Yamaha Star Owner'S Manual Download Page 56 | Manualshive

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Perio

d

ic maintenance an

d

a

d

justment

7-19

7

3. To increase the clutch 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 di-
rection (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 fur-

ther down the clutch cable, and
then loosen the locknut.

6. To increase the clutch lever free

play, turn the clutch lever free play
adjusting nut in direction (a). To
decrease the clutch lever free
play, turn the adjusting nut in di-
rection (b).

7. Tighten the locknut at the clutch

cable, and then slide the rubber
cover to its original position.

8. Tighten the locknut at the clutch

lever, and then slide the rubber
cover to its original position.

EAU22095

A

d

justin

g

the

b

rake lever free

play

Measure the brake lever free play as
shown.

Periodically check the brake lever free
play and, if necessary, adjust it as fol-
lows.

1. Loosen the locknut at the brake le-

ver.

2. To increase the brake lever free

play, turn the brake lever free play
adjusting screw in direction (a). To

1. Locknut
2. Clutch lever free play adjusting nut
3. Rubber cover

1. Locknut
2. Brake lever free play adjusting screw
3. Brake lever free play

Brake lever free play:

2.0–5.0 mm (0.08–0.20 in)

3

U46B78E0.book Page 19 Monday, July 4, 2016 2:29 PM

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Summary of Contents for Star

Page 1: ...DIC183 XV250H OWNER S MANUAL Read this manual carefully before operating this vehicle 46B 28199 78 English E...

Page 2: ...EAU46091 Read this manual carefully before operating this vehicle This manual should stay with this vehicle if it is sold U46B78E0 book Page 1 Monday July 4 2016 2 29 PM...

Page 3: ...high standards it is important that you and your Yamaha dealer pay close attention to the recommended maintenance schedules and operating instructions contained within this manual Yamaha continually...

Page 4: ...ential 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 o...

Page 5: ...ANUAL 2016 by Yamaha Motor Co Ltd 1st edition June 2016 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in...

Page 6: ...n chart 7 5 Removing and installing the panel 7 9 Checking the spark plugs 7 9 Engine oil and oil filter element 7 11 Cleaning the air filter element 7 13 Carburetor 7 15 Checking the engine idling sp...

Page 7: ...ycle 7 35 Front wheel 7 35 Rear wheel 7 37 Troubleshooting 7 38 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 info...

Page 8: ...e 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 av...

Page 9: ...ALWAYS WEAR AN APPROVED MOTORCYCLE HELMET eye protection and protective clothing 1TP 2118K A1 AVERTISSEMENT LIRE LE MANUEL DU PROPRIETAIRE AINSI QUE TOUTES LES ETIQUETTES AVANT D UTILISER CE VEHICULE...

Page 10: ...Location of important labels 1 3 1 Cold tire normal pressure should be set as follows 3CK 21668 A1 3CK 21668 B1 7 8 U46B78E0 book Page 3 Monday July 4 2016 2 29 PM...

Page 11: ...you Safe Riding Perform the pre operation checks each time you use the vehicle to make sure it is in safe operating condition Failure to inspect or maintain the vehi cle properly increases the possibi...

Page 12: ...o main tain control of the motorcycle The passenger should always hold onto the operator the seat strap or grab bar if equipped with both hands and keep both feet on the passenger footrests Never carr...

Page 13: ...rcycle is changed To avoid the possibility of an accident use extreme caution when adding cargo or accessories to your motorcycle Use extra care when riding a motorcycle that has added cargo or access...

Page 14: ...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 Ke...

Page 15: ...instruc tions before transporting the motorcy cle in another vehicle Remove all loose items from the motorcycle Check that the fuel cock if equipped is in the OFF position and that there are no fuel l...

Page 16: ...7 32 2 Steering lock page 4 8 3 Battery page 7 30 4 Fuses page 7 32 5 Helmet holder page 4 9 6 Shock absorber assembly spring preload adjusting ring page 4 9 7 Main switch page 4 1 8 Fuel cock page 4...

Page 17: ...3 Rider seat page 4 8 4 Fuel tank cap page 4 4 5 Air filter element page 7 13 6 Front turn signal position lights page 7 34 7 Brake pedal page 4 4 8 Rear brake light switch page 7 21 9 Owner s tool ki...

Page 18: ...struments 1 2 3 4 5 6 1 Clutch lever page 4 3 2 Left handlebar switches page 4 2 3 Speedometer unit page 4 2 4 Right handlebar switches page 4 2 5 Brake lever page 4 4 6 Throttle grip page 7 16 U46B78...

Page 19: ...ent EAU54371 Parking The taillight and position lights are on but all other electrical systems are off The key can be removed The key must be pushed in from the OFF position to be turned to NOTICE ECA...

Page 20: ...am and to for the low beam EAU12461 Turn signal switch To signal a right hand turn push this switch to To signal a left hand turn push this switch to When released the switch returns to the cen ter po...

Page 21: ...gage the clutch release the lever The lever should be pulled rapidly and released slowly for smooth clutch operation The clutch lever is equipped with a clutch switch which is part of the igni tion ci...

Page 22: ...brake press down on the brake pedal EAU13042 Fuel tank cap To open the fuel tank cap Insert the key into the lock and turn it 1 4 turn clockwise The lock will be re leased and the fuel tank cap can b...

Page 23: ...ks open flames or other sources of ignition such as the pilot lights of water heaters and clothes dryers 2 Do not overfill the fuel tank Stop filling when the fuel reaches the bottom of the filler tub...

Page 24: ...ethanol and that con taining methanol Gasohol containing ethanol can be used if the ethanol con tent does not exceed 10 E10 Gas ohol containing methanol is not recommended by Yamaha because it can ca...

Page 25: ...n the engine can be primed Turn the fuel cock lever to this position when the engine has been allowed to run out of fuel This sends fuel directly to the carburetor which will make starting easier Afte...

Page 26: ...lock is difficult to en gage try turning the handlebars back to the left slightly To unlock the steering 1 Open the steering lock cover and insert the key 2 Push the key in and turn it 1 8 turn count...

Page 27: ...hock absorber assemblies WARNING EWA10211 Always adjust both shock absorber assemblies equally otherwise poor handling and loss of stability may re sult Each shock absorber assembly is equipped with a...

Page 28: ...f system WARNING EWA10242 The vehicle must not be ridden with the sidestand down or if the side stand cannot be properly moved up or does not stay up otherwise the sidestand could contact the ground a...

Page 29: ...is up but the clutch le ver is not pulled It prevents starting when the transmission is in gear and the clutch lever is pulled but the side stand is still down It cuts the running engine when the tra...

Page 30: ...0 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...

Page 31: ...Before using this vehicle check the following points ITEM CHECKS PAGE Fuel Check fuel level in fuel tank Refuel if necessary Check fuel line for leakage 4 5 Engine oil Check oil level in engine If ne...

Page 32: ...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 clutc...

Page 33: ...For your safety pre operation checks 5 3 5 Battery Check fluid level Fill with distilled water if necessary 7 30 ITEM CHECKS PAGE U46B78E0 book Page 3 Monday July 4 2016 2 29 PM...

Page 34: ...er to check the electrical circuit 4 Turn the starter choke on and completely close the throttle See page 4 7 5 Start the engine by pushing the start switch If the engine fails to start release the st...

Page 35: ...not re quired when the engine is warm EAU16673 Shifting Shifting gears lets you control the amount of engine power available for starting off accelerating climbing hills etc The gear positions are sho...

Page 36: ...ond gear Make sure not to shift the transmission into the neutral posi tion 6 Open the throttle part way and gradually release the clutch lever 7 Follow the same procedure when shifting to the next hi...

Page 37: ...eration the engine oil must be changed and the oil filter car tridge or element replaced ECA11283 1000 1600 km 600 1000 mi Avoid prolonged operation above 1 2 throttle 1600 km 1000 mi and beyond The v...

Page 38: ...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 whi...

Page 39: ...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 mainte...

Page 40: ...mi or 6 months 11000 km 7000 mi or 12 months 16000 km 10000 mi or 18 months 21000 km 13000 mi or 24 months 26000 km 16000 mi or 30 months 1 Fuel line Check fuel and vacuum hoses for cracks or damage R...

Page 41: ...Replace gasket s if necessary No ITEM ROUTINE INITIAL ODOMETER READINGS 1000 km 600 mi or 1 month 6000 km 4000 mi or 6 months 11000 km 7000 mi or 12 months 16000 km 10000 mi or 18 months 21000 km 130...

Page 42: ...cific gravity and breather hose for proper opera tion 3 Clutch Check operation Adjust or replace cable 4 Front brake Check operation fluid level and for fluid leakage Adjust brake lever free play and...

Page 43: ...e Every 500 km 300 mi and after washing the motorcycle and riding in the rain or wet areas 13 Steering bearings Check bearing assemblies for looseness Moderately repack with lithium soap based grease...

Page 44: ...leak age Replace if necessary 22 Shock absorber as semblies Check operation and for oil leak age Replace if necessary 23 Engine oil Change warm engine before draining 24 Engine oil filter ele ment Rep...

Page 45: ...ter cylinder and caliper cylinder every two years Replace the brake hoses every four years or if cracked or damaged 27 Throttle grip Check operation Check throttle grip free play and adjust if necessa...

Page 46: ...panel and then push the rear of the panel in EAU19546 Checking the spark plugs The spark plugs are important engine components which are easy to check Since heat and deposits will cause any spark plu...

Page 47: ...e spark plug gap with a wire thickness gauge and if nec essary adjust the gap to specifi cation To install a spark plug 1 Clean the surface of the spark plug gasket and its mating surfa ce and then wi...

Page 48: ...dow locat ed 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...

Page 49: ...re to wipe off spilled oil on any parts after the engine and exhaust sys tem have cooled down NOTICE ECA11621 In order to prevent clutch slip page since the engine oil also lubricates the clutch do no...

Page 50: ...t it if necessary EAU3273A 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 i...

Page 51: ...handle it gently and carefully and do not twist or wring it ECA10512 6 Apply oil of the recommended type to the entire surface of the sponge material and then squeeze the excess oil out TIP The air f...

Page 52: ...er case joint and then tighten the clamp screw 12 Install the bolts EAU21252 Carburetor The carburetor is an important part of the engine and its emission control system which requires very sophisti c...

Page 53: ...ll 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...

Page 54: ...f 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 It is not recommended to patch a punctured tube...

Page 55: ...the specified wheels The wheel rims should be checked for cracks bends warp age or other damage and the spokes for looseness or damage before each ride If any damage is found have a Yamaha dealer re p...

Page 56: ...ch lever free play turn the adjusting nut in di rection b 7 Tighten the locknut at the clutch cable and then slide the rubber cover to its original position 8 Tighten the locknut at the clutch lever a...

Page 57: ...e brake pedal height and free play WARNING EWA10671 It is advisable to have a Yamaha dealer make these adjustments Brake pedal height The top of the brake pedal should be positioned at the specified d...

Page 58: ...he brake pedal free play check the operation of the brake light EAU22274 Brake light switches The brake light which is activated by the brake pedal and brake lever should come on just before braking t...

Page 59: ...is provided with a wear indicator which allows you to check the brake shoe wear without having to disassemble the brake To check the brake shoe wear check the position of the wear indicator while appl...

Page 60: ...es or plastic parts Always clean up spilled fluid immediately As the brake pads wear it is normal for the brake fluid level to gradually go down A low brake fluid level may indi cate worn brake pads a...

Page 61: ...frame swingarm and other parts To prevent this from occurring keep the drive chain slack within the specified limits ECA17791 EAU53052 To adjust the drive chain slack Consult a Yamaha dealer before ad...

Page 62: ...r out especially when riding in dusty or wet areas Service the drive chain as follows NOTICE ECA10584 The drive chain must be lubricated after washing the motorcycle riding in the rain or riding in we...

Page 63: ...damaged cables as soon as possible to prevent unsafe condi tions EWA10712 EAU49921 Checking and lubricating the throttle grip and cable The operation of the throttle grip should be checked before each...

Page 64: ...brake and clutch levers should be checked before each ride and the lever pivots should be lu bricated if necessary Brake lever Clutch lever Recommended lubricant Lithium soap based grease Recommended...

Page 65: ...e periodic maintenance and lubrication chart EAU23273 Checking the front fork The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic mainte...

Page 66: ...round See page 7 35 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 a...

Page 67: ...ly call a physician EYES Flush with water for 15 minutes and seek prompt medical attention Batteries produce explosive hy drogen gas Therefore keep sparks flames cigarettes etc away from the battery a...

Page 68: ...lead ECA16303 2 If the battery will be stored for more than two months check the specific gravity of the electrolyte at least once a month and fully charge the battery whenever nec essary 3 Fully char...

Page 69: ...If the fuse immediately blows again have a Yamaha dealer check the electrical system EAU53082 Replacing the headlight bulb If the headlight bulb burns out replace it as follows NOTICE ECA10661 Do not...

Page 70: ...5 Install the headlight bulb 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 EAU70550 Replacing...

Page 71: ...urn signal light bulb 1 Remove the turn signal light lens by removing the screws 2 Remove the burnt out bulb by pushing it in and turning it coun terclockwise 3 Insert a new bulb into the socket push...

Page 72: ...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 of...

Page 73: ...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 Install the wheel axle 4 Lower the front wh...

Page 74: ...usting nut on both ends of the swingarm 2 Loosen the axle nut and the brake torque rod nut at the brake shoe plate 3 Lift the rear wheel off the ground See page 7 35 4 Remove the brake pedal free play...

Page 75: ...age 7 20 WARNING EWA10661 After adjusting the brake pedal free play check the operation of the brake light EAU25852 Troubleshooting Although Yamaha motorcycles receive a thorough inspection before shi...

Page 76: ...riodic maintenance and adjustment 7 39 7 heaters or furnaces Gasoline or gasoline vapors can ignite or ex plode causing severe injury or prop erty damage U46B78E0 book Page 39 Monday July 4 2016 2 29...

Page 77: ...k the electrodes 3 Ignition Wet 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 comp...

Page 78: ...utlets with plastic bags 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 caps are tightly in stalled...

Page 79: ...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 w...

Page 80: ...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...

Page 81: ...ury from sparking make sure to ground the spark plug 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...

Page 82: ...I service SG type or higher JASO standard MA Engine oil quantity Oil change 1 40 L 1 48 US qt 1 23 Imp qt With oil filter removal 1 60 L 1 69 US qt 1 41 Imp qt Air filter Air filter element Wet elemen...

Page 83: ...f cm 29 psi Rear 225 kPa 2 25 kgf cm 33 psi Front wheel Wheel type Spoke wheel Rim size 18 x 1 60 Rear wheel Wheel type Spoke wheel Rim size 15M C x MT2 75 Front brake Type Hydraulic single disc brake...

Page 84: ...light 27 0 W 8 0 W 2 Rear turn signal light 27 0 W 2 Meter lighting 1 7 W 1 Neutral indicator light 1 7 W 1 High beam indicator light 1 7 W 1 Turn signal indicator light 3 0 W 1 Fuse s Main fuse 20 0...

Page 85: ...ON NUMBER ENGINE SERIAL NUMBER MODEL LABEL INFORMATION KEY IDENTIFICATION NUMBER EAU26401 Vehicle identification number The vehicle identification number is stamped into the steering head pipe Record...

Page 86: ...r is stamped into the key Record this number in the space provided and use it for reference when ordering a new key EAU48271 Vehicle Emission Control Informa tion label The Vehicle Emission Control In...

Page 87: ...minder that maintenance work is required It is not acceptable proof of maintenance work Maintenance interval Date of service Mileage Servicing dealer name and address Remarks 1000 km 600 mi or 1 mont...

Page 88: ...rmation 10 4 10 46000 km 28000 mi or 54 months 51000 km 31000 mi or 60 months Maintenance interval Date of service Mileage Servicing dealer name and address Remarks U46B78E0 book Page 4 Monday July 4...

Page 89: ...is transfer MUST be done by contacting the DEALER who will forward the following information to YAMAHA Section B Subsequent Owner The MOTORCYCLE has been fully assembled and set to the MANUFACTURER s...

Page 90: ...iable for special incidental or consequential damages howsoever caused whether by negligence or otherwise resulting directly or indirectly from the use of the MOTORCYCLE or the MOTORCYCLE having repla...

Page 91: ...h beam indicator light 4 1 Horn switch 4 2 I Identification numbers 10 1 Ignition circuit cut off system 4 11 Indicator lights 4 1 K Key identification number 10 2 L Labels location 1 1 M Main switch...

Page 92: ...ce 7 16 Vehicle Emission Control Information label 10 2 Vehicle identification number 10 1 W Warranty 10 5 Wheel bearings checking 7 29 Wheel front 7 35 Wheel rear 7 37 Wheels 7 18 U46B78E0 book Page...

Page 93: ...m right right out of the box Yamalube Take care of your Yamaha with legendary Yamalube oils lubricants and care products They re formulated and approved by the toughest judges we know the Yamaha engin...

Page 94: ...PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2016 07 0 3 1 CR E U46B78E0 book Page 1 Monday July 4 2016 2 29 PM...

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