Yamaha XV250 Manual

Yamaha Motor XV250

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4TN-28199-E2

XV250P

OWNER’S MANUAL

EAA00100 EAA20301

INTRODUCTION

Congratulations on your purchase of the

Yamaha XV250P. This model is the result of

Yamaha’s vast experience in the production

of fine sporting, touring, and pacesetting rac-

ing 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 mainte-

nance of this motorcycle. If you have any

questions about the operation or maintenance

of your motorcycle, please consult a Yamaha

dealer.

XV250P

OWNER’S MANUAL

1st Edition, January 2003

unauthorized use without the written

permission of Yamaha Motor Co., Ltd.

is expressly prohibited.

Printed in Japan

EAA10603

IMPORTANT MANUAL

INFORMATION

Particularly important information is distin-

guished in this manual by the following nota-

tions:

The Safety Alert Symbol means ATTENTION!

BECOME ALERT! YOUR SAFETY IS IN-

VOLVED!

WARNING

Failure to follow WARNING instructions could

result in severe injury or death to the motor-

cycle operator, a bystander or a person in-

specting or repairing the motorcycle.

CAUTION:

A CAUTION indicates special precautions

that must be taken to avoid damage to the

motorcycle.

NOTE:

A NOTE provides key information to make

procedures easier or clearer.

EUU00001

TE:

●This manual should be considered a per-

manent part of this motorcycle and

should remain with it even if the motor-

cycle is subsequently sold.

●Yamaha continually seeks advance-

ments in product design and quality.

Therefore, while this manual contains the

most current product information avail-

able at the time of printing, there may be

minor discrepancies between your

motorcycle and this manual. If there is

any question concerning this manual,

please consult your Yamaha dealer.

EUU60100

WARNING

PLEASE READ THIS MANUAL CAREFUL-

LY AND COMPLETELY BEFORE OPERAT-

ING THIS MOTORCYCLE.

CONTENTS

GIVE SAFETY THE RIGHT OF WAY .......1-1

DESCRIPTION ..........................................2-1

MOTORCYCLE IDENTIFICATION ...........3-1

Identification numbers ............................3-1

Key identification number .......................3-1

Frame serial number ..............................3-2

Model label .............................................3-2

CONTROL FUNCTIONS ...........................4-1

Main switch .............................................4-1

Indicator lights.........................................4-2

Speedometer ..........................................4-2

Handlebar switches ................................4-3

Clutch lever.............................................4-6

Shift pedal...............................................4-6

Front brake lever.....................................4-6

Rear brake pedal....................................4-6

Fuel tank cap ..........................................4-7

Fuel cock................................................ 4-8

Starter “CHOKE”.................................... 4-9

Steering lock ........................................ 4-10

Seat ...................................................... 4-10

Rear shock absorber adjustment......... 4-11

Sidestand .............................................4-11

Ignition circuit cut-off system................ 4-13

PRE-OPERATION CHECKS .................... 5-1

Brakes .................................................... 5-3

Front brake fluid leakage ....................... 5-3

Clutch ..................................................... 5-4

Throttle grip ............................................ 5-4

Engine oil................................................ 5-5

Chain...................................................... 5-5

Tires ....................................................... 5-6

Cast wheels............................................ 5-9

Chassis fasteners................................... 5-9

Lights, signals and switches ................ 5-10

Battery.................................................. 5-10

EAA30001

1-2

Fuel.......................................................5-10

OPERATION AND IMPORTANT

RIDING POINTS........................................6-1

Starting and warming up a cold

engine..................................................6-1

Starting a warm engine ..........................6-3

Shifting....................................................6-3

Engine break-in ......................................6-4

Parking....................................................6-5

PERIODIC MAINTENANCE AND

MINOR REPAIR ........................................7-1

Tool kit ....................................................7-1

Periodic maintenance/lubrication ...........7-3

Engine oil................................................7-6

Air filter....................................................7-9

Carburetor adjustment..........................7-12

Idle speed adjustment ..........................7-12

Throttle cable free play inspection........7-13

Valve clearance adjustment .................7-14

Spark plug inspection ...........................7-14

Front brake lever free play

adjustment ........................................ 7-15

Rear brake adjustment......................... 7-16

Brake light switch adjustment .............. 7-18

Checking the front brake pads and

rear brake shoes............................... 7-18

Inspecting the brake fluid level ............ 7-20

Brake fluid replacement ....................... 7-21

Clutch adjustment ................................ 7-21

Drive chain slack check ....................... 7-22

Drive chain slack adjustment ............... 7-23

Drive chain lubrication.......................... 7-25

Cable inspection and lubrication.......... 7-25

Throttle cable and grip lubrication........ 7-26

Brake and shift pedals ......................... 7-26

Brake and clutch levers........................ 7-26

Sidestand ............................................. 7-26

Rear suspension.................................. 7-26

Front fork inspection ............................ 7-27

Steering inspection .............................. 7-28

Wheel bearings.................................... 7-28

Battery.................................................. 7-28

1-3

Replenishing the battery fluid ...............7-30

Fuse replacement.................................7-31

Headlight bulb replacement..................7-31

Front wheel removal.............................7-33

Front wheel installation.........................7-34

Rear wheel removal..............................7-35

Rear wheel installation .........................7-37

Troubleshooting....................................7-38

Troubleshooting chart...........................7-39

CLEANING AND STORAGE.....................8-1

A. Cleaning .............................................8-1

B. Storage...............................................8-2

SPECIFICATIONS.....................................9-1

Conversion table.....................................9-5

1-1

GIVE SAFETY THE RIGHT OF WAY

EUU75901

Motorcycles are fascinating vehicles, which can give you an unsurpassed feeling of

power and freedom. However, they also impose certain limits, which you must accept;

even the best motorcycle does not ignore the laws of physics.

Regular care and maintenance are essential for preserving your motorcycle s value and’

operating condition. Moreover, what is true for the motorcycle is also true for the rider:

good performance depends on being in good shape. Riding under the influence of med-

ication, drugs and alcohol is, of course, out of the question. Motorcycle riders – more

than car drivers – must always be at their mental and physical best. Under the influence

of even small amounts of alcohol, there is a tendency to take dangerous risks.

Protective clothing is as essential for the motorcycle rider as seat belts are for car driv-

ers and passengers. Always wear a complete motorcycle suit (whether made of leather

or tear-resistant synthetic materials with protectors), sturdy boots, motorcycle gloves

and a properly fitting helmet. Optimum protective wear, however, should not encourage

carelessness. Though full-coverage helmets and suits, in particular, create an illusion

of total safety and protection, motorcyclists will always be vulnerable. Riders who lack

critical self-control run the risk of going too fast and are apt to take chances. This is even

more dangerous in wet weather. The good motorcyclist rides safely, predictably and de-

fensively – avoiding all dangers, including those caused by others.

Enjoy your ride!

2-1

EAA50000

DESCRIPTION

1. Tail/brake light

2. Rear turn signal light

3. Tool kit

4. Seat

5. Air filter

6. Front turn signal light

7. Brake pedal

8. Footrest

9. Headlight

10. Fuel tank

11. Rear wheel

12. Main switch

13. Shift pedal

14. Steering lock

15. Front wheel

16. Clutch lever

17. Handlebar switches

18. Speedometer

19. Brake lever

20. Throttle grip

3-1

EAA60000

MOTORCYCLE

IDENTIFICATION

EAA62000

Identification numbers

Record the key identification number, frame

serial number and model label information in

the spaces provided for assistance when or-

dering spare parts from a Yamaha dealer or

for reference in case the vehicle is stolen.

1. KEY IDENTIFICATION NUMBER:

2. FRAME SERIAL NUMBER:

3. MODEL LABEL INFORMATION:

EAA61400

Key identification number

The key identification number is stamped on

the key. Record this number in the space pro-

vided and use it for reference when obtaining

a new key.

1. Key identification number

3-2

EAA60201

Frame serial number

The frame serial number is stamped into the

steering head pipe.

1. Frame serial number

EAA62200

Model label

The model label is affixed to the frame under

the seat. (See page 4-10 for seat removal pro-

cedures.) Record the information on this label

in the space provided. This information will be

needed to order spare parts from your

Yamaha dealer.

1. Model label

4-1

EAB00000

CONTROL FUNCTIONS

EAB00100

Main switch

The main switch controls the ignition and light-

ing systems. Its operation is described below.

EAB00500

ON:

Electrical circuits are switched on. The engine

can be started. The key cannot be removed in

this position.

EAB00600

OFF:

All electrical circuits are switched off. The key

can be removed in this position.

EAB02002

P (Parking)

The taillight and auxiliary light come on but all

other circuits are off. With the key at “ ”OFF ,

push it into the main switch, turn it counter-

clockwise to “ ”P , and remove it. To cancel the

parking, turn the key clockwise.

EUU08800

TE:

Always turn the main switch to “ ”OFF and re-

move the key when the motorcycle is unat-

tended.

4-2

EAB10000

Indicator lights

1. Turn indicator light “ ”

2. Neutral indicator light “ ”

3. High beam indicator light “ ”

EAB10102

Turn indicator light “ ”

This indicator flashes when the turn signal

switch is moved to the left or right.

EAB13100

Neutral indicator light “ ”

This indicator comes on when the transmis-

sion is in neutral.

EAB13200

High beam indicator light “ ”

This indicator comes on when the headlight

high beam is used.

EAB40005

Speedometer

The speedometer shows riding speed. This

speedometer is equipped with an odometer

and trip odometer. The trip odometer can be

reset to “ ”0 with the reset knob. Use the trip

odometer to estimate how far you can ride on

a tank of fuel. This information will enable you

to plan fuel stops in the future.

1. Odometer 2. Trip odometer 3. Reset knob

4-3

EAB60000

Handlebar switches

1. PASS switch “ ”PASS 6. Engine stop switch

2. Dimmer switch “ENGINE STOP”

“ ” “ ”LIGHTS 7. Siren switch SIREN

3. Turn signal switch 8. Microphone switch “MIC”

“ ”TURN 9. Patrol switch

4. Horn switch “ ”HORN 10. Start switch “ ”START

5. Light switch “LIGHTS”11. Hazard switch “HAZARD”

EAB63201

Pass switch “ ”PASS

Press the switch to operate the passing light.

EAB60101

Dimmer switch “ ”LIGHTS

Turn the switch to “ ”HI for the high beam and

to “LO” for the low beam.

EAB62102

Turn signal switch “ ”TURN

To signal a right-hand turn, push the switch to

the right. To signal a left-hand turn, push the

switch to the left. Once the switch is released

it will return to the center position. To cancel

the signal, push the switch in after it has re-

turned to the center position.

EAB60201

Horn switch “ ”HORN

Press the switch to sound the horn.

EAB61202

Light switch “ ”LIGHTS

Turning this switch to “ ”PO turns on the auxil-

iary light, taillight and meter lights. Turning to

“ ”ON , turns the headlight on also.

4-4

EAB60902

Engine stop switch “ENGINE STOP”

The engine stop switch is a safety device for

use in an emergency such as when the motor-

cycle overturns or if trouble occurs in the throt-

tle system. Turn the switch to “ ”RUN to start

the engine. In case of emergency, turn the

switch to to stop the engine.“ ”OFF

EAB60702

Start switch “ ”START

The starter motor cranks the engine when

pushing the starter switch.

EUU30700

CAUTION:

See starting instructions prior to starting

the engine.

EAB62802

Hazard switch “HAZARD”

The hazard switch should be turned on under

emergency or hazardous conditions. All turn

signal lights will flash simultaneously when

this switch is turned on with the main switch in

the “ON” position.

EUU46100

CAUTION:

The battery can discharge from extended

use, making it difficult to operate the

starter.

EUU01101

TE:

Turn on the hazard switch to warn other driv-

ers if your motorcycle must be stopped where

it might be a traffic hazard.

4-5

Siren switch “ ”SIREN

The siren (if equipped) sounds intermittently

when this switch is set to “ ”SIREN . The siren

can only be used with the main switch in the

“ ”ON position.

Microphone switch “ ”MIC

The microphone (if equipped) can be used

when this switch is set to “ ”MIC with the main

switch in the “ ”ON position. This switch can

also be used when the patrol switch is in any

position except “ ”OFF with the main switch in

the “ON” position.

Patrol switch

This switch can only be used with the main

switch in the “ ”ON position. The following ta-

ble indicates which accessories are enabled

when the patrol switch is set to “ ”P , “M” “, or S”.

Accessory

Position

OFF P M S

Patrol light

Turn signal light

Microphone

Siren

4-6

EAB70003

Clutch lever

The clutch lever is located on the left handle-

bar, and the ignition circuit cut-off system is in-

corporated in the clutch lever holder. Pull the

clutch lever to the handlebar to disengage the

clutch, and release the lever to engage the

clutch. The lever should be pulled rapidly and

released slowly for smooth clutch operation.

(Refer to the engine starting procedures for a

description of the ignition circuit cut-off sys-

tem.)

EAB80001

Shift pedal

This motorcycle is equipped with a constant-

mesh 5-speed transmission.

The shift pedal is located on the left side of the

engine and is used in combination with the

clutch when shifting.

1. Shift pedal N. Neutral

EAB90001

Front brake lever

The front brake lever is located on the right

handlebar. Pull it toward the handlebar to ap-

ply the front brake.

EAB90101

Rear brake pedal

The rear brake pedal is on the right side of the

motorcycle. Press down on the brake pedal to

apply the rear brake.

4-7

EAC00101

Fuel tank cap

TO OPEN:

Insert the key and turn it 1/4 turn clockwise.

The lock will be released and the cap can be

opened.

1. Unlock.

TO CLOSE:

Push the tank cap into position with the key in-

serted. To remove the key, turn it counter-

clockwise to the original position.

EUU01200

TE:

This tank cap cannot be closed unless the key

is in the lock. The key cannot be removed if

the cap is not locked properly.

EUU61100

WARNING

Be sure the cap is properly installed and

locked in place before riding the motor-

cycle.

4-8

EAC10205

Fuel cock

The fuel cock supplies fuel from the tank to

the carburetors while also filtering it.

The fuel cock has three positions, which

should be set as illustrated.

ON: With the fuel cock in this position, fuel

flows to the carburetors when the en-

gine is running. Set the fuel cock to this

position when starting the engine and

for riding.

RES: This stands for “ ”reserve . If you are run-

ning out of fuel while riding with the fuel

cock in the “ON” position, quickly turn

the lever to this position. Otherwise the

engine may die and will have to be

primed (see below). After turning“ ”PRI

the lever to “ ”RES , fill the tank at the

first opportunity and be sure to set the

fuel cock back to “ ”ON !

4-9

PRI: This stands for “ ”prime . If the engine

has been allowed to run out of fuel, turn

the lever to the “ ”PRI position to send

fuel directly to the carburetors. This will

make starting easier. However, be sure

to turn the lever to the position (or“ ”ON

“ ”RES if you have not refuelled yet) af-

ter the engine has started.

EAC20502

Starter “CHOKE”

Starting a cold engine requires a richer air-fuel

mixture. A separate starter circuit supplies this

mixture.

Move in direction a to turn on the starter.

Move in direction b to turn off the starter.

1. Starter “CHOKE”

4-10

EAC30201

Steering lock

To lock the steering, turn the handlebars all

the way to the right. Open the steering lock

cover, turn the key 1/8 counterclockwise then

push the key in and turn it 1/8 turn clockwise.

After checking to see that the steering is

locked, remove the key from the lock and

close the cover. To release the lock, reverse

the above procedure.

1. Steering lock

EAC41503

Seat

To remove the rider seat, remove the bolts.

To install the rider seat, insert the projection

on the front of the seat into the holder on the

frame. Then tighten the bolts.

EUU01700

TE:

Make sure that the seat is securely fitted.

4-11

EAI57804

Rear shock absorber adjustment

This shock absorber is equipped with a spring

preload adjuster. Adjust spring preload as fol-

lows. Turn the adjusting ring in direction a to

increase spring preload and in direction b to

decrease spring preload.

COPY CI-18ECI-18E

EAD30101

Sidestand

This model is equipped with an ignition circuit

cut-off system. The motorcycle must not be

ridden when the sidestand is down. The side-

stand is located on the left side of the frame.

(Refer to page 6-1 for an explanation of this

system.)

Hard Standard Soft

Adjusting

position 5 4 3 2 1

Left Right

4-12

EUU68901

WARNING

This motorcycle must not be operated with

the sidestand in the down position. If the

stand is not properly retracted, it could

contact the ground and distract the opera-

tor, resulting in a possible loss of control.

Yamaha has designed into this motorcycle

a lockout system to assist the operator in

fulfilling the responsibility of retracting the

sidestand. Please check carefully the op-

erating instructions listed below and if

there is any indication of a malfunction, re-

turn the motorcycle to a Yamaha dealer

immediately for repair.

EAU03720

Ignition circuit cut-off system

The ignition circuit cut-off system (comprising

the sidestand switch, clutch switch and neu-

tral switch) has the following functions.

●It prevents starting when the transmis-

sion is in gear and the sidestand is up,

but the clutch lever is not pulled.

●It prevents starting when the transmis-

sion is in gear and the clutch lever is

pulled, but the sidestand is still down.

●It cuts the running engine when the trans-

mission is in gear and the sidestand is

moved down.

Periodically check the operation of the ignition

circuit cut-off system according to the follow-

ing procedure.

EW000045

WARNING

If a malfunction is noted, have a Yamaha

dealer check the system before riding.

CD-01E

4-13

With the engine turned off:

1. Move the sidestand down.

2. Make sure that the engine stop switch is set to “ ”.

3. Turn the key to “ON”.

4. Shift the transmission into the neutral position.

5. Push the start switch.

Does the engine start? The neutral switch may be defective.

The motorcycle should not be ridden until

checked by a Yamaha dealer.

With the engine still running:

6. Move the sidestand up.

7. Keep the clutch lever pulled.

8. Shift the transmission into gear.

9. Move the sidestand down.

Does the engine stall?

After the engine has stalled:

10. Move the sidestand up.

11. Keep the clutch lever pulled.

12. Push the start switch.

Does the engine start?

The sidestand switch may be defective.

The motorcycle should not be ridden until

checked by a Yamaha dealer.

The clutch switch may be defective.

The motorcycle should not be ridden until

checked by a Yamaha dealer.

NOTE:

This check is most reliable if performed with

a warmed-up engine.

YES

YES NO

The system is OK. The motorcycle can be ridden.

YES NO

5-1

PRE-OPERATION CHECKS

Before using this motorcycle, check the following points:

Item Routine Page

Front brake • Check operation, free play, fluid level and fluid leakage.

• Top-up with DOT4 (or DOT 3) brake fluid if necessary. 5-3 ~ 5-4,

7-15 ~ 7-21

Rear brake • Check operation, condition and free play.

• Adjust if necessary.

Clutch • Check operation, condition and free play.

• Adjust if necessary. 5-4, 7-21 ~ 7-22

Throttle grip/Housing • Check for smooth operation.

• Lubricate/Adjust if necessary. 5-4, 7-13, 7-26

Engine oil •Check oil level/add oil as required. 5-5, 7-6 ~ 7-9

Drive chain • Check chain slack and condition.

• Adjust if necessary. 5-5, 7-22 ~ 7-25

Wheels/Tires •Check tire pressure, wear, damage. 5-6 ~ 5-9, 7-33 ~ 7-37

Control/Meter cables • Check for smooth operation.

• Lubricate if necessary. 7-25

Brake and shift pedal

shafts

• Check for smooth operation.

• Lubricate if necessary. 7-26

Brake and clutch lever

pivots

• Check for smooth operation.

• Lubricate if necessary. 7-26

Sidestand pivot • Check for smooth operation.

• Lubricate if necessary. 7-26

5-2

TE:

Pre-operation checks should be made each time the motorcycle is used. Such an inspection can

be thoroughly accomplished in a very short time; and the added safety it assures is more than

worth the time involved.

WARNING

If any item in the PRE-OPERATION CHECK is not working properly, have it inspected and

repaired before operating the motorcycle.

Chassis fasteners • Check all chassis fittings and fasteners.

• Tighten/Adjust if necessary. 5-9

Fuel tank •Check fuel level/top-up as required. 5-10 ~ 5-11

Lights, signals and

switches •Check for proper operation. 5-10, 7-31 ~ 7-33

Battery •Check fluid level, top-up with distilled water if necessary. 5-10, 7-28 ~ 7-30

Item Routine Page

5-3

EAE13303

Brakes

1. Brake lever and brake pedal

Check for correct free play in the front

brake lever and rear brake pedal and ad-

just if necessary. (See page 7-15 for de-

tails.) Make sure the brakes are working

properly by checking at low speed shortly

after starting out.

EUU62300

WARNING

A soft, spongy feeling in the brake lever in-

dicates a failure in the brake system. Do

not operate the motorcycle until the failure

in the brake system is corrected. Ask a

Yamaha dealer for immediate repairs. A

soft, spongy feeling could indicate a haz-

ardous condition in the brake system.

2. Brake fluid

Check the brake fluid level. Fill the mas-

ter cylinder with brake fluid if necessary.

(See page 7-20 for details.)

EUU13100

TE:

If DOT 4 is not available, DOT 3 can be used.

3. Check the disc pads.

Refer to page 7-18.

4. Check the brake shoes.

Refer to page 7-18.

EUU02201

TE:

When this brake service is necessary, consult

a Yamaha dealer.

EAE11303

Front brake fluid leakage

Apply the brake for a few minutes. Check to

see if any brake fluid leaks out from the pipe

joints or the master cylinder.

Recommended brake fluid: DOT 4

5-4

EUU37801

CAUTION:

Brake fluid may deteriorate painted surfac-

es or plastic parts. Never spill any fluid. If

spilled, clean it up immediately.

EUU62500

WARNING

If brake fluid leakage is found, ask a

Yamaha dealer for immediate repairs.

Such leakage could indicate a hazardous

condition.

EAE20002

Clutch

Check the free play in the clutch lever and

make sure the clutch operates properly. If the

free play is incorrect, adjust it. (See page 7-21

for details.)

EAE30104

Throttle grip

Turn the throttle grip to see if it operates prop-

erly. Make sure the grip returns by spring

force when released. There should be a free

play of 3 ~ 5 mm at the throttle grip. If the free

play is incorrect, ask a Yamaha dealer to

make this adjustment.

5-5

EAE40105

Engine oil

Make sure the engine oil is at the specified

level. Fill with oil as necessary. (See page 7-6

for details.)

EUU32303

CAUTION:

Do not put in any chemical additives. Also,

be sure not to use oils labeled “ENERGY

CONSERVING II” or higher. Engine oil also

lubricates the clutch and additives could

cause clutch slippage.

EAE50001

Chain (See page 7-22 for details)

Check the general condition of the chain and

the chain slack before every ride. Lubricate

and adjust the chain as necessary.

-10° °0 10 20 30 40° ° ° °-20°

SAE 10W/30

SAE 20W/50

SAE 20W/40

SAE 10W/40

50°C

Recommended oil:

Recommended engine oil classification:

API Service “ ” “SE , SF” type or

equivalent

(e.g. “SF-SE”, , “SF-SE-CC”

“ ”SF-SE-SD etc.)

Oil quantity:

Total amount: 1.8 L

Periodic oil change: 1.4 L

With oil filter replacement: 1.6 L

5-6

EAE97900

Tires

To ensure maximum performance, long ser-

vice and safe operation, note the following:

1. Tire air pressure

Always check and adjust the tire pres-

sure before operating the motorcycle.

EUU67500

WARNING

Tire inflation pressure should be checked

and adjusted when the temperature of the

tire equals the ambient air temperature.

Tire inflation pressure must be adjusted

according to total weight of cargo, rider

and accessories (fairing, saddlebags, etc.

if approved for this model), and vehicle

speed.

COPY CE-32ECE-32E

Maximum load*: 180 kg

Cold tire pressure: Front Rear

Up to 90 kg

175 kPa

(1.75 kgf/cm2,

1.75 bar)

200 kPa

(2.0 kgf/cm2,

2.0 bar)

90 kg load ~

Maximum load*

200 kPa

(2.0 kgf/cm2,

2.0 bar)

225 kPa

(2.25 kgf/cm2,

2.25 bar)

* Load is the total weight of cargo, rider and accessories.

5-7

EUU67701

WARNING

Proper loading of your motorcycle is im-

portant for several characteristics of your

motorcycle, such as handling, braking,

performance and safety. Do not carry

loosely packed items that can shift. Se-

curely pack your heaviest items close to

the center of the motorcycle, and distrib-

ute the weight evenly from side to side.

Properly adjust the suspension for your

load, and check the condition and pres-

sure of your tires. NEVER OVERLOAD

YOUR MOTORCYCLE. Make sure the total

weight of the cargo, rider and accessories

(fairing, saddlebags, etc. if approved for

this model) does not exceed the maximum

load of the motorcycle. Operation of an

overloaded motorcycle could cause tire

damage, an accident, or even injury.

2. Tire inspection

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 side wall is cracked, contact a

Yamaha dealer immediately and have

the tire replaced.

5-8

1. Tread depth 2. Side wall 3. Wear indicator

COPY CE-10ECE-10E

COPY CE-16ECE-16E

EUU12600

TE:

These limits may be different by regulation

from country to country. If so, conform to the

limits specified by the regulations of your own

country.

EUU68402

WARNING

1. It is dangerous to ride with a worn-out

tire. When a tire tread begins to show

lines, have a Yamaha dealer replace

the tire immediately. Brakes, tires, and

related wheel parts replacement

should also be left to a Yamaha deal-

er.

2. Patching a punctured tube is not rec-

ommended. If it is absolutely neces-

sary to do so, use great care and

replace the tube as soon as possible

with a good quality replacement.

FRONT:

Manufacturer Size Type

CHENG SHIN 3.00-18 47P C916

REAR:

Manufacturer Size Type

CHENG SHIN 130/90-15 M/C 66P C915

Minimum tire tread depth (front

and rear) 1.0 mm

5-9

EAE93600

Cast wheels

EUU71200

WARNING

The wheels on this model are not designed

for use with tubeless tires. Do not attempt

to use tubeless tires on this model.

To ensure maximum performance, long ser-

vice, and safe operation, note the following:

1. Always inspect the wheels before a ride.

Check for cracks, bends, or warpage of

the wheels. If any abnormal condition ex-

ists in a wheel, consult a Yamaha dealer.

Do not attempt even small repairs to the

wheel. If a wheel is deformed or cracked,

it must be replaced.

2. Tires and wheels should be balanced

whenever either one is changed or re-

placed. Failure to have a wheel balanced

can result in poor performance, adverse

handling characteristics, and shortened

tire life.

3. After installing a tire, ride conservatively

to allow the tire to seat itself on the rim

properly. Failure to allow proper seating

may cause tire failure, resulting in dam-

age to the motorcycle and injury to the

rider.

EAE85101

Chassis fasteners

Always check the tightness of all chassis nuts,

bolts and screws before a ride. Take the

motorcycle to a Yamaha dealer or refer to the

Service Manual for correct tightening torque.

5-10

EAE71500

Lights, signals and switches

Check all the lights, meter lights and indicator

lights to make sure they are in working condi-

tion.

Check the operation of the handlebar switch-

es and main switch.

EAE70502

Battery

Check the fluid level and fill if necessary. Use

only distilled water if refilling is necessary.

(See page 7-28 for details.)

EAE80000

Fuel

Make sure there is sufficient fuel in the tank.

EUU61000

WARNING

Do not overfill the fuel tank. Avoid spilling

fuel on the hot engine. Do not fill the fuel

tank above the bottom of the filler tube as

shown in the illustration or it may overflow

when the fuel heats up later and expands.

1. Filler tube 2. Fuel level

5-11

EUU39302

CAUTION:

Always wipe off spilled fuel immediately

with a dry and clean soft cloth. Fuel may

deteriorate painted surfaces or plastic

parts.

EAE80300

Recommended fuel:

Regular unleaded gasoline

Fuel tank capacity:

Total:

9.5 L

Reserve:

2.6 L

6-1

EAF00000

OPERATION AND

IMPORTANT RIDING

POINTS

EUU67201

WARNING

1. Before riding this motorcycle, become

thoroughly familiar with all operating

controls and their functions. Consult

a Yamaha dealer regarding any con-

trol or function that you do not thor-

oughly understand.

2. Never start your engine or let it run for

any length of time in a closed area.

The exhaust fumes are poisonous and

can cause loss of consciousness and

death within a short time. Always op-

erate your motorcycle in an area with

adequate ventilation.

3. Before starting out, always be sure

the sidestand is up. Failure to retract

the sidestand completely can result in

a serious accident when you try to

turn a corner.

EAF19800

Starting and warming up a cold engine

EUU07401

TE:

This motorcycle is equipped with an ignition

circuit cut-off system.

See page 4-12 for an explanation of this sys-

tem.

6-2

1. Turn the fuel cock to “ ”ON .

2. Turn the main switch to “ ”ON and the en-

gine stop switch to “RUN”.

3. Shift transmission into neutral.

EUU03001

TE:

When the transmission is in neutral, the neu-

tral indicator light should be on. If the light

does not come on, ask a Yamaha dealer to in-

spect it.

4. Turn on the starter “ ”CHOKE and com-

pletely close the throttle grip.

5. Start the engine by pushing the start

switch.

EUU02501

TE:

If the engine fails to start, release the start

switch, wait a few seconds, then try again.

Each attempt should be as short as possible

to preserve the battery. Do not crank the en-

gine more than 10 seconds on any one at-

tempt.

6. After starting the engine, move the starter

to the halfway position.

EUU02600

TE:

For maximum engine life, always warm up the

engine before starting off. Never accelerate

hard with a cold engine.

7. After warming up the engine, turn off the

starter completely.

EUU02701

TE:

The engine is warm when it responds normal-

ly to the throttle with the starter “ ”CHOKE

turned off.

6-4

EAF30000

Engine break-in

There is never a more important period in the

life of your motorcycle than the period be-

tween zero and 1,000 km. For this reason we

ask that you carefully read the following mate-

rial. Because the engine is brand new, you

must not put an excessive load on it for the

first 1,000 km. The various parts in the engine

wear and polish themselves to the correct op-

erating clearances. During this period, pro-

longed full throttle operation, or any condition

which might result in excessive heating of the

engine, must be avoided.

EAF32101

1. 0 ~ 150 km:

Avoid operation above 1/3 throttle. Stop

the engine and let it cool for 5 to 10 min-

utes after every hour of operation. Vary

the speed of the motorcycle from time to

time. Do not operate it at one set throttle

position.

2. 150 ~ 500 km:

Avoid prolonged operation above 1/2

throttle. Rev the motorcycle freely

through the gears, but do not use full

throttle at any time.

3. 500 ~ 1,000 km:

Avoid cruising speeds in excess of 3/4

throttle.

EUU32001

CAUTION:

After 1,000 km of operation, be sure to re-

place the engine oil and oil filter.

4. 1,000 km and beyond:

Avoid prolonged full throttle operation.

Vary speeds occasionally.

EUU32200

CAUTION:

If any engine trouble should occur during

the break-in period, consult a Yamaha

dealer immediately.

6-5

EAF40001

Parking

When parking the motorcycle, stop the engine

and remove the key.

EUU63001

WARNING

The exhaust system is hot. Park the motor-

cycle in a place where pedestrians or chil-

dren are not likely to touch the motorcycle.

Do not park the motorcycle on a slope or

soft ground; the motorcycle may overturn.

7-1

EAH00000

PERIODIC

MAINTENANCE AND

MINOR REPAIR

EAH00400

Periodic inspection, adjustment and lubrica-

tion will keep your motorcycle in the safest

and most efficient condition possible. Safety is

an obligation of the motorcycle owner. The

maintenance and lubrication schedule chart

should be considered strictly as a guide to

general maintenance and lubrication inter-

vals. YOU MUST TAKE INTO CONSIDER-

ATION THAT WEATHER, TERRAIN,

GEOGRAPHICAL LOCATIONS, AND A VA-

RIETY OF INDIVIDUAL USES ALL TEND TO

DEMAND THAT EACH OWNER ALTER

THIS TIME SCHEDULE TO SHORTER IN-

TERVALS TO MATCH THE ENVIRON-

MENT. The most important points of

motorcycle inspection, adjustment, and lubri-

cation are explained in the following pages.

EUU63200

WARNING

If you are not familiar with motorcycle ser-

vice, this work should be done by a

Yamaha dealer.

EAH10300

Tool kit

The service information included in this man-

ual is intended to provide you, the owner, with

the necessary information for completing

some of your own preventive maintenance

and minor repairs. The tools provided in the

owner’s tool kit are to assist you in the perfor-

mance of periodic maintenance. However,

some other tools such as a torque wrench are

also necessary to perform the maintenance

correctly.

7-2

1. Tool kit

EUU18500

TE:

If you do not have necessary tools required

during a service operation, take your motor-

cycle to a Yamaha dealer for service.

EUU67100

WARNING

Modifications to this motorcycle not ap-

proved by Yamaha may cause loss of per-

formance, and render it unsafe for use.

Consult a Yamaha dealer before attempt-

ing any changes.

7-3

PERIODIC MAINTENANCE/LUBRICATION

ITEM ROUTINE BREAK-IN

1,000 km

EVERY

6,000 km

6 months

12,000 km

12 months

Valve(s)* • Check valve clearance.

• Adjust if necessary.

Spark plug(s) • Check condition.

• Clean or replace if necessary.

Air filter • Clean.

• Replace if necessary.

Carburetor* • Check idle speed/starter operation.

• Adjust if necessary.

Fuel line*

• Check fuel hose and vacuum pipe for cracks or

damage.

• Replace if necessary.

Fuel filter* • Check condition.

• Replace if necessary.

Engine oil • Replace (Warm engine before draining).

Engine oil filter* • Replace.

Front brake*

• Check operation/fluid leakage/See NOTE

(page 7-5).

• Correct if necessary.

Rear brake • Check operation.

• Adjust if necessary.

Clutch • Check operation.

• Adjust if necessary.

7-4

Rear arm pivot*

• Check rear arm assembly for looseness.

• Correct if necessary.

• Moderately repack every 24,000 km or

24 months.**

Wheels* • Check balance/damage/runout/spoke tightness.

• Replace if necessary.

Wheel bearings* • Check bearings assembly for looseness/damage.

• Replace if damaged.

Steering bearing*

• Check bearings assembly for looseness.

• Correct if necessary.

• Moderately repack every 24,000 km or

24 months.**

Front fork* • Check operation/oil leakage.

• Repair if necessary.

Rear shock absorber* • Check operation/oil leakage.

• Repair if necessary.

Drive chain

• Check chain slack/alignment.

• Adjust if necessary.

• Clean if necessary.

EVERY 500 km

Chassis fasteners* • Check all chassis fittings and fasteners.

• Correct if necessary.

Sidestand* • Check operation.

• Repair if necessary.

Sidestand switch* • Check operation.

• Clean or replace if necessary.

ITEM ROUTINE BREAK-IN

1,000 km

EVERY

6,000 km

6 months

12,000 km

12 months

7-5

* : It is recommended that these items be serviced by a Yamaha dealer.

** : Lithium soap base grease

TE:

Brake fluid replacement:

1. When disassembling the master cylinder or caliper cylinder, replace the brake fluid. Normally

check the brake fluid level and fill the master cylinder with fluid as required.

2. On the inner parts of the master cylinder and caliper cylinder, replace the oil seals every two

years.

3. Replace the brake/hoses every four years, or if cracked or damaged.

Battery*

• Check specific gravity.

• Check breather pipe for proper operation.

• Correct if necessary.

ITEM ROUTINE BREAK-IN

1,000 km

EVERY

6,000 km

6 months

12,000 km

12 months

7-6

EAH44705

Engine oil

1. Oil level inspection

a. Place the motorcycle on a level place

and hold it in an upright position. Warm

up the engine for several minutes.

EUU03901

TE:

Be sure the motorcycle is positioned straight

up when checking the oil level. A slight tilt to-

ward the side can result in false readings.

b. With the engine stopped, check the oil

level through the level window located at

the lower part of the right side crankcase

cover.

1. Level window 2. Maximum level mark

3. Minimum level mark

EUU04000

TE:

Wait a few minutes until the oil level settles

before checking.

c. The oil level should be between maxi-

mum and minimum marks. If the level is

low, add oil to the specified level.

7-7

2. Engine oil and oil filter element replace-

ment

a. Warm up the engine for a few minutes.

b. Stop the engine. Place an oil pan under

the engine and remove the oil filler cap.

1. Oil filler cap

c. Remove the drain plug and drain the oil.

1. Drain plug

d. Remove the oil filter cover bolts, oil filter

and O-ring.

1. Oil filter cover bolt ( 3)×

7-8

e. Reinstall the drain plug and tighten it to

the specified torque.

f. Install the new oil filter, new O-ring and

the filter cover. Tighten the oil filter cover

bolts to the specified torque.

1. Oil filter element 2. O-ring

EUU04101

TE:

Make sure the O-ring is seated properly.

g. Fill up the engine with the specified

amount of recommended oil. Install the

oil filler cap and tighten.

Tightening torque:

Drain plug:

34 Nm (3.4 m·kgf)

Tightening torque:

Oil filter cover bolt:

7 Nm (0.7 m·kgf)

Recommended oil:

See page 5-5

Oil quantity:

Total amount:

1.8 L

Periodic oil change:

1.4 L

With oil filter replacement:

1.6 L

7-9

EUU32401

CAUTION:

●Do not put in any chemical additives.

Engine oil also lubricates the clutch

and additives could cause clutch slip-

page.

●Be sure no foreign material enters the

crankcase.

h. Start the engine and warm up for a few

minutes. While warming up, check for oil

leakage. If oil leakage is found, stop the

engine immediately and check for the

cause.

EAH600A0

Air filter

The element should be cleaned at the speci-

fied intervals. It should be cleaned more fre-

quently if you are riding in unusually wet or

dusty areas.

1. Loosen the clamp.

1. Screw

2. Remove the bolts.

7-10

1. Bolt (× 2)

3. Remove the hoses and the air filter case.

1. Hose (× 2)

4. Remove the air filter case cover.

1. Screw (× 2)

5. Remove the wing bolt.

1. Wing bolt

7-11

6. Pull out the element.

7. Remove the element from its guide and

clean it with solvent. After cleaning, re-

move the remaining solvent by squeez-

ing the element.

1. Air filter element 2. Guide

8. Apply recommended oil to the entire sur-

face of the filter and squeeze out the ex-

cess oil. The element should be wet but

not dripping.

9. Install by reversing the removal proce-

dures.

EUU35701

CAUTION:

Make sure the element is properly seated

in the filter case.

Recommended oil:

SAE 10W30 type SE motor oil

7-12

EUU42400

CAUTION:

The engine should never be run without

the air filter element installed; excessive

piston and/or cylinder wear may result.

EAH93100

Carburetor adjustment

The carburetors are important parts of the en-

gine and requires very sophisticated adjust-

ment. Most adjustments should be left to a

Yamaha dealer who has the professional

knowledge and experience to do so. Howev-

er, the following may be serviced by the own-

er as part of routine maintenance.

EUU13700

TE:

A diagnostic tachometer must be used for this

procedure.

EUU47100

CAUTION:

The carburetors were set at the Yamaha

factory after many tests. If they are

changed, poor engine performance and

damage may result.

EAH92002

Idle speed adjustment

EUU13700

TE:

A diagnostic tachometer must be used for this

procedure.

1. Attach the tachometer. Start the engine

and warm it up for a few minutes at ap-

proximately 1,000 to 2,000 r/min. Occa-

sionally rev the engine to 4,000 to

5,000 r/min. The engine is warm when it

quickly responds to the throttle.

2. Set the idle to the specified engine speed

by adjusting the throttle stop screw. Turn

the screw in direction a to increase en-

gine speed and in direction b to de-

crease engine speed.

7-13

1. Throttle stop screw

EUU04500

TE:

If the specified idle speed cannot be obtained

by performing the above adjustment, consult

a Yamaha dealer.

EAH92202

Throttle cable free play inspection

There should be a free play of 3 ~ 5 mm at the

throttle grip. If the free play is incorrect, ask a

Yamaha dealer to make this adjustment.

a. Free play

Standard idle speed:

1,250 ~ 1,350 r/min

7-14

EAH90801

Valve clearance adjustment

The correct valve clearance changes with

use, resulting in improper fuel/air supply or

engine noise. To prevent this, the valve clear-

ance must be adjusted regularly. This adjust-

ment however, should be left to a professional

Yamaha service technician.

EAH20102

Spark plug inspection

The spark plug is an important engine compo-

nent and is easy to inspect. The condition of

the spark plug can indicate the condition of

the engine.

Normally, all spark plugs from the same en-

gine should have the same color on the white

insulator around the center electrode. The

ideal color at this point is a medium-to-light

tan color for a motorcycle that is being ridden

normally. If one spark plug shows a distinctly

different color, there could be something

wrong with the engine.

Do not attempt to diagnose such problems

yourself. Instead, take the motorcycle to a

Yamaha dealer. You should periodically re-

move and inspect the spark plugs because

heat and deposits will cause any spark plug to

slowly break down and erode. If electrode

erosion becomes excessive, or if carbon and

other deposits are excessive, you should re-

place the spark plug with the specified plug.

Before installing any spark plug, measure the

electrode gap with a wire thickness gauge.

Adjust the gap to specification.

Specified spark plug:

CR6HSA (NGK) or

U20FSR-U (DENSO)

7-15

1. Spark plug gap

When installing the spark plug, always clean

the gasket surface and use a new gasket.

Wipe off any grime from the threads and tight-

en the spark plug to the specified torque.

EUU03802

TE:

If a torque wrench is not available when you

are installing a spark plug, a good estimate of

the correct torque is 1/4 to 1/2 turn past finger

tight. Have the spark plug tightened to the

specified torque as soon as possible.

EAH80104

Front brake lever free play adjustment

The free play at the front brake lever should

be 2 ~ 5 mm.

1. Loosen the locknut.

2. Turn the adjusting bolt in direction a to

increase free play or in direction b to de-

crease free play.

3. After adjusting, tighten the locknut.

Spark plug gap:

0.6 ~ 0.7 mm

Tightening torque:

Spark plug:

12.5 Nm (1.25 m·kgf)

7-16

1. Locknut 2. Adjusting bolt 3. Free play

EUU81500

WARNING

●Check the brake lever free play. Be

sure the brake is working properly.

●A soft or spongy feeling in the brake

lever can indicate the presence of air

in the brake system. This air must be

removed by bleeding the brake sys-

tem before the motorcycle is operat-

ed. Air in the system will cause greatly

diminished braking capability and can

result in loss of control and an acci-

dent. Have a Yamaha dealer inspect

and bleed the system if necessary.

EAH87103

Rear brake adjustment

EUU64301

WARNING

It is advisable to have a Yamaha dealer

make this adjustment.

1. Pedal height

a. Loosen the locknut.

b. By turning the adjuster clockwise or

counterclockwise, adjust the brake pedal

position so that its top end is approxi-

mately 50 mm above the top of the foot-

rest.

c. Tighten the locknut.

7-20

EAH88202*

Inspecting the brake fluid level

Insufficient brake fluid may let air enter the

brake system, possibly causing the brakes to

become ineffective.

Before riding, check that the brake fluid is

above the lower level and replenish when

necessary.

Observe these precautions:

1. When checking the fluid level, make sure

the top of the master cylinder is level by

turning the handlebars.

2. Use only the designated quality brake flu-

id. Otherwise, the rubber seals may dete-

riorate, causing leakage and poor brake

performance.

EUU13100

TE:

If DOT 4 is not available, DOT 3 can be used.

3. Refill with the same type of brake fluid.

Mixing fluids may result in a harmful

chemical reaction and lead to poor brake

performance.

4. Be careful that water does not enter the

master cylinder when refilling. Water will

significantly lower the boiling point of the

fluid and may result in vapor lock.

5. Brake fluid may deteriorate painted sur-

faces or plastic parts. Always clean up

spilled fluid immediately.

6. Have a Yamaha dealer check the cause

if the brake fluid level goes down.

Recommended brake fluids: DOT 4

7-21

1. Lower level

EAH83501

Brake fluid replacement

1. Complete fluid replacement should be

done only by trained Yamaha service

personnel.

2. Have a Yamaha dealer replace the fol-

lowing components during periodic main-

tenance or when they are damaged or

leaking.

a. Replace all rubber seals every two years.

b. Replace all hoses every four years.

EAI00501

Clutch adjustment

The clutch lever free play should be adjusted

to 10 ~ 15 mm at the clutch lever. If the free

play is incorrect, adjust as follows.

1. Locknut 2. Adjuster a. Free play

Free play:

10 ~ 15 mm

7-23

a. Drive chain slack

EAI40102

Drive chain slack adjustment

1. Loosen the rear brake adjuster.

1. Adjuster

2. Remove the cotter pin from the axle nut.

1. Axle nut 2. Cotter pin 3. Locknut

4. Adjuster 5. Alignment marks

3. Loosen the axle nut.

4. Loosen the chain adjuster locknut on

each side of the swingarm. To tighten the

chain, turn the chain adjuster on each

side of the swingarm clockwise. To loos-

en the chain, turn each adjuster counter-

clockwise and push the wheel forward.

Turn each adjuster exactly the same

amount to maintain correct axle align-

ment. There are marks on each side of

7-24

the swingarm and a match mark on each

chain adjuster. Use these marks to align

the rear wheel.

EUU33301

CAUTION:

Too little chain slack will overload the en-

gine and other vital parts. Keep the slack

within the specified limits.

5. After adjusting, be sure to tighten each

chain adjuster locknut and the axle nut.

6. Insert a new cotter pin into the axle nut

and bend the end of the cotter pin as

shown. If the notch in the axle nut and the

cotter pin hole do not match, tighten the

nut slightly to align them.

Axle nut torque:

105 Nm (10.5 m·kgf)

1. Cotter pin

EUU64700

WARNING

Always use a new cotter pin on the axle

nut.

7. Adjust the free play in the brake pedal.

EUU64500

WARNING

Check the operation of the brake light after

adjusting the rear brake.

7-25

EAI40701

Drive chain lubrication

The chain consists of many parts which work

with each other. If the chain is not maintained

properly, it will wear out quickly, Therefore,

the chain must be serviced regularly. This ser-

vice is especially necessary when riding in

dusty areas. This motorcycle is equipped with

a sealed type chain. Steam cleaning, high-

pressure washes, and solvents can damage

chain so do not use these for cleaning it. Use

only kerosene to clean the drive chain. Wipe it

dry, and thoroughly lubricate it with SAE 30 ~

50W motor oil. Do not use any other lubri-

cants on the drive chain. They may contain

solvents that could damage the sealed chain.

EAI10701

Cable inspection and lubrication

EUU64601

WARNING

Damage to the outer housing of cables

may allow internal rusting and cause inter-

ference with cable movement. Replace

damaged cables as soon as possible to

prevent unsafe conditions.

Lubricate the inner cable and the cable end. If

it does not operate smoothly, ask a Yamaha

dealer to replace them.

Recommended lubricant:

SAE 10W30 motor oil

7-27

EAI20502

Front fork inspection

EUU65700

WARNING

Securely support the motorcycle so there

is no danger of it falling over.

1. Visual check

Check for scratches or damage on the in-

ner tube and excessive oil leakage from

the front fork.

2. Operation check

Place the motorcycle on a level place.

a. Hold the motorcycle in an upright position

and apply the front brake.

b. Push down hard on the handlebars seve-

ral times and check if the fork rebounds

smoothly.

EUU42500

CAUTION:

If any damage or unsmooth movement is

found with the front fork, consult a

Yamaha dealer.

7-28

EAI60301

Steering inspection

Periodically inspect the condition of the steer-

ing. Worn out or loose steering bearings may

be dangerous. Place a stand under the en-

gine to raise the front wheel off the ground.

Hold the lower end of the front forks and try to

move them forward and backward. If any free

play can be felt, ask a Yamaha dealer to in-

spect and adjust the steering. Inspection is

easier if the front wheel is removed.

EUU65700

WARNING

Securely support the motorcycle so there

is no danger of it falling over.

EAI60201

Wheel bearings

If there is play in the front or rear wheel hub or

if the wheel does not turn smoothly, have a

Yamaha dealer inspect the wheel bearings.

The wheel bearings should be inspected ac-

cording to the Maintenance Schedule.

EAI70001

Battery

Check the level of the battery electrolyte and

make sure that the terminals are tight. Add

distilled water if the electrolyte level is low.

7-29

EUU33601

CAUTION:

When inspecting the battery, be sure the

breather pipe is routed correctly. If the

breather pipe is positioned in such a way

as to cause battery electrolyte or gas to

exit onto the frame, structural and cosmet-

ic damage to the motorcycle can occur.

EUU65800

WARNING

Battery electrolyte is poisonous and dan-

gerous, causing severe burns, etc. It con-

tains sulfuric acid. Avoid contact with

skin, eyes or clothing.

Antidote:

EXTERNAL: Flush with water.

INTERNAL: Drink large quantities of water

or milk. Follow with milk of magnesia,

beaten egg, or vegetable oil. Call a physi-

cian immediately.

EYES: Flush with water for 15 minutes and

get prompt medical attention. Batteries

produce explosive gases. Keep sparks,

flame, cigarettes etc., away. Ventilate

when charging or using in an enclosed

space. Always shield your eyes when

working near batteries.

KEEP OUT OF REACH OF CHILDREN.

7-30

EAI70401

Replenishing the battery fluid

A poorly maintained battery will corrode and

discharge quickly. The battery fluid should be

checked at least once a month.

1. The level should be between the upper

and lower level marks. Use only distilled

water if refilling is necessary.

1. 2.“UPPER LEVEL” “LOWER LEVEL”

EUU33800

CAUTION:

Normal tap water contains minerals which

are harmful to a battery; therefore, refill

only with distilled water.

EUU65901

WARNING

Take care not to spill battery fluid on the

chain. Battery fluid may weaken the chain

causing shorter chain life and possibly re-

sult in an accident.

2. When the motorcycle will not be used for

a month or longer, remove the battery

and store it in a cool, dark place. Com-

pletely recharge the battery before reus-

ing.

3. If the battery will be stored for a longer

period than the above, check the specific

gravity of the fluid at least once a month

and recharge the battery when it is too

low.

4. Always make sure the connections are

correct when putting the battery back in

the motorcycle. Make sure the breather

pipe is properly connected and is not

damaged or obstructed.

7-31

EAI91801

Fuse replacement

1. The fuse case is located under the seat.

1. Main fuse 2. Signal fuse

3. Patrol fuse 4. Siren fuse

2. If a fuse is blown, turn off the ignition

switch and the switch of the circuit in

question. Install a new fuse of proper am-

perage. Turn on the switches and see if

the electrical device operates. If the fuse

immediately blows again, consult a

Yamaha dealer.

EUU34400

CAUTION:

Do not use fuses of higher amperage rat-

ing than those recommended. Substitu-

tion of a fuse of improper rating can cause

extensive electrical system damage and

possibly a fire.

EAI88300

Headlight bulb replacement

This motorcycle is equipped with a quartz

bulb headlight. If the headlight bulb burns out,

replace the bulb as follows:

1. Remove the screws holding the light unit

assembly.

Specified fuse:

Main: 20 A

Signal: 10 A

Patrol: 5 A

Siren: 5 A

7-33

4. Put a new bulb into position and secure it

in place with the bulb holder.

EUU34100

CAUTION:

Avoid touching the glass part of the bulb.

Keep it free from oil; otherwise, the trans-

parency of the glass, life of the bulb, and il-

luminous flux will be adversely affected. If

oil gets on the bulb, thoroughly clean it

with a cloth moistened with alcohol or lac-

quer thinner.

5. Install the cover.

6. Connect headlight coupler.

7. Install the light unit assembly.

If the headlight beam adjustment is nec-

essary, ask a Yamaha dealer to make

adjustment.

EAJ24402

Front wheel removal

EUU66201

WARNING

It is advisable to have a Yamaha dealer

service the wheel.

EUU65700

WARNING

Securely support the motorcycle so there

is no danger of it falling over.

1. Remove the speedometer cable from the

front wheel side.

1. Speedometer cable

7-34

2. Loosen the pinch bolt and wheel axle.

1. Pinch bolt 2. Wheel axle

3. Elevate the front wheel by placing a suit-

able stand under the engine.

4. Remove the wheel axle and the front

wheel. Make sure the motorcycle is prop-

erly supported.

EUU05400

TE:

Do not depress the brake lever when the disc

is off the caliper as the brake pads will be

forced shut.

EAJ28400

Front wheel installation

When installing the front wheel, reverse the

removal procedure. Pay attention to the fol-

lowing points:

1. Make sure the wheel hub and the speed-

ometer gear unit are installed with the

projections meshed into the slots.

2. Make sure there is enough gap between

the brake pads before inserting the brake

disc.

7-35

3. Make sure the slot in the speedometer

gear unit fits over the stopper on the front

fork outer tube.

4. Make sure the wheel axle is properly

torqued.

5. Tighten the pinch bolt.

6. After tightening the pinch bolt, push down

the front fork several times to check for

proper fork operation.

EAJ31202

Rear wheel removal

EUU66201

WARNING

It is advisable to have a Yamaha dealer

service the wheel.

EUU65700

WARNING

Securely support the motorcycle so there

is no danger of it falling over.

1. Elevate the rear wheel by placing a suit-

able stand under the engine.

2. Remove the cotter pin, nut and tension

bar bolt from the brake shoe plate.

Tightening torque:

Wheel axle:

59 Nm (5.9 m·kgf)

Pinch bolt torque:

20 Nm (2.0 m·kgf)

7-36

1. Tension bar 2. Cotter pin

3. Nut (tension bar bolt) 4. Brake rod

5. Brake adjuster

3. Remove the brake adjuster and brake

rod from the brake cam lever.

4. Loosen the locknuts and chain adjusters

on each side.

1. Axle nut 2. Cotter pin 3. Locknut

4. Adjuster 5. Alignment marks

5. Remove the axle nut cotter pin and the

axle nut.

6. Pull out the wheel axle and remove the

wheel assembly.

EUU05600

TE:

You do not have to disassemble the chain in

order to remove or install the rear wheel.

Produkt Specifikationer

Mærke:	Yamaha
Kategori:	Motor
Model:	XV250

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