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Yamaha Virago 250 Service Repair Workshop Manual 1989-2005

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🏷️ Basic Information Identification Make: Yamaha Model: Virago 250 Model Code: XV250 Generation Model Generation: First Generation Codes Vin Code: JYA codes for Japan, 5A4 for international markets 👋 Introduction...
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Taper: Motorcycle
Distributeur:
UGS: 259982
Yamaha Virago 250 Service Repair Workshop Manual 1989-2005
🏷️ Basic Information
Identification
Make:
Yamaha
Model:
Virago 250
Model Code:
XV250
Generation
Model Generation:
First Generation
Codes
Vin Code:
JYA codes for Japan, 5A4 for international markets
👋 Introduction
Market Position
Segment:
Cruiser/Custom Motorcycle
Target Audience:
Entry-level riders, custom enthusiasts, those seeking a classic cruiser experience.
Competitive Analysis
Key Competitors:
Honda Rebel 250, Kawasaki Vulcan 500 (though slightly larger displacement), Suzuki GZ250 Marauder.
Unique Selling Points:
Classic V-twin styling in a smaller, accessible package; reliable Yamaha engineering; customization potential.
Key Features
Manual Value Proposition:
Provides technicians and owners with the detailed, specific information required to maintain, diagnose, and repair the Yamaha Virago 250 effectively, replicating factory service procedures.
📋 Manual Details
Coverage Areas
Covered Years:
1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005
Covered Models:
All Virago 250 (XV250) variants
Geographic Coverage:
Covers specifications and procedures applicable to all global markets for the specified years.
Page Count
Estimated Page Count:
300-500
Manual Type
Manual Type:
Service Repair Workshop Manual
Authenticity:
OEM-equivalent factory service manual
Language
Language:
English
Format
Format:
Digital (PDF - INSTANT DOWNLOAD)
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine overhaul, cylinder head, valve train, piston, connecting rod, crankshaft, oil pump, lubrication system, cooling system (air-cooled), ignition system, fuel system (carburetor), exhaust system.
Transmission Drivetrain Systems:
Clutch, gearbox, final drive (chain), shifting mechanism.
Chassis Suspension Systems:
Frame, front fork (telescopic), rear suspension (swingarm, dual shock absorbers), steering system.
Braking Systems:
Front disc brake, rear drum brake, brake fluid, hydraulic lines, caliper/drum maintenance.
Electrical Systems:
Battery, charging system (alternator, regulator/rectifier), starting system (starter motor, solenoid), lighting (headlight, taillight, turn signals), instrumentation, ignition coils, wiring diagrams.
Fuel System:
Carburetor (Mikuni VM series), fuel tank, fuel petcock, fuel filter.
Bodywork Fittings:
Fenders, fuel tank, seat, handlebars, controls, footpegs, exhaust pipes, chrome trim.
Procedures Included
Maintenance Procedures:
Oil changes, filter replacement, spark plug checks/replacement, chain adjustment/lubrication, brake fluid flush, air filter cleaning/replacement, carburetor synchronization and cleaning.
Diagnostic Procedures:
Troubleshooting charts for common problems, engine performance diagnostics, electrical system fault finding.
Repair Procedures:
Complete engine disassembly and reassembly, carburetor rebuild, clutch replacement, fork seal replacement, wheel bearing service, electrical component replacement.
Technical Specifications:
Torque specifications for all fasteners, engine timings, clearances, fluid capacities, electrical component specifications.
Suspension Adjustments:
Front fork oil level and viscosity recommendations; rear shock pre-load adjustment (if applicable).
Wheel Tire Service:
Tire pressure specifications, tire inspection, wheel removal and installation, spoke tensioning (if applicable).
Technical Depth
Depth Of Coverage:
Comprehensive: Covers all aspects from basic owner maintenance to complete engine and chassis overhauls, suitable for professional technicians and experienced DIY enthusiasts.
Diagnostic Tools Required:
Basic hand tools, torque wrench, feeler gauges, multimeter, carburetor synchronization tool (optional but recommended).
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Likely text-searchable (OCR)
Print Quality
Printability:
High-quality for printing key sections or the entire manual
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
4-stroke, V-twin, SOHC
Displacement:
248 cc (15.1 cu. in.)
Bore X Stroke:
49.0 x 66.0 mm
Compression Ratio:
10.0:1
Cooling System:
Air-cooled
Valve Actuation:
SOHC, 2 valves per cylinder
Valve Clearance Intake:
0.06 - 0.11 mm (Cold)
Valve Clearance Exhaust:
0.06 - 0.11 mm (Cold)
Performance
Horsepower Output:
Approx. 20-22 hp @ 7,500 rpm (varies by market and year)
Torque Output:
Approx. 19-20 Nm (14-15 lb-ft) @ 6,000 rpm (varies by market and year)
Fuel System
Fuel Delivery:
Carburetor
Carburetor Model:
Mikuni VM22SS (single)
Fuel Type:
Unleaded gasoline, 87 octane (minimum)
🔧 Transmission
Standard
Transmission Type:
5-speed constant mesh
Clutch Type:
Wet multi-plate
Final Drive:
Chain drive
Features
Gear Ratios:
Detailed in manual (specific ratios vary slightly by year, but generally consistent).
📐 Dimensions
Exterior
Length:
Approx. 2190 mm (86.2 in.)
Width:
Approx. 760 mm (29.9 in.)
Height:
Approx. 1110 mm (43.7 in.)
Wheelbase:
Approx. 1485 mm (58.5 in.)
Ground Clearance:
Approx. 140 mm (5.5 in.)
Weights
Dry Weight:
Approx. 140 kg (309 lbs)
Wet Weight:
Approx. 148 kg (326 lbs)
Fuel Tank Capacity:
Approx. 10 Liters (2.6 US gal)
🛡️ Safety Features
Ratings
Safety Features Overview:
Standard motorcycle safety features. No specific crash test ratings applicable in the same way as cars.
Active Features
Braking System Type:
Front disc, Rear drum
Tire Type:
Tubed
Passive Features
Lighting:
Halogen headlight, LED taillight (some later models), incandescent turn signals.
💡 Technology Features
Infotainment
Infotainment System:
N/A (Standard motorcycle instrumentation)
Driver Assistance
Rider Aids:
None (This is a traditional motorcycle)
Connectivity
Connectivity Features:
None (This is a traditional motorcycle)
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 4,000 km (2,500 miles) or 6 months, whichever comes first.
Air Filter Check Interval:
Every 4,000 km (2,500 miles)
Spark Plug Check Interval:
Every 8,000 km (5,000 miles)
Chain Lubrication Adjustment:
Every 1,000 km (600 miles) or as needed.
Fluid Specifications
Engine Oil Type:
Yamalube 4-stroke motorcycle oil or equivalent, SAE 10W-40 API SG or higher.
Engine Oil Capacity:
Approx. 1.5 Liters (1.6 US qt) without filter change; 1.6 Liters (1.7 US qt) with filter change.
Brake Fluid Type:
DOT 3 or DOT 4
Fork Oil Type:
SAE 10W
Fork Oil Quantity:
Approx. 147 ml (4.9 US fl oz) per fork leg (check manual for exact spec).
Known Issues
Common Wear Items:
Clutch plates (especially with aggressive riding), carburetor jets/seals (clogging), fork seals (leaks), rear shock absorbers (loss of damping).
Electrical Concerns:
Aging wiring harnesses, regulator/rectifier failures (can be prone to overheating on some models), battery charging issues.
Carburetor Issues:
Difficult starting when cold, rough idle, hesitation, or sputtering due to clogged internal passages or worn O-rings.
📚 Vehicle History
Brand Heritage
Yamaha Legacy:
Yamaha Motor Company is renowned for its innovation, performance, and reliability across a wide range of powersports vehicles, including motorcycles, ATVs, and personal watercraft.
Model Evolution
Virago Lineage:
The Virago line was Yamaha's entry into the V-twin cruiser market, known for its accessible styling and comfortable ride. The 250cc model specifically targeted newer riders and those seeking a lighter, more maneuverable cruiser.
Production
Production Period:
1988-2007 (globally), with the manual covering 1989-2005.
Manufacturing Locations:
Primarily Japan, with potential assembly in other regions depending on the market.
🏆 Awards & Recognition
Recognitions
Industry Awards:
While the Virago 250 itself may not have specific individual awards listed, Yamaha as a brand has consistently received accolades for its engineering, reliability, and innovation in the motorcycle industry throughout the production run of this model.
Ratings
Consumer Reviews:
Generally positive for its intended purpose as an accessible cruiser, praised for ease of use and classic styling.
Certifications
Emission Standards:
Compliant with emission standards of its time, specific certifications vary by market and year (detailed in manual for specific regions).
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