Yamaha VIRAGO XV250R Owner'S Manual Download Page 41 | Manualshive

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-2

6

EAU00468

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 job, have
a Yamaha dealer perform it for you.

@

EW000062

WARNING

@

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 at-
tempting any changes.

@

1. Owner’s tool kit

E_U2UJ1B.book Page 2 Wednesday, May 29, 2002 1:56 PM

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Summary of Contents for VIRAGO XV250R

Page 1: ...2UJ 28199 1B LIT 11626 16 21 XV250R XV250RC OWNER S MANUAL ...

Page 2: ...EAU03438 ...

Page 3: ...orcycle If you have any questions concerning the operation or maintenance of your motorcycle please consult a Yamaha dealer The design and manufacture of this Yamaha motorcycle fully comply with the emis sions standards for clean air applicable at the date of manufacture Yamaha has met these standards without reducing the performance or economy of operation of the motorcycle To maintain these high...

Page 4: ... be taken to avoid damage to the motorcycle NOTE A NOTE provides key information to make procedures easier or clearer NOTE This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold Yamaha continually seeks advancements in product design and quality Therefore while this manual contains the most current product informat...

Page 5: ...T TO OPERATE THIS MOTORCYCLE UNTIL YOU HAVE AT TAINED ADEQUATE KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES REGULAR INSPECTIONS AND CAREFUL MAINTENANCE ALONG WITH GOOD RIDING SKILLS WILL ENSURE THAT YOU SAFELY ENJOY THE CAPABILITIES AND THE RELI ABILITY OF THIS MOTORCYCLE E_U2UJ1B book Page 2 Wednesday May 29 2002 1 56 PM ...

Page 6: ...2002 by Yamaha Motor Corporation U S A 1st edition April 2002 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 16 21 E_U2UJ1B book Page 3 Wednesday May 29 2002 1 56 PM ...

Page 7: ... Helmet holder 3 9 Adjusting the shock absorber assemblies 3 10 Sidestand 3 10 Ignition circuit cut off system 3 11 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 2 Starting a warm engine 5 3 Shifting 5 4 Engine break in 5 5 Parking 5 6 PERIODIC MAINTENANCE AND MINOR REPAIR 6 1 Periodic maintenance 6 1 Owner s...

Page 8: ... brake and shift pedals 6 26 Checking and lubricating the brake and clutch levers 6 26 Checking and lubricating the sidestand 6 27 Checking the front fork 6 27 Checking the steering 6 28 Checking the wheel bearings 6 28 Battery 6 29 Replacing the fuses 6 31 Replacing the headlight bulb 6 32 Supporting the motorcycle 6 33 Front wheel 6 34 Rear wheel 6 36 Troubleshooting 6 37 Troubleshooting chart 6...

Page 9: ... MECHANICAL CONDITIONS Safe riding 1 Always make pre operation checks Careful checks may help prevent an accident 2 This motorcycle is designed to carry the operator and a passenger 3 The failure of motorists to detect and recognize motorcycles in traffic is the predominating cause of automobile motorcycle accidents Many accidents have been caused by an automobile driver who did not see the motorc...

Page 10: ...undercornering insuf ficient lean angle for the speed a Always obey the speed limit and never travel faster than warranted by road and traffic conditions b Always signal before turning or changing lanes Make sure that other motorists can see you 6 The posture of the operator and passenger is important for proper control a The operator should keep both hands on the handlebar and both feet on the op...

Page 11: ... They become very hot and can cause burns Always wear protective clothing that covers your legs ankles and feet 6 Passengers should also observe the precautions mentioned above Modifications Modifications made to this motorcycle not approved by Yamaha or the removal of original equipment may render the motorcycle unsafe for use and may cause severe personal injury Modifications may also make your ...

Page 12: ...se items in cluding such cargo as sleeping bags duffel bags or tents can create unstable handling or slow steering response Accessories Genuine Yamaha accessories have been specifically designed for use on this motorcycle Since Yamaha cannot test all other accessories that may be available you must personally be responsible for the proper selection installation and use of non Yamaha accessories Us...

Page 13: ...y therefore such accessories are not recommended 2 Use caution when adding electrical accessories If electrical accessories exceed the capacity of the motorcycle s electrical system an electric failure could result which could cause a dangerous loss of lights or engine power Gasoline and exhaust gas 1 GASOLINE IS HIGHLY FLAMMABLE a Always turn the engine off when refueling b Take care not to spill...

Page 14: ...ould catch fire 4 When transporting the motorcycle in another vehicle make sure that it is kept upright and that the fuel cock is turned to ON or RES for vacuum type OFF for manual type If it should lean over gasoline may leak out of the carburetor or fuel tank 5 If you should swallow any gasoline inhale a lot of gasoline vapor or allow gasoline to get into your eyes see your doctor immediately If...

Page 15: ...SAFETY INFORMATION 1 1 7 EAU02977 Location of important labels Please read the following important labels carefully before operating this motorcycle E_U2UJ1B book Page 7 Wednesday May 29 2002 1 56 PM ...

Page 16: ...SAFETY INFORMATION 1 1 8 5 California only 1 2 4 California only 3 E_U2UJ1B book Page 8 Wednesday May 29 2002 1 56 PM ...

Page 17: ... page 3 8 3 Fuel tank page 3 4 4 Battery page 6 29 5 Fuses page 6 31 6 Helmet holder page 3 9 7 Shock absorber assembly spring preload adjusting ring page 3 10 8 Main switch page 3 1 9 Fuel cock page 3 6 10 Shift pedal page 3 3 E_U2UJ1B book Page 1 Wednesday May 29 2002 1 56 PM ...

Page 18: ...t 13 Rider seat page 3 8 14 Air filter element page 6 11 15 Front turn signal position light 16 Brake pedal page 3 4 17 Footrest 18 Owner s tool kit page 6 2 19 Shock absorber assembly spring preload adjusting ring page 3 10 E_U2UJ1B book Page 2 Wednesday May 29 2002 1 56 PM ...

Page 19: ...page 3 3 2 Left handlebar switches page 3 2 3 Speedometer unit page 3 2 4 Indicator lights page 3 1 5 Right handlebar switches page 3 3 6 Brake lever page 3 4 7 Throttle grip page 6 13 8 Fuel tank cap page 3 4 E_U2UJ1B book Page 3 Wednesday May 29 2002 1 56 PM ...

Page 20: ...be removed The key must be pushed in from the OFF position to be turned to P ECA00043 CAUTION Do not use the parking position for an extended length of time other wise the battery may discharge EAU00056 Indicator lights EAU00064 High beam indicator light HIGH BEAM This indicator light comes on when the high beam of the headlight is switched on EAU00062 Neutral indicator light NEUTRAL This indicato...

Page 21: ...stops EAU00118 Handlebar switches EAU00122 Dimmer switch LIGHTS Set the switch to HI for the high beam and to LO for the low beam EAU00125 Turn signal switch TURN To signal a right hand turn push this switch to the right To signal a left hand turn push this switch to the left When released the switch returns to the cen ter position To cancel the turn signal lights push the switch in after it has r...

Page 22: ... 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 The clutch lever is equipped with a clutch switch which is part of the igni tion circuit cut off system See page 3 11 for an explanation of the ignition circuit cut off system EAU00157 Shift pedal The shift pedal i...

Page 23: ...press down on the brake pedal EAU03712 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 be opened To close the fuel tank cap 1 Push the fuel tank cap into posi tion with the key inserted in the lock 2 Turn the key counterclockwise to the original position and then re move it 1 Brake lever 1 Brak...

Page 24: ...ller tube as shown EW000130 WARNING _ Do not overfill the fuel tank oth erwise it may overflow when the fuel warms up and expands Avoid spilling fuel on the hot engine _ EAU00185 CAUTION Immediately wipe off spilled fuel with a clean dry soft cloth since fuel may deteriorate painted surfac es or plastic parts EAU04265 1 Fuel tank filler tube 2 Fuel level Recommended fuel UNLEADED GASOLINE ONLY Fue...

Page 25: ...so hol containing ethanol and that contain ing methanol Gasohol containing ethanol can be used if the ethanol con tent does not exceed 10 Gasohol containing methanol is not recom mended by Yamaha because it can cause damage to the fuel system or ve hicle performance problems EAU04484 Fuel cock This motorcycle is equipped with a negative pressure fuel cock The fuel cock supplies fuel from the tank ...

Page 26: ...e 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 After the engine has started be sure to turn the lever to ON or RES if you have not refueled yet EAU00211 Starter choke lever Starting a cold engine requires a richer air fuel mixture which is supplied by the starter choke...

Page 27: ...the key 1 8 turn clockwise 4 Check that the steering is locked remove the key and then close the lock cover To unlock the steering 1 Open the steering lock cover and then insert the key 2 Push the key in turn it 1 8 turn counterclockwise so that it moves out and then release it 3 Remove the key and then close the lock cover EAU01072 Rider seat To remove the rider seat Remove the bolts and then pul...

Page 28: ...y secured before riding EAU00260 Helmet holder To open the helmet holder insert the key into the lock and then turn the key as shown To lock the helmet holder place it in the original position and then remove the key EW000030 WARNING Never ride with a helmet attached to the helmet holder since the helmet may hit objects causing loss of control and possibly an accident 1 Projection 2 Seat holder 1 ...

Page 29: ... a To de crease the spring preload and thereby soften the suspension turn the adjust ing ring on each shock absorber as sembly in direction b NOTE Align the appropriate notch in the ad justing ring with the position indicator on the shock absorber CI 10E EAU00330 Sidestand The sidestand is located on the left side of the frame Raise the sidestand or lower it with your foot while holding the motorc...

Page 30: ...nction properly EAU03720 Ignition circuit cut off system The ignition circuit cut off system com prising the sidestand switch clutch switch and neutral switch has the fol lowing functions It prevents starting when the trans mission is in gear and the side stand is up but the clutch lever is not pulled It prevents starting when the trans mission is in gear and the clutch lever is pulled but the sid...

Page 31: ...the clutch lever pulled 8 Shift the transmission into gear 9 Move the sidestand down Does the engine stall After the engine has stalled 10 Move the sidestand up 11 Keep the clutch lever pulled 12 Push the start switch Does the engine start The sidestand switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer The clutch switch may be defective The motorcycle sho...

Page 32: ...ne If necessary add recommended oil to specified level Check vehicle for oil leakage 6 8 6 9 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 hydraulic system for leakage 6 18 6 20 6 22 Rear brake Check operation Check ped...

Page 33: ...Correct if necessary 6 14 6 16 Brake and shift pedals Make sure that operation is smooth Lubricate pedal pivoting points if necessary 6 26 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 26 Sidestand Make sure that operation is smooth Lubricate pivot if necessary 6 27 Chassis fasteners Make sure that all nuts bolts and screws are properly t...

Page 34: ...usness and death within a short time Al ways make sure that there is ad equate ventilation Before starting out make sure that the sidestand is up If the sidestand is not raised com pletely it could contact the ground and distract the opera tor resulting in a possible loss of control EAU00376 CAUTION Make sure not to store personal items near the air cleaner in take otherwise air intake will be blo...

Page 35: ...er to ON 2 Turn the key to ON and make sure that the engine stop switch is set to RUN 3 Shift the transmission into the neu tral position NOTE _ When the transmission is in the neutral position the neutral indicator light should be on otherwise have a Yamaha dealer check the electrical cir cuit _ 4 Turn the starter choke on and completely close the throttle See page 3 7 for starter choke opera tio...

Page 36: ...of excessive exhaust emissions never leave the starter choke on long er than necessary The time necessary for starter choke use depends upon the ambient temperature Tempera tures above 10 C 50 F require about 7 seconds of starter choke use and temperatures below 10 C 50 F re quire about 35 seconds with the starter choke turned on then about 2 5 min utes with the starter choke in the half way posit...

Page 37: ...hile changing gears to avoid dam aging the engine transmission and drive train which are not designed to withstand the shock of forced shifting EAU02988 To start out and accelerate 1 Pull the clutch lever to disengage the clutch 2 Shift the transmission into first gear The neutral indicator light should go out 3 Open the throttle gradually and at the same time release the clutch lever slowly 4 At ...

Page 38: ...ation are shown in the table below CF 04E EAU01128 Engine break in There is never a more important period in the life of your engine than the period between 0 and 1 600 km 1 000 mi For this reason you should read the following material carefully Since the engine is brand new do not put an excessive load on it for the first 1 600 km 1 000 mi The various parts in the engine wear and polish them selv...

Page 39: ... filter element replaced and the oil strainer cleaned If any engine trouble should oc cur during the engine break in period immediately have a Yamaha dealer check the vehi cle _ EAU00460 Parking When parking stop the engine and then remove the key from the main switch EW000058 WARNING Since the engine and exhaust system can become very hot park in a place where pedestri ans or children are not lik...

Page 40: ...u are not familiar with motor cycle maintenance work have a Yamaha dealer do it for you EAU00467 PERIODIC MAINTENANCE PROPER PERIODIC MAINTENANCE OF YOUR MOTORCYCLE IS IMPOR TANT IN ORDER TO ENJOY LONG PLEASURABLE SERVICE ESPE CIALLY IMPORTANT ARE THE MAINTENANCE SERVICES RELAT ED TO EMISSIONS CONTROL THESE CONTROLS NOT ONLY FUNCTION TO ENSURE CLEANER AIR BUT ARE ALSO VITAL TO PROPER ENGINE OPERAT...

Page 41: ...ools 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 job have a Yamaha dealer perform it for you EW000062 WARNING 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 at tempting any...

Page 42: ...alve clearance when engine is cold 2 Spark plugs Check condition Adjust gap and clean Replace every 7 000 mi 11 000 km or 12 months Replace Replace 3 Crankcase ventilation system Check ventilation hose for cracks or damage Replace if necessary 4 Fuel line Check fuel hose and vacuum hose for cracks or damage Replace if necessary 5 Exhaust system Check for leakage Tighten if necessary Replace gasket...

Page 43: ... Adjust free play 6 Drive chain Check chain condition Adjust and lubricate chain thoroughly SAE 30W 50W motor oil Every 300 mi 500 km 7 Control and meter cable Apply chain lube thoroughly Yamaha Chain and Cable Lube or engine oil SAE 10W 30 API SE 8 Swingarm pivot shaft Check swingarm assembly for looseness Moderately repack Lithium soap based grease all purpose grease Check 9 Brake and clutch lev...

Page 44: ...n the inner parts of the master cylinder and caliper cylinder every two years Replace the brake hoses every four years or if cracked or damaged 12 Front fork Check operation and leakage 13 Steering bearings Check bearings assembly for looseness Moderately repack every 10 000 mi 16 000 km or 18 months Lithium soap based grease all purpose grease Repack 14 Wheel bearings Check bearings for smooth op...

Page 45: ...d ed in the owner s tool kit To check the spark plugs 1 Check that the porcelain insulator around the center electrode on each spark plug is a medium to light tan the ideal color when the motorcycle is ridden normally 2 Check that all spark plugs installed in the engine have the same color NOTE If any spark plug shows a distinctly dif ferent color the engine could be defec tive Do not attempt to d...

Page 46: ...the spark plug with the spark plug wrench and then tight en it to the specified torque NOTE If a torque wrench is not available when installing a spark plug a good estimate of the correct torque is 1 4 1 2 turn past finger tight However the spark plug should be tightened to the speci fied torque as soon as possible 4 Install the spark plug cap a Spark plug gap Spark plug gap 0 6 0 7 mm 0 02 0 03 i...

Page 47: ... clean it EAU04613 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 replaced at the intervals specified in the periodic maintenance and lubri cation 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 motorcy...

Page 48: ...icient oil of the recommended type to raise it to the correct level To change the engine oil with or without oil filter element replace ment 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 cap and drain bolt to drain the oil from the crankcase NOTE _ Skip steps 4 6 if the oil filter el...

Page 49: ...ngine oil also lubricates the clutch do not mix any chemical additives Do not use oils with a diesel speci fication of CD or oils of a higher quality than specified In addition do not use oils labeled ENERGY CONSERVING II or higher Make sure that no foreign mate rial enters the crankcase _ 1 Bolt 3 2 Oil filter element cover Tightening torque Oil filter element cover bolt 7 Nm 0 7 m kgf 5 1 ft lbf...

Page 50: ...t it if necessary EAU04182 Cleaning the air filter element The air filter element should be cleaned at the intervals specified in the periodic maintenance and lubrication chart Clean the air filter element more fre quently if you are riding in unusually wet or dusty areas 1 Remove the air filter case cover by removing the bolts and loosening the clamp screw 1 Bolt 2 1 Clamp screw 2 Air filter case...

Page 51: ...ent frame clean it with solvent and then squeeze the remaining solvent out 5 Apply oil of the recommended type to the entire surface of the sponge material and then squeeze the ex cess oil out NOTE _ The air filter element should be wet but not dripping _ 1 Screw 2 1 Wing nut 2 Air filter case 1 Sponge material 2 Air filter element frame Recommended oil Engine oil E_U2UJ1B book Page 12 Wednesday M...

Page 52: ...crews 9 Install the air filter case cover by installing the bolts 10 Tighten the clamp screw EAU01752 Adjusting the carburetor 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 EAU00635 Adjusting...

Page 53: ...sted before each ride EW000082 WARNING The tire air pressure must be checked and adjusted on cold tires i e when the temperature of the tires equals the ambient temperature The tire air pressure must be adjusted in accordance with the riding speed and with the total weight of rider passenger car go and accessories approved for this model CE 22E CE 07E 1 Sidewall 2 Tire wear indicator a Tire tread ...

Page 54: ...ways check the tires before operating the motorcycle If a tire tread shows crosswise lines minimum tread depth if the tire has a nail or glass fragments in it or if the sidewall is cracked con tact a Yamaha dealer immediately and have the tire replaced CE 10E CE 23E EAU00680 WARNING It is dangerous to ride with a worn out tire When a tire tread begins to show crosswise lines have a Yamaha dealer r...

Page 55: ...e broken in for it to develop its optimal characteristics EAU00691 Accessories and replacement parts EW000098 WARNING This motorcycle is not designed to pull a trailer or to be attached to a sidecar The accessories or replace ment parts you choose for your motorcycle should be designed spe cifically for this model and they must be securely mounted to main tain the inherent stability of the orig in...

Page 56: ...lutch 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 at the clutch lever in direction a to loos en the clutch cable 5 Loosen the locknut at the crankcase 6 To increase the clutch lever free play turn the adjusting nut in di rection a To decrease the clutch lever free play turn...

Page 57: ...cate 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 motorcycle Air in the hydraulic system will dimin ish the braking performance which may result in loss of con trol and an accident EAU03778 Adjusting the brake pedal position and free play EW000104 WARNING _ It is advisable to have a Yamaha dealer mak...

Page 58: ...e pedal free play and if necessary adjust it as follows To increase the brake pedal free play turn the adjusting nut at the brake rod in direction a To decrease the brake pedal free play turn the adjusting nut in direction b EW000106 WARNING _ After adjusting the drive chain slack or removing and installing the rear wheel always check the brake pedal free play If proper adjustment cannot be obtain...

Page 59: ...Checking the front brake pads and rear brake shoes The front brake pads and the rear brake shoes must be checked for wear at the intervals specified in the periodic maintenance and lubrication chart EAU00725 Front brake pads Each front brake pad is provided with a wear indicator groove which allows you to check the brake pad wear with out having to disassemble the brake To check the brake pad wear...

Page 60: ...brake flu id level may indicate worn brake pads and or brake system leakage If the brake fluid level is low be sure to check the brake pads for wear and the brake system for leakage Observe these precautions When checking the fluid level make sure that the top of the brake fluid reservoir is level Use only the recommended quali ty brake fluid otherwise the rubber seals may deteriorate causing leak...

Page 61: ...tion chart In addition have the oil seals of the brake master cylinder and caliper as well as the brake hose replaced at the intervals listed below or whenever they are dam aged or leaking Oil seals Replace every two years Brake hose Replace every four years EAU00744 Drive chain slack The drive chain slack should be checked before each ride and adjusted if necessary To check the drive chain slack ...

Page 62: ...g nut 2 Remove the cotter pin from the axle nut and then loosen the axle nut 3 Loosen the chain puller locknut at each end of the swingarm 4 To tighten the drive chain turn the adjusting nut at each end of the swingarm in direction a To loos en the drive chain turn the adjust ing nut at each end of the swingarm in direction b and then push the rear wheel forward Drive chain slack 30 40 mm 1 2 1 6 ...

Page 63: ...s and then tighten the axle nut to the specified torque 6 Insert a new cotter pin into the axle nut and then bend its ends as shown NOTE Make sure that two notches in the axle nut are aligned with the hole through the wheel axle otherwise further tight en the axle nut until they are EW000110 WARNING Always use a new cotter pin for the axle nut 7 Adjust the brake pedal free play See page 6 19 for b...

Page 64: ... 3 Thoroughly lubricate the drive chain with a special O ring chain lubricant ECA00052 CAUTION Do not use engine oil or any other lubricants for the drive chain as they may contain substances that could damage the O rings EAU03297 Checking and lubricating the cables The operation of all control cables and the condition of the cables should be checked before each ride and the ca bles and cable ends...

Page 65: ...e and shift pedals The operation of the brake and shift pedals should be checked before each ride and the pedal pivots should be lu bricated if necessary EAU03164 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 Recommended lubricant Lithium soap based grease ...

Page 66: ...ic main tenance and lubrication chart To check the condition EW000115 WARNING Securely support the motorcycle 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 motorcycle on a level surface and hold it in an upright position 2 While applying the front brake push down hard on the handle bars several ...

Page 67: ...support the motorcycle 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 EAU01144 Checking the wheel bearings The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrica tion chart...

Page 68: ...level 1 Place the motorcycle on a level surface and hold it in an upright position NOTE Make sure that the motorcycle is posi tioned straight up when checking the electrolyte level 2 Check the electrolyte level in the battery NOTE The electrolyte should be between the minimum and maximum level marks 3 If the electrolyte is at or below the minimum level mark add distilled water to raise it to the m...

Page 69: ...this may weaken it shorten chain life and possibly result in an accident KEEP THIS AND ALL BATTER IES OUT OF THE REACH OF CHILDREN EC000100 CAUTION Use only distilled water as tap water contains minerals that are harmful to the battery 4 Check and if necessary tighten the battery lead connections and correct the breather hose routing To store the battery 1 If the motorcycle will not be used for mo...

Page 70: ... follows 1 Turn the key to OFF and turn off the electrical circuit in question 2 Remove the blown fuse and then install a new fuse of the specified amperage EC000103 CAUTION _ 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 circuit in question to check if...

Page 71: ...e the bulb cover 3 Remove the headlight bulb holder by turning it counterclockwise and then remove the defective bulb EW000119 WARNING _ 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 position and then secure it with the bulb holder 1 Screw 2 1 Headlight coupler 2 ...

Page 72: ...e front and rear wheel or performing other mainte nance requiring the motorcycle to stand upright Check that the motor cycle is in a stable and level position before starting any maintenance A strong wooden box can be placed un der the engine for added stability To service the front wheel 1 Stabilize the rear of the motorcycle by using a motorcycle stand or if an additional motorcycle stand is not...

Page 73: ... Do not apply the brake after the wheel has been removed together with the brake disc otherwise the brake pads will be forced shut EAU04423 To install the front wheel 1 Install the speedometer gear unit into the wheel hub so that the pro jections mesh with the slots 2 Lift the wheel up between the fork legs NOTE _ Make sure that there is enough space between the brake pads before insert ing the br...

Page 74: ...torque 7 Push down hard on the handlebar several times to check for proper fork operation 8 Connect the speedometer cable 1 Speedometer gear unit 2 Retainer 3 Speedometer cable Tightening torque Wheel axle 59 Nm 5 9 m kgf 43 ft lbf Tightening torque Front wheel axle pinch bolt 20 Nm 2 0 m kgf 14 ft lbf E_U2UJ1B book Page 35 Wednesday May 29 2002 1 56 PM ...

Page 75: ...e shoe plate 4 Remove the brake pedal free play adjusting nut and then disconnect the brake rod at the brake cam shaft lever 5 Disconnect the brake torque rod from the brake shoe plate by re moving the nut and the bolt 6 Lift the rear wheel off the ground according to the procedure on page 6 33 7 Remove the axle nut 8 Pull the wheel axle out and then remove the wheel 1 Brake torque rod 2 Brake tor...

Page 76: ...tion and free play adjustment procedures EW000103 WARNING _ After adjusting the brake pedal free play check the operation of the brake light _ EAU01008 Troubleshooting Although Yamaha motorcycles receive 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 p...

Page 77: ...spark plugs and check 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 battery Open the throttle halfway and operate the electric starter Operate the electric starter 4 Battery The engine turns over quickly The engine turns over slowly The battery is good...

Page 78: ...ctrical couplers and connectors including the spark plug caps are tightly in stalled 3 Remove extremely stubborn dirt like oil burnt onto the crankcase with a degreasing agent and a brush but never apply such prod ucts onto seals gaskets sprock ets the drive chain and wheel axles Always rinse the dirt and degreaser off with water Cleaning ECA00010 CAUTION Avoid using strong acidic wheel cleaners e...

Page 79: ...d shield is scratched use a quali ty 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 bottlebrush for hard to reach areas Stubborn dirt and insects will come off more easily if the area is covered with a wet cloth for a few minutes before cleaning After ridin...

Page 80: ...paint damage caused by stones etc 7 Wax all painted surfaces 8 Let the motorcycle dry completely before storing or covering it EWA00001 WARNING 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 ac etone and wash the tires with warm water and a mild deter gent Before operating the motor cycle test i...

Page 81: ... 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 the cylinders piston rings etc from corrosion a Remove the spark plug caps and spark plugs b Pour a teaspoonful of engine oil into each spark plug bore c Install the spark plug caps ont...

Page 82: ... month in order to prevent the tires from becoming degraded in one spot 8 Cover the muffler outlets with plas tic bags to prevent moisture from entering them 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 cessively cold or warm place less than 0 C 30 F or more than 30 C 60 F For more informa tion on storing the bat...

Page 83: ... Lubrication system Wet sump Engine oil Type Recommended engine oil classification API Service SE SF SG or higher Quantity Without oil filter element replacement 1 4 L 1 2 Imp qt 1 5 US qt With oil filter element replacement 1 6 L 1 4 Imp qt 1 7 US qt Total amount dry engine 1 8 L 1 6 Imp qt 1 9 US qt Air filter Wet element 0 10 30 50 70 90 110 130 F YAMALUBE 4 20W 40 or SAE 20W 40 20 10 0 10 20 3...

Page 84: ...y reduction system Spur gear Primary reduction ratio 3 130 Secondary reduction system Chain drive Secondary reduction ratio 2 812 Number of drive chain sprocket teeth front rear 16 45 Transmission type Constant mesh 5 speed Operation Left foot Gear ratio 1st 2 643 2nd 1 684 3rd 1 261 4th 1 000 5th 0 821 Chassis Frame type Double cradle Caster angle 32 Trail 120 mm 4 7 in Tires Front Type With tube...

Page 85: ... Rear Type Spoke wheel Size 15M C MT 2 75 Brakes Front Type Single disc brake Operation Right hand Fluid DOT 4 Rear Type Drum brake Operation Right foot Suspension Front Telescopic fork Rear Swingarm Spring shock absorbers Front Coil spring oil damper Rear Coil spring oil damper Wheel travel Front 140 mm 5 5 in Rear 100 mm 3 9 in Electrical system Ignition system T C I digital Charging system Type...

Page 86: ... turn signal position light 12 V 27 8 W 2 Rear turn signal light 12 V 27 W 2 Meter lighting 14 V 3 W 1 Neutral indicator light 14 V 3 W 1 High beam indicator light 12 V 1 7 W 1 Turn signal indicator light 14 V 3 W 1 Fuses Main fuse 20 A Signaling system fuse 10 A E_U2UJ1B book Page 4 Wednesday May 29 2002 1 56 PM ...

Page 87: ...01E EAU01042 Key identification number The key identification number is stamped into the key Record this num ber in the space provided and use it for reference when ordering a new key EAU01043 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 used to identify you...

Page 88: ...under the rider seat See page 3 8 for rider seat removal and installation pro cedures Record the information on this label in the space provided This in formation will be needed when ordering spare parts from a Yamaha dealer 1 Model label E_U2UJ1B book Page 2 Wednesday May 29 2002 1 56 PM ...

Page 89: ...estigation and if it finds that a safety defect exists in group of vehicles it may order a recall and remedy campaign However NHTSA cannot become involved in individual problems between you your dealer or Yamaha Motor Corporation U S A To contact NHTSA you may either call the Auto Safety Hotline toll free at 1 800 424 9393 or 366 0123 in Washington D C area or write to NHTSA U S Department of Tran...

Page 90: ... 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 systems i e modification removal etc CL 01...

Page 91: ...printed only as a reminder that maintenance work is required It is not acceptable proof of maintenance work CL 06E Maintenance interval Date of service Mileage Servicing dealer name and address Remarks 600 mi 1 000 km or 1 month 4 000 mi 6 000 km or 6 months 7 000 mi 11 000 km or 12 months 10 000 mi 16 000 km or 18 months 13 000 mi 21 000 km or 24 months 16 000 mi 26 000 km or 30 months 19 000 mi ...

Page 92: ...or 42 months 25 000 mi 41 000 km or 48 months 28 000 mi 46 000 km or 54 months 31 000 mi 51 000 km or 60 months Maintenance interval Date of service Mileage Servicing dealer name and address Remarks E_U2UJ1B book Page 6 Wednesday May 29 2002 1 56 PM ...

Page 93: ...CONSUMER INFORMATION 9 7 9 EAU02918 YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY E_U2UJ1B book Page 7 Wednesday May 29 2002 1 56 PM ...

Page 94: ...CONSUMER INFORMATION 9 8 9 E_U2UJ1B book Page 8 Wednesday May 29 2002 1 56 PM ...

Page 95: ...CONSUMER INFORMATION 9 9 9 EAU01063 YAMAHA EXTENDED SERVICE Y E S E_U2UJ1B book Page 9 Wednesday May 29 2002 1 56 PM ...

Page 96: ...CONSUMER INFORMATION 9 10 9 E_U2UJ1B book Page 10 Wednesday May 29 2002 1 56 PM ...

Page 97: ...PRINTED IN JAPAN 2002 05 0 5 1 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD ...

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