Yamaha VIRAGO Owner'S Manual Download

Page: 37 / 92

PERIODIC MAINTENANCE AND MINOR REPAIR

6-2

WARNING

EWA10340

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.

2UJ1C.book Page 2 Monday, June 2, 2003 1:04 PM

Summary of Contents for VIRAGO

Page 1: ...2UJ 28199 1C LIT 11626 17 28 XV250S XV250SC OWNER S MANUAL ...

Page 2: ...EAU10041 2UJ1C book Page 1 Monday June 2 2003 1 04 PM ...

Page 3: ...motorcycle 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 emissions 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 hi...

Page 4: ...OKLET CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE DO NOT ATTEMPT TO OPERATE THIS MOTOR CYCLE 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 CAREFUL MAINTENANCE ALONG WITH GOOD RIDING SKILLS WILL ENSURE THAT YOU SAFELY ENJOY THE CAPABILITIES AND THE RELIABILI...

Page 5: ... Corporation U S A 1st edition May 2003 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 17 28 AFFIX DEALER LABEL HERE 2UJ1C book Page 2 Monday June 2 2003 1 04 PM ...

Page 6: ... the spark plugs 6 8 Canister for California only 6 9 Engine oil and oil filter element 6 10 Cleaning the air filter element 6 12 Adjusting the carburetor 6 14 Adjusting the throttle cable free play 6 14 Adjusting the valve clearance 6 14 Tires 6 15 Spoke wheels 6 16 Accessories and replacement parts 6 17 Adjusting the clutch lever free play 6 17 Adjusting the brake lever free play 6 18 Adjusting ...

Page 7: ...are 7 1 Storage 7 3 SPECIFICATIONS 8 1 CONSUMER INFORMATION 9 1 Identification numbers 9 1 Reporting safety defects 9 3 Motorcycle noise regulation 9 4 Maintenance record 9 5 YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY 9 7 YAMAHA EXTENDED SERVICE Y E S 9 9 2UJ1C book Page 2 Monday June 2 2003 1 04 PM ...

Page 8: ...idents have been caused by an automobile driver who did not see the motorcycle Making yourself conspicuous appears to be very effective in reducing the chance of this type of accident Therefore Wear a brightly colored jacket Use extra caution when ap proaching and passing through intersections since intersec tions are the most likely places for motorcycle accidents to oc cur Ride where other motor...

Page 9: ... face shield or goggles Wind in your unprotected eyes could contribute to an impairment of vision which could delay seeing a hazard The use of a jacket heavy boots trousers gloves etc is effective in preventing or reducing abrasions or lacerations Never wear loose fitting clothes otherwise they could catch on the control levers footrests or wheels and cause injury or an accident Never touch the en...

Page 10: ...ose provided under Load ing when mounting accessories Never install accessories or carry cargo that would impair the perfor mance of your motorcycle Care fully inspect the accessory before using it to make sure that it does not in any way reduce ground clearance or cornering clearance limit suspension travel steering travel or control operation or ob scure lights or reflectors Accessories fitted t...

Page 11: ...aust system may be hot therefore park the motorcycle in a place where pe destrians or children are not like ly to touch these hot areas Do not park the motorcycle on a slope or soft ground otherwise it may fall over Do not park the motorcycle near a flammable source e g a kero sene heater or near an open flame otherwise it could catch fire When transporting the motorcycle in another vehicle make s...

Page 12: ...SAFETY INFORMATION 1 5 1 EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle 2UJ1C book Page 5 Monday June 2 2003 1 04 PM ...

Page 13: ...SAFETY INFORMATION 1 6 1 1 3 2 4 California only 5 California only 2UJ1C book Page 6 Monday June 2 2003 1 04 PM ...

Page 14: ...ck page 3 8 3 Fuel tank page 3 5 4 Battery page 6 28 5 Fuses page 6 30 6 Helmet holder page 3 9 7 Shock absorber assembly spring preload adjusting ring page 3 9 8 Main switch page 3 1 9 Fuel cock page 3 6 10 Shift pedal page 3 4 2UJ1C book Page 1 Monday June 2 2003 1 04 PM ...

Page 15: ...gnal lights 3 Rider seat page 3 8 4 Air filter element page 6 12 5 Front turn signal position lights 6 Brake pedal page 3 4 7 Footrest 8 Owner s tool kit page 6 1 9 Shock absorber assembly spring preload adjusting ring page 3 9 2UJ1C book Page 2 Monday June 2 2003 1 04 PM ...

Page 16: ... lever 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 2 6 Brake lever page 3 4 7 Throttle grip page 6 14 8 Fuel tank cap page 3 5 2UJ1C book Page 3 Monday June 2 2003 1 04 PM ...

Page 17: ...are on but all other electrical systems are off The key can be removed The key must be pushed in from the OFF position to be turned to P CAUTION ECA11020 Do not use the parking position for an extended length of time other wise the battery may discharge EAU10980 Indicator lights EAU11040 Turn signal indicator light TURN This indicator light flashes when the turn signal switch is pushed to the left...

Page 18: ...l distance traveled The tripmeter shows the distance traveled 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 information will en able you to plan future fuel stops EAU12341 Handlebar switches Left Right 1 Odometer 2 Tripmeter 3 Tripmeter reset knob 4 Speedometer 1 Dimmer switch LIGHTS 2 Turn si...

Page 19: ... starting the engine Set this switch to OFF to stop the engine in case of an emergen cy such as when the vehicle overturns or when the throttle cable is stuck EAU12690 Start switch START Push this switch to crank the engine with the starter CAUTION ECA10050 See page 5 1 for starting instruc tions prior to starting the engine EAU12820 Clutch lever The clutch lever is located at the left handlebar g...

Page 20: ... stant mesh transmission equipped on this motorcycle EAU12890 Brake lever The brake lever is located at the right handlebar grip To apply the front brake pull the lever toward the handle bar grip EAU12941 Brake pedal The brake pedal is on the right side of the motorcycle To apply the rear brake press down on the brake pedal 1 Shift pedal 1 Brake lever 1 Brake pedal 2UJ1C book Page 4 Monday June 2 ...

Page 21: ...tank cap cannot be closed un less the key is in the lock In addition the key cannot be removed if the cap is not properly closed and locked WARNING EWA11090 Make sure that the fuel tank cap is properly closed before riding EAU13210 Fuel Make sure that there is sufficient fuel in the tank Fill the fuel tank to the bottom of the filler tube as shown WARNING EWA10880 Do not overfill the fuel tank oth...

Page 22: ...ol 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 EAU13580 Fuel cock This model is equipped with a negative pressure fuel cock The fuel cock sup plies fuel from the tank to the c...

Page 23: ...sition the engine can be primed Turn the fuel cock lever to this position when the engine has been al lowed 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 EAU13630 Starter choke lever Starting a cold engine requires a richer air fuel mixture which is suppl...

Page 24: ...ing 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 EAU14220 Rider seat To remove the rider seat Remove the bolts and then pull the rid er seat off To install the rider seat 1...

Page 25: ...d then remove the key WARNING EWA10160 Never ride with a helmet attached to the helmet holder since the helmet may hit objects causing loss of con trol and possibly an accident EAU14880 Adjusting the shock absorber assemblies Each shock absorber assembly is equipped with a spring preload adjust ing ring CAUTION ECA10100 Never attempt to turn an adjusting mechanism beyond the maximum or minimum set...

Page 26: ...our foot while holding the vehicle upright NOTE The built in sidestand switch is part of the ignition circuit cut off system which cuts the ignition in certain situations See further down for an explanation of the ignition circuit cut off system WARNING EWA10240 The vehicle must not be ridden with the sidestand down or if the side stand cannot be properly moved up or does not stay up otherwise the...

Page 27: ...t the clutch lever is not pulled It prevents starting when the trans mission is in gear and the clutch le ver is pulled but the sidestand is still down It cuts the running engine when the transmission is in gear and the sid estand is moved down Periodically check the operation of the ignition circuit cut off system according to the following procedure WARNING EWA10250 If a malfunction is noted hav...

Page 28: ...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 system is OK The motorcycle can be ridden This check is most reliable if performed with a warmed up engine The neutral switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer The sidestand switch may be defective The motorcycl...

Page 29: ...nsequences 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 Pre operation check list is no...

Page 30: ... wear Replace if necessary Check fluid level in reservoir If necessary add recommended brake fluid to specified level Check hydraulic system for leakage 6 18 6 21 6 21 Rear brake Check operation Check pedal free play Adjust if necessary 6 19 6 21 Clutch Check operation Lubricate cable if necessary Check lever free play Adjust if necessary 6 17 Throttle grip Make sure that operation is smooth Check...

Page 31: ... that operation is smooth Lubricate lever pivoting points if necessary 6 26 Sidestand Make sure that operation is smooth Lubricate pivot if necessary 6 26 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened Tighten if necessary Instruments lights signals and switches Check operation Correct if necessary Sidestand switch Check operation of ignition circuit cut off syst...

Page 32: ...e neutral position The transmission is in gear with the clutch lever pulled and the sid estand up WARNING EWA10290 Before starting the engine check the function of the igni tion 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 RUN 3 S...

Page 33: ... 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 position EAU16640 Starting a warm engine Follow the same procedure as for start ing a cold engine with the exception that the starter choke is not required when the engine is warm EAU16671 Shifting Shifting gears lets you cont...

Page 34: ...to second gear Make sure not to shift the transmission into the neutral posi tion 6 Open the throttle part way and gradually release the clutch lever 7 Follow the same procedure when shifting to the next higher gear NOTE Always shift gears at the recommended shift points EAU16700 To decelerate 1 Apply both the front and the rear brakes to slow the motorcycle 2 Shift the transmission into first gea...

Page 35: ...onged operation above 1 3 throttle 1000 1600 km 600 1000 mi Avoid prolonged operation above 1 2 throttle CAUTION ECA11281 After 1000 km 600 mi of operation the engine oil must be changed and the oil filter cartridge or element re placed 1600 km 1000 mi and beyond The vehicle can now be operated nor mally CAUTION ECA10270 If any engine trouble should occur during the engine break in period immediat...

Page 36: ...TANT ARE THE MAIN TENANCE SERVICES RELATED TO EMISSIONS CONTROL THESE CONTROLS NOT ONLY FUNCTION TO ENSURE CLEANER AIR BUT ARE ALSO VITAL TO PROPER EN GINE OPERATION AND MAXIMUM PERFORMANCE IN THE FOLLOW ING PERIODIC MAINTENANCE CHARTS THE SERVICES RELATED TO EMISSIONS CONTROL ARE GROUPED SEPARATELY THESE SERVICES REQUIRE SPECIALIZED DATA KNOWLEDGE AND EQUIP MENT YAMAHA DEALERS ARE TRAINED AND EQU...

Page 37: ...6 WARNING EWA10340 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 2UJ1C book Page 2 Monday June 2 2003 1 04 PM ...

Page 38: ...uel line Check fuel and vacuum hoses for cracks or damage Replace if necessary 2 Spark plugs Check condition Adjust gap and clean Replace every 7000 mi 11000 km or 12 months Replace Replace 3 Valve clearance Check and adjust valve clearance when engine is cold 4 Crankcase breather system Check breather hose for cracks or damage Replace if necessary 5 Idle speed Check and adjust engine idle speed 6...

Page 39: ...tery Check specific gravity and breath er hose for proper operation 3 Clutch Check operation Adjust or replace cable 4 Front brake Check operation fluid level and for fluid leakage Replace brake pads if necessary 5 Rear brake Check operation Adjust cable and replace brake shoes if necessary 6 Brake hose Check for cracks or damage Replace Every 4 years 7 Wheels Check runout spoke tightness and for ...

Page 40: ...repack with lithium soap based grease every 10000 mi 16000 km or 18 months Repack 13 Chassis fasteners Check all chassis fitting and fas teners Correct if necessary 14 Brake and clutch le ver pivot shafts Apply lithium soap based grease all purpose grease lightly 15 Brake and shift ped al pivot shafts Apply lithium soap based grease all purpose grease lightly 16 Sidestand pivot Check operation App...

Page 41: ... and for oil leak age Replace if necessary 20 Engine oil Change warm engine before draining 21 Engine oil filter ele ment Replace 22 Control and meter cables Apply Yamaha chain and cable lube or engine oil 10W 30 thor oughly 23 Throttle grip hous ing and cable Check operation and free play Adjust the throttle cable free play if necessary Lubricate the throttle grip housing and cable No ITEM ROUTIN...

Page 42: ... system When disassembling the master cylinder or caliper cylinder always replace the brake fluid Check the brake fluid level regularly and fill as required Replace the oil seals on 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 2UJ1C book Page 7 Monday June 2 2003 1 04 PM ...

Page 43: ...tor around the center electrode on each spark plug is a medium to light tan the ideal color when the vehicle 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 diagnose such problems yourself Instead have a Yamaha dealer check the vehicle 3 Check each...

Page 44: ...lug should be tightened to the speci fied torque as soon as possible 4 Install the spark plug cap EAU19680 Canister for California only This model is equipped with a canister to prevent the discharging of fuel vapor into the atmosphere Before operating this vehicle make sure to check the fol lowing Check each hose connection Check each hose and canister for cracks or damage Replace if dam aged Mak...

Page 45: ...off 3 Wait a few minutes until the oil set tles and then check the oil level through the check window located at the bottom right side of the crankcase NOTE The engine oil should be between the minimum and maximum level marks 4 If the engine oil is below the mini mum level mark add sufficient oil of the recommended type to raise it to the correct level To change the engine oil with or without oil ...

Page 46: ... the oil filler cap CAUTION ECA11620 In order to prevent clutch slip page since the engine 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 high er quality than specified In addition do not use oils labeled ENERGY CONSERVING II or higher 1 Bolt 2 Oil filter element cover 1 Oil filter element 2 O ring Tightening torque ...

Page 47: ...EAU32730 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 bolts and loosen the air filter joint clamp screw 2 Disconnect the hoses from the air filter case and then remove the air filter cas...

Page 48: ...ement into the air filter case and then tighten the wing nut CAUTION ECA10480 Make sure that the air filter ele ment is properly seated in the air filter case The engine should never be op erated without the air filter ele ment installed otherwise the piston s and or cylinder s may become excessively worn 9 Install the air filter case cover by in stalling the screws 10 Connect the hoses to the air...

Page 49: ...le free play The throttle cable free play should mea sure 3 0 5 0 mm 0 12 0 20 in at the throttle grip Periodically check the throttle cable free play and if neces sary have a Yamaha dealer adjust it EAU21400 Adjusting the valve clearance The valve clearance changes with use resulting in improper air fuel mixture and or engine noise To prevent this from occurring the valve clearance must be adjust...

Page 50: ...ms close to the center of the vehicle and distribute the weight evenly from side to side Properly adjust the suspension for your load and check the condition and pres sure of your tires NEVER OVER LOAD YOUR VEHICLE Make sure that the total weight of the cargo rid er passenger and accessories cowling saddlebags etc if ap proved for this model does not ex ceed the maximum load of the vehicle Operati...

Page 51: ...ter extensive tests only the tires listed below have been ap proved for this model by Yamaha Motor Co Ltd EAU21940 Spoke wheels To maximize the performance durabil ity and safe operation of your motor cycle note the following points regarding the specified wheels The wheel rims should be checked for cracks bends or warpage and the spokes for looseness or dam age before each ride If any dam age is ...

Page 52: ...r replacement parts may cause loss of handling stability and riding safety Since Yamaha cannot control the quality of accessories or parts manufactured by other companies Yamaha cannot be held liable for any consequences caused by the use of items which have not been approved by Yamaha EAU22040 Adjusting the clutch lever free play The clutch lever free play should mea sure 10 0 15 0 mm 0 39 0 59 i...

Page 53: ... nut in direction b 7 Tighten the locknut at the clutch le ver and the crankcase EAU22091 Adjusting the brake lever free play The brake lever free play should mea sure 2 0 5 0 mm 0 08 0 20 in as shown Periodically check the brake le ver free play and if necessary adjust it as follows 1 Loosen the locknut at the brake le ver 2 To increase the brake lever free play turn the adjusting bolt in di rect...

Page 54: ...WARNING EWA10670 It is advisable to have a Yamaha dealer make these adjustments Brake pedal position The top of the brake pedal should be positioned approximately 60 mm 2 36 in above the top of the footrest as shown Periodically check the brake pedal position and if necessary adjust it as follows 1 Loosen the locknut at the brake pedal 2 To raise the brake pedal turn the adjusting bolt in directio...

Page 55: ...e obtained as described have a Yamaha dealer make this ad justment After adjusting the brake pedal free play check the operation of the brake light EAU22270 Adjusting the rear brake light switch The rear brake light switch which is ac tivated by the brake pedal is properly adjusted when the brake light comes on just before braking takes effect If necessary adjust the brake light switch as follows ...

Page 56: ...ssemble the brake To check the brake shoe wear check the position of the wear indicator while applying the brake If a brake shoe has worn to the point that the wear indicator reaches the wear limit line have a Yamaha dealer replace the brake shoes as a set EAU22580 Checking the brake fluid level Front brake Insufficient brake fluid may allow air to enter the brake system possibly caus ing it to be...

Page 57: ...ke fluid at the intervals specified in the NOTE after the periodic mainte nance and lubrication 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 EAU22760 Drive chain slack The drive chain slack s...

Page 58: ...on b and then push the rear wheel forward NOTE Using the alignment marks on each side of the swingarm make sure that both chain pullers are in the same posi tion for proper wheel alignment CAUTION ECA10570 Improper drive chain slack will over load the engine as well as other vital parts of the motorcycle and can lead to chain slippage or breakage To prevent this from occurring keep the drive chain...

Page 59: ...cleaned and lubricated at the intervals specified 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 CAUTION ECA10580 The drive chain must be lubricated after washing the motorcycle or riding in the rain 1 Clean the drive chain with kero sene and a small soft brush CAUTION ECA11120 To...

Page 60: ...ot move smoothly have a Yamaha dealer check or replace it WARNING EWA10710 Damage to the outer housing of ca bles may result in internal rusting and cause interference with cable movement Replace damaged ca bles as soon as possible to prevent unsafe conditions EAU23110 Checking and lubricating the throttle grip and cable The operation of the throttle grip should be checked before each ride In addi...

Page 61: ...s should be lu bricated if necessary EAU23200 Checking and lubricating the sidestand The operation of the sidestand should be checked before each ride and the sidestand pivot and metal to metal contact surfaces should be lubricated if necessary WARNING EWA10730 If the sidestand does not move up and down smoothly have a Yamaha dealer check or repair it Recommended lubricant Lithium soap based greas...

Page 62: ...es to check if the front fork compresses and rebounds smoothly CAUTION ECA10590 If any damage is found or the front fork does not operate smoothly have a Yamaha dealer check or re pair it EAU23280 Checking the steering Worn or loose steering bearings may cause danger Therefore the operation of the steering must be checked as fol lows at the intervals specified in the pe riodic maintenance and lubr...

Page 63: ...ode and discharge quickly The electrolyte level battery lead connections and breather hose routing should be checked before each ride and at the in tervals specified in the periodic mainte nance and lubrication chart To check the electrolyte 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 straight up when checking the ...

Page 64: ...pace Take care not to spill electrolyte on the drive chain as 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 CAUTION ECA10610 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...

Page 65: ...lown replace it as 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 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 circuit in questi...

Page 66: ...y 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 bulb and the bulb life will be adversel...

Page 67: ...efore 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 motorcycle by using a motorcycle stand or if an additional motorcycle stand is not available by placing a jack un der the frame in front of the rear wheel 2 Raise the front wheel off the ground by using a motorcycle stand To service the rear w...

Page 68: ...e 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 EAU24931 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 b...

Page 69: ...Rear wheel EAU32750 To remove the rear wheel WARNING EWA10820 It is advisable to have a Yamaha dealer service the wheel Securely support the motor cycle so that there is no danger of it falling over 1 Remove the axle nut cotter pin 2 Loosen the chain puller locknut and the drive chain slack adjusting nut on both ends of the swingarm 1 Speedometer gear unit 2 Retainer 3 Speedometer cable Tightening...

Page 70: ...rear sprocket and then install the wheel by inserting the wheel axle from the right hand side 2 Install the brake rod onto the brake camshaft lever and then install the brake pedal free play adjusting nut onto the brake rod 3 Connect the brake torque rod to the brake shoe plate by installing the bolt and nut and then tighten the bolt to the specified torque 4 Adjust the drive chain slack See page ...

Page 71: ... 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 motorcycle require any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools experience and know how to service the motorcycle properly Use only genuine Yamaha ...

Page 72: ...he 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 g...

Page 73: ...ove 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 harsh chemical products ...

Page 74: ...ncluding chrome and nick el plated surfaces to prevent cor rosion After cleaning 1 Dry the motorcycle with a chamois 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 stainless steel parts including the exhaust system Even the thermally in duced discoloring of stainless steel exhaust systems can be...

Page 75: ...cle for sev eral months 1 Follow all the instructions in the Care section of this chapter 2 Turn the fuel cock lever to ON 3 Drain the carburetor float cham bers by loosening the drain bolts 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 de...

Page 76: ...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 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...

Page 77: ...ent 1 40 L 1 48 US qt 1 23 Imp qt With oil filter element replacement 1 60 L 1 69 US qt 1 41 Imp qt Air filter Air filter element Wet element Fuel Recommended fuel Unleaded gasoline only Fuel tank capacity 9 2 L 2 43 US gal 2 02 Imp gal CAL 9 5 L 2 51 US gal 2 09 Imp gal U49 Fuel reserve amount 2 6 L 0 69 US gal 0 57 Imp gal Carburetor Manufacturer MIKUNI Type x quantity BDS26 x 1 Spark plug s Man...

Page 78: ... condition 90 195 kg 198 430 lb CAL 90 196 kg 198 432 lb U49 Front 200 kPa 29 psi 2 00 kgf cm Rear 225 kPa 33 psi 2 25 kgf cm Front wheel Wheel type Spoke wheel Rim size 18x1 60 Rear wheel Wheel type Spoke wheel Rim size 15M C x MT2 75 Front brake Type Single disc brake Operation Right hand operation Recommended fluid Dot 4 Rear brake Type Drum brake Operation Right foot operation Front suspension...

Page 79: ...W 27 0 W 1 Front turn signal position light 12 V 27 W 8 0 W 2 Rear turn signal light 12 V 27 0 W 2 Meter lighting 14 V 3 0 W 1 Neutral indicator light 14 V 3 0 W 1 High beam indicator light 12 V 1 7 W 1 Turn signal indicator light 14 V 3 0 W 1 Fuses Main fuse 20 0 A Signaling system fuse 10 0 A 2UJ1C book Page 3 Monday June 2 2003 1 04 PM ...

Page 80: ... 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 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 used to identify your motorcycle and...

Page 81: ...label is affixed to the frame under the rider seat See page 3 8 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 2UJ1C book Page 2 Monday June 2 2003 1 04 PM ...

Page 82: ...nvestigation and if it finds that a safety defect exists in a 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 ...

Page 83: ... 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 systems i e modification removal etc...

Page 84: ...reminder that maintenance work is required It is not acceptable proof of maintenance work Maintenance interval Date of service Mileage Servicing dealer name and address Remarks 600 mi 1000 km or 1 month 4000 mi 6000 km or 6 months 7000 mi 11000 km or 12 months 10000 mi 16000 km or 18 months 13000 mi 21000 km or 24 months 16000 mi 26000 km or 30 months 19000 mi 31000 km or 36 months 22000 mi 36000 ...

Page 85: ...INFORMATION 9 6 9 28000 mi 46000 km or 54 months 31000 mi 51000 km or 60 months Maintenance interval Date of service Mileage Servicing dealer name and address Remarks 2UJ1C book Page 6 Monday June 2 2003 1 04 PM ...

Page 86: ...CONSUMER INFORMATION 9 7 9 EAU26661 YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY 2UJ1C book Page 7 Monday June 2 2003 1 04 PM ...

Page 87: ...CONSUMER INFORMATION 9 8 9 2UJ1C book Page 8 Monday June 2 2003 1 04 PM ...

Page 88: ...ered 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 vehicle rental emergency towi...

Page 89: ...acked 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 2UJ1C book Page 10 Monday June 2 2003 1 04 PM ...

Page 90: ...ication numbers 9 1 Ignition circuit cut off system 3 11 Indicator lights 3 1 K Key identification number 9 1 L Labels location of 1 5 M Main switch 3 1 Maintenance and lubrication periodic 6 4 Maintenance emission control system 6 3 Maintenance periodic 6 1 Maintenance record 9 5 Model label 9 2 N Neutral indicator light 3 1 Noise regulation 9 4 P Parking 5 4 Part locations 2 1 Pre operation chec...

Page 91: ...NDEX Vehicle identification number 9 1 W Warranty extended 9 9 Warranty limited 9 7 Wheel bearings checking 6 28 Wheel front 6 33 Wheel rear 6 34 Wheels 6 16 2UJ1C book Page 2 Monday June 2 2003 1 04 PM ...

Page 92: ...PRINTED IN JAPAN 2003 06 0 4 1 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD ...

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