Read this manual carefully before operating this vehicle.
U46B12E0.book Page 1 Friday, May 14, 2010 3:57 PM EAU10042 Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold.
U46B12E0.book Page 1 Friday, May 14, 2010 3:57 PM INTRODUCTION EAU10083 Congratulations on your purchase of the Yamaha XV250A1(C). This model is the result of Yamaha’s vast experience in the production of fine sporting, touring, and pacesetting racing machines. It represents 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.
U46B12E0.book Page 1 Friday, May 14, 2010 3:57 PM IMPORTANT MANUAL INFORMATION EAU10132 Particularly important information is distinguished in this manual by the following notations: This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. WARNING NOTICE TIP A WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.
U46B12E0.book Page 2 Friday, May 14, 2010 3:57 PM IMPORTANT MANUAL INFORMATION EAU10193 XV250A1(C) OWNER’S MANUAL ©2010 by Yamaha Motor Corporation, U.S.A. 1st edition, May 2010 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.
U46B12E0.book Page 1 Friday, May 14, 2010 3:57 PM TABLE OF CONTENTS LOCATION OF IMPORTANT LABELS .............................................1-1 FOR YOUR SAFETY – PRE-OPERATION CHECKS ............. 5-1 SAFETY INFORMATION ..................2-1 OPERATION AND IMPORTANT RIDING POINTS................................. 6-1 Starting and warming up a cold engine ......................................... 6-1 Starting a warm engine .................. 6-2 Shifting ...........................................
U46B12E0.book Page 2 Friday, May 14, 2010 3:57 PM TABLE OF CONTENTS Battery ..........................................7-30 Replacing the fuses ......................7-32 Replacing the headlight bulb ........7-33 Replacing the tail/brake light bulb ...........................................7-34 Replacing a turn signal light bulb ...........................................7-35 Supporting the motorcycle ............7-35 Front wheel ...................................7-36 Rear wheel ..........................
U46B12E0.book Page 1 Friday, May 14, 2010 3:57 PM LOCATION OF IMPORTANT LABELS EAU10384 1 Read and understand all of the labels on your vehicle. They contain important information for safe and proper operation of your vehicle. Never remove any labels from your vehicle. If a label becomes difficult to read or comes off, a replacement label is available from your Yamaha dealer.
U46B12E0.book Page 2 Friday, May 14, 2010 3:57 PM LOCATION OF IMPORTANT LABELS 1 2 4 California only 5 California only NOTICE 10D-2815N-00 3 Cold tire normal pressure should be set as follows. 175 200 1.75 2.00 25 29 200 225 2.00 2.
U46B12E0.book Page 1 Friday, May 14, 2010 3:57 PM SAFETY INFORMATION EAU10287 2 Be a Responsible Owner As the vehicle’s owner, you are responsible for the safe and proper operation of your motorcycle. Motorcycles are single-track vehicles. Their safe use and operation are dependent upon the use of proper riding techniques as well as the expertise of the operator. Every operator should know the following requirements before riding this motorcycle.
U46B12E0.book Page 2 Friday, May 14, 2010 3:57 PM SAFETY INFORMATION ● ● due to excessive speed or undercornering (insufficient lean angle for the speed). • Always obey the speed limit and never travel faster than warranted 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.
U46B12E0.book Page 3 Friday, May 14, 2010 3:57 PM SAFETY INFORMATION ● ● 2 Do not run engine in poorly ventilated or partially enclosed areas such as barns, garages, or carports. Do not run engine outdoors where engine exhaust can be drawn into a building through openings such as windows and doors. Loading Adding accessories or cargo to your motorcycle can adversely affect stability and handling if the weight distribution of the motorcycle is changed.
U46B12E0.book Page 4 Friday, May 14, 2010 3:57 PM SAFETY INFORMATION modifications not specifically recommended by Yamaha, even if sold and installed by a Yamaha dealer. Aftermarket Parts, Accessories, and Modifications While you may find aftermarket products similar in design and quality to genuine Yamaha accessories, recognize that some aftermarket accessories or modifications are not suitable because of potential safety hazards to you or others.
U46B12E0.book Page 5 Friday, May 14, 2010 3:57 PM SAFETY INFORMATION ● ● 2 ● ● ● Check that the fuel cock (if equipped) is in the “OFF” position and that there are no fuel leaks. Point the front wheel straight ahead on the trailer or in the truck bed, and choke it in a rail to prevent movement. Shift the transmission in gear (for models with a manual transmission).
U46B12E0.book Page 1 Friday, May 14, 2010 3:57 PM DESCRIPTION EAU10410 Left view 3 1. 2. 3. 4. 5. 6. 7. 8. 9. Fuel cock (page 4-7) 10.
U46B12E0.book Page 2 Friday, May 14, 2010 3:57 PM DESCRIPTION EAU10420 Right view 3 1. 2. 3. 4. 5. 6. 7. 8. 9. Owner’s tool kit (page 7-2) 10.
U46B12E0.book Page 3 Friday, May 14, 2010 3:57 PM DESCRIPTION EAU10430 Controls and instruments 3 1. 2. 3. 4. 5. 6. 7. 8.
U46B12E0.book Page 1 Friday, May 14, 2010 3:57 PM INSTRUMENT AND CONTROL FUNCTIONS EAU10450 Main switch EWA10072 EAU10981 Indicator lights WARNING Never turn the key to “OFF” while the vehicle is moving, otherwise the electrical systems will be switched off, which may result in loss of control or an accident. EAU10810 4 The main switch controls the ignition and lighting systems. The various main switch positions are described below.
U46B12E0.book Page 2 Friday, May 14, 2010 3:57 PM 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 EAU12348 Handlebar switches Left 4 1. 2. 3. 4. Odometer Tripmeter Tripmeter reset knob 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.
U46B12E0.book Page 3 Friday, May 14, 2010 3:57 PM INSTRUMENT AND CONTROL FUNCTIONS EAU12410 EAU12691 Dimmer switch “LIGHTS” Set the switch to “HI” for the high beam and to “LO” for the low beam. Start switch “START” Push this switch to crank the engine with the starter. See page 6-1 for starting instructions prior to starting the engine. EAU12440 4 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.
U46B12E0.book Page 4 Friday, May 14, 2010 3:57 PM INSTRUMENT AND CONTROL FUNCTIONS EAU12871 EAU12890 EAU12941 Shift pedal Brake lever Brake pedal 1. Shift pedal 1. Brake lever 1. Brake pedal The shift pedal is located on the left side of the motorcycle and is used in combination with the clutch lever when shifting the gears of the 5-speed constant-mesh transmission equipped on this motorcycle. The brake lever is located at the right handlebar grip.
U46B12E0.book Page 5 Friday, May 14, 2010 3:57 PM INSTRUMENT AND CONTROL FUNCTIONS EAU13041 Fuel tank cap EAU13212 TIP The fuel tank cap cannot be closed unless the key is in the lock. In addition, the key cannot be removed if the cap is not properly closed and locked. EWA11091 WARNING Make sure that the fuel tank cap is properly closed after filling fuel. Leaking fuel is a fire hazard. 4 1. Fuel tank cap 2. Unlock. Fuel Make sure there is sufficient gasoline in the tank.
U46B12E0.book Page 6 Friday, May 14, 2010 3:57 PM INSTRUMENT AND CONTROL FUNCTIONS 1 ately. If gasoline spills on your skin, wash with soap and water. If gasoline spills on your clothing, change your clothes. 2 EAU13313 1. Fuel tank filler tube 2. Maximum fuel level 3. Wipe up any spilled fuel immediately. NOTICE: Immediately wipe off spilled fuel with a clean, dry, soft cloth, since fuel may deteriorate painted surfaces or plastic parts. [ECA10071] 4. Be sure to securely close the fuel tank cap.
U46B12E0.book Page 7 Friday, May 14, 2010 3:57 PM INSTRUMENT AND CONTROL FUNCTIONS EAU13581 Fuel cock PRI RES This model is equipped with a negative pressure fuel cock. The fuel cock supplies fuel from the tank to the carburetor while also filtering it. The fuel cock lever positions are explained as follows and shown in the illustrations. 4 1 1 ON 1 1. Arrow mark positioned over “ON” With the fuel cock lever in this position, fuel flows to the carburetor when the engine is running.
U46B12E0.book Page 8 Friday, May 14, 2010 3:57 PM INSTRUMENT AND CONTROL FUNCTIONS EAU13630 EAU13730 Starter (choke) lever Steering lock 1. Starter (choke) lever 1. Steering lock To unlock the steering 1. Open the steering lock cover, and then insert the key. 2. Push the key in, turn it 1/8 turn counterclockwise so that it moves out, and then release it. 3. Remove the key, and then close the lock cover.
U46B12E0.book Page 9 Friday, May 14, 2010 3:57 PM INSTRUMENT AND CONTROL FUNCTIONS EAU14220 EAU14282 Rider seat Helmet holder To remove the rider seat Remove the bolts, and then pull the rider seat off. 1. Projection 2. Seat holder 4 2. Place the rider seat in the original position, and then tighten the bolts. 1. Bolt To install the rider seat 1. Insert the projection on the front of the rider seat into the seat holder as shown. TIP Make sure that the rider seat is properly secured before riding.
U46B12E0.book Page 10 Friday, May 14, 2010 3:57 PM INSTRUMENT AND CONTROL FUNCTIONS EAU14882 Adjusting the shock absorber assemblies Align the appropriate notch in the adjusting ring with the position indicator on the shock absorber. EWA10210 WARNING Always adjust both shock absorber assemblies equally, otherwise poor handling and loss of stability may result. ECA10101 To avoid damaging the mechanism, do not attempt to turn beyond the maximum or minimum settings. Adjust the spring preload as follows.
U46B12E0.book Page 11 Friday, May 14, 2010 3:57 PM INSTRUMENT AND CONTROL FUNCTIONS this system regularly and have a Yamaha dealer repair it if it does not function properly. 4 EAU48240 Ignition circuit cut-off system The ignition circuit cut-off system (comprising the sidestand switch, clutch switch and neutral switch) has the following functions. ● It prevents starting when the transmission is in gear and the sidestand is up, but the clutch lever is not pulled.
U46B12E0.book Page 12 Friday, May 14, 2010 3:57 PM INSTRUMENT AND CONTROL FUNCTIONS WARNING With the engine turned off: 1. Move the sidestand down. 2. Make sure that the engine stop switch is set to “RUN”. 3. Turn the key on. 4. Shift the transmission into the neutral position. 5. Push the start switch. Does the engine start? YES If a malfunction is noted, have a Yamaha dealer check the system before riding. The neutral switch may not be working correctly.
U46B12E0.book Page 1 Friday, May 14, 2010 3:57 PM FOR YOUR SAFETY – PRE-OPERATION CHECKS EAU15596 Inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the Owner’s Manual. EWA11151 WARNING Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equipment damage. Do not operate the vehicle if you find any problem.
U46B12E0.book Page 2 Friday, May 14, 2010 3:57 PM FOR YOUR SAFETY – PRE-OPERATION CHECKS ITEM CHECKS Check operation. Lubricate cable if necessary. Check lever free play. Adjust if necessary. PAGE Clutch • • • • Throttle grip • Make sure that operation is smooth. • Check throttle grip free play. • If necessary, have Yamaha dealer adjust throttle grip free play and lubricate cable and grip housing. Control cables • Make sure that operation is smooth. • Lubricate if necessary.
U46B12E0.book Page 3 Friday, May 14, 2010 3:57 PM FOR YOUR SAFETY – PRE-OPERATION CHECKS ITEM Battery CHECKS • Check fluid level. • Fill with distilled water if necessary.
U46B12E0.book Page 1 Friday, May 14, 2010 3:57 PM OPERATION AND IMPORTANT RIDING POINTS EAU15951 Read the Owner’s Manual carefully to become familiar with all controls. If there is a control or function you do not understand, ask your Yamaha dealer. EWA10271 WARNING Failure to familiarize yourself with the controls can lead to loss of control, which could cause an accident or injury.
U46B12E0.book Page 2 Friday, May 14, 2010 3:57 PM OPERATION AND IMPORTANT RIDING POINTS ECA11042 EAU16640 NOTICE Starting a warm engine For maximum engine life, never accelerate hard when the engine is cold! Follow the same procedure as for starting a cold engine with the exception that the starter (choke) is not required when the engine is warm. EAU16671 Shifting 1. Shift pedal 2.
U46B12E0.book Page 3 Friday, May 14, 2010 3:57 PM OPERATION AND IMPORTANT RIDING POINTS ECA10260 NOTICE ● ● 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 distances. The transmission is properly lubricated only when the engine is running. Inadequate lubrication may damage the transmission.
U46B12E0.book Page 4 Friday, May 14, 2010 3:57 PM OPERATION AND IMPORTANT RIDING POINTS EAU16841 Engine break-in 6 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 following 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.
U46B12E0.book Page 1 Friday, May 14, 2010 3:57 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU17243 EWA15121 EAU17302 WARNING Periodic inspection, adjustment, and lubrication will keep your vehicle in the safest and most efficient condition possible. Safety is an obligation of the vehicle owner/operator. The most important points of vehicle inspection, adjustment, and lubrication are explained on the following pages.
U46B12E0.book Page 2 Friday, May 14, 2010 3:57 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU17341 Owner’s tool kit 1. Owner’s tool kit 7 The owner’s tool kit is located behind panel A. (See page 7-9.) The service information included in this manual and the tools provided in the owner’s tool kit are intended to assist you in the performance of preventive maintenance and minor repairs. However, additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly.
U46B12E0.book Page 3 Friday, May 14, 2010 3:57 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU48470 TIP ● ● From 19000 mi (31000 km) or 36 months, repeat the maintenance intervals starting from 7000 mi (11000 km) or 12 months. Items marked with an asterisk require special tools, data and technical skills, have a Yamaha dealer perform the service. EAU17581 Periodic maintenance chart for the emission control system INITIAL No.
U46B12E0.book Page 4 Friday, May 14, 2010 3:57 PM PERIODIC MAINTENANCE AND ADJUSTMENT INITIAL No. ITEM 7 * Evaporative emission control system (for California only) ROUTINE 600 mi (1000 km) or 1 month • Check control system for damage. • Replace if necessary.
U46B12E0.book Page 5 Friday, May 14, 2010 3:57 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU32165 General maintenance and lubrication chart INITIAL No. ITEM ROUTINE 600 mi (1000 km) or 1 month ODOMETER READINGS 4000 mi (6000 km) or 6 months 7000 mi 10000 mi 13000 mi 16000 mi (11000 km) (16000 km) (21000 km) (26000 km) or or or or 12 months 18 months 24 months 30 months 1 * Air filter element • Clean with solvent. • Replace if necessary.
U46B12E0.book Page 6 Friday, May 14, 2010 3:57 PM PERIODIC MAINTENANCE AND ADJUSTMENT INITIAL No. ROUTINE 600 mi (1000 km) or 1 month 4000 mi (6000 km) or 6 months 7000 mi 10000 mi 13000 mi 16000 mi (11000 km) (16000 km) (21000 km) (26000 km) or or or or 12 months 18 months 24 months 30 months 9 * Wheel bearings • Check bearings for smooth operation. • Replace if necessary. √ √ √ √ √ 10 * Swingarm pivot bushes • Check bush assemblies for looseness. • Lubricate with lithium-soap-based grease.
U46B12E0.book Page 7 Friday, May 14, 2010 3:57 PM PERIODIC MAINTENANCE AND ADJUSTMENT INITIAL No. ITEM ROUTINE 600 mi (1000 km) or 1 month ODOMETER READINGS 4000 mi (6000 km) or 6 months 7000 mi 10000 mi 13000 mi 16000 mi (11000 km) (16000 km) (21000 km) (26000 km) or or or or 12 months 18 months 24 months 30 months 17 Shift pedal pivot shaft • Apply lithium-soap-based grease lightly. √ √ √ √ √ 18 Sidestand pivot • Check operation. • Apply lithium-soap-based grease lightly.
U46B12E0.book Page 8 Friday, May 14, 2010 3:57 PM PERIODIC MAINTENANCE AND ADJUSTMENT INITIAL No. ITEM 27 * Lights, signals and switches ROUTINE • Check operation. • Adjust headlight beam.
U46B12E0.book Page 9 Friday, May 14, 2010 3:57 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU18751 EAU19545 Removing and installing the panel Checking the spark plugs The panel shown needs to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time the panel needs to be removed and installed. To install the panel Secure the front of the panel, and then push the rear of the panel in.
U46B12E0.book Page 10 Friday, May 14, 2010 3:57 PM PERIODIC MAINTENANCE AND ADJUSTMENT 3. Check each spark plug for electrode erosion and excessive carbon or other deposits, and replace it if necessary. Specified spark plug: NGK/C6HSA DENSO/U20FS-U 1. Spark plug wrench 7 To check the spark plugs 1. Check that the porcelain insulator around the center electrode on each spark plug is a medium-tolight tan (the ideal color when the vehicle is ridden normally). 2.
U46B12E0.book Page 11 Friday, May 14, 2010 3:57 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU19681 Canister (for California only) ● Make sure that the canister breather is not blocked, and if necessary, clean it. EAU42105 Engine oil and oil filter element The engine oil level should be checked before each ride. In addition, the oil must be changed and the oil filter element replaced at the intervals specified in the periodic maintenance and lubrication chart. To check the engine oil level 1.
U46B12E0.book Page 12 Friday, May 14, 2010 3:57 PM PERIODIC MAINTENANCE AND ADJUSTMENT 3. Remove the engine oil filler cap, the engine oil drain bolt and its gasket to drain the oil from the crankcase. TIP Skip steps 4–6 if the oil filter element is not being replaced. 4. Remove the oil filter element cover by removing the screws. 1. Engine oil level check window 2. Maximum level mark 3. Minimum level mark 4.
U46B12E0.book Page 13 Friday, May 14, 2010 3:57 PM PERIODIC MAINTENANCE AND ADJUSTMENT Tightening torque: Engine oil drain bolt: 34 Nm (3.4 m·kgf, 25 ft·lbf) 8. Refill with the specified amount of the recommended engine oil, and then install and tighten the oil filler cap. 1. Oil filter element 2. O-ring 6. Install the oil filter element cover by installing the screws, then tightening them to the specified torque. Tightening torque: Oil filter element cover screw: 10 Nm (1.0 m·kgf, 7.
U46B12E0.book Page 14 Friday, May 14, 2010 3:57 PM PERIODIC MAINTENANCE AND ADJUSTMENT 3. Remove the air filter case cover by removing the screws. EAU32738 Cleaning the air filter element The air filter element should be cleaned or replaced at the intervals specified in the periodic maintenance and lubrication chart. Clean or, if necessary, replace the air filter element more frequently if you are riding in unusually wet or dusty areas. 1.
U46B12E0.book Page 15 Friday, May 14, 2010 3:57 PM PERIODIC MAINTENANCE AND ADJUSTMENT 5. Remove the sponge material from the air filter element frame, clean it with solvent, and then squeeze the remaining solvent out. WARNING! Use only a dedicated parts cleaning solvent. To avoid the risk of fire or explosion, do not use gasoline or solvents with a low flash point. [EWA10431] NOTICE: To avoid damaging the foam material, handle it gently and carefully, and do not twist or wring it.
U46B12E0.book Page 16 Friday, May 14, 2010 3:57 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU21251 Carburetor The carburetor is an important part of the engine and its emission control system, which requires very sophisticated adjustment. Therefore, carburetor adjustments should be left to Yamaha dealer, who has the necessary professional knowledge and experience.
U46B12E0.book Page 17 Friday, May 14, 2010 3:57 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU21401 EAU32524 Valve clearance Tires The valve clearance changes with use, resulting in improper air-fuel mixture and/or engine noise. To prevent this from occurring, the valve clearance must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart.
U46B12E0.book Page 18 Friday, May 14, 2010 3:57 PM PERIODIC MAINTENANCE AND ADJUSTMENT Tire inspection EWA10562 WARNING ● ● 1. Tire sidewall 2. Tire wear indicator 3. Tire tread depth 7 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, contact a Yamaha dealer immediately and have the tire replaced. Minimum tire tread depth (front and rear): 1.0 mm (0.
U46B12E0.book Page 19 Friday, May 14, 2010 3:57 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU21942 Spoke wheels EWA10610 WARNING EAU48372 Adjusting the clutch lever free play The wheels on this model are not designed for use with tubeless tires. Do not attempt to use tubeless tires on this model. To maximize the performance, durability, and safe operation of your motorcycle, note the following points regarding the specified wheels.
U46B12E0.book Page 20 Friday, May 14, 2010 3:57 PM PERIODIC MAINTENANCE AND ADJUSTMENT 6. To increase the clutch lever free play, turn the clutch lever free play adjusting nut in direction (a). To decrease the clutch lever free play, turn the adjusting nut in direction (b). 7. Tighten the locknut at the clutch cable, and then slide the rubber cover to its original position. 8. Tighten the locknut at the clutch lever, and then slide the rubber cover to its original position.
U46B12E0.book Page 21 Friday, May 14, 2010 3:57 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU22202 Adjusting the brake pedal height and free play 1. Loosen the locknut at the brake pedal. 2. To raise the brake pedal, turn the adjusting bolt in direction (a). To lower the brake pedal, turn the adjusting bolt in direction (b). Brake pedal free play The brake pedal free play should measure 20.0–30.0 mm (0.79–1.18 in) at the brake pedal end.
U46B12E0.book Page 22 Friday, May 14, 2010 3:57 PM PERIODIC MAINTENANCE AND ADJUSTMENT ● ● If proper adjustment cannot be obtained as described, have a Yamaha dealer make this adjustment. After adjusting the brake pedal free play, check the operation of the brake light.
U46B12E0.book Page 23 Friday, May 14, 2010 3:57 PM PERIODIC MAINTENANCE AND ADJUSTMENT indicator groove has almost disappeared, have a Yamaha dealer replace the brake pads as a set. EAU32344 Checking the brake fluid level ● 1 EAU22540 Rear brake shoes Use only the recommended quality brake fluid, otherwise the rubber seals may deteriorate, causing leakage and poor braking performance. Recommended brake fluid: DOT 4 2 ● 1 1. Minimum level mark 1. Brake shoe wear indicator 2.
U46B12E0.book Page 24 Friday, May 14, 2010 3:57 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU22721 7 EAU22760 Changing the brake fluid Drive chain slack Have a Yamaha dealer change the brake fluid at the intervals specified in the TIP after the periodic maintenance 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 damaged or leaking. ● Oil seals: Replace every two years.
U46B12E0.book Page 25 Friday, May 14, 2010 3:57 PM PERIODIC MAINTENANCE AND ADJUSTMENT 2. Remove the cotter pin from the axle nut, and then loosen the axle nut. 3. Loosen the drive chain puller locknut at each end of the swingarm. 4. To tighten the drive chain, turn the drive chain slack adjusting nut at each end of the swingarm in direction (a). To loosen the drive chain, turn the adjusting nut at each end of the swingarm in direction (b), and then push the rear wheel forward.
U46B12E0.book Page 26 Friday, May 14, 2010 3:57 PM PERIODIC MAINTENANCE AND ADJUSTMENT EWA10660 WARNING After adjusting the brake pedal free play, check the operation of the brake light. EAU23016 Checking and lubricating the cables The drive chain must be cleaned and lubricated at the intervals specified in the periodic maintenance and lubrication chart, otherwise it will quickly wear out, especially when riding in dusty or wet areas. Service the drive chain as follows.
U46B12E0.book Page 27 Friday, May 14, 2010 3:57 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU49920 Checking and lubricating the throttle grip and cable The operation of the throttle grip should be checked before each ride. In addition, the cable should be lubricated by a Yamaha dealer at the intervals specified in the periodic maintenance chart.
U46B12E0.book Page 28 Friday, May 14, 2010 3:57 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU23142 Checking and lubricating the brake and clutch levers Brake lever EAU23202 Recommended lubricants: Brake lever: Silicone grease Clutch lever: Lithium-soap-based grease 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.
U46B12E0.book Page 29 Friday, May 14, 2010 3:57 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAUM1651 Lubricating the swingarm pivots The swingarm pivots must be lubricated by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart. Recommended lubricant: Lithium-soap-based grease EAU23272 Checking the front fork The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart.
U46B12E0.book Page 30 Friday, May 14, 2010 3:57 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU23283 Checking the steering 7 Worn or loose steering bearings may cause danger. Therefore, the operation of the steering must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart. 1. Place a stand under the engine to raise the front wheel off the ground. (See page 7-35 for more information.
U46B12E0.book Page 31 Friday, May 14, 2010 3:57 PM PERIODIC MAINTENANCE AND ADJUSTMENT ● ● ● • EYES: Flush with water for 15 minutes and seek prompt medical attention. Batteries produce explosive hydrogen gas. Therefore, keep sparks, flames, cigarettes, etc., away from the battery and provide 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.
U46B12E0.book Page 32 Friday, May 14, 2010 3:57 PM PERIODIC MAINTENANCE AND ADJUSTMENT 3. Fully charge the battery before installation. NOTICE: When installing the battery, be sure the key is turned to “OFF”, then connect the positive lead before connecting the negative lead. EAU23601 Replacing the fuses [ECA16840] 7 4.
U46B12E0.book Page 33 Friday, May 14, 2010 3:57 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU23783 Replacing the headlight bulb This model is equipped with a quartz bulb headlight. If the headlight bulb burns out, replace it as follows. ECA10650 NOTICE Take care not to damage the following parts: ● Headlight bulb Do not touch the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the luminosity of the bulb, and the bulb life will be adversely affected.
U46B12E0.book Page 34 Friday, May 14, 2010 3:57 PM PERIODIC MAINTENANCE AND ADJUSTMENT 5. Install the headlight bulb cover, and then connect the coupler. 6. Install the headlight unit by installing the screws. 7. Have a Yamaha dealer adjust the headlight beam if necessary. EAU24133 Replacing the tail/brake light bulb 1. Remove the tail/brake light lens by removing the screws. 1. Tail/brake light bulb 1. Screw 7 2. Remove the burnt-out bulb by pushing it in and turning it counterclockwise. 7-34 3.
U46B12E0.book Page 35 Friday, May 14, 2010 3:57 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU24212 EAU24350 Replacing a turn signal light bulb Supporting the motorcycle 1. Remove the turn signal lens by removing the screws. 1. Turn signal light bulb 1. Screw 2. Remove the burnt-out bulb by pushing it in and turning it counterclockwise. 3. Insert a new bulb into the socket, push it in, and then turn it clockwise until it stops. 4. Install the lens by installing the screws.
U46B12E0.book Page 36 Friday, May 14, 2010 3:57 PM PERIODIC MAINTENANCE AND ADJUSTMENT a jack either under each side of the frame in front of the rear wheel or under each side of the swingarm. EAU24360 Front wheel EAU24601 To remove the front wheel EWA10821 WARNING To avoid injury, securely support the vehicle so there is no danger of it falling over. 1. Disconnect the speedometer cable from the front wheel. 7 1. Speedometer cable 2. Loosen the front wheel axle pinch bolt, then the wheel axle.
U46B12E0.book Page 37 Friday, May 14, 2010 3:57 PM PERIODIC MAINTENANCE AND ADJUSTMENT 7. While applying the front brake, push down hard on the handlebars several times to check if the front fork compresses and rebounds smoothly. 8. Connect the speedometer cable. 1. Speedometer gear unit 2. Lift the wheel up between the fork legs.
U46B12E0.book Page 38 Friday, May 14, 2010 3:57 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU25080 Rear wheel EAU32752 To remove the rear wheel EWA10821 WARNING To avoid injury, securely support the vehicle so there is no danger of it falling over. 1. Remove the axle nut cotter pin. 2. Fully loosen the chain puller locknut and the drive chain slack adjusting nut on both ends of the swingarm. 3. Loosen the axle nut and the brake torque rod nut at the brake shoe plate. 4.
U46B12E0.book Page 39 Friday, May 14, 2010 3:57 PM PERIODIC MAINTENANCE AND ADJUSTMENT 6. Tighten the brake torque rod nut to the specified torque. EAU25851 Troubleshooting Tightening torque: Brake torque rod nut: 23 Nm (2.3 m·kgf, 17 ft·lbf) 7. Adjust the drive chain slack. (See page 7-24.) 8. Tighten the locknuts, and then tighten the axle nut to the specified torques. Tightening torques: Drive chain puller locknut: 16 Nm (1.6 m·kgf, 12 ft·lbf) Axle nut: 105 Nm (10.5 m·kgf, 76 ft·lbf) 9.
U46B12E0.book Page 40 Friday, May 14, 2010 3:57 PM PERIODIC MAINTENANCE AND ADJUSTMENT heaters or furnaces. Gasoline or gasoline vapors can ignite or explode, causing severe injury or property damage.
U46B12E0.book Page 41 Friday, May 14, 2010 3:57 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU25932 Troubleshooting chart 1. Fuel There is enough fuel. Check the compression. There is no fuel. Supply fuel. Check the fuel level in the fuel tank. The engine does not start. Check the compressoin. 2. Compression There is compression. Check the ignition. There is no compression. Have a Yamaha dealer check the vehicle. Operate the electric starter. 3.
U46B12E0.book Page 1 Friday, May 14, 2010 3:57 PM MOTORCYCLE CARE AND STORAGE EAU37833 Matte color caution ECA15192 NOTICE Some models are equipped with matte colored finished parts. Be sure to consult a Yamaha dealer for advice on what products to use before cleaning the vehicle. Using a brush, harsh chemical products or cleaning compounds when cleaning these parts will scratch or damage their surface. Wax also should not be applied to any matte colored finished parts.
U46B12E0.book Page 2 Friday, May 14, 2010 3:57 PM MOTORCYCLE CARE AND STORAGE ● ● ● off any detergent residue using plenty of water, as it is harmful to plastic parts. 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 cleaning products, solvent or thinner, fuel (gasoline), rust removers or inhibitors, brake fluid, antifreeze or electrolyte.
U46B12E0.book Page 3 Friday, May 14, 2010 3:57 PM MOTORCYCLE CARE AND STORAGE 4. To prevent corrosion, it is recommended to apply a corrosion protection spray on all metal, including chrome- and nickel-plated, surfaces. 5. Use spray oil as a universal cleaner 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.
U46B12E0.book Page 4 Friday, May 14, 2010 3:57 PM MOTORCYCLE CARE AND STORAGE 3. Drain the carburetor float chambers by loosening the drain bolts; this will prevent fuel deposits from building up. Pour the drained fuel into the fuel tank. 4. Fill up the fuel tank and add fuel stabilizer (if available) to prevent the fuel tank from rusting and the fuel from deteriorating. 5. Perform the following steps to protect the cylinders, piston rings, etc. from corrosion. a.
U46B12E0.book Page 1 Friday, May 14, 2010 3:57 PM SPECIFICATIONS Dimensions: Overall length: 2190 mm (86.2 in) Overall width: 815 mm (32.1 in) Overall height: 1140 mm (44.9 in) Seat height: 685 mm (27.0 in) Wheelbase: 1490 mm (58.7 in) Ground clearance: 145 mm (5.71 in) Minimum turning radius: 2800 mm (110.
U46B12E0.book Page 2 Friday, May 14, 2010 3:57 PM SPECIFICATIONS Gear ratio: 1st: 37/14 (2.643) 2nd: 32/19 (1.684) 3rd: 29/23 (1.261) 4th: 26/26 (1.000) 5th: 23/28 (0.821) Chassis: Frame type: Double cradle Caster angle: 32.00 ° Trail: 120.0 mm (4.72 in) Front tire: Type: With tube Size: 3.
U46B12E0.book Page 3 Friday, May 14, 2010 3:57 PM SPECIFICATIONS Headlight: Bulb type: Halogen bulb Bulb voltage, wattage × quantity: Headlight: 12 V, 60 W/55 W × 1 Tail/brake light: 12 V, 8.0 W/27.0 W × 1 Front turn signal/position light: 12 V, 27 W/8.0 W × 2 Rear turn signal light: 12 V, 27.0 W × 2 Meter lighting: 14 V, 3.0 W × 1 Neutral indicator light: 14 V, 3.0 W × 1 High beam indicator light: 12 V, 1.7 W × 1 Turn signal indicator light: 14 V, 3.0 W × 1 Fuses: Main fuse: 20.
U46B12E0.book Page 1 Friday, May 14, 2010 3:57 PM CONSUMER INFORMATION EAU26352 Identification numbers EAU26390 EAU26400 Key identification number Vehicle identification number 1. Key identification number 1. Vehicle identification number The key identification number is stamped into the key. Record this number in the space provided and use it for reference when ordering a new key. The vehicle identification number is stamped into the steering head pipe. Record this number in the space provided.
U46B12E0.book Page 2 Friday, May 14, 2010 3:57 PM CONSUMER INFORMATION EAU26470 Model label EAU48061 Vehicle Emission Control Information label 1 1. Model label The model label is affixed to the frame under the rider seat. (See page 4-9.) Record the information on this label in the space provided. This information will be needed when ordering spare parts from a Yamaha dealer. 1.
U46B12E0.book Page 3 Friday, May 14, 2010 3:57 PM CONSUMER INFORMATION EAU26551 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.
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U46B12E0.book Page 5 Friday, May 14, 2010 3:57 PM 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.
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U46B12E0.book Page 7 Friday, May 14, 2010 3:57 PM CONSUMER INFORMATION EAU26663 YAMAHA MOTOR CORPORATION, U.S.A. STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY Yamaha Motor Corporation, U.S.A. hereby warrants that new Yamaha motorcycles will be free from defects in material and workmanship for the period of time stated herein, subject to certain stated limitations.
U46B12E0.book Page 8 Friday, May 14, 2010 3:57 PM CONSUMER INFORMATION WARRANTY QUESTIONS AND ANSWERS CUSTOMER SERVICE Q. What costs are my responsibility during the warranty period? A. 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.
U46B12E0.book Page 9 Friday, May 14, 2010 3:57 PM CONSUMER INFORMATION EAU26750 YAMAHA EXTENDED SERVICE (Y.E.S.) Keep your Yamaha protected even after your warranty expires with genuine Yamaha Extended Service (Y.E.S.). In addition, Travel and Recreation Interruption Protection (TRIP) is included at no extra cost.
U46B12E0.book Page 10 Friday, May 14, 2010 3:57 PM CONSUMER INFORMATION 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.
U46B12E0.book Page 1 Friday, May 14, 2010 3:57 PM INDEX A F Air filter element, cleaning .................... 7-14 B Battery .................................................. 7-30 Brake and clutch levers, checking and lubricating ........................................... 7-28 Brake and shift pedals, checking and lubricating ........................................... 7-27 Brake fluid, changing ............................ 7-24 Brake fluid level, checking .................... 7-23 Brake lever ........
U46B12E0.book Page 2 Friday, May 14, 2010 3:57 PM INDEX Turn signal switch ................................... 4-3 V Valve clearance .................................... 7-17 Vehicle Emission Control Information label .................................................... 10-2 Vehicle identification number ................ 10-1 W Warranty, extended............................... 10-9 Warranty, limited ................................... 10-7 Wheel bearings, checking.....................
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YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2010.05-0.
