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Yamaha XV250G Service Manual

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🏷️ Basic Information Identification Make: Yamaha Model: XV250G Model Nickname: Virago 250 Generation Generation Designation: First Generation (XV250) Codes Internal Model Code: XV250G 👋 Introduction Market Position Segment: Cruiser/Commuter Motorcycle Target Audience: Entry-level riders, commuters, custom enthusiasts seeking a reliable and classic-styled motorcycle. Competitive Analysis Competitors: Honda Shadow VT750 (larger displacement but similar styling), Kawasaki Vulcan 500, Suzuki Savage LS650 (different configuration but similar market niche). Key Features Design Philosophy: Classic cruiser styling with a compact and user-friendly package, emphasizing reliability and ease of maintenance. Engine Configuration: V-twin, air-cooled engine providing characteristic torque and sound. Drivetrain: Smooth power delivery via a five-speed transmission and final chain drive. Rideability: Low seat height and manageable weight contribute to excellent maneuverability and rider comfort, especially for shorter riders or urban environments. 📋 Manual Details Coverage Areas Covered Regions: Global (specifications may vary slightly by market) Page Count Estimated Page Count: 300-400 pages (typical for a comprehensive service manual of this type) Manual Type Manual Type: Factory Service Manual (FSM) / Workshop Manual Language Language: English Format Format: PDF (Downloadable) 📖 Manual Coverage Systems Covered Engine: Complete engine disassembly, assembly, tuning, and diagnostics. Includes top end (cylinder head, valves, camshafts), bottom end (crankshaft, connecting rods, pistons), lubrication system, cooling system (air-cooled), and fuel delivery (carburetors). Transmission: Gearbox operation, clutch system (wet multi-plate), shift mechanism, and final drive (chain drive) maintenance and repair. Chassis: Frame inspection, suspension (front fork, rear shock absorbers), steering system, wheel bearing maintenance, and tire specifications. Brakes: Front and rear brake systems, including hydraulic lines, master cylinders, calipers, brake pads, and brake shoe replacement and adjustment. Electrical System: Ignition system (CDI), starting system (electric starter), charging system (alternator, regulator/rectifier), lighting system (headlight, taillight, turn signals), instrumentation, and wiring diagrams. Fuel System: Carburetor(s) identification, disassembly, cleaning, adjustment, fuel tank, fuel pump (if applicable), and fuel lines. Exhaust System: Exhaust pipe and muffler removal, inspection, and replacement. Bodywork: Fender removal, seat removal, fuel tank removal, and fairing/panel component identification and installation. Procedures Included Preventative Maintenance: Detailed step-by-step instructions for oil changes, filter replacements, spark plug checks, chain lubrication and adjustment, brake adjustments, and general inspections. Troubleshooting: Diagnostic flowcharts and symptom-based troubleshooting guides for common electrical and mechanical issues. Repair Procedures: Comprehensive, illustrated instructions for component removal, repair, and reinstallation for all major systems. Tuning And Adjustment: Carburetor synchronization, ignition timing adjustments, valve clearance adjustments, and idle speed settings. Overhaul Procedures: Complete engine and transmission overhaul instructions, including torque specifications and critical measurements. Technical Depth Depth: Comprehensive: Covers everything from routine maintenance to complete engine rebuilding and advanced electrical diagnostics. Suitable for professional technicians and experienced DIY mechanics. 📊 Manual Specifications File Format File Format: PDF Print Quality Resolution: High-resolution, enabling clear viewing and printing of diagrams and text. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Searchability Searchable Text: Yes (Optimized for text search within the PDF) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, V-twin, air-cooled, SOHC Displacement: 234 cc Bore X Stroke: 49.0 mm x 66.0 mm Compression Ratio: 9.2:1 Valve Train: 2 valves per cylinder, SOHC Ignition System: CDI (Capacitor Discharge Ignition) Performance Horsepower: Approximately 17-18 HP @ 7500 RPM (Varies slightly by market and tuning) Torque: Approximately 14.5-15.5 ft-lbs @ 5500 RPM (Varies slightly by market and tuning) Fuel System Carburetor Type: Dual Mikuni carburetors (e.g., Mikuni VM30 x 2) Fuel Tank Capacity: 9.0 liters (approx. 2.4 US gallons) Fuel Type: Unleaded gasoline, minimum 87 octane 🔧 Transmission Standard Transmission Type: Constant mesh, 5-speed sequential Optional Optional Transmission: N/A Features Clutch Type: Wet, multi-plate Final Drive: Chain drive, O-ring sealed Gear Ratios: 1st: 2.750 (33/12), 2nd: 1.857 (26/14), 3rd: 1.375 (22/16), 4th: 1.090 (24/22), 5th: 0.916 (22/24) 📐 Dimensions Exterior Overall Length: 2175 mm (85.6 in) Overall Width: 785 mm (30.9 in) Overall Height: 1090 mm (42.9 in) Wheelbase: 1485 mm (58.5 in) Ground Clearance: 160 mm (6.3 in) Seat Height: 685 mm (27.0 in) Weights Dry Weight: 130 kg (286.6 lbs) Wet Weight: 148 kg (326.3 lbs) (approx., with fluids) Front Tire Size: 3.00-18 47P Rear Tire Size: 130/90-15M/C 66P Wheel Bolt Pattern: N/A (Cast wheels, typically 4-bolt hub) 🛡️ Safety Features Ratings Safety Certification: Meets relevant national/international motorcycle safety standards (e.g., DOT, ECE depending on market). Active Features Braking System: Front: Single hydraulic disc; Rear: Drum brake. Lighting: Halogen headlight, taillight, brake light, turn signals. Passive Features Frame Construction: Steel diamond frame. Suspension Travel: Front: Telescopic forks (approx. 140mm travel); Rear: Swingarm with twin shock absorbers (approx. 80mm travel). 💡 Technology Features Infotainment Infotainment System: Basic analog instrumentation: speedometer, odometer, tachometer (optional on some models), neutral indicator, oil pressure light, turn signal indicators. Driver Assistance Driver Assistance Features: N/A (Designed for simplicity and traditional motorcycle experience) Connectivity Connectivity Features: N/A (No built-in Bluetooth or smartphone integration) 🔧 Maintenance Service Intervals Engine...
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Yamaha XV250G Service ManualYamaha XV250G Service ManualYamaha XV250G Service ManualYamaha XV250G Service Manual
🏷️ Basic Information
Identification
Make:
Yamaha
Model:
XV250G
Model Nickname:
Virago 250
Generation
Generation Designation:
First Generation (XV250)
Codes
Internal Model Code:
XV250G
👋 Introduction
Market Position
Segment:
Cruiser/Commuter Motorcycle
Target Audience:
Entry-level riders, commuters, custom enthusiasts seeking a reliable and classic-styled motorcycle.
Competitive Analysis
Competitors:
Honda Shadow VT750 (larger displacement but similar styling), Kawasaki Vulcan 500, Suzuki Savage LS650 (different configuration but similar market niche).
Key Features
Design Philosophy:
Classic cruiser styling with a compact and user-friendly package, emphasizing reliability and ease of maintenance.
Engine Configuration:
V-twin, air-cooled engine providing characteristic torque and sound.
Drivetrain:
Smooth power delivery via a five-speed transmission and final chain drive.
Rideability:
Low seat height and manageable weight contribute to excellent maneuverability and rider comfort, especially for shorter riders or urban environments.
📋 Manual Details
Coverage Areas
Covered Regions:
Global (specifications may vary slightly by market)
Page Count
Estimated Page Count:
300-400 pages (typical for a comprehensive service manual of this type)
Manual Type
Manual Type:
Factory Service Manual (FSM) / Workshop Manual
Language
Language:
English
Format
Format:
PDF (Downloadable)
📖 Manual Coverage
Systems Covered
Engine:
Complete engine disassembly, assembly, tuning, and diagnostics. Includes top end (cylinder head, valves, camshafts), bottom end (crankshaft, connecting rods, pistons), lubrication system, cooling system (air-cooled), and fuel delivery (carburetors).
Transmission:
Gearbox operation, clutch system (wet multi-plate), shift mechanism, and final drive (chain drive) maintenance and repair.
Chassis:
Frame inspection, suspension (front fork, rear shock absorbers), steering system, wheel bearing maintenance, and tire specifications.
Brakes:
Front and rear brake systems, including hydraulic lines, master cylinders, calipers, brake pads, and brake shoe replacement and adjustment.
Electrical System:
Ignition system (CDI), starting system (electric starter), charging system (alternator, regulator/rectifier), lighting system (headlight, taillight, turn signals), instrumentation, and wiring diagrams.
Fuel System:
Carburetor(s) identification, disassembly, cleaning, adjustment, fuel tank, fuel pump (if applicable), and fuel lines.
Exhaust System:
Exhaust pipe and muffler removal, inspection, and replacement.
Bodywork:
Fender removal, seat removal, fuel tank removal, and fairing/panel component identification and installation.
Procedures Included
Preventative Maintenance:
Detailed step-by-step instructions for oil changes, filter replacements, spark plug checks, chain lubrication and adjustment, brake adjustments, and general inspections.
Troubleshooting:
Diagnostic flowcharts and symptom-based troubleshooting guides for common electrical and mechanical issues.
Repair Procedures:
Comprehensive, illustrated instructions for component removal, repair, and reinstallation for all major systems.
Tuning And Adjustment:
Carburetor synchronization, ignition timing adjustments, valve clearance adjustments, and idle speed settings.
Overhaul Procedures:
Complete engine and transmission overhaul instructions, including torque specifications and critical measurements.
Technical Depth
Depth:
Comprehensive: Covers everything from routine maintenance to complete engine rebuilding and advanced electrical diagnostics. Suitable for professional technicians and experienced DIY mechanics.
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Resolution:
High-resolution, enabling clear viewing and printing of diagrams and text.
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
Searchability
Searchable Text:
Yes (Optimized for text search within the PDF)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Four-stroke, V-twin, air-cooled, SOHC
Displacement:
234 cc
Bore X Stroke:
49.0 mm x 66.0 mm
Compression Ratio:
9.2:1
Valve Train:
2 valves per cylinder, SOHC
Ignition System:
CDI (Capacitor Discharge Ignition)
Performance
Horsepower:
Approximately 17-18 HP @ 7500 RPM (Varies slightly by market and tuning)
Torque:
Approximately 14.5-15.5 ft-lbs @ 5500 RPM (Varies slightly by market and tuning)
Fuel System
Carburetor Type:
Dual Mikuni carburetors (e.g., Mikuni VM30 x 2)
Fuel Tank Capacity:
9.0 liters (approx. 2.4 US gallons)
Fuel Type:
Unleaded gasoline, minimum 87 octane
🔧 Transmission
Standard
Transmission Type:
Constant mesh, 5-speed sequential
Optional
Optional Transmission:
N/A
Features
Clutch Type:
Wet, multi-plate
Final Drive:
Chain drive, O-ring sealed
Gear Ratios:
1st: 2.750 (33/12), 2nd: 1.857 (26/14), 3rd: 1.375 (22/16), 4th: 1.090 (24/22), 5th: 0.916 (22/24)
📐 Dimensions
Exterior
Overall Length:
2175 mm (85.6 in)
Overall Width:
785 mm (30.9 in)
Overall Height:
1090 mm (42.9 in)
Wheelbase:
1485 mm (58.5 in)
Ground Clearance:
160 mm (6.3 in)
Seat Height:
685 mm (27.0 in)
Weights
Dry Weight:
130 kg (286.6 lbs)
Wet Weight:
148 kg (326.3 lbs) (approx., with fluids)
Front Tire Size:
3.00-18 47P
Rear Tire Size:
130/90-15M/C 66P
Wheel Bolt Pattern:
N/A (Cast wheels, typically 4-bolt hub)
🛡️ Safety Features
Ratings
Safety Certification:
Meets relevant national/international motorcycle safety standards (e.g., DOT, ECE depending on market).
Active Features
Braking System:
Front: Single hydraulic disc; Rear: Drum brake.
Lighting:
Halogen headlight, taillight, brake light, turn signals.
Passive Features
Frame Construction:
Steel diamond frame.
Suspension Travel:
Front: Telescopic forks (approx. 140mm travel); Rear: Swingarm with twin shock absorbers (approx. 80mm travel).
💡 Technology Features
Infotainment
Infotainment System:
Basic analog instrumentation: speedometer, odometer, tachometer (optional on some models), neutral indicator, oil pressure light, turn signal indicators.
Driver Assistance
Driver Assistance Features:
N/A (Designed for simplicity and traditional motorcycle experience)
Connectivity
Connectivity Features:
N/A (No built-in Bluetooth or smartphone integration)
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 4,000 km (2,500 miles) or annually, whichever comes first.
Oil Filter Change:
Every 8,000 km (5,000 miles) or annually (replace with Yamaha P/N 5JX-13440-00 or equivalent).
Air Filter Cleaning:
Every 4,000 km (2,500 miles); replace as needed (Yamaha P/N 5JX-14451-00-00 or equivalent).
Spark Plug Check And Gap:
Every 4,000 km (2,500 miles). Recommended plugs: NGK CR8E or DPR8EA-9. Gap: 0.7-0.8 mm (0.028-0.031 in).
Valve Clearance Adjustment:
Every 8,000 km (5,000 miles). Intake: 0.05-0.10 mm (0.002-0.004 in); Exhaust: 0.07-0.12 mm (0.003-0.005 in).
Chain Lubrication And Adjustment:
Every 1,000 km (600 miles) or after washing/rain. Chain slack: 20-30 mm (0.79-1.18 in).
Fluid Specifications
Engine Oil Type:
Yamalube 4 (or equivalent motorcycle-specific SAE 10W-40 API SG or higher, JASO MA certified).
Engine Oil Capacity:
1.8 liters (1.9 US qt) without filter change; 1.9 liters (2.0 US qt) with filter change.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid.
Fork Oil Type:
Yamaha No. 10 (or equivalent SAE 10W fork oil).
Fork Oil Capacity:
Approximately 155 cc (5.2 US oz) per fork leg.
Known Issues
Carburetor Issues:
Pilot jet clogging can lead to hard starting or poor idling; synchronizing dual carbs is crucial for smooth operation.
Electrical Connectors:
Corrosion or looseness in electrical connectors can cause intermittent issues with lights, ignition, or charging system.
Regulator Rectifier:
The regulator/rectifier can be a point of failure, leading to battery charging issues; upgrades are sometimes considered.
Rear Shock ABSorbers:
Over time, rear shock damping may degrade, requiring replacement or refurbishment.
📚 Vehicle History
Brand Heritage
Yamaha Legacy:
Yamaha Motor Corporation, established in 1955, has a long and distinguished history in motorcycle manufacturing, known for innovation, performance, and reliability across a wide range of motorcycling segments.
Model Evolution
Virago Lineage:
The XV250G is part of Yamaha's Virago V-twin cruiser line, which debuted in the early 1980s. The 250cc model was designed as an accessible entry point into the cruiser segment, retaining the classic styling cues of its larger siblings.
Production
Production Years:
The XV250 (Virago 250) was produced for many years, with the XV250G designation likely referring to a specific market or configuration during its production run (e.g., 1988 onwards, with continuous updates).
Manufacturing Locations:
Primarily manufactured in Japan and potentially other Yamaha global facilities.
🏆 Awards & Recognition
Recognitions
Industry Acclaim:
While specific awards might be scarce for this entry-level model, the Virago 250 is consistently recognized for its reliability, affordability, and user-friendly nature, making it a popular choice for new riders and those seeking a classic aesthetic in a manageable package.
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