< YAMAHA TZR250(W) OWNER’S MANUAL 2XV-28199-2008 IDENTIFICATION NUMBERS RECORD 1, KEY NUMBER: 2. VEHICLE NUMBER (For Australia): FRAME NUMBER (Except for Australia): 3. ENGINE NUMBER: Your key identification number is stamped on your key as shown in the following illustration. Record this number in the space provided for reference if you need a new key, Key number Record your vehicle {or frame) and engine numbers in the spaces provided to assist you in ordering spare parts from your Yamaha deal- er or for reference in case your vehicle is sto- len, (See page 2-1.)TZR250(W) OWNER’S MANUAL ©1988 by Yamaha Motor Co., Ltd. 1st Edition, November 1988 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd, is expressly prohibited. Printed in Japan4.200 INTRODUCTION Congratulations on your purchase of the Yamaha TZR250(W). This model 1s 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 main- tenance of this motorcycle. If you have any questions about the operation or maintenance of your motorcycle, please consult a Yamaha dealer. voor NOTE: Some data in this manual may become out- dated due to future improvement on this model. If you have any questions about this manual or your motorcycle, please consult a Yamaha dealer. TECHNICAL PUBLICATIONS SERVICE DIVISION MOTORCYCLE GROUP YAMAHA MOTOR CO., LTD.at veo WARNING PLEASE READ THIS MANUAL CARE- FULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE. Particularly important information is distin- guished in this manual by the following no- tations: NOTE: A NOTE provides key information to make procedures easier or clearer. A CAUTION indicates special procedures that must be followed to avoid damage to the motoroyele. A WARNING indicates special procedures that must be followed to avoid injury to a motor- cycle operator or person inspecting or repair- ing the motorcycle. v.00 NOTE; — This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold.ure THINK OF YOUR SAFETY: Both motorcycles and mopeds are fascinating vehicles which give a tremendous feeling of freedom to their riders. They must be correctly maintained at all times in order to ensure optimum perfor- mance. However, as a rider you must also ensure that your physical condition is good, and that you are not tired, in order that you too can optimise your vehicle control. Medicines, drugs and alcohol should not be combined with riding. especially alcoho! which increases the individual's likelihood of taking risks. Alcohol is dangerous, even in small quantities: Correct protective riding gear is just as much a part of motorcycling safety as the safety belt is in the car; a good leather suit and gloves, sturdy boots and a good quality, proper- ly fitting crash heimet are ideal. But beware: good protective clothing can result in ‘th lividual being lulled into a false sense of security. When this happens more risks are taken and speeds increase... this particularily ap| ‘wet weather. The good motorcyclist therefore rides defensively and protectively in order to minimise risks.CONTENTS DESCRIPTION . att MOTORCYCLE IDENTIFICATION . ... 2-1 Vehicle identification number (For Australia)... ee eee cece 24 Frame serial number (Except for Australia) . Engine serial number... CONTROL FUNCTIONS .... Main switch 0.2... Indicator lights Oil warning light checking method Speedometer .. : Tachometer Engine temperature gauge Handlebar switches . Clutch lever 21 24 22 31 32 284 35 35 .37 Change pedal... ... . 37 Front brake lever . 1 37 Rear brake peda! 37 Fuel tank cap . Fuel cock + 38 . 38 Starter lever (CHOKE) 139 Kick starters... 0. ek Steering lock .. 2... 12 3-10 Parking 3-11 Seat lock... . 23-11 Helmet holder. Side cover. . Cowling removal «3-13 Front fork and rear shock absorber +314 Y.P.V.S. (Yamaha Power Valve System) 0. ee eee eee 3-15 Sidestand (For Australia, New Zealand) 3-16 Sidestand switch operation check (For Australia, New Zealand) PRE-OPERATION CHECKS... Brakes ......... Brake fluid leakage Clutch... Throttle grip . Engine olf .. Transmission oilCoolant ... wee 45 Chain cee 46 Tires . : 2 47 Tubeless tires and cast wheels 49 Fittings/ Fasteners Lous an Lights and signals 411 Switches... 412 Battery a se 412 Fuel... 5 2. 412 Fuel tank breather hose... 4.413 OPERATION AND IMPORTANT RIDING POINTS . 54 Starting a cold engine (Except for Australia, New Zealand)... -.. . -8-1 Starting a cold engine (For Australia, New Zealand) . . Engine warm-up. Starting a warm engine Shifting Engine break-in : Parking . . Lee 5G PERIODIC MAINTENANCE AND MINOR REPAIR Tool kit Periodic maintenance/ Lubrication oo Torque specifications ... Transmission oil level check Transmission oil replacement .. Cooling system Air filter... Carburetor ‘adjustment Idle speed adjustment. Throttle cable adjustment Spark plug inspection . Front brake adjustment Rear brake adjustment ... . Brake light switch adjustment. . Checking the front and rear brake pads Inspecting the brake fluid level. Brake fluid replacement Clutch adjustmentFree play adjustment . Drive chain slack check .... Drive chain slack adjustment .. Drive chain lubrication Cable inspection and lubrication. . 6-27 Throttle cable and grip lubrication. 6-28 Autolube pump adjustment Brake and change pedals Brake and ciutch levers . Sidestand .. Rear suspension . Front fork inspection .... Front fork adjustment. . Rear shock ....... Adjustment . . . Recommended combinations ‘of the front fork and the rear shock absorber settings . . Steering inspection . Wheel bearings . Battery. Replenishing the battery fluid . . 6-37 Fuse replacement ... Replacing the headlight bulb. Headlight beam adjustment, . Taillight bulb replacement Front wheel removal . .. Front wheel installation Rear wheel removal. Rear wheel installation . Troubleshooting ....... . Troubleshooting chart . CLEANING AND STORAGE. A. Cleaning .. B. Storage SPECIFICATIONS . NOISE REGULATION (For Australia) 9-1 WIRING DIAGRAMDESCRIPTION 1 Taitight 11 Seat 2 Rear flasher light 12 Helmet holder 3 Monoctoss suspension 13 Change pedal 4 Fuel tank 14 Cluteh lever 5 Front flasher ight 1 Handlebar saitches 8 Upper cowing 16 Speedometer 7 Lower cowling 17 Tachometer 8 Kick starter 4B Engine temperature gauge 9. Rear brake pedal 18. Front brake lever 10. Headlight 20 Main switch vow NOTE: The motorcycle you have purchased may differ slightly from these shown in the photographs.acco MOTORCYCLE IDENTIFICATION ‘A800 Vehicle identification number (For Aus- tralia) The vehicle identification number is stamped into the steering head pipe. The vehicle identification number is used to identify your motorcycle and may be used to register your motorcycle with the licensing authority in your state. nom Frame serial number (Except for Australia) ‘The frame serial number is stamped into the right side of the steering head pipe. 1 Vehicle identificavon number (For Austral) 1 Frame senal number {Except for Australia)ane Engine serial number The engine serial number is stamped into the right side of the engine. 1 Engine sonia! number von NOTE; The first three digits of these numbers are for model identification; the remaining digits are the unit production number. Keep a record of these numbers for reference when ordering parts from a Yamaha dealer. 22eon CONTROL FUNCTIONS oo Main switch The main switch controls the ignition and light- Ing systems; its operation is described below. PARKING a6. ON: Electrical circuits are switched on. The engine can be started. The key cannot be removed in this position. a ao OFF: All electrical circuits are switched off. The key can be removed in this position. san LOCK: The steering is locked in this position, and all electrical circuits are switched off. The key can be removed in this position. Refer to ““Steer- ing lock” (Page 3-10) for proper operation. PARKING: The steering 1s locked in this position, and the taillight and auxiliary light come on but all other circuits are off. The key can be removed in this position. veo NOTE: Always turn the main switch to “OFF” or “LOCK” and remove the key when the motor- cycle is unattended.o Indicator lights 2 “NEUTRAL” indicator ight {GH BEAM” mdicatar light IL” warning mdieator ight B10 “TURN” indicator light (orange): This indicator flashes when the turn switch 1s “ON”, e102 “NEUTRAL” indicator light (green): This indicator comes on when the transmission 1s in neutral. 32 a0 “HIGH BEAM” indicator light (blue): This indicator comes on when the headlight high beam 1s used. ow “OIL” warning indicator light (red): This indicator comes on when the oil level is low. This light circuit can be checked by the following procedure. use CAUTION: | Do not run the motorcycle until you know the motorcycle has enough engine oil.exe Oil warning light checking method Main switch “ON” ‘Ol warning indicator ‘Oil warning indicator light does not come on light comes on v ‘Wait a few seconds —_— Oil warning indicator tight], [O11 warning indicator electrical circuit. ahead with riding, goes off, light comes on. + + ‘Ask a Yamaha Engine oil level and elec- ‘Supply engine of dealer to inspect tncal cireutt are OK. Go vos + NOTE: If the main switch is tuned off after the ol warning light goes out and then immediately again the main switch is turned on, the oil warning light may not come on. This is not be- cause of failure. 33ouc0 Speedometer The odometer and trip odometer are built into the speedometer. The trip odometer can be reset to “0” with the reset switch. Use the odometer to estimate how far you can ride on a tank of fuel before going to “RESERVE”. This information will enable you to plan fuel stops in the future. 1 Speedometer 3. Odometer 2 Reset knob 4 Top odometer Tachometer This model is equipped with an electric tachom- eter so the rider can monitor the engine speed and keep it within the ideal power range. Do not operate in the red zone. Red zone: 10,000 r/min and aboveoso Engine temperature gauge This gauge indicates the coolant temperature when the main switch is ON The engine oper- ating temperature will vary with changes in weather and engine load. If the needle points to the red zone or higher, stop your motorey- cle and let the engine cool. (See page 6-9 for more detail.) 2 Red zone 1. Engine temperature gauge 36 “CAUTION; When the engine is overheated, do not continue riding. ry Handlebar switches: 3 “TURN” switen B00 “PASS” switch When you are passing a vehicle ahead, the passing light switch should be depressed so ‘that the headlight gives a signal to the rider. “LIGHTS” switcheso “LIGHTS” (Dimmer) switch Turn the switch to “HI for the high beam and to “LO” for the low beam aces “TURN” signal switch This model is equipped with self-cancelling turn signals. To signal a night-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 returned to the center position. If the switch Is not cancelled by hand, it will self- cancel after the motorcycle has travelled for about 10 seconds or approximately 160 meters (490 feet) whichever is greater. The self cancelling mechanism only operates when the motorcycle is moving; thus the signal will not self-cancel while you are stopped at an inter- section. 36 Boe “HORN” switch Press the switch to sound the horn, son “LIGHTS” switch Turn the light switch to “ON” to turn on the headlight, taillight, and meter lights. Turn the light switch to “PO” to turn on the auxiliary light, taillight, and meter lights. oun “ENGINE STOP” switch The engine stop switch is a safety device for use in an emergency such as when the motor- cycle overturns or when trouble occurs in the throttle system. The engine will not run when the engine stop switch is turned to “OFF.” tn case of emergency, tun the switch to “OFF.”em Clutch lever The clutch lever is located on the left handle- bar; it disengages or engages the clutch. 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 starts. m0 Change pedal The gear ratios of the constant-mesh 6-speed transmission are ideally spaced. The gears can be shifted by using the change pedal on the left side of the engine. 37 N Neutal Front brake lever The front brake lever 1s located on the right handlebar, Pull it toward the handlebar to ac- tivate the front brake. oa Rear brake pedal The rear brake pedal is on the right side of the motorcycle. Press down on the brake pedal to activate the rear brake.cos Fuel tank cap TO OPEN: Open the key cover. Insert the key and turn clockwise 1/4 turn. The lock will be released and the cap can be opened. TO CLOSE: Push the tank cap into position with the key inserted. To remove the key, turn it counter- clockwise to the original position. Then, close the key cover. vee NOTE: This tank cap cannot be closed unless the key is in the lock. The key cannot be removed if the cap ts not locked properly. Fuel cock The negative pressure fuel cock supplies fuel from the tank to the carburetors and also filters, the fuel. The fuel cock has the following three positions: ON: With the lever in this position, fuel flows if the engine ts running but stops if the engine is not running. This indicates reserve. If you run out of fuel while riding, move the lever to “PRI”, start the engine, then switch to “RES” FILL THE TANK AT THE FIRST O- PPORTUNITY. BE SURE TO SET THE LEVER TO “ON” AFTER RE- FUELING. RES:NOTE: The fuel cock operates on vacuum from the engine when set at “ON” or “RES.” if the line connecting the cock to the carburetor intake manifold is not connected or has a leak, the cock will not function properly, PRI: This indicates prime. With the lever in this position, fuel flows whether the en- gine 1s running or not. If the fuel tank 's completely empty, refill the tank, prime the carburetor in this position, and then switch to “ON” after starting the engine. cme Starter lever (CHOKE) When cold, the engine requires a richer air-fuel mixture for starting. A separate starter circuit supplies this mixture. Pull the starter lever up to open the circuit for starting. When the en- gine has warmed up, push the lever down to close the circutt.con Kick starter Rotate the kick starter away from the engine. Push the starter down lightly with your foot un- til the gears engage, then kick smoothly and forcefully to start the engine. This model has a primary kick starter so the engine can be start- ed in any gear if the clutch is disengaged. In normal practices, however, shift to neutral be- fore starting 1 Kick starter co Steering lock The steering is locked when the main switch 4s turned to “LOCK.” To lock the steering, turn the handlebars all the way to the left or right. With the key at “OFF,” push it into the main switch, turn the key counterclockwise to “LOCK,” and remove the key. To release the lock, turn the key clockwise OFF (Push) LOCK (Push PARKING 3101 Push ven WARNING Never turn the key to “LOCK” when the motorcycle is moving. Parking For “P”, push the key at “LOCK”, let the fingers off, and then turn it counterclockwise. To release, simply turn the key clockwise. coxa Seat lock To open the seat lock, insert the key in the lock D Release 3 Tun att and turn it clockwise. When reinstalling the seat, insert the lobes on the seat front into the receptacles on the frame, then push down the 2 © a avow ver NOTE: CEG Make sure that the seat 1s securely fitted. Never ride with a helmet in the helmet holder. It could interfere with rear wheel cm movement, causing loss of control and Helmet holder possibly an accident. To open the helmet holder, insert the key in |< the lock and turn it as shown. To lock the helmet holder, replace the holder 7% In its original position. Side cover To remove the side cover, follow these steps. 1. Remove the seat. 2. Remove the screws at the rear fender cover and slide the rear fender cover back- ward to unhook on the inside. 342.SS 3. Remove the screw and pull out the knobs. 7 4. To reinstall the cover, reverse the above steps. om Cowling removal To remove the cowling, remove the bolts as shown. * STEP 1.* STEP 2. comm Front fork and rear shock absorber The spring preload of the front fork and rear shock absorber can be adjusted to suit motor- cycle's load (ex: optional accessories etc ) and riding conditions. Refer to page 6-30 for proper adjustment procedure. 314ow Y.P.V.S. (Yamaha Power Valve System) The Y.P.V.S. is a vital part of the engine and requires very sophisticated adjustment. Adjust- ment should be left to a Yamaha dealer who has the professional knowledge and experience to do so. 216 cAUTION:: The Y.P.V.S. was set at the Yamaha fac- tory after many tests. If the settings are disturbed without having technical knowledge, poor engine performance and damage may result. The Y.P.V.S. operation can be heard in the fol- lowing instances: * When the main switch is turned on and the engine is started. When the engine stalls while the main switch is on. ee murine If the Y.P.V.S. does not operate, ask a Yamaha dealer.201 Sidestand (For Australia, New Zealand) 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 5-2 for an explanation of this system.} vse Cn 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 operator resulting in a possible loss of con- trol. Yamaha has designed into this motor- cycle a lockout system to assist the operator in fulfilling his responsibility of retracting the sidestand. Please check a6 carefully the operating instructions listed below and if there is any indication of a malfunction, you must return the motor- cycle to a Yamaha dealer immediately for repair. om: Sidestand switch operation check (For Australia, New Zealand) Check the operation of the sidestand switch against the information below.TURN MAIN SWITCH TO “ON” AND ENGINE STOP SWITCH TO “RUN”. TRANSMISSION IS IN NEUTRAL AND SIDESTAND IS DOWN. ¥ KICK THE KICK STARTER £ ENGINE WILL START | np PULL IN CLUTCH LEVER AND PUT TRANSMISSION IN GEAR + ENGINE WILL STALL. ¥ SIDESTAND SWITCH IS OK eet If improper operation is noted, consult a Yamaha dealer immediately. 317Before using this PRE-OPERATION CHECKS motorcycle, check the following points: term Routine Page Front and rear ‘Check operation, free play, fluid level, and plunger Leakage 43~44, 619~6.24 brakes Top-up with DOT #4 (or #3) brake fluid necossary Clutch ‘Check operation, condition and free play Adjust sf necessary 44, 6.24~6.25 Throttle gb! | Check for emorth operation Lubncate/Adjust f necessary 4.4, 617~6-18, 6-28 Housing ‘Autolube tank | Check oi! level/top up as required 44—45, 628 Transmission oil_| Check ol level/top-up as required 45, 67-69 Coslart 282" | Check coolant leve/top up 28 required 45 ~46, 6.9~6-13 Drve chan Check chain slack and condition Adjust necessary 46, 625-627 Wheels/Tires | Check te pressure, weer, damage 474-11, 6:40~6-46 GormrotiMeter | Check for smooth operation Lubncate it necessary 627 Brake and change sarees Check for smooth operation Lubniate #f necessary 6.28 Brake and clutch a persis Check for smooth operation Lubricate sf necessary 628 Sidestand pivot | Check for smooth operation Lubricate if necessary. 628-628 atitem Routine Page Check all chassis fittings and fasteners. Firungs/fasterners | Tignten/Adjust, if necessary on) 66 Fuel tank Check fuel level/top-up as required 412~ 413 Lights and signals | Check for proper operation 4-11, 637 ~6-40 Battery Check fluid level, top-up with distilled water if necessary 412, 6:34~6-36 NOTE: Pre-operation checks should be made each time the motorcycle is used. Such an inspection can be throughly accomplished in a very short time; and the added safety it assures is more than worth the time involved. ZIT) If any item in the Pre-Operation Check is not working properly, have it inspected and repaired before operating the motorcycle. 42£10 Brakes (See page 6-19 for more detail) 1. Brake lever and brake pedal Check for correct free play in the front brake lever and rear brake pedal. Make sure they are working properly. Check the brakes at low speed shortly after starting out If the free play 1s incorrect, adjust it. ves WARNING: A soft, spongy feeling in the brake lever {and/or brake pedal) indicates a failure in the brake system. Do not operate the motorcycle until the failure in the brake system is corrected. Ask a Yamaha deal- er for immediate repairs. A soft, spongy feeling could indicate a hazardous condi- tion in the brake system. 43 2. Brake fluid Check the brake fluid level. Add fluid if necessary. Recommended brake fluid: DOT #4 If DOT #4 is not available, #3 can be used. 3. Check the dise pads. Refer to page 6-21. vee NOTE; — When this brake service 1s necessary, ask a Yamaha dealer. Brake fluid leakage Apply each brake for a few minutes. Check to see if any brake fluid leaks out from the pipe joints or the master cylinder(s).ves If brake fluid leakage is found, ask a Yamaha dealer for immediate repairs. Such leakage could indicate a hazardous condition, ex0 Clutch (See page 6-24 for more detail) Check the free play in the clutch lever, and make sure the lever operates properly. If the free play is incorrect, adjust it. exo Throttle grip (See page 6-17 for more detail) Turn the throttle grip to see if it operates properly, and check the free play. Make sure the gnip returns by spring force when released, Ask a Yamaha dealer to make any necessary adjustments. 4a ea Engine oil Make sure the engine oil 1s at the specified level. Add ot! as necessary. Recommended oil: Yamaha oil 2T or equivalent air- cooled 2-stroke engine oll Oil quantitiy: Total amount: 1.4L (1.2 Imp at, 1.5 US qt) 1 Oil tank filler capvow NOTE: Be sure to push the cap into the filler neck un- til it is properly seated. es Transmission oil (See page 6-7 for more detail) Make sure the transmission oil is at the speci- fied level. Add oil as necessary. Recommended oil. SAE 10W30 type SE motor oil Oil quantity: Total amount: 1 L (0.9 Imp at, 1.1 US at) Periodic oil change: 4L (0.9 Imp qt, 1.1 US at) 46 xx Coolant Check the coolant level in the reservoir tank when the engine 1s cold. (The coolant level will vary with engine temperature.) The coolant level is satisfactory if 1t is between the FULL. and LOW marks on the tank. If the coolant level is at or below the LOW level, add tap water (soft water) to bring the level up to FULL. Change the coolant every two years. (See page 6-9 for more detail.) vee Do not remove the radiator cap when the engine is hot. Hard water or salt water is harmful to the engine. You may use distilled water if you can’t get soft water.mec NOTE; You can check the coolant level through the checking hole of the right-hand frame. — Reservoir tank capacity: Total: 250 cm? (0.22 Imp qt, 0.26 US qt) From LOW to FULL level: 190 em? (0.17 Imp qt, 0.20 US qt) 1. Checking hole eso Chain (See page 6-25 for more detail) Check the general condition of the chain and check the chain slack before every ride. Lubri- cate and adjust the chain as necessary. 1. Coolant reservoir tank cap 46909 Tires To ensure maximum performance, long serv- ice, and safe operation, note the following: 1. Tire air pressure ‘Always check and adjust the tire pressure before operating the motorcycle vow Ue] 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, passenger, and accessories (fairing, sad- dlebags, ete. if approved for this model), and vehicle speed. ay Ties wea ‘With oil and full fuel tank 144 kg (318 tb) Hoe tat Be wew Cate presse ee 180 kPa 200 kPa Up to 90 kg (198 Ib} load" | (1 8 kg/cm’, 42.0 kg/em?, deve | Soper 20 KPa | 200 KPa 0 kg (188 dagen’, | @atgren, Denar | pes 200 KPa [250 KPa High speed riding [20 kg/om?, | (23 kg/m’, 28 psi) 32 psih Load ie the total weight of cargo, nder, passenger, and acces- soresver GN Proper loading of your motorcycle is im- portant for the handling, braking, and other performance and safety characteris- tics of your motorcycle. Do not carry loosely packed items that can shift. Se- curely pack your heaviest items close to the center of the motorcycle, and destrib- 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 OVER- LOAD YOUR MOTORCYCLE. Make sure the total weight of the cargo, rider, pas- senger, and accessories (fairing, saddle- bags, ete. 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. 48 2. Tire inspection Always check the tires before operating the motorcycle. If a tre 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 him replace the tire. @ 1 T Tread depth 2 Side wail ‘3 Wear indicatorFRONT Manufacture Size Type Dunlop 10/8017 62H| Ka30F Yokohama 100/80-17 s2h| F205 REAR. Manufacture ‘Sze Type Dunlop 120/80-17 61H| K430 Yokohama 120/80-17 61H | R205 Minimum te weed depth (front and rear) 10 mn (0 04 in) vs WARNING It is dangerous to ride with a wornout tire. When a tire tread begins to show lines, have a Yamaha dealer replace the tire im- mediately. Brakes, tires, and related wheel parts replacement should be left to a Yamaha Service Technician. eo Tubeless tires and cast wheels This motorcycle is equipped with cast wheels designed for either tube or tubeless tires. Tube- less tires are installed as standard equipment. PAC cd Do not attempt to use tubeless tires on a wheel designed for use only with tube- type tires. Tire failure and personal injury may results from sudden deflation.Tubeless wre] FTube-type tre| Tube-type Wheel Tube-type Tires only Tubeless-type Wheel ~Tube-type or Tubeless tires veer @ WARNING: i ; 1 Ae valve a When using tube-type tires, be sure toin- 3 nye) 2 Aeaive stall the proper tube also. (Tubeless wheel 3. Cast whee! eee Tire Wal 410To ensure maximum performance, long serv- ice, 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 replaced. Failure to have a wheel balanced can result in poor performance, adverse handling characteristics, and shortened tire life. 3 After installing a tire, nde conservatively to allow the tire to seat itself on the rim properly. Failure to allow proper seating may cause tire failure, resulting in damage to the motorcycle and injury to the rider. 4, After repairing or replacing a tire, check to be sure the valve stem lock nut is se- curely fastened. If not, torque it as specified. Tightening torque 1.5 Nm (0.15 mekg, 1.1 ftelb} Fittings/Fasteners Always check the tightness of chassis fittings and fasteners before a ride. Use the chart on page 6-6 to find the correct torque. eno Lights and signals Check the headlight, flasher lights, taillight, brake light, meter lights, and all the indicator lights to make sure they are in working con- dition. anems Switches Check the operation of the headlight switch, turn switch, brake light switch, horn switch, main switch, etc. ems Battery (See page 6-34 for more detail) Check the fluid level and top-up if necessary. Use only distilled water if refilling is necessary. 0 Fuel Make sure there is sufficient fuel in the tank. veto WARNING: Do not ove: the fuel tank. Avoid spill- ing 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. 2 Fuel level Recommended fuel: Regular gasoline For Australia: Unleaded fuel only Fuel tank capacity: Total: 16 L (3.5 Imp gal, 4.2 US gal) Reserve: 4 L (0.9 Imp gal, 1.1 US gal)com Fuel tank breather hose This model is equipped with the fuel tank breather hose. Before using this motorcycle be sure to check the following: 1. Check hose connection. 2. Check hose for cracks or damage. Replace if damaged. 3. Make sure the bottom hose 1s not blocked. Clean it if necessary. 1 Fuel tank breather hose 2 Fuel tank 443.Fon OPERATION AND IMPORTANT RIDING POINTS ven GD UD) Before riding this motorcycle, become thoroughly familiar with all operating con- trols and their function. Consult a Yamaha dealer regarding any control or function that you do not thoroughly un- derstand, ves WARNIN: operate your motorcycle in an area with adequate ventilation. 2. 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. + 6 Starting a cold engine (Except for Austra- lia, New Zealand) 1. Turn the fuel cock to “ON.” 2. Turn the ignition key to “ON" and turn the engine stop switch to “RUN.” 3. Shift transmission into neutral. vow NOTE: 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 B41 When the transmission is in neutral, the neu- tral indicator light (green) should be on. If the light does not come on, ask a Yamaha dealer to inspect it.4, Operate the starter (CHOKE), and com- pletely close the throttle grip. Kick the kick starter to start the engine After the engine starts, warm it up for one ‘or two minutes. Make sure the starter Is returned to its original position before nding. 5. 6. Fa Starting a cold engine (For Australia, New Zealand) von NOTE: This motorcycle is equipped with an ignition circurt cut-off switch 1. The engine can be started only under the following condition: a. The transmission 1s in neutral. b. The sidestand 1s up, the transmission is in gear, and the clutch 1s disengaged. 2 Themotorcycle must not be ridden when the sidestand 1s down 82 va ZG) Before going through the following steps, check the function of the sidestand switch. (Refer to page 3-16.)TURN MAIN SWITt ENGINE STOP SWITCH TO “RUN” ‘CH TO "ON" AND a ee 7 IF TRANSMISSION 1S IN NEUTRAL AND SIDESTAND !S DOWN IF TRANSMISSION IS IN GEAR AND SIDESTAND IS UP L ¥ KICK THE KICK STARTER, ENGINE WILL START ¥ PULL IN CLUTCH LEVER AND KICK THE KICK STARTER, ENGINE WILL START RETRACT SIDESTAND AND PUT TRANSMISSION IN GEAR + MOTORCYCLE CAN BE RIDDEN MOTORCYCLE CAN BE RIDDENTurn the fuel cock to ON." 2 Tum the ignition key to “ON” and the en- gine stop switch to “RUN.” 3. Shift transmission into neutral vost NOTE: When the transmission 1s in neutral, the neu- tral indicator light (green) should be on. If the light does not come on, ask a Yamaha dealer to inspect it. 4. Operate the starter (CHOKE) and com- pletely close the throttle grip. 5. Kick the kick starter to start the engine. 6 After the engine starts, warm rt up for one or two minutes. Make sure the starter 1s returned to its original position before riding 64 Fo Engine warm-up To ensure maximum engine life, always warm up the engine before riding your motorcycle. Never accelerate hard with a cold engine. An engine is warm if it responds normally to the ‘throttle when the starter (CHOKE) is turned off. 08 Starting a warm engine The starter (CHOKE) 1s not required when the engine is warm. See “Break-in section” prior to operating the motorcycle for the first time.s20 Shifting The transmission lets you control the amount of power you have available at a given speed for starting, accelerating, climbing hills, etc. The use of the change pedal is shown in the lustration. (Page 3-7) To shift into NEUTRAL, depress the change pedal repeatedly until it reaches the end of its, travel {you will fee! a stop when you are in first gear) then raise the pedal slightly. vais cauTio 1. Do not coast for long periods with the engine off, and do not tow the motor- cycle a long distance. Even with gears in neutral, the transmission is oniy properly lubricated when the engine is running. Inadequate lubrication may damage the transmission. 85 2, Always use the clutch when chang- ing gears. The engine, transmission, and driveline are not designed to withstand the shock of forced shift- ing and can be damaged by shifting without the clutch. 200 Engine break-in There is never a more important period in the life of your motorcycle than the period between zero and 1,000 km (800 mi). For this reason we ask that you carefully read the following materi- al. Because the engine is brand new, you must not put an excessive load on it for the first 1,000 km (600 mi). The various parts in the engine wear and polish themselves to the correct oper- ating clearances. During this period, prolonged full throttle operation or any condition which might result in excessive heating of the engine, must be avoided.1. 0~500 km (0~300 mi). Avoid operation above 6,000 r/min. Stop the engine and let it cool for 5 to 10 minutes 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. 500~ 1,000 km (300 ~600 mi): Avoid prolonged operation above 7,000 r/min. Rev the motoreycle freely through the gears, but do not use full throttle at any time. vase ang After 1,000 km (600 mi) of operation, be sure to replace the transmission oil. 3. 1,000 km (600 mi) and beyond: Full throttle can be used 56 usar CAUTION: Never let engine speeds enter the red zone. um SAUTIONS: If any engine trouble should occur during the break-in period, consult a Yamaha dealer immediately. ay Parking When parking the motorcycle, stop the engine and remove the ignition key.vow GO Cel The muffler and exhaust pipe are hot. Park the motorcycle in a place where pedestri- ans or children are not likely to touch the motorcycle. Do not park the motorcycle on a slope or soft ground; the motorcycle may overturn, 87PERIODIC MAINTENANCE AND MINOR REPAIR ose Periodic inspection, adjustment, and lubrica- tion will keep your motorcycle in the safest and most efficient condition possible Safety is an obligation of the motoreycle owner. The main- tenance and lubrication schedule chart should be considered strictly as a guide to general maintenance and lubrication intervals YOU MUST TAKE INTO CONSIDERATION THAT WEATHER, TERRAIN, GEOGRAPHI- CAL LOCATIONS, AND A VARIETY OF IN- DIVIDUAL USES ALL TEND TO DEMAND THAT EACH OWNER ALTER THIS TIME SCHEDULE TO SHORTER INTERVALS TO MATCH HIS ENVIRONMENT. The most im- portant points of motorcycle inspection, adjust- ment, and lubncation are explained in the following pages 61 vee If you are not familiar with motorcycle service, this work should be done by a Yamaha dealer, wae Tool kit The sermice information included in this manual 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 too! kit are sufficient for most of these purposes; however a torque wrench 1s also necessary to properly tighten nuts and bolts.If you do not have a torque wrench available during a service operation requiring one, take your motorcycle to a Yamaha dealer to check the torque settings and adjust them as necessary 62 ven 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.PERIODIC MAINTENANCE/LUBRICATION Unit km (miles) EVERY BREAKIN | —~6,000 12,000 rem REMARKS 5: . 1,000 (600) | 14,0001 o | 48,0001 or months | 12 months ‘Spark plagls) Check condition Clean or replace necessary o o ° ‘Air filter Clean Replace 1 necessary o © buretor" ‘Check Idle speed’ synchronation/sterter operation o Carburetor Adjust necessary © © ° . ‘Check fuel hose and vacuum pipe for eracks S Ful ne ‘oF damage Replace if necessary ° ° ‘Check oi! level/ou leakage Corect i necessary Transmission of” Raplace every 12,000 (8,000) or 24 months REPLACE ° ° (Warm engine before draining | ‘Autolube pump Check operation Correct necessary Air bleeding o 6 o ake” ‘Check oneration/flud leakage’ See NOTE 5 Broke Correct if necessary © ° ‘Clutch ‘Check operation Adjust i necessary © o mm pwr Check rear arm assembly for looseness Rear arm prvot Correct # necessary Moderately repack *** ° FRoar suspension Ink | Check operation Apply grease lightly every S pvote* 24,000 (16,000) oF 24 months **" Wheele® Check balance demage/runout_Repan if necessary S 3° wings ‘Check boarings assembly for looseness/damage ‘Wheel bearng Replace if damaged ° ° 63Unit_km (rrles) EVERY BREAKIN [6000 | 12,000 ITEM REMARKS 1,000 (600) | {4,000} or (8,000) or Smonths | 12 months ‘hed bearings sesembl Tor tooseness steenng besnne” Comect f necossary. Moderately repack every ° ° 24000 (16,000) oF 24 months ** Front forks*, ‘Check operaton/oil leakage. Repair f necessary 2 Q Rear shock absorber” Check operation/oil leakage Repair if necessary oO oO heck coolant lookoge Repar necessary Replace > 5 Cooling system coolant every 24,000 (16,000) or 24 months, ~ 8 we chown Check chown slack/elignment Adwuct if necessary Drive cha Check chain sl EVERY 600 (00) TF check all chassis ftungs and fasterners 5 Fittings / Fasteners’ Cotract i necessary o oO fe) Sicestand™ Check operation Repar necessary a © © Sidestand switch (For Australia, New Check operation Clean or replace if necessary 3° oO ° Zealand . Theok spect gry Check breathor pipe for Battery proper operation Correct if necessary c ° It is recommended that these stems be serviced by 2 Yamaha deeler ++ Medium weight wheel bearing grease +++ Lithium soap base grease 64NOTE: Brake fluid replacement: 1. When disassembling the master cylinder or caliper cylinder, replace the brake fluid, Normal- ly check the brake fluid level and add the fluid as required. 2. On the inner parts of the master cylinder and caliper cylinder, replace the oll seals every two. years, 3. Replace the brake hoses every four years, or if cracked or damaged. 65som Torque specifications Use a torque wrench to tighten these items. It is recommended that these items be checked occasionally, especially before a long trip. Al- ways check the tightness of these items 7 whenever they are loosened for any reason. W7 Ste Oo vue | tory ‘omm | mm 2mm | 8mm 14mm | 10mm tem Torque arm | 12mm Nm [mag | ttl tam | 4mm pom | jgme Spark plug 2» | 20 | 1 Engine drain plug @ w | 16 | 2 Engine dran plug @) 2 | 22 | Water pump cover drain nee w | wf 2 Front whee! axle m | 73 | 6 Axle pinch bolt 20 20 4 Celiperistallavon bolt 3s | 35 | as Rear whes! ale nut wr | 1072 | a Rear wheel axle tock nut 45, 45 cd Catper tracker weiaiton | ge | gg | gy 66 boltwae Transmission oil level check 1. Warm up the engine for several minutes. 2. To check the oil level, the motorcycle must stand VERTICALLY with its both wheels on the ground. A slight tlt toward the side can produce false readings. With the engine stopped, check the oil level through the level window located at the right side crankcase cover 3 Minimum oi level 67 The oil level should be between maximum and minimum marks. If the level is low, add sufficient oil to raise it to the proper level. Recommended oil: SAE 10W30 type SE motor oil Ou quantity: 1L (0.9 Imp qt, 1.1 US ath vse [eduionit Do not add any chemical additives. Trans- mission oil also lubricates the clutch and additives could cause clutch slippage. Be sure no foreign material enters the crankcase.wa Transmission oil replacement 1, Remove the lower cowl. 1 Drain plug @) 2 Dram plug ©) 5. Reinstall the drain plug (make sure it is tight). 2. To drain the oil, warm up the engine for - several minutes. Drain plug torque: 3. Place an oil pan under the engine. @: 16 Nm (1.6 mekg, 12 ftelb) 4, Remove the drain plug and drain the oil. ®;: 22 Nm (2.2 mekg, 16 ftelb) 6. Add oil through the oil filler hole. 681 Filler cap Periodic ofl change: 1L (0.9 Imp gt, 11 US at) 7. After replacement of transmission oil, be sure to check for oll leaks 69 nee Cooling system The coolant is circulated by an impeller type pump mounted on the right-hand crankcase and driven by a gear. The coolant is drawn by the pump from the bottom tank of the radia- tor, through the pipe (1), and discharged into the cylinder and cylinder-head. The coolant passes from the cylinder to the cylinder-head through coolantpassages. After circulating around the combustion chamber jacket, it enters the radiator upper tank via the pipe (2) ‘The heated coolant from the engine then pass- es down through the finned tubes to the bot- tom tank of the radiator These finned tubes present a large surface area to the air and dis- sipate the heat. 1. If your motorcycle overheats2, Water pump 610 5K PENG ed Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be blown out under pressure, which could cause serious inju- ry. When open the radiator cap, note the following points. Wait until the engine has cooled. Place the thick rag like a towel over the radiator cap and slowly rotate the cap counterclockwise to the detent. This procedure allows any residual pressure to escape. When the hissing sound has stopped, press down on the cap while turning counterclockwise and remove it. if overheating is detected, perform the follow- ing checks.[Eom neteawe 1 b Remove the reservoir tank hose on the Cheah he caning radiator side, and drain the reservoir tank Soto forage Wai a to To euge nates lower of its coolant. for 0" (20°0 tee - al {200 pope 25) Ro teakags |} [Leskove ——_t T T hack se coctant wel | Wo | [ad sovian| [Anko Veworo ithe resrvo ( Gear to mepect and reear x] ——— Restart the engine Ite] engine overheats 2931, ase a Yemaho deter *6 inspect and repo 1 Reservor tank hose c. Remove the radiator cap by removing the stopper bolt. vor NOTE: If itis difficult to get the recommended coolant, tap water can be temporarily used, provided that it is changed to the recommended coolant as soon as possible. 2 Changing the coolant a. Remove the right-hand lower cowl, seat and fuel tank 1 Radiator capPlace a container under the engine. e. Remove the drain bolt. f. Drain the coolant completely and thoroughly flush the cooling system with clean tap water. g. Retighten the drain bolt. If the gasket is damaged, replace it. Drain bolt torque: 16 Nm (1.6 mekg, 12 ftelb) 612 h. Reinstall the reservoir tank hose. i, Pour the recommended coolant into the radiator until the radiator is full. Recommended coolant: High quality ethylene glycol anti- freeze containing corrosion inhibitors for aluminum engines. Coolant and water mixed ratio: 50% /50% Total amount: 135 L (1.2 Imp qt, 1.4 US qt) Reservoir tank capacity: 0.25 L (0.22 imp qt, 0.26 US qt) From LOW to FULL level: 0.19 L {0.17 Imp qt, 0.20 US qt)vate GANTION:: Hard water or salt water is harmful to the engine. You may use distilled water if you can’t get soft water. j. Reinstall the radiator cap. k. Run the engine several minutes to recheck ‘the coolant level in the radiator. If rt is low, add more coolant until it reaches the top of the radiator. NOTE: Temporarily install the fuel tank and start the engine for test 1. Fill the reservoir tank with coolant up to “FULL” level. 1 Coolant reservorr tank cap, m. Reinstall the reservoir tank cap and check for coolant leakage. If you find any leaks, ask a Yamaha dealer to inspect, n_ Install the fuel tank, seat and right-hand lower cowl.6s Air filter 1. Remove the seat and the bolt holding the o fuel tank. om a 1 Fuel pipe 2 Vacuum pipe 4. Remove the fuel tank and the screws holding the filter case cover. 1 Seat 1 Breather pipe 2. Fuol tank 2. Turn the fuel cock lever to “ON” and dis- connect the fuel pipe and vacuum pipe. 3. Remove the fuel cock from the frame.5. Remove the air filter element from its case, and clean it with solvent. After cleaning, remove the remaining solvent by squeezing the element. Recommended oil: Yamaha oll 2T or equivalent cooled 2-stroke engine oil —") 7. When installing the air filter element in its case, be sure its sealing surface matches the sealing surface of the case so there is no air leak. 8. The air filter element should be cleaned at the specified intervals. it should be cleaned more often if the motorcycle is operated in dusty or wet areas. 1 Agr filter element uae 6. Apply recommended oll to the entire sur- 'CADTION: face of the filter and squeeze out the ex- cess oil. The element should be wet but not dripping. The engine should never be run without the air cleaner element; excessive piston and/or cylinder wear may result. 645naw Carburetor adjustment The carburetor is a vital part of the engine and requires very sophisticated adjustment. Most adjustments should be left to a Yamaha deal- er who has the professional knowledge and ex- perience to do so. However, the following point may be serviced by the owner as part of this routine maintenance. The carburetor was set at the Yamaha fac- tory after many tests. If the settings are disturbed, poor engine performance and damage may result. 616 910 Idie speed adjustment 1, Start the engine and warm it up for a few minutes (normally, 1 or 2 minutes) at ap- proximately 1,000 to 2,000 r/min. Occa- sionally rev the engine to 4,000 to 5,000 t/min. The engine is warm when tt quickly responds to the throttle. ‘Set the idle to the specified engine speed by adjusting the throttle stop screw; turn the screw in to increase engine speed, tum the screw out to decrease engine speed. 1 Throttle stop screwTo adjust the idle speed, turn both throt- tle stop screws simultaneously by the same amount. Standard idle speed: 1,150 ~ 1,250 r/min vos NOTE: Hoe Throttle cable adjustment ose NOTE; — Before adjusting the throttle cable free play, the engine idling speed should be adjusted. The throttle cable should have a specified free play in the turning direction at the grip flange. If the play is incorrect, take the following steps for adjustment. If the specified idle speed cannot be obtained by performing the above adjustment, consult a Yamaha dealer. e17 Free play: 2~5 mm (0.08 ~0.20 in) 1. Loosen the lock nut 2. Turn the adjuster in or out until the ad- justment ts suitable. 3 Tighten the lock nut.1 Lock nut 2 Adjuster (0 08~0.20 nb non Spark plug inspection The spark plug ts an important engine compo- nent and Is easy to inspect. The condition of the spark plug can indicate something of the condition of the engine. Normally, all spark plugs from the same engine should have the same color on the white por- celain 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 618 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 remove and inspect the spark plug because heat and deposits will cause any spark plug to slowly break down and erode. If electrode erosion be- comes excessive, or if carbon and other deposits are excessive, you should replace the spark plug with a proper type plug. Standard spark plug: BR9ES (NGK)® 4 1 Spark plug gp Before installing any spark plug, measure the electrode gap with a wire thickness gauge; ad- just the gap to specification as necessary. Spark plug gap: 0.7~0 8 mm (0.028 ~0 031 in} When installing the plug, always clean the gasket surface and use a new gasket. Wipe off any grime from the threads, and torque the spark plug properly. 619 Spark plug torque: 20 Nm (2.0 mekg, 14 ftelb) vow NOTE: 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 turns past finger tight Have the spark plug torqued to the cor- rect value as soon as possible with a torque wrench Front brake adjustment The free play at the end of the front brake lever should be 2~5 mm (0.08~0.20 in) 1 Loosen the lock nut. 2. Turn the adjuster so that the brake lever movement at the lever end is 2~5 mm (0,08~ 0.20 in) before the adjuster con- tacts the master cylinder piston. After adjusting, tighten the lock nut.2 2-5 mm (0 08-0 20 my Check the brake lever free play. Be sure the brake is working properly. ve WARNING: Asoft 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 system before the motorcycle is operated. Air in the system will cause greatly diminished braking capability and can result in loss of control and an accident. Have a Yamaha dealer spect and bleed the system if necessary. kame Rear brake adjustment The brake pedal top end should be 55 mm (2.16 in) below the top of the footrest. If not, ask a Yamaha dealer. 6:20 1 Pedal height 65 mm (2 16 in)vee An incorrect free play indicates a hazardous condition 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. na Brake light switch adjustment The brake light switch is operated by move- ment of the brake pedal. To adjust, hold the main body of the switch with your hand so it does not rotate and turn the adjusting nut. Proper adjustment is achieved when the brake light comes on just before the brake begins to take effect. en 1 Main body Hae Checking the front and rear brake pads A wear indicator is attached to each brake pad to facilitate disc brake pad checks. This indi- cator permits a visual check without disassem- bling the pads. To check, depress the brake and inspect the wear indicator. If the wear in- dicator is ALMOST in contact with the disc plate, ask a Yamaha dealer to replace the pads.nee 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 the brake fluid level and replenish when necessary; observe these precautions: FRONT 1 Wear indicator e21 Lower level When checking the fluid level, make sure. the master cylinder top 1s horzontal by turning the handlebars Use only the designated quality brake fluid: otherwise, the rubber seals may de- teriorate, causing leakage and poor brake performance. 623 Recommended brake fluids: DOT #4 If DOT #4 is not available, #3 can be used. Refill with the same type of brake fluid; mixing fluids may result in a harmful chemical reaction and lead to poor per- formance. 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 erode painted surfaces or plastic parts. Always clean up spilled fluid immediately. Have a Yamaha dealer check the cause if the brake fluid level goes down.we Brake fluid replacement 1. Complete fluid replacement should be done only by trained Yamaha service per- sonnel, 2. Have a Yamaha dealer replace the follow- ing components when indicated in the schedule or when they are damaged or leaking. a. Replace all rubber seals every two years. b. Replace all hoses every four years. v0 Clutch adjustment This model has two clutch cable length ad- justers. The cable length adjusters are used to take up slack from cable stretch and to pro- vide sufficient free play for proper clutch operation. Normally, once the clutch cable length adjuster (crankcase) is properly set; the only adjustment required 1s maintenance of free play at the clutch cable length adjuster (handlebar lever). Free play adjustment The clutch should be adjusted to surt the rider's, preference; but, free play at the lever end should be 10~15 mm (0.4~0.6 in). Loosen either the handlebar lever adjuster lock nut or the cable length adjuster lock nut. Turn. the cable length adjuster either in or out until proper lever free play is achieved. Clutch lever free play: 10~15 mm (0.4~0.6 in) @10~15 mm (4-06 2 Adjuster 6241 Look nut 2 Aduster Drive chain slack check NOTE: Before checking and/or adjusting the chain slack, rotate the rear wheel through several revolutions. Check the chain slack several times to find the point where the chain is the tight- est. Check and/or adjust the chain slack where the rear wheel is in this “tight chain” position. 6.25 To check the chain slack the motorcycle must stand vertically with its both wheels on the ground and without a nder. Check the slack at the position shown tn the illustration. The normal vertical deflection 1s approximately 30~40 mm (1.2~1.6 in). If the deflection ex- ceeds 40 mm (1.6 in) adjust the chain slack. a 30~40 mm (12~16 inhaK Drive chain slack adjustment 1. Loosen the rear wheel axle lock nut, axle nut and caliper bracket installation boit. 1 Chain puller 3. Adjuster 2. Marks for affgnment 4, Lock nut 2. Loosen the lock nuts on each side. To tighten the chain, turn chain adjuster clockwise. To loosen the chain, turn the adjuster counterclockwise and push the wheel forward. Turn each adjuster exactly the same amount to maintain correct axle alignment. (There are marks on each side of swingarm and on each chain aduster; use them to check for proper alignment. Too small chain slack will overload the en- gine and other vital parts; keep the slack within the specified limits. 3. After adjusting, be sure to tighten the lock nuts. 4. Make sure the axle nut, axle lock nut and caliper bracket installation bolt are proper- ly torqued.Tightning torqu Axle ni 107 Nm (10 7 mekg, 77 ftelb) | Axle lock nut. 45 Nm (4.5 mekg, 32 ftelb) Cahper bracket bolt: 45 Nm (4.5 mekg, 32 ftelb) 07 Drive chain lubrication The chain consists of many parts which work against each other. If the chain is not main- tained properly, it will wear out rapidly, there- fore, form the habit of periodically servicing the chain. This service is especially necessary when riding in dusty conditions. This motorcycle has a drive chain with small rubber O-rings between the chain plates. Steam cleaning, high-pressure washes, and certain solvent can damage these O-rings. Use only kerosene to clean the drive chain. Wipe oa 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 sol vents that could damage the O-rings. Hor Cable inspection and lubrication ves ZAC Damage to the outer housing of the vari- ‘ous cables may cause corrosion and inter- fere with the movement of the cable. An unsafe condition may result so replace such cables as soon as possible. Lubricate the inner cable and the cable end. if they do not operate smoothly, ask a Yamaha dealer to replace them. Recommended lubricant: | SAE 10W30 motor oil |a Throttle cable and grip lubrication The throttle twist grip assembly should be greased at the time that the cable is lubricat- ed, since the grip must be removed to get at the end of the throttle cable, Two screws clamp the throttle housing to the handlebar. Once these two are removed, the end of the cable can be held high to pour in several drops of lubricant. With the throttle grip disassembled, coat the metal surface of the grip assembly with a suitable all-purpose grease. v8 Autolube pump adjustment The Autolube pump is a vital part of the en- gine and requires very sophisticated adjust- ment. Most adjusting should be left to a Yamaha dealer who has the professional knowledge and experience to do so. 28 oe Brake and change pedals Lubricate the pivoting parts. a Recommended lubricant: SAE 10W30 motor oil nein 10 Brake and clutch levers Lubricate the pivoting parts. Recommended lubricant: SAE 10W30 motor oil isn Sidestand Lubricate the pivoting parts. Check to see that the sidestand moves up and down smoothly. Recommended lubricant. SAE 10W30 motor oil Lodv7 WARNING: as If the sidestand movement is not smooth, consult a Yamaha dealer. eee ro Rear suspension Lubricate the pivoting parts. Recommended lubricatnt: Lithium soap base grease 208 Front fork inspection ves? 1, Visual check Check any scratch/damage on the inner tube and excessive oil leakage with a the front fork. 2. Operation check Place the motorcycle on a level place. a. Hold the motorcycle on an upright posi- tion with a nider’s hands on the handle- bar and apply the front brake. b. Pump the front fork up and down for several times. eustrr00 ‘eautlobi: If any damage or unsmooth movement is found with the front fork, consult a Yamaha dealer. ZUG} Securely support the motorcycle so there is no danger of it falling over. ee 6291 53K Front fork adjustment ees Always adjust each fork preload to the same setting. Uneven adjustment can cause poor handling and loss of stability. To increase the preload, turn the adjuster clock- wise. To decrease the preload, turn the adjuster counterclockwise. 1 Aghuster uae, ACAUT SUTION The grooves are there just to show the ad- justing level. 630