Yamaha XV250 1988-2008 Factory Service Repair Manual
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Basic Information Identification Make: Yamaha Model: XV250 Virago Common Model Designations: XV250, Virago 250, V-Star 250 (later models) Codes Chassis Codes: XV250 (general), specific VIN prefixes vary by year and region Introduction Market Position Segment: Entry-level cruiser, lightweight motorcycle Target Audience: Beginner riders, riders seeking an economical and easy-to-handle motorcycle for commuting and leisure riding Competitive Analysis Key Competitors: Honda Rebel 250, Kawasaki Vulcan 500 (though larger displacement), Suzuki Savage/Boulevard S40 (single cylinder), various smaller displacement import cruisers Key Features Design Philosophy: Classic V-twin cruiser styling, user-friendly ergonomics, reliable and accessible performance Unique Selling Points: V-twin engine character in a small displacement, low seat height for accessibility, reputation for reliability and ease of maintenance Manual Details Coverage Areas Covered Years: 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008 Engine Variants Covered: XV250 engine (248cc, V-twin) Page Count Estimated Page Count: Likely 400-600 pages (typical for comprehensive factory service manuals) Manual Type Manual Type: Factory Service Repair Manual Language Language: English (standard for factory manuals distributed globally, though regional variations exist) Format Format: PDF Download Manual Coverage Systems Covered Engine Systems: Engine assembly, disassembly, lubrication, cooling, intake, exhaust, fuel injection/carburetion, ignition system, starting system, engine diagnostics Transmission Systems: Clutch, transmission gear operation, shift mechanism, transmission lubrication, troubleshooting Chassis Systems: Frame, front suspension (forks), rear suspension (shock absorbers), steering system, wheels and tires, brake systems (front and rear, hydraulic/mechanical), drive chain/belt Electrical Systems: Battery, charging system (alternator/stator, regulator/rectifier), ignition system (CDI), lighting system (headlight, taillight, signals), starting system (starter motor, solenoid), instrumentation, wiring diagrams Bodywork And Trim: Fuel tank, seat assembly, fenders, side covers, handlebars, controls, mirrors, fairings (if applicable), graphics and decals Procedures Included Maintenance Procedures: 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 Troubleshooting Procedures: Diagnostic flowcharts for common problems, electrical troubleshooting, engine performance issues, starting problems, braking issues, suspension issues Repair Procedures: Detailed step-by-step instructions for component removal, installation, and overhaul; torque specifications for all fasteners; special tool recommendations Disassembly And Assembly: Complete engine rebuild, transmission overhaul, carburetor disassembly/cleaning/rebuilding, fork seal replacement, brake caliper service, electrical component replacement Technical Depth Diagnostic Capabilities: Advanced diagnostic procedures, including electrical system testing with multimeters, timing checks, compression testing, and fuel system analysis Rebuild Specifications: Complete specifications for engine and transmission rebuilding, including piston ring gap, bearing clearances, valve clearances, and more Electrical Diagrams: Detailed, comprehensive wiring diagrams with component locations and wire color codes Special Tooling: Identification of specific Yamaha special tools required for certain procedures, often with part numbers Manual Specifications File Format File Format: Portable Document Format (PDF) Print Quality Print Quality: High-resolution scans of original factory documentation, ensuring clarity of text and diagrams. Searchable text is common in professionally formatted PDFs. Binding Type Binding Type: Not Applicable (Digital PDF Download) Paper Type Paper Type: Not Applicable (Digital PDF Download) Accessibility Downloadable: Yes Compatibility Device Compatibility: Compatible with any device that can open PDF files (computers, tablets, smartphones) Engine Specifications Primary Engine Engine Type: Air-cooled, 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 (1.93 in x 2.60 in) Compression Ratio: 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. Ignition: CDI (Capacitor Discharge Ignition) Performance Horsepower: Approx. 18-20 hp @ 7,500 rpm (varies slightly by year and market) Torque: Approx. 1.7 kg-m (12.3 lb-ft) @ 6,000 rpm (varies slightly by year and market) Fuel System Carburetion: Dual Mikuni carburetors (e.g., VM24SH or similar) Fuel Capacity: Approx. 9.2 L (2.4 US gal) Fuel Type: Unleaded gasoline Transmission Standard Transmission Type: 5-speed constant mesh Clutch Type: Wet, multiple disc, cable-actuated Final Drive: Chain drive Features Gear Ratios: Specific gear ratios are detailed within the manual, crucial for performance tuning and diagnostics. Transmission Fluid: Yamaha motorcycle gear oil or equivalent (specific grade and capacity detailed in manual) Dimensions Exterior Length: Approx. 2,185 mm (86.0 in) Width: Approx. 715 mm (28.1 in) Height: Approx. 1,110 mm (43.7 in) Wheelbase: Approx. 1,485 mm (58.5 in) Ground Clearance: Approx. 140 mm (5.5 in) Weights Dry Weight: Approx. 147 kg (324 lbs) Wet Weight: Approx. 159 kg (350 lbs) (with all fluids) Wheels And Tires Front Tire Size: 3.00-18 4PR Rear Tire Size: 130/90-15 M/C 66P Wheel Type: Spoked wheels with chrome rims Wheelbase Specifications:...
Frame, front suspension (forks), rear suspension (shock absorbers), steering system, wheels and tires, brake systems (front and rear, hydraulic/mechanical), drive chain/belt
Electrical Systems:
Battery, charging system (alternator/stator, regulator/rectifier), ignition system (CDI), lighting system (headlight, taillight, signals), starting system (starter motor, solenoid), instrumentation, wiring diagrams
Bodywork And Trim:
Fuel tank, seat assembly, fenders, side covers, handlebars, controls, mirrors, fairings (if applicable), graphics and decals
Procedures Included
Maintenance Procedures:
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
Troubleshooting Procedures:
Diagnostic flowcharts for common problems, electrical troubleshooting, engine performance issues, starting problems, braking issues, suspension issues
Repair Procedures:
Detailed step-by-step instructions for component removal, installation, and overhaul; torque specifications for all fasteners; special tool recommendations
Advanced diagnostic procedures, including electrical system testing with multimeters, timing checks, compression testing, and fuel system analysis
Rebuild Specifications:
Complete specifications for engine and transmission rebuilding, including piston ring gap, bearing clearances, valve clearances, and more
Electrical Diagrams:
Detailed, comprehensive wiring diagrams with component locations and wire color codes
Special Tooling:
Identification of specific Yamaha special tools required for certain procedures, often with part numbers
Manual Specifications
File Format
File Format:
Portable Document Format (PDF)
Print Quality
Print Quality:
High-resolution scans of original factory documentation, ensuring clarity of text and diagrams. Searchable text is common in professionally formatted PDFs.
Binding Type
Binding Type:
Not Applicable (Digital PDF Download)
Paper Type
Paper Type:
Not Applicable (Digital PDF Download)
Accessibility
Downloadable:
Yes
Compatibility
Device Compatibility:
Compatible with any device that can open PDF files (computers, tablets, smartphones)
Engine Specifications
Primary Engine
Engine Type:
Air-cooled, 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 (1.93 in x 2.60 in)
Compression Ratio:
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.
Ignition:
CDI (Capacitor Discharge Ignition)
Performance
Horsepower:
Approx. 18-20 hp @ 7,500 rpm (varies slightly by year and market)
Torque:
Approx. 1.7 kg-m (12.3 lb-ft) @ 6,000 rpm (varies slightly by year and market)
Fuel System
Carburetion:
Dual Mikuni carburetors (e.g., VM24SH or similar)
Fuel Capacity:
Approx. 9.2 L (2.4 US gal)
Fuel Type:
Unleaded gasoline
Transmission
Standard
Transmission Type:
5-speed constant mesh
Clutch Type:
Wet, multiple disc, cable-actuated
Final Drive:
Chain drive
Features
Gear Ratios:
Specific gear ratios are detailed within the manual, crucial for performance tuning and diagnostics.
Transmission Fluid:
Yamaha motorcycle gear oil or equivalent (specific grade and capacity detailed in manual)
Dimensions
Exterior
Length:
Approx. 2,185 mm (86.0 in)
Width:
Approx. 715 mm (28.1 in)
Height:
Approx. 1,110 mm (43.7 in)
Wheelbase:
Approx. 1,485 mm (58.5 in)
Ground Clearance:
Approx. 140 mm (5.5 in)
Weights
Dry Weight:
Approx. 147 kg (324 lbs)
Wet Weight:
Approx. 159 kg (350 lbs) (with all fluids)
Wheels And Tires
Front Tire Size:
3.00-18 4PR
Rear Tire Size:
130/90-15 M/C 66P
Wheel Type:
Spoked wheels with chrome rims
Wheelbase Specifications:
Wheel alignment and spoke tensioning procedures are detailed in the manual.
Safety Features
Ratings
Crash Test Ratings:
Not applicable to motorcycles in the same way as automobiles. Safety focus is on handling, braking, and rider error prevention.
Active Features
Braking System:
Front: Single hydraulic disc brake; Rear: Drum brake.
Suspension Features:
Front: Telescopic fork; Rear: Swingarm with dual shock absorbers. Manual details fork oil types, capacities, and shock absorber adjustments.
Low seat height, upright riding position contributing to rider control and comfort.
Technology Features
Infotainment
Infotainment System:
Not applicable (basic motorcycle with analog instrumentation).
Driver Assistance
Driver Assistance Features:
Not applicable.
Connectivity
Connectivity Features:
Not applicable.
Instrumentation
Instrument Cluster:
Analog speedometer, tachometer (on some models), odometer, trip meter, turn signal indicators, neutral indicator, oil pressure warning light, high beam indicator.
Maintenance
Service Intervals
Oil Change Interval:
Every 3,000 - 5,000 km (1,800 - 3,000 miles) or annually, whichever comes first (specific recommendation in manual).
Spark Plug Service:
Inspect every 5,000 km (3,000 miles), replace as needed (specific gap and type in manual).
Valve Clearance Adjustment:
Initial check at 1,000 km (600 miles), then every 10,000 km (6,000 miles) or as per manual recommendations.
Brake Fluid Flush:
Every 2 years or as per manual, as brake fluid absorbs moisture.
Fluid Specifications
Engine Oil Type:
Yamalube 4 (or equivalent) SAE 10W-40 API SE or SF classification (specific grade and quantity in manual).
Fork Oil Type:
Specific viscosity and quantity (e.g., Yamalube fork oil 10W or equivalent) detailed in manual.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid (check manual for specific recommendation).
Coolant Type:
Not Applicable (Air-cooled engine)
Known Issues
Carburetor Issues:
Gumming of carburetors due to old fuel, requiring cleaning and synchronization. Idle speed instability.
Electrical Issues:
Corrosion of electrical connectors, failing rectifier/regulator, intermittent headlight or charging system issues.
Fuel System Issues:
Petcock diaphragm failure, fuel line degradation over time.
Suspension Wear:
Worn fork seals leading to oil leaks, worn rear shock absorbers affecting ride quality.
Filter Part Numbers
Oil Filter Part Number:
Specific Yamaha part number (e.g., 5JX-13440-00 or similar, needs manual verification).
Air Filter Part Number:
Specific Yamaha part number (e.g., 4X7-14411-00-00 or similar, needs manual verification).
Vehicle History
Brand Heritage
Yamaha Motor Corporation:
Founded in 1955, Yamaha is renowned for its musical instrument heritage and has a long and successful history in motorcycle manufacturing, known for innovation and performance.
Model Evolution
Virago Lineage:
The XV250 is part of Yamaha's Virago line of V-twin cruisers, which aimed to offer classic styling and accessible performance. It evolved from earlier Virago models and was later effectively succeeded by the V-Star 250.
Production
Initial Production Year:
1988
Production Duration:
Continuously produced from 1988 through 2008, and the platform continued as the V-Star 250 for several years thereafter.
Manufacturing Locations:
Primarily manufactured in Japan and potentially other Yamaha assembly plants globally.
Awards & Recognition
Recognitions
Industry Awards:
Not widely documented for specific awards, but consistently recognized for its longevity, ease of use, and reliability in the entry-level cruiser segment.
Ratings
Consumer Satisfaction:
Generally high consumer satisfaction due to its forgiving nature and low running costs.
Certifications
Emissions Standards:
Meets emissions standards applicable to its production years in various markets. Manual details specific emissions control components and procedures if applicable.
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