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Yamaha XVS250 Motorcycle User Manual

1. 1 Engine oil level check window 2 Maximum level mark 3 Minimum level mark 4 Engine oil filler cap 4 If the engine oil is below the mini mum level mark add sufficient oil of the recommended type to raise it to the correct level To change the engine oil with or without oil filter element replace ment 1 Start the engine warm it up for several minutes and then turn it off 6 8 1 Engine oil drain bolt 2 Oil pan NOTE Skip steps 4 6 if the oil filter element is not being replaced 4 Remove the oil filter element cover by removing the bolts PERIODIC MAINTENANCE AND MINOR REPAIR Tightening torque Oil filter element cover bolt 10 Nm 1 0 m kgf 7 2 ft Ibf NOTE Make sure that the O ring is properly seated 7 Install the engine oil drain bolt and then tighten it to the specified torque 1 Bolt 5 Remove and replace the oil filter element and O ring Tightening torque Engine oil drain bolt 34 Nm 3 4 m kgf 25 ft Ibf 8 Add the specified amount of the recommended engine oil and then install and tighten the oil filler cap Recommended engine oil See page 8 1 Oil quantity With oil filter element replacement 1 60 L 1 69 US qt 1 41 Imp qt Without oil filter element replace ment 1 40 L 1 48 US qt 1 23 Imp qt 1 Oil filter element 2 O ring 6 Install the oil filter element cover by installing t
2. 1 Fuel m There is enough fuel t Check the compression Check the fuel level in the fuel tank a ned rach e engine does not start There is no fuel Supply fuel gt Check the compression 2 Compression There is compression t Check the ignition Operate the electric starter gt Have a Yamaha dealer There is no compression gt check the Vehicle 3 Ignition Wet Wipe off with a dry cloth and correct the Open the throttle halfway and operate spark plug gaps or replace the spark plugs the electric starter Remove the spark plugs 1 and check the electrodes P The engine does not start Dry Have a Yamaha dealer check the vehicle Check the battery 4 Battery aero e engine MMS OVer L Ti The battery is good quickly The engine does not start Operate the electric starter gt gt Have a Yamaha dealer The engine turns over Check the battery lead connections check the vehicle slowly and charge the battery if necessary 6 36 MOTORCYCLE CARE AND STORAGE EAU26040 Care While the open design of a motorcycle reveals the attractiveness of the tech nology it also makes it more vulnera ble Rust and corrosion can develop even if high quality components are used A rusty exhaust pipe may go un noticed on a car however it detracts from the overall appearance of a motor cycle Frequent and proper care does not only comply with the terms of the w
3. 5 3 10 EAU15300 Sidestand The sidestand is located on the left side of the frame Raise the sidestand or lower it with your foot while holding the vehicle upright NOTE The built in sidestand switch is part of the ignition circuit cut off system which cuts the ignition in certain situations See further down for an explanation of the ignition circuit cut off system The vehicle must not be ridden with the sidestand down or if the side stand cannot be properly moved up or does not stay up otherwise the sidestand could contact the ground and distract the operator resulting in a possible loss of control Yamaha s ignition circuit cut off system has been designed to assist the operator in fulfilling the respon sibility of raising the sidestand be fore starting off Therefore check this system regularly as described EWA10240 below and have a Yamaha dealer re pair it if it does not function proper ly INSTRUMENT AND CONTROL FUNCTIONS EAU15311 Ignition circuit cut off system The ignition circuit cut off system com prising the sidestand switch clutch switch and neutral switch has the fol lowing functions It prevents starting when the trans mission is in gear and the side stand is up but the clutch lever is not pulled It prevents starting when the trans mission is in gear and the clutch le ver is pulled but the sidestand is still down Itcuts the running engine when the t
4. brake fluid level goes down sud denly have a Yamaha dealer check the cause 6 20 EAU22720 Changing the brake fluid Have a Yamaha dealer change the brake fluid at the intervals specified in the NOTE after the periodic mainte nance and lubrication chart In addition have the oil seals of the brake master cylinder and caliper as well as the brake hose replaced at the intervals listed below or whenever they are dam aged or leaking Oil seals Replace every two years Brake hose Replace every four years PERIODIC MAINTENANCE AND MINOR REPAIR EAU22760 Drive chain slack The drive chain slack should be checked before each ride and adjusted if necessary EAU22770 To check the drive chain slack 1 Place the motorcycle on a level surface and hold it in an upright po sition NOTE When checking and adjusting the drive chain slack the motorcycle should be positioned straight up and there should be no weight on it 2 Shift the transmission into the neu tral position 3 Move the rear wheel by pushing the motorcycle to locate the tight est portion of the drive chain and then measure the drive chain slack as shown Drive chain slack 30 0 40 0 mm 1 18 1 57 in 1 Drive chain slack 4 lf the drive chain slack is incorrect adjust it as follows EAU22821 To adjust the drive chain slack 1 Loosen the brake pedal free play adjusting nut axle nut and locknut at each end of th
5. EAU15950 EWA10270 e Become thoroughly familiar with all operating controls and their functions before riding Consult a Yamaha dealer re garding any control or function that you do not thoroughly un derstand e Never start the engine or oper ate it in a closed area for any length of time Exhaust fumes are poisonous and inhaling them can cause loss of con sciousness and death within a short time Always make sure that there is adequate ventila tion e Before starting out make sure that the sidestand is up If the sidestand is not raised com pletely it could contact the ground and distract the opera tor resulting in a possible loss of control EAU16400 Starting a cold engine In order for the ignition circuit cut off system to enable starting one of the following conditions must be met e The transmission is in the neutral position e The transmission is in gear with the clutch lever pulled and the sid estand up e Before starting the engine check the function of the igni tion circuit cut off system ac cording to the procedure described on page 3 11 e Never ride with the sidestand down EWA10290 _ Turn the fuel cock lever to ON 2 Turn the key to ON and make sure that the engine stop switch is set to O 3 Shift the transmission into the neu tral position 5 1 NOTE When the transmission is in the neutral position the neutral indicator light should be
6. INTRODUCTION EAU10100 Welcome to the Yamaha world of motorcycling As the owner of the XVS250 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 XVS250 The 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 con dition 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 IMPORTANT MANUAL INFORMATION EAU10150 Particularly important information is distinguished in this manual by the following notations A The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED 2 WARNING Failure to follow WARNING instructions could result in severe injury or death to the motor cycle operator a bystander or a person inspecting or repairing the motorcycle CAUTION A CAUTION indicates special precautions that must be taken to avoid damage to the motor cycle NOTE A NOTE provides key information to make procedures easier or clearer NOTE
7. oO for the high beam and to zo for the low beam EAU12460 Turn signal switch lt c gt To signal a right hand turn push this switch to gt To signal a left hand turn push this switch to lt s When re leased the switch returns to the center 3 4 position To cancel the turn signal lights push the switch in after it has re turned to the center position EAU12500 Horn switch gt Press this switch to sound the horn EAU12590 Light switch p q lt e Set this switch to p g to turn on the auxiliary light meter lighting and tail light Set the switch to 4 to turn on the headlight also Set the switch to e to turn off all the lights EAU12660 Engine stop switch ON Set this switch to CQ before starting the engine Set this switch to sy to stop the engine in case of an emergen cy such as when the vehicle overturns or when the throttle cable is stuck EAU12710 Start switch Push this switch to crank the engine with the starter ECA10050 CAUTION See page 5 1 for starting instruc tions prior to starting the engine INSTRUMENT AND CONTROL FUNCTIONS EAU12820 Clutch lever EAU12870 Shift pedal 1 Clutch lever The clutch lever is located at the left handlebar grip To disengage the clutch pull the lever toward the handle bar grip To engage the clutch release the lever The lever should be pulled r
8. This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold e Yamaha continually seeks advancements in product design and quality Therefore while this manual contains the most current product information available at the time of printing there may be minor discrepancies between your motorcycle and this manual If you have any questions concerning this manual please consult your Yamaha dealer PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE EWA10030 IMPORTANT MANUAL INFORMATION EAU10200 XVS250 OWNER S MANUAL 2003 by Yamaha Motor Co Lid 1st edition May 2003 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan TABLE OF CONTENTS SAFETY INFORMATION 1 1 OPERATION AND IMPORTANT Adjusting the brake pedal RIDING POINTS cceeeeeereeeeee 5 1 position and free play 6 17 DESCRIPTION o on 2 1 Starting a cold engine s e 5 1 Adjusting the rear brake Left VIOW aosida niia area 2 1 Starting a warm engine 6 5 2 light SWItCH nocere 6 18 Right ViOW eeen 2 2 Shifting iisi ie 5 2 Checking the front brake pads Controls and instruments 2 3 Tips for reducing fuel and rear brake shoes 6 19 CONSUMPTION niecce 5 3 Checking t
9. Vital components can start to deteriorate quickly and unexpectedly even if the vehicle remains unused for example as a result of exposure to the elements Any damage fluid leakage or loss of tire air pressure could have serious consequences Therefore it is very important in addition to a thorough visual inspec tion to check the following points before each ride NOTE Pre operation checks should be made each time the vehicle is used Such an inspection can be accomplished in a very short time and the added safety it assures is more than worth the time involved If any item in the Pre operation check list is not working properly have it inspected and repaired before operating the vehicle EWA11150 4 1 PRE OPERATION CHECKS Pre operation check list CHECKS EAU15601 e Check fuel level in fuel tank e Refuel if necessary e Check fuel line for leakage Engine oil e Check oil level in engine e If necessary add recommended oil to specified level e Check vehicle for oil leakage Front brake e Check operation e If soft or spongy have Yamaha dealer bleed hydraulic system e Check lever free play e Adjust if necessary e Check brake pads for wear e Replace if necessary e Check fluid level in reservoir e If necessary add recommended brake fluid to specified level e Check hydraulic system for leakage 6 16 6 19 6 19 Rear brake e Check operation e Check pedal free play e
10. keep the following precautions in mind e NEVER OVERLOAD THE MOTORCYCLE Operation of an overloaded motorcycle may re sult in tire damage loss of con trol or severe injury Make sure that the total weight of rider EWA11020 passenger cargo and accesso ries does not exceed the speci fied maximum load for the vehicle Do not carry along loosely packed items which can shift during a ride Securely pack the heaviest items close to the center of the motorcycle and distribute the weight evenly on both sides Adjust the suspension and tire air pressure with regard to the load Check the tire condition and air pressure before each ride PERIODIC MAINTENANCE AND MINOR REPAIR Tire inspection 1 Tire sidewall 2 Tire tread depth The tires must be checked before each ride If the center tread depth reaches the specified limit if the tire has a nail or glass fragments in it or if the sidewall is cracked have a Yamaha dealer re place the tire immediately Minimum tire tread depth front and rear 1 6 mm 0 06 in NOTE The tire tread depth limits may differ from country to country Always comply with the local regulations 6 14 Tire information This motorcycle is equipped with tube tires The front and rear tires should be of the same make and de sign otherwise the handling characteristics of the vehicle cannot be guaranteed e After extensive tests only the tires listed below
11. type MF battery which does not re quire any maintenance There is no need to check the electrolyte or to add distilled water ECA10620 CAUTION Never attempt to remove the battery cell seals as this would permanent ly damage the battery 6 26 PERIODIC MAINTENANCE AND MINOR REPAIR EWA10760 ECA10630 e KEEP THIS AND ALL BATTER IES OUT OF THE REACH OF CAUTION e Electrolyte is poisonous and CHILDREN e Always keep the battery dangerous since it contains sul charged Storing a discharged furic acid which causes severe To charge the battery battery can cause permanent burns Avoid any contact with skin eyes or clothing and al ways shield your eyes when working near batteries In case of 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 15 minutes and seek prompt medical attention Batteries produce explosive hy drogen gas Therefore keep sparks flames cigarettes etc away from the battery and pro vide sufficient ventilation when charging it in an enclosed space Have a Yamaha dealer charge the bat tery as soon as possible if it seems to have discharged Keep in mind that the battery tends to discharge more quickly if the vehicle is equipped with optional electrical accessories To store the battery 1 If the vehicle will not be used for
12. 5 Brake pedal free play adjusting nut 6 33 2 Lift the rear wheel off the ground according to the procedure on page 6 31 3 Disconnect the brake torque rod from the brake shoe plate by re moving the nut and the bolt 4 Remove the brake pedal free play adjusting nut and then disconnect the brake rod at the brake cam shaft lever 1 Wheel axle 2 Drive chain slack adjusting nut 3 Locknut 5 Loosen the locknut and the drive chain adjusting nut on both ends of the swingarm 6 Remove the axle nut and then pull the wheel axle out PERIODIC MAINTENANCE AND MINOR REPAIR 7 Push the wheel forward and then remove the drive chain from the rear sprocket NOTE The drive chain does not need to be disassembled in order to remove and install the wheel 8 Remove the wheel EAU25780 To install the rear wheel 1 Insert the wheel axle from the left hand side and then install the axle nut 2 Install the drive chain onto the rear sprocket and then adjust the drive chain slack See page 6 21 3 Lower the rear wheel so that it is on the ground 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 to the brake shoe plate by installing the bolt and the nut and then tight en the nut to the specified torque 6 34 Tightening torque Brake torque rod nut 23 Nm 2 3 m kgf 17 ft
13. SAFETY INFORMATION EAU10250 MOTORCYCLES ARE SINGLE TRACK VEHICLES THEIR SAFE USE AND OPERATION ARE DEPENDENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EX PERTISE OF THE OPERATOR EV ERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIREMENTS BEFORE RIDING THIS MOTOR CYCLE HE OR SHE SHOULD OBTAIN THOROUGH INSTRUC TIONS FROM A COMPETENT SOURCE ON ALL ASPECTS OF MOTORCYCLE OPERATION e OBSERVE THE WARNINGS AND MAINTENANCE REQUIRE MENTS IN THE OWNER S MAN UAL OBTAIN QUALIFIED TRAINING IN SAFE AND PROPER RIDING TECHNIQUES OBTAIN PROFESSIONAL TECH NICAL SERVICE AS INDICATED BY THE OWNER S MANUAL AND OR WHEN MADE NECES SARY BY MECHANICAL CONDI TIONS Safe riding e Always make __ pre operation checks Careful checks may help prevent an accident This motorcycle is designed to car ry the operator and a passenger e The failure of motorists to detect and recognize motorcycles in traf fic is the predominating cause of automobile motorcycle accidents Many accidents have been caused by an automobile driver who did not see the motorcycle Making yourself conspicuous appears to be very effective in reducing the chance of this type of accident Therefore e Wear a brightly colored jacket e Use extra caution when ap proaching and passing through intersections since intersec tions are the most likely places for motorcycle accidents to oc cur 1 1 e Ride where other mot
14. Wet multiple disc Transmission Primary reduction system Spur gear Primary reduction ratio 72 23 3 130 Secondary reduction system Chain drive Secondary reduction ratio 56 20 2 800 Transmission type Constant mesh 5 speed Operation Left foot operation Gear ratio 1st 37 14 2 643 2nd 32 19 1 684 3rd 29 23 1 261 Ath 26 26 1 000 5th 23 28 0 821 Chassis Frame type Double cradle Caster angle 35 0 Trail 135 0 mm 5 31 in Front tire Type With tube Size 80 100 18M C 47P Manufacturer model CHENG SHIN C 916 Manufacturer model IRC MARBELLA NF27 Rear tire Type With tube Size 130 90 15M C 66P Manufacturer model CHENG SHIN C 915 Manufacturer model IRC MARBELLA NR31 Loading Maximum load 180 kg 397 Ib Total weight of rider passenger cargo and accessories Tire air pressure measured on cold tires Loading condition 0 90 kg 0 198 Ib Front 175 kPa 25 psi 1 75 kgf cm Rear 200 kPa 29 psi 2 00 kgf cm Loading condition 90 180 kg 198 397 Ib Front 225 kPa 33 psi 2 25 kgf cm Rear 225 kPa 33 psi 2 25 kgf cm Front wheel Wheel type Spoke wheel Rim size 18x1 60 Rear wheel Wheel type Spoke wheel Rim size 15M C x MT3 00 Front brake Type Single disc brake Operation Right hand operation Recommended fluid Dot 4 SPECIFICATIONS Rear brake Type Drum brake Operation Right foot operation Front suspension Type Telescopic
15. fork Spring shock absorber type Coil spring oil damper Wheel travel 140 0 mm 5 51 in Rear suspension Type Swingarm Spring shock absorber type Coil spring oil damper Wheel travel 100 0 mm 3 94 in Electrical system Ignition system Transistorized coil ignition digital Charging system A C magneto Battery Model GT6B 3 Voltage capacity 12 V 6 0 Ah Headlight Bulb type Halogen bulb SPECIFICATIONS Bulb voltage wattage x quantity Headlight 12 V 60 W 55 0 W x 1 Tail brake light 12V 5W 21 0W x 1 Front turn signal light 12V 21 0Wx2 Rear turn signal light 12V 21 0Wx2 Auxiliary light 12V 40Wx1 Meter lighting 12V 1 7Wx1 Neutral indicator light 12V 1 7Wx1 High beam indicator light 12V 1 7Wx1 Turn signal indicator light 12V 1 7Wx1 Engine trouble warning light 12V 1 7Wx1 Fuses Main fuse 30 0A Headlight fuse 15 0A Signaling system fuse 10 0 A Ignition fuse 10 0 A Carburetor heater fuse 10 0 A 8 3 EAU26351 Identification numbers Record the key identification number vehicle identification number and mod el label information in the spaces pro vided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehi cle is stolen KEY IDENTIFICATION NUMBER Oo i VEHICLE IDENTIFICATION NUMBER Oooo MODEL LABEL INFORMATION CONSUMER INFORMATION EAU26381 Key identification number EAU26400 Vehicle identi
16. have been ap proved for this model by Yamaha Motor Co Lid EWA10460 Front tire Size 80 100 18M C 47P Manufacturer model CHENG SHIN C 916 IRC MARBELLA NF27 Rear tire Size 130 90 15M C 66P Manufacturer model CHENG SHIN C 915 IRC MARBELLA NR31 PERIODIC MAINTENANCE AND MINOR REPAIR EWA10570 Have a Yamaha dealer replace excessively worn tires Besides being illegal operating the motorcycle with excessively worn tires decreases riding sta bility and can lead to loss of control The replacement of all wheel and brake related parts includ ing the tires should be left to a Yamaha dealer who has the necessary professional knowl edge and experience It is not recommended to patch a punctured tube If unavoid able however patch the tube very carefully and replace it as soon as possible with a high quality product EAU21940 Spoke wheels To maximize the performance durabil ity and safe operation of your motor cycle note the following points regarding the specified wheels The wheel rims should be checked for cracks bends or warpage and the spokes for looseness or dam age before each ride If any dam age is found have a Yamaha dealer replace the wheel Do not attempt even the smallest repair to the wheel A deformed or cracked wheel must be replaced The wheel should be balanced whenever either the tire or wheel has been changed or replaced An unbalanced wheel can result in poor
17. more than one month remove the battery fully charge it and then place it in a cool dry place 2 Ifthe battery will be stored for more than two months check it at least once a month and fully charge it if necessary 3 Fully charge the battery before in stallation 4 After installation make sure that the battery leads are properly con nected to the battery terminals 6 27 battery damage To charge a sealed type MF battery a special constant volt age battery charger is required Using a conventional battery charger will damage the battery If you do not have access to a sealed type MF battery charg er have a Yamaha dealer charge your battery PERIODIC MAINTENANCE AND MINOR REPAIR EAU23550 Replacing the fuses The main fuse and the fuse box which contains the fuses for the individual cir cuits are located behind panel B See page 6 5 Main fuse Spare main fuse Headlight fuse Ignition fuse Signaling system fuse Carburetor heater fuse 7 Spare fuse oar WND If a fuse is blown replace it as follows 1 Turn the key to OFF and turn off the electrical circuit in question 2 Remove the blown fuse and then install a new fuse of the specified amperage Specified fuses Main fuse 30 0A Ignition fuse 10 0A Signaling system fuse 10 0A Headlight fuse 15 0 A Carburetor heater fuse 10 0 A ECA10640 CAUTION Do not use a fuse of a higher amper age r
18. motorcycle is in a stable and level position before starting any maintenance A strong wooden box can be placed under the engine for added stability To service the front wheel 1 Stabilize the rear of the motorcycle by using a motorcycle stand or if an additional motorcycle stand is not available by placing a jack un der the frame in front of the rear wheel 2 Raise the front wheel off the ground by using a motorcycle stand To service the rear wheel Raise the rear wheel off the ground by using a motorcycle stand or if a motor cycle stand is not available by placing 6 31 a jack either under each side of the frame in front of the rear wheel or under each side of the swingarm EAU24360 Front wheel EAU24660 To remove the front wheel Itis advisable to have a Yamaha dealer service the wheel Securely support the motor cycle so that there is no danger of it falling over EWA10820 1 Disconnect the speedometer ca ble from the front wheel 1 Speedometer cable 2 Loosen the front wheel axle pinch bolt 3 Remove the rubber cap and then loosen the wheel axle PERIODIC MAINTENANCE AND MINOR REPAIR 1 Front wheel axle pinch bolt 2 Rubber cap 3 Wheel axle 4 Lift the front wheel off the ground according to the procedure on page 6 31 5 Pull the wheel axle out and then remove the wheel ECA11070 CAUTION Do not apply the brake after the wheel has been removed togethe
19. pedal position and if necessary adjust it as follows 6 17 1 Loosen the locknut at the brake pedal 2 To raise the brake pedal turn the adjusting bolt in direction a To lower the brake pedal turn the ad justing bolt in direction b 1 Brake pedal position adjusting bolt 2 Locknut 3 Tighten the locknut After adjusting the brake pedal posi tion the brake pedal free play must be adjusted EWA11230 Brake pedal free play The brake pedal free play should mea sure 20 0 30 0 mm 0 79 1 18 in at the brake pedal end Periodically check the brake pedal free play and if neces sary adjust it as follows To increase the brake pedal free play turn the adjusting nut at the brake rod in direction a To decrease the brake pedal free play turn the adjusting nut in direction b 1 Brake pedal free play adjusting nut e After adjusting the drive chain slack or removing and installing the rear wheel always check the brake pedal free play EWA10680 PERIODIC MAINTENANCE AND MINOR REPAIR If proper adjustment cannot be obtained as described have a Yamaha dealer make this ad justment e After adjusting the brake pedal free play check the operation of the brake light 6 18 EAU22270 Adjusting the rear brake light switch 1 Rear brake light switch 2 Rear brake light switch adjusting nut The rear brake light switch which is ac tivated by the brake pedal is properly adjusted
20. performance adverse han dling characteristics and a short ened tire life Ride at moderate speeds after changing a tire since the tire sur face must first be broken in for it to develop its optimal characteris tics 6 15 EAU22040 Adjusting the clutch lever free play 1 Locknut 2 Clutch lever free play adjusting bolt 3 Clutch lever free play The clutch lever free play should mea sure 5 0 10 0 mm 0 20 0 39 in as shown Periodically check the clutch le ver free play and if necessary adjust it as follows 1 Loosen the locknut at the clutch le ver 2 To increase the clutch lever free play turn the adjusting bolt in di rection a To decrease the clutch lever free play turn the adjusting bolt in direction b 3 If the specified clutch lever free play could be obtained as de scribed above tighten the locknut and skip the rest of the procedure otherwise proceed as follows 4 Fully turn the adjusting bolt at the clutch lever in direction a to loos en the clutch cable 5 Loosen the locknut at the crank case ie a SAG 1 Locknut 2 Clutch lever free play adjusting nut crankcase 6 To increase the clutch lever free play turn the adjusting nut in direc tion a To decrease the clutch le ver free play turn the adjusting nut in direction b PERIODIC MAINTENANCE AND MINOR REPAIR 7 Tighten the locknut at the clutch le ver and the crankcase 6 16
21. properly installed before riding Immediately wipe off spilled fuel with a clean dry soft cloth since fuel may deteriorate painted surfac es or plastic parts EWA11140 EAU13320 Recommended fuel S ET REGULAR UNLEADED GASOLINE 2 Fuel level ONLY i Fuel tank capacity Make sure that there is sufficient fuel in 11 0 L 2 91 US gal 2 42 Imp gal the tank Fill the fuel tank to the bottom Fuel reserve amount of the filler tube as shown 3 4 L 0 90 US gal 0 75 Imp gal EWA10880 A WARNING EET 07N T i 0 e Do not overfill the fuel tank oth Use only unleaded gasoline The use erwise it may overflow when the of leaded gasoline will cause severe ECA11400 fuel warms up and expands damage to internal engine parts e Avoid spilling fuel on the hoten such as the valves and piston rings gine as well as to the exhaust system Your Yamaha engine has been de signed to use regular unleaded gaso line with a research octane number of 91 or higher If knocking or pinging oc curs use a gasoline of a different brand 3 7 INSTRUMENT AND CONTROL FUNCTIONS or premium unleaded fuel Use of un leaded fuel will extend spark plug life and reduce maintenance costs EAU13580 Fuel cock This model is equipped with a negative pressure fuel cock The fuel cock sup plies fuel from the tank to the carburetor while also filtering it The fuel cock lever positions are ex plained as follows and shown in
22. she can firmly place both feet on the passenger footrests Never ride under the influence of alcohol or other drugs A SAFETY INFORMATION This motorcycle is designed for on road use only therefore it is not suitable for off road use Protective apparel The majority of fatalities from motor cycle accidents are the result of head injuries The use of a safety helmet is the single most critical factor in the pre vention or reduction of head injuries e Always wear an approved helmet e Wear a face shield or goggles Wind in your unprotected eyes could contribute to an impairment of vision which could delay seeing a hazard The use of a jacket heavy boots trousers gloves etc is effective in preventing or reducing abrasions or lacerations e Never wear loose fitting clothes otherwise they could catch on the control levers footrests or wheels and cause injury or an accident Never touch the engine or exhaust system during or after operation They become very hot and can cause burns Always wear protec tive clothing that covers your legs ankles and feet e Passengers should also observe the precautions mentioned above Modifications Modifications made to this motorcycle not approved by Yamaha or the re moval of original equipment may ren der the motorcycle unsafe for use and may cause severe personal injury Modifications may also make your motorcycle illegal to use Loading and accessori
23. the il lustrations ON 1 Pointed end positioned over ON With the fuel cock lever in this position fuel flows to the carburetor when the engine is running Turn the fuel cock le ver to this position when starting the en gine and riding 3 8 RES 1 Pointed end positioned over RES This indicates reserve With the fuel cock lever in this position the fuel re serve is made available Quickly turn the fuel cock lever to this position if you run out of fuel while riding otherwise the engine may stall and will have to be primed see PRI After turning the fuel cock lever to RES refuel as soon as possible and be sure to turn the fuel cock lever back to ON PRI 1 Pointed end positioned over PRI This indicates prime With the fuel cock lever in this position the engine can be primed Turn the fuel cock lever to this position when the engine has been al lowed to run out of fuel This sends fuel directly to the carburetor which will make starting easier After the engine has started be sure to turn the lever to ON or RES if you have not refueled yet INSTRUMENT AND CONTROL FUNCTIONS EAU13590 Starter choke lever p EAU14281 Helmet holder 1 Starter choke lever x Starting a cold engine requires a richer air fuel mixture which is supplied by the starter choke Move the lever in direction a to
24. when the brake light comes on just before braking takes effect If necessary adjust the brake light switch as follows Turn the adjusting nut while holding the rear brake light switch in place To make the brake light come on earlier turn the adjusting nut in direction a To make the brake light come on later turn the adjusting nut in direction b PERIODIC MAINTENANCE AND MINOR REPAIR EAU22380 Checking the front brake pads and rear brake shoes The front brake pads and the rear brake shoes must be checked for wear at the intervals specified in the periodic main tenance and lubrication chart EAU22420 Front brake pads 1 Brake pad wear indicator groove Each front brake pad is provided with a wear indicator groove which allows you to check the brake pad wear with out having to disassemble the brake To check the brake pad wear check the wear indicator groove If a brake pad has worn to the point that the wear indicator groove has almost disap peared have a Yamaha dealer replace the brake pads as a set EAU22540 Rear brake shoes 1 Brake shoe wear limit line 2 Brake shoe wear indicator The rear brake is provided with a wear indicator which allows you to check the brake shoe wear without having to dis assemble the brake To check the brake shoe wear check the position of the wear indicator while applying the brake If a brake shoe has worn to the point that the wear indicator reaches the wear li
25. Adjust if necessary Clutch e Check operation e Lubricate cable if necessary e Check lever free play e Adjust if necessary Throttle grip e Make sure that operation is smooth e Check cable free play e If necessary have Yamaha dealer adjust cable free play and lubricate cable and grip housing 6 12 6 23 Control cables e Make sure that operation is smooth e Lubricate if necessary 4 2 PRE OPERATION CHECKS CHECKS PAGE e Check chain slack e Adjust if necessary e Check chain condition e Lubricate if necessary Drive chain 6 21 6 22 e Check for damage e Check tire condition and tread depth e Check air pressure e Correct if necessary Wheels and tires e Make sure that operation is smooth Brake and shit pedals e Lubricate pedal pivoting points if necessary e Make sure that operation is smooth Brake and clutch levers Ligier BAS e Lubricate lever pivoting points if necessary e Make sure that operation is smooth Sidestand e Lubricate pivot if necessary e Make sure that all nuts bolts and screws are properly tightened Chassis fasteners e Tighten if necessary Instruments lights signals e Check operation and switches e Correct if necessary e Check operation of ignition circuit cut off system Sidestand switch e If system is defective have Yamaha dealer check vehicle 4 3 OPERATION AND IMPORTANT RIDING POINTS
26. EAU22092 Adjusting the brake lever free play 1 Locknut 2 Brake lever free play adjusting screw 3 Brake lever free play The brake lever free play should mea sure 5 0 8 0 mm 0 20 0 31 in as shown Periodically check the brake le ver free play and if necessary adjust it as follows 1 Loosen the locknut at the brake le ver 2 To increase the brake lever free play turn the adjusting screw in di rection a To decrease the brake lever free play turn the adjusting screw in direction b 3 Tighten the locknut PERIODIC MAINTENANCE AND MINOR REPAIR EWA10630 e After adjusting the brake lever free play check the free play and make sure that the brake is working properly e A soft or spongy feeling in the brake lever can indicate the presence of air in the hydraulic system If there is air in the hy draulic system have a Yamaha dealer bleed the system before operating the motorcycle Air in the hydraulic system will dimin ish the braking performance which may result in loss of con trol and an accident EAU22201 Adjusting the brake pedal position and free play 1 Footrest 2 Distance between brake pedal and footrest 3 Brake pedal free play It is advisable to have a Yamaha dealer make these adjustments EWA10670 Brake pedal position The top of the brake pedal should be positioned approximately 76 6 mm 3 02 in above the top of the footrest as shown Periodically check the brake
27. apidly and released slowly for smooth clutch operation The clutch lever is equipped with a clutch switch which is part of the igni tion circuit cut off system See page 3 11 3 5 1 Shift pedal The shift pedal is located on the left side of the engine and is used in com bination with the clutch lever when shifting the gears of the 5 speed con stant mesh transmission equipped on this motorcycle INSTRUMENT AND CONTROL FUNCTIONS EAU12890 Brake lever EAU12941 Brake pedal 1 Brake lever The brake lever is located at the right handlebar grip To apply the front brake pull the lever toward the handle bar grip 1 Brake pedal The brake pedal is on the right side of the motorcycle To apply the rear brake press down on the brake pedal 3 6 EAU13000 Fuel tank cap 1 Unlock To remove the fuel tank cap Insert the key into the lock and turn it 1 4 turn clockwise The lock will be re leased and the fuel tank cap can be re moved To install the fuel tank cap 1 Push the fuel tank cap into position with the key inserted in the lock 2 Turn the key counterclockwise to the original position and then re move it INSTRUMENT AND CONTROL FUNCTIONS EAU13210 ECA10070 NOTE Fuel CAUTION The fuel tank cap cannot be installed unless the key is in the lock In addition the key cannot be removed if the cap is not properly installed and locked Make sure that the fuel tank cap is
28. arranty but it will also keep your motorcycle looking good extend its life and optimize its performance Before cleaning 1 Cover the muffler outlets with plas tic bags after the engine has cooled down 2 Make sure that all caps and covers as well as all electrical couplers and connectors including the spark plug caps are tightly in stalled 3 Remove extremely stubborn dirt like oil burnt onto the crankcase with a degreasing agent and a brush but never apply such prod ucts onto seals gaskets sprock ets the drive chain and wheel axles Always rinse the dirt and de greaser off with water Cleaning ECA10770 CAUTION e Avoid using strong acidic wheel cleaners especially on spoked wheels If such products are used on hard to remove dirt do not leave the cleaner on the af fected area any longer than in structed Also thoroughly rinse the area off with water immedi ately dry it and then apply a cor rosion protection spray Improper cleaning can damage windshields cowlings panels and other plastic parts Use only a soft clean cloth or sponge with mild detergent and water to clean plastic e Do not use any harsh chemical products on plastic parts Be sure to avoid using cloths or sponges which have been in contact with strong or abrasive 7 1 cleaning products solvent or thinner fuel gasoline rust re movers or inhibitors brake flu id antifreeze or electrolyte Do not use hig
29. at products to use ECA10800 CAUTION e Apply spray oil and wax spar ingly and make sure to wipe off any excess Never apply oil or wax to any rubber and plastic parts but treat them with a suitable care product Avoid using abrasive polishing compounds as they will wear away the paint MOTORCYCLE CARE AND STORAGE EAU26211 Storage Short term Always store your motorcycle in a cool dry place and if necessary protect it against dust with a porous cover ECA10810 CAUTION e Storing the motorcycle in a poorly ventilated room or cover ing it with a tarp while it is still wet will allow water and humid ity to seep in and cause rust e To prevent corrosion avoid damp cellars stables because of the presence of ammonia and areas where strong chemi cals are stored Long term Before storing your motorcycle for sev eral months 1 Follow all the instructions in the Care section of this chapter 2 Turn the fuel cock lever to ON 7 3 4 Drain the carburetor float cham bers by loosening the drain bolts this will prevent fuel deposits from building up Pour the drained fuel into the fuel tank Fill up the fuel tank and add fuel stabilizer if available to prevent the fuel tank from rusting and the fuel from deteriorating Perform the following steps to pro tect the cylinders piston rings etc from corrosion a Remove the spark plug caps and spark plugs
30. ating than recommended to avoid causing extensive damage to the electrical system and possibly a fire 3 Turn the key to ON and turn on the electrical circuit in question to check if the device operates 4 If the fuse immediately blows again have a Yamaha dealer check the electrical system 6 28 EAU23791 Replacing the headlight bulb This model is equipped with a quartz bulb headlight If the headlight bulb burns out replace it as follows 1 Remove the headlight unit by re moving the screws a 2 Disconnect the headlight coupler and then remove the bulb cover 1 Screw PERIODIC MAINTENANCE AND MINOR REPAIR 1 Headlight bulb cover 3 Unhook the headlight bulb holder and then remove the defective bulb 1 Headlight bulb holder Headlight bulbs get very hot There fore keep flammable products away from a lit headlight bulb and do not touch the bulb until it has cooled down EWA10790 4 Place a new headlight bulb into po sition and then secure it with the bulb holder ECA10660 CAUTION Do not touch the glass part of the headlight bulb to keep it free from oil otherwise the transparency of the glass the luminosity of the bulb and the bulb life will be adversely af 6 29 fected Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with al cohol or thinner 1 Do not touch the glass part of the bulb 5 Install t
31. b Pour a teaspoonful of engine oil into each spark plug bore c Install the spark plug caps onto the spark plugs and then place the spark plugs on the cylinder head so that the electrodes are grounded This will limit spark ing during the next step d Turn the engine over several times with the starter This will coat the cylinder walls with oil e Remove the spark plug caps from the spark plugs and then install the spark plugs and the spark plug caps MOTORCYCLE CARE AND STORAGE EWAIOBSO than 30 C 90 F For more in WARNING do gt o formation on storing the battery To prevent damage or injury from see page 6 26 sparking make sure to ground the spark plug electrodes while turning the engine over NOTE Make any necessary repairs before storing the motorcycle 6 Lubricate all control cables and the pivoting points of all levers and pedals as well as of the side stand centerstand 7 Check and if necessary correct the tire air pressure and then lift the motorcycle so that both of its wheels are off the ground Alterna tively turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot 8 Cover the muffler outlets with plas tic bags to prevent moisture from entering them 9 Remove the battery and fully charge it Store it in a cool dry place and charge it once a month Do not store the battery in an ex cessively cold or warm place
32. d excessive oil leakage 6 To check the operation 1 Place the vehicle on a level sur face and hold it in an upright posi tion 2 While applying the front brake push down hard on the handlebars several times to check if the front fork compresses and rebounds smoothly ECA10590 CAUTION If any damage is found or the front fork does not operate smoothly have a Yamaha dealer check or re pair it 6 25 EAU23280 Checking the steering Worn or loose steering bearings may cause danger Therefore the operation of the steering must be checked as fol lows at the intervals specified in the pe riodic maintenance and lubrication chart 1 Place a stand under the engine to raise the front wheel off the ground Securely support the vehicle so that there is no danger of it falling over EWA10750 2 Hold the lower ends of the front fork legs and try to move them for ward and backward If any free play can be felt have a Yamaha dealer check or repair the steering PERIODIC MAINTENANCE AND MINOR REPAIR EAU23290 EAU23380 Checking the wheel bearings Battery The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrica tion chart If there is play in the wheel hub or if the wheel does not turn smoothly have a Yamaha dealer check the wheel bearings 1 Battery The battery is located behind panel A See page 6 5 This model is equipped with a sealed
33. dealer adjust it PERIODIC MAINTENANCE AND MINOR REPAIR EAU21400 Adjusting the valve clearance The valve clearance changes with use resulting in improper air fuel mixture and or engine noise To prevent this from occurring the valve clearance must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart EAU21540 Tires To maximize the performance durabil ity and safe operation of your motor cycle note the following points regarding the specified tires Tire air pressure The tire air pressure should be checked and if necessary adjusted before each ride e The tire air pressure must be checked and adjusted on cold tires i e when the temperature of the tires equals the ambient temperature e The tire air pressure must be ad justed in accordance with the riding speed and with the total weight of rider passenger car go and accessories approved for this model EWA10500 6 13 Tire air pressure measured on cold tires 0 90 kg 0 198 Ib Front 175 kPa 25 psi 1 75 kgf cm Rear 200 kPa 29 psi 2 00 kgf cm 90 180 kg 198 397 Ib Front 225 kPa 33 psi 2 25 kgf cm Rear 225 kPa 33 psi 2 25 kgf cm Maximum load 180 kg 397 Ib Total weight of rider passenger car go and accessories Because loading has an enormous impact on the handling braking performance and safety characteris tics of your motorcycle you should
34. e make sure that it is kept upright and that the fuel cock is turned to ON or RES for vacuum type OFF for manual type If it should lean over gaso line may leak out of the carburetor or fuel tank If you should swallow any gaso line inhale a lot of gasoline vapor or allow gasoline to get into your eyes see your doctor immediately If any gasoline spills on your skin or clothing immediately wash the affected area with soap and water and change your clothes DESCRIPTION Left view Headlight page 6 28 Fuel cock page 3 8 Fuses page 6 28 Helmet holder page 3 9 Shock absorber assembly spring preload adjusting ring page 3 10 Shift pedal page 3 5 oOooarRWN 2 1 EAU10410 Right view Ch gt ye IR VY Ly A CA D N i LZ y PAE G Aah TS Balto WZE Ve ASS al LO J fra Cam ZIA Ses CZE tH Ko Cat a gt Cai A 8 7 1 Owner s tool kit page 6 1 2 Battery page 6 26 3 Air filter element page 6 10 4 Main switch steering lock page 3 1 5 Brake pedal page 3 6 6 Engine oil filter element page 6 8 7 Engine oil level check window page 6 8 8 Shock absorber assembly spring preload adjusting ring page 3 10 2 2 DESCRIPTION EAU10420 DESCRIPTION Controls and instruments Clutch lever page 3 5 Left handlebar switches page 3 4 Speedometer unit page 3 3 Right handlebar switches page 3 4 Brake lev
35. e periodic maintenance chart EAU23131 Checking and lubricating the brake and shift pedals ON The operation of the brake and shift pedals should be checked before each ride and the pedal pivots should be lu bricated if necessary Recommended lubricant Lithium soap based grease all pur pose grease PERIODIC MAINTENANCE AND MINOR REPAIR EAU23140 Checking and lubricating the brake and clutch levers EAU23200 Checking and lubricating the sidestand The operation of the brake and clutch levers should be checked before each ride and the lever pivots should be lu bricated if necessary Recommended lubricant Lithium soap based grease all pur pose grease 6 24 The operation of the sidestand should be checked before each ride and the sidestand pivot and metal to metal contact surfaces should be lubricated if necessary If the sidestand does not move up and down smoothly have a Yamaha dealer check or repair it EWA10730 Recommended lubricant Lithium soap based grease all pur pose grease PERIODIC MAINTENANCE AND MINOR REPAIR EAU23271 Checking the front fork The condition and operation of the front fork must be checked as follows at the intervals 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 falling over EWA10750 Check the inner tubes for scratches damage an
36. e drive chain as follows ECA10580 CAUTION The drive chain must be lubricated after washing the motorcycle or riding in the rain 1 Clean the drive chain with kero sene and a small soft brush ECA11120 CAUTION To prevent damaging the O rings do not clean the drive chain with steam cleaners high pressure washers or inappropriate solvents 2 Wipe the drive chain dry 3 Thoroughly lubricate the drive chain with a special O ring chain lubricant PERIODIC MAINTENANCE AND MINOR REPAIR ECA11110 CAUTION Do not use engine oil or any other lu bricants for the drive chain as they may contain substances that could damage the O rings EAU23100 Checking and lubricating the cables The operation of all control cables and the condition of the cables should be checked before each ride and the ca bles and cable ends should be lubricat ed if necessary If a cable is damaged or does not move smoothly have a Yamaha dealer check or replace it Recommended lubricant Engine oil EWA10720 A WARNING Damage to the outer sheath may in terfere with proper cable operation and will cause the inner cable to rust Replace a damaged cable as soon as possible to prevent unsafe conditions EAU23110 Checking and lubricating the throttle grip and cable The operation of the throttle grip should be checked before each ride In addi tion the cable should be lubricated or replaced at the intervals specified in th
37. e is ridden normally Check that all spark plugs installed in the engine have the same color NOTE 1 4 Install the spark plug cap N If any spark plug shows a distinctly dif ferent color the engine could be defec tive Do not attempt to diagnose such problems yourself Instead have a Yamaha dealer check the vehicle Spark plug gap 0 6 0 7 mm 0 024 0 028 in 6 7 1 Spark plug gap EAU19751 Engine oil and oil filter element The engine oil level should be checked before each ride In addition the oil must be changed and the oil filter ele ment replaced at the intervals specified in the periodic maintenance and lubri cation chart To check the engine oil level 1 Place the vehicle on a level sur face and hold it in an upright posi tion NOTE Make sure that the vehicle is positioned straight up when checking the oil level A slight tilt to the side can result in a false reading 2 Start the engine warm it up for several minutes and then turn it off 3 Wait afew minutes until the oil set tles and then check the oil level through the check window located at the bottom right side of the crankcase PERIODIC MAINTENANCE AND MINOR REPAIR NOTE The engine oil should be between the minimum and maximum level marks 2 Place an oil pan under the engine to collect the used oil 3 Remove the engine oil filler cap and drain bolt to drain the oil from the crankcase
38. e swingarm 6 21 1 Axle nut 2 Locknut 3 Brake pedal free play adjusting nut 2 To tighten the drive chain turn the adjusting nut at each end of the swingarm in direction a To loos en the drive chain turn the adjust ing nut at each end of the swingarm in direction b and then push the rear wheel forward NOTE Using the alignment marks on each side of the swingarm make sure that both adjusting nuts are in the same po sition for proper wheel alignment 1 Alignment marks 2 Drive chain slack adjusting nut 3 Locknut ECA10570 CAUTION Improper drive chain slack will over load the engine as well as other vital parts of the motorcycle and can lead to chain slippage or breakage To prevent this from occurring keep the drive chain slack within the specified limits 3 Tighten both locknuts and the axle nut to the specified torques PERIODIC MAINTENANCE AND MINOR REPAIR Tightening torques Locknut 16 Nm 1 6 m kgf 12 ft lbf Axle nut 104 Nm 10 4 m kgf 75 ft lbf 4 Adjust the brake pedal free play See page 6 17 After adjusting the brake pedal free play check the operation of the brake light EWA10660 6 22 EAU23020 Lubricating the drive chain The drive chain must be cleaned and lubricated at the intervals specified in the periodic maintenance and lubrica tion chart otherwise it will quickly wear out especially when riding in dusty or wet areas Service th
39. eeeeeseeoees 3 5 Shock absorber assemblies ACHUSTING ieee aae aaa aN 3 10 SideStand a eee eee eee eeeees 3 10 Sidestand checking and lubricating 6 24 Spark plugs Checking 0 e eee eee 6 6 Specifications Speedometer unit 5 Starter choke lever oo eee 3 9 Starting a cold engine ee 5 1 Start switch ue 3 4 Steering checking 6 25 Storage oo eee eeeeeeeeeee 1 3 Supporting the motorcycle 6 31 T Tail orake light bulb replacing Throttle cable free play adjusting Throttle grip and cable checking and lubricating seeen 6 23 TWIGS i cae Reteiencainicna ninte ieee 6 13 Tool kit 6 4 Troubleshooting 6 35 Troubleshooting chart 6 36 Turn signal indicator light 3 2 Turn signal light bulb replacing 6 30 Turn signal Switch eee ee 3 4 V Valve clearance adjusting 6 13 INDEX Vehicle identification number 9 1 Ww Wheel bearings checking Wheel front Wheel rear ceecceeeeeeeeeeeeeeeeeeeeeeeee YAMAHA YAMAHA MOTOR CO LTD PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2003 07 0 3x1 CR E
40. emoving and installing panels KY X AA NN RS AES yA a a MHA VK RY 1 Panel B The panels shown above need to be re moved to perform some of the mainte nance jobs described in this chapter Refer to this section each time a panel needs to be removed and installed EAU19521 Panel A To remove the panel 1 Slide the panel lock cover open in sert the key into the lock and then turn it 1 4 turn clockwise 1 Panel lock cover 2 Unlock 2 Pull the rear of the panel out with the key inserted in the lock and then slide the panel forward to re lease it in the front 6 5 To install the panel 1 Secure the front of the panel and then push the rear of the panel in with the key inserted in the lock 2 Turn the key counterclockwise to the original position remove it and then close the panel lock cover PERIODIC MAINTENANCE AND MINOR REPAIR EAU19161 To install the panel a EAU19543 1 Secure the front of the panel and Checking the spark plugs then push the rear of the panelin The spark plugs are important engine To remove the panel components which are easy to check 1 Remove the bolt M Since heat and deposits will cause any Pa spark plug to slowly erode the spark ran f plugs should be removed and checked in accordance with the periodic mainte nance and lubrication chart In addition A i ea G the condition of the spark plugs can re a i ay ao veal t
41. er page 3 6 Throttle grip page 6 12 Fuel tank cap page 3 6 NO oOBRWDND 2 3 EAU10430 EAU10460 Main switch steering lock orr ON LOCK P lt Parking The main switch steering lock controls the ignition and lighting systems and is used to lock the steering The various positions are described below EAU10630 ON All electrical systems are supplied with power and the engine can be started The key cannot be removed EAU10660 OFF All electrical systems are off The key can be removed INSTRUMENT AND CONTROL FUNCTIONS EAU10680 LOCK The steering is locked and all electrical systems are off The key can be re moved To lock the steering 1 Push 2 Turn 1 Turn the handlebars all the way to the left 2 Push the key in from the OFF po sition and then turn it to LOCK while still pushing it 3 Remove the key 3 1 To unlock the steering 1 1 Push 2 Turn Push the key in and then turn it to OFF while still pushing it Never turn the key to OFF or LOCK while the vehicle is moving otherwise the electrical systems will be switched off which may result in loss of control or an accident Make sure that the vehicle is stopped be fore turning the key to OFF or LOCK EWA10060 INSTRUMENT AND CONTROL FUNCTIONS EAU10880 p lt Parking The steering is locked and the taillight and auxiliary lig
42. es Adding accessories or cargo to your motorcycle can adversely affect stabili ty and handling if the weight distribution of the motorcycle is changed To avoid the possibility of an accident use ex treme caution when adding cargo or accessories to your motorcycle Use extra care when riding a motorcycle that has added cargo or accessories Here are some general guidelines to follow if loading cargo or adding acces sories to your motorcycle A SAFETY INFORMATION Loading The total weight of the operator pas senger accessories and cargo must not exceed the maximum load limit of 180 kg 397 Ib When loading within this weight limit keep the following in mind Cargo and accessory weight should be kept as low and close to the motorcycle as possible Make sure to distribute the weight as evenly as possible on both sides of the motorcycle to minimize imbal ance or instability Shifting weights can create a sud den imbalance Make sure that ac cessories and cargo are securely attached to the motorcycle before riding Check accessory mounts and cargo restraints frequently e Never attach any large or heavy items to the handlebar front fork or front fender These items in cluding such cargo as sleeping bags duffel bags or tents can create unstable handling or slow steering response Accessories Genuine Yamaha accessories have been specifically designed for use on this motorcycle Since Yamaha cannot t
43. es 6 17 Cc D Dimmer SWitCH ooo eee eee eee Drive chain lubricating i Drive chain slack ee eee E Engine break in ou eee eeeeeeeeeeeeeeeee 5 4 Engine idling speed 6 12 Engine oil and oil filter element we 6 8 Engine starting a Warm eee 5 2 Engine stop SWitCh c eee eee 3 4 Engine trouble warning light 3 2 Fuel consumption tips for reducing 5 3 Fuel tank Cap eee eseeeneeeeeees 3 6 Fuses replacing ee cece cece eee 6 28 Handlebar switches s s s Headlight bulb replacing Helmet holder ccccccecseeeeeeeeeeeeeteeees High beam indicator light Horn sSwitehi ssiririsiiieiiriirisiiia l Identification numbers ssassn Ignition circuit cut off system Indicator and warning lights 0 0 K Key identification number 9 1 L Light SWITCH s ssnicsis nienie 3 4 M Main switch steering lock 3 1 Model label cece eee cee eeneeeneeeeees 9 2 N Neutral indicator light ee 3 2 P Panels removing and installing 6 5 Parking siasii a Part locations a PASS SWItCH oe cece eee eset eeeeeeeaees Periodic maintenance and lubrication Chart eee ee sees 6 2 Pre operation check list INDEX R Rear brake light switch adjusting 6 18 S Safety information eee 1 1 Self diagnosis device eee 3 3 Shiga iaa epa gan 5 2 Shift Pedal oo ee ceeeeseesstesesees
44. essary to perform certain maintenance work correctly NOTE If you do not have the tools or experi ence required for a particular job have a Yamaha dealer perform it for you 6 1 EWA10350 Modifications not approved by Yamaha may cause loss of perfor mance and render the vehicle un safe for use Consult a Yamaha dealer before attempting any chang es EEE MAINTENANCE AND MINOR REPAIR EAU17701 Periodic maintenance and lubrication chart NOTE e The annual checks must be performed every year except if a kilometer based maintenance is performed in stead From 50000 km repeat the maintenance intervals starting from 10000 km items marked with an asterisk should be performed by a Yamaha dealer as they require special tools data and technical skills ODOMETER READING x 1000 km ANNUAL CHECK OR MAINTENANCE JOB 1 10 20 30 40 CHECK Fuel line e Check fuel and vacuum hoses for cracks or damage V V V V V e Check condition y y Spark plugs e Clean and regap e Replace e Check valve clearance e Adjust e Clean Valves Air filter element e Replace e Check operation e Adjust y y V Clutch Check operation fluid level and vehicle for fluid leakage V V V Front brake e Replace brake pads enever worn to the limit Check operation and adjust brake pedal free play V V V Rear brake Er e Replace brake shoes enever worn to the l
45. est all other accessories that may be available you must personally be re sponsible for the proper selection in stallation and use of non Yamaha accessories Use extreme caution when selecting and installing any ac cessories Keep the following guidelines in mind as well as those provided under Load ing when mounting accessories e Never install accessories or carry cargo that would impair the perfor mance of your motorcycle Care fully inspect the accessory before using it to make sure that it does not in any way reduce ground clearance or cornering clearance limit suspension travel steering travel or control operation or ob scure lights or reflectors e Accessories fitted to the handle bar or the front fork area can create instability due to improper weight distribution or aerody namic changes If accessories 1 3 are added to the handlebar or front fork area they must be as lightweight as possible and should be kept to a minimum Bulky or large accessories may seriously affect the stability of the motorcycle due to aerody namic effects Wind may at tempt to lift the motorcycle or the motorcycle may become un stable in cross winds These ac cessories may also cause instability when passing or being passed by large vehicles e Certain accessories can dis place the operator from his or her normal riding position This improper position limits the free dom of movement of the opera tor and may li
46. f routine maintenance ECA10550 CAUTION The carburetor has been set and ex tensively tested at the Yamaha fac tory Changing these settings without sufficient technical knowl edge may result in poor perfor mance of or damage to the engine EAU21340 Adjusting the engine idling speed The engine idling speed must be checked and if necessary adjusted as follows at the intervals specified in the periodic maintenance and lubrication chart The engine should be warm before making this adjustment NOTE The engine is warm when it quickly responds to the throttle e A diagnostic tachometer is needed to make this adjustment 1 Attach the tachometer to the spark plug lead 2 Check the engine idling speed and if necessary adjust it to spec ification by turning the throttle stop screw To increase the engine idling speed turn the screw in di rection a To decrease the en gine idling speed turn the screw in direction b PERIODIC MAINTENANCE AND MINOR REPAIR 1 Throttle stop screw 380 Adjusting the throttle cable free play Engine idling speed 1200 1400 r min 1 Throttle cable free play NOTE If the specified idling speed cannot be obtained as described above have a Yamaha dealer make the adjustment The throttle cable free play should mea sure 3 0 5 0 mm 0 12 0 20 in at the throttle grip Periodically check the throttle cable free play and if neces sary have a Yamaha
47. fication number 1 Key identification number The key identification number is stamped into the key tag Record this number in the space provided and use it for reference when ordering a new key 9 1 1 Vehicle identification number The vehicle identification number is stamped into the steering head pipe Record this number in the space pro vided NOTE The vehicle identification number is used to identify your motorcycle and may be used to register your motor cycle with the licensing authority in your area CONSUMER INFORMATION EAU26460 Model label 1 Model label The model label is affixed to the loca tion shown Record the information on this label in the space provided This in formation will be needed when ordering spare parts from a Yamaha dealer 9 2 A Air filter element cleaning 0 6 10 Anti theft alarm optional B Battery 0 eecceccsseseceseceeesseesseessneseeees 6 26 Brake and clutch levers checking and lubricating 0 0 eeeeee 6 24 Brake and shift pedals checking and lubricating 0 0 eee eee eens 6 24 Brake fluid changing cee 6 20 Brake fluid level checking 00 6 19 Brake lever occ eeeeeeeeeeees wi 3 6 Brake lever free play adjusting 6 16 Brake pads and shoes checking 6 19 Brake pedal 0 cee cece eee eeeeeeee 3 6 Brake pedal position and free play ACJUSTING 0 eee cece eee eeeeeeeeeeeae
48. h pressure wash ers or steam jet cleaners since they cause water seepage and deterioration in the following ar eas seals of wheel and swing arm bearings fork and brakes electric components couplers connectors instruments switches and lights breather hoses and vents For motorcycles equipped with a windshield Do not use strong cleaners or hard sponges as they will cause dulling or scratching Some cleaning com pounds for plastic may leave scratches on the windshield Test the product on a small hid den part of the windshield to make sure that it does not leave any marks If the windshield is scratched use a quality plastic polishing compound after washing After normal use Remove dirt with warm water a mild detergent and a soft clean sponge and then rinse thoroughly with clean water Use a toothbrush or bottlebrush for hard to reach areas Stubborn dirt and insects will come off more easily if the area is covered with a wet cloth for a few minutes before cleaning After riding in the rain near the sea or on salt sprayed roads Since sea salt or salt sprayed on roads during winter are extremely corrosive in combination with water carry out the following steps after each ride in the rain near the sea or on salt sprayed roads NOTE Salt sprayed on roads in the winter may remain well into spring 1 Clean the motorcycle with cold wa ter and a mild detergent after the engine has cooled d
49. he bolts then tightening them to the specified torque 6 9 ECA11620 CAUTION e In order to prevent clutch slip page since the engine oil also lubricates the clutch do not mix any chemical additives Do not use oils with a diesel speci fication of CD or oils of a high er quality than specified In addition do not use oils labeled ENERGY CONSERVING II or higher Make sure that no foreign mate rial enters the crankcase 9 Start the engine and then let it idle for several minutes while checking it for oil leakage If oil is leaking im mediately turn the engine off and check for the cause 10 Turn the engine off and then check the oil level and correct it if necessary EAU20660 Cleaning the air filter element The air filter element should be cleaned at the intervals specified in the periodic maintenance and lubrication chart Clean the air filter element more fre quently if you are riding in unusually wet or dusty areas 1 Remove the air filter case by re moving the bolts loosening the clamp screw then disconnecting the hose 1 Bolt 2 Clamp screw 3 Hose 2 Remove the air filter case cover by removing the screws PERIODIC MAINTENANCE AND MINOR REPAIR 1 Air filter case cover 2 Screw 3 Remove the air filter element by removing the screws 1 Air filter element 2 Screw 4 Lightly tap the air filter element to remove most of the dust and dirt and then bl
50. he brake fluid level 6 19 INSTRUMENT AND CONTROL Engine break in ecer 5 4 Changing the brake fluid 6 20 FUNCTIONS 000 eeeeeeeeeeeeeeeeeeeeees 3 1 Parking ipno Geant amp 5 4 Drive chain slack neee 6 21 Main switch steering lock 4 3 1 Lubricating the drive chain 6 22 Indicator and warning lights 3 2 PERIODIC MAINTENANCE AND Checking and lubricating the Speedometer unit c eee 3 3 MINOR REPAIR 6 1 cables aiii andrian aapi 6 23 Self diagnosis device cee 3 3 Owner s tool kit 0 ceeeeeeeeeeeeeeenees 6 1 Checking and lubricating the Anti theft alarm optional 3 3 Periodic maintenance and throttle grip and cable 6 23 Handlebar switches s e 3 4 lubrication Chart eee 6 2 Checking and lubricating the Clutch lever oo eeeeeeeeeeeteeeeeeenees 3 5 Removing and installing panels 6 5 brake and shift pedals 6 24 Shift pedal 0 0 ec eeeeeeeeeeeeeeeeeenees 3 5 Checking the spark plugs 6 6 Checking and lubricating the Brake lever sccceeccseeeeseeeeeeeeneees 3 6 Engine oil and oil filter element 6 8 brake and clutch levers 6 24 Brake pedal e cccceseeeeeeeeeees 3 6 Cleaning the air filter element 6 10 Checking and lubricating the Fuel tank cap eener 3 6 Adjusting the carburetor 6 11 sidestand eee 6 24 E E 3 7 Adjusting the engine idling Checking the fro
51. he condition of the engine Panel B p To remove a spark plug 2 Install the bolt 1 Remove the spark plug cap 1 Bolt 2 Pull the rear of the panel out and then slide the panel forward to re lease it in the front 1 Spark plug cap 2 Remove the spark plug as shown with the spark plug wrench includ ed in the owner s tool kit 6 6 PERIODIC MAINTENANCE AND MINOR REPAIR 3 Check each spark plug for elec 2 Clean the surface of the spark plug trode erosion and excessive car gasket and its mating surface and bon or other deposits and replace then wipe off any grime from the it if necessary spark plug threads 3 Install the spark plug with the Specified spark plug spark plug wrench and then tight NGK CR6HSA en it to the specified torque DENSO U20FSR U Tightening torque To install a spark plug Spark plug 1 Measure the spark plug gap with a 12 5 Nm 1 25 m kgf 9 0 ft Ibf wire thickness gauge and if nec essary adjust the gap to specifica NOTE tion If a torque wrench is not available when installing a spark plug a good estimate of the correct torque is 1 4 1 2 turn past finger tight However the spark plug should be tightened to the speci fied torque as soon as possible 1 Spark plug wrench To check the spark plugs 1 Check that the porcelain insulator around the center electrode on each spark plug is a medium to light tan the ideal color when the vehicl
52. he headlight bulb cover and then connect the coupler 6 Install the headlight unit by install ing the screws 7 Have a Yamaha dealer adjust the headlight beam if necessary EAU24131 Replacing the tail brake light bulb 1 Remove the tail brake light lens by removing the screws 1 Screw 2 Remove the defective bulb by pushing it in and turning it counter clockwise 1 Tail brake light bulb 3 Insert a new bulb into the socket push it in and then turn it clock wise until it stops 4 Install the lens by installing the screws ECA10680 CAUTION Do not overtighten the screws oth erwise the lens may break 6 30 PERIODIC MAINTENANCE AND MINOR REPAIR EAU24210 Replacing a turn signal light bulb 1 Remove the turn signal lens by re moving the screws 1 Screw 2 Remove the defective bulb by pushing it in and turning it counter clockwise PERIODIC MAINTENANCE AND MINOR REPAIR 1 Turn signal light bulb 3 Insert a new bulb into the socket push it in and then turn it clock wise until it stops 4 Install the lens by installing the screws ECA10680 CAUTION Do not overtighten the screws oth erwise the lens may break EAU24350 Supporting the motorcycle Since this model is not equipped with a centerstand follow these precautions when removing the front and rear wheel or performing other maintenance requiring the motorcycle to stand up right Check that the
53. heck the vehicle 5 4 EAU17200 Parking When parking stop the engine and then remove the key from the main switch e Since the engine and exhaust system can become very hot park in a place where pedestri ans or children are not likely to touch them e Do not park ona slope or on soft ground otherwise the vehicle may overturn EWA10310 PERIODIC MAINTENANCE AND MINOR REPAIR EAU17240 Safety is an obligation of the owner Pe riodic inspection adjustment and lubri cation will keep your vehicle in the safest and most efficient condition pos sible The most important points of in spection adjustment and lubrication are explained on the following pages The intervals given in the periodic maintenance and lubrication chart should be simply considered as a gen eral guide under normal riding condi tions However DEPENDING ON THE WEATHER TERRAIN GEOGRAPHI CAL LOCATION AND INDIVIDUAL USE THE MAINTENANCE INTER VALS MAY NEED TO BE SHORT ENED If you are not familiar with mainte nance work have a Yamaha dealer do it for you EWA10320 EAU17340 Owner s tool kit 1 Owner s tool kit The owner s tool kit is located behind panel A See page 6 5 The service information included in this manual and the tools provided in the owner s tool kit are intended to assist you in the performance of preventive maintenance and minor repairs How ever additional tools such as a torque wrench may be nec
54. ht are on but all other electrical systems are off The key can be removed The steering must be locked before the key can be turned to p lt ECA11020 CAUTION Do not use the parking position for an extended length of time other wise the battery may discharge EAU11001 Indicator and warning lights 1 High beam indicator light 20 2 Turn signal indicator light lt a p gt 3 Neutral indicator light N 4 Engine trouble warning light ws EAU11020 Turn signal indicator light lt gt gt This indicator light flashes when the turn signal switch is pushed to the left or right EAU11060 Neutral indicator light N This indicator light comes on when the transmission is in the neutral position 3 2 EAU11080 High beam indicator light o This indicator light comes on when the high beam of the headlight is switched on EAU11500 Engine trouble warning light This warning light comes on or flashes when an electrical circuit monitoring the engine is defective When this occurs have a Yamaha dealer check the self diagnosis system The electrical circuit of the warning light can be checked by turning the key to ON If the warning light does not come on for a few seconds then go off have a Yamaha dealer check the electrical circuit EAU11630 Speedometer unit 1 Speedometer 2 Odometer 3 Tripmeter 4 Tripmeter reset knob The
55. imit Check for cracks or damage V V Vy Brake hose e Replace Every 4 years CHECK OR MAINTENANCE JOB PERIODIC MAINTENANCE AND MINOR REPAIR ODOMETER READING x 1000 km 1 10 20 30 40 ANNUAL CHECK e Check runout spoke tightness and for damage e Tighten spokes if necessary Ni vf x Ni Tires e Check tread depth and for damage e Replace if necessary e Check air pressure e Correct if necessary Wheel bearings e Check bearing for looseness or damage vf 4 Swingarm e Check operation and for excessive play Vv oy e Lubricate with lithium soap based grease Every 50000 km Drive chain e Check chain slack e Make sure that the rear wheel is properly aligned e Clean and lubricate Every 1000 km and after washing the motorcycle or riding in the rain Steering bearings e Check bearing play and steering for roughness Vv 4 e Lubricate with lithium soap based grease Every 20000 km Chassis fasteners e Make sure that all nuts bolts and screws are properly tightened vf oy Sidestand e Check operation e Lubricate Sidestand switch e Check operation Front fork e Check operation and for oil leakage Shock absorber assem blies e Check operation and shock absorbers for oil leakage 4 y y 4 Carburetor e Check starter choke operation e Adj
56. lbf 6 Tighten the axle nut to the speci fied torque Tightening torque Axle nut 104 Nm 10 4 m kgf 75 ft lbf 7 Adjust the brake pedal position and free play See page 6 17 EWA10660 A WARNING After adjusting the brake pedal free play check the operation of the brake light PERIODIC MAINTENANCE AND MINOR REPAIR EAU25850 Troubleshooting Although Yamaha motorcycles receive a thorough inspection before shipment from the factory trouble may occur dur ing operation Any problem in the fuel compression or ignition systems for example can cause poor starting and loss of power The following troubleshooting chart represents a quick and easy procedure for checking these vital systems your self However should your motorcycle require any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools experience and know how to service the motorcycle properly Use only genuine Yamaha replace ment parts Imitation parts may look like Yamaha parts but they are often inferi or have a shorter service life and can lead to expensive repair bills 6 35 PERIODIC MAINTENANCE AND MINOR REPAIR EAU25891 Troubleshooting chart Keep away open flames and do not smoke while checking or working on the fuel system EWA10840
57. less than O C 30 F or more 7 4 SPECIFICATIONS Dimensions Overall length 2320 mm 91 3 in Overall width 910 mm 35 8 in Overall height 1075 mm 42 3 in Seat height 670 mm 26 4 in Wheelbase 1530 mm 60 2 in Ground clearance 150 mm 5 91 in Minimum turning radius 2900 mm 114 2 in Weight With oil and fuel 159 0 kg 351 Ib Engine Engine type Air cooled 4 stroke SOHC Cylinder arrangement V type 2 cylinder Displacement 249 0 cm 15 19 cu in Bore x stroke 49 0 x 66 0 mm 1 93 x 2 60 in Compression ratio 10 00 1 Starting system Electric starter Lubrication system Wet sump Engine oil Type SAE10W30 or SAE10W40 or SAE15W40 or SAE20W40 or SAE20W50 a0 ay 9 19 2D 90 40 50 C SAE 20W 50 Recommended engine oil grade API service SE SF SG type or higher Engine oil quantity Without oil filter element replacement 1 40 L 1 48 US qt 1 23 Imp qt With oil filter element replacement 1 60 L 1 69 US qt 1 41 Imp qt Air filter Air filter element Dry element Fuel Recommended fuel Regular unleaded gasoline only Fuel tank capacity 11 0 L 2 91 US gal 2 42 Imp gal Fuel reserve amount 3 4 L 0 90 US gal 0 75 Imp gal 8 1 Carburetor Manufacturer MIKUNI Type x quantity BDS26 x 1 Spark plug s Manufacturer model NGK CR6HSA Manufacturer model DENSO U20FSR U Spark plug gap 0 6 0 7 mm 0 024 0 028 in Clutch Clutch type
58. mit control ability therefore such accessories are not recommended Use caution when adding electri cal accessories If electrical acces sories exceed the capacity of the motorcycle s electrical system an electric failure could result which could cause a dangerous loss of lights or engine power A SAFETY INFORMATION Do not park the motorcycle on a Gasoline and exhaust gas GASOLINE IS HIGHLY FLAMMA slope or soft ground otherwise it BLE may fall over e Always turn the engine off when Do not park the motorcycle near Ee refueling Take care not to spill any gaso line on the engine or exhaust system when refueling Never refuel while smoking or in the vicinity of an open flame Never start the engine or let it run for any length of time in a closed area The exhaust fumes are poi sonous and may cause loss of consciousness and death within a short time Always operate your motorcycle in an area that has ad equate ventilation Always turn the engine off before leaving the motorcycle unattended and remove the key from the main switch When parking the motor cycle note the following e The engine and exhaust system may be hot therefore park the motorcycle in a place where pe destrians or children are not like ly to touch these hot areas a flammable source e g a kero sene heater or near an open flame otherwise it could catch fire When transporting the motorcycle in another vehicl
59. mit line have a Yamaha dealer replace the brake shoes as a set 6 19 Checking the brake fluid level Front brake 1 Minimum level mark Insufficient brake fluid may allow air to enter the brake system possibly caus ing it to become ineffective Before riding check that the brake fluid is above the minimum level mark and replenish if necessary A low brake fluid level may indicate worn brake pads and or brake system leakage If the brake fluid level is low be sure to check the brake pads for wear and the brake system for leakage Observe these precautions When checking the fluid level make sure that the top of the mas ter cylinder is level by turning the handlebars Use only the recommended quality brake fluid otherwise the rubber seals may deteriorate causing leakage and poor braking perfor mance Recommended brake fluid DOT 4 e Refill with the same type of brake fluid Mixing fluids may result in a harmful chemical reaction and lead to poor braking performance e Be careful that water does not en ter the master cylinder when refill ing Water will significantly lower the boiling point of the fluid and may result in vapor lock e Brake fluid may deteriorate paint ed surfaces or plastic parts Al ways clean up spilled fluid immediately e As the brake pads wear it is nor mal for the brake fluid level to grad ually go down However if the PERIODIC MAINTENANCE AND MINOR REPAIR
60. ne power available for starting off accelerating climbing hills etc The gear positions are shown in the il lustration NOTE To shift the transmission into the neu tral position press the shift pedal down repeatedly until it reaches the end of its travel and then slightly raise it OPERATION AND IMPORTANT RIDING POINTS ECA10260 CAUTION e Even with the transmission in the neutral position do not coast for long periods of time with the engine off and do not tow the motorcycle for long dis tances The transmission is properly lubricated only when the engine is running Inade quate lubrication may damage the transmission Always use the clutch while changing gears to avoid damag ing the engine transmission and drive train which are not designed to withstand the shock of forced shifting EAU32810 Recommended shift points for Switzerland only The recommended shift points during acceleration are shown in the table be low Shift up points 1st 2nd 23 km h 14 mi h 2nd gt 3rd 36 km h 22 mi h 3rd 4th 50 km h 31 mi h 4th gt 5th 60 km h 37 mi h NOTE When shifting down two gears at a time reduce the speed accordingly e g down to 35 km h 22 mi h when shifting from 4th to 2nd gear 5 3 EAU16800 Tips for reducing fuel consumption Fuel consumption depends largely on your riding style Consider the following tips to reduce fuel consumption Turn
61. nt fork 0 6 25 Buel COCK soetada 3 8 Spoed iiin clases 6 12 Checking the steering 04 6 25 Starter choke lever eeeeeeeeees 3 9 Adjusting the throttle cable Checking the wheel bearings 6 26 Helmet holder eccere 3 9 free play sssisicirncisiesnerninnrsnn 6 12 Battery scctesiectiniec tae 6 26 Adjusting the shock absorber Adjusting the valve clearance 6 13 Replacing the fuses 20 6 28 assemblies oo eeeeeseeeeeneeeeeees 3 10 Tires sains pra an a 6 13 Replacing the headlight bulb 6 28 Sidestand cceeceeeseeeeeeeeeeeeseeeees 3 10 Spoke wheels cceccceeseeeeeeees 6 15 Replacing the tail brake Ignition circuit cut off system 3 11 Adjusting the clutch lever light b lb so ses daca scant 6 30 free play eee 6 15 Replacing a turn signal PRE OPERATION CHECKG 4 1 Adjusting the brake lever hight b l issen nania eiin 6 30 Pre operation check list 4 4 2 Tree play iian kak anushetns 6 16 Supporting the motorcycle 6 31 Front Wheel ce eeeseeeeseeeeeseeeeeeees 6 32 Rear Wheel seceeesseeeeseeeeeeees 6 33 Troubleshooting seeen 6 35 Troubleshooting chart 6 36 MOTORCYCLE CARE AND STORAGE 7 1 Cae rre ena ea aaee do EA 7 1 Storag s bedded at a 7 3 SPECIFICATIONS eeeeeeee 8 1 CONSUMER INFORMATION 9 1 Identification numbers 9 1 TABLE OF CONTENTS A
62. on otherwise have a Yamaha dealer check the electrical cir cuit 4 Turn the starter choke on and completely close the throttle See page 3 9 5 Start the engine by pushing the start switch NOTE If the engine fails to start release the start switch wait a few seconds and then try again Each starting attempt should be as short as possible to pre serve the battery Do not crank the en gine more than 10 seconds on any one attempt ECA11370 CAUTION The engine trouble warning light should come on when the key is turned to ON and then go off after a few seconds If the engine trouble warning light comes on or flashes OPERATION AND IMPORTANT RIDING POINTS after starting immediately stop the engine and have a Yamaha dealer check the self diagnosis system 6 After starting the engine move the starter choke back halfway ECA11040 CAUTION For maximum engine life never ac celerate hard when the engine is cold 7 When the engine is warm turn the starter choke off NOTE The engine is warm when it responds normally to the throttle with the starter choke turned off EAU16640 Starting a warm engine Follow the same procedure as for start ing a cold engine with the exception that the starter choke is not required when the engine is warm 5 2 EAU16671 Shifting 1 Shift pedal 2 Neutral position Shifting gears lets you control the amount of engi
63. orists can see you Avoid riding in another motorist s blind spot Many motorcycle accidents in volve inexperienced operators In fact many operators who have been involved in accidents do not even have a current motorcycle li cense Make sure that you are qualified and that you only lend your motorcycle to other qualified op erators Know your skills and limits Staying within your limits may help you to avoid an accident We recommend that you prac tice riding your motorcycle where there is no traffic until you have become thoroughly famil iar with the motorcycle and all of its controls Many motorcycle accidents have been caused by error of the motor cycle operator A typical error made by the operator is veering wide on a turn due to EXCESSIVE SPEED or undercornering insuffi cient lean angle for the speed Always obey the speed limit and never travel faster than warrant ed by road and traffic conditions Always signal before turning or changing lanes Make sure that other motorists can see you The posture of the operator and passenger is important for proper control The operator should keep both hands on the handlebar and both feet on the operator foot rests during operation to main tain control of the motorcycle The passenger should always hold onto the operator seat strap or grab bar if equipped with both hands and keep both feet on the passenger footrests Never carry a passenger unless he or
64. ow the remaining dirt 6 10 out with compressed air as shown If the air filter element is damaged replace it Install the air filter element by in serting it into the air filter case then installing the screws Remove the clamp from the air fil ter check hose and then remove the plug from the check hose to drain any accumulated water PERIODIC MAINTENANCE AND MINOR REPAIR 1 Air filter check hose plug 2 Clamp 3 Air filter check hose 7 Install the plug into the check hose and then install the clamp ECA10480 CAUTION Make sure that the air filter ele ment is properly seated in the air filter case The engine should never be op erated without the air filter ele ment installed otherwise the piston s and or cylinder s may become excessively worn 8 Install the air filter case cover by in stalling the screws 9 Connect the hose 10 Install the air filter case by inserting the projection into the grommet in stalling the bolts then tightening the clamp screw 1 Projection 2 Grommet 3 Hose 6 11 EAU21280 Adjusting the carburetor The carburetor is an important part of the engine and requires very sophisti cated adjustment Therefore most car buretor adjustments should be left to a Yamaha dealer who has the neces sary professional knowledge and expe rience The adjustment described in the following section however may be ser viced by the owner as part o
65. own MOTORCYCLE CARE AND STORAGE ECA10790 CAUTION Do not use warm water since it in creases the corrosive action of the salt 2 After drying the motorcycle apply a corrosion protection spray on all metal including chrome and nick el plated surfaces to prevent cor rosion After cleaning 1 Dry the motorcycle with a chamois or an absorbing cloth 2 Immediately dry the drive chain and lubricate it to prevent it from rusting 3 Use a chrome polish to shine chrome aluminum and stainless steel parts including the exhaust system Even the thermally in duced discoloring of stainless steel exhaust systems can be re moved through polishing 7 2 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 damage caused by stones etc 7 Wax all painted surfaces 8 Let the motorcycle dry completely before storing or covering it EWA10930 A WARNING Make sure that there is no oil or wax on the brakes or tires If necessary clean the brake discs and brake linings with a regular brake disc cleaner or ac etone and wash the tires with warm water and a mild deter gent e Before operating the motor cycle test its braking perfor mance and cornering behavior NOTE Consult a Yamaha dealer for advice on wh
66. r with the brake disc otherwise the brake pads will be forced shut 6 32 EAU24921 To install the front wheel 1 Install the speedometer gear unit into the wheel hub so that the pro jections mesh with the slots 1 Speedometer gear unit 2 Lift the wheel up between the fork legs NOTE Make sure that there is enough space between the brake pads before insert ing the brake disc and that the slot in the speedometer gear unit fits over the retainer on the fork leg PERIODIC MAINTENANCE AND MINOR REPAIR 7 Connect the speedometer cable FAUE5OBH Rear wheel EAU25430 1 To remove the rear wheel Itis advisable to have a Yamaha dealer service the wheel Securely support the motor 1 Speedometer gear unit retainer cycle so that there is no danger of it falling over EWA10820 3 Insert the wheel axle 4 Lower the front wheel so that it is 1 Loosen the axle nut and the brake on the ground torque rod nut at the brake shoe 5 Tighten the wheel axle and front plate 6 wheel axle pinch bolt to the speci fied torques and then install the rubber cap Tightening torques Wheel axle 59 Nm 5 9 m kgf 43 ft Ibf Front wheel axle pinch bolt 20 Nm 2 0 m kgf 14 ft lbf 6 While applying the front brake 1 Axle nut push down hard on the handlebars 2 Brake torque rod several times to check if the front 3 Brake torque rod nut and bolt fork compresses and rebounds 4 Brake rod smoothly
67. ransmission is in gear and the sid estand is moved down Periodically check the operation of the ignition circuit cut off system according to the following procedure If a malfunction is noted have a Yamaha dealer check the system be fore riding EWA10250 3 11 With the engine turned off 1 Move the sidestand down 2 Make sure that the engine stop switch is turned on 3 Turn the key on 4 Shift the transmission into the neutral position 5 Push the start switch Does the engine start With the engine still running 6 Move the sidestand up 7 Keep the clutch lever pulled 8 Shift the transmission into gear 9 Move the sidestand down Does the engine stall INSTRUMENT AND CONTROL FUNCTIONS NOTE This check is most reliable if performed with a warmed up engine After the engine has stalled 10 Move the sidestand up 11 Keep the clutch lever pulled 12 Push the start switch Does the engine start The system is OK The motorcycle can be ridden 3 12 The neutral switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer The sidestand switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer The clutch switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer PRE OPERATION CHECKS EAU15591 The condition of a vehicle is the owner s responsibility
68. speedometer unit is equipped with a speedometer an odometer and a tripmeter The speedometer shows riding speed The odometer shows the total distance traveled The tripmeter shows the distance traveled since it was last set to zero with the reset knob The tripmeter can be used to estimate the distance that can be traveled with a full tank of fuel This information will en able you to plan future fuel stops INSTRUMENT AND CONTROL FUNCTIONS EAU12090 Self diagnosis device This model is equipped with a self diag nosis device for various electrical cir cuits If any of those circuits are defective the engine trouble warning light will come on or flash If this occurs have a Yamaha dealer check the vehicle ECA11170 CAUTION To prevent engine damage be sure to consult a Yamaha dealer as soon as possible if this occurs 3 3 EAU12330 Anti theft alarm optional This model can be equipped with an optional anti theft alarm by a Yamaha dealer Contact a Yamaha dealer for more information INSTRUMENT AND CONTROL FUNCTIONS Handlebar switches Left EAU12342 1 Pass switch O 2 Dimmer switch 20 20 3 Turn signal switch lt a 5 gt 4 Horn switch pe Right 1 Engine stop switch O R 2 Light switch p d e 3 Start switch EAU12350 Pass switch o Press this switch to flash the headlight EAU12400 Dimmer switch 0 20 Set this switch to
69. the starter choke off as soon as possible Shift up swiftly and avoid high en gine speeds during acceleration Donot rev the engine while shifting down and avoid high engine speeds with no load on the engine Turn the engine off instead of let ting it idle for an extended length of time e g in traffic jams at traffic lights or at railroad crossings EAU16841 Engine break in There is never a more important period in the life of your engine than the period between 0 and 1600 km 1000 mi For this reason you should read the follow ing material carefully Since the engine is brand new do not put an excessive load on it for the first 1600 km 1000 mi The various parts in the engine wear and polish themselves to the correct operating clearances During this period prolonged full throt tle operation or any condition that might result in engine overheating must be avoided EAU17021 0 1000 km 0 600 mi Avoid prolonged operation above 1 3 throttle 1000 1600 km 600 1000 mi Avoid prolonged operation above 1 2 throttle OPERATION AND IMPORTANT RIDING POINTS ECA11281 CAUTION After 1000 km 600 mi of operation the engine oil must be changed and the oil filter cartridge or element re placed 1600 km 1000 mi and beyond The vehicle can now be operated nor mally ECA10270 CAUTION If any engine trouble should occur during the engine break in period immediately have a Yamaha dealer c
70. turn on the starter choke Move the lever in direction b to turn off the starter choke 3 9 1 Helmet holder 2 Unlock To open the helmet holder insert the key into the lock and then turn the key as shown To lock the helmet holder place it in the original position and then remove the key Never ride with a helmet attached to the helmet holder since the helmet may hit objects causing loss of con trol and possibly an accident EWA10160 INSTRUMENT AND CONTROL FUNCTIONS EAU14880 Adjusting the shock absorber assemblies 1 Spring preload adjusting ring 2 Position indicator Each shock absorber assembly is equipped with a spring preload adjust ing ring ECA10100 CAUTION Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings EWA10210 Always adjust both shock absorber assemblies equally otherwise poor handling and loss of stability may result Adjust the spring preload as follows To increase the spring preload and thereby harden the suspension turn the adjusting ring on each shock ab sorber assembly in direction a To de crease the spring preload and thereby soften the suspension turn the adjust ing ring on each shock absorber as sembly in direction b NOTE Align the appropriate notch in the ad justing ring with the position indicator on the shock absorber Spring preload setting Minimum soft 1 Standard 2 Maximum hard
71. ust engine idling speed Engine oil e Change e Check oil level and vehicle for oil leakage 6 3 ITEM CHECK OR MAINTENANCE JOB ODOMETER READING x 1000 km 10 20 30 40 PERIODIC MAINTENANCE AND MINOR REPAIR ANNUAL CHECK Engine oil filter element e Replace Ni Ni Engine oil strainer e Clean Front and rear brake switches e Check operation 1 4 4 4 Moving parts and ca bles e Lubricate Throttle grip housing and cable e Check operation and free play e Adjust the throttle cable free play if necessary e Lubricate the throttle grip housing and cable Air induction system e Check the air cut off valve reed valve and hose for dam age e Replace the entire air induction system if necessary Muffler and exhaust pipe e Check the screw clamp for looseness Lights signals and switches e Check operation e Adjust headlight beam EAU18660 NOTE The air filter needs more frequent service if you are riding in unusually wet or dusty areas e Hydraulic brake service e Regularly check and if necessary correct the brake fluid level e Every two years replace the internal components of the brake master cylinder and caliper and change the brake fluid e Replace the brake hoses every four years and if cracked or damaged PERIODIC MAINTENANCE AND MINOR REPAIR EAU18770 R

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