Read this manual carefully before operating this vehicle.
U46B11E0.book Page 1 Wednesday, May 13, 2009 8:55 AM EAU10042 Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold.
U46B11E0.book Page 1 Wednesday, May 13, 2009 8:55 AM INTRODUCTION EAU10083 Congratulations on your purchase of the Yamaha XV250Z(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.
U46B11E0.book Page 1 Wednesday, May 13, 2009 8:55 AM 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.
U46B11E0.book Page 2 Wednesday, May 13, 2009 8:55 AM IMPORTANT MANUAL INFORMATION EAU10193 XV250Z(C) OWNER’S MANUAL ©2009 by Yamaha Motor Corporation, U.S.A. 1st edition, April 2009 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.
U46B11E0.book Page 1 Wednesday, May 13, 2009 8:55 AM 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 ...........................................
U46B11E0.book Page 2 Wednesday, May 13, 2009 8:55 AM TABLE OF CONTENTS Checking the wheel bearings .......7-29 Battery ..........................................7-30 Replacing the fuses ......................7-31 Replacing the headlight bulb ........7-32 Replacing the tail/brake light bulb ...........................................7-33 Replacing a turn signal light bulb ...........................................7-34 Supporting the motorcycle ............7-35 Front wheel ..................................
U46B11E0.book Page 1 Wednesday, May 13, 2009 8:55 AM LOCATION OF IMPORTANT LABELS EAU10383 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.
U46B11E0.book Page 2 Wednesday, May 13, 2009 8:55 AM 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.
U46B11E0.book Page 1 Wednesday, May 13, 2009 8:55 AM SAFETY INFORMATION EAU10283 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.
U46B11E0.book Page 2 Wednesday, May 13, 2009 8:55 AM 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.
U46B11E0.book Page 3 Wednesday, May 13, 2009 8:55 AM 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.
U46B11E0.book Page 4 Wednesday, May 13, 2009 8:55 AM 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.
U46B11E0.book Page 1 Wednesday, May 13, 2009 8:55 AM DESCRIPTION EAU10410 Left view 3 1. 2. 3. 4. 5. 6. 7. 8. 9. Fuel cock (page 4-7) 10.
U46B11E0.book Page 2 Wednesday, May 13, 2009 8:55 AM DESCRIPTION EAU10420 Right view 3 1. 2. 3. 4. 5. 6. 7. 8. 9. Owner’s tool kit (page 7-2) 10.
U46B11E0.book Page 3 Wednesday, May 13, 2009 8:55 AM DESCRIPTION EAU10430 Controls and instruments 3 1. 2. 3. 4. 5. 6. 7. 8.
U46B11E0.book Page 1 Wednesday, May 13, 2009 8:55 AM 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 The main switch controls the ignition and lighting systems. The various main switch positions are described below.
U46B11E0.book Page 2 Wednesday, May 13, 2009 8:55 AM 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.
U46B11E0.book Page 3 Wednesday, May 13, 2009 8:55 AM 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 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.
U46B11E0.book Page 4 Wednesday, May 13, 2009 8:55 AM INSTRUMENT AND CONTROL FUNCTIONS EAU12870 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 engine 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.
U46B11E0.book Page 5 Wednesday, May 13, 2009 8:55 AM 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. 1. Fuel tank cap 2. Unlock. Fuel Make sure there is sufficient gasoline in the tank.
U46B11E0.book Page 6 Wednesday, May 13, 2009 8:55 AM 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 EAU13301 4 1. Fuel tank filler tube 2. 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.
U46B11E0.book Page 7 Wednesday, May 13, 2009 8:55 AM 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. 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.
U46B11E0.book Page 8 Wednesday, May 13, 2009 8:55 AM INSTRUMENT AND CONTROL FUNCTIONS EAU13630 EAU13730 Starter (choke) lever Steering lock 1. Starter (choke) lever 1. Steering lock 4 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). To lock the steering 1. Turn the handlebar all the way to the right. 2.
U46B11E0.book Page 9 Wednesday, May 13, 2009 8:55 AM 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.
U46B11E0.book Page 10 Wednesday, May 13, 2009 8:55 AM 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. 4 ECA10101 To avoid damaging the mechanism, do not attempt to turn beyond the maximum or minimum settings.
U46B11E0.book Page 11 Wednesday, May 13, 2009 8:55 AM INSTRUMENT AND CONTROL FUNCTIONS below and have a Yamaha dealer repair it if it does not function properly. 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.
U46B11E0.book Page 12 Wednesday, May 13, 2009 8:55 AM 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 4 If a malfunction is noted, have a Yamaha dealer check the system before riding. NO The neutral switch may not be working correctly.
U46B11E0.book Page 1 Wednesday, May 13, 2009 8:55 AM 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.
U46B11E0.book Page 2 Wednesday, May 13, 2009 8:55 AM FOR YOUR SAFETY – PRE-OPERATION CHECKS ITEM CHECKS Clutch • • • • Throttle grip • Make sure that operation is smooth. • Check cable free play. • If necessary, have Yamaha dealer adjust cable free play and lubricate cable and grip housing. Control cables • Make sure that operation is smooth. • Lubricate if necessary. Drive chain • • • • Check chain slack. Adjust if necessary. Check chain condition. Lubricate if necessary.
U46B11E0.book Page 3 Wednesday, May 13, 2009 8:55 AM FOR YOUR SAFETY – PRE-OPERATION CHECKS ITEM Battery CHECKS • Check fluid level. • Fill with distilled water if necessary.
U46B11E0.book Page 1 Wednesday, May 13, 2009 8:55 AM 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.
U46B11E0.book Page 2 Wednesday, May 13, 2009 8:55 AM OPERATION AND IMPORTANT RIDING POINTS (choke) turned on, then about 2.5 minutes with the starter (choke) in the halfway position. 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. 1. Shift pedal 2.
U46B11E0.book Page 3 Wednesday, May 13, 2009 8:55 AM OPERATION AND IMPORTANT RIDING POINTS ECA10260 NOTICE ● ● 6 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.
U46B11E0.book Page 4 Wednesday, May 13, 2009 8:55 AM OPERATION AND IMPORTANT RIDING POINTS 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 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.
U46B11E0.book Page 1 Wednesday, May 13, 2009 8:55 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU17232 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.
U46B11E0.book Page 2 Wednesday, May 13, 2009 8:55 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU17341 Owner’s tool kit 1. Owner’s tool kit The owner’s tool kit is located behind panel A. (See page 7-8.) 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.
U46B11E0.book Page 3 Wednesday, May 13, 2009 8:55 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU17580 Periodic maintenance chart for the emission control system 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 Fuel line • Check fuel and vacuum hoses for cracks or damage. • Replace if necessary.
U46B11E0.book Page 4 Wednesday, May 13, 2009 8:55 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU32164 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.
U46B11E0.book Page 5 Wednesday, May 13, 2009 8:55 AM 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.
U46B11E0.book Page 6 Wednesday, May 13, 2009 8:55 AM 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.
U46B11E0.book Page 7 Wednesday, May 13, 2009 8:55 AM PERIODIC MAINTENANCE AND ADJUSTMENT INITIAL No. ITEM 27 * Lights, signals and switches ROUTINE • Check operation. • Adjust headlight beam.
U46B11E0.book Page 8 Wednesday, May 13, 2009 8:55 AM 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.
U46B11E0.book Page 9 Wednesday, May 13, 2009 8:55 AM 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.
U46B11E0.book Page 10 Wednesday, May 13, 2009 8:55 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU19681 Canister (for California only) ● Make sure that the canister breather is not blocked, and if necessary, clean it. EAU42103 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.
U46B11E0.book Page 11 Wednesday, May 13, 2009 8:55 AM PERIODIC MAINTENANCE AND ADJUSTMENT 1. Engine oil level check window 2. Maximum level mark 3. Minimum level mark 1. Engine oil filler cap 5. Remove and replace the oil filter element and O-ring. 4. If the engine oil is below the minimum level mark, add sufficient oil of the recommended type to raise it to the correct level. 7 To change the engine oil (with or without oil filter element replacement) 1.
U46B11E0.book Page 12 Wednesday, May 13, 2009 8:55 AM PERIODIC MAINTENANCE AND ADJUSTMENT Tightening torque: Oil filter element cover screw: 10 Nm (1.0 m·kgf, 7.2 ft·lbf) TIP Make sure that the O-ring is properly seated. 7. Install the engine oil drain bolt, and then tighten it to the specified torque. TIP Check the washer for damage and replace it if necessary. Tightening torque: Engine oil drain bolt: 34 Nm (3.4 m·kgf, 24 ft·lbf) Recommended engine oil: See page 9-1.
U46B11E0.book Page 13 Wednesday, May 13, 2009 8:55 AM 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.
U46B11E0.book Page 14 Wednesday, May 13, 2009 8:55 AM 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.
U46B11E0.book Page 15 Wednesday, May 13, 2009 8:55 AM 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.
U46B11E0.book Page 16 Wednesday, May 13, 2009 8:55 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU21401 EAU32522 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.
U46B11E0.book Page 17 Wednesday, May 13, 2009 8:55 AM PERIODIC MAINTENANCE AND ADJUSTMENT Tire inspection EWA10561 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.
U46B11E0.book Page 18 Wednesday, May 13, 2009 8:55 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU21941 Spoke wheels EWA10610 WARNING The wheels on this model are not designed for use with tubeless tires. Do not attempt to use tubeless tires on this model. ● Ride at moderate speeds after changing a tire since the tire surface must first be “broken in” for it to develop its optimal characteristics.
U46B11E0.book Page 19 Wednesday, May 13, 2009 8:55 AM PERIODIC MAINTENANCE AND ADJUSTMENT 3. To increase the clutch lever free play, turn the adjusting bolt in direction (a). To decrease the clutch lever free play, turn the adjusting bolt in direction (b). TIP If the specified clutch lever free play could be obtained as described above, skip steps 4–7. 6. To increase the clutch lever free play, turn the adjusting nut in direction (a).
U46B11E0.book Page 20 Wednesday, May 13, 2009 8:55 AM PERIODIC MAINTENANCE AND ADJUSTMENT 3. Tighten the locknut. EAU22201 EWA10630 WARNING ● ● After adjusting the brake lever free play, check the free play and make sure that the brake is working properly. A soft or spongy feeling in the brake lever can indicate the presence of air in the hydraulic system. If there is air in the hydraulic system, have a Yamaha dealer bleed the system before operating the motorcycle.
U46B11E0.book Page 21 Wednesday, May 13, 2009 8:55 AM PERIODIC MAINTENANCE AND ADJUSTMENT 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. Periodically check the brake pedal free play and, if necessary, 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).
U46B11E0.book Page 22 Wednesday, May 13, 2009 8:55 AM PERIODIC MAINTENANCE AND ADJUSTMENT 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 maintenance and lubrication chart. 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 2 EAU22420 Front brake pads 1 1.
U46B11E0.book Page 23 Wednesday, May 13, 2009 8:55 AM PERIODIC MAINTENANCE AND ADJUSTMENT ● Use only the recommended quality brake fluid, otherwise the rubber seals may deteriorate, causing leakage and poor braking performance. Recommended brake fluid: DOT 4 ● ● 7 ● ● Refill with the same type of brake fluid. Mixing fluids may result in a harmful chemical reaction and lead to poor braking performance. Be careful that water does not enter the master cylinder when refilling.
U46B11E0.book Page 24 Wednesday, May 13, 2009 8:55 AM PERIODIC MAINTENANCE AND ADJUSTMENT 1. Drive chain slack 4. If the drive chain slack is incorrect, adjust it as follows. EAU22861 To adjust the drive chain slack 1. Loosen the 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.
U46B11E0.book Page 25 Wednesday, May 13, 2009 8:55 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU23014 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. 1.
U46B11E0.book Page 26 Wednesday, May 13, 2009 8:55 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU23111 EAU23093 Checking and lubricating the cables Checking and lubricating the throttle grip and cable The operation of all control cables and the condition of the cables should be checked before each ride, and the cables and cable ends should be lubricated if necessary. If a cable is damaged or does not move smoothly, have a Yamaha dealer check or replace it.
U46B11E0.book Page 27 Wednesday, May 13, 2009 8:55 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU23142 Recommended lubricant: Lithium-soap-based grease Checking and lubricating the brake and clutch levers Brake lever Clutch lever 7 The operation of the brake and clutch levers should be checked before each ride, and the lever pivots should be lubricated if necessary.
U46B11E0.book Page 28 Wednesday, May 13, 2009 8:55 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU23202 Checking and lubricating the sidestand EAUM1650 Lubricating the swingarm pivots The swingarm pivots must be lubricated at the intervals specified in the periodic maintenance and lubrication chart.
U46B11E0.book Page 29 Wednesday, May 13, 2009 8:55 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU23283 Checking the steering ECA10590 NOTICE If any damage is found or the front fork does not operate smoothly, have a Yamaha dealer check or repair it. 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.
U46B11E0.book Page 30 Wednesday, May 13, 2009 8:55 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU23312 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 intervals specified in the periodic maintenance and lubrication chart. To check the electrolyte level 1. Place the vehicle on a level surface and hold it in an upright position.
U46B11E0.book Page 31 Wednesday, May 13, 2009 8:55 AM PERIODIC MAINTENANCE AND ADJUSTMENT 1. Battery 2. Battery breather hose 7 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. NOTICE: When removing the battery, be sure the key is turned to “OFF”, then disconnect the negative lead before disconnecting the positive lead. 3. Fully charge the battery before installation. 4.
U46B11E0.book Page 32 Wednesday, May 13, 2009 8:55 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU23783 Specified fuses: Main fuse: 20.0 A Signaling system fuse: 10.0 A Replacing the headlight bulb This model is equipped with a quartz bulb headlight. If the headlight bulb burns out, replace it as follows. ECA10650 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.
U46B11E0.book Page 33 Wednesday, May 13, 2009 8:55 AM 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. Headlight coupler 2. Headlight bulb cover 3.
U46B11E0.book Page 34 Wednesday, May 13, 2009 8:55 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU24212 Replacing a turn signal light bulb 1. Remove the turn signal lens by removing the screws. 1. Tail/brake light bulb 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. NOTICE: Do not overtighten the screws, otherwise the lens may break. [ECA10681] 1. Turn signal light bulb 1. Screw 2.
U46B11E0.book Page 35 Wednesday, May 13, 2009 8:55 AM PERIODIC MAINTENANCE AND ADJUSTMENT 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 upright. 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.
U46B11E0.book Page 36 Wednesday, May 13, 2009 8:55 AM PERIODIC MAINTENANCE AND ADJUSTMENT 1. Wheel axle 2. Front wheel axle pinch bolt 1. Speedometer gear unit 3. Lift the front wheel off the ground according to the procedure on page 7-35. 4. Pull the wheel axle out, and then remove the wheel. NOTICE: Do not apply the brake after the wheel has been removed together with the brake disc, otherwise the brake pads will be forced shut. [ECA11071] 2. Lift the wheel up between the fork legs.
U46B11E0.book Page 37 Wednesday, May 13, 2009 8:55 AM 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. EAU25080 Rear wheel EAU32751 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.
U46B11E0.book Page 38 Wednesday, May 13, 2009 8:55 AM PERIODIC MAINTENANCE AND ADJUSTMENT 7. Push the wheel forward, and then remove the drive chain from the rear sprocket. TIP The drive chain does not need to be disassembled in order to remove and install the rear wheel. 8. Remove the axle nut. 9. Pull the wheel axle out, and then remove the wheel. EAU32764 To install the rear wheel 1.
U46B11E0.book Page 39 Wednesday, May 13, 2009 8:55 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU25851 Troubleshooting 7 Although Yamaha motorcycles receive a thorough inspection before shipment from the factory, trouble may occur during 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 checking these vital systems yourself.
U46B11E0.book Page 40 Wednesday, May 13, 2009 8:55 AM 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.
U46B11E0.book Page 1 Wednesday, May 13, 2009 8:55 AM 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.
U46B11E0.book Page 2 Wednesday, May 13, 2009 8:55 AM 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.
U46B11E0.book Page 3 Wednesday, May 13, 2009 8:55 AM 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.
U46B11E0.book Page 4 Wednesday, May 13, 2009 8:55 AM 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.
U46B11E0.book Page 1 Wednesday, May 13, 2009 8:55 AM 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.
U46B11E0.book Page 2 Wednesday, May 13, 2009 8:55 AM SPECIFICATIONS 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.
U46B11E0.book Page 3 Wednesday, May 13, 2009 8:55 AM SPECIFICATIONS 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: 20.0 A Signaling system fuse: 10.
U46B11E0.book Page 1 Wednesday, May 13, 2009 8:55 AM 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.
U46B11E0.book Page 2 Wednesday, May 13, 2009 8:55 AM 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.
U46B11E0.book Page 3 Wednesday, May 13, 2009 8:55 AM 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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U46B11E0.book Page 5 Wednesday, May 13, 2009 8:55 AM 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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U46B11E0.book Page 7 Wednesday, May 13, 2009 8:55 AM 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.
U46B11E0.book Page 8 Wednesday, May 13, 2009 8:55 AM 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.
U46B11E0.book Page 9 Wednesday, May 13, 2009 8:55 AM 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.
U46B11E0.book Page 10 Wednesday, May 13, 2009 8:55 AM 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.
U46B11E0.book Page 1 Wednesday, May 13, 2009 8:55 AM INDEX A F Air filter element, cleaning .................... 7-13 B Battery .................................................. 7-30 Brake and clutch levers, checking and lubricating..................... 7-27 Brake and shift pedals, checking and lubricating..................... 7-26 Brake fluid, changing ............................ 7-23 Brake fluid level, checking .................... 7-22 Brake lever .............................................
U46B11E0.book Page 2 Wednesday, May 13, 2009 8:55 AM INDEX Turn signal light bulb, replacing ............ 7-34 Turn signal switch ................................... 4-3 V Valve clearance .................................... 7-16 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 2009.05-0.
