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Xmotos XZ 250R Owner's Manual

Manual is about: DIRT BIKE MOTOCROSS MOTARD

Summary of XZ 250R

  • Page 1

    1 operating instruction manual 2011 - 2012 xz 250r owner’s manual xz 250r v4 lc zs motocross dirt bike motard xz 250rm ver.2 10/2011.

  • Page 2: Xz250R -

    2 xz250r - lc / zs xz250rm xz250r v4 owner’s manual this manual should be considered a permanent part of the motorcycle and should remain if it is resold. This manual contains the latest product information available before printing. Xgroup corporation reserves the right to make changes at any time ...

  • Page 3: Important

    3 please write the serial numbers of your motorcycle in the boxes below chassis (vin) number engine number key number (if available) dealer stamp xgroup corporation reserves the right to modify any equipment, technical specifications, colors, materials, services offered and rendered, and the like so...

  • Page 4

    4 what is covered: xgroup corporation warrants that this product is free of defects in material and workmanship for a period of 6 months from the date of purchase, except as limited below. Warranty service and replacement parts are warranted only for the duration of the warranty on the original prod...

  • Page 5

    5 important warranty information introduction important safety information safety information for parents safety label information component locations serial number locations handle bar lever controls operating controls guages, indicators & display before riding protective gear & apparel is the moto...

  • Page 6

    6 congratulations on choosing your xmotos motorcycle. Your xmotos motorcycle was designed as a recreational motorcycle for off-road use only by a single rider. This motorcycle is ideal for riders with basic experience. (off-road) your xmotos motorcycle was designed as an on road motorcycle and to be...

  • Page 7

    7 your personal safety, and the safety of those around you, is extremely important. Operating this motorcycle safely is an important responsibility. Xgroup corporation has provided operating procedures and other information on labels and in this manual to help you make informed decisions about safet...

  • Page 8

    8 a motorcycle can provide many years of service and pleasure, provided you take responsibility for safety, properly maintain your motorcycle and understand the challenges you may encounter while riding. Listed below are some of the most important safety measures one should take when riding. Never r...

  • Page 9

    9 as a parent, your child‟s safety is your first priority. Riding an off-road motorcycle is very fun. However, just like riding a bicycle, bad decisions can result in injury. As a parent, you can greatly prevent accidents by making informed decisions about if, when and how your child will ride. Alwa...

  • Page 10

    10 this page will show you where to find the safety labels on your motorcycle. You will find that some labels warn you of potential hazards. Others will provide important safety and maintenance information. Please read them carefully and do not remove them. If your label wears off from riding or bec...

  • Page 11

    11 this page will show you where to find the safety labels on your motorcycle. You will find that some labels warn you of potential hazards. Others will provide important safety and maintenance information. Please read them carefully and do not remove them. If your label wears off from riding or bec...

  • Page 12

    12 when you ride a motorcycle off-road, you need to be able to operate the throttle, clutch, brakes, and other controls without stopping to look at them. Please read this section carefully before you ride your motorcycle. This section of the manual will show the location and operation of all the bas...

  • Page 13

    13 when you ride a motorcycle on-road, you need to be able to operate the throttle, clutch, brakes, and other controls without stopping to look at them. Please read this section carefully before you ride your motorcycle. This section of the manual will show the location and operation of all the basi...

  • Page 14

    14 component locations (off-road) rear brake pedal spark plug oil filter kick starter battery drive chain fuel valve air filter shift lever engine number chassis number side stand cdi box.

  • Page 15

    15 component locations (on-road) rear brake pedal oil filter kick starter battery drive chain fuel valve air filter shift lever engine number chassis number cdi box spark plug ignition coil.

  • Page 16

    16 vin – chassis number the vin number is located in one of three places on the chassis. 1. Right side of frame. 2. Left side of frame. 3. Steering head tube. Write this number in the vin box on page 3. Engine model & serial number the engine model number and serial number is stamped on the left sid...

  • Page 17

    17 clutch lever the clutch lever is located on the left side of the handlebar. Hand brake lever & throttle the hand brake lever and throttle is mounted on the right side of the handlebar. The adjusting screw can be used to change the basic position of the brake lever. Stop switch the stop switch tur...

  • Page 18

    18 left handlebar switches electric start button use this button to operate the starter motor. With the key ignition switch in the “on” position, the engine stop switch in the “run” position , and the transmission in the neutral position, pull the clutch lever and push the electric start button to s...

  • Page 19

    19 key ignition switch the ignition key is used to supply power from the battery to the electrical components of the motorcycle in the “on” position . Turn the switch to the “off” position when you are finished riding, or if you wish to stop the engine. Steering lock to lock the steering system, tur...

  • Page 20

    20 choke lever (xz250r – lc / zs) when pulling the choke lever fully toward the top , a cylinder in the carburetor is opened. Through this cylinder, the engine can take in additional fuel. This results in a rich fuel and air mixture, which is needed for a cold start. When pushing down the chock leve...

  • Page 21

    21 shift lever (v4 / rm) the shift lever is on the left side of the engine. The gear positions are shown in the illustration on page 28. Foot brake lever (v4 / rm) the brake lever is located on the right side of the engine. Its basic operation is to apply the rear brake to slow or stop the motorcycl...

  • Page 22

    22 speedometer and odometer the digital speedometer indicates the road speed of the motorcycle. The read-out displays the motorcycle road speed in increments of one kilometer (or mile) per hour. In the speedometer face is the electronic odometer and one trip meter. (a) multi-function display (1) tur...

  • Page 23: Are You Ready To Ride?

    23 before you ride, you must be absolutely sure that you and your motorcycle are ready to ride. To help you get prepared, this section of the manual will discuss how to evaluate your riding readiness and how to perform our recommended ore-ride inspection of your motorcycle. If you are a parent, plea...

  • Page 24

    24 before each and every ride you take, it is extremely important that you inspect the motorcycle and make sure any problems you find are corrected. A pre-ride inspection is a must because off-road riding can be very tough on a motorcycle and you do not want to have a breakdown for from help. Check ...

  • Page 25

    25 this section of the manual gives basic information on how to begin riding your motorcycle. In this section we will cover how to start and stop the engine, how to use the throttle and brakes, how to use the clutch and shift gears, and things you need to do when you are finished riding. Break-in pe...

  • Page 26

    26 always follow the proper starting procedure as described below. Starting when the engine is cold 1. Turn the key switch to the “on” position. 2. Make sure the transmission is in the neutral position. 3. Turn the fuel tap to the “on” position. 4. Pull and hold the choke lever. (v4 - rm) 5. Lift th...

  • Page 27

    27 if the engine fails to start after repeated attempts, it may be flooded with excess fuel. Follow the steps below to clear a flooded engine. 1. Press the engine stop switch and hold it. 2. Open the throttle completely. 3. Press the engine start switch and hold it for 5 seconds. (electric start) 4....

  • Page 28

    28 this motorcycle has five (5) forward gears for lc / zs / v4 series and six (6) forward gears for rm – (v4 – optional) series. (rm - (v4 - optional)) to start riding, after the engine has been warmed up and the side stand raised: (lc / zs / v4) 1. Close the throttle and squeeze the clutch lever al...

  • Page 29

    29 this section will cover basic braking technique for your motorcycle. To slow or stop the motorcycle, squeeze and hold the clutch lever and apply the front brake lever and rear brake pedal firmly and smoothly. If your speed is reduced a significant amount, you may need to downshift to a lower gear...

  • Page 30

    30 keeping your motorcycle in perfect operating condition is absolutely essential to your safety. It is also the best way to protect your investment, get maximum performance, avoid breakdowns, and have more fun. To help keep your motorcycle well maintained, this section includes a maintenance schedu...

  • Page 31

    31 to keep your motorcycle safe and reliable when you ride, regular inspections and service is required. Below you will find a maintenance schedule that describes when components need to be inspected or serviced. The maintenance schedule lists item that can be performed with basic mechanical skills ...

  • Page 32

    32 periodic maintenance schedule a clean and maintained motorcycle saves time and money! After 10 hours or 1000 km after 25 hours or 2500 km service after 5000 km check engine oil level change engine oil and oil filter use only petronas oil, see pg. 71 check, clean engine oil screens (2) change engi...

  • Page 33

    33 periodic maintenance schedule vital checks & care procedures to be conducted by the owner or the technician(s) before each start after every cleaning for cross country use once a year check oil level check brake fluid level check brake pads for wear check lighting system for proper operation chec...

  • Page 34

    34 fuel recommendation – any unleaded gasoline with an octane rating of 90 or higher. The engine in your motorcycle has been designed to run on any gasoline with a pump octane rating of 86 or higher. Most service stations will display the octane rating above each pump. Although it is not required, x...

  • Page 35

    35 checking & adding coolant. 1. With the engine cold, remove the radiator cap , and check the coolant level. The level of coolant is correct when it is at the bottom of the filler neck . If the level is below the filler neck, you must add more coolant. Xmotos recommends using high quality ethylene ...

  • Page 36

    36 using proper oil, and regularly checking, adding and changing oil will help extend the service life of your engine. Even the best oil wears out and becomes thinner. Changing oil helps get rid of dirt and deposits in the engine. Operating the engine with old or dirty oil may and may damage your en...

  • Page 37

    37 1. Start and run the engine at idle for 3-5 minutes, then stop it. 2. Wait about 2-3 minutes to allow the oil to properly distribute itself in the engine. 3. Stand the motorcycle on a support stand so that it is not leaning to either the right or left. 4. Remove the oil filler cap , wipe it clean...

  • Page 38

    38 1. Start and run the engine at idle for 3-5 minutes, then stop it. 2. Stand the motorcycle on a straight level surface so that it is not leaning to either the right or left & support it. 3. Remove the oil filler cap. (pg. 36) 4. Place the oil drain pan under the engine. 5. Remove the oil drain bo...

  • Page 39

    39 proper air filter maintenance is extremely important for off-road vehicles. A dirty, water-soaked, worn-out air filter will allow dirt, dust, mud or other impurities to pass into the engine. If you are riding in wet and/or muddy areas, you should service the air filter more often. Always replace ...

  • Page 40

    40 a. Throttle free-play should be 3 – 5 mm (0.10 – 0.20 in) b. If your throttle has more play than specified, adjustments need to be made. Follow the steps below: c. Minor adjustments are generally made with the upper adjuster. 1. Pull back the dust cover . 2. Loosen the lock nut 3. Turn the adjust...

  • Page 41

    41 remember, idle adjustment is not a real cure for other problems in your engines’ fuel delivery system. Adjusting the idle will not solve or compensate for a fault elsewhere in the engine. If you are having trouble, please contact your xmotos dealer. The engine must be at normal operating temperat...

  • Page 42

    42 in order to ensure the best performance and durability from the clutch, always be sure you have proper clutch free-play. Free-play is needed to ensure that the clutch has room for wear. A clutch with no free-play will begin to slip as the discs wear down. Failure to fix a slipping clutch can caus...

  • Page 43

    43 1. Loosen the lock nut 2. Move the integral cable adjuster and lock in to place with the adjuster nut to obtain the specified free-play. 3. Tighten the lock nut and check the adjustment. 4. Start the engine and pull the clutch lever in and shift into gear. Make sure the engine does not stall and ...

  • Page 44

    44 the recommended standard spark plug will work very well in most riding condition. However, if you plan on riding for extended periods of time at high speed or high engine rpm in hot climates, or plan extended riding in cold climates, a different plug may be recommended. A fouled (dirty) spark plu...

  • Page 45

    45 your motorcycle is equipped with hydraulic disc brakes on both the front and rear wheels. Hydraulic brakes require brake fluid for its operation. Both front and rear brakes have a brake fluid reservoir built into the master cylinders. Follow the procedures below to adjust the brake levers to the ...

  • Page 46

    46 hydraulic brakes require brake fluid for its operation. Both front and rear brakes have a brake fluid reservoir built into the master cylinders. Follow the procedures below to check and fill the cylinders with the specified brake fluid. Recommended brake fluid – dot 4 1. Clean all dirt and dust f...

  • Page 47

    47 hydraulic disc brake systems use a brake caliper to squeeze the rotors (brake disc) which causes the motorcycle to stop. Inside the brake caliper are brake pads. The brake pads are the part of the brake system that makes contact with the brake rotor. The pads must be checked in accordance with th...

  • Page 48

    48 loose, worn or damaged suspension components may affect the stability and handling of your motorcycle. If any of the suspension components seem to be worn or damaged, see your xmotos dealer for service and/or inspection. Your xmotos dealer is the most qualified to determine whether or not replace...

  • Page 49

    49 over time, the forks suck in air, creating a build-up that will have a bad effect on the performance of the forks. 1. Put a support on the bottom of the bike so that the front tire is off the ground. 2. Turn the air bleeder screw on the top of the fork counter-clockwise to release the air. 3. Mak...

  • Page 50

    50 the rear suspension of your motorcycle has 3 different adjustment points. It comes from the factory set to the softest setting. If you wish to make the rear suspension harder, follow the procedure below. Adjusting the rear shock is not hard, but like the front forks, changes should be made one at...

  • Page 51

    51 1. The high speed damping can be adjusted by turning the hexagonal portion of the compression adjuster 2. The high speed damping adjuster has 3 ½ turns or more. 3. To adjust to the standard position, turn the adjuster clockwise until it will no longer turn (do not force). This is the full hard se...

  • Page 52

    52 maintenance of spoke tension and wheel trueness (roundness) is critical to safe motorcycle operation. During the first 100miles of riding, spokes will loosen faster due to the initial seating of the parts. Excessively loose spokes will cause the motorcycle to become unstable at high speed and cou...

  • Page 53

    53 a flat tire or tire blowout can be very inconvenient and can even cause you to have an accident. Take the time to inspect your tires and wheels before you ride. For more information about handling a flat tire, refer to the section of this manual titled, resolving the unexpected.  inspect the tir...

  • Page 54

    54 new tires need proper break-in to assure maximum performance, just as the engine does. Wear-in the tread surface by gradually increasing your cornering lean angles over the first 160km (100 miles) before attempting maximum performance. Avoid hard acceleration, hard cornering, and hard braking for...

  • Page 55

    55 use the diagram below to determine if the sprockets need to be replaced. Never use a new chain with a damaged or worn sprocket. 1. Check the upper and lower rollers for wear and damage. 2. If the rollers are worn or damaged, they must be replaced before your next ride. 3. If the roller has been w...

  • Page 56

    56 1. Check the slider for wear fig. 1 2. If the wear limit has been reached fig. 3, it must be replaced. Fig. 1 1. Check the guide slider for wear fig 2. 2. Replace the guide slider if it is worn to the bottom of the wear limit. Fig. 3 - fig. 2 fig. 3 the sliders must be replaced if worn down too f...

  • Page 57

    57 follow the procedure below to adjust the drive chain slack. Be sure that you are parked on a level surface and the engine is turned off. 1. Loosen the rear axle nut 2. Loosen the lock nut on both right and left side. 3. Turn the adjusting bolts counter-clockwise to decrease slack in the chain, or...

  • Page 58

    58 if you have been riding in extremely muddy or dusty conditions, the drive chain should be removed and cleaned before you apply lubricant. Follow the procedure below to remove and clean or replace the drive chain with a new one. 1. Remove the master link retaining clip with needle nose pliers. Do ...

  • Page 59

    59 1. Examine the carburetor - be sure there is fuel flowing into the carburetor. Is there fuel flowing into the carburetor? No - clogged fuel hose/line or clogged fuel filter - clogged fuel valve - clogged fuel tank breather hose - sticking or stuck carburetor float yes - see step 2 2. Examine the ...

  • Page 60

    60 1. Examine the drive-train - raise the wheel of the ground and spin by hand. Does the wheel spin freely? No - brake dragging, improperly mounted brake pads - worn or damaged wheel bearings - bent axle yes - see step 2 2. Check the tire pressure - use a tire pressure gauge to check the tire pressu...

  • Page 61

    61 8. Carburetor inspection - disassemble the carburetor and check for clogs was the carburetor clogged and dirty? No - see step 9 yes - carburetor is not serviced frequently enough - contaminated fuel 9. Over heating inspection - check the engine for overheating is the engine overheating? No - go t...

  • Page 62

    62 2. Spark test - test for ignition spark by removing the spark plug and inserting it into the spark plug cap. Place the open end of the spark plug on a metal part of the engine and kick start the engine. You should see a nice blue spark on the end of the spark plug. A faint spark will not start th...

  • Page 63

    63 steering is heavy - steering stem nut too tight - damaged steering head bearings - check tire pressure either wheel has a wobble - excessive wheel bearing play - bent rim - improperly installed wheel hub - damaged swing-arm - bent frame - loose or broken spokes - old tires with “dry-rot” the moto...

  • Page 64

    64 if you encounter trouble during a ride, the first thing you should do is stop as soon as it is safely possible. Do not continue to ride if you have a flat tire, if you hear an unusual noise, or if your motorcycle just does not feel right. If you continue to ride, you will cause more damage the mo...

  • Page 65

    65 how you handle a flat tire on the trail will depend on the severity of the damage to the tire and/or the inner tube and what tools and supplies you keep with you. If you have a slow leak or a minor puncture, there are two ways you can try to make a temporary repair: 1. Use an aerosol tire sealer ...

  • Page 66

    66 torque specifications q g c d f e a h l j k m s u t r v z q y a b n o w x p ad a c af a e al a k aj ah a q a p a m an a o a r as a t au a v a w a x a b a a g d a y a 1 k.

  • Page 67

    67 notes: 1. Apply oil to threads. 2. Apply lock-tite liquid to threads. (red) 3. Apply lock-tite liquid to threads. (blue) 4. Apply grease to bolt, not threads. Specific engine torque specifications on pages 65, 66, 67. Name torque notes n•m ft•lbs aa brake hose bolt 32.4 24 ab clutch holder 10 7.5...

  • Page 68

    68 notes 1. Apply oil to threads. 2. Apply lock-tite liquid to threads. (red) 3. Apply lock-tite liquid to threads. (blue) 4. Apply grease to bolt, not threads. Name torque notes n•m ft•lbs a engine mount (front) 35 26 2 b oil drain cap 17.5 13 1 c engine mount (lower) 40.5 30 2 d sprocket bolts 16....

  • Page 69

    69 notes 1. Apply oil to threads. 2. Apply lock-tite to threads. (red) 3. Apply lock-tite to threads. (blue) 4. Apply grease to bolt, not threads. Name torque notes n•m ft•lbs a engine mount (front) 35 26 2 b oil drain bolt 17.5 13 1 c engine mount (lower) 40.5 30 2 d sprocket bolts 16.2 12 3 e swin...

  • Page 70

    70 notes: 1. Apply oil to threads. 2. Apply lock-tite liquid to threads. (red) 3. Apply lock-tite liquid to threads. (blue) 4. Apply grease to bolt, not threads. Name torque notes n•m ft•lbs a engine mount (top) 35 26 3 b do not remove //// //// //// c engine mount (upper) 40.5 30 3 d sprocket cover...

  • Page 71

    71 xz250r - lc xz250r - zs xz250r v4 / rm engine lc170mm-2a zs169mm zs177mm design 4 - stroke water cooled / 2 valve / single camshaft 4 - stroke water cooled / 4 valve / single camshaft displacement 249.4 ml 243 ml 249.6 ml bore / stroke 70 x 64.8 mm 69 x 65 mm 77 x 53.6 mm power max. 12.5 kw / 750...

  • Page 72

    72 xz250r - lc xz250r - zs xz250r v4 / rm frame high strength tensile steel forks xmotos t7 (s) series, inverted, dual adjustable 910mm xmotos t8 (z) series, dual adjustable wheel travel front xmotos t7 (s) series dual adjustable 245 mm // t8 (z) series 275 mm rear xmotos t8 (z) series 110 mm rear s...

  • Page 73

    73 wiring schematic (off-road / lc-zs-v4).

  • Page 74

    74 wiring schematic (on-road / rm).

  • Page 75

    75 wiring schematic (on-road / rm) model xz250rm revised 03/2011.

  • Page 76

    76 odometer or hour reading 00,000 km hr. Dealer stamp date signature odometer or hour reading km hr. Dealer stamp date signature odometer or hour reading km hr. Dealer stamp date signature odometer or hour reading km hr. Dealer stamp date signature odometer or hour reading km hr. Dealer stamp date ...

  • Page 77

    77 notes.

  • Page 78

    78 notes.