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Yamaha XT225S, Owner'S Manual

The Yamaha XT225S Owner's Manual is an essential resource for riders of this reliable and versatile motorcycle. Enhance your riding experience by downloading this comprehensive manual for free from our website. Take full advantage of your XT225S with detailed instructions, maintenance tips, and safety guidelines at your fingertips.

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TABLE OF CONTENTS

 

SAFETY INFORMATION  .............1-1

Location of important labels  ......1-5

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

Left view .....................................2-1
Right view...................................2-2

CONTROLS AND 
INSTRUMENTS ...........................3-1

Main switch/steering lock  ..........3-1
Indicator lights  ...........................3-2
Speedometer unit ......................3-2
Handlebar switches ...................3-3
Clutch lever  ...............................3-4
Shift pedal  .................................3-4
Brake lever  ................................3-4
Brake pedal  ...............................3-5
Fuel tank cap .............................3-5
Fuel ...........................................3-6
Fuel cock ...................................3-7
Starter (choke) knob “

 

1

 

” ..........3-8

Seat ...........................................3-8
Helmet holder ............................3-9
Adjusting the shock absorber 

assembly .................................3-9

Sidestand ................................3-11
Ignition circuit cut-off system ...3-12

PRE-OPERATION CHECKS ........ 4-1

Pre-operation check list  ............ 4-2

OPERATION AND IMPORTANT
RIDING POINTS ........................... 5-1

Starting and warming up a cold 

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

Starting a warm engine  ............. 5-2
Shifting ...................................... 5-2
Engine break-in  ......................... 5-4
Parking ...................................... 5-4

PERIODIC MAINTENANCE AND
MINOR REPAIR............................ 6-1

PERIODIC MAINTENANCE ...... 6-1
Owner’s tool kit  ......................... 6-1
Periodic maintenance chart for the 

emission control system .......... 6-3

General maintenance and 

lubrication chart ....................... 6-5

Removing and installing the

 cowling and panels  ................ 6-9

Checking the spark plug  ......... 6-10
Canister (for California only)  ... 6-11
Engine oil and oil filter 

element ................................. 6-12

Cleaning the air filter 

element ................................. 6-15

Cleaning the spark arrester ..... 6-16
Adjusting the carburetor .......... 6-17
Adjusting the throttle cable free 

play ....................................... 6-17

Adjusting the valve 

clearance .............................. 6-18

Tires ........................................ 6-18
Spoke wheels .......................... 6-20
Accessories and replacement 

parts ...................................... 6-21

Adjusting the clutch lever free 

play ....................................... 6-21

Adjusting the brake lever free 

play ....................................... 6-22

Adjusting the brake pedal 

position and free play ............ 6-23

Adjusting the rear brake light 

switch .................................... 6-24

Checking the front brake pads 

and rear brake shoes  ............ 6-25

Checking the brake fluid 

level ....................................... 6-25

Changing the brake fluid  ......... 6-26
Drive chain slack ..................... 6-27
Lubricating the drive chain  ...... 6-28
Checking and lubricating the 

cables .................................... 6-29

Summary of Contents for XT225S

Page 1: ...OWNER S MANUAL 5RK 28199 12 XT225SC LIT 11626 17 31 XT225S ...

Page 2: ...5RK 9 12_hyoushi2 3 4 22 03 10 03 PM Page 1 ...

Page 3: ...inspection and basic maintenance of this motorcycle If you aintenance of your motorcycle please consult a Yamaha dealer orcycle fully comply with the emissions standards for clean air applicable e standards without reducing the performance or economy of operation of it is important that you and your Yamaha dealer pay close attention to the ting instructions contained within this manual ...

Page 4: ...ND YOUR MOTORCYCLE RIDING TIPS BOOKLET CAREFULLY S MOTORCYCLE DO NOT ATTEMPT TO OPERATE THIS MOTORCY E KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AFE AND PROPER RIDING TECHNIQUES REGULAR INSPECTIONS GOOD RIDING SKILLS WILL ENSURE THAT YOU SAFELY ENJOY THIS MOTORCYCLE eans ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED instructions could result in severe injury or death to the motorcy r a per...

Page 5: ...EL HERE XT225S XT225SC OWNER S MANUAL Yamaha Motor Corporation U S A 1st edition April 2003 All rights reserved printing or unauthorized use ut the written permission of ha Motor Corporation U S A s expressly prohibited Printed in Japan P N LIT 11626 17 31 ...

Page 6: ...6 12 ing the air filter ent 6 15 Cleaning the spark arrester 6 16 Adjusting the carburetor 6 17 Adjusting the throttle cable free play 6 17 Adjusting the valve clearance 6 18 Tires 6 18 Spoke wheels 6 20 Accessories and replacement parts 6 21 Adjusting the clutch lever free play 6 21 Adjusting the brake lever free play 6 22 Adjusting the brake pedal position and free play 6 23 Adjusting the rear b...

Page 7: ...7 1 7 1 ge 7 3 FICATIONS 8 1 UMER INFORMATION 9 1 fication numbers 9 1 rting safety defects 9 3 rcycle noise regulation 9 4 enance record 9 5 AHA MOTOR RPORATION U S A REET AND ENDURO TORCYCLE LIMITED RRANTY 9 7 AHA EXTENDED RVICE Y E S 9 9 ...

Page 8: ...ely places or motorcycle accidents to oc ur Ride where other motorists can see you Avoid riding in another motorist s blind spot Many accidents involve inexperi enced operators In fact many op erators who have been involved in accidents do not even have a cur rent motorcycle license Make sure that you are qualified and that you only lend your mo torcycle to other qualified opera tors Know your ski...

Page 9: ...ec e clothing that covers your legs kles and feet Passengers should also observe the precautions mentioned above Modifications Modifications made to this motorcycle not approved by Yamaha or the re moval of original equipment may ren der the motorcycle unsafe for use and may cause severe personal injury Modifications may also make your mo torcycle illegal to use Loading and accessories Adding acce...

Page 10: ...nt fork area can reate instability due to improper weight distribution or aerody namic changes If accessories are added to the handlebar 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 b...

Page 11: ...ater or near an open lame otherwise it could catch ire hen transporting the motorcycle another vehicle make sure that s kept upright and that the fuel ck s are turned to ON or ES for vacuum type OFF r manual type If the motorcycle ould lean over gasoline may k out of the carburetor or fuel nk you should swallow any gaso e inhale a lot of gasoline vapor allow gasoline to get into your eyes see your...

Page 12: ...1 5 EAU10381 y before operating this vehicle 1 2 3 ...

Page 13: ...structions Do not incinerate puncture or open 4AA 22259 00 TIRE INFORMATION 3MH 21668 A0 Cold tire normal pressure should be set as follows 8 Up to 90kg 198 lbs load FRONT 125 kPa 1 25 kgf cm2 18 psi FRONT 150 kPa 1 50 kgf cm2 22 psi REAR 150 kPa 1 50 kgf cm2 22 psi REAR 175 kPa 1 75 kgf cm2 25 psi 8 90kg 198 lbs maximum load AD LE ng K 00 2 4 ...

Page 14: ...2 1 EAU10410 2 5 7 6 8 3 4 age 3 9 ng dial 8 Shift pedal page 3 4 ...

Page 15: ...DESCRIPTION 2 2 2 3 4 5 6 7 8 9 EAU10420 5 1 2 3 4 ...

Page 16: ...2 3 EAU10430 4 5 6 7 8 9 3 9 Fuel tank cap page 3 5 ...

Page 17: ... s are off The key can be re the steering e handlebars all the way to the ght sh the key in from the OFF po on release it and then turn it to OCK move the key To unlock the steering Insert the key and turn it to OFF WARNING EWA10070 Never turn the key to LOCK while the motorcycle is moving se 2 3 ...

Page 18: ... a tripmeter The speedometer shows riding 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 en able you to plan future fuel stops 1 Speedometer 2 Odometer 3 Tripmeter 4 Reset knob 1 2 3 ...

Page 19: ...tch in after it has re o the center position EAU12500 Horn switch Press this switch to sound the horn EAU12660 Engine stop switch Set this switch to before starting the engine Set this switch to to stop the engine in case of an emergen cy such as when the vehicle overturns or when the throttle cable is stuck EAU12710 Start switch Push this switch to crank the engine with the starter CAUTION ECA100...

Page 20: ...nd is used in com with the clutch lever when the gears of the 6 speed con esh transmission equipped on orcycle 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 edal 1 1 Brake lever 1 ...

Page 21: ...cap ert the fuel tank cap into the nk opening with the key inserted he lock and then turn the cap 1 urn clockwise rn the key 1 3 turn clockwise and then remove it NOTE The fuel tank cap cannot be installed unless the key is in the lock In addition the key cannot be removed if the cap is not properly installed and locked WARNING EWA10120 Make sure that the fuel tank cap is properly closed and locke...

Page 22: ...oline of a different brand or premi um unleaded fuel Use of unleaded fuel will extend spark plug life and reduce maintenance costs Gasohol There are two types of gasohol gaso hol containing ethanol and that contain ing methanol Gasohol containing ethanol can be used if the ethanol con tent does not exceed 10 Gasohol containing methanol is not recom mended by Yamaha because it can cause damage to t...

Page 23: ...flows arburetor Normal riding is done e lever in this position dicates reserve If you run out of fuel while riding move the lever to this position Fill the tank at the first oppor tunity Be sure to set the lever back to ON after refueling mark pointing to ON mark pointing to RES 1 1 ...

Page 24: ...nd pull the seat all the seat ert the projection on the front of seat into the seat holder as wn 2 Place the seat in the original posi tion and then tighten the bolts 3 Install the panels NOTE Make sure that the seat is properly se cured before riding 1 2 1 Projection 2 Seat holder 1 2 ...

Page 25: ...load and thereby harden the suspension turn the adjusting nut in direction a To decrease the spring pre load and thereby soften the sus pension turn the adjusting nut in direction b NOTE Use the special wrench included in the owner s tool kit to make the ad justment The spring preload setting is deter mined by measuring distance A shown in the illustration The long er distance A is the higher the ...

Page 26: ...n the actual number of clicks always represents the entire ad justing range To obtain a precise ad justment it would be advisable to check the number of clicks of the damping force adjusting mechanism and to mod ify the specifications as necessary WARNING EWA10220 This shock absorber contains highly pressurized nitrogen gas For prop er handling read and understand nd damping force adjusting dial 1...

Page 27: ...n of tion circuit cut off system ARNING EWA10240 hicle must not be ridden with estand down or if the side cannot be properly moved up es not stay up otherwise the and could contact the ground stract the operator resulting possible loss of control a s ignition circuit cut off m has been designed to assist erator in fulfilling the respon of raising the sidestand be arting off Therefore check this sy...

Page 28: ...L FUNCTIONS 3 12 ...

Page 29: ...e The neutral switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer The sidestand switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer The clutch switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer NOTE ...

Page 30: ...posure to the elements Any damage fluid leakage or loss ces Therefore it is very important in addition to a thorough visual inspec he vehicle is used Such an inspection can be accomplished in a very short worth the time involved EWA11150 ot working properly have it inspected and repaired before operating ...

Page 31: ...il to specified level l leakage 6 12 ve Yamaha dealer bleed hydraulic system ay or wear y reservoir commended brake fluid to specified level stem for leakage 6 25 ay 6 25 ecessary ay 6 21 ration is smooth ay Yamaha dealer adjust cable free play and lubricate cable 6 17 6 29 ration is smooth ary 6 29 ...

Page 32: ...0 ation is smooth ting points if necessary 6 29 ation is smooth ng points if necessary 6 30 ation is smooth essary 6 30 uts bolts and screws are properly tightened gnition circuit cut off system e have Yamaha dealer check vehicle 3 11 CHECKS PAGE ...

Page 33: ... engine stop switch is to ift transmission into the neutral position NOTE When the transmission is in the neutral position the neutral indicator light should be on otherwise have a Yamaha dealer check the electrical cir cuit 4 Turn the starter choke on and completely close the throttle See page 3 8 5 Start the engine by pushing the start switch NOTE If the engine fails to start release the start s...

Page 34: ...6671 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 il lustration NOTE To shift the transmission into the neu tral position press the shift pedal down repeatedly until it reaches the end of its 1 Shift pedal 2 Neutral position 1 5 4 3 2 1 N 6 2 ...

Page 35: ...w the motorcycle ift the transmission into first ar when the motorcycle reaches km h 12 5 mi h If the engine is out to stall or runs very roughly pull the clutch lever in and use the brakes to stop the motorcycle 3 Shift the transmission into the neu tral position when the motorcycle is almost completely stopped The neutral indicator light should come on EAU16740 Recommended shift points The recom...

Page 36: ... iod immediately have a maha dealer check the vehi EAU17170 Parking When parking stop the engine remove the key from the main switch and then turn the fuel cock lever to OFF WARNING EWA10310 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 Do not park on a slope or on soft ground otherwise the vehicle may overturn ...

Page 37: ... RELATED MISSIONS CONTROL ARE PED SEPARATELY THESE CES REQUIRE SPECIALIZED KNOWLEDGE AND EQUIP YAMAHA DEALERS ARE ED AND EQUIPPED TO PER THESE PARTICULAR SER EAU17310 Owner s tool kit The service information included in this manual and the tools provided in the owner s tool kit are intended to assist you in the performance of preventive maintenance and minor repairs How ever additional tools such ...

Page 38: ...ND MINOR REPAIR 6 2 ...

Page 39: ...trol system 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 cks or 000 here 000 Replace Replace clear old or ne idle ces ...

Page 40: ...maha dealer perform the service r 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 ...

Page 41: ...hart 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 e evel ee eces e brake mage Every 4 years htness sary for ...

Page 42: ...ing the motorcycle or riding in the rain for ith every 4 Repack and d se d se 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 ...

Page 43: ...ed ase place if r oil r oil ed before d cable 30 thor 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 ...

Page 44: ...ty areas caliper cylinder always replace the brake fluid Check the brake fluid level he master cylinder and caliper cylinder every two years or if cracked or damaged e play free p 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 ...

Page 45: ...d EAU18810 g A ove the cowling e the screw and then pull the off as shown all the cowling he cowling in the original posi d then install the screw EAU19291 A and B ove one of the panels e the screw and then pull the ff as shown To install the panel Place the panel in the original position and then install the screw w 1 1 Panel A 2 Screw 1 Panel B 2 Screw 1 2 1 2 ...

Page 46: ... have a a dealer check the vehicle eck the spark plug for electrode sion and excessive carbon or er deposits and replace it if necessary To install the spark plug 1 Measure the spark plug gap with a wire thickness gauge and if nec essary adjust the gap to specifica tion 2 Clean the surface of the spark plug gasket and its mating surface and then wipe off any grime from the plug wrench 1 Specified ...

Page 47: ...ly odel is equipped with a canister ent the discharging of fuel vapor into the atmosphere Check each hose connection Check each hose and canister for cracks or damage Replace if damaged Make sure the vent hose is not blocked Clean it if necessary ank uretor ter hose flow pipe 1 2 3 4 1 ...

Page 48: ...oil filter element cleaning rt the engine warm it up for eral minutes and then turn it ce an oil pan under the engine to collect the used oil 3 Remove the engine guard by re moving the bolt 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 e oil level check window um level mark um level mark 2 3 1 ...

Page 49: ... the oil filter ment move the oil filter element cover removing the bolts 8 Remove the oil filter element and O rings 9 Check the O rings for damage and e oil drain bolt g pression spring ainer 4 3 2 1 1 1 Oil filter element drain bolt 2 Oil filter element cover 3 Bolt 1 Oil filter element 2 O ring 2 1 3 2 1 2 2 ...

Page 50: ...fied In addition do not use oils labeled ENERGY CONSERVING II or higher Make sure that no foreign mate rial 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 im mediately 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...

Page 51: ...tire surface of the sponge material and then squeeze the ex cess oil out NOTE The sponge material should be wet but not dripping 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 element with the gray er element ge material er element frame 1 1 2 Recommended oil Yamaha foam air filter oil or o...

Page 52: ...ing exhaust mponents not start the engine when aning the exhaust system ure to select a well ventilated e of combustible materials to e spark arrester move the tailpipe by removing screw and then pulling it out of muffler 2 Tap the tailpipe lightly and then use a wire brush to remove any carbon deposits from the spark ar rester portion of the tailpipe 1 Muffler 2 Screw 1 Tailpipe 2 Spark arrester ...

Page 53: ...ated ment Therefore carburetor ad nts should be left to Yamaha who has the necessary profes nowledge and experience EAU21380 Adjusting 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 check the throttle cable free play and if neces sary have a Yamaha dealer adjust it 1 Throttle cable free play 1 ...

Page 54: ...speed and with the total ght of rider passenger car and accessories approved for this model WARNING EWA11020 Because loading has an enormous impact on the handling braking performance and safety characteris tics of your motorcycle you should keep the following precautions in mind NEVER OVERLOAD THE MO Tire air pressure measured on cold tires 0 0 90 0 kg 0 198 lb Front 125 kPa 18 psi 1 25 kgf cm2 R...

Page 55: ...ts may differ untry to country Always comply with the local regulations Tire information This motorcycle is equipped with tube tires WARNING EWA10460 The front and rear tires should be of the same make and de sign otherwise the handling characteristics of the vehicle cannot be guaranteed After extensive tests only the tires listed below have been approved for this model by ead depth idewall wear i...

Page 56: ...racks bends or warpage and the spokes for looseness or dam age before each ride If any dam age is found have a Yamaha dealer replace the wheel Do not attempt even the smallest repair to the wheel A deformed or cracked wheel must be replaced The wheel should be balanced whenever either the tire or wheel has been changed or replaced An unbalanced wheel can result in poor performance adverse han dlin...

Page 57: ...0 15 0 mm 0 39 0 59 in as shown Periodically check the clutch le ver free play and if necessary adjust it as follows 1 Loosen the locknut at the clutch le ver 2 To increase the clutch lever free play turn the adjusting bolt in di rection a To decrease the clutch lever free play turn the adjusting bolt in direction b 1 Locknut clutch lever 2 Adjusting bolt 3 Clutch lever free play 1 2 3 a b ...

Page 58: ... mm 0 08 0 20 in as shown Periodically check the brake le ver free play and if necessary adjust it as follows 1 Loosen the locknut at the brake le ver 2 To increase the brake lever free play turn the adjusting bolt in di rection a To decrease the brake lever free play turn the adjusting bolt in direction b 1 Locknut 2 Adjusting bolt 3 Brake lever free play 1 2 3 a b ...

Page 59: ...m n below the top of the footrest cally check the brake pedal po nd if necessary adjust it as fol osen the locknut at the brake dal 2 To raise the brake pedal turn the adjusting bolt in direction a To lower the brake pedal turn the ad justing bolt in direction b 3 Tighten the locknut WARNING EWA11230 After adjusting the brake pedal posi tion the brake pedal free play must be adjusted pedal positio...

Page 60: ... light switch The rear brake light switch which is ac tivated by the brake pedal is properly adjusted when the brake light comes on just before braking takes effect If necessary adjust the brake light switch as follows Turn the adjusting 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 ...

Page 61: ... the brake shoes as a EAU32341 Checking the brake fluid level Front brake Insufficient brake fluid may allow air to enter the brake system possibly caus ing it 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 su...

Page 62: ...e brake fluid at the intervals specified in the NOTE after the periodic mainte nance and lubrication chart In addition have the oil seals of the brake master cylinder and caliper as well as the brake hose replaced at the intervals listed below or whenever they are dam aged or leaking Oil seals Replace every two years Brake hose Replace every four years ...

Page 63: ...tighten the drive chain turn the adjusting plate on each side of the swingarm in direction a To loos en the drive chain turn the adjust ing plate on each side of the swingarm in direction b and then push the rear wheel forward NOTE Make sure that both adjusting plates are in the same position for proper chain slack 1 1 Brake pedal free play adjusting nut 2 Axle nut 3 Drive chain slack adjusting pl...

Page 64: ... must be lubricated washing the motorcycle or n the rain an the drive chain with kero e and a small soft brush ON ECA11120 ent damaging the O rings do an the drive chain with steam s high pressure washers or priate solvents pe the drive chain dry oroughly lubricate the drive in with a special O ring chain lubricant CAUTION ECA11110 Do not use engine oil or any other lu bricants for the drive chain...

Page 65: ...ide In addi e cable should be lubricated or d at the intervals specified in the c maintenance chart EAU23131 Checking and lubricating the brake and shift pedals The operation of the brake and shift pedals should be checked before each ride and the pedal pivots should be lu bricated if necessary Recommended lubricant Lithium soap based grease all purpose grease ...

Page 66: ...WA10730 idestand does not move up wn smoothly have a Yamaha check or repair it EAU23250 Lubricating the rear suspension The pivoting points of the rear suspen sion must be lubricated at the intervals specified in the periodic maintenance and lubrication chart commended lubricant Lithium soap based grease all purpose grease 1 Grease nipple Recommended lubricant Lithium soap based grease 1 5 1 ...

Page 67: ...of the steering must be checked as fol lows at the intervals specified in the pe riodic maintenance and lubrication chart 1 Place a stand under the engine to raise the front wheel off the ground WARNING EWA10750 Securely support the vehicle so that there is no danger of it falling over 2 Hold the lower ends of the front fork legs and try to move them for ward and backward If any free play can be f...

Page 68: ...tenance There is no need to check the electrolyte or to add distilled water CAUTION ECA10620 Never attempt to remove the battery cell seals as this would permanent ly damage the battery WARNING EWA10760 Electrolyte is poisonous and dangerous since it contains sul furic acid which causes severe burns Avoid any contact with skin eyes or clothing and al ways shield your eyes when working near batteri...

Page 69: ...rged ttery can cause permanent ttery damage charge a sealed type MF ttery a special constant volt e battery charger is required ing a conventional battery arger will damage the battery you do not have access to a aled type MF battery charg have a Yamaha dealer arge your battery EAU23500 Replacing the fuse The fuse holder is located behind panel B See page 6 9 If the fuse is blown replace it as fol...

Page 70: ... replace it as follows move cowling A See ge 6 9 move the headlight unit by re ving the bolts connect the headlight coupler d then remove the headlight b cover 4 Remove the headlight bulb holder by turning it counterclockwise and then remove the defective bulb ght unit 2 1 Headlight coupler 2 Headlight bulb cover 1 2 ...

Page 71: ... the coupler tall the headlight unit by install the bolts tall the cowling ve a Yamaha dealer adjust the adlight beam if necessary EAU24131 Replacing the tail brake light bulb 1 Remove the tail brake light lens by removing the screws 2 Remove the defective bulb by pushing it in and turning it counter clockwise ot touch the glass part of the bulb 1 1 Tail brake light bulb lens 2 Screw 1 2 ...

Page 72: ...e defective bulb by hing it in and turning it counter ckwise 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 CAUTION ECA11190 Do not overtighten the screw other wise the lens may break gnal light lens 1 1 Turn signal light bulb 1 ...

Page 73: ...0 To remove the front wheel WARNING EWA10820 It is advisable to have a Yamaha dealer service the wheel Securely support the motorcy cle so that there is no danger of it falling over 1 Remove the engine guard by re moving the bolt 2 Remove the brake disc cover by removing the screws 3 Remove the speedometer cable 1 Engine guard 2 Bolt 2 1 ...

Page 74: ... brake disc and that the slot in edometer gear unit fits over the on the fork leg 3 Insert the wheel axle and then in stall the axle nut 4 Lower the front wheel so that it is on the ground 5 Tighten the axle nut to the speci fied torque 6 Connect the speedometer cable and then install the speedometer cable holder by installing the screw 7 Install the brake disc cover by in stalling the screws omet...

Page 75: ...ree play usting nut and then disconnect e brake rod from the brake cam shaft 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 according to the procedure on page 6 37 6 Remove the axle nut 7 Push the wheel forward and then remove the drive chain from the rear sprocket e guard 2 1 1 Brake pedal f...

Page 76: ...See page 6 27 all the axle nut and then lower rear wheel so that it is on the und 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 pedal free play adjusting nut onto the brake rod 6 Adjust the brake pedal free play See page 6 23 WARNING EWA10660 After adjusting the brake pedal free play check the operation of the brake...

Page 77: ...ODIC MAINTENANCE AND MINOR REPAIR 6 41 2 3 4 5 6 7 8 9 ...

Page 78: ...ition Have a Yamaha dealer check the vehicle y cloth and correct the r replace the spark plug dealer check the vehicle The engine does not start Have a Yamaha dealer check the vehicle The engine does not start Check the battery The battery is good Check the battery lead connections and charge the battery if necessary Open the throttle halfway and operate the electric starter ...

Page 79: ...c not use any harsh chemical oducts on plastic parts Be re to avoid using cloths or sponges which have been in contact with strong or abrasive cleaning products solvent or thinner fuel gasoline rust re movers or inhibitors brake flu id antifreeze or electrolyte Do not use high pressure wash ers or steam jet cleaners since they cause water seepage and deterioration in the following ar eas seals of ...

Page 80: ...ed through polishing prevent corrosion it is recom nded to apply a corrosion pro tection spray on all metal including chrome and nickel plat ed surfaces 5 Use spray oil as a universal clean er to remove any remaining dirt 6 Touch up minor paint damage caused by stones etc 7 Wax all painted surfaces 8 Let the motorcycle dry completely before storing or covering it WARNING EWA10930 Make sure that th...

Page 81: ...el cock lever to FF 3 Drain the carburetor float chamber by loosening the drain bolt this will prevent fuel deposits from building up Pour the drained fuel into the fuel tank 4 Fill up the fuel tank and add fuel stabilizer if available to prevent the fuel tank from rusting and the fuel from deteriorating 5 Perform the following steps to pro tect the cylinder piston rings etc from corrosion a Remov...

Page 82: ...and charge it once a month not store the battery in an ex sively cold or warm place less n 0 C 30 F or more than C 90 F For more informa n on storing the battery see ge 6 32 ny necessary repairs before he motorcycle ...

Page 83: ...mp gal etor acturer KUNI Type x quantity BST34 x 1 Spark plug s Manufacturer model NGK DR8EA Manufacturer model DENSO X24ESR U Spark plug gap 0 6 0 7 mm 0 024 0 028 in Clutch Clutch type Wet multiple disc Transmission Primary reduction system Spur gear Primary reduction ratio 73 22 3 318 Secondary reduction system Chain drive Secondary reduction ratio 45 15 3 000 Transmission type Constant mesh 6 ...

Page 84: ...ype ke wheel e 2 15 Front brake Type Single disc brake Operation Right hand operation Recommended fluid Dot 4 Rear brake Type Drum brake Operation Right foot operation Front suspension Type Telescopic fork Spring shock absorber type Coil spring oil damper Wheel travel 225 0 mm 8 86 in Rear suspension Type Swingarm link suspension Spring shock absorber type Coil spring gas oil damper Wheel travel 1...

Page 85: ...SPECIFICATIONS 8 3 2 3 4 5 6 7 8 9 ...

Page 86: ...ehicle 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 motorcy cle with the licensing authority in your area entification number 1 1 Vehicle identification number 1 ...

Page 87: ...CONSUMER INFORMATION 9 2 2 3 4 5 6 7 8 9 ...

Page 88: ...g Yamaha Motor Corporation y open an investigation and if it finds that a safety defect exists in a group paign However NHTSA cannot become involved in individual problems oration U S A afety Hotline toll free at 1 800 424 9393 or 366 0123 in Washington D C sportation Washington D C 20590 You can also obtain other information ...

Page 89: ...ement of design incorporated into any new ve le or delivery to the ultimate purchaser or while it is in use or 2 the use of n has been removed or rendered inoperative by any person TITUTE TAMPERING ARE THE ACTS LISTED BELOW ystems i e modification removal etc xhaust system Muffler Exhaust pipe Silencer take system Air cleaner case Air cleaner element Intake duct ...

Page 90: ...and installed on your motorcycle will be required to document that with the emissions warranty The chart below is printed only as a reminder able proof of maintenance work Mileage Servicing dealer name and address Remarks ...

Page 91: ...CONSUMER INFORMATION 9 6 2 3 4 5 6 7 8 9 Mileage Servicing dealer name and address Remarks ...

Page 92: ...9 7 EAU26661 S A STREET AND ENDURO MOTORCYCLE LIMITED ...

Page 93: ...CONSUMER INFORMATION 9 8 2 3 4 5 6 7 8 9 ...

Page 94: ... and lodging when you are away from home This superb coverage goes into effect when you purchase Y E S so it applies to any warranty repairs as well as covered repairs during your entire Y E S plan period Y E S coverage is honored at any authorized Yamaha dealer nationwide Y E S coverage is transferable to a new owner if you sell or trade in That can make your Yamaha much more valuable This excell...

Page 95: ...CONSUMER INFORMATION 9 10 2 3 4 5 6 7 8 9 benefits of y knowing n after your amaha with We ll be ed ...

Page 96: ...PRINTED IN JAPAN 2002 5 0 6 1 E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2003 5 0 6 1 E 5RK 9 12_hyoushi 5 9 03 1 46 PM Page 1 ...

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