Yamaha WR25RB Owner'S Manual Download Page 6

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TABLE OF CONTENTS

LOCATION OF IMPORTANT
LABELS

............................................. 1-1

SAFETY INFORMATION

.................. 2-1

DESCRIPTION

.................................. 3-1

Left view .......................................... 3-1
Right view ........................................ 3-2
Controls and instruments................. 3-3

INSTRUMENT AND CONTROL
FUNCTIONS

....................................... 4-1

Main switch/steering lock ................ 4-1
Indicator lights and warning

lights ............................................ 4-2

assembly ................................... 4-17

EXUP system ............................... 4-18

Sidestand ..................................... 4-19
Ignition circuit cut-off system ........ 4-19

FOR YOUR SAFETY –
PRE-OPERATION CHECKS

............. 5-1

OPERATION AND IMPORTANT
RIDING POINTS

................................. 6-1

Starting the engine  .........................  6-1
Shifting ...........................................  6-2
Engine break-in  ..............................  6-3
Parking ...........................................  6-4

PERIODIC MAINTENANCE AND
ADJUSTMENT

................................... 7-1

Owner’s tool kit ............................... 7-2
Periodic maintenance chart for

the emission control system ....... 7-3

General maintenance and

lubrication chart .......................... 7-5

Removing and installing panels  .....  7-9
Checking the spark plug ...............  7-12
Canister (for California only)  ........  7-13
Engine oil and oil filter element  ....  7-13
Coolant .........................................  7-16
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 grip free

play ............................................ 7-22

Valve clearance ............................ 7-22
Tires .............................................. 7-22
Spoke wheels ............................... 7-24
Adjusting the clutch lever free

play ............................................ 7-24

Adjusting the brake lever free

play ............................................ 7-25

Checking the shift pedal ............... 7-26
Brake light switches ...................... 7-27
Checking the front and rear

brake pads ................................. 7-27

Checking the brake fluid level ....... 7-28
Changing the brake fluid ............... 7-29
Drive chain slack ........................... 7-29
Cleaning and lubricating the

drive chain ................................. 7-30

Checking and lubricating the

cables ........................................ 7-31

Checking and lubricating the

throttle grip and cable ................ 7-31

Checking and lubricating the

brake and clutch levers ............. 7-32

Checking and lubricating the

brake pedal ................................ 7-32

Checking and lubricating the

sidestand ................................... 7-33

Lubricating the swingarm pivots ... 7-33
Checking the front fork .................. 7-33
Checking the steering ................... 7-34

32C-9-18.book 1 ページ２０１１年７月６日　水曜日　午後５時５５分

Summary of Contents for WR25RB

Page 1: ...q Read this manual carefully before operating this vehicle OWNER S MANUAL WR25RB WR25RBC 32C 28199 18 LIT 11626 25 44 U32C18_Hyoshi indd 1 2011 07 12 14 52 25 ...

Page 2: ...EAU10042 Q Read this manual carefully before operating this vehicle This manual should stay with this vehicle if it is sold U32C18_Hyoshi indd 2 2011 07 12 14 52 26 ...

Page 3: ...le To maintain 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 dis...

Page 4: ... potential personal injury hazards Obey 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 WARN...

Page 5: ... Yamaha Motor Corporation U S A 1st edition June 2011 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 25 44 32C 9 18 book 2 ページ２０１１年７月６日水曜日午後５時５５分 ...

Page 6: ...al maintenance and lubrication chart 7 5 Removing and installing panels 7 9 Checking the spark plug 7 12 Canister for California only 7 13 Engine oil and oil filter element 7 13 Coolant 7 16 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 grip free play 7 22 Valve clearance 7 22 Tires 7 22 Spoke wheel...

Page 7: ...eel 7 41 Rear wheel 7 42 Troubleshooting 7 43 Troubleshooting charts 7 45 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 ...

Page 8: ... vehicle 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 5 3 32C 9 18 book 1 ページ２０１１年７月６日水曜日午後５時５５分 ...

Page 9: ...lothing 5GK 2118K 00 Cold tire normal pressure should be set as follows Up to 90 kg 198 lbs load 125 kPa 1 25 kgf cm2 18 psi 175 kPa 1 75 kgf cm2 25 psi 90 kg 198 lbs 150 kPa 1 50 kgf cm2 22 psi 200 kPa 2 00 kgf cm2 29 psi maximum load 32C 21668 00 WARNING This unit contains high pressure nitrogen gas Mishandling can cause explosion Read owner s manual for instructions Do not incinerate puncture o...

Page 10: ...LOCATION OF IMPORTANT LABELS 1 3 1 1 32C 9 18 book 3 ページ２０１１年７月６日水曜日午後５時５５分 ...

Page 11: ...LOCATION OF IMPORTANT LABELS 1 4 1 2 3 4 5 6 7 8 9 1 32C 9 18 book 4 ページ２０１１年７月６日水曜日午後５時５５分 ...

Page 12: ...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 you are approaching and passing th...

Page 13: ...ations 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 passenger should also observe the above precautions Avoid Carbon Monoxide Poisoning All engine...

Page 14: ...st the suspension for your load suspension ad justable models only and check the condition and pres sure 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 dling or a slow steering re sponse This vehicle is not designed to pull a trailer or to be attached to a...

Page 15: ...sed by large vehicles Certain accessories can dis place the operator from his or her normal riding position This improper position limits the free dom of movement of the opera tor and may limit control ability therefore such accessories are not recommended Use caution when adding electri cal accessories If electrical acces sories exceed the capacity of the motorcycle s electrical system an electri...

Page 16: ...hat could break Choose the location for the straps carefully so the straps will not rub against painted surfaces during transport The suspension should be com pressed somewhat by the tie downs if possible so that the motorcycle will not bounce exces sively during transport 32C 9 18 book 5 ページ２０１１年７月６日水曜日午後５時５５分 ...

Page 17: ...2 Fuse box page 7 36 3 Coolant reservoir page 7 16 4 Shock absorber assembly compression damping force adjusting screw page 4 17 5 Battery page 7 35 6 Main fuse page 7 36 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 32C 9 18 book 1 ページ２０１１年７月６日水曜日午後５時５５分 ...

Page 18: ...e fluid reservoir page 7 28 3 Air filter element page 7 18 4 Rear brake light switch page 7 27 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 32C 9 18 book 2 ページ２０１１年７月６日水曜日午後５時５５分 ...

Page 19: ...1 Clutch lever 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 22 8 Fuel tank cap page 4 11 32C 9 18 book 3 ページ２０１１年７月６日水曜日午後５時５５分 ...

Page 20: ... when the 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 electr...

Page 21: ...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 EAU11446 Coola...

Page 22: ...ed 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 key is turn...

Page 23: ...ading a stopwatch 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 speedome...

Page 24: ...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 by push ing the SELECT 2 button and then p...

Page 25: ... 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 it by pushing the SE LECT 1 button and SELECT 2 button together 2 Push the SELECT 1 button and SELECT 2 button together for at least two seconds t...

Page 26: ...riding Calibrating this meter in accor dance with the distances specified on the enduro course map will help famil iarize the rider with the course In addi tion calibrating the meter may also be necessary when using tire wheel chain sprocket sizes etc other than specified For further information con cerning the use of this meter please consult your nearby Yamaha dealer Calibrate the distance compe...

Page 27: ...f 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 error codes note the code number and then have a Yamaha dealer check the vehicle NOTICE ECA11590 If the display indicates an error code the vehicle should be checked as soon as ...

Page 28: ...uch as when 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 cl...

Page 29: ...eed con 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 1 Brake lever 1 1 Brake pedal 1 32C 9 18 book 10 ペー...

Page 30: ... fire hazard 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 s...

Page 31: ...s and piston rings 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 ...

Page 32: ... 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 EAU46281 Seat To remove the seat Remove the bolts and then slide the...

Page 33: ...e front fork 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 ...

Page 34: ...rce adjusting mechanism may not exactly match the above spec ifications due to small differences in production the actual number of clicks always represents the entire adjusting 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 direc...

Page 35: ...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 Lift the front wheel off the ground according to the procedure on page 7 40 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 all of th...

Page 36: ...load Rebound 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...

Page 37: ...r damping performance 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 s...

Page 38: ...circuit cut off system has been designed to assist the operator in fulfilling the respon sibility of raising the sidestand be fore starting off Therefore check this system regularly and have a Yamaha dealer repair it if it does not function properly EAU44892 Ignition circuit cut off system The ignition circuit cut off system com prising the sidestand switch clutch switch and neutral switch has the...

Page 39: ...s 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 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 ...

Page 40: ...efore using this 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 f...

Page 41: ... and lubricate cable and grip housing 7 22 7 31 Control cables Make sure that operation is smooth Lubricate if necessary 7 31 Drive chain Check chain slack Adjust if necessary Check chain condition Lubricate if necessary 7 29 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 that operation is smooth C...

Page 42: ...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 32C 9 18 book 3 ページ２０１１年７月６日水曜日午後５時５５分 ...

Page 43: ...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 EAU45127 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 position The ...

Page 44: ...sition 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 running Inade quate lubrication may damage the tra...

Page 45: ...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 the engine wear and polish themselv...

Page 46: ...3 Parking When parking 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 f...

Page 47: ... engine when performing maintenance unless otherwise specified A running 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 2 for more in formation about carbon monox ide WARNING EWA15460 Brake disc...

Page 48: ...ided 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 32C 9 18 book 2 ページ２０１１年７月６日水曜日午後５...

Page 49: ...11000km or 12 months 10000 mi 16000km or 18 months 13000 mi 21000km or 24 months 16000 mi 26000km 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 Valve clearance Check and adjust va...

Page 50: ...ry 8 Air induction system 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 11000km or 12 months 10000 mi 16000km or 18 months 13000 mi 21000km or 24 months 16000 mi 26000km or 30 months 32C 9 18 book 4 ページ２０１１年７月６日水曜日午後５時５５分 ...

Page 51: ...able 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 Check for correct routing and clamping Replace Every 4 years 6 Wheels Check runout spoke tightness and for damage Tighten spokes i...

Page 52: ...ium soap based grease Repack 12 Chassis fasteners Check all chassis fitting and fasteners 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 Ch...

Page 53: ...ange 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 Check operation Check throttle grip free play and adjust if necessary Lubricate cable and grip housing 27 Lights signals and switches Check operation Adjust headlight beam No ITEM ROUTINE ...

Page 54: ...e After disassembling the brake master cylinders and calipers always change the fluid Regularly check the brake fluid levels and fill the reservoirs as required 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 32C 9 18 book 8 ページ２０１１年７月６日水曜日午後５時５５分 ...

Page 55: ... some of the 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 32C 9 18 book 9 ページ２０１１年７月６日水曜日午後５時５５分 ...

Page 56: ...original posi tion and then install the collars 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 1 Bolt 2 Collar 3 Panel A 1 2 3 1 Bolt 2 Panel B 1 2 32C 9 18 book 10 ページ２０１１年７月６日水曜日午後５時５５分 ...

Page 57: ... the panel in the original position and then install the bolts Panel D To remove the panel 1 Remove the seat See page 4 13 2 Remove the bolt and washer and then remove the panel as shown To install the panel 1 Place the panel in the original posi tion and then install the washer and bolt 2 Install the seat 1 Panel C 2 Bolt 1 2 2 1 Bolt 2 Washer 3 Panel D 3 2 1 32C 9 18 book 11 ページ２０１１年７月６日水曜日午後...

Page 58: ... deposits it should be replaced Before installing a spark plug the spark plug gap should be measured with a wire thickness gauge and if necessary adjusted to specification Clean the surface of the spark plug gasket and its mating surface and then wipe off any grime from the spark plug threads TIP If a torque wrench is not available when installing a spark plug a good estimate of the correct torque...

Page 59: ...Place the vehicle on a level sur face and hold it in an upright posi tion A slight tilt to the side can result in a false reading 2 Start the engine warm it up for several minutes and then turn it off 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 TIP The engine oil should be between the minimum an...

Page 60: ...perly seated 8 Install the oil filter element cover by installing the bolts then tightening them to the specified torque 9 Install the engine oil drain bolt and its new gasket and then tighten the bolt to the specified torque 10 Refill with the specified amount of the recommended engine oil and then install and tighten the oil filler cap 1 Engine oil drain bolt 2 Gasket 1 2 1 Oil filter element co...

Page 61: ...ngine off and check for the cause 12 Turn the engine off wait a few min utes until the oil settles and then check the oil level and correct it if necessary NOTICE ECA11231 After changing the engine oil make sure to check the oil pressure as de scribed below Loosen the bleed bolt Start the engine and keep it idling until oil flows out If no oil comes out after one minute turn the engine off immedia...

Page 62: ...ove the coolant reservoir cap add coolant to the maximum level mark and then install the reservoir cap and the panel WARNING Remove only the coolant reservoir cap Never attempt to remove the ra diator cap when the engine is hot EWA15161 NOTICE If coolant is not available use distilled water or soft tap water instead Do not use hard water or salt water since it is harmful to the engine If water has...

Page 63: ...down 8 Install the coolant reservoir by placing it in the original position and then installing the bolts 9 Remove the coolant drain bolt and its gasket to drain the cooling sys tem 10 After the coolant is completely drained thoroughly flush the cool ing system with clean tap water 11 Install the coolant drain bolt and its new gasket and then tighten the bolt to the specified torque 12 Pour the sp...

Page 64: ...anels EAU44323 Cleaning the air filter element and check hose The air filter element should be cleaned or replaced at the intervals specified in the periodic maintenance and lubrica tion chart Clean or if necessary re place the air filter element more frequently if you are riding in unusually wet or dusty areas In addition the air filter check hose must be frequently checked and cleaned if necessa...

Page 65: ... not twist or wring it ECA10511 5 Apply oil of the recommended type to the entire surface of the sponge material and then squeeze the ex cess oil out TIP The sponge material should be wet but not dripping 6 Pull the sponge material over the air filter element frame 7 Insert the air filter element into the air filter case NOTICE Make sure that the air filter element is prop erly seated in the air f...

Page 66: ...brication chart WARNING EWA10980 Always let the exhaust system cool prior to touching exhaust components Do not start the engine when cleaning the exhaust system 1 Remove the spark arrester cap by removing the spark arrester cap bolts 2 Remove the tailpipe by pulling it out of the muffler and then remove the gasket 3 Tap the tailpipe lightly and then use a wire brush to remove any carbon deposits ...

Page 67: ...ch is located in the spark plug cap 2 Check the engine idling speed and if necessary adjust it to spec ification by turning the idle adjust ing screw 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 Tig...

Page 68: ...and lubrication chart EAU48352 Tires To maximize the performance durabil ity and safe operation of your motorcy cle note the following points regarding the specified tires Tire air pressure The tire air pressure should be checked and if necessary adjusted before each ride WARNING EWA10503 Operation of this vehicle with im proper tire pressure may cause se vere injury or death from loss of control ...

Page 69: ...low have been approved for this model by Yamaha Motor Co Ltd WARNING EWA10562 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 Tire air pressure measured on cold tires 0 90 kg 0 198 lb Front 125 kPa 1 25 kgf cm2 18 psi Rear 175 kPa 1 75 kgf cm2 25 psi 90 184 kg 198 406 lb CAL...

Page 70: ... The wheel rims should be checked for cracks bends warpage or oth er damage and the spokes for looseness or damage before each ride If any damage is found have a Yamaha dealer replace the wheel Do not attempt even the smallest repair to the wheel A de formed or cracked wheel must be replaced The wheel should be balanced whenever either the tire or wheel has been changed or replaced An unbalanced w...

Page 71: ...n the locknut at the clutch le ver and then slide the rubber cov er to its original position EAU48442 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 the brake lever 2 Loosen the locknut 3 To increase the brake lever fre...

Page 72: ...draulic 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 EAU44820 Checking the shift pedal The operation of the shift pedal should be checked before each ride If opera tion is not smooth have a Yamaha dealer che...

Page 73: ...ubrication chart EAU22430 Front brake pads Each front brake pad is provided with wear indicator grooves which allow you to check the brake pad wear with out having to disassemble the brake To check the brake pad wear check the wear indicator grooves If a brake pad has worn to the point that the wear indicator grooves have almost disap peared have a Yamaha dealer replace the brake pads as a set EAU...

Page 74: ...ge Refill with the same type of brake fluid Adding a brake fluid other than DOT 4 may result in a harmful chemical reaction Be careful that water does not enter the brake fluid reservoir when refilling Water will signifi cantly lower the boiling point of the fluid and may result in vapor lock NOTICE ECA17640 Brake fluid may damage painted sur faces or plastic parts Always clean up spilled fluid im...

Page 75: ...rcycle 2 Shift the transmission into the neu tral position 3 Push on the drive chain at the cen ter point between the chain ten sioner and the chain support mounting bolt with a force of 50 N 5 0 kgf 11 lbf 4 Measure drive chain slack be tween the swingarm and the top of the chain link closest to the swing arm as shown 5 If the drive chain slack is incorrect adjust it as follows EAU34317 To adjust...

Page 76: ...icated 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 NOTICE ECA10583 The drive chain must be lubricated after washing the motorcycle riding in the rain or riding in wet areas 1 Clean the drive chain with kero sene and a small soft brush NOTICE To preven...

Page 77: ...as possi ble to prevent unsafe condi tions EWA10711 EAU23114 Checking and lubricating the throttle grip and cable The operation of the throttle grip should be checked before each ride In addi tion the cable should be lubricated by a Yamaha dealer at the intervals speci fied in the periodic maintenance chart The throttle cable is equipped with a rubber cover Make sure that the cover is securely ins...

Page 78: ...ach ride and the lever pivots should be lu bricated if necessary EAU23182 Checking and lubricating the brake pedal The operation of the brake pedal should be checked before each ride and the pedal pivot should be lubricat ed if necessary Recommended lubricants Brake lever Silicone grease Clutch lever Lithium soap based grease Recommended lubricant Lithium soap based grease 32C 9 18 book 32 ページ２０１...

Page 79: ...ified in the periodic maintenance and lubrication chart EAU23272 Checking the front fork The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic main tenance and lubrication chart To check the condition Check the inner tubes for scratches damage and excessive oil leakage To check the operation 1 Place the vehicle on a level sur face and h...

Page 80: ...ront wheel off the ground See page 7 40 for more information WARNING To avoid injury securely support the vehicle so there is no danger of it falling over EWA10751 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 EAU23291 Checking the wheel bearings The front and rear wheel bearing...

Page 81: ...nd pro vide sufficient ventilation when charging it in an enclosed space KEEP THIS AND ALL BATTER IES OUT OF THE REACH OF CHILDREN To charge the battery Have a Yamaha dealer charge the bat tery as soon as possible if it seems to have discharged Keep in mind that the battery tends to discharge more quickly if the vehicle is equipped with optional electrical accessories NOTICE ECA16521 To charge a V...

Page 82: ...uses for the individual circuits is located be hind panel C See page 7 9 If a fuse is blown 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 WARNING Do not use a fuse of a higher amperage rating than recommended to avoid causing extensive dam age to the electrical system and pos...

Page 83: ...nosity 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 lens Do not affix any type of tinted film or stickers to the headlight lens Do not use a headlight bulb of a wattage higher than specified 1 Remove the headlight cowling to gether with the headlight unit by...

Page 84: ...oupler 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 EAU24181 Tail brake light This model is equipped with an LED type tail brake light If the tail brake light does not come on have a Yamaha dealer check it 1 Headlight coupler 2 Headlight bulb cover...

Page 85: ...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 EAU24313 Replacing the license plate light bulb 1 Remove the license plate light unit by removing the screws 2 Remove the license plate light bulb socket together with the bulb by pulling it out 1 Screw 1 1 Turn signal light...

Page 86: ...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 der the frame in front of the rear wheel 2 Raise the front wheel off the ground by using a motorcycle stand To service ...

Page 87: ...e spacers into both sides of the wheel hub NOTICE When installing the spacers be sure to install them on the correct side ECA17700 2 Lift the wheel up between the fork legs TIP Make sure that there is enough space between the brake pads before install ing the brake caliper onto the brake disc 3 Insert the wheel axle from the right hand side 4 Install the axle nut 5 Lower the front wheel so that it...

Page 88: ... not need to be disassembled in order to remove and install the rear wheel 7 While supporting the brake caliper pull the wheel axle out 8 Remove the drive chain pullers spacers and 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 EAU45193 To install the rear wheel 1 Install the spacers into...

Page 89: ... in the fuel compression or ignition systems for example can cause poor starting and loss of power The following troubleshooting charts represent quick and easy procedures 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 properl...

Page 90: ...IC MAINTENANCE AND ADJUSTMENT 7 44 1 2 3 4 5 6 7 8 9 heaters or furnaces Gasoline or gasoline vapors can ignite or ex plode causing severe injury or property damage 32C 9 18 book 44 ページ２０１１年７月６日水曜日午後５時５５分 ...

Page 91: ...a Yamaha dealer check the vehicle Remove the spark plug and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gap or replace the spark plug Have a Yamaha dealer check the vehicle The engine does not start Have a Yamaha dealer check the vehicle The engine does not start Check the battery Operate the electric starter 4 Battery The engine turns over quickly The engi...

Page 92: ...ape When the 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 ...

Page 93: ...the muffler 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 ...

Page 94: ...ge 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 corrosive in combination with water carry...

Page 95: ...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 EAU43202 Storage Short term Always store your motorcycle in a cool...

Page 96: ...nt damage or injury from sparking make sure to ground the spark 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 sidestand 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 wheel...

Page 97: ...eplacement 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 maxi mum 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 7 2 L 1 ...

Page 98: ...5 kgf cm2 18 psi Rear 175 kPa 1 75 kgf cm2 25 psi Loading condition 90 184 kg 198 406 lb CAL 90 185 kg 198 408 lb U49 Front 150 kPa 1 50 kgf cm2 22 psi Rear 200 kPa 2 00 kgf cm2 29 psi Front wheel Wheel type Spoke wheel Rim size 21x1 60 Rear wheel Wheel type Spoke wheel Rim size 18x2 15 Front brake Type Single disc brake Operation Right hand operation Specified brake fluid DOT 4 Rear brake Type Si...

Page 99: ... 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 sy...

Page 100: ...26381 Key identification number The key identification number is stamped into the key tag Record this number in the space provided and use it for reference when ordering a new key EAU26400 Vehicle identification number The vehicle identification number is stamped into the steering head pipe Record this number in the space pro vided TIP The vehicle identification number is used to identify your mot...

Page 101: ...rdering spare 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 32C 9 18 book 2 ページ２０１１年７...

Page 102: ...investigation 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 N...

Page 103: ... any new ve hicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW These acts include tampering with the following systems i e modification ...

Page 104: ...d only as a 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 220...

Page 105: ...ION 10 6 2 3 4 5 6 7 8 9 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 32C 9 18 book 6 ページ２０１１年７月６日水曜日午後５時５５分 ...

Page 106: ... registered for 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 o...

Page 107: ...request at any 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...

Page 108: ...ing for covered repairs There s no deductible to pay and repairs aren t pro rated You don t have any out of pocket expenses for covered repairs In addition Travel and Recreation Interruption Protection TRIP is included at no extra cost TRIP gives you up to 250 reimbursement per occurrence for any reasonable expenses you incur because your Yamaha needs covered service replacement vehicle rental eme...

Page 109: ...g factory backed protection even after your Yamaha Limited Warranty expires A special note If visiting your dealer isn t convenient contact Yamaha with your Primary ID number your frame number We ll be happy to help you get the Y E S coverage you need Yamaha Service Marketing P O Box 6555 Cypress CA 90630 1 866 YES EXTD 1 866 937 3983 32C 9 18 book 10 ページ２０１１年７月６日水曜日午後５時５５分 ...

Page 110: ...eam indicator light 4 2 Horn switch 4 9 I Identification numbers 10 1 Ignition circuit cut off system 4 19 Indicator lights 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 Matte color caution 8...

Page 111: ...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 41 Wheel rear 7 42 Wheels 7 24 32C 9 18 book 12 ページ２０１１年７月６日水曜日午後５時５５分 ...

Page 112: ...32C 9 18 book 13 ページ２０１１年７月６日水曜日午後５時５５分 ...

Page 113: ...Genuine Yamaha Accessories will fit right and perform right right out of the box Yamalube Take care of your Yamaha with legendary Yamalube oils lubricants and care products They re formulated and approved by the toughest judges we know the Yamaha engineering teams that know your Yamaha from the inside out Genuine Yamaha Service Manuals Get the same factory manual for your vehicle that the technici...

Page 114: ...PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2011 07 0 2 1 E U32C18_Hyoshi indd 4 2011 07 12 14 52 26 ...

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Yamaha WR25RB, Owner'S Manual

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