Yamaha Ybr125-Owners-Manual yamaha-ybr125-owners-manual … · manuals, instruction manuals, user...

27S-F8199-E0

YBR125

OWNER’S MANUAL

U27SE0E0.book Friday, February 22, 2008 8:54 AM

INTRODUCTIONEAU10100

Welcome to the Yamaha world of motorcycling!As the owner of the YBR125, you are benefiting from Yamaha’s vast experience and newest technology regarding the designand 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 YBR125. The owner’s manualdoes not only instruct you in how to operate, inspect and maintain your motorcycle, but also in how to safeguard yourself andothers 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 anyfurther 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!

U27SE0E0.book Page 1 Friday, February 22, 2008 8:54 AM

IMPORTANT MANUAL INFORMATIONEAU10151

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

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 motorcycleand this manual. If you have any questions concerning this manual, please consult your Yamaha dealer.

WARNINGEWA10030

PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE.

*Product and specifications are subject to change without notice.

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 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 the motorcycle.

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

WARNING

CAUTION:

NOTE:


IMPORTANT MANUAL INFORMATION

EAU37230

YBR125OWNER’S MANUAL

©2008 by Yamaha Motor Co., Ltd.1st edition, February 2008

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

Yamaha Motor Co., Ltd. is expressly prohibited.

Printed in China.


TABLE OF CONTENTSSAFETY INFORMATION ..................1-1

DESCRIPTION ..................................2-1Left view ..........................................2-1Right view ........................................2-2Controls and instruments.................2-3

INSTRUMENT AND CONTROL FUNCTIONS .......................................3-1

Main switch/steering lock ................3-1Indicator and warning lights ............3-2Speedometer unit ...........................3-2Tachometer ....................................3-3Self-diagnosis device ......................3-3Fuel gauge ......................................3-3Handlebar switches ........................3-4Clutch lever .....................................3-5Shift pedal .......................................3-5Brake lever .....................................3-5Brake pedal ....................................3-6Fuel tank cap ..................................3-6Fuel .................................................3-7Catalytic converters ........................3-8Kickstarter .......................................3-8Adjusting the shock absorber

assemblies ..................................3-8Carrier .............................................3-9Sidestand ........................................3-9Ignition circuit cut-off system ........3-10

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

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

Starting the engine ......................... 5-1Shifting ........................................... 5-2Tips for reducing fuel

consumption ............................... 5-3Engine break-in .............................. 5-3Parking ........................................... 5-4

PERIODIC MAINTENANCE AND MINOR REPAIR ................................. 6-1

Owner’s tool kit ............................... 6-1Periodic maintenance and

lubrication chart .......................... 6-2Removing and installing panels ..... 6-6Checking the spark plug ................. 6-7Engine oil ....................................... 6-9Cleaning the air filter element ...... 6-10Checking the engine idling

speed ........................................ 6-12Adjusting the throttle cable free

play ........................................... 6-12Valve clearance ............................ 6-13Tires ............................................. 6-13Cast wheels .................................. 6-15Adjusting the clutch lever free

play ........................................... 6-16

Checking the front brake lever free play ........................................... 6-17

Adjusting the brake pedal free play ........................................... 6-17

Checking the shift pedal .............. 6-18Adjusting the rear brake light

switch ....................................... 6-18Checking the front brake pads and

rear brake shoes ...................... 6-19Checking the front brake fluid

level .......................................... 6-19Changing the brake fluid .............. 6-20Drive chain slack .......................... 6-21Cleaning and lubricating the drive

chain ......................................... 6-22Checking and lubricating

the cables ................................. 6-23Checking and lubricating

the throttle grip and cable ......... 6-23Checking and lubricating

the brake and clutch levers ...... 6-23Checking and lubricating

the brake pedal ......................... 6-24Checking and lubricating the

centerstand and sidestand ....... 6-24Lubricating the swingarm

pivots ........................................ 6-25Checking the front fork ................. 6-25Checking the steering .................. 6-26Checking the wheel bearings ....... 6-26Battery ......................................... 6-27


TABLE OF CONTENTSReplacing the fuse ........................6-28Replacing the headlight bulb ........6-29Replacing the tail/brake light

bulb ...........................................6-30Replacing a turn signal light

bulb ...........................................6-31Replacing the auxiliary light

bulb ...........................................6-31Front wheel ...................................6-32Rear wheel ...................................6-34Troubleshooting ............................6-36Troubleshooting chart ...................6-37

MOTORCYCLE CARE AND STORAGE ..........................................7-1

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

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

CONSUMER INFORMATION.............9-1Identification numbers ....................9-1


1-1

1

SAFETY INFORMATION EAU10281

MOTORCYCLES ARE SINGLETRACK VEHICLES. THEIR SAFE USEAND OPERATION ARE DEPENDENTUPON THE USE OF PROPER RIDINGTECHNIQUES AS WELL AS THE EX-PERTISE OF THE OPERATOR. EV-ERY OPERATOR SHOULD KNOWTHE FOLLOWING REQUIREMENTSBEFORE RIDING THIS MOTOR-CYCLE.HE OR SHE SHOULD:

� OBTAIN THOROUGH INSTRUC-TIONS FROM A COMPETENTSOURCE ON ALL ASPECTS OFMOTORCYCLE OPERATION.

� OBSERVE THE WARNINGS ANDMAINTENANCE REQUIRE-MENTS IN THE OWNER’S MAN-UAL.

� OBTAIN QUALIFIED TRAININGIN SAFE AND PROPER RIDINGTECHNIQUES.

� OBTAIN PROFESSIONAL TECH-NICAL SERVICE AS INDICATEDBY THE OWNER’S MANUAL

AND/OR WHEN MADE NECES-SARY BY MECHANICAL CONDI-TIONS.

Safe riding� Always make pre-operation

checks. Careful checks may helpprevent an accident.

� This motorcycle is designed to car-ry the operator and a passenger.

� The failure of motorists to detectand recognize motorcycles in traf-fic is the predominating cause ofautomobile/motorcycle accidents.Many accidents have been causedby an automobile driver who didnot see the motorcycle. Makingyourself conspicuous appears tobe very effective in reducing thechance of this type of accident.Therefore:• Wear a brightly colored jacket.• Use extra caution when you are

approaching and passingthrough intersections, since in-tersections are the most likelyplaces for motorcycle accidentsto occur.

• Ride where other motorists cansee you. Avoid riding in anothermotorist’s blind spot.

� Many accidents involve inexperi-enced operators. In fact, many op-erators who have been involved inaccidents do not even have a cur-rent motorcycle license.• Make sure that you are qualified

and that you only lend yourmotorcycle to other qualified op-erators.

• Know your skills and limits.Staying within your limits mayhelp you to avoid an accident.

• We recommend that you prac-tice riding your motorcyclewhere there is no traffic until youhave become thoroughly famil-iar with the motorcycle and all ofits controls.

� Many accidents have been causedby error of the motorcycle opera-tor. A typical error made by the op-erator is veering wide on a turn


SAFETY INFORMATION

1-2

1

due to EXCESSIVE SPEED or un-dercornering (insufficient lean an-gle for the speed).• Always obey the speed limit and

never travel faster than warrant-ed by road and traffic conditions.

• Always signal before turning orchanging lanes. Make sure thatother motorists can see you.

� The posture of the operator andpassenger is important for propercontrol.• The operator should keep both

hands on the handlebar andboth feet on the operator foot-rests during operation to main-tain control of the motorcycle.

• The passenger should alwayshold onto the operator, the seatstrap or grab bar, if equipped,with both hands and keep bothfeet on the passenger footrests.

• Never carry a passenger unlesshe or she can firmly place bothfeet on the passenger footrests.

� Never ride under the influence ofalcohol or other drugs.

� This motorcycle is designed for on-road use only. It is not suitable foroff-road use.

Protective apparelThe majority of fatalities from motor-cycle accidents are the result of headinjuries. The use of a safety helmet isthe single most critical factor in the pre-vention or reduction of head injuries.

� Always wear an approved helmet.� Wear a face shield or goggles.

Wind in your unprotected eyescould contribute to an impairmentof vision that could delay seeing ahazard.

� The use of a jacket, heavy boots,trousers, gloves, etc., is effective inpreventing or reducing abrasionsor lacerations.

� Never wear loose-fitting clothes,otherwise they could catch on thecontrol levers, footrests, or wheelsand cause injury or an accident.

� Never touch the engine or exhaustsystem during or after operation.They become very hot and can

cause burns. Always wear protec-tive clothing that covers your legs,ankles, and feet.

� A passenger should also observethe above precautions.

ModificationsModifications made to this motorcyclenot approved by Yamaha, or the re-moval of original equipment, may ren-der the motorcycle unsafe for use andmay cause severe personal injury.Modifications may also make yourmotorcycle illegal to use.

Loading and accessoriesAdding accessories or cargo to yourmotorcycle can adversely affect stabili-ty and handling if the weight distributionof the motorcycle is changed. To avoidthe possibility of an accident, use ex-treme caution when adding cargo oraccessories to your motorcycle. Useextra care when riding a motorcyclethat has added cargo or accessories.Here are some general guidelines tofollow if loading cargo or adding acces-sories to your motorcycle:


SAFETY INFORMATION

1-3

1

LoadingThe total weight of the operator, pas-senger, accessories and cargo mustnot exceed the maximum load limit.

When loading within this weight limit,keep the following in mind:

� Cargo and accessory weightshould be kept as low and close tothe motorcycle as possible. Makesure to distribute the weight asevenly as possible on both sides ofthe motorcycle to minimize imbal-ance or instability.

� Shifting weights can create a sud-den imbalance. Make sure that ac-cessories and cargo are securelyattached to the motorcycle beforeriding. Check accessory mountsand cargo restraints frequently.

� Never attach any large or heavyitems to the handlebar, front fork,or front fender. These items, in-cluding such cargo as sleeping

bags, duffel bags, or tents, cancreate unstable handling or a slowsteering response.

AccessoriesGenuine Yamaha accessories havebeen specifically designed for use onthis motorcycle. Since Yamaha cannottest all other accessories that may beavailable, you must personally be re-sponsible for the proper selection, in-stallation and use of non-Yamahaaccessories. Use extreme cautionwhen selecting and installing any ac-cessories.Keep the following guidelines in mind,as well as those provided under “Load-ing” when mounting accessories.

� Never install accessories or carrycargo that would impair the perfor-mance of your motorcycle. Care-fully inspect the accessory beforeusing it to make sure that it doesnot in any way reduce groundclearance or cornering clearance,

limit suspension travel, steeringtravel or control operation, or ob-scure lights or reflectors.• Accessories fitted to the handle-

bar or the front fork area cancreate instability due to improperweight distribution or aerody-namic changes. If accessoriesare added to the handlebar orfront fork area, they must be aslightweight as possible andshould be kept to a minimum.

• Bulky or large accessories mayseriously affect the stability ofthe motorcycle due to aerody-namic effects. Wind may at-tempt to lift the motorcycle, orthe motorcycle may become un-stable in cross winds. These ac-cessories may also causeinstability when passing or beingpassed by large vehicles.

• Certain accessories can dis-place the operator from his orher normal riding position. Thisimproper position limits the free-dom of movement of the opera-

Maximum load:190 kg (419 lb)


SAFETY INFORMATION

1-4

1

tor and may limit control ability,therefore, such accessories arenot recommended.

� Use caution when adding electri-cal accessories. If electrical acces-sories exceed the capacity of themotorcycle’s electrical system, anelectric failure could result, whichcould cause a dangerous loss oflights or engine power.

Gasoline and exhaust gas� GASOLINE IS HIGHLY FLAMMA-

BLE:• Always turn the engine off when

refueling.• Take care not to spill any gaso-

line on the engine or exhaustsystem when refueling.

• Never refuel while smoking or inthe vicinity of an open flame.

� Never start the engine or let it runfor any length of time in a closedarea. The exhaust fumes are poi-sonous and may cause loss ofconsciousness and death within ashort time. Always operate yourmotorcycle in an area that has ad-equate ventilation.

� Always turn the engine off beforeleaving the motorcycle unattendedand remove the key from the mainswitch. When parking the motor-cycle, note the following:• The engine and exhaust system

may be hot, therefore, park themotorcycle in a place where pe-destrians or children are not like-ly to touch these hot areas.

• Do not park the motorcycle on aslope or soft ground, otherwise itmay fall over.

• Do not park the motorcycle neara flammable source, (e.g., a ker-osene heater, or near an openflame), otherwise it could catchfire.

� When transporting the motorcyclein another vehicle, make sure thatit is kept upright. If the motorcycleshould lean over, gasoline mayleak out of the fuel tank.

� If you should swallow any gaso-line, inhale a lot of gasoline vapor,or allow gasoline to get into youreyes, see your doctor immediately.If any gasoline spills on your skin

or clothing, immediately wash theaffected area with soap and waterand change your clothes.


DESCRIPTION

2-1

2

EAU10410

Left view

1

7 6 5

2,3,4

1. Headlight (page 6-29)2. Fuse (page 6-28)3. Battery (page 6-27)4. Owner’s tool kit (page 6-1)5. Shock absorber assembly spring preload adjusting ring (page 3-8)6. Engine oil drain bolt (page 6-9)7. Shift pedal (page 3-5)


DESCRIPTION

2-2

2

EAU10420

Right view

1

6 5 4 3

2

1. Carrier (page 3-9)2. Air filter element (page 6-10)3. Engine oil filler cap (page 6-9)4. Brake pedal (page 3-6)5. Kickstarter (page 3-8)6. Shock absorber assembly spring preload adjusting ring (page 3-8)


DESCRIPTION

2-3

2

EAU10430

Controls and instruments

1 7 8

910

2 3 4 65

1. Clutch lever (page 3-5)2. Left handlebar switches (page 3-4)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 3-4)8. Brake lever (page 3-5)

9. Throttle grip (page 6-12)10.Fuel tank cap (page 3-6)


INSTRUMENT AND CONTROL FUNCTIONS

3-1

3

EAU10460

Main switch/steering lock

The main switch/steering lock controlsthe ignition and lighting systems, and isused to lock the steering. The variouspositions are described below.

EAU33590

ONAll electrical circuits are supplied withpower; the meter lighting, taillight andauxiliary light come on, and the enginecan be started. The key cannot be re-moved.

NOTE:The headlight comes on automaticallywhen the engine is started and stays onuntil the key is turned to “OFF”, even ifthe engine stalls.

EAU10660

OFFAll electrical systems are off. The keycan be removed.

EAU43140

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

To lock the steering

1. Turn the handlebars all the way tothe left.

2. Push the key in from the “OFF” po-sition, and then turn it to “LOCK”while still pushing it.

3. Remove the key.

To unlock the steering

Insert the key and turn it to “OFF”.

WARNINGEWA10060

Never turn the key to “OFF” or“LOCK” while the vehicle is moving,otherwise the electrical systems willbe switched off, which may result inloss of control or an accident. Makesure that the vehicle is stopped be-fore turning the key to “OFF” or“LOCK”.

1. Push.2. Turn.

1. Turn.



3-2

3

EAU11003

Indicator and warning lights

EAU11020

Turn signal indicator light “ ” This indicator light flashes when theturn signal switch is pushed to the left orright.

EAU11060

Neutral indicator light “ ” This indicator light comes on when thetransmission is in the neutral position.

EAU11080

High beam indicator light “ ” This indicator light comes on when thehigh beam of the headlight is switchedon.

EAU45740

Engine trouble warning light “ ” This warning light comes on or flasheswhen an electrical circuit monitoring theengine is defective. When this occurs,have a Yamaha dealer check the self-diagnosis system. (See page 3-3 for anexplanation of the self-diagnosis de-vice.)The electrical circuit of the warning lightcan be checked by turning the key to“ON”. If the warning light does not comeon for a few seconds, then go off, havea Yamaha dealer check the electricalcircuit.

EAU11630

Speedometer unit

The speedometer unit is equipped witha speedometer, an odometer and atripmeter. The speedometer showsriding speed. The odometer shows thetotal distance traveled. The tripmetershows the distance traveled since itwas last set to zero with the reset knob.The tripmeter can be used to estimatethe distance that can be traveled with afull tank of fuel. This information will en-able you to plan future fuel stops.

1. Turn signal indicator light “ ”2. Neutral indicator light “ ”3. High beam indicator light “ ”4. Engine trouble warning light “ ”

1 2 3 4

1. Speedometer2. Odometer3. Tripmeter4. Tripmeter reset knob

1

4

3

2



3-3

3

EAU11851

Tachometer

The electric tachometer allows the riderto monitor the engine speed and keep itwithin the ideal power range.

CAUTION:ECA10031

Do not operate the engine in the ta-chometer red zone.Red zone: 10000 r/min and above

EAU12090

Self-diagnosis device This model is equipped with a self-diag-nosis device for various electrical cir-cuits.If any of those circuits are defective, theengine trouble warning light will comeon or flash. If this occurs, have aYamaha dealer check the vehicle.

CAUTION:ECA11170

To prevent engine damage, be sureto consult a Yamaha dealer as soonas possible if this occurs.

EAU37052

Fuel gauge

The fuel gauge indicates the amount offuel in the fuel tank. The needle movestowards “E” (Empty) as the fuel leveldecreases. When the needle reachesthe red zone, approximately 3.0 L (0.79US gal, 0.66 Imp.gal) remain in the fueltank. If this occurs, refuel as soon aspossible.

NOTE:The main switch must be turned to“ON” for the fuel gauge to display anaccurate fuel level reading.

1. Tachometer2. Tachometer red zone

12

1. Fuel gauge2. Red zone

1

2



3-4

3

EAU12347

Handlebar switches

Left

Right

EAU12400

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

EAU12460

Turn signal switch “ / ” To signal a right-hand turn, push thisswitch to “ ”. To signal a left-handturn, push this switch to “ ”. When re-leased, the switch returns to the centerposition. To cancel the turn signallights, push the switch in after it has re-turned to the center position.

EAU12500

Horn switch “ ” Press this switch to sound the horn.

EAU12710

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

CAUTION:ECA10050

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

EAU41700

The engine trouble warning light willcome on when the key is turned to “ON”and the start switch is pushed, but thisdoes not indicate a malfunction.

1. Dimmer switch “ / ”2. Turn signal switch “ / ”3. Horn switch “ ”

1. Start switch “ ”



3-5

3

EAU12820

Clutch lever

The clutch lever is located at the lefthandlebar grip. To disengage theclutch, pull the lever toward the handle-bar grip. To engage the clutch, releasethe lever. The lever should be pulledrapidly and released slowly for smoothclutch operation.The clutch lever is equipped with aclutch switch, which is part of the igni-tion circuit cut-off system. (See page3-10.)

EAU12870

Shift pedal

The shift pedal is located on the leftside of the engine and is used in com-bination with the clutch lever whenshifting the gears of the 5-speed con-stant-mesh transmission equipped onthis motorcycle.

EAU12890

Brake lever

The brake lever is located at the righthandlebar grip. To apply the frontbrake, pull the lever toward the handle-bar grip.

1. Clutch lever 1. Shift pedal

1

1. Brake lever

1



3-6

3

EAU12941

Brake pedal

The brake pedal is on the right side ofthe motorcycle. To apply the rearbrake, press down on the brake pedal.

EAU13001

Fuel tank cap

To remove the fuel tank capInsert the key into the lock and turn it1/4 turn clockwise. The lock will be re-leased and the fuel tank cap can be re-moved.

To install the fuel tank cap1. 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.

NOTE:The fuel tank cap cannot be installedunless the key is in the lock. In addition,the key cannot be removed if the cap isnot properly installed and locked.

WARNINGEWA11140

Make sure that the fuel tank cap isproperly installed before riding.

1. Brake pedal

11. Fuel tank cap2. Unlock.

1 2



3-7

3

EAU13220

Fuel

Make sure that there is sufficient fuel inthe tank. When refueling, be sure to in-sert the pump nozzle into the fuel tankfiller hole and to fill the tank to the bot-tom of the filler tube as shown.

WARNINGEWA10880

� Do not overfill the fuel tank, oth-erwise it may overflow when thefuel warms up and expands.

� Avoid spilling fuel on the hot en-gine.

CAUTION:ECA10070

Immediately wipe off spilled fuelwith a clean, dry, soft cloth, sincefuel may deteriorate painted surfac-es or plastic parts.

EAU13320

CAUTION:ECA11400

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

Your Yamaha engine has been de-signed to use regular unleaded gaso-line with a research octane number of91 or higher. If knocking (or pinging) oc-curs, use a gasoline of a different brand

or premium unleaded fuel. Use of un-leaded fuel will extend spark plug lifeand reduce maintenance costs.

1. Fuel tank filler tube2. Fuel level

1 2

Recommended fuel:REGULAR UNLEADED GASOLINE ONLY

Fuel tank capacity:12.0 L (3.17 US gal, 2.64 Imp.gal)

Fuel reserve amount:3.0 L (0.79 US gal, 0.66 Imp.gal)



3-8

3

EAU13443

Catalytic converters This vehicle is equipped with catalyticconverters in the exhaust system.

WARNINGEWA10860

The exhaust system is hot after op-eration. Make sure that the exhaustsystem has cooled down before do-ing any maintenance work.

CAUTION:ECA16490

The following precautions must beobserved to prevent a fire hazard orother damages.

� Use only unleaded gasoline.The use of leaded gasoline willcause unrepairable damage tothe catalytic converters.

� Never park the vehicle near pos-sible fire hazards such as grassor other materials that easilyburn.

� Do not allow the engine to idletoo long.

EAU43150

Kickstarter

If the engine fails to start by pushing thestart switch, try to start it by using thekickstarter. To start the engine, fold outthe kickstarter lever, move it down light-ly with your foot until the gears engage,and then push it down smoothly butforcefully. This model is equipped witha primary kickstarter, allowing the en-gine to be started in any gear if theclutch is disengaged and the sidestandis up. However, shifting the transmis-sion into the neutral position beforestarting is recommended.

EAU14880

Adjusting the shock absorber assemblies

Each shock absorber assembly isequipped with a spring preload adjust-ing ring.

CAUTION:ECA10100

Never attempt to turn an adjustingmechanism beyond the maximum orminimum settings.

1. Kickstarter lever

1. Spring preload adjusting ring2. Position indicator

(a)

(b)

2

1

U27SE0E0.book Page 8 Friday, April 11, 2008 4:46 PM


3-9

3

WARNINGEWA10210

Always adjust both shock absorberassemblies equally, otherwise poorhandling and loss of stability mayresult.

Adjust the spring preload as follows.To increase the spring preload andthereby harden the suspension, turnthe adjusting ring on each shock ab-sorber assembly in direction (a). To de-crease the spring preload and therebysoften the suspension, turn the adjust-ing ring on each shock absorber as-sembly in direction (b).

NOTE:Align the appropriate notch in the ad-justing ring with the position indicatoron the shock absorber.

EAU15111

Carrier

WARNINGEWA10171

� Do not exceed the load limit of 3kg (6.6 lb) for the carrier.

� Do not exceed the maximumload of 190 kg (419 lb) for the ve-hicle.

EAU15301

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

NOTE:The built-in sidestand switch is part ofthe ignition circuit cut-off system, whichcuts the ignition in certain situations.(See further down for an explanation ofthe ignition circuit cut-off system.)

WARNINGEWA10240

The vehicle must not be ridden withthe sidestand down, or if the side-stand cannot be properly moved up(or does not stay up), otherwise thesidestand could contact the groundand distract the operator, resultingin a possible loss of control.Yamaha’s ignition circuit cut-offsystem has been designed to assistthe operator in fulfilling the respon-sibility of raising the sidestand be-fore starting off. Therefore, checkthis system regularly as described

Spring preload setting:Minimum (soft):

1Standard:

3Maximum (hard):

5

1. Carrier

1

U27SE0E0.book Page 9 Friday, April 11, 2008 4:46 PM


3-10

3

below and have a Yamaha dealer re-pair it if it does not function proper-ly.

EAU43161

Ignition circuit cut-off system The ignition circuit cut-off system (com-prising the sidestand switch, clutchswitch 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 isnot pulled.

� It prevents starting when the trans-mission is in gear and the clutch le-ver is pulled, but the sidestand isstill down.

� It cuts the running engine when thetransmission is in gear and the sid-estand is moved down.

Periodically check the operation of theignition circuit cut-off system accordingto the following procedure.

WARNINGEWA10260

� The vehicle must be placed onthe centerstand during this in-spection.

� If a malfunction is noted, have aYamaha dealer check the sys-tem before riding.



3-11

3

With the engine turned off:1. Move the sidestand down.2. Turn the key on. 3. Shift the transmission into the neutral position.4. Push the start switch or push the kickstarter lever down.Does the engine start?

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?

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 system is OK. The motorcycle can be ridden.

The neutral switch may be defective.The motorcycle should not be ridden untilchecked by a Yamaha dealer.

The sidestand switch may be defective.The motorcycle should not be ridden untilchecked by a Yamaha dealer.

The clutch switch may be defective.The motorcycle should not be ridden untilchecked by a Yamaha dealer.

YES NO

YES NO

YES NO


PRE-OPERATION CHECKS

4-1

4

EAU15593

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 lossof 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 shorttime; and the added safety it assures is more than worth the time involved.

WARNINGEWA11150

If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operatingthe vehicle.



4-2

4

EAU15605

Pre-operation check list ITEM CHECKS PAGE

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

3-7

Engine oil• Check oil level in engine.• If necessary, add recommended oil to specified level.• Check vehicle for oil leakage.

6-9

Front brake

• Check operation.• If soft or spongy, have Yamaha dealer bleed hydraulic system.• Check brake pads for wear.• Replace if necessary.• Check fluid level in reservoir.• If necessary, add recommended brake fluid to specified level.• Check hydraulic system for leakage.

6-19, 6-19

Rear brake• Check operation.• Check pedal free play.• Adjust if necessary.

6-17, 6-19

Clutch

• Check operation.• Lubricate cable if necessary.• Check lever free play.• Adjust if necessary.

6-16

Throttle grip

• Make sure that operation is smooth.• Check cable free play.• If necessary, have Yamaha dealer adjust cable free play and lubricate cable and

grip housing.

6-12, 6-23

Control cables • Make sure that operation is smooth.• Lubricate if necessary. 6-23

Drive chain

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

6-21, 6-22



4-3

4

Wheels and tires

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

6-13, 6-15

Shift pedal • Make sure that operation is smooth.• Correct if necessary. —

Brake pedal • Make sure that operation is smooth.• Lubricate pedal pivoting point if necessary. 6-24

Brake and clutch levers • Make sure that operation is smooth.• Lubricate lever pivoting points if necessary. 6-23

Centerstand, sidestand • Make sure that operation is smooth.• Lubricate pivots if necessary. 6-24

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

Instruments, lights, signals and switches

• Check operation.• Correct if necessary. —

Sidestand switch • Check operation of ignition circuit cut-off system.• If system is defective, have Yamaha dealer check vehicle. 3-9

ITEM CHECKS PAGE


OPERATION AND IMPORTANT RIDING POINTS

5-1

5

EAU15950

WARNINGEWA10270

� Become thoroughly familiarwith all operating controls andtheir functions before riding.Consult a Yamaha dealer re-garding any control or functionthat you do not thoroughly un-derstand.

� Never start the engine or oper-ate it in a closed area for anylength of time. Exhaust fumesare poisonous, and inhalingthem can cause loss of con-sciousness and death within ashort time. Always make surethat there is adequate ventila-tion.

� Before starting out, make surethat the sidestand is up. If thesidestand is not raised com-pletely, it could contact theground and distract the opera-tor, resulting in a possible lossof control.

EAU45310

NOTE:This model is equipped with a lean an-gle sensor to stop the engine in case ofa turnover. To start the engine after aturnover, be sure to turn the mainswitch to “OFF” and then to “ON”. Fail-ing to do so will prevent the engine fromstarting even though the engine willcrank when pushing the start switch.

EAU43181

Starting the engine In order for the ignition circuit cut-offsystem to enable starting, one of thefollowing conditions must be met:

� The transmission is in the neutralposition.

� The transmission is in gear withthe clutch lever pulled and the sid-estand up.

WARNINGEWA10290

� Before starting the engine,check the function of the igni-tion circuit cut-off system ac-cording to the proceduredescribed on page 3-10.

� Never ride with the sidestanddown.

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

tral position.

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



5-2

5

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

NOTE:If the engine fails to start when usingthe start switch, release it, wait a fewseconds, and then try again. Eachstarting attempt should be as short aspossible to preserve the battery. Do notcrank the engine more than 10 secondson any one attempt. If the engine doesnot start with the starter motor, try usingthe kickstarter.

CAUTION:ECA11370

The engine trouble warning lightshould come on when the key isturned to “ON”, and then go off aftera few seconds. If the engine troublewarning light comes on or flashesafter starting, immediately stop theengine, and have a Yamaha dealercheck the self-diagnosis system.

CAUTION:ECA11040

For maximum engine life, never ac-celerate hard when the engine iscold!

EAU16671

Shifting

Shifting gears lets you control theamount of engine power available forstarting 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 downrepeatedly until it reaches the end of itstravel, and then slightly raise it.

1. Shift pedal2. Neutral position



5-3

5

CAUTION:ECA10260

� Even with the transmission inthe neutral position, do notcoast for long periods of timewith the engine off, and do nottow the motorcycle for long dis-tances. The transmission isproperly lubricated only whenthe engine is running. Inade-quate lubrication may damagethe transmission.

� Always use the clutch whilechanging gears to avoid damag-ing the engine, transmission,and drive train, which are notdesigned to withstand theshock of forced shifting.

EAU16810

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

� Shift up swiftly, and avoid high en-gine speeds during acceleration.

� Do not rev the engine while shiftingdown, and avoid high enginespeeds with no load on the engine.

� Turn the engine off instead of let-ting it idle for an extended length oftime (e.g., in traffic jams, at trafficlights or at railroad crossings).

EAU16830

Engine break-in There is never a more important periodin the life of your engine than the periodbetween 0 and 1000 km (600 mi). Forthis reason, you should read the follow-ing material carefully.Since the engine is brand new, do notput an excessive load on it for the first1000 km (600 mi). The various parts inthe engine wear and polish themselvesto the correct operating clearances.During this period, prolonged full-throt-tle operation or any condition that mightresult in engine overheating must beavoided.

EAU37250

0–500 km (0–300 mi)Avoid prolonged operation above 6000r/min.After every hour of operation, stop theengine, and then let it cool for five to tenminutes.Vary the engine speed from time totime. Do not operate the engine at oneset throttle position.



5-4

5

500–1000 km (300–600 mi)Avoid prolonged operation above 7500r/min.Rev the engine freely through thegears, but do not use full throttle at anytime.

CAUTION:ECA10280

After 1000 km (600 mi) of operation,the engine oil must be changed.

1000 km (600 mi) and beyondThe vehicle can now be operated nor-mally.

CAUTION:ECA10310

� Keep the engine speed out ofthe tachometer red zone.

� If any engine trouble should oc-cur during the engine break-inperiod, immediately have aYamaha dealer check the vehi-cle.

EAU17212

Parking When parking, stop the engine, andthen remove the key from the mainswitch.

WARNINGEWA10310

� Since the engine and exhaustsystem can become very hot,park in a place where pedestri-ans or children are not likely totouch them.

� Do not park on a slope or on softground, otherwise the vehiclemay overturn.

CAUTION:ECA10380

Never park in an area where thereare fire hazards such as grass orother flammable materials.


PERIODIC MAINTENANCE AND MINOR REPAIR

6-1

6

EAU17240

Safety is an obligation of the owner. Pe-riodic inspection, adjustment and lubri-cation will keep your vehicle in thesafest and most efficient condition pos-sible. The most important points of in-spection, adjustment, and lubricationare explained on the following pages.The intervals given in the periodicmaintenance and lubrication chartshould be simply considered as a gen-eral guide under normal riding condi-tions. However, DEPENDING ON THEWEATHER, TERRAIN, GEOGRAPHI-CAL LOCATION, AND INDIVIDUALUSE, THE MAINTENANCE INTER-VALS MAY NEED TO BE SHORT-ENED.

WARNINGEWA10320

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

EAU17340

Owner’s tool kit

The owner’s tool kit is located behindpanel A. (See page 6-6.)The service information included in thismanual and the tools provided in theowner’s tool kit are intended to assistyou in the performance of preventivemaintenance and minor repairs. How-ever, additional tools such as a torquewrench may be necessary to performcertain maintenance work correctly.

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

WARNINGEWA10350

Modifications not approved byYamaha may cause loss of perfor-mance and render the vehicle un-safe for use. Consult a Yamahadealer before attempting any chang-es.

1. Owner’s tool kit

1



6-2

6

EAU17715

Periodic maintenance and lubrication chart

NOTE:� The annual checks must be performed every year, except if a kilometer-based maintenance, or for the UK, a

mileage-based maintenance, is performed instead.� From 30000 km (17500 mi), repeat the maintenance intervals starting from 6000 km (3500 mi).� Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical

skills.

NO. ITEM CHECK OR MAINTENANCE JOB

ODOMETER READINGANNUAL CHECK1000 km

(600 mi)6000 km (3500 mi)

12000 km (7000 mi)

18000 km (10500 mi)

24000 km (14000 mi)

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

2 Spark plug• Check condition.• Clean and regap. √ √

• Replace. √ √

3 * Valves • Check valve clearance.• Adjust. √ √ √ √

4 Air filter element• Clean. √ √

• Replace. √ √

5 Clutch • Check operation.• Adjust. √ √ √ √ √

6 * Front brake• Check operation, fluid level and

vehicle for fluid leakage. √ √ √ √ √ √

• Replace brake pads. Whenever worn to the limit



6-3

6

7 * Rear brake• Check operation and adjust brake

pedal free play. √ √ √ √ √ √

• Replace brake shoes. Whenever worn to the limit

8 * Brake hose• Check for cracks or damage. √ √ √ √ √

• Replace. Every 4 years

9 * Wheels • Check runout and for damage. √ √ √ √

10 * Tires

• Check tread depth and for dam-age.

• Replace if necessary.• Check air pressure.• Correct if necessary.

√ √ √ √ √

11 * Wheel bearings • Check bearing for looseness or damage. √ √ √ √

12 * Swingarm pivot bushes

• Check bush assemblies for loose-ness. √ √ √ √

• Lubricate with lithium-soap-based grease. Every 50000 km (30000 mi)

13 Drive chain

• Check chain slack, alignment and condition.

• Adjust and lubricate chain with a special O-ring chain lubricant thoroughly.

Every 1000 km (600 mi) and after washing the motorcycle or riding in the rain

14 * Steering bearings

• Check bearing play and steering for roughness. √ √ √ √ √

• Lubricate with lithium-soap-based grease. Every 24000 km (14000 mi)



(600 mi)6000 km (3500 mi)

12000 km (7000 mi)

18000 km (10500 mi)

24000 km (14000 mi)



6-4

6

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

16 Brake lever pivot shaft • Lubricate with silicone grease. √ √ √ √ √

17 Brake pedal pivot shaft

• Lubricate with lithium-soap-based grease. √ √ √ √ √

18 Clutch lever pivot shaft

• Lubricate with lithium-soap-based grease. √ √ √ √ √

19 Sidestand, center-stand

• Check operation.• Lubricate. √ √ √ √ √

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

21 * Front fork • Check operation and for oil leak-age. √ √ √ √

22 * Shock absorber as-semblies

• Check operation and shock ab-sorbers for oil leakage. √ √ √ √

23 * Fuel injection • Check engine idle speed. √ √ √ √ √ √

24 Engine oil• Change.• Check oil level and vehicle for oil

leakage.√ √ √ √ √ √

25 * Front and rear brake switches • Check operation. √ √ √ √ √ √

26 Moving parts and cables • Lubricate. √ √ √ √ √



(600 mi)6000 km (3500 mi)

12000 km (7000 mi)

18000 km (10500 mi)

24000 km (14000 mi)



6-5

6

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.• 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.

27 * Throttle grip hous-ing and cable

• Check operation and free play.• Adjust the throttle cable free play

if necessary.• Lubricate the throttle grip housing

and cable.

√ √ √ √ √

28 * Air induction sys-tem

• Check the air cut-off valve, reed valve, and hose for damage.

• Replace any damaged parts if necessary.

√ √ √ √ √

29 * Lights, signals and switches

• Check operation.• Adjust headlight beam. √ √ √ √ √ √



(600 mi)6000 km (3500 mi)

12000 km (7000 mi)

18000 km (10500 mi)

24000 km (14000 mi)



6-6

6

EAU18771

Removing and installing pan-els The panels shown need to be removedto perform some of the maintenancejobs described in this chapter. Refer tothis section each time a panel needs tobe removed and installed.

EAU36961

Panel A

To remove the panel1. Slide the panel lock cover open, in-

sert the key into the lock, and thenturn it 1/4 turn clockwise.

2. Pull the front of the panel out withthe key inserted in the lock, andthen slide the panel forward to re-lease it in the rear.

To install the panel1. Secure the rear of the panel, and

then push the front of the panel inwith the key inserted in the lock.1. Panel A

11. Panel B

1. Panel lock cover2. Unlock.

1

1

2



6-7

6

2. While pushing the panel inward,turn the key counterclockwise tothe original position, remove it, andthen close the panel lock cover.

EAU37070

Panel B

To remove the panel1. Remove the screw.

2. Pull the front of the panel out, andthen slide the panel forward to re-lease it in the rear.

To install the panel1. Secure the rear of the panel, and

then push the front of the panel in.

2. Install the screw.

EAU19603

Checking the spark plug The spark plug is an important enginecomponent, which is easy to check.Since heat and deposits will cause anyspark plug to slowly erode, the sparkplug should be removed and checkedin accordance with the periodic mainte-nance and lubrication chart. In addition,the condition of the spark plug can re-veal the condition of the engine.

To remove the spark plug1. Remove the spark plug cap.

2. Remove the spark plug as shown,with the spark plug wrench includ-ed in the owner’s tool kit.

1. Screw

1

1. Spark plug cap

11



6-8

6

To check the spark plug1. Check that the porcelain insulator

around the center electrode of thespark plug is a medium-to-light tan(the ideal color when the vehicle isridden normally).

NOTE:If the spark plug shows a distinctly dif-ferent color, the engine could be oper-ating improperly. Do not attempt todiagnose such problems yourself. In-stead, have a Yamaha dealer checkthe vehicle.

2. Check the spark plug for electrodeerosion and excessive carbon orother deposits, and replace it ifnecessary.

To install the spark plug1. Measure the spark plug gap with a

wire thickness gauge and, if nec-essary, adjust the gap to specifica-tion.

2. Clean the surface of the spark pluggasket and its mating surface, andthen wipe off any grime from thespark plug threads.

3. Install the spark plug with thespark plug wrench, and then tight-en it to the specified torque.

NOTE:If a torque wrench is not available wheninstalling a spark plug, a good estimateof the correct torque is 1/4–1/2 turnpast finger tight. However, the sparkplug should be tightened to the speci-fied torque as soon as possible.

4. Install the spark plug cap.

1. Spark plug wrench

Specified spark plug:NGK/CR6HSA

1. Spark plug gap

Spark plug gap:0.6–0.7 mm (0.024–0.028 in)

Tightening torque:Spark plug:

12.5 Nm (1.25 m·kgf, 9.0 ft·lbf)



6-9

6

EAU37171

Engine oil The engine oil level should be checkedbefore each ride. In addition, the oilmust be changed at the intervals spec-ified in the periodic maintenance andlubrication chart.

To check the engine oil level1. Place the vehicle on the center-

stand.

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

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

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

NOTE:The engine oil should be between theminimum and maximum level marks.

4. If the engine oil is at or below theminimum level mark, add sufficientoil of the recommended type toraise it to the correct level.

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

To change the engine oil1. Start the engine, warm it up for

several minutes, and then turn itoff.

2. Place an oil pan under the engineto collect the used oil.

3. Remove the engine oil filler capand drain bolt to drain the oil fromthe crankcase.

1. Engine oil filler cap

1. Dipstick2. Maximum level mark3. Minimum level mark 1. Engine oil drain bolt

2. Oil pan



6-10

6

4. Install the engine oil drain bolt, andthen tighten it to the specifiedtorque.

5. Refill with the specified amount ofthe recommended engine oil, andthen install and tighten the engineoil filler cap.

CAUTION:ECA11620

� In order to prevent clutch slip-page (since the engine oil alsolubricates the clutch), do notmix any chemical additives. Donot use oils with a diesel speci-fication of “CD” or oils of a high-er quality than specified. Inaddition, do not use oils labeled“ENERGY CONSERVING II” orhigher.

� Make sure that no foreign mate-rial enters the crankcase.

6. Start the engine, and then let it idlefor several minutes while checkingit for oil leakage. If oil is leaking, im-mediately turn the engine off andcheck for the cause.

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

EAU37121

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

1. Remove panel B. (See page 6-6.)2. Remove the air filter case cover by

removing the screws.

3. Remove the air filter element.

Tightening torque:Engine oil drain bolt:

20 Nm (2.0 m·kgf, 14 ft·lbf)

Recommended engine oil:See page 8-1.

Oil change quantity:1.00 L (1.06 US qt, 0.88 Imp.qt)

1. “CD” specification2. “ENERGY CONSERVING II”

1

2

1. Screw2. Air filter case cover

2

1

1



6-11

6

4. Remove the sponge material fromthe air filter element.

5. Lightly tap the air filter element toremove most of the dust and dirt,and then blow the remaining dirtout with compressed air on themesh side as shown. If the air filterelement is damaged, replace it.

6. Clean the sponge material withsolvent, then squeeze the remain-ing solvent out, and be sure to letthe sponge material dry before in-stalling it into the air filter element.If the sponge material is damaged,replace it.

WARNINGEWA10430

Use only a dedicated parts cleaningsolvent. To avoid the risk of fire orexplosion, do not use gasoline orsolvents with a low flash point.

CAUTION:ECA15100

To avoid damaging the sponge ma-terial, handle it gently and carefully,and do not twist it.

7. Install the sponge material into theair filter element, and then installthe air filter element into the air fil-ter case.

CAUTION:ECA10480

� Make sure that the air filter ele-ment is properly seated in theair filter case.

� The engine should never be op-erated without the air filter ele-ment installed, otherwise thepiston(s) and/or cylinder(s) maybecome excessively worn.

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

1. Air filter element2. Sponge material

21

1. Air filter element

1



6-12

6

9. Check the hose at the bottom ofthe air filter case for accumulateddust or water, and if necessary,drain it by removing the clamp, andthen removing the plug.

10. Install the plug into the checkhose, and then install the clamp.

11. Install the panel.

EAU44730

Checking the engine idling speed The engine idling speed must bechecked as follows and, if necessary,adjusted by a Yamaha dealer at the in-tervals specified in the periodic mainte-nance and lubrication chart.Start the engine and warm it up for sev-eral minutes at 1000–2000 r/min whileoccasionally revving it to 4000–5000r/min.

EAU21370

Adjusting the throttle cable free play

The throttle cable free play should mea-sure 3.0–7.0 mm (0.12–0.28 in) at thethrottle grip. Periodically check thethrottle cable free play and, if neces-sary, adjust it as follows.

NOTE:The engine idling speed must be cor-rectly adjusted before checking and ad-justing the throttle cable free play.

1. Loosen the locknut.

1. Clamp2. Air filter check hose plug

Engine idling speed:1300–1500 r/min

1. Throttle cable free play2. Locknut3. Throttle cable free play adjusting nut



6-13

6

2. To increase the throttle cable freeplay, turn the adjusting nut in direc-tion (a). To decrease the throttlecable free play, turn the adjustingnut in direction (b).

3. Tighten the locknut.

EAU21401

Valve clearance The valve clearance changes with use,resulting in improper air-fuel mixtureand/or engine noise. To prevent thisfrom occurring, the valve clearancemust be adjusted by a Yamaha dealerat the intervals specified in the periodicmaintenance and lubrication chart.

EAU21561

Tires To maximize the performance, durabil-ity, and safe operation of your motor-cycle, note the following pointsregarding the specified tires.

Tire air pressureThe tire air pressure should be checkedand, if necessary, adjusted before eachride.

WARNINGEWA10500

� The tire air pressure must bechecked and adjusted on coldtires (i.e., when the temperatureof the tires equals the ambienttemperature).

� The tire air pressure must be ad-justed in accordance with theriding speed and with the totalweight of rider, passenger, car-go, and accessories approvedfor this model.



6-14

6WARNING

EWA11020

Because loading has an enormousimpact on the handling, braking,performance and safety characteris-tics of your motorcycle, you shouldkeep the following precautions inmind.

� NEVER OVERLOAD THEMOTORCYCLE! Operation of anoverloaded motorcycle may re-sult in tire damage, loss of con-trol, or severe injury. Make surethat the total weight of rider,

passenger, cargo, and accesso-ries does not exceed the speci-fied maximum load for thevehicle.

� Do not carry along looselypacked items, which can shiftduring a ride.

� Securely pack the heaviestitems close to the center of themotorcycle and distribute theweight evenly on both sides.

� Adjust the suspension and tireair pressure with regard to theload.

� Check the tire condition and airpressure before each ride.

Tire inspection

The tires must be checked before eachride. If the center tread depth reachesthe specified limit, if the tire has a nail orglass fragments in it, or if the sidewall iscracked, have a Yamaha dealer re-place the tire immediately.

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

Tire air pressure (measured on cold tires):

0–90 kg (0–198 lb):Front:

175 kPa (1.75 kgf/cm², 25 psi)Rear:

200 kPa (2.00 kgf/cm², 29 psi)90–190 kg (198–419 lb):

Front:175 kPa (1.75 kgf/cm², 25 psi)

Rear:280 kPa (2.80 kgf/cm², 41 psi)

Maximum load*:190 kg (419 lb)

* Total weight of rider, passenger, car-go and accessories

1. Tire sidewall2. Tire tread depth

Minimum tire tread depth (front and rear):

1.6 mm (0.06 in)



6-15

6

Tire informationThis motorcycle is equipped with castwheels and tubeless tires.

WARNINGEWA10460

� The front and rear tires shouldbe of the same make and de-sign, otherwise the handlingcharacteristics of the vehiclecannot be guaranteed.

� After extensive tests, only thetires listed below have been ap-proved for this model byYamaha Motor Co., Ltd.

WARNINGEWA10470

� Have a Yamaha dealer replaceexcessively worn tires. Besidesbeing illegal, operating the vehi-cle with excessively worn tiresdecreases riding stability andcan lead to loss of control.

� The replacement of all wheeland brake related parts, includ-ing the tires, should be left to aYamaha dealer, who has thenecessary professional knowl-edge and experience.

EAU21960

Cast wheels To maximize the performance, durabil-ity, and safe operation of your vehicle,note the following points regarding thespecified wheels.

� The wheel rims should be checkedfor cracks, bends or warpage be-fore each ride. If any damage isfound, have a Yamaha dealer re-place the wheel. Do not attempteven the smallest repair to thewheel. A deformed or crackedwheel must be replaced.

� The wheel should be balancedwhenever either the tire or wheelhas been changed or replaced. Anunbalanced wheel can result inpoor performance, adverse han-dling characteristics, and a short-ened tire life.

� Ride at moderate speeds afterchanging a tire since the tire sur-face must first be “broken in” for itto develop its optimal characteris-tics.

Front tire:Size:

3.00-18 47PManufacturer/model:

CHENG SHIN/C-6039Rear tire:

Size:3.50-16 58P

Manufacturer/model:CHENG SHIN/C-289



6-16

6

EAU22032

Adjusting the clutch lever free play

The clutch lever free play should mea-sure 10.0–15.0 mm (0.39–0.59 in) asshown. Periodically check the clutch le-ver free play and, if necessary, adjust itas follows.

1. Loosen the locknut at the clutch le-ver.

2. To increase the clutch lever freeplay, turn the clutch lever free playadjusting bolt in direction (a). Todecrease the clutch lever free play,turn the adjusting bolt in direction(b).

3. If the specified clutch lever freeplay could be obtained as de-scribed above, tighten the locknutand skip the rest of the procedure,otherwise, proceed as follows.

4. Fully turn the adjusting bolt in di-rection (a) to loosen the clutch ca-ble.

5. Loosen the locknut further downthe clutch cable.

6. To increase the clutch lever freeplay, turn the clutch lever free playadjusting nut in direction (a). Todecrease the clutch lever free play,turn the adjusting nut in direction(b).

7. Tighten both locknuts.

1. Locknut (clutch lever)2. Clutch lever free play adjusting bolt3. Clutch lever free play

1. Locknut (clutch cable)2. Clutch lever free play adjusting nut (clutch

cable)

1

2

(a)

(b)



6-17

6

EAUT1221

Checking the front brake lever free play

The brake lever free play should mea-sure 0.0–7.0 mm (0.00–0.28 in) asshown. Periodically check the brake le-ver free play and, if necessary, have aYamaha dealer check the brake sys-tem.

WARNINGEWA10641

An incorrect brake lever free play in-dicates a hazardous condition in thebrake system. Do not operate the ve-hicle until the brake system hasbeen checked or repaired by aYamaha dealer.

EAU39812

Adjusting the brake pedal free play

The brake pedal free play should mea-sure 20.0–30.0 mm (0.79–1.18 in) atthe brake pedal end as shown. Period-ically check the brake pedal free playand, if necessary, adjust it as follows.To increase the brake pedal free play,turn the adjusting nut at the brake rod indirection (a). To decrease the brakepedal free play, turn the adjusting nut indirection (b).

WARNINGEWA10680

� After adjusting the drive chainslack or removing and installingthe rear wheel, always check thebrake pedal free play.

� If proper adjustment cannot beobtained as described, have aYamaha dealer make this ad-justment.

� After adjusting the brake pedalfree play, check the operation ofthe brake light.

1. Brake lever free play 1. Brake pedal free play

1. Brake pedal free play adjusting nut

1(a)

(b)



6-18

6

EAU44820

Checking the shift pedal The operation of the shift pedal shouldbe checked before each ride. If opera-tion is not smooth, have a Yamahadealer check the vehicle.

EAU22291

Adjusting the rear brake light switch

The rear brake light switch, which is ac-tivated by the brake pedal, is properlyadjusted when the brake light comeson just before braking takes effect. Ifnecessary, adjust the brake light switchas follows.

1. Remove panel B. (See page 6-6.)2. Turn the adjusting nut while hold-

ing the rear brake light switch inplace. To make the brake lightcome on earlier, turn the adjustingnut in direction (a). To make thebrake light come on later, turn theadjusting nut in direction (b).

3. Install the panel.

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



6-19

6

EAU22380

Checking the front brake pads and rear brake shoes The front brake pads and the rear brakeshoes must be checked for wear at theintervals specified in the periodic main-tenance and lubrication chart.

EAU22430

Front brake pads

Each front brake pad is provided withwear indicator grooves, which allowyou to check the brake pad wear with-out having to disassemble the brake.To check the brake pad wear, checkthe wear indicator grooves. If a brakepad has worn to the point that the wear

indicator grooves have almost disap-peared, have a Yamaha dealer replacethe brake pads as a set.

EAU43170

Rear brake shoes

The rear brake is provided with a wearindicator, which allows you to check thebrake shoe wear without having to dis-assemble the brake. To check thebrake shoe wear, check the position ofthe wear indicator while applying thebrake. If a brake shoe has worn to thepoint that the wear indicator reachesthe wear limit mark, have a Yamahadealer replace the brake shoes as aset.

EAU37001

Checking the front brake fluid level

Insufficient brake fluid may allow air toenter the brake system, possibly caus-ing it to become ineffective.Before riding, check that the brake fluidis above the minimum level mark andreplenish if necessary. A low brake fluidlevel may indicate worn brake padsand/or brake system leakage. If thebrake fluid level is low, be sure to checkthe brake pads for wear and the brakesystem for leakage.Observe these precautions:

1. Brake pad wear indicator groove

1. Brake shoe wear limit mark2. Brake shoe wear indicator

1

2

1. Minimum level mark



6-20

6

� When checking the fluid level,make sure that the top of the mas-ter cylinder is level by turning thehandlebars.

� Use only the recommended qualitybrake fluid, otherwise the rubberseals may deteriorate, causingleakage and poor braking perfor-mance.

NOTE:If DOT 4 is not available, DOT 3 can beused.

� Refill with the same type of brakefluid. Mixing fluids may result in aharmful chemical reaction andlead to poor braking performance.

� Be careful that water does not en-ter the master cylinder when refill-ing. Water will significantly lowerthe boiling point of the fluid andmay result in vapor lock.

� Brake fluid may deteriorate paint-ed surfaces or plastic parts. Al-ways clean up spilled fluidimmediately.

� As the brake pads wear, it is nor-mal for the brake fluid level to grad-ually go down. However, if thebrake fluid level goes down sud-denly, have a Yamaha dealercheck the cause.

EAU22720

Changing the brake fluid Have a Yamaha dealer change thebrake fluid at the intervals specified inthe NOTE after the periodic mainte-nance and lubrication chart. In addition,have the oil seals of the brake mastercylinder and caliper as well as thebrake hose replaced at the intervalslisted below or whenever they are dam-aged or leaking.

� Oil seals: Replace every twoyears.

� Brake hose: Replace every fouryears.

Recommended brake fluid:DOT 4



6-21

6

EAU22760

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

EAU22793

To check the drive chain slack1. Place the motorcycle on the cen-

terstand.2. Shift the transmission into the neu-

tral position.3. Spin the rear wheel several times

to locate the tightest portion of thedrive chain.

4. Measure the drive chain slack asshown.

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

EAU37112

To adjust the drive chain slack1. Loosen the brake pedal free play

adjusting nut, brake torque rod nut,and axle nut.

2. Loosen the chain puller locknut ateach end of the swingarm.

3. To tighten the drive chain, turn theadjusting bolt at each end of theswingarm in direction (a). To loos-en the drive chain, turn the adjust-ing bolt at each end of theswingarm in direction (b), and thenpush the rear wheel forward.

NOTE:Using the alignment marks on eachside of the swingarm, make sure thatboth chain pullers are in the same posi-tion for proper wheel alignment.

1. Drive chain slack

Drive chain slack:20.0–30.0 mm (0.79–1.18 in)

1. Drive chain slack adjusting bolt2. Chain puller locknut3. Axle nut4. Brake torque rod nut5. Brake pedal free play adjusting nut

45

1 23

1. Alignment marks2. Chain puller locknut3. Drive chain slack adjusting bolt



6-22

6

CAUTION:ECA10570

Improper drive chain slack will over-load the engine as well as other vitalparts of the motorcycle and can leadto chain slippage or breakage. Toprevent this from occurring, keepthe drive chain slack within thespecified limits.

4. Tighten both locknuts, and thentighten the axle nut and braketorque rod nut to their specifiedtorques.

5. Adjust the brake pedal free play.(See page 6-17.)

WARNINGEWA10660

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

EAU23022

Cleaning and lubricating the drive chain The drive chain must be cleaned andlubricated at the intervals specified inthe periodic maintenance and lubrica-tion chart, otherwise it will quickly wearout, especially when riding in dusty orwet areas. Service the drive chain asfollows.

CAUTION:ECA10581

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

1. Clean the drive chain with kero-sene and a small soft brush.

CAUTION:ECA11120

To prevent damaging the O-rings, donot clean the drive chain with steamcleaners, high-pressure washers orinappropriate solvents.

2. Wipe the drive chain dry.3. Thoroughly lubricate the drive

chain with a special O-ring chainlubricant.

CAUTION:ECA11110

Do not use engine oil or any other lu-bricants for the drive chain, as theymay contain substances that coulddamage the O-rings.

Tightening torques:Axle nut:

80 Nm (8.0 m·kgf, 58 ft·lbf)Brake torque rod nut:

19 Nm (1.9 m·kgf, 13 ft·lbf)



6-23

6

EAU23100

Checking and lubricating the cables The operation of all control cables andthe condition of the cables should bechecked before each ride, and the ca-bles and cable ends should be lubricat-ed if necessary. If a cable is damagedor does not move smoothly, have aYamaha dealer check or replace it.

WARNINGEWA10720

Damage to the outer sheath may in-terfere with proper cable operationand will cause the inner cable torust. Replace a damaged cable assoon as possible to prevent unsafeconditions.

EAU23111

Checking and lubricating the throttle grip and cable The operation of the throttle grip shouldbe checked before each ride. In addi-tion, the cable should be lubricated atthe intervals specified in the periodicmaintenance chart.

EAU23142

Checking and lubricating the brake and clutch levers

Brake lever

Clutch lever

The operation of the brake and clutchlevers should be checked before eachride, and the lever pivots should be lu-bricated if necessary.

Recommended lubricant:Engine oil



6-24

6

EAU23182

Checking and lubricating the brake pedal

The operation of the brake pedalshould be checked before each ride,and the pedal pivot should be lubricat-ed if necessary.

EAU23212

Checking and lubricating the centerstand and sidestand

The operation of the centerstand andsidestand should be checked beforeeach ride, and the pivots and metal-to-metal contact surfaces should be lubri-cated if necessary.

WARNINGEWA10740

If the centerstand or sidestand doesnot move up and down smoothly,have a Yamaha dealer check or re-pair it.

Recommended lubricants:Brake lever:

Silicone greaseClutch lever:

Lithium-soap-based grease

Recommended lubricant:Lithium-soap-based grease




6-25

6

EAUM1650

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

EAU23271

Checking the front fork The condition and operation of the frontfork must be checked as follows at theintervals specified in the periodic main-tenance and lubrication chart.

To check the condition

WARNINGEWA10750

Securely support the vehicle so thatthere is no danger of it falling over.

Check the inner tubes for scratches,damage and excessive oil leakage.

To check the operation1. Place the vehicle on a level sur-

face and hold it in an upright posi-tion.

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

CAUTION:ECA10590

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




6-26

6

EAU23280

Checking the steering Worn or loose steering bearings maycause danger. Therefore, the operationof the steering must be checked as fol-lows at the intervals specified in the pe-riodic maintenance and lubricationchart.

1. Place a stand under the engine toraise the front wheel off theground.

WARNINGEWA10750

Securely support the vehicle so thatthere is no danger of it falling over.

2. Hold the lower ends of the frontfork legs and try to move them for-ward and backward. If any freeplay can be felt, have a Yamahadealer check or repair the steering.

EAU23290

Checking the wheel bearings The front and rear wheel bearings mustbe checked at the intervals specified inthe periodic maintenance and lubrica-tion chart. If there is play in the wheelhub or if the wheel does not turnsmoothly, have a Yamaha dealer checkthe wheel bearings.



6-27

6

EAU23380

Battery

The battery is located behind panel A.(See page 6-6.)This model is equipped with a sealed-type (MF) battery, which does not re-quire any maintenance. There is noneed to check the electrolyte or to adddistilled water.

CAUTION:ECA10620

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

WARNINGEWA10760

� Electrolyte is poisonous anddangerous since it contains sul-furic acid, which causes severeburns. Avoid any contact withskin, eyes or clothing and al-ways shield your eyes whenworking near batteries. In caseof contact, administer the fol-lowing FIRST AID.• EXTERNAL: Flush with plenty

of water.• INTERNAL: Drink large quan-

tities of water or milk and im-mediately call a physician.

• EYES: Flush with water for 15minutes and seek promptmedical attention.

� Batteries produce explosive hy-drogen gas. Therefore, keepsparks, flames, cigarettes, etc.,away from the battery and pro-vide sufficient ventilation whencharging it in an enclosedspace.

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

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

To store the battery1. If the vehicle will not be used for

more than one month, remove thebattery, fully charge it, and thenplace it in a cool, dry place.

2. If the battery will be stored for morethan two months, check it at leastonce a month and fully charge it ifnecessary.

3. Fully charge the battery before in-stallation.

4. After installation, make sure thatthe battery leads are properly con-nected to the battery terminals.

1. Battery2. Negative battery lead (black)3. Positive battery lead (red)

2 3

1



6-28

6

CAUTION:ECA10630

� Always keep the batterycharged. Storing a dischargedbattery can cause permanentbattery damage.

� To charge a sealed-type (MF)battery, a special (constant-volt-age) battery charger is required.Using a conventional batterycharger will damage the battery.If you do not have access to asealed-type (MF) battery charg-er, have a Yamaha dealercharge your battery.

EAU43211

Replacing the fuse The fuse is located behind panel A.(See page 6-6.)To access the fuse, remove the starterrelay coupler.

The spare fuse is located on the rear ofthe starter relay holder.To access the spare fuse, remove thestarter relay (together with its holder) bypulling it out, then turn the starter relayover.

If the fuse is blown, replace it as fol-lows.

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

2. Remove the blown fuse, and theninstall a new fuse of the specifiedamperage.

1. Starter relay coupler

1. Fuse2. Starter relay

1

1

2

1. Starter relay2. Starter relay holder3. Spare fuse

Specified fuse:15.0 A

21

3



6-29

6

CAUTION:ECA10640

Do not use a fuse of a higher amper-age rating than recommended toavoid causing extensive damage tothe electrical system and possibly afire.

3. Turn the key to “ON” and turn onthe electrical circuits to check if thedevices operate.

4. If the fuse immediately blowsagain, have a Yamaha dealercheck the electrical system.

EAU43190

Replacing the headlight bulb This model is equipped with a quartzbulb headlight. If the headlight bulbburns out, replace it as follows.

1. Remove the headlight unit by re-moving the screws.

2. Remove the headlight bulb socketcover.

3. Remove the headlight bulb socket(together with the bulb) by turningit counterclockwise.

4. Remove the defective bulb bypushing it in and turning it counter-clockwise.

1. Screw

1. Headlight bulb socket cover

1. Headlight bulb socket

1



6-30

6

WARNINGEWA10790

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

5. Insert a new bulb into the socket,push it in, and then turn it clock-wise until it stops.

CAUTION:ECA10660

Do not touch the glass part of theheadlight bulb to keep it free fromoil, otherwise the transparency ofthe glass, the luminosity of the bulb,and the bulb life will be adversely af-

fected. Thoroughly clean off any dirtand fingerprints on the headlightbulb using a cloth moistened with al-cohol or thinner.

6. Install the socket (together with thebulb) by turning it clockwise.

7. Install the headlight bulb socketcover.

8. Install the headlight unit by install-ing the screws.

9. Have a Yamaha dealer adjust theheadlight beam if necessary.

EAU24131

Replacing the tail/brake light bulb

1. Remove the tail/brake light lens byremoving the screws.


1. Headlight bulb

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

1



6-31

6


4. Install the lens by installing thescrews.

CAUTION:ECA10680

Do not overtighten the screws, oth-erwise the lens may break.

EAU24202

Replacing a turn signal light bulb

1. Remove the turn signal light lensby removing the screw.



4. Install the lens by installing thescrew.

CAUTION:ECA11190

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

EAU37270

Replacing the auxiliary light bulb If the auxiliary light bulb burns out, re-place it as follows.

1. Remove the headlight unit by re-moving the screws.

2. Remove the socket (together withthe bulb) by pulling it out.

1. Tail/brake light bulb

1

1. Screw

1

1. Screw



6-32

6

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

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

bulb) by pushing it in.6. Install the headlight unit by install-

ing the screws.

EAU24360

Front wheel

EAU37041

To remove the front wheel

WARNINGEWA10820

� It is advisable to have a Yamahadealer service the wheel.

� Securely support the motor-cycle so that there is no dangerof it falling over.

1. Place the motorcycle on the cen-terstand.

2. Disconnect the speedometer ca-ble from the front wheel.

3. Remove the rubber caps from theends of the wheel axle by pullingthem off.

4. Remove the axle nut and thewasher.

1. Auxiliary light bulb socket

1. Auxiliary light bulb

1. Speedometer cable

1. Rubber cap2. Axle nut3. Washer



6-33

6

5. Pull the wheel axle out, and thenremove the wheel.

CAUTION:ECA11070

Do not apply the brake after thewheel has been removed togetherwith the brake disc, otherwise thebrake pads will be forced shut.

EAU37030

To install the front wheel1. Install the speedometer gear unit

into the wheel hub so that the pro-jections mesh with the slots.

2. Lift the wheel up between the forklegs.

NOTE:Make sure that there is enough spacebetween the brake pads before insert-ing the brake disc and that the slot inthe speedometer gear unit fits over theretainer on the fork leg.

3. Insert the wheel axle, making surethe washer on the left side is in-stalled with the beveled side facingoutward, and then install the axlenut.

4. Take the motorcycle off the center-stand so that the front wheel is onthe ground.

5. Tighten the axle nut to the speci-fied torque, and then install bothrubber caps so that they fit over thewashers.

1. Rubber cap2. Wheel axle3. Washer

1. Speedometer gear unit 1. Speedometer gear unit retainer

Tightening torque:Axle nut:

59 Nm (5.9 m·kgf, 43 ft·lbf)



6-34

6

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

7. Connect the speedometer cable.

EAU25080

Rear wheel

EAU37180

To remove the rear wheel

WARNINGEWA10820

� It is advisable to have a Yamahadealer service the wheel.

� Securely support the motor-cycle so that there is no dangerof it falling over.

1. Loosen the axle nut and the braketorque rod nut at the brake shoeplate.

2. Disconnect the brake torque rodfrom the brake shoe plate by re-moving the cotter pin, the nut, andthe bolt.

3. Place the motorcycle on the cen-terstand.

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

1. Axle nut2. Brake torque rod3. Brake torque rod cotter pin4. Brake torque rod nut and bolt

3

2

1

4



6-35

6

5. Loosen the chain puller locknutand the drive chain slack adjustingbolt on both ends of the swingarm.

6. Remove the axle nut, and then pullthe wheel axle out.

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

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

8. Remove the wheel.

EAU37192

To install the rear wheel1. Install the wheel by inserting the

wheel axle from the left-hand side.2. Install the drive chain onto the rear

sprocket.3. Install the axle nut.4. Install the brake rod onto the brake

camshaft lever, and then install thebrake pedal free play adjusting nutonto the brake rod.

5. Connect the brake torque rod tothe brake shoe plate by installingthe bolt and nut.

6. Adjust the drive chain slack. (Seepage 6-21.)

7. Take the motorcycle off the center-stand so that the rear wheel is onthe ground.

8. Tighten the brake torque rod nutand axle nut to the specifiedtorques.

9. Insert a new cotter pin.10. Adjust the brake pedal free play.

(See page 6-17.)

WARNINGEWA10660

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

1. Brake pedal free play adjusting nut2. Brake rod3. Brake camshaft lever

1. Wheel axle2. Chain puller locknut3. Drive chain slack adjusting bolt

12

3

Tightening torques:Brake torque rod nut:

19 Nm (1.9 m·kgf, 13 ft·lbf)Axle nut:

80 Nm (8.0 m·kgf, 58 ft·lbf)



6-36

6

EAU25850

Troubleshooting Although Yamaha motorcycles receivea thorough inspection before shipmentfrom the factory, trouble may occur dur-ing operation. Any problem in the fuel,compression, or ignition systems, forexample, can cause poor starting andloss of power.The following troubleshooting chartrepresents a quick and easy procedurefor checking these vital systems your-self. However, should your motorcyclerequire any repair, take it to a Yamahadealer, whose skilled technicians havethe necessary tools, experience, andknow-how to service the motorcycleproperly.Use only genuine Yamaha replace-ment parts. Imitation parts may look likeYamaha parts, but they are often inferi-or, have a shorter service life and canlead to expensive repair bills.



6-37

6

EAU45730

Troubleshooting chart

WARNINGEWA10840

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

Check the fuel level inthe fuel tank.

1. FuelThere is enough fuel.

There is no fuel.

Check the compression.

Supply fuel. The engine does not start. Check the compression.

Operate the electric starteror the kickstarter.

2. CompressionThere is compression.

There is no compression.

Check the ignition.

Have a Yamaha dealercheck the vehicle.

Remove the spark plugand check the electrodes.

3. Ignition Wipe off with a dry cloth and correct thespark plug gap, or replace the spark plug.

Have a Yamaha dealer check the vehicle.

The engine does not start.Have a Yamaha dealercheck the vehicle.

The engine does not start.Check the battery.

Operate the electric starter.

4. BatteryThe engine turns over quickly.

The engine turns over slowly.

The battery is good.

Check the battery lead connections,and charge the battery if necessary.

Dry

WetOperate the electric starteror the kickstarter.


MOTORCYCLE CARE AND STORAGE

7-1

7

EAU37833

Matte color caution

CAUTION:ECA15192

Some models are equipped withmatte colored finished parts. Besure to consult a Yamaha dealer foradvice on what products to use be-fore cleaning the vehicle. Using abrush, harsh chemical products orcleaning compounds when cleaningthese parts will scratch or damagetheir surface. Wax also should notbe applied to any matte colored fin-ished parts.

EAU26002

Care While the open design of a motorcyclereveals the attractiveness of the tech-nology, it also makes it more vulnera-ble. Rust and corrosion can developeven if high-quality components areused. A rusty exhaust pipe may go un-noticed on a car, however, it detractsfrom the overall appearance of a motor-cycle. Frequent and proper care doesnot only comply with the terms of thewarranty, but it will also keep yourmotorcycle looking good, extend its lifeand optimize its performance.

Before cleaning1. Cover the muffler outlet with a

plastic bag after the engine hascooled down.

2. Make sure that all caps and coversas well as all electrical couplersand connectors, including thespark plug cap, are tightly in-stalled.

3. Remove extremely stubborn dirt,like oil burnt onto the crankcase,with a degreasing agent and abrush, but never apply such prod-

ucts onto seals, gaskets, sprock-ets, the drive chain and wheelaxles. Always rinse the dirt and de-greaser off with water.

Cleaning

CAUTION:ECA10771

� Avoid using strong acidic wheelcleaners, especially on spokedwheels. If such products areused on hard-to-remove dirt, donot leave the cleaner on the af-fected area any longer than in-structed. Also, thoroughly rinsethe area off with water, immedi-ately dry it, and then apply a cor-rosion protection spray.

� Improper cleaning can damageplastic parts such as cowlings,panels, windshields, headlightlenses, meter lenses, etc. Useonly a soft, clean cloth orsponge with mild detergent andwater to clean plastic.

� Do not use any harsh chemicalproducts on plastic parts. Besure to avoid using cloths orsponges which have been in



7-2

7

contact with strong or abrasivecleaning products, solvent orthinner, fuel (gasoline), rust re-movers or inhibitors, brake flu-id, antifreeze or electrolyte.

� Do not use high-pressure wash-ers or steam-jet cleaners sincethey cause water seepage anddeterioration in the following ar-eas: seals (of wheel and swing-arm bearings, fork and brakes),electric components (couplers,connectors, instruments,switches and lights), breatherhoses and vents.

� For motorcycles equipped witha windshield: Do not use strongcleaners or hard sponges asthey will cause dulling orscratching. Some cleaning com-pounds for plastic may leavescratches on the windshield.Test the product on a small hid-den part of the windshield tomake sure that it does not leaveany marks. If the windshield is

scratched, use a quality plasticpolishing compound afterwashing.

After normal useRemove dirt with warm water, a milddetergent, and a soft, clean sponge,and then rinse thoroughly with cleanwater. Use a toothbrush or bottlebrushfor hard-to-reach areas. Stubborn dirtand insects will come off more easily ifthe area is covered with a wet cloth fora few minutes before cleaning.

After riding in the rain, near the sea oron salt-sprayed roadsSince sea salt or salt sprayed on roadsduring winter are extremely corrosive incombination with water, carry out thefollowing steps after each ride in therain, near the sea or on salt-sprayedroads.

NOTE:Salt sprayed on roads in the winter mayremain well into spring.

1. Clean the motorcycle with cold wa-ter and a mild detergent, after theengine has cooled down.

CAUTION:ECA10790

Do not use warm water since it in-creases the corrosive action of thesalt.

2. Apply a corrosion protection sprayon all metal, including chrome- andnickel-plated, surfaces to preventcorrosion.

After cleaning1. Dry the motorcycle with a chamois

or an absorbing cloth.2. Immediately dry the drive chain

and lubricate it to prevent it fromrusting.

3. Use a chrome polish to shinechrome, aluminum and stainless-steel parts, including the exhaustsystem. (Even the thermally in-duced discoloring of stainless-steel exhaust systems can be re-moved through polishing.)



7-3

7

4. To prevent corrosion, it is recom-mended to apply a corrosion pro-tection spray on all metal,including chrome- and nickel-plat-ed, surfaces.

5. Use spray oil as a universal clean-er to remove any remaining dirt.

6. Touch up minor paint damagecaused by stones, etc.

7. Wax all painted surfaces.8. Let the motorcycle dry completely

before storing or covering it.

WARNINGEWA11130

� Make sure that there is no oil orwax on the brakes or tires.

� If necessary, clean the brakediscs and brake linings with aregular brake disc cleaner or ac-etone, and wash the tires withwarm water and a mild deter-gent. Before riding at higherspeeds, test the motorcycle’sbraking performance and cor-nering behavior.

CAUTION:ECA10800

� Apply spray oil and wax spar-ingly and make sure to wipe offany excess.

� Never apply oil or wax to anyrubber and plastic parts, buttreat them with a suitable careproduct.

� Avoid using abrasive polishingcompounds as they will wearaway the paint.

NOTE:Consult a Yamaha dealer for advice onwhat products to use.

EAU43200

Storage

Short-termAlways store your motorcycle in a cool,dry place and, if necessary, protect itagainst dust with a porous cover.

CAUTION:ECA10810

� Storing the motorcycle in apoorly ventilated room or cover-ing it with a tarp, while it is stillwet, will allow water and humid-ity to seep in and cause rust.

� To prevent corrosion, avoiddamp cellars, stables (becauseof the presence of ammonia)and areas where strong chemi-cals are stored.

Long-termBefore storing your motorcycle for sev-eral months:

1. Follow all the instructions in the“Care” section of this chapter.

2. Fill up the fuel tank and add fuelstabilizer (if available) to preventthe fuel tank from rusting and thefuel from deteriorating.



7-4

7

3. Perform the following steps to pro-tect the cylinder, piston rings, etc.from corrosion.a. Remove the spark plug cap

and spark plug.b. Pour a teaspoonful of engine oil

into the spark plug bore.c. Install the spark plug cap onto

the spark plug, and then placethe spark plug on the cylinderhead so that the electrodes aregrounded. (This will limit spark-ing during the next step.)

d. Turn the engine over severaltimes with the starter. (This willcoat the cylinder wall with oil.)

e. Remove the spark plug capfrom the spark plug, and theninstall the spark plug and thespark plug cap.

WARNINGEWA10950

To prevent damage or injury fromsparking, make sure to ground thespark plug electrodes while turningthe engine over.

4. Lubricate all control cables and thepivoting points of all levers andpedals as well as of the side-stand/centerstand.

5. Check and, if necessary, correctthe tire air pressure, and then liftthe motorcycle so that both of itswheels are off the ground. Alterna-tively, turn the wheels a little everymonth in order to prevent the tiresfrom becoming degraded in onespot.

6. Cover the muffler outlet with aplastic bag to prevent moisturefrom entering it.

7. Remove the battery and fullycharge it. Store it in a cool, dryplace and charge it once a month.Do not store the battery in an ex-cessively cold or warm place [lessthan 0 °C (30 °F) or more than 30°C (90 °F)]. For more informationon storing the battery, see page6-27.

NOTE:Make any necessary repairs beforestoring the motorcycle.


SPECIFICATIONS

8-1

8

Dimensions:Overall length:

2055 mm (80.9 in)Overall width:

845 mm (33.3 in)Overall height:

1125 mm (44.3 in)Seat height:

760 mm (29.9 in)Wheelbase:

1290 mm (50.8 in)Ground clearance:

140 mm (5.51 in)Minimum turning radius:

1750 mm (68.9 in)Weight:

With oil and fuel:130.0 kg (287 lb)

Engine:Engine type:

Air cooled 4-stroke, SOHCCylinder arrangement:

Forward-inclined single cylinderDisplacement:

123.7 cm³Bore × stroke:

54.0 × 54.0 mm (2.13 × 2.13 in)Compression ratio:

10.00 :1Starting system:

Electric starter and kickstarterLubrication system:

Wet sump

Engine oil:Type:

SAE 10W-30, SAE 10W-40, SAE 15W-40, SAE 20W-40 or SAE 20W-50

Recommended engine oil grade:API service SG type or higher, JASO standard MA

Engine oil quantity:Periodic oil change:

1.00 L (1.06 US qt, 0.88 Imp.qt)Air filter:

Air filter element:Dry element

Fuel:Recommended fuel:

Regular unleaded gasoline onlyFuel tank capacity:

12.0 L (3.17 US gal, 2.64 Imp.gal)Fuel reserve amount:

3.0 L (0.79 US gal, 0.66 Imp.gal)

Fuel injection:Throttle body:

Manufacturer:MIKUNI

Type/quantity:AC26-6/1

Spark plug (s):Manufacturer/model:

NGK/CR6HSASpark plug gap:

0.6–0.7 mm (0.024–0.028 in)Clutch:

Clutch type:Wet, multiple-disc

Transmission:Primary reduction system:

Helical gearPrimary reduction ratio:

68/20 (3.400)Secondary reduction system:

Chain driveSecondary reduction ratio:

43/14 (3.071)Transmission type:

Constant mesh 5-speedOperation:

Left foot operationGear ratio:

1st:37/14 (2.643)

2nd:32/18 (1.778)

3rd:25/19 (1.316)

-20 -10 0 10 20 30 40 50 ˚C

SAE 10W-30

SAE 15W-40

SAE 20W-40

SAE 20W-50

SAE 10W-40

SAE 10W-50


SPECIFICATIONS

8-2

8

4th:23/22 (1.045)

5th:21/24 (0.875)

Chassis:Frame type:

DiamondCaster angle:

27.42 °Trail:

102.0 mm (4.02 in)Front tire:

Type:Tubeless

Size:3.00-18 47P

Manufacturer/model:CHENG SHIN/C-6039

Rear tire:Type:

TubelessSize:

3.50-16 58PManufacturer/model:

CHENG SHIN/C-289Loading:

Maximum load:190 kg (419 lb)(Total weight of rider, passenger, cargo and accessories)

Tire air pressure (measured on cold tires):

Loading condition:0–90 kg (0–198 lb)

Front:175 kPa (1.75 kgf/cm², 25 psi)

Rear:200 kPa (2.00 kgf/cm², 29 psi)

Loading condition:90–190 kg (198–419 lb)Front:

175 kPa (1.75 kgf/cm², 25 psi)Rear:

280 kPa (2.80 kgf/cm², 41 psi)Front wheel:

Wheel type:Cast wheel

Rim size:J18M/CxMT1.85

Rear wheel:Wheel type:

Cast wheelRim size:

J16M/CxMT2.15Front brake:

Type:Single disc brake

Operation:Right hand operation

Recommended fluid:DOT 3 or 4

Rear brake:Type:

Drum brakeOperation:

Right foot operation

Front suspension:Type:

Telescopic forkSpring/shock absorber type:

Coil spring/oil damperWheel travel:

110.0 mm (4.33 in)Rear suspension:

Type:Swingarm

Spring/shock absorber type:Coil spring/oil damper

Wheel travel:105.0 mm (4.13 in)

Electrical system:Ignition system:

TCI (digital)Charging system:

AC magnetoBattery:

Model:YTX7L-BS

Voltage, capacity:12 V, 6.0 Ah

Headlight:Bulb type:

IncandescenceBulb voltage, wattage × quantity:

Headlight:12 V, 35 W/35.0 W × 1

Tail/brake light:12 V, 5.0 W/21.0 W × 1

Front turn signal light:12 V, 10.0 W × 2

U27SE0E0.book Page 2 Wednesday, February 27, 2008 2:29 PM

SPECIFICATIONS

8-3

8

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 × 1

Engine trouble warning light:14 V, 3.0 W × 1

Fuse:Fuse:

15.0 A


CONSUMER INFORMATION

9-1

9

EAU26351

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

VEHICLE IDENTIFICATION NUMBER:

MODEL LABEL INFORMATION:

EAU26381

Key identification number

The key identification number isstamped into the key tag. Record thisnumber in the space provided and useit for reference when ordering a newkey.

EAU26400

Vehicle identification number

The vehicle identification number isstamped into the steering head pipe.Record this number in the space pro-vided.

NOTE:The vehicle identification number isused to identify your motorcycle andmay be used to register your motor-cycle with the licensing authority in yourarea.

1. Key identification number 1. Vehicle identification number

1


CONSUMER INFORMATION

9-2

9

EAU36980

Model label

The model label is affixed to the framebehind panel A. (See page 6-6.)Record the information on this label inthe space provided. This informationwill be needed when ordering spareparts from a Yamaha dealer.

1. Model label

1


INDEXA

Air filter element, cleaning .................... 6-10Auxiliary light bulb, replacing ................ 6-31

BBattery .................................................. 6-27Brake and clutch levers,

checking and lubricating..................... 6-23Brake fluid, changing ............................ 6-20Brake fluid level, checking .................... 6-19Brake lever ............................................. 3-5Brake pads and shoes, checking.......... 6-19Brake pedal ............................................ 3-6Brake pedal, checking and

lubricating ........................................... 6-24Brake pedal free play, adjusting ........... 6-17

CCables, checking and lubricating.......... 6-23Care........................................................ 7-1Carrier..................................................... 3-9Catalytic converters ................................ 3-8Centerstand and sidestand,

checking and lubricating..................... 6-24Clutch lever............................................. 3-5Clutch lever free play, adjusting ........... 6-16

DDimmer switch ........................................ 3-4Drive chain, cleaning and lubricating.... 6-22Drive chain slack .................................. 6-21

EEngine break-in ...................................... 5-3Engine idling speed, checking .............. 6-12Engine oil ................................................ 6-9Engine trouble warning light ................... 3-2

FFront brake lever free play, checking ....6-17Front fork, checking...............................6-25Fuel .........................................................3-7Fuel consumption, tips for reducing ........5-3Fuel gauge ..............................................3-3Fuel tank cap...........................................3-6Fuse, replacing......................................6-28

HHandlebar switches.................................3-4Headlight bulb, replacing.......................6-29High beam indicator light.........................3-2Horn switch .............................................3-4

IIdentification numbers .............................9-1Ignition circuit cut-off system.................3-10Indicator and warning lights ....................3-2

KKey identification number........................9-1Kickstarter ...............................................3-8

MMain switch/steering lock ........................3-1Matte color, caution.................................7-1Model label..............................................9-2

NNeutral indicator light ..............................3-2

PPanels, removing and installing ..............6-6Parking ....................................................5-4Part locations ..........................................2-1Periodic maintenance and

lubrication chart.....................................6-2Pre-operation check list...........................4-2

RRear brake light switch, adjusting ......... 6-18

SSafety information................................... 1-1Self-diagnosis device.............................. 3-3Shifting.................................................... 5-2Shift pedal............................................... 3-5Shift pedal, checking............................. 6-18Shock absorber assemblies, adjusting ... 3-8Sidestand................................................ 3-9Spark plug, checking .............................. 6-7Specifications.......................................... 8-1Speedometer unit ................................... 3-2Starting the engine.................................. 5-1Start switch ............................................. 3-4Steering, checking ................................ 6-26Storage ................................................... 7-3Swingarm pivots, lubricating ................. 6-25

TTachometer............................................. 3-3Tail/brake light bulb, replacing .............. 6-30Throttle cable free play, adjusting......... 6-12Throttle grip and cable,

checking and lubricating ..................... 6-23Tires...................................................... 6-13Tool kit .................................................... 6-1Troubleshooting .................................... 6-36Troubleshooting chart ........................... 6-37Turn signal indicator light ........................ 3-2Turn signal light bulb, replacing ............ 6-31Turn signal switch ................................... 3-4

VValve clearance .................................... 6-13Vehicle identification number.................. 9-1


INDEXW

Wheel bearings, checking..................... 6-26Wheel (front) ......................................... 6-32Wheel (rear) .......................................... 6-34Wheels .................................................. 6-15


YAMAHA MOTOR CO., LTD.PRINTED IN CHINA

2008.02-0.3×2 CR(E)

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