Yamaha VIRAGO XV250V User manual

LIT-11666-19-23 2UJ-28107-11
XV250V(C)
ASSEMBLY MANUAL

EAA00002
FOREWORD
This Assembly Manual contains the information required for the correct assembly of this Yamaha vehi-
cle prior to delivery to the customer. Since some external parts of the vehicle have been removed at
the Yamaha factory for the convenience of packing, assembly by the Yamaha dealer is required. It
should be noted that the assembled vehicle should be thoroughly cleaned, inspected, and adjusted pri-
or to delivery to the customer.
EAA00005
NOTICE
The service specifications given in this assembly manual are based on the model as manufactured.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and sig-
nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and
will appear in future editions of this manual where applicable.
The procedures below are described in the order that the procedures are carried out correctly and com-
pletely. Failure to do so can result in poor performance and possible harm to the vehicle and/or rider.
CONCERNING CRATE DAMAGE:
Follow the instructions in the Dealer Warranty Handbook, Procedure Section.
Particularly important information is distinguished in this manual by the following notations.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY
IS INVOLVED!
Failure to follow WARNING instructions could result in severe injury or death to
the vehicle operator, a bystander, or a person checking or repairing the vehicle.
A CAUTION indicates special precautions that must be taken to avoid damage to
the vehicle.
A NOTE provides key information to make procedures easier or clearer.
EAA00001
XV250V(C)
ASSEMBLY MANUAL
©2005 by Yamaha Motor Corporation, U.S.A.
First Edition, May 2005
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
Printed in U.S.A.
P/N LIT-11666-19-23
WARNING
CAUTION:
NOTE:

EAA00008
SYMBOLS USED IN THE
ASSEMBLY MANUAL
In order to simplify descriptions in this
assembly manual, the following symbols
are used:
(1): Coat with lithium-soap-based grease.
(2): Tighten to 10 Nm.
(10 Nm = 1.0 m · kg, 7.2 ft · lb)
(3): Towards the front of the vehicle
(4): Clearance required
(5): Install so that the arrow mark faces
upward.
(6): Apply motor oil.
(7): Made of rubber or plastics
(8):
A: Ref. No. (indicating the order of
operations.)
B: Part name
C: Quantity of parts per vehicle
D: Place where parts are held
V: Stored in plastic bag
C: Stored in carton box
S: Fixed inside the steel frame
and/or contained in the Sty-
rofoam tray (upper or lower)
: Temporarily installed or
secured
E: Size or material of parts
d/D: Diameter of part
: Length of part
e.g., 5 (0.20) = 5 mm (0.20 in)
*
EAA00040
PREPARATION
To assemble the vehicle correctly, sup-
plies (e.g. oils, greases, and shop rags)
and sufficient working space are required.
Workshop
The workshop where the vehicle is assem-
bled should be clean, spacious, and have
a level floor.
Self-protection
Protect your eyes with suitable safety
glasses or goggles when using com-
pressed air, when grinding or when doing
any operation which may cause particles
to fly off.
Protect hands and feet by wearing safety
gloves or shoes.
(1) (2)
(3) (4)
(5) (6)
(7)
(8)
10
FWD
UP
d
Dd
dDd

–1–
EAA00100
SETUP PROCEDURES
Perform the setup procedures in the order indicated by the numbers. Always follow the order as shown.

–2–
EAA00109
1. FRONT FENDER
A: Fasten the brake hose with the
speedometer cable guide.
B: Pass the speedometer cable
through the speedometer
cable guide.
WARNING
_
Proper cable routing is essen-
tial to assure safe vehicle oper-
ation.
Refer to “CABLE ROUTING”.
C: Tighten the bolts to specifica-
tion.
CAUTION:
_
Be careful not to scratch the
front fender with the front fork
outer tube.
D: Align the projections on the
front reflectors with the slots in
the front reflector bracket and
speedometer cable guide.
Bolt
16 Nm (1.6 m · kg, 11 ft · lb)
EAA00204
2. FRONT WHEEL
A: Clean the brake disc.
B: Clean the front wheel axle.
C: Clean the collar.
D:
WARNING
_
Take care not to get grease on
the brake disc or inner surface
of the brake pads. If you do so,
clean using a rag dampened
with a solvent. Foreign material
on braking surface can cause
impaired braking action.
E: Make sure the projections in
the wheel hub are meshed
with the slots in the speedom-
eter gear unit.
F: Lift the front wheel and install
the front wheel axle.
NOTE:
_
Do not depress the brake lever
when the caliper is off the brake
disc.
G: Make sure the projection
(torque stopper) on the front
fork is placed in the slot in the
speedometer gear unit as
shown.
H: Tighten the front wheel axle to
specification.
I: Tighten the axle pinch bolt to
specification.
J: Connect the speedometer
cable to the speedometer gear
unit.
Front wheel axle
59 Nm (5.9 m · kg, 43 ft · lb)
Axle pinch bolt
20 Nm (2.0 m · kg, 14 ft · lb)
1 Front fender 1 C
2 Front reflector bracket 1 V
3 Speedometer cable guide 1 V
4 Front brake hose holder 1 V
5 Flange bolt 4 V d = 8 (0.31), = 12 (0.47)
6 Front reflector 2 V
7 Flange nut 2 V d = 5 (0.20)
1 Front wheel 1 S
2Collar 1 V
3 Speedometer gear unit 1 V
4 Front wheel axle 1
5 Axle pinch bolt 1 d = 8 (0.31), = 35 (1.38)
6 Speedometer cable 1
*
*
*

–3–
EAA00209
3. LEAD HOLDER
A: Pass the wire harness through
the lead holder.
NOTE:
_
Refer to “CABLE ROUTING”.
EAA00014
4. HANDLEBAR
Before 2012 models
A: Clean the right handlebar end.
Apply light coat grease.
B: Install the handlebar holders
with the arrow mark facing for-
ward.
CAUTION:
_
First tighten the bolts on the
front side, and then tighten the
bolts on the rear side.
C: Align the punch mark on the
handlebar with the top of the
lower handlebar holders.
D: Tighten the bolts to specifica-
tion.
WARNING
_
Proper cable routing is essen-
tial to assure safe vehicle oper-
ation.
Refer to “CABLE ROUTING”.
Bolt
23 Nm (2.3 m · kg, 17 ft · lb)
EAA00014
4. HANDLEBAR
For 2012 models
A: Clean the right handlebar end.
Apply light coat grease.
B: Install the handlebar holders
with the arrow mark facing for-
ward.
CAUTION:
_
First tighten the bolts on the
front side, and then tighten the
bolts on the rear side.
C: Align the punch mark on the
handlebar with the top of the
lower handlebar holders.
D: Tighten the bolts to specifica-
tion.
WARNING
_
Proper cable routing is essen-
tial to assure safe vehicle oper-
ation.
Refer to “CABLE ROUTING”.
Bolt
23 Nm (2.3 m · kg, 17 ft · lb)
1 Lead holder 1 V
2 Flange bolt 1 V d = 6 (0.24), = 12 (0.47)
1 Indicator light assembly 1
2 Screw 2 V d = 4 (0.16), = 35 (1.38)
3 Handlebar 1 S
4 Upper handlebar holder 2 V
5 Hexagon socket bolt 4 V d = 8 (0.32), = 25 (0.98)
6Plug 4 V
A
C
B
D
23 6
5
4
3
2
1
*
1 Handlebar 1 S
2 Upper handlebar holder 2 V
3 Hexagon socket bolt 4 V
4Plug 4 V
A
C
B
D
2
1
4
3
23

–4–
EAA00018
5. THROTTLE GRIP
ASSEMBLY
Before 2012 models
A: The stopper (a) should be
touching the inner surface of
the right handlebar switch.
B: Slip the throttle grip over the
right handlebar completely
and then slide it back about
1 mm (0.04 in).
C: Check the throttle grip for
smooth action.
WARNING
_
Proper cable routing is essen-
tial to assure safe vehicle oper-
ation.
Refer to “CABLE ROUTING”.
EAA00018
5. THROTTLE GRIP
ASSEMBLY
For 2012 models
A: The stopper (a) should be
touching the inner surface of
the right handlebar switch.
B: Slip the throttle grip over the
right handlebar completely
and then slide it back about
1.5 mm (0.06 in).
C: Check the throttle grip for
smooth action.
WARNING
_
Proper cable routing is essen-
tial to assure safe vehicle oper-
ation.
Refer to “CABLE ROUTING”.
EAA00032
6. FRONT BRAKE
MASTER CYLINDER
A: Lubricate the pivoting parts of
the brake lever.
B: Make sure that the “UP” mark
on the holder is pointed
upward.
C: Tighten the bolts to specifica-
tion.
D: Check the brake lever for
smooth action.
WARNING
Proper cable and hose routing
is essential to assure safe vehi-
cle operation.
Refer to “CABLE ROUTING”.
Recommended lubricants
Yamaha cable lube or motor
oil
Bolt
7 Nm (0.7 m · kg, 5.1 ft · lb)
1 Throttle grip assembly 1
2 Screw 2 d = 5 (0.20), = 40 (1.57)
d = 5 (0.20), = 45 (1.77)
3 Grip end 1 V
4 Hexagon socket bolt 1 V d = 6 (0.24), = 75 (2.95)
5 Damper 1 V
6 Flange nut 1 V d = 6 (0.24)
1mm
(0.04in)
CB
A
653
4
2
1
a
*
*
1 Throttle grip assembly 1
2 Screw 2 d = 5 (0.20), = 40 (1.57)
d = 5 (0.20), = 45 (1.77)
3 Grip end 1 V
1.5mm
(0.06in)
C
B
A
3
2
1
a
*
*
1Front brake master cylinder
assembly 1
2Front brake master cylinder
holder 1V
3 Bolt with washer 2 V d = 6 (0.24), = 25 (0.98)
*

–5–
EAA00035
7. LEFT HANDLEBAR
SWITCH
Before 2012 models
A: Align the slot on the left han-
dlebar switch with the projec-
tion on the clutch lever holder.
B: Pass the starter cable through
the cable guide.
WARNING
_
Proper cable routing is essen-
tial to assure safe vehicle oper-
ation.
Refer to “CABLE ROUTING”.
EAA00035
7. LEFT HANDLEBAR
SWITCH
For 2012 models
A: Align the slot on the left han-
dlebar switch with the projec-
tion on the clutch lever holder.
B: Pass the starter cable through
the cable guide.
WARNING
_
Proper cable routing is essen-
tial to assure safe vehicle oper-
ation.
Refer to “CABLE ROUTING”.
1 Left handlebar switch 1
2 Screw 2 V d = 5 (0.20), = 35 (1.38)
3Starterlever 1
4 Starter cable 1
5 Special washer 1
6 Washer 1 d = 6 (0.24)
7 Screw 1 d = 6 (0.24), = 10 (0.39)
8 Grip end 1 V
9 Hexagon socket bolt 1 V d = 6 (0.24), = 75 (2.95)
10 Damper 1 V
11 Flange nut 1 V d = 6 (0.24)
A
11
10
8
9
1
6
7
2
5
B
4
3
2
*
*
*
*
*
*
1 Left handlebar switch 1
2 Screw 2 V d = 5 (0.20), = 35 (1.38)
3Starterlever 1
4 Starter cable 1
5 Special washer 1
6 Washer 1 d = 6 (0.24)
7 Screw 1 d = 6 (0.24), = 10 (0.39)
8 Grip end 1 V
A
8
1
6
7
2
5
B
4
3
2
*
*
*
*
*
*

–6–
EAA00049
8. CLUTCH CABLE
A: Lubricate the pivoting part of
the clutch lever.
B: To install the clutch cable, be
sure to proceed as follows:
a. Turn in the adjuster on the
lever holder until tight. Next,
align the slit in the adjuster
and cable socket with the slit
in the lever holder.
b. Insert the cable end into the
lever hole. Next, while pulling
the outer cable in the direction
opposite to the lever, seat the
outer cable into the cable
socket.
NOTE:
_
Check the clutch lever for smooth
action.
Refer to “ADJUSTMENTS AND
PREDELIVERY SERVICE”.
WARNING
_
Proper cable routing is essen-
tial to assure safe vehicle oper-
ation.
Refer to “CABLE ROUTING”.
C: Install the rubber cover onto
the end of the clutch lever.
D: Make sure that the clutch
cable end (engine side) is
positioned correctly.
Recommended lubricants
Yamaha cable lube or motor
oil
EAA00039
9. CABLE TIES
Before 2012 models
A: Fasten the left handlebar
switch lead and clutch switch
lead with two plastic bands.
B: Fasten the right handlebar
switch lead and front brake
light switch lead with two plas-
tic bands.
NOTE:
_
Refer to “CABLE ROUTING”.
1 Clutch cable 1
2 Clutch switch 1
D
*
*
1 Plastic band 4 V
EAA00039
9. CABLE TIES
For 2012 models
A: Fasten the left handlebar
switch lead and clutch switch
lead with two plastic bands.
B: Fasten the right handlebar
switch lead and front brake
light switch lead with two plas-
tic bands.
NOTE:
_
Refer to “CABLE ROUTING”.
1 Plastic band 4 V

–7–
EAA00054
10. FRONT TURN SIGNAL
LIGHTS
A: Install the turn signal light with
a chocolate color lead on the
left side. Next, install the turn
signal light with a dark green
color lead on the right side.
B: Pass the clutch cable, starter
cable, front brake hose, and
throttle cables through the
cable guide.
NOTE:
Refer to “CABLE ROUTING”.
C: Connect the front turn signal
light leads to the wire harness.
The leads of identical colors
should be connected.
NOTE:
_
Refer to “CABLE ROUTING”.
D: Tighten the nuts to specifica-
tion.
Nut
23 Nm (2.3 m · kg, 17 ft · lb)
EAA00213
11. HEADLIGHT LENS UNIT
AND LEFT SIDE COVER
A: Connect the headlight coupler
to the headlight.
NOTE:
_
Refer to “CABLE ROUTING”.
12. REARVIEW MIRRORS
1 Front turn signal light 2 C
2 Front turn signal light bracket 2
3 Bolt 2 V d = 6 (0.24), = 30 (1.18)
4 Flange nut 2 V d = 6 (0.24)
5 Cable guide 1 V
6 Nut 2 V d = 12 (0.47)
*
1 Headlight lens unit 1
2Screw 1d = 5 (0.20), = 14 (0.55)
1V
3 Left side cover 1 C
4 Screw 1 V d = 4 (0.16), = 12 (0.47)
5 Hexagon socket bolt 1 V d = 4 (0.16), = 20 (0.79)
A
1
2
4
35
*
*
1 Rearview mirror 2 C
1

–8–
13. SHIFT PEDAL
A: Align the punch mark with the
slot.
B: Tighten the bolt to specifica-
tion.
Bolt
10 Nm (1.0 m · kg, 7.2 ft · lb)
EAA00069
14. LEFT FOOTREST
A:
NOTE:
_
After installing a footrest, check
that it moves smoothly.
EAA00054
15. REAR TURN SIGNAL
LIGHTS
A: Install the turn signal light with
a chocolate color lead on the
left side. Next, install the turn
signal light with a dark green
color lead on the right side.
B: Connect the rear turn signal
light leads to the wire harness.
The leads of identical colors
should be connected.
NOTE:
_
Refer to “CABLE ROUTING”.
C: Tighten the nuts to specifica-
tion.
D: Tighten the nuts to specifica-
tion.
Nut
8 Nm (0.8 m · kg, 5.8 ft · lb)
Nut
10 Nm (1.0 m · kg, 7.2 ft · lb)
1 Shift pedal 1 S
2 Bolt 1 V d = 6 (0.24), = 20 (0.79)
1Leftfootrest 1 S
2 Washer 1 V d = 10 (0.39), D = 27 (1.06)
3 Washer 1 V d = 10 (0.39), D = 30 (1.18)
4 Cap nut 2 V d = 10 (0.39)
1 Rear turn signal light 2 C
2 Rear turn signal light bracket 2 V
3 Bolt 2 V d = 6 (0.24), = 30 (1.18)
4 Flange nut 2 V d = 6 (0.24)
5 Nut 2 V d = 12 (0.47)
6Cap 2 V

–9–
16. LICENSE PLATE
BRACKET
AA00189
17. BATTERY
A: Installing the battery.
NOTE:
_
Refer to “ADJUSTMENTS AND
PREDELIVERY SERVICE”.
B: First, connect the positive lead
(red lead) to the positive termi-
nal.
C: Second, connect the negative
lead (black lead) to the nega-
tive terminal.
NOTE:
_
Refer to “CABLE ROUTING”.
D: Tighten the bolts to specifica-
tion.
Bolt
7 Nm (0.7 m · kg, 5.1 ft · lb)
1 License plate bracket 1 C
2 Flange bolt 2 V d = 6 (0.24), = 10 (0.39)
3 Rear reflector 1 V
4 Nut 1 V d = 5 (0.20)
2
1
3
4
1 Battery 1
2 Battery breather hose 1
3 Battery band 1
4 Rider seat 1
5 Flange bolt 2 d = 6 (0.24), = 16 (0.63)
*
*
*
*
*

–10–
EEAA00900
CABLE ROUTING
WARNING
_
Proper cable and lead routing are essential to insure safe vehi-
cle operation.
(1) Throttle cables
(2) Front brake hose
(3) Right handlebar switch lead
(4) Front brake light switch lead
(5) Left handlebar switch lead
(6) Clutch switch lead
(7) Starter cable
(8) Clutch cable
(9) Speedometer cable
(10)Wire harness
(11)Indicator light lead (Before 2012 models)
(12)Speedometer lead
(13)Left front turn signal light leads
(14)Right front turn signal light leads
(15)Headlight unit
(i) Before 2012 models
(ii) For 2012 models
2
1
A
G
F
B34
5
6C
7
8
D
E
9
35
6
11
15
14
10
13
6
H
7
8
4
H
1
2
I
10
11
2
1
A
G
F
4
7
8
D
E
9
5
10
12
3 B C 6 5
i ii

–11–
(A) Pass the throttle cables through and to the front of the cable guide.
(B) Fasten the right handlebar switch lead and front brake light switch lead
with two plastic bands.
(C) Fasten the left handlebar switch lead and clutch switch lead with two
plastic bands.
(D) Pass the clutch cable through the small guide that is attached to the
cable guide.
(E) Pass the speedometer cable in front of the lower bracket.
(F) Fasten the front brake hose behind the lower bracket.
(G) Pass the wire harness through the lead holder.
(H) To handlebar
(I) To headlight
2
1
A
G
F
B34
5
6C
7
8
D
E
9
35
6
11
15
14
10
13
6
H
7
8
4
H
1
2
I
10
11
2
1
A
G
F
4
7
8
D
E
9
5
10
12
3 B C 6 5
i ii

–12–
(1) Negative battery lead
(2) Main switch lead
(3) Fuse holder
(4) Right rear turn signal light connectors
(5) Tail/brake light connectors
(6) Left rear turn signal light connectors
(7) Rectifier/regulator lead
(8) Wire harness
(9) Positive battery lead
(10)Battery
(11)Frame
(12)Battery breather hose
(13)Front brake hose
(14)Speedometer cable
(A) Fasten the main switch lead and neutral switch lead with a plastic locking
tie.
(B) 50 mm (1.97 in)
(C) Fasten the wire harness and positive battery lead with the clamp.
(D) Fasten the positive battery leads with a plastic locking tie, making sure
that the leads do not protrude past the line shown on top of the frame in
the illustration. Face the end of the plastic tie downward.
(E) Pass the speedometer cable through the speedometer cable guide.
(F) Fasten the front brake hose with the speedometer cable guide.

–13–
EAA01100
ADJUSTMENTS AND PREDELIVERY
SERVICE
Perform the predelivery service in the order indicated by the letters.
Always follow the order as shown.

–14–
EAA01003
A. CHECKING AND CHARGING
THE BATTERY
1. Charge:
The battery must be charged properly
before using for the first time. This ini-
tial charge will prolong the life of the
battery.
(a) Upper level line
(b) Lower level line
CAUTION:
_
Never try to add battery electrolyte to a
battery that is installed on a vehicle.
Even a skilled mechanic will spill
enough acid to damage metal parts.
Always remove the battery before fill-
ing with electrolyte and during charg-
ing. Always completely clean the
exterior of the battery before installing.
a. Remove all filler caps from the battery
and remove the breather hose cap (1).
NOTE:
_
Place the battery on a level place.
b. Cool the electrolyte to below 30 °C
(86 °F).
c. Pour electrolyte into each cell little by
little up to the upper level line, and
leave it for a while. When the battery
fluid permeates the plates and separa-
tors, the fluid level begins to lower. Add
electrolyte and bring back to upper
level line.
NOTE:
_
Fill the battery with electrolyte (diluted sul-
furic acid).
WARNING
_
Battery electrolyte is dangerous; it con-
tains sulfuric acid and therefore is poi-
sonous and highly caustic. Always
follow these preventive measures:
●Avoid bodily contact with electrolyte
as it can cause severe burns or per-
manent eye injury.
●Wear protective eye gear when han-
dling or working near batteries.
Antidote (EXTERNAL):
●SKIN-Flush with water.
●EYES-Flush with water for 15 min-
utes and get immediate medical
attention.
Antidote (INTERNAL):
●Drink large quantities of water or
milk follow with milk of magnesia,
beaten egg, or vegetable oil. Get
immediate medical attention.
Batteries also generate explosive
hydrogen gas, therefore you should
always follow these preventive mea-
sures:
●Charge batteries in a well-ventilated
area.
●Keep batteries away from fire,
sparks, or open flames (e.g., welding
equipment, lighted cigarettes, etc.).
●DO NOT SMOKE when charging or
handling batteries.
KEEP BATTERIES AND ELECTROLYTE
OUT OF THE REACH OF CHILDREN.
d. Connect the battery to a battery
charger.
e. Set the battery charger rate at 1/10 of
the battery capacity and charge the
battery for 10 hours.
f. Turn the battery charger off, then dis-
connect it from the battery.
g. Check the specific gravity of each cell
with a hydrometer. If the hydrometer
readings are below the specification,
charging is necessary.
h. Install the filler caps, and thoroughly
wipe off the fluid around the filler caps.
Wipe off the battery completely before
installation.
2. Install:
a. The breather hose should be con-
nected and routed properly.
WARNING
_
When inspecting the battery, be sure
the breather hose is routed correctly. If
the battery breather hose touches the
frame in such a way as to cause battery
electrolyte or gas to exit onto the
frame, structural and cosmetic damage
to the vehicle can occur.
b. Make sure that the main switch is
turned off, and install the battery in the
battery box.
c. Connect the positive lead first, and
then connect the negative lead.
CAUTION:
_
Make sure that the battery leads are
connected correctly. Reversing leads
can seriously damage the electrical
system.
Charging rate
1.0 A ×10 hours
Battery capacity
12 V, 10 Ah
Specific gravity
1.280 at 20 °C (68 °F)

–15–
EAA01005
B. DRAINING THE FUEL
1. Put a rag under the carburetor drain
hose so fuel does not contact the
crankcase.
2. Loosen the drain screw (1) and drain
the standing fuel.
WARNING
_
FUEL IS HIGHLY FLAMMABLE:
●Always turn off the engine when
draining fuel.
●Take care not to spill any fuel on the
engine or exhaust pipe(s)/muffler(s)
when draining fuel.
●Never drain fuel while smoking or in
the vicinity of an open flame.
3. Tighten the drain screw securely.
EAA01009
C. MEASURING THE TIRE
PRESSURE
1. Measure:
●tire pressure
Out of specification →Adjust.
WARNING
_
●The tire pressure should only be
checked and regulated when the tire
temperature equals the ambient air
temperature.
●The tire pressure and the suspen-
sion must be adjusted according to
the total weight (including cargo,
rider, passenger, and accessories)
and the anticipated riding speed.
●Operation of an overloaded vehicle
could cause tire damage, an acci-
dent, or an injury.
NEVER OVERLOAD THE VEHICLE.
*Load is the total weight of cargo, rider,
passenger, and accessories.
Basic
weight:
With oil and
full fuel tank
147.0 kg (324 lb) (U49)
148.0 kg (326 lb) (CAL)
Maximum
load*
196 kg (432 lb) (U49)
195 kg (430 lb) (CAL)
Cold tire
pressure Front Rear
Up to 90 kg
load*
175 kPa
(1.75 kgf/cm2,
25 psi)
200 kPa
(2.00 kgf/cm2,
29 psi)
90 ~ 196 kg
(U49)
90 ~ 195 kg
(CAL)
200 kPa
(2.00 kgf/cm2,
29 psi)
225 kPa
(2.25 kgf/cm2,
33 psi)

–16–
EAA01012
D. CHECKING THE ENGINE OIL
LEVEL
1. Stand the vehicle on a level surface.
NOTE:
_
●Place the vehicle on a suitable stand.
●Make sure that the vehicle is upright.
2. Check:
●engine oil level
The engine oil level should be between
the minimum level mark (a) and maxi-
mum level mark (b).
Below the minimum level mark →Add
the recommended engine oil to the
proper level.
CAUTION:
_
●Engine oil also lubricates the clutch
and the wrong oil types or additives
could cause clutch slippage. There-
fore, do not add any chemical addi-
tives.
●Do not allow foreign materials to
enter the crankcase.
NOTE:
_
API Service “SE”, “SF” and “SG” type or
equivalent (e.g., “SF-SE”, “SF-SE-CC”,
“SF-SE-SD”)
3. Start the engine, warm it up for several
minutes, and then turn it off.
4. Check the engine oil level again.
NOTE:
_
Before checking the engine oil level, wait a
few minutes until the oil has settled.
Recommended engine oil
At -10 °C (10 °F) or higher
Yamalube 4 (10W30) or SAE 10W30
engine oil
At 5 °C (40 °F) or lower
Yamalube 4 (20W40) or SAE 20W40
engine oil
Quantity
Without oil filter element replacement
1.40 L (1.23 Imp qt, 1.48 US qt)
EAA01022
E. ADJUSTING THE THROTTLE
CABLE FREE PLAY
NOTE:
_
Prior to adjusting throttle cable free play,
the engine idling speed should be
adjusted.
1. Measure:
●throttle cable free play (a)
Out of specification →Adjust.
2. Adjust:
a. Loosen the locknut (1).
b. Turn the adjusting nut (2) in direction
(b) or (c) until the specified throttle
cable free play is obtained.
c. Tighten the locknut.
WARNING
_
After adjusting the throttle cable free
play, turn the handlebar to the right and
to the left to ensure that this does not
cause the engine idling speed to
change.
Throttle cable free play (at the flange of
the throttle grip)
3.0 ~ 5.0 mm (0.12 ~ 0.20 in)
Direction
(b)
Throttle cable free play
is increased.
Direction
(c)
Throttle cable free play
is decreased.

–17–
EAA01020
F. ADJUSTING THE ENGINE
IDLING SPEED
NOTE:
_
Prior to adjusting the engine idling speed,
the air filter should be clean, and the
engine should have adequate compres-
sion.
1. Start the engine and let it warm up for
several minutes.
2. Attach:
●engine tachometer
(to the spark plug lead of cylinder #1)
3. Measure:
●engine idling speed
Out of specification →Adjust.
4. Adjust:
●engine idling speed
a. Turn the throttle stop screw (1) in direc-
tion (a) or (b) until the specified engine
idling speed is obtained.
Engine idling speed
1,350 ~ 1,450 r/min
Direction
(a)
Engine idling speed is
increased.
Direction
(b)
Engine idling speed is
decreased.
EAA01025
G. ADJUSTING THE FRONT
BRAKE
1. Measure:
●brake lever free play (a)
Out of specification →Adjust.
2. Adjust:
●brake lever free play
a. Loosen the locknut (1).
b. Turn the adjusting screw (2) in direction
(b) or (c) until the specified brake lever
free play is obtained.
c. Tighten the locknut.
WARNING
_
A soft or spongy feeling in the brake
lever can indicate the presence of air in
the brake system. Before the vehicle is
operated, the air must be removed by
bleeding the brake system. Air in the
brake system will considerably reduce
braking performance and could result
in loss of control and possibly an acci-
dent. Therefore, check the brake sys-
tem and bleed if necessary.
CAUTION:
_
After adjusting the brake lever free
play, make sure that there is no brake
drag.
Brake lever free play (at the end of the
brake lever)
2.0 ~ 5.0 mm (0.08 ~ 0.20 in)
Direction
(b)
Brake lever free play is
increased.
Direction
(c)
Brake lever free play is
decreased.