Yamaha 2011 WR250X Owner'S Manual Download | Manualshive

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PERIODIC MAINTENANCE AND ADJUSTMENT

7-23

7

EAU44820

Checking the shift pedal

The operation of the shift pedal should
be checked before each ride. If opera-
tion is not smooth, have a Yamaha
dealer check the vehicle.

EAU22273

Brake light switches

The brake light, which is activated by
the brake pedal and brake lever, should
come on just before braking takes ef-
fect. If necessary, adjust the rear brake
light switch as follows, but the front
brake light switch should be adjusted
by a Yamaha dealer.
Turn the rear brake light switch adjust-
ing nut while holding the rear brake light
switch in place. To make the brake light
come on earlier, turn the adjusting nut
in direction (a). To make the brake light
come on later, turn the adjusting nut in
direction (b).

EAU22392

Checking the front and rear
brake pads

The front and rear brake pads must be
checked for wear at the intervals spec-
ified in the periodic maintenance and
lubrication chart.

EAU22430

Front brake pads

Each front brake pad is provided with
wear indicator grooves, which allow
you to check the brake pad wear with-
out having to disassemble the brake.
To check the brake pad wear, check
the wear indicator grooves. If a brake
pad has worn to the point that the wear

1. Rear brake light switch

2. Rear brake light switch adjusting nut

1

2

(b)

(a)

1. Brake pad wear indicator groove

1

1

U32D25E0.book Page 23 Wednesday, January 20, 2010 10:59 AM

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Summary of Contents for 2011 WR250X

Page 1: ...DIC183 WR250XZ OWNER S MANUAL Read this manual carefully before operating this vehicle 32D 28199 25 ...

Page 2: ...EAU46090 Read this manual carefully before operating this vehicle This manual should stay with this vehicle if it is sold U32D25E0 book Page 1 Wednesday January 20 2010 10 59 AM ...

Page 3: ...n 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 p...

Page 4: ... 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 U32D25E0 book Page 1 Wed...

Page 5: ...L 2010 by Yamaha Motor Co Ltd 1st edition January 2010 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan U32D25E0 book Page 2 Wednesday January 20 2010 10 59 AM ...

Page 6: ...maintenance chart for the emission control system 7 2 General maintenance and lubrication chart 7 3 Removing and installing panels 7 7 Checking the spark plug 7 9 Engine oil and oil filter element 7 10 Coolant 7 13 Cleaning the air filter element and check hose 7 16 Adjusting the engine idling speed 7 17 Checking the throttle cable free play 7 18 Valve clearance 7 18 Tires 7 19 Spoke wheels 7 20 A...

Page 7: ...ense plate light bulb 7 36 Replacing an auxiliary light bulb 7 36 Supporting the motorcycle 7 37 Front wheel 7 37 Rear wheel 7 38 Troubleshooting 7 40 Troubleshooting charts 7 41 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 U32D25E0 book Page 2 Wed...

Page 8: ...le 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 1 4 3 U32D25E0 book Page 1 Wednesday January 20 2010 10 59 AM ...

Page 9: ...n Sie die Bedienungsanleitung bevor Sie dieses Fahrzeug fahren Antes de conducir este vehículo lea el Manual del Propietario 4AA 22259 40 Cold tire normal pressure should be set as follows Up to 90 kg 198 lbs load 200 kPa 2 00 kgf cm2 29 psi 200 kPa 2 00 kgf cm2 29 psi 90 kg 198 lbs 200 kPa 2 00 kgf cm2 29 psi 225 kPa 2 25 kgf cm2 33 psi maximum load 32C 21668 10 1 2 3 4 U32D25E0 book Page 2 Wedne...

Page 10: ...LOCATION OF IMPORTANT LABELS 1 3 1 1 2 U32D25E0 book Page 3 Wednesday January 20 2010 10 59 AM ...

Page 11: ...ION OF IMPORTANT LABELS 1 4 1 STATIONARY NOISE TEST INFORMATION TESTED 88 dB A AT 5000 r min SILENCINGSYSTEM YAMAHA IDENTIFICATION 32D 32D 2118G 20 1 2 U32D25E0 book Page 4 Wednesday January 20 2010 10 59 AM ...

Page 12: ...senger 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 yo...

Page 13: ...vy 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 engine or exhaust sys tem become very hot during or af ter operation and can cause burns A passenge...

Page 14: ...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 large or heavy items to the handlebar front fork or f...

Page 15: ...ar 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 also cause instability when passing or being passed by large vehicles Certain ac...

Page 16: ...e downs or suitable straps that are attached to solid parts of the motorcycle such as the frame or upper front fork triple clamp and not for example to rubber mounted handlebars or turn sig nals or parts that could break Choose the location for the straps carefully so the straps will not rub against painted sur faces during transport The suspension should be com pressed somewhat by the tie downs i...

Page 17: ...e 7 32 3 Coolant reservoir page 7 13 4 Shock absorber assembly compression damping force adjusting screw page 4 17 5 Battery page 7 31 6 Main fuse page 7 32 7 Owner s tool kit page 7 1 8 Helmet holder page 4 14 9 Front fork compression damping force adjusting screw page 4 14 U32D25E0 book Page 1 Wednesday January 20 2010 10 59 AM ...

Page 18: ... Air filter element page 7 16 3 Rear brake light switch page 7 23 4 Bleed screw page 4 16 5 Engine oil filler cap page 7 10 6 Engine oil level check window page 7 10 7 Shock absorber assembly rebound damping force adjusting knob page 4 17 U32D25E0 book Page 2 Wednesday January 20 2010 10 59 AM ...

Page 19: ... page 4 9 2 Left handlebar switches page 4 8 3 Main switch steering lock page 4 1 4 Multi function display page 4 3 5 Right handlebar switches page 4 8 6 Brake lever page 4 10 7 Throttle grip page 7 18 8 Fuel tank cap page 4 11 U32D25E0 book Page 3 Wednesday January 20 2010 10 59 AM ...

Page 20: ...ne is started and stays on until the key is turned to OFF even if the engine stalls EAU10661 OFF All electrical systems are off The key can be removed WARNING EWA10061 Never turn the key to OFF or LOCK while the vehicle is moving Otherwise the electrical systems will be switched off which may result in loss of control or an accident EAU10683 LOCK The steering is locked and all electrical systems a...

Page 21: ...imately 2 1 L 0 55 US gal 0 46 Imp gal When this occurs refuel as soon as possible The electrical circuit of the warning light can be checked by turning the key to ON The warning light should come on for a few seconds and then go off If the warning light does not come on initially when the key is turned to ON or if the warning light remains on have a Yamaha dealer check the electrical circuit EAU1...

Page 22: ... detected in the electrical circuit monitoring the engine If this oc curs have a Yamaha dealer check the self diagnosis system See page 4 8 for an explanation of the self diagnosis device The electrical circuit of the warning light can be checked by turning the key to ON The warning light should come on for a few seconds and then go off If the warning light does not come on initially when the key ...

Page 23: ...can be calibrated to pro vide a more accurate tripmeter reading a stopwatch which shows the time that has been accumulated since the start of stopwatch measure ment a self diagnosis device TIP Be sure to turn the key to ON be fore using the SELECT 1 SE LECT 2 and RESET buttons When the key is turned to ON all of the display segments of the multi function display will appear and then disappear in o...

Page 24: ...tripmeter TIP To change from the measurement mode to the basic mode the stopwatch and the distance compensation tripme ter must be stopped To reset a tripmeter select it by push ing the SELECT 2 button and then push the RESET button for at least one second If you do not reset the fuel reserve tripmeter manually it will reset itself automatically and the display will return to the prior mode after ...

Page 25: ...p eration stop it by pushing the SE LECT 1 button and SELECT 2 button together 2 Push the SELECT 1 button and SELECT 2 button together for at least two seconds to change to the basic mode Measurement mode for the stop watch When the measurement mode is se lected the stopwatch is displayed and it can be started manually or automatical ly Manual start The manual start is the default setting for the ...

Page 26: ...stances specified on the enduro course map will help famil iarize the rider with the course In addi tion calibrating the meter may also be necessary when using tire wheel chain sprocket sizes etc other than specified For further information con cerning the use of this meter please consult your nearby Yamaha dealer Calibrate the distance compensation tripmeter as follows To increase the reading pus...

Page 27: ...evice for various electrical cir cuits If a problem is detected in any of those circuits the engine trouble warning light will come on and the display will indi cate an error code If the display indicates any error codes note the code number and then have a Yamaha dealer check the vehicle NOTICE ECA11590 If the display indicates an error code the vehicle should be checked as soon as possible in or...

Page 28: ... vehicle overturns or when the throttle cable is stuck EAU12711 Start switch Push this switch to crank the engine with the starter See page 6 1 for start ing instructions prior to starting the en gine EAU41700 The engine trouble warning light will come on when the key is turned to ON and the start switch is pushed but this does not indicate a malfunction EAU12820 Clutch lever The clutch lever is l...

Page 29: ...sh transmission equipped on this motorcycle EAU12890 Brake lever The brake lever is located at the right handlebar grip To apply the front brake pull the lever toward the handle bar grip EAU12941 Brake pedal The brake pedal is on the right side of the motorcycle To apply the rear brake press down on the brake pedal 1 Shift pedal 1 1 Brake lever 1 1 Brake pedal 1 U32D25E0 book Page 10 Wednesday Jan...

Page 30: ... riding Leaking fuel is a fire hazard EAU13212 Fuel Make sure there is sufficient gasoline in the tank WARNING EWA10881 Gasoline and gasoline vapors are extremely flammable To avoid fires and explosions and to reduce the risk of injury when refueling follow these instructions 1 Before refueling turn off the en gine and be sure that no one is sit ting on the vehicle Never refuel while smoking or wh...

Page 31: ...pills on your clothing change your clothes EAU13390 NOTICE ECA11400 Use only unleaded gasoline The use of leaded gasoline will cause severe damage to internal engine parts such as the valves and piston rings as well as to the exhaust system Your Yamaha engine has been de signed to use premium unleaded gaso line with a research octane number of 95 or higher If knocking or pinging oc curs use a gaso...

Page 32: ...ot exhaust system Make sure that the exhaust sys tem has cooled down before do ing any maintenance work Do not allow the engine to idle more than a few minutes Long idling can cause a build up of heat NOTICE ECA10701 Use only unleaded gasoline The use of leaded gasoline will cause unre pairable damage to the catalytic converter EAU46280 Seat To remove the seat Remove the bolts and then pull the se...

Page 33: ...ARNING EWA10180 Always adjust both fork legs equal ly otherwise poor handling and loss of stability may result This front fork is equipped with rebound damping force adjusting screws and compression damping force adjusting screws NOTICE ECA10101 To avoid damaging the mechanism do not attempt to turn beyond the maximum or minimum settings Rebound damping force To increase the rebound damping force ...

Page 34: ...xactly match the above spec ifications due to small differences in production the actual number of clicks always represents the entire adjusting range To obtain a precise adjustment 1 Rebound damping force adjusting screw Rebound damping setting Minimum soft 17 click s in direction b Standard 10 click s in direction b Maximum hard 1 click s in direction b With the adjusting screw fully turned in d...

Page 35: ... rough condi tions the air temperature and pressure in the front fork will rise This will in crease the spring preload and harden the front suspension If this occurs bleed the front fork as follows 1 Elevate the front wheel by placing a suitable stand under the engine TIP When bleeding the front fork there should be no weight on the front end of the vehicle 2 Remove the bleed screws and al low all...

Page 36: ...mping force To increase the rebound damping force and thereby harden the rebound damp ing turn the adjusting knob in direction a To decrease the rebound damping force and thereby soften the rebound damping turn the adjusting knob in di rection b Compression damping force To increase the compression damping force and thereby harden the compres sion damping turn the adjusting screw in direction a To...

Page 37: ...ormance Do not dispose of a damaged or worn out shock absorber as sembly yourself Take the shock absorber assembly to a Yamaha dealer for any service EAU41941 EXUP system This model is equipped with Yamaha s EXUP EXhaust Ultimate Power valve system This system boosts engine power by means of a valve that regu lates the inner diameter of the exhaust pipe The EXUP system valve is con stantly adjuste...

Page 38: ...designed to assist the operator in fulfilling the respon sibility of raising the sidestand be fore starting off Therefore check this system regularly as described below and have a Yamaha dealer re pair it if it does not function proper ly EAU44892 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...

Page 39: ...ove 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 switch ...

Page 40: ... vehicle check the following points ITEM CHECKS PAGE Fuel Check fuel level in fuel tank Refuel if necessary Check fuel line for leakage 4 11 Engine oil Check oil level in engine If necessary add recommended oil to specified level Check vehicle for oil leakage 7 10 Coolant Check coolant level in reservoir If necessary add recommended coolant to specified level Check cooling system for leakage 7 13 ...

Page 41: ...st cable free play and lubricate cable and grip housing 7 18 7 28 Control cables Make sure that operation is smooth Lubricate if necessary 7 27 Drive chain Check chain slack Adjust if necessary Check chain condition Lubricate if necessary 7 25 7 27 Wheels and tires Check for damage Check tire condition and tread depth Check air pressure Correct if necessary 7 19 7 20 Shift pedal Make sure that ope...

Page 42: ...l 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 system If system is not working correctly have Yamaha dealer check vehicle 4 19 ITEM CHECKS PAGE U32D25E0 book Page 3 Wednesday January 20 2010 10 59 AM ...

Page 43: ... if left idling for 20 minutes In this case the multi function display indicates error code 70 but this is not a mal function Push the start switch to clear the error code and to restart the engine EAU45125 Starting the engine In order for the ignition circuit cut off system to enable starting one of the following conditions must be met The transmission is in the neutral position The transmission ...

Page 44: ...ne power available for starting off accelerating climbing hills etc The gear positions are shown in the il lustration TIP To shift the transmission into the neu tral position 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 ...

Page 45: ...ollow 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 Avoid prolonged operation ...

Page 46: ...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 U32D25E0 book Page 4 Wednesday January 20 2010 10 59 AM ...

Page 47: ...WA15121 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 to death See page 2 1 for more in formation about carbon monox ide WARNING...

Page 48: ... 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 hoses for cracks or damage 2 Spark plug Check condition Clean and regap Replace 3 Valves Check valve clearance Adjust Every 40000 km 24000 mi 4 Fuel inj...

Page 49: ...or fluid leakage Adjust brake lever free play Replace brake pads Whenever worn to the limit 4 Rear brake Check operation fluid level and vehicle for fluid leakage Replace brake pads Whenever worn to the limit 5 Brake hoses Check for cracks or damage Replace Every 4 years 6 Wheels Check runout spoke tightness and for damage Tighten spokes if necessary 7 Tires Check tread depth and for dam age Repla...

Page 50: ...p based grease Every 50000 km 30000 mi 12 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 13 Brake lever pivot shaft Lubricate with silicone grease 14 Brake pedal pivot shaft Lubricate with lithium soap based grease 15 Clutch lever pivot shaft Lubricate with lithium soap based grease 16 Sidestand Check operation Lubricate with lithium soap based grease 17 Sidestan...

Page 51: ...d vehicle for coolant leakage Change Every 3 years 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 JOB ...

Page 52: ...usty 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 cylinders and calipers and change the brake fluid Replace the brake hoses every four years and if cracked or damaged U32D25E0 book Page 6 Wednesday January 20 2010 10 59 AM ...

Page 53: ...maintenance jobs described in this chapter Refer to this section each time a panel needs to be removed and installed EAU45131 Panel A To remove the panel 1 Remove the seat See page 4 13 2 Remove the bolts and collars 1 Panel A 2 Panel B 1 2 1 Panel C 1 Panel D 1 1 1 Bolt 2 Collar 2 1 2 1 U32D25E0 book Page 7 Wednesday January 20 2010 10 59 AM ...

Page 54: ...rs and bolts 2 Install the seat Panel B To remove the panel 1 Remove the seat See page 4 13 2 Remove the bolt and then remove the panel as shown To install the panel 1 Place the panel in the original posi tion and then install the bolt 2 Install the seat Panel C To remove the panel 1 Remove the bolts 1 Bolt 2 Panel A 1 2 1 Bolt 2 Panel B 1 2 1 Panel C 2 Bolt 1 2 2 U32D25E0 book Page 8 Wednesday Ja...

Page 55: ...deposits will cause any spark plug to slowly erode it should be removed and checked in ac cordance with the periodic mainte nance and lubrication chart In addition the condition of the spark plug can re veal the condition of the engine The porcelain insulator around the cen ter electrode of the spark plug should be a medium to light tan the ideal color when the vehicle is ridden normally If the sp...

Page 56: ... cap simply twist it back and forth while pulling it out to install it twist it back and forth while pushing it in EAU45143 Engine oil and oil filter ele ment The engine oil level should be checked before each ride In addition the oil must be changed and the oil filter ele ment replaced at the intervals specified in the periodic maintenance and lubri cation chart To check the engine oil level 1 Pl...

Page 57: ...ve the engine oil filler cap the engine oil drain bolt and its gasket to drain the oil from the crankcase TIP Skip steps 5 8 if the oil filter element is not being replaced 5 Remove the oil filter element cover by removing the bolts 6 Remove the oil filter element and O rings 7 Install a new oil filter element and new O rings 1 Engine oil filler cap 2 Maximum level mark 3 Minimum level mark 4 Engi...

Page 58: ...ase 11 Start the engine and then let it idle for several minutes while checking it for oil leakage If oil is leaking im mediately turn the engine off and check for the cause 12 Turn the engine off wait a few min utes until the oil settles and then check the oil level and correct it if necessary NOTICE ECA11231 After changing the engine oil make sure to check the oil pressure as de scribed below Lo...

Page 59: ... level in the cool ant reservoir TIP The coolant should be between the minimum and maximum level marks 3 If the coolant is at or below the minimum level mark remove pan el C See page 7 7 remove the reservoir cap add coolant to the maximum level mark and then in stall the reservoir cap and the pan el WARNING Remove only the coolant reservoir cap Never at tempt to remove the radiator cap when the en...

Page 60: ...he engine to collect the used coolant 4 Remove the radiator cap retaining bolt and radiator cap WARNING Never attempt to remove the ra diator cap when the engine is hot EWA10381 5 Remove the coolant reservoir by removing the bolts 6 Remove the coolant reservoir cap 7 Drain the coolant from the coolant reservoir by turning it upside down 8 Install the coolant reservoir by placing it in the original...

Page 61: ...s the top of the radia tor and then install the radiator cap and its retaining bolt 17 Check the coolant level in the res ervoir If necessary remove the coolant reservoir cap add coolant to the maximum level mark and then install the cap 18 Start the engine and then check the vehicle for coolant leakage If coolant is leaking have a Yamaha dealer check the cooling system 19 Install the panels 1 Coo...

Page 62: ...ver outward as shown 3 Unhook the holding clip and then pull the air filter element out 4 Remove the sponge material from the air filter element frame clean it with solvent and then squeeze the remaining solvent out WARNING Use only a dedicated parts cleaning solvent To avoid the risk of fire or explosion do not use gasoline or solvents with a low flash point EWA10431 NOTICE To avoid damaging the ...

Page 63: ...k the hose at the bottom of the air filter case for accumulated dirt or water 2 If dirt or water is visible remove the hose clean it and then install it EAU45322 Adjusting the engine idling speed The engine idling speed must be checked and if necessary adjusted as follows TIP A digital tachometer is needed to make this adjustment 1 Position the digital tachometer at the ignition coil which is loca...

Page 64: ...lly check the throttle cable 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 Idle adjusting screw Engi...

Page 65: ...model WARNING EWA10511 Never overload your vehicle Opera tion of an overloaded vehicle could cause an accident Tire inspection The tires must be checked before each ride If the tire shows crosswise lines minimum tread depth if the tire has a nail or glass fragments in it or if the sidewall is cracked have a Yamaha dealer replace the tire immediately TIP The tire tread depth limits may differ from ...

Page 66: ...as soon as possible with a high quality product 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 regarding the specified wheels The wheel rims should be checked for cracks bends or wa...

Page 67: ...h lever free play turn the clutch lever free play adjusting bolt in direction 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 in di rection a to loosen the clutch ca ble 5 Slide the rubber cover back further down the clutch cable and then l...

Page 68: ...e locknut 3 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 4 Tighten the locknut and then slide the rubber cover to its original po sition WARNING EWA10630 After adjusting the brake lever free play check the free play and make sure that the brake is working properly A...

Page 69: ...e 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 EAU22392 Checking the front and rear brake pads The front and rear brake pads must be checked for wear at the intervals spec ified in the periodic maintenance and lubrication chart EAU22430 Front brake pads Each front brake pad is provided with...

Page 70: ... become ineffective Before riding check that the brake fluid is above the minimum level mark and replenish if necessary A low brake fluid level may indicate worn brake pads and or brake system leakage If the brake fluid level is 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 brake f...

Page 71: ...er cylinders and calipers as well as the brake hoses re placed at the intervals listed below or whenever they are damaged or leak ing Oil seals Replace every two years Brake hoses Replace every four years EAU22760 Drive chain slack The drive chain slack should be checked before each ride and adjusted if necessary EAU47222 To check the drive chain slack 1 Place the motorcycle on the side stand TIP ...

Page 72: ...l as other vital parts of the motorcycle and can lead to chain slippage or breakage To prevent this from occurring keep the drive chain slack with in the specified limits ECA10571 TIP 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 3 Tighten the axle nut then the lock nuts to their specified torques ...

Page 73: ...ts 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 ea...

Page 74: ...ler at the intervals speci fied in the periodic maintenance chart EAU23142 Checking and lubricating the brake and clutch levers Brake lever Clutch lever The operation of the brake and clutch levers should be checked before each ride and the lever pivots should be lu bricated if necessary Recommended lubricants Brake lever Silicone grease Clutch lever Lithium soap based grease U32D25E0 book Page 28...

Page 75: ... 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 EAUM1651 Lubricating the swingarm piv ots The swingarm pivots must be lubricat ed by a Yamaha dealer at the intervals specified in the periodic maintenance and lubr...

Page 76: ... fork compresses and rebounds smoothly NOTICE ECA10590 If any damage is found or the front fork does not operate smoothly have a Yamaha dealer check or re pair it EAU23283 Checking the steering Worn or loose steering bearings may cause danger Therefore the operation of the steering must be checked as fol lows at the intervals specified in the pe riodic maintenance and lubrication chart 1 Place a s...

Page 77: ...ns sul furic acid which causes severe burns Avoid any contact with skin eyes or clothing and al ways shield your eyes when working near batteries In case of contact administer the fol lowing FIRST AID EXTERNAL Flush with plenty of water INTERNAL Drink large quan tities of water or milk and im mediately call a physician EYES Flush with water for 15 minutes and seek prompt medical attention Batterie...

Page 78: ...it and then place it in a cool dry place NOTICE When removing the battery be sure the key is turned to OFF then discon nect the negative lead before disconnecting the positive lead ECA16302 2 If the battery will be stored for more than two months check it at least once a month and fully charge it if necessary 3 Fully charge the battery before in stallation NOTICE ECA16530 Always keep the battery c...

Page 79: ...OTICE ECA10650 Take care not to damage the follow ing parts Headlight bulb Do not touch the glass part of the headlight 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...

Page 80: ...eadlight bulb into po sition and then secure it with the bulb holder 5 Install the headlight bulb cover and then connect the coupler 6 Install the headlight cowling to gether with the headlight unit by placing it in the original position and then installing the bolts 7 Have a Yamaha dealer adjust the headlight beam if necessary 1 Do not touch the glass part of the bulb 1 Bolt 1 1 1 Headlight coupl...

Page 81: ...e turn signal light lens by removing the screw 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 screw NOTICE Do not over tighten the screw otherwise the lens may break ECA11191 1 Screw 2 Turn signal light lens 1 2 1 Turn signal light bulb 1 U32...

Page 82: ...light unit by installing the screws EAU45222 Replacing an auxiliary light bulb If the auxiliary light bulb burns out re place it as follows 1 Remove the headlight unit See page 7 33 2 Remove the auxiliary light socket together with the bulb by pulling it out 3 Remove the burnt out bulb by pull ing it out 4 Insert a new bulb into the socket 5 Install the auxiliary light socket to gether with the bu...

Page 83: ...dditional motorcycle stand is not available by placing a jack un der the frame in front of the rear wheel 2 Raise the front wheel off the ground by using a motorcycle stand To service the rear wheel Raise the rear wheel off the ground by using a motorcycle stand or if a motor cycle stand is not available by placing a jack either under each side of the frame in front of the rear wheel or under each...

Page 84: ...ront wheel so that it is on the ground and then put the sidestand down 5 Tighten the axle nut and the wheel axle pinch bolts to their specified torques 6 Push down hard on the handlebar several times to check for proper fork operation EAU25080 Rear wheel EAU45182 To remove the rear wheel WARNING EWA10821 To avoid injury securely support the vehicle so there is no danger of it falling over 1 Loosen...

Page 85: ...eel 1 Install the wheel and the brake cal iper bracket by inserting the wheel axle from the left hand side TIP Make sure that the retainer on the brake caliper bracket is inserted into the slot in the swingarm Make sure that there is enough space between the brake pads be fore installing the wheel 2 Install the drive chain onto the rear sprocket 3 Install the washer and the axle nut 4 Lower the re...

Page 86: ...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 make sure there are no open fl...

Page 87: ...amaha dealer check the vehicle Remove the spark plug and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gap or replace the spark plug Have a Yamaha dealer check the vehicle The engine does not start Have a Yamaha dealer check the vehicle The engine does not start Check the battery Operate the electric starter 4 Battery The engine turns over quickly The engine ...

Page 88: ...ssing sound has stopped press down on the cap while turning it counterclockwise and then remove the cap TIP If coolant is not available tap water can be temporarily used instead provided that it is changed to the recommended coolant as soon as possible Wait until the engine has cooled Check the coolant level in the reservoir and radiator The coolant level is OK The coolant level is low Check the c...

Page 89: ...tlet with a plastic bag after the engine has cooled down 2 Make sure that all caps and covers as well as all electrical couplers and connectors including the spark plug cap are tightly in stalled 3 Remove extremely stubborn dirt like oil burnt onto the crankcase with a degreasing agent and a brush but never apply such prod ucts onto seals gaskets sprock ets the drive chain and wheel axles Always r...

Page 90: ...d detergent 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 corrosiv...

Page 91: ...c 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 EAU43201 Storage Short term Always sto...

Page 92: ...k plug elec trodes while turning the en gine over EWA10951 4 Lubricate all control cables and the pivoting points of all levers and pedals as well as of the side stand centerstand 5 Check and if necessary correct the tire air pressure and then lift the motorcycle so that both of its wheels are off the ground Alterna tively turn the wheels a little every month in order to prevent the tires from bec...

Page 93: ...oil filter element replacement 1 40 L 1 48 US qt 1 23 Imp qt Cooling system Coolant reservoir capacity up to the maximum level mark 0 25 L 0 26 US qt 0 22 Imp qt Radiator capacity including all routes 0 90 L 0 95 US qt 0 79 Imp qt Air filter Air filter element Wet element Fuel Recommended fuel Premium unleaded gasoline only Fuel tank capacity 7 6 L 2 01 US gal 1 67 Imp gal Fuel reserve amount 2 1 ...

Page 94: ...psi Loading condition 90 185 kg 198 408 lb Front 200 kPa 2 00 kgf cm 29 psi Rear 225 kPa 2 25 kgf cm 33 psi Front wheel Wheel type Spoke wheel Rim size 17M C x MT3 00 Rear wheel Wheel type Spoke wheel Rim size 17M C x MT4 00 Front brake Type Single disc brake Operation Right hand operation Recommended fluid DOT 4 Rear brake Type Single disc brake Operation Right foot operation Recommended fluid DO...

Page 95: ... 5 0 W 1 Meter lighting EL Electroluminescent Neutral indicator light LED High beam indicator light LED Turn signal indicator light LED Fuel level warning light LED Coolant temperature warning light LED Engine trouble warning light LED Fuses Main fuse 30 0 A Headlight fuse 15 0 A Signaling system fuse 10 0 A Ignition fuse 7 5 A Radiator fan fuse 7 5 A Fuel injection system fuse 7 5 A Backup fuse 7...

Page 96: ...entification 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 EAU26460 Model label The model label is affixed to the loca tion shown Record the information on this label in the space provided This in ...

Page 97: ...on 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 U32D25E0 book Page 2 Wednesday...

Page 98: ...ing 7 33 Helmet holder 4 14 High beam indicator light 4 2 Horn switch 4 9 I Identification numbers 10 1 Ignition circuit cut off system 4 19 Indicator lights and warning lights 4 2 L Labels location 1 1 License plate light bulb replacing 7 36 M Main switch steering lock 4 1 Maintenance and lubrication periodic 7 3 Maintenance emission control system 7 2 Matte color caution 8 1 Model label 10 1 Mul...

Page 99: ...INDEX V Valve clearance 7 18 Vehicle identification number 10 1 W Wheel bearings checking 7 31 Wheel front 7 37 Wheel rear 7 38 Wheels 7 20 U32D25E0 book Page 2 Wednesday January 20 2010 10 59 AM ...

Page 100: ...A5 yoko_Blank fm Page 1 Tuesday April 8 2003 11 43 AM ...

Page 101: ...A5 yoko_Blank fm Page 1 Tuesday April 8 2003 11 43 AM ...

Page 102: ...PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2010 02 0 3 1 CR E DIC183 ...

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