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Yamaha XV250 Virago Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Yamaha Model: XV250 Virago Common Name: Virago 250 Type: Cruiser Motorcycle Codes Chassis Code: XV250 👋 Introduction Market Position Segment: Entry-level to mid-range cruiser motorcycle,...
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Yamaha XV250 Virago Service Repair Workshop Manual
🏷️ Basic Information
Identification
Make:
Yamaha
Model:
XV250 Virago
Common Name:
Virago 250
Type:
Cruiser Motorcycle
Codes
Chassis Code:
XV250
👋 Introduction
Market Position
Segment:
Entry-level to mid-range cruiser motorcycle, popular for its comfort and reliability
Target Audience:
New riders, urban commuters, weekend cruisers, DIY mechanics
Competitive Analysis
Key Competitors:
Honda Shadow VT750/VT600, Suzuki Boulevard S40/Intruder 250, Kawasaki Vulcan S/Eliminator 250
Key Features
Vehicle Strengths:
Reliable V-twin engine, comfortable riding position, classic styling, low seat height, fuel efficiency
Manual Advantage:
Official and comprehensive coverage, detailed procedures, essential for proper maintenance and repair
📋 Manual Details
Coverage Areas
Primary Coverage:
All aspects of repair and service procedures
Secondary Coverage:
Maintenance, diagnostics, troubleshooting, assembly, disassembly
Page Count
Estimated Page Count:
300-400
Manual Type
Type:
Service Repair Workshop Manual
Language
Language:
English
Format
Format:
Digital (likely PDF), potentially print
📖 Manual Coverage
Systems Covered
Engine:
Engine overhaul, top end, bottom end, timing, cooling system
Fuel System:
Carburetor(s) adjustment and overhaul, fuel pump, fuel tank, fuel lines
Transmission:
Clutch operation and replacement, gearbox disassembly and assembly, shift mechanism
Electrical System:
Ignition system, charging system (stator, regulator/rectifier), lighting, starting system, wiring diagrams
Suspension:
Front fork overhaul, rear shock absorber replacement, linkage maintenance
Brakes:
Front and rear brake system maintenance, caliper overhaul, master cylinder, brake fluid replacement
Chassis:
Frame inspection, steering head bearing service, swingarm and pivot bearings
Bodywork:
Panel removal and installation, seat, fenders, fuel tank mounting
Procedures Included
Regular Maintenance:
Oil changes, filter replacements, chain adjustment, lubrication points
Troubleshooting:
Diagnostic flowcharts, common fault diagnosis, symptom-based repair guidance
Major Repairs:
Engine rebuilds, transmission overhauls, suspension component replacement
Specifications:
Torque values, clearances, fluid types and capacities, electrical resistance values
Technical Depth
Depth:
Comprehensive: from basic fluid checks to complete engine and transmission rebuilds
📊 Manual Specifications
File Format
Digital Quality:
High-resolution scans or digitally created content, searchable text where available
Print Quality
Print Option:
Printable pages, professional layout
Binding Type
Binding:
N/A (for digital) / Spiral or perfect bound (if printed)
Paper Type
Paper Quality:
N/A (for digital) / Durable, high-quality paper stock (if printed)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Air-cooled, 4-stroke, SOHC, V-twin
Displacement:
248 cc (15.1 cu. in.)
Bore X Stroke:
49.0 mm x 66.0 mm (1.93 in x 2.60 in)
Compression Ratio:
22.0 : 1
Valve Clearance Intake:
0.04 - 0.08 mm (0.0016 - 0.0031 in)
Valve Clearance Exhaust:
0.04 - 0.08 mm (0.0016 - 0.0031 in)
Performance
Horsepower:
Approx. 18-20 HP @ 7500 RPM (varies by market and specific model year)
Torque:
Approx. 19-21 Nm @ 6000 RPM (varies by market and specific model year)
Fuel System
Carburetor Type:
Single Mikuni VM26 or similar (specific model may vary, e.g., 34mm CV carb)
Fuel Capacity:
Approx. 9.5 Liters (2.5 US gal)
Fuel Type:
Unleaded gasoline, minimum Octane Rating 87 (RON+MON)/2
Lubrication System
Oil Capacity With Filter:
Approx. 1.4 Liters (1.5 US qt)
Recommended Oil Viscosity:
SAE 10W-40 or 20W-40, API SE or SF classification or higher
Ignition System
Ignition Type:
CDI (Capacitor Discharge Ignition)
Spark Plug Gap:
0.6 - 0.7 mm (0.024 - 0.028 in)
🔧 Transmission
Standard
Type:
5-speed constant mesh
Drive Method:
Chain drive
Clutch Type:
Wet multi-plate
Features
Gear Ratios:
Refer to specific model year manual for detailed ratios (e.g., 1st: 2.750, 2nd: 1.875, 3rd: 1.375, 4th: 1.100, 5th: 0.917)
Transmission Fluid Capacity:
N/A (integrated with engine oil)
Transmission Fluid Type:
Yamalube 4 (or equivalent) SAE 10W-40
📐 Dimensions
Exterior
Overall Length:
Approx. 2135 mm (84.1 in)
Overall Width:
Approx. 730 mm (28.7 in)
Overall Height:
Approx. 1060 mm (41.7 in)
Seat Height:
Approx. 685 mm (27.0 in)
Wheelbase:
Approx. 1490 mm (58.7 in)
Weights
Dry Weight:
Approx. 145 kg (320 lbs)
Wet Weight:
Approx. 156 kg (344 lbs) (with all fluids)
Front Tire Size:
3.00-18 4PR
Rear Tire Size:
130/90-15 M/C 66P
Wheelbase Type:
Spoke wheels
🛡️ Safety Features
Ratings
Crash Test Ratings:
N/A (Motorcycle specific ratings not applicable like automotive)
Active Features
Braking System:
Front: Disc brake, Rear: Drum brake (some later models may have rear disc)
Headlight:
Halogen 12V 60/55W
Passive Features
Frame Construction:
Steel, diamond type
Rider Ergonomics:
Low seat height and relaxed riding posture enhance rider control and comfort
💡 Technology Features
Infotainment
System:
Basic analog instrumentation: speedometer, odometer, tachometer (on some models), neutral indicator, oil pressure warning light.
Driver Assistance
Features:
None (focus on essential riding components)
Connectivity
Features:
None
🔧 Maintenance
Service Intervals
First Service:
1,000 km (600 miles) or 6 months
Subsequent Service:
Every 6,000 km (3,750 miles) or 12 months
Valve Adjustment Interval:
Refer to manual, typically around 12,000 km (7,500 miles)
Fluid Specifications
Engine Oil Type:
Yamalube 4 (or equivalent) SAE 10W-40 or 20W-40
Brake Fluid Type:
DOT 3 or DOT 4 (check manual for specific recommendation)
Coolant Type:
N/A (Air-cooled)
Known Issues
Common Wear Items:
Clutch wear, carburetor jetting issues (gumming), fork seal leaks, charging system (stator/rectifier) failures
Troubleshooting Focus:
Carburetor cleaning and synchronization, electrical connector checks, timing adjustments
📚 Vehicle History
Brand Heritage
Yamaha Motorcycles:
Yamaha Motor Corporation is a Japanese manufacturer with a long history of producing high-quality motorcycles, known for innovation and performance across various categories.
Model Evolution
Virago Lineage:
The Virago line was Yamaha's entry into the cruiser market, emphasizing classic styling with modern engineering. The XV250, introduced in the mid-1980s, became a long-running model due to its accessibility and reliability.
Production
Production Years:
Originally introduced in 1987 and produced for many years, with minor updates over time. Specific model years covered by this manual are crucial for exact specification accuracy.
Manufacturing Location:
Primarily Japan, with potential manufacturing in other Yamaha facilities.
🏆 Awards & Recognition
Recognitions
Industry Awards:
While specific awards for the XV250 Virago might be scarce, it has consistently received praise for its reliability and value within the entry-level cruiser segment throughout its production run.
Ratings
User Reviews:
Generally positive for its intended use, often cited as a great first motorcycle.
Certifications
Manufacturing Standards:
Manufactured under Yamaha's stringent quality control standards.
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