maintenance 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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1-1
1
SAFETY INFORMATION
EAU10281
MOTORCYCLES ARE SINGLE TRACK
VEHICLES. THEIR SAFE USE AND
OPERATION ARE DEPENDENT UPON
THE USE OF PROPER RIDING
TECHNIQUES AS WELL AS THE
EXPERTISE OF THE OPERATOR.
EVERY OPERATOR SHOULD KNOW
THE FOLLOWING REQUIREMENTS
BEFORE RIDING THIS MOTORCYCLE.
HE OR SHE SHOULD:l
OBTAIN THOROUGH
INSTRUCTIONS FROM A
COMPETENT SOURCE ON ALL
ASPECTS OF MOTORCYCLE
OPERATION.
l
OBSERVE THE WARNINGS AND
MAINTENANCE
REQUIREMENTS IN THE
OWNER’S MANUAL.
l
OBTAIN QUALIFIED TRAINING IN
SAFE AND PROPER RIDING
TECHNIQUES.
l
OBTAIN PROFESSIONAL
TECHNICAL SERVICE AS
INDICATED BY THE OWNER’S
MANUAL AND/OR WHEN MADE
NECESSARY BY MECHANICAL
CONDITIONS.Safe riding
l
Always make pre-operation checks.
Careful checks may help prevent
an accident.
l
This motorcycle is designed to
carry the operator and a passenger.
l
The failure of motorists to detect
and recognize motorcycles in traffic
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 appears to be
very effective in reducing the
chance of this type of accident.
Therefore:lWear a brightly colored jacket.lUse extra caution when you are
approaching and passing through
intersections, since intersections
are the most likely places for
motorcycle accidents to occur.lRide where other motorists can
see you. Avoid riding in another
motorist’s blind spot.
l
Many accidents involve
inexperienced operators. In fact, many operators who have been
involved in accidents do not even
have a current motorcycle license.
lMake sure that you are qualified
and that you only lend your
motorcycle to other qualified
operators.lKnow your skills and limits.
Staying within your limits may
help you to avoid an accident.lWe recommend that you
practice riding your motorcycle
where there is no traffic until you
have become thoroughly familiar
with the motorcycle and all of its
controls.
l
Many accidents have been caused
by error of the motorcycle operator.
A typical error made by the operator
is veering wide on a turn due to
EXCESSIVE SPEED or
undercornering (insufficient lean
angle for the speed).lAlways obey the speed limit and
never travel faster than warranted
by road and traffic conditions.lAlways signal before turning or
changing lanes. Make sure that
other motorists can see you.
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3-8
3
INSTRUMENT AND CONTROL FUNCTIONS
ECA10070
Immediately wipe off spilled fuel with
a clean, dry, soft cloth, since fuel may
deteriorate painted surfaces or plastic
parts.
EAU33500
Recommended fuel:REGULAR UNLEADED GASOLINE ONLY
Fuel tank capacity: 19.2 L (5.07 US gal) (4.22 Imp. gal)
Fuel reserve amount (when the fuel level warning light comes on):
4.5 L (1.19 US gal) (1.00 Imp. gal)
ECA11400
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 designed
to use regular unleaded gasoline with a
research octane number of 91 or higher.
If knocking (or pinging) occurs, use a gasoline of a different brand. Use of
unleaded fuel will extend spark plug life
and reduce maintenance costs.
EAU13431
Catalytic converterThis model is equipped with a catalytic
converter in the exhaust system.
EWA10860
The exhaust system is hot after
operation. Make sure that the exhaust
system has cooled down before
doing any maintenance work.
ECA10700
The following precautions must be
observed to prevent a fire hazard or
other damages.l
l l
l
l
Use only unleaded gasoline. The
use of leaded gasoline will cause
unrepairable damage to the
catalytic converter.
l
l l
l
l
Never park the vehicle near
possible fire hazards such as
grass or other materials that
easily burn.
l
l l
l
l
Do not allow the engine to idle
too long.
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6-1
6
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU17240
Safety is an obligation of the owner.
Periodic inspection, adjustment and
lubrication will keep your vehicle in the
safest and most efficient condition
possible. The most important points of
inspection, adjustment, and lubrication
are explained on the following pages.
The intervals given in the periodic
maintenance and lubrication chart
should be simply considered as a
general guide under normal riding
conditions. However, DEPENDING ON
THE WEATHER, TERRAIN,
GEOGRAPHICAL LOCATION, AND
INDIVIDUAL USE, THE
MAINTENANCE INTERVALS MAY
NEED TO BE SHORTENED.
EWA10320
If you are not familiar with
maintenance work, have a Yamaha
dealer do it for you.
EAU17390
Owner’s tool kit1. Owner’s tool kit
2. BandThe owner’s tool kit is located under the
seat. (See page 3-9.)
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.
However, additional tools such as a
torque wrench may be necessary to
perform certain maintenance work
correctly.If you do not have the tools or experience
required for a particular job, have a
Yamaha dealer perform it for you.
EWA10350
Modifications not approved by
Yamaha may cause loss of
performance and render the vehicle
unsafe for use. Consult a Yamaha
dealer before attempting any changes.
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6-2
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PERIODIC MAINTENANCE AND MINOR REPAIR
EAU17707
Periodic maintenance and lubrication chartl
l l
l
l
The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.
l
From 50000 km, repeat the maintenance intervals starting from 10000 km.
l
Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical
skills.
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6-3
6
PERIODIC MAINTENANCE AND MINOR REPAIR
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6-4
6
PERIODIC MAINTENANCE AND MINOR REPAIR
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6-5
6
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU18660
l
The air filter needs more frequent service if you are riding in unusuall\
y wet or dusty areas.
l
Hydraulic brake servicel
Regularly check and, if necessary, correct the brake fluid level.
l
Every two years replace the internal components of the brake master cylinder and caliper, and change the brake
fluid.
l
Replace the brake hoses every four years and if cracked or damaged.
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6-6
6
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU18721
Removing and installing the
cowling and panelsThe cowling and panels shown need to
be removed to perform some of the
maintenance jobs described in this
chapter. Refer to this section each time
the cowling or a panel needs to be
removed and installed.
1
1. Panel B
12
1. Cowling
2. Panel A
EAU19040
Cowling
2
1
1. Screw
2. Quick fastenerTo remo
ve the co
wling
1. Remove the seat and panel A. (See pages 3-9 and 6-6.) 2. Remove the screws, and then pull
the cowling off as shown.
To install the co
wling
1. Place the cowling in the original position, and then install the
screws.
2. Install the panel and the seat.
EAUW0110
Panels A and BTo remo
ve one of the panels
1
2
1. Screw
2. Quick fastener
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6-7
6
PERIODIC MAINTENANCE AND MINOR REPAIR
1. Remove the seat. (See page 3-9.)
2. Remove the screws, and then pullthe panel to the outside as shown.To install the panel1. Place the panel in the original position, and install the screws.
2. Install the seat.
EAU19630
Checking the spark plugl
The spark plug is an important
engine component, which is easy
to check. Since heat and deposits
will cause any spark plug to slowly
erode, the spark plug should be
removed and checked in
accordance with the periodic
maintenance and lubrication chart.
In addition, the condition of the
spark plug can reveal the condition
of the engine.
To remove the spark plug 1. Remove cowling. (See page 6-6.)
1. Spark plug cap2. Remove the spark plug cap.
3. Remove the spark plug as shown, with the spark plug wrench included
in the owner’s tool kit.
1. Spark plug wrenchTo check the spark plug1. Check that the porcelain insulator around the center electrode of the
spark plug is a medium-to-light tan
(the ideal color when the
motorcycle is ridden normally).If the spark plug shows a distinctly
different color, the engine could be
defective. Do not attempt to diagnose
such problems yourself. Instead, have
a Yamaha dealer check the motorcycle.2. Check the spark plug for electrodeerosion and excessive carbon or
other deposits, and replace it if
necessary.
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