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PERIODIC MAINTENANCE AND MINOR REPAIR

6-31

2

3

4

5

6

7

8

9

EAU24350

Supporting the machine

Since this model is not equipped with a
centerstand, follow these precautions
when removing the front and rear
wheel or performing other maintenance
requiring the machine to stand upright.
Check that the machine is in a stable
and level position 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 the rear wheel.

2. Raise the front wheel off the

ground by using a machine stand.

To service the rear wheel

Raise the rear wheel off the ground by
using a machine stand or, if a machine
stand is not available, by placing a jack
either under each side of the frame in
front of the rear wheel or under each
side of the swingarm.

EAU24360

Front wheel

EAU24670

To remove the front wheel

WARNING

EWA10820

●

It is advisable to have a Yamaha
dealer service the wheel.

●

Securely support the machine
so that there is no danger of it

falling over.

1. Remove the tripmeter cable from

the front wheel.

2. Loosen the wheel axle holder nuts,

then the wheel axle.

3. Lift the front wheel off the ground

according to the procedure on
page 6-31.

4. Pull the wheel axle out, and then

remove the wheel.

CAUTION:

ECA11070

Do not apply the brake after the
wheel has been removed together
with the brake disc, otherwise the

brake pads will be forced shut.

EAU24961

To install the front wheel

1. Install the tripmeter gear unit into

the wheel hub so that the projec-
tions mesh with the slots.

1. Tripmeter cable
2. Wheel axle holder nut
3. Wheel axle

1

2

(

×

4

)

3

1. Tripmeter gear unit

1

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Summary of Contents for TTR250V

Page 1: ...LIT 11626 19 30 5GF 28199 17 TTR250V C OWNER S MANUAL ...

Page 2: ......

Page 3: ...uring 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 4: ...UR MOTORCYCLE RIDING TIPS BOOKLET CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MACHINE DO NOT ATTEMPT TO OPERATE THIS MACHINE UNTIL YOU HAVE ATTAINED ADEQUATE KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES REGULAR INSPECTIONS AND CARE FUL MAINTENANCE ALONG WITH GOOD RIDING SKILLS WILL ENSURE THAT YOU SAFELY ENJOY THE CAPA BIL...

Page 5: ...SE ONLY IT IS ILLEGAL TO OPERATE THIS MACHINE ON ANY PUBLIC STREET ROAD OR HIGHWAY SUCH USE IS PROHIBITED BY LAW THIS MA CHINE COMPLIES WITH ALMOST ALL STATE OFF HIGHWAY NOISE LEVEL AND SPARK ARRESTER LAWS AND REGULATIONS PLEASE CHECK YOUR LOCAL RIDING LAWS AND REGULATIONS BEFORE OPERATING THIS MACHINE ...

Page 6: ...TR250V OWNER S MANUAL 2005 by Yamaha Motor Corporation U S A 1st edition April 2005 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 19 30 ...

Page 7: ...ving and installing the cowling and panels 6 6 Checking the spark plug 6 7 Engine oil and oil filter element 6 8 Cleaning the air filter element 6 12 Cleaning the spark arrester 6 13 Carburetor 6 14 Checking the throttle cable free play 6 14 Valve clearance 6 15 Tires 6 15 Spoke wheels 6 17 Accessories and replacement parts 6 17 Adjusting the clutch lever free play 6 18 Adjusting the brake lever f...

Page 8: ...STORAGE 7 1 Care 7 1 Storage 7 3 SPECIFICATIONS 8 1 CONSUMER INFORMATION 9 1 Identification numbers 9 1 Motorcycle noise regulation 9 3 Maintenance record 9 4 YAMAHA MOTOR CORPORATION U S A OFF ROAD MOTORCYCLE LIMITED WARRANTY 9 5 YAMAHA EXTENDED SERVICE Y E S 9 7 ...

Page 9: ...xperi enced operators Make sure that you are qualified and that you only lend your ma chine to other qualified opera tors Know your skills and limits Staying within your limits may help you to avoid an accident Many accidents have been caused by error of the machine operator A typical error made by the operator is veering wide on a turn due to EXCESSIVE SPEED or undercor nering insufficient lean a...

Page 10: ...ust not exceed the maximum load limit of 90 kg 198 lb When loading within this weight limit keep the following in mind 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 sides of the machine to minimize imbal ance or instability Shifting weights can create a sud den imbalance Make sure that ac cesso...

Page 11: ...d exhaust gas GASOLINE IS HIGHLY FLAMMA BLE Always turn the engine off when refueling Take care not to spill any gaso line on the engine or exhaust pipe s muffler s when refuel ing Never refuel while smoking or in the vicinity of an open flame Never start the engine or let it run for any length of time in a closed area The exhaust fumes are poi sonous and may cause loss of consciousness and death ...

Page 12: ...ne inhale a lot of gasoline vapor or allow gasoline to get into your eyes see your doctor immediate ly If any gasoline spills on your skin or clothing immediately wash the affected area with soap and water and change your clothes ...

Page 13: ...SAFETY INFORMATION 1 6 1 EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle 1 2 3 4 ...

Page 14: ...ELS NEVER CARRY A PASSENGER You increase you operate this vehicle on a public road EXPERIENCED RIDER ONLY 8 8 8 8 8 5PA 2118K 00 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 carry a passenger BEFORE YOU OPERATE THIS VEHICLE READ 1 3 2 4 Riding as...

Page 15: ...eadlight page 6 29 2 Front fork air valve page 3 7 3 Fuel cock page 3 5 4 Starter choke knob page 3 6 5 Air filter element page 6 12 6 Shock absorber assembly rebound damping force adjusting dial page 3 9 7 Shift pedal page 3 2 8 Front fork damping adjusting screw page 3 7 ...

Page 16: ...arrester page 6 13 2 Battery page 6 27 3 Fuse page 6 28 4 Shock absorber assembly compression damping force adjusting knob page 3 9 5 Main switch page 3 1 6 Engine oil filter element page 6 8 7 Brake pedal page 3 3 8 Shock absorber assembly spring preload adjusting nut page 3 9 ...

Page 17: ...EAU10430 Controls and instruments 1 2 3 4 5 6 7 1 Clutch lever page 3 2 2 Left handlebar switch page 3 1 3 Tripmeter page 3 1 4 Right handlebar switches page 3 1 5 Brake lever page 3 3 6 Throttle grip page 6 14 7 Fuel tank cap page 3 3 ...

Page 18: ...e removed EAU10660 OFF All electrical systems are off The key can be removed EAU11830 Tripmeter The tripmeter shows the distance trav eled since it was last set to zero with the reset knob The tripmeter can be used to estimate the distance that can be traveled with a full tank of fuel This in formation will enable you to plan future fuel stops EAU12343 Handlebar switches Left Right OFF ON 1 Tripme...

Page 19: ...his switch to crank the engine with the starter CAUTION ECA10050 See page 5 1 for starting instruc tions prior to starting the engine EAU31640 Clutch lever The clutch lever is located at the left handlebar grip To disengage the clutch pull the lever toward the handle bar grip To engage the clutch release the lever The lever should be pulled rapidly and released slowly for smooth clutch operation T...

Page 20: ...e pedal is on the right side of the machine To apply the rear brake press down on the brake pedal EAU13180 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 clock wise WARNING EWA11090 Make sure that the fuel tank cap is properly closed before riding 1 Brake lever 1 1 Brake pedal 1 1...

Page 21: ... the exhaust system Your Yamaha engine has been de signed to use regular unleaded gaso line 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 premi um unleaded fuel Use of unleaded fuel will extend spark plug life and reduce maintenance costs Gasohol There are two types of gasohol gaso ho...

Page 22: ...ies fuel from the tank to the carburetor while filtering it al so 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 carburetor Normal riding is done with the lever in this position RES This indicates reserve If you run out of 1 Fuel tan...

Page 23: ...tarting a cold engine requires a richer 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 EAU13960 Seat To remove the seat Remove the bolts and then pull the seat off To install the seat 1 Insert the projections on the front of the seat into the seat holders as shown 1 Starter...

Page 24: ...as follows 1 Lift the front wheel off the ground according to the procedure on page 6 31 NOTE When checking and adjusting the air pressure there should be no weight on the front end of the vehicle 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 optional air pressure gauge is avail able at a Yamaha dealer 4 To increase the s...

Page 25: ...h fork leg in direction a To decrease the damping force and thereby soften the damping turn the ad justing screw on each fork leg in di rection b CAUTION ECA10100 Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings 3 Securely install the rubber caps Spring rate Minimum soft Air pressure 0 kPa 0 psi 0 kgf cm2 Standard Air pressure 0 kPa 0 psi 0 kgf cm2 Maximum hard A...

Page 26: ... justing dial and a compression damping force adjusting knob CAUTION ECA10100 Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings Spring preload 1 Loosen the locknut 2 To increase the spring preload and thereby harden the suspension turn the adjusting nut in direction a To decrease the spring pre load and thereby soften the sus pension turn the adjusting nut in dire...

Page 27: ...g force adjusting mechanism may not exactly match the above spec ifications due to small differences in production the actual number of clicks always represents the entire adjusting range To obtain a precise adjustment it would be advisable to check the num ber of clicks of each damping force ad justing mechanism and to modify the specifications as necessary WARNING EWA10220 This shock absorber co...

Page 28: ...may explode due to excessive gas pressure Do not deform or damage the gas cylinder in any way as this will result in poor damping per formance Always have a Yamaha dealer service the shock absorber EAU15390 Starting circuit cut off system The starting circuit cut off system com prising the clutch switch and the neutral switch prevents starting when the transmission is in gear and the clutch lever ...

Page 29: ...l 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 a warmed up engine YES The system is OK The motorcycle can ...

Page 30: ...pressure could have serious consequences Therefore it is very important in addition to a thorough visual inspec tion to check the following points before each ride NOTE Pre operation checks should be made each time the vehicle is used Such an inspection can be accomplished in a very short time and the added safety it assures is more than worth the time involved WARNING EWA11150 If any item in the ...

Page 31: ...ry Check fluid level in reservoir If necessary add recommended brake fluid to specified level Check hydraulic system for leakage 6 19 6 20 Rear brake Check operation If soft or spongy have Yamaha dealer bleed hydraulic system Check brake pads for wear Replace if necessary Check fluid level in reservoir If necessary add recommended brake fluid to specified level Check hydraulic system for leakage 6...

Page 32: ...15 6 17 Brake and shift pedals Make sure that operation is smooth Lubricate pedal pivoting points if necessary 6 24 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 24 Sidestand Make sure that operation is smooth Lubricate pivot if necessary 6 25 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened Tighten if nec...

Page 33: ...n gear with the clutch lever pulled WARNING EWA11320 Before starting the engine check the function of the start ing circuit cut off system ac cording to the procedure described on page 3 11 Never ride with the sidestand down 1 Turn the fuel cock lever to ON 2 Turn the key to ON and make sure that the engine stop switch is set to 3 Shift the transmission into the neu tral position 4 Turn the starte...

Page 34: ... into the neu tral position press the shift pedal down repeatedly until it reaches the end of its travel and then slightly raise it CAUTION ECA10260 Even with the transmission in the neutral position do not coast for long periods of time with the engine off and do not tow the machine for long dis tances The transmission is properly lubricated only when the engine is running Inade quate lubrication...

Page 35: ...rom the temporary build up of heat cruise at a lower engine speed 0 10 hours Avoid prolonged operation above 1 2 throttle After every hour of operation stop the engine and then let it cool for five to ten minutes Vary the engine speed from time to time Do not operate the engine at one set throttle position 10 20 hours Avoid prolonged operation above 3 4 throttle Rev the engine freely through the g...

Page 36: ...u EAU17310 Owner s tool kit The service information included in this manual and the tools provided in the owner s tool kit are intended to assist you in the performance of preventive maintenance and minor repairs How ever additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly NOTE If you do not have the tools or experi ence required for a particular...

Page 37: ...i 2000 km or 12 months 1 Fuel line Check fuel hoses for cracks or damage Replace if necessary 2 Spark plug Check condition Adjust gap and clean 3 Valve clearance Check and adjust valve clearance when engine is cold 4 Air filter element Clean with solvent Replace if necessary 5 Crankcase breather system Check ventilation hose for cracks or damage and drain any deposits Replace if necessary 6 Carbur...

Page 38: ... or damage Replace Every 4 years 5 Wheels Check runout spoke tightness and for damage Tighten spokes if necessary 6 Tires Check tread depth and for damage Replace if necessary Check air pressure Correct if necessary 7 Wheel bearings Check bearings for smooth operation Replace if necessary 8 Swingarm pivot bearings Check bearing assemblies for looseness Moderately repack with lithium soap based gre...

Page 39: ... Spark arrester Clean 16 Front fork Check operation and for oil leakage Replace if necessary 17 Shock absorber assembly Check operation and for oil leakage Replace if necessary 18 Rear suspension link pivots Apply molybdenum disulfide grease lightly 19 Control and meter cables Apply Yamaha chain and cable lube or engine oil 10W 30 thor oughly 20 Throttle grip housing and cable Check operation and ...

Page 40: ... you are riding in unusually wet or dusty areas Hydraulic brake service Regularly check and if necessary correct the brake fluid level Every two years replace the internal components of the brake master cylinders and calipers and change the brake fluid Replace the brake hoses every four years and if cracked or damaged ...

Page 41: ...ion each time the cowling or a panel needs to be re moved and installed EAU18850 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 EAU19292 Panels A and B To remove one of the panels Remove the screw and then pull the panel off as shown 1 Cowling A 2 Panel A...

Page 42: ...the engine To remove the spark plug 1 Remove the spark plug cap 2 Remove the spark plug as shown with the spark plug wrench includ ed in the owner s tool kit To check the spark plug 1 Check that the porcelain insulator around the center electrode of the spark plug is a medium to light tan the ideal color when the vehicle is ridden normally NOTE If the spark plug shows a distinctly dif ferent color...

Page 43: ...AU19784 Engine oil and oil filter element The engine oil level should be checked before each ride In addition the oil must be changed and the oil filter ele ment cleaned at the intervals specified in the General maintenance and lubri cation chart To check the engine oil level 1 Place the vehicle on a level sur face and hold it in an upright posi tion NOTE Make sure that the vehicle is positioned s...

Page 44: ...ment cleaning 1 Start the engine warm it up for several minutes and then turn it off 2 Place an 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 NOTE Check each washer for damage and re place them if necessary 4 Remove the oil filter element drain bolt to drain the oil from the oil filter element 1 Engine oil le...

Page 45: ...ts then tightening them to the specified torque NOTE Make sure that the O rings are properly seated 10 Install the engine oil drain bolt and then tighten it to the specified torque 11 Install the engine oil filter element drain bolt and then tighten it to the specified torque 12 Add the specified amount of the recommended engine oil and then install and tighten the oil filler cap 1 Oil filter elem...

Page 46: ...cause 14 Turn the engine off and then check the oil level and correct it if necessary CAUTION ECA10970 After replacing the engine oil make sure to check the oil pressure as de scribed below Remove the bleed bolt from the engine oil filter element cover Start the engine and keep it idling until oil flows out If no oil comes out after one minute turn the engine off immediately so it will not seize I...

Page 47: ... Remove the sponge material from the air filter element frame 5 Clean the sponge material with solvent and then squeeze the re maining solvent out 6 Apply oil of the recommended type to the entire surface of the sponge material and then squeeze the ex cess oil out NOTE The sponge material should be wet but not dripping 7 Install the sponge material onto the frame insert the air filter ele ment int...

Page 48: ...ied in the periodic maintenance and lubrication chart NOTE Make sure to select a well ventilated area free of combustible materials to clean the spark arrester 1 Remove the tailpipe by removing the bolts and then pulling it out of the muffler 2 Tap the tailpipe lightly and then use a wire brush to remove any carbon deposits from the spark ar rester portion of the tailpipe and in side of the tailpi...

Page 49: ...etor The carburetor is an important part of the engine and its emission control sys tem which requires very sophisticated adjustment Therefore carburetor ad justments should be left to Yamaha dealer who has the necessary profes sional knowledge and experience EAU21381 Checking the throttle cable free play The throttle cable free play should mea sure 3 0 5 0 mm 0 12 0 20 in at the throttle grip Per...

Page 50: ...es i e when the temperature of the tires equals the ambient temperature The tire air pressure must be ad justed in accordance with the riding speed and with the total weight of rider cargo and ac cessories approved for this model WARNING EWA10450 Because loading has an enormous impact on the handling braking performance and safety characteris tics of your vehicle you should keep the following prec...

Page 51: ... the handling characteristics of the vehicle cannot be guaranteed After extensive tests only the tires listed below have been ap proved for this model by Yamaha Motor Co Ltd WARNING EWA10570 Have a Yamaha dealer replace excessively worn tires Besides being illegal operating the ma chine with excessively worn tires decreases riding stability and can lead to loss of control The replacement of all wh...

Page 52: ...after changing a tire since the tire sur face must first be broken in for it to develop its optimal characteris tics EAU22011 Accessories and replacement parts WARNING EWA10621 This vehicle is not designed to pull a trailer or to be attached to a sidecar The accessories or replacement parts you choose for your vehicle should be designed specifically for this model and they must be se curely mounte...

Page 53: ...r free play turn the adjusting bolt in direction b 3 If the specified clutch lever free play could be obtained as de scribed above tighten the locknut and skip the rest of the procedure otherwise proceed as follows 4 Fully turn the adjusting bolt in di rection a to loosen the clutch ca ble 5 Loosen the locknut further down the clutch cable 6 To increase the clutch lever free play turn the adjustin...

Page 54: ...ighten the locknut WARNING EWA10630 After adjusting the brake lever free play check the free play and make sure that the brake is working properly A soft or spongy feeling in the brake lever can indicate the presence of air in the hydraulic system If there is air in the hy draulic system have a Yamaha dealer bleed the system before operating the machine Air in the hydraulic system will dimin ish t...

Page 55: ...he brake system possibly caus ing 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 fluid level is low be sure to check the brake pads for wear and the brake system for leakage Observe these precautions When checking the fluid leve...

Page 56: ... and lubrication chart In addition have the oil seals of the master cylin ders and calipers as well as the brake hoses replaced at the intervals listed below or whenever they are damaged or leaking Oil seals Replace every two years Brake hoses Replace every four years EAU22760 Drive chain slack The drive chain slack should be checked before each ride and adjusted if necessary EAU22771 To check the...

Page 57: ...r wheel alignment CAUTION ECA10570 Improper drive chain slack will over load the engine as well as other vital parts of the machine and can lead to chain slippage or breakage To pre vent this from occurring keep the drive chain slack within the speci fied limits 3 Tighten the axle nut to the speci fied torque 4 Insert a new cotter pin into the axle nut and then bend its ends as shown NOTE Make sur...

Page 58: ...te solvents 2 Wipe the drive chain dry 3 Thoroughly lubricate the drive chain with a special O ring chain lubricant CAUTION ECA11110 Do not use engine oil or any other lu bricants for the drive chain as they may contain substances that could damage the O rings EAU23090 Checking and lubricating the cables The operation of all control cables and the condition of the cables should be checked before e...

Page 59: ...rt EAU23140 Checking 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 lu bricated if necessary EAU23180 Lubricating the brake pedal The operation of the brake pedal should be checked before each ride and the pedal pivot should be lubricat ed if necessary Recommended lubricant Lithium soap base...

Page 60: ...e intervals specified in the periodic main tenance and lubrication chart To check the condition WARNING EWA10750 Securely support the vehicle so that there is no danger of it falling over 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 2 While applying the front brake push down h...

Page 61: ...he ground WARNING EWA10750 Securely support the vehicle so that there is no danger of it falling over 2 Hold the lower ends of the front fork legs and try to move them for ward and backward If any free play can be felt have a Yamaha dealer check or repair the steering EAU23290 Checking the wheel bearings The front and rear wheel bearings must be checked at the intervals specified in the periodic m...

Page 62: ...on Batteries produce explosive 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 KEEP THIS AND ALL BATTER IES OUT OF THE REACH OF CHILDREN To charge the battery Have a Yamaha dealer charge the bat tery as soon as possible if it seems to have discharged Keep in mind that the battery tends to disc...

Page 63: ...e 6 6 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 CAUTION ECA10640 Do not use a fuse of a higher amper age rating than recommended to avoid causing extensive damage to the electrical system and possibly a fire 3 Turn the key to ON and turn on the electrical circu...

Page 64: ...ARNING EWA10790 Headlight bulbs get very hot There fore keep flammable products away from a lit headlight bulb and do not touch the bulb until it has cooled down 4 Place a new headlight bulb into po sition and then secure it with the bulb holder CAUTION ECA10660 Do not touch the glass part of the headlight bulb to keep it free from oil otherwise the transparency of the glass the luminosity of the ...

Page 65: ...Replacing the taillight bulb 1 Remove the taillight lens by re moving the screws 2 Remove the defective bulb by pushing it in and turning it counter clockwise 3 Insert a new bulb into the socket push it in and then turn it clock wise until it stops 4 Install the lens by installing the screws CAUTION ECA10680 Do not overtighten the screws oth erwise the lens may break 1 Do not touch the glass part ...

Page 66: ...achine stand or if a machine stand is not available by placing a jack either under each side of the frame in front of the rear wheel or under each side of the swingarm EAU24360 Front wheel EAU24670 To remove the front wheel WARNING EWA10820 It is advisable to have a Yamaha dealer service the wheel Securely support the machine so that there is no danger of it falling over 1 Remove the tripmeter cab...

Page 67: ...e holder nuts to the specified 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 While applying the front brake push down hard on the handlebars several times to check if the front fork compresses and rebounds smoothly 6 Connect the tripmeter cable 1 Retainer 2 Wheel axle 3 Wheel ax...

Page 68: ...re on page 6 31 3 Remove each swingarm end cover by removing the screws 4 Push the wheel forward and then remove the drive chain from the rear sprocket NOTE The drive chain does not need to be disassembled in order to remove and install the wheel 5 Remove the wheel CAUTION ECA11070 Do not apply the brake after the wheel has been removed together with the brake disc otherwise the brake pads will be...

Page 69: ...eive a thorough inspection before shipment from the factory trouble may occur dur ing 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 easy procedure for checking these vital systems your self However should your machine re quire any repair take it to a Yamaha dealer wh...

Page 70: ...ere is no compression Check the ignition Have a Yamaha dealer check the vehicle Remove the spark plug and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gap or replace the spark plug Have a Yamaha dealer check the vehicle The engine does not start Have a Yamaha dealer check the vehicle The engine does not start Check the battery Operate the electric starter 4 ...

Page 71: ...s are used on hard to remove dirt do not leave the cleaner on the af fected area any longer than in structed Also thoroughly rinse the area off with water immedi ately dry it and then apply a cor rosion protection spray Improper cleaning can damage windshields cowlings panels and other plastic parts Use only a soft clean cloth or sponge with mild detergent and water to clean plastic Do not use any...

Page 72: ...hamois or an absorbing cloth 2 Immediately dry the drive chain and lubricate it to prevent it from rusting 3 Use a chrome polish to shine chrome aluminum and stain less steel parts including the ex haust system Even the thermally induced discoloring of stain less steel exhaust systems can be removed through polishing 4 To prevent corrosion it is recom mended to apply a corrosion pro tection spray ...

Page 73: ... a fuel cock that has an OFF position Turn the fuel cock lever to OFF 3 Drain the carburetor float chamber by loosening 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 pro tect th...

Page 74: ...ift the machine so that both of its wheels are off the ground Alterna tively turn the wheels a little every month in order to prevent the tires from 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 ex cessive...

Page 75: ...lement replacement 1 10 L 1 16 US qt 0 97 Imp qt With oil filter element replacement 1 20 L 1 27 US qt 1 06 Imp qt Air filter Air filter element Wet element Fuel Recommended fuel Unleaded gasoline only Fuel tank capacity 9 5 L 2 51 US gal 2 09 Imp gal Fuel reserve amount 2 0 L 0 53 US gal 0 44 Imp gal Carburetor Manufacturer TEIKEI Type quantity Y30P x 1 Spark plug s Manufacturer model NGK CR9E Ma...

Page 76: ... size 21x1 60 Rear wheel Wheel type Spoke wheel Rim size 18x2 15 Front brake Type Single disc brake Operation Right hand operation Recommended fluid DOT 4 Rear brake Type Single disc brake Operation Right foot operation Recommended fluid DOT 4 Front suspension Type Telescopic fork Spring shock absorber type Coil air spring oil damper Wheel travel 280 0 mm 11 02 in Rear suspension Type Swingarm lin...

Page 77: ...SPECIFICATIONS 8 3 1 2 3 4 5 6 7 8 9 Fuse Fuse 15 0 A ...

Page 78: ...LABEL INFORMATION EAU26381 Key identification number The key identification number is stamped into the key tag Record this number in the space provided and use it for reference when ordering a new key EAU26400 Vehicle identification number The vehicle identification number is stamped into the steering head pipe Record this number in the space pro vided NOTE The vehicle identification number is use...

Page 79: ... EAU26480 Model label The model label is affixed to the frame under the seat See page 3 6 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 1 ...

Page 80: ...n incorporated into any new ve hicle 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 person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW These acts include tampering with the following system...

Page 81: ...RMATION 9 4 1 2 3 4 5 6 7 8 9 EAU26651 Maintenance record Have a Yamaha dealer complete this record when the machine is serviced Maintenance interval Date of service Mileage Servicing dealer name and address Remarks ...

Page 82: ...CONSUMER INFORMATION 9 5 2 3 4 5 6 7 8 9 EAU26670 YAMAHA MOTOR CORPORATION U S A OFF ROAD MOTORCYCLE LIMITED WARRANTY ...

Page 83: ...CONSUMER INFORMATION 9 6 1 2 3 4 5 6 7 8 9 ...

Page 84: ... have to pay anything for covered repairs There s no deductible to pay and repairs aren t pro rated You don t have any out of pocket expenses for covered repairs In addition Travel and Recreation Interruption Protection TRIP is included at no extra cost TRIP gives you up to 150 reimbursement per occurrence for any reasonable expenses you incur because your Yamaha needs covered service replacement ...

Page 85: ...ng you ll have strong factory backed protection even after your Yamaha Limited Warranty expires A special note If visiting your dealer isn t convenient contact Yamaha with your Primary ID number your frame number We ll be happy to help you get the Y E S coverage you need Yamaha Service Marketing P O Box 6555 Cypress CA 90630 1 866 YES EXTD 1 866 937 3983 ...

Page 86: ...bulb replacing 6 29 I Identification numbers 9 1 K Key identification number 9 1 L Labels location of 1 5 Light switch 3 2 M Main switch 3 1 Maintenance and lubrication periodic 6 3 Maintenance emission control system 6 2 Maintenance record 9 4 Model label 9 2 N Noise regulation 9 3 P Parking 5 3 Part locations 2 1 Pre operation check list 4 2 S Safety information 1 1 Seat 3 6 Shifting 5 2 Shift p...

Page 87: ...PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2005 5 1 1 1 E ...

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