Yamaha VIRAGO XV250V User manual

LIT-11666-19-23 2UJ-28107-11
XV250V(C)
ASSEMBLY MANUAL

EAA00002
FOREWORD
This Assembly Manual contains the information required for the correct assembly of this Yamaha vehi-
cle prior to delivery to the customer. Since some external parts of the vehicle have been removed at
the Yamaha factory for the convenience of packing, assembly by the Yamaha dealer is required. It
should be noted that the assembled vehicle should be thoroughly cleaned, inspected, and adjusted pri-
or to delivery to the customer.
EAA00005
NOTICE
The service specifications given in this assembly manual are based on the model as manufactured.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and sig-
nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and
will appear in future editions of this manual where applicable.
The procedures below are described in the order that the procedures are carried out correctly and com-
pletely. Failure to do so can result in poor performance and possible harm to the vehicle and/or rider.
CONCERNING CRATE DAMAGE:
Follow the instructions in the Dealer Warranty Handbook, Procedure Section.
Particularly important information is distinguished in this manual by the following notations.
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.
EAA00001
XV250V(C)
ASSEMBLY MANUAL
©2005 by Yamaha Motor Corporation, U.S.A.
First Edition, May 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.
P/N LIT-11666-19-23
WARNING
CAUTION:
NOTE:

EAA00008
SYMBOLS USED IN THE
ASSEMBLY MANUAL
In order to simplify descriptions in this
assembly manual, the following symbols
are used:
(1): Coat with lithium-soap-based grease.
(2): Tighten to 10 Nm.
(10 Nm = 1.0 m · kg, 7.2 ft · lb)
(3): Towards the front of the vehicle
(4): Clearance required
(5): Install so that the arrow mark faces
upward.
(6): Apply motor oil.
(7): Made of rubber or plastics
(8):
A: Ref. No. (indicating the order of
operations.)
B: Part name
C: Quantity of parts per vehicle
D: Place where parts are held
V: Stored in plastic bag
C: Stored in carton box
S: Fixed inside the steel frame
and/or contained in the Sty-
rofoam tray (upper or lower)
: Temporarily installed or
secured
E: Size or material of parts
d/D: Diameter of part
: Length of part
e.g., 5 (0.20) = 5 mm (0.20 in)
*
EAA00040
PREPARATION
To assemble the vehicle correctly, sup-
plies (e.g. oils, greases, and shop rags)
and sufficient working space are required.
Workshop
The workshop where the vehicle is assem-
bled should be clean, spacious, and have
a level floor.
Self-protection
Protect your eyes with suitable safety
glasses or goggles when using com-
pressed air, when grinding or when doing
any operation which may cause particles
to fly off.
Protect hands and feet by wearing safety
gloves or shoes.
(1) (2)
(3) (4)
(5) (6)
(7)
(8)
10
FWD
UP
d
Dd
dDd

–1–
EAA00100
SETUP PROCEDURES
Perform the setup procedures in the order indicated by the numbers. Always follow the order as shown.

–2–
EAA00109
1. FRONT FENDER
A: Fasten the brake hose with the
speedometer cable guide.
B: Pass the speedometer cable
through the speedometer
cable guide.
WARNING
_
Proper cable routing is essen-
tial to assure safe vehicle oper-
ation.
Refer to “CABLE ROUTING”.
C: Tighten the bolts to specifica-
tion.
CAUTION:
_
Be careful not to scratch the
front fender with the front fork
outer tube.
D: Align the projections on the
front reflectors with the slots in
the front reflector bracket and
speedometer cable guide.
Bolt
16 Nm (1.6 m · kg, 11 ft · lb)
EAA00204
2. FRONT WHEEL
A: Clean the brake disc.
B: Clean the front wheel axle.
C: Clean the collar.
D:
WARNING
_
Take care not to get grease on
the brake disc or inner surface
of the brake pads. If you do so,
clean using a rag dampened
with a solvent. Foreign material
on braking surface can cause
impaired braking action.
E: Make sure the projections in
the wheel hub are meshed
with the slots in the speedom-
eter gear unit.
F: Lift the front wheel and install
the front wheel axle.
NOTE:
_
Do not depress the brake lever
when the caliper is off the brake
disc.
G: Make sure the projection
(torque stopper) on the front
fork is placed in the slot in the
speedometer gear unit as
shown.
H: Tighten the front wheel axle to
specification.
I: Tighten the axle pinch bolt to
specification.
J: Connect the speedometer
cable to the speedometer gear
unit.
Front wheel axle
59 Nm (5.9 m · kg, 43 ft · lb)
Axle pinch bolt
20 Nm (2.0 m · kg, 14 ft · lb)
1 Front fender 1 C
2 Front reflector bracket 1 V
3 Speedometer cable guide 1 V
4 Front brake hose holder 1 V
5 Flange bolt 4 V d = 8 (0.31), = 12 (0.47)
6 Front reflector 2 V
7 Flange nut 2 V d = 5 (0.20)
1 Front wheel 1 S
2Collar 1 V
3 Speedometer gear unit 1 V
4 Front wheel axle 1
5 Axle pinch bolt 1 d = 8 (0.31), = 35 (1.38)
6 Speedometer cable 1
*
*
*

–3–
EAA00209
3. LEAD HOLDER
A: Pass the wire harness through
the lead holder.
NOTE:
_
Refer to “CABLE ROUTING”.
EAA00014
4. HANDLEBAR
Before 2012 models
A: Clean the right handlebar end.
Apply light coat grease.
B: Install the handlebar holders
with the arrow mark facing for-
ward.
CAUTION:
_
First tighten the bolts on the
front side, and then tighten the
bolts on the rear side.
C: Align the punch mark on the
handlebar with the top of the
lower handlebar holders.
D: Tighten the bolts to specifica-
tion.
WARNING
_
Proper cable routing is essen-
tial to assure safe vehicle oper-
ation.
Refer to “CABLE ROUTING”.
Bolt
23 Nm (2.3 m · kg, 17 ft · lb)
EAA00014
4. HANDLEBAR
For 2012 models
A: Clean the right handlebar end.
Apply light coat grease.
B: Install the handlebar holders
with the arrow mark facing for-
ward.
CAUTION:
_
First tighten the bolts on the
front side, and then tighten the
bolts on the rear side.
C: Align the punch mark on the
handlebar with the top of the
lower handlebar holders.
D: Tighten the bolts to specifica-
tion.
WARNING
_
Proper cable routing is essen-
tial to assure safe vehicle oper-
ation.
Refer to “CABLE ROUTING”.
Bolt
23 Nm (2.3 m · kg, 17 ft · lb)
1 Lead holder 1 V
2 Flange bolt 1 V d = 6 (0.24), = 12 (0.47)
1 Indicator light assembly 1
2 Screw 2 V d = 4 (0.16), = 35 (1.38)
3 Handlebar 1 S
4 Upper handlebar holder 2 V
5 Hexagon socket bolt 4 V d = 8 (0.32), = 25 (0.98)
6Plug 4 V
A
C
B
D
23 6
5
4
3
2
1
*
1 Handlebar 1 S
2 Upper handlebar holder 2 V
3 Hexagon socket bolt 4 V
4Plug 4 V
A
C
B
D
2
1
4
3
23

–4–
EAA00018
5. THROTTLE GRIP
ASSEMBLY
Before 2012 models
A: The stopper (a) should be
touching the inner surface of
the right handlebar switch.
B: Slip the throttle grip over the
right handlebar completely
and then slide it back about
1 mm (0.04 in).
C: Check the throttle grip for
smooth action.
WARNING
_
Proper cable routing is essen-
tial to assure safe vehicle oper-
ation.
Refer to “CABLE ROUTING”.
EAA00018
5. THROTTLE GRIP
ASSEMBLY
For 2012 models
A: The stopper (a) should be
touching the inner surface of
the right handlebar switch.
B: Slip the throttle grip over the
right handlebar completely
and then slide it back about
1.5 mm (0.06 in).
C: Check the throttle grip for
smooth action.
WARNING
_
Proper cable routing is essen-
tial to assure safe vehicle oper-
ation.
Refer to “CABLE ROUTING”.
EAA00032
6. FRONT BRAKE
MASTER CYLINDER
A: Lubricate the pivoting parts of
the brake lever.
B: Make sure that the “UP” mark
on the holder is pointed
upward.
C: Tighten the bolts to specifica-
tion.
D: Check the brake lever for
smooth action.
WARNING
Proper cable and hose routing
is essential to assure safe vehi-
cle operation.
Refer to “CABLE ROUTING”.
Recommended lubricants
Yamaha cable lube or motor
oil
Bolt
7 Nm (0.7 m · kg, 5.1 ft · lb)
1 Throttle grip assembly 1
2 Screw 2 d = 5 (0.20), = 40 (1.57)
d = 5 (0.20), = 45 (1.77)
3 Grip end 1 V
4 Hexagon socket bolt 1 V d = 6 (0.24), = 75 (2.95)
5 Damper 1 V
6 Flange nut 1 V d = 6 (0.24)
1mm
(0.04in)
CB
A
653
4
2
1
a
*
*
1 Throttle grip assembly 1
2 Screw 2 d = 5 (0.20), = 40 (1.57)
d = 5 (0.20), = 45 (1.77)
3 Grip end 1 V
1.5mm
(0.06in)
C
B
A
3
2
1
a
*
*
1Front brake master cylinder
assembly 1
2Front brake master cylinder
holder 1V
3 Bolt with washer 2 V d = 6 (0.24), = 25 (0.98)
*

–5–
EAA00035
7. LEFT HANDLEBAR
SWITCH
Before 2012 models
A: Align the slot on the left han-
dlebar switch with the projec-
tion on the clutch lever holder.
B: Pass the starter cable through
the cable guide.
WARNING
_
Proper cable routing is essen-
tial to assure safe vehicle oper-
ation.
Refer to “CABLE ROUTING”.
EAA00035
7. LEFT HANDLEBAR
SWITCH
For 2012 models
A: Align the slot on the left han-
dlebar switch with the projec-
tion on the clutch lever holder.
B: Pass the starter cable through
the cable guide.
WARNING
_
Proper cable routing is essen-
tial to assure safe vehicle oper-
ation.
Refer to “CABLE ROUTING”.
1 Left handlebar switch 1
2 Screw 2 V d = 5 (0.20), = 35 (1.38)
3Starterlever 1
4 Starter cable 1
5 Special washer 1
6 Washer 1 d = 6 (0.24)
7 Screw 1 d = 6 (0.24), = 10 (0.39)
8 Grip end 1 V
9 Hexagon socket bolt 1 V d = 6 (0.24), = 75 (2.95)
10 Damper 1 V
11 Flange nut 1 V d = 6 (0.24)
A
11
10
8
9
1
6
7
2
5
B
4
3
2
*
*
*
*
*
*
1 Left handlebar switch 1
2 Screw 2 V d = 5 (0.20), = 35 (1.38)
3Starterlever 1
4 Starter cable 1
5 Special washer 1
6 Washer 1 d = 6 (0.24)
7 Screw 1 d = 6 (0.24), = 10 (0.39)
8 Grip end 1 V
A
8
1
6
7
2
5
B
4
3
2
*
*
*
*
*
*

–6–
EAA00049
8. CLUTCH CABLE
A: Lubricate the pivoting part of
the clutch lever.
B: To install the clutch cable, be
sure to proceed as follows:
a. Turn in the adjuster on the
lever holder until tight. Next,
align the slit in the adjuster
and cable socket with the slit
in the lever holder.
b. Insert the cable end into the
lever hole. Next, while pulling
the outer cable in the direction
opposite to the lever, seat the
outer cable into the cable
socket.
NOTE:
_
Check the clutch lever for smooth
action.
Refer to “ADJUSTMENTS AND
PREDELIVERY SERVICE”.
WARNING
_
Proper cable routing is essen-
tial to assure safe vehicle oper-
ation.
Refer to “CABLE ROUTING”.
C: Install the rubber cover onto
the end of the clutch lever.
D: Make sure that the clutch
cable end (engine side) is
positioned correctly.
Recommended lubricants
Yamaha cable lube or motor
oil
EAA00039
9. CABLE TIES
Before 2012 models
A: Fasten the left handlebar
switch lead and clutch switch
lead with two plastic bands.
B: Fasten the right handlebar
switch lead and front brake
light switch lead with two plas-
tic bands.
NOTE:
_
Refer to “CABLE ROUTING”.
1 Clutch cable 1
2 Clutch switch 1
D
*
*
1 Plastic band 4 V
EAA00039
9. CABLE TIES
For 2012 models
A: Fasten the left handlebar
switch lead and clutch switch
lead with two plastic bands.
B: Fasten the right handlebar
switch lead and front brake
light switch lead with two plas-
tic bands.
NOTE:
_
Refer to “CABLE ROUTING”.
1 Plastic band 4 V

–7–
EAA00054
10. FRONT TURN SIGNAL
LIGHTS
A: Install the turn signal light with
a chocolate color lead on the
left side. Next, install the turn
signal light with a dark green
color lead on the right side.
B: Pass the clutch cable, starter
cable, front brake hose, and
throttle cables through the
cable guide.
NOTE:
Refer to “CABLE ROUTING”.
C: Connect the front turn signal
light leads to the wire harness.
The leads of identical colors
should be connected.
NOTE:
_
Refer to “CABLE ROUTING”.
D: Tighten the nuts to specifica-
tion.
Nut
23 Nm (2.3 m · kg, 17 ft · lb)
EAA00213
11. HEADLIGHT LENS UNIT
AND LEFT SIDE COVER
A: Connect the headlight coupler
to the headlight.
NOTE:
_
Refer to “CABLE ROUTING”.
12. REARVIEW MIRRORS
1 Front turn signal light 2 C
2 Front turn signal light bracket 2
3 Bolt 2 V d = 6 (0.24), = 30 (1.18)
4 Flange nut 2 V d = 6 (0.24)
5 Cable guide 1 V
6 Nut 2 V d = 12 (0.47)
*
1 Headlight lens unit 1
2Screw 1d = 5 (0.20), = 14 (0.55)
1V
3 Left side cover 1 C
4 Screw 1 V d = 4 (0.16), = 12 (0.47)
5 Hexagon socket bolt 1 V d = 4 (0.16), = 20 (0.79)
A
1
2
4
35
*
*
1 Rearview mirror 2 C
1