Yamaha DT230N Owner`s manual

OWNER’S MANUAL
DT230(N)
YAMAHA MOTOR CO., LTD.
PRINTED ON RECYCLED PAPER
PRINTED IN JAPAN
2000·7–0.1×1(E) !
4TP-28199-21
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INTRODUCTION
Congratulations on your purchase of the Yamaha DT230. 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.
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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.
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IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following notations:
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The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!
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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.
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A CAUTION indicates special precautions that must be taken to avoid damage to
the motorcycle.
NOTE:
A NOTE provides key information to make procedures easier or clearer.
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NOTE:
8 This manual should be considered a permanent part of this motorcycle and should remain
with it even if the motorcycle is subsequently sold.
8 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.
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IMPORTANT MANUAL INFORMATION
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PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING
THIS MOTORCYCLE.
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DT230 (N)
OWNER’S MANUAL
©2000 by Yamaha Motor Co., Ltd.
1st Edition, July 2000
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Japan.
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TABLE OF CONTENTS
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SAFETY INFORMATION.....................................1-1
Safe riding.........................................................1-1
Protective apparel .............................................1-3
Modification.......................................................1-3
Loading and accessories ..................................1-3
Gasoline and exhaust gas ................................1-5
Location of important labels ..............................1-7
DESCRIPTION ....................................................2-1
Left view............................................................2-1
Right view .........................................................2-2
Controls and instruments ..................................2-3
INSTRUMENT AND CONTROL FUNCTIONS ....3-1
Main switch/steering lock ..................................3-1
Indicator and warning lights ..............................3-2
Speedometer unit .............................................3-3
Handlebar switches ..........................................3-5
Clutch lever .......................................................3-6
Shift pedal .........................................................3-6
Brake lever........................................................3-6
Brake pedal.......................................................3-7
Fuel tank cap ....................................................3-7
Fuel ...................................................................3-8
2-stroke engine oil ............................................3-8
Fuel cock ..........................................................3-9
Starter (choke) lever “1”................................3-10
Seat ................................................................3-10
Helmet holder .................................................3-11
Adjusting the front fork ....................................3-11
Adjusting the shock absorber assembly .........3-12
YPVS ..............................................................3-15
Sidestand ........................................................3-16
Ignition circuit cut-off system ..........................3-16
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PRE-OPERATION CHECKS ...............................4-1
Pre-operation check list ....................................4-1
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OPERATION AND IMPORTANT RIDING
POINTS................................................................5-1
Starting and warming up a cold engine ............5-1
Starting a warm engine .....................................5-2
Shifting ..............................................................5-2
Tips for reducing fuel consumption ...................5-3
Engine break-in.................................................5-3
Parking..............................................................5-4
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PERIODIC MAINTENANCE AND MINOR
REPAIR................................................................6-1
Owner’s tool kit .................................................6-1
Periodic maintenance and lubrication chart ......6-2
Removing and installing cowlings .....................6-5
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TABLE OF CONTENTS
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Removing and installing panels ........................6-6
Checking the spark plug ...................................6-7
Transmission oil ................................................6-9
Coolant ...........................................................6-10
Changing the coolant ......................................6-12
Cleaning the air filter element .........................6-14
Adjusting the carburetor..................................6-15
Adjusting the engine idling speed ...................6-16
Adjusting the throttle cable free play...............6-16
Tires ................................................................6-17
Spoke wheels .................................................6-20
Adjusting the clutch lever free play .................6-20
Adjusting the brake lever free play .................6-21
Adjusting the brake pedal position ..................6-22
Adjusting the rear brake light switch ...............6-23
Checking the front and rear brake pads .........6-23
Checking the brake fluid level .........................6-24
Changing the brake fluid .................................6-25
Drive chain slack.............................................6-25
Lubricating the drive chain ..............................6-26
Checking and lubricating the cables ...............6-27
Checking and lubricating the throttle grip and
cable .............................................................6-28
Adjusting the Autolube pump ..........................6-28
Checking and lubricating the brake and shift
pedals ...........................................................6-29
Checking and lubricating the brake and clutch
levers ............................................................6-29
Checking and lubricating the sidestand ..........6-29
Lubricating the rear suspension......................6-30
Checking the front fork....................................6-30
Checking the steering .....................................6-31
Checking the wheel bearings..........................6-31
Battery ............................................................6-32
Replacing the fuse ..........................................6-33
Replacing the headlight bulb ..........................6-34
Replacing a turn signal light bulb ....................6-36
Replacing the tail/brake light bulb ...................6-37
Replacing the license plate light bulb .............6-37
Supporting the motorcycle ..............................6-38
Front wheel .....................................................6-39
Rear wheel......................................................6-40
Troubleshooting ..............................................6-42
Troubleshooting charts ...................................6-43
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MOTORCYCLE CARE AND STORAGE .............7-1
Care ..................................................................7-1
Storage .............................................................7-4
8
SPECIFICATIONS ...............................................8-1
How to use the conversion table.......................8-5
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TABLE OF CONTENTS
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CONSUMER INFORMATION..............................9-1
Identification numbers record ...........................9-1
Key identification number .................................9-1
Vehicle identification number ............................9-1
Model label .......................................................9-2
Motorcycle noise regulation (for Australia) .......9-2
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Q SAFETY INFORMATION
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MOTORCYCLES 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 MOTORCYCLE.
HE OR SHE SHOULD:
1. OBTAIN THOROUGH INSTRUCTIONS FROM A COMPETENT SOURCE ON ALL ASPECTS
OF MOTORCYCLE OPERATION.
2. OBSERVE THE WARNINGS AND MAINTENANCE REQUIREMENTS IN THE OWNER’S MANUAL.
3. OBTAIN QUALIFIED TRAINING IN SAFE AND PROPER RIDING TECHNIQUES.
4. OBTAIN PROFESSIONAL TECHNICAL SERVICE AS INDICATED BY THE OWNER’S MANUAL
AND/OR WHEN MADE NECESSARY BY MECHANICAL CONDITIONS.
Safe riding
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1. Always make pre-operation checks. Careful checks may help prevent an accident.
2. This motorcycle is designed to carry the operator and a passenger.
3. The failure of motorists to detect and recognize motorcycles in traffic is the predominating cause
of automobile/motorcycle accidents. Many accidents have been caused by an automobile driver
who did not see the motorcycle. Making yourself conspicuous appears to be very effective in
reducing the chance of this type of accident.
Therefore:
a. Wear a brightly colored jacket.
b. Use extra caution when approaching and passing through intersections, since intersections
are the most likely places for motorcycle accidents to occur.
c. Ride where other motorists can see you. Avoid riding in another motorist’s blind spot.
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Q SAFETY INFORMATION
4. Many accidents involve inexperienced operators. In fact, many operators who have been
involved in accidents do not even have a current motorcycle license.
a. Make sure that you are qualified and that you only lend your motorcycle to other qualified operators.
b. Know your skills and limits. Staying within your limits may help you to avoid an accident.
c. We recommend that you practice riding your motorcycle where there is no traffic until you have
become thoroughly familiar with the motorcycle and all of its controls.
5. Many accidents have been caused by error of the motorcycle operator. A typical error made by
the operator is veering wide on a turn due to EXCESSIVE SPEED or undercornering (insufficient
lean angle for the speed).
a. Always obey the speed limit and never travel faster than warranted by road and traffic conditions.
b. Always signal before turning or changing lanes. Make sure that other motorists can see you.
6. The posture of the operator and passenger is important for proper control.
a. The operator should keep both hands on the handlebar and both feet on the operator footrests
during operation to maintain control of the motorcycle.
b. The passenger should always hold onto the operator, the seat strap or grab bar, if equipped,
with both hands and keep both feet on the passenger footrests.
c. Never carry a passenger unless he or she can firmly place both feet on the passenger
footrests.
7. Never ride under the influence of alcohol or other drugs.
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Q SAFETY INFORMATION
Protective apparel
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The majority of fatalities from motorcycle 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.
1. Always wear an approved helmet.
2. Wear a face shield or goggles. Wind in your unprotected eyes could contribute to an impairment
of vision that could delay seeing a hazard.
3. The use of a jacket, heavy boots, trousers, gloves, etc., is effective in preventing or reducing
abrasions or lacerations.
4. Never wear loose-fitting clothes, otherwise they could catch on the control levers, footrests, or
wheels and cause injury or an accident.
5. 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.
6. Passengers should also observe the precautions mentioned above.
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Modifications
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Modifications made to this motorcycle not approved by Yamaha, or the removal of original equipment,
may render the motorcycle unsafe for use and may cause severe personal injury. Modifications may
also make your motorcycle illegal to use.
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Loading and accessories
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Adding accessories or cargo to your motorcycle can adversely affect stability and handling if the
weight distribution of the motorcycle is changed. To avoid the possibility of an accident, use extreme
caution when adding cargo or accessories to your motorcycle. Use extra care when riding a motorcycle that has added cargo or accessories. Here are some general guidelines to follow if loading cargo
or adding accessories to your motorcycle:
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Q SAFETY INFORMATION
Loading
The total weight of the operator, passenger, accessories and cargo must not exceed the maximum
load limit of 180 kg. When loading within this weight limit, keep the following in mind:
1. Cargo and accessory weight should be kept as low and close to the motorcycle as possible.
Make sure to distribute the weight as evenly as possible on both sides of the motorcycle to minimize imbalance or instability.
2. Shifting weights can create a sudden imbalance. Make sure that accessories and cargo are
securely attached to the motorcycle before riding. Check accessory mounts and cargo restraints
frequently.
3. 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 motorcycle. 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 the following guidelines in mind, as well as those provided under “Loading” when mounting
accessories.
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Q SAFETY INFORMATION
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1. Never install accessories or carry cargo that would impair the performance of your motorcycle.
Carefully inspect the accessory before using it to make sure that it does not in any way reduce
ground clearance or cornering clearance, limit suspension travel, steering travel or control operation, or obscure lights or reflectors.
a. 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.
b. Bulky or large accessories may seriously affect the stability of the motorcycle due to aerodynamic effects. Wind may attempt to lift the motorcycle, or the motorcycle may become unstable
in cross winds. These accessories may also cause instability when passing or being passed by
large vehicles.
c. 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.
2. Use caution when adding electrical accessories. If electrical accessories exceed the capacity of
the motorcycle’s electrical system an electric failure could result, which could cause a dangerous
loss of lights or engine power.
Gasoline and exhaust gas
1. GASOLINE IS HIGHLY FLAMMABLE:
a. Always turn the engine off when refueling.
b. Take care not to spill any gasoline on the engine or exhaust system when refueling.
c. Never refuel while smoking or in the vicinity of an open flame.
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Q SAFETY INFORMATION
2. 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 motorcycle in an area that has adequate ventilation.
3. Always turn the engine off before leaving the motorcycle unattended and remove the key from
the main switch. When parking the motorcycle, note the following:
a. The engine and exhaust system may be hot, therefore, park the motorcycle in a place where
pedestrians or children are not likely to touch these hot areas.
b. Do not park the motorcycle on a slope or soft ground, otherwise it may fall over.
c. Do not park the motorcycle near a flammable source (e.g., a kerosene heater, or near an open
flame), otherwise it could catch fire.
4. When transporting the motorcycle 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 motorcycle should lean over, gasoline may leak out of the carburetor or fuel tank.
5. If you should swallow any gasoline, inhale a lot of gasoline vapor, or allow gasoline to get into
your eyes, 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.
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Q SAFETY INFORMATION
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Location of important labels
Please read the following important labels carefully before operating this motorcycle.
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WARNING
4
Before you operate this vehicle,
read the owner’s manual.
3HP-21568-00
English
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4AA-22259-40
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DESCRIPTION
Left view
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1. Headlight
2. Rear shock absorber compression
damping adjusting knob
3. Fuel cock
4. Starter (choke) lever “1”
5. Air filter element
6. 2-stroke engine oil tank
7. Helmet holder
11
(page 6-34)
(page 3-14)
(page 3-9)
(page 3-10)
(page 6-14)
(page 3-8)
(page 3-11)
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8. Rear shock absorber spring preload
adjusting nut
(page 3-13)
9. Rear shock absorber rebound damping
adjusting dial
(page 3-14)
10. Shift pedal
(page 3-6)
11. YPVS
(page 3-15)
12. Front fork compression damping
adjusting screw
(page 3-12)
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DESCRIPTION
Right view
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13.
14.
15.
16.
17.
18.
Coolant reservoir
Owner’s tool kit
Battery
Fuse
Radiator cap
Brake pedal
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8
(page 6-11)
(page 6-1)
(page 6-32)
(page 6-33)
(page 6-12)
(page 3-7, 6-22)
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DESCRIPTION
Controls and instruments
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1.
2.
3.
4.
5.
Clutch lever
Left handlebar switches
Speedometer unit
Main switch/steering lock
Right handlebar switches
(page 3-6, 6-20)
(page 3-5)
(page 3-3)
(page 3-1)
(page 3-5)
6. Brake lever
7. Throttle grip
8. Fuel tank cap
2-3
(page 3-6, 6-21)
(page 6-16, 6-28)
(page 3-7)
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INSTRUMENT AND CONTROL FUNCTIONS
ON
OFF
FF
K
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LOC
LOCK
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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”.
ON
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Main switch/steering lock
The main switch/steering lock controls
the ignition and lighting systems, and
is used to lock the steering. The various positions are described below.
EAU00031
ON
All electrical systems are supplied
with power, and the headlight, meter
lighting, taillight and license plate
light come on, and the engine can be
started. The key cannot be removed.
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EAU00040
LOCK
The steering is locked, and all electrical systems are off. The key can 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.
EAU00038
OFF
All electrical systems are off. The key
can be removed.
1
To unlock the steering
Push the key in, and then turn it to
“OFF” while still pushing it.
3-1
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INSTRUMENT AND CONTROL FUNCTIONS
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1. Oil level/coolant temperature warning
light “WARNING”
2. Oil level symbol “7”
3. Coolant temperature symbol “
”
4. Turn signal indicator light “5”
5. High beam indicator light “&”
6. Neutral indicator light “N”
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Indicator and warning lights
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Oil level/coolant temperature
warning light “WARNING”
This warning light has the following
three functions.
8 When the engine oil level is low,
the warning light comes on and
symbol “7” flashes. If this
occurs, stop the engine immediately and add engine oil to the
specified level.
8 When the coolant temperature is
too high, the warning light comes
on and symbol “
” flashes.
Stop the motorcycle and allow it
to idle until the coolant temperature goes down. If the temperature does not go down, stop the
engine. (See the “Engine overheating” section on page 6-44 for
further instructions.)
8 When the engine oil level is low
and the coolant temperature is
too high, the warning light flashes and symbols “7” and “
”
come on.
To check that the warning light is
working properly:
8 Put the transmission in neutral or
apply the clutch lever.
8 Turn the engine stop switch to
“#” and the key to “ON”.
8 The light will come on and symbol “7” will appear in the display.
3-2
If the warning light does not come on,
have a Yamaha dealer inspect the
electrical circuit.
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8 Do not operate the motorcycle
until you know that the engine
oil level is sufficient.
8 Do not operate the engine if it
is overheated.
NOTE:
Even if the oil is filled to the specified
level, the indicator light may flicker
when riding on a slope or during sudden acceleration or deceleration, but
this is normal.
EAU00057
Turn signal indicator light “5”
This indicator light flashes when the
turn signal switch is pushed to the left
or right.
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INSTRUMENT AND CONTROL FUNCTIONS
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6
1. Oil level/coolant temperature warning
light “WARNING”
2. Oil level symbol “7”
3. Coolant temperature symbol “
”
4. Turn signal indicator light “5”
5. High beam indicator light “&”
6. Neutral indicator light “N”
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High beam indicator light “&”
This indicator light comes on when
the high beam of the headlight is
switched on.
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Neutral indicator light “N”
This indicator light comes on when
the transmission is in the neutral
position.
1.
2.
3.
4.
5.
6.
2 3
When in mode “A”:
8 The upper tripmeter can be reset
to zero.
8 The display can be switched
between the clock and the
odometer.
8 The clock can be set.
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5
1
2
3
When in mode “B”:
8 The lower tripmeter can be reset.
8 The lower tripmeter can be
switched between forward count
and reverse count.
Reset button “RESET”
Upper trip odometer
Lower trip odometer
Digital speedometer
Odometer/Clock “ODO/CLOCK”
Mode select button “SELECT”
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5
EAU00100
Speedometer unit
The speedometer unit is equipped
with a digital speedometer, an
odometer, two tripmeters and a clock.
The speedometer shows riding
speed. The odometer shows the total
distance traveled. The tripmeter
shows the distance traveled since it
was last set to zero.
The mode select button is used to
switch between modes “A” and “B”.
3-3
Select the modes as follows:
1. Turn the key to “ON”.
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8
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INSTRUMENT AND CONTROL FUNCTIONS
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5
4
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2
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1.
2.
3.
4.
5.
6.
Reset button “RESET”
Upper trip odometer
Lower trip odometer
Digital speedometer
Odometer/Clock “ODO/CLOCK”
Mode select button “SELECT”
NOTE:
When the key is turned to “ON”, the
speedometer displays “188 km/h” for
a few seconds, during which time the
electrical circuit is being checked.
Mode “A”
To set the upper tripmeter to zero,
push the reset button for at least one
second.
To display the clock or odometer
reading, push the mode select button
for one to three seconds.
To set the clock:
1. Push the mode select button
until the hour digits flash.
2. Push the reset button to change
the hour digits.
3. Push the mode select button,
and the minute digits will flash.
4. Push the reset button to change
the minute digits.
5. Push the mode select button
again to set the clock.
2. Push the mode select button to
display a mode.
3-4
Mode “B”
To set the lower tripmeter to zero,
push the reset button for at least one
second.
To switch the tripmeter between forward count and reverse count, push
the mode select button for one to
three seconds. A minus sign – will
appear when in the reverse count
mode.
To set the reverse count distance:
1. Push the mode select button
until the digit for the hundreds
flashes.
2. Push the reset button to change
the hundreds.
3. Repeat this procedure to change
the tens and ones.
4. Push the mode select button
again to set the tripmeter.
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INSTRUMENT AND CONTROL FUNCTIONS
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2
1
Horn switch “*”
Press this switch to sound the horn.
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2
3
2
3
1. Dimmer switch
2. Turn signal switch
3. Horn switch “*”
1. Engine stop switch
2. Start switch “,”
4
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Engine stop switch
Set this switch to “$” to stop the
engine in case of an emergency,
such as when the motorcycle overturns or when the throttle cable is
stuck.
Handlebar switches
EAU00121
Dimmer switch
Set this switch to “&” for the high
beam and to “%” for the low beam.
EAU00127
Turn signal switch
To signal a right-hand turn, push this
switch to “6”. To signal a left-hand
turn, push this switch to “4”. 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.
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6
7
EAU00143
Start switch “,”
Push this switch to crank the engine
with the starter.
cC
EC000005
See page 5-1 for starting instructions prior to starting the engine.
3-5
8
9
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Page 24
INSTRUMENT AND CONTROL FUNCTIONS
1
1
6
5
4
3
2
N
1
1
2
3
4
1. Clutch lever
EAU00152
5
6
7
8
9
Clutch lever
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 ignition circuit cut-off system. (See page
3-16 for an explanation of the ignition
circuit cut-off system.)
1
1. Shift pedal
N. Neutral
1. Brake lever
EAU00158
EAU00157
Shift pedal
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.
3-6
Brake lever
The brake lever is located at the right
handlebar grip. To apply the front
brake, pull the lever toward the handlebar grip.
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Page 25
INSTRUMENT AND CONTROL FUNCTIONS
b
1
a
1
NOTE:
The fuel tank cap cannot be installed
unless the key is in the lock. In addition, the key cannot be removed if the
cap is not properly installed and
locked.
1
EW000023
3
w
1. Brake pedal
EAU00162
Brake pedal
The brake pedal is on the right side
of the motorcycle. To apply the rear
brake, press down on the brake
pedal.
1. Fuel tank cap
a. Unlock
b. Open
EAU00177
Fuel tank cap
To remove the fuel tank cap
1. Insert the key into the lock and
turn it 1/4 turn counterclockwise.
2. Turn the fuel tank cap 1/3 turn
counterclockwise and pull it off.
To install the fuel tank cap
1. Insert the fuel tank cap into the
tank opening with the key inserted in the lock, and then turn the
cap 1/3 turn clockwise.
2. Turn the key 1/4 turn clockwise,
and then remove it.
3-7
Make sure that the fuel tank cap is
properly closed and locked before
riding.
2
4
5
6
7
8
9
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Page 26
INSTRUMENT AND CONTROL FUNCTIONS
1
EAU00185
cC
2
Immediately wipe off spilled fuel
with a clean, dry, soft cloth, since
fuel may deteriorate painted surfaces or plastic parts.
1
2
3
4
6
7
8
9
2
EAU00192
1. Filler tube
2. Fuel level
EAU01183
5
1
Fuel
Make sure that there is sufficient fuel
in the tank. Fill the fuel tank to the
bottom of the filler tube as shown in
the illustration.
w
EW000130
Recommended fuel:
Regular gasoline
For Australia:
Unleaded fuel only
Fuel tank capacity:
Total amount:
11.0 L
Reserve amount:
2.0 L
8 Do not overfill the fuel tank,
otherwise it may overflow
when the fuel warms up and
expands.
8 Avoid spilling fuel on the hot
engine.
3-8
1. 2-stroke engine oil tank cap
2. 2-stroke engine oil tank
EAU01413
2-stroke engine oil
Make sure that there is sufficient oil in
the 2-stroke engine oil tank. If necessary, add oil as follows.
1. Remove panel A. (See page 6-6
for panel removal and installation
procedures.)
2. Remove the 2-stroke engine oil
tank cap and add the recommended oil.
3. Install the 2-stroke engine oil
tank cap and the panel.
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Page 27
INSTRUMENT AND CONTROL FUNCTIONS
NOTE:
Make sure that the 2-stroke engine
oil tank cap is properly closed.
OFF: Closed position
ON: Normal position
RES
RES
OFF
Recommended oil:
Yamalube 2 or equivalent
2-stroke engine oil (JASO
grade “FC”)
Oil quantity:
1.3 L
1
OFF
ON
FUEL
ON
1
ON
1. Arrow mark positioned over “OFF”
2
FUEL
1
1. Arrow mark positioned over “ON”
EAU03050
Fuel cock
The fuel cock supplies fuel from the
tank to the carburetor while filtering it
also.
The fuel cock has three positions:
ON
With the lever in this position, fuel
flows to the carburetor. Normal riding
is done with the lever in this position.
3
4
5
6
7
OFF
With the lever in this position, fuel will
not flow. Always return the lever to
this position when the engine is not
running.
3-9
8
9
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Page 28
INSTRUMENT AND CONTROL FUNCTIONS
RES: Reserve position
RES
1
2
3
4
5
6
7
8
a
RES
1
OFF
ON
FUEL
1
1. Arrow mark positioned over “RES”
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!
b
1
1. Starter (choke) lever “1”
1. Bolt (×2)
EAU02976
EAU00240
Starter (choke) lever “1”
Seat
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).
To remove the seat
Remove the bolts, and then pull the
seat off.
9
3-10
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Page 29
INSTRUMENT AND CONTROL FUNCTIONS
EAU03589
1
Adjusting the front fork
1
This front fork is equipped with damping force adjusting screws.
a
w
Always adjust both fork legs
equally, otherwise poor handling
and loss of stability may result.
2
1. Projection (×2)
2. Seat holder (×2)
To install the seat
1. Insert the projections on the front
of the seat into the seat holders
as shown.
2. Place the seat in the original
position, and then tighten the
bolts.
NOTE:
Make sure that the seat is properly
secured before riding.
1. Helmet holder
a. Open
1
EW000035
2
3
4
EAU00260
Helmet holder
To open the helmet holder, insert the
key into the lock, and then turn the
key as shown.
To lock the helmet holder, place it in
the original position, and then remove
the key.
5
6
7
8
EW000030
w
9
Never ride with a helmet attached
to the helmet holder, since the helmet may hit objects, causing loss
of control and possibly an accident.
3-11
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Page 30
INSTRUMENT AND CONTROL FUNCTIONS
1
1
4
5
6
7
8
9
17 clicks in direction b*
Standard
14 clicks in direction b*
Maximum (hard)
1 click in direction b*
* With the adjusting screw fully turned in direction a
2
3
Minimum (soft)
a
b
1. Compression damping adjusting screw
Adjust the damping force as follows.
1. Remove the rubber cap from the
bottom of each fork leg.
2. To increase the damping force
and thereby harden the suspension, turn the adjusting screw in
direction a. To decrease the
damping force and thereby soften the suspension, turn the
adjusting screw in direction b.
3. Install the rubber caps.
ECA00034
cC
Be sure to install the rubber caps
to prevent dust, etc. from entering
the fork legs.
NOTE:
To determine the maximum damping
force setting, push the adjusting
screw up, turn it in direction a until it
stops, and then one click in direction
b.
3-12
EAU03672
Adjusting the shock
absorber assembly
This shock absorber assembly is
equipped with a spring preload
adjusting nut, a rebound damping
force adjusting dial and a compression damping force adjusting knob.
cC
EC000015
Never attempt to turn an adjusting
mechanism beyond the maximum
or minimum settings.
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Page 31
INSTRUMENT AND CONTROL FUNCTIONS
a
1
1
b
1. Special wrench
Spring preload
1. Loosen the locknut.
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.
a
2
Spring preload:
Minimum (soft):
Distance A = 252 mm
Standard:
Distance A = 244 mm
Maximum (hard):
Distance A = 234 mm
1
2
3
3. Tighten the locknut to the specified torque.
1. Adjusting nut
2. Locknut
a. Distance “A”
NOTE:
8 Use the special wrench included
in the owner’s tool kit to make
the adjustment.
8 The spring preload setting is
determined by measuring distance A, shown in the illustration.
The shorter distance A is, the
higher the spring preload; the
longer distance A is, the lower
the spring preload.
3-13
5
Tightening torque:
Locknut:
41 Nm (4.1 m0kg)
cC
4
6
ECA00076
Always tighten the locknut against
the adjusting nut, and then tighten
the locknut to the specified torque.
7
8
9
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Page 32
INSTRUMENT AND CONTROL FUNCTIONS
1
2
1
1
a
b
a
b
3
4
5
6
7
1. Adjusting dial
1. Adjusting knob
Rebound damping force
To increase the rebound damping
force and thereby harden the
rebound damping, turn the adjusting
dial in direction a. To decrease the
rebound damping force and thereby
soften the rebound damping, turn the
adjusting dial in direction b.
Compression damping force
To increase the compression damping force and thereby harden the
compression damping, turn the
adjusting knob in direction a. To
decrease the compression damping
force and thereby soften the compression damping, turn the adjusting
knob in direction b.
8
9
Minimum (soft)
16 clicks in direction b*
Standard
9 clicks in direction b*
Minimum (soft)
5 clicks in direction a*
1 click in direction b*
Standard
8 clicks in direction a*
Maximum (hard)
22 clicks in direction a*
Maximum (hard)
* With the adjusting dial fully turned in direction a
* With the adjusting knob fully turned in direction b
3-14
NOTE:
Although the total number of clicks of
a damping force adjusting mechanism may not exactly match the
above specifications due to small differences in production, the actual
number of clicks always represents
the entire adjusting range. To obtain
a precise adjustment, it would be
advisable to check the number of
clicks of each damping force adjusting mechanism and to modify the
specifications as necessary.
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Page 33
INSTRUMENT AND CONTROL FUNCTIONS
w
EW000041
This shock absorber contains
highly pressurized nitrogen gas.
For proper handling, read and
understand the following information before handling the shock
absorber. The manufacturer cannot be held responsible for property damage or personal injury that
may result from improper handling.
8 Do not tamper with or attempt
to open the gas cylinder.
8 Do not subject the shock
absorber to an open flame or
other high heat sources, otherwise it may explode due to
excessive gas pressure.
8 Do not deform or damage the
gas cylinder in any way, as
this will result in poor damping performance.
8 Always have a Yamaha dealer
service the shock absorber.
Since the YPVS is an important part
of the engine and requires very
sophisticated adjustment, have a
Yamaha dealer, who has the necessary professional knowledge and
experience, make this adjustment.
1
cC
1. YPVS
EAU00326
YPVS
This model is equipped with the
YPVS
(Yamaha
Power
Valve
System). This system boosts engine
performance and efficiency by means
of a variable valve in the exhaust
port. The YPVS valve is constantly
adjusted in accordance with the
engine speed by a computer-controlled servomotor.
3
YPVS operation noises can be heard
in the following instances:
8 When the key is turned to “ON”
and the engine is started.
8 When the engine stalls with the
key in the “ON” position.
EC000024
If the YPVS does not operate, have
a Yamaha dealer check it.
3-15
2
EC000023
The YPVS 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.
cC
1
4
5
6
7
8
9
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Page 34
INSTRUMENT AND CONTROL FUNCTIONS
EAU00330
Sidestand
1
2
3
4
5
6
7
The sidestand is located on the left
side of the frame. Raise the sidestand or lower it with your foot while
holding the motorcycle upright.
NOTE:
The built-in sidestand switch is part of
the ignition circuit cut-off system,
which cuts the ignition in certain situations. (See further down for an
explanation of the ignition circuit cutoff system.)
EW000044
w
The motorcycle must not be ridden
with the sidestand down, or if the
sidestand cannot be properly
moved up (or does not stay up),
otherwise the sidestand could contact the ground and distract the
operator, resulting in a possible
loss of control. Yamaha’s ignition
circuit cut-off system has been
designed to assist the operator in
fulfilling the responsibility of raising the sidestand before starting
off. Therefore, check this system
regularly as described below and
have a Yamaha dealer repair it if it
does not function properly.
8
9
EAU00331
Ignition circuit cut-off
system
The ignition circuit cut-off system
(comprising the sidestand switch,
clutch switch and neutral switch) has
the following functions.
8 It prevents starting when the
transmission is in gear and the
sidestand is up, but the clutch
lever is not pulled.
8 It It prevents starting when the
transmission is in gear and the
clutch lever is pulled, but the
sidestand is still down.
8 It It cuts the running engine when
the sidestand is moved down.
Periodically check the operation of
the ignition circuit cut-off system
according to the following procedure.
w
EW000045
If a malfunction is noted, have a
Yamaha dealer check the system
before riding.
3-16
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Page 35
INSTRUMENT AND CONTROL FUNCTIONS
NOTE:
This check is most reliable if performed with
a warmed-up engine.
With the engine turned off:
1. Move the sidestand down.
2. Make sure that the engine stop switch is set to “#”.
3. Turn the key to “ON”.
4. Shift the transmission into the neutral position.
5. Push the start switch.
Does the engine start?
YES
2
The neutral switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
NO
With the engine still running:
6. Move the sidestand up.
7. Keep the clutch lever pulled.
8. Shift the transmission into gear.
9. Move the sidestand down.
Does the engine stall?
YES
3
4
5
The sidestand switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
NO
After the engine has stalled:
10. Move the sidestand up.
11. Keep the clutch lever pulled.
12. Push the start switch.
Does the engine start?
YES
1
6
7
8
The clutch switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
NO
The system is OK. The motorcycle can be ridden.
3-17
9
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Page 36
EAU01114
PRE-OPERATION CHECKS
1
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
2
ITEM
3
• Check fuel level in fuel tank.
• Refuel if necessary.
• Check fuel line for leakage.
3-7–3-8
Two-stroke engine oil
• Check oil level in oil tank.
• If necessary, add recommended oil to specified level.
• Check vehicle for oil leakage.
3-8–3-9
Transmission oil
• Check oil level in transmission case.
• If necessary, add recommended oil to specified level.
6-9–6-10
Coolant
• Check coolant level in reservoir.
• If necessary, add recommended coolant to specified level.
• Check cooling system for leakage.
6-10–6-13
Front brake
•
•
•
•
•
•
•
Check operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check lever free play.
Adjust if necessary.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.
3-6, 6-21–6-25
Rear brake
•
•
•
•
•
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.
3-7, 6-22–6-25
5
7
PAGE
Fuel
4
6
CHECKS
8
9
4-1
4TP-9-21
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Page 37
PRE-OPERATION CHECKS
ITEM
CHECKS
PAGE
Clutch
•
•
•
•
Check operation.
Lubricate cable if necessary.
Check lever free play.
Adjust if necessary.
3-6, 6-20–6-21
Throttle grip
•
•
•
•
Make sure that operation is smooth.
Lubricate throttle grip, housing and cable if necessary.
Check free play.
Adjust if necessary.
6-16–6-17, 6-28
Control cables
• Make sure that operation is smooth.
• Lubricate if necessary.
Drive chain
•
•
•
•
Check chain slack.
Adjust if necessary.
Check chain condition.
Lubricate if necessary.
6-25–6-27
Wheels and tires
•
•
•
•
Check for damage.
Check tire condition and tread depth.
Check air pressure.
Correct if necessary.
6-17–6-20
Brake and shift pedals
• Make sure that operation is smooth.
• Lubricate pedal pivoting points if necessary.
6-29
Brake and clutch levers
• Make sure that operation is smooth.
• Lubricate lever pivoting points if necessary.
6-29
Sidestand
• Make sure that operation is smooth.
• Lubricate pivot if necessary.
6-29
4-2
1
2
3
6-27
4
5
6
7
8
9
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Page 38
PRE-OPERATION CHECKS
ITEM
1
2
3
4
5
6
CHECKS
Chassis fasteners
• Make sure that all nuts, bolts and screws are properly tightened.
• Tighten if necessary.
Instruments, lights, signals and switches
• Check operation.
• Correct if necessary.
Sidestand switch
• Check operation of ignition circuit cut-off system.
• If system is defective, have Yamaha dealer check vehicle.
PAGE
—
3-5, 6-34–6-38
3-16–3-17
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
w
If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operating the motorcycle.
7
8
9
4-3
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Page 39
EAU00372
OPERATION AND IMPORTANT RIDING POINTS
w
EAU00373
8 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.
8 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.
8 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.
EAU01860
Starting and warming up a
cold engine
In order for the ignition circuit cut-off
system to enable starting, one of the
following conditions must be met:
8 The transmission is in the neutral
position.
8 The transmission is in gear with
the clutch lever pulled and the
sidestand up.
EW000054
w
8 Before starting the engine,
check the function of the ignition circuit cut-off system
according to the procedure
described on page 3-17.
8 Never ride with the sidestand
down.
1. Turn the fuel cock lever to “ON”.
2. Turn the key to “ON” and make
sure that the engine stop switch
is set to “#”.
3. Shift the transmission into the
neutral position.
NOTE:
When the transmission is in the neutral position, the neutral indicator light
should be on, otherwise have a
Yamaha dealer check the electrical
circuit.
4. Turn the starter (choke) on and
completely close the throttle.
(See page 3-10 for starter
(choke) operation.)
5. Start the engine by pushing the
start switch.
1
2
3
4
5
6
7
8
9
5-1
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Page 40
OPERATION AND IMPORTANT RIDING POINTS
1
2
3
4
5
6
7
8
9
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 10 seconds on any
one attempt.
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.
1
1. Shift pedal
N. Neutral
6. After starting the engine, move
the starter (choke) knob/lever
back halfway.
cC
6
5
4
3
2
N
1
EAU00423
Shifting
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.
ECA00045
For maximum engine life, never
accelerate hard when the engine is
cold!
7. When the engine is warm, turn
the starter (choke) off.
NOTE:
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.
NOTE:
The engine is warm when it responds
normally to the throttle with the starter
(choke) turned off.
5-2
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Page 41
OPERATION AND IMPORTANT RIDING POINTS
cC
EC000048
8 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.
8 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.
EAU00424
Tips for reducing fuel
consumption
Fuel consumption depends largely on
your riding style. Consider the following tips to reduce fuel consumption:
8 Thoroughly warm up the engine.
8 Turn the starter (choke) off as
soon as possible.
8 Shift up swiftly, and avoid high
engine speeds during acceleration.
8 Do not rev the engine while shifting down, and avoid high engine
speeds with no load on the
engine.
8 Turn the engine off instead of letting it idle for an extended length
of time (e.g., in traffic jams, at
traffic lights or at railroad crossings).
5-3
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.
1
2
3
4
5
6
7
8
9
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Page 42
OPERATION AND IMPORTANT RIDING POINTS
EAU00455
1
2
3
4
5
6
7
8
9
0–150 km
8 Avoid prolonged operation above
1/3 throttle.
8 After every hour of operation,
stop the engine, and then let it
cool for five to ten minutes.
8 Vary the engine speed from time
to time. Do not operate the
engine at one set throttle position.
1,000 km and beyond
Avoid prolonged full-throttle operation. Vary the engine speed occasionally.
EC000049
cC
If any engine trouble should occur
during the engine break-in period,
immediately have a Yamaha dealer
check the vehicle.
150–500 km
8 Avoid prolonged operation above
1/2 throttle.
8 Rev the engine freely through
the gears, but do not use full
throttle at any time.
500–1,000 km
Avoid prolonged operation above 3/4
throttle.
EC000060
cC
After 1,000 km of operation, the
transmission oil must be changed.
5-4
EAU00457
Parking
When parking, stop the engine,
remove the key from the main switch,
and then turn the fuel cock lever to
“OFF”.
w
EW000058
8 Since the engine and exhaust
system can become very hot,
park in a place where pedestrians or children are not likely
to touch them.
8 Do not park on a slope or on
soft ground, otherwise the
motorcycle may overturn.
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Page 43
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,
GEOGRAPHICAL LOCATION, AND
INDIVIDUAL USE, THE MAINTENANCE INTERVALS MAY NEED TO
BE SHORTENED.
w
EW000060
If you are not familiar with motorcycle maintenance work, have a
Yamaha dealer do it for you.
NOTE:
If you do not have the tools or experience required for a particular job,
have a Yamaha dealer perform it for
you.
1
w
1. Owner’s tool kit
EAU01175
Owner’s tool kit
The owner’s tool kit is located behind
panel B. (See page 6-7 for panel
removal and installation 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.
6-1
1
2
EW000063
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.
3
4
5
6
7
8
9
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Page 44
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU03540
Periodic maintenance and lubrication chart
1
2
NOTE:
8 The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.
8 From 30,000 km, repeat the maintenance intervals starting from 6,000 km.
8 Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and
technical skills.
3
4
NO.
CHECK OR MAINTENANCE JOB
ODOMETER READING (×1,000 km)
1
6
12
18
24
ANNUAL
CHECK
Fuel line
• Check fuel hoses for cracks or damage.
√
√
√
√
√
2
Spark plug
• Replace.
√
√
√
√
√
3
Air filter element
• Clean.
• Replace.
√
1
5
ITEM
*
6
4
Clutch
7
5
*
Front brake
8
6
*
Rear brake
9
7
*
Brake hoses
8
*
Wheels
√
√
• Check operation.
• Adjust.
• Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)
• Replace brake pads.
• Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)
• Replace brake pads.
• Check for cracks or damage.
• Replace. (See NOTE on page 6-4.)
• Check runout, spoke tightness and for damage.
• Tighten spokes if necessary.
6-2
√
√
√
√
√
√
√
√
√
√
√
√
Whenever worn to the limit
√
√
√
√
√
√
√
Whenever worn to the limit
√
√
√
Every 4 years
√
√
√
√
√
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Page 45
PERIODIC MAINTENANCE AND MINOR REPAIR
NO.
9
10
11
ITEM
CHECK OR MAINTENANCE JOB
ODOMETER READING (×1,000 km)
1
6
12
18
24
ANNUAL
CHECK
*
Tires
• Check tread depth and for damage.
• Replace if necessary.
• Check air pressure.
• Correct if necessary.
√
√
√
√
1
*
*
Wheel bearings
• Check bearing for looseness or damage.
√
√
√
√
2
Swingarm
• Check operation and for excessive play.
√
√
√
√
12
Drive chain
• Check chain slack.
• Make sure that the rear wheel is properly aligned.
• Clean and lubricate.
• Check bearing play and steering for roughness.
• Lubricate with lithium-soap-based grease
Every 500 km and after washing the motorcycle
or riding in the rain.
√
√
√
√
Every 24,000km
4
√
13
*
Steering bearings
14
*
Chassis fasteners
• Make sure that all nuts, bolts and screws are properly tightened.
√
√
√
√
√
Sidestand
• Check operation.
• Lubricate.
√
√
√
√
√
Sidestand switch
• Check operation.
√
√
√
√
√
Front fork
• Check operation and for oil leakage.
√
√
√
√
√
√
√
√
√
√
√
√
15
16
17
*
*
√
Rear shock absorber
• Check operation and shock absorber for oil leakage.
assembly
Rear suspension relay
• Check operation.
arm and connecting arm
• Lubricate with molybdenum disulfide grease.
pivoting points
18
*
19
*
20
*
Carburetor
21
*
Autolube pump
• Check starter (choke) operation.
• Adjust engine idling speed.
• Check operation.
• Bleed if necessary.
√
√
√
6-3
√
√
√
3
5
6
7
8
√
√
√
√
√
√
9
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Page 46
PERIODIC MAINTENANCE AND MINOR REPAIR
NO.
1
2
3
4
22
• Check oil level and vehicle for leakage.
• Change.
• Check coolant level and vehicle for coolant leakage.
• Change.
ODOMETER READING (×1,000 km)
1
6
12
18
24
√
√
√
√
√
√
√
√
√
√
√
Every 3 years
• Check operation.
√
ITEM
Transmission oil
23
*
Cooling system
24
*
Front and rear brake
switches
CHECK OR MAINTENANCE JOB
25
Moving parts and cables • Lubricate.
26
Lights, signals and
switches
*
• Check operation.
• Adjust headlight beam.
√
ANNUAL
CHECK
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
EAU03541
5
6
7
NOTE:
8 The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
8 Hydraulic brake service
8 Regularly check and, if necessary, correct the brake fluid level.
8 Every two years replace the internal components of the brake master cylinder and caliper, and change the brake fluid.
8 Replace the brake hoses every four years and if cracked or damaged.
8
9
6-4
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Page 47
PERIODIC MAINTENANCE AND MINOR REPAIR
2
1
1
1
1
2
3
1. Cowling A
2. Cowling B
1. Screw (×4)
1. Screw (×3)
EAU00484
EAU01065
Removing and installing
cowlings
The cowlings shown above need to
be removed to perform some of the
maintenance jobs described in this
chapter. Refer to this section each
time a cowling needs to be removed
and installed.
4
EAU00482
Cowling A
To remove the cowling
Remove the cowling screws, and
then pull the cowling off as shown.
Cowling B
To remove the cowling
Remove the screws, and then take
the cowling off.
To install the cowling
Place the cowling in the original position, and then install the screws.
To install the cowling
Place the cowling in the original position, and then install the screws.
5
6
7
8
9
6-5
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Page 48
PERIODIC MAINTENANCE AND MINOR REPAIR
1
1
1
1
2
3
4
1. Panel A
1. Panel B
EAU01122
5
6
7
Removing and installing
panels
The panels shown above need to be
removed to perform some of the
maintenance jobs described in this
chapter.
1. Screw
Refer to this section each time a
panel needs to be removed and
installed.
EAU00488
Panel A
To remove the panel
Remove the screw, and then pull the
panel off as shown.
To install the panel
Place the panel in the original position, and then install the screw.
8
9
6-6
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Page 49
PERIODIC MAINTENANCE AND MINOR REPAIR
1
1
1
1. Screw
1. Spark plug cap
1. Spark plug wrench
EAU00488
Panel B
To remove the panel
Remove the screw, and then pull the
panel off as shown.
To install the panel
Place the panel in the original position, and then install the screw.
EAU01833
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.
6-7
2. Remove the spark plug as
shown, with the spark plug
wrench included in the owner’s
tool kit.
6
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Page 50
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
5
To check the spark plug
1. Check that the porcelain insulator around the center electrode
of the spark plug is a medium-tolight 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.
6
7
8
9
2. Check the spark plug for electrode erosion and excessive carbon or other deposits, and
replace it if necessary.
Specified spark plug:
BR9ES (NGK)
Tightening torque:
Spark plug:
20 Nm (2.0 m0kg)
a
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.
Spark plug gap:
0.7–0.8 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.
6-8
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 specified torque as
soon as possible.
4. Install the spark plug cap.
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Page 51
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU03109
Transmission oil
2
Oil level inspection
1. Place the motorcycle on a level
place and hold it in an upright
position. Warm up the engine for
several minutes.
3
NOTE:
Be sure the motorcycle is positioned
straight up when checking the oil
level. A slight tilt toward the side can
result in false readings.
1
1
1
2
3
1. Oil level window
2. Maximum level
3. Minimum level
1. Oil filler cap
2. With the engine stopped, check
the oil level through the level
window located at the right side
crankcase cover.
Transmission oil replacement
1. Warm up the engine for several
minutes.
2. Stop the engine. Place an oil pan
under the engine to catch the oil
and remove the oil filler cap.
4
5
6
NOTE:
Wait a few minutes until the oil level
settles before checking.
7
3. The oil level should be between
the maximum and minimum level
on the level window. If the level
is low, add sufficient oil to raise it
to the specified level.
9
6-9
8
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Page 52
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU01808
1
1
2
5
6
7
8
9
1. Drain bolt
3. Remove the drain bolt and drain
the oil.
4. Install the drain bolt and tighten it
to the specified torque.
Tightening torque:
Drain bolt:
15 Nm (1.5 m0kg)
5. Fill the engine with sufficient oil
to reach the specified level.
Install the oil filler cap and tighten it.
Coolant
To check the coolant level
1. Place the motorcycle on a level
surface and hold it in an upright
position.
EC000079
cC
3
4
Recommended oil:
See page 8-1.
Oil quantity:
Total amount: 0.85 L
Periodic oil change: 0.8 L
In order to prevent clutch slippage
(since the transmission oil also
lubricates the clutch), do not mix
any chemical additives with the oil.
6. Start the engine and warm up for
a few minutes. While warming
up, check for oil leakage. If oil
leakage is found, stop the engine
immediately and check for
cause.
6-10
NOTE:
8 The coolant level must be
checked on a cold engine since
the level varies with engine temperature.
8 Make sure that the motorcycle is
positioned straight up when
checking the coolant level. A
slight tilt to the side can result in
a false reading.
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Page 53
PERIODIC MAINTENANCE AND MINOR REPAIR
3
1
2
1. Maximum level mark
2. Minimum level mark
3. Coolant reservoir
2. Remove panel B. (See page 6-7
for panel removal and installation
procedures.)
3. Check the coolant level in the
coolant reservoir.
NOTE:
The coolant should be between the
minimum and maximum level marks.
4. If the coolant is at or below the
minimum level mark, open the
reservoir cap, add coolant to the
maximum level mark, and then
close the reservoir cap.
w
Coolant reservoir capacity:
0.36 L
EC000080
cC
8 If coolant is not available, use
distilled water or soft tap water
instead. Do not use hard water
or salt water since it is harmful
to the engine.
8 If water has been used instead
of coolant, replace it with
coolant as soon as possible,
otherwise the engine may not
be sufficiently cooled and the
cooling system will not be protected against frost and corrosion.
8 If water has been added to the
coolant, have a Yamaha dealer
check the antifreeze content of
the coolant as soon as possible, otherwise the effectiveness of the coolant will be
reduced.
6-11
EW000067
Never attempt to remove the radiator cap when the engine is hot.
5. Install the panel.
NOTE:
If the engine overheats, see page
6-44 for further instructions.
1
2
3
4
5
6
7
8
9
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Page 54
PERIODIC MAINTENANCE AND MINOR REPAIR
2
1
1
1
2
2
1
3
3
4
1. Radiator cap stopper bolt
2. Radiator cap
5
Changing the coolant
1. Coolant drain bolt
EAU03101
6
7
8
1. Put the motorcycle on a level
place.
2. Remove cowling B and panel B.
(See pages 6-5 and 6-7 for cowling and panel removal and installation procedures.)
3. Remove the radiator cap stopper
bolt and the radiator cap.
4. Place a container under the
engine and remove the coolant
drain bolt.
9
1. Maximum level mark
2. Minimum level mark
3. Reservoir tank hose
5. Disconnect the reservoir tank
hose on the reservoir tank side
and drain the coolant from the
reservoir tank.
6. After draining the coolant, thoroughly flush the cooling system
with clean tap water.
7. Replace the coolant drain bolt
washer if it is damaged and tighten the coolant drain bolt to the
specified torque.
Tightening torque:
Coolant drain bolt:
10 Nm (1.0 m0kg)
6-12
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Page 55
PERIODIC MAINTENANCE AND MINOR REPAIR
8. Install the reservoir tank hose.
9. Pour the recommended coolant
into the radiator until it is full.
Recommended antifreeze:
High quality ethylene glycol
antifreeze containing corrosion
inhibitors for aluminum
engines.
Antifreeze and water mixing ratio:
1:1
Total amount:
1.26 L
Reservoir tank capacity:
0.36 L
EC000080
cC
8 If coolant is not available, use
distilled water or soft tap water
instead. Do not use hard water
or salt water since it is harmful
to the engine.
8 If water has been used instead
of coolant, replace it with
coolant as soon as possible,
otherwise the engine may not
be sufficiently cooled and the
cooling system will not be protected against frost and corrosion.
8 If water has been added to the
coolant, have a Yamaha dealer
check the antifreeze content of
the coolant as soon as possible, otherwise the effectiveness of the coolant will be
reduced.
6-13
10. Install the radiator cap.
11. Run the engine several minutes.
Stop the engine and recheck the
coolant level in the radiator. If it
is low, add more coolant until it
reaches the top of the radiator.
12. Install the radiator cap stopper
bolt.
13. Fill the reservoir tank with
coolant up to maximum level.
14. Install the reservoir tank cap and
check for coolant leakage.
NOTE:
If any leakage is found, ask a
Yamaha dealer to inspect the cooling
system.
15. Install the cowling and the panel.
1
2
3
4
5
6
7
8
9
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Page 56
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
1
2
1
2
3
4
1. Screw (×3)
2. Air filter case cover
5
Cleaning the air filter
element
EAU03671
6
7
8
9
3. Pull the air filter element out from
the air filter case.
1.
2.
3.
4.
Air filter element guide
Air filter element frame
Sponge material
Wing nut
4. Remove the wing nut , and then
pull the air filter element off of
the guide.
5. Remove the sponge material
from the air filter element frame.
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 A. (See page 6-6
for removal and installation procedures.)
2. Remove the air filter case cover
by removing the screws.
6-14
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Page 57
PERIODIC MAINTENANCE AND MINOR REPAIR
1
3
2
4
8. Install the sponge material onto
the frame, place the air filter element in the original position on
the guide, and then tighten the
wing nut.
9. Insert the air filter element into
the air filter case.
EC000082
cC
6. Clean the sponge material with
solvent, and then squeeze the
remaining solvent out.
7. Apply oil of the recommended
type to the entire surface of the
sponge material, and then
squeeze the excess oil out.
NOTE:
The sponge material should be wet
but not dripping.
8 Make sure that the air filter element is properly seated in the
air filter case.
8 The engine should never be
operated without the air filter
element installed, otherwise
the piston(s) and/or cylinder(s)
may
become
excessively
worn.
10. Install the air filter case cover by
installing the screws.
11. Install the panel.
Recommended oil:
2-stroke engine oil
6-15
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.
cC
1
2
3
4
5
EC000094
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
7
8
9
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Page 58
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU01168
1
Adjusting the engine idling
speed
1
2
3
4
The engine idling speed must be
checked and, if necessary, adjusted
as follows at the intervals specified in
the periodic maintenance and lubrication chart.
NOTE:
A diagnostic tachometer is needed to
make this adjustment.
5
6
7
8
9
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
responds to the throttle.
a
a
b
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.
Engine idling speed:
1,300–1,400 r/min
NOTE:
If the specified idling speed cannot
be obtained as described above,
have a Yamaha dealer make the
adjustment.
6-16
a. Throttle cable free play
EAU00634
Adjusting the throttle cable
free play
The throttle cable free play should
measure 3–5 mm at the throttle grip.
Periodically check the throttle cable
free play and, if necessary, adjust it
as follows.
NOTE:
The engine idling speed must be correctly adjusted before checking and
adjusting the throttle cable free play.
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Page 59
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU03593
1
Tire air pressure
(measured on cold tires)
Tires
2
To maximize the performance, durability, and safe operation of your
motorcycle, note the following points
regarding the specified tires.
b
a
1. Adjusting nut
2. Locknut
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.
Tire air pressure
The tire air pressure should be
checked and, if necessary, adjusted
before each ride.
Load*
Front
Rear
Up to 88 kg
125 kPa
1.25 kg/cm2
1.25 bar
150 kPa
1.50 kg/cm2
1.50 bar
1
88 kg–
maximum
150 kPa
1.50 kg/cm2
1.50 bar
175 kPa
1.75 kg/cm2
1.75 bar
2
3
Maximum load*
180 kg
* Total weight of rider, passenger, cargo and
accessories
4
EW000082
w
5
8 The tire air pressure must be
checked and adjusted on cold
tires (i.e., when the temperature of the tires equals the
ambient temperature).
8 The tire air pressure must be
adjusted in accordance with
the riding speed and with the
total weight of rider, passenger, cargo, and accessories
approved for this model.
6-17
6
7
8
9
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PERIODIC MAINTENANCE AND MINOR REPAIR
w
1
2
3
4
5
6
7
8
9
EWA00012
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.
8 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.
8 Do not carry along loosely
packed items, which can shift
during a ride.
8 Securely pack the heaviest
items close to the center of the
motorcycle and distribute the
weight evenly on both sides.
8 Adjust the suspension and tire
air pressure with regard to the
load.
8 Check the tire condition and
air pressure before each ride.
a
2
1
1. Side wall
2. Wear indicator
a. 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.
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.
6-18
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PERIODIC MAINTENANCE AND MINOR REPAIR
w
EW000079
8 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.
8 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
w
8 The front and rear tires should
be of the same make and
design, otherwise the handling
characteristics of the motorcycle cannot be guaranteed.
8 After extensive tests, only the
tires listed below have been
approved for this model by
Yamaha Motor Co., Ltd.
FRONT
Manufacturer
Size
Type
INOUE
3.00-21 51P
GP-21F
CHENG SHIN
3.00-21 51P
M-6033
REAR
Manufacturer
Size
Type
INOUE
4.60-18 63P
GP-22R
CHENG SHIN
4.60-18 63P
M-6034
w
EAU00680
8 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.
8 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.
8 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 high-quality product.
1
2
3
4
5
6
7
8
9
6-19
4TP-9-21
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PERIODIC MAINTENANCE AND MINOR REPAIR
EAU00685
Spoke wheels
1
2
3
4
5
6
7
8
9
To maximize the performance, durability, and safe operation of your
motorcycle, note the following points
regarding the specified wheels.
8 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.
8 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.
8 Ride at moderate speeds after
changing a tire since the tire surface must first be “broken in” for
it to develop its optimal characteristics.
a
a. Clutch lever free play
EAU02996
Adjusting the clutch lever
free play
The clutch lever free play should
measure 10–15 mm as shown.
Periodically check the clutch lever
free play and, if necessary, adjust it
as follows.
6-20
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Page 63
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2 a
b
1.
2.
3.
4.
3 4 a
b
Locknut (Clutch lever)
Adjusting bolt
Locknut (Clutch cable)
Adjusting nut
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.
1
2
c
b
1
2
a
3
1. Locknut
2. Adjusting bolt
c. Brake lever free play
4
EAU00696
Adjusting the brake lever
free play
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 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.
The brake lever free play should
measure 2–5 mm as shown.
Periodically check the brake lever
free play and, if necessary, adjust it
as follows.
1. Loosen the locknut at the brake
lever.
2. To increase the brake lever free
play, turn the adjusting bolt in
direction a. To decrease the
brake lever free play, turn the
adjusting bolt in direction b.
3. Tighten the locknut.
6-21
5
6
7
8
9
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PERIODIC MAINTENANCE AND MINOR REPAIR
w
1
2
3
4
5
6
7
8
EW000099
8 After adjusting the brake lever
free play, check the free play
and make sure that the brake
is working properly.
8 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.
w
1
a
1. Footrest
a. Brake pedal position
EAU00712
Adjusting the brake pedal
position
The top of the brake pedal should be
positioned approximately 15 mm
below the top of the footrest as
shown. Periodically check the brake
pedal position and, if necessary,
have a Yamaha dealer adjust it.
9
6-22
EW000109
A soft or spongy feeling in the
brake pedal 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.
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Page 65
PERIODIC MAINTENANCE AND MINOR REPAIR
FRONT
1
REAR
1
1
1
2
a
2
b
3
1. Brake light switch
2. Adjusting nut
1. Indicator groove
1. Indicator groove
EAU01314
EAU00713
Adjusting the rear brake light
switch
The rear brake light switch, which is
activated by the brake pedal, is properly adjusted when the brake light
comes on just before braking takes
effect. If necessary, adjust the brake
light switch as follows.
Turn the adjusting nut while holding
the rear brake light switch in place.
To make the brake light come on earlier, turn the adjusting nut in direction
a. To make the brake light come on
later, turn the adjusting nut in direction b.
Checking the front and rear
brake pads
The front and rear brake pads must
be checked for wear at the intervals
specified in the periodic maintenance
and lubrication chart. Each brake pad
is provided with a wear indicator
groove, which allows you to check
the brake pad wear without having to
disassemble the brake.
6-23
To check the brake pad wear, check
the wear indicator grooves. If a brake
pad has worn to the point that the
wear indicator groove has almost disappeared, have a Yamaha dealer
replace the brake pads as a set.
4
5
6
7
8
9
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PERIODIC MAINTENANCE AND MINOR REPAIR
FRONT
REAR
1
1
1
2
3
4
1. Minimum level mark
1. Minimum level mark
EAU03196
5
6
7
8
9
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.
Observe these precautions:
8 When checking the fluid level,
make sure that the top of the
master cylinder or brake fluid
reservoir is level.
8 Use only the recommended quality brake fluid, otherwise the rubber seals may deteriorate, causing leakage and poor braking
performance.
Recommended brake fluid:
DOT 4
6-24
8 Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking performance.
8 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.
8 Brake fluid may deteriorate painted surfaces or plastic parts.
Always clean up spilled fluid
immediately.
8 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.
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Page 67
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU03073
EAU00744
Changing the brake fluid
Drive chain slack
Have a Yamaha dealer change the
brake fluid at the intervals specified in
the periodic maintenance and lubrication chart. In addition, have the oil
seals of the master cylinder and
caliper as well as the brake hoses
replaced at the intervals listed below
or whenever they are damaged or
leaking.
8 Oil seals: Replace every two
years.
8 Brake hoses: Replace every four
years.
The drive chain slack should be
checked before each ride and adjusted if necessary.
1
2
To check the drive chain slack
1. Place the motorcycle on a level
surface and hold it in an upright
position.
NOTE:
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.
a
a. Drive chain slack
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:
40–60 mm
4. If the drive chain slack is incorrect, adjust it as follows.
6-25
3
4
5
6
7
8
9
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PERIODIC MAINTENANCE AND MINOR REPAIR
1
a
b
2
3
4
1. Axle nut
2. Chain adjusting plate
EAU03594
5
6
7
8
9
To adjust the drive chain slack
1. Loosen the axle nut.
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.
EAU03006
Lubricating the drive chain
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.
1
2
EC000096
cC
3. Tighten the axle nut to the specified torque.
Tightening torque:
Axle nut:
104 Nm (10.4 m0kg)
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.
cC
EC000097
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.
cC
ECA00053
To prevent damaging the O-rings,
do not clean the drive chain with
steam cleaners, high-pressure
washers or inappropriate solvents.
NOTE:
Make sure that both adjusting plates
are in the same position for proper
wheel alignment.
2. Wipe the drive chain dry.
6-26
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PERIODIC MAINTENANCE AND MINOR REPAIR
3. Thoroughly lubricate the drive
chain with a special O-ring chain
lubricant.
cC
w
EW000112
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.
ECA00052
Do not use engine oil or any other
lubricants for the drive chain, as
they may contain substances that
could damage the O-rings.
1
2
3
4
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
6-27
5
6
7
8
9
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Page 70
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU03209
Checking and lubricating the
throttle grip and cable
1
2
3
4
5
6
7
8
9
The operation of the throttle grip and
the condition of the throttle cable
should be checked before each ride,
and the cable should be lubricated or
replaced if necessary.
NOTE:
Since the throttle grip must be
removed to access the throttle cable
end, the throttle grip and the cable
should always be lubricated at the
same time.
4. Grease the metal-to-metal contact surface of the throttle grip,
and then install the grip by
installing the screws.
Recommended lubricant:
Throttle cable:
Engine oil
Throttle grip housing and grip:
Lithium-soap-based grease
(all-purpose grease)
1. Remove the throttle grip by
removing the screws.
2. Disconnect the throttle cable,
hold it up, and then apply several
drops of oil to the cable end,
allowing it to trickle into the
sheath.
3. Connect the throttle cable, and
then grease the inside of the
throttle grip housing.
6-28
EAU00774
Adjusting the Autolube
pump
The Autolube pump is a vital and
sophisticated component of the
engine, which must be adjusted by a
Yamaha dealer at the intervals specified in the periodic maintenance and
lubrication chart.
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Page 71
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
EAU03370
EAU03164
EAU03165
Checking and lubricating the
brake and shift pedals
Checking and lubricating the
brake and clutch levers
Checking and lubricating the
sidestand
The operation of the brake and shift
pedals should be checked before
each ride, and the pedal pivots
should be lubricated if necessary.
The operation of the brake and clutch
levers should be checked before
each ride, and the lever pivots should
be lubricated if necessary.
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.
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
w
6
7
EW000113
If the sidestand does not move up
and down smoothly, have a
Yamaha dealer check or repair it.
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
6-29
5
8
9
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Page 72
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU02939
1
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.
1
2
3
To check the condition
4
1. Grease nipple (×2)
EAU00790
5
6
7
8
Lubricating the rear
suspension
The pivoting points of the rear suspension must be lubricated at the
intervals specified in the periodic
maintenance and lubrication chart.
EW000115
w
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.
Recommended lubricant:
Molybdenum disulfide grease
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.
cC
9
EC000098
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or
repair it.
6-30
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Page 73
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU00794
EAU01144
Checking the steering
Checking the wheel bearings
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.
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.
w
EW000115
Securely support the motorcycle
so that there is no danger of it
falling over.
1
2
3
4
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.
5
6
7
8
9
6-31
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Page 74
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
5
6
7
1. Battery
EAU00800
Battery
This motorcycle is equipped with a
sealed-type (MF) battery, which does
not require any maintenance. There
is no need to check the electrolyte or
to add distilled water.
EC000101
8
cC
9
EW000116
w
1
Never attempt to remove the battery cell seals, as this would permanently damage the battery.
8 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.
8 EXTERNAL:
Flush
with
plenty of water.
8 INTERNAL:
Drink
large
quantities of water or milk
and immediately call a
physician.
8 EYES: Flush with water for
15 minutes and seek prompt
medical attention.
8 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.
6-32
8 KEEP THIS AND ALL BATTERIES OUT OF THE REACH OF
CHILDREN.
To charge the battery
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 motorcycle
is equipped with optional electrical
accessories.
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PERIODIC MAINTENANCE AND MINOR REPAIR
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 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.
EC000102
cC
1
8 Always keep the battery
charged. Storing a discharged
battery can cause permanent
battery damage.
8 To charge a sealed-type (MF)
battery, a special (constantvoltage) battery charger is
required. Using a conventional
battery charger will damage
the battery. If you do not have
access to a sealed-type (MF)
battery
charger,
have
a
Yamaha dealer charge your
battery.
1
2
3
1. Fuse
2. Spare fuse
4
EAU00804
Replacing the fuse
If the fuse is blown, replace it as follows.
1. Turn the key 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:
30A
6-33
2
5
6
7
8
9
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PERIODIC MAINTENANCE AND MINOR REPAIR
cC
1
2
EC000103
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
4
5
6
3. Turn the key 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.
EAU03592
Replacing the headlight bulb
1
This motorcycle is equipped with a
quartz bulb headlight. If the headlight
bulb burns out, replace it as follows:
1. Remove cowling A together with
the headlight unit. (See page 6-5
for cowling removal and installation procedures.)
1. Headlight coupler
2. Disconnect the headlight coupler, and then remove the headlight bulb cover.
7
8
9
6-34
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PERIODIC MAINTENANCE AND MINOR REPAIR
1
1
a
1
2
3
1. Headlight bulb cover
1. Headlight bulb holder
a. Do not touch this area
3. Unhook the headlight bulb holder, and then remove the defective bulb.
EW000119
w
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.
4. Put a new bulb into position, and
then secure it with the bulb holder.
6-35
cC
4
EC000106
Avoid touching the glass part of
the bulb. Keep it free from oil; otherwise, the transparency of the
glass, life of the bulb, and luminous flux will be adversely affected. If oil gets on the bulb, thoroughly clean it with a cloth
moistened with alcohol or lacquer
thinner.
5. Install the bulb cover, and then
connect the coupler.
5
6
7
8
9
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PERIODIC MAINTENANCE AND MINOR REPAIR
1
6. Install the cowling together with
the headlight unit.
7. Have a Yamaha dealer adjust
the headlight beam if necessary.
1
2
1
2
3
4
1. Screw
2. Lens
1. Bulb
5
Replacing a turn signal light
bulb
EAU03497
6
1. Remove the turn signal light lens
by removing the screw.
7
8
2. Remove the defective bulb by
pushing it in and turning it counterclockwise.
3. Insert a new bulb into the socket,
push it in, and then turn it clockwise until it stops.
4. Install the lens by installing the
screw.
cC
ECA00065
Do not overtighten the screw, otherwise the lens may break.
9
6-36
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PERIODIC MAINTENANCE AND MINOR REPAIR
1
1
1
2
2
1
3
1. Screw (×2)
2. Lens
1. Bulb
EAU01623
Replacing the tail/brake light
bulb
1. Remove the tail/brake light lens
by removing the screws.
1. Nut (×2)
2. Remove the defective bulb by
pushing it in and turning it counterclockwise.
3. Insert a new bulb into the socket,
push it in, and then turn it clockwise until it stops.
4. Install the lens by installing the
screws.
4
EAU01624
Replacing the license plate
light bulb
1. Remove the license plate light by
removing the nuts.
5
6
7
EC000108
8
Do not overtighten the screws,
otherwise the lens may break.
9
cC
6-37
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PERIODIC MAINTENANCE AND MINOR REPAIR
EAU01579
1
1
2
1
3
4
5
6
7
1. Nut (×2)
2. Remove the license plate light
lens by removing the nuts.
1. Bulb (×2)
3. Remove the defective bulb by
pulling it out.
4. Insert a new bulb into the socket.
5. Install the lens by installing the
nuts.
6. Install the license plate light by
installing the nuts.
8
9
6-38
Supporting the motorcycle
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.
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PERIODIC MAINTENANCE AND MINOR REPAIR
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.
3. Pull the wheel axle out, and then
remove the wheel.
cC
1
ECA00048
Do not apply the brake after the
wheel has been removed together
with the brake disc, otherwise the
brake pads will be forced shut.
2
1. Axle holder nut (×4)
2. Wheel axle
1
2
3
4
EAU00879
Front wheel
5
To remove the front wheel
EW000122
w
6
8 It is advisable to have a
Yamaha dealer service the
wheel.
8 Securely support the motorcycle so that there is no danger
of it falling over.
1. Loosen the wheel axle holder
nuts, then the wheel axle.
2. Lift the front wheel off the ground
according to the procedure on
page 6-38.
6-39
7
8
9
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PERIODIC MAINTENANCE AND MINOR REPAIR
EAU03678
1
To install the front wheel
1. Lift the wheel up between the
fork legs and guide the brake
disc between the brake pads.
2
3
4
5
6
7
8
9
NOTE:
Make sure that there is enough
space between the brake pads
before inserting the brake disc.
2. Insert the wheel axle.
3. Lower the front wheel so that it is
on the ground.
4. Tighten the wheel axle to the
specified torque.
NOTE:
Tighten the upper nuts first, and then
the lower ones. When the nuts are
tightened in this sequence, there
should be a gap at the bottom of the
axle holder.
Tightening torque:
Axle holder nut:
10 Nm (1.0 m0kg)
5. Push down hard on the handlebar several times to check for
proper fork operation.
1
1. Axle nut
EAU03588
Rear wheel
To remove the rear wheel
w
EW000122
8 It is advisable to have a
Yamaha dealer service the
wheel.
8 Securely support the motorcycle so that there is no danger
of it falling over.
Tightening torque:
Wheel axle:
58 Nm (5.8 m0kg)
5. Tighten the axle holder nuts to
the specified torque.
1. Loosen the axle nut.
2. Lift the rear wheel off the ground
according to the procedure on
page 6-38.
6-40
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PERIODIC MAINTENANCE AND MINOR REPAIR
EAU01806
To install the rear wheel
1. Install the drive chain onto the
rear sprocket, and then insert the
wheel axle from the left side.
1
1
2
1. Swingarm end bolt (×2)
3. Remove the swingarm end bolt
from each end of the swingarm.
4. Push the wheel forward, and
then remove the drive chain from
the rear sprocket.
NOTE:
The drive chain does not need to be
disassembled in order to remove and
install the rear wheel.
5. Remove the wheel.
ECA00048
cC
Do not apply the brake after the
wheel has been removed together
with the brake disc, otherwise the
brake pads will be forced shut.
6-41
NOTE:
Make sure that there is enough
space between the brake pads
before inserting the brake disc
between the pads.
2. Install the swingarm end bolts,
and then lower the rear wheel so
that it is on the ground.
3. Adjust the drive chain slack.
(See page 6-26 for drive chain
slack adjustment procedures.)
4. Tighten the axle nut and
swingarm end bolts to the specified torques.
Tightening torque:
Axle nut:
103 Nm (10.3 m0kg)
Swingarm end bolts:
3 Nm (0.3 m0kg)
3
4
5
6
7
8
9
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Page 84
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU03087
Troubleshooting
1
2
3
4
5
6
7
8
9
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 charts
represent quick and easy procedures
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.
6-42
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Page 85
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU01581
Troubleshooting charts
Starting problems or poor engine performance
EW000125
w
1
Keep away open flames and do not smoke while checking or working on the fuel system.
2
1. Fuel
3
Enough fuel.
Go to compression check.
No fuel.
Supply fuel.
Check if there is fuel
in the fuel tank.
2. Compression
4
Engine doesn’t start, go to
compression check.
5
There is compression.
Go to ignition check.
No compression.
Ask a Yamaha dealer to inspect.
Use electric starter.
6
3. Ignition
Remove spark
plug and check
electrodes.
Wet.
Wipe clean with dry cloth and correct
spark gap or replace spark plug.
Dry.
Ask a Yamaha dealer to inspect.
Open throttle half-way and start
the engine.
7
8
Engine doesn’t start, go to battery
check.
4. Battery
Engine turns over
quickly.
Battery good.
Engine turns over
slowly.
Check connections or
recharge.
Engine doesn’t start, ask a
Yamaha dealer to inspect.
Use electric starter.
6-43
9
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Page 86
PERIODIC MAINTENANCE AND MINOR REPAIR
Engine overheating
EW000070
w
1
2
3
8 Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be
blown out under pressure, which could cause serious injury. Be sure to wait until the engine has cooled.
8 After removing the radiator cap retaining bolt, place a thick rag, like a towel, over the radiator cap, and then
slowly rotate the cap counterclockwise to the detent to allow any residual pressure to escape. When the
hissing sound has stopped, press down on the cap while turning it counterclockwise, and then remove the
cap.
4
5
Level is low, check the
cooling system for leakage.
6
7
Wait until the engine
has cooled.
Check the coolant level in the
reservoir tank and/or radiator.
Level is OK.
8
9
Leakage.
Ask a Yamaha dealer to inspect
and repair the cooling system.
No
leakage.
Add coolant (See NOTE.)
Restart the engine. If the engine overheats again, ask a
Yamaha dealer to inspect and repair the cooling system.
NOTE:
If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommended
coolant as soon as possible.
6-44
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Page 87
EAU03521
MOTORCYCLE CARE AND STORAGE
Care
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. Cover the muffler outlet with a
plastic bag after the engine has
cooled down.
2. Make sure that all caps and covers as well as all electrical couplers and connectors, including
the spark plug cap, are tightly
installed.
3. 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
cC
ECA00010
8 Avoid using strong acidic
wheel cleaners, especially on
spoked wheels. If such products are used on hard-toremove dirt, do not leave the
cleaner on the affected area
any longer than instructed.
Also, thoroughly rinse the area
off with water, immediately dry
it, and then apply a corrosion
protection spray.
8 Improper cleaning can damage
windshields, cowlings, panels
and other plastic parts. Use
only a soft, clean cloth or
sponge with mild detergent
and water to clean plastic.
1
2
3
4
5
6
7
8
9
7-1
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Page 88
MOTORCYCLE CARE AND STORAGE
1
2
3
4
5
6
7
8
9
8 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, fuel (gasoline),
rust removers or inhibitors,
brake fluid, antifreeze or electrolyte.
8 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.
8 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
windshield. Test the product
on 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.
7-2
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.
NOTE:
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.
cC
ECA00012
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.
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Page 89
MOTORCYCLE CARE AND STORAGE
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.)
4. To prevent corrosion, it is recommended to apply a corrosion protection spray on all metal, including chrome- and nickel-plated,
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.
EWA00001
w
8 Make sure that there is no oil
or wax on the brakes or tires.
If 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.
8 Before operating the motorcycle test its braking performance and cornering behavior.
cC
ECA00013
8 Apply spray oil and wax sparingly and make sure to wipe
off any excess.
8 Never apply oil or wax to any
rubber and plastic parts, but
treat them with a suitable care
product.
8 Avoid using abrasive polishing compounds as they will
wear away the paint.
NOTE:
Consult a Yamaha dealer for advice
on what products to use.
1
2
3
4
5
6
7
8
9
7-3
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Page 90
MOTORCYCLE CARE AND STORAGE
Storage
2
Short-term
Always store your motorcycle in a
cool, dry place and, if necessary, protect it against dust with a porous
cover.
3
cC
1
4
5
6
7
8
9
ECA00014
8 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.
8 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”.
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.
7-4
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.
w
EWA00003
To prevent damage or injury from
sparking, make sure to ground the
spark plug electrodes while turning the engine over.
4TP-9-21
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Page 91
MOTORCYCLE CARE AND STORAGE
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 0°C or more
than 30°C). For more information
on storing the battery, see page
6-33.
1
2
3
4
NOTE:
Make any necessary repairs before
storing the motorcycle.
5
6
7
8
9
7-5
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Page 92
EAU01038
SPECIFICATIONS
Specifications
1
2
3
4
5
6
Model
Engine oil
DT230(N)
Type
Dimensions
Overall length
Overall width
Overall height
1,410 mm
Minimum turning radius
1.3 L
Transmission oil
1,200 mm
Wheel base
Basic weight
(with oil and full fuel tank)
Total amount
800 mm
865 mm
Ground clearance
Capacity
2,225 mm
Seat height
2-stroke engine oil
Type
SAE 10W30 type SE motor oil
Capacity
300 mm
2,100 mm
Periodic oil change
0.8 L
Total amount
0.85 L
Cooling system capacity
133 kg
Engine
Engine type
Liquid cooled 2-stroke
7
Cylinder arrangement
Forward inclined single
cylinder
8
Displacement
224 cm3
Bore × Stroke
66.8 × 64.0 mm
9
Compression ratio
6.5:1
Starting system
Electric starter
Lubrication system
Separate lubrication
(Yamaha autolube)
(total amount)
1.26 L
Air filter
Wet type element
Fuel
Type
Regular gasoline
(except for Australia)
Unleaded fuel only
(for Australia)
Fuel tank capacity
11 L
Reserve amount
2L
Carburetor
8-1
Manufacturer
MIKUNI
Model×quantity
TM30×1
4TP-9-21
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Page 93
SPECIFICATIONS
Spark plug
Tires
Manufacturer/model
NGK/BR9ES
Type
Gap
0.7–0.8 mm
Front
Clutch type
Wet, multiple-disc
Transmission
Primary reduction system
Helical gear
Primary reduction ratio
54/21 (2.571)
Secondary reduction system
Chain drive
Secondary reduction ratio
3.437
Number of drive chain
sprocket teeth (rear/front)
55/16
Transmission type
Constant mesh 6-speed
Operation
Gear ratio
3.00-21 51P
Manufacturer/
model
INOUE/GP-21F
CHENG SHIN/M-6033
3
Size
4.60-18 63P
4
Manufacturer/
model
INOUE/GP-22R
CHENG SHIN/M-6034
Air pressure (cold tire)
6
up to 88 kg load*
Front
125 kPa (1.25 kg/cm2, 1.25 bar)
Rear
150 kPa (1.50 kg/cm2, 1.50 bar)
1.875
3rd
1.411
88 kg load–Maximum
load*
4th
1.142
Front
150 kPa (1.50 kg/cm2, 1.50 bar)
5th
0.956
Rear
175 kPa (1.75 kg/cm2, 1.75 bar)
6th
0.818
27°
Trail
114 mm
8-2
7
8
* Load is total weight of cargo, rider, passenger and accessories.
Chassis
Semi double cradle
5
180 kg
2nd
Caster angle
2
Size
Maximum load*
2.750
Frame type
1
Rear
Left foot
1st
With tube
9
4TP-9-21
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Page 94
SPECIFICATIONS
1
Front
2
3
4
5
Type
Spoke wheel
Size
1.60 × 21
Type
Spoke wheel
Size
2.15 × 18
Rear
Coil-gas spring/oil damper
Front
250 mm
Rear
240 mm
Ignition system
C.D.I.
Charging system
Front
Type
C.D.I. magneto
Standard output
14 V, 12 A @5,000 r/min
Type
GT6B-3
Voltage, capacity
12 V, 6 AH
Type
Single disc brake
Operation
Right hand
Fluid
DOT 4
Type
Single disc brake
Operation
Right foot
Headlight type
Fluid
DOT 4
Bulb voltage, wattage × quantity
Battery
Rear
Suspension
9
Coil spring/oil damper
Electrical system
Brakes
8
Front
Wheel travel
Rear
6
7
Spring/shock absorber
Wheels
Front
Telescopic fork
Rear
Swingarm
(new monocross)
8-3
Halogen bulb
Headlight
12 V, 60/55W × 1
Tail/brake light
12 V, 5/21W × 1
Front turn signal light
12 V, 21W × 2
Rear turn signal light
12 V, 21W × 2
Licence plate light
12 V, 5W × 2
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Page 95
SPECIFICATIONS
Neutral indicator light
12 V, 3W × 1
High beam indicator light
12 V, 3W × 1
Turn signal indicator light
12 V, 3W × 1
Oil level/coolant temperature
warning light
LED
Fuse
1
2
3
30A
4
5
6
7
8
9
8-4
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Page 96
SPECIFICATIONS
EAU01064
Conversion table
CONVERSION TABLE
2
All specification data in this manual are listed in SI and
METRIC UNITS.
Use this table to convert METRIC unit data to
IMPERIAL unit data.
3
Ex.
1
METRIC TO IMPERIAL
Metric unit
Multiplier
Imperial unit
Torque
m • kg
m • kg
cm • kg
cm • kg
7.233
86.794
0.0723
0.8679
ft • lb
in• lb
ft • lb
in • lb
Weight
kg
g
2.205
0.03527
lb
oz
Speed
km/hr
0.6214
mph
Distance
km
m
m
cm
mm
0.6214
3.281
1.094
0.3937
0.03937
mi
ft
yd
in
in
6
Volume/
Capacity
cc (cm3)
cc (cm3)
L (liter)
L (liter)
0.03527
0.06102
0.8799
0.2199
oz (IMP liq.)
cu • in
qt (IMP liq.)
gal (IMP liq.)
7
Misc.
kg/mm
kg/cm2
Centigrade (°C)
55.997
14.2234
9/5 + 32
lb/in
psi (lb/in2)
Fahrenheit (°F)
4
5
METRIC
** mm
2 mm
MULTIPLIER
×
×
0.03937
0.03937
IMPERIAL
=
=
** in
0.08 in
8
9
8-5
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Page 97
EAU01039
CONSUMER INFORMATION
EAU02944
Identification numbers
Record the key identification number,
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.
1. KEY IDENTIFICATION
NUMBER:
2. VEHICLE IDENTIFICATION
NUMBER:
1
1
2
1
3
1. Key identification number
1. Vehicle identification number
EAU01041
4
EAU01043
Key identification number
Vehicle identification number
The key identification number is
stamped into the key tag.
Record this number in the space provided and use it for reference when
ordering a new key.
The vehicle identification number is
stamped into the steering head pipe.
Record this number in the space provided.
1
6
9-1
6
7
NOTE:
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.
3. MODEL LABEL INFORMATION:
5
8
9
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Page 98
CONSUMER INFORMATION
EAU01388
Motorcycle noise regulation
(for Australia)
1
1
2
3
4
1. Model label
EAU01049
5
6
7
8
9
Model label
The model label is affixed to the location shown in the figure. Record the
information on this label in the space
provided. This information will be
needed when ordering spare parts
from a Yamaha dealer.
TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED:
Owners are warned that the law may
prohibit:
(a) 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; and
(b) The use of the vehicle after such
device or element of design has
been removed or rendered inoperative by any person.
9-2
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Page 99
1
2
3
4
5
6
7
8
9
4TP-9-21
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Page 100
OWNER’S MANUAL
DT230(N)
YAMAHA MOTOR CO., LTD.
PRINTED ON RECYCLED PAPER
PRINTED IN JAPAN
2000·7–0.1×1(E) !
4TP-28199-21