Yamaha XV250 1988-2008 Workshop Repair Service Manual

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This manual covers the XV250, also known as the Virago 250 or V-Star 250, a lightweight cruiser motorcycle produced from 1988 to 2008. Renowned for its classic styling and user-friendly...

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Taper: Motorcycle

Distributeur:

UGS: 66395

Mots clés: 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

Variantes de produits

Description

This manual covers the XV250, also known as the Virago 250 or V-Star 250, a lightweight cruiser motorcycle produced from 1988 to 2008. Renowned for its classic styling and user-friendly design, the XV250 is powered by an air-cooled, V-twin engine and is a popular choice for new riders and urban commuters. Its engineering emphasizes reliability and manageable performance, making it a dependable option in the cruiser segment. The motorcycle features a steel tube frame for structural integrity and a low seat height for enhanced rider comfort and control. This comprehensive workshop service manual provides detailed guidance for the maintenance, repair, and diagnostics of the XV250. It covers all essential systems, including engine overhaul, fuel and ignition systems, transmission and clutch, electrical components, chassis, suspension, brakes, and bodywork. The manual includes routine maintenance procedures, troubleshooting guides for common issues, component rebuilding instructions, wiring diagrams, and precise technical specifications such as torque values and clearances. With 287 pages of information in English, this manual is an indispensable resource for owners and technicians aiming to keep their XV250 in optimal condition.

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

XV250

Nickname:

Virago 250 / V-Star 250

Codes

Chassis Codes:

XV250S, XV250S2 (example, specific codes may vary by region)

Engine Codes:

XV250, 3LW (example, specific codes may vary by region)

👋 Introduction

Market Position

Segment:

Lightweight cruiser motorcycle.

Target Audience:

New riders, urban commuters, those seeking a stylish and manageable cruiser.

Competitive Analysis

Competitors:

Honda Rebel 250, Kawasaki Vulcan 250, Suzuki Savage 400 (though slightly larger).

Key Features

Engine Layout:

V-twin, air-cooled.

Design Philosophy:

Classic cruiser styling with a compact and user-friendly package.

Manual Utility:

Essential for owners and technicians performing maintenance, repairs, and diagnostics.

📋 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

Models Covered:

Yamaha XV250 Virago, Yamaha XV250 V-Star

Page Count

Total Pages:

Manual Type

Type:

Workshop Service Manual / Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Overhaul:

Complete disassembly, inspection, repair, and reassembly of the engine.

Fuel System:

Carburetor(s) adjustment, cleaning, rebuilding, fuel pump, fuel lines.

Ignition System:

CDI unit, spark plugs, ignition timing, wiring.

Transmission And Clutch:

Clutch operation, adjustment, replacement, gearbox disassembly and assembly, gear shifting.

Electrical System:

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

Chassis And Frame:

Frame inspection, steering head bearings, swingarm, suspension.

Front Suspension:

Fork disassembly, seal replacement, oil levels and types, spring specifications.

Rear Suspension:

Shock absorber inspection, adjustment, mounting.

Brakes:

Front and rear brake system inspection, pad replacement, fluid bleeding, caliper maintenance.

Cooling System:

Air-cooled engine specific checks and maintenance.

Exhaust System:

Inspection and maintenance of exhaust pipes and mufflers.

Wheels And Tires:

Wheel bearing maintenance, tire pressure, rim inspection.

Bodywork And Trim:

Fender, tank, seat, and other cosmetic component removal and installation.

Procedures Included

Routine Maintenance:

Oil changes, filter replacement, spark plug service, chain adjustment, brake checks.

Troubleshooting:

Diagnostic charts and symptom-based problem solving for common issues.

Component Rebuilding:

Detailed steps for rebuilding carburetors, brake calipers, and other wear items.

Wiring Diagrams:

Comprehensive electrical schematics for easy diagnosis and repair.

Torque Specifications:

Precise torque values for critical fasteners across all systems.

Clearances And Tolerances:

Specifications for valve clearances, piston-to-cylinder wall, etc.

Technical Depth

Depth:

Comprehensive, suitable for professional technicians and advanced DIY mechanics.

Diagnostic Capabilities:

Includes troubleshooting guides for identifying and resolving mechanical and electrical faults.

Rebuild Instructions:

Detailed, step-by-step instructions for major component rebuilds.

📊 Manual Specifications

File Format

File Type:

Print Quality

Resolution:

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

Binding Type

Binding:

N/A (Digital PDF format)

Paper Type

Paper:

N/A (Digital PDF format)

Searchability

Text Search:

Likely searchable PDF, allowing users to quickly find specific information.

Compatibility

Device Compatibility:

Viewable on any device with a PDF reader (computers, tablets, smartphones).

⚙️ Engine Specifications

Primary Engine

Type:

4-stroke, V-twin, SOHC, 2 valves per cylinder

Displacement:

248 cc (15.1 cu in)

Bore X Stroke:

49.0 mm x 66.0 mm (approx.)

Compression Ratio:

22.5 : 1 (approx.)

Performance

Horsepower:

Approx. 18-20 HP @ 7,500 RPM (varies slightly by year and region)

Torque:

Approx. 19-20 Nm (14-15 lb-ft) @ 5,500 RPM (varies slightly by year and region)

Fuel System

Carburetor Type:

Mikuni VM34 (typically single downdraft carburetor, some variants may differ)

Fuel Delivery:

Gravity feed from fuel tank (may include a fuel pump on some models/years).

Fuel Type:

Unleaded gasoline, minimum octane rating of 87 (RON+MON)/2 (AKI).

Lubrication System

Oil Type:

API SE, SF or SG class, SAE 20W-40 or 10W-30 motorcycle oil.

Oil Capacity:

Approx. 1.4 Liters (1.5 US qt) without filter change; 1.6 Liters (1.7 US qt) with filter change.

Ignition System

Ignition Type:

CDI (Capacitor Discharge Ignition)

Spark Plug Type:

NGK DPR7EA-9 or equivalent

Spark Plug Gap:

0.7 - 0.8 mm (0.028 - 0.031 in)

🔧 Transmission

Standard

Type:

5-speed constant mesh

Optional

Optional Transmissions:

N/A (Only one standard transmission offered).

Features

Clutch Type:

Wet, multiple-disc

Final Drive:

Chain drive

Transmission Oil Type:

API GL-4 SAE 80 or 90 hypoid gear oil (refer to manual for specific Yamaha recommendations).

Transmission Oil Capacity:

Approx. 0.5 Liters (0.5 US qt)

📐 Dimensions

Exterior

Overall Length:

Approx. 2,185 mm (86.0 in)

Overall Width:

Approx. 760 mm (29.9 in)

Overall Height:

Approx. 1,100 mm (43.3 in)

Wheelbase:

Approx. 1,490 mm (58.7 in)

Ground Clearance:

Approx. 145 mm (5.7 in)

Seat Height:

Approx. 710 mm (28.0 in)

Weights

Dry Weight:

Approx. 130 kg (287 lbs)

Wet Weight:

Approx. 147 kg (324 lbs) (with all fluids and a full tank)

Fuel Capacity:

12 Liters (3.2 US gal), including a 2.5L (0.7 gal) reserve.

Wheels And Tires

Front Tire Size:

3.00-18 4PR

Rear Tire Size:

130/90-15 M/C 66P

Front Brake Size:

210 mm (8.3 in) Disc

Rear Brake Size:

130 mm (5.1 in) Drum

🛡️ Safety Features

Ratings

Crash Test Ratings:

N/A (Motorcycles are not subject to automotive crash testing standards).

Active Features

Braking System:

Single front disc brake, rear drum brake for adequate stopping power.

Lighting:

Headlight, taillight, brake lights, turn signals for visibility.

Passive Features

Frame Construction:

Steel tube frame for rigidity and rider support.

Ergonomics:

Low seat height and relaxed riding posture contribute to rider control and comfort.

💡 Technology Features

Infotainment

Features:

N/A (This is a 1988-2008 model, lacking modern infotainment systems).

Driver Assistance

Features:

N/A (No electronic rider aids or driver assistance features typical of modern vehicles).

Connectivity

Features:

N/A (No Bluetooth, USB, or other connectivity options).

Engine Management

System:

Basic CDI ignition system and mechanical carburetor for fuel delivery. No ECU or sophisticated engine management.

🔧 Maintenance

Service Intervals

Initial Service:

First service typically around 600 miles (1,000 km) for oil change, chain adjustment, and general inspection.

Regular Oil Change:

Every 2,000-3,000 miles (3,000-5,000 km) or every 6 months, whichever comes first.

Air Filter Cleaning Replacement:

Inspect every 3,000 miles (5,000 km); clean or replace as needed.

Spark Plug Replacement:

Replace every 6,000-10,000 miles (10,000-15,000 km) or as per manual recommendation.

Valve Clearance Adjustment:

Inspect and adjust every 6,000-12,000 miles (10,000-20,000 km) or as indicated in the manual.

Brake Fluid Change:

Replace every 2 years or as recommended by the manual.

Fluid Specifications

Engine Oil:

API SE, SF or SG class, SAE 20W-40 or 10W-30 motorcycle oil.

Transmission Oil:

API GL-4 SAE 80 or 90 hypoid gear oil.

Brake Fluid:

DOT 3 or DOT 4 conforming to FMVSS 116.

Fork Oil:

Yamaha's recommended fork oil or equivalent SAE 10W (refer to manual for exact type and quantity).

Known Issues

Carburetor Issues:

Can be prone to fuel delivery issues if not maintained, leading to poor idling or acceleration. Carburetor synchronization (if applicable) is crucial.

Starter Clutch:

Some models might experience wear in the starter clutch mechanism over time, leading to slipping or grinding sounds.

Electrical Connections:

Corrosion or loose connections in the electrical system can cause intermittent faults. Regular inspection of grounds and connectors is recommended.

Front Forks:

Fork seals can degrade over time, leading to oil leaks. Regular cleaning of fork tubes and inspection of seals is advised.

📚 Vehicle History

Brand Heritage

Manufacturer:

Yamaha Motor Company is a Japanese manufacturer of motorcycles, marine products, and other motorized products.

Foundation:

Founded in 1955, Yamaha has a long history of innovation in motorcycle design and engineering.

Model Evolution

Introduction Year:

The XV250 Virago was introduced in the mid-1980s as a smaller displacement option within Yamaha's popular Virago cruiser line.

Model Line:

Part of the 'Virago' series, known for its V-twin engines and classic styling. Later versions were marketed as 'V-Star 250' in some markets, continuing the cruiser lineage.

Design Changes:

While the core design remained consistent throughout its production run (1988-2008 covered here), minor updates to styling, emissions controls, and potentially carburetor jetting occurred over the years.

Production

Manufacturing Location:

Primarily manufactured in Japan by Yamaha.

Production Run:

The XV250 platform has been in continuous production for a significant period, with this manual covering a substantial segment of its development.

🏆 Awards & Recognition

Recognitions

Type:

N/A (Specific industry awards for this particular model are not widely documented).

Ratings

Reliability:

Generally considered a reliable and robust motorcycle, known for its longevity with proper maintenance.

Certifications

Emissions:

Compliance with emissions standards of its era, which were less stringent than current regulations. Manual will contain relevant emissions system information.