Download Yamaha AT135 Owner`s manual

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A. Read this manual carefully before operating this vehicle .
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OWNER'S MANUAL
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Read this manual carefully before operating this vehicle. This manual should stay with this veh icle if it is sold.
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INTRODUCTION
Welcome to the Yamaha world of motorcycling!
As the owner of the AT135, you are benefiting fro m Yamaha's vast experience and newest technology regarding the design
and manufacture of high-quality prod ucts, wh ich have earned Yamaha a reputation for dependability.
Please take the time to read this manual thorou ghly, so as to enjoy all advantages of your AT135. Tile Owne r's Manual does
not only instruct you in how to operate, inspect and maintain your motorcycle , but also in how to safeguard you rself and others from trouble and injury.
In addition, the many tips given in this manual will help keep you r motorcycl e in the best possible condition. If you have any
further questions, do not hesitate to contact your Yamaha dealer.
The Yamaha team wishes you many safe and pleasant rides. So, remember to put safety fi rst!
Yamaha continually seeks advancements in product design and quality. Therefore, wh ile this manual contains the most cu rre nt product information available at the time of printing, the re may be minor discrepancies between you r motorcycle and this
manual. If there is any question concern ing this manual, please consult a Yamaha dealer.
EWA 10031
A
WARNING
Please read thi s manual carefully and completely before operating this motorcycle.
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IMPORTANT MANUAL INFORMATION
EAU10 132
Particularly important information is distingu ished in this manual by the following notations:
This is the safety alert symbol. 11 is Llsed to alert you t o potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possibl1e injury or
death.
~WARNING
A WARNING indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
A NOTICE indicates special precaut ions that must be taken to avoid damage to the
vehicle or other property.
A TIP provides key information to make procedu res easier or clearer,
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IMPORTANT MANUAL INFORMATION
EAUJ7430
AT135
OWNER'S MANUAL
©2008 by Thai Yamaha Motor Co., Ltd.
1st edition, October 2008
All rights reserved.
Any reprinting or unauthori zed use
without the written perm ission of
Thai Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Thailand.
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TABLE OF CONTENTS
LOCATION OF IMPORTANT
LABELS """""""""""""""""""""""""""""""" ""' " 1- 1
FOR YOUR SAFETY - PREOPERATION CHECKS ........ ""
SAFETY INFORMATION ........ .. ""."" "",2-1
Hel mets """" """"" """" """"",., .. ... " .. "." .. 2-5
OPERATION AND IMPORTANT
RIDING POINTS ........ ... .................... .. 6-1
Starting a cold engine ... " ..... . ... ..... 6-1
Starting off .......... .......... ... ............. .. 6-2
Acceleration and deceleration .. .. .... 6-2
Braking ........................................... 6-2
Tips for reducing fuel
consum ption .............. ........... ...... 6-3
Engine break-in ........ ....... .. ............. 6-3
Parking ............... ....... " .. ......... .. ...... 6-5
General note ...... ............. .... ........... 6-6
DESCRIPTION "" ... .. "" ....... "." .... " ........ 3- 1
Left view " ..... ..... "" ..... .. .......... " ... ..... 3-1
Right view ."""" """"""""" "" ,,,"",,,"",, ,,,,,, "" 3-2
Controls and instruments ""." .. " "",, ,3-3
INSTRUMENT AN D CONTROL
FUNCTIONS ............ " ........ """"'"""""""..4- 1
Main switch/steering lock ... " .. ..... ... .4-1
Keyho le cover ... ........ ... ....... .. ... ...... .4-2
Indicato r and warning lights .... ... ... .4-3
Speedometer ...... ............. ......... ..... .4-3
Fuel gauge ...... ....... ... .... ....... .. ...... " .4-4
Digital coolant temperature
gauge/odomete r ......... .... ............ .4-4
Handlebar switches ....................... .4-5
Front brake lever ................ ... .. ... ... .4-5
Rear brake lever .......... .......... ... .. .. . .4-6
Fuel tank cap ....... .... ................ .. .. .. .4-6
Fuel ............ .. . " ... ,'" .................. "" ... 4-7
Catalytic converter .... ...... ............. ...4-8
Kickstarter " ............... ... ....... ... ... ... ...4-9
Seat ..... .............. ..... ....................... .4-9
Helme! holders ....... ..................... .4-1 0
Convenience hook ... .... .. ........... ... .4-10
Sto rage compartment ............. ..... .4-11
PERIODIC MAINTENANCE AND
ADJUSTMENT .............. .. ....... .. ... "" 7-1
Owner's tool kit ..... .......................... 7-1
Periodic maintenance chart for
the emission control system ..... .. 7-2
General maintenance and
lubrication chart .......................... . 7-3
Removing and installing cowlings
and panels ............. .. ... ................ 7-6
Checking the spark plug ................. 7-8
Engine oil and oil stra ine r ............... 7-9
Final transmissio n oil .................... 7-11
Coolant ...... .. ........ .. .. ........ .. " ........ 7- 12
Air filter and V-belt case air filter
elements ... ..... ...... .. .... .... ........... 7 -1 3
Adjusting the carburetor ...... ......... 7-16
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.. ... 5-1
Adjusting t he engine idl ing
speed .... .... ..... .. ................ ........ . 7- 16
Adjusting the throttle cable
free play ............... .. ... ... ........ ..... 7- 17
Valve cl ea ran ce .................... ... .... 7- 17
T ires ..... ... .. .. ...." ........... ... .... .. ..... .. 7- 18
Wheels ............. .............. ....... ....... 7-20
Checking the f ront brake lever
free play .... ..... .................... ....... 7-20
Adjusting the rear brake lever
free play ............. .................. ... .. 7-21
Checking the front b rake pads
and rear brake shoes ............... 7-22
Checking the brake fluid level .. .... 7-22
Changi ng the brake fluid ...... ... .... 7-23
Check ing the V-belt .. ......... .. .... .. .. 7-24
Checking and lubricating the
cables ....... ....................... ... ...... 7-24
Checking and lubricating th e
throttle grip and cable .......... ..... 7-24
Lubricating the front and rear
brake levers ................... ........... 7-25
Checking and lubricating the
centerstand and sidestand ... .... 7-25
Checking t he front fork ..... .... ........ 7-26
Checking the steering ........... ....... 7-27
Checking the wheel bearings .. ... .. 7-27
Battery ...... ............................ .... .. . 7-28
Replacing the fuse ..... ... ...... ....... .. 7-29
Replacing a headlight bulb .......... 7-30
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TABLE OF CONTENTS
Replacing the tail/brake
lig ht bulb .... ...... ........................ .7-31
Replacing a turn signal
lig ht bulb .......... ... ................. ......7-32
Replacing a front turn signal
light bulb ....... ...... ............. .......... 7-33
Replacing an auxiliary ligh!
bulb ................................. .......... 7-33
Troubleshooting .. .. ....... ............. .... 7-34
Troubleshooting charts ................. 7-35
MOTORCYCLE CAR E AND
STORAGE ... .... ............... ............. . 8-1
Care .. ........... ...... .... ..... .. .. .... ...... ... ... 8- 1
Stora ge . __ ...... .. .................... ...... ..... . 8-3
SPECIFICATIONS ... ..................... ... ... 9-1
CONSUM ER INFORMATION ....... .... 10-1
Identification numbers ..... .. ........... 10- 1
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LOCATION OF IMPORTANT LABELS
E AU t 0383
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Read and understand all of the labels on your vehicle . They contain important information fo r safe and proper operation of
you r vehicle. Never remove any labels from your vehicle. If a label becomes difficult to read or comes off, a replacement label
is available from your Ya maha dealer.
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Be a Responsible Owner
As tt1e vehicle' s owner, you a re responsible for the safe and proper operation
of your motorcycle.
Motorcycles are single-t rack vehicles.
Their safe use and operation are dependent upon the use of prope r riding
techniques as well as the expertise of
the operator. Every operator should
know the following requirements before
riding this motorcycle.
He or she should:
• Obtain thorough instruct ions from
a competent source on all aspects
of motorcycle operation.
• Observe the warnings and maintenance requ irements in this Owner' s Manual.
• Obtai n qualified training in safe
and proper riding techniques.
• Obtain professional technical service as indicated in this Owner's
Manual and/or when made necessary by mechanical conditions.
Safe Riding
Perform the pre-operation checks eac h
time you use the vehicle to make sure it
is in safe operating condition. Failure to
inspect or maintain the vehicle properly
increases the possibility of an accident
or eq uipment damage. See page 5- 1
for a list of pre-operation checks.
• Th is motorcycle is designed to
carry the operator and a passenger.
• The failure of motorists to detect
and recog nize motorcycles in traffic is the predom inating cause of
automobile/motorcycle accidents.
been
Many accidents have
caused by an automobile driver
who did not see the moto rcycle .
Making you rse lf conspicuous appears to be very effective in reducing the chance of this type of
accident.
Therefore:
• Wea r a brightly colored jacket.
• Use extra caution when you are
approaching
and
passing
through intersections, since in2-1
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tersections are the most likely
places for motorcycle accidents
to occur.
• Ride w here oth er motorists can
see you. Avoid riding in another •
motorist's bl in d spot.
• Many acciden ts involve inexperienced operators . In fact, many operators who have been involved in
accidents do not even have a cu rren t motorcycle license.
• Make sure that you are qualified
and that you only lend your moto rcycle to other qualifi ed operato rs.
• Know you r ski lls and limits.
Staying with in your lim its may
help you to avoid an accident.
• We recommend that you practice riding your motorcycle
where there is no traffic unti l you
have become thoroughly familia r with the motorcycle and all of
its controls.
• Many accidents have been
caused by error of the motorcycle
operator. A typical error made by
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the operator is veering wide on a
turn due to excessive speed or undercornering (insufficient lean angie for the speed).
• Always obey the speed limit and
never travel faste r than warranted by road and traffi c conditions.
• Always signal before turning or
changing lanes. Make sure that
other motorists can see you.
• The posture of the operator and
passenger is important for proper
control.
• The operator should keep both
hands on the handleba r and
both feet on the operator footrests during operation to maintain control of the motorcycle .
• The passe nger should always
hold onto the ope rator, the seat
strap or grab bar, if eq uipped,
with both hands and keep both
feet on the passenger footrests.
Neve r carry a passenger unless
he or she can fi rmly place both
feet on the passenger footrests.
• Never ride under the influence of
alcohol or other drugs.
Protective apparel
The majority of fatal ities from motorcycle accidents are the result of head injuries. The use of a safety helmet is the
single most critical factor in the prevention or reduction of head injuri es.
• Always wear an approved helmet.
• Wear a face shield or goggles.
Wind in your unprotected eyes
could contribute to an impairment
of vision that could delay seeing a
hazard.
• The use of a jacket, heavy boots,
trousers, gloves, etc., is effective
in preventing or reduc ing abrasions or lacerations.
• Never wear loose-fitting clothes,
otherwise they could catch on the
control levers , footrests, or wheels
and cause inju ry or an accident.
• Always wear protective cloth ing
that covers your legs, an kles, and
feet. The engine or exhaust sys2-2
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tem become very hot during or after operation and can cause
bu rns.
• A passenger should also obse rve
the above precautions .
Avoid Carbon Monoxide Poisoning
All engine exhaust contains ca rbon
monoxide, a deadly gas. Breath ing carbon monoxide ca n cause headaches,
dizziness, drowsiness, nausea, confusion, and eventually death.
Carbon Monoxide is a colorless , odorless, tasteless gas which may be
present even if you do not see or smell
any engine exh aust. Deadly levels of
carbon monoxide can collect rapidly
and you can qu ic kly be overcome and
unable to save yourself. Also, deadly
levels of carbon monoxide can linger
for hou rs or days in enclosed o r poorly
ventilated areas. If you experience any
symptoms of carbon monoxid e poisoning, leave the area immediately, get
fresh air, and SEEK MEDICAL TREATMENT.
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ill SAFETY INFORMATION
• Do not ru n engine indoors. Even if
you try to ventilate engine exhaust
with fans or open windows and
doors, carbon monoxide can rapidly reach dangerous levels.
• Do not run engine in poorly ventilated or partially enclosed areas
such as barns, garages, or carports.
• Do not run engine outdoors where
engine exhaust can be drawn into
a building through openings such
as windows and doors.
loading
Addi ng accesso ries or cargo to your
motorcycle can adve rsely affect stabi lity and handling if the weight distribution
of the motorcycle is changed. To avoid
the possibility of an accident, use extreme caution when adding cargo or
accessories to your motorcycle. Use
extra care when riding a motorcycle
that has added cargo or accessories.
Here, along with the information about
accessories below, are some general
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guidelines to follow if loading cargo to
your motorcycle :
The total weight of the operato r,
passenger, accessories and cargo
must not exceed the maximum load
limit. Operat ion of an overloaded vehicle could cause an accident.
Maximum load :
160 kg (353 Ib)
When loading within this we ight limit,
keep the following in mind:
• Cargo and accessory weight
should be kept as low and close to
the motorcycle as possible. Securely pack your heaviest items as
close to the center of the vehicle
as possible and make sure to distri bute the weight as evenly as
possible on both sides of the motorcycle to minimize imbalance o r
instability.
• Shifting weights can create a sudden imbalance. Make su re that accessori es and cargo are securely
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attached to the motorcycle before
riding. Check accessory mounts
and cargo restraints frequ ently.
• Properly adjust the suspension
for your load, and check the
condition and pressure of your
tires.
• Never attach any large or heavy
items to the handlebar, front
fork, or front fende r. These
items, including such cargo as
sleeping bags, duff el bags, or
tents, can create unstable handling or a slow steering response.
• This vehicle is not designed t o
pull a trailer o r t o be attached to
a sidecar.
Genuine Yamaha Accessories
Choos ing accessories for your vehicle
is an important decision. Genuine
Yamaha accessories, which are available only from a Yamaha dealer, have
been designed, tested, and approved
by Yamaha for use on your vehicle.
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Aftermarket Parts, Accessories, and
Modificatio ns
While you may find aftermarket products similar in design and quality to
genuine Yamaha accessories, recognize that some aftermarket accessories
or modifi cations are not suitable because of potential safety hazards to
you or othe rs. Installing aftermarket
products or having other modifications
performed to you r vehicle that change
any of the vehicle's design or operation
characteristics can put you and others
at greater risk of serious injury or death.
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You are responsible for injuries related
to changes in the veh icle.
Keep the followi ng guidel ines in mind,
as well as those provided under "Loading" when mounting accessories .
• Never install accessories or carry
carg o that would impair the performance of your motorcycle. Carefully inspect the accessory before
using it to make sure that it does
not in any way reduce ground
clearance or come rin g clearance,
limit suspension travel, steering
travel or contro l operation, or obscure lights or refl ectors.
• Accessories fitted to the handlebar or the front fork area can
create instabil ity due to improper weight distribution or aerodynamic changes. If accessories
are added to the handlebar or
front fork area, they must be as
lightweight as poss ible and
sho uld be kept to a minimum.
• Bulky or large accessories may
seriously affect the stabi lity of
the motorcycle due to aerody2-4
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Many companies with no connection to
Yamaha manufacture parts and accessories or offer other modifications for
Yamaha vehicles. Yamaha is not in a
position to test the prod ucts that these
aftermarket
companies
produce.
Therefore, Yamaha can neither endorse nor recommend the use of accessories not sold by Yamaha or
modifications not specifically recommended by Yamaha, even if sold and
installed by a Yamaha dealer.
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namic effects. Wind may attempt to lift the motorcycle, or
the motorcycle may become unstable in cross winds. These accessories may also cause
instability when passing o r being passed by large vehicles.
• Certain accessories can displace the operator from his or
her normal riding position. This
improper position limits the freedom of movement of the operator and may limit control ability,
therefore, such accessories are
not recomme nded.
• Use caution when adding electri cal accessories. If electrical accessories exceed the capacity of the
moto rcycle's electrical system, an
electric failure cou ld result, which
could cause a dangerous loss of
lights or engine power.
Aftermarket Tires and Rims
The tires and rims that came with your
motorcycle were designed to match
the performance capabilities and to
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provide the best combination of handling, braking , and comfort. Other
tires, rims, sizes , and combinations
may not be appropriate. Refer to page
7 -18 for tire specifications and more
information on replacing your tires.
EAUU0030
Helmets
Operating this ve hicle without an approved motorcycle helmet increases
you r chances of a seve re head injury or
death in the event of an accident. The
majority of fatalities from motorcycle or
scoote r accidents are the result of head
injuries. The use of a safety hel met is
the single most critical factor in the prevention or red uction of head inju ries.
Always select an approved
motorcycle helmet
Pay attention to th e following when
choosing a motorcyc le helmet.
• The helmet must meet the safety
standard "TIS".
• The helmet size must match the
size of the rider's head.
• Never subject a helmet to heavy
shocks.
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Correctly helmet wearing
Z AUU000 7
Inco rrectly helmet wearing
Wearing the helmet correctly
Always connect the chi n strap. In the
case of an accident, the helmet has a
much less chance of coming off if the
chi n strap is connected.
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Types of helmets and thei r usage
• Half-type use only for riding at
low speeds
•
• FUll-type: use only for riding at
low to mid-range speeds
• Full-face-type: use for riding at
mid-range to high speeds
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DESCRIPTION
EAU10410
left view
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6 7
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ZAUU0345
1.
2.
3.
4.
5.
6.
HeadlighUauxiliary lights (page 7-30, 7-33)
Front tum signal lights (page 7-33)
Convenience hook (page 4-10)
Throttle stop screw (page 7-16)
Owner's tool kit (page 7-1)
Tail/brake light (page 7-31)
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7. Rear tum signal lights (page 7-32)
8. Kickstarter (page 4-9)
9. Engine oil drain bolt A (page 7-9)
10. Engine oil drain bolt B (page 7-9)
11. V-belt case air filter element (page 7-13)
12. Air filter element (page 7-13)
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DESCRIPTION
EAU 10420
Right view
1
2 3 4
5
6
7
8
ZAUU0346
1,
2.
3.
4_
5.
6.
7.
8.
Fuel tank cap (page 4-6)
Fuse/starter relay (page 7-29)
Storage compartment (page 4-11 )
Battery (page 7-28)
Seat lock (page 4-9)
Front brake fluid reservoir (page 7-22)
Coolant reservoir (page 7-12)
Dipstick (page 7-9)
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DESCRIPTION
)ls and instruments
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2
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6
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rake lever (page 4-6)
rlCIebar switches (page 4-5)
luge (page 4-4)
;meIer (page 4-3)
coolant temperature gauge/odometer (page 4-4)
andlebar swrtches (page 4-5)
rake lever (page 4-5)
Nitchlsteering lock (page 4-1 )
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INSTRUMENT AND CONTROL FUNCTIONS
To lock the steering
~
Main switch/steering lock
ON
All electrical circuits are supplied with
power, and the engine can be started.
The key cannot be removed.
TIP ________~~~--~
The headlight, auxiliary lights, meter
lighting and taillight come on automatically when the engine is started.
The main switch/steering lock controls
the ignition and lighting systems, and is
used to lock the steering, and is used to
open the seat also. The variou s main
switch positions are described below.
TIP ______~~~--~~_
The main switch is equipped with a
keyhole oover. (See page 4-2 for keyhole cover opening and dosing procedures.)
OFF
All electrical systems are off. The key
can be removed.
AWAANING
Never tum the key to " OFP' or
" LOCK" while the vehicle is moving.
Otherwise the electrical system s will
be switched off, which may result in
lo ss of control or an accident.
EM." '''''
LOCK
The steering is locked, and all electrical
systems are off, The key can be removed.
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1. Tum the handlebars a1l lhe way 10
the left.
2. Push Ihe key in from the ~OFF" position, release it, and then tum it to
"LOCK".
3. Remove the key.
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INSTRUMENT AND CONTROL FUNCTIONS
I
To unlock the steering
tum the key to the lett to open the cov-
Keyhole cover
er.
2
To close the keyhole cover
1
Insert the key and turn it to "OFF".
1. Ignition key
2 . Salely key
To open the keyhole cover
Insert the key head into the keyhole
cover receptacle as shown, and then
tum the key to the right to close the
cover.
Insert the key head into the keyhole
cover receptacle as shown, and then
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INSTRUMENT AND CONTROL FUNCTIONS
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Indicator and warning lights
EAU1l484
Engine trouble warning light "6"
This warning light comes on if a problem is detected in the electrical circuit
monitoring the engine. If this occurs,
have a Yamaha dealer check the selldiagnosis system.
The electrical circuit of the warning light
can be checked by turning the key to
"ON The warning light should come
on for a few seconds, and then go off.
If the warning light does not come on
initially when lhe key is turned to ~ON",
or if the warning light remains on, have
a Yamaha dealer check the electrical
circuit.
Speedometer
12
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1. Left-Ium signal indicatollight ".0-
2. Engine trouble warning light' 6 •
3. High beam indicator light "ro"
<I. Right-Ium signal indicato r light -<>"
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Turn signal indicator light " ¢ 0"
This indicator light flashes when the
tum signal switch is pushed to the left
or right.
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High beam indicator light" ro "
This indicator light comes on when the
high beam of the headlight is switched
on.
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1. Speedometer
2. Speedometer noodle
The speedometer shows the riding
speed.
When the key is turned to "OW, the
speedometer needle will sweep once
across the speed range and then return
to zero in order 10 test the electrical circuit.
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INSTRUMENT AND CONTROL FUNCTIONS
Fuel gauge
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Do not allow the fuel tank to empty itself
completely.
Digital coolant temperature
gauge/odometer
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1. Fucl gauge
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2. Fuel gauge needle
1 Digital cooIant lemperature gauge
3. Red 2:onc
2_ Digital odometer
The fuel gauge indicates the amount of
fuel in the fuel tank. When the key is
turned to kON ~, the fuel gauge needle
will sweep once across the fuel level
range and then return to "P' (Empty) in
order to test the electrical circuit. The
needle moves towards "E" as the fuel
level decreases. When the needle
reaches the red zone, approximately
1.0 L (0.26 US gal) (0.22 Imp.gal) remain in the fuel tank. If this occurs, refuel as soon as possible.
When the key is turned to kON", the display segments of the digital coolant
temperature gauge will sweep once
across the temperature range and then
return to "C" in order to test the electrical circuit.
The odometer shows the total distance
traveled.
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Do not continue to operate the engine if it is overheating.
4-4
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INSTRUMENT AND CONTROL FUNCTIONS
Handlebar switches
Left
1:::---':::
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1. Dimmer switch " 101110 "
Tum signal switch "9/ 9"
To signal a rig,t-hand tum, push this
switch to " 0 ", To signal a left-hand
lum , push this switch to ~ ¢ ". When released, the switch returns to the center
posllion. To cancel the tum signal
lights, push the switch in after it has returned to the center position.
2. Tum signal switch "0/0"
3. Horn switch " Ioo:r '
Right
Horn switch " Ioo:r "
Press this switch to sound the hom .
Start s witc h " (i)"
Push this switch while applying the
front or rear brake to crank the engine
with the starter. See page 6- 1 lor starting instructions prior to starting the engine.
' -5
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Dimmer switch " 10/ 10"
Set this switch to MK) ~ for the high
beam and to · .Y for the low beam.
1
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Front brake lever
1. Front brake lever
The front brake lever is located on the
right handlebar grip. To apply the I ront
brake, pull this lever toward the handlebar grip.
+-
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INSTRUMENT AND CONTROL FUNCTIONS
To install the fuel tank cap
Fuel tank cap
Rear brake lever
1
./1
1 Rear brake lever
The rear brake lever is located on the
left handlebar grip. To apply the rear
brake, pull this lever toward the handlebar grip.
1. Fuel tank cap
a. Open.
b. Close.
To remove the fuel tank cap
1. Open the seat. (See page 4-9.)
2. Tum the fuel lank cap counlerck>ckwise and pull it off.
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1. Insert the fuel tank cap into the
tank opening and tum it clockwise
until the ~ t:.. ~ marks on the cap and
tank are aligned.
2. Close the seal.
"WARNING
Make sure that the fuel tank cap is
properly closed after filling fuel.
Leaking fuel is a fire hazard.
+-
INSTRUMENT AND CONTROL FUNCTIONS
"""''''2
Fuel
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1. Fuel tank filler tube
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2. Fucl ievcl
2
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Make sure there is sufficient gasoli ne in
the tank.
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A
WARNING
Gasoline and gasoline vapors are
extremely flammable. To avoid fires
and explosions and to reduce the
risk of injury when refueling, follow
these instructions.
1. Before refueling, tum off the engine and be sure that no one is sitting on the vehicle. Never refuel
while smoking, or while in the vicinity 01 spar1<s, open flames, or
other sources of ignition such as
the pilot lights of water heaters and
clothes dryers.
2. Do not averiill the fuel lank. Stop
fillin g when the fuel reaches the
bottom of the filler tube. Because
fuel expands when it heats up,
heat from the engine or the sun
can cause fuel to spill out of the
fuel tank.
3. Wipe up any spilled fuel immediately_ NOTICE: Immediately
wipe off spilled fuel with a
clean, dry, soft cloth, since fuel
may deteriorate painted surfaces or plastic parts. l.eAl OO"1
4. Be sure to securely close the fuel
lank cap.
A
WARNING
Gasoline is poisonous and can
cause injury or death. Hand~ gasoline with care. Never siphon gasoline by mouth. H you should swallow
some gasoline or inhale a lot of gasoline vapor, or get some gasoline in
your eyes, see your doctor immedi-
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ately. If gasoline spills on your skin,
wash with soap and water. ff gasoline spills on your clothing, change
your clothes.
Recommended fuel:
Regular unleaded gasoline or
gasohol (91 min. pump octane)
Fuel tank capacity:
4.8 L (1.27 US gal) (l .06 lmp.gal)
OTICE
Use only unleaded gasoline. The
use of leaded gasoline will cause severe damage to internal engine
parts, such as the valves and piston
rings, as well as to the exhaust system.
Gasohol
Gasohol is a mixture of unleaded gasoline and ethanol. Gasohol contains
90% gasoline and 10% ethanol which
is called "E l 0".
Yamaha products can use gasohol
IE10] Octane 91 or higher. However,
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INSTRUMENT AND CONTROL FUNCTII
m filling with gasohol, cold engine
rting may be difficult. Therefore, be
e 10 follow the procedures in UStarta cold engine
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ing gasohol may cause engine
uble depending on the engine. If
.ohol is used and engine trouble
:urs, contact your Yamaha dealIS soon as possible_
Catalytic converter
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This model is equipped with a catalytic
converter in the exhaust system.
A
WARNING
The exhaust system is hot after operation. To prevent a fire hazard or
burns:
• Do not park the vehicle near
possible fire hazards such as
grass or other materials that
easily burn.
• Park the vehicle in a place
where pedestrians or children
are not likely to touch the hot
exhaust system.
• Make sure that the exhaust system has cooled down before doing any maintenance work.
• 00 not allow the engine to idle
more than a few minutes. long
idling can cause a build-up of
heat.
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Use only unleaded gasolin
use of leaded gasoline will
unrepairable damage to the co
converter.
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INSTRUMENT AND CONTROL FUNCTIONS
Kickstarter
To close the seat
Seal
To open the seat
1. Place the motorcycle on the centerstand.
2. Insert the key into the main switch,
and then tum it counterclockwise
1. Fold the seat down, and then push
it down to lock it in place.
2. Remove the key from the main
switch if the motorcycle will be left
unattended.
np ____~~--~----~_
Make sure that the seat is properly secured before riding.
to "QPEW.
1. Kickstarter
.+
If the engine fails to start by pushing the
start switch, try 10 start it by using the
kickstarter. To start the engine, fold out
the kickstarter lever, move it down lightly with your foot until the gears engage,
and then push it down smoothly but
forcefully.
1. Seal lock
2. Seat
np ____~--~~--~~_
Do not push inward when turning the
key.
3. Fold the seat up.
4-9
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INSTRUMENT AND CONTROL FUNCTIONS
Helmet holders
I
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To release a helmet from a helmet
holder
Open the seat. remove the helmet from
the helmet holder, and then close the
seat.
Convenience hook
1. Corwenience hook
1. Helmel holder
The helmet holders are located under
the seat.
. . WARNING
• Do not exceed the load limit of
1.0 kg (2.2 Ib) for the conve-
To secure a helmet to a helmet holder
1. Open the seat. (See page 4-9.)
2. Attach a helmet to a helmet holder, and then securely close the
seat. WARNING! Never ride
with a helmet attached to the
helmet holder, since the helmet
may hit objects, causing loss
of control and possibly an accident. IEWA,O'61 )
nience hook.
• Do not exceed the maximum
load of 160 kg (353 Ib) for the
motorcycle.
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INSTRUMENT AND CONTROL FUNCTIONS
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Storage compartment
I. Storage compartment
2. Cover
There is a storage compartment
equipped with a lid under the seat.
(See page 4-9 for seat opening and
closing procedures.)
. . WARNING
• Do not exceed the load limit of
5.0 kg (11.0 Ib) for the storage
compartment.
• Do not exceed the maximum
load of 160 kg (353Ib) for the vehicle.
Keep the following points in mind
when using the storage compartment.
• Since the storage compartment
accumulates heat when exposed to the sun, do not store
anything susceptible to heat insideil.
• To avoid humidity from spreading th rough the storage compartment, wrap wet articles in a
plastic bag before storing them
in the compartment.
• Since the storage compartment
may get wet while the scooter is
being washed, wrap any articles
stored in the compartment in a
plastic bag.
• Do not keep anything valuable
or breakable in the storage
compartment.
To store a helmet in the storage compartment, place the helmet upsidedown with the lront facing forward.
4 - 11
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• Some helmets cannot be stored in
the storage compartment because
01their size or shape.
• Do not leave your motorcycle unattended with the seat open.
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--:'\':,":} 5POf8199_El.book Page I Thursday, January 15, 2009 1:10 PM
(~)
FOR YOUR SAFETY - PRE-OPERATION CHECKS
I
EAU15596
Inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition. Always follow the inspection
and maintenance procedures and schedules described in the Owner's Manual.
EWA11151
A
WARNING
Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equipment damage.
Do not operate the vehicle if you find any problem. If a problem cannot be corrected by the procedures provided in
this manual, have the vehicle inspected by a Yamaha dealer.
Before using this vehicle, check the following points:
CHECKS
ITEM
- (~)
PAGE
Fuel
• Check fuel level in fuel tank.
• Refuel if necessary.
• Check fuel line lor leakage.
4-7
Engine oil
• Check oil level in engine,
• II necessary, add recommended oil to specified level.
• Check vehicle for oil leakage,
7-9
Final transmission oil
• Check vehicle for oil leakage.
7-1 1
Coolant
• Check coolant level in reservoir.
• If necessary, add recommended coolant to specified level.
• Check cooling system lor leakage.
7-12
Front brake
•
•
•
•
•
•
•
7-22
,
Check operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check brake pads for wear.
Replace il necessary.
Check fluid level in reservoir.
II necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.
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- (~:r·--5PO-"8 1 99 _E l.book
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Page 2 Thursday, January 15,2009 110 PM
FOR YOUR SAFETY - PRE-OPERATION CHECKS
ITEM
CHECKS
Rear brake
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.
Control cables
• Make sure that operation is smooth.
• Lubricate if necessary.
Wheels and tires
•
•
•
•
Brake levers
• Make sure that operation is smooth.
• Lubricate lever pivoting pOints if necessary.
7-25
Centerstand, sidestand
• Make sure that operation is smooth.
• Lubricate pivots if necessary.
7-25
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.
-
Check operation_
Lubricate cable if necessary_
Check lever free play,
Adjust if necessary.
7-21,7-24
Check for damage.
Check tire condition and tread depth.
Check air pressure.
Correct if necessary.
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•
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7-17,7-24
7-24
7-18,7-20
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OPERATION AND IMPORTANT RIDING POINTS
EAVT1IOI
Starling a cold engine
Read the Owner's Manual carefully to
become familiar with all controls. If
there is a control or function you do not
understand, ask your Yamaha dealer.
A
WARNING
Failure to familiarize yourseH with
the controls can lead to loss of control, which CQuid cause an accident
or injury.
See page 6-3 for engine break-in instructions prior to operating the vehicle for the first time.
1. Turn the key to "ON",
2. Close the throttle grip completely.
1. Start switch -6)-
3. Start the engine by pushing the
start switch or by kicking the kickstarter, while applying the front or
rear brake. NOTICE: For maximum engine life, never accelerate hard when the engine is
cold!
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4. If the engine fail s to start by pushing the start switch, release the
switch, wait a few seconds, and
then try again. Each starting attempt should be as short as possible to preserve the battery. Do not
crank the engine more than 5 seconds on anyone attempt. If the engine does not start with the starter
motor, try using the kickstarter.
411.
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OPERATION AND IMPORTANT RIDING POINTS
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Starting off
Acceleration and deceleration
TIP
Before starting off, allow the engine to
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Braking
Front
1
warm up.
1. While pulling the rear brake lever
with your left hand and hokling the
-,
,
grab bar with your right hand, push
the scooter off the centerstand.
2. Sit astride the seal, and then adjust the rear view mirrors.
3. Switch the tum signals on.
4. Check for oncoming traffic, and
then slowly turn the throttle grip
(on the right) in ord er to take off.
5. Switch the turn signals off.
J
1. Throttle grip
The speed can be adjusted by opening
and closing the throttle. To increase the
speed, lurn the throttle grip in direction
(a). To reduce the speed , lum the throttle grip in direction (b).
Rear
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OPERATION AND IMPORTANT RIDING POINTS
A
•
•
•
•
WARNING
Avoid braking hard or suddenly
(especially when leaning over to
one side), otherwise the scooter
may skid or overturn.
Railroad crossings, streetcar
rails, iron plates on road construction sites, and manhole
covers become extremely slippery when weL Therefore, slow
down when approaching such
areas and cross them with caution.
Keep in mind that braking on a
wet road is much more difficult.
Ride slowly down a hill, as braking downhill can be very diffi-
Tips for reducing fuel
consumption
Fuel consumption depends largely on
your riding style. Consider the following
tips to reduce fuel consumption:
• Avoid high engine speeds during
acceleration.
• Avoid high engine speeds with no
load on the engine.
• Tum the engine oft instead of letting it idle for an extended length of
time (e.g., in traffic jams, at traffic
lights or at railroad crossings).
cult.
1. Close the throttle completely.
2. Apply both front and rear brakes
simultaneously while gradually increasing the pressure.
6-3
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Engine break-in
There is never a more important period
in the life of your engine than the period
between 0 and 1000 km (600 mil. For
this reason, you should read the following material carefully.
Since the engine is brand new, do not
put an excessive load on it for the first
1000 km (600 mil. The various parts in
the engine wear and polish themselves
to the correct operating clearances.
During this period, prolonged full-throttle operation or any condition that might
result in engine overheating must be
avoided.
"
OPERATION AND IMPORTANT RIDING POINTS
0--150 km (C}-9() mil
Avoid prolonged operation above 314
throttle.
150-500 km (90-300 mil
150-500Km
1/2
Avoid prolonged operation above 113
throttle .
After every hour of operation, stop the
engine, and then let it cool for five to len
minutes.
Vary the engine speed from time to
lime. Do not operate the engine al one
set throttle position.
Avoid prolonged operation above 1/2
throttle.
Rev the engine freely through the
gears, but do not use full throttle at any
time.
500-1000 km (300-600 mil
~ 500- 1 000Km~
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1000 km (600 mil and beyond
~
1000Km-
I
Avoid prolonged full-throttle operation.
Vary the engine speed occasionally.
NOTICE: After 1000 km (600 mil of
operation, the engine oil must be
changed. the oil filter cartridge or
element replaced, and the oil strainer cleaned. It any engine trouble
should occur during the engine
break-in period, immediately h\ve a
Yamaha dealer check the vehicle.
(~+5POf8199_ELbook
-
Page 5 Thursday , January 15,2009 110 PM
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OPERATION AND IMPORTANT RIDING POINTS
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Parking
When parking, stop the engine, and
then remove the key from the main
switch.
EWA10311
A
WARNING
• Since the engine and exhaust
system can become very hot,
park in a place where pedestrians or children are not likely to
touch them and be burned.
• Do not park on a slope or on
soft ground, otherwise the vehicle may overturn, increasing the
risk of a fuel leak and fire.
• Do not park near grass or other
flammable
materials which
might catch fire.
+-
6-5
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OPERATION AND IMPORTANT RIDING POINTS
EAW .... '
General note
Much can be gained from the correct use and maintenance 01a motorcycle.
1. THE CUSTOMERS CAN USE THE FULLEST
POTENTIAL OF YAMAHA MOTORCYCLES
2. A MOTORCYCLE CAN KEEP ITS PERFORMANCE
CAPABILITY FOR A lONGEATIME
Compariso n of wear on engine parts
(piston, piston ring. cylinder, etc.)
HX)'.
Wilt! maintenance
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covered (km)
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E~ine
overhaul. cylinder
boring. piston ring change, etc.
OPERATION AND IMPORTANT RIDING POI
3. FUEL COST AND REPAIR EXPENSES CAN BE
KEPTTO A MIN IMUM
Distance covered (km)
I
@
4. A MOTORCYCLE CAN DEMAND A HIGH PRICE
WHEN IT IS TRADED IN AS A USED PRODUCT
~
Cu stomer·s running cost
(fuel cosl plu s maintenance and repair e)(pen ses)
W,thout maintenance t
5
(3ig repairs at higher expenses
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000 0
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Witt1 maintenance
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Distance covered (km) ~
6-7
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PERIODIC MAINTENANCE AND ADJUSTMENT
Periodic inspection, adjustment , and
lubrication will keep your vehicte in the
salest and most efficient condition
possible. Safety is an obligation of the
vehicle owner/operator. The most important points of vehicle inspection.
adjustment , and lubrication are explained on the following pages.
The intervats given in the periodic
maintenance and lubrication chart
should be simply considered as a general guide under normal riding conditions. However, depending on the
weather, terrain, geographical location.
and individual use, the maintenance intervals may need to be shortened.
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AWAANING
Failure to properly maintain the vehicle or performing maintenance activities incorrectly may increase
your risk of injury or death during
service or while using the vehicle. If
you are not familiar with vehicle ser-
vice, have a Yamaha dealer perform
service.
Owner's tool kit
AWAANING
Turn off the engine when performing
maintenance
unless
otherwise
specified.
• A running engine has moving
parts that can c~tch on body
parts or clothing and e~ctrical
parts that can cause shocks or
fires.
• Running the engine while servicing can lead to eye injury,
burns, fire, or carbon monoxide
poisoning - poss ibly leading to
death. See page 2-2 for more information about carbon monoxide.
1. Owner's tool kH
The owner's 1001 kil is located under
the passenger seal. (See page 4-9.)
The service infonnalion included in this
manual and the lools provided in the
owner's tool kit are intended to ' assist
you in the periormance of preventive
maintenance and minor repa irs. However. additional tools such as a torque
wrench may be necessary to periorm
certain maintenance work correctly.
TlP _ _ _ _ _ _ __ __
If you do not have the tools or experience required for a particular job, have
a Yamaha dealer perlonn it for you.
7-1
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Page 2 Monday. January
--(tJi e
19.2009 4:07 PM
if
PERIODIC MAINTENANCE AND ADJUSTMENT
EAU46880
TIP ______________________
~
_______________________________________________________
• The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.
• From 16000 km , repeat the maintenance intervals starting from 4000 km.
• Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
EAU46930
Periodic maintenance chart for the emission control system
ODOMETER READING (km)
NO.
ITEM
CHECK OR MAINTENANCE JOB
1000
1
2
3
4
5
6
-Jr
·
·
·
·
·
Fuel line
• Check fuel and vacuum hoses for cracks or damage.
Spark plug
• Check condition.
• Clean and regap.
,
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• Replace.
Valves
• Check valve clearance.
• Adjust.
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Carburetor
• Adjust engine idling speed.
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Muffler and exhaust pipe
• Check the screw c1amp(s) for looseness.
Air induction system
• Check the air cut·off valve, reed valve, and hose for damage.
• Replace any damaged parts if necessary.
7-2
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ANNUAL
7000 10000 13000 CHECK
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5POJ8199_ELbook Page 3 Thursday, January 15,2009 1:10 PM
PERIODIC MAINTENANCE AND ADJUSTMENT
EAUU0091
General maintenance and lubrication chart
ODOMETER READING (km)
ITEM
NO.
1
Air filter element
2
V-belt case air filter
element
3
4
5
6
7
8
9
10
11
CHECK OR MAINTENANCE JOB
• Check condition.
1000
4000
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7000 10000 13000
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ANNUAL
CHECK
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• Replace.
Every 16000 km (10000 mil
• Clean.
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Battery
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• Check battery voltage.
• Change battery if necessary,
Front brake
• Check operation, fluid level and vehicle for fluid leakage.
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Rear brake
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·
·
·
·
·
··
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Whenever worn to the limit
• Replace brake pads,
• Check operation and adjust brake lever free play,
Brake hose
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Whenever worn to the limit
• Replace brake shoes,
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• Check for cracks or damage.
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Every 4 years
• Replace,
Wheels
• Check runout and for damage,
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Wheels
• Check runout, spoke tightness and for damage.
• Tighten spokes if necessary,
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Tires
•
•
•
•
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Check tread depth and for damage.
Replace if necessary,
Check air pressure,
Correct if necessary,
Wheel bearings
• Check bearing for looseness or damage.
Swingarm
• Check operation and for excessive play,
• Lubricate with lithium-soap-based grease.
7-3
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Every 13000 km (8000 mil
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-(~}'-5POf8 1 99_E lbook
Page4 Thursday , January 15, 2009 I 10 PM
PERIODIC MAINTENANCE AND ADJUSTMENT
NO.
12
13
·
·
14
15
16
·
·
17
18
19
·
·
20
21
·
22
·
23
24
25
ITEM
Steering bearings
CHECK OR MAINTENANCE JOB
• Check bearing play and steering for roughness.
ODOMETER READING (km)
1000
4000
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• Lubricate with lithium-soap-based grease.
7000 10000 13000
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ANNUAL
CHECK
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Every 13000 km (8000 mil
Chassis fasteners
• Make sure that all nuts, bolts and screws are properly tightened.
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Sidestand,
centerstand
• Check operation.
• Lubricate.
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Front fork
• Check operation and for oil leakage.
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Shock absorber
assemblies
• Check operation and shock absorbers lor oil leakage.
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Engine oil
• Change,
• Check oil level and vehicle for oil leakage,
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Engine oil strainer
• Clean,
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Cooling system
• Check coolant level and vehicle for coolant leakage.
"
"
"
"
"
• Change.
Final transmission oil
• Check vehicle for oil leakage.
V-belt
• Check for damage and wear.
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Every 3000 km
(1800 mil
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Every 3 years
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Every 10000 km (6000 mil
• Change.
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Every 25000 km (16000 mil
• Replace.
Front and rear brake
switches
• Check operation.
·
Moving parts and cables
• Lubricate.
Throttle grip housing
and cable
·
• Check operation and free play.
• Adjust the throttle cable free play if necessary.
• Lubricate the throttle grip housing and cable.
Lights, signals and
switches
• Check operation.
• Adjust headlight beam.
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PERIODIC MAINTENANCE AND ADJUSTMENT
EAUI 8660
TIP ______
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• 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 intemal 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.
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PERIODIC MAINTENANCE AND ADJUSTMENT
Removing and installing
cowlings and panels
The cowlings and panels shown need
to be removed to per10rm some of the
maintenance jobs described in this
chapter. Refer to this section each time
a cowling or panel needs to be removed and installed.
To install the cowling
Place the cowling in the original position, and then install the screws.
CowlingC
To remove the cowling
Cowlings A and B
To remove one of the cowlings
Remove the cowling screws, and then
pull the cowling off as shown.
1. Remove cowlings A and B. (See
page 7-6.)
2. Remove the bolts and screws
shown, and then take the cowling
off.
1. Cowling A
2. Cowling C
3. Panel A
2 --_--'
2
ZAUU0376
1. Cowling A
1. Cowling C
2. Screw (x7)
2. Screw (~)
3. Bolt ( ~1 )
1. Cowling B
2. Panel B
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PERIODIC MAINTENANCE AND ADJUSTMENT
Panels A and B
To remove one of the panels
To install the panel
Place the panel in the original position ,
and then install the screw.
Remove the screw, and then pull the
panel off as shown.
I. Screw (x4)
To install the cowling
1. Place the cowling in the original
position, and then install the bolts
and screws.
2. Inslall cowlings A and B.
+
1. Panel B
2. Screw (x3)
7-7
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PERIODIC MAINTENANCE AND ADJUSTME
I
stead, have a Yamaha dealer (
the vehide.
Checking the spark plug
The spark plug is an important engine
2. Check the spark plug for elec
erosion and excessive carbl
other deposits, and replace
necessary.
component, which is easy to check.
Sinee heat and deposits will cause any
spark plug to slowly erode, the spark
plug should be removed and checked
in accordance with the periodic maintenance and lubrication chart. In addition,
the condition of the spark plug can reveal the condition of the engine_
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To remove the spark plug
1. Place the vehicle on the centerstand.
2. Remove panelS. (See page 7-6.)
3. Remove the spark plug cap.
Specified spark plug:
NGKlCR7E
1. Spark plug wrench
4. Remove the spark plug as shown,
with the spark plug wrench included in the owner's tool kit.
To check the spark plug
To install the spark plug
1. Measure the spark plug gap ~
wire thickness gauge and, if
essary, adjust the gap to spe<
tion.
1. Check thai the porcelain insulator
around the center electrode of the
spark plug is a medium-to-light Ian
(the ideal color when the vehicle is
ridden normally).
np, __~~~____~____
If the spark plug shows a distinctly different color, the engine could be operating improperly. Do not attempt to
diagnose such problems yourself. In1. Sparl!.plug
7-8
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I. Spark plug gap
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PERIODIC MAINTENANCE AND ADJUSTMENT
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Spark plug gap:
0.7-0.8 mm (0.027-0.031 in)
,
,
2. Clean the surlace of the spark
plug gasket and its mating surface, and then wipe off any grime
from the sparK plug threads.
3. Install the spark plug with the
spark plug wrench , and then tighten it to the specifi ed torque.
TIghtening torque:
Spark plug:
12.5 Nm (1.25 m·kgl, 9.0 ft·fbl)
TIP ______- -______- -
Engine oil and oil strainer
The engine 'oil level should be checked
before each ride. In addition, the oil
must be changed and the oil strainer
cleaned at the intervals specified in the
periodic maintenance and lubrication
chart.
3. Wait a few minutes until the oil setties, remove the oil filler cap, wipe
the dipstick dean, insert it back
into the oil filler hole (without
screwing it in), and then remove it
again to check: the oil level.
To check the engine oil level
1. Place the vehicle on the centerstand. A slight tilt to the side can
result in a false reading.
2. Start the engine, warm it up for
several minutes. and then tum it
off.
If a torque wrench is not available when
1. Dipstick
installing a spark plug, a good estimate
of the correct torque is 1/4-1 /2 tum
past finger tight. However, the spark
plug should be tightened to the specified torque as soon as possible.
2. Maximum level mar1\:
3. Minimum leve! miU1<.
TlP ______-
______-
__-
The engine oil should be between the
minimum and maximum level marks.
4. Install the spark plug cap.
5. Install the panel.
4. If the engine oil is at or below the
minimum level mark, add sufficient
oil of the recommended type to
raise it to the correct level.
1. OiIliler cap
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PERIODIC MAINTENANCE AND ADJUSTMENT
5. Insert lhe dipstick into the oi ll~ ler
hole, and then tighten the oil liller
cap.
dra in bolt, the O·ring , compres·
s ion s pring , and oil strainer will
fall out. Take care nol to lose
these parts. ((CAI100'1
To change the engine oil and clean
the oil strainer
1. Start the engine, warm it up for
several minutes, and then tum it
off.
2. Place an oil pan under the engine
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10 collect the used oil.
1. Strainer
2. Compression spring
2
1
I. Engine Oil drain bolt A
2. Engine Oil drain bolt B
3. Remove the engine oil filler cap
and drain bolt A to drain the oil
from the crankcase. NOnCE:
When removing the eng ine oil
6. Install the engine oil strainer, compression spring , a -ring and engine
oil drain bolt, and then tighten the
drain bolt to the specified torque.
np ____~~~~~----~
Make sure that the O-ring is property
seated.
Tightening torque:
Engine oil drain bolt A:
20 Nm (2.0 m .kgf, 15 ft·lbf)
Engine oil drain boll B:
20 Nm (2.0 m.kgf, 15 ft.lbt)
7. Refill with the specified amount of
3. ().ring
the recommended engine oil, and
then install and tighten the oil filler
np __~__~__- -__--~­
cap.
When only changing the engine oil, remove drain bolt A. When changing the
engine oil and cleaning the engine oil
strainer. remove drain bolt B also.
4. Clean the engine oil strainer with
solvent, and then check it for damage and replace it if necessary.
5. Check the O-ring for damage and
replace it if necessary.
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Recommended engine oil:
See page 9-1.
Oil quantity:
0.80 l (0.85 US qt) (0.70 tmp.ql)
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PERIODIC MAINTENANCE AND ADJUSTMENT
np ______
~~~~----
Be sure to wipe off spi11ed oil on any
parts after the engine and exhaust system have cooled down.
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• In order to prevent clutch slippage (since the engine oil also
lubricates the clutch), do not
m ix any chemical additives. Do
not use oils with a diesel specification of " CD" or oils of a
higher quality than specified. In
addition, do not use oils labeled
" ENERGY CONSERVING II" or
higher.
• Make sure that no foreign material enters the crankcase.
8. Start the engine, and then let it idle
for several minutes while checking
it for oil leakage. If oil is leaking.
immediately turn the engine off
and check for the cause.
9. Tum the engine off, and then
check the oil level and correct it if
necessary.
Final transmission oil
1. Anal transmission oil d rain bah
1. Final transmission oil 'iller cap
The final transmission case must be
checked for oil leakage before each
ride. If any leakage is found, have a
Yamaha dealer check and repair the
scooter. In addition. the final transmission oil must be changed as follows at
the intervals specified in the periodic
maintenance and lubrication chart.
1. Start the engine, warm up the final
transmission oil by riding the
scooter for severaf minutes, and
then stop the engine.
2. Place the scooler on the centerstand.
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3. Place an oil pan under the fin al
transmission case 10 collect the
used oil.
4. Remove the final transmission oil
filler cap and final transmission
drain bolt to drain the oil from the
final transmission case.
5. Install the final transmission oil
drain bolt, and then tighten it to the
specified torque.
Tightening tOfque:
Final transmission oil drain bolt:
22 Nm (22 m·kgf. 162 1t·1:>f)
(0)
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PERIODIC MAINTENANCE AND ADJUSTMENT
6. Refill with the specified amount of
the recommended final transmission oil, and then install and tighten the oil filler cap. WARNING!
Make sure that no foreign material enters the final transmission case. Make sure that no oil
gets on the tire or wheel. {EWA1I 3I1 1
The coolant level should be checked
before each ride. In addition. the coolant must be changed at the intervals
specified in the periodic maintenance
and lubrication chart.
Recommended final transmi ssion oil:
To check the coolant level
1. Place the vehicle on the centerstand.
See page 9-1.
Oil quantity:
0. 12 L (0.13 US qt, 0.1 1 Imp.qt)
7. Check the final transmission case
for oil leakage. If oil is leaking,
check for the cause.
Coolant
TIP .,,-_ _ _ __ _ _ ____
• The coolanllevel must be checked
on a cold engine since the level
varies with engine temperature.
• Make sure that the vehicle is positioned straight up when checking
the coolant level. A slight tilt to the
side can result in a false reading.
2. Check the coolant level in the coolant reservoir.
np --~~~~~~~----c­
The coolant should be between the
minimum and maximum level marks.
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1. Maximum level mark
2. Minimum level mark
3. If the coolant is at or below the
minimum level mark, remove panel B (See page 7-6.), remove the
reservoir cap. add coolant 10 the
maximum level mark, and then install the reservoir cap and the panel. WARNING! Never anempt to
remove the radiator cap when
the engine is haL [EWA10Je l[ NOTICE: If coolant is not available,
use distilled water or soft tap
water instead. Do not use hard
water or salt w ater since it is
harmful to the engine. If water
has been u sed instead of cool-
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PERIODIC MAINTENANCE AND ADJUSTMENT
ant, replace it with coolant as
soon as possible, otherwise
the cooling system will not be
protected against Irost and
corrosion. If water has been
added to the coolant, have a
Yamaha dealer cheek the anti·
freeze content of the coolant as
soon as possible, otherwise
the effectiveness of the coolant
will be reduced. IECIo.l""~
np ~__~~~__~~__~__
• The radiator fan switches on when
the engine is started and switches
off when the engine is stopped.
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Air filter and V-belt case air
filter elements
tervals specified in the periodic mainte-
The air filter element should be
checked and replace if necessary and
the V-belt case air filter element should
be cleaned at the intervals specified in
the periodic maintenance and lubrication chart. Service the air filter elements
more frequentty if you are riding in unusually wei or dusty areas.
nance and lubrication chart. Have a
Yamaha dealer change the coolant.
WARNING ! Never attempt to remove the radiator cap when the engine is hot_ I[W~'O>&'I
Checking and replacing the air filter
element
1. Place the vehicle on the centerstand.
• If the engine overtleals, see page
7-35 for furth er instructions.
Changing the coolant
The coolant must be changed at the in-
I. CooIan\ rasetVOir cap
Coolant reservoir capacity (up to the
maximum tevel mark):
0.25 l (0.26 US qt) (0.22 Imp.ql)
1. Air tiller case coyer
2. Screw (~6)
7-1 3
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SPOJ 819'lJ: lbook r'!:Ic I4
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PERIODIC MAINTENANCE AND ADJUSTMENT
!
2. Remove panel A. (See page 7-6
for panel removal and installation
procedures.)
3. Remove the air filter case cover by
removing the screws.
4. Remove the air filter element by
pulling it out.
1
1. Air filter element (Wet type)
6. Place the air fiher element in its
original position.
7. Install the air filter case cover by
installing the screws.
8. Install the panel.
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1. Air fiHer element (Wet type)
5. Check the air filter element for excessive dirt or damage and replace it if necessary.
1. V-be1t case air filter cover
2. Bolt (x4)
3. Remove the element by pulling it
out.
Cleaning the V-belt case air fitter element
1. Place the vehicle on the centerstand.
2. Remove the V-belt air filter case
cover by removing the bolts.
1. V-belt air filter eiemeol
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PERIODIC MAINTENANCE AND ADJUSTMENT
np ~__~~~~~~~~
The element should be wet but not
dripping.
Recommended oil:
Yamaha foam air filter oil or other
quality foam air filter oil
7. Install the element into the filter
case.
4. Clean the element with solvent,
and then squeeze the remaining
solvent out.
5. Check the element for damage
and replace it if necessary.
6. Apply oil of the recommended type
to the entire surface of the element, and then squeeze the excess oil out. WARNING! Use only
a dedicated parts cleaning solvent. To avoid the risk of fire or
explosion, do nol use gasoline
or solvents with a low flash
point. [EW~'<M3I1 NOTICE: To avoid
damaging the air filter element,
handle it gently and carefully.
and do not twist it. I':CA10i2'j
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8. Place the air filter case cover in its
original position, and then install
the bolls. NOTICE: Make sure
that each filter element is properly seated in its case. The en-
1. Air filter check hose
2. Clamp
gine should never be operated
without the filter elements installed, otherwise the piston(s)
andlor cylinder(s) may become
excessively worn. lle~1om1 1
Cleaning the air fiher check hose
and caps
1. Check each cap at the bottom left
and right side of the air filler case
and the hose at the bottom of the
V-belt case for accumulated dirt or
waler.
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1. Check hose
2. Clamp
2. If dirt or water is visible, remove
the cap or hose, clean it, and then
install it.
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PERIODIC MAINTENANCE AND ADJUSTMENT
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Adjusting the carburetor
The carburetor is an important part of
the engine and requires very sophisticated adjustment. Therefore. most carburetor adjustments should be left to a
Yamaha dealer. who has the necessary professional knowledge and experience. The adjustment described in
the following section, however, may be
serviced by the owner as part of rou tine
maintenance.
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The carburetor has been set and extensively tested at the Yamaha factory. Changing these settings
without sufficient technical knowledge may result in poor performance of o r damage to the engine.
Adjusting the engine idling
speed
The engine idling speed must be
checked and, if necessary, adjusted as
follows at the intervals specified in the
periodic maintenance and lubrication
chart.
The engine should be warm before
making this adjustment.
TlP _ _ _ _ _ _ _ _ _
5. Remove the rubber cap and insert
a Phillips screwdriver into the
thronle stop screw hole.
6. To increase the engine idling
speed, tum the screw in direction
(a). To decrease the engine idling
speed, tum the screw in direction
(b).
~
• The engine is warm when it quickly responds to the throttle.
• A diagnostic tachometer is needed
to make this adjustment.
1. Open the seat. (See page 4-9 lor
seat opening and closing procedures.)
2. Remove panel B. (See page 7-6
lor panel removal and installation
procedures.)
3. Attach the tachometer to the spa(\(
plug lead.
4 . Check the engine idling speed
and, if necessary, adjust it to specification as follows.
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1. Th rottle stop screw
Engine idling speed:
1400-1600 r/min
TlP _~~~~~~~~
If the specified idling speed cannot be
obtained as described above, have a
Yamaha dealer make the adjustment.
7. Install the panel and close the
seal.
PERIODIC MAINTENANCE AND ADJUSTMENT
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Adjusting the throttle cable
free play
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2. To increase the IhroWe cable free
play, tum the adjusting nut in direction (a). To decrease the throt-
tle cable free play, tum the
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1. loosen the locknut.
adjusting nut in direction (b).
3. Tighten the locknut.
2
1. Thronle cable free play adjusting nut
2. Locknut
3. Cable cover
c. ThroCUe cable free play
The throttle cable free play should
measure 3.0-7.0 mm (0.12--0.28 in) at
the throttle grip. Periodically check.the
throttle cable free play and, if neces·
sary, adjust it as follows.
TIP _ _--,--,_ _ _ _ _ __
The engine idling speed must be correctly adjusted before checking and adjusting the throttle cable free play.
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Valve clearance
The valve clearance changes with use,
resulting in improper air-fuel mixture
and/or engine noise. To prevent this
from occurring, the valve clearance
must be adjusted by a Yamaha dealer
at the intervals specified in the periodic
maintenance and lubrication chart.
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PERIODIC MAINTENANCE AND ADJUSTMENT
!
Tires
To maximize the perfonnance, durability, and safe operation of your motorcycle, note the following points regarding
the specified tires.
Tire air pressure
The ti re air pressure should be
checked and, if necessary, adjusted
before each ride.
EV/Al ",",'
A
WARNING
Operation of this vehicle with improper tire pressure may cause severe injury or death from loss of
control.
• The tire air pressure must be
checked and adjusted on cold
tires (i.e., when the temperature
of the tires equals the ambient
temperature).
• The tire air pressure must be
adjusted in accordance with the
riding speed and with the total
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weight of rider, passenger, cargo, and accessories approved
for this model.
Tire air pressure (measured on cold
A
WARNING
Never overload your vehicle. Operation of an overloaded vehicle could
cause an accident.
tires):
Up to 90 kg (198Ib):
Front:
' 200 kPa (2.00 kgflcm 2•
29 psi)
Rear:
225 kPa (2.25 kgflcm 2,
33 psi)
90 kg (l98lb) to ma xi mum load:
Front:
200 kPa (2.00 kgflcm 2,
29 psi)
Rear:
225 kPa (2.25 kgflcm>',
33 psi)
Maximum load':
160 kg (353 Ib)
Total weight of rider. passenger,
cargo and accessories
7"
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Tire inspection
+1. Tire sidewall
2. Ti re wear indicator
3. Tire tread depth
The tires must be checked before each
ride. If the tire shows crosswise lines
(minimum tread depth), if the tire has a
nail or glass fragments in it. or if the
sidewall is cracked, have a Yamaha
dealer replace the tire immediately.
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PERIODIC MAINTENANCE AND ADJUSTMENT
Minimum tire tread depth (front and
rear):
1.0 mm (0.04 in)
TIP -0----:---:-:---::-::---::-----;:::;The tire tread depth limits may differ
from country to country. Always comply
with the local regulations.
Front tire:
Size:
70190-14MIC 36P
Manufacturer/model:
IAC/NF59E, (TUBElESS)
DUNLOPID 11 0M,DllOL
Rear tire:
Size:
80190-16MIC 48P
Manufacturer/mode l:
IAC/NR76E, (TUBELESS)
Tire information
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This motorcycle is equipped with tube
tires.
A
WARNING
The front and rear tires should be of
the same make and design, otherwise the handling characteristics of
the vehicle may be different, which
could lead to an accident
After extensive tests, only the tires listed below have been approved for this
model by Yamaha Motor Co., Ltd.
A
WARNING
• It is dangerous to ride with a
worn-out tire. When a tire tread
begins to show crosswise lines,
have a Yamaha dealer replace
the tire immediately.
• The replacement of all wheeland brake-related parts, including the tires, should be len to a
Yamaha dealer, who has the
necessary professional knowledge and experience.
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• It is not recommended to patch
a punctured tUbe. If unavoid·
able, however, patch the tube
very carefully and replace it as
soon as possible with a highquality product.
!-!) SPOjSI99~l:i l.booI: I'ag~ 2(} ThursJ.y, Janu:lJ)' l'i , 2009 1:10 PM
PERIODIC MAINTENANCE AND ADJUSTMENT
Wheels
To maximize the perfonnance, durability, and safe operation of your motorcycle, note the following points regarding
the specified wheels.
• The wheel rims should be checked
lor cracks, bends or warpage, and
the spokes for looseness (for
spoke wheel model) or damage
before each ride. II any damage is
found, have a Yamaha dealer replace the wheel. Do not attempt
even the smallest repair to the
wheel. A deformed or cracked
wheel must be replaced.
• The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced. An
unbalanced wheel can result in
poor performance, adverse handling characteristics, and a shortened tire life.
• Ride at moderate speeds after
changing a tire since the tire surface must first be "broken in" for it
to develop its optimal characteristics.
Checking the front brake lever
free play
There should be no free play at the
brake lever end. If there is free play,
have a Yamaha dealer inspect the
brake system.
. . WARNING
A soft or spongy feeling in the brake
lever can indicate the presence of
air in the hydraulic system. tf there
is air in the hydraulic system, have a
Yamaha dealer bleed the system before operating the vehicle. Air in the
hydraulic system will diminish the
braking performance, which may re7-20
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PERIODIC MAINTENANCE AND ADJUSTMENT
suit in loss of control and an accide nt.
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Adjusting the rear brake lever
free play
1
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1. Rear brake IeVCf free play
The brake lever free play should measure 10.0-20.0 mm (0.394-0.787 in)
as shown. Periodically check the brake
lever free play and. if necessary, adjust
it as follows.
To increase the brake lever free play,
lum the adjusting nut at the brake shoe
plate in direction (a). To decrease the
brake lever free play, tum the adjusting
nul in direction (b).
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1_ Rear brake lever free play adjusting n
""WARNING
H proper adjustment cannot I
tained as described, have a Vi
dealer make this adjustment.
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PERIODIC MAINTENANCE AND ADJUSTMENT
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Checking the front brake pads
and rear brake shoes
The front brake pads and the rear
brake shoes must be checked for wear
at the intervals specified in the periodic
maintenance and lubrication chart.
peared, have a Yamaha dealer replace
the brake pads as a set.
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Checking the brake fluid level
Rear brake shoes
Front brake pads
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1. Minimum level mark
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1. Brake shoe wear indicator
2. Brake shoe wear limit line
out having to disassemble the brake.
To check the brake pad wear, check
the wear indicator grooves. If a brake
The rear brake is provided with a wear
indicator, which allows you to check the
brake shoe wear without having to disassemble the brake. To check the
brake shoe wear, check the position of
the wear indicator while applying the
brake. If a brake shoe has wom to the
point that the wear indicator reaches
the wear limit line, have a Yamaha
dealer replace the brake shoes as a
pad has worn to the point that the wear
set.
1. Brake pad wear indicator groove (x2)
Each Iront brake pad is provided with
wear indicator grooves, which allow
you to check the brake pad wear with-
Insufficient brake fluid may allow air to
enter the brake system, possibly causing it 10 become ineffective.
Before riding, check that the brake fluid
is above the minimum level mark and
replenish if necessary. A low brake fluid level may indicate wom brake pads
and/Of brake system leakage. If the
brake fluid level is low, be sure to check
the brake pads fOf wear and the brake
system lor leakage.
ObselVe these precautions:
indicator grooves have almost disap7-22
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• When checking the fluid level,
make sure that the top 01 the master cylinder is level by turning the
handlebars.
• Use only the recommended quality brake fluid, otherwise the rubber
seals may deteriorate, causing
leakage and poor braking performance.
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PERIODIC MAINTENANCE AND ADJUSTMENT
• As the brake pads wear, it is nor-
mal for the brake fluid level to
gradually go down. However, if the
brake fluid level goes down suddenly, have a Yamaha dealer
check the cause.
Recommended brake lIuid:
DOT 4
• Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking performance.
• Be careful that water does nol enter the master cylinder when refitting. Water will significantly lower
the boiting point of the flui d and
may result in vapor lock.
• Brake fluid may deteriorate painted surfaces or plastic parts. Always clean up spilled fluid
immediately.
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Changing the brake fluid
Have a Yamaha dealer change the
brake fluid at the intervals specified in
the TIP after the periodic maintenance
and lubrication chart. In addition. have
the oil seals 01 the brake master cylinder and caliper as well as the brake
hose replaced at the intervals listed below or whenever they are damaged or
leaking.
• Oil seals: Replace every two
years.
• Brake hose: Replace every four
years.
(~
PERIODIC MAINTENANCE AND ADJUSTMENT
I
Checking the V-belt
The V-be" must be checked and replaced by a Yamaha dealer at the intervals specified
in
the
periodic
maintenance and lubrication chart
E.oUJ» l1l
Checking and lubricating the
throttle grip and cable
The operation of all control cables and
The operation of the throttle grip should
be checked before each ride. In addition, the cable should be lubricated at
the intervals specified in the periodic
maintenance chart.
the condition of the cables should be
checked before each ride, and the cables and cable ends should be lubricated jf necessary. If a cable is damaged
or does not move smoothly, have a
yamaha dealer check or replace it.
WARNING! Damage to the outer
sheath may interfere with proper
cable operation and will cause the
inner cable to rust. Replace a damaged cable as soon as possible to
prevent unsafe conditions. IEWA 10721 J
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Recommended lubricant:
Engine oil
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Checking and lubricating the
cables
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PERIODIC MAINTENANCE AND ADJUSTMENT
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Lubricating the front and rear
brake levers
Recommended lubricant:
lithium-soap-based grease
,
The pivoting points of the front and fear
brake levers must be lubricated at the
intervals specified in the periodic maintenance and lubrication chart.
Checking and lubricating the
centerstand and sidestand
The operation of the centerstand and
sidestand should be checked before
each ride , and the pivots and metal-Iometal contact surfaces should be lubri cated if necessary.
A
WARNING
H the centerstand or sidestand does
not move up and down smoothly,
have a Yamaha dealer check or repair il Otherwise, the centerstand or
sidesland could contact the ground
and distract the operator, resulting
in a possibte loss of control.
I
7-25
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PERIODIC MAINTENANCE AND ADJUSTMENT
Recommended lubricant:
Ulhium-soap-based grease
Checking the front fork
The condition and operation of the front
lork must be checked as follows at the
intervals specified in the periodic maintenance and lubrication chart.
To check the condition
Check the inner tubes for scratches,
damage and excessive oil leakage.
To check the operation
1. Place the vehicle Ofl a level surface and hold it in an upright position. WARNING! To avoid injury,
securely support the vehicle so
there Is no danger of it falling
over. lI',""I075'1
2. While applying the front brake,
push down hard on the handlebars
several times 10 check if the front
fork compresses and rebounds
smoothly.
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If any damage is found or the front
fork does not operate smoothly,
have 8 Yamaha dealer check or re-
pair it.
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SPO]& I99 . F. l. book Pise 27 1'bunoday Ja..."ary IS , 2009 u n I'M
PERIODIC MAINTENANCE AND ADJUSTMENT
Checking the steering
Worn or loose steering bearings may
cause danger. Therefore, the operation
of the steering must be checked as follows at the intervals specified in the pe.riodic maintenance and lubrication
2. Hold the lower ends of the front
fork legs and
try to move them for-
ward and backward. II any free
play can be felt, have a Yamaha
dealer check or repair the steering.
1>
The front and rear wheel bearings must
be checked at the intervals specified in
the periodic maintenance and lubrica-
tion chart II there is play in the wheel
hub or if the wheel does not tum
smoothly, have a Yamaha dealer
chart.
I
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Checking the wheel bearings
check the wheel bearings.
1. Place a stand under the engine to
raise the front wheel off the
ground. (See page 7-25 for more
information.)
WARNING!
To
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the vehicle so there is no danger of It falling over. I(WA, 01$'1
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PERIODIC MAINTENANCE AND ADJUSTMENT
I
Battery
This model is equipped with a VRLA
(Valve Regulated Lead Acid) battery.
There is no need to check the electrolyte or to add distilled water. However,
the battery lead connections need to be
checked and, if necessary, tightened.
ways shield your eyes when
working near batteries. In case
of contact, administer the following FIRST AID.
• EXTERNAL: Flush with plenty
of water.
• INTERNAL: Drink large quantities of water or milk and immediately call a physician.
• EVES: Rush with water for 15
minutes and seek prompt
medical attention.
1. Batteey band
• Batteries produce explosive hy-
drogen gas. Therefore, keep
sparks, flames, cigarettes, etc.,
away from the battery and provide sufficient ventilation when
1 Ba1tery cover
2. Screw (x2)
A
WARNING
• Electrolyte is poisonous and
dangerous since it contains sui·
furic acid, which causes severe
burns. Avoid any contact with
skin, eyes or clothing and al·
2. Remove the battery cover by removing the screws.
charging
it
in
an
enclosed
space.
• KEEP THIS AND ALL SATIERIES OUT OF THE REACH OF
CHILDREN.
To access the battery
1. Open the seat. (See page 4-9.)
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2. Satteey
3. Positive ballery lead
4 . Negative battery lead
To charge the battery
Have a Yamaha dealer charge the battery as soon as possible if it seems to
have discharged. Keep in mind that the
battery tends to discharge more quickly
if the vehicle is equipped with optional
electrical accessories.
To charge a VRLA (Valve Regulated
Lead Acid) battery, a special (corr
+
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f
PERIODIC MAINTENANCE AND ADJUSTMENT
stant-voltage) battery charger is required. Using a conventional battery
charger will damage the battery. If
you do not have access to a con·
stant-voltage battery charger, have
a Yamaha dealer charge your bat-
tery.
4. After installation , make sure that
the battery leads are properly connected to the battery terminals.
Replacing the fuse
TlCE
Always keep the battery charged.
Storing a discharged battery can
cause permanent battery damage_
To store the battery
1. If the vehicle will not be used for
more than one month, remove the
battery, fully charge iI , and then
place it in a cool, dry place. NOnCE: When removing the battery, be sure the key is turned
to " OFF". then disconnect the
negative lead before disconnecting the positive lead. [EC"'63021
2. If the battery will be stored for
more than two months, check it al
least once a month and full y
charge it if necessary.
3. Fully charge the battery before installation.
1. Fuse cover
2. Screw (x l)
The fuse holder is located in the storage compartment under the seat, behind the starter relay cover. (See page
4-9 for seat opening procedures.)
If the fu se is blown, replace it as follows.
1. Tum the key to "OFF' and turn off
all electrical circuits.
2. Remove the starter relay cover by
removing the screw.
3. Pull the starter relay out.
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PERIODIC MAINTENANCE AND ADJUSTMENT
6. Instali lhe starter relay cover by installing the screw.
7. Tum the key to ~ONM and tum on
the electrical circuits to check if the
devices operate.
8. If the fuse immediately blows
again, have a Yamaha dealer
check the electrical system.
~Lay
ave the blown fuse, and then
II a new fu se of the specified
~ rage . WARNING! Do not
a fuse of a higher amperrating than recommended
avoid causing extensive
age to the electrical sysand possibly a fire. 1I="~ ' SI"1
I'.M.UI I ~ I
Replacing a headlight bulb
If a headlight bulb bums Qut, replace
it
as fol1ows.
Do not touch the glass part of the
headlight bulb to keep it fTee from
oil, otherwise the transparency of
the glass, the luminosity of the bulb,
and the bulb life will be adversely affected. Thoroughly clean off any dirt
and fingerprints on the headlight
bulb using a cloth moistened w ith
alcohol or thinner.
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ad fuse:
e the starter relay into the
,a1 position .
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1. CowWngC
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PERIODIC MAINTENANCE AND ADJUSTMENT
~"
1. Place the motorcycle on the cen·
tersland.
2. Remove cowling C. (See page 7-6
for removing procedure.)
Replacing the taillbrake light
bulb
1. Open the seal. (See page 4-9.)
2. Remove the panel by removing
the screws, and then pulling the
panel outward.
1. Headlight but> holder
5. Place a new bulb into position, and
then secu re it with the bulb holder.
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1. Headlight bllib covo r (1'2)
3. Remove the headlight bulb cover
by turning i' counterclockwise.
4. Remove the headlight bulb holder
by pushing it inward and turning it
counterclockwise, and lhen remove the bulb.
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1. 00 noI touch \he glass pari 01 the bub.
6. Inslailihe cowling.
7. Have a Yamaha dealer adjust the
headlight beam if necessary.
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1. Rear panel
2. Screw (x2)
3. Rubbercap
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IS. 2009 1 10 PM
PERIODIC MAINTENANCE AND ADJUSTMENT
5. Insert a new bulb into the socket,
push it in. and then tum it clockwise until it stops.
6. Install the socket (together with the
bulb) by tuming it clockwise.
7. Install the panel and the seat.
-.~
Replacing a tum signal light
bulb
1. Tailltlfake Iiglt bub socItet
3. Remove the socket (together with
the bulb) by tuming it counterclockwise.
4. Remove the bumt out bulb by
pushing it in and tuming it counterclockwise.
1. Rear 1urn signal
~ght
lens
2. Screw
1. Remove the tum signal light lens
by removing the screw.
2. Remove the bumt-out bulb by
pushing it in and tuming it counter-
clockwise.
3. Insert a new bulb into the socket,
push it in, and then tum it clockwise until it stops.
4. Install the lens by installing the
screw. NOTICE: Do not overtighten the screw, otherwise
the lens may break. {EGA ' ''", '
I. TaiUbfake Mght bulb
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PERIODIC MAINTENANCE AND ADJUSTMENT
~
Replacing a front turn signal
lighl bulb
If a front turn signal light bulb bums out,
replace it as follows.
1. Remove cowling A (if replacing the
left lurn signal light bulb) or cowling B (if replacing the right tum signallight bulb). (See page 7-6. For
4. Insert a new bulb into the socket.
5. Install the turn signal light socket
(together with the bulb) by turning
it clockwise .
6. Install the cowli ng.
removal and installation procedures.)
2. Remove the lum signal light socket (together with the bulb) by luming it counterclockwise.
3. Remove the defective bulb by pulling it out.
~,
Replacing an auxiliary light
bulb
This model is equipped with two auxiliary lights. If an auxiliary light bulb
bums out, replace it as follows.
1. Remove cowling C. (Seepage 7-6
for removal and installation proce.
dures.)
2. Remove the auxiliary light socket
(together with the bulb) by turning
it counterclockwise.
1.
Aux~ia'Y
light bulb
3. Remove the burnt out bulb by pulling it out.
4. Insert a new bulb into the socket.
1. Front tum signal light bulb
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PERIODIC MAINTENANCE AND ADJUSTMENT
5. Install the auxiliary light socket (together with the bulb) by turning it
clockwise.
6 . Instailihe cowling.
Troubleshooting
Although Yamaha motorcycles receive
a thorough inspection before shipment
from the factory, trouble may occurduring operation. Any problem in the fuel,
compression, or ignition systems, for
example, can cause poor starting and
loss of power.
The following troubleshooting charts
represent quick and easy procedures
lor checking these vital systems yourself. However, should your motorcycle
require any repair, take it to a Yamaha
dealer, whose skilled technicians have
the necessary tools, experience, and
know-how to service the motorcycle
properly.
Use only genuine Yamaha replacement parts. Imitation parts may look
like Yamaha parts, but they are often
inferior, have a shorter service life and
can lead to expensive repair bills.
~W"' 5' "
. . WARNING
When checking the fuel system, do
not smoke, and make sure there are
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no open names or sparks in the area, including pilot lights from water
heaters or furnaces. Gasoline or
gasoline vapors can igni te or explode, causing severe injury or
property damage.
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\~5POjgI99_El.book Page 35 Thursday, January 15, 2009 1:10 PM
f
PERIODIC MAINTENANCE AND ADJUSTMENT
EAU25922
Troubleshooting charts
Starting problems or poor engine performance
1. Fuel
There is enough lueL
Check the luel level in
the fuel tank.
The engine does not start.
Check the compression.
There is no fuel.
I
2. Compression
There is compression,
Check the ignition,
+
Operate the electric starter,
There is no compression .
•
3. Ignition
Remove the spark plug
and check the electrodes,
4. Battery
Have a Yamaha dealer
check the vehicle.
Wipe off with a dry cloth and correct the
spark plug gap, or replace the spark plug,
B-1
Have a Yamaha dealer check the vehicle.
The engine turns over
quickly.
The battery is good,
The engine turns over
slowly,
Check the battery lead connections,
and charge the battery if necessary.
Operate the electric starter,
7-35
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The engine does not start.
Have a Yamaha dealer
check the vehicle.
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PERIODIC MAINTENANCE AND ADJUSTMENT
if
Engine overheating
( WA."""'l
A
WARNING
• Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be
blown out under pressure, which could cause serious injury. Be sure to wait until the engine has cooled.
• After removing the radiator cap retaining bolt, place a thick rag, like a towel, over the radiator cap, and then
slowly rotate the cap counterclockwise to the detent to allow any residual pressure to escape. When the hissing sound has stopped, press down on the cap while turning it counterclockwise, and then remove the cap.
@
The coolant ~vel is low.
Check the cooling system
lor leakage.
Wait unlil lhe
engine lias cooled.
Have a Yamaha dealer chock
and repair the cooling sysklm.
Add coolant (See TIP.)
Ched< the coolant level in the
reservoir and radiator.
The coolant level
is OK.
Start tho engine. If \he engine overheats again, have a
Yamalla deale. clleck and
dle cooling system.
'epa"
TIP ~~~~~________~____~~~~__~~~~~~~________~~
If coolant is not available, tap water can be temporarily used instead , provided that it is changed to the recommended coolant
as soon as possible.
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I
MOTORCYCLE CARE AND STORAGE
Care
While the open design of a motorcycle
reveals the attractiveness of the technology. it also makes il more vulnera-
ble. Rust and corrosion can develop
even if high-quality components are
used. A rusty exhaust pipe may go un-
noticed on a car, however, il detracts
from the overall appearance of a motorcycle. Frequent and proper care
does nol only comply with the terms 01
the warranty, but it will also keep your
motorcycle looking good, extend its life
and optimize its petiormance.
Before cleaning
1. Cover the muffler outlet with a
plastic bag after the engine has
cooled down.
2. Make sure that all caps and covers
as well as all electrical couplers
and connectors, including the
spark plug cap, are tightly installed.
3. Remove extrem ~y stubborn dirt,
like oil burnt onto the crankcase,
with a degreasing agent and a
brush, but never apply such prod·
ucts onto seals, gaskets and
wheel axles. Always rinse the dirt
and degreaser off with water.
Cleaning
• Avoid using strong acidic wheel
cleaners, especially on spoked
wheels. If such products are
used on hard-to-remove dirt, do
not leave the cleaner on the affected area any longer than instructed. Also, thoroughly rinse
the area off with water, immediately dry it, and then apply a
corrosion protection spray.
• Improper cleaning can damage
plastic parts (such as cowlings,
panels, windshields, headlight
lenses, meter lenses, etc.) and
the mufflers. Use only a soft,
clean cloth or sponge with wa-
ler to clean plastic. However, if
the plastic parts cannot be thoroughly cleaned with waler, diluted mild detergent with water
may be used. Be sure to rinse
off any detergent residue using
plenty of water, as it is harmful
to plastic parts.
• Do not use any harsh chemical
products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
contact with strong or abrasive
cleaning products, solvent or
thinner, fuel (gasoline), rust removers or inhibitors, brake lIuid, antifreeze or electrolyte.
• Do not use high-pressure
washers or steam-jet cleaners
since they cause water seepage and deterioration in the following areas: seals (of wheel
and swingarm bearings, fork
and brakes), electric components {couplers, connectors,
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Sf'O _FS l99 _E Lbvok POSo 2 l1'...-..hy. J",.uary IS. 2009 1.1 0 PM
MOTORCYCLE CARE AND STORAGE
I
1
I
instruments,
switches
and
lights), breather hoses and
vents.
• For scooters equipped with a
windshield: 00 not use strong
cleaners or hard sponges as
they will cause dulling or
scratching.
Some cleaning
compounds for plastic may
leave scratches on the wind·
shield. Test the product on a
small hidden part of the w indshield to make sure that it does
not leave any marks. II the
windshield is scratched, use a
quality plastic polishing compound after washing.
After normal use
Remove dirt with warm water, a mild
detergent, and a soft, clean sponge,
and then rinse thoroughly with clean
water. Use a toothbrush or bonlebrush
for hard-la-reach areas. Stubborn dirt
and insects will come off more easily if
the area is covered with a wet cloth lor
a few minutes before cleaning.
After riding in the rain or near the sea
ince sea salt is extremely corrosive carry out the following steps after each
ride in the rain or near the sea.
1. Clean the motorcycle with cold
water and a mild detergent after
the engine has cooled down. NOTICE: Do not use warm water
since it increases the corrosive
action of the salt. I(G~ ' 011l \ 1
2. Apply a corrosion protection spray
on all metal, including chromeand nickel-plated, surlaces to prevent corrosion.
After cleaning
1. Dry the motorcycle with a chamois
or an abSOlbing cloth.
2. Use a chrome polish 10 shine
chrome, aluminum and stainlesssleel parts, including the exhaust
system. (Even the Ihermally in-
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3.
4.
5.
6.
7.
A
duced discoloring of stainlesssleel exhaust systems can be removed through polishing.)
To prevent corrosion, it is recommended to apply a corrosion protection spray on all metal,
including chrome- and nickel-plated , surtaces.
Use spray oil as a universal cleaner to remove any remaining dirt.
Touch up minor paint damage
caused by stones, etc.
Wax all painted surfaces.
Let the motorcycle dry completely
before storing or covering it.
WARNING
Contaminants on the brakes or tires
can cause loss of control.
• Make sure that there is no oil or
wax on the brakes or tires. H
necessary, clean the brake
discs and brake linings with a
regular brake disc cleaner or acetone, and wash the tires with
warm water and a mild detergent
,~~
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MOTORCYCLE CARE AND STORAGE
• Before operating the scooter
test its braking perfonnance
and cornering behavior.
OTIC
• Apply spray oil and wax sparingly and make sure to wipe off
any excess.
• Never apply oil or wax to any
rubber parts, plastic parts or
headlight, taillight and meter
lenses, but treat them with a
suitable care product
• Avoid using abrasive polishing
compounds as they will wear
away the paint.
np ~--~~--~~~~---c
• Consuh a Yamaha dealer for advice on what products to use.
• Washing, rainy weather or humid
climates can cause the headlight
lens to fog. Turning the headlight
on for a short period of time will
help remove the moisture from the
lens.
~,
Storage
Short-term
Always store your scooter in a cool, dry
place and, if necessary, protect it
against dust with a porous cover.
N
• Storing the scooter in a poorly
ventilated room or covering it
with a tarp, while it is still wet,
will allow water and humidity to
seep in and cause rust.
• To prevent corrosion, avoid
damp cellars, stables (because
of the presence of ammonia)
and areas where strong chemicals are stored.
Long-term
Before storing your scooter for several
months:
1. Follow all the instructions in the
~Care" section of this chapter.
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2. Drain the carburetor float chamber
by loosening the drain boit; this will
prevent fuel deposits from building
up. Pour the drained fuel into the
fuel tank.
3. Fill up the fu el tank and add fuel
stabilizer (if available) to prevent
the fuel tank hom rusting and the
fuel from deteriorating.
4. Per10rm the following steps 10 proteet the cylinder, piston rings, etc.
from corrosion.
a. Remove the spark plug cap
and spark plug.
b. Pour a teaspoonful of engine
oil inlo the spark plug bore.
c. Install the spark plug cap onto
the spark plug , and then place
the spark plug on the cylinder
head so that the electrodes are
grounded. (This will limit spark~
ing during the next step.)
d. Tum lhe engine over several
times with the starter. (This will
coat the cylinder wall with oil.)
WARNING! To prevent damage or injury from sparking,
MOTORCYCLE CARE AND STORAGE
make sure to ground the
spark plug electrodes while
turning the engine over.
t(W""09!i' l
5.
I
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6.
7.
8.
e. Remove the spark plug cap
from the spark plug, and then
install the spark plug and the
spark plug cap.
Lubricate all control cables and the
pivoting points of all levers and
pedals as well as of the sideslandJ
centerstand.
Check and , if necessary, correct
the lire air pressure, and then lift
the scooter so that both 01 its
wheels are off the ground. Aherna·
lively, tum the wheels a litHe every
month in order to prevent the tires
from becoming degraded in one
spot.
Cover the muffler outlet with a
plastic bag to prevent moisture
from entering it.
Remove the banery and fully
charge it. Store it in a cool, dry
place and charge it once a month.
Do not store the battery in an ex-
cessively cold or warm place [less
than 0 °C (30 OF) or more than
30 °C (90 °F)I. For more infonnation on storing the battery, see
page 7-28.
np ____________~~~Make any necessary repairs before
storing the scooter.
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SPECIFICATIONS
Dimensions;
OveraJllengtfl:
1950 mm (76.8 in)
Overall widlh:
678 mm (26.7 in)
Overall height:
1057 mm {41.6 in)
Seat height:
770 mm (30.3 in)
Wheelbase:
1290 mm (SO.8 in)
Ground clearance:
130mm(5.1 in)
Minimum turning radius :
1938 mm (76.3 in)
Weight:
With oil and fuol:
11 0.6 kg (243.81b)
Engine:
Engine type:
Liquid cooled 4-51roke. SOHC
Cylinder arrangement:
Forward-inclined single cylinder
Displacement:
132.6 cm 3 (8.1 cu.in)
Bore x stroke:
54.0 x 57.9 mm (2.13 x 2.28 in)
Compression ratio:
10.80 :1
Starting system:
Bectric starter and kickstarter
Lubrication system:
Engine oil:
carburetor:
Type:
SAE20W-40 or SAE20W-SO
Recommendecl engine oil grade:
API service SG type or higher, JASO
standard MA Of MB
Engine oil Quantity:
Periodic o~ change:
0.80 L (0.85 US ql) (0.70 Imp.QI)
Final transmissian oil:
ellt-
Spark plug (s):
Manulacturerlmodel:
NGK/CR7E
Spark. plug gap:
0.7-{}.8 mm (0.028--0.031 in)
Clutch:
Type:
Yamalube 4 Stroke or SAE 10W-30 API
Service "SE" type motor 011
Final transmission oil quantity:
0.23 L (0.24 US ql) (0.20 Imp.qI)
Cooling system:
Recommended coolant:
YAMAHA GENUINE COOLANT only
Coolant reservoir capacity (up to the
maximum level mark):
0.25 L (0.26 US qt) (0.22 Imp.qI)
Radiator capacity (induding al routes) :
0.51 L (0.54 US qt) (0.45 Imp.qt)
Air filter:
Air lilter element:
Wet element
Fuel:
Recommended fuel;
REl{JJ1ar unleaded gasoline or gasohol
(91 min . pump oclane)
Fuel tank capacity:
4.8 L (1.27 US gal) (1.06 Imp.gal)
Wet somp
@
Manufacturer:
MIKUNI
Type x quantity:
BS26 x 1
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Clulch type:
Dry, centrifugal automalic
Transmission:
Primary reduction system:
Helical gear
Primary reduction ratio:
42/16 (2.625)
Secondary reduction system:
Helical gear
Soc.:ondary reduction ratio:
46112 (3.833)
Single speed automatic (rearlffOnt):
2.273-0.822: I
Transmission type:
V-beII automatic
Operation:
Centrifugal automalic
Chassis:
Frame type :
Sleefluoo underbone
Caster angle:
26.00 •
Trai:
110 .5 mm (4.35 in)
t
---4 1_ ~_
SPECIFICATIONS
Front tire:
Type:
With l ube (Spoke wheel)!
Tutleless (Cast wheel)
Size:
70190- 1636P
Manufaclurerlmodel:
IRCTIIF59 e OUNlOP!Ul 10 M, Dl l OL
Rear tire:
Type:
-<!oj
With tube (Spoke wheel)!
Tubeless (Cast wheel)
Size:
B<W9D-16 48P
Manufacturer/model:
IRClNR76 E DUNLOPfOl10 M, 0110l
Loading:
160 kg (353Ib)
(Total weight 01 rider. passenger. cargo and
accessories)
Tire air pressure (measured on cold
tires):
Front:
200 kPa (29 psi) (2.00 kgllW)
Rear:
225 kPa (33 psi) (2.25 kgf/cm 2)
Front wheel:
Wheel type:
Spoke wheeVCasl wheel
Rim size:
16x 1.40/16xMT1.6
E~trical
Rear wheel:
Wheel type:
Spoke wheellCast wheel
Rim size :
16xl.6OI16xMT1.6
't-
system:
Ignition system:
DC. COl
Charging system:
AC magneto
Battery:
Front brake:
Type:
Model:
Single disc brake
Operation:
Right hand opera~on
Recommended fluid:
Voltage, capacity:
12 V, 3.5 Ah
GTZSS
Headlight:
Bulb type:
Incandescence
DOH
Rear brake:
Bulb voltage, wattage x quantity:
Type:
Drum brake
Operation:
left hand operation
Front suspension:
Type:
Telescopic fork
Sprin9'shocl< absorber type:
Coil spring/oil damper
Wheel travel:
100.0 mm (3.94 in)
Rear suspension:
Type:
Unit swing
Springlshock absorber type:
Coil springloil damper
Wheel travel:
90.0 mm (3.54 in)
Headlight:
12V, 25WI25.0Wx2
Tailibrake light:
12 V, 5 .0 W121.0 W x 1
Front turn Sigoollight:
12V,10.0Wx2
Rear tum signal light:
12V, 10.0W x2
Auxiliary light:
12V,3.4Wx2
Meter lighting:
LED
High beam indicator light:
12V,1 .4 Wx l
Tum signal indicator light:
LEO
Engina trouble waming ligI"It:
LEO
Fuse:
Fuse:
10.0 A
9-2
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-4-SPO_F8199_El.bOOk Pagel Tlwrsday, January 15,2009 1:10PM
CONSUMER INFORMATION
EAU26450
Engine serial number
1. Engine serial number
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The engine serial number is stamped
into the final gear case.
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10-2
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