Yamaha TT-R230W Owner`s manual

OWNER’S MANUAL
TT-R230W
YAMAHA MOTOR DA AMAZÔNIA LTDA.
LIT-11626-20-02
1C6-F8199-13
INTRODUCTION
Congratulations on your purchase of the Yamaha TTR230W. This model is the result of Yamaha’s vast experience in the
production of fine sporting, touring, and pacesetting racing machines. It represents the high degree of craftsmanship and
reliability that have made Yamaha a leader in these fields.
This manual will give you an understanding of the operation, inspection, and basic maintenance of this motorcycle. If you
have any questions concerning the operation or maintenance of your motorcycle, please consult a Yamaha dealer.
1
IMPOR
TANT MANUAL INFORMA
TION
IMPORT
INFORMATION
Particularly important information is distinguished in this manual by the following notations:
The Safety Alert Symbol means A
TTENTION! BECOME ALER
T! YOUR SAFETY IS INVOL
VED!
ATTENTION!
ALERT!
INVOLVED!
1
ARNING instructions could result in severe injury or death to the motorcycle
Failure to follow W
WARNING
operator
operator,, a bystander or a person inspecting or repairing the motorcycle.
A CAUTION indicates special precautions that must be taken to avoid damage to the motorcycle.
A NOTE provides key information to make procedures easier or clearer.
l
l
This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle
is subsequently sold.
Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most
current product information available at the time of printing, there may be minor discrepancies between your motorcycle
and this manual. If you have any questions concerning this manual, please consult your Yamaha dealer.
IMPOR
TANT MANUAL INFORMA
TION
IMPORT
INFORMATION
PLEASE READ THIS MANUAL AND THE “YOU AND YOUR MOT
ORCYCLE: RIDING TIPS” BOOKLET CAREFULL
Y
MOTORCYCLE:
CAREFULLY
AND COMPLETEL
Y BEFORE OPERA
TING THIS MACHINE. DO NOT A
TTEMPT T
O OPERA
TE THIS MOT
ORCYCLE
MOTORCYCLE
COMPLETELY
OPERATING
ATTEMPT
TO
OPERATE
UNTIL YOU HA
VE A
TT
AINED ADEQUA
TE KNOWLEDGE OF ITS CONTROLS AND OPERA
TING FEA
TURES AND
HAVE
ATT
TTAINED
ADEQUATE
OPERATING
FEATURES
UNTIL YOU HA
VE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES. REGULAR INSPECTIONS AND
HAVE
T YOU SAFEL
Y ENJOY THE
CAREFUL MAINTENANCE, ALONG WITH GOOD RIDING SKILLS, WILL ENSURE THA
SAFELY
THAT
ABILITIES AND THE RELIABILITY OF THIS MOT
ORCYCLE.
CAP
MOTORCYCLE.
CAPABILITIES
THIS MACHINE IS DESIGNED AND MANUF
MANUFACTURED
ONLY
TO
OPERATE
ACTURED FOR OFF-ROAD USE ONL
Y. IT IS ILLEGAL T
O OPERA
TE
AY. SUCH USE IS PROHIBITED BY LA
W. THIS MACHINE
LAW
STREET,, ROAD OR HIGHW
HIGHWA
THIS MACHINE ON ANY PUBLIC STREET
COMPLIES WITH ALMOST ALL ST
ATE OFF-HIGHW
AY NOISE LEVEL AND SP
ARK ARRESTER LA
WS AND
STA
OFF-HIGHWA
SPARK
LAWS
REGULA
TIONS. PLEASE CHECK YOUR LOCAL RIDING LA
WS AND REGULA
TIONS BEFORE OPERA
TING THIS
REGULATIONS.
LAWS
REGULATIONS
OPERATING
MACHINE.
IMPORTANT MANUAL INFORMATION
1
AFFIX DEALER
LABEL HERE
TTR230W
OWNER’S MANUAL
 2006 by Yamaha Motor da Amazônia Ltda.
1st edition, May 2006
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor da Amazônia Ltda.
is expressly prohibited.
Printed in Brazil.
P/N LIT-11626-20-02
TABLE OF CONTENTS
SAFETY INFORMA
TION .................... 1-1
INFORMATION
Location of important labels ............ 1-6
DESCRIPTION ................................... 2-1
Left view ........................................... 2-1
Right view ........................................ 2-2
Controls and instruments ................ 2-3
INSTRUMENT AND CONTROL
FUNCTION ......................................... 3-1
Main switch ...................................... 3-1
Handlebar switches ......................... 3-1
Clutch lever ...................................... 3-2
Shift pedal ........................................ 3-2
Brake lever ...................................... 3-2
Brake pedal ..................................... 3-3
Fuel tank cap ................................... 3-3
Fuel .................................................. 3-3
Fuel tank breather hose .................. 3-5
Fuel cock ......................................... 3-5
Starter (choke) knob ........................ 3-6
Seat ................................................. 3-6
Adjusting the shock absorber
assembly ...................................... 3-7
Starting circuit cut-off system .......... 3-8
PRE-OPERA
TION CHECKS .............. 4-1
PRE-OPERATION
Pre-operation check list ................... 4-1
OPERA
TION AND IMPOR
TANT RIDING
OPERATION
IMPORT
POINTS .............................................. 5-1
Starting and warming up a cold
engine .......................................... 5-1
Starting a warm engine .................... 5-2
Shifting ............................................. 5-2
Engine break-in ............................... 5-3
Parking ............................................ 5-4
PERIODIC MAINTENANCE AND
MINOR REP
AIR ................................. 6-1
REPAIR
Periodic maintenance chart for
theemission control system .......... 6-2
General maintenance
and lubrication chart .................... 6-3
Removing and installing the
panels .......................................... 6-6
Checking the spark plug .................. 6-7
Engine oil and oil filter element ....... 6-8
Cleaning the air filter element ....... 6-11
Cleaning the spark arrester ........... 6-13
Adjusting the carburetor ................ 6-14
Adjusting the throttle cable
free play .................................... 6-14
Adjusting the valve clearance ........ 6-14
Tires ............................................... 6-15
Spoke wheels ................................ 6-17
Accessories and replacement
parts .......................................... 6-17
Adjusting the clutch lever
free play .................................... 6-18
Adjusting the brake pedal
position ....................................... 6-18
Checking the front brake
pads and rear brake shoes ....... 6-19
Checking the brake fluid level ....... 6-20
Changing the brake fluid ............... 6-21
Drive chain slack ........................... 6-21
Lubricating the drive chain ............ 6-22
Checking and lubricating
the cables .................................. 6-23
Checking and lubricating
the throttle grip and cable ......... 6-23
Checking and lubricating
the brake and clutch levers ....... 6-23
Lubricating the brake pedal ........... 6-24
Checking and lubricating the
sidestand .................................... 6-24
Checking the front fork .................. 6-24
Checking the steering .................... 6-25
Checking the wheel bearings ........ 6-26
Battery ........................................... 6-26
Replacing the fuse ......................... 6-27
Supporting the motorcycle ............. 6-28
Front wheel .................................... 6-28
Rear wheel .................................... 6-29
Troubleshooting ............................. 6-30
Troubleshooting chart .................... 6-31
TABLE OF CONTENTS
MOT
ORCYCLE CARE AND
MOTORCYCLE
ST
ORAGE .......................................... 7-1
STORAGE
Care ................................................. 7-1
Storage ............................................ 7-3
SPECIFICA
TIONS .............................. 8-1
SPECIFICATIONS
CONSUMER INFORMA
TION ............. 9-1
INFORMATION
Identification numbers ..................... 9-1
Motorcycle noise regulation ............. 9-2
Maintenance record ......................... 9-3
YAMAHA MOTOR CORPORATION,
U.S.A. OFF-ROAD MOTORCYCLE
LIMITED WARRANTY .................. 9-4
YAMAHA EXTENDED SERVICE
(Y.E.S.) ......................................... 9-6
SAFETY INFORMA
TION
INFORMATION
MACHINES ARE SINGLE TRACK
VEHICLES. THEIR SAFE USE AND
OPERATION ARE DEPENDENT
UPON THE USE OF PROPER RIDING
TECHNIQUES AS WELL AS THE
EXPERTISE OF THE OPERATOR.
EVERY OPERATOR SHOULD KNOW
THE FOLLOWING REQUIREMENTS
BEFORE RIDING THIS MACHINE.
HE OR SHE SHOULD:
l OBTAIN
THOROUGH
INSTRUCTIONS FROM A
COMPETENT SOURCE ON ALL
ASPECTS
OF
MACHINE
OPERATION.
l OBSERVE THE WARNINGS AND
M A I N T E N A N C E
REQUIREMENTS IN THE
OWNER’S MANUAL.
l OBTAIN QUALIFIED TRAINING
IN SAFE AND PROPER RIDING
TECHNIQUES.
l OBTAIN
PROFESSIONAL
TECHNICAL SERVICE AS
INDICATED BY THE OWNER’S
MANUAL AND/OR WHEN MADE
NECESSARY BY MECHANICAL
CONDITIONS.
Safe riding
l Always make pre-operation
checks. Careful checks may help
prevent an accident.
l This machine is designed for offroad use only, therefore, it is illegal
to operate it on public streets,
roads, or highways. Off-road use
on public lands may be illegal.
Please check local regulations
before riding.
l This machine is designed to carry
the operator only. No passengers.
l Many
accidents
involve
inexperienced operators.
• Make sure that you are qualified
and that you only lend your
machine to other qualified
operators.
• Know your skills and limits.
Staying within your limits may
help you to avoid an accident.
l Many accidents have been caused
by error of the machine operator. A
typical error made by the operator
is veering wide on a turn due to
EXCESSIVE
SPEED
or
undercornering (insufficient lean
1-1
angle for the speed). Never travel
faster than warranted by
conditions.
l Ride cautiously in unfamiliar areas.
You may encounter hidden
obstacles that could cause an
accident.
l The posture of the operator is
important for proper control. The
operator should keep both hands
on the handlebar and both feet on
the operator footrests during
operation to maintain control of the
machine.
l Never ride under the influence of
alcohol or other drugs.
Protective apparel
The majority of fatalities from machine
accidents are the result of head injuries. The use of a safety helmet is the
single most critical factor in the
prevention or reduction of head injuries.
l Always wear an approved helmet.
l Wear a face shield or goggles.
Wind in your unprotected eyes
could contribute to an impairment
of vision that could delay seeing a
1
SAFETY INFORMA
TION
INFORMATION
hazard.
The use of a jacket, heavy boots,
trousers, gloves, etc., is effective
in preventing or reducing abrasions
or lacerations.
l Never wear loose-fitting clothes,
otherwise they could catch on the
control levers, footrests, or wheels
and cause injury or an accident.
Never touch the engine or exhaust
system during or after operation.
They become very hot and can
cause burns. Always wear
protective clothing that covers your
legs, ankles, and feet.
Modifications
Modifications made to this machine not
approved by Yamaha, or the removal
of original equipment, may render the
machine unsafe for use and may cause severe personal injury. Modifications
may also make your machine illegal to
use.
l
1
Loading and accessories
Adding accessories or cargo to your
machine can adversely affect stability
and handling if the weight distribution
of the machine is changed. To avoid the
possibility of an accident, use extreme
caution when adding cargo or
accessories to your machine. Use extra care when riding a machine that has
added cargo or accessories. Here are
some general guidelines to follow if
loading cargo or adding accessories to
your machine:
Loading
The total weight of the operator,
accessories and cargo must not exceed
the maximum load limit of 90.0 kg (198
lb). When loading within this weight limit,
keep the following in mind:
l Cargo and accessory weight
should be kept as low and close to
the machine as possible. Make
sure to distribute the weight as
evenly as possible on both sides
of the machine to minimize
imbalance or instability.
l Shifting weights can create a
sudden imbalance. Make sure that
accessories and cargo are
1-2
securely attached to the machine
before riding. Check accessory
mounts and cargo restraints
frequently.
l Never attach any large or heavy
items to the handlebar, front fork,
or front fender. These items,
including such cargo as sleeping
bags, duffel bags, or tents, can
create unstable handling or a slow
steering response.
Accessories
Genuine Yamaha accessories have
been specifically designed for use on
this machine. Since Yamaha cannot test
all other accessories that may be
available, you must personally be
responsible for the proper selection,
installation and use of non-Yamaha
accessories. Use extreme caution when
selecting and installing any accessories.
Keep these guidelines in mind for
mounting accessories in addition to
those provided under “Loading”.
l Never install accessories or carry
cargo that would impair the
performance of your machine.
Carefully inspect the accessory
before using it to make sure that it
SAFETY INFORMA
TION
INFORMATION
does not in any way reduce ground
clearance or cornering clearance,
limit suspension travel, steering
travel or control operation, or
obscure lights or reflectors.
• Accessories fitted to the
handlebar or the front fork area
can create instability due to
improper weight distribution or
aerodynamic changes. If
accessories are added to the
handlebar or front fork area, they
must be as lightweight as
possible and should be kept to a
minimum.
• Bulky or large accessories may
seriously affect the stability of the
machine due to aerodynamic
effects. Wind may attempt to lift
the machine, or the machine
may become unstable in cross
winds.
• Certain
accessories can
displace the operator from his or
her normal riding position. This
improper position limits the
freedom of movement of the
operator and may limit control
ability,
therefore,
such
accessories
are
not
recommended.
l Use caution when adding electrical
accessories.
If
electrical
accessories exceed the capacity of
the machine’s electrical system an
electric failure could result, which
could cause a dangerous loss of
lights or engine power.
Gasoline and exhaust gas
l GASOLINE
IS
HIGHLY
FLAMMABLE:
• Always turn the engine off when
refueling.
• Take care not to spill any
gasoline on the engine or
exhaust pipe(s)/muffler(s) when
refueling.
• Never refuel while smoking or in
the vicinity of an open flame.
l Never start the engine or let it run
for any length of time in a closed
area. The exhaust fumes are
poisonous and may cause loss of
consciousness and death within a
short time. Always operate your
machine in an area that has
adequate ventilation.
l Always turn the engine off before
1-3
l
l
leaving the machine unattended
and remove the key from the main
switch. When parking the machine,
note the following:
• The engine and exhaust pipe(s)/
muffler(s) may be hot, therefore,
park the machine in a place
where pedestrians or children
are not likely to touch these hot
areas.
• Do not park the machine on a
slope or soft ground, otherwise
it may fall over.
• Do not park the machine near a
flammable source (e.g., a
kerosene heater, or near an
open flame), otherwise it could
catch fire.
When transporting the machine in
another vehicle, make sure that it
is kept upright and that the fuel
cock(s) are turned to “ON” or “RES”
(for vacuum type)/”OFF” (for manual type). If the machine should
lean over, gasoline may leak out
of the carburetor or fuel tank.
If you should swallow any gasoline,
inhale a lot of gasoline vapor, or
allow gasoline to get into your eyes,
1
SAFETY INFORMA
TION
INFORMATION
1
see your doctor immediately. If any
gasoline spills on your skin or
clothing, immediately wash the
affected area with soap and water
and change your clothes.
1-4
SAFETY INFORMA
TION
INFORMATION
1
1-5
SAFETY INFORMATION
Location of important labels
Please read the following important labels carefully before operating this vehicle.
1
1-6
SAFETY INFORMATION
3
1
WARNING
1
Riding as a passenger can cause the
vehicle to go out of control.
Loss of control can cause a collision or
rollover, which can result in severe injury
or death.
NEVER ride as a passenger.
3XJ-2151H-A1
4
TIRE INFORMATION
Cold tire normal pressure should be set as
follows.
FRONT: 100kPa, (1.00kgf/cm2), 15psi
REAR:
100kPa, (1.00kgf/cm2), 15psi
2
3RV-21668-A0
WARNING
• BEFORE YOU OPERATE THIS VEHICLE, READ
THE OWNER’S MANUAL AND ALL LABELS.
• NEVER CARRY A PASSENGER. You increase
your risk of losing control if you carry a passenger.
• NEVER OPERATE THIS VEHICLE ON PUBLIC
ROADS. You can collide with another vehicle if
you operate this vehicle on a public road.
• ALWAYS WEAR AN APPROVED MOTORCYCLE
HELMET, eye protection, and protective clothing.
5
WARNING
This unit contains high pressure nitrogen gas.
Mishandling can cause explosion.
• Read owner´s manual for instruction.
• Do not incinerate, puncture or open.
3PT-2118K-A0
4AA-22259-80
1-7
DESCRIPTION
Left view
2
1. Fuel cock (page 3-5)
2. Starter (choke) knob (page 3-6)
3. Air filter element (page 6-11)
4. Shift pedal (page 3-2)
2-1
DESCRIPTION
Right view
2
1. Spark arrester (page 6-13)
2. Fuse (page 6-27)
3. Battery (page 6-26)
4. Shock absorver assembly spring preload adjusting nut (page 3-7)
5. Engine oil filter element (page 6-8)
6. Brake pedal (page 3-3)
2-2
DESCRIPTION
Controls and instruments
2
1. Clutch lever (page 3-2)
2. Engine stop switch (page 3-1)
3. Main switch (page 3-1)
4. Start switch (page 3-1)
5. Brake lever (page 3-2)
6. Throttle grip (page 6-14)
7. Fuel tank cap (page 3-3)
2-3
INSTRUMENT AND CONTROL FUNCTIONS
Main switch
Handlebar switches
Left
Engine stop switch “ ”
Push this switch to stop the engine in
case of an emergency, such as when
the motorcycle overturns or when the
throttle cable is stuck.
Start switch “ ”
Push this switch to crank the engine with
the starter.
1. Engine stop switch “
The main switch controls the ignition
systems. The various main switch
positions are described below.
See page 5-1 for starting instructions
prior to starting the engine.
Right
ON
All electrical systems are supplied with
power, and the engine can be started.
OFF
All electrical systems are off.
1. Start switch “
“
“
3-1
3
INSTRUMENT AND CONTROL FUNCTIONS
Clutch lever
Shift pedal
1. Clutch lever
1. Shift pedal
The clutch lever is located at the left
handlebar grip. To disengage the clutch,
pull the lever toward the handlebar grip.
To engage the clutch, release the lever.
The lever should be pulled rapidly and
released slowly for smooth clutch
operation.
The clutch lever is equipped with a
clutch switch, which is part of the starting
circuit cut-off system. (See page 3-8.)
The shift pedal is located on the left side
of the engine and is used in combination
with the clutch lever when shifting the
gears of the 6-speed constant-mesh
transmission equipped on this
motorcycle.
Brake lever
3
1. Brake lever
3-2
The brake lever is located at the right
handlebar grip. To apply the front brake,
pull the lever toward the handlebar grip.
INSTRUMENT AND CONTROL FUNCTIONS
Brake pedal
Fuel tank cap
Fuel
1
1
2
3
1. Brake pedal
The brake pedal is on the right side of
the motorcycle. To apply the rear brake,
press down on the brake pedal.
2
1. Fuel tank cap
2. Remove
1. Fuel tank filter tube
2. Fuel lever
To remove the fuel tank cap, turn it
counterclockwise, and then pull it off.
To install the fuel tank cap, insert it into
the tank opening, and then turn it
clockwise.
Make sure that there is sufficient fuel in
the tank. Fill the fuel tank to the bottom
of the filler tube as shown.
l
Make sure that the fuel tank cap is
properly closed before riding.
3-3
l
Do not overfill the fuel tank,
otherwise it may overflow when
the fuel warms up and expands.
A void spilling fuel on the hot
engine.
INSTRUMENT AND CONTROL FUNCTIONS
Immediately wipe off spilled fuel with
a clean, dry
dry,, soft cloth, since fuel may
deteriorate painted surfaces or
plastic parts.
3
Recommended fuel:
UNLEADED GASOLINE ONLY
Fuel tank capacity:
8.0 L (2.11 us.gal) (1.76 imp.gal)
Fuel reserve amount:
1.8 L (0.48 us.gal) (0.40 imp.gal)
Use only unleaded gasoline. The use
of leaded gasoline will cause severe
damage to internal engine parts,
such as the valves and piston rings,
as well as to the exhaust system.
Your Yamaha engine has been
designed to use regular unleaded
gasoline with a pump octane number
[(R+M)/2] of 86 or higher, or a research
octane number of 91 or higher. If
knocking (or pinging) occurs, use a
gasoline of a different brand or premium
unleaded fuel. Use of unleaded fuel will
extend spark plug life and reduce
maintenance costs.
Gasohol
l There are two types of gasohol:
gasohol containing ethanol and that
containing methanol. Gasohol
containing ethanol can be used if
the ethanol content does not
exceed 10%. Gasohol containing
methanol is not recommended by
Yamaha because it can cause
damage to the fuel system or
vehicle performance problems.
3-4
INSTRUMENT AND CONTROL FUNCTIONS
Fuel tank breather hose
1
Fuel cock
ON
The fuel cock supplies fuel from the tank
to the carburetor while filtering it also.
The fuel cock has three positions:
RES
OFF
OFF
ON
ON
RES
FUEL
1
OFF
1. Fuel tank breather hose
Before operating the motorcycle:
l Check the fuel tank breather hose
connection.
l Check the fuel tank breather hose
for cracks or damage, and replace
it if damaged.
l Make sure that the end of the fuel
tank breather hose is not blocked,
and clean it if necessary.
ON
1. Arrow mark positioned over “ON”
FUEL
1
1. Arrow mark positioned over “OFF”
With the lever in this position, fuel will
not flow. Always return the lever to this
position when the engine is not running.
3-5
With the lever in this position, fuel flows
to the carburetor. Normal riding is done
with the lever in this position.
3
INSTRUMENT AND CONTROL FUNCTIONS
Starter (choke) knob “
RES
”
To remove the seat
Remove the bolts, and then pull the seat
off.
RES
(b)
RES
Seat
(a)
OFF
3
ON
FUEL
1
1
1. Arrow mark positioned over “RES”
This indicates reserve. If you run out of
fuel while riding, move the lever to this
position. Fill the tank at the first
opportunity. Be sure to set the lever
back to “ON” after refueling!
1. Starter (choke) knob “
”
Starting a cold engine requires a richer
air-fuel mixture, which is supplied by the
starter (choke).
Move the knob in direction (a) to turn
on the starter (choke).
Move the knob in direction (b) to turn
off the starter (choke).
3-6
1. Bold
To install the seat
1. Insert the projections on the front
of the seat into the seat holders as
shown.
INSTRUMENT AND CONTROL FUNCTIONS
Adjusting the shock
absorber assembly
1. Projection
2. Seat holder
2. Place the seat in the original
position, and then tighten the bolts.
This shock absorber assembly is
equipped with a spring preload adjusting
nut.
2. To increase the spring preload and
thereby harden the suspension,
turn the adjusting nut in direction
(a). To decrease the spring preload
and thereby soften the suspension,
turn the adjusting nut in direction
(b).
Never attempt to turn an adjusting
mechanism beyond the maximum or
minimum settings.
l
Spring preload
l
Make sure that the seat is properly
secured before riding.
1. Locknut
2. Adjusting nut
1. Loosen the locknut.
3-7
A special wrench is needed to
make this adjustment and it can be
obtained at a Yamaha dealer.
The spring preload setting is
determined by measuring distance
A, shown in the illustration. The
shorter the distance A is, the higher
the spring preload; the longer
distance A is, the lower the spring
preload.
3
INSTRUMENT AND CONTROL FUNCTIONS
3
Spring preload:
Minimum (soft):
Distance A = 194 mm (7.6 in)
Standard:
Distance A = 204 mm (8.0 in)
Maximum (hard):
Distance A = 206 mm (8.1 in)
3. Tighten the locknut to the specified
torque.
Tightening torque:
Locknut:
70 Nm (7.0 m.kgf, 51 ft.lbf)
This shock absorber contains highly
pressurized nitrogen gas. For proper
handling, read and understand the
following
information
before
handling the shock absorber
absorber.. The
manufacturer cannot be held
responsible for property damage or
personal injury that may result from
improper handling.
l Do not tamper with or attempt
to open the gas cylinder
cylinder..
l Do not subject the shock
absorber to an open flame or
other high heat sources,
otherwise it may explode due to
excessive gas pressure.
l Do not deform or damage the
gas cylinder in any way
way,, as this
will result in poor damping
performance.
amaha dealer
l Always have a Y
Yamaha
service the shock absorber
absorber..
Always tighten the locknut against
the adjusting nut, and then tighten
the locknut to the specified torque.
3-8
Starting circuit cut-of
cut-offf
system
The starting circuit cut-off system
(comprising the clutch switch and the
neutral switch) prevents starting when
the transmission is in gear and the
clutch lever is not pulled.
Periodically check the operation of the
starting circuit cut-off system according
to the following procedure.
If a malfunction is noted,
Yamaha dealer check the
before riding.
have a
system
INSTRUMENT AND CONTROL FUNCTIONS
3
3-9
PRE-OPERA
TION CHECKS
PRE-OPERATION
The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly,
even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or
loss of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thorough visual
inspection, to check the following points before each ride.
Pre-operation check list
CHECKS
ITEM
PAGE
Fuel
• Check fuel level in fuel tank.
• Refuel if necessary.
• Check fuel line for leakage.
3-3
Engine oil
• Check oil level in engine.
• If necessary, add recommended oil to specified level.
• Check vehicle for oil leakage.
6-8
Front brake
•
•
•
•
•
•
•
•
•
Rear brake
• Check operation.
• Check pedal free play
• Adjust if necessary
Clutch
•
•
•
•
4
Check operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check lever free play.
Adjust if necessary.
Check brake pads for wear.
Replace if necessary.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.
6-19 ~ 6-21
6-18 ~ 6-20
Check operation.
Lubricate cable if necessary.
Check lever free play.
Adjust if necessary.
6-18
4-1
PRE-OPERA
TION CHECKS
PRE-OPERATION
ITEM
Throttle grip
Control cables
Drive chain
Wheels and tires
•
•
•
•
CHECKS
PAGE
Make sure that operation is smooth.
Check cable free play.
If necessary, have Yamaha dealer adjust cable free play and lubricate cable and
grip housing.
6-14
6-23
• Make sure that operation is smooth.
• Lubricate if necessary.
•
•
•
•
Check chain slack.
Adjust if necessary.
Check chain condition.
Lubricate if necessary.
•
•
•
•
Check for damage.
Check tire condition and tread depth.
Check air pressure.
Correct if necessary.
6-23
6-21 ~ 6-22
4
6-15 ~ 6-17
Brake and shift pedals
• Make sure that operation is smooth.
• Lubricate pedal pivoting points if necessary.
6-24
Brake and clutch levers
• Make sure that operation is smooth.
• Lubricate lever pivoting points if necessary.
6-23
Sidestand
• Make sure that operation is smooth.
• Lubricate pivot if necessary.
6-24
Chassis fasteners
• Make sure that all nuts, bolts and screws are properly tightened.
• Tighten if necessary.
_
Switches
• Check operation.
• Correct if necessary.
_
Engine stop switch
• Check operation.
3-1
4-2
PRE-OPERA
TION CHECKS
PRE-OPERATION
Pre-operation checks should be made each time the vehicle is used. Such an inspection can be accomplished in a very
short time; and the added safety it assures is more than worth the time involved.
If any item in the Pre-operation check list is not working properly
properly,, have it inspected and repaired before operating
the vehicle.
4
4-3
OPERA
TION AND IMPOR
TANT RIDING POINTS
OPERATION
IMPORT
l
l
l
This model is designed for offroad use only
only.. In most instances,
it is illegal to ride this model
(either day or night) on any
public street or highway
highway..
Never start the engine or operate
it in a closed area for any length
of time. Exhaust fumes are
poisonous, and inhaling them
can
cause
loss
of
consciousness and death within
a short time. Always make sure
that
there
is
adequate
ventilation.
Before starting out, make sure
that the sidestand is up. If the
sidestand is not raised
completely
completely,, it could contact the
ground and distract the
operator
operator,, resulting in a possible
loss of control.
Starting and warming up a
cold engine
In order for the starting circuit cut-off
system to enable starting, one of the
following conditions must be met.
l The transmission is in the neutral
position.
l The transmission is in gear with the
clutch lever pulled.
l
l
Before starting the engine,
check the function of the
starting circuit cut-of
cut-offf system
according to the procedure
described on page 3-8.
Never ride with the sidestand
down.
1. Turn the fuel cock lever to “ON”.
2. Push the main switch to “ON”.
3. Shift the transmission into the
neutral position.
4. Turn the starter (choke) on and
completely close the throttle. (See
page 3-6.)
5-1
5. Start the engine by pushing the
start switch.
If the engine fails to start, release the
start switch, wait a few seconds, and
then try again. Each starting attempt
should be as short as possible to preserve the battery. Do not crank the
engine more than 10 seconds on any
one attempt.
6. After starting the engine, move the
starter (choke) back halfway.
For maximum engine life, always
warm the engine up before starting
off. Never accelerate hard when the
engine is cold!
7. When the engine is warm, turn the
starter (choke) off.
5
OPERA
TION AND IMPOR
TANT RIDING POINTS
OPERATION
IMPORT
Starting a warm engine
The engine is warm when it responds
normally to the throttle with the starter
(choke) turned off.
Shifting
Follow the same procedure as for
starting a cold engine with the exception
that the starter (choke) is not required
when the engine is warm.
1. Shift pedal
2. Neutral position
5
Shifting gears lets you control the
amount of engine power available for
starting off, accelerating, climbing hills,
etc.
The gear positions are shown in the
illustration.
To shift the transmission into the neutral
position, press the shift pedal down
repeatedly until it reaches the end of its
travel, and then slightly raise it.
5-2
OPERA
TION AND IMPOR
TANT RIDING POINTS
OPERATION
IMPORT
Engine break-in
l
l
Even with the transmission in
the neutral position, do not
coast for long periods of time
with the engine off, and do not
tow the motorcycle for long
distances. The transmission is
properly lubricated only when
the
engine
is
running.
Inadequate lubrication may
damage the transmission.
Always use the clutch while
changing gears to avoid
damaging
the
engine,
transmission, and drive train,
which are not designed to
withstand the shock of forced
shifting.
There is never a more important period
in the life of your engine than the first
20 hours of riding. 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
20 hours of operation. The various parts
in the engine wear and polish
themselves to the correct operating
clearances. During this period,
prolonged full-throttle operation or any
condition that might result in engine
overheating must be avoided. However,
momentary full-throttle operation under
load (i.e., two to three seconds
maximum) does not harm the engine.
Each full-throttle acceleration should be
followed with a substantial rest period
for the engine. To allow the engine to
cool down from the temporary buildup
of heat, cruise at a lower engine speed.
5-3
0-10 hours
l Avoid prolonged operation above
1/2 throttle.
l After every hour of operation, stop
the engine, and then let it cool for
five to ten minutes.
l Vary the engine speed from time
to time. Do not operate the engine
at one set throttle position.
10-20 hours
l Avoid prolonged operation above
3/4 throttle.
l Rev the engine freely through the
gears, but do not use full throttle at
any time.
After break-in
Avoid prolonged full-throttle operation.
Vary the engine speed occasionally.
If any engine trouble should occur
during the engine break-in period,
immediately have a Y
amaha dealer
Yamaha
check the vehicle.
5
OPERA
TION AND IMPOR
TANT RIDING POINTS
OPERATION
IMPORT
Parking
When parking, stop the engine, push
the main switch to “OFF”, and then turn
the fuel cock lever to “OFF”.
l
l
5
Since the engine and exhaust
system can become very hot,
park in a place where
pedestrians or children are not
likely to touch them.
Do not park on a slope or on soft
ground, otherwise the vehicle
may overturn.
5-4
PERIODIC MAINTENANCE AND MINOR REP
AIR
REPAIR
Safety is an obligation of the owner.
Periodic inspection, adjustment and
lubrication will keep your vehicle in the
safest and most efficient condition
possible. The most important points of
motorcycle inspection, adjustment, and
lubrication are explained on the
following pages.
Modifications not approved by
Yamaha may cause loss of
performance, excessive emissions,
and render the vehicle unsafe for
use.
Consult a Y
amaha dealer before
Yamaha
attempting any changes.
l
l
If you are not familiar with
maintenance work, have a Y
amaha
Yamaha
dealer do it for you.
6-1
Caution for high pressured
water using.
• W ater comes in exhaust
silencer port, and going to
inside of the engine if no
protection. From air intake
port of side cover also water
going to inside of the engine.
Technique for cover assembly/
disassembly
• There is a few disadvantge for
service-ability to give priority
for outside appearance.
the first time for
• At
disassembly/assembly
disassembly/assembly.. there
are possibility to broken at
fitting portion due to nom
experience.
6
PERIODIC MAINTENANCE AND MINOR REP
AIR
REPAIR
Periodic maintenance chart for the emission control system
From 4200 mi (7000km) or 9 months, repeat the maintenance intervals starting from 1800 mi (3000 km) or 3 months.
Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and
technical skills.
l
l
No.
1
*
2
6
ITEM
CHECKS AND MAITENANCE JOBS
INITIAL
600 mi
(1000 km) or
1 month
EVERY
1800 mi
3000mi
(3000 km) or (5000 km) or
3 months
6 months
Fuel line
• Check fuel hoses for cracks or damage.
• Replace if necessary.
c
c
c
Spark plug
• Check condition.
• Adjust gap and clean.
c
c
c
3
*
Valve clearance
• Check and adjust valve clearance when engine is cold
c
c
c
4
*
Air filter element
• Clean with solvent.
• Replace if necessary.
c
c
c
5
*
Crankcase breather
system
• Check ventilation hose for cracks or damage and drain
any deposits.
• Repalce if necessary
c
c
c
Carburetor
• Check engine idling speed and starter operation.
• Adjust if necessary.
c
c
c
6
*
7
Exhaust system
• Check for leakage.
• Tighten if necessary.
• Replace gasket(s) if necessary
c
c
c
8
Engine oil
• Change (warm engine before draining.)
c
c
c
9
Engine oil filter elements
• Clean
c
c
c
6-2
PERIODIC MAINTENANCE AND MINOR REP
AIR
REPAIR
General maintenance and lubrication chart
ITEM
No.
1
CHECKS AND MAITENANCE JOBS
INITIAL
600 mi
(1000 km) or
1 month
EVERY
1800 mi
3000mi
(3000 km) or (5000 km) or
3 months
6 months
Clutch
• Check operation.
• Adjust or replace cable.
c
c
c
2
*
Front brake
• Check operation, fluid level, and for fluid leakage.
• Replace brake pads if necessary.
c
c
c
3
*
Rear brake
• Check operation.
• Replace brake shoes if necessary.
c
c
c
4
*
Brake hoses
• Check for craks or damage.
• Replace.
c
c
c
Every 4 years
5
*
Wheels
• Check runout, spoke tightness and for damage.
• Tighten spokes if necessary.
c
c
c
6
*
Tires
•
•
•
•
Check tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.
c
c
c
7
*
Wheel bearings
• Check bearing for smooth operation.
• Replace if necessary.
c
c
c
8
*
Swingarm pivot bearings
• Check bearing assemblies for looseness.
• Moderately repack with lithium-soap-based grease.
c
c
c
Drive chain
• Check chain slack/alignment and condition.
• Adjust and lubricate chain with a special O-ring chain
lubricant thoroughly.
9
6-3
Every ride
6
PERIODIC MAINTENANCE AND MINOR REP
AIR
REPAIR
No.
6
CHECKS AND MAITENANCE JOBS
INITIAL
600 mi
(1000 km) or
1 month
• Check bearing assemblies for looseness.
• Moderately repack with lithium-soap-based grease
every 1200 mi (2000 km) or 12 months (whichever comes
first)
c
c
c
ITEM
EVERY
1800 mi
3000mi
(3000 km) or (5000 km) or
3 months
6 months
10 *
Steering bearing
11 *
Chassis fasteners
• Check all chassis fitting and fasteners.
• Correct if necessary.
c
c
c
12
Brake and clutch lever
pivot shafts
• Apply lithium-soap-based grease (all-purpose grease)
lightly.
c
c
c
13
Brake and shift pedal
pivot shafts
• Apply lithium-soap-based grease (all-purpose grease)
lightly.
c
c
c
14
Sidestand pivot
• Check operation.
• Apply lithium-soap-based grease (all-purpose grease)
lightly.
c
c
c
15 *
Spark arrester
• Clean.
c
c
16 *
Front fork
• Ckeck operation and for oil leakage.
• Replace if necessary.
c
c
17 *
Shock absorber assembly
• Ckeck operation and for oil leakage.
• Replace if necessary.
c
c
18 *
Rear suspension link
pivots
• Apply molybdenum disulfide grease lightly.
c
c
6-4
PERIODIC MAINTENANCE AND MINOR REP
AIR
REPAIR
ITEM
No.
CHECKS AND MAITENANCE JOBS
INITIAL
600 mi
(1000 km) or
1 month
EVERY
1800 mi
3000mi
(3000 km) or (5000 km) or
3 months
6 months
19 *
Control cables
• Apply Yamaha chain and cable lube or engine oil 10W-30
thoroughly.
c
c
c
20 *
Throttle grip housing and
cable
• Check operation and free play.
• Adjust the throttle cable free play if necessary.
• Lubricate the throttle grip housing and cable.
c
c
c
l The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
l Hydraulic brake service
• After disassembling the brake master cylinder and caliper, always change the fluid. Regularly
•
•
check the brake fluid
level and fill the reservoir as required.
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.
6-5
6
PERIODIC MAINTENANCE AND MINOR REP
AIR
REPAIR
Removing and installing the
panels
the panel needs to be removed and
installed.
Panel A
To remove the panel
Remove the screw.
Panel B
To remove the panel
1. Remove the screw.
2. Pull the panel B to your direction.
To make it easier, use the opening
1 of the cover 2.
1. Panel A
6
1. Screw
2. Painel A
To install the panel
Place the panel in the original position,
and then install the screw.
3. Pull the panel B in the arrow
direction.
1. Panel B
The panels shown above need to be
removed to perform some of the
maintenance jobs described in this
chapter. Refer to this section each time
6-6
To install de panel
PERIODIC MAINTENANCE AND MINOR REP
AIR
REPAIR
1. Install the panel B under the seat.
2. To install the panel B, follow the
sequence below (1,2,3)
Checking the spark plug
The spark plug is an important engine
component, which is easy to check.
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
maintenance and lubrication chart. In
addition, the condition of the spark plug
can reveal the condition of the engine.
To remove the spark plug
1. Remove the spark plug cap.
2. Remove the spark plug.
To check the spark plug
1. Check that the porcelain insulator
around the center electrode of the
spark plug is a medium-to-light tan
(the ideal color when the vehicle is
ridden normally).
3. Check if panel B is securely
installed, other wise dirty can enter
in the air filter an engine damage
may occur
If the spark plug shows a distinctly
different color, the engine could be
defective. Do not attempt to diagnose
such problems yourself. Instead, have
a Yamaha dealer check the vehicle.
6-7
6
PERIODIC MAINTENANCE AND MINOR REP
AIR
REPAIR
2. Check the spark plug for electrode
erosion and excessive carbon or
other deposits, and replace it if
necessary.
Specified spark plug:
NGK/DR8EA
To install the spark plug
1. Measure the spark plug gap with a
wire thickness gauge and, if
necessary, adjust the gap to
specification.
2. Clean the surface of the spark plug
gasket and its mating surface, and
then wipe off any grime from the
spark plug threads.
3. Install the spark plug with the spark
plug wrench, and then tighten it to
the specified torque.
Tightening torque:
Spark plug:
18 Nm (1.8 m.kgf, 13 ft.lbf)
If a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4 - 1/2 turn
past finger tight. However, the spark
plug should be tightened to the specified
torque as soon as possible.
6
1
4. Install the spark plug cap.
1. Spark plug gap:
Spark plug gap:
0,6~0,7 mm (0,024~0,028 in)
Engine oil and oil filter
element
The engine oil level should be checked
before each ride. In addition, the oil
must be changed and the oil filter
element cleaned at the intervals
specified in the General maintenance
and lubrication chart.
To check the engine oil level
1. Place the vehicle on a level surface
and hold it in an upright position.
Make sure that the vehicle is positioned
straight up when checking the oil level.
A slight tilt to the side can result in a
false reading.
2. Start the engine, warm it up for
several minutes, and then turn it off.
3. Wait a few minutes until the oil
settles, and then check the oil level
through the check window located
at the lower part of the right side of
the crankcase.
The engine oil should be between the
minimum and maximum level marks.
6-8
PERIODIC MAINTENANCE AND MINOR REP
AIR
REPAIR
When removing the oil drain plug,
the o-ring, compression spring and
oil strainer will fall out. T
ake care not
Take
to lose these parts.
4. Remove the oil filter element drain
bolt to drain the oil from the oil filter
element.
1. Engine oil level check window
2. Maximum level mark
3. Minimum level mark
1. Engine oil filter bolt
4. If the engine oil is below the
minimum level mark, add sufficient
oil of the recommended type to
raise it to the correct level.
To change the engine oil (with or
without oil filter element cleaning)
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 bolt and
drain bolt to drain the oil from the
crankcase.
6
1. Oil filter element cover
2. Oil filter element drain bolt
1. Drain plug
2. O-ring
3. Compression spring
4. Oil strainer
6-9
Skip steps 5 - 9 if the oil filter element is
not being cleaned.
PERIODIC MAINTENANCE AND MINOR REP
AIR
REPAIR
5. Remove the oil filter element cover
by removing the bolts.
6. Remove the oil filter element and
O-rings.
Tightening torque:
Oil filter element cover bolt:
7 Nm (0.7 m.kgf, 5.1 ft.lbf)
Make sure that the O-rings are properly
seated.
6
1. Oil filter element
2. O-ring (x2)
7. Check the O-rings for damage and
replace them if necessary.
8. Clean the oil filter element with
solvent, and then install it.
Check the oil filter element for damage
and replace it if necessary.
10.Install the engine oil drain bolt, and
then tighten it to the specified
torque.
11.Install the engine oil filter element
drain bolt, and then tighten it to the
specified torque.
Tightening torques:
Engine oil drain bolt:
43 Nm (4.3 m.kgf, 3.1 ft.lbf)
Oil filter element drain bolt:
10 Nm (1.0 m.kgf, 7.2 ft.lbf)
12. Add the specified amount of the
recommended engine oil, and then
install and tighten the oil filler cap.
9. Install the oil filter element cover by
installing the bolts, then tightening
them to the specified torque.
6-10
Recommended oil:
See page 8-1.
Oil quantity:
Without oil filter element
replacement:
1.0 L (1.06 us.qt) (0.91 imp.qt)
With oil filter element replacement:
1.10 L (1.16 us.qt) (0.97 imp.qt)
In order to prevent clutch
slippage (since the engine oil
also lubricates the clutch), do
not mix any chemical additives
with the oil.
Make sure that no foreign material enters the crankcase.
13.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.
14.Turn the engine off, and then check
the oil level and correct it if
necessary.
PERIODIC MAINTENANCE AND MINOR REP
AIR
REPAIR
Cleaning the air filter element
After replacing the engine oil, make
sure to check the oil pressure as
described below
below..
l Remove the bleed bolt in the
cylinder head.
l Start the engine and keep it
idling until oil flows out. If no oil
comes out after one minute, turn
the engine off immediately so it
will not seize. If this occurs, have
amaha dealer repair the
a Y
Yamaha
vehicle.
l After checking the oil pressure,
tighten the bleed bolt to the
specified torque.
The air filter element should be cleaned
at the intervals specified in the periodic
maintenance and lubrication chart.
Clean the air filter element more
frequently if you are riding in unusually
wet or dusty areas.
1. Remove panel B. (See page 6-6.)
2. Pull the air filter element out of the
air filter case.
1. Bleed bolt
Tightening torque:
Bleed bolt:
7Nm (0,7m.kgf, 5,0 ft.lbf)
6
1. Air filter element
6-11
PERIODIC MAINTENANCE AND MINOR REP
AIR
REPAIR
3. Remove the wing nut, washer, air
filter element, air filter guide from
the air filter element frame.
5. Apply oil of the recommended type
to the entire surface of the air filter
element, and then squeeze the
excess oil out.
l
l
The air filter element should be wet but
not dripping.
Recommended oil:
Yamaha foam air filter oil or other
quality air filter oil
6
1. Wingnut
2. Washer
3. Air filter element
4. Air filter guide
4. Clean the air filter element with
solvent, and then squeeze the
remaining solvent out.
6. Install the air filter guide, air filter
element, washer, wing nut onto the
frame, insert into the air filter case.
6-12
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) and/or cylinder(s) may
become excessively worn.
7. Install the panel.
PERIODIC MAINTENANCE AND MINOR REP
AIR
REPAIR
Cleaning the spark arrester
1
2
Make sure to select a well-ventilated
area free of combustible materials to
clean the spark arrester.
1. Remove the tailpipe by removing
the bolts, and then pulling it out of
the muffler.
1. Tailpipe
2. Spark arrester
1(×3)
1. Purging bolt
3. Insert the tailpipe into the muffler,
and then install and tighten the
bolts.
Make sure to align the bolt holes when
inserting the tailpipe.
1. Bolt
4. Remove the purging bolt.
2. Tap the tailpipe lightly, and then use
a wire brush to remove any carbon
deposits from the spark arrester
portion of the tailpipe.
6-13
5. Start the engine and rev it
approximately twenty times while
momentarily creating exhaust
system back pressure using a shop
towel to block the end of the
muffler.
6. Stop the engine and allow the
exhaust pipe to cool.
7. Install the purging bolt and tighten
it.
6
PERIODIC MAINTENANCE AND MINOR REP
AIR
REPAIR
Adjusting the carburetor
The carburetor is an important part of
the engine and requires very
sophisticated adjustment. Therefore,
most carburetor adjustments should be
left to a Yamaha dealer, who has the
necessary professional knowledge and
experience. However, the following may
be serviced by the owner as part of
routine maintenance.
6
The carburetor has been set and
extensively tested at the Y
amaha
Yamaha
factory
factory.. Changing these settings
without
sufficient
technical
knowledge may result in poor
performance of or damage to the
engine.
Adjusting the throttle cable
free play
1.Throttle cable free play
The throttle cable free play should
measure 3 ~ 5.0 mm (0.12 ~ 0,20 in) at
the throttle grip. Periodically check the
throttle cable free play and, if necessary,
have a Yamaha dealer adjust it.
6-14
Adjusting the valve clearance
The valve clearance changes with use,
resulting in improper air-fuel mixture
and/or engine noise. To prevent this
from occurring, the valve clearance
must be adjusted by a Yamaha dealer
at the intervals specified in the periodic
maintenance and lubrication chart.
PERIODIC MAINTENANCE AND MINOR REP
AIR
REPAIR
Tires
To maximize the performance,
durability, and safe operation of your
motorcycle, note the following points
regarding the specified tires.
Tire air pressure
The tire air pressure should be checked
and, if necessary, adjusted before each
ride.
Off-road riding:
Front:
100 kPa (15 psi)
(1.00 kgf/cm2)
Rear:
100 kPa (15 psi)
(1.00 kgf/cm2)
Maximum load*:
90.0 kg (198 lb)
* Total weight of rider, cargo and
accessories
l
l
l
l
l
l
The tire air pressure must
bechecked and adjusted on cold
tires (i.e., when the temperature
of the tires equals the ambient
temperature).
The tire air pressure must be
adjusted in accordance with the
riding speed and with the total
weight of rider
rider,, cargo, and
accessories approved for this
model.
Because loading has an enormous
impact on the handling, braking,
performance
and
safety
characteristics of your vehicle, you
should
keep
the
following
precautions in mind.
OVERLOAD THE
l NEVER
VEHICLE! Operation of an
overloaded vehicle may result in
tire damage, loss of control, or
severe injury
injury.. Make sure that the
total weight of rider
rider,, cargo, and
accessories does not exceed the
specified maximum load for the
vehicle.
6-15
Do not carry along loosely
packed items, which can shift
during a ride.
Securely pack the heaviest items
close to the center of the vehicle
and distribute the weight evenly
on both sides.
Adjust the suspension and tire
air pressure with regard to the
load.
Check the tire condition and air
pressure before each ride.
Tire inspection
6
2
1
1. Tire sidewall
2. Tire tread depth
PERIODIC MAINTENANCE AND MINOR REP
AIR
REPAIR
The tires must be checked before each
ride. If a tire tread depth reaches the
specified limit, if the tire has a nail or
glass fragments in it, or if the sidewall
is cracked, have a Yamaha dealer
replace the tire immediately.
Minimum tire tread depth
(front and rear):
4.0 mm (0.16 in)
Tire information
This motorcycle is equipped with spoke
wheels and tube tires.
Front tire:
Size:
80/100-21 NHS
Manufacturer/model:
PIRELLI MT 320 H
Rear tire:
Size:
100/100-18 NHS
Manufacturer/model:
PIRELLI MT 320
l
6
l
l
The front and rear tires should
be of the same make and design,
otherwise
the
handling
characteristics of the vehicle
cannot be guaranteed.
After extensive tests, only the
tires listed below have been
approved for this model by
Yamaha Motor da Amazônia
Ltda.
l
l
Have a Y
amaha dealer replace
Yamaha
excessively worn tires. Besides
being illegal, operating the
machine with excessively worn
tires decreases riding stability
and can lead to loss of control.
The replacement of all wheeland
brake-related parts, including
the tires, should be left to a
Yamaha dealer
dealer,, who has the
necessary
professional
knowledge and experience.
It is not recommended to patch
a
punctured
tube.
If
unavoidable, however
however,, patch the
6-16
tube very carefully and replace
it as soon as possible with a
high-quality product.
PERIODIC MAINTENANCE AND MINOR REP
AIR
REPAIR
Spoke wheels
To maximize the performance,
durability, and safe operation of your
motorcycle, note the following points
regarding the specified wheels.
l The wheel rims should be checked
for cracks, bends or warpage, and
the spokes for looseness or
damage before each ride. If any
damage is found, have a Yamaha
dealer replace the wheel. Do not
attempt even the smallest repair to
the wheel. A deformed or cracked
wheel must be replaced.
l The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced. An
unbalanced wheel can result in
poor performance, adverse
handling characteristics, and a
shortened tire life.
l Ride at moderate speeds after
changing a tire since the tire
surface must first be “broken in” for
it to develop its optimal
characteristics.
Accessories and
replacement parts
This motorcycle is not designed to
pull a trailer or to be attached to a
sidecar
sidecar.. The accessories or
replacement parts you choose for
your motorcycle should be designed
specifically for this model, and they
must be securely mounted to
maintain the inherent stability of the
original design. Genuine Y
amaha
Yamaha
Parts and Accessories are designed
and tested to be compatible with
your motorcycle. Please consider
Genuine Y
amaha Parts and
Yamaha
Accessories before making a
purchase. Use of non-Y
amahanon-Yamahaapproved
accessories
or
replacement parts may cause loss of
handling stability and riding safety
safety..
Since Y
amaha cannot control the
Yamaha
quality of accessories or parts
manufactured by other companies,
Yamaha cannot be held liable for any
6-17
consequences caused by the use of
items which have not been approved
by Y
amaha.
Yamaha.
6
PERIODIC MAINTENANCE AND MINOR REP
AIR
REPAIR
Adjusting the clutch lever
free play
6
1. Locknut (clutch lever)
2. Adjusting bolt
3. Locknut (clutch cable)
4. Adjusting nut
5. Clutch lever free play
adjusting bolt in direction (b).
3. If the specified clutch lever free play
could be obtained as described
above, tighten the locknut and skip
the rest of the procedure, otherwise
proceed as follows.
4. Fully turn the adjusting bolt in
direction (a) to loosen the clutch
cable.
5. Loosen the locknut further down
the clutch cable.
6. To increase the clutch lever free
play, turn the adjusting nut in
direction (a). To decrease the
clutch lever free play, turn the
adjusting nut in direction (b).
7. Tighten both locknuts.
The clutch lever free play should
measure 10 ~ 15 mm (0,39 ~ 0,59 in)
as shown. Periodically check the clutch
lever free play and, if necessary, adjust
it as follows.
1. Loosen the locknut at the clutch
lever.
2. To increase the clutch lever free
play, turn the adjusting bolt in
direction (a). To decrease the
clutch lever free play, turn the
Adjusting the brake pedal
position
For brake pedal adjustment, be sure
to proceed as follows (it is advisable
to have a Y
amaha dealer make this
Yamaha
adjustment.)
1. Adjuster
2. Locknut
1. Pedal height.
a. Loosen the locknut.
b. By turning the adjuster clockwise
or counterclockwise adjust the
brake pedal position so that its top
end is 3 mm (0.12 in) below the
top of footrest.
c. Tighten the locknut.
6-18
PERIODIC MAINTENANCE AND MINOR REP
AIR
REPAIR
Checking the front brake
pads and rear brake shoes
After adjusting the pedal height
adjust brake pedal free play
play..
2. Free play
The rear brake pedal free play
should be adjusted to 20 ~ 30 mm
(0.8 ~ 1.2 in) at the brake pedal
end. Turn the adjuster on the brake
rod clockwise to reduce play or
counterclockwise to increase play.
a. Pedal height
b. Free play
•
•
Brake pedal free play should be
checked whenever the chain is
adjusted or the rear wheel is
removed and then reisntalled.
If it is impossible to make proper
adjustment, consult a Y
amaha
Yamaha
dealer
dealer..
1. Adjuster
6-19
The front brake pads and rear brake
shoes must be checked for wear at the
intervals specified in the periodic
maintenance and lubrication chart.
Each brake pad/ shoes are provided
with a wear indicator groove, which
allows you to check the brake pad/
shoes wear without having to
disassemble the brake. To check the
brake pad/ shoes wear, check the wear
indicator grooves. If a brake pad/ shoes
have worn to the point that the wear
indicator groove have almost
disappeared, have a Yamaha dealer
replace the brake pads/ shoes as a set.
Front brake
Apply the brake and inspect the wear
indicator. If the wear indicator is almost
in contact with the disc plate ask a
Yamaha dealer to replace the pads.
6
PERIODIC MAINTENANCE AND MINOR REP
AIR
REPAIR
Checking the brake fluid
level
Front brake
1
LOWER
1. Wear indicator groove
6
Rear brake
Apply the brake and inspect the wear
indicator. If the indicator reaches the
wear limit line, ask a Yamaha dealer to
replace the shoes.
1. Wear limit
2. Wear indicator
l
Recommended brake fluid:
DOT 4
l
1. Lower level
l
Insufficient brake fluid may allow air to
enter the brake system, possibly
causing it to become ineffective.
Before riding, check that the brake fluid
is above the minimum level mark and
replenish if necessary. A low brake fluid
level may indicate worn brake pads and/
or brake system leakage. If the brake
fluid level is low, be sure to check the
brake pads for wear and the brake
system for leakage.
Observe these precautions:
l When checking the fluid level,
6-20
make sure that the top of the brake
fluid reservoir is level.
Use only the recommended quality
brake fluid, otherwise the rubber
seals may deteriorate, causing
leakage and poor braking
performance.
l
l
Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and lead
to poor braking performance.
Be careful that water does not enter
the brake fluid reservoir when
refilling. Water will significantly
lower the boiling point of the fluid
and may result in vapor lock.
Brake fluid may deteriorate painted
surfaces or plastic parts. Always
clean up spilled fluid immediately.
As the brake pads wear, it is normal for the brake fluid level to
gradually go down. However, if the
brake fluid level goes down
suddenly, have a Yamaha dealer
check the cause.
PERIODIC MAINTENANCE AND MINOR REP
AIR
REPAIR
Changing the brake fluid
Drive chain slack
Have a Yamaha dealer change the
brake fluid at the intervals specified in
the NOTE after the periodic
maintenance and lubrication chart. In
addition, have the oil seals of the master
cylinders and calipers as well as the
brake hoses replaced at the intervals
listed below or whenever they are
damaged or leaking.
l Oil seals: Replace every two years.
l Brake hoses: Replace every four
years.
The drive chain slack should be
checked before each ride and adjusted
if necessary.
To check the drive chain slack
1. Place the motorcycle on a level
surface and hold it in an upright
position.
A. Drive chain slack
When checking and adjusting the drive
chain slack, the motorcycle should be
positioned straight up and there should
be no weight on it.
2. Shift the transmission into the
neutral position.
3. Move the rear wheel by pushing the
motorcycle to locate the tightest
portion of the drive chain, and then
measure the drive chain slack as
shown.
Drive chain slack:
45 ~ 60 mm (1.77 ~ 2.36 in)
4. If the drive chain slack is incorrect,
adjust it as follows.
To adjust the drive chain slack
1. Loosen the rear brake adjuster and
the axlenut.
2. To tighten the drive chain, turn the
adjusting plate on each side of the
swingarm in direction (a). To loosen
the drive chain, turn the adjusting
plate on each side of the swingarm
in direction (b), and then push the
rear wheel forward.
Make sure that both adjusting plates are
in the same position for proper wheel
alignment.
6-21
6
PERIODIC MAINTENANCE AND MINOR REP
AIR
REPAIR
Lubricating the drive chain
The drive chain must be cleaned and
lubricated at the intervals specified in
the periodic maintenance and
lubrication chart, otherwise it will quickly
wear out, especially when riding in dusty
or wet areas. Service the drive chain
as follows.
1. Adjuster
2. Adjusting plate
3. Axle nut
6
Improper drive chain slack will
overload the engine as well as other
vital parts of the motorcycle and can
lead to chain slippage or breakage.
To prevent this from occurring, keep
the drive chain slack within the
specified limits.
3. Tighten the axle nut to the specified
torque.
Tightening torque
torque:
Axle nut:
80 Nm (8.0 m.kgf, 58 ft.lbf)
The drive chain must be lubricated
after washing the motorcycle or
riding in the rain.
1. Clean the drive chain with kerosene
and a small soft brush.
0211
E
C
A
1
To prevent damaging the O-rings, do
not clean the drive chain with steam
cleaners, high-pressure washers or
inappropriate solvents.
2. Wipe the drive chain dry.
3. Thoroughly lubricate the drive chain
with a special O-ring chain
lubricant.
6-22
Do not use engine oil or any other
lubricants for the drive chain, as they
may contain substances that could
damage the O-rings.
PERIODIC MAINTENANCE AND MINOR REP
AIR
REPAIR
Checking and lubricating the
cables
Checking and lubricating the
throttle grip and cable
The operation of all control cables and
the condition of the cables should be
checked before each ride, and the
cables and cable ends should be
lubricated if necessary. If a cable is
damaged or does not move smoothly,
have a Yamaha dealer check or replace
it.
The operation of the throttle grip should
be checked before each ride. In
addition, the cable should be lubricated
or replaced at the intervals specified in
the periodic maintenance chart.
Recommended lubricant:
Yamaha Chain and Cable Lube or
engine oil SAE 10W-30 (API SE)
Checking and lubricating the
brake and clutch levers
The operation of the brake and clutch
levers should be checked before each
ride, and the lever pivots should be
lubricated if necessary.
Damage to the outer housing of
cables may result in internal rusting
and cause interference with cable
movement. Replace damaged cables
as soon as possible to prevent
unsafe conditions.
Recommended lubricant:
Lithium-soap-based grease (allpurpose grease)
6-23
6
PERIODIC MAINTENANCE AND MINOR REP
AIR
REPAIR
Lubricating the brake pedal
Checking and lubricating the
sidestand
Checking the front fork
The condition and operation of the front
fork must be checked as follows at the
intervals specified in the periodic
maintenance and lubrication chart.
To check the condition
Securely support the motorcycle so
that there is no danger of it falling
over
over..
6
The operation of the brake pedal should
be checked before each ride, and the
pedal pivot should be lubricated if
necessary.
Recommended lubricant:
Lithium-soap-based grease (allpurpose grease)
The operation of the sidestand should
be checked before each ride, and the
sidestand pivot and metal-to-metal
contact surfaces should be lubricated
if necessary.
If the sidestand does not move up
and down smoothly
amaha
smoothly,, have a Y
Yamaha
dealer check or repair it.
Recommended lubricant:
Lithium-soap-based grease (allpurpose grease)
6-24
1. Check the inner tubes for
scratches, damage and excessive
oil leakage.
To check the operation
1. Place the motorcycle on a level
surface and hold it in an upright
position.
2. While applying the front brake,
push down hard on the handlebars
several times to check if the front
fork compresses and rebounds
smoothly.
PERIODIC MAINTENANCE AND MINOR REP
AIR
REPAIR
Checking the steering
Worn or loose steering bearings may
cause danger. Therefore, the operation
of the steering must be checked as
follows at the intervals specified in the
periodic maintenance and lubrication
chart.
1. Place a stand under the engine to
raise the front wheel off the ground.
Securely support the motorcycle so
that there is no danger of it falling
over
over..
If any damage is found or the front
fork does not operate smoothly
smoothly,, have
aY
amaha dealer check or repair it.
Yamaha
2. Hold the lower ends of the front fork
legs and try to move them forward
and backward. If any free play can
be felt, have a Yamaha dealer
check or repair the steering.
6-25
6
PERIODIC MAINTENANCE AND MINOR REP
AIR
REPAIR
Checking the wheel bearings
Battery
The front and rear wheel bearings must
be checked at the intervals specified in
the periodic maintenance and
lubrication chart. If there is play in the
wheel hub or if the wheel does not turn
smoothly, have a Yamaha dealer check
the wheel bearings.
l
1. Battery
6
The battery is located behind panel A.
(See page 6-6.)
This model is equipped with a sealedtype (MF) battery, which does not
require any maintenance. There is no
need to check the electrolyte or to add
distilled water.
l
Never attempt to remove the battery
cell seals, as this would permanently
damage the battery
battery..
l
6-26
Electrolyte is poisonous and
dangerous since it contains
sulfuric acid, which causes
severe burns. A
void any contact
Avoid
with skin, eyes or clothing and
always shield your eyes when
working near batteries. In case
of contact, administer the
following FIRST AID.
• EXTERNAL: Flush with plenty
of water
water..
• INTERNAL: Drink large
quantities of water or milk and
immediately call a physician.
• EYES: Flush with water for 15
minutes and seek prompt
medical attention.
Batteries produce explosive
hydrogen gas. Therefore, keep
sparks, flames, cigarettes, etc.,
away from the battery and
provide sufficient ventilation
when charging it in an enclosed
space.
KEEP
THIS
AND
ALL
PERIODIC MAINTENANCE AND MINOR REP
AIR
REPAIR
Replacing the fuse
BA
TTERIES OUT OF THE
BATTERIES
REACH OF CHILDREN.
l
To charge the battery
1. Have a Yamaha dealer charge the
battery as soon as possible if it
seems to have discharged. Keep
in mind that the battery tends to
discharge more quickly if the
vehicle is equipped with optional
electrical accessories.
To store the battery
1. If the vehicle will not be used for
more than one month, remove the
battery, fully charge it, and then
place it in a cool, dry place.
2. If the battery will be stored for more
than two months, check it at least
once a month and fully charge it if
necessary.
3. Fully charge the battery before
installation.
4. After installation, make sure that
the battery leads are properly
connected to the battery terminals.
l
Always keep the battery
charged. Storing a discharged
battery can cause permanent
battery damage.
To charge a sealed-type (MF)
battery
battery,, a special (constantvoltage) battery charger is
required. Using a conventional
battery charger will damage the
battery
battery.. If you do not have
access to a sealed-type (MF)
battery charger
amaha
charger,, have a Y
Yamaha
dealer charge your battery
battery..
1. Fuse
2. Spare fuse
The fuse holder is located behind panel
A. (See page 6-6.)
If the fuse is blown, replace it as follows.
1. Push the main switch to “OFF” and
turn off all electrical circuits.
2. Remove the blown fuse, and then
install a new fuse of the specified
amperage.
Specified fuse:
10 A
6-27
6
PERIODIC MAINTENANCE AND MINOR REP
AIR
REPAIR
Do not use a fuse of a higher
amperage rating than recommended
to avoid causing extensive damage
to the electrical system and possibly
a fire.
3. Push the main swith to “ON” and
turn on the electrical circuits to
check if the devices operate.
4. If the fuse immediately blows again,
have a Yamaha dealer check the
electrical system.
6
Supporting the motorcycle
Front wheel
Since this model is not equipped with a
centerstand, follow these precautions
when removing the front and rear wheel
or performing other maintenance
requiring the motorcycle to stand
upright. Check that the motorcycle is in
a stable and level position before
starting any maintenance. A strong
wooden box can be placed under the
engine for added stability.
To service the front wheel
1. Stabilize the rear of the motorcycle
by using a motorcycle stand or, if
an additional motorcycle stand is
not available, by placing a jack
under the frame in front of the rear
wheel.
2. Raise the front wheel off the ground
by using a motorcycle stand.
To service the rear wheel
Raise the rear wheel off the ground by
using a motorcycle stand or, if a
motorcycle stand is not available, by
placing a jack either under each side of
the frame in front of the rear wheel or
under each side of the swingarm.
To remove the front wheel
6-28
l
l
It is advisable to have a Y
amaha
Yamaha
dealer service the wheel.
Securely support the motorcycle
so that there is no danger of it
falling over
over..
1. Loosen the wheel axle.
2. Lift the front wheel off the ground
according to the procedure on page
6-28.
PERIODIC MAINTENANCE AND MINOR REP
AIR
REPAIR
3. Pull the wheel axle out, and then
remove the wheel.
Do not apply the brake after the
wheel has been removed together
with the brake disc, otherwise the
brake pads will be forced shut.
To install the front wheel
1. Insert the wheel axle, and then
tighten it to the specified torque.
Tightening torque:
Wheel axle:
80 Nm (8.0 m.kgf, 58 ft.lbf)
Rear wheel
To remove the rear wheel
l
l
It is advisable to have a Y
amaha
Yamaha
dealer service the wheel.
Securely
support
the
motorcycle so that there is no
danger of it falling over
over..
4. Lift the rear wheel off the ground
according to the procedure on
page 6-28.
5. Remove the axle nut.
6. Push the wheel forward, and then
remove the drive chain from the
rear sprocket.
1. Remove the brake adjuster.
2. Remove the brake rod from the
brake cam lever
3. Loosen the axle nut
6
2. While applying the front brake,
push down hard on the handlebars
several times to check if the front
fork compresses and rebounds
smoothly.
The drive chain does not need to be
disassembled in order to remove and
install the wheel.
7. Remove the wheel.
1. Adjuster
2. Brake rod
3. Brake cam lever
4. Axle nut
6-29
PERIODIC MAINTENANCE AND MINOR REP
AIR
REPAIR
To install the rear wheel
1. Install the wheel.
2. Install the drive chain onto the rear
sprocket.
3. Be sure the slot in the brake shoe
plate is fit over the stopper on the
rear arm.
Tightening torque:
Axle nut:
80 Nm (8.0 m.kgf, 58 ft.lbf)
7. Adjust the rear brake (see pag 618)
6
4. Make sure the rear wheer axle is
inserted from the left-hand side and
that the chain, pullers are installed
with the punched side outward.
5. Adjust the drive chain slack. (See
page 6-21.)
6. Tighten the axle nut to the specified
torque.
6-30
Troubleshooting
Although Yamaha motorcycles receive
a thorough inspection before shipment
from the factory, trouble may occur
during operation. Any problem in the
fuel, compression, or ignition systems,
for example, can cause poor starting
and loss of power.
The following troubleshooting chart
represents a quick and easy procedure
for checking these vital systems
yourself. However, should your
motorcycle require any repair, take it to
a Yamaha dealer, whose skilled
technicians have the necessary tools,
experience, and know-how to service
the motorcycle properly.
Use only genuine Yamaha replacement
parts. Imitation parts may look like
Yamaha parts, but they are often inferior, have a shorter service life and can
lead to expensive repair bills.
PERIODIC MAINTENANCE AND MINOR REP
AIR
REPAIR
Troubleshooting chart
Keep away open flames and do not smoke while checking or working on the fuel system.
1. Fuel
There is enough fuel.
Check the compression.
There is no fuel.
Supply fuel.
There is compression.
Check the ignition.
There is no compression.
Have a Yamaha dealer
check the vehicle.
Check the fuel level in
the fuel tank.
The engine does not start.
Check the compression.
2. Compression
Operate the electric starter.
3. Ignition
6
Wet
Wipe off with a dry cloth and correct the
spark plug gap, or replace the spark plug.
Open the throttle halfway and operate
the electric starter.
Dry
Have a Yamaha dealer check the vehicle.
The engine does not start.
Check the battery.
Remove the spark plug
and check the electrodes.
4. Battery
The engine turns over
quickly.
The battery is good.
The engine turns over
slowly.
Check the battery lead connections,
and charge the battery if necessary.
Operate the electric starter.
6-31
The engine does not start.
Have a Yamaha dealer
check the vehicle.
MOT
ORCYCLE CARE AND ST
ORAGE
MOTORCYCLE
STORAGE
Care
7
While the open design of a motorcycle
reveals the attractiveness of the
technology, it also makes it more
vulnerable. Rust and corrosion can
develop even if high-quality
components are used. A rusty exhaust
pipe may go unnoticed on a car,
however, it detracts from the overall
appearance of a motorcycle. Frequent
and proper care does not only comply
with the terms of the warranty, but it will
also keep your motorcycle looking good,
extend its life and optimize its
performance.
Before cleaning
1. When washing the motorcycle with
high pressured water, cover the
parts following.
a. Silencer exhaust port.
b. Side cover air intake port.
2. Close the air intake port for the
water protection at each port, right
and left of side covers while
washing by high pressured water.
3. Cover the muffler outlet with a
plastic bag after the engine has
cooled down.
4. Make sure that all caps and covers
as well as all electrical couplers and
connectors, including the spark
plug cap, are tightly installed.
5. Remove extremely stubborn dirt,
like oil burnt onto the crankcase,
with a degreasing agent and a
brush, but never apply such
products onto seals, gaskets,
sprockets, the drive chain and
wheel axles. Always rinse the dirt
and degreaser off with water.
Cleaning
l
l
Avoid using strong acidic wheel
cleaners, especially on spoked
wheels. If such products are
used on hard-to-remove dirt, do
not leave the cleaner on the
affected area any longer than
instructed. Also, thoroughly
rinse the area of
offf with water
water,,
immediately dry it, and then
apply a corrosion protection
spray
spray..
Improper cleaning can damage
windshields, cowlings, panels
and other plastic parts. Use only
a soft, clean cloth or sponge
7-1
l
l
l
with mild detergent and water to
clean plastic.
Do not use any harsh chemical
products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
contact with strong or abrasive
cleaning products, solvent or
thinner
thinner,, fuel (gasoline), rust
removers or inhibitors, brake
fluid, antifreeze or electrolyte.
Do not use high-pressure
washers or steam-jet cleaners
since they cause water seepage
and deterioration in the
following areas: seals (of wheel
and swingarm bearings, fork
and
brakes),
electric
components
(couplers,
connectors,
instruments,
switches and lights), breather
hoses and vents.
For motorcycles equipped with
a windshield: Do not use strong
cleaners or hard sponges as
they will cause dulling or
scratching. Some cleaning
compounds for plastic may
leave scratches on the
MOT
ORCYCLE CARE AND ST
ORAGE
MOTORCYCLE
STORAGE
windshield. T
est the product on
Test
a small hidden part of the
windshield to make sure that it
does not leave any marks. If the
windshield is scratched, use a
quality
plastic
polishing
compound after washing.
After normal use
Remove dirt with warm water, a mild
detergent, and a soft, clean sponge, and
then rinse thoroughly with clean water.
Use a toothbrush or bottlebrush for
hard-to-reach areas. Stubborn dirt and
insects will come off more easily if the
area is covered with a wet cloth for a
few minutes before cleaning.
After riding in the rain, near the sea or
on salt-sprayed roads
Since sea salt or salt sprayed on roads
during winter are extremely corrosive in
combination with water, carry out the
following steps after each ride in the
rain, near the sea or on salt-sprayed
roads.
Salt sprayed on roads in the winter may
remain well into spring.
1. Clean the motorcycle with cold
water and a mild detergent, after
the engine has cooled down.
Do not use warm water since it
increases the corrosive action of the
salt.
2. Apply a corrosion protection spray
on all metal, including chrome- and
nickel-plated, surfaces to prevent
corrosion.
After cleaning
1. Dry the motorcycle with a chamois
or an absorbing cloth.
2. Immediately dry the drive chain and
lubricate it to prevent it from rusting.
3. Use a chrome polish to shine
chrome, aluminum and stainlesssteel parts, including the exhaust
system. (Even the thermally
induced discoloring of stainlesssteel exhaust systems can be
removed through polishing.)
7-2
4. To prevent corrosion, it is
recommended to apply a corrosion
protection spray on all metal,
including chrome- and nickelplated, surfaces.
5. Use spray oil as a universal cleaner
to remove any remaining dirt.
6. Touch up minor paint damage
caused by stones, etc.
7. Wax all painted surfaces.
8. Let the motorcycle dry completely
before storing or covering it.
l
l
Make sure that there is no oil or
wax on the brakes or tires. If
necessary
necessary,, clean the brake discs
and brake linings with a regular
brake disc cleaner or acetone,
and wash the tires with warm
water and a mild detergent.
Before operating the motorcycle
test its braking performance and
cornering behavior
behavior..
7
MOT
ORCYCLE CARE AND ST
ORAGE
MOTORCYCLE
STORAGE
Storage
l
l
l
Apply spray oil and wax
sparingly and make sure to wipe
off any excess.
Never apply oil or wax to any
rubber and plastic parts, but
treat them with a suitable care
product.
Avoid using abrasive polishing
compounds as they will wear
away the paint.
Short-term
Always store your motorcycle in a cool,
dry place and, if necessary, protect it
against dust with a porous cover.
l
l
Consult a Yamaha dealer for advice on
what products to use.
7
Storing the motorcycle in a
poorly ventilated room or
covering it with a tarp, while it is
still wet, will allow water and
humidity to seep in and cause
rust.
To prevent corrosion, avoid
damp cellars, stables (because
of the presence of ammonia) and
areas where strong chemicals
are stored.
Long-term
Before storing your motorcycle for
several months:
1. Follow all the instructions in the
“Care” section of this chapter.
2. For motorcycles equipped with a
fuel cock that has an “OFF”
position: Turn the fuel cock lever
to “OFF”.
7-3
3. Drain the carburetor float chamber
by loosening the drain bolt; this will
prevent fuel deposits from building
up. Pour the drained fuel into the
fuel tank.
4. Fill up the fuel tank and add fuel
stabilizer (if available) to prevent
the fuel tank from rusting and the
fuel from deteriorating.
5. Perform the following steps to
protect the cylinder, piston rings,
etc. from corrosion.
a. Remove the spark plug cap and
spark plug.
b. Pour a teaspoonful of engine oil
into the spark plug bore.
c. Install the spark plug cap onto the
spark plug, and then place the
spark plug on the cylinder head so
that the electrodes are grounded.
(This will limit sparking during the
next step.)
d. Turn the engine over several times
with the starter. (This will coat the
cylinder wall with oil.)
e. Remove the spark plug cap from
the spark plug, and then install the
spark plug and the spark plug cap.
MOT
ORCYCLE CARE AND ST
ORAGE
MOTORCYCLE
STORAGE
To prevent damage or injury from
sparking, make sure to ground the
spark plug electrodes while turning
the engine over
over..
6. Lubricate all control cables and the
pivoting points of all levers and
pedals as well as of the sidestand/
centerstand.
7. Check and, if necessary, correct
the tire air pressure, and then lift
the motorcycle so that both of its
wheels are off the ground.
Alternatively, turn the wheels a little
every month in order to prevent the
tires from becoming degraded in
one spot.
8. Cover the muffler outlet with a
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 than 0o C
(30oF) or more than 30oC (90oF)].
For more information on storing the
battery, see page 6-26.
Make any necessary repairs before
storing the motorcycle.
7
7-4
SPECIFICA
TIONS
SPECIFICATIONS
Dimensions:
Overall length:
2065 mm (81.3 in)
Overall width:
800 mm (31.5 in)
Overall height:
1180 mm (46.5 in)
Seat height:
870 mm (34.2 in)
Starting system:
Electric starter
Fuel reserve amount:
1.8 L (0.48 us.gal) (0.4 imp.gal)
Lubrication system:
Wet sump
Engine oil:
Type:
YAMALUBE 4, SAE10W30 or
SAE20W40
0°
Wheelbase:
1385 mm (54.5 in)
10 °
30 ° 50 ° 70 ° 90 ° 110° 130°F
YAMALUBE 4 (10W30)
or SAE 10W30
Ground clearance:
295 mm (11.6 in)
YAMALUBE 4 (20W40)
or SAE 20W40
Minimum turning radius:
2100 mm (82.7 in)
- 20 ° - 10 °
0°
10 ° 20 ° 30 ° 40 ° 50°C
Engine:
8
Recommended engine oil glade:
API service SE, SF, SG type or higher
Engine oil quantity:
Engine type:
Air cooled 4-stroke, SOHC
Without oil filter element replacement:
1.0 L (1.1 us.qt) (0.90 Imp.qt)
Cylinder arrangement:
Forward inclined single cylinder
With oil filter element replacement:
1.1 L (1.2 us.qt) (1.0 Imp.qt)
Displacement:
223 cm3
(13.61 cu.in)
Bore X stroke:
70.0 X 58.0 mm (2.76 X 2.28 in)
Compression ratio:
9.50 : 1
Manufacturer:
TEIKEI
Type x quantity:
Y26P x 1
Spark plug(s):
Manufacturer/model:
NGK/DR8EA
Spark plug gap:
0.6–0.7 mm (0.024–0.028 in)
Clutch:
Clutch type:
Wet, multiple-disc
Transmission:
Weight:
With oil and fuel:
116.0 kg (256 lb)
Carburetor:
Air filter:
Air filter element:
Wet element
Primary reduction system:
Spur gear
Primary reduction ratio:
73/22 (3.318)
Secondary reduction system:
Chain drive
Secondary reduction ratio:
49/13 (3.769)
Transmission type:
Constant mesh 6-speed
Fuel:
Recommended fuel:
Unleaded gasoline only
Fuel tank capacity:
8.0 L (2.11 us.gal) (1.76 imp.gal)
8-1
Operation:
Left foot operation
Gear ratio:
1st:
38/13 (2.923)
SPECIFICA
TIONS
SPECIFICATIONS
2nd:
34/18 (1.889)
Maximum load:
90.0 kg (198 lb)
3rd:
30/21 (1.428)
(Total weight of rider, passenger, cargo and
accessories)
4th:
27/24 (1.125)
5th:
25/27 (0.925)
6th:
23/29 (0.793)
Chassis:
Frame type:
Diamond
Caster angle:
27.0 °
Trail:
111.0 mm (4.4 in)
Front tire:
Type:
With tube
Size:
80/100-21 NHS
Manufacturer/model:
PIRELLI/MT320H
Rear tire:
Type:
With tube
Size:
100/100-18 NHS
Manufacturer/model:
PIRELLI/MT320
Operation:
Right foot operation
Tire air pressure (measured on cold
tires):
Off-road riding:
Front:
100 kPa (15 psi) (1.00 kgf/cm2)
Rear:
100 kPa (15 psi) (1.00 kgf/cm2)
Front wheel:
Front suspension:
Type:
Telescopic fork
Spring/shock absorber type:
Coil spring/oil damper
Wheel travel:
240.0 mm (9.45 in)
Rear suspension:
Type:
Swingarm (link suspension)
Wheel type:
Spoke wheel
Spring/shock absorber type:
Coil-gas spring/oil damper
Rim size:
21x1.60
Wheel travel:
220.0 mm (8.66 in)
Rear wheel:
Electrical system:
Wheel type:
Spoke wheel
Ignition system:
DC. C.D.I.
Rim size:
18x1.85
Charging system:
A.C. magneto
Front brake:
Type:
Single disc brake
Operation:
Right hand operation
Recommended fluid:
Dot 4
Rear brake:
Type:
Drum brake
8-2
Battery:
Model:
YTX5L-BS
Voltage, capacity:
12 V, 4.0 Ah
Fuse:
Fuse:
10.0 A
8
CONSUMER INFORMA
TION
INFORMATION
Identification numbers
Vehicle identification number
Model label
Record vehicle identification number
and model label information in the
spaces provided below for assistance
when ordering spare parts from a
Yamaha dealer or for reference in case
the vehicle is stolen.
VEHICLE IDENTIFICATION NUMBER:
1. Vehicle identification number
MODEL LABEL INFORMATION:
9
The vehicle identification number is
stamped into the steering head pipe.
Record this number in the space
provided.
The vehicle identification number is
used to identify your motorcycle and
may be used to register your motorcycle
with the licensing authority in your area.
9-1
1. Model label
The model label is affixed to the frame.
Record the information on this label in
the space provided. This information will
be needed when ordering spare parts
from a Yamaha dealer.
CONSUMER INFORMA
TION
INFORMATION
Motorcycle noise regulation
TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED:
Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other
than for purposes of maintenance, repair, or replacement of any device or element of design incorporated into any new
vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or (2) the use
of the vehicle after such device or element of design has been removed or rendered inoperative by any person.
“AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW”.
These acts include tampering with the following systems; i.e., modification, removal, etc.
Exhaust system
• Muffler
• Exhaust pipe
• Silencer
Intake system
• Air cleaner case
• Air cleaner element
• Intake duct
9
9-2
CONSUMER INFORMA
TION
INFORMATION
Maintenance record
Have a Yamaha dealer complete this record when the motorcycle is serviced.
Maintenance
interval
Date of
service
Servicing dealer
name and address
Mileage
9
9-3
Remarks
CONSUMER INFORMATION
YAMAHA MOTOR CORPORATION, U.S.A. OFF-ROAD MOTORCYCLE LIMITED WARRANTY
Yamaha Motor Corporation, USA hereby warrants
that new Yamaha off-road motorcycles purchased
from an authorized Yamaha motorcycle dealer in the
continental United States will be free from defects
in material and workmanship for the period of time
stated herein, subject to certain stated limitations.
Covered off-road motorcycles are those units certified
by Yamaha to EPA noise regulations and come
equipped from the factory with USDA-FS approved
spark arresters.
THE PERIOD OF WARRANTY for Yamaha off-road
motorcycles shall be ninety (90) days from the date
of purchase, with no mileage limitation.
PRODUCT EXCLUDED FROM WARRANTY include
those used for non-Yamaha-authorized renting,
leasing, or other commercial purposes.
D U R I N G T H E P E R I O D O F WARRANTY any
authorized Yamaha motorcycle dealer will free of
charge, repair or replace, at Yamaha’s option, any
part adjudged defective by Yamaha due to faulty
workmanship or material from the factory. Parts used
in warranty repairs will be warranted for the balance
of the product’s warranty period. All parts replace
under warranty become property of Yamaha Motor
Corporation, USA.
GENERAL EXCLUSIONS from this warranty shall
include any failures caused by:
a. Competition or racing use.
b. Installation of parts or accessories that are not
qualitatively equivalent to genuine Yamaha parts.
c. Abnormal strain, neglect, or abuse.
d. Lack of proper maintenance.
e. Accident or collision damage.
f. Modification to original parts.
g. Damage due to improper transportation.
SPECIFIC EXCLUSIONS from this warranty shall
include parts replaced due to normal wear or routine
maintenance.
THE CUSTOMER’S RESPONSIBILITY under this
warranty shall be to:
1. Operate and maintain the motorcycle as
specified in the appropriate Owner’s Manual, and
2. Give notice to an authorized Yamaha motorcycle
dealer of any and all apparent defects within ten
(10) days after discovery, and make the
motorcycle available at that time for inspection
and repairs at such dealer’s place of business.
WARRANTY TRANSFER: To tranfer the warranty from
the original purchaser to any subsequent purchaser(s),
it is imperative that the motorcycle be inspected and
registered for warranty by an authorized Yamaha
motorcycle dealer. In order for this warranty to remain in
effect, this inspection and registration must take place
within ten (10) days after transfer of ownership to the
subsequent purchaser. A reasonable dealer imposed fee
may be charged for this inspection.
EMISSION CONTROL SYSTEM WARRANTY
Yamaha Motor Corporation, USA also warrants to the
ultimate purchaser and each subsequent purchaser of
each 2006 and later model Yamaha motorcycle covered
by this warranty that the vehicle is designed, built, and
equipped so as to conform at the time of sale with all
U.S. emissions standards applicable at the time of
manufacture and that it is free from defects in materials
and workmanship which would cause it not to meet these
standards within the period listed immediately below.
Failures other than those resulting from defects in material or workmanship which arise solely as a result of owner
abuse and/or lack of proper maintenance are not covered
by this warranty.
9-4
All Off-Road Models
Thirty (30) months from the original purchase date.
YAMAHA MOTOR CORPORATION, USA MAKES NO
OTHER WARRANTY OF ANY KIND, EXPRESSED OR
IMPLIED. ALL IMPLIED WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS
AND TIME LIMITS STATED IN THIS WARRANTY ARE
HEREBY DISCLAIMED BY YAMAHA MOTOR
CORPORATION, USA AND EXCLUDED FRON THIS
WARRANTY.
SOME STATES SO NOT ALLOW LIMITATIONS ON
HOW LONG AN IMPLIED WARRANTY LASTS, SO
THE ABOVE LIMITATION MAY NOT APPLY TO YOU.
ALSO EXCLUDED FROM THIS WARRANTY ARE ANY
INCIDENTAL OR CONSEQUENTIAL DAMAGES
INCLUDING LOSS OF USE. SOME STATES DO NOT
ALLOW THE EXCLUSION OR LIMITATION OF
INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO
THE ABOVE EXCLUSION MAY NOT APPLY TO YOU.
THIS WARRANTY GIVES YOU SPECIFIC LEGAL
RIGHTS, AND YOU MAY ALSO HAVE OTHER RIGHTS
WHICH VARY FROM STATE TO STATE.
YAMAHA MOTOR CORPORATION, USA
Post Office Box 6555
Cypress, California 90630
9
CONSUMER INFORMATION
WARRANTY QUESTIONS AND ANSWERS
Q.
A.
What costs are my responsibility during the warranty period?
The customer’s responsibility includes all costs of normal maintenance
services, no-warranty repairs, accident and collision damages, and oil,
oil filters, air filters, spark plugs and brake shoes.
Q.
A.
What are some examples of “abnormal” strain, neglect or abuse?
These terms are general and overlap each other in areas. Specific
examples include:
Running the machine out of oil, sustained high-rpm, full-throttle, operating
the machine with a broken or damaged part which causes another part
to fail, damage or failure due to improper or careless transportation and
or tie down. If you have any specific questions on operation or
maintenance, please contact your delaer for advice.
Q.
A.
CUSTOMER SERVICE
If your machine requires warranty service, you must take it to any authorized
Yamaha Motorcycle dealer within the continental United States. Be sure to
bring your warrant registration card or other valid proof of the original date of
purchase. If a question or problem arises regarding warranty, first contact
the owner of the dealership. Since all warranty matters are handled at the
dealer level, this person is in the best position to help you. If you are still not
satisfied and require additional assistance, please write:
YAMAHA MOTOR COPORATION U.S.A.
CUSTOMER RELATIONS DEPARTMENT
P.O. Box 6555
Cypress, Califórnia 90630
When contacting Yamaha Motor Corporation, U.S.A. don’t forget to include
any important information such as names, addresses, model, V.I.N. (frame
number), dates, and receipts.
Does the warranty cover incidental costs such as towing or transportation
due to a failure?
No. The warranty is limited to repair of the machine itself.
CHANGE OF ADDRESS
Q.
A.
Q.
A.
Q.
A.
9
Q.
A.
May I perform any or all of the recommended maitenance shown in the
Owner’s Manual instead of having the dealer do them?
Yes, if you are a qualified mechanic and follow the procedures specified
in the Owner’s and Service Manual. We do recommend, however, that
items requiring special tools or equipment be done by Yamaha Motorcycle
dealer.
The federal government requires each manufacturer of a motor vehicle to
maintain a complete, up-to-date list of all first purchasers against the
possibility of a safety-related defect and recall. This list in compiled from the
purchase registrations sent to Yamaha Motor Corporation, U.S.A. by the selling
dealer at the time of your pruchase.
Will the warranty be void or cancelled if I do not operate or maintain my
new motorcylcle exactly as specified in the Owner’s Manual?
No. The warranty on a new motorcycle cannot be “voided” or “cancelled”
However, if a particular failure is caused by operation or maintenance
other than as shown in the Owner’s Manual, that failure may not be
covered under warranty.
If you should move after you have purchase your new motorcycle, please
advise us of your new address by sending a postcard listing your motorcycle
model name, V.I.N. (frame number), dealer number (or dealer’s name) as it
is shown on your warranty card, your name and new mailing address. Mail to:
YAMAHA MOTOR CORPORATION, U.S.A.
P.O. Box 6555
Cypress, California 90630
Attention: Warranty Department
What responsibility does my dealer have under this warranty?
Each Yamaha Motorcycle dealer is expected to:
1. Completely set up every new machine before sale.
2. Explain the operation, maintenace, and warranty requirements to
your satisfaction at the time of sale, and upon your request at any
later date.
3. Each Yamaha Motorcycle dealer is held responsible for his setup,
service and warranty repair work.
This will ensure that Yamaha Motor Corporation, U.S.A. has an up-to-date
registration record in accordance with federal law.
Is the warranty transferable to second owner’s?
Yes. The remainder of the existing warranty can be transferred upon
request. The unit has to be inspected and re-registered by an authorized
Yamaha Motorcycle dealer for the policy to remain effective.
9-5
CONSUMER INFORMA
TION
INFORMATION
YAMAHA EXTENDED SER
VICE (Y
.E.S.)
SERVICE
(Y.E.S.)
Keep your Yamaha protected even after your warranty
expires with genuine Yamaha Extended Service (Y.E.S.).
In addition, Travel and Recreation Interruption Protection
(TRIP) is included at no extra cost. TRIP gives you up to
$150 reimbursement per occurrence for any reasonable
expenses you incur because your Yamaha needs
covered service: replacement vehicle rental, emergency
towing, phone calls, even food and lodging when you are
away from home. This superb coverage goes into effect
when you purchase Y.E.S., so it applies to any warranty
repairs as well as covered repairs during your entire
Y.E.S. plan period.
Y.E.S. is designed and administered by Yamaha Motor
Corporation to provide maximum owner satisfaction. You
get uninterrupted factory-backed coverage for extra
peace of mind.
Y.E.S. is flexible. You choose the plan that’s right for
you: 12 months, 24 months, 36 months or, on certain
models, even 48 months beyond your warranty period.
Y.E.S. coverage is honored at any authorized Yamaha
dealer nationwide.
Y.E.S. is designed and administered by the same
Yamaha people who handle your warranty – and it
shows in the comprehensive coverage benefits. There
are no mileage limitations. Coverage isn’t limited to
“moving parts” or the “drive train” like many other plans.
And Y.E.S. covers manufacturing defects just like the
warranty. See the sample contract at your Yamaha
dealer to see how comforting uninterrupted factorybacked protection can be.
Y.E.S. coverage is transferable to a new owner if you
sell or trade-in. That can make your Yamaha much more
valuable!
This excellent Y.E.S. plan coverage is only available to
Yamaha owners like you, and only while your Yamaha is still
within the Yamaha Limited Warranty period. So visit your
authorized Yamaha dealer to get all the facts. He can show
you how easy it is to protect your investment with Yamaha
Extended Service.
You don’t have to pay anything for covered repairs.
There’s no deductible to pay, and repairs aren’t
“pro-rated.” You don’t have any “out-of-pocket” expenses
for covered repairs.
9
9-6
CONSUMER INFORMA
TION
INFORMATION
We urge you to act now. You’ll get the excellent benefits of
TRIP coverage right away, and you’ll rest easy knowing
you’ll have strong factory-backed protection even after your
Yamaha Limited Warranty expires.
A special note:
If visiting your dealer isn’t convenient, contact Yamaha with
your Primary ID number (your frame number). We’ll be
happy to help you get the Y.E.S. coverage you need.
Yamaha Service Marketing
P.O. Box 6555
Cypress, CA 90630
1-(866)-YES-EXTD (1-866-937-3983)
9
9-7
OWNER’S MANUAL
TT-R230V
YAMAHA MOTOR DA AMAZÔNIA LTDA.
LIT-11626-19-56
1C6-F8199-12