🏷️ Basic Information

Make:

Yamaha

Model:

Virago 250 / Route 66

Product Type:

Service and Repair Manual

Internal Product Code:

YAM-VIR250-R66-88-05

👋 Introduction

Segment:

Entry-level cruiser motorcycle, popular for new riders and comfortable commuting

Competitors:

Honda Rebel series, Kawasaki Vulcan 500, Suzuki Intruder 750 (though larger displacement)

Vehicle Highlights:

Torquey V-twin engine, comfortable riding posture, classic cruiser styling, reliable performance

Benefit To Owner:

Empowers owners to perform routine maintenance and repairs, saving money and extending the life of their vintage Yamaha motorcycle

📋 Manual Details

Model Years Covered:

1988, 1990, 1995, 2005

Variant Coverage:

Virago 250, Route 66

Estimated Pages:

300-400

Type:

Comprehensive Service Manual

Language:

English

Format:

Digital (PDF)

📖 Manual Coverage

Engine:

Full engine overhaul, carburetor tuning, ignition system, cooling system, lubrication

Drivetrain:

Clutch operation, transmission gears, final drive maintenance (chain/sprockets), lubrication

Brakes:

Front and rear brake system inspection, adjustment, fluid replacement, caliper service

Suspension:

Front fork (telescopic) disassembly, service, oil replacement; rear shock absorber inspection and replacement

Electrical:

Wiring diagrams, battery maintenance, charging system (stator/regulator/rectifier), lighting system, starter motor, ignition coil

Fuel System:

Fuel tank, petcock operation, fuel lines, carburetor (Mikuni VM series) cleaning and adjustment, fuel filter replacement

Exhaust:

Exhaust system inspection, gasket replacement, muffler maintenance

Chassis:

Frame inspection, steering head bearing service, wheel bearing maintenance

Maintenance:

Regular scheduled maintenance, oil and filter changes, brake adjustments, chain lubrication and adjustment, air filter cleaning/replacement, spark plug replacement

Troubleshooting:

Diagnostic procedures for common starting, running, and electrical issues; symptom-based fault finding

Repair:

Detailed step-by-step instructions for component disassembly, repair, reassembly, and adjustment

Rebuilds:

Engine top-end rebuild, carburetor overhaul, brake caliper servicing

Depth:

From basic rider maintenance to complete engine and transmission overhauls; advanced electrical diagnostics

Diagnostic Tools:

Information on using standard motorcycle tools and diagnostic techniques

📊 Manual Specifications

Digital Quality:

High-resolution scans, searchable text (OCR optimized where possible), zoomable diagrams

Print Readability:

Designed for clear printing of diagrams, schematics, and text

Digital Accessibility:

Instant download, accessible on multiple devices

Print Considerations:

While digital, the clarity supports professional printing on a workshop manual paper stock

⚙️ Engine Specifications

Configuration:

Air-cooled, 4-stroke, V-twin

Displacement:

249 cc (15.2 cu. in.)

Bore X Stroke:

49.0 mm x 66.0 mm (1.93 in x 2.60 in)

Compression Ratio:

9.7:1

Valve Train:

SOHC, 2 valves per cylinder

Horsepower:

Approx. 21-23 hp @ 7500 rpm (varies by year and tuning)

Torque:

Approx. 20-22 Nm @ 6000 rpm (varies by year and tuning)

Carburetion:

Single Mikuni VM24SS downdraft carburetor

Fuel Capacity:

Approx. 12.0 L (3.17 US gal)

Type:

Wet sump

Type:

CDI (Capacitor Discharge Ignition)

Method:

Air cooling

🔧 Transmission

Type:

5-speed constant mesh

Clutch:

Wet, multi-disc

Final Drive:

Chain drive

📐 Dimensions

Overall Length:

Approx. 2175 mm (85.6 in)

Overall Width:

Approx. 750 mm (29.5 in)

Overall Height:

Approx. 1105 mm (43.5 in)

Wheelbase:

Approx. 1485 mm (58.5 in)

Dry Weight:

Approx. 140 kg (308.6 lbs)

Wet Weight:

Approx. 155 kg (341.7 lbs)

Front Tire:

3.00-18 4PR

Rear Tire:

120/90-16M/C 64P

Front Brake:

Disc brake, hydraulic

Rear Brake:

Drum brake

🛡️ Safety Features

NHTSA Rating:

Not Applicable (Motorcycle)

Handling:

Low seat height, stable chassis geometry contribute to rider confidence

Lighting:

Halogen headlight, tail light, turn signals

💡 Technology Features

Features:

Basic analog instrumentation (speedometer, tachometer, odometer, tripmeter), headlight, taillight, turn signals. No modern electronic features.

Features:

N/A (Motorcycle)

Features:

N/A (Motorcycle)

🔧 Maintenance

Oil Change:

Every 3,000-5,000 km (1,800-3,000 miles) or annually. Consult manual for specific intervals.

Spark Plug Replacement:

Every 10,000-15,000 km (6,000-9,000 miles).

Air Filter Cleaning:

Every 5,000 km (3,000 miles) or as needed based on riding conditions.

Brake Fluid Flush:

Every 2 years.

Engine Oil:

SAE 20W-40 or 10W-40 motorcycle specific oil (API SG or higher). Capacity: Approx. 1.4 L (1.5 US qt) without filter change, 1.6 L (1.7 US qt) with filter change.

Brake Fluid:

DOT 3 or DOT 4 hydraulic brake fluid.

Fork Oil:

Yamaha Fork Oil (or equivalent SAE 10W fork oil). Capacity: Approx. 370-380 ml per fork leg.

Common Complaints:

Carburetor gumming due to fuel degradation if left sitting, occasional charging system issues (stator/regulator), front fork seal leaks, exhaust pipe corrosion.

Carburetor Cleaning:

Crucial for smooth running; requires careful disassembly and cleaning of jets and passages. Ethanol resistance of rubber components should be considered.

📚 Vehicle History

Yamaha Legacy:

Yamaha Motor Company, founded in 1955, is renowned for its innovation in motorcycles, musical instruments, and other powered products. Known for engineering excellence and performance.

Virago Lineage:

The Virago line, introduced in the early 1980s, represented Yamaha's entry into the V-twin cruiser market. The 250cc model, including the Route 66 variant, was a popular choice for its approachable styling and manageable performance.

Production Period:

Virago 250 models produced from the mid-1980s through the early 2000s, with the Route 66 being a specific trim package.

Manufacturing Origin:

Primarily manufactured in Japan.

🏆 Awards & Recognition

Market Reception:

Consistently well-received for its user-friendliness, reliability, and classic styling within the entry-level cruiser segment.

Ownership Satisfaction:

High owner satisfaction for its dependable operation and low running costs.