Yamaha XV250P User Manual

OWNER’S MANUAL

XV250P

4TN-28199-E2

EAA00100 EAA20301

XV250P

OWNER’S MANUAL

©2003 by Yamaha Motor Co., Ltd.

1st Edition, January 2003
All rights reserved. Any reprinting or
unauthorized use without the written

permission of Yamaha Motor Co., Ltd.

is expressly prohibited.

Printed in Japan

Congratulations on your purchase of the
Yamaha XV250P. This model is the result of
Yamaha’s vast experience in the production
of fine sporting, touring, and pacesetting rac­ing machines. It represents the high degree of
craftsmanship and reliability that have made
Yamaha a leader in these fields.
This manual will give you an understanding of
the operation, inspection, and basic mainte­nance of this motorcycle. If you have any
questions about the operation or maintenance
of your motorcycle, please consult a Yamaha
dealer.

INTRODUCTION

EAA10603

IMPORTANT MANUAL

INFORMATION

Particularly important information is distin­guished in this manual by the following nota­tions:

The Safety Alert Symbol means ATTENTION!
BECOME ALERT! YOUR SAFETY IS IN­VOLVED!

WARNING

Failure to follow WARNING instructions could
result in severe injury or death to the motor­cycle operator, a bystander or a person in­specting or repairing the motorcycle.

CAUTION:

A CAUTION indicates special precautions
that must be taken to avoid damage to the
motorcycle.

NOTE:

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

EUU00001

NOTE:

●

This manual should be considered a per­manent part of this motorcycle and
should remain with it even if the motor­cycle is subsequently sold.

●

Yamaha continually seeks advance­ments in product design and quality.
Therefore, while this manual contains the
most current product information avail­able at the time of printing, there may be
minor discrepancies between your
motorcycle and this manual. If there is
any question concerning this manual,
please consult your Yamaha dealer.

EUU60100

WARNING

PLEASE READ THIS MANUAL CAREFUL­LY AND COMPLETELY BEFORE OPERAT­ING THIS MOTORCYCLE.

EAA30001

CONTENTS

GIVE SAFETY THE RIGHT OF WAY .......1-1

DESCRIPTION ..........................................2-1

MOTORCYCLE IDENTIFICATION ...........3-1

Identification numbers ............................3-1

Key identification number .......................3-1

Frame serial number ..............................3-2

Model label .............................................3-2

CONTROL FUNCTIONS ...........................4-1

Main switch .............................................4-1

Indicator lights.........................................4-2

Speedometer ..........................................4-2

Handlebar switches ................................4-3

Clutch lever.............................................4-6

Shift pedal...............................................4-6

Front brake lever.....................................4-6

Rear brake pedal ....................................4-6

Fuel tank cap ..........................................4-7

Fuel cock................................................ 4-8

Starter “CHOKE” .................................... 4-9

Steering lock ........................................ 4-10

Seat ...................................................... 4-10

Rear shock absorber adjustment......... 4-11

Sidestand ............................................. 4-11

Ignition circuit cut-off system................ 4-13

PRE-OPERATION CHECKS .................... 5-1

Brakes .................................................... 5-3

Front brake fluid leakage ....................... 5-3

Clutch ..................................................... 5-4

Throttle grip ............................................ 5-4

Engine oil................................................ 5-5

Chain ...................................................... 5-5

Tires ....................................................... 5-6

Cast wheels............................................ 5-9

Chassis fasteners................................... 5-9

Lights, signals and switches ................ 5-10

Battery .................................................. 5-10

Fuel.......................................................5-10

OPERATION AND IMPORTANT

RIDING POINTS........................................6-1

Starting and warming up a cold

engine..................................................6-1

Starting a warm engine ..........................6-3

Shifting....................................................6-3

Engine break-in ......................................6-4

Parking....................................................6-5

PERIODIC MAINTENANCE AND

MINOR REPAIR ........................................7-1

Tool kit ....................................................7-1

Periodic maintenance/lubrication ...........7-3

Engine oil................................................7-6

Air filter.................................................... 7-9

Carburetor adjustment..........................7-12

Idle speed adjustment ..........................7-12

Throttle cable free play inspection........7-13

Valve clearance adjustment .................7-14

Spark plug inspection ...........................7-14

Front brake lever free play

adjustment ........................................ 7-15

Rear brake adjustment......................... 7-16

Brake light switch adjustment .............. 7-18

Checking the front brake pads and

rear brake shoes............................... 7-18

Inspecting the brake fluid level ............ 7-20

Brake fluid replacement ....................... 7-21

Clutch adjustment ................................ 7-21

Drive chain slack check ....................... 7-22

Drive chain slack adjustment ............... 7-23

Drive chain lubrication.......................... 7-25

Cable inspection and lubrication.......... 7-25

Throttle cable and grip lubrication........ 7-26

Brake and shift pedals ......................... 7-26

Brake and clutch levers........................ 7-26

Sidestand ............................................. 7-26

Rear suspension .................................. 7-26

Front fork inspection ............................ 7-27

Steering inspection .............................. 7-28

Wheel bearings .................................... 7-28

Battery.................................................. 7-28

1-2

Replenishing the battery fluid ...............7-30

Fuse replacement.................................7-31

Headlight bulb replacement..................7-31

Front wheel removal .............................7-33

Front wheel installation.........................7-34

Rear wheel removal..............................7-35

Rear wheel installation .........................7-37

Troubleshooting....................................7-38

Troubleshooting chart...........................7-39

CLEANING AND STORAGE.....................8-1

A. Cleaning .............................................8-1

B. Storage...............................................8-2

SPECIFICATIONS.....................................9-1

Conversion table.....................................9-5

1-3

EUU75901

GIVE SAFETY THE RIGHT OF WAY

Motorcycles are fascinating vehicles, which can give you an unsurpassed feeling of
power and freedom. However, they also impose certain limits, which you must accept;
even the best motorcycle does not ignore the laws of physics.
Regular care and maintenance are essential for preserving your motorcycle’s value and
operating condition. Moreover, what is true for the motorcycle is also true for the rider:
good performance depends on being in good shape. Riding under the influence of med­ication, drugs and alcohol is, of course, out of the question. Motorcycle riders – more
than car drivers – must always be at their mental and physical best. Under the influence
of even small amounts of alcohol, there is a tendency to take dangerous risks.
Protective clothing is as essential for the motorcycle rider as seat belts are for car driv­ers and passengers. Always wear a complete motorcycle suit (whether made of leather
or tear-resistant synthetic materials with protectors), sturdy boots, motorcycle gloves
and a properly fitting helmet. Optimum protective wear, however, should not encourage
carelessness. Though full-coverage helmets and suits, in particular, create an illusion
of total safety and protection, motorcyclists will always be vulnerable. Riders who lack
critical self-control run the risk of going too fast and are apt to take chances. This is even
more dangerous in wet weather. The good motorcyclist rides safely, predictably and de­fensively – avoiding all dangers, including those caused by others.
Enjoy your ride!

1-1

EAA50000

DESCRIPTION

1. Tail/brake light

2. Rear turn signal light

3. Tool kit

4. Seat

5. Air filter

6. Front turn signal light

7. Brake pedal

8. Footrest

9. Headlight

10. Fuel tank

2-1

11. Rear wheel

12. Main switch

13. Shift pedal

14. Steering lock

15. Front wheel

16. Clutch lever

17. Handlebar switches

18. Speedometer

19. Brake lever

20. Throttle grip

EAA60000

MOTORCYCLE

IDENTIFICATION

EAA62000

Identification numbers

Record the key identification number, frame
serial number and model label information in
the spaces provided for assistance when or­dering spare parts from a Yamaha dealer or
for reference in case the vehicle is stolen.

1. KEY IDENTIFICATION NUMBER:

2. FRAME SERIAL NUMBER:

3. MODEL LABEL INFORMATION:

EAA61400

Key identification number

The key identification number is stamped on
the key. Record this number in the space pro­vided and use it for reference when obtaining
a new key.

1. Key identification number

3-1

EAA60201

Frame serial number

The frame serial number is stamped into the
steering head pipe.

1. Frame serial number

EAA62200

Model label

The model label is affixed to the frame under
the seat. (See page 4-10 for seat removal pro­cedures.) Record the information on this label
in the space provided. This information will be
needed to order spare parts from your
Yamaha dealer.

1. Model label

3-2

EAB00000

CONTROL FUNCTIONS

EAB00100

Main switch

The main switch controls the ignition and light­ing systems. Its operation is described below.

EAB00500

ON:
Electrical circuits are switched on. The engine
can be started. The key cannot be removed in
this position.

EAB00600

OFF:
All electrical circuits are switched off. The key
can be removed in this position.

EAB02002

P (Parking)
The taillight and auxiliary light come on but all
other circuits are off. With the key at “OFF”,
push it into the main switch, turn it counter­clockwise to “P”, and remove it. To cancel the
parking, turn the key clockwise.

EUU08800

NOTE:

Always turn the main switch to “OFF” and re­move the key when the motorcycle is unat­tended.

4-1

EAB10000

Indicator lights

1. Turn indicator light “”

2. Neutral indicator light “”

3. High beam indicator light “”

EAB10102

Turn indicator light “”

This indicator flashes when the turn signal
switch is moved to the left or right.

EAB13100

Neutral indicator light “”

This indicator comes on when the transmis­sion is in neutral.

EAB13200

High beam indicator light “”

This indicator comes on when the headlight
high beam is used.

EAB40005

Speedometer

The speedometer shows riding speed. This
speedometer is equipped with an odometer
and trip odometer. The trip odometer can be
reset to “0” with the reset knob. Use the trip
odometer to estimate how far you can ride on
a tank of fuel. This information will enable you
to plan fuel stops in the future.

1. Odometer 2. Trip odometer 3. Reset knob

4-2

EAB60000

Handlebar switches

1. PASS switch “PASS” 6. Engine stop switch

2. Dimmer switch “ENGINE STOP”
“LIGHTS” 7. Siren switch “SIREN”

3. Turn signal switch 8. Microphone switch “MIC”
“TURN” 9. Patrol switch

4. Horn switch “HORN” 10. Start switch “START”

5. Light switch “LIGHTS” 11. Hazard switch “HAZARD”

EAB60101

Dimmer switch “LIGHTS”

Turn the switch to “HI” for the high beam and
to “LO” for the low beam.

EAB62102

Turn signal switch “TURN”

To signal a right-hand turn, push the switch to
the right. To signal a left-hand turn, push the
switch to the left. Once the switch is released
it will return to the center position. To cancel
the signal, push the switch in after it has re­turned to the center position.

EAB60201

Horn switch “HORN”

Press the switch to sound the horn.

EAB63201

Pass switch “PASS”

Press the switch to operate the passing light.

EAB61202

Light switch “LIGHTS”

Turning this switch to “PO” turns on the auxil­iary light, taillight and meter lights. Turning to
“ON”, turns the headlight on also.

4-3

EAB60902

Engine stop switch “ENGINE STOP”

The engine stop switch is a safety device for
use in an emergency such as when the motor­cycle overturns or if trouble occurs in the throt­tle system. Turn the switch to “RUN” to start
the engine. In case of emergency, turn the
switch to “OFF” to stop the engine.

EAB60702

Start switch “START”

The starter motor cranks the engine when
pushing the starter switch.

EUU30700

CAUTION:

See starting instructions prior to starting
the engine.

EAB62802

Hazard switch “HAZARD”

The hazard switch should be turned on under
emergency or hazardous conditions. All turn
signal lights will flash simultaneously when
this switch is turned on with the main switch in
the “ON” position.

EUU46100

CAUTION:

The battery can discharge from extended
use, making it difficult to operate the
starter.

EUU01101

NOTE:

Turn on the hazard switch to warn other driv­ers if your motorcycle must be stopped where
it might be a traffic hazard.

4-4

Siren switch “SIREN”

The siren (if equipped) sounds intermittently
when this switch is set to “SIREN”. The siren
can only be used with the main switch in the
“ON” position.

Microphone switch “MIC”

The microphone (if equipped) can be used
when this switch is set to “MIC” with the main
switch in the “ON” position. This switch can
also be used when the patrol switch is in any
position except “OFF” with the main switch in
the “ON” position.

Patrol switch

This switch can only be used with the main
switch in the “ON” position. The following ta­ble indicates which accessories are enabled
when the patrol switch is set to “P”, “M”, or “S”.

Accessory

Patrol light

Turn signal light

Microphone

Siren

Position

OFF P M S

4-5

EAB70003

Clutch lever

The clutch lever is located on the left handle­bar, and the ignition circuit cut-off system is in­corporated in the clutch lever holder. Pull the
clutch lever to the handlebar to disengage the
clutch, and release the lever to engage the
clutch. The lever should be pulled rapidly and
released slowly for smooth clutch operation.
(Refer to the engine starting procedures for a
description of the ignition circuit cut-off sys­tem.)

1. Shift pedal N. Neutral

EAB80001

Shift pedal

This motorcycle is equipped with a constant­mesh 5-speed transmission.
The shift pedal is located on the left side of the
engine and is used in combination with the
clutch when shifting.

EAB90001

Front brake lever

The front brake lever is located on the right
handlebar. Pull it toward the handlebar to ap­ply the front brake.

EAB90101

Rear brake pedal

The rear brake pedal is on the right side of the
motorcycle. Press down on the brake pedal to
apply the rear brake.

4-6

EAC00101

Fuel tank cap

TO OPEN:
Insert the key and turn it 1/4 turn clockwise.
The lock will be released and the cap can be
opened.

1. Unlock.

TO CLOSE:
Push the tank cap into position with the key in­serted. To remove the key, turn it counter­clockwise to the original position.

EUU01200

NOTE:

This tank cap cannot be closed unless the key
is in the lock. The key cannot be removed if
the cap is not locked properly.

EUU61100

WARNING

Be sure the cap is properly installed and
locked in place before riding the motor­cycle.

4-7

EAC10205

Fuel cock

The fuel cock supplies fuel from the tank to
the carburetors while also filtering it.
The fuel cock has three positions, which
should be set as illustrated.
ON: With the fuel cock in this position, fuel

flows to the carburetors when the en­gine is running. Set the fuel cock to this
position when starting the engine and
for riding.

RES: This stands for “reserve”. If you are run-

ning out of fuel while riding with the fuel
cock in the “ON” position, quickly turn
the lever to this position. Otherwise the
engine may die and will have to be
primed (see “PRI” below). After turning
the lever to “RES”, fill the tank at the
first opportunity and be sure to set the
fuel cock back to “ON”!

4-8

PRI: This stands for “prime”. If the engine

has been allowed to run out of fuel, turn
the lever to the “PRI” position to send
fuel directly to the carburetors. This will
make starting easier. However, be sure
to turn the lever to the “ON” position (or
“RES” if you have not refuelled yet) af­ter the engine has started.

EAC20502

Starter “CHOKE”

Starting a cold engine requires a richer air-fuel
mixture. A separate starter circuit supplies this
mixture.
Move in direction a to turn on the starter.
Move in direction b to turn off the starter.

1. Starter “CHOKE”

4-9

EAC30201

Steering lock

To lock the steering, turn the handlebars all
the way to the right. Open the steering lock
cover, turn the key 1/8 counterclockwise then
push the key in and turn it 1/8 turn clockwise.
After checking to see that the steering is
locked, remove the key from the lock and
close the cover. To release the lock, reverse
the above procedure.

1. Steering lock

EAC41503

Seat

To remove the rider seat, remove the bolts.

To install the rider seat, insert the projection
on the front of the seat into the holder on the
frame. Then tighten the bolts.

EUU01700

NOTE:

Make sure that the seat is securely fitted.

4-10

Left Right

EAI57804

Rear shock absorber adjustment

This shock absorber is equipped with a spring
preload adjuster. Adjust spring preload as fol­lows. Turn the adjusting ring in direction a to
increase spring preload and in direction b to
decrease spring preload.

COPY CI-18ECI-18E

Adjusting
position

Hard

54321

Standard

Soft

EAD30101

Sidestand

This model is equipped with an ignition circuit
cut-off system. The motorcycle must not be
ridden when the sidestand is down. The side­stand is located on the left side of the frame.
(Refer to page 6-1 for an explanation of this
system.)

4-11

EUU68901

WARNING

This motorcycle must not be operated with
the sidestand in the down position. If the
stand is not properly retracted, it could
contact the ground and distract the opera­tor, resulting in a possible loss of control.
Yamaha has designed into this motorcycle
a lockout system to assist the operator in
fulfilling the responsibility of retracting the
sidestand. Please check carefully the op­erating instructions listed below and if
there is any indication of a malfunction, re­turn the motorcycle to a Yamaha dealer
immediately for repair.

EAU03720

Ignition circuit cut-off system

The ignition circuit cut-off system (comprising
the sidestand switch, clutch switch and neu­tral switch) has the following functions.

●

It prevents starting when the transmis­sion is in gear and the sidestand is up,
but the clutch lever is not pulled.

●

It prevents starting when the transmis­sion is in gear and the clutch lever is
pulled, but the sidestand is still down.

●

It cuts the running engine when the trans­mission is in gear and the sidestand is

moved down.
Periodically check the operation of the ignition
circuit cut-off system according to the follow­ing procedure.

EW000045

WARNING

If a malfunction is noted, have a Yamaha
dealer check the system before riding.

CD-01E

4-12

With the engine turned off:

1. Move the sidestand down.

2. Make sure that the engine stop switch is set to “ ”.

3. Turn the key to “ON”.

4. Shift the transmission into the neutral position.

5. Push the start switch.

Does the engine start?

YES

With the engine still running:

6. Move the sidestand up.

7. Keep the clutch lever pulled.

8. Shift the transmission into gear.

9. Move the sidestand down.

Does the engine stall?

NO

YES NO

After the engine has stalled:

10. Move the sidestand up.

11. Keep the clutch lever pulled.

12. Push the start switch.

Does the engine start?

YES NO

The system is OK.

The motorcycle can be ridden.

NOTE:

This check is most reliable if performed with
a warmed-up engine.

The neutral switch may be defective.

The motorcycle should not be ridden

checked by a Yamaha dealer.

The sidestand switch may be defective.

The motorcycle should not be ridden

checked by a Yamaha dealer.

The clutch switch may be defective.

The motorcycle should not be ridden

checked by a Yamaha dealer.

until

until

until

4-13

PRE-OPERATION CHECKS

Before using this motorcycle, check the following points:

Item Routine Page

Front brake

Rear brake

Clutch

Throttle grip/Housing

Engine oil

Drive chain

Wheels/Tires

Control/Meter cables

Brake and shift pedal
shafts

Brake and clutch lever
pivots

Sidestand pivot

• Check operation, free play, fluid level and fluid leakage.

• Top-up with DOT4 (or DOT 3) brake fluid if necessary.

• Check operation, condition and free play.

• Adjust if necessary.

• Check operation, condition and free play.

• Adjust if necessary.

• Check for smooth operation.

• Lubricate/Adjust if necessary.

• Check oil level/add oil as required. 5-5, 7-6 ~ 7-9

• Check chain slack and condition.

• Adjust if necessary.

• Check tire pressure, wear, damage. 5-6 ~ 5-9, 7-33 ~ 7-37

• Check for smooth operation.

• Lubricate if necessary.

• Check for smooth operation.

• Lubricate if necessary.

• Check for smooth operation.

• Lubricate if necessary.

• Check for smooth operation.

• Lubricate if necessary.

5-3 ~ 5-4,

7-15 ~ 7-21

5-4, 7-21 ~ 7-22

5-4, 7-13, 7-26

5-5, 7-22 ~ 7-25

7-25

7-26

7-26

7-26

5-1

Item Routine Page

Chassis fasteners

Fuel tank

Lights, signals and
switches

Battery

• Check all chassis fittings and fasteners.

• Tighten/Adjust if necessary.

• Check fuel level/top-up as required. 5-10 ~ 5-11

• Check for proper operation. 5-10, 7-31 ~ 7-33

• Check fluid level, top-up with distilled water if necessary. 5-10, 7-28 ~ 7-30

5-9

NOTE:

Pre-operation checks should be made each time the motorcycle is used. Such an inspection can
be thoroughly accomplished in a very short time; and the added safety it assures is more than
worth the time involved.

WARNING

If any item in the PRE-OPERATION CHECK is not working properly, have it inspected and
repaired before operating the motorcycle.

5-2

EAE13303

Brakes

1. Brake lever and brake pedal
Check for correct free play in the front
brake lever and rear brake pedal and ad­just if necessary. (See page 7-15 for de­tails.) Make sure the brakes are working
properly by checking at low speed shortly
after starting out.

EUU62300

WARNING

A soft, spongy feeling in the brake lever in­dicates a failure in the brake system. Do
not operate the motorcycle until the failure
in the brake system is corrected. Ask a
Yamaha dealer for immediate repairs. A
soft, spongy feeling could indicate a haz­ardous condition in the brake system.

2. Brake fluid
Check the brake fluid level. Fill the mas­ter cylinder with brake fluid if necessary.
(See page 7-20 for details.)

Recommended brake fluid: DOT 4

EUU13100

NOTE:

If DOT 4 is not available, DOT 3 can be used.

3. Check the disc pads.
Refer to page 7-18.

4. Check the brake shoes.
Refer to page 7-18.

EUU02201

NOTE:

When this brake service is necessary, consult
a Yamaha dealer.

EAE11303

Front brake fluid leakage

Apply the brake for a few minutes. Check to
see if any brake fluid leaks out from the pipe
joints or the master cylinder.

5-3