2009 Yamaha VIRAGO 250 / V STAR 250 Motorcycle Service Manual

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 replacement 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 clearance 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/cm 2 , 65.3 ~ 79.8 psi) ---- Pressure check location CRANKCASE BOLT ---- Cylinder head Volume 14.10 ~ 14.50 cm 3 (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

2009 Yamaha VIRAGO 250 / V STAR 250 Motorcycle Service Manual

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