PERIODIC MAINTENANCE AND ADJUSTMENT. Yamaha TT-R 230
Below you will find brief information for motorcycle TT-R 230. This motorcycle is designed for off-road use only, therefore, it is illegal to operate it on public streets, roads, or highways, even a dirt or gravel one. Off-road use on public lands may be illegal. The TT-R 230 is designed to carry the operator only. No passengers.
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UB6820E0.book Page 1 Wednesday, July 9, 2014 10:50 AM
7
PERIODIC MAINTENANCE AND ADJUSTMENT
EAU39945
Periodic maintenance chart for the emission control system
TIP
From 7000 km (4200 mi) or 18 months, repeat the maintenance intervals starting from 3000 km (1800 mi) or 6 months.
Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
No.
ITEM CHECKS AND MAINTENANCE JOBS
1
2
3
4
*
*
Valve clearance
Air filter element
5 *
Crankcase breather system
6
7
8
9
*
*
*
Fuel line
Spark plug
Carburetor
Exhaust system
Spark arrester
Engine oil
• Check fuel hoses for cracks or damage.
• Replace if necessary.
• Check condition.
• Adjust gap and clean.
• Check and adjust valve clearance when engine is cold.
• Clean with solvent.
• Replace if necessary.
• Check ventilation hose for cracks or damage and drain any deposits.
• Replace if necessary.
• Check engine idling speed and starter operation.
• Adjust if necessary.
• Check for leakage.
• Tighten if necessary.
• Replace gasket(s) if necessary.
• Clean.
• Change (warm engine before draining).
INITIAL
1000 km
(600 mi) or
1 month or
30 hours
√
√
√
ODOMETER READINGS
3000 km
(1800 mi) or
6 months or
90 hours
5000 km
(3000 mi) or
12 months or
150 hours
√ √
√
√
√
√
√
√
√
√
√
√
√
√
√
√
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UB6820E0.book Page 2 Wednesday, July 9, 2014 10:50 AM
No.
ITEM
PERIODIC MAINTENANCE AND ADJUSTMENT
CHECKS AND MAINTENANCE JOBS
10 Engine oil filter element
• Clean.
• Check engine oil level and for leakage.
INITIAL
1000 km
(600 mi) or
1 month or
30 hours
√
ODOMETER READINGS
3000 km
(1800 mi) or
6 months or
90 hours
5000 km
(3000 mi) or
12 months or
150 hours
√ √
7
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UB6820E0.book Page 3 Wednesday, July 9, 2014 10:50 AM
7
PERIODIC MAINTENANCE AND ADJUSTMENT
EAU3534D
General maintenance and lubrication chart
TIP
From 7000 km (4200 mi) or 18 months, repeat the maintenance intervals starting from 3000 km (1800 mi) or 6 months.
Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
No.
1 * Clutch
ITEM
2 * Front brake
CHECKS AND MAINTENANCE JOBS
INITIAL
1000 km
(600 mi) or
1 month or
30 hours
√
√
ODOMETER READINGS
3000 km
(1800 mi) or
6 months or
90 hours
√
√
Whenever worn to the limit
5000 km
(3000 mi) or
12 months or
150 hours
√
√
3 * Rear brake
4 * Brake hoses
5 * Brake fluid
6 * Wheels
7 * Tires
• Check operation.
• Adjust if necessary.
• Check operation, fluid level, and for fluid leakage.
• Replace brake pads.
• Check operation.
• Adjust brake pedal free play and replace brake shoes if necessary.
• Check for cracks or damage.
• Check for correct routing and clamping.
• Replace.
• 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.
√
√
√
√
Every 4 years
Every 2 years
√
√
√
√
√
√
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UB6820E0.book Page 4 Wednesday, July 9, 2014 10:50 AM
No.
ITEM
PERIODIC MAINTENANCE AND ADJUSTMENT
CHECKS AND MAINTENANCE JOBS
INITIAL
1000 km
(600 mi) or
1 month or
30 hours
ODOMETER READINGS
3000 km
(1800 mi) or
6 months or
90 hours
5000 km
(3000 mi) or
12 months or
150 hours
√ √
√ √
8 *
9 * Swingarm pivot bearings
10
11 *
12 *
13
14
15
16
17
18 *
19 *
Wheel bearings
Drive chain
Steering bearings
Chassis fasteners
Brake lever pivot shaft
Brake pedal pivot shaft
Clutch lever pivot shaft
Shift pedal pivot shaft
Sidestand pivot
Front fork
Shock absorber assembly
• Check bearings for smooth operation.
• Replace if necessary.
• Check bearing assemblies for looseness.
• Moderately repack with lithium-soap-based grease.
• Check chain slack/alignment and condition.
• Adjust and lubricate chain with Yamaha chain lubricant or other suitable chain lubricant thoroughly.
• Check bearing assemblies for looseness.
• Moderately repack with lithium-soap-based grease.
• Check all chassis fitting and fasteners.
• Correct if necessary.
• Apply silicone grease lightly.
• Apply lithium-soap-based grease lightly.
• Apply lithium-soap-based grease (all-purpose grease) lightly.
• Apply lithium-soap-based grease (all-purpose grease) lightly.
• Check operation.
• Apply lithium-soap-based grease lightly.
• Check operation and for oil leakage.
• Replace if necessary.
• Check operation and for oil leakage.
• Replace if necessary.
√
√
√
Every ride
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
7
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UB6820E0.book Page 5 Wednesday, July 9, 2014 10:50 AM
PERIODIC MAINTENANCE AND ADJUSTMENT
No.
ITEM CHECKS AND MAINTENANCE JOBS
20 *
Rear suspension link pivots
21 *
22 *
Control cables
Throttle grip
• Check operation.
• Lubricate with lithium-soap-based grease.
• Apply Yamaha cable lubricant or other suitable cable lubricant thoroughly.
• Check operation.
• Check throttle grip free play, and adjust if necessary.
• Lubricate cable and grip housing.
INITIAL
1000 km
(600 mi) or
1 month or
30 hours
√
ODOMETER READINGS
3000 km
(1800 mi) or
6 months or
90 hours
√
5000 km
(3000 mi) or
12 months or
150 hours
√
√
√ √
√ √ √
EAU40001
7 TIP
The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
7-5
UB6820E0.book Page 6 Wednesday, July 9, 2014 10:50 AM
PERIODIC MAINTENANCE AND ADJUSTMENT
EAU18752
Removing and installing the panel
The panel shown needs to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time the panel needs to be removed and installed.
1. Panel
Panel
EAU19211
To remove the panel
Remove the screws, and then take the panel off.
1. Bolt
2. Panel
To install the panel
Place the panel in the original position, and then install the screws.
EAU19623
Checking the spark plug
The spark plug is an important engine component, which should be checked periodically, preferably by a Yamaha dealer. Since heat and deposits will cause any spark plug to slowly erode, it 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.
The porcelain insulator around the center electrode of the spark plug should be a medium-to-light tan (the ideal color when the vehicle is ridden normally). If the spark plug shows a distinctly different color, the engine could be operating improperly. Do not attempt to diagnose such problems yourself. Instead, have a Yamaha dealer check the vehicle.
If the spark plug shows signs of electrode erosion and excessive carbon or other deposits, it should be replaced.
Specified spark plug:
NGK/DR8EA
7
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UB6820E0.book Page 7 Wednesday, July 9, 2014 10:50 AM
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PERIODIC MAINTENANCE AND ADJUSTMENT
Before installing a spark plug, the spark plug gap should be measured with a wire thickness gauge and, if necessary, adjusted to specification.
TIP
If a torque wrench is not available when installing a spark plug, a good estimate of the correct torque is 1/4–
1/2 turn past finger tight. However, the spark plug should be tightened to the specified torque as soon as possible.
EAUW0613
Engine oil and oil filter element
The engine oil level should be checked before each ride. In addition, the oil must be changed and the oil filter element cleaned at the intervals specified in the periodic maintenance and lubrication chart.
1. Spark plug gap
Spark plug gap:
0.6–0.7 mm (0.024–0.028 in)
Clean the surface of the spark plug gasket and its mating surface, and then wipe off any grime from the spark plug threads.
Tightening torque:
Spark plug:
18 Nm (1.8 m·kgf, 13 ft·lbf)
To check the engine oil level
1. Place the vehicle on a level surface and hold it in an upright position. A slight tilt to the side can result in a false reading.
2. Start the engine, warm it up for several minutes, and then turn it off.
3. Wait a few minutes until the oil settles, and then check the oil level through the check window located at the bottom-right side of the crankcase.
TIP
The engine oil should be between the minimum and maximum level marks.
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UB6820E0.book Page 8 Wednesday, July 9, 2014 10:50 AM
PERIODIC MAINTENANCE AND ADJUSTMENT
4. Remove the engine oil filler bolt and drain bolt to drain the oil from the crankcase. NOTICE: When removing the engine oil drain bolt, the O-ring, compression spring, and oil strainer will fall out. Take care not to lose these parts.
[ECA11002]
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. Place the vehicle on a level surface.
2. Start the engine, warm it up for several minutes, and then turn it off.
3. Place an oil pan under the engine to collect the used oil.
1. Engine oil filler bolt
5. Remove the oil filter element drain bolt to drain the oil from the oil filter element.
1. Engine oil drain bolt
2. O-ring
3. Compression spring
4. Oil strainer
TIP
Skip steps 5–9 if the oil filter element is not being cleaned.
6. Remove the oil filter element cover by removing the bolts.
7
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UB6820E0.book Page 9 Wednesday, July 9, 2014 10:50 AM
7
PERIODIC MAINTENANCE AND ADJUSTMENT
1. Oil filter element cover
2. Oil filter element drain bolt
7. Remove the oil filter element and
O-rings.
1. Oil filter element
2. O-ring
8. Check the O-rings for damage and replace them if necessary.
9. Clean the oil filter element with solvent, and then install it.
TIP
Check the oil filter element for damage and replace it if necessary.
10. Install the oil filter element cover by installing the bolts, then tightening them to the specified torque.
Tightening torques:
Engine oil drain bolt:
43 Nm (4.3 m·kgf, 31 ft·lbf)
Oil filter element drain bolt:
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
13. Refill with the specified amount of the recommended engine oil, and then install and tighten the engine oil filler bolt.
Tightening torque:
Oil filter element cover bolt:
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Recommended oil:
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)
TIP
Make sure that the O-rings are properly seated.
11. Install the engine oil drain bolt, and then tighten it to the specified torque.
12. Install the engine oil filter element drain bolt, and then tighten it to the specified torque.
TIP
Be sure to wipe off spilled oil on any parts after the engine and exhaust system have cooled down.
ECA11621
NOTICE
In order to prevent clutch slip- page (since the engine oil also lubricates the clutch), do not mix any chemical additives. Do not use oils with a diesel speci-
7-9
UB6820E0.book Page 10 Wednesday, July 9, 2014 10:50 AM fication of “CD” or oils of a higher quality than specified. In addition, do not use oils labeled
“ENERGY CONSERVING II” or higher.
Make sure that no foreign mate- rial enters the crankcase.
14. Start the engine, and then let it idle for several minutes while checking it for oil leakage. If oil is leaking, immediately turn the engine off and check for the cause.
15. Turn the engine off, and then check the oil level and correct it if necessary.
ECA11232
NOTICE
After changing the engine oil, make sure to check the oil pressure as described below.
Loosen the bleed bolt.
Start the engine and keep it idling until oil flows out. If no oil comes out after one minute, turn the engine off immediately so it will not seize. If this occurs, have a Yamaha dealer repair the vehicle.
PERIODIC MAINTENANCE AND ADJUSTMENT
After checking the oil pressure, tighten the bleed bolt to the specified torque.
1. Bleed bolt
Tightening torque:
Bleed bolt:
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
EAUW0634
Cleaning the air filter element
The air filter element should be cleaned at the intervals specified in the periodic maintenance and lubrication chart.
Clean the air filter element more frequently if you are riding in unusually wet or dusty areas.
1. Remove the air filter element case cover by removing the screws, and then pulling it outward and sliding it forward.
1. Air filter case cover
2. Bolt
2. Pull the air filter element out of the air filter case.
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UB6820E0.book Page 11 Wednesday, July 9, 2014 10:50 AM
PERIODIC MAINTENANCE AND ADJUSTMENT
7
1. Air filter element
3. Remove the wing nut and washer from the air filter element.
1. Nut
2. Washer
4. Remove the sponge material from the air filter element frame.
1. Sponge material
2. Air filter element frame
5. Clean the sponge material with solvent, and then squeeze the remaining solvent out. WARNING!
To avoid the risk of fire or explosion, do not use gasoline or solvents with a low flash point.
[EWAW0022]
NOTICE: To avoid damaging the foam material, handle it gently and carefully, and do not twist or wring it.
[ECA10512]
6. Apply oil of the recommended type to the entire surface of the sponge material, and then squeeze the excess oil out.
TIP
The sponge material should be wet but not dripping.
Recommended oil:
Yamaha foam air filter oil or other quality foam air filter oil
7. Pull the sponge material over the air filter element frame.
8. Install the washer and wing nut, and then insert the air filter element into the air filter case.
NOTICE: Make sure that the air filter element is properly seated
7-11
UB6820E0.book Page 12 Wednesday, July 9, 2014 10:50 AM
PERIODIC MAINTENANCE AND ADJUSTMENT 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.
[ECA10482]
9. Install the air filter case cover and screws.
EAU39931
Adjusting the carburetor
The carburetor is an important part of the engine and requires very sophisticated adjustment. Therefore, most carburetor adjustments should be left to a Yamaha dealer, who has the necessary professional knowledge and experience. The adjustment described in the following section, however, may be serviced by the owner as part of routine maintenance.
ECA10551
NOTICE
The carburetor has been set and extensively tested at the Yamaha factory. Changing these settings without sufficient technical knowledge may result in poor performance of or damage to the engine.
EAU21363
Adjusting the engine idling speed
The engine idling speed must be checked and, if necessary, adjusted as follows at the intervals specified in the periodic maintenance and lubrication chart.
TIP
A diagnostic tachometer is needed to make this adjustment.
1. Attach the tachometer to the spark plug lead.
2. Start the engine and warm it up for several minutes at 1000–2000 r/min while occasionally revving it to 4000–5000 r/min.
TIP
The engine is warm when it quickly responds to the throttle.
3. Check the engine idling speed and, if necessary, adjust it to specification by turning the throttle stop screw. To increase the engine idling speed, turn the screw in
7
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UB6820E0.book Page 13 Wednesday, July 9, 2014 10:50 AM
PERIODIC MAINTENANCE AND ADJUSTMENT direction (a). To decrease the engine idling speed, turn the screw in direction (b).
EAU21385
Checking the throttle grip free play
EAU21402
Valve clearance
The valve clearance changes with use, resulting in improper air-fuel mixture and/or engine noise. To prevent this from occurring, the valve clearance must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart.
7
1. Adjusting bolt
Engine idling speed:
1400–1600 r/min
TIP
If the specified idling speed cannot be obtained as described above, have a
Yamaha dealer make the adjustment.
1. Throttle grip free play
The throttle grip free play should measure 3.0–5.0 mm (0.12–0.20 in) at the inner edge of the throttle grip. Periodically check the throttle grip free play and, if necessary, have a Yamaha dealer adjust it.
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UB6820E0.book Page 14 Wednesday, July 9, 2014 10:50 AM
PERIODIC MAINTENANCE AND ADJUSTMENT
EAUW1835
Tires
Tires are the only contact between the vehicle and the road. Safety in all conditions of riding depends on a relatively small area of road contact. Therefore, it is essential to maintain the tires in good condition at all times and replace them at the appropriate time with the specified tires.
weight of rider, cargo, and accessories approved for this model.
Front:
100 kPa (1.00 kgf/cm², 15 psi)
Rear:
100 kPa (1.00 kgf/cm², 15 psi)
Tire air pressure
The tire air pressure should be checked and, if necessary, adjusted before each ride.
EWA10442
WARNING
Operation of this vehicle with improper tire pressure may cause severe injury or death from loss of control.
The tire air pressure must be checked and adjusted on cold tires (i.e., when the temperature of the tires equals the ambient temperature).
The tire air pressure must be adjusted in accordance with the riding speed and with the total
EWA10512
WARNING
Never overload your vehicle. Operation of an overloaded vehicle could cause an accident.
Tire inspection
1. Tire sidewall
2. Tire tread depth
1
2
7-14
The tires must be checked before each ride. If a tire tread depth reaches the specified limit, if the tire has a nail or glass fragments in it, or if the sidewall is cracked, have a Yamaha dealer replace the tire immediately.
Minimum tire tread depth (front and rear):
4.0 mm (0.16 in)
TIP
The tire tread depth limits may differ from country to country. Always comply with the local regulations.
Tire information
This motorcycle is equipped with spoke wheels and tube tires.
Tires age, even if they have not been used or have only been used occasionally. Cracking of the tread and sidewall rubber, sometimes accompanied by carcass deformation, is an evidence of ageing. Old and aged tires shall be checked by tire specialists to ascertain their suitability for further use.
7
UB6820E0.book Page 15 Wednesday, July 9, 2014 10:50 AM
7
PERIODIC MAINTENANCE AND ADJUSTMENT
EWA10462
WARNING
The front and rear tires should be of the same make and design, otherwise the handling characteristics of the vehicle may be different, which could lead to an accident.
After extensive tests, only the tires listed below have been approved for this model by Yamaha Motor da Amazônia
Ltda.
Front tire:
Size:
80/100-21 51R
Manufacturer/model:
PIRELLI/MT320H
Rear tire:
Size:
100/100-18 59R
Manufacturer/model:
PIRELLI/MT320
EWA10572
WARNING
Have a Yamaha dealer replace excessively worn tires. Besides being illegal, operating the motorcycle with excessively worn tires decreases riding stability and can lead to loss of control.
The replacement of all wheel- and brake-related parts, including the tires, should be left to a
Yamaha dealer, who has the necessary professional knowledge and experience.
It is not recommended to patch a punctured tube. If unavoidable, however, patch the tube very carefully and replace it as soon as possible with a highquality product.
Ride at moderate speeds after changing a tire since the tire surface must first be “broken in” for it to develop its optimal characteristics.
EAU21944
Spoke wheels
EWA10611
WARNING
The wheels on this model are not designed for use with tubeless tires.
Do not attempt to use tubeless tires on this model.
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, warpage or other damage, 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.
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UB6820E0.book Page 16 Wednesday, July 9, 2014 10:50 AM
PERIODIC MAINTENANCE AND ADJUSTMENT
EAU22036
Adjusting the clutch lever free play
1. Locknut (clutch lever)
2. Adjusting bolt
3. Locknut (clutch cable)
4. Adjusting nut
5. Clutch lever free play
The clutch lever free play should measure 10.0–15.0 mm (0.39–0.59 in) as shown. Periodically check the clutch lever free play and, if necessary, adjust it as follows.
1. Slide the rubber cover back at the clutch lever.
2. Loosen the locknut.
3. To increase the clutch lever free play, turn the clutch lever free play adjusting bolt in direction (a). To decrease the clutch lever free play, turn the adjusting bolt in direction (b).
TIP
If the specified clutch lever free play could be obtained as described above, skip steps 4–7.
4. Fully turn the adjusting bolt in direction (a) to loosen the clutch cable.
5. Loosen the locknut further down the clutch cable.
6. To increase the clutch lever free play, turn the clutch lever free play adjusting nut in direction (a). To decrease the clutch lever free play, turn the adjusting nut in direction (b).
7. Tighten the locknut at the clutch cable.
8. Tighten the locknut at the clutch lever, and then slide the rubber cover to its original position.
EAU37914
Checking the brake lever free play
1. Front brake lever free play
There should be no free play at the brake lever end. If there is free play, have a Yamaha dealer inspect the brake system.
EWA14212
WARNING
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 vehicle. Air in the hydraulic system will diminish the
7-16
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UB6820E0.book Page 17 Wednesday, July 9, 2014 10:50 AM
7
PERIODIC MAINTENANCE AND ADJUSTMENT braking performance, which may result in loss of control and an accident.
Adjusting the brake pedal
EAUW0653
height 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).
3. Tighten the locknut.
EWA11232
WARNING
After adjusting the brake pedal height, the brake pedal free play must be adjusted.
Brake pedal free play
1. Brake pedal position
2. Brake pedal free play
EWA10671
WARNING
It is advisable to have a Yamaha dealer make these adjustments.
Brake pedal height
The top of the brake pedal should be positioned approximately 3.0 mm (0.12
in) below the top of the footrest. Periodically check the brake pedal height and, if necessary, adjust it as follows.
1. Loosen the locknut at the brake pedal.
1. Adjusting bolt
2. Locknut
The brake pedal free play should measure 20.0–30.0 mm (0.79–1.18 in) as shown. Periodically check the brake pedal free play and, if necessary, adjust it as follows.
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UB6820E0.book Page 18 Wednesday, July 9, 2014 10:50 AM
PERIODIC MAINTENANCE AND ADJUSTMENT
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).
EAU22382
Checking the front brake pads and rear brake shoes
The front brake pads and the rear brake shoes must be checked for wear at the intervals specified in the periodic maintenance and lubrication chart.
touches the brake disc, have a
Yamaha dealer replace the brake pads as a set.
Rear brake shoes
EAU22541
EAU36891
Front brake pads
1. Adjusting bolt
EWAW0031
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.
1. Brake pad wear indicator groove
Each front brake pad is provided with wear indicators, which allows you to check the brake pad wear without having to disassemble the brake. To check the brake pad wear, check the position of the wear indicators while applying the brake. If a brake pad has worn to the point that a wear indicator almost
1. Brake shoe wear limit line
2. Brake shoe wear indicator
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 shoes as a set.
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7
PERIODIC MAINTENANCE AND ADJUSTMENT
EAU32346
Checking the brake fluid level
Before riding, check that the brake fluid is above the minimum level mark.
Check the brake fluid level with the top of the reservoir level. Replenish the brake fluid if necessary.
1. Lower level
Specified brake fluid:
DOT 4
EWA15991
WARNING
Improper maintenance can result in loss of braking ability. Observe these precautions:
Insufficient brake fluid may al- low air to enter the brake system, reducing braking performance.
Clean the filler cap before re- moving. Use only DOT 4 brake fluid from a sealed container.
Use only the specified brake flu- id; otherwise, the rubber seals may deteriorate, causing leakage.
Refill with the same type of brake fluid. Adding a brake fluid other than DOT 4 may result in a harmful chemical reaction.
Be careful that water does not enter the brake fluid reservoir when refilling. Water will significantly lower the boiling point of the fluid and may result in vapor lock.
ECA17641
NOTICE
Brake fluid may damage painted surfaces or plastic parts. Always clean up spilled fluid immediately.
As the brake pads wear, it is normal for the brake fluid level to gradually go down. A low brake fluid level may indicate worn brake pads and/or brake system leakage; therefore, be sure to check the brake pads for wear and the brake system for leakage. If the brake fluid level goes down suddenly, have a
Yamaha dealer check the cause before further riding.
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PERIODIC MAINTENANCE AND ADJUSTMENT
EAU22724
Changing the brake fluid
Have a Yamaha dealer change the brake fluid at the intervals specified in 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.
EAU22762
Drive chain slack
The drive chain slack should be checked before each ride and adjusted if necessary.
EAU22775
To check the drive chain slack
1. Place the motorcycle on the sidestand.
TIP
When checking and adjusting the drive chain slack, there should be no weight on the motorcycle.
2. Shift the transmission into the neutral position.
3. Measure the drive chain slack as shown.
Drive chain slack:
45.0–60.0 mm (1.77–2.36 in)
1. Drive chain slack
4. If the drive chain slack is incorrect, adjust it as follows.
To adjust the drive chain slack
EAUW0663
Consult a Yamaha dealer before adjusting the drive chain slack.
1. Loosen the brake pedal free play adjusting nut.
2. Loosen the axle nut.
3. To tighten the drive chain, turn the drive chain slack adjusting plate on each side of the swingarm in direction (a). To loosen the drive chain, turn the adjusting plate on each side of the swingarm in direction (b), and then push the rear wheel forward. NOTICE: Improp-
7-20
7
UB6820E0.book Page 21 Wednesday, July 9, 2014 10:50 AM
7
PERIODIC MAINTENANCE AND ADJUSTMENT er 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.
[ECA10572]
TIP
Make sure that both adjusting plates are in the same position for proper wheel alignment.
1. Adjusting nut
2. Adjusting plate
3. Axle nut
4. Tighten the axle nut to the specified torque.
Tightening torque:
Axle nut:
80 Nm (8.0 m·kgf, 58 ft·lbf)
5. Adjust the brake pedal free play.
6. Make sure that the drive chain pullers are in the same position, the drive chain slack is correct, and the drive chain moves smoothly.
EAU23026
Cleaning and lubricating the drive chain
The drive chain must be cleaned and lubricated at the intervals specified in the periodic maintenance and lubrication chart, otherwise it will quickly wear out, especially when riding in dusty or wet areas. Service the drive chain as follows.
ECA10584
NOTICE
The drive chain must be lubricated after washing the motorcycle, riding in the rain or riding in wet areas.
1. Clean the drive chain with kerosene and a small soft brush.
NOTICE: To prevent damaging the O-rings, do not clean the drive chain with steam cleaners, high-pressure washers or inappropriate solvents.
[ECA11122]
2. Wipe the drive chain dry.
3. Thoroughly lubricate the drive chain with a special O-ring chain lubricant. NOTICE: Do not use engine oil or any other lubricants for the drive chain, as they
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PERIODIC MAINTENANCE AND ADJUSTMENT may contain substances that could damage the O-rings.
[ECA11112]
EAU23098
Checking and lubricating the cables
The operation of all control cables and the condition of the cables should be checked before each ride, and the cables and cable ends should be lubricated if necessary. If a cable is damaged or does not move smoothly, have a Yamaha dealer check or replace it. WARNING! Damage to the outer 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.
[EWA10712]
Recommended lubricant:
Yamaha cable lubricant or other suitable cable lubricant
EAU23115
Checking and lubricating the throttle grip and cable
The operation of the throttle grip should be checked before each ride. In addition, the cable should be lubricated by a Yamaha dealer at the intervals specified in the periodic maintenance chart.
The throttle cable is equipped with a rubber cover. Make sure that the cover is securely installed. Even though the cover is installed correctly, it does not completely protect the cable from water entry. Therefore, use care not to pour water directly onto the cover or cable when washing the vehicle. If the cable or cover becomes dirty, wipe clean with a moist cloth.
7
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PERIODIC MAINTENANCE AND ADJUSTMENT
EAU23144
Checking and lubricating the brake and clutch levers
The operation of the brake and clutch levers should be checked before each ride, and the lever pivots should be lubricated if necessary.
Brake lever
EAU23185
Checking and lubricating the brake pedal
The operation of the brake pedal should be checked before each ride, and the pedal pivot should be lubricated if necessary.
EAU23203
Checking and lubricating the sidestand
7
Recommended lubricants:
Brake lever:
Silicone grease
Clutch lever:
Lithium-soap-based grease
Recommended lubricant:
Lithium-soap-based 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.
EWA10732
WARNING
If the sidestand does not move up and down smoothly, have a Yamaha dealer check or repair it. Otherwise, the sidestand could contact the ground and distract the operator, resulting in a possible loss of control.
Recommended lubricant:
Lithium-soap-based grease
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PERIODIC MAINTENANCE AND ADJUSTMENT
EAU23273
Checking the front fork
The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart.
To check the condition
Check the inner tubes for scratches, damage and excessive oil leakage.
To check the operation
1. Place the vehicle on a level surface and hold it in an upright position. WARNING! To avoid injury, securely support the vehicle so there is no danger of it falling over.
[EWA10752]
2. While applying the front brake, push down hard on the handlebars several times to check if the front fork compresses and rebounds smoothly.
ECA10591
NOTICE
If any damage is found or the front fork does not operate smoothly, have a Yamaha dealer check or repair it.
EAU23284
Checking the steering
Worn or loose steering bearings may cause danger. Therefore, the operation of the steering must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart.
1. Place a stand under the engine to raise the front wheel off the
ground. (See page 7-27 for more
information.) WARNING! To avoid injury, securely support the vehicle so there is no danger of it falling over.
[EWA10752]
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.
7
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PERIODIC MAINTENANCE AND ADJUSTMENT
EAU23292
Checking the wheel bearings
The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart. If there is play in the wheel hub or if the wheel does not turn smoothly, have a Yamaha dealer check the wheel bearings.
Battery
EAU23389
1. Battery
The battery is located behind panel.
This model is equipped with a VRLA
(Valve Regulated Lead Acid) battery.
There is no need to check the electrolyte or to add distilled water. However, the battery lead connections need to be checked and, if necessary, tightened.
EWA10761
WARNING
Electrolyte is poisonous and dangerous since it contains sulfuric acid, which causes severe burns. Avoid any contact with skin, eyes or clothing and al-
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PERIODIC MAINTENANCE AND ADJUSTMENT ways shield your eyes when working near batteries. In case of contact, administer the following FIRST AID.
• EXTERNAL: Flush with plenty of water.
• INTERNAL: Drink large quantities of water or milk and immediately call a physician.
• EYES: Flush with water for 15 minutes and seek prompt medical attention.
Batteries produce explosive hy- drogen gas. Therefore, keep sparks, flames, cigarettes, etc., away from the battery and provide sufficient ventilation when charging it in an enclosed space.
KEEP THIS AND ALL BATTER-
IES OUT OF THE REACH OF
CHILDREN.
ECA10621
NOTICE
Never attempt to remove the battery cell seals, as this would permanently damage the battery.
To charge the battery
Have a Yamaha dealer charge the battery as soon as possible if it seems to have discharged. Keep in mind that the battery tends to discharge more quickly if the vehicle is equipped with optional electrical accessories.
ECA16522
NOTICE
To charge a VRLA (Valve Regulated
Lead Acid) battery, a special (constant-voltage) battery charger is required. Using a conventional battery charger will damage the battery.
To store the battery
1. If the vehicle will not be used for more than one month, remove the battery, fully charge it, and then place it in a cool, dry place.
NOTICE: When removing the battery, be sure the key is turned to “OFF”, then disconnect the negative lead before disconnecting the positive lead.
[ECA16303]
2. If the battery will be stored for more than two months, check it at least once a month and fully charge it if necessary.
3. Fully charge the battery before installation. NOTICE: When installing the battery, be sure the key is turned to “OFF”, then connect the positive lead before connecting the negative lead.
[ECA16841]
4. After installation, make sure that the battery leads are properly connected to the battery terminals.
ECA16531
NOTICE
Always keep the battery charged.
Storing a discharged battery can cause permanent battery damage.
7
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7
PERIODIC MAINTENANCE AND ADJUSTMENT
EAUW0625
Replacing the fuse
Specified fuse:
10.0 A
3. Push the ignition switch to set it to
“ON”.
4. If the fuse immediately blows again, have a Yamaha dealer check the electrical system.
EAU24351
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.
1. Fuse
2. Spare fuse
The fuse holder is located behind pan-
If the fuse is blown, replace it as follows.
1. Push the ignition switch to set it to
“OFF”.
2. Remove the blown fuse, and then install a new fuse of the specified amperage. WARNING! Do not use a fuse of a higher amperage rating than recommended to avoid causing extensive damage to the electrical system and possibly a fire.
[EWA15132]
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
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PERIODIC MAINTENANCE AND ADJUSTMENT a jack either under each side of the frame in front of the rear wheel or under each side of the swingarm.
Front wheel
EAU24361
EAU56231
4. Pull the wheel axle out, and then remove the wheel. NOTICE: Do not apply the brake after the wheel and brake disc have been removed, otherwise the brake pads will be forced shut.
[ECA11073]
To remove the front wheel
EWA10822
WARNING
To avoid injury, securely support the vehicle so there is no danger of it falling over.
1. Loosen the axle nut.
2. Lift the front wheel off the ground according to the procedure in the previous section “Supporting the motorcycle”.
3. Remove the axle nut and washer.
To install the front wheel
1. Lift the wheel up between the fork legs.
TIP
Make sure that there is enough space between the brake pads before inserting the brake disc into the caliper.
2. Insert the wheel axle, and then install the washer and axle nut.
3. Lower the front wheel so that it is on the ground.
4. Tighten the axle nut to the specified torque.
1. Axle nut
Tightening torque:
Axle nut:
80 Nm (8.0 m·kgf, 58 ft·lbf)
5. Push down hard on the handlebar several times to check for proper fork operation.
7-28
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7
PERIODIC MAINTENANCE AND ADJUSTMENT
Rear wheel
EAU25081
EAU56600
2. Remove the brake pedal free play adjusting nut, and then disconnect the brake rod from the brake camshaft lever.
TIP
The drive chain does not need to be disassembled in order to remove and install the wheel.
7. Remove the wheel.
To remove the rear wheel
EWA10822
WARNING
To avoid injury, securely support the vehicle so there is no danger of it falling over.
1. Loosen the axle nut.
1. Adjusting nut
2. Brake rod
3. Brake camshaft lever
4. Axle nut
3. Turn the drive chain adjusting plate on each side of the swingarm fully in direction (a).
4. Lift the rear wheel off the ground according to the procedure on
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.
To install the rear wheel
1. Insert the wheel axle from the lefthand side.
TIP
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.
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PERIODIC MAINTENANCE AND ADJUSTMENT
2. Install the drive chain onto the rear sprocket, and then install the axle nut.
3. Adjust the drive chain slack. (See page 7-20.)
4. Lower the rear wheel so that it is on the ground.
5. Tighten the axle nut to the specified torque.
Tightening torque:
Axle nut:
80 Nm (8.0 m·kgf, 58 ft·lbf)
6. Install the brake rod onto the brake camshaft lever, and then install the brake pedal free play adjusting nut onto the brake rod.
7. Adjust the brake pedal free play.
EWA10661
WARNING
After adjusting the brake pedal free play, check the operation of the brake light.
EAU25852
Troubleshooting
Although Yamaha motorcycles receive a thorough inspection before shipment from the factory, trouble may occur during operation. Any problem in the fuel, compression, or ignition systems, for example, can cause poor starting and loss of power.
The following troubleshooting chart represents a quick and easy procedure for checking these vital systems yourself. However, should your motorcycle require any repair, take it to a Yamaha dealer, whose skilled technicians have the necessary tools, experience, and know-how to service the motorcycle properly.
Use only genuine Yamaha replacement parts. Imitation parts may look like Yamaha parts, but they are often inferior, have a shorter service life and can lead to expensive repair bills.
EWA15142
WARNING
When checking the fuel system, do not smoke, and make sure there are no open flames or sparks in the area, including pilot lights from water
7-30 heaters or furnaces. Gasoline or gasoline vapors can ignite or explode, causing severe injury or property damage.
7
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7
PERIODIC MAINTENANCE AND ADJUSTMENT
Troubleshooting chart
1. Fuel
Check the fuel level in the fuel tank.
2. Battery
Operate the electric starter.
3. Ignition
Remove the spark plug and check the electrodes.
4. Compression
Operate the electric starter.
There is enough fuel.
There is no fuel.
Check the battery.
Supply fuel.
The engine does not start.
Check the battery.
The engine turns over quickly.
The engine turns over slowly.
Wet
The battery is good.
Check the battery lead connections, and have a Yamaha dealer charge the battery if necessary.
Wipe off with a dry cloth and correct the spark plug gap, or replace the spark plug.
Dry Have a Yamaha dealer check the vehicle.
The engine does not start.
Check the ignition.
Open the throttle halfway and operate the electric starter.
The engine does not start.
Check the compression.
There is compression.
There is no compression.
The engine does not start.
Have a Yamaha dealer check the vehicle.
Have a Yamaha dealer check the vehicle.
EAU25905
7-31
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Key Features
- Off-road use only
- Single-track vehicle
- 6-speed constant-mesh transmission
- Starter (choke) for cold engine starting
- Spring preload adjusting nut
- Starting circuit cut-off system