Download - Virago Owners Manual
PRINTED IN JAPAN2003.02-0.3×1 CR
(E)
PRINTED ON RECYCLED PAPERYAMAHA MOTOR CO., LTD.
4TN-28199-E2
XV250P
OWNER’S MANUAL
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-6.fmL
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-INT.fmR
ODUCTION
n your purchase of the This model is the result ofperience in the productionuring, and pacesetting rac-presents the high degree of reliability that have made
in these fields.ive you an understanding ofpection, and basic mainte-torcycle. If you have anye operation or maintenance, please consult a Yamaha
EAA00100 EAA20301
INTR
Congratulations oYamaha XV250P.Yamaha’s vast exof fine sporting, toing machines. It recraftsmanship andYamaha a leader This manual will gthe operation, insnance of this moquestions about thof your motorcycledealer.
XV250POWNER’S MANUAL
©2003 by Yamaha Motor Co., Ltd.1st Edition, January 2003
All rights reserved. Any reprinting orunauthorized use without the written
permission of Yamaha Motor Co., Ltd.is expressly prohibited.
Printed in Japan
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-INT.fmL
EAA10603
cates special precautionsn to avoid damage to the
key information to makeor clearer.
specting or repairing the motorcycle.
IMPORTANT MANUAL INFORMATION
Particularly important information is distin-guished in this manual by the following nota-tions:
The Safety Alert Symbol means ATTENTION!BECOME ALERT! YOUR SAFETY IS IN-VOLVED!
WARNINGFailure to follow WARNING instructions couldresult in severe injury or death to the motor-cycle operator, a bystander or a person in-
CAUTION:A CAUTION indithat must be takemotorcycle.
NOTE:A NOTE providesprocedures easier
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-INT.fmR
HIS MANUAL CAREFUL-TELY BEFORE OPERAT-CYCLE.
EUU00001
NOTE:� This manual should be considered a per-
manent part of this motorcycle andshould remain with it even if the motor-cycle is subsequently sold.
� Yamaha continually seeks advance-ments in product design and quality.Therefore, while this manual contains themost current product information avail-able at the time of printing, there may beminor discrepancies between yourmotorcycle and this manual. If there isany question concerning this manual,please consult your Yamaha dealer.
EUU60100
WARNINGPLEASE READ TLY AND COMPLEING THIS MOTOR
L D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-4tnTOC.fm
GIVE
DES
MOTIdeKeFraMo
CONMaIndSpHaCluShFroReFu
....................................... 4-8” .................................... 4-9
..................................... 4-10
..................................... 4-10orber adjustment......... 4-11..................................... 4-11ut-off system................ 4-13
CHECKS .................... 5-1....................................... 5-3 leakage ....................... 5-3
....................................... 5-4
....................................... 5-4
....................................... 5-5
....................................... 5-5
....................................... 5-6
....................................... 5-9rs................................... 5-9nd switches ................ 5-10
..................................... 5-10
EAA30001
CONTENTS
SAFETY THE RIGHT OF WAY .......1-1
CRIPTION ..........................................2-1
ORCYCLE IDENTIFICATION ...........3-1ntification numbers ............................3-1y identification number .......................3-1me serial number ..............................3-2del label .............................................3-2
TROL FUNCTIONS...........................4-1in switch .............................................4-1icator lights.........................................4-2eedometer ..........................................4-2ndlebar switches ................................4-3tch lever.............................................4-6ift pedal...............................................4-6nt brake lever.....................................4-6ar brake pedal ....................................4-6el tank cap ..........................................4-7
Fuel cock.........Starter “CHOKESteering lock ...Seat .................Rear shock absSidestand ........Ignition circuit c
PRE-OPERATIONBrakes .............Front brake fluidClutch ..............Throttle grip .....Engine oil.........Chain ...............Tires ................Cast wheels.....Chassis fasteneLights, signals aBattery .............
RD:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-4tnTOC.fm
er free play ...................................... 7-15justment......................... 7-16tch adjustment .............. 7-18ront brake pads and oes............................... 7-18
brake fluid level ............ 7-20lacement ....................... 7-21ent ................................ 7-21ck check ....................... 7-22ck adjustment ............... 7-23rication.......................... 7-25n and lubrication.......... 7-25
and grip lubrication........ 7-26t pedals ......................... 7-26ch levers........................ 7-26...................................... 7-26on.................................. 7-26ection ............................ 7-27ction .............................. 7-28s .................................... 7-28...................................... 7-28
1-2
Fuel.......................................................5-10
OPERATION AND IMPORTANT RIDING POINTS........................................6-1
Starting and warming up a cold engine..................................................6-1
Starting a warm engine ..........................6-3Shifting....................................................6-3Engine break-in ......................................6-4Parking....................................................6-5
PERIODIC MAINTENANCE ANDMINOR REPAIR ........................................7-1
Tool kit ....................................................7-1Periodic maintenance/lubrication ...........7-3Engine oil ................................................7-6Air filter....................................................7-9Carburetor adjustment..........................7-12Idle speed adjustment ..........................7-12Throttle cable free play inspection........7-13Valve clearance adjustment .................7-14Spark plug inspection ...........................7-14
Front brake levadjustment ..
Rear brake adBrake light swiChecking the f
rear brake shInspecting the Brake fluid repClutch adjustmDrive chain slaDrive chain slaDrive chain lubCable inspectioThrottle cable Brake and shifBrake and clutSidestand .......Rear suspensiFront fork inspSteering inspeWheel bearingBattery............
L D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-4tnTOC.fm
1-3
Replenishing the battery fluid ...............7-30Fuse replacement.................................7-31Headlight bulb replacement..................7-31Front wheel removal .............................7-33Front wheel installation.........................7-34Rear wheel removal..............................7-35Rear wheel installation .........................7-37Troubleshooting....................................7-38Troubleshooting chart...........................7-39
CLEANING AND STORAGE.....................8-1A. Cleaning .............................................8-1B. Storage...............................................8-2
SPECIFICATIONS.....................................9-1Conversion table.....................................9-5
1-1
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-1.fmR
GIVE SAFETY THE RIGHT OF WAYEUU75901
Motorcycles are fascinating vehicles, which can give you an unsurpassed feeling ofpower 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 andoperating 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 med-ication, drugs and alcohol is, of course, out of the question. Motorcycle riders – morethan car drivers – must always be at their mental and physical best. Under the influenceof 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 driv-ers and passengers. Always wear a complete motorcycle suit (whether made of leatheror tear-resistant synthetic materials with protectors), sturdy boots, motorcycle glovesand a properly fitting helmet. Optimum protective wear, however, should not encouragecarelessness. Though full-coverage helmets and suits, in particular, create an illusionof total safety and protection, motorcyclists will always be vulnerable. Riders who lackcritical self-control run the risk of going too fast and are apt to take chances. This is evenmore dangerous in wet weather. The good motorcyclist rides safely, predictably and de-fensively – avoiding all dangers, including those caused by others.Enjoy your ride!
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-2.fmL
EA
ht11. Rear wheel12. Main switch13. Shift pedal14. Steering lock15. Front wheel16. Clutch lever17. Handlebar switches18. Speedometer19. Brake lever20. Throttle grip
2-1
4. Seat5. Air filter6. Front turn signal light7. Brake pedal8. Footrest9. Headlight
10. Fuel tank
A50000
DE
SCRIPTION1. Tail/brake light2. Rear turn signal lig3. Tool kit
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-3.fmR
numbertion number is stamped onis number in the space pro-r reference when obtaining
ber
3-1
EAA60000
MOTORCYCLEIDENTIFICATION
EAA62000
Identification numbersRecord the key identification number, frameserial number and model label information inthe spaces provided for assistance when or-dering spare parts from a Yamaha dealer orfor reference in case the vehicle is stolen.1. KEY IDENTIFICATION NUMBER:
2. FRAME SERIAL NUMBER:
3. MODEL LABEL INFORMATION:
EAA61400
Key identificationThe key identificathe key. Record thvided and use it foa new key.
1. Key identification num
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-3.fmL
EAA60201 EAA62200
affixed to the frame under 4-10 for seat removal pro-
he information on this labeled. This information will be spare parts from your
3-2
Frame serial numberThe frame serial number is stamped into thesteering head pipe.
1. Frame serial number
Model labelThe model label isthe seat. (See pagecedures.) Record tin the space providneeded to orderYamaha dealer.
1. Model label
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-4.fmR
ts are switched off. The key this position.
uxiliary light come on but alloff. With the key at “OFF”,ain switch, turn it counter-nd remove it. To cancel theey clockwise.
ain switch to “OFF” and re-en the motorcycle is unat-
4-1
EAB00000
CONTROL FUNCTIONS
EAB00100
Main switchThe main switch controls the ignition and light-ing systems. Its operation is described below.
EAB00500
ON:Electrical circuits are switched on. The enginecan be started. The key cannot be removed inthis position.
EAB00600
OFF:All electrical circuican be removed in
EAB02002
P (Parking)The taillight and aother circuits are push it into the mclockwise to “P”, aparking, turn the kEUU08800
NOTE:Always turn the mmove the key whtended.
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-4.fmL
EAB10000 EAB13200
tor light “ ”es on when the headlight.
shows riding speed. Thisuipped with an odometer
The trip odometer can bee reset knob. Use the tripte how far you can ride on
information will enable you the future.
rip odometer 3. Reset knob
4-2
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 signalswitch is moved to the left or right.
EAB13100
Neutral indicator light “ ”This indicator comes on when the transmis-sion is in neutral.
High beam indicaThis indicator comhigh beam is usedEAB40005
SpeedometerThe speedometer speedometer is eqand trip odometer.reset to “0” with thodometer to estimaa tank of fuel. Thisto plan fuel stops in
1. Odometer 2. T
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-4.fmR
LIGHTS” “HI” for the high beam and beam.
h “TURN”and turn, push the switch tol a left-hand turn, push thence the switch is released
center position. To cancelhe switch in after it has re-r position.
RN”o sound the horn.
HTS” to “PO” turns on the auxil-nd meter lights. Turning to
adlight on also.
4-3
EAB60000
Handlebar switches
1. PASS switch “PASS” 6. Engine stop switch2. Dimmer switch “ENGINE STOP”
“LIGHTS” 7. Siren switch “SIREN”3. Turn signal switch 8. Microphone switch “MIC”
“TURN” 9. Patrol switch4. Horn switch “HORN” 10.Start switch “START”5. Light switch “LIGHTS” 11.Hazard switch “HAZARD”
EAB63201
Pass switch “PASS”Press the switch to operate the passing light.
EAB60101
Dimmer switch “Turn the switch toto “LO” for the low
EAB62102
Turn signal switcTo signal a right-hthe right. To signaswitch to the left. Oit will return to thethe signal, push tturned to the cente
EAB60201
Horn switch “HOPress the switch t
EAB61202
Light switch “LIGTurning this switchiary light, taillight a“ON”, turns the he
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-4.fmL
EAB60902 EAB62802
AZARD” should be turned on underardous conditions. All turnlash simultaneously when on with the main switch in
ischarge from extendeddifficult to operate the
switch to warn other driv-cle must be stopped where hazard.
4-4
Engine stop switch “ENGINE STOP”The engine stop switch is a safety device foruse in an emergency such as when the motor-cycle overturns or if trouble occurs in the throt-tle system. Turn the switch to “RUN” to startthe engine. In case of emergency, turn theswitch to “OFF” to stop the engine.
EAB60702
Start switch “START”The starter motor cranks the engine whenpushing the starter switch.EUU30700
CAUTION:See starting instructions prior to startingthe engine.
Hazard switch “HThe hazard switchemergency or hazsignal lights will fthis switch is turnedthe “ON” position.EUU46100
CAUTION:The battery can duse, making it starter.
EUU01101
NOTE:Turn on the hazarders if your motorcyit might be a traffic
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-4.fmR
Position
FF P M S
4-5
Siren switch “SIREN”The siren (if equipped) sounds intermittentlywhen this switch is set to “SIREN”. The sirencan only be used with the main switch in the“ON” position.
Microphone switch “MIC”The microphone (if equipped) can be usedwhen this switch is set to “MIC” with the mainswitch in the “ON” position. This switch canalso be used when the patrol switch is in anyposition except “OFF” with the main switch inthe “ON” position.
Patrol switchThis switch can only be used with the mainswitch in the “ON” position. The following ta-ble indicates which accessories are enabledwhen the patrol switch is set to “P”, “M”, or “S”.
Accessory O
Patrol light
Turn signal light
Microphone
Siren
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-4.fmL
EAB70003
N. Neutral
ver is located on the rightward the handlebar to ap-
al is on the right side of thedown on the brake pedal toe.
4-6
Clutch leverThe clutch lever is located on the left handle-bar, and the ignition circuit cut-off system is in-corporated in the clutch lever holder. Pull theclutch lever to the handlebar to disengage theclutch, and release the lever to engage theclutch. The lever should be pulled rapidly andreleased slowly for smooth clutch operation.(Refer to the engine starting procedures for adescription of the ignition circuit cut-off sys-tem.)
EAB80001
Shift pedalThis motorcycle is equipped with a constant-mesh 5-speed transmission.The shift pedal is located on the left side of theengine and is used in combination with theclutch when shifting.
1. Shift pedal
EAB90001
Front brake leverThe front brake lehandlebar. Pull it toply the front brake.
EAB90101
Rear brake pedalThe rear brake pedmotorcycle. Press apply the rear brak
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-4.fmR
ot be closed unless the key key cannot be removed ifed properly.
is properly installed andbefore riding the motor-
4-7
EAC00101
Fuel tank capTO OPEN:Insert the key and turn it 1/4 turn clockwise.The lock will be released and the cap can beopened.
1. Unlock.
TO CLOSE:Push the tank cap into position with the key in-serted. To remove the key, turn it counter-clockwise to the original position.
EUU01200
NOTE:This tank cap cannis in the lock. Thethe cap is not lock
EUU61100
WARNINGBe sure the caplocked in place cycle.
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-4.fmL
EAC10205
for “reserve”. If you are run-el while riding with the fuel
“ON” position, quickly turnhis position. Otherwise the die and will have to be “PRI” below). After turning“RES”, fill the tank at the
nity and be sure to set theck to “ON”!
4-8
Fuel cockThe fuel cock supplies fuel from the tank tothe carburetors while also filtering it.The fuel cock has three positions, whichshould be set as illustrated.ON: With the fuel cock in this position, fuel
flows to the carburetors when the en-gine is running. Set the fuel cock to thisposition when starting the engine andfor riding.
RES: This stands ning out of fucock in the the lever to tengine mayprimed (seethe lever to first opportufuel cock ba
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-4.fmR
ine requires a richer air-fuele starter circuit supplies this
a to turn on the starter.b to turn off the starter.
4-9
PRI: This stands for “prime”. If the enginehas been allowed to run out of fuel, turnthe lever to the “PRI” position to sendfuel directly to the carburetors. This willmake starting easier. However, be sureto turn the lever to the “ON” position (or“RES” if you have not refuelled yet) af-ter the engine has started.
EAC20502
Starter “CHOKE”Starting a cold engmixture. A separatmixture.Move in direction Move in direction
1. Starter “CHOKE”
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-4.fmL
EAC30201 EAC41503
r seat, remove the bolts.
seat, insert the projectionseat into the holder on then the bolts.
seat is securely fitted.
4-10
Steering lockTo lock the steering, turn the handlebars allthe way to the right. Open the steering lockcover, turn the key 1/8 counterclockwise thenpush the key in and turn it 1/8 turn clockwise.After checking to see that the steering islocked, remove the key from the lock andclose the cover. To release the lock, reversethe above procedure.
1. Steering lock
SeatTo remove the ride
To install the rideron the front of the frame. Then tighteEUU01700
NOTE:Make sure that the
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-4.fmR
ipped with an ignition circuite motorcycle must not be
idestand is down. The side-n the left side of the frame.1 for an explanation of this
Right
4-11
EAI57804
Rear shock absorber adjustmentThis shock absorber is equipped with a springpreload adjuster. Adjust spring preload as fol-lows. Turn the adjusting ring in direction a toincrease spring preload and in direction b todecrease spring preload.COPY CI-18ECI-18E
EAD30101
SidestandThis model is equcut-off system. Thridden when the sstand is located o(Refer to page 6-system.)
Hard Standard Soft
Adjusting position
5 4 3 2 1
Left
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-4.fmL
EUU68901 EAU03720
t-off system cut-off system (comprisingch, clutch switch and neu- following functions.arting when the transmis-r and the sidestand is up,lever is not pulled.arting when the transmis-r and the clutch lever is
sidestand is still down.ing engine when the trans-gear and the sidestand is
the operation of the ignitionm according to the follow-
s noted, have a Yamahasystem before riding.
4-12
WARNINGThis motorcycle must not be operated withthe sidestand in the down position. If thestand is not properly retracted, it couldcontact the ground and distract the opera-tor, resulting in a possible loss of control.Yamaha has designed into this motorcyclea lockout system to assist the operator infulfilling the responsibility of retracting thesidestand. Please check carefully the op-erating instructions listed below and ifthere is any indication of a malfunction, re-turn the motorcycle to a Yamaha dealerimmediately for repair.
Ignition circuit cuThe ignition circuitthe sidestand swittral switch) has the
� It prevents stsion is in geabut the clutch
� It prevents stsion is in geapulled, but the
� It cuts the runnmission is in moved down.
Periodically check circuit cut-off systeing procedure.EW000045
WARNINGIf a malfunction idealer check the
CD-01E
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-4.fmR
switch may be defective.ycle should not be ridden until a Yamaha dealer.
d switch may be defective.ycle should not be ridden until a Yamaha dealer.
witch may be defective.ycle should not be ridden until a Yamaha dealer.
most reliable if performed with engine.
4-13
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?
The neutral The motorcchecked by
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?
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?
The sidestanThe motorcchecked by
The clutch sThe motorcchecked by
NO
NOTE:This check isa warmed-up
YES
YES NO
The system is OK. The motorcycle can be ridden.
YES NO
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-5.fmL
Page
age.ry. 5-3 ~ 5-4,
7-15 ~ 7-21
5-4, 7-21 ~ 7-22
5-4, 7-13, 7-26
5-5, 7-6 ~ 7-9
5-5, 7-22 ~ 7-25
5-6 ~ 5-9, 7-33 ~ 7-37
7-25
7-26
7-26
7-26
5-1
PRE-OPERATION CHECKS
Before using this motorcycle, check the following points:
Item Routine
Front brake • Check operation, free play, fluid level and fluid leak• Top-up with DOT4 (or DOT 3) brake fluid if necessa
Rear brake • Check operation, condition and free play.• Adjust if necessary.
Clutch • Check operation, condition and free play.• Adjust if necessary.
Throttle grip/Housing • Check for smooth operation. • Lubricate/Adjust if necessary.
Engine oil • Check oil level/add oil as required.
Drive chain • Check chain slack and condition. • Adjust if necessary.
Wheels/Tires • Check tire pressure, wear, damage.
Control/Meter cables • Check for smooth operation. • Lubricate if necessary.
Brake and shift pedal shafts
• Check for smooth operation. • Lubricate if necessary.
Brake and clutch lever pivots
• Check for smooth operation. • Lubricate if necessary.
Sidestand pivot • Check for smooth operation. • Lubricate if necessary.
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-5.fmR
used. Such an inspection canafety it assures is more than
erly, have it inspected and
5-9
5-10 ~ 5-11
5-10, 7-31 ~ 7-33
ssary. 5-10, 7-28 ~ 7-30
Page
5-2
NOTE:Pre-operation checks should be made each time the motorcycle is be thoroughly accomplished in a very short time; and the added sworth the time involved.
WARNINGIf any item in the PRE-OPERATION CHECK is not working proprepaired before operating the motorcycle.
Chassis fasteners • Check all chassis fittings and fasteners.• Tighten/Adjust if necessary.
Fuel tank • Check fuel level/top-up as required.
Lights, signals and switches • Check for proper operation.
Battery • Check fluid level, top-up with distilled water if nece
Item Routine
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-5.fmL
EAE13303
ilable, DOT 3 can be used.
c pads. 7-18.ke shoes. 7-18.
rvice is necessary, consult
leakager a few minutes. Check toid leaks out from the pipe
r cylinder.
rake fluid: DOT 4
5-3
Brakes1. Brake lever and brake pedal
Check for correct free play in the frontbrake lever and rear brake pedal and ad-just if necessary. (See page 7-15 for de-tails.) Make sure the brakes are workingproperly by checking at low speed shortlyafter starting out.
EUU62300
WARNINGA soft, spongy feeling in the brake lever in-dicates a failure in the brake system. Donot operate the motorcycle until the failurein the brake system is corrected. Ask aYamaha dealer for immediate repairs. Asoft, spongy feeling could indicate a haz-ardous condition in the brake system.
2. Brake fluidCheck the brake fluid level. Fill the mas-ter cylinder with brake fluid if necessary.(See page 7-20 for details.)
EUU13100
NOTE:If DOT 4 is not ava
3. Check the disRefer to page
4. Check the braRefer to page
EUU02201
NOTE:When this brake sea Yamaha dealer.
EAE11303
Front brake fluid Apply the brake fosee if any brake flujoints or the maste
Recommended b
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-5.fmR
lay in the clutch lever andtch operates properly. If thect, adjust it. (See page 7-21
rip to see if it operates prop-the grip returns by springed. There should be a freet the throttle grip. If the freeask a Yamaha dealer to
ent.
5-4
EUU37801
CAUTION:Brake fluid may deteriorate painted surfac-es or plastic parts. Never spill any fluid. Ifspilled, clean it up immediately.
EUU62500
WARNINGIf brake fluid leakage is found, ask aYamaha dealer for immediate repairs.Such leakage could indicate a hazardouscondition.
EAE20002
ClutchCheck the free pmake sure the clufree play is incorrefor details.)
EAE30104
Throttle gripTurn the throttle gerly. Make sure force when releasplay of 3 ~ 5 mm aplay is incorrect, make this adjustm
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-5.fmL
EAE40105 EUU32303
chemical additives. Also,e oils labeled “ENERGYor higher. Engine oil alsotch and additives couldage.
-22 for details) condition of the chain andfore every ride. Lubricate
in as necessary.
5-5
Engine oilMake sure the engine oil is at the specifiedlevel. Fill with oil as necessary. (See page 7-6for details.)
CAUTION:Do not put in any be sure not to usCONSERVING II” lubricates the clucause clutch slipp
EAE50001
Chain (See page 7Check the generalthe chain slack beand adjust the cha
-10° 0° 10° 20° 30° 40°-20°
SAE 10W/30
SAE 20W/50
SAE 20W/40
SAE 10W/40
50°CRecommended oil:
Recommended engine oil classification:API Service “SE”, “SF” type or equivalent(e.g. “SF-SE”, “SF-SE-CC”, “SF-SE-SD” etc.)
Oil quantity:Total amount: 1.8 LPeriodic oil change: 1.4 LWith oil filter replacement: 1.6 L
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-5.fmR
2E180 kg
Front Rear
175 kPa(1.75 kgf/cm2,
1.75 bar)
200 kPa(2.0 kgf/cm2,
2.0 bar)
200 kPa(2.0 kgf/cm2,
2.0 bar)
225 kPa(2.25 kgf/cm2,
2.25 bar)
t of cargo, rider and accessories.
5-6
EAE97900
TiresTo ensure maximum performance, long ser-vice and safe operation, note the following:1. Tire air pressure
Always check and adjust the tire pres-sure before operating the motorcycle.
EUU67500
WARNINGTire inflation pressure should be checkedand adjusted when the temperature of thetire equals the ambient air temperature.Tire inflation pressure must be adjustedaccording to total weight of cargo, riderand accessories (fairing, saddlebags, etc.if approved for this model), and vehiclespeed.
COPY CE-32ECE-3Maximum load*:
Cold tire pressure:
Up to 90 kg
90 kg load ~Maximum load*
* Load is the total weigh
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-5.fmL
EUU67701
the tires before operatingle. If a tire tread showss (minimum tread depth), ifail or glass fragments in it,wall is cracked, contact aer immediately and haved.
5-7
WARNINGProper loading of your motorcycle is im-portant for several characteristics of yourmotorcycle, such as handling, braking,performance and safety. Do not carryloosely packed items that can shift. Se-curely pack your heaviest items close tothe center of the motorcycle, and distrib-ute the weight evenly from side to side.Properly adjust the suspension for yourload, and check the condition and pres-sure of your tires. NEVER OVERLOADYOUR MOTORCYCLE. Make sure the totalweight of the cargo, rider and accessories(fairing, saddlebags, etc. if approved forthis model) does not exceed the maximumload of the motorcycle. Operation of anoverloaded motorcycle could cause tiredamage, an accident, or even injury.
2. Tire inspectionAlways checkthe motorcyccrosswise linethe tire has a nor if the side Yamaha dealthe tire replace
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-5.fmR
be different by regulationuntry. If so, conform to the
the regulations of your own
us to ride with a worn-out tire tread begins to showa Yamaha dealer replacediately. Brakes, tires, andeel parts replacementbe left to a Yamaha deal-
unctured tube is not rec-If it is absolutely neces-so, use great care and
tube as soon as possiblequality replacement.
5-8
1. Tread depth 2. Side wall 3. Wear indicator
COPY CE-10ECE-10E
COPY CE-16ECE-16E
EUU12600
NOTE:These limits mayfrom country to colimits specified bycountry.
EUU68402
WARNING1. It is dangero
tire. When alines, have the tire immerelated whshould also er.
2. Patching a pommended. sary to do replace the with a good
FRONT:
Manufacturer Size Type
CHENG SHIN 3.00-18 47P C916
REAR:
Manufacturer Size Type
CHENG SHIN 130/90-15 M/C 66P C915
Minimum tire tread depth (front and rear)
1.0 mm
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-5.fmL
EAE93600
a tire, ride conservativelyre to seat itself on the rimre to allow proper seatinge failure, resulting in dam-torcycle and injury to the
ightness of all chassis nuts, before a ride. Take themaha dealer or refer to the correct tightening torque.
5-9
Cast wheelsEUU71200
WARNINGThe wheels on this model are not designedfor use with tubeless tires. Do not attemptto use tubeless tires on this model.
To ensure maximum performance, long ser-vice, and safe operation, note the following:1. Always inspect the wheels before a ride.
Check for cracks, bends, or warpage ofthe wheels. If any abnormal condition ex-ists in a wheel, consult a Yamaha dealer.Do not attempt even small repairs to thewheel. If a wheel is deformed or cracked,it must be replaced.
2. Tires and wheels should be balancedwhenever either one is changed or re-placed. Failure to have a wheel balancedcan result in poor performance, adversehandling characteristics, and shortenedtire life.
3. After installingto allow the tiproperly. Failumay cause tirage to the morider.
EAE85101
Chassis fastenersAlways check the tbolts and screwsmotorcycle to a YaService Manual for
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-5.fmR
sufficient fuel in the tank.
e fuel tank. Avoid spillingngine. Do not fill the fuelottom of the filler tube astration or it may overflow
ats up later and expands.
2. Fuel level
5-10
EAE71500
Lights, signals and switchesCheck all the lights, meter lights and indicatorlights to make sure they are in working condi-tion.Check the operation of the handlebar switch-es and main switch.
EAE70502
BatteryCheck the fluid level and fill if necessary. Useonly distilled water if refilling is necessary.(See page 7-28 for details.)
EAE80000
FuelMake sure there isEUU61000
WARNINGDo not overfill thfuel on the hot etank above the bshown in the illuswhen the fuel he
1. Filler tube
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-5.fmL
EUU39302
5-11
CAUTION:Always wipe off spilled fuel immediatelywith a dry and clean soft cloth. Fuel maydeteriorate painted surfaces or plasticparts.
EAE80300
Recommended fuel:Regular unleaded gasoline
Fuel tank capacity:Total:
9.5 LReserve:
2.6 L
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-6.fmR
ing out, always be sured is up. Failure to retractd completely can result inccident when you try tor.
ming up a cold engine
equipped with an ignitionm. an explanation of this sys-
6-1
EAF00000
OPERATION ANDIMPORTANT RIDING
POINTS
EUU67201
WARNING1. Before riding this motorcycle, become
thoroughly familiar with all operatingcontrols and their functions. Consulta Yamaha dealer regarding any con-trol or function that you do not thor-oughly understand.
2. Never start your engine or let it run forany length of time in a closed area.The exhaust fumes are poisonous andcan cause loss of consciousness anddeath within a short time. Always op-erate your motorcycle in an area withadequate ventilation.
3. Before startthe sidestanthe sidestana serious aturn a corne
EAF19800
Starting and warEUU07401
NOTE:This motorcycle iscircuit cut-off systeSee page 4-12 fortem.
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-6.fmL
he engine, move the starter position.
ne life, always warm up therting off. Never accelerategine.
up the engine, turn off thetely.
when it responds normal-with the starter “CHOKE”
6-2
1. Turn the fuel cock to “ON”.2. Turn the main switch to “ON” and the en-
gine stop switch to “RUN”.3. Shift transmission into neutral.
EUU03001
NOTE:When the transmission is in neutral, the neu-tral indicator light should be on. If the lightdoes not come on, ask a Yamaha dealer to in-spect it.
4. Turn on the starter “CHOKE” and com-pletely close the throttle grip.
5. Start the engine by pushing the startswitch.
EUU02501
NOTE:If the engine fails to start, release the startswitch, wait a few seconds, then try again.Each attempt should be as short as possibleto preserve the battery. Do not crank the en-gine more than 10 seconds on any one at-tempt.
6. After starting tto the halfway
EUU02600
NOTE:For maximum engiengine before stahard with a cold en
7. After warmingstarter comple
EUU02701
NOTE:The engine is warmly to the throttle turned off.
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-6.fmR
t for long periods with thend do not tow the motor-distance. Even with gearshe transmission is onlyicated when the engine isdequate lubrication maytransmission.the clutch when changingngine, transmission, and not designed to with-
ock of forced shifting andaged by shifting withouttch.
6-3
EAF10802
Starting a warm engineThe starter “CHOKE” is not required when theengine is warm.EUU31401
CAUTION:See the “Engine break-in” section prior tooperating the motorcycle for the first time.
EAF20003
ShiftingThe transmission lets you control the amountof power you have available at a given speedfor starting, accelerating, climbing hills, etc.The use of the shift pedal is shown in the illus-tration. (Page 4-6)To shift into neutral, depress the shift pedalrepeatedly until it reaches the end of its travel,then raise the pedal slightly.
EUU31501
CAUTION:1. Do not coas
engine off, acycle a long in neutral, tproperly lubrrunning. Inadamage the
2. Always use gears. The edriveline arestand the shcan be damusing the clu
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-6.fmL
EAF30000
:ed operation above 1/2
the motorcycle freelyears, but do not use fulltime.m: speeds in excess of 3/4
operation, be sure to re-oil and oil filter.
beyond:ed full throttle operation.ccasionally.
ble should occur duringiod, consult a Yamahaly.
6-4
Engine break-inThere is never a more important period in thelife of your motorcycle than the period be-tween zero and 1,000 km. For this reason weask that you carefully read the following mate-rial. Because the engine is brand new, youmust not put an excessive load on it for thefirst 1,000 km. The various parts in the enginewear and polish themselves to the correct op-erating clearances. During this period, pro-longed full throttle operation, or any conditionwhich might result in excessive heating of theengine, must be avoided.EAF32101
1. 0 ~ 150 km:Avoid operation above 1/3 throttle. Stopthe engine and let it cool for 5 to 10 min-utes after every hour of operation. Varythe speed of the motorcycle from time totime. Do not operate it at one set throttleposition.
2. 150 ~ 500 kmAvoid prolongthrottle. Revthrough the gthrottle at any
3. 500 ~ 1,000 kAvoid cruisingthrottle.
EUU32001
CAUTION:After 1,000 km ofplace the engine
4. 1,000 km andAvoid prolongVary speeds o
EUU32200
CAUTION:If any engine trouthe break-in perdealer immediate
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-6.fmR
6-5
EAF40001
ParkingWhen parking the motorcycle, stop the engineand remove the key.EUU63001
WARNINGThe exhaust system is hot. Park the motor-cycle in a place where pedestrians or chil-dren are not likely to touch the motorcycle.Do not park the motorcycle on a slope orsoft ground; the motorcycle may overturn.
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-6.fmL
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-7.fmR
iliar with motorcycle ser- should be done by a
ation included in this man-rovide you, the owner, withformation for completingn preventive maintenance. The tools provided in the to assist you in the perfor-
ic maintenance. However,uch as a torque wrench are perform the maintenance
7-1
EAH00000
PERIODICMAINTENANCE AND
MINOR REPAIR
EAH00400
Periodic inspection, adjustment and lubrica-tion will keep your motorcycle in the safestand most efficient condition possible. Safety isan obligation of the motorcycle owner. Themaintenance and lubrication schedule chartshould be considered strictly as a guide togeneral maintenance and lubrication inter-vals. YOU MUST TAKE INTO CONSIDER-ATION THAT WEATHER, TERRAIN,GEOGRAPHICAL LOCATIONS, AND A VA-RIETY OF INDIVIDUAL USES ALL TEND TODEMAND THAT EACH OWNER ALTERTHIS TIME SCHEDULE TO SHORTER IN-TERVALS TO MATCH THE ENVIRON-MENT. The most important points ofmotorcycle inspection, adjustment, and lubri-cation are explained in the following pages.
EUU63200
WARNINGIf you are not famvice, this workYamaha dealer.
EAH10300
Tool kitThe service informual is intended to pthe necessary insome of your owand minor repairsowner’s tool kit aremance of periodsome other tools salso necessary tocorrectly.
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-7.fmL
EUU67100
this motorcycle not ap-a may cause loss of per-nder it unsafe for use.a dealer before attempt-
7-2
1. Tool kit
EUU18500
NOTE:If you do not have necessary tools requiredduring a service operation, take your motor-cycle to a Yamaha dealer for service.
WARNINGModifications to proved by Yamahformance, and reConsult a Yamahing any changes.
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-7.fmR
BREAK-IN1,000 km
EVERY
6,000 km or
6 months
12,000 km or
12 months
7-3
PERIODIC MAINTENANCE/LUBRICATION
ITEM ROUTINE
Valve(s)* • Check valve clearance. • Adjust if necessary.
Spark plug(s) • Check condition. • Clean or replace if necessary.
Air filter • Clean. • Replace if necessary.
Carburetor* • Check idle speed/starter operation.• Adjust if necessary.
Fuel line*• Check fuel hose and vacuum pipe for cracks or
damage. • Replace if necessary.
Fuel filter* • Check condition. • Replace if necessary.
Engine oil • Replace (Warm engine before draining).
Engine oil filter* • Replace.
Front brake*• Check operation/fluid leakage/See NOTE
(page 7-5).• Correct if necessary.
Rear brake • Check operation. • Adjust if necessary.
Clutch • Check operation. • Adjust if necessary.
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-7.fmL
EVERY 500 km
REAK-IN1,000 km
EVERY
6,000 km or
6 months
12,000 km or
12 months
7-4
Rear arm pivot*
• Check rear arm assembly for looseness.• Correct if necessary.• Moderately repack every 24,000 km or
24 months.**
Wheels* • Check balance/damage/runout/spoke tightness.• Replace if necessary.
Wheel bearings* • Check bearings assembly for looseness/damage.• Replace if damaged.
Steering bearing*
• Check bearings assembly for looseness.• Correct if necessary.• Moderately repack every 24,000 km or
24 months.**
Front fork* • Check operation/oil leakage. • Repair if necessary.
Rear shock absorber* • Check operation/oil leakage. • Repair if necessary.
Drive chain• Check chain slack/alignment. • Adjust if necessary.• Clean if necessary.
Chassis fasteners* • Check all chassis fittings and fasteners.• Correct if necessary.
Sidestand* • Check operation. • Repair if necessary.
Sidestand switch* • Check operation. • Clean or replace if necessary.
ITEM ROUTINE B
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-7.fmR
lace the brake fluid. Normally as required.eplace the oil seals every two
aged.
BREAK-IN1,000 km
EVERY
6,000 km or
6 months
12,000 km or
12 months
7-5
* : It is recommended that these items be serviced by a Yamaha dealer.** : Lithium soap base grease
NOTE:Brake fluid replacement:1. When disassembling the master cylinder or caliper cylinder, rep
check the brake fluid level and fill the master cylinder with fluid2. On the inner parts of the master cylinder and caliper cylinder, r
years.3. Replace the brake/hoses every four years, or if cracked or dam
Battery*• Check specific gravity.• Check breather pipe for proper operation.• Correct if necessary.
ITEM ROUTINE
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-7.fmL
EAH44705
2. Maximum level mark
s until the oil level settles
should be between maxi-imum marks. If the level is the specified level.
7-6
Engine oil1. Oil level inspectiona. Place the motorcycle on a level place
and hold it in an upright position. Warmup the engine for several minutes.
EUU03901
NOTE:Be sure the motorcycle is positioned straightup when checking the oil level. A slight tilt to-ward the side can result in false readings.
b. With the engine stopped, check the oillevel through the level window located atthe lower part of the right side crankcasecover.
1. Level window3. Minimum level mark
EUU04000
NOTE:Wait a few minutebefore checking.
c. The oil level mum and minlow, add oil to
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-7.fmR
oil filter cover bolts, oil filter
3)
7-72. Engine oil and oil filter element replace-ment
a. Warm up the engine for a few minutes.b. Stop the engine. Place an oil pan under
the engine and remove the oil filler cap.
1. Oil filler cap
c. Remove the drain plug and drain the oil.
1. Drain plug
d. Remove the and O-ring.
1. Oil filter cover bolt (×
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-7.fmL
ng is seated properly.
ngine with the specifiedommended oil. Install thed tighten.
e: bolt:·kgf)
il:
ange:
placement:
7-8
e. Reinstall the drain plug and tighten it tothe specified torque.
f. Install the new oil filter, new O-ring andthe filter cover. Tighten the oil filter coverbolts to the specified torque.
1. Oil filter element 2. O-ring
EUU04101
NOTE:Make sure the O-ri
g. Fill up the eamount of recoil filler cap an
Tightening torque:Drain plug:
34 Nm (3.4 m·kgf)
Tightening torquOil filter cover
7 Nm (0.7 m
Recommended oSee page 5-5
Oil quantity:Total amount:
1.8 LPeriodic oil ch
1.4 LWith oil filter re
1.6 L
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-7.fmR
ld be cleaned at the speci-ould be cleaned more fre- riding in unusually wet or
amp.
olts.
7-9
EUU32401
CAUTION:� Do not put in any chemical additives.
Engine oil also lubricates the clutchand additives could cause clutch slip-page.
� Be sure no foreign material enters thecrankcase.
h. Start the engine and warm up for a fewminutes. While warming up, check for oilleakage. If oil leakage is found, stop theengine immediately and check for thecause.
EAH600A0
Air filterThe element shoufied intervals. It shquently if you aredusty areas.1. Loosen the cl
1. Screw
2. Remove the b
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-7.fmL
ir filter case cover.
ing bolt.
7-10
1. Bolt (× 2)
3. Remove the hoses and the air filter case.
1. Hose (× 2)
4. Remove the a
1. Screw (× 2)
5. Remove the w
1. Wing bolt
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-7.fmR
ersing the removal proce-
ement is properly seated
7-11
6. Pull out the element.7. Remove the element from its guide and
clean it with solvent. After cleaning, re-move the remaining solvent by squeez-ing the element.
1. Air filter element 2. Guide
8. Apply recommended oil to the entire sur-face of the filter and squeeze out the ex-cess oil. The element should be wet butnot dripping.
9. Install by revdures.
EUU35701
CAUTION:Make sure the elin the filter case.
Recommended oil:SAE 10W30 type SE motor oil
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-7.fmL
EUU42400 EUU47100
were set at the Yamahaany tests. If they arengine performance andlt.
ment
meter must be used for this
hometer. Start the enginep for a few minutes at ap-,000 to 2,000 r/min. Occa-the engine to 4,000 tohe engine is warm when itds to the throttle.the specified engine speede throttle stop screw. Turnirection a to increase en-nd in direction b to de- speed.
7-12
CAUTION:The engine should never be run withoutthe air filter element installed; excessivepiston and/or cylinder wear may result.
EAH93100
Carburetor adjustmentThe carburetors are important parts of the en-gine and requires very sophisticated adjust-ment. Most adjustments should be left to aYamaha dealer who has the professionalknowledge and experience to do so. Howev-er, the following may be serviced by the own-er as part of routine maintenance.EUU13700
NOTE:A diagnostic tachometer must be used for thisprocedure.
CAUTION:The carburetors factory after mchanged, poor edamage may resu
EAH92002
Idle speed adjustEUU13700
NOTE:A diagnostic tachoprocedure.
1. Attach the tacand warm it uproximately 1sionally rev 5,000 r/min. Tquickly respon
2. Set the idle to by adjusting ththe screw in dgine speed acrease engine
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-7.fmR
e play inspection free play of 3 ~ 5 mm at the free play is incorrect, ask a make this adjustment.
7-13
1. Throttle stop screw
EUU04500
NOTE:If the specified idle speed cannot be obtainedby performing the above adjustment, consulta Yamaha dealer.
EAH92202
Throttle cable freThere should be athrottle grip. If theYamaha dealer to
a. Free play
Standard idle speed:1,250 ~ 1,350 r/min
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-7.fmL
EAH90801
diagnose such problemstake the motorcycle to aou should periodically re- the spark plugs becauseill cause any spark plug to
n and erode. If electrodexcessive, or if carbon and
excessive, you should re-g with the specified plug.
y spark plug, measure the a wire thickness gauge.pecification.
lug:K) orENSO)
7-14
Valve clearance adjustmentThe correct valve clearance changes withuse, resulting in improper fuel/air supply orengine noise. To prevent this, the valve clear-ance must be adjusted regularly. This adjust-ment however, should be left to a professionalYamaha service technician.
EAH20102
Spark plug inspectionThe spark plug is an important engine compo-nent and is easy to inspect. The condition ofthe spark plug can indicate the condition ofthe engine.Normally, all spark plugs from the same en-gine should have the same color on the whiteinsulator around the center electrode. Theideal color at this point is a medium-to-lighttan color for a motorcycle that is being riddennormally. If one spark plug shows a distinctlydifferent color, there could be somethingwrong with the engine.
Do not attempt toyourself. Instead, Yamaha dealer. Ymove and inspectheat and deposits wslowly break dowerosion becomes eother deposits areplace the spark plu
Before installing anelectrode gap withAdjust the gap to s
Specified spark pCR6HSA (NGU20FSR-U (D
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-7.fmR
is not available when yourk plug, a good estimate of
is 1/4 to 1/2 turn past fingerpark plug tightened to thes soon as possible.
free play adjustmenthe front brake lever should
cknut.sting bolt in direction a to
play or in direction b to de-lay.g, tighten the locknut.
7-15
1. Spark plug gap
When installing the spark plug, always cleanthe gasket surface and use a new gasket.Wipe off any grime from the threads and tight-en the spark plug to the specified torque.
EUU03802
NOTE:If a torque wrenchare installing a spathe correct torquetight. Have the sspecified torque a
EAH80104
Front brake leverThe free play at tbe 2 ~ 5 mm.1. Loosen the lo2. Turn the adju
increase freecrease free p
3. After adjustin
Spark plug gap:0.6 ~ 0.7 mm
Tightening torque:Spark plug:
12.5 Nm (1.25 m·kgf)
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-7.fmL
of control and an acci- Yamaha dealer inspect system if necessary.
ment
have a Yamaha dealerent.
knut.e adjuster clockwise orise, adjust the brake pedalat its top end is approxi-
m above the top of the foot-
locknut.
7-16
in the brake system. This air must beremoved by bleeding the brake sys-tem before the motorcycle is operat-ed. Air in the system will cause greatlydiminished braking capability and can
mately 50 mrest.
c. Tighten the
1. Locknut 2. Adjusting bolt 3. Free play
EUU81500
WARNING� Check the brake lever free play. Be
sure the brake is working properly.� A soft or spongy feeling in the brake
lever can indicate the presence of air
result in lossdent. Have aand bleed the
EAH87103
Rear brake adjustEUU64301
WARNINGIt is advisable tomake this adjustm
1. Pedal heighta. Loosen the locb. By turning th
counterclockwposition so th
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-7.fmR
the pedal height adjustplay.
e pedal free play should be ~ 30 mm at the brake ped-
he adjuster on the brake rodeduce free play or counter-ncrease free play.
y)
7-17
1. Footrest2. Pedal height3. Free play
1. Locknut 2. Adjuster (for pedal height)
EUU64400
WARNINGAfter adjusting brake pedal free
2. Free playThe rear brakadjusted to 20al end. Turn tclockwise to rclockwise to i
1. Adjuster (for free pla
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-7.fmL
EUU69800
2. Adjusting nut
nt brake pads and rear
provided on each brake.lows checking of brakeithout disassembling the
7-18
WARNING1. The rear brake pedal adjustment must
be checked whenever the chain is ad-justed or the rear wheel is removedand then reinstalled.
2. Check the operation of the brake lightafter adjusting the rear brake.
EAH83301
Brake light switch adjustmentThe brake light switch is operated by move-ment of the brake pedal. To adjust, hold themain body of the switch so it does not rotateand turn the adjusting nut. Proper adjustmentis achieved when the brake light comes onjust before the brake begins to take effect.
1. Main body
EAH81401
Checking the frobrake shoesA wear indicator isThis indicator alpad/shoe wear wbrake.
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-7.fmR
nd inspect the wear indica-
ches the wear limit line, askto replace the shoes.
2. Wear limit line
7-19
EAH87401
FRONTApply the brake and inspect the wear indica-tor. If the brake pads are worn to the wear lim-it, have a Yamaha dealer replace the pads.
1. Wear indicator a. Wear limit 0.8 mm
EAH82601
REARApply the brake ator.If the indicator reaa Yamaha dealer
1. Wear indicator
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-7.fmL
EAH88202*
same type of brake fluid.may result in a harmful
tion and lead to poor brake
t water does not enter ther when refilling. Water willwer the boiling point of theresult in vapor lock.ay deteriorate painted sur-tic parts. Always clean upmediately.ha dealer check the causeid level goes down.
7-20
Inspecting the brake fluid levelInsufficient brake fluid may let air enter thebrake system, possibly causing the brakes tobecome ineffective.Before riding, check that the brake fluid isabove the lower level and replenish whennecessary.Observe these precautions:1. When checking the fluid level, make sure
the top of the master cylinder is level byturning the handlebars.
2. Use only the designated quality brake flu-id. Otherwise, the rubber seals may dete-riorate, causing leakage and poor brakeperformance.
EUU13100
NOTE:If DOT 4 is not available, DOT 3 can be used.
3. Refill with theMixing fluids chemical reacperformance.
4. Be careful thamaster cylindesignificantly lofluid and may
5. Brake fluid mfaces or plasspilled fluid im
6. Have a Yamaif the brake flu
Recommended brake fluids: DOT 4
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-7.fmR
ntee play should be adjusted the clutch lever. If the freedjust as follows.
Adjuster a. Free play
7-21
1. Lower level
EAH83501
Brake fluid replacement1. Complete fluid replacement should be
done only by trained Yamaha servicepersonnel.
2. Have a Yamaha dealer replace the fol-lowing components during periodic main-tenance or when they are damaged orleaking.
a. Replace all rubber seals every two years.b. Replace all hoses every four years.
EAI00501
Clutch adjustmeThe clutch lever frto 10 ~ 15 mm atplay is incorrect, a
1. Locknut 2.
Free play:10 ~ 15 mm
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-7.fmL
EAI40801
check
everal times and find thef the chain. Check and/orck while it’s in this tightest
slack the motorcycle mustp with both wheels on thet rider. Check the slack at in the illustration. Normal
ately 30 ~ 40 mm. If them, adjust.
7-22
1. Loosen the locknut at the handlebar.2. Turn the adjuster in or out until proper le-
ver free play is obtained.3. Tighten the locknut.4. If the free play is still incorrect, make an
adjustment at the crankcase side.
1. Locknut 2. Adjuster
EUU17800
NOTE:If proper adjustment cannot be obtained orthe clutch does not work correctly, ask aYamaha dealer to inspect the internal clutchmechanism.
Drive chain slackEUU04801
NOTE:Spin the wheel stightest position oadjust the chain slaposition.
To check the chainbe held straight uground and withouthe position shownslack is approximslack exceeds 40 m
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-7.fmR
tter pin from the axle nut.
tter pin 3. Locknutnment marks
e nut.hain adjuster locknut one swingarm. To tighten the chain adjuster on each
ngarm clockwise. To loos-urn each adjuster counter- push the wheel forward.juster exactly the sameintain correct axle align-re marks on each side of
7-23
a. Drive chain slackEAI40102
Drive chain slack adjustment1. Loosen the rear brake adjuster.
1. Adjuster
2. Remove the co
1. Axle nut 2. Co4. Adjuster 5. Alig
3. Loosen the axl4. Loosen the c
each side of thchain, turn theside of the swien the chain, tclockwise andTurn each adamount to mament. There a
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-7.fmL
shown. If the notch in the axle nut and the
w cotter pin on the axle
play in the brake pedal.EUU64500
on of the brake light after brake.
7-24
cotter pin hole do not match, tighten thenut slightly to align them.
WARNINGCheck the operatiadjusting the rear
the swingarm and a match mark on eachchain adjuster. Use these marks to alignthe rear wheel.
EUU33301
CAUTION:Too little chain slack will overload the en-gine and other vital parts. Keep the slackwithin the specified limits.
5. After adjusting, be sure to tighten eachchain adjuster locknut and the axle nut.
6. Insert a new cotter pin into the axle nutand bend the end of the cotter pin as
Axle nut torque:105 Nm (10.5 m·kgf)
1. Cotter pin
EUU64700
WARNINGAlways use a nenut.
7. Adjust the free
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-7.fmR
and lubrication
outer housing of cablesl rusting and cause inter-ble movement. Replace as soon as possible toonditions.
r cable and the cable end. Ife smoothly, ask a Yamahahem.
lubricant:motor oil
7-25
EAI40701
Drive chain lubricationThe chain consists of many parts which workwith each other. If the chain is not maintainedproperly, it will wear out quickly, Therefore,the chain must be serviced regularly. This ser-vice is especially necessary when riding industy areas. This motorcycle is equipped witha sealed type chain. Steam cleaning, high-pressure washes, and solvents can damagechain so do not use these for cleaning it. Useonly kerosene to clean the drive chain. Wipe itdry, and thoroughly lubricate it with SAE 30 ~50W motor oil. Do not use any other lubri-cants on the drive chain. They may containsolvents that could damage the sealed chain.
EAI10701
Cable inspectionEUU64601
WARNINGDamage to the may allow internaference with cadamaged cablesprevent unsafe c
Lubricate the inneit does not operatdealer to replace t
Recommended SAE 10W30
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-7.fmL
EAI10201 EAI31101
ing parts. Check to see thates up and down smoothly.
oes not move smoothly, dealer.
ing parts.
ubricant:otor oil
ubricant:ase grease
7-26
Throttle cable and grip lubricationThe throttle twist grip assembly should begreased at the time that the cable is lubricat-ed, since the grip must be removed to get atthe end of the throttle cable. After removingthe screws, hold the end of the cable up in theair and put in several drops of lubricant. Withthe throttle grip disassembled, coat the metalsurface of the grip assembly with a suitableall-purpose grease.EAI30601
Brake and shift pedalsLubricate the pivoting parts.
EAI30700
Brake and clutch leversLubricate the pivoting parts.
SidestandLubricate the pivotthe sidestand mov
EUU70401
WARNINGIf the sidestand dconsult a Yamaha
EAI31300
Rear suspensionLubricate the pivot
Recommended lubricant:SAE 10W30 motor oil
Recommended lubricant:SAE 10W30 motor oil
Recommended lSAE 10W30 m
Recommended lLithium soap b
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-7.fmR
7-27
EAI20502
Front fork inspectionEUU65700
WARNINGSecurely support the motorcycle so thereis no danger of it falling over.
1. Visual checkCheck for scratches or damage on the in-ner tube and excessive oil leakage fromthe front fork.
2. Operation checkPlace the motorcycle on a level place.
a. Hold the motorcycle in an upright positionand apply the front brake.
b. Push down hard on the handlebars seve-ral times and check if the fork reboundssmoothly.
EUU42500
CAUTION:If any damage or unsmooth movement isfound with the front fork, consult aYamaha dealer.
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-7.fmL
EAI60301 EUU65700
the motorcycle so therefalling over.
e front or rear wheel hub ornot turn smoothly, have aspect the wheel bearings.s should be inspected ac-tenance Schedule.
the battery electrolyte ande terminals are tight. Add electrolyte level is low.
7-28
Steering inspectionPeriodically inspect the condition of the steer-ing. Worn out or loose steering bearings maybe dangerous. Place a stand under the en-gine to raise the front wheel off the ground.Hold the lower end of the front forks and try tomove them forward and backward. If any freeplay can be felt, ask a Yamaha dealer to in-spect and adjust the steering. Inspection iseasier if the front wheel is removed.
WARNINGSecurely supportis no danger of it
EAI60201
Wheel bearingsIf there is play in thif the wheel does Yamaha dealer inThe wheel bearingcording to the Main
EAI70001
BatteryCheck the level ofmake sure that thdistilled water if the
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-7.fmR
te is poisonous and dan-severe burns, etc. It con-cid. Avoid contact withhing.
h with water. large quantities of waterwith milk of magnesia,
egetable oil. Call a physi-. water for 15 minutes andical attention. Batteries
ve gases. Keep sparks,s etc., away. Ventilateor using in an enclosedshield your eyes whenteries.EACH OF CHILDREN.
7-29
EUU33601
CAUTION:When inspecting the battery, be sure thebreather pipe is routed correctly. If thebreather pipe is positioned in such a wayas to cause battery electrolyte or gas toexit onto the frame, structural and cosmet-ic damage to the motorcycle can occur.
EUU65800
WARNINGBattery electrolygerous, causing tains sulfuric askin, eyes or clotAntidote:EXTERNAL: FlusINTERNAL: Drinkor milk. Follow beaten egg, or vcian immediatelyEYES: Flush withget prompt medproduce explosiflame, cigarettewhen charging space. Always working near batKEEP OUT OF R
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-7.fmL
EAI70401 EUU65901
spill battery fluid on theid may weaken the chainhain life and possibly re-t.
orcycle will not be used fornger, remove the battery a cool, dark place. Com-
ge the battery before reus-
will be stored for a longere above, check the specificfluid at least once a month the battery when it is too
sure the connections areputting the battery back ine. Make sure the breatherrly connected and is notbstructed.
7-30
Replenishing the battery fluidA poorly maintained battery will corrode anddischarge quickly. The battery fluid should bechecked at least once a month.1. The level should be between the upper
and lower level marks. Use only distilledwater if refilling is necessary.
1. “UPPER LEVEL” 2. “LOWER LEVEL”
EUU33800
CAUTION:Normal tap water contains minerals whichare harmful to a battery; therefore, refillonly with distilled water.
WARNINGTake care not to chain. Battery flucausing shorter csult in an acciden
2. When the mota month or loand store it inpletely recharing.
3. If the battery period than thgravity of the and rechargelow.
4. Always makecorrect when the motorcyclpipe is propedamaged or o
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-7.fmR
of higher amperage rat-recommended. Substitu-mproper rating can causecal system damage and
placementis equipped with a quartzhe headlight bulb burns out,s follows:crews holding the light unit
20 A10 A5 A5 A
7-31
EAI91801
Fuse replacement1. The fuse case is located under the seat.
1. Main fuse 2. Signal fuse3. Patrol fuse 4. Siren fuse
2. If a fuse is blown, turn off the ignitionswitch and the switch of the circuit inquestion. Install a new fuse of proper am-perage. Turn on the switches and see ifthe electrical device operates. If the fuseimmediately blows again, consult aYamaha dealer.
EUU34400
CAUTION:Do not use fusesing than those tion of a fuse of iextensive electripossibly a fire.
EAI88300
Headlight bulb reThis motorcycle bulb headlight. If treplace the bulb a1. Remove the s
assembly.
Specified fuse:Main:Signal:Patrol:Siren:
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-7.fmL
holder counterclockwise to remove the defective bulb.
roducts and your handslb while it is on, as it is
h the bulb until it cools
7-32
1. Light unit assembly 2. Screw (× 2)
2. Disconnect the headlight coupler, removethe light unit assembly and then the cover.
1. Headlight coupler 2. Cover
3. Turn the bulb remove it and
1. Bulb holder
EUU66001
WARNINGKeep flammable paway from the buhot. Do not toucdown.
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-7.fmR
val
o have a Yamaha dealerl.
t the motorcycle so there falling over.
peedometer cable from thede.
7-33
4. Put a new bulb into position and secure itin place with the bulb holder.
EUU34100
CAUTION:Avoid touching the glass part of the bulb.Keep it free from oil; otherwise, the trans-parency of the glass, life of the bulb, and il-luminous flux will be adversely affected. Ifoil gets on the bulb, thoroughly clean itwith a cloth moistened with alcohol or lac-quer thinner.
5. Install the cover.6. Connect headlight coupler.7. Install the light unit assembly.
If the headlight beam adjustment is nec-essary, ask a Yamaha dealer to makeadjustment.
EAJ24402
Front wheel remoEUU66201
WARNINGIt is advisable tservice the wheeEUU65700
WARNINGSecurely supporis no danger of it
1. Remove the sfront wheel si
1. Speedometer cable
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-7.fmL
EAJ28400
llatione front wheel, reverse the. Pay attention to the fol-
wheel hub and the speed-unit are installed with theshed into the slots.
re is enough gap betweens before inserting the brake
7-34
2. Loosen the pinch bolt and wheel axle.
1. Pinch bolt 2. Wheel axle
3. Elevate the front wheel by placing a suit-able stand under the engine.
4. Remove the wheel axle and the frontwheel. Make sure the motorcycle is prop-erly supported.
EUU05400
NOTE:Do not depress the brake lever when the discis off the caliper as the brake pads will beforced shut.
Front wheel instaWhen installing thremoval procedurelowing points:1. Make sure the
ometer gear projections me
2. Make sure thethe brake paddisc.
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-7.fmR
the pinch bolt, push downeveral times to check forration.
al
have a Yamaha dealer
the motorcycle so therealling over.
r wheel by placing a suit-er the engine.otter pin, nut and tensione brake shoe plate.
7-35
3. Make sure the slot in the speedometergear unit fits over the stopper on the frontfork outer tube.
4. Make sure the wheel axle is properlytorqued.
5. Tighten the pinch bolt.
6. After tighteningthe front fork sproper fork ope
EAJ31202
Rear wheel removEUU66201
WARNINGIt is advisable toservice the wheel.
EUU65700
WARNINGSecurely support is no danger of it f
1. Elevate the reaable stand und
2. Remove the cbar bolt from th
Tightening torque:Wheel axle:
59 Nm (5.9 m·kgf)
Pinch bolt torque:20 Nm (2.0 m·kgf)
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-7.fmL
r pin 3. Locknutment marks
xle nut cotter pin and the
heel axle and remove thely.
disassemble the chain in install the rear wheel.
7-36
1. Tension bar 2. Cotter pin3. Nut (tension bar bolt) 4. Brake rod5. Brake adjuster
3. Remove the brake adjuster and brakerod from the brake cam lever.
4. Loosen the locknuts and chain adjusterson each side.
1. Axle nut 2. Cotte4. Adjuster 5. Align
5. Remove the aaxle nut.
6. Pull out the wwheel assemb
EUU05600
NOTE:You do not have toorder to remove or
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-7.fmR
ion of the brake light afterr brake.
7-37
EAJ34001
Rear wheel installationWhen installing the rear wheel, reverse the re-moval procedure. Pay attention to the follow-ing points:1. Adjust the drive chain.2. Make sure the following parts are proper-
ly torqued, and a new cotter pin is in-stalled.
EUU78000
WARNINGAlways use a new cotter pin.
3. Adjust the rear brake. (See page 7-16)
EUU64500
WARNINGCheck the operatadjusting the rea
Tightening torque:Axle nut:
105 Nm (10.5 m·kgf)Tension bar bolt:
23 Nm (2.3 m·kgf)
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-7.fmL
EAJ50002
7-38
TroubleshootingAlthough Yamaha motorcycles receive a rigidinspection before shipment from the factory,trouble may occur during operation.Any problem in the fuel, compression, or igni-tion systems can cause poor starting and lossof power. The troubleshooting chart describesa quick, easy procedure for making checks.If your motorcycle requires any repair, bring itto a Yamaha dealer. The skilled technicians ata Yamaha dealership have the tools, experi-ence, and know-how to properly service yourmotorcycle. Use only genuine Yamaha partson your motorcycle. Imitation parts may looklike Yamaha parts, but they are often inferior.Consequently, they have a shorter service lifeand can lead to expensive repair bills.
7-39
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-7.fmR
Check the fuel level inthe fuel tank.
1. FuelThere is enough fuel.
There is no fuel.
Check the compression.
Supply fuel.
Operate the electric starter.
2. CompressionThere is compression.
There is no compression.
Check the ignition.
Have a Yamaha dealercheck the vehicle.
spark plugse electrodes.
nWet
Dry
Wipe off with a dry cloth and correct the spark plug gaps, or replace the spark plugs.
Have a Yamaha dealer check the vehicle. The engine does not start.Check the battery.
Open the throttle halfway and operatethe electric starter.
electric starter.
ry The engine turns over quickly.
The engine turns over slowly.
The battery is good.
Check the electrolyte and batterylead connections, and charge thebattery if necessary.
The engine does not start. Have a Yamaha dealer check the vehicle.
The engine does not start. Check the compressoin.
EAJ51800
Troubleshooting chartEUU66300
WARNINGNever check the fuel system while smoking or in the vicinity of an open flame.
Remove theand check th
3. Ignitio
Operate the
4. Batte
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-8.fmL
EAK00000 EUU34602
ressure may cause watererioration of wheel bear-, brakes, transmissional parts.repair bills have resultedh pressure detergent ap-
s those available in coin-hers.
jority of the dirt has beensh all surfaces with warmd, detergent-type soap. An or bottle brush is handy for places.otorcycle off immediatelyer and dry all surfaces withan towel, or soft absorbent
and lubricate it to prevent
8-1
CLEANING ANDSTORAGE
EAK02000
A. CLEANINGFrequent, thorough cleaning of your motor-cycle will not only enhance its appearance butwill improve its general performance and ex-tend the useful life of many components.1. Before cleaning the motorcycle:a. Block off the end of the exhaust pipe to
prevent water entry; a plastic bag andstrong rubber band may be used.
b. Make sure the spark plugs and all fillercaps are properly installed.
2. If the engine case is excessively greasy,apply degreaser with a paint brush. Donot apply degreaser to the chain, sprock-ets, or wheel axles.
3. Rinse the dirt and degreaser off with agarden hose. Use only enough pressureto do the job.
CAUTION:Excessive hose pseepage and detings, front forkseals and electricMany expensive from improper higplications such aoperated car was
4. Once the mahosed off, wawater and milold toothbrushhard-to-get-at
5. Rinse the mwith clean wata chamois, clecloth.
6. Dry the chainrust.
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-8.fmR
empty fuel tank, pour a cup0 or 20W40 motor oil in thee tank to coat the inner sur-hly and drain off the excesshe tank. spark plug, pour about onef SAE 10W30 or 20W40ach spark plug hole and re-ark plugs. Turn the enginetimes (ground spark plug the cylinder walls with oil.
starter motor to crank thehe spark plug wires, andrevent sparking.
ain and lubricate it (refer toubrication”).ontrol cables.frame to raise both wheels.
8-2
7. Clean the seat with a vinyl upholsterycleaner to keep the cover pliable andglossy.
8. Automotive type wax may be applied toall painted and chrome-plated surfaces.Avoid combination cleaner-waxes. Manycontain abrasives which may mar thepaint or protective finish. When finished,start the engine and let it idle for severalminutes.
EAK02101
B. STORAGELong term storage (60 days or more) of yourmotorcycle will require some preventive pro-cedures to guard against deterioration. Afterthoroughly cleaning the motorcycle, preparefor storage as follows:1. Drain the fuel tank, fuel lines and carbu-
retor float bowls.
2. Remove the of SAE 10W3tank, shake thfaces thorougoil. Reinstall t
3. Remove eachtablespoon omotor oil in einstall the spover several leads) to coat
EUU66400
WARNINGWhen using the engine, remove tground them to p
4. Clean the ch“Drive chain l
5. Lubricate all c6. Block up the
off the ground
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-8.fmL
8-3
7. Tie a plastic bag over the exhaust pipeoutlet to prevent moisture from entering.
8. If storing in a humid or salt-air atmo-sphere, coat all exposed metal surfaceswith a light film of oil. Do not apply oil toany rubber parts or the seat cover.
9. Remove the battery and charge it. Storeit in a dry place and recharge it once amonth. Do not store the battery in an ex-cessively warm or cold place (less than0°C or more than 30°C).
EUU05800
NOTE:Make any necessary repairs before storingthe motorcycle.
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-9.fmR
XV250P
gasoline, SOHC
9-1
SPECIFICATIONS
Model
Dimension:Overall lengthOverall widthOverall heightSeat heightWheel baseMinimum ground clearance
2,215 mm770 mm
1,150 mm695 mm
1,495 mm150 mm
Basic weight:With oil and full fuel tank 150 kg
Minimum turning radius: 2,800 mm
Engine:TypeCylinder arrangementDisplacementBore × StrokeCompression ratioStarting system
Air cooled 4-stroke,V-2 cylinder248 cm3
49 × 66 mm10 : 1Electric starter
Lubrication system: Wet sump
Engine oil (4-cycle)TypeCapacity
Periodic oil changeWith oil filter replacementTotal amount
See page 5-5.
1.4 L1.6 L1.8 L
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-9.fmL
soline
0FSR-U/DENSO
eed
XV250P
9-2
Air filter: Wet type element
Fuel:TypeTank capacityReserve amount
Regular unleaded ga9.5 L2.6 L
Carburetor:Type/Manufacturer BDS26/MIKUNI
Spark plug:Type/ManufacturerGap
CR6HSA/NGK or U20.6 ~ 0.7 mm
Clutch type: Wet, multi-disc
Transmission:Primary reduction systemPrimary reduction ratioSecondary reduction systemSecondary reduction ratioTransmission typeOperationGear ratio: 1st
2nd3rd4th5th
Spur gear72/23 (3.130)Chain drive45/16 (2.813)Constant mesh 5-spLeft foot operation37/14 (2.643)32/19 (1.684)29/23 (1.261)26/26 (1.000)23/28 (0.821)
Model
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-9.fmR
n
perper
torAH
XV250P
9-3
Chassis:Frame typeCaster angleTrail
Double cradle32.0°119 mm
Tire:TypeSize : Front
Rear
With tube3.00-18 47P130/90-15 M/C 66P
Brake:Front brake typeOperationRear brake typeOperation
Single, disc brakeRight hand operatioDrum brakeRight foot operation
Suspension:FrontRear
Telescopic forkSwingarm
Shock absorber:FrontRear
Coil spring, oil damCoil spring, oil dam
Wheel travel:FrontRear
140 mm100 mm
Electrical:Ignition systemGenerator systemBattery type/Capacity
TCI (Digital)AC magneto generaGM10-3A-2/12V 10
Model
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-9.fmL
XV250P
9-4
Headlight type: Halogen bulb
Bulb wattage × Quantity:HeadlightTail/brake lightTurn signal lightMeter lightAuxiliary light
12V 60W/55W × 112V 5W/21W × 112V 21W × 412V 1.7W × 112V 3.4W × 1
Indicator light wattage × Quantity:Neutral indicator lightHigh beam indicator lightTurn indicator light
12V 1.7W × 112V 1.7W × 112V 3W × 1
Model
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-9.fmR
version tableEM TO IMPERIAL SYSTEM
nit Conversion fac-tor Imperial unit
× 7.233× 86.794× 0.0723× 0.8679
ft·lbfin·lbfft·lbfin·lbf
× 2.205× 0.03527
lboz
× 0.6214 mi/h
× 0.6214× 3.281× 1.094× 0.3937× 0.03937
miftydinin
× 0.03527× 0.06102× 0.8799× 0.2199
oz (IMP liq.)cu·inqt (IMP liq.)gal (IMP liq.)
× 55.997× 14.2234× 1.8 + 32
lb/inpsi (lbf/in2)°F
EAU04
CS-04E
All sin S
Useto I
Exa
MET
9-5
513
Conversion table
pecification data in this manual are listedI and METRIC UNITS.
this table to convert METRIC unit valuesMPERIAL unit values.
mple:
RIC VALUE CONVERSION FACTOR
IMPERIAL VALUE
2 mm × 0.03937 = 0.08 in
ConMETRIC SYST
Metric u
Torque
m·kgfm·kgfcm·kgfcm·kgf
Weight kgg
Speed km/h
Distance
kmmmcmmm
Volume,Capacity
cc (cm3)cc (cm3)L (liter)L (liter)
Miscellaneouskg/mmkgf/cm2
°C
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-6.fmL
D:\Yuki-Data\Yuki_YMC\HM02L006_XV250P-E2\English\E-6.fmL
PRINTED IN JAPAN2003.02-0.3×1 CR
(E)
PRINTED ON RECYCLED PAPERYAMAHA MOTOR CO., LTD.
4TN-28199-E2
XV250P
OWNER’S MANUAL
WIRING DIAGRAM
COLOR CODE
B .........L .........G .........Y .........R .........
BlackBlueGreenYellowRed
P .........Or .......Br ........Ch .......Gy .......
PinkOrangeBrownChocolateGray
Sb .......Dg .......G/Y .....G/W.....Y/B ......
Sky blueDark greenGreen/YellowGreen/WhiteYellow/Black
Y/R ......R/B ......R/G .....R/Y ...... R/W .....
Yellow/RedRed/BlackRed/GreenRed/YellowRed/White
Br/W ....W/B .....W .........B/Y ......B/R ......
Brown/WhiteWhite/BlackWhiteBlack/YellowBlack/Red
L/Y ......L/R ......L/W .....
Blue/YellowBlue/RedBlue/White
Neutral switchA.C. magnetoRectifier/regulatorFrame earthMain switchMain fuseWire plus leadBatteryWire minus leadStarter relayStarter motorClutch switchRelaySidestand switchIgnitor unitIgnition coilHandlebar switch (R)Front brake switchMicrophone switchSiren switchPatrol switchEngine stop switch
1.2.3.4.5.6.7.8.9.
10.11.12.13.14.15.16.17.18.19.20.21.22.
Start switchHazard switchThermo switch (option)Patrol fuseRear patrol lightCarburetor heaterDiodeSignal fuseSiren fuse MicrophoneSirenPatrol relayCord flasher relayFlasher relayFront patrol lightWire earth leadHornFlasher relaySpeedometerNeutral indicator lightHigh beam indicator lightTurn indicator lightMeter lightRear brake switchTail/brake lightHandlebar switch (L)Light switchDimmer switchPass switchHorn switchTurn signal switchAuxiliary lightHeadlightFront turn signal lightRear turn signal lightMeter light (option)Fuel gauge (option)Fuel sender (option)
23.24.25.26.27.28.29.30.31.32.33.34.35.36.37.38.39.40.41.42.43.44.45.46.47.48.49.50.51.52.53.54.55.56.57.58.59.60.
q
q
B
U
R/WGy
Gy
A
A
F1
W W
W
W W
W
L/Y
G/W
Sb
G/W
L/Y
L
W
Sb
W
W
W
W
W
2
RR3
B
WB
W WR
OFF
ON
P
5
R
L
Br
L/R
R
L
Br
L/R
Br L
R
8
9
6 7
L/W
0
A
R
R/B
C
B/YSb
L/W GB/R W/B
L/WR/B
L/YL/W
L/Y
B/YB
B
L/W B/Y
B/Y L/Y
BB
B
B
L/Y
L/Y
L/Y
B
D
GyOr R/B
B
L/YL/YG/W
B
E
R/B
L/YG/W
R/W
Or
Or
A
A
F
Or
R/WR/W
Gy
R/WR/W
OrGy
A
MAIN HARNESS ING. COIL
L/Y
4
B
Br/W
Ch
Dg
Ch
Br/W
Dg
Y/B
G
R/B R/Y
B/R
Br
R/Y
Y/BB/R
GBr
R/B
B
R/WY/B
R/B
Y/BR/W
BR/W
(RED)(RED)
ON
OFF
Dg
Br/W
Ch
NP
S
M
OFF
ON
OFF
ON
OFF
RUN
OFF
ON
OFF
B
R/BR/W
GBr B R/Y Y/BR/B
Y/B
G
I J L
K
M
L/W
G/Y
L/WBr
B
BrL/W
G/YB
(BLACK)(BLACK)
G/Y
Br
B
B
H
P
Br L/R
Br
S
T
Q
R/BR/G
BBr
Br R/B
BR/B R/G
Br X
B
B
Y
Br
f
LY
g
Y
B
V
Y
Z
Br/W
Br B
\[
PO
ON
OFF
LO
HI
N
L
R
ON
OFF
ON
OFFP
Y
B R/Y
L
G
R/Y
PL
YG
B
DgCh
Y/RBr/WG
P ChDgB
ChDg
Br/W
(BROWN) (BROWN)
h
i j k
l m
B
G Y
Y B
G
on
B
B
B/YB/Y
O RR
B/Y
Br
Br/W
Br
Br/W
]^
Br/W
p
B
p
Sb
B
Br/W Br
L
Br
Sb
BL
Br/W
Br
Y
Sb
L
Br/W
b
c
d
e
(BLACK)
(BLACK)
r
Br
L
G
LBr
B
BrL
GB
BG
GB
t
G/W
L/Y
L/R
R
Sb
R/W
Gy
R/W
Or
R/W
Gy
R/W
Or
a
B
(BLACK)(BLACK)
G/Y
Br
L/R
Br
Br
Br Br
Br
Br
Br
R
R/Y
B
W
R GY/B
B
R/B
R/B B
P
Br
sBG
G
B
B
B
B
Dg
Ch
Ch
Dg
B
YLR/YL/R
(BLACK)
(BLACK)
(BLUE) (BLUE)
Br
(BLACK)(BLACK)
(BLACK)(BLACK)
+V
#2
#1
SS
GND