OWNER’S MANUAL TTR250V(C) LIT-11626-19-30 5GF-28199-17
INTRODUCTION EAU10060 Congratulations on your purchase of the Yamaha TTR250V. 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 machine.
IMPORTANT MANUAL INFORMATION EAU10160 Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Failure to follow WARNING instructions could result in severe injury or death to the WARNING machine operator, a bystander or a person inspecting or repairing the machine. A CAUTION indicates special precautions that must be taken to avoid damage to CAUTION: the machine.
IMPORTANT MANUAL INFORMATION EWA10040 WARNING THIS MACHINE IS DESIGNED AND MANUFACTURED FOR OFF-ROAD USE ONLY. IT IS ILLEGAL TO OPERATE THIS MACHINE ON ANY PUBLIC STREET, ROAD OR HIGHWAY. SUCH USE IS PROHIBITED BY LAW. THIS MACHINE COMPLIES WITH ALMOST ALL STATE OFF-HIGHWAY NOISE LEVEL AND SPARK ARRESTER LAWS AND REGULATIONS. PLEASE CHECK YOUR LOCAL RIDING LAWS AND REGULATIONS BEFORE OPERATING THIS MACHINE.
IMPORTANT MANUAL INFORMATION EAU10192 AFFIX DEALER LABEL HERE TTR250V OWNER’S MANUAL ©2005 by Yamaha Motor Corporation, U.S.A. 1st edition, April 2005 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.
TABLE OF CONTENTS SAFETY INFORMATION ...................1-1 Location of important labels .............1-5 DESCRIPTION ...................................2-1 Left view ...........................................2-1 Right view .........................................2-2 Controls and instruments..................2-3 INSTRUMENT AND CONTROL FUNCTIONS ........................................3-1 Main switch ......................................3-1 Tripmeter .........................................
TABLE OF CONTENTS Troubleshooting chart ....................6-35 MACHINE CARE AND STORAGE ...........................................7-1 Care .................................................7-1 Storage ............................................7-3 SPECIFICATIONS ..............................8-1 CONSUMER INFORMATION ..............9-1 Identification numbers .....................9-1 Motorcycle noise regulation .............9-3 Maintenance record .........................9-4 YAMAHA MOTOR CORPORATION, U.S.A.
SAFETY INFORMATION EAU10332 THIS MACHINE IS A SINGLE TRACK VEHICLE. ITS SAFE USE AND OPERATION IS 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 MACHINE. HE OR SHE SHOULD: ● OBTAIN THOROUGH INSTRUCTIONS FROM A COMPETENT SOURCE ON ALL ASPECTS OF MACHINE OPERATION. THE WARNINGS ● OBSERVE AND MAINTENANCE REQUIREMENTS IN THE OWNER’S MANUAL.
SAFETY INFORMATION ● 1 ● trousers, gloves, etc., is effective in preventing or reducing abrasions or lacerations. Never wear loose-fitting clothes, otherwise they could catch on the control levers, footrests, or wheels and cause injury or an accident. Never touch the engine or exhaust system during or after operation. They become very hot and can cause burns. Always wear protective clothing that covers your legs, ankles, and feet.
SAFETY INFORMATION or cornering clearance, limit suspension travel, steering travel or control operation, or obscure lights or reflectors. Accessories fitted to the handlebar or the front fork area can create instability due to improper weight distribution or aerodynamic changes. If accessories are added to the handlebar or front fork area, they must be as lightweight as possible and should be kept to a minimum.
SAFETY INFORMATION 1 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.
SAFETY INFORMATION EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle.
SAFETY INFORMATION 1 3 1 WARNING WARNING 8 BEFORE YOU OPERATE THIS VEHICLE, READ Riding as a passenger can cause the vehicle to go out of control. Loss of control can cause a collision or rollover, which can result in severe injury or death. NEVER ride as a passenger. THE OWNER'S MANUAL AND ALL LABELS. 8 NEVER CARRY A PASSENGER. You increase your risk of losing control if you carry a passenger. 8 NEVER OPERATE THIS VEHICLE ON PUBLIC ROADS.
DESCRIPTION EAU10410 Left view 1 2 3 4 5 1 2 3 4 5 6 7 8 8 9 7 1. Headlight (page 6-29) 2. Front fork air valve (page 3-7) 3. Fuel cock (page 3-5) 4. Starter (choke) knob (page 3-6) 5. Air filter element (page 6-12) 6. Shock absorber assembly rebound damping force adjusting dial (page 3-9) 7. Shift pedal (page 3-2) 6 8.
DESCRIPTION EAU10420 Right view 1 2 3 4 5 2 3 4 5 6 7 8 7 1. Spark arrester (page 6-13) 2. Battery (page 6-27) 3. Fuse (page 6-28) 4. Shock absorber assembly compression damping force adjusting knob (page 3-9) 5. Main switch (page 3-1) 6. Engine oil filter element (page 6-8) 7. Brake pedal (page 3-3) 6 8.
DESCRIPTION EAU10430 Controls and instruments 1 2 3 4 5 1 2 3 4 5 6 7 7 8 9 1. Clutch lever (page 3-2) 2. Left handlebar switch (page 3-1) 3. Tripmeter (page 3-1) 4. Right handlebar switches (page 3-1) 5. Brake lever (page 3-3) 6. Throttle grip (page 6-14) 7.
INSTRUMENT AND CONTROL FUNCTIONS EAU10450 Main switch ON EAU11830 Tripmeter 1 OFF EAU12343 Handlebar switches Left 1 2 3 2 The main switch controls the ignition and lighting systems. The various main switch positions are described below. EAU10630 ON All electrical systems are supplied with power, and the engine can be started. The key cannot be removed. 1. Tripmeter 2. Tripmeter reset knob The tripmeter shows the distance traveled since it was last set to zero with the reset knob.
INSTRUMENT AND CONTROL FUNCTIONS EAU12540 Light switch “ ” Set this switch to “ ” to turn on the headlight and the taillight. 1 2 3 CAUTION: Always turn the key to “OFF” and light switch to “OFF” when the engine is not running, otherwise the headlight will stay on and the battery may discharge due to extended use. EAU12660 6 7 Engine stop switch “ / ” Set this switch to “ ” before starting the engine.
INSTRUMENT AND CONTROL FUNCTIONS EAU12890 Brake lever EAU12941 Brake pedal EAU13180 Fuel tank cap 1 1 1 2 3 2 1. Brake lever The brake lever is located at the right handlebar grip. To apply the front brake, pull the lever toward the handlebar grip. 1. Brake pedal The brake pedal is on the right side of the machine. To apply the rear brake, press down on the brake pedal. 4 1. Fuel tank cap 2. Remove. To remove the fuel tank cap, turn it counterclockwise, and then pull it off.
INSTRUMENT AND CONTROL FUNCTIONS EAU13210 Fuel 1 1 2 EAU13300 Recommended fuel: UNLEADED GASOLINE ONLY Fuel tank capacity: 9.5 L (2.51 US gal) (2.09 Imp.gal) Fuel reserve amount: 2.0 L (0.53 US gal) (0.44 Imp.gal) 2 3 4 5 6 1. Fuel tank filler tube 2. Fuel level ECA11400 Make sure that there is sufficient fuel in the tank. Fill the fuel tank to the bottom of the filler tube as shown. EWA10880 7 ● 8 ● 9 fuel may deteriorate painted surfaces or plastic parts.
INSTRUMENT AND CONTROL FUNCTIONS EAU13410 Fuel tank breather hose 1 EAU13560 Fuel cock The fuel cock supplies fuel from the tank to the carburetor while filtering it also. The fuel cock has three positions: OFF ON RES OFF ON FUEL 2 1 ON 3 RES OFF 1. Arrow mark positioned over “ON” 1. Fuel tank breather hose Before operating the machine: ● Check the fuel tank breather hose connection. ● Check the fuel tank breather hose for cracks or damage, and replace it if damaged.
INSTRUMENT AND CONTROL FUNCTIONS fuel while riding, move the lever to this position. Fill the tank at the first opportunity. Be sure to set the lever back to “ON” after refueling! EAU13600 Starter (choke) knob “ ” To remove the seat Remove the bolts, and then pull the seat off. (b) 1 EAU13960 Seat (a) 2 3 1(×2) 1 4 1. Starter (choke) knob “ 5 6 7 ” Starting a cold engine requires a richer air-fuel mixture, which is supplied by the starter (choke).
INSTRUMENT AND CONTROL FUNCTIONS EAU14671 1(×2) Adjusting the front fork 2 1 The front fork is equipped with air valves for adjusting the spring rate and screws for adjusting the damping force. EWA10190 2(×2) WARNING There should be no difference in air pressure between the fork legs. 2 3 1. Projection 2. Seat holder 2. Place the seat in the original position, and then tighten the bolts. NOTE: Make sure that the seat is properly secured before riding.
INSTRUMENT AND CONTROL FUNCTIONS 1 2 3 Spring rate: Minimum (soft): Air pressure = 0 kPa (0 psi) (0 kgf/cm2) Standard: Air pressure = 0 kPa (0 psi) (0 kgf/cm2) Maximum (hard): Air pressure = 40 kPa (5.8 psi) (0.4 kgf/cm2) ECA10090 4 5 CAUTION: Never exceed the maximum air pressure, otherwise the front fork oil seals may become damaged. EWA10180 6 7 WARNING Always adjust both fork legs equally, otherwise poor handling and loss of stability may result. 1 1 (b) 1. Rubber cap (a) 1.
INSTRUMENT AND CONTROL FUNCTIONS EAU15070 ECA10960 CAUTION: Be sure to install the rubber caps to prevent dust, etc. from entering the fork legs. NOTE: Although the total number of clicks of a damping force adjusting mechanism may not exactly match the above specifications due to small differences in production, the actual number of clicks always represents the entire adjusting range.
INSTRUMENT AND CONTROL FUNCTIONS rection (b). Tightening torque: Locknut: 70 Nm (7.0 m·kgf, 51 ft·lbf) 1 ECA11240 2 CAUTION: Always tighten the locknut against the adjusting nut, and then tighten the locknut to the specified torque. 3 4 Rebound damping force Rebound damping setting: Minimum (soft): 16 clicks in direction (b)* Standard: 8 clicks in direction (b)* Maximum (hard): 1 click in direction (b)* * With the adjusting dial fully turned in direction (a) 1 1 7 (b) (a) (b) (a) 8 1.
INSTRUMENT AND CONTROL FUNCTIONS er handling, read and understand the following information before handling the shock absorber. The manufacturer cannot be held responsible for property damage or personal injury that may result from improper handling. ● Do not tamper with or attempt to open the gas cylinder. ● Do not subject the shock absorber to an open flame or other high heat sources, otherwise it may explode due to excessive gas pressure.
INSTRUMENT AND CONTROL FUNCTIONS 1 2 3 4 5 6 With the engine turned off: 1. Make sure that the engine stop switch is set to “ 2. Turn the key to “ON”. 3. Shift the transmission into the neutral position. 4. Push the start switch. Does the engine start? YES NOTE: This check is most reliable if performed with a warmed-up engine. ”. The neutral switch may be defective. The motorcycle should not be ridden until checked by a Yamaha dealer. NO 5. Turn the engine off. 6. Shift the transmission into gear.
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 inspection, to check the following points before each ride.
PRE-OPERATION CHECKS EAU15603 Pre-operation check list ITEM CHECKS ● 1 Fuel ● ● 2 ● Engine oil ● ● ● 3 ● ● 4 ● Front brake ● ● 5 ● ● ● 6 ● ● 7 ● Rear brake ● ● ● 8 ● ● 9 Clutch ● ● ● ● Throttle grip ● ● Check fuel level in fuel tank. Refuel if necessary. Check fuel line for leakage. Check oil level in engine. If necessary, add recommended oil to specified level. Check vehicle for oil leakage. Check operation. If soft or spongy, have Yamaha dealer bleed hydraulic system.
PRE-OPERATION CHECKS ITEM Control cables CHECKS ● ● ● Drive chain ● ● ● ● Wheels and tires ● ● ● Brake and shift pedals Brake and clutch levers Sidestand Chassis fasteners Instruments, lights, signals and switches Engine stop switch ● ● ● ● ● ● ● ● ● ● ● Make sure that operation is smooth. Lubricate if necessary. Check chain slack. Adjust if necessary. Check chain condition. Lubricate if necessary. Check for damage. Check tire condition and tread depth. Check air pressure. Correct if necessary.
OPERATION AND IMPORTANT RIDING POINTS EAU15960 EWA10280 1 ● 2 3 ● 4 5 6 7 8 9 ● WARNING This model is designed for off-road use only. In most instances, it is illegal to ride this model (either day or night) on any public street or highway. Never start the engine or operate it in a closed area for any length of time. Exhaust fumes are poisonous, and inhaling them can cause loss of consciousness and death within a short time. Always make sure that there is adequate ventilation.
OPERATION AND IMPORTANT RIDING POINTS EAU16640 Starting a warm engine EAU16671 Shifting 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. 2 6 5 4 3 2 N 1 1 ● 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 illustration.
OPERATION AND IMPORTANT RIDING POINTS EAU16850 Engine break-in 1 2 3 4 5 6 7 8 9 There is never a more important period in the life of your engine than the first 20 hours of riding. 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 20 hours of operation. The various parts in the engine wear and polish themselves to the correct operating clearances.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU17291 EAU17310 Owner’s tool kit Safety is an obligation of the owner. Periodic inspection, adjustment and lubrication will keep your vehicle in the safest and most efficient condition possible. The most important points of vehicle inspection, adjustment, and lubrication are explained on the following pages. EWA10320 WARNING If you are not familiar with maintenance work, have a Yamaha dealer do it for you.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU35230 Periodic maintenance chart for the emission control system 1 NOTE: ● From 1800 mi (3000 km) or 18 months, repeat the maintenance intervals starting from 600 mi (1000 km) or 6 months. ● Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. 2 3 INITIAL No.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU35340 General maintenance and lubrication chart INITIAL No. 1 ITEM Clutch 2 * Front brake 3 * Rear brake 4 * Brake hoses CHECKS AND MAINTENANCE JOBS ● ● ● ● ● ● ● ● 5 * Wheels ● ● ● 6 * Tires ● ● ● 7 * Wheel bearings 8 * Swingarm pivot bearings ● ● ● ● ● 9 Drive chain ● ● 10 * Steering bearings ● Check operation. Adjust or replace cable. Check operation, fluid level, and for fluid leakage. Replace brake pads if necessary.
PERIODIC MAINTENANCE AND MINOR REPAIR INITIAL No.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU18670 NOTE: ● The air filter needs more frequent service if you are riding in unusually wet or dusty areas. ● Hydraulic brake service Regularly check and, if necessary, correct the brake fluid level. Every two years replace the internal components of the brake master cylinders and calipers, and change the brake fluid. Replace the brake hoses every four years and if cracked or damaged.
PERIODIC MAINTENANCE AND MINOR REPAIR To install the cowling Place the cowling in the original position, and then install the screws. EAU18721 Removing and installing the cowling and panels 1 2 3 1 The cowling and panels shown need to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time the cowling or a panel needs to be removed and installed.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU19602 Checking the spark plug 1 2 1. Screw 2. Panel B To install the panel Place the panel in the original position, and then install the screw. The spark plug is an important engine component, which is easy to check. Since heat and deposits will cause any spark plug to slowly erode, the spark plug should be removed and checked in accordance with the periodic maintenance and lubrication chart.
PERIODIC MAINTENANCE AND MINOR REPAIR Specified spark plug: NGK/CR9E DENSO/U27ESR-N 1 2 3 To install the spark plug 1. Measure the spark plug gap with a wire thickness gauge and, if necessary, adjust the gap to specification. 4 5 6 1 3. Install the spark plug with the spark plug wrench, and then tighten it to the specified torque. Tightening torque: Spark plug: 12.5 Nm (1.25 m·kgf, 9.
PERIODIC MAINTENANCE AND MINOR REPAIR NOTE: The engine oil should be between the minimum and maximum level marks. to collect the used oil. 3. Remove the engine oil filler bolt and drain bolt to drain the oil from the crankcase. 2 1 2 3 1. Engine oil level check window 2. Maximum level mark 3. Minimum level mark 1 1 3 1. Engine oil drain bolt 1. Engine oil filler bolt NOTE: Check each washer for damage and replace them if necessary. 4.
PERIODIC MAINTENANCE AND MINOR REPAIR 3 1 2(×2) 1 2(×3) 1 NOTE: Make sure that the O-rings are properly seated. 2 3 4 5 6 7 8 9 1. Oil filter element drain bolt 2. Bolt 3. Oil filter element cover NOTE: Skip steps 5–9 if the oil filter element is not being cleaned. 5. Remove the oil filter element cover by removing the bolts. 6. Remove the oil filter element and O-rings. Tightening torque: Oil filter element cover bolt: 10 Nm (1.0 m·kgf, 7.2 ft·lbf) 1. Oil filter element 2. O-ring 7.
PERIODIC MAINTENANCE AND MINOR REPAIR Recommended oil: See page 8-1. Oil quantity: Without oil filter element replacement: 1.10 L (1.16 US qt) (0.97 Imp.qt) With oil filter element replacement: 1.20 L (1.27 US qt) (1.06 Imp.qt) ECA11620 CAUTION: ● In order to prevent clutch slippage (since the engine oil also lubricates the clutch), do not mix any chemical additives. Do not use oils with a diesel specification of “CD” or oils of a higher quality than specified.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU20890 Cleaning the air filter element 1 2 3 The air filter element should be cleaned at the intervals specified in the periodic maintenance and lubrication chart. Clean the air filter element more frequently if you are riding in unusually wet or dusty areas. 1. Remove panel A. (See page 6-6.) 2. Remove the air filter case cover by removing the holding clips. 4 1(×3) 6 7 9 1. Air filter element 4. Remove the sponge material from the air filter element frame.
PERIODIC MAINTENANCE AND MINOR REPAIR CAUTION: ● Make sure that the air filter element is properly seated in the air filter case. ● The engine should never be operated without the air filter element installed, otherwise the piston(s) and/or cylinder(s) may become excessively worn. 8. Install the panel. side of the tailpipe housing. EAU21241 ECA10480 Cleaning the spark arrester The spark arrester should be cleaned at the intervals specified in the periodic maintenance and lubrication chart.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU21251 Carburetor 1 2 1 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. EAU21381 Checking the throttle cable free play 1 3 1. Purging bolt 4 5 6 7 5.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU21401 EAU35830 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. To maximize the performance, durability, and safe operation of your machine, note the following points regarding the specified tires.
PERIODIC MAINTENANCE AND MINOR REPAIR ● 1 ● 2 3 4 ● during a ride. Securely pack the heaviest items close to the center of the vehicle and distribute the weight evenly on both sides. Adjust the suspension and tire air pressure with regard to the load. Check the tire condition and air pressure before each ride. has a nail or glass fragments in it, or if the sidewall is cracked, have a Yamaha dealer replace the tire immediately. Minimum tire tread depth (front and rear): 4.0 mm (0.
PERIODIC MAINTENANCE AND MINOR REPAIR high-quality product. EAU21940 Spoke wheels To maximize the performance, durability, and safe operation of your machine, 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 damage before each ride. If any damage 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.
PERIODIC MAINTENANCE AND MINOR REPAIR been approved by Yamaha. EAU22030 Adjusting the clutch lever free play 1 2 1 2 (a) 3 4 (a) 5 (b) 3 (b) 4 5 6 7 8 9 1. Locknut (clutch lever) 2. Adjusting bolt 3. Locknut (clutch cable) 4. Adjusting nut 5. Clutch lever free play The clutch lever free play should measure 10.0–15.0 mm (0.39–0.59 in) as shown. Periodically check the clutch lever free play and, if necessary, adjust it as follows. 1. Loosen the locknut at the clutch lever. 2.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU22092 Adjusting the brake lever free play 3. Tighten the locknut. ● 1 (b) 3 (a) 2 1. Brake lever free play adjusting screw 2. Locknut 3. Brake lever free play The brake lever free play should measure 2.0–5.0 mm (0.08–0.20 in) as shown. Periodically check the brake lever free play and, if necessary, adjust it as follows. 1. Loosen the locknut at the brake lever. 2. To increase the brake lever free play, turn the adjusting screw in direction (a).
PERIODIC MAINTENANCE AND MINOR REPAIR 1 2 3 4 5 The front and rear brake pads must be checked for wear at the intervals specified in the periodic maintenance and lubrication chart. Each brake pad is provided with a wear indicator, which allows you to check the brake pad wear without having to disassemble the brake. To check the brake pad wear, check the position of the wear indicator while applying the brake.
PERIODIC MAINTENANCE AND MINOR REPAIR ● ● refilling. Water will significantly lower the boiling point of the fluid and may result in vapor lock. Brake fluid may deteriorate painted surfaces or plastic parts. Always clean up spilled fluid immediately. As the brake pads wear, it is normal for the brake fluid level to gradually go down. However, if the brake fluid level goes down suddenly, have a Yamaha dealer check the cause.
PERIODIC MAINTENANCE AND MINOR REPAIR are in the same position for proper wheel alignment. 2 (b) 1 2 1 Tightening torque: Axle nut: 105 Nm (10.5 m·kgf, 76 ft·lbf) 4. Insert a new cotter pin into the axle nut, and then bend its ends as shown. 3 1 3 1. Drive chain slack 4 (a) 4. If the drive chain slack is incorrect, adjust it as follows. 5 EAU22910 6 7 8 9 To adjust the drive chain slack 1. Remove the cotter pin from the axle nut, and then loosen the axle nut. 2.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU23022 Cleaning and lubricating the drive chain 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. ECA11110 CAUTION: Do not use engine oil or any other lubricants for the drive chain, as they may contain substances that could damage the O-rings.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU23111 Checking and lubricating the throttle grip and cable 1 2 EAU23140 Checking and lubricating the brake and clutch levers EAU23180 Lubricating the brake pedal The operation of the throttle grip should be checked before each ride. In addition, the cable should be lubricated at the intervals specified in the periodic maintenance chart.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU23200 Checking and lubricating the sidestand 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 maintenance and lubrication chart. 2 To check the condition EWA10750 WARNING Securely support the vehicle so that there is no danger of it falling over.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU23280 1 2 3 4 5 6 7 EAU23290 Checking the steering Checking the wheel bearings 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.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU23380 Battery 1 dangerous since it contains sulfuric acid, which causes severe burns. Avoid any contact with skin, eyes or clothing and always shield your eyes when working near batteries. In case of contact, administer the following FIRST AID. EXTERNAL: Flush with plenty of water. INTERNAL: Drink large quantities of water or milk and immediately call a physician. EYES: Flush with water for 15 minutes and seek prompt medical attention.
PERIODIC MAINTENANCE AND MINOR REPAIR 1 2 battery, a special (constant-voltage) battery charger is required. Using a conventional battery charger will damage the battery. If you do not have access to a sealed-type (MF) battery charger, have a Yamaha dealer charge your battery. EAU23502 Replacing the fuse 1 2 3. Turn the key to “ON” and turn on the electrical circuits to check if the devices operate. 4. If the fuse immediately blows again, have a Yamaha dealer check the electrical system.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU23841 Replacing the headlight bulb This model is equipped with a quartz bulb headlight. If the headlight bulb burns out, replace it as follows. 1. Remove cowling A together with the headlight unit. (See page 6-6.) 2. Disconnect the headlight coupler, and then remove the bulb cover. 1 1 2 3 2 1 1. Headlight coupler 2. Headlight bulb cover 3.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU24191 1 Replacing the taillight bulb 1 1. Remove the taillight lens by removing the screws. 1 2 2 3 1. Do not touch the glass part of the bulb. 4 5 6 7 5. Install the headlight bulb cover, and then connect the coupler. 6. Install the cowling together with the headlight unit. 7. Have a Yamaha dealer adjust the headlight beam if necessary. 1(×2) 1. Screw 2. Taillight lens 2. Remove the defective bulb by pushing it in and turning it counterclockwise.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU24350 Supporting the machine 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 machine to stand upright. Check that the machine 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.
PERIODIC MAINTENANCE AND MINOR REPAIR 1 2 2. Lift the wheel up between the fork legs. 4. Tighten the wheel axle holder nuts to the specified torque. NOTE: Make sure that there is enough space between the brake pads before inserting the brake disc and that the slot in the tripmeter gear unit fits over the retainer on the fork leg. NOTE: Tighten the upper nuts first, and then the lower ones. When the nuts are tightened in this sequence, there should be a gap at the bottom of the axle holder.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU25080 Rear wheel page 6-31. 3. Remove each swingarm end cover by removing the screws. EAU25280 To remove the rear wheel EWA10820 ● ● WARNING It is advisable to have a Yamaha dealer service the wheel. Securely support the machine so that there is no danger of it falling over. 1. Remove the axle nut cotter pin, and then loosen the axle nut. 2 1(×2) 2 2(×2) 2(×2) 1. Swingarm end cover 2. Screw 4.
PERIODIC MAINTENANCE AND MINOR REPAIR between the brake pads before inserting the brake disc between the pads. 1 2 3 4 2. Install the drive chain onto the rear sprocket. 3. Install each swingarm end cover by installing the screws, and then lower the rear wheel so that it is on the ground. 4. Adjust the drive chain slack. (See page 6-21.) 5. Tighten the axle nut to the specified torque, and then install the cotter pin. 5 6 Tightening torque: Axle nut: 105 Nm (10.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU25901 Troubleshooting chart EWA10840 WARNING Keep away open flames and do not smoke while checking or working on the fuel system. 1. Fuel There is enough fuel. Check the compression. There is no fuel. Supply fuel. There is compression. Check the ignition. There is no compression. Have a Yamaha dealer check the vehicle. Check the fuel level in the fuel tank. 2 The engine does not start. Check the compression. 2.
MACHINE CARE AND STORAGE EAU26000 Care 1 2 3 4 5 6 7 8 9 While the open design of a machine reveals the attractiveness of the technology, it also makes it more vulnerable. Rust and corrosion can develop even if high-quality components are used. A rusty exhaust pipe may go unnoticed on a car, however, it detracts from the overall appearance of a machine.
MACHINE 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.
MACHINE CARE AND STORAGE away the paint. 1 2 3 4 5 6 7 8 9 NOTE: Consult a Yamaha dealer for advice on what products to use. EAU26150 Storage Short-term Always store your machine in a cool, dry place and, if necessary, protect it against dust with a porous cover. ECA10810 CAUTION: ● Storing the machine in a poorly ventilated room or covering it with a tarp, while it is still wet, will allow water and humidity to seep in and cause rust.
MACHINE CARE AND STORAGE spark plug cap. EWA10950 WARNING To prevent damage or injury from sparking, make sure to ground the spark plug electrodes while turning the engine over. than 30 °C (90 °F)]. For more information on storing the battery, see page 6-27. NOTE: Make any necessary repairs before storing the machine. 2 6. Lubricate all control cables and the pivoting points of all levers and pedals as well as of the sidestand/ centerstand. 7.
SPECIFICATIONS EAU2633D Dimensions: 1 2 3 4 5 6 7 8 9 Overall length: 2095 mm (82.5 in) Overall width: 835 mm (32.9 in) Overall height: 1260 mm (49.6 in) Seat height: 915 mm (36.0 in) Wheelbase: 1405 mm (55.3 in) Ground clearance: 305 mm (12.01 in) Minimum turning radius: 2200 mm (86.6 in) Weight: With oil and fuel: 124.0 kg (273 lb) Engine: Engine type: Air cooled 4-stroke, DOHC Cylinder arrangement: Forward-inclined single cylinder Displacement: 249.0 cm3 (15.19 cu.in) Bore × stroke: 73.0 × 59.
SPECIFICATIONS 5th: 24/27 (0.889) 6th: 22/29 (0.759) Chassis: Frame type: Semi double cradle Caster angle: 26.00 ° Trail: 108.0 mm (4.25 in) Front tire: Type: With tube Size: 80/100-21 51M Manufacturer/model: DUNLOP/D739FA Rear tire: Type: With tube Size: 100/100-18 59M Manufacturer/model: DUNLOP/D739 Maximum load: 90 kg (198 lb) * (Total weight of rider, passenger, cargo and accessories) Tire air pressure (measured on cold tires): Off-road riding: Front: 100 kPa (15 psi) (1.
SPECIFICATIONS Fuse: Fuse: 15.
CONSUMER INFORMATION EAU26351 Identification numbers Record the key identification number, vehicle identification number and model label information in the spaces provided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen. KEY IDENTIFICATION NUMBER: EAU26381 Key identification number 1 2 1 3 1.
CONSUMER INFORMATION EAU26480 Model label 1 1 2 3 4 5 6 7 1. Model label The model label is affixed to the frame under the seat. (See page 3-6.) Record the information on this label in the space provided. This information will be needed when ordering spare parts from a Yamaha dealer.
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 of any device or element of design incorporated into any new vehicle 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 d
CONSUMER INFORMATION EAU26651 Maintenance record Have a Yamaha dealer complete this record when the machine is serviced.
CONSUMER INFORMATION EAU26670 YAMAHA MOTOR CORPORATION, U.S.A.
CONSUMER INFORMATION 1 2 3 4 5 6 7 8 9 9-6
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.
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. 1 2 3 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.
INDEX A Fuel ........................................................... 3-4 Fuel cock ................................................... 3-5 Fuel tank breather hose ............................ 3-5 Fuel tank cap............................................. 3-3 Fuse, replacing........................................ 6-28 Accessories and replacement parts ........6-17 Air filter element, cleaning .......................6-12 B Battery .....................................................
YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2005.5–1.
