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Yamaha TT-R Owner'S Manual Download Page 63

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PERIODIC MAINTENANCE AND MINOR REPAIR

EAU01314

Checking the front and rear
brake pads

The front and rear brake pads must
be checked for wear at the intervals
specified in the periodic maintenance
and lubrication chart. Each brake pad
is provided with a wear indicator
groove, which allows you to check
the brake pad wear without having to
disassemble the brake. 

1

1.

Indicator groove

FRONT

EAU03196

Checking the brake fluid
level

Insufficient brake fluid may allow air
to enter the brake system, possibly
causing it to 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 level is low, be
sure to check the brake pads for
wear and the brake system for leak-
age.

LOWER

1

1.

Minimum level mark

FRONT

To check the brake pad wear, check
the wear indicator grooves. If a brake
pad has worn to the point that the
wear indicator groove has almost dis-
appeared, have a Yamaha dealer
replace the brake pads as a set.

1

1.

Indicator groove

REAR

Summary of Contents for TT-R

Page 1: ...OWNER S MANUAL TTR250N C ...

Page 2: ......

Page 3: ......

Page 4: ...EAU03438 ...

Page 5: ...ting touring and pacesetting racing machines It represents the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields This manual will give you an understanding of the operation inspection and basic maintenance of this machine If you have any questions concerning the operation or maintenance of your machine please consult a Yamaha dealer ...

Page 6: ...l precautions that must be taken to avoid damage to the machine A NOTE provides key information to make procedures easier or clearer Q w cC NOTE NOTE 8 This manual should be considered a permanent part of this machine and should remain with it even if the machine is subsequently sold 8 Yamaha continually seeks advancements in product design and quality Therefore while this manual contains the most...

Page 7: ...ROPER RIDING TECHNIQUES REGULAR INSPECTIONS AND CAREFUL MAINTENANCE ALONG WITH GOOD RIDING SKILLS WILL ENSURE THAT YOU SAFELY ENJOY THE CAPABILITIES AND THE RELIABILITY OF THIS MACHINE EAU00006 w THIS MACHINE IS DESIGNED AND MANUFACTURED FOR OFF ROAD USE ONLY IT IS ILLEGAL TO OPERATE THIS MACHINE ON ANY PUBLIC STREET ROAD OR HIGHWAY SUCH USE IS PROHIBITED BY LAW THIS MACHINE COMPLIES WITH ALMOST A...

Page 8: ...Motor Corporation U S A 1st Edition June 2000 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in Japan P N LIT 11626 14 32 EAU03336 AFFIX DEALER LABEL HERE ...

Page 9: ...e pedal 3 3 Fuel tank cap 3 3 Fuel 3 4 Fuel tank breather hose 3 5 Fuel cock 3 5 Starter choke knob 1 3 6 Seat 3 6 Adjusting the front fork 3 7 Adjusting the shock absorber assembly 3 9 Ignition circuit cut off system 3 12 PRE OPERATION CHECKS 4 1 Pre operation check list 4 1 OPERATION AND IMPORTANT RIDING POINTS 5 1 Starting and warming up a cold engine 5 1 Starting a warm engine 5 3 Shifting 5 3...

Page 10: ... lubricating the cables 6 24 Checking and lubricating the brake and shift pedals 6 25 Checking and lubricating the brake and clutch levers 6 25 Checking and lubricating the sidestand 6 25 Checking the front fork 6 26 Checking the steering 6 26 Checking the wheel bearings 6 27 Battery 6 27 Replacing the fuse 6 29 Replacing the headlight bulb 6 30 Replacing the taillight bulb 6 31 Supporting the mac...

Page 11: ...Off road motorcycle limited warranty 9 7 Yamaha extended service Y E S 9 9 TABLE OF CONTENTS ...

Page 12: ...eful checks may help prevent an accident 2 This machine is designed for off road use only therefore it is illegal to operate it on public streets roads or highways Off road use on public lands may be illegal Please check local regu lations before riding 3 This machine is designed to carry the operator only No passengers 4 Many accidents involve inexperienced operators a Make sure that you are qual...

Page 13: ... use of a safety helmet is the single most critical factor in the prevention or reduction of head injuries 1 Always wear an approved helmet 2 Wear a face shield or goggles Wind in your unprotected eyes could contribute to an impairment of vision that could delay seeing a hazard 3 The use of a jacket heavy boots trousers gloves etc is effective in preventing or reducing abrasions or lacerations 4 N...

Page 14: ...o follow if loading cargo or adding accessories to your machine Loading The total weight of the operator accessories and cargo must not exceed the maximum load limit of 90 kg 198 lb When loading within this weight limit keep the following in mind 1 Cargo and accessory weight should be kept as low and close to the machine as possible Make sure to distribute the weight as evenly as possible on both ...

Page 15: ...tion or obscure lights or reflectors a Accessories fitted to the handlebar or the front fork area can create instability due to improper weight distribution or aerodynamic changes If accessories are added to the handlebar or front fork area they must be as lightweight as possible and should be kept to a minimum b Bulky or large accessories may seriously affect the stability of the machine due to a...

Page 16: ...llowing a The engine and exhaust pipe s muffler s may be hot therefore park the machine in a place where pedestrians or children are not likely to touch these hot areas b Do not park the machine on a slope or soft ground otherwise it may fall over c Do not park the machine near a flammable source e g a kerosene heater or near an open flame otherwise it could catch fire 4 When transporting the mach...

Page 17: ...Q SAFETY INFORMATION 1 2 3 4 5 6 7 8 9 ...

Page 18: ...Q SAFETY INFORMATION 1 2 3 4 5 6 7 8 9 EAU02977 Location of important labels Please read the following important labels carefully before operating this machine 1 2 3 4 ...

Page 19: ...59 00 1 2 Q SAFETY INFORMATION WARNING q THE OWNER S MANUAL AND ALL LABELS NEVER CARRY A PASSENGER You increase you operate this vehicle on a public road EXPERIENCED RIDER ONLY 8 8 8 8 8 4ES 2118K A0 ALWAYS WEAR AN APPROVED MOTORCYCLE HELMET eye protection and protective clothing ROADS You can collide with another vehicle if NEVER OPERATE THIS VEHICLE ON PUBLIC your risk of losing control if you c...

Page 20: ...k air valve page 3 7 3 Fuel cock page 3 5 4 Starter choke knob 1 page 3 6 5 Air filter element page 6 11 6 Rear shock absorber rebound damping adjusting dial page 3 10 7 Shift pedal page 3 2 8 Front fork compression damping adjusting screw page 3 8 1 3 4 5 6 7 8 2 Left view ...

Page 21: ...ster page 6 12 10 Battery page 6 27 11 Fuse page 6 29 12 Rear shock absorber compression damping adjusting knob page 3 11 13 Main switch page 3 1 14 Engine oil filter element page 6 10 15 Brake pedal page 3 3 6 19 9 10 11 12 13 14 15 Right view ...

Page 22: ...Clutch lever page 3 2 6 18 2 Left handlebar switch page 3 1 3 Tripmeter page 3 1 4 Right handlebar switches page 3 2 5 Brake lever page 3 3 6 18 6 Throttle grip page 6 14 7 Fuel tank cap page 3 3 1 2 3 4 5 6 7 Controls and instruments ...

Page 23: ...ce it was last set to zero with the reset knob The tripmeter can be used to estimate the distance that can be traveled with a full tank of fuel This information will enable you to plan future fuel stops 1 Tripmeter 2 Reset knob EAU00027 INSTRUMENT AND CONTROL FUNCTIONS 1 2 3 4 5 6 7 8 9 1 EAU00118 Handlebar switches EAU01865 Light switch Set this switch to to turn on the headlight and taillight EC...

Page 24: ...ated at the left handlebar grip To disengage the clutch pull the lever toward the han dlebar grip To engage 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 circuit cut off system See page 3 12 for an explanation of the ignition circuit cut off system 1 Cl...

Page 25: ... Brake pedal The brake pedal is on the right side of the machine To apply the rear brake press down on the brake pedal 1 a 1 Fuel tank cap a Open EAU00179 Fuel tank cap To remove the fuel tank cap turn it counterclockwise and then pull it off To install the fuel tank cap insert it into the tank opening and then turn it clockwise EWA00025 w Make sure that the fuel tank cap is properly closed before...

Page 26: ...2 Imp gal 2 64 US gal Reserve amount 2 0 L 0 44 Imp gal 0 53 US gal Your Yamaha engine has been designed to use regular unleaded gasoline with a pump octane number R M 2 of 86 or higher or a research octane number of 91 or higher If knocking or pinging occurs use a gasoline of a different brand or premium unleaded fuel Use of unleaded fuel will extend spark plug life and reduce maintenance costs I...

Page 27: ... 1 Fuel tank breather hose ON FUEL RES OFF 1 ON 1 Arrow mark pointing to ON EAU03050 Fuel cock The fuel cock supplies fuel from the tank to the carburetor while filtering it also The fuel cock has three positions OFF With the lever in this position fuel will not flow Always return the lever to this position when the engine is not running ON With the lever in this position fuel flows to the carbure...

Page 28: ...ng OFF ON FUEL RES 1 RES 1 Arrow mark pointing to RES RES reserve position 1 a b EAU03032 Starter choke knob 1 Starting a cold engine requires a rich er air fuel mixture which is supplied by the starter choke Move the knob in direction a to turn on the starter choke Move the knob in direction b to turn off the starter choke 1 Starter choke knob 1 EAU00240 Seat To remove the seat Remove the bolts a...

Page 29: ...e fork legs Spring rate The total spring rate is adjusted by changing the air pressure as follows 1 Elevate the front wheel by plac ing a suitable stand under the engine NOTE When checking and adjusting the air pressure there should be no weight on the front end of the machine 2 Remove the air valve cap from each fork leg 3 Check the air pressure in each fork leg with an air pressure gauge NOTE An...

Page 30: ... damaged EW000035 w Always adjust both fork legs equally otherwise poor handling and loss of stability may result 5 Securely install the air valve caps Spring rate Minimum soft Air pressure 0 kPa 0 kgf cm2 0 psi Standard Air pressure 0 kPa 0 kgf cm2 0 psi Maximum hard Air pressure 40 kPa 0 4 kgf cm2 5 8 psi 1 Damping force 1 Remove the rubber cap from each fork leg 1 Rubber cap 1 a b 1 Compression...

Page 31: ...orber assembly is equipped with a spring preload adjusting nut a rebound damping force adjusting dial and a compres sion damping force adjusting knob EC000015 cC Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings 1 2 c b a 1 Locknut 2 Adjusting nut c Distance A Spring preload 1 Loosen the locknut 2 To increase the spring preload and thereby harden the suspen sion t...

Page 32: ... in direction a To decrease the rebound damping force and thereby soften the rebound damping turn the adjusting dial in direction b INSTRUMENT AND CONTROL FUNCTIONS 1 2 3 4 5 6 7 8 9 1 b a 1 Rebound damping force adjusting dial Spring preload Minimum soft Distance A 236 mm 9 3 in Standard Distance A 228 mm 9 0 in Maximum hard Distance A 224 mm 8 8 in Tightening torque Locknut 70 Nm 7 0 m0kg 51 ft0...

Page 33: ...of each damping force adjust ing mechanism and to modify the specifications as necessary EAU00315 w This shock absorber contains highly pressurized nitrogen gas For proper handling read and understand the following informa tion before handling the shock absorber The manufacturer can not be held responsible for proper ty damage or personal injury that may result from improper han dling 8 Do not tam...

Page 34: ...er is pulled Periodically check the operation of the ignition circuit cut off system according to the following procedure 1 Turn the key to ON and set the engine stop switch to 2 Put the transmission in gear and raise the sidestand 3 Apply the front or rear brake 4 Push the start switch If the engine does not start the clutch switch is OK EW000045 w If a malfunction is noted have a Yamaha dealer c...

Page 35: ...switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer 5 Turn the engine off 6 Shift the transmission into gear 7 Keep the clutch lever pulled 8 Push the start switch Does the engine start The clutch switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer NO NOTE This check is most reliable if performed with a warmed up eng...

Page 36: ...essary Check fuel line for leakage 3 3 3 6 Engine oil Check oil level in engine If necessary add recommended oil to specified level Check vehicle for oil leakage 6 8 6 11 Front brake Check operation If soft or spongy have Yamaha dealer bleed hydraulic system Check lever free play Adjust if necessary Check fluid level in reservoir If necessary add recommended brake fluid to specified level Check hy...

Page 37: ...Check for damage Check tire condition and tread depth Check air pressure Correct if necessary 6 15 6 17 Brake and shift pedals Make sure that operation is smooth Lubricate pedal pivoting points if necessary 6 25 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 25 Sidestand Make sure that operation is smooth Lubricate pivot if necessary 6 25 ...

Page 38: ...n inspection can be accomplished in a very short time and the added safety it assures is more than worth the time involved EWA00033 w If any item in the Pre operation check list is not working properly have it inspected and repaired before operat ing the machine Engine stop switch Check operation 3 2 ITEM CHECKS PAGE ...

Page 39: ...und and distract the opera tor resulting in a possible loss of control EAU03600 Starting and warming up a cold engine In order for the ignition circuit cut off system to enable starting one of the following conditions must be met 8 The transmission is in the neutral position 8 The transmission is in gear with the clutch lever pulled EW000054 w 8 Before starting the engine check the function of the...

Page 40: ...rt switch NOTE If the engine fails to start release the start switch wait a few seconds and then try again Each starting attempt should be as short as possible to pre serve the battery Do not crank the engine more than 10 seconds on any one attempt 6 After starting the engine move the starter choke knob lever back halfway ECA00055 cC For maximum engine life always warm the engine up before startin...

Page 41: ...ssion into the neu tral position press the shift pedal down repeatedly until it reaches the end of its travel and then slightly raise it EC000048 cC 8 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 machine for long dis tances The transmission is properly lubricated only when the engine is running Inadequate lubricatio...

Page 42: ...onds maximum does not harm the engine Each full throttle acceleration should be followed with a substantial rest period for the engine To allow the engine to cool down from the temporary buildup of heat cruise at a lower engine speed EC000049 cC If any engine trouble should occur during the engine break in period immediately have a Yamaha dealer check the vehicle 0 10 hours 8 Avoid prolonged opera...

Page 43: ...e remove the key from the main switch and then turn the fuel cock lever to OFF EW000058 w 8 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 8 Do not park on a slope or on soft ground otherwise the machine may overturn ...

Page 44: ...equired for a particular job have a Yamaha dealer perform it for you EW000062 w Modifications not approved by Yamaha may cause loss of perfor mance excessive emissions and render the vehicle unsafe for use Consult a Yamaha dealer before attempting any changes EAU03453 Safety is an obligation of the owner Periodic inspection adjustment and lubrication will keep your vehicle in the safest and most e...

Page 45: ...Crankcase breather 9 Check ventilation hose for cracks or damage and drain 5 any deposits system 9 Replace if necessary 6 Carburetor 9 Check engine idling speed and starter operation 9 Adjust if necessary 9 Check for leakage 7 Exhaust system 9 Retighten if necessary 9 Replace gasket if necessary 9 Check oil level and vehicle for oil leakage 8 Engine oil 9 Correct if necessary 9 Change Warm engine ...

Page 46: ...pressure 9 Correct if necessary 15 Wheel bearings 9 Check bearing for looseness or damage 9 Replace if necessary 9 Check chain slack 16 Drive chain 9 Adjust if necessary Make sure that the rear wheel is Every Ride properly aligned 9 Clean and lubricate 9 Check bearing play and steering for roughness 17 Steering bearings 9 Correct accordingly 9 Lubricate with lithium soap base grease every 1 200 mi...

Page 47: ...rake fluid level regularly and fill as required 9 Replace the oil seals on the inner parts of the master cylinder and caliper cylinder every two years 9 Replace the brake hoses every four years or if cracked or damaged Initial EVERY 100 mi 600 mi 1 200 mi No ITEM CHECKS AND MAINTENANCE JOBS 150 km or 1 000 km or 2 000 km or 1 month 6 months 12 months 22 Rear shock absorber 9 Check operation and sh...

Page 48: ...of the maintenance jobs described in this chapter 1 Panel B 1 Screw 3 Refer to this section each time the cowling or a panel needs to be removed and installed EAU00484 Cowling A To remove the cowling Remove the cowling screws and then pull the cowling off as shown To install the cowling Place the cowling in the original posi tion and then install the screws 1 2 1 Cowling A 2 Panel A ...

Page 49: ... In addition the condition of the spark plug can reveal the condition of the engine To remove the spark plug 1 Remove the spark plug cap 1 Spark plug cap 1 1 Screw EAU00488 Panel A To remove the panel Remove the screw and then pull the panel off as shown To install the panel Place the panel in the original posi tion and then install the screw 1 1 EAU00488 Panel B To remove the panel Remove the scr...

Page 50: ... be defective Do not attempt to diagnose such problems yourself Instead have a Yamaha dealer check the machine 2 Check the spark plug for elec trode erosion and excessive car bon or other deposits and replace it if necessary To install the spark plug 1 Measure the spark plug gap with a wire thickness gauge and if necessary adjust the gap to specification 2 Clean the surface of the spark plug gaske...

Page 51: ...enance and lubrication chart To check the engine oil level 1 Place the motorcycle on a level surface and hold it in an upright position NOTE Make sure that the motorcycle is positioned straight up when checking the oil level A slight tilt to the side can result in a false reading 2 Start the engine warm it up for several minutes and then turn it off 1 3 2 1 Level window 2 Maximum level mark 3 Mini...

Page 52: ...oil pan under the engine to collect the used oil 3 Remove the engine oil filler bolt and drain bolt to drain the oil from the crankcase 1 2 4 3 4 Remove the oil filter element drain bolt to drain the oil from the oil filter element NOTE Skip steps 5 9 if the oil filter element is not being cleaned 5 Remove the oil filter element cover by removing the bolts 1 Oil filter element drain bolt 2 Oil fil...

Page 53: ...all the engine oil drain bolt and then tighten it to the speci fied torque EC000066 cC 8 In order to prevent clutch slip page since the engine oil also lubricates the clutch do not mix any chemical additives with the oil 8 Make sure that no foreign material enters the crankcase Tightening torque Engine oil drain bolt 20 Nm 2 0 m0kg 14 5 ft0lb Recommended oil See page 8 1 Oil quantity Without oil f...

Page 54: ...o oil comes out after one minute turn the engine off immediately so it will not seize If this occurs have a Yamaha dealer repair the vehi cle 8 After checking the oil pres sure tighten the bleed bolt to the specified torque EAU03602 Cleaning the air filter element The air filter element should be cleaned at the intervals specified in the periodic maintenance and lubrica tion chart Clean the air fi...

Page 55: ...e of the sponge material and then squeeze the excess oil out NOTE The sponge material should be wet but not dripping Recommended oil Engine oil 1 2 3 4 7 Install the sponge material onto the frame insert the air filter ele ment into the air filter case and then install the air filter case cover by installing the holding clips EC000082 cC 8 Make sure that the air filter ele ment is properly seated ...

Page 56: ...ng bolt 2 Tap the tailpipe lightly and then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe 3 Insert the tailpipe into the muf fler and then install and tighten the bolts NOTE Make sure to align the bolt holes when inserting the tailpipe 2 1 1 Tailpipe 2 Spark arrester EAU01761 Cleaning the spark arrester NOTE Make sure to select a well ventilated are...

Page 57: ...y Changing these settings without sufficient technical knowl edge may result in poor perfor mance of or damage to the engine EAU00635 Adjusting the throttle cable free play The throttle cable free play should measure 3 5 mm 0 12 0 20 in at the throttle grip Periodically check the throttle cable free play and if necessary have a Yamaha dealer adjust it a a Throttle cable free play EAU00637 Adjustin...

Page 58: ...on both sides 8 Adjust the suspension and tire air pressure with regard to the load 8 Check the tire condition and air pressure before each ride Front Rear Off road riding 100 kPa 1 00 kgf cm2 15 0 psi 100 kPa 1 00 kgf cm2 15 0 psi EAU03677 Tires To maximize the performance dura bility and safe operation of your motorcycle note the following points regarding the specified tires Tire air pressure T...

Page 59: ...d be left to a Yamaha dealer who has the necessary profession al knowledge and experience 8 It is not recommended to patch a punctured tube If unavoidable however patch the tube very carefully and replace it as soon as possible with a high quality product Tire information This motorcycle is equipped with spoke wheels and tube tires EW000078 w 8 The front and rear tires should be of the same make a...

Page 60: ... parts may cause loss of han dling stability and riding safety Since Yamaha cannot control the quality of accessories or parts manufactured by other companies EAU00685 Spoke wheels To maximize the performance dura bility and safe operation of your machine note the following points regarding the specified wheels 8 The wheel rims should be checked for cracks bends or warpage and the spokes for loose...

Page 61: ...should measure 2 5 mm 0 08 0 20 in as shown Periodically check the brake lever free play and if necessary adjust it as follows 1 Loosen the locknut at the brake lever 2 To increase the brake lever free play turn the adjusting bolt in direction a To decrease the brake lever free play turn the adjusting bolt in direction b 3 Tighten the locknut 1 Adjusting bolt 2 Locknut c Brake lever free play 3 If...

Page 62: ... may result in loss of control and an accident a EAU00712 Adjusting the brake pedal position The top of the brake pedal should be positioned approximately 10 mm 0 39 in below the top of the footrest as shown Periodically check the brake pedal position and if neces sary have a Yamaha dealer adjust it a Brake pedal position EW000109 w A soft or spongy feeling in the brake pedal can indicate the pres...

Page 63: ...ficient brake fluid may allow air to enter the brake system possibly causing it to 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 level is low be sure to check the brake pads for wear and the brake system for leak age LOWER 1 1 Minimu...

Page 64: ...ter cylinder and caliper as well as the brake hoses replaced at the intervals listed below or whenever they are damaged or leaking 8 Oil seals Replace every two years 8 Brake hoses Replace every four years 8 Refill with the same type of brake fluid Mixing fluids may result in a harmful chemical reaction and lead to poor braking perfor mance 8 Be careful that water does not enter the master cylinde...

Page 65: ...Drive chain slack 1 2 3 a b EAU01269 To adjust the drive chain slack 1 Remove the cotter pin from the axle nut and then loosen the axle nut 2 To tighten the drive chain turn the adjusting plate on each side of the swingarm in direction a To loosen the drive chain turn the adjusting plate on each side of the swingarm in direction b and then push the rear wheel for ward 1 Cotter pin 2 Axle nut 3 Cha...

Page 66: ...ified in the periodic maintenance and lubrica tion chart otherwise it will quickly wear out especially when riding in dusty or wet areas Service the drive chain as follows EC000097 cC The drive chain must be lubricated after washing the machine or rid ing in the rain 1 Clean the drive chain with kerosene and a small soft brush ECA00053 cC To prevent damaging the O rings do not clean the drive chai...

Page 67: ...maha dealer check or replace it EW000111 w Damage to the outer housing of cables may result in internal rust ing and cause interference with cable movement Replace dam aged cables as soon as possible to prevent unsafe conditions Recommended lubricant Yamaha Chain and Cable Lube or engine oil SAE 10W 30 API SE 3 Thoroughly lubricate the drive chain with a special O ring chain lubricant ECA00052 cC ...

Page 68: ...cking and lubricating the brake and clutch levers The operation of the brake and clutch levers should be checked before each ride and the lever pivots should be lubricated if necessary Recommended lubricant Lithium soap based grease all purpose grease EAU00775 Checking and lubricating the brake and shift pedals The operation of the brake and shift pedals should be checked before each ride and the ...

Page 69: ...s may cause danger Therefore the opera tion of the steering must be checked as follows at the intervals specified in the periodic maintenance and lubrica tion chart 1 Place a stand under the engine to raise the front wheel off the ground EW000115 w Securely support the machine so that there is no danger of it falling over To check the operation 1 Place the machine on a level surface and hold it in...

Page 70: ...is would per manently damage the battery 1 1 Battery EAU01144 Checking the wheel bearings The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart If there is play in the wheel hub or if the wheel does not turn smoothly have a Yamaha dealer check the wheel bearings 2 Hold the lower ends of the front fork legs and try to move the...

Page 71: ...rom the battery and provide sufficient ventilation when charging it in an enclosed space 8 KEEP THIS AND ALL BATTER IES OUT OF THE REACH OF CHILDREN To charge the battery Have a Yamaha dealer charge the battery as soon as possible if it seems to have discharged Keep in mind that the battery tends to dis charge more quickly if the machine is equipped with optional electrical accessories To store th...

Page 72: ...e fuse holder is located behind panel B See page 6 6 for panel removal and installation procedures If the fuse is blown replace it as fol lows 1 Turn the key to OFF and turn off all electrical circuits 2 Remove the blown fuse and then install a new fuse of the specified amperage 1 2 1 Fuse 2 Spare fuse EC000103 cC Do not use a fuse of a higher amperage rating than recommend ed to avoid causing ext...

Page 73: ...l and installa tion procedures 2 Disconnect the headlight cou pler and then remove the head light bulb cover 1 Coupler 1 1 Bulb holder cover 1 1 Bulb holder 3 Remove the headlight bulb hold er by turning it counterclockwise and then remove the defective bulb EW000119 w Headlight bulbs get very hot Therefore keep flammable prod ucts away from a lit headlight bulb and do not touch the bulb until it ...

Page 74: ...ersely affected Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with alcohol or thinner 5 Install the bulb cover and then connect the coupler a a Do not touch this area 1 2 EAU03604 Replacing the taillight bulb 1 Remove the taillight lens by removing the screws 1 Screw 2 2 Lens 6 Install the cowling together with the headlight unit 7 Have a Yamaha deale...

Page 75: ...main tenance requiring the machine to stand upright Check that the machine is in a stable and level posi tion before starting any maintenance A strong wooden box can be placed under the engine for added stability To service the front wheel 1 Stabilize the rear of the machine by using a machine stand or if an additional machine stand is not available by placing a jack under the frame in front of th...

Page 76: ... then the wheel axle 1 Tripmeter cable 2 Axle holder nut 4 3 Wheel axle 3 Lift the front wheel off the ground according to the procedure on page 6 32 4 Pull the wheel axle out and then remove the wheel ECA00048 cC Do not apply the brake after the wheel has been removed together with the brake disc otherwise the brake pads will be forced shut EAU03606 To install the front wheel 1 Install the tripme...

Page 77: ...ied torque NOTE Tighten the upper nuts first and then the lower ones When the nuts are tightened in this sequence there should be a gap at the bottom of the axle holder 5 Push down hard on the handle bar several times to check for proper fork operation Tightening torque Wheel axle 58 Nm 5 8 m0kg 42 ft0lb Tightening torque Axle holder nut 10 Nm 1 0 m0kg 7 2 ft0lb a 1 1 Wheel axle a Gap 6 After tigh...

Page 78: ...ot need to be disassembled in order to remove and install the wheel 5 Remove the wheel ECA00048 cC Do not apply the brake after the wheel has been removed together with the brake disc otherwise the brake pads will be forced shut EAU03070 Rear wheel To remove the rear wheel EW000122 w 8 It is advisable to have a Yamaha dealer service the wheel 8 Securely support the machine so that there is no dang...

Page 79: ...5 Nm 10 5 m0kg 76 ft0lb EW000110 w Always use a new cotter pin for the axle nut EAU01008 Troubleshooting Although Yamaha motorcycles receive a thorough inspection before shipment from the factory trouble may occur during operation Any problem in the fuel compression or ignition systems for example can cause poor starting and loss of power The following troubleshooting chart represents a quick and ...

Page 80: ...to inspect Wet Dry Wipe clean with dry cloth and Open the throttle half way and start Ask a Yamaha dealer to inspect Engine turns over Engine turns over Battery good Check connections Use the electric starter Check if there is fuel Enough fuel No fuel Go to compression check Supply fuel in the fuel tank electrodes plug and check quickly slowly or recharge Engine doesn t start go to battery check t...

Page 81: ...d cov ers as well as all electrical cou plers and connectors including the spark plug cap are tightly installed 3 Remove extremely stubborn dirt like oil burnt onto the crankcase with a degreasing agent and a brush but never apply such products onto seals gaskets sprockets the drive chain and wheel axles Always rinse the dirt and degreaser off with water Cleaning ECA00010 cC 8 Avoid using strong a...

Page 82: ...ake sure that it does not leave any marks If the windshield is scratched use a quality plastic polishing compound after washing After normal use Remove dirt with warm water a mild detergent and a soft clean sponge and then rinse thoroughly with clean water Use a toothbrush or bottle brush for hard to reach areas Stubborn dirt and insects will come off more easily if the area is covered with a wet ...

Page 83: ...remaining dirt 6 Touch up minor paint damage caused by stones etc 7 Wax all painted surfaces 8 Let the machine dry completely before storing or covering it EWA00001 w 8 Make sure that there is no oil or wax on the brakes or tires If necessary clean the brake discs and brake linings with a regular brake disc cleaner or acetone and wash the tires with warm water and a mild detergent 8 Before operati...

Page 84: ...ning the drain bolt this will prevent fuel deposits from building up Pour the drained fuel into the fuel tank 4 Fill up the fuel tank and add fuel stabilizer if available to prevent the fuel tank from rusting and the fuel from deteriorating 5 Perform the following steps to protect the cylinder piston rings etc from corrosion a Remove the spark plug cap and spark plug b Pour a teaspoonful of engine...

Page 85: ... turn the wheels a little every month in order to pre vent the tires from becoming degraded in one spot 8 Cover the muffler outlet with a plastic bag to prevent moisture from entering it 9 Remove the battery and fully charge it Store it in a cool dry place and charge it once a month Do not store the battery in an excessively cold or warm place less than 0 C 30 F or more than 30 C 90 F For more inf...

Page 86: ...Starting system Electric starter Lubrication system Wet sump Engine oil Type Recommended engine oil classification API Service SE SF SG type or higher cC Be sure to use motor oils that do not contain anti friction modifiers Passenger car motor oils often labeled Energy Conserving contain anti friction additives which will cause clutch and or starter clutch slippage resulting in reduced component l...

Page 87: ...disc Transmission Primary reduction system Spur gear Primary reduction ratio 74 24 3 083 Secondary reduction system Chain drive Secondary reduction ratio 4 000 Number of drive chain sprocket teeth rear front 52 13 Transmission type Constant mesh 6 speed Operation Left foot operation Gear ratio 1st 2 467 2nd 1 813 3rd 1 364 4th 1 080 5th 0 889 6th 0 759 Chassis Frame type Semi double cradle Caster ...

Page 88: ...5 18 Brakes Front Type Single disc brake Operation Right hand Fluid DOT 4 Rear Type Single disc brake Operation Right foot Fluid DOT 4 Suspension Front Type Telescopic fork Rear Type Swingarm link suspension Spring Shock absorber Front Coil spring oil damper Rear Coil spring gas oil damper Wheel travel Front 280 mm 11 02 in Rear 280 mm 11 02 in Electrical Ignition system C D I Charging system Type...

Page 89: ...1 2 3 4 5 6 7 8 9 SPECIFICATIONS Headlight type Halogen bulb Bulb voltage wattage quantity Headlight 12 V 35 36 5W 1 Taillight 12 V 21 5W 1 Fuse 15A ...

Page 90: ... into the steering head pipe Record this number in the space pro vided NOTE The vehicle identification number is used to identify your machine and may be used to register your machine with the licensing authority in your area EAU02944 Identification numbers Record the key identification number vehicle identification number and model label information in the spaces provided below for assistance whe...

Page 91: ...bel The model label is affixed to the frame under the seat See page 3 6 for seat removal and installation pro cedures Record the information on this label in the space provided This information will be needed when ordering spare parts from a Yamaha dealer 1 Model label ...

Page 92: ... incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any per son AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW These acts include tampering with the following systems...

Page 93: ...1 2 3 4 5 6 7 8 9 CONSUMER INFORMATION ...

Page 94: ...RMATION 1 2 3 4 5 6 7 8 9 EAU02932 Maintenance record Have a Yamaha dealer complete this record when the motorcycle is serviced Maintenance interval Date of service Mileage Servicing dealer name and address Remarks ...

Page 95: ...CONSUMER INFORMATION 1 2 3 4 5 6 7 8 9 Maintenance interval Date of service Mileage Servicing dealer name and address Remarks ...

Page 96: ...CONSUMER INFORMATION 1 2 3 4 5 6 7 8 9 EAU02922 ...

Page 97: ...CONSUMER INFORMATION 1 2 3 4 5 6 7 8 9 ...

Page 98: ...CONSUMER INFORMATION 1 2 3 4 5 6 7 8 9 ...

Page 99: ...CONSUMER INFORMATION 1 2 3 4 5 6 7 8 9 ...

Page 100: ...PRINTED IN JAPAN PRINTED ON RECYCLED PAPER See your Authorized YAMAHA Dealer for a Genuine YAMAHA Service Manual PROTECT YOUR INVESTMENT Use Genuine YAMAHA Parts And Accessories YAMAHA MOTOR CO LTD ...

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