Documente Academic
Documente Profesional
Documente Cultură
XV250S
XV250SC
LIT-11626-17-28 2UJ-28199-1C
EAU10041
INTRODUCTION
EAU10080
Congratulations on your purchase of the Yamaha XV250/XV250C. This model is the result of Yamaha’s
vast experience in the production of fine sporting, touring, and pacesetting racing machines. It repre-
sents the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields.
This manual will give you an understanding of the operation, inspection, and basic maintenance of this
motorcycle. If you have any questions concerning the operation or maintenance of your motorcycle,
please consult a Yamaha dealer.
The design and manufacture of this Yamaha motorcycle fully comply with the emissions standards for
clean air applicable at the date of manufacture. Yamaha has met these standards without reducing the
performance or economy of operation of the motorcycle. To maintain these high standards, it is impor-
tant that you and your Yamaha dealer pay close attention to the recommended maintenance schedules
and operating instructions contained within this manual.
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 motor-
WARNING cycle operator, a bystander or a person inspecting or repairing the motorcycle.
A CAUTION indicates special precautions that must be taken to avoid damage to the motor-
CAUTION: cycle.
NOTE:
● This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle
is subsequently sold.
● Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most
current product information available at the time of printing, there may be minor discrepancies between your motorcycle
and this manual. If you have any questions concerning this manual, please consult your Yamaha dealer.
EWA10010
WARNING
PLEASE READ THIS MANUAL AND THE “YOU AND YOUR MOTORCYCLE: RIDING TIPS” BOOKLET CAREFULLY
AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE. DO NOT ATTEMPT TO OPERATE THIS MOTOR-
CYCLE UNTIL YOU HAVE ATTAINED ADEQUATE KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES
AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES. REGULAR INSPECTIONS
AND CAREFUL MAINTENANCE, ALONG WITH GOOD RIDING SKILLS, WILL ENSURE THAT YOU SAFELY ENJOY
THE CAPABILITIES AND THE RELIABILITY OF THIS MOTORCYCLE.
EAU10192
AFFIX DEALER
LABEL HERE
XV250S/XV250SC
OWNER’S MANUAL
©2003 by Yamaha Motor Corporation, U.S.A.
1st edition, May 2003
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
Printed in Japan.
P/N LIT-11626-17-28
TABLE OF CONTENTS
SAFETY INFORMATION ..................1-1 Pre-operation check list .................. 4-2 Adjusting the clutch lever free
Location of important labels ............1-5 play ........................................... 6-17
OPERATION AND IMPORTANT Adjusting the brake lever free
DESCRIPTION ..................................2-1 RIDING POINTS................................. 5-1 play ........................................... 6-18
Left view ..........................................2-1 Starting and warming up a cold Adjusting the brake pedal position
Right view ........................................2-2 engine ......................................... 5-1 and free play ............................. 6-19
Controls and instruments.................2-3 Starting a warm engine .................. 5-2 Adjusting the rear brake light
Shifting ........................................... 5-2 switch ....................................... 6-20
INSTRUMENT AND CONTROL Engine break-in .............................. 5-4 Checking the front brake pads
FUNCTIONS .......................................3-1 Parking ........................................... 5-4 and rear brake shoes ............... 6-21
Main switch .....................................3-1 Checking the brake fluid level ...... 6-21
Indicator lights ................................3-1 PERIODIC MAINTENANCE AND Changing the brake fluid .............. 6-22
Speedometer unit ...........................3-2 MINOR REPAIR ................................. 6-1 Drive chain slack .......................... 6-22
Handlebar switches ........................3-2 PERIODIC MAINTENANCE ........... 6-1 Lubricating the drive chain ........... 6-24
Clutch lever .....................................3-3 Owner’s tool kit ............................... 6-1 Checking and lubricating the
Shift pedal .......................................3-4 Periodic maintenance chart for the cables ....................................... 6-25
Brake lever .....................................3-4 emission control system ............. 6-3 Checking and lubricating the
Brake pedal ....................................3-4 General maintenance and throttle grip and cable ............... 6-25
Fuel tank cap ..................................3-5 lubrication chart .......................... 6-4 Checking and lubricating the
Fuel .................................................3-5 Checking the spark plugs ............... 6-8 brake and shift pedals .............. 6-26
Fuel cock ........................................3-6 Canister (for California only) .......... 6-9 Checking and lubricating the
Starter (choke) lever .......................3-7 Engine oil and oil filter element .... 6-10 brake and clutch levers ............ 6-26
Steering lock ...................................3-8 Cleaning the air filter element ...... 6-12 Checking and lubricating the
Rider seat .......................................3-8 Adjusting the carburetor ............... 6-14 sidestand .................................. 6-26
Helmet holder .................................3-9 Adjusting the throttle cable free Checking the front fork ................. 6-27
Adjusting the shock absorber play ........................................... 6-14 Checking the steering .................. 6-27
assemblies ..................................3-9 Adjusting the valve clearance ...... 6-14 Checking the wheel bearings ....... 6-28
Sidestand ......................................3-10 Tires ............................................. 6-15 Battery ......................................... 6-28
Ignition circuit cut-off system ........3-11 Spoke wheels ............................... 6-16 Replacing the fuses ..................... 6-30
Accessories and replacement Replacing the headlight bulb ....... 6-31
PRE-OPERATION CHECKS ..............4-1 parts .......................................... 6-17 Supporting the motorcycle ........... 6-32
TABLE OF CONTENTS
Front wheel ...................................6-33
Rear wheel ...................................6-34
Troubleshooting ............................6-36
Troubleshooting chart ...................6-37
SPECIFICATIONS .............................8-1
CONSUMER INFORMATION.............9-1
Identification numbers ....................9-1
Reporting safety defects .................9-3
Motorcycle noise regulation ............9-4
Maintenance record ........................9-5
YAMAHA MOTOR CORPORATION,
U.S.A. STREET AND ENDURO
MOTORCYCLE LIMITED
WARRANTY ...............................9-7
YAMAHA EXTENDED SERVICE
(Y.E.S.) .......................................9-9
SAFETY INFORMATION
EAU10250
AND/OR WHEN MADE NECES- • Ride where other motorists can
SARY BY MECHANICAL CONDI- see you. Avoid riding in another
MOTORCYCLES ARE SINGLE TIONS. motorist’s blind spot.
1 TRACK VEHICLES. THEIR SAFE USE ● Many motorcycle accidents in-
AND OPERATION ARE DEPENDENT Safe riding volve inexperienced operators. In
UPON THE USE OF PROPER RIDING ● Always make pre-operation fact, many operators who have
TECHNIQUES AS WELL AS THE EX- checks. Careful checks may help been involved in accidents do not
PERTISE OF THE OPERATOR. EV- prevent an accident. even have a current motorcycle li-
ERY OPERATOR SHOULD KNOW ● This motorcycle is designed to car- cense.
THE FOLLOWING REQUIREMENTS ry the operator and a passenger. • Make sure that you are qualified
BEFORE RIDING THIS MOTOR- ● The failure of motorists to detect and that you only lend your
CYCLE. and recognize motorcycles in traf- motorcycle to other qualified op-
HE OR SHE SHOULD: fic is the predominating cause of erators.
● OBTAIN THOROUGH INSTRUC- automobile/motorcycle accidents. • Know your skills and limits.
TIONS FROM A COMPETENT Many accidents have been caused Staying within your limits may
SOURCE ON ALL ASPECTS OF by an automobile driver who did help you to avoid an accident.
MOTORCYCLE OPERATION. not see the motorcycle. Making • We recommend that you prac-
● OBSERVE THE WARNINGS AND yourself conspicuous appears to tice riding your motorcycle
MAINTENANCE REQUIRE- be very effective in reducing the where there is no traffic until you
MENTS IN THE OWNER’S MAN- chance of this type of accident. have become thoroughly famil-
UAL. Therefore: iar with the motorcycle and all of
● OBTAIN QUALIFIED TRAINING • Wear a brightly colored jacket. its controls.
IN SAFE AND PROPER RIDING • Use extra caution when ap- ● Many motorcycle accidents have
TECHNIQUES. proaching and passing through been caused by error of the motor-
● OBTAIN PROFESSIONAL TECH- intersections, since intersec- cycle operator. A typical error
NICAL SERVICE AS INDICATED tions are the most likely places made by the operator is veering
BY THE OWNER’S MANUAL for motorcycle accidents to oc-
cur.
1-1
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SAFETY INFORMATION
wide on a turn due to EXCESSIVE ● This motorcycle is designed for on- cause burns. Always wear protec-
SPEED or undercornering (insuffi- road use only, therefore, it is not tive clothing that covers your legs,
cient lean angle for the speed). suitable for off-road use. ankles, and feet.
• Always obey the speed limit and ● Passengers should also observe 1
never travel faster than warrant- Protective apparel the precautions mentioned above.
ed by road and traffic conditions. The majority of fatalities from motor-
• Always signal before turning or cycle accidents are the result of head Modifications
changing lanes. Make sure that injuries. The use of a safety helmet is Modifications made to this motorcycle
other motorists can see you. the single most critical factor in the pre- not approved by Yamaha, or the re-
● The posture of the operator and vention or reduction of head injuries. moval of original equipment, may ren-
passenger is important for proper ● Always wear an approved helmet. der the motorcycle unsafe for use and
control. ● Wear a face shield or goggles. may cause severe personal injury.
• The operator should keep both Wind in your unprotected eyes Modifications may also make your
hands on the handlebar and could contribute to an impairment motorcycle illegal to use.
both feet on the operator foot- of vision which could delay seeing
rests during operation to main- a hazard. Loading and accessories
tain control of the motorcycle. ● The use of a jacket, heavy boots, Adding accessories or cargo to your
• The passenger should always trousers, gloves, etc., is effective in motorcycle can adversely affect stabili-
hold onto the operator, seat preventing or reducing abrasions ty and handling if the weight distribution
strap, or grab bar, if equipped, or lacerations. of the motorcycle is changed. To avoid
with both hands and keep both ● Never wear loose-fitting clothes, the possibility of an accident, use ex-
feet on the passenger footrests. otherwise they could catch on the treme caution when adding cargo or
• Never carry a passenger unless control levers, footrests, or wheels accessories to your motorcycle. Use
he or she can firmly place both and cause injury or an accident. extra care when riding a motorcycle
feet on the passenger footrests. ● Never touch the engine or exhaust that has added cargo or accessories.
● Never ride under the influence of system during or after operation. Here are some general guidelines to
alcohol or other drugs. They become very hot and can follow if loading cargo or adding acces-
sories to your motorcycle:
1-2
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SAFETY INFORMATION
Loading Accessories are added to the handlebar or
The total weight of the operator, pas- Genuine Yamaha accessories have front fork area, they must be as
senger, accessories and cargo must been specifically designed for use on lightweight as possible and
1 not exceed the maximum load limit of this motorcycle. Since Yamaha cannot should be kept to a minimum.
195 kg (430 lb) (CAL) / 196 kg (432 lb) test all other accessories that may be • Bulky or large accessories may
(U49). When loading within this weight available, you must personally be re- seriously affect the stability of
limit, keep the following in mind: sponsible for the proper selection, in- the motorcycle due to aerody-
● Cargo and accessory weight stallation and use of non-Yamaha namic effects. Wind may at-
should be kept as low and close to accessories. Use extreme caution tempt to lift the motorcycle, or
the motorcycle as possible. Make when selecting and installing any ac- the motorcycle may become un-
sure to distribute the weight as cessories. stable in cross winds. These ac-
evenly as possible on both sides of Keep the following guidelines in mind, cessories may also cause
the motorcycle to minimize imbal- as well as those provided under “Load- instability when passing or being
ance or instability. ing” when mounting accessories. passed by large vehicles.
● Shifting weights can create a sud- ● Never install accessories or carry • Certain accessories can dis-
den imbalance. Make sure that ac- cargo that would impair the perfor- place the operator from his or
cessories and cargo are securely mance of your motorcycle. Care- her normal riding position. This
attached to the motorcycle before fully inspect the accessory before improper position limits the free-
riding. Check accessory mounts using it to make sure that it does dom of movement of the opera-
and cargo restraints frequently. not in any way reduce ground tor and may limit control ability,
● Never attach any large or heavy clearance or cornering clearance, therefore, such accessories are
items to the handlebar, front fork, limit suspension travel, steering not recommended.
or front fender. These items, in- travel or control operation, or ob- ● Use caution when adding electri-
cluding such cargo as sleeping scure lights or reflectors. cal accessories. If electrical acces-
bags, duffel bags, or tents, can • Accessories fitted to the handle- sories exceed the capacity of the
create unstable handling or slow bar or the front fork area can motorcycle’s electrical system, an
steering response. create instability due to improper electric failure could result, which
weight distribution or aerody- could cause a dangerous loss of
namic changes. If accessories lights or engine power.
1-3
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SAFETY INFORMATION
Gasoline and exhaust gas • Do not park the motorcycle on a
● GASOLINE IS HIGHLY FLAMMA- slope or soft ground, otherwise it
BLE: may fall over.
• Always turn the engine off when • Do not park the motorcycle near 1
refueling. a flammable source (e.g. a kero-
• Take care not to spill any gaso- sene heater, or near an open
line on the engine or exhaust flame), otherwise it could catch
system when refueling. fire.
• Never refuel while smoking or in ● When transporting the motorcycle
the vicinity of an open flame. in another vehicle, make sure that
● Never start the engine or let it run it is kept upright and that the fuel
for any length of time in a closed cock is turned to “ON” or “RES” (for
area. The exhaust fumes are poi- vacuum type) / “OFF” (for manual
sonous and may cause loss of type). If it should lean over, gaso-
consciousness and death within a line may leak out of the carburetor
short time. Always operate your or fuel tank.
motorcycle in an area that has ad- ● If you should swallow any gaso-
equate ventilation. line, inhale a lot of gasoline vapor,
● Always turn the engine off before or allow gasoline to get into your
leaving the motorcycle unattended eyes, see your doctor immediately.
and remove the key from the main If any gasoline spills on your skin
switch. When parking the motor- or clothing, immediately wash the
cycle, note the following: affected area with soap and water
• The engine and exhaust system and change your clothes.
may be hot, therefore, park the
motorcycle in a place where pe-
destrians or children are not like-
ly to touch these hot areas.
1-4
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SAFETY INFORMATION
EAU10381
1-5
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SAFETY INFORMATION
1 4 California only
5 California only
1-6
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DESCRIPTION
EAU10410
Left view
DESCRIPTION
EAU10420
Right view
1. Tail/brake light
2. Rear turn signal lights
3. Rider seat (page 3-8)
4. Air filter element (page 6-12)
5. Front turn signal/position lights
6. Brake pedal (page 3-4)
7. Footrest
8. Owner’s tool kit (page 6-1)
9. Shock absorber assembly spring preload adjusting ring (page 3-9)
2-2
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DESCRIPTION
EAU10430
2-3
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CAUTION: 3
Do not use the parking position for
an extended length of time, other-
wise the battery may discharge.
1. High beam indicator light “HIGH BEAM”
The main switch controls the ignition
2. Neutral indicator light “NEUTRAL”
and lighting systems. The various main 3. Turn signal indicator light “TURN”
switch positions are described below.
EAU11040
EAU10510 Turn signal indicator light “TURN”
ON This indicator light flashes when the
All electrical systems are supplied with turn signal switch is pushed to the left or
power, and the headlight, meter light- right.
ing, taillight and position lights come
on, and the engine can be started. The EAU11070
3-1
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1. Odometer
2. Tripmeter 1. Dimmer switch “LIGHTS”
3. Tripmeter reset knob 2. Turn signal switch “TURN”
4. Speedometer 3. Horn switch “HORN”
The speedometer unit is equipped with Right
a speedometer, an odometer and a
tripmeter. The speedometer shows
riding speed. The odometer shows the
total distance traveled. The tripmeter
shows the distance traveled since it
was last set to zero with the reset knob.
The tripmeter can be used to estimate
the distance that can be traveled with a
full tank of fuel. This information will en-
able you to plan future fuel stops. 1. Engine stop switch “ENGINE STOP”
2. Start switch “START”
3-2
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EAU12690
Start switch “START”
Push this switch to crank the engine
with the starter.
3-3
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The shift pedal is located on the left The brake lever is located at the right The brake pedal is on the right side of
side of the engine and is used in com- handlebar grip. To apply the front the motorcycle. To apply the rear
bination with the clutch lever when brake, pull the lever toward the handle- brake, press down on the brake pedal.
shifting the gears of the 5-speed con- bar grip.
stant-mesh transmission equipped on
this motorcycle.
3-4
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WARNING
Make sure that the fuel tank cap is 3
properly closed before riding.
3-5
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ECA11400
CAUTION:
1. Arrow mark positioned over “ON”
Use only unleaded gasoline. The use
of leaded gasoline will cause severe With the fuel cock lever in this position,
damage to internal engine parts, fuel flows to the carburetor when the
such as the valves and piston rings, engine is running. Turn the fuel cock le-
as well as to the exhaust system. ver to this position when starting the en-
Your Yamaha engine has been de- gine and riding.
signed to use regular unleaded gaso-
line with a pump octane number
3-6
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1. Arrow mark positioned over “RES” 1. Arrow mark positioned over “PRI”
1. Starter (choke) lever
This indicates reserve. With the fuel This indicates prime. With the fuel cock
cock lever in this position, the fuel re- lever in this position, the engine can be Starting a cold engine requires a richer
serve is made available. Quickly turn “primed”. Turn the fuel cock lever to this air-fuel mixture, which is supplied by
the fuel cock lever to this position if you position when the engine has been al- the starter (choke).
run out of fuel while riding, otherwise lowed to run out of fuel. This sends fuel Move the lever in direction (a) to turn on
the engine may stall and will have to be directly to the carburetor, which will the starter (choke).
primed (see “PRI”). After turning the make starting easier. After the engine Move the lever in direction (b) to turn off
fuel cock lever to “RES”, refuel as soon has started, be sure to turn the lever to the starter (choke).
as possible and be sure to turn the fuel “ON” (or “RES” if you have not refueled
cock lever back to “ON”! yet).
3-7
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Steering lock 1. Open the steering lock cover, and Rider seat
then insert the key.
2. Push the key in, turn it 1/8 turn To remove the rider seat
counterclockwise so that it moves Remove the bolts, and then pull the rid-
out, and then release it. er seat off.
3. Remove the key, and then close
the lock cover.
3
1. Steering lock
3-8
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3
1. Projection
2. Seat holder
1. Helmet holder
2. Place the rider seat in the original 2. Unlock. 1. Spring preload adjusting ring
position, and then tighten the bolts. 2. Position indicator
To open the helmet holder, insert the
NOTE: key into the lock, and then turn the key Each shock absorber assembly is
Make sure that the rider seat is properly as shown. equipped with a spring preload adjust-
secured before riding. To lock the helmet holder, place it in the ing ring.
original position, and then remove the ECA10100
key. CAUTION:
EWA10160
Never attempt to turn an adjusting
WARNING
mechanism beyond the maximum or
Never ride with a helmet attached to minimum settings.
the helmet holder, since the helmet
may hit objects, causing loss of con-
trol and possibly an accident.
3-9
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3-10
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WARNING
If a malfunction is noted, have a
Yamaha dealer check the system be-
fore riding.
3-11
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3-12
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PRE-OPERATION CHECKS
EAU15591
The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly,
even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss
of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thorough visual inspec-
tion, to check the following points before each ride.
NOTE:
Pre-operation checks should be made each time the vehicle is used. Such an inspection can be accomplished in a very short
time; and the added safety it assures is more than worth the time involved.
EWA11150
4
WARNING
If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operating
the vehicle.
4-1
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PRE-OPERATION CHECKS
EAU15601
4-2
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PRE-OPERATION CHECKS
ITEM CHECKS PAGE
4-3
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5-1
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5-2
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EAU17021
5-4
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6-1
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WARNING
Modifications not approved by
Yamaha may cause loss of perfor-
mance, excessive emissions, and
render the vehicle unsafe for use.
Consult a Yamaha dealer before at-
tempting any changes.
6-2
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6-3
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6-4
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6-5
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NOTE:
From 19000 mi (31000 km) or 36 months, repeat the maintenance intervals starting from 7000 mi (11000 km) or 12 months.
6-6
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NOTE:
● The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
● Hydraulic brake system
• When disassembling the master cylinder or caliper cylinder, always replace the brake fluid. Check the brake fluid level
regularly and fill as required.
• Replace the oil seals on the inner parts of the master cylinder and caliper cylinder every two years.
• Replace the brake hoses every four years or if cracked or damaged.
6-7
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6-8
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Tightening torque:
Spark plug:
12.5 Nm (1.25 m·kgf, 9.0 ft·lbf)
NOTE:
If a torque wrench is not available when
installing a spark plug, a good estimate
6 of the correct torque is 1/4–1/2 turn
past finger tight. However, the spark 1. Canister cover
plug should be tightened to the speci- 2. Canister breather
fied torque as soon as possible. 3. Canister
4. Install the spark plug cap. This model is equipped with a canister
to prevent the discharging of fuel vapor
into the atmosphere. Before operating
this vehicle, make sure to check the fol-
lowing:
● Check each hose connection.
● Check each hose and canister for
cracks or damage. Replace if dam-
aged.
6-9
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6-10
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6-11
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1. Bolt
1. Hose
2. Air filter case
6-12
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CAUTION:
● Make sure that the air filter ele-
ment is properly seated in the
air filter case.
● The engine should never be op-
1. Screw erated without the air filter ele-
ment installed, otherwise the
4. Remove the air filter element by piston(s) and/or cylinder(s) may
1. Sponge material
removing the wing nut. 2. Air filter element frame become excessively worn.
6
6. Apply oil of the recommended type 9. Install the air filter case cover by in-
to the entire surface of the sponge stalling the screws.
material, and then squeeze the ex- 10. Connect the hoses to the air filter
cess oil out. case.
11. Install the air filter case onto the air
NOTE: filter joint, and then tighten the air
The air filter element should be wet but filter joint clamp screw.
not dripping. 12. Install the bolts.
1. Wing nut
Recommended oil:
2. Air filter case
Yamaha foam air filter oil or other
quality air filter oil
6-13
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Adjusting the carburetor Adjusting the throttle cable Adjusting the valve clearance
The carburetor is an important part of free play The valve clearance changes with use,
the engine and its emission control sys- resulting in improper air-fuel mixture
tem, which requires very sophisticated and/or engine noise. To prevent this
adjustment. Therefore, carburetor ad- from occurring, the valve clearance
justments should be left to Yamaha must be adjusted by a Yamaha dealer
dealer, who has the necessary profes- at the intervals specified in the periodic
sional knowledge and experience. maintenance and lubrication chart.
6-14
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in it, or if the sidewall is cracked, con- This motorcycle is equipped with spoke Spoke wheels
tact a Yamaha dealer immediately and wheels and tube tires. To maximize the performance, durabil-
have the tire replaced. EWA10460 ity, and safe operation of your motor-
WARNING cycle, note the following points
Minimum tire tread depth (front and ● The front and rear tires should regarding the specified wheels.
rear): ● The wheel rims should be checked
be of the same make and de-
1.0 mm (0.04 in) for cracks, bends or warpage, and
sign, otherwise the handling
EWA10560 characteristics of the vehicle the spokes for looseness or dam-
cannot be guaranteed. age before each ride. If any dam-
WARNING
● After extensive tests, only the age is found, have a Yamaha
● It is dangerous to ride with a dealer replace the wheel. Do not
worn-out tire. When a tire tread tires listed below have been ap-
proved for this model by attempt even the smallest repair to
begins to show crosswise lines, the wheel. A deformed or cracked
have a Yamaha dealer replace Yamaha Motor Co., Ltd.
wheel must be replaced.
the tire immediately. ● The wheel should be balanced 6
● The replacement of all wheel- Front tire: whenever either the tire or wheel
and brake-related parts, includ- Size:
3.00-18 47P has been changed or replaced. An
ing the tires, should be left to a unbalanced wheel can result in
Manufacturer/model:
Yamaha dealer, who has the CHENG SHIN/C-916 poor performance, adverse han-
necessary professional knowl- Rear tire: dling characteristics, and a short-
edge and experience. Size: ened tire life.
● It is not recommended to patch 130/90-15M/C 66P
Manufacturer/model: ● Ride at moderate speeds after
a punctured tube. If unavoid- changing a tire since the tire sur-
CHENG SHIN/C-915
able, however, patch the tube face must first be “broken in” for it
very carefully and replace it as to develop its optimal characteris-
soon as possible with a high- tics.
quality product.
6-16
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Accessories and replacement use of items which have not been Adjusting the clutch lever free
parts approved by Yamaha. play
EWA10620
WARNING
This motorcycle is not designed to
pull a trailer or to be attached to a
sidecar. The accessories or replace-
ment parts you choose for your
motorcycle should be designed spe-
cifically for this model, and they
must be securely mounted to main-
tain the inherent stability of the orig- 1. Locknut
inal design. Genuine Yamaha Parts 2. Clutch lever free play adjusting bolt
and Accessories are designed and 3. Clutch lever free play
6 tested to be compatible with your
motorcycle. Please consider Genu- The clutch lever free play should mea-
ine Yamaha Parts and Accessories sure 10.0–15.0 mm (0.39–0.59 in) as
before making a purchase. Use of shown. Periodically check the clutch le-
non-Yamaha-approved accessories ver free play and, if necessary, adjust it
or replacement parts may cause as follows.
loss of handling stability and riding 1. Loosen the locknut at the clutch le-
safety. Since Yamaha cannot control ver.
the quality of accessories or parts 2. To increase the clutch lever free
manufactured by other companies, play, turn the adjusting bolt in di-
Yamaha cannot be held liable for rection (a). To decrease the clutch
lever free play, turn the adjusting
bolt in direction (b).
6-17
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play could be obtained as de- ver and the crankcase. Adjusting the brake lever free
scribed above, tighten the locknut play
and skip the rest of the procedure,
otherwise proceed as follows.
4. Fully turn the adjusting bolt at the
clutch lever in direction (a) to loos-
en the clutch cable.
5. Loosen the locknut at the crank-
case.
1. Locknut
2. Brake lever free play adjusting bolt
3. Brake lever free play
6
The brake lever free play should mea-
sure 2.0–5.0 mm (0.08–0.20 in) as
shown. Periodically check the brake le-
ver free play and, if necessary, adjust it
1. Locknut as follows.
2. Clutch lever free play adjusting nut 1. Loosen the locknut at the brake le-
(crankcase)
ver.
6. To increase the clutch lever free 2. To increase the brake lever free
play, turn the adjusting nut in direc- play, turn the adjusting bolt in di-
tion (a). To decrease the clutch le- rection (a). To decrease the brake
ver free play, turn the adjusting nut lever free play, turn the adjusting
in direction (b). bolt in direction (b).
3. Tighten the locknut.
6-18
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WARNING
Brake pedal position After adjusting the brake pedal posi-
The top of the brake pedal should be tion, the brake pedal free play must
positioned approximately 60 mm (2.36 be adjusted.
in) above the top of the footrest as
shown. Periodically check the brake
pedal position and, if necessary, adjust
it as follows.
6-19
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The brake pedal free play should mea- obtained as described, have a Adjusting the rear brake light
sure 20.0–30.0 mm (0.79–1.18 in) at Yamaha dealer make this ad- switch
the brake pedal end. Periodically check justment.
the brake pedal free play and, if neces- ● After adjusting the brake pedal
sary, adjust it as follows. free play, check the operation of
To increase the brake pedal free play, the brake light.
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).
6-20
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Checking the front brake pads peared, have a Yamaha dealer replace Checking the brake fluid level
and rear brake shoes the brake pads as a set. Front brake
The front brake pads and the rear brake
shoes must be checked for wear at the EAU22540
EAU22420
Front brake pads
brake fluid, otherwise the rubber Changing the brake fluid Drive chain slack
seals may deteriorate, causing Have a Yamaha dealer change the The drive chain slack should be
leakage and poor braking perfor- brake fluid at the intervals specified in checked before each ride and adjusted
mance. the NOTE after the periodic mainte- if necessary.
nance and lubrication chart. In addition,
Recommended brake fluid: have the oil seals of the brake master EAU22770
To check the drive chain slack
DOT 4 cylinder and caliper as well as the
1. Place the motorcycle on a level
brake hose replaced at the intervals
● Refill with the same type of brake surface and hold it in an upright po-
listed below or whenever they are dam-
fluid. Mixing fluids may result in a sition.
aged or leaking.
harmful chemical reaction and ● Oil seals: Replace every two NOTE:
lead to poor braking performance. years. When checking and adjusting the drive
● Be careful that water does not en- ● Brake hose: Replace every four chain slack, the motorcycle should be
ter the brake fluid reservoir when years. positioned straight up and there should
refilling. Water will significantly be no weight on it. 6
lower the boiling point of the fluid
and may result in vapor lock. 2. Shift the transmission into the neu-
● Brake fluid may deteriorate paint- tral position.
ed surfaces or plastic parts. Al- 3. Move the rear wheel by pushing
ways clean up spilled fluid the motorcycle to locate the tight-
immediately. est portion of the drive chain, and
● As the brake pads wear, it is nor- then measure the drive chain slack
mal for the brake fluid level to grad- as shown.
ually go down. However, if the
Drive chain slack:
brake fluid level goes down sud- 30.0–40.0 mm (1.18–1.57 in)
denly, have a Yamaha dealer
check the cause.
6-22
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6-23
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CAUTION:
The drive chain must be lubricated
after washing the motorcycle or
riding in the rain.
1. Clean the drive chain with kero-
sene and a small soft brush. 6
ECA11120
1. Cotter pin
CAUTION:
NOTE: To prevent damaging the O-rings, do
Make sure that two notches in the axle not clean the drive chain with steam
nut are aligned with the hole through cleaners, high-pressure washers or
the wheel axle, otherwise further tight- inappropriate solvents.
en the axle nut until they are.
2. Wipe the drive chain dry.
EWA10700 3. Thoroughly lubricate the drive
WARNING chain with a special O-ring chain
Always use a new cotter pin for the lubricant.
axle nut.
6-24
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Recommended lubricant:
Yamaha Chain and Cable Lube or
engine oil SAE 10W-30 (API SE)
EWA10710
6 WARNING
Damage to the outer housing of ca-
bles may result in internal rusting
and cause interference with cable
movement. Replace damaged ca-
bles as soon as possible to prevent
unsafe conditions.
6-25
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Checking and lubricating the Checking and lubricating the Checking and lubricating the
brake and shift pedals brake and clutch levers sidestand
The operation of the brake and shift The operation of the brake and clutch The operation of the sidestand should
pedals should be checked before each levers should be checked before each be checked before each ride, and the
ride, and the pedal pivots should be lu- ride, and the lever pivots should be lu- sidestand pivot and metal-to-metal
bricated if necessary. bricated if necessary. contact surfaces should be lubricated if
necessary.
Recommended lubricant: Recommended lubricant: EWA10730
Recommended lubricant:
Lithium-soap-based grease (all-pur- 6
pose grease)
6-26
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6-27
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6-28
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Specified fuses:
Main fuse:
20.0 A
Signaling system fuse:
10.0 A
6-30
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CAUTION:
3. Remove the headlight bulb holder
by turning it counterclockwise, and Do not touch the glass part of the
then remove the defective bulb. headlight bulb to keep it free from
6 oil, otherwise the transparency of
the glass, the luminosity of the bulb,
1. Screw
and the bulb life will be adversely af-
2. Disconnect the headlight coupler, fected. Thoroughly clean off any dirt
and then remove the bulb cover. and fingerprints on the headlight
bulb using a cloth moistened with al-
cohol or thinner.
6-31
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6-32
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Front wheel
EAU24600
To remove the front wheel
EWA10820
WARNING
● It is advisable to have a Yamaha
dealer service the wheel.
● Securely support the motor-
cycle so that there is no danger 1. Wheel axle 1. Speedometer gear unit
of it falling over. 2. Front wheel axle pinch bolt
2. Lift the wheel up between the fork
1. Disconnect the speedometer ca- 3. Lift the front wheel off the ground legs.
ble from the front wheel. according to the procedure on
NOTE:
page 6-32.
6 4. Pull the wheel axle out, and then Make sure that there is enough space
remove the wheel. between the brake pads before insert-
ECA11070 ing the brake disc and that the slot in
CAUTION: the speedometer gear unit fits over the
retainer on the fork leg.
Do not apply the brake after the
wheel has been removed together
with the brake disc, otherwise the
brake pads will be forced shut.
1. Speedometer cable
EAU24931
2. Loosen the front wheel axle pinch To install the front wheel
bolt, then the wheel axle. 1. Install the speedometer gear unit
into the wheel hub so that the pro-
jections mesh with the slots.
6-33
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WARNING
● It is advisable to have a Yamaha
dealer service the wheel.
● Securely support the motor-
1. Speedometer gear unit cycle so that there is no danger
2. Retainer of it falling over.
3. Speedometer cable
1. Remove the axle nut cotter pin.
3. Insert the wheel axle. 2. Loosen the chain puller locknut
4. Lower the front wheel so that it is and the drive chain slack adjusting
on the ground. nut on both ends of the swingarm. 6
5. Tighten the wheel axle to the spec-
ified torque.
Tightening torque:
Wheel axle:
59 Nm (5.9 m·kgf, 43 ft·lbf)
Tightening torque:
Front wheel axle pinch bolt:
20 Nm (2.0 m·kgf, 14 ft·lbf)
6-34
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3. Loosen the axle nut and the brake 7. Push the wheel forward, and then Tightening torque:
6
torque rod nut at the brake shoe remove the drive chain from the Brake torque rod bolt:
23 Nm (2.3 m·kgf, 17 ft·lbf)
plate. rear sprocket.
4. Lift the rear wheel off the ground 4. Adjust the drive chain slack. (See
NOTE:
according to the procedure on page 6-22.)
The drive chain does not need to be
page 6-32. 5. Install the axle nut, and then lower
disassembled in order to remove and
5. Remove the brake pedal free play the rear wheel so that it is on the
install the rear wheel.
adjusting nut, and then disconnect ground.
the brake rod at the brake cam- 8. Remove the axle nut. 6. Tighten the axle nut to the speci-
shaft lever. 9. Pull the wheel axle out, and then fied torque, and then insert a new
6. Disconnect the brake torque rod remove the wheel. cotter pin into the axle nut.
from the brake shoe plate by re-
moving the nut and the bolt.
6-35
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6-36
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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.
Check the fuel level in
the fuel tank.
The engine does not start.
There is no fuel. Supply fuel.
Check the compressoin.
2. Compression
There is compression. Check the ignition.
Operate the electric starter.
Have a Yamaha dealer
There is no compression.
check the vehicle.
6
3. Ignition Wipe off with a dry cloth and correct the Open the throttle halfway and operate
Wet
spark plug gaps, or replace the spark plugs. the electric starter.
Remove the spark plugs
and check the electrodes.
The engine does not start.
Dry Have a Yamaha dealer check the vehicle.
Check the battery.
6-37
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7-2
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7-4
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SPECIFICATIONS
Dimensions: Engine oil: Carburetor:
Overall length: Type: Manufacturer:
2190 mm (86.2 in) YAMALUBE 4, SAE10W30 or SAE20W40 MIKUNI
Overall width: Type x quantity:
815 mm (32.1 in) BDS26 x 1
Overall height: 0° 10° 30° 50° 70° 90° 110° 130°F Spark plug(s):
1140 mm (44.9 in) Manufacturer/model:
YAMALUBE 4 (10W30)
Seat height: or SAE 10W30 NGK/C6HSA
685 mm (27.0 in) Manufacturer/model:
Wheelbase: YAMALUBE 4 (20W40) DENSO/U20FS-U
or SAE 20W40
1490 mm (58.7 in) Spark plug gap:
Ground clearance: 0.6–0.7 mm (0.024–0.028 in)
–20° –10° 0° 10° 20° 30° 40° 50°C
145 mm (5.71 in) Clutch:
Minimum turning radius: Clutch type:
2800 mm (110.2 in) Wet, multiple-disc
Weight: Recommended engine oil grade:
API service SE, SF, SG type or higher
Transmission:
With oil and fuel: Primary reduction system:
Engine oil quantity:
147.0 kg (324 lb) (U49) Spur gear
Without oil filter element replacement:
148.0 kg (326 lb) (CAL) Primary reduction ratio:
1.40 L (1.48 US qt) (1.23 Imp.qt)
Engine: 72/23 (3.130)
With oil filter element replacement:
Engine type: Secondary reduction system:
1.60 L (1.69 US qt) (1.41 Imp.qt)
Air cooled 4-stroke, SOHC Chain drive
Cylinder arrangement:
Air filter:
Secondary reduction ratio:
Air filter element:
V-type 2-cylinder 45/16 (2.812) 8
Wet element
Displacement: Transmission type:
249.0 cm³ (15.19 cu.in) Fuel: Constant mesh 5-speed
Bore × stroke: Recommended fuel:
Operation:
49.0 × 66.0 mm (1.93 × 2.60 in) Unleaded gasoline only
Left foot operation
Compression ratio: Fuel tank capacity:
10.00 :1 9.2 L (2.43 US gal) (2.02 Imp.gal) (CAL)
Starting system: 9.5 L (2.51 US gal) (2.09 Imp.gal) (U49)
Electric starter Fuel reserve amount:
Lubrication system: 2.6 L (0.69 US gal) (0.57 Imp.gal)
Wet sump
8-1
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SPECIFICATIONS
Gear ratio: Loading: Operation:
1st: Maximum load: Right hand operation
37/14 (2.643) 195 kg (430 lb) (CAL) Recommended fluid:
2nd: 196 kg (432 lb) (U49) Dot 4
32/19 (1.684) (Total weight of rider, passenger, cargo and Rear brake:
3rd: accessories) Type:
29/23 (1.261) Tire air pressure (measured on cold Drum brake
4th: tires): Operation:
26/26 (1.000) Loading condition: Right foot operation
5th: 0–90 kg (0–198 lb) Front suspension:
23/28 (0.821) Front: Type:
Chassis: 175 kPa (25 psi) (1.75 kgf/cm²) Telescopic fork
Frame type: Rear: Spring/shock absorber type:
Double cradle 200 kPa (29 psi) (2.00 kgf/cm²) Coil spring/oil damper
Caster angle: Loading condition: Wheel travel:
32.0 ° 90–195 kg (198–430 lb) (CAL) 140.0 mm (5.51 in)
Trail: 90–196 kg (198–432 lb) (U49) Rear suspension:
120.0 mm (4.72 in) Front: Type:
Front tire: 200 kPa (29 psi) (2.00 kgf/cm²) Swingarm
Type: Rear: Spring/shock absorber type:
With tube 225 kPa (33 psi) (2.25 kgf/cm²) Coil spring/oil damper
Size: Front wheel: Wheel travel:
3.00-18 47P Wheel type: 100.0 mm (3.94 in)
8 Manufacturer/model: Spoke wheel Electrical system:
CHENG SHIN/C-916 Rim size: Ignition system:
Rear tire: 18x1.60 Transistorized coil ignition (digital)
Type: Rear wheel: Charging system:
With tube Wheel type: A.C. magneto
Size: Spoke wheel Battery:
130/90-15M/C 66P Rim size: Model:
Manufacturer/model: 15M/C x MT2.75 GM10-3A-2
CHENG SHIN/C-915 Front brake: Voltage, capacity:
Type: 12 V, 10.0 Ah
Single disc brake
8-2
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SPECIFICATIONS
Headlight:
Bulb type:
Halogen bulb
Bulb voltage, wattage x quantity:
Headlight:
12 V, 60 W/55.0 W × 1
Tail/brake light:
12 V, 8 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: 8
10.0 A
8-3
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CONSUMER INFORMATION
EAU26351 EAU26390 EAU26400
9-1
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CONSUMER INFORMATION
EAU26470
Model label
1. Model label
9-2
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CONSUMER INFORMATION
EAU26550
9-3
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CONSUMER INFORMATION
EAU26560
9-4
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CONSUMER INFORMATION
EAU26611
Maintenance record
Copies of work orders and/or receipts for parts purchased and installed on your motorcycle will be required to document that
maintenance has been completed in accordance with the emissions warranty. The chart below is printed only as a reminder
that maintenance work is required. It is not acceptable proof of maintenance work.
Maintenance Date of Servicing dealer
Mileage Remarks
interval service name and address
600 mi
(1000 km) or
1 month
4000 mi
(6000 km) or
6 months
7000 mi
(11000 km) or
12 months
10000 mi
(16000 km) or
18 months
13000 mi
(21000 km) or
24 months
16000 mi
(26000 km) or
30 months
19000 mi
9 (31000 km) or
36 months
22000 mi
(36000 km) or
42 months
25000 mi
(41000 km) or
48 months
9-5
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CONSUMER INFORMATION
Maintenance Date of Servicing dealer
Mileage Remarks
interval service name and address
28000 mi
(46000 km) or
54 months
31000 mi
(51000 km) or
60 months
9-6
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CONSUMER INFORMATION
EAU26661
9-7
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CONSUMER INFORMATION
9-8
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CONSUMER INFORMATION
EAU26750
9-9
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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. Box 6555
Cypress, CA 90630
1-(866)-YES-EXTD (1-866-937-3983)
9-10
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INDEX
A F R
Accessories and replacement parts...... 6-17 Front fork, checking .............................. 6-27 Rear brake light switch, adjusting ......... 6-20
Air filter element, cleaning..................... 6-12 Fuel......................................................... 3-5 Rider seat................................................3-8
B Fuel cock ................................................ 3-6 S
Battery................................................... 6-28 Fuel tank cap .......................................... 3-5 Safety defects, reporting .........................9-3
Brake and clutch levers, checking and Fuses, replacing ................................... 6-30 Safety information ...................................1-1
lubricating ........................................... 6-26 H Shifting ....................................................5-2
Brake and shift pedals, checking and Handlebar switches ................................ 3-2 Shift pedal ............................................... 3-4
lubricating ........................................... 6-26 Headlight bulb, replacing ...................... 6-31 Shock absorber assemblies, adjusting....3-9
Brake fluid, changing ............................ 6-22 Helmet holder ......................................... 3-9 Sidestand ..............................................3-10
Brake fluid level, checking .................... 6-21 High beam indicator light ........................ 3-2 Sidestand, checking and lubricating......6-26
Brake lever.............................................. 3-4 Horn switch............................................. 3-3 Spark plugs, checking .............................6-8
Brake lever free play, adjusting............. 6-18 I Specifications .......................................... 8-1
Brake pads and shoes, checking .......... 6-21 Identification numbers ............................ 9-1 Speedometer unit.................................... 3-2
Brake pedal............................................. 3-4 Ignition circuit cut-off system ................ 3-11 Starter (choke) lever................................ 3-7
Brake pedal position and free play, Indicator lights ........................................ 3-1 Starting and warming up a cold
adjusting ............................................. 6-19 K engine ................................................... 5-1
C Key identification number ....................... 9-1 Start switch..............................................3-3
Cables, checking and lubricating .......... 6-25 L Steering, checking.................................6-27
Canister (for California only) ................... 6-9 Labels, location of................................... 1-5 Steering lock ........................................... 3-8
Carburetor,adjusting ............................. 6-14 M Storage....................................................7-3
Care ........................................................ 7-1 Main switch............................................. 3-1 Supporting the motorcycle .................... 6-32
Clutch lever ............................................. 3-3 Maintenance and lubrication, periodic .... 6-4 T
Clutch lever free play, adjusting............ 6-17 Maintenance, emission control system... 6-3 Throttle cable free play, adjusting ......... 6-14
D Maintenance, periodic ............................ 6-1 Throttle grip and cable, checking and
Dimmer switch ........................................ 3-3 Maintenance record................................ 9-5 lubricating ........................................... 6-25
Drive chain, lubricating.......................... 6-24 Model label ............................................. 9-2 Tires ......................................................6-15
Drive chain slack................................... 6-22 N Tool kit..................................................... 6-1
E Troubleshooting .................................... 6-36
Neutral indicator light.............................. 3-1
Engine break-in....................................... 5-4 Noise regulation...................................... 9-4 Troubleshooting chart ...........................6-37
Engine oil and oil filter element ............. 6-10 Turn signal indicator light ........................ 3-1
P
Engine, starting a warm .......................... 5-2 Turn signal switch ...................................3-3
Parking ................................................... 5-4
Engine stop switch .................................. 3-3 Part locations.......................................... 2-1
V
Valve clearance, adjusting .................... 6-14
Pre-operation check list .......................... 4-2
INDEX
Vehicle identification number.................. 9-1
W
Warranty, extended ................................ 9-9
Warranty, limited..................................... 9-7
Wheel bearings, checking .................... 6-28
Wheel (front) ......................................... 6-33
Wheel (rear).......................................... 6-34
Wheels.................................................. 6-16