Yamaha XT250W Owner'S Manual Download | Manualshive

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-23

1

2

8

9

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.

4. Tighten the axle nut to the speci-

fied torque.

5. Adjust the brake pedal free play.

(See page 6-18.)

WARNING

EWA10660

After adjusting the brake pedal free
play, check the operation of the

brake light.

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.

Tightening torque:

Axle nut:

85 Nm (8.5 m·kgf, 62 ft·lbf)

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Summary of Contents for XT250W

Page 1: ...4FD 28199 2E XT250W OWNER S MANUAL ProCarManuals com ...

Page 2: ...ProCarManuals com ...

Page 3: ... thoroughly so as to enjoy all advantages of your XT250W The owner s manual does not only instruct you in how to operate inspect and maintain your motorcycle but also in how to safeguard yourself and others from trouble and injury In addition the many tips given in this manual will help keep your motorcycle in the best possible condition If you have any further questions do not hesitate to contact...

Page 4: ... and this manual If you have any questions concerning this manual please consult your Yamaha dealer WARNING EWA10030 PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE Product and specifications are subject to change without notice The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED Failure to follow WARNING instructions could result in sever...

Page 5: ... XT250W OWNER S MANUAL 2006 by Yamaha Motor Co Ltd 1st edition May 2006 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan ProCarManuals com ...

Page 6: ...nd panels 6 5 Checking the spark plug 6 6 Engine oil and oil filter element 6 7 Cleaning the air filter element 6 10 Adjusting the carburetor 6 12 Adjusting the engine idling speed 6 12 Adjusting the throttle cable free play 6 13 Valve clearance 6 13 Tires 6 14 Spoke wheels 6 16 Adjusting the clutch lever free play 6 16 Adjusting the brake lever free play 6 17 Adjusting the brake pedal position an...

Page 7: ... Supporting the motorcycle 6 32 Front wheel 6 32 Rear wheel 6 34 Troubleshooting 6 36 Troubleshooting chart 6 37 MOTORCYCLE CARE AND STORAGE 7 1 Care 7 1 Storage 7 3 SPECIFICATIONS 8 1 CONSUMER INFORMATION 9 1 Identification numbers 9 1 Motorcycle noise regulation for Australia 9 2 ProCarManuals com ...

Page 8: ...ot see the motorcycle Making yourself conspicuous appears to be very effective in reducing the chance of this type of accident Therefore Wear a brightly colored jacket Use extra caution when ap proaching and passing through intersections since intersec tions are the most likely places for motorcycle accidents to oc cur Ride where other motorists can see you Avoid riding in another motorist s blind...

Page 9: ...educing abrasions or lacerations Never wear loose fitting clothes otherwise they could catch on the control levers footrests or wheels and cause injury or an accident Never touch the engine or exhaust system during or after operation They become very hot and can cause burns Always wear protec tive clothing that covers your legs ankles and feet Passengers should also observe the precautions mention...

Page 10: ...motorcycle Care fully inspect the accessory before using it to make sure that it does not in any way reduce ground clearance or cornering clearance limit suspension travel steering travel or control operation or ob scure lights or reflectors Accessories fitted to the handle bar or the front fork area can create instability due to improper weight distribution or aerody namic changes If accessories ...

Page 11: ... the motorcycle in a place where pe destrians or children are not like ly to touch these hot areas Do not park the motorcycle on a slope or soft ground otherwise it may fall over Do not park the motorcycle near a flammable source e g a ker osene heater or near an open flame otherwise it could catch fire When transporting the motorcycle in another vehicle make sure that it is kept upright and that ...

Page 12: ...SAFETY INFORMATION 1 5 1 EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle 1 2 3 ProCarManuals com ...

Page 13: ...al 5PA 21568 00 Prima di usare il veicolo leggete il manuale di istruzioni Lire le manuel du propriétaire avant d utiliser ce véhicule Lesen Sie die Bedienungsanleitung bevor Sie dieses Fahrzeug fahren Antes de conducir este vehículo lea el Manual del Propietario 3 3TT 21668 00 ProCarManuals com ...

Page 14: ... 6 29 2 Fuel cock page 3 6 3 Air filter element page 6 10 4 Helmet holder page 3 8 5 Owner s tool kit page 6 1 6 Shock absorber assembly spring preload adjusting nut page 3 9 7 Shock absorber assembly rebound damping force adjusting dial page 3 9 8 Shift pedal page 3 4 ProCarManuals com ...

Page 15: ...ION 2 2 2 3 4 5 6 7 8 9 EAU10420 Right view 1 5 2 3 4 1 Battery page 6 27 2 Fuse page 6 28 3 Engine oil filter element page 6 7 4 Engine oil level check window page 6 7 5 Brake pedal page 3 5 ProCarManuals com ...

Page 16: ... 3 1 Clutch lever page 3 4 2 Left handlebar switches page 3 3 3 Starter choke knob page 3 7 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 8 Throttle grip page 6 13 9 Fuel tank cap page 3 5 ProCarManuals com ...

Page 17: ...moved EAU10680 LOCK The steering is locked and all electrical systems are off The key can be re moved To lock the steering 1 Turn the handlebars all the way to the left 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 in and then turn it to OFF while still pushing it WARNING EWA10060 Never turn the key to ...

Page 18: ... is switched on EAU11630 Speedometer unit The speedometer unit is equipped with a speedometer an odometer and 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 in...

Page 19: ...itch in after it has re turned to 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 EAU12690 Start switch START Push this switch to crank the engine with the starter...

Page 20: ...r is equipped with a clutch switch which is part of the igni tion circuit cut off system See page 3 11 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 6 speed con stant mesh transmission equipped on this motorcycle EAU12890 Brake lever The brake lever is located at the right handlebar gr...

Page 21: ...wise and pull it off To install the fuel tank cap 1 Insert the fuel tank cap into the tank opening with the key inserted 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 key is in the lock In addition the key cannot be removed if the cap is not properly installed and locked WARNING EWA101...

Page 22: ...ston rings as well as to the exhaust system Your Yamaha engine has been de signed to use regular unleaded gaso line with a research octane number of 91 or higher If knocking or pinging oc curs use a gasoline of a different brand or premium unleaded fuel Use of un leaded fuel will extend spark plug life and reduce maintenance costs EAU13561 Fuel cock The fuel cock supplies fuel from the tank to the...

Page 23: ...this position Fill the tank at the first oppor tunity Be sure to set the lever back to ON after refueling EAU13600 Starter choke knob Starting a cold engine requires a richer air fuel mixture which is supplied by the starter choke Move the knob in direction a to turn on the starter choke Move the knob in direction b to turn off the starter choke 1 Arrow mark pointing to ON 1 Arrow mark pointing to...

Page 24: ...he bolts 3 Install the panels NOTE Make sure that the seat is properly se cured before riding EAU14290 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 re move it WARNING EWA10160 Never ride with a helmet attached to the helmet holder since the helmet may hit objects causing ...

Page 25: ...sting 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 spring preload the shorter dis tance A is the lower the spring preload 3 Tighten the locknut to the specified torque CAUTION ECA11240 Always tighten the lock...

Page 26: ...ions as necessary WARNING EWA10220 This shock absorber contains highly pressurized nitrogen gas For prop er handling read and understand the following information before handling the shock absorber The manufacturer cannot be held 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...

Page 27: ...he operator in fulfilling the respon sibility of raising the sidestand be fore starting off Therefore check this system regularly as described below and have a Yamaha dealer re pair it if it does not function proper ly EAU15311 Ignition circuit cut off system The ignition circuit cut off system com prising the sidestand switch clutch switch and neutral switch has the fol lowing functions It preven...

Page 28: ...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 system is OK The motorcycle can be ridden This check is most reliable if performed with a warmed up engine The neutral switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer The sidestand switch may be d...

Page 29: ...could have serious consequences Therefore it is very important in addition to a thorough visual inspec tion to check the following points before each ride NOTE Pre operation checks should be made each time the vehicle is used Such an inspection can be accomplished in a very short time and the added safety it assures is more than worth the time involved WARNING EWA11150 If any item in the Pre opera...

Page 30: ... Check brake pads for wear Replace if necessary Check fluid level in reservoir If necessary add recommended brake fluid to specified level Check hydraulic system for leakage 6 17 6 19 6 20 Rear brake Check operation Check pedal free play Adjust if necessary 6 18 6 19 Clutch Check operation Lubricate cable if necessary Check lever free play Adjust if necessary 6 16 Throttle grip Make sure that oper...

Page 31: ...ints if necessary 6 24 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 25 Sidestand Make sure that operation is smooth Lubricate pivot if necessary 6 25 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened Tighten if necessary Instruments lights signals and switches Check operation Correct if necessary Sidestand...

Page 32: ...ch lever pulled and the sid estand up WARNING EWA10290 Before starting the engine check the function of the igni tion circuit cut off system ac cording to the procedure described on page 3 11 Never ride with the sidestand down 1 Turn the fuel cock lever to ON 2 Turn the key to ON and make sure that the engine stop switch is set to 3 Shift the transmission into the neu tral position NOTE When the t...

Page 33: ...ke is not required when the engine is warm EAU16671 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 travel and then slightly raise it CAUTION E...

Page 34: ...e while shifting down and avoid high engine speeds with no load on the engine Turn the engine off instead of let ting it idle for an extended length of time e g in traffic jams at traffic lights or at railroad crossings EAU16841 Engine break in There is never a more important period in the life of your engine than the period between 0 and 1600 km 1000 mi For this reason you should read the follow ...

Page 35: ... engine break in period immediately have a Yamaha dealer check the vehi cle 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 t...

Page 36: ... VALS MAY NEED TO BE SHORT ENED WARNING EWA10320 If you are not familiar with mainte nance work have a Yamaha dealer do it for you EAU17320 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 as a torque wrench may be n...

Page 37: ...OB ODOMETER READING 1000 km ANNUAL CHECK 1 6 12 18 24 1 Fuel line Check fuel hoses for cracks or damage 2 Spark plug Check condition Clean and regap Replace 3 Valves Check valve clearance Adjust 4 Air filter element Clean Replace 5 Clutch Check operation Adjust 6 Front brake Check operation fluid level and vehicle for fluid leak age Replace brake pads Whenever worn to the limit 7 Rear brake Check ...

Page 38: ...for roughness Lubricate with lithium soap based grease Every 24000 km 15 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 16 Sidestand Check operation Lubricate 17 Sidestand switch Check operation 18 Front fork Check operation and for oil leakage 19 Shock absorber assem bly Check operation and shock absorber for oil leakage 20 Rear suspension relay arm and connecti...

Page 39: ...der and caliper and change the brake fluid Replace the brake hoses every four years and if cracked or damaged 25 Front and rear brake switches Check operation 26 Moving parts and cables Lubricate 27 Throttle grip housing and cable Check operation and free play Adjust the throttle cable free play if necessary Lubricate the throttle grip housing and cable 28 Lights signals and switches Check operati...

Page 40: ... each time the cowling or a panel needs to be re moved and installed EAU18810 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 the original posi tion and then install the screw EAU19292 Panels A and B To remove one of the panels Remove the screw and then pull the panel off as shown 1 Cowling A 2 Panel A 1 2 1 Panel ...

Page 41: ... 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 To check the spark plug 1 Check that the porcelain insulator around the center electrode of the spark plug is a medium to light tan the ideal color when the vehicle is ridden normally NOTE If the spark plug shows a distinctly dif ferent color the engin...

Page 42: ... 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 ele ment cleaned at the intervals specified in the General maintenance and lubri cation chart To check the engine oil level 1 Place the vehicle on a level sur face and hold it in an upright posi tion NOTE Make sure that the vehicle is positioned straight...

Page 43: ... 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 CAUTION ECA11000 When removing the engine oil drain bolt the O ring compression spring and oil strainer will fall out Take care not to lose these parts NOTE Check the O ring for damage and re place it if necessary 5 Clean the ...

Page 44: ...nd drain bolt then tightening them to the speci fied torques NOTE Make sure that the O ring is properly seated 12 Install the engine oil strainer com pression spring O ring and engine oil drain bolt and then tighten the drain bolt to the specified torque CAUTION ECA10420 Before installing the engine oil drain bolt do not forget to install the 1 Engine oil drain bolt 2 O ring 3 Compression spring 4...

Page 45: ...king 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 guard by install ing the bolt EAU20851 Cleaning the air filter element The air filter element should be cleaned at the intervals specified in the periodic maintenance and lubrication chart Clean the air filter element more fre quently i...

Page 46: ... and then insert the air filter element into the air filter case NOTE Install the air filter element with the gray side facing forward and with the UP mark pointing 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 beco...

Page 47: ...21340 Adjusting the engine idling speed The engine idling speed must be checked and if necessary adjusted as follows at the intervals specified in the periodic maintenance and lubrication chart The engine should be warm before making this adjustment NOTE The engine is warm when it quickly responds to the throttle A diagnostic tachometer is needed to make this adjustment 1 Attach the tachometer to ...

Page 48: ...e cable free play 1 Loosen the locknut 2 To increase the throttle cable free play turn the adjusting nut in direc tion a To decrease the throttle cable free play turn the adjusting nut in direction b 3 Tighten the locknut EAU21401 Valve clearance The valve clearance changes with use resulting in improper air fuel mixture and or engine noise To prevent this from occurring the valve clearance must b...

Page 49: ...ur motorcycle you should keep the following precautions in mind NEVER OVERLOAD THE MO TORCYCLE Operation of an overloaded motorcycle may re sult in tire damage loss of con trol or severe injury Make sure that the total weight of rider passenger cargo and accesso ries does not exceed the speci fied maximum load for the vehicle Do not carry along loosely packed items which can shift during a ride Se...

Page 50: ...isted below have been ap proved for this model by Yamaha Motor Co Ltd WARNING EWA10560 It is dangerous to ride with a worn out tire When a tire tread begins to show crosswise lines have a Yamaha dealer replace the tire immediately The replacement of all wheel and brake related parts includ ing the tires should be left to a Yamaha dealer who has the necessary professional knowl edge and experience ...

Page 51: ...s optimal characteris tics EAU22041 Adjusting the clutch lever free play The clutch lever free play should mea sure 10 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 tu...

Page 52: ...a To decrease the brake lever free play turn the adjusting screw 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 t...

Page 53: ...rn 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 Brake pedal free play The brake pedal free play should mea sure 20 0 30 0 mm 0 79 1 18 in as shown Periodically check the brake pedal free play and if necessary adjust it as ...

Page 54: ...ng nut while holding the rear brake light switch in place To make the brake light come on earlier turn the adjusting nut in direction a To make the brake light come on later turn the adjusting nut in direction b EAU22380 Checking the front brake pads and rear brake shoes The front brake pads and the rear brake shoes must be checked for wear at the intervals specified in the periodic main tenance a...

Page 55: ...he wear limit line have a Yamaha dealer replace the brake shoes as a set EAU32343 Checking the front brake fluid level 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 ...

Page 56: ...ake fluid may deteriorate paint ed surfaces or plastic parts Al ways clean up spilled fluid immediately As the brake pads wear it is nor mal for the brake fluid level to grad ually go down However if the brake fluid level goes down sud denly have a Yamaha dealer check the cause EAU22720 Changing the brake fluid Have a Yamaha dealer change the brake fluid at the intervals specified in the NOTE afte...

Page 57: ...as shown 4 If the drive chain slack is incorrect adjust it as follows EAU22830 To adjust the drive chain slack 1 Loosen the brake pedal free play adjusting nut 2 Loosen the axle nut 3 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 ...

Page 58: ...dic 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 wi...

Page 59: ...ll cause the inner cable to rust Replace a damaged cable as soon as possible to prevent unsafe conditions EAU23111 Checking and lubricating the throttle grip and cable The operation of the throttle grip should be checked before each ride In addi tion the cable should be lubricated at the intervals specified in the periodic maintenance chart EAU23131 Checking and lubricating the brake and shift ped...

Page 60: ...nd pivot and metal to metal contact surfaces should be lubricated if necessary WARNING EWA10730 If the sidestand does not move up and down smoothly have a Yamaha dealer 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 Recommended lubricant Lithium s...

Page 61: ...andlebars several times to check if the front fork compresses and rebounds smoothly CAUTION ECA10590 If any damage is found or the front fork does not operate smoothly have a Yamaha dealer check or re pair it EAU23280 Checking the steering Worn or loose steering bearings may cause danger Therefore the operation of the steering must be checked as fol lows at the intervals specified in the pe riodic...

Page 62: ... battery which does not require any maintenance 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 sh...

Page 63: ... dry place 2 If the battery will be stored for more than two months check it at least once a month and fully charge it if necessary 3 Fully charge the battery before in stallation 4 After installation make sure that the battery leads are properly con nected to the battery terminals CAUTION ECA10630 Always keep the battery charged Storing a discharged battery can cause permanent battery damage To c...

Page 64: ...n have a Yamaha dealer check the electrical system EAU23811 Replacing the headlight bulb This model is equipped with a quartz bulb headlight If the headlight bulb burns out replace it as follows 1 Remove cowling A See page 6 5 2 Remove the headlight unit by re moving the bolts 3 Disconnect the headlight coupler and then remove the headlight bulb cover 4 Remove the headlight bulb holder by turning ...

Page 65: ...d the bulb life will be adversely af fected Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with al cohol or thinner 6 Install the bulb cover and then connect the coupler 7 Install the headlight unit by install ing the bolts 8 Install the cowling 9 Have a Yamaha dealer adjust the headlight beam if necessary EAU24131 Replacing the tail brake light bulb 1...

Page 66: ...placing a turn signal light bulb 1 Remove the turn signal light lens by removing the screw 2 Remove the defective bulb by pushing it in and turning it counter clockwise 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 1 Tail brake light bul...

Page 67: ...otorcycle stand is not available by placing a jack un der the frame in front of the rear wheel 2 Raise the front wheel off the ground by using a motorcycle stand To service the rear wheel Raise the rear wheel off the ground by using a motorcycle stand or if a motor cycle stand is not available by placing a jack either under each side of the frame in front of the rear wheel or under each side of th...

Page 68: ... with the slots 2 Lift the wheel up between the fork legs NOTE Make sure that there is enough space between the brake pads before insert ing 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 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 C...

Page 69: ...pedal free play adjusting nut and then disconnect the 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 32 6 Remove the axle nut 7 Push the wheel forward and then remove the drive chain from the rear sprocket 1 Engine guard ...

Page 70: ...tainer on the swingarm 2 Install the drive chain onto the rear sprocket and then adjust the drive chain slack See page 6 22 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 pedal free play adjusting nut onto the brake rod 6 Adjust the brak...

Page 71: ... of power The following troubleshooting chart represents a quick and easy procedure for checking these vital systems your self However should your motorcycle require any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools experience and know how to service the motorcycle properly Use only genuine Yamaha replace ment parts Imitation parts may look like Yamaha parts ...

Page 72: ...o compression Check the ignition Have a Yamaha dealer check the vehicle Remove the spark plug and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gap or replace the spark plug Have a Yamaha dealer check the vehicle The engine does not start Have a Yamaha dealer check the vehicle The engine does not start Check the battery Operate the electric starter 4 Battery ...

Page 73: ... used on hard to remove dirt do not leave the cleaner on the af fected area any longer than in structed Also thoroughly rinse the area off with water immedi ately dry it and then apply a cor rosion protection spray Improper cleaning can damage windshields cowlings panels and other plastic parts Use only a soft clean cloth or sponge with mild detergent and water to clean plastic Do not use any hars...

Page 74: ...g cloth 2 Immediately dry the drive chain and lubricate it to prevent it from rusting 3 Use a chrome polish to shine chrome aluminum and stain less steel parts including the ex haust system Even the thermally induced discoloring of stain less steel exhaust systems can be removed through polishing 4 To prevent corrosion it is recom mended to apply a corrosion pro tection spray on all metal includin...

Page 75: ...d with a fuel cock that has an OFF posi tion Turn the fuel cock lever to OFF 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 ...

Page 76: ...then lift the motorcycle so that both of its wheels are off the ground Alterna tively turn the wheels a little every month in order to prevent the tires from becoming 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 e...

Page 77: ...Engine oil quantity Without oil filter element removal 1 00 L 1 06 US qt 0 88 Imp qt With oil filter element removal 1 10 L 1 16 US qt 0 97 Imp qt Air filter Air filter element Wet element Fuel Recommended fuel Unleaded gasoline only Fuel tank capacity 8 8 L 2 32 US gal 1 94 Imp gal Fuel reserve amount 2 0 L 0 53 US gal 0 44 Imp gal Carburetor Manufacturer MIKUNI Type quantity BST34 x 1 Spark plug...

Page 78: ...90 kg 0 198 lb Front 125 kPa 18 psi 1 25 kgf cm2 Rear 150 kPa 22 psi 1 50 kgf cm2 Loading condition 90 183 kg 198 403 lb Front 150 kPa 22 psi 1 50 kgf cm2 Rear 175 kPa 25 psi 1 75 kgf cm2 Front wheel Wheel type Spoke wheel Rim size 21x1 60 Rear wheel Wheel type Spoke wheel Rim size 18x2 15 Front brake Type Single disc brake Operation Right hand operation Recommended fluid DOT 3 or 4 Rear brake Typ...

Page 79: ...attage quantity Headlight 12 V 35 W 35 0 W 1 Tail brake light 12 V 5 0 W 21 0 W 1 Front turn signal light 12 V 21 0 W 2 Rear turn signal light 12 V 21 0 W 2 Meter lighting 12 V 3 4 W 1 Neutral indicator light 12 V 3 4 W 1 High beam indicator light 12 V 3 4 W 1 Turn signal indicator light 12 V 3 4 W 1 Fuse Fuse 15 0 A ProCarManuals com ...

Page 80: ...RMATION EAU26390 Key identification number The key identification number is stamped into the key Record this num ber in the space provided and use it for reference when ordering a new key EAU26400 Vehicle identification number The vehicle identification number is stamped into the steering head pipe Record this number in the space pro vided NOTE The vehicle identification number is used to identify...

Page 81: ...ITH NOISE CON TROL SYSTEM PROHIBITED Owners are warned that the law may prohibit The removal or rendering inopera tive by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the pur pose of noise control prior to its sale or delivery to the ultimate pur chaser or while it is in use and The use of the vehic...

Page 82: ...indicator light 3 2 Horn switch 3 3 I Identification numbers 9 1 Ignition circuit cut off system 3 11 Indicator lights 3 2 K Key identification number 9 1 L Labels location of 1 5 M Main switch steering lock 3 1 Model label 9 2 N Neutral indicator light 3 2 Noise regulation for Australia 9 2 P Parking 5 4 Part locations 2 1 Periodic maintenance and lubrication chart 6 2 Pre operation check list 4 ...

Page 83: ...INDEX Vehicle identification number 9 1 W Wheel bearings checking 6 27 Wheel front 6 32 Wheel rear 6 34 Wheels 6 16 ProCarManuals com ...

Page 84: ...ProCarManuals com ...

Page 85: ...ProCarManuals com ...

Page 86: ...PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2006 6 0 1 1 E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2006 6 0 1 1 E ProCarManuals com ...

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