2016 YAMAHA MT-25 fork

Table of contentsSafety information............................ 1-1
Description....................................... 2-1
Left view ......................................... 2-1
Right view ....................................... 2-2
Controls and instruments ............... 2-3
Instrument and control functions... 3-1
Main switch/steering lock............... 3-1
Indicator lights and warning
lights............................................ 3-2
Multi-function meter unit ................ 3-4
Handlebar switches ...................... 3-10
Clutch lever .................................. 3-11
Shift pedal .................................... 3-12
Brake lever.................................... 3-12
Brake pedal .................................. 3-12
Fuel tank cap ................................ 3-13
Fuel ............................................... 3-13
Fuel tank breather hose and
overflow hose ............................ 3-15
Catalytic converter ....................... 3-15
Seats ............................................ 3-16
Helmet holders ............................. 3-17
Storage compartment .................. 3-18
Adjusting the shock absorber
assembly ................................... 3-18
Luggage strap holders ................. 3-19
Sidestand ..................................... 3-19
Ignition circuit cut-off system ....... 3-20For your safety – pre-operation
checks............................................... 4-1
Operation and important riding
points................................................. 5-1
Starting the engine .......................... 5-1
Shifting ............................................ 5-2
Tips for reducing fuel
consumption ................................ 5-3
Engine break-in ............................... 5-3
Parking ............................................ 5-4
Periodic maintenance and
adjustment........................................ 6-1
Owner’s tool kit ............................... 6-1
Periodic maintenance chart for
the emission control system ........ 6-3
General maintenance and
lubrication chart ........................... 6-4
Checking the spark plugs ............... 6-8
Engine oil and oil filter cartridge...... 6-9
Coolant.......................................... 6-12
Replacing the air filter element
and cleaning the check hose..... 6-13
Checking the throttle grip
free play ..................................... 6-15
Valve clearance ............................. 6-15
Tires .............................................. 6-15
Cast wheels................................... 6-17
Adjusting the clutch lever
free play ..................................... 6-17Checking the brake lever
free play..................................... 6-18
Brake light switches ..................... 6-19
Checking the front and rear
brake pads ................................ 6-19
Checking the brake fluid level ...... 6-20
Changing the brake fluid .............. 6-21
Drive chain slack........................... 6-21
Cleaning and lubricating the
drive chain ................................. 6-23
Checking and lubricating the
cables ........................................ 6-24
Checking and lubricating the
throttle grip and cable ............... 6-24
Checking and lubricating the
brake and shift pedals............... 6-24
Checking and lubricating the
brake and clutch levers ............. 6-25
Checking and lubricating the
sidestand................................... 6-26
Lubricating the swingarm
pivots......................................... 6-26
Checking the front fork ................. 6-26
Checking the steering................... 6-27
Checking the wheel bearings ....... 6-27
Battery .......................................... 6-28
Replacing the fuses ...................... 6-29
Replacing the headlight bulb ........ 6-30
Auxiliary light ................................ 6-31
Tail/brake light .............................. 6-31UB04E0E0.book Page 1 Wednesday, September 2, 2015 3:51 PM

Safety information
1-3
1Avoid Carbon Monoxide Poisoning
All engine exhaust contains carbon
monoxide, a deadly gas. Breathing
carbon monoxide can cause head-
aches, dizziness, drowsiness, nausea,
confusion, and eventually death.
Carbon Monoxide is a colorless, odor-
less, tasteless gas which may be
present even if you do not see or smell
any engine exhaust. Deadly levels of
carbon monoxide can collect rapidly
and you can quickly be overcome and
unable to save yourself. Also, deadly
levels of carbon monoxide can linger
for hours or days in enclosed or poorly
ventilated areas. If you experience any
symptoms of carbon monoxide poi-
soning, leave the area immediately, get
fresh air, and SEEK MEDICAL TREAT-
MENT.
Do not run engine indoors. Even if
you try to ventilate engine exhaust
with fans or open windows and
doors, carbon monoxide can rap-
idly reach dangerous levels.
Do not run engine in poorly venti-
lated or partially enclosed areas
such as barns, garages, or car-
ports.Do not run engine outdoors where
engine exhaust can be drawn into
a building through openings such
as windows and doors.
Loading
Adding accessories or cargo to your
motorcycle can adversely affect stabil-
ity and handling if the weight distribu-
tion of the motorcycle is changed. To
avoid the possibility of an accident, use
extreme caution when adding cargo or
accessories to your motorcycle. Use
extra care when riding a motorcycle
that has added cargo or accessories.
Here, along with the information about
accessories below, are some general
guidelines to follow if loading cargo to
your motorcycle:
The total weight of the operator, pas-
senger, accessories and cargo must
not exceed the maximum load limit.
Operation of an overloaded vehicle
could cause an accident.When loading within this weight limit,
keep the following in mind:
Cargo and accessory weight
should be kept as low and close to
the motorcycle as possible. Se-
curely pack your heaviest items as
close to the center of the vehicle
as possible and make sure to dis-
tribute the weight as evenly as
possible on both sides of the mo-
torcycle to minimize imbalance or
instability.
Shifting weights can create a sud-
den imbalance. Make sure that
accessories and cargo are se-
curely attached to the motorcycle
before riding. Check accessory
mounts and cargo restraints fre-
quently.
• Properly adjust the suspension
for your load (suspension-ad-
justable models only), and
check the condition and pres-
sure of your tires.
• 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
Maximum load:
160 kg (353 lb)
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Safety information
1-4
1 tents, can create unstable han-
dling or a slow steering re-
sponse.
This vehicle is not designed to
pull a trailer or to be attached to
a sidecar.
Genuine Yamaha Accessories
Choosing accessories for your vehicle
is an important decision. Genuine
Yamaha accessories, which are avail-
able only from a Yamaha dealer, have
been designed, tested, and approved
by Yamaha for use on your vehicle.
Many companies with no connection
to Yamaha manufacture parts and ac-
cessories or offer other modifications
for Yamaha vehicles. Yamaha is not in
a position to test the products that
these aftermarket companies produce.
Therefore, Yamaha can neither en-
dorse nor recommend the use of ac-
cessories not sold by Yamaha or
modifications not specifically recom-
mended by Yamaha, even if sold and
installed by a Yamaha dealer.Aftermarket Parts, Accessories, and
Modifications
While you may find aftermarket prod-
ucts similar in design and quality to
genuine Yamaha accessories, recog-
nize that some aftermarket accesso-
ries or modifications are not suitable
because of potential safety hazards to
you or others. Installing aftermarket
products or having other modifications
performed to your vehicle that change
any of the vehicle’s design or operation
characteristics can put you and others
at greater risk of serious injury or
death. You are responsible for injuries
related to changes in the vehicle.
Keep the following guidelines in mind,
as well as those provided under “Load-
ing” when mounting accessories.
Never install accessories or carry
cargo that would impair the per-
formance of your motorcycle.
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 opera-
tion, or obscure lights or reflec-
tors.
• Accessories fitted to the han-
dlebar or the front fork area can
create instability due to improp-
er weight distribution or aerody-
namic 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.
• Bulky or large accessories may
seriously affect the stability of
the motorcycle due to aerody-
namic effects. Wind may at-
tempt to lift the motorcycle, or
the motorcycle may become
unstable in cross winds. These
accessories may also cause in-
stability when passing or being
passed by large vehicles.
• Certain accessories can dis-
place the operator from his or
her normal riding position. This
improper position limits the
freedom of movement of the
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Safety information
1-5
1operator and may limit control
ability, therefore, such accesso-
ries are not recommended.
Use caution when adding electri-
cal accessories. If electrical ac-
cessories exceed the capacity of
the motorcycle’s electrical sys-
tem, an electric failure could re-
sult, which could cause a
dangerous loss of lights or engine
power.
Aftermarket Tires and Rims
The tires and rims that came with your
motorcycle were designed to match
the performance capabilities and to
provide the best combination of han-
dling, braking, and comfort. Other
tires, rims, sizes, and combinations
may not be appropriate. Refer to page
6-15 for tire specifications and more in-
formation on replacing your tires.
Transporting the Motorcycle
Be sure to observe following instruc-
tions before transporting the motorcy-
cle in another vehicle.
Remove all loose items from the
motorcycle.Check that the fuel cock (if
equipped) is in the “OFF” position
and that there are no fuel leaks.
Point the front wheel straight
ahead on the trailer or in the truck
bed, and choke it in a rail to pre-
vent movement.
Shift the transmission in gear (for
models with a manual transmis-
sion).
Secure the motorcycle with tie-
downs or suitable straps that are
attached to solid parts of the mo-
torcycle, such as the frame or up-
per front fork triple clamp (and not,
for example, to rubber-mounted
handlebars or turn signals, or
parts that could break). Choose
the location for the straps carefully
so the straps will not rub against
painted surfaces during transport.
The suspension should be com-
pressed somewhat by the tie-
downs, if possible, so that the mo-
torcycle will not bounce exces-
sively during transport.
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Periodic maintenance and adjustment
6-6
6
21*Front fork• Check operation and for oil leak-
age.√√√√
22*Shock absorber as-
sembly• Check operation and shock ab-
sorber for oil leakage.√√√√
23 Engine oil• Change. (See pages 3-4 and 6-9.)√When the oil change indicator flashes
• Check oil level and vehicle for oil
leakage.Every 5000 km (3000 mi)√
24Engine oil filter car-
tridge•Replace.√√√
25*Cooling system• Check coolant level and vehicle
for coolant leakage.√√√√√
• Change coolant. Every 3 years
26*Front and rear
brake switches• Check operation.√√√√√√
27Moving parts and
cables• Lubricate.√√√√√
28*Throttle grip• Check operation.
• Check throttle grip free play, and
adjust if necessary.
• Lubricate cable and grip housing.√√√√√
29*Lights, signals and
switches• Check operation.
• Adjust headlight beam.√√√√√√ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING
ANNUAL
CHECK 1000 km
(600 mi)10000 km
(6000 mi)20000 km
(12000 mi)30000 km
(18000 mi)40000 km
(24000 mi)
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Periodic maintenance and adjustment
6-26
6
EAU23203
Checking and lubricating the
sidestandThe operation of the sidestand should
be checked before each ride, and the
sidestand pivot and metal-to-metal
contact surfaces should be lubricated
if necessary.
WARNING
EWA10732
If the sidestand does not move up
and down smoothly, have a Yamaha
dealer check or repair it. Otherwise,
the sidestand could contact the
ground and distract the operator, re-
sulting in a possible loss of control.
EAUM1653
Lubricating the swingarm piv-
otsThe swingarm pivots must be lubricat-
ed by a Yamaha dealer at the intervals
specified in the periodic maintenance
and lubrication chart.
EAU23273
Checking the front forkThe condition and operation of the
front fork must be checked as follows
at the intervals specified in the periodic
maintenance and lubrication chart.
To check the condition
Check the inner tubes for scratches,
damage and excessive oil leakage.
To check the operation
1. Place the vehicle on a level sur-
face and hold it in an upright posi-
tion. WARNING! To avoid injury,
securely support the vehicle so
there is no danger of it falling
over.
[EWA10752]
2. While applying the front brake,
push down hard on the handle-
bars several times to check if the
front fork compresses and re-
bounds smoothly.
Recommended lubricant:
Lithium-soap-based grease
Recommended lubricant:
Lithium-soap-based grease
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Periodic maintenance and adjustment
6-27
6
NOTICE
ECA10591
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or re-
pair it.
EAU23285
Checking the steeringWorn or loose steering bearings may
cause danger. Therefore, the operation
of the steering must be checked as fol-
lows at the intervals specified in the
periodic maintenance and lubrication
chart.
1. Raise the front wheel off the
ground. (See page 6-33.)
WARNING! To avoid injury, se-
curely support the vehicle so
there is no danger of it falling
over.
[EWA10752]
2. Hold the lower ends of the front
fork legs and try to move them for-
ward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the steer-
ing.
EAU23292
Checking the wheel bearingsThe front and rear wheel bearings must
be checked at the intervals specified in
the periodic maintenance and lubrica-
tion chart. If there is play in the wheel
hub or if the wheel does not turn
smoothly, have a Yamaha dealer
check the wheel bearings.
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Periodic maintenance and adjustment
6-34
6
EAU24361
Front wheel
EAUN0670
To remove the front wheel
WARNING
EWA10822
To avoid injury, securely support the
vehicle so there is no danger of it
falling over.1. Loosen the axle nut and the brake
caliper bolts.2. Lift the front wheel off the ground
according to the procedure in the
previous section “Supporting the
motorcycle”.
3. Remove the brake caliper (togeth-
er with the reflector on each side)
by removing the bolts. NOTICE:
Do not apply the brake after the
brake caliper has been re-
moved, otherwise the brake
pads will be forced shut.
[ECA22240]
4. Remove the axle nut.
5. Pull the wheel axle out, and then
remove the wheel.
To install the front wheel
1. Lift the wheel up between the fork
legs.2. Insert the wheel axle from the right
side and then install the axle nut.
3. Install the brake caliper (together
with the reflectors on each side)
by installing the bolts.
TIPMake sure that there is enough space
between the brake pads before install-
ing the brake caliper onto the brake
disc.4. Lower the front wheel so that it is
on the ground, and then put the
sidestand down.
5. Tighten the wheel axle and the
brake caliper bolts to the specified
torques.
6. Push down hard on the handlebar
several times to check for proper
fork operation.
1. Axle nut
1
1. Brake caliper bolt
1
Tightening torques:
Wheel axle:
60 Nm (6.0 m·kgf, 44 ft·lbf)
Brake caliper bolt:
35 Nm (3.5 m·kgf, 25 ft·lbf)
UB04E0E0.book Page 34 Wednesday, September 2, 2015 3:51 PM