Yamaha XG250, Owner'S Manual

Page 1: ...4D6 28199 E0 XG250 OWNER S MANUAL ...

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Page 3: ...aha a reputation for dependability y so as to enjoy all advantages of your XG250 The owner s manual does d maintain your motorcycle but also in how to safeguard yourself and oth help keep your motorcycle in the best possible condition If you have any Yamaha dealer asant rides So remember to put safety first ...

Page 4: ...iscrepancies between your motorcycle oncerning this manual please consult your Yamaha dealer EWA10030 ND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS WARNING instructions could result in severe injury or death to the tor a bystander or a person inspecting or repairing the motorcy ates special precautions that must be taken to avoid damage to key in...

Page 5: ...RMATION EAU10200 XG250 OWNER S MANUAL 5 by Yamaha Motor Co Ltd 1st edition March 2005 All rights reserved printing or unauthorized use ut the written permission of Yamaha Motor Co Ltd s expressly prohibited Printed in Japan ...

Page 6: ...ree play 6 16 Adjusting the rear brake light switch 6 17 Checking the front and rear brake pads 6 17 Checking the brake fluid level 6 18 Changing the brake fluid 6 19 Drive chain slack 6 19 Cleaning and lubricating the drive chain 6 20 Checking and lubricating the cables 6 21 Checking and lubricating the throttle grip and cable 6 21 Checking and lubricating the brake and shift pedals 6 22 Checking...

Page 7: ...TABLE OF CONTENTS ...

Page 8: ...oid riding in another motorist s blind spot Many accidents involve inexperi enced operators In fact many op erators who have been involved in accidents do not even have a cur rent motorcycle license Make sure that you are qualified and that you only lend your mo torcycle to other qualified opera tors Know your skills and limits Staying within your limits may help you to avoid an accident We recomm...

Page 9: ... for use and ause severe personal injury ations may also make your mo torcycle illegal to use Loading and accessories Adding accessories or cargo to your motorcycle can adversely affect stabili ty and handling if the weight distribution of the motorcycle is changed To avoid the possibility of an accident use ex treme caution when adding cargo or accessories to your motorcycle Use extra care when r...

Page 10: ...pt to lift the motorcycle or he motorcycle may become un table in cross winds These ac essories may also cause instability when passing or being passed by large vehicles Certain accessories can dis place the operator from his or her normal riding position This improper position limits the free dom of movement of the opera tor and may limit control ability therefore such accessories are not recomme...

Page 11: ... ould lean over gasoline may ak out of the carburetor or fuel nk you should swallow any gaso e inhale a lot of gasoline vapor allow gasoline to get into your es see your doctor immediate If any gasoline spills on your n or clothing immediately wash e affected area with soap and ter and change your clothes ...

Page 12: ...2 1 EAU10410 3 4 2 6 5 7 ...

Page 13: ...DESCRIPTION 2 2 2 3 4 5 6 7 8 9 EAU10420 2 3 4 5 6 ...

Page 14: ...2 3 EAU10430 3 4 5 6 7 8 9 9 Fuel tank cap page 3 5 ...

Page 15: ...he OFF po on and then turn it to LOCK ile still pushing it move the key To unlock the steering Push the key into the main switch and then turn it to OFF while still pushing it WARNING EWA10060 Never turn the key to OFF or LOCK while the vehicle is moving otherwise the electrical systems will be switched off which may result in loss of control or an accident Make sure that the vehicle is stopped be...

Page 16: ...d a tripmeter The speedometer shows riding speed The odometer shows the total distance traveled The tripmeter shows the distance traveled since it was last set to zero with the reset knob The tripmeter can be used to estimate the distance that can be traveled with a full tank of fuel This information will en able you to plan future fuel stops 1 Reset knob 2 Speedometer 3 Odometer 4 Tripmeter 1 2 3...

Page 17: ...witch in after it has re to the center position EAU12500 Horn switch Press this switch to sound the horn EAU12660 Engine stop switch Set this switch to before starting the engine Set this switch to to stop the engine in case of an emergen cy such as when the vehicle overturns or when the throttle cable is stuck EAU12710 Start switch Push this switch to crank the engine with the starter CAUTION ECA...

Page 18: ...nd is used in com with the clutch lever when the gears of the 5 speed con esh transmission equipped on orcycle EAU12890 Brake lever The brake lever is located at the right handlebar grip To apply the front brake pull the lever toward the handle bar grip edal 1 1 Brake lever 1 ...

Page 19: ...ll the fuel tank cap sh and install the fuel tank cap o position with the key inserted the lock rn the key counterclockwise to e original position and then re ove it NOTE 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 WARNING EWA11140 Make sure that the fuel tank cap is properly installed bef...

Page 20: ...of a different brand ium unleaded fuel Use of un fuel will extend spark plug life uce maintenance costs EAU13560 Fuel cock The fuel cock supplies fuel from the tank to the carburetor while filtering it al so The fuel cock has three positions OFF With the lever in this position fuel will not flow Always return the lever to this position when the engine is not running commended fuel REGULAR UNLEADED...

Page 21: ...por Be sure to set the lever back to ter refueling EAU13600 Starter choke knob Starting a cold engine requires a richer air fuel mixture which is supplied by the starter choke Move the knob in direction a to turn on the starter choke Move the knob in direction b to turn off the starter choke 1 Starter choke knob 1 a b ...

Page 22: ...the helmet holder insert the key into the lock and then turn the key as shown To lock the helmet holder place it in the original position and then remove the key WARNING EWA10160 Never ride with a helmet attached to the helmet holder since the helmet may hit objects causing loss of con trol and possibly an accident tion holder 1 1 Helmet holder 2 Open 1 2 ...

Page 23: ...301 Sidestand The sidestand is located on the left side of the frame Raise the sidestand or lower it with your foot while holding the vehicle upright NOTE The built in sidestand switch is part of the ignition circuit cut off system which cuts the ignition in certain situations See further down for an explanation of the ignition circuit cut off system WARNING EWA10240 The vehicle must not be ridden...

Page 24: ...r and the side nd is up but the clutch lever is pulled revents starting when the trans sion is in gear and the clutch le is pulled but the sidestand is down uts the running engine when the nsmission is in gear and the sid and is moved down cally check the operation of the circuit cut off system according llowing procedure ARNING EWA10250 alfunction is noted have a a dealer check the system be ing ...

Page 25: ...ine The neutral switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer The sidestand switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer The clutch switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer NOTE ...

Page 26: ...osure to the elements Any damage fluid leakage or loss ces Therefore it is very important in addition to a thorough visual inspec e he vehicle is used Such an inspection can be accomplished in a very short worth the time involved EWA11150 ot working properly have it inspected and repaired before operating ...

Page 27: ...bleed hydraulic system ay or wear ry reservoir ecommended brake fluid to specified level stem for leakage 6 16 6 17 6 18 ve Yamaha dealer bleed hydraulic system or wear ry reservoir ecommended brake fluid to specified level stem for leakage 6 17 6 18 ecessary ay 6 16 ration is smooth ay Yamaha dealer adjust cable free play and lubricate cable 6 13 6 21 ...

Page 28: ...th 6 13 6 15 ation is smooth ting points if necessary 6 22 ation is smooth ing points if necessary 6 22 ation is smooth cessary 6 23 uts bolts and screws are properly tightened gnition circuit cut off system e have Yamaha dealer check vehicle 3 9 CHECKS PAGE ...

Page 29: ...to ift the transmission into the neu l position he transmission is in the neutral n the neutral indicator light should be on otherwise have a Yamaha dealer check the electrical cir cuit 4 Turn the starter choke on and completely close the throttle See page 3 7 5 Start the engine by pushing the start switch NOTE If the engine fails to start release the start switch wait a few seconds and then try a...

Page 30: ...ontrol the amount of engine power available for starting off accelerating climbing hills etc The gear positions are shown in the il lustration NOTE To shift the transmission into the neu tral position press the shift pedal down repeatedly until it reaches the end of its travel and then slightly raise it CAUTION ECA10260 Even with the transmission in 1 Shift pedal 2 Neutral position 1 1 2 3 4 5 N 2...

Page 31: ... in There is never a more important period in the life of your engine than the period between 0 and 1600 km 1000 mi For this reason you should read the follow ing material carefully Since the engine is brand new do not put an excessive load on it for the first 1600 km 1000 mi The various parts in the engine wear and polish themselves to the correct operating clearances During this period prolonged...

Page 32: ...ove from the main switch and then fuel cock lever to OFF ARNING EWA10310 ce the engine and exhaust stem can become very hot k in a place where pedestri s or children are not likely to ch them not park on a slope or on soft ound otherwise the vehicle y overturn ...

Page 33: ...erformance of preventive nance and minor repairs How dditional tools such as a torque may be necessary to perform maintenance work correctly do not have the tools or experi equired for a particular job have aha dealer perform it for you WARNING EWA10350 Modifications not approved by Yamaha may cause loss of perfor mance and render the vehicle un safe for use Consult a Yamaha dealer before attempti...

Page 34: ...d by a Yamaha dealer as they require special tools data and technical MAINTENANCE JOB ODOMETER READING 1000 km ANNUAL CHECK 1 10 20 30 40 cracks or damage ce d level and vehicle for fluid leak Whenever worn to the limit d level and vehicle for fluid leak Whenever worn to the limit damage Every 4 years tightness and for damage cessary ...

Page 35: ...n with a special O ring chain Every 500 km and after washing the motorcycle or riding in the rain and steering for roughness m soap based grease Every 50000 km uts bolts and screws are properly d for oil leakage d shock absorber for oil leakage bdenum disulfide grease e operation speed vehicle for oil leakage MAINTENANCE JOB ODOMETER READING 1000 km ANNUAL CHECK 1 10 20 30 40 ...

Page 36: ... frequently when riding in unusually wet or dusty areas the brake fluid level onents of the brake master cylinders and calipers and change the brake and if cracked or damaged free play ble free play if necessary grip housing and cable m MAINTENANCE JOB ODOMETER READING 1000 km ANNUAL CHECK 1 10 20 30 40 ...

Page 37: ...f the panels e the screw and then pull the ff To install the panel Place the panel in the original position and then install the screw Panels B and E To remove one of the panels Remove the bolt and washer and then remove the panel by sliding it forward as shown D E F 1 2 1 Screw 1 ...

Page 38: ...y 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 nance and lubrication chart In addition the condition of the spark plug can re veal the condition of the engine To remove the spark plug 1 Remove the spark plug cap 2 Remove the spark plug as shown with the spark plug wrench includ ed in t...

Page 39: ...all the spark plug with the ark plug wrench and then tight en it to the specified torque NOTE If a torque wrench is not available when installing a spark plug a good estimate of the correct torque is 1 4 1 2 turn past finger tight However the spark plug should be tightened to the speci fied torque as soon as possible 4 Install the spark plug cap ecified spark plug NGK DR7EA k plug gap ark plug gap...

Page 40: ...ise o the correct level nge the engine oil with or t oil filter element replace rt the engine warm it up for eral minutes and then turn it ce an oil pan under the engine to collect the used oil 3 Remove the engine oil filler bolt and drain bolt to drain the oil from the crankcase mum level mark um level mark e oil level check window 1 2 3 1 Engine oil filler bolt 1 ...

Page 41: ...l filter ement eps 5 7 if the oil filter element is ng replaced move the oil filter element cover removing the bolts 6 Remove and replace the oil filter element and O rings NOTE Make sure that the O rings are properly seated er element drain bolt 1 1 Bolt 2 Oil filter element cover 1 2 ...

Page 42: ...r Make sure that no foreign mate rial enters the crankcase 11 Start the engine and then let it idle for several minutes while checking it for oil leakage If oil is leaking im mediately turn the engine off and check for the cause 12 Turn the engine off and then check the oil level and correct it if necessary ening torques gine oil drain bolt 20 Nm 2 0 m kgf 14 5 ft lbf filter element drain bolt 10 ...

Page 43: ...thout the air filter ele ent installed otherwise the ston s and or cylinder s may come excessively worn stall the air filter case cover by in alling the screws 6 Install the seat To clean the air filter check hose 1 Remove panel C See page 6 5 2 Check the hose on the side of the air filter case for accumulated dirt or water 3 If dirt or water is visible remove the hose clean it and then install it...

Page 44: ...c tachometer is needed make this adjustment ach the tachometer to the spark g lead eck the engine idling speed d if necessary adjust it to spec ation by turning the throttle stop ew To increase the engine ng speed turn the screw in di tion a To decrease the en e idling speed turn the screw in ection b NOTE If the specified idling speed cannot be obtained as described above have a Yamaha dealer mak...

Page 45: ...e durabil ity and safe operation of your motorcy cle note the following points regarding the specified tires Tire air pressure The tire air pressure should be checked and if necessary adjusted before each ride WARNING EWA10500 The tire air pressure must be checked and adjusted on cold tires i e when the temperature of the tires equals the ambient temperature The tire air pressure must be ad justed...

Page 46: ...the tire has a nail or glass fragments in it or if the sidewall is cracked have a Yamaha dealer re place the tire immediately NOTE The tire tread depth limits may differ from country to country Always comply with the local regulations Tire information This motorcycle is equipped with tube tires WARNING EWA10460 The front and rear tires should be of the same make and de sign otherwise the handling ...

Page 47: ...m age before each ride If any dam age is found have a Yamaha dealer replace the wheel Do not attempt even the smallest repair to the wheel A deformed or cracked wheel must be replaced The wheel should be balanced whenever either the tire or wheel has been changed or replaced An unbalanced wheel can result in poor performance adverse han dling characteristics and a short ened tire life Ride at mode...

Page 48: ...rec n a To decrease the clutch le free play turn the adjusting nut direction b hten both locknuts EAU22092 Adjusting the brake lever free play The brake lever free play should mea sure 2 0 5 0 mm 0 08 0 20 in as shown Periodically check the brake le ver free play and if necessary adjust it as follows 1 Loosen the locknut at the brake le ver 2 To increase the brake lever free play turn the adjustin...

Page 49: ...e brake light come on later turn usting nut in direction b EAU22390 Checking the front and rear brake pads The front and rear brake pads must be checked for wear at the intervals spec ified in the periodic maintenance and lubrication chart EAU22420 Front brake pads Each front brake pad is provided with a wear indicator groove which allows you to check the brake pad wear with out having to disassem...

Page 50: ...ke pads for wear and the brake system for leakage Observe these precautions When checking the fluid level make sure that the top of the brake fluid reservoir is level Use only the recommended quality brake fluid otherwise the rubber seals may deteriorate causing leakage and poor braking perfor mance Refill with the same type of brake fluid Mixing fluids may result in a harmful chemical reaction an...

Page 51: ...rs ake hoses Replace every four ars 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 When checking and adjusting the drive chain slack there should be no weight on the motorcycle 2 Shift the transmission into the neu tral position 3 Move the rear wheel ...

Page 52: ...ica tion chart otherwise it will quickly wear out especially when riding in dusty or wet areas Service the drive chain as follows CAUTION ECA10581 The drive chain must be lubricated after washing the motorcycle and riding in the rain 1 Clean the drive chain with kero sene and a small soft brush CAUTION ECA11120 To prevent damaging the O rings do not clean the drive chain with steam cleaners high p...

Page 53: ...y have a a dealer check or replace it ARNING EWA10720 ge to the outer sheath may in with proper cable operation ill cause the inner cable to Replace a damaged cable as as possible to prevent unsafe ons EAU23111 Checking and lubricating the throttle grip and cable The operation of the throttle grip should be checked before each ride In addi tion the cable should be lubricated at the intervals speci...

Page 54: ...g the brake and clutch levers Brake lever 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 commended lubricant Lithium soap based grease all purpose grease ...

Page 55: ... lubricated if ary ARNING EWA10730 sidestand does not move up wn smoothly have a Yamaha check or repair it EAU23240 Lubricating the rear suspension The pivoting points of the rear suspen sion must be lubricated at the intervals specified in the periodic maintenance and lubrication chart ecommended lubricant Lithium soap based grease all purpose grease Recommended lubricant Molybdenum disulfide gre...

Page 56: ...ust be checked as fol lows at the intervals specified in the pe riodic maintenance and lubrication chart 1 Place a stand under the engine to raise the front wheel off the ground WARNING EWA10750 Securely support the vehicle so that there is no danger of it falling over 2 Hold the lower ends of the front fork legs and try to move them for ward and backward If any free play can be felt have a Yamaha...

Page 57: ... EAU23390 Battery The battery is located behind panel F See page 6 5 This model is equipped with a sealed type MF battery which does not require any maintenance There is no need to check the electrolyte or to add distilled water 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 discharge more qu...

Page 58: ...if cessary ly charge the battery before in lation er installation make sure that battery leads are properly con cted to the battery terminals ON ECA10630 ways keep the battery arged Storing a discharged tery can cause permanent tery damage charge a sealed type MF tery a special constant volt e battery charger is required ng a conventional battery arger will damage the battery ou do not have access...

Page 59: ... on e electrical circuits to check if the vices operate the fuse immediately blows ain have a Yamaha dealer eck the electrical system EAU37920 Replacing the headlight bulb This model is equipped with a quartz bulb headlight If the headlight bulb burns out replace it as follows 1 Remove the headlight rim by re moving the screws 2 Remove the headlight unit by re moving the screws 1 Headlight rim 2 S...

Page 60: ... to keep it free from erwise the transparency of the glass the luminosity of the bulb and the bulb life will be adversely af fected Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with al cohol or thinner 6 Connect the headlight coupler 7 Install the headlight unit by install ing the screws 8 Install the headlight rim by install ing the screws 9 Have a ...

Page 61: ...ops stall the lens by installing the rews ION ECA10680 overtighten the screws oth the lens may break EAU24202 Replacing a turn signal light bulb 1 Remove the turn signal light lens by removing the screw 2 Remove the defective bulb by pushing it in and turning it counter clockwise rake light bulb 1 1 Screw 2 Turn signal light lens 2 1 ...

Page 62: ...ve the headlight rim by re ving the screws move the headlight unit by re ving the screws 3 Remove the socket together with the bulb by pulling it out 4 Remove the defective bulb by pull ing it out 5 Insert a new bulb into the socket ght rim 2 1 Headlight unit 2 Screw 1 Auxiliary light bulb socket 2 1 1 ...

Page 63: ...is t available by placing a jack un r the frame in front of the rear eel ise the front wheel off the ound by using a motorcycle and vice the rear wheel he rear wheel off the ground by motorcycle stand or if a motor tand is not available by placing either under each side of the n front of the rear wheel or under de of the swingarm EAU24360 Front wheel EAU24580 To remove the front wheel WARNING EWA1...

Page 64: ...nsert brake disc and that the slot in edometer gear unit fits over the on the fork leg ert the wheel axle and then in l the axle nut wer the front wheel so that it is the ground hten the axle nut to the speci d torque 6 Connect the speedometer cable ner 1 Tightening torque Axle nut 85 Nm 8 5 m kgf 61 5 ft lbf ...

Page 65: ... Remove the drive chain adjusting plates 8 Remove the wheel by pulling it to the back CAUTION ECA11070 Do not apply the brake after the wheel has been removed together with the brake disc otherwise the brake pads will be forced shut EAU37860 To install the rear wheel 1 Install the drive chain adjusting plates the wheel and the brake nut n adjusting plate 2 1 a 1 Chain adjusting plate 2 Wheel axle ...

Page 66: ...oor starting and loss of power The following troubleshooting chart represents a quick and easy procedure for checking these vital systems your self 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 Use only genuine Yamaha replace ment parts Imitation parts may lo...

Page 67: ...on Check the ignition Have a Yamaha dealer check the vehicle dry cloth and correct the or replace the spark plug a dealer check the vehicle The engine does not start Have a Yamaha dealer check the vehicle The engine does not start Check the battery The battery is good Check the battery lead connections and charge the battery if necessary Open the throttle halfway and operate the electric starter ...

Page 68: ...egreasing agent and a sh but never apply such prod s onto seals gaskets sprock ets the drive chain and wheel axles Always rinse the dirt and de greaser off with water Cleaning CAUTION ECA10770 Avoid using strong acidic wheel cleaners especially on spoked wheels If such products are used on hard to remove dirt do not leave the cleaner on the af fected area any longer than in structed Also thoroughl...

Page 69: ...e corrosive action of the ply a corrosion protection spray on all metal including chrome and nickel plated surfaces to prevent corrosion After cleaning 1 Dry the motorcycle with a chamois or an absorbing cloth 2 Immediately dry the drive chain and lubricate it to prevent it from rusting 3 Use a chrome polish to shine chrome aluminum and stain less steel parts including the ex haust system Even the...

Page 70: ...it is still wet will allow water and humid ity to seep in and cause rust To prevent corrosion avoid damp cellars stables because of the presence of ammonia and areas where strong chemi cals are stored Long term Before storing your motorcycle for sev eral months 1 Follow all the instructions in the Care section of this chapter 2 For motorcycles equipped with a fuel cock that has an OFF posi tion Tu...

Page 71: ...ycle so that both of its eels are off the ground Alterna ely turn the wheels a little every onth in order to prevent the tires m becoming degraded in one ot ver the muffler outlet with a astic bag to prevent moisture m entering it emove the battery and fully arge it Store it in a cool dry ace and charge it once a month o not store the battery in an ex ssively cold or warm place ss than 0 C 30 F or...

Page 72: ... L 0 50 US gal 0 42 Imp gal Carburetor Manufacturer TEIKEI Type quantity MV33 x 1 Spark plug s Manufacturer model NGK DR7EA Spark plug gap 0 6 0 7 mm 0 024 0 028 in Clutch Clutch type Wet multiple disc Transmission Primary reduction system Spur gear Primary reduction ratio 74 24 3 083 Secondary reduction system Chain drive Secondary reduction ratio 45 15 3 000 Transmission type Constant mesh 5 spe...

Page 73: ...c brake tion ht hand operation mmended fluid T 4 Rear brake Type Single disc brake Operation Right foot operation Recommended fluid DOT 4 Front suspension Type Telescopic fork Spring shock absorber type Coil spring oil damper Wheel travel 180 0 mm 7 09 in Rear suspension Type Swingarm link suspension Spring shock absorber type Coil spring gas oil damper Wheel travel 172 0 mm 6 77 in Electrical sys...

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Page 75: ...ring a new EAU26400 Vehicle identification number The vehicle identification number is stamped into the steering head pipe Record this number in the space pro vided NOTE The vehicle identification number is used to identify your motorcycle and may be used to register your motorcy cle with the licensing authority in your area dentification number 1 Vehicle identification number 1 ...

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Page 77: ...rmation 1 1 Seat 3 8 Shifting 5 2 Shift pedal 3 4 Shock absorber 3 9 Sidestand 3 9 Sidestand checking and lubricating 6 23 Spark plug checking 6 6 Specifications 8 1 Speedometer unit 3 2 Starter choke knob 3 7 Starting a cold engine 5 1 Start switch 3 3 Steering checking 6 24 Storage 7 3 Storage pouch 3 9 Supporting the motorcycle 6 31 T Tail brake light bulb replacing 6 29 Throttle cable free pla...

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