3xt-28199-2g tw200ew · this motorcycle is designed to car-ry the operator and a passenger. the...

3XT-28199-2G

TW200EW

OWNER’S MANUAL

INTRODUCTION

EAU10100

Welcome to the Yamaha world of motorcycling!As the owner of the TW200EW, you are benefiting from Yamaha’s vast experience and newest technology regarding thedesign and manufacture of high-quality products, which have earned Yamaha a reputation for dependability.Please take the time to read this manual thoroughly, so as to enjoy all advantages of your TW200EW. The owner’s manualdoes not only instruct you in how to operate, inspect and maintain your motorcycle, but also in how to safeguard yourself andothers from trouble and injury.In addition, the many tips given in this manual will help keep your motorcycle in the best possible condition. If you have anyfurther questions, do not hesitate to contact your Yamaha dealer.The Yamaha team wishes you many safe and pleasant rides. So, remember to put safety first!

IMPORTANT MANUAL INFORMATION

EAU10151

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

NOTE:

�

This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycleis subsequently sold.

�

Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the mostcurrent product information available at the time of printing, there may be minor discrepancies between your motorcycle

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

WARNING

EWA10030

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

*Product and specifications are subject to change without notice.

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

Failure to follow WARNING instructions could result in severe injury or death to themotorcycle operator, a bystander, or a person inspecting or repairing the motorcy-cle.

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

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

WARNING

CAUTION:

NOTE:

IMPORTANT MANUAL INFORMATION

EAU10200

TW200EWOWNER’S MANUAL

©2006 by Yamaha Motor Co., Ltd.1st edition, April 2006

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

Yamaha Motor Co., Ltd. is expressly prohibited.

Printed in Japan.

TABLE OF CONTENTS

SAFETY INFORMATION

...................1-1Location of important labels .............1-5

DESCRIPTION

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

INSTRUMENT AND CONTROL FUNCTIONS

........................................3-1Main switch/steering lock .................3-1Indicator lights .................................3-2Speedometer unit ............................3-2Handlebar switches .........................3-3Clutch lever ......................................3-4Shift pedal ........................................3-4Brake lever ......................................3-4Brake pedal .....................................3-5Fuel tank cap ...................................3-5Fuel ..................................................3-6Fuel cock .........................................3-6Starter (choke) knob “

1

” .................3-7Kickstarter ........................................3-8Seat .................................................3-8Helmet holder ..................................3-9Shock absorber ...............................3-9Carrier ..............................................3-9Luggage strap holders ...................3-10Sidestand .......................................3-10Ignition circuit cut-off system .........3-11

PRE-OPERATION CHECKS

.............. 4-1Pre-operation check list ................... 4-2

OPERATION AND IMPORTANT RIDING POINTS

.................................. 5-1Starting a cold engine ..................... 5-1Starting a warm engine ................... 5-2Shifting ............................................ 5-2Tips for reducing fuel

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

PERIODIC MAINTENANCE AND MINOR REPAIR

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

chart ............................................. 6-2Removing and installing the cowling

and panels ................................... 6-5Checking the spark plug .................. 6-6Engine oil and oil filter element ....... 6-8Cleaning the air filter element and

check hose ................................. 6-11Adjusting the carburetor ................ 6-12Adjusting the engine idling

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

play ............................................ 6-13Valve clearance ............................. 6-13Tires .............................................. 6-14

Spoke wheels ............................... 6-16Adjusting the clutch lever free

play ............................................ 6-16Adjusting the brake lever free

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

and free play .............................. 6-18Adjusting the rear brake light

switch ......................................... 6-19Checking the front brake pads and

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

level ........................................... 6-20Changing the brake fluid ............... 6-21Drive chain slack ........................... 6-22Cleaning and lubricating the drive

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

cables ........................................ 6-24Checking and lubricating the throttle

grip and cable ............................ 6-24Checking and lubricating the brake

and shift pedals ......................... 6-24Checking and lubricating the brake

and clutch levers ........................ 6-25Checking and lubricating the

sidestand ................................... 6-25Lubricating the rear suspension .... 6-25Checking the front fork .................. 6-26Checking the steering ................... 6-26Checking the wheel bearings ........ 6-27

TABLE OF CONTENTS

Battery ...........................................6-27Replacing the fuse .........................6-30Replacing the headlight bulb .........6-30Replacing the tail/brake light

bulb ............................................6-32Replacing a turn signal light

bulb ............................................6-33Supporting the motorcycle .............6-33Front wheel ....................................6-34Rear wheel ....................................6-35Troubleshooting .............................6-37Troubleshooting chart ....................6-38

MOTORCYCLE CARE AND STORAGE

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

SPECIFICATIONS

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

CONSUMER INFORMATION

..............9-1Identification numbers .....................9-1Motorcycle noise regulation

(for Australia) ................................9-2

1-1

1

SAFETY INFORMATION

EAU10311

MOTORCYCLES ARE SINGLETRACK VEHICLES. THEIR SAFEUSE AND OPERATION ARE DEPEN-DENT UPON THE USE OF PROPERRIDING TECHNIQUES AS WELL ASTHE EXPERTISE OF THE OPERA-TOR. EVERY OPERATOR SHOULDKNOW THE FOLLOWING REQUIRE-MENTS BEFORE RIDING THIS MO-TORCYCLE.HE OR SHE SHOULD:

�

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

�

OBSERVE THE WARNINGSAND MAINTENANCE REQUIRE-MENTS IN THE OWNER’S MAN-UAL.

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OBTAIN QUALIFIED TRAININGIN SAFE AND PROPER RIDINGTECHNIQUES.

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OBTAIN PROFESSIONAL TECH-NICAL SERVICE AS INDICATEDBY THE OWNER’S MANUALAND/OR WHEN MADE NECES-SARY BY MECHANICAL CONDI-

TIONS.

Safe riding

�

Always make pre-operationchecks. Careful checks may helpprevent an accident.

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

�

The failure of motorists to detectand recognize motorcycles in traf-fic is the predominating cause ofautomobile/motorcycle accidents.Many accidents have been causedby an automobile driver who didnot see the motorcycle. Makingyourself conspicuous appears tobe very effective in reducing thechance of this type of accident.

�

Therefore:

�

Wear a brightly colored jacket.

�

Use extra caution when ap-proaching and passing throughintersections, since intersec-tions are the most likely placesfor motorcycle accidents to oc-cur.

�

Ride where other motorists cansee you. Avoid riding in another

motorist’s blind spot.

�

Many accidents involve inexperi-enced operators. In fact, many op-erators who have been involved inaccidents do not even have a cur-rent motorcycle license.

�

Make sure that you are qualifiedand that you only lend your mo-torcycle to other qualified opera-tors.

�

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

�

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

�

Many accidents have been causedby error of the motorcycle opera-tor. A typical error made by the op-erator is veering wide on a turndue to EXCESSIVE SPEED or un-dercornering (insufficient lean an-gle for the speed).

�

Always obey the speed limit andnever travel faster than warrant-

SAFETY INFORMATION

1-2

1

ed by road and traffic conditions.

�

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

�

The posture of the operator andpassenger is important for propercontrol.

�

The operator should keep bothhands on the handlebar andboth feet on the operator foot-rests during operation to main-tain control of the motorcycle.

�

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

�

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

�

Never ride under the influence ofalcohol or other drugs.

Protective apparel

The majority of fatalities from motorcy-cle accidents are the result of head in-juries. The use of a safety helmet is thesingle most critical factor in the preven-

tion or reduction of head injuries.

�

Always wear an approved helmet.

�

Wear a face shield or goggles.Wind in your unprotected eyescould contribute to an impairmentof vision that could delay seeing ahazard.

�

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

�

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

�

Never touch the engine or exhaustsystem during or after operation.They become very hot and cancause burns. Always wear protec-tive clothing that covers your legs,ankles, and feet.

�

Passengers should also observethe precautions mentioned above.

Modifications

Modifications made to this motorcyclenot approved by Yamaha, or the re-moval of original equipment, may ren-

der the motorcycle unsafe for use andmay cause severe personal injury.Modifications may also make your mo-torcycle illegal to use.

Loading and accessories

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

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

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

Maximum load:

180 kg (397 lb)

SAFETY INFORMATION

1-3

1

�

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

�

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

�

Never attach any large or heavyitems to the handlebar, front fork,or front fender. These items, in-cluding such cargo as sleepingbags, duffel bags, or tents, cancreate unstable handling or a slowsteering response.

AccessoriesGenuine Yamaha accessories havebeen specifically designed for use onthis motorcycle. Since Yamaha cannottest all other accessories that may beavailable, you must personally be re-sponsible for the proper selection, in-

stallation and use of non-Yamahaaccessories. Use extreme cautionwhen selecting and installing any ac-cessories.Keep the following guidelines in mind,as well as those provided under “Load-ing” when mounting accessories.

�

Never install accessories or carrycargo that would impair the perfor-mance of your motorcycle. Care-fully inspect the accessory beforeusing it to make sure that it doesnot in any way reduce groundclearance or cornering clearance,limit suspension travel, steeringtravel or control operation, or ob-scure lights or reflectors.

�

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

�

Bulky or large accessories mayseriously affect the stability of

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

�

Certain accessories can dis-place the operator from his orher normal riding position. Thisimproper position limits the free-dom of movement of the opera-tor and may limit control ability,therefore, such accessories arenot recommended.

�

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

Gasoline and exhaust gas

�

GASOLINE IS HIGHLY FLAMMA-BLE:

�

Always turn the engine off when

SAFETY INFORMATION

1-4

1

refueling.

�

Take care not to spill any gaso-line on the engine or exhaustsystem when refueling.

�

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

�

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

�

Always turn the engine off beforeleaving the motorcycle unattendedand remove the key from the mainswitch. When parking the motorcy-cle, note the following:

�

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

�

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

�

Do not park the motorcycle near

a flammable source (e.g., a ker-osene heater, or near an openflame), otherwise it could catchfire.

�

When transporting the motorcyclein another vehicle, make sure thatit is kept upright and that the fuelcock(s) are turned to “ON” or“RES” (for vacuum type)/“OFF”(for manual type). If the motorcycleshould lean over, gasoline mayleak out of the carburetor or fueltank.

�

If you should swallow any gaso-line, inhale a lot of gasoline vapor,or allow gasoline to get into youreyes, see your doctor immediate-ly. If any gasoline spills on yourskin or clothing, immediately washthe affected area with soap andwater and change your clothes.

SAFETY INFORMATION

1-5

1

EAU10381

Location of important labels

Please read the following important labels carefully before operating this vehicle.

1 2

3

SAFETY INFORMATION

1-6

11

2

4AA-22259-40

Before you operate this vehicle, read the owner’s manual.

5PA-21568-00

Prima di usare il veicolo, leggete il manuale di istruzioni.Lire le manuel du propriétaire avant d’utiliser ce véhicule.Lesen Sie die Bedienungsanleitung bevor Sie dieses Fahrzeug fahren.Antes de conducir este vehículo, lea el Manual del Propietario.

3

2-1

1

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3

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8

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DESCRIPTION

EAU10410

Left view

1 2 3

457 6

1. Fuel cock (page 3-6)2. Helmet holder (page 3-9)3. Luggage strap holder (page 3-10)4. Drive chain slack adjusting plate5. Air filter element (page 6-11)6. Starter (choke) knob (page 3-7)7. Shift pedal (page 3-4)

DESCRIPTION

2-2

2

3

4

5

6

7

8

9

EAU10420

Right view

1 2

6 5

43

789

1. Carrier (page 3-9)2. Battery (page 6-27)3. Kickstarter (page 3-8)4. Engine oil filter element (page 6-8)5. Engine oil level check window (page 6-8)6. Brake pedal (page 3-5)7. Owner’s tool kit (page 6-1)8. Fuse (page 6-30)

9. Luggage strap holder (page 3-10)

DESCRIPTION

2-3

1

2

3

4

5

6

7

8

9

EAU10430

Controls and instruments

1 2 3 4 5 6 7 8

9

1. Clutch lever (page 3-4)2. Left handlebar switches (page 3-3)3. Speedometer unit (page 3-2)4. Main switch/steering lock (page 3-1)5. Indicator lights (page 3-2)6. Right handlebar switches (page 3-3)7. Brake lever (page 3-4)8. Throttle grip (page 6-13)

9. Fuel tank cap (page 3-5)

3-1

2

3

4

5

6

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8

9


EAU10460

Main switch/steering lock

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

EAU10510

ON

All electrical systems are supplied withpower, and the headlight, meter light-ing, taillight and position lights comeon, and the engine can be started. Thekey cannot be removed.

EAU10660

OFF

All electrical systems are off. The keycan be removed.

EAU10710

LOCK

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

1. Turn the handlebars all the way tothe left or right.

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

3. Remove the key.

To unlock the steeringInsert the key and turn it to “OFF”.

WARNING

EWA10070

Never turn the key to “LOCK” while

the motorcycle is moving.

LOCK

OFFON

1. Push.2. Release.3. Turn.

1 2 3


3-2

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9

EAU10980

Indicator lights

EAU11020

Turn signal indicator light “ ”

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

EAU11060

Neutral indicator light “ ”

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

EAU11080

High beam indicator light “ ”

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

EAU11630

Speedometer unit

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

1. Turn signal indicator light “ ”

2. High beam indicator light “ ”

3. Neutral indicator light “ ”

31 2

1. Speedometer2. Odometer3. Tripmeter4. Reset knob

4

2

3

1


3-3

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3

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9

EAU12346

Handlebar switches

Left

Right

EAU12400

Dimmer switch “ / ”

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

EAU12460

Turn signal switch “ / ”

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

EAU12500

Horn switch “ ”

Press this switch to sound the horn.

EAU12660

Engine stop switch “ / ”

Set this switch to “ ” before startingthe engine. Set this switch to “ ” tostop the engine in case of an emergen-cy, such as when the vehicle overturnsor when the throttle cable is stuck.

EAU12710

Start switch “ ”

Push this switch to crank the enginewith the starter.

CAUTION:

ECA10050

See page 5-1 for starting instruc-

tions prior to starting the engine.

1. Dimmer switch “ / ”

2. Turn signal switch “ / ”

3. Horn switch “ ”

1 2

3

1. Engine stop switch “ / ”

2. Start switch “ ”

1

2


3-4

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9

EAU12820

Clutch lever

The clutch lever is located at the lefthandlebar grip. To disengage theclutch, pull the lever toward the handle-bar grip. To engage the clutch, releasethe lever. The lever should be pulledrapidly and released slowly for smoothclutch operation.The clutch lever is equipped with aclutch switch, which is part of the igni-tion circuit cut-off system. (Seepage 3-11.)

EAU12870

Shift pedal

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

EAU12890

Brake lever

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

1. Clutch lever

1

1. Shift pedal

1

N

5432

1

1. Brake lever

1


3-5

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9

EAU12941

Brake pedal

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

EAU32280

Fuel tank cap

To remove the fuel tank cap

1. Insert the key into the lock and turnit 1/3 turn counterclockwise.

2. Turn the fuel tank cap 1/3 turncounterclockwise and pull it off.

To install the fuel tank cap

1. Insert the fuel tank cap into thetank opening with the key insertedin the lock, and then turn the cap 1/3 turn clockwise.

2. Turn the key 1/3 turn clockwise,and then remove it.

NOTE:

The fuel tank cap cannot be installedunless the key is in the lock. In addition,the key cannot be removed if the cap is

not properly installed and locked.

WARNING

EWA10120

Make sure that the fuel tank cap isproperly closed and locked before

riding.

1. Brake pedal

1

1. Fuel tank cap2. Unlock.

1

2


3-6

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EAU13211

Fuel

Make sure that there is sufficient fuel inthe tank. Fill the fuel tank to the bottomof the filler tube as shown.

WARNING

EWA10880

�

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

�

Avoid spilling fuel on the hot en-

gine.

CAUTION:

ECA10070

Immediately wipe off spilled fuelwith a clean, dry, soft cloth, since

fuel may deteriorate painted surfac-

es or plastic parts.

EAU13330

CAUTION:

ECA11400

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

as well as to the exhaust system.

Your Yamaha engine has been de-signed to use regular unleaded gaso-line with a research octane number of91 or higher. If knocking (or pinging) oc-curs, use a gasoline of a different brandor premium unleaded fuel. Use of un-leaded fuel will extend spark plug lifeand reduce maintenance costs.

EAU13561

Fuel cock

The fuel cock supplies fuel from thetank to the carburetor while filtering it al-so.The fuel cock has three positions:

OFF

With the lever in this position, fuel willnot flow. Always return the lever to thisposition when the engine is not running.

1. Fuel tank filler tube2. Fuel level

1

2

Recommended fuel:

UNLEADED GASOLINE ONLY

Fuel tank capacity:

7.0 L (1.85 US gal) (1.54 Imp.gal)

Fuel reserve amount:

1.7 L (0.45 US gal) (0.37 Imp.gal)

1. Arrow mark positioned over “OFF”

RES

ONFUEL

OFF

1


3-7

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3

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9

ON

With the lever in this position, fuel flowsto the carburetor. Normal riding is donewith the lever in this position.

RES

This indicates reserve. If you run out offuel while riding, move the lever to thisposition. Fill the tank at the first oppor-tunity. Be sure to set the lever back to“ON” after refueling!

EAU13600

Starter (choke) knob “ ”

Starting a cold engine requires a richerair-fuel mixture, which is supplied bythe starter (choke).Move the knob in direction (a) to turn onthe starter (choke).Move the knob in direction (b) to turn offthe starter (choke).

1. Arrow mark positioned over “ON”

1. Arrow mark positioned over “RES”

ONFUEL

RES

OFF

1ON

OFF

ONFUEL

RES

1

RES

1. Starter (choke) knob “ ”

1

(a)(b)


3-8

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EAU13660

Kickstarter

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

EAU13970

Seat

To remove the seat

Remove the bolts, and then pull theseat off.

To install the seat

1. Insert the projection on the front ofthe seat into the seat holder asshown.

2. Place the seat in the original posi-tion, and then tighten the bolts.

NOTE:

Make sure that the seat is properly se-

cured before riding.

1. Kickstarter

1

1. Bolt

1

1. Projection2. Seat holder

12


3-9

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3

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9

EAU14281

Helmet holder

To open the helmet holder, insert thekey into the lock, and then turn the keyas shown.To lock the helmet holder, place it in theoriginal position, and then remove thekey.

WARNING

EWA10160

Never ride with a helmet attached tothe helmet holder, since the helmetmay hit objects, causing loss of con-

trol and possibly an accident.

EAU15090

Shock absorber

WARNING

EWA10220

This shock absorber contains highlypressurized nitrogen gas. For prop-er handling, read and understandthe following information beforehandling the shock absorber. Themanufacturer cannot be held re-sponsible for property damage orpersonal injury that may result fromimproper handling.

�

Do not tamper with or attempt toopen the gas cylinder.

�

Do not subject the shock ab-sorber to an open flame or otherhigh heat sources, otherwise itmay explode due to excessivegas pressure.

�

Do not deform or damage thegas cylinder in any way, as thiswill result in poor damping per-formance.

�

Always have a Yamaha dealer

service the shock absorber.

EAU15110

Carrier

WARNING

EWA10170

�

Do not exceed the load limit of3 kg (7 lb) for the carrier.

�

Do not exceed the maximumload of 180 kg (397 lb) for the ve-

hicle.

1. Helmet holder

1

1. Carrier

1


3-10

1

2

3

4

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9

EAU15170

Luggage strap holders

There are four luggage strap holdersbelow the carrier.

EAU15301

Sidestand

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

NOTE:

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

the ignition circuit cut-off system.)

WARNING

EWA10240

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

pair it if it does not function proper-

ly.

1. Luggage strap holder

1

1


3-11

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9

EAU15311

Ignition circuit cut-off system

The ignition circuit cut-off system (com-prising the sidestand switch, clutchswitch and neutral switch) has the fol-lowing functions.

�

It prevents starting when the trans-mission is in gear and the side-stand is up, but the clutch lever isnot pulled.

�

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

�

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

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

WARNING

EWA10250

If a malfunction is noted, have aYamaha dealer check the system be-

fore riding.


3-12

1

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3

4

5

6

7

8

9

With the engine turned off:1. Move the sidestand down.2. Make sure that the engine stop switch is turned on.3. Turn the key on. 4. Shift the transmission into the neutral position.5. Push the start switch.Does the engine start?

With the engine still running:6. Move the sidestand up.7. Keep the clutch lever pulled.8. Shift the transmission into gear.9. Move the sidestand down.Does the engine stall?

After the engine has stalled:10. Move the sidestand up.11. Keep the clutch lever pulled.12. Push the start switch.Does the engine start?

The system is OK. The motorcycle can be ridden.

This check is most reliable if performed witha warmed-up engine.

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

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

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

YES NO

YES NO

YES NO

NOTE:

4-1

2

3

4

5

6

7

8

9


EAU15591

The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly,even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or lossof tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thorough visual inspec-tion, to check the following points before each ride.

NOTE:

Pre-operation checks should be made each time the vehicle is used. Such an inspection can be accomplished in a very short

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

WARNING

EWA11150

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

the vehicle.


4-2

1

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3

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7

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9

EAU15605

Pre-operation check list

ITEM CHECKS PAGE

Fuel

�

Check fuel level in fuel tank.

�

Refuel if necessary.

�

Check fuel line for leakage.3-6

Engine oil

�

Check oil level in engine.

�

If necessary, add recommended oil to specified level.

�

Check vehicle for oil leakage.6-8

Front brake

�

Check operation.

�

If soft or spongy, have Yamaha dealer bleed hydraulic system.

�

Check lever free play.

�

Adjust if necessary.

�

Check brake pads for wear.

�

Replace if necessary.

�

Check fluid level in reservoir.

�

If necessary, add recommended brake fluid to specified level.

�

Check hydraulic system for leakage.

6-17, 6-19, 6-20

Rear brake

�

Check operation.

�

Check pedal free play.

�

Adjust if necessary.6-18, 6-19

Clutch

�

Check operation.

�

Lubricate cable if necessary.

�

Check lever free play.

�


6-16

Throttle grip

�

Make sure that operation is smooth.

�

Check cable free play.

�

If necessary, have Yamaha dealer adjust cable free play and lubricate cable and grip housing.

6-13, 6-24

Control cables

�


�

Lubricate if necessary.6-24


4-3

2

3

4

5

6

7

8

9

Drive chain

�

Check chain slack.

�


�

Check chain condition.

�

Lubricate if necessary.

6-22, 6-23

Wheels and tires

�

Check for damage.

�

Check tire condition and tread depth.

�

Check air pressure.

�

Correct if necessary.

6-14, 6-16

Brake and shift pedals

�


�

Lubricate pedal pivoting points if necessary.6-24

Brake and clutch levers

�


�

Lubricate lever pivoting points if necessary.6-25

Sidestand

�


�

Lubricate pivot if necessary.6-25

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.—

Sidestand switch

�

Check operation of ignition circuit cut-off system.

�

If system is defective, have Yamaha dealer check vehicle.3-10

Battery

�

Check fluid level.

�

Fill with distilled water if necessary.6-27

ITEM CHECKS PAGE

5-1

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6

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8

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EAU15950

WARNING

EWA10270

�

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

�

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

�

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

of control.

EAU16530

Starting a cold engine

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

�

The transmission is in the neutralposition.

�

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

WARNING

EWA10290

�

Before starting the engine,check the function of the igni-tion circuit cut-off system ac-cording to the proceduredescribed on page 3-11.

�

Never ride with the sidestand

down.

1. Turn the fuel cock lever to “ON”.2. Turn the key to “ON” and make

sure that the engine stop switch isset to “ ”.

3. Shift the transmission into the neu-tral position.

NOTE:

When the transmission is in the neutralposition, the neutral indicator light

should be on, otherwise have aYamaha dealer check the electrical cir-

cuit.

4. Turn the starter (choke) on andcompletely close the throttle. (Seepage 3-7.)

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

NOTE:

If the engine fails to start by pushing thestart switch, release the switch, wait afew seconds, and then try again. Eachstarting attempt should be as short aspossible to preserve the battery. Do notcrank the engine more than 10 secondson any one attempt. If the engine doesnot start with the starter motor, try using

the kickstarter.

6. After starting the engine, move thestarter (choke) back halfway.

CAUTION:

ECA11040

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

cold!

7. When the engine is warm, turn the


5-2

2

3

4

5

6

7

8

9

starter (choke) off.

NOTE:

The engine is warm when it respondsnormally to the throttle with the starter

(choke) turned off.

EAU16640

Starting a warm engine

Follow the same procedure as for start-ing a cold engine with the exceptionthat the starter (choke) is not requiredwhen the engine is warm.

EAU16671

Shifting

Shifting gears lets you control theamount of engine power available forstarting off, accelerating, climbing hills,etc.The gear positions are shown in the il-lustration.

NOTE:

To shift the transmission into the neu-tral position, press the shift pedal downrepeatedly until it reaches the end of its

travel, and then slightly raise it.

CAUTION:

ECA10260

�

Even with the transmission in

1. Shift pedal2. Neutral position

1

N

5432

12


5-3

1

2

3

4

5

6

7

8

9

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

�

Always use the clutch whilechanging gears to avoid damag-ing the engine, transmission,and drive train, which are notdesigned to withstand the

shock of forced shifting.

EAU16800

Tips for reducing fuel consumption

Fuel consumption depends largely onyour riding style. Consider the followingtips to reduce fuel consumption:

�

Turn the starter (choke) off assoon as possible.

�

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

�

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

�

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

EAU16841

Engine break-in

There is never a more important periodin the life of your engine than the periodbetween 0 and 1600 km (1000 mi). Forthis reason, you should read the follow-ing material carefully.Since the engine is brand new, do notput an excessive load on it for the first1600 km (1000 mi). The various parts inthe engine wear and polish themselvesto the correct operating clearances.During this period, prolonged full-throt-tle operation or any condition that mightresult in engine overheating must beavoided.

EAU32311

0–1000 km (0–600 mi)

Avoid prolonged operation above 1/3throttle.

1000–1600 km (600–1000 mi)

Avoid prolonged operation above 1/2throttle.

1600 km (1000 mi) and beyond

The vehicle can now be operated nor-mally.


5-4

2

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4

5

6

7

8

9

CAUTION:

ECA12711

�

After 1000 km (600 mi) of opera-tion, the engine oil must bechanged, the oil filter elementand the oil strainer cleaned.

�

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

cle.

EAU17170

Parking

When parking, stop the engine, removethe key from the main switch, and thenturn the fuel cock lever to “OFF”.

WARNING

EWA10310

�

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

�

Do not park on a slope or on softground, otherwise the vehicle

may overturn.

6-1

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3

4

5

6

7

8

9


EAU17240

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

WARNING

EWA10320

If you are not familiar with mainte-nance work, have a Yamaha dealer

do it for you.

EAU17340

Owner’s tool kit

The owner’s tool kit is located behindpanel B. (See page 6-5.)The service information included in thismanual and the tools provided in theowner’s tool kit are intended to assistyou in the performance of preventivemaintenance and minor repairs. How-ever, additional tools such as a torquewrench may be necessary to performcertain maintenance work correctly.

NOTE:

If you do not have the tools or experi-ence required for a particular job, have

a Yamaha dealer perform it for you.

WARNING

EWA10350

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

es.

1. Owner’s tool kit

1


6-2

2

3

4

5

6

7

8

9

EAU17710

Periodic maintenance and lubrication chart NOTE:

�

The annual checks must be performed every year, except if a kilometer-based maintenance is performed in-stead.

�

From 30000 km, repeat the maintenance intervals starting from 6000 km.

�

Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical

skills.

NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (

×

1000 km) ANNUAL CHECK1 6 12 18 24

1 *

Fuel line

�

Check fuel hoses for cracks or damage.

√ √ √ √ √

2

Spark plug

�

Check condition.

�

Clean and regap.

√ √

�

Replace.

√ √

3 *

Valves

�

Check valve clearance.

�

Adjust.

√ √ √ √

4

Air filter element

�

Clean.

√ √

�

Replace.

√ √

5 *

Battery

�

Check electrolyte level and specific gravity.

�

Make sure that the breather hose is properly routed.

√ √ √ √ √

6

Clutch

�

Check operation.

�

Adjust.

√ √ √ √ √

7 *

Front brake

�

Check operation, fluid level and vehicle for fluid leak-age.

√ √ √ √ √ √

�

Replace brake pads. Whenever worn to the limit

8 *

Rear brake

�

Check operation and adjust brake pedal free play.

√ √ √ √ √ √

�

Replace brake shoes. Whenever worn to the limit

9 *

Brake hose

�

Check for cracks or damage.

√ √ √ √ √

�

Replace. Every 4 years


6-3

1

2

3

4

5

6

7

8

9

10

*

Wheels

�

Check runout, spoke tightness and for damage.

�

Tighten spokes if necessary.

√ √ √ √

11

*

Tires

�

Check tread depth and for damage.

�

Replace if necessary.

�

Check air pressure.

�

Correct if necessary.

√ √ √ √ √

12

*

Wheel bearings

�

Check bearing for looseness or damage.

√ √ √ √

13

*

Swingarm

�

Check operation and for excessive play.

√ √ √ √

�

Lubricate with lithium-soap-based grease. Every 24000 km

14

Drive chain

�

Check chain slack, alignment and condition.

�

Adjust and thoroughly lubricate chain with engine oil.Every 500 km and after washing the motorcycle or

riding in the rain

15

*

Steering bearings

�

Check bearing play and steering for roughness.

√ √ √ √ √

�

Lubricate with lithium-soap-based grease. Every 24000 km

16

*

Chassis fasteners

�

Make sure that all nuts, bolts and screws are properly tightened.

√ √ √ √ √

17

Sidestand

�

Check operation.

�

Lubricate.

√ √ √ √ √

18

*

Sidestand switch

�

Check operation.

√ √ √ √ √ √

19

*

Front fork

�

Check operation and for oil leakage.

√ √ √ √

20

*

Shock absorber assem-bly

�

Check operation and shock absorber for oil leakage.

√ √ √ √

21

*

Carburetor

�

Check starter (choke) operation.

�

Adjust engine idling speed.

√ √ √ √ √ √

22

Engine oil

�

Change.

�

Check oil level and vehicle for oil leakage.

√ √ √ √ √ √

23

Engine oil filter element

�

Clean.

√ √ √

24

*

Engine oil strainer

�

Clean.

√

25

*

Front and rear brake switches

�

Check operation.

√ √ √ √ √ √


×

1000 km) ANNUAL CHECK1 6 12 18 24


6-4

2

3

4

5

6

7

8

9

EAU18660

NOTE:

�

The air filter needs more frequent service if you are riding in unusually wet or dusty areas.

�

Hydraulic brake service

�

Regularly check and, if necessary, correct the brake fluid level.

�

Every two years replace the internal components of the brake master cylinder and caliper, and change the brake fluid.

�

Replace the brake hoses every four years and if cracked or damaged.

26

Moving parts and cables

�

Lubricate.

√ √ √ √ √

27

*

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.

√ √ √ √ √

28

*

Lights, signals and switches

�

Check operation.

�

Adjust headlight beam.

√ √ √ √ √ √


×

1000 km) ANNUAL CHECK1 6 12 18 24


6-5

1

2

3

4

5

6

7

8

9

EAU18721

Removing and installing the cowling and panels

The cowling and panels shown need tobe removed to perform some of themaintenance jobs described in thischapter. Refer to this section each timethe cowling or a panel needs to be re-moved and installed.

EAU18810

Cowling A

To remove the cowlingRemove the screw, and then pull thecowling off as shown.

To install the cowlingPlace the cowling in the original posi-tion, and then install the screw.

EAU32451

Panel A

To remove the panelRemove the screws, and then pull thepanel out at the area shown.

To install the panelPlace the panel in the original position,and then install the screws.

1. Cowling A2. Panel A

1

2

1. Panel B

1. Screw

1

1

1. Panel A2. Screw

2

1


6-6

2

3

4

5

6

7

8

9

Panel B

To remove the panelPull the panel off as shown.

To install the panelPlace the panel in the original position.

EAU19603

Checking the spark plug

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

To remove the spark plug

1. Remove the spark plug cap.

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

1. Panel B

1

1. Spark plug cap

1


6-7

1

2

3

4

5

6

7

8

9

To check the spark plug

1. Check that the porcelain insulatoraround the center electrode of thespark plug is a medium-to-light tan(the ideal color when the vehicle isridden normally).

NOTE:

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

the vehicle.

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

necessary.

To install the spark plug

1. Measure the spark plug gap with awire thickness gauge and, if nec-essary, adjust the gap to specifica-tion.

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

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

NOTE:

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

fied torque as soon as possible.

4. Install the spark plug cap.

1. Spark plug wrench

1

Specified spark plug:

NGK/DR8EADENSO/X24ESR-U

1. Spark plug gap

Spark plug gap:

0.6–0.7 mm (0.024–0.028 in)

1

Tightening torque:

Spark plug:17.5 Nm (1.75 m·kgf, 12.5 ft·lbf)


6-8

2

3

4

5

6

7

8

9

EAU19792

Engine oil and oil filter element

The engine oil level should be checkedbefore each ride. In addition, the oilmust be changed and the oil filter ele-ment cleaned at the intervals specifiedin the periodic maintenance and lubri-cation chart.

To check the engine oil level

1. Place the vehicle on a level sur-face and hold it in an upright posi-tion.

NOTE:

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

false reading.

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

3. Wait a few minutes until the oil set-tles, and then check the oil levelthrough the check window locatedat the bottom-right side of thecrankcase.

NOTE:

The engine oil should be between the

minimum and maximum level marks.

4. If the engine oil is below the mini-mum level mark, add sufficient oilof the recommended type to raiseit to the correct level.

To change the engine oil (with or without oil filter element cleaning)

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

2. Place an oil pan under the engine

to collect the used oil.3. Remove the engine oil filler cap

and drain bolt to drain the oil fromthe crankcase.

1. Engine oil level check window2. Maximum level mark3. Minimum level mark

23

1

1. Engine oil filler cap

1


6-9

1

2

3

4

5

6

7

8

9

CAUTION:

ECA11000

When removing the engine oil drainbolt, the O-ring, compressionspring, and oil strainer will fall out.

Take care not to lose these parts.

NOTE:

Skip steps 4–9 if the oil filter element is

not being cleaned.

4. Remove the oil filter element drainbolt to drain the oil from the oil filterelement.

5. Remove the oil filter element coverby removing the bolts.

6. Remove the oil filter element andO-rings.

1. Engine oil drain bolt

1

1. O-ring2. Compression spring3. Oil strainer

3

2

1

1. Oil filter element cover2. Bolt3. Oil filter element drain bolt

1. Oil filter element2. O-ring

1

32

1

2

2


6-10

2

3

4

5

6

7

8

9

7. Check the O-ring for damage andreplace it if necessary.

8. Clean the oil filter element with sol-vent, and then install it.

NOTE:

Check the oil filter element for damage

and replace it if necessary.

9. Install the oil filter element cover byinstalling the bolts and the drainbolt, then tightening them to thespecified torques.

NOTE:

Make sure that the O-rings are properly

seated.

10. Clean the oil strainer with solvent,and then check it for damage andreplace it if necessary.

11. Install the oil strainer, compressionspring, O-ring and engine oil drainbolt, and then tighten the drain boltto the specified torque.

12. Add the specified amount of therecommended engine oil, and theninstall and tighten the oil filler cap.

CAUTION:

ECA11620

�

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

�

Make sure that no foreign mate-

rial enters the crankcase.

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

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

Tightening torques:

Oil filter element cover bolt:10 Nm (1.0 m·kgf, 7.2 ft·lbf)

Oil filter element drain bolt:10 Nm (1.0 m·kgf, 7.2 ft·lbf)

Tightening torque:

Engine oil drain bolt:43 Nm (4.3 m·kgf, 31 ft·lbf)

Recommended engine oil:

See page 8-1.

Oil quantity:

Without oil filter element removal:1.00 L (1.06 US qt) (0.88 Imp.qt)

With oil filter element removal:1.10 L (1.16 US qt) (0.97 Imp.qt)


6-11

1

2

3

4

5

6

7

8

9

EAU20831

Cleaning the air filter element and check hose

The air filter element should be cleanedat the intervals specified in the periodicmaintenance and lubrication chart.Clean the air filter element more fre-quently if you are riding in unusuallywet or dusty areas. In addition, the airfilter check hose must be frequentlychecked and cleaned if necessary.

To clean the air filter element

1. Remove panel A. (See page 6-5.)2. Remove the air filter case cover by

removing the screws.

3. Pull the air filter element out.4. Remove the sponge material from

the air filter element frame, clean itwith solvent, and then squeeze theremaining solvent out.

5. Apply oil of the recommended type

to the entire surface of the spongematerial, and then squeeze the ex-cess oil out.

NOTE:

The sponge material should be wet but

not dripping.

6. Pull the sponge material over theair filter element frame.

7. Insert the element into the air filtercase.

CAUTION:

ECA10480

�

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

�

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

become excessively worn.

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

9. Install the panel.

1. Air filter case cover2. Screw

1

22

1. Sponge material2. Air filter element frame

12

Recommended oil:

Foam air filter oil


6-12

2

3

4

5

6

7

8

9

To clean the air filter check hose

1. Check the hose at the bottom ofthe air filter case for accumulateddirt or water.

2. If dirt or water is visible, removethe hose, clean it, and then installit.

EAU21280

Adjusting the carburetor

The carburetor is an important part ofthe engine and requires very sophisti-cated adjustment. Therefore, most car-buretor adjustments should be left to aYamaha dealer, who has the neces-sary professional knowledge and expe-rience. The adjustment described in thefollowing section, however, may be ser-viced by the owner as part of routinemaintenance.

CAUTION:

ECA10550

The carburetor has been set and ex-tensively tested at the Yamaha fac-tory. Changing these settingswithout sufficient technical knowl-edge may result in poor perfor-

mance of or damage to the engine.

EAU21340

Adjusting the engine idling speed

The engine idling speed must bechecked and, if necessary, adjusted asfollows at the intervals specified in theperiodic maintenance and lubricationchart.The engine should be warm beforemaking this adjustment.

NOTE:

�

The engine is warm when it quicklyresponds to the throttle.

�

A diagnostic tachometer is needed

to make this adjustment.

1. Attach the tachometer to the sparkplug lead.

2. Check the engine idling speedand, if necessary, adjust it to spec-ification by turning the throttle stopscrew. To increase the engineidling speed, turn the screw in di-rection (a). To decrease the en-gine idling speed, turn the screw indirection (b).

1. Hose

1


6-13

1

2

3

4

5

6

7

8

9

NOTE:

If the specified idling speed cannot beobtained as described above, have a

Yamaha dealer make the adjustment.

EAU21381

Checking the throttle cable free play

The throttle cable free play should mea-sure 3.0–5.0 mm (0.12–0.20 in) at thethrottle grip. Periodically check thethrottle cable free play and, if neces-sary, have a Yamaha dealer adjust it.

EAU21401

Valve clearance

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

1. Throttle stop screw

Engine idling speed:

1350–1550 r/min

(a)

1

(b)

1. Throttle cable free play

1


6-14

2

3

4

5

6

7

8

9

EAU21571

Tires

To maximize the performance, durabil-ity, and safe operation of your motorcy-cle, note the following points regardingthe specified tires.

Tire air pressure

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

WARNING

EWA10500

�

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

�

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

for this model.

WARNING

EWA10530

Proper loading of your motorcycle isimportant for several characteristicsof your motorcycle; such as han-dling, braking, performance andsafety. Do not carry loosely packeditems that can shift. Securely packyour heaviest items close to the cen-ter of the motorcycle, and distributethe weight evenly from side to side.Check the condition and pressure ofyour tires. NEVER OVERLOADYOUR MOTORCYCLE. Make sure

the total weight of the cargo, rider,passenger, and accessories (fairing,saddlebags, etc. if approved for thismodel) does not exceed the maxi-mum load of the motorcycle. Opera-tion of an overloaded motorcyclecould cause tire damage, an acci-

dent, or even injury.

Tire inspection

The tires must be checked before eachride. If the tire shows crosswise lines(minimum tread depth), if the tire has anail or glass fragments in it, or if thesidewall is cracked, have a Yamaha

Tire air pressure (measured on cold tires):

0–90 kg (0–198 lb):

Front:125 kPa (18 psi) (1.25 kgf/cm

2

)Rear:

125 kPa (18 psi) (1.25 kgf/cm

2

)

90–180 kg (198–397 lb):

Front:150 kPa (22 psi) (1.50 kgf/cm

2

)Rear:

175 kPa (25 psi) (1.75 kgf/cm

2

)

Maximum load*:

180 kg (397 lb)* Total weight of rider, passenger, car-

go and accessories

1. Tire sidewall2. Tire wear indicator3. Tire tread depth

12

3


6-15

1

2

3

4

5

6

7

8

9

dealer replace the tire immediately.

NOTE:

The tire tread depth limits may differfrom country to country. Always comply

with the local regulations.

Tire information

This motorcycle is equipped with tubetires.

WARNING

EWA10460

�

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

�

After extensive tests, only thetires listed below have been ap-proved for this model by

Yamaha Motor Co., Ltd.

WARNING

EWA10560

�

It is dangerous to ride with aworn-out tire. When a tire treadbegins to show crosswise lines,have a Yamaha dealer replacethe tire immediately.

�

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

�

It is not recommended to patcha punctured tube. If unavoid-able, however, patch the tubevery carefully and replace it assoon as possible with a

high-quality product.

Minimum tire tread depth (front and rear):

1.0 mm (0.04 in)

Front tire:

Size:130/80-18M/C 66P

Manufacturer/model:BRIDGESTONE/TW31

Rear tire:

Size:180/80-14M/C 78P

Manufacturer/model:BRIDGESTONE/TW34


6-16

2

3

4

5

6

7

8

9

EAU21940

Spoke wheels

To maximize the performance, durabil-ity, and safe operation of your motorcy-cle, note the following points regardingthe specified wheels.

�

The wheel rims should be checkedfor cracks, bends or warpage, andthe spokes for looseness or dam-age before each ride. If any dam-age is found, have a Yamahadealer replace the wheel. Do notattempt even the smallest repair tothe wheel. A deformed or crackedwheel must be replaced.

�

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

�

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

EAU22041

Adjusting the clutch lever free play

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

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

2. To increase the clutch lever freeplay, turn the adjusting bolt in di-rection (a). To decrease the clutchlever free play, turn the adjusting

bolt in direction (b).

NOTE:

If the specified clutch lever free playcould be obtained as described above,tighten the locknut and skip the rest ofthe procedure, otherwise proceed as

follows.

3. Fully turn the adjusting bolt at theclutch lever in direction (a) to loos-en the clutch cable.

4. Loosen the locknut at the crank-case.

5. To increase the clutch lever freeplay, turn the adjusting nut in direc-tion (a). To decrease the clutch le-

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

1

2

3

(a)

(b)

1. Locknut (crankcase)2. Adjusting nut

(b)

(a)

2 1


6-17

1

2

3

4

5

6

7

8

9

ver free play, turn the adjusting nutin direction (b).

6. Tighten the locknut at the clutch le-ver and the crankcase.

EAU22092

Adjusting the brake lever free play

The brake lever free play should mea-sure 5.0–8.0 mm (0.20–0.31 in) asshown. Periodically check the brake le-ver free play and, if necessary, adjust itas follows.

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

2. To increase the brake lever freeplay, turn the adjusting screw in di-rection (a). To decrease the brakelever free play, turn the adjustingscrew in direction (b).

3. Tighten the locknut.

WARNING

EWA10630

�

After adjusting the brake leverfree play, check the free playand make sure that the brake isworking properly.

�

A soft or spongy feeling in thebrake lever can indicate thepresence of air in the hydraulicsystem. If there is air in the hy-draulic system, have a Yamahadealer bleed the system beforeoperating the motorcycle. Air inthe hydraulic system will dimin-ish the braking performance,which may result in loss of con-

trol and an accident.

1. Locknut2. Brake lever free play adjusting screw3. Brake lever free play

1 2 3

(b)

(a)


6-18

2

3

4

5

6

7

8

9

EAU22192

Adjusting the brake pedal position and free play

WARNING

EWA10670

It is advisable to have a Yamaha

dealer make these adjustments.

Brake pedal position

The top of the brake pedal should bepositioned approximately 15.0 mm(0.59 in) below the top of the footrest.Periodically check the brake pedal po-sition and, if necessary, adjust it as fol-lows.

1. Loosen the locknut at the brakepedal.

2. To raise the brake pedal, turn theadjusting bolt in direction (a). Tolower the brake pedal, turn the ad-justing bolt in direction (b).

3. Tighten the locknut.

WARNING

EWA11230

After adjusting the brake pedal posi-tion, the brake pedal free play must

be adjusted.

Brake pedal free play

The brake pedal free play should mea-sure 20.0–30.0 mm (0.79–1.18 in) asshown. Periodically check the brake

pedal free play and, if necessary, adjustit as follows.

To increase the brake pedal free play,turn the adjusting nut at the brake rod indirection (a). To decrease the brakepedal free play, turn the adjusting nut indirection (b).

1. Brake pedal position

1

1. Locknut2. Adjusting bolt3. Brake pedal position

21

3

(a)

(b)

1. Brake pedal free play

1


6-19

1

2

3

4

5

6

7

8

9

WARNING

EWA10680

�

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

�

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

�

After adjusting the brake pedalfree play, check the operation of

the brake light.

EAU22270

Adjusting the rear brake light switch

The rear brake light switch, which is ac-tivated by the brake pedal, is properlyadjusted when the brake light comeson just before braking takes effect. Ifnecessary, adjust the brake light switchas follows.Turn the adjusting nut while holding therear brake light switch in place. Tomake the brake light come on earlier,turn the adjusting nut in direction (a). Tomake the brake light come on later, turnthe adjusting nut in direction (b).

EAU22380

Checking the front brake pads and rear brake shoes

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

EAU22430

Front brake pads

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

1. Brake pedal free play adjusting nut

1(a)

(b)

1. Rear brake light switch2. Adjusting nut

1

2(a) (b)

1. Brake pad wear indicator groove

1


6-20

2

3

4

5

6

7

8

9

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

EAU22540

Rear brake shoes

The rear brake is provided with awear indicator, which allows you tocheck the brake shoe wear withouthaving to disassemble the brake. Tocheck the brake shoe wear, check theposition of the wear indicator whileapplying the brake. If a brake shoehas worn to the point that the wear in-dicator reaches the wear limit line,have a Yamaha dealer replace the

brake shoes as a set.

EAU32343

Checking the front brake fluid level

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

Observe these precautions:

�

When checking the fluid level,make sure that the top of the mas-

1. Wear indicator2. Wear limit line

21

1. Minimum level mark

1


6-21

1

2

3

4

5

6

7

8

9

ter cylinder is level by turning thehandlebars.

�

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

�

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

�

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

�

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

�

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

check the cause.

EAU22720

Changing the brake fluid

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

�

Oil seals: Replace every twoyears.

�

Brake hose: Replace every fouryears.

Recommended brake fluid:

DOT 4


6-22

2

3

4

5

6

7

8

9

EAU22760

Drive chain slack

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

EAU22771

To check the drive chain slack

1. Place the motorcycle on the side-stand.

NOTE:

When checking and adjusting the drivechain slack, there should be no weight

on the motorcycle.

2. Shift the transmission into the neu-tral position.

3. Move the rear wheel by pushingthe motorcycle to locate the tight-est portion of the drive chain, andthen measure the drive chain slackas shown.

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

EAU22830

To adjust the drive chain slack

1. Loosen the brake pedal free playadjusting nut.

2. Loosen the axle nut.3. To tighten the drive chain, turn the

adjusting plate on each side of theswingarm in direction (a). To loos-en the drive chain, turn the adjust-ing plate on each side of theswingarm in direction (b), and thenpush the rear wheel forward.

NOTE:

Make sure that both adjusting platesare in the same position for proper

wheel alignment.

CAUTION:

ECA10570

Improper drive chain slack will over-

Drive chain slack:

35.0–60.0 mm (1.38–2.36 in)

1. Drive chain slack

1

1. Brake pedal free play adjusting nut2. Axle nut3. Adjusting plate

3

2

1

(a)

(b)


6-23

1

2

3

4

5

6

7

8

9

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

specified limits.

4. Tighten the axle nut to the speci-fied torque.

5. Adjust the brake pedal free play.(See page 6-18.)

WARNING

EWA10660

After adjusting the brake pedal freeplay, check the operation of the

brake light.

EAU23013

Cleaning and lubricating the drive chain

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

CAUTION:

ECA10581

The drive chain must be lubricatedafter washing the motorcycle and

riding in the rain.

1. Remove all dirt and mud from thedrive chain with a brush or cloth.

NOTE:

For a thorough cleaning, have aYamaha dealer remove the drive chain

and soak it in solvent.

2. Spray Yamaha Chain and CableLube or a high-quality spray-typedrive chain lubricant on both sidesand on the middle of the chain,making sure that all side platesand rollers have been sufficiently

oiled.

Tightening torque:

Axle nut:90 Nm (9.0 m·kgf, 65 ft·lbf)


6-24

2

3

4

5

6

7

8

9

EAU23100

Checking and lubricating the cables

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

WARNING

EWA10720

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

conditions.

EAU23111

Checking and lubricating the throttle grip and cable

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

EAU23131

Checking and lubricating the brake and shift pedals

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

Recommended lubricant:

Engine oil


Lithium-soap-based grease (all-pur-pose grease)


6-25

1

2

3

4

5

6

7

8

9

EAU23140

Checking and lubricating the brake and clutch levers

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

EAU23200

Checking and lubricating the sidestand

The operation of the sidestand shouldbe checked before each ride, and thesidestand pivot and metal-to-metalcontact surfaces should be lubricated ifnecessary.

WARNING

EWA10730

If the sidestand does not move upand down smoothly, have a Yamaha

dealer check or repair it.

EAU23250

Lubricating the rear suspension

The pivoting points of the rear suspen-sion must be lubricated at the intervalsspecified in the periodic maintenanceand lubrication chart.





1. Grease nipple


Lithium-soap-based grease

1


6-26

2

3

4

5

6

7

8

9

EAU23271

Checking the front fork

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

To check the condition

WARNING

EWA10750

Securely support the vehicle so that

there is no danger of it falling over.

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

To check the operation

1. Place the vehicle on a level sur-face and hold it in an upright posi-tion.

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

CAUTION:

ECA10590

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

pair it.

EAU23280

Checking the steering

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

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

WARNING

EWA10750

Securely support the vehicle so that

there is no danger of it falling over.

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


6-27

1

2

3

4

5

6

7

8

9

EAU23290

Checking the wheel bearings

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

EAU23361

Battery

A poorly maintained battery will corrodeand discharge quickly. The electrolytelevel, battery lead connections andbreather hose routing should bechecked before each ride and at the in-tervals specified in the periodic mainte-nance and lubrication chart.

To check the electrolyte level

1. Remove the seat. (See page 3-8.)2. Disconnect the negative battery

lead from the battery.3. Disconnect the positive battery

lead and the battery breather hosefrom the battery.

4. Unhook the battery band, and thenpull the battery out of the batterycompartment.


6-28

2

3

4

5

6

7

8

9

5. Place the battery on a level sur-face, and then check the electro-lyte level in the battery.

NOTE:

The electrolyte should be between the

minimum and maximum level marks.

6. If the electrolyte is at or below theminimum level mark, add distilledwater to raise the electrolyte to themaximum level mark.

WARNING

EWA10760

�

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

�

EXTERNAL: Flush with plenty

of water.

�

INTERNAL: Drink large quan-tities of water or milk and im-mediately call a physician.

�

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

�

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

�

KEEP THIS AND ALL BATTER-IES OUT OF THE REACH OF

CHILDREN.

CAUTION:

ECA10610

Use only distilled water, as tap watercontains minerals that are harmful

to the battery.

7. Place the battery in the batterycompartment, and then hook thebattery band onto the holder.

8. Connect the breather hose to thebattery and make sure that it isproperly routed.

1. Battery2. Negative battery lead3. Positive battery lead (red)4. Battery breather hose5. Battery band

4

1 2

35

1. Maximum level mark2. Minimum level mark

1

2


6-29

1

2

3

4

5

6

7

8

9

9. Connect and tighten the positivebattery lead to the battery’s posi-tive (+) terminal.

10. Connect and tighten the negativebattery lead to the battery’s nega-

tive (-) terminal.11. Install the seat.

To store the battery

1. If the vehicle will not be used formore than one month, remove thebattery, fully charge it, and thenplace it in a cool, dry place.

2. If the battery will be stored for morethan two months, check the specif-ic gravity of the electrolyte at leastonce a month and fully charge thebattery whenever necessary.

3. Fully charge the battery before in-stallation.

4. After installation, make sure thatthe battery leads are properly con-nected to the battery terminals andthat the breather hose is properlyrouted, in good condition, and notobstructed.

CAUTION:

ECA10600

If the breather hose is positioned insuch a way that the frame is ex-posed to electrolyte or gas expelledfrom the battery, the frame couldsuffer structural and external dam-

ages.

1. Battery breather hose

1. Battery2. Battery breather hose

1

1

2


6-30

2

3

4

5

6

7

8

9

EAU23502

Replacing the fuse

The fuse holder is located behind panelB. (See page 6-5.)If the fuse is blown, replace it as fol-lows.

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

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

CAUTION:

ECA10640

Do not use a fuse of a higher amper-

age rating than recommended toavoid causing extensive damage tothe electrical system and possibly a

fire.

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

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

EAU23811

Replacing the headlight bulb

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

1. Remove cowling A. (Seepage 6-5.)

2. Remove the headlight unit by re-moving the bolts.

3. Disconnect the headlight coupler,and then remove the headlightbulb cover.

1. Fuse2. Spare fuse

Specified fuse:

20.0 A

1

2

1. Bolt

1


6-31

1

2

3

4

5

6

7

8

9

4. Remove the headlight bulb holderby turning it counterclockwise, andthen remove the defective bulb.

WARNING

EWA10790

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

down.

5. Place a new bulb into position, andthen secure it with the bulb holder.

CAUTION:

ECA10660

Do not touch the glass part of theheadlight bulb to keep it free fromoil, otherwise the transparency ofthe glass, the luminosity of the bulb,and the bulb life will be adversely af-fected. Thoroughly clean off any dirt

and fingerprints on the headlightbulb using a cloth moistened with al-

cohol or thinner.

6. Install the bulb cover, and thenconnect the coupler.

7. Install the headlight unit by install-ing the bolts.

1. Headlight coupler2. Headlight bulb cover

1

2

1. Headlight bulb holder

1

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

1


6-32

2

3

4

5

6

7

8

9

8. Install the cowling.9. Have a Yamaha dealer adjust the

headlight beam if necessary.

EAU24131

Replacing the tail/brake light bulb

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

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

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

4. Install the lens by installing thescrews.

CAUTION:

ECA10680

Do not overtighten the screws, oth-

erwise the lens may break.

1. Screw

1

1. Tail/brake light bulb

1


6-33

1

2

3

4

5

6

7

8

9

EAU24210

Replacing a turn signal light bulb

1. Remove the turn signal lens by re-moving the screws.

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

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

4. Install the lens by installing thescrews.

CAUTION:

ECA10680

Do not overtighten the screws, oth-

erwise the lens may break.

EAU24350

Supporting the motorcycle

Since this model is not equipped with acenterstand, follow these precautionswhen removing the front and rearwheel or performing other maintenancerequiring the motorcycle to stand up-right. Check that the motorcycle is in astable and level position before startingany maintenance. A strong woodenbox can be placed under the engine foradded stability.

To service the front wheel

1. Stabilize the rear of the motorcycleby using a motorcycle stand or, ifan additional motorcycle stand isnot available, by placing a jack un-der the frame in front of the rearwheel.

2. Raise the front wheel off theground by using a motorcyclestand.

To service the rear wheel

Raise the rear wheel off the ground byusing a motorcycle stand or, if a motor-cycle stand is not available, by placinga jack either under each side of the

1. Screw2. Turn signal light lens3. Turn signal light bulb

2

3

1


6-34

2

3

4

5

6

7

8

9

frame in front of the rear wheel or undereach side of the swingarm.

EAU24360

Front wheel

EAU24580

To remove the front wheel

WARNING

EWA10820

�

It is advisable to have a Yamahadealer service the wheel.

�

Securely support the motorcy-cle so that there is no danger of

it falling over.

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

2. Loosen the axle nut.

3. Lift the front wheel off the ground

according to the procedure onpage 6-33.

4. Remove the axle nut, pull thewheel axle out, and then removethe wheel.

CAUTION:

ECA11070

Do not apply the brake after thewheel has been removed togetherwith the brake disc, otherwise the

brake pads will be forced shut.

EAU24981

To install the front wheel

1. Install the speedometer gear unitinto the wheel hub so that the pro-jections mesh with the slots.

1. Speedometer cable2. Axle nut

1

2

1. Speedometer gear unit

1


6-35

1

2

3

4

5

6

7

8

9

2. Lift the wheel up between the forklegs.

NOTE:

Make sure that there is enough spacebetween the brake pads before insert-ing the brake disc and that the slot inthe speedometer gear unit fits over the

retainer on the fork leg.

3. Insert the wheel axle, and then in-stall the axle nut.

4. Lower the front wheel so that it ison the ground.

5. Tighten the axle nut to the speci-fied torque.

6. Connect the speedometer cable.

EAU25080

Rear wheel

EAU25420

To remove the rear wheel

WARNING

EWA10820

�

It is advisable to have a Yamahadealer service the wheel.

�

Securely support the motorcy-cle so that there is no danger of

it falling over.

1. Loosen the axle nut.2. Remove the brake pedal free play

adjusting nut, and then disconnectthe brake rod from the brake cam-shaft lever.

3. Turn the drive chain adjustingplate on each side of the swingarmfully in direction (a).

1. Retainer2. Speedometer cable

21

Tightening torque:



6-36

2

3

4

5

6

7

8

9

4. Lift the rear wheel off the groundaccording to the procedure onpage 6-33.

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

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

NOTE:

The drive chain does not need to bedisassembled in order to remove and

install the wheel.

7. Remove the wheel.

EAU25761

To install the rear wheel

1. Insert the wheel axle from theleft-hand side.

NOTE:

Make sure that the drive chain adjust-ing plates are installed with thepunched sides facing to the outsideand that the slot in the brake shoe plate

fits over the retainer on the swingarm.

2. Install the drive chain onto the rearsprocket, and then adjust the drivechain slack. (See page 6-22.)

3. Install the axle nut, and then lowerthe rear wheel so that it is on theground.

4. Tighten the axle nut to the speci-

fied torque.

5. Install the brake rod onto the brakecamshaft lever, and then install thebrake pedal free play adjusting nutonto the brake rod.

6. Adjust the brake pedal free play.(See page 6-18.)

WARNING

EWA10660

After adjusting the brake pedal freeplay, check the operation of the

brake light.

1. Axle nut2. Brake pedal free play adjusting nut3. Brake rod4. Brake camshaft lever5. Drive chain slack adjusting plate

5

2

1

3 4

(a)

1. Retainer

1

Tightening torque:



6-37

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EAU25850

Troubleshooting

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


6-38

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EAU25962

Troubleshooting chart

WARNING

EWA10840

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

Check the fuel level in the fuel tank.

1. FuelThere isenough fuel.

There isno fuel.

Check the compression.

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

Operate theelectric starter.

2. CompressionThere is compression.

There is no compression.

Check the ignition.

Have a Yamaha dealer check the vehicle.

Remove the spark plug and check the electrodes.

3. IgnitionWet

Dry

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

Have a Yamaha dealer check the vehicle.

The engine does not start. Have a Yamaha dealer check the vehicle.

The engine does not start.Check the battery.

Open the throttle halfway and operate the electric starter.

Operate theelectric starter.

4. BatteryThe engine turns overquickly.

The engine turns overslowly.

The battery is good.

Check fluid, recharge, check connections.

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EAU26001

Care

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

Before cleaning

1. Cover the muffler outlet with aplastic bag after the engine hascooled down.

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

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

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

Cleaning

CAUTION:

ECA10770

�

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

�

Improper cleaning can damagewindshields, cowlings, panelsand other plastic parts. Use onlya soft, clean cloth or spongewith mild detergent and water toclean plastic.

�

Do not use any harsh chemicalproducts on plastic parts. Besure to avoid using cloths orsponges which have been incontact with strong or abrasive

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

�

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

�

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

washing.


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

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

NOTE:

Salt sprayed on roads in the winter may

remain well into spring.

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

CAUTION:

ECA10790

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

salt.

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

After cleaning

1. Dry the motorcycle with a chamoisor an absorbing cloth.

2. Immediately dry the drive chainand lubricate it to prevent it fromrusting.

3. Use a chrome polish to shinechrome, aluminum and stain-less-steel parts, including the ex-haust system. (Even the thermallyinduced discoloring of stain-less-steel exhaust systems can beremoved through polishing.)

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

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

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

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

before storing or covering it.

WARNING

EWA11130

�

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

�

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

nering behavior.

CAUTION:

ECA10800

�

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

�

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

�

Avoid using abrasive polishingcompounds as they will wear

away the paint.


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NOTE:

Consult a Yamaha dealer for advice on

what products to use.

EAU26150

Storage

Short-term

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

CAUTION:

ECA10810

�

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

�

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

cals are stored.

Long-term

Before storing your motorcycle for sev-eral months:

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

2. For motorcycles equipped with afuel cock that has an “OFF” posi-tion: Turn the fuel cock lever to

“OFF”.3. Drain the carburetor float chamber

by loosening the drain bolt; this willprevent fuel deposits from buildingup. Pour the drained fuel into thefuel tank.

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

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

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

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

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

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

e. Remove the spark plug capfrom the spark plug, and then


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install the spark plug and thespark plug cap.

WARNING

EWA10950

To prevent damage or injury fromsparking, make sure to ground thespark plug electrodes while turning

the engine over.

6. Lubricate all control cables and thepivoting points of all levers andpedals as well as of the sidestand/centerstand.

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

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

9. Remove the battery and fullycharge it. Store it in a cool, dryplace and charge it once a month.Do not store the battery in an ex-cessively cold or warm place [less

than 0 °C (30 °F) or more than30 °C (90 °F)]. For more informa-tion on storing the battery, seepage 6-27.

NOTE:

Make any necessary repairs before

storing the motorcycle.

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9

SPECIFICATIONS

EAU2633H

Dimensions:

Overall length: 2090 mm (82.3 in)

Overall width: 820 mm (32.3 in)

Overall height: 1120 mm (44.1 in)

Seat height: 790 mm (31.1 in)

Wheelbase: 1330 mm (52.4 in)

Ground clearance: 260 mm (10.24 in)

Minimum turning radius: 2300 mm (90.6 in)

Weight:

With oil and fuel: 126.0 kg (278 lb)

Engine:

Engine type: Air cooled 4-stroke, SOHC

Cylinder arrangement: Forward-inclined single cylinder

Displacement: 196.0 cm

3

Bore

×

stroke: 67.0

×

55.7 mm (2.64

×

2.19 in)Compression ratio:

9.50 :1Starting system:

Electric starter and kickstarter

Lubrication system: Wet sump

Engine oil:

Type: SAE10W30, SAE10W40, SAE15W40,SAE20W40 or SAE20W50

Recommended engine oil grade: API service SE, SF, SG type or higher

Engine oil quantity:

Without oil filter element removal: 1.00 L (1.06 US qt) (0.88 Imp.qt)

With oil filter element removal: 1.10 L (1.16 US qt) (0.97 Imp.qt)

Air filter:

Air filter element: Wet element

Fuel:

Recommended fuel: Unleaded gasoline only

Fuel tank capacity: 7.0 L (1.85 US gal) (1.54 Imp.gal)

Fuel reserve amount: 1.7 L (0.45 US gal) (0.37 Imp.gal)

Carburetor:

Manufacturer: TEIKEI

Type

×

quantity: MV28 x 1

Spark plug (s):

Manufacturer/model: NGK/DR8EA

Manufacturer/model: DENSO/X24ESR-U

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

Clutch:

Clutch type: Wet, multiple-disc

Transmission:

Primary reduction system: Spur gear

Primary reduction ratio: 73/22 (3.318)

Secondary reduction system: Chain drive

Secondary reduction ratio: 45/14 (3.214)

Transmission type: Constant mesh 5-speed

Operation: Left foot operation

Gear ratio:

1st: 34/12 (2.833)

2nd: 34/19 (1.789)

-20 -10 0 10 20 30 40 50 ˚C

SAE 10W-30

SAE 15W-40

SAE 20W-40

SAE 20W-50

SAE 10W-40

SPECIFICATIONS

8-2

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3rd: 29/22 (1.318)

4th: 26/25 (1.040)

5th: 23/28 (0.821)

Chassis:

Frame type: Diamond

Caster angle: 26.08 °

Trail: 96.0 mm (3.78 in)

Front tire:

Type: With tube

Size: 130/80-18M/C 66P

Manufacturer/model: BRIDGESTONE/TW31

Rear tire:

Type: With tube

Size: 180/80-14M/C 78P

Manufacturer/model: BRIDGESTONE/TW34

Loading:

Maximum load: 180 kg (397 lb)

* (Total weight of rider, passenger, cargo and accessories)

Tire air pressure (measured on coldtires):

Loading condition: 0–90 kg (0–198 lb)

Front: 125 kPa (18 psi) (1.25 kgf/cm

2

)Rear:

125 kPa (18 psi) (1.25 kgf/cm

2

)Loading condition:

90–180 kg (198–397 lb)Front:

150 kPa (22 psi) (1.50 kgf/cm

2

)Rear:

175 kPa (25 psi) (1.75 kgf/cm

2

)

Front wheel:

Wheel type: Spoke wheel

Rim size: 18x2.50

Rear wheel:

Wheel type: Spoke wheel

Rim size: 14M/C x MT4.50

Front brake:

Type: Single disc brake

Operation: Right hand operation

Recommended fluid: DOT 4

Rear brake:

Type: Drum brake

Operation: Right foot operation

Front suspension:

Type: Telescopic fork

Spring/shock absorber type: Coil spring/oil damper

Wheel travel: 160.0 mm (6.30 in)

Rear suspension:

Type: Swingarm (monocross)

Spring/shock absorber type: Coil spring/gas-oil damper

Wheel travel: 150.0 mm (5.91 in)

Electrical system:

Ignition system: CDI

Charging system: AC magneto

Battery:

Model: YB7C-A

Voltage, capacity: 12 V, 7.0 Ah

Headlight:

Bulb type: Halogen bulb

SPECIFICATIONS

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Bulb voltage, wattage

×

quantity:

Headlight: 12 V, 60 W/55.0 W

×

1Tail/brake light:

12 V, 5.0 W/21.0 W

×

1Front turn signal light:

12 V, 21.0 W

×

2Rear turn signal light:

12 V, 21.0 W

×

2Meter lighting:

12 V, 3.4 W

×

1Neutral indicator light:

12 V, 3.4 W

×

1High beam indicator light:

12 V, 3.4 W

×

1Turn signal indicator light:

12 V, 3.4 W

×

1

Fuse:

Fuse: 20.0 A

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EAU26351

Identification numbers

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

VEHICLE IDENTIFICATION NUMBER:

MODEL LABEL INFORMATION:

EAU26390

Key identification number

The key identification number isstamped into the key. Record this num-ber in the space provided and use it forreference when ordering a new key.

EAU26400

Vehicle identification number

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

NOTE:

The vehicle identification number isused to identify your motorcycle andmay be used to register your motorcy-cle with the licensing authority in your

area.

1. Key identification number

1

1. Vehicle identification number

1


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EAU26460

Model label

The model label is affixed to the loca-tion shown. Record the information onthis label in the space provided. This in-formation will be needed when orderingspare parts from a Yamaha dealer.

EAU26570

Motorcycle noise regulation (for Australia)

TAMPERING WITH NOISE CON-TROL SYSTEM PROHIBITED:

Owners are warned that the law mayprohibit:

�

The removal or rendering inopera-tive by any person other than forpurposes of maintenance, repairor replacement, of any device orelement of design incorporatedinto any new vehicle for the pur-pose of noise control prior to itssale or delivery to the ultimate pur-chaser or while it is in use; and

�

The use of the vehicle after suchdevice or element of design hasbeen removed or rendered inoper-ative by any person.

1. Model label

1

INDEX

A

Air filter element and check hose, cleaning .................................................6-11

B

Battery .....................................................6-27Brake and clutch levers, checking and

lubricating ..............................................6-25Brake and shift pedals, checking and

lubricating ..............................................6-24Brake fluid, changing ...............................6-21Brake fluid level, checking .......................6-20Brake lever ................................................3-4Brake lever free play, adjusting ...............6-17Brake pads and shoes, checking.............6-19Brake pedal ...............................................3-5Brake pedal position and free play,

adjusting ................................................6-18

C

Cables, checking and lubricating.............6-24Carburetor, adjusting ...............................6-12Care...........................................................7-1Carrier........................................................3-9Clutch lever................................................3-4Clutch lever free play, adjusting ..............6-16Cowling and panels, removing and

installing ..................................................6-5

D

Dimmer switch ...........................................3-3Drive chain, cleaning and lubricating.......6-23Drive chain slack .....................................6-22

E

Engine break-in .........................................5-3Engine idling speed .................................6-12Engine oil and oil filter element..................6-8

Engine, starting a warm.............................5-2Engine stop switch ....................................3-3

F

Front fork, checking.................................6-26Fuel ...........................................................3-6Fuel cock ...................................................3-6Fuel consumption, tips for reducing ..........5-3Fuel tank cap.............................................3-5Fuse, replacing........................................6-30

H

Handlebar switches ...................................3-3Headlight bulb, replacing.........................6-30Helmet holder ............................................3-9High beam indicator light...........................3-2Horn switch................................................3-3

I

Identification numbers ...............................9-1Ignition circuit cut-off system ...................3-11Indicator lights ...........................................3-2

K

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

L

Labels, location of .....................................1-5Luggage strap holders.............................3-10

M

Main switch/steering lock ..........................3-1Model label ................................................9-2

N

Neutral indicator light.................................3-2Noise regulation (for Australia)..................9-2

P

Parking ......................................................5-4

Part locations ............................................ 2-1Periodic maintenance and lubrication

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

R

Rear brake light switch, adjusting ........... 6-19Rear suspension, lubricating................... 6-25

S

Safety information ..................................... 1-1Seat........................................................... 3-8Shifting ...................................................... 5-2Shift pedal ................................................. 3-4Shock absorber ......................................... 3-9Sidestand ................................................ 3-10Sidestand, checking and lubricating........ 6-25Spark plug, checking................................. 6-6Specifications ............................................ 8-1Speedometer unit...................................... 3-2Starter (choke) knob.................................. 3-7Starting a cold engine ............................... 5-1Start switch................................................ 3-3Steering, checking................................... 6-26Storage...................................................... 7-3Supporting the motorcycle ...................... 6-33

T

Tail/brake light bulb, replacing ................ 6-32Throttle cable free play, checking ........... 6-13Throttle grip and cable, checking and

lubricating ............................................. 6-24Tires ........................................................ 6-14Tool kit....................................................... 6-1Troubleshooting ...................................... 6-37Troubleshooting chart ............................. 6-38Turn signal indicator light .......................... 3-2

INDEX

Turn signal light bulb, replacing .............. 6-33Turn signal switch ..................................... 3-3

V

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

W

Wheel bearings, checking....................... 6-27Wheel (front) ........................................... 6-34Wheel (rear) ............................................ 6-35Wheels .................................................... 6-16

PRINTED ON RECYCLED PAPERYAMAHA MOTOR CO., LTD.

PRINTED IN JAPAN2006.6–0.1×1 !

(E)

PRINTED ON RECYCLED PAPERYAMAHA MOTOR CO., LTD.

PRINTED IN JAPAN2006.6–0.1×1 !

(E)

3xt-28199-2g tw200ew · this motorcycle is designed to car-ry the operator and a passenger. the...

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