Yamaha MT-25 Owner'S Manual Download Page 40

Page: 40 / 93

5-3

For your safety – pre-operation checks

Chassis fasteners

Make sure that all nuts, bolts and screws are properly tightened.

Tighten if necessary.

—

Instruments, lights, signals
and switches

Check operation.

Correct if necessary.

—

Sidestand switch

Check operation of ignition circuit cut-off system.

If system is not working correctly, have Yamaha dealer check vehicle.

4-18

Sidestand

Make sure that operation is smooth.

Lubricate pivot if necessary.

7-26

Summary of Contents for MT-25

Page 1: ...MTN250 OWNER S MANUAL Read this manual carefully before operating this vehicle BDA F8199 30 DI ...

Page 2: ...s from trouble and injury In addition the many tips given in this manual will help keep your motorcycle in the best possible condition If you have any further questions do not hesitate 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 c...

Page 3: ... used to alert you to potential personal injury hazards Obey 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 e...

Page 4: ...AUN0430 MTN250 OWNER S MANUAL 2020 by Yamaha Motor Co Ltd 1st edition June 2020 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Malaysia ...

Page 5: ...nce and adjustment 7 1 Owner s tool kit 7 1 Periodic maintenance chart for the emission control system 7 2 General maintenance and lubrication chart 7 4 Checking the spark plugs 7 9 Engine oil and oil lter cartridge 7 10 Coolant 7 13 Replacing the air lter element and cleaning the check hose 7 14 Checking the throttle grip free play 7 16 Valve clearance 7 16 Tires 7 16 Cast wheels 7 18 Adjusting t...

Page 6: ...ulb 7 32 Supporting the motorcycle 7 33 Front wheel 7 33 Rear wheel 7 34 Troubleshooting 7 36 Troubleshooting charts 7 37 Motorcycle care and storage 8 1 Matte color caution 8 1 Care 8 1 Storage 8 3 tions 9 1 Consumer information 10 1 Identi cation numbers 10 1 Vehicle data recording 10 2 Index 11 1 ...

Page 7: ... important labels 1 1 1 EAUN2190 Read and understand all of the labels on your vehicle They contain important information for safe and proper operation of your vehicle Never remove any labels from your vehicle 1 2 ...

Page 8: ...Location of important labels 1 2 1 100kPa 1bar kPa psi kPa psi 200 29 225 33 200 29 225 33 2 1 Before you operate this vehicle read the owner s manual BDA1 F8199 E0 BDA1 F8199 E0 ...

Page 9: ...ime you use the vehicle to make sure it is in safe operating condition Failure to inspect or maintain the vehi cle properly increases the possibility of an accident or equipment damage See page 5 1 for a list of pre operation checks t This motorcycle is designed to carry the operator and a passen ger t The failure of motorists to detect and recognize motorcycles in traf fic is the predominating ca...

Page 10: ...eep both feet on the passenger footrests Never carry a passenger unless he or she can firmly place both feet on the passenger footrests t Never ride under the influence of alcohol or other drugs t This motorcycle is designed for on road use only It is not suitable for off road use Protective Apparel The majority of fatalities from motorcy cle accidents are the result of head in juries The use of a...

Page 11: ...n when adding cargo or accessories to your motorcycle Use extra care when riding a motorcycle that has added cargo or accessories Here along with the information about accessories below are some general guidelines to follow if loading cargo to your motorcycle The total weight of the operator pas senger accessories and cargo must not exceed the maximum load limit Operation of an overloaded vehicle ...

Page 12: ...d to your vehicle that change any of the vehicle s design or operation characteristics can put you and others at greater risk of serious injury or death You are responsible for injuries related to changes in the vehicle Keep the following guidelines in mind as well as those provided under Load ing when mounting accessories t Never install accessories or carry cargo that would impair the per forman...

Page 13: ...e 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 location for the straps carefully so the straps will not rub against painted surfaces during transport t The suspension should be com pressed somewhat by the tie downs...

Page 14: ... 2 6 2 Correct usage Wrong usage Types of helmets and their usage t Full type use only for riding at low to mid range speeds t Full face type use for riding at mid range to high speeds ZAUU0003 ZAUU0007 ZAUU0005 ZAUU0006 ...

Page 15: ...ge 7 30 3 Owner s tool kit page 7 1 4 Passenger seat lock page 4 14 5 Storage compartment page 4 16 6 Shock absorber assembly spring preload adjusting ring page 4 17 7 Shift pedal page 4 11 8 Engine oil drain bolt page 7 10 9 Engine oil filter cartridge page 7 10 1 2 3 4 5 9 8 7 6 ...

Page 16: ...ery page 7 29 3 Fuel tank cap page 4 12 5 Headlight page 7 32 6 Engine oil filler cap page 7 10 7 Engine oil level check window page 7 10 8 Brake pedal page 4 12 9 Rear brake light switch page 7 20 10 Rear brake fluid reservoir page 7 21 4 Dimmer 1 2 10 9 8 7 6 3 4 5 ...

Page 17: ...r page 4 11 2 Left handlebar switches page 4 10 3 Multi function meter unit page 4 3 4 Main switch steering lock page 4 1 5 Front brake fluid reservoir page 7 21 6 Right handlebar switches page 4 10 7 Throttle grip page 7 16 8 Brake lever page 4 11 1 2 4 5 6 7 8 3 ...

Page 18: ...ng the engine t 5IF IFBEMJHIUT XJMM UVSO PO BVUPNBUJD when the engine is turned on EAU54301 OFF All electrical systems are PGG The key can be removed WARNING EWA16371 Never turn the key to OFF or LOCK while the vehicle is moving Other wise the electrical systems will be switched off which may result in loss of control or an accident EAU60861 LOCK The steering is locked and all electrical systems a...

Page 19: ...eam of the headlight is switched on EAU62530 Oil pressure warning light This warning light comes on if the en gine oil pressure is low If the warning light does not come on initially when the key is turned to ON have a Yamaha dealer check the elec trical circuit NOTICE ECA21210 If the warning light comes on when the engine is running stop the en gine immediately and check oil level If the oil leve...

Page 20: ...he engine trouble warning light will come on while the start switch is pushed but this does not indi cate a malfunction t EAU80372 Shift light indicator O This light can be set to come on and go off at select engine speeds The engine speed that drives the lights on or off is set TIP When the vehicle is turned on the light will come on for a few seconds and then go off If the light does not come on...

Page 21: ...te the engine in the ta chometer red zone Red zone 14000 r min and above 1 Tachometer 2 Tachometer red zone 1 2 Change the units displayed The units shown can be changed bet ween kilometers and miles To change the units displayed press SELECT button until the units change MPH MPG mile Fuel meter The fuel meter indicates the amount of fuel in the fuel tank The display segments of the fuel meter dec...

Page 22: ... increases If the hot segment flickers immediately turn off the engine and allow the engine to cool see pages 7 38 Coolant temperature meter The coolant temperature meter indi cates the temperature of the coolant 2 Use the RESET button for adju sting the clock 1 Clock 1 Coolant temperature meter 1 MPH MPG mile 1 MPH MPG mile Transmission gear display This display shows the selected gear The neutra...

Page 23: ...tripmeter you want to reset and then push RESET button TIP t The tripmeters will lock at 9999 9 but can be manually reset Fuel reserve tripmeter When the fuel level becomes low the last segment of the fuel meter will start flashing The fuel reserve tripmeter TRIP F will automatically appear and start counting the distance traveled from that point To reset the fuel reserve tripmeter push the RESET ...

Page 24: ...ion display can be set to either MPG km L or L 100 km 1 1 Average fuel consumption display The average fuel consumption display can be set to either AVE_ _ _ MPG AVE_ _ _ km L or AVE_ _ _ L 100 km This display shows the average fuel consumption since it was last reset 1 MPG The distance that can be traveled on 1 0 Imp gal of fuel un der the current riding conditions is shown L 100 km The amount of...

Page 25: ...llowing flashing pat tern settings t On the indicator light stays on when activated This set ting is selected when the indi cator light stays on t Flash the indicator light flashes when activated This setting is selected when the indicator light flashes four times per second t Off the indicator light is deac tivated in other words it does not come on or flash This setting is selected when the indi...

Page 26: ... mode changes to the brightness setting mode To set the rpm when the gearshift indicator light is off To adjust the brightness 1 Push the RESET button to select the desired shift indicator light brightness level 2 Push the SELECT button to con firm the selected brightness level The display exits the shift timing light control mode and returns to the standard multi function dis play mode Self diagn...

Page 27: ...ned to the center position EAU12501 Horn switch Press this switch to sound the horn EAU68270 Start Engine stop switch To crank the engine with the starter set this switch to and then slide the switch toward See page 6 2 for starting instructions prior to starting the engine Set this switch to to stop the en gine in case of an emergency such as when the vehicle overturns or when the throttle cable ...

Page 28: ...wly for smooth clutch operation See page 6 3 EAU12875 Shift pedal The shift pedal is located on the left side of the motorcycle To shift the transmission to a higher gear move the shift pedal up To shift to the trans mission to a lower gear move the shift pedal down See page 6 3 EAU12892 Brake lever The brake lever is located on the right side of the handlebar To apply the front brake pull the lev...

Page 29: ... to match the riding speed even with ABS The ABS performs best with long braking distances On certain surfaces such as rough or gravel roads the brak ing distance may be longer with the ABS than without The ABS is monitored by an ECU which will revert the system to conven The ABS performs a self diagno sis test each time the vehicle first starts off after the key is turned to ON and the vehicle ha...

Page 30: ...1 4 turn counterclockwise remove it and then close the lock cover 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 EWA11092 Make sure that the fuel tank cap is properly closed after filling fuel Leaking fuel is a fire hazard 1 Fuel tank cap lock cover 2 Unlock 1 2 sensor or wheel sensor ...

Page 31: ... out of the fuel tank 3 Wipe up any spilled fuel immedi ately NOTICE Immediately wipe off spilled fuel with a clean dry soft cloth since fuel may deteriorate painted surfaces or plastic parts ECA10072 4 Be sure to securely close the fuel tank cap WARNING EWA15152 Gasoline is poisonous and can cause injury or death Handle gaso line with care Never siphon gasoline by mouth If you should swallow some...

Page 32: ...ch as grass or other materials that easily burn t Park the vehicle in a place where pedestrians or children are not likely to touch the hot exhaust system Make sure that the exhaust sys tem has cooled down before doing any maintenance work t Do not allow the engine to idle more than a few minutes Long idling can cause a build up of heat 1 Fuel tank overflow hose 2 Fuel tank breather hose 2 1 t EAU...

Page 33: ...t backward 1 Projection 2 Seat holder 1 2 2 1 Center cover 2 Screw 1 Rider seat 2 Bolt 1 2 1 2 To install the rider seat 1 Insert the projection on the front of the rider seat into the seat holder as shown and then place the seat in the original position 2 Install the rider seat bolts 3 Install the center cover by install ing the screws 4 Install the passenger seat TIP Make sure that the seats are...

Page 34: ...an accident EWA10162 To release a helmet from a helmet holder Remove the passenger seat remove the helmet from the helmet holder and then install the seat 1 Helmet holder 1 1 Helmet 2 Passenger seat 1 2 EAU62550 Storage compartment The storage compartment is located under the passenger seat See page 4 14 When storing documents or other items in the storage compartment be sure to wrap them in a pla...

Page 35: ...tion a To decrease the spring preload and there by soften the suspension turn the ad justing ring in direction b t Align the appropriate notch in the adjusting ring with the position in dicator on the shock absorber t Use the special wrench and the extension bar included in the own er s tool kit to make the adjust ment EAU15152 Luggage strap holders There is a luggage strap holder on each passenge...

Page 36: ... contact the ground and distract the operator resulting in a possible loss of control Yamaha s ignition circuit cut off system has been designed to assist the operator in fulfilling the respon sibility of raising the sidestand be fore starting off Therefore check this system regularly and have a Yamaha dealer repair it if it does not function properly EAU44895 Ignition circuit cut off system This ...

Page 37: ...ne stall After the engine has stalled 10 Move the sidestand up 11 Pull the clutch lever 12 Push the start switch Does the engine start The system is OK The motorcycle can be ridden YES NO YES NO YES NO The neutral switch may not be working The motorcycle should not be ridden until checked by a Yamaha dealer The clutch switch may not be working The motorcycle should not be ridden until checked by a...

Page 38: ...nts E G A P S K C E H C M E T I Fuel t Check fuel level in fuel tank t Refuel if necessary t Check fuel line for leakage t Check fuel tank breather hose and overflow hose for obstructions cracks or damage and check hose connections 4 13 4 14 Engine oil t Check oil level in engine t If necessary add recommended oil to specified level t Check vehicle for oil leakage 7 10 Coolant t Check coolant leve...

Page 39: ...rip free play t If necessary have Yamaha dealer adjust throttle grip free play and lubricate ca ble and grip housing 7 16 7 25 Control cables t Make sure that operation is smooth t Lubricate if necessary 7 24 Drive chain t Check chain slack t Adjust if necessary t Check chain condition t Lubricate if necessary 7 22 7 24 Wheels and tires t Check for damage t Check tire condition and tread depth t C...

Page 40: ...cessary Instruments lights signals and switches t Check operation t Correct if necessary Sidestand switch t Check operation of ignition circuit cut off system t If system is not working correctly have Yamaha dealer check vehicle 4 18 E G A P S K C E H C M E T I Sidestand t Make sure that operation is smooth t Lubricate pivot if necessary 7 26 ...

Page 41: ... 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 EAU17094 0 1000 km 0 600 mi Avoid prolonged operation above 7000 r min NOTICE After 1000 km 600 mi of operation the engine oil must be c...

Page 42: ... the engine stop switch to run TIP Do not start if the engine trouble warning light and the oil pressure light is on EAUN2220 Starting the engine In order for the starting circuit cut off system to enable starting one of the following conditions must be met t The transmission is in the neutral position t The transmission is in gear with the clutch lever pulled 2 The engine trouble warning light sh...

Page 43: ...on press the shift pedal down repeatedly until it reaches the end of its travel and then slightly raise it NOTICE ECA10261 t 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 trans...

Page 44: ...ine off instead of let ting it idle for an extended length of time e g in traffic jams at traf fic lights or at railroad crossings EAU17214 Parking When parking stop the engine and then remove the key from the main switch WARNING EWA10312 t Since the engine and exhaust system can become very hot park in a place where pedestri ans or children are not likely to touch them and be burned t Do not park...

Page 45: ...15123 Turn off the engine when performing maintenance unless otherwise specified t A running engine has moving parts that can catch on body parts or clothing and electrical parts that can cause shocks or fires t Running the engine while ser vicing can lead to eye injury burns fire or carbon monoxide poisoning possibly leading to death See page 2 2 for more in formation about carbon monox ide WARNI...

Page 46: ...riodic maintenance chart for the emission control system NO ITEM CHECK OR MAINTENANCE JOB ODOMETER READING whichever comes first ANNUAL CHECK 1000 km or 1 month 5000 km or 5 months 10000 km or 10 months 15000 km or 15 months 20000 km or 20 months 1 Fuel line t Check fuel hoses for cracks or damage 2 Fuel filter t Check condition t Replace if necessary 3 Spark plugs t Check condition t Clean and re...

Page 47: ...METER READING whichever comes first ANNUAL CHECK 1000 km or 1 month 5000 km or 5 months 10000 km or 10 months 15000 km or 15 months 20000 km or 20 months 7 Air induction sys tem t Check the air cut off valve reed valve and hose for damage t Replace any damaged parts if necessary ...

Page 48: ...maha diagnostic tool t Check the error codes 2 Air filter element i m 0 0 0 9 m k 0 0 0 5 1 y r e v E e c a l p e R t 3 Air filter check hose t Clean 4 Battery t Check voltage t Charge if necessary 5 Clutch t Check operation t Adjust 6 Front brake t Check operation fluid level and vehicle for fluid leakage t i m i l e h t o t n r o w r e v e n e h W s d a p e k a r b e c a l p e R t 7 Rear brake t...

Page 49: ... t Check bearings for looseness or damage 13 Swingarm t Check operation and for exces sive play t Lubricate with lithium soap based grease Every 20000 km 12000 mi 14 Drive chain t Check chain slack alignment and condition t Adjust and lubricate chain with a special O ring chain lubricant thoroughly Every 1000 km 600 mi and after washing the motorcycle riding in the rain or riding in wet areas NO I...

Page 50: ...ed grease 19 Clutch lever pivot shaft t Lubricate with lithium soap based grease 20 Shift pedal pivot shaft t Lubricate with lithium soap based grease 21 Sidestand t Check operation t Lubricate with lithium soap based grease 23 Front fork t Check operation and for oil leak age 24 Shock absorber as sembly t Check operation and shock ab sorber for oil leakage t Check operation NO ITEM CHECK OR MAINT...

Page 51: ...28 Front and rear brake switches t Check operation 29 Moving parts and cables t Lubricate NO ITEM CHECK OR MAINTENANCE JOB ODOMETER READING whichever comes first ANNUAL CHECK 1000 km or 1 month 5000 km or 5 months 10000 km or 10 months 15000 km or 15 months 20000 km or 20 months 30 Throttle grip t Check operation t Check throttle grip free play and adjust if necessary t Lubricate cable and grip ho...

Page 52: ...ing in unusually wet or dusty areas t Hydraulic brake service t Regularly check and if necessary correct the brake fluid level t Every two years replace the internal components of the brake master cylinders and calipers and change the brake fluid t Replace the brake hoses every four years and if cracked or damaged ...

Page 53: ...ctly different color the engine could be operating improperly Do not at tempt to diagnose such problems yourself Instead have a Yamaha deal er check the vehicle If a spark plug shows signs of elec trode erosion and excessive carbon or other deposits it should be replaced Before installing a spark plug the spark plug gap should be measured with a wire thickness gauge and if necessary adjusted to sp...

Page 54: ...evel 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 cartridge replace ment 1 Place the vehicle on a level sur face 2 Start the eng...

Page 55: ...ng of the new oil lter cartridge TIP Make sure that the O ring is properly seated 8 Install the new oil lter cartridge with an oil lter wrench and then tighten it to the speci ed torque with a torque wrench 9 Install the engine oil drain bolt and its new gasket and then tighten the bolt to the speci ed torque TIP Install the new gasket as shown 1 Oil lter wrench 2 Oil lter cartridge Tightening tor...

Page 56: ...gine and then let it idle for several minutes while checking it for oil leakage If oil is leaking immediately turn the engine off and check for the cause TIP After the engine is started the engine oil pressure warning light should go off NOTICE ECA20860 If the oil pressure warning light flick ers or remains on even if the oil level is correct immediately turn the en gine off and have a Yamaha deal...

Page 57: ...e coolant is at or below the minimum level mark remove the coolant reservoir cover by remov ing the bolts remove the coolant reservoir cap and then add cool ant to the maximum level mark WARNING Remove only the coolant reservoir cap Never at tempt to remove the radiator cap when the engine is hot EWA15162 NOTICE If coolant is not available use distilled water or soft tap water instead Do not use h...

Page 58: ...ed in the periodic maintenance and lubrication chart Replace the air filter element more frequently if you are riding in un usually wet or dusty areas In addition the air filter check hose must be fre quently checked and cleaned if neces sary To replace the air filter element 1 Remove the rider seat See page 4 14 2 Remove the left side panel bolts 3 Remove the left side panel by re moving the lowe...

Page 59: ...e excessively worn ECA10482 7 Install the air filter case cover by installing the screws and then place the rubber covers in their original positions 8 Place the left side panel in the original position and then install the bolts 9 Install the rider seat To clean the air filter check hose 1 Check the hose on the front of the air filter case for accumulated dirt or water 2 If dirt or water is visib...

Page 60: ...performed when the engine is cold EAU82720 Tires Tires are the only contact between the vehicle and the road Safety in all con ditions of riding depends on a relatively small area of road contact Therefore it is essential to maintain the tires in good condition at all times and replace them at the appropriate time with the speci fied tires Tire air pressure The tire air pressure should be checked ...

Page 61: ...placement of all wheel and brake related parts includ ing the tires should be left to a Yamaha dealer who has the necessary professional knowl edge and experience to do so t 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 model is equipped with tubeless tires and tire air valves Tires a...

Page 62: ...maha dealer replace the wheel Do not attempt even the smallest repair to the wheel A de formed or cracked wheel must be replaced t 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 EAUN2251 Adjusting the clutch lever free play Measure the clutch ...

Page 63: ... nut in di rection b 4 Tighten the locknut EAU37914 Checking the brake lever free play There should be no free play at the brake lever end If there is free play have a Yamaha dealer inspect the brake system WARNING EWA14212 A soft or spongy feeling in the brake lever can indicate the presence of air in the hydraulic system If there is air in the hydraulic system have a Yamaha dealer bleed the syst...

Page 64: ... on later turn the ad justing nut in direction b TIP The front brake light switch should be serviced by a Yamaha dealer EAU22393 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 EAU22433 Front brake pads Each front brake pad is provided with wear indicator grooves which allow ...

Page 65: ...m level mark Check the brake fluid level with the top of the reservoir level Replenish the brake fluid if necessary Front brake Rear brake WARNING EWA15991 Improper maintenance can result in loss of braking ability Observe these precautions 1 Brake pad wear indicator groove 1 1 1 Minimum level mark 1 1 Minimum level mark Specified brake fluid DOT 4 1 NOTICE ECA17641 Brake fluid may damage painted ...

Page 66: ...ers and brake calipers as well as the brake hoses replaced at the intervals listed below or sooner if they are damaged or leaking t Brake seals every 2 years t Brake hoses every 4 years t Insufficient brake fluid may al low air to enter the brake sys tem reducing braking performance t Clean the filler cap before re moving Use only DOT 4 brake fluid from a sealed container EAU22762 Drive chain slac...

Page 67: ... ad justing the drive chain slack 1 Remove the drive chain puller cap and then loosen the axle nut and the locknut on each side of the swingarm 2 To tighten the drive chain turn the drive chain slack adjusting nut on each side of the swingarm in di rection a To loosen the drive chain turn the adjusting nut on each side of the swingarm in di rection b and then push the rear wheel forward Drive chai...

Page 68: ...ve chain with steam cleaners high pressure washers or inap propriate solvents ECA11122 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 Tightening torques Axle nut 57 N m 5 7 kgf m 42 lb ft Locknut 16 N m 1 6 kgf m 12 lb ft may contain substances that could damag...

Page 69: ...tion the cable should be lubricat ed by a Yamaha dealer at the intervals specified in the periodic maintenance chart EAU44276 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 Brake pedal Shift pedal Recommended lubricant Lithium soap based grease ...

Page 70: ...cating the sidestand The operation of the sidestand should be checked before each ride and the sidestand pivot and metal to metal contact surfaces should be lubricated if necessary WARNING EWA10732 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 co...

Page 71: ...peration of the front fork must be checked as follows at the intervals specified in the periodic maintenance 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 an upright posi tion WARNING To avoid injury securely support the vehicle so there is no danger of ...

Page 72: ... the front wheel off the ground See page 7 33 WARNING To avoid injury se curely support the vehicle so there is no danger of it falling over EWA10752 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 steer ing EAU23292 Checking the wheel bearings The front and rear wheel bearings must be che...

Page 73: ...osive hy drogen gas Therefore keep sparks flames cigarettes etc away from the battery and pro vide sufficient ventilation when charging it in an enclosed space t KEEP THIS AND ALL BATTER IES OUT OF THE REACH OF CHILDREN 1 Battery 2 Negative battery lead black 3 Positive battery lead red 1 2 3 NOTICE Never attempt to remove the battery cell seals as this would permanently damage the battery To char...

Page 74: ...ry can cause permanent battery damage EAU62773 Replacing the fuses The main fuse is located under the passenger seat The fuse box which contains the fuses for the individual cir cuits is located behind the center pan el To access the main fuse proceed as follows 1 Remove the passenger seat See page 4 14 2 Remove the tray by removing the quick fasteners 3 Pull back the starter relay cover 1 Quick f...

Page 75: ... to the electrical system and possibly a fire EWA15132 3 Turn the key to ON and turn on the electrical circuit in question to check if the device operates 4 If the fuse immediately blows again have a Yamaha dealer check the electrical system 1 Fuse box 1 Ignition fuse 2 Signaling system fuse 3 Headlight fuse 4 Backup fuse for clock 5 Radiator fan motor fuse 6 Spare fuse 1 6 1 2 3 4 5 Specified fus...

Page 76: ...ary light 2 Headlight low beam 3 Headlight high beam Vehicle lights EAU62670 Replacing the license plate light bulb 1 Remove the mudguard by remov ing the quick fasteners 2 Remove the rear fender lower panel by removing the bolts and screws 3 Remove the license plate light bulb socket together with the bulb by pulling it out 4 Remove the burnt out bulb by pulling it out 1 Mudguard 2 Quick fastener...

Page 77: ...x can be placed un der the engine for added stability To service the front wheel 1 Stabilize the rear of the motorcy cle by using a motorcycle stand or if an additional motorcycle stand is not available by placing a jack under 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 usin...

Page 78: ...bolts TIP Make sure that there is enough space between the brake pads before install ing the brake caliper onto the brake disc 4 Lower the front wheel so that it is on the ground and then put the sidestand down 5 Tighten the axle nut and the brake caliper bolts to the specified torques 6 Push down hard on the handlebar several times to check for proper fork operation EAU25081 Rear wheel EAU62612 T...

Page 79: ...brake after the wheel and brake disc have been removed otherwise the brake pads will be forced shut ECA11073 To install the rear wheel 1 Install the wheel and the brake cal iper bracket by inserting the wheel axle from the left hand side TIP t Make sure that the slot in the brake caliper bracket is fit over the retainer on the swingarm t Make sure that there is enough space between the brake pads ...

Page 80: ...these vital systems your self However should your motorcycle require any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools experience and know how to service the motorcycle properly Use only genuine Yamaha replace ment parts Imitation parts may look like Yamaha parts but they are often inferior have a shorter service life and can lead to expensive repair bills WA...

Page 81: ...r replace the spark plugs Have a Yamaha dealer check the vehicle Operate the electric starter 4 Compression There is compression There is no compression The engine does not start Have a Yamaha dealer check the vehicle Have a Yamaha dealer check the vehicle The engine does not start Check the compression Operate the electric starter 2 Battery The engine turns over quickly The engine turns over slow...

Page 82: ... the hissing 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 cool ant 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 Che...

Page 83: ...ng 1 Cover the muffler outlet with a plastic bag after the engine has cooled down 2 Make sure that all caps and cov ers as well as all electrical cou plers 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 cha...

Page 84: ...horoughly 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 or near the sea Since sea salt is extremely corrosive carry out the following steps after each ride in the rain or near the sea 1 Clean the motorcycle with cold water...

Page 85: ...s as they will wear away the paint TIP t Consult a Yamaha dealer for ad vice on what products to use t 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 EAU26183 Storage Short term Always store your motorcycle in a cool dry place and if necessary protect it against dust with a ...

Page 86: ...electrodes while turning the engine over EWA10952 e Remove the spark plug caps from the spark plugs and then install the spark plugs and the spark plug caps 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...

Page 87: ... change 1 80 L 1 90 US qt 1 58 Imp qt With oil filter removal 2 10 L 2 22 US qt 1 85 Imp qt Coolant quantity Coolant reservoir up to the maximum level mark 0 25 L 0 26 US qt 0 22 Imp qt Radiator including all routes 0 84 L 0 89 US qt 0 74 Imp qt Fuel Recommended fuel Unleaded gasoline only Fuel tank capacity 14 L 3 7 US gal 3 1 Imp gal Fuel reserve amount 3 0 L 0 79 US gal 0 66 Imp gal Fuel inject...

Page 88: ...Telescopic fork Rear suspension Type Monoshock Electrical system System voltage 12 V Battery Model GTZ8V Voltage capacity 12 V 7 0 Ah 10 HR Bulb wattage Headlight LED Brake tail light LED Front turn signal light LED Rear turn signal light LED Auxiliary light LED License plate light 5 0 W ...

Page 89: ...tolen VEHICLE IDENTIFICATION NUMBER ENGINE SERIAL NUMBER Vehicle identification number The vehicle identification number is stamped into the frame under the pas senger seat See page 4 14 TIP The vehicle identification number is used to identify your vehicle and may be used to register it with the licensing authority in your area Engine serial number The engine serial number is stamped into the cra...

Page 90: ...en maintenance checks or service procedures are performed Although the sensors and recorded data will vary by model the main data points are t Vehicle status and engine perfor mance data t Fuel injection and emission relat ed data Yamaha will not disclose this data to a third party except t With the consent of the vehicle owner t Where obligated by law t For use by Yamaha in litigation t For gener...

Page 91: ...10 Helmet holders 4 16 Helmets 2 5 High beam indicator light 4 2 Horn switch 4 10 I Identification numbers 10 1 Indicator lights and warning lights 4 2 L Labels location 1 1 License plate light bulb replacing 7 32 Luggage strap holders 4 17 M Main switch steering lock 4 1 Maintenance and lubrication periodic 7 5 Maintenance emission control system 7 3 Matte color caution 8 1 Multi function meter u...

Page 92: ...11 2 11 Index V Valve clearance 7 16 Vehicle identification number 10 1 Vehicle lights 7 32 W Wheel bearings checking 7 28 Wheel front 7 33 Wheel rear 7 34 Wheels 7 18 ...

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Yamaha MT-25, Owner'S Manual

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