XT225T/TC Owner`s Manual

XT225T/TC Owner`s Manual

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU17231

Safety is an obligation of the owner. Periodic inspection, adjustment and lubrication will keep your vehicle in the safest and most efficient condition possible. The most important points of motorcycle inspection, adjustment, and lubrication are explained on the following pages.

Maintenance, replacement, or repair of the emission control devices and systems may be performed by any repair establishment or individual that is certified (if applicable).

EWA10320

WARNING

If you are not familiar with maintenance work, have a Yamaha dealer do it for you.

EAU17301

PERIODIC MAINTENANCE

PROPER PERIODIC MAINTENANCE

OF YOUR VEHICLE IS IMPORTANT

IN ORDER TO ENJOY LONG, PLEA-

SURABLE SERVICE. ESPECIALLY

IMPORTANT ARE THE MAINTE-

NANCE SERVICES RELATED TO

EMISSIONS CONTROL. THESE

CONTROLS NOT ONLY FUNCTION

TO ENSURE CLEANER AIR, BUT

ARE ALSO VITAL TO PROPER EN-

GINE OPERATION AND MAXIMUM

PERFORMANCE. IN THE FOLLOW-

ING PERIODIC MAINTENANCE

CHARTS, THE SERVICES RELATED

TO EMISSIONS CONTROL ARE

GROUPED SEPARATELY. THESE

SERVICES REQUIRE SPECIALIZED

DATA, KNOWLEDGE, AND EQUIP-

MENT. YAMAHA DEALERS ARE

TRAINED AND EQUIPPED TO PER-

FORM THESE PARTICULAR SER-

VICES.

Owner’s tool kit

1

EAU17310

1. Owner’s tool kit

The service information included in this manual and the tools provided in the owner’s tool kit are intended to assist you in the performance of preventive maintenance and minor repairs. However, additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly.

NOTE:

If you do not have the tools or experience required for a particular job, have a Yamaha dealer perform it for you.

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PERIODIC MAINTENANCE AND MINOR REPAIR

EWA10340

WARNING

Modifications not approved by

Yamaha may cause loss of performance, excessive emissions, and render the vehicle unsafe for use.

Consult a Yamaha dealer before attempting any changes.

6-2

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU17580

Periodic maintenance chart for the emission control system

No.

ITEM ROUTINE

INITIAL

600 mi

(1000 km) or

1 month

ODOMETER READINGS

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

1 *

Fuel line

2

3

Spark plug

Spark arrester

4 *

Valve clearance

5 *

Crankcase breather

system

6 *

Idle speed

7 *

Exhaust system

Check fuel hoses for cracks or damage.

Replace if necessary.

Check condition.

Adjust gap and clean.

Replace at 7000 mi (11000 km) or 12 months and thereafter every 6000 mi (10000 km) or 12 months.

Clean.

Check and adjust valve clearance when engine is cold.

Check breather hose for cracks or damage.

Replace if necessary.

Check and adjust engine idle speed.

Check for leakage.

Tighten if necessary.

Replace gasket(s) if necessary.

Replace.

Replace.

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PERIODIC MAINTENANCE AND MINOR REPAIR

1

2

3

No.

ITEM ROUTINE

INITIAL

600 mi

(1000 km) or

1 month

ODOMETER READINGS

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

8 *

Evaporative emis-

sion control system

(For California only)

Check control system for damage.

Replace if necessary.

* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.

6-4

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU32161

General maintenance and lubrication chart

No.

1 *

Air filter element

2 *

Clutch

3 *

Front brake

4 *

Rear brake

5 *

Brake hose

6 *

Wheels

7 *

Tires

ITEM

8 *

Wheel bearings

ROUTINE

Clean with solvent.

Replace if necessary.

Check operation.

Adjust or replace cable.

Check operation, fluid level, and for fluid leakage.

Replace brake pads if necessary.

Check operation.

Adjust cable and replace brake shoes if necessary.

Check for cracks or damage.

Replace.

Check runout, spoke tightness and for damage.

Tighten spokes if necessary.

Check tread depth and for damage.

Replace if necessary.

Check air pressure.

Correct if necessary.

Check bearings for smooth operation.

Replace if necessary.

INITIAL

600 mi

(1000 km) or

1 month

ODOMETER READINGS

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

√ √ √ √ √

Every 4 years

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6-5

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PERIODIC MAINTENANCE AND MINOR REPAIR

No.

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10

11

12

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*

ITEM

Drive chain

Steering bearings

*

Chassis fasteners

Brake and clutch lever pivot shafts

Brake and shift pedal pivot shafts

Sidestand pivot

*

Sidestand switch

ROUTINE

INITIAL

600 mi

(1000 km) or

1 month

ODOMETER READINGS

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

Check chain slack/alignment and condition.

Adjust and lubricate chain with a special O-ring chain lubricant thoroughly.

Check bearing assembly for looseness.

Moderately repack with lithium-soap-based grease every

10000 mi (16000 km) or 18 months.

Check all chassis fitting and fasteners.

Correct if necessary.

Apply lithium-soap-based grease (all-purpose grease) lightly.

Apply lithium-soap-based grease (all-purpose grease) lightly.

Check operation.

Apply lithium-soap-based grease (all-purpose grease) lightly.

Check operation and replace if necessary.

Every 300 mi (500 km) and after washing the motorcycle or riding in the rain

Repack.

6-6

PERIODIC MAINTENANCE AND MINOR REPAIR

No.

ITEM ROUTINE

INITIAL

600 mi

(1000 km) or

1 month

ODOMETER READINGS

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

16 *

Front fork

17 *

Shock absorber assembly

18 *

Rear suspension link pivots

19

Engine oil

Check operation and for oil leakage.

Replace if necessary.

Check operation and for oil leakage.

Replace if necessary.

Apply lithium-soap-based grease until new grease shows.

Change (warm engine before draining).

20

21

Engine oil filter element

Engine oil strainer

22 *

Control and meter cables

23 *

Throttle grip housing and cable

Clean.

Clean.

Apply Yamaha chain and cable lube or engine oil 10W-30 thoroughly.

Check operation and free play.

Adjust the throttle cable free play if necessary.

Lubricate the throttle grip housing and cable.

√ √

* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.

NOTE:

From 19000 mi (31000 km) or 36 months, repeat the maintenance intervals starting from 7000 mi (11000 km) or 12 months.

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PERIODIC MAINTENANCE AND MINOR REPAIR

EAU17620

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.

6-8

EAU18721

Removing and installing the cowling and panels

The cowling and panels shown need to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time the cowling or a panel needs to be removed and installed.

PERIODIC MAINTENANCE AND MINOR REPAIR

1

To install the cowling

Place the cowling in the original position, and then install the screw.

EAU19292

Panels A and B

To remove one of the panels

Remove the screw, and then pull the panel off as shown.

1. Panel B

1 2

EAU18810

Cowling A

To remove the cowling

Remove the screw, and then pull the cowling off as shown.

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2

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1. Cowling A

2. Panel A

1. Panel A

2. Screw

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9

1

1. Screw

6-9

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PERIODIC MAINTENANCE AND MINOR REPAIR

1

2

1. Panel B

2. Screw

To install the panel

Place the panel in the original position, and then install the screw.

EAU19602

Checking the spark plug

The spark plug is an important engine component, which is easy to check.

Since heat and deposits will cause any spark plug to slowly erode, the spark plug should be removed and checked in accordance with the periodic maintenance and lubrication chart. In addition, the condition of the spark plug can reveal the condition of the engine.

To remove the spark plug

1. Remove the spark plug cap.

1

1. Spark plug cap

2. Remove the spark plug as shown, with the spark plug wrench included in the owner’s tool kit.

1

1. Spark plug wrench

To check the spark plug

1. Check that the porcelain insulator around the center electrode of the spark plug is a medium-to-light tan

(the ideal color when the vehicle is ridden normally).

NOTE:

If the spark plug shows a distinctly different color, the engine could be defective. Do not attempt to diagnose such problems yourself. Instead, have a

Yamaha dealer check the vehicle.

2. Check the spark plug for electrode erosion and excessive carbon or other deposits, and replace it if

6-10

PERIODIC MAINTENANCE AND MINOR REPAIR

necessary.

Specified spark plug:

NGK/DR8EA

DENSO/X24ESR-U

1

3. Install the spark plug with the spark plug wrench, and then tighten it to the specified torque.

Tightening torque:

Spark plug:

17.5 Nm (1.75 m·kgf, 12.5 ft·lbf)

To install the spark plug

1. Measure the spark plug gap with a wire thickness gauge and, if necessary, adjust the gap to specification.

NOTE:

If a torque wrench is not available when installing a spark plug, a good estimate of the correct torque is 1/4–1/2 turn past finger tight. However, the spark plug should be tightened to the specified torque as soon as possible.

4. Install the spark plug cap.

EAU19671

Canister (for California only)

3

4

1. Fuel tank

2. Carburetor

3. Canister

4. Vent hose

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2

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7

1. Spark plug gap

Spark plug gap:

0.6–0.7 mm (0.024–0.028 in)

2. Clean the surface of the spark plug gasket and its mating surface, and then wipe off any grime from the spark plug threads.

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1. Overflow hose

This model is equipped with a canister to prevent the discharging of fuel vapor

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6-11

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PERIODIC MAINTENANCE AND MINOR REPAIR

into the atmosphere.

Check each hose connection.

Check each hose and canister for cracks or damage. Replace if damaged.

Make sure the vent hose is not blocked. Clean it if necessary.

EAU19812

Engine oil and oil filter element

The engine oil level should be checked before each ride. In addition, the oil must be changed and the oil filter element cleaned at the intervals specified in the General maintenance and lubrication chart.

To check the engine oil level

1. Place the vehicle on a level surface and hold it in an upright position.

NOTE:

Make sure that the vehicle is positioned straight up when checking the oil level.

A slight tilt to the side can result in a false reading.

2. Start the engine, warm it up for several minutes, and then turn it off.

3. Wait a few minutes until the oil settles, and then check the oil level through the check window located at the bottom right side of the engine guard.

6-12

NOTE:

The engine oil should be between the minimum and maximum level marks.

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3

1

1. Engine oil level check window

2. Maximum level mark

3. Minimum level mark

4. If the engine oil is below the minimum level mark, add sufficient oil of the recommended type to raise it to the correct level.

To change the engine oil (with or without oil filter element cleaning)

1. Start the engine, warm it up for several minutes, and then turn it off.

2. Place an oil pan under the engine to collect the used oil.

3. Remove the engine guard by removing the bolt.

PERIODIC MAINTENANCE AND MINOR REPAIR

6. Remove the oil filter element drain bolt to drain the oil from the oil filter element.

1

4 3 2 1

2

2

1

1. Engine guard

2. Bolt

4. Remove the engine oil filler cap and drain bolt along with the

O-ring, compression spring, and engine oil strainer, to drain the oil from the crankcase.

1. Engine oil filler cap

ECA11000

CAUTION:

When removing the engine oil drain bolt, the O-ring, compression spring, and oil strainer will fall out.

Take care not to lose these parts.

NOTE:

Check the O-ring for damage and replace it if necessary.

5. Clean the engine oil strainer with solvent.

NOTE:

Skip steps 6–11 if the oil filter element is not being cleaned.

1

1. Engine oil drain bolt

2. O-ring

3. Compression spring

4. Oil strainer

7. Remove the oil filter element cover by removing the bolts.

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PERIODIC MAINTENANCE AND MINOR REPAIR

2

1

3

(

×

2)

1. Oil filter element drain bolt

2. Oil filter element cover

3. Bolt

8. Remove the oil filter element and

O-rings.

1

replace them if necessary.

10. Clean the oil filter element with solvent, and then install it.

NOTE:

Check the oil filter element for damage and replace it if necessary.

11. Install the oil filter element cover by installing the bolts and drain bolt, then tightening them to the specified torques.

Tightening torques:

Oil filter element cover bolt:

10 Nm (1.0 m·kgf, 7.2 ft·lbf)

Oil filter element drain bolt:

10 Nm (1.0 m·kgf, 7.2 ft·lbf)

bolt, do not forget to install the

O-ring, compression spring, and oil strainer in position.

Tightening torque:

Engine oil drain bolt:

43 Nm (4.3 m·kgf, 31 ft·lbf)

13. Add the specified amount of the recommended engine oil, and then install and tighten the oil filler cap.

Recommended oil:

See page 8-1.

Oil quantity:

Without oil filter element removal:

1.00 L (1.06 US qt) (0.88 Imp.qt)

With oil filter element removal:

1.10 L (1.16 US qt) (0.97 Imp.qt)

2

(

×

2)

1. Oil filter element

2. O-ring

9. Check the O-rings for damage and

NOTE:

Make sure that the O-ring is properly seated.

12. Install the engine oil strainer, compression spring, O-ring and engine oil drain bolt, and then tighten the drain bolt to the specified torque.

ECA10420

CAUTION:

Before installing the engine oil drain

6-14

ECA11620

CAUTION:

In order to prevent clutch slippage (since the engine oil also lubricates the clutch), do not mix any chemical additives. Do not use oils with a diesel specification of “CD” or oils of a higher quality than specified. In

PERIODIC MAINTENANCE AND MINOR REPAIR

addition, do not use oils labeled

“ENERGY CONSERVING II” or higher.

Make sure that no foreign material enters the crankcase.

14. Start the engine, and then let it idle for several minutes while checking it for oil leakage. If oil is leaking, immediately turn the engine off and check for the cause.

15. Turn the engine off, and then check the oil level and correct it if necessary.

16. Install the engine guard by installing the bolt.

EAU20840

Cleaning the air filter element

The air filter element should be cleaned at the intervals specified in the periodic maintenance and lubrication chart.

Clean the air filter element more frequently if you are riding in unusually wet or dusty areas.

1. Remove panel A. (See page 6-9.)

2. Remove the air filter case cover by removing the screws.

1

1

1. Air filter element

4. Remove the sponge material from the air filter element frame.

2

3

4

5

6

7

2

1. Air filter case cover

2. Screw

3. Pull the air filter element out from the air filter case.

1 2

1. Sponge material

2. Air filter element frame

5. Clean the sponge material with solvent, and then squeeze the remaining solvent out.

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6-15

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PERIODIC MAINTENANCE AND MINOR REPAIR

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6. Apply oil of the recommended type to the entire surface of the sponge material, and then squeeze the excess oil out.

NOTE:

The sponge material should be wet but not dripping.

Recommended oil:

Yamaha foam air filter oil or other quality air filter oil

7. Install the sponge material onto the air filter element frame, and then insert the air filter element into the air filter case.

NOTE:

Install the air filter element with the gray side facing forward and with the “UP” mark pointing as shown.

1

EAU21233

Cleaning the spark arrester

The spark arrester should be cleaned at the intervals specified in the Periodic maintenance and lubrication chart.

EWA10980

WARNING

Always let the exhaust system cool prior to touching exhaust components.

Do not start the engine when cleaning the exhaust system.

1. “UP” mark

ECA10480

CAUTION:

Make sure that the air filter element is properly seated in the air filter case.

The engine should never be operated without the air filter element installed, otherwise the piston(s) and/or cylinder(s) may become excessively worn.

8. Install the air filter case cover by installing the screws.

9. Install the panel.

NOTE:

Make sure to select a well-ventilated area free of combustible materials to clean the spark arrester.

1. Remove the tailpipe by removing the screw, and then pulling it out of the muffler.

6-16

1

2

1. Muffler

2. Screw

2. Tap the tailpipe lightly, and then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe.

PERIODIC MAINTENANCE AND MINOR REPAIR

3. Insert the tailpipe into the muffler, and then install and tighten the screw.

NOTE:

Make sure to align the screw holes when inserting the tailpipe.

EAU21250

Adjusting the carburetor

The carburetor is an important part of the engine and its emission control system, which requires very sophisticated adjustment. Therefore, carburetor adjustments should be left to Yamaha dealer, who has the necessary professional knowledge and experience.

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1. Tailpipe

2. Spark arrester

6-17

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PERIODIC MAINTENANCE AND MINOR REPAIR

EAU21380

Adjusting the throttle cable free play

1

EAU21400

Adjusting the valve clearance

The valve clearance changes with use, resulting in improper air-fuel mixture and/or engine noise. To prevent this from occurring, the valve clearance must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart.

1. Throttle cable free play

The throttle cable free play should measure 3.0–5.0 mm (0.12–0.20 in) at the throttle grip. Periodically check the throttle cable free play and, if necessary, have a Yamaha dealer adjust it.

EAU21630

Tires

To maximize the performance, durability, and safe operation of your motorcycle, note the following points regarding the specified tires.

Tire air pressure

The tire air pressure should be checked and, if necessary, adjusted before each ride.

EWA10500

WARNING

The tire air pressure must be checked and adjusted on cold tires (i.e., when the temperature of the tires equals the ambient temperature).

The tire air pressure must be adjusted in accordance with the riding speed and with the total weight of rider, passenger, cargo, and accessories approved for this model.

6-18

Tire air pressure (measured on cold tires):

0–90 kg (0–198 lb) :

Front:

125 kPa (18 psi) (1.25 kgf/cm

2

)

Rear:

150 kPa (22 psi) (1.50 kgf/cm

2

)

90–183 kg (198–403 lb) :

Front:

150 kPa (22 psi) (1.50 kgf/cm

2

)

Rear:

175 kPa (25 psi) (1.75 kgf/cm

2

)

Maximum load*:

183 kg (403 lb)

* Total weight of rider, passenger, cargo and accessories

EWA11020

WARNING

Because loading has an enormous impact on the handling, braking, performance and safety characteristics of your motorcycle, you should keep the following precautions in mind.

NEVER OVERLOAD THE MO-

TORCYCLE! Operation of an overloaded motorcycle may result in tire damage, loss of control, or severe injury. Make sure

PERIODIC MAINTENANCE AND MINOR REPAIR

Tire inspection

that the total weight of rider, passenger, cargo, and accessories does not exceed the specified maximum load for the vehicle.

Do not carry along loosely packed items, which can shift during a ride.

Securely pack the heaviest items close to the center of the motorcycle and distribute the weight evenly on both sides.

Adjust the suspension and tire air pressure with regard to the load.

Check the tire condition and air pressure before each ride.

2

1

3

1. Tire tread depth

2. Tire sidewall

3. Tire wear indicator

The tires must be checked before each ride. If the tire shows crosswise lines

(minimum tread depth), if the tire has a nail or glass fragments in it, or if the sidewall is cracked, have a Yamaha dealer replace the tire immediately.

Minimum tire tread depth (front and rear):

1.0 mm (0.04 in)

NOTE:

The tire tread depth limits may differ from country to country. Always comply

6-19

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PERIODIC MAINTENANCE AND MINOR REPAIR

with the local regulations.

Tire information

This motorcycle is equipped with tube tires.

EWA10460

WARNING

The front and rear tires should be of the same make and design, otherwise the handling characteristics of the vehicle cannot be guaranteed.

After extensive tests, only the tires listed below have been approved for this model by

Yamaha Motor Co., Ltd.

Front tire:

Size:

2.75-21 45P

Manufacturer/model:

BRIDGESTONE/TW27

CHENG SHIN/C-6006

Rear tire:

Size:

120/80-18M/C 62P

Manufacturer/model:

BRIDGESTONE/TW30

CHENG SHIN/C-6006

EWA10560

WARNING

It is dangerous to ride with a worn-out tire. When a tire tread begins to show crosswise lines, have a Yamaha dealer replace the tire immediately.

The replacement of all wheeland brake-related parts, including the tires, should be left to a

Yamaha dealer, who has the necessary professional knowledge and experience.

It is not recommended to patch a punctured tube. If unavoidable, however, patch the tube

6-20

very carefully and replace it as soon as possible with a high-quality product.

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU21940

Spoke wheels

To maximize the performance, durability, and safe operation of your motorcycle, note the following points regarding the specified wheels.

● The wheel rims should be checked for cracks, bends or warpage, and the spokes for looseness or dam-

● age before each ride. If any damage is found, have a Yamaha dealer replace the wheel. Do not attempt even the smallest repair to the wheel. A deformed or cracked wheel must be replaced.

The wheel should be balanced whenever either the tire or wheel

● has been changed or replaced. An unbalanced wheel can result in poor performance, adverse handling characteristics, and a shortened tire life.

Ride at moderate speeds after changing a tire since the tire surface must first be “broken in” for it to develop its optimal characteristics.

EAU22011

Accessories and replacement parts

EWA10621

WARNING

This vehicle is not designed to pull a trailer or to be attached to a sidecar.

The accessories or replacement parts you choose for your vehicle should be designed specifically for this model, and they must be securely mounted to maintain the inherent stability of the original design. Genuine Yamaha Parts and

Accessories are designed and tested to be compatible with your vehicle. Please consider Genuine

Yamaha Parts and Accessories before making a purchase. Use of non-Yamaha-approved accessories or replacement parts may cause loss of handling stability and riding safety. Since Yamaha cannot control the quality of accessories or parts manufactured by other companies, Yamaha cannot be held liable for any consequences caused by

6-21

the use of items which have not been approved by Yamaha.

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PERIODIC MAINTENANCE AND MINOR REPAIR

EAU22041

Adjusting the clutch lever free play

3

1

2

(a)

(b)

NOTE:

If the specified clutch lever free play could be obtained as described above, tighten the locknut and skip the rest of the procedure, otherwise proceed as follows.

3. Fully turn the adjusting bolt at the clutch lever in direction (a) to loosen the clutch cable.

4. Loosen the locknut at the crankcase.

1. Locknut (clutch lever)

2. Adjusting bolt

3. Clutch lever free play

The clutch lever free play should measure 10.0–15.0 mm (0.39–0.59 in) as shown. Periodically check the clutch lever free play and, if necessary, adjust it as follows.

1. Loosen the locknut at the clutch lever.

2. To increase the clutch lever free play, turn the adjusting bolt in direction (a). To decrease the clutch lever free play, turn the adjusting bolt in direction (b).

(b)

(a)

1

2

1. Locknut (crankcase)

2. Adjusting nut

5. To increase the clutch lever free play, turn the adjusting nut in direction (a). To decrease the clutch le-

6-22 ver free play, turn the adjusting nut in direction (b).

6. Tighten the locknut at the clutch lever and the crankcase.

EAU22092

Adjusting the brake lever free play

1 2

(b)

(a)

3

1. Locknut

2. Adjusting bolt

3. Brake lever free play

The brake lever free play should measure 2.0–5.0 mm (0.08–0.20 in) as shown. Periodically check the brake lever free play and, if necessary, adjust it as follows.

1. Loosen the locknut at the brake lever.

2. To increase the brake lever free play, turn the adjusting screw in direction (a). To decrease the brake lever free play, turn the adjusting screw in direction (b).

PERIODIC MAINTENANCE AND MINOR REPAIR

3. Tighten the locknut.

EWA10630

WARNING

After adjusting the brake lever free play, check the free play and make sure that the brake is working properly.

A soft or spongy feeling in the brake lever can indicate the presence of air in the hydraulic system. If there is air in the hydraulic system, have a Yamaha dealer bleed the system before operating the motorcycle. Air in the hydraulic system will diminish the braking performance, which may result in loss of control and an accident.

EAU22191

Adjusting the brake pedal position and free play

1

1. Brake pedal position

EWA10670

WARNING

It is advisable to have a Yamaha dealer make these adjustments.

Brake pedal position

The top of the brake pedal should be positioned approximately 10.0 mm

(0.39 in) below the top of the footrest.

Periodically check the brake pedal position and, if necessary, adjust it as follows.

1. Loosen the locknut at the brake pedal.

6-23

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PERIODIC MAINTENANCE AND MINOR REPAIR

2. To raise the brake pedal, turn the adjusting bolt in direction (a). To lower the brake pedal, turn the adjusting bolt in direction (b).

Brake pedal free play

(a)

2

1

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1

(b)

1. Adjusting bolt

2. Locknut

3. Tighten the locknut.

EWA11230

WARNING

After adjusting the brake pedal position, the brake pedal free play must be adjusted.

1. Brake pedal free play

The brake pedal free play should measure 20.0–30.0 mm (0.79–1.18 in) as shown. Periodically check the brake pedal free play and, if necessary, adjust it as follows.

To increase the brake pedal free play, turn the adjusting nut at the brake rod in direction (a). To decrease the brake pedal free play, turn the adjusting nut in direction (b).

9

(a)

(b)

1

1. Brake pedal free play adjusting nut

EWA10680

WARNING

After adjusting the drive chain slack or removing and installing the rear wheel, always check the brake pedal free play.

If proper adjustment cannot be obtained as described, have a

Yamaha dealer make this adjustment.

After adjusting the brake pedal free play, check the operation of the brake light.

6-24

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU22270

Adjusting the rear brake light switch

2

1

(a)

EAU22380

Checking the front brake pads and rear brake shoes

The front brake pads and the rear brake shoes must be checked for wear at the intervals specified in the periodic maintenance and lubrication chart.

EAU22420

(b)

Front brake pads

indicator groove has almost disappeared, have a Yamaha dealer replace the brake pads as a set.

Rear brake shoes

2

EAU22540

1

1

1. Rear brake light switch

2. Adjusting nut

The rear brake light switch, which is activated by the brake pedal, is properly adjusted when the brake light comes on just before braking takes effect. If necessary, adjust the brake light switch as follows.

Turn the adjusting nut while holding the rear brake light switch in place. To make the brake light come on earlier, turn the adjusting nut in direction (a). To make the brake light come on later, turn the adjusting nut in direction (b).

1. Wear indicator groove

Each front brake pad is provided with a wear indicator groove, which allows you to check the brake pad wear without having to disassemble the brake.

To check the brake pad wear, check the wear indicator groove. If a brake pad has worn to the point that the wear

6-25

1. Wear indicator

2. Wear limit line

The rear brake is provided with a wear indicator, which allows you to check the brake shoe wear without having to disassemble the brake. To check the brake shoe wear, check the position of the wear indicator while applying the brake. If a brake shoe has worn to the point that the wear indicator reaches the wear limit line, have a Yamaha dealer replace the

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PERIODIC MAINTENANCE AND MINOR REPAIR

brake shoes as a set.

EAU32341

Checking the brake fluid level

Front brake

1

1. Minimum level mark

Insufficient brake fluid may allow air to enter the brake system, possibly causing it to become ineffective.

Before riding, check that the brake fluid is above the minimum level mark and replenish if necessary. A low brake fluid level may indicate worn brake pads and/or brake system leakage. If the brake fluid level is low, be sure to check the brake pads for wear and the brake system for leakage.

Observe these precautions:

When checking the fluid level, make sure that the top of the mas-

6-26

● ter cylinder is level by turning the handlebars.

Use only the recommended quality brake fluid, otherwise the rubber seals may deteriorate, causing leakage and poor braking performance.

Recommended brake fluid:

DOT 4

Refill with the same type of brake fluid. Mixing fluids may result in a harmful chemical reaction and lead to poor braking performance.

Be careful that water does not enter the master cylinder when refilling. Water will significantly lower the boiling point of the fluid and may result in vapor lock.

Brake fluid may deteriorate painted surfaces or plastic parts. Always clean up spilled fluid immediately.

As the brake pads wear, it is normal for the brake fluid level to gradually go down. However, if the

PERIODIC MAINTENANCE AND MINOR REPAIR

brake fluid level goes down suddenly, have a Yamaha dealer check the cause.

EAU22720

Changing the brake fluid

Have a Yamaha dealer change the brake fluid at the intervals specified in the NOTE after the periodic maintenance and lubrication chart. In addition, have the oil seals of the brake master cylinder and caliper as well as the brake hose replaced at the intervals listed below or whenever they are damaged or leaking.

Oil seals: Replace every two years.

Brake hose: Replace every four years.

EAU22760

Drive chain slack

The drive chain slack should be checked before each ride and adjusted if necessary.

EAU22770

To check the drive chain slack

1. Place the motorcycle on a level surface and hold it in an upright position.

NOTE:

When checking and adjusting the drive chain slack, the motorcycle should be positioned straight up and there should be no weight on it.

2. Shift the transmission into the neutral position.

3. Move the rear wheel by pushing the motorcycle to locate the tightest portion of the drive chain, and then measure the drive chain slack as shown.

Drive chain slack:

35.0–45.0 mm (1.38–1.77 in)

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6-27

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PERIODIC MAINTENANCE AND MINOR REPAIR

1

1. Drive chain slack

4. If the drive chain slack is incorrect, adjust it as follows.

EAU22830

To adjust the drive chain slack

1. Loosen the brake pedal free play adjusting nut.

1

(b)

(a)

3

2

1. Brake pedal free play adjusting nut

2. Axle nut

3. Drive chain slack adjusting plate

2. Loosen the axle nut.

3. To tighten the drive chain, turn the adjusting plate on each side of the swingarm in direction (a). To loosen the drive chain, turn the adjusting plate on each side of the swingarm in direction (b), and then push the rear wheel forward.

NOTE:

Make sure that both adjusting plates are in the same position for proper wheel alignment.

ECA10570

CAUTION:

Improper drive chain slack will overload the engine as well as other vital parts of the motorcycle and can lead to chain slippage or breakage. To prevent this from occurring, keep the drive chain slack within the specified limits.

4. Tighten the axle nut to the specified torque.

Tightening torque:

Axle nut:

85 Nm (8.5 m·kgf, 62 ft·lbf)

5. Adjust the brake pedal free play.

(See page 6-23.)

EWA10660

WARNING

After adjusting the brake pedal free play, check the operation of the brake light.

6-28

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU23021

Lubricating the drive chain

The drive chain must be cleaned and lubricated at the intervals specified in the periodic maintenance and lubrication chart, otherwise it will quickly wear out, especially when riding in dusty or wet areas. Service the drive chain as follows.

ECA10581

CAUTION:

The drive chain must be lubricated after washing the motorcycle and riding in the rain.

1. Clean the drive chain with kerosene and a small soft brush.

ECA11120

CAUTION:

To prevent damaging the O-rings, do not clean the drive chain with steam cleaners, high-pressure washers or inappropriate solvents.

2. Wipe the drive chain dry.

3. Thoroughly lubricate the drive chain with a special O-ring chain lubricant.

ECA11110

CAUTION:

Do not use engine oil or any other lubricants for the drive chain, as they may contain substances that could damage the O-rings.

EAU23090

Checking and lubricating the cables

The operation of all control cables and the condition of the cables should be checked before each ride, and the cables and cable ends should be lubricated if necessary. If a cable is damaged or does not move smoothly, have a

Yamaha dealer check or replace it.

Recommended lubricant:

Yamaha Chain and Cable Lube or engine oil SAE 10W-30 (API

SE)

EWA10710

WARNING

Damage to the outer housing of cables may result in internal rusting and cause interference with cable movement. Replace damaged cables as soon as possible to prevent unsafe conditions.

6-29

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PERIODIC MAINTENANCE AND MINOR REPAIR

EAU23110

Checking and lubricating the throttle grip and cable

The operation of the throttle grip should be checked before each ride. In addition, the cable should be lubricated or replaced at the intervals specified in the periodic maintenance chart.

EAU23131

Checking and lubricating the brake and shift pedals

EAU23140

Checking and lubricating the brake and clutch levers

The operation of the brake and shift pedals should be checked before each ride, and the pedal pivots should be lubricated if necessary.

Recommended lubricant:

Lithium-soap-based grease

(all-purpose grease)

The operation of the brake and clutch levers should be checked before each ride, and the lever pivots should be lubricated if necessary.

Recommended lubricant:

Lithium-soap-based grease

(all-purpose grease)

6-30

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU23200

Checking and lubricating the sidestand

The operation of the sidestand should be checked before each ride, and the sidestand pivot and metal-to-metal contact surfaces should be lubricated if necessary.

EWA10730

WARNING

If the sidestand does not move up and down smoothly, have a Yamaha dealer check or repair it.

Recommended lubricant:

Lithium-soap-based grease

(all-purpose grease)

EAU23250

Lubricating the rear suspension

1

(

×

3)

1

(

×

2)

1. Grease nipple

The pivoting points of the rear suspension must be lubricated at the intervals specified in the periodic maintenance and lubrication chart.

Recommended lubricant:

Lithium-soap-based grease

EAU23271

Checking the front fork

The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart.

To check the condition

EWA10750

WARNING

Securely support the vehicle so that there is no danger of it falling over.

Check the inner tubes for scratches, damage and excessive oil leakage.

To check the operation

1. Place the vehicle on a level surface and hold it in an upright position.

2. While applying the front brake, push down hard on the handlebars several times to check if the front fork compresses and rebounds smoothly.

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PERIODIC MAINTENANCE AND MINOR REPAIR

ECA10590

CAUTION:

If any damage is found or the front fork does not operate smoothly, have a Yamaha dealer check or repair it.

EAU23280

Checking the steering

Worn or loose steering bearings may cause danger. Therefore, the operation of the steering must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart.

1. Place a stand under the engine to raise the front wheel off the ground.

EWA10750

WARNING

Securely support the vehicle so that there is no danger of it falling over.

2. Hold the lower ends of the front fork legs and try to move them forward and backward. If any free play can be felt, have a Yamaha dealer check or repair the steering.

6-32

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU23290

Checking the wheel bearings

The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart. If there is play in the wheel hub or if the wheel does not turn smoothly, have a Yamaha dealer check the wheel bearings.

EAU23370

Battery

This model is equipped with a sealed-type (MF) battery, which does not require any maintenance. There is no need to check the electrolyte or to add distilled water.

ECA10620

CAUTION:

Never attempt to remove the battery cell seals, as this would permanently damage the battery.

EWA10760

WARNING

Electrolyte is poisonous and dangerous since it contains sulfuric acid, which causes severe burns. Avoid any contact with skin, eyes or clothing and always shield your eyes when working near batteries. In case

of contact, administer the following FIRST AID.

EXTERNAL: Flush with plenty of water.

INTERNAL: Drink large quantities of water or milk and im-

6-33

mediately call a physician.

EYES: Flush with water for 15 minutes and seek prompt medical attention.

Batteries produce explosive hydrogen gas. Therefore, keep sparks, flames, cigarettes, etc., away from the battery and provide sufficient ventilation when charging it in an enclosed space.

KEEP THIS AND ALL BATTER-

IES OUT OF THE REACH OF

CHILDREN.

To charge the battery

Have a Yamaha dealer charge the battery as soon as possible if it seems to have discharged. Keep in mind that the battery tends to discharge more quickly if the vehicle is equipped with optional electrical accessories.

To store the battery

1. If the vehicle will not be used for more than one month, remove the battery, fully charge it, and then place it in a cool, dry place.

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PERIODIC MAINTENANCE AND MINOR REPAIR

2. If the battery will be stored for more than two months, check it at least once a month and fully charge it if necessary.

3. Fully charge the battery before installation.

4. After installation, make sure that the battery leads are properly connected to the battery terminals.

ECA10630

CAUTION:

Always keep the battery charged. Storing a discharged battery can cause permanent battery damage.

To charge a sealed-type (MF) battery, a special (constant-voltage) battery charger is required.

Using a conventional battery charger will damage the battery.

If you do not have access to a sealed-type (MF) battery charger, have a Yamaha dealer charge your battery.

Replacing the fuse

1

2

EAU23500

1. Fuse

2. Spare fuse

The fuse holder is located behind panel

B. (See page 6-9.)

If the fuse is blown, replace it as follows.

1. Turn the key to “OFF” and turn off all electrical circuits.

2. Remove the blown fuse, and then install a new fuse of the specified amperage.

Specified fuse:

20.0 A

ECA10640

CAUTION:

Do not use a fuse of a higher amperage rating than recommended to avoid causing extensive damage to the electrical system and possibly a fire.

3. Turn the key to “ON” and turn on the electrical circuits to check if the devices operate.

4. If the fuse immediately blows again, have a Yamaha dealer check the electrical system.

6-34

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU23811

Replacing the headlight bulb

This model is equipped with a quartz bulb headlight. If the headlight bulb burns out, replace it as follows.

1. Remove cowling A. (See page 6-9.)

2. Remove the headlight unit by removing the bolts.

1

2

1

1

2

1. Headlight unit

2. Bolt

3. Disconnect the headlight coupler, and then remove the headlight bulb cover.

1. Headlight coupler

2. Headlight bulb cover

4. Remove the headlight bulb holder by turning it counterclockwise, and then remove the defective bulb.

1. Headlight bulb holder

EWA10790

WARNING

Headlight bulbs get very hot. Therefore, keep flammable products away from a lit headlight bulb, and do not touch the bulb until it has cooled down.

5. Place a new bulb into position, and then secure it with the bulb holder.

ECA10660

CAUTION:

Do not touch the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the luminosity of the bulb, and the bulb life will be adversely af-

6-35

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1

PERIODIC MAINTENANCE AND MINOR REPAIR fected. Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with alcohol or thinner.

EAU24131

Replacing the tail/brake light bulb

1. Remove the tail/brake light lens by removing the screws.

1

1

1

1. Do not touch the glass part of the bulb.

6. Install the bulb cover, and then connect the coupler.

7. Install the headlight unit by installing the bolts.

8. Install the cowling.

9. Have a Yamaha dealer adjust the headlight beam if necessary.

2

1. Tail/brake light lens

2. Screw

2. Remove the defective bulb by pushing it in and turning it counterclockwise.

1. Tail/brake light bulb

3. Insert a new bulb into the socket, push it in, and then turn it clockwise until it stops.

4. Install the lens by installing the screws.

ECA10680

CAUTION:

Do not overtighten the screws, otherwise the lens may break.

6-36

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU24201

Replacing a turn signal light bulb

1. Remove the turn signal light lens by removing the screw.

1

1

2

1. Turn signal light lens

2. Screw

2. Remove the defective bulb by pushing it in and turning it counterclockwise.

1. Turn signal light bulb

3. Insert a new bulb into the socket, push it in, and then turn it clockwise until it stops.

4. Install the lens by installing the screw.

ECA11190

CAUTION:

Do not overtighten the screw, otherwise the lens may break.

EAU24350

Supporting the motorcycle

Since this model is not equipped with a centerstand, follow these precautions when removing the front and rear wheel or performing other maintenance requiring the motorcycle to stand upright. Check that the motorcycle is in a stable and level position before starting any maintenance. A strong wooden box can be placed under the engine for added stability.

To service the front wheel

1. Stabilize the rear of the motorcycle by using a motorcycle stand or, if an additional motorcycle stand is not available, by placing a jack under the frame in front of the rear wheel.

2. Raise the front wheel off the ground by using a motorcycle stand.

To service the rear wheel

Raise the rear wheel off the ground by using a motorcycle stand or, if a motorcycle stand is not available, by placing a jack either under each side of the

6-37

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PERIODIC MAINTENANCE AND MINOR REPAIR

frame in front of the rear wheel or under each side of the swingarm.

Front wheel

EAU24360

EAU24690

To remove the front wheel

EWA10820

WARNING

It is advisable to have a Yamaha dealer service the wheel.

Securely support the motorcycle so that there is no danger of it falling over.

1. Remove the engine guard by removing the bolt.

1

2

1. Engine guard

2. Bolt

2. Remove the brake disc cover by removing the screws.

6-38

3. Remove the speedometer cable holder by removing the screw.

4. Disconnect the speedometer cable from the front wheel.

5. Remove the axle nut.

2

1

3

4

5

1. Brake disc cover

2. Screw

3. Speedometer cable holder

4. Speedometer cable

5. Axle nut

6. Lift the front wheel off the ground according to the procedure on page 6-37.

7. Pull the wheel axle out, and then remove the wheel.

ECA11070

CAUTION:

Do not apply the brake after the

PERIODIC MAINTENANCE AND MINOR REPAIR wheel has been removed together with the brake disc, otherwise the brake pads will be forced shut.

retainer on the fork leg.

stalling the screws.

8. Install the engine guard by installing the bolt.

EAU25011

To install the front wheel

1. Install the speedometer gear unit into the wheel hub so that the projections mesh with the slots.

1

1

1. Speedometer gear unit

2. Lift the wheel up between the fork legs.

NOTE:

Make sure that there is enough space between the brake pads before inserting the brake disc and that the slot in the speedometer gear unit fits over the

1. Retainer

3. Insert the wheel axle, and then install the axle nut.

4. Lower the front wheel so that it is on the ground.

5. Tighten the axle nut to the specified torque.

Tightening torque:

Axle nut:

85 Nm (8.5 m·kgf, 62 ft·lbf)

6. Connect the speedometer cable, and then install the speedometer cable holder by installing the screw.

7. Install the brake disc cover by in-

6-39

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PERIODIC MAINTENANCE AND MINOR REPAIR

Rear wheel

EAU25080 the brake rod from the brake camshaft lever.

EAU25470

To remove the rear wheel

EWA10820

WARNING

It is advisable to have a Yamaha dealer service the wheel.

Securely support the motorcycle so that there is no danger of it falling over.

1. Remove the engine guard by removing the bolt.

1

3 (a)

5

4

1

2

1. Engine guard

2. Bolt

2. Remove the brake pedal free play adjusting nut, and then disconnect

2

1. Brake pedal free play adjusting nut

2. Brake rod

3. Brake camshaft lever

4. Axle nut

5. Chain adjusting plate

3. Loosen the axle nut.

4. Turn the drive chain adjusting plate on each side of the swingarm fully in direction (a).

5. Lift the rear wheel off the ground according to the procedure on page 6-37.

6. Remove the axle nut.

7. Push the wheel forward, and then remove the drive chain from the rear sprocket.

6-40

NOTE:

The drive chain does not need to be disassembled in order to remove and install the wheel.

8. Pull the wheel axle out, and then remove the wheel.

EAU25791

To install the rear wheel

1. Insert the wheel axle from the left-hand side.

PERIODIC MAINTENANCE AND MINOR REPAIR

1

1. Retainer

NOTE:

Make sure that the drive chain adjusting plates are installed with the punched sides facing to the outside and that the slot in the brake shoe plate fits over the retainer on the swingarm.

2. Install the drive chain onto the rear sprocket, and then adjust the drive chain slack. (See page 6-27.)

3. Install the axle nut, and then lower the rear wheel so that it is on the ground.

4. Tighten the axle nut to the specified torque.

Tightening torque:

Axle nut:

85 Nm (8.5 m·kgf, 62 ft·lbf)

5. Install the brake rod onto the brake camshaft lever, and then install the brake pedal free play adjusting nut onto the brake rod.

6. Adjust the brake pedal free play.

(See page 6-23.)

EWA10660

WARNING

After adjusting the brake pedal free play, check the operation of the brake light.

7. Install the engine guard by installing the bolt.

EAU25850

Troubleshooting

Although Yamaha motorcycles receive a thorough inspection before shipment from the factory, trouble may occur during operation. Any problem in the fuel, compression, or ignition systems, for example, can cause poor starting and loss of power.

The following troubleshooting chart represents a quick and easy procedure for checking these vital systems yourself. However, should your motorcycle require any repair, take it to a Yamaha dealer, whose skilled technicians have the necessary tools, experience, and know-how to service the motorcycle properly.

Use only genuine Yamaha replacement parts. Imitation parts may look like

Yamaha parts, but they are often inferior, have a shorter service life and can lead to expensive repair bills.

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6-41

PERIODIC MAINTENANCE AND MINOR REPAIR

1

2

3

4

5

Troubleshooting chart

WARNING

Keep away open flames and do not smoke while checking or working on the fuel system.

1. Fuel

Check the fuel level in the fuel tank.

There is enough fuel.

Check the compression.

There is no fuel.

Supply fuel.

The engine does not start.

Check the compression.

2. Compression

Operate the electric starter.

There is compression.

Check the ignition.

There is no compression.

Have a Yamaha dealer check the vehicle.

6

7

3. Ignition

Remove the spark plug and check the electrodes.

Wet

Wipe off with a dry cloth and correct the spark plug gap, or replace the spark plug.

Open the throttle halfway and operate the electric starter.

8

Dry

Have a Yamaha dealer check the vehicle.

The engine does not start.

Check the battery.

9

4. Battery

Operate the electric starter.

The engine turns over quickly.

The engine turns over slowly.

The battery is good.

Check the battery lead connections, and charge the battery if necessary.

The engine does not start.

Have a Yamaha dealer check the vehicle.

6-42

EAU25901

EWA10840

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