2016 YAMAHA MT-25 fuel cap

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
1-5
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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Description
2-2
2
EAU10421
Right view
1
98 76 5 23
4
1. Fuse box (page 6-29)
2. Battery (page 6-28)
3. Fuel tank cap (page 3-13)
4. Headlight (page 6-30)
5. Engine oil filler cap (page 6-9)
6. Engine oil level check window (page 6-9)
7. Brake pedal (page 3-12)
8. Rear brake light switch (page 6-19)9. Rear brake fluid reservoir (page 6-20)UB04E0E0.book Page 2 Wednesday, September 2, 2015 3:51 PM

Instrument and control functions
3-13
3
EAU13075
Fuel tank capTo open the fuel tank cap
Open the fuel tank cap lock cover, in-
sert the key into the lock, and then turn
it 1/4 turn clockwise. The lock will be
released and the fuel tank cap can be
opened.
To close the fuel tank cap
1. Push the fuel tank cap into posi-
tion with the key inserted in the
lock.
2. Turn the key counterclockwise to
the original position, remove it,
and then close the lock cover.
TIPThe fuel tank cap cannot be closed un-
less the key is in the lock. In addition,
the key cannot be removed if the cap is
not properly closed and locked.
WARNING
EWA11092
Make sure that the fuel tank cap is
properly closed after filling fuel.
Leaking fuel is a fire hazard.
EAU13222
FuelMake sure there is sufficient gasoline in
the tank.
WARNING
EWA10882
Gasoline and gasoline vapors are
extremely flammable. To avoid fires
and explosions and to reduce the
risk of injury when refueling, follow
these instructions.1. Before refueling, turn off the en-
gine and be sure that no one is sit-
ting on the vehicle. Never refuel
while smoking, or while in the vi-
cinity of sparks, open flames, or
other sources of ignition such as
the pilot lights of water heaters
and clothes dryers.
2. Do not overfill the fuel tank. When
refueling, be sure to insert the
pump nozzle into the fuel tank filler
hole. Stop filling when the fuel
reaches the bottom of the filler
tube. Because fuel expands when
it heats up, heat from the engine or
the sun can cause fuel to spill out
of the fuel tank.
1. Fuel tank cap lock cover
2. Unlock.
1 2
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Instrument and control functions
3-14
3
3. Wipe up any spilled fuel immedi-
ately. NOTICE: Immediately
wipe off spilled fuel with a clean,
dry, soft cloth, since fuel may
deteriorate painted surfaces or
plastic parts.
[ECA10072]
4. Be sure to securely close the fuel
tank cap.
WARNING
EWA15152
Gasoline is poisonous and can
cause injury or death. Handle gaso-
line with care. Never siphon gasoline
by mouth. If you should swallow
some gasoline or inhale a lot of gas-
oline vapor, or get some gasoline in
your eyes, see your doctor immedi-ately. If gasoline spills on your skin,
wash with soap and water. If gaso-
line spills on your clothing, change
your clothes.
EAU49743
NOTICE
ECA11401
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 de-
signed to use regular unleaded gaso-
line with a research octane number of
95 or higher. If knocking (or pinging)
occurs, use a gasoline of a differentbrand or premium unleaded fuel. Use
of unleaded fuel will extend spark plug
life and reduce maintenance costs.
Gasohol
There are two types of gasohol: gaso-
hol containing ethanol and that con-
taining methanol. Gasohol containing
ethanol can be used if the ethanol con-
tent does not exceed 10% (E10). Gas-
ohol containing methanol is not
recommended by Yamaha because it
can cause damage to the fuel system
or vehicle performance problems.
1. Fuel tank filler tube
2. Maximum fuel level
2
1
Recommended fuel:
Regular unleaded gasoline (Gasohol
[E10] acceptable)
Fuel tank capacity:
14 L (3.7 US gal, 3.1 Imp.gal)
Fuel reserve amount:
3.0 L (0.79 US gal, 0.66 Imp.gal)
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Periodic maintenance and adjustment
6-36
6 To install the rear wheel
1. Install the wheel and the brake cal-
iper bracket by inserting the wheel
axle from the left-hand side.
TIPMake sure that the slot in the
brake caliper bracket is fit over the
retainer on the swingarm.
Make sure that there is enough
space between the brake pads
before installing the wheel.2. Install the drive chain onto the rear
sprocket.
3. Install the axle nut.4. Lower the rear wheel so that it is
on the ground, and then put the
sidestand down.
5. Adjust the drive chain slack. (See
page 6-21.)
6. Tighten the axle nut, and then
tighten the locknuts to the speci-
fied torques.
7. Install the drive chain puller caps.
EAU25872
TroubleshootingAlthough Yamaha motorcycles receive
a thorough inspection before shipment
from the factory, trouble may occur
during operation. Any problem in the
fuel, compression, or ignition systems,
for example, can cause poor starting
and loss of power.
The following troubleshooting charts
represent quick and easy procedures
for checking these vital systems your-
self. However, should your motorcycle
require any repair, take it to a Yamaha
dealer, whose skilled technicians have
the necessary tools, experience, and
know-how to service the motorcycle
properly.
Use only genuine Yamaha replace-
ment parts. Imitation parts may look
like Yamaha parts, but they are often
inferior, have a shorter service life and
can lead to expensive repair bills.
WARNING
EWA15142
When checking the fuel system, do
not smoke, and make sure there are
no open flames or sparks in the ar-
ea, including pilot lights from water
1. Retainer
2. Slot
1
2
Tightening torques:
Axle nut:
57 Nm (5.7 m·kgf, 41 ft·lbf)
Locknut:
16 Nm (1.6 m·kgf, 12 ft·lbf)
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Motorcycle care and storage
7-4
7
EAU26183
StorageShort-term
Always store your motorcycle in a cool,
dry place and, if necessary, protect it
against dust with a porous cover. Be
sure the engine and the exhaust sys-
tem are cool before covering the mo-
torcycle.NOTICE
ECA10811
Storing the motorcycle in a
poorly ventilated room or cover-
ing it with a tarp, while it is still
wet, will allow water and humid-
ity to seep in and cause rust.
To prevent corrosion, avoid
damp cellars, stables (because
of the presence of ammonia)
and areas where strong chemi-
cals are stored.Long-term
Before storing your motorcycle for sev-
eral months:
1. Follow all the instructions in the
“Care” section of this chapter.2. Fill up the fuel tank and add fuel
stabilizer (if available) to prevent
the fuel tank from rusting and the
fuel from deteriorating.
3. Perform the following steps to
protect the cylinders, piston rings,
etc. from corrosion.
a. Remove the spark plug caps
and spark plugs.
b. Pour a teaspoonful of engine
oil into each spark plug bore.
c. Install the spark plug caps onto
the spark plugs, and then
place the spark plugs on the
cylinder head so that the elec-
trodes are grounded. (This will
limit sparking during the next
step.)
d. Turn the engine over several
times with the starter. (This will
coat the cylinder walls with oil.)
WARNING! To prevent dam-
age or injury from sparking,
make sure to ground the
spark plug electrodes while
turning the engine over.
[EWA10952]
e. Remove the spark plug caps
from the spark plugs, and then
install the spark plugs and the
spark plug caps.
4. Lubricate all control cables and
the pivoting points of all levers and
pedals as well as of the side-
stand/centerstand.
5. Check and, if necessary, correct
the tire air pressure, and then lift
the motorcycle so that both of its
wheels are off the ground. Alterna-
tively, turn the wheels a little every
month in order to prevent the tires
from becoming degraded in one
spot.
6. Cover the muffler outlet with a
plastic bag to prevent moisture
from entering it.
7. Remove the battery and fully
charge it. Store it in a cool, dry
place and charge it once a month.
Do not store the battery in an ex-
cessively cold or warm place [less
than 0 °C (30 °F) or more than 30
°C (90 °F)]. For more information
on storing the battery, see page
6-28.
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Specifications
8-1
8
Dimensions:Overall length:
2090 mm (82.3 in)
Overall width:
745 mm (29.3 in)
Overall height:
1035 mm (40.7 in)
Seat height:
780 mm (30.7 in)
Wheelbase:
1380 mm (54.3 in)
Ground clearance:
160 mm (6.30 in)
Minimum turning radius:
2.7 m (8.86 ft)Weight:Curb weight:
165 kg (364 lb)Engine:Combustion cycle:
4-stroke
Cooling system:
Liquid cooled
Valve train:
DOHC
Cylinder arrangement:
Inline
Number of cylinders:
2-cylinder
Displacement:
250 cm3
Bore × stroke:
60.0 × 44.1 mm (2.36 × 1.74 in)Compression ratio:
11.6 : 1
Starting system:
Electric starter
Lubrication system:
Wet sump
Engine oil:Recommended brand:
YAMALUBE
SAE viscosity grades:
10W-40
Recommended engine oil grade:
API service SG type or higher, JASO
standard MA
Engine oil quantity:
Oil change:
1.80 L (1.90 US qt, 1.58 Imp.qt)
With oil filter removal:
2.10 L (2.22 US qt, 1.85 Imp.qt)Coolant quantity:Coolant reservoir (up to the maximum level
mark):
0.25 L (0.26 US qt, 0.22 Imp.qt)
Radiator (including all routes):
0.96 L (1.01 US qt, 0.84 Imp.qt)Air filter:Air filter element:
Oil-coated paper elementFuel:Recommended fuel:
Regular unleaded gasoline (Gasohol [E10]
acceptable)
Fuel tank capacity:
14 L (3.7 US gal, 3.1 Imp.gal)Fuel reserve amount:
3.0 L (0.79 US gal, 0.66 Imp.gal)
Fuel injection:Throttle body:
ID mark:
1WD1 00Spark plug(s):Manufacturer/model:
NGK/CR9E
Spark plug gap:
0.7–0.8 mm (0.028–0.031 in)Clutch:Clutch type:
Wet, multiple-discDrivetrain:Primary reduction ratio:
3.043 (70/23)
Final drive:
Chain
Secondary reduction ratio:
3.071 (43/14)
Transmission type:
Constant mesh 6-speed
Gear ratio:
1st:
2.667 (40/15)
2nd:
1.882 (32/17)
3rd:
1.455 (32/22)
4th:
1.200 (30/25)
5th:
1.037 (28/27)
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