Yamaha 2009 XV250Y Owner'S Manual Download Page 69

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PERIODIC MAINTENANCE AND ADJUSTMENT

7-34

3. Loosen the axle nut and the brake

torque rod nut at the brake shoe
plate.

4. Lift the rear wheel off the ground

according to the procedure on
page 7-31.

5. Remove the brake pedal free play

adjusting nut, and then disconnect
the brake rod at the brake cam-
shaft lever.

6. Disconnect the brake torque rod

from the brake shoe plate by re-
moving the nut and the bolt.

7. Push the wheel forward, and then

remove the drive chain from the
rear sprocket.

TIP

The drive chain does not need to be
disassembled in order to remove and
install the rear wheel.

8. Remove the axle nut.
9. Pull the wheel axle out, and then

remove the wheel.

EAU32762

To install the rear wheel

1. Install the drive chain onto the rear

sprocket, and then install the
wheel by inserting the wheel axle
from the right-hand side.

2. Install the brake rod onto the brake

camshaft lever, and then install the
brake pedal free play adjusting nut
onto the brake rod.

3. Connect the brake torque rod to

the brake shoe plate by installing
the bolt and nut, and then tighten
the bolt to the specified torque.

4. Install the axle nut, and then lower

the rear wheel so that it is on the
ground.

5. Adjust the drive chain slack. (See

page 7-21.)

6. Tighten the axle nut to the speci-

fied torque, and then insert a new
cotter pin into the axle nut.

WARNING! Always use a new
cotter pin for the axle nut.

[EWA10701]

7. Adjust the brake pedal position

and free play. (See page 7-17.)

WARNING

EWA10660

After adjusting the brake pedal free
play, check the operation of the
brake light.

1. Brake torque rod
2. Brake torque rod bolt and nut

3. Brake rod

4. Brake pedal free play adjusting nut
5. Brake camshaft lever

Tightening torque:

Brake torque rod bolt:

23 Nm (2.3 m·kgf, 17 ft·lbf)

Tightening torque:

Axle nut:

104 Nm (10.4 m·kgf, 75 ft·lbf)

U2UJ26E0.book Page 34 Thursday, May 22, 2008 10:21 AM

Summary of Contents for 2009 XV250Y

Page 1: ...XV250Y OWNER S MANUAL Read this manual carefully before operating this vehicle 2UJ 28199 26 ...

Page 2: ...EAU46090 Read this manual carefully before operating this vehicle This manual should stay with this vehicle if it is sold U2UJ26E0 book Page 1 Thursday May 22 2008 10 21 AM ...

Page 3: ...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 to contact your Yamaha dealer The Yamaha team wishes you many safe and pleasant rides So remember to put safety first Yamaha continually seeks advancements in product design and quality Therefore while this manual contains the most cur rent ...

Page 4: ...ey all safety messages that follow this symbol to avoid possible injury or death A WARNING indicates a hazardous situation which if not avoided could result in death or serious injury A NOTICE indicates special precautions that must be taken to avoid damage to the vehicle or other property A TIP provides key information to make procedures easier or clearer WARNING NOTICE TIP U2UJ26E0 book Page 1 T...

Page 5: ...ANUAL 2008 by Yamaha Motor Co Ltd 1st edition May 2008 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan U2UJ26E0 book Page 2 Thursday May 22 2008 10 21 AM ...

Page 6: ...lubrication chart 7 2 Removing and installing the panel 7 6 Checking the spark plugs 7 6 Engine oil and oil filter element 7 8 Cleaning the air filter element 7 10 Adjusting the carburetor 7 12 Adjusting the engine idling speed 7 12 Checking the throttle cable free play 7 13 Valve clearance 7 13 Tires 7 14 Spoke wheels 7 15 Adjusting the clutch lever free play 7 16 Adjusting the brake lever free p...

Page 7: ...signal light bulb 7 30 Supporting the motorcycle 7 31 Front wheel 7 32 Rear wheel 7 33 Troubleshooting 7 35 Troubleshooting chart 7 36 MOTORCYCLE CARE AND STORAGE 8 1 Matte color caution 8 1 Care 8 1 Storage 8 3 SPECIFICATIONS 9 1 CONSUMER INFORMATION 10 1 Identification numbers 10 1 Motorcycle noise regulation for Australia 10 2 U2UJ26E0 book Page 2 Thursday May 22 2008 10 21 AM ...

Page 8: ... vehicle They contain important information for safe and proper operation of your vehicle Never remove any labels from your vehicle If a label becomes difficult to read or comes off a replacement label is available from your Yamaha dealer 2 U2UJ26E0 book Page 1 Thursday May 22 2008 10 21 AM ...

Page 9: ...you operate this vehicle read the owner s manual Prima di usare il veicolo leggete il manuale di istruzioni Lire le manuel du propriétaire avant d utiliser ce véhicule Lesen Sie die Bedienungsanleitung bevor Sie dieses Fahrzeug fahren Antes de conducir este vehículo lea el Manual del Propietario 5RU 21568 01 U2UJ26E0 book Page 2 Thursday May 22 2008 10 21 AM ...

Page 10: ...passenger The failure of motorists to detect and recognize motorcycles in traf fic is the predominating cause of automobile motorcycle accidents Many accidents have been caused by an automobile driver who 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...

Page 11: ...d contribute to an impairment of vision that could delay seeing a hazard The use of a jacket heavy boots trousers gloves etc is effective in preventing 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 Always wear protective clothing that covers your legs ankles and feet The eng...

Page 12: ... of the motorcycle to minimize imbalance or instabili ty Shifting weights can create a sud den imbalance Make sure that ac cessories and cargo are securely attached to the motorcycle before riding Check accessory mounts and cargo restraints frequently Properly adjust the suspension for your load suspension ad justable models only and check the condition and pres sure of your tires Never attach any...

Page 13: ...ight distribution or aerody namic changes If accessories are added to the handlebar or front fork area they must be as lightweight as possible and should be kept to a minimum Bulky or large accessories may seriously affect the stability of the motorcycle due to aerody namic effects Wind may at tempt to lift the motorcycle or the motorcycle may become un stable in cross winds These ac cessories may...

Page 14: ...age 4 8 3 Fuel tank page 4 5 4 Battery page 7 26 5 Fuses page 7 28 6 Helmet holder page 4 10 7 Shock absorber assembly spring preload adjusting ring page 4 10 8 Main switch page 4 1 9 Fuel cock page 4 7 10 Shift pedal page 4 4 U2UJ26E0 book Page 1 Thursday May 22 2008 10 21 AM ...

Page 15: ...3 Rider seat page 4 9 4 Air filter element page 7 10 5 Front turn signal light page 7 30 6 Brake pedal page 4 5 7 Footrest 8 Rear brake light switch page 7 19 9 Owner s tool kit page 7 1 10 Shock absorber assembly spring preload adjusting ring page 4 10 U2UJ26E0 book Page 2 Thursday May 22 2008 10 21 AM ...

Page 16: ...ver page 4 4 2 Left handlebar switches page 4 2 3 Speedometer unit page 4 2 4 Indicator lights page 4 1 5 Right handlebar switches page 4 2 6 Brake lever page 4 4 7 Throttle grip page 7 13 8 Fuel tank cap page 4 5 U2UJ26E0 book Page 3 Thursday May 22 2008 10 21 AM ...

Page 17: ... WARNING EWA10072 Never turn the key to OFF while the vehicle is moving otherwise the electrical systems will be switched off which may result in loss of con trol or an accident EAU10980 Indicator lights EAU11040 Turn signal indicator light TURN This indicator light flashes when the turn signal switch is pushed to the left or right EAU11070 Neutral indicator light NEUTRAL This indicator light come...

Page 18: ...ter shows the total distance traveled The tripmeter shows the distance traveled since it was last set to zero with the reset knob The tripmeter can be used to estimate the distance that can be traveled with a full tank of fuel This information will en able you to plan future fuel stops EAU12347 Handlebar switches Left 1 Odometer 2 Tripmeter 3 Tripmeter reset knob 4 Speedometer 1 Pass switch PASS 2...

Page 19: ...gine Set this switch to OFF to stop the engine in case of an emergen cy such as when the vehicle overturns or when the throttle cable is stuck EAU12691 Start switch START Push this switch to crank the engine with the starter See page 6 1 for start ing instructions prior to starting the en gine EAU12752 Hazard switch HAZARD With the key in the ON position use this switch to turn on the hazard light...

Page 20: ...clutch switch which is part of the igni tion circuit cut off system See page 4 11 EAU12870 Shift pedal The shift pedal is located on the left side of the engine and is used in com bination with the clutch lever when shifting the gears of the 5 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...

Page 21: ...ed To close the fuel tank cap 1 Push the fuel tank cap into position with the key inserted in the lock 2 Turn the key counterclockwise to the original position and then re move it TIP The fuel tank cap cannot be closed un less the key is in the lock In addition the key cannot be removed if the cap is not properly closed and locked WARNING EWA11091 Make sure that the fuel tank cap is properly close...

Page 22: ...e painted surfaces or plastic parts ECA10071 4 Be sure to securely close the fuel tank cap WARNING EWA15151 Gasoline is poisonous and can cause injury or death Handle gaso line with care Never siphon gaso line by mouth If you should swallow some gasoline or inhale a lot of gas oline vapor or get some gasoline in your eyes see your doctor immedi ately If gasoline spills on your skin wash with soap ...

Page 23: ...ition fuel flows to the carburetor when the engine is running Turn the fuel cock le ver to this position when starting the en gine and riding RES This indicates reserve With the fuel cock lever in this position the fuel re serve is made available Quickly turn the fuel cock lever to this position if you run out of fuel while riding otherwise the engine may stall and will have to be primed see PRI A...

Page 24: ...r air fuel mixture which is supplied by the starter choke Move the lever in direction a to turn on the starter choke Move the lever in direction b to turn off the starter choke EAU13730 Steering lock To lock the steering 1 Turn the handlebar all the way to the right 2 Open the steering lock cover and then insert the key 3 Turn the key 1 8 turn counterclock wise push it in while turning the handleb...

Page 25: ... lock cover EAU14220 Rider seat To remove the rider seat Remove the bolts and then pull the rid er seat off To install the rider seat 1 Insert the projection on the front of the rider seat into the seat holder as shown 2 Place the rider seat in the original position and then tighten the bolts TIP Make sure that the rider seat is properly secured before riding 1 Bolt 1 Projection 2 Seat holder U2UJ...

Page 26: ...to turn beyond the maximum or minimum settings WARNING EWA10210 Always adjust both shock absorber assemblies equally otherwise poor handling and loss of stability may result Adjust the spring preload as follows To increase the spring preload and thereby harden the suspension turn the adjusting ring on each shock ab sorber assembly in direction a To de crease the spring preload and thereby soften t...

Page 27: ... 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 EAU15313 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 It prevents starting...

Page 28: ...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 not be working correctly The motorcycle should not be ridden until checked by a Yamaha dealer The sidestand switch may not be working correctly The motorcycle should not be ridden until checked by a Yamaha dealer The clutch swi...

Page 29: ...d in the Owner s Manual WARNING EWA11151 Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equipment damage Do not operate the vehicle if you find any problem If a problem cannot be corrected by the procedures provided in this manual have the vehicle inspected by a Yamaha dealer Before using this vehicle check the following points U2UJ26E0 book Page 1 ...

Page 30: ...ace if necessary Check fluid level in reservoir If necessary add recommended brake fluid to specified level Check hydraulic system for leakage 7 17 7 19 7 20 Rear brake Check operation Lubricate cable if necessary Check pedal free play Adjust if necessary 7 17 7 19 Clutch Check operation Lubricate cable if necessary Check lever free play Adjust if necessary 7 16 Throttle grip Make sure that operat...

Page 31: ...that operation is smooth Lubricate lever pivoting points if necessary 7 24 Sidestand Make sure that operation is smooth Lubricate pivot if necessary 7 24 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened Tighten if necessary Instruments lights signals and switches Check operation Correct if necessary Sidestand switch Check operation of ignition circuit cut off syste...

Page 32: ... switch is set to RUN 3 Shift the transmission into the neu tral position See page 6 2 The neutral indicator light should come on If not ask a Yamaha dealer to check the electrical circuit 4 Turn the starter choke on and completely close the throttle See page 4 8 5 Start the engine by pushing the start switch If the engine fails to start release the start switch wait a few sec onds and then try ag...

Page 33: ...on press the shift pedal down repeatedly until it reaches the end of its travel and then slightly raise it NOTICE ECA10260 Even with the transmission in the neutral position do not coast for long periods of time with the engine off and do not tow the motorcycle for long dis tances The transmission is properly lubricated only when the engine is running Inade quate lubrication may damage the transmi...

Page 34: ...ason you should read the follow ing material carefully Since the engine is brand new do not put an excessive load on it for the first 1600 km 1000 mi The various parts in the engine wear and polish themselves to the correct operating clearances During this period prolonged full throt tle operation or any condition that might result in engine overheating must be avoided EAU17022 0 1000 km 0 600 mi ...

Page 35: ...d exhaust system can become very hot park in a place where pedestri ans or children are not likely to touch them and be burned Do not park on a slope or on soft ground otherwise the vehicle may overturn increasing the risk of a fuel leak and fire Do not park near grass or other flammable materials which might catch fire U2UJ26E0 book Page 4 Thursday May 22 2008 10 21 AM ...

Page 36: ...miliar with vehicle ser vice have a Yamaha dealer perform service WARNING EWA15121 Turn off the engine when performing maintenance unless otherwise specified A running engine has moving parts that can catch on body parts or clothing and electrical parts that can cause shocks or fires Running the engine while ser vicing can lead to eye injury burns fire or carbon monoxide poisoning possibly leading...

Page 37: ...aha dealer as they require special tools data and 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 and vacuum hoses for cracks or damage 2 Spark plugs Check condition Clean and regap Replace 3 Valves Check valve clearance Adjust 4 Air filter element Clean Repl...

Page 38: ...Wheels Check runout spoke tightness and for damage Tighten spokes if necessary 11 Tires Check tread depth and for dam age Replace if necessary Check air pressure Correct if necessary 12 Wheel bearings Check bearing for looseness or damage 13 Swingarm pivot bushes Check bush assemblies for loose ness Lubricate with lithium soap based grease Every 50000 km 30000 mi NO ITEM CHECK OR MAINTENANCE JOB O...

Page 39: ...7 Brake lever pivot shaft Lubricate with silicone grease 18 Brake pedal pivot shaft Lubricate with lithium soap based grease 19 Clutch lever pivot shaft Lubricate with lithium soap based grease 20 Shift pedal pivot shaft Lubricate with lithium soap based grease 21 Sidestand Check operation Lubricate 22 Sidestand switch Check operation 23 Front fork Check operation and for oil leak age 24 Shock abs...

Page 40: ...peration Adjust engine idling speed 26 Engine oil Change Check oil level and vehicle for oil leakage 27 Engine oil filter ele ment Replace 28 Front and rear brake switches Check operation 29 Moving parts and cables Lubricate 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 Lights sign...

Page 41: ...panel and then push the rear of the panel in EAU19544 Checking the spark plugs The spark plugs are important engine components which are easy to check Since heat and deposits will cause any spark plug to slowly erode the spark plugs should be removed and checked in accordance with the periodic mainte nance and lubrication chart In addition the condition of the spark plugs can re veal the condition...

Page 42: ...park plug 1 Measure the spark plug gap with a wire thickness gauge and if nec essary adjust the gap to specifica tion 2 Clean the surface of the spark plug gasket and its mating surface and then wipe off any grime from the spark plug threads 3 Install the spark plug with the spark plug wrench and then tight en it to the specified torque TIP If a torque wrench is not available when installing a spa...

Page 43: ...at the bottom right side of the crankcase TIP The engine oil should be between the minimum and maximum level marks 4 If the engine oil is below the mini mum level mark add sufficient oil of the recommended type to raise it to the correct level To change the engine oil with or without oil filter element replace ment 1 Start the engine warm it up for several minutes and then turn it off 2 Place an o...

Page 44: ...der 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 Screw 2 Oil filter element cover 1 Oil filter element 2 O ring Ti...

Page 45: ...ed or replaced at the intervals specified in the periodic maintenance and lubrica tion chart Clean or if necessary re place the air filter element more frequently if you are riding in unusually wet or dusty areas 1 Remove the bolts and loosen the air filter case joint clamp screw 2 Disconnect the hoses from the air filter case and then remove the air filter case 1 CD specification 2 ENERGY CONSERV...

Page 46: ...ndle it gently and carefully and do not twist or wring it ECA10511 6 Apply oil of the recommended type to the entire surface of the sponge material and then squeeze the ex cess oil out TIP The air filter element should be wet but not dripping 7 Pull the sponge material over the air filter element frame 8 Insert the element into the air filter case and then tighten the wing nut NOTICE Make sure tha...

Page 47: ...the owner as part of routine maintenance NOTICE ECA10550 The carburetor has been set and ex tensively tested at the Yamaha fac tory Changing these settings without sufficient technical knowl edge may result in poor perfor mance of or damage to the engine EAU21340 Adjusting the engine idling speed The engine idling speed must be checked and if necessary adjusted as follows at the intervals specifie...

Page 48: ... check the throttle cable free play and if neces sary have a Yamaha dealer adjust it EAU21401 Valve clearance The valve clearance changes with use resulting in improper air fuel mixture and or engine noise To prevent this from occurring the valve clearance must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart 1 Throttle stop screw Engine i...

Page 49: ...car go and accessories approved for this model WARNING EWA10511 Never overload your vehicle Opera tion of an overloaded vehicle could cause an accident Tire inspection Always check the tires before operating the motorcycle If a tire tread shows crosswise lines minimum tread depth if the tire has a nail or glass fragments in it or if the sidewall is cracked con tact a Yamaha dealer immediately and ...

Page 50: ...ad to an accident After extensive tests only the tires list ed below have been approved for this model by Yamaha Motor Co Ltd EAU21940 Spoke wheels To maximize the performance durabil ity and safe operation of your motor cycle 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 rid...

Page 51: ...ch lever free play could be obtained as described above tighten the locknut and skip the rest of the procedure otherwise proceed as follows 3 Fully turn the adjusting bolt at the clutch lever in direction a to loos en the clutch cable 4 Loosen the locknut at the crank case 5 To increase the clutch lever free play turn the adjusting nut in direc tion a To decrease the clutch le ver free play turn t...

Page 52: ... 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 EAU22201 Adjusting the brake pedal po sition and free play WARNING EWA10670 It is advisable to have a Yam...

Page 53: ...ake pedal free play and if neces sary adjust it as follows To increase the brake pedal free play turn the adjusting nut at the brake rod in direction a To decrease the brake pedal free play turn the adjusting nut in direction b WARNING EWA10680 After adjusting the drive chain slack or removing and installing the rear wheel always check the brake pedal free play If proper adjustment cannot be obtai...

Page 54: ...ake pads Each front brake pad is provided with a wear indicator groove which allows you to check the brake pad wear with out having to disassemble the brake To check the brake pad wear check the wear indicator groove If a brake pad has worn to the point that the wear indicator groove has almost disap peared have a Yamaha dealer replace the brake pads as a set EAU22540 Rear brake shoes The rear bra...

Page 55: ...mful chemical reaction and lead to poor braking performance Be careful that water does not en ter the master cylinder when refill ing 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 gra...

Page 56: ... pin from the axle nut and then loosen the axle nut 3 Loosen the chain puller locknut at each end of the swingarm 4 To tighten the drive chain turn the drive chain slack adjusting nut at each end of the swingarm in direc tion a To loosen the drive chain turn the adjusting nut at each end of the swingarm in direction b and then push the rear wheel for ward NOTICE Improper drive chain slack will ove...

Page 57: ...he periodic maintenance and lubrica tion chart otherwise it will quickly wear out especially when riding in dusty or wet areas Service the drive chain as follows NOTICE ECA10581 The drive chain 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 NOTICE To prevent damaging the O rings do not clean the drive chain with ...

Page 58: ...ly have a Yamaha dealer check or replace it WARNING Damage to the outer sheath may interfere with proper ca ble operation and will cause the in ner cable to rust Replace a damaged cable as soon as possible to prevent unsafe conditions EWA10721 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 s...

Page 59: ...g and lubricating the sidestand The operation of the sidestand should be checked before each ride and the sidestand pivot and metal to metal contact surfaces should be lubricated if necessary WARNING EWA10731 If the sidestand does not move up and down smoothly have a Yamaha dealer check or repair it Otherwise the sidestand could contact the ground and distract the operator re sulting in a possible...

Page 60: ...nner tubes for scratches damage and excessive oil leakage To check the operation 1 Place the vehicle on a level sur face and hold it in an upright posi tion WARNING To avoid injury securely support the vehicle so there is no danger of it falling over EWA10751 2 While applying the front brake push down hard on the handlebars several times to check if the front fork compresses and rebounds smoothly ...

Page 61: ...e front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrica tion chart If there is play in the wheel hub or if the wheel does not turn smoothly have a Yamaha dealer check the wheel bearings EAU23312 Battery A poorly maintained battery will corrode and discharge quickly The electrolyte level battery lead connections and breather hose routing sh...

Page 62: ...garettes etc away from the battery and pro vide sufficient ventilation when charging it in an enclosed space Take care not to spill electrolyte on the drive chain as this may weaken it shorten chain life and possibly result in an accident KEEP THIS AND ALL BATTER IES OUT OF THE REACH OF CHILDREN 4 Check and if necessary tighten the battery lead connections and correct the breather hose routing To ...

Page 63: ...ers are located under the rider seat See page 4 9 If a fuse is blown replace it as follows 1 Turn the key to OFF and turn off the electrical circuit in question 2 Remove the blown fuse and then install a new fuse of the specified amperage WARNING Do not use a fuse of a higher amperage rating than recommended to avoid causing extensive dam age to the electrical system and possibly a fire EWA15131 3...

Page 64: ...ned with al cohol or thinner 1 Remove the headlight unit by re moving the screws 2 Disconnect the headlight coupler and then remove the bulb cover 3 Remove the headlight bulb holder by turning it counterclockwise and then remove the burnt out bulb 4 Place a new headlight bulb into po sition and then secure it with the bulb holder 5 Install the headlight bulb cover and then connect the coupler 6 In...

Page 65: ...he socket push it in and then turn it clock wise until it stops 4 Install the lens by installing the screws NOTICE Do not over tighten the screws otherwise the lens may break ECA10681 EAU24212 Replacing a turn signal light bulb 1 Remove the turn signal lens by re moving the screws 2 Remove the burnt out bulb by pushing it in and turning it counter clockwise 1 Screw 1 Tail brake light bulb 1 Screw ...

Page 66: ...nd level position before starting any maintenance A strong wooden box can be placed under the engine for added stability To service the front wheel 1 Stabilize the rear of the motorcycle by using a motorcycle stand 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...

Page 67: ...l NOTICE Do not apply the brake after the wheel has been removed to gether with the brake disc oth erwise the brake pads will be forced shut ECA11071 EAU24932 To install the front wheel 1 Install the speedometer gear unit into the wheel hub so that the pro jections mesh with the slots 2 Lift the wheel up between the fork legs TIP Make sure that there is enough space between the brake pads before i...

Page 68: ... wheel EAU32751 To remove the rear wheel WARNING EWA10821 To avoid injury securely support the vehicle so there is no danger of it falling over 1 Remove the axle nut cotter pin 2 Loosen the chain puller locknut and the drive chain slack adjusting nut on both ends of the swingarm 1 Speedometer gear unit 2 Retainer 3 Speedometer cable Tightening torque Wheel axle 59 Nm 5 9 m kgf 43 ft lbf Tightening...

Page 69: ...side 2 Install the brake rod onto the brake camshaft lever and then install the brake pedal free play adjusting nut onto the brake rod 3 Connect the brake torque rod to the brake shoe plate by installing the bolt and nut and then tighten the bolt to the specified torque 4 Install the axle nut and then lower the rear wheel so that it is on the ground 5 Adjust the drive chain slack See page 7 21 6 T...

Page 70: ...equire 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 Yamaha parts but they are often inferi or have a shorter service life and can lead to expensive repair bills WARNING EWA15141 When checking the fuel system do not smoke and...

Page 71: ... 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 operate the electric starter Operate the electric starter 4 Battery The engine turns over quickly The engine turns over slowly The battery is good Check the electrolyte and battery lead connections...

Page 72: ...uffler outlets with plas tic bags 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 caps 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 ets the drive chain and wheel axl...

Page 73: ...or hard to reach areas 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 sp...

Page 74: ...or NOTICE ECA10800 Apply spray oil and wax spar ingly and make sure to wipe off any excess Never apply oil 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 TIP Consult a Yamaha dealer for advice on what products to use EAU26212 Storage Short term Always store your motorcycle in a cool dry pl...

Page 75: ...ury from sparking make sure to ground the spark plug electrodes while turning the engine over EWA10951 e Remove the spark plug caps from the spark plugs and then install the spark plugs and the spark plug caps 6 Lubricate all control cables and the pivoting points of all levers and pedals as well as of the side stand centerstand 7 Check and if necessary correct the tire air pressure and then lift ...

Page 76: ...eplacement 1 40 L 1 48 US qt 1 23 Imp qt With oil filter element replacement 1 60 L 1 69 US qt 1 41 Imp qt Air filter Air filter element Wet element Fuel Recommended fuel Unleaded gasoline only Fuel tank capacity 9 5 L 2 51 US gal 2 09 Imp gal Fuel reserve amount 2 6 L 0 69 US gal 0 57 Imp gal Carburetor Manufacturer MIKUNI Type quantity BDS26 x 1 Spark plug s Manufacturer model NGK C6HSA Manufact...

Page 77: ...25 kPa 2 25 kgf cm 33 psi Front wheel Wheel type Spoke wheel Rim size 18x1 60 Rear wheel Wheel type Spoke wheel Rim size 15M C x MT2 75 Front brake Type Single disc brake Operation Right hand operation Recommended fluid DOT 4 Rear brake Type Drum brake Operation Right foot operation Front suspension Type Telescopic fork Spring shock absorber type Coil spring oil damper Wheel travel 140 0 mm 5 51 i...

Page 78: ...gnal light 12 V 21 0 W 2 Meter lighting 14 V 3 0 W 1 Neutral indicator light 14 V 3 0 W 1 High beam indicator light 12 V 1 7 W 1 Turn signal indicator light 14 V 3 0 W 1 Fuses Main fuse 20 0 A Signaling system fuse 10 0 A U2UJ26E0 book Page 3 Thursday May 22 2008 10 21 AM ...

Page 79: ...identification number The key identification number is stamped into the key Record this num ber 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 TIP The vehicle identification number is used to identify your motorcycle and m...

Page 80: ...YSTEM PROHIBITED Owners are warned that the law may prohibit a 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 b The use of the vehicle after such de...

Page 81: ...4 3 I Identification numbers 10 1 Ignition circuit cut off system 4 11 Indicator lights 4 1 K Key identification number 10 1 L Labels location 1 1 M Main switch 4 1 Matte color caution 8 1 Model label 10 2 N Neutral indicator light 4 1 Noise regulation for Australia 10 2 P Panel removing and installing 7 6 Parking 6 4 Part locations 3 1 Pass switch 4 3 Periodic maintenance and lubrication chart 7 ...

Page 82: ...ulb replacing 7 30 Turn signal switch 4 3 V Valve clearance 7 13 Vehicle identification number 10 1 W Wheel bearings checking 7 26 Wheel front 7 32 Wheel rear 7 33 Wheels 7 15 U2UJ26E0 book Page 2 Thursday May 22 2008 10 21 AM ...

Page 83: ...U2UJ26E0 book Page 3 Thursday May 22 2008 10 21 AM ...

Page 84: ...PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2008 06 0 3 1 CR E ...

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