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OWNER’S MANUAL
TTR250R(C)
LIT-11626-16-24 |
5GF-28199-14 |
EAU03438
EAU00000
INTRODUCTION
Congratulations on your purchase of the Yamaha TTR250R. This model is the result of Yamaha’s vast experience in the production of fine sporting, touring, and pacesetting racing machines. It represents the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields.
This manual will give you an understanding of the operation, inspection, and basic maintenance of this machine. If you have any questions concerning the operation or maintenance of your machine, please consult a Yamaha dealer.
EAU00003
IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following notations:
Q
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
wFailure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander or a person inspecting or repairing the
machine.
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A CAUTION indicates special precautions that must be taken to avoid damage |
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NOTE: |
A NOTE provides key information to make procedures easier or clearer. |
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NOTE:
8This manual should be considered a permanent part of this machine and should remain with it even if the machine is subsequently sold.
8Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most current product information available at the time of printing, there may be minor discrepancies between your machine and this manual. If you have any questions concerning this manual, please consult your Yamaha dealer.
IMPORTANT MANUAL INFORMATION
EW000000
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PLEASE READ THIS MANUAL AND THE “YOU AND YOUR MOTORCYCLE: RIDING TIPS” BOOKLET CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MACHINE. DO NOT ATTEMPT TO OPERATE THIS MACHINE UNTIL YOU HAVE ATTAINED ADEQUATE KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES. REGULAR INSPECTIONS AND CAREFUL MAINTENANCE, ALONG WITH GOOD RIDING SKILLS, WILL ENSURE THAT YOU SAFELY ENJOY THE CAPABILITIES AND THE RELIABILITY OF THIS MACHINE.
EAU00006
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THIS MACHINE IS DESIGNED AND MANUFACTURED FOR OFF-ROAD USE ONLY. IT IS ILLEGAL TO OPERATE THIS MACHINE ON ANY PUBLIC STREET, ROAD OR HIGHWAY. SUCH USE IS PROHIBITED BY LAW. THIS MACHINE COMPLIES WITH ALMOST ALL STATE OFF-HIGHWAY NOISE LEVEL AND SPARK ARRESTER LAWS AND REGULATIONS. PLEASE CHECK YOUR LOCAL RIDING LAWS AND REGULATIONS BEFORE OPERATING THIS MACHINE.
AFFIX DEALER
LABEL HERE
EAU04247
TTR250R
OWNER’S MANUAL
©2002 by Yamaha Motor Corporation, U.S.A. 1st edition, April 2002
All rights reserved.
Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited.
Printed in Japan.
P/N LIT-11626-16-24
EAU00009
TABLE OF CONTENTS
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...................................SAFETY INFORMATION |
1-1 |
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.......................................................Safe riding |
1-1 |
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Protective apparel ........................................... |
1-2 |
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Modifications ................................................... |
1-3 |
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Loading and accessories ................................ |
1-3 |
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Gasoline and exhaust gas ............................... |
1-5 |
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Location of important labels ............................ |
1-7 |
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DESCRIPTION |
2-1 |
2 |
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Left view .......................................................... |
2-1 |
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Right view ........................................................ |
2-2 |
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Controls and instruments ................................ |
2-3 |
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INSTRUMENT AND CONTROL |
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3 |
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FUNCTIONS ...................................................... |
3-1 |
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Main switch ..................................................... |
3-1 |
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Tripmeter ......................................................... |
3-1 |
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Handlebar switches ......................................... |
3-1 |
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Clutch lever ..................................................... |
3-2 |
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Shift pedal ....................................................... |
3-2 |
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Brake lever ...................................................... |
3-3 |
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Brake pedal ..................................................... |
3-3 |
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Fuel tank cap ................................................... |
3-3 |
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Fuel ................................................................. |
3-4 |
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Fuel tank breather hose .................................. |
3-5 |
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Fuel cock ......................................................... |
3-5 |
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Starter (choke) knob ........................................ |
3-6 |
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Seat ................................................................. |
3-7 |
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Adjusting the front fork .................................... |
3-7 |
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Adjusting the shock absorber assembly ........ |
3-10 |
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Starting circuit cut-off system ........................ |
3-12 |
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PRE-OPERATION CHECKS |
4-1 |
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4 |
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Pre-operation check list ................................... |
4-1 |
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OPERATION AND IMPORTANT RIDING |
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5 |
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POINTS .............................................................. |
5-1 |
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Starting and warming up a cold engine ........... |
5-1 |
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Starting a warm engine ................................... |
5-3 |
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Shifting ............................................................ |
5-3 |
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Engine break-in ............................................... |
5-4 |
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Parking ............................................................ |
5-5 |
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PERIODIC MAINTENANCE AND MINOR |
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6 |
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REPAIR .............................................................. |
6-1 |
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Owner’s tool kit ................................................ |
6-1 |
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Periodic maintenance and lubrication chart .... |
6-2 |
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Removing and installing the cowling and |
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panels .......................................................... |
6-5 |
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Checking the spark plug .................................. |
6-6 |
TABLE OF CONTENTS
Engine oil and oil filter element ....................... |
6-8 |
Cleaning the air filter element ....................... |
6-12 |
Cleaning the spark arrester ........................... |
6-13 |
Adjusting the carburetor ................................ |
6-14 |
Adjusting the throttle cable free play ............. |
6-14 |
Adjusting the valve clearance ....................... |
6-15 |
Tires .............................................................. |
6-15 |
Spoke wheels ................................................ |
6-17 |
Accessories and replacement parts .............. |
6-18 |
Adjusting the clutch lever free play ............... |
6-19 |
Adjusting the brake lever free play ................ |
6-19 |
Adjusting the brake pedal position ................ |
6-20 |
Checking the front and rear brake pads ........ |
6-21 |
Checking the brake fluid level ....................... |
6-21 |
Changing the brake fluid ............................... |
6-22 |
Drive chain slack ........................................... |
6-23 |
Lubricating the drive chain ............................ |
6-24 |
Checking and lubricating the cables ............. |
6-25 |
Checking and lubricating the throttle grip |
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and cable ................................................... |
6-26 |
Checking and lubricating the brake and |
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shift pedals ................................................. |
6-26 |
Checking and lubricating the brake and |
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clutch levers ............................................... |
6-26 |
Checking and lubricating the sidestand ........ |
6-27 |
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Checking the front fork .................................. |
6-27 |
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Checking the steering ................................... |
6-28 |
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Checking the wheel bearings ........................ |
6-28 |
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Battery ........................................................... |
6-29 |
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Replacing the fuse ....................................... |
6-30 |
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Replacing the headlight bulb ......................... |
6-31 |
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Replacing the taillight bulb ............................ |
6-33 |
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Supporting the machine ................................ |
6-33 |
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Front wheel ................................................... |
6-34 |
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Rear wheel .................................................... |
6-36 |
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Troubleshooting ............................................ |
6-38 |
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Troubleshooting chart ................................... |
6-39 |
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MACHINE CARE AND STORAGE |
7-1 |
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7 |
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Care ................................................................ |
7-1 |
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Storage ............................................................ |
7-4 |
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SPECIFICATIONS |
8-1 |
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Specifications .................................................. |
8-1 |
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CONSUMER INFORMATION |
9-1 |
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Identification numbers ..................................... |
9-1 |
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Key identification number ................................ |
9-1 |
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Vehicle identification number .......................... |
9-1 |
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Model label ...................................................... |
9-2 |
TABLE OF CONTENTS
Motorcycle noise regulation ............................ |
9-3 |
Maintenance record ........................................ |
9-5 |
Off-road motorcycle limited warranty .............. |
9-7 |
Yamaha extended service (Y.E.S.) ................. |
9-9 |
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EAU02912 |
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QSAFETY INFORMATION |
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MACHINES ARE SINGLE TRACK VEHICLES. THEIR SAFE USE AND OPERATION ARE DEPEN- |
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DENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EXPERTISE OF |
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THE OPERATOR. EVERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIREMENTS |
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BEFORE RIDING THIS MACHINE. |
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HE OR SHE SHOULD: |
1.OBTAIN THOROUGH INSTRUCTIONS FROM A COMPETENT SOURCE ON ALL ASPECTS OF MACHINE OPERATION.
2.OBSERVE THE WARNINGS AND MAINTENANCE REQUIREMENTS IN THE OWNER’S MANUAL.
3.OBTAIN QUALIFIED TRAINING IN SAFE AND PROPER RIDING TECHNIQUES.
4.OBTAIN PROFESSIONAL TECHNICAL SERVICE AS INDICATED BY THE OWNER’S MANUAL AND/OR WHEN MADE NECESSARY BY MECHANICAL CONDITIONS.
Safe riding
1.Always make pre-operation checks. Careful checks may help prevent an accident.
2.This machine is designed for off-road use only, therefore, it is illegal to operate it on public streets, roads, or highways. Off-road use on public lands may be illegal. Please check local regulations before riding.
3.This machine is designed to carry the operator only. No passengers.
4.Many accidents involve inexperienced operators.
a.Make sure that you are qualified and that you only lend your machine to other qualified operators.
b.Know your skills and limits. Staying within your limits may help you to avoid an accident.
5.Many accidents have been caused by error of the machine 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). Never travel faster than warranted by conditions.
1-1
QSAFETY INFORMATION
6.Ride cautiously in unfamiliar areas. You may encounter hidden obstacles that could cause an accident.
7.The posture of the operator is important for proper control. The operator should keep both hands
on the handlebar and both feet on the operator footrests during operation to maintain control of |
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the machine. |
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8. Never ride under the influence of alcohol or other drugs. |
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Protective apparel
The majority of fatalities from machine accidents are the result of head injuries. The use of a safety helmet is the single most critical factor in the prevention or reduction of head injuries.
1.Always wear an approved helmet.
2.Wear a face shield or goggles. Wind in your unprotected eyes could contribute to an impairment of vision that could delay seeing a hazard.
3.The use of a jacket, heavy boots, trousers, gloves, etc., is effective in preventing or reducing abrasions or lacerations.
4.Never wear loose-fitting clothes, otherwise they could catch on the control levers, footrests, or wheels and cause injury or an accident.
5.Never touch the engine or exhaust system during or after operation. They become very hot and can cause burns. Always wear protective clothing that covers your legs, ankles, and feet.
1-2
QSAFETY INFORMATION
Modifications
Modifications made to this machine not approved by Yamaha, or the removal of original equipment, 1 may render the machine unsafe for use and may cause severe personal injury. Modifications may
also make your machine illegal to use.
Loading and accessories
Adding accessories or cargo to your machine can adversely affect stability and handling if the weight distribution of the machine is changed. To avoid the possibility of an accident, use extreme caution when adding cargo or accessories to your machine. Use extra care when riding a machine that has added cargo or accessories. Here are some general guidelines to follow if loading cargo or adding accessories to your machine:
Loading
The total weight of the operator, accessories and cargo must not exceed the maximum load limit of 90 kg (198 lb). When loading within this weight limit, keep the following in mind:
1.Cargo and accessory weight should be kept as low and close to the machine as possible. Make sure to distribute the weight as evenly as possible on both sides of the machine to minimize imbalance or instability.
2.Shifting weights can create a sudden imbalance. Make sure that accessories and cargo are securely attached to the machine before riding. Check accessory mounts and cargo restraints frequently.
3.Never attach any large or heavy items to the handlebar, front fork, or front fender. These items, including such cargo as sleeping bags, duffel bags, or tents, can create unstable handling or a slow steering response.
1-3
QSAFETY INFORMATION
Accessories
Genuine Yamaha accessories have been specifically designed for use on this machine. Since Yamaha cannot test all other accessories that may be available, you must personally be responsible 1 for the proper selection, installation and use of non-Yamaha accessories. Use extreme caution when selecting and installing any accessories.
Keep these guidelines in mind for mounting accessories in addition to those provided under “Loading”.
1.Never install accessories or carry cargo that would impair the performance of your machine. Carefully inspect the accessory before using it to make sure that it does not in any way reduce ground clearance or cornering clearance, limit suspension travel, steering travel or control operation, or obscure lights or reflectors.
a.Accessories fitted to the handlebar or the front fork area can create instability due to improper weight distribution or aerodynamic changes. If accessories are added to the handlebar or front fork area, they must be as lightweight as possible and should be kept to a minimum.
b.Bulky or large accessories may seriously affect the stability of the machine due to aerodynamic effects. Wind may attempt to lift the machine, or the machine may become unstable in cross winds.
c.Certain accessories can displace the operator from his or her normal riding position. This improper position limits the freedom of movement of the operator and may limit control ability, therefore, such accessories are not recommended.
2.Use caution when adding electrical accessories. If electrical accessories exceed the capacity of the machine’s electrical system an electric failure could result, which could cause a dangerous loss of lights or engine power.
1-4
QSAFETY INFORMATION
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Gasoline and exhaust gas |
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1. GASOLINE IS HIGHLY FLAMMABLE: |
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a. Always turn the engine off when refueling. |
b.Take care not to spill any gasoline on the engine or exhaust pipe(s)/muffler(s) when refueling.
c.Never refuel while smoking or in the vicinity of an open flame.
2.Never start the engine or let it run for any length of time in a closed area. The exhaust fumes are poisonous and may cause loss of consciousness and death within a short time. Always operate your machine in an area that has adequate ventilation.
3.Always turn the engine off before leaving the machine unattended and remove the key from the main switch. When parking the machine, note the following:
a.The engine and exhaust pipe(s)/muffler(s) may be hot, therefore, park the machine in a place where pedestrians or children are not likely to touch these hot areas.
b.Do not park the machine on a slope or soft ground, otherwise it may fall over.
c.Do not park the machine near a flammable source (e.g., a kerosene heater, or near an open flame), otherwise it could catch fire.
4.When transporting the machine in another vehicle, make sure that it is kept upright and that the fuel cock(s) are turned to “ON” or “RES” (for vacuum type)/”OFF” (for manual type). If the machine should lean over, gasoline may leak out of the carburetor or fuel tank.
5.If you should swallow any gasoline, inhale a lot of gasoline vapor, or allow gasoline to get into your eyes, see your doctor immediately. If any gasoline spills on your skin or clothing, immediately wash the affected area with soap and water and change your clothes.
1-5
QSAFETY INFORMATION
1
1-6
QSAFETY INFORMATION
EAU02977
Location of important labels
Please read the following important labels carefully before operating this machine.
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1-7
QSAFETY INFORMATION
1
qWARNING
Riding as a passenger can cause the vehicle to go out of control.
Loss of control can cause a collision or rollover, which can result in severe injury or death.
NEVER ride as a passenger.
3XJ-2151H-A0
3
q WARNING
8BEFORE YOU OPERATE THIS |
VEHICLE, READ |
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THE OWNER'S MANUAL AND |
ALL LABELS. |
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8NEVER CARRY A PASSENGER. You increase your risk of losing control if you carry a passenger.
8NEVER OPERATE THIS VEHICLE ON PUBLIC
ROADS. You can collide with another vehicle if you operate this vehicle on a public road.
8ALWAYS WEAR AN APPROVED MOTORCYCLE HELMET,eye protection, and protective clothing.
8EXPERIENCED RIDER ONLY.
5PA-2118K-00
2
qWARNING
This unit contains high pressure nitrogen gas. Mishandling can cause explosion.
8Read owner's manual for instructions.
8Do not incinerate, puncture or open.
YAMAHA |
4AA-22259-80 |
4
TIRE INFORMATION
Cold tire normal pressure should be set as follows.
FRONT : 100 kPa,{1.00 kgf/cm2}, 15 psi REAR : 100 kPa,{1.00 kgf/cm2}, 15 psi
3RV-21668-A0
1-8
EAU00026
DESCRIPTION
Left view
1 |
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3 |
4 |
5 |
2
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8 |
7 |
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6 |
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1. |
Headlight |
(page 6-31) |
6. |
Shock absorber rebound |
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2. |
Front fork air valve |
(page 3-7) |
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damping adjusting dial |
(page 3-11) |
3. |
Fuel cock |
(page 3-5) |
7. |
Shift pedal |
(page 3-2) |
4. |
Starter (choke) knob |
(page 3-6) |
8. |
Front fork damping adjusting |
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5. |
Air filter element |
(page 6-12) |
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screw |
(page 3-9) |
2-1
DESCRIPTION
Right view
9 |
10 |
11 |
12 |
13 |
2
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16 |
15 |
14 |
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9. |
Spark arrester |
(page 6-13) |
14. |
Engine oil filter element |
(page 6-9) |
10. |
Battery |
(page 6-29) |
15. |
Brake pedal |
(page 3-3, 6-20) |
11. |
Fuse |
(page 6-30) |
16. |
Shock absorber spring preload |
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12. |
Shock absorber compression |
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adjusting nut |
(page 3-10) |
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damping adjusting knob |
(page 3-11) |
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13. |
Main switch |
(page 3-1) |
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2-2
DESCRIPTION
Controls and instruments
1 2 3 4 5
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1. |
Clutch lever |
(page 3-2, 6-19) |
6. |
Throttle grip |
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(page 6-14) |
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2. |
Left handlebar switch |
(page 3-1) |
7. |
Fuel tank cap |
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(page 3-3) |
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3. |
Tripmeter |
(page 3-1) |
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4. |
Right handlebar switches |
(page 3-2) |
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5. |
Brake lever |
(page 3-3, 6-19) |
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2-3
EAU00027 |
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INSTRUMENT AND CONTROL FUNCTIONS |
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ON |
OFF |
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1. |
Tripmeter |
1. |
Light switch “:” |
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2. |
Reset knob |
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EAU00028 |
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EAU00118 |
Main switch
The main switch controls the ignition and lighting systems. The various main switch positions are described below.
EAU00036
ON
All electrical systems are supplied with power, and the engine can be started. The key cannot be removed.
EAU00038
OFF
All electrical systems are off. The key can be removed.
EAU01760
Tripmeter
The tripmeter shows the distance traveled since it was last set to zero with the reset knob. The tripmeter can be used to estimate the distance that can be traveled with a full tank of fuel. This information will enable you to plan future fuel stops.
Handlebar switches
EAU04305
Light switch “:”
Set this switch to “:” to turn on the headlight and the taillight.
ECA00037
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Always turn the key to “OFF” and light switch to “OFF” when the engine is not running, otherwise the headlight will stay on and the battery may discharge due to extended use.
3-1
INSTRUMENT AND CONTROL FUNCTIONS
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1.Engine stop switch “#/$”
2.Start switch “START”
EAU03890
Engine stop switch “#/$”
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 machine overturns or when the throttle cable is stuck.
EAU00141
Start switch “START”
Push this switch to crank the engine with the starter.
EC000005
cC
See page 5-1 for starting instructions prior to starting the engine.
1. Clutch lever
EAU00152
Clutch lever
The 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 for an explanation of the ignition circuit cut-off system.)
1 
1. Shift pedal
EAU00157
Shift pedal
The 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 6-speed constant-mesh transmission equipped on this machine.
3-2
INSTRUMENT AND CONTROL FUNCTIONS
1 |
1 |
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1. Brake lever
EAU00158
Brake lever
The brake lever is located at the right handlebar grip. To apply the front brake, pull the lever toward the handlebar grip.
1. Brake pedal
EAU00162
Brake pedal
The brake pedal is on the right side of the machine. To apply the rear brake, press down on the brake pedal.
1
a
3
1. Fuel tank cap a. Remove.
EAU00179
Fuel tank cap
To remove the fuel tank cap, turn it counterclockwise, and then pull it off. To install the fuel tank cap, insert it into the tank opening, and then turn it clockwise.
EWA00025
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Make sure that the fuel tank cap is properly closed before riding.
3-3
INSTRUMENT AND CONTROL FUNCTIONS
1 2
3
1.Filler tube
2.Fuel level
EAU03753
Fuel
Make sure that there is sufficient fuel in the tank. Fill the fuel tank to the bottom of the filler tube as shown.
EW000130
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8Do not overfill the fuel tank, otherwise it may overflow when the fuel warms up and expands.
8Avoid spilling fuel on the hot engine.
EAU00185
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Immediately wipe off spilled fuel with a clean, dry, soft cloth, since fuel may deteriorate painted surfaces or plastic parts.
EAU04265
Recommended fuel: UNLEADED GASOLINE ONLY
Fuel tank capacity: Total amount:
10.0 L
(2.2 lmp gal, 2.64 US gal) Reserve amount:
2.0 L
(0.44 lmp gal, 0.53 US gal)
ECA00104
cC
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.
3-4
INSTRUMENT AND CONTROL FUNCTIONS
Your Yamaha engine has been designed to use regular unleaded gasoline with a pump octane number [(R+M)/2] of 86 or higher, or a research octane number of 91 or higher. If knocking (or pinging) occurs, use a gasoline of a different brand or premium unleaded fuel. Use of unleaded fuel will extend spark plug life and reduce maintenance costs.
Gasohol
There are two types of gasohol: gasohol containing ethanol and that containing methanol. Gasohol containing ethanol can be used if the ethanol content does not exceed 10%. Gasohol containing methanol is not recommended by Yamaha because it can cause damage to the fuel system or vehicle performance problems.
1
1. Fuel tank breather hose
EAU02955
Fuel tank breather hose
Before operating the machine:
8Check the fuel tank breather hose connection.
8Check the fuel tank breather hose for cracks or damage, and replace it if damaged.
8Make sure that the end of the fuel tank breather hose is not blocked, and clean it if necessary.
OFF: closed position |
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RES |
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OFF |
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ON |
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1 |
3 |
1. Arrow mark positioned over “OFF”
EAU03050
Fuel cock
The fuel cock supplies fuel from the tank to the carburetor while filtering it also.
The fuel cock has three positions:
OFF
With the lever in this position, fuel will not flow. Always return the lever to this position when the engine is not running.
3-5
INSTRUMENT AND CONTROL FUNCTIONS
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ON: normal position |
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RES |
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OFF |
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ON |
1 |
1. Arrow mark positioned over “ON”
ON
With the lever in this position, fuel flows to the carburetor. Normal riding is done with the lever in this position.
RES: reserve position |
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RES |
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OFF |
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FUEL |
1 |
ON |
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1. Arrow mark positioned over “RES”
RES
This indicates reserve. If you run out of fuel while riding, move the lever to this position. Fill the tank at the first opportunity. Be sure to set the lever back to “ON” after refueling!
b a 
1
1.Starter (choke) knob “1”
EAU04038
Starter (choke) knob “1”
Starting a cold engine requires a richer air-fuel mixture, which is supplied by the starter (choke).
Move the knob in direction a to turn on the starter (choke).
Move the knob in direction b to turn off the starter (choke).
3-6
INSTRUMENT AND CONTROL FUNCTIONS
1
1. Bolt (×2)
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Projection (×2) |
2. |
Seat holder (×2) |
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Adjusting the front fork
The front fork is equipped with air valves for adjusting the spring rate and screws for adjusting the damping force.
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There should be no difference in air pressure between the fork legs.
Seat
To remove the seat
Remove the bolts, and then pull the seat off.
To install the seat
1.Insert the projections on the front of the seat into the seat holders as shown.
2.Place the seat in the original position, and then tighten the bolts.
NOTE:
Make sure that the seat is properly secured before riding.
Spring rate
The total spring rate is adjusted by changing the air pressure as follows.
1.Lift the front wheel off the ground according to the procedure on page 6-33.
NOTE:
When checking and adjusting the air pressure, there should be no weight on the front end of the machine.
3-7
INSTRUMENT AND CONTROL FUNCTIONS
2 1
3
1.Air valve cap
2.Air valve
2.Remove the air valve cap from each fork leg.
3.Check the air pressure in each fork leg with an air pressure gauge.
NOTE:
An optional air pressure gauge is available at a Yamaha dealer.
4.To increase the spring rate and thereby harden the suspension, increase the air pressure with an air pump. To decrease the spring rate and thereby soften the suspension, decrease the air pressure by pushing each valve stem down.
Spring rate: Minimum (soft):
Air pressure = 0 kPa (0 kgf/cm2, 0 psi)
Standard:
Air pressure = 0 kPa (0 kgf/cm2, 0 psi)
Maximum (hard):
Air pressure = 40 kPa (0.4 kgf/cm2, 5.8 psi)
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Never exceed the maximum air pressure, otherwise the front fork oil seals may become damaged.
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Always adjust both fork legs equally, otherwise poor handling and loss of stability may result.
5.Securely install the air valve caps.
3-8
INSTRUMENT AND CONTROL FUNCTIONS
1
1. Rubber cap
1 b
a
1. Damping force adjusting screw
Damping force |
2. To increase |
the damping force |
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and thereby harden the damping, |
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each fork leg. |
turn the adjusting screw on each |
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fork leg in direction a. To |
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decrease the damping force and |
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thereby soften the damping, turn |
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the adjusting screw on each fork |
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leg in direction b. |
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Minimum (soft) |
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20 clicks in direction b* |
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Standard |
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11 clicks in direction b* |
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Maximum (hard) |
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1 click in direction b* |
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* With the adjusting screw fully turned in direction a |
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Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings.
3. Securely install the rubber caps.
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Be sure to install the rubber caps to prevent dust, etc. from entering the fork legs.
NOTE:
Although the total number of clicks of a damping force adjusting mechanism may not exactly match the above specifications due to small differences in production, the actual number of clicks always represents the entire adjusting range. To obtain a precise adjustment, it would be advisable to check the number of clicks of each damping force adjusting mechanism and to modify the specifications as necessary.
3-9
INSTRUMENT AND CONTROL FUNCTIONS
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Adjusting the shock |
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2 b |
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absorber assembly |
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This shock absorber assembly is |
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equipped with a spring preload |
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adjusting nut, a rebound damping |
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force adjusting dial and a compres- |
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a |
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sion damping force adjusting knob. |
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Locknut |
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Never attempt to turn an adjusting |
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Adjusting nut |
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mechanism beyond the maximum |
Spring preload |
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or minimum settings. |
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Loosen the locknut. |
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2. |
To increase the spring preload |
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and thereby harden the suspen- |
sion, turn the adjusting nut in direction a. To decrease the spring preload and thereby soften the suspension, turn the adjusting nut in direction b.
NOTE:
8A special wrench is needed to make this adjustment and it can be obtained at a Yamaha dealer.
8The spring preload setting is determined by measuring distance A, shown in the illustration. The shorter the distance A is, the higher the spring preload; the longer distance A is, the lower the spring preload.
Spring preload: Minimum (soft):
Distance A = 236 mm (9.3 in) Standard:
Distance A = 228 mm (9.0 in) Maximum (hard):
Distance A = 224 mm (8.8 in)
3.Tighten the locknut to the specified torque.
3-10
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