the brake torque rod nut to remove the drive chain from the the specified torque. rear sprocket. Tightening torque: Brake torque rod nut: The drive chain does not need to be 23 Nm (2.3 m·kgf, 17 ft·lbf) disassembled in order to remove and 7.
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 plugs 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.
Some models are equipped with ble. Rust and corrosion can develop matte colored finished parts. Be Cleaning sure to consult a Yamaha dealer for even if high-quality components are ECA10772 advice on what products to use be- used. A rusty exhaust pipe may go un-...
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MOTORCYCLE CARE AND STORAGE off any detergent residue using Test the product on a small hid- plenty of water, as it is harmful den part of the windshield to Salt sprayed on roads in the winter may to plastic parts. make sure that it does not leave remain well into spring.
WARNING To prevent corrosion, avoid Contaminants on the brakes or tires Consult a Yamaha dealer for ad- damp cellars, stables (because can cause loss of control. vice on what products to use. of the presence of ammonia)
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MOTORCYCLE CARE AND STORAGE 3. Drain the carburetor float cham- spark plug electrodes while °C (90 °F)]. For more information bers by loosening the drain bolts; turning the engine over. on storing the battery, see page this will prevent fuel deposits from 7-30.
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.
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This information illustration. This label shows specifica- will be needed when ordering spare tions related to exhaust emissions as parts from a Yamaha dealer. required by federal law, state law and Environment Canada. 10-2...
If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Yamaha Motor Corporation, U.S.A. If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign.
CONSUMER INFORMATION EAU26560 Motorcycle noise regulation TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or element of design incorporated into any new ve- hicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.
CONSUMER INFORMATION EAU26611 Maintenance record Copies of work orders and/or receipts for parts purchased and installed on your motorcycle will be required to document that maintenance has been completed in accordance with the emissions warranty. The chart below is printed only as a reminder that maintenance work is required.
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CONSUMER INFORMATION Maintenance Date of Servicing dealer Mileage Remarks interval service name and address 28000 mi (46000 km) or 54 months 31000 mi (51000 km) or 60 months 10-6...
CONSUMER INFORMATION EAU26663 YAMAHA MOTOR CORPORATION, U.S.A. STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY Yamaha Motor Corporation, U.S.A. hereby warrants that CUSTOMER’S RESPONSIBILITY under this Engine new Yamaha motorcycles will be free from defects in warranty shall be to: Displacement Period...
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CUSTOMER SERVICE What costs are my responsibility during the warranty period? If your machine requires warranty service, you must take it to any authorized Yamaha The customer’s responsibility includes all costs of normal maintenance services, motorcycle dealer within the continental United States. Be sure to bring your warranty non-warranty repairs, accident and collision damages, and oil, oil filters, air filters, registration card or other valid proof of the original date of purchase.
This excellent Y.E.S. plan coverage is only available to dealer to see how comforting uninterrupted factory- Yamaha owners like you, and only while your Yamaha is still backed protection can be. within the Yamaha Limited Warranty period. So visit your authorized Yamaha dealer to get all the facts.
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Yamaha Limited Warranty expires. A special note: If visiting your dealer isn’t convenient, contact Yamaha with your Primary ID number (your frame number). We’ll be happy to help you get the Y.E.S. coverage you need.
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INDEX Air filter element, cleaning ....7-13 Front fork, checking.......7-28 Rear brake light switch, adjusting ..7-21 Fuel ............4-5 Rider seat ..........4-9 Fuel cock..........4-7 Battery ..........7-30 Fuel tank cap...........4-5 Brake and clutch levers, Safety defects, reporting....... 10-3 Fuses, replacing........7-31 checking and lubricating.....
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INDEX Turn signal light bulb, replacing .... 7-34 Turn signal switch ........4-3 Valve clearance ........7-16 Vehicle Emission Control Information label ......... 10-2 Vehicle identification number ....10-1 Warranty, extended....... 10-9 Warranty, limited ........10-7 Wheel bearings, checking..... 7-29 Wheel (front) .........
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YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2009.05-0.6×1 CR...