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A5-yoko_Blank.

fm Page 1 Tuesday, April 8, 2003 11:43 AM

Read this manual carefully before operating this vehicle.

OWNERS MANUAL

SX-4 225

54D-F8199-E0
U5YPE0E0.book Page 2 Wednesday, February 23, 2005 4:22 PM

EAU46090

Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it sold.
U5YPE0E0.book Page 1 Wednesday, February 23, 2005 4:22 PM

EAU10050
INTRODUCTION
EAU10102

Welcome to the Yamaha world of motorcycling!


As the owner of the SCORPIO (54D), you are benefiting from Yamahas vast experience and newest technology
regarding the design and manufacture of high-quality products, which have earned Yamaha a reputation for dependability.
Please take the time to read this manual thoroughly, so as to enjoy all advantages of your SCORPIO (54D). The Owner's
Manual does not only instruct you in how to operate, inspect and maintain your motorcycle, but also in how to safeguard
yourself and others from trouble and injury.
In addition, the many tips given in this manual will help keep your motorcycle in the best possible condition. If you have any
further questions, do not hesitate to contact your Yamaha dealer.
The Yamaha team wishes you many safe and pleasant rides. So, remember to put safety first!
Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most cur-
rent product information available at the time of printing, there may be minor discrepancies between your motorcycle and this
manual. If there is any question concerning this manual, please consult a Yamaha dealer.
EWA10031

WARNING
Please read this manual carefully and completely before operating this motorcycle.
IMPORTANT MANUAL INFORMATION EAU10122

EAU10132

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


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

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

A NOTICE indicates special precautions that must be taken to avoid damage to


NOTICE: the vehicle or other property.

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


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

IMPORTANT MANUAL INFORMATION

EAUN0020

SCORPIO (54D)
OWNERS MANUAL
2010 by Yamaha Indonesia Motor Mfg
1st edition, October 2010
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Indonesia Motor Manufacturing
is expressly prohibited.
Printed in Indonesia
U5YPE0E0.book Page 1 Wednesday, February 23, 2005 4:22 PM

TABLE OF CONTENTS
EAU10210

SAFETY INFORMATION ..................1-1 OPERATION AND IMPORTANT Checking the brake lever
RIDING POINTS................................. 5-1 free play .................................... 6-18
DESCRIPTION ..................................2-1 Starting and warming up a Adjusting the brake pedal
Left view ...........................................2-1 cold engine ................................. 5-1 free play .................................... 6-18
Right view.........................................2-2 Starting a warm engine .................. 5-2 Adjusting the rear brake light
Controls and instruments.................2-3 Shifting ........................................... 5-2 switch ....................................... 6-19
Tips for reducing fuel Checking the front brake pads and
INSTRUMENT AND CONTROL consumption ............................... 5-3 rear brake shoes ...................... 6-19
FUNCTIONS .......................................3-1 Engine break-in .............................. 5-3 Checking the front brake
Main switch/steering lock ................3-1 Parking ........................................... 5-5 fluid level .................................. 6-20
Key hole cover ................................3-2 General note .................................. 5-6 Changing the brake fluid .............. 6-20
Indicator lights ................................3-2 Drive chain slack .......................... 6-21
Speedometer unit ...........................3-2 PERIODIC MAINTENANCE AND Cleaning and lubricating the
Fuel gauge ......................................3-3 MINOR REPAIR ................................. 6-1 drive chain ................................ 6-23
Handlebar switches ........................3-3 Owners tool kit ............................... 6-1 Checking and lubricating the
Shift pedal .......................................3-4 Periodic maintenance and cables ....................................... 6-23
Brake lever .....................................3-4 lubrication chart .......................... 6-2 Checking and lubricating the
Brake pedal ....................................3-4 Removing and installing the throttle grip and cable ............... 6-23
Fuel tank cap ..................................3-5 cowlings and panel ..................... 6-5 Lubricating the brake lever .......... 6-24
Fuel .................................................3-5 Checking the spark plug ................. 6-8 Lubricating the brake pedal ......... 6-24
Starter (choke) lever ........................3-6 Engine oil .................................... 6-10 Checking and lubricating the
Kickstarter .......................................3-7 Engine oil filter element ................... 6-11 centerstand and sidestand ....... 6-24
Seat ................................................3-7 Cleaning the air filter element ...... 6-12 Lubricating the
Helmet holders ...............................3-8 Adjusting the carburetor ............... 6-13 swingarm pivots ........................ 6-25
Storage compartment .....................3-8 Adjusting the engine idling Checking the front fork ................. 6-25
Sidestand ........................................3-8 speed ........................................ 6-14 Checking the steering .................. 6-26
Adjusting the throttle cable Checking the wheel bearings ....... 6-26
PRE-OPERATION CHECKS ..............4-1 free play .................................... 6-14 Battery ......................................... 6-27
Pre-operation check list ..................4-2 Valve clearance ............................ 6-15 Replacing the fuse ....................... 6-28
Tires ............................................. 6-15
Wheels ......................................... 6-17
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TABLE OF CONTENTS
Replacing the head light bulb ............ 6-29
Replacing a front turn signal ligh
bulb/Auxilliary bulb ......................... 6-29
Replacing a rear turn signal/tail/
brake/light bulb .............................. 6-30
Front wheel ....................................... 6-31
Rear wheel ......................................... 6-32
Troubleshooting charts ..................... 6-35

MOTORCYCLE CARE AND


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

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

CONSUMER INFORMATION .............. 9-1


Identification numbers ....................... 9-1
To close the keyhole cover

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EAU45762

LOCATION OF IMPORTANT LABELS


EAU10384
LOCATION OF IMPORTANT LABELS
1-

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

1
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EAU10222

SAFETY INFORMATION
EAU10313
Safe Riding tersections are the most likely
Be a Responsible Owner
Perform the pre-operation checks each places for motorcycle accidents
As the vehicles owner, you are respon-
time you use the vehicle to make sure it to occur.
sible for the safe and proper operation
is in safe operating condition. Failure to Ride where other motorists can 1
of your motorcycle.
inspect or maintain the vehicle properly see you. Avoid riding in another
Motorcycles are single-track vehicles.
increases the possibility of an accident motorists blind spot.
Their safe use and operation are de-
or equipment damage. See page 5-1 Many accidents involve inexperi-
pendent upon the use of proper riding
for a list of pre-operation checks. enced operators. In fact, many op-
techniques as well as the expertise of
This motorcycle is designed to erators who have been involved in
the operator. Every operator should
carry the operator and a passen- accidents do not even have a cur-
know the following requirements before
ger. rent motorcycle license.
riding this motorcycle.
The failure of motorists to detect Make sure that you are qualified
He or she should:
and recognize motorcycles in traf- and that you only lend your mo-
Obtain thorough instructions from
fic is the predominating cause of torcycle to other qualified opera-
a competent source on all aspects
automobile/motorcycle accidents. tors.
of motorcycle operation.
Many accidents have been Know your skills and limits.
Observe the warnings and mainte-
caused by an automobile driver Staying within your limits may
nance requirements in this Own-
who did not see the motorcycle. help you to avoid an accident.
ers Manual.
Making yourself conspicuous ap- We recommend that you prac-
Obtain qualified training in safe
pears to be very effective in reduc- tice riding your motorcycle
and proper riding techniques.
ing the chance of this type of where there is no traffic until you
Obtain professional technical ser-
accident. have become thoroughly famil-
vice as indicated in this Owners
Therefore: iar with the motorcycle and all of
Manual and/or when made neces-
Wear a brightly colored jacket. its controls.
sary by mechanical conditions.
Use extra caution when you are Many accidents have been
approaching and passing caused by error of the motorcycle
through intersections, since in- operator. A typical error made by
1-1
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SAFETY INFORMATION
the operator is veering wide on a Never ride under the influence of tem become very hot during or af-
turn due to excessive speed or un- alcohol or other drugs. ter operation and can cause
dercornering (insufficient lean an- burns.
1 gle for the speed). Protective apparel A passenger should also observe
Always obey the speed limit and The majority of fatalities from motorcy- the above precautions.
never travel faster than warrant- cle accidents are the result of head in-
ed by road and traffic condi- juries. The use of a safety helmet is the Avoid Carbon Monoxide Poisoning
tions. single most critical factor in the preven- All engine exhaust contains carbon
Always signal before turning or tion or reduction of head injuries. monoxide, a deadly gas. Breathing car-
changing lanes. Make sure that Always wear an approved helmet. bon monoxide can cause headaches,
other motorists can see you. Wear a face shield or goggles. dizziness, drowsiness, nausea, confu-
The posture of the operator and Wind in your unprotected eyes sion, and eventually death.
passenger is important for proper could contribute to an impairment Carbon Monoxide is a colorless, odor-
control. of vision that could delay seeing a less, tasteless gas which may be
The operator should keep both hazard. present even if you do not see or smell
hands on the handlebar and The use of a jacket, heavy boots, any engine exhaust. Deadly levels of
both feet on the operator foot- trousers, gloves, etc., is effective carbon monoxide can collect rapidly
rests during operation to main- in preventing or reducing abra- and you can quickly be overcome and
tain control of the motorcycle. sions or lacerations. unable to save yourself. Also, deadly
The passenger should always Never wear loose-fitting clothes, levels of carbon monoxide can linger
hold onto the operator, the seat otherwise they could catch on the for hours or days in enclosed or poorly
strap or grab bar, if equipped, control levers, footrests, or wheels ventilated areas. If you experience any
with both hands and keep both and cause injury or an accident. symptoms of carbon monoxide poison-
feet on the passenger footrests. Always wear protective clothing ing, leave the area immediately, get
Never carry a passenger unless that covers your legs, ankles, and fresh air, and SEEK MEDICAL TREAT-
he or she can firmly place both feet. The engine or exhaust sys- MENT.
feet on the passenger footrests.
1-2
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SAFETY INFORMATION
Do not run engine indoors. Even if guidelines to follow if loading cargo to attached to the motorcycle before
you try to ventilate engine exhaust your motorcycle: riding. Check accessory mounts
with fans or open windows and The total weight of the operator, and cargo restraints frequently.
doors, carbon monoxide can rap- passenger, accessories and cargo Properly adjust the suspension 1
idly reach dangerous levels. must not exceed the maximum load for your load, and check the
Do not run engine in poorly venti- limit. Operation of an overloaded ve- condition and pressure of your
lated or partially enclosed areas hicle could cause an accident. tires.
such as barns, garages, or car- Never attach any large or heavy
ports. Maximum load: items to the handlebar, front
Do not run engine outdoors where 180 kg (397 lb) fork, or front fender. These
engine exhaust can be drawn into items, including such cargo as
When loading within this weight limit,
a building through openings such sleeping bags, duffel bags, or
keep the following in mind:
as windows and doors. tents, can create unstable han-
Cargo and accessory weight
dling or a slow steering re-
Loading should be kept as low and close to
sponse.
Adding accessories or cargo to your the motorcycle as possible. Se-
This vehicle is not designed to
motorcycle can adversely affect stabili- curely pack your heaviest items as
pull a trailer or to be attached to
ty and handling if the weight distribution close to the center of the vehicle
a sidecar.
of the motorcycle is changed. To avoid as possible and make sure to dis-
the possibility of an accident, use ex- tribute the weight as evenly as Genuine Yamaha Accessories
treme caution when adding cargo or possible on both sides of the mo- Choosing accessories for your vehicle
accessories to your motorcycle. Use torcycle to minimize imbalance or is an important decision. Genuine
extra care when riding a motorcycle instability. Yamaha accessories, which are avail-
that has added cargo or accessories. Shifting weights can create a sud- able only from a Yamaha dealer, have
Here, along with the information about den imbalance. Make sure that ac- been designed, tested, and approved
accessories below, are some general cessories and cargo are securely by Yamaha for use on your vehicle.

1-3
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SAFETY INFORMATION
Many companies with no connection to characteristics can put you and others Bulky or large accessories may
Yamaha manufacture parts and acces- at greater risk of serious injury or death. seriously affect the stability of
sories or offer other modifications for You are responsible for injuries related the motorcycle due to aerody-
1 to changes in the vehicle. namic effects. Wind may at-
Yamaha vehicles. Yamaha is not in a
position to test the products that these Keep the following guidelines in mind, tempt to lift the motorcycle, or
aftermarket companies produce. as well as those provided under Load- the motorcycle may become un-
Therefore, Yamaha can neither en- ing when mounting accessories. stable in cross winds. These ac-
dorse nor recommend the use of ac- Never install accessories or carry cessories may also cause
cessories not sold by Yamaha or cargo that would impair the perfor- instability when passing or be-
modifications not specifically recom- mance of your motorcycle. Care- ing passed by large vehicles.
mended by Yamaha, even if sold and fully inspect the accessory before Certain accessories can dis-
installed by a Yamaha dealer. using it to make sure that it does place the operator from his or
not in any way reduce ground her normal riding position. This
Aftermarket Parts, Accessories, and clearance or cornering clearance, improper position limits the free-
Modifications limit suspension travel, steering dom of movement of the opera-
While you may find aftermarket prod- travel or control operation, or ob- tor and may limit control ability,
ucts similar in design and quality to scure lights or reflectors. therefore, such accessories are
genuine Yamaha accessories, recog- Accessories fitted to the handle- not recommended.
nize that some aftermarket accessories bar or the front fork area can Use caution when adding electri-
or modifications are not suitable be- create instability due to improp- cal accessories. If electrical acces-
cause of potential safety hazards to er weight distribution or aerody- sories exceed the capacity of the
you or others. Installing aftermarket namic changes. If accessories motorcycles electrical system, an
products or having other modifications are added to the handlebar or electric failure could result, which
performed to your vehicle that change front fork area, they must be as could cause a dangerous loss of
any of the vehicles design or operation lightweight as possible and lights or engine power.
should be kept to a minimum.

1-4
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DESCRIPTION
EAU10420

Left view
1 2 3

4 5 6

1. Fuel cock (Page 3-7) 4. Starter (choke) lever (Page 3-8)


2. Helmet holder (Page 6-1) 5. Shift pedal (Page 3-5)
3. Owners tool kit (Page 3-10) 6. Air filter element (Page 6-10)

2-1
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DESCRIPTION
EAU10410

Right view 7 8

12 11 10 9

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

2-2
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DESCRIPTION
EAU10430

Controls and instruments


1 2 3 4 5 6 7

8
9

1. Clutch lever (Page 3-5,6-17) 6. Right handlebar switches (Page 3-4)


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

2-3
U5YPE0E0.book Page 1 Wednesday, February 23, 2005 4:22 PM

INSTRUMENT AND CONTROL FUNCTIONS


3-
EAU1044H

EAU10460
To lock the steering To unlock the steering
Main switch/steering lock

3 3

1. Push.
1. Push. 2. Turn
2. Turn
The main switch/steering lock controls
the ignition and lighting systems, and is EAU10700 Push the key in to the main switch,
used to lock the steering. The various LOCK and then turn it to "OFF" while still pu-
positions are described below. The steering is locked, and all electrical shing it.
EAU37441
systems are off. The key can be re-
ON moved. EWA10060

All electrical systems are supplied with WWARNING


WARNI
W ARNING
ARNING
NG
1. Turn the handlebars all the way to
power, and the meter lighting comes the left or right. Never turn the key to OFF or
on, and the engine can be started. The 2. Push the key in from the OFF po- LOCK while the vehicle is moving,
key cannot be removed. sition, and then turn it to "LOCK" otherwise the electrical systems will
EAU10660
while still pushing it. be switched off, which may result in
OFF loss of control or an accident. Make
3. Remove the key.
All electrical systems are off. The key sure that the vehicle is stopped be-
can be removed. fore turning the key to OFF or
LOCK.

3-1
U5YPE0E0.book Page 2 Wednesday, February 23, 2005 4:22 PM

INSTRUMENT AND CONTROL FUNCTIONS


Indicator lights EAU10981
EAU11080
Speedometer unit
EAU11630

High beam indicator light 2


This indicator light comes on when the
high beam of the headlight is switched
on. 1

3
4
3
1 2 3 1 1. Speedometer
1. Turn signal indicator light " 5 " 2. Odometer
2. Neutral indicator light "N" 3. Tripmeter
4. Reset knob
3. High beam indicator light " & "
EAU11040 The speedometer unit is equipped with
Turn signal indicator light a speedometer, an odometer and trip-
This indicator light flashes when the meter. The speedometer shows riding
turn signal switch is pushed to the left speed. The odometer shows the total
or right. distance traveled.
EAU11060
EAU11080 The tripmeter shows the distance tra-
Neutral indicator light " "
veled since it was last set to zero with
This indicator light comes on when the reset knob. The tripmeter can be
the transmission is in the neutral used to estimate the distance that can
position. be traveled with a full tank of fuel.
This information will enable you to plan
future fuel stops.

3-2
12140

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INSTRUMENT AND CONTROL FUNCTIONS


EAU11880 EAU12140

Tachometer Fuel gauge Handlebar switches


EAU12347

1
3
The fuel gauge indicates the amount of Left
1 2 3
fuel in the fuel tank. The needle moves
towards E (Empty) as the fuel level
decreases. When the needle reaches
When the needle reaches "E", refuel
as soon as possible.
3
TIP:
2
Do not allow the fuel tank to empty 5 4
1. Tachometer itself completely.
2. Red zone 1. Light switch : /'/1
3. Fuel gauge 2. Pass switch &
3. Dimmer switch /
4. Turn signal switch
The tachometer allows the rider to mo- 5. Horn switch HORN
nitor the engine speed and keep it wi- EAU12590
thin the ideal power range. Light switch " : / '/1 "
ECA10031 Set this switch to ' to turn on
NOTICE :
the auxiliary light, meter lighting and tail-
Do not operate the engine in the light. Set the switch to : to turn on
Tachometer red zone. the headlight also. Set the switch to
Red zone: 10.000 r/min and above. 1 to turn off all the lights.

Pass switch " EAU12350

Press this switch to flash the head-


light.

3-3
INSTRUMENT AND CONTROL FUNCTIONS
EAU12400
Right 1 Clutch lever
EAU12850

Dimmer switch /
Set this switch to for the high
beam and to for the low beam.
EAU12460
Turn signal switch /
To signal a right-hand turn, push this
3 1
switch to . To signal a left-hand
turn, push this switch to . When re- 2 3
leased, the switch returns to the center
position. To cancel the turn signal
1. Engine stop switch " #/$ "
lights, push the switch in after it has re-
2. Start switch " " 1. Clutch lever
turned to the center position.
EAU12660
EAU12500 Engine stop switch #/$ The clutch lever is located at the left
Horn switch HORN
Set this switch to # before starting handlebar grip. To disengage the
Press this switch to sound the horn.
the engine. Set this switch to $ to clutch, pull the lever toward the han-
stop the engine in case of an emer- dlebar grip. To engage the clutch,
gency, such as when the motorcycle release the lever. The lever should
overturns or when the throttle cable is be pulled rapidly and released slowly
stuck. EAU12710
for smooth clutch operation.
Start switch ,
Push this switch to crank the engine
with the starter.
ECA10050

NOTICE :
CAUTION:
See page 5-1 for starting instruction
prior starting the engine.

3-4
er

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INSTRUMENT AND CONTROL FUNCTIONS


EAU12890 EAU12941
Shift pedal
EAU12880

Brake lever Brake pedal

1
5 1
4
3
3 2
N
1 .
1
1. Shift pedal 1. Brake lever 1. Brake pedal.
N. Neutral
The brake lever is located at the right The brake pedal is on the right side of
The shift pedal is located on the left handlebar grip. To apply the front the motorcycle. To apply the rear
side of the engine and is used in brake, pull the lever toward the handle- brake, press down on the brake pedal.
combination with the clutch lever bar grip.
when shifting the gears of the
5-speed constant-mesh transmission
equipped on this motorcycle.
TIP:
Use your toes or heel to shift up and
your toes to shift down.

3-5
l)

U5YPE0E0.book Page 5 Wednesday, February 23, 2005 4:22 PM

INSTRUMENT AND CONTROL FUNCTIONS


Fuel tank cap
EAU13074
To close the fuel tank cap EAU13212

Fuel
1. Push the fuel tank cap into the po-
sition with the key inserted in the
> lock.
2. Turn the key counterclokwise to

=
the original position, remove it,
and then close the lock cover.
3
TIP:
The fuel tank cap cannot be closed
1 unless the key is in the lock. In addition,
the key cannot be removed if the cap 1. Fuel tank filler tube
1. Fuel tank cap lock cover cap is not properly closed and locked. 2. Fuel level
a. Open
b. Unlock Make sure there is sufficient gasoline
EWA11091

Open the fuel tank cap lock cover, WARNING in the tank.
insert the key into the lock and turn it Make sure that the fuel tank cap is EWA10881

1/4 turn clockwise. The lock will be properly closed after filling fuel. WARNING
W
W ARNI
ARNINGNG
NG
be released and the fuel tank cap can Leaking fuel is a fire hazard. Gasoline and gasoline vapors are
be opened. extremely flammable. To avoid fires
and explosions and to reduce the
risk of injury when refueling, follow
these instructions.

3-6
A5-yoko_Blank.fm Page 1 Tuesday, April 8, 2003 11:43 AM

INSTRUMENT AND CONTROL FUNCTIONS


EAU13242
1. Before refueling, turn off the engi- 3. Wipe up any spilled fuel immedia-
ne and be sure that no one is sitt- tely. NOTICE: Immediately wipe
Recommended fuel:
ing on the vehicle. Never refuel off spilled fuel with a clean. dry,
Reguler unleaded gasoline only
while smoking, or while in the soft cloth, since fuel may dete-
Fuel tank capacity:
vicinity of sparks, open flames, riorate painted surfaces or plas-
tic parts. [ECA10071] Total amount:
or other sources of ignition such 13 L
as the pilot lights of water heaters Fuel reserve amount:
and clothes dryers. 4. Be sure to securely close the fuel
3 3.0 L
tank cap.
2. Do not overfill the fuel tank. Stop EWA15151

filling when the fuel reaches the WARNING


WARNI
ARNING
NG ECA11400
NOTICE :
bottom of the filler tube. Because Gasoline is poisonous and can cau- Use only unleaded gasoline. The use
fuel expands when it heats up, se injury or death. Handle gasoline of leaded gasoline will cause severe
heat from the engine or the sun with care. Never siphon gasoline damage to internal engine parts,
can cause fuel to spill out of the by mouth. If you should awallow such as the valves and piston rings,
fuel tank. some gasoline or inhale a lot of ga- as well as to the exhaust system.
soline vapor, or get some gasoline
in your eyes, see your doctor imme-
diately. If gasoline spills on your skin,
wash with soap and water. If gaso-
line spills on your clothing, change
your clothes.

3-7
RES: Reserve position

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

INSTRUMENT AND CONTROL FUNCTIONS


EAU13561
Fuel cock ON: Normal position RES: Reserve position
OFF: Closed position RES
RES
RES
RES OFF
FUEL OFF
OFF ON
FUEL
FUEL ON 3
ON ON

The fuel cock supplies fuel from the ON RES


tank to carburetor whilw filtering it With the lever in this position, fuel This indicates reserve. If you run out
also. flows to the carburetor. Normal riding of fuel while riding, move the lever to
is done with the lever is position. this position. Fill the tank at the first
The fuel cock has three positions: opportunity. Be sure to set the lever
back to "ON" after refueling!
OFF
Whit the lever in this position, fuel will
not flow. Always return the lever to
this position when the engine is not
running.

3-8
A5-yoko_Blank.fm Page 1 Tuesday, April 8, 2003 11:43 AM

INSTRUMENT AND CONTROL FUNCTIONS


EAU13590 EAU13660

Starter (choke) lever Kickstarter This model is equipped with a primary


kickstarter, allowing the engine to be
1 started in any gear if the clutch is
1 disengaged. However, shifting the
transmission into the neutral position
b before starting is recommended.
a
3
2
1. Starter (choke) lever CHOKE 1. Kickstarter
2. Footrest

Starting a cold engine requires a richer


To start the engine, fold the right foot-
air-fuel mixture, which is supplied by rest inward, and then fold out the
the starter (choke). kickstarter lever. Move it down lightly
Move the lever in direction (a) to turn on with your foot until the gears engage,
the starter (choke). and then push it down smoothly but
Move the lever in direction (b) to turn off forcefully. Fold the footrest outward
the starter (choke). to it original position.

3-9
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INSTRUMENT AND CONTROL FUNCTIONS


EAU13790 EAU14311

Seat 2 Helmet holders


1

a 1
3

1. Projection
2. Seat holder
a. Unlock. 1. Helmet holder

To remove the seat To install the seat The helmet holders are located under
the seat.
1. Insert the key into the seat lock, and 1. Insert the projection on the front
then turn it clockwise of the seat into the seat holder To secure a helmet to a helmet holder
as shown. 1. Open the seat. (See page 3-9 for
2. Pull the seat off.
2. Push the rear of the seat down to removal and installation prose-
lock it in place. dures.)
3. Turn the key counter clockwise 2. Attach a helmet to a helmet holder,
and then remove it. and then securely close the seat.
WARNI!NGNever ride with a
WARNING
TIP: helmet attached to the helmet
Make sure that the seat is properly holder, since the helmet may
secured before riding. hit objects, causing loss of control
and possibly an accident. [EWA10161]

3-10
1

U5YPE0E0.book Page 9 Wednesday, February 23, 2005 4:22 PM

INSTRUMENT AND CONTROL FUNCTIONS


EAU37490
To release a helmet to a helmet holder Sidestand
Open the seat, remove the helmet from The sidestand is located on the left side
the helmet holder, and then close the of the frame. Raise the sidestand or
seat. lower it with your foot while holding the
vehicle upright.
EWA14190

WARNING
3 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.

3-11
U5YPE0E0.book Page 1 Wednesday, February 23, 2005 4:22 PM

EAU15582

PRE-OPERATION CHECKS
EAU15596

Inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition. Always follow the
inspection and maintenance procedures and schedules described in the Owner's Manual.
EWA11151
WARNING
Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equipment damage.
Do not operate the vehicle if you find any problem. If a problem cannot be corrected by the procedures provided
in this manual, have the vehicle inspected by a Yamaha dealer.
Before using this vehicles, check the following points:

4-1
U5YPE0E0.book Page 2 Wednesday, February 23, 2005 4:22 PM

PRE-OPERATION CHECKS
EAU15610

Pre-operation check list


ITEM CHECKS PAGE

Check fuel level in fuel tank.


Fuel Refuel if necessary. 3-6
Check fuel line for leakage.
Check oil level in engine.
Engine oil If necessary, add recommended oil to specified level. 6-8
Check vehicle for oil leakage.

Check operation
Front and rear suspension 6-23
Check oil suspention for leakage.
4
Check operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check brake pads for wear.
Front brake Replace if necessary. 6-18, 6-19
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.
Check operation.
Rear brake Check pedal free play. 6-17
Adjust if necessary.
Make sure that operation is smooth.
Check cable free play.
Throttle grip 6-12, 6-13
If necessary, have Yamaha dealer adjust cable free play and lubricate cable and
grip housing.
Make sure that operation is smooth.
Control cables 6-21
Lubricate if necessary.
Check chain slack.
Adjust if necessary.
Drive chain 6-19, 6-20
Check chain condition.
Lubricate if necessary.

4-2
U5YPE0E0.book Page 3 Wednesday, February 23, 2005 4:22 PM

PRE-OPERATION CHECKS
ITEM CHECKS PAGE

Check for damage.


Check tire condition and tread depth.
Wheels and tires 6-13, 6-15
Check air pressure.
Correct if necessary.
Make sure that operation is smooth.
Brake and shift pedal 6-16
Lubricate pedal pivoting point if necessary.
Make sure that operation is smooth.
Brake and clutch lever 6-16
Lubricate lever pivoting point if necessary.
Make sure that operation is smooth.
Centerstand, sidestand 6-22
Lubricate pivots if necessary.
4
Make sure that all nuts, bolts and screws are properly tightened.
Chassis fasteners
Tighten if necessary.
Instruments, lights, signals Check operation.

and switches Correct if necessary.
Check fluid level.
Battery 6-25
Fill with distilled water if necessary.

4-3
U5YPE0E0.book Page 1 Wednesday, February 23, 2005 4:22 PM

OPERATION AND IMPORTANT RIDING POINTS


EAU15942

EAU16540

EAU15951
Before starting out, make sure Starting and warming up a
Read the Owner's Manual carefully to that the sidestand is up. If the cold engine
become familiar with all controls. If sidestand is not raised com-
there is a control or function you do not pletely, it could contact the
understand, ask your Yamaha dealer. ground and distract the opera-
RES
tor, resulting in a possible loss
WARNING
EWA10270
of control. OFF
FUEL
Become thoroughly familiar ECAN0070
ON
with all operating controls and NOTICE
NOTICE:::
NOTICE
their functions before riding. ON
Do not ride through deep water
Consult a Yamaha dealer re- (including puddles), otherwise the
5
garding any control or function engine may be damaged.
that you do not thoroughly un- In order for the ignition circuit cut-off
derstand. system to enable starting, one of the
following conditions must be met:
Never start the engine or oper-
ate it in a closed area for any
The transmission is in the neutral
length of time. Exhaust fumes position.
are poisonous, and inhaling The transmission is in gear with the
them can cause loss of con- clutch lever pulled.
sciousness and death within a 1. Turn the fuel cock lever to ON
short time. Always make sure 2. Turn the key to ON and make
that there is adequate ventila- sure that the engine stop switch
tion. is set to # .
3. Shift the transmission into the
neutral position.

5-1
U5YPE0E0.book Page 2 Wednesday, February 23, 2005 4:22 PM

OPERATION AND IMPORTANT RIDING POINTS


EAU16640
TIP: Starting a warm engine
When the transmission is in the neutral 6. After starting the engine, move Follow the same procedure as for start-
position, the neutral indicator light the starter (choke) back halfway. ing a cold engine with the exception
should be on, otherwise have a Yamaha NOTICE: For maximum engine that the starter (choke) is not required
dealer check the electrical circuit. life, always warm the engine when the engine is warm.
up before starting off. Never
4. Turn the starter (choke) on and accelerate hard when the engine
completely close the throttle. (See is cold! [ECA11131]
page 3-8.) 7. When the engine is warm, turn the
5. Start the engine by pushing the starter (choke) off.
start switch or by pushing the kick-
TIP :
starter lever down.
The engine is warm when it responds
TIP : normally to the throttle with the starter 5
If the engine fails to start by pushing the (choke) turned off.
start switch, release the switch, wait a
few seconds, and then try again. Each
starting attempt should be as short as
possible to preserve the battery. Do not
crank the engine more than 10 seconds
on any one attempt. If the engine does
not start with the starter motor, try using
the kickstarter.

5-2
U5YPE0E0.book Page 3 Wednesday, February 23, 2005 4:22 PM

OPERATION AND IMPORTANT RIDING POINTS


EAU16671 EAU16800
Shifting NOTICE:
ECA10260
Tips for reducing fuel
8 Even with the transmission in consumption
the neutral position, do not Fuel consumption depends largely on
5 coast for long periods of time your riding style. Consider the following
4 with the engine off, and do not tips to reduce fuel consumption:
3 tow the motorcycle for long Turn the starter (choke) off as
2 distances. The transmission is soon as possible.
N
properly lubricated only when Shift up swiftly, and avoid high en-
1
1 the engine is running. gine speeds during acceleration.
Inadequate lubrication may Do not rev the engine while shifting
1. Shift pedal damage the transmission. down, and avoid high engine
N. Neutral position 8 Always use the clutch while speeds with no load on the engine.
5 changing gears to avoid dam- Turn the engine off instead of let-
Shifting gears lets you control the
aging the engine, transmis-
amount of engine power available for ting it idle for an extended length of
sion, and drive train, which are
starting off, accelerating, climbing hills, time (e.g., in traffic jams, at traffic
not designed to withstand the
etc. shock of forced shifting. lights or at railroad crossings).

TIP:
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.

5-3
U5YPE0E0.book Page 4 Wednesday, February 23, 2005 4:22 PM

OPERATION AND IMPORTANT RIDING POINTS


EAU16830 EAU16970

Engine break-in 0500 km (0-300 mi) 5001,000 km (300-600 mi)


There is never a more important period
in the life of your engine than the period
between 0 and 1000 km (600 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
1000 km (600 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 8 Avoid prolonged operation above 8 Avoid prolonged operation above 5
result in engine overheating must be 4.700 r/min. 6.600 r/min.
avoided. 8 After every hour of operation, 8 Rev the engine freely through
stop the engine, and then let it the gears, but do not use full
cool for five to ten minutes. throttle at any time. NOTICE:
8 Vary the engine speed from time After 1000 km of operation, the
to time. Do not operate the
engine oil must be changed, and
engine at one set throttle posi-
tion. the oil filter element cleaned.
[ECA10321]

5-4
U5YPE0E0.book Page 5 Wednesday, February 23, 2005 4:22 PM

OPERATION AND IMPORTANT RIDING POINTS


EAU17171
1,000 km (600 mi) and beyond Parking
When parking, stop the engine, and
then remove the key from the main
switch, and then turn the fuel cock
lever to "OFF".
EWA10310

WARNING
Since the engine and exhaust
system can become very hot,
park in a place where pedestri-
ans or children are not likely to
5 touch them.
The vehicle can now be operated
Do not park on a slope or on soft
normally.
ECA10310
ground, otherwise the vehicle
NOTICE: may overturn.
8 Keep the engine speed out of
the tachometer red zone.
8 If any engine trouble should
occur during the engine break-
in period, immediately have a
Yamaha dealer check the vehicle.

5-5
U5YPE0E0.book Page 6 Wednesday, February 23, 2005 4:22 PM

OPERATION AND IMPORTANT RIDING POINTS


EAU37601

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

1. THE CUSTOMERS CAN USE THE FULLEST 2. A MOTORCYCLE CAN KEEP ITS PERFORMANCE
POTENTIAL OF YAMAHA MOTORCYCLES CAPABILITY FOR A LONGER TIME

Comparison of wear on engine parts


(piston, piston ring, cylinder, etc.)
100% With maintenance

Perfect operative
condition
Without 5
maintenance

Distance
covered (km) Engine overhaul, cylinder
boring, piston ring change, etc.

5-6
U5YPE0E0.book Page 7 Wednesday, February 23, 2005 4:22 PM

OPERATION AND IMPORTANT RIDING POINTS

3. FUEL COST AND REPAIR EXPENSES CAN BE 4. A MOTORCYCLE CAN DEMAND A HIGH PRICE
KEPT TO A MINIMUM WHEN IT IS TRADED IN AS A USED PRODUCT

Fuel consumption
With maintenance
100%

Without
maintenance
Distance covered (km)

5 Customers running cost


(fuel cost plus maintenance and repair expenses)
S Without maintenance
Big repairs at higher expenses
With maintenance

Distance covered (km)

5-7
U5YPE0E0.book Page 1 Wednesday, February 23, 2005 4:22 PM

PERIODIC MAINTENANCE AND MINOR REPAIR


EAU17229

Owners tool kit


EAU17241 EAU17381

TIP :
Safety is an obligation of the owner. Pe- If you do not have the tools or experi-
riodic inspection, adjustment and lubri- 1 ence required for a particular job, have
cation will keep your vehicle in the a Yamaha dealer perform it for you.
safest and most efficient condition pos-
sible. The most important points of in- EWA10350

spection, adjustment, and lubrication WARNING


are explained on the following pages. Modifications not approved by
The intervals given in the periodic Yamaha may cause loss of perfor-
maintenance and lubrication chart mance and render the vehicle un-
should be simply considered as a gen- safe for use. Consult a Yamaha
eral guide under normal riding condi- 1. Owners tool kit dealer before attempting any chang-
tions. However, DEPENDING ON THE es.
WEATHER, TERRAIN, GEOGRAPHI- The owners tool kit is located inside the
CAL LOCATION, AND INDIVIDUAL storage compartment under the seat. EAUN0100
6
USE, THE MAINTENANCE INTER- (See page 3-9.) ECAN0080

The service information included in this NOTICE:


VALS MAY NEED TO BE SHORT-
ENED. manual and the tools provided in the Improper disposal of drained fluids
EWA10320 owners tool kit are intended to assist (i.e., oil, coolant,etc) and battery
WARNING you in the performance of preventive are harmful to the environment.
If you are not familiar with mainte- maintenance and minor repairs. How- Contact a Yamaha dealer for pro-
nance work, have a Yamaha dealer ever, additional tools such as a torque per disposal to protect the envi-
do it for you. wrench may be necessary to perform
ronment.
certain maintenance work correctly.

6-1
U5YPE0E0.book Page 2 Wednesday, February 23, 2005 4:22 PM

PERIODIC MAINTENANCE AND MINOR REPAIR


EAU17710

Periodic maintenance and lubrication chart


TIP :
The annual checks must be performed every year, except if a kilometer-based maintenance is performed in-
stead.
From 12000 km, repeat the maintenance intervals starting from 3000 km.
Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical
skills.

ODOMETER READING ( 1000 km) ANNUAL


NO. ITEM CHECK OR MAINTENANCE JOB
0.5 3 6 9 12 CHECK

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

2 Spark plug Clean and regap.
6 Replace.
Check valve clearance.
3 * Valves
Adjust.
Clean.
4 Air filter element
Replace.
Check electrolyte level and specific gravity.
5 * Battery
Make sure that the breather hose is properly routed.
Check operation, fluid level and vehicle for fluid leakage.
6 * Front brake
Replace brake pads. Whenever worn to the limit
Check operation and adjust brake pedal free play.
7 * Rear brake
Replace brake shoes. Whenever worn to the limit
Check for cracks or damage.
8 * Brake hose
Replace. Every 4 years

6-2
U5YPE0E0.book Page 3 Wednesday, February 23, 2005 4:22 PM

PERIODIC MAINTENANCE AND MINOR REPAIR


ODOMETER READING ( 1000 km) ANNUAL
NO. ITEM CHECK OR MAINTENANCE JOB
0.5 3 6 9 12 CHECK

9 * Wheels Check runout, and for damage.

Check tread depth and for damage.


Replace if necessary.
10 * Tires
Check air pressure.
Correct if necessary.
11 * Wheel bearings Check bearing for looseness or damage.
Check operation and for excessive play.
12 * Swingarm
Lubricate with lithium-soap-based grease. Every 24000 km
Check chain slack, alignment and condition. Every 500 km and after washing the motorcycle or
13 Drive chain
Adjust and thoroughly lubricate chain with engine oil. riding in the rain
Check bearing play and steering for roughness.
14 * Steering bearings
Lubricate with lithium-soap-based grease. Every 24000 km 6
Make sure that all nuts, bolts and screws are properly
15 * Chassis fasteners
tightened.
Check operation.
16 Sidestand, centerstand
Lubricate.
17 * Front fork Check operation and for oil leakage.
Shock absorber assem-
18 * Check operation and shock absorber for oil leakage.
bly
Check starter (choke) operation.
19 * Carburetor
Adjust engine idling speed.
Change.
20 Engine oil
Check oil level and vehicle for oil leakage.
21 Elemen oil filter (Ch) Change (Cl) Clean Cl Cl Ch Cl Ch

6-3
U5YPE0E0.book Page 4 Wednesday, February 23, 2005 4:22 PM

PERIODIC MAINTENANCE AND MINOR REPAIR


ODOMETER READING ( 1000 km) ANNUAL
NO. ITEM CHECK OR MAINTENANCE JOB
0.5 3 6 9 12 CHECK

Check operation
22 * Front suspention
Check for oil leakage
Front and rear brake
23 * Check operation.
switches
Moving parts and ca-
24 Lubricate.
bles
Check operation and free play.
Throttle grip housing
25 * Adjust the throttle cable free play if necessary.
and cable
Lubricate the throttle grip housing and cable.
Check the air cut-off valve, reed valve, and hose for dam-
26 * Air induction system age.
Replace any damaged parts if necessary.
Lights, signals and Check operation.
6 27 *
switches Adjust headlight beam.

EAU18660

TIP :
The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
Hydraulic brake service
Regularly check and, if necessary, correct the brake fluid level.
Every two years replace the internal components of the brake master cylinder and caliper, and change the brake fluid.
Replace the brake hoses every four years and if cracked or damaged.

6-4
U5YPE0E0.book Page 5 Wednesday, February 23, 2005 4:22 PM

PERIODIC MAINTENANCE AND MINOR REPAIR


EAU18771

Removing and installing the 2 1


cowlings and panel 1
The cowlings and panel shown above
need to be removed to perform some of
the maintenance jobs described in this
chapter. Refer to this section each time
a cowling or the panel needs to be re-
moved and installed 2

1. Panel/cover 1. Projection
2. Screw 2. Holder
EAU19400

To remove the panel To install the panel


1. Remove the seat (See age 3-8 for 1. Pleace the panel in the original po- 6
seat removal and instalation pro- sition, and then install the screws
cedures.)
TIP :
2. Remove the screws, and then pull
Make sure that projection fits into the
the panel off as shown.
grommet

2. Install the seat.

6-5
1. Spark plug wrence
wrence1. Spark plug wrence

U5YPE0E0.book Page 7 Wednesday, February 23, 2005 4:22 PM

PERIODIC MAINTENANCE AND MINOR REPAIR


EAU19603
Checking the spark plug To check the spark plug
1. Check that the porcelain insulator
around the center electrode of the
spark plug is a medium-to-light tan
(the ideal color when the vehicle is
1 ridden normally).
TIP :
If the spark plug shows a distinctly dif-
ferent color, the engine could be defec-
tive. Do not attempt to diagnose such
1 problems yourself. Instead, have a
Yamaha dealer check the vehicle.
1. Spark plug cap.
2. Check the spark plug for electrode
6 The spark plug is an important engine To remove the spark plug erosion and excessive carbon or
component, which is easy to check. 1. Remove the spark plug cap. other deposits, and replace it if
Since heat and deposits will cause any 2. Remove the spark plug as shown, necessary.
spark plug to slowly erode, the spark with the spark plug wrench inclu-
plug should be removed and checked Specified spark plug:
ded in the owner's tool kit.
in accordance with the periodic mainte- D8EA (NGK) or
nance and lubrication chart. In addition, X24ES-U (DENSO)
the condition of the spark plug can re-
veal the condition of the engine.

6-6
U5YPE0E0.book Page 8 Wednesday, February 23, 2005 4:22 PM

PERIODIC MAINTENANCE AND MINOR REPAIR


Tightening torque:
Spark plug:
17.5 Nm (1.75 mkgf, 10.1 ftlbf)

TIP :
If a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/41/2 turn
past finger tight. However, the spark
1. Spark plug gap plug should be tightened to the speci-
To install the spark plug fied torque as soon as possible.
1. Measure the spark plug gap with a
wire thickness gauge and, if nec- 4. Install the spark plug cap.
essary, adjust the gap to specifica-
6
tion.
Spark plug gap:
0.70.8 mm (0.0270.031 in)

2. Clean the surface of the spark plug


gasket and its mating surface, and
then wipe off any grime from the
spark plug threads.
3. Install the spark plug with the
spark plug wrench, and then tight-
en it to the specified torque.

6-7
face and hold it in an upright po-

U5YPE0E0.book Page 9 Wednesday, February 23, 2005 4:22 PM

PERIODIC MAINTENANCE AND MINOR REPAIR


EAU19772

Engine oil and oil filter


element
The engine oil level should be checked 4
before each ride. In addition, the oil 1
must be changed and the oil filter ele- 2
ment replaced at the intervals specified
in the periodic maintenance and lubri- 3 1
cation chart

To check the engine oil level 1. Engine oil drain bolt


1. Engine oil level check window
1. Place the vehicle on a level sur- 2. Maximum level mark
face and hold it in an upright po- To change the engine oil (with or whit-
3. Minimum level mark
sition A slight tilt to the side can 4. Engine oil filler bolt out oil filter element cleaning)
result in a false reading.
6 2. Start the engine, warm it up for TIP: 1. Start the engine, warm it up for
several minutes, and then turn it The engine oil should be between the several minutes, and then turn it off.
off. minimum and maximum level marks. 2. Place an oil pan under the engine
3. Wait a few minutes until the oil set- to collect the used oil.
tles, and then check the oil level 4. If the engine oil is at or below the 3. Remove the engine oil filler cap
through the check window located minimum level mark, add sufficient and drain bolt to drain the oil, from
at the bottom-right side of the oil of the recommended type to crankcase.
crankcase. raise it to the correct level. 4. Check the washers for damage
and replace them if necessary.

6-8
U5YPE0E0.book Page 11 Wednesday, February 23, 2005 4:22 PM

PERIODIC MAINTENANCE AND MINOR REPAIR


10. Install the oil filter element cover by
installing the bolts, then tightening
2
3 them to the specified torque.

2 Tightening torque:
Oil filter element cover bolt:
10 Nm (1.0 mkgf, 7.2 ftlbf)
1
1 TIP:
Make sure that the O-ring is properly
1. Oil filter element drain bolt seated.
1. Oli filter element
2. Oli filter element cover
2. O-ring (3)
3. Bolt (2)
11. Install the oil filter element drain
5. Remove the oil filter element drain 6. Remove the oil filter element cover bolt, and then tighten it to the
bolt to drain the oil from the oil fil- by removing the bolts. specified torque.
6
ter element. 7. Remove the oil filter element and 12. Install the engine oil drain bolt, and
TIP : O-rings. and then tighten it to the specified
Skip step 6-10 if the oil filter element is 8. Check the O-rings for damage and torque.
not being cleaned. replace it if necessary.
9. Clean the oil filter element with Tightening torque:
solvent, and then install it. Oil filter element drain bolt:
10 Nm (1.0 mkgf, 7.2 ftlbf)
TIP :
Engine oil drain bolt:
Check the oil filter element for damage 20 Nm (2.0 mkgf, 14.4 ftlbf)
and repalce it if necessary.

6-9
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PERIODIC MAINTENANCE AND MINOR REPAIR


EAU20832

13. Refill with the specified amount 14. Start the engine, and then let it idle Cleaning the air filter element
of the recommended oil, and then for several minutes while checking and check hose
install and tighten the oil filler bolt. it for oil leakage. If oil is leaking, im-
The air filter element should be cleaned
mediately turn the engine off and
at the intervals specified in the perio-
Recommended engine oil: check for the cause.
See page 8-1. dic maintenance and lubrication chart.
15. Turn the engine off, and then
Oil quantity: Clean the air filter element more fre-
check the oil level and correct it if
With oil filter element removal: quently if you are riding in unusually
1.30 L (1.24 US qt) (1.13 Imp.qt) necessary.
wet or dusty areas.
Without oil filter element removal:
In addition, the air filter check hose
1.20 L (1.14 US qt) (1.04 Imp.qt)
must be frequently checked and cle-
Total amount (dry engine)
aned if necessary.
1.40 L (1.33 US qt) (1.21 Imp.qt)

ECA10390

66 NOTICE:
In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives
with the oil.
Make sure that no foreign mate-
rial enters the crankcase.

6-10
A5-yoko_Blank.fm Page 1 Tuesday, April 8, 2003 11:43 AM

PERIODIC MAINTENANCE AND MINOR REPAIR

2
1
2

1
3
1. Sponge material
1. Air filter case cover 2. Element guide
2. Screw (4) 3. Air filter element frame TIP :
The sponge material should be wet
To clean the air filter element but not dripping.
1. Remove left side panel (See 3. Pull the air filter out.
page 6-5) 4. Remove the sponge material 6
2. Remove the air filter case cover from the air filter element frame, Recommended oil:
by removing the screws. clean it with solvent, and squee- _

Foam air filter oil


ze the remaining solvent out.
5. Apply oil of the recommended _

type to the entire surface of the


excess oil out.

6-11
U5YPE0E0.book Page 14 Wednesday, February 23, 2005 4:22 PM

PERIODIC MAINTENANCE AND MINOR REPAIR


EAU39930

Adjusting the carburetor


6. Pull the sponge material over the The carburetor is an important part of
air filter element frame. the engine and requires very sophisti-
7. Insert the air filter element into the cated adjustment. Therefore, most car-
air filter case.NOTICE: Make su- buretor adjustments should be left to a
re that the air filter element is Yamaha dealer, who has the neces-
properly seated in the air filter sary professional knowledge and expe-
case. The engine should never rience. The adjustment described in
be operated without the air filter the following section, however, may be
1
element installed, otherwise the serviced by the owner as part of rou-
piston(s) and/or cylinder(s) may 1. Hose (2) tine maintenance.
become excessively worn. ECA10550
[ECA10481] To clean the air filter check hose NOTICE:
8. Install the air filter case cover by in- 1. Check the hose at the buttom of The carburetor has been set and ex-
6 stalling the screws. the air filter case for accumulated tensively tested at the Yamaha fac-
9. Install the panel. dirt or water. tory. Changing these settings
2. If dirt or water is visible, remove without sufficient technical knowl-
the hose, clean it, and then install edge may result in poor perfor-
it. mance of or damage to the engine.

6-12
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PERIODIC MAINTENANCE AND MINOR REPAIR


EAU21320
EAU21370
Adjusting the engine idling Adjusting the throttle cable
speed free play
The engine idling speed must be
The throttle cable free play should mea-
checked and, if necessary, adjusted as b sure 3.05.0 mm (0.120.20 in) at the
follows at the intervals specified in the
throttle grip. Periodically check the
periodic maintenance and lubrication a throttle cable free play and, if neces-
chart.
sary, adjust it as follows.
The engine should be warm before 1
making this adjustment. TIP :
1. Throttle stop screw The engine idling speed must be cor-
TIP:
rectly adjusted before checking and ad-
The engine is warm when it quickly
justing the throttle cable free play.
responds to the throttle. Engine idling speed:
13001500 r/min

Check the engine idling speed and, if


TIP : 6
necessary, adjust it to specification by
turning the throttle stop screw. If the specified idling speed cannot be
To increase the engine idling speed, obtained as described above, have a
turn the screw in direction (a). To de- Yamaha dealer make the adjustment.
crease the engine idling speed, turn
the screw in direction (b).

6-13
U5YPE0E0.book Page 16 Wednesday, February 23, 2005 4:22 PM

PERIODIC MAINTENANCE AND MINOR REPAIR


EAU21401 EAU21550

Valve clearance Tires


The valve clearance changes with use, To maximize the performance, durabil-
c
resulting in improper air-fuel mixture ity, and safe operation of your motor-
and/or engine noise. To prevent this cycle, note the following points
from occurring, the valve clearance regarding the specified tires.
b 1 must be adjusted by a Yamaha dealer
at the intervals specified in the periodic Tire air pressure
2 maintenance and lubrication chart. The tire air pressure should be checked
a
and, if necessary, adjusted before each
1. Locknut ride.
2. Adjusting nut EWA10500
c. Free play
WARNING
1. Lossen the locknut The tire air pressure must be
2. To increase the throttle cable free checked and adjusted on cold
6 play, turn the adjusting nut in direc- tires (i.e., when the temperature
tion (a). To decrease the throttle of the tires equals the ambient
cable free play, turn the adjusting temperature).
nut in direction (b). The tire air pressure must be ad-
3. Tighten the locknut. justed in accordance with the
riding speed and with the total
weight of rider, passenger, car-
go, and accessories approved
for this model.

6-14
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PERIODIC MAINTENANCE AND MINOR REPAIR


Tire air pressure (measured on cold the total weight of the cargo, rider, Minimum tire tread depth (front and
tires): passenger, and accessories (fairing, rear):
0100 kg (0220 lb): saddlebags, etc. if approved for this 1.0 mm (0.04 in)
Front: model) does not exceed the maxi-
200 kPa (29 psi) (2.00 kgf/cm) mum load of the motorcycle. Opera-
Rear: TIP :
200 kPa (29 psi) (2.00 kgf/cm) tion of an overloaded motorcycle The tire tread depth limits may differ
90180 kg (220356 lb): could cause tire damage, an acci- from country to country. Always comply
Front: dent, or even injury. with the local regulations.
200 kPa (29 psi) (2.00 kgf/cm)
Rear:
225 kPa (33 psi) (2.25 kgf/cm) Tire inspection
Tire information
Maximum load*:
180 kg (356 lb) This motorcycle is equipped with tube
* Total weight of rider, passenger, car- tires.
go and accessories EWA10460

WARNING
EWA10510
The front and rear tires should 6
WARNING
be of the same make and de-
Proper loading of your motorcycle is sign, otherwise the handling
important for several characteristics characteristics of the vehicle
of your motorcycle; such as han- cannot be guaranteed.
dling, braking, performance and 1. Tire sidewall After extensive tests, only the
safety. Do not carry loosely packed 2. Tire wear indicator tires listed below have been ap-
items that can shift. Securely pack 3. Tire tread depth proved for this model by
your heaviest items close to the cen- Yamaha Motor Co., Ltd.
The tires must be checked before each
ter of the motorcycle, and distribute
ride. If the tire shows crosswise lines
the weight evenly from side to side.
(minimum tread depth), if the tire has a
Check the condition and pressure of
nail or glass fragments in it, or if the
your tires. NEVER OVERLOAD
sidewall is cracked, have a Yamaha
YOUR MOTORCYCLE. Make sure
dealer replace the tire immediately.
6-15
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PERIODIC MAINTENANCE AND MINOR REPAIR


EAU22000
very carefully and replace it as Wheels
Front tire:
Size: soon as possible with a high- EWA10610

quality product. WARNING


WARNING
80/100-18 47P
Manufacturer/model: The wheels on this model are not
IRC/ NR65 designed for use with tubeless
Rear tire: tires. Do not attempt to use tube-
Size: less tires on this model.
100/90-18 56P
Manufacturer/model: To maximize the performance, durabil-
IRC/ NR65 ity, and safe operation of your motor-
cycle, note the following points
EWA10560 regarding the specified wheels.
WARNING The wheel rims should be checked
It is dangerous to ride with a for cracks, bends, warpage, or da-
worn-out tire. When a tire tread mage before each ride. If any da-
6
begins to show crosswise lines, mage is found, have a Yamaha
have a Yamaha dealer replace dealer replace the wheel. Do not
the tire immediately. attempt even the smallest repair
The replacement of all wheel- to the wheel. A deformed or
and brake-related parts, includ- cracked wheel must be replaced.
ing the tires, should be left to a The wheel should be balanced
Yamaha dealer, who has the whenever either the tire or wheel
necessary professional knowl- has been changed or replaced. An
edge and experience. unbalanced wheel can result in
It is not recommended to patch poor performance, adverse han-
a punctured tube. If unavoid- dling characteristics, and a short-
able, however, patch the tube ened tire life.

6-16
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PERIODIC MAINTENANCE AND MINOR REPAIR


EAU22031
Ride at moderate speeds after Adjusting the clutch lever 3. If the specified clutch lever free
changing a tire since the tire sur- free play play could be obtained as
face must first be broken in for it described above, tighten the
to develop its optimal characteris- locknut and skip the rest of the
tics. procedure, otherwise proceed as
follows.
4. Fully turn the adjusting bolt in
direction a to loosen the clutch
cable.

1. Locknut (clutch lever)


2. Adjusting bolt

The clutch lever free play should 6


measure 1015 mm as shown.
Periodically check the clutch lever
free play and, if necessary, adjust it
as follows.
1. Loosen the locknut at the clutch
lever.
2. To increase the clutch lever free
play, turn the adjusting bolt in
direction a. To decrease the
clutch lever free play, turn the
adjusting bolt in direction b.

6-17
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PERIODIC MAINTENANCE AND MINOR REPAIR


EAU22093 EWA10630

1 Adjusting the brake lever free WARNING


b play After adjusting the brake lever free
a 2 play, check the free play and make
1 2 c sure that the brake is working pro-
perly.
A soft or spongy feeling in the brake
lever can indicate the presence of air
in the hydraulic system. If there is air
in the hydraulic system, have a
1. Locknut (clutch cable)
2. Adjusting nut Yamaha dealer bleed the system be-
fore operating the motorcycle. Air in
5. Loosen the locknut further down 1. Locknut C. Free play the hydraulic system will diminish
the clutch cable. 2. Adjusting bolt the braking performance, which may
6. To increase the clutch lever free The brake lever free play should mea- result in loss of control and an acci-
6 play, turn the adjusting nut in dent.
sure 2-5 mm as shwon. Periodically
direction a. To decrease the check the brake lever free play and, if
clutch lever free play, turn the necessary, adjust it as follows.
adjusting nut in direction b.
1. Loosen the locknut at the brake
7. Tighten both locknuts.
lever.
2. To increase the brake lever free
play, turn the adjusting bolt in
direction a. To decrease the
brake lever free play, turn the
adjusting bolt in direction b.
3. Tighten the locknuts.

6-18
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PERIODIC MAINTENANCE AND MINOR REPAIR


EAU22220

Adjusting the brake pedal


position and free play.
EWA10670

WARNING
It is advisable to have a Yamaha dea- 1 C
ler make this adjustments. c
2 b a

1. Locknut C.. Brake pedal free play


2. Adjusting bolt
EWA11230
C. Brake pedal position
WARNING
Brake pedal position After adjusting the brake pedal posi-
The top of the brake pedal should be tion, the brake pedal free play must
positioned approximately 30 mm adjusted. 6
(1.18 in) below the top of the footrest.
Periodically check the brake pedal Brake pedal free play
position and, if necessary, adjust it as The brake pedal free play should mea-
follows. sure 20.030.0 mm (0.801.18 in) as
1. Loosen the locknut at the brake shown. Periodically check the brake
pedal. pedal free play and necessary, adjust
2. To raise the brake pedal, turn the it as follows.
adjusting bolt in direction (a). To
lower the brake pedal, turn the
adjusting bolt in direction (b).
3. Tighten the locknut.

6-19
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PERIODIC MAINTENANCE AND MINOR REPAIR


EWA10680 EAU22270

WARNING Adjusting the rear brake light


After adjusting the drive chain switch
slack or removing and installing
the rear wheel, always check the 1
brake pedal free play.
2
If proper adjustment cannot be
obtained as described, have a
Yamaha dealer make this ad- a
justment. b
1. Brake pedal free play adjusting nut After adjusting the brake pedal
free play, check the operation of
To increase the brake pedal free play, the brake light.
1. Rear brake light switch
turn the adjusting nut in direction (a). To 2. Rear brake light switch adjusting nut
decrease the brake pedal free play,
6 turn the adjusting nut in direction (b). The rear brake light switch, which is ac-
tivated by the brake pedal, is properly
adjusted when the brake light comes
on just before braking takes effect. If
necessary, adjust the brake light switch
as follows.
Turn the adjusting nut while holding the
rear brake light switch in place. To
make the brake light come on earlier,
turn the adjusting nut in direction (a). To
make the brake light come on later, turn
the adjusting nut in direction (b).

6-20
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PERIODIC MAINTENANCE AND MINOR REPAIR


EAU22380
EAU22540
Checking the front brake pads Each front brake pad is provided with Rear brake shoes
and rear brake shoes wear indicator grooves, which allow
Front brake pads
EAU22430 you to check the brake pad wear with-
out having to disassemble the brake.
To check the brake pad wear, check
the wear indicator grooves. If a brake
pad has worn to the point that the wear
indicator grooves have almost disap-
peared, have a Yamaha dealer replace
the brake pads as a set.

1. Brake shoe wear indicator


2. Brake shoe wear limit line
1. Brake pad wear indicator groove
The rear brake is provided with a wear 6
The front brake pads and the rear brake indicator, which allows you to check the
shoes must be checked for wear at the brake shoe wear without having to dis-
intervals specified in the periodic main- assemble the brake. To check the
tenance and lubrication chart. brake shoe wear, check the position of
the wear indicator while applying the
brake. If a brake shoe has worn to the
point that the wear indicator reaches
the wear limit line, have a Yamaha
dealer replace the brake shoes as a
set.

6-21
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PERIODIC MAINTENANCE AND MINOR REPAIR


EAU37001
When checking the fluid level, Brake fluid may deteriorate paint-
Checking the front brake fluid make sure that the top of the mas- ed surfaces or plastic parts. Al-
level ter cylinder is level by turning the ways clean up spilled fluid
handlebars. immediately.
Use only the recommended quality As the brake pads wear, it is nor-
1 brake fluid, otherwise the rubber mal for the brake fluid level to grad-
seals may deteriorate, causing ually go down. However, if the
leakage and poor braking perfor- brake fluid level goes down sud-
mance. denly, have a Yamaha dealer
check the cause.
Recommended brake fluid:
EAU22720
DOT 4
Changing the brake fluid
1. Minimum level mark Have a Yamaha dealer change the
TIP : brake fluid at the intervals specified in
Insufficient brake fluid may allow air to If DOT 4 is not available, DOT 3 can be
enter the brake system, possibly caus- the NOTE after the periodic mainte-
6 used.
ing it to become ineffective. nance and lubrication chart. In addition,
Before riding, check that the brake fluid Refill with the same type of brake have the oil seals of the brake master
is above the minimum level mark and fluid. Mixing fluids may result in a cylinder and caliper as well as the
replenish if necessary. A low brake fluid harmful chemical reaction and brake hose replaced at the intervals
level may indicate worn brake pads lead to poor braking performance. listed below or whenever they are dam-
and/or brake system leakage. If the Be careful that water does not en- aged or leaking.
ter the master cylinder when refill- Oil seals: Replace (b) every two
brake fluid level is low, be sure to check
ing. Water will significantly lower years.
the brake pads for wear and the brake
the boiling point of the fluid and Brake hose: Replace every four
system for leakage.
may result in vapor lock. years.
Observe these precautions:

6-22
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PERIODIC MAINTENANCE AND MINOR REPAIR


EAU22760
Drive chain slack
The drive chain slack should be check- 2
ed before each ride and adjusted if
necessary. a

EAU22793
To check the drive chain slack 1 b
a
1. Place the motorcycle on the cen- 3
terstand. 4
2. Shift the transmission into the neu-
1. Drive chain slack 1. Axle nut
tral position.
2. Lock nut
3. Spin the rear wheel several times 4. Measure the drive chain slack as
3. Adjusting nut
to locate the tightest portion of the shown.
4. Alignment mark
drive chain.
Drive chain slack: EAU22822
20.030.0 mm (0.781.18 in) To adjust the drive chain slack 6
5. If the drive chain slack is incorrect, 1. Loosen the brake pedal free play
adjust it as follows. adjusting nut, the axle nut, and the
chain puller locknut at each end
of the swingarm.

6-23
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PERIODIC MAINTENANCE AND MINOR REPAIR


2. To tighten the drive chain, turn the
Tightening torques:
adjusting nut at each end of the Lock nut:
swingarm in direction (a), To loos- 2 10 Nm (1.0 mkgf, 7.36 ftlbf)
en the drive chain, turn the adjusting Axle nut:
a 88 Nm (1.9 mkgf, 64.7 ftlbf)
nut at each end of the swingarm
in direction (b), and then push the
rear wheel forward. NOTICE: Im- b TIP :
1 When tightening the axle nut, hold the
proper drive chain slack will
3 wheel axle with a wrench to keep it from
overload the engine as well as
4 turning.
other vital parts of the motorcy-
cle and can lead to chain slippage 1. Axle nut
4. Adjust the brake pedal free play.
or breakage. To prevent this from 2. Lock nut
(See page 6-19)
occurring, keep the drive chain 3. Adjusting nut
slack within the sspecified limits. 4. Alignment mark EWA10660

6 ECA10571
TIP : WARNING
Using the alignment marks on each After adjusting the brake pedal free
side of the swingarm, make sure that play, check the operation of the
both chain pullers are in the same posi- brake light.
tion for proper wheel alignment.

3. Tighten both locknuts, and the axle


nut to the specified torques.

6-24
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PERIODIC MAINTENANCE AND MINOR REPAIR


EAU23025
EAU23101
Cleaning and lubricating the 3. Thoroughly lubricate the drive chain Checking and lubricating the
drive chain with a special O-ring chain lubricant cables
The drive chain must be cleaned and NOTICE: do not use engine oil or
lubricated at the intervals specified in any other lubricants for the drive
the periodic maintenance and lubrica- chain, as they may contain sub-
tion chart, otherwise it will quickly wear stances that could damage the
out, especially when riding in dusty or O-rings. [ECA11111]
wet areas. Service the drive chain as
follows.
ECA10583

NOTICE:
The drive chain must be lubricated
after washing the motorcycle and
riding in the rain or riding in the wet The operation of all control cables and
area. the condition of the cables should be
checked before each ride, and the ca- 6
1. Clean the drive chain with kerosene bles and cable ends should be lubricat-
and small soft brush. NOTICE: To ed if necessary. If a cable is damaged
prevent damaging the O-rings, or does not move smoothly, have a
do not clean the drive chain with Yamaha dealer check or replace it.
steam cleaners, high-pressure wa- WARNING ! Damage to the outer
shers or inappropriate solvents. sheath may interfere with proper ca-
[ECA11121] ble operation and will cause the
2. Wipe the drive chain dry. inner cable to rust. Replace a dama-
ged cable as soon as possible to
prevent unsafe conditions. [EWA10721]

6-25
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PERIODIC MAINTENANCE AND MINOR REPAIR


EAU23133 EAU43610

Recommended lubricant: Checking and lubricating the Checking and lubricating the
Engine oil brake and shift pedals brake and clutch levers
EAU23111

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 at
the intervals specified in the periodic
maintenance chart.

The operation of the brake and shift The operation of the brake and clutch
6 pedals should be checked before levers should be checked before
each ride, and the pedal pivots should each ride, and the lever pivots should
be lubricated if necessary. be lubricated if necessary.

Recommended lubricant: Recommended lubricant:


Lithium-soap-based grease Lithium-soap-based grease
(all-purpose grease) (all-purpose grease)

6-26
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PERIODIC MAINTENANCE AND MINOR REPAIR


EAU23230
Checking and lubricating the Lubricating the swingarm
centerstand and sidestand pivots
The pivoting point of the rear suspen-
tion must be lubricated at the intervals
specified in the periodic maintenance
and lubrication chart.

Recommended lubricant:
Lithium-soap-based grease

Recommended lubricant:
Lithium-soap-based grease (all-pur-
pose grease)
The operation of the centerstand and
6
sidestand should be checked before
each ride, and the pivots and metal-to-
metal contact surfaces should be lubri-
cated if necessary.
EWA10740

WARNING
If the centerstand or sidestand does
not move up and down smoothly,
have a Yamaha dealer check or re-
pair it.

6-27
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PERIODIC MAINTENANCE AND MINOR REPAIR


EAU45511

Checking the steering


EAU23272

Checking the front fork


The condition and operation of the front Worn or loose steering bearings may
fork must be checked as follows at the cause danger. Therefore, the operation
intervals specified in the periodic main- of the steering must be checked as fol-
tenance and lubrication chart. lows at the intervals specified in the pe-
riodic maintenance and lubrication
To check the condition chart.
1. Place the vehicle on the center-
Check the inner tubes for scratches, stand. WARNING: To avoid in-
damage and excessive oil leakage. jury securely support the vehi-
cle so that there is no danger of
To check the operation it falling over. [EWA10751]
1. Place the vehicle on a level sur- 2. While applying the front brake,
face and hold it in an upright posi- push down hard on the handlebars
tion.WARNING! To avoid injury several times to check if the front
6 fork compresses and rebounds
securely support the vehicle so
that there is no danger of it fal- smoothly.
ling over. [EWA10751] ECA10590
NOTICE:
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or re-
pair it.

6-28
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PERIODIC MAINTENANCE AND MINOR REPAIR


EAU23322
EAU23290

Checking the wheel bearings Battery


The front and rear wheel bearings must A poorly maintained battery will corrode
be checked at the intervals specified in and discharge quickly. The electrolyte
the periodic maintenance and lubrica- level, battery lead connections and
tion chart. If there is play in the wheel breather hose routing should be
hub or if the wheel does not turn checked before each ride and at the in-
smoothly, have a Yamaha dealer check tervals specified in the periodic mainte-
the wheel bearings. nance and lubrication chart.

To check the electrolyte level


1. Place the vehicle on a level sur-
2. Hold the lower ends of the front face and hold it in an upright posi-
fork legs and try to move them for- tion.
ward and backward. If any free TIP :
play can be felt, have a Yamaha Make sure that the vehicle is positioned 6
dealer check or repair the steering. straight up when checking the electro-
lyte level.
2. Remove right side panel. (See
page 6-5 for panel removal and
installation procedures.
3. Check the electrolyte level in the
battery.
TIP :
The electrolyte should be between the
minimum and maximum level marks.

6-29
ry: lead
Use
ECA10611
Use
only
from
only
distilled
the
distilled
battery.

U5YPE0E0.book Page 28 Wednesday, February 23, 2005 4:22 PM

PERIODIC MAINTENANCE AND MINOR REPAIR


_

ECA10610
ways shield your eyes when NOTICE:
working near batteries. In case
Use only distilled water, as tap water
of contact, administer the fol-
1 contains minerals that are harmful
lowing FIRST AID.
to the battery.
EXTERNAL: Flush with plenty
2 of water. 5. Check and, if necessary, tighten
INTERNAL: Drink large quan- the battery lead connections and
tities of water or milk and im- correct the breather hose routing.
1. Maximum level mark
mediately call a physician. 6. Instal the panel.
EYES: Flush with water for 15
2. Minimum level mark
minutes and seek prompt
4. If the electrolyte is at or below the medical attention.
minimum level mark, Batteries produce explosive hy-
Add distilled water to raise the drogen gas. Therefore, keep
electrolyte to the maximum level sparks, flames, cigarettes, etc.,
6 mark. NOTICE : Use only distilled away from the battery and pro-
water, as tap water contains mine- vide sufficient ventilation when
rals that are harmful to the battery. charging it in an enclosed
[EWA10770]
space.
Take care not to spill electrolyte
WARNING EWA10770

on the drive chain, as this may


Electrolyte is poisonous and weaken it, shorten chain life and
dangerous since it contains sul- possibly result in an accident.
furic acid, which causes severe KEEP THIS AND ALL BATTER-
burns. Avoid any contact with IES OUT OF THE REACH OF
skin, eyes or clothing and al- CHILDREN.

6-30
s.
.

U5YPE0E0.book Page 29 Wednesday, February 23, 2005 4:22 PM

PERIODIC MAINTENANCE AND MINOR REPAIR


EAU23481

To store the battery Replacing the fuse


2. Remove the blown fuse, and then
1. If the vehicle will not be used for install a new fuse of the specified
more than one month, remove the 1
amperage. WARNING : Do not use
battery, fully charge it, and then
a fuse of a higher amperage ra-
place it in a cool, dry place.
ting than recommended to avoid
NOTICE: When removing the
causing extensive damage to the
battery, be sure the key is
electrical system and possibly a
turned to OFF, then discon-
fire. [EWA15131]
nect the negative lead before
disconnecting the positive lead.
[ECA16302]
1. Fuse Specified fuse 15 A
2. If the battery will be stored for
more than two months, check it at
least once a month and fully The fuse holder is located behind right 3. Turn the key to ON and turn on
side panel. (See page 6-5 for panels the electrical circuits to check if the
charge it if necessary. devices operate. 6
3. Fully charge the battery before in- removal and installation procedures)
4. If the fuse immediately blows
stallation. If the fuse is blown, replace it as follows.
again, have a Yamaha dealer
4. After installation, make sure that check the electrical system.
the battery leads are properly con- 1. Turn the key to OFF and turn
nected to the battery terminals. off all electrical circuits.
ECA16530
NOTICE
NOTICE
_

Always keep the battery charged.


Storing a discharged battery can
cause permanent battery damage.
_

6-31
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PERIODIC MAINTENANCE AND MINOR REPAIR


EAUU0891 --- > EAUN *****

Replacing a headlight bulb or


a position light bulb
1
1

Do not touch this area 1. Headlight mounting bolt.


1. Screw (2) 2. Headlight adjusting bolt.
If a headlight bulb or a position light
6 bulb burns out, replace it as follows.
1. Place the motorcycle on the center- 3. Remove headlight mounting bolt.
Headlight bulb.
ECA10660
stand. 4. Remove headlight adjusting bolt
NOTICE: 2. Remove the headlight side cover 5. Remove headlight unit from head-
Do not touch the glass part of the by removing screws. light stay.
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 affected. Thoroughly
clean off any dirt and fingerprints
on the headlight bulb using a cloth
moistened with alcohol or thinner

6-32
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PERIODIC MAINTENANCE AND MINOR REPAIR


ECAU0070
NOTICE:
3 If a headlight bulb of different watt-
age than recommended is used, it
1
may cause the battery to discharge
or affect the headlight lighting.
2
8. Install the headlight unit by
installing the screws.
1
9. Install the headlight side cover by
1. Headlight bulb socket
installing screws.
2. Headlight bulb 10. Have a Yamaha dealer adjust the 1. Position light bulb socket
3. Position light bulb headlight beam if necessary.
6. Remove the position light bulb socket
6. Remove headlight bulb socket and
Position light bulb. (together with the bulb) by pulling out. 6
then remove the burnt-out bulb. 6
1. Place the motorcycle on the center- 7. Insert a new bulb into the socket by
7. Place a new headlight bulb into pushing it until it stop.
stand.
position, and then secure it with 8. Install the socket (together with the
2. Remove the headlight side cover
bulb socket. by removing screws. bulb) by pushing it.
3. Remove head light mounting bolt. 9. Install the headlight side cover by
4. Remove head light adjusting bolt installing the screws.
5. Remove head light from head light 1 0. Have a Yamaha dealer adjust the
stay. headlight beam if necessary.

6-33
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PERIODIC MAINTENANCE AND MINOR REPAIR


EAU24204
EAU24082

Replacing the tail/brake light Replacing a turn signal light


bulb bulb
1
1

1. Tail/brake light bulb


1. Screw
3. Remove the burnt out bulb by pu- 2. Bulb
1. Tail/brake light bulb socket 3. Lens
shing it in and turning it counter- 6
6 1. Remove the turn signal light lens
6 1. Remove the seat. (See page 3-7) clockwise.
4. Insert a new bulb into the socket, by removing the screw.
2. Remove the socket (together with
push it in, and then turn it clock- 2. Remove the defective bulb by
the bulb) by turning it counter-
wise until it stops. pulling it out
clockwise. 3. Insert a new bulb into the socket
5. Install the socket (together with
the bulb) by turning it clockwise. push it in
4. Place the lens in the original
_

6. Install the seat.


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

6-34
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PERIODIC MAINTENANCE AND MINOR REPAIR


EAU24360
Front wheel
4. Pull the wheel axle out, and then
remove the wheel. NOTICE: Do-
not apply the brake after the
wheel has been removed toge- 1
ther with the brake disc, other-
wise the brake pads will be for-
ced shut. [ECA11071]
1 EAU37770

2 To install the front wheel


1. Install the speedometer gear unit 1. Speedometer gear unit
1. Speedometer cable into the wheel hub so that the pro- 2. Lift the wheel up between the fork
2. Axle nut and washer jection on the wheel hub fits in ei- legs.
EAU37761
ther slot of the speedometer gear
To remove the front wheel unit. TIP : 6
EWA10821 Make sure that there is enough space
WARNING between the brake pads before insert-
To avoid injury, secutely support the ing the brake disc and that the retainer
vehicle so there is no danger of it in the speedometer gear unit fits over
falling over. the slot on the fork leg.

1. Place the motorcycle on the cen-


terstand.
2. Disconnect the speedometer cable
from the front wheel.
3. Remove the axle nut, and the washer.

6-35
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PERIODIC MAINTENANCE AND MINOR REPAIR


Rear wheel
EAU35080

TIP :
When tightening the axle nut, hold the
wheel axle with a wrench to keep it from
turning.

6. While applying the front brake,


push down hard on the handlebars
several times to check if the front
1. Retainer
fork compresses and rebounds
2. Slot smoothly.
7. Connect the speedometer cable.
3. Insert the wheel axle, and then in- 1. Axle nut and washer
stall the axle nut. 2. Drive chain adjusting nut
4. Take the motorcycle off the center- 3. Locknut drive chain adjusting nut
6 4. Brake torque rod nut
stand so that the front wheel is on
the ground. EAU37782

5. Tighten the axle nut to the speci- To remove the rear wheel
EWA10821
fied torque. WARNING
WARNING

Tightening torque: To avoid injury, securely support


Axle nut: the vehicle so there is no danger
40 Nm (4.0 mkgf, 29 ftlbf) of it falling over.

1. Loosen the axle nut.


2. Loosen the locknut and the drive
chain slack adjusting nut on both
ends of the swingarm.

6-36
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PERIODIC MAINTENANCE AND MINOR REPAIR


EAU25782

6. Remove the brake pedal free play To install the rear wheel
adjusting nut, and then disconnect 1. Insert the wheel axle from the left-
the brake rod from the brake cam- hand side, and then install the wa-
shaft lever. sher and axle nut.
7. Remove the axle nut and the wa- 2. Install the drive chain onto the rear
sher, and then pull the wheel axle sprocket.
out. 3. Lower the rear wheel so that it is
TIP : on the ground, and then put the
Do not remove the washer on the right sidestand down.
side of the wheel axle so as to not 4. Install the brake rod onto the brake
lose it. camshaft lever, and then install the
1. Brake camshaft lever brake pedal free play adjusting nut
2. Brake pedal free play adjusting nut
8. Push the wheel forward, and then onto the brake rod.
3. Brake torque rod nut and bolt
remove the drive chain from the 5. Connect the brake torque rod to 6
4. Brake rod
5. Washer and Axle nut rear sprocket. the brake shoe plate by installing
TIP : the bolt and the nut, and then tigh-
3. Loosen the brake torque rod nut at The drive chain does not need to be ten the nut to the specified torque.
the brake shoe plate. disassembled in order to remove and
4. Disconnect the brake torque rod install the wheel. Tightening torques:
from the brake shoe plate by remo- Brake torque rod nut:
ving the cotter pin, the nut, the wa- 19 Nm (1.9 mkgf, 14 ftlbf)
9. Remove the wheel.
sher and the bolt.
5. Place the motorcycle on the center-
stand.

6-37
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PERIODIC MAINTENANCE AND MINOR REPAIR


EAU25851 EWA15141

6. Adjust the drive chain slack. (See- Troubleshooting WARNING


WARNING
page 6-21.) Although Yamaha motorcycles receive
7. Tighten the axle nut to the specified a thorough inspection before shipment When checking the fuel system, do
torque. from the factory, trouble may occur dur- not smoke, and make sure there are
ing operation. Any problem in the fuel, no open flames or sparks in the
Tightening torque: compression, or ignition systems, for area, including pilot lights from
Axle nut: example, can cause poor starting and water heaters or furnaces.
60 Nm (6.0 mkgf, 43 ftlbf)
loss of power. Gasoline or gasoline vapors can
The following troubleshooting charts ignite or explode, causing severe
8. Adjust the brake pedal free play. represent quick and easy procedures injury or property damage.
(See page 6-18.) for checking these vital systems your-
EWA10660
self. However, should your motorcycle
WARNING require any repair, take it to a Yamaha
After adjusting the brake pedal free dealer, whose skilled technicians have
6 play, check the operation of the the necessary tools, experience, and
brake light. 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.

6-38
U5YPE0E0.book Page 36 Wednesday, February 23, 2005 4:22 PM

PERIODIC MAINTENANCE AND MINOR REPAIR


EAU37620

Troubleshooting charts

Starting problems or poor engine performance


EWA10840

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

1. Fuel There is
Check the compression.
enough fuel.
Check the fuel level in
the fuel tank.
There is The engine does not start.
Supply fuel.
no fuel. Check the compression.

2. Compression
There is compression. Check the ignition.
Operate the
electric starter or the 6
kickstarter. Have a Yamaha dealer
There is no compression.
check the vehicle.

3. Ignition Wipe off with a dry cloth and correct the Open the throttle halfway and
Wet
spark plug gap, or replace the spark plug. operate the electric starter.
Remove the spark plug
and check the electrodes.
The engine does not start.
Dry Have a Yamaha dealer check the vehicle.
Check the battery.

4. Battery The engine turns over


The battery is good.
quickly.
Operate the The engine does not start. Have a
electric starter. Yamaha dealer check the vehicle.
The engine turns over Check lead connections, and
slowly. charge the battery if necessary.

6-39
U5YPE0E0.book Page 1 Wednesday, February 23, 2005 4:22 PM

MOTORCYCLE CARE AND STORAGE


EAU25981

EAU26000
ucts onto seals, gaskets, sprock- cleaning products, solvent or
Care ets, the drive chain and wheel thinner, fuel (gasoline), rust re-
While the open design of a motorcycle axles. Always rinse the dirt and de- movers or inhibitors, brake flu-
reveals the attractiveness of the tech- greaser off with water. id, antifreeze or electrolyte.
nology, it also makes it more vulnera- Do not use high-pressure wash-
ble. Rust and corrosion can develop Cleaning
ECA10770
ers or steam-jet cleaners since
even if high-quality components are they cause water seepage and
used. A rusty exhaust pipe may go un- NOTICE:
deterioration in the following ar-
noticed on a car, however, it detracts Avoid using strong acidic wheel
eas: seals (of wheel and swing-
from the overall appearance of a motor- cleaners, especially on spoked
arm bearings, fork and brakes),
cycle. Frequent and proper care does wheels. If such products are
electric components (couplers,
not only comply with the terms of the used on hard-to-remove dirt, do
connectors, instruments,
warranty, but it will also keep your not leave the cleaner on the af-
switches and lights), breather
motorcycle looking good, extend its life fected area any longer than in-
hoses and vents.
and optimize its performance. structed. Also, thoroughly rinse
For motorcycles equipped with
the area off with water, immedi-
a windshield: Do not use strong
Before cleaning ately dry it, and then apply a cor-
cleaners or hard sponges as
7 1. Cover the muffler outlet with a rosion protection spray.
they will cause dulling or
plastic bag after the engine has Improper cleaning can damage
scratching. Some cleaning com-
cooled down. windshields, cowlings, panels
pounds for plastic may leave
2. Make sure that all caps and covers and other plastic parts. Use only
scratches on the windshield.
as well as all electrical couplers a soft, clean cloth or sponge
Test the product on a small hid-
and connectors, including the with mild detergent and water to
den part of the windshield to
spark plug cap, are tightly in- clean plastic.
make sure that it does not leave
stalled. Do not use any harsh chemical
any marks. If the windshield is
3. Remove extremely stubborn dirt, products on plastic parts. Be
scratched, use a quality plastic
like oil burnt onto the crankcase, sure to avoid using cloths or
polishing compound after
with a degreasing agent and a sponges which have been in
washing.
brush, but never apply such prod- contact with strong or abrasive
7-1
U5YPE0E0.book Page 2 Wednesday, February 23, 2005 4:22 PM

MOTORCYCLE CARE AND STORAGE


After normal use 2. Apply a corrosion protection spray 7. Wax all painted surfaces.
Remove dirt with warm water, a mild on all metal, including chrome- and 8. Let the motorcycle dry completely
detergent, and a soft, clean sponge, nickel-plated, surfaces to prevent before storing or covering it.
and then rinse thoroughly with clean corrosion.
water. Use a toothbrush or bottlebrush
for hard-to-reach areas. Stubborn dirt After cleaning
EWA10930

and insects will come off more easily if 1. Dry the motorcycle with a chamois WARNING
the area is covered with a wet cloth for or an absorbing cloth. Make sure that there is no oil or
a few minutes before cleaning. 2. Immediately dry the drive chain wax on the brakes or tires. If
and lubricate it to prevent it from necessary, clean the brake
After riding in the rain, near the sea or rusting. discs and brake linings with a
on salt-sprayed roads 3. Use a chrome polish to shine regular brake disc cleaner or ac-
Since sea salt or salt sprayed on roads chrome, aluminum and stainless- etone, and wash the tires with
during winter are extremely corrosive in steel parts, including the exhaust warm water and a mild deter-
combination with water, carry out the system. (Even the thermally in- gent.
following steps after each ride in the duced discoloring of stainless- Before operating the motor-
rain, near the sea or on salt-sprayed steel exhaust systems can be re- cycle test its braking perfor-
roads. moved through polishing.) mance and cornering behavior. 7
TIP : 4. To prevent corrosion, it is recom-
Salt sprayed on roads in the winter may mended to apply a corrosion pro- ECA10800

remain well into spring. tection spray on all metal, NOTICE:


including chrome- and nickel-plat- Apply spray oil and wax spar-
1. Clean the motorcycle with cold wa- ed, surfaces. ingly and make sure to wipe off
ter and a mild detergent, after the 5. Use spray oil as a universal clean- any excess.
engine has cooled down. NOTICE: er to remove any remaining dirt.
Do not use warm water since it 6. Touch up minor paint damage
increases the corrosive action caused by stones, etc.
of the salt. [ECA10791]

7-2
U5YPE0E0.book Page 3 Wednesday, February 23, 2005 4:22 PM

MOTORCYCLE CARE AND STORAGE


EAU26151
Never apply oil or wax to any Storage 3. Drain the carburetor float chamber
rubber and plastic parts, but by loosening the drain bolt; this will
Short-term
treat them with a suitable care prevent fuel deposits from building
Always store your motorcycle in a cool,
product. up. Pour the drained fuel into the
dry place and, if necessary, protect it
Avoid using abrasive polishing fuel tank.
against dust with a porous cover.
compounds as they will wear ECA10810 4. Fill up the fuel tank and add fuel
away the paint. NOTICE::
NOTICE stabilizer (if available) to prevent
the fuel tank from rusting and the
Storing the motorcycle in a
TIP : fuel from deteriorating.
poorly ventilated room or cover-
Consult a Yamaha dealer for advice on 5. Perform the following steps to pro-
ing it with a tarp, while it is still
what products to use. tect the cylinder, piston rings, etc.
wet, will allow water and humid-
from corrosion.
ity to seep in and cause rust.
a. Remove the spark plug cap
To prevent corrosion, avoid
and spark plug.
damp cellars, stables (because
b. Pour a teaspoonful of engine oil
of the presence of ammonia)
into the spark plug bore.
and areas where strong chemi-
c. Install the spark plug cap onto
7 cals are stored.
the spark plug, and then place
Long-term the spark plug on the cylinder
Before storing your motorcycle for sev- head so that the electrodes are
eral months: grounded. (This will limit spark-
1. Follow all the instructions in the ing during the next step.)
Care section of this chapter.
2. For motorcycles equipped with a
fuel cock that has an OFF posi-
tion: Turn the fuel cock lever to
OFF.

7-3
U5YPE0E0.book Page 4 Wednesday, February 23, 2005 4:22 PM

MOTORCYCLE CARE AND STORAGE


d. Turn the engine over several 6. Lubricate all control cables and the TIP :
times with the starter. (This will pivoting points of all levers and Make any necessary repairs before
coat the cylinder wall with oil.) pedals as well as of the side- storing the motorcycle.
WARNING ! To prevent da- stand/centerstand.
mage or injury from spar- 7. Check and, if necessary, correct
king, make sure to ground the tire air pressure, and then lift
the spark plug electrodes the motorcycle so that both of its
while turning the engine over. wheels are off the ground. Alterna-
[EWA10951] tively, turn the wheels a little every
e. Remove the spark plug cap month in order to prevent the tires
from the spark plug, and then from becoming degraded in one
install the spark plug and the spot.
spark plug cap. 8. Cover the muffler outlet with a
plastic bag to prevent moisture
from entering it.
9. Remove the battery and fully
charge it. Store it in a cool, dry
7
place and charge it once a month.
Do not store the battery in an ex-
cessively cold or warm place [less
than 0 C (30 F) or more than 30
C (90 F)]. For more information
on storing the battery, see page
6-28.

7-4
U5YPE0E0.book Page 1 Wednesday, February 23, 2005 4:22 PM

SPECIFICATIONS
EAU26320

Dimensions: Spark plug (s):


Overall length: Lubrication system: Manufacturer/model:
2025 mm (79.7 in) Wet sump NGK DP8EA-9
Overall width: Engine oil: Spark plug gap:
765 mm (30.1 in) Type: 0.80.9 mm (0.0310.035 in)
Overall height: YAMALUBE 4 T SJ. 20W-50 MA Clutch:
1095 mm (43.1 in) or SAE20W40 or SAE20W50 Clutch type:
Seat height: Recommended engine oil grade: Wet, multiple-disc
770 mm (30.3 in) API service SF, SG type or higher Transmission:
Wheelbase: JASO MA Primary reduction system:
1295 mm (50.1 in) Engine oil quantity: Spur gear
Ground clearance: Periodic oil change : Primary reduction ratio:
165 mm (6.50 in) 1.2 L (1.26 US qt) (0.96 Imp.qt) 74/24 (3.083)
Minimum turning radius: Whit oil filter element replacement : Secondary reduction system:
2100 mm (82.7 in) Chain drive
1.3 L (1.36 US qt) (1.04 lmp.qt)
Weight: Secondary reduction ratio:
Total Capasity
With oil and fuel: 44/15 (2.933)
1.4 L (1.47 US qt) (1.12 Imp.qt)
141 kg (331 lb) Transmission type:
Engine: Air filter: Constant mesh 5-speed
Engine type: Air filter element: Operation:
Air cooled 4-stroke, SOHC Wet type element Left foot operation
Cylinder arrangement: Fuel: Gear ratio:
Forward-inclined single cylinder Recommended fuel: 1st:
8 Displacement: Regular unleaded gasoline only 36/14 (2.571)
223 cm Fuel tank capacity: 2nd:
Bore stroke: 13.4 L (3.54 US gal) (2.95 Imp.gal) 32/19(1.684)
70.0 58.0 mm (2.76 x 2.28 in) Fuel reserve amount: 3rd:
Compression ratio: 2.4 L (0.63 US gal) (0.93 Imp.gal) 28/22 (1.273)
9.5 : 1 4th:
Carburetor:
Starting system: 26/25 (1.040)
Manufacturer:
Electric starter and kickstarter 5th:
MIKUNI
23/27 (0.852)
Type quantity:
BS30 x 1

8-1
U5YPE0E0.book Page 2 Wednesday, February 23, 2005 4:22 PM

SPECIFICATIONS
Chassis: Front suspension:
Frame type: Rear: Type:
Double cradle 200 kPa (29 psi) (2.00 kgf/cm) Telescopic fork
Caster angle: Loading condition:
Spring/shock absorber type:
25.3 100 kg - Maximum load
Coil spring/oil damper
Front:
Trail: Wheel travel:
85.0 mm 200 kPa (29 psi) (2.00 kgf/cm)
140.0 mm
Rear:
Front tire: Rear suspension:
225 kPa (33 psi) (2.25 kgf/cm)
Type: Type:
With tube
Front wheel:
Swingarm (Monocross suspension)
Wheel type:
Size: Spring/shock absorber type:
Casting wheel
80/100-18 47P Coil spring/oil damper
Rim size:
Manufacturer/model: Wheel travel:
18x1.60
IRC/NR65 100.0 mm
Rear wheel:
Rear tire: Electrical system:
Wheel type:
Type: Ignition system:
Casting wheel
With tube DC. CDI
Rim size:
Size: Charging system:
18x2.15
100/90-18 56P CDI magneto
Front brake:
Manufacturer/model: Battery:
Type:
IRC/NR65 Model:
Single disc brake
Loading: GM 7B-4B/YB 7B-B
Operation:
Maximum load:
Right hand operation
Voltage, capacity: 8
180 kg (397 lb) 12 V, 7,0 Ah
Recommended fluid:
(Total weight of rider, passenger, cargo
DOT 3 or 4
Headlight:
and accessories) Bulb type:
Rear brake:
Tire air pressure (measured on cold Halogen bulb
Type:
tires): Drum brake
Bulb voltage, wattage quantity:
Loading condition: Headlight:
Operation:
up to 100 kg 12 V, 35 W/36.5 W 1
Right foot operation
Front: Tail/brake light:
200 kPa (29 psi) (2.00 kgf/cm) 12 V, 5.0 W/21.0 W 1

8-2
U5YPE0E0.book Page 3 Wednesday, February 23, 2005 4:22 PM

SPECIFICATIONS
Front turn signal light:
12 V, 10.0 W 2
Rear turn signal light:
12 V, 10.0 W 2
Position light:
12 V, 3.4 W 1
Meter lighting:
12 V, 3.4 W 2
Neutral indicator light:
12 V, 3.4 W 1
High beam indicator light:
12 V, 3.4 W 1
Turn signal indicator light:
12 V, 3.4 W 2

Fuse:
Fuse:
15 A

8-3
U5YPE0E0.book Page 1 Wednesday, February 23, 2005 4:22 PM

EAU26343
CONSUMER INFORMATION
EAU26390 EAU26410
EAU26360

Identification numbers Key identification number Vehicle identification number


Record the key identification number,
vehicle identification number and en-
gine serial number in the spaces pro- 1
vided below for assistance when
ordering spare parts from a Yamaha 1
dealer or for reference in case the vehi-
cle is stolen.
KEY IDENTIFICATION NUMBER:

1. Key identification number

The key identification number is 1. Vehicle identification number


stamped into the key. Record this The vehicle identification number is
VEHICLE IDENTIFICATION number in the space provided and use stamped into the rear frame.
NUMBER: it for reference when ordering a new
key. TIP :
The vehicle identification number is
used to identify your vehicle and may
be used to register it with the licensing
authority in your area.
ENGINE SERIAL NUMBER: 9

9-1
U5YPE0E0.book Page 2 Wednesday, February 23, 2005 4:22 PM

CONSUMER INFORMATION
EAU26440

Engine serial number

1. Engine serial number

The engine serial number is stamped


into the crankcase.

9-2
U5YPE0E0.book Page 5 Wednesday, February 23, 2005 4:22 PM
YAMAHA INDONESIA MOTOR MANUFACTURING
PRINTED IN INDONESIA