Yamaha TTR250 User Manual

OWNER’S MANUAL

TTR250P(C)

LIT-11626-15-29

5GF-28199-13

EAU03438

EAU00000

INTRODUCTION

Congratulations on your purchase of the Yamaha TTR250P. 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.

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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.

	cC	A CAUTION indicates special precautions that must be taken to avoid damage to
		the machine.

NOTE: A NOTE provides key information to make procedures easier or clearer.

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

w

PLEASE READ THIS MANUAL AND THE “YOU AND YOUR MACHINE: 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.

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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 OFFHIGHWAY 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

TTR250P

OWNER’S MANUAL

©2001 by Yamaha Motor Corporation, U.S.A. 1st edition, June 2001

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-11626-15-29

EAU00009

TABLE OF CONTENTS

	1	..................................SAFETY INFORMATION	1-1
		......................................................Safe riding	1-1
		Protective apparel ..........................................	1-2
		Modifications ..................................................	1-3
		Loading and accessories ...............................	1-3
		Gasoline and exhaust gas .............................	1-5
		Location of important labels ...........................	1-7
		DESCRIPTION	2-1
	2
		Left view	2-1
		Right view ......................................................	2-2
		Controls and instruments ...............................	2-3
		INSTRUMENT AND CONTROL
	3
		FUNCTIONS	3-1
		Main switch ....................................................	3-1
		Tripmeter ........................................................	3-1
		Handlebar switches ........................................	3-1
		Clutch lever ....................................................	3-2
		Shift pedal ......................................................	3-2
		Brake lever .....................................................	3-3
		Brake pedal ....................................................	3-3
		Fuel tank cap .................................................	3-3
		Fuel ................................................................	3-4
		Fuel tank breather hose .................................	3-5

		Fuel cock ........................................................	3-5
		Starter (choke) knob .....................................	3-6
		Seat ................................................................	3-6
		Adjusting the front fork ...................................	3-7
		Adjusting the shock absorber assembly ........	3-9
		Starting circuit cut-off system .......................	3-12
		PRE-OPERATION CHECKS	4-1
	4
		Pre-operation check list	4-1
		OPERATION AND IMPORTANT RIDING
	5
		POINTS	5-1
		Starting and warming up a cold engine ..........	5-1
		Starting a warm engine ..................................	5-3
		Shifting ...........................................................	5-3
		Engine break-in ..............................................	5-4
		Parking ...........................................................	5-5
		PERIODIC MAINTENANCE AND MINOR
	6
		.............................................................REPAIR	6-1
		Owner’s tool kit ..............................................	6-1
		Periodic maintenance and lubrication chart ...	6-2
		Removing and installing the cowling and
		panels ..........................................................	6-5
		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 ............	6-17
Adjusting the clutch lever free play ..............	6-18
Adjusting the brake lever free play ...............	6-19
Adjusting the brake pedal position ...............	6-19
Checking the front and rear brake pads .......	6-20
Checking the brake fluid level ......................	6-21
Changing the brake fluid ..............................	6-22
Drive chain slack ..........................................	6-22
Lubricating the drive chain ...........................	6-24
Checking and lubricating the cables ............	6-24
Checking and lubricating the throttle grip
and cable .....................................................	6-25
Checking and lubricating the brake and
shift pedals .................................................	6-25
Checking and lubricating the brake and
clutch levers ...............................................	6-26
Checking and lubricating the sidestand .......	6-26

		Checking the front fork .................................	6-26
		Checking the steering ..................................	6-27
		Checking the wheel bearings .......................	6-28
		Battery ..........................................................	6-28
		Replacing the fuse ......................................	6-30
		Replacing the headlight bulb ........................	6-30
		Replacing the taillight bulb ...........................	6-32
		Supporting the machine ...............................	6-33
		Front wheel ..................................................	6-33
		Rear wheel ...................................................	6-35
		Troubleshooting ...........................................	6-37
		Troubleshooting chart ..................................	6-38
		MACHINE CARE AND STORAGE	7-1
	7
		Care	7-1
		Storage ..........................................................	7-4
		SPECIFICATIONS	8-1
	8
		CONSUMER INFORMATION	9-1
	9
		Identification numbers ....................................	9-1
		Key identification number ...............................	9-1
		Vehicle identification number .........................	9-1
		Model label .....................................................	9-2

TABLE OF CONTENTS

Motorcycle noise regulation ...........................	9-3
Maintenance record .......................................	9-4
Off-road motorcycle limted warranty ................	9-6
Yamaha extended service (Y.E.S.) ................	9-8

EAU02912

Q SAFETY INFORMATION

		MACHINES ARE SINGLE TRACK VEHICLES. THEIR SAFE USE AND OPERATION ARE DEPEN-
		DENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EXPERTISE OF
	1	THE OPERATOR. EVERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIREMENTS
		BEFORE RIDING THIS MACHINE.
		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

Q SAFETY 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	1
the machine.
8. Never ride under the influence of alcohol or other drugs.

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

Q SAFETY 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

Q SAFETY 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

	Q SAFETY INFORMATION
	Gasoline and exhaust gas
	1. GASOLINE IS HIGHLY FLAMMABLE:
1	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

Q SAFETY INFORMATION

1

1-6

Q SAFETY INFORMATION

Location of important labels

Please read the following important labels carefully before operating this machine.

1

1

2

3

4

EAU02977

Labels, location of

1-7

Q SAFETY INFORMATION

1

q WARNING

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

8 BEFORE YOU OPERATE THIS VEHICLE, READ

1

THE OWNER'S MANUAL AND ALL LABELS.

8 NEVER CARRY A PASSENGER. You increase your risk of losing control if you carry a passenger.

8 NEVER OPERATE THIS VEHICLE ON PUBLIC ROADS. You can collide with another vehicle if you operate this vehicle on a public road.

8 ALWAYS WEAR AN APPROVED MOTORCYCLE HELMET,eye protection, and protective clothing.

8 EXPERIENCED RIDER ONLY.

5PA-2118K-00

2

q WARNING

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

2

3

4

5

2

	8	7		6
1.	Headlight	(page 6-30)	6.	Shock absorber rebound
2.	Front fork air valve	(page 3-7)		damping adjusting dial	(page 3-10)
3.	Fuel cock	(page 3-5)	7.	Shift pedal	(page 3-2)
4.	Starter (choke) knob	(page 3-6)	8.	Front fork compression damping
5.	Air filter element	(page 6-12)		adjusting screw	(page 3-8)

2-1

DESCRIPTION

Right view

9

10

11

12

13

2

		15		14
9.	Spark arrester	(page 6-13)	14.	Engine oil filter element	(page 6-10)
10.	Battery	(page 6-28)	15.	Brake pedal	(page 3-3, 6-19)
11.	Fuse	(page 6-30)
12.	Shock absorber compression
	damping adjusting knob	(page 3-11)
13.	Main switch	(page 3-1)

2-2

DESCRIPTION

Controls and instruments

1

2

3

4

5

2

			7			6
1.	Clutch lever	(page 3-2, 6-18)	6.		Throttle grip		(page 6-14)
2.	Left handlebar switch	(page 3-1)	7.		Fuel tank cap		(page 3-3)
3.	Tripmeter	(page 3-1)
4.	Right handlebar switches	(page 3-2)
5.	Brake lever	(page 3-3, 6-19)

2-3

	EAU00027			INSTRUMENT AND CONTROL FUNCTIONS
	ON	OFF			1
							1
				2				3
			1.	Tripmeter			1. Light switch “:”
		EAU00028	2.	Reset knob				EAU00118
						EAU01760
	Main switch						Handlebar switches
		Main switch	Tripmeter					Handlebar switches
	The main switch controls the ignition							EAU04305
			The tripmeter		shows the	distance
	and lighting systems. The various						Light switch “:”
			traveled since it was last set to zero
							Set this switch to “:” to turn on the
	main switch positions are described
			with the reset		knob. The	tripmeter
							headlight and taillight.
	below.
			can be used to estimate the distance
								ECA00037
		EAU00036	that can be traveled with a full tank of				cC
			fuel. This information will enable you
	ON						Always turn the key to “OFF” and
			to plan future fuel stops.
	All electrical systems are supplied						light switch to “OFF” when the
	with power, and the engine can be						engine is not running, otherwise
	started. The key cannot be removed.						the headlight will stay on and the
							battery may discharge due to
		EAU00038					extended use.
	OFF

All electrical systems are off. The key can be removed.

3-1

INSTRUMENT AND CONTROL FUNCTIONS

						1
	3	1	2
	1. Engine stop switch “#/$”				1. Clutch lever
	2. Start switch “START”						EAU00152
				EAU03890
					Clutch lever
	Engine stop switch “#/$”						Clutch lever
				Engine stop switch	The clutch lever is located at the left
	Set this switch to “#” before starting
					handlebar grip. To disengage the
	the engine. Set this switch to “$” to
					clutch, pull the lever toward the han-
	stop the engine in case of an emer-
					dlebar	grip. To engage the	clutch,
	gency,	such as	when the	machine
					release	the lever. The lever	should
	overturns or when the throttle cable is
					be pulled rapidly and released slowly
	stuck.
					for smooth clutch operation.
				EAU00141
					The clutch lever is equipped with a
	Start switch “START”			Start switch
	Push this switch to crank the engine				clutch switch, which is part of the igni-
	with the starter.				tion circuit cut-off system. (See page
	cC			EC000005 3-12 for an explanation of the ignition
					circuit cut-off system.)

See page 5-1 for starting instructions prior to starting the engine.

1

1. Shift pedal

	EAU00157
Shift pedal	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

1. Brake lever

	EAU00158
Brake lever	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	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. Open.

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

w

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	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

w

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

cC

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.

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.

3-4

INSTRUMENT AND CONTROL FUNCTIONS

1

1. Fuel tank breather hose

EAU02955

Fuel tank breather hose 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

RES

OFF

ON

1

1. Arrow mark positioned over “OFF”

	EAU03050
Fuel cock	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.

ON: normal position
RES
OFF
FUEL
ON
ON	1	3
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.

3-5

INSTRUMENT AND CONTROL FUNCTIONS

RES: reserve position
RES
OFF
FUEL	1
ON
3

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) knob1“”

EAU04038

Starter (choke) knob “1” Starter (choke) knob

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).

1

1. Bolt (×2)

EAU00240

Seat

To remove the seat

Remove the bolts, and then pull the seat off.

3-6

		INSTRUMENT AND CONTROL FUNCTIONS
	1	EAU04363		2 1
		Adjusting the front fork
		The front fork is equipped with air
		valves for adjusting the spring rate
		and screws for adjusting the damping
		force.
		EW000036
	2	w		3
		There should be no difference in
1. Projection (×2)		air pressure between the fork legs.	1.	Air valve cap
2.	Seat holder (×2)		2.	Air valve

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 motorcycle.

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.

3-7

INSTRUMENT AND CONTROL FUNCTIONS

		Spring rate
		Minimum (soft):
		Air pressure = 0 kPa			1
		(0 kgf/cm2, 0 psi)						1
		Standard:
		Air pressure = 0 kPa
		(0 kgf/cm2, 0 psi)					b	a
3
		Maximum (hard):
		Air pressure = 40 kPa			1. Rubber cap		1. Compression damping force adjusting
		(0.4 kgf/cm2, 5.8 psi)			Damping force		screw
							2. To increase the	damping force
					1. Remove the rubber cap from
			EC000012				and thereby harden the damping,
		cC			each fork leg.
							turn the adjusting screw on each
		Never exceed the maximum air
							fork leg in direction a. To
		pressure, otherwise the front fork					decrease the damping force and
		oil seals may become damaged.					thereby soften the damping, turn
							the adjusting screw on each fork

	EW000035	leg in direction b.
w

Always adjust both fork legs equally, otherwise poor handling and loss of stability may result.

5.Securely install the air valve caps.

Minimum (soft)	20 clicks in direction b*
Standard	11 clicks in direction b*
Maximum (hard)	1 click in direction b*

* With the adjusting screw fully turned in direction a

3-8

INSTRUMENT AND CONTROL FUNCTIONS

EC000015

cC

Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings.

3. Securely install the rubber caps.

ECA00034

cC

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.

	EAU03676
Adjusting the shock
absorber assembly	Shock absorber assembly, adjusting

This shock absorber assembly is equipped with a spring preload adjusting nut, a rebound damping force adjusting dial and a compression damping force adjusting knob.

EC000015

cC

Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings.

1	2 b
	a
	A	3

1.Locknut

2.Adjusting nut

Spring preload

1.Loosen the locknut.

2.To increase the spring preload and thereby harden the suspension, turn the adjusting nut in direction a. To decrease the spring preload and thereby soften the suspension, turn the adjusting nut in direction b.

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INSTRUMENT AND CONTROL FUNCTIONS

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.

3The 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.

Tightening torque: Locknut:

70 Nm (7.0 m0kgf, 51 ft0lb)

ECA00076

cC

Always tighten the locknut against the adjusting nut, and then tighten the locknut to the specified torque.

1

ba

1. Rebound damping force adjusting dial

Rebound damping force

To increase the rebound damping force and thereby harden the rebound damping, turn the adjusting dial in direction a. To decrease the rebound damping force and thereby soften the rebound damping, turn the adjusting dial in direction b.

Minimum (soft)	16 clicks in direction b*
Standard	8 clicks in direction b*
Maximum (hard)	1 click in direction b*

* With the adjusting dial fully turned in direction a

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