Yamaha XV250 Virago 250 Motorcycle Complete Workshop Service Repair Manual 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005

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🏷️ Basic Information Identification Make: Yamaha Model: XV250 Virago 250 Model Nickname: Virago 250 Vehicle Type: Motorcycle Codes Chassis Code: XV250 👋 Introduction Market Position Target Audience: DIY motorcycle owners,...

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Type: Motorcycle

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Sku: 475916

Tags: 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 Featured Motorcycle Motorcycles Virago XV250 Virago 250 Yamaha

Product variants

Description

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

XV250 Virago 250

Model Nickname:

Virago 250

Vehicle Type:

Motorcycle

Codes

Chassis Code:

XV250

👋 Introduction

Market Position

Target Audience:

DIY motorcycle owners, independent repair shops, aspiring mechanics.

Value Proposition:

Enables significant cost savings on maintenance and repairs by empowering users to perform work themselves.

Competitive Analysis

Competitors:

Official Yamaha service manuals, other third-party repair manuals (e.g., Haynes, Clymer) for the same model.

Key Features

Feature 1:

Step-by-step instructions with illustrations/pictures.

Feature 2:

Covers all systems and procedures A-Z.

Feature 3:

Instant digital delivery.

Feature 4:

Printable and transferable to multiple devices.

Feature 5:

Customer satisfaction guarantee.

📋 Manual Details

Coverage Areas

Model Years Covered:

1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005

Engine Variants Covered:

Trim Levels Covered:

Transmission Types Covered:

Page Count

Estimated Page Count:

Refer to specific edition; typically 300-500 pages for complete workshop manuals.

Manual Type

Manual Type:

Complete Workshop Service Repair Manual

Language

Language:

English

Format

Format:

Downloadable Digital File (PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Full engine disassembly, assembly, inspection, overhaul (cylinder head, pistons, crankshaft, camshafts, valve timing, lubrication system).

Fuel System:

Carburetor service and adjustment, fuel tank, fuel lines, fuel pump (if applicable).

Ignition System:

CDI ignition system, spark plugs, ignition timing, troubleshooting.

Transmission And Drivetrain:

Clutch operation and service, gearbox internal inspection and repair, final drive (chain maintenance and adjustment).

Suspension:

Front fork service (oil change, seal replacement), rear shock absorber inspection and replacement, swingarm maintenance.

Brakes:

Front and rear brake system service (hydraulic fluid replacement, caliper overhaul, pad replacement, brake line inspection, drum brake adjustment for rear if applicable).

Electrical System:

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

Cooling System:

Air-cooled engine thermal management, cylinder head fin cleaning.

Chassis And Frame:

Frame inspection, steering head bearing service, wheel bearing service.

Bodywork And Fittings:

Seat removal, fuel tank removal and installation, side covers, fenders, handlebars, levers, cables.

Procedures Included

Routine Maintenance:

Oil and filter changes, chain adjustment, brake fluid checks, tire pressure checks, spark plug inspection.

Troubleshooting:

Diagnostic procedures for common issues, fault finding charts.

Major Repairs:

Engine rebuilds, transmission overhauls, suspension component replacement.

Electrical Diagnostics:

Circuit tracing, component testing, wiring harness repair.

Carburetor Tuning:

Adjustment procedures for optimal performance and fuel economy.

Electrical System Troubleshooting:

Detailed wiring diagrams, diagnostic flowcharts for electrical faults, testing procedures for components like the stator, rectifier/regulator, and starter motor.

Frame And Suspension Geometry:

Specifications for steering head bearing adjustment, wheel alignment, and basic chassis setup.

Technical Depth

Depth Of Coverage:

Comprehensive, covering everything from basic maintenance to full engine and component overhauls.

Diagnostic Capabilities:

Detailed troubleshooting guides and symptom-based fault finding.

Rebuild Procedures:

Step-by-step instructions for rebuilding major components.

📊 Manual Specifications

File Format

File Type:

Searchability:

Likely searchable text, dependent on original scan quality.

Print Quality

Printability:

Printable, user can print entire manual or specific sections.

Binding Type

Binding Type:

N/A (Digital File)

Paper Type

Paper Type:

N/A (Digital File)

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-stroke, SOHC, V-twin

Displacement:

249 cc (248cc actual)

Bore X Stroke:

49.0 mm x 66.0 mm

Compression Ratio:

21.2:1 (Note: This appears unusually high, likely a typo in product description or common misconception. Typical would be around 9.0-10.0:1. Actual manual would confirm.)

Cooling System:

Air-cooled

Valves Per Cylinder:

Valve Clearance Intake:

0.08 - 0.13 mm (0.003 - 0.005 in)

Valve Clearance Exhaust:

0.13 - 0.18 mm (0.005 - 0.007 in)

Performance

Horsepower:

Approx. 16-21 HP (varies by market and specific year)

Torque:

Approx. 19-20 Nm (varies by market and specific year)

Fuel System

Carburetion:

Dual Mikuni carburetors (e.g., VM24SC or similar)

Fuel Type:

Unleaded gasoline

Oil Capacity

Engine Oil Capacity:

Approx. 1.4 L (1.5 US qt) without filter change; Approx. 1.6 L (1.7 US qt) with filter change. (Refer to manual for exact capacity).

Oil Type

Recommended Oil Viscosity:

SAE 10W-40 or 10W-30 motorcycle oil, meeting API SE or SF classification or higher.

🔧 Transmission

Standard

Transmission Type:

5-speed constant mesh

Optional

Optional Transmissions:

N/A (Standard for this model)

Features

Clutch Type:

Wet, multi-plate

Final Drive:

Chain drive

📐 Dimensions

Exterior

Length:

Approx. 2185 mm (86.0 in)

Width:

Approx. 735 mm (28.9 in)

Height:

Approx. 1135 mm (44.7 in)

Wheelbase:

Approx. 1490 mm (58.7 in)

Weights

Dry Weight:

Approx. 147 kg (324 lbs)

Wet Weight:

Approx. 159 kg (350 lbs)

Fuel Capacity

Fuel Tank Capacity:

12.0 L (3.2 US gal)

🛡️ Safety Features

Ratings

Safety Ratings:

N/A (Motorcycle safety is assessed through various standards and design features, not standardized crash ratings like cars).

Active Features

Active Safety Features:

Responsive braking system, balanced chassis for stability.

Passive Features

Passive Safety Features:

Durable frame construction, rider ergonomics designed for control.

💡 Technology Features

Infotainment

Infotainment System:

N/A (Basic motorcycle instrumentation: speedometer, odometer, gear indicator, neutral light, turn signal indicators, high beam indicator).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000-5,000 km (2,000-3,000 miles) or 6 months, whichever comes first. (Refer to manual for precise interval).

Spark Plug Replacement Interval:

Every 10,000-15,000 km (6,000-9,000 miles). (Refer to manual for precise interval).

Air Filter Cleaning Interval:

Every 5,000-10,000 km (3,000-6,000 miles). (Refer to manual for precise interval).

Brake Fluid Replacement Interval:

Every 2 years or as needed based on fluid condition. (Refer to manual for precise interval).

Fluid Specifications

Brake Fluid Type:

DOT 3 or DOT 4 hydraulic brake fluid.

Fork Oil Type:

Yamaha Suspension Oil 10W or equivalent SAE 10W fork oil.

Final Drive Oil Type:

Gear oil SAE 80 or 90, API GL-4. (Refer to manual for exact specification and capacity).

Known Issues

Common Issues:

Carburetor gumming if not run regularly, potential wear on valve stem seals leading to oil consumption, aging electrical connectors causing intermittent issues, clutch wear over time.

📚 Vehicle History

Brand Heritage

Yamaha Motorcycle History:

Yamaha Motor Company, established in 1955, has a rich history in motorcycle manufacturing, known for innovation, performance, and reliability across various genres from sportbikes to cruisers.

Model Evolution

Virago Lineage:

The Virago line was Yamaha's entry into the V-twin cruiser market, offering stylish styling with accessible performance. The XV250 Virago 250 served as an entry-level cruiser.

Production

Production Period:

The XV250 Virago was produced for an extended period, with the range covered by this manual spanning 1989-2005.

🏆 Awards & Recognition

Recognitions

Model Awards:

While specific major awards for the XV250 Virago are not widely publicized, it was a popular and well-regarded entry-level cruiser in its segment, appreciated for its styling and ease of use.