periodic maintenance and adjustment

Read this manual carefully before operating this vehicle.

OWNER’S MANUAL

TT250RY

4PX-28199-2E

EAU46090

Q

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

INTRODUCTION

EAU10102

Welcome to the Yamaha world of motorcycling!

As the owner of the TT250RY, you are benefiting from Yamaha’s vast experience and newest technology regarding the design and manufacture of high-quality products, which have earned Yamaha a reputation for dependability.

Please take the time to read this manual thoroughly, so as to enjoy all advantages of your TT250RY. The Owner’s Manual does not only instruct you in how to operate, inspect and maintain your motorcycle, but also in how to safeguard yourself and others from trouble and injury.

In addition, the many tips given in this manual will help keep your motorcycle in the best possible condition. If you have any further questions, do not hesitate to contact your Yamaha dealer.

The Yamaha team wishes you many safe and pleasant rides. So, remember to put safety first!

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

EWA10031

WARNING

Please read this manual carefully and completely before operating this motorcycle.

IMPORTANT MANUAL INFORMATION

EAU10132

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

This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

WARNING

NOTICE

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

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

TIP

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

IMPORTANT MANUAL INFORMATION

EAU10200

TT250RY

OWNER’S MANUAL

©2008 by Yamaha Motor Co., Ltd.

1st edition, April 2008

All rights reserved.

Any reprinting or unauthorized use without the written permission of

Yamaha Motor Co., Ltd. is expressly prohibited.

Printed in Japan.

TABLE OF CONTENTS

LOCATION OF IMPORTANT

LABELS

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

SAFETY INFORMATION

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

Adjusting the shock absorber assembly .................................... 4-11

Sidestand ...................................... 4-13

Ignition circuit cut-off system ......... 4-13

DESCRIPTION

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

Left view ...........................................3-1

Right view .........................................3-2

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

FOR YOUR SAFETY –

PRE-OPERATION CHECKS

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

Pre-operation check list ................... 5-2

INSTRUMENT AND CONTROL

FUNCTIONS

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

Main switch ......................................4-1

Indicator lights .................................4-1

Speedometer unit ............................4-2

Handlebar switches .........................4-2

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

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

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

Brake pedal .....................................4-4

Fuel tank cap ...................................4-5

Fuel ..................................................4-5

Fuel tank breather hose ...................4-6

Fuel cock .........................................4-7

Starter (choke) knob “ 1 ” .................4-8

Kickstarter ........................................4-8

Steering lock ....................................4-8

Seat .................................................4-9

Helmet holder ..................................4-9

Adjusting the front fork ...................4-10

OPERATION AND IMPORTANT

RIDING POINTS

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

Starting a cold engine ..................... 6-1

Starting a warm engine ................... 6-2

Shifting ............................................ 6-2

Tips for reducing fuel consumption ................................ 6-3

Engine break-in ............................... 6-3

Parking ............................................ 6-4

PERIODIC MAINTENANCE AND

ADJUSTMENT

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

Owner’s tool kit ................................ 7-1

Periodic maintenance and lubrication chart ............................................. 7-2

Removing and installing the cowling and panels ................................... 7-6

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

Engine oil and oil filter element ....... 7-8

Cleaning the air filter element ....... 7-11

Adjusting the carburetor ................ 7-13

Adjusting the engine idling speed ......................................... 7-13

Checking the throttle cable free play ............................................ 7-14

Valve clearance ............................ 7-14

Tires .............................................. 7-14

Spoke wheels ............................... 7-16

Adjusting the clutch lever free play ............................................ 7-16

Adjusting the brake lever free play ............................................ 7-17

Adjusting the rear brake light switch ......................................... 7-18

Checking the front and rear brake pads ........................................... 7-18

Checking the brake fluid level ....... 7-19

Changing the brake fluid ............... 7-20

Drive chain slack ........................... 7-20

Cleaning and lubricating the drive chain .......................................... 7-21

Checking and lubricating the cables ........................................ 7-22

Checking and lubricating the throttle grip and cable ............................ 7-22

Checking and lubricating the brake and clutch levers ........................ 7-23

Checking and lubricating the brake pedal .......................................... 7-23

Checking and lubricating the sidestand ................................... 7-23

Checking the front fork .................. 7-24

Checking the steering ....................7-24

Checking the wheel bearings ........7-25

Battery ...........................................7-25

Replacing the fuse .........................7-27

Replacing the headlight bulb .........7-27

Replacing the tail/brake light bulb ............................................7-28

Replacing a turn signal light bulb ............................................7-29

Replacing the license plate light bulb ............................................7-30

Supporting the motorcycle .............7-31

Front wheel ....................................7-31

Rear wheel ....................................7-33

Troubleshooting .............................7-34

Troubleshooting chart ....................7-35

MOTORCYCLE CARE AND

STORAGE

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

Matte color caution ..........................8-1

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

Storage ............................................8-3

SPECIFICATIONS

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

CONSUMER INFORMATION

............10-1

Identification numbers ...................10-1

Motorcycle noise regulation

(for Australia) ..............................10-2

TABLE OF CONTENTS

LOCATION OF IMPORTANT LABELS

EAU10383

1

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

1 2 3

1-1

1

4AA-22259-40

2

Before you operate this vehicle, read the owner’s manual.

Prima di usare il veicolo, leggete il manuale di istruzioni.

Lire le manuel du propriétaire avant d’utiliser ce véhicule.

Lesen Sie die Bedienungsanleitung bevor Sie dieses Fahrzeug fahren.

Antes de conducir este vehículo, lea el Manual del Propietario.

5PA-21568-01

LOCATION OF IMPORTANT LABELS

3

3TT-21668-00

5

6

7

8

9

3

4

1

2

1-2

1

2


Be a Responsible Owner

As the vehicle’s owner, you are responsible for the safe and proper operation of your motorcycle.

Motorcycles are single-track vehicles.

Their safe use and operation are dependent upon the use of proper riding techniques as well as the expertise of the operator. Every operator should know the following requirements before riding this motorcycle.

He or she should:

● Obtain thorough instructions from a competent source on all aspects

● of motorcycle operation.

Observe the warnings and maintenance requirements in this Owner’s Manual.

●

●

Obtain qualified training in safe and proper riding techniques.

Obtain professional technical service as indicated in this Owner’s

Manual and/or when made necessary by mechanical conditions.

Safe Riding

EAU10313

Perform the pre-operation checks each time you use the vehicle to make sure it is in safe operating condition. Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equipment damage. See page 5-1 for a list of pre-operation checks.

● 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 you are approaching and passing through intersections, since intersections are the most likely places for motorcycle accidents to occur.

Ride where other motorists can see you. Avoid riding in another

2-1

●

●

●

● motorist’s blind spot.

Many accidents involve inexperienced operators. In fact, many operators who have been involved in

● accidents do not even have a current 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 under-

● cornering (insufficient lean angle for the speed).

Always obey the speed limit and never travel faster than warrant-

●

●

●

● ed 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 maintain 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.

tion 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.

Always wear protective clothing that covers your legs, ankles, and feet. The engine or exhaust system become very hot during or after operation and can cause burns.

A passenger should also observe the above precautions.

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 preven-

Avoid Carbon Monoxide Poisoning

All engine exhaust contains carbon monoxide, a deadly gas. Breathing carbon monoxide can cause headaches, dizziness, drowsiness, nausea, confu-


sion, and eventually death.

Carbon Monoxide is a colorless, odorless, tasteless gas which may be present even if you do not see or smell any engine exhaust. Deadly levels of carbon monoxide can collect rapidly and you can quickly be overcome and unable to save yourself. Also, deadly levels of carbon monoxide can linger for hours or days in enclosed or poorly ventilated areas. If you experience any symptoms of carbon monoxide poisoning, leave the area immediately, get fresh air, and SEEK MEDICAL TREAT-

MENT.

● Do not run engine indoors. Even if you try to ventilate engine exhaust

●

● with fans or open windows and doors, carbon monoxide can rapidly reach dangerous levels.

Do not run engine in poorly ventilated or partially enclosed areas such as barns, garages, or carports.

Do not run engine outdoors where engine exhaust can be drawn into a building through openings such as windows and doors.

1

2

2-2

1

2


Loading

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, along with the information about accessories below, are some general guidelines to follow if loading cargo to your motorcycle:

The total weight of the operator, passenger, accessories and cargo must not exceed the maximum load limit.

Operation of an overloaded vehicle could cause an accident.

Maximum load:

180 kg (397 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. Securely pack your heaviest items as

●

● close to the center of the vehicle as possible and 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 ac-

●

● cessories and cargo are securely attached to the motorcycle before riding. Check accessory mounts and cargo restraints frequently.

Properly adjust the suspension for your load, and check the condition and pressure of your tires.

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.

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

Genuine Yamaha Accessories

Choosing accessories for your vehicle is an important decision. Genuine

Yamaha accessories, which are available only from a Yamaha dealer, have been designed, tested, and approved by Yamaha for use on your vehicle.

Many companies with no connection to

Yamaha manufacture parts and accessories or offer other modifications for

Yamaha vehicles. Yamaha is not in a position to test the products that these aftermarket companies produce.

Therefore, Yamaha can neither endorse nor recommend the use of accessories not sold by Yamaha or modifications not specifically recommended by Yamaha, even if sold and installed by a Yamaha dealer.

Aftermarket Parts, Accessories, and Modifications

While you may find aftermarket products similar in design and quality to genuine Yamaha accessories, recognize that some aftermarket accessories or modifications are not suitable because of potential safety hazards to you

2-3

or others. Installing aftermarket products or having other modifications performed to your vehicle that change any of the vehicle’s design or operation characteristics can put you and others at greater risk of serious injury or death.

You are responsible for injuries related to changes in the vehicle.

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 obscure lights or reflectors.

Accessories fitted to the handlebar or the front fork area can create instability due to improper weight distribution or aerodynamic changes. If accessories are added to the handlebar or front fork area, they must be as

●

●

● lightweight as possible and should be kept to a minimum.

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


Aftermarket Tires and Rims

The tires and rims that came with your motorcycle were designed to match the performance capabilities and to provide the best combination of handling, braking, and comfort. Other tires, rims, sizes, and combinations may not be appropriate. Refer to page 7-14 for tire specifications and more information on replacing your tires.

1

2

2-4

DESCRIPTION

Left view

1

5

6

7

8

9

3

4

1

2

8

1. Headlight (page 7-27)

2. Fuel cock (page 4-7)

3. Starter (choke) knob (page 4-8)

4. Air filter element (page 7-11)

5. Owner’s tool kit (page 7-1)

6. Helmet holder (page 4-9)

7. Shift pedal (page 4-4)

8. Front fork damping adjusting screw (page 4-10)

2 3 4 5 6

7

3-1

EAU10410

DESCRIPTION

EAU10420

Right view

1 2 3 4 5 6 7

10

1. Battery (page 7-25)

2. Fuse (page 7-27)

3. Kickstarter (page 4-8)

4. Shock absorber assembly compression damping force adjusting knob (page 4-11)

5. Main switch (page 4-1)

6. Front fork air valve (page 4-10)

7. Steering lock (page 4-8)

9 8

8. Engine oil filter element (page 7-8)

9. Brake pedal (page 4-4)

10. Shock absorber assembly rebound damping force adjusting dial

(page 4-11)

3-2

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 4-3)

2. Left handlebar switches (page 4-2)

3. Speedometer unit (page 4-2)

4. Right handlebar switches (page 4-2)

5. Brake lever (page 4-4)

6. Throttle grip (page 7-14)

7. Fuel tank cap (page 4-5)

1 2 3

7

3-3

4 5

6

EAU10430

Main switch

ON OFF

The main switch controls the ignition and lighting systems. The various main switch positions are described below.

EAU10490

ON

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

EAU45751

OFF

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

INSTRUMENT AND CONTROL FUNCTIONS

EAU10980 EAU10450

EWA10072

WARNING

Never turn the key to “OFF” while the vehicle is moving, otherwise the electrical systems will be switched off, which may result in loss of control or an accident.

Indicator lights

1 2

3

2

3

1. Turn signal indicator light “

2. High beam indicator light “ ”

3. Neutral indicator light “ ”

”

4

5

Turn signal indicator light “

EAU11020

”

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

EAU11060

Neutral indicator light “ ”

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

6

7

8

9

4-1

5

6

7

8

9

4

3

2

1


High beam indicator light “ ”

EAU11080

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

Speedometer unit

1

4

EAU11630

2

Handlebar switches

Left

1

3

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.

2

3

1. Dimmer switch “ / ”

2. Turn signal switch “ / ”

3. Horn switch “ ”

EAU12347

4-2


Right

EAU12500

Horn switch “ ”

Press this switch to sound the horn.

Clutch lever

EAU12820

1

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 “START”

EAU12400

Dimmer switch “ / ”

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

EAU12691

Start switch “START”

Push this switch to crank the engine with the starter. See page 6-1 for starting instructions prior to starting the engine.

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.

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 4-13.)

2

3

4

5

6

7

8

9

4-3


EAU12870

Shift pedal Brake lever

EAU12890

Brake pedal

EAU12941

1

2

8

9

1

1

1

3

4

5

6

7

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.

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.

4-4


Fuel tank cap

2

1

1. Fuel tank cap

2. Remove.

To remove the fuel tank cap, turn it counterclockwise, and then pull it off.

To install the fuel tank cap, insert it into the tank opening, and then turn it clockwise.

EWA11091

WARNING

Make sure that the fuel tank cap is properly closed after filling fuel.

Leaking fuel is a fire hazard.

EAU13182 EAU13212

Fuel

Make sure there is sufficient gasoline in the tank.

EWA10881

WARNING

Gasoline and gasoline vapors are extremely flammable. To avoid fires and explosions and to reduce the risk of injury when refueling, follow these instructions.

1. Before refueling, turn off the engine and be sure that no one is sitting on the vehicle. Never refuel while smoking, or while in the vicinity of sparks, open flames, or other sources of ignition such as the pilot lights of water heaters and clothes dryers.

2. Do not overfill the fuel tank. Stop filling when the fuel reaches the bottom of the filler tube. Because fuel expands when it heats up, heat from the engine or the sun can cause fuel to spill out of the fuel tank.

1

2

1. Fuel tank filler tube

2. Fuel level

3. Wipe up any spilled fuel immediately.

NOTICE:

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

[ECA10071]

4. Be sure to securely close the fuel tank cap.

EWA15151

WARNING

Gasoline is poisonous and can cause injury or death. Handle gasoline with care. Never siphon gasoline by mouth. If you should swallow some gasoline or inhale a lot of gasoline vapor, or get some gasoline in

4-5

2

3

4

5

6

7

8

9

2

1

INSTRUMENT AND CONTROL FUNCTIONS your eyes, see your doctor immediately. If gasoline spills on your skin, wash with soap and water. If gasoline spills on your clothing, change your clothes.

leaded fuel will extend spark plug life and reduce maintenance costs.

Fuel tank breather hose

EAU13412

1

EAU13332

3

4

5

6

7

8

9

Recommended fuel:

UNLEADED GASOLINE ONLY

Fuel tank capacity:

9.5 L (2.51 US gal, 2.09 Imp.gal)

Fuel reserve amount:

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

ECA11400

NOTICE

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 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 un-

1. Fuel tank breather hose

Before operating the motorcycle:

● Check the fuel tank breather hose connection.

● Check the fuel tank breather hose for cracks or damage, and replace

● it if damaged.

Make sure that the fuel tank breather hose is not blocked, and clean it if necessary.

4-6


EAU13561

Fuel cock

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

The fuel cock has three positions:

ON

OFF

RES

ON

FUEL

OFF

ON

1

This indicates reserve. If you run out of fuel while riding, move the lever to this position. Fill the tank at the first opportunity. Be sure to set the lever back to

“ON” after refueling!

2

3

RES

OFF

ON

FUEL

1

1. Arrow mark positioned over “OFF”

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

1. Arrow mark positioned over “ON”

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

RES

RES

RES

OFF

ON

FUEL

1

4

5

6

7

8

9

1. Arrow mark positioned over “RES”

4-7


Starter (choke) knob “ ”

EAU13600

Kickstarter

EAU13660

Steering lock

EAU13740

1

2

(a)

(b)

1

3

1

1

4

5

6

7

8

9

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. Kickstarter

If the engine fails to start by pushing the start switch, try to start it by using the kickstarter. To start the engine, fold out the kickstarter lever, move it down lightly with your foot until the gears engage, and then push it down smoothly but forcefully. This model is equipped with a primary kickstarter, allowing the engine to be started in any gear if the clutch is disengaged. However, shifting the transmission into the neutral position before starting is recommended.

1. Steering lock

To lock the steering

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

2. Open the steering lock cover, and then insert the key.

3. Turn the key 1/8 turn counterclockwise, push it in, and then turn it 1/8 turn clockwise.

4. Check that the steering is locked, remove the key, and then close the lock cover.

To unlock the steering

Reverse the above procedure.

4-8

EAU13960

Seat

To remove the seat

Remove the bolts, and then pull the seat off.


EAU14282

1

Helmet holder

2

2

1

1. Bolt

To install the seat

1. Insert the projections on the front of the seat into the seat holders as shown.

1. Projection

2. Seat holder

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

TIP

Make sure that the seat is properly secured before riding.

1

1. Helmet holder

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

To lock the helmet holder, place it in the original position, and then remove the key.

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.

[EWA10161]

3

4

5

6

7

8

9

4-9

1

2

3

4

5

6

7

8

9


EAU14673

Adjusting the front fork

EWA10180

WARNING

Always adjust both fork legs equally, otherwise poor handling and loss of stability may result.

The front fork is equipped with air valves for adjusting the spring rate and screws for adjusting the damping force.

ECA10091

NOTICE

To avoid damaging the front fork oil seals, do not exceed the maximum air pressure.

each fork leg.

2

1

Spring rate

The total spring rate is adjusted by changing the air pressure as follows.

1. Lift the front wheel off the ground according to the procedure on page 7-31.

TIP

When checking and adjusting the air pressure, there should be no weight on the front end of the vehicle.

2. Remove the air valve cap from

1. Front fork air valve cap

2. Front fork air valve

3. Check the air pressure in each fork leg with an air pressure gauge.

TIP

An optional air pressure gauge is available at a Yamaha dealer.

4. To increase the spring rate and thereby harden the suspension, increase the air pressure with an air pump. To decrease the spring rate and thereby soften the suspension, decrease the air pressure by pushing each valve stem down.

4-10

Spring rate:

Minimum (soft):

Air pressure = 0 kPa (0 kgf/cm

2

,

0 psi)

Standard:

Air pressure = 0 kPa (0 kgf/cm

2

,

0 psi)

Maximum (hard):

Air pressure = 40 kPa (0.4 kgf/ cm

2

, 5.8 psi)

5. Securely install the air valve caps.

Damping force

1. Remove the rubber cap from each fork leg.

1

1. Rubber cap

2. To increase the damping force and thereby harden the damping, turn


the adjusting screw on each fork leg in direction (a). To decrease the damping force and thereby soften the damping, turn the adjusting screw on each fork leg in direction (b).

(b)

1. Damping force adjusting screw

1

(a)

Damping setting:

Minimum (soft):

20 clicks in direction (b)*

Standard:


Maximum (hard):


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

rubber caps to prevent dust, etc. from entering the fork legs.

[ECA10961]

TIP

Although the total number of clicks of a damping force adjusting mechanism may not exactly match the above specifications due to small differences in production, the actual number of clicks always represents the entire adjusting range. To obtain a precise adjustment, it would be advisable to check the number of clicks of each damping force adjusting mechanism and to modify the specifications as necessary.

ECA10101

NOTICE

To avoid damaging the mechanism, do not attempt to turn beyond the maximum or minimum settings.

EAU14972

Adjusting the shock absorber assembly

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

ECA10101

NOTICE

To avoid damaging the mechanism, do not attempt to turn beyond the maximum or minimum settings.

Spring preload

Have a Yamaha dealer adjust the spring preload.

3. Securely install the rubber caps.

NOTICE:

Be sure to install the

2

3

4

5

6

7

8

9

4-11

1

2

3

4

5

6

7

8

9


Rebound damping force

1

Compression damping force

1

(b)

(a)

Compression damping setting:

Minimum (soft):

5 click(s) in direction (a)*

Standard:


Maximum (hard):


* With the adjusting knob fully turned in direction (b)

(b)

(a)

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):

16 click(s) in direction (b)*

Standard:


Maximum (hard):


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

1. Compression damping force adjusting knob

To increase the compression damping force and thereby harden the compression damping, turn the adjusting knob in direction (a). To decrease the compression damping force and thereby soften the compression damping, turn the adjusting knob in direction (b).

TIP

To obtain a precise adjustment, it is advisable to check the actual total number of clicks or turns of each damping force adjusting mechanism. This adjustment range may not exactly match the specifications listed due to small differences in production.

4-12


EAU15301

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.

TIP

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.

4-13

EAU15313

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 side-

● stand is up, but the clutch lever is not pulled.

It prevents starting when the transmission is in gear and the clutch le-

● ver 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.

TIP

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

2

3

4

5

6

7

8

9

5

6

7

8

9

3

4

1

2


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.

WARNING

If a malfunction is noted, have a Yamaha dealer check the system before riding.

The neutral switch may not be working correctly.

The motorcycle should not be ridden until checked by a Yamaha dealer.

The sidestand switch may not be working correctly.


The clutch switch may not be working correctly.


4-14

FOR YOUR SAFETY – PRE-OPERATION CHECKS

EAU15595

Inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the Owner’s Manual.

EWA11151

WARNING

Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equipment damage.

Do not operate the vehicle if you find any problem. If a problem cannot be corrected by the procedures provided in this manual, have the vehicle inspected by a Yamaha dealer.

Before using this vehicle, check the following points:

2

3

4

5

6

7

8

9

5-1


1

2

3

4

5

6

7

8

9

Pre-operation check list

ITEM

Fuel

Engine oil

Front brake

Rear brake

Clutch

Throttle grip

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

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.

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

Check brake pads for wear.


Check fluid level in reservoir.

If necessary, add recommended brake fluid to specified level.

Check hydraulic system for leakage.

Check operation.

Lubricate cable if necessary.

Check lever free play.


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.

5-2

PAGE

4-5

7-8

7-17, 7-18, 7-19

7-18, 7-19

7-16

7-14, 7-22

EAU15605

ITEM

Control cables

Drive chain

Wheels and tires

Brake and shift pedals

Brake and clutch levers

Sidestand

Chassis fasteners

Instruments, lights, signals and switches

Sidestand switch


●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

CHECKS


Lubricate if necessary.

Check chain slack.


Check chain condition.

Lubricate if necessary.

Check for damage.

Check tire condition and tread depth.

Check air pressure.

Correct if necessary.


Lubricate pedal pivoting points if necessary.


Lubricate lever pivoting points if necessary.


Lubricate pivot if necessary.

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

Tighten if necessary.

Check operation.


Check operation of ignition circuit cut-off system.

If system is not working correctly, have Yamaha dealer check vehicle.

PAGE

7-22

7-20, 7-21

7-14, 7-16

7-23

7-23

7-23

—

—

4-13

2

3

4

5

6

7

8

9

5-3

1

2

3

4

5

6

7

8

9

OPERATION AND IMPORTANT RIDING POINTS

EAU15951

Read the Owner’s Manual carefully to become familiar with all controls. If there is a control or function you do not understand, ask your Yamaha dealer.

EWA10271

WARNING

Failure to familiarize yourself with the controls can lead to loss of control, which could cause an accident or injury.

EAU16534

Starting 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.

See page 4-13 for more information.

1. Turn the fuel cock lever to “ON”.

2. Turn the key to “ON” and make sure that the engine stop switch is set to “ ”.

3. Shift the transmission into the neutral position. (See page 6-2.) The neutral indicator light should come on. If not, ask a Yamaha dealer to check the electrical circuit.

4. Turn the starter (choke) on and completely close the throttle. (See page 4-8.)

5. Start the engine by pushing the start switch or by pushing the kickstarter lever down.

If the engine fails to start, release the start switch, wait a few seconds, and then try again. Each

6-1 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.

NOTICE:

For maximum engine life, never accelerate hard when the engine is cold!

[ECA11041]

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

TIP

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

(choke) turned off.


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.

TIP

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.

ECA10260

NOTICE

●

Even with the transmission in

6-2

●

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.

2

3

4

5

6

7

8

9

8

9

7

1

2

3

4

5

6


EAU16800

Tips for reducing fuel consumption

Fuel consumption depends largely on your riding style. Consider the following tips to reduce fuel consumption:

● Turn the starter (choke) off as soon as possible.

● Shift up swiftly, and avoid high engine speeds during acceleration.

●

●

Do not rev the engine while shifting down, and avoid high engine speeds with no load on the engine.

Turn the engine off instead of letting it idle for an extended length of time (e.g., in traffic jams, at traffic lights or at railroad crossings).

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.

EAU17031

1600 km (1000 mi) and beyond

The vehicle can now be operated normally.

ECA10270

NOTICE

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

0–1000 km (0–600 mi)

Avoid prolonged operation above 1/3 throttle.

NOTICE:

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

[ECA11441]

1000–1600 km (600–1000 mi)

Avoid prolonged operation above 1/2 throttle.

6-3

EAU17171

Parking

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

EWA10311

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 and be burned.

Do not park on a slope or on soft ground, otherwise the vehicle may overturn, increasing the risk of a fuel leak and fire.

Do not park near grass or other flammable materials which might catch fire.


5

6

7

8

9

2

3

4

6-4

1

2

3

4

5

6

7

8

9

PERIODIC MAINTENANCE AND ADJUSTMENT

EAU17241

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

The intervals given in the periodic maintenance and lubrication chart should be simply considered as a general guide under normal riding conditions. However, depending on the weather, terrain, geographical location, and individual use, the maintenance intervals may need to be shortened.

EWA10321

WARNING

Failure to properly maintain the vehicle or performing maintenance activities incorrectly may increase your risk of injury or death during service or while using the vehicle. If you are not familiar with vehicle service, have a Yamaha dealer perform service.

EWA15121

WARNING

Turn off the engine when performing maintenance unless otherwise specified.

●

A running engine has moving parts that can catch on body

●

parts or clothing and electrical parts that can cause shocks or fires.

Running the engine while servicing can lead to eye injury, burns, fire, or carbon monoxide poisoning – possibly leading to death. See page 2-1 for more information about carbon monoxide.

Owner’s tool kit

1

EAU17341

1. Owner’s tool kit

The owner’s tool kit is located behind panel A. (See page 7-6.)

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.

TIP

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

7-1


EAU1770A

Periodic maintenance and lubrication chart

TIP

●

●

●

The annual checks must be performed every year, except if a kilometer-based maintenance, or for the UK, a mileage-based maintenance, is performed instead.

From 50000 km (30000 mi), repeat the maintenance intervals starting from 10000 km (6000 mi).

Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.

NO.

1 *

Fuel line

2

Spark plug

3 *

Valves

4

5

Air filter element

Clutch

ITEM

6 *

Front brake

7 *

Rear brake

CHECK OR MAINTENANCE JOB

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

Check fuel hoses for cracks or damage.

Check condition.

Clean and regap.

Replace.

Check valve clearance.

Adjust.

Clean.

Replace.

Check operation.

Adjust.

Check operation, fluid level and vehicle for fluid leakage.

Adjust brake lever free play.

Replace brake pads.

Check operation, fluid level and vehicle for fluid leakage.

Replace brake pads.

1000 km

(600 mi)

√

ODOMETER READING

10000 km

(6000 mi)

20000 km

(12000 mi)

30000 km

(18000 mi)

40000 km

(24000 mi)

√ √ √ √

√

√

√

√

√

Every 20000 km (12000 mi)

√

√

√ √

√

√

√

ANNUAL

CHECK

√

√

√

√

√

√ √

Whenever worn to the limit

√ √

Whenever worn to the limit

√

√

√

√

2

3

4

5

6

7

8

9

7-2

1

2

3

4

5

6

7

8

9


NO.

8 *

9 *

10

11

12

13

14

*

*

*

*

Wheels

Tires

ITEM

Brake hoses

Wheel bearings

Swingarm

Drive chain

Steering bearings

15 *

Chassis fasteners

16

17

Brake lever pivot shaft

Brake pedal pivot shaft


1000 km

(600 mi)


10000 km

(6000 mi)

√

20000 km

(12000 mi)

30000 km

(18000 mi)

√

Every 4 years

√

√ √

Every 20000 km (12000 mi)

40000 km

(24000 mi)

√

ANNUAL

CHECK

√

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

Check for cracks or damage.

Replace.

Check runout, spoke tightness and for damage.

Tighten spokes if necessary.

Check tread depth and for damage.


Check air pressure.


Check bearing for looseness or damage.

Check operation and for excessive play.

Check chain slack, alignment and condition.

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

Check bearing play and steering for roughness.

Lubricate with lithium-soap-based grease.

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

●

Lubricate with silicone grease.

●


√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

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

√

√

√

7-3


NO.

ITEM CHECK OR MAINTENANCE JOB

18

19

20 *

21 *

22 *

23 *

24 *

25

26

27 *

28

29 *

Clutch lever pivot shaft

Sidestand

Sidestand switch

Front fork

●

●

●

●

●

●


Check operation.

Lubricate.

Check operation.

Check operation and for oil leakage.

Check operation and shock absorber for oil leakage.

Shock absorber assembly

Rear suspension relay arm and connecting arm pivoting points

●

Check operation.

Carburetor

Engine oil

●

●

●

●

Check starter (choke) operation.

Adjust engine idling speed.

Change.

Check oil level and vehicle for oil leakage.

Engine oil filter element

Front and rear brake switches

Moving parts and cables

●

●

●

Clean.

Check operation.

Lubricate.

Throttle grip housing and cable

●

●

●

Check operation and free play.

Adjust the throttle cable free play if necessary.

Lubricate the throttle grip housing and cable.

1000 km

(600 mi)

√


10000 km

(6000 mi)

20000 km

(12000 mi)

30000 km

(18000 mi)

40000 km

(24000 mi)

√ √ √ √

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

ANNUAL

CHECK

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

7-4

2

3

4

5

6

7

8

9

7

8

9


1

NO.

ITEM

30 *

Lights, signals and switches

●

●


Check operation.

Adjust headlight beam.

1000 km

(600 mi)

√


10000 km

(6000 mi)

20000 km

(12000 mi)

30000 km

(18000 mi)

√ √ √

40000 km

(24000 mi)

√

ANNUAL

CHECK

√

EAU18670

2

3

4

5

TIP

●

●

●

●

●

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

Hydraulic brake service

Regularly check and, if necessary, correct the brake fluid level.

Every two years replace the internal components of the brake master cylinders and calipers, and change the brake fluid.

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

6

7-5

EAU18722

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.


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

7-6

1

2

3

4

5

6

7

8

9


2

1

1. Screw

2. Panel B

To install the panel

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

EAU19603

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.

1

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. 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).

TIP

If the spark plug shows a distinctly different color, the engine could be operating improperly. 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

7-7

1. Spark plug gap

Spark plug gap:

0.7–0.8 mm (0.028–0.031 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.


necessary.

Specified spark plug:

NGK/CR9E

DENSO/U27ESR-N

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

Tightening torque:

Spark plug:

12.5 Nm (1.25 m·kgf, 9.0 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.

TIP

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.

1

EAU19788

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. 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 crankcase.

TIP

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

7-8

2

3

4

5

6

7

8

9


element.

3

1

2

1

2

3

1 2

1

3

4

5

6

7

8

9

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.

1. Engine oil filler bolt

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

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

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

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

1. Engine oil drain bolt

1

TIP

Check each washer for damage and replace them if necessary.

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

7-9

1. Oil filter element drain bolt

2. Bolt

3. Oil filter element cover

TIP

Skip steps 5–9 if the oil filter element is not being cleaned.

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

6. Remove the oil filter element and

O-rings.


2


Oil filter element cover bolt:

10 Nm (1.0 m·kgf, 7.2 ft·lbf)

1

1. Oil filter element

2. O-ring

7. Check the O-rings for damage and replace them if necessary.

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

TIP

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

9. Install the oil filter element cover by installing the bolts, then tightening them to the specified torque.

TIP

Make sure that the O-rings are properly seated.

10. Install the engine oil drain bolt, and then tighten it to the specified torque.

11. Install the engine oil filter element drain bolt, and then tighten it to the specified torque.

Tightening torques:

Engine oil drain bolt:

20 Nm (2.0 m·kgf, 14.5 ft·lbf)

Oil filter element drain bolt:

10 Nm (1.0 m·kgf, 7.2 ft·lbf)

12. Refill with the specified amount of the recommended engine oil, and then install and tighten the engine oil filler bolt.

Recommended oil:

See page 9-1.

Oil quantity:

Without oil filter element replacement:

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

With oil filter element replacement:

1.20 L (1.27 US qt, 1.06 Imp.qt)

TIP

Be sure to wipe off spilled oil on any parts after the engine and exhaust system have cooled down.

ECA11620

NOTICE

●

●

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 addition, do not use oils labeled

“ENERGY CONSERVING II” or higher.

Make sure that no foreign material enters the crankcase.

2

3

4

5

6

7

8

9

7-10

1

2

3

4

5

6

7

8

9


1

2

●

idling until oil flows out. If no oil comes out after one minute, turn the engine off immediately so it will not seize. If this occurs, have a Yamaha dealer repair the vehicle.

After checking the oil pressure, tighten the bleed bolt to the specified torque.

EAU20903

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 7-6.)

2. Remove the air filter case cover by removing the holding clips.

1. “CD” specification

2. “ENERGY CONSERVING II”

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

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

ECA10970

NOTICE

After replacing the engine oil, make sure to check the oil pressure as described below.

●

Remove the bleed bolt from the engine oil filter element cover.

●

Start the engine and keep it

1

1. Bleed bolt


Bleed bolt:

7 Nm (0.7 m·kgf, 5.0 ft·lbf)

1

1. Holding clip

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

7-11

1


1

3

2

4 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.

[ECA10481]

8. Install the panel.

2

1. Air filter element

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

1

6. Apply oil of the recommended type to the entire surface of the sponge material, and then squeeze the excess oil out.

TIP

The sponge material should be wet but not dripping.

2

1. Sponge material

2. Air filter element frame

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

Recommended oil:

Yamaha foam air filter oil or other quality foam air filter oil

7. Install the sponge material onto the frame, insert the air filter element into the air filter case, and then install the air filter case cover by installing the holding clips.

NOTICE:

Make sure that the air filter element is properly seated

7-12

5

6

3

4

7

8

9

1

2

3

4

5

6

7

8

9


EAU21280

Adjusting the carburetor

The carburetor is an important part of the engine and requires very sophisticated adjustment. Therefore, most carburetor adjustments should be left to a

Yamaha dealer, who has the necessary professional knowledge and experience. The adjustment described in the following section, however, may be serviced by the owner as part of routine maintenance.

ECA10550

NOTICE

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

EAU21340

Adjusting the engine idling speed

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

The engine should be warm before making this adjustment.

TIP

●

●

The engine is warm when it quickly responds to the throttle.

A diagnostic tachometer is needed to make this adjustment.

1. Attach the tachometer to the spark plug lead.

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

(b)

1

1. Throttle stop screw

Engine idling speed:

1250–1350 r/min

(a)

TIP

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

Yamaha dealer make the adjustment.

7-13


EAU21382

Checking the throttle cable free play

1

EAU21401

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.

EAU21631

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.

EWA10501

WARNING

Operation of this vehicle with improper tire pressure may cause severe injury or death from loss of control.

●

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.

2

3

4

5

6

7

8

9

7-14

1

2

3

4

5

6

7

8

9


Tire air pressure (measured on cold tires):

0–90 kg (0–198 lb):

Front:

125 kPa (1.25 kgf/cm

2

, 18 psi)

Rear:


2

, 22 psi)

90–180 kg (198–397 lb):

Front:


2

, 22 psi)

Rear:


2

, 25 psi)

Off-road riding:

Front:


2

, 18 psi)

Rear:


2

, 22 psi)

Maximum load*:

180 kg (397 lb)

* Total weight of rider, passenger, cargo and accessories

EWA10511

WARNING

Never overload your vehicle. Operation of an overloaded vehicle could cause an accident.

Tire inspection

2

1

1. Tire tread depth

2. Tire sidewall

3. Tire wear indicator

3

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)

TIP

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

Tire information

This motorcycle is equipped with tube tires.

EWA10461

WARNING

The front and rear tires should be of the same make and design, otherwise the handling characteristics of the vehicle may be different, which could lead to an accident.

After extensive tests, only the tires listed below have been approved for this model by Yamaha Motor Co., Ltd.

Front tire:

Size:

3.00-21 51P

Manufacturer/model:

DUNLOP/D605F

Rear tire:

Size:

4.60-18 63P

Manufacturer/model:

DUNLOP/D605

●

EWA10560

WARNING

It is dangerous to ride with a

7-15


●

●

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

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

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

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

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 damage before each ride. If any damage is found, have a Yamaha dealer replace the wheel. Do not

● attempt even the smallest repair to the wheel. A deformed or cracked wheel must be replaced.

The wheel should be balanced whenever either the tire or wheel has been changed or replaced. An unbalanced wheel can result in poor performance, adverse han-

● dling 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.

EAU22032

Adjusting the clutch lever free play

5

1 2

(a)

3 4

(a)

(b)

(b)

1. Locknut (clutch lever)

2. Adjusting bolt

3. Locknut (clutch cable)

4. Adjusting nut

5. 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 clutch lever free play adjusting bolt in direction (a).

2

3

4

5

6

7

8

9

7-16

1

2

3

4

5

6

7

8

9


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

3. If the specified clutch lever free play could be obtained as described above, tighten the locknut and skip the rest of the procedure, otherwise, proceed as follows.

4. Fully turn the adjusting bolt in direction (a) to loosen the clutch cable.

5. Loosen the locknut further down the clutch cable.

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

7. Tighten both locknuts.

EAU22093

Adjusting the brake lever free play

2

1

(b)

(a)

3

1. Brake lever free play adjusting screw

2. Locknut

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 brake lever free play adjusting screw in direction

(a). To decrease the brake lever free play, turn the adjusting screw in direction (b).

7-17

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.


Adjusting the rear brake light switch

EAU22271 EAU22390

Checking the front and rear brake pads

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

1

2

EAU22430

Front brake pads

(a)

(b)

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 rear brake light switch 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 wear indicator grooves, which allow you to check the brake pad wear without having to disassemble the brake.

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

Rear brake pads

1

EAU22460

1. Wear indicator

Each rear brake pad is provided with a wear indicator, which allows you to check the brake pad wear without having to disassemble the brake. To check the brake pad wear, check the position of the wear indicator while applying the brake. If a brake pad has worn to the point that the wear indicator almost touches the brake disc, have a Yamaha dealer replace the brake pads as a set.

7-18

2

3

4

5

6

7

8

9

1

2

3

4

5

6

7

8

9


EAU22580

Checking the brake fluid level

Front brake

1

LOWER


Rear brake

1

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 brake

● fluid reservoir is level.

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

Recommended brake fluid:

DOT 4


Insufficient brake fluid may allow air to

●

●

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

Be careful that water does not enter the brake fluid reservoir when

7-19

●

● refilling. Water will significantly lower the boiling point of the fluid and may result in vapor lock.

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

As the brake pads wear, it is normal for the brake fluid level to gradually go down. However, if the brake fluid level goes down suddenly, have a Yamaha dealer check the cause.


EAU22721

Changing the brake fluid

Have a Yamaha dealer change the brake fluid at the intervals specified in the TIP 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.

EAU22773

To check the drive chain slack

1. Place the motorcycle on the sidestand.

TIP

When checking and adjusting the drive chain slack, there should be no weight on the motorcycle.

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:

35.0–50.0 mm (1.38–1.97 in)

1

1. Drive chain slack

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

EAU22912

To adjust the drive chain slack

1. Remove the cotter pin from the axle nut, and then loosen the axle nut.

2. To tighten the drive chain, turn the drive chain 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.

NOTICE:

Improper drive chain slack will overload the engine

2

3

4

5

6

7

8

9

7-20

1

2

3

4

5

6

7

8

9

PERIODIC MAINTENANCE AND ADJUSTMENT 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.

[ECA10571]

TIP

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

1

(b)

(a)

2

3


Axle nut:

105 Nm (10.5 m·kgf, 76 ft·lbf)

4. Insert a new cotter pin into the axle nut, and then bend its ends as shown.

WARNING! Always use a new cotter pin for the axle nut.

[EWA10701]

1. Cotter pin

1

1. Cotter pin

2. Axle nut

3. Drive chain adjusting plate

3. Tighten the axle nut to the specified torque.

TIP

Make sure that two notches in the axle nut are aligned with the hole through the wheel axle, otherwise further tighten the axle nut until they are.

EAU23023

Cleaning and 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

NOTICE

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.

NOTICE:

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

[ECA11121]

2. Wipe the drive chain dry.

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

NOTICE:

Do not use engine oil or any other lubricants for the drive chain, as they

7-21

PERIODIC MAINTENANCE AND ADJUSTMENT may contain substances that could damage the O-rings.

[ECA11111]

EAU23101

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.

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

[EWA10721]

Recommended lubricant:

Engine oil

EAU23111

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 at the intervals specified in the periodic maintenance chart.

2

3

4

5

6

7

8

9

7-22


EAU23142

Checking and lubricating the brake and clutch levers

EAU23182

Checking and lubricating the brake pedal

EAU23202

Checking and lubricating the sidestand

1

2

3

4

5

6

7

8

9

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

Recommended lubricants:

Brake lever:

Silicone grease

Clutch lever:

Lithium-soap-based grease

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



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

EWA10731

WARNING

If the sidestand does not move up and down smoothly, have a Yamaha dealer check or repair it. Otherwise, the sidestand could contact the ground and distract the operator, resulting in a possible loss of control.



7-23

EAU23272

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

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


push down hard on the handlebars several times to check if the front fork compresses and rebounds smoothly.

ECA10590

NOTICE

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

EAU23282

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. (See page 7-31 for more information.)

WARNING! To avoid injury, securely support the vehicle so there is no danger of it falling over.

[EWA10751]

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.

To check the operation

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

WARNING! To avoid injury, securely support the vehicle so there is no danger of it falling over.

[EWA10751]

2. While applying the front brake,

7-24

2

3

4

5

6

7

8

9

5

6

8

9

7

4

3

1

2


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.

Battery

1

EAU23383

1. Battery

The battery is located behind panel .

(See page 7-6.)

This model is equipped with a VRLA

(Valve Regulated Lead Acid) battery.

There is no need to check the electrolyte or to add distilled water. However, the battery lead connections need to be checked and, if necessary, tightened.

ECA10620

NOTICE

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

7-25


●

●

●

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 fol-

●

●

●

lowing FIRST AID.

EXTERNAL: Flush with plenty of water.

INTERNAL: Drink large quantities of water or milk and immediately call a physician.

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

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

KEEP THIS AND ALL BATTER-

IES OUT OF THE REACH OF

CHILDREN.

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.

NOTICE:

When removing the battery, be sure the key is turned to “OFF”, then disconnect the negative lead before disconnecting the positive lead.

[ECA16302]

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.

ECA10631

NOTICE

●

●

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

To charge a VRLA (Valve Regulated Lead Acid) 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 constant-voltage battery charger, have a Yamaha dealer charge your battery.

7-26

2

3

4

5

6

7

8

9

1

2

3

4

5

6

7

8

9


Replacing the fuse

EAU23461

possibly a fire.

[EWA15131]

Specified fuse:

15.0 A

1

2

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.

EAU23814

Replacing the headlight bulb

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

ECA10660

NOTICE

Do not touch the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the luminosity of the bulb, and the bulb life will be adversely affected. Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with alcohol or thinner.

1. Fuse

2. Spare fuse

The fuse holder is located beside the battery compartment behind panel B.

(See page 7-6.)

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.

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

1

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

1. Remove cowling A. (See

7-27

page 7-6.)

2. Remove the headlight unit by removing the bolts.


1

EAU24133

Replacing the tail/brake light bulb

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

1

2

1. Bolt

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

4. Remove the headlight bulb holder by turning it counterclockwise, and then remove the burnt-out bulb.

1. Headlight bulb holder

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

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

7. Place the headlight unit in the original position, and then install the bolts.

8. Install the cowling.

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

3

2

4

1

5

1. Screw

2. Tail/brake light lens

2. Remove the burnt-out bulb by pushing it in and turning it counterclockwise.

6

7

8

9

7-28

8

9

5

6

7

3

4

2

1


1

EAU24204

Replacing a turn signal light bulb

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

1

2

1

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.

NOTICE:

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

[ECA10681]

1. Screw

2. Turn signal light lens

2. Remove the burnt-out 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.

NOTICE:

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

[ECA11191]

7-29

EAU24303

Replacing the license plate light bulb

1. Remove the license plate light by removing the nuts.

PERIODIC MAINTENANCE AND ADJUSTMENT may break.

[ECA11421]

6. Install the license plate light by installing the nuts.

1

1

2

3

1. Nut

2. Remove the license plate light lens by removing the nuts.

1. Nut

3. Remove the burnt-out bulb by pulling it out.

1

4

5

6

7

8

9

1. Bulb

4. Insert a new bulb into the socket.

5. Install the lens by installing the nuts.

NOTICE:

Do not overtighten the nuts, otherwise the lens

7-30

1

2

3

4

5

6

7

8

9


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.

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

Front wheel

EAU24360

EAU24641

To remove the front wheel

EWA10821

WARNING

To avoid injury, securely support the vehicle so there is no danger of it falling over.

1. Disconnect the speedometer cable from the front wheel.

2. Loosen the wheel axle holder nuts, then the wheel axle.

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.

3

1

2

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

1. Speedometer cable

2. Axle holder nut

3. Wheel axle

3. Lift the front wheel off the ground

7-31


according to the procedure on page 7-31.

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

NOTICE:

Do not apply the brake after the wheel has been removed together with the brake disc, otherwise the brake pads will be forced shut.

[ECA11071]

TIP

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 retainer on the fork leg.

1

EAU24950

To install the front wheel

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

specified tightening torque. Tighten the upper nuts first and then lower ones. When tightened in this sequence, there should be a gap formed at the bottom of the axle holder.

1

3

2

1

1. Speedometer gear unit

2. Lift the wheel up between the fork legs.

1. Retainer

3. Insert the wheel axle.

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

5. Tighten the wheel axle to the specified torque.


Wheel axle:

58 Nm (5.8 m·kgf, 42 ft·lbf)

6. Tighten the axle holder nuts to the

7-32

1. Upper nut

2. Lower nut

3. Gap


Axle holder nut:

10 Nm (1.0 m·kgf, 7.2 ft·lbf)

7. After tightening the axle holder nuts, push down hard on the handlebars several times while applying the front brake to check if the front fork compresses and rebounds smoothly.

2

3

4

5

6

7

8

9

1

2

3

4

5

6

7

8

9


8. Connect the speedometer cable.

EAU25080

Rear wheel

EAU25262

To remove the rear wheel

EWA10821

WARNING

To avoid injury, securely support the vehicle so there is no danger of it falling over.

1. Remove the cotter pin, and then loosen the axle nut.

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

3

2

1

1. Cotter pin

2. Axle nut

3. Drive chain adjusting plate

2. Lift the rear wheel off the ground according to the procedure on page 7-31.

TIP

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

4. Remove the axle nut.

5. Pull the wheel axle out.

6. Remove the spacer, the drive chain adjusting plates, and the wheel.

EAU25541

To install the rear wheel

1. Install the drive chain onto the rear sprocket.

2. Install the wheel axle, spacer, and

7-33


drive chain adjusting plates.

TIP

●

●

Make sure that there is enough space between the brake pads before inserting the brake disc between the brake pads.

Make sure that the wheel axle is inserted from the left-hand side and that the drive chain adjusting plates are installed with the punched sides facing to the outside.

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

4. Adjust the drive chain slack. (See page 7-20.)

5. Tighten the axle nut to the specified torque, and then install the cotter pin.

WARNING! Always use a new cotter pin for the axle nut.

[EWA10701]


Axle nut:

105 Nm (10.5 m·kgf, 76 ft·lbf)

EAU25851

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.

EWA15141

WARNING

When checking the fuel system, do not smoke, and make sure there are no open flames or sparks in the area, including pilot lights from water

7-34

heaters or furnaces. Gasoline or gasoline vapors can ignite or explode, causing severe injury or property damage.

2

3

4

5

6

7

8

9


1

Troubleshooting chart

1. Fuel

There is enough fuel.

Check the fuel level in the fuel tank.

There is no fuel.

2

3

2. Compression

Operate the electric starter.

There is compression.

There is no compression.

4

5

6

3. Ignition

Remove the spark plug and check the electrodes.

Wet

Dry

Check the compression.

Supply fuel.

The engine does not start.

Check the compression.

Check the ignition.

Have a Yamaha dealer check the vehicle.

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.


Check the battery.

7

8

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.



9

7-35

EAU25902

MOTORCYCLE CARE AND STORAGE

EAU37833

Matte color caution

ECA15192

NOTICE

Some models are equipped with matte colored finished parts. Be sure to consult a Yamaha dealer for advice on what products to use before cleaning the vehicle. Using a brush, harsh chemical products or cleaning compounds when cleaning these parts will scratch or damage their surface. Wax also should not be applied to any matte colored finished parts.

EAU26003

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 prod-

8-1 ucts onto seals, gaskets, sprockets, the drive chain and wheel axles. Always rinse the dirt and degreaser off with water.

Cleaning

ECA10771

NOTICE

●

●

●

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 plastic parts such as cowlings, panels, windshields, headlight lenses, meter lenses, etc. 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 sponges which have been in

2

3

4

5

6

7

8

9

1

2

3

4

5

6

7

8

9


●

●

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 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.

TIP

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.

NOTICE:

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

[ECA10791]

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

8-2


caused by stones, etc.

7. Wax all painted surfaces.

8. Let the motorcycle dry completely before storing or covering it.

EWA11131

WARNING

Contaminants on the brakes or tires can cause loss of control.

●

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 riding at higher speeds, test the motorcycle’s braking performance and cornering behavior.

ECA10800

NOTICE

●

●

Apply spray oil and wax sparingly and make sure to wipe off any excess.

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

●

product.

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

TIP

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

Storage

EAU26151

Short-term

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

ECA10810

NOTICE

●

●

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

8-3

2

3

4

5

6

7

8

9

1

2

3

4

5

6

7

8

9


“OFF”.

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

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

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

from corrosion.

a. Remove the spark plug cap and spark plug.

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

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.)

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

[EWA10951] e. Remove the spark plug cap from the spark plug, and then install the spark plug and the spark plug cap.

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

7-25.

TIP

Make any necessary repairs before storing the motorcycle.

8-4

Dimensions:

Overall length:

2195 mm (86.4 in)

Overall width:

835 mm (32.9 in)

Overall height:

1255 mm (49.4 in)

Seat height:

910 mm (35.8 in)

Wheelbase:

1410 mm (55.5 in)

Ground clearance:

300 mm (11.81 in)

Minimum turning radius:

2200 mm (86.6 in)

Weight:

With oil and fuel:

131.0 kg (289 lb)

Engine:

Engine type:

Air cooled 4-stroke, DOHC

Cylinder arrangement:

Forward-inclined single cylinder

Displacement:

249.0 cm

3

Bore

×

stroke:

73.0

×

59.6 mm (2.87

×

2.35 in)

Compression ratio:

10.20 :1

Starting system:

Electric starter and kickstarter

EAU2633P Lubrication system:

Wet sump

Engine oil:

Type:

SAE 10W-30, SAE 10W-40, SAE 15W-40,

SAE 20W-40 or SAE 20W-50

-20 -10 0 10 20 30 40 50 ˚C

SAE 10W-30

SAE 10W-40

SAE 10W-50

SAE 15W-40

SAE 20W-40

SAE 20W-50

Recommended engine oil grade:

API service SG type or higher, JASO standard MA

Engine oil quantity:

Without oil filter element replacement:

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

With oil filter element replacement:

1.20 L (1.27 US qt, 1.06 Imp.qt)

Air filter:

Air filter element:

Wet element

Fuel:

Recommended fuel:

Unleaded gasoline only

Fuel tank capacity:

9.5 L (2.51 US gal, 2.09 Imp.gal)

SPECIFICATIONS

Fuel reserve amount:

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

Carburetor:

Manufacturer:

TEIKEI

Type

×

quantity:

Y30P x 1

Spark plug (s):

Manufacturer/model:

NGK/CR9E

Manufacturer/model:

DENSO/U27ESR-N

Spark plug gap:

0.7–0.8 mm (0.028–0.031 in)

Clutch:

Clutch type:

Wet, multiple-disc

Transmission:

Primary reduction system:

Spur gear

Primary reduction ratio:

74/24 (3.083)

Secondary reduction system:

Chain drive

Secondary reduction ratio:

44/14 (3.143)

Transmission type:

Constant mesh 6-speed

Operation:

Left foot operation

Gear ratio:

1st:

37/15 (2.467)

9-1

2

3

4

5

6

7

8

9

1

2

3

4

5

6

7

8

9

SPECIFICATIONS

2nd:

29/16 (1.813)

3rd:

30/22 (1.364)

4th:

27/25 (1.080)

5th:

24/27 (0.889)

6th:

22/29 (0.759)

Chassis:

Frame type:

Semi double cradle

Caster angle:

26.00 °

Trail:

106.0 mm (4.17 in)

Front tire:

Type:

With tube

Size:

3.00-21 51P

Manufacturer/model:

DUNLOP/D605F

Rear tire:

Type:

With tube

Size:

4.60-18 63P

Manufacturer/model:

DUNLOP/D605

Loading:

Maximum load:

180 kg (397 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:


2

, 18 psi)

Rear:


2

, 22 psi)

Loading condition:

90–180 kg (198–397 lb)

Front:


2

, 22 psi)

Rear:


2

, 25 psi)

Off-road riding:

Front:


2

, 18 psi)

Rear:


2

, 22 psi)

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:

Single disc brake

Operation:

Right foot operation

Recommended fluid:

DOT 4

Front suspension:

Type:

Telescopic fork

Spring/shock absorber type:

Coil-air spring/oil damper

Wheel travel:

280.0 mm (11.02 in)

Rear suspension:

Type:

Swingarm (link suspension)

Spring/shock absorber type:

Coil spring/gas-oil damper

Wheel travel:

280.0 mm (11.02 in)

Electrical system:

Ignition system:

DC. CDI

9-2

Charging system:

AC magneto

Battery:

Model:

GT7B-4

Voltage, capacity:

12 V, 6.5 Ah

Headlight:

Bulb type:

Halogen bulb

Bulb voltage, wattage

×

quantity:

Headlight:

12 V, 60 W/55.0 W

×

1

Tail/brake light:

12 V, 5.0 W/21.0 W

×

1

Front turn signal light:

12 V, 21.0 W

×

2

Rear turn signal light:

12 V, 21.0 W

×

2

License plate light:

12 V, 5.0 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:

15.0 A

9-3

SPECIFICATIONS

5

6

7

8

9

2

3

4

5

6

VEHICLE IDENTIFICATION

NUMBER:

7

4

1

2

3


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

8

MODEL LABEL INFORMATION:

9

EAU26381

Vehicle identification number

EAU26400

1

1. Key identification number

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

1. Vehicle identification number

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

Record this number in the space provided.

TIP

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.

10

10-1


Model label

1

1. Model label

The model label is affixed to the frame under the rider seat. (See page 4-9.)

Record the information on this label in the space provided. This information will be needed when ordering spare parts from a Yamaha dealer.

EAU26470 EAU26570

Motorcycle noise regulation

(for Australia)

TAMPERING WITH NOISE CON-

TROL SYSTEM PROHIBITED:

Owners are warned that the law may prohibit:

● 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 pur-

● pose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use; and

The use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

2

3

4

5

6

7

8

9

10

10-2

INDEX

A

B

Air filter element, cleaning....................... 7-11

Battery..................................................... 7-25

Brake and clutch levers, checking and lubricating ............................................. 7-23

Brake fluid, changing .............................. 7-20

Brake fluid level, checking ...................... 7-19

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

Brake lever free play, adjusting............... 7-17

Brake pedal............................................... 4-4

C

Brake pedal, checking and lubricating .... 7-23

D

Cables, checking and lubricating ............ 7-22

Carburetor, adjusting .............................. 7-13

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

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

Clutch lever free play, adjusting.............. 7-16

Cowling and panels, removing and installing.................................................. 7-6

Dimmer switch .......................................... 4-3

Drive chain, cleaning and lubricating ...... 7-21

E

Drive chain slack..................................... 7-20

F

Engine break-in......................................... 6-3

Engine idling speed................................. 7-13

Engine oil and oil filter element ................. 7-8

Engine, starting a warm ............................ 6-2

Engine stop switch .................................... 4-3

Front and rear brake pads, checking ...... 7-18

Front fork, adjusting ................................ 4-10

Front fork, checking ................................ 7-24

Fuel............................................................4-5

Fuel cock ...................................................4-7

Fuel consumption, tips for reducing...........6-3

Fuel tank breather hose.............................4-6

Fuel tank cap .............................................4-5

H

Fuse, replacing ........................................7-27

Handlebar switches ...................................4-2

Headlight bulb, replacing .........................7-27

Helmet holder ............................................4-9

High beam indicator light ...........................4-2

Horn switch ................................................4-3

I

Identification numbers..............................10-1

Ignition circuit cut-off system ...................4-13

K

Indicator lights............................................4-1

L

Key identification number ........................10-1

Kickstarter..................................................4-8

Labels, location..........................................1-1

M

License plate light bulb, replacing ...........7-30

N

Main switch ................................................4-1

Matte color, caution ...................................8-1

Model label ..............................................10-2

Neutral indicator light .................................4-1

P

Noise regulation (for Australia) ................10-2

Parking.......................................................6-4

Part locations .............................................3-1

Periodic maintenance and lubrication chart ........................................................7-2

R

Pre-operation check list ............................. 5-2

S

Rear brake light switch, adjusting............ 7-18

Safety information ..................................... 2-1

Seat ........................................................... 4-9

Shifting ...................................................... 6-2

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

Shock absorber assembly, adjusting....... 4-11

Sidestand ................................................ 4-13

Sidestand, checking and lubricating ........ 7-23

Spark plug, checking ................................. 7-7

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

Speedometer unit ...................................... 4-2

Starter (choke) knob .................................. 4-8

Starting a cold engine................................ 6-1

Start switch ................................................ 4-3

Steering, checking ................................... 7-24

Steering lock.............................................. 4-8

Storage ...................................................... 8-3

T

Supporting the motorcycle....................... 7-31

Tail/brake light bulb, replacing................. 7-28

Throttle cable free play, checking............ 7-14

Throttle grip and cable, checking and lubricating.............................................. 7-22

Tires ........................................................ 7-14

Tool kit ....................................................... 7-1

Troubleshooting....................................... 7-34

Troubleshooting chart.............................. 7-35

Turn signal indicator light .......................... 4-1

Turn signal light bulb, replacing............... 7-29

Turn signal switch...................................... 4-3

V

W

Valve clearance .......................................7-14

Vehicle identification number...................10-1

Wheel bearings, checking .......................7-25

Wheel (front) ............................................7-31

Wheel (rear).............................................7-33

Wheels.....................................................7-16

INDEX

PRINTED ON RECYCLED PAPER

YAMAHA MOTOR CO., LTD.

PRINTED IN JAPAN

2008.5–0.3

×1 !

(E)

No results