Yamaha XT225C Owner'S Manual Download | Manualshive

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6-22

PERIODIC MAINTENANCE AND MINOR REPAIR

6

3. If the specified clutch lever free

play could be obtained as
described above, tighten the
locknut and skip the rest of the
procedure, otherwise proceed as
follows.

4. Fully turn the adjusting bolt in

direction

a

to loosen the clutch

cable.

5. Loosen the locknut further down

the clutch cable.

6. To increase the clutch lever free

play, turn the adjusting nut in
direction

a

. To decrease the

clutch lever free play, turn the
adjusting nut in direction

b

.

7. Tighten both locknuts.

1

2

a

b

1.

Locknut (clutch cable)

2.

Adjusting nut

EW000099

w

8

After adjusting the brake lever
free play, check the free play
and make sure that the brake
is working properly.

8

A soft or spongy feeling in the
brake lever can indicate the
presence of air in the
hydraulic system. If there is air
in the hydraulic system, have
a Yamaha dealer bleed the
system before operating the
motorcycle. Air in the
hydraulic system will diminish
the braking performance,
which may result in loss of
control and an accident.

EAU00696

Adjusting the brake lever
free play

The brake lever free play should
measure 2–5 mm (0.08–0.20 in) as
shown. Periodically check the brake
lever free play and, if necessary,
adjust it as follows.

1. Loosen the locknut at the brake

lever.

2. To increase the brake lever free

play, turn the adjusting bolt in
direction

a

. To decrease the

brake lever free play, turn the
adjusting bolt in direction

b

.

3. Tighten the locknut.

c

1 2

a

b

1.

Locknut

2.

Adjusting bolt

c.

Free play

5RK-9-11(US) 4/26/02 7:16 PM Page 62

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Summary of Contents for XT225C

Page 1: ...5RK 28199 11 LIT 11626 16 22 OWNER S MANUAL XT225R C ...

Page 2: ......

Page 3: ...his motorcycle If you have any questions concerning the operation or maintenance of your motorcy cle please consult a Yamaha dealer The design and manufacture of this Yamaha motorcycle fully comply with the emissions standards for clean air applicable at the date of manufacture Yamaha has met these standards without reduc ing the performance or economy of operation of the motorcycle To maintain th...

Page 4: ...ken to avoid damage to the motorcycle A NOTE provides key information to make procedures easier or clearer Q w cC NOTE NOTE 8 This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold 8 Yamaha continually seeks advancements in product design and quality Therefore while this manual contains the most current product inf...

Page 5: ...TEMPT TO OPERATE THIS MOTORCYCLE UNTIL YOU HAVE ATTAINED ADE QUATE KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES REGULAR INSPEC TIONS AND CAREFUL MAINTENANCE ALONG WITH GOOD RIDING SKILLS WILL ENSURE THAT YOU SAFELY ENJOY THE CAPABILITIES AND THE RELIABILITY OF THIS MOTORCYCLE 5RK 9 11 US 4 26 02 7 15 PM Page 3 ...

Page 6: ... edition April 2002 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in Japan P N LIT 11626 16 22 EAU04247 AFFIX DEALER LABEL HERE 5RK 9 11 US 4 26 02 7 15 PM Page 4 ...

Page 7: ... Fuel tank cap 3 5 Fuel 3 5 Fuel cock 3 7 Starter choke knob 3 8 Seat 3 8 Helmet holder 3 9 Adjusting the shock absorber assembly 3 9 Sidestand 3 12 Ignition circuit cut off system 3 12 PRE OPERATION CHECKS 4 1 Pre operation check list 4 1 OPERATION AND IMPORTANT RIDING POINTS 5 1 Starting and warming up a cold engine 5 1 Starting a warm engine 5 3 Shifting 5 3 Recommended shift points 5 5 Engine ...

Page 8: ...ging the brake fluid 6 27 Drive chain slack 6 27 Lubricating the drive chain 6 29 Checking and lubricating the cables 6 29 Checking and lubricating the throttle grip and cable 6 30 Checking and lubricating the brake and shift pedals 6 30 Checking and lubricating the brake and clutch levers 6 31 Checking and lubricating the sidestand 6 31 Lubricating the rear suspension 6 31 Checking the front fork...

Page 9: ...ntification number 9 1 Vehicle identification number 9 1 Model label 9 2 Reporting safety defects 9 3 Motorcycle noise regulation 9 4 Maintenance record 9 6 Street and enduro motorcycle limited warranty 9 8 Yamaha extended service Y E S 9 10 9 5RK 9 11 US 4 26 02 7 15 PM Page 7 ...

Page 10: ...SARY BY MECHANICAL CONDITIONS Safe riding 1 Always make pre operation checks Careful checks may help prevent an accident 2 This motorcycle is designed to carry the operator and a passenger 3 The failure of motorists to detect and recognize motorcycles in traffic is the predominating cause of automobile motorcycle accidents Many accidents have been caused by an automobile driver who did not see the...

Page 11: ...ng wide on a turn due to EXCESSIVE SPEED or undercornering insufficient lean angle for the speed a Always obey the speed limit and never travel faster than warranted by road and traffic condi tions b Always signal before turning or changing lanes Make sure that other motorists can see you 6 The posture of the operator and passenger is important for proper control a The operator should keep both ha...

Page 12: ...eration They become very hot and can cause burns Always wear protective clothing that covers your legs ankles and feet 6 Passengers should also observe the precautions mentioned above Modifications Modifications made to this motorcycle not approved by Yamaha or the removal of original equipment may render the motorcycle unsafe for use and may cause severe personal injury Modifications may also mak...

Page 13: ...tems including such cargo as sleeping bags duffel bags or tents can create unstable handling or a slow steering response Accessories Genuine Yamaha accessories have been specifically designed for use on this motorcycle Since Yamaha cannot test all other accessories that may be available you must personally be responsible for the proper selection installation and use of non Yamaha accessories Use e...

Page 14: ...l ability therefore such accessories are not recommended 2 Use caution when adding electrical accessories If electrical accessories exceed the capacity of the motorcycle s electrical system an electric failure could result which could cause a dangerous loss of lights or engine power Gasoline and exhaust gas 1 GASOLINE IS HIGHLY FLAMMABLE a Always turn the engine off when refueling b Take care not ...

Page 15: ...uld catch fire 4 When transporting the motorcycle in another vehicle make sure that it is kept upright and that the fuel cock s are turned to ON or RES for vacuum type OFF for manual type If the motor cycle should lean over gasoline may leak out of the carburetor or fuel tank 5 If you should swallow any gasoline inhale a lot of gasoline vapor or allow gasoline to get into your eyes see your doctor...

Page 16: ...1 7 QSAFETY INFORMATION 1 EAU02977 Location of important labels Please read the following important labels carefully before operating this motorcycle 1 4 2 3 5RK 9 11 US 4 26 02 7 15 PM Page 14 ...

Page 17: ...READ THE OWNER S MANUAL AND ALL LABELS ALWAYS WEAR AN APPROVED MOTORCYCLE HELMET eye protection and protective clothing 5GK 2118K 00 1 2 EMISSION HOSE ROUTING CARB FROM FUEL TANK CANISTER TO ATMOSPHERE 4YN 21686 00 3 California only 4 5RK 9 11 US 4 26 02 7 16 PM Page 15 ...

Page 18: ... filter element page 6 14 4 Helmet holder page 3 9 5 Owner s tool kit page 6 1 6 Shock absorber spring preload adjusting nut page 3 10 7 Shock absorber rebound damping adjusting dial page 3 11 8 Shift pedal page 3 4 1 2 5 7 6 8 3 4 Left view 5RK 9 11 US 4 26 02 7 16 PM Page 16 ...

Page 19: ...page 6 33 10 Fuse page 6 35 11 Engine oil filter element page 6 11 12 Engine oil level check window page 6 10 13 Brake pedal page 3 4 6 23 14 Spark arrester page 6 16 13 14 9 10 11 12 Right view 5RK 9 11 US 4 26 02 7 16 PM Page 17 ...

Page 20: ...rter choke knob page 3 8 4 Speedometer unit page 3 2 5 Main switch steering lock page 3 1 6 Right handlebar switches page 3 3 7 Brake lever page 3 4 6 22 8 Throttle grip page 6 17 6 30 9 Fuel tank cap page 3 5 1 2 4 5 6 7 8 9 3 Controls and instruments 5RK 9 11 US 4 26 02 7 16 PM Page 18 ...

Page 21: ... can be started The key cannot be removed EAU00038 OFF All electrical systems are off The key can be removed ON OFF LOCK To unlock the steering Insert the key and turn it to OFF EW000017 w Never turn the key to LOCK while the motorcycle is moving EAU00043 LOCK The steering is locked and all electri cal systems are off The key can be removed To lock the steering 1 Turn the handlebars all the way to...

Page 22: ...g speed The odometer shows the total distance traveled The tripmeter shows the distance traveled since it was last set to zero with the reset knob The tripmeter can be used to estimate the distance that can be traveled with a full tank of fuel This information will enable you to plan future fuel stops 1 2 3 4 1 Speedometer 2 Odometer 3 Tripmeter 4 Reset knob EAU00118 Handlebar switches EAU03888 Di...

Page 23: ...lutch switch which is part of the igni tion circuit cut off system See page 3 12 for an explanation of the ignition circuit cut off system 1 1 Clutch lever EAU03890 Engine stop switch Set this switch to before starting the engine Set this switch to to stop the engine in case of an emer gency such as when the motorcycle overturns or when the throttle cable is stuck EAU00143 Start switch Push this s...

Page 24: ...n this motorcycle INSTRUMENT AND CONTROL FUNCTIONS 3 1 1 Shift pedal EAU00158 Brake lever The brake lever is located at the right handlebar grip To apply the front brake pull the lever toward the han dlebar grip 1 1 Brake lever EAU00162 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 1 Brake pedal 5RK 9 11 US 4 26 02 7 16 P...

Page 25: ...l tank otherwise it may overflow when the fuel warms up and expands 8 Avoid spilling fuel on the hot engine 1 2 1 Fuel level 2 Filler tube To install the fuel tank cap 1 Insert the fuel tank cap into the tank opening with the key insert ed in the lock and then turn the cap 1 3 turn clockwise 2 Turn the key 1 3 turn clockwise and then remove it NOTE The fuel tank cap cannot be installed unless the ...

Page 26: ...rch octane number of 91 or higher If knocking or pinging occurs use a gasoline of a different brand or premium unleaded fuel Use of unleaded fuel will extend spark plug life and reduce maintenance costs Gasohol There are two types of gasohol gasohol containing ethanol and that containing methanol Gasohol con taining ethanol can be used if the ethanol content does not exceed 10 Gasohol containing m...

Page 27: ...w mark positioned over OFF RES This indicates reserve If you run out of fuel while riding move the lever to this position Fill the tank at the first opportunity Be sure to set the lever back to ON after refueling F U E L F U E 1 1 Arrow mark positioned over RES ON With the lever in this position fuel flows to the carburetor Normal riding is done with the lever in this position F U E L F U E 1 1 Ar...

Page 28: ...n a to turn on the starter choke Move the knob in direction b to turn off the starter choke INSTRUMENT AND CONTROL FUNCTIONS 3 1 a b 1 Starter choke knob 1 EAU02949 Seat To remove the seat 1 Remove panels A and B See page 6 7 for panel removal and installation procedures 2 Remove the bolts and pull the seat off 1 1 Bolt 2 5RK 9 11 US 4 26 02 7 16 PM Page 26 ...

Page 29: ...ly is equipped with a spring preload adjusting nut and a rebound damping force adjusting dial EC000015 cC Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings EAU00261 Helmet holder To open the helmet holder insert the key into the lock and then turn the key as shown To lock the helmet holder turn the key to the original position and then remove it EW000030 w Never r...

Page 30: ... adjustment 8 The spring preload setting is determined by measuring dis tance A shown in the illustration The longer distance A is the higher the spring preload the shorter distance A is the lower the spring preload a a Distance A 3 Tighten the locknut to the speci fied torque ECA00076 cC Always tighten the locknut against the adjusting nut and then tighten the locknut to the specified torque Spri...

Page 31: ... not subject the shock absorber to an open flame or other high heat sources other wise it may explode due to excessive gas pressure 8 Do not deform or damage the gas cylinder in any way as this will result in poor damp ing performance 8 Always have a Yamaha dealer service the shock absorber NOTE Although the total number of clicks of the damping force adjusting mecha nism may not exactly match the...

Page 32: ...r in fulfilling the responsibility of rais ing the sidestand before starting off Therefore check this system regularly as described below and have a Yamaha dealer repair it if it does not function properly EAU03720 Ignition circuit cut off system The ignition circuit cut off system comprising the sidestand switch clutch switch and neutral switch has the following functions 8 It prevents starting w...

Page 33: ...ep the clutch lever pulled 8 Shift the transmission into gear 9 Move the sidestand down Does the engine stall After the engine has stalled 10 Move the sidestand up 11 Keep the clutch lever pulled 12 Push the start switch Does the engine start The sidestand switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer The clutch switch may be defective The motorcycle ...

Page 34: ...Check fuel level in fuel tank Refuel if necessary Check fuel line for leakage 3 5 3 6 Engine oil Check oil level in engine If necessary add recommended oil to specified level Check vehicle for oil leakage 6 10 6 13 Front brake Check operation If soft or spongy have Yamaha dealer bleed hydraulic system Check lever free play Adjust if necessary Check fluid level in reservoir If necessary add recomme...

Page 35: ...sary 6 18 6 20 Brake and shift pedals Make sure that operation is smooth Lubricate pedal pivoting points if necessary 6 30 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 31 Sidestand Make sure that operation is smooth Lubricate pivot if necessary 6 31 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened Tighten...

Page 36: ...ch an inspection can be accomplished in a very short time and the added safety it assures is more than worth the time involved EWA00033 w If any item in the Pre operation check list is not working properly have it inspected and repaired before operat ing the motorcycle 5RK 9 11 US 4 26 02 7 16 PM Page 34 ...

Page 37: ...t the opera tor resulting in a possible loss of control EAU00376 cC 8 Make sure not to store person al items near the air cleaner intake otherwise air intake will be blocked and performance will suffer 8 Make sure not to put anything near the battery and its termi nals otherwise electrical fail ure and acid corrosion may result EAU01751 Starting and warming up a cold engine In order for the igniti...

Page 38: ...ine more than 10 seconds on any one attempt 6 After starting the engine move the starter choke knob back halfway ECA00055 cC For maximum engine life always warm the engine up before starting off Never accelerate hard when the engine is cold 7 When the engine is warm turn the starter choke off NOTE The engine is warm when it responds normally to the throttle with the starter choke turned off To avo...

Page 39: ...ing Inadequate lubrication may damage the transmission 8 Always use the clutch while changing gears to avoid dam aging the engine transmis sion and drive train which are not designed to withstand the shock of forced shifting EAU00423 Shifting Shifting gears lets you control the amount of engine power available for starting off accelerating climbing hills etc The gear positions are shown in the ill...

Page 40: ...ransmission into the neutral position 6 Open the throttle part way and gradually release the clutch lever 7 Follow the same procedure when shifting to the next higher gear NOTE Always shift gears at the recommend ed shift points EAU00427 To decelerate 1 Apply both the front and the rear brakes to slow the motorcycle 2 Shift the transmission into first gear when the motorcycle reach es 20 km h 12 5...

Page 41: ...d full throttle operation or any condition that might result in engine overheating must be avoided EAU04234 0 150 km 0 90 mi 8 Avoid prolonged operation above 1 3 throttle 8 After every hour of operation stop the engine and then let it cool for five to ten minutes 8 Vary the engine speed from time to time Do not operate the engine at one set throttle posi tion 150 500 km 90 300 mi 8 Avoid prolonge...

Page 42: ... should occur during the engine break in period immediately have a Yamaha dealer check the vehicle EAU00457 Parking When parking stop the engine remove the key from the main switch and then turn the fuel cock lever to OFF EW000058 w 8 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 8 Do not park on a slope or on so...

Page 43: ...ools provided in the owner s tool kit are intended to assist you in the performance of pre ventive maintenance and minor repairs However additional tools such as a torque wrench may be nec essary to perform certain mainte nance work correctly 1 1 Owner s tool kit EAU00467 PERIODIC MAINTENANCE PROPER PERIODIC MAINTE NANCE OF YOUR MOTORCYCLE IS IMPORTANT IN ORDER TO ENJOY LONG PLEASURABLE SERVICE ES...

Page 44: ...equired for a particular job have a Yamaha dealer perform it for you EW000062 w Modifications not approved by Yamaha may cause loss of perfor mance excessive emissions and render the vehicle unsafe for use Consult a Yamaha dealer before attempting any changes 5RK 9 11 US 4 26 02 7 16 PM Page 42 ...

Page 45: ...nths 3 Crankcase 9 Check breather hose for cracks or damage breather system 9 Replace if necessary 4 Fuel line 9 Check fuel hose for cracks or damage 9 Replace if necessary 9 Check for leakage 5 Exhaust system 9 Tighten if necessary 9 Replace gasket s if necessary 6 Spark arrester 9 Clean 7 Idle speed 9 Check and adjust engine idle speed 9 Adjust cable free play Evaporative 9 Check control system ...

Page 46: ... filter and strainer if damaged 9 Wet type filter elements 3 Air filter element must be washed and dampened with oil 9 Adjust free play 9 Check fluid leakage Front see NOTE page 6 6 4 Brake system 9 Correct if necessary 9 Replace pads if necessary Front 9 Replace shoes if necessary Rear 5 Clutch 9 Adjust free play 9 Check chain condition Special O ring chain Every 500 km 300 mi and after washing t...

Page 47: ...rpose grease 9 Check operation and free play Throttle grip 9 Adjust the throttle cable Lithium soap based 11 housing and free play if necessary grease all purpose cable 9 Lubricate the throttle grip grease housing and cable 9 Check operation and Lithium soap based 12 Sidestand pivot lubricate grease all purpose 9 Apply chain lube lightly grease 13 Front fork 9 Check operation and leakage 9 Check b...

Page 48: ... if you are riding in unusually wet or dusty areas 8 Hydraulic brake system 9 When disassembling the master cylinder or caliper cylinder always replace the brake fluid Check the brake fluid level regularly and fill as required 9 Replace the oil seals on the inner parts of the master cylinder and caliper cylinder every two years 9 Replace the brake hoses every four years or if cracked or damaged 5R...

Page 49: ...ed and installed 1 3 2 1 Cowling A 2 Panel A 3 Panel B EAU00488 Panel A To remove the panel Remove the screw and then pull the panel off as shown To install the panel Place the panel in the original posi tion and then install the screw 1 2 1 Panel A 2 Screw EAU01145 Cowling A To remove the cowling Remove the screw and then pull the cowling off as shown To install the cowling Place the cowling in t...

Page 50: ...in the owner s tool kit 1 1 Spark plug wrench EAU01833 Checking the spark plug The spark plug is an important engine component which is easy to check Since heat and deposits will cause any spark plug to slowly erode the spark plug should be removed and checked in accordance with the periodic maintenance and lubrication chart In addition the condition of the spark plug can reveal the condition of t...

Page 51: ...e when installing a spark plug a good estimate of the correct torque is 1 4 1 2 turn past finger tight However the spark plug should be tightened to the specified torque as soon as possible 4 Install the spark plug cap To install the spark plug 1 Measure the spark plug gap with a wire thickness gauge and if necessary adjust the gap to specification 2 Clean the surface of the spark plug gasket and ...

Page 52: ...Engine oil and oil filter element The engine oil level should be checked before each ride In addition the oil must be changed and the oil filter element cleaned at the intervals specified in the General maintenance and lubrication chart To check the engine oil level 1 Place the motorcycle on a level surface and hold it in an upright position NOTE Make sure that the motorcycle is positioned straigh...

Page 53: ...he correct level 2 3 1 1 Engine oil level check window 2 Maximum level mark 3 Minimum level mark 4 Remove the engine oil filler cap and drain bolt along with the O ring compression spring and engine oil strainer to drain the oil from the crankcase 1 1 Engine oil filler cap To change the engine oil with or without oil filter element cleaning 1 Start the engine warm it up for several minutes and the...

Page 54: ...he oil filter element and O rings 9 Check the O rings for damage and replace them if necessary 10 Clean the oil filter element with solvent and then install it NOTE Check the oil filter element for dam age and replace it if necessary 11 Install the oil filter element cover by installing the bolts and drain bolt then tightening them to the specified torques 1 2 1 Oil filter element 2 O ring 2 6 Rem...

Page 55: ...reign material enters the crankcase 14 Start the engine and then let it idle for several minutes while checking it for oil leakage If oil is leaking immediately turn the engine off and check for the cause 15 Turn the engine off and then check the oil level and correct it if necessary 16 Install the engine guard by installing the bolt 13 Add the specified amount of the recommended engine oil and th...

Page 56: ...ly if you are riding in unusually wet or dusty areas 1 Remove panel A See page 6 7 for removal and installation pro cedures 2 Remove the air filter case cover by removing the screws 2 1 1 Air filter case cover 2 Screw 3 4 Remove the sponge material from the air filter element frame 1 2 1 Sponge material 2 Air filter element frame 3 Pull the air filter element out from the air filter case 1 1 Air f...

Page 57: ...ilter case 8 8 The engine should never be operated without the air filter element installed otherwise the piston and or cylinder may become excessively worn 8 Install the air filter case cover by installing the screws 9 Install the panel 7 Install the sponge material onto the air filter element frame and then insert the air filter element into the air filter case NOTE Install the air filter elemen...

Page 58: ...ke sure to select a well ventilated area free of combustible materials to clean the spark arrester 2 Tap the tailpipe lightly and then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe 3 Insert the tailpipe into the muf fler and then install and tighten the screw NOTE Make sure to align the screw holes when inserting the tailpipe 1 2 1 Tailpipe 2 Spark ...

Page 59: ... valve clearance The valve clearance changes with use resulting in improper air fuel mix ture and or engine noise To prevent this from occurring the valve clear ance must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart EAU00635 Adjusting the throttle cable free play The throttle cable free play should measure 3 5 mm 0 12 0 20 in at the th...

Page 60: ...performance and safety character istics of your motorcycle you should keep the following precau tions in mind 8 NEVER OVERLOAD THE MOTORCYCLE Operation of an overloaded motorcycle may result in tire damage loss of control or severe injury Make sure that the total weight of rider passenger cargo and accessories does not exceed the specified maximum load for the vehicle 8 Do not carry along loosely ...

Page 61: ... inspection The tires must be checked before each ride If the tire shows crosswise lines minimum tread depth if the tire has a nail or glass fragments in it or if the sidewall is cracked have a Yamaha dealer replace the tire imme diately NOTE The tire tread depth limits may differ from country to country Always com ply with the local regulations 1 2 a 1 Sidewall 2 Wear indicator a Tire tread depth...

Page 62: ...ng a tire since the tire sur face must first be broken in for it to develop its optimal charac teristics EAU00685 Spoke wheels To maximize the performance dura bility and safe operation of your motorcycle note the following points regarding the specified wheels 8 The wheel rims should be checked for cracks bends or warpage and the spokes for looseness or damage before each ride If any damage is fo...

Page 63: ...ries or replace ment parts may cause loss of handling stability and riding safe ty Since Yamaha cannot control the quality of accessories or parts EAU02996 Adjusting the clutch lever free play The clutch lever free play should measure 10 15mm 0 4 0 6 in as shown Periodically check the clutch lever free play and if necessary adjust it as follows 1 Loosen the locknut at the clutch lever 2 To increas...

Page 64: ... brake is working properly 8 A soft or spongy feeling in the brake lever can indicate the presence of air in the hydraulic system If there is air in the hydraulic system have a Yamaha dealer bleed the system before operating the motorcycle Air in the hydraulic system will diminish the braking performance which may result in loss of control and an accident EAU00696 Adjusting the brake lever free pl...

Page 65: ...s a a Brake pedal position Brake pedal free play The brake pedal free play should measure 20 30 mm 0 8 1 2 in as shown Periodically check the brake pedal free play and if necessary adjust it as follows a a Brake pedal free play 1 Loosen the locknut at the brake pedal 2 To raise the brake pedal turn the adjusting bolt in direction a To lower the brake pedal turn the adjusting bolt in direction b 3 ...

Page 66: ... adjust the brake light switch as follows Turn the adjusting nut while holding the rear brake light switch in place To make the brake light come on ear lier turn the adjusting nut in direction a To make the brake light come on later turn the adjusting nut in direc tion b 1 2 a b 1 Rear brake light switch 2 Adjusting nut EW000106 w 8 After adjusting the drive chain slack or removing and installing ...

Page 67: ... the wear indicator while applying the brake If a brake shoe has worn to the point that the wear indicator reaches the wear limit line have a Yamaha dealer replace the brake shoes as a set 2 1 1 Wear indicator 2 Wear limit line EAU00725 Front brake pads Each front brake pad is provided with a wear indicator groove which allows you to check the brake pad wear without having to disassemble the brake...

Page 68: ...8 As the brake pads wear it is nor mal for the brake fluid level to gradually go down However if the brake fluid level goes down suddenly have a Yamaha dealer check the cause Observe these precautions 8 When checking the fluid level make sure that the top of the brake fluid reservoir is level 8 Use only the recommended qual ity brake fluid otherwise the rub ber seals may deteriorate caus ing leaka...

Page 69: ...ion into the neutral position 3 Move the rear wheel by pushing the motorcycle to locate the tight est portion of the drive chain and then measure the drive chain slack as shown 4 If the drive chain slack is incor rect adjust it as follows a a Drive chain slack EAU00744 Drive chain slack The drive chain slack should be checked before each ride and adjust ed if necessary To check the drive chain sla...

Page 70: ...ng plate EW000103 w After adjusting the brake pedal free play check the operation of the brake light NOTE Make sure that both adjusting plates are in the same position for proper wheel alignment EC000096 cC Improper drive chain slack will overload the engine as well as other vital parts of the motorcycle and can lead to chain slippage or breakage To prevent this from occurring keep the drive chain...

Page 71: ... drive chain with steam cleaners high pressure washers or inappropriate solvents 2 Wipe the drive chain dry EAU03297 Checking and lubricating the cables The operation of all control cables and the condition of the cables should be checked before each ride and the cables and cable ends should be lubricated if necessary If a cable is damaged or does not move smoothly have a Yamaha dealer check or re...

Page 72: ...ft pedals The operation of the brake and shift pedals should be checked before each ride and the pedal pivots should be lubricated if necessary EAU04034 Checking and lubricating the throttle grip and cable The operation of the throttle grip should be checked before each ride In addition the cable should be lubri cated or replaced at the intervals specified in the periodic maintenance chart Recomme...

Page 73: ...ic maintenance and lubrication chart 1 1 1 Grease nipple 5 EAU03165 Checking and lubricating the sidestand The operation of the sidestand should be checked before each ride and the sidestand pivot and metal to metal contact surfaces should be lubricated if necessary EW000113 w If the sidestand does not move up and down smoothly have a Yamaha dealer check or repair it Recommended lubricant Lithium ...

Page 74: ...ore the opera tion of the steering must be checked as follows at the intervals specified in the periodic maintenance and lubrica tion chart 1 Place a stand under the engine to raise the front wheel off the ground EW000115 w Securely support the motorcycle so that there is no danger of it falling over To check the operation 1 Place the motorcycle on a level surface and hold it in an upright positio...

Page 75: ... any maintenance There is no need to check the electrolyte or to add distilled water EC000101 cC Never attempt to remove the bat tery cell seals as this would per manently damage the battery EAU01144 Checking the wheel bearings The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart If there is play in the wheel hub or if the w...

Page 76: ...de sufficient ventilation when charging it in an enclosed space To charge the battery Have a Yamaha dealer charge the battery as soon as possible if it seems to have discharged Keep in mind that the battery tends to dis charge more quickly if the motorcycle is equipped with optional electrical accessories To store the battery 1 If the motorcycle will not be used for more than one month remove the ...

Page 77: ...ing than recommend ed to avoid causing extensive damage to the electrical system and possibly a fire 3 Turn the key to ON and turn on the electrical circuits to check if the devices operate 4 If the fuse immediately blows again have a Yamaha dealer check the electrical system EAU01307 Replacing the fuse The fuse holder is located behind panel B See page 6 8 for panel removal and installation proce...

Page 78: ... bulb burns out replace it as follows 1 Remove cowling A See page 6 7 for cowling removal and installation procedures 3 Disconnect the headlight cou pler and then remove the head light bulb cover 1 2 1 Headlight coupler 2 Headlight bulb cover 2 Remove the headlight unit by removing the bolts 1 2 1 Headlight unit 2 Bolt 3 5RK 9 11 US 4 26 02 7 16 PM Page 76 ...

Page 79: ...b holder 8 Install the cowling 9 Have a Yamaha dealer adjust the headlight beam if necessary EC000105 cC Do not touch the glass part of the headlight bulb to keep it free from oil otherwise the transparency of the glass the luminosity of the bulb and the bulb life will be adversely affected Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with alcohol or...

Page 80: ...ulb 1 Remove the tail brake light lens by removing the screws 1 2 1 Lens 2 Screw 2 2 Remove the defective bulb by pushing it in and turning it coun terclockwise 3 Insert a new bulb into the socket push it in and then turn it clock wise until it stops 4 Install the lens by installing the screw ECA00065 cC Do not overtighten the screw oth erwise the lens may break 1 1 Bulb 5RK 9 11 US 4 26 02 7 16 P...

Page 81: ... wheel or under each side of the swingarm EAU01579 Supporting the motorcycle Since this model is not equipped with a centerstand follow these precau tions when removing the front and rear wheel or performing other main tenance requiring the motorcycle to stand upright Check that the motor cycle is in a stable and level position before starting any maintenance A strong wooden box can be placed unde...

Page 82: ...er the wheel has been removed together with the brake disc otherwise the brake pads will be forced shut 2 Remove the brake disc cover by removing the screws 3 Remove the speedometer cable holder by removing the screw 4 Disconnect the speedometer cable from the front wheel 5 Remove the axle nut 6 Lift the front wheel off the ground according to the procedure on page 6 39 7 Pull the wheel axle out a...

Page 83: ...rew 7 Install the brake disc cover by installing the screws 8 Install the engine guard by installing the bolt NOTE Make sure that there is enough space between the brake pads before inserting the brake disc and that the slot in the speedometer gear unit fits over the retainer on the fork leg 3 Insert the wheel axle and then install the axle nut 4 Lower the front wheel so that it is on the ground 5...

Page 84: ...chain does not need to be disassembled in order to remove and install the wheel 8 Pull the wheel axle out and then remove the wheel 2 Remove the brake pedal free play adjusting nut and then dis connect the brake rod from the brake camshaft lever 3 Loosen the axle nut 4 Turn the drive chain adjusting plate on each side of the swingarm fully in direction a 5 Lift the rear wheel off the ground accord...

Page 85: ...all the engine guard by installing the bolt 2 Install the drive chain onto the rear sprocket and then adjust the drive chain slack See page 6 28 for drive chain slack adjust ment procedures 3 Install the axle nut and then lower the rear wheel so that it is on the ground 4 Tighten the axle nut to the speci fied torque 5 Install the brake rod onto the brake camshaft lever and then install the brake ...

Page 86: ...llowing troubleshooting chart represents a quick and easy proce dure for checking these vital systems yourself However should your motorcycle require any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools experience and know how to service the motorcycle properly Use only genuine Yamaha replace ment parts Imitation parts may look like Yamaha parts but they are oft...

Page 87: ...sion Supply fuel The engine does not start Check the compression 4 Battery Wet Dry Wipe off with a dry cloth and correct the Have a Yamaha dealer check the vehicle Remove the spark the electrodes plug and check Open throttle halfway and operate The engine does not start Check the battery the electric starter spark plug gap or replace the spark plug The engine turns The engine turns The battery is ...

Page 88: ...as all electrical cou plers and connectors including the spark plug cap are tightly installed 3 Remove extremely stubborn dirt like oil burnt onto the crankcase with a degreasing agent and a brush but never apply such products onto seals gaskets sprockets the drive chain and wheel axles Always rinse the dirt and degreaser off with water Cleaning ECA00010 cC 8 Avoid using strong acidic wheel cleane...

Page 89: ...t leave any marks If the windshield is scratched use a quality plastic polishing compound after washing After normal use Remove dirt with warm water a mild detergent and a soft clean sponge and then rinse thoroughly with clean water Use a toothbrush or bottle brush 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 ...

Page 90: ...minor paint damage caused by stones etc 7 Wax all painted surfaces 8 Let the motorcycle dry complete ly before storing or covering it EWA00001 w 8 Make sure that there is no oil or wax on the brakes or tires If necessary clean the brake discs and brake linings with a regular brake disc cleaner or acetone and wash the tires with warm water and a mild detergent 8 Before operating the motorcy cle tes...

Page 91: ...drained fuel into the fuel tank 4 Fill up the fuel tank and add fuel stabilizer if available to prevent the fuel tank from rusting and the fuel from deteriorating 5 Perform the following steps to protect the cylinder piston rings etc from corrosion a Remove the spark plug cap and spark plug b Pour a teaspoonful of engine oil into the spark plug bore c Install the spark plug cap onto the spark plug...

Page 92: ... degraded in one spot 8 Cover the muffler outlet with a plastic bag to prevent moisture from entering it 9 Remove the battery and fully charge it Store it in a cool dry place and charge it once a month Do not store the battery in an excessively cold or warm place less than 0 C 30 F or more than 30 C 90 F For more information on storing the battery see page 6 34 NOTE Make any necessary repairs befo...

Page 93: ...ication system Wet sump Engine oil Type Recommended engine oil classification API Service SE SF SG type or higher cC In order to prevent clutch slippage since the engine oil also lubricates the clutch do not mix any chemical additives Do not use oils with a diesel specification of CD or oils of a higher quality than specified In addition do not use oils labeled ENERGY CONSERVING II or higher Quant...

Page 94: ...n ratio 3 318 Secondary reduction system Chain drive Secondary reduction ratio 3 000 Number of drive chain sprocket teeth rear front 45 15 Transmission type Constant mesh 6 speed Operation Left foot Gear ratio 1st 3 090 2nd 2 000 3rd 1 428 4th 1 125 5th 0 925 6th 0 793 Chassis Frame type Diamond Caster angle 26 5 Trail 102 mm 4 02 in Tire Front Type With tube Size 2 75 21 45P Manufacturer BRIDGEST...

Page 95: ...heel Size 21 1 60 Rear Type Spoke wheel Size 18 2 15 Brakes Front Type Single disc brake Operation Right hand Fluid DOT 4 Rear Type Drum brake Operation Right foot Suspension Front Type Telescopic fork Rear Type Swingarm link suspension Spring shock absorber Front Coil spring oil damper Rear Coil spring gas oil damper Wheel travel Front 225 mm 8 86 in Rear 190 mm 7 48 in Electrical Ignition system...

Page 96: ...V 60 55W 1 Tail brake light 12V 8 27W 1 Front turn signal position light 12V 27 8W 2 Rear turn signal light 12V 27W 2 Meter lighting 12V 3 4W 1 Neutral indicator light 12V 3 4W 1 High beam indicator light 12V 3 4W 1 Turn signal indicator light 12V 3 4W 1 Fuse 20A 5RK 9 11 US 4 26 02 7 16 PM Page 94 ...

Page 97: ...043 Vehicle identification number The vehicle identification number is stamped into the steering head pipe Record this number in the space pro vided NOTE The vehicle identification number is used to identify your motorcycle and may be used to register your motor cycle with the licensing authority in your area 1 1 Vehicle identification number EAU01042 Key identification number The key identificati...

Page 98: ...to the frame under the seat See page 3 8 for seat removal and installation pro cedures Record the information on this label in the space provided This information will be needed when ordering spare parts from a Yamaha dealer 1 1 Model label 5RK 9 11 US 4 26 02 7 16 PM Page 96 ...

Page 99: ... an 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 either call the Auto Safety Hotline toll free at 1 800 424 9393 or 366 0123 in Washington D C area or write to NHTSA U S Departmen...

Page 100: ...ew vehicle 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 per son AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW These acts include tampering with the following systems i e modification remova...

Page 101: ...9 5 CONSUMER INFORMATION 9 5RK 9 11 US 4 26 02 7 16 PM Page 99 ...

Page 102: ...h the emissions warranty The chart below is printed 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 1 000 km or 1 month 4 000 mi 6 000 km or 6 months 7 000 mi 11 000 km or 12 months 10 000 mi 16 000 km or 18 months 13 000 mi 21 000 km or 24 months 5RK 9 ...

Page 103: ...000 km or 36 months 22 000 mi 36 000 km or 42 months 25 000 mi 41 000 km or 48 months 28 000 mi 46 000 km or 54 months 31 000 mi 51 000 km or 60 months Maintenance interval Date of service Mileage Servicing dealer name and address Remarks 5RK 9 11 US 4 26 02 7 16 PM Page 101 ...

Page 104: ...9 8 CONSUMER INFORMATION 9 EAU02918 YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY 5RK 9 11 US 4 26 02 7 16 PM Page 102 ...

Page 105: ...9 9 CONSUMER INFORMATION 9 5RK 9 11 US 4 26 02 7 16 PM Page 103 ...

Page 106: ...9 10 CONSUMER INFORMATION 9 EAU01063 YAMAHA EXTENDED SERVICE Y E S 5RK 9 11 US 4 26 02 7 16 PM Page 104 ...

Page 107: ...9 11 9 5RK 9 11 US 4 26 02 7 16 PM Page 105 ...

Page 108: ...PRINTED IN JAPAN 2002 5 0 7 1 E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD ...

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