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Yamaha XT250T User Manual

Yamaha XT250T
86 pages
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4FD-28199-2C
XT250T
PRINTED ON RECYCLED PAPER
YAMAHA MOTOR CO., LTD.
PRINTED IN JAPAN
2004.5–0.1x1 !
(E)
OWNER’S MANUAL
4FD-9-2C_hyoushi 4/9/04 2:53 PM Page 1
ProCarManuals.com

Table of Contents

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Yamaha XT250T Specifications

General IconGeneral
BrandYamaha
ModelXT250T
CategoryMotorcycle
LanguageEnglish

Summary

Introduction to Your Yamaha Motorcycle

Welcome and Manual Purpose

Introduction to the owner's manual and its benefits for motorcycle operation.

Important Manual Information and Notations

Understanding Manual Notations

Explains symbols like WARNING, CAUTION, and NOTE used in the manual for critical information.

General Operating Warning

Emphasizes the importance of reading the manual carefully before operating the motorcycle.

Safety Information Overview

Essential Safe Riding Practices

Guidelines for safe operation, including pre-operation checks, visibility, and operator awareness.

Operator Responsibilities and Training

Ensuring proper training, knowing skills, and practicing safe motorcycle operation.

Protective Apparel Guidelines

Details on essential protective gear like helmets, jackets, boots, and gloves for rider safety.

Motorcycle Modifications and Safety

Warns against unauthorized modifications that can compromise safety and legality.

Safe Loading and Accessory Use

Guidance on how adding accessories or cargo affects stability and safe operation.

Weight Limits and Accessory Considerations

Details on maximum load capacity and how accessories affect motorcycle stability and handling.

Electrical Accessory Safety Precautions

Advice on using electrical accessories and their potential impact on the motorcycle's electrical system.

Gasoline and Exhaust Gas Safety

Precautions regarding gasoline flammability, refueling, and safe operation in areas with exhaust fumes.

Safe Parking Procedures

Guidelines for parking the motorcycle safely, considering engine heat and vehicle stability.

Location of Important Safety Labels

Highlights the location of critical labels on the motorcycle for user awareness.

Tire Pressure Information

Specifies correct cold tire pressure for different load conditions to ensure safe handling.

Description of Motorcycle Components

Left Side Component Identification

Identifies components on the left side: headlight, fuel cock, air filter, helmet holder, tool kit, shock absorber, shift pedal.

Right Side Component Identification

Identifies components on the right side: battery, fuse, engine oil filter, oil level window, brake pedal.

Handlebar Controls and Instruments

Diagram of handlebar controls and instrument panel: clutch, switches, speedometer, main switch, throttle, brake lever, fuel cap.

Instrument and Control Functions

Main Switch and Steering Lock Operation

Explains the functions of the main switch (ON, OFF, LOCK) and how to lock/unlock the steering.

Warning: Steering Lock Operation

Crucial warning about not turning the key to 'OFF' or 'LOCK' while the vehicle is moving.

Understanding Indicator Lights

Describes the high beam, turn signal, and neutral indicator lights on the instrument panel.

Speedometer Unit Functions

Details the speedometer, odometer, and tripmeter functions for monitoring riding speed and distance.

Handlebar Switch Operations

Explains the function of left and right handlebar switches like dimmer, turn signal, horn, and engine stop.

Start Switch Operation

Instructions on how to use the electric starter switch to crank the engine.

Caution: Starting Engine Procedure

Advises referring to page 5-1 for starting instructions before using the starter switch.

Clutch Lever Operation

Describes how to use the clutch lever for engaging and disengaging the clutch smoothly.

Shift Pedal Functionality

Explains the role of the shift pedal in changing gears for the 6-speed transmission.

Front Brake Lever Operation

How to apply the front brake by pulling the brake lever on the right handlebar.

Rear Brake Pedal Operation

Instructions on how to apply the rear brake by pressing the brake pedal.

Fuel Tank Cap Removal and Installation

Step-by-step guide for removing and installing the fuel tank cap securely.

Warning: Fuel Tank Cap Security

Ensures the fuel tank cap is properly closed and locked before riding to prevent accidents.

Fueling and Fuel Capacity

Information on recommended fuel, tank capacity, reserve amount, and how to refuel safely.

Fuel Cock Positions and Operation

Explains the three positions (OFF, FUEL, RES) of the fuel cock for fuel flow control.

Starter (Choke) Knob Operation

How to use the starter (choke) knob to enrich the air-fuel mixture for cold engine starting.

Seat Removal and Installation

Step-by-step instructions for removing and installing the motorcycle seat.

Helmet Holder Usage and Security

Details on how to open, lock, and use the helmet holder, along with a safety warning.

Warning: Helmet Holder Safety

Warns against riding with a helmet attached to the holder due to potential loss of control.

Adjusting Rear Shock Absorber Preload

Guide to adjusting the spring preload on the rear shock absorber for ride firmness.

Caution: Shock Absorber Adjustment Limits

Advises against adjusting the mechanism beyond its maximum or minimum settings.

Adjusting Rear Shock Absorber Damping

Instructions for adjusting the rebound damping force on the rear shock absorber.

Warning: Shock Absorber Gas Pressure

Highlights safety precautions for handling the high-pressure nitrogen gas in the shock absorber.

Sidestand Operation and Safety

Explains how to use the sidestand and its role in the ignition circuit cut-off system.

Warning: Sidestand Safety Precautions

Stresses the danger of riding with the sidestand down or improperly secured.

Ignition Circuit Cut-off System Functions

Details the functions of the ignition system, including sidestand, clutch, and neutral switches.

Troubleshooting the Ignition Circuit Cut-off System

Provides a step-by-step guide to diagnose potential malfunctions in the ignition circuit cut-off system.

Pre-Operation Checks

Importance of Pre-Operation Checks

Emphasizes the owner's responsibility for vehicle condition and the necessity of pre-ride checks.

Warning: Malfunctioning Pre-Operation Items

Instructs to have the vehicle inspected and repaired if any pre-operation check item is not working.

Pre-Operation Check List: Fuel and Engine Oil

Checklist for fuel level, refueling, engine oil level, and oil leakage before riding.

Pre-Operation Check List: Brakes and Clutch

Checklist for front/rear brake operation, pads, fluid, and clutch operation and free play.

Pre-Operation Check List: Throttle and Control Cables

Checklist for throttle grip operation, cable play, and lubrication of control cables.

Pre-Operation Check List: Drive Chain and Tires

Checklist for drive chain slack, condition, lubrication, and tire condition, tread depth, and pressure.

Pre-Operation Check List: Pedals, Levers, Sidestand, and Fasteners

Checklist for brake/shift pedals, brake/clutch levers, sidestand, chassis fasteners, and switches.

Pre-Operation Check List: Sidestand Switch

Checklist for the ignition circuit cut-off system operation, specifically the sidestand switch.

Operation and Important Riding Points

Starting and Warming Up a Cold Engine

Procedure for starting a cold engine, including pre-start checks and using the choke.

Warning: Cold Engine Starting Precautions

Emphasizes pre-start checks, ventilation, sidestand position, and avoiding operation in closed areas.

Caution: Cold Engine Warm-Up Period

Advises on warming the engine up properly for maximum engine life before accelerating hard.

Starting and Warming Up a Warm Engine

Procedure for starting a warm engine, noting that the starter (choke) is not required.

Gear Shifting Techniques

Explains how to shift gears to control engine power for acceleration, climbing, and starting.

Tips for Improving Fuel Consumption

Provides advice on riding style and operation to reduce fuel usage.

Engine Break-In Period Guidelines

Crucial information on the break-in period (0-1600 km) for engine longevity and performance.

Caution: Engine Break-In Oil Change

Mandates engine oil change, filter cleaning, and strainer cleaning after 1000 km of break-in.

Safe Parking Procedures

Instructions on stopping the engine, removing the key, and turning the fuel cock to OFF.

Warning: Hot Engine and Parking Safety

Warns about hot engine/exhaust parts and parking on unstable ground to prevent burns or overturns.

Periodic Maintenance and Minor Repair

Owner's Tool Kit Contents and Use

Describes the tools provided in the kit and their use for basic maintenance and minor repairs.

Warning: Maintenance Expertise Required

Advises consulting a Yamaha dealer if unfamiliar with maintenance work.

Warning: Unauthorized Modifications

Warns that modifications not approved by Yamaha can reduce performance and safety.

Periodic Maintenance and Lubrication Chart Overview

Presents a comprehensive chart detailing maintenance intervals for various motorcycle components.

Notes on Maintenance Chart Interpretation

Provides guidance on annual checks, interval repetition, and items requiring dealer service.

Maintenance Chart: Tires, Bearings, and Swingarm

Details maintenance schedule for tires, wheel bearings, swingarm, drive chain, and steering bearings.

Maintenance Chart: Chassis, Sidestand, and Fork

Covers maintenance for chassis fasteners, sidestand, front fork, and shock absorber assembly.

Maintenance Chart: Brakes, Throttle, and Lights

Details maintenance for brake switches, throttle grip, cables, lights, signals, and switches.

Notes on Air Filter and Brake System Maintenance

Highlights air filter servicing in dusty areas and hydraulic brake system maintenance.

Removing and Installing Cowling and Panels

Instructions for removing and reinstalling the main cowling and side panels for maintenance access.

Checking and Replacing the Spark Plug

Guide to checking spark plug condition, color, and wear for engine health diagnosis.

Note: Spark Plug Diagnosis Interpretation

Advises consulting a dealer for engine diagnosis based on spark plug condition.

Installing the Spark Plug Correctly

Steps for measuring spark plug gap, cleaning, installing, and tightening the spark plug.

Checking Engine Oil Level

Procedure for checking the engine oil level, including warming the engine and using the check window.

Engine Oil Level Check Procedure

Detailed steps and notes for accurately checking the engine oil level.

Changing Engine Oil and Strainer

Step-by-step guide for draining old oil, cleaning the strainer, and replacing the engine oil.

Caution: Engine Oil Drain Components

Warns about losing small parts like O-ring and compression spring when draining engine oil.

Replacing the Oil Filter Element

Instructions for removing, cleaning, and installing the oil filter element and cover.

Oil Filter Element Tightening Torques

Specifies the correct torque values for installing the oil filter element cover and drain bolt.

Adding Engine Oil and Guards

Guidance on adding the correct amount of engine oil and reinstalling the engine guard.

Caution: Engine Oil Additives and Quality

Warns against using additives or lower-quality oils that can cause clutch slippage or engine damage.

Cleaning the Air Filter Element

Steps for cleaning the air filter element, especially in dusty conditions, and removing the air filter case cover.

Servicing the Air Filter Element Sponge

Instructions for cleaning the sponge material, applying oil, and installing the air filter element.

Caution: Air Filter Installation

Stresses correct seating of the air filter element and the danger of operating without it.

Carburetor Adjustment Recommendations

Advises that carburetor adjustments should ideally be done by a Yamaha dealer due to complexity.

Adjusting Engine Idling Speed

Procedure for checking and adjusting the engine idling speed using the throttle stop screw.

Adjusting Throttle Cable Free Play

Steps to adjust the throttle cable free play at the grip and locknut.

Valve Clearance Adjustment Recommendations

Explains that valve clearance adjustments require a Yamaha dealer due to their complexity.

Tire Air Pressure Specifications

Details correct cold tire pressure settings based on load conditions for safe operation.

Warning: Motorcycle Loading Precautions

Warns against overloading the motorcycle and advises on secure packing and weight distribution.

Tire Inspection and Minimum Tread Depth

Guidance on checking tire tread depth, sidewall condition, and wear indicators.

Approved Tire Specifications

Lists the specific tire sizes and models approved by Yamaha for this motorcycle.

Warning: Tire Wear and Replacement

Stresses the danger of riding on worn tires and recommends dealer replacement for wheel/brake parts.

Spoke Wheel Checks and Maintenance

Advice on checking spoke wheels for damage, balance, and new tire break-in procedures.

Adjusting Clutch Lever Free Play

Steps for adjusting the clutch lever free play using the locknut and adjusting bolt.

Clutch Lever Free Play Adjustment Details

Detailed steps for clutch lever free play adjustment, including locknut and adjusting nut at the crankcase.

Adjusting Front Brake Lever Free Play

Procedure to adjust the free play of the front brake lever using adjusting screws.

Front Brake Lever Free Play Adjustment Notes

Final steps and warnings for adjusting front brake lever free play and checking brake function.

Adjusting Rear Brake Pedal Position

Guide to adjusting the rear brake pedal position relative to the footrest.

Warning: Brake Pedal Position Adjustment

Reminds to adjust brake pedal free play after adjusting its position for proper braking.

Adjusting Rear Brake Pedal Free Play

Steps to adjust the rear brake pedal free play using the adjusting nut at the brake rod.

Adjusting Rear Brake Light Switch

Procedure to adjust the rear brake light switch for timely activation before braking.

Checking Front Brake Pad Wear

How to check front brake pad wear using the wear indicator groove without disassembly.

Checking Rear Brake Shoe Wear

How to check rear brake shoe wear using the wear indicator and limit line.

Checking Front Brake Fluid Level

Guidance on checking the front brake fluid level and replenishing if necessary.

Recommended Brake Fluid Type

Specifies DOT 4 as the recommended brake fluid and warns against mixing fluids.

Brake Fluid Replacement Recommendations

Advises dealer service for brake fluid changes and replacement of seals and hoses.

Checking Drive Chain Slack

Procedure for checking the drive chain slack before each ride.

Adjusting Drive Chain Slack

Step-by-step guide to adjust drive chain slack using adjusting plates and axle nut.

Lubricating the Drive Chain

Instructions for cleaning and lubricating the drive chain with O-ring chain lubricant.

Checking and Lubricating Control Cables

Guidance on checking cable operation, condition, and lubricating them if necessary.

Checking Throttle Grip and Cable Lubrication

Procedure for checking throttle grip operation and lubricating the throttle cable.

Brake and Shift Pedal Lubrication

Instructions for checking and lubricating the brake and shift pedal pivots.

Brake and Clutch Lever Lubrication

Guidance on checking and lubricating the pivots of the brake and clutch levers.

Sidestand Lubrication and Operation Check

Steps for checking sidestand operation and lubricating its pivot and contact surfaces.

Lubricating Rear Suspension Pivoting Points

Instructions for lubricating the grease nipples on the rear suspension pivoting points.

Checking Front Fork Condition and Operation

Guidance on checking the front fork's inner tubes and operation for smooth compression and rebound.

Checking Steering Bearing Play

Procedure to check for wear or looseness in the steering bearings.

Checking Wheel Bearing Play

How to check for play in the wheel hubs and smooth wheel rotation.

Sealed-Type Battery Maintenance

Information on the sealed-type battery, its maintenance, charging, and storage.

Caution: Battery Handling and Charging

Warnings about handling electrolyte, explosive gas, and using correct chargers for sealed batteries.

Replacing a Blown Fuse

Step-by-step instructions for replacing a blown fuse with one of the correct amperage.

Caution: Fuse Amperage Rating

Warns against using a fuse with a higher amperage rating to prevent electrical damage or fire.

Replacing the Headlight Bulb

Procedure for replacing the motorcycle's headlight bulb, including removing the cowling and unit.

Headlight Bulb Replacement Details

Steps for removing the old bulb, installing a new one, and securing the headlight unit.

Warning: Hot Headlight Bulb

Advises caution as headlight bulbs get very hot and require cooling before handling.

Caution: Handling Headlight Bulb Glass

Warns against touching the glass part of the bulb with oil to maintain transparency and lifespan.

Replacing Tail/Brake Light Bulb

Instructions for removing the lens, replacing the defective bulb, and reinstalling the lens.

Replacing Turn Signal Light Bulb

Procedure for replacing a turn signal light bulb by removing the lens and turning the bulb.

Caution: Overtightening Light Lens Screws

Warns against overtightening screws when installing light lenses to prevent breakage.

Motorcycle Support for Maintenance

Precautions for supporting the motorcycle safely when removing wheels or performing other maintenance.

Servicing the Front Wheel

Steps to stabilize the motorcycle and raise the front wheel for servicing.

Servicing the Rear Wheel

Instructions on how to raise the rear wheel off the ground for maintenance.

Removing the Front Wheel

Step-by-step guide to remove the front wheel, including engine guard, brake disc cover, and axle.

Warning: Front Wheel Service Safety

Advises dealer service for wheels and secure support to prevent injury from falling.

Caution: Brake Application During Wheel Removal

Warns against applying the brake after the wheel has been removed to avoid forcing brake pads shut.

Installing the Front Wheel Components

Steps for installing the speedometer gear unit, lifting the wheel, and tightening the axle nut.

Removing the Rear Wheel

Procedure to remove the rear wheel, including engine guard, brake pedal nut, and axle.

Warning: Rear Wheel Service Safety

Advises dealer service for wheels and secure support to prevent injury from falling.

Rear Wheel Installation and Chain Adjustment

Steps for installing the rear wheel, chain, axle nut, and adjusting drive chain slack.

Note: Drive Chain During Wheel Removal

Clarifies that the drive chain does not need to be disassembled for wheel removal/installation.

Rear Wheel Axle Nut Tightening Torque

Specifies the correct torque for tightening the rear wheel axle nut.

Troubleshooting Common Motorcycle Problems

Introduction to troubleshooting, emphasizing dealer service for complex issues and use of genuine parts.

Troubleshooting Chart: Fuel, Compression, Ignition, Battery

A guide to diagnose common starting problems related to fuel, compression, ignition, and battery.

Warning: Fuel System Safety During Troubleshooting

Warns against open flames and smoking when working on the fuel system.

Motorcycle Care and Storage

Importance of Motorcycle Care and Cleaning

Explains why regular care is vital for appearance, lifespan, performance, and warranty compliance.

Pre-Cleaning Preparations

Steps to take before cleaning, like covering the muffler and ensuring caps are installed.

Caution: Cleaning Product Usage

Warns against using harsh cleaners, high-pressure washers, or abrasive materials on specific parts.

General Cleaning Procedures

Steps for cleaning the motorcycle after normal use and after riding in rain or near salt.

Caution: Cleaning After Salt Exposure

Advises against using warm water when cleaning after salt exposure due to increased corrosive action.

Post-Cleaning Care and Protection

Steps for drying, polishing, protecting metal surfaces, and touching up paint.

Warning: Post-Cleaning Brake and Tire Safety

Ensures no oil or wax is on brakes/tires and advises testing braking performance after cleaning.

Surface Protection and Paint Touch-up

Advice on using spray oil, touching up paint, waxing surfaces, and preparing for storage.

Short-Term and Long-Term Storage Guidelines

Provides instructions for storing the motorcycle for short-term and long-term periods.

Caution: Storage Environment and Rust Prevention

Warns against storing in damp, poorly ventilated areas or near corrosive chemicals.

Long-Term Storage: Engine and Cylinder Protection

Steps to protect the engine cylinder, piston rings, etc., from corrosion during long-term storage.

Warning: Sparking Hazard During Storage Prep

Warns about potential sparking when turning the engine over and to ground the spark plug electrodes.

Specifications

Motorcycle Dimensions and Weight

Lists overall dimensions, wheelbase, ground clearance, and weight of the motorcycle.

Engine Specifications and Type

Details engine type, cooling, cylinder arrangement, displacement, bore, stroke, and compression ratio.

Recommended Engine Oil and Quantity

Specifies engine oil types, grades, and capacities based on temperature and filter replacement.

Transmission Gear Ratios and Type

Details the gear ratios for each gear, primary/secondary reduction, and transmission type.

Maximum Load Capacity

Specifies the maximum load the motorcycle can safely carry, including rider, passenger, and cargo.

Tire Air Pressure Specifications by Load

Lists recommended cold tire pressures for different loading conditions.

Headlight and Bulb Specifications

Details the headlight bulb type, voltage, wattage, and quantity.

Fuse Specification

Specifies the amperage rating for the motorcycle's fuse.

Consumer Information

Key and Vehicle Identification Numbers

Instructions for recording key and vehicle identification numbers for parts ordering and reference.

Recording Key Identification Number

Explains how to find and record the key identification number for new key orders.

Recording Vehicle Identification Number

Details how to locate and record the VIN for motorcycle identification and registration.

Model Label Information

Location and importance of the model label for ordering spare parts.

Motorcycle Noise Regulation (Australia)

Information regarding tampering with noise control systems and legal prohibitions.

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