A5-yoko Blank.fm Page 1 Tuesday, April 8, 2003 11:43 AMA5-yoko_Blank.fm Page 1 Tuesday, April 8, 2003 11:43 AM 54D-F8199-E0 OWNER’S MANUAL Read this manual carefully before operating

A5-yoko_Blank.fm Page 1 Tuesday, April 8, 2003 11:43 AM

54D-F8199-E0

OWNER’S MANUAL

Read this manual carefully before operating this vehicle.

SX-4 225

U5YPE0E0.book Page 2 Wednesday, February 23, 2005 4:22 PM

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

EAU46090


EAU10050

EWA10031

INTRODUCTIONEAU10102

Welcome to the Yamaha world of motorcycling!As the owner of the SCORPIO (54D), you are benefiting from Yamaha’s vast experience and newest technology regarding the design and manufacture of high-quality products, which have earned Yamaha a reputation for dependability.Please take the time to read this manual thoroughly, so as to enjoy all advantages of your SCORPIO (54D). The Owner'sManual does not only instruct you in how to operate, inspect and maintain your motorcycle, but also in how to safeguardyourself and others from trouble and injury.In addition, the many tips given in this manual will help keep your motorcycle in the best possible condition. If you have anyfurther questions, do not hesitate to contact your Yamaha dealer.The Yamaha team wishes you many safe and pleasant rides. So, remember to put safety first!Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most cur-rent product information available at the time of printing, there may be minor discrepancies between your motorcycle and thismanual. If there is any question concerning this manual, please consult a Yamaha dealer.

WARNING

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

IMPORTANT MANUAL INFORMATIONEAU10132

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

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

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

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

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

NOTICE:

TIP:

EAU10122

or death.

WARNING


IMPORTANT MANUAL INFORMATION

EAUN0020

SCORPIO (54D) OWNER’S MANUAL

©2010 by Yamaha Indonesia Motor Mfg 1st edition, October 2010

All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Indonesia Motor Manufacturing is expressly prohibited.

Printed in Indonesia

TABLE OF CONTENTSOPERATION AND IMPORTANT RIDING POINTS................................. 5-1

Starting and warming up a cold engine ................................. 5-1

Starting a warm engine .................. 5-2Shifting ........................................... 5-2Tips for reducing fuel

consumption ............................... 5-3Engine break-in .............................. 5-3Parking ........................................... 5-5General note .................................. 5-6

PERIODIC MAINTENANCE AND MINOR REPAIR ................................. 6-1

Owner’s tool kit ............................... 6-1Periodic maintenance and

lubrication chart .......................... 6-2Removing and installing the

cowlings and panel ..................... 6-5Checking the spark plug ................. 6-8Engine oil .................................... 6-10

Cleaning the air filter element ...... 6-12Adjusting the carburetor ............... 6-13Adjusting the engine idling

speed ........................................ 6-14Adjusting the throttle cable

free play .................................... 6-14Valve clearance ............................ 6-15Tires ............................................. 6-15Wheels ......................................... 6-17

Checking the brake lever free play .................................... 6-18

Adjusting the brake pedal free play .................................... 6-18

Adjusting the rear brake light switch ....................................... 6-19

Checking the front brake pads and rear brake shoes ...................... 6-19

Checking the front brake fluid level .................................. 6-20

Changing the brake fluid .............. 6-20Drive chain slack .......................... 6-21Cleaning and lubricating the

drive chain ................................ 6-23Checking and lubricating the

cables ....................................... 6-23Checking and lubricating the

throttle grip and cable ............... 6-23Lubricating the brake lever .......... 6-24Lubricating the brake pedal ......... 6-24Checking and lubricating the

centerstand and sidestand ....... 6-24Lubricating the

swingarm pivots ........................ 6-25Checking the front fork ................. 6-25Checking the steering .................. 6-26Checking the wheel bearings ....... 6-26Battery ......................................... 6-27Replacing the fuse ....................... 6-28


EAU10210

Engine oil filter element ................... 6-11

SAFETY INFORMATION ..................1-1

DESCRIPTION ..................................2-1Left view ...........................................2-1Right view.........................................2-2Controls and instruments.................2-3

INSTRUMENT AND CONTROL FUNCTIONS .......................................3-1

Main switch/steering lock ................3-1Key hole cover ................................3-2Indicator lights ................................3-2Speedometer unit ...........................3-2Fuel gauge ......................................3-3Handlebar switches ........................3-3Shift pedal .......................................3-4Brake lever .....................................3-4Brake pedal ....................................3-4Fuel tank cap ..................................3-5Fuel .................................................3-5Starter (choke) lever ........................3-6Kickstarter .......................................3-7Seat ................................................3-7Helmet holders ...............................3-8Storage compartment .....................3-8Sidestand ........................................3-8

PRE-OPERATION CHECKS ..............4-1Pre-operation check list ..................4-2

TABLE OF CONTENTS


Replacing the head light bulb ............ 6-29Replacing a front turn signal ligh bulb/Auxilliary bulb ......................... 6-29Replacing a rear turn signal/tail/

brake/light bulb .............................. 6-30

Rear wheel ......................................... 6-32Troubleshooting charts ..................... 6-35

MOTORCYCLE CARE AND STORAGE............................................ 7-1

Care .................................................. 7-1Storage ............................................. 7-3

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

CONSUMER INFORMATION .............. 9-1Identification numbers ....................... 9-1

Front wheel ....................................... 6-31


To close the keyhole coverTo close the keyhole coverTo close the keyhole coverTo close the keyhole coverTo close the keyhole coverTo close the keyhole coverTo close the keyhole coverTo close the keyhole coverTo close the keyhole coverTo close the keyhole coverTo close the keyhole coverTo close the keyhole coverTo close the keyhole coverTo close the keyhole coverTo close the keyhole coverTo close the keyhole coverTo close the keyhole coverTo close the keyhole coverTo close the keyhole coverTo close the keyhole coverTo close the keyhole coverTo close the keyhole coverTo close the keyhole coverTo close the keyhole coverTo close the keyhole coverTo close the keyhole coverTo close the keyhole coverTo close the keyhole coverTo close the keyhole coverTo close the keyhole coverTo close the keyhole coverTo close the keyhole coverTo close the keyhole coverTo close the keyhole coverTo close the keyhole coverTo close the keyhole coverTo close the keyhole coverTo close the keyhole coverTo close the keyhole coverTo close the keyhole coverTo close the keyhole coverTo close the keyhole coverTo close the keyhole coverTo close the keyhole coverTo close the keyhole coverTo close the keyhole cover

LOCATION OF IMPORTANT LABELSEAU10384

1-LOCATION OF IMPORTANT LABELS

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

EAU45762

1

1


1-1

SAFETY INFORMATION EAU10222

EAU10313 Safe Riding tersections are the most likelyBe a Responsible Owner

Perform the pre-operation checks each places for motorcycle accidentsAs the vehicle’s owner, you are respon-

time you use the vehicle to make sure it to occur.sible for the safe and proper operation

is in safe operating condition. Failure to • Ride where other motorists canof your motorcycle.

inspect or maintain the vehicle properly see you. Avoid riding in anotherMotorcycles are single-track vehicles.

increases the possibility of an accident motorist’s blind spot.Their safe use and operation are de-

or equipment damage. See page 5-1 ● Many accidents involve inexperi-pendent upon the use of proper riding

for a list of pre-operation checks. enced operators. In fact, many op-techniques as well as the expertise of

● This motorcycle is designed to erators who have been involved inthe operator. Every operator should

carry the operator and a passen- accidents do not even have a cur-know the following requirements before

ger. rent motorcycle license.riding this motorcycle.

● The failure of motorists to detect • Make sure that you are qualifiedHe or she should:

and recognize motorcycles in traf- and that you only lend your mo-● Obtain thorough instructions from

fic is the predominating cause of torcycle to other qualified opera-a competent source on all aspects

automobile/motorcycle accidents. tors.of motorcycle operation.

Many accidents have been • Know your skills and limits.● Observe the warnings and mainte-

caused by an automobile driver Staying within your limits maynance requirements in this Own-

who did not see the motorcycle. help you to avoid an accident.er’s Manual.

Making yourself conspicuous ap- • We recommend that you prac-● Obtain qualified training in safe

pears to be very effective in reduc- tice riding your motorcycleand proper riding techniques.

ing the chance of this type of where there is no traffic until you● Obtain professional technical ser-

accident. have become thoroughly famil-vice as indicated in this Owner’s

Therefore: iar with the motorcycle and all ofManual and/or when made neces-

• Wear a brightly colored jacket. its controls.sary by mechanical conditions.

• Use extra caution when you are ● Many accidents have beenapproaching and passing caused by error of the motorcyclethrough intersections, since in- operator. A typical error made by


SAFETY INFORMATION

1-2

1

the operator is veering wide on a ● Never ride under the influence of tem become very hot during or af-turn due to excessive speed or un- alcohol or other drugs. ter operation and can causedercornering (insufficient lean an- burns.gle for the speed). Protective apparel ● A passenger should also observe• Always obey the speed limit and The majority of fatalities from motorcy- the above precautions.

never travel faster than warrant- cle accidents are the result of head in-ed by road and traffic condi- juries. The use of a safety helmet is the Avoid Carbon Monoxide Poisoningtions. single most critical factor in the preven- All engine exhaust contains carbon

• Always signal before turning or tion or reduction of head injuries. monoxide, a deadly gas. Breathing car-changing lanes. Make sure that ● Always wear an approved helmet. bon monoxide can cause headaches,other motorists can see you. ● Wear a face shield or goggles. dizziness, drowsiness, nausea, confu-

● The posture of the operator and Wind in your unprotected eyes sion, and eventually death.passenger is important for proper could contribute to an impairment Carbon Monoxide is a colorless, odor-control. of vision that could delay seeing a less, tasteless gas which may be• The operator should keep both hazard. present even if you do not see or smell

hands on the handlebar and ● The use of a jacket, heavy boots, any engine exhaust. Deadly levels ofboth feet on the operator foot- trousers, gloves, etc., is effective carbon monoxide can collect rapidlyrests during operation to main- in preventing or reducing abra- and you can quickly be overcome andtain control of the motorcycle. sions or lacerations. unable to save yourself. Also, deadly

• The passenger should always ● Never wear loose-fitting clothes, levels of carbon monoxide can lingerhold onto the operator, the seat otherwise they could catch on the for hours or days in enclosed or poorlystrap or grab bar, if equipped, control levers, footrests, or wheels ventilated areas. If you experience anywith both hands and keep both and cause injury or an accident. symptoms of carbon monoxide poison-feet on the passenger footrests. ● Always wear protective clothing ing, leave the area immediately, getNever carry a passenger unless that covers your legs, ankles, and fresh air, and SEEK MEDICAL TREAT-he or she can firmly place both feet. The engine or exhaust sys- MENT.feet on the passenger footrests.


SAFETY INFORMATION

1-3

1

● Do not run engine indoors. Even if guidelines to follow if loading cargo to attached to the motorcycle beforeyou try to ventilate engine exhaust your motorcycle: riding. Check accessory mountswith fans or open windows and The total weight of the operator, and cargo restraints frequently.doors, carbon monoxide can rap- passenger, accessories and cargo • Properly adjust the suspensionidly reach dangerous levels. must not exceed the maximum load for your load, and check the

● Do not run engine in poorly venti- limit. Operation of an overloaded ve- condition and pressure of yourlated or partially enclosed areas hicle could cause an accident. tires.such as barns, garages, or car- • Never attach any large or heavyports. Maximum load: items to the handlebar, front

● Do not run engine outdoors where 180 kg (397 lb) fork, or front fender. Theseengine exhaust can be drawn into items, including such cargo as

When loading within this weight limit,a building through openings such sleeping bags, duffel bags, or

keep the following in mind:as windows and doors. tents, can create unstable han-

● Cargo and accessory weightdling or a slow steering re-

should be kept as low and close toLoadingAdding accessories or cargo to yourmotorcycle can adversely affect stabili-ty and handling if the weight distributionof the motorcycle is changed. To avoidthe possibility of an accident, use ex-treme caution when adding cargo oraccessories to your motorcycle. Useextra care when riding a motorcyclethat has added cargo or accessories.Here, along with the information aboutaccessories below, are some general

sponse.the motorcycle as possible. Se-

● This vehicle is not designed tocurely pack your heaviest items as

pull a trailer or to be attached toclose to the center of the vehicle

a sidecar.as possible and make sure to dis-tribute the weight as evenly as Genuine Yamaha Accessories

Choosing accessories for your vehicleis an important decision. GenuineYamaha accessories, which are avail-able only from a Yamaha dealer, havebeen designed, tested, and approvedby Yamaha for use on your vehicle.

possible on both sides of the mo-torcycle to minimize imbalance orinstability.

● Shifting weights can create a sud-den imbalance. Make sure that ac-cessories and cargo are securely


SAFETY INFORMATION

1-4

1

Many companies with no connection toYamaha manufacture parts and acces-sories or offer other modifications forYamaha vehicles. Yamaha is not in aposition to test the products that theseaftermarket companies produce.Therefore, Yamaha can neither en-dorse nor recommend the use of ac-cessories not sold by Yamaha ormodifications not specifically recom-mended by Yamaha, even if sold andinstalled by a Yamaha dealer.

Aftermarket Parts, Accessories, andModificationsWhile you may find aftermarket prod-ucts similar in design and quality togenuine Yamaha accessories, recog-nize that some aftermarket accessoriesor modifications are not suitable be-cause of potential safety hazards toyou or others. Installing aftermarketproducts or having other modificationsperformed to your vehicle that changeany of the vehicle’s design or operation

You are responsible for injuries relatedto changes in the vehicle.Keep the following guidelines in mind,as well as those provided under “Load-ing” when mounting accessories.

● Never install accessories or carrycargo that would impair the perfor-mance of your motorcycle. Care-fully inspect the accessory beforeusing it to make sure that it doesnot in any way reduce groundclearance or cornering clearance,limit suspension travel, steeringtravel or control operation, or ob-scure lights or reflectors.• Accessories fitted to the handle-

bar or the front fork area cancreate instability due to improp-er weight distribution or aerody-namic changes. If accessoriesare added to the handlebar orfront fork area, they must be aslightweight as possible andshould be kept to a minimum.

namic effects. Wind may at-tempt to lift the motorcycle, orthe motorcycle may become un-stable in cross winds. These ac-cessories may also causeinstability when passing or be-ing passed by large vehicles.

• Certain accessories can dis-place the operator from his orher normal riding position. Thisimproper position limits the free-dom of movement of the opera-tor and may limit control ability,therefore, such accessories arenot recommended.

● Use caution when adding electri-cal accessories. If electrical acces-sories exceed the capacity of themotorcycle’s electrical system, anelectric failure could result, whichcould cause a dangerous loss oflights or engine power.

characteristics can put you and othersat greater risk of serious injury or death.

• Bulky or large accessories mayseriously affect the stability ofthe motorcycle due to aerody-


DESCRIPTION

2

EAU10420

Left view

2-1

1. Fuel cock (Page 3-7) 4.2. (Page 6-1) 5. Shift pedal (Page 3-5)3. (Page 3-10) 6.

Starter (choke) lever (Page 3-8)

Air filter element (Page 6-10)Helmet holderOwner’s tool kit

1 2 3

5 64

2-2


DESCRIPTIONEAU10410

Right view

2

7. Fuse (Page 6-32) 10.Engine oil level check window (Page 6-8)8. Kickstarter (Page 3-9) 11.Brake pedal (Page 3-6,6-18)9. Engine oil filter element (Page 6-8) 12.Battery (Page 6-30)

7 8

12 101111 9

DESCRIPTION

.


2

2-3

Controls and instrumentsEAU10430

1. Clutch lever (Page 3-5,6-17) 6. Right handlebar switches (Page 3-4)2. Left handlebar switches (Page 3-3) 7. Brake lever (Page 3-5,6-18)3. Speedometer unit (Page 3-2) 8. Throttle grip (Page 6-13,6-26)4. Main switch/steering lock (Page 3-1) 9. Fuek tank cap (Page 3-6)5. Tachometer/Fuel gauge (Page 3-3)

1 2 3 4 5 6 7

8

9


3-1

3

EAU1044H3-INSTRUMENT AND CONTROL FUNCTIONS

3

EAU10460

Main switch/steering lock To lock the steering

EAU10700

LOCKThe steering is locked, and all electricalsystems are off. The key can be re-moved.

1. Turn the handlebars all the way tothe left or right.

2. Push the key in from the “OFF” po-sition, and then turn it to "LOCK"while still pushing it.

3. Remove the key.

To unlock the steering

Push the key in to the main switch,

EWA10060

WWWARNIARNINGNGARNING

Never turn the key to “OFF” or“LOCK” while the vehicle is moving,otherwise the electrical systems willbe switched off, which may result inloss of control or an accident. Makesure that the vehicle is stopped be-fore turning the key to “OFF” or“LOCK”.

1. Push.2. Turn

The main switch/steering lock controlsthe ignition and lighting systems, and isused to lock the steering. The variouspositions are described below.

EAU37441 ONAll electrical systems are supplied withpower, and the meter lighting comeson, and the engine can be started. Thekey cannot be removed.

EAU10660

OFFAll electrical systems are off. The keycan be removed.

and then turn it to "OFF" while still pu-shing it.

WARNING

1. Push.2. Turn

XL01391

Line

INSTRUMENT AND CONTROL FUNCTIONS

3-2

3

EAU11080

High beam indicator light “ ”This indicator light comes on when thehigh beam of the headlight is switchedon.

EAU11040

Turn signal indicator light “ ”This indicator light flashes when theturn signal switch is pushed to the leftor right.


Speedometer unit EAU11630

1. Speedometer2. Odometer3. Tripmeter4. Reset knob

The speedometer unit is equipped witha speedometer, an odometer and trip-meter. The speedometer shows riding speed. The odometer shows the total distance traveled.The tripmeter shows the distance tra-veled since it was last set to zero withthe reset knob. The tripmeter can be used to estimate the distance that canbe traveled with a full tank of fuel. This information will enable you to planfuture fuel stops.

EAU10981

EAU11060

Neutral indicator light " "EAU11080

This indicator light comes on whenthe transmission is in the neutralposition.

Indicator lights

5

&

1. Turn signal indicator light " "2. Neutral indicator light "N" 3. High beam indicator light " "

1 2 3 1

1

2

3

4

xl01023


INSTRUMENT AND CONTROL FUNCTIONSTachometer

EAU11880

1. Tachometer 2. Red zone 3. Fuel gauge

The tachometer allows the rider to mo-nitor the engine speed and keep it wi-thin the ideal power range.

ECA10031

Do not operate the engine in the Tachometer red zone.Red zone: 10.000 r/min and above.

NOTICE :

121401214012140121401214012140

Fuel gauge EAU12140

The fuel gauge indicates the amount offuel in the fuel tank. The needle movestowards “E” (Empty) as the fuel leveldecreases. When the needle reachesWhen the needle reaches "E", refuelas soon as possible.

TIP:Do not allow the fuel tank to emptyitself completely.

Handlebar switches EAU12347

Left

EAU12590

:Light switch " / ' 1/ "Set this switch to “ '” to turn on the auxiliary light, meter lighting and tail-light. Set the switch to “:” to turn onthe headlight also. Set the switch to“1” to turn off all the lights.

Pass switch “ " EAU12350

Press this switch to flash the head-light.

45

1 2 3

1. Light switch2. Pass switch “&”3. Dimmer switch /4. Turn signal switch5. Horn switch “HORN”

: 1 /'/

3-3

3

1

2

3


3-4

3

Right

1. Engine stop switch " " 2. Start switch " "

Horn switch “HORN” EAU12500

Press this switch to sound the horn.

EAU12460

Turn signal switch “ / ” To signal a right-hand turn, push this 3switch to .“ ” To signal a left-handturn, push this switch to “ ”. When re-leased, the switch returns to the centerposition. To cancel the turn signallights, push the switch in after it has re-turned to the center position.

EAU12400

Dimmer switch “ / ” Set this switch to f“ ” or the highbeam and to for“ ” the low beam.

#/$

1

2

Engine stop switch “ EAU12660

#/$”Set this switch to “#” before startingthe engine. Set this switch to “$” tostop the engine in case of an emer-gency, such as when the motorcycleoverturns or when the throttle cable isstuck.

EAU12710

Start switch “,”Push this switch to crank the enginewith the starter.

ECA10050

CAUTION:

See page 5-1 for starting instructionprior starting the engine.

NOTICE :

Clutch leverEAU12850

1. Clutch lever

The clutch lever is located at the lefthandlebar grip. To disengage theclutch, pull the lever toward the han-dlebar grip. To engage the clutch,release the lever. The lever shouldbe pulled rapidly and released slowlyfor smooth clutch operation.

1


EAU12890

Brake lever

er

1. Brake lever 1. Brake pedal.

The brake lever is located at the right The brake pedal is on the right side ofhandlebar grip. To apply the front the motorcycle. To apply the rearbrake, pull the lever toward the handle- brake, press down on the brake pedal.bar grip.


3-5

3

EAU12941

Brake pedal

3

Shift pedal EAU12880

1. Shift pedalN. Neutral

The shift pedal is located on the leftside of the engine and is used incombination with the clutch leverwhen shifting the gears of the5-speed constant-mesh transmissionequipped on this motorcycle.

TIP:Use your toes or heel to shift up andyour toes to shift down.

11N2345

11

.


3-6

3

EAU13074Fuel tank cap


l)l)

EWA11091

WARNINGMake sure that the fuel tank cap isproperly closed after filling fuel.

insert the key into the lock and turn it 1/4 turn clockwise. The lock will bebe released and the fuel tank cap canbe opened.

1. Fuel tank cap lock cover a. Open

1. Push the fuel tank cap into the po-sition with the key inserted in the lock.

2. Turn the key counterclokwise to the original position, remove it, and then close the lock cover.

To close the fuel tank cap

TIP: The fuel tank cap cannot be closedunless the key is in the lock. In addition,the key cannot be removed if the capcap is not properly closed and locked.

Fuel EAU13212

1. Fuel tank filler tube2. Fuel level

Make sure there is sufficient gasolinein the tank.

EWA10881

WWWWARNIARNIARNIARNINGNGNGNGGasoline and gasoline vapors areextremely flammable. To avoid firesand explosions and to reduce therisk of injury when refueling, followthese instructions.

WARNING

b. Unlock

Open the fuel tank cap lock cover,

Leaking fuel is a fire hazard.

�

�

1


INSTRUMENT AND CONTROL FUNCTIONS1. Before refueling, turn off the engi-

ne and be sure that no one is sitt-ing on the vehicle. Never refuelwhile smoking, or while in thevicinity of sparks, open flames,or other sources of ignition suchas the pilot lights of water heatersand clothes dryers.

2. Do not overfill the fuel tank. Stopfilling when the fuel reaches thebottom of the filler tube. Becausefuel expands when it heats up,heat from the engine or the suncan cause fuel to spill out of thefuel tank.

3. Wipe up any spilled fuel immedia-tely. NOTICE: Immediately wipeoff spilled fuel with a clean. dry,soft cloth, since fuel may dete-riorate painted surfaces or plas-tic parts. [ECA10071]

4. Be sure to securely close the fueltank cap.

EWA15151

WWARNIARNINGNG

Gasoline is poisonous and can cau-se injury or death. Handle gasolinewith care. Never siphon gasolineby mouth. If you should awallowsome gasoline or inhale a lot of ga-soline vapor, or get some gasolinein your eyes, see your doctor imme-diately. If gasoline spills on your skin,wash with soap and water. If gaso-line spills on your clothing, changeyour clothes.

WARNING ECA11400

Use only unleaded gasoline. The useof leaded gasoline will cause severedamage to internal engine parts,such as the valves and piston rings,as well as to the exhaust system.

NOTICE :

EAU13242

Recommended fuel:Reguler unleaded gasoline only

Fuel tank capacity:Total amount:

13 LFuel reserve amount:

3.0 L

3-7

3



RES: R

eserve positionR

ES: Reserve position

RES: R

eserve positionR


RES: R

eserve positionR


RES: R

eserve positionR


RES: R

eserve positionR


RES: R

eserve positionR


RES: R

eserve positionR


RES: R

eserve positionR


RES: R

eserve positionR


RES: R

eserve positionR


RES: R

eserve positionR


RES: R

eserve positionR


RES: R

eserve positionR


RES: R

eserve positionR


RES: R

eserve positionR


RES: R

eserve positionR


RES: R

eserve positionR


RES: R

eserve positionR


RES: R

eserve positionR


RES: R

eserve positionR


RES: R

eserve positionR


RES: R

eserve positionR


RES: R

eserve positionR


RES: R

eserve positionR


RES: R

eserve positionR


RES: R

eserve positionR


RES: R

eserve positionR


RES: R

eserve positionR


RES: R

eserve position

Fuel cock EAU13561

ON: Normal position RES: Reserve positionOFF: Closed position RES

RES

RESRES OFF

FUEL OFFOFF ON

FUELFUEL ON

ON ON

OFFWhit the lever in this position, fuel willnot flow. Always return the lever tothis position when the engine is notrunning.

The fuel cock supplies fuel from thetank to carburetor whilw filtering italso.

The fuel cock has three positions:

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

RESThis indicates reserve. If you run outof fuel while riding, move the lever tothis position. Fill the tank at the first opportunity. Be sure to set the leverback to "ON" after refueling!

3-8

3


INSTRUMENT AND CONTROL FUNCTIONSEAU13590

Starter (choke) lever

Starting a cold engine requires a richerair-fuel mixture, which is supplied bythe starter (choke).Move the lever in direction (a) to turn onthe starter (choke).Move the lever in direction (b) to turn offthe starter (choke).

1b

a

.1 Starter (choke) lever “CHOKE”

1

21. Kickstarter2. Footrest

EAU13660

Kickstarter

3-9

3

To start the engine, fold the right foot-rest inward, and then fold out thekickstarter lever. Move it down lightly with your foot until the gears engage, and then push it down smoothly butforcefully. Fold the footrest outward to it original position.

This model is equipped with a primary kickstarter, allowing the engine to be started in any gear if the clutch isdisengaged. However, shifting thetransmission into the neutral positionbefore starting is recommended.


3-10


3

a. Unlock.

To remove the seat1. Insert the key into the seat lock, and

then turn it clockwise

2. Pull the seat off.

EAU13790

Seat

To install the seat1. Insert the projection on the front

of the seat into the seat holderas shown.

2. Push the rear of the seat down tolock it in place.

3. Turn the key counter clockwise

TIP: Make sure that the seat is properlysecured before riding.

1. Projection2. Seat holder

Helmet holders EAU14311

1. Helmet holder

The helmet holders are located underthe seat.

To secure a helmet to a helmet holder1. Open the seat. (See page 3-9 for

2. Attach a helmet to a helmet holder,and then securely close the seat.

WARNIWARNING ! NGNever ride with ahelmet attached to the helmetholder, since the helmet mayhit objects, causing loss of controland possibly an accident. [EWA10161]

and then remove it.

removal and installation prose- dures.)

a

21

1


3-11


Sidestand EAU37490

The sidestand is located on the left sideof the frame. Raise the sidestand orlower it with your foot while holding thevehicle upright.

EWA14190

WARNINGThe vehicle must not be ridden withthe sidestand down, or if the side-stand cannot be properly moved up(or does not stay up), otherwise thesidestand could contact the groundand distract the operator, resultingin a possible loss of control.

WARNING3

1

To release a helmet to a helmet holderOpen the seat, remove the helmet from

the helmet holder, and then close the seat.

PRE-OPERATION CHECKS

4-1


EAU15582

EAU15596

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

Before using this vehicles, check the following points:

Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equipment damage. Do not operate the vehicle if you find any problem. If a problem cannot be corrected by the procedures provided in this manual, have the vehicle inspected by a Yamaha dealer.

WARNING EWA11151

4


4-2

4

EAU15610

Pre-operation check list ITEM CHECKS PAGE

Fuel• Check fuel level in fuel tank.• Refuel if necessary.• Check fuel line for leakage.

3-6

Engine oil• Check oil level in engine.• If necessary, add recommended oil to specified level.• Check vehicle for oil leakage.

6-8

Front and rear suspension • Check operation• Check oil suspention for leakage.

6-23

Front brake

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

6-18, 6-19

Rear brake• Check operation.• Check pedal free play.• Adjust if necessary.

6-17

Throttle grip• 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.

6-12, 6-13

Control cables • Make sure that operation is smooth.• Lubricate if necessary. 6-21

Drive chain• Check chain slack.• Adjust if necessary.• Check chain condition.• Lubricate if necessary.

6-19, 6-20



4-3

4

Wheels and tires

Brake and shift pedal

Brake and clutch lever

Centerstand, sidestand

Chassis fasteners

Instruments, lights, signals and switches

Battery

• Check for damage.• Check tire condition and tread depth.• Check air pressure.• Correct if necessary.

6-13, 6-15

• Make sure that operation is smooth.• Lubricate pedal pivoting point if necessary. 6-16

• Make sure that operation is smooth.• Lubricate lever pivoting point if necessary. 6-16

• Make sure that operation is smooth.• Lubricate pivots if necessary. 6-22

• Make sure that all nuts, bolts and screws are properly tightened.• Tighten if necessary. —

• Check operation.• Correct if necessary. —

• Check fluid level.• Fill with distilled water if necessary. 6-25

ITEM CHECKS PAGE


OPERATION AND IMPORTANT RIDING POINTS

5-1

5

EAU15951

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

EWA10270WARNING

� Become thoroughly familiarwith all operating controls andtheir functions before riding.Consult a Yamaha dealer re-garding any control or functionthat you do not thoroughly un-derstand.

� Never start the engine or oper-ate it in a closed area for anylength of time. Exhaust fumesare poisonous, and inhalingthem can cause loss of con-sciousness and death within ashort time. Always make surethat there is adequate ventila-tion.

� Before starting out, make surethat the sidestand is up. If thesidestand is not raised com-pletely, it could contact theground and distract the opera-tor, resulting in a possible lossof control.


EAU15942

ECAN0070

NOTICE:NOTICE :Do not ride through deep water(including puddles), otherwise theengine may be damaged.

NOTICE :

Starting and warming up a cold engine

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

“#” is set to .3. Shift the transmission into the

neutral position.

RES

OFF

FUELON

ON

EAU16540

In order for the ignition circuit cut-offsystem to enable starting, one of thefollowing conditions must be met:

The transmission is in the neutralposition. The transmission is in gear with theclutch lever pulled.

�

�

1. Turn the fuel cock lever to “ON”

5-2

5

Starting a warm engine EAU16640

Follow the same procedure as for start-ing a cold engine with the exceptionthat the starter (choke) is not requiredwhen the engine is warm.


TIP :If the engine fails to start by pushing thestart switch, release the switch, wait afew seconds, and then try again. Eachstarting attempt should be as short aspossible to preserve the battery. Do notcrank the engine more than 10 secondson any one attempt. If the engine doesnot start with the starter motor, try usingthe kickstarter.


4. Turn the starter (choke) on andcompletely close the throttle. (Seepage 3-8.)

5. Start the engine by pushing thestart switch or by pushing the kick-starter lever down.

TIP:When the transmission is in the neutralposition, the neutral indicator lightshould be on, otherwise have a Yamahadealer check the electrical circuit.

6. After starting the engine, movethe starter (choke) back halfway.NOTICE: For maximum enginelife, always warm the engine up before starting off. Neveraccelerate hard when the engineis cold! [ECA11131]

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

TIP :The engine is warm when it respondsnormally to the throttle with the starter(choke) turned off.


5-3

5

EAU16800

Tips for reducing fuel consumption Fuel consumption depends largely onyour riding style. Consider the followingtips to reduce fuel consumption:

� Turn the starter (choke) off assoon as possible.

� Shift up swiftly, and avoid high en-gine speeds during acceleration.

� Do not rev the engine while shiftingdown, and avoid high enginespeeds with no load on the engine.

� Turn the engine off instead of let-ting it idle for an extended length oftime (e.g., in traffic jams, at trafficlights or at railroad crossings).


Shifting EAU16671

5432N1

1

1. Shift pedalN. Neutral position

Shifting gears lets you control theamount of engine power available forstarting off, accelerating, climbing hills,etc.

TIP: To shift the transmission into the neu-tral position, press the shift pedaldown repeatedly until it reaches theend of its travel, and then slightlyraise it.

ECA10260

88 Even with the transmission inthe neutral position, do notcoast for long periods of timewith the engine off, and do nottow the motorcycle for longdistances. The transmission isproperly lubricated only whenthe engine is running.Inadequate lubrication maydamage the transmission.

88 Always use the clutch whilechanging gears to avoid dam-aging the engine, transmis-sion, and drive train, which arenot designed to withstand theshock of forced shifting.

NOTICE:


5-4


5

Engine break-in EAU16830

There is never a more important periodin the life of your engine than the periodbetween 0 and 1000 km (600 mi). Forthis reason, you should read the follow-ing material carefully.Since the engine is brand new, do notput an excessive load on it for the first1000 km (600 mi). The various parts inthe engine wear and polish themselvesto the correct operating clearances.During this period, prolonged full-throt-tle operation or any condition that mightresult in engine overheating must beavoided.

EAU16970

0–500 km 500–1,000 km (0-300 mi) (300-600 mi)

8 Avoid prolonged operation above 8 Avoid prolonged operation above4.700 r/min. 6.600 r/min.

8 After every hour of operation, 8 Rev the engine freely through stop the engine, and then let it the gears, but do not use fullcool for five to ten minutes. throttle at any time.

8 Vary the engine speed from timeto time. Do not operate theengine at one set throttle posi-tion.

NOTICE:

[ECA10321]

After 1000 km of operation, theengine oil must be changed, andthe oil filter element cleaned.


5-5

5

Parking EAU17171

When parking, stop the engine, andthen remove the key from the mainswitch, and then turn the fuel cock

WARNINGEWA10310

� Since the engine and exhaustsystem can become very hot,park in a place where pedestri-ans or children are not likely totouch them.

� Do not park on a slope or on softground, otherwise the vehiclemay overturn.


1,000 km (600 mi) and beyond

The vehicle can now be operatednormally.

ECA10310

88 Keep the engine speed out ofthe tachometer red zone.

88 If any engine trouble shouldoccur during the engine break-in period, immediately have aYamaha dealer check the vehicle.

NOTICE:

lever to "OFF".



5-6

5

EAU37601

General note Much can be gained from the correct use and maintenance of a motorcycle.

1. THE CUSTOMERS CAN USE THE FULLESTPOTENTIAL OF YAMAHA MOTORCYCLES

2. A MOTORCYCLE CAN KEEP ITS PERFORMANCECAPABILITY FOR A LONGER TIME

Comparison of wear on engine parts(piston, piston ring, cylinder, etc.)

100%

Perfe

ct o

pera

tive

cond

ition Without

maintenance

Distancecovered (km) Engine overhaul, cylinder

boring, piston ring change, etc.

With maintenance



5-7

5

3. FUEL COST AND REPAIR EXPENSES CAN BEKEPT TO A MINIMUM

4. A MOTORCYCLE CAN DEMAND A HIGH PRICEWHEN IT IS TRADED IN AS A USED PRODUCT

Fuel consumption

100%

Withoutmaintenance

Distance covered (km)

With maintenance

Customer’s running cost(fuel cost plus maintenance and repair expenses)

Without maintenance

With maintenance

Big repairs at higher expenses

Distance covered (km)

S

PERIODIC MAINTENANCE AND MINOR REPAIR

6-1

6

EAU17241

Safety is an obligation of the owner. Pe-riodic inspection, adjustment and lubri-cation will keep your vehicle in thesafest and most efficient condition pos-sible. The most important points of in-spection, adjustment, and lubricationare explained on the following pages.The intervals given in the periodicmaintenance and lubrication chartshould be simply considered as a gen-eral guide under normal riding condi-tions. However, DEPENDING ON THEWEATHER, TERRAIN, GEOGRAPHI-CAL LOCATION, AND INDIVIDUALUSE, THE MAINTENANCE INTER-VALS MAY NEED TO BE SHORT-ENED.

WARNINGEWA10320

If you are not familiar with mainte-nance work, have a Yamaha dealerdo it for you.

EAU17381Owner’s tool kit TIP :If you do not have the tools or experi-ence required for a particular job, havea Yamaha dealer perform it for you.

WARNINGEWA10350

Modifications not approved byYamaha may cause loss of perfor-mance and render the vehicle un-safe for use. Consult a Yamahadealer before attempting any chang-es.

1. Owner’s tool kit

The owner’s tool kit is located inside thestorage compartment under the seat.(See page 3-9.)The service information included in thismanual and the tools provided in theowner’s tool kit are intended to assistyou in the performance of preventivemaintenance and minor repairs. How-ever, additional tools such as a torquewrench may be necessary to performcertain maintenance work correctly.


EAU17229

EAUN0100

NOTICE: ECAN0080

Improper disposal of drained fluids(i.e., oil, coolant,etc) and batteryare harmful to the environment.Contact a Yamaha dealer for pro-per disposal to protect the envi-ronment.

1


6-2

6

EAU17710

Periodic maintenance and lubrication chart TIP :

� The annual checks must be performed every year, except if a kilometer-based maintenance is performed in-stead.

� From 12000 km, repeat the maintenance intervals starting from 3000 km.� Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical

skills.

NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1000 km) ANNUAL

CHECK

1 * Fuel line • Check fuel and vacuum hoses for cracks or damage. √ √ √ √ √

2 Spark plug• Check condition.• Clean and regap. √ √

• Replace. √ √

3 * Valves • Check valve clearance.• Adjust. √ √ √ √

4 Air filter element• Clean. √ √

• Replace. √ √

5 * Battery • Check electrolyte level and specific gravity.• Make sure that the breather hose is properly routed. √ √ √ √ √

6 * Front brake• Check operation, fluid level and vehicle for fluid leakage. √ √ √ √ √ √

• Replace brake pads. Whenever worn to the limit

7 * Rear brake• Check operation and adjust brake pedal free play. √ √ √ √ √ √

• Replace brake shoes. Whenever worn to the limit

8 * Brake hose• Check for cracks or damage. √ √ √ √ √

• Replace. Every 4 years


0.5 3 6 9 12


6-3

6

9 * Wheels • Check runout, and for damage. √ √ √ √

10 * Tires• Check tread depth and for damage.• Replace if necessary.• Check air pressure.• Correct if necessary.

√ √ √ √ √

11 * Wheel bearings • Check bearing for looseness or damage. √ √ √ √

12 * Swingarm• Check operation and for excessive play. √ √ √ √

• Lubricate with lithium-soap-based grease. Every 24000 km

13 Drive chain • Check chain slack, alignment and condition.• Adjust and thoroughly lubricate chain with engine oil.

Every 500 km and after washing the motorcycle or riding in the rain

14 * Steering bearings• Check bearing play and steering for roughness. √ √ √ √ √

• Lubricate with lithium-soap-based grease. Every 24000 km

15 * Chassis fasteners • Make sure that all nuts, bolts and screws are properly tightened. √ √ √ √ √

16 Sidestand, centerstand • Check operation.• Lubricate. √ √ √ √ √

17 * Front fork • Check operation and for oil leakage. √ √ √ √

18 * Shock absorber assem-bly • Check operation and shock absorber for oil leakage. √ √ √ √

19 * Carburetor • Check starter (choke) operation.• Adjust engine idling speed. √ √ √ √ √ √

20 Engine oil • Change.• Check oil level and vehicle for oil leakage. √ √ √ √ √ √

21 Elemen oil filter • (Ch) Change (Cl) Clean Cl Cl Ch Cl Ch


CHECK


0.5 3 6 9 12


6-4

6

EAU18660

TIP :� The air filter needs more frequent service if you are riding in unusually wet or dusty areas.� Hydraulic brake service

• Regularly check and, if necessary, correct the brake fluid level.• Every two years replace the internal components of the brake master cylinder and caliper, and change the brake fluid.• Replace the brake hoses every four years and if cracked or damaged.

22 * Front suspention• Check operation √ √ √ √ √

• Check for oil leakage

23 * Front and rear brake switches • Check operation. √ √ √ √ √ √

24 Moving parts and ca-bles • Lubricate. √ √ √ √ √

25 * Throttle grip housing and cable

• Check operation and free play.• Adjust the throttle cable free play if necessary.• Lubricate the throttle grip housing and cable.

√ √ √ √ √

26 * Air induction system• Check the air cut-off valve, reed valve, and hose for dam-

age.• Replace any damaged parts if necessary.

√ √ √ √ √

27 * Lights, signals and switches

• Check operation.• Adjust headlight beam. √ √ √ √ √ √


CHECK


0.5 3 6 9 12


6-5

6


1. Panel/cover 2. Screw

1. Projection2. Holder

The cowlings and panel shown aboveneed to be removed to perform some ofthe maintenance jobs described in thischapter. Refer to this section each timea cowling or the panel needs to be re-moved and installed

EAU18771

Removing and installing the cowlings and panel

EAU19400

To remove the panel1. Remove the seat (See age 3-8 for

seat removal and instalation pro-cedures.)

2. Remove the screws, and then pullthe panel off as shown.

To install the panel1. Pleace the panel in the original po-

sition, and then install the screws

TIP :Make sure that projection fits into thegrommet

2. Install the seat.

2

1

1

2


6-6

EAU19603

Checking the spark plug

The spark plug is an important enginecomponent, which is easy to check.Since heat and deposits will cause anyspark plug to slowly erode, the sparkplug should be removed and checkedin accordance with the periodic mainte-nance and lubrication chart. In addition,the condition of the spark plug can re-veal the condition of the engine.


1. Spark plug wrence

1. Spark plug wrence1. Spark plug w

rence1. Spark plug w










































































rence

6

1

1. Spark plug cap.

To remove the spark plug

1. Remove the spark plug cap.2. Remove the spark plug as shown,

with the spark plug wrench inclu-ded in the owner's tool kit.

1

To check the spark plug1. Check that the porcelain insulator

around the center electrode of thespark plug is a medium-to-light tan(the ideal color when the vehicle isridden normally).

TIP :If the spark plug shows a distinctly dif-ferent color, the engine could be defec-tive. Do not attempt to diagnose suchproblems yourself. Instead, have aYamaha dealer check the vehicle.

2. Check the spark plug for electrodeerosion and excessive carbon orother deposits, and replace it ifnecessary.

Specified spark plug:D8EA (NGK) orX24ES-U (DENSO)


6-7

6

To install the spark plug1. Measure the spark plug gap with a

wire thickness gauge and, if nec-essary, adjust the gap to specifica-tion.

TIP :If a torque wrench is not available wheninstalling a spark plug, a good estimateof the correct torque is 1/4–1/2 turnpast finger tight. However, the sparkplug should be tightened to the speci-fied torque as soon as possible.

4. I nstall the spark plug cap.

1. Spark plug gap

Spark plug gap:0.7–0.8 mm (0.027–0.031 in)

2. Clean the surface of the spark pluggasket and its mating surface, andthen wipe off any grime from thespark plug threads.

3. Install the spark plug with thespark plug wrench, and then tight-en it to the specified torque.

Tightening torque:Spark plug:

17.5 Nm (1.75 m·kgf, 10.1 ft·lbf)



6-8

6


EAU19772

Engine oil and oil filter element The engine oil level should be checkedbefore each ride. In addition, the oilmust be changed and the oil filter ele-ment replaced at the intervals specifiedin the periodic maintenance and lubri-cation chart

face and hold it in an upright po-face and hold it in an upright po-face and hold it in an upright po-face and hold it in an upright po-face and hold it in an upright po-face and hold it in an upright po-face and hold it in an upright po-face and hold it in an upright po-face and hold it in an upright po-face and hold it in an upright po-face and hold it in an upright po-face and hold it in an upright po-face and hold it in an upright po-face and hold it in an upright po-face and hold it in an upright po-face and hold it in an upright po-face and hold it in an upright po-face and hold it in an upright po-face and hold it in an upright po-face and hold it in an upright po-face and hold it in an upright po-face and hold it in an upright po-face and hold it in an upright po-face and hold it in an upright po-face and hold it in an upright po-face and hold it in an upright po-face and hold it in an upright po-face and hold it in an upright po-face and hold it in an upright po-face and hold it in an upright po-face and hold it in an upright po-face and hold it in an upright po-face and hold it in an upright po-face and hold it in an upright po-face and hold it in an upright po-face and hold it in an upright po-face and hold it in an upright po-face and hold it in an upright po-face and hold it in an upright po-face and hold it in an upright po-face and hold it in an upright po-face and hold it in an upright po-face and hold it in an upright po-face and hold it in an upright po-face and hold it in an upright po-face and hold it in an upright po-face and hold it in an upright po-face and hold it in an upright po-face and hold it in an upright po-face and hold it in an upright po-face and hold it in an upright po-face and hold it in an upright po-face and hold it in an upright po-face and hold it in an upright po-

To check the engine oil level1. Place the vehicle on a level sur-

face and hold it in an upright po-sition A slight tilt to the side can

2. Start the engine, warm it up forseveral minutes, and then turn itoff.

3. Wait a few minutes until the oil set-tles, and then check the oil levelthrough the check window locatedat the bottom-right side of thecrankcase.

41 2

3

1. Engine oil level check window2. Maximum level mark3. Minimum level mark4. Engine oil filler bolt

The engine oil should be between theminimum and maximum level marks.

4. If the engine oil is at or below theminimum level mark, add sufficientoil of the recommended type toraise it to the correct level.

TIP: result in a false reading.

To change the engine oil (with or whit-

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

2. Place an oil pan under the engineto collect the used oil.

3. Remove the engine oil filler capand drain bolt to drain the oil, fromcrankcase.

4. Check the washers for damage and replace them if necessary.

out oil filter element cleaning)

1

1. Engine oil drain bolt


6-9

6


TIP :Skip step 6-10 if the oil filter element isnot being cleaned.

6. Remove the oil filter element coverby removing the bolts.

32

1

1. Oil filter element drain bolt2. Oli filter element cover3. Bolt (×2)

5. Remove the oil filter element drain bolt to drain the oil from the oil fil-ter element.

2

1

1. Oli filter element 2. O-ring (×3)

7. Remove the oil filter element andO-rings.

8. Check the O-rings for damage and replace it if necessary.

9. Clean the oil filter element withsolvent, and then install it.

TIP :Check the oil filter element for damage and repalce it if necessary.

10. Install the oil filter element cover byinstalling the bolts, then tighteningthem to the specified torque.

Tightening torque:Oil filter element cover bolt:

10 Nm (1.0 m·kgf, 7.2 ft·lbf)

TIP: Make sure that the O-ring is properlyseated.

11. Install the oil filter element drainbolt, and then tighten it to thespecified torque.

12. Install the engine oil drain bolt, andand then tighten it to the specifiedtorque.

Tightening torque:Oil filter element drain bolt:

10 Nm (1.0 m·kgf, 7.2 ft·lbf)Engine oil drain bolt:

20 Nm (2.0 m·kgf, 14.4 ft·lbf)


6-10

6


13. Refill with the specified amount of the recommended oil, and theninstall and tighten the oil filler bolt.

EAU20832

Cleaning the air filter element

6

14. Start the engine, and then let it idlefor several minutes while checkingit for oil leakage. If oil is leaking, im-mediately turn the engine off andcheck for the cause.

15. Turn the engine off, and thencheck the oil level and correct it ifnecessary.

Recommended engine oil:See page 8-1.

Oil quantity:With oil filter element removal:

1.30 L (1.24 US qt) (1.13 Imp.qt)Without oil filter element removal:

1.20 L (1.14 US qt) (1.04 Imp.qt)Total amount (dry engine)

1.40 L (1.33 US qt) (1.21 Imp.qt)

ECA10390

NOTICE: � In order to prevent clutch slip-

page (since the engine oil alsolubricates the clutch), do notmix any chemical additiveswith the oil.

� Make sure that no foreign mate-rial enters the crankcase.

The air filter element should be cleaned at the intervals specified in the perio-dic maintenance and lubrication chart.Clean the air filter element more fre-quently if you are riding in unusually wet or dusty areas.

and check hose

In addition, the air filter check hosemust be frequently checked and cleaned if necessary.



6

1

2

1. Air filter case cover2. Screw (×4)

To clean the air filter element1. Remove left side panel (See

page 6-5) 2. Remove the air filter case cover

by removing the screws.

3. Pull the air filter out. 4. Remove the sponge material

from the air filter element frame,clean it with solvent, and squee-ze the remaining solvent out.

5. Apply oil of the recommended type to the entire surface of the excess oil out.

1

2

3

1. Sponge material2. Element guide3. Air filter element frame TIP :

The sponge material should be wet but not dripping.

Recommended oil: _ Foam air filter oil

_

6-11


6-12

8. I nstall the air filter case cover by in-stalling the screws.

Adjusting the carburetor EAU39930

The carburetor is an important part ofthe engine and requires very sophisti-cated adjustment. Therefore, most car-buretor adjustments should be left to aYamaha dealer, who has the neces-sary professional knowledge and expe-rience. The adjustment described in the following section, however, may be serviced by the owner as part of rou-tine maintenance.


7. Insert the air filter element into theair filter case.NOTICE: Make su-

re that the air filter element isproperly seated in the air filtercase. The engine should neverbe operated without the air filterelement installed, otherwise thepiston(s) and/or cylinder(s) maybecome excessively worn.[ECA10481]

ECA10550

The carburetor has been set and ex-tensively tested at the Yamaha fac-tory. Changing these settingswithout sufficient technical knowl-edge may result in poor perfor-mance of or damage to the engine.

NOTICE:

6

6. Pull the sponge material over the air filter element frame.

9. I nstall the panel.

11. Hose (×2)

To clean the air filter check hose 1. Check the hose at the buttom of

the air filter case for accumulated

2. If dirt or water is visible, remove the hose, clean it, and then install

dirt or water.

it.


6-13

6TIP :If the specified idling speed cannot beobtained as described above, have aYamaha dealer make the adjustment.

EAU21370

Adjusting the throttle cable free play The throttle cable free play should mea-sure 3.0–5.0 mm (0.12–0.20 in) at thethrottle grip. Periodically check thethrottle cable free play and, if neces-sary, adjust it as follows.

TIP :The engine idling speed must be cor-rectly adjusted before checking and ad-justing the throttle cable free play.Engine idling speed:

1300–1500 r/min


EAU21320

Adjusting the engine idling speed The engine idling speed must bechecked and, if necessary, adjusted as

at the intervals specified in the maintenance and lubrication

gine should be warm beforethis adjustment.

TIP:The engine is warm when it quicklyresponds to the throttle.

Check the engine idling speed and, ifnecessary, adjust it to specification byturning the throttle stop screw.To increase the engine idling speed,turn the screw in direction (a). To de-crease the engine idling speed, turnthe screw in direction (b).

follows periodicchart.The enmaking

b

a

1

1. Throttle stop screw


6-14

6

Valve clearance The valve clearance changes with use,resulting in improper air-fuel mixtureand/or engine noise. To prevent thisfrom occurring, the valve clearancemust be adjusted by a Yamaha dealerat the intervals specified in the periodicmaintenance and lubrication chart.

EAU21550

Tires To maximize the performance, durabil-ity, and safe operation of your motor-cycle, note the following pointsregarding the specified tires.

Tire air pressureThe tire air pressure should be checkedand, if necessary, adjusted before eachride.

WARNINGEWA10500

� The tire air pressure must bechecked and adjusted on coldtires (i.e., when the temperatureof the tires equals the ambienttemperature).

� The tire air pressure must be ad-justed in accordance with theriding speed and with the totalweight of rider, passenger, car-go, and accessories approvedfor this model.


1. Lossen the locknut

2. To increase the throttle cable freeplay, turn the adjusting nut in direc-tion (a). To decrease the throttlecable free play, turn the adjustingnut in direction (b).

3. Tighten the locknut.

c

b 1

2a

1. Locknut2. Adjusting nutc. Free play

EAU21401


6-15

6WARNING

EWA10510

Proper loading of your motorcycle isimportant for several characteristicsof your motorcycle; such as han-dling, braking, performance andsafety. Do not carry loosely packeditems that can shift. Securely packyour heaviest items close to the cen-ter of the motorcycle, and distributethe weight evenly from side to side.Check the condition and pressure ofyour tires. NEVER OVERLOADYOUR MOTORCYCLE. Make sure

the total weight of the cargo, rider,passenger, and accessories (fairing,saddlebags, etc. if approved for thismodel) does not exceed the maxi-mum load of the motorcycle. Opera-tion of an overloaded motorcyclecould cause tire damage, an acci-dent, or even injury.

Tire inspection

The tires must be checked before eachride. If the tire shows crosswise lines(minimum tread depth), if the tire has anail or glass fragments in it, or if thesidewall is cracked, have a Yamahadealer replace the tire immediately.

TIP :The tire tread depth limits may differfrom country to country. Always complywith the local regulations.

Tire informationThis motorcycle is equipped with tubetires.

WARNINGEWA10460

� The front and rear tires shouldbe of the same make and de-sign, otherwise the handlingcharacteristics of the vehiclecannot be guaranteed.

� After extensive tests, only thetires listed below have been ap-proved for this model byYamaha Motor Co., Ltd.

Tire air pressure (measured on cold tires):

0–100 kg (0–220 lb):Front:

200 kPa (29 psi) (2.00 kgf/cm²)Rear:

200 kPa (29 psi) (2.00 kgf/cm²)90–180 kg (220–356 lb):

Front:200 kPa (29 psi) (2.00 kgf/cm²)

Rear:225 kPa (33 psi) (2.25 kgf/cm²)

Maximum load*:180 kg (356 lb)

* Total weight of rider, passenger, car-go and accessories

1. Tire sidewall2. Tire wear indicator3. Tire tread depth

Minimum tire tread depth (front and rear):

1.0 mm (0.04 in)



6-16

6

WARNINGEWA10560

� It is dangerous to ride with aworn-out tire. When a tire treadbegins to show crosswise lines,have a Yamaha dealer replacethe tire immediately.

� The replacement of all wheel-and brake-related parts, includ-ing the tires, should be left to aYamaha dealer, who has thenecessary professional knowl-edge and experience.

� It is not recommended to patcha punctured tube. If unavoid-able, however, patch the tube

very carefully and replace it assoon as possible with a high-quality product.

Front tire:Size:

80/100-18 47PManufacturer/model:

IRC/ NR65

Rear tire:Size:


IRC/ NR65


WEAU22000

heels WARNING EWA10610

The wheels on this model are notdesigned for use with tubeless tires. Do not attempt to use tube-less tires on this model.

To maximize the performance, durabil-ity, and safe operation of your motor-cycle, note the following pointsregarding the specified wheels.

� The wheel rims should be checkedfor cracks, bends, warpage, or damage before each ride. If any da-mage 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 balancedwhenever either the tire or wheelhas been changed or replaced. Anunbalanced wheel can result inpoor performance, adverse han-dling characteristics, and a short-ened tire life.

WARNING



6

� Ride at moderate speeds afterchanging a tire since the tire sur-face must first be “broken in” for itto develop its optimal characteris-tics.

EAU22031

Adjusting the clutch lever 3. If the specified clutch lever freefree play play could be obtained as

described above, tighten thelocknut and skip the rest of theprocedure, otherwise proceed asfollows.

4. Fully turn the adjusting bolt indirection a to loosen the clutchcable.

1. Locknut (clutch lever)2. Adjusting bolt

The clutch lever free play shouldmeasure 10–15 mm as shown.Periodically check the clutch leverfree play and, if necessary, adjust itas follows.1. Loosen the locknut at the clutch

lever.2. To increase the clutch lever free

play, turn the adjusting bolt indirection a. To decrease theclutch lever free play, turn theadjusting bolt in direction b.

6-17


PERIODIC MAINTENANCE AND MINOR REPAIR1

2ab

clutch cable) nut

5. Loosen the locknut further downthe clutch cable.

6. To increase the clutch lever freeplay, turn the adjusting nut indirection a. To decrease theclutch lever free play, turn theadjusting nut in direction b.

7. Tighten both locknuts.

1. Locknut (2. Adjusting

EAU22093

Adjusting the brake lever free play

The brake lever free play should mea-sure 2-5 mm as shwon. Periodicallycheck the brake lever free play and, ifnecessary, adjust it as follows.

EWA10630

WARNING

Yamaha dealer bleed the system be-fore operating the motorcycle. Air inthe hydraulic system will diminishthe braking performance, which mayresult in loss of control and an acci-dent.6

6-18

1 c2

1. Locknut2. Adjusting bolt

C. Free play

1. Loosen the locknut at the brakelever.

2. To increase the brake lever freeplay, turn the adjusting bolt indirection a. To decrease thebrake lever free play, turn theadjusting bolt in direction b.

3. Tighten the locknuts.

� After adjusting the brake lever free play, check the free play and makesure that the brake is working pro-perly.

� A soft or spongy feeling in the brakelever can indicate the presence of airin the hydraulic system. If there is airin the hydraulic system, have a



6

1 C

c2 b a

1. Locknut .C. Brake pedal free play2. Adjusting boltC. Brake pedal position

The brake pedal free play should mea-sure 20.0–30.0 mm (0.80–1.18 in) asshown. Periodically check the brakepedal free play and necessary, adjustit as follows.

EWA10670

WARNINGIt is advisable to have a Yamaha dea-ler make this

EAU22220

Adjusting the brake pedal position and free play.

adjustments.

The top of the brake pedal should bepositioned approximately 30 mm (1.18 in) below the top of the footrest.Periodically check the brake pedal position and, if necessary, adjust it as follows.

Brake pedal position

2. To raise the brake pedal, turn theadjusting bolt in direction (a). To lower the brake pedal, turn the adjusting bolt in direction (b).

1. Loosen the locknut at the brake

3. Tighten the locknut.

pedal.

EWA11230

WARNINGAfter adjusting the brake pedal posi-tion, the brake pedal free play must adjusted.

Brake pedal free play

6-19


6-20

6

To increase the brake pedal free play,turn the adjusting nut in direction (a). Todecrease the brake pedal free play,turn the adjusting nut in direction (b).

EWA10680

WARNING� After adjusting the drive chain

slack or removing and installingthe rear wheel, always check thebrake pedal free play.

� If proper adjustment cannot beobtained as described, have aYamaha dealer make this ad-justment.After adjusting the brake pedalfree play, check the operation ofthe brake light.

�


1. Brake pedal free play adjusting nut

EAU22270

Adjusting the rear brake light switch

1

2

a

b

1. Rear brake light switch2. Rear brake light switch adjusting nut

The rear brake light switch, which is ac-tivated by the brake pedal, is properlyadjusted when the brake light comeson just before braking takes effect. Ifnecessary, adjust the brake light switchas follows.Turn the adjusting nut while holding therear brake light switch in place. Tomake the brake light come on earlier,turn the adjusting nut in direction (a). Tomake the brake light come on later, turnthe adjusting nut in direction (b).


6-21

6

EAU22380

Checking the front brake pads and rear brake shoes Front brake pads EAU22430

1. Brake pad wear indicator groove

The front brake pads and the rear brakeshoes must be checked for wear at theintervals specified in the periodic main-tenance and lubrication chart.

Each front brake pad is provided withwear indicator grooves, which allowyou to check the brake pad wear with-out having to disassemble the brake.To check the brake pad wear, checkthe wear indicator grooves. If a brakepad has worn to the point that the wearindicator grooves have almost disap-peared, have a Yamaha dealer replacethe brake pads as a set.

EAU22540

Rear brake shoes

The rear brake is provided with a wearindicator, which allows you to check thebrake shoe wear without having to dis-assemble the brake. To check thebrake shoe wear, check the position ofthe wear indicator while applying thebrake. If a brake shoe has worn to thepoint that the wear indicator reachesthe wear limit line, have a Yamahadealer replace the brake shoes as aset.

1. Brake shoe wear indicator2. Brake shoe wear limit line



6-22

6

EAU37001

Checking the front brake fluid level

Insufficient brake fluid may allow air toenter the brake system, possibly caus-ing it to become ineffective.Before riding, check that the brake fluidis above the minimum level mark andreplenish if necessary. A low brake fluidlevel may indicate worn brake padsand/or brake system leakage. If thebrake fluid level is low, be sure to checkthe brake pads for wear and the brakesystem for leakage.Observe these precautions:

� When checking the fluid level,make sure that the top of the mas-ter cylinder is level by turning thehandlebars.

� Use only the recommended qualitybrake fluid, otherwise the rubberseals may deteriorate, causingleakage and poor braking perfor-mance.

TIP :If DOT 4 is not available, DOT 3 can beused.

� Refill with the same type of brakefluid. Mixing fluids may result in aharmful chemical reaction andlead to poor braking performance.

� Be careful that water does not en-ter the master cylinder when refill-ing. Water will significantly lowerthe boiling point of the fluid andmay result in vapor lock.

� Brake fluid may deteriorate paint-ed surfaces or plastic parts. Al-ways clean up spilled fluidimmediately.

� As the brake pads wear, it is nor-mal for the brake fluid level to grad-ually go down. However, if thebrake fluid level goes down sud-denly, have a Yamaha dealercheck the cause.

1. Minimum level mark

Recommended brake fluid:DOT 4


(b)

Changing the brake fluid EAU22720

Have a Yamaha dealer change thebrake fluid at the intervals specified inthe NOTE after the periodic mainte-nance and lubrication chart. In addition,have the oil seals of the brake mastercylinder and caliper as well as thebrake hose replaced at the intervalslisted below or whenever they are dam-aged or leaking.

� Oil seals: Replace every twoyears.

� Brake hose: Replace every fouryears.

1


6-23

6

Drive chain slack EAU22760

1. Drive chain slack

The drive chain slack should be check-ed before each ride and adjusted ifnecessary.

EAU22793

To check the drive chain slack1. Place the motorcycle on the cen-

terstand.2. Shift the transmission into the neu-

tral position.3. Spin the rear wheel several times

to locate the tightest portion of thedrive chain.

4. Measure the drive chain slack asshown.

Drive chain slack:20.0–30.0 mm (0.78–1.18 in)

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

EAU22822

To adjust the drive chain slack1. Loosen the brake pedal free play

adjusting nut, the axle nut, and thechain puller locknut at each end


a 1

43

2

a

b

of the swingarm.

1. Axle nut 2. Lock nut 3. Adjusting nut4. Alignment mark


6-24

TIP :When tightening the axle nut, hold thewheel axle with a wrench to keep it fromturning.

4. Adjust the brake pedal free play.(See page 6-19)

EWA10660

WARNINGAfter adjusting the brake pedal freeplay, check the operation of thebrake light.

TIP :Using the alignment marks on eachside of the swingarm, make sure thatboth chain pullers are in the same posi-tion for proper wheel alignment.

Tightening torques:Lock nut:

10 Nm (1.0 m·kgf, 7.36 ft·lbf)Axle nut:

88 Nm (1.9 m·kgf, 64.7 ft·lbf)


en the drive chain, turn the adjustingnut at each end of the swingarmin direction (b), and then push therear wheel forward. NOTICE: Im-

2. To tighten the drive chain, turn theadjusting nut at each end of theswingarm in direction (a), To loos-

ECA10571

proper drive chain slack will overload the engine as well as other vital parts of the motorcy-cle and can lead to chain slippage or breakage. To prevent this fromoccurring, keep the drive chain slack within the sspecified limits.

6 WARNING

3. Tighten both locknuts, and the axle nut to the specified torques.

1

43

2

a

b

1. Axle nut 2. Lock nut 3. Adjusting nut4. Alignment mark


6-25

6

Checking and EAU231

lubricating the 01

cables

The operation of all control cables andthe condition of the cables should bechecked before each ride, and the ca-bles and cable ends should be lubricat-ed if necessary. If a cable is damagedor does not move smoothly, have aYamaha dealer check or replace it.WARNING ! Damage to the outersheath may interfere with proper ca-ble operation and will cause theinner cable to rust. Replace a dama-ged cable as soon as possible toprevent unsafe conditions. [EWA10721]


EAU23025

Cleaning and lubricating the drive chain The drive chain must be cleaned andlubricated at the intervals specified inthe periodic maintenance and lubrica-tion chart, otherwise it will quickly wearout, especially when riding in dusty orwet areas. Service the drive chain asfollows.

NOTICE:ECA10583

e chain must be lubricatedashing the motorcycle and

The drivafter wriding inarea.

the rain or riding in the wet

1. Clean the drive chain with kerosene and small soft brush. NOTICE: To prevent damaging the O-rings,do not clean the drive chain withsteam cleaners, high-pressure wa-shers or inappropriate solvents. [ECA11121]

2. Wipe the drive chain dry.

3. Thoroughly lubricate the drive chain with a special O-ring chain lubricant NOTICE: do not use engine oil orany other lubricants for the drivechain, as they may contain sub-stances that could damage theO-rings. [ECA11111]



EAU231

Checking and lubricating the 11

throttle grip and cable The operation of the throttle grip shouldbe checked before each ride. In addi-tion, the cable should be lubricated atthe intervals specified in the periodicmaintenance chart.

Recommended lubricant:Engine oil

The operation of the brake and shiftpedals should be checked beforeeach ride, and the pedal pivots shouldbe lubricated if necessary.

Recommended lubricant:Lithium-soap-based grease (all-purpose grease)

EAU23133

Checking and lubricating the brake and shift pedals

Checking and lubricating the EA

U43610

brake and clutch levers

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

Recommended lubricant:Lithium-soap-based grease (all-purpose grease)

6

6-26


6-27

6

Checking and lubricating the centerstand and sidestand

The operation of the centerstand andsidestand should be checked beforeeach ride, and the pivots and metal-to-metal contact surfaces should be lubri-cated if necessary.

WARNINGEWA10740

If the centerstand or sidestand doesnot move up and down smoothly,have a Yamaha dealer check or re-pair it.

Recommended lubricant:Lithium-soap-based grease (all-pur-pose grease)


Lubricating the swingarm EAU23230

pivots The pivoting point of the rear suspention must be lubricated at the intervals specified in the periodic maintenance and lubrication chart.

Recommended lubricant:Lithium-soap-based grease


6-28

6

Checking the front fork EAU23272

The condition and operation of the frontfork must be checked as follows at theintervals specified in the periodic main-tenance and lubrication chart.

To check the condition

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

To check the operation1. Place the vehicle on a level sur-

face and hold it in an upright posi-tion.WARNING! To avoid injurysecurely support the vehicle so

[EWA10751]

that there is no danger of it fal-

2. While applying the front brake,push down hard on the handlebarsseveral times to check if the frontfork compresses and reboundssmoothly.


ling over. ECA10590

NOTICE:If any damage is found or the frontfork does not operate smoothly,have a Yamaha dealer check or re-pair it.

EAU45511

Checking the steering Worn or loose steering bearings maycause danger. Therefore, the operationof the steering must be checked as fol-lows at the intervals specified in the pe-riodic maintenance and lubricationchart.

1. Place the vehicle on the center-stand. WARNING: To avoid injury securely support the vehi-

[EWA10751]

cle so that there is no danger of it falling over.


6-29

6

2. Hold the lower ends of the frontfork legs and try to move them for-ward and backward. If any freeplay can be felt, have a Yamahadealer check or repair the steering.


Checking the wheel beariE

nAU2

gs 3290

The front and rear wheel bearings mustbe checked at the intervals specified inthe periodic maintenance and lubrica-tion chart. If there is play in the wheelhub or if the wheel does not turnsmoothly, have a Yamaha dealer checkthe wheel bearings.

EAU23322

Battery A poorly maintained battery will corrodeand discharge quickly. The electrolytelevel, battery lead connections andbreather hose routing should bechecked before each ride and at the in-tervals specified in the periodic mainte-nance and lubrication chart.

To check the electrolyte level1. Place the vehicle on a level sur-

face and hold it in an upright posi-tion.

TIP :Make sure that the vehicle is positionedstraight up when checking the electro-lyte level.

2. Remove right side panel. (See page 6-5 for panel removal and

TIP :The electrolyte should be between theminimum and maximum level marks.

installation procedures. 3. Check the electrolyte level in the

battery.


6-30

6

ry lead from the battery.


























































: Use only distilled


















Use only distilled

Use only distilled

Use only distilled

Use only distilled

Use only distilled

Use only distilled

Use only distilled

Use only distilled

Use only distilled

Use only distilled

Use only distilled

Use only distilled

Use only distilled

Use only distilled

Use only distilled

Use only distilled

Use only distilled

Use only distilled

Use only distilled

Use only distilled

Use only distilled

Use only distilled

Use only distilled

Use only distilled

Use only distilled

Use only distilled

Use only distilled

Use only distilled

Use only distilled

Use only distilled

Use only distilled

Use only distilled

Use only distilled

Use only distilled

Use only distilled

Use only distilled

Use only distilled

Use only distilled

Use only distilled

Use only distilled

Use only distilled

Use only distilled

Use only distilled

Use only distilled

Use only distilled

Use only distilled

ECA10611

ECA10611

ECA10611

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ECA10611


_

4. If the electrolyte is at or below theminimum level mark, Add distilled water to raise theelectrolyte to the maximum levelmark. NOTICE : Use only distilled

� Electrolyte is poisonous anddangerous since it contains sul-furic acid, which causes severeburns. Avoid any contact withskin, eyes or clothing and al-

ways shield your eyes whenworking near batteries. In caseof contact, administer the fol-lowing FIRST AID.• EXTERNAL: Flush with plenty

of water.• INTERNAL: Drink large quan-

tities of water or milk and im-mediately call a physician.

• EYES: Flush with water for 15minutes and seek promptmedical attention.

� Batteries produce explosive hy-drogen gas. Therefore, keepsparks, flames, cigarettes, etc.,away from the battery and pro-vide sufficient ventilation whencharging it in an enclosedspace.

� Take care not to spill electrolyteon the drive chain, as this mayweaken it, shorten chain life andpossibly result in an accident.

� KEEP THIS AND ALL BATTER-IES OUT OF THE REACH OFCHILDREN.

1. Maximum level mark2. Minimum level mark

water, as tap water contains mine-rals that are harmful to the battery.[EWA10770]

WARNING EWA10770•

ECA10610

Use only distilled water, as tap watercontains minerals that are harmfulto the battery.

5. Check and, if necessary, tightenthe battery lead connections andcorrect the breather hose routing.

6. Instal the panel.

NOTICE:

1

2


6-31

6

s.s.s.s.s.s.s.s.s.s.s.s.s.s.s.s.s.


To store the battery1. If the vehicle will not be used for

more than one month, remove thebattery, fully charge it, and thenplace it in a cool, dry place.NOTICE: When removing thebattery, be sure the key isturned to “OFF”, then discon-nect the negative lead beforedisconnecting the positive lead.[ECA16302]

2. If the battery will be stored formore than two months, check it atleast once a month and fullycharge it if necessary.

3. Fully charge the battery before in-stallation.

4. After installation, make sure thatthe battery leads are properly con-nected to the battery terminals.

ECA16530

NOTICE_

Always keep the battery charged.Storing a discharged battery cancause permanent battery damage. _

NOTICE

..

1. Fuse

The fuse holder is located behind rightside panel. (See page 6-5 for panelsremoval and installation procedures)If the fuse is blown, replace it as follows.

1. Turn the key to “OFF” and turnoff all electrical circuits.

Replacing the fuse EAU23481

Specified fuse 15 A

3. Turn the key to “ON” and turn onthe electrical circuits to check if thedevices operate.

4. If the fuse immediately blowsagain, have a Yamaha dealercheck the electrical system.

2. Remove the blown fuse, and theninstall a new fuse of the specifiedamperage. WARNING : Do not usea fuse of a higher amperage ra-ting than recommended to avoidcausing extensive damage to theelectrical system and possibly afire. [EWA15131]

1



6-32

6

EAUU0891 --- > EAUN *****

Replacing a headlight bulb ora position light bulb

1. Headlight mounting bolt. 2. Headlight adjusting bolt.1. Screw (×2)

If a headlight bulb or a position lightbulb burns out, replace it as follows.Headlight bulb.

Do not touch the glass part of theheadlight bulb to keep it free fromoil, otherwise the transparency ofthe glass, the luminosity of thebulb, and the bulb life will beadversely affected. Thoroughlyclean off any dirt and fingerprintson the headlight bulb using a clothmoistened with alcohol or thinner

1. Place the motorcycle on the center-stand.

2. Remove the headlight side coverby removing screws.

3. Remove headlight mounting bolt. 4. Remove headlight adjusting bolt 5. Remove headlight unit from head-

light stay. NOTICE:

ECA10660

1

Do not touch this area

1

1

2



66

7. Place a new headlight bulb into position, and then secure it with

bulb socket.

ECAU0070

If a headlight bulb of different wattage than recommended is used, itmay cause the battery to dischargeor affect the headlight lighting.

8. Instal l the headlight unit byinstalling the screws.

9. Install the headlight side cover byinstalling screws.

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

Position light bulb.1. Place the motorcycle on the center-

stand. 2. Remove the headlight side cover

by removing screws.3. Remove head light mounting bolt. 4. Remove head light adjusting bolt 5. Remove head light from head light

stay.

1. Position light bulb socket

6. Remove the position light bulb socket(together with the bulb) by pulling out.

7. Insert a new bulb into the socket bypushing it until it stop.

8. Install the socket (together with the bulb) by pushing it.

9. Install the headlight side cover by installing the screws.

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

1. Headlight bulb socket 2. Headlight bulb

6. Remove headlight bulb socket and then remove the burnt-out bulb.

1

NOTICE:

3. Position light bulb

6-33

1

2

31


PERIODIC MAINTENANCE AND MINOR REPAIREAU24082

Replacing the tail/brake light bulb

1. Tail/brake light bulb socket

1. Remove the seat. (See page 3-7)2. Remove the socket (together with

the bulb) by turning it counter- clockwise.

6-34

66

1. Tail/brake light bulb

3. Remove the burnt out bulb by pu-shing it in and turning it counter-clockwise.

4. Insert a new bulb into the socket,push it in, and then turn it clock-wise until it stops.

5. Install the socket (together with_

the bulb) by turning it clockwise.6. Install the seat.

EAU24204

Replacing a turn signal lightbulb

1. Screw2. Bulb3. Lens

61. Remove the turn signal light lens

by removing the screw.2. Remove the defective bulb by

pulling it out3. Insert a new bulb into the socket

push it in4. Place the lens in the original

position by installing the screw.NOTICE: Do not overtighten the screw, otherwise the lens may break. [ECA11191]

11



6-35

6

EAU24360

Front wheel

To remove the front wheel EAU37761

EWA10821

WARNING To avoid injury, secutely support the

vehicle so there is no danger of itfalling over.

1. Place the motorcycle on the cen-terstand.

2. Disconnect the speedometer cablefrom the front wheel.

3. Remove the axle nut, and the washer.

2. Lift the wheel up between the forklegs.

TIP :Make sure that there is enough spacebetween the brake pads before insert-ing the brake disc and that the retainerin the speedometer gear unit fits overthe slot on the fork leg.

1. Speedometer cable

2. Axle nut and washer

4. Pull the wheel axle out, and thenremove the wheel. NOTICE: Do-not apply the brake after thewheel has been removed toge-ther with the brake disc, other-wise the brake pads will be forced shut. [ECA11071]

EAU37770

To install the front wheel1. Install the speedometer gear unit

into the wheel hub so that the pro-jection on the wheel hub fits in ei-ther slot of the speedometer gearunit.

1. Speedometer gear unit

WARNING

12

1



6-36

6

To remove the rear wheel EAU37782

WARNINGEWA10821

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

1. Loosen the axle nut.2. Loosen the locknut and the drive

chain slack adjusting nut on both ends of the swingarm.

1. Axle nut and washer2. Drive chain adjusting nut3. Locknut drive chain adjusting nut 4. Brake torque rod nut

WARNING

EAU35080Rear wheel

3. Insert the wheel axle, and then in-stall the axle nut.

4. Take the motorcycle off the center-stand so that the front wheel is onthe ground.

5. Tighten the axle nut to the speci-fied torque.

1. Retainer2. Slot

Tightening torque:Axle nut:

40 Nm (4.0 m·kgf, 29 ft·lbf)

6. While applying the front brake,push down hard on the handlebarsseveral times to check if the frontfork compresses and reboundssmoothly.

7. Connect the speedometer cable.

TIP :When tightening the axle nut, hold thewheel axle with a wrench to keep it fromturning.

yamaha



6-37

6

TIP :The drive chain does not need to bedisassembled in order to remove andinstall the wheel.

EAU25782To install the rear wheel

1. Brake camshaft lever 2. Brake pedal free play adjusting nut 3. Brake torque rod nut and bolt 4. Brake rod 5. Washer and Axle nut

4. Disconnect the brake torque rod from the brake shoe plate by removing the cotter pin, the nut, the washer and the bolt.

5. Place the motorcycle on the centerstand.

6. Remove the brake pedal free play adjusting nut, and then disconnect the brake rod from the brake cam-shaft lever.

7. Remove the axle nut and the washer, and then pull the wheel axle out.

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

9. Remove the wheel.

TIP :Do not remove the washer on the right side of the wheel axle so as to not lose it.

1. Insert the wheel axle from the left- hand side, and then install the wa-sher and axle nut.

2. Install the drive chain onto the rear sprocket.

3. Lower the rear wheel so that it is on the ground, and then put the sidestand down.

4. Install the brake rod onto the brake camshaft lever, and then install the brake pedal free play adjusting nut onto the brake rod.

5. Connect the brake torque rod tothe brake shoe plate by installing the bolt and the nut, and then tigh-ten the nut to the specified torque.

Tightening torques:Brake torque rod nut:

19 Nm (1.9 m·kgf, 14 ft·lbf)

3. Loosen the brake torque rod nut at the brake shoe plate.



6-38

6

EAU25851

Troubleshooting Although Yamaha motorcycles receivea thorough inspection before shipmentfrom the factory, trouble may occur dur-ing operation. Any problem in the fuel,compression, or ignition systems, forexample, can cause poor starting andloss of power.The following troubleshooting chartsrepresent quick and easy proceduresfor checking these vital systems your-self. However, should your motorcyclerequire any repair, take it to a Yamahadealer, whose skilled technicians havethe necessary tools, experience, andknow-how to service the motorcycleproperly.Use only genuine Yamaha replace-ment parts. Imitation parts may look likeYamaha parts, but they are often inferi-or, have a shorter service life and canlead to expensive repair bills.

8. Adjust the brake pedal free play.(See page 6-18.)

EWA10660

WARNING

After adjusting the brake pedal freeplay, check the operation of thebrake light.

EWA15141

WARNING

When checking the fuel system, donot smoke, and make sure there areno open flames or sparks in thearea, including pilot lights fromwater heaters or furnaces.Gasoline or gasoline vapors canignite or explode, causing severeinjury or property damage.

WARNING6. Adjust the drive chain slack. (See- page 6-21.)

7. Tighten the axle nut to the specified torque.

Tightening torque:Axle nut:

60 Nm (6.0 m·kgf, 43 ft·lbf)


6-39

6

EAU37620

Troubleshooting charts

Starting problems or poor engine performance

WARNINGEWA10840

Keep away open flames and do not smoke while checking or working on the fuel system.

Check the fuel level in the fuel tank.

1. FuelThere isenough fuel.

There isno fuel.

Check the compression.

Supply fuel. The engine does not start.Check the compression.

Operate theelectric starter or thekickstarter.

2. CompressionThere is compression.

There is no compression.

Check the ignition.

Have a Yamaha dealer check the vehicle.

Remove the spark plug and check the electrodes.

3. IgnitionWet

Dry

Wipe off with a dry cloth and correct the spark plug gap, or replace the spark plug.

Have a Yamaha dealer check the vehicle.

The engine does not start. Have a Yamaha dealer check the vehicle.

The engine does not start.Check the battery.

Open the throttle halfway and operate the electric starter.

Operate theelectric starter.

4. BatteryThe engine turns overquickly.

The engine turns overslowly.

The battery is good.


Check lead connections, andcharge the battery if necessary.

MOTORCYCLE CARE AND STORAGE

7-1

7

EAU26000

Care While the open design of a motorcyclereveals the attractiveness of the tech-nology, it also makes it more vulnera-ble. Rust and corrosion can developeven if high-quality components areused. A rusty exhaust pipe may go un-noticed on a car, however, it detractsfrom the overall appearance of a motor-cycle. Frequent and proper care doesnot only comply with the terms of thewarranty, but it will also keep yourmotorcycle looking good, extend its lifeand optimize its performance.

Before cleaning1. Cover the muffler outlet with a

plastic bag after the engine hascooled down.

2. Make sure that all caps and coversas well as all electrical couplersand connectors, including thespark plug cap, are tightly in-stalled.

3. Remove extremely stubborn dirt,like oil burnt onto the crankcase,with a degreasing agent and abrush, but never apply such prod-

ucts onto seals, gaskets, sprock-ets, the drive chain and wheelaxles. Always rinse the dirt and de-greaser off with water.

CleaningECA10770

� Avoid using strong acidic wheelcleaners, especially on spokedwheels. If such products areused on hard-to-remove dirt, donot leave the cleaner on the af-fected area any longer than in-structed. Also, thoroughly rinsethe area off with water, immedi-ately dry it, and then apply a cor-rosion protection spray.

� Improper cleaning can damagewindshields, cowlings, panelsand other plastic parts. Use onlya soft, clean cloth or spongewith mild detergent and water toclean plastic.

� Do not use any harsh chemicalproducts on plastic parts. Besure to avoid using cloths orsponges which have been incontact with strong or abrasive

cleaning products, solvent orthinner, fuel (gasoline), rust re-movers or inhibitors, brake flu-id, antifreeze or electrolyte.

� Do not use high-pressure wash-ers or steam-jet cleaners sincethey cause water seepage anddeterioration in the following ar-eas: seals (of wheel and swing-arm bearings, fork and brakes),electric components (couplers,connectors, instruments,switches and lights), breatherhoses and vents.

� For motorcycles equipped witha windshield: Do not use strongcleaners or hard sponges asthey will cause dulling orscratching. Some cleaning com-pounds for plastic may leavescratches on the windshield.Test the product on a small hid-den part of the windshield tomake sure that it does not leaveany marks. If the windshield isscratched, use a quality plasticpolishing compound afterwashing.


EAU25981

NOTICE:



7-2

After normal useRemove dirt with warm water, a milddetergent, and a soft, clean sponge,and then rinse thoroughly with cleanwater. Use a toothbrush or bottlebrushfor hard-to-reach areas. Stubborn dirtand insects will come off more easily ifthe area is covered with a wet cloth fora few minutes before cleaning.

After riding in the rain, near the sea oron salt-sprayed roadsSince sea salt or salt sprayed on roadsduring winter are extremely corrosive incombination with water, carry out thefollowing steps after each ride in therain, near the sea or on salt-sprayedroads.

TIP :Salt sprayed on roads in the winter mayremain well into spring.

1. Clean the motorcycle with cold wa-ter and a mild detergent, after theengine has cooled down. NOTICE:

[ECA10791]

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

2. Apply a corrosion protection sprayon all metal, including chrome- andnickel-plated, surfaces to preventcorrosion.

After cleaning1. Dry the motorcycle with a chamois

or an absorbing cloth.2. Immediately dry the drive chain

and lubricate it to prevent it fromrusting.

3. Use a chrome polish to shinechrome, aluminum and stainless-steel parts, including the exhaustsystem. (Even the thermally in-duced discoloring of stainless-steel exhaust systems can be re-moved through polishing.)

4. To prevent corrosion, it is recom-mended to apply a corrosion pro-tection spray on all metal,including chrome- and nickel-plat-ed, surfaces.

5. Use spray oil as a universal clean-er to remove any remaining dirt.

6. Touch up minor paint damagecaused 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. Ifnecessary, clean the brakediscs and brake linings with aregular brake disc cleaner or ac-etone, and wash the tires withwarm water and a mild deter-gent.

� Before operating the motor-cycle test its braking perfor-mance and cornering behavior.

ECA10800

NOTICE:� Apply spray oil and wax spar-

ingly and make sure to wipe offany excess.

7


7-3


� Never apply oil or wax to anyrubber and plastic parts, buttreat them with a suitable careproduct.

� Avoid using abrasive polishingcompounds as they will wearaway the paint.

TIP :Consult a Yamaha dealer for advice onwhat products to use.

Storage EAU26151

Short-termAlways store your motorcycle in a cool,dry place and, if necessary, protect itagainst dust with a porous cover.

ECA10810

NOTICE :� Storing the motorcycle in a

poorly ventilated room or cover-ing it with a tarp, while it is stillwet, will allow water and humid-ity to seep in and cause rust.

� To prevent corrosion, avoiddamp cellars, stables (becauseof the presence of ammonia)and areas where strong chemi-cals are stored.

Long-termBefore storing your motorcycle for sev-eral months:

1. Follow all the instructions in the“Care” section of this chapter.

2. For motorcycles equipped with afuel cock that has an “OFF” posi-tion: Turn the fuel cock lever to“OFF”.

3. Drain the carburetor float chamberby loosening the drain bolt; this willprevent fuel deposits from buildingup. Pour the drained fuel into thefuel tank.

4. Fill up the fuel tank and add fuelstabilizer (if available) to preventthe fuel tank from rusting and thefuel from deteriorating.

5. Perform the following steps to pro-tect 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 placethe spark plug on the cylinderhead so that the electrodes aregrounded. (This will limit spark-ing during the next step.)

NOTICE:

7


7-4

7


WARNING ! To prevent da-

[EWA10951]

mage or injury from spar-king, make sure to ground the spark plug electrodes while turning the engine over.

6. Lubricate all control cables and thepivoting points of all levers andpedals as well as of the side-stand/centerstand.

7. Check and, if necessary, correctthe tire air pressure, and then liftthe motorcycle so that both of itswheels are off the ground. Alterna-tively, turn the wheels a little everymonth in order to prevent the tiresfrom becoming degraded in onespot.

8. Cover the muffler outlet with aplastic bag to prevent moisturefrom entering it.

9. Remove the battery and fullycharge it. Store it in a cool, dryplace and charge it once a month.Do not store the battery in an ex-cessively cold or warm place [lessthan 0 °C (30 °F) or more than 30°C (90 °F)]. For more informationon storing the battery, see page6-28.

TIP :Make any necessary repairs beforestoring the motorcycle.

d. Turn the engine over severaltimes with the starter. (This willcoat the cylinder wall with oil.)

e. Remove the spark plug capfrom the spark plug, and theninstall the spark plug and thespark plug cap.

SPECIFICATIONS

8-1

8

Dimensions:Overall length:

2025 mm (79.7 in) Overall width:

765 mm (30.1 in) Overall height:

1095 mm (43.1 in) Seat height:

770 mm (30.3 in) Wheelbase:

1295 mm (50.1 in) Ground clearance:

165 mm (6.50 in) Minimum turning radius:

2100 mm (82.7 in) Weight:

With oil and fuel:141 kg (331 lb)

Engine:Engine type:

Air cooled 4-stroke, SOHCCylinder arrangement:

Forward-inclined single cylinderDisplacement:

223 cm³ Bore × stroke:

70.0 × 58.0 mm (2.76 x 2.28 in) Compression ratio:

9.5 : 1Starting system:

Electric starter and kickstarter

Spark plug (s):Manufacturer/model:

NGK DP8EA-9 Spark plug gap:

0.8–0.9 mm (0.031–0.035 in)Clutch:

Clutch type:Wet, multiple-disc

Transmission:Primary reduction system:

Spur gearPrimary reduction ratio:

74/24 (3.083)Secondary reduction system:

Chain driveSecondary reduction ratio:

44/15 (2.933)Transmission type:

Constant mesh 5-speedOperation:

Left foot operationGear ratio:

1st:36/14 (2.571)

2nd:32/19(1.684)

3rd:28/22 (1.273)

4th:26/25 (1.040)


EAU26320

Lubrication system:Wet sump

Engine oil:Type:

YAMALUBE 4 T SJ. 20W-50 MA or SAE20W40 or SAE20W50

Recommended engine oil grade:API service SF, SG type or higherJASO MA

Engine oil quantity:Periodic oil change :

1.2 L (1.26 US qt) (0.96 Imp.qt)Whit oil filter element replacement :

1.3 L (1.36 US qt) (1.04 lmp.qt)

Air filter:Air filter element:

Wet type elementFuel:

Recommended fuel:Regular unleaded gasoline only

Fuel tank capacity:13.4 L (3.54 US gal) (2.95 Imp.gal)

Carburetor:Manufacturer:

MIKUNIType × quantity:

BS30 x 1

Total Capasity 1.4 L (1.47 US qt) (1.12 Imp.qt)

5th:23/27 (0.852)

Fuel reserve amount:2.4 L (0.63 US gal) (0.93 Imp.gal)

SPECIFICATIONS

8-2

8

Caster angle:25.3 °

Trail:85.0 mm

Front tire:Type:

With tubeSize:


IRC/NR65

Loading:Maximum load:

180 kg (397 lb)(Total weight of rider, passenger, cargo and accessories)

Tire air pressure (measured on cold tires):

Rear tire:Type:

With tubeSize:


IRC/NR65

Rear:200 kPa (29 psi) (2.00 kgf/cm²)

Loading condition:100 kg - Maximum loadFront:

200 kPa (29 psi) (2.00 kgf/cm²)Rear:

225 kPa (33 psi) (2.25 kgf/cm²)Front wheel:

Wheel type:Casting wheel

Rim size:18x1.60

Rear wheel:Wheel type:

Casting wheelRim size:

18x2.15

Loading condition:up to 100 kg Front:

200 kPa (29 psi) (2.00 kgf/cm²)

Front brake:Type:

Single disc brake Operation:

Right hand operationRecommended fluid:

DOT 3 or 4Rear brake:

Type:Drum brake

Operation:Right foot operation

Spring/shock absorber type:Coil spring/oil damper

Wheel travel:140.0 mm

Rear suspension:Type:

Swingarm (Monocross suspension) Spring/shock absorber type:

Coil spring/oil damperWheel travel:

100.0 mm Electrical system:

Ignition system:DC. CDI

Charging system:CDI magneto

Battery:Model:

GM 7B-4B/YB 7B-B Voltage, capacity:

12 V, 7,0 AhHeadlight:

Bulb type:Halogen bulb

Bulb voltage, wattage × quantity:Headlight:

12 V, 35 W/36.5 W × 1Tail/brake light:

12 V, 5.0 W/21.0 W × 1

Front suspension:Type:

Telescopic fork


Chassis:Frame type:

Double cradle

SPECIFICATIONS

8-3

8

Position light:12 V, 3.4 W × 1

Meter lighting:12 V, 3.4 W × 2

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 × 2

Fuse:Fuse:

15 A


Front turn signal light:12 V, 10.0 W × 2

Rear turn signal light:12 V, 10.0 W × 2

CONSUMER INFORMATION

9-1

9

EAU26360

Identification numbers Record the key identification number,vehicle identification number and en-gine serial number in the spaces pro-vided below for assistance whenordering spare parts from a Yamahadealer or for reference in case the vehi-cle is stolen.KEY IDENTIFICATION NUMBER:

VEHICLE IDENTIFICATION NUMBER:

ENGINE SERIAL NUMBER:

Key identification number

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

Vehicle identification number

1. Key identification number

1. Vehicle identification number

The vehicle identification number isstamped into the rear frame.

TIP :The vehicle identification number isused to identify your vehicle and maybe used to register it with the licensingauthority in your area.


EAU26410

EAU26343

1

EAU26390

1

CONSUMER INFORMATION

9-2

9

Engine serial number

1. Engine serial number

The engine serial number is stampedinto the crankcase.


EAU26440

1


YAMAHA INDONESIA MOTOR MANUFACTURINGPRINTED IN INDONESIA

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A5-yoko Blank.fm Page 1 Tuesday, April 8, 2003 11:43 AMA5-yoko_Blank.fm Page 1 Tuesday, April 8, 2003 11:43 AM 54D-F8199-E0 OWNER’S MANUAL Read this manual carefully before operating