Yamaha XV250 1988-2008 Service Repair Workshop Manual

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The XV250 Virago, also known as the Virago 250, is a classic cruiser motorcycle that debuted as part of the first generation XV250 series. Produced from 1988 through 2008, this...

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Typ: Motorcycle

Anbieter:

Art.-Nr: 57996

Stichworte: 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 Misc Motorcycle Motorcycles XV250 Yamaha

Produktvarianten

Beschreibung

The XV250 Virago, also known as the Virago 250, is a classic cruiser motorcycle that debuted as part of the first generation XV250 series. Produced from 1988 through 2008, this model is celebrated for its accessible V-twin engine, providing a characteristic sound and smooth power delivery. Its design features classic cruiser aesthetics, including a low seat height, teardrop fuel tank, and chrome accents, making it an attractive option for riders seeking timeless styling. The XV250 Virago was positioned as an entry-level motorcycle, competing with other 250cc cruisers by offering a user-friendly riding experience, manageable power, and the low-maintenance benefit of a shaft drive system. This comprehensive Service Repair Workshop Manual for the XV250 Virago (XV250 chassis code) covers models from 1988 to 2008. It is designed to assist owners, mechanics, and technicians in maintaining and repairing the motorcycle. The manual details various systems, including the engine mechanicals, fuel system, ignition, transmission, drivetrain, chassis, braking, electrical, and bodywork. It provides step-by-step procedures for scheduled maintenance, troubleshooting, and complete repairs, such as engine and transmission overhauls, electrical diagnostics, and carburetor tuning. The manual also includes essential technical specifications, torque values, fluid requirements, and diagnostic information to ensure the vehicle is kept in optimal condition.

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

XV250 Virago

Nickname:

Virago 250

Generation

Model Generation:

First Generation (XV250)

Codes

Chassis Code:

XV250

👋 Introduction

Market Position

Positioning:

The Yamaha XV250 Virago was positioned as an entry-level cruiser, offering classic styling and a manageable engine for new riders or those seeking a relaxed riding experience.

Competitive Analysis

Competitors:

Competed with other 250cc class cruisers from brands like Honda (e.g., Shadow 250), Kawasaki (e.g., Eliminator 250), and Suzuki (e.g., Intruder 250).

Key Features

Engine Configuration:

V-twin engine providing characteristic cruiser styling and sound.

Styling:

Classic cruiser aesthetics with a low seat height, teardrop fuel tank, and ample chrome accents.

Drivetrain:

Shaft drive for low maintenance compared to chain drive systems.

Accessibility:

User-friendly for beginners, with manageable power delivery and approachable ergonomics.

📋 Manual Details

Coverage Areas

Years Covered:

1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008

Page Count

Estimated Pages:

Approximately 300-400 pages (typical for a comprehensive service manual)

Manual Type

Type:

Service Repair Workshop Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine disassembly, assembly, inspection, tuning, valve clearance adjustment, piston and cylinder inspection, crankshaft and connecting rod checks.

Fuel System:

Carburetor identification, disassembly, cleaning, adjustment, fuel pump operation, fuel filter replacement.

Ignition System:

CDI unit testing, spark plug specifications, ignition coil testing, timing adjustment (if applicable).

Transmission Drivetrain:

Clutch operation, clutch plate inspection and replacement, gear shifting mechanism, transmission gear inspection and repair, final drive (shaft drive) maintenance.

Chassis Frame:

Frame inspection, steering head bearing maintenance and replacement, fork overhaul, shock absorber specifications and testing.

Braking System:

Front and rear brake caliper maintenance, brake pad inspection and replacement, brake fluid replacement, brake line inspection, master cylinder overhaul.

Electrical System:

Wiring diagrams, battery testing and maintenance, starter motor operation, charging system (alternator/stator testing), lighting system troubleshooting, fuse box layout.

Wheels Tires:

Wheel bearing inspection and replacement, tire pressure recommendations, wheel balancing, rim specifications.

Exhaust System:

Exhaust pipe and muffler inspection, gasket replacement.

Bodywork Trim:

Fairing removal and installation, seat removal, fender inspection.

Procedures Included

Scheduled Maintenance:

Oil change intervals, filter replacement schedules, spark plug replacement, air filter cleaning/replacement, brake fluid flush, coolant replacement (if applicable), lubrication points.

Troubleshooting Diagnostics:

Step-by-step troubleshooting guides for common performance issues, electrical faults, starting problems, and braking system anomalies.

Engine Repair:

Complete engine rebuild procedures, piston ring replacement, valve seat grinding, camshaft replacement.

Transmission Repair:

Gearbox disassembly and reassembly, clutch adjustment and replacement, transmission bearing replacement.

Electrical Diagnosis:

Fault finding for lighting, charging, and starting systems using wiring diagrams and test procedures.

Carburetor Tuning:

Detailed instructions for idle speed adjustment, mixture control, and synchronization (if applicable).

Brake Servicing:

Brake pad replacement, caliper servicing, brake fluid bleeding and flushing.

Suspension Fork Rebuild:

Front fork seal replacement, oil level and type specifications, damping adjustment.

Technical Depth

Depth:

Comprehensive: Covers basic maintenance to complete engine and transmission rebuilds, electrical system diagnostics, and chassis component overhauls.

Diagnostic Tools:

Specifies required tools for diagnosis and repair, including torque wrenches, multimeter, feeler gauges, and specialized service tools.

Specifications Data:

Includes detailed specifications for all major components, torque values, tolerances, fluid capacities, and electrical values.

📊 Manual Specifications

File Format

Format:

Searchable Text:

Likely searchable due to PDF format, allowing for quick information retrieval.

Print Quality

Quality:

High-resolution, clear diagrams and text suitable for printing.

Binding Type

Binding:

N/A (Digital Download - PDF)

Paper Type

Paper:

N/A (Digital Download - PDF)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Air-cooled, 4-stroke, 45-degree V-twin

Displacement:

249 cc (248.8 cc)

Bore X Stroke:

49.0 mm x 66.0 mm

Compression Ratio:

10.0:1

Valve Train:

SOHC, 2 valves per cylinder

Performance

Horsepower:

Approximately 20-22 hp @ 7,500 rpm (varies slightly by year and market)

Torque:

Approximately 18-20 Nm (13-15 lb-ft) @ 6,000 rpm (varies slightly by year and market)

Fuel System

Fuel Delivery:

Carbureted (typically Mikuni BS26 twin carburetors)

Fuel Tank Capacity:

Approximately 9.2 Liters (2.4 US gallons)

🔧 Transmission

Standard

Transmission Type:

5-speed constant mesh

Clutch Type:

Wet, multiple disc, cable operated

Final Drive:

Shaft drive

Features

Gear Ratios:

Specific gear ratios are detailed within the manual for each gear.

Transmission Oil Type:

Yamaha recommends specific motorcycle gear oil; refer to manual for exact specifications (e.g., SAE 80 or 90)

📐 Dimensions

Exterior

Length:

Approximately 2,185 mm (86.0 in)

Width:

Approximately 785 mm (30.9 in)

Height:

Approximately 1,100 mm (43.3 in)

Wheelbase:

Approximately 1,490 mm (58.7 in)

Seat Height:

Approximately 705 mm (27.8 in)

Weights

Dry Weight:

Approximately 148 kg (326 lbs)

Wet Weight:

Approximately 157 kg (346 lbs) (with all fluids)

Gross Vehicle Weight Rating:

Refer to manual for specific GVWR.

🛡️ Safety Features

Ratings

Safety Standards:

Conforms to applicable safety standards for its class and era; specific crash test ratings are not generally applicable to motorcycles in the same way as cars.

Active Features

Braking System:

Front disc brake, rear drum brake (some later models may have offered front ABS as an option, though less common on the XV250).

Passive Features

Frame Construction:

Steel cradle frame providing rigidity and rider support.

Lighting:

Headlight, taillight, turn signals for visibility.

💡 Technology Features

Infotainment

Infotainment System:

N/A (This model predates modern integrated infotainment systems.)

Driver Assistance

Anti-lock Braking System (ABS) was not standard and rarely an option on this model. The manual will focus on traditional braking systems.

Connectivity

Connectivity Features:

N/A (No electronic connectivity features).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 3,000-5,000 km (1,800-3,000 miles) or every 6 months, whichever comes first. Refer to manual for precise interval.

Air Filter Cleaning:

Recommended inspection every 3,000 km (1,800 miles), cleaning/replacement as needed based on conditions.

Spark Plug Replacement:

Typically at 10,000-12,000 km (6,000-7,500 miles) or as indicated by wear. Manual will specify exact interval and spark plug type (e.g., NGK DPR7EA-9).

Brake Fluid Replacement:

Recommended every 2 years or 20,000 km (12,000 miles) to prevent contamination and maintain braking performance. Use DOT 4 fluid.

Fluid Specifications

Engine Oil Type:

Yamalube 4 (or equivalent API SG, JASO MA certified 10W-40 or 20W-50 motorcycle oil). Consult manual for precise viscosity based on ambient temperature.

Engine Oil Capacity:

Approximately 1.4 Liters (1.5 US quarts) without filter change, 1.6 Liters (1.7 US quarts) with filter change.

Brake Fluid Type:

DOT 4

Known Issues

Carburetor Performance:

Carburetors can sometimes become clogged with age or infrequent use, leading to poor idle or performance issues. Regular cleaning and adjustment are key.

Starter Clutch:

Some models may experience wear in the starter clutch mechanism, leading to a grinding noise or failure to crank the engine. This is a known repair item detailed in the manual.

Shaft Drive Maintenance:

While low maintenance, the shaft drive spline lubrication should be checked periodically as per the manual's recommendations to prevent wear and seizure.

Valve Adjustment Frequency:

Valve clearance should be checked and adjusted according to the manual's recommended intervals (typically every 10,000-12,000 km) to ensure optimal performance and prevent valve damage.

📚 Vehicle History

Brand Heritage

Yamaha Motors Legacy:

Yamaha Motor Corporation, a subsidiary of Yamaha Corporation, has a long and storied history in motorcycle manufacturing, known for innovation, performance, and reliability across various segments.

Model Evolution

Virago Lineage:

The XV250 Virago is part of Yamaha's popular Virago line of V-twin cruisers, which spanned various displacements and were known for their classic styling and accessible nature.

Production

Production Years Model:

The XV250 Virago was produced for a significant period, from its introduction in the mid-1980s through the late 2000s, indicating its enduring appeal and market success.

Manufacturing Locations:

Primarily manufactured in Japan, with potential assembly in other regions depending on market specificities.

🏆 Awards & Recognition

Recognitions

Awards And Accolades:

While specific awards are not widely documented, the XV250 Virago was recognized for its value, comfort, and stylish design within the entry-level cruiser market, contributing to its long production run and popularity.