Yamaha VIRAGO XV250P User manual

PRINTED IN JAPAN
2003.02-0.3×1 CR
(E)
PRINTED ON RECYCLED PAPER
YAMAHA MOTOR CO., LTD.
4TN-28199-E2
XV250P
OWNER’S MANUAL

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EAA00100 EAA20301
INTRODUCTION
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 rac-
ing 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 mainte-
nance of this motorcycle. If you have any
questions about the operation or maintenance
of your motorcycle, please consult a Yamaha
dealer.
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

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EAA10603
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!
WARNING
Failure to follow WARNING instructions could
result in severe injury or death to the motor-
cycle operator, a bystander or a person in-
specting 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.

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EUU00001
N
O
TE:
●This manual should be considered a per-
manent part of this motorcycle and
should 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 the
most current product information avail-
able 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 CAREFUL-
LY AND COMPLETELY BEFORE OPERAT-
ING THIS MOTORCYCLE.

CONTENTS
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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
EAA30001

1-2
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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

1-3
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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

1-1
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GIVE SAFETY THE RIGHT OF WAY
EUU75901
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 med-
ication, 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 driv-
ers 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 de-
fensively –avoiding all dangers, including those caused by others.
Enjoy your ride!

2-1
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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
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

3-1
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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 or-
dering 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 pro-
vided and use it for reference when obtaining
a new key.
1. Key identification number

3-2
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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 pro-
cedures.) 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

4-1
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EAB00000
CONTROL FUNCTIONS
EAB00100
Main switch
The main switch controls the ignition and light-
ing 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 counter-
clockwise to “P”, and remove it. To cancel the
parking, turn the key clockwise.
EUU08800
N
O
TE:
Always turn the main switch to “OFF”and re-
move the key when the motorcycle is unat-
tended.

4-2
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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 transmis-
sion 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

4-3
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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”
EAB63201
Pass switch “PASS”
Press the switch to operate the passing light.
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 re-
turned to the center position.
EAB60201
Horn switch “HORN”
Press the switch to sound the horn.
EAB61202
Light switch “LIGHTS”
Turning this switch to “PO”turns on the auxil-
iary light, taillight and meter lights. Turning to
“ON”, turns the headlight on also.

4-4
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EAB60902
Engine stop switch “ENGINE STOP”
The engine stop switch is a safety device for
use 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 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
N
O
TE:
Turn on the hazard switch to warn other driv-
ers if your motorcycle must be stopped where
it might be a traffic hazard.

4-5
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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 ta-
ble indicates which accessories are enabled
when the patrol switch is set to “P”, “M”, or “S”.
Accessory
Position
OFF P M S
Patrol light
Turn signal light
Microphone
Siren

4-6
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EAB70003
Clutch lever
The 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 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 sys-
tem.)
EAB80001
Shift pedal
This motorcycle is equipped with a constant-
mesh 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.
1. Shift pedal N. Neutral
EAB90001
Front brake lever
The front brake lever is located on the right
handlebar. Pull it toward the handlebar to ap-
ply 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.

4-7
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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 in-
serted. To remove the key, turn it counter-
clockwise to the original position.
EUU01200
N
O
TE:
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 motor-
cycle.

4-8
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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 en-
gine 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”!