Owner's Manual

Read this manual carefully before operating this vehicle.

OWNER’S MANUAL

55D-F8199-32 Baca buku panduan dengan teliti sebelum mengendalikan motosikal ini. Buku panduan ini diberi percuma dengan pembelian motosikal

Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it sold.

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Welcome to the Yamaha world of motorcycling! As the owner of the Yamaha T135 SE, you are benefiting from Yamaha’s vast experience and newest technology regarding the design and manufacture of high-quality products, which have earned Yamaha a reputation for dependability. Please take the time to read this manual thoroughly, so as to enjoy all advantages of your Yamaha T135 SE. The Owner’s Manual does not only instruct you in how to operate, inspect and maintain your motorcycle, but also in how to safeguard yourself and others from trouble and injury. In addition, the many tips given in this manual will help keep your motorcycle in the best possible condition. If you have any further questions, do not hesitate to contact your Yamaha dealer. The Yamaha team wishes you many safe and pleasant rides. So, remember to put safety first! Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most cur- rent product information available at the time of printing, there may be minor discrepancies between your motorcycle and this manual. If there is any question concerning this manual, please consult a Yamaha dealer.

WARNING Please read this manual carefully and completely before operating this motorcycle. IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following notations: This is the safety alert simbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this simbol to avoid possible injury or death.

WARNING A WARNING indicates a hazardous situation which, if not avoid, could result in death or serious injury.

A NOTICE indicates special precautions that must be taken to avoid damage to NOTICE the vehicle or other property.

TIP A TIP provides key information to make procedures easier or clearer. IMPORTANT MANUAL INFORMATION

T135SE OWNER”S MANUAL ©2016 by Yamaha Motor CO., Ltd 1st edition, January 2016 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd is expressly prohibited. Printed in Malaysia TABLE OF CONTENTS

LOCATION OF IMPORTANT LABELS..1-1 OPERATION AND IMPORTANT Checking the brake lever RIDING POINTS...... 5-1 free play ...... 6-22 SAFETY INFORMATION ...... 1-2 Starting and warming up a Adjusting the brake pedal DESCRIPTION ...... 2-1 cold engine ...... 5-1 free play ...... 6-22 Left view ...... 2-1 Starting a warm engine ...... 5-2 Adjusting the rear brake light Right view...... 2-2 Shifting ...... 5-3 switch ...... 6-23 Controls and instruments...... 2-3 Tips for reducing fuel Checking the front brake pads and consumption ...... 5-3 rear brake shoes ...... 6-23 INSTRUMENT AND CONTROL Engine break-in ...... 5-4 Checking the front brake FUNCTIONS ...... 3-1 Parking ...... 5-5 fluid level ...... 6-24 Main switch/steering lock ...... 3-1 General note ...... 5-6 Changing the brake fluid ...... 6-25 Keyhole cover ...... 3-2 Drive chain slack ...... 6-25 Indicator and warning lights ...... 3-3 PERIODIC MAINTENANCE AND Cleaning and lubricating the Speedometer unit ...... 3-4 MINOR REPAIR ...... 6-1 drive chain ...... 6-27 Fuel gauge ...... 3-4 Owner’s tool kit ...... 6-1 Checking and lubricating the Handlebar switches ...... 3-4 Periodic maintenance and cables ...... 6-28 Shift pedal ...... 3-5 lubrication chart ...... 6-2 Checking and lubricating the Brake lever ...... 3-6 Removing and installing the throttle grip and cable ...... 6-28 Brake pedal ...... 3-6 cowlings and panel ...... 6-5 Lubricating the brake lever ...... 6-29 Fuel tank cap ...... 3-6 Checking the spark plug ...... 6-7 Lubricating the brake pedal ...... 6-29 Fuel ...... 3-7 Engine oil and oil filter element .... 6-10 Checking and lubricating the Catalytic converter ...... 3-8 Coolant ...... 6-13 centerstand and sidestand ...... 6-29 Starter (choke) lever ...... 3-8 Cleaning the air filter element ...... 6-15 Lubricating the Kickstarter ...... 3-9 Adjusting the carburetor ...... 6-17 swingarm pivots ...... 6-30 Seat ...... 3-9 Adjusting the engine idling Checking the front fork ...... 6-30 Helmet holders ...... 3-9 speed ...... 6-17 Checking the steering ...... 6-31 Storage compartment ...... 3-10 Adjusting the throttle cable Checking the wheel bearings ...... 6-31 Sidestand ...... 3-10 free play ...... 6-18 Battery ...... 6-32 Valve clearance ...... 6-19 Replacing the fuse ...... 6-33 PRE-OPERATION CHECKS...... 4-1 Tires ...... 6-19 Replacing a headlight bulb ...... 6-34 Pre-operation check list ...... 4-2 Wheel ...... 6-21 TABLE OF CONTENTS

Replacing a front turn signal light bulb or an auxiliary light bulb ....6-35 Rear turn signal light and tail/brake light ...... 6-35 Front wheel ...... 6-36 Rear wheel ...... 6-37 Troubleshooting ...... 6-39 Troubleshooting charts ...... 6-40

MOTORCYCLE CARE AND STORAGE ...... 7-1 Care ...... 7-1 Storage ...... 7-3

SPECIFICATIONS ...... 8-1

CONSUMER INFORMATION...... 9-1 Identification numbers ...... 9-1 LOCATION OF IMPORTANT LABELS

1-LOCATION OF IMPORTANT LABELS Read and understand all of the labels on your vehicle. They contain important information for safe and proper operation of your vehicle. Never remove any labels from your vehicle. If a label becomes difficult to read or comes off, a replacement label 1 is available from your Yamaha dealer.

1-1 SAFETY INFORMATION Safe Riding tersections are the most likely Be a Responsible Owner Perform the pre-operation checks each places for motorcycle accidents As the vehicle’s owner, you are respon- time you use the vehicle to make sure it to occur. sible for the safe and proper operation is in safe operating condition. Failure to • Ride where other motorists can 1 of your motorcycle. inspect or maintain the vehicle properly see you. Avoid riding in another Motorcycles are single-track vehicles. increases the possibility of an accident motorist’s blind spot. Theirsafeuseandoperationarede- or equipment damage. See page 5-1 Many accidents involve inexperi- pendent upon the use of proper riding for a list of pre-operation checks. enced operators. In fact, many op- techniques as well as the expertise of This motorcycle is designed to erators who have been involved in the operator. Every operator should carry the operator and a passenger. accidentsdonotevenhaveacur- know the following requirements before rent motorcycle license. riding this motorcycle. The failure of motorists to detect • Make sure that you are qualified He or she should: and recognize motorcycles in traf- and that you only lend your motor Obtain thorough instructions from fic is the predominating cause of cycle to other qualified operators a competent source on all aspects automobile/motorcycle accidents. of motorcycle operation. Many accidents have been • Know your skills and limits. Observe the warnings and mainte- caused by an automobile driver Staying within your limits may nance requirements in this Own- who did not see the motorcycle. help you to avoid an accident. er’s Manual. Making yourself conspicuous ap- • We recommend that you prac- Obtain qualified training in safe pearstobeveryeffectiveinreduc- tice riding your motorcycle and proper riding techniques. ing the chance of this type of where there is no traffic until you Obtain professional technical ser- accident. have become thoroughly famil- vice as indicated in this Owner’s Therefore: iar with the motorcycle and all of Manual and/or when made neces- • Wear a brightly colored jacket. its controls. sary by mechanical conditions. • Use extra caution when you are Many accidents have been approaching and passing caused by error of the motorcycle through intersections, since in- operator. A typical error made by 1-2 SAFETY INFORMATION the operator is veering wide on a Never ride under the influence of tem become very hot during or af- turn due to excessive speed or un- alcohol or other drugs. ter operation and can cause dercornering (insufficient lean an- burns. 1 gle for the speed). Protective apparel A passenger should also observe • Always obey the speed limit and The majority of fatalities from motorcy- the above precautions. never travel faster than warrant- cle accidents are the result of head in- ed by road and traffic condi- juries. The use of a safety helmet is the Avoid Carbon Monoxide Poisoning tions. single most critical factor in the preven- All engine exhaust contains carbon • Always signal before turning or tion or reduction of head injuries. monoxide, a deadly gas. Breathing car- changing lanes. Make sure that Always wear an approved helmet. bon monoxide can cause headaches, other motorists can see you. Wear a face shield or goggles. dizziness, drowsiness, nausea, confu- The posture of the operator and Wind in your unprotected eyes sion, and eventually death. passenger is important for proper could contribute to an impairment Carbon Monoxide is a colorless, odor- control. of vision that could delay seeing a less, tasteless gas which may be • The operator should keep both hazard. present even if you do not see or smell hands on the handlebar and The use of a jacket, heavy boots, any engine exhaust. Deadly levels of both feet on the operator foot- trousers, gloves, etc., is effective carbon monoxide can collect rapidly rests during operation to main- in preventing or reducing abra- and you can quickly be overcome and tain control of the motorcycle. sions or lacerations. unable to save yourself. Also, deadly • The passenger should always Never wear loose-fitting clothes, levels of carbon monoxide can linger hold onto the operator, the seat otherwise they could catch on the for hours or days in enclosed or poorly strap or grab bar, if equipped, control levers, footrests, or wheels ventilated areas. If you experience any with both hands and keep both and cause injury or an accident. symptoms of carbon monoxide poison- feet on the passenger footrests. Always wear protective clothing ing, leave the area immediately, get Never carry a passenger unless that covers your legs, ankles, and fresh air, and SEEK MEDICAL TREAT- he or she can firmly place both feet. The engine or exhaust sys- MENT. feet on the passenger footrests. 1-3 SAFETY INFORMATION

Do not run engine indoors. Even if guidelines to follow if loading cargo to attached to the motorcycle before you try to ventilate engine exhaust your motorcycle: riding. Check accessory mounts with fans or open windows and The total weight of the operator, and cargo restraints frequently. doors, carbon monoxide can rap- passenger, accessories and cargo • Properly adjust the suspension 1 idly reach dangerous levels. must not exceed the maximum load foryourload,andcheckthe Do not run engine in poorly venti- limit. Operation of an overloaded ve- condition and pressure of your lated or partially enclosed areas hicle could cause an accident. tires. such as barns, garages, or car- • Never attach any large or heavy ports. Maximum load: items to the handlebar, front Do not run engine outdoors where 150 kg (331 lb) fork, or front fender. These engine exhaust can be drawn into items, including such cargo as When loading within this weight limit, a building through openings such sleeping bags, duffel bags, or keep the following in mind: as windows and doors. tents, can create unstable han- Cargo and accessory weight dling or a slow steering re- Loading should be kept as low and close to sponse. Adding accessories or cargo to your the motorcycle as possible. Se- This vehicle is not designed to motorcycle can adversely affect stabili- curely pack your heaviest items as pull a trailer or to be attached to ty and handling if the weight distribution close to the center of the vehicle a sidecar. of the motorcycle is changed. To avoid aspossibleandmakesuretodis- the possibility of an accident, use ex- tribute the weight as evenly as Genuine Yamaha Accessories treme caution when adding cargo or possible on both sides of the mo- Choosing accessories for your vehicle accessories to your motorcycle. Use torcycle to minimize imbalance or is an important decision. Genuine extra care when riding a motorcycle instability. Yamaha accessories, which are avail- that has added cargo or accessories. Shifting weights can create a sud- able only from a Yamaha dealer, have Here, along with the information about den imbalance. Make sure that ac- been designed, tested, and approved accessories below, are some general cessories and cargo are securely by Yamaha for use on your vehicle. 1-4 SAFETY INFORMATION

Many companies with no connection to characteristics can put you and others • Bulky or large accessories may Yamaha manufacture parts and acces- at greater risk of serious injury or death. seriously affect the stability of sories or offer other modifications for You are responsible for injuries related the motorcycle due to aerody- 1 Yamaha vehicles. Yamaha is not in a to changes in the vehicle. namic effects. Wind may at- position to test the products that these Keep the following guidelines in mind, tempt to lift the motorcycle, or aftermarket companies produce. as well as those provided under “Load- the motorcycle may become un- Therefore, Yamaha can neither en- ing” when mounting accessories. stable in cross winds. These ac- dorse nor recommend the use of ac- Never install accessories or carry cessories may also cause cessories not sold by Yamaha or cargothatwouldimpairtheperfor- instability when passing or be- modifications not specifically recom- mance of your motorcycle. Care- ing passed by large vehicles. mended by Yamaha, even if sold and fully inspect the accessory before • Certain accessories can dis- installed by a Yamaha dealer. usingittomakesurethatitdoes place the operator from his or not in any way reduce ground her normal riding position. This Aftermarket Parts, Accessories, and clearance or cornering clearance, improper position limits the free- Modifications limit suspension travel, steering dom of movement of the opera- While you may find aftermarket prod- travel or control operation, or ob- tor and may limit control ability, ucts similar in design and quality to scure lights or reflectors. therefore, such accessories are genuine Yamaha accessories, recog- • Accessories fitted to the handle- not recommended. nize that some aftermarket accessories bar or the front fork area can Use caution when adding electri- or modifications are not suitable be- create instability due to improp- cal accessories. If electrical acces- cause of potential safety hazards to er weight distribution or aerody- sories exceed the capacity of the you or others. Installing aftermarket namic changes. If accessories motorcycle’s electrical system, an products or having other modifications are added to the handlebar or electric failure could result, which performed to your vehicle that change front fork area, they must be as could cause a dangerous loss of any of the vehicle’s design or operation lightweight as possible and lights or engine power. should be kept to a minimum. 1-5 DESCRIPTION

Left view 1 2 34 5 6 7,8

10 9

1. Front turn signal/auxiliary lights (page 6-35) 6. Seat lock (page 3-9) 2. Headlight (page 6-34) 7. Tail/brake light (page 6-35) 3. Battery (page 6-32) 8. Rear turn signal lights (page 6-35) 4. Storage compartment (page 3-10) 9. Shift pedal (page 3-6) 5. Owner’s tool kit (page 6-1) 10.Coolant reservoir (page 6-14)

2-1 DESCRIPTION

Right view 1 2 3 4 5 6

10 9 8 7

1. Kickstarter (page 3-9) 6. Front brake fluid reservoir (page 6-24) 2. Fuel tank cap (page 3-6) 7. Engine oil filter element (page 6-11) 3. Fuse (page 6-33) 8. Brake pedal (page 3-6) 4. Helmet holder (page 3-9) 9. Engine oil drain bolt (page 6-11) 5. Air filter element (page 6-15) 10.Engine oil filler cap (page 6-11)

2-2 DESCRIPTION

Controls and instruments

1234567

Left handlebar switches (page 3-4) 1. 5. Right handlebar switch (page 3-5) . Speedometer unit (page 3-4) 2 6. Brake lever (page 3-6) 3. Fuel gauge (page 3-4) 7. Throttle grip (page 6-18) 4. Main switch/steering lock (page 3-1)

2-3 INSTRUMENT AND CONTROL FUNCTIONS

Main switch/steering lock LOCK To unlock the steering The steering is locked, and all electrical OFF systems are off. The key can be re- 12 ON moved. To lock the steering

3 LOCK 3

Insert the key and turn it to “OFF”.

The main switch/steering lock controls WARNING the ignition and lighting systems, and is 1. Push. Never turn the key to “OFF” or used to lock the steering. The various 2. Turn. “LOCK” while the vehicle is moving, positions are described below. otherwise the electrical systems will 1. Turn the handlebars all the way to be switched off, which may result in ON the left. loss of control or an accident. Make All electrical systems are supplied with 2. Push the key in from the “OFF” po- sure that the vehicle is stopped be- power, and the meter lighting comes sition, and then turn it to "LOCK" fore turning the key to “OFF” or on, and the engine can be started. The 3. Remove the key. “LOCK”. key cannot be removed. OFF All electrical systems are off. The key can be removed.

3-1 INSTRUMENT AND CONTROL FUNCTIONS

Keyhole cover

1._ push shut bottom

To open the keyhole cover To close the keyhole cover 1. Shutter key Insert the key head into the key hole For open and close keyhole cover Push the push shut bottom after cover receptacle as shown, and remove the key. 2. Ignition switch then turn the key to the right to open For starting the engine _ the cover.

3-2 INSTRUMENT AND CONTROL FUNCTIONS

When the engine is running, the Gear position indicator lights “1” Indicator and warning lights warning light will come on if the en- “2” “3”, and “4” gine overheats or if an electrical 12 3 4 5 The respective indicator light comes on circuit is defective. when the transmission is in the 1st, To determine which of the above is 2nd, 3rd or 4th gear position. occurring, stop the vehicle when it N issafetodoso,thenturnthemain High beam indicator light “ ” switch to “OFF”, and then back to 3 This indicator light comes on when the “ON”. high beam of the headlight is switched If the warning light stays on, this in- on. dicates the engine is overheating. Keep the engine turned off and al- 1. Turn signal indicator light " " low it to cool. 2. Neutral indicator light “ ” Coolant temperature warning light 3. Gear position indicator light “1” “2” “3” “4” “” NOTICE 4. High beam indicator light “ ” This warning light comes on when the Do not operate the engine if it is 5.Coolant temperatur warning light “ ” engine overheats. When this occurs, overheated. stop the engine immediately and allow the engine to cool. If the warning light flashes, this in- Turn signal indicator light “ ” This warning light also has a self-diag- dicates there is a defective electri- This indicator light flashes when the nosis device function for various electrical circuit. Have a Yamaha dealer turn signal switch is pushed to the left or cal circuits. check the vehicle. right. Whenthemainswitchisturnedto The electrical circuit of the warning light Neutral indicator light “ ” “ON” and the engine is not run- can be checked by turning the key to This indicator light comes on when the ning, the warning light will flash if “ON”. transmission is in the neutral position. an electrical circuit is defective. If If the warning light does not come on this occurs, have a Yamaha dealer for a few seconds, then go off, have a check the vehicle. Yamaha dealer check the electrical cir- 3-3 cuit. INSTRUMENT AND CONTROL FUNCTIONS Speedometer unit Fuel gauge Handlebar switches Left

1 1 2 2 3

1. Speedometer 1. Fuel gauge 1. Dimmer switch “ / ” 2. Odometer 2. Red zone 2. Turn signal switch “ / ” The speedometer unit is equipped with The fuel gauge indicates the amount of 3. Horn switch “ ” a speedometer and an odometer. The fuel in the fuel tank. The needle moves Dimmer switch “ / ” speedometer shows riding speed. The towards “E” (Empty) as the fuel level odometer shows the total distance trav- decreases. When the needle reaches Set this switch to “”for the high eled. the red zone, approximately 1.0 L (0.26 beam and to “” for the low beam. US gal) (0.22 Imp.gal) remain in the fuel tank. If this occurs, refuel as soon as possible. TIP Do not allow the fuel tank to empty itself completely. The main switch must be turned to “ON” for the fuel gauge to display an accurate fuel level reading. 3-4 INSTRUMENT AND CONTROL FUNCTIONS

Right Shift pedal Turn signal switch “ / ” To signal a right-hand turn, push this switch to“”Tosignalaleft-hand . turn,pushthisswitchto“ ”.Whenre- leased, the switch returns to the center position. To cancel the turn signal lights, push the switch in after it has re- 3 turned to the center position. 1 Horn switch “”. Press this switch to sound the horn. 1 1.Startswitch“ ” 1. Shift pedal Start switch “ ” The shift pedal is located on the left Push this switch to crank the engine side of the engine. This motorcycle is with the starter. equipped with a constant-mesh 4 speed transmission. NOTICE See page 5-1 for starting instruc- TIP tions prior to starting the engine. Use your toes to shift up and your heel to shift down.

3-5 INSTRUMENT AND CONTROL FUNCTIONS

Brake lever Brake pedal Fuel tank cap

1 1. Fuel tank cap 1. Brake lever 1. Brake pedal 2. “ ” mark The brake lever is located at the right Thebrakepedalisontherightsideof To remove the fuel tank cap handlebar grip. To apply the front brake, the motorcycle. To apply the rear 1. Open the seat. (See page 3-9.) pull the lever toward the handlebar brake,pressdownonthebrakepedal. 2. Turn the fuel tank cap counter- grip. clockwise and pull it off. To Install the fuel tank cap 1. Insert the fuel tank cap into the tank opening and turn it clockwise until the “ ” marks on the cap and tank are aligned. 2. Close the seat. WARNINGWARNING Make sure that the fuel tank cap is properly closed before riding. 3-6 INSTRUMENT AND CONTROL FUNCTIONS

Fuel 1. Before refueling, turn off the engi- 3. Wipe up any spilled fuel imme- ne and be sure that no one is sitt- diately. NOTICE: Immediately ing on the vehicle. Never refuel wipe off spilled fuel with a cle- while smoking, or while in the an, dry, soft cloth, since fuel vicinity of sparks, open flames, may deteriorate painted surfa- or other sources of ignition such ces or plastic parts. as the pilot lights of water heaters 4. Be sure to securely close the fuel 3 and clothes dryers. tank cap.

2. Do not overfill the fuel tank. Stop WWARNINGWARNIARNINGNG filling when the fuel reaches the 1. Fuel tank filler tube Gasoline is poisonous and can bottom of the filler tube. Because 2. Fuel level cause injury or death. Handle gaso- fuel expands when it heats up, line with care. Never siphon ga- Make sure there is sufficient gasoline heat from the engine or the sun soline by mouth. If you should in the tank. can cause fuel to spill out of the swallow some gasoline or inhale a fuel tank. lot of gasoline vapor, or get some WARNINGWARNI NG gasoline in your eyes, see your Gasoline and gasoline vapors are doctor immediately. If gasoline extremely flammable. To avoid fires spills on your skin, wash with soap and explosions and to reduce the and water. If gasoline spills on your risk of injury when refueling, follow clothing, change your clothes. these instructions.

3-7 INSTRUMENT AND CONTROL FUNCTIONS

Catalytic converter Starter (choke) lever “ ” Recommended fuel: Regular unleaded gasoline only Thismodelisequippedwithacatalytic Fuel tank capacity: converter in the exhaust system. 4.0 L (1.06 US gal) (0.88 Imp.gal) WARNING The exhaust system is hot after op- NOTICE eration. Make sure that the exhaust Use only unleaded gasoline. The use system has cooled down before do- 3 of leaded gasoline will cause severe ing any maintenance work. damage to internal engine parts, such as the valves and piston rings, NOTICE 1. Starter (choke) lever “ ” as well as to the exhaust system. The following precautions must be Starting a cold engine requires a richer observed to prevent a fire hazard or air-fuel mixture, which is supplied by other damages. the starter (choke). Use only unleaded gasoline. Move the lever in direction (a) to turn on The use of leaded gasoline will the starter (choke). cause unrepairable damage to Move the lever in direction (b) to turn off the catalytic converter. the starter (choke). Never park the vehicle near possible fire hazards such as grass or other materials that easily burn. Do not allow the engine to idle too long.

3-8 INSTRUMENT AND CONTROL FUNCTIONS

Kickstarter Seat Helmet holders

2 1

1 3

1. Kickstarter 1. Seat lock If the engine fails to start by pushing the 1. Helmet holder 2. Seat start switch, try to start it by using the The helmet holders are located under kickstarter. To start the engine, fold out To open the seat the seat. the kickstarter lever, move it down light- 1. Insert the key in the lock, and then ly with your foot until the gears engage, turn it as shown. To secure a helmet to a helmet hold- and then push it down smoothly but 2. Fold the seat up. er 1. Open the seat. (See page 3-9.) forcefully. To close the seat 2. Attach a helmet to a helmet holder, 1. Fold the seat down, and then push and then securely close the seat. it down to lock it in place. 2. Remove the key. WARNING! Never ride with a helmet attached to the helmet TIP holder, since the helmet may hit Make sure that the seat is properly se- objects, causing loss of control cured before riding. and possibly an accident.

3-9 INSTRUMENT AND CONTROL FUNCTIONS

To release a helmet from a helmet Storage compartment Sidestand holder The sidestand is located on the left side Open the seat, remove the helmet from of the frame. Raise the sidestand or the helmet holder, and then close the lower it with your foot while holding the seat. 1 vehicle upright.

WARNING The vehicle must not be ridden with 3 the sidestand down, or if the sidestand cannot be properly moved up (or does not stay up), otherwise the sidestand could contact the ground 1. Storage compartment and distract the operator, resulting The storage compartment is located in a possible loss of control. under the seat. (See page 3-9.) When storing the owner’s manual or other documents in the storage compartment, be sure to wrap them in a plastic bag so that they will not get wet. When washing the vehicle, be careful not to let any water enter the storage compartment.

3-10 PRE-OPERATION CHECKS

Inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the Owner's Manual. WARNING Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equipment damage. Do not operate the vehicle if you find any problem. If a problem cannot be corrected by the procedures provided in this manual, have the vehicle inspected by a Yamaha dealer. Before using this vehicles, check the following points:

4-1 PRE-OPERATION CHECKS

Pre-operation check list ITEM CHECKS PAGE

• Check fuel level in fuel tank. Fuel • Refuel if necessary. 3-7 • Check fuel line for leakage. • Check oil level in engine. Engine oil • If necessary, add recommended oil to specified level. 6-10 • Check vehicle for oil leakage. • Check coolant level in reservoir. Coolant • If necessary, add recommended coolant to specified level. 6-13 •Checkcoolingsystemforleakage. 4 • Check operation. • If soft or spongy, have Yamaha dealer bleed hydraulic system. • Check brake pads for wear. Front brake • Replace if necessary. 6-22, 6-24 • Check fluid level in reservoir. • If necessary, add recommended brake fluid to specified level. • Check hydraulic system for leakage. • Check operation. Rear brake • Check pedal free play. 6-22 •Adjustifnecessary. • Make sure that operation is smooth. • Lubricate if necessary. Throttle grip • Check free play. 6-18 • Adjust if necessary. • Make sure that operation is smooth. Control cables • Lubricate if necessary. 6-28 • Check chain slack Drive chain • Adjust if necessary. 6-22, 6-25 • Check chain condition. • Lubricate if necessery

4-2 PRE-OPERATION CHECKS

ITEM CHECKS PAGE

• Check for damage. •Checktireconditionandtreaddepth. Wheels and tires 6-19, 6-21 • Check air pressure. • Correct if necessary. • Make sure that operation is smooth. Brake pedal 6-29 • Lubricate pedal pivoting point if necessary. • Make sure that operation is smooth. Brake lever 6-22 • Lubricate lever pivoting point if necessary. • Make sure that operation is smooth. 4 Centerstand, sidestand 6-29 • Lubricate pivots if necessary. 4 • Make sure that all nuts, bolts and screws are properly tightened. Chassis fasteners — • Tighten if necessary. Instruments, lights, signals •Checkoperation. — and switches •Correctifnecessary. • Check fluid level. Battery 6-32 • Fill with distilled water if necessary.

4-3 OPERATION AND IMPORTANT RIDING POINTS

Read the Owner's Manual carefully to Before starting out, make sure Starting and warming up a become familiar with all controls. If that the sidestand is up. If the cold engine there is a control or function you do not sidestand is not raised com- 1. Turn the key to “ON”. understand, ask your Yamaha dealer. pletely, it could contact the 2. Shift the transmission into the neu- ground and distract the opera- tral position. tor, resulting in a possible loss WARNING TIP of control. Become thoroughly familiar When the transmission is in the neutral with all operating controls and position, the neutral indicator light their functions before riding. NOTICE should be on, otherwise have a Consult a Yamaha dealer re- Do not ride through deep water Yamaha dealer check the electrical cir- 5 garding any control or function (including puddles), otherwise the cuit. that you do not thoroughly un- engine may be damaged. derstand. 3. Place the vehicle on the center- Never start the engine or oper- stand. ate it in a closed area for any WARNING length of time. Exhaust fumes are poisonous, and inhaling Before starting the engine, make them can cause loss of con- sure the transmission is in neutral sciousness and death within a and that the vehicle is placed on the short time. Always make sure centerstand. that there is adequate ventila- 4. Turn the starter (choke) on and tion. completely close the throttle. (See page 3-8.) 5. Start the engine by pushing the start switch or by pushing the kickstarter lever down. 5-1 OPERATION AND IMPORTANT RIDING POINTS

TIP Starting a warm engine If the engine fails to start by pushing the NOTICE Follow the same procedure as for start- start switch, release the switch, wait a For maximum engine life, always ing a cold engine with the exception few seconds, and then try again. Each warm the engine up before starting that the starter (choke) is not required starting attempt should be as short as off. Never accelerate hard when the when the engine is warm. possible to preserve the battery. Do not engine is cold! crank the engine more than 10 seconds 7. When the engine is warm, turn the on any one attempt. If the engine does starter (choke) off. notstartwiththestartermotor,tryusing the kickstarter. TIP Theengineiswarmwhenitresponds 5 normally to the throttle with the starter NOTICE (choke) turned off. The coolant temperature warning light should come on when the key is turned to “ON”, and then go off after a few seconds. If the coolant temperature warning light comes on after starting, immediately stop the engine, and have a Yamaha dealer check the electrical circuit. 6. Afterstartingtheengine,movethe starter (choke) back halfway.

5-2 OPERATION AND IMPORTANT RIDING POINTS

Shifting TIP Tips for reducing fuel 2 To shift the transmission into the neu- consumption tral position, press the shift pedal Fuel consumption depends largely on N down repeatedly until it reaches the your riding style. Consider the following end of its travel, and then slightly tips to reduce fuel consumption: 1 raise it. Turn the starter (choke) off as 2 soon as possible. 3 Shiftupswiftly,andavoidhighen- NOTICE gine speeds during acceleration. 4 Donotrevtheenginewhileshifting Make sure that the transmission down, and avoid high engine 1 is completely shifted into gear. 5 speeds with no load on the engine. Be sure to fully close the throttle 1. Shift pedal Turn the engine off instead of let- grip when shifting. 2. Neutral position ting it idle for an extended length of Make sure the neutral indicator time (e.g., in traffic jams, at traffic Shifting gears lets you control the light comes on when the trans- lights or at railroad crossings). amount of engine power available for mission is in the neutral position. starting off, accelerating, climbing hills, etc. The gear positions are shown in the illustration.

5-3 OPERATION AND IMPORTANT RIDING POINTS

Engine break-in 0–150 km (0–90 mi) 150–500 km (90–300 mi) There is never a more important period in the life of your engine than the period between0and1000km(600mi).For this reason, you should read the following material carefully. Since the engine is brand new, do not put an excessive load on it for the first 1000 km (600 mi). The various parts in the engine wear and polish themselves 5 to the correct operating clearances. During this period, prolonged full-throttle operation or any condition that might Avoid prolonged operation above 1/3 Avoid prolonged operation above 1/2 result in engine overheating must be throttle. throttle. avoided. After every hour of operation, stop the Rev the engine freely through the engine, and then let it cool for five to ten gears, but do not use full throttle at any minutes. time. Vary the engine speed from time to time. Do not operate the engine at one set throttle position.

5-4 OPERATION AND IMPORTANT RIDING POINTS

500–1000 km (300–600 mi) 1000 km (600 mi) and beyond Parking When parking, stop the engine, and then remove the key from the main switch.

WARNING Since the engine and exhaust system can become very hot, park in a place where pedestri- ans or children are not likely to touch them. 5 Avoid prolonged operation above 3/4 Avoid prolonged full-throttle operation. Do not park on a slope or on soft ground, otherwise the vehicle throttle. Vary the engine speed occasionally. may overturn. NOTICE: After 1000 km (600 mi) of operation, the engine oil must be NOTICE changed, the oil filter cartridge or element replaced, and the oil strain- Neverparkinanareawherethere are fire hazards such as grass or er cleaned. If any engine trouble other flammable materials. should occur during the engine break-in period, immediately have a Yamaha dealer check the vehicle.

5-5 OPERATION AND IMPORTANT RIDING POINTS

General note Much can be gained from the correct use and maintenance of a motorcycle.

1. THE CUSTOMERS CAN USE THE FULLEST 2. A MOTORCYCLE CAN KEEP ITS PERFORMANCE POTENTIAL OF YAMAHA MOTORCYCLES CAPABILITY FOR A LONGER TIME

Comparison of wear on engine parts (piston, piston ring, cylinder, etc.) 100% With maintenance

Without maintenance Perfect operative Perfect condition

Distance covered (km) Engine overhaul, cylinder boring, piston ring change, etc.

5-6 OPERATION AND IMPORTANT RIDING POINTS

3. FUEL COST AND REPAIR EXPENSES CAN BE 4. A MOTORCYCLE CAN DEMAND A HIGH PRICE KEPT TO A MINIMUM WHEN IT IS TRADED IN AS A USED PRODUCT

Fuel consumption With maintenance 100%

Without maintenance Distance covered (km) 5

Customer’s running cost (fuel cost plus maintenance and repair expenses) S Without maintenance Big repairs at higher expenses With maintenance

Distance covered (km)

5-7 PERIODIC MAINTENANCE AND MINOR REPAIR Owner’s tool kit TIP Safety is an obligation of the owner. Pe- If you do not have the tools or experi- riodic inspection, adjustment and lubri- ence required for a particular job, have cation will keep your vehicle in the 1 a Yamaha dealer perform it for you. safest and most efficient condition possible. The most important points of inspection, adjustment, and lubrication WARNING are explained on the following pages. Modifications not approved by The intervals given in the periodic Yamaha may cause loss of perfor- maintenance and lubrication chart mance and render the vehicle un- should be simply considered as a gen- 1. Owner’s tool kit safe for use. Consult a Yamaha eral guide under normal riding condi- dealer before attempting any chang- The owner’s tool kit is located inside the 6 tions. However, DEPENDING ON THE es. WEATHER, TERRAIN, GEOGRAPHI- storage compartment under the seat. (See page 3-9.) CAL LOCATION, AND INDIVIDUAL NOTICE USE, THE MAINTENANCE INTER- The service information included in this VALS MAY NEED TO BE SHORT- manual and the tools provided in the Improper disposal of drained fluids ENED. owner’s tool kit are intended to assist (i.e., oil, coolant,etc) and battery youintheperformanceofpreventive are harmful to the environment. WARNING maintenance and minor repairs. How- Contact a Yamaha dealer for pro- If you are not familiar with mainte- ever, additional tools such as a torque per disposal to protect the envi- nance work, have a Yamaha dealer wrench may be necessary to perform ronment. do it for you. certain maintenance work correctly.

6-1 PERIODIC MAINTENANCE AND MINOR REPAIR Periodic maintenance and lubrication chart TIP The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead. From 12000 km, repeat the maintenance intervals starting from 3000 km. Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills

ODOMETER READING (x 1000 km) ANNUAL NO. ITEM CHECK OR MAINTENANCE JOB 0.5 3 6 9 12 CHECK

1 * Fuel line • Check fuel and vacuum hoses for cracks or damage. √√√√ √ •Checkcondition. √√ 2 Spark plug •Cleanandregap. •Replace. √√ 6 • Check valve clearance. 3 * Valves √ •Adjust. •Clean. √√√ √ 4 Air filter element •Replace. √√

5 * Battery •Checkvoltase and battery terminal. √√√√ √

• Check operation, fluid level and vehicle for fluid leakage. √√√√√ √ 6 * Front brake • Replace brake pads. Whenever worn to the limit • Check operation and adjust brake pedal free play. √√√√√ ? 7 * Rear brake • Replace brake shoes. Whenever worn to the limit

• Check for cracks or damage. √√√√ √ 8 * Brake hose •Replace. Every4years 6-2 PERIODIC MAINTENANCE AND MINOR REPAIR

ODOMETER READING (x 1000 km) ANNUAL NO. ITEM CHECK OR MAINTENANCE JOB 0.5 3 6 9 12 CHECK

9 * Wheels •Checkrunout and for damage. √√√√

• Check tread depth and for damage. •Replaceifnecessary. 10 * Tires •Checkairpressure. √√√√ √ • Correct if necessary. 11 * Wheel bearings • Check bearing for looseness or damage. √ √ √ √ • Check operation and for excessive play. √√√√ 12 * Swingarm • Lubricate with lithium-soap-based grease. Every 24000 km • Check chain slack, alignment and condition. Every 500 km and after washing the motorcycle or 13 Drive chain • Adjust and thoroughly lubricate chain with engine oil. riding in the rain 6 • Check bearing play and steering for roughness. √√√√√ 14 * Steering bearings • Lubricate with lithium-soap-based grease. Every 24000 km • Make sure that all nuts, bolts and screws are properly 15 * Chassis fasteners tightened. √√√√ √ •Checkoperation. 16 Sidestand, centerstand •Lubricate. √√√√ √ 17 * Front fork • Check operation and for oil leakage. √ √√√ Shock absorber assem- 18 * • Check operation and shock absorber for oil leakage. bly √√√√ • Check starter (choke) operation. 19 * Carburetor • Adjust engine idling speed. √√√√√ √ •Change. 20 Engine oil • Check oil level and vehicle for oil leakage. √√√√√ √ 21 Engine oil filter element •Replace. √ √√ 6-3 PERIODIC MAINTENANCE AND MINOR REPAIR

ODOMETER READING (x 1000 km) ANNUAL NO. ITEM CHECK OR MAINTENANCE JOB 0.5 3 6 9 12 CHECK

• Check coolant level and vehicle for coolant leakage. √√√√ √ 22 * Cooling system • Change. Every 3 years Front and rear brake 23 * • Check operation. switches √√√√√ √ Moving parts and ca- 24 •Lubricate. bles √√√√ √ • Check operation and free play. Throttle grip housing 25 * • Adjust the throttle cable free play if necessary. and cable √√√√ √ • Lubricate the throttle grip housing and cable. • Check the air cut-off valve, reed valve, and hose for dam- 26 * Air induction system age. √√√√ √ • Replace any damaged parts if necessary. 6 Lights, signals and • Check operation. 27 * switches • Adjust headlight beam. √√√√√ √

TIP The air filter needs more frequent service if you are riding in unusually wet or dusty areas. Hydraulic brake service • Regularly check and, if necessary, correct the brake fluid level. • Every two years replace the internal components of the brake master cylinder and caliper, and change the brake fluid. • Replace the brake hoses every four years and if cracked or damaged.

6-4 PERIODIC MAINTENANCE AND MINOR REPAIR

The cowlings and panel shown above Cowling C Removing and installing the need to be removed to perform some of cowlings and panel the maintenance jobs described in this To remove the cowling Remove the bolts and screw shown, 2 chapter. Refer to this section each time a cowling or the panel needs to be re- and then take the cowling off. 3 1 moved and installed. 1

Cowlings A and B To remove one of the cowlings Remove the cowling bolts, and then pull the cowling off as shown.

1. Cowling A 2. Cowling C 1 6 3. Cowling D 1 1. Bolt 2 1

2 1. Cowling A 1 2. Bolt

To install the cowling 1. Bolt 1. Cowling B Place the cowling in the original posi- 2. Panel A tion, and then install the bolts. 6-5 PERIODIC MAINTENANCE AND MINOR REPAIR

1 1 1 1. Bolt 1. Screw 1. Screw

To install the cowling 1 To install the cowling Place the cowling in the original posi- 1. Place the cowling in the original tion, and then install the bolts and position, and then install the bolts 6 screw. and screws. 2. Install cowlings A and B. 2 Cowling D To remove the cowling 1. Remove cowlings A and B. (See page 6-5.) 2. Remove the bolts and screws shown, and then take the license 1. Screw bracket plate and the cowling off. 2. Cowling A

6-6 PERIODIC MAINTENANCE AND MINOR REPAIR

Panel A Checking the spark plug The spark plug is an important engine 2 component, which is easy to check. 3 Since heat and deposits will cause any spark plug to slowly erode, the spark plug should be removed and checked in accordance with the periodic mainte- 1 nanceandlubricationchart.Inaddition, the condition of the spark plug can re- veal the condition of the engine. 1. Panel A To remove the panel 2. Screw 1. Open the seat. (See page 3-9.) 3. Bolt 2. Remove the screw and bolts, and 6 then pull the panel off as shown. To install the panel Place the panel in the original position, and then install the screw and bolts.

6-7 PERIODIC MAINTENANCE AND MINOR REPAIR

1. Resonator bolt 1. Resonator 1. Spark plug wrench 2. Spark plug cap To remove the spark plug 5. Remove the spark plug as shown, 1. Remove cowling B. (See page 3. Move the resonator away as 6 with the spark plug wrench includ- 6-5.) shown. ed in the owner’s tool kit. 2. Remove the resonator bolt. 4. Remove the spark plug cap.

6-8 PERIODIC MAINTENANCE AND MINOR REPAIR

To check the spark plug TIP 1. Check that the porcelain insulator Ifatorquewrenchisnotavailablewhen around the center electrode of the installing a spark plug, a good estimate spark plug is a medium-to-light tan of the correct torque is 1/4–1/2 turn (the ideal color when the vehicle is past finger tight. However, the spark ridden normally). plug should be tightened to the speci- TIP fied torque as soon as possible. If the spark plug shows a distinctly dif- 4. Install the spark plug cap. ferent color, the engine could be defec- 5. Place the resonator in the original tive. Do not attempt to diagnose such 1. Spark plug gap position, and then tighten the bolt problems yourself. Instead, have a to the specified torque. Yamaha dealer check the vehicle. Spark plug gap: 0.8–0.9 mm (0.031–0.035 in) 6 2. Check the spark plug for electrode Tightening torque: erosion and excessive carbon or 2. Clean the surface of the spark plug Resonator bolt: 10 Nm (1.0 m·kgf, 7.2 ft·lbf) other deposits, and replace it if gasket and its mating surface, and then wipe off any grime from the necessary. 6. Install the cowling. spark plug threads. Specified spark plug: 3. Install the spark plug with the NGK/CPR8EA-9/DENSO U24EPR-9 spark plug wrench, and then tighten it to the specified torque. To install the spark plug 1. Measure the spark plug gap with a Tightening torque: Spark plug: wire thickness gauge and, if nec- 12.5 Nm (1.25 m·kgf, 9.0 ft·lbf) essary, adjust the gap to specifica- tion.

6-9 PERIODIC MAINTENANCE AND MINOR REPAIR

Engine oil and oil filter element Theengineoillevelshouldbechecked before each ride. In addition, the oil must be changed and the oil filter element replaced at the intervals specified in the periodic maintenance and lubrication chart. 1. Engine oil filler cap 1. Dipstick To check the engine oil level 2. Maximum level mark 1. Place the vehicle on the center- 3. Minimum level mark stand. A slight tilt to the side can 3. Wait a few minutes until the oil set- TIP tles, remove the oil filler cap, wipe 6 result in a false reading. The engine oil should be between the thedipstickclean,insertitback 2.Starttheengine,warmitupfor minimum and maximum level marks. several minutes, and then turn it into the oil filler hole (without off. screwing it in), and then remove it again to check the oil level. 4. If the engine oil is at or below the minimum level mark, add sufficient oil of the recommended type to raise it to the correct level. 5. Insert the dipstick into the oil filler hole, and then tighten the oil filler cap.

6-10 PERIODIC MAINTENANCE AND MINOR REPAIR

To change the engine oil (with or without oil filter element replacement) 1. Start the engine, warm it up for several minutes, and then turn it off. 2. Place an oil pan under the engine to collect the used oil. 3. Remove the engine oil filler cap 1. Engine oil drain bolt 1. Bolt and drain bolt along with the O- 2. Oil filter element cover ring, compression spring, and en- 2. O-ring 3. Compression spring 5. Remove the oil filter element cover gine oil strainer, to drain the oil 4. Strainer by removing the bolts. 6 from the crankcase. NOTICE: 5. Oil pan When removing the engine oil 6. Remove and replace the oil filter drain bolt, the O-ring, compres- TIP element and O-ring. sion spring, and oil strainer will Check the O-ring for damage and replace it if necessary. fall out. Take care not to lose these parts. 4. Clean the engine oil strainer with solvent. TIP Skip steps 5–7 if the oil filter element is not being replaced.

6-11 PERIODIC MAINTENANCE AND MINOR REPAIR

_ 8. Install the engine oil strainer, com- Recommended engine oil: pression spring, O-ring and engine See page 8-1. oil drain bolt, and then tighten the Oil quantity: drain bolt to the specified torque. With oil filter element replacement: NOTICE: Before installing the 0.90 L (0.95 US qt, 0.79 Imp.qt) engine oil drain bolt, do not for- Without oil filter element replacement: get to install the O-ring, com- 0.80 L (0.85 US qt, 0.70 Imp.qt) pression spring, and oil strainer in position. 1. Oil filter element 2. O-ring Tightening torque: 7. Install the oil filter element cover by Engine oil drain bolt: installing the bolts, then tightening 32 Nm (3.2 m·kgf, 23 ft·lbf) 6 them to the specified torque. 9. Refill with the specified amount of Tightening torque: the recommended engine oil, and Oil filter element cover bolt: then install and tighten the oil filler 10 Nm (1.0 m·kgf, 7.2 ft·lbf) cap.

TIP MakesurethattheO-ringisproperly seated.

6-12 PERIODIC MAINTENANCE AND MINOR REPAIR

TIP _ Coolant TIP Be sure to wipe off spilled oil on any The coolant level should be checked The coolant level must be checked parts after the engine and exhaust sys- before each ride. In addition, the cool- on a cold engine since the level tem have cooled down. ant must be changed at the intervals varies with engine temperature. _ specified in the periodic maintenance Make sure that the vehicle is posi- and lubrication chart. tioned straight up when checking NOTICE the coolant level. A slight tilt to the side can result in a false reading. Yamalube 4T SJ. 20W-50 MA or To check the coolant level SAE 20W-40 or SAE 20W-50. The coolant level should be checked as 2. Check the coolant level in the cool- Recomended engine oil grade: follows before each ride. In addition, ant reservoir. API service SF, SG, type or higher the coolant must be changed at the in- JASO MA. tervals specified in the periodic mainte- 6 Make sure that no foreign mate- nance and lubrication chart. rial enters the crankcase. 1. Place the vehicle on the center- 6 stand. 10. Start the engine, and then let it idle for several minutes while checking it for oil leakage. If oil is leaking, immediately turn the engine off and check for the cause. 11. Turn the engine off, and then check the oil level and correct it if necessary.

6-13 PERIODIC MAINTENANCE AND MINOR REPAIR

system will not be protected against frost and corrosion. If water has been added to the coolant, have a Yamaha dealer check the antifreeze content of the coolant as soon as possible, otherwise the effective- ness of the coolant will be reduced. 1. Maximum level mark 1. Coolant reservoir cap retainer bolt 2. Minimum level mark 2. Coolant reservoir cap retainer 3. Coolant reservoir cap Coolant reservoir capacity (up to the TIP maximum level mark): 0.28 L (0.30 US qt, 0.25 Imp.qt) The coolant should be between the voir cap. Never attempt to re- 6 move the radiator cap when the minimum and maximum level marks. 6. Install the coolant reservoir cap. engine is hot. NOTICE: If 7. Place the coolant reservoir cap re- 3. If the coolant is at or below the coolant is not available, use tainer in the original position, and minimum level mark, remove cowl- distilled water or soft tap water then tighten the bolt to the speci- ing A. (See page 6-5.) instead. Do not use hard water 4. Loosen the coolant reservoir cap fied torque. or salt water since it is harmful retainer bolt, and then lift the re- to the engine. If water has been tainer upward. Tightening torque: used instead of coolant, re- 5. Remove the coolant reservoir Coolant reservoir cap retainer bolt: place it with coolant as soon as cap, and then add coolant to the 7 Nm (0.7 m·kgf, 5 ft·lbf) possible, otherwise the cooling maximum level mark. WARNING! 8. Install the cowling. Remove only the coolant reser-

6-14 PERIODIC MAINTENANCE AND MINOR REPAIR

Changing the coolant Cleaning the air filter element 1 The coolant must be changed at the in- The air filter element should be cleaned tervals specified in the periodic mainte- at the intervals specified in the periodic nance and lubrication chart. Have a maintenance and lubrication chart. Yamaha dealer change the coolant. Clean the air filter element more fre- WARNING! Never attempt to re- quently if you are riding in unusually move the radiator cap when the en- wet or dusty areas. gine is hot. 1.RemovepanelA.(Seepage6-7.) 2. Remove the air filter case cover by removing the screws and clamp, 1. Air filter element andthenpulltheairfilterelement out. 6

1. Air filter case cover 2. Screw 3. Clamp

6-15 PERIODIC MAINTENANCE AND MINOR REPAIR

4. Insert the air filter element into the air filter case with the arrow mark on the top pointing inward. NOTICE: Make sure that the air filter element is properly seated in the air filter case. The engine should never be operated without the air filter element installed, otherwise the piston(s) 1. Air filter element and/or cylinder(s) may become 1. Carburetor air vent hose 3. Lightly tap the air filter element to excessively worn. remove most of the dust and dirt, 5. Install the air filter case cover by TIP and then blow the remaining dirt installing the screws. Make sure that the carburetor air 6 out with compressed air as shown. vent hose is routed as shown. If the air filter element is damaged, If dust or water collects in the air fil- replace it. ter check hose, remove the clamp from it, and then remove the plug to drain the hose.

6-16 PERIODIC MAINTENANCE AND MINOR REPAIR

Adjusting the carburetor Adjusting the engine idling The carburetor is an important part of speed the engine and requires very sophisti- The engine idling speed must be cated adjustment. Therefore, most car- checked and, if necessary, adjusted as buretor adjustments should be left to a follows at the intervals specified in the Yamaha dealer, who has the neces- periodic maintenance and lubrication 2 1 sary professional knowledge and expe- chart. rience. The adjustment described in the The engine should be warm before following section, however, may be ser- making this adjustment. viced by the owner as part of routine TIP 1. Air filter check hose maintenance. 2. Clamp Theengineiswarmwhenitquickly responds to the throttle. 6. Install the panel. NOTICENO T I CE : 6 A diagnostic tachometer is needed The carburetor has been set and ex- to make this adjustment. tensively tested at the Yamaha factory. Changing these settings 1. Remove cowling B. (See page without sufficient technical knowl- 6-5.) edge may result in poor perfor- 2. Attach the diagnostic tachometer mance of or damage to the engine. to the spark plug lead.

6-17 PERIODIC MAINTENANCE AND MINOR REPAIR TIP: Adjusting the throttle cable If the specified idling speed cannot be free play obtained as described above, have a 1 b Yamaha dealer make the adjustment. 4. Install the cowling. a 1 (a)

1. Throttle stop screw (b) 3 2 3. Check the engine idling speed and, if necessary, adjust it to spec- 1. Throttle cable free play 6 ification by turning the throttle stop 2. Locknut screw. To increase the engine 3. Adjusting nut idling speed, turn the screw in di- The throttle cable free play should mea- rection (a). To decrease the en- sure 3.0–7.0 mm (0.12–0.28 in) at the gine idling speed, turn the screw in throttle grip. Periodically check the direction (b). throttle cable free play and, if neces- Engine idling speed: sary, adjust it as follows. 1300–1500 r/min TIP Theengineidlingspeedmustbecor- rectly adjusted before checking and adjusting the throttle cable free play. 1. Loosen the locknut.

6-18 PERIODIC MAINTENANCE AND MINOR REPAIR

2. To increase the throttle cable free Valve clearance Tires play, turn the adjusting nut in direc- The valve clearance changes with use, To maximize the performance, durabil- tion (a). To decrease the throttle resulting in improper air-fuel mixture ity, and safe operation of your motor- cable free play, turn the adjusting and/or engine noise. To prevent this cycle, note the following points nut in direction (b). from occurring, the valve clearance regarding the specified tires. 3. Tighten the locknut. must be adjusted by a Yamaha dealer at the intervals specified in the periodic Tire air pressure maintenance and lubrication chart. The tire air pressure should be checked and, if necessary, adjusted before each ride.

WARNING The tire air pressure must be 6 checked and adjusted on cold tires (i.e., when the temperature of the tires equals the ambient temperature).

weight of rider, passenger, cargo, and accessories approved for this model.

6-19 PERIODIC MAINTENANCE AND MINOR REPAIR Tire inspection Tire air pressure (measured on cold the weight evenly from side to side. tires): Check the condition and pressure of 0–90 kg (0–198 lb): your tires. NEVER OVERLOAD Front: YOUR MOTORCYCLE. Make sure 200 kPa (29 psi) (2.00 kgf/cm²) the total weight of the cargo, rider, Rear: 225 kPa (33 psi) (2.25 kgf/cm²) passenger, and accessories (fairing, 90–150kg(198–331 lb): saddlebags, etc. if approved for this Front: model) does not exceed the maxi- 200 kPa (29 psi) (2.00 kgf/cm²) mum load of the motorcycle. Opera- Rear: tion of an overloaded motorcycle 225 kPa (33 psi) (2.25 kgf/cm²) could cause tire damage, an acci- 1. Tire sidewall Maximum load*: 2. Tire wear indicator 150kg(331 lb) dent, or even injury. 3. Tire tread depth * Total weight of rider, passenger, cargo and accessories The tires must be checked before each 6 ride. If the tire shows crosswise lines WARNING (minimum tread depth), if the tire has a nail or glass fragments in it, or if the Proper loading of your motorcycle is sidewall is cracked, have a Yamaha important for several characteristics dealer replace the tire immediately. dling, braking, performance and Minimum tire tread depth (front and safety. Do not carry loosely packed rear): items that can shift. Securely pack 1.0 mm (0.04 in) your heaviest items close to the cen- TIP ter of the motorcycle, and distribute The tire tread depth limits may differ from country to country. Always comply with the local regulations. 6-20 PERIODIC MAINTENANCE AND MINOR REPAIR

Tire information Wheels This motorcycle is equipped with WARNING To maximize the performance, durabil- tubeless tires. It is dangerous to ride with a ity, and safe operation of your motor- worn-out tire. When a tire tread WWARNINGARNING cycle, note the following points begins to show crosswise lines, regarding the specified wheels. The front and rear tires should have a Yamaha dealer replace The wheel rims should be checked be of the same make and de- the tire immediately. for cracks, bends or warpage, and sign, otherwise the handling the spokes for looseness or dam- characteristics of the vehicle age before each ride. If any dam- cannot be guaranteed. age is found, have a Yamaha After extensive tests, only the dealer replace the wheel. Do not tires listed below have been ap- attempt even the smallest repair to proved for this model by the wheel. A deformed or cracked 6 Yamaha Motor Co., Ltd. wheel must be replaced. The wheel should be balanced Front tire: whenever either the tire or wheel Size: 70/90-17M/C 38P has been changed or replaced. An Manufacturer/model: unbalanced wheel can result in Vee Rubber/V322F poor performance, adverse handling characteristics, and a short- Rear tire: Size: 80/90-17M/C 44P ened tire life. Manufacturer/model: Ride at moderate speeds after Vee Rubber/V322F changing a tire since the tire surface must first be “broken in” for it to develop its optimal characteristics.

6-21 PERIODIC MAINTENANCE AND MINOR REPAIR

Checking the brake lever free Adjusting the brake pedal free play play

(a) a 1 (b) 1

1. Brake pedal free play adjusting nut

There should be no free play at the 1. Brake pedal free play WARNING 6 brake lever end. If there is free play, The brake pedal free play should mea- After adjusting the drive chain have a Yamaha dealer inspect the sure 25.0–35.0 mm (0.98–1.38 in) at slack or removing and installing brake system. the brake pedal end as shown. Period- the rear wheel, always check the WARNING ically check the brake pedal free play brake pedal free play. and, if necessary, adjust it as follows. If proper adjustment cannot be A soft or spongy feeling in the brake To increase the brake pedal free play, obtained as described, have a lever can indicate the presence of air turn the adjusting nut in direction (a). To Yamaha dealer make this ad- in the hydraulic system. If there is air decrease the brake pedal free play, justment. in the hydraulic system, have a turn the adjusting nut in direction (b). After adjusting the brake pedal Yamaha dealer bleed the system be- free play, check the operation of fore operating the motorcycle. Air in the brake light. the hydraulic system will diminish the braking performance, which may result in loss of control and an accident. 6-22 PERIODIC MAINTENANCE AND MINOR REPAIR

Adjusting the rear brake light Checking the front brake pads Front brake pads switch and rear brake shoes The front brake pads and the rear brake shoes must be checked for wear at the intervals specified in the periodic maintenance and lubrication chart. 1 1

1. Rear brake light switch 1. Brake pad wear indicator groove 6 2. Rear brake light switch adjusting nut Each front brake pad is provided with The rear brake light switch, which is ac- wear indicator grooves, which allow tivated by the brake pedal, is properly you to check the brake pad wear with- adjusted when the brake light comes outhavingtodisassemblethebrake. on just before braking takes effect. If To check the brake pad wear, check necessary, adjust the brake light switch the wear indicator grooves. If a brake as follows. pad has worn to the point that the wear Turn the adjusting nut while holding the indicator grooves have almost disap- rear brake light switch in place. To peared, have a Yamaha dealer replace make the brake light come on earlier, the brake pads as a set. turn the adjusting nut in direction (a). To make the brake light come on later, turn the adjusting nut in direction (b).

6-23 PERIODIC MAINTENANCE AND MINOR REPAIR

Rear brake shoes Checking the front brake fluid Observe these precautions: level When checking the fluid level, 1 2 make sure that the top of the master cylinder is level by turning the handlebars. Useonlytherecommendedquality 1 brake fluid, otherwise the rubber seals may deteriorate, causing leakage and poor braking performance.

Recommended brake fluid: 1. Brake shoe wear limit line DOT 4 2. Brake shoe wear indicator 1. Minimum level mark 6 TIP: The rear brake is provided with a wear Insufficient brake fluid may allow air to indicator, which allows you to check the enter the brake system, possibly caus- If DOT 4 is not available, DOT 3 can be brake shoe wear without having to dis- ingittobecomeineffective. used. assemble the brake. To check the Before riding, check that the brake fluid Refill with the same type of brake brake shoe wear, check the position of is above the minimum level mark and fluid. Mixing fluids may result in a the wear indicator while applying the replenish if necessary. A low brake fluid harmful chemical reaction and brake. If a brake shoe has worn to the lead to poor braking performance. point that the wear indicator reaches Be careful that water does not en- thewearlimitline,haveaYamaha ter the master cylinder when refill- dealer replace the brake shoes as a the brake pads for wear and the brake ing. Water will significantly lower set. system for leakage. the boiling point of the fluid and may result in vapor lock.

6-24 PERIODIC MAINTENANCE AND MINOR REPAIR

Brake fluid may deteriorate paint- Changing the brake fluid Drive chain slack ed surfaces or plastic parts. Al- Have a Yamaha dealer change the The drive chain slack should be ways clean up spilled fluid brake fluid at the intervals specified in checked before each ride and adjusted immediately. the NOTE after the periodic mainte- if necessary. As the brake pads wear, it is nor- nance and lubrication chart. In addition, mal for the brake fluid level to grad- have the oil seals of the brake master To check the drive chain slack ually go down. However, if the cylinder and caliper as well as the 1. Place the motorcycle on the cen- brake fluid level goes down sud- brakehosereplacedattheintervals terstand. denly, have a Yamaha dealer listed below or whenever they are dam- 2. Shift the transmission into the neu- check the cause. aged or leaking. tral position. Oil seals: Replace every two 3. Spin the rear wheel several times years. to locate the tightest portion of the Brake hose: Replace every four drive chain. 6 years. 4. Measure the drive chain slack as shown.

6-25 PERIODIC MAINTENANCE AND MINOR REPAIR

To adjust the drive chain slack Right side

1 a b 3 1 1 2 2

1. Drive chain slack 1. Brake pedal free play adjusting nut Drive chain slack : 2. Axle nut 1. Axle nut 6 2. Adjusting plate 25.0–35.0 mm (0.98–1.38 in) 3. Stopper alignment. 1. Loosen the brake pedal free play 5. If the drive chain slack is incorrect, adjusting nut. per drive chain slack will over- adjust it as follows. 2. Loosen the axle nut, and brake load the engine as well as other torque rod nut. vital parts of the motorcycle and 3. To tighten the drive chain, turn the can lead to chain slippage or drive chain slack adjusting plate breakage. To prevent this from on each side of the swing arm occurring, keep the drive chain in direction (a). To loosen thedri- slack within the specified limits. ve chain, turn the adjusting plate on each side of the swingarm in direction (b), and then push the rear wheel forward. NOTICE: Impro-

6-26 PERIODIC MAINTENANCE AND MINOR REPAIR

Left side 4. Tighten the axle nut and brake Cleaning and lubricating the torque rod nut to the specified drive chain 2 torques. The drive chain must be cleaned and lubricated at the intervals specified in b a Tightening torques: 3 Axle nut: the periodic maintenance and lubrica- 60 Nm (6.0 m·kgf, 43 ft·lbf) tion chart, otherwise it will quickly wear Brake torque rod nut: out, especially when riding in dusty or 19 Nm (1.9 m·kgf, 14 ft·lbf) wet areas. Service the drive chain as follows. 1 5. Adjust the brake pedal free play. (See page 6-22.) 1. Axle nut NOTICE 2. Adjusting plate The drive chain must be lubricated 3. Stopper alignment. WARNING after washing the motorcycle and 6 After adjusting the brake pedal free riding in the rain. TIP: play, check the operation of the Make sure that both adjusting plates 1. Remove all dirt and mud from the brake light. are in the same position for proper drivechainwithabrushorcloth. wheel alignment. TIP : For a thorough cleaning, have a Yamaha dealer remove the drive chain and soak it in solvent.

6-27 PERIODIC MAINTENANCE AND MINOR REPAIR

2. Spray Yamaha Chain and Cable Checking and lubricating the Checking and lubricating the Lube or a high-quality spray-type cables throttle grip and cable drive chain lubricant on both sides The operation of all control cables and The operation of the throttle grip should andonthemiddleofthechain, the condition of the cables should be be checked before each ride. In addi- making sure that all side plates checked before each ride, and the cation, the cable should be lubricated at and rollers have been sufficiently bles and cable ends should be lubricat- the intervals specified in the periodic oiled. ed if necessary. If a cable is damaged maintenance chart. or does not move smoothly, have a Yamaha dealer check or replace it.

Recommended lubricant: Engine oil

6 WARNING Damage to the outer sheath may in- terfere with proper cable operation and will cause the inner cable to rust. Replace a damaged cable as soon as possible to prevent unsafe conditions.

6-28 PERIODIC MAINTENANCE AND MINOR REPAIR

Checking and lubricating the Lubricating the brake pedal Checking and lubricating the brake lever centerstand and sidestand

The operation of the brake pedal The operation of the centerstand and 6 The operation of the brake lever should should be checked before each ride, sidestand should be checked before be checked before each read, and the and the pedal pivot should be lubricat- each ride, and the pivots and metal-to- lever pivots should be lubricated if ed if necessary. metal contact surfaces should be lubri- necessary. cated if necessary. Recommended lubricant: Recommended lubricant: LhLtii thiumium--sosoapap-bas-gbaseed d grreae(alasse e (alll-pu-purr-- WARNING Engine oil ppoosrse e greg eaasse) If the centerstand or sidestand does not move up and down smoothly, have a Yamaha dealer check or repair it.

Recommended lubricant: Lithium-soap-based grease (all-pur- pose grease) 6-29 PERIODIC MAINTENANCE AND MINOR REPAIR

Lubricating the swingarm Checking the front fork pivots The condition and operation of the front The swingarm pivots must be lubricat- fork must be checked as follows at the ed at the intervals specified in the peri- intervals specified in the periodic main- odic maintenance and lubrication chart. tenance and lubrication chart.

Recommended lubricant: To check the condition Lithium-soap-based grease Check the inner tubes for scratches, damage and excessive oil leakage.

To check the operation 1. Place the vehicle on a level sur- NOTICE faceandholditinanuprightposi- If any damage is found or the front tion.WARNING! To avoid injury fork does not operate smoothly, 6 securely support the vehicle so have a Yamaha dealer check or re- that there is no danger of it fall pair it. ling over. 2. While applying the front brake, push down hard on the handlebars several times to check if the front fork compresses and rebounds smoothly.

6-30 PERIODIC MAINTENANCE AND MINOR REPAIR

Checking the steering Checking the wheel bearings Worn or loose steering bearings may The front and rear wheel bearings must cause danger. Therefore, the operation be checked at the intervals specified in ofthesteeringmustbecheckedasfol- the periodic maintenance and lubrica- lows at the intervals specified in the pe- tion chart. If there is play in the wheel riodic maintenance and lubrication hub or if the wheel does not turn chart. smoothly, have a Yamaha dealer check 1. Place a stand under the engine to the wheel bearings. raise the front wheel off the ground. WARNING! To avoid injury securely support the vehicle so that there is no danger of it fal- 6 ling over. 2. Hold the lower ends of the front fork legs and try to move them for-

play can be felt, have a Yamaha dealer check or repair the steering.

6-31 PERIODIC MAINTENANCE AND MINOR REPAIR

Battery WARNING _ KEEP THIS AND ALL BATTER- Electrolyte is poisonous and IES OUT OF THE REACH OF dangerous since it contains sul- 2 CHILDREN. furic acid, which causes severe _ burns. Avoid any contact with To charge the battery skin, eyes or clothing and al- Have a Yamaha dealer charge the bat- ways shield your eyes when tery as soon as possible if it seems to 1 working near batteries. In case have discharged. Keep in mind that the of contact, administer the fol- battery tends to discharge more quickly lowing FIRST AID. if the vehicle is equipped with optional • EXTERNAL: Flush with plenty 1. Negative battery lead electrical accessories. 2. Positive battery lead of water. ThismodelisequippedwithaVRLA • INTERNAL: Drink large quan- NOTICE 6 _ (Valve Regulated Lead Acid) battery. tities of water or milk and im- To charge a VRLA (Valve Regulated mediately call a physician. There is no need to check the electro- Lead Acid) battery, a special (con- • EYES: Flush with water for lyte or to add distilled water. However, stant-voltage) battery charger is re- the battery lead connections need to be 15 minutes and seek prompt quired. Using a conventional battery medical attention. checked and, if necessary, tightened. charger will damage the battery. If Batteries produce explosive hy- you do not have access to a con- NOTICE drogen gas. Therefore, keep stant-voltage battery charger, have _ sparks, flames, cigarettes, etc., Never attempt to remove the battery a Yamaha dealer charge your bat- away from the battery and pro- cell seals, as this would permanent- tery. vide sufficient ventilation when _ ly damage the battery. charging it in an enclosed space.

6-32 PERIODIC MAINTENANCE AND MINOR REPAIR

To store the battery Replacing the fuse 2. Remove the blown fuse, and then 1. If the vehicle will not be used for install a new fuse of the specified more than one month, remove the amperage. WARNING !: Do not battery, fully charge it, and then 2 place it in a cool, dry place. use a fuse of a higher amperage NOTICE: When removing the 1 rating than recommended to a- battery, be sure the key is void causing extensive damage - turned to “OFF”, then discon- to the electrical system and pos nect the negative lead before sibly a fire. disconnecting the positive lead. 2. If the battery will be stored for Specified fuse: 10.0 A more than two months, check it at 1. Spare fuse least once a month and fully 2. Fuse charge it if necessary. 3. Turn the key to “ON” and turn on The fuse holder is located under the 3. Fully charge the battery before in- the electrical circuits to check if the 6 seat. (See page 3-9.) stallation. devices operate. If the fuse is blown, replace it as fol- 4. After installation, make sure that 4. If the fuse immediately blows lows. the battery leads are properly con- again, have a Yamaha dealer 1. Turn the key to “OFF” and turn off nected to the battery terminals. check the electrical system. all electrical circuits. NONOTICETTIICE _ Always keep the battery charged. Storing a discharged battery can cause permanent battery damage.

6-33 PERIODIC MAINTENANCE AND MINOR REPAIR Replacing a headlight bulb NOTICE Do not touch the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the luminosity of the bulb, and the bulb life will be adversely af- 1 fected. Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with al- 1. Do not touch the glass part of the bulb. cohol or thinner. 1. Headlight bulb holder 4. Install the cowling. If a headlight bulb burns out, replace WARNING 5. Have a Yamaha dealer adjust the as follows. Headlight bulbs get very hot. There- 6 headlight beam if necessary. 1. Remove cowling A. (See page fore, keep flammable products away 6-5.) from a lit headlight bulb, and do not 2. Remove the headlight bulb holder touch the bulb until it has cooled by pushing it inward and turning down. counterclockwise, and then re move the defective bulb. 3. Place a new bulb into position, and then secure it with the bulb holder.

6-34 PERIODIC MAINTENANCE AND MINOR REPAIR

Replacing a front turn signal Rear turn signal light and light bulb or an auxiliary light tail/brake light bulb If a rear turn signal light or the tail/brake 1 light does not come on, have a Yamaha 1 dealer check its electrical circuit or replace the bulb. 2

1. Bulb

6 1. Turn signal light bulb socket 3. Remove the defective bulb by pull- 2. Auxiliary light bulb socket ing it out. 4. Insert a new bulb into the socket. 5. Install the socket (together with the If a front turn signal light or an auxiliary bulb) by turning it clockwise. light bulb burns out, replace it as fol- 6. Install the cowlings. lows. 1. Remove front panel and cowlings B, (See page 6-5.) 2. Remove the socket (together with the bulb) by turning it counterclockwise.

6-35 PERIODIC MAINTENANCE AND MINOR REPAIR Front wheel

2 1 2 1. Speedometer gear unit 1. Speedometer cable 1. Speedometer cable 2. Axle nut and washer 2. Axle nut and washer To install the front wheel 4. Pull the wheel axle out, and then 1. Install the speedometer gear unit 6 To remove the front wheel remove the wheel. NOTICE: Do- into the wheel hub so that the pro- jection on the wheel hub fits in ei- WWARNINGARNING wheel has been removed together slot of the speedometer gear unit. To avoid injury, secutely support the ther with the brake disc, other- 2. Lift the wheel up between the fork vehicle so there is no danger of it wise the brake pads will be for- legs. falling over. ced shut. TIP : Make sure that there is enough space between the brake pads before inserting the brake disc and that the retainer in the speedometer gear unit fits over theslotontheforkleg.

6-36 PERIODIC MAINTENANCE AND MINOR REPAIR TIP: When tightening the axle nut, hold the Rear wheel wheel axle with a wrench to keep it from To remove the rear wheel turning.

6. While applying the front brake, 2 1 push down hard on the handlebars 3 several times to check if the front fork compresses and rebounds smoothly. 7. Connect the speedometer cable. 1. Retainer 1 2 2. Slot 1. Brake pedal free paly adjusting nut 6 3. Insert the wheel axle, and then in- 2. Brake torque rod nut and bolt stall the washer and the axle nut. 3. Axle nut 4. Take the motorcycle off the centerstand so that the front wheel is on WARNING the ground. It is advisable to have a Yamaha 5. Tighten the axle nut to the speci- dealer service the wheel. fied torque. Securely support the motorcycle so that there is no danger Tightening torque: of it falling over. Axle nut: 40 Nm (4.0 m·kgf, 29 ft·lbf) 1. Loosen the axle nut. 2. Remove the brake pedal free play adjusting nut, and then disconnect the brake rod from the brake camshaft lever. 6-37 PERIODIC MAINTENANCE AND MINOR REPAIR

TIP: The drive chain does not need to be disassembled in order to remove and 2 3 install the wheel. a 2 7. Remove the wheel.

1 To install the rear wheel 1. Install the drive chain onto the rear sprocket. 1 1. Chain adjusting plate 2. Install the wheel by inserting the 2. Brake rod wheel axle from the right-hand 1. Axle nut 3. Brake camshaft lever side. 2. Chain adjusting plate 6 3. Turn the drive chain adjusting plate TIP: on each side of the swingarm fully Make sure chain adjusting plate is 3. in direction (a) installed onto the wheel axle before axle nut. 4. Lift the rear wheel off the ground installing the wheel axle. 4. Install the brake rod onto the brake according to the procedure. camshaft lever, and then install the 5. Remove the axle nut, and then pull brake pedal free play adjusting nut the wheel axle out. onto the brake rod. 5. Connect the brake torque rod to 6. Push the wheel forward, and then the brake shoe plate by installing remove the drive chain from the the bolt, the washer and the nut. rear sprocket. 6. Adjust the drive chain slack. (See page 6-26.)

6-38 PERIODIC MAINTENANCE AND MINOR REPAIR

7. Take the motorcycle off the centerstand so that the rear wheel is on Troubleshooting the ground. Although Yamaha motorcycles receive 8. Tighten the brake torque rod nut a thorough inspection before shipment and axle nut to the specified from the factory, trouble may occur dur- torques. ing operation. Any problem in the fuel, compression, or ignition systems, for TIP: example, can cause poor starting and When tightening the axle nut, hold the loss of power. wheel axle with a wrench to keep it from The following troubleshooting charts turning. represent quick and easy procedures for checking these vital systems your- Tightening torques: self. However, should your motorcycle 6 Braketorquerodnut: require any repair, take it to a Yamaha 19 Nm (1.9 m·kgf, 14 ft·lbf) dealer, whose skilled technicians have Axle nut: the necessary tools, experience, and 60 Nm (6.0 m·kgf, 43 ft·lbf) know-how to service the motorcycle 9. Insert a new cotter pin. properly. 10. Adjust the brake pedal free play. Use only genuine Yamaha replace- (See page 6-22.) ment parts. Imitation parts may look like Yamaha parts, but they are often inferi- WARNING or, have a shorter service life and can After adjusting the brake pedal free lead to expensive repair bills. play, check the operation of the brake light.

6-39 PERIODIC MAINTENANCE AND MINOR REPAIR

Troubleshooting charts

Starting problems or poor engine performance

WARNING Keep away open flames and do not smoke while checking or working on the fuel system.

1. Fuel There is Check the compression. enough fuel. Check the fuel level in the fuel tank. There is Supply fuel. The engine does not start. no fuel. Check the compression.

2. Compression 6 There is compression. Check the ignition. Operate the electric starter or the kickstarter. Have a Yamaha dealer There is no compression. check the vehicle.

3. Ignition Wipe off with a dry cloth and correct the Wet Open the throttle halfway and spark plug gap, or replace the spark plug. operate the electric starter. Remove the spark plug and check the electrodes. The engine does not start. Dry Have a Yamaha dealer check the vehicle. Check the battery.

4. Battery The engine turns over The battery is good. quickly. Operate the The engine does not start. Have a electric starter. Yamaha dealer check the vehicle. The engine turns over Check the electrolyte and battery slowly. lead connections, and charge the battery if necessary.

6-40 PERIODIC MAINTENANCE AND MINOR REPAIR

Engine overheating

WARNING Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury. Be sure to wait until the engine has cooled. After removing the radiator cap retaining bolt, place a thick rag, like a towel, over the radiator cap, and then slowly rotate the cap counterclockwise to the detent to allow any residual pressure to escape. When the hissing sound has stopped, press down on the cap while turning it counterclockwise, and then remove the cap.

There is Have a Yamaha dealer check The coolant level is low. leakage. and repair the cooling system. Check the cooling system for leakage. There is Add coolant. (See NOTE.) Wait until the Check the coolant level in the no leakage. 6 engine has cooled. reservoir and radiator. The coolant level Start the engine. If the engine overheats again, have a is OK. Yamaha dealer check and repair the cooling system.

TIP: If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommended coolant as soon as possible.

6-41 MOTORCYCLE CARE AND STORAGE

Care ucts onto seals, gaskets, sprock- cleaning products, solvent or While the open design of a motorcycle ets, the drive chain and wheel thinner, fuel (gasoline), rust re- reveals the attractiveness of the tech- axles. Always rinse the dirt and de- movers or inhibitors, brake flu- nology, it also makes it more vulnera- greaser off with water. id, antifreeze or electrolyte. ble. Rust and corrosion can develop Cleaning Do not use high-pressure wash- even if high-quality components are ers or steam-jet cleaners since used. A rusty exhaust pipe may go un- NOTICENOTICE they cause water seepage and noticed on a car, however, it detracts Avoid using strong acidic wheel deterioration in the following ar- from the overall appearance of a motor- cleaners, especially on spoked eas: seals (of wheel and swing- cycle. Frequent and proper care does wheels. If such products are arm bearings, fork and brakes), not only comply with the terms of the used on hard-to-remove dirt, do electric components (couplers, warranty, but it will also keep your not leave the cleaner on the af- connectors, instruments, motorcycle looking good, extend its life fected area any longer than in- switches and lights), breather andoptimizeitsperformance. structed. Also, thoroughly rinse hoses and vents. For motorcycles equipped with Before cleaning the area off with water, immedi- a windshield: Do not use strong 1.Coverthemuffleroutletwitha ately dry it, and then apply a cor- cleaners or hard sponges as plastic bag after the engine has rosion protection spray. they will cause dulling or 7 cooled down. Improper cleaning can damage scratching. Some cleaning com- 2. Make sure that all caps and covers windshields, cowlings, panels pounds for plastic may leave as well as all electrical couplers and other plastic parts. Use only scratches on the windshield. and connectors, including the a soft, clean cloth or sponge Test the product on a small hid- spark plug cap, are tightly in- with mild detergent and water to den part of the windshield to stalled. clean plastic. make sure that it does not leave 3. Remove extremely stubborn dirt, Do not use any harsh chemical any marks. If the windshield is like oil burnt onto the crankcase, products on plastic parts. Be scratched, use a quality plastic with a degreasing agent and a sure to avoid using cloths or polishing compound after brush, but never apply such prod- sponges which have been in contact with strong or abrasive washing. 7-1 MOTORCYCLE CARE AND STORAGE

After normal use 4. To prevent corrosion, it is recom- Remove dirt with warm water, a mild NOTICE mended to apply a corrosion pro- detergent, and a soft, clean sponge, Do not use warm water since it in- tection spray on all metal, and then rinse thoroughly with clean creases the corrosive action of the including chrome- and nickel-plat- water. Use a toothbrush or bottlebrush salt. ed, surfaces. for hard-to-reach areas. Stubborn dirt 2. Apply a corrosion protection spray 5. Use spray oil as a universal clean- and insects will come off more easily if on all metal, including chrome- and er to remove any remaining dirt. theareaiscoveredwithawetclothfor nickel-plated, surfaces to prevent 6. Touch up minor paint damage a few minutes before cleaning. corrosion. caused by stones, etc. 7. Wax all painted surfaces. Afterridingintherain,neartheseaor After cleaning 8. Let the motorcycle dry completely on salt-sprayed roads 1. Dry the motorcycle with a chamois before storing or covering it. Since sea salt or salt sprayed on roads or an absorbing cloth. during winter are extremely corrosive in WARNING 2. Immediately dry the drive chain combination with water, carry out the and lubricate it to prevent it from Make sure that there is no oil or followingstepsaftereachrideinthe rusting. wax on the brakes or tires. If rain, near the sea or on salt-sprayed 3. Use a chrome polish to shine necessary, clean the brake 7 roads. chrome, aluminum and stainless- discs and brake linings with a TIP: steel parts, including the exhaust regular brake disc cleaner or ac- Salt sprayed on roads in the winter may system. (Even the thermally in- etone, and wash the tires with remain well into spring. duced discoloring of stainless- warm water and a mild deter- steel exhaust systems can be re- gent. 1. Clean the motorcycle with cold wa- moved through polishing.) Before operating the motor- ter and a mild detergent, after the cycle test its braking perfor- engine has cooled down. mance and cornering behavior.

7-2 MOTORCYCLE CARE AND STORAGE

Long-term NOTICE Storage Before storing your motorcycle for sev- Short-term Apply spray oil and wax spar- eral months: Always store your motorcycle in a cool, ingly and make sure to wipe off 1. Follow all the instructions in the dry place and, if necessary, protect it any excess. “Care” section of this chapter. against dust with a porous cover. Never apply oil or wax to any 2. For motorcycles equipped with a rubber and plastic parts, but NOTICE fuel cock that has an “OFF” posi- treat them with a suitable care tion: Turn the fuel cock lever to Storing the motorcycle in a product. “OFF”. poorly ventilated room or cover- Avoid using abrasive polishing 3. Drain the carburetor float chamber ing it with a tarp, while it is still compounds as they will wear by loosening the drain bolt; this will wet, will allow water and humid- away the paint. prevent fuel deposits from building ity to seep in and cause rust. up. Pour the drained fuel into the To prevent corrosion, avoid TIP: fuel tank. damp cellars, stables (because Consult a Yamaha dealer for advice on 4. Fill up the fuel tank and add fuel of the presence of ammonia) what products to use. stabilizer (if available) to prevent and areas where strong chemi- 7 the fuel tank from rusting and the cals are stored. fuel from deteriorating.

7-3 MOTORCYCLE CARE AND STORAGE

5. Perform the following steps to pro- WARNING °C (90 °F)]. For more information tect the cylinder, piston rings, etc. on storing the battery, see page To prevent damage or injury from from corrosion. 6-28. sparking, make sure to ground the a. Remove the spark plug cap spark plug electrodes while turning TIP: and spark plug. the engine over. b. Pour a teaspoonful of engine oil Make any necessary repairs before into the spark plug bore. 6. Lubricate all control cables and the storing the motorcycle. c. Install the spark plug cap onto pivoting points of all levers and the spark plug, and then place pedals as well as of the side- the spark plug on the cylinder stand/centerstand. head so that the electrodes are 7. Check and, if necessary, correct grounded. (This will limit spark- the tire air pressure, and then lift ing during the next step.) the motorcycle so that both of its d. Turn the engine over several wheels are off the ground. Alterna- times with the starter. (This will tively, turn the wheels a little every 7 coat the cylinder wall with oil.) month in order to prevent the tires e. Remove the spark plug cap from becoming degraded in one from the spark plug, and then spot. install the spark plug and the 8. Cover the muffler outlet with a spark plug cap. plastic bag to prevent moisture from entering it. 9. 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 excessively cold or warm place [less than0°C(30°F)ormorethan30 7-4 SPECIFICATIONS

Dimensions: Engine oil: Spark plug (s): Overall length: Type: Manufacturer/model: 1960 mm (77.2 in) YAMALUBE 4T SJ 20W-50 MA or NGK CPR8EA-9/ DENSO U24EPR-9 Overall width: SAE20W40 or SAE20W50 Spark plug gap: 695 mm (27.4 in) Recommended engine oil grade: 0.8–0.9 mm (0.031–0.035 in) Overall height: API service SF, SG type or higher Clutch: 1080 mm (42.5 in) JASO MA Clutch type: Seat height: Engine oil quantity: Wet, multiple-disc and centrifugal 775 mm (30.5 in) Without oil filter element replacement: automatic Wheelbase: 0.80 L (0.85 US qt) (0.70 Imp.qt) Transmission: 1255mm(49.4 in) With oil filter element replacement: Primary reduction system: Ground clearance: 0.90 L (0.95 US qt) (0.79 Imp.qt) Spur gear 130mm(5.12 in) Cooling system: Primary reduction ratio: Minimum turning radius: Coolant reservoir capacity (maximum 69/24 (2.875) 1930mm(76.0 in) level) YAMAHA GENUINE COOLANT: Secondary reduction system: Weight: 0.28 L (0.30 US qt) (0.25 Imp.qt) Chain drive With oil and fuel: Radiator capacity (including all routes): Secondary reduction ratio: 111 kg (245 lb) 0.62 L (0.66 US qt) (0.55 Imp.qt) 39/15 (2.600) Engine: Air filter: Transmission type: Engine type: Air filter element: Constant mesh 4-speed Liquid cooled 4-stroke, SOHC Dry element Operation: Cylinder arrangement: Fuel: Left foot operation 8 Forward-inclined single cylinder Recommended fuel: Gear ratio: Displacement: Regular unleaded gasoline only 1st: 134 cm³ (8.20 cu.in) Fuel tank capacity: 34/12 (2.833) Bore ? stroke: 4.0 L (1.06 US gal) (0.88 Imp.gal) 2nd: 54.0 ? 58.7 mm (2.13 ? 2.31 in) Carburetor: 30/16 (1.875) Compression ratio: Manufacturer: 3rd: 10.90 :1 MIKUNI 23/17 (1.353) Starting system: 4th: Type ? quantity: Electric starter and kickstarter 23/22 (1.045) BS25 x1 Lubrication system: Wet sump 8-1 SPECIFICATIONS

Chassis: Tire air pressure (measured on cold Rear brake: Frame type: tires): Type: Diamond Loading condition: Drum brake Caster angle: 0–90 kg (0–198 lb) Operation: 25.60 ° Front: Right foot operation Trail: 200 kPa (29 psi) (2.00 kgf/cm²) Front suspension: 80.0 mm (3.1 in) Rear: Type: Front tire: 225 kPa (33 psi) (2.25 kgf/cm²) Telescopic fork Type: Loading condition: Spring/shock absorber type: Tubeless 90–150kg(198–331 lb) Coil spring/oil damper Size: Front: Wheel travel: 70/90-17M/C 38P 200 kPa (29 psi) (2.00 kgf/cm²) 100.0 mm (3.94 in) Manufacturer/model: Rear: Rear suspension: 225 kPa (33 psi) (2.25 kgf/cm²) Vee Rubber/V322F Type: Front wheel: Swingarm (monocross) Wheel type: Spring/shock absorber type: Rear tire: Cast wheel Coil spring/oil damper Type: Rim size: Wheel travel: Tubeless 17x1.40 90.0 mm (3.54 in) Size: Rear wheel: Electrical system: 80/90-17M/C 44P Wheel type: Ignition system: 8 Manufacturer/model: Cast wheel DC. CDI Vee Rubber/V322F Rim size: Charging system: 17x1.60 AC magneto Front brake: Battery: Loading: Type: Model: Maximum load: Single disc brake GTZ 5 150kg(331 lb) Operation: Voltage, capacity: (Total weight of rider, passenger, cargo and Right hand operation 12 V, 3.5 Ah accessories) Recommended fluid: Headlight: DOT 3 or 4 Bulb type: Krypton bulb 8-2 SPECIFICATIONS

Bulb voltage, wattage x quantity: Headlight: 12 V, 32 W/32.0 W x 1 Tail/brake light: 12 V, 3.0 W x 1 Front turn signal light: 12 V, 10.0 W x 2 Rear turn signal light: 12 V, 10.0 W x 2 Auxiliary light: 12 V, 0.8 W x 2 Meter lighting: 12 V, 1.7 W x 2 Neutral indicator light: 12 V, 1.7 W x 1 Gear position indicator light: 12 V, 1.7 W x 4 High beam indicator light: 12 V, 1.7 W x 1 Turn signal indicator light: 12 V, 3.0 W x 2 Coolant temperature warning light: 8 12 V, 1.7 W x 1 Fuse: Fuse: 10.0 A

8-3 CONSUMER INFORMATION

Identification numbers Key identification number Vehicle identification number Record the key identification number, vehicle identification number and engine serial number in the spaces pro- 1 vided below for assistance when 1 ordering spare parts from a Yamaha dealer or for reference in case the vehi- cleisstolen. KEY IDENTIFICATION NUMBER:

1. Key identification number 1. Vehicle identification number The key identification number is The vehicle identification number is stamped into the key. Record this num- stamped into the rear frame. VEHICLE IDENTIFICATION ber in the space provided and use it for TIP: NUMBER: reference when ordering a new key. The vehicle identification number is used to identify your vehicle and may be used to register it with the licensing authority in your area. 9 ENGINE SERIAL NUMBER:

9-1 CONSUMER INFORMATION

Engine serial number

1. Engine serial number The engine serial number is stamped into the crankcase.

9-2