Yamaha 2008 WR250XX Owner'S Manual Download | Manualshive

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PERIODIC MAINTENANCE AND MINOR REPAIR

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4

5

6

7

8

9

EAU22093

Adjusting the brake lever free
play

The brake lever free play should mea-
sure 5.0–8.0 mm (0.20–0.31 in) as
shown. Periodically check the brake le-
ver free play and, if necessary, adjust it
as follows.

1. Loosen the locknut at the brake le-

ver.

2. To increase the brake lever free

play, turn the brake lever free play
adjusting screw in direction (a). To
decrease the brake lever free play,
turn the adjusting screw in direc-
tion (b).

3. Tighten the locknut.

WARNING

EWA10630

●

After adjusting the brake lever
free play, check the free play
and make sure that the brake is
working properly.

●

A soft or spongy feeling in the
brake lever can indicate the
presence of air in the hydraulic
system. If there is air in the hy-
draulic system, have a Yamaha
dealer bleed the system before
operating the motorcycle. Air in
the hydraulic system will dimin-
ish the braking performance,
which may result in loss of con-

trol and an accident.

EAU22271

Adjusting the rear brake light
switch

The rear brake light switch, which is ac-
tivated by the brake pedal, is properly
adjusted when the brake light comes
on just before braking takes effect. If
necessary, adjust the brake light switch
as follows.
Turn the rear brake light switch adjust-
ing nut while holding the rear brake light
switch in place. To make the brake light
come on earlier, turn the adjusting nut
in direction (a). To make the brake light
come on later, turn the adjusting nut in
direction (b).

1. Locknut
2. Brake lever free play adjusting screw
3. Brake lever free play

3

1

2

(b)

(a)

1. Rear brake light switch
2. Adjusting nut

1

2

(b)

(a)

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Summary of Contents for 2008 WR250XX

Page 1: ...32D 28199 21 WR250XX OWNER S MANUAL ...

Page 2: ......

Page 3: ...s manual thoroughly so as to enjoy all advantages of your WR250XX The owner s manual does not only instruct you in how to operate inspect and maintain your motorcycle but also in how to safeguard yourself and others from trouble and injury In addition the many tips given in this manual will help keep your motorcycle in the best possible condition If you have any further questions do not hesitate t...

Page 4: ...otorcycle and this manual If you have any questions concerning this manual please consult your Yamaha dealer WARNING EWA10030 PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE Product and specifications are subject to change without notice The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED Failure to follow WARNING instructions could result...

Page 5: ...10200 WR250XX OWNER S MANUAL 2007 by Yamaha Motor Co Ltd 1st edition September 2007 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan ...

Page 6: ...and lubrication chart 6 2 Removing and installing panels 6 6 Checking the spark plug 6 8 Engine oil and oil filter element 6 9 Coolant 6 12 Cleaning the air filter element and check hose 6 15 Adjusting the engine idling speed 6 17 Checking the throttle cable free play 6 18 Valve clearance 6 18 Tires 6 18 Spoke wheels 6 20 Adjusting the clutch lever free play 6 21 Adjusting the brake lever free pla...

Page 7: ...y light bulb 6 36 Supporting the motorcycle 6 37 Front wheel 6 37 Rear wheel 6 38 Troubleshooting 6 40 Troubleshooting charts 6 41 MOTORCYCLE CARE AND STORAGE 7 1 Matte color caution 7 1 Care 7 1 Storage 7 3 SPECIFICATIONS 8 1 CONSUMER INFORMATION 9 1 Identification numbers 9 1 Motorcycle noise regulation for Australia 9 2 ...

Page 8: ... did not see the motorcycle Making yourself conspicuous appears to be very effective in reducing the chance of this type of accident Therefore Wear a brightly colored jacket Use extra caution when you are approaching and passing through intersections since in tersections are the most likely places for motorcycle accidents to occur Ride where other motorists can see you Avoid riding in another moto...

Page 9: ...reventing or reducing abrasions or lacerations Never wear loose fitting clothes otherwise they could catch on the control levers footrests or wheels and cause injury or an accident Never touch the engine or exhaust system during or after operation They become very hot and can cause burns Always wear protec tive clothing that covers your legs ankles and feet A passenger should also observe the abov...

Page 10: ... of your motorcycle Care fully inspect the accessory before using it to make sure that it does not in any way reduce ground clearance or cornering clearance limit suspension travel steering travel or control operation or ob scure lights or reflectors Accessories fitted to the handle bar or the front fork area can create instability due to improper weight distribution or aerody namic changes If acc...

Page 11: ...ng The engine and exhaust system may be hot therefore park the motorcycle in a place where pe destrians or children are not like ly to touch these hot areas Do not park the motorcycle on a slope or soft ground otherwise it may fall over Do not park the motorcycle near a flammable source e g a ker osene heater or near an open flame otherwise it could catch fire When transporting the motorcycle in a...

Page 12: ...SAFETY INFORMATION 1 5 1 EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle 2 1 4 3 ...

Page 13: ...d utiliser ce véhicule Lesen Sie die Bedienungsanleitung bevor Sie dieses Fahrzeug fahren Antes de conducir este vehículo lea el Manual del Propietario 32D 21668 10 Cold tire normal pressure should be set as follows Up to 90 kg 198 lbs load 200 kPa 2 00 kgf cm2 29 psi 200 kPa 2 00 kgf cm2 29 psi 90 kg 198 lbs 200 kPa 2 00 kgf cm2 29 psi 225 kPa 2 25 kgf cm2 33 psi maximum load 3 4 4AA 22259 40 ...

Page 14: ...SAFETY INFORMATION 1 7 1 1 ...

Page 15: ...SAFETY INFORMATION 1 8 1 1 ...

Page 16: ...sting screw page 3 13 2 Fuse box page 6 32 3 Coolant reservoir page 6 12 4 Shock absorber assembly compression damping force adjusting screw page 3 15 5 Battery page 6 31 6 Main fuse page 6 32 7 Owner s tool kit page 6 1 8 Helmet holder page 3 13 9 Front fork compression damping force adjusting screw page 3 13 ...

Page 17: ... 5 4 6 1 Rear brake fluid reservoir page 6 23 2 Air filter element page 6 15 3 Rear brake light switch page 6 22 4 Engine oil filler cap page 6 9 5 Engine oil level check window page 6 9 6 Shock absorber assembly rebound damping force adjusting dial page 3 15 ...

Page 18: ...ments 1 2 3 4 5 6 8 7 1 Clutch lever page 3 9 2 Left handlebar switches page 3 8 3 Main switch steering lock page 3 1 4 Multi function display page 3 3 5 Right handlebar switches page 3 8 6 Brake lever page 3 10 7 Throttle grip page 6 18 8 Fuel tank cap page 3 11 ...

Page 19: ...y is turned to OFF even if the engine stalls EAU10660 OFF All electrical systems are off The key can be removed EAU10680 LOCK The steering is locked and all electrical systems are off The key can be re moved To lock the steering 1 Turn the handlebars all the way to the left 2 Push the key in from the OFF po sition and then turn it to LOCK while still pushing it 3 Remove the key To unlock the steer...

Page 20: ...rning light This warning light comes on when the fuel level drops below approximately 2 1 L 0 55 US gal 0 46 Imp gal When this occurs refuel as soon as possible The electrical circuit of the warning light can be checked by turning the key to ON If the warning light does not come on for a few seconds then go off have a Yamaha dealer check the electrical cir cuit EAU11440 Coolant temperature warning...

Page 21: ...curs have a Yamaha dealer check the self diagno sis system The electrical circuit of the warning light can be checked by turning the key to ON If the warning light does not come on for a few seconds then go off have a Yamaha dealer check the electrical circuit NOTE This warning light will come on when the key is turned to ON and the start switch is pushed but this does not indi cate a malfunction ...

Page 22: ... tripme ter which shows the accumulated distance traveled since set to zero and which can be calibrated to pro vide a more accurate tripmeter reading a stopwatch which shows the time that has been accumulated since the start of stopwatch measure ment a self diagnosis device NOTE Be sure to turn the key to ON be fore using the SELECT 1 SELECT 2 and RESET but tons When the key is turned to ON all of...

Page 23: ...ic mode and push the SELECT 2 button to display the fuel reserve tripmeter NOTE To change from the measurement mode to the basic mode the stopwatch and the distance compensation tripme ter must be stopped To reset a tripmeter select it by push ing the SELECT 2 button and then push the RESET button for at least one second If you do not reset the fuel reserve tripmeter manually it will reset itself ...

Page 24: ...atch is in op eration stop it by pushing the SELECT 1 button and SELECT 2 button together 2 Push the SELECT 1 button and SELECT 2 button together for at least two seconds to change to the basic mode Measurement mode for the stop watch When the measurement mode is se lected the stopwatch is displayed and it can be started manually or automatical ly Manual start The manual start is the default setti...

Page 25: ...ccor dance with the distances specified on the enduro course map will help famil iarize the rider with the course In addi tion calibrating the meter may also be necessary when using tire wheel chain sprocket sizes etc other than specified For further information con cerning the use of this meter please consult your nearby Yamaha dealer Calibrate the distance compensation tripmeter as follows To in...

Page 26: ...del is equipped with a self diag nosis device for various electrical cir cuits If any of those circuits are defective the engine trouble warning light will come on and then the display will indicate a two digit error code If the display indicates any error codes note the code number and then have a Yamaha dealer check the vehicle CAUTION ECA11590 If the display indicates an error code the vehicle ...

Page 27: ...s when the vehicle overturns or when the throttle cable is stuck EAU12710 Start switch Push this switch to crank the engine with the starter CAUTION ECA10050 See page 5 1 for starting instruc tions prior to starting the engine EAU41700 The engine trouble warning light will come on when the key is turned to ON and the start switch is pushed but this does not indicate a malfunction EAU12820 Clutch l...

Page 28: ...the gears of the 6 speed con stant mesh transmission equipped on this motorcycle EAU12890 Brake lever The brake lever is located at the right handlebar grip To apply the front brake pull the lever toward the handle bar grip EAU12941 Brake pedal The brake pedal is on the right side of the motorcycle To apply the rear brake press down on the brake pedal 1 Shift pedal 1 1 Brake lever 1 1 Brake pedal ...

Page 29: ...d unless the key is in the lock In addition the key cannot be removed if the cap is not properly installed and locked WARNING EWA10120 Make sure that the fuel tank cap is properly closed and locked before riding EAU13211 Fuel Make sure that there is sufficient fuel in the tank Fill the fuel tank to the bottom of the filler tube as shown WARNING EWA10880 Do not overfill the fuel tank oth erwise it ...

Page 30: ...WARNING EWA10860 The exhaust system is hot after op eration Make sure that the exhaust system has cooled down before do ing any maintenance work CAUTION ECA10700 The following precautions must be observed to prevent a fire hazard or other damages Use only unleaded gasoline The use of leaded gasoline will cause unrepairable damage to the catalytic converter Never park the vehicle near pos sible fir...

Page 31: ... helmet holder since the helmet may hit objects causing loss of con trol and possibly an accident EAU45200 Adjusting the front fork This front fork is equipped with rebound damping force adjusting screws and compression damping force adjusting screws WARNING EWA10180 Always adjust both fork legs equal ly otherwise poor handling and loss of stability may result Rebound damping force To increase the...

Page 32: ... settings NOTE Although the total number of clicks of a damping force adjusting mechanism may not exactly match the above spec ifications due to small differences in production the actual number of clicks always represents the entire adjusting range To obtain a precise adjustment it would be advisable to check the num ber of clicks of each damping force ad justing mechanism and to modify the speci...

Page 33: ...wise poor handling and loss of sta bility may result 3 Install the bleed screws EAU45260 Adjusting the shock absorber assembly This shock absorber assembly is equipped with a spring preload adjust ing ring a rebound damping force ad justing dial and a compression damping force adjusting screw CAUTION ECA10100 Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings Sprin...

Page 34: ...gh the total number of clicks of a damping force adjusting mechanism may not exactly match the above spec ifications due to small differences in production the actual number of clicks 1 Distance A Spring preload Minimum soft Distance A 216 mm 8 50 in Standard Distance A 211 5 mm 8 33 in Maximum hard Distance A 206 mm 8 11 in 1 1 Rebound damping force adjusting dial Rebound damping setting Minimum ...

Page 35: ...nder Do not subject the shock ab sorber to an open flame or other high heat sources otherwise it may explode due to excessive gas pressure Do not deform or damage the gas cylinder in any way as this will result in poor damping per formance Always have a Yamaha dealer service the shock absorber EAU41940 EXUP system This model is equipped with Yamaha s EXUP EXhaust Ultimate Power valve system This s...

Page 36: ...o assist the operator in fulfilling the respon sibility of raising the sidestand be fore starting off Therefore check this system regularly as described below and have a Yamaha dealer re pair it if it does not function proper ly EAU44890 Ignition circuit cut off system The ignition circuit cut off system com prising the sidestand switch clutch switch and neutral switch has the fol lowing functions...

Page 37: ...ission 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 system is OK The motorcycle can be ridden The neutral switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer The sidestand switch may be defective The motorcycl...

Page 38: ... pressure could have serious consequences Therefore it is very important in addition to a thorough visual inspec tion to check the following points before each ride NOTE Pre operation checks should be made each time the vehicle is used Such an inspection can be accomplished in a very short time and the added safety it assures is more than worth the time involved WARNING EWA11150 If any item in the...

Page 39: ...operation If soft or spongy have Yamaha dealer bleed hydraulic system Check lever free play Adjust if necessary Check brake pads for wear Replace if necessary Check fluid level in reservoir If necessary add recommended brake fluid to specified level Check hydraulic system for leakage 6 22 6 23 Rear brake Check operation If soft or spongy have Yamaha dealer bleed hydraulic system Check brake pads f...

Page 40: ...Check air pressure Correct if necessary 6 18 6 20 Brake and shift pedals Make sure that operation is smooth Lubricate pedal pivoting points if necessary 6 27 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 28 Sidestand Make sure that operation is smooth Lubricate pivot if necessary 6 29 Chassis fasteners Make sure that all nuts bolts and sc...

Page 41: ...is equipped with a lean an gle sensor to stop the engine in case of a turnover To start the engine after a turnover be sure to turn the main switch to OFF and then to ON Fail ing to do so will prevent the engine from starting even though the engine will crank when pushing the start switch EAU45120 Starting the engine In order for the ignition circuit cut off system to enable starting one of the fo...

Page 42: ...seconds and then try again Each starting attempt should be as short as possible to pre serve the battery Do not crank the en gine more than 10 seconds on any one attempt CAUTION ECA11130 For maximum engine life always warm the engine up before starting off Never accelerate hard when the engine is cold EAU16671 Shifting Shifting gears lets you control the amount of engine power available for starti...

Page 43: ... shifting down and avoid high engine speeds with no load on the engine Turn the engine off instead of let ting it idle for an extended length of time e g in traffic jams at traffic lights or at railroad crossings EAU16841 Engine break in There is never a more important period in the life of your engine than the period between 0 and 1600 km 1000 mi For this reason you should read the follow ing mat...

Page 44: ...in period immediately have a Yamaha dealer check the vehicle EAU17212 Parking When parking stop the engine and then remove the key from the main switch WARNING EWA10310 Since the engine and exhaust system can become very hot park in a place where pedestri ans or children are not likely to touch them Do not park on a slope or on soft ground otherwise the vehicle may overturn CAUTION ECA10380 Never ...

Page 45: ... TO BE SHORT ENED WARNING EWA10320 If you are not familiar with mainte nance work have a Yamaha dealer do it for you EAU35010 Owner s tool kit The owner s tool kit is located inside the tool box The service information included in this manual and the tools provided in the owner s tool kit are intended to assist you in the performance of preventive maintenance and minor repairs How ever additional ...

Page 46: ... technical skills NO ITEM CHECK OR MAINTENANCE JOB ODOMETER READING ANNUAL CHECK 1000 km 600 mi 10000 km 6000 mi 20000 km 12000 mi 30000 km 18000 mi 40000 km 24000 mi 1 Fuel line Check fuel hoses for cracks or damage 2 Spark plug Check condition Clean and regap Replace 3 Valves Check valve clearance Adjust Every 40000 km 24000 mi 4 Air filter element Clean Replace 5 Clutch Check operation Adjust 6...

Page 47: ...hain Check chain slack alignment and condition Adjust and lubricate chain with a special O ring chain lubricant thoroughly Every 500 km 300 mi and after washing the motorcycle or riding in the rain 14 Steering bearings Check bearing play and steer ing for roughness Lubricate with lith ium soap based grease Every 50000 km 30000 mi 15 Chassis fasteners Make sure that all nuts bolts and screws are pr...

Page 48: ... absorber assembly Check operation and shock absorber for oil leakage 24 Rear suspension relay arm and con necting arm pivoting points Check operation 25 Engine oil Change Check oil level and vehicle for oil leakage Every 5000 km 3000 mi 26 Engine oil filter ele ment Replace 27 Cooling system Check coolant level and vehi cle for coolant leakage Change Every 3 years 28 Front and rear brake switches...

Page 49: ...ur years and if cracked or damaged 30 Throttle grip hous ing and cable Check operation and free play Adjust the throttle cable free play if necessary Lubricate the throttle grip housing and cable 31 Air induction system Check the air cut off valve reed valve and hose for dam age Replace any damaged parts if necessary 32 EXUP system Check operation cable free play and pulley position 33 Lights sign...

Page 50: ... jobs described in this chapter Refer to this section each time a panel needs to be removed and installed EAU45131 Panel A To remove the panel 1 Remove the seat See page 3 12 2 Remove the bolts and collars 3 Pull the front part of the panel out ward and then remove the panel by pulling it off 1 Panel A 2 Panel B 1 2 1 Panel C 1 Panel D 1 1 1 Bolt 1 Bolt 2 Panel A 1 1 2 ...

Page 51: ...See page 3 12 2 Remove the bolt and then remove the panel as shown To install the panel 1 Place the panel in the original po sition and then install the bolt 2 Install the seat Panel C To remove the panel 1 Remove the bolts 2 Lift the bottom of the panel slightly and then slide the panel forward To install the panel Place the panel in the original position and then install the bolts 1 Bolt 2 Panel...

Page 52: ...emoved and checked in ac cordance with the periodic mainte nance and lubrication chart In addition the condition of the spark plug can re veal the condition of the engine The porcelain insulator around the cen ter electrode of the spark plug should be a medium to light tan the ideal color when the vehicle is ridden normally If the spark plug shows a distinctly differ ent color the engine could be ...

Page 53: ...l should be checked before each ride In addition the oil must be changed and the oil filter ele ment replaced at the intervals specified in the periodic maintenance and lubri cation chart To check the engine oil level 1 Place the vehicle on a level sur face and hold it in an upright posi tion NOTE Make sure that the vehicle is positioned straight up when checking the oil level A slight tilt to the...

Page 54: ...e 2 Start the engine warm it up for several minutes and then turn it off 3 Place an oil pan under the engine to collect the used oil 4 Remove the engine oil filler cap and drain bolt to drain the oil from the crankcase NOTE Check the washer for damage and re place it if necessary NOTE Skip steps 5 7 if the oil filter element is not being replaced 5 Remove the oil filter element cover by removing t...

Page 55: ...TION ECA11620 In order to prevent clutch slip page since the engine oil also lubricates the clutch do not mix any chemical additives Do not use oils with a diesel speci fication of CD or oils of a high er quality than specified In addition do not use oils labeled ENERGY CONSERVING II or higher Make sure that no foreign mate rial enters the crankcase 1 Oil filter element cover 2 Oil filter element ...

Page 56: ...ng the oil pressure tighten the bleed bolt to the specified torque EAU20070 Coolant The coolant level should be checked before each ride In addition the cool ant must be changed at the intervals specified in the periodic maintenance and lubrication chart EAU20252 To check the coolant level 1 Place the vehicle on a level sur face and hold it in an upright posi tion NOTE The coolant level must be ch...

Page 57: ...ed to the coolant have a Yamaha dealer check the antifreeze content of the coolant as soon as possible otherwise the effectiveness of the coolant will be reduced WARNING EWA10380 Never attempt to remove the radiator cap when the engine is hot NOTE The radiator fan is automatically switched on or off according to the coolant temperature in the radia tor If the engine overheats see page 6 41 for fur...

Page 58: ...e original position and then installing the bolts 8 Remove the coolant drain bolt to drain the cooling system 9 After the coolant is completely drained thoroughly flush the cool ing system with clean tap water 10 Install the coolant drain bolt and then tighten it to the specified torque NOTE Check the washer for damage and re place it if necessary 11 Pour the specified amount of the 1 Radiator cap...

Page 59: ...6 Check the coolant level in the res ervoir If necessary remove the coolant reservoir cap add coolant to the maximum level mark and then install the cap 17 Start the engine and then check the vehicle for coolant leakage If coolant is leaking have a Yamaha dealer check the cooling system EAU44321 Cleaning the air filter element and check hose The air filter element should be cleaned at the interval...

Page 60: ...frame 7 Insert the air filter element into the air filter case CAUTION ECA10480 Make sure that the air filter ele ment is properly seated in the air filter case The engine should never be op erated without the air filter ele ment installed otherwise the piston s and or cylinder s may become excessively worn 8 Place the holding clip in the origi nal position 9 Close the air filter case cover and th...

Page 61: ... is needed to make this adjustment 1 Attach the tachometer to the spark plug lead 2 Check the engine idling speed and if necessary adjust it to spec ification by turning the idle adjust ing screw To increase the engine idling speed turn the screw in di rection a To decrease the en gine idling speed turn the screw in direction b NOTE If the specified idling speed cannot be obtained as described abo...

Page 62: ... Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart EAU21630 Tires To maximize the performance durabil ity and safe operation of your motorcy cle note the following points regarding the specified tires Tire air pressure The tire air pressure should be checked and if necessary adjusted before each ride WARNING EWA10500 The tire air pressure must be checked an...

Page 63: ...venly on both sides Adjust the suspension and tire air pressure with regard to the load Check the tire condition and air pressure before each ride Tire inspection The tires must be checked before each ride If the tire shows crosswise lines minimum tread depth if the tire has a nail or glass fragments in it or if the sidewall is cracked have a Yamaha dealer replace the tire immediately NOTE The tir...

Page 64: ...e tube very carefully and replace it as soon as possible with a high quality product EAU21940 Spoke wheels To maximize the performance durabil ity and safe operation of your motorcy cle note the following points regarding the specified wheels The wheel rims should be checked for cracks bends or warpage and the spokes for looseness or dam age before each ride If any dam age is found have a Yamaha d...

Page 65: ...n direction b 3 If the specified clutch lever free play could be obtained as de scribed above tighten the locknut and skip the rest of the procedure otherwise proceed as follows 4 Fully turn the adjusting bolt in di rection a to loosen the clutch ca ble 5 Loosen the locknut further down the clutch cable 6 To increase the clutch lever free play turn the clutch lever free play adjusting nut in direc...

Page 66: ...nce of air in the hydraulic system If there is air in the hy draulic system have a Yamaha dealer bleed the system before operating the motorcycle Air in the hydraulic system will dimin ish the braking performance which may result in loss of con trol and an accident EAU22271 Adjusting the rear brake light switch The rear brake light switch which is ac tivated by the brake pedal is properly adjusted...

Page 67: ...brake pad has worn to the point that the wear indicator grooves have almost disap peared have a Yamaha dealer replace the brake pads as a set EAU45300 Rear brake pads Each rear brake pad is provided with a wear indicator which allows you to check the brake pad wear without hav ing to disassemble the brake To check the brake pad wear check if the brake pad has worn to the wear indicator If a brake ...

Page 68: ...mical reaction and lead to poor braking performance Be careful that water does not en ter the brake fluid reservoir when refilling Water will significantly lower the boiling point of the fluid and may result in vapor lock Brake fluid may deteriorate paint ed surfaces or plastic parts Al ways clean up spilled fluid immediately As the brake pads wear it is nor mal for the brake fluid level to grad u...

Page 69: ...d the lock nut on each side of the swingarm 2 To tighten the drive chain turn the adjusting bolt on each side of the swingarm in direction a To loos en the drive chain turn the adjust ing bolt on each side of the swingarm in direction b and then push the rear wheel forward NOTE Using the alignment marks on each side of the swingarm make sure that both chain pullers are in the same posi tion for pr...

Page 70: ... must be lubricated after washing the motorcycle and riding in the rain 1 Clean the drive chain with kero sene and a small soft brush CAUTION ECA11120 To prevent damaging the O rings do not clean the drive chain with steam cleaners high pressure washers or inappropriate solvents 2 Wipe the drive chain dry 3 Thoroughly lubricate the drive chain with a special O ring chain lubricant CAUTION ECA11110...

Page 71: ... terfere with proper cable operation and will cause the inner cable to rust Replace a damaged cable as soon as possible to prevent unsafe conditions EAU23111 Checking and lubricating the throttle grip and cable The operation of the throttle grip should be checked before each ride In addi tion the cable should be lubricated at the intervals specified in the periodic maintenance chart EAU44271 Check...

Page 72: ...lutch levers Brake lever Clutch lever The operation of the brake and clutch levers should be checked before each ride and the lever pivots should be lu bricated if necessary Recommended lubricant Lithium soap based grease Recommended lubricants Brake lever Silicone grease Clutch lever Lithium soap based grease ...

Page 73: ...nance and lubrication chart EAU23271 Checking the front fork The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic main tenance and lubrication chart To check the condition WARNING EWA10750 Securely support the vehicle so that there is no danger of it falling over Check the inner tubes for scratches damage and excessive oil leakage To c...

Page 74: ...fore the operation of the steering must be checked as fol lows at the intervals specified in the pe riodic maintenance and lubrication chart 1 Place a stand under the engine to raise the front wheel off the ground WARNING EWA10750 Securely support the vehicle so that there is no danger of it falling over 2 Hold the lower ends of the front fork legs and try to move them for ward and backward If any...

Page 75: ...ischarged Keep in mind that the battery tends to discharge more quickly if the vehicle is equipped with optional electrical accessories WARNING EWA10760 Electrolyte is poisonous and dangerous since it contains sul furic acid which causes severe burns Avoid any contact with skin eyes or clothing and al ways shield your eyes when working near batteries In case of contact administer the fol lowing FI...

Page 76: ... battery leads are properly con nected to the battery terminals CAUTION ECA10630 Always keep the battery charged Storing a discharged battery can cause permanent battery damage To charge a sealed type MF battery a special constant volt age battery charger is required Using a conventional battery charger will damage the battery If you do not have access to a sealed type MF battery charg er have a Y...

Page 77: ...tely blows again have a Yamaha dealer check the electrical system EAU45210 Replacing the headlight bulb This model is equipped with a quartz bulb headlight If the headlight bulb burns out replace it as follows 1 Remove the headlight cowling to gether with the headlight unit by removing the bolts and pulling up ward as shown 2 Disconnect the headlight coupler and then remove the bulb cover 1 Fuel i...

Page 78: ...adlight bulb to keep it free from oil otherwise the transparency of the glass the luminosity of the bulb and the bulb life will be adversely af fected Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with al cohol or thinner 5 Install the headlight bulb cover and then connect the coupler 6 Install the headlight cowling to gether with the headlight unit b...

Page 79: ...a turn signal light bulb 1 Remove the turn signal light lens by removing the screw 2 Remove the defective bulb by pushing it in and turning it counter clockwise 3 Insert a new bulb into the socket push it in and then turn it clock wise until it stops 4 Install the lens by installing the screw CAUTION ECA11190 Do not overtighten the screw other wise the lens may break 1 Screw 2 Turn signal light le...

Page 80: ...nstall the license plate light unit by installing the screws EAU45220 Replacing an auxiliary light bulb If the auxiliary light bulb burns out re place it as follows 1 Remove the headlight unit See page 6 33 2 Remove the auxiliary light socket together with the bulb by pulling it out 3 Remove the defective bulb by pull ing it out 4 Insert a new bulb into the socket 5 Install the auxiliary light soc...

Page 81: ... or if an additional motorcycle stand is not available by placing a jack un der the frame in front of the rear wheel 2 Raise the front wheel off the ground by using a motorcycle stand To service the rear wheel Raise the rear wheel off the ground by using a motorcycle stand or if a motor cycle stand is not available by placing a jack either under each side of the frame in front of the rear wheel or...

Page 82: ...nch bolts and axle nut 4 Lower the front wheel so that it is on the ground 5 Tighten the axle nut and the wheel axle pinch bolts to their specified torques 6 Push down hard on the handlebar several times to check for proper fork operation EAU25080 Rear wheel EAU45180 To remove the rear wheel WARNING EWA10820 It is advisable to have a Yamaha dealer service the wheel Securely support the motorcy cle...

Page 83: ...nd the brake cal iper bracket by inserting the wheel axle from the left hand side NOTE Make sure that the retainer on the brake caliper bracket is inserted into the slot in the swingarm Make sure that there is enough space between the brake pads be fore installing the wheel 2 Install the drive chain onto the rear sprocket 3 Install the washer and the axle nut and then lower the rear wheel so that ...

Page 84: ...g and loss of power The following troubleshooting charts represent quick and easy procedures for checking these vital systems your self However should your motorcycle require any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools experience and know how to service the motorcycle properly Use only genuine Yamaha replace ment parts Imitation parts may look like Yama...

Page 85: ... 2 Compression There is compression There is no compression Check the ignition Have a Yamaha dealer check the vehicle Remove the spark plug and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gap or replace the spark plug Have a Yamaha dealer check the vehicle The engine does not start Have a Yamaha dealer check the vehicle The engine does not start Check the b...

Page 86: ...sidual pressure to escape When the hissing sound has stopped press down on the cap while turning it counterclockwise and then remove the cap NOTE If coolant is not available tap water can be temporarily used instead provided that it is changed to the recommended coolant as soon as possible Wait until the engine has cooled Check the coolant level in the reservoir and radiator The coolant level is O...

Page 87: ...ance Before cleaning 1 Cover the muffler outlet with a plastic bag after the engine has cooled down 2 Make sure that all caps and covers as well as all electrical couplers and connectors including the spark plug cap are tightly in stalled 3 Remove extremely stubborn dirt like oil burnt onto the crankcase with a degreasing agent and a brush but never apply such prod ucts onto seals gaskets sprock e...

Page 88: ...Stubborn dirt and insects will come off more easily if the area is covered with a wet cloth for a few minutes before cleaning After riding in the rain near the sea or on salt sprayed roads Since sea salt or salt sprayed on roads during winter are extremely corrosive in combination with water carry out the following steps after each ride in the rain near the sea or on salt sprayed roads NOTE Salt s...

Page 89: ...l or wax to any rubber and plastic parts but treat them with a suitable care product Avoid using abrasive polishing compounds as they will wear away the paint NOTE Consult a Yamaha dealer for advice on what products to use EAU43200 Storage Short term Always store your motorcycle in a cool dry place and if necessary protect it against dust with a porous cover CAUTION ECA10810 Storing the motorcycle...

Page 90: ...amage or injury from sparking make sure to ground the spark plug electrodes while turning the engine over 4 Lubricate all control cables and the pivoting points of all levers and pedals as well as of the sidestand centerstand 5 Check and if necessary correct the tire air pressure and then lift the motorcycle so that both of its wheels are off the ground Alterna tively turn the wheels a little ever...

Page 91: ...7 US qt 1 14 Imp qt With oil filter element replacement 1 40 L 1 48 US qt 1 23 Imp qt Cooling system Coolant reservoir capacity up to the maxi mum level mark 0 25 L 0 26 US qt 0 22 Imp qt Radiator capacity including all routes 0 90 L 0 95 US qt 0 79 Imp qt Air filter Air filter element Wet element Fuel Recommended fuel Premium unleaded gasoline only Fuel tank capacity 7 6 L 2 01 US gal 1 67 Imp ga...

Page 92: ...t 200 kPa 29 psi 2 00 kgf cm2 Rear 200 kPa 29 psi 2 00 kgf cm2 Loading condition 90 185 kg 198 408 lb Front 200 kPa 29 psi 2 00 kgf cm2 Rear 225 kPa 33 psi 2 25 kgf cm2 Front wheel Wheel type Spoke wheel Rim size 17M C x MT3 00 Rear wheel Wheel type Spoke wheel Rim size 17M C x MT4 00 Front brake Type Single disc brake Operation Right hand operation Recommended fluid DOT 4 Rear brake Type Single d...

Page 93: ...0 0 W 2 Auxiliary light 12 V 5 0 W 1 License plate light 12 V 5 0 W Meter lighting EL Electroluminescent Neutral indicator light LED High beam indicator light LED Turn signal indicator light LED Fuel level warning light LED Coolant temperature warning light LED Engine trouble warning light LED Fuses Main fuse 30 0 A Headlight fuse 15 0 A Signaling system fuse 10 0 A Ignition fuse 7 5 A Radiator fa...

Page 94: ...EL INFORMATION EAU26381 Key identification number The key identification number is stamped into the key tag Record this number in the space provided and use it for reference when ordering a new key EAU26400 Vehicle identification number The vehicle identification number is stamped into the steering head pipe Record this number in the space pro vided NOTE The vehicle identification number is used t...

Page 95: ...WITH NOISE CON TROL SYSTEM PROHIBITED Owners are warned that the law may prohibit The removal or rendering inopera tive by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the pur pose of noise control prior to its sale or delivery to the ultimate pur chaser or while it is in use and The use of the vehi...

Page 96: ...32 H Handlebar switches 3 8 Headlight bulb replacing 6 33 Helmet holder 3 13 High beam indicator light 3 2 Horn switch 3 9 I Identification numbers 9 1 Ignition circuit cut off system 3 18 Indicator and warning lights 3 2 K Key identification number 9 1 L Labels location of 1 5 License plate light bulb replacing 6 36 M Main switch steering lock 3 1 Matte color caution 7 1 Model label 9 2 Multi fun...

Page 97: ...al indicator light 3 2 Turn signal light bulb replacing 6 35 Turn signal switch 3 9 V Valve clearance 6 18 Vehicle identification number 9 1 W Wheel bearings checking 6 31 Wheel front 6 37 Wheel rear 6 38 Wheels 6 20 ...

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Page 100: ...PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2007 11 0 1 1 E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2007 11 0 1 1 E ...

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