yamaha - Project Moped Manual

~YAMAHA
f). sr "'
OWNER'S MANUAL
38 K-28199-71
A-604
IDENTIFICATION NUMBERS RECORD
1. KEY NUMBER:
Your key identification number is stamped
on your key as shown in the following illustration.
Record this number in the space provided for
reference if you need a new key.
2. VEHICLE NUMBER:
Key number
3. ENGINE NUMBER:
Record your vehicle and engine numbers in
the spaces provided to assist you in ordering
spare parts from your Yamaha dealer or for
reference in case your vehicle is stolen. (See
page 3-1)
DT50W
OWNER'S MANUAL
©1988 by Yamaha Motor Co., Ltd.
1st Edition, June 1988
All rights reserved. Any reprinting or
unauthorized use without the written
permission of yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Japan
U-001
A-200
INTRODUCTION
Congratulations on your purchase of the
Yamaha DT50W. 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 about the operation or maintenance of your motorcycle, please consult
a Yamaha dealer.
NOTE:~~~~~~~~~~~~
Some data in this manual may become outdated due to future improvement on this
model. If you have any questions about this
manual or your motorcycle, please consult a
Yamaha dealer.
TECHNICAL PUBLICATIONS
SERVICE DIVISION
MOTORCYCLE GROUP.
YAMAHA MOTOR CO .. LTD.
A-101
U-601
&WARNING:
PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE
OPERATING THIS MOTORCYCLE.
Particularly important information is distinguished in this manual by the following notations:
NOTE:
A NOTE provides key information to make
procedures easier or clearer.
A CAUTION indicates special procedures that
must be followed to avoid damage to the
motorcycle.
&WARNING:
A WARNING indicates special procedures
that must be followed to avoid injury to a
motorcycle operator or person inspecting or
repairing the motorcycle.
U-000
NOTE:~~~~~~~~~~~~­
This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold.
U-754
LI':, TIPS FOR SAFETY
TWO-WHEELED 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.
HE OR SHE SHOULD:
1. OBTAIN THOROUGH INSTRUCTIONS FROM A COMPETENT SOURCE ON
ALL ASPECTS OF MOTORCYCLE OPERATION.
2. OBSERVE THE WARNINGS AND MAINTENANCE REQUIREMENTS IN THE
OWNER'S MANUAL.
3. OBTAIN QUALIFIED TRAINING IN SAFE AND PROPER RIDING TECHNIQUES.
4. OBTAIN PROFESSIONAL TECHNICAL SERVICE AS INDICATED BY THE
OWNER'S MANUAL AND/OR WHEN MADE NECESSARY BY MECHANICAL
CONDITIONS.
,
______
---
SAFE RIDING
1. Always make pre-operation checks. Careful checks may help prevent an accident.
2. This motorcycle is designed to carry the operator only No passengers.
3. The failure of motorists to detect and recognize motorcycles in traffic is the
predominating cause of automobile/motorcycle accidents. Many accidents
have been caused by an automobile driver who did not see the mtorcycle.
Making yourself conspicuous appears to be very effective in reducing the
chance of this type of accident.
Therefore:
a. Wear a brightly colored jacket.
b. Use extra caution when you approach and pass through intersections,
since intersections are the most likely places for motorcycle accidents.
c. Ride where other motorists can see you. Avoid riding in another motorist's
"blind spot."
4. Many accidents involve inexperienced operators. In fact, many operators
who have been involved in accidents do not even have a current motorcycle
license.
a. Make sure you are qualified. Also, only lend your motorcycle to experienced operators.
b. Know your skills and limits. Staying within your limits may help you to
avoid an accident.
c. We recommend that you practice riding your motorcycle where there is
no traffic until you have become thoroughly familiar with your motorcycle
and all of its controls.
5. Many motorcycle accidents have been caused by motorcycle operator errors.
A typical error made by the operator is veering wide on a turn due to EXCESSIVE SPEED or undercornering (insufficient lean angle for the speed).
a. Always obey the speed limits and never travel faster than warranted by
road and traffic conditions.
b. Always signal before turning or changing lanes. Make sure other motorists
see you.
6. Operator's posture is important for proper control.
The operator should keep both hands on the handlebars and both feet on the
operator footrests during operation to maintian control of the motorcycle.
7. Never ride under the influence of alcohol or drugs.
PROTECTIVE APPAREL
The majority of fatalities from motorcycle accidents are the result of head injuries. The use of a safety helmet is the single most critical factor in the prevention or reduction of head injuries.
- --- - - - - - - -
------- - - -
1. Always wear an approved helmet.
2. Wear a face shield or goggles. Wind on your unprotected eyes could contribute to an impairment of vision which could delay seeing a hazard.
3. The use of heavy boots, jacket, trousers, gloves, etc. is effective in preventing
or reducing abrations or lacerations.
4. Never wear loose fitting clothing. It could catch on the control levers,
footrests, or wheels and cause injury or accident.
5. Never touch the engine or exhaust system during or after operation. They
become very hot and can cause burns. Always wear protective clothings that
covers your legs, ankles, and feet.
MODIFICATION
Modifications made to the motorcycle not approved by Yamaha, or the removal
of original equipment, may render your motorcycle unsafe for use and may cause
severe personal injury. Modifications may also make your motorcycle illegal to
use.
LOADING AND ACCESSORIES
Adding accessories or cargo to your motorcycle can adversely affect stability
and handling if the weight distribution of the machine is changed. To avoid the
possibility of an accident, extreme caution should be used if adding cargo or
accessories to your motorcycle. Use extra care if riding a motorcycle which has
added cargo or accessories. Here are some general guidelines to follow if loading
cargo or adding accessories to your motorcycle:
LOADING
The total weight of the operator, accessories and cargo must not exceed
the maximum load limit of 157 lbs. (71 kg).
When loading within these weight limits, keep the following in mind:
1. Cargo and accessory weight should be kept as low and close to the motorcycle
as possible. Be sure to distribute the weight as evenly as possible on both
sides of the machine to minimize imbalance or instability.
2. Shifting weights can create a sudden imbalance. Make sure that accessories
and cargo are securely attached to the motorcycle before riding. Recheck
accessory mounts and cargo restraints frequently.
3. Never attach any large or heavy items to the handlebars, front forks, or front
fender. These items, including such cargo as sleeping bags, duffle bags, or
tents, can create unstable handling or slow steering response.
ACCESSORIES
Genuine Yamaha accessories have been specifically designed for use on this
motorcycle. Since Yamaha cannot test all other accessories which may be
available, you must personally be responsible for the proper selection, installation and use of non-Yamaha accessories. You should use extreme caution when
selecting and installing any accessories.
Keep in mind these guidelines for mounting accessories in addition to those
provided under "LOADING''.
1. Never install accessories or carry cargo that would impair the performance
of your motorcycle. Carefully inspect the accessory before using it to make
sure it does not in any way reduce ground clearance or cornering clearance,
limit suspension travel, steering travel or control operation, or obscure lights
or reflectors.
a. Accessories fitted to the handlebar or the front fork area can create instability due to improper weight distribution or aerodynamic changes. If
accessories are added to the handlebar or front fork area, they must be
as light weight as possible and should be kept to a minimum.
b. Bulky or large accessories may seriously affect the stability of the motorcycle due to aerodynamic effects. Wind may attempt to lift the motorcycle, or the motorcycle may become unstable in cross winds. These
accessories may also cause instability when being passed by or passing
large vehicle.
c. Certain accessories can displace the operator from his or her normal riding
position. This improper position limits the freedom of movement of the
operator and may limit control ability. Therefore such accessories are
not recommended.
2. Caution must be used if adding electrical accessories. If these accessories
exceed the capacity of motorcycle's electrical system, an electric failure could
result, which could cause a dangerous loss of lights or engine power.
GASOLINE AND EXHAUST GAS
1. GASOLINE IS HIGHLY FLAMMABLE:
a. Always turn off the engine when refueling.
b. Take care not to spill any gasoline on the engine or exhaust
pipe(s)/muffler(s) when refueling.
c. Never refuel while smoking or in the vicinity of an open flame.
2. Never start the engine or let it run for any length of time in a closed area.
The exhaust fumes are poisonous and may cause loss of consciousness and
death within a short time. Always operate your motorycle in an area that
has adequate ventilation.
3. Always turn off the engine before leaving the motorcycle unattended and
remove the ignition key. When parking the motorcycle, note the following:
a. The engine and exhaust pipe(s)/muffler(s) may be hot. Park the motorcycle
in a place where pedestrians or children are not likely to touch these hot
areas.
b. Do not park the motorcycle on a slope or soft ground: the motorcycle
may fall over.
c. Do not park the motorcycle near an flammable source, e.g. a kerosene
heater, or near an open flame. The motorcycle could catch fire.
4. When transporting the motorcycle in another vehicle, be sure it is kept upright
and that the fuel cock(s) is turned to "ON" or "RES" (for vacuum type)/"OFF"
(for manual type). If it should lean over, gasoline may leak out of the carburetor or fuel tank.
5. If you should swallow any gasoline, inhale a lot of gasoline vapor, or allow
gasoline to get in your eye(s), see your doctor immediately. If any gasoline
spills on your skin or clothing, immediately wash with soap and water and
change your clothes.
A-305
CONTENTS
LOCATION OF THE
IMPORTANT LABELS ......................... . 1 -1
DESCRIPTION ....................................... 2-1
MOTORCYCLE IDENTIFICATION ....... 3-1
Vehicle identification number ............. 3-1
Engine serial number .......................... 3-1
CONTROL FUNCTIONS .......................
Main switch .. .......... ...... .. ...... ..............
Indicator lights ....................................
Oil warning light checking method ....
Speedometer.......................................
Tachometer .........................................
Engine temperature gauge .................
Handlebar switches ............................
Clutch lever .........................................
Change pedal......................................
Front brake lever .................................
4-1
4-1
4-2
4-3
4-4
4-4
4-4
4-5
4-6
4-6
4- 7
Rear brake pedal................................. 4- 7
Fuel cock ............................................ 4- 7
Starter knob (CHOKE) ....................... 4-8
Kick starter .......................................... 4-8
Steering lock ....................................... 4-9
Helmet holder ........ .......... ............ ....... 4-9
Note handling of the Yamaha
Energy Induction system .................. 4-10
Sidestand .......................................... 4-11
Sidestand switch operation check ... 4-11
PRE-OPERATION CHECKS ..................
Brakes .................................................
Clutch .................................................
Throttle grip ........................................
Engine oil ............................................
Transmission oil ..................................
Coolant ...............................................
Chain ...................................................
Tires ....................................................
5-1
5-3
5-3
5-3
5-3
5-4
5-5
5-6
5-6
Wheels ................................................
Fittings/Fasteners ...............................
Lights and signals ...............................
Switches .. .. .. ... ...... .... ... .. ... .. ... .. ... ... .. ...
Battery .................................................
Fuel .....................................................
5-8
5-9
5-9
5-9
5-9
5-9
OPERATION AND IMPORTANT
RIDING POINTS ...................................
Starting a cold engine ........................
Engine warm-up .................................
Starting a warm engine ......................
Shifting ...............................................
Engine break-in ..................................
Parking................................................
6-1
6-1
6-3
6-3
6-3
6-4
6-5
PERIODIC MAINTENANCE AND
MINOR REPAIR ....................................
Tool kit ................................................
Periodic maintenance/lubrication ......
Torque specifications ..........................
Transmission oil level check ...............
7-1
7-1
7-3
7-5
7-6
Transmission oil replacement ............. 7 -7
Cooling system................................. 7-8
Fuel cock cleaning ............................ 7-11
Air filter ............................................. 7-11
Carburetor adjustment ...................... 7-13
Idle speed adjustment ....................... 7-13
Throttle cable adjustment ................. 7-14
Spark plug inspection....................... 7 -15
Front brake adjustment ..................... 7-16
Rear brake adjustment.. .................... 7-17
Brake light switch adjustment .......... 7-18
Checking the brake shoes ................ 7-19
Clutch adjustment ............................ 7 -19
Mechanism adjustment .................... 7-20
Drive chain slack check .................... 7-20
Drive chain slack adjustment.. .......... 7-21
Drive chain lubrication ..................... 7-22
Cable inspection and lubrication ...... 7-23
Throttle cable and grip lubrication ... 7-23
Autolube pump adjustment .............. 7 24
Brake and change pedals ................. 7-24
Brake and clutch levers .................... 7-24
Sidestand ..........................................
Front fork inspection ........................
Rear shock ( Monocross suspension
"De Carbon" system .........................
Steering inspection ...........................
Wheel bearings.................................
Battery ...............................................
Replenishing the battery fluid ..........
Fuse replacement ..............................
Replacing the headlight bulb ...........
Headlight beam adjustment .............
Replacing the taillight
and flasher light bulb ........................
Front wheel removal. ........................
Front wheel installation ....................
Rear wheel removal ..........................
Rear wheel installation .. ........ ... .. ... ...
Troubleshooting ...............................
Troubleshooting chart ......................
7-24
7-24
7-26
7-26
7 -27
7-27
7-28
7-29
7-30
7-30
7-31
7-31
7-32
7 -33
7-34
7-35
7-36
CLEANING AND STORAGE ................. 8-1
A. Cleaning ......................................... 8-1
B. Storage ........................................... 8-2
SPECIFICATIONS ................................. 9-1
WIRING DIAGRAM
A-400
LOCATION OF THE IMPORTANT LABELS
Please read following labels carefully before operating this motorcycle.
2
3
1·1
4
(j)("_M_F_D-.-,-Y~Y-A_M_A_H~A-M~O-T_O_R_C_D-.-.-,-T-D-.:::::::::=A:::::::::;--:-(5:0:6-1~~~~.....
GVWR •••• kg GAWR FRONT • •••• kg, WITH •••• (B) TIRE,
•••••RIM. AT •on PSI COLD. REAR - **"• Kg. WITH
••••• (B) TIRE, •••• AIM, AT •••• PSI COLD.
I
WARNING
I
OPERATOR ONLY
THIS VEHICLE CONFORMS TO ALL APPLICABLE FEDERAL MOTORVEHICLE
SAFETY STANDARDS IN EFFECT ON THE DATE OF MANUFACTURE
SHOWN ABOVE.
VEHICLE ID NO.
8
TYPE CLASSIFICATION··· MOTORCYCLE.
NO PASSENGERS
I AVERTISSEMENTI
OPERATEUR UNIOUEMENT
PAS DE PASSAGERS
®
HOW TO LAYOUT
IBATTERYI BREATHER
PIPE
CAUTION
!BATTERY REMOVAL ANO INSTALLATION!
1.Bc careful
21A-00
001 10 SPiash tho electrolyte to
the drive chain,
2.Remove the breather pipe before
demountrng the baucry,
3.After insrnlling the battery, be sure 10
connect the breather pipe into place.
1-2
A-500
DESCRIPTION
1. Tail/Brake light
2. Rear flasher light
3. Monocross suspension
4. Kick starter
5. Front fender
6. Brake pedal
7. Footrest
8. Front fork
9. Headlight
10. Fu et tank
11. Seat
14 15
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
Silencer
Change pedal
Clutch lever
Handlebar switch
Speedometer
Main switch
Tachometer
Brake lever
Throttle grip
Front flasher light
Radiator
U-002
j
,
I
;
NOTE: ~~~~~~~~~~~~~
The motorcycle you have purchased may differ
slightly from those shown in the photographs.
i
I
\~
2-1
A-701
A·600
A-800
MOTORCYCLE
IDENTIFICATION
Vehicle identification number
The vehicle identification number is stamped
into the steering head pipe.
Engine serial number
The engine serial number is stamped into the
right side of the engine.
1. Engine serial number
U-003
1. Vehicle identification number
U-004
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 state.
- - - - - - - - - - - - - - - - - - 3-1
NOTE: _ _ _ _ _ _ _ _ _ _ __
The first three digits of these numbers are for
model identification; the remaining digits are
the unit production number. Keep a record
of these numbers for reference when ordering
parts from a Yamaha dealer.
U-006
B-000
NOTE:~~~~~~~~~~~~
CONTROL FUNCTIONS
When the engine is started, the headlight and
meter lights come on automatically, and the
lights stay on until the main switch is turned
to "OFF" even if the engine stalls.
B·001
Main switch
The main switch controls the ignition and
lighting systems; its operation is described
below.
OFF
B-006
OFF:
All electrical circuits are switched off. The
key can be removed in this position.
ON
8-007
LOCK:
The steering is locked in this position, and
all electrical circuits are switched off. The key
can be removed in this position. Refer to
"Steering lock" (Page 4-9) for proper operation.
B-014
U-007
ON:
Electrical circuits are switched on and taillight
comes on. The engine can be started. The
key cannot be removed in this position.
Always turn the main switch to "OFF" or
"LOCK" and remove the key when the motorcycle is unattended.
NOTE=~~~~~~~~~~~~­
4'1
8-100
B-103
Indicator lights
"HIGH BEAM" indicator light (blue):
This indicator comes on when the headlignt
high beam is used.
4
B-107
"OIL" warning indicator light (red):
This indicator comes on when the oil level
is low: This light circuit can be checked by
the following procedure.
CJ
0
U-300
Do not run the motorcycle until you
know the motorcycle has enough en-
1. "TURN" indicator light
2. "NEUTRAL" indicator light
3. "OJ L" warning indicator light
gine oil.
4. "HIGH BEAM" indicator light
B-101
"TURN" indicator light (orange):
This indicator flashes when the turn switch
is "ON".
B-102
"NEUTRAL" indicator light (green):
This indicator comes on when the transmission is in neutral.
4·2
B-302
Oil warning light checking method
\Main switch "ON".
CB3·03
I
I
!Gears in "NEUTRAL".
I
I
t
t
Oil warning indicator
light does not come on.
Oil warning indicator
light comes on.
j
Shift into gear.
I
Ask a Yamaha
dealer to inspect
electrical circuit.
t
I
Oil warning indicator light
does not come on.
Oil warning indicator
light comes on.
I
I
Engine oil level and electrical circuit are OK. Go
ahead with riding.
4-3
!supply engine oil.
I
B-407
U-304
Speedometer
The odometer is built into the speedometer.
Do not operate in the red zone
Red zone: 10,000 r/min and above
3
B-501
Engine temperature gauge
This gauge indicates the coolant temperature
when the main switch is ON. The engine
operating temperature will vary with changes
in weather and engine load. If the needle
points to the red zone or higher, stop your
motorcycle and let the engine cool. (See page
7-8 for more detail.)
2
1. Speedometer
3. Tachometer
2. Odometer
4. Red zone
B-403
Tachometer
This model is equipped with a tachometer
so the rider can monitor the engine speed and
keep it within the ideal power range.
4-4
B-600
Handlebar switches:
40 C (104 F)
';/
c
.-"'.l
®
I
~
.... 125°C
.
,,. \
I I
(257°F)'-
I
1. Engine temperature gauge
-
'
·--
.. . ....
2
2. Red zone
U-305
1. "LIGHTS" (Dimmer) switch
3. "HORN" switch
2. "TURN" switch
B-601
When the engine is overheated, do not
continue riding.
"LIGHTS" (Dimmer) switch
Turn the switch to "HI" for the high beam
and to "LO" for the low beam.
B-605
"TURN" signal switch
This is a three-way switch: the center position
is off; turn to the "L" to turn on the left flasher
and to the "R" for the right flasher. Be sure
to turn the switch off after completing a turn.
4.5
B-602
B-701
"HORN" switch
Press the switch to sound the horn.
Clutch lever
The clutch lever: is located on the left handlebar; it disengages or engages the clutch.
Pull the clutch lever to the handlebar to disengage the clutch, and release the lever to
engage the clutch. The lever should be pulled
rapidly and released slowly for smooth starts.
B-609
"ENGINE STOP" switch
the engine stop switch is a safety device for
use in an emergency such as when the motorcycle overturns or when trouble occurs in
the throttle system. The engine will not run
when the engine stop switch is turned to
"OFF." In case of emergency, turn the switch
to "OFF."
B-800
Change pedal
The gear ratios of the constant-mesh 6-speed
transmission are ideally spaced. The gears
can be shifted by using the change pedal on
the left side of the engine.
1. "ENGINE STOP" switch
4 _6
@
Neutral
B-900
Front brake lever
The front brake lever is located on the right
handlebar. Pull it toward the handlebar to
activate the front brake.
B-901
Rear brake pedal
The rear brake pedal is on the right side of
the motorcycle. Press down on the brake
pedal to activate the rear brake.
ON
C-101
Fuel cock
The fuel cock supplys fuel from the tank to
carburetor while filtering the fuel. The fuel
cock has the three positions:
4-7
OFF: With the lever in this position, fuel will
not flow. Always return the lever to this
position when the engine is not running.
ON: With the lever in this position, fuel
flows to the carburetor. Normal riding
is done with the lever in this position.
RES: This indicates reserve. If you run out
of fuel while riding, move the lever to
this position. FILL THE TANK AT THE
FIRST OPPORTUNITY. BE SURE TO
SET THE LEVER TO "ON" AFTER
REFUELING.
C-202
C-602
Starter knob (CHOKE)
When cold, the engine requires a richer airfuel mixture for starting. A separate starter
circuit supplies this mixture. Pull the starter
knob out to open the circuit for starting. When
the engine has warmed up, push the knob
in to close the circuit.
Kick starter
Rotate the kick starter away from the engine.
Push the starter down lightly with your foot
until the gears engage, then kick smoothly
and forcefully to start the engine. This model
has a primary kick starter so the engine can
be started in any gear if the clutch is disengaged. In normal practices, however, shift to
neutral before starting.
:~
1. Starter knob
1. Kick starter
4.S
C-300
Steering lock
The steering is locked when the main switch
is turned to "LOCK." To lock the steering, turn
the handlebars all the way to the left or right.
With the key at "OFF," push it into the main
switch, turn the key countertlockwise to
"LOCK," and remove the key. To release the
lock, turn the key clockwise.
1. Push
OFF
2. Release
3. Turn
U-614
L1' WARNING:
Never turn the key to "LOCK" when
the motorcycle is moving.
C-500
Helmet holder
To open the helmet holder, insert the key in
the lock and turn it as shown. To lock the
helmet holder, replace the holder in its original
position.
4.9
···-
------D-550
Note on handling of the Yamaha Energy
Induction System (Y.E.l.S.)
Handle the air chamber and hose with special
care. Improper installation or damaged parts
will result in poor performance. Replace any
cracked or damaged parts immediately. No
modification of this system in any form is not
allowed.
CD-
1. Helmet holder
2. Open
&WARNING:
Never ride with a helmet in the helmet
holder. It could interfere with rear
wheel movement, causing loss of
control and possibly an accident.
U-376
%;1tt((!,a;blrt;{{;!i!ll
'::;,;~\'<;:.;/'''W:.;;'f':::;c:.o"C~~~if-0'%.c _ _ _ _ _ _ _ _ _ __
Never attempt to modify the Yamaha
Energy Induction System.
4-10
D-301
cycle to a Yamaha dealer immediately
for repair.
Sidestand
This model is equipped with an ignition circuit cut-off system. The motorcycle must not
be ridden when the sidestand is down. The
sidestand is located on the left side of the
frame. (Refer to page 6-2 for an explanation
of this system.)
D-305
Sidestand switch operation check
Check the operation of the sidestand switch
against the information below.
U-689
CD3-02
;hWARNING:
TURN MAIN SWITCH TO .. ON"" AND ENGINE
STOP SWITCH TO .. RUN.
This motorcycle must not be operated
with the sidestand in the down position. If the stand is not properly retracted, it could contact the ground
and distract the operator resulting in
a possible loss of control. Yamaha has
designed into this motorcycle a lockout
system to assist the operator in fulfilling his responsibility of retracting
the sidestand. Please check carefully
the operating instructions listed below
and if there is any indication of a malfunction, you must return the motor-
l
TRANSMISSION IS IN NEUTRAL AND
SIDESTAND IS DOWN.
l
KICK THE KICK STARTER.
4-11
·---------
I ENGINE WILL START.
l
PULL IN CLUTCH LEVER AND PUT
TARANSMISSION IN GEAR.
I ENGINE WILL STALL.
I SIDESTAND SWITCH IS OK.
U-691
&WARNING:
If improper operation is noted, consult
a Yamaha dealer immediately.
4·12
PRE-OPERATION CHECKS
Before using this motorcycle. check the following points:
Item
-
Routine
Page
Front and rear brakes
Check operation, condition and free play.
Adjust if necessary.
5-3,7-16~7-19
Clutch
Check operation, condition and free play.
Adjust if necessary.
5-3. 7-19-7-20
Throttle grip/Housing
Check for smooth operation. Lubricate if necessary.
Autolube tank
Check oil level/top up as repuired.
Transmission oil
Check oil level/top-up as required.
5-4-5-5,7-6-7-8
Coolant reservoir tank
Check coolant level/top up as required.
5-5-5-6,7-8- 7-11
5-6.7-20- 7-23
5-6-5-9
5-3. 7-23
7-24
Drive chain
Check chain slack and condition. Adjust if necessary.
Wheels/Tires
Check tire pressure, wear, damage and spoketightness
Fittings/ Fasteners
Check all chassis fittings and fasteners.
Tighten/ Adjust, if necessary.
Fuel tank
Check fuel level/top-up as required.
Lights and signals
Check for proper operation.
5-9.7-30- 7-32
Battery
Check fluid level, top-up with distilled
water if necessarry.
5-9,7-27-7-29
5-9. 7-5
5-9~5-10
NOTE:~~~~~~~~~~~~~~~~~~~~~~~~~~~~
Pre-operation checks should be made each time the motorcycle is used. Such an inspection
can be throughly accomplished in a very short time; and the added safety it assures is
more than worth the time involved.
LL, WARNING:
If any item in the Pre-Operation Check is not working properly, have it inspected
and repaired before operating the motorcycle.
5-2
E·115
E-301
Brakes (See page 7-16 for more detail)
1 . Brake lever and brake pedal
Check for correct free play in the front
brake lever and rear brake pedal. Make
sure they are working properly. Check
the brakes at low speed shortly after
starting out. If the free play is incorrect,
adjust it.
2. Check the brake shoes.
Refer to page 7-19.
Throttle grip (See page 7-23 for more
detail)
Turn the throttle grip to see if it operates
properly, and check the free play. Make sure
the grip returns by spring force when released.
Ask a Yamaha dealer to make any necessary
adjustments.
E-413
Engine oil
Make sure the engine oil is at the specified
level. Add oil as necessary.
U-022
NOTE: _ _ _ _ _ _ _ _ _ _ __
When this brake service is necessary, ask a
Yamaha dealer.
E-200
Clutch (See page 7-19 for more detail)
Check the free play in the clutch lever, and
make sure the lever operates properly. If the
free play is incorrect, adjust it.
1. Oil tank filler cap
5-3
E-404
Transmission oil (See page 7-6 for more
detail)
Make sure the transmission oil is at the specified level. Add oil as necessary.
Recommended oil:
Yamalube 2-cycle oil or
air-cooled 2-stroke engine oil
Oil quantity:
Total amount
1.3 L(1.1 Imp qt, 1.4 US qt)
Recommended oil:
YAMALUBE 4 (10W30) or
SAE 1 OW30 type SE motor oil
Oil quantity:
Total amount:
0.75 L(0.66 Imp qt, 0.79 US qt)
Periodic oil change:
0.7 L(0.61 Imp qt, 0.74 US qt)
U-042
NOTE; _ _ _ _ _ _ _ _ _ _ __
Be sure to push the cap into the filler neck
until it is properly seated.
5-4
E-600
U-626
Coolant
Check the coolant level in the reservoir tank
when the engine is cold. (The coolant level
will vary with engine temperature.) The
coolant level is satisfactory if it is between
the FU LL and LOW marks on the tank. If the
coolant level is at or below the LOW level,
add tap water (soft water) to bring the level
up to FULL. Change the coolant every two
years. (See page 7-8 for more detail.)
Lh WARNING:
Do not remove the radiator cap when
the engine is hot.
Hard water or salt water is harmful to
the engine. You may use distilled water
if you can't get soft water.
Reservoir tank capacity:
Total:
0.38 L (0.33 Imp qt, 0.40 US qt)
From LOW to FULL level:
0.20 L (0.18 Imp qt, 0.21 US qt)
CD
E-500
1. "FULL" level
Chain (See page 7-20 for more detail)
Check the general condition of the chain and
check the chain slack before every ride. Lubricate and adjust the chain as necessary.
2. "LOW" level
5-5
E-910
CES-01
Tires
To ensure maximum performance, long service, and safe operation, note the following:
1 . Tire air pressure
Always check and adjust the tire pressure
before operating the motorcycle.
Basic weight
With oil and full fuel tank
Maximum
load~
Cold tire pressure
0 kg (0 lb) ~
Maximum load*
~Load
U-696
&WARNING:
86 kg (190 lb)
71 kg (157 lb)
Front
Rear
130 kPa
(1.3 kg/cm 2,
18 psi)
130 kPa
(1.3 kg/cm 2 •
18 psi)
is the total weight of cargo, rider, and accessories.
U-711
&WARNING:
Tire inflation pressure should be
checked and adjusted when the temperature of the tire equals the ambient
air temperature. Tire inflation pressure
must be adjusted according to total
weight of cargo, rider, and accessories
(fairing, saddlebags, etc. if approved
for this model), and vehicle speed.
Proper loading of your motorcycle is
important for the handling, braking,
and other performance and safety
characteristics of your motorcycle. Do
not carry loosely packed items that can
shift. Securely pack your heaviest
items close to the center of the motorcycle, and destribute the weight
evenly from side to side. Check the
condition and pressure of your tires.
5-6
NEVER OVERLOAD YOUR MOTORCYCLE. Make sure the total weight of
the cargo, rider, and accessories (fairing, saddlebags, etc. if approved for
this model) does not exceed the maximum load of the motorcycle. Operation of an overloaded motorcycle could
cause tire damage, an accident, or even
injury.
®
1.
2. Tire inspection
Always check the tires before operating
the motorcycle. If a tire tread shows
crosswise lines (minimum tread depth),
if the tire has a nail or glass fragments
in it, or if the side wall is cracked, contact
a Yamaha dealer or other qualified mechanic immediately and have him replace
the tire.
Tread depth
2.
3.
Side wall
Wear indicator
CE9-02
FRONT:
[
Type
Manufacture
Size
INOUE
2.50-194PR
REAR:
I
Size
INOUE
3.00 - 17 4 PR
Minimum tire tread
depth (front and rear)
5-7
Type
Manufacture
1.0 mm (0.04 in)
U-700
1 . Always inspect the wheels before a ride.
Check for cracks, bends, or warpage of
the wheel; be sure the spokes are tight
and undamaged. If any abnormal condition exists in a wheel, consult a Yamaha
dealer. Do not attempt even small repairs
to the wheel. If a wheel is deformed or
cracked, it must be replaced.
2. Tires and wheels should be balanced
whenever either one is changed or replaced. Failure to have a wheel balanced
can result in poor performance, adverse
handling characteristics, and shortened
tire life.
3. After installing a tire, ride conservatively
to allow the tire to seat itself on the rim
properly. Failure to allow proper seating
may cause tire failure, resulting in damage to the motorcycle and injury to the
rider.
&WARNING:
1. It is dangerous to ride with a
worn-out tire. When a tire tread
begins to show lines. Have a Yamaha dealer replace the tire immediately. Brakes, tires, and related
wheel parts replacement should
be left to a Yamaha Service Technician.
2. Patching a punctured tube is not
recommended. If it is absolutely
necessary to do so, use great care
and replace the tube as soon as
possible with a good quality replacement.
E-934
Wheels
To ensure maximum performance, long service, and safe operation, note the following:
5-8
E·850
E-800
Fittings/Fasteners
Always check the tightness of chassis fittings
and fasteners before a ride. Use the chart on
page 7-5 to find the correct torque.
Fuel
Make sure there is sufficient fuel in the tank.
E-700
Lights and signals
Check the headlight, flasher lights, taillight,
brake light, meter lights, and all the indicator
lights to make sure they are in working condition.
E-704
Switches
Check the operation of the headlight switch,
turn switch, brake light switch, horn switch,
main switch, etc.
1. Filler tube
2. Fuel level
U-610
&WARNING:
E-705
·Do not overfill the fuel tank. Avoid
spilling fuel on the hot engine. Do not
fill the fuel tank above the bottom of
the filler tube as shown in the illustration or it may overflow when the
fuel heats up later and expands.
Battery (See page 7-27 for more detail)
Check the fluid level and top-up if necessary.
Use only distilled water if refilling is necessary.
5-9
E-803
be used if ethanol content does not exceed
10%. Gasohol containing methanol is not
recommended by Yamaha because it can
cause fuel system damage or vehicle performance problems.
Recommended fuel:
REGULAR UNLEADED GASOLINE
Fuel tank capacity:
Total: 8.5 L (1.9 Imp gal, 2.2 US gal)
Reserve: 2.0 L (0.4 Imp gal, 0.5 US gal)
Your Yamaha engine has been designed to
use regular unleaded gasoline with a pump
octane number ( [R + M]/2) of 86 or higher,
or research octane number of 91 or higher.
If knocking or pinging occurs, use a different
brand of gasoline or premium unleaded fuel.
Unleaded fuel will give you longer spark plug
life and reduced maintenance cost. If unleaded gasoline is not available, then leaded
regular gasoline can be used.
Gasohol
There are two types of gasohol, gasohol
containing ethanol and that containing
methanol. Gasohol containing ethanol can
5·10
F-000
OPERATION AND
IMPORTANT RIDING
POINTS
2.
U-672
&WARNING:
Before riding this motorcycle, become
thoroughly familiar with all operating
controls and their function. Consult a
Yamaha dealer regarding any control
or function that you do not thoroughly
understand.
Before starting out, always be sure
the sidestand is up. Failure to retract the sidestand completely can
result in- a serious accident when
you try to turn a corner.
F-123
Starting a cold engine
U-074
NOTE: _ _ _ _ _ _ _ _ _ _ _ __
This motorcycle is equipped with an ignition
circuit cut-off switch.
1. The engine can be started only under the
following conditions:
a. The transmission is in neutral.
b. The sidestand is up,/the transmission is
in gear, and the cluti::h is disengaged.
2. The motorcycle must not be ridden when
the sidestand is down.
U-628
&WARNING:
1. Never start your engine or let it run
for any length of time in a closed
area. The exhaust fumes are poisonous and can cause loss of consciousness and death within a short
time. Always operate your motorcycle in an area with adequate
ventilation.
6-1
U-709
&WARNING:
Before going through the following
steps, check the function of the sidestanp switch. (Refer to page 4-11.)
CF1-02
TURN MAIN SWITCH TO ""ON"" AND
ENGINE STOP SWITCH TO "RUN"
I
j
IF TRANSMISSION IS IN NEUTRAL
AND SIDESTAND IS DOWN
IF TRANSMISSION IS IN GEAR
AND SIDESTAND IS UP
I
PULL IN CLUTCH LEVER AND KICK
THE KICK STARTER; ENGINE WILL START
KICK THE KICK STARTER;
ENGINE WILL START
I
RETRACT SIDESTAND AND
PUT TRANSMISSION IN GEAR
I
MOTORCYCLE CAN BE RIDDEN
MOTORCYCLE CAN BE RIDDEN
6·2
1. Turn the fuel cock to "ON."
2. Turn the ignition key to "ON" ahd the
engine stop switch to "RUN."
3. Shift transmission into neutral
U-030
MOTE:~~~~~~~~~~~~­
When the transm1ss1on is in neutral, the
neutral indicator light (green) should be on.
If the light does not come on, ask a Yamaha
dealer to inspect it.
4. Operate the starter (CHOKE) and completely close the throttle grip.
5. Kick the kick starter to start the engine.
6. After the engine starts, warm it up for
one or two minutes. Make sure the starter
is returned to its original position before
riding.
F-110
Engine warm-up
To ensure maximum engine life, always warm
up the engine before riding your motorcycle.
Never accelerate hard with a cold engine.
An engine is warm if it responds normally to
the throttle when the starter (CHOKE) is
turned off.
F-108
Starting a warm engine
The starter (CHOKE) is not required when
the engine is warm.
U-314
See "Break-in section" prior to operating the motorcycle for the first time.
F-200
Shifting
The transmission lets you control the amount
of power you have available at a given speed
for starting, accelerating, climbing hills, etc.
The use of the change pedal is shown in the
illustration. (Page 4-6)
F-300
Engine break-in
There is never a more important period in the
life of your motorcycle than the period between zero and 1,000 km (600 mi). For this
reason we ask that you carefully read the
following material. Because the engine is
brand new, you must not put an excessive
load on it for the first 1,000 km (600 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 which
might result in excessive heating of the engine, must be avoided.
To shift into NEUTRAL, depress the change
pedal repeatedly until it reaches the end of
its travel (you will feel a stop when you are
in first gear) then raise the pedal slightly.
U·315
<hB,;:,)(~tlhl'I'J<Kl"
'tl~tt:e;~~1J{~~~~t!1
~~~~~~~~~~~
1 . Do not coast for long periods with
the engine off, and do not tow the
motorcycle a long distance. Even
with gears in neutral, the transmission is only properly lubricated
when the engine is running. Inadequate lubrication may damage the
transmission.
2. Always use the clutch when
changing gears. The engine, transmission, and driveline are not designed to withstand the shock of
forced shifting and can be damaged by shifting without the
clutch.
F-309
1. 0 - 500 km (0 - 300 mi):
Avoid operation above 4,000 r/min. Stop
the engine and let it cool for 5 to 1O
minutes after every hour of operation.
Vary the speed of the motorcycle from
time to time. Do not operate it at one set
throttle position.
6-4
F-401
Parking
When parking the motorcycle, stop the engine and remove the ignition key. Turn the
fuel cock to "OFF' whenever stopping the
engine.
2. 500 - 1,000 km (300 - 600 mi):
. Avoid prolonged operation above 5,000
r /min. Rev the motorcycle freely through
the gears, but do not use full throttle at
any time.
U-354
&WARNING:
After 1,000 km (600 mi) of operation,
be sure to replace the transmission oil.
The muffler and exhaust pipe are hot.
Park the motorcycle in a place where
pedestrians or children are not likely
to touch the motorcycle.
Do not park the motorcycle on'a slope
or soft ground; the motorcycle may
overturn.
3. 1,000 km (600 mi) and beyond:
Full throttle can be used.
U-387
Never let engine speeds enter the red
zone.
U-322
If any engine trouble should occur
during the break-in period, consult a
Yamaha dealer immediately.
6-5
U-632
H-000
PERIODIC
MAINTENANCE AND
MINOR REPAIR
Lt WARNING:
If you are not familiar with motorcycle
service, this work should be done by a
Yamaha dealer.
H-004
Periodic inspection, adjustment, and lubrication will keep your motorcycle in the safest
and most efficient condition possible. Safety
is an obligation of the motorcycle owner. The
maintenance and lubrication schedule chart
should be considered strictly as a guide to
general maintenance and lubrication intervals. YOU MUST TAKE INTO CONSIDERATION THAT WEATHER, TERRAIN, GEOGRAPHICAL LOCATIONS, AND A VARIETY OF INDIVIDUAL USES ALL TEND
TO DEMAND THAT EACH OWNER ALTER
THIS TIME SCHEDULE TO SHORTER INTERVALS TO MATCH HIS ENVIRONMENT.
The most important points of motorcycle inspection, adjustment, and lubrication are
explained in the following pages.
H-101
Tool kit
The service information included in this manual is intended to provide you, the owner,
with the necessary information for completing some of your own preventive maintenance and minor repairs. The tools provided
in the owner's tool kit are sufficient for most
of these purposes; however a torque wrench
is also necessary to properly tighten nuts and
bolts.
7-1
lJ-671
&WARNING:
Modifications to this motorcycle not
approved by Yamaha may cause loss
of performance, and render it unsafe
for use. Consult a Yamaha dealer before attempting any changes.
1. Tool kit
U-060
NOTE: _ _ _ _ _ _ _ _ _ _ __
If you do not have a torque wrench available
during a service operation requiring one, take
your motorcycle to a Yamaha dealer to check
the torque settings a~d adjust them as necessary.
7·2
PERIODIC MAINTENANCE/LUBRICATION
Unit: km (miles)
EVERY
ITEM
REMARKS
BREAK-IN
1,000(600)
3,000
(2,000) or
6 months
6,000
(4,000) or
12 months
Spark plug(s)
Air filter
Check condition. Clean or replace if necessary.
Clean. Replace if necessary.
0
0
0
0
0
Carburetor~
Check idle speed(/synchronization)/starter operation.
Adjust if necessary.
0
0
0
0
0
REPLACE
0
0
0
0
0
0
0
0
0
0
0
0
0
Fuel line•
Transmission oil"
Check fuel hose (and vacuum pipe) for cracks
or damage. Replace if necessary.
Check oil level/oil leakage. Correct if necesarry.
Replace every 12,000 (8,000) or 24, months
(Warm engine before draining.)
Brake
Check operation. Correct if necessary.
Air bleeding.
Check operation. Adjust it necessary.
Clutch'
Check operation. Adjust if necessarry.
Autofube pump*
Wheels*
Wheel bearings•
Steering bearing•
Front forks'
Rear shock absorber·
Check ba!ance/damage/runout/spoke tightness.
Repair if necesarry.
Check bearings assembly for looseness/damage.
Replace if damaged.
Check bearings assembly for looseness.
Correct if necessary.
Moderately repack every 24,000 (16,000)
or 24 months.'>
Check operation/oil leakage. Repair if necessary.
Check operation/oil leakage. Repa'1r If necessary.
7-3
0
0
0
0
0
0
EVERY
ITEM
REMARKS
Cooling system
Check coolant leakage. Repair if necesarry.
Replace coolant every 24,000 {16,000) or
24 months.
Drive chain
Check chain slack/alignment. Adjust if necessary.
Clean and lube.
Fittings/ Fasteners·
Sideststand·
Sidestand switch
Battery·
Check all chassis fittings and fasterners.
Correct if necessary.
Check operation. Repair if necessary.
Check operation. Clean or replace if necessary.
Check specific gravity.
Check breather pipe for proper operation.
Correct if necessary.
It is recommended that these items be serviced by a Yamaha dealer.
Medium weight wheel bearing grease.
7-4
BREAK-IN
1,000(600)
3,000
{2,000) or
6 months
6,000
(4,000) or
12 months
0
0
EVERY 500 (300)
0
0
0
0
0
0
0
0
0
0
0
H-3111
Torque specifications
Use a torque wrench to tighten these items.
It is recommended that these items be
checked occasionally, especially before a
long trip.
Always check the tighteness of these items
whenever they are loosened for any reason.
Torque
hem
Spark plug
Drain plug-Transmission
Front wheel axle
Rear wheel axle
Drain bolt-Cylinder side
Drain bolt- Housing cover
side
Tension bar bolt
0
Nm
m·kg
ft•lb
25
20
45
60
14
2.5
2.0
4.5
6.0
1.4
18
14
32
43
10
8
0.8
6
18
1.8
13
A
(Nut)
10 mm
12 mm
14 mm
17 mm
19 mm
22mm
7-5
B
(Bolt)
6mm
8mm
10mm
12 mm
14mm
16 mm
General torque
specifications
Nm
m·kg
ft·lb
6
15
30
55
85
130
0.6
1.5
3.0
5.5
8.5
13.0
4.3
11
22
40
61
94
H-403
Transmission o·il level check
1. To check the oil level, the motorcycle
must stand VERTICALLY with its both
wheels 0'1 the ground. A slight tilt toward
the side can produce false readings.
2. When checking the oil level, stop the
ef1gine and rer;;ove the dip stick. Rest
the dip stick on the threads of the hole.
3. The dip stick has a minimum and maximum mark; the oil level should be between the two. If the level is low add
oil to raise it to the proper level.
1. Dip stick
2
Maximum level
3. Minimum level
Recommended oil:
YAMALUBE 4(1 OW30) or SAE
1OW30 type SE motor oil
Oil quantity:
0.75 L (0.66 Imp qt, 0.79 US qt)
1. Oil filler cap
7-6
Do not add any chemical additives.
Trans mission oil also lubricates the
clutch and additives could cause clutch
slippage.
U-324
Be sure no foreign material enters the
crankcase.
H-404
Transmission oil replacement
1. To drain the oil, warm up the engine for
several minutes.
2. Place an oil pan under the engine.
3. Remove the drain plug and drain the oil.
1. Drain plug
4. Reinstall the drain plug (make sure it is
tight).
Drain plug torque:
20 Nm (2.0 m·kg, 14 ft·lb)
5. Add oil through the dip stick hoJe.
Periodic oil change:
0.7 L (0.61 Imp qt, 0.74 US qt)
1 . If your motorcycle overheats
6. After replacement of transmission oil,
be sure to check for oil leaks.
U-705K
&WARNING:
H-509K
Do not remove the radiator cap when
the engine and radiator are hot.
Scalding hot fluid and steam may be
blown out under pressure, which could
cause serious injury. When the engine
has cooled, open the radiator cap by
the following procedure: Remove the
radiator cover by removing the screw.
Place a thick rag, like a towel, over the
radiator cap, slowly rotate the cap
counterclockwise to the detent. This
procedure allows any residual pressure
to escape. When the hissing sound has
stopped, press down on the cap while
turning counterclockwise and remove
it.
Cooling system
The coolant is circulated by an impeller type
pump mounted on the right-hand crankcase
and driven by a gear. The coolant is drawn
by the pump from the bottom tank of the
radiator, through the pipe, and discharged
into the cylinder-head and cylinder head.
The coolant passes from the cylinder through
coolantpassages. After circulating around the
combustion chamber jacket,it enters the radiator upper tank via the pipe. The heated
coolant from the engine then passes down
through the finned tubes to the bottom tank
of the radiator. These finned tubes present a
large surface area to the air and dissipate the
heat.
7-8
If overheating is detected, perform the following checks:
2. Changing the coolant
a. Remove the radiator cover and radiator
cap.
b. Place a container under the engine.
c. Remove the drain bolts.
Engine overheating
Check the cooling
system for leakage.
Wait until the temp.
guage indicates tower
than 50"C (122°F) line
{see page 5-5)
Check the coolant level
in the reservoir tank
and/or radiator.
No leakage.
Add coolant•
Leakage
Ask a Yamaha
dealer to inspect
and repair.
OK
Restart the engine. If the
engine overheats again,
ask a Yamaha dealer to
inspect and repair.
1. Drain bolts
U-043
2. Hosing cover
3. Cylinder
d. Drain the coolant completely, and thoroughly flush the cooling system with
clean tap water.
e. Retighten the drain bolts. If the gasket
is damaged, replace it.
NOTE: _ _ _ _ _ _ _ _ _ __
If it is difficult to get the recommended coolant, tap water can be temporarily used,
provided that it is changed to the recommended coolant as soon as possible.
7.9
U-309
Tightening torque:
Drain bolts:
Cylinder side
14 Nm (1.4 m·kg, 10 ft·lb)
Housing cover side
8 Nm (0.8 m·kg, 6 ft·lb)
Hard water or salt water is harmful to
the engine. You may use distilled water
if you can't get soft water.
g. Reinstall the radiator cap.
h. Run the engine several munutes to recheck the coolant level in the radiator.
If it is low, add more coolant until it
reachez the top of the radiator.
f. Pour the recommended coolant into the
radiator is full.
Recommended coolant:
High quality ethylene glycol
anti-freeze containing corrosion
inhibitors for aluminum engines.
Coolant and water mixed ratio:
50%/50%
Total amount:
O.? L (0.53 Imp qt, 0.63 US qt)
Reservoir tanJ< capacity:
0.3fl L (0.33 Imp qt, 0.40 US qt)
From LOW to FULL level:
0.20 L (0,18 Imp qt, 0.21 US qt)
1. "FULL" level
7-10
2. "LOW" level
Fill the reservoir tank with coolant up to
"FULL" level.
J. Reinstall the reservoir tank cap and check
for coolant leakage.
2. After removing the filter cup, remove and
clean the filter screen. At the same time,
you should examine the condition of the
filter gasket. Replace if damaged.
3. When reassembling, be careful not to
clamp the filter cup too tightly as this
may unseat the 0-ring and lead to a fuel
leak.
1.
U-044
NOTE:~~~~~~~~~~~~­
lf you fina any leaks, ask a Yamaha dealer to
inspect.
H-635
Air filter
1 . Remove the side cover.
2. Remove the air filter case fitting screws
and the filter case cover.
k. Install the radiator cover.
H-600
Fuel G,Ock cleaning
The fuel cpck has a built-in filter to remove
any particles before they reach the carburetor.
If the filter becomes blocked, fuel cannot
enter the carburetor.
1. First, turn the cock lever to the "OFF"
then remove the filter cup and clean the
bottom of the cup with solvent.
7-11
3. Remove the element from its case, and
clean it with solvent.
®
1. Air filter element
5. When installing the element in its case,
be sure its sealing surface matches the
sealing surface of the case sothere is
no air leak.
6. The element should be cleaned at the
specified intervals. It should be cleaned
more often if tl;te motorcycle is operated
in dusty or wet areas.
4. Apply recommended oil to the entire
surface of the filter and squeeze out the
excess oil. The element should be wet
but not dripping.
Recommended oil:
Yamalube 2-cycle oil or
air-cooled 2-stroke engine oil
7-12
U-326
H-901
w;wwm"'
'"W•.·.44.''"':'\.tk''
'l'l··.n1£t
fit \ ~Wtti
Idle speed adjustment
1. Start the engine and warm it up for a few
minutes (normally, 1 or 2 minutes) at
approximately 1,000 to 2,000 r/min.
Occasionally rev the engine to 4,000 to
5,000 r/min. The engine is warm when
it quickly responds to the throttle.
2. Set the idle to the specified engine speed
by adjusting the throttle stop screw; turn
the screw in to increase engine speed,
turn tfle screw out to decrease engine
speed.
-f%>,·-"'.:,_,.i:0:-'S:~->~··0>'"?•.:«.':-,,;-&-~~-"''-----------
The engine should never be run without
the air cleaner element; excessive piston and/or cylinder wear may result.
H-900
Carburetor adjustment
The carburetor is a vital part of the engine
and requires very sophisticated adjustment.
Most adjustments should be left to a Yamaha
dealer who has the professional knowledge
and experience to do so. However, the following point may be serviced by the owner
as part of this routine maintenance.
U-330
f;1~'ii'.~7i(il!ll'ifj\J;J{1
t-i~l§ftf:l?%.Y:i(}(,;;.~±:'_f-.}·i----------The carburetor was set at the Yamaha
factory after many tests. If the settings
are disturbed, poor engine performance and damage may result.
1. Throttle stop screw
7-13
Standard idle speed:
1,300 r/min
U-045
NOTE: _ _ _ _ _ _ _ _ _ _ _ __
If the specified idle speed cannot be obtained
by performing the above adjustment, consult
a Yamaha dealer.
H-903
Throttle cable adjustment
1.
Lock nut
2. Adjuster
a. 2,..,, 5 mm (0.08......, 0.2 in)
U-064
NOTE: _ _ _ _ _ _ _ _ _ _ _ __
Before adjusting the throttle cable free play,
the engine idling speed should be adjusted.
1. Loosen the lock nut.
2. Turn the adjuster in or out until the adjustment is suitable.
3. Tighten the lock nut.
The throttle cable should have a specified free
play in the turning direction at the grip flange.
If the play is incorrect, take the following steps
for adjustment.
Free play:
2 -5 mm (0.08 - 0.2 in)
7-14
H-203
Spark plug inspection
The spark plug is an important engine component and is easy to inspect. The condition
of the spark plug can indicate something of
the condition of the engine. The ideal color
on the white porcelain insulator around the
center electrode is a medium to light tan colol
for a motorcycle that is being ridden normally.
Do not attempt to diagnose any problems
yourself. Instead, take the motorcycle to a
Yamaha dealer. You should periodically remove and inspect the spark plug because heat
and deposits will cause the spark plug to
slowly break down and erode. If electrode
erosion becomes excessive, or if carbon and
other deposits are excessive, you should replace the spark plug with a proper type plug.
1. Spark plug gap
Before installing the spark plug, measure the
electrode gap with a wire thickness gauge;
adjust the gap to specification as necessary.
Spark plug gap:
0.7 - 0.8 mm (0.028 - 0.031 in)
When installing the plug, always clean the
gasket surface and use a new gasket. Wipe
off any grime from the threads, and torque.
the spark plug properly.
Standard spark plug:
BRSES (NGK)
7-15
Spark plug torque:
25 Nm (2.5 m·kg, 18 ft·lb)
U-038
NOTE: _ _ _ _ _ _ _ _ _ _ _ __
'
If a torque wrench is not available when you
are installing a spark plug, a good estimate
of the correct torque is 1 /4 to 1 /2 turns past
finger tight. Have the spark plug torqued to
the correct value as soon as possible with a
torque wrench.
-- - -
,( ,.--------.:
\
a. 5""8 mm (0.2-0.3 in)
U-732K
6 WARNING:
H-855
Front brake adjustment
When it is impossible to make the
The front brake should be adjusted to suit the
rider's preference; but free play at the brake
lever pivot point should be 5 - 8 mm (0.2
- 0.3 in). Adjustment is accomplished at the
front brake hub. To adjust, turn the adjuster
clockwise to reduce play; turn it counterclockwise to increase play.
proper
dealer.
7-16
adjustment,
ask
a
Yamaha
b. By turning the adjuster clockwise or
counterclockwise, adjust the brake peaal
position so that its top end is approx.20
mm (0.8 in) belovythetopofthefootrest.
c. Secure the adjuster lock nut.
U-644
&WARNING:
After adjusting the pedal height, adjust
brake pedal free play.
1. Adjuster
2. Free play
The rear brake should be adjusted to suit
the rider's preference; but free play at the
brake pedal end must be 20 - 30 mm
(0.8 - 1.2 in). Turn the adjuster on the
brake rod clockwise to reduce play; .turn
the adjuster counterclockwise to increase play.
H-849
Rear brake adjustment
U-643
LL WARNING:
For brake pedal adjustment, be sure to
proceed as follows: (It is advisable to
have a Yamaha dealer make this adjustment.)
1. Pedal height
a. Loosen the adjuster lock nut (for pedal
height).
7-17
U-698
& WARNING:
1. The rear brake pedal adjustment
must be checked anytime chain is
adjusted or rear wheel is removed
and then reinstalled.
2. Check the operation of the brake
light after adjusting the rear brake.
H-833
Brake light switch adjustment
The brake light switch is operated by movement of the brake pedal. To adjust, hold the
main body of the switch with your hand so
it does not rotate and turn the adjusting nut.
Proper adjustment is achieved when the
brake light comes on just before the brake
begins to take effect.
1. Adjuster bolt (For pedal height)
2. Lock nut
a. 20 mm (0.8 in)
b. 20 ,..._,30 mm (0.8,...., 1.2 in)
1. Adjuster
7-18
2
1. Wear limit
1. Brake light switch
2. Wear indicator
1-012
H-816
Cluch adjustment
The clutch should be adjusted to suit the
rider's preference, but free play at the lever
pivot should be 2 -·3 mm (0.08 - 0.12 in).
Loosen the adjuster lock nut. Next turn the
length .adjuster either in or out until proper
lever free play is achieved.
Checking the brake shoes
A wear indicator is attached to each· brake
to facilitate brake shoes check. This indicator
permits a visual check without disassembling
the brake. To check, look at the wear indicator
while depressing the brake pedal or pulling
the brake lever. If the indicator reaches~o the
wear limit line, ask a Yamaha dealer to replace
shoes.
Clutch lever free play:
2 - 3 mm (0.08 - 0.12 in)
7-19
1-408
Drive chain slack check
U-048
~
NOTE:
Before checking and/or adjusting the chain
slack, rotate the rear wheel through several
revolutions. Check the chain slack several
times to find the point where the chain is the
tightest. Check and/or adjust the chain slack
where the rear wheel is in this "tight chain"
position.
-..i®
~
,'"'---------JCI
'v--------{
(J
-- -
- -
~o-
1. Adjuster
2. Lock nut
a.
2"'3 mm (0.08"'0.12 in)
/-014K
To check the chain slack the motorcycle must
stand vertically with its both wheels on the
ground and without a rider. Check the slack
at the position shown in the illustration. The
normal vertical deflection is approximately
40 ~ 50 mm (1.6 - 2.0 in). If the deflection
exceeds 50 mm (2.0 in) adjust the chain slack.
Mechanism adjustment
When it is impossible to make an adjustment
at the clutch lever, ask a Yamaha dealer for
adjustment of the internal clutch mechanism.
7-20
on each side of swingarm and on each
chain adjuster; use them to check for
proper alignment.)
000000000
1
®
a. 40,....,50mm (1.6,....,2.0in)
1-414
3
Drive chain slack adjustment
1. Loosen the rear brake adjuster.
2. Remove the cotter pin from the rear
wheel axle nut.
3. Loosen the rear wheel axle nut.
4. To tighten the chain, turn chain adjuster
clockwise. To loosen the chain, turn the
adjuster counterclockwise and push the
wheel forward. Turn each adfuster ex•
actly the same amount to maintain correct axle alignment. (There are marks
1. Cotterpin
2. Axle nut
4. Marks for alignment
3. Adjuster
U-333
i~f·:?i!i·-~?'--~o;.,,'''t·Qkf~<:
Ili•.<•~tg:i}.•2,§\ _ _ _ _ _ __
Too small chain slack will overload the
engine and other vital parts; keep the
slack within the specified limits.
7-21
5. After adjusting, be sure to tighten the
axle nut.
Axle nut torque:
60 Nm (6.0 m·kg, 43 ft·lb)
6. Insert a new cotter pin into the rear wheel
axle nut and bend the end of the cotter
pin as shown in the illustration. (If the
nut notch and the cotter pin hole do not
match tighten the nut slightly to align
them.)
7. Adjust the free play in the brake pedal.
U-645
di.WARNING:
U-647
di WARNING:
Check the operation of the brake light
after adjusting the rear brake.
Always use a new cotter pin on the axle
nut.
1-406
Drive chain lubrication
The chain consists of many parts which work
against each other. If the chain is not maintained properly, it will wear out rapidly,
therefore, service the chain regularly.
7-22
This service is especially necessary when
riding in dusty conditions.
1 . Use any of the many brands of spray type
chain lubricant. First, remove all dirt and
mud from the chain with a brush or cloth
then spray a lubricant between both rows
of side plates and on all center rollers.
This should be performed every 500 km
(300 mi).
2. To clean the chain, remove the chain
from the motorcycle, dip it in solvent,
and clean out as much dirt as possible.
Take the chain out of the solvent and
dry it. Immediately lubricate the chain
to prevent rust.
cable. An unsafe condition may result
so replace such cables as soon as possible.
Lubricate the inner cable and the cable end.
If they do not operate smoothly, ask a Yamaha
dealer to replace them.
Recommended lubricant:
Yamaha Chain and Cable Lube or
SAE 1OW30 motor oil
1-102
Throttle cable and grip lubrication
The throttle twist grip assembly should be
greased at thetime that the cable is lubricated,
since the grip must be removed to get at the
end of the throttle cable. Two screws clamp
the throttle housing to the handlebar. Once
these two are removed, the end of the cable
can be held high to pour in several drops of
lubricant. With the throttle grip disassembled,
coat the metal surface of the grip assembly
with a suitable all-purpose grease.
1-101
Cable inspection and lubrication
U-646
&WARNING:
Damage to the outer housing of the
various cables may cause corrosion and
interfere with the movement of the
7-23
1-108
!-312
Autolube pump adjustment
The Autolube pump is a vital part of the engine and requires very sophisticated adjustment. Most adjusting should be left to a
Yamaha dealer who has the professional
knowledge and experience to do so.
Sidestand
Lubricate the pivoting parts. Check to see that
the sidestand move up and down smoothly.
Recommended lubricant:
Yamaha Chain and Cable Lube or
SAE 1OW30 motor oil
1-302
Brake and change pedals
Lubricate the pivoting parts.
U-704
&WARNING:
If the sidestand movement is not
smooth, consult a Yamaha dealer.
Recommended lubricant:
Yamaha Chain and Cable Lube or
SAE 1OW30 motor oil
l-205K
Front fork inspection
l-303
U-657
Brake and clutch levers
Lubricate the pivoting parts.
&WARNING:
Securely support the motorcycle so
there is no danger of it falling over.
Recommended lubricant:
Yamaha Chain and Cable Lube or
SAE 1 OW30 motor oil
7-24
1 . Visual check
Check any scratch/damage on the inner
tube and excessive oil leakage with the
front fork.
U-121K
NOTE: _ _ _ _ _ _ _ _ _ _ __
If you find any leaks or damage, ask a Yamaha
dealer to inspect.
2. Operation check
Place the motorcycle on a level place.
a. Hold the motorcycle on an upright position with a rider's hands on the handlebar and apply the front brake.
b. Pump the front fork up and down for
several times.
U-122K
NOTE: _ _ _ _ _ _ _ _ _ _ __
If the front fork movement is not smooth
consult a Yamaha dealer.
7-25
1-515
will result in poor damping performance.
4. Bring your shock absorber to
Yamaha dealer for any service.
Rear shock (Monocross suspension
"De Carbon" system)
a
U-673
&WARNING:
This shock absorber contains highly
pressurized nitrogen gas. 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.
1. Do not tamper with or attempt to
open the cylinder assembly.
2. Do not subject shock absorber to
an open flame or other high heat
source. This may cause the unit
to explode due to excessive gas
pressure.
3. Do not deform or damage the cylinder in any way. Cylinder damage
1-603
Steering inspection
Periodically inspect the condition of the
steering. Worn out or loose steering bearings
may be dangerous.
Place a block under the engine to raise the
front wheel off the ground.
Hold the lower end of the front forks and try
to move them forward and backward. If any
free play can be felt, ask a Yamaha dealer to
inspect and adjust the steering. Inspection
is easier if the front wheel is removed.
7-26
!-700
Battery
Check the level of the battery electrolyte and
see that the terminals are tight. Add distilled
water if the electrolyte level is low.
U-336
When inspecting the battery, be sure
the breather pipe is routed correctly.
If the breather pipe touches the frame
or exits in such a way as to cause battery electrolyte or gas to exit onto the
frame, structural and cosmetic damage
to the motorcycle can occur.
U·657
&WARNING:
Securely support the motorcycle so
there is no danger of it falling over.
U-658
1-602
&WARNING:
Wheel bearings
If the wheel bearings in the front or rear wheel
allow play in the wheel hub or if the wheel
does not turn smoothly, have a Yamaha dealer
inspect the wheel bearings. The wheel bearings should be inspected according to the
Maintenance Schedule.
Battery electrolyte is poisonous and
dangerous, causing severe burns, etc.
It contains sulfuric acid. Avoid contact
with skin, eyes or clothing.
7-27
Antidote: EXTERNAL-Flush with water. INTERNAL-Drink large quantities
of water or milk. Follow with milk of
magnesia, beaten egg, or vegetable oil.
Call a physician immediately.
Eyes: Flush with water for 15 minutes
and get prompt medical attention.
Batteries produce explosive gases.
Keep sparks, flame, cigarettes etc.,
away. Ventilate when charging or using in an enclosed space. Always shield
your eyes when working near batteries.
KEEP OUT OF REACH OF CHILDREN.
CJ
GS
1. Upper level
2. Lower level
U-338
Normal tap water contains minerals
which are harmful to a battery; therefore, refill only with distilled water.
1-704
Replenishing the battery fluid
A poorly maintained battery will deteriorate
quickly. The battery fluid should be checked
at least once a month.
1. _The level should be between the upper
and lower level marks. Use only distilled
water if refilling is necessary.
U-659
Lt.WARNING:
Battery fluid on the chain can cause
premature failure and possibly an accident.
7-28
1-910
Fuse replacement
If a fuse is blown, turn off the ignition switch
and the switch in the circuit in question. Install a new fuse of proper amperage.
Turn on the switches, and see if the electrical
device operates. If the fuse immediately blows
again, consult a Yamaha dealer.
2. When the motorcycle will not be used
for a month or longer, remove the battery
and store it in a cool, dark place. Completely recharge the battery before reusing.
3. If the battery will be stored for a longer
period than the above, check the specific
gravity of the fluid at least once a month
and recharge the battery when it is too
low.
4. Always make sure the connections are
correct when putting the battery back
in the motorcycle.
Make sure the breather pipe is properly
connected and is not damaged or obstructed.
2
1. Main fuse
7-29
2. Spare fuse .
U-344
1. Horizontal adjustment:
To adjust the beam to the right, turn the
adjuster clockwise.
To adjust the beam to the left, turn the
adjuster counterclockwise.
2. Vertical adjustment:
To raise the beam, turn the adjuster
counterclockwise.
To lower the beam, turn the adjuster
clockwise.
'mtii$~1Jmte'i':''
~:\:.,.>.)<:,,;;~~·:_:si::/:·)J.;-':\.?c./\{ _ _ _ _ _ _ _ _ _ __
Do not use fuses of higher amperage
rating than those recommended. Substitution of a fuse of improper rating
can cause extensive electrical system
damage and possibly a fire.
1-807
Replacing the headlight bulb
This motorcycle is equipped with a sealed
beam headlight. If the headlight burns out,
ask a Yamaha dealer to replace the bulb and
adjust the unit.
1-819
Headlight beam adjustment
U-343
'.·i,1~~~§1:.t~IJl:~f;
-----------
For the headlight beam adjustment,
be sure to proceed as follows; (It is
advisable to have a Yamaha dealer
make this adjustment.)
1. Horizontal adjuster screw
7-30
2. Vertical adjuster screw
J-401
Replacing the taillight and flasher light
bulb:
1 . Remove the two screws, and now the
lens can be removed. Replace the oil seal,
if damaged.
2. Push in the bulb and turn it about 30°
to remove the bu lb.
3. For installation, reverse the above procedure.
U-073
1. Speedometer cable
NOTE:~~~~~~~~~~~~
3. Remove the brake cable: loosen all cable
adjusters and remove the cable from
handlebar lever holder. Then remove the
cable from cam lever at the front brake
shoe plate.
4. Remove the cotter pin from front wheel
axle and remove the axle nut.
Make sure the oil seal is positioned properly.
J-204
Front wheel removal
1. Elevate the front wheel by placing a
suitable stand under the engine.
2. Remove the speedometer cable from
front brake shoe plate: first remove the
clip and then pull cable out.
7-31
2. Be sure the boss on the outer fork tube
correctly engages with the locating slot
on the brake shoe plate.
CD
\
\
I
1. Cotter pin
5. Turn and pull out the front wheel axle;
the wheel assembly can now be removed.
3. Make sure the axle nut is properly torqued, and a new cotter piri is installed.
J-210
Front wheel installation
When installing the front wheel, reverse the
removal procedure.
Pay attention to the following points:
1. Make sure the wheel hub and the brake
shoe plate assembly are installed with
the projections meshed into the slots.
U-647
&WARNING:
Always use a new cotter pin on the axle
nut.
7-32
Axle nut torque:
45 Nm (4.5 m·kg, 32 ft·lb)
4. Adjust the free play in the brake lever.
J-364K
Rear wheel removal
U-662
&WARNING:
It is advisable to have a Yamaha dealer
service the rear wheel.
1. Adjuster
2. Brake rod
3, Tention bar
3. Disconnect the drive chain.
4. Remove the cotter pin from the wheel
axle and remove the rear wheel axle nut.
5. Then the rear wheel assembly, collar,
chain puller(s). etc., can be removed
from the motorcycle by pulling out the
wheel axle.
1. Elevate the rear wheel by placing a suitable stand under the engine.
2. Remove the tension bar and the brake
rod from the brake shoe plate. The
rension bar can be removed by removing
the cotter pin and nut from the tension
bar blot. The brake rad can be removed
by removing the adjuster.
7.33
1. Cotter pin
2. Adjust the drive chain.
3. Make sure the axle nut and tension bar
bolt are properly torqued, and a new
cotter pin is installed.
J-365K
Rear wheel installation
When installing the rear wheel, reverse the
removal procedure. Pay attention to the following points:
1. When connecting the chain, make certain the closed end of the master link clip
is facing the direction of rotation.
U-647
6WARNING:
Always use a new cotter pin on the axle
nut.
7-34
J-500
U-716
Troubleshooting
Although Yamaha motorcycles receive a rigid
inspection before shipment from the factory,
trouble may occur during operation. Any
problem in the fuel, compression, or ignition
systems can cause poor starting and a loss
of power. The troubleshooting chart describes a quick, easy procedure for checking
these systems.
If your motorcycle requires any repair, bring
it to a Yamaha dealer. The skilled technicians
at a Yamaha dealer have the tools, experience,
and know-how to properly service your
motorcycle. Use only genuine Yamaha parts
on your motorcycle. Imitation parts may look
like Yamaha parts, but they are often inferior.
Consequently, they have a shorter service life
and can lead to expensive repair bills.
&WARNING:
Always use a new cotter pin on the
tension bar bolt.
Tightening torque:
Axle nut:
60 Nm (6.0 m·kg, 43 ft·lb)
Tension bar bolt:
18 Nm (1.8 m·kg, 13 ft·lb)
4. Adjust the rear brake. (See page 7-17.)
U-645
&WARNING:
Check the operation of the brake light
after adjusting the rear brake.
7.35
J-504
Troubleshooting chart
U-663
Mit.!d~ 11 MW
Never check the fuel system
while smoking or in the vicinity ~----~
of.an open flame.
Remove the fuel
cock filter cup
Full of fuel
Check fuel flow
Water or dirt
mixed in fuel
Clean filter cup
No fuel
Fuel cock clogged
No irregularity up
to fuel cock
CJS-03
1. Fual
Check if there
is fuel in the
fuel tank
There is
fuel
Turn the fuel
cock to "OFF"
Some fuel
Turn the ft..el
cock to "RES"
No fuel
Clean fuel cock
Restart engine
Supply fuel
2. Compression
Kick the kick lever
see if there is
compression
There is compression
Compression normal
No compression
Ask Yamaha dealer to inspect
to
3. Ignition
Remove plug and
check electrode
Wipe clean with
dry cloth
Attach plug cap and
ground to chassis
Jgnition system normal
Turn switch on
and kick strongly
Adjust plug gap
or replace plug
Ask Yamaha dealer to inspect
7-36
K-000
CLEANING AND
STORAGE
Excessive hose pressure may cause
water seepage and contamination of
wheel bearings, front forks, brakes and
transmission seals. Many expensive
repair bills have resulted from improper high pressure detergent applications such as those available in
coin-operated car washers.
K-009
A. CLEANING
Frequent thorough cleaning of your motorcycle will not only enhance its appearance
but will improve its general performance and
extend the useful life of many components.
1. Before cleaning the motorcycle:
a. Block 'off the end of exhaust pipe to
prevent water entry; a plastic bag and
strong rubber band may b.e used.
b. Make sure the spark plug (s) and all filler
caps are properly installed.
2. If the engine case is excessively greasy,
apply degreaser with a paint brush. Do
not apply degreaser to the chain,
sprockets, or wheel axles.
3. Rinse the dirt and degreaser off with a
garden hose, use only enough pressure
to do the job.
4. Once the majority of the dirt has been
hosed off, wash all surfaces with warm
water and mild, detergent-type soap.
An old tooth brush or bottle brush is
handy for hard-to-get-to places.
5. Rinse the motorcycle off immediately
with clean water and dry all surfaces
with a chamois, clean towel, or soft absorbent cloth.
6. Dry the chain and lubricate it to prevent
rust.
8·1
7. Clean the seat with a vinyl upholstery
cleaner to keep the cover pliable and
glossy.
8. Automotive-type wax may be applied
to all painted and chrome-plated surfaces.
Avoid
combination
cleaner-waxes. Many contain abrasives
which may mar the paint or protective
finish. When finished, start the engine
and let it idle for several minutes.
3.
4.
K-007
B. STORAGE
Long term storage (60 days or· more) of your
motorcycle will require some preventive procedures to guard against deterioration. After
thoroughly cleaning the motorcycle, prepare
it for storage as follows:
1. Drain the fuel tank, fuel lines, and carburetor float bowl(s).
2. Remove the empty fuel tank, pour a cup
of SAE 1OW30 or 20W40 motor oil in
tank, shake the tank to coat the inner
5.
6.
7.
8.
8-2
surfaces thoroughly and drain off the
excess oil. Reinstall the tank.
Remove the spark plug(s), pour about
one tablespoon of SAE 1OW30 or
20W40 motor oil in spark plug hole(s)
and reinstall spark plugs. Kick the engine
over several times (with ignition off) to
coat the cylinder walls with oil.
Remove the drive chain. Thoroughly
clean the chain with solvent and lubricate. Reinstall the chain or store it in a
plastic bag (tied to frame for safe-keeping).
Lubricate all control cables.
Block up the frame to raise both wheels
off the ground.
Tie a plastic bag over the exhaust pipe
outlet to prevent moisture from entering.
If storing in a humid or salt-air atmosphere, coat all exposed metal surfaces
with a light film of oil. Do not apply oil
to any rubber parts or the seat cover.
9. Remove the battery and charge it. Store
it in a dry place and recharge it once a
month. Do not store the battery in an
excessively warm or cold place (less than
O' C (30' F) or more than 30' C (90' F)).
U-058
NOTE:~~~~~~~~~~~~
Make any necessary repairs before storing the
motorcycle.
8-3
SPECIFICATIONS
Model
DT50W
Dimension:
Overall length
1,960 mm
845 mm
1, 100 mm
785 mm
1,235 mm
265 mm
Overall width
Overall height
Seat height
Wheel base
Minimum ground clearance
(77 .2
(33.3
(43.3
(30.9
(48.6
( 10.4
in)
in)
in)
in)
in)
in)
Basic weight:
With oil and full fuel tank
86 kg (190 lb)
Minimum turning radius:
2,000 mm (78.7 in)
Engine:
Type
Model
3BK4
Cylinder arrangement
Single cylinder, Forward inclined
Displacement
49 cm 3
40.0 x 39.2 mm ( 1.57 x 1.54 in)
6.5 : 1
Liquid cooled, 2-stroke, gasoline
Bore x Stroke
Compression ratio
Starti~g system
Kick starter
Separate lubrication (Yamaha Autolube)
Lubrication system
9-1
Model
DT50W
Engine oil (2-cycle):
Type
Capacity
Yamalube 2-cycle oil or air cooled 2-stroke engine oil
1.3 L (1.1 Imp qt, 1.4 US qt)
Transmission oil:
Type
YAMALUBE 4 (10W30) or
SAE 10W30 type SE motor oil
Capacity
Periodic oil change
0.7 L (0.61 Imp qt, 0.74 US qt)
0.75 L (0.66 Imp qt, 0.79 US qt)
Total amount
Radiator capacity:
(Including all routes)
0.6 L (0.53 Imp qt, 0.63 US qt)
Air filter:
Wet type element
Fuel:
Type
Tank capacity
REGULAR UNLEADED GASOLINE
8.5 L (1.9 Imp gal, 2.2 US gal)
2.0 L (0.4 Imp gal, 0.5 US gal)
Reserve amount
Carburetor:
Type/manufacturer
VM16SS/MIKUNI
Spark plug:
Type/Manufacturer
Gap
BR8ES/NGK
0.7 ~ 0.8 mm (0.028
9-2
~
0.031 in)
Model
DT50W
Wet, multi-disc
Clutch type:
----·--·
Transmission:
Primary reduction system
Helical gear
Primary reducf1on ratio
68/19 (3.578)
Chain drive
48/13 (3.692)
Constant meth 6-speed
Secondary reduction system
Secondary reduction ratio
Transmission type
Operation
Left foot operation
Gear ratio
39/12
34/16
31/20
27 /22
26/25
24/26
1st
2nd
3rd
4th
5th.
6th
(3.250)
(2.125)
( 1.550)
( 1.227)
( 1.040)
(0.923)
Chassis:
Frame type
Caster angle
Trail
Semi double cradle
28.33°
98 mm (3.86 in)
---·-
Tire:
Type
With tube
2.50-19 4PR
3.00-17 4PR
Size - Front
Rear
9-3
Model
DT50W
Brake:
Drum brake
Front brake type
Opei'ation
Right hand operation
Rear brake type
Drum brake
Operation
Right foot operation
Suspension:
Front
Rear
Telescopic fork
Swing arm (Monocross suspension)
Shock absorber:
Front
Rear
Air, Coil spring, Oil damper
Gas, Coil spring, Oil damper
Wheel travel:
170 mm (6.7 in)
150 mm (5.9 in)
Front
Rear
Electrical:
CDI magneto
Flywheel magneto
6N48-2A/6V 4AH
Ignition system
Generator system
Battery type/capacity
Headlight type:
Sealed beam
9-4
Model
DTSOW
Bulb wattage/quantity:
Headlight
Tail/brake light
Flasher light
25W/25W
5.3W/25W
17W x 4
3Wx2
Meter light
Indicator light wattage/quantity:
3W
3W
3W
3W
"NEUTRAL"
"HIGH BEAM"
"OIL"
''TURN"
9.5
-MEMO-
-MEMO,-
..................................
··~·
................................................................................................................... .
... ,.,, •... ,.,, .. , ••..•.......... , ............................••...•••.•••••••••••••••••••••••.•••••••••••.•.•••.• v····································
--···--·
-MEMO-
YAMAHA MOTOR CO.,LTD.
!WATA, JAPAN
PRINTED IN JAPAN
88 • 6 - 0.5 x 1
(!I! I
CR
DT50W WIRING DIAGRAM
Front flasher
light (Right)
ClignotClH a vane
(Droit)
PLAN DE CABLAGE DE LA DTSOW
:!i~c~INE STOP"
Main switch
Commutatcur
Contactcur it clO: Spark plug llohinc
~NIB~ ~'~
Ignition coil
Oil level $Witch
Earth
Contactcur de
~ i ~ "$~ ?I~ 1
B•mgic
'"""""''
nivcau d'huil<:
Mn
'
Neutral switch
Contactcur de
point-mort
@~~~neto
COi unit
MagnCto
Bloc C.D.I.
CD!
,.,,1,dk
~·~
"1 ",,, TL______
Front brake switch(§="'
.,, _____ _
Contacteurs avant
~
,,,~,;iv----· --t---t'
de feu stop
r.
.
I[:.::]-·
: ~ ~t ~~ ;.::~,,, " " "'
'..i
~~
L_~-~ ···~~~
IF H
Control unit
Bloc de
: ·)
T ~l
...
~
)"·:--
L==·==t!::-t::-===ltit==·=···:::.=:=:=:'==±±=f==:!.LlL~l- ·-CJ<J_J"
___r-("""\
L-------·-.--jf-+ ------!++- ·------·-+--- --f+f---f-+_-_-_·------~,'~~=.':,'~.:-~
~---------+--l------H-+--·--------o+-~
··--·-+-+~c------+tt
Rear flasher light
(Right)
Clignolcur arri/>re
(Droil)
--·----------+-------rt-t---t-.
~----------f---------1-f-f--··
•
-r,,-Q<:J- ·,,, __
~-·---L•---c::J<J
f---.-
Y/P\
Rectifire/
regulator
Rcdn"~cm/
rCgulateur
Con!actcur
d'avcrtisscur
"HORN"
COLOR CODE/
CODE DE COULEUR
R
B ...... Black
Noir
Green
G.
Vert
y ...... Yellow
Jaune
L .......Blue
Bleu
p
0,
Ch
"TURN" switch
Commutatcur dl'S
Cnmmutatcur de fcu de
clignotants "TURN" crois.-;emcnt "LIGHTS"
(Dimmer)
Handlebar switch (Left)
Commutatcur sur guidon (Gauche)
Red
Rouge
Pink
Rose
.Orange
Orange
.Chocolate
Cho co lat
Br.
Sb
Dg
W,
.Brown
Brun
,Sky blue
Bleu ciel
.Dark green
Vert fence
,White
Blanc
B/R
B/W
G/Y
G/R
.Black/Red
Noir/Rouge
,Black/White
Noir/Blanc
Green/Yellow
Vert/Jaune
Green/Red
Vert/Rouge
Y/R
L/Y
L/W
R/W
Yellow/Red
Jaune/Rouge
Blue/Yellow
Bleu/Jaune
Blue/White
Bleu/Blanc
Red/White
Rouge/Blanc
Br/W.
W/R,
.Brown/White
Brun/Blanc
.White/Red
Blanc/Rouge
A-604
ENREGISTREMENT
DES NUMEROS D'IDENTIFICATION
1. NUMERO DE CLE
Enregistrez ce numero a J'endroit prevu pour
reference si vous avez besoin d'une nouvelle
c1e.
c=J
YW
2. NUMERO DE VEHICULE
~-".::>
Ii
Num6ro de c16
3. NUMERO DE MOTEUR
Votrc numero d'identification de cle est grave
sur votre de comme indique a la figure suivante.
Enregistrez les numeros de vehicule et de
moteur aux emplacements prevus pour vous
permettre de commander des pieces de rcchange a votre concessionnaire Yamaha ou
COmme reference dans Je cas OU VOtre vehicu]e
scrait vole. (Voir page 3-1)
L£·66L8Z·>l9£
VHVWVA~

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