clutch YAMAHA YBR250 2007 Owners Manual

TABLE OF CONTENTESSAFETY INFORMATION .................... 1-1
DESCRIPTION ................................... 2-1Left 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
Speedometer ................................. 3 - 2
Tachometer .................................... 3 - 3
Multi-function display ................... 3 - 3
Handlebar switches ...................... 3 - 4
Clutch lever ................................... 3 - 5
Shift pedal ..................................... 3 - 6
Brake lever .................................... 3 - 6
Brake pedal ................................... 3 - 6
Fuel tank cap ................................. 3 - 7
Fuel ................................................ 3 - 7
Catalytic converter ........................ 3 - 8
Seat ................................................ 3 - 9
Helmet holder ................................ 3 - 9
Storage compartment .................3-10
Adjusting the shock aborber
assemblies ............................... 3-10
Luggage strap holders ...............3-11
Sidestand ..................................... 3-11
Ignition circuit cut-off system .....3-12 PRE-OPERATION CHECKS .............. 4-1
Pre-operation check list ............... 4 - 2
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
MINOR REPAIR .................................. 6-1 Owner’s tool kit .............................. 6 - 1
Periodic maintenance and lubrication chart ......................... 6 - 2
Removing and installing the cowling and panels ................... 6 - 6
Checking the spark plug .............. 6 - 7
Engine oil and oil filter element ... 6-8
Cleaning the air filter element ... 6-11
Checking the engine idling
speed ........................................ 6-12
Checking the throttle cable free play .................................... 6-12
Valve clearance .. ........................6-12
Tires ............................................. 6-13
Cast wheels ................................. 6-15
Adjusting the clutch lever free play .................................... 6-15Adjusting the brake pedal
position and free play .............6-16
Adjusting the rear brake light switch ........................................ 6-17
Checking the front brake pads
and rear brake shoes ..............6-17
Checking the front brake fluid level .......................................... 6-18
Changing the brake fluid ...........6-18
Drive chain slack ........................6-19
Cleaning and lubricating the
drive chain ............................... 6-20
Checking and lubricating the cables ....................................... 6-21
Checking and lubricating the throttle grip and cable .............6-21
Checking and lubricating the
brake and clutch levers ...........6-21
Checking and lubricating the brake and shift pedals ............6-22
Checking and lubricating the sidestand .................................. 6-22
Lubricating the rear
suspension .............................. 6-23
Checking the front fork ...............6-23
Checking the steering ................6-24
Checking the wheel bearings ....6-24
Battery .......................................... 6-24
Replacing the fuses ....................6-26
Replacing the headlight bulb ....6-27
Replacing a turn signal light bulb or the tail/brake light bulb .......6-28
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2-3
2
DESCRIPTION
EAU10430
Controls and instruments1. Clutch lever
2. Left handlebar switches
3. Speedometer
4. Display
5. Tachometer
6. Front brake lever
7. Throttle grip
8. Right handlebar switches
9. Main switch
10. Fuel tank cap
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3-5
3
INSTRUMENT AND CONTROL FUNCTIONS
EAU12350
Pass switch “
”
Press this switch to flash the headlight.
EAU12400
Dimmer switch “
/
”
Set this switch to “
” for the high beam
and to “
” for the low beam.
EAU12460
Turn signal switch “
/
”
To signal a right-hand turn, push this
switch to “
”. To signal a left-hand turn,
push this switch to “
”. When released,
the switch returns to the center position.
To cancel the turn signal lights, push the
switch in after it has returned to the
center position.
EAU12500
Horn switch “
”
Press this switch to sound the horn.
EAU12660
Engine stop switch “
/
”
Set this switch to “
” before starting
the engine. Set this switch to “
” to stop
the engine in case of an emergency, such
as when the motorcycle overturns or
when the throttle cable is stuck.EAU12710
Start switch “
”
Push this switch to crank the engine with
the starter.
ECA10050
See page 5-1 for starting instructions
prior to starting the engine.
EAU12820
Clutch lever1. Clutch leverThe clutch lever is located at the left
handlebar grip. To disengage the clutch,
pull the lever toward the handlebar 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 ignition circuit
cut-off system. (See page 3-12.)
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3-6
3
INSTRUMENT AND CONTROL FUNCTIONS
EAU12870
Shift pedal1. Shift pedalThe shift pedal is located on the left side
of the engine and is used in combination
with the clutch lever when shifting the
gears of the 5-speed constant-mesh
transmission equipped on this
motorcycle.
EAU12890
Brake lever
1
1. Front brake leverThe brake lever is located at the right
handlebar grip. To apply the front brake,
pull the lever toward the handlebar grip.
EAU12941
Brake pedal
1
1. Brake pedalThe brake pedal is on the right side of
the motorcycle. To apply the rear brake,
press down on the brake pedal.
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3-12
3
INSTRUMENT AND CONTROL FUNCTIONSbelow and have a Yamaha dealer
repair it if it does not function
properly.
EAU15311
Ignition circuit cut-off systemThe ignition circuit cut-off system
(comprising the sidestand switch, clutch
switch and neutral switch) has the
following functions. It prevents starting when the transmission is in gear and the
sidestand is up, but the clutch lever
is not pulled.
 It prevents starting when the transmission is in gear and the
clutch lever is pulled, but the
sidestand is still down.
 It cuts the running engine when the transmission is in gear and the
sidestand is moved down.
Periodically check the operation of the
ignition circuit cut-off system according
to the following procedure.
EWA10250
If a malfunction is noted, have a
Yamaha dealer check the system
before riding.
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3-13
3
INSTRUMENT AND CONTROL FUNCTIONS
With the engine turned off:
1. Move the sidestand down.
2. Make sure that the engine stop switch is turned on.
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.
This check is most reliable if performed with
a warmed-up engine.The neutral switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
The sidestand switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
The clutch switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
YES NO YES NO YES NO NOTE:
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5-1
5
OPERATION AND IMPORTANT RIDING POINTS
EAU15950
EWA10270
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Become thoroughly familiar
with all operating controls and
their functions before riding.
Consult a Yamaha dealer
regarding any control or function
that you do not thoroughly
understand.
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Never start the engine or operate
it in a closed area for any length
of time. Exhaust fumes are
poisonous, and inhaling them
can cause loss of
consciousness and death within
a short time. Always make sure
that there is adequate
ventilation.
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Before starting out, make sure
that the sidestand is up. If the
sidestand is not raised
completely, it could contact the
ground and distract the operator,
resulting in a possible loss of
control.
EAUW0090
Starting the engineIn order for the ignition circuit cut-off
system to enable starting, one of the
following conditions must be met:l
The transmission is in the neutral
position.
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The transmission is in gear with the
clutch lever pulled and the
sidestand up.
EWA10290
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Before starting the engine, check
the function of the ignition
circuit cut-off system according
to the procedure described on
page 3-12.
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Never ride with the sidestand
down.
1. Turn the key to “ON” and make sure
that the engine stop switch is set
to “
”.
ECAW0041
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The engine trouble warning light
should come on for a few
seconds, then go off. If the warning light does not go off,
ask a Yamaha dealer to check the
motorcycle.
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The speedometer needle will
sweep across the speed range
and then return to zero. The
tachometer needle will sweep
across the r/min range and then
return to zero. If either needle
does not sweep across their
ranges, ask a Yamaha dealer to
check the motorcycle.
2. Shift the transmission into the
neutral position.When the transmission is in the neutral
position, the neutral indicator light should
be on, otherwise have a Yamaha dealer
check the electrical circuit.3. Start the engine by pushing thestart switch.If the engine fails to start, release the
start switch, wait a few seconds, and
then try again. Each starting attempt
should be as short as possible to
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5-2
5
OPERATION AND IMPORTANT RIDING POINTSpreserve the battery. Do not crank the
engine more than 10 seconds on any
one attempt.
ECA11040
For maximum engine life, never
accelerate hard when the engine is
cold!The engine is warm when it quickly
responds to the throttle.
EAU16671
ShiftingShifting gears lets you control the
amount of engine power available for
starting off, accelerating, climbing hills,
etc.
The gear positions are shown in the
illustration.
1 2 3 4 5
N
2
1
1. Shift pedal
2. Neutral positionTo shift the transmission into the neutral
position, press the shift pedal down
repeatedly until it reaches the end of its
travel, and then slightly raise it.
ECA10260
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Even with the transmission in
the neutral position, do not coast
for long periods of time with the engine off, and do not tow the
motorcycle for long distances.
The transmission is properly
lubricated only when the engine
is running. Inadequate
lubrication may damage the
transmission.
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Always use the clutch while
changing gears to avoid
damaging the engine,
transmission, and drive train,
which are not designed to
withstand the shock of forced
shifting.
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6-10
6
PERIODIC MAINTENANCE AND MINOR REPAIR
2
2
1
1. Oil filter element
2. O-ringMake sure that the O-rings are properly
seated.7. Install the oil filter element coverby installing the bolts, then
tightening them to the specified
torque.Tightening torque:Oil filter element cover bolt: 10 Nm (1,0 m.kgf, 7.4 ft.lbf)8. Install the engine oil drain bolt, and
then tighten it to the specified
torque.
9. Install the oil filter element drain bolt, and then tighten it to the
specified torque.
Tightening torque:Engine oil drain bolt: 20 Nm (2.0 m.kgf, 15 ft.lbf)
Oil filter element drain bolt: 7 Nm (0.7 m.kgf, 5.25 ft.lbf)10. Add the specified amount of the
recommended engine oil, and then
install and tighten the oil filler bolt.Recommended engine oil:See page 8-1
Oil quantity: Without oil filter element
replacement:1.35 L (1.43 US qt) (1.19
Imp.qt)
With oil filter element replacement:1.45 L (1.53 US qt) (1.28
Imp.qt)
ECA11620
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In order to prevent clutch
slippage (since the engine oil
also lubricates the clutch), do not
mix any chemical additives. Do
not use oils with a diesel
specification of “CD” or oils of a
higher quality than specified. In addition, do not use oils labeled
“ENERGY CONSERVING II” or
higher.
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Make sure that no foreign
material enters the crankcase.
11. Start the engine, and then let it idle
for several minutes while checking
it for oil leakage. If oil is leaking,
immediately turn the engine off and
check for the cause.
12. Turn the engine off, and then check the oil level and correct it if
necessary.
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6
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU21960
Cast wheelsTo maximize the performance, durability,
and safe operation of your motorcycle,
note the following points regarding the
specified wheels.l
The wheel rims should be checked
for cracks, bends or warpage before
each ride. If any damage is found,
have a Yamaha dealer replace the
wheel. Do not attempt even the
smallest repair to the wheel. A
deformed or cracked wheel must be
replaced.
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The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced. An
unbalanced wheel can result in poor
performance, adverse handling
characteristics, and a shortened
tire life.
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Ride at moderate speeds after
changing a tire since the tire surface
must first be “broken in” for it to
develop its optimal characteristics.
EAU22020
Adjusting the clutch lever
free play1. Locknut
2. Clutch lever free play adjusting bolt
3. Clutch lever free playThe clutch lever free play should
measure 10.0 - 15.0 mm (0.39 - 0.59 in)
as shown. Periodically check the clutch
lever free play and, if necessary, adjust
it as follows.1. Loosen the locknut at the clutch lever.
2. To increase the clutch lever free play, turn the adjusting bolt in
direction (a). To decrease the clutch
lever free play, turn the adjusting
bolt in direction (b).
3. Tighten the locknut.
If the specified free play cannot be
obtained as described above or if the
clutch does not operate correctly, have
a Yamaha dealer check the internal
clutch mechanism.
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