Yamaha XV250 1988-2008 Workshop Repair Service Manual

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🏷️ Basic Information Identification Make: Yamaha Model: XV250 Nickname: Virago 250 / V-Star 250 Codes Chassis Codes: XV250S, XV250S2 (example, specific codes may vary by region) Engine Codes: XV250, 3LW (example, specific codes may vary by region) 👋 Introduction Market Position Segment: Lightweight cruiser motorcycle. Target Audience: New riders, urban commuters, those seeking a stylish and manageable cruiser. Competitive Analysis Competitors: Honda Rebel 250, Kawasaki Vulcan 250, Suzuki Savage 400 (though slightly larger). Key Features Engine Layout: V-twin, air-cooled. Design Philosophy: Classic cruiser styling with a compact and user-friendly package. Manual Utility: Essential for owners and technicians performing maintenance, repairs, and diagnostics. 📋 Manual Details Coverage Areas Years Covered: 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008 Models Covered: Yamaha XV250 Virago, Yamaha XV250 V-Star Page Count Total Pages: 287 Manual Type Type: Workshop Service Manual / Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Overhaul: Complete disassembly, inspection, repair, and reassembly of the engine. Fuel System: Carburetor(s) adjustment, cleaning, rebuilding, fuel pump, fuel lines. Ignition System: CDI unit, spark plugs, ignition timing, wiring. Transmission And Clutch: Clutch operation, adjustment, replacement, gearbox disassembly and assembly, gear shifting. Electrical System: Wiring diagrams, battery, charging system (stator, regulator/rectifier), lighting, starter motor, ignition switch. Chassis And Frame: Frame inspection, steering head bearings, swingarm, suspension. Front Suspension: Fork disassembly, seal replacement, oil levels and types, spring specifications. Rear Suspension: Shock absorber inspection, adjustment, mounting. Brakes: Front and rear brake system inspection, pad replacement, fluid bleeding, caliper maintenance. Cooling System: Air-cooled engine specific checks and maintenance. Exhaust System: Inspection and maintenance of exhaust pipes and mufflers. Wheels And Tires: Wheel bearing maintenance, tire pressure, rim inspection. Bodywork And Trim: Fender, tank, seat, and other cosmetic component removal and installation. Procedures Included Routine Maintenance: Oil changes, filter replacement, spark plug service, chain adjustment, brake checks. Troubleshooting: Diagnostic charts and symptom-based problem solving for common issues. Component Rebuilding: Detailed steps for rebuilding carburetors, brake calipers, and other wear items. Wiring Diagrams: Comprehensive electrical schematics for easy diagnosis and repair. Torque Specifications: Precise torque values for critical fasteners across all systems. Clearances And Tolerances: Specifications for valve clearances, piston-to-cylinder wall, etc. Technical Depth Depth: Comprehensive, suitable for professional technicians and advanced DIY mechanics. Diagnostic Capabilities: Includes troubleshooting guides for identifying and resolving mechanical and electrical faults. Rebuild Instructions: Detailed, step-by-step instructions for major component rebuilds. 📊 Manual Specifications File Format File Type: PDF Print Quality Resolution: High-resolution, clear text and diagrams suitable for printing. Binding Type Binding: N/A (Digital PDF format) Paper Type Paper: N/A (Digital PDF format) Searchability Text Search: Likely searchable PDF, allowing users to quickly find specific information. Compatibility Device Compatibility: Viewable on any device with a PDF reader (computers, tablets, smartphones). ⚙️ Engine Specifications Primary Engine Type: 4-stroke, V-twin, SOHC, 2 valves per cylinder Displacement: 248 cc (15.1 cu in) Bore X Stroke: 49.0 mm x 66.0 mm (approx.) Compression Ratio: 22.5 : 1 (approx.) Performance Horsepower: Approx. 18-20 HP @ 7,500 RPM (varies slightly by year and region) Torque: Approx. 19-20 Nm (14-15 lb-ft) @ 5,500 RPM (varies slightly by year and region) Fuel System Carburetor Type: Mikuni VM34 (typically single downdraft carburetor, some variants may differ) Fuel Delivery: Gravity feed from fuel tank (may include a fuel pump on some models/years). Fuel Type: Unleaded gasoline, minimum octane rating of 87 (RON+MON)/2 (AKI). Lubrication System Oil Type: API SE, SF or SG class, SAE 20W-40 or 10W-30 motorcycle oil. Oil Capacity: Approx. 1.4 Liters (1.5 US qt) without filter change; 1.6 Liters (1.7 US qt) with filter change. Ignition System Ignition Type: CDI (Capacitor Discharge Ignition) Spark Plug Type: NGK DPR7EA-9 or equivalent Spark Plug Gap: 0.7 - 0.8 mm (0.028 - 0.031 in) 🔧 Transmission Standard Type: 5-speed constant mesh Optional Optional Transmissions: N/A (Only one standard transmission offered). Features Clutch Type: Wet, multiple-disc Final Drive: Chain drive Transmission Oil Type: API GL-4 SAE 80 or 90 hypoid gear oil (refer to manual for specific Yamaha recommendations). Transmission Oil Capacity: Approx. 0.5 Liters (0.5 US qt) 📐 Dimensions Exterior Overall Length: Approx. 2,185 mm (86.0 in) Overall Width: Approx. 760 mm (29.9 in) Overall Height: Approx. 1,100 mm (43.3 in) Wheelbase: Approx. 1,490 mm (58.7 in) Ground Clearance: Approx. 145 mm (5.7 in) Seat Height: Approx. 710 mm (28.0 in) Weights Dry Weight: Approx. 130 kg (287 lbs) Wet Weight: Approx. 147 kg (324 lbs) (with all fluids and a full tank) Fuel Capacity: 12 Liters (3.2 US gal), including a 2.5L (0.7 gal) reserve. Wheels And Tires Front Tire Size: 3.00-18 4PR Rear Tire Size: 130/90-15 M/C 66P Front Brake Size: 210 mm (8.3 in) Disc Rear Brake Size: 130 mm (5.1 in) Drum 🛡️ Safety Features Ratings Crash Test Ratings:...

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Type: Motorcycle

Sku: 66395

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Availability: In stock

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

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Description

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

XV250

Nickname:

Virago 250 / V-Star 250

Codes

Chassis Codes:

XV250S, XV250S2 (example, specific codes may vary by region)

Engine Codes:

XV250, 3LW (example, specific codes may vary by region)

👋 Introduction

Market Position

Segment:

Lightweight cruiser motorcycle.

Target Audience:

New riders, urban commuters, those seeking a stylish and manageable cruiser.

Competitive Analysis

Competitors:

Honda Rebel 250, Kawasaki Vulcan 250, Suzuki Savage 400 (though slightly larger).

Key Features

Engine Layout:

V-twin, air-cooled.

Design Philosophy:

Classic cruiser styling with a compact and user-friendly package.

Manual Utility:

Essential for owners and technicians performing maintenance, repairs, and diagnostics.

📋 Manual Details

Coverage Areas

Years Covered:

1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008

Models Covered:

Yamaha XV250 Virago, Yamaha XV250 V-Star

Page Count

Total Pages:

Manual Type

Type:

Workshop Service Manual / Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Overhaul:

Complete disassembly, inspection, repair, and reassembly of the engine.

Fuel System:

Carburetor(s) adjustment, cleaning, rebuilding, fuel pump, fuel lines.

Ignition System:

CDI unit, spark plugs, ignition timing, wiring.

Transmission And Clutch:

Clutch operation, adjustment, replacement, gearbox disassembly and assembly, gear shifting.

Electrical System:

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

Chassis And Frame:

Frame inspection, steering head bearings, swingarm, suspension.

Front Suspension:

Fork disassembly, seal replacement, oil levels and types, spring specifications.

Rear Suspension:

Shock absorber inspection, adjustment, mounting.

Brakes:

Front and rear brake system inspection, pad replacement, fluid bleeding, caliper maintenance.

Cooling System:

Air-cooled engine specific checks and maintenance.

Exhaust System:

Inspection and maintenance of exhaust pipes and mufflers.

Wheels And Tires:

Wheel bearing maintenance, tire pressure, rim inspection.

Bodywork And Trim:

Fender, tank, seat, and other cosmetic component removal and installation.

Procedures Included

Routine Maintenance:

Oil changes, filter replacement, spark plug service, chain adjustment, brake checks.

Troubleshooting:

Diagnostic charts and symptom-based problem solving for common issues.

Component Rebuilding:

Detailed steps for rebuilding carburetors, brake calipers, and other wear items.

Wiring Diagrams:

Comprehensive electrical schematics for easy diagnosis and repair.

Torque Specifications:

Precise torque values for critical fasteners across all systems.

Clearances And Tolerances:

Specifications for valve clearances, piston-to-cylinder wall, etc.

Technical Depth

Depth:

Comprehensive, suitable for professional technicians and advanced DIY mechanics.

Diagnostic Capabilities:

Includes troubleshooting guides for identifying and resolving mechanical and electrical faults.

Rebuild Instructions:

Detailed, step-by-step instructions for major component rebuilds.

📊 Manual Specifications

File Format

File Type:

Print Quality

Resolution:

High-resolution, clear text and diagrams suitable for printing.

Binding Type

Binding:

N/A (Digital PDF format)

Paper Type

Paper:

N/A (Digital PDF format)

Searchability

Text Search:

Likely searchable PDF, allowing users to quickly find specific information.

Compatibility

Device Compatibility:

Viewable on any device with a PDF reader (computers, tablets, smartphones).

⚙️ Engine Specifications

Primary Engine

Type:

4-stroke, V-twin, SOHC, 2 valves per cylinder

Displacement:

248 cc (15.1 cu in)

Bore X Stroke:

49.0 mm x 66.0 mm (approx.)

Compression Ratio:

22.5 : 1 (approx.)

Performance

Horsepower:

Approx. 18-20 HP @ 7,500 RPM (varies slightly by year and region)

Torque:

Approx. 19-20 Nm (14-15 lb-ft) @ 5,500 RPM (varies slightly by year and region)

Fuel System

Carburetor Type:

Mikuni VM34 (typically single downdraft carburetor, some variants may differ)

Fuel Delivery:

Gravity feed from fuel tank (may include a fuel pump on some models/years).

Fuel Type:

Unleaded gasoline, minimum octane rating of 87 (RON+MON)/2 (AKI).

Lubrication System

Oil Type:

API SE, SF or SG class, SAE 20W-40 or 10W-30 motorcycle oil.

Oil Capacity:

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

Ignition System

Ignition Type:

CDI (Capacitor Discharge Ignition)

Spark Plug Type:

NGK DPR7EA-9 or equivalent

Spark Plug Gap:

0.7 - 0.8 mm (0.028 - 0.031 in)

🔧 Transmission

Standard

Type:

5-speed constant mesh

Optional

Optional Transmissions:

N/A (Only one standard transmission offered).

Features

Clutch Type:

Wet, multiple-disc

Final Drive:

Chain drive

Transmission Oil Type:

API GL-4 SAE 80 or 90 hypoid gear oil (refer to manual for specific Yamaha recommendations).

Transmission Oil Capacity:

Approx. 0.5 Liters (0.5 US qt)

📐 Dimensions

Exterior

Overall Length:

Approx. 2,185 mm (86.0 in)

Overall Width:

Approx. 760 mm (29.9 in)

Overall Height:

Approx. 1,100 mm (43.3 in)

Wheelbase:

Approx. 1,490 mm (58.7 in)

Ground Clearance:

Approx. 145 mm (5.7 in)

Seat Height:

Approx. 710 mm (28.0 in)

Weights

Dry Weight:

Approx. 130 kg (287 lbs)

Wet Weight:

Approx. 147 kg (324 lbs) (with all fluids and a full tank)

Fuel Capacity:

12 Liters (3.2 US gal), including a 2.5L (0.7 gal) reserve.

Wheels And Tires

Front Tire Size:

3.00-18 4PR

Rear Tire Size:

130/90-15 M/C 66P

Front Brake Size:

210 mm (8.3 in) Disc

Rear Brake Size:

130 mm (5.1 in) Drum

🛡️ Safety Features

Ratings

Crash Test Ratings:

N/A (Motorcycles are not subject to automotive crash testing standards).

Active Features

Braking System:

Single front disc brake, rear drum brake for adequate stopping power.

Lighting:

Headlight, taillight, brake lights, turn signals for visibility.

Passive Features

Frame Construction:

Steel tube frame for rigidity and rider support.

Ergonomics:

Low seat height and relaxed riding posture contribute to rider control and comfort.

💡 Technology Features

Infotainment

Features:

N/A (This is a 1988-2008 model, lacking modern infotainment systems).

Driver Assistance

Features:

N/A (No electronic rider aids or driver assistance features typical of modern vehicles).

Connectivity

Features:

N/A (No Bluetooth, USB, or other connectivity options).

Engine Management

System:

Basic CDI ignition system and mechanical carburetor for fuel delivery. No ECU or sophisticated engine management.

🔧 Maintenance

Service Intervals

Initial Service:

First service typically around 600 miles (1,000 km) for oil change, chain adjustment, and general inspection.

Regular Oil Change:

Every 2,000-3,000 miles (3,000-5,000 km) or every 6 months, whichever comes first.

Air Filter Cleaning Replacement:

Inspect every 3,000 miles (5,000 km); clean or replace as needed.

Spark Plug Replacement:

Replace every 6,000-10,000 miles (10,000-15,000 km) or as per manual recommendation.

Valve Clearance Adjustment:

Inspect and adjust every 6,000-12,000 miles (10,000-20,000 km) or as indicated in the manual.

Brake Fluid Change:

Replace every 2 years or as recommended by the manual.

Fluid Specifications

Engine Oil:

API SE, SF or SG class, SAE 20W-40 or 10W-30 motorcycle oil.

Transmission Oil:

API GL-4 SAE 80 or 90 hypoid gear oil.

Brake Fluid:

DOT 3 or DOT 4 conforming to FMVSS 116.

Fork Oil:

Yamaha's recommended fork oil or equivalent SAE 10W (refer to manual for exact type and quantity).

Known Issues

Carburetor Issues:

Can be prone to fuel delivery issues if not maintained, leading to poor idling or acceleration. Carburetor synchronization (if applicable) is crucial.

Starter Clutch:

Some models might experience wear in the starter clutch mechanism over time, leading to slipping or grinding sounds.

Electrical Connections:

Corrosion or loose connections in the electrical system can cause intermittent faults. Regular inspection of grounds and connectors is recommended.

Front Forks:

Fork seals can degrade over time, leading to oil leaks. Regular cleaning of fork tubes and inspection of seals is advised.

📚 Vehicle History

Brand Heritage

Manufacturer:

Yamaha Motor Company is a Japanese manufacturer of motorcycles, marine products, and other motorized products.

Foundation:

Founded in 1955, Yamaha has a long history of innovation in motorcycle design and engineering.

Model Evolution

Introduction Year:

The XV250 Virago was introduced in the mid-1980s as a smaller displacement option within Yamaha's popular Virago cruiser line.

Model Line:

Part of the 'Virago' series, known for its V-twin engines and classic styling. Later versions were marketed as 'V-Star 250' in some markets, continuing the cruiser lineage.

Design Changes:

While the core design remained consistent throughout its production run (1988-2008 covered here), minor updates to styling, emissions controls, and potentially carburetor jetting occurred over the years.

Production

Manufacturing Location:

Primarily manufactured in Japan by Yamaha.

Production Run:

The XV250 platform has been in continuous production for a significant period, with this manual covering a substantial segment of its development.

🏆 Awards & Recognition

Recognitions

Type:

N/A (Specific industry awards for this particular model are not widely documented).

Ratings

Reliability:

Generally considered a reliable and robust motorcycle, known for its longevity with proper maintenance.

Certifications

Emissions:

Compliance with emissions standards of its era, which were less stringent than current regulations. Manual will contain relevant emissions system information.