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OWNER’S MANUAL

YBR125ED
3D9-F8199-EA
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U3D9EAE0.book Page 1 Thursday, December 28, 2006 10:35 AM

INTRODUCTION
EAU10100

Welcome to the Yamaha world of motorcycling!


As the owner of the YBR125ED, 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 YBR125ED. 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!
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IMPORTANT MANUAL INFORMATION


EAU10151

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


The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!

Failure to follow WARNING instructions could result in severe injury or death to the
WARNING motorcycle operator, a bystander, or a person inspecting or repairing the motor-
cycle.

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


CAUTION: the motorcycle.

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

NOTE:
● 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 dealer.
EWA10030

WARNING
PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE.
*Product and specifications are subject to change without notice.
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IMPORTANT MANUAL INFORMATION

EAU37230

YBR125ED
OWNER’S MANUAL
©2006 by Yamaha Motor Co., Ltd.
1st edition, December 2006
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in China.
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TABLE OF CONTENTS
SAFETY INFORMATION ..................1-1 PRE-OPERATION CHECKS ............. 4-1 Adjusting the clutch lever
Pre-operation check list .................. 4-2 free play .................................... 6-16
DESCRIPTION ..................................2-1 Checking the front brake lever
Left view ..........................................2-1 OPERATION AND free play .................................... 6-17
Right view ........................................2-2 IMPORTANT RIDING POINTS .......... 5-1 Adjusting the brake pedal
Controls and instruments.................2-3 Starting a cold engine .................... 5-1 free play .................................... 6-18
Starting a warm engine .................. 5-2 Adjusting the rear brake
INSTRUMENT AND Shifting ........................................... 5-2 light switch ................................ 6-18
CONTROL FUNCTIONS ....................3-1 Tips for reducing fuel Checking the front brake pads
Main switch/steering lock ................3-1 consumption ............................... 5-3 and rear brake shoes ............... 6-19
Indicator lights ................................3-2 Engine break-in .............................. 5-3 Checking the front brake
Speedometer unit ...........................3-2 Parking ........................................... 5-4 fluid level .................................. 6-20
Tachometer ....................................3-3 Changing the brake fluid .............. 6-21
Fuel gauge ......................................3-3 PERIODIC MAINTENANCE AND Drive chain slack .......................... 6-21
Handlebar switches ........................3-3 MINOR REPAIR ................................. 6-1 Cleaning and lubricating
Clutch lever .....................................3-4 Owner’s tool kit ............................... 6-1 the drive chain .......................... 6-22
Shift pedal .......................................3-4 Periodic maintenance and Checking and lubricating
Brake lever .....................................3-5 lubrication chart .......................... 6-2 the cables ................................. 6-23
Brake pedal ....................................3-5 Removing and installing panels ..... 6-6 Checking and lubricating
Fuel tank cap ..................................3-5 Checking the spark plug ................. 6-7 the throttle grip and cable ......... 6-23
Fuel .................................................3-6 Engine oil ....................................... 6-9 Checking and lubricating
Catalytic converter ..........................3-7 Cleaning the air filter element ...... 6-10 the brake and shift pedals ........ 6-24
Fuel cock ........................................3-7 Adjusting the carburetor ............... 6-12 Checking and lubricating
Starter (choke) lever ........................3-8 Adjusting the engine idling the brake and clutch levers ...... 6-24
Kickstarter .......................................3-9 speed ........................................ 6-12 Checking and lubricating the
Adjusting the shock absorber Adjusting the throttle cable centerstand and sidestand ....... 6-25
assemblies ..................................3-9 free play .................................... 6-13 Lubricating the swingarm
Carrier ...........................................3-10 Valve clearance ............................ 6-14 pivots ........................................ 6-25
Luggage strap holders ..................3-10 Tires ............................................. 6-14 Checking the front fork ................. 6-26
Sidestand ......................................3-10 Cast wheels .................................. 6-16 Checking the steering .................. 6-26
Ignition circuit cut-off system ........3-11 Checking the wheel bearings ....... 6-27
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TABLE OF CONTENTS
Battery ..........................................6-27
Replacing the fuse ........................6-29
Replacing the headlight bulb ........6-30
Replacing the tail/
brake light bulb ..........................6-32
Replacing a turn signal
light bulb ....................................6-32
Replacing the auxiliary
light bulb ....................................6-33
Front wheel ...................................6-33
Rear wheel ...................................6-35
Troubleshooting ............................6-37
Troubleshooting chart ...................6-38

MOTORCYCLE CARE AND


STORAGE ..........................................7-1
Matte color caution .........................7-1
Care ................................................7-1
Storage ...........................................7-3

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

CONSUMER INFORMATION.............9-1
Identification numbers ....................9-1
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SAFETY INFORMATION
EAU10251
AND/OR WHEN MADE NECES- • Ride where other motorists can
SARY BY MECHANICAL CONDI- see you. Avoid riding in another
MOTORCYCLES ARE SINGLE TIONS. motorist’s blind spot.
1 TRACK VEHICLES. THEIR SAFE USE ● Many motorcycle accidents in-
AND OPERATION ARE DEPENDENT Safe riding volve inexperienced operators. In
UPON THE USE OF PROPER RIDING ● Always make pre-operation fact, many operators who have
TECHNIQUES AS WELL AS THE EX- checks. Careful checks may help been involved in accidents do not
PERTISE OF THE OPERATOR. EV- prevent an accident. even have a current motorcycle li-
ERY OPERATOR SHOULD KNOW ● This motorcycle is designed to car- cense.
THE FOLLOWING REQUIREMENTS ry the operator and a passenger. • Make sure that you are qualified
BEFORE RIDING THIS MOTOR- ● The failure of motorists to detect and that you only lend your
CYCLE. and recognize motorcycles in traf- motorcycle to other qualified op-
HE OR SHE SHOULD: fic is the predominating cause of erators.
● OBTAIN THOROUGH INSTRUC- automobile/motorcycle accidents. • Know your skills and limits.
TIONS FROM A COMPETENT Many accidents have been caused Staying within your limits may
SOURCE ON ALL ASPECTS OF by an automobile driver who did help you to avoid an accident.
MOTORCYCLE OPERATION. not see the motorcycle. Making • We recommend that you prac-
● OBSERVE THE WARNINGS AND yourself conspicuous appears to tice riding your motorcycle
MAINTENANCE REQUIRE- be very effective in reducing the where there is no traffic until you
MENTS IN THE OWNER’S MAN- chance of this type of accident. have become thoroughly famil-
UAL. Therefore: iar with the motorcycle and all of
● OBTAIN QUALIFIED TRAINING • Wear a brightly colored jacket. its controls.
IN SAFE AND PROPER RIDING • Use extra caution when ap- ● Many motorcycle accidents have
TECHNIQUES. proaching and passing through been caused by error of the motor-
● OBTAIN PROFESSIONAL TECH- intersections, since intersec- cycle operator. A typical error
NICAL SERVICE AS INDICATED tions are the most likely places made by the operator is veering
BY THE OWNER’S MANUAL for motorcycle accidents to oc-
cur.

1-1
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SAFETY INFORMATION
wide on a turn due to EXCESSIVE ● This motorcycle is designed for on- cause burns. Always wear protec-
SPEED or undercornering (insuffi- road use only, therefore, it is not tive clothing that covers your legs,
cient lean angle for the speed). suitable for off-road use. ankles, and feet.
• Always obey the speed limit and ● Passengers should also observe 1
never travel faster than warrant- Protective apparel the precautions mentioned above.
ed by road and traffic conditions. The majority of fatalities from motor-
• Always signal before turning or cycle accidents are the result of head Modifications
changing lanes. Make sure that injuries. The use of a safety helmet is Modifications made to this motorcycle
other motorists can see you. the single most critical factor in the pre- not approved by Yamaha, or the re-
● The posture of the operator and vention or reduction of head injuries. moval of original equipment, may ren-
passenger is important for proper ● Always wear an approved helmet. der the motorcycle unsafe for use and
control. ● Wear a face shield or goggles. may cause severe personal injury.
• The operator should keep both Wind in your unprotected eyes Modifications may also make your
hands on the handlebar and could contribute to an impairment motorcycle illegal to use.
both feet on the operator foot- of vision which could delay seeing
rests during operation to main- a hazard. Loading and accessories
tain control of the motorcycle. ● The use of a jacket, heavy boots, Adding accessories or cargo to your
• The passenger should always trousers, gloves, etc., is effective in motorcycle can adversely affect stabili-
hold onto the operator, seat preventing or reducing abrasions ty and handling if the weight distribution
strap, or grab bar, if equipped, or lacerations. of the motorcycle is changed. To avoid
with both hands and keep both ● Never wear loose-fitting clothes, the possibility of an accident, use ex-
feet on the passenger footrests. otherwise they could catch on the treme caution when adding cargo or
• Never carry a passenger unless control levers, footrests, or wheels accessories to your motorcycle. Use
he or she can firmly place both and cause injury or an accident. extra care when riding a motorcycle
feet on the passenger footrests. ● Never touch the engine or exhaust that has added cargo or accessories.
● Never ride under the influence of system during or after operation. Here are some general guidelines to
alcohol or other drugs. They become very hot and can follow if loading cargo or adding acces-
sories to your motorcycle:

1-2
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SAFETY INFORMATION
Loading bags, duffel bags, or tents, can limit suspension travel, steering
The total weight of the operator, pas- create unstable handling or slow travel or control operation, or ob-
senger, accessories and cargo must steering response. scure lights or reflectors.
1 not exceed the maximum load limit. Accessories • Accessories fitted to the handle-
Genuine Yamaha accessories have bar or the front fork area can
Maximum load: been specifically designed for use on create instability due to improper
198 kg (437 lb) this motorcycle. Since Yamaha cannot weight distribution or aerody-
test all other accessories that may be namic changes. If accessories
When loading within this weight limit,
available, you must personally be re- are added to the handlebar or
keep the following in mind:
sponsible for the proper selection, in- front fork area, they must be as
● Cargo and accessory weight
stallation and use of non-Yamaha lightweight as possible and
should be kept as low and close to
accessories. Use extreme caution should be kept to a minimum.
the motorcycle as possible. Make
when selecting and installing any ac- • Bulky or large accessories may
sure to distribute the weight as
cessories. seriously affect the stability of
evenly as possible on both sides of
Keep the following guidelines in mind, the motorcycle due to aerody-
the motorcycle to minimize imbal-
as well as those provided under “Load- namic effects. Wind may at-
ance or instability.
ing” when mounting accessories. tempt to lift the motorcycle, or
● Shifting weights can create a sud-
● Never install accessories or carry the motorcycle may become un-
den imbalance. Make sure that ac-
cargo that would impair the perfor- stable in cross winds. These ac-
cessories and cargo are securely
mance of your motorcycle. Care- cessories may also cause
attached to the motorcycle before
fully inspect the accessory before instability when passing or being
riding. Check accessory mounts
using it to make sure that it does passed by large vehicles.
and cargo restraints frequently.
not in any way reduce ground • Certain accessories can dis-
● Never attach any large or heavy
clearance or cornering clearance, place the operator from his or
items to the handlebar, front fork,
her normal riding position. This
or front fender. These items, in-
improper position limits the free-
cluding such cargo as sleeping
dom of movement of the opera-

1-3
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SAFETY INFORMATION
tor and may limit control ability, ● Always turn the engine off before eyes, see your doctor immediately.
therefore, such accessories are leaving the motorcycle unattended If any gasoline spills on your skin
not recommended. and remove the key from the main or clothing, immediately wash the
● Use caution when adding electri- switch. When parking the motor- affected area with soap and water 1
cal accessories. If electrical acces- cycle, note the following: and change your clothes.
sories exceed the capacity of the • The engine and exhaust system
motorcycle’s electrical system, an may be hot, therefore, park the
electric failure could result, which motorcycle in a place where pe-
could cause a dangerous loss of destrians or children are not like-
lights or engine power. ly to touch these hot areas.
• Do not park the motorcycle on a
Gasoline and exhaust gas slope or soft ground, otherwise it
● GASOLINE IS HIGHLY FLAMMA- may fall over.
BLE: • Do not park the motorcycle near
• Always turn the engine off when a flammable source (e.g. a kero-
refueling. sene heater, or near an open
• Take care not to spill any gaso- flame), otherwise it could catch
line on the engine or exhaust fire.
system when refueling. ● When transporting the motorcycle
• Never refuel while smoking or in in another vehicle, make sure that
the vicinity of an open flame. it is kept upright and that the fuel
● Never start the engine or let it run cock is turned to “ON” or “RES” (for
for any length of time in a closed vacuum type) / “OFF” (for manual
area. The exhaust fumes are poi- type). If it should lean over, gaso-
sonous and may cause loss of line may leak out of the carburetor
consciousness and death within a or fuel tank.
short time. Always operate your ● If you should swallow any gaso-
motorcycle in an area that has ad- line, inhale a lot of gasoline vapor,
equate ventilation. or allow gasoline to get into your
1-4
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DESCRIPTION
EAU10410

Left view

1. Headlight (page 6-30) 9. Shift pedal (page 3-4)


2. Fuel cock (page 3-7)
3. Fuse (page 6-29)
4. Battery (page 6-27)
5. Owner’s tool kit (page 6-1)
6. Luggage strap holder (page 3-10)
7. Shock absorber assembly spring preload adjusting ring (page 3-9)
8. Engine oil drain bolt (page 6-9)

2-1
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DESCRIPTION
EAU10420

Right view

1. Carrier (page 3-10)


2. Air filter element (page 6-10)
3. Engine oil filler cap (page 6-9)
4. Brake pedal (page 3-5)
5. Kickstarter (page 3-9)
6. Shock absorber assembly spring preload adjusting ring (page 3-9)
7. Luggage strap holder (page 3-10)

2-2
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DESCRIPTION
EAU10430

Controls and instruments

1. Clutch lever (page 3-4) 9. Throttle grip (page 6-13)


2. Left handlebar switches (page 3-3) 10.Fuel tank cap (page 3-5)
3. Main switch/steering lock (page 3-1)
4. Speedometer (page 3-2)
5. Fuel gauge (page 3-3)
6. Tachometer (page 3-3)
7. Right handlebar switch (page 3-3)
8. Brake lever (page 3-5)

2-3
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INSTRUMENT AND CONTROL FUNCTIONS


EAU10460 EAU10660
To unlock the steering
Main switch/steering lock OFF
All electrical systems are off. The key
can be removed.

EAU43140
LOCK
The steering is locked, and all electrical
systems are off. The key can be re-
moved. 3

To lock the steering 1. Turn.


The main switch/steering lock controls Insert the key and turn it to “OFF”.
the ignition and lighting systems, and is EWA10060

used to lock the steering. The various WARNING


positions are described below.
Never turn the key to “OFF” or
EAU33590
“LOCK” while the vehicle is moving,
ON otherwise the electrical systems will
All electrical circuits are supplied with be switched off, which may result in
power; the meter lighting, taillight and loss of control or an accident. Make
auxiliary light come on, and the engine sure that the vehicle is stopped be-
1. Push.
can be started. The key cannot be re- 2. Turn.
fore turning the key to “OFF” or
moved. “LOCK”.
1. Turn the handlebars all the way to
NOTE: the left.
The headlight comes on automatically 2. Push the key in from the “OFF” po-
when the engine is started and stays on sition, and then turn it to “LOCK”
until the key is turned to “OFF”, even if while still pushing it.
the engine stalls. 3. Remove the key.
3-1
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INSTRUMENT AND CONTROL FUNCTIONS


EAU10980 EAU11080 EAU11630

Indicator lights High beam indicator light “ ” Speedometer unit


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

1. Left turn signal indicator light “ ” 1. Speedometer


2. Neutral indicator light “ ” 2. Odometer
3. High beam indicator light “ ” 3. Tripmeter
4. Right turn signal indicator light “ ” 4. Tripmeter reset knob

EAU11030
The speedometer unit is equipped with
Turn signal indicator lights “ ” and a speedometer, an odometer and a
“ ” tripmeter. The speedometer shows
The corresponding indicator light flash- riding speed. The odometer shows the
es when the turn signal switch is total distance traveled. The tripmeter
pushed to the left or right. shows the distance traveled since it
was last set to zero with the reset knob.
EAU11060
The tripmeter can be used to estimate
Neutral indicator light “ ”
the distance that can be traveled with a
This indicator light comes on when the
full tank of fuel. This information will en-
transmission is in the neutral position.
able you to plan future fuel stops.

3-2
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INSTRUMENT AND CONTROL FUNCTIONS


EAU11851 EAU37051 EAU12347

Tachometer Fuel gauge Handlebar switches


Left

1. Tachometer 1. Fuel gauge


2. Tachometer red zone 2. Red zone 1. Dimmer switch “ / ”
2. Turn signal switch “ / ”
The electric tachometer allows the rider The fuel gauge indicates the amount of
3. Horn switch “ ”
to monitor the engine speed and keep it fuel in the fuel tank. The needle moves
within the ideal power range. towards “E” (Empty) as the fuel level Right
ECA10031
decreases. When the needle reaches
CAUTION: the red zone, approximately 1.7 L (0.45
Do not operate the engine in the ta- US gal) (0.37 Imp.gal) remain in the
chometer red zone. fuel tank. If this occurs, refuel as soon
Red zone: 10000 r/min and above as possible.
NOTE:
● Do not allow the fuel tank to empty
itself completely.
● The main switch must be turned to
1. Start switch “ ”
“ON” for the fuel gauge to display
an accurate fuel level reading.

3-3
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INSTRUMENT AND CONTROL FUNCTIONS


EAU12400 EAU12820 EAU12870
Dimmer switch “ / ” Clutch lever Shift pedal
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
switch to “ ”. To signal a left-hand
3 turn, push this switch to “ ”. When re-
leased, the switch returns to the center
position. To cancel the turn signal
lights, push the switch in after it has re- 1. Clutch lever 1. Shift pedal
turned to the center position.
The clutch lever is located at the left The shift pedal is located on the left
EAU12500
handlebar grip. To disengage the side of the engine and is used in com-
Horn switch “ ” clutch, pull the lever toward the handle- bination with the clutch lever when
Press this switch to sound the horn. bar grip. To engage the clutch, release shifting the gears of the 5-speed con-
the lever. The lever should be pulled stant-mesh transmission equipped on
EAU12710
rapidly and released slowly for smooth this motorcycle.
Start switch “ ”
clutch operation.
Push this switch to crank the engine
The clutch lever is equipped with a
with the starter.
ECA10050
clutch switch, which is part of the igni-
CAUTION: tion circuit cut-off system. (See page
3-11.)
See page 5-1 for starting instruc-
tions prior to starting the engine.

3-4
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INSTRUMENT AND CONTROL FUNCTIONS


EAU12890 EAU12941 EAU13001

Brake lever Brake pedal Fuel tank cap

1. Brake lever 1. Brake pedal 1. Unlock.

The brake lever is located at the right The brake pedal is on the right side of
To remove the fuel tank cap
handlebar grip. To apply the front the motorcycle. To apply the rear
Insert the key into the lock and turn it
brake, pull the lever toward the handle- brake, press down on the brake pedal.
1/4 turn clockwise. The lock will be re-
bar grip.
leased and the fuel tank cap can be re-
moved.

To install the fuel tank cap


1. Push the fuel tank cap into position
with the key inserted in the lock.
2. Turn the key counterclockwise to
the original position, and then re-
move it.

3-5
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INSTRUMENT AND CONTROL FUNCTIONS


EAU13220 ECA10070
NOTE: Fuel CAUTION:
The fuel tank cap cannot be installed
Immediately wipe off spilled fuel
unless the key is in the lock. In addition,
with a clean, dry, soft cloth, since
the key cannot be removed if the cap is
fuel may deteriorate painted surfac-
not properly installed and locked.
es or plastic parts.
EWA11140

WARNING EAU13320
3 Make sure that the fuel tank cap is
properly installed before riding.
Recommended fuel:
1. Fuel tank filler tube REGULAR UNLEADED GASOLINE
ONLY
2. Fuel level
Fuel tank capacity:
Make sure that there is sufficient fuel in 12.0 L (3.17 US gal) (2.64 Imp.gal)
Fuel reserve amount:
the tank. When refueling, be sure to in- 1.7 L (0.45 US gal) (0.37 Imp.gal)
sert the pump nozzle into the fuel tank
filler hole and to fill the tank to the bot- ECA11400

tom of the filler tube as shown. CAUTION:


EWA10880
Use only unleaded gasoline. The use
WARNING
of leaded gasoline will cause severe
● Do not overfill the fuel tank, oth- damage to internal engine parts,
erwise it may overflow when the such as the valves and piston rings,
fuel warms up and expands. as well as to the exhaust system.
● Avoid spilling fuel on the hot en-
gine. Your Yamaha engine has been de-
signed to use regular unleaded gaso-
line with a research octane number of
91 or higher. If knocking (or pinging) oc-
curs, use a gasoline of a different brand
3-6
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INSTRUMENT AND CONTROL FUNCTIONS


or premium unleaded fuel. Use of un- EAU13431 EAU37210

leaded fuel will extend spark plug life Catalytic converter Fuel cock
and reduce maintenance costs. This model is equipped with a catalytic The fuel cock supplies fuel from the
converter in the exhaust system. tank to the carburetor while filtering it al-
EWA10860
so.
WARNING
NOTE:
The exhaust system is hot after op-
Depending on the model, the positions
eration. Make sure that the exhaust
indicated on the fuel cock differ as
system has cooled down before do- 3
shown in the following illustrations.
ing any maintenance work.
ECA10700 The fuel cock has three positions:
CAUTION:
“OFF” or “ ”
The following precautions must be
observed to prevent a fire hazard or
other damages.
● Use only unleaded gasoline.
The use of leaded gasoline will
cause unrepairable damage to
the catalytic converter.
● Never park the vehicle near pos-
sible fire hazards such as grass
or other materials that easily
burn. 1. Arrow mark pointing to “OFF” or “ ”
● Do not allow the engine to idle
With the lever in this position, fuel will
too long. not flow. Always return the lever to this
position when the engine is not running.

3-7
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INSTRUMENT AND CONTROL FUNCTIONS


“ON” or “ ” This indicates reserve. If you run out of EAU13590

fuel while riding, move the lever to this Starter (choke) lever “ ”
position. Fill the tank at the first oppor-
tunity. Be sure to set the lever back to
“ON” or “ ” after refueling!

1. Arrow mark pointing to “ON” or “ ”


1. Starter (choke) lever “ ”
With the lever in this position, fuel flows
to the carburetor. Normal riding is done Starting a cold engine requires a richer
with the lever in this position. air-fuel mixture, which is supplied by
the starter (choke).
“RES” or “ ” Move the lever in direction (a) to turn on
the starter (choke).
Move the lever in direction (b) to turn off
the starter (choke).

1. Arrow mark pointing to “RES” or “ ”

3-8
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INSTRUMENT AND CONTROL FUNCTIONS


EAU43150 EAU14880 EWA10210

Kickstarter Adjusting the shock absorber WARNING


assemblies Always adjust both shock absorber
assemblies equally, otherwise poor
handling and loss of stability may
result.
Adjust the spring preload as follows.
To increase the spring preload and 3
thereby harden the suspension, turn
the adjusting ring on each shock ab-
sorber assembly in direction (a). To de-
1. Kickstarter
crease the spring preload and thereby
1. Spring preload adjusting ring soften the suspension, turn the adjust-
If the engine fails to start by pushing the
2. Position indicator
start switch, try to start it by using the ing ring on each shock absorber as-
kickstarter. To start the engine, fold out Each shock absorber assembly is sembly in direction (b).
the kickstarter lever, move it down light- equipped with a spring preload adjust- NOTE:
ly with your foot until the gears engage, ing ring. Align the appropriate notch in the ad-
and then push it down smoothly but ECA10100

CAUTION: justing ring with the position indicator


forcefully. This model is equipped with
on the shock absorber.
a primary kickstarter, allowing the en- Never attempt to turn an adjusting
gine to be started in any gear if the mechanism beyond the maximum or
clutch is disengaged and the sidestand minimum settings. Spring preload setting:
is up. However, shifting the transmis- Minimum (soft):
1
sion into the neutral position before Standard:
starting is recommended. 2
Maximum (hard):
5

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INSTRUMENT AND CONTROL FUNCTIONS


EAU15110 EAU15190 EAU15301

Carrier Luggage strap holders Sidestand


The sidestand is located on the left side
of the frame. Raise the sidestand or
lower it with your foot while holding the
vehicle upright.
NOTE:
The built-in sidestand switch is part of
3
the ignition circuit cut-off system, which
cuts the ignition in certain situations.
(See further down for an explanation of
1. Carrier 1. Luggage strap holder the ignition circuit cut-off system.)
EWA10170
There are four luggage strap holders EWA10240

WARNING below the rear of the seat. WARNING


● Do not exceed the load limit of 3 The vehicle must not be ridden with
kg (6.6 lb) for the carrier. the sidestand down, or if the side-
● Do not exceed the maximum stand cannot be properly moved up
load of 198 kg (437 lb) for the ve- (or does not stay up), otherwise the
hicle. sidestand could contact the ground
and distract the operator, resulting
in a possible loss of control.
Yamaha’s ignition circuit cut-off
system has been designed to assist
the operator in fulfilling the respon-
sibility of raising the sidestand be-
fore starting off. Therefore, check
this system regularly as described

3-10
U3D9EAE0.book Page 11 Thursday, December 28, 2006 10:35 AM

INSTRUMENT AND CONTROL FUNCTIONS


below and have a Yamaha dealer re- EAU43160

pair it if it does not function proper- Ignition circuit cut-off system


ly. The ignition circuit cut-off system (com-
prising the sidestand switch, clutch
switch and neutral switch) has the fol-
lowing functions.
● It prevents starting when the trans-
mission is in gear and the side-
stand is up, but the clutch lever is 3
not pulled.
● It prevents starting when the trans-
mission is in gear and the clutch le-
ver is pulled, but the sidestand is
still down.
● It cuts the running engine when the
transmission is in gear and the sid-
estand is moved down.
Periodically check the operation of the
ignition circuit cut-off system according
to the following procedure.
EWA10260

WARNING
● The vehicle must be placed on
the centerstand during this in-
spection.
● If a malfunction is noted, have a
Yamaha dealer check the sys-
tem before riding.

3-11
U3D9EAE0.book Page 12 Thursday, December 28, 2006 10:35 AM

INSTRUMENT AND CONTROL FUNCTIONS

With the engine turned off:


NOTE:
1. Move the sidestand down.
2. Turn the key on.
This check is most reliable if performed with
3. Shift the transmission into the neutral position. a warmed-up engine.
4. Push the start switch or push the kickstarter lever down.
Does the engine start?
The neutral switch may be defective.
3 YES NO The motorcycle should not be ridden until
checked by a Yamaha dealer.
With the engine still running:
5. Move the sidestand up.
6. Keep the clutch lever pulled.
7. Shift the transmission into gear.
8. Move the sidestand down.
Does the engine stall?
The sidestand switch may be defective.
YES NO The motorcycle should not be ridden until
checked by a Yamaha dealer.
After the engine has stalled:
9. Move the sidestand up.
10. Keep the clutch lever pulled.
11. Push the start switch or push the kickstarter lever down.
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.

3-12
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PRE-OPERATION CHECKS
EAU15592

The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly,
even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss
of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thorough visual inspec-
tion, to check the following points before each ride.
NOTE:
Pre-operation checks should be made each time the vehicle is used. Such an inspection can be accomplished in a very short
time; and the added safety it assures is more than worth the time involved.
EWA11150
4
WARNING
If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operating
the vehicle.

4-1
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PRE-OPERATION CHECKS
EAU15605

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. 6-9
• Check vehicle for oil leakage.
• Check operation.
• If soft or spongy, have Yamaha dealer bleed hydraulic system.
4 • Check brake pads for wear.
Front brake • Replace if necessary. 6-19, 6-20
• 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. 6-18, 6-19
• Adjust if necessary.
• Check operation.
• Lubricate cable if necessary.
Clutch 6-16
• Check lever free play.
• Adjust if necessary.
• Make sure that operation is smooth.
• Check cable free play.
Throttle grip 6-13, 6-23
• If necessary, have Yamaha dealer adjust cable free play and lubricate cable and
grip housing.
• Make sure that operation is smooth.
Control cables 6-23
• Lubricate if necessary.
• Check chain slack.
• Adjust if necessary.
Drive chain 6-21, 6-22
• Check chain condition.
• Lubricate if necessary.
4-2
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PRE-OPERATION CHECKS
ITEM CHECKS PAGE

• Check for damage.


• Check tire condition and tread depth.
Wheels and tires 6-14, 6-16
• Check air pressure.
• Correct if necessary.
• Make sure that operation is smooth.
Brake and shift pedals 6-24
• Lubricate pedal pivoting points if necessary.
• Make sure that operation is smooth.
Brake and clutch levers 6-24
• Lubricate lever pivoting points if necessary.
• Make sure that operation is smooth.
Centerstand, sidestand 6-25
• 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 operation of ignition circuit cut-off system.
Sidestand switch 3-10
• If system is defective, have Yamaha dealer check vehicle.
• Check fluid level.
Battery 6-27
• Fill with distilled water if necessary.

4-3
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OPERATION AND IMPORTANT RIDING POINTS


EAU15950 EAU43470

Starting a cold engine NOTE:


EWA10270
In order for the ignition circuit cut-off When the transmission is in the neutral
WARNING system to enable starting, one of the position, the neutral indicator light
● Become thoroughly familiar following conditions must be met: should be on, otherwise have a
with all operating controls and ● The transmission is in the neutral Yamaha dealer check the electrical cir-
their functions before riding. position. cuit.
Consult a Yamaha dealer re- ● The transmission is in gear with
4. Turn the starter (choke) on and
garding any control or function the clutch lever pulled and the sid- completely close the throttle. (See
that you do not thoroughly un- estand up. page 3-8.)
derstand. EWA10290
5. Start the engine by pushing the
● Never start the engine or oper- WARNING
start switch or by pushing the kick-
ate it in a closed area for any ● Before starting the engine,
5 starter lever down.
length of time. Exhaust fumes check the function of the igni-
are poisonous, and inhaling tion circuit cut-off system ac- NOTE:
them can cause loss of con- cording to the procedure If the engine fails to start when using
sciousness and death within a described on page 3-11. the start switch, release it, wait a few
short time. Always make sure ● Never ride with the sidestand seconds, and then try again. Each
that there is adequate ventila- down. starting attempt should be as short as
tion. possible to preserve the battery. Do not
1. Turn the fuel cock lever to “ON” or
● Before starting out, make sure crank the engine more than 10 seconds
“ ”.
that the sidestand is up. If the on any one attempt. If the engine does
2. Turn the key to “ON”.
sidestand is not raised com- not start with the starter motor, try using
3. Shift the transmission into the neu-
pletely, it could contact the the kickstarter.
tral position.
ground and distract the opera-
tor, resulting in a possible loss
of control.

5-1
U3D9EAE0.book Page 2 Thursday, December 28, 2006 10:35 AM

OPERATION AND IMPORTANT RIDING POINTS


ECA11040 EAU16640 EAU16671

CAUTION: Starting a warm engine Shifting


For maximum engine life, never ac- Follow the same procedure as for start-
celerate hard when the engine is ing a cold engine with the exception
cold! that the starter (choke) is not required
when the engine is warm.
6. 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. 1. Shift pedal
2. Neutral position
5
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 il-
lustration.
NOTE:
To shift the transmission into the neu-
tral position, press the shift pedal down
repeatedly until it reaches the end of its
travel, and then slightly raise it.

5-2
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OPERATION AND IMPORTANT RIDING POINTS


ECA10260 EAU16800 EAU16830

CAUTION: Tips for reducing fuel con- Engine break-in


● Even with the transmission in sumption There is never a more important period
the neutral position, do not Fuel consumption depends largely on in the life of your engine than the period
coast for long periods of time your riding style. Consider the following between 0 and 1000 km (600 mi). For
with the engine off, and do not tips to reduce fuel consumption: this reason, you should read the follow-
tow the motorcycle for long dis- ● Turn the starter (choke) off as ing material carefully.
tances. The transmission is soon as possible. Since the engine is brand new, do not
properly lubricated only when ● Shift up swiftly, and avoid high en- put an excessive load on it for the first
the engine is running. Inade- gine speeds during acceleration. 1000 km (600 mi). The various parts in
quate lubrication may damage ● Do not rev the engine while shifting the engine wear and polish themselves
the transmission. down, and avoid high engine to the correct operating clearances.
● Always use the clutch while speeds with no load on the engine. During this period, prolonged full-throt-
5 tle operation or any condition that might
changing gears to avoid damag- ● Turn the engine off instead of let-
ing the engine, transmission, ting it idle for an extended length of result in engine overheating must be
and drive train, which are not time (e.g., in traffic jams, at traffic avoided.
designed to withstand the lights or at railroad crossings).
EAU37250
shock of forced shifting.
0–500 km (0–300 mi)
Avoid prolonged operation above 6000
r/min.
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.

5-3
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OPERATION AND IMPORTANT RIDING POINTS


500–1000 km (300–600 mi) EAU37200

Avoid prolonged operation above 7500 Parking


r/min. When parking, stop the engine, remove
Rev the engine freely through the the key from the main switch, and then
gears, but do not use full throttle at any turn the fuel cock lever to “OFF” or “ ”.
EWA10310
time.
ECA10280
WARNING
CAUTION: ● Since the engine and exhaust
After 1000 km (600 mi) of operation, system can become very hot,
the engine oil must be changed. park in a place where pedestri-
ans or children are not likely to
1000 km (600 mi) and beyond touch them.
The vehicle can now be operated nor- ● Do not park on a slope or on soft
mally. ground, otherwise the vehicle 5
ECA10310
may overturn.
CAUTION:
ECA10380
● Keep the engine speed out of CAUTION:
the tachometer red zone.
● If any engine trouble should oc- Never park in an area where there
cur during the engine break-in are fire hazards such as grass or
period, immediately have a other flammable materials.
Yamaha dealer check the vehi-
cle.

5-4
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PERIODIC MAINTENANCE AND MINOR REPAIR


EAU17240 EAU17340 EWA10350

Owner’s tool kit WARNING


Safety is an obligation of the owner. Pe- Modifications not approved by
riodic inspection, adjustment and lubri- Yamaha may cause loss of perfor-
cation will keep your vehicle in the mance and render the vehicle un-
safest and most efficient condition pos- safe for use. Consult a Yamaha
sible. The most important points of in- dealer before attempting any chang-
spection, adjustment, and lubrication es.
are explained on the following pages.
The intervals given in the periodic
maintenance and lubrication chart
should be simply considered as a gen- 1. Owner’s tool kit
eral guide under normal riding condi-
tions. However, DEPENDING ON THE The owner’s tool kit is located behind
WEATHER, TERRAIN, GEOGRAPHI- panel B. (See page 6-6.)
6 CAL LOCATION, AND INDIVIDUAL The service information included in this
USE, THE MAINTENANCE INTER- manual and the tools provided in the
VALS MAY NEED TO BE SHORT- owner’s tool kit are intended to assist
ENED. you in the performance of preventive
EWA10320 maintenance and minor repairs. How-
WARNING ever, additional tools such as a torque
If you are not familiar with mainte- wrench may be necessary to perform
nance work, have a Yamaha dealer certain maintenance work correctly.
do it for you. NOTE:
If you do not have the tools or experi-
ence required for a particular job, have
a Yamaha dealer perform it for you.

6-1
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PERIODIC MAINTENANCE AND MINOR REPAIR


EAU17711

Periodic maintenance and lubrication chart


NOTE:
● The annual checks must be performed every year, except if a kilometer-based maintenance is performed in-
stead.
● From 30000 km, repeat the maintenance intervals starting from 6000 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
1 6 12 18 24 CHECK

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


2 * Fuel cock filter • Check condition. √ √
• Check condition.
√ √
3 Spark plug • Clean and regap. 6
• Replace. √ √
• Check valve clearance.
4 * Valves √ √ √ √
• Adjust.
• Clean. √ √
5 Air filter element
• Replace. √ √
• Check electrolyte level and specific gravity.
6 * Battery √ √ √ √ √
• Make sure that the breather hose is properly routed.
• Check operation.
7 Clutch √ √ √ √ √
• Adjust.
• Check operation, fluid level and vehicle for fluid leakage. √ √ √ √ √ √
8 * Front brake
• Replace brake pads. Whenever worn to the limit

6-2
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PERIODIC MAINTENANCE AND MINOR REPAIR


ODOMETER READING (× 1000 km) ANNUAL
NO. ITEM CHECK OR MAINTENANCE JOB
1 6 12 18 24 CHECK

• Check operation and adjust brake pedal free play. √ √ √ √ √ √


9 * Rear brake
• Replace brake shoes. Whenever worn to the limit
• Check for cracks or damage. √ √ √ √ √
10 * Brake hose
• Replace. Every 4 years
11 * Wheels • Check runout and for damage. √ √ √ √
• Check tread depth and for damage.
• Replace if necessary.
12 * Tires √ √ √ √ √
• Check air pressure.
• Correct if necessary.
13 * Wheel bearings • Check bearing for looseness or damage. √ √ √ √
• Check bush assemblies for looseness. √ √ √ √
14 * Swingarm pivot bushes
• Lubricate with lithium-soap-based grease. Every 50000 km
6
• Check chain slack, alignment and condition.
Every 1000 km and after washing the motorcycle or
15 Drive chain • Adjust and lubricate chain with a special O-ring chain lu-
riding in the rain
bricant thoroughly.
• Check bearing play and steering for roughness. √ √ √ √ √
16 * Steering bearings
• Lubricate with lithium-soap-based grease. Every 24000 km
• Make sure that all nuts, bolts and screws are properly
17 * Chassis fasteners √ √ √ √ √
tightened.
Brake and clutch lever
18 • Lubricate with lithium-soap-based grease. √ √ √ √ √
pivot shafts
Brake and shift pedal
19 • Lubricate with lithium-soap-based grease. √ √ √ √ √
pivot shafts
• Check operation.
20 Sidestand, centerstand √ √ √ √ √
• Lubricate.

6-3
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PERIODIC MAINTENANCE AND MINOR REPAIR


ODOMETER READING (× 1000 km) ANNUAL
NO. ITEM CHECK OR MAINTENANCE JOB
1 6 12 18 24 CHECK

21 * Sidestand switch • Check operation. √ √ √ √ √ √


22 * Front fork • Check operation and for oil leakage. √ √ √ √
Shock absorber assem-
23 * • Check operation and shock absorbers for oil leakage. √ √ √ √
blies
• Check starter (choke) operation.
24 * Carburetor √ √ √ √ √ √
• Adjust engine idling speed.
• Change.
25 Engine oil √ √ √ √ √ √
• Check oil level and vehicle for oil leakage.
Front and rear brake
26 * • Check operation. √ √ √ √ √ √
switches
Moving parts and ca-
27 • Lubricate. √ √ √ √ √
bles

Throttle grip housing


• Check operation and free play. 6
28 * • 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-
29 * Air induction system age. √ √ √ √ √
• Replace any damaged parts if necessary.
Lights, signals and • Check operation.
30 * √ √ √ √ √ √
switches • Adjust headlight beam.

EAU18660

NOTE:
● 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.
6-4
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PERIODIC MAINTENANCE AND MINOR REPAIR


• 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.

6-5
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PERIODIC MAINTENANCE AND MINOR REPAIR


EAU18771
2. Pull the front of the panel out, and
Removing and installing pan- then slide the panel forward to re-
els lease it in the rear.
The panels shown need to be removed
to perform some of the maintenance
jobs described in this chapter. Refer to
this section each time a panel needs to
be removed and installed.

1. Panel B

EAU37070
Panel A
To install the panel
To remove the panel
1. Secure the rear of the panel, and
1. Remove the screw. 6
then push the front of the panel in.

1. Panel A

1. Screw
2. Install the screw.

6-6
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PERIODIC MAINTENANCE AND MINOR REPAIR


EAU36961 EAU19603
Panel B Checking the spark plug
The spark plug is an important engine
To remove the panel component, which is easy to check.
1. Slide the panel lock cover open, in- Since heat and deposits will cause any
sert the key into the lock, and then spark plug to slowly erode, the spark
turn it 1/4 turn clockwise. plug should be removed and checked
in accordance with the periodic mainte-
nance and lubrication chart. In addition,
the condition of the spark plug can re-
veal the condition of the engine.
To install the panel
1. Secure the rear of the panel, and
To remove the spark plug
then push the front of the panel in
1. Remove the spark plug cap.
with the key inserted in the lock.
6
1. Panel lock cover
2. Unlock.

2. Pull the front of the panel out with


the key inserted in the lock, and
then slide the panel forward to re-
lease it in the rear.

1. Spark plug cap


2. While pushing the panel inward,
2. Remove the spark plug as shown,
turn the key counterclockwise to
with the spark plug wrench includ-
the original position, remove it, and
ed in the owner’s tool kit.
then close the panel lock cover.

6-7
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PERIODIC MAINTENANCE AND MINOR REPAIR


2. Check the spark plug for electrode 2. Clean the surface of the spark plug
erosion and excessive carbon or gasket and its mating surface, and
other deposits, and replace it if then wipe off any grime from the
necessary. spark plug threads.
3. Install the spark plug with the
Specified spark plug: spark plug wrench, and then tight-
NGK/CR6HSA en it to the specified torque.

To install the spark plug Tightening torque:


1. Measure the spark plug gap with a Spark plug:
1. Spark plug wrench 12.5 Nm (1.25 m·kgf, 9.0 ft·lbf)
wire thickness gauge and, if nec-
To check the spark plug essary, adjust the gap to specifica-
tion. NOTE:
1. Check that the porcelain insulator
If a torque wrench is not available when
around the center electrode of the
installing a spark plug, a good estimate
spark plug is a medium-to-light tan 6
of the correct torque is 1/4–1/2 turn
(the ideal color when the vehicle is
past finger tight. However, the spark
ridden normally).
plug should be tightened to the speci-
NOTE: fied torque as soon as possible.
If the spark plug shows a distinctly dif-
4. Install the spark plug cap.
ferent color, the engine could be oper-
ating improperly. Do not attempt to
diagnose such problems yourself. In-
1. Spark plug gap
stead, have a Yamaha dealer check
the vehicle. Spark plug gap:
0.6–0.7 mm (0.024–0.028 in)

6-8
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PERIODIC MAINTENANCE AND MINOR REPAIR


EAU37170
4. If the engine oil is at or below the
Engine oil minimum level mark, add sufficient
The engine oil level should be checked oil of the recommended type to
before each ride. In addition, the oil raise it to the correct level.
must be changed at the intervals spec- 5. Insert the dipstick into the oil filler
ified in the periodic maintenance and hole, and then tighten the oil filler
lubrication chart. cap.

To check the engine oil level To change the engine oil


1. Place the vehicle on the center- 1. Start the engine, warm it up for
1. Engine oil filler cap
stand. several minutes, and then turn it
NOTE: NOTE: off.
Make sure that the vehicle is positioned The engine oil should be between the 2. Place an oil pan under the engine
straight up when checking the oil level. minimum and maximum level marks. to collect the used oil.
A slight tilt to the side can result in a 3. Remove the engine oil filler cap
6 and drain bolt to drain the oil from
false reading.
the crankcase.
2. Start the engine, warm it up for
several minutes, and then turn it
off.
3. Wait a few minutes until the oil set-
tles, remove the oil filler cap, wipe
the dipstick clean, insert it back
into the oil filler hole (without
screwing it in), and then remove it
1. Dipstick
again to check the oil level. 2. Maximum level mark
3. Minimum level mark 1. Engine oil drain bolt
2. Oil pan

6-9
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PERIODIC MAINTENANCE AND MINOR REPAIR


4. Install the engine oil drain bolt, and ● Make sure that no foreign mate- EAU37121

then tighten it to the specified rial enters the crankcase. Cleaning the air filter element
torque. The air filter element should be cleaned
6. Start the engine, and then let it idle at the intervals specified in the periodic
for several minutes while checking maintenance and lubrication chart.
Tightening torque:
Engine oil drain bolt: it for oil leakage. If oil is leaking, im- Clean the air filter element more fre-
20 Nm (2.0 m·kgf, 14 ft·lbf) mediately turn the engine off and quently if you are riding in unusually
check for the cause. wet or dusty areas.
5. Add the specified amount of the 7. Turn the engine off, and then 1. Remove panel A. (See page 6-6.)
recommended engine oil, and then check the oil level and correct it if 2. Remove the air filter case cover by
install and tighten the engine oil fill- necessary. removing the screws.
er cap.

Recommended engine oil:


See page 8-1.
Oil change quantity:
1.00 L (1.06 US qt) (0.88 Imp.qt) 6
ECA11620

CAUTION:
● In order to prevent clutch slip-
page (since the engine oil also
1. Screw
lubricates the clutch), do not 2. Air filter case cover
mix any chemical additives. Do
not use oils with a diesel speci- 3. Remove the air filter element.
fication of “CD” or oils of a high-
er quality than specified. In
addition, do not use oils labeled
“ENERGY CONSERVING II” or
higher.
6-10
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PERIODIC MAINTENANCE AND MINOR REPAIR


EWA10430

WARNING
Use only a dedicated parts cleaning
solvent. To avoid the risk of fire or
explosion, do not use gasoline or
solvents with a low flash point.
ECA15100

CAUTION:
To avoid damaging the sponge ma-
1. Sponge material 1. Air filter element terial, handle it gently and carefully,
2. Air filter element and do not twist it.
6. Clean the sponge material with
4. Remove the sponge material from solvent, then squeeze the remain- 7. Install the sponge material into the
the air filter element. ing solvent out, and be sure to let air filter element, and then install
5. Lightly tap the air filter element to the sponge material dry before in- the air filter element into the air fil-
6 remove most of the dust and dirt, stalling it into the air filter element. ter case.
and then blow the remaining dirt If the sponge material is damaged, ECA10480

out with compressed air on the replace it. CAUTION:


mesh side as shown. If the air filter ● Make sure that the air filter ele-
element is damaged, replace it. ment is properly seated in the
air filter case.
● The engine should never be op-
erated without the air filter ele-
ment installed, otherwise the
piston(s) and/or cylinder(s) may
become excessively worn.
8. Install the air filter case cover by in-
stalling the screws.

6-11
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PERIODIC MAINTENANCE AND MINOR REPAIR


9. Check the hose at the bottom of EAU21280 EAU21320

the air filter case for accumulated Adjusting the carburetor Adjusting the engine idling
dust or water, and if necessary, The carburetor is an important part of speed
drain it by removing the clamp, and the engine and requires very sophisti- The engine idling speed must be
then removing the plug. cated adjustment. Therefore, most car- checked and, if necessary, adjusted as
buretor adjustments should be left to a follows at the intervals specified in the
Yamaha dealer, who has the neces- periodic maintenance and lubrication
sary professional knowledge and expe- chart.
rience. The adjustment described in the The engine should be warm before
following section, however, may be ser- making this adjustment.
viced by the owner as part of routine
maintenance. NOTE:
ECA10550 The engine is warm when it quickly re-
CAUTION: sponds to the throttle.
The carburetor has been set and ex- Check the engine idling speed and, if
1. Clamp
tensively tested at the Yamaha fac- necessary, adjust it to specification by 6
2. Air filter check hose plug
tory. Changing these settings turning the throttle stop screw. To in-
10. Install the plug into the check without sufficient technical knowl- crease the engine idling speed, turn the
hose, and then install the clamp. edge may result in poor perfor- screw in direction (a). To decrease the
11. Install the panel. mance of or damage to the engine. engine idling speed, turn the screw in
direction (b).

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PERIODIC MAINTENANCE AND MINOR REPAIR


EAU21370
2. To increase the throttle cable free
Adjusting the throttle cable play, turn the adjusting nut in direc-
free play tion (a). To decrease the throttle
cable free play, turn the adjusting
nut in direction (b).
3. Tighten the locknut.

1. Throttle stop screw

Engine idling speed:


1300–1500 r/min 1. Throttle cable free play
2. Locknut
3. Throttle cable free play adjusting nut
NOTE:
6
If the specified idling speed cannot be The throttle cable free play should mea-
obtained as described above, have a sure 3.0–7.0 mm (0.12–0.28 in) at the
Yamaha dealer make the adjustment. throttle grip. Periodically check the
throttle cable free play and, if neces-
sary, adjust it as follows.
NOTE:
The engine idling speed must be cor-
rectly adjusted before checking and ad-
justing the throttle cable free play.
1. Loosen the locknut.

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PERIODIC MAINTENANCE AND MINOR REPAIR


EAU21401 EAU21561

Valve clearance Tires Tire air pressure (measured on cold


tires):
The valve clearance changes with use, To maximize the performance, durabil- 0–90 kg (0–198 lb):
resulting in improper air-fuel mixture ity, and safe operation of your motor- Front:
and/or engine noise. To prevent this cycle, note the following points 175 kPa (25 psi) (1.75 kgf/cm²)
from occurring, the valve clearance regarding the specified tires. Rear:
must be adjusted by a Yamaha dealer 200 kPa (29 psi) (2.00 kgf/cm²)
90–198 kg (198–437 lb):
at the intervals specified in the periodic Tire air pressure Front:
maintenance and lubrication chart. The tire air pressure should be checked 175 kPa (25 psi) (1.75 kgf/cm²)
and, if necessary, adjusted before each Rear:
ride. 280 kPa (41 psi) (2.80 kgf/cm²)
EWA10500 Maximum load*:
WARNING 198 kg (437 lb)
* Total weight of rider, passenger, car-
● The tire air pressure must be go and accessories
checked and adjusted on cold
tires (i.e., when the temperature EWA11020
6
of the tires equals the ambient WARNING
temperature). Because loading has an enormous
● The tire air pressure must be ad- impact on the handling, braking,
justed in accordance with the performance and safety characteris-
riding speed and with the total tics of your motorcycle, you should
weight of rider, passenger, car- keep the following precautions in
go, and accessories approved mind.
for this model. ● NEVER OVERLOAD THE
MOTORCYCLE! Operation of an
overloaded motorcycle may re-
sult in tire damage, loss of con-
trol, or severe injury. Make sure
that the total weight of rider,
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PERIODIC MAINTENANCE AND MINOR REPAIR


passenger, cargo, and accesso- Tire inspection Tire information
ries does not exceed the speci- This motorcycle is equipped with cast
fied maximum load for the wheels and tubeless tires.
vehicle. EWA10460

● Do not carry along loosely WARNING


packed items, which can shift ● The front and rear tires should
during a ride. be of the same make and de-
● Securely pack the heaviest sign, otherwise the handling
items close to the center of the characteristics of the vehicle
motorcycle and distribute the cannot be guaranteed.
weight evenly on both sides. 1. Tire sidewall ● After extensive tests, only the
● Adjust the suspension and tire 2. Tire tread depth tires listed below have been ap-
air pressure with regard to the proved for this model by
load. The tires must be checked before each Yamaha Motor Co., Ltd.
● Check the tire condition and air ride. If the center tread depth reaches
6 pressure before each ride. the specified limit, if the tire has a nail or
Front tire:
glass fragments in it, or if the sidewall is Size:
cracked, have a Yamaha dealer re- 2.75-18 42P
place the tire immediately. Manufacturer/model:
CHENG SHIN/C-910
Minimum tire tread depth (front and Rear tire:
rear): Size:
1.6 mm (0.06 in) 90/90-18 57P
Manufacturer/model:
CHENG SHIN/C-905
NOTE:
The tire tread depth limits may differ
from country to country. Always comply
with the local regulations.

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EWA10470 EAU21960 EAU22041

WARNING Cast wheels Adjusting the clutch lever free


● Have a Yamaha dealer replace To maximize the performance, durabil- play
excessively worn tires. Besides ity, and safe operation of your vehicle,
being illegal, operating the vehi- note the following points regarding the
cle with excessively worn tires specified wheels.
● The wheel rims should be checked
decreases riding stability and
can lead to loss of control. for cracks, bends or warpage be-
● The replacement of all wheel fore each ride. If any damage is
and brake related parts, includ- found, have a Yamaha dealer re-
ing the tires, should be left to a place the wheel. Do not attempt
Yamaha dealer, who has the even the smallest repair to the
necessary professional knowl- wheel. A deformed or cracked
1. Locknut
edge and experience. wheel must be replaced. 2. Clutch lever free play adjusting bolt
● The wheel should be balanced 3. Clutch lever free play
whenever either the tire or wheel 6
has been changed or replaced. An The clutch lever free play should mea-
unbalanced wheel can result in sure 10.0–15.0 mm (0.39–0.59 in) as
poor performance, adverse han- shown. Periodically check the clutch le-
dling characteristics, and a short- ver free play and, if necessary, adjust it
ened tire life. as follows.
● Ride at moderate speeds after 1. Loosen the locknut at the clutch le-
changing a tire since the tire sur- ver.
face must first be “broken in” for it 2. To increase the clutch lever free
to develop its optimal characteris- play, turn the adjusting bolt in di-
tics. rection (a). To decrease the clutch
lever free play, turn the adjusting
bolt in direction (b).

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PERIODIC MAINTENANCE AND MINOR REPAIR


5. To increase the clutch lever free EAUT1220
NOTE: Checking the front brake lever
play, turn the adjusting nut in direc-
If the specified clutch lever free play free play
tion (a). To decrease the clutch le-
could be obtained as described above,
ver free play, turn the adjusting nut
tighten the locknut and skip the rest of
in direction (b).
the procedure, otherwise proceed as
6. Tighten the locknut at the clutch le-
follows.
ver and the crankcase.
3. Fully turn the adjusting bolt at the
clutch lever in direction (a) to loos-
en the clutch cable.
4. Loosen the locknut at the crank-
case.
1. Brake lever free play

The brake lever free play should mea-


6 sure 0.0–7.0 mm (0.00–0.28 in) as
shown. Periodically check the brake le-
ver free play and, if necessary, have a
Yamaha dealer check the brake sys-
tem.
EWA10640

WARNING
1. Locknut (crankcase)
An incorrect brake lever free play in-
2. Clutch lever free play adjusting nut (crank-
case)
dicates a hazardous condition in the
brake system. Do not operate the
motorcycle until the brake system
has been checked or repaired by a
Yamaha dealer.

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PERIODIC MAINTENANCE AND MINOR REPAIR


EAU39811 EAU22291

Adjusting the brake pedal free Adjusting the rear brake light
play switch

1. Brake pedal free play adjusting nut

1. Brake pedal free play 1. Rear brake light switch


2. Rear brake light switch adjusting nut
The brake pedal free play should mea-
sure 20.0–30.0 mm (0.79–1.18 in) at The rear brake light switch, which is ac- 6
the brake pedal end as shown. Period- tivated by the brake pedal, is properly
ically check the brake pedal free play adjusted when the brake light comes
and, if necessary, adjust it as follows. on just before braking takes effect. If
To increase the brake pedal free play, necessary, adjust the brake light switch
turn the adjusting nut at the brake rod in as follows.
direction (a). To decrease the brake 1. Remove panel A. (See page 6-6.)
pedal free play, turn the adjusting nut in 2. Turn the adjusting nut while hold-
direction (b). ing 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).
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PERIODIC MAINTENANCE AND MINOR REPAIR


3. Install the panel. EAU22380
indicator grooves have almost disap-
Checking the front brake pads peared, have a Yamaha dealer replace
and rear brake shoes the brake pads as a set.
The front brake pads and the rear brake
shoes must be checked for wear at the EAU43170

intervals specified in the periodic main- Rear brake shoes


tenance and lubrication chart.

EAU22430
Front brake pads

6 1. Brake shoe wear limit mark


2. Brake shoe wear indicator

The rear brake is provided with a wear


1. Brake pad wear indicator groove
indicator, which allows you to check the
brake shoe wear without having to dis-
Each front brake pad is provided with assemble the brake. To check the
wear indicator grooves, which allow brake shoe wear, check the position of
you to check the brake pad wear with- the wear indicator while applying the
out having to disassemble the brake. brake. If a brake shoe has worn to the
To check the brake pad wear, check point that the wear indicator reaches
the wear indicator grooves. If a brake the wear limit mark, have a Yamaha
pad has worn to the point that the wear dealer replace the brake shoes as a
set.

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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-
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:
DOT 4
1. Minimum level mark
NOTE:
Insufficient brake fluid may allow air to If DOT 4 is not available, DOT 3 can be
enter the brake system, possibly caus- used. 6
ing it to become ineffective.
Before riding, check that the brake fluid ● Refill with the same type of brake
is above the minimum level mark and fluid. Mixing fluids may result in a
replenish if necessary. A low brake fluid harmful chemical reaction and
level may indicate worn brake pads lead to poor braking performance.
and/or brake system leakage. If the ● Be careful that water does not en-
brake fluid level is low, be sure to check ter the master cylinder when refill-
the brake pads for wear and the brake ing. Water will significantly lower
system for leakage. the boiling point of the fluid and
Observe these precautions: may result in vapor lock.

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PERIODIC MAINTENANCE AND MINOR REPAIR


EAU22720 EAU22760

Changing the brake fluid Drive chain slack Drive chain slack:
20.0–30.0 mm (0.79–1.18 in)
Have a Yamaha dealer change the The drive chain slack should be
brake fluid at the intervals specified in checked before each ride and adjusted 5. If the drive chain slack is incorrect,
the NOTE after the periodic mainte- if necessary. adjust it as follows.
nance and lubrication chart. In addition,
have the oil seals of the brake master EAU22793
EAU37112
To check the drive chain slack To adjust the drive chain slack
cylinder and caliper as well as the
1. Place the motorcycle on the cen- 1. Loosen the brake pedal free play
brake hose replaced at the intervals
terstand. adjusting nut, brake torque rod nut,
listed below or whenever they are dam-
2. Shift the transmission into the neu- and axle nut.
aged or leaking.
tral position.
● Oil seals: Replace every two
3. Spin the rear wheel several times
years.
to locate the tightest portion of the
● Brake hose: Replace every four
drive chain.
years.
4. Measure the drive chain slack as
6
shown.

1. Drive chain slack adjusting bolt


2. Chain puller locknut
3. Axle nut
4. Brake torque rod nut
5. Brake pedal free play adjusting nut

2. Loosen the chain puller locknut at


1. Drive chain slack
each end of the swingarm.

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PERIODIC MAINTENANCE AND MINOR REPAIR


3. To tighten the drive chain, turn the ECA10570 EAU23022

adjusting bolt at each end of the CAUTION: Cleaning and lubricating the
swingarm in direction (a). To loos- Improper drive chain slack will over- drive chain
en the drive chain, turn the adjust- load the engine as well as other vital The drive chain must be cleaned and
ing bolt at each end of the parts of the motorcycle and can lead lubricated at the intervals specified in
swingarm in direction (b), and then to chain slippage or breakage. To the periodic maintenance and lubrica-
push the rear wheel forward. prevent this from occurring, keep tion chart, otherwise it will quickly wear
the drive chain slack within the out, especially when riding in dusty or
NOTE: wet areas. Service the drive chain as
specified limits.
Using the alignment marks on each follows.
side of the swingarm, make sure that 4. Tighten both locknuts, and then ECA10581

both chain pullers are in the same posi- tighten the axle nut and brake CAUTION:
tion for proper wheel alignment. torque rod nut to their specified The drive chain must be lubricated
torques. after washing the motorcycle and
riding in the rain.
Tightening torques:
6
Axle nut: 1. Clean the drive chain with kero-
80 Nm (8.0 m·kgf, 58 ft·lbf) sene and a small soft brush.
Brake torque rod nut: ECA11120
19 Nm (1.9 m·kgf, 13 ft·lbf)
CAUTION:
5. Adjust the brake pedal free play. To prevent damaging the O-rings, do
(See page 6-18.) not clean the drive chain with steam
EWA10660 cleaners, high-pressure washers or
1. Alignment marks WARNING inappropriate solvents.
2. Chain puller locknut After adjusting the brake pedal free
3. Drive chain slack adjusting bolt
2. Wipe the drive chain dry.
play, check the operation of the 3. Thoroughly lubricate the drive
brake light. chain with a special O-ring chain
lubricant.

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PERIODIC MAINTENANCE AND MINOR REPAIR


ECA11110 EAU23100 EAU23111

CAUTION: Checking and lubricating the Checking and lubricating the


Do not use engine oil or any other lu- cables throttle grip and cable
bricants for the drive chain, as they The operation of all control cables and The operation of the throttle grip should
may contain substances that could the condition of the cables should be be checked before each ride. In addi-
damage the O-rings. checked before each ride, and the ca- tion, the cable should be lubricated at
bles and cable ends should be lubricat- the intervals specified in the periodic
ed if necessary. If a cable is damaged maintenance chart.
or does not move smoothly, have a
Yamaha dealer check or replace it.

Recommended lubricant:
Engine oil

EWA10720

WARNING
6
Damage to the outer sheath may in-
terfere with proper cable operation
and will cause the inner cable to
rust. Replace a damaged cable as
soon as possible to prevent unsafe
conditions.

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PERIODIC MAINTENANCE AND MINOR REPAIR


EAU23131 EAU23140

Checking and lubricating the Recommended lubricant: Checking and lubricating the
Lithium-soap-based grease (all-pur-
brake and shift pedals pose grease) brake and clutch levers
Brake lever

Clutch lever
6

The operation of the brake and shift


pedals should be checked before each
ride, and the pedal pivots should be lu- The operation of the brake and clutch
bricated if necessary. levers should be checked before each
ride, and the lever pivots should be lu-
bricated if necessary.

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PERIODIC MAINTENANCE AND MINOR REPAIR


EAU23211 EAUM1650
Recommended lubricant: Checking and lubricating the Lubricating the swingarm piv-
Lithium-soap-based grease (all-pur-
pose grease) centerstand and sidestand ots
The swingarm pivots must be lubricat-
ed at the intervals specified in the peri-
odic maintenance and lubrication chart.

Recommended lubricant:
Lithium-soap-based grease

The operation of the centerstand and


sidestand should be checked before
6 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.

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

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PERIODIC MAINTENANCE AND MINOR REPAIR


EAU23271 EAU23280

Checking the front fork Checking the steering


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.
EWA10750
1. Place a stand under the engine to
WARNING raise the front wheel off the
Securely support the vehicle so that ECA10590 ground.
there is no danger of it falling over. CAUTION: EWA10750

If any damage is found or the front WARNING


Check the inner tubes for scratches,
fork does not operate smoothly, Securely support the vehicle so that
damage and excessive oil leakage.
have a Yamaha dealer check or re- there is no danger of it falling over.
To check the operation pair it. 2. Hold the lower ends of the front 6
1. Place the vehicle on a level sur- fork legs and try to move them for-
face and hold it in an upright posi- ward and backward. If any free
tion. play can be felt, have a Yamaha
2. While applying the front brake, dealer check or repair the steering.
push down hard on the handlebars
several times to check if the front
fork compresses and rebounds
smoothly.

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PERIODIC MAINTENANCE AND MINOR REPAIR


EAU23290 EAU23321

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-
face and hold it in an upright posi-
tion.
NOTE:
6
Make sure that the vehicle is positioned
straight up when checking the electro-
lyte level.
2. Remove panel B. (See page 6-6.)
3. Check the electrolyte level in the
battery.
NOTE:
The electrolyte should be between the
minimum and maximum level marks.

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working near batteries. In case ECA10610

of contact, administer the fol- CAUTION:


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

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PERIODIC MAINTENANCE AND MINOR REPAIR


that the breather hose is properly EAU43211

routed, in good condition, and not Replacing the fuse


obstructed. The fuse is located behind panel B.
ECA10600 (See page 6-6.)
CAUTION: To access the fuse, remove the starter
If the breather hose is positioned in relay coupler.
such a way that the frame is ex-
posed to electrolyte or gas expelled
from the battery, the frame could
1. Battery breather hose suffer structural and external dam-
ages.
6. Install the panel.

To store the battery


1. If the vehicle will not be used for
6 more than one month, remove the 1. Starter relay coupler
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 the specif-
ic gravity of the electrolyte at least
once a month and fully charge the
battery whenever necessary.
3. Fully charge the battery before in-
stallation.
4. After installation, make sure that
the battery leads are properly con- 1. Fuse
nected to the battery terminals and

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PERIODIC MAINTENANCE AND MINOR REPAIR


The spare fuse is located on the rear of ECA10640 EAU43190

the starter relay holder. CAUTION: Replacing the headlight bulb


To access the spare fuse, remove the Do not use a fuse of a higher amper- This model is equipped with a quartz
starter relay (together with its holder) by age rating than recommended to bulb headlight. If the headlight bulb
pulling it out, then turn the starter relay avoid causing extensive damage to burns out, replace it as follows.
over. the electrical system and possibly a 1. Remove the headlight unit by re-
fire. moving the screws.

3. 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.

6
1. Spare fuse
1. Screw
If the fuse is blown, replace it as fol-
lows. 2. Remove the headlight bulb socket
1. Turn the key to “OFF” and turn off cover.
all electrical circuits.
2. Remove the blown fuse, and then
install a new fuse of the specified
amperage.

Specified fuse:
15.0 A

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PERIODIC MAINTENANCE AND MINOR REPAIR


fected. Thoroughly clean off any dirt
and fingerprints on the headlight
bulb using a cloth moistened with al-
cohol or thinner.

1. Headlight bulb socket cover 1. Headlight bulb

3. Remove the headlight bulb socket EWA10790

(together with the bulb) by turning WARNING


it counterclockwise. Headlight bulbs get very hot. There-
fore, keep flammable products away 1. Do not touch the glass part of the bulb.
6 from a lit headlight bulb, and do not 6. Install the socket (together with the
touch the bulb until it has cooled bulb) by turning it clockwise.
down. 7. Install the headlight bulb socket
5. Insert a new bulb into the socket, cover.
push it in, and then turn it clock- 8. Install the headlight unit by install-
wise until it stops. ing the screws.
ECA10660
9. Have a Yamaha dealer adjust the
CAUTION: headlight beam if necessary.
1. Headlight bulb socket Do not touch the glass part of the
4. Remove the defective bulb by headlight bulb to keep it free from
pushing it in and turning it counter- oil, otherwise the transparency of
clockwise. the glass, the luminosity of the bulb,
and the bulb life will be adversely af-

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PERIODIC MAINTENANCE AND MINOR REPAIR


EAU24131 EAU24202

Replacing the tail/brake light Replacing a turn signal light


bulb bulb
1. Remove the tail/brake light lens by 1. Remove the turn signal light lens
removing the screws. by removing the screw.

1. Tail/brake light bulb

3. Insert a new bulb into the socket,


push it in, and then turn it clock-
wise until it stops.
1. Screw 4. Install the lens by installing the 1. Screw
screws. 6
2. Remove the defective bulb by ECA10680 2. Remove the defective bulb by
pushing it in and turning it counter- CAUTION: pushing it in and turning it counter-
clockwise. Do not overtighten the screws, oth- clockwise.
erwise the lens may break. 3. Insert a new bulb into the socket,
push it in, and then turn it clock-
wise until it stops.
4. Install the lens by installing the
screw.
ECA11190

CAUTION:
Do not overtighten the screw, other-
wise the lens may break.

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PERIODIC MAINTENANCE AND MINOR REPAIR


EAU37270 EAU24360

Replacing the auxiliary light Front wheel


bulb
EAU37041
If the auxiliary light bulb burns out, re- To remove the front wheel
place it as follows. EWA10820

1. Remove the headlight unit by re- WARNING


moving the screws. ● It is advisable to have a Yamaha
dealer service the wheel.
● Securely support the motor-
1. Auxiliary light bulb socket cycle so that there is no danger
of it falling over.
3. Remove the defective bulb by pull-
ing it out. 1. Place the motorcycle on the cen-
terstand.
2. Disconnect the speedometer ca-
6 ble from the front wheel.
1. Screw

2. Remove the socket (together with


the bulb) by pulling it out.

1. Auxiliary light bulb

4. Insert a new bulb into the socket.


5. Install the socket (together with the 1. Speedometer cable
bulb) by pushing it in.
6. Install the headlight unit by install-
ing the screws.
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PERIODIC MAINTENANCE AND MINOR REPAIR


3. Remove the rubber caps from the
ends of the wheel axle by pulling
them off.

1. Rubber cap 1. Speedometer gear unit


2. Wheel axle
3. Washer 2. Lift the wheel up between the fork
legs.
1. Rubber cap
5. Pull the wheel axle out, and then
2. Axle nut
remove the wheel. NOTE:
3. Washer ECA11070 Make sure that there is enough space 6
4. Remove the axle nut and the CAUTION: between the brake pads before insert-
washer. Do not apply the brake after the ing the brake disc and that the slot in
wheel has been removed together the speedometer gear unit fits over the
with the brake disc, otherwise the retainer on the fork leg.
brake pads will be forced shut.

EAU37030
To install the front wheel
1. Install the speedometer gear unit
into the wheel hub so that the pro-
jections mesh with the slots.

6-34
U3D9EAE0.book Page 35 Thursday, December 28, 2006 10:35 AM

PERIODIC MAINTENANCE AND MINOR REPAIR


6. While applying the front brake, EAU25080

push down hard on the handlebars Rear wheel


several times to check if the front EAU37180
fork compresses and rebounds To remove the rear wheel
smoothly. EWA10820

7. Connect the speedometer cable. WARNING


● It is advisable to have a Yamaha
dealer service the wheel.
● Securely support the motor-
1. Speedometer gear unit retainer cycle so that there is no danger
of it falling over.
3. Insert the wheel axle, making sure
the washer on the left side is in- 1. Loosen the axle nut and the brake
stalled with the beveled side facing torque rod nut at the brake shoe
outward, and then install the axle plate.
6 nut. 2. Disconnect the brake torque rod
4. Take the motorcycle off the center- from the brake shoe plate by re-
stand so that the front wheel is on moving the cotter pin, the nut, and
the ground. the bolt.
5. Tighten the axle nut to the speci-
fied torque, and then install both
rubber caps so that they fit over the
washers.

Tightening torque:
Axle nut:
59 Nm (5.9 m·kgf, 43 ft·lbf)

6-35
U3D9EAE0.book Page 36 Thursday, December 28, 2006 10:35 AM

PERIODIC MAINTENANCE AND MINOR REPAIR


6. Remove the axle nut, and then pull
the wheel axle out.
7. Push the wheel forward, and then
remove the drive chain from the
rear sprocket.
NOTE:
The drive chain does not need to be
disassembled in order to remove and
install the wheel.
1. Axle nut 1. Brake pedal free play adjusting nut
2. Brake torque rod 2. Brake rod 8. Remove the wheel.
3. Brake torque rod cotter pin 3. Brake camshaft lever
EAU37192
4. Brake torque rod nut and bolt
5. Loosen the chain puller locknut To install the rear wheel
3. Place the motorcycle on the cen- and the drive chain slack adjusting 1. Install the wheel by inserting the
terstand. bolt on both ends of the swingarm. wheel axle from the left-hand side. 6
4. Remove the brake pedal free play 2. Install the drive chain onto the rear
adjusting nut, and then disconnect sprocket.
the brake rod from the brake cam- 3. Install the axle nut.
shaft lever. 4. Install the brake rod onto the brake
camshaft lever, and then install the
brake pedal free play adjusting nut
onto the brake rod.
5. Connect the brake torque rod to
the brake shoe plate by installing
the bolt and nut.
1. Wheel axle
2. Chain puller locknut
6. Adjust the drive chain slack. (See
3. Drive chain slack adjusting bolt page 6-21.)

6-36
U3D9EAE0.book Page 37 Thursday, December 28, 2006 10:35 AM

PERIODIC MAINTENANCE AND MINOR REPAIR


7. Take the motorcycle off the center- EAU25850

stand so that the rear wheel is on Troubleshooting


the ground. Although Yamaha motorcycles receive
8. Tighten the brake torque rod nut a thorough inspection before shipment
and axle nut to the specified from the factory, trouble may occur dur-
torques. ing operation. Any problem in the fuel,
compression, or ignition systems, for
Tightening torques: example, can cause poor starting and
Brake torque rod nut: loss of power.
19 Nm (1.9 m·kgf, 13 ft·lbf) The following troubleshooting chart
Axle nut: represents a quick and easy procedure
80 Nm (8.0 m·kgf, 58 ft·lbf)
for checking these vital systems your-
9. Insert a new cotter pin. self. However, should your motorcycle
10. Adjust the brake pedal free play. require any repair, take it to a Yamaha
(See page 6-18.) dealer, whose skilled technicians have
6 EWA10660 the necessary tools, experience, and
WARNING know-how to service the motorcycle
After adjusting the brake pedal free properly.
play, check the operation of the Use only genuine Yamaha replace-
brake light. 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.

6-37
U3D9EAE0.book Page 38 Thursday, December 28, 2006 10:35 AM

PERIODIC MAINTENANCE AND MINOR REPAIR


EAU25962

Troubleshooting chart
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.
There is no compression.
Have a Yamaha dealer 6
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 fluid, recharge,
slowly. check connections.

6-38
U3D9EAE0.book Page 1 Thursday, December 28, 2006 10:35 AM

MOTORCYCLE CARE AND STORAGE


EAU37833 EAU26002
ucts onto seals, gaskets, sprock-
Matte color caution Care ets, the drive chain and wheel
ECA15192
While the open design of a motorcycle axles. Always rinse the dirt and de-
CAUTION: reveals the attractiveness of the tech- greaser off with water.
Some models are equipped with nology, it also makes it more vulnera-
matte colored finished parts. Be ble. Rust and corrosion can develop Cleaning
sure to consult a Yamaha dealer for even if high-quality components are ECA10771

advice on what products to use be- used. A rusty exhaust pipe may go un- CAUTION:
fore cleaning the vehicle. Using a noticed on a car, however, it detracts ● Avoid using strong acidic wheel
brush, harsh chemical products or from the overall appearance of a motor- cleaners, especially on spoked
cleaning compounds when cleaning cycle. Frequent and proper care does wheels. If such products are
these parts will scratch or damage not only comply with the terms of the used on hard-to-remove dirt, do
their surface. Wax also should not warranty, but it will also keep your not leave the cleaner on the af-
be applied to any matte colored fin- motorcycle looking good, extend its life fected area any longer than in-
ished parts. and optimize its performance. structed. Also, thoroughly rinse
the area off with water, immedi-
Before cleaning ately dry it, and then apply a cor-
1. Cover the muffler outlet with a rosion protection spray.
7
plastic bag after the engine has ● Improper cleaning can damage
cooled down. plastic parts such as cowlings,
2. Make sure that all caps and covers panels, windshields, headlight
as well as all electrical couplers lenses, meter lenses, etc. Use
and connectors, including the only a soft, clean cloth or
spark plug cap, are tightly in- sponge with mild detergent and
stalled. water to clean plastic.
3. Remove extremely stubborn dirt, ● Do not use any harsh chemical
like oil burnt onto the crankcase, products on plastic parts. Be
with a degreasing agent and a sure to avoid using cloths or
brush, but never apply such prod- sponges which have been in
7-1
U3D9EAE0.book Page 2 Thursday, December 28, 2006 10:35 AM

MOTORCYCLE CARE AND STORAGE


contact with strong or abrasive scratched, use a quality plastic 1. Clean the motorcycle with cold wa-
cleaning products, solvent or polishing compound after ter and a mild detergent, after the
thinner, fuel (gasoline), rust re- washing. engine has cooled down.
movers or inhibitors, brake flu- ECA10790

id, antifreeze or electrolyte. CAUTION:


After normal use
● Do not use high-pressure wash- Do not use warm water since it in-
Remove dirt with warm water, a mild
ers or steam-jet cleaners since creases the corrosive action of the
detergent, and a soft, clean sponge,
they cause water seepage and salt.
and then rinse thoroughly with clean
deterioration in the following ar-
water. Use a toothbrush or bottlebrush 2. Apply a corrosion protection spray
eas: seals (of wheel and swing-
for hard-to-reach areas. Stubborn dirt on all metal, including chrome- and
arm bearings, fork and brakes),
and insects will come off more easily if nickel-plated, surfaces to prevent
electric components (couplers,
the area is covered with a wet cloth for corrosion.
connectors, instruments,
a few minutes before cleaning.
switches and lights), breather
After cleaning
hoses and vents.
After riding in the rain, near the sea or 1. Dry the motorcycle with a chamois
● For motorcycles equipped with
on salt-sprayed roads or an absorbing cloth.
a windshield: Do not use strong
Since sea salt or salt sprayed on roads 2. Immediately dry the drive chain
cleaners or hard sponges as 7
during winter are extremely corrosive in and lubricate it to prevent it from
they will cause dulling or
combination with water, carry out the rusting.
scratching. Some cleaning com-
following steps after each ride in the 3. Use a chrome polish to shine
pounds for plastic may leave
rain, near the sea or on salt-sprayed chrome, aluminum and stainless-
scratches on the windshield.
roads. steel parts, including the exhaust
Test the product on a small hid-
system. (Even the thermally in-
den part of the windshield to NOTE:
duced discoloring of stainless-
make sure that it does not leave Salt sprayed on roads in the winter may
steel exhaust systems can be re-
any marks. If the windshield is remain well into spring.
moved through polishing.)

7-2
U3D9EAE0.book Page 3 Thursday, December 28, 2006 10:35 AM

MOTORCYCLE CARE AND STORAGE


4. To prevent corrosion, it is recom- ECA10800 EAU37220

mended to apply a corrosion pro- CAUTION: Storage


tection spray on all metal, ● Apply spray oil and wax spar-
including chrome- and nickel-plat- ingly and make sure to wipe off Short-term
ed, surfaces. any excess. Always store your motorcycle in a cool,
5. Use spray oil as a universal clean- ● Never apply oil or wax to any dry place and, if necessary, protect it
er to remove any remaining dirt. rubber and plastic parts, but against dust with a porous cover.
ECA10810
6. Touch up minor paint damage treat them with a suitable care CAUTION:
caused by stones, etc. product.
● Storing the motorcycle in a
7. Wax all painted surfaces. ● Avoid using abrasive polishing
8. Let the motorcycle dry completely compounds as they will wear poorly ventilated room or cover-
before storing or covering it. away the paint. ing it with a tarp, while it is still
EWA11130 wet, will allow water and humid-
WARNING NOTE: ity to seep in and cause rust.
● Make sure that there is no oil or Consult a Yamaha dealer for advice on ● To prevent corrosion, avoid
wax on the brakes or tires. what products to use. damp cellars, stables (because
● If necessary, clean the brake of the presence of ammonia)
7 discs and brake linings with a and areas where strong chemi-
regular brake disc cleaner or ac- cals are stored.
etone, and wash the tires with
warm water and a mild deter- Long-term
gent. Before riding at higher Before storing your motorcycle for sev-
speeds, test the motorcycle’s eral months:
braking performance and cor- 1. Follow all the instructions in the
nering behavior. “Care” section of this chapter.
2. Turn the fuel cock lever to “OFF” or
“ ”.

7-3
U3D9EAE0.book Page 4 Thursday, December 28, 2006 10:35 AM

MOTORCYCLE CARE AND STORAGE


3. Drain the carburetor float chamber EWA10950
°C (90 °F)]. For more information
by loosening the drain bolt; this will WARNING on storing the battery, see page
prevent fuel deposits from building To prevent damage or injury from 6-27.
up. Pour the drained fuel into the sparking, make sure to ground the
NOTE:
fuel tank. spark plug electrodes while turning
Make any necessary repairs before
4. Fill up the fuel tank and add fuel the engine over.
storing the motorcycle.
stabilizer (if available) to prevent
6. Lubricate all control cables and the
the fuel tank from rusting and the
pivoting points of all levers and
fuel from deteriorating.
pedals as well as of the side-
5. Perform the following steps to pro-
stand/centerstand.
tect the cylinder, piston rings, etc.
7. Check and, if necessary, correct
from corrosion.
the tire air pressure, and then lift
a. Remove the spark plug cap
the motorcycle so that both of its
and spark plug.
wheels are off the ground. Alterna-
b. Pour a teaspoonful of engine oil
tively, turn the wheels a little every
into the spark plug bore.
month in order to prevent the tires
c. Install the spark plug cap onto
from becoming degraded in one
the spark plug, and then place 7
spot.
the spark plug on the cylinder
8. Cover the muffler outlet with a
head so that the electrodes are
plastic bag to prevent moisture
grounded. (This will limit spark-
from entering it.
ing during the next step.)
9. Remove the battery and fully
d. Turn the engine over several
charge it. Store it in a cool, dry
times with the starter. (This will
place and charge it once a month.
coat the cylinder wall with oil.)
Do not store the battery in an ex-
e. Remove the spark plug cap
cessively cold or warm place [less
from the spark plug, and then
than 0 °C (30 °F) or more than 30
install the spark plug and the
spark plug cap.
7-4
U3D9EAE0.book Page 1 Thursday, December 28, 2006 10:35 AM

SPECIFICATIONS
Dimensions: Engine oil: Carburetor:
Overall length: Type: Manufacturer:
1980 mm (78.0 in) SAE10W30, SAE10W40, SAE15W40, MIKUNI
Overall width: SAE20W40 or SAE20W50 Type × quantity:
745 mm (29.3 in) VM22SH x 1
Overall height: -20 -10 0 10 20 30 40 50 ˚C Spark plug (s):
1080 mm (42.5 in) Manufacturer/model:
Seat height: SAE 10W-30
NGK/CR6HSA
780 mm (30.7 in) SAE 10W-40 Spark plug gap:
Wheelbase: 0.6–0.7 mm (0.024–0.028 in)
1290 mm (50.8 in) SAE 15W-40 Clutch:
Ground clearance: Clutch type:
SAE 20W-40
175 mm (6.89 in) Wet, multiple-disc
Minimum turning radius: SAE 20W-50 Transmission:
1750 mm (68.9 in) Primary reduction system:
Weight: Helical gear
With oil and fuel: Recommended engine oil grade:
Primary reduction ratio:
122.0 kg (269 lb) API service SG type or higher, JASO
68/20 (3.400)
standard MA
Engine: Secondary reduction system:
Engine oil quantity:
Engine type: Chain drive
Periodic oil change:
Air cooled 4-stroke, SOHC Secondary reduction ratio:
1.00 L (1.06 US qt) (0.88 Imp.qt)
Cylinder arrangement: 45/14 (3.214)
Forward-inclined single cylinder
Air filter:
Transmission type:
Air filter element:
8 Displacement: Constant mesh 5-speed
Dry element
123.7 cm³ Operation:
Bore × stroke: Fuel: Left foot operation
54.0 × 54.0 mm (2.13 × 2.13 in) Recommended fuel:
Gear ratio:
Compression ratio: Regular unleaded gasoline only
1st:
10.00 :1 Fuel tank capacity:
37/14 (2.643)
Starting system: 12.0 L (3.17 US gal) (2.64 Imp.gal)
2nd:
Electric starter and kickstarter Fuel reserve amount:
32/18 (1.778)
Lubrication system: 1.7 L (0.45 US gal) (0.37 Imp.gal)
3rd:
Wet sump 25/19 (1.316)

8-1
U3D9EAE0.book Page 2 Thursday, December 28, 2006 10:35 AM

SPECIFICATIONS
4th: Front: Front suspension:
23/22 (1.045) 175 kPa (25 psi) (1.75 kgf/cm²) Type:
5th: Rear: Telescopic fork
21/24 (0.875) 200 kPa (29 psi) (2.00 kgf/cm²) Spring/shock absorber type:
Chassis: Loading condition: Coil spring/oil damper
Frame type: 90–198 kg (198–437 lb) Wheel travel:
Diamond Front: 120.0 mm (4.72 in)
Caster angle: 175 kPa (25 psi) (1.75 kgf/cm²) Rear suspension:
26.33 ° Rear: Type:
Trail: 280 kPa (41 psi) (2.80 kgf/cm²) Swingarm
90.0 mm (3.54 in) Front wheel: Spring/shock absorber type:
Front tire: Wheel type: Coil spring/oil damper
Type: Cast wheel Wheel travel:
Tubeless Rim size: 105.0 mm (4.13 in)
Size: J18 x MT1.85 Electrical system:
2.75-18 42P Rear wheel: Ignition system:
Manufacturer/model: Wheel type: DC. CDI
CHENG SHIN/C-910 Cast wheel Charging system:
Rear tire: Rim size: AC magneto
Type: J18 x MT1.85 Battery:
Tubeless Front brake: Model:
Size: Type: CB5L-B
90/90-18 57P Single disc brake Voltage, capacity:
Manufacturer/model: Operation: 12 V, 5.0 Ah 8
CHENG SHIN/C-905 Right hand operation Headlight:
Loading: Recommended fluid: Bulb type:
Maximum load: DOT 3 or 4 Incandescence
198 kg (437 lb) Rear brake: Bulb voltage, wattage × quantity:
(Total weight of rider, passenger, cargo and Type: Headlight:
accessories) Drum brake 12 V, 35 W/35.0 W × 1
Tire air pressure (measured on cold Operation: Tail/brake light:
tires): Right foot operation 12 V, 5.0 W/21.0 W × 1
Loading condition: Front turn signal light:
0–90 kg (0–198 lb) 12 V, 10.0 W × 2
8-2
U3D9EAE0.book Page 3 Thursday, December 28, 2006 10:35 AM

SPECIFICATIONS
Rear turn signal light:
12 V, 10.0 W × 2
Auxiliary light:
12 V, 5.0 W × 1
Meter lighting:
12 V, 1.7 W × 4
Neutral indicator light:
14 V, 3.0 W × 1
High beam indicator light:
14 V, 3.0 W × 1
Turn signal indicator light:
14 V, 3.0 W × 2
Fuse:
Fuse:
15.0 A

8-3
U3D9EAE0.book Page 1 Thursday, December 28, 2006 10:35 AM

CONSUMER INFORMATION
EAU26351 EAU26381 EAU26400

Identification numbers Key identification number Vehicle identification number


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

1. Key identification number 1. Vehicle identification number

The key identification number is The vehicle identification number is


stamped into the key tag. Record this stamped into the steering head pipe.
VEHICLE IDENTIFICATION number in the space provided and use Record this number in the space pro-
NUMBER: it for reference when ordering a new vided.
key.
NOTE:
The vehicle identification number is
used to identify your motorcycle and
may be used to register your motor-
MODEL LABEL INFORMATION: cycle with the licensing authority in your
area. 9

9-1
U3D9EAE0.book Page 2 Thursday, December 28, 2006 10:35 AM

CONSUMER INFORMATION
EAU36980
Model label

1. Model label

The model label is affixed to the frame


behind panel B. (See page 6-6.)
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
U3D9EAE0.book Page 1 Thursday, December 28, 2006 10:35 AM

INDEX
A F Periodic maintenance and
Air filter element, cleaning .................... 6-10 Front brake lever free play, checking ....6-17 lubrication chart .................................... 6-2
Auxiliary light bulb, replacing ................ 6-33 Front fork, checking...............................6-26 Pre-operation check list .......................... 4-2
B Fuel .........................................................3-6 R
Battery .................................................. 6-27 Fuel cock.................................................3-7 Rear brake light switch, adjusting ......... 6-18
Brake and clutch levers, Fuel consumption, tips for reducing ........5-3 S
checking and lubricating..................... 6-24 Fuel gauge ..............................................3-3 Safety information................................... 1-1
Brake and shift pedals, Fuel tank cap...........................................3-5 Shifting.................................................... 5-2
checking and lubricating..................... 6-24 Fuse, replacing......................................6-29 Shift pedal............................................... 3-4
Brake fluid, changing ............................ 6-21 H Shock absorber assemblies, adjusting ... 3-9
Brake fluid level, checking .................... 6-20 Handlebar switches .................................3-3 Sidestand.............................................. 3-10
Brake lever ............................................. 3-5 Headlight bulb, replacing.......................6-30 Spark plug, checking .............................. 6-7
Brake pads and shoes, checking.......... 6-19 High beam indicator light.........................3-2 Specifications.......................................... 8-1
Brake pedal ............................................ 3-5 Horn switch .............................................3-4 Speedometer unit ................................... 3-2
Brake pedal free play, adjusting ........... 6-18 I Starter (choke) lever ............................... 3-8
C Identification numbers .............................9-1 Starting a cold engine ............................. 5-1
Cables, checking and lubricating.......... 6-23 Ignition circuit cut-off system .................3-11 Start switch ............................................. 3-4
Carburetor, adjusting ............................ 6-12 Indicator lights .........................................3-2 Steering, checking ................................ 6-26
Care........................................................ 7-1 K Storage ................................................... 7-3
Carrier................................................... 3-10 Key identification number........................9-1 Swingarm pivots, lubricating ................. 6-25
Catalytic converter.................................. 3-7 Kickstarter ...............................................3-9 T
Centerstand and sidestand, L Tachometer............................................. 3-3
checking and lubricating..................... 6-25 Luggage strap holders ..........................3-10 Tail/brake light bulb, replacing .............. 6-32
Clutch lever............................................. 3-4 M Throttle cable free play, adjusting......... 6-13
Clutch lever free play, adjusting ........... 6-16 Main switch/steering lock ........................3-1 Throttle grip and cable,
D Matte color, caution.................................7-1 checking and lubricating ..................... 6-23
Dimmer switch ........................................ 3-4 Model label..............................................9-2 Tires...................................................... 6-14
Drive chain, cleaning and lubricating.... 6-22 N Tool kit .................................................... 6-1
Drive chain slack .................................. 6-21 Troubleshooting .................................... 6-37
Neutral indicator light ..............................3-2
E Troubleshooting chart ........................... 6-38
P
Engine break-in ...................................... 5-3 Turn signal indicator lights ...................... 3-2
Panels, removing and installing ..............6-6
Engine idling speed .............................. 6-12 Turn signal light bulb, replacing ............ 6-32
Parking ....................................................5-4
Engine oil................................................ 6-9 Turn signal switch ................................... 3-4
Part locations ..........................................2-1
Engine, starting a warm.......................... 5-2
U3D9EAE0.book Page 2 Thursday, December 28, 2006 10:35 AM

INDEX
V
Valve clearance .................................... 6-14
Vehicle identification number .................. 9-1
W
Wheel bearings, checking..................... 6-27
Wheel (front) ......................................... 6-33
Wheel (rear) .......................................... 6-35
Wheels .................................................. 6-16
U3D9EAE0.book Page 3 Thursday, December 28, 2006 10:35 AM
YAMAHA MOTOR CO., LTD.
PRINTED IN CHINA
2007.01-0.3×1 CR
(E)