Yamaha XV250 1988-2008 Full Service Repair Manual

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The Yamaha XV250 Virago, produced from 1988 to 2008, is a lightweight cruiser motorcycle celebrated for its classic V-twin styling and accessible design. Engineered with a 234 cc air-cooled V-twin...

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Type: Motorcycle

Vendor:

Sku: 57680

Tags: 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

Product variants

Description

The Yamaha XV250 Virago, produced from 1988 to 2008, is a lightweight cruiser motorcycle celebrated for its classic V-twin styling and accessible design. Engineered with a 234 cc air-cooled V-twin engine, it offers a comfortable riding experience, making it an ideal choice for new riders and urban commuting. Its reliable shaft drive, manageable seat height, and user-friendly ergonomics contribute to its reputation as a dependable and enjoyable motorcycle. The XV250 Virago embodies a commitment to quality craftsmanship and rider satisfaction, offering a blend of style and practicality that has made it a enduring model in the cruiser segment. This comprehensive Full Service & Repair Manual, covering the Yamaha XV250 Virago from 1988 to 2008, provides detailed guidance for maintenance, troubleshooting, and repair. It encompasses all major systems, including the engine, fuel, ignition, transmission, brakes, and electrical components. Within its over 300 pages, you will find step-by-step procedures for routine maintenance, engine overhauls, carburetor tuning, and electrical diagnostics. This manual is an essential resource for owners, mechanics, and technicians seeking to ensure the optimal performance, reliability, and longevity of their XV250 Virago.

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

XV250 Virago

Common Name:

XV250 Virago

Codes

Chassis Code Prefix:

Engine Code Prefix:

👋 Introduction

Market Position

Vehicle Segment:

Lightweight cruiser motorcycle, popular for beginners and urban commuting.

Competitive Analysis

Competitors Historical:

Honda Rebel 250, Kawasaki Vulcan 500 (though larger), Suzuki Savage 650 (also larger but similar cruiser ethos).

Key Features

Design Philosophy:

Classic V-twin cruiser styling, comfortable ergonomics, reliable shaft drive, accessible seat height.

Target Audience:

New riders, city dwellers, riders seeking a low-maintenance, stylish cruiser.

📋 Manual Details

Coverage Areas

Years Covered:

1988-2008

Page Count

Estimated Pages:

Manual Type

Type:

Full Service & Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Complete overhaul, diagnosis, troubleshooting, component replacement (e.g., pistons, rings, valves, camshafts, crankshaft, bearings).

Fuel System:

Carburetor overhaul, jetting, synchronization, fuel pump, fuel lines, fuel filter replacement.

Ignition System:

CDI unit, spark plugs, ignition coils, timing adjustments, troubleshooting.

Transmission:

Gearbox disassembly/assembly, clutch operation and adjustment, shift mechanism.

Drivetrain:

Final drive (bevel gear) inspection and maintenance, shaft drive system.

Brakes:

Front and rear brake system service, hydraulic system bleeding, pad/shoe replacement, caliper/master cylinder overhaul.

Suspension:

Front fork overhaul and oil change, rear shock absorber inspection and replacement.

Electrical System:

Wiring diagrams, battery service, charging system (stator, regulator/rectifier), lighting, switches, fuses, starter motor.

Cooling System:

Air-cooled engine specifics, cylinder head fin cleaning.

Frame And Bodywork:

Frame inspection, fairing and panel removal/installation, seat, fenders.

Wheels And Tires:

Tire pressure, wheel bearing inspection, spoke adjustment (if applicable).

Procedures Included

Routine Maintenance:

Oil changes, filter replacement, chain adjustment, brake fluid replacement, spark plug replacement, air filter cleaning/replacement.

Troubleshooting:

Diagnostic flowcharts, common problem identification and solutions for starting, running, and electrical issues.

Engine Rebuild:

Detailed steps for full engine disassembly, inspection, repair, and reassembly.

Carburetor Tuning:

Mixture adjustment, idle speed setting, synchronization procedures.

Electrical Diagnostics:

Using multimeters, interpreting wiring diagrams, tracing faults.

Brake System Service:

Bleeding procedures, component replacement, hydraulic system maintenance.

Suspension Adjustment:

Fork oil changes, rear shock adjustment (if applicable).

Technical Depth

Depth:

Comprehensive, from basic adjustments to complete engine and electrical system overhauls.

Diagnostic Tools Required:

Basic hand tools, torque wrench, multimeter, feeler gauges, specialized tools (e.g., carburetor synchronizer, valve spring compressor - often noted if needed).

📊 Manual Specifications

File Format

File Type:

Searchable:

Printable:

Print Quality

Image Resolution:

High (suitable for clear diagrams and text)

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Air-cooled, four-stroke, 70-degree V-twin

Displacement:

234 cc (cubic centimeters)

Bore X Stroke:

49.0 mm x 66.0 mm

Compression Ratio:

10.0:1

Valve Train:

SOHC (Single Overhead Camshaft), 2 valves per cylinder

Cooling Method:

Forced air cooling

Performance

Horsepower Estimate:

Approx. 16-18 HP (at 7,500 rpm)

Torque Estimate:

Approx. 1.8 kgf-m (13 lb-ft) (at 6,000 rpm)

Fuel System

Fuel Delivery:

Dual carburetors (Mikuni VM24SS or similar)

Fuel Type:

Unleaded gasoline

Fuel Tank Capacity:

Approx. 9.2 Liters (2.4 US gal)

🔧 Transmission

Standard

Transmission Type:

5-speed constant mesh

Clutch Type:

Wet, multi-plate

Features

Drive Type:

Shaft drive

Fluid Specifications

Transmission Oil Type:

Yamalube 4 (or equivalent API SG, SAE 10W-40)

Transmission Oil Capacity:

Approx. 1.8 Liters (1.9 US qt)

📐 Dimensions

Exterior

Length:

Approx. 2,135 mm (84.1 in)

Width:

Approx. 790 mm (31.1 in)

Height:

Approx. 1,065 mm (41.9 in)

Wheelbase:

Approx. 1,485 mm (58.5 in)

Weights

Dry Weight:

Approx. 146 kg (322 lbs)

Wet Weight:

Approx. 157 kg (346 lbs)

Wheels Tires

Front Tire Size:

3.00-18 4PR

Rear Tire Size:

130/90-15 M/C 66P

Front Brake Type:

Rear Brake Type:

🛡️ Safety Features

Ratings

Safety Features Standard:

Basic motorcycle safety features, good visibility.

Active Features

Active Safety:

Responsive braking system, predictable handling.

Passive Features

Passive Safety:

Sturdy frame construction.

💡 Technology Features

Infotainment

Infotainment Features:

Basic analogue instrumentation (speedometer, tachometer, odometer, neutral indicator, turn signal indicators).

Driver Assistance

Driver Assistance Systems:

Connectivity

Connectivity Features:

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 4,000 km (2,500 miles) or 6 months.

Oil Filter Replacement:

Every 8,000 km (5,000 miles) or 12 months (concurrent with oil change).

Spark Plug Replacement:

Every 10,000 km (6,000 miles) or 12 months.

Air Filter Cleaning:

Every 4,000 km (2,500 miles), replace if damaged or excessively dirty.

Brake Fluid Replacement:

Every 2 years or as per manual recommendations (due to moisture absorption).

Clutch Adjustment:

As needed, check free play at least every 8,000 km (5,000 miles).

Fluid Specifications

Engine Oil Type:

Yamalube 4 (or equivalent API SG, JASO MA, SAE 10W-40)

Engine Oil Capacity:

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

Brake Fluid Type:

DOT 3 or DOT 4 (check specific year manual for exact spec)

Coolant Type:

Air-cooled (no coolant)

Known Issues

Common Wear Items:

Clutch plates, brake pads/shoes, fork seals, carburetor diaphragms (age-related).

Carburetor Issues:

Can become gummed up with stale fuel, leading to starting problems or rough running; synchronization can drift over time.

Electrical Issues:

Aging wiring can lead to intermittent faults, regulator/rectifier failure can impact charging.

Part Numbers Example

Oil Filter Part Number:

Yamaha 5JX-13440-00-00 (common replacement, verify for specific year)

Air Filter Part Number:

Yamaha 5JX-14451-00-00 (common replacement, verify for specific year)

Spark Plug Part Number:

NGK DPR7EA-9 (common, verify for specific year)

📚 Vehicle History

Brand Heritage

Yamaha Legacy:

Yamaha Motor Company is renowned for its innovation in motorcycles, musical instruments, and marine products. In motorcycles, they have a long history of performance and reliability.

Model Evolution

Xv250 Lineage:

The XV250 Virago was part of Yamaha's Virago line of cruisers, known for their V-twin engines and classic styling. It served as an entry-level cruiser, offering accessible styling and a manageable engine for new riders.

Production

Production Period:

1988-2008 (and continued in some markets with minor updates).

Manufacturing Origin:

Primarily Japan (though assembly may have occurred in other locations for specific markets).

🏆 Awards & Recognition

Recognitions

Model Awards:

While specific awards for the XV250 are not widely documented, the Virago line was consistently praised for its styling and value, making it a popular choice in its segment.