TZR50 - Motorcycle YAMAHA - Free user manual and instructions

USER MANUAL TZR50 YAMAHA

INTRODUCTION EAU10100 Welcome to the Yamaha world of motorcycling! As the owner of the TZR50, you are benefiting from Yamaha'’s vast experience and newest technology regarding the design and manufacture of high-quality products, which have earned Yamaha a reputation for dependability. Please take the time to read this manual thoroughly, so as to enjoy all advantages of your TZR50. The owner's manual does not only instruct you in how to operate, inspect and maintain your motorcycle, but also in how to safeguard your- self 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!

EAU0150 Particularly important information is distinguished in this manual by the following notations:

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! WARNING Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator, a bystander, or a person inspecting or repairing the motorcy- cle. CAUTION A CAUTION indicates special precautions that must be taken to avoid damage to the motorcycle. More: A NOTE provides key information to make procedures easier or clearer. NOTE: e This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold. @ Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most current product information available at the time of printing, there may be minor discrepancies between your motorcycle and this manual. If you have any questions concerning this manual, please consult your Yamaha dea- ler.

©2005 by YAMAHA MOTOR SPAIN S.A. 1st edition, January 2005 All rights reserved. Any reprinting or unauthorized use Without the written permission of YAMAHA MOTOR SPAIN S.A. is expressly prohibited. Printed in Spain.

SAFETY INFORMATION DESCRIPTION... Left view Right view Controls and instruments

INSTRUMENT AND CONTROL

FUNCTIONS .… Main switch/steering lock Indicator lights … Speedometer uni Tachometer Handiebar switche: Catalytic converter. 2-stroke engine oi Fuel cock ……. Starter (choke) leve Seat. Storage compartment Sidestand. Ignition circuit cut-off system … PRE-OPERATION CHECKS Pre-operation check list.

OPERATION AND IMPORTANT RIDING

POINTS... Starting a cold engine Shifting.. Tips for reducing fuel consumption: Engine break-in Parking.

PERIODIC MAINTENANCE AND

MINOR RAPAIR. Owner's tool ki Periodic maintenance and lubrication chart. Removing and installing cowlings Checking the spark plug … Transmission oil … To check the coolant level. Adjusting the carburetor. Adjusting the engine idling spee Adjusting the throttle cable free play. Tires Cast wheels Adjusting the clucth lever free play 6-12 Adjusting the brake pedal position and free play. …6-13 Adjusting the rear brake light switch … 6-13 Front brake pads 6-14 Rear brake pads 6-14 Checking the brake fluid level 6-14 Changjing the brake fluid … 6-15

Drive Chain slack. -6-16 Checking and lubricating the cables .…6-17 Checking and lubricating the brake and shift pedals… ….6-17 Checking and lubricating the brake and cluctch levers … . Checking and lubricating the sidestand….. Checking the front fork Checking the steering. Checking the wheel bearings Battery …. Replacing the fuse. Replacing the headlight bulb Replacing a turn signal light bulb or the tail/brake light bulb . . Replacing the license plate light bulb Supporting the mortorcycl Troubleshooting Troubleshooting chart: Engine overheating…

aching and passing through intersections, since intersec- TIONS. tions are the most likely places EXPERTISE OF THE OPERATOR. for motorcycle accidents to EVERY OPERATOR SHOULD KNOW Safe riding occur.

THE FOLLOWING REQUIREMENTS

CLE. HE OR SHE SHOULD: @e Always make pre-operation -_Ride where other motorists can checks. Careful checks may help see you. Avoid riding in anot- prevent an accident. her motorist's blind spot. accidents @e OBTAIN THOROUGH INSTRUC-

TECHNIQUES. e This motorcycle is designed to @e Many motorcycle carry the operator and a passen- ger. e The failure of motorists to detect and recognize motorcycles in traffic is the predominating cause of automobile/motorcycle acci- dents. Many accidents have been caused by an automobile driver who did not see the motorcycle. Making yourself conspicuous appears to be very effective in reducing the chance of this type of accident. involve inexperienced operators. In fact, many operators who have been involved in accidents do not even have a current motorcycle license. + Make sure that you are quali- fied and that you only lend your motorcycle to other qualified operators. ° Know your skills and limits. Staying within your limits may help you to avoid an accident.

5WX-F8199-E1.qxd 14/12/2004 15:05 Pâgina 10 À À SAFETY INFORMATION + We recommend that you prac- tice riding your motorcycle where there is no traffic until you have become thoroughly familiar with the motorcycle and all of its controls. Many motorcycle accidents have been caused by error of the motorcycle operator. A typical error made by the operator is veering wide on a turn due to EXCESSIVE SPEED or undercor- nering (insufficient lean angle for the speed). + Always obey the speed limit and never travel faster than warranted by road and traffic conditions. Always signal before turning or changing lanes. Make sure that other motorists can see you. The posture of the operator and passenger is important for proper control. + The operator should keep both hands on the handlebar and both feet on the operator foo- trests during operation to maintain control of the motorcycle. + The passenger should always hold onto the operator, seat strap, or grab bar, if equipped, With both hands and keep both feet on the passenger foo- trests. + Never carry a passenger unless he or she can firmly pla- ce both feet on the passenger footrests. © Never ride under the influence of alcohol or other drugs. e This motorcycle is designed for on-road use only, therefore, it is not suitable for off-road use. Protective apparel The majority of fatalities from motorcycle accidents are the result of head injuries. The use of a safety hel- met is the single most critical factor in the prevention or reduction of head injuries. © Always wear an approved hel- met. e Wear a face shield or goggles. Wind in your unprotected eyes could contribute to an impair- ment of vision which could delay seeing a hazard. e The use of a jacket, heavy boots, trousers, gloves, etc., is effective in preventing or reducing abra- sions or lacerations. e Never wear loose-fitting clothes, otherwise they could catch on the control levers, footrests, or wheels and cause injury or an accident. e Never touch the engine or exhaust system during or after operation. They become very hot and can cause burns. Always wear protective clothing that covers your legs, ankles, and feet. © Passengers should also observe the precautions mentioned abo- ve.

5WX-F8199-E1.qxd 14/12/2004 15:05 Pâgina 11 À SAFETY INFORMATION À Modifications Modifications made to this motorcy- cle not approved by Yamaha, or the removal of original equipment, may render the motorcycle unsafe for use and may cause severe personal injury. Modifications may also make your motorcycle illegal to use. Loading and accessories Adding accessories or cargo to your motorcycle can adversely affect sta- bility and handling if the weight distri- bution of the motorcycle is changed. To avoid the possibility of an acci- dent, use extreme caution when adding cargo or accessories to your motorcycle. Use extra care when riding a motorcycle that has added cargo or accessories. Here are some general guidelines to follow if loading cargo or adding accessories to your motorcycle: Loading The total weight of the operator, pas- senger, accessories and cargo must not exceed the maximum load limit. Maximum load: 195 Kg (429,98 Ib) When loading within this weight limit, keep the following in mind: e Cargo and accessory weight should be kept as low and close to the motorcycle as possible. Make sure to distribute the weight as evenly as possible on both sides of the motorcycle to minimize imbalance or instability. e Shifting weights can create a sudden imbalance. Make sure that accessories and cargo are securely attached to the motorcycle before riding. Check accessory mounts and cargo res- traints frequently. e Never attach any large or heavy items to the handlebar, front fork, or front fender. These items, including such cargo as sleeping bags, duffel bags, or tents, can create unstable handling or slow steering response. Accessories Genuine Yamaha accessories have been specifically designed for use on this motorcycle. Since Yamaha can- not test all other accessories that may be available, you must personally be responsible for the proper selection, installation and use of non-Yamaha accessories. Use extreme caution when selecting and installing any accessories. Keep the following guidelines in mind, as well as those provided under “Loa- ding” when mounting accessories. e Never install accessories or carry cargo that would impair the per- formance of your motorcycle. Carefully inspect the accessory before using it to make sure that it does not in any way reduce ground clearance or cornering clearance, limit suspension tra- vel, steering travel or control ope- ration, or obscure lights or reflec- tors.

5WX-F8199-E1.qxd 14/12/2004 15:05 Pâgina 12 D À SAFETY INFORMATION - Accessories fitted to the hand- lebar or the front fork area can create instability due to impro- per weight distribution or aerodynamic changes. If accessories are added to the handlebar or front fork area, they must be as lightweight as possible and should be kept to a minimum. Bulky or large accessories may seriously affect the stability of the motorcycle due to aerody- namic effects. Wind may attempt to lift the motorcycle, or the motorcycle may become unstable in cross winds. These accessories may also cause instability when passing or being passed by large vehicles. + Certain accessories can dis- place the operator from his or her normal riding position. This improper position limits the fre- edom of movement of the ope- rator and may limit control abi- lity, therefore, such accessories are not recom- mended. e Use caution when adding electri- cal accessories. If electrical accessories exceed the capacity of the motorcycle’s electrical sys- tem, an electric failure could result, which could cause a dan- gerous loss of lights or engine power. Gasoline and exhaust gas

© GASOLINE IS HIGHLY FLAMMA-

BLE: + Always turn the engine off when refueling. + Take care not to spill any gaso- line on the engine or exhaust system when refueling. + Never refuel while smoking or in the vicinity of an open flame. Never start the engine or let it run for any length of time in a closed area. The exhaust fumes are poi- sonous and may cause loss of consciousness and death within a short time. Always operate your motorcycle in an area that has adequate ventilation. © Always turn the engine off before leaving the motorcycle unatten- ded and remove the key from the main switch. When parking the motorcycle, note the following: + The engine and exhaust sys- tem may be hot, therefore, park the motorcycle in a place where pedestrians or children are not likely to touch these hot areas. + Do not park the motorcycle on a slope or soft ground, other- wise it may fall over. + Do not park the motorcycle near a flammable source (e.g. a kerosene heater, or near an open flame), otherwise it could catch fire. When transporting the motorcy- cle in another vehicle, make sure that it is kept upright and that the fuel cock is turned to “ON” or “RES” (for vacuum type) / “OFF” (for manual type). If it should lean over, gasoline may leak out of the carburetor or fuel tank.

5SWX-F8199-E1.qxd 14/12/2004 15:05 Pâgina 13 D SAFETY INFORMATION À ef you should swallow any gasoli- ne, inhale a lot of gasoline vapor, or allow gasoline to get into your eyes, see your doctor immedia- tely. If any gasoline spills on your skin or clothing, immediately wash the affected area with soap and water and change your clot- hes.

EAU10460 Main switch/steering lock The main switch/steering lock con- trols the ignition and lighting systems, and is used to lock the steering. The various positions are described below.

All electrical circuits are supplied with power, and the engine can be started. The key cannot be removed. NOTE: The headlight, meter lighting and tai- light come on automatically when the engine is started. EAU10660 OFF All electrical systems are off. The key can be removed. EAU10670 “Ov The 2-stroke engine oil level warning light should come on. (See page 3-2.) EaUMI020 “Ov The coolant temperature warning light should come on when the key is tur- ned to “O”. (See page 3-2.) EAU10680 LOCK The steering is locked, and all electri- cal systems are off. The key can be removed. To lock the steering

1. Turn the handlebars all the way to

2. Push the key in from the “OFF”

position, and then turn it to “LOCK” while still pushing it.

3-1 To unlock the steering Push the key in, and then turn it to “OFF” while still pushing it. À WARNING Never turn the key to “OFF” or “LOCK” while the vehicle is moving, otherwise the electrical systems will be switched off, which may result in loss of control or an accident. Make sure that the vehi- cle is stopped before turning the key to “OFF” or “LOCK”. EWA10060 EAUTOSEO Indicator lights

1. Turn signal indicator light “++”

2. Neutral indicator light “N

3. Oil level warning light “SE”

4. Coolant temperature warning light “

EAU 1020 Turn signal indicator light “++” This indicator light flashes when the turn signal switch is pushed to the left or right. EAU 1060 Neutral indicator light “N°” This indicator light comes on when the transmission is in the neutral posi- tion. Eaur1120 Oil level warning light “7” This warning light comes on when the engine oil level is low. The electrical circuit of the warning light can be checked by turning the key to “ON”. If the warning light does not come on for a few seconds, then go off, have a Yamaha dealer check the electrical circuit. NOTE: Even if the oil level is sufficient, the warning light may flicker when riding on a slope or during sudden accelera- tion or deceleration, but this is not a malfunction. Eau 1440 Coolant temperature warning light “Er This warning light comes on when the engine overheats. When this occurs, stop the engine immediately and allow the engine to cool. The electrical circuit of the warning light can be checked by turning the key to “ON”. If the warning light does not come on for a few seconds, then go off, have a Yamaha dealer check the electrical circuit. CAUTION Do not operate the engine i overheated. EcA10020

The speedometer unit is equipped With a speedometer and an odometer. The speedometer shows riding spe- ed. The odometer shows the total dis- tance traveled.

The tachometer allows the rider to monitor the engine speed and keep it within the ideal power range. CAUTION Do not operate the engine in the tachometer red zone. Red zone: 10000 r/min and above ECA10020 Eure Handlebar switches

8. Turn signal switch “

EaU+2250 Pass switch “20” Press this switch to flash the head- light. EAUr2400 Dimmer switch “20/20” Set this switch to “=D” for the high beam and to ” for the low beam. EAU+2440 Turn signal switch “TURN” To signal a right-hand turn, push this switch to the right. To signal a left- 3-3 hand turn, push this switch to the left. When released, the switch returns to the center position. To cancel the turn signal lights, push the switch in after it has returned to the center position. EAU+2500 Horn switch “x” Press this switch to sound the horn. EAU+2660 Engine stop switch “O/” 1.Stop switch “

Set this switch to “Q” before starting the engine. Set this switch to “R” to stop the engine in case of an emer- gency, such as when the motorcycle overturns or when the throttle cable is stuck.

EaUi2590 Start switch “START” Push this switch to crank the engine with the starter. CAUTION See page 5-1 for starting instruc- tions prior to starting the engine. ETES EcA10050 Clutch lever

The clutch lever is located at the left handlebar grip. To disengage the clutch, pull the lever toward the hand- lebar grip. To engage the clutch, rele- ase the lever. The lever should be pulled rapidly and released slowly for smooth clutch operation. The clutch lever is equipped with a clutch switch, which is part of the ignition circuit cut-off system. (See page 3-8.) Shift pedal EAU+2870

The shift pedal is located on the left side of the engine and is used in com- bination with the clutch lever when shifting the gears of the 6-speed constant-mesh transmission equip- ped on this motorcycle.

The brake lever is located at the right handlebar grip. To apply the front bra- ke, pull the lever toward the handle- bar grip.

The brake pedal is on the right side of the motorcycle. To apply the rear bra- ke, press down on the brake pedal. EAU+3000 Fuel tank cap

To remove the fuel tank cap Insert the key into the lock and turn it 1/4 turn clockwise. The lock will be released and the fuel tank cap can be removed. To install the fuel tank cap

1. Push the fuel tank cap into posi-

tion with the key inserted in the lock.

2. Turn the key counterclockwise to

the original position, and then remove it. NOTE: The fuel tank cap cannot be installed unless the key is in the lock. In addi- tion, the key cannot be removed if the cap is not properly installed and loc- ked. À WARNING Make sure that the fuel tank cap is properly installed before riding. EVENT) 3-5

ONLY Fuel tank capacity: 13,8 L (3.03 Imp.gal) Fuel reserve amount: 2,2 L (0.48 Imp.gal) Your Yamaha engine has been desig- ned to use regular unleaded gasoline with a research octane number of 91 or higher. If knocking (or pinging) occurs, use a gasoline of a different brand or premium unleaded fuel. Use of unleaded fuel will extend spark plug life and reduce maintenance costs.

eaursast Catalytic converter This model is equipped with a cataly- tic converter in the exhaust system. À WARNING The exhaust system is hot after operation. Make sure that the exhaust system has cooled down before doing any maintenance work. EWao8so EcA10700 CAUTION The following precautions must be observed to prevent a fire hazard or other damages. e Use only unleaded gasoline. The use of leaded gasoline will cause unrepairable damage to the catalytic converter. e Never park the vehicle near possible fire hazards such as grass or other materials that easily burn. e Do not allow the engine to idle too long. EAUT3460 2-stroke engine oil

1. 2-stroke engine oil tank

2. 2-stroke engine oil tank cap

Make sure that there is sufficient oil in the 2-stroke engine oil tank. Add the recommended 2-stroke engine oil if necessary. NOTE: Make sure that the 2-stroke engine oil tank cap is properly installed. 3-6 Recommended oil: Yamalube 2 or equivalent 2-stroke engine oil (JASO grade “FC”, or ISO grades “EG-C” or “EG-D”) Oil quantity: 1,35 L (1,18 Imp.qft) EAU2560

1. Fuel reserve switch

The fuel cock supplies fuel from the tank to the carburetor while filtering it also. The fuel cock has three positions: OFF With the lever in this position, fuel will not flow. Always return the lever to this position when the engine is not running.

With the lever in this position, fuel flows to the carburetor. Normal riding is done with the lever in this position. RES This indicates reserve. If you run out of fuel while riding, move the lever to this position. Fill the tank at the first opportunity. Be sure to set the lever back to “ON” after refueling! EAUT3500 Starter (choke) lever “Nf° Starting a cold engine requires a richer air-fuel mixture, which is sup- plied by the starter (choke). Move the lever in direction (a) to turn on the starter (choke). Move the lever in direction (b) to turn off the starter (choke). EAU+3940 Seat

1. Insert the key into the seat lock,

and then turn it clockwise.

2. While holding the key in that

position, lift the rear of the seat, and then pull the seat off. To install the seat

1. Insert the projection on the front

of the seat into the seat holder as shown.

2. Push the rear of the seat down to

lock it in place. 3-7

NOTE: Make sure that the seat is properly secured before riding. EAUta4t1 Storage compartment U-lock This storage compartment is desig- ned to hold an optional genuine Yamaha U-LOCK. (Other locks may not fit) When placing a U-LOCK in the storage compartment, securely fasten it with the straps. When the U- LOCK is not in the storage compart- ment, be sure to secure the straps to prevent losing them.

When storing the owner's manual or other documents in the storage com- partment, be sure to wrap them in a plastic bag so that they will not get wet. When washing the motorcycle, be careful not to let any water enter the storage compartment. EAUS300 Sidestand

The sidestand is located on the left side of the frame. Raise the sidestand or lower it with your foot while holding the motorcycle upright. NOTE: The built-in sidestand switch is part of the ignition circuit cut-off system, which cuts the ignition in certain situations. (See further down for an explanation of the ignition circuit cut- off system.) À WARNING The vehicle must not be ridden the sidestand down, or if the sides- tand 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. Yama- ha's ignition circuit cut-off system has been designed to assist the operator in fulfilling the responsibi- lity of raising the sidestand before starting off. Therefore, check this system regularly as described below and have a Yamaha dealer repair it if it does not function pro- perly. EWA10240 3-8 Eauiseit Ignition circuit cut-off system The ignition circuit cut-off system (comprising the sidestand switch, clutch switch and neutral switch) has the following functions. @ lt prevents starting when the transmission is in gear and the sidestand is up, but the clutch lever is not pulled. @ lt prevents starting when the transmission is in gear and the clutch lever is pulled, but the sidestand is still down. e lt cuts the running engine when the transmission is in gear and the sidestand is moved down. Periodically check the operation of the ignition circuit cut-off system according to the following procedure. EWA 1250 WARNING If a malfunction is noted, have a Yamaha dealer check the system before riding.

With the engine turned off:

1. Move the sidestand down NOTE:

2. Make sure that the engine stop switch is turned on. This check is most reliable if performed with

3. Turn the key on. à warmed-up engine.

4. Shift the transmission into the neutral position.

5. Push the start switch

Does the engine start? The neutral switch may be defective. YES NO The motorcycle should not be ridden until checked by a Yamaha dealer. With the engine still running:

6. Move the sidestand up.

7.Keep the clutch lever pulled.

8. Shift the transmission into gear.

9. Move the sidestand down.

Does the engine stall? The sidestand switch may be defective. YES NO 1 The motorcycle should not be ridden until checked by a Yamaha dealer. After the engine has stalled:

10. Move the sidestand up.

11. Keep the clutch lever pulled.

12. Push the start switch.

Does the engine start? The clutch switch may be defective. YES NO The motorcycle should not be ridden until checked by a Yamaha dealer. The system is OK. The motorcycle can be ridden.

NOTE: This check is most reliable if performed with a warmed-up engine. 3-10

5WX-F8199-E1.qxd 14/12/2004 15:05 Pâgina 27 D PRE-OPERATION CHECKS Eauissor The condition of a vehicle is the owners responsibility. Vital compo- nents can start to deteriorate quickly and unexpectedly, even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thorough visual inspection, to check the follo- Wing points before each ride. NOTE: Pre-operation checks should be made each time the vehicle is used. Such an inspection can be accom- plished in a very short time; and the added safety it assures is more than worth the time involved. À WARNING If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operating the vehicle. EWAT1S0

+ Check fuel level in fuel tank. Fuel + Refuel if necessary. 3-5 + Check fuel line for leakage. + Check oil level in oil tank. 2-stroke engine oil + If necessary, add recommended oil to specified level. 3-6 + Check vehicle for oil leakage. + Check oil level in transmission case. Transmission oil « If necessary, add recommended oil to specified level. 6-6 | 4. + Check coolant level in reservoir. Coolant + If necessary, add recommended coolant to specified level. 6-8 + Check cooling system for leakage. + Check operation. + If soft or spongy, have Yamaha dealer bleed hydraulic system. + Check lever free play. + Adjust if necessary. Front brake + Check brake pads for wear. 6-14 + Replace if necessary. + Check fluid level in reservoir. + If necessary, add recommended brake fluid to specified level. + Check hydraulic system for leakage. + Check operation. + If soft or spongy, have Yamaha dealer bleed hydraulic system. + Check brake pads for wear. Rear brake + Replace if necessary. 6-14 + Check fluid level in reservoir. + If necessary, add recommended brake fluid to specified level. + Check hydraulic system for leakage. + Check operation. + Lubricate cable if necessary. + Check lever free play. + Adjust if necessary. Clutch

+ Make sure Ihat operation is smoofn. ; + Check cable free play. Throttle grip + Ifnecessary, have Yamaha dealer adjust cable free play and 6-9 lubricate cable and grip housing.

• Make sure that operation is smooth. [ Gontrol cables + Lubricate if necessary. e17 + Check chain slack. cha + Adjust if necessary. Drive chain + Check chain condition. 6-16 + Lubricate if necessary. + Check for damage. . + Check tire condition and tread depth. Wheels and tires à Check ar preneures 6-10 + Correct if necessary. + Make sure that operation is smooth. [ Brake and olutch levers + Lubricate lever pivoting points if necessary. 6-18 _ + Make sure Ihat operation is smooth. u Sidestand + Lubricate pivot if necessary. ad ; + Make sure that all nuts, bolts and screws are properly tightened. = Chassis fasteners Tighten if necessary. Instruments, Nights, signal + Check operation. = and switches « Correct if necessary. Engine stop switch + Check operation. 33 Sidestand switch + Check operation of ignifion cireuit cut-oif system. 38 + If system is defective, have Yamaha dealer check vehicle.

Pâgina 30 À EaU16000 Starting a cold engine In order for the ignition circuit cut-off system to enable starting, one of the following conditions must be met: e The transmission is in the neutral position. e The transmission is in gear with the clutch lever pulled and the sidestand up. À WARNING e Before starting the engine, check the function of the igni- tion circuit cut-off system according to the procedure described on page 3-9. e Never ride with the sidestand down. EWa10290 . Turn the fuel cock lever to “ON”.

2. Turn the key to “ON” and make

sure that the engine stop switch is set to “O”.

8. Shift the transmission into the

neutral position. NOTE: When the transmission is in the neu- tral position, the neutral indicator light should be on, otherwise have a Yamaha dealer check the electrical circuit.

4. Turn the starter (choke) on and

completely close the throttle. (See page 3-7.)

5. Start the engine by pushing the

start switch. NOTE: If the engine fails to start, release the start switch, wait a few seconds, and then try again. Each starting attempt should be as short as possible to pre- serve the battery. Do not crank the engine more than 10 seconds on any one attempt. ECATT160 CAUTION If the oil level warning light flickers or remains on after starting, imme- diately stop the engine, and then check the engine oil level and the vehicle for oil leakage. If necessary, add engine oil, and then check the 5-1 warning light again. If the warning light does not go off after starting With sufficient engine oil, have a Yamaha dealer check the electrical circuit.

6. After starting the engine, move

the starter (choke) back halfway. Ecar Do CAUTION For maximum engine life, never accelerate hard when the engine is cold!

7. When the engine is warm, turn

the starter (choke) off. NOTE: The engine is warm when it responds normally to the throttle with the starter (choke) turned off.

Shifting gears lets you control the amount of engine power available for starting off, accelerating, climbing hills, etc. The gear positions are shown in the illustration. NOTE: To shift the transmission into the neu- tral position, press the shift pedal down repeatedly until it reaches the end of its travel, and then slightly rai- se it. ECA10250 CAUTION e Even with the transmission in the neutral position, do not coast for long periods of time With the engine off, and do not tow the motorcycle for long distances. The transmission is properly lubricated only when the engine is running. Inade- quate lubrication may damage the transmission. e Always use the clutch while changing gears to avoid dama- ging the engine, transmission, and drive train, which are not designed to withstand the shock of forced shifting. 5-2 EAU16800 Tips for reducing fuel consumption Fuel consumption depends largely on your riding style. Consider the follo- Wing tips to reduce fuel consumption: e Turn the starter (choke) off as soon as possible. @e Shift up swiftly, and avoid high engine speeds during accelera- tion. @e Do not rev the engine while shif- ting down, and avoid high engine speeds with no load on the engi- ne. @e Turn the engine off instead of let- ting it idle for an extended length of time (e.g., in traffic jams, at traffic lights or at railroad cros- sings).

Pâgina 32 À EAU16830 Engine break-in There is never a more important period in the life of your engine than the period between O0 and 1000 km (600 mi). For this reason, you should read the following 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 themsel- ves to the correct operating clearan- ces. During this period, prolonged full-throttle operation or any condition that might result in engine overhea- ting must be avoided. EaU16860 0-150 km (0-90 mi) Avoid prolonged operation above 1/3 throttle. After every hour of operation, stop the engine, and then let it cool for five to ten minutes. Vary the engine speed from time to time. Do not operate the engine at one set throttle position. 150-500 km (90-300 mi) Avoid prolonged operation above 1/2 throttle. 500-1000 km (300-600 mi) Avoid prolonged operation above 3/4 throttle. CAUTION After 1000 km (600 mi) of operation, the engine oil must be changed. 1000 km (600 mi) and beyond Avoid prolonged full-throttle opera- tion. Vary the speed occasionally.

EGA10270 CAUTION If any engine trouble should occur during the engine break-in period, immediately have a Yamaha dealer check the vehicle. EcA10280 Eaurr17o Parking When parking, stop the engine, remo- ve the key from the main switch, and then turn the fuel cock lever to “OFF”. 5-3 Ewaosio À WARNING e Since the engine and exhaust system can become very hot, park in a place where pedes- trians or children are not likely to touch them. e Do not park on a slope or on soft ground, otherwise the vehicle may overturn.

Eaurr2o Safety is an obligation of the owner. Periodic inspection, adjustment and lubrication will keep your vehicle in the safest and most efficient condi- tion possible. The most important points of inspection, adjustment, and lubrication are explained on the follo- Wing pages. The intervals given in the periodic maintenance and lubrication chart should be simply considered as a general guide under normal riding conditions. However, DEPENDING

ON THE WEATHER, TERRAIN, GEO-

GRAPHICAL LOCATION, AND INDIVI-

DUAL USE, THE MAINTENANCE

INTERVALS MAY NEED TO BE

SHORTENED. À WARNING If you are not familiar with mainte- nance work, have a Yamaha dealer do it for you. EWA10320 EAU+7380 Owner's tool kit

The owner's tool kit is located under the seat. (See page 3-7 for.) The service information included in this manual and the tools provided in the owner’s tool kit are intended to assist you in the performance of pre- ventive maintenance and minor repairs. However, additional tools such as a torque wrench may be necessary to perform certain mainte- nance work correctly. 6-1 NOTE: If you do not have the tools or expe- rience required for a particular job, have a Yamaha dealer perform it for you. À WARNING Modifications not approved by Yamaha may cause loss of perfor- mance and render the vehicle unsafe for use. Consult a Yamaha dealer before attempting any chan- ges. EWAT03S0

PERIODIC MAINTENANCE AND MINOR REPAIR

EAUr7710 Periodic maintenance and lubrication chart NOTE: e The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead. © From 30000 km, repeat the maintenance intervals starting from 6000 km. e liems marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. ODOMETER READING (x 1000 Km) | ANNUAL ITEM CHEK OR MAINTENANCE JOB 1 6 | 12 | 18 | 24 | cueck

• | Fuel line Check fuel and vacuum hoses for cracks or damage. V v Ÿ Ÿ v Spark plug Replace. V v v v v us Clean. V Ü 8 | | Air filter element Replace. 7 7 Check operation. 4] |Clutch Adjust. v v v v v Check operation, fluid level and vehicle for fluid leakage. v V v Ü Ü v 5 || Front brake Replace brake pads. Whenever worn to the limit Check operation, fluid level and vehicle for fluid leakage. VIVIVI VI VI 6 |‘ | Rear brake Replace brake pads. Whenever worn to the limit Check for cracks or damage. LYIvVI VI VI v 7 |*| Brake hose Replace. Every 4 years 8 |*| Wheels Check runout and for damage. Ï v Ï M Ï V [ V Ï 6-2

ODOMETER READING (x 1000 Km) | ANNUAL ol ITEM CHEK OR MAINTENANCE JOB 1 6 12 18 | 24 | check Check tread depth and for damage. ln Replace if necessary. 9 ||Tires Check air pressure. Ÿ Ÿ Ÿ Ÿ Ÿ Correct if necessary. Ho|* | Wheel bearings Check bearing for looseness or damage. V V V V Check operation and for excessive play. V V v V H1|*| Swingarm Tee Lubricate with lithium-soap-based grease. Every 24000 km [21 | prive chaï Check chain slack, alignment and condition. Every 500 km and after washing rive chain Adjust and thoroughly lubricate chain with engine oil. the motorcycle or riding in the rain Lol: | stecring bear Check bearing play and steering for roughness. VIVIVI VI VI eering bearings Lubricate with lithium-soap-based grease. Every 24000 km . _ Make sure that all nuts, bolts and screws are H4/*| Chassis fasteners proper tightened, Ÿ Ÿ Ÿ Ÿ Ÿ . Check operation. H5| | Sidestand Lubricate, Ÿ Ÿ Ÿ Ÿ V 6" | Sidestand switch Check operation. v V V v V v 7" | Front fork Check operation and for oil leakage. V V V V gl. | Shock absorber Check operation and shock absorber for oil leakage. V V V V assembly . Check starter (choke) operation. j19/* | Carburetor Adjust engine idling speed. V Ÿ Ÿ V Ÿ V . Check operation. P0|" | Autolube pump Bleed if necessary. V V V V . Check oil level. v V V v V v b1| | Transmission oil Change. V V 6-3

23|* | Air filter element Replace. 7 7 EAU867o NOTE: e The air filter needs more frequent service if you are riding in unusually wet or dusty areas. e Hydraulic brake service

• Regularly check and, if necessary, correct the brake fluid level. «Every two years replace the internal components of the brake master cylinders and calipers, and change the bra- ke fluid.
• Replace the brake hoses every four years and if cracked or damaged.

EAUt87et Removing and installing cowlings

The cowlings shown need to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time a cowling needs to be removed and installed. EAU18880 Cowling A

1. Screws (x 7 Right side)

(x 6 Left side) To remove the cowling

1. Remove the cowling screws.

2. Push the cowling in lightly, and

then pull it back as shown. ECat1200 CAUTION Take care not to damage the tabs on the cowling when removing and or installing it. 6-5 To install the cowling

1. Insert the tabs on the cowling

into the slots as shown, and then push the cowling in until it snaps into place.

2. Install the cowling screws.

(x 7 Linkerkant) To remove the cowling Remove the screws, and then take the cowling off. To install the cowling Place the cowling in the original posi- tion, and then install the screws.

The spark plug is an important engine component, which should be chec- ked periodically, preferably by a Yamaha dealer. Since heat and depo- sits will cause any spark plug to slowly erode, it should be removed and checked in accordance with the periodic maintenance and lubrication chart. In addition, the condition of the spark plug can reveal the condition of the engine. The porcelain insulator around the center electrode of the spark plug should be a medium-to-light tan (the ideal color when the vehicle is ridden normally). If the spark plug shows a distinctly different color, the engine could be defective. Do not attempt to diagnose such problems yourself. Instead, have a Yamaha dealer check the vehicle. If the spark plug shows signs of elec- trode erosion and excessive carbon or other deposits, it should be repla- ced. Specified spark plug: BR9ES (NGK) Before installing a spark plug, the spark plug gap should be measured With a wire thickness gauge and, if necessary, adjusted to specification. Spark plug gap: 0,6 - 0,7 mm (0,023-0,027 in) Clean the surface of the spark plug gasket and its mating surface, and then wipe off any grime from the spark plug threads. 6-6 Tightening torque: Spark plug: 20 Nm (2,0 mekgf) NOTE: If a torque wrench is not available When installing a spark plug, a good estimate of the correct torque is 1/4-1/2 turn past finger tight. Howe- ver, the spark plug should be tighte- ned to the specified torque as soon as possible. EAUM1270 Transmission oil

PERIODIC MAINTENANCE AND MINOR REPAIR

The transmission oil level should be checked before each ride. In addition, the oil must be changed at the inter- vals specified in the periodic mainte- nance and lubrication chart. To check the transmission oil level

1. Place the vehicle on a level surfa-

ce and hold it in an upright posi- tion. NOTE: Make sure that the vehicle is positio- ned straight up when checking the oil level. A slight tilt to the side can result in a false reading.

2. Remove the oil check bolt, and

then check the oil level. NOTE: The oil should be at the brim of the check hole.

3. If the oil is below the brim of the

check hole, remove the oil filler cap, add sufficient oil of the recommended type to raise it to the correct level, and then install the oil filler cap.

4. Install the oil check bolt, and then

tighten it to the specified torque. Tightening torque: Oil check bolt: 3 Nm (0,3 mekgf) To change the transmission oil

1. Place an oil pan under the trans-

mission oil case to collect the used oil.

2. Remove the drain bolt and the oil

check bolt to drain the oil.

3. Install the drain bolt and the

check bolt, and then tighten them to the specified torque. Tightening torque: Transmission oil drain bolt: 17 Nm (1,7 mekgf) Oil check bolt: 3 Nm (0,3 mekgf) 6-7

4. Remove the oil filer cap, add the

specified amount of the recom- mended transmission oil, and then install and tighten the oil filler cap. Recommended transmission oil: See page 8-1. Oil change quantity: 0,75 L (0,65 imp.at) Ecau:020 CAUTION Make sure that no foreign material enters the transmission case.

5. Start the engine and let it idle for

several minutes while checking the transmission oil case for oil leakage. If oil is leaking, imme- diately turn the engine off and check for the cause.

EAU20t70 Ecaio47o CAUTION e If coolant is not available, use distilled water or soft tap water instead. Do not use hard water or salt water since it is harmful to the engine. e If water has been used instead of coolant, replace it with coo- lant as soon as possible, other-

1. Panel wise the engine may not be

sufficiently cooled and the coo-

1. Place the vehicle ona level surfa- z gene panel Was ee nes sa) ling system will not be protec-

ce and hold it in an upright posi- . e U e coolant level in the ted against frost and corrosion. tion. coolant reservoir. e If water has been added to the NOTE: NOTE: coolant, have a Yamaha dealer check the antifreeze content of the coolant as soon as possible, otherwise the effectiveness of © The coolant level must be chec- The coolant should be between the ked on a cold engine since the Minimum and maximum level marks. level varies with engine tempera- 4. If the coolant is at or below the the coolant will be reduced. ture. . : minimum level mark, open the e Make sure that the vehicle is reservoir cap, add coolant to the EWA10S80 positioned straight up when maximum level mark, and then checking the coolant level. A close the reservoir cap. nnuadharadia slight tilt to the side can result in Never attempt to remove the radi a false reading. Coolant reservoir capacity: tor cap when the engine is hot. 0,45 L (0.39 Imp.qt) 5. Install the panel. 6-8

NOTE: If the engine overheats, see page 6-5 for further instructions. Eauz1200 Adjusting the carburetor The carburetor is an important part of the engine and requires very sophisti- cated adjustment. Therefore, all car- buretor adjustments should be left to a Yamaha dealer, who has the neces- sary professional knowledge and experience. Adjusting the engine idling speed

1. Idie aedjusting bolt

The engine idling speed must be checked and, if necessary, adjusted as follows at the intervals specified in the periodic maintenance and lubrica- tion chart. The engine should be warm before making this adjustment. NOTE: The engine is warm when it quickly responds to the throttle. Check the engine idling speed and, if necessary, adjust it to specification by turning the throttle stop screw. To increase the engine idling speed, turn the screw in direction (a). To decrease the engine idling speed, turn the screw in direction (b). Engine idling speed: 1700 - 2000 tpm 6-9 NOTE: If the specified idling speed cannot be obtained as described above, have a Yamaha dealer make the adjustment. ET] Adjusting the throttle cable free play @) Throttle cable free play The throttle cable free play should measure 2-5 mm (0,08-0,2 in) at the throttle grip. Periodically check the throttle cable free play and, if neces- sary, adjust it as follows. NOTE: The engine idling speed must be correctly adjusted before checking and adjusting the throttle cable free play.

2. To increase the throttle cable free

play, turn the adjusting nut in direction (a). To decrease the throttle cable free play, turn the adjusting nut in direction (b).

3. Tighten the locknut.

EAUz1500 Tires To maximize the performance, durabi- lity, and safe operation of your motorcycle, note the following points regarding the specified tires. Tire air pressure The tire air pressure should be chec- ked and, if necessary, adjusted befo- re each ride. À WARNING e The tire air pressure must be checked and adjusted on cold tires (ï.e., when the temperatu- EWatoaso re of the tires equals the ambient temperature). e The tire air pressure must be adjusted in accordance with the riding speed and with the total weight of rider, cargo, and accessories approved for this model. Front: 180 kPa (25,6 psi) (1,8 kgf/cm?) Rear: 200 kPa (28,4 psi) (2,0 kgf/cm2) 90 kg (198 Ib) to maximum load: Front: 190 kPa (27 psi) (1,9 kgf/cm2) Rear: 230 kPa (32,7 psi) (2,3 kgf/cm2) High-speed riding: Front: 190 kPa (27 psi) (1,9 kgf/cm2) Rear: 230 kPa (32,7 psi) (2,3 kgf/cm2) Maximum load*: 195 kg (429,9 Ib) l Total weight of rider, cargo and accessories 6-10 EWa10450 À WARNING Because loading has an enormous impact on the handling, braking, performance and safety characte- ristics of your vehicle, you should keep the following precautions in mind. e NEVER OVERLOAD THE VEHI- CLE! Operation of an overloa- ded vehicle may result in tire damage, loss of control, or severe injury. Make sure that the total weight of rider, cargo, and accessories does not exceed the specified maximum load for the vehicle. e Do not carry along loosely pac- ked items, which can shift during a ride. e Securely pack the heaviest items close to the center of the vehicle and distribute the weight evenly on both sides. © Adjust the suspension and tire air pressure with regard to the load. e Check the tire condition and air pressure before each ride.

Tire inspection The tires must be checked before each ride. If the center tread depth reaches the specified limit, if the tire has a nail or glass fragments in it, or if the sidewall is cracked, have a Yama- ha dealer replace the tire immediately. Minimum tire tread depth (front and rear):

NOTE: The tire tread depth limits may differ from country to country. Always comply with the local regulations. EWAto47o À WARNING e Have a Yamaha dealer replace excessively worn tires. Besides being illegal, operating the vehicle with excessively worn tires decreases riding stability and can lead to loss of control. e The replacement of all wheel and brake related parts, inclu- ding the tires, should be left to a Yamaha dealer, who has the necessary professional know- ledge and experience. Tire information This motorcycle is equipped with cast wheels and tubeless tires with valves. À WARNING e The front and rear tires should be of the same make and design, otherwise the handling characteristics of the motorcy- cle cannot be guaranteed. e After extensive tests, only the tires listed below have been approved for this model by Yamaha Motor España, S.A. 6-11 EWAtO480 e Always make sure that the val- ve caps are securely installed to prevent air pressure leaka- ge. e Use only the tire valves and val- ve cores listed below to avoid tire deflation during a high- speed ride. Front tire: Size: 100/80-17 Manufacturer/model: PIRELLI Rear tire: Size: 130/70-17 Manufacturer/model: PIRELLI EWA10600 À WARNING is fitted with This motorcycle super-high-speed tires. Note the following points in order to make the most efficient use of these tires. e Use only the specified replace- ment tires. Other tires may run the danger of bursting at super high speeds.

e Brand-new tires can have a relatively poor grip on certain road surfaces until they have been “broken in”. Therefore, it is advisable before doing any high-speed riding to ride con- servatively for approximately 100 km (60 mi) after installing a new tire. e The tires must be warmed up before a high-speed run. © Always adjust the tire air pres- sure according to the opera- ting conditions. ERUZ1960 To maximize the performance, durabi- lity, and safe operation of your motorcycle, note the following points regarding the specified wheels. e The wheel rims should be chec- ked for cracks, bends or warpage before each ride. If any damage is found, have a Yamaha dealer replace the wheel. Do not attempt even the smallest repair to the wheel. À deformed or crac- ked wheel must be replaced. e The wheel should be balanced whenever either the tire or wheel has been changed or replaced. An unbalanced wheel can result in poor performance, adverse handling characteristics, and a shortened tire life. e Ride at moderate speeds after changing a tire since the tire sur- face must first be “broken in” for it to develop its optimal characte- ristics. EaU204t Adjusting the clutch lever free play

6-12 The clutch lever free play should mea- sure 2-5 mm (0,08-0,2 in) as shown. Periodically check the clutch lever free play and, if necessary, adjust it as follows.

1. Loosen the locknut at the clutch

play, turn the adjusting bolt in direction (a). To decrease the clutch lever free play, turn the adjusting bolt in direction (b). NOTE: If the specified clutch lever free play could be obtained as described abo- ve, tighten the locknut and skip the rest of the procedure, otherwise pro- ceed as follows.

3. Fully turn the adjusting bolt at the

clutch lever in direction (a) to loo- sen the clutch cable.

play, turn the adjusting nut in direction (a). To decrease the clutch lever free play, turn the

PERIODIC MAINTENANCE AND MINOR REPAIR

adjusting nut in direction (b).

6. Tighten the locknut at the clutch

lever and the crankcase. Adjusting the brake pedal position and free play

1. Position adjusting boit

À WARNING It is advisable to have a Yamaha dealer make these adjustments. EWA10870 Brake pedal position The top of the brake pedal should be aligned with the top of the footrest as shown. Periodically check the brake pedal position and, if necessary, adjust it as follows.

1. Loosen the locknut at the brake

2. To raise the brake pedal, turn the

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

8. Tighten the locknut.

À WARNING After adjusting the brake pedal position, the brake pedal free play must be adjusted. EWAT1220 Brake pedal free play

The brake pedal free play should measure 10-15 mm (0,39-59 in) at the brake pedal end. Periodically check the brake pedal free play and, if necessary, adjust it as follows. 6-13 To increase the brake pedal free play, turn the adjusting nut at the brake rod in direction (a). To decrease the brake pedal free play, turn the adjusting nut in direction (b). À WARNING After adjusting the brake pedal free play, check the operation of the brake light. EWatoGso Adjusting the rear brake light switch

The rear brake light switch, which is activated by the brake pedal, is pro- perly 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). EAU?2420 Front brake pads Each front brake pad is provided with a wear indicator groove, which allows you to check the brake pad wear wit- hout having to disassemble the brake. To check the brake pad wear, check the wear indicator groove. If a brake pad has worn to the point that the wear indicator groove has almost disappeared, have a Yamaha dealer replace the brake pads as a set. EAU?2480 Rear brake pads Each rear brake pad is provided with a wear indicator groove, which allows you to check the brake pad wear wit- hout having to disassemble the brake. Check the brake pad wear as follows.

1. Remove the brake caliper bolt,

and then tilt the caliper forward to inspect the wear indicator groo- ve. f a brake pad has worn to the point that the wear indicator gro- ove has almost disappeared, have a Yamaha dealer replace the brake pads as a set. 6-14

2. Install the brake caliper bolt, and

then tighten it to the specified torque. Tightening torque: Brake caliper bolt: 30 Nm (3,0 mekgf) EAU22610 Checking the brake fluid level _ FRONT Insufficient brake fluid may allow air to enter the brake system, possibly causing it to become ineffective.

Before riding, check that the brake fluid is above the minimum level mark and replenish if necessary. A low bra- ke fluid level may indicate worn brake pads and/or brake system leakage. If the brake level is low, be sure to check the brake pads for wear and the brake system for leakage. Observe these precautions: e When checking the fluid level, make sure that the top of the brake fluid reservoir is level by turning the handlebars. @e Use only the recommended qua- lity brake fluid, otherwise the rub- ber seals may deteriorate, cau- sing leakage and poor braking performance. Recommended brake fluid: DOT 4 NOTE: If DOT 4 is not available, DOT 3 can be used for the front brake system. e Refill with the same type of brake fluid. Mixing fluids may result in a harmful chemical reaction and lead to poor braking performan- ce. e Be careful that water does not enter the brake fluid reservoir when refilling. Water will signifi- cantly lower the boiling point of the fluid and may result in vapor lock. e Brake fluid may deteriorate pain- ted surfaces or plastic parts. Always clean up spilled fluid immediately. 6-15 e As the brake pads wear, it is nor- mal for the brake fluid level to gradually go down. However, if the brake fluid level goes down suddenly, have a Yamaha dealer check the cause. EAU2?720 Changing the brake fluid Have a Yamaha dealer change the brake fluid at the intervals specified in the NOTE after the periodic mainte- nance and lubrication chart. In addi- tion, have the oil seals of the brake master cylinder and caliper as well as the brake hose replaced at the inter- vals listed below or whenever they are damaged or leaking. @e Oil seals: Replace every two years. @e Brake hose: Replace every four years.

EAU22760 Drive chain slack (a) Drive chain slack The drive chain slack should be chec- ked before each ride and adjusted if necessary. au To check the drive chain slack

1. Place the motorcycle on the

sidestand. NOTE: When checking and adjusting the dri- ve chain slack, there should be no weight on the motorcycle.

2. Shift the transmission into the

3. Move the rear wheel by pushing

the motorcycle to locate the tigh- test portion of the drive chain, and then measure the drive chain slack as shown. Drive chain slack: 40-50 mm (1,5 -1,9 in) adjusting nut at each end of the swingarm in direction (b), and then push the rear wheel forward. NOTE:

4. If the drive chain slack is inco-

rrect, adjust it as follows. EAU22020 To adjust the drive chain slack \ NS LC :

1. Remove the cotter pin from the axle

at each end of the swingarm.

8. To tighten the drive chain, turn

the adjusting nut at each end of the swingarm in direction (a). To loosen the drive chain, turn the 6-16 Using the alignment marks on each side of the swingarm, make sure that both adjusting nuts are in the same position for proper wheel alignment. ECATOSS CAUTION Improper drive chain slack will overload the engine as well as other vital parts of the motorcycle and can lead to chain slippage or breakage. To prevent this from occurring, keep the drive chain slack within the specified limits.

4. Tighten the locknuts, and then

tighten the axle nut to the speci- fied torque. Tightening torque: Axle nut: 90 Nm (9,0 mekgf)

5. Insert a new cotter pin into the

axle nut, and then bend its ends as shown.

NOTE: NOTE: Make sure that two notches in the axle nut are aligned with the hole through the wheel axle, otherwise further tighten the axle nut until they are. À WARNING Always use a new cotter pin for the axle nut. EWAT0700 Eauraoi? Lubricating the drive chain The drive chain must be cleaned and lubricated at the intervals specified in the periodic maintenance and lubrica- tion chart, otherwise it will quickly wear out, especially when riding in dusty or wet areas. Service the drive chain as follows. CAUTION The drive chain must be lubricated after washing the motorcycle and riding in the rain. Ecatoset

1. Remove all dirt and mud from the

drive chain with a brush or cloth. For a thorough cleaning, have a Yamaha dealer remove the drive chain and soak it in solvent.

2. Spray Yamaha Chain and Cable

Lube or a high-quality spray-type drive chain lubricant on both sides and on the middle of the chain, making sure that all side plates and rollers have been suf- ficiently oiled. EAUx9100 Checking and lubricating the cables The operation of all control cables and the condition of the cables should be checked before each ride, and the cables and cable ends should be lubricated if necessary. If a cable is damaged or does not move smoothly, have a Yamaha dealer check or repla- ce it. Recommended lubricant: Engine oil 6-17 EWA10720 À WARNING Damage to the outer sheath may interfere with proper cable opera- tion and will cause the inner cable to rust. Replace a damaged cable as soon as possible to prevent unsafe conditions. Checking and lubricating the brake and shift pedals The operation of the brake and shift pedals should be checked before each ride, and the pedal pivots should be lubricated if necessary. Recommended lubricant: Lithium-soap-based grease (all- purpose grease)

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU23140 Checking and lubricating the brake and clutch levers The operation of the brake and clutch levers should be checked before each ride, and the lever pivots should be lubricated if necessary. Recommended lubricant: Lithium-soap-based grease (all- purpose grease) EAU22200 Checking and lubricating the sidestand The operation of the sidestand should be checked before each ride, and the sidestand pivot and metal-to-metal contact surfaces should be lubricated if necessary. WARNING If the sidestand does not move up and down smoothly, have a Yama- ha dealer check or repair it. EWa10720 Recommended lubricant: Lithium-soap-based grease (all- purpose grease) 6-18 EAU23271 Checking the front fork The condition and operation of the front fork must be checked as follows at the intervals specified in the perio- dic maintenance and lubrication chart. To check the condition À WARNING Securely support the motorcycle so that there is no danger of it falling over. EWA10750 Check the inner tubes for scratches, damage and excessive oil leakage. To check the operation

1. Place the motorcycle on a level

surface and hold it in an upright position.

2. While applying the front brake,

push down hard on the handle- bars several times to check if the front fork compresses and rebounds smoothly. CAUTION If any damage is found or the front fork does not operate smoothly, have a Yamaha dealer check or repair it. ECA10500 EAU2S280 Checking the steering Worn or loose steering bearings may cause danger. Therefore, the opera- tion of the steering must be checked as follows at the intervals specified in the periodic maintenance and lubrica- tion chart.

1. Place a stand under the engine to

raise the front wheel off the ground. À WARNING Securely support the motorcycle so that there is no danger of it falling over. EWA10750

2. Hold the lower ends of the front

fork legs and try to move them forward and backward. If any free play can be felt, have a Yamaha dealer check or repair the stee- ring. EAUx2200 Checking the wheel bearings The front and rear wheel bearings must be checked at the intervals spe- cified in the periodic maintenance and lubrication chart. If there is play in the wheel hub or if the wheel does not turn smoothly, have a Yamaha dealer check the wheel bearings. 6-19 EAU23440

This motorcycle is equipped with a sealed-type (MF) battery, which does not require any maintenance. There is no need to check the electrolyte or to add distilled water. To charge the battery Have a Yamaha dealer charge the battery as soon as possible if it seems to have discharged. Keep in mind that the battery tends to discharge more quickly if the motorcycle is equipped with optional electrical accessories.

EWa1076o À WARNING e Electrolyte is poisonous and dangerous since it contains sulfuric acid, which causes severe burns. Avoid any con- tact with skin, eyes or clothing and always shield your eyes when working near batteries. In case of contact, administer the following FIRST AID. + EXTERNAL: Flush with plenty of water. INTERNAL: Drink large quan- tities of water or milk and immediately call a physician. + EYES: Flush with water for 15 minutes and seek prompt medical attention. e Batteries produce explosive hydrogen gas. Therefore, keep sparks, flames, cigaret- tes, etc., away from the bat- tery and provide sufficient ventilation when charging it in an enclosed space. e KEEP THIS AND ALL BATTE-

CHILDREN. To store the battery

1. Ifthe motorcycle will not be used

for more than one month, remove the battery, fully charge it, and then place it in a cool, dry place.

2. If the battery will be stored for

more than two months, check it at least once a month and fully charge it if necessary.

3. Fully charge the battery before

4. After installation, make sure that

the battery leads are properly connected to the battery termi- nals. CAUTION © Always keep the battery char- ged. Storing a discharged bat- tery can cause permanent bat- tery damage. EcA106s0 6-20 e To charge a sealed-type (MF) battery, a special (constant- voltage) battery charger is required. Using a conventional battery charger will damage the battery. If you do not have access to a sealed-type (MF) battery charger, have a Yamaha dealer charge your battery. ERUZSE0 Replacing the fuse

The fuse box is located under the seat. (See page 3-7.) If the fuse is blown, replace it as follows.

1. Turn the key to “OFF” and turn off

all electrical circuits.

2. Remove the blown fuse, and then

install a new fuse of the specified amperage. Specified fuse: 10A ECA1OS40 CAUTION Do not use a fuse of a higher ampe- rage rating than recommended to avoid causing extensive damage to the electrical system and possibly a fire.

8. Turn the key to “ON” and turn on

the electrical circuits to check if the devices operate.

4. If the fuse immediately blows

again, have a Yamaha dealer check the electrical system. Eauz2900 Replacing the headlight bulb This model is equipped with a quartz bulb headlight. If the headlight bulb burns out, replace it as follows.

1. Remove the headlight bulb cover,

and then disconnect the head- light lead connectors.

2. Unhook the headlight bulb hol-

der, and then remove the defecti- ve bulb. À WARNING Headlight bulbs get very hot. The- refore, keep flammable products away from a lit headlight bulb, and do not touch the bulb until it has cooled down. EWA10790

3. Place a new headlight bulb into

position, and then secure it with the bulb holder. CAUTION Do not touch the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the luminosity of the bulb, and the bulb life will be adver- sely affected. Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth mois- tened with alcohol or thinner. ECA10660

4. Connect the headlight lead con-

nectors, and then install the bulb cover.

. Remove the lens by removing the Replacing a turn signal light bulb or the tail/brake light bulb screws. . Remove the defective bulb by pushing it in and turning it coun- terclockwise. Insert a new bulb into the socket, push it in, and then turn it clock- wise until it stops.

4. Install the lens by installing the

screws. CAUTION Do not overtighten the screws, otherwise the lens may break. EcA10680

. Install the socket (together with

Remove the license plate light cover by removing the screw. Remove the socket (together With the bulb) by pulling it out. Remove the defective bulb by pulling it out. Insert a new bulb into the socket. the bulb) by pushing it in. . Install the license plate light cover by installing the screw. 6-22 EaU24250 Supporting the motorcycle Since this model is not equipped with a centerstand, follow these precau- tions when removing the front and rear wheel or performing other main- tenance requiring the motorcycle to stand upright. Check that the motorcycle is in a stable and level position before starting any mainte- nance. A strong wooden box can be placed under the engine for added stability. To service the front wheel

1. Stabilize the rear of the motorcy-

cle by using a motorcycle stand or, if an additional motorcycle stand is not available, by placing a jack under the frame in front of the rear wheel.

2. Raise the front wheel off the

ground by using a motorcycle stand.

To service the rear wheel like Yamaha parts, but they are often Raise the rear wheel off the ground by inferior, have a shorter service life and using a motorcycle stand or, if a can lead to expensive repair bills. motorcycle stand is not available, by placing a jack either under each side of the frame in front of the rear wheel or under each side of the swingarm. Eau2s87o Troubleshooting Although Yamaha motorcycles recei- ve a thorough inspection before ship- ment from the factory, trouble may occur during operation. Any problem in the fuel, compression, or ignition systems, for example, can cause poor starting and loss of power. The following troubleshooting charts represent quick and easy procedures for checking these vital systems your- self. However, should your motorcy- cle require any repair, take it to a Yamaha dealer, whose skilled techni- cians have the necessary tools, expe- rience, and know-how to service the motorcycle properly. Use only genuine Yamaha replace- ment parts. Imitation parts may look 6-23

Troubleshooting charts Starting problems or poor engine performance À WARNING EAU592 EWa10840 Keep away open flames and do not smoke while checking or working on the fuel system.

Check the fuel level in the fuel tank.

There is enough fuel.

Check the compression.

Suppiy fuel. > ex The engine does not start. the compression. Operate the electric starter. There is compression. Check the ignition.

There is no compression

Have à Yamaha dealer check the vehicle. Operate the electric starter. quickly.

3. lgnition Wet Wipe off it a dry cloth and correcte |_, | Open the throttle halfway and operate

"L"*) spark plug gap, or replace the spark plug the electric starter. Remove the spark plug and check the electrodes. [7] Ÿ The engine does not start. Le] oy Have à Yamaha dealer check the vehicle Dee bte

The engine turns over slow. Check the battery lead connections, and charge the battery if necessary. The engine does notstart. Have a Yamaha dealer check the vehicle. 6-24

Engine overheating À WARNING @e Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury. Be sure to wait until the engine has cooled. e After removing the radiator cap retaining bol, place a thick rag, like a towel, over the radiator cap, and then slowly rotate the cap counterclockwise to the detent to allow any residual pressure to escape. When the his- sing sound has stopped, press down on the cap while turning it counterclockwise, and then remove the cap. EWA10400 There is Have à Yamaha dealer check The coolant level is low. leakage. and repair the cooling system Check the cooling system for leakage True Wait until the Check the coolant level in the no leakage. | ”L Add coofant. (See NOTE.) engine has cooled. |” reservoir and radiator. The coolant level Startthe engine. fthe engine overheats again, have à is OK. ?] Yamaha dealer check and repair the cooling system. NOTE: If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommended coolant as soon as possible. 6-25

EAU26000 Care While the open design of a motorcy- cle reveals the attractiveness of the technology, it also makes it more vul- nerable. Rust and corrosion can develop even if high-quality compo- nents are used. A rusty exhaust pipe may go unnoticed on a car, however, it detracts from the overall appearan- ce of a motorcycle. Frequent and pro- per care does not only comply with the terms of the warranty, but it will also keep your motorcycle looking good, extend its life and optimize its performance. Before cleaning

1. Cover the muffler outlet with a

plastic bag after the engine has cooled down.

2. Make sure that all caps and

covers as well as all electrical couplers and connectors, inclu- ding the spark plug cap, are tightly installed.

3. Remove extremely stubborn dirt,

like oil burnt onto the crankcase, With a degreasing agent and a brush, but never apply such pro- ducts onto seals, gaskets, sproc- kets, the drive chain and wheel axles. Always rinse the dirt and degreaser off with water. Cleaning CAUTION e Avoid using strong acidic whe- el cleaners, especially on spo- ked wheels. If such products are used on hard-to-remove dirt, do not leave the cleaner on the affected area any longer than instructed. Also, tho- roughly rinse the area off with water, immediately dry it, and then apply a corrosion protec- tion spray. © Improper cleaning can damage windshields, cowlings, panels and other plastic parts. Use only a soft, clean cloth or spon- ge with mild detergent and water to clean plastic. e Do not use any harsh chemical products on plastic parts. Be sure to avoid using cloths or sponges which have been in contact with strong or abrasive Ecato7ro 7-1 cleaning products, solvent or thinner, fuel (gasoline), rust removers or inhibitors, brake fluid, antifreeze or electrolyte. Do not use high-pressure was- hers or steam-jet cleaners sin- ce they cause water seepage and deterioration in the follo- Wing areas: seals (of wheel and swingarm bearings, fork and brakes), electric components (couplers, connectors, instru- ments, switches and lights), breather hoses and vents. For motorcycles equipped with a windshield: Do not use strong cleaners or hard sponges as they will cause dulling or scrat- ching. Some cleaning com- pounds for plastic may leave scratches on the windshield. Test the product on a small hid- den part of the windshield to make sure that it does not lea- ve any marks. If the windshield is scratched, use a quality plastic polishing compound after washing.

After normal use Remove dirt with warm water, a mild detergent, and a soft, clean sponge, and then rinse thoroughly with clean water. Use a toothbrush or bottle- brush for hard-to-reach areas. Stub- born dirt and insects will come off more easily if the area is covered with a wet cloth for a few minutes before cleaning. After riding in the rain, near the sea or on salt-sprayed roads Since sea salt or salt sprayed on roads during winter are extremely corrosive in combination with water, carry out the following steps after each ride in the rain, near the sea or on salt-sprayed roads. NOTE: Salt sprayed on roads in the winter may remain well into spring.

1. Clean the motorcycle with cold

water and a mild detergent, after the engine has cooled down. ECA10790 CAUTION Do not use warm water since it increases the corrosive action of the salt.

2. Apply a corrosion protection

spray on all metal, including chrome- and nickel-plated, surfa- ces to prevent corrosion. After cleaning

1. Dry the motorcycle with a cha-

mois or an absorbing cloth.

2. Immediately dry the drive chain

and lubricate it to prevent it from rusting.

3. Use a chrome polish to shine

chrome, aluminum and stainless- steel parts, including the exhaust system. (Even the thermally indu- ced discoloring of stainless-steel exhaust systems can be removed through polishing.)

4. To prevent corrosion, it is recom-

mended to apply a corrosion pro- tection spray on all metal, inclu- ding chrome- and nickel-plated, surfaces. 7-2

5. Use spray oil as a universal clea-

ner to remove any remaining dirt.

6. Touch up minor paint damage

caused by stones, etc.

7. Wax all painted surfaces.

8. Let the motorcycle dry comple-

tely before storing or covering it. À WARNING e Make sure that there is no oil or wax on the brakes or tires. If necessary, clean the brake discs and brake linings with a regular brake disc cleaner or acetone, and wash the tires with warm water and a mild detergent. e Before operating the motorcy- cle test its braking performan- ce and cornering behavior. EWatoss0 ECA10800 CAUTION e Apply spray oil and wax spa- ringly and make sure to wipe off any excess.

e Never apply oil or wax to any rubber and plastic parts, but treat them with a suitable care product. e Avoid using abrasive polishing compounds as they will wear away the paint. NOTE: Consult a Yamaha dealer for advice on what products to use. EAUz6150 Storage Short-term Always store your motorcycle in a cool, dry place and, if necessary, pro- tect it against dust with a porous cover. CAUTION © Storing the motorcycle in a poorly ventilated room or cove- ring it with a tarp, while it is still wet, will allow water and humi- dity to seep in and cause rust. e To prevent corrosion, avoid damp cellars, stables (because of the presence of ammonia) Ecatosio and areas where strong chemi- cals are stored. Long-term Before storing your motorcycle for several months:

1. Follow all the instructions in the

“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”.

8. Drain the carburetor float cham-

ber by loosening the drain bolt; this will prevent fuel deposits from building up. Pour the drai- ned fuel into the fuel tank.

4. Fill up the fuel tank and add fuel

stabilizer (if available) to prevent the fuel tank from rusting and the fuel from deteriorating.

5. Perform the following steps to

protect the cylinder, piston rings, etc. from corrosion. a. Remove the spark plug cap and spark plug. b. Pour a teaspoonful of engine oil into the spark plug bore. 7-3 c. Install the spark plug cap onto the spark plug, and then place the spark plug on the cylinder head so that the electrodes are grounded. (This will limit sparking during the next step.) d. Turn the engine over several times with the starter. (This will coat the cylinder wall with oil.) e. Remove the spark plug cap from the spark plug, and then install the spark plug and the spark plug cap. WARNING To prevent damage or injury from sparking, make sure to ground the spark plug electrodes while turning the engine over. EWa10950

6. Lubricate all control cables and

the pivoting points of all levers and pedals as well as of the sidestand/centerstand.

7. Check and, if necessary, correct

the tire air pressure, and then lift the motorcycle so that both of its Wheels are off the ground. Alter- natively, turn the wheels a little every month in order to prevent

the tires from becoming degra- ded in one spot.

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 place and charge it once a month. Do not store the battery in an excessively cold or warm pla- ce [less than 0 °C (30 °F) or more than 30 °C (90 ‘F)]. For more information on storing the bat- tery, see page 6-19. NOTE: Make any necessary repairs before storing the motorcycle. 7-4

Engine Engine type Liquid cooled 2-stroke Cylinder arrangement Forward-inclined single cylinder Displacement

Starting system Electric starter Lubrication system EAU26339 Separate lubrication (Yamaha autolube) Transmission oil Oil change quantity 0.75L Coolant reservoir capacity (up to the maxi- mum level mark) 0.71L Radiator capacity (including all routes) 0.70L Air filter element Wet element Fuel Fuel tank capacity 138L Fuel reserve amount 22L Carburetor Manufacturer Dell'Orto Type x quantity PHBN 16 NS / 1 Spark plug (s) Manufacturer/model

Spark plug gap 0.6-0.7 mm Clutch type Wet, multiple-disc Transmission Primary reduction system Helical gear Primary reduction ratio 71 x 20 (3.550) Secondary reduction system Chain drive 8-1 Secondary reduction ratio 47 x 11 (4.270) Transmission type Constant mesh 6-speed Gear ratio 1st 36 x 12 (3.000) 2nd 33 x 16 (2.062) 3rd 29 x 19 (1.526) Ath 27 x 22 (1.227) Sth 25 x 24 (1.041) 6th 24 x 25 (0.960) Chassis Frame type Double cradie Caster angle

Front tire Type Tubeless Size 100/80-17 52H Manufacturer/model PIRELLI Rear tire Type Tubeless

Electrical system Ignition system DC. CDI Charging system CDI magneto Model YTAL-BS Voltage, capacity 12 V, 3.0 Ah Bulb type Incandescence 8-2 Bulb voltage, wattage x quantity Headlight 12 V, 25 W/25.0 W x2 Tail/brake light 12 V, 5.0 W/21.0 W x 1 Front turn signal light 12 V, 16.0 W Rear turn signal light 12V,10.0Wx2 Neutral indicator light LED Oil level warning light LED Turn signal indicator light LED Coolant temperature warning light LED Main fuse

Identification numbers Record the key identification number, vehicle identification number and model label information in the spaces provided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen. KEY IDENTIFICATION NUMBER: VEHICLE IDENTIFICATION NUMBER: MODEL LABEL INFORMATION:

The frame serial number is stamped into the steering head pipe. NOTE: The frame serial number is used to identify your motorcycle and may be used to register your motorcycle with the licensing authority in your area. 9-1

1. Key identification number

EaU26290 Key identification number The key identification number is stamped into the key.Record this number in the space provided and use it for reference when ordering a new key.

The model label is affixed to the frame under the seat. (See page 3-7.) Record the information on this label in the space provided. This information will be needed when ordering spare parts from a Yamaha dealer. 9-2

5WX-F8199-E1.qxd 14/12/2004 15:05 Pâgina 66 A E Replacing the fuse . Adjusting the brake pedal position and Engine break-in Replacing the headlight bulb. free play … Engine overheating Replacing the license plate light bulb. Adjusting the carburetor Adjusting the clucth lever free play Adjusting the engine idling speed Adjusting the rear brake light switch Adjusting the throttle cable free play.…

Battery. Brake lever. Brake pedal

Care. Cast wheels .. Catalytic converter Clucht lever Controls and instruments Changing the brake fluid. Checking and lubricating the brake and cluctch levers.. Checking and lubricating the brake and shift pedals . Checking and lubricating the cables Checking and lubricating the sidestand..6-18 Checking the brake fluid level Checking the front fork.. Checking the spark plug Checking the steering Checking the wheel bearings .

2-stroke engine oi Drive Chain slack

Frame serial number Front brake pads. Fuel cock Fuel tank cap

Parking Periodic maintenance and lubrication chart... Pre-operation check list.

Rear brake pads . Removing and installing cowlings Replacing a tu signal light bulb or the tai/brake light bulb... Right view … Seat. Shift pedal. Shifting Sidestand Speedometer unit Starter (choke) leve: Starting a cold engine: Storage... Storage compartment Supporting the mortorcycle

Tachometer Tips for reducing fuel consumption. Tires … To check the coolant level Transmission oi Troubleshooting Troubleshooting charts