Yamaha TW200C Owner`s manual

Yamaha TW200C Owner`s manual
5FY-9-17_hyoushi
5/7/04 8:24 AM
Page 1
OWNER’S MANUAL
TW200T1
TW200T1C
YAMAHA MOTOR CO., LTD.
PRINTED ON RECYCLED PAPER
PRINTED IN JAPAN
!
2002·5–0.6×1(E)
2004.6–0.8×1 !
(E)
LIT-11626-18-27
5FY-28199-17
5FY-9-17_hyoushi2&3
4/9/04 2:40 PM
Page 1
INTRODUCTION
EAU10080
Congratulations on your purchase of the Yamaha TW200/TW200C. This model is the result of Yamaha’s vast experience in
the production of fine sporting, touring, and pacesetting racing machines. It represents the high degree of craftsmanship and
reliability that have made Yamaha a leader in these fields.
This manual will give you an understanding of the operation, inspection, and basic maintenance of this motorcycle. If you
have any questions concerning the operation or maintenance of your motorcycle, please consult a Yamaha dealer.
The design and manufacture of this Yamaha motorcycle fully comply with the emissions standards for clean air applicable
at the date of manufacture. Yamaha has met these standards without reducing the performance or economy of operation of
the motorcycle. To maintain these high standards, it is important that you and your Yamaha dealer pay close attention to the
recommended maintenance schedules and operating instructions contained within this manual.
IMPORTANT MANUAL INFORMATION
EAU10130
Particularly important information is distinguished in this manual by the following notations:
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!
WARNING
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.
EWA10010
WARNING
PLEASE READ THIS MANUAL AND THE “YOU AND YOUR MOTORCYCLE: RIDING TIPS” BOOKLET CAREFULLY
AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE. DO NOT ATTEMPT TO OPERATE THIS MOTORCYCLE UNTIL YOU HAVE ATTAINED ADEQUATE KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES
AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES. REGULAR INSPECTIONS
AND CAREFUL MAINTENANCE, ALONG WITH GOOD RIDING SKILLS, WILL ENSURE THAT YOU SAFELY ENJOY
THE CAPABILITIES AND THE RELIABILITY OF THIS MOTORCYCLE.
IMPORTANT MANUAL INFORMATION
EAU10192
AFFIX DEALER
LABEL HERE
TW200T1/TW200T1(C)
OWNER’S MANUAL
©2004 by Yamaha Motor Corporation, U.S.A.
1st edition, April 2004
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
Printed in Japan.
P/N LIT-11626-18-27
TABLE OF CONTENTS
SAFETY INFORMATION ...................1-1
Location of important labels .............1-5
PRE-OPERATION CHECKS .............. 4-1
Pre-operation check list ................... 4-2
DESCRIPTION ...................................2-1
Left view ...........................................2-1
Right view .........................................2-2
Controls and instruments..................2-3
OPERATION AND IMPORTANT
RIDING POINTS .................................. 5-1
Starting and warming up a cold
engine .......................................... 5-1
Starting a warm engine ................... 5-2
Shifting ............................................ 5-2
Engine break-in ............................... 5-4
Parking ............................................ 5-4
INSTRUMENT AND CONTROL
FUNCTIONS ........................................3-1
Main switch/steering lock .................3-1
Indicator lights .................................3-2
Speedometer unit ............................3-2
Handlebar switches .........................3-3
Clutch lever ......................................3-4
Shift pedal ........................................3-4
Brake lever ......................................3-4
Brake pedal .....................................3-5
Fuel tank cap ...................................3-5
Fuel ..................................................3-6
Fuel cock .........................................3-7
Starter (choke) knob “1” .................3-8
Seat .................................................3-8
Helmet holder ..................................3-9
Shock absorber ...............................3-9
Carrier ..............................................3-9
Luggage strap holders ...................3-10
Sidestand .......................................3-10
Ignition circuit cut-off system .........3-11
PERIODIC MAINTENANCE AND
MINOR REPAIR .................................. 6-1
PERIODIC MAINTENANCE ............ 6-1
Owner’s tool kit ................................ 6-1
Periodic maintenance chart for the
emission control system .............. 6-3
General maintenance and
lubrication chart ........................... 6-4
Removing and installing the cowling
and panels ................................... 6-8
Checking the spark plug .................. 6-9
Canister (for California only) ......... 6-11
Engine oil and oil filter element ..... 6-11
Cleaning the air filter element and
check hose ................................. 6-14
Cleaning the spark arrester ........... 6-15
Adjusting the carburetor ................ 6-16
Adjusting the throttle cable free
play ............................................ 6-16
Adjusting the valve clearance ....... 6-17
Tires .............................................. 6-17
Spoke wheels ............................... 6-19
Accessories and replacement
parts ........................................... 6-19
Adjusting the clutch lever free
play ............................................ 6-20
Adjusting the brake lever free
play ............................................ 6-21
Adjusting the brake pedal position
and free play .............................. 6-22
Adjusting the rear brake light
switch ......................................... 6-23
Checking the front brake pads and
rear brake shoes ........................ 6-23
Checking the front brake fluid
level ........................................... 6-24
Changing the brake fluid ............... 6-25
Drive chain slack ........................... 6-26
Lubricating the drive chain ............ 6-27
Checking and lubricating the
cables ........................................ 6-28
Checking and lubricating the
throttle grip and cable ................ 6-28
Checking and lubricating the
brake and shift pedals ............... 6-28
Checking and lubricating the
brake and clutch levers .............. 6-29
Checking and lubricating the
sidestand ................................... 6-29
Lubricating the rear suspension .... 6-29
TABLE OF CONTENTS
Checking the front fork ..................6-30
Checking the steering ....................6-30
Checking the wheel bearings ........6-31
Battery ...........................................6-31
Replacing the fuse .........................6-34
Replacing the headlight bulb .........6-34
Replacing the tail/brake light
bulb ............................................6-36
Replacing a turn signal light
bulb ............................................6-37
Supporting the motorcycle .............6-37
Front wheel ....................................6-38
Rear wheel ....................................6-39
Troubleshooting .............................6-41
Troubleshooting chart ....................6-42
MOTORCYCLE CARE AND
STORAGE ...........................................7-1
Care .................................................7-1
Storage ............................................7-3
SPECIFICATIONS ..............................8-1
CONSUMER INFORMATION..............9-1
Identification numbers .....................9-1
Reporting safety defects ..................9-3
Motorcycle noise regulation .............9-4
Maintenance record .........................9-5
YAMAHA MOTOR CORPORATION,
U.S.A. STREET AND ENDURO
MOTORCYCLE LIMITED
WARRANTY ................................ 9-7
YAMAHA EXTENDED SERVICE
(Y.E.S.) ........................................ 9-9
SAFETY INFORMATION
EAU10310
1
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.
THE WARNINGS
● OBSERVE
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 NECES-
SARY BY MECHANICAL CONDITIONS.
Safe riding
● Always
make
pre-operation
checks. Careful checks may help
prevent an accident.
● This motorcycle is designed to carry the operator and a passenger.
● The failure of motorists to detect
and recognize motorcycles in traffic is the predominating cause of
automobile/motorcycle accidents.
Many accidents have been caused
by an automobile driver who did
not see the motorcycle. Making
yourself conspicuous appears to
be very effective in reducing the
chance of this type of accident.
● Therefore:
Wear a brightly colored jacket.
Use extra caution when approaching and passing through
intersections, since intersections are the most likely places
for motorcycle accidents to occur.
●
●
●
●
●
●
1-1
Ride where other motorists can
see you. Avoid riding in another
motorist’s blind spot.
Many accidents involve inexperienced operators. In fact, many operators who have been involved in
accidents do not even have a current motorcycle license.
Make sure that you are qualified
and that you only lend your motorcycle to other qualified operators.
Know your skills and limits.
Staying within your limits may
help you to avoid an accident.
We recommend that you practice riding your motorcycle
where there is no traffic until you
have become thoroughly familiar with the motorcycle and all of
its controls.
Many accidents have been caused
by error of the motorcycle operator. A typical error made by the operator is veering wide on a turn
due to EXCESSIVE SPEED or un●
●
SAFETY INFORMATION
dercornering (insufficient lean angle for the speed).
Always obey the speed limit and
never travel faster than warranted by road and traffic conditions.
Always signal before turning or
changing lanes. Make sure that
other motorists can see you.
The posture of the operator and
passenger is important for proper
control.
The operator should keep both
hands on the handlebar and
both feet on the operator footrests during operation to maintain control of the motorcycle.
The passenger should always
hold onto the operator, the seat
strap or grab bar, if equipped,
with both hands and keep both
feet on the passenger footrests.
Never carry a passenger unless
he or she can firmly place both
feet on the passenger footrests.
Never ride under the influence of
alcohol or other drugs.
●
●
●
●
●
●
●
Protective apparel
The majority of fatalities from motorcycle accidents are the result of head injuries. The use of a safety helmet is the
single most critical factor in the prevention or reduction of head injuries.
● Always wear an approved helmet.
● Wear a face shield or goggles.
Wind in your unprotected eyes
could contribute to an impairment
of vision that could delay seeing a
hazard.
● The use of a jacket, heavy boots,
trousers, gloves, etc., is effective in
preventing or reducing abrasions
or lacerations.
● Never wear loose-fitting clothes,
otherwise they could catch on the
control levers, footrests, or wheels
and cause injury or an accident.
● Never touch the engine or exhaust
system during or after operation.
They become very hot and can
cause burns. Always wear protective clothing that covers your legs,
ankles, and feet.
1-2
●
Passengers should also observe
the precautions mentioned above.
Modifications
Modifications made to this motorcycle
not approved by Yamaha, or the removal of original equipment, may render the motorcycle unsafe for use and
may cause severe personal injury.
Modifications may also make your motorcycle illegal to use.
Loading and accessories
Adding accessories or cargo to your
motorcycle can adversely affect stability and handling if the weight distribution
of the motorcycle is changed. To avoid
the possibility of an accident, use extreme caution when adding cargo or
accessories to your motorcycle. Use
extra care when riding a motorcycle
that has added cargo or accessories.
Here are some general guidelines to
follow if loading cargo or adding accessories to your motorcycle:
Loading
The total weight of the operator, passenger, accessories and cargo must
1
SAFETY INFORMATION
1
not exceed the maximum load limit of
179 kg (395 lb) (CAL) 180 kg (397 lb)
(U49). When loading within this weight
limit, keep the following in mind:
● Cargo and accessory weight
should be kept as low and close to
the motorcycle as possible. Make
sure to distribute the weight as
evenly as possible on both sides of
the motorcycle to minimize imbalance or instability.
● Shifting weights can create a sudden imbalance. Make sure that accessories and cargo are securely
attached to the motorcycle before
riding. Check accessory mounts
and cargo restraints frequently.
● Never attach any large or heavy
items to the handlebar, front fork,
or front fender. These items, including such cargo as sleeping
bags, duffel bags, or tents, can
create unstable handling or a slow
steering response.
Accessories
Genuine Yamaha accessories have
been specifically designed for use on
this motorcycle. Since Yamaha cannot
test all other accessories that may be
available, you must personally be responsible for the proper selection, installation and use of non-Yamaha
accessories. Use extreme caution
when selecting and installing any accessories.
Keep the following guidelines in mind,
as well as those provided under “Loading” when mounting accessories.
● Never install accessories or carry
cargo that would impair the performance of your motorcycle. Carefully inspect the accessory before
using it to make sure that it does
not in any way reduce ground
clearance or cornering clearance,
limit suspension travel, steering
travel or control operation, or obscure lights or reflectors.
Accessories fitted to the handlebar or the front fork area can
create instability due to improper
weight distribution or aerody-
●
●
●
1-3
namic changes. If accessories
are added to the handlebar or
front fork area, they must be as
lightweight as possible and
should be kept to a minimum.
Bulky or large accessories may
seriously affect the stability of
the motorcycle due to aerodynamic effects. Wind may attempt to lift the motorcycle, or
the motorcycle may become unstable in cross winds. These accessories may also cause
instability when passing or being
passed by large vehicles.
Certain accessories can displace the operator from his or
her normal riding position. This
improper position limits the freedom of movement of the operator and may limit control ability,
therefore, such accessories are
not recommended.
Use caution when adding electrical accessories. If electrical accessories exceed the capacity of the
●
SAFETY INFORMATION
motorcycle’s electrical system an
electric failure could result, which
could cause a dangerous loss of
lights or engine power.
Gasoline and exhaust gas
● GASOLINE IS HIGHLY FLAMMABLE:
Always turn the engine off when
refueling.
Take care not to spill any gasoline on the engine or exhaust
system when refueling.
Never refuel while smoking or in
the vicinity of an open flame.
● Never start the engine or let it run
for any length of time in a closed
area. The exhaust fumes are poisonous and may cause loss of
consciousness and death within a
short time. Always operate your
motorcycle in an area that has adequate ventilation.
● Always turn the engine off before
leaving the motorcycle unattended
and remove the key from the main
switch. When parking the motorcy-
cle, note the following:
The engine and exhaust system
may be hot, therefore, park the
motorcycle in a place where pedestrians or children are not likely to touch these hot areas.
Do not park the motorcycle on a
slope or soft ground, otherwise it
may fall over.
Do not park the motorcycle near
a flammable source (e.g., a kerosene heater, or near an open
flame), otherwise it could catch
fire.
When transporting the motorcycle
in another vehicle, make sure that
it is kept upright and that the fuel
cock(s) are turned to “ON” or
“RES” (for vacuum type)/“OFF”
(for manual type). If the motorcycle
should lean over, gasoline may
leak out of the carburetor or fuel
tank.
If you should swallow any gasoline, inhale a lot of gasoline vapor,
or allow gasoline to get into your
●
●
●
●
●
●
●
●
1-4
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
SAFETY INFORMATION
EAU10381
Location of important labels
Please read the following important labels carefully before operating this vehicle.
1
1
2 3
7
8
1-5
4 5 6
SAFETY INFORMATION
1
6
WARNING
WARNING
BEFORE YOU OPERATE THIS VEHICLE, READ
THE OWNER’S MANUAL AND ALL LABELS.
ALWAYS WEAR AN APPROVED MOTORCYCLE
HELMET, eye protection, and protective clothing.
Improper loading can cause loss of control.
Read owner’s manual for proper loading.
3JJ—28446—A1
5GK-2118K-00
7
2
WARNING
CAUTION
This unit contains high pressure nitrogen gas.
Mishandling can cause explosion.
8 Read owner's manual for instructions.
8 Do not incinerate, puncture or open.
Read owner’s manual before servicing battery.
Electrolyte will damage metal parts or paint.
If electrolyte spills, wash area with fresh
water immediately.
Be sure to connect breather hose after
installing battery.
4AA-22259-80
8
3JL-28177-A0
3 CALIFORNIA ONLY
4
WARNING
CARB.
FROM
FUEL TANK
NEVER sit here.
3MX-24875-A0
5
CANISTER
TO ATMOSPHERE
4YN-21686-00
LOAD LIMIT
3 kg {7 lbs}
3TB-24877-A0
1-6
1
DESCRIPTION
EAU10410
Left view
3
1 2
4
1
2
3
4
5
6
7
87
8
9
1. Fuel tank cap (page 3-5)
2. Fuel cock (page 3-7)
3. Helmet holder (page 3-9)
4. Luggage strap holder (page 3-10)
5. Drive chain slack adjusting plate
6. Air filter element (page 6-14)
7. Starter (choke) knob (page 3-8)
8. Shift pedal (page 3-4)
2-1
6
5
DESCRIPTION
EAU10420
Right view
1
2
2
3
4
5
6
7
8
7
6 5
4
1. Carrier (page 3-9)
2. Battery (page 6-31)
3. Engine oil level check window (page 6-11)
4. Brake pedal (page 3-5)
5. Owner’s tool kit (page 6-1)
6. Fuse (page 6-34)
7. Luggage strap holder (page 3-10)
8. Spark arrester (page 6-15)
3
8
9
2-2
DESCRIPTION
EAU10430
Controls and instruments
1
1
2
3
4
5
6
2
3
4
5
9
6
7
8
9
1. Clutch lever (page 3-4)
2. Left handlebar switches (page 3-3)
3. Speedometer unit (page 3-2)
4. Main switch/steering lock (page 3-1)
5. Indicator lights (page 3-2)
6. Right handlebar switches (page 3-3)
7. Brake lever (page 3-4)
8. Throttle grip (page 6-16)
9. Fuel tank cap (page 3-5)
2-3
7
8
INSTRUMENT AND CONTROL FUNCTIONS
EAU10460
Main switch/steering lock
OFF
EAU10710
LOCK
The steering is locked, and all electrical
systems are off. The key can be removed.
To lock the steering
ON
To unlock the steering
Insert the key and turn it to “OFF”.
EWA10070
WARNING
Never turn the key to “LOCK” while
the motorcycle is moving.
2
1
LOCK
2
3
4
The main switch/steering lock controls
the ignition and lighting systems, and is
used to lock the steering. The various
positions are described below.
EAU10510
ON
All electrical systems are supplied with
power, and the headlight, meter lighting, taillight and position lights come
on, and the engine can be started. The
key cannot be removed.
EAU10660
3
5
6
1. Push.
2. Release.
3. Turn.
7
Turn the handlebars all the way to the
left or right.
1. Push the key in from the “OFF” position, release it, and then turn it to
“LOCK”.
2. Remove the key.
OFF
All electrical systems are off. The key
can be removed.
3-1
8
9
INSTRUMENT AND CONTROL FUNCTIONS
EAU10980
Indicator lights
1
2
EAU11080
High beam indicator light “ ”
This indicator light comes on when the
high beam of the headlight is switched
on.
3
1
2
EAU11630
Speedometer unit
1
4
2
3
3
4
5
1. Turn signal indicator light “
2. High beam indicator light “
3. Neutral indicator light “
1. Speedometer
2. Odometer
3. Tripmeter
4. Reset knob
”
”
”
6
EAU11020
7
Turn signal indicator light “
”
This indicator light flashes when the
turn signal switch is pushed to the left or
right.
8
The speedometer unit is equipped with
a speedometer, an odometer and a
tripmeter. The speedometer shows
riding speed. The odometer shows the
total distance traveled. The tripmeter
shows the distance traveled since it
was last set to zero with the reset knob.
The tripmeter can be used to estimate
the distance that can be traveled with a
full tank of fuel. This information will enable you to plan future fuel stops.
EAU11060
9
Neutral indicator light “ ”
This indicator light comes on when the
transmission is in the neutral position.
3-2
INSTRUMENT AND CONTROL FUNCTIONS
EAU12343
Handlebar switches
Right
EAU12500
Horn switch “
”
Press this switch to sound the horn.
Left
1
EAU12660
Engine stop switch “ / ”
Set this switch to “ ” before starting
the engine. Set this switch to “ ” to
stop the engine in case of an emergency, such as when the vehicle overturns
or when the throttle cable is stuck.
1 2
2
3
1. Engine stop switch “
2. Start switch “
1. Dimmer switch “
/
2. Turn signal switch “
3. Horn switch “
”
/
”
3
4
”
EAU12710
”
/
2
EAU12400
”
Dimmer switch “ / ”
Set this switch to “ ” for the high
beam and to “ ” for the low beam.
EAU12460
Turn signal switch “ / ”
To signal a right-hand turn, push this
switch to “ ”. To signal a left-hand
turn, push this switch to “ ”. When released, the switch returns to the center
position. To cancel the turn signal
lights, push the switch in after it has returned to the center position.
3-3
Start switch “ ”
Push this switch to crank the engine
with the starter.
ECA10050
CAUTION:
See page 5-1 for starting instructions prior to starting the engine.
5
6
7
8
9
INSTRUMENT AND CONTROL FUNCTIONS
EAU12820
Clutch lever
EAU12870
Shift pedal
EAU12890
Brake lever
1
1
1
5
4
3
2
N
1
2
3
1
4
5
6
7
8
9
1. Clutch lever
The clutch lever is located at the left
handlebar grip. To disengage the
clutch, pull the lever toward the handlebar grip. To engage the clutch, release
the lever. The lever should be pulled
rapidly and released slowly for smooth
clutch operation.
The clutch lever is equipped with a
clutch switch, which is part of the ignition circuit cut-off system. (See
page 3-11.)
1. Shift pedal
1. Brake lever
The shift pedal is located on the left
side of the engine and is used in combination with the clutch lever when
shifting the gears of the 5-speed constant-mesh transmission equipped on
this motorcycle.
3-4
The brake lever is located at the right
handlebar grip. To apply the front
brake, pull the lever toward the handlebar grip.
INSTRUMENT AND CONTROL FUNCTIONS
EAU12941
Brake pedal
EAU32280
NOTE:
The fuel tank cap cannot be installed
unless the key is in the lock. In addition,
the key cannot be removed if the cap is
not properly installed and locked.
Fuel tank cap
2
1
1
1. Brake pedal
The brake pedal is on the right side of
the motorcycle. To apply the rear
brake, press down on the brake pedal.
1. Fuel tank cap
2. Unlock.
To remove the fuel tank cap
1. Insert the key into the lock and turn
it 1/3 turn counterclockwise.
2. Turn the fuel tank cap 1/3 turn
counterclockwise and pull it off.
To install the fuel tank cap
1. Insert the fuel tank cap into the
tank opening with the key inserted
in the lock, and then turn the cap 1/
3 turn clockwise.
2. Turn the key 1/3 turn clockwise,
and then remove it.
3-5
EWA10120
2
WARNING
Make sure that the fuel tank cap is
properly closed and locked before
riding.
3
4
5
6
7
8
9
INSTRUMENT AND CONTROL FUNCTIONS
EAU13210
Fuel
1
1
EAU13300
2
2
3
4
5
6
Recommended fuel:
UNLEADED GASOLINE ONLY
Fuel tank capacity:
7.0 L (1.85 US gal) (1.54 Imp.gal)
Fuel reserve amount:
1.7 L (0.45 US gal) (0.37 Imp.gal)
ECA11400
1. Fuel tank filler tube
2. Fuel level
Make sure that there is sufficient fuel in
the tank. Fill the fuel tank to the bottom
of the filler tube as shown.
EWA10880
7
●
8
9
fuel may deteriorate painted surfaces or plastic parts.
●
WARNING
Do not overfill the fuel tank, otherwise it may overflow when the
fuel warms up and expands.
Avoid spilling fuel on the hot engine.
ECA10070
CAUTION:
Immediately wipe off spilled fuel
with a clean, dry, soft cloth, since
CAUTION:
Use only unleaded gasoline. The use
of leaded gasoline will cause severe
damage to internal engine parts,
such as the valves and piston rings,
as well as to the exhaust system.
Your Yamaha engine has been designed to use regular unleaded gasoline with a pump octane number
[(R+M)/2] of 86 or higher, or a research
octane number of 91 or higher. If
knocking (or pinging) occurs, use a
gasoline of a different brand or premium unleaded fuel. Use of unleaded fuel
will extend spark plug life and reduce
3-6
maintenance costs.
Gasohol
There are two types of gasohol: gasohol containing ethanol and that containing methanol. Gasohol containing
ethanol can be used if the ethanol content does not exceed 10%. Gasohol
containing methanol is not recommended by Yamaha because it can
cause damage to the fuel system or vehicle performance problems.
INSTRUMENT AND CONTROL FUNCTIONS
EAU13560
Fuel cock
The fuel cock supplies fuel from the
tank to the carburetor while filtering it also.
The fuel cock has three positions:
OFF
ON
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
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
5
6
RES
1. Arrow mark positioned over “OFF”
With the lever in this position, fuel will
not flow. Always return the lever to this
position when the engine is not running.
4
7
RES
8
OFF
ON
1
FUEL
9
1. Arrow mark positioned over “RES”
This indicates reserve. If you run out of
3-7
INSTRUMENT AND CONTROL FUNCTIONS
EAU13600
Starter (choke) knob “
”
EAU13970
Seat
To remove the seat
1. Remove the bolts, and then pull
the seat off.
1
2
1
1
2
(b)
(a)
3
4
5
6
7
1. Projection
2. Seat holder
1. Starter (choke) knob “
”
Starting a cold engine requires a richer
air-fuel mixture, which is supplied by
the starter (choke).
Move the knob in direction (a) to turn on
the starter (choke).
Move the knob in direction (b) to turn off
the starter (choke).
1(×2)
1. Bolt
To install the seat
1. Insert the projection on the front of
the seat into the seat holder as
shown.
8
9
3-8
2. Place the seat in the original position, and then tighten the bolts.
NOTE:
Make sure that the seat is properly secured before riding.
INSTRUMENT AND CONTROL FUNCTIONS
EAU14281
Helmet holder
EAU15090
Shock absorber
EAU15110
Carrier
EWA10220
1
1. Helmet holder
To open the helmet holder, insert the
key into the lock, and then turn the key
as shown.
To lock the helmet holder, place it in the
original position, and then remove the
key.
EWA10160
WARNING
Never ride with a helmet attached to
the helmet holder, since the helmet
may hit objects, causing loss of control and possibly an accident.
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.
3-9
1
2
3
4
1. Carrier
EWA10170
●
●
WARNING
Do not exceed the load limit of
3 kg (7 lb) for the carrier.
Do not exceed the maximum
load of TW200: 180 kg (397 lb)/
TW200C: 179 kg (395 lb) for the
vehicle.
5
6
7
8
9
INSTRUMENT AND CONTROL FUNCTIONS
EAU15170
Luggage strap holders
1(×2)
1
2
3
4
5
6
7
8
9
1(×2)
1. Luggage strap holder
There are four luggage strap holders
below the carrier.
EAU15300
Sidestand
The sidestand is located on the left side
of the frame. Raise the sidestand or
lower it with your foot while holding the
vehicle upright.
NOTE:
The built-in sidestand switch is part of
the ignition circuit cut-off system, which
cuts the ignition in certain situations.
(See further down for an explanation of
the ignition circuit cut-off system.)
EWA10240
WARNING
The vehicle must not be ridden with
the sidestand down, or if the sidestand cannot be properly moved up
(or does not stay up), otherwise the
sidestand could contact the ground
and distract the operator, resulting
in a possible loss of control.
Yamaha’s ignition circuit cut-off
system has been designed to assist
the operator in fulfilling the responsibility of raising the sidestand before starting off. Therefore, check
3-10
this system regularly as described
below and have a Yamaha dealer repair it if it does not function properly.
INSTRUMENT AND CONTROL FUNCTIONS
EAU15311
Ignition circuit cut-off system
The ignition circuit cut-off system (comprising the sidestand switch, clutch
switch and neutral switch) has the following functions.
● It prevents starting when the transmission is in gear and the sidestand is up, but the clutch lever is
not pulled.
● It prevents starting when the transmission is in gear and the clutch lever is pulled, but the sidestand is
still down.
● It cuts the running engine when the
transmission is in gear and the sidestand is moved down.
Periodically check the operation of the
ignition circuit cut-off system according
to the following procedure.
2
3
4
5
6
7
8
EWA10250
WARNING
If a malfunction is noted, have a
Yamaha dealer check the system before riding.
9
3-11
INSTRUMENT AND CONTROL FUNCTIONS
1
2
3
4
5
6
With the engine turned off:
1. Move the sidestand down.
2. Make sure that the engine stop switch is turned on.
3. Turn the key on.
4. Shift the transmission into the neutral position.
5. Push the start switch.
Does the engine start?
YES
NOTE:
This check is most reliable if performed with
a warmed-up engine.
NO
The neutral switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
NO
The sidestand switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
NO
The clutch switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
With the engine still running:
6. Move the sidestand up.
7. Keep the clutch lever pulled.
8. Shift the transmission into gear.
9. Move the sidestand down.
Does the engine stall?
YES
7
8
9
After the engine has stalled:
10. Move the sidestand up.
11. Keep the clutch lever pulled.
12. Push the start switch.
Does the engine start?
YES
The system is OK. The motorcycle can be ridden.
3-12
PRE-OPERATION CHECKS
EAU15591
The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly,
even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss
of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thorough visual inspection, to check the following points before each ride.
NOTE:
Pre-operation checks should be made each time the vehicle is used. Such an inspection can be accomplished in a very short
time; and the added safety it assures is more than worth the time involved.
2
EWA11150
3
WARNING
If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operating
the vehicle.
4
5
6
7
8
9
4-1
PRE-OPERATION CHECKS
EAU15602
Pre-operation check list
ITEM
CHECKS
●
1
Fuel
●
●
2
●
Engine oil
●
●
●
3
●
●
4
●
Front brake
●
●
5
●
●
●
6
●
Rear brake
●
●
7
●
Clutch
8
●
●
●
●
9
Throttle grip
Control cables
●
●
●
●
Check fuel level in fuel tank.
Refuel if necessary.
Check fuel line for leakage.
Check oil level in engine.
If necessary, add recommended oil to specified level.
Check vehicle for oil leakage.
Check operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check lever free play.
Adjust if necessary.
Check brake pads for wear.
Replace if necessary.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.
Check operation.
Check pedal free play.
Adjust if necessary.
Check operation.
Lubricate cable if necessary.
Check lever free play.
Adjust if necessary.
Make sure that operation is smooth.
Check cable free play.
If necessary, have Yamaha dealer adjust cable free play and lubricate cable
and grip housing.
Make sure that operation is smooth.
Lubricate if necessary.
4-2
PAGE
3-6
6-11
6-21, 6-23, 6-24
6-22, 6-23
6-20
6-16, 6-28
6-28
PRE-OPERATION CHECKS
ITEM
CHECKS
●
Drive chain
●
●
●
●
Wheels and tires
●
●
●
Brake and shift pedals
Brake and clutch levers
Sidestand
Chassis fasteners
Instruments, lights, signals
and switches
Sidestand switch
Battery
●
●
●
●
●
●
●
●
●
●
●
●
●
●
Check chain slack.
Adjust if necessary.
Check chain condition.
Lubricate if necessary.
Check for damage.
Check tire condition and tread depth.
Check air pressure.
Correct if necessary.
Make sure that operation is smooth.
Lubricate pedal pivoting points if necessary.
Make sure that operation is smooth.
Lubricate lever pivoting points if necessary.
Make sure that operation is smooth.
Lubricate pivot if necessary.
Make sure that all nuts, bolts and screws are properly tightened.
Tighten if necessary.
Check operation.
Correct if necessary.
Check operation of ignition circuit cut-off system.
If system is defective, have Yamaha dealer check vehicle.
Check fluid level.
Fill with distilled water if necessary.
PAGE
6-26, 6-27
6-17, 6-19
2
6-28
3
6-29
4
6-29
—
—
5
6
3-10
7
6-31
8
9
4-3
OPERATION AND IMPORTANT RIDING POINTS
●
1
2
3
●
4
5
6
7
8
9
●
EAU15950
EAU32290
EWA10270
Starting and warming up a
cold engine
WARNING
Become thoroughly familiar
with all operating controls and
their functions before riding.
Consult a Yamaha dealer regarding any control or function
that you do not thoroughly understand.
Never start the engine or operate it in a closed area for any
length of time. Exhaust fumes
are poisonous, and inhaling
them can cause loss of consciousness and death within a
short time. Always make sure
that there is adequate ventilation.
Before starting out, make sure
that the sidestand is up. If the
sidestand is not raised completely, it could contact the
ground and distract the operator, resulting in a possible loss
of control.
In order for the ignition circuit cut-off
system to enable starting, one of the
following conditions must be met:
● The transmission is in the neutral
position.
● The transmission is in gear with
the clutch lever pulled and the sidestand up.
EWA10290
●
●
WARNING
Before starting the engine,
check the function of the ignition circuit cut-off system according to the procedure
described on page 3-11.
Never ride with the sidestand
down.
1. Turn the fuel cock lever to “ON”.
2. Turn the key to “ON” and make
sure that the engine stop switch is
set to “ ”.
3. Shift transmission into the neutral
position.
5-1
NOTE:
When the transmission is in the neutral
position, the neutral indicator light
should be on, otherwise have a
Yamaha dealer check the electrical circuit.
4. Turn the starter (choke) on and
completely close the throttle. (See
page 3-8.)
5. Start the engine by pushing the
start switch.
NOTE:
If the engine fails to start, release the
start switch, wait a few seconds, and
then try again. Each starting attempt
should be as short as possible to preserve the battery. Do not crank the engine more than 10 seconds on any one
attempt.
6. After starting the engine, move the
starter (choke) back halfway.
ECA11130
CAUTION:
For maximum engine life, always
warm the engine up before starting
OPERATION AND IMPORTANT RIDING POINTS
off. Never accelerate hard when the
engine is cold!
7. When the engine is warm, turn the
starter (choke) off.
NOTE:
The engine is warm when it responds
normally to the throttle with the starter
(choke) turned off. To avoid the possibility of excessive exhaust emissions,
never leave the starter (choke) on longer than necessary. The time necessary
for starter (choke) use depends upon
the ambient temperature. Temperatures above 10 °C (50 °F) require about
7 seconds of starter (choke) use and
temperatures below 10 °C (50 °F) require about 35 seconds with the starter
(choke) turned on, then about 2.5 minutes with the starter (choke) in the halfway position.
EAU16640
Starting a warm engine
EAU16671
Shifting
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.
2
5
4
3
2
N
1
2
3
1
1. Shift pedal
2. Neutral position
5-2
4
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.
5
NOTE:
To shift the transmission into the neutral position, press the shift pedal down
repeatedly until it reaches the end of its
travel, and then slightly raise it.
8
6
7
9
OPERATION AND IMPORTANT RIDING POINTS
ECA10260
1
2
3
4
5
6
7
8
9
CAUTION:
● Even with the transmission in
the neutral position, do not
coast for long periods of time
with the engine off, and do not
tow the motorcycle for long distances. The transmission is
properly lubricated only when
the engine is running. Inadequate lubrication may damage
the transmission.
● Always use the clutch while
changing gears to avoid damaging the engine, transmission,
and drive train, which are not
designed to withstand the
shock of forced shifting.
3. Open the throttle gradually, and at
the same time, release the clutch
lever slowly.
4. At the recommended shift points
shown in the following table, close
the throttle, and at the same time,
quickly pull the clutch lever in.
5. Shift the transmission into second
gear. (Make sure not to shift the
transmission into the neutral position.)
6. Open the throttle part way and
gradually release the clutch lever.
7. Follow the same procedure when
shifting to the next higher gear.
NOTE:
Always shift gears at the recommended
shift points.
EAU16680
To start out and accelerate
1. Pull the clutch lever to disengage
the clutch.
2. Shift the transmission into first
gear. The neutral indicator light
should go out.
EAU16700
To decelerate
1. Apply both the front and the rear
brakes to slow the motorcycle.
2. Shift the transmission into first
gear when the motorcycle reaches
20 km/h (12.5 mi/h). If the engine is
5-3
about to stall or runs very roughly,
pull the clutch lever in and use the
brakes to stop the motorcycle.
3. Shift the transmission into the neutral position when the motorcycle
is almost completely stopped. The
neutral indicator light should come
on.
EAU16720
Recommended shift points
The recommended shift points during
acceleration and deceleration are
shown in the table below.
Shift up points:
1st → 2nd: 15 km/h (9.3 mi/h)
2nd → 3rd: 20 km/h (12.5 mi/h)
3rd → 4th: 30 km/h (18.6 mi/h)
4th → 5th: 40 km/h (24.9 mi/h)
Shift down points:
5th → 4th: 20 km/h (12.5 mi/h)
4th → 3rd: 20 km/h (12.5 mi/h)
3rd → 2nd: 20 km/h (12.5 mi/h)
2nd → 1st: 20 km/h (12.5 mi/h)
OPERATION AND IMPORTANT RIDING POINTS
EAU16841
Engine break-in
There is never a more important period
in the life of your engine than the period
between 0 and 1600 km (1000 mi). For
this reason, you should read the following material carefully.
Since the engine is brand new, do not
put an excessive load on it for the first
1600 km (1000 mi). The various parts in
the engine wear and polish themselves
to the correct operating clearances.
During this period, prolonged full-throttle operation or any condition that might
result in engine overheating must be
avoided.
EAU17170
ECA12711
CAUTION:
● After 1000 km (600 mi) of operation, the engine oil must be
changed, the oil filter element
and the oil strainer cleaned.
● If any engine trouble should occur during the engine break-in
period, immediately have a
Yamaha dealer check the vehicle.
Parking
When parking, stop the engine, remove
the key from the main switch, and then
turn the fuel cock lever to “OFF”.
EWA10310
●
●
WARNING
Since the engine and exhaust
system can become very hot,
park in a place where pedestrians or children are not likely to
touch them.
Do not park on a slope or on soft
ground, otherwise the vehicle
may overturn.
2
3
4
5
6
EAU32311
7
0–1000 km (0–600 mi)
Avoid prolonged operation above 1/3
throttle.
1000–1600 km (600–1000 mi)
Avoid prolonged operation above 1/2
throttle.
1600 km (1000 mi) and beyond
The vehicle can now be operated normally.
8
9
5-4
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU17231
1
2
3
4
5
Safety is an obligation of the owner. Periodic inspection, adjustment and lubrication will keep your vehicle in the
safest and most efficient condition possible. The most important points of motorcycle inspection, adjustment, and
lubrication are explained on the following pages.
Maintenance, replacement, or repair
of the emission control devices and
systems may be performed by any
repair establishment or individual
that is certified (if applicable).
EWA10320
6
7
8
9
WARNING
If you are not familiar with maintenance work, have a Yamaha dealer
do it for you.
EAU17301
PERIODIC MAINTENANCE
PROPER PERIODIC MAINTENANCE
OF YOUR VEHICLE IS IMPORTANT
IN ORDER TO ENJOY LONG, PLEASURABLE SERVICE. ESPECIALLY
IMPORTANT ARE THE MAINTENANCE SERVICES RELATED TO
EMISSIONS CONTROL. THESE
CONTROLS NOT ONLY FUNCTION
TO ENSURE CLEANER AIR, BUT
ARE ALSO VITAL TO PROPER ENGINE OPERATION AND MAXIMUM
PERFORMANCE. IN THE FOLLOWING
PERIODIC
MAINTENANCE
CHARTS, THE SERVICES RELATED
TO EMISSIONS CONTROL ARE
GROUPED SEPARATELY. THESE
SERVICES REQUIRE SPECIALIZED
DATA, KNOWLEDGE, AND EQUIPMENT. YAMAHA DEALERS ARE
TRAINED AND EQUIPPED TO PERFORM THESE PARTICULAR SERVICES.
6-1
EAU17330
Owner’s tool kit
1
1. Owner’s tool kit
The owner’s tool kit is located behind
panel B. (See page 6-8.)
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
PERIODIC MAINTENANCE AND MINOR REPAIR
a Yamaha dealer perform it for you.
EWA10340
WARNING
Modifications not approved by
Yamaha may cause loss of performance, excessive emissions, and
render the vehicle unsafe for use.
Consult a Yamaha dealer before attempting any changes.
2
3
4
5
6
7
8
9
6-2
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU17580
Periodic maintenance chart for the emission control system
INITIAL
1
No.
ITEM
ROUTINE
2
●
1 * Fuel line
3
●
●
●
4
2
Spark plug
3
Spark arrester
●
5
6
7
4 * Valve clearance
5 * Idle speed
●
●
●
●
8
9
6 * Exhaust system
Evaporative emis7 * sion control system
(For California only)
●
●
●
●
Check fuel hoses for cracks or
damage.
Replace if necessary.
Check condition.
Adjust gap and clean.
Replace at 7000 mi (11000
km) or 12 months and thereafter every 6000 mi (10000 km)
or 12 months.
Clean.
Check and adjust valve clearance when engine is cold.
Check and adjust engine idle
speed.
Check for leakage.
Tighten if necessary.
Replace gasket(s) if necessary.
Check control system for damage.
Replace if necessary.
600 mi
(1000 km)
or
1 month
√
ODOMETER READINGS
4000 mi
(6000 km)
or
6 months
7000 mi
10000 mi
13000 mi
16000 mi
(11000 km) (16000 km) (21000 km) (26000 km)
or
or
or
or
12 months 18 months 24 months 30 months
√
√
√
√
√
√
Replace.
√
Replace.
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.
6-3
√
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU32161
General maintenance and lubrication chart
INITIAL
No.
ITEM
1 * Air filter element
ROUTINE
●
●
●
2 * Battery
3 * Clutch
●
●
●
4 * Front brake
●
●
5 * Rear brake
6 * Brake hose
●
●
●
●
7 * Wheels
●
●
8 * Tires
●
●
●
Clean with solvent.
Replace if necessary.
Check specific gravity and
breather hose for proper operation.
Check operation.
Adjust or replace cable.
Check operation, fluid level,
and for fluid leakage.
Replace brake pads if necessary.
Check operation.
Adjust cable and replace brake
shoes if necessary.
Check for cracks or damage.
Replace.
Check runout, spoke tightness
and for damage.
Tighten spokes if necessary.
Check tread depth and for
damage.
Replace if necessary.
Check air pressure.
Correct if necessary.
600 mi
(1000 km)
or
1 month
ODOMETER READINGS
4000 mi
(6000 km)
or
6 months
7000 mi
10000 mi
13000 mi
16000 mi
(11000 km) (16000 km) (21000 km) (26000 km)
or
or
or
or
12 months 18 months 24 months 30 months
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
2
3
4
5
6
√
√
√
√
√
√
√
√
√
Every 4 years
√
√
√
√
√
√
7
√
8
9
√
6-4
√
√
√
√
PERIODIC MAINTENANCE AND MINOR REPAIR
INITIAL
No.
ITEM
ROUTINE
1
●
2
9 * Wheel bearings
●
●
3
10 *
Swingarm pivot
bushes
●
4
●
5
11
Drive chain
6
7
●
●
12 * Steering bearings
●
8
●
13 * Chassis fasteners
9
●
14
Brake and clutch
lever pivot shafts
●
Check bearings for smooth
operation.
Replace if necessary.
Check bush assemblies for
looseness.
Apply lithium-soap-based
grease until new grease
shows.
Check chain slack/alignment
and condition.
Adjust and lubricate chain with
a special O-ring chain lubricant
thoroughly.
Check bearing assembly for
looseness.
Moderately repack with lithium-soap-based grease every
10000 mi (16000 km) or 18
months.
Check all chassis fitting and
fasteners.
Correct if necessary.
Apply lithium-soap-based
grease (all-purpose grease)
lightly.
600 mi
(1000 km)
or
1 month
ODOMETER READINGS
4000 mi
(6000 km)
or
6 months
7000 mi
10000 mi
13000 mi
16000 mi
(11000 km) (16000 km) (21000 km) (26000 km)
or
or
or
or
12 months 18 months 24 months 30 months
√
√
√
√
√
√
√
√
√
Every 300 mi (500 km) and after washing the motorcycle or riding in the rain
√
6-5
√
√
Repack.
√
√
√
√
√
√
√
√
√
√
√
√
PERIODIC MAINTENANCE AND MINOR REPAIR
INITIAL
No.
15
ITEM
Brake and shift pedal
pivot shafts
ROUTINE
●
●
16
Sidestand pivot
17 * Sidestand switch
●
●
●
18 * Front fork
●
19 *
20
21
22
23 *
Shock absorber
assembly
Engine oil
Engine oil filter element
Engine oil strainer
Control and meter
cables
●
●
●
Apply lithium-soap-based
grease (all-purpose grease)
lightly.
Check operation.
Apply lithium-soap-based
grease (all-purpose grease)
lightly.
Check operation and replace if
necessary.
Check operation and for oil
leakage.
Replace if necessary.
Check operation and for oil
leakage.
Replace if necessary.
Change (warm engine before
draining).
600 mi
(1000 km)
or
1 month
√
√
ODOMETER READINGS
4000 mi
(6000 km)
or
6 months
7000 mi
10000 mi
13000 mi
16000 mi
(11000 km) (16000 km) (21000 km) (26000 km)
or
or
or
or
12 months 18 months 24 months 30 months
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
●
Clean.
√
√
√
●
Clean.
Apply Yamaha chain and cable
lube or engine oil 10W-30 thoroughly.
√
√
√
●
√
6-6
√
√
√
√
2
3
4
5
6
7
8
√
9
PERIODIC MAINTENANCE AND MINOR REPAIR
INITIAL
No.
ITEM
ROUTINE
1
●
2
Throttle grip housing and cable
24 *
3
●
●
600 mi
(1000 km)
or
1 month
Check operation and free play.
Adjust the throttle cable free
play if necessary.
Lubricate the throttle grip
housing and cable.
ODOMETER READINGS
4000 mi
(6000 km)
or
6 months
√
7000 mi
10000 mi
13000 mi
16000 mi
(11000 km) (16000 km) (21000 km) (26000 km)
or
or
or
or
12 months 18 months 24 months 30 months
√
√
√
√
* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.
4
NOTE:
From 19000 mi (31000 km) or 36 months, repeat the maintenance intervals starting from 7000 mi (11000 km) or 12 months.
5
EAU17620
6
7
NOTE:
● The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
● Hydraulic brake system
When disassembling the master cylinder or caliper cylinder, always replace the brake fluid. Check the brake fluid level
regularly and fill as required.
Replace the oil seals on the inner parts of the master cylinder and caliper cylinder every two years.
Replace the brake hoses every four years or if cracked or damaged.
●
8
●
●
9
6-7
PERIODIC MAINTENANCE AND MINOR REPAIR
To install the cowling
Place the cowling in the original position, and then install the screw.
EAU18721
Removing and installing the
cowling and panels
1
The cowling and panels shown need to
be removed to perform some of the
maintenance jobs described in this
chapter. Refer to this section each time
the cowling or a panel needs to be removed and installed.
2
1
EAU32451
Panel A
To remove the panel
Remove the screws, and then pull the
panel out at the area shown.
2
3
1. Panel B
4
1
EAU18810
Cowling A
To remove the cowling
Remove the screw, and then pull the
cowling off as shown.
2(×2)
5
6
7
1. Panel A
2. Screw
1. Cowling A
2. Panel A
To install the panel
Place the panel in the original position,
and then install the screws.
1
1. Screw
6-8
8
9
PERIODIC MAINTENANCE AND MINOR REPAIR
To install the panel
Place the panel in the original position.
1
2
3
4
Panel B
To remove the panel
Pull the panel off as shown.
EAU19602
Checking the spark plug
The spark plug is an important engine
component, which is easy to check.
Since heat and deposits will cause any
spark plug to slowly erode, the spark
plug should be removed and checked
in accordance with the periodic maintenance and lubrication chart. In addition,
the condition of the spark plug can reveal the condition of the engine.
To remove the spark plug
1. Remove the spark plug cap.
5
1
6
7
1
8
9
1. Panel B
1. Spark plug cap
2. Remove the spark plug as shown,
with the spark plug wrench included in the owner’s tool kit.
6-9
PERIODIC MAINTENANCE AND MINOR REPAIR
necessary.
Specified spark plug:
NGK/DR8EA
DENSO/X24ESR-U
1
1. Spark plug wrench
To check the spark plug
1. Check that the porcelain insulator
around the center electrode of the
spark plug is a medium-to-light tan
(the ideal color when the vehicle is
ridden normally).
NOTE:
If the spark plug shows a distinctly different color, the engine could be defective. Do not attempt to diagnose such
problems yourself. Instead, have a
Yamaha dealer check the vehicle.
2. Check the spark plug for electrode
erosion and excessive carbon or
other deposits, and replace it if
To install the spark plug
1. Measure the spark plug gap with a
wire thickness gauge and, if necessary, adjust the gap to specification.
3. Install the spark plug with the
spark plug wrench, and then tighten it to the specified torque.
Tightening torque:
Spark plug:
17.5 Nm (1.75 m·kgf, 12.5 ft·lbf)
2
NOTE:
If a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4–1/2 turn
past finger tight. However, the spark
plug should be tightened to the specified torque as soon as possible.
4. Install the spark plug cap.
1
3
4
5
6
7
1. Spark plug gap
8
Spark plug gap:
0.6–0.7 mm (0.024–0.028 in)
2. Clean the surface of the spark plug
gasket and its mating surface, and
then wipe off any grime from the
spark plug threads.
6-10
9
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU19671
Canister (for California only)
1
1
2
2
3
4
5
6
7
8
9
3
4
1. Rollover valve
2. Carburetor
3. Canister
4. Vent hose
This model is equipped with a canister
to prevent the discharging of fuel vapor
into the atmosphere.
● Check each hose connection.
● Check each hose and canister for
cracks or damage. Replace if
damaged.
● Make sure the vent hose is not
blocked. Clean it if necessary.
EAU19792
Engine oil
element
and
oil
filter
The engine oil level should be checked
before each ride. In addition, the oil
must be changed and the oil filter element cleaned at the intervals specified
in the periodic maintenance and lubrication chart.
To check the engine oil level
1. Place the vehicle on a level surface and hold it in an upright position.
NOTE:
Make sure that the vehicle is positioned
straight up when checking the oil level.
A slight tilt to the side can result in a
false reading.
2. Start the engine, warm it up for
several minutes, and then turn it
off.
3. Wait a few minutes until the oil settles, and then check the oil level
through the check window located
at the bottom-right side of the
crankcase.
6-11
NOTE:
The engine oil should be between the
minimum and maximum level marks.
1
2
3
1. Engine oil level check window
2. Maximum level mark
3. Minimum level mark
4. If the engine oil is below the minimum level mark, add sufficient oil
of the recommended type to raise
it to the correct level.
To change the engine oil (with or
without oil filter element cleaning)
1. Start the engine, warm it up for
several minutes, and then turn it
off.
2. Place an oil pan under the engine
to collect the used oil.
PERIODIC MAINTENANCE AND MINOR REPAIR
3. Remove the engine oil filler cap
and drain bolt to drain the oil from
the crankcase.
bolt, the O-ring, compression
spring, and oil strainer will fall out.
Take care not to lose these parts.
3
1
1
2
2(×2)
1
3
2
1. Engine oil filler cap
1. O-ring
2. Compression spring
3. Oil strainer
NOTE:
Skip steps 4–9 if the oil filter element is
not being cleaned.
4. Remove the oil filter element drain
bolt to drain the oil from the oil filter
element.
1
6
8
2
9
1. Oil filter element
2. O-ring
6-12
5
7
ECA11000
CAUTION:
When removing the engine oil drain
4
5. Remove the oil filter element cover
by removing the bolts.
6. Remove the oil filter element and
O-rings.
1
1. Engine oil drain bolt
3
1. Oil filter element cover
2. Bolt
3. Oil filter element drain bolt
2
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
5
6
7
8
9
7. Check the O-ring for damage and
replace it if necessary.
8. Clean the oil filter element with solvent, and then install it.
NOTE:
Check the oil filter element for damage
and replace it if necessary.
9. Install the oil filter element cover by
installing the bolts and the drain
bolt, then tightening them to the
specified torques.
Tightening torques:
Oil filter element cover bolt:
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Oil filter element drain bolt:
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
NOTE:
Make sure that the O-rings are properly
seated.
10. Clean the oil strainer with solvent,
and then check it for damage and
replace it if necessary.
11. Install the oil strainer, compression
spring, O-ring and engine oil drain
bolt, and then tighten the drain bolt
to the specified torque.
●
Tightening torque:
Engine oil drain bolt:
43 Nm (4.3 m·kgf, 31 ft·lbf)
12. Add the specified amount of the
recommended engine oil, and then
install and tighten the oil filler cap.
Recommended engine oil:
See page 8-1.
Oil quantity:
Without oil filter element removal:
1.00 L (1.06 US qt) (0.88 Imp.qt)
With oil filter element removal:
1.10 L (1.16 US qt) (0.97 Imp.qt)
ECA11620
CAUTION:
● In order to prevent clutch slippage (since the engine oil also
lubricates the clutch), do not
mix any chemical additives. Do
not use oils with a diesel specification of “CD” or oils of a
higher quality than specified. In
addition, do not use oils labeled “ENERGY CONSERVING
6-13
II” or higher.
Make sure that no foreign material enters the crankcase.
13. Start the engine, and then let it idle
for several minutes while checking
it for oil leakage. If oil is leaking, immediately turn the engine off and
check for the cause.
14. Turn the engine off, and then
check the oil level and correct it if
necessary.
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU20820
Cleaning the air filter element
and check hose
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. In addition, the air
filter check hose must be frequently
checked and cleaned if necessary.
To clean the air filter element
1. Remove panel A. (See page 6-8.)
2. Remove the air filter case cover by
removing the screws.
4. Remove the sponge material from
the air filter element frame, clean it
with solvent, and then squeeze the
remaining solvent out.
1
2
1. Sponge material
2. Air filter element frame
2(×2)
1. Air filter case cover
2. Screw
NOTE:
The sponge material should be wet but
not dripping.
Recommended oil:
Yamaha foam air filter oil or other
quality air filter oil
1
2(×2)
material, and then squeeze the excess oil out.
5. Apply oil of the recommended type
to the entire surface of the sponge
3. Pull the air filter element out.
6-14
6. Pull the sponge material over the
air filter element frame.
7. Insert the element into the air filter
case.
2
3
4
5
ECA10480
CAUTION:
● Make sure that the air filter element is properly seated in the
air filter case.
● The engine should never be operated without the air filter element installed, otherwise the
piston(s) and/or cylinder(s) may
become excessively worn.
8. Install the air filter case cover by installing the screws.
9. Install the panel.
6
7
8
9
PERIODIC MAINTENANCE AND MINOR REPAIR
To clean the air filter check hose
1. Check the hose at the bottom of
the air filter case for accumulated
dirt or water.
1
EAU21233
Cleaning the spark arrester
The spark arrester should be cleaned
at the intervals specified in the Periodic
maintenance and lubrication chart.
EWA10980
2
●
3
1
4
5
6
7
8
1. Air filter check hose
2. If dirt or water is visible, remove
the hose, clean it, and then install
it.
●
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.
2
1
1. Muffler
2. Screw
2. Tap the tailpipe lightly, and then
use a wire brush to remove any
carbon deposits from the spark arrester portion of the tailpipe.
1. Remove the tailpipe by removing
the screw, and then pulling it out of
the muffler.
1
9
2
1. Tailpipe
2. Spark arrester
6-15
PERIODIC MAINTENANCE AND MINOR REPAIR
3. Insert the tailpipe into the muffler,
and then install and tighten the
screw.
NOTE:
Make sure to align the screw holes
when inserting the tailpipe.
EAU21250
Adjusting the carburetor
The carburetor is an important part of
the engine and its emission control system, which requires very sophisticated
adjustment. Therefore, carburetor adjustments should be left to Yamaha
dealer, who has the necessary professional knowledge and experience.
EAU21380
Adjusting the throttle cable
free play
2
1
3
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, have a Yamaha dealer adjust it.
5
6
7
8
9
6-16
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU21400
1
2
3
EAU21571
Adjusting the valve clearance
Tires
The valve clearance changes with use,
resulting in improper air-fuel mixture
and/or engine noise. To prevent this
from occurring, the valve clearance
must be adjusted by a Yamaha dealer
at the intervals specified in the periodic
maintenance and lubrication chart.
To maximize the performance, durability, and safe operation of your motorcycle, note the following points regarding
the specified tires.
Tire air pressure
The tire air pressure should be checked
and, if necessary, adjusted before each
ride.
EWA10500
4
●
5
6
7
8
9
●
WARNING
The tire air pressure must be
checked and adjusted on cold
tires (i.e., when the temperature
of the tires equals the ambient
temperature).
The tire air pressure must be adjusted in accordance with the
riding speed and with the total
weight of rider, passenger, cargo, and accessories approved
for this model.
6-17
Tire air pressure (measured on cold
tires):
0–90 kg (0–198 lb) :
Front:
125 kPa (18 psi) (1.25 kgf/cm2)
Rear:
125 kPa (18 psi) (1.25 kgf/cm2)
90–179 kg (198–395 lb) (CAL)
90–180 kg (198–397 lb) (U49) :
Front:
150 kPa (22 psi) (1.50 kgf/cm2)
Rear:
175 kPa (25 psi) (1.75 kgf/cm2)
Maximum load*:
179 kg (395 lb) (CAL)
180 kg (397 lb) (U49)
* Total weight of rider, passenger, cargo and accessories
EWA10530
WARNING
Proper loading of your motorcycle
is important for several characteristics of your motorcycle; such as
handling, braking, performance and
safety. Do not carry loosely packed
items that can shift. Securely pack
your heaviest items close to the
center of the motorcycle, and distribute the weight evenly from side
PERIODIC MAINTENANCE AND MINOR REPAIR
to side. Check the condition and
pressure of your tires. NEVER
OVERLOAD YOUR MOTORCYCLE.
Make sure the total weight of the
cargo, rider, passenger, 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.
Tire inspection
ride. If the tire shows crosswise lines
(minimum tread depth), if the tire has a
nail or glass fragments in it, or if the
sidewall is cracked, have a Yamaha
dealer replace the tire immediately.
Minimum tire tread depth (front and
rear):
1.0 mm (0.04 in)
NOTE:
The tire tread depth limits may differ
from country to country. Always comply
with the local regulations.
Yamaha Motor Co., Ltd.
Front tire:
Size:
130/80-18M/C 66P
Manufacturer/model:
BRIDGESTONE/TW31
Rear tire:
Size:
180/80-14M/C 78P
Manufacturer/model:
BRIDGESTONE/TW34
●
EWA10460
1
2
1. Tire sidewall
2. Tire wear indicator
3. Tire tread depth
The tires must be checked before each
●
●
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
6-18
3
EWA10560
Tire information
This motorcycle is equipped with tube
tires.
3
2
●
●
WARNING
It is dangerous to ride with a
worn-out tire. When a tire tread
begins to show crosswise lines,
have a Yamaha dealer replace
the tire immediately.
The replacement of all wheeland brake-related parts, including the tires, should be left to a
Yamaha dealer, who has the
necessary professional knowledge and experience.
It is not recommended to patch
a punctured tube. If unavoidable, however, patch the tube
4
5
6
7
8
9
PERIODIC MAINTENANCE AND MINOR REPAIR
very carefully and replace it as
soon as possible with a
high-quality product.
1
2
3
4
5
6
7
8
9
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.
6-19
EAU22011
Accessories and replacement
parts
EWA10621
WARNING
This vehicle is not designed to pull a
trailer or to be attached to a sidecar.
The accessories or replacement
parts you choose for your vehicle
should be designed specifically for
this model, and they must be securely mounted to maintain the inherent stability of the original
design. Genuine Yamaha Parts and
Accessories are designed and tested to be compatible with your vehicle. Please consider Genuine
Yamaha Parts and Accessories before making a purchase. Use of
non-Yamaha-approved accessories
or replacement parts may cause
loss of handling stability and riding
safety. Since Yamaha cannot control the quality of accessories or
parts manufactured by other companies, Yamaha cannot be held liable
for any consequences caused by
PERIODIC MAINTENANCE AND MINOR REPAIR
the use of items which have not
been approved by Yamaha.
EAU22041
Adjusting the clutch lever free
play
1 (a)
3
(b)
2
1. Locknut (clutch lever)
2. Adjusting bolt
3. Clutch lever free play
The clutch lever free play should measure 10.0–15.0 mm (0.39–0.59 in) as
shown. Periodically check the clutch lever free play and, if necessary, adjust it
as follows.
1. Loosen the locknut at the clutch lever.
2. To increase the clutch lever free
play, turn the adjusting bolt in direction (a). To decrease the clutch
lever free play, turn the adjusting
bolt in direction (b).
6-20
NOTE:
If the specified clutch lever free play
could be obtained as described above,
tighten the locknut and skip the rest of
the procedure, otherwise proceed as
follows.
3. Fully turn the adjusting bolt at the
clutch lever in direction (a) to loosen the clutch cable.
4. Loosen the locknut at the crankcase.
2
3
4
5
(a)
6
(b)
7
2 1
1. Locknut (crankcase)
2. Adjusting nut
5. To increase the clutch lever free
play, turn the adjusting nut in direction (a). To decrease the clutch le-
8
9
PERIODIC MAINTENANCE AND MINOR REPAIR
1
ver free play, turn the adjusting nut
in direction (b).
6. Tighten the locknut at the clutch lever and the crankcase.
EAU22092
Adjusting the brake lever free
play
EWA10630
●
3
1 2
2
3. Tighten the locknut.
(b)
●
3
(a)
4
5
6
7
8
9
1. Locknut
2. Adjusting bolt
3. Brake lever free play
The brake lever free play should measure 5.0–8.0 mm (0.20–0.31 in) as
shown. Periodically check the brake lever free play and, if necessary, adjust it
as follows.
1. Loosen the locknut at the brake lever.
2. To increase the brake lever free
play, turn the adjusting screw in direction (a). To decrease the brake
lever free play, turn the adjusting
screw in direction (b).
6-21
WARNING
After adjusting the brake lever
free play, check the free play
and make sure that the brake is
working properly.
A soft or spongy feeling in the
brake lever can indicate the
presence of air in the hydraulic
system. If there is air in the hydraulic system, have a Yamaha
dealer bleed the system before
operating the motorcycle. Air in
the hydraulic system will diminish the braking performance,
which may result in loss of control and an accident.
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU22192
Adjusting the brake pedal
position and free play
2. To raise the brake pedal, turn the
adjusting bolt in direction (a). To
lower the brake pedal, turn the adjusting bolt in direction (b).
pedal free play and, if necessary, adjust
it as follows.
2
3
1
1
(a)
1
1. Brake pedal position
EWA10670
WARNING
It is advisable to have a Yamaha
dealer make these adjustments.
Brake pedal position
The top of the brake pedal should be
positioned approximately 15.0 mm
(0.59 in) below the top of the footrest.
Periodically check the brake pedal position and, if necessary, adjust it as follows.
1. Loosen the locknut at the brake
pedal.
3
4
(b)
2
1. Brake pedal free play
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).
1. Locknut
2. Adjusting bolt
3. Brake pedal position
3. Tighten the locknut.
EWA11230
WARNING
After adjusting the brake pedal position, the brake pedal free play must
be adjusted.
Brake pedal free play
The brake pedal free play should measure 20.0–30.0 mm (0.79–1.18 in) as
shown. Periodically check the brake
6-22
5
6
7
8
9
PERIODIC MAINTENANCE AND MINOR REPAIR
(a) 1
EAU22270
EAU22380
Adjusting the rear brake light
switch
Checking the front brake pads
and rear brake shoes
(b)
1
2
1
3
(a)
1. Brake pedal free play adjusting nut
4
5
●
●
8
●
9
EAU22430
Front brake pads
EWA10680
6
7
2
(b)
The front brake pads and the rear brake
shoes must be checked for wear at the
intervals specified in the periodic maintenance and lubrication chart.
WARNING
After adjusting the drive chain
slack or removing and installing
the rear wheel, always check the
brake pedal free play.
If proper adjustment cannot be
obtained as described, have a
Yamaha dealer make this adjustment.
After adjusting the brake pedal
free play, check the operation of
the brake light.
1. Brake light switch
2. Adjusting nut
The rear brake light switch, which is activated by the brake pedal, is properly
adjusted when the brake light comes
on just before braking takes effect. If
necessary, adjust the brake light switch
as follows.
Turn the adjusting nut while holding the
rear brake light switch in place. To
make the brake light come on earlier,
turn the adjusting nut in direction (a). To
make the brake light come on later, turn
the adjusting nut in direction (b).
6-23
1(×3)
1. Brake pad wear indicator groove
Each front brake pad is provided with
wear indicator grooves, which allow
you to check the brake pad wear without having to disassemble the brake.
To check the brake pad wear, check
the wear indicator grooves. If a brake
pad has worn to the point that the wear
PERIODIC MAINTENANCE AND MINOR REPAIR
indicator grooves have almost disappeared, have a Yamaha dealer replace
the brake pads as a set.
shoes as a set.
EAU32343
Checking the front brake fluid
level
Insufficient brake fluid may allow air to
enter the brake system, possibly causing it to become ineffective.
Before riding, check that the brake fluid
is above the minimum level mark and
replenish if necessary. A low brake fluid
level may indicate worn brake pads
and/or brake system leakage. If the
brake fluid level is low, be sure to check
the brake pads for wear and the brake
system for leakage.
EAU22540
Rear brake shoes
1
2
2
3
4
5
6
1. Wear indicator
2. Wear limit line
The rear brake is provided with a wear
indicator, which allows you to check
the brake shoe wear without having to
disassemble the brake. To check the
brake shoe wear, check the position
of the wear indicator while applying
the brake. If a brake shoe has worn to
the point that the wear indicator
reaches the wear limit line, have a
Yamaha dealer replace the brake
1
7
8
9
1. Minimum level mark
Observe these precautions:
● When checking the fluid level,
6-24
PERIODIC MAINTENANCE AND MINOR REPAIR
1
●
2
3
make sure that the top of the master cylinder is level by turning the
handlebars.
Use only the recommended quality
brake fluid, otherwise the rubber
seals may deteriorate, causing
leakage and poor braking performance.
ually go down. However, if the
brake fluid level goes down suddenly, have a Yamaha dealer
check the cause.
Recommended brake fluid:
DOT 4
4
●
5
6
●
7
8
●
9
●
Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking performance.
Be careful that water does not enter the master cylinder when refilling. Water will significantly lower
the boiling point of the fluid and
may result in vapor lock.
Brake fluid may deteriorate painted surfaces or plastic parts. Always clean up spilled fluid
immediately.
As the brake pads wear, it is normal for the brake fluid level to grad6-25
EAU22720
Changing the brake fluid
Have a Yamaha dealer change the
brake fluid at the intervals specified in
the NOTE after the periodic maintenance and lubrication chart. In addition,
have the oil seals of the brake master
cylinder and caliper as well as the
brake hose replaced at the intervals
listed below or whenever they are damaged or leaking.
● Oil seals: Replace every two
years.
● Brake hose: Replace every four
years.
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU22760
1
Drive chain slack
The drive chain slack should be
checked before each ride and adjusted
if necessary.
(a)
2
EAU22770
To check the drive chain slack
1. Place the motorcycle on a level
surface and hold it in an upright position.
NOTE:
When checking and adjusting the drive
chain slack, the motorcycle should be
positioned straight up and there should
be no weight on it.
2. Shift the transmission into the neutral position.
3. Move the rear wheel by pushing
the motorcycle to locate the tightest portion of the drive chain, and
then measure the drive chain slack
as shown.
(b)
1
2
3
3
1. Drive chain slack
4. If the drive chain slack is incorrect,
adjust it as follows.
EAU22830
To adjust the drive chain slack
1. Loosen the brake pedal free play
adjusting nut.
1. Brake pedal free play adjusting nut
2. Axle nut
3. Adjusting plate
2. Loosen the axle nut.
3. To tighten the drive chain, turn the
adjusting plate on each side of the
swingarm in direction (a). To loosen the drive chain, turn the adjusting plate on each side of the
swingarm in direction (b), and then
push the rear wheel forward.
NOTE:
Make sure that both adjusting plates
are in the same position for proper
wheel alignment.
Drive chain slack:
35.0–60.0 mm (1.38–2.36 in)
6-26
4
5
6
7
8
9
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU23012
ECA10570
3
CAUTION:
Improper drive chain slack will overload the engine as well as other vital
parts of the motorcycle and can lead
to chain slippage or breakage. To
prevent this from occurring, keep
the drive chain slack within the
specified limits.
4
4. Tighten the axle nut to the specified torque.
1
2
5
6
7
8
9
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
Tightening torque:
Axle nut:
90 Nm (9.0 m·kgf, 65 ft·lbf)
5. Adjust the brake pedal free play.
(See page 6-22.)
EWA10660
WARNING
After adjusting the brake pedal free
play, check the operation of the
brake light.
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
6-27
oiled.
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU23090
EAU23110
EAU23131
Checking and lubricating the
cables
Checking and lubricating the
throttle grip and cable
Checking and lubricating the
brake and shift pedals
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 or
replaced at the intervals specified in the
periodic maintenance chart.
2
3
4
Recommended lubricant:
Yamaha Chain and Cable Lube
or engine oil SAE 10W-30 (API
SE)
The operation of the brake and shift
pedals should be checked before each
ride, and the pedal pivots should be lubricated if necessary.
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.
Recommended lubricant:
Lithium-soap-based
(all-purpose grease)
grease
5
6
7
8
9
6-28
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU23140
EAU23200
Checking and lubricating the
brake and clutch levers
Checking and lubricating the
sidestand
EAU23250
Lubricating
suspension
the
rear
1
2
1(×2)
3
4
5
6
7
8
9
The operation of the brake and clutch
levers should be checked before each
ride, and the lever pivots should be lubricated if necessary.
Recommended lubricant:
Lithium-soap-based
(all-purpose grease)
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.
1. Grease nipple
The pivoting points of the rear suspension must be lubricated at the intervals
specified in the periodic maintenance
and lubrication chart.
EWA10730
grease
WARNING
If the sidestand does not move up
and down smoothly, have a Yamaha
dealer check or repair it.
Recommended lubricant:
Lithium-soap-based
(all-purpose grease)
6-29
grease
Recommended lubricant:
Lithium-soap-based grease
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU23271
EAU23280
Checking the front fork
Checking the steering
The condition and operation of the front
fork must be checked as follows at the
intervals specified in the periodic maintenance and lubrication chart.
To check the condition
Worn or loose steering bearings may
cause danger. Therefore, the operation
of the steering must be checked as follows at the intervals specified in the periodic maintenance and lubrication
chart.
1. Place a stand under the engine to
raise the front wheel off the
ground.
EWA10750
WARNING
Securely support the vehicle so that
there is no danger of it falling over.
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.
ECA10590
CAUTION:
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or repair it.
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.
2
3
4
5
6
7
8
9
6-30
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU23290
1
2
3
EAU23361
Checking the wheel bearings
Battery
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.
A poorly maintained battery will corrode
and discharge quickly. The electrolyte
level, battery lead connections and
breather hose routing should be
checked before each ride and at the intervals specified in the periodic maintenance and lubrication chart.
To check the electrolyte level
1. Remove the seat. (See page 3-8.)
2. Disconnect the negative battery
lead from the battery.
3. Disconnect the positive battery
lead and the battery breather hose
from the battery.
4. Unhook the battery band, and then
pull the battery out of the battery
compartment.
4
5
6
7
8
9
6-31
PERIODIC MAINTENANCE AND MINOR REPAIR
4
●
1
5
1
lowing FIRST AID.
EXTERNAL: Flush with plenty
of water.
INTERNAL: Drink large quantities of water or milk and immediately call a physician.
EYES: Flush with water for 15
minutes and seek prompt
medical attention.
Batteries produce explosive hydrogen gas. Therefore, keep
sparks, flames, cigarettes, etc.,
away from the battery and provide sufficient ventilation when
charging it in an enclosed
space.
KEEP THIS AND ALL BATTERIES OUT OF THE REACH OF
CHILDREN.
3
●
2
2
●
1. Battery
2. Negative battery lead
3. Positive battery lead (red)
4. Battery breather hose
5. Battery band
5. Place the battery on a level surface, and then check the electrolyte level in the battery.
NOTE:
The electrolyte should be between the
minimum and maximum level marks.
●
1. Maximum level mark
2. Minimum level mark
6. If the electrolyte is at or below the
minimum level mark, add distilled
water to raise the electrolyte to the
maximum level mark.
EWA10760
●
WARNING
Electrolyte is poisonous and
dangerous since it contains sulfuric acid, which causes severe
burns. Avoid any contact with
skin, eyes or clothing and always shield your eyes when
working near batteries. In case
of contact, administer the fol-
●
ECA10610
CAUTION:
Use only distilled water, as tap water
contains minerals that are harmful
to the battery.
7. Place the battery in the battery
compartment, and then hook the
6-32
2
3
4
5
6
7
8
9
PERIODIC MAINTENANCE AND MINOR REPAIR
1
battery band onto the holder.
8. Connect the breather hose to the
battery and make sure that it is
properly routed.
2
1
3
4
5
1. Battery breather hose
6
1
7
2
8
9
1. Battery
2. Battery breather hose
9. Connect and tighten the positive
battery lead to the battery’s positive (+) terminal.
10. Connect and tighten the negative
battery lead to the battery’s negative (-) terminal.
11. Install the seat.
To store the battery
1. If the vehicle will not be used for
more than one month, remove the
battery, fully charge it, and then
place it in a cool, dry place.
2. If the battery will be stored for more
than two months, check the specific gravity of the electrolyte at least
once a month and fully charge the
battery whenever necessary.
3. Fully charge the battery before installation.
4. After installation, make sure that
the battery leads are properly connected to the battery terminals and
that the breather hose is properly
routed, in good condition, and not
obstructed.
ECA10600
CAUTION:
If the breather hose is positioned in
6-33
such a way that the frame is exposed to electrolyte or gas expelled
from the battery, the frame could
suffer structural and external damages.
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU23501
Replacing the fuse
The fuse holder is located behind panel
B. (See page 6-8.)
If the fuse is blown, replace it as follows.
1. Turn the key to “OFF” and turn off
all electrical circuits.
2. Remove the blown fuse, and then
install a new fuse of the specified
amperage.
2
EAU23811
ECA10640
CAUTION:
Do not use a fuse of a higher amperage rating than recommended to
avoid causing extensive damage to
the electrical system and possibly a
fire.
3. Turn the key to “ON” and turn on
the electrical circuits to check if the
devices operate.
4. If the fuse immediately blows
again, have a Yamaha dealer
check the electrical system.
Replacing the headlight bulb
This model is equipped with a quartz
bulb headlight. If the headlight bulb
burns out, replace it as follows.
1. Remove
cowling
A.
(See
page 6-8.)
2. Remove the headlight unit by removing the bolts.
2
3
4
5
1(×2)
6
7
1. Bolt
1
3. Disconnect the headlight coupler,
and then remove the headlight
bulb cover.
1. Fuse
2. Spare fuse
Specified fuse:
20.0 A
6-34
8
9
PERIODIC MAINTENANCE AND MINOR REPAIR
1
fected. Thoroughly clean off any dirt
and fingerprints on the headlight
bulb using a cloth moistened with alcohol or thinner.
1
2
1
2
1
3
4
5
6
7
8
9
1. Headlight coupler
2. Headlight bulb cover
4. Remove the headlight bulb holder
by turning it counterclockwise, and
then remove the defective bulb.
1. Headlight bulb holder
EWA10790
WARNING
Headlight bulbs get very hot. Therefore, keep flammable products away
from a lit headlight bulb, and do not
touch the bulb until it has cooled
down.
5. Place a new bulb into position, and
then secure it with the bulb holder.
ECA10660
CAUTION:
Do not touch the glass part of the
headlight bulb to keep it free from
oil, otherwise the transparency of
the glass, the luminosity of the bulb,
and the bulb life will be adversely af6-35
1. Do not touch the glass part of the bulb.
6. Install the bulb cover, and then
connect the coupler.
7. Install the headlight unit by installing the bolts.
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU24131
Replacing the tail/brake light
bulb
1
1. Remove the tail/brake light lens by
removing the screws.
2
1(×2)
3
8. Install the cowling.
9. Have a Yamaha dealer adjust the
headlight beam if necessary.
1. Tail/brake light bulb
3. Insert a new bulb into the socket,
push it in, and then turn it clockwise until it stops.
4. Install the lens by installing the
screws.
1. Screw
2. Remove the defective bulb by
pushing it in and turning it counterclockwise.
ECA10680
CAUTION:
Do not overtighten the screws, otherwise the lens may break.
4
5
6
7
8
9
6-36
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU24201
Replacing a turn signal light
bulb
1
1. Remove the turn signal light lens
by removing the screw.
ECA11190
CAUTION:
Do not overtighten the screw, otherwise the lens may break.
1
2
3
3
2
4
5
6
7
8
9
1. Screw
2. Bulb
3. Turn signal light lens
2. Remove the defective bulb by
pushing it in and turning it counterclockwise.
3. Insert a new bulb into the socket,
push it in, and then turn it clockwise until it stops.
4. Install the lens by installing the
screw.
6-37
EAU24350
Supporting the motorcycle
Since this model is not equipped with a
centerstand, follow these precautions
when removing the front and rear
wheel or performing other maintenance
requiring the motorcycle to stand upright. Check that the motorcycle is in a
stable and level position before starting
any maintenance. A strong wooden
box can be placed under the engine for
added stability.
To service the front wheel
1. Stabilize the rear of the motorcycle
by using a motorcycle stand or, if
an additional motorcycle stand is
not available, by placing a jack under the frame in front of the rear
wheel.
2. Raise the front wheel off the
ground by using a motorcycle
stand.
To service the rear wheel
Raise the rear wheel off the ground by
using a motorcycle stand or, if a motorcycle stand is not available, by placing
a jack either under each side of the
PERIODIC MAINTENANCE AND MINOR REPAIR
frame in front of the rear wheel or under
each side of the swingarm.
EAU24360
Front wheel
EAU24580
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. Disconnect the speedometer cable from the front wheel.
2. Loosen the axle nut.
1
according to the procedure on
page 6-37.
4. Remove the axle nut, pull the
wheel axle out, and then remove
the wheel.
ECA11070
CAUTION:
Do not apply the brake after the
wheel has been removed together
with the brake disc, otherwise the
brake pads will be forced shut.
EAU24981
To install the front wheel
1. Install the speedometer gear unit
into the wheel hub so that the projections mesh with the slots.
2
3
4
5
6
7
2
8
9
1. Speedometer cable
2. Axle nut
3. Lift the front wheel off the ground
6-38
1
1. Speedometer gear unit
PERIODIC MAINTENANCE AND MINOR REPAIR
2. Lift the wheel up between the fork
legs.
1
2
NOTE:
Make sure that there is enough space
between the brake pads before inserting the brake disc and that the slot in
the speedometer gear unit fits over the
retainer on the fork leg.
EAU25080
Tightening torque:
Axle nut:
90 Nm (9.0 m·kgf, 65 ft·lbf)
6. Connect the speedometer cable.
1
2
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. Loosen the axle nut.
2. Remove the brake pedal free play
adjusting nut, and then disconnect
the brake rod from the brake camshaft lever.
3. Turn the drive chain adjusting
plate on each side of the swingarm
fully in direction (a).
6
7
9
EWA10820
●
5
8
EAU25420
To remove the rear wheel
●
3
4
Rear wheel
1. Speedometer gear unit retainer
2. Speedometer cable
3. Insert the wheel axle, and then install the axle nut.
4. Lower the front wheel so that it is
on the ground.
5. Tighten the axle nut to the specified torque.
6-39
PERIODIC MAINTENANCE AND MINOR REPAIR
7. Remove the wheel.
2
3
4
EAU25761
To install the rear wheel
1. Insert the wheel axle from the
left-hand side.
5
(a)
1
1. Axle nut
2. Brake pedal free play adjusting nut
3. Brake rod
4. Brake camshaft lever
5. Drive chain slack adjusting plate
NOTE:
Make sure that the drive chain adjusting plates are installed with the
punched sides facing to the outside
and that the slot in the brake shoe plate
fits over the retainer on the swingarm.
4. Lift the rear wheel off the ground
according to the procedure on
page 6-37.
5. Remove the axle nut, and then pull
the wheel axle out.
6. Push the wheel forward, and then
remove the drive chain from the
rear sprocket.
NOTE:
The drive chain does not need to be
disassembled in order to remove and
install the wheel.
the rear wheel so that it is on the
ground.
4. Tighten the axle nut to the specified torque.
Tightening torque:
Axle nut:
90 Nm (9.0 m·kgf, 65 ft·lbf)
2
5. Install the brake rod onto the brake
camshaft lever, and then install the
brake pedal free play adjusting nut
onto the brake rod.
6. Adjust the brake pedal free play.
(See page 6-22.)
3
4
5
EWA10660
WARNING
After adjusting the brake pedal free
play, check the operation of the
brake light.
1
6
7
8
9
1. Retainer
2. Install the drive chain onto the rear
sprocket, and then adjust the drive
chain slack. (See page 6-26.)
3. Install the axle nut, and then lower
6-40
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU25850
Troubleshooting
1
2
3
4
5
6
7
8
9
Although Yamaha motorcycles receive
a thorough inspection before shipment
from the factory, trouble may occur during operation. Any problem in the fuel,
compression, or ignition systems, for
example, can cause poor starting and
loss of power.
The following troubleshooting 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.
6-41
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU25962
Troubleshooting chart
EWA10840
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.
2
The engine does not start.
Check the compression.
3
4
2. Compression
There is compression.
Check the ignition.
There is no compression.
Have a Yamaha dealer
check the vehicle.
Operate the
electric starter.
5
6
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 electric starter.
Have a Yamaha dealer check the vehicle.
The engine does not start.
Check the battery.
Remove the spark plug
and check the electrodes.
Dry
4. Battery
Operate the
electric starter.
The engine turns over
quickly.
The battery is good.
The engine turns over
slowly.
Check fluid, recharge,
check connections.
6-42
7
8
9
The engine does not start. Have a
Yamaha dealer check the vehicle.
MOTORCYCLE CARE AND STORAGE
EAU26000
Care
1
2
3
4
5
6
7
8
9
While the open design of a motorcycle
reveals the attractiveness of the technology, it also makes it more vulnerable. Rust and corrosion can develop
even if high-quality components are
used. A rusty exhaust pipe may go unnoticed on a car, however, it detracts
from the overall appearance of a motorcycle. Frequent and proper care does
not only comply with the terms of the
warranty, but it will also keep your motorcycle looking good, extend its life
and optimize its performance.
Before cleaning
1. Cover the muffler outlet with a
plastic bag after the engine has
cooled down.
2. Make sure that all caps and covers
as well as all electrical couplers
and connectors, including the
spark plug cap, are tightly installed.
3. Remove extremely stubborn dirt,
like oil burnt onto the crankcase,
with a degreasing agent and a
brush, but never apply such products onto seals, gaskets, sprockets, the drive chain and wheel
axles. Always rinse the dirt and degreaser off with water.
Cleaning
ECA10770
CAUTION:
● Avoid using strong acidic wheel
cleaners, especially on spoked
wheels. If such products are
used on hard-to-remove dirt, do
not leave the cleaner on the affected area any longer than instructed. Also, thoroughly rinse
the area off with water, immediately dry it, and then apply a corrosion protection spray.
● Improper cleaning can damage
windshields, cowlings, panels
and other plastic parts. Use only
a soft, clean cloth or sponge
with mild detergent and water to
clean plastic.
● Do not use any harsh chemical
products on plastic parts. Be
sure to avoid using cloths or
7-1
●
●
sponges which have been in
contact with strong or abrasive
cleaning products, solvent or
thinner, fuel (gasoline), rust removers or inhibitors, brake fluid, antifreeze or electrolyte.
Do not use high-pressure washers or steam-jet cleaners since
they cause water seepage and
deterioration in the following areas: seals (of wheel and swingarm bearings, fork and brakes),
electric components (couplers,
connectors,
instruments,
switches and lights), breather
hoses and vents.
For motorcycles equipped with
a windshield: Do not use strong
cleaners or hard sponges as
they will cause dulling or
scratching. Some cleaning compounds for plastic may leave
scratches on the windshield.
Test the product on a small hidden part of the windshield to
make sure that it does not leave
MOTORCYCLE CARE AND STORAGE
any marks. If the windshield is
scratched, use a quality plastic
polishing
compound
after
washing.
After normal use
Remove dirt with warm water, a mild
detergent, and a soft, clean sponge,
and then rinse thoroughly with clean
water. Use a toothbrush or bottlebrush
for hard-to-reach areas. Stubborn dirt
and insects will come off more easily if
the area is covered with a wet cloth for
a few minutes before cleaning.
After riding in the rain, near the sea or
on salt-sprayed roads
Since sea salt or salt sprayed on roads
during winter are extremely corrosive in
combination with water, carry out the
following steps after each ride in the
rain, near the sea or on salt-sprayed
roads.
NOTE:
Salt sprayed on roads in the winter may
remain well into spring.
1. Clean the motorcycle with cold wa-
ter and a mild detergent, after the
engine has cooled down.
ECA10790
CAUTION:
Do not use warm water since it increases the corrosive action of the
salt.
2. Apply a corrosion protection spray
on all metal, including chrome- and
nickel-plated, surfaces to prevent
corrosion.
After cleaning
1. Dry the motorcycle with a chamois
or an absorbing cloth.
2. Immediately dry the drive chain
and lubricate it to prevent it from
rusting.
3. Use a chrome polish to shine
chrome, aluminum and stainless-steel parts, including the exhaust system. (Even the thermally
induced discoloring of stainless-steel exhaust systems can be
removed through polishing.)
4. To prevent corrosion, it is recommended to apply a corrosion pro7-2
tection spray on all metal,
including chrome- and nickel-plated, surfaces.
5. Use spray oil as a universal cleaner to remove any remaining dirt.
6. Touch up minor paint damage
caused by stones, etc.
7. Wax all painted surfaces.
8. Let the motorcycle dry completely
before storing or covering it.
EWA10930
●
●
WARNING
Make sure that there is no oil or
wax on the brakes or tires. If
necessary, clean the brake
discs and brake linings with a
regular brake disc cleaner or acetone, and wash the tires with
warm water and a mild detergent.
Before operating the motorcycle test its braking performance
and cornering behavior.
ECA10800
CAUTION:
● Apply spray oil and wax spar-
2
3
4
5
6
7
8
9
MOTORCYCLE CARE AND STORAGE
●
1
2
3
4
5
6
7
8
9
●
ingly and make sure to wipe off
any excess.
Never apply oil or wax to any
rubber and plastic parts, but
treat them with a suitable care
product.
Avoid using abrasive polishing
compounds as they will wear
away the paint.
NOTE:
Consult a Yamaha dealer for advice on
what products to use.
EAU26150
Storage
Short-term
Always store your motorcycle in a cool,
dry place and, if necessary, protect it
against dust with a porous cover.
ECA10810
CAUTION:
● Storing the motorcycle in a
poorly ventilated room or covering it with a tarp, while it is still
wet, will allow water and humidity to seep in and cause rust.
● To prevent corrosion, avoid
damp cellars, stables (because
of the presence of ammonia)
and areas where strong chemicals are stored.
Long-term
Before storing your motorcycle for several months:
1. Follow all the instructions in the
“Care” section of this chapter.
2. For motorcycles equipped with a
fuel cock that has an “OFF” position: Turn the fuel cock lever to
“OFF”.
7-3
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
MOTORCYCLE CARE AND STORAGE
from the spark plug, and then
install the spark plug and the
spark plug cap.
EWA10950
WARNING
To prevent damage or injury from
sparking, make sure to ground the
spark plug electrodes while turning
the engine over.
6. Lubricate all control cables and the
pivoting points of all levers and
pedals as well as of the sidestand/
centerstand.
7. Check and, if necessary, correct
the tire air pressure, and then lift
the motorcycle so that both of its
wheels are off the ground. Alternatively, turn the wheels a little every
month in order to prevent the tires
from becoming degraded in one
spot.
8. Cover the muffler outlet with a
plastic bag to prevent moisture
from entering it.
9. Remove the battery and fully
charge it. Store it in a cool, dry
place and charge it once a month.
Do not store the battery in an excessively cold or warm place
[less than 0 °C (30 °F) or more
than 30 °C (90 °F)]. For more information on storing the battery,
see page 6-31.
NOTE:
Make any necessary repairs before
storing the motorcycle.
2
3
4
5
6
7
8
9
7-4
SPECIFICATIONS
1
2
3
4
5
6
Overall length:
2090 mm (82.3 in)
Overall width:
820 mm (32.3 in)
Overall height:
1120 mm (44.1 in)
Seat height:
790 mm (31.1 in)
Wheelbase:
1325 mm (52.2 in)
Ground clearance:
265 mm (10.43 in)
Minimum turning radius:
1900 mm (74.8 in)
Weight:
With oil and fuel:
126.0 kg (278 lb) (U49)
127.0 kg (280 lb) (CAL)
Engine:
7
8
9
Engine type:
Air cooled 4-stroke, SOHC
Cylinder arrangement:
Forward-inclined single cylinder
Displacement:
196.0 cm3 (11.96 cu.in)
Bore × stroke:
67.0 × 55.7 mm (2.64 × 2.19 in)
Compression ratio:
9.50 :1
Starting system:
Electric starter
Carburetor:
Lubrication system:
Wet sump
EAU26337
Dimensions:
Engine oil:
Type:
YAMALUBE 4, SAE10W30 or SAE20W40
0°
10°
30° 50° 70° 90° 110° 130°F
YAMALUBE 4 (10W30)
or SAE 10W30
YAMALUBE 4 (20W40)
or SAE 20W40
–20° –10°
0°
10° 20° 30° 40° 50°C
Recommended engine oil grade:
API service SE, SF, SG type or higher
Engine oil quantity:
Without oil filter element removal:
1.00 L (1.06 US qt) (0.88 Imp.qt)
With oil filter element removal:
1.10 L (1.16 US qt) (0.97 Imp.qt)
Air filter:
Air filter element:
Wet element
Fuel:
Recommended fuel:
Unleaded gasoline only
Fuel tank capacity:
7.0 L (1.85 US gal) (1.54 Imp.gal)
Fuel reserve amount:
1.7 L (0.45 US gal) (0.37 Imp.gal)
8-1
Manufacturer:
TEIKEI
Type x quantity:
MV28 x 1
Spark plug(s):
Manufacturer/model:
NGK/DR8EA
Manufacturer/model:
DENSO/X24ESR-U
Spark plug gap:
0.6–0.7 mm (0.024–0.028 in)
Clutch:
Clutch type:
Wet, multiple-disc
Transmission:
Primary reduction system:
Spur gear
Primary reduction ratio:
73/22 (3.318)
Secondary reduction system:
Chain drive
Secondary reduction ratio:
50/14 (3.571)
Transmission type:
Constant mesh 5-speed
Operation:
Left foot operation
Gear ratio:
1st:
34/12 (2.833)
2nd:
34/19 (1.789)
SPECIFICATIONS
3rd:
29/22 (1.318)
4th:
26/25 (1.040)
5th:
23/28 (0.821)
Chassis:
Frame type:
Diamond
Caster angle:
26.00 °
Trail:
95.0 mm (3.74 in)
Front tire:
Type:
With tube
Size:
130/80-18M/C 66P
Manufacturer/model:
BRIDGESTONE/TW31
Rear tire:
Type:
With tube
Size:
180/80-14M/C 78P
Manufacturer/model:
BRIDGESTONE/TW34
Loading:
Maximum load:
179 kg (395 lb) (CAL)
180 kg (397 lb) (U49)
* (Total weight of rider, passenger, cargo
and accessories)
Tire air pressure (measured on cold
tires):
Loading condition:
0–90 kg (0–198 lb)
Front:
125 kPa (18 psi) (1.25 kgf/cm2)
Rear:
125 kPa (18 psi) (1.25 kgf/cm2)
Loading condition:
90–179 kg (198–395 lb) (CAL)
90–180 kg (198–397 lb) (U49)
Front:
150 kPa (22 psi) (1.50 kgf/cm2)
Rear:
175 kPa (25 psi) (1.75 kgf/cm2)
Front wheel:
Wheel type:
Spoke wheel
Rim size:
18x2.50
Rear brake:
Type:
Drum brake
Operation:
Right foot operation
Front suspension:
Type:
Telescopic fork
Spring/shock absorber type:
Coil spring/oil damper
Wheel travel:
160.0 mm (6.30 in)
Rear suspension:
Type:
Swingarm (monocross)
Spring/shock absorber type:
Coil spring/gas-oil damper
Wheel travel:
150.0 mm (5.91 in)
2
3
4
5
6
Electrical system:
Rear wheel:
Ignition system:
C.D.I.
Charging system:
A.C. magneto
Wheel type:
Spoke wheel
Rim size:
14M/C x MT4.50
Battery:
Front brake:
Type:
Single disc brake
Operation:
Right hand operation
Recommended fluid:
DOT 4
8-2
Model:
GM7CZ-3D
Voltage, capacity:
12 V, 7.0 Ah
Headlight:
Bulb type:
Halogen bulb
7
8
9
SPECIFICATIONS
Bulb voltage, wattage x quantity:
1
2
3
4
5
Headlight:
12 V, 60 W/55.0 W × 1
Tail/brake light:
12 V, 8.0/27.0 W × 1
Front turn signal/position light:
12 V, 27 W/8.0 W × 2
Rear turn signal light:
12 V, 27.0 W × 2
Meter lighting:
12 V, 3.4 W × 1
Neutral indicator light:
12 V, 3.4 W × 1
High beam indicator light:
12 V, 3.4 W × 1
Turn signal indicator light:
12 V, 3.4 W × 1
Fuse:
6
Fuse:
20.0 A
7
8
9
8-3
CONSUMER INFORMATION
EAU26351
Identification numbers
EAU26390
Key identification number
Record the key identification number,
vehicle identification number and model label information in the spaces provided below for assistance when
ordering spare parts from a Yamaha
dealer or for reference in case the vehicle is stolen.
KEY IDENTIFICATION NUMBER:
1
1
2
3
1. Key identification number
VEHICLE
BER:
IDENTIFICATION
NUM-
EAU26400
Vehicle identification number
The key identification number is
stamped into the key. Record this number in the space provided and use it for
reference when ordering a new key.
1. Vehicle identification number
The vehicle identification number is
stamped into the steering head pipe.
Record this number in the space provided.
NOTE:
The vehicle identification number is
used to identify your motorcycle and
may be used to register your motorcycle with the licensing authority in your
area.
MODEL LABEL INFORMATION:
9-1
4
5
6
7
8
9
CONSUMER INFORMATION
EAU26460
Model label
1
2
1
3
4
5
6
1. Model label
The model label is affixed to the location shown. Record the information on
this label in the space provided. This information will be needed when ordering
spare parts from a Yamaha dealer.
7
8
9
9-2
CONSUMER INFORMATION
EAU26550
Reporting safety defects
If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately
inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Yamaha Motor Corporation,
U.S.A. If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group
of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in individual problems
between you, your dealer, or Yamaha Motor Corporation, U.S.A.
To contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1-800-424-9393 (or 366-0123 in Washington, D.C.
area) or write to: NHTSA, U.S. Department of Transportation, Washington, D.C. 20590. You can also obtain other information
about motor vehicle safety from the Hotline.
2
3
4
5
6
7
8
9
9-3
CONSUMER INFORMATION
EAU26560
Motorcycle noise regulation
1
2
3
4
5
6
TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED:
Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other
than for purposes of maintenance, repair, or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or (2) the use of
the vehicle after such device or element of design has been removed or rendered inoperative by any person.
“AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW”.
These acts include tampering with the following systems; i.e., modification, removal, etc.
Exhaust system
● Muffler
● Exhaust pipe
● Silencer
Intake system
● Air cleaner case
● Air cleaner element
● Intake duct
7
8
9
9-4
CONSUMER INFORMATION
EAU26611
Maintenance record
Copies of work orders and/or receipts for parts purchased and installed on your motorcycle will be required to document that
maintenance has been completed in accordance with the emissions warranty. The chart below is printed only as a reminder
that maintenance work is required. It is not acceptable proof of maintenance work.
Maintenance
interval
Date of
service
Servicing dealer
name and address
Mileage
600 mi
(1000 km) or
1 month
4000 mi
(6000 km) or
6 months
7000 mi
(11000 km) or
12 months
10000 mi
(16000 km) or
18 months
13000 mi
(21000 km) or
24 months
16000 mi
(26000 km) or
30 months
19000 mi
(31000 km) or
36 months
22000 mi
(36000 km) or
42 months
Remarks
2
3
4
5
6
7
8
9
9-5
CONSUMER INFORMATION
Maintenance
interval
1
2
3
Date of
service
Servicing dealer
name and address
Mileage
25000 mi
(41000 km) or
48 months
28000 mi
(46000 km) or
54 months
31000 mi
(51000 km) or
60 months
4
5
6
7
8
9
9-6
Remarks
CONSUMER INFORMATION
EAU26661
YAMAHA MOTOR CORPORATION, U.S.A. STREET AND ENDURO MOTORCYCLE LIMITED
WARRANTY
2
3
4
5
6
7
8
9
9-7
CONSUMER INFORMATION
1
2
3
4
5
6
7
8
9
9-8
CONSUMER INFORMATION
EAU26750
YAMAHA EXTENDED SERVICE (Y.E.S.)
Keep your Yamaha protected even after your warranty
expires with genuine Yamaha Extended Service (Y.E.S.).
In addition, Travel and Recreation Interruption Protection
(TRIP) is included at no extra cost. TRIP gives you up to
$150 reimbursement per occurrence for any reasonable
expenses you incur because your Yamaha needs
covered service: replacement vehicle rental, emergency
towing, phone calls, even food and lodging when you are
away from home. This superb coverage goes into effect
when you purchase Y.E.S., so it applies to any warranty
repairs as well as covered repairs during your entire
Y.E.S. plan period.
Y.E.S. is designed and administered by Yamaha Motor
Corporation to provide maximum owner satisfaction. You
get uninterrupted factory-backed coverage for extra
peace of mind.
Y.E.S. is flexible. You choose the plan that’s right for
you: 12 months, 24 months, 36 months or, on certain
models, even 48 months beyond your warranty period.
Y.E.S. is designed and administered by the same
Yamaha people who handle your warranty – and it
shows in the comprehensive coverage benefits. There
are no mileage limitations. Coverage isn’t limited to
“moving parts” or the “drive train” like many other plans.
And Y.E.S. covers manufacturing defects just like the
warranty. See the sample contract at your Yamaha
dealer to see how comforting uninterrupted factorybacked protection can be.
3
Y.E.S. coverage is honored at any authorized Yamaha
dealer nationwide.
4
Y.E.S. coverage is transferable to a new owner if you
sell or trade-in. That can make your Yamaha much more
valuable!
5
This excellent Y.E.S. plan coverage is only available to
Yamaha owners like you, and only while your Yamaha is still
within the Yamaha Limited Warranty period. So visit your
authorized Yamaha dealer to get all the facts. He can show
you how easy it is to protect your investment with Yamaha
Extended Service.
You don’t have to pay anything for covered repairs.
There’s no deductible to pay, and repairs aren’t
“pro-rated.” You don’t have any “out-of-pocket” expenses
for covered repairs.
2
6
7
8
9
9-9
CONSUMER INFORMATION
We urge you to act now. You’ll get the excellent benefits of
TRIP coverage right away, and you’ll rest easy knowing
you’ll have strong factory-backed protection even after your
Yamaha Limited Warranty expires.
1
2
3
A special note:
If visiting your dealer isn’t convenient, contact Yamaha with
your Primary ID number (your frame number). We’ll be
happy to help you get the Y.E.S. coverage you need.
Yamaha Service Marketing
P.O. Box 6555
Cypress, CA 90630
1-(866)-YES-EXTD (1-866-937-3983)
4
5
6
7
8
9
9-10
INDEX
A
E
Accessories and replacement parts ........6-19
Air filter element and check hose,
cleaning .................................................6-14
Engine break-in ......................................... 5-4
Engine oil and oil filter element ............... 6-11
Engine, starting a warm............................. 5-2
Engine stop switch .................................... 3-3
B
Battery .....................................................6-31
Brake and clutch levers, checking and
lubricating ..............................................6-29
Brake and shift pedals, checking and
lubricating ..............................................6-28
Brake fluid, changing ...............................6-25
Brake fluid level, checking .......................6-24
Brake lever ................................................3-4
Brake lever free play, adjusting ...............6-21
Brake pads and shoes, checking.............6-23
Brake pedal ...............................................3-5
Brake pedal position and free play,
adjusting ................................................6-22
D
Dimmer switch ...........................................3-3
Drive chain, lubricating ............................6-27
Drive chain slack .....................................6-26
Neutral indicator light ................................ 3-2
Noise regulation ........................................ 9-4
P
Parking ...................................................... 5-4
Part locations ............................................ 2-1
Pre-operation check list............................. 4-2
F
Front fork, checking................................. 6-30
Fuel ........................................................... 3-6
Fuel cock ................................................... 3-7
Fuel tank cap............................................. 3-5
Fuse, replacing........................................ 6-34
R
Rear brake light switch, adjusting ........... 6-23
Rear suspension, lubricating................... 6-29
S
H
Safety defects, reporting ........................... 9-3
Safety information ..................................... 1-1
Seat........................................................... 3-8
Shifting ...................................................... 5-2
Shift pedal ................................................. 3-4
Shock absorber ......................................... 3-9
Sidestand ................................................ 3-10
Sidestand, checking and lubricating........ 6-29
Spark plug, checking................................. 6-9
Specifications ............................................ 8-1
Speedometer unit...................................... 3-2
Starter (choke) knob.................................. 3-8
Starting and warming up a cold
engine ..................................................... 5-1
Start switch................................................ 3-3
Steering, checking................................... 6-30
Storage...................................................... 7-3
Supporting the motorcycle ...................... 6-37
Handlebar switches ................................... 3-3
Headlight bulb, replacing......................... 6-34
Helmet holder ............................................ 3-9
High beam indicator light........................... 3-2
Horn switch................................................ 3-3
I
C
Cables, checking and lubricating .............6-28
Canister (for California only) ....................6-11
Carburetor,adjusting ................................6-16
Care ...........................................................7-1
Carrier........................................................3-9
Cleaning the spark arrester .....................6-15
Clutch lever................................................3-4
Clutch lever free play, adjusting ..............6-20
Cowling and panels, removing and
installing ..................................................6-8
N
Identification numbers ............................... 9-1
Ignition circuit cut-off system ................... 3-11
Indicator lights ........................................... 3-2
K
Key identification number .......................... 9-1
L
Labels, location of ..................................... 1-5
Luggage strap holders............................. 3-10
M
Main switch/steering lock .......................... 3-1
Maintenance and lubrication, periodic....... 6-4
Maintenance, emission control system ..... 6-3
Maintenance, periodic ............................... 6-1
Maintenance record................................... 9-5
Model label ................................................ 9-2
T
Tail/brake light bulb, replacing ................ 6-36
Throttle cable free play, adjusting ........... 6-16
Throttle grip and cable, checking and
lubricating ............................................. 6-28
INDEX
Tires ........................................................ 6-17
Tool kit ...................................................... 6-1
Troubleshooting ...................................... 6-41
Troubleshooting chart ............................. 6-42
Turn signal indicator light .......................... 3-2
Turn signal light bulb, replacing .............. 6-37
Turn signal switch ..................................... 3-3
V
Valve clearance, adjusting ...................... 6-17
Vehicle identification number .................... 9-1
W
Warranty, extended................................... 9-9
Warranty, limited ....................................... 9-7
Wheel bearings, checking....................... 6-31
Wheel (front) ........................................... 6-38
Wheel (rear) ............................................ 6-39
Wheels .................................................... 6-19
5FY-9-17_hyoushi
5/7/04 8:24 AM
Page 1
OWNER’S MANUAL
TW200T1
TW200T1C
YAMAHA MOTOR CO., LTD.
PRINTED ON RECYCLED PAPER
PRINTED IN JAPAN
!
2002·5–0.6×1(E)
2004.6–0.8×1 !
(E)
LIT-11626-18-27
5FY-28199-17
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