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PERIODIC MAINTENANCE AND MINOR REPAIR

6-27

2

3

4

5

6

7

8

9

CAUTION:

ECA10570

Improper drive chain slack will over-
load the engine as well as other vital
parts of the motorcycle and can lead
to chain slippage or breakage. To
prevent this from occurring, keep
the drive chain slack within the

specified limits.

3. Tighten the axle nut to the speci-

fied torque.

EAU23022

Cleaning and lubricating the
drive chain

The drive chain must be cleaned and
lubricated at the intervals specified in
the periodic maintenance and lubrica-
tion chart, otherwise it will quickly wear
out, especially when riding in dusty or
wet areas. Service the drive chain as
follows.

CAUTION:

ECA10581

The drive chain must be lubricated
after washing the motorcycle and

riding in the rain.

1. Clean the drive chain with kero-

sene and a small soft brush.

CAUTION:

ECA11120

To prevent damaging the O-rings, do
not clean the drive chain with steam
cleaners, high-pressure washers or

inappropriate solvents.

2. Wipe the drive chain dry.
3. Thoroughly lubricate the drive

chain with a special O-ring chain
lubricant.

CAUTION:

ECA11110

Do not use engine oil or any other lu-
bricants for the drive chain, as they
may contain substances that could

damage the O-rings.

1. Drive chain slack adjusting plate
2. Stopper
3. Axle nut

Tightening torque:

Axle nut:

85 Nm (8.5 m·kgf, 61.5 ft·lbf)

1

3

2

(a)

(b)

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Summary of Contents for XT250

Page 1: ...3C5 28199 10 XT250XC OWNER S MANUAL XT250X ...

Page 2: ...EAU10041 ...

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

Page 4: ...DING 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 H GOOD RIDING SKILLS WILL ENSURE THAT YOU SAFELY ENJOY F THIS MOTORCYCLE without notice Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS WARNING instructions could result in severe injury or death to the tor a byst...

Page 5: ...OWNER S MANUAL amaha Motor Corporation U S A 1st edition June 2007 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 21 52 AFFIX DEALER LABEL HERE ...

Page 6: ... 6 19 Tires 6 19 Spoke wheels 6 21 Accessories and replacement parts 6 22 Adjusting the clutch lever free play 6 22 Adjusting the brake lever free play 6 23 Adjusting the rear brake light switch 6 24 Checking the front and rear brake pads 6 24 Checking the brake fluid level 6 25 Changing the brake fluid 6 26 Drive chain slack 6 26 Cleaning and lubricating the drive chain 6 27 Checking and lubricat...

Page 7: ...TABLE OF CONTENTS AHA EXTENDED SERVICE E S 9 9 ...

Page 8: ...sts can ee 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 skills and limits Staying within your limits may help you to avoid an a...

Page 9: ... made to this motorcycle proved by Yamaha or the re 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 accessories or cargo to your motorcycle can adversely affect stabili ty and handling if the weight distribution of the motorcycle is changed To avoid the po...

Page 10: ...ght as possible and hould be kept to a minimum Bulky or large accessories may eriously affect the stability of the motorcycle due to aerody namic effects Wind may at tempt to lift the motorcycle or the motorcycle may become un stable in cross winds These ac cessories may also cause instability when passing or being passed by large vehicles Certain accessories can dis place the operator from his or...

Page 11: ... 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 ak 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 es see your doctor immediate If any gasoline spills on your n or clothing immediately wash e affected area with soap and ter and change your clothes...

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

Page 13: ...SAFETY INFORMATION 1 6 1 3 AD LE ng 8K 00 3TT 21668 00 ...

Page 14: ...1 7 1 2 ...

Page 15: ...SAFETY INFORMATION 1 8 1 s 9 80 ...

Page 16: ...2 1 EAU10410 1 2 4 3 ...

Page 17: ...DESCRIPTION 2 2 2 3 4 5 6 7 8 9 EAU10420 2 3 4 5 6 ...

Page 18: ...2 3 EAU10430 6 8 3 5 7 9 4 9 Fuel tank cap page 3 6 ...

Page 19: ... left or right 2 Push the key in from the OFF po sition and then turn it to LOCK while still pushing it 3 Remove the key To unlock the steering Push the key into the main switch and then turn it to OFF while still pushing it WARNING EWA10060 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 ...

Page 20: ...witch is pushed to the left or EAU11060 indicator light icator light comes on when the ssion is in the neutral position EAU11080 High beam indicator light This indicator light comes on when the high beam of the headlight is switched on beam indicator light ignal indicator light al indicator light 1 2 3 ...

Page 21: ...ear in order to test the electrical circuit To switch the speedometer and odometer tripmeter displays be tween miles and kilometers press the SELECT button for at least two seconds Odometer clock and tripmeter modes Pushing the SELECT button switches the display between the odometer mode ODO and the tripmeter modes TRIP in the following order ODO TRIP top TRIP bottom ODO To reset a tripmeter selec...

Page 22: ...rn signal switch To signal a right hand turn push this switch to To signal a left hand turn push this switch to When re leased the switch returns to the center position To cancel the turn signal lights push the switch in after it has re turned to the center position er switch ignal switch switch 1 2 3 1 Engine stop switch 2 Start switch 1 2 ...

Page 23: ...ever should be pulled and released slowly for smooth operation utch lever is equipped with a switch which is part of the igni ircuit cut off system See 12 EAU12870 Shift pedal The shift pedal is located on the left side of the engine and is used in com bination with the clutch lever when shifting the gears of the 5 speed con stant mesh transmission equipped on this motorcycle h lever 1 1 Shift ped...

Page 24: ...el tank cap lock cover 2 Insert the key into the lock and turn it 1 4 turn clockwise The lock will be released and the fuel tank cap can be removed To install the fuel tank cap 1 Push and install the fuel tank cap into position with the key inserted in the lock 2 Turn the key counterclockwise to the original position and then re move it pedal 1 1 Fuel tank cap lock cover 2 Unlock 1 2 ...

Page 25: ...AUTION ECA11400 Use only unleaded gasoline The use of leaded gasoline will cause severe damage to internal engine parts such as the valves and piston rings as well as to the exhaust system Your Yamaha engine has been de signed to use regular unleaded gaso line with a pump octane number R M 2 of 86 or higher or a research octane number of 91 or higher If knocking or pinging occurs use a gasoline of...

Page 26: ...s e lever in this position fuel will Always return the lever to this when the engine is not running ON With the lever in this position fuel flows to the carburetor Normal riding is done with the lever in this position RES d end positioned under OFF 1 1 Pointed end positioned over ON 1 Pointed end positioned over RES 1 1 ...

Page 27: ...h is supplied by rter choke he knob in direction a to turn on rter choke he knob in direction b to turn off rter choke EAU13970 Seat To remove the seat Remove the bolts and then pull the seat off To install the seat 1 Insert the projection on the front of the seat into the seat holder as shown er choke knob 1 a b 1 Bolt 1 ...

Page 28: ... is equipped with a spring preload adjust ing ring It is recommended to have a Yamaha dealer adjust the spring preload How ever if you choose to make this adjust ment yourself obtain a special wrench at a Yamaha dealer CAUTION ECA10100 Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings 1 Loosen the locknut 2 To increase the spring preload and thereby harden the sus...

Page 29: ...d re sponsible for property damage or personal injury that may result from improper handling Do not tamper with or attempt to open the gas cylinder Do not subject the shock ab sorber to an open flame or other high heat sources otherwise it may explode due to excessive gas pressure Do not deform or damage the gas cylinder in any way as this will result in poor damping per formance Always have a Yam...

Page 30: ...and the side stand is up but the clutch lever is not pulled It prevents starting when the trans mission is in gear and the clutch le ver is pulled but the sidestand is still down It cuts the running engine when the transmission is in gear and the sid estand is moved down Periodically check the operation of the ignition circuit cut off system according to the following procedure WARNING EWA10250 If...

Page 31: ...ine 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 32: ...osure to the elements Any damage fluid leakage or loss ces Therefore it is very important in addition to a thorough visual inspec e 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 33: ... bleed hydraulic system ay or wear ry reservoir commended brake fluid to specified level stem for leakage 6 23 6 24 6 25 ve Yamaha dealer bleed hydraulic system or wear ry reservoir commended brake fluid to specified level stem for leakage 6 24 6 25 ecessary ay 6 22 ration is smooth ay Yamaha dealer adjust cable free play and lubricate cable 6 19 6 28 ...

Page 34: ...th 6 19 6 21 ation is smooth ting points if necessary 6 28 ation is smooth ing points if necessary 6 29 ation is smooth cessary 6 30 uts bolts and screws are properly tightened gnition circuit cut off system e have Yamaha dealer check vehicle 3 12 CHECKS PAGE ...

Page 35: ...nsmission into the neutral sition he 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 9 5 Start the engine by pushing the start switch NOTE If the engine fails to start release the start switch wait a few seconds and then try again Ea...

Page 36: ...ontrol 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 travel and then slightly raise it CAUTION ECA10260 Even with the transmission in 1 Shift pedal 2 Neutral position 1 1 2 3 4 5 N 2...

Page 37: ...ion into first ar when the motorcycle reaches km h 12 5 mi h If the engine is out to stall or runs very roughly ll the clutch lever in and use the akes to stop the motorcycle ift the transmission into the neu l position when the motorcycle almost completely stopped The utral indicator light should come on EAU16720 Recommended shift points The recommended shift points during acceleration and decele...

Page 38: ...period ately have a Yamaha dealer he vehicle 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 39: ...SE CES REQUIRE SPECIALIZED KNOWLEDGE AND EQUIP YAMAHA DEALERS ARE ED AND EQUIPPED TO PER THESE PARTICULAR SER EAU17330 Owner s tool kit The owner s tool kit is located behind panel B See page 6 9 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...

Page 40: ...ND MINOR REPAIR 6 2 ...

Page 41: ... 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 acks or 000 hereaf 00 km Replace Replace clear ld r e idle ces or dam ...

Page 42: ...dealer perform the service ve dam arts 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: ...000 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 dam Replace Replace at 13000 mi 21000 km and there after every 12000 mi 20000 km evel eces evel eces mage Every 4 years htness sary for ...

Page 44: ...washing the motorcycle or riding in the rain es for ith Repack and htly d d d 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: ...lace if r oil r oil before d cable 10W 30 ee play free ip 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 46: ...uently when riding in unusually wet or dusty areas ders and calipers always change the fluid Regularly check the brake fluid onents of the brake master cylinders and calipers and change the brake and if cracked or damaged 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 ...

Page 47: ...both projections at the bottom of the cowling by pulling it downward and then pull the cowl ing forward as shown To install the cowling 1 Place the cowling in the original position 2 Install the bolts EAU44850 Panels A and B To remove one of the panels 1 Remove the screw and collar B C 1 2 1 1 Projection 1 1 ...

Page 48: ...ling it forward as shown ll the panel e collar and panel in their origi tion and then install the screw Panel C To remove the panel 1 Remove the seat See page 3 9 2 Remove the bolt and washer and A B 1 1 Panel A 1 Panel B 1 1 ...

Page 49: ...ll cause any spark plug to slowly erode the spark plug should be removed and checked in accordance with the periodic mainte nance and lubrication chart In addition the condition of the spark plug can re veal the condition of the engine To remove the spark plug 1 Remove the spark plug cap 2 Remove the spark plug as shown with the spark plug wrench includ ed in the owner s tool kit 1 Spark plug cap ...

Page 50: ...e spark plug with the spark plug wrench and then tight en it to the specified torque NOTE If a torque wrench is not available 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 speci fied torque as soon as possible 4 Install the spark plug cap fied spark plug K DR7EA plug gap k plug gap 0 7 mm 0 024...

Page 51: ...can result in a ading art the engine warm it up for veral minutes and then turn it ait a few minutes until the oil set s and then check the oil level ough the check window located the bottom right side of the ankcase NOTE The engine oil should be between the minimum and maximum level marks 4 If the engine oil is below the mini mum level mark add sufficient oil of the recommended type to raise it t...

Page 52: ...l filter element drain bolt to drain the oil from the oil filter element NOTE Skip steps 5 7 if the oil filter element is not being replaced 5 Remove the oil filter element cover by removing the bolts e oil drain bolt e oil drain bolt er 1 2 1 Oil filter element drain bolt 1 ...

Page 53: ...pilled oil on any parts after the engine and exhaust sys tem have cooled down CAUTION ECA11620 In order to prevent clutch slip page since the engine oil also lubricates the clutch do not mix any chemical additives Do not use oils with a diesel speci er element g tening torque filter element cover bolt 10 Nm 1 0 m kgf 7 2 ft lbf 1 2 2 Tightening torques Engine oil drain bolt 20 Nm 2 0 m kgf 14 5 ft...

Page 54: ...e the seat See page 3 9 move the air filter case cover by moving the screws 3 Pull the air filter element out 4 Insert a new air filter element into the air filter case as shown CAUTION ECA10480 Make sure that the air filter ele ment is properly seated in the air filter case The engine should never be op erated without the air filter ele ment installed otherwise the piston s and or cylinder s may ...

Page 55: ...hing exhaust mponents o not start the engine when eaning the exhaust system sure to select a well ventilated ee of combustible materials to he spark arrester move the tailpipe by removing e screw and then pulling it out of e 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 and in side of the tailpipe housing...

Page 56: ...e EAU21311 Checking the engine idling speed The engine idling speed must be checked as follows and if necessary adjusted by a Yamaha dealer at the in tervals specified in the periodic mainte nance and lubrication chart Start the engine and warm it up for sev eral minutes at 1000 2000 r min while occasionally revving it to 4000 5000 r min NOTE The engine is warm when it quickly re sponds to the thr...

Page 57: ...e 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 EWA10500 The tire air pressure must be checked and adjusted on cold tires i e when the temperature of the tires equals the ambient temperature The tire air pressure must be ad justed...

Page 58: ...with regard to the d eck the tire condition and air ssure before each ride Tire 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 immediately NOTE The tire tread depth limits may differ from country to country Always comply 1 ...

Page 59: ... the performance durabil ity and safe operation of your motorcy cle note the following points regarding the specified wheels The wheel rims should be checked for cracks bends or warpage and the spokes for looseness or dam age before each ride If any dam age is 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 repla...

Page 60: ...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 1 Locknut clutch lever 2 Adjusting bolt 3 Adjusting nut 4 Locknut clutch cable 5 Clutch lever free play 1 2 b a a b 5 3 4 ...

Page 61: ...sting rew in direction b 3 Tighten the locknut WARNING EWA10630 After adjusting the brake lever free play check the free play and make sure that the brake is working properly 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 hy draulic system have a Yamaha dealer bleed the system before operating the motorcycle Air in the hy...

Page 62: ...rake worn to the point that the wear indicator groove has almost disap peared have a Yamaha dealer replace the brake pads as a set EAU36720 Rear brake pads Each rear 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 t...

Page 63: ...id otherwise the rubber als may deteriorate causing akage and poor braking perfor ance fill with the same type of brake d Mixing fluids may result in a rmful chemical reaction and ad to poor braking performance careful that water does not en the brake fluid reservoir when refilling Water will significantly lower the boiling point of the fluid and may result in vapor lock Brake fluid may deteriorat...

Page 64: ...e drive chain and n measure the drive chain slack shown 4 If the drive chain slack is incorrect adjust it as follows EAU22960 To adjust the drive chain slack 1 Loosen the axle nut 2 To 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 wh...

Page 65: ...N ECA10581 ive chain must be lubricated washing the motorcycle and in the rain ean the drive chain with kero ne and a small soft brush ION ECA11120 vent damaging the O rings do an the drive chain with steam rs high pressure washers or opriate solvents pe the drive chain dry oroughly lubricate the drive ain with a special O ring chain bricant CAUTION ECA11110 Do not use engine oil or any other lu b...

Page 66: ...ould cked before each ride In addi e cable should be lubricated at rvals specified in the periodic ance chart EAU23133 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 ...

Page 67: ...2 king and lubricating the and clutch levers lever lever eration of the brake and clutch should be checked before each nd the lever pivots should be lu bricated if necessary Recommended lubricants Brake lever Silicone grease Clutch lever Lithium soap based grease ...

Page 68: ...riodic main tenance and lubrication chart To check the condition WARNING EWA10750 Securely support the vehicle so that there is no danger of it falling over 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 hold it in an upright posi tion 2 While applying the front brake push down hard on the handlebars several t...

Page 69: ...d as fol the intervals specified in the pe maintenance and lubrication ace a stand under the engine to se the front wheel off the ound ARNING EWA10750 ely support the vehicle so that s no danger of it falling over ld the lower ends of the front k legs and try to move them for rd and backward If any free ay can be felt have a Yamaha aler check or repair the steering ...

Page 70: ...ce 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 batteries In case of contact administer the fol lowing FIRST AID EXTERNAL Flush with plenty of water INTERNAL Drink large quan tities of water or milk and im mediately call a physician EYES Flush with water for 15 minutes and seek prompt medical attent...

Page 71: ...er arge your battery EAU23502 Replacing the fuse The fuse holder is located behind panel C See page 6 9 If the fuse is blown replace it as fol lows 1 Turn the key to OFF and turn off all electrical circuits 2 Remove the blown fuse and then install a new fuse of the specified amperage 1 Fuse 2 Spare fuse Specified fuse 20 0 A 1 2 ...

Page 72: ...lb ut 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 1 1 Headlight coupler 2 Headlight bulb cover 1 2 ...

Page 73: ...light unit in the orig al position and then install the lts stall 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 Tail brake light lens 2 Screw 1 2 ...

Page 74: ... defective bulb by shing 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 ignal light lens 1 1 Turn signal light bulb 1 ...

Page 75: ...EAUW0211 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 Loosen the axle nut 2 Lift the front wheel off the ground according to the procedure on page 6 37 3 Remove the axle nut pull the 1 Axle nut 1 ...

Page 76: ...have a Yamaha dealer service the wheel Securely support the motorcy cle so that there is no danger of it falling over 1 Loosen the axle nut 2 Lift the rear wheel off the ground according to the procedure on page 6 37 3 Turn the drive chain adjusting plate on each side of the swingarm fully in direction a 4 Push the wheel forward and then remove the drive chain from the rear sprocket ...

Page 77: ... the brake caliper bracket by inserting the wheel axle from the right hand side NOTE Make sure that the drive chain ad justing plates are installed with the punched sides facing to the out side and that the retainer on the swingarm is inserted into the slot in the brake caliper bracket Make sure that there is enough space between the brake pads be fore installing the wheel 2 Install the drive chai...

Page 78: ...r starting and power llowing troubleshooting chart nts a quick and easy procedure cking these vital systems your wever should your motorcycle any repair take it to a Yamaha whose skilled technicians have essary tools experience and ow to service the motorcycle ly genuine Yamaha replace rts Imitation parts may look like a parts but they are often inferi e a shorter service life and can expensive re...

Page 79: ...ion Check the ignition Have a Yamaha dealer check the vehicle ry cloth and correct the or 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 80: ...nt onto the crankcase h a degreasing agent and a sh but never apply such prod ucts onto seals gaskets sprock ets the drive chain and wheel axles Always rinse the dirt and de greaser off with water Cleaning CAUTION ECA10771 Avoid using strong acidic wheel cleaners especially on spoked wheels If such products are used on hard to remove dirt do not leave the cleaner on the af fected area any longer t...

Page 81: ...rcycle with cold wa and a mild detergent after the gine has cooled down CAUTION ECA10790 Do not use warm water since it in creases the corrosive action of the salt 2 Apply a corrosion protection spray on all metal including chrome and nickel plated surfaces to prevent corrosion After cleaning 1 Dry the motorcycle with a chamois or an absorbing cloth 2 Immediately dry the drive chain and lubricate ...

Page 82: ...motorcycle in a poorly ventilated room or cover ing it with a tarp while it is still wet will allow water and humid ity to seep in and cause rust To prevent corrosion avoid damp cellars stables because of the presence of ammonia and areas where strong chemi cals are stored Long term Before storing your motorcycle for sev eral months 1 Follow all the instructions in the Care section of this chapter...

Page 83: ...nd then lift e motorcycle so that both of its eels are off the ground Alterna ely turn the wheels a little every onth in order to prevent the tires m becoming degraded in one ot ver the muffler outlet with a astic bag to prevent moisture m entering it emove the battery and fully arge it Store it in a cool dry ace and charge it once a month o not store the battery in an ex ssively cold or warm plac...

Page 84: ... amount L 0 50 US gal 0 42 Imp gal Carburetor Manufacturer TEIKEI Type quantity MV33 x 1 Spark plug s Manufacturer model NGK DR7EA 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 74 24 3 083 Secondary reduction system Chain drive Secondary reduction ratio 48 15 3 200 Transmission type Constant mes...

Page 85: ...l type oke wheel ze M C x MT2 15 brake gle disc brake Operation Right hand operation Recommended fluid DOT 4 Rear brake Type Single disc brake Operation Right foot operation Recommended fluid DOT 4 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...

Page 86: ...8 3 ...

Page 87: ...ring a new EAU26400 Vehicle identification number The vehicle identification number is stamped into the steering head pipe Record this number in the space pro vided NOTE The vehicle identification number is used to identify your motorcycle and may be used to register your motorcy cle with the licensing authority in your area dentification number 1 Vehicle identification number 1 ...

Page 88: ...9 2 ...

Page 89: ...to notifying Yamaha Motor Corporation ay open an investigation and if it finds that a safety defect exists in a group mpaign However NHTSA cannot become involved in individual problems poration U S A ety Hotline toll free at 1 888 327 4236 TTY 1 800 424 9153 go to http SA 400 Seventh Street SW Washington DC 20590 You can also obtain http www safercar gov ...

Page 90: ...corporated into any new ve e or delivery to the ultimate purchaser or while it is in use or 2 the use of has been removed or rendered inoperative by any person TITUTE TAMPERING ARE THE ACTS LISTED BELOW ystems i e modification removal etc haust system Muffler Exhaust pipe Silencer ake system Air cleaner case Air cleaner element Intake duct ...

Page 91: ...9 EAU26611 rchased and installed on your motorcycle will be required to document that with the emissions warranty The chart below is printed only as a reminder table proof of maintenance work Mileage Servicing dealer name and address Remarks ...

Page 92: ...9 6 Mileage Servicing dealer name and address Remarks ...

Page 93: ...ted y below Failures other than those resulting cts in material or workmanship which arise a result of owner abuse and or lack of proper ce are not covered by this warranty Period 6 000 km 3 750 miles or five years whichever occurs first 12 000 km 7 465 miles or five years whichever occurs first 18 000 km 11 185 miles or five years whichever occurs first 30 000 km 18 641 miles or five years whiche...

Page 94: ... Cypress California 90630 When contacting Yamaha Motor Corporation U S A don t forget to include any important information such as names addresses model V I N frame number dates and receipts CHANGE OF ADDRESS The federal government requires each manufacturer of a motor vehicle to maintain a complete up to date list of all first purchasers against the possibility of a safety related defect and reca...

Page 95: ...towing phone calls even food 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 mu...

Page 96: ...9 10 benefits of y knowing after your maha with We ll be d ...

Page 97: ... 2 1 Pre operation check list 4 2 R Rear brake light switch adjusting 6 24 Rear suspension lubricating 6 30 S Safety defects reporting 9 3 Safety information 1 1 Seat 3 9 Shifting 5 2 Shift pedal 3 5 Shock absorber assembly adjusting 3 10 Sidestand 3 12 Sidestand checking and lubricating 6 30 Spark arrester cleaning 6 17 Spark plug checking 6 11 Specifications 8 1 Starter choke knob 3 9 Starting a...

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1981 GL500 Interstate

Brand: Honda Pages: 47

Brand: Honda Pages: 280

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