clutch YAMAHA WR 250X 2009 Owners Manual
[x] Cancel search | Manufacturer: YAMAHA, Model Year: 2009, Model line: WR 250X, Model: YAMAHA WR 250X 2009Pages: 98, PDF Size: 2.11 MB
Page 6 of 98
TABLE OF CONTENTS
SAFETY 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 and warning lights .............3-2
Multi-function display .......................3-3
Handlebar switches .........................3-9
Clutch lever ....................................3-10
Shift pedal ......................................3-10
Brake lever ....................................3-10
Brake pedal ...................................3-11
Fuel tank cap .................................3-11
Fuel ................................................3-12
Catalytic converter .........................3-13
Seat ...............................................3-14
Helmet holder ................................3-14
Adjusting the front fork ...................3-15
Front fork bleeding .........................3-16
Adjusting the shock absorber
assembly ....................................3-17
EXUP system ................................3-19
Sidestand .......................................3-19
Ignition circuit cut-off system .........3-20
FOR 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 .............. 6-2
General maintenance and
lubrication chart ........................... 6-3
Removing and installing panels ...... 6-7
Checking the spark plug .................. 6-9
Engine oil and oil filter element ..... 6-10
Coolant .......................................... 6-13
Cleaning the air filter element and
check hose ................................. 6-16
Adjusting the engine idling
speed ......................................... 6-18
Checking the throttle cable free
play ............................................ 6-18
Valve clearance ............................. 6-19
Tires .............................................. 6-19Spoke wheels ............................... 6-21
Adjusting the clutch lever free
play ............................................ 6-21
Adjusting the brake lever free
play ............................................ 6-22
Adjusting the rear brake light
switch ......................................... 6-23
Checking the front and rear brake
pads ........................................... 6-23
Checking the brake fluid level ....... 6-24
Changing the brake fluid ............... 6-25
Drive chain slack ........................... 6-25
Cleaning and lubricating the drive
chain .......................................... 6-26
Checking and lubricating the
cables ........................................ 6-27
Checking and lubricating the
throttle grip and cable ................ 6-27
Checking and lubricating the
brake and clutch levers .............. 6-28
Checking and lubricating the
brake pedal ................................ 6-28
Checking and lubricating the
sidestand ................................... 6-29
Lubricating the rear suspension .... 6-29
Checking the front fork .................. 6-29
Checking the steering ................... 6-30
Checking the wheel bearings ........ 6-31
Battery ........................................... 6-31
Replacing the fuses ...................... 6-32
Replacing the headlight bulb ........ 6-33
Page 14 of 98
DESCRIPTION
2-3
1
2
3
4
5
6
7
8
9
EAU10430
Controls and instruments
12 34 5 6
8
7
1. Clutch lever (page 3-10)
2. Left handlebar switches (page 3-9)
3. Main switch/steering lock (page 3-1)
4. Multi-function display (page 3-3)
5. Right handlebar switches (page 3-9)
6. Brake lever (page 3-10)
7. Throttle grip (page 6-18)
8. Fuel tank cap (page 3-11)
Page 24 of 98
INSTRUMENT AND CONTROL FUNCTIONS
3-10
1
2
3
4
5
6
7
8
9
EAU12820
Clutch lever
The clutch lever is located at the left
handlebar grip. To disengage the
clutch, pull the lever toward the handle-
bar grip. To engage the clutch, release
the lever. The lever should be pulled
rapidly and released slowly for smooth
clutch operation.
The clutch lever is equipped with a
clutch switch, which is part of the igni-
tion circuit cut-off system. (See
page 3-20.)
EAU12870
Shift pedal
The shift pedal is located on the left
side of the engine and is used in com-
bination with the clutch lever when
shifting the gears of the 6-speed con-
stant-mesh transmission equipped on
this motorcycle.
EAU12890
Brake lever
The brake lever is located at the right
handlebar grip. To apply the front
brake, pull the lever toward the handle-
bar grip.
1. Clutch lever
1
1. Shift pedal
1
1. Brake lever
1
Page 34 of 98
INSTRUMENT AND CONTROL FUNCTIONS
3-20
1
2
3
4
5
6
7
8
9
EAU44892
Ignition circuit cut-off system
The ignition circuit cut-off system (com-
prising the sidestand switch, clutch
switch and neutral switch) has the fol-
lowing functions.
It prevents starting when the trans-
mission is in gear and the side-
stand is up, but the clutch lever is
not pulled.
It prevents starting when the trans-
mission is in gear and the clutch le-
ver is pulled, but the sidestand is
still down.
It cuts the running engine when the
transmission is in gear and the sid-
estand is moved down.
Periodically check the operation of the
ignition circuit cut-off system according
to the following procedure.
Page 35 of 98
INSTRUMENT AND CONTROL FUNCTIONS
3-21
2
34
5
6
7
8
9
With the engine turned off:
1. Move the sidestand down.
2. Make sure that the engine stop switch is set to “
3. Turn the key on.
4. Shift the transmission into the neutral position.
5. Push the start switch.
Does the engine start?
With the engine still running:
6. Move the sidestand up.
7. Keep the clutch lever pulled.
8. Shift the transmission into gear.
9. Move the sidestand down.
Does the engine stall?
After the engine has stalled:
10. Move the sidestand up.
11. Keep the clutch lever pulled.
12. Push the start switch.
Does the engine start?
The system is OK. The motorcycle can be ridden.The neutral switch may not be working correctly.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
The sidestand switch may not be working correctly.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
The clutch switch may not be working correctly.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
YES NO YES NO YES NO
If a malfunction is noted, have a Yamaha
dealer check the system before riding.
WARNING
”.
Page 37 of 98
FOR YOUR SAFETY – PRE-OPERATION CHECKS
4-2
2
3
45
6
7
8
9
Rear 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 recommended brake fluid to specified level.
Check hydraulic system for leakage.6-23, 6-24
Clutch
Check operation.
Lubricate cable if necessary.
Check lever free play.
Adjust if necessary.6-21
Throttle grip
Make sure that operation is smooth.
Check cable free play.
If necessary, have Yamaha dealer adjust cable free play and lubricate cable
and grip housing.6-18, 6-27
Control cables
Make sure that operation is smooth.
Lubricate if necessary.6-27
Drive chain
Check chain slack.
Adjust if necessary.
Check chain condition.
Lubricate if necessary.6-25, 6-26
Wheels and tires
Check for damage.
Check tire condition and tread depth.
Check air pressure.
Correct if necessary.6-19, 6-21
Shift pedal
Make sure that operation is smooth.
Correct if necessary.—
Brake pedal
Make sure that operation is smooth.
Lubricate pedal pivoting point if necessary.6-28
Brake and clutch levers
Make sure that operation is smooth.
Lubricate lever pivoting points if necessary.6-28
ITEM CHECKS PAGE
Page 39 of 98
5-1
2
3
4
56
7
8
9
OPERATION AND IMPORTANT RIDING POINTS
EAU15951
Read the Owner’s Manual carefully to
become familiar with all controls. If
there is a control or function you do not
understand, ask your Yamaha dealer.
WARNING
EWA10271
Failure to familiarize yourself with
the controls can lead to loss of con-
trol, which could cause an accident
or injury.
EAU46632
TIP
This model is equipped with:
a lean angle sensor to stop the en-
gine in case of a turnover. In this
case, the multi-function display in-
dicates error code 30, but this is
not a malfunction. Turn the key to
“OFF” and then to “ON” to clear the
error code. Failing to do so will pre-
vent the engine from starting even
though the engine will crank when
pushing the start switch.
an engine auto-stop system. The
engine stops automatically if left
idling for 20 minutes. In this case,
the multi-function display indicates
error code 70, but this is not a mal-
function. Push the start switch to
clear the error code and to restart
the engine.
EAU45123
Starting the engine
In order for the ignition circuit cut-off
system to enable starting, one of the
following conditions must be met:
The transmission is in the neutral
position.
The transmission is in gear with
the clutch lever pulled and the sid-
estand up.
See page 3-20 for more informa-
tion.
1. Turn the key to “ON” and make
sure that the engine stop switch is
set to “”.
The following warning lights
should come on for a few seconds,
then go off.
Fuel level warning light
Coolant temperature warning light
Engine trouble warning light
NOTICE
ECA15482
If a warning light does not go off, see
page 3-2 for the corresponding
warning light circuit check.
2. Shift the transmission into the neu-
tral position. (See page 5-2.) The
Page 40 of 98
OPERATION AND IMPORTANT RIDING POINTS
5-2
1
2
3
4
5
6
7
8
9
neutral indicator light should come
on. If not, ask a Yamaha dealer to
check the electrical circuit.
3. Start the engine by pushing the
start switch.
NOTICE:
For maxi-
mum engine life, never acceler-
ate hard when the engine is
cold!
[ECA11041]
If the engine fails to start, release
the start switch, wait a few sec-
onds, and then try again. Each
starting attempt should be as short
as possible to preserve the bat-
tery. Do not crank the engine more
than 10 seconds on any one at-
tempt.
EAU16671
Shifting
Shifting gears lets you control the
amount of engine power available for
starting off, accelerating, climbing hills,
etc.
The gear positions are shown in the il-
lustration.
TIP
To shift the transmission into the neu-
tral position, press the shift pedal down
repeatedly until it reaches the end of its
travel, and then slightly raise it.
NOTICE
ECA10260
Even with the transmission inthe neutral position, do not
coast for long periods of time
with the engine off, and do not
tow the motorcycle for long dis-
tances. The transmission is
properly lubricated only when
the engine is running. Inade-
quate lubrication may damage
the transmission.
Always use the clutch while
changing gears to avoid damag-
ing the engine, transmission,
and drive train, which are not
designed to withstand the
shock of forced shifting.
1. Shift pedal
2. Neutral position
1
1 2 3 4 5N26
Page 45 of 98
PERIODIC MAINTENANCE AND ADJUSTMENT
6-3
2
3
4
5
67
8
9
EAU1770B
General maintenance and lubrication chart
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)
1
Air filter element
Clean.
√√
Replace.
√√
2
Clutch
Check operation.
Adjust.
√√√√√
3*
Front brake
Check operation, fluid level and
vehicle for fluid leakage.
Adjust brake lever free play.
√√√√√√
Replace brake pads. Whenever worn to the limit
4*
Rear brake
Check operation, fluid level and
vehicle for fluid leakage.
√√√√√√
Replace brake pads. Whenever worn to the limit
5*
Brake hoses
Check for cracks or damage.
√√√√√
Replace. Every 4 years
6*
Wheels
Check runout, spoke tightness
and for damage.
Tighten spokes if necessary.
√√√√
7*
Tires
Check tread depth and for dam-
age.
Replace if necessary.
Check air pressure.
Correct if necessary.
√√√√√
8*
Wheel bearings
Check bearing for looseness or
damage.
√√√√
9*
Swingarm
Check operation and for exces-
sive play.
√√√√
Page 46 of 98
PERIODIC MAINTENANCE AND ADJUSTMENT
6-4
1
2
3
4
5
6
7
8
9
10
Drive chain
Check chain slack, alignment and
condition.
Adjust and lubricate chain with a
special O-ring chain lubricant
thoroughly.Every 500 km (300 mi) and after washing the motorcycle or riding in the rain
11
*
Steering bearings
Check bearing play and steering
for roughness.
√√√√√
Lubricate with lithium-soap-based
grease.Every 50000 km (30000 mi)
12
*
Chassis fasteners
Make sure that all nuts, bolts and
screws are properly tightened.
√√√√√
13
Brake lever pivot
shaft
Lubricate with silicone grease.
√√√√√
14
Brake pedal pivot
shaft
Lubricate with lithium-soap-based
grease.
√√√√√
15
Clutch lever pivot
shaft
Lubricate with lithium-soap-based
grease.
√√√√√
16
Sidestand
Check operation.
Lubricate.
√√√√√
17
*
Sidestand switch
Check operation.
√√√√√√
18
*
Front fork
Check operation and for oil leak-
age.
√√√√
19
*
Shock absorber
assembly
Check operation and shock
absorber for oil leakage.
√√√√
20
*
Rear suspension
relay arm and con-
necting arm pivoting
points
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)