welcome to hong leong yamaha motor2019/01/01 · t115sec . owner’s manual does not only instruct...

INTRODUCTION

WARNING

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

Welcome to the Yamaha world of motorcycling!As the owner of the T115S / T115SE / T115SEC, 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 T115S / T115SE / T115SEC . Owner’s Manual does not only instruct you in how to operate, inspect and maintain your motorcycle, but also in how to safeguard yourself 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 any further 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 current product information available at the time of printing, there may be minor discrepancies between your motorcycle and this manual. If there is any question concerning this manual, please consult a Yamaha dealer.

IMPORTANT MANUAL INFORMATION

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

NOTICE:

TIP :

WARNING

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

A WARNING indicates a hazardous situation which, if not avoid, could resultin 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.

TABLE OF CONTENTSLOCATION OF IMPORTANT LABEL ....................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 ........................3-1

Indicator lights ..............................................3-3Speedometer unit .....................................3-3Fuel gauge ....................................................3-4Handlebar switches ....................................3-4Shift pedal .....................................................3-5Brake lever ...................................................3-5Brake pedal .................................................3-5Fuel tank cap ...............................................3-6Fuel .................................................................. 3-6Starter ( choke) lever ................................ 3-7Kickstarter ...................................................... 3-8Seat .................................................................. 3-8Helmet holders .......................................... 3-9Storage compartment ............................ 3-9Sidestand ....................................................... 3-9

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

OPERATION AND IMPORTANT RIDING POINTS ................................................. 5-1

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

Replacing the air filter element ............ 6-12

Adjusting the engine idlingspeed .......................................................... 6-14

Adjusting the throttle cablefree play ................................................... 6-14Valve clearance ....................................... 6-15Tires ............................................................... 6-15Wheels ........................................................ 6-17

Checking the brake lever free play ..................................................... 6-18Adjusting the brake pedal free play .................................................... 6-18Adjusting the rear brake light switch ......................................................... 6-19Checking the front brake pads and rear brake shoes ...................................... 6-19Checking the front brake fluid level ................................................... 6-20Changing the brake f luid .................... 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

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

SAFETY INFORMATION ..................................1-2

Key hole cover . ..........................................3-2

T115S/T115SE/T115SECOWNER’S MANUAL

©2013 by Yamaha Motor Co., Ltd.1st edition, August 2013

All rights reserved.Any reprinting or unauthorized use without the written permission of

Yamaha Motor Co., Ltd is expressly prohibited.

Printed in Malaysia

IMPORTANT MANUAL INFORMATION

LOCATION OF IMPORTANT LABELS

1-1

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

1

1-2

Safe Riding tersections are the most likelyBe a Responsible Owner Perform the pre-operation checks each places for motorcycle accidents

time you use the vehicle to make sure it to occur.

is in safe operating condition. Failure to • Ride where other motorists can

inspect or maintain the vehicle properlysee you. Avoid riding in another

increases the possibility of an accidentmotorist’s blind spot.

or equipment damage. See page 5-1Many accidents involve inexperi-

for a list of pre-operation checks.enced operators. In fact, many op-

This motorcycle is designed toerators who have been involved in

carry the operator and a passen-accidents do not even have a cur-

ger.rent motorcycle license.

The failure of motorists to detect• Make sure that you are qualified

He or she should:and recognize motorcycles in traf-

and that you only lend your mo-

Obtain thorough instructions fromfic is the predominating cause of

torcycle to other qualified opera-

a competent source on all aspectsautomobile/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 may

nance 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 motorcycle

and proper riding techniques.

ing the chance of this type ofwhere 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 of

Manual 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 been

approaching and passing caused by error of the motorcycle

through intersections, since in- operator. A typical error made by

SAFETY INFORMATION

As the vehicle’s owner, you are responsible for the safe and proper operation of your motorcycle.Motorcycles are single-track vehicles.Their safe use and operation are dependent upon the use of proper riding techniques as well as the expertise of the operator. Every operator should know the following requirements before riding this motorcycle.

1

SAFETY INFORMATION

1-3

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 smellhands 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 alwaysNever wear loose-fitting clothes, levels of carbon monoxide can lingerhold onto the operator, the seatotherwise 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 bothand 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 unlessthat covers your legs, ankles, and fresh air, and SEEK MEDICAL TREAT-he or she can firmly place bothfeet. The engine or exhaust sys- MENT.feet on the passenger footrests.

1

SAFETY INFORMATION

1-4

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 theDo 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, frontDo not run engine outdoors where 150 kg (331 lb) fork, or front fender. Theseengine exhaust can be drawn into items, including such cargo asWhen loading within this weight limita building through openings such sleeping bags, duffel bags, orkeep the following in mind:as windows and doors. tents, can create unstable han-Cargo and accessory weight

dling 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 aspull a trailer or to be attached toclose to the center of the vehiclea sidecar.as possible and make sure to dis-

tribute the weight as evenly as Genuine Yamaha AccessoriesChoosing 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

1

SAFETY INFORMATION

1-5

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-

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3

7 8

4 5 61 2

1

DESCRIPTION

Left view

. Front Turn signal light /Auxilliary (page 6-28) 5 . Owner tool kit (page 6-1) 2 . Headlight (page 6-27) 6. Tail/brake light (page 6-2) 3 . Mirror 7. Shift pedal (page 5-2) 4 . Helmet holder (page 6-17) 8. Engine oil drain bolt (page 6-8)

2-1

2

1 2 3 4 10

5 6 7 8 9

2-2

DESCRIPTION

Right view

1. Fuel tank cap egap( 3-7) 6. Kick starter (page 6-18)2. Rear brake light switch (page 3-7) 7. Brake pedal

10. Pilot light

(page 6-8)

(page 6-5)

3. Battery (page 3-6) 8. Engine oil filter element )61-6 egap(4. Front brake reservoir (page 6-25) 9. Air filter (page 6-9)5. Engine oil filler cap egap( 3-8)

2

DESCRIPTION

2-3

Controls and instruments

1. Left handlebar switches (page 3-4)2. Speedometer unit (page 3-3)3. Fuel meter (page 3-4)

4. Main switchRight handlebar switchesThrottle grip.

(page 3-1) 5. (page 3-4)6. (page 6-21)

2

3-1

INSTRUMENT AND CONTROL FUNCTIONSMain switch/steering lock

OF FAll electrical systems are off. The keycan be removed.

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

To lock the steering1. Turn the handlebars all the way to

the left.2. P ush the key in from the “OFF ” po-

sition, release it, and then turn it

3. R emove the key.

To unlock the steeringInsert the key in, and then turn it to“ OF F ”.

WARNINGNever turn the key to “OFF” or “ LOCK ” while the motorcycle ismoving, otherwise the electricalsystems will be switched off, whichmay result in loss of control or anaccident. Make sure that the motor-cycle is stopped before turning thekey to “ OFF ” or “ LOCK ” .

TIP :

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

to "LOCK"

L OCK

OF F (Push/Release)

LOCK (Insert)

OF F

The main switch/steering lock controls the ignition and lighting systems, and is used to lock the steering and is used to open the seat also. The various position are described below.

The main switch is equipped with a key cover. (see page 3-2 for opening and closing prosedure)

3

Keyhole cover

3-2

1. push shut bottom

1. Shutter key To open the keyhole cover To close the keyhole cover

Push the push shut bottom afterremove the key.

For open and close keyhole cover Insert the key head into the key holecover receptacle as shown, and2. Ignition switchthen turn the key to the left to openFor starting the enginethe cover.

INSTRUMENT AND CONTROL FUNCTIONS

1 2

3

Engine trouble warning light " "This warning light comes on or flasheswhen an electrical circuit monitoringthe engine is defective. When thisoccur, have a Yamaha dealer checkthe self diagnosis system.The electrical circuit of the warninglight can be checked by turning thekey to "ON". The warning light willlight up for a few seconds. If lightdoes not light up or stays light up,please procced to Yamaha dealerto check it’s fault.


High beam indicator lightThis indicator light comes on when thehigh beam of the headlight is switchedon.

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

“ ”

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

Indicator lights

1. Turn signal indicator light " "

2. High beam indicator light “ ”3.4.5. Engine trouble warning light " "

Neutral indicator light " "

Gear position indicator lights "1","2","3", and "4"The respective indicator light comes on when the transmission is in the 1st, 2nd, 3rd or 4th gear position.

The speedometer unit is equipped witha speedometer and an odometer. Thespeedometer shows riding speed. Theodometer shows the total distance trav-eled.

Gear position indicator light “1” “2” “3” “4”

1. Speedometer2. Odometer

1 2 3 4 5 1 2

Turn signal indicator light

3

3-3

Press this switch to sound the horn.

Start switch " "


3-4

The fuel gauge indicates the amount offuel in the fuel tank. The needle movestowards “E” (Empty) as the fuel leveldecreases. When the needle reachesthe red zone, approximately 1.0 L (0.26US gal) (0.22 Imp.gal) remain in thefuel tank. If this occurs, refuel as soonas possible.

TIP :Do not allow the fuel tank to emptyitself completely.The main switch must be turned to“ON” for the fuel gauge to display

Turn signal switch “ / ” To signal a right-hand turn, push thisswitch 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.

Horn switch “ ”

“ ”NOTICE :

See page 5-1 for starting instruc-tions prior to starting the engine.

Handlebar switchesLeft

Start switch “ "Push this switch to crank the enginewith the starter.

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

Fuel gauge

1.2.

Red zone Fuel gauge Dimmer switch “ / ”

Turn signal switch “ / ”3.

Horn switch “ ”1.2.

Right

1.

3

Shift pedal Brake lever

1. Brake lever 1. Brake pedal.

The shift pedal is located on the left The brake lever is located at the right The brake pedal is on the right side ofside of the engine. This motorcycle is handlebar grip. To apply the front the motorcycle. To apply the rearequipped with a constant-mesh 4 brake, pull the lever toward the handle- brake, press down on the brake pedal.speed transmission. bar grip.

TIP :Use your toes to shift up and your heelto shift down.


3-5

Brake p edal

1. Shift pedal

1 1

1

3


3-6

Fuel tank cap

To remove the fuel tank cap1. Open the seat. (See page 3-8).2. Turn the fuel tank cap counter-

clockwise and pull it off.

To install the fuel tank cap1. Insert the fuel tank cap into the

tank opening and turn it clockwiseuntil the m“ ” arks on the cap andtank are aligned.

2. Close the seat.

1. Fuel tank filler tube2. Fuel level

1. Fuel tank cap2. " " Aligner mark

WARNING

Fuel

WWWARNIARNIARNI NGNGNGWARNING

Make sure there is sufficient gasolinein the tank.

1. 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.

3

12

Gasoline and gasoline vapors are extremely flammable. To avoid fire and explosions and to reduce the risk of injury when refueling, follow these instructions.

Make sure that the fuel tank cap is properly closed before riding.

Do not overfill the fuel tank. Stop filling when the fuel reaches the bottom of the filler tube. Because fuel expands when it heats up, heat from the engine or the sun can cause fuel to spill out of the fuel tank.

3


3-7

3. Wipe up any spilled fuel imme-diately. NOTICE: Immediatelywipe off spilled fuel with a cle -an, dry, soft cloth, since fuelmay deteriorate painted sur-faces or plastic parts.

4. Be sure to securely close thefuel tank cap.

WWARNIARNI NGNG

Recommended fuel:Regular unleaded gasoline only

Fuel tank capacity:4.1 L

NOTICE :

WARNING

Gasoline is poisonous and can cause injury or death. Handle gasoline with care. Never siphon gasoline by mouth. If you should swallow some gasoline or inhale a lot of gasoline vapor, or get some gasoline in your eyes, see your doctor immediately. If gasoline spills on your skin, wash with soap and water. If gasoline spills on your clothing, change your clothes.

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

3


3-8

Kick starter Seat

1. Kickstarter 1. Seat lock

If the engine fails to start by pushing thestart switch, try to start it by using thekickstarter. To start the engine, fold outthe kickstarter lever, move it down light-ly with your foot until the gears engage,and then push it down smoothly butforcefully.

SeatTo open the seat1. Place the motorcycle on the center-

stand.2. Insert the key into the main switch,

and then turn it counterclockwise to"OPEN".

TIP :Do not push inward when turning thekey.

3. Fold the seat up.

To close the seat1. Fold the seat down, and then

push it down to lock it in place.2. Remove the key from the main

switch if the motorcycle will be left unattended.

TIP : Make sure that the seat is properly secured before riding.

2

11

2. Seat

3


3-9

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

WARNING

The 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.

Storage compartment

WARNING

Helmet holders

1. Helmet holder

1. Storage compartmentThe helmet holders are located under

The storage compartment is locatedthe seat.

under the seat. (See page 3-8.)To secure a helmet to a helmet holder

When storing the owner ’s manual or1. Open the seat. (See page 3-8.)

other documents in the storage com-2. Attach a helmet to a helmet holder,

partment, be sure to wrap them in aand then securely close the seat.

plastic bag so that they will not get wet.WARNING ! Never ride with a

When washing the vehicle, be careful

helmet attached to the helmet

not to let any water enter the storage

holder, since the helmet may

compartment.

hit objects, causing loss of controland possibly an accident.

To release a helmet to a helmet holderOpen the seat, remove the helmet fromthe helmet holder, and then close theseat.

1

1

3

PRE-OPERATION CHECKS

4-1

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

Before using this vehicle, 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 providedin this manual, have the vehicle inspected by a Yamaha dealer.

WARNING

4


4-2

Pre-operation check list ITEM CHECKS PAGE

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

3-7

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 lea kage.

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 necess ary. 6-2 1

Drive chain

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

6-19, 6-2 0

4


4-3

Wheels and tires

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

6-1 3, 6-15

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

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

Centerstand, sidestand • Make sure that operation is smooth.• Lubricate pivots if necessary. 6-2 2

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

Instruments, lights, signals and switches

• Check operation.• Correct if necessary. —

Battery • Check Voltage. 6-2 5

ITEM CHECKS PAGE

4

OPERATION AND IMPORTANT RIDING POINTS

5-1

Read the Owner's Manual carefully to become familiar with all controls. If there is a control or function you do notunderstand, ask your Yamaha dealer.

WARNING

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.

Starting and warming up a cold engine

1. Turn the key to “ON ”.2. Shift the transmission into the neu-

tral position.

TIP :When the transmission is in the neutralposition, the neutral indicator lightshould be on, otherwise have aYamaha dealer check the electrical cir-cuit.

3. Place the vehicle on the center-stand.

WARNING

Before starting the engine, makesure the transmission is in neutraland that the vehicle is placed on thecenterstand.

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

NOTICE:NOTICE :

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

NOTICE :

5


5-2

Starting a warm engine Follow the same procedure as for start-ing a cold engine.

Shifting

Shifting gears lets you control theamount of engine power available forstarting off, accelerating, climbing hills,etc. When shifting gears, fully return thethrottle grip. The use of the shift pedalis shown in the illustration.

1. Shift pedalN. Neutral position

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.

5. NOTICE: For maximum enginelife, always warm the engineup before starting off. Neveraccelerate hard when the engineis cold!

5


5-3

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

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).

Engine break-in 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.

NOTICE :

Make sure that the transmissionis completely shifted into gear.Be sure to fully close the throttlegrip when shifting.

Make sure the neutral indicatorlight comes on when the trans -mission is in the neutral posi-tion.

5


5-4

150–500 km (90–300 mi)

Avoid prolonged operation above 1/2throttle. Rev the engine freely throughthe gears, but do not use full throttle at any time.

500 –1000 km (300 –600 mi)

Avoid prolonged operation above 3/4throttle.

0-150 km (0-90 mi)

Avoid prolonged operation above 1/3throttle.After every hour of operation, stop theengine, and then let it cool for five to tenminutes.Vary the engine speed from time totime. Do not operate the engine at oneset throttle position.

5


5-5

ParkingWhen parking, stop the engine, andthen remove the key from the mainswitch.

WARNING

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.

1000 km (600 mi) and beyond

Avoid prolonged full-throttle o peration.Vary the engine speed occasionally.NOTICE: After 1000 km (600 mi) of operation, the engine oil must bechanged, the oil filter cartridgeor element replaced, and the oilstrainer cleaned. If any enginetrouble should occur during theengine break-in period, immedia-tely have a Yamaha dealer checkthe vehicle.

5


5-6

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

5-7

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


5

6-1

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.

WARNING

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

Owner’s tool kit

The owner ’s tool kit is located inside thestorage compartment under the seat.(See page 3-8.)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.

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

WARNING

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

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

NOTICE :

1

PERIODIC MAINTENANCE AND MINOR REPAIR

6


6-2

Periodic maintenance and lubrication chart

TIP :The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.From 8,000 km, repeat the maintenance intervals starting from 4,000 km.Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technicalskills.

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• Check.

• Replace.

5 * Battery • Check Voltage & terminals.

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

• Replace brake pads. Whenever worn to the limit

Every 16,000 km

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 2 4 6 8

6


6-3

9 * Wheels• Check runout, spoke tightness and for damage.• Tighten spokes if necessary (for spoke wheel).

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 24,000 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 24,000 km

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

16 Sidestand, centerstand • Check operation.• Lubrica te.

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

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

19 * Fuel Injection • Adjust engine idling speed.

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

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


CHECK0.5 2 4 6 8

6

6-4

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 cables • 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 damage.• Replace any damaged parts if necessary.

27 * Lights, signals and switches• Check operation.• Adjust headlight beam.


CHECK0.5 2 4 6 8


6


6-5

Removing and installing the cowlings and panel

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.

1. Cowling A 4. Side cover2. Cowling B 5. Rear panel3. Panel

To install and remove cowling.

Remove cowling ARemove screw Cowling shown,and then take the Cowling A out.

1. Cowling A2. Screw ( x4 )

1. Cowling rear2. Screw ( x6 )

To install Cowling A

Place the Cowling in the original position, and then install the screw.

12

35

4

6

6-6


1. Cowling B2. Screw ( x2 )

1. Cowling B2. “Screw” Cowling ( x4 )

1. Cover cowling B2. “Screw” cowling ( x2 )

1. “Screw” cowling ( x2 )

Cowling B

To remove cowling B Remove screws cowling B as shownand remove cowling B.

To install cowling B Install cowling B in the original positionand install screws.

6


6-7

Panel Rear panel

To remove the panel1. Open the seat. (See page 3-8.)2. Remove the screw and bolts, and

then pull the panel off as shown.

1. Panel1. Rear panel2. Screw

2. Screw3. Bolt

To install the panelPlace the panel in the original position,and then install the screw and bolts.

To remove rear panel1. Remove screw.2. Pull rear portion upwards and slide to the rear to remove rear panel.

To install rear panel

1. Place rear panel portion first and press fit the front portion.2. Install screws.

6


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 wrench

Side cover

1. Battery cover2. Screw ( x 1 )

1. Side cover2. Screw ( x4 )

1. Side cover2. Front screw ( x 1 )

To remove side coverRemove screw from side coveras shown and remove side cover.

To install side coverInstall side cover as shown init’s position and install screw.

6-8

6

To remove the spark plug

1. Place the vehicle on the center-stand.

2. Remove panel* (see page 6-5) 3. Remove the spark plug cap.4. Remove the spark plug as shown

with the spark plug wrench includedin the owner tool kit.


6-9

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.

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.

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.

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. Install the spark plug cap .

Specified spark plug:NGK CR6HSA / DENSO U20FSR-U

1. Spark plug gap

Spark plug gap:0. 6–0.7 mm (0.0 23–0.0 27in)

Tightening torque:Spark plug:

12.5 Nm (1.25 m·kgf, 9.0 ft ·lbf)

5. Install the panel.

6


6-10

Engine OilThe engine oil level should be checkedbefore each ride. In addition, the oilmust be changed in the periodic main-nance and lubrication chart.

To check the engine oil level1. Pl ace the vehicle on the center-

stand.

TIP :Make sure that the vehicle is positionedstraight up when checking the oil level.A slight tilt to the side can result in afalse reading.

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

3. Wait a few minutes until the oil set-tles, remove the oil filler cap, wipethe dipstick clean, insert it backinto the oil filler hole (withoutscrewing it in), and then remove itagain to check the oil level.

TIP :The engine oil should be between theminimum and maximum level marks. 4. If the engine oil is at or below the

minimum level mark, add sufficientoil of the recommended type toraise it to the correct level.

5. Insert the dipstick into the oil fillerhole, and then tighten the oil fillercap.

1. Engine oil filler cap 1. Dipstick2. Maximum level mark

3. Minimum level mark

2

1

3

11

6


6-11

NOTICE :

Before installing the engine oil drainbolt, do not forget to install thewasher bolt.

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

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

To change the engine oil

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, fromcrankcas e.

1. Engine oil drain bolt

TIP :Skip step 4-6 if the oil filter element isnot being replaced.

1. Bolt2. Oil filter element cover

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

5. Remove and replace the oil filterelement and O-ring.

1. Oil filter element

2. O-ring

Tightening torque:E ngine filter element cover bolt:

10 Nm (1.0 m·kgf, 7.2 ft·lbf)

7. Install the engine drain bolt, andthen tighten the drain bolt to the

1

2

specified torque.

1

6


6-12

9. 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.

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

Tightening torque:Engine oil drain bolt:

20 Nm (2.0 m·kgf, 20 ft·lbf)

8. Add the specified amount of therecommended engine oil, and theninstall and tighten the oil filler cap.

Recommended engine oil:See page 8-1.

Oil quantity:Total amount

1 L (1.05 US qt) (0. 80 Imp.qt)Periodic oil change :

0.80 L (0.85 US qt) (0. 70 Imp.qt)

NOTICE :

Before installing the engine oil drainbolt, do not forget to install thewasher bolt.

Replacing the air filter element

The air filter element should be replacedat the intervals specified in the periodicmaintenance and lubrication chart.C lean the air filter element more fre-quently if you are riding in unusuallywet or dusty areas.

1. Remove cowling (see page 6- 5).2. Remove the air filter case cover by

removing the screws and thenpull the air filter element out.

1. Air filter2. Air filter case cover

NOTICE :

Always use Yamalube oil only.Make sure that no foreign mate-rial enters the crankcase. 1

2

6

NOTICE :

This model uses viscous typeair filter element that does notrequire any cleaning. Onceachieving distance of 16,000kmreplace with new air filterelement.


6-13

5. Install the air filter case cover by in-stalling the screws.

TIP :If dust or water collects in the air filtercheck hose, remove the clamp from it,and then remove the plug to drain thehose.

6. Install the cowling.

1. Air filter element

3. Remove used air filter element and replace it with new.

4. 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.

1

6

6


6-14

Adjusting the engine idlingspeed The engine idling speed must bechecked and, if necessary, adjusted asfollows at the intervals specified in theperiodic maintenance and lubricationchart.The engine should be warm beforemaking this adjustment.

TIP :The engine is warm when it quicklyresponds to the throttle.A diagnostic tachometer is neededto make this adjustment.

1. Remove cowling A. (See page6-5.)

2. Attach the diagnostic tachometerto the spark plug lead.

3. Check the engine idling speedand, if necessary, adjust it to spec-ification by turning the idling adjustscrew. To increase the engineidling speed, turn the screw in di-rection (a). To decrease the en-gine idling speed, turn the screw indirection (b).

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

4. Install the cowling.

Adjusting the throttle cable free play

The throttle cable free play should mea-sure 3.0 –7.0 mm (0.12 –0.28 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.

1. Idling adjust screw

Engine idling speed:1300 –1500 r/min

1. Throttle cable free play

a

6

6


6-15

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. T ighten the locknut.

Valve clearanceThe 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.

TiresTo 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.

WARNING

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. Locknut2. Adjusting nut

1. Loosen the locknut

6


6-16

WARNINGProper 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 (tube / tubeless tires)

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

Tire informationThis motorcycle is equipped with tubetires for spoke wheels and tubeless forcast wheels.

WARNING

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): (tube / tubeless tires)

0–90 kg (0 –198 lb):Front:

200 kPa (29 psi) (2.00 kgf/cm2)Rear:

225 kPa (33 psi) (2.25 kgf/cm2)90–110 kg (198 –243 lb):

Front:200 kPa (29 psi) (2.00 kgf/cm2)

Rear:225 kPa (33 psi) (2.25 kgf/cm2)

Maximum load*:150 kg (331 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)

The tires must be checked before each ride. If the tire shows crosswise lines (minimum tread depth), if the tire has a nail or glass fragments in it, or if the sidewall is cracked, have a Yamaha dealer replace the tire immediately.

6

6


6-17

WARNING

It is dangerous to ride with a

WARNING

Do not incinerate, puncture or openair / gas chamber.

worn-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.

Wheels To maximize the performance, durabil-

Air / gas shock absorber (cast wheels)Air / gas shock absorber uses extramembrane to separate oil from theair chamber.

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

The wheel rims should be checkedfor cracks, bends or warpage, andthe spokes for looseness (for spoke

each ride. If any damage is found,have a Yamaha dealer replacethe wheel. Do not attempt eventhe smallest repair to the wheel.A deformed or cracked wheel mustbe 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.Ride at moderate speeds afterchanging a tire since the tire sur-face must first be “broken in ” for itto develop its optimal characteris-tics.

Front tire:

Tube for spoke wheelsTubeless for cast wheels

Size:70/90 -17M/C 38P

Manufacturer/model:Vee Rubber / V322F

Rear tire:Size:

80/90-17M/C 44PManufacturer/model:

Vee Rubber / V322R

wheel model) or damage before

1. Oil2. Membrane3. Air / gas chamber (High pressure)

6

6-18

Checking the brake lever free play

There should be no free play at thebrake lever end. If there is free play,have a Yamaha dealer inspect thebrake system.

WARNING

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 aYamaha 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.

Adjusting the brake pedal free play

The brake pedal free play should mea-sure 25.0 –35.0 mm (0.98 –1.38 in) atthe brake pedal end as shown. Period-ically check the brake pedal free playand, if necessary, adjust it as follows.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).

1. Brake pedal free play1. Brake pedal free play adjusting nut

WARNING

After adjusting the drive chainslack 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.

(a)

(b)

(a)

(b)1


6

1 2


6-19

Adjusting the rear brake lightswitch

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).

Checking the front brake pads and rear brake shoesFront brake pads

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

1. Brake pad wear indicator groove 1. Brake shoe wear limit line2. Brake shoe wear indicator

1 1

The front brake pads and the rear brake shoes must be checked for wear at the intervals specified in the periodic maintenance and lubrication chart.Each front brake pad is provided with wear indicator grooves, which allow you to check the brake pad wear without having to disassemble the brake. To check the brake pad wear, check the wear indicator grooves. If a brake pad has worn to the point that the wear indicator grooves have almost disappeared, have a Yamaha dealer replace the brake pads as a set.

6


6-20

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 Changing the brake fluid

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


6-21

Drive chain slack

1. Drive chain slack

The drive chain slack should bechecked before each ride and adjustedif necessary.

To check the drive chain slack

1. P lace the motorcycle on the cen-terstand.

2. Shift the transmission into the neu-tral position.

3. Spin the rear wheel several timesto locate the tightest portion of thedrive chain.

4. Measure the drive chain slack asshown.

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

To adjust the drive chain slack

1. Locknut2. Drive chain slack adjusting nut 3. Axle nut

1. Loosen the brake pedal free playadjusting nut and the brake torquerod nut.

2. Loos en the axle nut, then loosenthe locknut at each end of theswingarm.

Drive chain slack:25.0 –35.0 mm (0.9 8–1.38 in)

1

(a)

(b)

2 3

a

6


6-22

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

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

WARNING

After adjus ting the brake pedal freeplay, check the operation of thelight.

brake

1. Locknut2. Drive chain slack adjusting nut.3. Alignment marks

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:Axle nut:

60 Nm (6.0 m·kgf, 43 ft ·lbf)Brake torque rod nut:

19 Nm (1.9 m·kgf, 14 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-

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

proper drive chain slack will overload the engine as well asother 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 specified limits.

WARNING

4. Tighten both locknuts, and then tighten the axle nut and braketorque rod nut to their specified torque.

12

(a)

(b)

3

6


6-23

Checking and lubricating the 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.

Checking and lubricating the 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

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 :

The drive chain must be lubricatedafter washing the motorcycle andriding in the rain.

1. Remove all dirt and mud from thedrive chain with a brush or cloth.

TIP :For a thorough cleaning, have aYamaha dealer remove the drive chainand soak it in solvent.

2. Spray Yamaha Chain and CableLube or a high-quality spray-typedrive chain lubricant on both sidesand on the middle of the chain,making sure that all side platesand rollers have been sufficientlyoiled.

6

6-24

Lubricating the brake lever

The pivoting point of the brake lever The operation of the brake pedalmust be lubricated at the intervals should be checked before each ride,specified in the periodic maintenance and the pedal pivot should be lubricat-and lubrication chart. ed if necessary.

Recommended lubricant: Recommended lubricant:Engine oil Lithium-soap-based grease (all-pur-

pose grease)

Lubricating the brake pedal 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.

WARNING

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)


6


6-25

Lubricating the swingarm pivotsThe swingarm pivots must be lubricat-ed at the intervals specified in the peri-odic maintenance and lubrication chart.

Checking the front fork 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

securely support the vehicle so that there is no danger of it fal-

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 injury

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

Recommended lubricant:Lithium-soap-based grease

ling over.

NOTICE :

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

6


6-26

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 a stand under the engine toraise the front wheel off the ground.WARNING! To avoid injury se-curely support the vehicle so that there is no danger of it fal-

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 bearings 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.

ling over. 6

PERIODIC MAINTENANCE AND MINOR REPAIRBattery

This model is equipped with a VRLA(Valve Regulated Lead Acid) battery.There is no need to check the electro-lyte or to add distilled water. However,the battery lead connections need to bechecked and, if necessary, tightened.

1. Battery terminals

NOTICE :Never attempt to remove the batterycell seals, as this would permanent-ly damage the battery.

WARNINGElectrolyte 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 for15 minutes 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 enclosed space.

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

To charge the battery

Have a Yamaha dealer charge the bat-tery as soon as possible if it seems tohave discharged. Keep in mind that thebattery tends to discharge more quicklyif the vehicle is equipped with optionalelectrical accessories.

NOTICE :

To charge a VRLA (Valve RegulatedLead Acid) battery, a special (con-stant-voltage) battery charger is re-quired. Using a conventional batterycharger will damage the battery. Ifyou do not have access to a con-stant-voltage battery charger, havea Yamaha dealer charge your bat-tery.

WARNING

1

6

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6-28

Replacing the fuse 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.

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.

NOTICEAlways keep the battery charged.Storing a discharged battery cancause permanent battery damage.

NOTICE :

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

Specified fuse:7.5 A

1. Spare fuse and main fuse

The fuse holder is located under theseat. (See page 3-8.)If the fuse is blown, replace it as fol-lows.

1. Turn the key to “OFF ” and turn offall electrical circuits .

2. Remove the blown fuse, and theninstall a new fuse of the specifiedamperage. WARNING! : Do not use a fuse of a higher amperagerating than recommended to a-void causing extensive damage to the electrical system and possibly a fire.

1

6

6-29

3. Place a new bulb into position, andthen secure it with the bulb holder.

NOTICE :

Do not touch the glass part of theheadlight bulb to keep it free fromoil, otherwise the transparency ofthe glass, the luminosity of the bulb,and the bulb life will be adversely af-fected. Thoroughly clean off any dirtand fingerprints on the headlightbulb using a cloth moistened with al-cohol or thinner.

Replacing a headlight bulb

1. Headlight bulb holder

If a headlight bulb burns out, replaceas follows.

1. Remove cowling B. (See page6-6.)

2. Remove the headlight bulb holderby pushing it inward and turning counterclockwise, and then re-move the defective bulb.

Headlight bulbs get very hot. Therefore, keep flammable products awayfrom a lit headlight bulb, and do nottouch the bulb until it has cooleddown.

1. Do not touch the glass part of the bulb.

4. Install the cowling.5. Have a Yamaha dealer adjust the

headlight beam if necessary.

Replacing a front turn signallight bulb or an auxiliary light bulb

If a front turn signal light or an auxiliarylight bulb burns out, replace it as fol-lows.

1. Remove front panel and cowlings B,(See page 6-6.)

2. Remove the socket (together withthe bulb) by turning it counter-clockwise.

3. Remove the defective bulb by pull-ing it out.

1. Turn signal light bulb socket2. Auxiliary light bulb socket

2. Cowling B

3. Cowling B

WARNINGWARNING


6


6-30

3. Remove the burnt-out tail/brake light bulb by pushing it in and

turning it counterclockwise

Remove the burnt-out rear turn light bulb by pulling it out. 4. Insert a new bulb tail/brake light into the socket, push it in, and

then turn it clockwise until it stops.Insert a new bulb rear turn in to

the socket. 5. Install the lens by installing the screws. NOTICE: Do not over-

1. Bulb

4. Insert a new bulb into the socket.5. Install the socket (together with the

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

tighten the screws, other wisethe lens may break.

6. Install side cover and rear panel.

Replacing a turn signal light bulb or the tail/brake light bulb

1. Outer lens

2. Outer lens screw

1. Inner lens

2. Inner lens screw

1. Remove rear panel and side co-ver (see page 6-7)

2. Remove the 2 pcs lens by removing the screws.

3. Side cover

6


6-31

Front wheel

To remo ve the front wheel

WARNING

To avoid injury, securely support thevehicle so there is no danger of itfalling over.

1. P lace the m otorcycle on the cen-terstand.

2. Disconnect the speedometer cable from 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 cable2. 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 together with the brake disc, otherwise the brake pads will be for- ced shut.

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


6-32

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.

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

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.

Rear wheel

To remove the rear wheel

WARNING

To avoid injury, securely supportthe vehicle so there is no dangerof it falling over.

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

chain slack adjusting nut on bothends of the swingarm.

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

1. Retainer2. Slot

Tightening torque:Axle nut:

40 Nm (4.0 m·kgf, 29 ft ·lbf)

1. Axle nut and washer2. Drive chain adjusting nut3. Locknut drive chain adjusting nut4. Brake torque rod nut

WARNING

123

4

12

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6-33

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

To install the rear wheel

1. Brake camshaft lever 2. Brake pedal free play adjusting nut 3. Brake torque rod nut and bolt 4. Brake rod5. Washer and Axle nut

4. Disconnect the brake torque rod from the brake shoe plate by remo-ving the cotter pin, the nut, the wa-sher and the bolt.

5. Place the motorcycle on the centerstand.

6. Remove the brake pedal free playadjusting nut, and then disconnectthe brake rod from the brake cam-shaft lever.

7. Remove the axle nut and the wa-sher, and then pull the wheel axleout.

8. Push the wheel forward, and thenremove the drive chain from therear sprocket.

9. Remove the wheel.

TIP :Do not remove the washer on the rightside of the wheel axle so as to notlose 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 rearsprocket.

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

4. Install the brake rod onto the brakecamshaft lever, and then install thebrake pedal free play adjusting nutonto the brake rod.

5. Connect the brake torque rod tothe brake shoe plate by installingthe 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)

14

2 3

5

6


TroubleshootingAlthough 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 6-1 8.)

WARNING

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

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

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6-35

Troubleshooting charts Starting problems or poor engine performance

WARNING

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.

6

MOTORCYCLE CARE AND STORAGE

7-1

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 cleaning

1. Cover the muffler outlet with aplastic 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.

Cleaning

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.

NOTICE :

7

MOTORCYCLE CARE AND STORAGE

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 :Do not use warm water since itincreases the corrosive actionof 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.

WARNING

Make sure that there is no oil orwax on the brakes or tires. Ifnecessary, cle

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