PW80(X) - Motorcycle Owners Manuals

PW80(X) - Motorcycle Owners Manuals
OWNER’S MANUAL
MANUEL DU PROPRIÉTAIRE
BEDIENUNGSANLEITUNG
PW80(X)
3RV-28199-8H
PRINTED ON RECYCLED PAPER
IMPRIMÉ SUR PAPIER RECYCLÉ
AUF RECYCLINGPAPIER GEDRUCKT
YAMAHA MOTOR CO., LTD.
PRINTED IN JAPAN
2007.4–0.7×1 !
(E, F, G)
OWNER’S MANUAL
PW80(X)
3RV-28199-8H-E0
INTRODUCTION
EAU41580
Congratulations on your purchase of the Yamaha PW80(X). This model is the result of Yamaha’s vast experience in the production of fine sporting, touring, and pacesetting racing machines. It represents the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields.
This manual will give you an understanding of the operation, inspection, and basic maintenance of this motorcycle. If you
have any questions concerning the operation or maintenance of your motorcycle, please consult a Yamaha dealer.
The design and manufacture of this Yamaha motorcycle fully comply with the emissions standards for clean air applicable
at the date of manufacture. Yamaha has met these standards without reducing the performance or economy of operation of
the motorcycle. To maintain these high standards, it is important that you and your Yamaha dealer pay close attention to the
recommended maintenance schedules and operating instructions contained within this manual.
AN IMPORTANT SAFETY MESSAGE:
● READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE. MAKE SURE
YOU UNDERSTAND ALL INSTRUCTIONS.
● PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE MOTORCYCLE.
● NEVER OPERATE A MOTORCYCLE WITHOUT PROPER TRAINING OR INSTRUCTION.
● WEIGHT OF THE RIDER SHOULD NOT EXCEED 40 kg (88 lb).
AN IMPORTANT NOTE TO PARENTS:
This motorcycle is not a toy. Before you let your child ride this motorcycle, you should understand the instructions and warnings in this Owner’s Manual. Then be sure your child understands and will follow them. Children differ in skills, physical abilities, and judgment. Some children may not be able to operate a motorcycle safely. Parents should supervise their child’s
use of the motorcycle at all times. Parents should permit continued use only if they determine that the child has the ability to
operate the motorcycle safely.
Your motorcycle was delivered with a removable power reduction plate. Yamaha recommends that all beginners start off with
the power reduction plate installed to limit the engine power available while they learn. Parents should decide when to remove the power reduction plate from the motorcycle for more power as their youngster’s riding skills improve. Once the rider
can operate with skill at the top speed permitted by power reduction plate installed, the power reduction plate can be removed.
INTRODUCTION
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 THE OWNER’S MANUAL.
● OBTAIN QUALIFIED TRAINING IN SAFE AND PROPER RIDING TECHNIQUES.
● OBTAIN PROFESSIONAL TECHNICAL SERVICE AS INDICATED BY THE OWNER’S MANUAL AND/OR WHEN
MADE NECESSARY BY MECHANICAL CONDITIONS.
IMPORTANT MANUAL INFORMATION
EAU41090
Particularly important information is distinguished in this manual by the following notations:
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!
WARNING
Failure to follow WARNING instructions could result in severe injury or death to the
motorcycle operator, a bystander or a person inspecting or repairing the motorcycle.
CAUTION:
A CAUTION indicates special precautions that must be taken to avoid damage to
the motorcycle.
NOTE:
A NOTE provides key information to make procedures easier or clearer.
NOTE:
● This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle
is subsequently sold.
● Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most
current product information available at the time of printing, there may be minor discrepancies between your motorcycle
and this manual. If you have any questions concerning this manual, please consult your Yamaha dealer.
IMPORTANT MANUAL INFORMATION
EWA10030
WARNING
PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE.
EWA14350
WARNING
THIS MOTORCYCLE IS DESIGNED AND MANUFACTURED FOR OFF-ROAD USE ONLY. IT IS ILLEGAL TO OPERATE THIS MOTORCYCLE ON ANY PUBLIC STREET, ROAD OR HIGHWAY. SUCH USE IS PROHIBITED BY LAW.
THIS MOTORCYCLE COMPLIES WITH ALMOST ALL STATE OFF-HIGHWAY NOISE LEVEL AND SPARK ARRESTER
LAWS AND REGULATIONS. PLEASE CHECK YOUR LOCAL RIDING LAWS AND REGULATIONS BEFORE OPERATING THIS MOTORCYCLE.
*Product and specifications are subject to change without notice.
IMPORTANT MANUAL INFORMATION
EAU10200
PW80(X)
OWNER’S MANUAL
©2007 by Yamaha Motor Co., Ltd.
1st edition, March 2007
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
SAFETY INFORMATION ...................1-1
Safe riding ........................................1-1
Location of important labels .............1-4
DESCRIPTION ...................................2-1
Left view ...........................................2-1
Right view .........................................2-2
Controls and instruments..................2-3
INSTRUMENT AND CONTROL
FUNCTIONS ........................................3-1
Handlebar switch .............................3-1
Power reduction plate ......................3-1
Shift pedal ........................................3-1
Brake lever ......................................3-2
Brake pedal .....................................3-2
Fuel tank cap ...................................3-2
Fuel ..................................................3-3
Fuel tank breather hose ...................3-4
2-stroke engine oil ...........................3-4
Fuel cock .........................................3-5
Starter (choke) lever “1” .................3-6
Kickstarter ........................................3-6
Seat .................................................3-6
Shock absorber ...............................3-7
PRE-OPERATION CHECKS ...............4-1
Pre-operation check list ...................4-2
OPERATION AND IMPORTANT
RIDING POINTS .................................. 5-1
Starting and warming up a cold
engine .......................................... 5-1
Starting a warm engine ................... 5-2
Shifting ............................................ 5-2
Engine break-in ............................... 5-3
Parking ............................................ 5-4
PERIODIC MAINTENANCE AND
MINOR REPAIR .................................. 6-1
Owner’s tool kit ................................ 6-1
Periodic maintenance and lubrication
chart ............................................. 6-2
Checking the spark plug .................. 6-5
Removing the power reduction
plate ............................................. 6-6
Transmission oil .............................. 6-7
Cleaning the air filter element ......... 6-8
Cleaning the spark arrester ............. 6-9
Adjusting the carburetor ................ 6-10
Adjusting the engine idling
speed ......................................... 6-11
Adjusting the throttle cable free
play ............................................ 6-11
Tires .............................................. 6-12
Spoke wheels ................................ 6-13
Accessories and replacement
parts ........................................... 6-14
Adjusting the brake lever free
play ............................................ 6-14
Adjusting the brake pedal free
play ............................................ 6-15
Checking the front and rear brake
shoes ......................................... 6-16
Drive chain slack ........................... 6-16
Cleaning and lubricating the drive
chain .......................................... 6-18
Checking and lubricating the
cables ........................................ 6-19
Checking and lubricating the throttle
grip and cable ............................ 6-19
Adjusting the Autolube pump ........ 6-19
Checking and lubricating the brake
and shift pedals ......................... 6-20
Checking and lubricating the brake
lever ........................................... 6-20
Checking and lubricating the
sidestand ................................... 6-21
Checking the front fork .................. 6-21
Checking the steering ................... 6-22
Checking the wheel bearings ........ 6-22
Supporting the motorcycle ............ 6-23
Front wheel ................................... 6-23
Rear wheel .................................... 6-26
Troubleshooting ............................ 6-27
Troubleshooting chart ................... 6-28
MOTORCYCLE CARE AND
STORAGE........................................... 7-1
Matte color caution .......................... 7-1
Care ................................................ 7-1
TABLE OF CONTENTS
Storage ............................................7-3
SPECIFICATIONS ..............................8-1
CONSUMER INFORMATION..............9-1
Identification numbers .....................9-1
SAFETY INFORMATION
EAU41211
Safe riding
●
1
●
●
●
Always
make
pre-operation
checks. Careful checks may help
prevent an accident.
This motorcycle is designed for
off-road use only, therefore, it is illegal to operate it on public streets,
roads, or highways, even a dirt or
gravel one. Off-road use on public
lands may be illegal. Please check
local regulations before riding.
This motorcycle is designed to carry the operator only. No passengers.
Many accidents involve inexperienced operators.
Make sure that the operator is
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.
Many accidents have been caused
by error of the motorcycle operator. A typical error made by the operator is veering wide on a turn
due to EXCESSIVE SPEED or un●
●
●
●
●
●
●
dercornering (insufficient lean angle for the speed). Never travel
faster than warranted by conditions.
Ride cautiously in unfamiliar areas. You may encounter hidden
obstacles that could cause an accident.
The posture of the operator is important for proper control. The operator should keep both hands on
the handlebar and both feet on the
operator footrests during operation
to maintain control of the motorcycle.
Never ride under the influence of
alcohol or other drugs.
Be sure the transmission is in neutral before starting the engine.
Protective apparel
The majority of fatalities from motorcycle accidents are the result of head injuries. The use of a safety helmet is the
single most critical factor in the prevention or reduction of head injuries.
● Always wear an approved helmet.
● Wear a face shield or goggles.
1-1
●
●
●
Wind in your unprotected eyes
could contribute to an impairment
of vision that could delay seeing a
hazard.
The use of a jacket, heavy boots,
trousers, gloves, etc., is effective in
preventing or reducing abrasions
or lacerations.
Never wear loose-fitting clothes,
otherwise they could catch on the
control levers, footrests, or wheels
and cause injury or an accident.
Never touch the engine or exhaust
system during or after operation.
They become very hot and can
cause burns. Always wear protective clothing that covers your legs,
ankles, and feet.
Modifications
Modifications made to this motorcycle
not approved by Yamaha, or the removal of original equipment, may render the motorcycle unsafe for use and
may cause severe personal injury.
Modifications may also make your motorcycle illegal to use.
SAFETY INFORMATION
Loading and accessories
Adding accessories 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 accessories to
your motorcycle. Use extra care when
riding a motorcycle that has added accessories. Here are some general
guidelines to follow if adding accessories to your motorcycle:
Loading
● The weight of the operator must
not exceed 40 kg (88 lb).
● Accessory weight should be kept
as low and close to the motorcycle
as possible. Make sure to distribute the weight as evenly as possible on both sides of the motorcycle
to minimize imbalance or instability.
● Shifting weights can create a sudden imbalance. Make sure that accessories are securely attached to
the motorcycle before riding.
Check accessory mounts fre-
●
quently.
Never attach any large or heavy
items to the handlebar, front fork,
or front fender.
Accessories
Genuine Yamaha accessories have
been specifically designed for use on
this motorcycle. Since Yamaha cannot
test all other accessories that may be
available, you must personally be responsible for the proper selection, installation and use of non-Yamaha
accessories. Use extreme caution
when selecting and installing any accessories.
Keep these guidelines in mind for
mounting accessories in addition to
those provided under “Loading”.
● Never install accessories or 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.
1-2
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.
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
●
●
●
●
1
SAFETY INFORMATION
electric failure could result, which
could cause a dangerous loss of
engine power.
1
Gasoline and exhaust gas
● GASOLINE IS HIGHLY FLAMMABLE:
Always turn the engine off when
refueling.
Take care not to spill any gasoline on the engine or exhaust
pipe/muffler when refueling.
Never refuel while smoking or in
the vicinity of an open flame.
● Never start the engine or let it run
for any length of time in a closed
area. The exhaust fumes are poisonous and may cause loss of
consciousness and death within a
short time. Always operate your
motorcycle in an area that has adequate ventilation.
● Always turn the engine off before
leaving the motorcycle unattended. When parking the motorcycle,
note the following:
The engine and exhaust pipe/
muffler may be hot, therefore,
●
●
●
●
●
●
park the motorcycle in a place
where pedestrians or children
are not likely to touch these hot
areas.
Do not park the motorcycle on a
slope or soft ground, otherwise it
may fall over.
Do not park the motorcycle near
a flammable source (e.g., a kerosene heater, or near an open
flame), otherwise it could catch
fire.
When transporting the motorcycle
in another vehicle, make sure that
it is kept upright and that the fuel
cock is turned to “OFF”. If the motorcycle should lean over, gasoline
may leak out of the carburetor or
fuel tank.
If you should swallow any gasoline, inhale a lot of gasoline vapor,
or allow gasoline to get into your
eyes, see your doctor immediately. If any gasoline spills on your
skin or clothing, immediately wash
the affected area with soap and
water and change your clothes.
●
●
1-3
SAFETY INFORMATION
EAU41370
Location of important labels
Please read the following important labels carefully before operating this vehicle.
1
3
1-4
2
1
SAFETY INFORMATION
5
4
1
1-5
SAFETY INFORMATION
1
4
1
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.
5
5PA-21568-00
3
Cold tire normal pressure should be set as
follows.
FRONT : 100 kPa,{1.00 kgf/cm2}, 15 psi
REAR
: 100 kPa,{1.00 kgf/cm2}, 15 psi
3RV-21668-A0
1-6
DESCRIPTION
EAU10410
Left view
1
1
2 3
4
5
2
3
4
5
6
7
7
8
9
1. Air filter element (page 6-8)
2. Fuel cock (page 3-5)
3. Throttle stop screw (page 6-11)
4. Starter (choke) lever (page 3-6)
5. 2-stroke engine oil tank (page 3-4)
6. Sidestand (page 6-21)
7. Shift pedal (page 3-1)
2-1
6
DESCRIPTION
EAU10420
Right view
1
2
3
2
3
4
5
6
7
6
5
4
8
1. Spark arrester (page 6-9)
2. Seat (page 3-6)
3. Transmission oil filler cap (page 6-7)
4. Spark plug cap (page 6-5)
5. Brake pedal (page 3-2)
6. Kickstarter (page 3-6)
9
2-2
DESCRIPTION
EAU10430
Controls and instruments
1
1
2
2
3
4
5
6
7
4
8
9
1. Right handlebar switch (page 3-1)
2. Brake lever (page 3-2)
3. Throttle grip (page 6-11)
4. Fuel tank cap (page 3-2)
2-3
3
INSTRUMENT AND CONTROL FUNCTIONS
EAU40660
Handlebar switch
EAU41590
Power reduction plate
1
1. Engine stop switch “ENGINE STOP”
EAU41130
Engine stop switch “ENGINE STOP”
Set this switch to “RUN” before starting
the engine. Set this switch to “OFF” to
stop the engine.
Your motorcycle was delivered with a
power reduction plate. Yamaha recommends that all beginning riders start off
with the power reduction plate installed
to limit the amount of power available
while they learn.
Parents should decide when to adjust
the motorcycle for more power as their
youngster’s riding skills improve. Once
the rider can operate with skill at the top
speed with the power reduction plate
installed, the power reduction plate can
be removed. (See page 6-6.)
EAU39850
Shift pedal
2
1
1. Shift pedal
This motorcycle is equipped with a constant-mesh 3-speed transmission. The
shift pedal is located on the left side of
the engine. Neutral is at the bottom position.
3
4
5
6
7
8
9
3-1
INSTRUMENT AND CONTROL FUNCTIONS
EAU12890
Brake lever
EAU12941
Brake pedal
EAU13181
Fuel tank cap
1
1
1
2
3
4
5
6
1
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
1. Fuel tank cap
The brake pedal is on the right side of
the motorcycle. To apply the rear
brake, press down on the brake pedal.
7
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.
EWA11090
WARNING
Make sure that the fuel tank cap is
properly closed before riding.
8
9
3-2
INSTRUMENT AND CONTROL FUNCTIONS
EAU13220
Fuel
1
2
ECA10070
CAUTION:
Immediately wipe off spilled fuel
with a clean, dry, soft cloth, since
fuel may deteriorate painted surfaces or plastic parts.
91 or higher. If knocking (or pinging) occurs, use a gasoline of a different brand
or premium unleaded fuel. Use of unleaded fuel will extend spark plug life
and reduce maintenance costs.
2
EAU41960
3
1. Fuel tank filler tube
2. Fuel level
Make sure that there is sufficient fuel in
the tank. When refueling, be sure to insert the pump nozzle into the fuel tank
filler hole and to fill the tank to the bottom of the filler tube as shown.
EWA10880
●
●
WARNING
Do not overfill the fuel tank, otherwise it may overflow when the
fuel warms up and expands.
Avoid spilling fuel on the hot engine.
Recommended fuel:
For Europe: REGULAR UNLEADED
GASOLINE ONLY
Except for Europe: UNLEADED
GASOLINE ONLY
Fuel tank capacity:
4.9 L (1.29 US gal) (1.08 Imp.gal)
Fuel reserve amount:
1.0 L (0.26 US gal) (0.22 Imp.gal)
ECA15590
CAUTION:
Use only unleaded gasoline. The use
of leaded gasoline will cause severe
damage to internal engine parts,
such as the 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
3-3
4
5
6
7
8
9
INSTRUMENT AND CONTROL FUNCTIONS
EAU13412
Fuel tank breather hose
1
1
2
EAU41201
2-stroke engine oil
tank cap and add the recommended oil.
Make sure that there is sufficient oil in
the 2-stroke engine oil tank. If the
2-stroke engine oil is at or below the
minimum level as shown in the illustration, add a sufficient amount of the recommended 2-stroke engine oil as
follows.
1
2
3
4
5
6
7
8
9
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.
1
1. 2-stroke engine oil tank
2. 2-stroke engine oil tank cap
Recommended oil:
See page 8-1.
Oil quantity:
0.95 L (1.00 US qt) (0.84 Imp.qt)
1. Minimum level
NOTE:
Make sure that the motorcycle is positioned straight up when checking the
2-stroke engine oil level. A slight tilt to
the side can result in a false reading.
1. Remove the seat. (See page 3-6.)
2. Remove the 2-stroke engine oil
3-4
3. Install the 2-stroke engine oil tank
cap.
NOTE:
Make sure that the 2-stroke engine oil
tank cap is properly closed.
4. Install the seat.
INSTRUMENT AND CONTROL FUNCTIONS
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
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!
RES
OFF
ON
OFF
FUEL
2
1
ON
3
RES
1. Arrow mark positioned over “ON”
OFF
ON
FUEL
1
With the lever in this position, fuel flows
to the carburetor. Normal riding is done
with the lever in this position.
RES
With the lever in this position, fuel will
not flow. Always return the lever to this
position when the engine is not running.
5
6
RES
1. Arrow mark positioned over “OFF”
4
7
RES
8
OFF
ON
1
FUEL
1. Arrow mark positioned over “RES”
3-5
9
INSTRUMENT AND CONTROL FUNCTIONS
EAU13590
Starter (choke) lever “
1
”
EAU13680
Kickstarter
EAU41140
Seat
To remove the seat
Remove the nuts, and then pull the seat
off.
1
(b)
2
3
1
(a)
4
5
6
7
1. Starter (choke) lever “
”
Starting a cold engine requires a richer
air-fuel mixture, which is supplied by
the starter (choke).
Move the lever in direction (a) to turn on
the starter (choke).
Move the lever in direction (b) to turn off
the starter (choke).
1. Kickstarter
To start the engine, fold out the kickstarter lever, move it down lightly with
your foot until the gears engage, and
then push it down smoothly but forcefully.
1
1. Nut
To install the seat
1. Insert the projection on the front of
the seat into the seat holder as
shown.
8
9
3-6
INSTRUMENT AND CONTROL FUNCTIONS
EAU15090
2
1
1. Seat holder
2. Projection
2. Place the seat in the original position, and then tighten the nuts.
NOTE:
Make sure that the seat is properly secured before riding.
Shock absorber
EWA10220
WARNING
This shock absorber contains highly
pressurized nitrogen gas. For proper handling, read and understand
the following information before
handling the shock absorber. The
manufacturer cannot be held responsible for property damage or
personal injury that may result from
improper handling.
● Do not tamper with or attempt to
open the gas cylinder.
● Do not subject the shock absorber to an open flame or other
high heat sources, otherwise it
may explode due to excessive
gas pressure.
● Do not deform or damage the
gas cylinder in any way, as this
will result in poor damping performance.
● Always have a Yamaha dealer
service the shock absorber.
3-7
2
3
4
5
6
7
8
9
PRE-OPERATION CHECKS
EAU15593
1
2
3
The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly,
even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss
of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thorough visual inspection, to check the following points before each ride.
NOTE:
Pre-operation checks should be made each time the vehicle is used. Such an inspection can be accomplished in a very short
time; and the added safety it assures is more than worth the time involved.
EWA11150
4
WARNING
If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operating
the vehicle.
5
6
7
8
9
4-1
PRE-OPERATION CHECKS
EAU15605
Pre-operation check list
ITEM
CHECKS
●
Fuel
●
●
●
2-stroke engine oil
●
●
Transmission oil
●
●
●
Front brake
●
●
●
●
Rear brake
●
●
●
Throttle grip
Control cables
●
●
●
●
●
Drive chain
●
●
●
●
Wheels and tires
●
●
●
Check fuel level in fuel tank.
Refuel if necessary.
Check fuel line for leakage.
Check oil level in oil tank.
If necessary, add recommended oil to specified level.
Check vehicle for oil leakage.
Check oil level in transmission case.
If necessary, add recommended oil to specified level.
Check operation.
Lubricate cable if necessary.
Check lever free play.
Adjust if necessary.
Check operation.
Check pedal free play.
Adjust if necessary.
Make sure that operation is smooth.
Check cable free play.
If necessary, have Yamaha dealer adjust cable free play and lubricate cable
and grip housing.
Make sure that operation is smooth.
Lubricate if necessary.
Check chain slack.
Adjust if necessary.
Check chain condition.
Lubricate if necessary.
Check for damage.
Check tire condition and tread depth.
Check air pressure.
Correct if necessary.
4-2
PAGE
3-3
3-4
2
6-7
3
6-14, 6-16
4
5
6-15, 6-16
6
6-11, 6-19
7
6-19
6-16, 6-18
6-12, 6-13
8
9
PRE-OPERATION CHECKS
ITEM
Brake and shift pedals
1
Brake lever
Sidestand
2
3
Chassis fasteners
Engine stop switch
CHECKS
●
●
●
●
●
●
●
●
●
Make sure that operation is smooth.
Lubricate pedal pivoting points if necessary.
Make sure that operation is smooth.
Lubricate lever pivoting point if necessary.
Make sure that operation is smooth.
Lubricate pivot if necessary.
Make sure that all nuts, bolts and screws are properly tightened.
Tighten if necessary.
Check operation.
4
5
6
7
8
9
4-3
PAGE
6-20
6-20
6-21
—
3-1
OPERATION AND IMPORTANT RIDING POINTS
EAU41680
EWA14620
●
●
●
WARNING
This model is designed for
off-road use only. Become thoroughly familiar with all operating controls and their functions
before riding. Consult a Yamaha
dealer regarding any control or
function that you do not thoroughly understand.
Never start the engine or operate it in a closed area for any
length of time. Exhaust fumes
are poisonous, and inhaling
them can cause loss of consciousness and death within a
short time. Always make sure
that there is adequate ventilation.
Before starting out, make sure
that the sidestand is up. If the
sidestand is not raised completely, it could contact the
ground and distract the operator, resulting in a possible loss
of control.
EAU41151
Starting and warming up a
cold engine
1. Turn the fuel cock lever to “ON”.
2. Set the engine stop switch to
“RUN”.
3. Shift the transmission into the neutral position.
7. When the engine is warm, turn the
starter (choke) off.
NOTE:
The engine is warm when it responds
normally to the throttle with the starter
(choke) turned off.
2
EWA14410
WARNING
Be sure to shift the transmission into neutral before starting
the engine.
Never ride with the sidestand
down.
3
4. Turn the starter (choke) on and
completely close the throttle. (See
page 3-6.)
5. Start the engine by pushing the
kickstarter lever down.
6. After starting the engine, move the
starter (choke) back halfway.
6
●
●
4
5
7
8
ECA11130
CAUTION:
For maximum engine life, always
warm the engine up before starting
off. Never accelerate hard when the
engine is cold!
5-1
9
OPERATION AND IMPORTANT RIDING POINTS
EAU16660
Starting a warm engine
1
2
3
4
5
6
7
8
9
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. Instead, start
the engine with the throttle slightly
open.
NOTE:
If the engine does not start after several kicks, try again with the throttle 1/4 to
1/2 open.
EAU39901
Shifting
3
2
1
N
1
2
1. Shift pedal
2. Neutral position
This motorcycle has a 3-speed transmission with a centrifugal, automatic
clutch. Shifting gears lets you control
the amount of engine power available
for starting off, accelerating, climbing
hills, etc.
The gear positions are shown in the illustration.
NOTE:
To shift the transmission into the neutral position, press the shift pedal down
repeatedly until it reaches the end of its
travel.
5-2
ECA15441
CAUTION:
● Even with the transmission in
the neutral position, do not
coast for long periods of time
with the engine off, and do not
tow the motorcycle for long distances. The transmission is
properly lubricated only when
the engine is running. Inadequate lubrication may damage
the transmission.
● Always release the throttle grip
before changing gears to avoid
damaging the engine, transmission, and drive train, which are
not designed to withstand the
shock of shifting when the throttle grip is open.
EAU39910
To start out and accelerate
1. Close the throttle.
2. Shift into first gear and release the
shift pedal.
ECA15460
CAUTION:
Always close the throttle before
OPERATION AND IMPORTANT RIDING POINTS
shifting gears, otherwise damage to
the engine and drive train may result.
3. Open the throttle gradually.
4. Once the motorcycle has reached
a speed high enough to change
gears, close the throttle.
5. Shift into second gear and release
the shift pedal.
6. Open the throttle gradually.
7. Follow the same procedure when
shifting to the next higher gear.
EAU16710
To decelerate
1. Close the throttle and apply both
the front and the rear brakes to
slow the motorcycle.
2. Downshift through the gears and
shift the transmission into the neutral position when the motorcycle
is almost completely stopped.
EAU39920
Engine break-in
There is never a more important period
in the life of your engine than the first 5
hours of riding. It is also important to accustom the rider to the motorcycle during this time. Please read the following
information carefully.
Since the engine is brand new, do not
put an excessive load on it for the first 5
hours of operation. The various parts in
the engine wear and polish themselves
to the correct operating clearances.
During this period, prolonged full-throttle operation or any condition that might
result in engine overheating must be
avoided.
However,
momentary
full-throttle operation under load (i.e.,
two to three seconds maximum) does
not harm the engine. Each full-throttle
acceleration should be followed with a
substantial rest period for the engine.
To allow the engine to cool down from
the temporary buildup of heat, cruise at
a lower engine speed.
After the first 5 hours of operation, thoroughly check the motorcycle for loose
parts, oil leakage and any other problems. Be sure to inspect and make ad5-3
justments thoroughly, especially cable
and drive chain slack and loose
spokes. In addition, check all fittings
and fasteners for looseness, and tighten if necessary.
ECA10270
CAUTION:
If any engine trouble should occur
during the engine break-in period,
immediately have a Yamaha dealer
check the vehicle.
2
3
4
5
6
7
8
9
OPERATION AND IMPORTANT RIDING POINTS
EAU17190
Parking
When parking, stop the engine, and
then turn the fuel cock lever to “OFF”.
EWA10310
1
2
●
3
4
5
●
WARNING
Since the engine and exhaust
system can become very hot,
park in a place where pedestrians or children are not likely to
touch them.
Do not park on a slope or on soft
ground, otherwise the vehicle
may overturn.
6
7
8
9
5-4
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU41950
EAU17320
Owner’s tool kit
Safety is an obligation of the owner. Periodic inspection, adjustment and lubrication will keep your vehicle in the
safest and most efficient condition possible. The most important points of motorcycle inspection, adjustment, and
lubrication are explained on the following pages.
Maintenance, replacement, or repair
of the emission control devices and
systems may be performed by any
repair establishment or individual
that is certified (if applicable).
The service information included in this
manual and the tools provided in the
owner’s tool kit are intended to assist
you in the performance of preventive
maintenance and minor repairs. However, additional tools such as a torque
wrench may be necessary to perform
certain maintenance work correctly.
NOTE:
If you do not have the tools or experience required for a particular job, have
a Yamaha dealer perform it for you.
EWA10320
EWA10350
WARNING
If you are not familiar with maintenance work, have a Yamaha dealer
do it for you.
WARNING
Modifications not approved by
Yamaha may cause loss of performance and render the vehicle unsafe for use. Consult a Yamaha
dealer before attempting any changes.
2
3
4
5
6
7
8
9
6-1
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU41763
Periodic maintenance and lubrication chart
1
NOTE:
● From 160 hours, repeat the maintenance intervals starting from 40 hours.
● Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical
skills.
2
INITIAL
3
NO.
4
1
5
6
*
ITEM
Fuel line
2
Spark plug
3
Air filter element
4
*
Clutch
5
*
Front brake
7
8
6
*
Rear brake
9
7
*
Wheels
CHECK OR MAINTENANCE JOB
Check fuel hoses for cracks or damage.
Replace if necessary.
Check condition.
Adjust gap and clean.
Replace if necessary.
Clean with solvent.
Replace if necessary.
Check operation.
Adjust if necessary.
Check operation.
Adjust brake lever free play.
Replace brake shoes.
Check operation.
Adjust brake pedal free play.
Replace brake shoes.
Check runout, spoke tightness and for
damage.
Tighten spokes if necessary.
6-2
10
hours
20
hours
40
hours
THEREAFTER EVERY
80
hours
40
hours
Whenever worn to the limit
Whenever worn to the limit
80
hours
160
hours
PERIODIC MAINTENANCE AND MINOR REPAIR
INITIAL
NO.
8
*
ITEM
Tires
9
*
Wheel bearings
10
*
Steering bearings
11
12
Drive chain
*
13
14
15
16
Chassis fasteners
Sidestand pivot
*
Front fork
*
Shock absorber
assembly
*
Carburetor
CHECK OR MAINTENANCE JOB
Check tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.
Check bearings for smooth operation.
Replace if necessary.
Check bearing assemblies for looseness.
Moderately repack with lithium-soap-based
grease.
Check chain slack/alignment and condition.
Adjust and lubricate chain with Yamaha
chain and cable lube thoroughly.
Remove and clean.
Check all chassis fitting and fasteners.
Correct if necessary.
Check operation.
Apply lithium-soap-based grease (all-purpose grease) lightly.
Check operation and for oil leakage.
Replace if necessary.
Check operation and for oil leakage.
Replace if necessary.
Check engine idling speed and starter
operation.
Clean.
Replace if necessary.
6-3
10
hours
20
hours
40
hours
THEREAFTER EVERY
80
hours
40
hours
80
hours
160
hours
2
3
4
Every ride
5
6
7
8
9
PERIODIC MAINTENANCE AND MINOR REPAIR
INITIAL
NO.
ITEM
1
17
*
Autolube pump
2
18
Transmission oil
3
4
5
6
7
19
*
Control cables
20
*
Throttle grip housing
and cable
21
Brake lever pivot shaft
22
Brake pedal pivot
shaft
23
*
Cylinder head and
exhaust system
24
*
Spark arrester
CHECK OR MAINTENANCE JOB
10
hours
20
hours
40
hours
Check operation.
Correct if necessary.
Bleed.
Check for oil leakage.
Correct if necessary.
Change.
Apply Yamaha chain and cable lube or
engine oil 10W-30 lightly.
Check operation and free play.
Apply Yamaha chain and cable lube or
engine oil 10W-30 lightly.
Apply lithium-soap-based grease (all-purpose grease) lightly.
Apply lithium-soap-based grease (all-purpose grease) lightly.
Check for leakage.
Tighten if necessary.
Decarbonize if necessary.
Clean.
8
9
NOTE:
The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
6-4
THEREAFTER EVERY
80
hours
40
hours
80
hours
160
hours
PERIODIC MAINTENANCE AND MINOR REPAIR
other deposits, and replace it if
necessary.
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.
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
Specified spark plug:
NGK/BP6HS (AUS)(NZL)
NGK/BPR6HS
(AUT)(BEL)(CHE)(DEU)(DNK)
(ESP)(FIN)(FRA)(GBR)(GRC)(IRL)
(NLD)(NOR)(PRT)(SWE)(ZAF)
DENSO/W20FP (AUS)(NZL)
2
3
1. Spark plug wrench
To check the spark plug
1. Check that the porcelain insulator
around the center electrode of the
spark plug is a medium-to-light tan
(the ideal color when the vehicle is
ridden normally).
NOTE:
If the spark plug shows a distinctly different color, the engine could be 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
6-5
To install the spark plug
1. Measure the spark plug gap with a
wire thickness gauge and, if necessary, adjust the gap to specification.
4
5
6
7
1
8
9
1. Spark plug gap
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU41100
1
2
3
4
Spark plug gap:
0.6–0.7 mm (0.024–0.028 in)
Removing the power
reduction plate
2. Clean the surface of the spark plug
gasket and its mating surface, and
then wipe off any grime from the
spark plug threads.
3. Install the spark plug with the
spark plug wrench, and then tighten it to the specified torque.
To obtain full engine performance capability, removing the power reduction
plate is required.
Tightening torque:
Spark plug:
25 Nm (2.5 m·kgf, 18.1 ft·lbf)
7
8
1. Remove the exhaust manifold by
removing the bolts.
3
1. Exhaust manifold
2. Gasket
3. Power reduction plate
NOTE:
Store the power reduction plate with the
owner’s manual so that it is readily
available whenever you want to reduce
the engine power.
NOTE:
If a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4–1/2 turn
past finger tight. However, the spark
plug should be tightened to the specified torque as soon as possible.
4. Install the exhaust manifold by installing the bolts.
1
Tightening torque:
Exhaust manifold bolt:
18 Nm (1.8 m·kgf, 13.0 ft·lbf)
4. Install the spark plug cap.
9
2
EWA14580
WARNING
Always let the exhaust system cool
prior to touching exhaust components.
5
6
1
1. Exhaust manifold bolt
2. Remove the gasket.
3. Remove the power
plate.
6-6
reduction
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU19942
Transmission oil
The transmission oil level should be
checked before each ride. In addition,
the transmission oil must be changed
at the intervals specified in the periodic
maintenance and lubrication chart.
To check the transmission oil level
1
2. Wait a few minutes until the oil settles, remove the oil filler cap, wipe
the dipstick clean, insert it back
into the oil filler hole (without
screwing it in), and then remove it
again to check the oil level.
NOTE:
The transmission oil should be between the minimum and maximum level marks.
2
3
4
straight up when checking the oil level.
A slight tilt to the side can result in a
false reading.
1
1. Transmission oil filler cap
2. Dipstick
3. Maximum level mark
4. Minimum level mark
3. If the oil is below the minimum level mark, add sufficient oil of the
recommended type to raise it to
the correct level.
4. Insert the dipstick into the oil filler
hole, and then tighten the oil filler
cap.
1. Place the vehicle on a level surface and hold it in an upright position.
To change the transmission oil
2
1
3
1. Transmission oil drain bolt
4
1. Place an oil pan under the transmission to collect the used oil.
2. Remove the oil filler cap and drain
bolt to drain the oil from the transmission.
3. Install the transmission oil drain
bolt, and then tighten it to the specified torque.
Tightening torque:
Transmission oil drain bolt:
20 Nm (2.0 m·kgf, 14.5 ft·lbf)
4. Add the specified amount of the
recommended transmission oil,
and then install and tighten the oil
filler cap.
NOTE:
Make sure that the vehicle is positioned
6-7
5
6
7
8
9
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU41161
Recommended transmission oil:
See page 8-1.
Oil change quantity:
0.65 L (0.69 US qt) (0.57 Imp.qt)
1
ECA10452
2
3
4
5
6
7
8
9
CAUTION:
● In order to prevent clutch slippage (since the transmission 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 transmission.
5. Start the engine, and then let it idle
for several minutes while checking
the transmission for oil leakage. If
oil is leaking, immediately turn the
engine off and check for the cause.
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 the air filter case cover by
removing the screws.
3. Remove the sponge material from
the air filter case cover, clean it
with solvent, and then squeeze the
remaining solvent out.
1
2
2
2
1. Air filter case cover
2. Screw
1
2. Pull the air filter element out.
1. Sponge material
2. Air filter case cover
6-8
PERIODIC MAINTENANCE AND MINOR REPAIR
●
ment is properly seated in the
air filter case.
The engine should never be operated without the air filter element installed, otherwise the
piston(s) and/or cylinder(s) may
become excessively worn.
7. Install the air filter case cover by installing the screws.
EAU41230
Cleaning the spark arrester
The spark arrester should be cleaned
at the intervals specified in the periodic
maintenance and lubrication chart.
EWA10980
●
●
4. Apply oil of the recommended type
to the entire surface of the sponge
material, and then squeeze the excess oil out.
WARNING
Always let the exhaust system
cool prior to touching exhaust
components.
Do not start the engine when
cleaning the exhaust system.
NOTE:
Make sure to select a well-ventilated
area free of combustible materials to
clean the spark arrester.
NOTE:
The sponge material should be wet but
not dripping.
1. Remove the tailpipe by removing
the bolt, and then pulling it out of
the muffler.
Recommended oil:
Yamaha foam air filter oil or other
quality foam air filter oil
2
3
4
5
6
7
8
5. Install the sponge material onto
the air filter case cover.
6. Insert the air filter element into the
air filter case.
9
ECA10480
CAUTION:
● Make sure that the air filter ele6-9
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU39930
Adjusting the carburetor
1
1
2
1
3
2
3
1. Bolt
4
5
6
7
2. Tap the tailpipe lightly, and then
use a wire brush to remove any
carbon deposits from the spark arrester portion of the tailpipe and inside of the tailpipe housing.
1. Tailpipe
2. Spark arrester
3. Bolt
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
3. Insert the tailpipe into the muffler,
and then install and tighten the
bolt.
NOTE:
Make sure to align the bolt hole when
inserting the tailpipe.
8
9
6-10
CAUTION:
The carburetor has been set and extensively tested at the Yamaha factory. Changing these settings
without sufficient technical knowledge may result in poor performance of or damage to the engine.
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU21340
EAU21370
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.
NOTE:
● 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).
Adjusting the throttle cable
free play
(b)
(a)
2
1
1
3
1. Throttle stop screw
Engine idling speed:
1650–1750 r/min
NOTE:
If the specified idling speed cannot be
obtained as described above, have a
Yamaha dealer make the adjustment.
4
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, adjust it as follows.
NOTE:
The engine idling speed must be correctly adjusted before checking and adjusting the throttle cable free play.
1. Loosen the locknut.
2. To increase the throttle cable free
play, turn the adjusting nut in direction (a). To decrease the throttle
6-11
5
6
7
8
9
PERIODIC MAINTENANCE AND MINOR REPAIR
cable free play, turn the adjusting
nut in direction (b).
(a)
2
1
(b)
2
5
EWA14380
●
3. Tighten the locknut.
6
7
8
2
1
Tire air pressure
The tire air pressure should be checked
and, if necessary, adjusted before each
ride.
4
1. Locknut
2. Adjusting nut
Tire inspection
To maximize the performance, durability, and safe operation of your motorcycle, note the following points regarding
the specified tires.
1
3
EAU39820
Tires
●
WARNING
The tire air pressure must be
checked and adjusted on cold
tires (i.e., when the temperature
of the tires equals the ambient
temperature).
The tire air pressure must be adjusted in accordance with the
weight of the rider, the riding
speed, and the riding conditions.
1. Tire sidewall
2. Tire tread depth
The tires must be checked before each
ride. If the center tread depth reaches
the specified limit, if the tire has a nail or
glass fragments in it, or if the sidewall is
cracked, have a Yamaha dealer replace the tire immediately.
Minimum tire tread depth (front and
rear):
4.0 mm (0.16 in)
9
Standard tire air pressure:
Front:
100 kPa (15 psi) (1.00 kgf/cm2)
Rear:
100 kPa (15 psi) (1.00 kgf/cm2)
6-12
Tire information
This motorcycle is equipped with spoke
wheels and tube tires.
PERIODIC MAINTENANCE AND MINOR REPAIR
EWA10460
●
●
WARNING
The front and rear tires should
be of the same make and design, otherwise the handling
characteristics of the vehicle
cannot be guaranteed.
After extensive tests, only the
tires listed below have been approved for this model by
Yamaha Motor Co., Ltd.
Front tire:
Size:
2.50-14 4PR
Manufacturer/model:
CHENG SHIN/KNOBBY
Rear tire:
Size:
3.00-12 4PR
Manufacturer/model:
CHENG SHIN/KNOBBY
●
●
loss of control.
The
replacement
of
all
wheel-and 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.
EWA14390
●
WARNING
Have a Yamaha dealer replace
excessively worn tires. Operating the motorcycle with excessively worn tires decreases
riding stability and can lead to
6-13
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 handling characteristics, and a shortened tire life.
● Ride at moderate speeds after
changing a tire since the tire surface must first be “broken in” for it
to develop its optimal characteristics.
2
3
4
5
6
7
8
9
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU40431
Accessories and replacement
parts
EAU22120
Adjusting the brake lever free
play
EWA14481
1
2
3
4
5
6
7
8
9
WARNING
The accessories or replacement
parts you choose for your vehicle
should be designed specifically for
this model, and they must be securely mounted to maintain the inherent stability of the original
design. Genuine Yamaha Parts and
Accessories are designed and tested to be compatible with your vehicle. Yamaha recommends the use of
Genuine Yamaha Parts and Accessories before making a purchase.
Use of non-Yamaha-approved accessories or replacement parts may
cause loss of handling stability and
riding safety. Since Yamaha cannot
control the quality of accessories or
parts manufactured by other companies, Yamaha cannot be held liable
for any consequences caused by
the use of items which have not
been approved by Yamaha.
(a)
1
2
(b)
3
1. Brake lever free play
2. Locknut
3. Adjusting bolt
The brake lever free play should measure 10.0–20.0 mm (0.39–0.79 in) as
shown. Periodically check the brake lever free play and, if necessary, adjust it
as follows.
1. Loosen the locknut at the brake lever.
2. To increase the brake lever free
play, turn the adjusting bolt in direction (a). To decrease the brake
lever free play, turn the adjusting
bolt in direction (b).
6-14
3. If the specified brake 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 at the
brake lever in direction (a) to loosen the brake cable.
5. Loosen the locknut at the brake
shoe plate.
6. To increase the brake lever free
play, turn the adjusting nut in direction (a). To decrease the brake lever free play, turn the adjusting nut
in direction (b).
2
(a)
1
(b)
1. Locknut
2. Adjusting nut
7. Tighten the locknut at the brake
PERIODIC MAINTENANCE AND MINOR REPAIR
shoe plate and at the brake lever.
EAU39811
Adjusting the brake pedal free
play
1
(a)
2
(b)
3
1
1. Brake pedal free play adjusting nut
4
1. Brake pedal free play
The brake pedal free play should measure 10.0–20.0 mm (0.39–0.79 in) at
the brake pedal end as shown. Periodically check the brake pedal free play
and, if necessary, adjust it as follows.
To increase the brake pedal free play,
turn the adjusting nut at the brake rod in
direction (a). To decrease the brake
pedal free play, turn the adjusting nut in
direction (b).
6-15
5
6
7
8
9
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU41052
Checking the front and rear
brake shoes
1
2
3
4
5
Rear
EAU22760
Drive chain slack
The drive chain slack should be
checked before each ride and adjusted
if necessary.
The front and rear brake shoes must be
checked for wear at the intervals specified in the periodic maintenance and
lubrication chart.
NOTE:
The wheels must be removed to check
brake shoe lining thickness.
● To remove the front wheel: See
page 6-23.
● To remove the rear wheel: See
page 6-26.
EAU22773
To check the drive chain slack
1. Place the motorcycle on the sidestand.
If the lining thickness of a brake shoe is
less than 1.5 mm (0.06 in), have a
Yamaha dealer replace the brake
shoes as a set.
NOTE:
When checking and adjusting the drive
chain slack, there should be no weight
on the motorcycle.
8
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.
9
Drive chain slack:
40.0–53.0 mm (1.57–2.09 in)
Front
6
NOTE:
Be sure to measure the brake lining at
the thinnest portion.
7
6-16
PERIODIC MAINTENANCE AND MINOR REPAIR
2
3
4
2
3
1
(a)
1
5
1
2
(b)
4
3
1. Drive chain slack
4. If the drive chain slack is incorrect,
adjust it as follows.
EAU40110
To adjust the drive chain slack
1. Loosen the brake pedal free play
adjusting nut, axle nut, and locknut
at each end of the swingarm.
1. Brake pedal free play adjusting nut
2. Locknut
3. Drive chain slack adjusting nut
4. Wheel axle
2. To tighten the drive chain, turn the
adjusting nut at each end of the
swingarm in direction (a). To loosen the drive chain, turn the adjusting nut at each end of the
swingarm in direction (b), and then
push the rear wheel forward.
NOTE:
Using the alignment marks on each
side of the swingarm, make sure that
both adjusting nuts are in the same position for proper wheel alignment.
6-17
1. Alignment marks
2. Drive chain slack adjusting nut
3. Locknut
4. Washer
5. Axle nut
4
5
ECA10570
CAUTION:
Improper drive chain slack will overload the engine as well as other vital
parts of the motorcycle and can lead
to chain slippage or breakage. To
prevent this from occurring, keep
the drive chain slack within the
specified limits.
3. Tighten both locknuts and the axle
nut to the specified torques.
6
7
8
9
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU23013
1
Tightening torques:
Locknut:
6.5 Nm (0.7 m·kgf, 4.7 ft·lbf)
Axle nut:
60 Nm (6.0 m·kgf, 43.4 ft·lbf)
2
4. Adjust the brake pedal free play.
(See page 6-15.)
3
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
4
5
6
7
8
9
CAUTION:
The drive chain must be lubricated
after washing the motorcycle and
riding in the rain.
1. Remove all dirt and mud from the
drive chain with a brush or cloth.
NOTE:
For a thorough cleaning, have a
Yamaha dealer remove the drive chain
and soak it in solvent.
2. Spray Yamaha Chain and Cable
Lube or a high-quality spray-type
drive chain lubricant on both sides
and on the middle of the chain,
making sure that all side plates
and rollers have been sufficiently
6-18
oiled.
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU41840
EAU23111
Checking and lubricating the
cables
Checking and lubricating the
throttle grip and cable
The operation of all control cables and
the condition of the cables should be
checked before each ride, and the cables and cable ends should be lubricated if necessary. If a cable is damaged
or does not move smoothly, have a
Yamaha dealer check or replace it.
The operation of the throttle grip should
be checked before each ride. In addition, the cable should be lubricated at
the intervals specified in the periodic
maintenance chart.
EAU23120
Adjusting the Autolube pump
The Autolube pump is a vital and sophisticated component of the engine,
which must be adjusted by a Yamaha
dealer at the intervals specified in the
periodic maintenance and lubrication
chart.
2
3
Recommended lubricant:
Yamaha Chain and Cable Lube or
engine oil SAE 10W-30 (API SE)
4
5
EWA10710
WARNING
Damage to the outer housing of cables may result in internal rusting
and cause interference with cable
movement. Replace damaged cables as soon as possible to prevent
unsafe conditions.
6
7
8
9
6-19
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU44270
Checking and lubricating the
brake and shift pedals
EAU43620
Recommended lubricant:
Lithium-soap-based grease (all-purpose grease)
Checking and lubricating the
brake lever
1
2
3
4
1. Grease nipple
5
The operation of the brake lever should
be checked before each ride, and the
lever pivots should be lubricated if necessary.
6
7
Recommended lubricant:
Lithium-soap-based grease (all-purpose grease)
8
9
The operation of the brake and shift
pedals should be checked before each
ride, and the pedal pivots should be lubricated if necessary.
6-20
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU23200
Checking and lubricating the
sidestand
EAU23271
Checking the front fork
The condition and operation of the front
fork must be checked as follows at the
intervals specified in the periodic maintenance and lubrication chart.
2
To check the condition
EWA10750
WARNING
Securely support the vehicle so that
there is no danger of it falling over.
The operation of the sidestand should
be checked before each ride, and the
sidestand pivot and metal-to-metal
contact surfaces should be lubricated if
necessary.
EWA10730
WARNING
If the sidestand does not move up
and down smoothly, have a Yamaha
dealer check or repair it.
Recommended lubricant:
Lithium-soap-based grease (all-purpose grease)
Check the inner tubes for scratches,
damage and excessive oil leakage.
To check the operation
1. Place the vehicle on a level surface and hold it in an upright position.
2. While applying the front brake,
push down hard on the handlebars
several times to check if the front
fork compresses and rebounds
smoothly.
6-21
3
ECA10590
CAUTION:
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or repair it.
4
5
6
7
8
9
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU23280
1
2
3
4
5
6
7
EAU23290
Checking the steering
Checking the wheel bearings
Worn or loose steering bearings may
cause danger. Therefore, the operation
of the steering must be checked as follows at the intervals specified in the periodic maintenance and lubrication
chart.
1. Place a stand under the engine to
raise the front wheel off the
ground.
The front and rear wheel bearings must
be checked at the intervals specified in
the periodic maintenance and lubrication chart. If there is play in the wheel
hub or if the wheel does not turn
smoothly, have a Yamaha dealer check
the wheel bearings.
EWA10750
WARNING
Securely support the vehicle so that
there is no danger of it falling over.
2. Hold the lower ends of the front
fork legs and try to move them forward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the steering.
8
9
6-22
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU24350
Supporting the motorcycle
frame in front of the rear wheel or under
each side of the swingarm.
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.
EAU24360
Front wheel
EAU41530
To remove the front wheel
EWA10820
●
●
WARNING
It is advisable to have a Yamaha
dealer service the wheel.
Securely support the motorcycle so that there is no danger of
it falling over.
1. Remove the brake cable holder by
removing the bolt.
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.
2
3
4
5
1
2
6
7
8
9
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. Brake cable holder
2. Bolt
2. Loosen the brake cable locknut
and the brake cable free play ad6-23
PERIODIC MAINTENANCE AND MINOR REPAIR
justing nut at the front wheel hub.
1
2
1
1
4
5
6
7
2
3
2
3
1
(a)
2
4
5
1. Adjusting nut
2. Locknut
3. Washer
4. Axle nut
5. Brake camshaft lever
3. Loosen the locknut at the brake lever, and then turn the adjusting
bolt fully in direction (a).
1. Adjusting bolt
2. Locknut
1. Washer
2. Axle nut
4. Disconnect the brake cable from
the front brake lever.
5. Disconnect the brake cable from
the brake camshaft lever.
6. Remove the axle nut and washer.
7. Lift the front wheel off the ground
according to the procedure on
page 6-23.
8. Pull the wheel axle out, and then
remove the wheel.
EAU41550
To install the front wheel
1. Install the brake shoe plate into the
wheel hub as shown.
8
9
6-24
PERIODIC MAINTENANCE AND MINOR REPAIR
(See page 6-14.)
10. Push down hard on the handlebar
several times to check for proper
fork operation.
1
1
2
3
1. Brake shoe plate
2. Lift the wheel up between the fork
legs.
NOTE:
Make sure that the slot in the brake
shoe plate fits over the retainer on the
fork leg.
1. Retainer
3. Insert the wheel axle, and then install the washer and axle nut.
4. Lower the front wheel so that it is
on the ground.
5. Connect the brake cable at the
wheel hub.
6. Connect the brake cable at the
front brake lever.
7. Install the brake cable holder by installing the bolt.
8. Tighten the axle nut to the specified torque.
Tightening torque:
Axle nut:
35 Nm (3.5 m·kgf, 25.3 ft·lbf)
9. Adjust the brake lever free play.
6-25
4
5
6
7
8
9
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU25080
Rear wheel
adjusting nut, and then disconnect
the brake rod from the brake camshaft lever.
EAU41560
1
2
3
4
To remove the rear wheel
3
EWA10820
●
●
WARNING
It is advisable to have a Yamaha
dealer service the wheel.
Securely support the motorcycle so that there is no danger of
it falling over.
4
5
6
7
2
1
swingarm.
5. Lift the rear wheel off the ground
according to the procedure on
page 6-23.
6. Remove the axle nut and washer,
and then pull the wheel axle out.
7. Push the wheel forward, and then
remove the drive chain from the
rear sprocket.
8
10
9
1. Loosen the axle nut.
5
1
2
6
7
5
8
9
4
3
1. Drive chain slack adjusting nut
2. Locknut
3. Chain puller
4. Washer
5. Axle nut
2. Remove the brake pedal free play
1. Brake pedal free play adjusting nut
2. Spacer
3. Chain puller
4. Wheel axle
5. Drive chain slack adjusting nut
6. Locknut
7. Brake torque rod
8. Brake torque rod bolt
9. Cotter pin
10. Brake torque rod nut
3. Disconnect the brake torque rod
from the brake shoe plate by removing the cotter pin, the nut, and
the bolt.
4. Loosen the locknut and drive chain
adjusting nut on each end of the
6-26
NOTE:
The drive chain does not need to be
disassembled in order to remove and
install the wheel.
8. Remove the spacer, chain pullers
and wheel by pulling it back.
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU41570
To install the rear wheel
1. Install the drive chain onto the rear
sprocket.
2. Install the wheel by inserting the
chain pullers, spacer and then insert the wheel axle from the
right-hand side.
3. Install the brake rod onto the brake
camshaft lever, and then install the
brake pedal free play adjusting nut
onto the brake rod.
4. Connect the brake torque rod onto
the brake shoe plate by installing
the bolt and nut, and then tighten
the nut to the specified torque.
7. Adjust the drive chain slack. (See
page 6-16.)
8. Tighten the axle nut to the specified torque.
Tightening torque:
Axle nut:
60 Nm (6.0 m·kgf, 43.4 ft·lbf)
9. Adjust the brake pedal free play.
(See page 6-15.)
Tightening torque:
Brake torque rod nut:
15.5 Nm (1.6 m·kgf, 11.2 ft·lbf)
5. Insert a new cotter pin into the
brake torque rod bolt.
EWA10830
WARNING
Always use a new cotter pin.
EAU25850
Troubleshooting
Although Yamaha motorcycles receive
a thorough inspection before shipment
from the factory, trouble may occur during operation. Any problem in the fuel,
compression, or ignition systems, for
example, can cause poor starting and
loss of power.
The following troubleshooting chart
represents a quick and easy procedure
for checking these vital systems yourself. However, should your motorcycle
require any repair, take it to a Yamaha
dealer, whose skilled technicians have
the necessary tools, experience, and
know-how to service the motorcycle
properly.
Use only genuine Yamaha replacement parts. Imitation parts may look like
Yamaha parts, but they are often inferior, have a shorter service life and can
lead to expensive repair bills.
2
3
4
5
6
7
8
9
6. Install the washer and axle nut,
and then lower the rear wheel so
that it is on the ground.
6-27
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU25971
Troubleshooting chart
EWA10840
1
2
3
WARNING
Keep away open flames and do not smoke while checking or working on the fuel system.
1. Fuel
Check the fuel level in
the fuel tank.
There is
enough fuel.
Check the compression.
There is
no fuel.
Supply fuel.
The engine does not start.
Check the compression.
4
2. Compression
5
There is compression.
Check the ignition.
There is
no compression.
Have a Yamaha dealer
check the vehicle.
Operate the kickstarter.
6
7
8
9
3. Ignition
Wet
Wipe off with a dry cloth and correct the
spark plug gap, or replace the spark plug.
Open the throttle halfway and operate
the kickstarter.
Dry
Have a Yamaha dealer check the vehicle.
The engine does not start.
Have a Yamaha dealer check the vehicle.
Remove the spark plug
and check the electrodes.
6-28
MOTORCYCLE CARE AND STORAGE
EAU37833
Matte color caution
EAU40462
Care
ECA15192
CAUTION:
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.
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 prod7-1
ucts onto seals, gaskets, sprockets, the drive chain and wheel
axles. Always rinse the dirt and degreaser off with water.
Cleaning
ECA10771
CAUTION:
● Avoid using strong acidic wheel
cleaners, especially on spoked
wheels. If such products are
used on hard-to-remove dirt, do
not leave the cleaner on the affected area any longer than instructed. Also, thoroughly rinse
the area off with water, immediately dry it, and then apply a corrosion protection spray.
● Improper cleaning can damage
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
MOTORCYCLE CARE AND STORAGE
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 or near the sea
Since sea salt is extremely corrosive,
carry out the following steps after each
ride in the rain or near the sea.
1. Clean the motorcycle with cold water and a mild detergent, after the
engine has cooled down.
ECA10790
CAUTION:
Do not use warm water since it increases the corrosive action of the
salt.
2. Apply a corrosion protection spray
on all metal, including chrome- and
nickel-plated, surfaces to prevent
corrosion.
7-2
After cleaning
1. Dry the motorcycle with a chamois
or an absorbing cloth.
2. Immediately dry the drive chain
and lubricate it to prevent it from
rusting.
3. Use a chrome polish to shine
chrome, aluminum and stainless-steel parts, including the exhaust system. (Even the thermally
induced discoloring of stainless-steel exhaust systems can be
removed through polishing.)
4. To prevent corrosion, it is recommended to apply a corrosion protection spray on all metal,
including chrome- and nickel-plated, surfaces.
5. Use spray oil as a universal cleaner to remove any remaining dirt.
6. Touch up minor paint damage
caused by stones, etc.
7. Wax all painted surfaces.
8. Let the motorcycle dry completely
before storing or covering it.
EWA14500
●
WARNING
Make sure that there is no oil or
MOTORCYCLE CARE AND STORAGE
●
wax on the tires.
If necessary, wash the tires with
warm water and a mild detergent. Before riding at higher
speeds, test the motorcycle’s
braking performance and cornering behavior.
EAU40651
Storage
Short-term
Always store your motorcycle in a cool,
dry place and, if necessary, protect it
against dust with a porous cover.
ECA10810
ECA10800
CAUTION:
● 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.
NOTE:
Consult a Yamaha dealer for advice on
what products to use.
CAUTION:
● Storing the motorcycle in a
poorly ventilated room or covering it with a tarp, while it is still
wet, will allow water and humidity to seep in and cause rust.
● To prevent corrosion, avoid
damp cellars, stables (because
of the presence of ammonia)
and areas where strong chemicals are stored.
Long-term
Before storing your motorcycle for several months:
1. Follow all the instructions in the
“Care” section of this chapter.
2. For motorcycles equipped with a
fuel cock that has an “OFF” position: Turn the fuel cock lever to
7-3
“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.)
e. Remove the spark plug cap
from the spark plug, and then
2
3
4
5
6
7
8
9
MOTORCYCLE CARE AND STORAGE
install the spark plug and the
spark plug cap.
EWA10950
1
2
3
4
5
6
7
8
9
WARNING
To prevent damage or injury from
sparking, make sure to ground the
spark plug electrodes while turning
the engine over.
6. Lubricate all control cables and the
pivoting points of all levers and
pedals as well as of the sidestand.
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.
NOTE:
Make any necessary repairs before
storing the motorcycle.
7-4
SPECIFICATIONS
EAU2633K
Dimensions:
Overall length:
1540 mm (60.6 in)
Overall width:
640 mm (25.2 in)
Overall height:
880 mm (34.6 in)
Seat height:
635 mm (25.0 in)
Wheelbase:
1055 mm (41.5 in)
Ground clearance:
185 mm (7.28 in)
Minimum turning radius:
1700 mm (66.9 in)
Weight:
With oil and fuel:
61.0 kg (134 lb)
Engine:
Engine type:
Air cooled 2-stroke
Cylinder arrangement:
Forward-inclined single cylinder
Displacement:
79.0 cm3
Bore × stroke:
47.0 × 45.6 mm (1.85 × 1.80 in)
Compression ratio:
6.60 :1
Starting system:
Kickstarter
Lubrication system:
Separate lubrication (Yamaha autolube)
Engine oil:
Type:
YAMALUBE 2 or 2-stroke engine oil (JASO
FC grade) or (ISO EG-C or EG-D grade)
Engine oil quantity:
Quantity:
0.95 L (1.00 US qt) (0.84 Imp.qt)
Transmission oil:
Type:
YAMALUBE 4 (10W30) or SAE 10W30
Oil change quantity:
0.65 L (0.69 US qt) (0.57 Imp.qt)
Spark plug (s):
Manufacturer/model:
NGK/BP6HS (AUS)(NZL)
NGK/BPR6HS
(AUT)(BEL)(CHE)(DEU)(DNK)(ESP)(FIN)
(FRA)(GBR)(GRC)(IRL)(NLD)(NOR)(PRT)
(SWE)(ZAF)
Manufacturer/model:
DENSO/W20FP (AUS)(NZL)
Spark plug gap:
0.6–0.7 mm (0.024–0.028 in)
Clutch:
Clutch type:
Wet, multiple-disc automatic
2
3
4
Transmission:
Air filter:
Air filter element:
Wet element
Fuel:
Recommended fuel:
Regular
unleaded
gasoline
only
(AUT)(BEL)(CHE)(DEU)(DNK)(ESP)(FIN)
(FRA)(GBR)(GRC)(IRL)(NLD)(NOR)(PRT)
(SWE)(ZAF)
Unleaded gasoline only (AUS)(NZL)
Fuel tank capacity:
4.9 L (1.29 US gal) (1.08 Imp.gal)
Fuel reserve amount:
1.0 L (0.26 US gal) (0.22 Imp.gal)
Primary reduction system:
Helical gear
Primary reduction ratio:
66/21 (3.143)
Secondary reduction system:
Chain drive
Secondary reduction ratio:
32/15 (2.133)
Transmission type:
Constant mesh 3-speed
Operation:
Left foot operation
Gear ratio:
1st:
39/12 (3.250)
2nd:
29/16 (1.812)
Carburetor:
Manufacturer:
MIKUNI
Type × quantity:
VM15SC x 1
8-1
5
6
7
8
9
SPECIFICATIONS
3rd:
22/17 (1.294)
Chassis:
1
2
Frame type:
Steel tube backbone
Caster angle:
26.00 °
Trail:
62.0 mm (2.44 in)
Front tire:
3
4
5
6
7
Type:
With tube
Size:
2.50-14 4PR
Manufacturer/model:
CHENG SHIN/KNOBBY
Rear tire:
Type:
With tube
Size:
3.00-12 4PR
Manufacturer/model:
CHENG SHIN/KNOBBY
Loading:
8
9
Maximum rider weight:
40.0 kg (88 lb)
Maximum load:
40 kg (88 lb)
* (Total weight of rider, cargo and
accessories)
Tire air pressure (measured on cold
tires):
Front:
100 kPa (15 psi) (1.00 kgf/cm2)
Rear:
100 kPa (15 psi) (1.00 kgf/cm2)
Front wheel:
Rear suspension:
Type:
Swingarm (monocross)
Spring/shock absorber type:
Coil spring/gas-oil damper
Wheel travel:
95.0 mm (3.74 in)
Electrical system:
Wheel type:
Spoke wheel
Rim size:
14x1.40
Ignition system:
CDI
Rear wheel:
Wheel type:
Spoke wheel
Rim size:
12x1.60
Front brake:
Type:
Drum brake
Operation:
Right hand operation
Rear brake:
Type:
Drum brake
Operation:
Right foot operation
Front suspension:
Type:
Telescopic fork
Spring/shock absorber type:
Coil spring/oil damper
Wheel travel:
110.0 mm (4.33 in)
8-2
CONSUMER INFORMATION
EAU40790
Identification numbers
EAU26400
Vehicle identification number
Record the vehicle identification number and model label information in the
spaces provided below for assistance
when ordering spare parts from a
Yamaha dealer or for reference in case
the vehicle is stolen.
VEHICLE IDENTIFICATION
NUMBER:
1
1
2
3
1. Vehicle identification number
MODEL LABEL INFORMATION:
EAU26480
Model label
The vehicle identification number is
stamped into the steering head pipe.
Record this number in the space provided.
NOTE:
The vehicle identification number is
used to identify your motorcycle and
may be used to register your motorcycle with the licensing authority in your
area.
9-1
1. Model label
The model label is affixed to the frame
under the seat. (See page 3-6.) Record
the information on this label in the
space provided. This information will be
needed when ordering spare parts from
a Yamaha dealer.
4
5
6
7
8
9
INDEX
A
Accessories and replacement parts........ 6-14
Air filter element, cleaning......................... 6-8
Autolube pump, adjusting ....................... 6-19
B
Brake and shift pedals, checking and
lubricating ............................................. 6-20
Brake lever................................................ 3-2
Brake lever, checking and lubricating ..... 6-20
Brake lever free play, adjusting............... 6-14
Brake pedal............................................... 3-2
Brake pedal free play, adjusting.............. 6-15
Brake shoes, checking............................ 6-16
I
Identification numbers................................9-1
K
Kickstarter..................................................3-6
L
Labels, location of......................................1-4
M
Matte color, caution ...................................7-1
Model label ................................................9-1
P
Parking.......................................................5-4
Part locations .............................................2-1
Periodic maintenance and lubrication
chart ........................................................6-2
Power reduction plate ................................3-1
Power reduction plate, removing ...............6-6
Pre-operation check list .............................4-2
C
Cables, checking and lubricating ............ 6-19
Carburetor, adjusting .............................. 6-10
Care .......................................................... 7-1
D
S
Drive chain, cleaning and lubricating ...... 6-18
Drive chain slack..................................... 6-16
Safety information......................................1-1
Seat ...........................................................3-6
Shifting.......................................................5-2
Shift pedal..................................................3-1
Shock absorber..........................................3-7
Sidestand, checking and lubricating ........6-21
Spark arrester, cleaning.............................6-9
Spark plug, checking .................................6-5
Specifications.............................................8-1
Starter (choke) lever ..................................3-6
Starting and warming up a cold engine .....5-1
Steering, checking ...................................6-22
Storage ......................................................7-3
Supporting the motorcycle .......................6-23
E
Engine break-in......................................... 5-3
Engine idling speed................................. 6-11
Engine oil .................................................. 3-4
Engine, starting a warm ............................ 5-2
Engine stop switch .................................... 3-1
F
Front fork, checking ................................ 6-21
Fuel ........................................................... 3-3
Fuel cock................................................... 3-5
Fuel tank breather hose ............................ 3-4
Fuel tank cap ............................................ 3-2
H
Handlebar switch ...................................... 3-1
T
Throttle cable free play, adjusting............6-11
Throttle grip and cable, checking and
lubricating.............................................. 6-19
Tires ........................................................ 6-12
Tool kit....................................................... 6-1
Transmission oil ........................................ 6-7
Troubleshooting....................................... 6-27
Troubleshooting chart.............................. 6-28
V
Vehicle identification number .................... 9-1
W
Wheel bearings, checking ....................... 6-22
Wheel (front)............................................ 6-23
Wheel (rear) ............................................ 6-26
Wheels .................................................... 6-13
YAMAHA MOTOR CO., LTD.
PRINTED ON RECYCLED PAPER
PRINTED IN JAPAN
2007.4–0.7×1 !
(E)
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