maintenance YAMAHA MT-25 2016 Owners Manual

Table of contentsSafety information............................ 1-1
Description....................................... 2-1
Left view ......................................... 2-1
Right view ....................................... 2-2
Controls and instruments ............... 2-3
Instrument and control functions... 3-1
Main switch/steering lock............... 3-1
Indicator lights and warning
lights............................................ 3-2
Multi-function meter unit ................ 3-4
Handlebar switches ...................... 3-10
Clutch lever .................................. 3-11
Shift pedal .................................... 3-12
Brake lever.................................... 3-12
Brake pedal .................................. 3-12
Fuel tank cap ................................ 3-13
Fuel ............................................... 3-13
Fuel tank breather hose and
overflow hose ............................ 3-15
Catalytic converter ....................... 3-15
Seats ............................................ 3-16
Helmet holders ............................. 3-17
Storage compartment .................. 3-18
Adjusting the shock absorber
assembly ................................... 3-18
Luggage strap holders ................. 3-19
Sidestand ..................................... 3-19
Ignition circuit cut-off system ....... 3-20For your safety – pre-operation
checks............................................... 4-1
Operation and important riding
points................................................. 5-1
Starting the engine .......................... 5-1
Shifting ............................................ 5-2
Tips for reducing fuel
consumption ................................ 5-3
Engine break-in ............................... 5-3
Parking ............................................ 5-4
Periodic maintenance and
adjustment........................................ 6-1
Owner’s tool kit ............................... 6-1
Periodic maintenance chart for
the emission control system ........ 6-3
General maintenance and
lubrication chart ........................... 6-4
Checking the spark plugs ............... 6-8
Engine oil and oil filter cartridge...... 6-9
Coolant.......................................... 6-12
Replacing the air filter element
and cleaning the check hose..... 6-13
Checking the throttle grip
free play ..................................... 6-15
Valve clearance ............................. 6-15
Tires .............................................. 6-15
Cast wheels................................... 6-17
Adjusting the clutch lever
free play ..................................... 6-17Checking the brake lever
free play..................................... 6-18
Brake light switches ..................... 6-19
Checking the front and rear
brake pads ................................ 6-19
Checking the brake fluid level ...... 6-20
Changing the brake fluid .............. 6-21
Drive chain slack........................... 6-21
Cleaning and lubricating the
drive chain ................................. 6-23
Checking and lubricating the
cables ........................................ 6-24
Checking and lubricating the
throttle grip and cable ............... 6-24
Checking and lubricating the
brake and shift pedals............... 6-24
Checking and lubricating the
brake and clutch levers ............. 6-25
Checking and lubricating the
sidestand................................... 6-26
Lubricating the swingarm
pivots......................................... 6-26
Checking the front fork ................. 6-26
Checking the steering................... 6-27
Checking the wheel bearings ....... 6-27
Battery .......................................... 6-28
Replacing the fuses ...................... 6-29
Replacing the headlight bulb ........ 6-30
Auxiliary light ................................ 6-31
Tail/brake light .............................. 6-31UB04E0E0.book Page 1 Wednesday, September 2, 2015 3:51 PM

1-1
1
Safety information
EAU1028B
Be a Responsible Owner
As the vehicle’s owner, you are re-
sponsible for the safe and proper oper-
ation of your motorcycle.
Motorcycles are single-track vehicles.
Their safe use and operation are de-
pendent upon the use of proper riding
techniques as well as the expertise of
the operator. Every operator should
know the following requirements be-
fore riding this motorcycle.
He or she should:
Obtain thorough instructions from
a competent source on all aspects
of motorcycle operation.
Observe the warnings and mainte-
nance requirements in this Own-
er’s Manual.
Obtain qualified training in safe
and proper riding techniques.
Obtain professional technical ser-
vice as indicated in this Owner’s
Manual and/or when made neces-
sary by mechanical conditions.Never operate a motorcycle with-
out proper training or instruction.
Take a training course. Beginners
should receive training from a cer-
tified instructor. Contact an autho-
rized motorcycle dealer to find out
about the training courses nearest
you.
Safe Riding
Perform the pre-operation checks
each time you use the vehicle to make
sure it is in safe operating condition.
Failure to inspect or maintain the vehi-
cle properly increases the possibility of
an accident or equipment damage.
See page 4-1 for a list of pre-operation
checks.
This motorcycle is designed to
carry the operator and a passen-
ger.
The failure of motorists to detect
and recognize motorcycles in traf-
fic is the predominating cause of
automobile/motorcycle accidents.
Many accidents have been
caused by an automobile driver
who did not see the motorcycle.
Making yourself conspicuous ap-pears to be very effective in reduc-
ing the chance of this type of
accident.
Therefore:
• Wear a brightly colored jacket.
• Use extra caution when you are
approaching and passing
through intersections, since in-
tersections are the most likely
places for motorcycle accidents
to occur.
• Ride where other motorists can
see you. Avoid riding in another
motorist’s blind spot.
• Never maintain a motorcycle
without proper knowledge.
Contact an authorized motorcy-
cle dealer to inform you on ba-
sic motorcycle maintenance.
Certain maintenance can only
be carried out by certified staff.UB04E0E0.book Page 1 Wednesday, September 2, 2015 3:51 PM

Instrument and control functions
3-14
3
3. Wipe up any spilled fuel immedi-
ately. NOTICE: Immediately
wipe off spilled fuel with a clean,
dry, soft cloth, since fuel may
deteriorate painted surfaces or
plastic parts.
[ECA10072]
4. Be sure to securely close the fuel
tank cap.
WARNING
EWA15152
Gasoline is poisonous and can
cause injury or death. Handle gaso-
line with care. Never siphon gasoline
by mouth. If you should swallow
some gasoline or inhale a lot of gas-
oline vapor, or get some gasoline in
your eyes, see your doctor immedi-ately. If gasoline spills on your skin,
wash with soap and water. If gaso-
line spills on your clothing, change
your clothes.
EAU49743
NOTICE
ECA11401
Use only unleaded gasoline. The use
of leaded gasoline will cause severe
damage to internal engine parts,
such as the valves and piston rings,
as well as to the exhaust system.Your Yamaha engine has been de-
signed to use regular unleaded gaso-
line with a research octane number of
95 or higher. If knocking (or pinging)
occurs, use a gasoline of a differentbrand or premium unleaded fuel. Use
of unleaded fuel will extend spark plug
life and reduce maintenance costs.
Gasohol
There are two types of gasohol: gaso-
hol containing ethanol and that con-
taining methanol. Gasohol containing
ethanol can be used if the ethanol con-
tent does not exceed 10% (E10). Gas-
ohol containing methanol is not
recommended by Yamaha because it
can cause damage to the fuel system
or vehicle performance problems.
1. Fuel tank filler tube
2. Maximum fuel level
2
1
Recommended fuel:
Regular unleaded gasoline (Gasohol
[E10] acceptable)
Fuel tank capacity:
14 L (3.7 US gal, 3.1 Imp.gal)
Fuel reserve amount:
3.0 L (0.79 US gal, 0.66 Imp.gal)
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Instrument and control functions
3-15
3
EAU51172
Fuel tank breather hose and
overflow hoseBefore operating the motorcycle:
Check each hose connection.
Check each hose for cracks or
damage, and replace if necessary.
Make sure that the end of each
hose is not blocked, and clean if
necessary.
EAU13434
Catalytic converterThis model is equipped with a catalytic
converter in the exhaust system.
WARNING
EWA10863
The exhaust system is hot after op-
eration. To prevent a fire hazard or
burns:
Do not park the vehicle near
possible fire hazards such as
grass or other materials that
easily burn.
Park the vehicle in a place
where pedestrians or children
are not likely to touch the hot
exhaust system.
Make sure that the exhaust sys-
tem has cooled down before
doing any maintenance work.
Do not allow the engine to idle
more than a few minutes. Long
idling can cause a build-up of
heat.
NOTICE
ECA10702
Use only unleaded gasoline. The use
of leaded gasoline will cause unre-
pairable damage to the catalytic
converter.
1. Fuel tank overflow hose
2. Fuel tank breather hose
2
1
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For your safety – pre-operation checks
4-1
4
EAU15599
Inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition. Always follow the inspection
and maintenance procedures and schedules described in the Owner’s Manual.
WARNING
EWA11152
Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equipment damage.
Do not operate the vehicle if you find any problem. If a problem cannot be corrected by the procedures provided in
this manual, have the vehicle inspected by a Yamaha dealer.Before using this vehicle, check the following points:
ITEM CHECKS PAGE
Fuel• Check fuel level in fuel tank.
• Refuel if necessary.
• Check fuel line for leakage.
• Check fuel tank breather hose and overflow hose for obstructions, cracks or
damage, and check hose connections.3-13, 3-15
Engine oil• Check oil level in engine.
• If necessary, add recommended oil to specified level.
• Check vehicle for oil leakage.6-9
Coolant• Check coolant level in reservoir.
• If necessary, add recommended coolant to specified level.
• Check cooling system for leakage.6-12
Front brake• Check operation.
• If soft or spongy, have Yamaha dealer bleed hydraulic system.
• Check brake pads for wear.
• Replace if necessary.
• Check fluid level in reservoir.
• If necessary, add specified brake fluid to specified level.
• Check hydraulic system for leakage.6-19, 6-20
UB04E0E0.book Page 1 Wednesday, September 2, 2015 3:51 PM

Periodic maintenance and adjustment
6-1
6
EAU17246
Periodic inspection, adjustment, and
lubrication will keep your vehicle in the
safest and most efficient condition
possible. Safety is an obligation of the
vehicle owner/operator. The most im-
portant points of vehicle inspection,
adjustment, and lubrication are ex-
plained on the following pages.
The intervals given in the periodic
maintenance charts should be simply
considered as a general guide under
normal riding conditions. However, de-
pending on the weather, terrain, geo-
graphical location, and individual use,
the maintenance intervals may need to
be shortened.
WARNING
EWA10322
Failure to properly maintain the vehi-
cle or performing maintenance ac-
tivities incorrectly may increase
your risk of injury or death during
service or while using the vehicle. If
you are not familiar with vehicle ser-
vice, have a Yamaha dealer perform
service.
WARNING
EWA15123
Turn off the engine when performing
maintenance unless otherwise
specified.
A running engine has moving
parts that can catch on body
parts or clothing and electrical
parts that can cause shocks or
fires.
Running the engine while ser-
vicing can lead to eye injury,
burns, fire, or carbon monoxide
poisoning – possibly leading to
death. See page 1-3 for more in-
formation about carbon monox-
ide.
WARNING
EWA15461
Brake discs, calipers, drums, and
linings can become very hot during
use. To avoid possible burns, let
brake components cool before
touching them.
EAUB1402
Owner’s tool kitThe owner’s tool kit is located on the
bottom of the passenger seat (see
page 3-16) and is held in place with an
O-ring.
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. How-
ever, additional tools such as a torque
wrench may be necessary to perform
certain maintenance work correctly.1. Owner’s tool kit
2. O-ring
1
2
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Periodic maintenance and adjustment
6-2
6
TIPIf you do not have the tools or experi-
ence required for a particular job, have
a Yamaha dealer perform it for you.
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Periodic maintenance and adjustment
6-3
6
EAU46862
TIPThe annual checks must be performed every year, except if a kilometer-based maintenance, or for the UK, a
mileage-based maintenance, is performed instead.
From 50000 km (30000 mi), repeat the maintenance intervals starting from 10000 km (6000 mi).
Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and tech-
nical skills.
EAU46911
Periodic maintenance chart for the emission control systemNO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING
ANNUAL
CHECK 1000 km
(600 mi)10000 km
(6000 mi)20000 km
(12000 mi)30000 km
(18000 mi)40000 km
(24000 mi)
1*Fuel line• Check fuel hoses for cracks or
damage.√√√√√
2*Spark plugs• Check condition.
• Clean and regap.√√
• Replace.√√
3*Va l ve s• Check valve clearance.
•Adjust.Every 40000 km (24000 mi)
4*Fuel injection sys-
tem• Adjust synchronization.√√√√√
5*Muffler and ex-
haust pipe• Check the screw clamp(s) for
looseness.√√√√√
6*Air induction sys-
tem• Check the air cut-off valve, reed
valve, and hose for damage.
• Replace any damaged parts if
necessary.√√√√√
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Periodic maintenance and adjustment
6-4
6
EAU1770M
General maintenance and lubrication chartNO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING
ANNUAL
CHECK 1000 km
(600 mi)10000 km
(6000 mi)20000 km
(12000 mi)30000 km
(18000 mi)40000 km
(24000 mi)
1 Air filter element•Replace.√√
2 Air filter check hose• Clean.√√√√√
3Clutch• Check operation.
•Adjust.√√√√√
4*Front brake• Check operation, fluid level and
vehicle for fluid leakage.√√√√√√
• Replace brake pads. Whenever worn to the limit
5*Rear brake• Check operation, fluid level and
vehicle for fluid leakage.√√√√√√
• Replace brake pads. Whenever worn to the limit
6*Brake hoses• Check for cracks or damage.
• Check for correct routing and
clamping.√√√√√
• Replace. Every 4 years
7*Brake fluid• Change. Every 2 years
8*Wheels• Check runout and for damage.√√√√
9*Tires• Check tread depth and for dam-
age.
• Replace if necessary.
• Check air pressure.
• Correct if necessary.√√√√√
10*Wheel bearings• Check bearings for looseness or
damage.√√√√
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Periodic maintenance and adjustment
6-5
6
11*Swingarm• Check operation and for exces-
sive play.√√√√
• Lubricate with lithium-soap-
based grease.Every 50000 km (30000 mi)
12 Drive chain• Check chain slack, alignment and
condition.
• Adjust and lubricate chain with a
special O-ring chain lubricant
thoroughly. Every 800 km (500 mi) and after washing the motorcycle, riding in the rain or
riding in wet areas
13*Steering bearings• Check bearing play and steering
for roughness.√√√√√
• Lubricate with lithium-soap-
based grease.Every 20000 km (12000 mi)
14*Chassis fasteners• Make sure that all nuts, bolts and
screws are properly tightened.√√√√√
15Brake lever pivot
shaft• Lubricate with silicone grease.√√√√√
16Brake pedal pivot
shaft• Lubricate with lithium-soap-
based grease.√√√√√
17Clutch lever pivot
shaft• Lubricate with lithium-soap-
based grease.√√√√√
18Shift pedal pivot
shaft• Lubricate with lithium-soap-
based grease.√√√√√
19 Sidestand• Check operation.
• Lubricate with lithium-soap-
based grease.√√√√√
20*Sidestand switch• Check operation.√√√√√√ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING
ANNUAL
CHECK 1000 km
(600 mi)10000 km
(6000 mi)20000 km
(12000 mi)30000 km
(18000 mi)40000 km
(24000 mi)UB04E0E0.book Page 5 Wednesday, September 2, 2015 3:51 PM