Yamaha 2010 XV250Z Owner'S Manual Download | Manualshive

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PERIODIC MAINTENANCE AND ADJUSTMENT

7-19

7

EAU22201

Adjusting the brake pedal po-
sition and free play

WARNING

EWA10670

It is advisable to have a Yamaha
dealer make these adjustments.

Brake pedal position

The top of the brake pedal should be
positioned approximately 60.0 mm
(2.36 in) above the top of the footrest as
shown. Periodically check the brake
pedal position and, if necessary, adjust
it as follows.

1. Loosen the locknut at the brake

pedal.

2. To raise the brake pedal, turn the

adjusting bolt in direction (a). To
lower the brake pedal, turn the ad-
justing bolt in direction (b).

3. Tighten the locknut.

WARNING

EWA11230

After adjusting the brake pedal posi-
tion, the brake pedal free play must
be adjusted.

Brake pedal free play

The brake pedal free play should mea-
sure 20.0–30.0 mm (0.79–1.18 in) at
the brake pedal end. Periodically check
the brake 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.

1. Footrest

2. Distance between brake pedal and footrest
3. Brake pedal free play

1. Locknut
2. Brake pedal position adjusting bolt

1. Brake pedal free play adjusting nut

U1BE20E0.book Page 19 Tuesday, May 12, 2009 5:52 PM

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Summary of Contents for 2010 XV250Z

Page 1: ...DIC183 XV250Z Read this manual carefully before operating this vehicle 1BE 28199 20 OWNER S MANUAL ...

Page 2: ...EAU46090 Read this manual carefully before operating this vehicle This manual should stay with this vehicle if it is sold U1BE20E0 book Page 1 Tuesday May 12 2009 5 52 PM ...

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: ...bey 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 U1BE20E0 book Page 1 ...

Page 5: ...ANUAL 2009 by Yamaha Motor Co Ltd 1st edition April 2009 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan U1BE20E0 book Page 2 Tuesday May 12 2009 5 52 PM ...

Page 6: ...m 7 2 General maintenance and lubrication chart 7 3 Removing and installing the panel 7 7 Checking the spark plugs 7 7 Engine oil and oil filter element 7 9 Cleaning the air filter element 7 11 Adjusting the carburetor 7 13 Adjusting the engine idling speed 7 13 Checking the throttle cable free play 7 14 Valve clearance 7 14 Tires 7 15 Spoke wheels 7 16 Adjusting the clutch lever free play 7 17 Ad...

Page 7: ...placing a turn signal light bulb 7 33 Supporting the motorcycle 7 33 Front wheel 7 34 Rear wheel 7 36 Troubleshooting 7 37 Troubleshooting chart 7 39 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 U1BE20E0 book Page 2 Tuesday May 12 2009 5 52 PM ...

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 3 2 1 U1BE20E0 book Page 1 Tuesday May 12 2009 5 52 PM ...

Page 9: ...e 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 1 STATIONARY NOISE TEST INFORMATION TESTED 86 dB A AT 4000 r min SILENCINGSYSTEM YAMAHA IDENTIFICATION 3DM 14711 1BE 2118G 00 U1BE20E0 book Page 2 Tuesd...

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: ...ld 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 en...

Page 12: ...s 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 an...

Page 13: ...eight 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 ma...

Page 14: ... page 4 8 3 Fuel tank page 4 5 4 Battery page 7 28 5 Fuses page 7 30 6 Helmet holder page 4 9 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 U1BE20E0 book Page 1 Tuesday May 12 2009 5 52 PM ...

Page 15: ... 3 Rider seat page 4 9 4 Air filter element page 7 11 5 Front turn signal light page 7 33 6 Brake pedal page 4 5 7 Footrest 8 Rear brake light switch page 7 20 9 Owner s tool kit page 7 1 10 Shock absorber assembly spring preload adjusting ring page 4 10 U1BE20E0 book Page 2 Tuesday May 12 2009 5 52 PM ...

Page 16: ...ever 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 14 8 Fuel tank cap page 4 5 U1BE20E0 book Page 3 Tuesday May 12 2009 5 52 PM ...

Page 17: ...d 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 EAU10981 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 com...

Page 18: ...eter 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 EAU12348 Handlebar switches Left 1 Odometer 2 Tripmeter 3 Tripmeter reset knob 4 Speedometer 1 Pass switch PASS ...

Page 19: ...ngine 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 ligh...

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 fron...

Page 21: ...ned 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 clos...

Page 22: ...ure 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 and water If gaso line spills on your clothing chan...

Page 23: ...ckly 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 After turning the fuel cock lever to RES refuel as soon as possible and be sure to turn the fuel cock lever back to ON PRI This indicates prime With the fuel cock lever in this position the engine can be primed Turn the fuel cock lever to this positio...

Page 24: ...en the steering lock cover and then insert the key 3 Turn the key 1 8 turn counterclock wise push it in while turning the handlebar slightly to the left and then turn the key 1 8 turn clock wise 4 Check that the steering is locked remove the key and then close the lock cover To unlock the steering 1 Open the steering lock cover and then insert the key 2 Push the key in turn it 1 8 turn countercloc...

Page 25: ...TIP Make sure that the rider seat is properly secured before riding EAU14282 Helmet holder To open the helmet holder insert the key into the lock and then turn the key as shown To lock the helmet holder place it in the original position and then remove the key WARNING Never ride with a helmet attached to the helmet hold er since the helmet may hit objects causing loss of control and possibly an ac...

Page 26: ... shock absorber EAU15303 Sidestand The sidestand is located on the left side of the frame Raise the sidestand or lower it with your foot while holding the vehicle upright TIP The built in sidestand switch is part of the ignition circuit cut off system which cuts the ignition in certain situations See page 4 11 for an explanation of the ignition circuit cut off system WARNING EWA10240 The vehicle m...

Page 27: ...ans mission is in gear and the side stand is up but the clutch lever is not pulled It prevents starting when the trans mission is in gear and the clutch le ver is pulled but the sidestand is still down It cuts the running engine when the transmission is in gear and the sid estand is moved down Periodically check the operation of the ignition circuit cut off system according to the following proced...

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 sw...

Page 29: ... Before using this vehicle check the following points ITEM CHECKS PAGE Fuel Check fuel level in fuel tank Refuel if necessary Check fuel line for leakage 4 6 Engine oil Check oil level in engine If necessary add recommended oil to specified level Check vehicle for oil leakage 7 9 Front brake Check operation If soft or spongy have Yamaha dealer bleed hydraulic system Check lever free play Adjust if...

Page 30: ...on and tread depth Check air pressure Correct if necessary 7 15 7 16 Brake and shift pedals Make sure that operation is smooth Lubricate pedal pivoting points if necessary 7 25 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 7 26 Sidestand Make sure that operation is smooth Lubricate pivot if necessary 7 26 Chassis fasteners Make sure that al...

Page 31: ...FOR YOUR SAFETY PRE OPERATION CHECKS 5 3 5 Battery Check fluid level Fill with distilled water if necessary 7 28 ITEM CHECKS PAGE U1BE20E0 book Page 3 Tuesday May 12 2009 5 52 PM ...

Page 32: ...sure that the engine stop 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...

Page 33: ...ion 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 transm...

Page 34: ...eason 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 EAU17023 0 1000 km 0 600 mi...

Page 35: ...nd 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 U1BE20E0 book Page 4 Tuesday May 12 2009 5 52 PM ...

Page 36: ...amiliar 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 leadin...

Page 37: ...a dealer as they require special tools data and technical skills EAU46910 Periodic maintenance chart for the emission control system 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 V...

Page 38: ...d 3 Clutch Check operation Adjust 4 Front brake Check operation fluid level and vehicle for fluid leakage Adjust brake lever free play Replace brake pads Whenever worn to the limit 5 Rear brake Check operation and adjust brake pedal free play Replace brake shoes Whenever worn to the limit 6 Brake hose Check for cracks or damage Replace Every 4 years 7 Wheels Check runout spoke tightness and for da...

Page 39: ...nd steering for roughness Lubricate with lithium soap based grease Every 20000 km 12000 mi 13 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 14 Brake lever pivot shaft Lubricate with silicone grease 15 Brake pedal pivot shaft Lubricate with lithium soap based grease 16 Clutch lever pivot shaft Lubricate with lithium soap based grease 17 Shift pedal pivot shaft Lu...

Page 40: ... for oil leakage 23 Engine oil filter ele ment Replace 24 Front and rear brake switches Check operation 25 Moving parts and cables Lubricate 26 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 27 Lights signals and switches Check operation Adjust headlight beam NO ITEM CHECK OR MAINTENANCE ...

Page 41: ...ck and if necessary correct the brake fluid level Every two years replace the internal components of the brake master cylinder and caliper and change the brake fluid Replace the brake hoses every four years and if cracked or damaged U1BE20E0 book Page 6 Tuesday May 12 2009 5 52 PM ...

Page 42: ... panel and then push the rear of the panel in EAU19545 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 conditio...

Page 43: ... spark plug gap with a wire thickness gauge and if nec essary adjust the gap to specifica tion To install a spark plug 1 Clean the surface of the spark plug gasket and its mating surface and then wipe off any grime from the spark plug threads 2 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 sp...

Page 44: ... 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 ...

Page 45: ...oled down NOTICE 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 Screw 2 Oil filter element cover 1...

Page 46: ... element should be cleaned 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 Bolt 1 Ai...

Page 47: ...andle 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 th...

Page 48: ... 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 specifi...

Page 49: ...y 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 ...

Page 50: ... 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 51: ...lead to an accident After extensive tests only the tires list ed below have been approved for this model by Yamaha Motor Co Ltd EAU21941 Spoke wheels WARNING EWA10610 The wheels on this model are not de signed for use with tubeless tires Do not attempt to use tubeless tires on this model To maximize the performance durabil ity and safe operation of your motorcy cle note the following points regard...

Page 52: ... clutch lever 2 Loosen the locknut 3 To increase the clutch lever free play turn the adjusting bolt in di rection a To decrease the clutch lever free play turn the adjusting bolt in direction b TIP If the specified clutch lever free play could be obtained as described above skip steps 4 7 4 Fully turn the adjusting bolt at the clutch lever in direction a to loos en the clutch cable 5 Loosen the lo...

Page 53: ...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...

Page 54: ...11230 After adjusting the brake pedal posi tion the brake pedal free play must be adjusted Brake pedal free play The brake pedal free play should mea sure 20 0 30 0 mm 0 79 1 18 in at the brake pedal end Periodically check the brake 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 bra...

Page 55: ... earlier turn the adjusting nut in direction a To make the brake light come on later turn the adjusting nut in direction b EAU22380 Checking the front brake pads and rear brake shoes The front brake pads and the rear brake shoes must be checked for wear at the intervals specified in the periodic main tenance and lubrication chart EAU22420 Front brake pads Each front brake pad is provided with a we...

Page 56: ...s low be sure to check the brake pads for wear and the brake system for leakage Observe these precautions When checking the fluid level make sure that the top of the mas ter cylinder is level by turning the handlebars Use only the recommended quality brake fluid otherwise the rubber seals may deteriorate causing leakage and poor braking perfor mance Refill with the same type of brake fluid Mixing ...

Page 57: ...ed before each ride and adjusted if necessary EAU22773 To check the drive chain slack 1 Place the motorcycle on the side stand TIP When checking and adjusting the drive chain slack there should be no weight on the motorcycle 2 Shift the transmission into the neu tral position 3 Move the rear wheel by pushing the motorcycle to locate the tight est portion of the drive chain and then measure the dri...

Page 58: ...ent marks on each side of the swingarm make sure that both chain pullers are in the same posi tion for proper wheel alignment 5 Tighten the locknuts and then tighten the axle nut to the specified torque 6 Insert a new cotter pin into the axle nut and then bend its ends as shown WARNING Always use a new cotter pin for the axle nut EWA10701 TIP Make sure that two notches in the axle nut are aligned ...

Page 59: ...nts ECA11121 2 Wipe the drive chain dry 3 Thoroughly lubricate the drive chain with a special O ring chain lubricant NOTICE Do not use engine oil or any other lubri cants for the drive chain as they may contain substances that could damage the O rings ECA11111 EAU23101 Checking and lubricating the cables The operation of all control cables and the condition of the cables should be checked before e...

Page 60: ...n the cable should be lubricated at the intervals specified in the periodic maintenance chart EAU44271 Checking and lubricating the brake and shift pedals The operation of the brake and shift pedals should be checked before each ride and the pedal pivots should be lu bricated if necessary Recommended lubricant Lithium soap based grease U1BE20E0 book Page 25 Tuesday May 12 2009 5 52 PM ...

Page 61: ...nd 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 loss of control Recommended lubricants Brake lever Silicone...

Page 62: ...inner 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 63: ...he 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 s...

Page 64: ...igarettes 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 65: ...ders 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 ...

Page 66: ...rints on the headlight bulb using a cloth moistened with al cohol or thinner Headlight lens Do not affix any type of tinted film or stickers to the headlight lens Do not use a headlight bulb of a wattage higher than specified 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 counter...

Page 67: ...tail brake light bulb 1 Remove the tail brake light lens by removing the screws 2 Remove the burnt out 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 screws NOTICE Do not over tighten the screws otherwise the lens may break ECA10681 1 Screw 1 Tail brake light bulb ...

Page 68: ...ront and rear wheel or performing other maintenance requiring the motorcycle to stand up right Check that the motorcycle is in a stable and 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 avai...

Page 69: ...e front wheel axle pinch bolt then the wheel axle 3 Lift the front wheel off the ground according to the procedure on page 7 33 4 Pull the wheel axle out and then remove the wheel 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 EAU24933 To install the front wheel 1 Install the speedometer gear unit ...

Page 70: ...e sidestand down 5 Tighten the wheel axle to the spec ified torque 6 Tighten the front wheel axle pinch bolt to the specified torque 7 While applying the front brake push down hard on the handlebars several times to check if the front fork compresses and rebounds smoothly 8 Connect the speedometer cable 1 Speedometer gear unit 1 Speedometer gear unit 2 Retainer 3 Speedometer cable Tightening torqu...

Page 71: ...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 EAU32764 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 camsha...

Page 72: ...y occur dur ing operation Any problem in the fuel compression or ignition systems for example can cause poor starting and loss of power The following troubleshooting chart represents a quick and easy procedure 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...

Page 73: ...ERIODIC MAINTENANCE AND ADJUSTMENT 7 38 7 heaters or furnaces Gasoline or gasoline vapors can ignite or ex plode causing severe injury or property damage U1BE20E0 book Page 38 Tuesday May 12 2009 5 52 PM ...

Page 74: ...t 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 connection...

Page 75: ...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 axles Alwa...

Page 76: ...and a soft clean sponge and then rinse thoroughly with clean water Use a toothbrush or bottlebrush for 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 combina...

Page 77: ...xcess 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 ad vice on what products to use Washing rainy weather or humid climates can cause the headlight lens to fog Turning the headlight on for a short period of time will help remove the moisture...

Page 78: ...jury 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 79: ...ment replacement 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 Type quantity BDS26 x 1 Spark plug s Manufacturer model NGK C6HSA Manufacturer model DEN...

Page 80: ... 225 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...

Page 81: ...ignal 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 U1BE20E0 book Page 3 Tuesday May 12 2009 5 52 PM ...

Page 82: ... 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 ...

Page 83: ...SYSTEM 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 d...

Page 84: ... 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 Maintenance and lubrication periodic 7 3 Maintenance emission control system 7 2 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 7 Parking 6 4 Part locations 3 1 Pass switch 4...

Page 85: ...INDEX V Valve clearance 7 14 Vehicle identification number 10 1 W Wheel bearings checking 7 28 Wheel front 7 34 Wheel rear 7 36 Wheels 7 16 U1BE20E0 book Page 2 Tuesday May 12 2009 5 52 PM ...

Page 86: ...A5 yoko_Blank fm Page 1 Tuesday April 8 2003 11 43 AM ...

Page 87: ...A5 yoko_Blank fm Page 1 Tuesday April 8 2003 11 43 AM ...

Page 88: ...PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2009 05 0 3 1 CR E DIC183 ...

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