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Troubleshooting
Related Manuals for Yamaha XT250T
Summary of Contents for Yamaha XT250T
- Page 1 OWNER’S MANUAL XT250T 4FD-28199-2C...
- Page 3 EAU10100 Welcome to the Yamaha world of motorcycling! As the owner of the XT250, you are benefiting from Yamaha’s vast experience and newest technology regarding the design and manufacture of high-quality products, which have earned Yamaha a reputation for dependability.
- Page 4 This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold. Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most current product information available at the time of printing, there may be minor discrepancies between your motorcycle and this manual.
- Page 5 IMPORTANT MANUAL INFORMATION EAU10200 XT250T OWNER’S MANUAL ©2004 by Yamaha Motor Co., Ltd. 1st edition, April 2004 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan.
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Page 6: Table Of Contents
TABLE OF CONTENTS SAFETY INFORMATION ....1-1 OPERATION AND IMPORTANT RIDING Adjusting the brake lever free Location of important labels .....1-5 POINTS ..........5-1 play ..........6-17 Starting and warming up a cold Adjusting the brake pedal position DESCRIPTION ........2-1 engine .......... 5-1 and free play ...... - Page 7 TABLE OF CONTENTS Replacing a turn signal light bulb ..........6-31 Supporting the motorcycle .....6-32 Front wheel ........6-33 Rear wheel ........6-34 Troubleshooting ......6-36 Troubleshooting chart ....6-37 MOTORCYCLE CARE AND STORAGE ...........7-1 Care ..........7-1 Storage ..........7-3 SPECIFICATIONS ......8-1 CONSUMER INFORMATION....9-1 Identification numbers .....9-1 Motorcycle noise regulation (for Australia) ........9-2...
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Page 8: Safety Information
SAFETY INFORMATION EAU10310 SARY BY MECHANICAL CONDI- Ride where other motorists can MOTORCYCLES SINGLE TIONS. see you. Avoid riding in another TRACK VEHICLES. THEIR SAFE Safe riding motorist’s blind spot. USE AND OPERATION ARE DEPEN- Always make pre-operation Many accidents involve inexperi- DENT UPON THE USE OF PROPER checks. - Page 9 Modifications made to this motorcycle never travel faster than warrant- single most critical factor in the preven- not approved by Yamaha, or the re- ed by road and traffic conditions. tion or reduction of head injuries. moval of original equipment, may ren- Always signal before turning or Always wear an approved helmet.
- Page 10 If accessories 183 kg (403 lb). When loading within this motorcycle. Since Yamaha cannot are added to the handlebar or this weight limit, keep the following in test all other accessories that may be...
- Page 11 SAFETY INFORMATION motorcycle’s electrical system an cle, note the following: eyes, see your doctor immediate- electric failure could result, which The engine and exhaust system ly. If any gasoline spills on your could cause a dangerous loss of may be hot, therefore, park the skin or clothing, immediately wash lights or engine power.
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Page 12: Location Of Important Labels
SAFETY INFORMATION EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle. - Page 13 SAFETY INFORMATION Before you operate this vehicle, read the owner’s manual. Prima di usare il veicolo, leggete il manuale di istruzioni. Lire le manuel du propri étaire avant d ’utiliser ce v éhicule. Lesen Sie die Bedienungsanleitung bevor Sie dieses Fahrzeug fahren. Antes de conducir este vehículo, lea el Manual del Propietario.
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Page 14: Description
DESCRIPTION EAU10410 Left view 1. Headlight (page 6-29) 8. Shift pedal (page 3-4) 2. Fuel cock (page 3-6) 3. Air filter element (page 6-10) 4. Helmet holder (page 3-8) 5. Owner’s tool kit (page 6-1) 6. Shock absorber assembly spring preload adjusting nut (page 3-9) 7. -
Page 15: Right View
DESCRIPTION EAU10420 Right view 1. Battery (page 6-28) 2. Fuse (page 6-29) 3. Engine oil filter element (page 6-7) 4. Engine oil level check window (page 6-7) 5. Brake pedal (page 3-5) -
Page 16: Controls And Instruments
DESCRIPTION EAU10430 Controls and instruments 1. Clutch lever (page 3-4) 9. Fuel tank cap (page 3-5) 2. Left handlebar switches (page 3-3) 3. Starter (choke) knob (page 3-7) 4. Speedometer unit (page 3-2) 5. Main switch/steering lock (page 3-1) 6. Right handlebar switches (page 3-3) 7. -
Page 17: Instrument And Control Functions
INSTRUMENT AND CONTROL FUNCTIONS EAU10460 EAU10680 To unlock the steering Main switch/steering lock LOCK Push the key in, and then turn it to The steering is locked, and all electrical “OFF” while still pushing it. systems are off. The key can be re- EWA10060 moved. -
Page 18: Indicator Lights
INSTRUMENT AND CONTROL FUNCTIONS EAU10980 EAU11080 EAU11630 Indicator lights High beam indicator light “ ” Speedometer unit This indicator light comes on when the high beam of the headlight is switched 1. Speedometer 1. High beam indicator light “ ” 2. -
Page 19: Handlebar Switches
INSTRUMENT AND CONTROL FUNCTIONS EAU12343 Right EAU12500 Handlebar switches Horn switch “ ” Press this switch to sound the horn. Left EAU12660 Engine stop switch “ ” Set this switch to “ ” before starting the engine. Set this switch to “ ”... -
Page 20: Clutch Lever
INSTRUMENT AND CONTROL FUNCTIONS EAU12820 EAU12870 EAU12890 Clutch lever Shift pedal Brake lever 1. Clutch lever 1. Shift pedal 1. Brake lever The clutch lever is located at the left The shift pedal is located on the left The brake lever is located at the right handlebar grip. -
Page 21: Brake Pedal
INSTRUMENT AND CONTROL FUNCTIONS EAU12941 EAU32280 NOTE: Brake pedal Fuel tank cap The fuel tank cap cannot be installed unless the key is in the lock. In addition, the key cannot be removed if the cap is not properly installed and locked. EWA10120 WARNING Make sure that the fuel tank cap is... -
Page 22: Fuel
1. Arrow mark pointing to “OFF” EWA10880 WARNING With the lever in this position, fuel will Your Yamaha engine has been de- Do not overfill the fuel tank, oth- not flow. Always return the lever to this signed to use regular unleaded gaso- erwise it may overflow when the position when the engine is not running. -
Page 23: Starter (Choke) Knob "1
INSTRUMENT AND CONTROL FUNCTIONS fuel while riding, move the lever to this EAU13600 Starter (choke) knob “ ” position. Fill the tank at the first oppor- tunity. Be sure to set the lever back to “ON” after refueling! 1. Arrow mark pointing to “ON” 1. -
Page 24: Seat
INSTRUMENT AND CONTROL FUNCTIONS EAU13981 EAU14290 Seat Helmet holder To remove the seat 1. Remove panels A and B. (See page 6-5.) 2. Remove the bolts and pull the seat off. (×2) 1. Projection 2. Seat holder 1. Helmet holder 2. -
Page 25: Adjusting The Shock Absorber Assembly
INSTRUMENT AND CONTROL FUNCTIONS EAU14930 thereby harden the suspension, preload. Adjusting the shock absorber turn the adjusting nut in direction assembly (a). To decrease the spring pre- Spring preload: This shock absorber assembly is Minimum (soft): load and thereby soften the sus- Distance A = 36.5 mm (1.4 in) equipped with a spring preload adjust- pension, turn the adjusting nut in... - Page 26 To obtain a precise ad- Always have a Yamaha dealer damping, turn the adjusting dial in di- justment, it would be advisable to check service the shock absorber.
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Page 27: Sidestand
EAU15311 Sidestand Ignition circuit cut-off system below and have a Yamaha dealer re- The sidestand is located on the left side The ignition circuit cut-off system (com- pair it if it does not function proper- of the frame. - Page 28 5. Push the start switch. Does the engine start? The neutral switch may be defective. The motorcycle should not be ridden until checked by a Yamaha dealer. With the engine still running: 6. Move the sidestand up. 7. Keep the clutch lever pulled.
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Page 29: Pre-Operation Checks
PRE-OPERATION CHECKS EAU15591 The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly, even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss of tire air pressure could have serious consequences. -
Page 30: Pre-Operation Check List
Adjust if necessary. Make sure that operation is smooth. Check cable free play. Throttle grip 6-13, 6-24 If necessary, have Yamaha dealer adjust cable free play and lubricate cable and grip housing. Make sure that operation is smooth. Control cables 6-24... - Page 31 Make sure that all nuts, bolts and screws are properly tightened. Chassis fasteners — Tighten if necessary. Instruments, lights, signals Check operation. — and switches Correct if necessary. Check operation of ignition circuit cut-off system. Sidestand switch 3-11 If system is defective, have Yamaha dealer check vehicle.
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Page 32: Operation And Important Riding Points
Yamaha dealer check the electrical cir- following conditions must be met: Consult a Yamaha dealer re- cuit. The transmission is in the neutral garding any control or function position. -
Page 33: Starting A Warm Engine
OPERATION AND IMPORTANT RIDING POINTS off. Never accelerate hard when the EAU16640 EAU16671 Starting a warm engine Shifting engine is cold! Follow the same procedure as for start- 7. When the engine is warm, turn the ing a cold engine with the exception starter (choke) off. -
Page 34: Tips For Reducing Fuel
OPERATION AND IMPORTANT RIDING POINTS EAU16800 EAU16841 ECA10260 Tips reducing fuel Engine break-in CAUTION: consumption There is never a more important period Even with the transmission in in the life of your engine than the period Fuel consumption depends largely on the neutral position, do not between 0 and 1600 km (1000 mi). -
Page 35: Parking
Yamaha dealer check the vehi- ans or children are not likely to cle. touch them. Do not park on a slope or on soft ground, otherwise the vehicle may overturn. -
Page 36: Periodic Maintenance And Minor Repair
If you are not familiar with mainte- NOTE: nance work, have a Yamaha dealer If you do not have the tools or experi- do it for you. ence required for a particular job, have a Yamaha dealer perform it for you. -
Page 37: Periodic Maintenance And Lubrication Chart
The annual checks must be performed every year, except if a kilometer-based maintenance is performed in- stead. From 30000 km, repeat the maintenance intervals starting from 6000 km. Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. ODOMETER READING (× 1000 km) - Page 38 PERIODIC MAINTENANCE AND MINOR REPAIR ODOMETER READING (× 1000 km) ANNUAL ITEM CHECK OR MAINTENANCE JOB CHECK Check tread depth and for damage. Replace if necessary. √ √ √ √ √ 10 * Tires Check air pressure. Correct if necessary. √...
- Page 39 PERIODIC MAINTENANCE AND MINOR REPAIR ODOMETER READING (× 1000 km) ANNUAL ITEM CHECK OR MAINTENANCE JOB CHECK Front and rear brake √ √ √ √ √ √ 25 * Check operation. switches √ √ √ √ √ Moving parts and cables Lubricate.
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Page 40: Removing And Installing The Cowling And Panels
PERIODIC MAINTENANCE AND MINOR REPAIR EAU18721 To install the cowling Removing and installing the Place the cowling in the original posi- cowling and panels tion, and then install the screw. The cowling and panels shown need to be removed to perform some of the EAU19292 Panels A and B maintenance jobs described in this... -
Page 41: Checking The Spark Plug
Do not attempt to diagnose such problems yourself. Instead, have a Yamaha dealer check the vehicle. 1. Spark plug cap 2. Remove the spark plug as shown, 2. Check the spark plug for electrode... - Page 42 PERIODIC MAINTENANCE AND MINOR REPAIR necessary. 3. Install the spark plug with the EAU19812 Engine filter spark plug wrench, and then tight- Specified spark plug: element en it to the specified torque. NGK/DR8EA The engine oil level should be checked DENSO/X24ESR-U Tightening torque: before each ride.
- Page 43 PERIODIC MAINTENANCE AND MINOR REPAIR 3. Remove the engine guard by re- NOTE: moving the bolt. The engine oil should be between the minimum and maximum level marks. 1. Engine oil filler cap ECA11000 CAUTION: 1. Engine guard 2. Bolt When removing the engine oil drain 1.
- Page 44 PERIODIC MAINTENANCE AND MINOR REPAIR 6. Remove the oil filter element drain replace them if necessary. bolt to drain the oil from the oil filter 10. Clean the oil filter element with sol- (×2) element. vent, and then install it. NOTE: 4 3 2 1 Check the oil filter element for damage...
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Page 45: Cleaning The Air Filter Element
PERIODIC MAINTENANCE AND MINOR REPAIR bolt, do not forget to install the addition, do not use oils labeled EAU20851 Cleaning the air filter element O-ring, compression spring, and oil “ENERGY CONSERVING II” or The air filter element should be cleaned strainer in position. - Page 46 PERIODIC MAINTENANCE AND MINOR REPAIR side facing forward and with the “UP” mark pointing as shown. 6. Apply oil of the recommended type 1. Air filter element to the entire surface of the sponge 4. Remove the sponge material from material, and then squeeze the ex- the air filter element frame.
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Page 47: Adjusting The Carburetor
Therefore, most car- checked and, if necessary, adjusted as buretor adjustments should be left to a follows at the intervals specified in the Yamaha dealer, who has the neces- periodic maintenance and lubrication sary professional knowledge and expe- chart. -
Page 48: Adjusting The Throttle Cable Free Play
(b). resulting in improper air-fuel mixture and/or engine noise. To prevent this from occurring, the valve clearance must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart. 1. Locknut 1. -
Page 49: Tires
PERIODIC MAINTENANCE AND MINOR REPAIR EAU21630 that the total weight of rider, Tires Tire air pressure (measured on cold passenger, cargo, and accesso- tires): To maximize the performance, durabil- ries does not exceed the speci- 0–90 kg (0–198 lb) : ity, and safe operation of your motorcy- Front: fied maximum load for the... - Page 50 (minimum tread depth), if the tire has a have a Yamaha dealer replace nail or glass fragments in it, or if the the tire immediately. sidewall is cracked, have a Yamaha The replacement of all wheel- dealer replace the tire immediately. and brake-related parts, includ-...
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Page 51: Spoke Wheels
If any dam- age is found, have a Yamaha dealer replace the wheel. Do not attempt even the smallest repair to 1. Locknut (clutch lever) the wheel. -
Page 52: Adjusting The Brake Lever Free Play
PERIODIC MAINTENANCE AND MINOR REPAIR bolt in direction (b). ver free play, turn the adjusting nut EAU22092 Adjusting the brake lever free in direction (b). NOTE: play 6. Tighten the locknut at the clutch le- If the specified clutch lever free play ver and the crankcase. -
Page 53: Adjusting The Brake Pedal Position And Free Play
1. Adjusting bolt WARNING the hydraulic system will dimin- 2. Locknut ish the braking performance, It is advisable to have a Yamaha 3. Tighten the locknut. which may result in loss of con- dealer make these adjustments. EWA11230 trol and an accident. -
Page 54: Adjusting The Rear Brake Light
If obtained as described, have a turn the adjusting nut at the brake rod in necessary, adjust the brake light switch Yamaha dealer make this ad- direction (a). To decrease the brake as follows. justment. -
Page 55: Checking The Front Brake Pads And Rear Brake Shoes
EAU22380 indicator groove has almost disap- brake shoes as a set. Checking the front brake pads peared, have a Yamaha dealer replace and rear brake shoes the brake pads as a set. The front brake pads and the rear brake... -
Page 56: Checking The Brake Fluid Level
EAU32341 ter cylinder is level by turning the brake fluid level goes down sud- Checking the brake fluid level handlebars. denly, have a Yamaha dealer Front brake Use only the recommended quality check the cause. brake fluid, otherwise the rubber... -
Page 57: Changing The Brake Fluid
EAU22720 EAU22760 Changing the brake fluid Drive chain slack Have a Yamaha dealer change the The drive chain slack should be brake fluid at the intervals specified in checked before each ride and adjusted the NOTE after the periodic mainte- if necessary. -
Page 58: Lubricating The Drive Chain
PERIODIC MAINTENANCE AND MINOR REPAIR EAU23021 ECA10570 Lubricating the drive chain CAUTION: The drive chain must be cleaned and Improper drive chain slack will over- lubricated at the intervals specified in load the engine as well as other vital the periodic maintenance and lubrica- parts of the motorcycle and can lead tion chart, otherwise it will quickly wear to chain slippage or breakage. -
Page 59: Checking And Lubricating The Cables
If a cable is damaged periodic maintenance chart. or does not move smoothly, have a Yamaha dealer check or replace it. Recommended lubricant: Engine oil EWA10720 WARNING... -
Page 60: Checking And Lubricating The Brake And Shift Pedals
EWA10730 WARNING If the sidestand does not move up and down smoothly, have a Yamaha dealer check or repair it. The operation of the brake and shift The operation of the brake and clutch pedals should be checked before each... -
Page 61: Lubricating The Rear Suspension
Check the inner tubes for scratches, fork does not operate smoothly, damage and excessive oil leakage. 1. Grease nipple have a Yamaha dealer check or re- To check the operation The pivoting points of the rear suspen- 1. Place the vehicle on a level sur- pair it. -
Page 62: Checking The Steering
2. Hold the lower ends of the front fork legs and try to move them for- ward and backward. If any free play can be felt, have a Yamaha dealer check or repair the steering. 6-27... -
Page 63: Battery
To charge the battery dangerous since it contains sul- To charge a sealed-type (MF) Have a Yamaha dealer charge the bat- furic acid, which causes severe battery, a special (constant-volt- tery as soon as possible if it seems to burns. -
Page 64: Replacing The Fuse
The fuse holder is located behind panel 4. If the fuse immediately blows B. (See page 6-5.) again, have a Yamaha dealer If the fuse is blown, replace it as fol- check the electrical system. lows. 1. Turn the key to “OFF” and turn off all electrical circuits. - Page 65 8. Install the cowling. ECA10660 9. Have a Yamaha dealer adjust the CAUTION: headlight beam if necessary. Do not touch the glass part of the headlight bulb to keep it free from...
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Page 66: Replacing The Tail/Brake Light Bulb
PERIODIC MAINTENANCE AND MINOR REPAIR EAU24131 EAU24201 Replacing the tail/brake light Replacing a turn signal light bulb bulb 1. Remove the tail/brake light lens by 1. Remove the turn signal light lens removing the screws. by removing the screw. 1. Tail/brake light bulb 3. -
Page 67: Supporting The Motorcycle
PERIODIC MAINTENANCE AND MINOR REPAIR EAU24350 frame in front of the rear wheel or under Supporting the motorcycle each side of the swingarm. Since this model is not equipped with a centerstand, follow these precautions when removing the front and rear wheel or performing other maintenance requiring the motorcycle to stand up- right. -
Page 68: Front Wheel
EAU25011 WARNING To install the front wheel 1. Install the speedometer gear unit It is advisable to have a Yamaha into the wheel hub so that the pro- dealer service the wheel. jections mesh with the slots. Securely support the motorcy- cle so that there is no danger of it falling over. -
Page 69: Rear Wheel
8. Install the engine guard by install- ing the bolt. EAU25470 To remove the rear wheel EWA10820 WARNING It is advisable to have a Yamaha dealer service the wheel. Securely support the motorcy- cle so that there is no danger of it falling over. 1. Retainer 1. - Page 70 PERIODIC MAINTENANCE AND MINOR REPAIR the brake rod from the brake cam- shaft lever. 1. Retainer NOTE: The drive chain does not need to be NOTE: 1. Brake pedal free play adjusting nut disassembled in order to remove and Make sure that the drive chain adjust- 2.
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Page 71: Troubleshooting
After adjusting the brake pedal free self. However, should your motorcycle play, check the operation of the require any repair, take it to a Yamaha brake light. dealer, whose skilled technicians have the necessary tools, experience, and 7. -
Page 72: Troubleshooting Chart
Remove the spark plug and check the electrodes. The engine does not start. Have a Yamaha dealer check the vehicle. Check the battery. 4. Battery The engine turns over The battery is good. -
Page 73: Motorcycle Care And Storage
MOTORCYCLE CARE AND STORAGE EAU26000 brush, but never apply such prod- sponges which have been in Care ucts onto seals, gaskets, sprock- contact with strong or abrasive While the open design of a motorcycle ets, the drive chain and wheel cleaning products, solvent or reveals the attractiveness of the tech- axles. - Page 74 MOTORCYCLE CARE AND STORAGE any marks. If the windshield is ter and a mild detergent, after the tection spray metal, scratched, use a quality plastic engine has cooled down. including chrome- and nickel-plat- polishing compound after ed, surfaces. ECA10790 CAUTION: washing.
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Page 75: Storage
NOTE: tect the cylinder, piston rings, etc. wet, will allow water and humid- Consult a Yamaha dealer for advice on from corrosion. ity to seep in and cause rust. what products to use. - Page 76 MOTORCYCLE CARE AND STORAGE from the spark plug, and then place and charge it once a month. install the spark plug and the Do not store the battery in an ex- spark plug cap. cessively cold or warm place [less than 0 °C (30 °F) or more EWA10950 WARNING than 30 °C (90 °F)].
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Page 77: Specifications
SPECIFICATIONS EAU26337 Engine oil: Carburetor: Dimensions: Type: Manufacturer: Overall length: SAE10W30 or SAE10W40 or SAE15W40 MIKUNI 2100 mm (82.7 in) or SAE20W40 or SAE20W50 Type x quantity: Overall width: BST34 x 1 -20 -10 10 20 30 40 50 ˚C 800 mm (31.5 in) Spark plug(s): Overall height:... - Page 78 SPECIFICATIONS 3rd: Loading: Operation: 30/21 (1.428) Right hand operation Maximum load: 4th: Recommended fluid: 183 kg (403 lb) 27/24 (1.125) DOT 3 or 4 * (Total weight of rider, passenger, cargo 5th: Rear brake: and accessories) 25/27 (0.925) Tire air pressure (measured on cold Type: 6th: Drum brake...
- Page 79 SPECIFICATIONS Headlight: Bulb type: Halogen bulb Bulb voltage, wattage x quantity: Headlight: 12 V, 35 W/35.0 W × 1 Tail/brake light: 12 V, 5.0/21.0 W × 1 Front turn signal light: 12 V, 21.0 W × 2 Rear turn signal light: 12 V, 21.0 W ×...
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Page 80: Consumer Information
Record the key identification number, vehicle identification number and mod- el label information in the spaces pro- vided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehi- cle is stolen. KEY IDENTIFICATION NUMBER: 1. -
Page 81: Motorcycle Noise Regulation (For Australia)
This information will be The use of the vehicle after such needed when ordering spare parts from device or element of design has a Yamaha dealer. been removed or rendered inoper- ative by any person. - Page 82 INDEX Air filter element, cleaning....... 6-10 Front fork, checking .........6-26 Rear brake light switch, adjusting.... 6-19 Fuel............3-6 Rear suspension, lubricating ....6-26 Fuel cock ...........3-6 Battery............. 6-28 Fuel consumption, tips for reducing...5-3 Brake and clutch levers, checking and Safety information ........1-1 Fuel tank cap ..........3-5 lubricating ..........
- Page 83 INDEX Vehicle identification number.....9-1 Wheel bearings, checking .......6-27 Wheel (front) ..........6-33 Wheel (rear)..........6-34 Wheels.............6-16...
- Page 86 YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2004.5–0.1x1 !