XT225T/TC Owner`s Manual

XT225T/TC Owner`s Manual

5RK-9-13_hyoushi 4/9/04 2:49 PM Page 1

PRINTED ON RECYCLED PAPER

YAMAHA MOTOR CO., LTD.

PRINTED IN JAPAN

2002·5–0.6

×

1(E)

!

(E)

LIT-11626-18-25

OWNER’S MANUAL

XT225T

XT225TC

5RK-28199-13

5RK-9-13_hyoushi2&3 4/9/04 2:50 PM Page 1

INTRODUCTION

EAU10080

Congratulations on your purchase of the Yamaha XT225/XT225C. This model is the result of Yamaha’s vast experience in the production of fine sporting, touring, and pacesetting racing machines. It represents the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields.

This manual will give you an understanding of the operation, inspection, and basic maintenance of this motorcycle. If you have any questions concerning the operation or maintenance of your motorcycle, please consult a Yamaha dealer.

The design and manufacture of this Yamaha motorcycle fully comply with the emissions standards for clean air applicable at the date of manufacture. Yamaha has met these standards without reducing the performance or economy of operation of the motorcycle. To maintain these high standards, it is important that you and your Yamaha dealer pay close attention to the recommended maintenance schedules and operating instructions contained within this manual.

IMPORTANT MANUAL INFORMATION

EAU10130

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

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

INVOLVED!

WARNING

CAUTION:

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.

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.

NOTE:

This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold.

Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most current product information available at the time of printing, there may be minor discrepancies between your motorcycle and this manual. If you have any questions concerning this manual, please consult your Yamaha dealer.

EWA10010

WARNING

PLEASE READ THIS MANUAL AND THE “YOU AND YOUR MOTORCYCLE: RIDING TIPS” BOOKLET CAREFULLY

AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE. DO NOT ATTEMPT TO OPERATE THIS MOTORCY-

CLE UNTIL YOU HAVE ATTAINED ADEQUATE KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES

AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES. REGULAR INSPECTIONS

AND CAREFUL MAINTENANCE, ALONG WITH GOOD RIDING SKILLS, WILL ENSURE THAT YOU SAFELY ENJOY

THE CAPABILITIES AND THE RELIABILITY OF THIS MOTORCYCLE.

IMPORTANT MANUAL INFORMATION

EAU10192

AFFIX DEALER

LABEL HERE

XT225T/XT225TC

OWNER’S MANUAL

©2004 by Yamaha Motor Corporation, U.S.A.

1st edition, April 2004

All rights reserved.

Any reprinting or unauthorized use without the written permission of

Yamaha Motor Corporation, U.S.A. is expressly prohibited.

Printed in Japan.

P/N LIT-11626-18-25

TABLE OF CONTENTS

SAFETY INFORMATION

...................1-1

Location of important labels .............1-5

DESCRIPTION

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

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

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

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

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

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

Parking ............................................ 5-4

INSTRUMENT AND CONTROL

FUNCTIONS

........................................3-1

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

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

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

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

Clutch lever ......................................3-4

Shift pedal ........................................3-4

Brake lever ......................................3-4

Brake pedal .....................................3-5

Fuel tank cap ...................................3-5

Fuel ..................................................3-6

Fuel cock .........................................3-7

Starter (choke) knob “

1

” .................3-8

Seat .................................................3-8

Helmet holder ..................................3-9

Adjusting the shock absorber assembly ......................................3-9

Sidestand .......................................3-11

Ignition circuit cut-off system .........3-12

PRE-OPERATION CHECKS

...............4-1

Pre-operation check list ...................4-2

PERIODIC MAINTENANCE AND

MINOR REPAIR

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

PERIODIC MAINTENANCE ............ 6-1

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

Periodic maintenance chart for the emission control system .............. 6-3

General maintenance and lubrication chart ........................... 6-5

Removing and installing the cowling and panels ...................... 6-9

Checking the spark plug ................ 6-10

Canister (for California only) ......... 6-11

Engine oil and oil filter element ..... 6-12

Cleaning the air filter element ....... 6-15

Cleaning the spark arrester ........... 6-16

Adjusting the carburetor ................ 6-17

Adjusting the throttle cable free play ............................................ 6-18

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

Tires .............................................. 6-18

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

Accessories and replacement parts ........................................... 6-21

Adjusting the clutch lever free play ............................................ 6-22

Adjusting the brake lever free play ............................................ 6-23

Adjusting the brake pedal position and free play .............................. 6-23

Adjusting the rear brake light switch ......................................... 6-25

Checking the front brake pads and rear brake shoes ................ 6-25

Checking the brake fluid level ....... 6-26

Changing the brake fluid ............... 6-27

Drive chain slack ........................... 6-27

Lubricating the drive chain ............ 6-29

Checking and lubricating the cables ........................................ 6-29

Checking and lubricating the throttle grip and cable ................ 6-30

Checking and lubricating the brake and shift pedals ............... 6-30

Checking and lubricating the brake and clutch levers .............. 6-30

Checking and lubricating the sidestand ................................... 6-31

Lubricating the rear suspension .... 6-31

Checking the front fork .................. 6-31

Checking the steering ................... 6-32

Checking the wheel bearings ........ 6-33

Battery ........................................... 6-33

Replacing the fuse .........................6-34

Replacing the headlight bulb .........6-35

Replacing the tail/brake light bulb ............................................6-36

Replacing a turn signal light bulb ............................................6-37

Supporting the motorcycle .............6-37

Front wheel ....................................6-38

Rear wheel ....................................6-40

Troubleshooting .............................6-41

Troubleshooting chart ....................6-42

MOTORCYCLE CARE AND

STORAGE

...........................................7-1

Care .................................................7-1

Storage ............................................7-3

SPECIFICATIONS

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

CONSUMER INFORMATION

..............9-1

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

Reporting safety defects ..................9-3

Motorcycle noise regulation .............9-4

Maintenance record .........................9-5

YAMAHA MOTOR CORPORATION,

U.S.A. STREET AND ENDURO

MOTORCYCLE LIMITED

WARRANTY .................................9-7

YAMAHA EXTENDED SERVICE

(Y.E.S.) ........................................9-9

TABLE OF CONTENTS

1

SAFETY INFORMATION

EAU10310

MOTORCYCLES ARE SINGLE

TRACK VEHICLES. THEIR SAFE

USE AND OPERATION ARE DEPEN-

DENT UPON THE USE OF PROPER

RIDING TECHNIQUES AS WELL AS

THE EXPERTISE OF THE OPERA-

TOR. EVERY OPERATOR SHOULD

KNOW THE FOLLOWING REQUIRE-

MENTS BEFORE RIDING THIS MO-

TORCYCLE.

HE OR SHE SHOULD:

OBTAIN THOROUGH INSTRUC-

TIONS FROM A COMPETENT

SOURCE ON ALL ASPECTS OF

MOTORCYCLE OPERATION.

OBSERVE THE WARNINGS

AND MAINTENANCE REQUIRE-

MENTS IN THE OWNER’S MAN-

UAL.

OBTAIN QUALIFIED TRAINING

IN SAFE AND PROPER RIDING

TECHNIQUES.

OBTAIN PROFESSIONAL TECH-

NICAL SERVICE AS INDICATED

BY THE OWNER’S MANUAL

AND/OR WHEN MADE NECES-

SARY BY MECHANICAL CONDI-

TIONS.

Safe riding

● Always make pre-operation checks. Careful checks may help prevent an accident.

This motorcycle is designed to carry the operator and a passenger.

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:

Wear a brightly colored jacket.

Use extra caution when approaching and passing through intersections, since intersections are the most likely places for motorcycle accidents to occur.

1-1

Ride where other motorists can see you. Avoid riding in another motorist’s blind spot.

Many accidents involve inexperienced operators. In fact, many operators who have been involved in accidents do not even have a cur-

● rent motorcycle license.

Make sure that you are qualified and that you only lend your motorcycle to other qualified operators.

Know your skills and limits.

Staying within your limits may help you to avoid an accident.

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.

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 un-

● dercornering (insufficient lean an-

● gle for the speed).

Always obey the speed limit and never travel faster than warranted by road and traffic conditions.

Always signal before turning or changing lanes. Make sure that

● other motorists can see you.

The posture of the operator and passenger is important for proper control.

The operator should keep both hands on the handlebar and both feet on the operator footrests during operation to main-

● tain control of the motorcycle.

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.

Never carry a passenger unless he or she can firmly place both feet on the passenger footrests.

Never ride under the influence of alcohol or other drugs.

Protective apparel

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.

Always wear an approved helmet.

Wear a face shield or goggles.

Wind in your unprotected eyes could contribute to an impairment

● of vision that could delay seeing a hazard.

The use of a jacket, heavy boots, trousers, gloves, etc., is effective in preventing or reducing abrasions or lacerations.

Never wear loose-fitting clothes, otherwise they could catch on the

● control levers, footrests, or wheels and cause injury or an accident.

Never touch the engine or exhaust system during or after operation.

They become very hot and can cause burns. Always wear protective clothing that covers your legs, ankles, and feet.

SAFETY INFORMATION

● Passengers should also observe the precautions mentioned above.

Modifications

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.

Loading and accessories

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:

Loading

The total weight of the operator, passenger, accessories and cargo must

1

1-2

1

SAFETY INFORMATION

not exceed the maximum load limit of

183 kg (403 lb). When loading within this weight limit, keep the following in mind:

● 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.

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.

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.

● 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 ob-

● scure lights or reflectors.

Accessories fitted to the handlebar or the front fork area can create instability due to improper weight distribution or aerody-

1-3

● namic changes. If accessories are added to the handlebar or front fork area, they must be as lightweight as possible and should be kept to a minimum.

Bulky or large accessories may seriously affect the stability of the 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.

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.

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

● GASOLINE IS HIGHLY FLAMMA-

BLE:

Always turn the engine off when

● refueling.

Take care not to spill any gasoline on the engine or exhaust system when refueling.

Never refuel while smoking or in the vicinity of an open flame.

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.

Always turn the engine off before leaving the motorcycle unattended and remove the key from the main switch. When parking the motorcy-

● cle, note the following:

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.

Do not park the motorcycle on a

● slope or soft ground, otherwise it may fall over.

Do not park the motorcycle near a flammable source (e.g., a kerosene heater, or near an open flame), otherwise it could catch fire.

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.

If you should swallow any gasoline, inhale a lot of gasoline vapor, or allow gasoline to get into your

SAFETY INFORMATION

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.

1

1-4

1

SAFETY INFORMATION

Location of important labels

Please read the following important labels carefully before operating this vehicle.

1 2 3

EAU10381

4

1-5

1

WARNING

BEFORE YOU OPERATE THIS VEHICLE, READ

THE OWNER’S MANUAL AND ALL LABELS.

ALWAYS WEAR AN APPROVED MOTORCYCLE

HELMET,

eye protection, and protective clothing.

5GK-2118K-00

3 California only

CARB.

FROM

FUEL TANK

TO ATMOSPHERE

CANISTER

4YN-21686-00

SAFETY INFORMATION

2

WARNING

This unit contains high pressure nitrogen gas.

Mishandling can cause explosion.

8

8

Read owner's manual for instructions.

Do not incinerate, puncture or open.

4AA-22259-80

4

1

1-6

DESCRIPTION

Left view

5

6

7

8

9

3

4

1

2

1 2 3 4 5

1. Headlight (page 6-35)

2. Fuel cock (page 3-7)

3. Air filter element (page 6-15)

4. Helmet holder (page 3-9)

5. Owner’s tool kit (page 6-1)

6. Shock absorber assembly spring preload adjusting nut (page 3-9)

7. Shock absorber assembly rebound damping force adjusting dial

(page 3-9)

8 7 6

8. Shift pedal (page 3-4)

2-1

EAU10410

Right view

1 2

6

1. Battery (page 6-33)

2. Fuse (page 6-34)

3. Engine oil filter element (page 6-12)

4. Engine oil level check window (page 6-12)

5. Brake pedal (page 3-5)

6. Spark arrester (page 6-16)

5 4 3

2-2

DESCRIPTION

EAU10420

5

6

7

8

9

2

3

4

DESCRIPTION

Controls and instruments

5

6

7

8

9

3

4

1

2

1. Clutch lever (page 3-4)

2. Left handlebar switches (page 3-3)

3. Starter (choke) knob (page 3-8)

4. Speedometer unit (page 3-2)

5. Main switch/steering lock (page 3-1)

6. Right handlebar switches (page 3-3)

7. Brake lever (page 3-4)

8. Throttle grip (page 6-18)

1 2

3 4 5

9

6

7

9. Fuel tank cap (page 3-5)

8

2-3

EAU10430

INSTRUMENT AND CONTROL FUNCTIONS

Main switch/steering lock

EAU10460

OFF

ON

EAU10710

LOCK

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

To lock the steering

To unlock the steering

Insert the key and turn it to “OFF”.

EWA10070

WARNING

Never turn the key to “LOCK” while the motorcycle is moving.

1 2 3

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.

EAU10510

ON

All electrical systems are supplied with power, and the headlight, meter lighting, taillight and position lights come on, and the engine can be started. The key cannot be removed.

EAU10660

OFF

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

1. Push.

2. Release.

3. Turn.

Turn the handlebars all the way to the left or right.

1. Push the key in from the “OFF” position, release it, and then turn it to

“LOCK”.

2. Remove the key.

3-1

5

6

7

8

9

2

3

4

1

2

INSTRUMENT AND CONTROL FUNCTIONS

Indicator lights

1

2

EAU10980

High beam indicator light “

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

EAU11080

Speedometer unit

1

4

N

3

3

4

5

1. High beam indicator light “

2. Turn signal indicator light “

3. Neutral indicator light “ ”

6

7

8

Turn signal indicator light “

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

EAU11020

9

EAU11060

Neutral indicator light “ ”

This indicator light comes on when the transmission is in the neutral position.

3

2

EAU11630

1. Speedometer

2. Odometer

3. Tripmeter

4. Reset knob

The speedometer unit is equipped with a speedometer, an odometer and a tripmeter. 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 with the reset knob.

The tripmeter can be used to estimate the distance that can be traveled with a full tank of fuel. This information will enable you to plan future fuel stops.

3-2

Handlebar switches

Left

1

2

3

1. Dimmer switch “

2. Turn signal switch “

3. Horn switch “ ”

/

/

EAU12343

Right

INSTRUMENT AND CONTROL FUNCTIONS

1

EAU12500

Horn switch “ ”

Press this switch to sound the horn.

2

EAU12660

Engine stop switch “ / ”

Set this switch to “ ” before starting the engine. Set this switch to “ ” to stop the engine in case of an emergency, such as when the vehicle overturns or when the throttle cable is stuck.

1. Engine stop switch “

2. Start switch “ ”

/ ”

Dimmer switch “

Set this switch to “

/

beam and to “

EAU12400

” for the high

” for the low beam.

EAU12460

Turn signal switch “ / ”

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

EAU12710

Start switch “ ”

Push this switch to crank the engine with the starter.

ECA10050

CAUTION:

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

2

3

4

5

6

7

8

9

3-3

INSTRUMENT AND CONTROL FUNCTIONS

EAU12820

Clutch lever Shift pedal

EAU12870

Brake lever

1

EAU12890

1

1

2

3

4

5

6

7

8

9

1

1. 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 3-12.)

1. 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.

1. Brake lever

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

3-4

INSTRUMENT AND CONTROL FUNCTIONS

Brake pedal

1

EAU12941

Fuel tank cap

3

2

1

1. Brake pedal

The brake pedal is on the right side of the motorcycle. To apply the rear brake, press down on the brake pedal.

1. Fuel tank cap

2. Unlock.

3. Open.

To remove the fuel tank cap

1. Insert the key into the lock and turn it 1/3 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 1/3 turn clockwise, and then remove it.

EAU32280

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.

EWA10120

WARNING

Make sure that the fuel tank cap is properly closed and locked before riding.

2

3

4

5

6

7

8

9

3-5

1

2

3

4

5

6

7

8

9

INSTRUMENT AND CONTROL FUNCTIONS

Fuel

1

2

EAU13210

fuel may deteriorate painted surfaces or plastic parts.

EAU13300

Recommended fuel:

UNLEADED GASOLINE ONLY

Fuel tank capacity:

8.8 L (2.32 US gal) (1.94 Imp.gal)

Fuel reserve amount:

2.0 L (0.53 US gal) (0.44 Imp.gal)

1. Fuel level

2. Fuel tank filler tube

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

EWA10880

WARNING

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

Avoid spilling fuel on the hot engine.

ECA10070

CAUTION:

Immediately wipe off spilled fuel with a clean, dry, soft cloth, since

ECA11400

CAUTION:

Use only unleaded gasoline. The use of leaded gasoline will cause severe damage to internal engine parts, such as the valves and piston rings, as well as to the exhaust system.

Your Yamaha engine has been designed to use regular unleaded gasoline with a pump octane number

[(R+M)/2] of 86 or higher, or a research octane number of 91 or higher. If knocking (or pinging) occurs, use a gasoline of a different brand or premium unleaded fuel. Use of unleaded fuel will extend spark plug life and reduce

3-6 maintenance costs.

Gasohol

There are two types of gasohol: gasohol containing ethanol and that containing methanol. Gasohol containing ethanol can be used if the ethanol content does not exceed 10%. Gasohol containing methanol is not recommended by Yamaha because it can cause damage to the fuel system or vehicle performance problems.

EAU13560

Fuel cock

The fuel cock supplies fuel from the tank to the carburetor while filtering it also.

The fuel cock has three positions:

OFF

ON

INSTRUMENT AND CONTROL FUNCTIONS

1

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!

2

1

1. Arrow mark pointing to “OFF”

With the lever in this position, fuel will not flow. Always return the lever to this position when the engine is not running.

1. Arrow mark pointing to “ON”

With the lever in this position, fuel flows to the carburetor. Normal riding is done with the lever in this position.

RES

1

5

6

3

4

7

8

9

1. Arrow mark pointing to “RES”

This indicates reserve. If you run out of

3-7

1

2

INSTRUMENT AND CONTROL FUNCTIONS

Starter (choke) knob “

(a)

1

(b)

EAU13600 EAU13981

Seat

To remove the seat

1. Remove panels A and B. (See page 6-9.)

2. Remove the bolts and pull the seat off.

2

1

3

4

5

6

7

8

1

(

×

2)

1. Starter (choke) knob “ ”

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

Move the knob in direction (a) to turn on the starter (choke).

Move the knob in direction (b) to turn off the starter (choke).

1. Bolt

To install the seat

1. Insert the projection on the front of the seat into the seat holder as shown.

1. Projection

2. Seat holder

2. Place the seat in the original position, and then tighten the bolts.

3. Install the panels.

NOTE:

Make sure that the seat is properly secured before riding.

9

3-8

INSTRUMENT AND CONTROL FUNCTIONS

Helmet holder

1

2

EAU14290

1. Helmet holder

2. Unlock.

To open the helmet holder, insert the key into the lock, and then turn the key as shown.

To lock the helmet holder, turn the key to the original position, and then remove it.

EWA10160

WARNING

Never ride with a helmet attached to the helmet holder, since the helmet may hit objects, causing loss of control and possibly an accident.

EAU14930

Adjusting the shock absorber assembly

This shock absorber assembly is equipped with a spring preload adjusting nut and a rebound damping force adjusting dial.

ECA10100

CAUTION:

Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings.

Spring preload

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).

1

(b)

(a)

1

2

1. Spring preload adjusting nut

2. Locknut

1. Loosen the locknut.

2. To increase the spring preload and

1. Distance A

NOTE:

Use the special wrench included in the owner’s tool kit to make the adjustment.

The spring preload setting is determined by measuring distance A, shown in the illustration. The longer distance A is, the higher the spring preload; the shorter distance A is, the lower the spring

3-9

2

3

4

5

6

7

8

9

1

2

3

4

5

6

7

8

9

INSTRUMENT AND CONTROL FUNCTIONS

preload.

Rebound damping force

Spring preload:

Minimum (soft):

Distance A = 36.5 mm (1.4 in)

Standard:

Distance A = 43.5 mm (1.7 in)

Maximum (hard):

Distance A = 48.0 mm (1.8 in)

(b)

1

(a)

3. Tighten the locknut to the specified torque.

Tightening torque:

Locknut:

54 Nm (5.4 m·kgf, 39 ft·lbf)

ECA11240

CAUTION:

Always tighten the locknut against the adjusting nut, and then tighten the locknut to the specified torque.

1. Rebound damping force adjusting dial

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).

Rebound damping setting:

Minimum (soft):

20 clicks in direction (b)*

Standard:

9 clicks in direction (b)*

Maximum (hard):

1 click in direction (b)*

* With the adjusting dial fully turned in direction (a)

NOTE:

Although the total number of clicks of the 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 the damping force adjusting mechanism and to modify the specifications as necessary.

EWA10220

WARNING

This shock absorber contains highly pressurized nitrogen gas. For proper handling, read and understand the following information before

3-10

INSTRUMENT AND CONTROL FUNCTIONS handling the shock absorber. The manufacturer cannot be held responsible for property damage or personal injury that may result from improper handling.

Do not tamper with or attempt to open the gas cylinder.

Do not subject the shock absorber to an open flame or other

high heat sources, otherwise it may explode due to excessive gas pressure.

Do not deform or damage the gas cylinder in any way, as this will result in poor damping performance.

Always have a Yamaha dealer service the shock absorber.

EAU15300

Sidestand

The sidestand is located on the left side of the frame. Raise the sidestand or lower it with your foot while holding the vehicle 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 cut-off system.)

EWA10240

WARNING

The vehicle 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.

3-11

2

3

4

5

6

7

8

9

1

2

3

4

5

6

7

8

9

INSTRUMENT AND CONTROL FUNCTIONS

EAU15311

Ignition circuit cut-off system

The ignition circuit cut-off system (comprising the sidestand switch, clutch switch and neutral switch) has the following functions.

● It prevents starting when the transmission is in gear and the sidestand is up, but the clutch lever is

● not pulled.

It prevents starting when the transmission is in gear and the clutch lever is pulled, but the sidestand is still down.

It cuts the running engine when the transmission is in gear and the sidestand is moved down.

Periodically check the operation of the ignition circuit cut-off system according to the following procedure.

EWA10250

WARNING

If a malfunction is noted, have a

Yamaha dealer check the system before riding.

3-12

INSTRUMENT AND CONTROL FUNCTIONS

With the engine turned off:

1. Move the sidestand down.

2. Make sure that the engine stop switch is turned on.

3. Turn the key on.

4. Shift the transmission into the neutral position.

5. Push the start switch.

Does the engine start?

YES

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

NO

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 NO

The system is OK.

The motorcycle can be ridden.

NOTE:

This check is most reliable if performed with a warmed-up engine.

The neutral switch may be defective.

The motorcycle should not be ridden

until checked by a Yamaha dealer.

The sidestand switch may be defective.

The motorcycle should not be ridden

until checked by a Yamaha dealer.

The clutch switch may be defective.

The motorcycle should not be ridden

until checked by a Yamaha dealer.

5

6

7

8

9

2

3

4

3-13

7

8

9

6

5

1

2

3

4

PRE-OPERATION CHECKS

EAU15591

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.

NOTE:

Pre-operation checks should be made each time the vehicle is used. Such an inspection can be accomplished in a very short time; and the added safety it assures is more than worth the time involved.

EWA11150

WARNING

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

4-1

PRE-OPERATION CHECKS

EAU15602

Pre-operation check list

ITEM

Fuel

Engine oil

Front brake

Rear brake

Clutch

Throttle grip

Control cables

CHECKS

Check fuel level in fuel tank.

Refuel if necessary.

Check fuel line for leakage.

Check oil level in engine.

If necessary, add recommended oil to specified level.

Check vehicle for oil leakage.

Check operation.

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

Check lever free play.

Adjust if necessary.

Check brake pads for wear.

Replace if necessary.

Check fluid level in reservoir.

If necessary, add recommended brake fluid to specified level.

Check hydraulic system for leakage.

Check operation.

Check pedal free play.

Adjust if necessary.

Check operation.

Lubricate cable if necessary.

Check lever free play.

Adjust if necessary.

Make sure that operation is smooth.

Check cable free play.

If necessary, have Yamaha dealer adjust cable free play and lubricate cable and grip housing.

Make sure that operation is smooth.

Lubricate if necessary.

PAGE

3-6

6-12

6-23, 6-25, 6-26

6-23, 6-25

6-22

6-18, 6-30

6-29

2

3

4

5

6

7

8

9

4-2

8

9

1

2

3

4

5

6

7

PRE-OPERATION CHECKS

ITEM

Drive chain

Wheels and tires

Brake and shift pedals

Brake and clutch levers

Sidestand

Chassis fasteners

Instruments, lights, signals and switches

Sidestand switch

CHECKS

Check chain slack.

Adjust if necessary.

Check chain condition.

Lubricate if necessary.

Check for damage.

Check tire condition and tread depth.

Check air pressure.

Correct if necessary.

Make sure that operation is smooth.

Lubricate pedal pivoting points if necessary.

Make sure that operation is smooth.

Lubricate lever pivoting points if necessary.

Make sure that operation is smooth.

Lubricate pivot if necessary.

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

Tighten if necessary.

Check operation.

Correct if necessary.

Check operation of ignition circuit cut-off system.

If system is defective, have Yamaha dealer check vehicle.

4-3

PAGE

6-27, 6-29

6-18, 6-21

6-30

6-30

6-31

3-11

OPERATION AND IMPORTANT RIDING POINTS

EAU15950

EWA10270

WARNING

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

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

Never start the engine or operate it in a closed area for any length of time. Exhaust fumes are poisonous, and inhaling them can cause loss of consciousness and death within a short time. Always make sure that there is adequate ventilation.

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.

EAU32290

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:

The transmission is in the neutral position.

The transmission is in gear with the clutch lever pulled and the sidestand up.

EWA10290

WARNING

Before starting the engine, check the function of the ignition circuit cut-off system according to the procedure described on page 3-12.

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 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 3-8.)

5. Start the engine by pushing the start switch.

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.

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

ECA11130

CAUTION:

For maximum engine life, always

5-1

2

3

4

5

6

7

8

9

1

2

3

4

5

6

7

8

9

OPERATION AND IMPORTANT RIDING POINTS warm the engine up before starting off. Never accelerate hard when the engine is cold!

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

NOTE:

The engine is warm when it responds normally to the throttle with the starter

(choke) turned off. To avoid the possibility of excessive exhaust emissions, never leave the starter (choke) on longer than necessary. The time necessary for starter (choke) use depends upon the ambient temperature. Temperatures above 10 °C (50 °F) require about

7 seconds of starter (choke) use and temperatures below 10 °C (50 °F) require about 35 seconds with the starter

(choke) turned on, then about 2.5 minutes with the starter (choke) in the halfway position.

EAU16640

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.

Shifting

2

6

5

4

3

2

N

1

1

EAU16671

1. Shift pedal

2. Neutral position

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.

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.

5-2

OPERATION AND IMPORTANT RIDING POINTS

ECA10260

CAUTION:

Even with the transmission in the neutral position, do not coast for long periods of time with the engine off, and do not tow the motorcycle for long distances. The transmission is properly lubricated only when the engine is running. Inadequate lubrication may damage the transmission.

Always use the clutch while changing gears to avoid damaging the engine, transmission, and drive train, which are not designed to withstand the shock of forced shifting.

3. Open the throttle gradually, and at the same time, release the clutch lever slowly.

4. At the recommended shift points shown in the following table, close the throttle, and at the same time, quickly pull the clutch lever in.

5. Shift the transmission into second gear. (Make sure not to shift the transmission into the neutral position.)

6. Open the throttle part way and gradually release the clutch lever.

7. Follow the same procedure when shifting to the next higher gear.

NOTE:

Always shift gears at the recommended shift points.

EAU16680

To start out and accelerate

1. Pull the clutch lever to disengage the clutch.

2. Shift the transmission into first gear. The neutral indicator light should go out.

EAU16700

To decelerate

1. Apply both the front and the rear brakes to slow the motorcycle.

2. Shift the transmission into first gear when the motorcycle reaches

20 km/h (12.5 mi/h). If the engine is about to stall or runs very roughly, pull the clutch lever in and use the brakes to stop the motorcycle.

3. Shift the transmission into the neutral position when the motorcycle is almost completely stopped. The neutral indicator light should come on.

EAU16740

Recommended shift points

The recommended shift points during acceleration and deceleration are shown in the table below.

Shift up points:

1st

2nd

2nd: 16 km/h (10 mi/h)

3rd: 24 km/h (15 mi/h)

4th: 32 km/h (20 mi/h) 3rd

4th

5th

5th: 40 km/h (25 mi/h)

6th: 48 km/h (30 mi/h)

Shift down points:

6th

5th

5th: 20 km/h (12.5 mi/h)

4th

4th: 20 km/h (12.5 mi/h)

3rd

2nd

3rd: 20 km/h (12.5 mi/h)

2nd: 20 km/h (12.5 mi/h)

1st: 20 km/h (12.5 mi/h)

5-3

2

3

4

5

6

7

8

9

1

2

3

4

5

6

OPERATION AND IMPORTANT RIDING POINTS

EAU16841

Engine break-in

There is never a more important period in the life of your engine than the period between 0 and 1600 km (1000 mi). 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

1600 km (1000 mi). 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.

ECA12711

CAUTION:

After 1000 km (600 mi) of operation, the engine oil must be changed, the oil filter element and the oil strainer cleaned.

If any engine trouble should occur during the engine break-in period, immediately have a

Yamaha dealer check the vehicle.

EAU17170

Parking

When parking, stop the engine, remove the key from the main switch, and then turn the fuel cock lever to “OFF”.

EWA10310

WARNING

Since the engine and exhaust system can become very hot, park in a place where pedestrians or children are not likely to touch them.

Do not park on a slope or on soft ground, otherwise the vehicle may overturn.

7

8

9

EAU32311

0–1000 km (0–600 mi)

Avoid prolonged operation above 1/3 throttle.

1000–1600 km (600–1000 mi)

Avoid prolonged operation above 1/2 throttle.

1600 km (1000 mi) and beyond

The vehicle can now be operated normally.

5-4

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU17231

Safety is an obligation of the owner. Periodic inspection, adjustment and lubrication will keep your vehicle in the safest and most efficient condition possible. The most important points of motorcycle inspection, adjustment, and lubrication are explained on the following pages.

Maintenance, replacement, or repair of the emission control devices and systems may be performed by any repair establishment or individual that is certified (if applicable).

EWA10320

WARNING

If you are not familiar with maintenance work, have a Yamaha dealer do it for you.

EAU17301

PERIODIC MAINTENANCE

PROPER PERIODIC MAINTENANCE

OF YOUR VEHICLE IS IMPORTANT

IN ORDER TO ENJOY LONG, PLEA-

SURABLE SERVICE. ESPECIALLY

IMPORTANT ARE THE MAINTE-

NANCE SERVICES RELATED TO

EMISSIONS CONTROL. THESE

CONTROLS NOT ONLY FUNCTION

TO ENSURE CLEANER AIR, BUT

ARE ALSO VITAL TO PROPER EN-

GINE OPERATION AND MAXIMUM

PERFORMANCE. IN THE FOLLOW-

ING PERIODIC MAINTENANCE

CHARTS, THE SERVICES RELATED

TO EMISSIONS CONTROL ARE

GROUPED SEPARATELY. THESE

SERVICES REQUIRE SPECIALIZED

DATA, KNOWLEDGE, AND EQUIP-

MENT. YAMAHA DEALERS ARE

TRAINED AND EQUIPPED TO PER-

FORM THESE PARTICULAR SER-

VICES.

Owner’s tool kit

1

EAU17310

1. Owner’s tool kit

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

NOTE:

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

2

3

4

5

6

7

8

9

6-1

5

6

7

8

9

4

3

1

2

PERIODIC MAINTENANCE AND MINOR REPAIR

EWA10340

WARNING

Modifications not approved by

Yamaha may cause loss of performance, excessive emissions, and render the vehicle unsafe for use.

Consult a Yamaha dealer before attempting any changes.

6-2

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU17580

Periodic maintenance chart for the emission control system

No.

ITEM ROUTINE

INITIAL

600 mi

(1000 km) or

1 month

ODOMETER READINGS

4000 mi

(6000 km) or

6 months

7000 mi

(11000 km) or

12 months

10000 mi

(16000 km) or

18 months

13000 mi

(21000 km) or

24 months

16000 mi

(26000 km) or

30 months

1 *

Fuel line

2

3

Spark plug

Spark arrester

4 *

Valve clearance

5 *

Crankcase breather

system

6 *

Idle speed

7 *

Exhaust system

Check fuel hoses for cracks or damage.

Replace if necessary.

Check condition.

Adjust gap and clean.

Replace at 7000 mi (11000 km) or 12 months and thereafter every 6000 mi (10000 km) or 12 months.

Clean.

Check and adjust valve clearance when engine is cold.

Check breather hose for cracks or damage.

Replace if necessary.

Check and adjust engine idle speed.

Check for leakage.

Tighten if necessary.

Replace gasket(s) if necessary.

Replace.

Replace.

2

3

4

5

6

7

8

9

6-3

5

6

7

8

9

4

PERIODIC MAINTENANCE AND MINOR REPAIR

1

2

3

No.

ITEM ROUTINE

INITIAL

600 mi

(1000 km) or

1 month

ODOMETER READINGS

4000 mi

(6000 km) or

6 months

7000 mi

(11000 km) or

12 months

10000 mi

(16000 km) or

18 months

13000 mi

(21000 km) or

24 months

16000 mi

(26000 km) or

30 months

8 *

Evaporative emis-

sion control system

(For California only)

Check control system for damage.

Replace if necessary.

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

6-4

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU32161

General maintenance and lubrication chart

No.

1 *

Air filter element

2 *

Clutch

3 *

Front brake

4 *

Rear brake

5 *

Brake hose

6 *

Wheels

7 *

Tires

ITEM

8 *

Wheel bearings

ROUTINE

Clean with solvent.

Replace if necessary.

Check operation.

Adjust or replace cable.

Check operation, fluid level, and for fluid leakage.

Replace brake pads if necessary.

Check operation.

Adjust cable and replace brake shoes if necessary.

Check for cracks or damage.

Replace.

Check runout, spoke tightness and for damage.

Tighten spokes if necessary.

Check tread depth and for damage.

Replace if necessary.

Check air pressure.

Correct if necessary.

Check bearings for smooth operation.

Replace if necessary.

INITIAL

600 mi

(1000 km) or

1 month

ODOMETER READINGS

4000 mi

(6000 km) or

6 months

7000 mi

(11000 km) or

12 months

10000 mi

(16000 km) or

18 months

13000 mi

(21000 km) or

24 months

16000 mi

(26000 km) or

30 months

√ √ √ √ √

Every 4 years

2

3

4

5

6

7

8

9

6-5

1

2

3

4

5

6

7

8

9

PERIODIC MAINTENANCE AND MINOR REPAIR

No.

9

10

11

12

13

14

15

*

ITEM

Drive chain

Steering bearings

*

Chassis fasteners

Brake and clutch lever pivot shafts

Brake and shift pedal pivot shafts

Sidestand pivot

*

Sidestand switch

ROUTINE

INITIAL

600 mi

(1000 km) or

1 month

ODOMETER READINGS

4000 mi

(6000 km) or

6 months

7000 mi

(11000 km) or

12 months

10000 mi

(16000 km) or

18 months

13000 mi

(21000 km) or

24 months

16000 mi

(26000 km) or

30 months

Check chain slack/alignment and condition.

Adjust and lubricate chain with a special O-ring chain lubricant thoroughly.

Check bearing assembly for looseness.

Moderately repack with lithium-soap-based grease every

10000 mi (16000 km) or 18 months.

Check all chassis fitting and fasteners.

Correct if necessary.

Apply lithium-soap-based grease (all-purpose grease) lightly.

Apply lithium-soap-based grease (all-purpose grease) lightly.

Check operation.

Apply lithium-soap-based grease (all-purpose grease) lightly.

Check operation and replace if necessary.

Every 300 mi (500 km) and after washing the motorcycle or riding in the rain

Repack.

6-6

PERIODIC MAINTENANCE AND MINOR REPAIR

No.

ITEM ROUTINE

INITIAL

600 mi

(1000 km) or

1 month

ODOMETER READINGS

4000 mi

(6000 km) or

6 months

7000 mi

(11000 km) or

12 months

10000 mi

(16000 km) or

18 months

13000 mi

(21000 km) or

24 months

16000 mi

(26000 km) or

30 months

16 *

Front fork

17 *

Shock absorber assembly

18 *

Rear suspension link pivots

19

Engine oil

Check operation and for oil leakage.

Replace if necessary.

Check operation and for oil leakage.

Replace if necessary.

Apply lithium-soap-based grease until new grease shows.

Change (warm engine before draining).

20

21

Engine oil filter element

Engine oil strainer

22 *

Control and meter cables

23 *

Throttle grip housing and cable

Clean.

Clean.

Apply Yamaha chain and cable lube or engine oil 10W-30 thoroughly.

Check operation and free play.

Adjust the throttle cable free play if necessary.

Lubricate the throttle grip housing and cable.

√ √

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

NOTE:

From 19000 mi (31000 km) or 36 months, repeat the maintenance intervals starting from 7000 mi (11000 km) or 12 months.

2

3

4

5

6

7

8

9

6-7

5

6

7

8

9

4

3

1

2

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU17620

NOTE:

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

Hydraulic brake system

When disassembling the master cylinder or caliper cylinder, always replace the brake fluid. Check the brake fluid level regularly and fill as required.

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

Replace the brake hoses every four years or if cracked or damaged.

6-8

EAU18721

Removing and installing the cowling and panels

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

PERIODIC MAINTENANCE AND MINOR REPAIR

1

To install the cowling

Place the cowling in the original position, and then install the screw.

EAU19292

Panels A and B

To remove one of the panels

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

1. Panel B

1 2

EAU18810

Cowling A

To remove the cowling

Remove the screw, and then pull the cowling off as shown.

1

2

2

3

4

5

6

7

1. Cowling A

2. Panel A

1. Panel A

2. Screw

8

9

1

1. Screw

6-9

1

2

3

4

5

6

7

8

9

PERIODIC MAINTENANCE AND MINOR REPAIR

1

2

1. Panel B

2. Screw

To install the panel

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

EAU19602

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.

1

1. Spark plug cap

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

1

1. Spark plug wrench

To check the spark plug

1. Check that the porcelain insulator around the center electrode of the spark plug is a medium-to-light tan

(the ideal color when the vehicle is ridden normally).

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 vehicle.

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

6-10

PERIODIC MAINTENANCE AND MINOR REPAIR

necessary.

Specified spark plug:

NGK/DR8EA

DENSO/X24ESR-U

1

3. Install the spark plug with the spark plug wrench, and then tighten it to the specified torque.

Tightening torque:

Spark plug:

17.5 Nm (1.75 m·kgf, 12.5 ft·lbf)

To install the spark plug

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

NOTE:

If a torque wrench is not available when installing a spark plug, a good estimate of the correct torque is 1/4–1/2 turn past finger tight. However, the spark plug should be tightened to the specified torque as soon as possible.

4. Install the spark plug cap.

EAU19671

Canister (for California only)

3

4

1. Fuel tank

2. Carburetor

3. Canister

4. Vent hose

1

2

2

3

4

5

6

7

1. Spark plug gap

Spark plug gap:

0.6–0.7 mm (0.024–0.028 in)

2. Clean the surface of the spark plug gasket and its mating surface, and then wipe off any grime from the spark plug threads.

1

1. Overflow hose

This model is equipped with a canister to prevent the discharging of fuel vapor

8

9

6-11

1

2

3

4

5

6

7

8

9

PERIODIC MAINTENANCE AND MINOR REPAIR

into the atmosphere.

Check each hose connection.

Check each hose and canister for cracks or damage. Replace if damaged.

Make sure the vent hose is not blocked. Clean it if necessary.

EAU19812

Engine oil and oil filter element

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

To check the engine oil level

1. Place the vehicle on a level surface and hold it in an upright position.

NOTE:

Make sure that the vehicle is positioned straight up when checking the oil level.

A slight tilt to the side can result in a false reading.

2. Start the engine, warm it up for several minutes, and then turn it off.

3. Wait a few minutes until the oil settles, and then check the oil level through the check window located at the bottom right side of the engine guard.

6-12

NOTE:

The engine oil should be between the minimum and maximum level marks.

2

3

1

1. Engine oil level check window

2. Maximum level mark

3. Minimum level mark

4. If the engine oil is below the minimum level mark, add sufficient oil of the recommended type to raise it to the correct level.

To change the engine oil (with or without oil filter element cleaning)

1. Start the engine, warm it up for several minutes, and then turn it off.

2. Place an oil pan under the engine to collect the used oil.

3. Remove the engine guard by removing the bolt.

PERIODIC MAINTENANCE AND MINOR REPAIR

6. Remove the oil filter element drain bolt to drain the oil from the oil filter element.

1

4 3 2 1

2

2

1

1. Engine guard

2. Bolt

4. Remove the engine oil filler cap and drain bolt along with the

O-ring, compression spring, and engine oil strainer, to drain the oil from the crankcase.

1. Engine oil filler cap

ECA11000

CAUTION:

When removing the engine oil drain bolt, the O-ring, compression spring, and oil strainer will fall out.

Take care not to lose these parts.

NOTE:

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

5. Clean the engine oil strainer with solvent.

NOTE:

Skip steps 6–11 if the oil filter element is not being cleaned.

1

1. Engine oil drain bolt

2. O-ring

3. Compression spring

4. Oil strainer

7. Remove the oil filter element cover by removing the bolts.

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6-13

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PERIODIC MAINTENANCE AND MINOR REPAIR

2

1

3

(

×

2)

1. Oil filter element drain bolt

2. Oil filter element cover

3. Bolt

8. Remove the oil filter element and

O-rings.

1

replace them if necessary.

10. Clean the oil filter element with solvent, and then install it.

NOTE:

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

11. Install the oil filter element cover by installing the bolts and drain bolt, then tightening them to the specified torques.

Tightening torques:

Oil filter element cover bolt:

10 Nm (1.0 m·kgf, 7.2 ft·lbf)

Oil filter element drain bolt:

10 Nm (1.0 m·kgf, 7.2 ft·lbf)

bolt, do not forget to install the

O-ring, compression spring, and oil strainer in position.

Tightening torque:

Engine oil drain bolt:

43 Nm (4.3 m·kgf, 31 ft·lbf)

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

Recommended oil:

See page 8-1.

Oil quantity:

Without oil filter element removal:

1.00 L (1.06 US qt) (0.88 Imp.qt)

With oil filter element removal:

1.10 L (1.16 US qt) (0.97 Imp.qt)

2

(

×

2)

1. Oil filter element

2. O-ring

9. Check the O-rings for damage and

NOTE:

Make sure that the O-ring is properly seated.

12. Install the engine oil strainer, compression spring, O-ring and engine oil drain bolt, and then tighten the drain bolt to the specified torque.

ECA10420

CAUTION:

Before installing the engine oil drain

6-14

ECA11620

CAUTION:

In order to prevent clutch slippage (since the engine oil also lubricates the clutch), do not mix any chemical additives. Do not use oils with a diesel specification of “CD” or oils of a higher quality than specified. In

PERIODIC MAINTENANCE AND MINOR REPAIR

addition, do not use oils labeled

“ENERGY CONSERVING II” or higher.

Make sure that no foreign material enters the crankcase.

14. Start the engine, and then let it idle for several minutes while checking it for oil leakage. If oil is leaking, immediately turn the engine off and check for the cause.

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

16. Install the engine guard by installing the bolt.

EAU20840

Cleaning the air filter element

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 6-9.)

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

1

1

1. Air filter element

4. Remove the sponge material from the air filter element frame.

2

3

4

5

6

7

2

1. Air filter case cover

2. Screw

3. Pull the air filter element out from the air filter case.

1 2

1. Sponge material

2. Air filter element frame

5. Clean the sponge material with solvent, and then squeeze the remaining solvent out.

8

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6-15

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PERIODIC MAINTENANCE AND MINOR REPAIR

1

3

2

4

6. 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.

Recommended oil:

Yamaha foam air filter oil or other quality air filter oil

7. Install the sponge material onto the air filter element frame, and then insert the air filter element into the air filter case.

NOTE:

Install the air filter element with the gray side facing forward and with the “UP” mark pointing as shown.

1

EAU21233

Cleaning the spark arrester

The spark arrester should be cleaned at the intervals specified in the Periodic maintenance and lubrication chart.

EWA10980

WARNING

Always let the exhaust system cool prior to touching exhaust components.

Do not start the engine when cleaning the exhaust system.

1. “UP” mark

ECA10480

CAUTION:

Make sure that the air filter element is properly seated in the air filter case.

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

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

9. Install the panel.

NOTE:

Make sure to select a well-ventilated area free of combustible materials to clean the spark arrester.

1. Remove the tailpipe by removing the screw, and then pulling it out of the muffler.

6-16

1

2

1. Muffler

2. Screw

2. Tap the tailpipe lightly, and then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe.

PERIODIC MAINTENANCE AND MINOR REPAIR

3. Insert the tailpipe into the muffler, and then install and tighten the screw.

NOTE:

Make sure to align the screw holes when inserting the tailpipe.

EAU21250

Adjusting the carburetor

The carburetor is an important part of the engine and its emission control system, which requires very sophisticated adjustment. Therefore, carburetor adjustments should be left to Yamaha dealer, who has the necessary professional knowledge and experience.

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1. Tailpipe

2. Spark arrester

6-17

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PERIODIC MAINTENANCE AND MINOR REPAIR

EAU21380

Adjusting the throttle cable free play

1

EAU21400

Adjusting the valve clearance

The valve clearance changes with use, resulting in improper air-fuel mixture and/or engine noise. To prevent this from occurring, the valve clearance must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart.

1. Throttle cable free play

The throttle cable free play should measure 3.0–5.0 mm (0.12–0.20 in) at the throttle grip. Periodically check the throttle cable free play and, if necessary, have a Yamaha dealer adjust it.

EAU21630

Tires

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

Tire air pressure

The tire air pressure should be checked and, if necessary, adjusted before each ride.

EWA10500

WARNING

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

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.

6-18

Tire air pressure (measured on cold tires):

0–90 kg (0–198 lb) :

Front:

125 kPa (18 psi) (1.25 kgf/cm

2

)

Rear:

150 kPa (22 psi) (1.50 kgf/cm

2

)

90–183 kg (198–403 lb) :

Front:

150 kPa (22 psi) (1.50 kgf/cm

2

)

Rear:

175 kPa (25 psi) (1.75 kgf/cm

2

)

Maximum load*:

183 kg (403 lb)

* Total weight of rider, passenger, cargo and accessories

EWA11020

WARNING

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

NEVER OVERLOAD THE MO-

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

PERIODIC MAINTENANCE AND MINOR REPAIR

Tire inspection

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

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

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

Adjust the suspension and tire air pressure with regard to the load.

Check the tire condition and air pressure before each ride.

2

1

3

1. Tire tread depth

2. Tire sidewall

3. Tire wear indicator

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 (0.04 in)

NOTE:

The tire tread depth limits may differ from country to country. Always comply

6-19

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PERIODIC MAINTENANCE AND MINOR REPAIR

with the local regulations.

Tire information

This motorcycle is equipped with tube tires.

EWA10460

WARNING

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

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

Yamaha Motor Co., Ltd.

Front tire:

Size:

2.75-21 45P

Manufacturer/model:

BRIDGESTONE/TW27

CHENG SHIN/C-6006

Rear tire:

Size:

120/80-18M/C 62P

Manufacturer/model:

BRIDGESTONE/TW30

CHENG SHIN/C-6006

EWA10560

WARNING

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

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

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

It is not recommended to patch a punctured tube. If unavoidable, however, patch the tube

6-20

very carefully and replace it as soon as possible with a high-quality product.

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU21940

Spoke wheels

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

● The wheel rims should be checked for cracks, bends or warpage, and the spokes for looseness or dam-

● age before each ride. If any damage is found, have a Yamaha dealer replace the wheel. Do not attempt even the smallest repair to the wheel. A deformed or cracked wheel must be replaced.

The wheel should be balanced whenever either the tire or wheel

● has been changed or replaced. An unbalanced wheel can result in poor performance, adverse handling characteristics, and a shortened tire life.

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

EAU22011

Accessories and replacement parts

EWA10621

WARNING

This vehicle is not designed to pull a trailer or to be attached to a sidecar.

The accessories or replacement parts you choose for your vehicle should be designed specifically for this model, and they must be securely mounted to maintain the inherent stability of the original design. Genuine Yamaha Parts and

Accessories are designed and tested to be compatible with your vehicle. Please consider Genuine

Yamaha Parts and Accessories before making a purchase. Use of non-Yamaha-approved accessories or replacement parts may cause loss of handling stability and riding safety. Since Yamaha cannot control the quality of accessories or parts manufactured by other companies, Yamaha cannot be held liable for any consequences caused by

6-21

the use of items which have not been approved by Yamaha.

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PERIODIC MAINTENANCE AND MINOR REPAIR

EAU22041

Adjusting the clutch lever free play

3

1

2

(a)

(b)

NOTE:

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.

3. Fully turn the adjusting bolt at the clutch lever in direction (a) to loosen the clutch cable.

4. Loosen the locknut at the crankcase.

1. Locknut (clutch lever)

2. Adjusting bolt

3. Clutch lever free play

The clutch lever free play should measure 10.0–15.0 mm (0.39–0.59 in) as shown. Periodically check the clutch lever free play and, if necessary, adjust it as follows.

1. Loosen the locknut at the clutch lever.

2. To increase the clutch lever free play, turn the adjusting bolt in direction (a). To decrease the clutch lever free play, turn the adjusting bolt in direction (b).

(b)

(a)

1

2

1. Locknut (crankcase)

2. Adjusting nut

5. To increase the clutch lever free play, turn the adjusting nut in direction (a). To decrease the clutch le-

6-22 ver free play, turn the adjusting nut in direction (b).

6. Tighten the locknut at the clutch lever and the crankcase.

EAU22092

Adjusting the brake lever free play

1 2

(b)

(a)

3

1. Locknut

2. Adjusting bolt

3. Brake lever free play

The brake lever free play should measure 2.0–5.0 mm (0.08–0.20 in) 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 screw in direction (a). To decrease the brake lever free play, turn the adjusting screw in direction (b).

PERIODIC MAINTENANCE AND MINOR REPAIR

3. Tighten the locknut.

EWA10630

WARNING

After adjusting the brake lever free play, check the free play and make sure that the brake is working properly.

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.

EAU22191

Adjusting the brake pedal position and free play

1

1. Brake pedal position

EWA10670

WARNING

It is advisable to have a Yamaha dealer make these adjustments.

Brake pedal position

The top of the brake pedal should be positioned approximately 10.0 mm

(0.39 in) below the top of the footrest.

Periodically check the brake pedal position and, if necessary, adjust it as follows.

1. Loosen the locknut at the brake pedal.

6-23

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2

PERIODIC MAINTENANCE AND MINOR REPAIR

2. To raise the brake pedal, turn the adjusting bolt in direction (a). To lower the brake pedal, turn the adjusting bolt in direction (b).

Brake pedal free play

(a)

2

1

3

4

5

6

7

8

1

(b)

1. Adjusting bolt

2. Locknut

3. Tighten the locknut.

EWA11230

WARNING

After adjusting the brake pedal position, the brake pedal free play must be adjusted.

1. Brake pedal free play

The brake pedal free play should measure 20.0–30.0 mm (0.79–1.18 in) as shown. Periodically check the brake pedal free play and, if necessary, adjust it as follows.

To increase the brake pedal free play, turn the adjusting nut at the brake rod in direction (a). To decrease the brake pedal free play, turn the adjusting nut in direction (b).

9

(a)

(b)

1

1. Brake pedal free play adjusting nut

EWA10680

WARNING

After adjusting the drive chain slack or removing and installing the rear wheel, always check the brake pedal free play.

If proper adjustment cannot be obtained as described, have a

Yamaha dealer make this adjustment.

After adjusting the brake pedal free play, check the operation of the brake light.

6-24

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU22270

Adjusting the rear brake light switch

2

1

(a)

EAU22380

Checking the front brake pads and rear brake shoes

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

EAU22420

(b)

Front brake pads

indicator groove has almost disappeared, have a Yamaha dealer replace the brake pads as a set.

Rear brake shoes

2

EAU22540

1

1

1. Rear brake light switch

2. Adjusting nut

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).

1. Wear indicator groove

Each front brake pad is provided with a wear indicator groove, which allows you to check the brake pad wear without having to disassemble the brake.

To check the brake pad wear, check the wear indicator groove. If a brake pad has worn to the point that the wear

6-25

1. Wear indicator

2. Wear limit line

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

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PERIODIC MAINTENANCE AND MINOR REPAIR

brake shoes as a set.

EAU32341

Checking the brake fluid level

Front brake

1

1. Minimum level mark

Insufficient brake fluid may allow air to enter the brake system, possibly causing it to become ineffective.

Before riding, check that the brake fluid is above the minimum level mark and replenish if necessary. A low brake fluid level may indicate worn brake pads and/or brake system leakage. If the brake fluid level is low, be sure to check the brake pads for wear and the brake system for leakage.

Observe these precautions:

When checking the fluid level, make sure that the top of the mas-

6-26

● ter cylinder is level by turning the handlebars.

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

Recommended brake fluid:

DOT 4

Refill with the same type of brake fluid. Mixing fluids may result in a harmful chemical reaction and lead to poor braking performance.

Be careful that water does not enter the master cylinder when refilling. Water will significantly lower the boiling point of the fluid and may result in vapor lock.

Brake fluid may deteriorate painted surfaces or plastic parts. Always clean up spilled fluid immediately.

As the brake pads wear, it is normal for the brake fluid level to gradually go down. However, if the

PERIODIC MAINTENANCE AND MINOR REPAIR

brake fluid level goes down suddenly, have a Yamaha dealer check the cause.

EAU22720

Changing the brake fluid

Have a Yamaha dealer change the brake fluid at the intervals specified in the NOTE after the periodic maintenance and lubrication chart. In addition, have the oil seals of the brake master cylinder and caliper as well as the brake hose replaced at the intervals listed below or whenever they are damaged or leaking.

Oil seals: Replace every two years.

Brake hose: Replace every four years.

EAU22760

Drive chain slack

The drive chain slack should be checked before each ride and adjusted if necessary.

EAU22770

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.

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:

35.0–45.0 mm (1.38–1.77 in)

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6-27

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PERIODIC MAINTENANCE AND MINOR REPAIR

1

1. Drive chain slack

4. If the drive chain slack is incorrect, adjust it as follows.

EAU22830

To adjust the drive chain slack

1. Loosen the brake pedal free play adjusting nut.

1

(b)

(a)

3

2

1. Brake pedal free play adjusting nut

2. Axle nut

3. Drive chain slack adjusting plate

2. Loosen the axle nut.

3. 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.

NOTE:

Make sure that both adjusting plates are in the same position for proper wheel alignment.

ECA10570

CAUTION:

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.

4. Tighten the axle nut to the specified torque.

Tightening torque:

Axle nut:

85 Nm (8.5 m·kgf, 62 ft·lbf)

5. Adjust the brake pedal free play.

(See page 6-23.)

EWA10660

WARNING

After adjusting the brake pedal free play, check the operation of the brake light.

6-28

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU23021

Lubricating the drive chain

The drive chain must be cleaned and lubricated at the intervals specified in the periodic maintenance and lubrication chart, otherwise it will quickly wear out, especially when riding in dusty or wet areas. Service the drive chain as follows.

ECA10581

CAUTION:

The drive chain must be lubricated after washing the motorcycle and riding in the rain.

1. Clean the drive chain with kerosene and a small soft brush.

ECA11120

CAUTION:

To prevent damaging the O-rings, do not clean the drive chain with steam cleaners, high-pressure washers or inappropriate solvents.

2. Wipe the drive chain dry.

3. Thoroughly lubricate the drive chain with a special O-ring chain lubricant.

ECA11110

CAUTION:

Do not use engine oil or any other lubricants for the drive chain, as they may contain substances that could damage the O-rings.

EAU23090

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:

Yamaha Chain and Cable Lube or engine oil SAE 10W-30 (API

SE)

EWA10710

WARNING

Damage to the outer housing of cables may result in internal rusting and cause interference with cable movement. Replace damaged cables as soon as possible to prevent unsafe conditions.

6-29

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PERIODIC MAINTENANCE AND MINOR REPAIR

EAU23110

Checking and lubricating the throttle grip and cable

The operation of the throttle grip should be checked before each ride. In addition, the cable should be lubricated or replaced at the intervals specified in the periodic maintenance chart.

EAU23131

Checking and lubricating the brake and shift pedals

EAU23140

Checking and lubricating the brake and clutch levers

The operation of the brake and shift pedals should be checked before each ride, and the pedal pivots should be lubricated if necessary.

Recommended lubricant:

Lithium-soap-based grease

(all-purpose grease)

The operation of the brake and clutch levers should be checked before each ride, and the lever pivots should be lubricated if necessary.

Recommended lubricant:

Lithium-soap-based grease

(all-purpose grease)

6-30

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU23200

Checking and lubricating the sidestand

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.

EWA10730

WARNING

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)

EAU23250

Lubricating the rear suspension

1

(

×

3)

1

(

×

2)

1. Grease nipple

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

Recommended lubricant:

Lithium-soap-based grease

EAU23271

Checking the front fork

The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart.

To check the condition

EWA10750

WARNING

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

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

To check the operation

1. Place the vehicle 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.

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PERIODIC MAINTENANCE AND MINOR REPAIR

ECA10590

CAUTION:

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

EAU23280

Checking the steering

Worn or loose steering bearings may cause danger. Therefore, the operation of the steering must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart.

1. Place a stand under the engine to raise the front wheel off the ground.

EWA10750

WARNING

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

2. Hold the lower ends of the front fork legs and try to move them forward and backward. If any free play can be felt, have a Yamaha dealer check or repair the steering.

6-32

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU23290

Checking the wheel bearings

The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart. If there is play in the wheel hub or if the wheel does not turn smoothly, have a Yamaha dealer check the wheel bearings.

EAU23370

Battery

This model 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.

ECA10620

CAUTION:

Never attempt to remove the battery cell seals, as this would permanently damage the battery.

EWA10760

WARNING

Electrolyte is poisonous and dangerous since it contains sulfuric acid, which causes severe burns. Avoid any contact with skin, eyes or clothing and always shield your eyes when working near batteries. In case

of contact, administer the following FIRST AID.

EXTERNAL: Flush with plenty of water.

INTERNAL: Drink large quantities of water or milk and im-

6-33

mediately call a physician.

EYES: Flush with water for 15 minutes and seek prompt medical attention.

Batteries produce explosive hydrogen gas. Therefore, keep sparks, flames, cigarettes, etc., away from the battery and provide sufficient ventilation when charging it in an enclosed space.

KEEP THIS AND ALL BATTER-

IES OUT OF THE REACH OF

CHILDREN.

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 vehicle is equipped with optional electrical accessories.

To store the battery

1. If the vehicle will not be used for more than one month, remove the battery, fully charge it, and then place it in a cool, dry place.

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PERIODIC MAINTENANCE AND MINOR REPAIR

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.

ECA10630

CAUTION:

Always keep the battery charged. Storing a discharged battery can cause permanent battery damage.

To charge a sealed-type (MF) battery, a special (constant-voltage) 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.

Replacing the fuse

1

2

EAU23500

1. Fuse

2. Spare fuse

The fuse holder is located behind panel

B. (See page 6-9.)

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:

20.0 A

ECA10640

CAUTION:

Do not use a fuse of a higher amperage rating than recommended to avoid causing extensive damage to the electrical system and possibly a fire.

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.

6-34

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU23811

Replacing the headlight bulb

This model is equipped with a quartz bulb headlight. If the headlight bulb burns out, replace it as follows.

1. Remove cowling A. (See page 6-9.)

2. Remove the headlight unit by removing the bolts.

1

2

1

1

2

1. Headlight unit

2. Bolt

3. Disconnect the headlight coupler, and then remove the headlight bulb cover.

1. Headlight coupler

2. Headlight bulb cover

4. Remove the headlight bulb holder by turning it counterclockwise, and then remove the defective bulb.

1. Headlight bulb holder

EWA10790

WARNING

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

5. Place a new bulb into position, and then secure it with the bulb holder.

ECA10660

CAUTION:

Do not touch the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the luminosity of the bulb, and the bulb life will be adversely af-

6-35

2

3

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7

8

9

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5

6

7

8

9

3

2

1

PERIODIC MAINTENANCE AND MINOR REPAIR fected. Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with alcohol or thinner.

EAU24131

Replacing the tail/brake light bulb

1. Remove the tail/brake light lens by removing the screws.

1

1

1

1. Do not touch the glass part of the bulb.

6. Install the bulb cover, and then connect the coupler.

7. Install the headlight unit by installing the bolts.

8. Install the cowling.

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

2

1. Tail/brake light lens

2. Screw

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

1. Tail/brake light bulb

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.

ECA10680

CAUTION:

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

6-36

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU24201

Replacing a turn signal light bulb

1. Remove the turn signal light lens by removing the screw.

1

1

2

1. Turn signal light lens

2. Screw

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

1. Turn signal light bulb

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.

ECA11190

CAUTION:

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

EAU24350

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.

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

6-37

2

3

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5

6

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8

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1

2

3

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6

7

8

9

PERIODIC MAINTENANCE AND MINOR REPAIR

frame in front of the rear wheel or under each side of the swingarm.

Front wheel

EAU24360

EAU24690

To remove the front wheel

EWA10820

WARNING

It is advisable to have a Yamaha dealer service the wheel.

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

1. Remove the engine guard by removing the bolt.

1

2

1. Engine guard

2. Bolt

2. Remove the brake disc cover by removing the screws.

6-38

3. Remove the speedometer cable holder by removing the screw.

4. Disconnect the speedometer cable from the front wheel.

5. Remove the axle nut.

2

1

3

4

5

1. Brake disc cover

2. Screw

3. Speedometer cable holder

4. Speedometer cable

5. Axle nut

6. Lift the front wheel off the ground according to the procedure on page 6-37.

7. Pull the wheel axle out, and then remove the wheel.

ECA11070

CAUTION:

Do not apply the brake after the

PERIODIC MAINTENANCE AND MINOR REPAIR wheel has been removed together with the brake disc, otherwise the brake pads will be forced shut.

retainer on the fork leg.

stalling the screws.

8. Install the engine guard by installing the bolt.

EAU25011

To install the front wheel

1. Install the speedometer gear unit into the wheel hub so that the projections mesh with the slots.

1

1

1. Speedometer gear unit

2. Lift the wheel up between the fork legs.

NOTE:

Make sure that there is enough space between the brake pads before inserting the brake disc and that the slot in the speedometer gear unit fits over the

1. Retainer

3. Insert the wheel axle, and then install the axle nut.

4. Lower the front wheel so that it is on the ground.

5. Tighten the axle nut to the specified torque.

Tightening torque:

Axle nut:

85 Nm (8.5 m·kgf, 62 ft·lbf)

6. Connect the speedometer cable, and then install the speedometer cable holder by installing the screw.

7. Install the brake disc cover by in-

6-39

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9

PERIODIC MAINTENANCE AND MINOR REPAIR

Rear wheel

EAU25080 the brake rod from the brake camshaft lever.

EAU25470

To remove the rear wheel

EWA10820

WARNING

It is advisable to have a Yamaha dealer service the wheel.

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

1. Remove the engine guard by removing the bolt.

1

3 (a)

5

4

1

2

1. Engine guard

2. Bolt

2. Remove the brake pedal free play adjusting nut, and then disconnect

2

1. Brake pedal free play adjusting nut

2. Brake rod

3. Brake camshaft lever

4. Axle nut

5. Chain adjusting plate

3. Loosen the axle nut.

4. Turn the drive chain adjusting plate on each side of the swingarm fully in direction (a).

5. Lift the rear wheel off the ground according to the procedure on page 6-37.

6. Remove the axle nut.

7. Push the wheel forward, and then remove the drive chain from the rear sprocket.

6-40

NOTE:

The drive chain does not need to be disassembled in order to remove and install the wheel.

8. Pull the wheel axle out, and then remove the wheel.

EAU25791

To install the rear wheel

1. Insert the wheel axle from the left-hand side.

PERIODIC MAINTENANCE AND MINOR REPAIR

1

1. Retainer

NOTE:

Make sure that the drive chain adjusting plates are installed with the punched sides facing to the outside and that the slot in the brake shoe plate fits over the retainer on the swingarm.

2. Install the drive chain onto the rear sprocket, and then adjust the drive chain slack. (See page 6-27.)

3. Install the axle nut, and then lower the rear wheel so that it is on the ground.

4. Tighten the axle nut to the specified torque.

Tightening torque:

Axle nut:

85 Nm (8.5 m·kgf, 62 ft·lbf)

5. Install the brake rod onto the brake camshaft lever, and then install the brake pedal free play adjusting nut onto the brake rod.

6. Adjust the brake pedal free play.

(See page 6-23.)

EWA10660

WARNING

After adjusting the brake pedal free play, check the operation of the brake light.

7. Install the engine guard by installing the bolt.

EAU25850

Troubleshooting

Although Yamaha motorcycles receive a thorough inspection before shipment from the factory, trouble may occur during operation. Any problem in the fuel, compression, or ignition systems, for example, can cause poor starting and loss of power.

The following troubleshooting chart represents a quick and easy procedure for checking these vital systems yourself. However, should your motorcycle require any repair, take it to a Yamaha dealer, whose skilled technicians have the necessary tools, experience, and know-how to service the motorcycle properly.

Use only genuine Yamaha replacement parts. Imitation parts may look like

Yamaha parts, but they are often inferior, have a shorter service life and can lead to expensive repair bills.

2

3

4

5

6

7

8

9

6-41

PERIODIC MAINTENANCE AND MINOR REPAIR

1

2

3

4

5

Troubleshooting chart

WARNING

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

1. Fuel

Check the fuel level in the fuel tank.

There is enough fuel.

Check the compression.

There is no fuel.

Supply fuel.

The engine does not start.

Check the compression.

2. Compression

Operate the electric starter.

There is compression.

Check the ignition.

There is no compression.

Have a Yamaha dealer check the vehicle.

6

7

3. Ignition

Remove the spark plug and check the electrodes.

Wet

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

Open the throttle halfway and operate the electric starter.

8

Dry

Have a Yamaha dealer check the vehicle.

The engine does not start.

Check the battery.

9

4. Battery

Operate the electric starter.

The engine turns over quickly.

The engine turns over slowly.

The battery is good.

Check the battery lead connections, and charge the battery if necessary.

The engine does not start.

Have a Yamaha dealer check the vehicle.

6-42

EAU25901

EWA10840

EAU26000

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

ECA10770

CAUTION:

Avoid using strong acidic wheel cleaners, especially on spoked wheels. If such products are used on hard-to-remove dirt, do not leave the cleaner on the affected area any longer than instructed. Also, thoroughly rinse the area off with water, immediately dry it, and then apply a corrosion protection spray.

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.

Do not use any harsh chemical products on plastic parts. Be sure to avoid using cloths or

7-1

MOTORCYCLE CARE AND STORAGE

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.

Do not use high-pressure washers or steam-jet cleaners since they cause water seepage and deterioration in the following areas: seals (of wheel and swingarm bearings, fork and brakes), electric components (couplers, connectors, instruments, switches and lights), breather hoses and vents.

For motorcycles equipped with a windshield: Do not use strong cleaners or hard sponges as they will cause dulling or scratching. Some cleaning compounds for plastic may leave scratches on the windshield.

Test the product on a small hidden part of the windshield to make sure that it does not leave

2

3

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6

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8

9

1

2

3

4

5

6

7

8

9

MOTORCYCLE CARE AND STORAGE any marks. If the windshield is scratched, use a quality plastic polishing compound after washing.

After normal use

Remove dirt with warm water, a mild detergent, and a soft, clean sponge, and then rinse thoroughly with clean water. Use a toothbrush or bottlebrush for hard-to-reach areas. Stubborn dirt and insects will come off more easily if the area is covered with a wet cloth for a few minutes before cleaning.

After riding in the rain, near the sea or on salt-sprayed roads

Since sea salt or salt sprayed on roads during winter are extremely corrosive in combination with water, carry out the following steps after each ride in the rain, near the sea or on salt-sprayed roads.

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.

ECA10790

CAUTION:

Do not use warm water since it increases the corrosive action of the salt.

2. Apply a corrosion protection spray on all metal, including chrome- and nickel-plated, surfaces to prevent corrosion.

After cleaning

1. Dry the motorcycle with a chamois or an absorbing cloth.

2. Immediately dry the drive chain and lubricate it to prevent it from rusting.

3. Use a chrome polish to shine chrome, aluminum and stainless-steel parts, including the exhaust system. (Even the thermally induced discoloring of stainless-steel 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.

EWA10930

WARNING

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.

Before operating the motorcycle test its braking performance and cornering behavior.

ECA10800

CAUTION:

Apply spray oil and wax spar-

7-2

ingly and make sure to wipe off any excess.

Never apply oil or wax to any rubber and plastic parts, but treat them with a suitable care product.

Avoid using abrasive polishing compounds as they will wear away the paint.

NOTE:

Consult a Yamaha dealer for advice on what products to use.

EAU26150

Storage

Short-term

Always store your motorcycle in a cool, dry place and, if necessary, protect it against dust with a porous cover.

ECA10810

CAUTION:

Storing the motorcycle in a poorly ventilated room or covering it with a tarp, while it is still wet, will allow water and humidity to seep in and cause rust.

To prevent corrosion, avoid damp cellars, stables (because of the presence of ammonia) and areas where strong chemicals are stored.

Long-term

Before storing your motorcycle for several months:

1. Follow all the instructions in the

“Care” section of this chapter.

2. For motorcycles equipped with a fuel cock that has an “OFF” position: Turn the fuel cock lever to

“OFF”.

7-3

MOTORCYCLE CARE AND STORAGE

3. Drain the carburetor float chamber by loosening the drain bolt; this will prevent fuel deposits from building up. Pour the drained fuel into the fuel tank.

4. Fill up the fuel tank and add fuel stabilizer (if available) to prevent the fuel tank from rusting and the fuel from deteriorating.

5. Perform the following steps to protect the cylinder, piston rings, etc.

from corrosion.

a. Remove the spark plug cap and spark plug.

b. Pour a teaspoonful of engine oil into the spark plug bore.

c. Install the spark plug cap onto the spark plug, and then place the spark plug on the cylinder head so that the electrodes are grounded. (This will limit sparking during the next step.) d. Turn the engine over several times with the starter. (This will coat the cylinder wall with oil.) e. Remove the spark plug cap

2

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MOTORCYCLE CARE AND STORAGE

from the spark plug, and then install the spark plug and the spark plug cap.

EWA10950

WARNING

To prevent damage or injury from sparking, make sure to ground the spark plug electrodes while turning the engine over.

6. Lubricate all control cables and the pivoting points of all levers and pedals as well as of the sidestand/ centerstand.

7. Check and, if necessary, correct the tire air pressure, and then lift the motorcycle so that both of its wheels are off the ground. Alternatively, turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot.

8. Cover the muffler outlet with a plastic bag to prevent moisture from entering it.

9. Remove the battery and fully charge it. Store it in a cool, dry place and charge it once a month.

Do not store the battery in an excessively cold or warm place

[less than 0 °C (30 °F) or more than 30 °C (90 °F)]. For more information on storing the battery, see page 6-33.

NOTE:

Make any necessary repairs before storing the motorcycle.

7-4

Dimensions:

Overall length:

2100 mm (82.7 in)

Overall width:

805 mm (31.7 in)

Overall height:

1160 mm (45.7 in)

Seat height:

810 mm (31.9 in)

Wheelbase:

1350 mm (53.1 in)

Ground clearance:

285 mm (11.22 in)

Minimum turning radius:

1900 mm (74.8 in)

Weight:

With oil and fuel:

121.0 kg (267 lb)

Engine:

Engine type:

Air cooled 4-stroke, SOHC

Cylinder arrangement:

Forward-inclined single cylinder

Displacement:

223.0 cm

3

(13.61 cu.in)

Bore

×

stroke:

70.0

×

58.0 mm (2.76

×

2.28 in)

Compression ratio:

9.50 :1

Starting system:

Electric starter

Lubrication system:

Wet sump

EAU26337

Engine oil:

Type:

YAMALUBE 4, SAE10W30 or SAE20W40

0

°

10

°

30

°

50

°

70

°

90

°

110

°

130

°

F

YAMALUBE 4 (10W30) or SAE 10W30

YAMALUBE 4 (20W40) or SAE 20W40

–20

°

–10

°

0

°

10

°

20

°

30

°

40

°

50

°

C

Recommended engine oil grade:

API service SE, SF, SG type or higher

Engine oil quantity:

Without oil filter element removal:

1.00 L (1.06 US qt) (0.88 Imp.qt)

With oil filter element removal:

1.10 L (1.16 US qt) (0.97 Imp.qt)

Air filter:

Air filter element:

Fuel:

Wet element

Recommended fuel:

Unleaded gasoline only

Fuel tank capacity:

8.8 L (2.32 US gal) (1.94 Imp.gal)

Fuel reserve amount:

2.0 L (0.53 US gal) (0.44 Imp.gal)

Carburetor:

Manufacturer:

MIKUNI

8-1

SPECIFICATIONS

Type x quantity:

BST34 x 1

Spark plug(s):

Manufacturer/model:

NGK/DR8EA

Manufacturer/model:

DENSO/X24ESR-U

Spark plug gap:

0.6–0.7 mm (0.024–0.028 in)

Clutch:

Clutch type:

Wet, multiple-disc

Transmission:

Primary reduction system:

Spur gear

Primary reduction ratio:

73/22 (3.318)

Secondary reduction system:

Chain drive

Secondary reduction ratio:

45/15 (3.000)

Transmission type:

Constant mesh 6-speed

Operation:

Left foot operation

Gear ratio:

1st:

34/11 (3.090)

2nd:

30/15 (2.000)

3rd:

30/21 (1.428)

2

3

4

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2

3

4

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6

7

8

9

SPECIFICATIONS

4th:

27/24 (1.125)

5th:

25/27 (0.925)

6th:

23/29 (0.793)

Chassis:

Frame type:

Diamond

Caster angle:

26.50 °

Trail:

102.0 mm (4.02 in)

Front tire:

Type:

With tube

Size:

2.75-21 45P

Manufacturer/model:

BRIDGESTONE/TW27

Manufacturer/model:

CHENG SHIN/C-6006

Rear tire:

Type:

With tube

Size:

120/80-18M/C 62P

Manufacturer/model:

BRIDGESTONE/TW30

Manufacturer/model:

CHENG SHIN/C-6006

Loading:

Maximum load:

183 kg (403 lb)

* (Total weight of rider, passenger, cargo and accessories)

Tire air pressure (measured on cold tires):

Loading condition:

0–90 kg (0–198 lb)

Front:

125 kPa (18 psi) (1.25 kgf/cm

2

)

Rear:

150 kPa (22 psi) (1.50 kgf/cm

2

)

Loading condition:

90–183 kg (198–403 lb)

Front:

150 kPa (22 psi) (1.50 kgf/cm

2

)

Rear:

175 kPa (25 psi) (1.75 kgf/cm

2

)

Front wheel:

Wheel type:

Spoke wheel

Rim size:

21x1.60

Rear wheel:

Wheel type:

Spoke wheel

Rim size:

18x2.15

Front brake:

Type:

Single disc brake

Operation:

Right hand operation

Recommended fluid:

DOT 4

Rear brake:

Type:

Drum brake

Operation:

Right foot operation

Front suspension:

Type:

Telescopic fork

Spring/shock absorber type:

Coil spring/oil damper

Wheel travel:

225.0 mm (8.86 in)

Rear suspension:

Type:

Swingarm (link suspension)

Spring/shock absorber type:

Coil spring/gas-oil damper

Wheel travel:

190.0 mm (7.48 in)

Electrical system:

Ignition system:

C.D.I.

Charging system:

A.C. magneto

Battery:

Model:

GT6B-3

Voltage, capacity:

12 V, 6.0 Ah

8-2

Headlight:

Bulb type:

Halogen bulb

Bulb voltage, wattage x quantity:

Headlight:

12 V, 60 W/55.0 W

×

1

Tail/brake light:

12 V, 8.0/27.0 W

×

1

Front turn signal/position light:

12 V, 27 W/8.0 W

×

2

Rear turn signal light:

12 V, 27.0 W

×

2

Meter lighting:

12 V, 3.4 W

×

1

Neutral indicator light:

12 V, 3.4 W

×

1

High beam indicator light:

12 V, 3.4 W

×

1

Turn signal indicator light:

12 V, 3.4 W

×

1

Fuse:

Fuse:

20.0 A

8-3

SPECIFICATIONS

5

6

7

8

9

2

3

4

1

2

3

CONSUMER INFORMATION

EAU26351

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.

KEY IDENTIFICATION NUMBER:

Key identification number

1

EAU26390

Vehicle identification number

EAU26400

1

4

5

6

7

8

9

VEHICLE IDENTIFICATION NUM-

BER:

1. Key identification number

The key identification number is stamped into the key. Record this number in the space provided and use it for reference when ordering a new key.

MODEL LABEL INFORMATION:

1. Vehicle identification number

The vehicle identification number is stamped into the steering head pipe.

Record this number in the space provided.

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.

9-1

Model label

1

EAU26480

1. Model label

The model label is affixed to the frame under the seat. (See page 3-8.) Record the information on this label in the space provided. This information will be needed when ordering spare parts from a Yamaha dealer.

CONSUMER INFORMATION

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4

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2

3

CONSUMER INFORMATION

EAU26550

Reporting safety defects

If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Yamaha Motor Corporation,

U.S.A. If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in individual problems between you, your dealer, or Yamaha Motor Corporation, U.S.A.

To contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1-800-424-9393 (or 366-0123 in Washington, D.C.

area) or write to: NHTSA, U.S. Department of Transportation, Washington, D.C. 20590. You can also obtain other information about motor vehicle safety from the Hotline.

9-3

CONSUMER INFORMATION

EAU26560

Motorcycle noise regulation

TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED:

Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

“AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW”.

These acts include tampering with the following systems; i.e., modification, removal, etc.

Exhaust system

Muffler

Exhaust pipe

Silencer

Intake system

Air cleaner case

Air cleaner element

Intake duct

2

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9

CONSUMER INFORMATION

EAU26611

Maintenance record

Copies of work orders and/or receipts for parts purchased and installed on your motorcycle will be required to document that maintenance has been completed in accordance with the emissions warranty. The chart below is printed only as a reminder that maintenance work is required. It is not acceptable proof of maintenance work.

Date of service

Mileage

Servicing dealer name and address

Remarks

Maintenance interval

600 mi

(1000 km) or

1 month

4000 mi

(6000 km) or

6 months

7000 mi

(11000 km) or

12 months

10000 mi

(16000 km) or

18 months

13000 mi

(21000 km) or

24 months

16000 mi

(26000 km) or

30 months

19000 mi

(31000 km) or

36 months

22000 mi

(36000 km) or

42 months

9-5

Maintenance interval

25000 mi

(41000 km) or

48 months

28000 mi

(46000 km) or

54 months

31000 mi

(51000 km) or

60 months

Date of service

Mileage

CONSUMER INFORMATION

Servicing dealer name and address

Remarks

5

6

7

8

9

2

3

4

9-6

5

6

7

8

9

3

4

1

2

CONSUMER INFORMATION

EAU26661

YAMAHA MOTOR CORPORATION, U.S.A. STREET AND ENDURO MOTORCYCLE LIMITED

WARRANTY

9-7

9-8

CONSUMER INFORMATION

5

6

7

8

9

2

3

4

CONSUMER INFORMATION

1

2

3

4

5

6

7

8

YAMAHA EXTENDED SERVICE (Y.E.S.)

Keep your Yamaha protected even after your warranty expires with genuine Yamaha Extended Service (Y.E.S.).

Y.E.S. is designed and administered by Yamaha Motor

Corporation to provide maximum owner satisfaction. You get uninterrupted factory-backed coverage for extra peace of mind.

Y.E.S. is flexible. You choose the plan that’s right for you: 12 months, 24 months, 36 months or, on certain models, even 48 months beyond your warranty period.

Y.E.S. is designed and administered by the same

Yamaha people who handle your warranty – and it shows in the comprehensive coverage benefits. There are no mileage limitations. Coverage isn’t limited to

“moving parts” or the “drive train” like many other plans.

And Y.E.S. covers manufacturing defects just like the warranty. See the sample contract at your Yamaha dealer to see how comforting uninterrupted factorybacked protection can be.

You don’t have to pay anything for covered repairs.

There’s no deductible to pay, and repairs aren’t

“pro-rated.” You don’t have any “out-of-pocket” expenses for covered repairs.

9

In addition, Travel and Recreation Interruption Protection

(TRIP) is included at no extra cost. TRIP gives you up to

$150 reimbursement per occurrence for any reasonable expenses you incur because your Yamaha needs covered service: replacement vehicle rental, emergency towing, phone calls, even food and lodging when you are away from home. This superb coverage goes into effect when you purchase Y.E.S., so it applies to any warranty repairs as well as covered repairs during your entire

Y.E.S. plan period.

Y.E.S. coverage is honored at any authorized Yamaha dealer nationwide.

Y.E.S. coverage is transferable to a new owner if you sell or trade-in. That can make your Yamaha much more valuable!

This excellent Y.E.S. plan coverage is only available to

Yamaha owners like you, and only while your Yamaha is still within the Yamaha Limited Warranty period. So visit your authorized Yamaha dealer to get all the facts. He can show you how easy it is to protect your investment with Yamaha

Extended Service.

EAU26750

9-9

We urge you to act now. You’ll get the excellent benefits of

TRIP coverage right away, and you’ll rest easy knowing you’ll have strong factory-backed protection even after your

Yamaha Limited Warranty expires.

A special note:

If visiting your dealer isn’t convenient, contact Yamaha with your Primary ID number (your frame number). We’ll be happy to help you get the Y.E.S. coverage you need.

Yamaha Service Marketing

P.O. Box 6555

Cypress, CA 90630

1-(866)-YES-EXTD (1-866-937-3983)

CONSUMER INFORMATION

5

6

7

8

9

2

3

4

9-10

INDEX

A

B

Accessories and replacement parts........ 6-21

Air filter element, cleaning....................... 6-15

Battery..................................................... 6-33

Brake and clutch levers, checking and lubricating ............................................. 6-30

Brake and shift pedals, checking and lubricating ............................................. 6-30

Brake fluid, changing .............................. 6-27

Brake fluid level, checking ...................... 6-26

Brake lever................................................ 3-4

C

Brake lever free play, adjusting............... 6-23

Brake pads and shoes, checking ............ 6-25

Brake pedal............................................... 3-5

Brake pedal position and free play, adjusting ............................................... 6-23

D

Cables, checking and lubricating ............ 6-29

Canister (for California only) ................... 6-11

Carburetor,adjusting ............................... 6-17

Care .......................................................... 7-1

Cleaning the spark arrester..................... 6-16

Clutch lever ............................................... 3-4

Clutch lever free play, adjusting.............. 6-22

Cowling and panels, removing and installing.................................................. 6-9

Dimmer switch .......................................... 3-3

Drive chain, lubricating............................ 6-29

E

Drive chain slack..................................... 6-27

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

Engine oil and oil filter element ............... 6-12

I

F

Engine, starting a warm .............................5-2

Engine stop switch.....................................3-3

H

Front fork, checking .................................6-31

Fuel............................................................3-6

Fuel cock ...................................................3-7

Fuel tank cap .............................................3-5

Fuse, replacing ........................................6-34

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

Headlight bulb, replacing .........................6-35

Helmet holder ............................................3-9

High beam indicator light ...........................3-2

Horn switch ................................................3-3

K

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

Ignition circuit cut-off system ...................3-12

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

L

Key identification number ..........................9-1

M

Labels, location of......................................1-5

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

Maintenance and lubrication, periodic .......6-5

Maintenance, emission control system......6-3

Maintenance, periodic................................6-1

Maintenance record ...................................9-5

N

Model label ................................................9-2

Neutral indicator light .................................3-2

Noise regulation.........................................9-4

P

R

Parking ...................................................... 5-4

Part locations............................................. 2-1

Pre-operation check list ............................. 4-2

Rear brake light switch, adjusting............ 6-25

S

Rear suspension, lubricating ................... 6-31

T

Safety defects, reporting ........................... 9-3

Safety information ..................................... 1-1

Seat ........................................................... 3-8

Shifting ...................................................... 5-2

Shift pedal ................................................. 3-4

Shock absorber assembly, adjusting......... 3-9

Sidestand ................................................ 3-11

Sidestand, checking and lubricating ........ 6-31

Spark plug, checking ............................... 6-10

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

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

Starter (choke) knob .................................. 3-8

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

Start switch ................................................ 3-3

Steering, checking ................................... 6-32

Storage ...................................................... 7-3

Supporting the motorcycle....................... 6-37

Tail/brake light bulb, replacing................. 6-36

Throttle cable free play, adjusting ........... 6-18

Throttle grip and cable, checking and lubricating.............................................. 6-30

Tires ........................................................ 6-18

Tool kit ....................................................... 6-1

Troubleshooting....................................... 6-41

Troubleshooting chart.............................. 6-42

Turn signal indicator light...........................3-2

Turn signal light bulb, replacing ...............6-37

V

Turn signal switch ......................................3-3

W

Valve clearance, adjusting.......................6-18

Vehicle identification number.....................9-1

Warranty, extended ...................................9-9

Warranty, limited........................................9-7

Wheel bearings, checking .......................6-33

Wheel (front) ............................................6-38

Wheel (rear).............................................6-40

Wheels.....................................................6-21

INDEX

5RK-9-13_hyoushi 4/9/04 2:49 PM Page 1

PRINTED ON RECYCLED PAPER

YAMAHA MOTOR CO., LTD.

PRINTED IN JAPAN

2002·5–0.6

×

1(E)

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(E)

LIT-11626-18-25

OWNER’S MANUAL

XT225T

XT225TC

5RK-28199-13

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