Yamaha WR250X Page 47 Owner'S Manual Download | Manualshive

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PERIODIC MAINTENANCE AND ADJUSTMENT

7-2

7

EAU35011

Owner’s tool kit

The owner’s tool kit is located inside the
tool box.
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.

TIP

If you do not have the tools or experi-
ence required for a particular job, have
a Yamaha dealer perform it for you.

1. Tool box

1

U32C15E0.book Page 2 Tuesday, July 14, 2009 11:43 AM

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Summary of Contents for WR250X

Page 1: ...DIC183 32C 28199 15 WR25XZ C OWNER S MANUAL Read this manual carefully before operating this vehicle LIT 11626 23 57 ...

Page 2: ...EAU10042 Read this manual carefully before operating this vehicle This manual should stay with this vehicle if it is sold U32C15E0 book Page 1 Tuesday July 14 2009 11 43 AM ...

Page 3: ...ntain these high standards it is important that you and your Yamaha dealer pay close attention to the recommended maintenance schedules and operating instructions contained within this manual Yamaha continually seeks advancements in product design and quality Therefore while this manual contains the most cur rent product information available at the time of printing there may be minor discrepancie...

Page 4: ...ey all safety messages that follow this symbol to avoid possible injury or death A WARNING indicates a hazardous situation which if not avoided could result in death or serious injury A NOTICE indicates special precautions that must be taken to avoid damage to the vehicle or other property A TIP provides key information to make procedures easier or clearer WARNING NOTICE TIP U32C15E0 book Page 1 T...

Page 5: ... Motor Corporation U S A 1st edition June 2009 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 23 57 U32C15E0 book Page 2 Tuesday July 14 2009 11 43 AM ...

Page 6: ...d lubrication chart 7 5 Removing and installing panels 7 9 Checking the spark plug 7 11 Canister for California only 7 12 Engine oil and oil filter element 7 13 Coolant 7 15 Cleaning the air filter element and check hose 7 18 Cleaning the spark arrester 7 20 Adjusting the engine idling speed 7 21 Checking the throttle cable free play 7 21 Valve clearance 7 22 Tires 7 22 Spoke wheels 7 24 Adjusting...

Page 7: ...oubleshooting 7 43 Troubleshooting charts 7 44 MOTORCYCLE CARE AND STORAGE 8 1 Matte color caution 8 1 Care 8 1 Storage 8 3 SPECIFICATIONS 9 1 CONSUMER INFORMATION 10 1 Identification numbers 10 1 Reporting safety defects 10 3 Motorcycle noise regulation 10 4 Maintenance record 10 5 YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY 10 7 YAMAHA EXTENDED SERVICE Y E S 10 9...

Page 8: ...icle They contain important information for safe and proper operation of your vehicle Never remove any labels from your vehicle If a label becomes difficult to read or comes off a replacement label is available from your Yamaha dealer 2 1 4 3 5 U32C15E0 book Page 1 Tuesday July 14 2009 11 43 AM ...

Page 9: ...118K 00 WARNING This unit contains high pressure nitrogen gas Mishandling can cause explosion Read owner s manual for instructions Do not incinerate puncture or open 4AA 22259 80 32C 21668 10 Cold tire normal pressure should be set as follows Up to 90 kg 198 lbs load 200 kPa 2 00 kgf cm2 29 psi 200 kPa 2 00 kgf cm2 29 psi 90 kg 198 lbs 200 kPa 2 00 kgf cm2 29 psi 225 kPa 2 25 kgf cm2 33 psi maximu...

Page 10: ...LOCATION OF IMPORTANT LABELS 1 3 1 1 U32C15E0 book Page 3 Tuesday July 14 2009 11 43 AM ...

Page 11: ...LOCATION OF IMPORTANT LABELS 1 4 1 1 U32C15E0 book Page 4 Tuesday July 14 2009 11 43 AM ...

Page 12: ...assenger The failure of motorists to detect and recognize motorcycles in traf fic is the predominating cause of automobile motorcycle accidents Many accidents 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 ...

Page 13: ...eavy 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 Always wear protective clothing that covers your legs ankles and feet The engine or exhaust sys tem become very hot during or af ter operation and can cause burns A passen...

Page 14: ...sories and cargo are securely attached to the motorcycle before riding Check accessory mounts and cargo restraints frequently Properly adjust the suspension for your load and check the con dition and pressure of your tires Never attach any large or heavy items to the handlebar front fork or front fender These items including such cargo as sleeping bags duffel bags or tents can create unstable han ...

Page 15: ...lebar or front fork area they must be as lightweight as possible and should be kept to a minimum Bulky or large accessories may seriously affect the stability of the motorcycle due to aerody namic effects Wind may at tempt to lift the motorcycle or the motorcycle may become un stable in cross winds These ac cessories may also cause instability when passing or being passed by large vehicles Certain...

Page 16: ...page 7 35 3 Coolant reservoir page 7 15 4 Shock absorber assembly compression damping force adjusting screw page 4 17 5 Battery page 7 34 6 Main fuse page 7 35 7 Owner s tool kit page 7 2 8 Helmet holder page 4 14 9 Front fork compression damping force adjusting screw page 4 14 U32C15E0 book Page 1 Tuesday July 14 2009 11 43 AM ...

Page 17: ...rvoir page 7 27 3 Air filter element page 7 18 4 Rear brake light switch page 7 26 5 Bleed screw page 4 16 6 Engine oil filler cap page 7 13 7 Engine oil level check window page 7 13 8 Shock absorber assembly rebound damping force adjusting knob page 4 17 U32C15E0 book Page 2 Tuesday July 14 2009 11 43 AM ...

Page 18: ...ver page 4 9 2 Left handlebar switches page 4 8 3 Main switch steering lock page 4 1 4 Multi function display page 4 3 5 Right handlebar switches page 4 8 6 Brake lever page 4 10 7 Throttle grip page 7 21 8 Fuel tank cap page 4 11 U32C15E0 book Page 3 Tuesday July 14 2009 11 43 AM ...

Page 19: ...engine is started and stays on until the key is turned to OFF even if the engine stalls EAU10661 OFF All electrical systems are off The key can be removed WARNING EWA10061 Never turn the key to OFF or LOCK while the vehicle is moving Otherwise the electrical systems will be switched off which may result in loss of control or an accident EAU10683 LOCK The steering is locked and all electrical syste...

Page 20: ...mately 2 1 L 0 55 US gal 0 46 Imp gal When this occurs refuel as soon as possible The electrical circuit of the warning light can be checked by turning the key to ON The warning light should come on for a few seconds and then go off If the warning light does not come on initially when the key is turned to ON or if the warning light remains on have a Yamaha dealer check the electrical circuit EAU11...

Page 21: ...is detected in the electrical circuit monitoring the engine If this oc curs have a Yamaha dealer check the self diagnosis system See page 4 8 for an explanation of the self diagnosis device The electrical circuit of the warning light can be checked by turning the key to ON The warning light should come on for a few seconds and then go off If the warning light does not come on initially when the ke...

Page 22: ...pwatch which shows the time that has been accumulated since the start of stopwatch measure ment a self diagnosis device TIP Be sure to turn the key to ON be fore using the SELECT 1 SE LECT 2 and RESET buttons When the key is turned to ON all of the display segments of the multi function display will appear and then disappear in order to test the electrical circuit To switch the speedometer and odo...

Page 23: ... reading changes due to the movement and inclination of the ve hicle If the fuel level warning light comes on while riding in the measurement mode change to the basic mode and push the SELECT 2 button to display the fuel reserve tripmeter TIP To change from the measurement mode to the basic mode the stopwatch and the distance compensation tripme ter must be stopped To reset a tripmeter select it b...

Page 24: ...hanging from the basic mode to the measurement mode With the odometer selected push the SELECT 1 button and SELECT 2 button together for at least two seconds to change to the measurement mode Changing from the measurement mode to the basic mode TIP The stopwatch must be stopped before changing to the basic mode 1 Check that the stopwatch is not in operation If the stopwatch is in op eration stop i...

Page 25: ...when the vehicle is stopped To stop and or resume counting repeat steps 3 and 4 Measurement mode for calibrating the distance compensation tripme ter s reading The distance compensation tripmeter is a feature intended to provide a more accurate tripmeter reading for enduro riding Calibrating this meter in accor dance with the distances specified on the enduro course map will help famil iarize the ...

Page 26: ...t the distance compensation tripmeter and the stopwatch to zero by pushing the RESET but ton for at least two seconds Self diagnosis device This model is equipped with a self diag nosis device for various electrical cir cuits If a problem is detected in any of those circuits the engine trouble warning light will come on and the display will indi cate an error code If the display indicates any erro...

Page 27: ...the vehicle overturns or when the throttle cable is stuck EAU12711 Start switch Push this switch to crank the engine with the starter See page 6 1 for start ing instructions prior to starting the en gine EAU41700 The engine trouble warning light will come on when the key is turned to ON and the start switch is pushed but this does not indicate a malfunction EAU12820 Clutch lever The clutch lever i...

Page 28: ... 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 1 Brake lever 1 1 Brake pedal 1 U32C15E0 book Page 10 Tuesday Ju...

Page 29: ...EAU13221 Fuel Make sure there is sufficient gasoline in the tank WARNING EWA10881 Gasoline and gasoline vapors are extremely flammable To avoid fires and explosions and to reduce the risk of injury when refueling follow these instructions 1 Before refueling turn off the en gine and be sure that no one is sit ting on the vehicle Never refuel while smoking or while in the vi cinity of sparks open fl...

Page 30: ...ngs as well as to the exhaust system Your Yamaha engine has been de signed to use premium unleaded gaso line with a pump octane number R M 2 of 91 or higher or a research octane number of 95 or higher If knocking or pinging occurs use a gasoline of a different brand Use of un leaded fuel will extend spark plug life and reduce maintenance costs Gasohol There are two types of gasohol gaso hol contai...

Page 31: ... hot exhaust system Make sure that the exhaust sys tem has cooled down before do ing any maintenance work Do not allow the engine to idle more than a few minutes Long idling can cause a build up of heat NOTICE ECA10701 Use only unleaded gasoline The use of leaded gasoline will cause unre pairable damage to the catalytic converter EAU46280 Seat To remove the seat Remove the bolts and then pull the ...

Page 32: ...k WARNING EWA10180 Always adjust both fork legs equal ly otherwise poor handling and loss of stability may result This front fork is equipped with rebound damping force adjusting screws and compression damping force adjusting screws NOTICE ECA10101 To avoid damaging the mechanism do not attempt to turn beyond the maximum or minimum settings Rebound damping force To increase the rebound damping for...

Page 33: ... 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 1 Rebound damping force adjusting screw Rebound damping setting Minimum soft 17 click s in direction b Standard 10 click s in direction b Maximum hard 1 click s in direction b With the adjusting screw fully turned in...

Page 34: ...ely rough condi tions the air temperature and pressure in the front fork will rise This will in crease the spring preload and harden the front suspension If this occurs bleed the front fork as follows 1 Elevate the front wheel by placing a suitable stand under the engine TIP When bleeding the front fork there should be no weight on the front end of the vehicle 2 Remove the bleed screws and al low ...

Page 35: ... damping force To increase the rebound damping force and thereby harden the rebound damp ing turn the adjusting knob in direction a To decrease the rebound damping force and thereby soften the rebound damping turn the adjusting knob in di rection b Compression damping force To increase the compression damping force and thereby harden the compres sion damping turn the adjusting screw in direction a...

Page 36: ...erformance Do not dispose of a damaged or worn out shock absorber as sembly yourself Take the shock absorber assembly to a Yamaha dealer for any service EAU41941 EXUP system This model is equipped with Yamaha s EXUP EXhaust Ultimate Power valve system This system boosts engine power by means of a valve that regu lates the inner diameter of the exhaust pipe The EXUP system valve is con stantly adju...

Page 37: ...n designed to assist the operator in fulfilling the respon sibility of raising the sidestand be fore starting off Therefore check this system regularly as described below and have a Yamaha dealer re pair it if it does not function proper ly EAU44892 Ignition circuit cut off system The ignition circuit cut off system com prising the sidestand switch clutch switch and neutral switch has the fol lowi...

Page 38: ... Move the sidestand up 11 Keep the clutch lever pulled 12 Push the start switch Does the engine start The system is OK The motorcycle can be ridden The neutral switch may not be working correctly The motorcycle should not be ridden until checked by a Yamaha dealer The sidestand switch may not be working correctly The motorcycle should not be ridden until checked by a Yamaha dealer The clutch switc...

Page 39: ...is vehicle check the following points ITEM CHECKS PAGE Fuel Check fuel level in fuel tank Refuel if necessary Check fuel line for leakage 4 11 Engine oil Check oil level in engine If necessary add recommended oil to specified level Check vehicle for oil leakage 7 13 Coolant Check coolant level in reservoir If necessary add recommended coolant to specified level Check cooling system for leakage 7 1...

Page 40: ... adjust cable free play and lubricate cable and grip housing 7 21 7 31 Control cables Make sure that operation is smooth Lubricate if necessary 7 30 Drive chain Check chain slack Adjust if necessary Check chain condition Lubricate if necessary 7 28 7 30 Wheels and tires Check for damage Check tire condition and tread depth Check air pressure Correct if necessary 7 22 7 24 Shift pedal Make sure tha...

Page 41: ... 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 system If system is not working correctly have Yamaha dealer check vehicle 4 19 ITEM CHECKS PAGE U32C15E0 book Page 3 Tuesday July 14 2009 11 43 AM ...

Page 42: ...e stops automatically if left idling for 20 minutes In this case the multi function display indicates error code 70 but this is not a mal function Push the start switch to clear the error code and to restart the engine EAU45124 Starting the engine In order for the ignition circuit cut off system to enable starting one of the following conditions must be met The transmission is in the neutral posit...

Page 43: ...o shift the transmission into the neu tral position press the shift pedal down repeatedly until it reaches the end of its travel and then slightly raise it NOTICE 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 motorcycle for long dis tances The transmission is properly lubricated only when the engine is runni...

Page 44: ...d shift points during acceleration and deceleration are shown in the table below EAU16841 Engine break in There is never a more important period in the life of your engine than the period between 0 and 1600 km 1000 mi For this reason you should read the follow ing material carefully Since the engine is brand new do not put an excessive load on it for the first 1600 km 1000 mi The various parts in ...

Page 45: ...rking stop the engine and then remove the key from the main switch WARNING EWA10311 Since the engine and exhaust system can become very hot park in a place where pedestri ans or children are not likely to touch them and be burned Do not park on a slope or on soft ground otherwise the vehicle may overturn increasing the risk of a fuel leak and fire Do not park near grass or other flammable material...

Page 46: ...unning engine has moving parts that can catch on body parts or clothing and electrical parts that can cause shocks or fires Running the engine while ser vicing can lead to eye injury burns fire or carbon monoxide poisoning possibly leading to death See page 2 1 for more in formation about carbon monox ide EAU17302 Emission controls not only function to ensure cleaner air but are also vital to prop...

Page 47: ...wner 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 TIP If you do not have the tools or experi ence required for a particular job have a Yamaha dealer perform it for you 1 Tool box 1 U32C15E0 book Page 2 Tuesday July 14 2009 11 43 AM...

Page 48: ... 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 1 Fuel line Check fuel hoses for cracks or damage Replace if necessary 2 Spark plug Check condition Adjust gap and clean Replace at 7000 mi 11000 km or 12 months and thereafter every 6000 mi 10000 km or 12 months Replace Replace 3 Spark arrester Clean 4 Va...

Page 49: ...or dam age Replace if necessary 8 Air induction sys tem Check the air cut off valve reed valve and hose for damage Replace any damaged parts No ITEM ROUTINE INITIAL ODOMETER READINGS 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 U32C15E0 book Page 4 Tuesday July 14 200...

Page 50: ...replace cable 3 Front brake Check operation fluid level and for fluid leakage Adjust brake lever free play and replace brake pads if necessary 4 Rear brake Check operation fluid level and for fluid leakage Replace brake pads if necessary 5 Brake hoses Check for cracks or damage Replace Every 4 years 6 Wheels Check runout spoke tightness and for damage Tighten spokes if necessary 7 Tires Check trea...

Page 51: ...grease Repack 12 Chassis fasteners Check all chassis fitting and fas teners Correct if necessary 13 Brake lever pivot shaft Apply silicone grease lightly 14 Brake pedal pivot shaft Apply lithium soap based grease lightly 15 Clutch lever pivot shaft Apply lithium soap based grease lightly 16 Sidestand pivot Check operation Apply lithium soap based grease lightly 17 Sidestand switch Check operation ...

Page 52: ... Change with ethylene glycol anti freeze coolant every 24 months Change 24 Front and rear brake switches Check operation 25 Control cables Apply Yamaha chain and cable lube or engine oil thoroughly 26 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 ROUTINE INITIAL ODOMETER READINGS...

Page 53: ...ired 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 27 Lights signals and switches Check operation Adjust headlight beam No ITEM ROUTINE INITIAL ODOMETER READINGS 600 mi 1000 km or 1 month 4000 mi 6000 km or 6 months 7000 mi 11000 km or 12 months 10000 mi 16000 ...

Page 54: ...e maintenance jobs described in this chapter Refer to this section each time a panel needs to be removed and installed EAU45131 Panel A To remove the panel 1 Remove the seat See page 4 13 2 Remove the bolts and collars 1 Panel A 2 Panel B 1 2 1 Panel C 1 Panel D 1 1 1 Bolt 2 Collar 2 1 2 1 U32C15E0 book Page 9 Tuesday July 14 2009 11 43 AM ...

Page 55: ...llars and bolts 2 Install the seat Panel B To remove the panel 1 Remove the seat See page 4 13 2 Remove the bolt and then remove the panel as shown To install the panel 1 Place the panel in the original posi tion and then install the bolt 2 Install the seat Panel C To remove the panel 1 Remove the bolts 1 Bolt 2 Panel A 1 2 1 Bolt 2 Panel B 1 2 1 Panel C 2 Bolt 1 2 2 U32C15E0 book Page 10 Tuesday ...

Page 56: ...d deposits will cause any spark plug to slowly erode it should be removed and checked in ac cordance with the periodic mainte nance and lubrication chart In addition the condition of the spark plug can re veal the condition of the engine The porcelain insulator around the cen ter electrode of the spark plug should be a medium to light tan the ideal color when the vehicle is ridden normally If the ...

Page 57: ...nition coil coupler may get damaged The spark plug cap may be difficult to remove because the rubber seal on the end of the cap fits tightly To remove the spark plug cap simply twist it back and forth while pulling it out to install it twist it back and forth while pushing it in EAU19681 Canister for California only This model is equipped with a canister to prevent the discharging of fuel vapor in...

Page 58: ...P 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 filter element replace ment 1 Place the vehicle on a level sur face 2 Start the engine warm it up for several minutes and then turn it off 3 Place an oil p...

Page 59: ...NOTICE 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 Make sure that no foreign mate rial enters the crankcase 1 Oil filter element cover 2 Oil filter elemen...

Page 60: ...er checking the oil pressure tighten the bleed bolt to the specified torque EAU20070 Coolant The coolant level should be checked before each ride In addition the cool ant must be changed at the intervals specified in the periodic maintenance and lubrication chart EAU20253 To check the coolant level 1 Place the vehicle on a level sur face and hold it in an upright posi tion TIP The coolant level mu...

Page 61: ...nd corrosion If water has been added to the coolant have a Yamaha dealer check the anti freeze content of the coolant as soon as possible otherwise the effectiveness of the coolant will be reduced ECA10472 EAU45155 To change the coolant 1 Place the vehicle on a level sur face and let the engine cool if nec essary 2 Remove panels A and C See page 7 9 3 Place a container under the engine to collect ...

Page 62: ... eral minutes and then turn it off 16 Remove the radiator cap to check the coolant level in the radiator If necessary add sufficient coolant until it reaches the top of the radia tor and then install the radiator cap and its retaining bolt 17 Check the coolant level in the res ervoir If necessary remove the coolant reservoir cap add coolant to the maximum level mark and then install the cap 1 Bolt...

Page 63: ...nd cleaned if necessary To clean the air filter element 1 Remove panel B See page 7 9 2 Open the air filter case cover by re moving the screw and pulling the case cover outward as shown 3 Unhook the holding clip and then pull the air filter element out 4 Remove the sponge material from the air filter element frame clean it with solvent and then squeeze the remaining solvent out WARNING Use only a ...

Page 64: ...ted without the air filter ele ment installed otherwise the piston s and or cylinder s may become excessively worn ECA10481 8 Place the holding clip in the origi nal position 9 Close the air filter case cover and then install the screw 10 Install the panel To clean the air filter check hose 1 Check the hose at the bottom of the air filter case for accumulated dirt or water 2 If dirt or water is vi...

Page 65: ... remove the gasket 3 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 tailpipe housing 4 Install the gasket and then insert the tailpipe into the muffler and align the bolt holes 5 Install the spark arrester cap by in stalling the bolts and then tighten ing them to the specified torque TIP Make sure...

Page 66: ...ew To increase the engine idling speed turn the screw in di rection a To decrease the en gine idling speed turn the screw in direction b TIP If the specified idling speed cannot be obtained as described above have a Yamaha dealer make the adjustment EAU21382 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 Periodically ...

Page 67: ...e se vere injury or death from loss of control 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 ad justed in accordance with the riding speed and with the total weight of rider passenger car go and accessories approved for this model WARNING EWA10511 Never overload your vehicle Opera ...

Page 68: ...or Co Ltd WARNING EWA10561 It is dangerous to ride with a worn out tire When a tire tread begins to show crosswise lines have a Yamaha dealer replace the tire immediately The replacement of all wheel and brake related parts includ ing the tires should be left to a Yamaha dealer who has the necessary professional knowl edge and experience It is not recommended to patch a punctured tube If unavoid a...

Page 69: ...either the tire or wheel has been changed or replaced An unbalanced wheel can result in poor performance adverse han dling characteristics and a short ened tire life Ride at moderate speeds after changing a tire since the tire sur face must first be broken in for it to develop its optimal characteris tics EAU48372 Adjusting the clutch lever free play The clutch lever free play should mea sure 10 0...

Page 70: ...cable and then slide the rubber cover to its original position 8 Tighten the locknut at the clutch le ver and then slide the rubber cov er to its original position EAU48440 Adjusting the brake lever free play The brake lever free play should mea sure 5 0 8 0 mm 0 20 0 31 in as shown Periodically check the brake le ver free play and if necessary adjust it as follows 1 Slide the rubber cover back at...

Page 71: ...f necessary adjust the rear brake light switch as follows but the front brake light switch should be adjusted by a Yamaha dealer Turn the rear brake light switch adjust ing nut while holding the rear brake light switch in place To make the brake light come on earlier turn the adjusting nut in direction a To make the brake light come on later turn the adjusting nut in direction b EAU22392 Checking ...

Page 72: ...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 level make sure that the top of the brake...

Page 73: ...ster cylinders and calipers as well as the brake hoses re placed at the intervals listed below or whenever they are damaged or leak ing 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 EAU47222 To check the drive chain slack 1 Place the motorcycle on the side stand TI...

Page 74: ...e en gine 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 slack with in the specified limits ECA10571 TIP Using the alignment marks on each side of the swingarm make sure that both drive chain pullers are in the same position for proper wheel alignment 3 Tighten the locknuts and then tighten the axle nut ...

Page 75: ...ipe the drive chain dry 3 Thoroughly lubricate the drive chain with a special O ring chain lubricant NOTICE Do not use engine oil or any other lubri cants for the drive chain as they may contain substances that could damage the O rings ECA11111 EAU23093 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...

Page 76: ...dealer at the intervals speci fied in the periodic maintenance chart EAU23142 Checking and lubricating the brake and clutch levers Brake lever Clutch lever 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 lubricants Brake lever Silicone grease Clutch lever Lithium soap based grease U32C15E0 book Page...

Page 77: ... if necessary WARNING EWA10731 If the sidestand does not move up and down smoothly have a Yamaha dealer check or repair it Otherwise the sidestand could contact the ground and distract the operator re sulting in a possible loss of control EAUM1651 Lubricating the swingarm piv ots The swingarm pivots must be lubricat ed by a Yamaha dealer at the intervals specified in the periodic maintenance and l...

Page 78: ...ont fork compresses and rebounds smoothly NOTICE ECA10590 If any damage is found or the front fork does not operate smoothly have a Yamaha dealer check or re pair it EAU23283 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 lubrication chart 1 Place ...

Page 79: ...ains sul furic acid which causes severe burns Avoid any contact with skin eyes or clothing and al ways shield your eyes when working near batteries In case of contact administer the fol lowing FIRST AID EXTERNAL Flush with plenty of water INTERNAL Drink large quan tities of water or milk and im mediately call a physician EYES Flush with water for 15 minutes and seek prompt medical attention Batter...

Page 80: ...e it and then place it in a cool dry place NOTICE When removing the battery be sure the key is turned to OFF then discon nect the negative lead before disconnecting the positive lead ECA16302 2 If the battery will be stored for more than two months check it at least once a month and fully charge it if necessary 3 Fully charge the battery before in stallation NOTICE ECA16530 Always keep the battery...

Page 81: ...llows NOTICE ECA10650 Take care not to damage the follow ing parts Headlight bulb Do not touch the glass part of the headlight bulb to keep it free from oil otherwise the transpar ency of the glass the luminosity of the bulb and the bulb life will be adversely affected Thor oughly clean off any dirt and fin gerprints on the headlight bulb using a cloth moistened with al cohol or thinner Headlight ...

Page 82: ... headlight bulb into po sition and then secure it with the bulb holder 5 Install the headlight bulb cover and then connect the coupler 6 Install the headlight cowling to gether with the headlight unit by placing it in the original position and then installing the bolts 7 Have a Yamaha dealer adjust the headlight beam if necessary 1 Do not touch the glass part of the bulb 1 Bolt 1 1 1 Headlight cou...

Page 83: ...e screw 2 Remove the socket together with the bulb by turning it counter clockwise 3 Remove the burnt out bulb by pull ing it out 4 Insert a new bulb into the socket 5 Install the socket together with the bulb by turning it clockwise 6 Install the turn signal light unit by installing the screw NOTICE Do not overtighten the screw oth erwise the lens may break ECA11191 1 Screw 1 1 Turn signal light ...

Page 84: ...forming other maintenance requiring the motorcycle to stand up right Check that the motorcycle 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 motorcycle by using a motorcycle stand or if an additional motorcycle stand is not available by placing a jack un...

Page 85: ...h bolts and axle nut 2 Lift the front wheel off the ground according to the procedure on page 7 39 3 Remove the axle nut 4 Pull the wheel axle out and then remove the wheel NOTICE Do not apply the brake after the wheel has been removed to gether with the brake disc oth erwise the brake pads will be forced shut ECA11071 EAU45171 To install the front wheel 1 Lift the wheel up between the fork legs 1...

Page 86: ...so there is no danger of it falling over 1 Loosen the axle nut 2 Lift the rear wheel off the ground according to the procedure on page 7 39 3 Remove the axle nut and washer 4 Loosen the locknut on each side of the swingarm 5 Turn the drive chain slack adjust ing bolts fully in direction a 6 Push the wheel forward and then remove the drive chain from the rear sprocket TIP The drive chain does not n...

Page 87: ...e brake caliper bracket is inserted into the slot in the swingarm Make sure that there is enough space between the brake pads be fore installing the wheel 2 Install the drive chain onto the rear sprocket 3 Install the washer and the axle nut 4 Lower the rear wheel so that it is on the ground and then put the sidestand down 5 Adjust the drive chain slack See page 7 28 6 Tighten the axle nut to the ...

Page 88: ...quire 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 replace ment parts Imitation parts may look like Yamaha parts but they are often inferi or have a shorter service life and can lead to expensive repair bills WARNING EWA15141 When checking the fuel system do not smoke and ...

Page 89: ... 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 Battery The engine turns over quickly The engin...

Page 90: ... hissing sound has stopped press down on the cap while turning it counterclockwise and then remove the cap TIP If coolant is not available tap water can be temporarily used instead provided that it is changed to the recommended coolant as soon as possible Wait until the engine has cooled Check the coolant level in the reservoir and radiator The coolant level is OK The coolant level is low Check th...

Page 91: ...outlet with a plastic bag after the engine has cooled down 2 Make sure that all caps and covers as well as all electrical couplers and connectors including the spark plug cap 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...

Page 92: ...ild 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 riding in the rain near the sea or on salt sprayed roads Since sea salt or salt sprayed on roads during winter are extremely corros...

Page 93: ...stic parts but treat them with a suitable care product Avoid using abrasive polishing compounds as they will wear away the paint TIP Consult a Yamaha dealer for ad vice on what products to use Washing rainy weather or humid climates can cause the headlight lens to fog Turning the headlight on for a short period of time will help remove the moisture from the lens EAU43201 Storage Short term Always ...

Page 94: ...ark plug elec trodes while turning the en gine over EWA10951 4 Lubricate all control cables and the pivoting points of all levers and pedals as well as of the side stand centerstand 5 Check and if necessary correct the tire air pressure and then lift the motorcycle 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 b...

Page 95: ...1 30 L 1 37 US qt 1 14 Imp qt With oil filter element replacement 1 40 L 1 48 US qt 1 23 Imp qt Cooling system Coolant reservoir capacity up to the maximum level mark 0 25 L 0 26 US qt 0 22 Imp qt Radiator capacity including all routes 0 90 L 0 95 US qt 0 79 Imp qt Air filter Air filter element Wet element Fuel Recommended fuel Premium unleaded gasoline only Fuel tank capacity WR25XZ 7 6 L 2 01 US...

Page 96: ...198 lb Front 200 kPa 2 00 kgf cm 29 psi Rear 200 kPa 2 00 kgf cm 29 psi Loading condition WR25XZ 90 185 kg 198 408 lb WR25XZC 90 184 kg 198 406 lb Front 200 kPa 2 00 kgf cm 29 psi Rear 225 kPa 2 25 kgf cm 33 psi Front wheel Wheel type Spoke wheel Rim size 17M C x MT3 00 Rear wheel Wheel type Spoke wheel Rim size 17M C x MT4 00 Front brake Type Single disc brake Operation Right hand operation Recom...

Page 97: ...21 0 W 2 License plate light 12 V 5 0 W Meter lighting EL Electroluminescent Neutral indicator light LED High beam indicator light LED Turn signal indicator light LED Fuel level warning light LED Coolant temperature warning light LED Engine trouble warning light LED Fuses Main fuse 30 0 A Headlight fuse 15 0 A Signaling system fuse 10 0 A Ignition fuse 7 5 A Radiator fan fuse 7 5 A Fuel injection ...

Page 98: ...tification 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 TIP The vehicle identification number is used to identify your motorcycle and ma...

Page 99: ...e parts from a Yamaha dealer EAU48270 Vehicle Emission Control Informa tion label The Vehicle Emission Control Informa tion label is affixed at the location in the illustration This label shows specifica tions related to exhaust emissions as required by federal law state law and Environment Canada 1 Model label 1 1 Vehicle Emission Control Information label 1 U32C15E0 book Page 2 Tuesday July 14 2...

Page 100: ... 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 call the Vehicle Safety Hotline toll free at 1 888 327 4236 TTY 1 800 424 9153 go to http www safercar gov or write to Administrator NHTSA 400 Seve...

Page 101: ...icle 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 E...

Page 102: ...minder that maintenance work is required It is not acceptable proof of maintenance work Maintenance interval Date of service Mileage Servicing dealer name and address Remarks 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 km...

Page 103: ...RMATION 10 6 10 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 U32C15E0 book Page 6 Tuesday July 14 2009 11 43 AM ...

Page 104: ...r warranty by an authorized Yamaha motorcycle dealer In order for this warranty to remain in effect this inspection and registration must take place within ten 10 days after transfer An inspection and registration fee will be charged for this service EMISSION CONTROL SYSTEM WARRANTY Yamaha Motor Corporation U S A also warrants to the ultimate purchaser and each subsequent purchaser of each Yamaha ...

Page 105: ...y later date Each Yamaha motorcycle dealer is held responsible for his setup service and warranty repair work Is the warranty transferable to second owners Yes The remainder of the existing warranty can be transferred upon request The unit has to be inspected and re registered by an authorized Yamaha motorcycle dealer for the policy to remain effective CUSTOMER SERVICE If your machine requires war...

Page 106: ...ed 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 towing...

Page 107: ...ked 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 U32C15E0 book Page 10 Tuesday July 14 2009 11 43 AM ...

Page 108: ...36 Helmet holder 4 14 High beam indicator light 4 2 Horn switch 4 9 I Identification numbers 10 1 Ignition circuit cut off system 4 19 Indicator and warning lights 4 2 K Key identification number 10 1 L Labels location 1 1 License plate light bulb replacing 7 39 M Main switch steering lock 4 1 Maintenance and lubrication periodic 7 5 Maintenance emission control system 7 3 Maintenance record 10 5 ...

Page 109: ... switch 4 9 V Valve clearance 7 22 Vehicle Emission Control Information label 10 2 Vehicle identification number 10 1 W Warranty extended 10 9 Warranty limited 10 7 Wheel bearings checking 7 34 Wheel front 7 40 Wheel rear 7 41 Wheels 7 24 U32C15E0 book Page 2 Tuesday July 14 2009 11 43 AM ...

Page 110: ...A5 yoko_Blank fm Page 1 Tuesday April 8 2003 11 43 AM ...

Page 111: ...A5 yoko_Blank fm Page 1 Tuesday April 8 2003 11 43 AM ...

Page 112: ...PRINTED IN JAPAN 2009 07 0 3 1 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD DIC183 ...

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