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Introduction
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Market Position
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Segment:
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Entry-level cruiser, lightweight motorcycle
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Target Audience:
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Beginner riders, riders seeking an economical and easy-to-handle motorcycle for commuting and leisure riding
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Competitive Analysis
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Key Competitors:
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Honda Rebel 250, Kawasaki Vulcan 500 (though larger displacement), Suzuki Savage/Boulevard S40 (single cylinder), various smaller displacement import cruisers
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Key Features
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Design Philosophy:
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Classic V-twin cruiser styling, user-friendly ergonomics, reliable and accessible performance
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Unique Selling Points:
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V-twin engine character in a small displacement, low seat height for accessibility, reputation for reliability and ease of maintenance
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Manual Details
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Coverage Areas
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Covered Years:
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1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008
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Engine Variants Covered:
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XV250 engine (248cc, V-twin)
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Page Count
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Estimated Page Count:
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Likely 400-600 pages (typical for comprehensive factory service manuals)
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Manual Type
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Manual Type:
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Factory Service Repair Manual
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Language
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Language:
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English (standard for factory manuals distributed globally, though regional variations exist)
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Format
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Format:
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PDF Download
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Manual Coverage
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Systems Covered
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Engine Systems:
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Engine assembly, disassembly, lubrication, cooling, intake, exhaust, fuel injection/carburetion, ignition system, starting system, engine diagnostics
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Transmission Systems:
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Clutch, transmission gear operation, shift mechanism, transmission lubrication, troubleshooting
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Chassis Systems:
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Frame, front suspension (forks), rear suspension (shock absorbers), steering system, wheels and tires, brake systems (front and rear, hydraulic/mechanical), drive chain/belt
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Electrical Systems:
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Battery, charging system (alternator/stator, regulator/rectifier), ignition system (CDI), lighting system (headlight, taillight, signals), starting system (starter motor, solenoid), instrumentation, wiring diagrams
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Bodywork And Trim:
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Fuel tank, seat assembly, fenders, side covers, handlebars, controls, mirrors, fairings (if applicable), graphics and decals
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Procedures Included
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Maintenance Procedures:
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Oil changes, filter replacement, spark plug service, air filter cleaning/replacement, chain adjustment/lubrication, brake fluid flush, coolant checks/flushes (if liquid-cooled, though XV250 is air-cooled), tire pressure checks, battery maintenance, general inspection points
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Troubleshooting Procedures:
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Diagnostic flowcharts for common problems, electrical troubleshooting, engine performance issues, starting problems, braking issues, suspension issues
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Repair Procedures:
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Detailed step-by-step instructions for component removal, installation, and overhaul; torque specifications for all fasteners; special tool recommendations
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Disassembly And Assembly:
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Complete engine rebuild, transmission overhaul, carburetor disassembly/cleaning/rebuilding, fork seal replacement, brake caliper service, electrical component replacement
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Technical Depth
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Diagnostic Capabilities:
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Advanced diagnostic procedures, including electrical system testing with multimeters, timing checks, compression testing, and fuel system analysis
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Rebuild Specifications:
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Complete specifications for engine and transmission rebuilding, including piston ring gap, bearing clearances, valve clearances, and more
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Electrical Diagrams:
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Detailed, comprehensive wiring diagrams with component locations and wire color codes
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Special Tooling:
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Identification of specific Yamaha special tools required for certain procedures, often with part numbers
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Engine Specifications
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Primary Engine
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Engine Type:
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Air-cooled, 4-stroke, V-twin, SOHC, 2 valves per cylinder
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Displacement:
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248 cc (15.1 cu. in.)
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Bore X Stroke:
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49.0 mm x 66.0 mm (1.93 in x 2.60 in)
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Compression Ratio:
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20.5:1 (This is extremely low and likely incorrect based on typical engine specs. Factory manuals usually list around 9.0:1 to 10.5:1. Assuming a typo in the source data and will use a common range for this engine type if exact data isn't provided by the manual description.) - **Correction**: Based on common knowledge of the XV250, the compression ratio is closer to 9.7:1. The provided data needs verification from the manual itself.
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Ignition:
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CDI (Capacitor Discharge Ignition)
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Performance
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Horsepower:
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Approx. 18-20 hp @ 7,500 rpm (varies slightly by year and market)
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Torque:
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Approx. 1.7 kg-m (12.3 lb-ft) @ 6,000 rpm (varies slightly by year and market)
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Fuel System
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Carburetion:
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Dual Mikuni carburetors (e.g., VM24SH or similar)
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Fuel Capacity:
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Approx. 9.2 L (2.4 US gal)
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Fuel Type:
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Unleaded gasoline
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Maintenance
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Service Intervals
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Oil Change Interval:
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Every 3,000 - 5,000 km (1,800 - 3,000 miles) or annually, whichever comes first (specific recommendation in manual).
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Spark Plug Service:
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Inspect every 5,000 km (3,000 miles), replace as needed (specific gap and type in manual).
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Valve Clearance Adjustment:
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Initial check at 1,000 km (600 miles), then every 10,000 km (6,000 miles) or as per manual recommendations.
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Brake Fluid Flush:
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Every 2 years or as per manual, as brake fluid absorbs moisture.
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Fluid Specifications
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Engine Oil Type:
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Yamalube 4 (or equivalent) SAE 10W-40 API SE or SF classification (specific grade and quantity in manual).
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Fork Oil Type:
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Specific viscosity and quantity (e.g., Yamalube fork oil 10W or equivalent) detailed in manual.
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Brake Fluid Type:
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DOT 3 or DOT 4 hydraulic brake fluid (check manual for specific recommendation).
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Coolant Type:
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Not Applicable (Air-cooled engine)
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Known Issues
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Carburetor Issues:
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Gumming of carburetors due to old fuel, requiring cleaning and synchronization. Idle speed instability.
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Electrical Issues:
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Corrosion of electrical connectors, failing rectifier/regulator, intermittent headlight or charging system issues.
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Fuel System Issues:
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Petcock diaphragm failure, fuel line degradation over time.
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Suspension Wear:
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Worn fork seals leading to oil leaks, worn rear shock absorbers affecting ride quality.
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Filter Part Numbers
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Oil Filter Part Number:
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Specific Yamaha part number (e.g., 5JX-13440-00 or similar, needs manual verification).
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Air Filter Part Number:
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Specific Yamaha part number (e.g., 4X7-14411-00-00 or similar, needs manual verification).
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