Yamaha 2011 Star XV250A Owner'S Manual Download Page 54 | Manualshive

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PERIODIC MAINTENANCE AND ADJUSTMENT

7-18

7

EAU21942

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 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
dealer replace the wheel. Do not
attempt even the smallest repair to
the wheel. A deformed or cracked
wheel must be replaced.

●

The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced. An
unbalanced wheel can result in
poor performance, adverse han-
dling characteristics, and a short-
ened tire life.

EAU22043

Adjusting the clutch lever free
play

The clutch lever free play should mea-
sure 10.0–15.0 mm (0.39–0.59 in) as
shown. Periodically check the clutch le-
ver free play and, if necessary, adjust it
as follows.

1. Slide the rubber cover back at the

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 locknut at the crank-

case.

1. Clutch lever free play

2. Locknut
3. Clutch lever free play adjusting bolt

4. Rubber cover

1

2

3

4

1. Locknut

2. Clutch lever free play adjusting nut (crank-

case)

3. Rubber cover

U1BE21E0.book Page 18 Wednesday, May 12, 2010 2:16 PM

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Summary of Contents for 2011 Star XV250A

Page 1: ...DIC183 XV250A OWNER S MANUAL Read this manual carefully before operating this vehicle 1BE 28199 21 ...

Page 2: ...EAU46090 Read this manual carefully before operating this vehicle This manual should stay with this vehicle if it is sold U1BE21E0 book Page 1 Wednesday May 12 2010 2 16 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: ...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 U1BE21E0 book Page 1 W...

Page 5: ...NUAL 2010 by Yamaha Motor Co Ltd 1st edition April 2010 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan U1BE21E0 book Page 2 Wednesday May 12 2010 2 16 PM ...

Page 6: ... General maintenance and lubrication chart 7 4 Removing and installing the panel 7 8 Checking the spark plugs 7 8 Engine oil and oil filter element 7 10 Cleaning the air filter element 7 12 Adjusting the carburetor 7 14 Adjusting the engine idling speed 7 14 Checking the throttle grip free play 7 15 Valve clearance 7 15 Tires 7 16 Spoke wheels 7 18 Adjusting the clutch lever free play 7 18 Adjusti...

Page 7: ...signal light bulb 7 34 Supporting the motorcycle 7 35 Front wheel 7 35 Rear wheel 7 37 Troubleshooting 7 39 Troubleshooting chart 7 40 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 U1BE21E0 book Page 2 Wednesday May 12 2010 2 16 PM ...

Page 8: ...ehicle 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 U1BE21E0 book Page 1 Wednesday May 12 2010 2 16 PM ...

Page 9: ...should be set as follows 225 2 25 33 200 2 00 29 200 2 00 29 175 1 75 25 3CK 21668 A1 2 1 STATIONARY NOISE TEST INFORMATION TESTED 86 dB A AT 4000 r min SILENCINGSYSTEM YAMAHA IDENTIFICATION 3DM 14711 1BE 2118G 00 U1BE21E0 book Page 2 Wednesday May 12 2010 2 16 PM ...

Page 10: ...assenger 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: ...r 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 also cause instability when passing or being passed by large vehicles Certain access...

Page 14: ...ie downs or suitable straps that are attached to solid parts of the mo torcycle such as the frame or up per front fork triple clamp and not for example to rubber mounted handlebars or turn signals or parts that could break Choose the lo cation for the straps carefully so the straps will not rub against painted surfaces during transport The suspension should be com pressed somewhat by the tie downs...

Page 15: ...page 4 8 3 Fuel tank page 4 5 4 Battery page 7 30 5 Fuses page 7 31 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 U1BE21E0 book Page 1 Wednesday May 12 2010 2 16 PM ...

Page 16: ...3 Rider seat page 4 9 4 Air filter element page 7 12 5 Front turn signal light page 7 34 6 Brake pedal page 4 5 7 Footrest 8 Rear brake light switch page 7 21 9 Owner s tool kit page 7 2 10 Shock absorber assembly spring preload adjusting ring page 4 10 U1BE21E0 book Page 2 Wednesday May 12 2010 2 16 PM ...

Page 17: ...lutch lever 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 15 8 Fuel tank cap page 4 5 U1BE21E0 book Page 3 Wednesday May 12 2010 2 16 PM ...

Page 18: ... 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 come...

Page 19: ...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 EAU12348 Handlebar switches Left 1 Odometer 2 Tripmeter 3 Tripmeter reset knob 4 Speedometer 1 Pass switch PASS 2...

Page 20: ...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 21: ...utch switch which is part of the igni tion circuit cut off system See page 4 11 EAU12871 Shift pedal The shift pedal is located on the left side of the motorcycle and is used in combination 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 22: ...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 23: ...o 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 change yo...

Page 24: ...kly 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 position...

Page 25: ...n 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 counterclock...

Page 26: ...IP 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 acc...

Page 27: ...indicator on the shock absorber EAU15304 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 EWA102...

Page 28: ...the trans 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 sidestand is moved down Periodically check the operation of the ignition circuit cut off system according to the following p...

Page 29: ...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 30: ...efore 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 10 Front brake Check operation If soft or spongy have Yamaha dealer bleed hydraulic system Check lever free play Adjust if ...

Page 31: ...condition and tread depth Check air pressure Correct if necessary 7 16 7 18 Brake and shift pedals Make sure that operation is smooth Lubricate pedal pivoting points if necessary 7 26 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 7 27 Sidestand Make sure that operation is smooth Lubricate pivot if necessary 7 28 Chassis fasteners Make sure ...

Page 32: ...FOR YOUR SAFETY PRE OPERATION CHECKS 5 3 5 Battery Check fluid level Fill with distilled water if necessary 7 30 ITEM CHECKS PAGE U1BE21E0 book Page 3 Wednesday May 12 2010 2 16 PM ...

Page 33: ...ake sure that the engine stop switch is set to RUN 3 Shift the transmission into the neu tral position The neutral indicator light should come on If not ask a Yamaha dealer to check the elec trical 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 ond...

Page 34: ...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 35: ...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 EAU17023 0 1000 km 0 600 mi ...

Page 36: ...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 U1BE21E0 book Page 4 Wednesday May 12 2010 2 16 PM ...

Page 37: ...n 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 to death See page 2 1 for more in formation about carbon monox ide WARNING EWA15460 Brake discs calipers ...

Page 38: ...owner s tool kit are intended to assist you in the performance of preventive maintenance and minor repairs How ever additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly TIP If you do not have the tools or experi ence required for a particular job have a Yamaha dealer perform it for you 1 Owner s tool kit U1BE21E0 book Page 2 Wednesday May 12 2010 ...

Page 39: ...ools 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 Valves Check valve clearance Adjust...

Page 40: ... 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 dam...

Page 41: ...earings Check bearing play and 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 1...

Page 42: ...e 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 Check operation Check throttle grip free play and adjust if necessary Lubricate cable and grip housing 27 Lights signals and switches Check operation Adjust headlight beam NO ITEM CHECK OR MAINTENANCE JOB ODOMETER READING ANNUAL CHECK 1000 k...

Page 43: ...or dusty areas Hydraulic brake service Regularly check 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 U1BE21E0 book Page 7 Wednesday May 12 2010 2 16 PM ...

Page 44: ...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 condition...

Page 45: ...e 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 s...

Page 46: ... oil level through the check window located 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 sever...

Page 47: ...then install and tighten the oil filler cap TIP Be sure to wipe off spilled oil on any parts after the engine and exhaust sys tem have cooled 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 1 Screw 2 Oil filter element cover 1 Oil filter element 2 O ring Tightening torque...

Page 48: ...l level and correct it if necessary EAU32738 Cleaning the air filter element The air filter 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 Di...

Page 49: ...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 50: ...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 51: ...iodi cally check the throttle grip free play and if necessary have a Yamaha deal er 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...

Page 52: ...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 53: ...very carefully and replace it as soon as possible with a high quality product Ride at moderate speeds after changing a tire since the tire surface must first be broken in for it to develop its optimal characteristics Tire information This motorcycle is equipped with spoke wheels and tube tires WARNING EWA10461 The front and rear tires should be of the same make and design other wise the handling c...

Page 54: ...ance adverse han dling characteristics and a short ened tire life EAU22043 Adjusting the clutch lever free play The clutch lever free play should mea sure 10 0 15 0 mm 0 39 0 59 in as shown Periodically check the clutch le ver free play and if necessary adjust it as follows 1 Slide the rubber cover back at the clutch lever 2 Loosen the locknut 3 To increase the clutch lever free play turn the adju...

Page 55: ... 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 56: ...231 After adjusting the brake pedal height 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 pe...

Page 57: ...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 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 ...

Page 58: ... 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 f...

Page 59: ...d 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 driv...

Page 60: ...IP Using the alignment marks on each side of the swingarm make sure that both drive chain pullers are in the same position for proper wheel alignment 5 Tighten the locknuts and then tighten the axle nut to the specified torques 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 ...

Page 61: ...s NOTICE ECA10583 The drive chain must be lubricated after washing the motorcycle riding in the rain or riding in wet areas 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 steam cleaners high pressure washers or inap propriate solvents ECA11121 2 Wipe the drive chain dry 3 Thoroughly lubricate the drive chain wi...

Page 62: ...place damaged cables as soon as possi ble to prevent unsafe conditions EWA10711 EAU49920 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 by a Yamaha dealer at the intervals speci fied in the periodic maintenance chart EAU44272 Checking and lubricating the brake and shift pedals Br...

Page 63: ...er 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 U1BE21E0 book Page 27 Wednesday May 12 2010 2 16 PM ...

Page 64: ...e periodic maintenance and lubrication chart EAU23272 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 Check the 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 a...

Page 65: ...ff the ground See page 7 35 for more information WARNING To avoid injury securely support the vehicle so there is no danger of it falling over EWA10751 2 Hold the lower ends of the front fork legs and try to move them for ward and backward If any free play can be felt have a Yamaha dealer check or repair the steering EAU23291 Checking the wheel bearings The front and rear wheel bearings must be ch...

Page 66: ...en gas Therefore keep sparks flames cigarettes 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 To check the electrolyte level 1 Place the vehicle on a level sur...

Page 67: ...ttery leads are properly con nected to the battery terminals and that the breather hose is properly routed in good condition and not obstructed NOTICE If the breather hose is positioned in such a way that the frame is ex posed to electrolyte or gas ex pelled from the battery the frame could suffer structural and external damages ECA10601 EAU23601 Replacing the fuses The main fuse and the signaling...

Page 68: ...t bulb to keep it free from oil otherwise the transpar ency of the glass the luminosity of the bulb and the bulb life will be adversely affected Thor oughly clean off any dirt and fin gerprints 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 t...

Page 69: ...cover and then connect the coupler 6 Install the headlight unit by install ing the screws 7 Have a Yamaha dealer adjust the headlight beam if necessary EAU24133 Replacing the 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 1 Headlight coupler 2 Headlight bulb cover 1 Headlight bulb holder ...

Page 70: ... 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 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 Tail brake light bulb 1 Screw 1 ...

Page 71: ...ycle 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 under each side of the swi...

Page 72: ... Make sure that there is enough space between the brake pads before insert ing the brake disc and that the slot in the speedometer gear unit fits over the retainer on the fork leg 3 Insert the wheel axle 4 Lower the front wheel so that it is on the ground and then put the sidestand down 5 Tighten the wheel axle to the spec ified torque 6 Tighten the front wheel axle pinch bolt to the specified tor...

Page 73: ...ad justing nut on both ends of the swingarm 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 35 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 bol...

Page 74: ...el so that it is on the ground and then put the sidestand down 6 Tighten the brake torque rod nut to the specified torque 7 Adjust the drive chain slack See page 7 23 8 Tighten the locknuts and then tighten the axle nut to the specified torques 9 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 tha...

Page 75: ...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 76: ... 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 77: ...utlets 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 Alway...

Page 78: ...nd 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 combinat...

Page 79: ...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 from the lens EAU26213 Storage Short term ...

Page 80: ...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 81: ...nt 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 DENSO...

Page 82: ...ear 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...

Page 83: ...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 U1BE21E0 book Page 3 Wednesday May 12 2010 2 16 PM ...

Page 84: ...ation 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 may be used to register your motorcy cle with the licensing authority in your area EAU26470 Model label The model label is affixed to the frame under the rider seat See page 4 9 Record the information on this label in the space ...

Page 85: ...rson 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 device or element of design has been removed or rendered inoper ative by any person U1BE21E0 book Page 2 Wednesd...

Page 86: ... 2 Horn switch 4 3 I Identification numbers 10 1 Ignition circuit cut off system 4 11 Indicator lights 4 1 L Labels location 1 1 M Main switch 4 1 Maintenance and lubrication periodic 7 4 Maintenance emission control system 7 3 Matte color caution 8 1 Model label 10 1 N Neutral indicator light 4 1 Noise regulation for Australia 10 2 P Panel removing and installing 7 8 Parking 6 4 Part locations 3 ...

Page 87: ...INDEX V Valve clearance 7 15 Vehicle identification number 10 1 W Wheel bearings checking 7 29 Wheel front 7 35 Wheel rear 7 37 Wheels 7 18 U1BE21E0 book Page 2 Wednesday May 12 2010 2 16 PM ...

Page 88: ...A5 yoko_Blank fm Page 1 Tuesday April 8 2003 11 43 AM ...

Page 89: ...A5 yoko_Blank fm Page 1 Tuesday April 8 2003 11 43 AM ...

Page 90: ...PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2010 05 0 3 1 CR E DIC183 ...

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