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Yamaha 2004 Virago 250 Owner's Manual

1. plate rear sprocket 4 Lift the rear nies off pa ground NOTE 4 Adjust the drive chain slack See a to the procedure on The drive chain does not need to be page 6 22 5 g the brake pedal free play di8assembled in order to remove and _ 5 Install the axle nut and then lower Se OVE MNE DIAN pedar Mee Play inetall iherear widel the rear wheel so that it is on the adjusting nut and then disconnect ground the brake rod at the brake cam 8 Remove the axle nut 6 Tighten the axle nut to the speci shaft lever 9 Pull the wheel axle out and then fied torque and then insert a new 6 Disconnect the brake torque rod remove the wheel cotter pin into the axle nut from the brake shoe plate by re moving the nut and the bolt 6 35 Tightening torque Axle nut 104 Nm 10 4 m kgf 75 ft lbf EWA10700 Always use a new cotter pin for the axle nut 7 Adjust the brake pedal position and free play See page 6 19 EWA10660 A WARNING After adjusting the brake pedal free play check the operation of the brake light PERIODIC MAINTENANCE AND MINOR REPAIR EAU25850 Troubleshooting Although Yamaha motorcycles receive a thorough inspection before shipment from the factory trouble may occur dur ing operation Any problem in the fuel compression or ignition systems for example can cause poor starting and loss of power The following troubleshooting chart represents a quick and easy procedure for
2. 1 Do not touch the glass part of the bulb 5 6 Install the headlight bulb cover and then connect the coupler Install the headlight unit by install ing the screws Have a Yamaha dealer adjust the headlight beam if necessary PERIODIC MAINTENANCE AND MINOR REPAIR EAU24350 Supporting the motorcycle Since this model is not equipped with a centerstand follow these precautions when removing the front and rear wheel or performing other maintenance requiring the motorcycle to stand up right Check that the motorcycle is in a stable and level position before starting any maintenance A strong wooden box can be placed under the engine for added stability To service the front wheel 1 Stabilize the rear of the motorcycle by using a motorcycle stand or if an additional motorcycle stand is not available by placing a jack un der the frame in front of the rear wheel 2 Raise the front wheel off the ground by using a motorcycle stand To service 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 6 32 a jack either under each side of the frame in front of the rear wheel or under each side of the swingarm PERIODIC MAINTENANCE AND MINOR REPAIR EAU24360 Front wheel EAU24600 To remove the front wheel Itis advisable to have a Yamaha dealer service the wheel e Securely support the motor cycle so th
3. 7 Push down hard on the handlebar R heel EAU25080 several times to check for proper ear whee fork operation EAU32750 Connect the speedometer cable To remove the rear wheel EWA10820 Itis advisable to have a Yamaha dealer service the wheel e Securely support the motor cycle so that there is no danger of it falling over Remove the axle nut cotter pin 2 Loosen the chain puller locknut and the drive chain slack adjusting nut on both ends of the swingarm 6 34 PERIODIC MAINTENANCE AND MINOR REPAIR EAU32760 To install the rear wheel 1 Install the drive chain onto the rear sprocket and then install the wheel by inserting the wheel axle from the right hand side 2 Install the brake rod onto the brake camshaft lever and then install the brake pedal free play adjusting nut onto the brake rod 1 Axle nut 1 Brake torque rod 3 Connect the brake torque rod to 2 Axle nut cotter pin 2 Brake torque rod bolt and nut the brake shoe plate by installing 3 Chain puller locknut 3 Brake rod the bolt and nut and then tighten 4 Drive chain slack adjusting nut 4 Brake pedal free play adjusting nut the bolt to the specified torque 5 Alignment marks 5 Brake camshaft lever 6 3 Loosen the axle nut and the brake 7 Push the wheel forward and then Tightening torque i Brake torque rod bolt torque rod nut at the brake shoe remove the drive chain from the 23 Nm 2 3 m kgf 17 ft lbf
4. Cleaning ECA10770 CAUTION e 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 than in structed Also thoroughly rinse the area off with water immedi ately dry it and then apply a cor rosion protection spray e 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 e Do not use any harsh chemical products on plastic parts Be sure to avoid using cloths or sponges which have been in contact with strong or abrasive 7 1 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 wheel and swing arm bearings fork and brakes electric components couplers connectors instruments switches and lights breather hoses and vents For motorcycles equipped with a windshield Do not use strong cleaners or hard sponges as they will cause dulling or scratching Some cleaning com pounds for plastic may leave scratches on the windshield Test the product on a small hid den part of the windshield to make sure that it does not leave any marks If the windshield is sc
5. SPECIFIC EXCLUSIONS from this warranty shall include parts replaced due to normal wear or routine maintenance CONSUMER INFORMATION THE CUSTOMER S RESPONSIBILITY under this war ranty shall be to 1 Operate and maintain the motorcycle as specified in the appropriate Owner s Manual and 2 Give notice to an authorized Yamaha motorcycle dealer of any and all apparent defects within ten 10 days after discovery and make the machine available at that time for inspection and repairs at such dealer s place of business WARRANTY TRANSFER To transfer the warranty from the original purchaser to any subsequent pur chaser it is imperative that the machine be inspected and registered for warranty by an authorized Yamaha motorcycle dealer In order for this warranty to remain in effect this inspection and registration must take place within ten 10 days after transfer An inspection and registration fee will be charged for this service EMISSIONS CONTROL SYSTEM WARRANTY Yamaha Motor Corporation U S A also warrants to the ultimate purchaser and each subsequent purchaser of each Yamaha motorcycle covered by this warranty with a displacement of 50cc or greater that the vehi cle is designed built and equipped so as to conform at the time of sale with all U S emissions standards applicable at the time of manufacture and that it is free from defects in materials and workmanship which would cause it not to meet these standards within t
6. YAMAHA EAU10041 A WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm YAMAHA LIT CALIF 65 01 INTRODUCTION EAU10080 Congratulations on your purchase of the Yamaha XV250 XV250C This model is the result of Yamaha s vast experience in the production of fine sporting touring and pacesetting racing machines It repre sents the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields This manual will give you an understanding of the operation inspection and basic maintenance of this motorcycle If you have any questions concerning the operation or maintenance of your motorcycle please consult a Yamaha dealer The design and manufacture of this Yamaha motorcycle fully comply with the emissions standards for clean air applicable at the date of manufacture Yamaha has met these standards without reducing the performance or economy of operation of the motorcycle To maintain these high standards it is impor tant that you and your Yamaha dealer pay close attention to the recommended maintenance schedules and operating instructions contained within this manual IMPORTANT MANUAL INFORMATION EAU10130 Particularly important information is distinguished in this manual by the following notations A The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED 2 WARNIN
7. PERIODIC MAINTENANCE AND MINOR REPAIR Tire information This motorcycle is equipped with spoke wheels and tube tires e The front and rear tires should be of the same make and de sign otherwise the handling characteristics of the vehicle cannot be guaranteed e After extensive tests only the tires listed below have been ap proved for this model by Yamaha Motor Co Lid EWA10460 Front tire Size 3 00 18 47P Manufacturer model CHENG SHIN C 916 Rear tire Size 130 90 15M C 66P Manufacturer model CHENG SHIN C 915 6 16 EAU21940 Spoke wheels To maximize the performance durabil ity and safe operation of your motor cycle 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 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 dling characteristics and a short ened tire life Ride at moderate speeds after changing a tire since the tire sur face must first be broken in for it to develop its optimal characteris tics PERIODIC MAINTENANCE AND MINOR REPAIR EAU22010 Accessories and replacem
8. have a Yamaha dealer bleed the system before operating the motorcycle Air in the hydraulic system will dimin ish the braking performance which may result in loss of con trol and an accident EAU22201 Adjusting the brake pedal position and free play NEG yy ay o KE IIZ 1 Footrest 2 Distance between brake pedal and footrest 3 Brake pedal free play It is advisable to have a Yamaha dealer make these adjustments EWA10670 Brake pedal position The top of the brake pedal should be positioned approximately 60 mm 2 36 in above the top of the footrest as shown Periodically check the brake pedal position and if necessary adjust it as follows 6 19 1 Loosen the locknut at the brake pedal 2 To raise the brake pedal turn the adjusting bolt in direction a To lower the brake pedal turn the ad justing bolt in direction b 1 Locknut 2 Brake pedal position adjusting bolt 3 Tighten the locknut After adjusting the brake pedal posi tion the brake pedal free play must be adjusted EWA11230 Brake pedal free play The brake pedal free play should mea sure 20 0 30 0 mm 0 79 1 18 in at the brake pedal end Periodically check the brake pedal free play and if neces sary adjust it as follows To increase the brake pedal free play turn the adjusting nut at the brake rod in direction a To decrease the brake pedal free play turn the adjusting nut in direction b 1 Brake
9. Manual No The warranty on a new motorcycle cannot be voided or cancelled However if a particular failure is caused by operation or maintenance other than as shown in the Owner s Manual that failure may not be covered under warranty What responsibility does my dealer have under this warranty Each Yamaha Motorcycle dealer is expected to 1 Completely set up every new machine before sale 2 Explain the operation maintenance and warranty requirements to your satis faction at the time of sale and upon your request at any later date 3 Each Yamaha Motorcycle dealer is held responsible for his setup service and warranty repair work Is the warranty transferable to second owners Yes The remainder of the existing warranty can be transferred upon request The unit has to be inspected and re registered by an authorized Yamaha Motorcycle dealer for the policy to remain effective CONSUMER INFORMATION CUSTOMER SERVICE If your machine requires warranty service you must take it to any authorized Yamaha Motorcycle dealer within the continental United States Be sure to bring your warranty registration card or other valid proof of the original date of purchase If a question or problem arises regarding warranty first con tact the owner of the dealership Since all warranty matters are handled at the dealer level this person is in the best position to help you If you are still not satisfied and require additional assi
10. THE FOLLOWING REQUIREMENTS BEFORE RIDING THIS MOTOR CYCLE HE OR SHE SHOULD OBTAIN THOROUGH INSTRUC TIONS FROM A COMPETENT SOURCE ON ALL ASPECTS OF MOTORCYCLE OPERATION e OBSERVE THE WARNINGS AND MAINTENANCE REQUIRE MENTS IN THE OWNER S MAN UAL OBTAIN QUALIFIED TRAINING IN SAFE AND PROPER RIDING TECHNIQUES OBTAIN PROFESSIONAL TECH NICAL SERVICE AS INDICATED BY THE OWNER S MANUAL AND OR WHEN MADE NECES SARY BY MECHANICAL CONDI TIONS Safe riding e Always make __ pre operation checks Careful checks may help prevent an accident This motorcycle is designed to car ry the operator and a passenger e The failure of motorists to detect and recognize motorcycles in traf fic is the predominating cause of automobile motorcycle accidents Many accidents have been caused by an automobile driver who did not see the motorcycle Making yourself conspicuous appears to be very effective in reducing the chance of this type of accident Therefore e Wear a brightly colored jacket e Use extra caution when ap proaching and passing through intersections since intersec tions are the most likely places for motorcycle accidents to oc cur 1 1 e Ride where other motorists can see you Avoid riding in another motorist s blind spot Many motorcycle accidents in volve inexperienced operators In fact many operators who have been involved in accidents do not even have a current motorcycle l
11. and or cylinder s may 6 removing the wing nut 2 Air filter element frame become excessively worn 1 Screw 9 Install the air filter case cover by in stalling the screws 10 Connect the hoses to the air filter 6 Apply oil of the recommended type to the entire surface of the sponge material and then squeeze the ex cess oil out pasg to 11 Install the air filter case onto the air NOTE filter joint and then tighten the air The air filter element should be wet but filter joint clamp screw not dripping 12 Install the bolts 1 Wing nut 2 Air filter case Recommended oil Yamaha foam air filter oil or other quality air filter oil PERIODIC MAINTENANCE AND MINOR REPAIR EAU21250 Adjusting the carburetor The carburetor is an important part of the engine and its emission control sys tem which requires very sophisticated adjustment Therefore carburetor ad justments should be left to Yamaha dealer who has the necessary profes sional knowledge and experience EAU21380 Adjusting the throttle cable free play 1 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 6 14 EAU21400 Adjusting the valve clearance The valve clearance changes with use resulting in improper air fuel mixture and or engine noise To prev
12. by a Yamaha dealer The clutch switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer PRE OPERATION CHECKS EAU15591 The condition of a vehicle is the owner s responsibility Vital components can start to deteriorate quickly and unexpectedly even if the vehicle remains unused for example as a result of exposure to the elements Any damage fluid leakage or loss of tire air pressure 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 If any item in the Pre operation check list is not working properly have it inspected and repaired before operating the vehicle EWA11150 4 1 PRE OPERATION CHECKS Pre operation check list CHECKS EAU15601 e Check fuel level in fuel tank e Refuel if necessary e Check fuel line for leakage Engine oil e Check oil level in engine e If necessary add recommended oil to specified level e Check vehicle for oil leakage Front brake e Check operation e If soft or spongy have Yamaha dealer bleed hydraulic system e Check lever free play e Adjust if necessary e Check brake pads for wear e Replace if necessa
13. dealer check or re pair it 6 27 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 maintenance and lubrication chart 1 Place a stand under the engine to raise the front wheel off the ground Securely support the vehicle so that there is no danger of it falling over EWA10750 2 Hold the lower ends of the front fork legs and try to move them for ward and backward If any free play can be felt have a Yamaha dealer check or repair the steering PERIODIC MAINTENANCE AND MINOR REPAIR EAU23290 Checking the wheel bearings The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrica tion chart If there is play in the wheel hub or if the wheel does not turn smoothly have a Yamaha dealer check the wheel bearings 6 28 EAU23310 Battery A poorly maintained battery will corrode and discharge quickly The electrolyte level battery lead connections and breather hose routing should be checked before each ride and at the in tervals specified in the periodic mainte nance and lubrication chart To check the electrolyte 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 up when checking the electro lyte level 2
14. of a higher amper age rating than recommended to avoid causing extensive damage to the electrical system and possibly a fire 3 Turn the key to ON and turn on the electrical circuit in question to check if the device operates 4 If the fuse immediately blows again have a Yamaha dealer check the electrical system PERIODIC MAINTENANCE AND MINOR REPAIR EAU23780 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 the headlight unit by re moving the screws 1 Headlight coupler 2 Headlight bulb cover 3 Remove the headlight bulb holder by turning it counterclockwise and then remove the defective bulb 1 Screw 2 Disconnect the headlight coupler and then remove the bulb cover 1 Headlight bulb holder 6 31 EWA10790 Headlight bulbs get very hot There fore keep flammable products away from a lit headlight bulb and do not touch the bulb until it has cooled down 4 Place a new headlight bulb into po sition and then secure it with the bulb holder ECA10660 CAUTION Do not touch the glass part of the headlight bulb to keep it free from oil otherwise the transparency of the glass the luminosity of the bulb and the bulb life will be adversely af fected Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with al cohol or thinner
15. over 6 EWA10950 Lubricate all control cables and the pivoting points of all levers and pedals as well as of the side stand centerstand Check and if necessary correct the tire air pressure and then lift the motorcycle so that both of its wheels are off the ground Alterna tively turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot Cover the muffler outlets with plas tic bags to prevent moisture from entering them 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 ex cessively cold or warm place less than 0 C 30 F or more than 30 NOTE Make any necessary repairs before storing the motorcycle C 90 F For more information on storing the battery see page 6 28 7 4 SPECIFICATIONS Dimensions Engine oil Carburetor Overall length Type Manufacturer 2190 mm 86 2 in YAMALUBE 4 SAE10W30 or SAE20W40 MIKUNI Overall width Type x quantity 815 mm 32 1 in BDS26 x 1 Overall height 10 30 50 70 90 110 130 F Spark plug s 1140 mm 44 9 in pe N Manufacturer model ni _ gt YAMALUBE 4 10W30 a ees 0 6 0 7 mm 0 024 0 028 in 10 20 30 40 50 C ee lt G Ground clearance Seat height or SAE 10W30 NGK C6HSA 685 mm 27 0 in 1 aE S S E Manufacturer model Wheelbase 1 YAMALUBE 4 20W40 DENSO U20F
16. pressure e Correct if necessary ROUTINE INITIAL PERIODIC MAINTENANCE AND MINOR REPAIR 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 Wheel bearings e Check bearings for smooth oper ation e Replace if necessary Swingarm pivot bearings e Check bearing assemblies for looseness e Moderately repack with lithium soap based grease Drive chain e Check chain slack alignment and condition e Adjust and lubricate chain with a special O ring chain lubricant thoroughly Every 600 mi 1000 km and after washing the motorcycle or riding in the rain Steering bearings e Check bearing assembly for looseness e Moderately repack with lithium soap based grease every 10000 mi 16000 km or 18 months Chassis fasteners e Check all chassis fitting and fas teners e Correct if necessary Brake and clutch le ver pivot shafts e Apply lithium soap based grease all purpose grease lightly Brake and shift ped al pivot shafts e Apply lithium soap based grease all purpose grease lightly Sidestand pivot e Check operation e Apply lithium soap based grease all purpose grease lightly 6 5 PERIODIC MAINTENANCE AN
17. steel exhaust systems can be re moved through polishing 7 2 4 To prevent corrosion it is recom mended 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 EWA10930 A WARNING Make sure that there is no oil or wax on the brakes or tires If necessary clean the brake discs and brake linings with a regular brake disc cleaner or ac etone and wash the tires with warm water and a mild deter gent e Before operating the motor cycle test its braking perfor mance and cornering behavior NOTE Consult a Yamaha dealer for advice on what products to use ECA10800 CAUTION e Apply spray oil and wax spar ingly and make sure to wipe off any excess Never apply oil or wax to any rubber and plastic parts but treat them with a suitable care product Avoid using abrasive polishing compounds as they will wear away the paint MOTORCYCLE CARE AND STORAGE EAU32640 Storage Short term Always store your motorcycle in a cool dry place and if necessary protect it against dust with a porous cover ECA10810 CAUTION e Storing the motorcycle in a poorly ventilated room or cover ing it with a tarp while it is still wet
18. will allow water and humid ity to seep in and cause rust e 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 2 Turn the fuel cock lever to ON 7 3 3 4 Drain the carburetor float cham bers by loosening the drain bolts this will prevent fuel deposits from building up Pour the drained fuel into the fuel tank Fill up the fuel tank and add fuel stabilizer if available to prevent the fuel tank from rusting and the fuel from deteriorating Perform the following steps to pro tect the cylinders piston rings etc from corrosion a Remove the spark plug caps and spark plugs b Pour a teaspoonful of engine oil into each spark plug bore c Install the spark plug caps onto the spark plugs and then place the spark plugs on the cylinder head so that the electrodes are grounded This will limit spark ing during the next step d Turn the engine over several times with the starter This will coat the cylinder walls with oil e Remove the spark plug caps from the spark plugs and then install the spark plugs and the spark plug caps MOTORCYCLE CARE AND STORAGE To prevent damage or injury from sparking make sure to ground the spark plug electrodes while turning the engine
19. 0 Shift pedal page 3 4 Steering lock page 3 8 Fuel tank page 3 5 Battery page 6 28 Fuses page 6 30 Helmet holder page 3 9 Shock absorber assembly spring preload adjusting ring page 3 9 Main switch page 3 1 Fuel cock page 3 6 2 1 EAU10410 Right view OANDOARWND Tail brake light Rear turn signal lights Rider seat page 3 8 Air filter element page 6 12 Front turn signal position lights Brake pedal page 3 4 Footrest Owner s tool kit page 6 1 Shock absorber assembly spring preload adjusting ring page 3 9 DESCRIPTION EAU10420 DESCRIPTION EAU10430 Controls and instruments 1 2 34 o1 e gt E CAL ib Yi wre SS ake i AN DNN GS z A I 5 Ay Py 8 Clutch lever page 3 3 Left handlebar switches page 3 2 Speedometer unit page 3 2 Indicator lights page 3 1 Right handlebar switches page 3 2 Brake lever page 3 4 Throttle grip page 6 14 Fuel tank cap page 3 5 NOU AON 2 3 EAU10450 Main switch The main switch controls the ignition and lighting systems The various main switch positions are described below EAU10510 ON All electrical systems are supplied with power and the headlight meter light ing taillight and position lights come on and the engine can be started The key cannot be removed EAU10660 OFF All electrical systems are
20. 0 W 55 0 W x 1 Tail orake light 12 V 8 W 27 0 W x 1 Front turn signal position light 12 V 27 W 8 0W x 2 Rear turn signal light 12 V 27 0Wx2 Meter lighting 14V 3 0W x1 Neutral indicator light 14V 3 0W x1 High beam indicator light 12V 1 7Wx1 Turn signal indicator light 14V 3 00Wx1 Fuses Main fuse 20 0A Signaling system fuse 10 0A 8 3 SPECIFICATIONS CONSUMER INFORMATION EAU26351 Identification numbers Record the key identification number vehicle identification number and mod el label information in the spaces pro vided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehi cle is stolen KEY IDENTIFICATION NUMBER VEHICLE IDENTIFICATION NUMBER i MODEL LABEL INFORMATION EAU26390 Key identification number OWS US 1 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 9 1 EAU26400 Vehicle identification number 1 Vehicle identification number The vehicle identification number is stamped into the steering head pipe Record this number in the space pro vided NOTE The vehicle identification number is used to identify your motorcycle and may be used to register your motor cycle with the licensing authority in your area EAU26470 Model label ce Zi CN N
21. 0SC OWNER S MANUAL 2003 by Yamaha Motor Corporation U S A 1st edition May 2003 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in Japan P N LIT 11626 17 28 TABLE OF CONTENTS SAFETY INFORMATION 1 1 Location of important labels 1 5 DESCRIPTION ceeeeeeeeeeees 2 1 L eft Vie We iernare 2 1 Right ViOW esere 2 2 Controls and instruments 2 3 INSTRUMENT AND CONTROL FUNCTIONS o n 3 1 Main Switch cceceeseeeeeeeeeeeees 3 1 Indicator lights eeen 3 1 Speedometer unit e eeeee 3 2 Handlebar switches cen 3 2 Clutch lever ccccscceeeeseeesteeees 3 3 Shift pedal 0 ee eeeeeeeeeseeseeeenees 3 4 Brake lever o eecececeeeeeeseeeeeeeeeeeeee 3 4 Brake pedal sissien 3 4 Fuel tank Cap sesser 3 5 Fuel EE A dre nei 3 5 FuelCOCK Tersa aa tad sig teas 3 6 Starter choke lever n se 3 7 Steering lock 2 eeeeeeeeeteeseeeeees 3 8 Rider seat psti o piii 3 8 Helmet holder cccceeseeeeeees 3 9 Adjusting the shock absorber assemblies ooo ee eeeeeeeeeeeeeeeeees 3 9 Sidestand ceeeeeseeeseeeeseeeseeeees 3 10 Ignition circuit cut off system 3 11 PRE OPERATION CHECKG 4 1 Pre operation check list 4 2 OPERATION AND IMPORTANT RIDING POINTS 0 cec
22. 1 Model label The model label is affixed to the frame under the rider seat See page 3 8 Record the information on this label in the space provided This information will be needed when ordering spare parts from a Yamaha dealer 9 2 CONSUMER INFORMATION CONSUMER INFORMATION EAU26550 Reporting safety defects If you believe that your vehicle has a defect which could cause a crash or could cause injury or death you should immediately inform the National Highway Traffic Safety Administration NHTSA in addition to notifying Yamaha Motor Corporation U S A If NHTSA receives similar complaints it may open an investigation and if it finds that a safety defect exists in a group of vehicles it may order a recall and remedy campaign However NHTSA cannot become involved in individual problems between you your dealer or Yamaha Motor Corporation U S A To contact NHTSA you may either call the Auto Safety Hotline toll free at 1 800 424 9393 or 366 0123 in Washington D C area or write to NHTSA U S Department of Transportation Washington D C 20590 You can also obtain other information about motor vehicle safety from the Hotline 9 3 CONSUMER INFORMATION EAU26560 Motorcycle noise regulation TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the following acts or the causing thereof 1 The removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement o
23. Check the electrolyte level in the battery NOTE The electrolyte should be between the minimum and maximum level marks UPPER LEVEL LOWER LEVEL 1 Maximum level mark 2 Minimum level mark 3 If the electrolyte is at or below the minimum level mark add distilled water to raise it to the maximum level mark EWA10770 e 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 batteries In case of contact administer the fol lowing FIRST AID e EXTERNAL Flush with plenty of water PERIODIC MAINTENANCE AND MINOR REPAIR e INTERNAL Drink large quan tities of water or milk and im mediately call a physician e EYES Flush with water for 15 minutes and seek prompt medical attention Batteries produce explosive hy drogen gas Therefore keep sparks flames cigarettes etc away from the battery and pro vide sufficient ventilation when charging it in an enclosed space Take care not to spill electrolyte on the drive chain as this may weaken it shorten chain life and possibly result in an accident KEEP THIS AND ALL BATTER IES OUT OF THE REACH OF CHILDREN ECA10610 CAUTION Use only distilled water as tap water contains minerals that are harmful to the battery 4 Check and if necessary tighten the battery lead co
24. D MINOR REPAIR ROUTINE 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 Sidestand switch e Check operation and replace if necessary J Ni Ni Ni Ni Ni Front fork e Check operation and for oil leak age e Replace if necessary Shock absorber as semblies e Check operation and for oil leak age e Replace if necessary Engine oil e Change warm engine before draining Engine oil filter ele ment e Replace Control and meter cables e Apply Yamaha chain and cable lube or engine oil 10W 30 thor oughly Throttle grip hous ing and cable e Check operation and free play e Adjust the throttle cable free play if necessary e Lubricate the throttle grip housing and cable Since these items require special tools data and technical skills have a Yamaha dealer perform the service NOTE From 19000 mi 31000 km or 36 months repeat the maintenance intervals starting from 7000 mi 11000 km or 12 months PERIODIC MAINTENANCE AND MINOR REPAIR EAU17620 NOTE The air filter needs more frequent service if you are riding in unusually wet or dusty areas Hydraulic brake system e When disassembling the master cylinder or
25. G Failure to follow WARNING instructions could result in severe injury or death to the motor cycle operator a bystander or a person inspecting or repairing the motorcycle CAUTION A CAUTION indicates special precautions that must be taken to avoid damage to the motor cycle NOTE A NOTE provides key information to make procedures easier or clearer NOTE This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold e Yamaha continually seeks advancements in product design and quality Therefore while this manual contains the most current product information available at the time of printing there may be minor discrepancies between your motorcycle and this manual If you have any questions concerning this manual please consult your Yamaha dealer PLEASE READ THIS MANUAL AND THE YOU AND YOUR MOTORCYCLE RIDING TIPS BOOKLET CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE DO NOT ATTEMPT TO OPERATE THIS MOTOR CYCLE UNTIL YOU HAVE ATTAINED ADEQUATE KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES REGULAR INSPECTIONS AND CAREFUL MAINTENANCE ALONG WITH GOOD RIDING SKILLS WILL ENSURE THAT YOU SAFELY ENJOY THE CAPABILITIES AND THE RELIABILITY OF THIS MOTORCYCLE EWA10010 IMPORTANT MANUAL INFORMATION EAU10192 LABEL HERE i AFFIX DEALER o _ XV250S XV25
26. INTENANCE AND MINOR REPAIR Tightening torque Engine oil drain bolt NOTE Skip steps 4 6 if the oil filter element is not being replaced 4 Remove the oil filter element cover by removing the bolts 34 Nm 3 4 m kgf 25 ft Ibf 8 Add the specified amount of the recommended engine oil and then install and tighten the oil filler cap Recommended engine oil See page 8 1 1 Oil filter element Oil quantity 2 O ring With oil filter element replacement oe 1 60 L 1 69 US qt 1 41 Imp qt 6 Install the oil filter element cover by Without oil filter element replace installing the bolts then tightening ment them to the specified torque 1 40 L 1 48 US qt 1 23 Imp qt ECA11620 ie Tightening torque 3 2 Oil filter element cover Oil filter element cover bolt CAUTION _ 5 Remove and replace the oil filter a In order To prevent clutch slip element and O ring page since the engine oil also l NOTE lubricates the clutch do not Make sure that the O ring is properly mix any chemical additives Do seated not use oils with a diesel speci fication of CD or oils of a high 7 Install the engine oil drain bolt and er quality than specified In then tighten it to the specified addition do not use oils labeled torque ENERGY CONSERVING II or higher 6 11 PERIODIC MAINTENANCE AND MINOR REPAIR e Make sure that no foreign mate CI ina the air filt l ent ria
27. ON Maintenance Servicing dealer z Mileage Remarks interval g name and address 28000 mi 46000 km or 54 months 31000 mi 51000 km or 60 months 9 6 Yamaha Motor Corporation U S A hereby warrants each new model Yamaha motorcycle will be free from defects in material and workmanship for the period of time stated herein subject to certain stated limitations THE PERIOD OF WARRANTY for Yamaha motorcycles originally equipped with headlight stoplight and turn signals shall be one 1 year from the date of purchase with no mileage limitation MODELS EXCLUDED FROM WARRANTY include those used for non Yamaha authorized renting leas ing or other commercial purposes and TZ models DURING THE PERIOD OF WARRANTY any authorized Yamaha motorcycle dealer will free of charge repair or replace any part adjudged defective by Yamaha due to faulty workmanship or material from the factory Parts used in warranty repairs will be warranted for the balance of the product s warranty period All parts replaced under warranty become property of Yamaha Motor Corp U S A GENERAL EXCLUSIONS from this warranty shall include any failures caused by a Competition or racing use b Installation of parts or accessories that are not qualitatively equivalent to genuine Yamaha parts Abnormal strain neglect or abuse Lack of proper maintenance Accident or collision damage Modification to original parts moao
28. S U 1490 mm 58 7 in i gt SAE POWA i Spark plug gap 145 mm 5 71 in ee Clutch Minimum turning radius Clutch type 2800 mm 110 2 in 7 Wet multiple disc Weight Recommended engine oil grade Transmission are API service SE SF SG type or higher gt With oil and fuel Faa Primary reduction system Engine oil quantity 147 0 kg 324 Ib U49 ps Spur gear Without oil filter element replacement 148 0 kg 326 Ib CAL 1 40 L 1 48 US qt 1 23 Imp qt Primary reduction ratio eit type With oil filter element replacement an ae system i t 1 41 Imp qt Air cooled 4 stroke SOHC ope 1 60 LE Chee Ua mp Chain drive i j Air filter Sl Cylinder arrangement Air filter el t Secondary reduction ratio V type 2 cylinder Th i ae 45 16 2 812 8 Displacement Fuel ayer Transmission type 249 0 cm 15 19 cu in uers l Constant mesh 5 speed Bore x stroke Recommended fuel Operation 49 0 x 66 0 mm 1 93 x 2 60 in Unleaded gasoline only Left foot operation Compression ratio Fuel tank capacity 10 00 1 9 2 L 2 43 US gal 2 02 Imp gal CAL Starting system 9 5 L 2 51 US gal 2 09 Imp gal U49 Fuel reserve amount 2 6 L 0 69 US gal 0 57 Imp gal Electric starter Lubrication system Wet sump 8 1 SPECIFICATIONS Gear ratio 1st 37 14 2 643 2nd 32 19 1 684 3rd 29 23 1 261 Ath 26 26 1 000 5th 23 28 0 821 Chassis Frame type Double cradle Caster angle 32 0 Tra
29. at there is no danger of it falling over EWA10820 1 Disconnect the speedometer ca ble from the front wheel 1 Speedometer cable 2 Loosen the front wheel axle pinch bolt then the wheel axle 1 Wheel axle 2 Front wheel axle pinch bolt 3 Lift the front wheel off the ground according to the procedure on page 6 32 4 Pull the wheel axle out and then remove the wheel ECA11070 CAUTION Do not apply the brake after the wheel has been removed together with the brake disc otherwise the brake pads will be forced shut EAU24931 To install the front wheel 1 Install the speedometer gear unit into the wheel hub so that the pro jections mesh with the slots 6 33 1 Speedometer gear unit 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 1 Speedometer gear unit 2 Retainer 3 Speedometer cable 3 4 5 Insert the wheel axle Lower the front wheel so that it is on the ground Tighten the wheel axle to the spec ified torque Tightening torque 6 Wheel axle 59 Nm 5 9 m kgf 43 ft Ibf Tighten the front wheel axle pinch bolt to the specified torque Tightening torque Front wheel axle pinch bolt 20 Nm 2 0 m kgf 14 ft Ibf PERIODIC MAINTENANCE AND MINOR REPAIR
30. ate the drive chain with a special O ring chain lubricant PERIODIC MAINTENANCE AND MINOR REPAIR ECA11110 CAUTION 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 EAU23090 Checking and lubricating the cables The operation of all control cables and the condition of the cables should be checked before each ride and the ca bles and cable ends should be lubricat ed if necessary If a cable is damaged or does not move smoothly have a Yamaha dealer check or replace it Recommended lubricant Yamaha Chain and Cable Lube or engine oil SAE 10W 30 API SE EWA10710 Damage to the outer housing of ca bles may result in internal rusting and cause interference with cable movement Replace damaged ca bles as soon as possible to prevent unsafe conditions 6 25 EAU23110 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 or replaced at the intervals specified in the periodic maintenance chart PERIODIC MAINTENANCE AND MINOR REPAIR 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 EAU23140 Checking and lubricating the brake and clutch levers The operation of the b
31. caliper cylinder always replace the brake fluid Check the brake fluid level regularly and fill as required e Replace the oil seals on the inner parts of the master cylinder and caliper cylinder every two years e Replace the brake hoses every four years or if cracked or damaged 6 7 EAU19543 Checking the spark plugs The spark plugs are important engine components which are easy to check Since heat and deposits will cause any spark plug to slowly erode the spark plugs should be removed and checked in accordance with the periodic mainte nance and lubrication chart In addition the condition of the spark plugs can re veal the condition of the engine To remove a spark plug 1 Remove the spark plug cap 1 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 wrench To check the spark plugs 1 Check that the porcelain insulator around the center electrode on each spark plug is a medium to light tan the ideal color when the vehicle is ridden normally 2 Check that all spark plugs installed in the engine have the same color NOTE If any spark plug shows a distinctly dif ferent color the engine could be defec tive Do not attempt to diagnose such problems yourself Instead have a Yamaha dealer check the vehicle 6 8 PERIODIC MAINTENANCE AND MINOR REPAIR 3 Check each spark plug for elec trode erosion and exces
32. 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 but they are often inferi or have a shorter service life and can lead to expensive repair bills 6 36 Troubleshooting chart Keep away open flames and do not smoke while checking or working on the fuel system 1 Fuel Check the fuel level in the fuel tank Check the compression PERIODIC MAINTENANCE AND MINOR REPAIR 2 Compression Operate the electric starter 3 Ignition Remove the spark plugs and check the electrodes 4 Battery Operate the electric starter The engine turns over quickly The engine turns over The battery is good H slowly Check the electrolyte and battery m There is enough fuel The engine does not start gt There is no fuel Supply fuel gt Check the compressoin m There is compression Check the ignition c gt There is no compression gt navaa Yamaha dealer check the vehicle Wipe off with a dry cloth and correct the Open th
33. ck operation e Correct if necessary Sidestand switch e Check operation of ignition circuit cut off system e If system is defective have Yamaha dealer check vehicle Battery e Check fluid level e Fill with distilled water if necessary 4 3 OPERATION AND IMPORTANT RIDING POINTS EAU15950 EWA10270 e Become thoroughly familiar with all operating controls and their functions before riding Consult a Yamaha dealer re garding any control or function that you do not thoroughly un derstand e Never start the engine or oper ate it in a closed area for any length of time Exhaust fumes are poisonous and inhaling them can cause loss of con sciousness and death within a short time Always make sure that there is adequate ventila tion e Before starting out make sure that the sidestand is up If the sidestand is not raised com pletely it could contact the ground and distract the opera tor resulting in a possible loss of control EAU32620 Starting and warming up a cold engine In order for the ignition circuit cut off system to enable starting one of the following conditions must be met e The transmission is in the neutral position e The transmission is in gear with the clutch lever pulled and the sid estand up e 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 e Never ride with the sid
34. e 5 1 Starting and warming up a cold ONGING a c ovis lanes 5 1 Starting a warm engine 6 5 2 SHUN Gis ETE 5 2 Engine break in cecce 5 4 Parkin es oinar inania 5 4 PERIODIC MAINTENANCE AND MINOR REPAIR 6 1 PERIODIC MAINTENANCE 6 1 Owner s tool kit 0 0 0 eeeeeeeeeeeeeeeees 6 1 Periodic maintenance chart for the emission control system 6 3 General maintenance and lubrication Chart essee 6 4 Checking the spark plugs 6 8 Canister for California only 6 9 Engine oil and oil filter element 6 10 Cleaning the air filter element 6 12 Adjusting the carburetor 6 14 Adjusting the throttle cable free Plays dir yana ane aoa eddie 6 14 Adjusting the valve clearance 6 14 INOS ative iain areas cere cts 6 15 Spoke wheels cesceeseeeeeeeees 6 16 Accessories and replacement Pals aii th wi et 6 17 Adjusting the clutch lever free Play riranin eles 6 17 Adjusting the brake lever free play iner a r 6 18 Adjusting the brake pedal position and free play asee 6 19 Adjusting the rear brake light SWIICH sa cdesesietadelatetiaciedeiateatiiens 6 20 Checking the front brake pads and rear brake shoes 6 21 Checking the brake fluid level 6 21 Changing the brake fluid 6 22 Drive chain slack nee 6 22 Lubricating the drive chain 6 24 Checking and lubricating the Cables asinasina a 6 25 Checki
35. e fuel cock lever to this position when the engine has been al lowed to run out of fuel This sends fuel directly to the carburetor which will make starting easier After the engine has started be sure to turn the lever to ON or RES if you have not refueled yet 3 7 EAU13630 Starter choke lever 1 Starter choke lever Starting a cold engine requires a richer air fuel mixture which is supplied by the starter choke Move the lever in direction a to turn on the starter choke Move the lever in direction b to turn off the starter choke INSTRUMENT AND CONTROL FUNCTIONS au1s730 To unlock the steering cia 1 Open the steering lock cover and Rider seat then insert the key 2 Push the key in turn it 1 8 tum TO remove the rider seat counterclockwise so that it moves Remove the bolts and then pull the rid out and then release it er seat off 3 Remove the key and then close the lock cover Steering lock 1 Steering lock To lock the steering 1 Turn the handlebar all the way to the right 2 Open the steering lock cover and then insert the key To install the rider seat 3 Turn the key 1 8 turn counterclock 1 Insert the projection on the front of wise push it in while turning the the rider seat into the seat holder handlebar slightly to the left and as shown then turn the key 1 8 turn clock wise 4 Check that the steering is locked remove the key and then c
36. e throttle halfway and operate m Wet m i spark plug gaps or replace the spark plugs the electric starter gt t The engine does not start Dry Have a Yamaha dealer check the vehicle Check the battery r m lead connections and charge the battery if necessary 6 37 The engine does not start Have a Yamaha dealer check the vehicle EAU25931 EWA10840 EAU26040 Care While the open design of a motorcycle reveals the attractiveness of the tech nology it also makes it more vulnera ble Rust and corrosion can develop even if high quality components are used A rusty exhaust pipe may go un noticed on a car however it detracts from the overall appearance of a motor cycle Frequent and proper care does not only comply with the terms of the warranty but it will also keep your motorcycle looking good extend its life and optimize its performance Before cleaning 1 Cover the muffler outlets with plas tic bags after the engine has cooled down 2 Make sure that all caps and covers as well as all electrical couplers and connectors including the spark plug caps are tightly in stalled 3 Remove extremely stubborn dirt like oil burnt onto the crankcase with a degreasing agent and a brush but never apply such prod MOTORCYCLE CARE AND STORAGE ucts onto seals gaskets sprock ets the drive chain and wheel axles Always rinse the dirt and de greaser off with water
37. e 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 necessary to perform certain maintenance work correctly NOTE If you do not have the tools or experi ence required for a particular job have a Yamaha dealer perform it for you EWA10340 Modifications not approved by Yamaha may cause loss of perfor mance excessive emissions and render the vehicle unsafe for use Consult a Yamaha dealer before at tempting any changes PERIODIC MAINTENANCE AND MINOR REPAIR 6 2 PERIODIC MAINTENANCE AND MINOR REPAIR Periodic maintenance chart for the emission control system ROUTINE INITIAL ODOMETER READINGS EAU17580 600 mi 1000 km or 1 month 4000 mi 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 Fuel line e Check fuel and vacuum hoses for cracks or damage e Replace if necessary Spark plugs e Check condition e Adjust gap and clean e Replace every 7000 mi 11000 km or 12 months Replace Replace Valve clearance e Check and adjust valve clearance when engine is cold Crankcase breather system e Check breather hose for cracks or damage e Replace if necessary Idle speed e Check and adjust engine idle s
38. emoved if the cap is not properly closed and locked Make sure that the fuel tank cap is properly closed before riding EWA11090 3 5 EAU13210 Fuel 1 Fuel tank filler tube 2 Fuel level Make sure that there is sufficient fuel in the tank Fill the fuel tank to the bottom of the filler tube as shown e Do not overfill the fuel tank oth erwise it may overflow when the fuel warms up and expands e Avoid spilling fuel on the hot en gine EWA10880 INSTRUMENT AND CONTROL FUNCTIONS ECA10070 CAUTION Immediately wipe off spilled fuel with a clean dry soft cloth since fuel may deteriorate painted surfac es or plastic parts EAU13300 Recommended fuel UNLEADED GASOLINE ONLY Fuel tank capacity 9 2 L 2 43 US gal 2 02 Imp gal CAL 9 5 L 2 51 US gal 2 09 Imp gal U49 Fuel reserve amount 2 6 L 0 69 US gal 0 57 Imp gal ECA11400 CAUTION 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 a different brand or premi um unleaded fuel Use of unleaded fuel will extend spark plug life and reduce maintenance costs Gasohol Th
39. ent parts This motorcycle is not designed to pull a trailer or to be attached to a sidecar The accessories or replace ment parts you choose for your motorcycle should be designed spe cifically for this model and they must be securely mounted to main tain the inherent stability of the orig inal design Genuine Yamaha Parts and Accessories are designed and tested to be compatible with your motorcycle Please consider Genu ine Yamaha Parts and Accessories before making a purchase Use of non Yamaha approved accessories or replacement parts may cause loss of handling stability and riding safety Since Yamaha cannot control the quality of accessories or parts manufactured by other companies Yamaha cannot be held liable for EWA10620 any consequences caused by the use of items which have not been approved by Yamaha 6 17 EAU22040 Adjusting the clutch lever free play 1 Locknut 2 Clutch lever free play adjusting bolt 3 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 turn the adjusting bolt in direction b PERIODIC MAINTENANCE AND MINOR REPAIR 7 Tighten the locknut at the clutch le ve
40. ent this from occurring the valve clearance must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart PERIODIC MAINTENANCE AND MINOR REPAIR EAU32520 Tires To maximize the performance durabil ity and safe operation of your motor cycle 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 e The tire air pressure must be checked and adjusted on cold tires i e when the temperature of the tires equals the ambient temperature e The tire air pressure must be ad justed in accordance with the riding speed and with the total weight of rider passenger car go and accessories approved for this model EWA10500 Tire air pressure measured on cold tires 0 90 kg 0 198 Ib Front 175 kPa 25 psi 1 75 kgf cm Rear 200 kPa 29 psi 2 00 kgf cm 90 195 kg 198 430 Ib CAL 90 196 kg 198 432 Ib U49 Front 200 kPa 29 psi 2 00 kgf cm Rear 225 kPa 33 psi 2 25 kgf cm Maximum load 195 kg 430 Ib CAL 196 kg 432 Ib U49 Total weight of rider passenger car go and accessories Proper loading of your vehicle is im portant for several characteristics of your vehicle such as handling braking performance and safety Do not carry loosely packed items that can shift Securely pack your heavi est items close to the cente
41. er toward the handle bar grip To engage the clutch release the lever The lever should be pulled rapidly and released slowly for smooth clutch operation The clutch lever is equipped with a clutch switch which is part of the igni tion circuit cut off system See page 3 11 INSTRUMENT AND CONTROL FUNCTIONS EAU12870 Shift pedal 1 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 EAU12890 Brake lever 1 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 3 4 EAU12941 Brake pedal 1 Brake pedal The brake pedal is on the right side of the motorcycle To apply the rear brake press down on the brake pedal EAU13040 Fuel tank cap 1 Fuel tank cap 2 Unlock To open the fuel tank cap Insert the key into the lock and turn it 1 4 turn clockwise The lock will be re leased and the fuel tank cap can be opened To close the fuel tank cap 1 Push 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 INSTRUMENT AND CONTROL FUNCTIONS NOTE The fuel tank cap cannot be closed un less the key is in the lock In addition the key cannot be r
42. ere 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 the fuel system or ve hicle performance problems 3 6 EAU13580 Fuel cock This model is equipped with a negative pressure fuel cock The fuel cock sup plies fuel from the tank to the carburetor while also filtering it The fuel cock lever positions are ex plained as follows and shown in the il lustrations ON 1 Arrow mark positioned over ON With the fuel cock lever in this position fuel flows to the carburetor when the engine is running Turn the fuel cock le ver to this position when starting the en gine and riding RES INSTRUMENT AND CONTROL FUNCTIONS PRI 1 Arrow mark positioned over RES This indicates reserve With the fuel cock lever in this position the fuel re serve is made available Quickly turn the fuel cock lever to this position if you run out of fuel while riding otherwise the engine may stall and will have to be primed see PRI After turning the fuel cock lever to RES refuel as soon as possible and be sure to turn the fuel cock lever back to ON 1 Arrow mark positioned over PRI This indicates prime With the fuel cock lever in this position the engine can be primed Turn th
43. estand down EWA10290 _ Turn the fuel cock lever to ON 2 Turn the key to ON and make sure that the engine stop switch is set to RUN 3 Shift the transmission into the neu tral position 5 1 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 7 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 Each starting attempt should be as short as possible to pre serve the battery Do not crank the en gine more than 10 seconds on any one attempt 6 After starting the engine move the starter choke back halfway ECA11130 CAUTION For maximum engine life always warm the engine up before starting off Never accelerate hard when the engine is cold 7 When the engine is warm turn the starter choke off NOTE The engine is warm when it responds normally to the throttle with the starter choke turned off To avoid the possi bility of excessive exhaust emissions never leave the starter choke on long er than necessary The time necessary for starter choke use depends upon the ambient temperature Tempera tures above 10 C 50 F require about 7 seconds of starter choke use a
44. f any device or element of design incorporated into any new ve hicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW These acts include tampering with the following systems i e modification removal etc Exhaust system e Muffler e Exhaust pipe e Silencer Intake system e Air cleaner case e Air cleaner element e Intake duct 9 4 CONSUMER INFORMATION EAU26611 Maintenance record Copies of work orders and or receipts for parts purchased and installed on your motorcycle will be required to document that maintenance has been completed in accordance with the emissions warranty The chart below is printed only as a reminder that maintenance work is required It is not acceptable proof of maintenance work Maintenance Date of interval service 600 mi 1000 km or 1 month 4000 mi 6000 km or 6 months 7000 mi 11000 km or 12 months 10000 mi 16000 km or 18 months 13000 mi 21000 km or 24 months 16000 mi 26000 km or 30 months 19000 mi 31000 km or 36 months 22000 mi 36000 km or 42 months 25000 mi 41000 km or 48 months Servicing dealer name and address Remarks Mileage CONSUMER INFORMATI
45. gt 3rd 20 km h 12 5 mi h 3rd 2nd 20 km h 12 5 mi h 2nd gt 1st 20 km h 12 5 mi h EAU16841 Engine break in There is never a more important period in the life of your engine than the period between 0 and 1600 km 1000 mi For this reason you should read the follow ing material carefully Since the engine is brand new do not put an excessive load on it for the first 1600 km 1000 mi The various parts in the engine wear and polish themselves to the correct operating clearances During this period prolonged full throt tle operation or any condition that might result in engine overheating must be avoided EAU17021 0 1000 km 0 600 mi Avoid prolonged operation above 1 3 throttle 1000 1600 km 600 1000 mi Avoid prolonged operation above 1 2 throttle OPERATION AND IMPORTANT RIDING POINTS ECA11281 CAUTION After 1000 km 600 mi of operation the engine oil must be changed and the oil filter cartridge or element re placed 1600 km 1000 mi and beyond The vehicle can now be operated nor mally ECA10270 CAUTION If any engine trouble should occur during the engine break in period immediately have a Yamaha dealer check the vehicle 5 4 EAU17200 Parking When parking stop the engine and then remove the key from the main switch e 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 e Do no
46. he periods listed immediately below Failure other than those resulting from defects in material or workman ship which arise solely as a result of owner abuse and or lack of proper maintenance are not covered by this warranty YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY ENGINE DISPLACEMENT 50cc to 169cc PERIOD 12 000 km 7 465 miles or five years whichever occurs first 170cc to 279cc 18 000 km 11 185 miles or five years whichever occurs first 280cc or over 30 000 km 18 641 miles or five years whichever occurs first YAMAHA MOTOR CORPORATION U S A MAKES NO OTHER WARRANTY OF ANY KIND EXPRESSED OR IMPLIED ALL IMPLIED WARRANTIES OF MER CHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS AND TIME LIMITS STATED IN THIS WARRANTY ARE HEREBY DISCLAIMED BY YAMAHA MOTOR COR PORATION U S A AND EXCLUDED FROM THIS WARRANTY SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU ALSO EXCLUDED FROM THIS WARRANTY ARE ANY IN CIDENTAL OR CONSEQUENTIAL DAMAGES INCLUD ING LOSS OF USE SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES SO THE ABOVE EXCLUSION MAY NOT APPLY TO YOU THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE YAMAHA MOTOR CORPORATION U S A P O Box 6555 Cypress Califor
47. i cense Make sure that you are qualified and that you only lend your motorcycle to other qualified op erators Know your skills and limits Staying within your limits may help you to avoid an accident We recommend that you prac tice riding your motorcycle where there is no traffic until you have become thoroughly famil iar with the motorcycle and all of its controls Many motorcycle accidents have been caused by error of the motor cycle operator A typical error made by the operator is veering wide on a turn due to EXCESSIVE SPEED or undercornering insuffi cient lean angle for the speed Always obey the speed limit and never travel faster than warrant ed by road and traffic conditions Always signal before turning or changing lanes Make sure that other motorists can see you The posture of the operator and passenger is important for proper control The operator should keep both hands on the handlebar and both feet on the operator foot rests during operation to main tain control of the motorcycle The passenger should always hold onto the operator seat strap or grab bar if equipped with both hands and keep both feet on the passenger footrests Never carry a passenger unless he or she can firmly place both feet on the passenger footrests Never ride under the influence of alcohol or other drugs A SAFETY INFORMATION This motorcycle is designed for on road use only therefore it is not suitable for
48. ift the transmission into first gear The neutral indicator light should go out 3 Open the throttle gradually and at the same time release the clutch lever slowly 4 At the recommended shift points shown in the following table close the throttle and at the same time quickly pull the clutch lever in 5 Shift the transmission into second gear Make sure not to shift the transmission into the neutral posi tion 6 Open the throttle part way and gradually release the clutch lever 7 Follow the same procedure when shifting to the next higher gear NOTE Always shift gears at the recommended shift points EAU16700 To decelerate 1 Apply both the front and the rear brakes to slow the motorcycle 2 Shift the transmission into first gear when the motorcycle reaches 20 km h 12 5 mi h If the engine is about to stall or runs very roughly pull the clutch lever in and use the brakes to stop the motorcycle 5 3 3 Shift the transmission into the neu tral position when the motorcycle is almost completely stopped The neutral indicator light should come on EAU16720 Recommended shift points The recommended shift points during acceleration and deceleration are shown in the table below Shift up points 1st 2nd 16 km h 9 9 mi h 2nd gt 3rd 24 km h 14 9 mi h 3rd 4th 32 km h 19 9 mi h 4th gt 5th 40 km h 24 9 mi h Shift down points 5th gt 4th 20 km h 12 5 mi h 4th
49. il 120 0 mm 4 72 in Front tire Type With tube Size 3 00 18 47P 8 Manufacturer model CHENG SHIN C 916 Rear tire Type With tube Size 130 90 15M C 66P Manufacturer model CHENG SHIN C 915 Loading Maximum load 195 kg 430 Ib CAL 196 kg 432 Ib U49 Total weight of rider passenger cargo and accessories Tire air pressure measured on cold tires Loading condition 0 90 kg 0 198 Ib Front 175 kPa 25 psi 1 75 kgf cm Rear 200 kPa 29 psi 2 00 kgf cm Loading condition 90 195 kg 198 430 Ib CAL 90 196 kg 198 432 Ib U49 Front 200 kPa 29 psi 2 00 kgf cm Rear 225 kPa 33 psi 2 25 kgf cm Front wheel Wheel type Spoke wheel Rim size 18x1 60 Rear wheel Wheel type Spoke wheel Rim size 15M C x MT2 75 Front brake Type Single disc brake 8 2 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 140 0 mm 5 51 in Rear suspension Type Swingarm Spring shock absorber type Coil spring oil damper Wheel travel 100 0 mm 3 94 in Electrical system Ignition system Transistorized coil ignition digital Charging system A C magneto Battery Model GM10 3A 2 Voltage capacity 12 V 10 0 Ah Headlight Bulb type Halogen bulb Bulb voltage wattage x quantity Headlight 12 V 6
50. ith a full tank of fuel This information will en able you to plan future fuel stops 3 2 EAU12341 Handlebar switches Left 1 Dimmer switch LIGHTS 2 Turn signal switch TURN 3 Horn switch HORN Right 1 Engine stop switch ENGINE STOP 2 Start switch START EAU12410 Dimmer switch LIGHTS Set the switch to HI for the high beam and to LO for the low beam EAU12440 Turn signal switch TURN To signal a right hand turn push this switch to the right To signal a left hand turn push this switch to the left When released the switch returns to the cen ter position To cancel the turn signal lights push the switch in after it has re turned to the center position EAU12510 Horn switch HORN Press this switch to sound the horn EAU12650 Engine stop switch ENGINE STOP Set this switch to RUN before starting the engine Set this switch to OFF 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 INSTRUMENT AND CONTROL FUNCTIONS ECA10050 CAUTION See page 5 1 for starting instruc tions prior to starting the engine 3 3 EAU12820 Clutch lever 1 Clutch lever The clutch lever is located at the left handlebar grip To disengage the clutch pull the lev
51. l enters the crankcase caning ihe air iiter elemen Thee air filter element should be cleaned 9 Start the engine and then letitidle at the intervals specified in the periodic for several minutes while checking maintenance and lubrication chart it for oil leakage If oil is leaking im Clean the air filter element more fre mediately turn the engine off and quently if you are riding in unusually check for the cause wet or dusty areas 10 Turn the engine off and then 1 Remove the bolts and loosen the check the oil level and correct it if air filter joint clamp screw necessary 1 Air filter joint clamp screw 2 Air filter case cover 3 Air filter case 2 Disconnect the hoses from the air filter case and then remove the air filter case 1 Bolt 1 Hose 2 Air filter case PERIODIC MAINTENANCE AND MINOR REPAIR 3 Remove the air filter case cover by 5 Remove the sponge material from 7 Pull the sponge material over the removing the screws the air filter element frame clean it air filter element frame with solvent and then squeeze the 8 Insert the element into the air filter remaining solvent out case and then tighten the wing nut ECA10480 CAUTION 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 o ment installed otherwise the 4 Remove the air filter element by E Bpongematha piston s
52. lose the lock cover 3 8 A AK 1 Projection 2 Seat holder 2 Place the rider seat in the original position and then tighten the bolts NOTE Make sure that the rider seat is properly secured before riding INSTRUMENT AND CONTROL FUNCTIONS EAU14280 Helmet holder 1 Helmet holder 2 Unlock To open the helmet holder insert the key into the lock and then turn the key as shown To lock the helmet holder place it in the original position and then remove the key Never ride with a helmet attached to the helmet holder since the helmet may hit objects causing loss of con trol and possibly an accident EWA10160 3 9 EAU14880 Adjusting the shock absorber assemblies A a b eedi 1 Spring preload adjusting ring 2 Position indicator Each shock absorber assembly is equipped with a spring preload adjust ing ring ECA10100 CAUTION Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings INSTRUMENT AND CONTROL FUNCTIONS EWA10210 Always adjust both shock absorber assemblies equally otherwise poor handling and loss of stability may result Adjust the spring preload as follows To increase the spring preload and thereby harden the suspension turn the adjusting ring on each shock ab sorber assembly in direction a To de crease the spring preload and thereby soften the suspension turn the adjust ing ring on each shock abs
53. nd temperatures below 10 C 50 F re quire about 35 seconds with the starter choke turned on then about 2 5 min utes with the starter choke in the half way position OPERATION AND IMPORTANT RIDING POINTS EAU16640 Starting a warm engine Follow the same procedure as for start ing a cold engine with the exception that the starter choke is not required when the engine is warm 5 2 EAU16671 Shifting 1 Shift pedal 2 Neutral position 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 OPERATION AND IMPORTANT RIDING POINTS ECA10260 CAUTION e Even with the transmission in the neutral position do not coast for long periods of time with the engine off and do not tow the motorcycle for long dis tances The transmission is properly lubricated only when the engine is running Inade quate lubrication may damage the transmission Always use the clutch while changing gears to avoid damag ing the engine transmission and drive train which are not designed to withstand the shock of forced shifting EAU16680 To start out and accelerate 1 Pull the clutch lever to disengage the clutch 2 Sh
54. ng and lubricating the throttle grip and cable 6 25 Checking and lubricating the brake and shift pedals 6 26 Checking and lubricating the brake and clutch levers 6 26 Checking and lubricating the sidestand asien 6 26 Checking the front fork 6 27 Checking the steering 4 6 27 Checking the wheel bearings 6 28 Battery arnoia 6 28 Replacing the fuses aeee 6 30 Replacing the headlight bulb 6 31 Supporting the motorcycle 6 32 Front wheel ccceeeeeeeeeeeees 6 33 Rear Wheel seceeesseeeeseeeeeeees 6 34 Troubleshooting seenen 6 36 Troubleshooting chart 6 37 MOTORCYCLE CARE AND STORAGE 7 1 CANO cic desde bes devices Ear E eas aiit 7 1 Storag sce eaten ere 7 3 SPECIFICATIONS eeeeeeeee 8 1 CONSUMER INFORMATION 9 1 Identification numbers sss 9 1 Reporting safety defects 9 3 Motorcycle noise regulation 9 4 Maintenance record seee 9 5 YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY scsecsssssseessssseseeeees 9 7 YAMAHA EXTENDED SERVICE VES E 20 ean 9 9 TABLE OF CONTENTS A SAFETY INFORMATION EAU10250 MOTORCYCLES ARE SINGLE TRACK VEHICLES THEIR SAFE USE AND OPERATION ARE DEPENDENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EX PERTISE OF THE OPERATOR EV ERY OPERATOR SHOULD KNOW
55. nia 90630 EAU26661 PP po gt OP Pp P WARRANTY QUESTIONS AND ANSWERS What costs are my responsibility during the warranty period The customer s responsibility includes all costs of normal maintenance services non warranty repairs accident and collision damages and oil oil filters air filters spark plugs and brake shoes What are some examples of abnormal strain neglect or abuse These terms are general and overlap each other in areas Specific examples include Running the machine out of oil sustained high rpm full throttle operating the machine with a broken or damaged part which causes another part to fail damage or failure due to improper or careless transportation and or tie down If you have any specific questions on operation or maintenance please contact your dealer for advice Does the warranty cover incidental costs such as towing or transportation due to a failure No The warranty is limited to repair of the machine itself May perform any or all of the recommended maintenance shown in the Owner s Manual instead of having the dealer do them Yes if you are a qualified mechanic and follow the procedures specified in the Owner s and Service Manual We do recommend however that items requiring special tools or equipment be done by Yamaha Motorcycle dealer Q Will the warranty be void or cancelled if do not operate or maintain my new motor PP cycle exactly as specified in the Owner s
56. nnections and correct the breather hose routing 6 29 1 Battery 2 Battery breather hose To store the battery 1 If the motorcycle will not be used for more than one month remove the battery fully charge it and then place it in a cool dry place If the battery will be stored for more than two months check the specif ic gravity of the electrolyte at least once a month and fully charge the battery whenever necessary Fully charge the battery before in stallation After installation make sure that the battery leads are properly con nected to the battery terminals and that the breather hose is properly routed in good condition and not obstructed ECA10600 CAUTION If the breather hose is positioned in such a way that the frame is ex posed to electrolyte or gas expelled from the battery the frame could suffer structural and external dam ages PERIODIC MAINTENANCE AND MINOR REPAIR EAU23600 Replacing the fuses 1 Main fuse 2 Signaling system fuse The main fuse and the signaling sys tem fuse holders are located under the rider seat See page 3 8 If a fuse is blown replace it as follows 1 Turn the key to OFF and turn off the electrical circuit in question 2 Remove the blown fuse and then install a new fuse of the specified amperage Specified fuses Main fuse 20 0A Signaling system fuse 10 0A 6 30 ECA10640 CAUTION Do not use a fuse
57. off The key can be removed INSTRUMENT AND CONTROL FUNCTIONS EAU10810 P Parking The taillight and position lights are on but all other electrical systems are off The key can be removed The key must be pushed in from the OFF position to be turned to P ECA11020 CAUTION Do not use the parking position for an extended length of time other wise the battery may discharge 3 1 EAU10980 Indicator lights 1 High beam indicator light HIGH BEAM 2 Neutral indicator light NEUTRAL 3 Turn signal indicator light TURN EAU11040 Turn signal indicator light TURN This indicator light flashes when the turn signal switch is pushed to the left or right EAU11070 Neutral indicator light NEUTRAL This indicator light comes on when the transmission is in the neutral position INSTRUMENT AND CONTROL FUNCTIONS EAU11090 High beam indicator light HIGH BEAM This indicator light comes on when the high beam of the headlight is switched on EAU11630 Speedometer unit 1 Odometer 2 Tripmeter 3 Tripmeter reset knob 4 Speedometer 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 w
58. off road use Protective apparel The majority of fatalities from motor cycle accidents are the result of head injuries The use of a safety helmet is the single most critical factor in the pre vention or reduction of head injuries e Always wear an approved helmet e Wear a face shield or goggles Wind in your unprotected eyes could contribute to an impairment of vision which could delay seeing a hazard The use of a jacket heavy boots trousers gloves etc is effective in preventing or reducing abrasions or lacerations e 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 e 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 motorcycle 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 possibility of an accident use ex treme caution when adding ca
59. orber as sembly in direction b NOTE Align the appropriate notch in the ad justing ring with the position indicator on the shock absorber Spring preload setting Minimum soft 1 Standard 2 Maximum hard 5 EAU15300 Sidestand The sidestand is located on the left side of the frame Raise the sidestand or lower it with your foot while holding the vehicle upright NOTE The built in sidestand switch is part of the ignition circuit cut off system which cuts the ignition in certain situations See further down for an explanation of the ignition circuit cut off system The vehicle must not be ridden with the sidestand down or if the side stand cannot be properly moved up or does not stay up otherwise the sidestand could contact the ground and distract the operator resulting in a possible loss of control Yamaha s ignition circuit cut off system has been designed to assist the operator in fulfilling the respon sibility of raising the sidestand be fore starting off Therefore check this system regularly as described EWA10240 3 10 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 prevents starting when the trans mission is in gear and the side stand is up but the clu
60. pedal free play adjusting nut EWA10680 e After adjusting the drive chain slack or removing and installing the rear wheel always check the brake pedal free play PERIODIC MAINTENANCE AND MINOR REPAIR If proper adjustment cannot be obtained as described have a Yamaha dealer make this ad justment e After adjusting the brake pedal free play check the operation of the brake light 6 20 EAU22270 Adjusting the rear brake light switch Oo Ly LA W 1 Rear brake light switch 2 Rear brake light switch adjusting nut 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 on later turn the adjusting nut in direction b PERIODIC MAINTENANCE AND MINOR REPAIR 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 and lubrication chart EAU22420 Front brake pads A 1 Brake pad wear indicator groove Each front brake pad is provided with a wear indicator groove which allows you to check the brake pad wear with out having to disas
61. peed Exhaust system e Check for leakage e Tighten if necessary e Replace gasket s if necessary Evaporative emis sion control system For California only Since these items require special tools data and technical skills have a Yamaha dealer perform the service e Check control system for dam age e Replace if necessary 6 3 PERIODIC MAINTENANCE AND MINOR REPAIR General maintenance and lubrication chart ROUTINE INITIAL ODOMETER READINGS EAU32161 600 mi 1 month 4000 mi 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 Air filter element e Clean with solvent e Replace if necessary Ni Ni Ni Ni Battery e Check specific gravity and breath er hose for proper operation Ni NI Clutch e Check operation e Adjust or replace cable Front brake e Check operation fluid level and for fluid leakage e Replace brake pads if necessary Rear brake e Check operation e Adjust cable and replace brake shoes if necessary Ni Brake hose e Check for cracks or damage Ni Ni e Replace Every 4 years e Check runout spoke tightness and for damage e Tighten spokes if necessary Ni Ni e Check tread depth and for dam age e Replace if necessary e Check air
62. ppage or breakage To prevent this from occurring keep the drive chain slack within the specified limits 5 Tighten the locknuts and then tighten the axle nut to the specified torque Tightening torque Axle nut 104 Nm 10 4 m kgf 75 ft lbf 6 Insert a new cotter pin into the axle nut and then bend its ends as shown 1 Cotter pin NOTE Make sure that two notches in the axle nut are aligned with the hole through the wheel axle otherwise further tight en the axle nut until they are Always use a new cotter pin for the axle nut EWA10700 PERIODIC MAINTENANCE AND MINOR REPAIR 7 Adjust the brake pedal free play See page 6 19 After adjusting the brake pedal free play check the operation of the brake light EWA10660 6 24 EAU23020 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 ECA10580 CAUTION The drive chain must be lubricated after washing the motorcycle or riding in the rain 1 Clean the drive chain with kero sene and a small soft brush ECA11120 CAUTION 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 lubric
63. r element The engine oil level should be checked before each ride In addition the oil must be changed and the oil filter ele ment replaced at the intervals specified in the periodic 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 up when checking the oil level A slight tilt to the side can result in a false reading 2 Start the engine warm it up for several minutes and then turn it off 3 Wait afew minutes until the oil set tles and then check the oil level through the check window located at the bottom right side of the crankcase PERIODIC MAINTENANCE AND MINOR REPAIR NOTE The engine oil should be between the minimum and maximum level marks 1 Engine oil level check window 2 Maximum level mark 3 Minimum level mark 4 If the engine oil is below the mini mum level mark add sufficient oil of the recommended type to raise it to the correct level To change the engine oil with or without oil filter element replace ment 1 Start the engine warm it up for several minutes and then turn it off 6 10 2 Place an oil pan under the engine to collect the used oil 3 Remove the engine oil filler cap and drain bolt to drain the oil from the crankcase yaa 1 Engine oil filler cap 1 Engine oil drain bolt PERIODIC MA
64. r and the crankcase EAU22091 Adjusting the brake lever free play 3 If the specified clutch lever free play could be obtained as de scribed above tighten the locknut and skip the rest of the procedure otherwise proceed as follows 4 Fully turn the adjusting bolt at the clutch lever in direction a to loos en the clutch cable 5 Loosen the locknut at the crank case 1 Locknut 2 Brake lever free play adjusting bolt 3 Brake lever free play S The brake lever free play should mea sure 2 0 5 0 mm 0 08 0 20 in as shown Periodically check the brake le ver free play and if necessary adjust it 1 Locknut as follows 2 Clutch lever free play adjusting nut 1 Loosen the locknut at the brake le crankcase ver 6 To increase the clutch lever free 2 To increase the brake lever free play turn the adjusting nut in direc tion a To decrease the clutch le ver free play turn the adjusting nut in direction b 6 18 3 play turn the adjusting bolt in di rection a To decrease the brake lever free play turn the adjusting bolt in direction b Tighten the locknut PERIODIC MAINTENANCE AND MINOR REPAIR EWA10630 e After adjusting the brake lever free play check the free play and make sure that the brake is working properly e 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
65. r of the vehicle and distribute the weight evenly from side to side Properly adjust the suspension for your load EWA10510 6 15 and check the condition and pres sure of your tires NEVER OVER LOAD YOUR VEHICLE Make sure that the total weight of the cargo rid er passenger and accessories cowling saddlebags etc if ap proved for this model does not ex ceed the maximum load of the vehicle Operation of an overloaded vehicle could cause tire damage an accident or even injury Tire inspection Ye 2 1 Tire sidewall 2 Tire wear indicator 3 Tire tread depth Always check the tires before operating the motorcycle If a tire tread shows crosswise lines minimum tread depth if the tire has a nail or glass fragments in it or if the sidewall is cracked con tact a Yamaha dealer immediately and have the tire replaced Minimum tire tread depth front and rear 1 0 mm 0 04 in 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 e 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 It is not recommended to patch a punctured tube If unavoid able however patch the tube very carefully and replace it as soon as possible with a high quality product
66. rake and clutch levers should be checked before each ride and the lever pivots should be lu bricated if necessary Recommended lubricant Lithium soap based grease all pur pose grease Recommended lubricant Lithium soap based grease all pur pose grease 6 26 EAU23200 Checking and lubricating the sidestand The operation of the sidestand should be checked before each ride and the sidestand pivot and metal to metal contact surfaces should be lubricated if necessary If the sidestand does not move up and down smoothly have a Yamaha dealer check or repair it EWA10730 Recommended lubricant Lithium soap based grease all pur pose grease PERIODIC MAINTENANCE AND MINOR REPAIR EAU23271 Checking the front fork The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic main tenance and lubrication chart To check the condition Securely support the vehicle so that there is no danger of it falling over EWA10750 Check the inner tubes for scratches damage and excessive oil leakage 6 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 times to check if the front fork compresses and rebounds smoothly ECA10590 CAUTION If any damage is found or the front fork does not operate smoothly have a Yamaha
67. raking perfor mance Recommended brake fluid DOT 4 e Refill with the same type of brake fluid Mixing fluids may result in a harmful chemical reaction and lead to poor braking performance e Be careful that water does not en ter the brake fluid reservoir when refilling Water will significantly lower the boiling point of the fluid and may result in vapor lock e Brake fluid may deteriorate paint ed surfaces or plastic parts Al ways clean up spilled fluid immediately e 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 PERIODIC MAINTENANCE AND MINOR REPAIR EAU22720 Changing the brake fluid Have a Yamaha dealer change the 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 6 22 EAU22760 Drive chain slack The drive chain slack should be checked before each ride and adjusted if necessary EAU22770 To check the drive chain slack 1 Place the motorcycle on a level surface and hold it in an upright po sition NOTE When checking and adjusting the drive chain
68. ratched use a quality plastic polishing compound after washing MOTORCYCLE CARE AND STORAGE After normal use Remove dirt with warm water a mild detergent and a soft clean sponge and then rinse thoroughly with clean water Use a toothbrush or bottlebrush for hard to reach areas Stubborn dirt and insects will come off more easily if the area is covered with a wet cloth for a few minutes before cleaning After riding in the rain near the sea or on salt sprayed roads Since sea salt or salt sprayed on roads during winter are extremely corrosive in combination with water carry out the following steps after each ride in the rain near the sea or on salt sprayed roads NOTE Salt sprayed on roads in the winter may remain well into spring 1 Clean the motorcycle with cold wa ter and a mild detergent after the engine has cooled down ECA10790 CAUTION Do not use warm water since it in creases the corrosive action of the salt 2 After drying the motorcycle apply a corrosion protection spray on all metal including chrome and nick el plated surfaces to prevent cor rosion After cleaning 1 Dry the motorcycle with a chamois or an absorbing 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 stainless steel parts including the exhaust system Even the thermally in duced discoloring of stainless
69. rgo or accessories to your motorcycle Use extra care when riding a motorcycle that has added cargo or accessories Here are some general guidelines to follow if loading cargo or adding acces sories to your motorcycle A SAFETY INFORMATION Loading The total weight of the operator pas senger accessories and cargo must not exceed the maximum load limit of 195 kg 430 Ib CAL 196 kg 432 Ib U49 When loading within this weight limit keep the following in mind Cargo and accessory weight should be kept as low and close to the motorcycle as possible Make sure to distribute the weight as evenly as possible on both sides of the motorcycle to minimize imbal ance or instability Shifting weights can create a sud den imbalance Make sure that ac cessories and cargo are securely attached to the motorcycle before riding Check accessory mounts and cargo restraints frequently e Never attach any large or heavy items to the handlebar front fork or front fender These items in cluding such cargo as sleeping bags duffel bags or tents can create unstable handling or slow steering response Accessories Genuine Yamaha accessories have been specifically designed for use on this motorcycle Since Yamaha cannot test all other accessories that may be available you must personally be re sponsible for the proper selection in stallation and use of non Yamaha accessories Use extreme caution when selecting and in
70. ry e Check fluid level in reservoir e If necessary add recommended brake fluid to specified level e Check hydraulic system for leakage 6 18 6 21 6 21 Rear brake e Check operation e Check pedal free play e Adjust if necessary Clutch e Check operation e Lubricate cable if necessary e Check lever free play e Adjust if necessary Throttle grip e Make sure that operation is smooth e Check cable free play e If necessary have Yamaha dealer adjust cable free play and lubricate cable and grip housing 6 14 6 25 Control cables e Make sure that operation is smooth e Lubricate if necessary 4 2 PRE OPERATION CHECKS CHECKS PAGE Drive chain e Check chain slack e Adjust if necessary e Check chain condition e Lubricate if necessary 6 22 6 24 Wheels and tires e Check for damage e Check tire condition and tread depth e Check air pressure e Correct if necessary Brake and shift pedals e Make sure that operation is smooth e Lubricate pedal pivoting points if necessary Brake and clutch levers e Make sure that operation is smooth e Lubricate lever pivoting points if necessary Sidestand e Make sure that operation is smooth e Lubricate pivot if necessary Chassis fasteners e Make sure that all nuts bolts and screws are properly tightened e Tighten if necessary Instruments lights signals and switches e Che
71. s s s 6 28 Wheel front eeeeseeesseseseesseeseeeoeee 6 33 Wheel rear 6 34 INDEX See your Authorized YAMAHA Dealer for a Genuine YAMAHA Service Manual PRINTED IN JAPAN 2003 06 0 4x1 CR E
72. semble the brake To check the brake pad wear check the wear indicator groove If a brake pad has worn to the point that the wear indicator groove has almost disap peared have a Yamaha dealer replace the brake pads as a set EAU22540 Rear brake shoes O 3 1 Brake shoe wear indicator 2 Brake shoe wear limit line The rear brake is provided with a wear indicator which allows you to check the brake shoe wear without having to dis assemble the brake To check the brake shoe wear check the position of the wear indicator while applying the brake If a brake shoe has worn to the point that the wear indicator reaches the wear limit line have a Yamaha dealer replace the brake shoes as a set 6 21 Checking the brake fluid level Front brake 1 Minimum level mark 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 sure to check the brake pads for wear and the brake system for leakage Observe these precautions When checking the fluid level make sure that the top of the brake fluid reservoir is level Use only the recommended quality brake fluid otherwise the rubber seals may deteriorate causing leakage and poor b
73. sfaction You get uninterrupted factory backed coverage for extra peace of mind e Y E S is flexible You choose the plan that s right for you 12 months 24 months 36 months or on certain models even 48 months beyond your warranty period e Y E S is designed and administered by the same Yamaha people who handle your warranty and it shows in the comprehensive coverage benefits There are no mileage limitations Coverage isn t limited to moving parts or the drive train like many other plans And Y E S covers manufacturing defects just like the warranty See the sample contract at your Yamaha dealer to see how comforting uninterrupted factory backed protection can be e You don t have to pay anything for covered repairs There s no deductible to pay and repairs aren t pro rated You don t have any out of pocket expenses for covered repairs 9 9 e In addition Travel and Recreation Interruption Protection TRIP is included at no extra cost TRIP gives you up to 150 reimbursement per occurrence for any reasonable expenses you incur because your Yamaha needs covered service replacement vehicle rental emergency 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 e Y E S coverage is honored at any authori
74. sive car bon or other deposits and replace it if necessary Specified spark plug NGK C6HSA DENSO U20FS U To install a spark plug 1 Measure the spark plug gap with a wire thickness gauge and if nec essary adjust the gap to specifica tion 1 Spark plug gap Spark plug gap 0 6 0 7 mm 0 024 0 028 in PERIODIC MAINTENANCE AND MINOR REPAIR 2 Clean the surface of the spark plug f i F EAU 19880 Make sure that the canister breath gasket and its mating surface and Canister for California only er is not blocked and if necessary then wipe off any grime from the clean it spark plug threads 3 Install the spark plug with the spark plug wrench and then tight en it to the specified torque Tightening torque Spark plug 12 5 Nm 1 25 m kgf 9 0 ft Ibf NOTE If a torque wrench is not available when installing a spark plug a good estimate 6 of the correct torque is 1 4 1 2 turn past finger tight However the spark 4 Canister cover plug should be tightened to the speci gt Canister breather fied torque as soon as possible 3 Canister 4 Install the spark plug cap This model is equipped with a canister to prevent the discharging of fuel vapor into the atmosphere Before operating this vehicle make sure to check the fol lowing Check each hose connection Check each hose and canister for cracks or damage Replace if dam aged 6 9 EAU19751 Engine oil and oil filte
75. slack the motorcycle should be positioned straight up and there should be no weight on it 2 Shift the transmission into the neu tral position 3 Move the rear wheel by pushing the motorcycle to locate the tight est portion of the drive chain and then measure the drive chain slack as shown Drive chain slack 30 0 40 0 mm 1 18 1 57 in PERIODIC MAINTENANCE AND MINOR REPAIR 1 Drive chain slack 4 lf the drive chain slack is incorrect adjust it as follows 6 To adjust the drive chain slack 1 Loosen the brake pedal free play adjusting nut 1 Brake pedal free play adjusting nut 2 Remove the cotter pin from the axle nut and then loosen the axle nut 3 Loosen the chain puller locknut at each end of the swingarm 4 To tighten the drive chain turn the adjusting nut at each end of the swingarm in direction a To loos en the drive chain turn the adjust ing nut at each end of the swingarm in direction b and then push the rear wheel forward NOTE Using the alignment marks on each side of the swingarm make sure that both chain pullers are in the same posi tion for proper wheel alignment 6 23 Axle nut 1 2 Cotter pin 3 Chain puller locknut 4 Drive chain slack adjusting nut 5 Alignment marks ECA10570 CAUTION Improper drive chain slack will over load the engine as well as other vital parts of the motorcycle and can lead to chain sli
76. stalling any ac cessories Keep the following guidelines in mind as well as those provided under Load ing when mounting accessories e Never install accessories or carry cargo that would impair the perfor mance of your 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 e 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 1 3 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 become un stable in cross winds These ac cessories may also cause instability when passing or being passed by large vehicles e Certain accessories can dis place the operator from his or her normal riding position This improper position limits the free dom of movement of the opera tor and may limit control ability therefore such accessories are not recommended Use caution when adding electri cal accessories If electrical acces sories exceed the capacity of the motorcycle s electrical
77. stance please write YAMAHA MOTOR CORPORATION U S A CUSTOMER RELATIONS DEPARTMENT P O Box 6555 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 recall This list is compiled from the purchase registrations sent to Yamaha Motor Corporation U S A by the selling dealer at the time of your purchase If you should move after you have purchased your new motorcycle please advise us of your new address by sending a postcard listing your motorcycle model name V I N frame number dealer number or dealer s name as it is shown on your warranty card your name and new mailing address Mail to YAMAHA MOTOR CORPORATION U S A P O Box 6555 Cypress California 90630 Attention Warranty Department This will ensure that Yamaha Motor Corporation U S A has an up to date registration record in accordance with federal law CONSUMER INFORMATION YAMAHA EXTENDED SERVICE Y E S Keep your Yamaha protected even after your warranty expires with genuine Yamaha Extended Service Y E S e Y E S is designed and administered by Yamaha Motor Corporation to provide maximum owner sati
78. system an electric failure could result which could cause a dangerous loss of lights or engine power A SAFETY INFORMATION Do not park the motorcycle on a Gasoline and exhaust gas GASOLINE IS HIGHLY FLAMMA slope or soft ground otherwise it BLE may fall over e Always turn the engine off when Do not park the motorcycle near Ee refueling Take care not to spill any gaso line on the engine or exhaust system when refueling Never refuel while smoking or in the vicinity of an open flame Never start the engine or let it run for any length of time in a closed area The exhaust fumes are poi sonous and may cause loss of consciousness and death within a short time Always operate your motorcycle in an area that has ad equate ventilation Always turn the engine off before leaving the motorcycle unattended and remove the key from the main switch When parking the motor cycle note the following e The engine and exhaust system may be hot therefore park the motorcycle in a place where pe destrians or children are not like ly to touch these hot areas a flammable source e g a kero sene 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 the fuel cock is turned to ON or RES for vacuum type OFF for manual type If it should lean over gaso line may leak out of the carb
79. t park ona slope or on soft ground otherwise the vehicle may overturn EWA10310 PERIODIC MAINTENANCE AND MINOR REPAIR EAU17231 Safety is an obligation of the owner Pe riodic inspection adjustment and lubri cation will keep your vehicle in the safest and most efficient condition pos sible The most important points of motorcycle inspection adjustment and lubrication are explained on the follow ing pages Maintenance replacement or repair of the emission control devices and systems may be performed by any repair establishment or individual that is certified if applicable EWA10320 A WARNING If you are not familiar with mainte nance work have a Yamaha dealer do it for you EAU17300 PERIODIC MAINTENANCE PROPER PERIODIC MAINTENANCE OF YOUR MOTORCYCLE IS IMPOR TANT IN ORDER TO ENJOY LONG PLEASURABLE SERVICE ESPE CIALLY IMPORTANT ARE THE MAIN TENANCE SERVICES RELATED TO EMISSIONS CONTROL THESE CONTROLS NOT ONLY FUNCTION TO ENSURE CLEANER AIR BUT ARE ALSO VITAL TO PROPER EN GINE OPERATION AND MAXIMUM PERFORMANCE IN THE FOLLOW ING PERIODIC MAINTENANCE CHARTS THE SERVICES RELATED TO EMISSIONS CONTROL ARE GROUPED SEPARATELY THESE SERVICES REQUIRE SPECIALIZED DATA KNOWLEDGE AND EQUIP MENT YAMAHA DEALERS ARE TRAINED AND EQUIPPED TO PER FORM THESE PARTICULAR SER VICES 6 1 EAU17310 Owner s tool kit 1 Owner s tool kit The service information included in this manual and th
80. tch 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 Itcuts 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 If a malfunction is noted have a Yamaha dealer check the system be fore riding EWA10250 INSTRUMENT AND CONTROL FUNCTIONS 3 11 With the engine turned off 1 Move the sidestand down 2 Make sure that the engine stop switch is turned on 3 Turn the key on 4 Shift the transmission into the neutral position 5 Push the start switch Does the engine start With the engine still running 6 Move the sidestand up 7 Keep the clutch lever pulled 8 Shift the transmission into gear 9 Move the sidestand down Does the engine stall INSTRUMENT AND CONTROL FUNCTIONS NOTE This check is most reliable if performed with a warmed up engine 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 3 12 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
81. ting Brake pads and shoes checking Brake pedal eseseseeeerreeieerrerrerrrernenne Brake pedal position and free play adjusting eeeeeeeeeeeeeereeereerrerrerrnereens 6 19 c Cables checking and lubricating 6 25 Canister for California only 0 6 9 Carburetor adjusting ee 6 14 Care woe eee wT Clutch lever ceeecesseesnereeseeees i 3 3 Clutch lever free play adjusting 6 17 D Dimmer SWitCH o oo eee eee 3 3 Drive chain lubricating 6 24 Drive chain slack 6 22 E Engine break in eee Engine oil and oil filter element A Engine starting a Warm ee Engine stop sWitch eee eee F Front fork checking 6 27 Fuel tank cap oo eee cece eeteeeeneeeeees 3 5 Fuses replacing s es 6 30 H Handlebar switches eee Headlight bulb replacing Helmet holder 0 0 eee eeeeeeeeeeeeees High beam indicator light Horn Swithin l Identification NUMbeTrS sses 9 1 Ignition circuit cut off system 3 11 Indicator lights sesser 3 1 K Key identification number 9 1 L Labels location Of ccccccesseeeeeeeees 1 5 M Main SWItCH eee eeeereeeeeeeeeee 3 1 Maintenance and lubrication periodic 6 4 Maintenance emission control system 6 3 Maintenance periodic cee 6 1 Maintenance record wa 9 5 Model label cccceeceeeeeeeeeeeeeeeeeeeeeees 9 2 N Neutral indica
82. tor light Noise regulation P Parking ieioea eaea Part locationS 04 Pre operation check list R Rear brake light switch adjusting Rider seat sesseeseeesrrreresrirerirreeerrreeses S Safety defects reporting 9 3 Safety information cee eee eee 1 1 Shifting se scic sets tees athe Saipa aaa 5 2 Shift padal vi teniseri andris 3 4 Shock absorber assemblies adjusting 3 9 Sidestand s eseeessesessrreseserreeesrusrersrnseene 3 10 Sidestand checking and lubricating 6 26 Spark plugs checking eee eee 6 8 Specifications a 8 1 Speedometer unit wi 2 Starter choke lever 3 7 Starting and warming up a cold ON GING i ccsccndesetstisensdeneesersedtecdenttarsevrenpde 5 1 Start switch 3 3 Steering checking 6 27 Steering lOCK ec ceeecesesseeesreeeneesseeeees 3 8 Storage ipo airaa a raa aanak 7 3 Supporting the motorcycle 6 32 T Throttle cable free play adjusting 6 14 Throttle grip and cable checking and l bricating snnnd dierees 6 25 Tires 6 15 Tool Kit we 6 1 Troubleshooting 6 36 Troubleshooting chart 6 37 Turn signal indicator light 0 3 1 Turn signal SWitCh oo cee 3 3 V Valve clearance adjusting 0 6 14 Vehicle identification number 9 1 Ww Warranty extended Warranty limited wed Wheel bearings checking
83. uretor or fuel tank If you should swallow any gaso line inhale a lot of gasoline vapor or allow gasoline to get into your eyes see your doctor immediately If any gasoline spills on your skin or clothing immediately wash the affected area with soap and water and change your clothes A SAFETY INFORMATION EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle 1 5 A SAFETY INFORMATION 4 California only AWARNING BEFORE YOU OPERATE THIS VEHICLE READ THE OWNER S MANUAL AND ALL LABELS EMISSION HOSE ROUTING ALWAYS WEAR AN APPROVED MOTORCYCLE HELMET eye protection and protective clothing SGK 2118K 00 FROM FUEL_TANK CAUTION Read owner s manual before servicing battery Electrolyte will damage metal parts or paint CANISTER If electrolyte spills wash area with fresh TO ATMOSPHERE water immediately Be sure to connect breather hose after installing battery 4YN 21686 00 3JL 28177 A0 TIRE INFORMATION Cold tire normal pressure should be set as follows Up to 90 kg 198 Ibs load FRONT 175 kPa 1 75 kgf cm 25 psi AIR FILTER REAR 200 kPa 2 00 kgf crn2 29 psi 90 kg 198 Ibs maximum load FRONT 200 kPa 2 00 kgf cm 29 psi 3BG 21684 A0 REAR 225 kPa 2 25 kgf cm 33 psi 3CK 21668 A0 j DESCRIPTION Left view OANDOABRWND CNS Headlight page 6 31 1
84. zed Yamaha dealer nationwide e 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 excellent Y E S plan coverage is only available to Yamaha owners like you and only while your Yamaha is still within the Yamaha Limited Warranty period So visit your authorized Yamaha dealer to get all the facts He can show you how easy it is to protect your investment with Yamaha Extended Service EAU26750 We urge you to act now You ll get the excellent benefits of TRIP coverage right away and you ll rest easy knowing you ll have strong factory backed protection even after your Yamaha Limited Warranty expires A special note If visiting your dealer isn t convenient contact Yamaha with your Primary ID number your frame number We ll be happy to help you get the Y E S coverage you need Yamaha Service Marketing P O Box 6555 Cypress CA 90630 1 866 YES EXTD 1 866 937 3983 9 10 CONSUMER INFORMATION Y YAMAHA EXTENDED SERVICE INDEX A Accessories and replacement parts 6 17 Air filter element cleaning 02 6 12 B TEIA EAEE NEE A EE ETAT 6 28 Brake and clutch levers checking and l bricating siina 6 26 Brake and shift pedals checking and lubricating iit ccteca cv eeveetssere entirety Brake fluid changing s es Brake fluid level checking Brake leVer ue ee eects eee eeee Brake lever free play adjus

Yamaha 2004 Virago 250 Owner's Manual

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