LIT-11616-19-23

2UJ-28197-12

XV250V(C)

SUPPLEMENTARY

SERVICE MANUAL

FOREWORD

This Supplementary Service Manual has been prepared to introduce new service and data for the

XV250V(C). For complete service information procedures it is necessary to use this Supplementary

Service Manual together with the following manual.

XV250U/XV250UC SERVICE MANUAL: LIT-11616-06-18 (2UJ-28197-10)

XV250G/XV250GC SUPPLEMENTARY SERVICE MANUAL:

LIT-11616-09-69 (2UJ-28197-11)

XV250V(C)

SUPPLEMENTARY

SERVICE MANUAL

©2005 by Yamaha Motor Corporation, U.S.A.

First edition, October 2005

All rights reserved.

Any reproduction or unauthorized use

without the written permission of

Yamaha Motor Corporation, U.S.A.

is expressly prohibited.

Printed in U.S.A.

LIT-11616-19-23

EAS00003

NOTICE

This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha

dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic

in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on

Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair

these types of vehicles. Repair and maintenance work attempted by anyone without this knowledge

is likely to render the vehicle unsafe and unfit for use.

This model has been designed and manufactured to perform within certain specifications in regard

to performance and emissions. Proper service with the correct tools is necessary to ensure that the

vehicle will operate as designed. If there is any question about a service procedure, it is imperative

that you contact a Yamaha dealer for any service information changes that apply to this model. This

policy is intended to provide the customer with the most satisfaction from his vehicle and to conform

with federal environmental quality objectives.

Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and

significant changes in specifications or procedures will be forwarded to all authorized Yamaha

dealers and will appear in future editions of this manual where applicable.

NOTE:

• This Service Manual contains information regarding periodic maintenance to the emission control

system. Please read this material carefully.

• Designs and specifications are subject to change without notice.

EAS00004

IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR

SAFETY IS INVOLVED!

Failure to follow WARNING instructions could result in severe injury or death

to the vehicle operator, a bystander or a person checking or repairing the

vehicle.

A CAUTION indicates special precautions that must be taken to avoid

damage to the vehicle.

A NOTE provides key information to make procedures easier or clearer.

WARNING

CAUTION:

NOTE:

EAS00007

HOW TO USE THIS MANUAL

This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive

explanations of all installation, removal, disassembly, assembly, repair and check procedures are

laid out with the individual steps in sequential order.

1 The manual is divided into chapters. An abbreviation and symbol in the upper right corner of

each page indicate the current chapter.

Refer to “SYMBOLS”.

2 Each chapter is divided into sections. The current section title is shown at the top of each page,

except in Chapter 3 (“PERIODIC CHECKS AND ADJUSTMENTS”), where the sub section title(s)

appears.

3 Sub section titles appear in smaller print than the section title.

4 To help identify parts and clarify procedure steps, there are exploded diagrams at the start of

each removal and disassembly section.

5 Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a

disassembly step.

6 Symbols indicate parts to be lubricated or replaced.

Refer to “SYMBOLS”.

7 A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of

parts, notes in jobs, etc.

8 Jobs requiring more information (such as special tools and technical data) are described sequen-

tially.

SYMBOLS

The following symbols are not relevant to

every vehicle.

Symbols 1 to 8 indicate the subject of each

chapter.

1 General information

2 Specifications

3 Periodic checks and adjustments

4 Engine

5 Carburetor

6 Chassis

7 Electrical system

8 Troubleshooting

Symbols 9 to F indicate the following.

9 Serviceable with engine mounted

0 Filling fluid

A Lubricant

B Special tool

C Tightening torque

D Wear limit, clearance

E Engine speed

F Electrical data

Symbols G to L in the exploded diagrams

indicate the types of lubricants and lubrication

points.

G Engine oil

H Gear oil

I Molybdenum disulfide oil

J Wheel bearing grease

K Lithium-soap-based grease

L Molybdenum disulfide grease

Symbols M to N in the exploded diagrams

indicate the following.

M Apply locking agent (LOCTITE^®).

N Replace the part.

1

2

3

4

5

6

7

8

9

0

A

B

C

D

E

F

G

H

I

J

K

L

M

N

GEN

INFO

SPEC

CHK

ADJ

ENG

CARB

CHAS

–

+

ELEC

TRBL

SHTG

T R

.

.

E

G

M

B

LS

M

LT

New

CONTENTS

SPECIFICATIONS.............................................................................................. 1

GENERAL SPECIFICATIONS ..................................................................... 1

ENGINE SPECIFICATIONS......................................................................... 1

CHASSIS SPECIFICATIONS....................................................................... 8

ELECTRICAL SPECIFICATIONS .............................................................. 10

CABLE ROUTING ...................................................................................... 12

PERIODIC CHECKS AND ADJUSTMENTS.................................................... 21

INTRODUCTION........................................................................................ 21

PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL

SYSTEM.................................................................................................... 21

GENERAL MAINTENANCE AND LUBRICATION CHART ........................ 22

CARBURETOR................................................................................................. 24

AIR INDUCTION SYSTEM......................................................................... 24

AIR INJECTION ................................................................................... 24

AIR CUT-OFF VALVE.......................................................................... 24

AIR CUT-OFF VALVE ASSEMBLY ..................................................... 25

CHECKING THE AIR INDUCTION SYSTEM ...................................... 27

CANISTER (FOR CALIFORNIA ONLY)..................................................... 28

CHECKING THE ROLLOVER VALVE................................................. 29

CHECKING THE CANISTER............................................................... 29

– 1 –

SPEC

SPECIFICATIONS

GENERAL SPECIFICATIONS

ENGINE SPECIFICATIONS

Item

Standard

Limit

Model code

2UJN (USA)

3BGF (California)

----

----

Weight

Wet (with oil and a full fuel tank)

147 kg (324 lb) (USA)

148 kg (326 lb) (California)

----

----

Maximum load (total of cargo, rider,

passenger, and accessories)

196 kg (432 lb) (USA)

195 kg (430 lb) (California)

----

----

Item

Standard

Limit

Fuel

Recommended fuel

Unleaded gasoline only

----

Fuel tank capacity

9.5 L (2.09 Imp gal, 2.51 US gal) (USA)

9.2 L (2.02 Imp gal, 2.43 US gal) (Califor-

nia)

----

----

Fuel reserve amount

2.6 L (0.57 Imp gal, 0.69 US gal)

----

Engine oil

Lubrication system

Wet sump

----

Recommended oil

YAMALUBE 4, SAE10W30 or SAE20W40

API service SE, SF, SG type or higher

----

----

Quantity

Total amount

1.8 L (1.58 Imp qt, 1.90 US qt)

----

Without oil filter element replace-

ment

1.4 L (1.23 Imp qt, 1.48 US qt)

----

With oil filter element replacement

1.6 L (1.41 Imp qt, 1.69 US qt)

----

10˚

30˚ 50˚ 70˚ 90˚ 110˚

0˚

130˚F

–10˚

0˚

10˚ 20˚ 30˚

40˚

–20˚

50˚C

YAMALUBE 4 (10W30) or

SAE 10W30

YAMALUBE 4 (20W40) or

SAE 20W40

GENERAL SPECIFICATIONS/

ENGINE SPECIFICATIONS

– 2 –

SPEC

ENGINE SPECIFICATIONS

Oil pump

Oil pump type

Trochoid

----

Inner-rotor-to-outer-rotor-tip clear-

ance

Less than 0.15 mm (0.0059 in)

0.23 mm

(0.0091 in)

Outer-rotor-to-oil-pump-housing

clearance

0.03 ~ 0.09 mm (0.0012 ~ 0.0035 in)

0.16 mm

(0.0063 in)

Relief valve opening pressure

450 ~ 550 kPa

(4.5 ~ 5.5 kgf/cm², 65.3 ~ 79.8 psi)

----

Pressure check location

CRANKCASE BOLT

----

Cylinder head

Volume

14.10 ~ 14.50 cm³ (0.86 ~ 0.88 cu.in)

----

Max warpage

----

0.03 mm

(0.0012 in)

Camshafts

Drive system

Chain drive (left)

----

Camshaft cap inside diameter

22.000 ~ 22.021 mm (0.8661 ~ 0.8670 in)

----

Camshaft journal diameter

21.960 ~ 21.980 mm (0.8646 ~ 0.8654 in)

----

Camshaft-journal-to-camshaft cap

clearance

0.020 ~ 0.061 mm (0.0008 ~ 0.0024 in)

0.08 mm

(0.0031 in)

Intake camshaft lobe dimensions

Measurement A

26.190 mm (1.0311 in)

26.090 mm

(1.0272 in)

Measurement B

21.045 mm (0.8285 in) (Cylinder #1)

21.087 mm (0.8302 in) (Cylinder #2)

20.945 mm

(0.8246 in)

20.987 mm

(0.8263 in)

Item

Standard

Limit

A

B

– 3 –

SPEC

ENGINE SPECIFICATIONS

Exhaust camshaft lobe dimensions

Measurement A

26.190 mm (1.0311 in)

26.090 mm

(1.0272 in)

Measurement B

21.087 mm (0.8302 in) (Cylinder #1)

20.987 mm

(0.8263 in)

21.045 mm (0.8285 in) (Cylinder #2)

20.945 mm

(0.8246 in)

Camshaft runout limit

----

0.015 mm

(0.0006 in)

Valves, valve seats, valve guides

Valve clearance (cold)

Intake

0.08 ~ 0.12 mm (0.0032 ~ 0.0047 in)

----

Exhaust

0.10 ~ 0.14 mm (0.0039 ~ 0.0055 in)

----

Valve dimensions

Valve head diameter A

Intake

25.90 ~ 26.10 mm (1.0197 ~ 1.0276 in)

----

Exhaust

21.90 ~ 22.10 mm (0.8622 ~ 0.8701 in)

----

Valve face width B

Intake

1.40 ~ 3.20 mm (0.0551 ~ 0.1260 in)

----

Exhaust

1.70 ~ 2.80 mm (0.0669 ~ 0.1102 in)

----

Valve seat width C

Intake

0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in)

1.6 mm

(0.06 in)

Exhaust

0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in)

1.6 mm

(0.06 in)

Valve margin thickness D

Intake

0.4 ~ 0.8 mm (0.0157 ~ 0.0315 in)

----

Exhaust

0.8 ~ 1.2 mm (0.0315 ~ 0.0472 in)

----

Item

Standard

Limit

A

B

B

C

D

A

Head Diameter

Face Width

Seat Width

Margin Thickness

– 4 –

SPEC

ENGINE SPECIFICATIONS

Valve stem diameter

Intake

4.975 ~ 4.990 mm (0.1959 ~ 0.1965 in)

4.950 mm

(0.1949 in)

Exhaust

4.960 ~ 4.975 mm (0.1953 ~ 0.1959 in)

4.953 mm

(0.1950 in)

Valve guide inside diameter

Intake

5.000 ~ 5.012 mm (0.1969 ~ 0.1973 in)

5.030 mm

(0.1980 in)

Exhaust

5.000 ~ 5.012 mm (0.1969 ~ 0.1973 in)

5.030 mm

(0.1980 in)

Valve-stem-to-valve-guide clearance

Intake

0.010 ~ 0.037 mm (0.0004 ~ 0.0015 in)

0.080 mm

(0.0032 in)

Exhaust

0.025 ~ 0.052 mm (0.0010 ~ 0.0020 in)

0.100 mm

(0.0039 in)

Valve stem runout

----

0.020 mm

(0.0008 in)

Valve seat width

Intake

0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in)

1.6 mm

(0.06 in)

Exhaust

0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in)

1.6 mm

(0.06 in)

Valve springs

Free length

Intake

39.91 mm (1.57 in)

38.91 mm

(1.53 in)

Exhaust

39.91 mm (1.57 in)

38.91 mm

(1.53 in)

Installed length (valve closed)

Intake

25.70 mm (1.01 in)

----

Exhaust

25.70 mm (1.01 in)

----

Spring rate (K1)

Intake

10.32 N/mm (1.05 kgf/mm, 58.93 lb/in)

----

Exhaust

10.32 N/mm (1.05 kgf/mm, 58.93 lb/in)

----

Spring rate (K2)

Intake

13.40 N/mm (1.37 kgf/mm, 76.51 lb/in)

----

Exhaust

13.40 N/mm (1.37 kgf/mm, 76.51 lb/in)

----

Item

Standard

Limit

– 5 –

SPEC

ENGINE SPECIFICATIONS

Compressed spring force (installed)

Intake

137.0 ~ 157.0 N

(13.97 ~ 16.01 kgf, 30.80 ~ 35.29 lb)

----

Exhaust

137.0 ~ 157.0 N

(13.97 ~ 16.01 kgf, 30.80 ~ 35.29 lb)

----

Spring tilt

Intake

----

2.5°/1.7 mm

(2.5°/0.07 in)

Exhaust

----

2.5°/1.7 mm

(2.5°/0.07 in)

Winding direction (top view)

Intake

Clockwise

----

Exhaust

Clockwise

----

Cylinders

Bore

48.990 ~ 49.030 mm (1.9287 ~ 1.9303 in)

49.100 mm

(1.9331 in)

Measure point

45.0 mm (1.77 in)

----

Item

Standard

Limit

– 6 –

SPEC

ENGINE SPECIFICATIONS

Pistons

Piston-to-cylinder clearance

0.020 ~ 0.040 mm (0.0008 ~ 0.0016 in)

0.15 mm

(0.0059 in)

Diameter “D”

48.960 ~ 49.000 mm (1.9276 ~ 1.9291 in)

----

Height “H”

6.0 mm (0.24 in)

----

Offset

0.50 mm (0.0197 in)

----

Piston pin bore inside diameter

13.002 ~ 13.013 mm (0.5119 ~ 0.5123 in)

13.043 mm

(0.5135 in)

Piston pin outside diameter

12.996 ~ 13.000 mm (0.5117 ~ 0.5118 in)

12.976 mm

(0.5109 in)

Clutch

Clutch type

Wet, multiple disc

----

Clutch release method

Inner push, cam push

----

Clutch lever free play

10 ~ 15 mm (0.39 ~ 0.59 in)

----

Friction plate thickness

2.90 ~ 3.10 mm (0.114 ~ 0.122 in)

2.50 mm

(0.0984 in)

Plate quantity

5 pcs

----

Clutch plate thickness

1.90 ~ 2.10 mm (0.075 ~ 0.083 in)

----

Plate quantity

4 pcs

----

Maximum warpage

----

0.05 mm

(0.0020 in)

Clutch spring free length

34.6 mm (1.36 in)

33.6 mm

(1.32 in)

Spring quantity

4 pcs

----

Clutch housing thrust clearance

0.080 ~ 0.330 mm (0.0032 ~ 0.0130 in)

----

Clutch housing radial clearance

0.010 ~ 0.044 mm (0.0004 ~ 0.0017 in)

----

Push rod bending limit

----

0.50 mm

(0.0197 in)

Shifting mechanism

Shift mechanism type

Shift drum and guide bar

----

Shift fork thickness

4.76 ~ 4.89 mm (0.1874 ~ 0.1925 in)

----

Fuel pump

Pump type

Vacuum

----

Model/manufacturer

3DM/MIKUNI

----

Item

Standard

Limit

H

D

– 7 –

SPEC

ENGINE SPECIFICATIONS

Carburetor

Type/quantity

BDS26/1

----

Manufacturer

MIKUNI

----

I.D.mark

2UJ 01 (USA)

3BG 01 (California)

----

----

Main jet

#110

----

Main air jet

#60

----

Jet needle

4DM3-1

----

Needle jet

O-0

----

Pilot air jet

#155

----

Pilot outlet

0.85

----

Pilot jet

#17.5

----

Bypass 1

0.8

----

Bypass 2

0.8

----

Bypass 3

0.8

----

Pilot screw turns out

3-1/4

----

Valve seat size

1

----

Starter jet

#25

----

Starter jet

0.7

----

Throttle valve size

#140

----

Fuel level

7.5 ~ 8.5 mm (0.30 ~ 0.33 in)

----

Idling condition

Engine idling speed

1,350 ~ 1,450 r/min

----

Oil temperature

85 ~ 95 °C (185 ~ 203 °F)

----

Throttle cable free play

3.0 ~ 5.0 mm (0.12 ~ 0.20 in)

----

Item

Standard

Limit

– 8 –

SPEC

CHASSIS SPECIFICATIONS

CHASSIS SPECIFICATIONS

Item

Standard

Limit

Front tire

Tire type

With tube

----

Size

3.00-18 47P

----

Model/manufacturer

CHENG SHIN/C-916

----

Tire pressure (cold)

0 ~ 90 kg (0 ~ 198 lbs)

175 kPa (1.75 kgf/cm², 25 psi)

----

90 kg (198 lbs) ~ maximum load

200 kPa (2.00 kgf/cm², 29 psi)

----

Minimum tire tread depth

----

1.0 mm

(0.04 in)

Rear tire

Tire type

With tube

----

Size

130/90-15 M/C 66P

----

Model/manufacturer

CHENG SHIN/C-915

----

Tire pressure (cold)

0 ~ 90 kg (0 ~ 198 lbs)

200 kPa (2.00 kgf/cm², 29 psi)

----

90 kg (198 lbs) ~ maximum load

225 kPa (2.25 kgf/cm², 33 psi)

----

Minimum tire tread depth

----

1.0 mm

(0.04 in)

Rear brake

Brake type

Drum brake

----

Operation

Right foot operation

----

Brake pedal position

60 mm (2.36 in)

----

Brake pedal free play

20 ~ 30 mm (0.79 ~ 1.18 in)

----

Drum brake type

Leading, trailing

----

Brake drum inside diameter

130 mm (5.12 in)

131 mm

(5.16 in)

Lining thickness

4.5 mm (0.18 in)

2.0 mm

(0.08 in)

Shoe spring free length

50.5 mm (1.99 in)

----

Steering

Steering bearing type

Angular bearing

----

Lock-to-lock angle (left)

38.0°

----

Lock-to-lock angle (right)

38.0°

----

– 9 –

SPEC

CHASSIS SPECIFICATIONS

Front suspension

Type

Telescopic fork

----

Front fork type

Coil spring/oil damper

----

Front fork travel

140.0 mm (5.51 in)

----

Fork spring free length

415.0 mm (16.34 in)

410.0 mm

(16.14 in)

Collar length

100.0 mm (3.94 in)

----

Spring rate (K1)

3.95 N/mm (0.40 kgf/mm, 22.55 lb/in)

----

Spring rate (K2)

5.65 N/mm (0.58 kgf/mm, 32.26 lb/in)

----

Spring stroke (K1)

0 ~ 106.0 mm (0 ~ 4.17 in)

----

Spring stroke (K2)

106.0 ~ 140.0 mm (4.17 ~ 5.51 in)

----

Inner tube outer diameter

33.0 mm (1.30 in)

----

Optional spring available

No

----

Recommended oil

Yamaha fork oil 10 WT or equivalent

----

Quantity

245.0 cm³ (8.64 Imp oz, 8.28 US oz)

----

Level

120.0 mm (4.72 in)

----

Drive chain

Type/manufacturer

520DS/DAIDO

----

Link quantity

114

----

Drive chain slack

30 ~ 40 mm (1.18 ~ 1.57 in)

----

Maximum 15-link section

242.9 mm (9.56 in)

----

Item

Standard

Limit