Yamaha AT115 Nouvo Owner Manual

PRINTED IN INDONESIA

YAMAHA MOTOR CO., LTD.

OWNER’S MANUAL

AT115

5MX-F8199-E0

Engine start procedure

Before pushing start button, make sure to apply the Front or Rear Brake and that the

Sidestand is retracted.

Engine oil replacement

Engine oil replacement : Every 2000 km.

Recommended oil : SAE20W - 50 type

SF Class Motor Oil

V-belt inspection

Periodic maintenance must be performed by any authorized Yamaha Dealer (Refer to the Owner's Manual for details.)

Load limit

Convenience hook : 1 kg, Helmet box: 5 kg

5MX-F835Y-00

U5MXE0.book Page 1 Thursday, December 20, 2001 2:08 PM

EAU00000 INTRODUCTION

Congratulations on your purchase of the Yamaha AT115. 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.

AT115


©2001 by Yamaha Motor Co., Ltd.

1st edition, December 2001

All rights reserved.

Any reprinting or unauthorized use without the written permission of

Yamaha Motor Co., Ltd.

is expressly prohibited.

Printed in Indonesia.

EAU04229*


IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following notations:

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS

INVOLVED!

EAU00005

WARNING

Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator, a bystander, or a person inspecting or repairing the motorcycle.

CAUTION:

NOTE:

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.

_

_

NOTE:

● 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.

EW000002

_

WARNING

_

PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING

THIS MOTORCYCLE.


EAU00009

1

GIVE SAFETY THE RIGHT OF WAY .................1-1

2

DESCRIPTION ...................................................2-1

Left view .............................................................2-1

Right view...........................................................2-2

Controls and instruments ...................................2-3

3

INSTRUMENT AND CONTROL FUNCTIONS ....3-1

Main switch/steering lock ..................................3-1

Indicator lights ...................................................3-2

Speedometer unit ..............................................3-2

Fuel gauge ........................................................3-2

Handlebar switches ...........................................3-3

Front brake lever ...............................................3-4

Rear brake lever ................................................3-4

Fuel tank cap .....................................................3-4

Fuel ...................................................................3-5

Starter (choke) lever ..........................................3-6

Kickstarter .........................................................3-6

Seat ...................................................................3-6

Helmet box ........................................................3-7

Convenience hook .............................................3-8

4

PRE-OPERATION CHECKS ...............................4-1

Pre-operation check list .....................................4-1

TABLE OF CONTENTS

5

OPERATION AND IMPORTANT RIDING

POINTS................................................................5-1

Starting and warming up a cold engine .............5-1

Starting a warm engine .....................................5-2

Starting off .........................................................5-2

Acceleration and deceleration ...........................5-3

Braking ..............................................................5-3

Engine break-in .................................................5-4

Parking ..............................................................5-5

General note ......................................................5-6

6

PERIODIC MAINTENANCE AND MINOR

REPAIR................................................................6-1

Owner’s tool kit ..................................................6-1

Periodic maintenance and lubrication chart ......6-2

Removing and installing the cowling and panels ............................................................6-4

Checking the spark plug ....................................6-7

Engine oil and oil strainer ..................................6-9

Final transmission oil .......................................6-11

Cleaning the air filter element, V-belt case air filter elements, and check hoses ............6-13

Adjusting the carburetor ..................................6-16

Adjusting the engine idling speed ...................6-17

Adjusting the throttle cable free play ...............6-17

Adjusting the valve clearance .........................6-18


TABLE OF CONTENTS

Tires ................................................................ 6-19

Spoke wheels .................................................. 6-21

Checking the front brake lever free play .......... 6-21

Adjusting the rear brake lever free play .......... 6-22

Checking the front brake pads and rear brake shoes ................................................. 6-23

Checking the brake fluid level ......................... 6-24

Changing the brake fluid ................................. 6-25

Checking the V-belt ......................................... 6-25

Checking and lubricating the cables ............... 6-25

Checking and lubricating the throttle grip and cable ..................................................... 6-26

Lubricating the front and rear brake levers ..... 6-26

Checking and lubricating the centerstand and sidestand .............................................. 6-27

Checking the front fork .................................... 6-27

Checking the steering ..................................... 6-28

Checking the wheel bearings .......................... 6-29

Battery ............................................................. 6-29

Replacing the fuse .......................................... 6-31

Replacing a headlight bulb .............................. 6-33

Replacing a front turn signal light bulb ............ 6-34

Replacing the tail/brake light bulb or a rear turn signal light bulb .................................... 6-35

Troubleshooting .............................................. 6-37

Troubleshooting chart ..................................... 6-38

7

MOTORCYCLE CLEANING AND STORAGE..... 7-1

A. CLEANING .................................................... 7-1

B. STORAGE ..................................................... 7-1

8

SPECIFICATIONS............................................... 8-1

Specifications .................................................... 8-1

9

CONSUMER INFORMATION.............................. 9-1

Identification numbers ....................................... 9-1

Frame serial number ......................................... 9-1

Engine serial number ........................................ 9-1


EAU00021 GIVE SAFETY THE RIGHT OF WAY

Motorcycles are fascinating vehicles, which can give you an unsurpassed feeling of power and freedom. However, they also impose certain limits, which you must accept; even the best motorcycle does not ignore the laws of physics.

Regular care and maintenance are essential for preserving value and operating condition of your motorcycle. Moreover, what is true for the motorcycle is also true for the rider: good performance depends on being in good shape. Riding under the influence of medication, drugs and alcohol is, of course, out of the question. Motorcycle riders—more than car drivers—must always be at their mental and physical best. Under the influence of even small amounts of alcohol, there is a tendency to take dangerous risks.

Protective clothing is as essential for the motorcycle rider as seat belts are for car drivers and passengers. Always wear a complete motorcycle suit (whether made of leather or tear-resistant synthetic materials with protectors), sturdy boots, motorcycle gloves and a properly fitting helmet.

Optimum protective wear, however, should not encourage carelessness. Although full-coverage helmets and suits, in particular, create an illusion of total safety and protection, motorcyclists will always be vulnerable. Riders who lack critical self-control run the risk of going too fast and are apt to take chances. This is even more dangerous in wet weather. The good motorcyclist rides safely, predictably and defensively—avoiding all dangers, including those caused by others.

Enjoy your ride!

1

2

3

4

5

6

7

8

9

1-1

2


DESCRIPTION

Left view

1. Convenience hook

2. Throttle stop screw

(page 3-8)

(page 6-17)

3. Helmet box, Owner’s tool kit (page 3-7, page 6-1)

4. Kickstarter

5. Engine oil drain bolt B

6. Engine oil drain bolt A

(page 3-6)

(page 6-10)

(page 6-10)

2-1

EAU00026


Right view

DESCRIPTION

2

7. Engine oil filler cap

8. Air filter element

9. Battery

10. Fuses

(page 6-9)

(page 6-13)

(page 6-29)

(page 6-31)

2-2

2


DESCRIPTION

Controls and instruments

1. Rear brake lever

2. Starter choke lever

3. Left handlebar switches

4. Speedometer unit

(page 3-4)

(page 3-6)

(page 3-3)

(page 3-2)

2-3

5. Fuel gauge

6. Start switch

7. Throttle grip

8. Front brake lever

(page 3-2)

(page 3-3)

(page 6-17)

(page 3-4)


EAU00027 INSTRUMENT AND CONTROL FUNCTIONS

Main switch/steering lock

EAU00029

The main switch/steering lock controls the ignition and lighting systems, and is used to lock the steering. The various positions are described below.

EAU00040

LOCK

The steering is locked, and all electrical systems are off. The key can be removed.

EAU00030*

ON

All electrical systems are supplied with power, and the meter lighting comes on, and the engine can be started. The key cannot be removed.

To lock the steering

1. Turn the handlebars all the way to the left.

2. Push the key in from the “OFF” position, and then turn it to “LOCK” while still pushing it.

3. Remove the key.

1. Push.

2. Turn.

To unlock the steering

Push the key in, and then turn it to

“OFF” while still pushing it.

EW000016

_

WARNING

_

Never turn the key to “OFF” or

“LOCK” while the motorcycle is moving, otherwise the electrical systems will be switched off, which may result in loss of control or an accident. Make sure that the motorcycle is stopped before turning the key to “OFF” or “LOCK”.

EAU00038

OFF

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

3-1

3


INSTRUMENT AND CONTROL FUNCTIONS

3

1. Left turn signal indicator light “

2. Right turn signal indicator light “

3. High beam indicator light “ ”

”

”

Indicator lights

EAU00056

EAU04121

Turn signal indicator lights “ ” and “ ”

The corresponding indicator light flashes when the turn signal switch is pushed to the left or right.

1. Speedometer

2. Odometer

EAU00098

Speedometer unit

The speedometer unit is equipped with a speedometer and an odometer. The speedometer shows riding speed. The odometer shows the total distance traveled.

EAU00063

High beam indicator light “ ”

This indicator light comes on when the high beam of the headlight is switched on.

1. Fuel gauge

EAU02950*

Fuel gauge

The fuel gauge indicates the amount of fuel in the fuel tank. The needle moves towards “E” (Empty) as the fuel level decreases. When the needle reaches the red line, refuel as soon as possible.

_

_

NOTE:

● Do not allow the fuel tank to empty itself completely.

● Turning the key to “OFF” cancel the fuel gauge reading.

3-2



EAU03888

Dimmer switch “ / ”

Set this switch to “ ” for the high beam and to “ ” for the low beam.

1. Light switch “ / ”

2. Dimmer switch “ / ”

3. Turn signal switch “

4. Horn switch “HORN”

/ ”

EAU00118

EAU03889

Turn signal switch “ / ”

To signal a right-hand turn, push this switch to “ ”. To signal a left-hand turn, push this switch to “ ”. When released, the switch returns to the center position. To cancel the turn signal lights, push the switch in after it has returned to the center position.

Handlebar switches

EAU02948*

Light switch “ / ”

Set the light switch to “ ” to turn on the headlight and the taillight. Set this switch to “ ” to turn them off.

EAU00130

Horn switch “HORN”

Press this switch to sound the horn.

1. Start switch “START”

EAU00143

Start switch “START”

Push this switch to crank the engine with the starter.

EC000005

_

CAUTION:

_

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

3

3-3



3


EAU03882

Front brake lever

The front brake lever is located on the right handlebar grip. To apply the front brake, pull this lever toward the handlebar grip.

1. Rear brake lever

EAU00163

Rear brake lever

The rear brake lever is located on the left handlebar grip. To apply the rear brake, pull this lever toward the handlebar grip.

1. Fuel tank cap a. Open.

b. Close.

Fuel tank cap

EAU03468*

To remove the fuel tank cap

1. Open the seat. (See page 3-6 for seat opening and closing procedures.)

2. Turn the fuel tank cap counterclockwise and pull it off.

3-4



EAU00185

_

CAUTION:

_

Immediately wipe off spilled fuel with a clean, dry, soft cloth, since fuel may deteriorate painted surfaces or plastic parts.

EAU00187*

Recommended fuel:

Regular gasoline

Fuel tank capacity:

Total amount:

4.9 L

To install the fuel tank cap

1. Insert the fuel tank cap into the tank opening and turn it clockwise until the alignment marks on the cap and tank are aligned.

2. Close the seat.

EW000024

_

WARNING

_

Make sure that the fuel tank cap is properly installed before riding.

1. Fuel tank filler tube

2. Fuel level

EAU03753

Fuel

Make sure that there is sufficient fuel in the tank. Fill the fuel tank to the bottom of the filler tube as shown.

EW000130

_

_

●

●

WARNING

Do not overfill the fuel tank, otherwise it may overflow when the fuel warms up and expands.

Avoid spilling fuel on the hot engine.

3

3-5



3

1. Starter (choke) lever “ ”

Starter (choke) lever “ ”

EAU03839

Starting a cold engine requires a richer air-fuel mixture, which is supplied by the starter (choke).

Move the lever in direction a

to turn on the starter (choke).

Move the lever in direction b

to turn off the starter (choke).

1. Kickstarter

EAU00214

Kickstarter

To start the engine, fold out the kickstarter lever, move it down lightly with your foot until the gears engage, and then push it down smoothly but forcefully.

1. Open.

Seat

EAU03802*

To open the seat

1. Place the motorcycle on the centerstand.

2. Insert the key into the main switch, and then turn it counterclockwise.

_

NOTE:

Do not push inward when turning the

_ key.

3. Fold the seat up.

3-6



To close the seat

1. Fold the seat down, and then push it down to lock it in place.

2. Remove the key from the main switch if the motorcycle will be left unattended.

_

NOTE:

Make sure that the seat is properly se-

_ cured before riding. 1. Helmet box

EAU03450*

Helmet box

There is a helmet box under the seat.

(See page 3-6 for seat opening and closing procedures.)

EWA00005*

_

_

●

●

WARNING

Do not exceed the load limit of

5 kg for the helmet box.

Do not exceed the maximum load of 116 kg for the vehicle.

EC000010*

_

CAUTION:

_

Keep the following points in mind when using the helmet box.

● Since the helmet box accumulates heat when exposed to the

● sun, do not store anything susceptible to heat inside it.

To avoid humidity from spreading through the helmet box,

●

● wrap wet articles in a plastic bag before storing them in the box.

Since the helmet box may get wet while the motorcycle is being washed, wrap any articles stored in the box in a plastic bag.

Do not keep anything valuable or breakable in the helmet box.

3

3-7


3


To store a helmet in the helmet box, place the helmet upside-down with the front facing forward.

_

_

NOTE:

● Some helmets cannot be stored in the helmet box because of their

● size or shape.

Do not leave your motorcycle unattended with the seat open. 1. Convenience hook

_

EAUT0020*

Convenience hook

_

EWT00002*

●

●

WARNING

Do not exceed the load limit of

1 kg for the convenience hook.

Do not exceed the maximum load of 116 kg for the vehicle.

3-8


EAU01114 PRE-OPERATION CHECKS

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.

EAU03439

Pre-operation check list

CO-01E

Fuel

Engine oil

ITEM

Final transmission oil

Front brake

Rear brake

Throttle grip

Control cables

Wheels and tires

CHECKS

• Check fuel level in fuel tank.

• Refuel if necessary.

• Check fuel line for leakage.

• Check oil level in engine.

• If necessary, add recommended oil to specified level.

• Check vehicle for oil leakage.


• Check operation.

• If soft or spongy, have Yamaha dealer bleed hydraulic system.

• Check fluid level in reservoir.

• If necessary, add recommended brake fluid to specified level.

• Check hydraulic system for leakage.


• Check lever free play.

• Adjust if necessary.

• 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.


• Lubricate if necessary.

• Check for damage.

• Check tire condition and tread depth.

• Check air pressure.

• Correct if necessary.

PAGE

3-5

6-9

6-11–6-12

6-21–6-24

6-22–6-23

6-17–6-18, 6-26

6-25

6-19–6-21

4-1

4


PRE-OPERATION CHECKS

4

Brake levers

ITEM

Centerstand, sidestand

Chassis fasteners

Instruments, lights, signals and switches

Battery

CHECKS


• Lubricate lever pivoting points if necessary.


• Lubricate pivots if necessary.

• Make sure that all nuts, bolts and screws are properly tightened.

• Tighten if necessary.


• Correct if necessary.

• Check fluid level.

• Fill with distilled water if necessary.

PAGE

6-26

6-27

—

—

6-29–6-31

_

_

NOTE:

Pre-operation checks should be made each time the motorcycle 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.

EWA00033

_

WARNING

_

If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operating the motorcycle.

4-2


EAU00372 OPERATION AND IMPORTANT RIDING POINTS

EAU00373*

_

_

●

●

●

●

WARNING

Become thoroughly familiar with all operating controls and their functions before riding.

Consult a Yamaha dealer regarding any control or function that you do not thoroughly understand.

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.

For safety, always start the engine with the centerstand.

Before starting out, make sure that the sidestand is up. If the sidestand is not raised completely, it could contact the ground and distract the operator, resulting in a possible loss of control.

1. Starter (choke) lever “ ”

EAU00416*

Starting and warming up a cold engine

EC000046

_

_

CAUTION:

See page 5-4 for engine break-in instructions prior to operating the vehicle for the first time.

1. Turn the key to “ON”.

2. Turn on the starter (choke) and completely close the throttle grip.

(See page 3-6 for starter (choke) operation.)

1. Start switch “START”

2. Kickstarter

3. Start the engine by pushing the start switch, while applying the front or rear brake or by pushing the kickstarter lever down.

_

NOTE:

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 5 seconds on any one attempt. If the engine does not start with the starter motor, try using the kickstarter with the motorcycle on the

_ centerstand.

5-1

5


5

OPERATION AND IMPORTANT RIDING POINTS

4. After starting the engine, move the starter (choke) back about halfway.

ECA00055

_

CAUTION:

_

For maximum engine life, always warm the engine up before starting off. Never accelerate hard when the engine is cold!

5. When the engine is warm, turn the starter (choke) off.

EAU01258

Starting a warm engine

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.

_

_

NOTE:

For maximum engine life, always warm up the engine before riding your motorcycle. Never accelerate hard with a cold engine.

EAU00433*

Starting off

_

NOTE:

Before starting off, allow the engine to

_ warm up.

1. While pulling the rear brake lever with your left hand and holding the grab bar with your right hand, push the motorcycle off the centerstand.

2. Sit astride the seat, and then adjust the rear view mirrors.

3. Switch the turn signal on.

4. Check for oncoming traffic, and then slowly turn the throttle grip

(on the right) in order to take off.

5. Switch the turn signal off.

5-2



Front Rear

EAU00434

Acceleration and deceleration

The speed can be adjusted by opening and closing the throttle. To increase the speed, turn the throttle grip in direction a

. To reduce the speed, turn the throttle grip in direction b

.

EAU00435*

Braking

1. Close the throttle completely.

2. Apply both front and rear brakes simultaneously while gradually increasing the pressure.

EW000057*

_

●

WARNING

Avoid braking hard or suddenly

(especially when leaning over to one side), otherwise the motorcycle may skid or overturn.

_

●

●

●

Railroad crossings, streetcar rails, iron plates on road construction sites, and manhole covers become extremely slippery when wet. Therefore, slow down when approaching such areas and cross them with caution.

Keep in mind that braking on a wet road is much more difficult.

Ride slowly down a hill, as braking downhill can be very difficult.

5

5-3


5


EAU00436

Engine break-in

There is never a more important period in the life of your engine than the period between 0 and 1,000 km. 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

1,000 km. 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.

EAU00447*

0–150 km

● Avoid prolonged operation above

1/3 throttle.

● After every hour of operation, stop the engine, and then let it cool for

● five to ten minutes.

Vary the engine speed from time to time. Do not operate the engine at one set throttle position.

150–500 km

● Avoid prolonged operation above

1/2 throttle.

● Rev the engine freely through the gears, but do not use full throttle at any time.

EC000058*

_

CAUTION:

_

After 500 km of operation, the engine oil and the final transmission oil must be changed and the engine oil strainer cleaned.

500–1,000 km

Avoid prolonged operation above

3/4 throttle.

1,000 km and beyond

Avoid prolonged full-throttle operation.

Vary the speed occasionally.

EC000049

_

_

CAUTION:

If any engine trouble should occur during the engine break-in period, immediately have a Yamaha dealer check the vehicle.

5-4


EAU00460

Parking

When parking, stop the engine, and then remove the key from the main switch.

EW000058

_

_

●

●

WARNING

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 motorcycle may overturn.


5

5-5

5



General note

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

2. A MOTORCYCLE CAN KEEP ITS PERFORMANCE

CAPABILITY FOR A LONGER TIME

1. THE CUSTOMERS CAN USE THE FULLEST

POTENTIAL OF YAMAHA MOTORCYCLES

5-6



3. FUEL COST AND REPAIR EXPENSES CAN BE

KEPT TO A MINIMUM

4. A MOTORCYCLE CAN DEMAND A HIGH PRICE

WHEN IT IS TRADED IN AS A USED PRODUCT

5

5-7


6

EAU00462 PERIODIC MAINTENANCE AND MINOR REPAIR

EAU00464

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 inspection, adjustment, and lubrication are explained on the following pages.

The intervals given in the periodic maintenance and lubrication chart should be simply considered as a general guide under normal riding conditions. However, DEPENDING ON THE

WEATHER, TERRAIN, GEOGRAPHI-

CAL LOCATION, AND INDIVIDUAL

USE, THE MAINTENANCE INTER-

VALS MAY NEED TO BE SHORT-

ENED.

EW000060

_

WARNING

_

If you are not familiar with motorcycle maintenance work, have a

Yamaha dealer do it for you.

1. Owner’s tool kit

EAU03846*

Owner’s tool kit

The owner’s tool kit is located on the bottom of the seat. (See page 3-6 for seat opening and closing procedures.)

The service information included in this manual and the tools provided in the owner’s tool kit are intended to assist you in the performance of preventive maintenance and minor repairs. However, additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly.

_

_

NOTE:

If you do not have the tools or experience required for a particular job, have a Yamaha dealer perform it for you.

EW000063

_

WARNING

_

Modifications not approved by

Yamaha may cause loss of performance and render the vehicle unsafe for use. Consult a Yamaha dealer before attempting any changes.

6-1


PERIODIC MAINTENANCE AND MINOR REPAIR

CP-03E

NO.

1 * Fuel line

ITEM

2 Spark plug

3 * Valves

4

5

Air filter element

V-belt case air filter elements

6 * Battery

7 * Front brake

8 * Rear brake

9 * Wheels

10 * Wheel bearings

11 * Swingarm

12 * Steering bearings

13 * Chassis fasteners

14 Sidestand/centerstand

15 * Front fork

EAU00473

Periodic maintenance and lubrication chart

CHECK OR MAINTENANCE JOB

• Check fuel hoses and vacuum hose for cracks or damage.

• Check condition.

• Clean and regap.

• Replace if necessary.

• Check valve clearance.

• Adjust.

• Clean. Replace if necessary.

• Clean. Replace if necessary.

• Check electrolyte level and specific gravity.

• Make sure that the breather hose is properly routed.

• Check operation, fluid level and vehicle for fluid leakage.

(See NOTE on page 6-3.)

• Replace brake pads if necessary.

• Check operation and adjust brake lever free play.

• Replace brake shoes if necessary.

• Check runout, spoke tightness and for damage.

• Tighten spokes if necessary.

• Check bearing for looseness or damage.

• Check operation and for excessive play.

• Lubricate with lithium-soap based grease, every 24,000 km.

• Check bearing play and steering for roughness.

• Lubricate with lithium-soap-based grease, every 12,000 km.

• Make sure that all nuts, bolts and screws are properly tightened.


• Lubricate.

• Check operation and for oil leakage.

6-2

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

ODOMETER READING ( × 1,000 km)

0.5

2 4 8 12

√ √ √ √

√ √

√ √

√

√

√

√

√

√

√

√

√

√

√

√

√

√ √ √ √

√ √ √ √

√

√

√

√ √ √ √

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

6


6


NO.

ITEM CHECK OR MAINTENANCE JOB

ODOMETER READING (

×

1,000 km)

0.5

2 4 8 12

16 *

Shock absorber assemblies

• Check operation and shock absorbers for oil leakage.

√ √ √ √

17

18

* Carburetor

Engine oil

• Check starter (choke) operation.

• Adjust engine idling speed.

• Change.

• Check oil level and vehicle for oil leakage.

√

√

√

√

√ √

Every 2,000 km

√

19

20

21

* Engine oil strainer


* V-belt

• Clean.


• Change.

• Check the damage and wear.

• Replace.

√

√

√

√ √ √

Every 10,000 km

√

√

√ √

Every 25,000 km (See NOTE.)

√

22 *

Front and rear brake switches


√ √ √ √ √

23 Moving parts and cables • Lubricate.

√ √ √ √

24 *

Lights, signals and switches


• Adjust headlight beam.

√ √ √ √ √

_

* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.

EAU03057*

_

NOTE:

● From 16,000 km, repeat the maintenance intervals starting from 4,000 km.

●

●

●

Depending on riding conditions, the V-belt replacement interval may vary.

The air filter needs more frequent service if you are riding in unusually wet or dusty areas.

Hydraulic brake system

• After disassembling the brake master cylinder, and caliper cylinder, always change the fluid. Regularly check the brake fluid level and fill reservoir as required.

• Replace the oil seals on the inner parts of the brake master cylinder and caliper cylinder every two years.

• Replace the brake hose every four years or if cracked or damaged.

6-3



1. Panel A

2. Panel B

3. Cowling B

4. Cowling A

EAU03516

Removing and installing the cowling and panels

The cowling and panels shown above need to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time the cowling or a panel needs to be removed and installed.

1. Panel A

2. Screw ( × 2)

EAU01074*

Panel A

To remove the panel

Remove the screws, and then pull the panel off as shown.

To install the panel

Place the panel in the original position, and then install the screws.

_

_

NOTE:

Make sure that the projections fit into the grommets and that the tabs fit into the slots.

6

6-4



6

1. Screw ( × 2)

2. Panel B

EAU03971

Panel B

To remove the panel

1. Open the seat. (See page 3-6 for seat opening and closing procedures.)

2. Remove the screws, and then pull the panel off as shown.

1. Screw ( × 2)

2. Cowling A

3. License plate bracket

EAU03886*

Cowling A

To remove the cowling

1. Remove the license plate bracket by removing the screws.

1. Screw ( × 2)

2. Cowling A

2. Remove the screws on cowling A.

To install the panel

Place the panel in the original position, and then install the screws.

6-5



1. Screw ( × 6)

2. Cowling B

3. Remove the screws on cowling B.

4. Pull cowling A off as shown.

_

_

NOTE:

When removing cowling A, pull out on the areas shown from bottom to top.

To install the cowling

1. Align the tabs in cowling A with the slots of cowling B, and then push cowling A into the original position.

_

_

NOTE:

When installing cowling A, push in on the areas shown from top to bottom.

2. Install the screws on cowling B.

3. Install the screws on cowling A.

4. Install the license plate bracket by installing the screws.

6

6-6


6


1. Spark plug cap

Checking the spark plug

EAUT0004*

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.

1. Spark plug wrench

3. Remove the spark plug as shown, with the spark plug wrench included in the owner’s tool kit.

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 motorcycle is ridden normally).

_

NOTE:

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 motorcycle.

2. Check the spark plug for electrode erosion and excessive carbon or other deposits, and replace it if necessary.

Specified spark plug:

CR7HSA (NGK)

To remove the spark plug

1. Remove panel A. (See page 6-4 for panel removal and installation procedures.)

2. Remove the spark plug cap.

6-7



Tightening torque:

Spark plug:

12.5 Nm (1.25 m·kgf) a. Spark plug gap

To install the spark plug

1. Measure the spark plug gap with a wire thickness gauge and, if necessary, adjust the gap to specification.

_

NOTE:

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 speci-

_ fied torque as soon as possible.

4. Install the spark plug cap.

5. Install the panel.

Spark plug gap:

0.6–0.7 mm

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.

6

6-8


6


EAUT0016*

Engine oil and oil strainer

The engine oil level should be checked before each ride. In addition, the oil must be changed and the oil strainer cleaned at the intervals specified in the periodic maintenance and lubrication chart.

To check the engine oil level


_

NOTE:

Make sure that the motorcycle 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.

1. Engine oil filler cap

3. Wait a few minutes until the oil settles, remove the oil filler cap, wipe the dipstick clean, insert it back into the oil filler hole (without screwing it in), and then remove it again to check the oil level.

1. Dipstick

2. Maximum level mark

3. Minimum level mark

_

NOTE:

The engine oil should be between the

_ minimum and maximum level marks.

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.

6-9


To change the engine oil and clean the oil strainer

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.


_

_

1. Engine oil drain bolt A

2. Engine oil drain bolt B

3. Remove the engine oil filler cap and drain bolts to drain the oil from the crankcase.

NOTE:

When only changing the engine oil, remove engine oil drain bolt A only.

1. Strainer

2. Compression spring

3. O-ring

EC000070*

_

CAUTION:

_

When removing the engine oil drain bolt B, the O-ring, spring, and oil strainer will fall out. Take care not to lose these parts.

4. Clean the oil strainer with solvent, and then check it for damage and replace it if necessary.

5. Check the O-ring for damage and replace it if necessary.

6. Install the oil strainer, spring, O-ring and engine oil drain bolts, and then tighten the drain bolts to the specified torque.

6-10

6


6


Tightening torques:

Engine oil drain bolt A:

20 Nm (2.0 m·kgf)

Engine oil drain bolt B:

20 Nm (2.0 m·kgf)

_

_

NOTE:

Make sure that the O-ring is properly seated.

7. Add the specified amount of the recommended engine oil, and then install and tighten the engine oil filler cap.

Recommended engine oil:

See page 8-1.

Oil quantity:

Periodic oil change:

0.8 L

Total amount (dry engine):

0.9 L

ECA00105

_

_

CAUTION:

● In order to prevent clutch slippage (since the engine oil also lubricates the clutch), do not mix any chemical additives with

● the oil or use oils of grade “CD” or higher. In addition, do not use oils labeled “ENERGY CON-

SERVING II” or higher.

Make sure that no foreign material enters the crankcase.

8. 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.

9. Turn the engine off, and then check the oil level and correct it if necessary.

1. Oil filler cap

EAU04228*


The final transmission case must be checked for oil leakage before each ride. If any leakage is found, have a

Yamaha dealer check and repair the motorcycle. In addition, the final transmission oil must be changed as follows at the intervals specified in the periodic maintenance and lubrication chart.

1. Start the engine, warm it up by riding the motorcycle for several minutes, and then stop the engine.


3. Place an oil pan under the final transmission case to collect the used oil.

6-11



1. Final transmission oil drain bolt

4. Remove the oil filler cap and drain bolt to drain the oil from the final transmission case.

5. Install the final transmission oil drain bolt, and then tighten it to the specified torque.

_

_

●

●

EWA00062

WARNING

Make sure that no foreign material enters the final transmission case.

Make sure that no oil gets on the tire or wheel.

7. Check the final transmission case for oil leakage. If oil is leaking, check for the cause.

Tightening torque:

Final transmission oil drain bolt:

22 Nm (2.2 m·kgf)

6. Add the specified amount of the recommended final transmission oil, and then install and tighten the oil filler cap.

Recommended final transmission oil:

See page 8-1.

Oil quantity:

0.1 L

6

6-12



EAUM0058*

Cleaning the air filter element,

V-belt case air filter elements, and check hoses

The air filter and the V-belt case air filter elements should be cleaned at the intervals specified in the periodic maintenance and lubrication chart. Clean both filter elements more frequently if you are riding in unusually wet or dusty areas. In addition, the air filter check hoses must be frequently checked and cleaned if necessary.

1. Air filter case cover

2. Screw ( × 5)

3. Remove the air filter case cover by removing the screws.

1. Air filter element

4. Pull the air filter element out.

6

Cleaning the air filter element



6-13



5. Lightly tap the air filter element to remove most of the dust and dirt, and then blow the remaining dirt out with compressed air.

6. Check the air filter element for damage and replace it if necessary.

7. Insert the air filter element into the air filter case.

8. Install the air filter case cover by installing the screws.


1. V-belt case air filter cover A

2. Bolt ( × 2)

Cleaning the V-belt case air filter elements

1. Remove V-belt case air filter cover

A by removing the bolts.

1. V-belt case air filter cover B

2. Bolt ( × 3)

2. Remove V-belt case air filter cover

B by removing the bolts.

6

6-14



6

1. Air filter element ( × 2)

3. Remove the air filter elements, and then blow out the dirt with compressed air as shown.

4. Check each air filter element for damage and replace them if necessary.

5. Install the air filter elements.

6. Install V-belt case air filter cover B by installing the bolts.

7. Install V-belt case air filter cover A by installing the bolts.

EC000092*

_

_

CAUTION:

● Make sure that each filter element is properly seated in its

● case.

The engine should never be operated without the air filter element installed, otherwise the piston and/or cylinder may become excessively worn.

6-15



1. Check hose ( × 2)

To clean the air filter check hoses

1. Check each hose at the bottom of the air filter case and the V-belt case for accumulated dirt or water.

1. Check hose

2. If dirt or water is visible, remove the hose, clean it, and then install it.

EAU00629

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. The adjustment described in the following section, however, may be serviced by the owner as part of routine maintenance.

EC000094

_

CAUTION:

_

The carburetor has been set and extensively tested at the Yamaha factory. Changing these settings without sufficient technical knowledge may result in poor performance of or damage to the engine.

6

6-16


6


EAU01168

Adjusting the engine idling speed

The engine idling speed must be checked and, if necessary, adjusted as follows at the intervals specified in the periodic maintenance and lubrication chart.

EAU00634*

Adjusting the throttle cable free play

The throttle cable free play should measure 3–7 mm at the throttle grip.

Periodically check the throttle cable free play and, if necessary, adjust it as follows.

_

_

NOTE:

A diagnostic tachometer is needed to make this adjustment.

1. Attach the tachometer to the spark plug lead.

2. Start the engine and warm it up for several minutes at 1,000–

2,000 r/min while occasionally revving it to 4,000–5,000 r/min.

_

NOTE:

The engine is warm when it quickly re-

_ sponds to the throttle.

1. Throttle stop screw

3. Check the engine idling speed and, if necessary, adjust it to specification by turning the throttle stop screw. To increase the engine idling speed, turn the screw in direction a

. To decrease the engine idling speed, turn the screw in direction b

.

_

_

NOTE:

The engine idling speed must be correctly adjusted before checking and adjusting the throttle cable free play.

Engine idling speed:

1,500–1,700 r/min

_

_

NOTE:

If the specified idling speed cannot be obtained as described above, have a

Yamaha dealer make the adjustment.

6-17


1. Throttle cable free play adjusting nut

2. Locknut

3. Cable cover c. Throttle cable free play

1. Loosen the locknut.

2. To increase the throttle cable free play, turn the adjusting nut in direction a

. To decrease the throttle cable free play, turn the adjusting nut in direction b

.

3. Tighten the locknut.

_

_

NOTE:

After adjusting the throttle free play, be sure to place the cable cover in the original position.


EAU00637

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.

6

6-18


6


EAU03790*

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.

EW000091

_

WARNING

_

The tire air pressure must be checked and adjusted on cold tires

(i.e., when the temperature of the tires equals the ambient temperature).

CE-24E

Tire air pressure

(measured on cold tires)

Front Rear

200 kPa

(2.00 kgf/cm

2

)

CE-07E

Maximum load*

225 kPa

(2.25 kgf/cm

116 kg

* Total weight of rider, passenger, cargo and accessories

2

)

EW000087

_

WARNING

_

Because loading has an enormous impact on the handling, braking, performance and safety characteristics of your motorcycle, you should keep the following precautions in mind.

● NEVER OVERLOAD THE

MOTORCYCLE! Operation of an overloaded motorcycle may result in tire damage, loss of control, or severe injury. Make sure

●

●

●

● that the total weight of rider, passenger, cargo, and accessories does not exceed the specified maximum load for the vehicle.

Do not carry along loosely packed items, which can shift during a ride.

Securely pack the heaviest items close to the center of the motorcycle and distribute the weight evenly on both sides.

Adjust the tire air pressure with regard to the load.

Check the tire condition and air pressure before each ride.

6-19



1. Sidewall

2. Tire wear indicator a. Tire tread depth

Tire inspection

The tires must be checked before each ride. If the tire shows crosswise lines

(minimum tread depth), 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.

CE-23E

Minimum tire tread depth

(front and rear)

1.0 mm

_

_

NOTE:

The tire tread depth limits may differ from country to country. Always comply with the local regulations.

_

_

EW000079

●

●

WARNING

Have a Yamaha dealer replace excessively worn tires. Besides being illegal, operating the motorcycle 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, who has the necessary professional knowledge and experience.

Tire information

This motorcycle is equipped with tube tires.

EW000078

_

●

●

_

CE-10E

FRONT

WARNING

The front and rear tires should be of the same make and design, otherwise the handling characteristics of the motorcycle cannot be guaranteed.

After extensive tests, only the tires listed below have been approved for this model by

Yamaha Motor Co., Ltd.

Manufacturer

Dunlop

Size

70/90-16 36P

Model

D110

REAR

Manufacturer

Dunlop

Size

80/90-16 43P

Model

D110

6

6-20


6


EAU00680

_

_

●

●

●

WARNING

It is dangerous to ride with a worn-out tire. When a tire tread begins to show crosswise lines, have a Yamaha dealer replace the tire immediately.

The replacement of all wheeland brake-related parts, including the tires, should be left to a

Yamaha dealer, who has the necessary professional knowledge and experience.

It is not recommended to patch a punctured tube. If unavoidable, however, patch the tube very carefully and replace it as soon as possible with a highquality product.

EAU00685

Spoke wheels

To maximize the performance, durability, and safe operation of your motorcycle, note the following points regarding the specified wheels.

● 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.

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.

Ride at moderate speeds after changing a tire since the tire surface must first be “broken in” for it to develop its optimal characteristics.

6-21


EAU03851*

Checking the front brake lever free play

Since this model is equipped with a hydraulic front brake, adjusting the brake lever free play is not needed.

However, it is necessary to check the brake fluid level and check the hydraulic system for leakage.



EW000099*

_

WARNING

_

A soft or spongy feeling in the brake lever can indicate the presence of air in the hydraulic system. If there is air in the hydraulic system, have a

Yamaha dealer bleed the system before operating the motorcycle. Air in the hydraulic system will diminish the braking performance, which may result in loss of control and an accident. a. Rear brake lever free play

EAU00704*

Adjusting the rear brake lever free play

The rear brake lever free play should measure 10–20 mm as shown. Periodically check the rear brake lever free play and, if necessary, adjust it as follows.

1. Rear brake lever free play adjusting nut

To increase the rear brake lever free play, turn the adjusting nut at the brake shoe plate in direction a

. To decrease the rear brake lever free play, turn the adjusting nut in direction b

.

EW000101

_

WARNING

_

If proper adjustment cannot be obtained as described, have a Yamaha dealer make this adjustment.

6

6-22


6


EAU00720

Checking the front brake pads and rear brake shoes

The front brake pads and the rear brake shoes must be checked for wear at the intervals specified in the periodic maintenance and lubrication chart.

Front Rear

1. Brake pad wear indicator groove ( × 3)

EAU03938

Front brake pads

Each front brake pad is provided with wear indicator grooves, which allow you to check the brake pad wear without having to disassemble the brake.

To check the brake pad wear, check the wear indicator grooves. If a brake pad has worn to the point that the wear indicator grooves have almost disappeared, have a Yamaha dealer replace the brake pads as a set.

1. Brake shoe wear indicator

2. Brake shoe wear limit line

EAU04502

Rear brake shoes

The rear brake is provided with a wear indicator, which allows you to check the brake shoe wear without having to disassemble the brake. To check the brake shoe wear, check the position of the wear indicator while applying the brake. If a brake shoe has worn to the point that the wear indicator reaches the wear limit line, have a Yamaha dealer replace the brake shoes as a set.

6-23



Observe these precautions:

● When checking the fluid level, make sure that the top of the master cylinder is level by turning the handlebars.

● Use only the recommended quality brake fluid, otherwise the rubber seals may deteriorate, causing leakage and poor braking performance.


EAU00732

Checking the brake fluid level

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 level is low, be sure to check the brake pads for wear and the brake system for leakage.

Recommended brake fluid: DOT 4

_

NOTE:

If DOT 4 is not available, DOT 3 can be

_ used.

● 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 master cylinder 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.

6

6-24


6


EAU03985

Changing the brake fluid

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 brake master cylinder and caliper as well as the brake hose replaced at the intervals listed below or whenever they are damaged or leaking.

● Oil seals: Replace every two years.

● Brake hose: Replace every four years.

EAU00770*

Checking the V-belt

The V-belt must be checked by a

Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart.

_

NOTE:

It is recommended to replace the V-belt

_ every 25,000 km.

EAU02962

Checking and lubricating the cables

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.

Recommended lubricant:

Engine oil

EW000112

_

WARNING

_

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

6-25


EAU04034

Checking and lubricating the throttle grip and cable

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.


EAU03118

Lubricating the front and rear brake levers

The pivoting points of the front and rear brake levers must be lubricated at the intervals specified in the periodic maintenance and lubrication chart.


Lithium-soap-based grease

(all-purpose grease)

6

6-26




Lithium-soap-based grease

(all-purpose grease)

6

EAU03371

Checking and lubricating the centerstand and sidestand

The operation of the centerstand and sidestand should be checked before each ride, and the pivots and metal-tometal contact surfaces should be lubricated if necessary.

EW000114

_

WARNING

_

If the centerstand or sidestand does not move up and down smoothly, have a Yamaha dealer check or repair it.

EAU02939

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

EW000115

WARNING

_

Securely support the motorcycle so that there is no danger of it falling over.

_

Check the inner tubes for scratches, damage and excessive oil leakage.

6-27



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.

EC000098

_

_

CAUTION:

If any damage is found or the front fork does not operate smoothly, have a Yamaha dealer check or repair it.

EAU00794

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.

EW000115

_

WARNING

_

Securely support the motorcycle so that there is no danger of it falling over.

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

6-28


6


EAU01144

Checking the wheel bearings

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.

EAU03806*

Battery

A poorly maintained battery will corrode and discharge quickly. The electrolyte level, battery lead connections and breather hose routing should be checked before each ride and at the intervals specified in the periodic maintenance and lubrication chart.

To check the electrolyte level


1. Negative battery lead

2. Battery band

3. Battery breather hose

2. Unhook the battery band, and then disconnect the negative battery lead from the battery.

3. Pull the battery breather hose out as shown.

4. Pull the battery out of the battery compartment.

6-29



1. Maximum level mark


5. Place the battery on a level surface, and then check the electrolyte level in the battery.

_

_

NOTE:

The electrolyte should be between the minimum and maximum level marks.

6. If the electrolyte is at or below the minimum level mark, add distilled water to raise the electrolyte to the maximum level mark.

EW000116

_

●

●

WARNING

Electrolyte is poisonous and dangerous since it contains sulfuric acid, which causes severe burns. Avoid any contact 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.

• 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 BATTER-

IES OUT OF THE REACH OF

CHILDREN.

_

EC000100

_

CAUTION:

_

Use only distilled water, as tap water contains minerals that are harmful to the battery.

7. Check and, if necessary, tighten the positive battery lead to the positive battery terminal.

8. Place the battery in the battery compartment.

9. Connect and tighten the negative battery lead to the negative battery terminal.

6

6-30


6


1. Battery breather hose

10. Place the breather hose into the original position and make sure that it is properly routed.

11. Hook the battery band onto the holder.


To store the battery

1. If the motorcycle 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 the specific gravity of the electrolyte at least once a month and fully charge the battery whenever necessary.

3. Fully charge the battery before installation.

4. After installation, make sure that the battery leads are properly connected to the battery terminals and that the breather hose is properly routed, in good condition, and not obstructed.

EC000099

_

CAUTION:

_

If the breather hose is positioned in such a way that the frame is exposed to electrolyte or gas expelled from the battery, the frame could suffer structural and external damages.

EAU01307*

Replacing the fuse

The fuse is located behind panel A.

(See page 6-4 for panel removal and installation procedures.)

If the fuse is blown, replace it as follows.

1. Turn the key to “OFF” and turn off all electrical circuits.

2. Pull the battery out of the battery compartment. (See page 6-29, “To check the electrolyte level” for battery removal and installation procedures.)

6-31


1. Starter relay

3. Pull the starter relay out.


5. Place the starter relay into the original position.

6. Place the battery in the battery compartment.

7. Turn the key to “ON” and turn on the electrical circuits to check if the devices operate.

8. If the fuse immediately blows again, have a Yamaha dealer check the electrical system.

1. Fuse

2. Spare fuse

4. Remove the blown fuse, and then install a new fuse of the specified amperage.

Specified fuse: 10 A

EC000103

_

_

CAUTION:

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.

6

6-32


6


EAU04134*

Replacing a headlight bulb

If a headlight bulb burns out, replace it as follows.

EC000107

_

CAUTION:

_

It is advisable to have a Yamaha dealer perform this job.


2. Remove cowling A. (See page 6-5 for cowling removal and installation procedures.)

1. Headlight bulb cover ( × 2)

3. Remove the headlight bulb cover by turning it counterclockwise.

1. Headlight bulb socket ( × 2)

4. Remove the socket by pushing it in and turning it counterclockwise.

5. Remove the defective bulb.

EW000119

_

WARNING

_

Headlight bulbs get very hot. Therefore, keep flammable products away from a lit headlight bulb, and do not touch the bulb until it has cooled down.

6. Place a new headlight bulb into position.

7. Install the socket by pushing it in and turning it clockwise.

6-33



8. Install the headlight bulb cover by turning it clockwise.

9. Install the cowling.

10. Have a Yamaha dealer adjust the headlight beam if necessary.

EAUT0022*

Replacing a front turn signal light bulb

EC000107

_

_

CAUTION:



2. Remove cowling A. (See page 6-5 for cowling removal and installation procedures.)

1. Turn signal light bulb socket ( × 2)

3. Remove the socket (together with the bulb) by turning it counterclockwise.


5. Insert a new bulb into position.

6. Install the socket (together with the bulb) by turning it clockwise.

7. Install the cowling.

6

6-34



6

1. Screw ( × 2)

EAUS0013*

Replacing the tail/brake light bulb or a rear turn signal light bulb

EC000107

CAUTION:

_


_

Place the motorcycle on the centerstand.

1. Tab

2. Slot

2. Remove the screws, unhook the tab from the slot, and then pull the tail/brake light lens outward.

Tail/brake light bulb

1. Remove panel B. (See page 6-5 for panel removal and installation procedures.)

1. Tail/brake light bulb

3. Remove the defective bulb by pushing it in and turning it counterclockwise.

4. Insert a new bulb into the socket, push it in, and then turn it clockwise until it stops.

5. Place the tail/brake light lens into the original position, and then install the screws.

EC000108

_

_

CAUTION:

Do not overtighten the screws, otherwise the lens may break.


6-35


Turn signal light bulb

1. Remove the tail/brake light lens.

(See “Tail/brake light bulb” for lens removal and installation procedures.)


2. Pull the turn signal light lens off.

1. Turn signal light bulb ( × 2)


4. Insert a new bulb into position.

5. Place the turn signal light lens into the original position.

6. Install the tail/brake light lens.

6

6-36


6


EAU01008

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.

6-37



EAU03473

Troubleshooting chart

EW000125

WARNING

_

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

_

CT-1FE

1. Fuel

There is enough fuel.

Check the compression.

Check the fuel level in the fuel tank.

There is no fuel.

Supply fuel.

The engine does not start.

Check the compression.

2. Compression

Operate the electric starter.

There is compression.

There is no compression.

Check the ignition.

Have a Yamaha dealer check the vehicle.

6

3. Ignition

Remove the spark plug and check electrodes.

Wet

Dry

Wipe off with a dry cloth and correct the spark plug gap, or replace the spark plug.

Have a Yamaha dealer check the vehicle.

Open the throttle halfway and operate the electric starter.

The engine does not start.

Check the battery.

4. Battery

Operate the electric starter.

The engine turns over quickly.

The engine turns over slowly.

The battery is good.

Check fluid, recharge, check connections.

The engine does not start. Have a

Yamaha dealer check the vehicle.

6-38


7

EAK00000 MOTORCYCLE CLEANING AND STORAGE

EAK01302*

A. CLEANING

Frequent, thorough cleaning of your motorcycle will not only enhance its appearance but will improve its general performance and extend the useful life of many components.

1. Rinse the dirt and degreaser off with a garden hose.

EUU34602

CAUTION:

_

Excessive hose pressure may cause water seepage and deterioration of wheel bearings, front fork, brakes, transmission seals and electrical parts.

2. After cleaning the motorcycle, dry all surfaces with a chamois, clean towel, or soft absorbent cloth.

3. Automotive-type wax may be applied to all painted and chromeplated surfaces. When finished, start the engine and let it idle for several minutes.

EAK00700*

B. STORAGE

Long term storage (60 days or more) of your motorcycle will require some preventive procedures to guard against deterioration. After thoroughly cleaning the motorcycle, prepare for storage as follows:

1. Drain the fuel tank, fuel lines, and carburetor float bowl(s).

2. Lubricate all control cables.

3. Block up the frame to raise both wheels off the ground.

4. Tie a plastic bag over the exhaust pipe outlet to prevent moisture from entering.

5. If storing in a humid or salt-air atmosphere, coat all exposed metal surfaces with a light film of oil. Do not apply oil to any rubber parts or the seat cover.

6. Remove the battery and charge it.

Store it in a dry place and recharge it once a month. Do not store the battery in an excessively warm or cold place (less than 0 °C or more than 30 °C).

EUU05800

_

NOTE:

Make any necessary repairs before storing the motorcycle.

7-1


EAU01038

Specifications

CS-01E

Model

Dimensions

AT115

Overall length

Overall width

Overall height

Seat height

Wheelbase

Ground clearance

1,935 mm

675 mm

1,070 mm

755 mm

1,280 mm

135 mm

Minimum turning radius 1,900 mm

Basic weight (with oil and full fuel tank)

Maximum load*

103 kg

116 kg

* Total weight of rider, passenger, cargo and accessories

Engine

Engine type

Cylinder arrangement

Displacement

Bore

×

stroke

Compression ratio

Starting system

Lubrication system

Forced air-cooled 4-stroke,

SOHC

Forward inclined single cylinder

113.7 cm

3

50.0

×

57.9 mm

8.8:1

Electric and kickstarter

Wet sump

SPECIFICATIONS

Engine oil

Type

Capacity

Periodic oil change

Total amount (dry engine)


Type

Quantity

Air filter

Fuel

Type

Fuel tank capacity

Carburetor

Manufacturer

Model × quantity

Spark plug

Manufacturer/Type

Gap

Clutch type

SAE 20W-50 API Service “SF” type motor oil

0.8 L

0.9 L

SAE 10W-40 API Service “SE” type motor oil

0.1 L

Dry element

REGULAR GASOLINE

4.9 L

MIKUNI

BS25 × 1

NGK / CR7HSA

0.6–0.7 mm

V-belt automatic

8

8-1


8

SPECIFICATIONS

Transmission

Primary reduction system

Primary reduction ratio

Secondary reduction system

Secondary reduction ratio

Number of drive chain sprocket teeth (rear/front)

Transmission type

Operation

Chassis

Frame type

Caster angle

Trail

Tires

Front

Type

Size

Manufacturer/ model

Rear

Type

Size

Manufacturer/ model

Helical gear

3.133

Spur gear

3.583

43/12

V-belt automatic

Centrifugal automatic type

Steel tube underbone

25°

112 mm

Tube tire

70/90-16 36P

Dunlop/D110

Tube tire

80/90-16 43P

Dunlop/D110

8-2

Tire air pressure

(measured on cold tires)

Front

Rear

Wheels

Front

Type

Size

Rear

Type

Size

Brakes

Front

Type

Operation

Fluid

Rear

Type

Operation

Suspension

Front

Type

Rear

Type

Telescopic fork

Unit swing

200 kPa (2.00 kgf/cm

2

)

225 kPa (2.25 kgf/cm

2

)

Spoke wheel

16 × 1.40

Spoke wheel

16 × 1.60

Single disc brake

Right hand

DOT 3 or 4

Drum brake

Left hand


Spring/shock absorbers

Front

Rear

Wheel travel

Coil spring / oil damper

Coil spring / oil damper

Electrical

Ignition system

Charging system

Type

Standard output

Battery

Model

Voltage, capacity

Headlight bulb type

Bulb voltage, wattage × quantity

Headlight

Tail/brake light

Turn signal light

Meter lighting

High beam indicator light

Turn signal indicator light

Fuse

DC. C.D.I.

A.C. magneto

14 V, 105 W@ 5,000 r/min

Local made

12 V, 7 Ah

Incandesce bulb

12 V, 25/25 W

×

2

12 V, 5/21 W × 1

12 V, 10 W × 4

12 V, 1.7 W

×

1

12 V, 3.4 W

×

1

12 V, 1.7 W × 1

12 V, 3.4 W × 2

10 A

8-3

SPECIFICATIONS

8


9

1. FRAME SERIAL NUMBER:

CA-02E

2. ENGINE SERIAL NUMBER:

CA-02E

EAU01039 CONSUMER INFORMATION

EAU02945*

Identification numbers

Record the key identification number and engine serial number in the spaces provided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen.

1. Frame serial number

EAU01046

Frame serial number

The frame serial number is stamped into the frame.

_

NOTE:

The frame serial number is used to identify your motorcycle and may be used to register your motorcycle with

_ the licensing authority in your area.

1. Engine serial number

EAU01048*

Engine serial number

The engine serial number is stamped into the final transmission case.

9-1

Engine start procedure

Before pushing start button, make sure to apply the Front or Rear Brake and that the

Sidestand is retracted.

Engine oil replacement

Engine oil replacement : Every 2000 km.

Recommended oil : SAE20W - 50 type

SF Class Motor Oil

V-belt inspection

Periodic maintenance must be performed by any authorized Yamaha Dealer (Refer to the Owner's Manual for details.)

Load limit

Convenience hook : 1 kg, Helmet box: 5 kg

5MX-F835Y-00

PRINTED IN INDONESIA

YAMAHA MOTOR CO., LTD.


AT115

5MX-F8199-E0

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