User manual YAMAHA DT125R-2000

OWNER'S MANUAL DT125R 3MB-28199-E7 INTRODUCTION EAU00001 Welcome to the Yamaha world of motorcycling! As the owner of a DT125R, you are benefiting from Yamaha's vast experience in and newest technology for the design and the 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 your DT125R's advantages. The owner's manual does not only instruct you in how to operate, inspect and maintain your motorcycle, but also in how to safeguard yourself and others from trouble and injury. In addition, the many tips given in this manual will help to keep your motorcycle in the best possible condition. If you have any further questions, do not hesitate to contact your Yamaha dealer. The Yamaha team wishes you many safe and pleasant rides. So, remember to put safety first! 1 2 4 5 6 7 8 9 IMPORTANT MANUAL INFORMATION EAU00005 Particularly important information is distinguished in this manual by the following notations: 1 2 3 4 5 NOTE: 6 7 8 9 NOTE: 8 This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold. 8 Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most current product information available at the time of printing, there may be minor discrepancies between your motorcycle and this manual. If there is any question concerning this manual, please consult your Yamaha dealer. A NOTE provides key information to make procedures easier or clearer. Q w cC The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator, a bystander or a person inspecting or repairing the motorcycle. A CAUTION indicates special precautions that must be taken to avoid damage to the motorcycle. IMPORTANT MANUAL INFORMATION w EW000002 PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE. 1 2 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 EAU03337 DT125R OWNER'S MANUAL © 2000 by Yamaha Motor Co., Ltd. 1st Edition, December 2000 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan. EAU00009 TABLE OF CONTENTS 1 2 GIVE SAFETY THE RIGHT OF WAY..................1-1 DESCRIPTION ....................................................2-1 Left view............................................................2-1 Right view .........................................................2-2 Controls/Instruments.........................................2-3 INSTRUMENT AND CONTROL FUNCTIONS ....3-1 Main switch .......................................................3-1 Indicator lights...................................................3-1 Oil level indicator circuit check..........................3-2 Speedometer ....................................................3-3 Tachometer.......................................................3-3 Engine temperature gauge ...............................3-4 Handlebar switches ..........................................3-4 Clutch lever .......................................................3-5 Shift pedal .........................................................3-5 Front brake lever...............................................3-6 Rear brake pedal ..............................................3-6 Fuel tank cap ....................................................3-6 Fuel (except for Switzerland and Austria) .........3-7 Fuel (for Switzerland and Austria) ....................3-7 Catalyzer (for Switzerland and Austria) ............3-8 Two-stroke engine oil........................................3-9 Fuel cock ..........................................................3-9 Starter (choke) "1".........................................3-10 Kick starter ......................................................3-11 Steering lock ...................................................3-11 Seat ................................................................3-12 Helmet holder .................................................3-12 Rear shock absorber adjustment ....................3-13 Rear carrier .....................................................3-14 Note on handling of the Yamaha Energy Induction System (Y.E.I.S.).............................3-14 Y.P.V.S. (Yamaha Power Valve System) ......................3-15 Sidestand ........................................................3-15 Sidestand switch operation check ..................3-16 1 2 3 4 5 6 7 8 9 3 4 PRE-OPERATION CHECKS ...............................4-1 Pre-operation check list ....................................4-1 OPERATION AND IMPORTANT RIDING POINTS................................................................5-1 Starting the engine............................................5-1 Starting a warm engine .....................................5-3 Shifting ..............................................................5-4 Recommended shift points (for Switzerland only) ........................................5-4 Tips for reducing fuel consumption ...................5-5 Engine break-in.................................................5-5 Parking..............................................................5-6 5 TABLE OF CONTENTS 6 1 2 3 4 5 6 7 8 9 PERIODIC MAINTENANCE AND MINOR REPAIR................................................................6-1 Tool kit ..............................................................6-1 Periodic maintenance and lubrication chart ......6-3 Cowling removal and installation ......................6-6 Cowling A..........................................................6-6 Cowling B..........................................................6-7 Cowling C .........................................................6-8 Panel removal and installation ..........................6-8 Panel D .............................................................6-9 Panel E .............................................................6-9 Spark plug.......................................................6-10 Transmission oil ..............................................6-11 Cooling system ...............................................6-12 Changing the coolant ......................................6-13 Air filter............................................................6-15 Carburetor adjustment ....................................6-16 Idle speed adjustment.....................................6-17 Throttle cable free play adjustment.................6-17 Tires ................................................................6-18 Wheels ............................................................6-20 Clutch lever free play adjustment ...................6-21 Front brake lever free play adjustment ...........6-21 Rear brake pedal height adjustment ...............6-22 Brake light switch adjustment .........................6-23 Checking the front and rear brake pads .........6-23 Inspecting the brake fluid level .......................6-24 Brake fluid replacement ..................................6-25 Drive chain slack check ..................................6-25 Drive chain slack adjustment ..........................6-26 Drive chain lubrication ....................................6-26 Cable inspection and lubrication .....................6-27 Throttle cable and grip lubrication...................6-27 Autolube pump adjustment .............................6-28 Brake and shift pedal lubrication.....................6-28 Brake and clutch lever lubrication ...................6-28 Sidestand lubrication ......................................6-29 Front fork inspection .......................................6-29 Steering inspection .........................................6-30 Wheel bearings ...............................................6-30 Battery ............................................................6-31 Fuse replacement ...........................................6-33 Headlight bulb replacement ............................6-33 Turn signal light bulb replacement ..................6-35 Tail/brake light bulb replacement ....................6-35 Supporting the motorcycle ..............................6-36 Front wheel removal .......................................6-36 Front wheel installation ...................................6-37 Rear wheel removal ........................................6-38 Rear wheel installation....................................6-39 Troubleshooting ..............................................6-39 Troubleshooting chart .....................................6-40 TABLE OF CONTENTS 7 MOTORCYCLE CARE AND STORAGE .............7-1 Care ..................................................................7-1 Storage .............................................................7-4 SPECIFICATIONS ...............................................8-1 How to use the conversion table.......................8-5 CONSUMER INFORMATION..............................9-1 Identification number records ...........................9-1 Key identification number .................................9-1 Vehicle identification number ............................9-1 Model label .......................................................9-2 1 2 3 4 5 6 7 8 9 8 9 Q GIVE SAFETY THE RIGHT OF WAY EAU00021 1 2 3 4 5 6 7 8 9 Motorcycles are fascinating vehicles, which can give you an unsurpassed feeling of power and freedom. However, they also impose certain limits, which you must accept; even the best motorcycle does not ignore the laws of physics. Regular care and maintenance are essential for preserving your motorcycle's value and operating condition. Moreover, what is true for the motorcycle is also true for the rider: good performance depends on being in good shape. Riding under the influence of medication, drugs and alcohol is, of course, out of the question. Motorcycle riders - more than car drivers - must always be at their mental and physical best. Under the influence of even small amounts of alcohol, there is a tendency to take dangerous risks. Protective clothing is as essential for the motorcycle rider as seat belts are for car drivers and passengers. Always wear a complete motorcycle suit (whether made of leather or tear-resistant synthetic materials with protectors), sturdy boots, motorcycle gloves and a properly fitting helmet. Optimum protective wear, however, should not encourage carelessness. Though full-coverage helmets and suits, in particular, create an illusion of total safety and protection, motorcyclists will always be vulnerable. Riders who lack critical self-control run the risk of going too fast and are apt to take chances. This is even more dangerous in wet weather. The good motorcyclist rides safely, predictably and defensively - avoiding all dangers, including those caused by others. Enjoy your ride! 1-1 EAU00026 DESCRIPTION Left view 1 2 3 4 5 6 7 1 23 4 5 6 10 8 9 1. 2. 3. 4. 5. 6. Headlight Radiator cap Fuel cock Air filter Coolant reservoir tank Helmet holder (page 6-33) (page 6-13) (page 3-9) (page 6-15) (page 6-13) (page 3-12) 98 7. 8. 9. 10. 7 Starter (choke) Shift pedal Y.E.I.S. Y.P.V.S. (page 3-10) (page 3-5, 5-4) (page 3-14) (page 3-15) 2-1 DESCRIPTION Right view 11 12 13 1 2 3 4 5 6 7 15 14 8 11. 12. 13. 14. 15. Tool kit Fuse Engine oil tank Rear brake pedal Rear shock absorber spring preload adjusting nut (page 6-1) (page 6-33) (page 3-9) (page 3-6, 6-22) (page 3-13) 2-2 9 DESCRIPTION Controls/Instruments 16 1 2 3 4 5 6 7 8 9 17 18 19 20 21 22 25 16. 17. 18. 19. 20. Clutch lever Left handlebar switches Speedometer Coolant temperature gauge Tachometer (page 3-5, 6-21) (page 3-4) (page 3-3) (page 3-4) (page 3-3) 24 21. 22. 23. 24. 25. 2-3 23 Right handlebar switches Front brake lever Throttle grip Fuel tank cap Main switch (page 3-5) (page 3-6, 6-27) (page 6-17, 6-27) (page 3-6) (page 3-1) EAU00027 INSTRUMENT AND CONTROL FUNCTIONS EAU00063 ON OFF 4 123 High beam indicator light "&" This indicator comes on when the headlight high beam is used. EAU01313 1 2 3 4 5 6 7 8 9 EAU00028 Main switch The main switch controls the ignition and lighting systems. Its operation is described below. EAU00036 1. 2. 3. 4. Turn indicator light "5" High beam indicator light "&" Neutral indicator light "N" Oil level indicator light "7" EAU00056 Oil level indicator light "7" This indicator comes on when the oil level is low. This light circuit can be checked by the procedure on page 32. cC EC000000 Indicator lights EAU00057 Do not run the motorcycle until you know it has sufficient engine oil. NOTE Even if the oil is filled to the specified level, the indicator light may flicker when riding on a slope or during sudden acceleration or deceleration, but this is normal. ON Electrical circuits are switched on. The engine can be started. The key cannot be removed in this position. EAU00038 Turn indicator light "5" This indicator flashes when the turn switch is moved to the left or right. EAU00061 OFF All electrical circuits are switched off. The key can be removed in this position. Neutral indicator light "N" This indicator comes on when the transmission is in neutral. 3-1 INSTRUMENT AND CONTROL FUNCTIONS EAU00075 Oil level indicator circuit check 1 Turn the main switch to "ON". 2 Put the transmission in neutral. 3 4 5 Shift into gear. 6 7 8 9 Ask a Yamaha dealer to inspect electrical circuit. Engine oil level and electrical circuit are OK. Go ahead with riding. Supply engine oil. Oil level indicator light does not come on. Oil level indicator light comes on. Oil level indicator light does not come on. Oil level indicator light comes on. 3-2 INSTRUMENT AND CONTROL FUNCTIONS 2 1 NOTE: (for German model equipped with speed limiter only) This motorcycle is equipped with a speed limiter which prevents it from exceeding a top speed of 80 km/h. 1. Tachometer 2. Red zone EAU00102 EAU01087 1 1 2 2 3 4 5 6 7 4 1. 2. 3. 4. Speedometer Odometer Trip odometer Reset knob 3 Tachometer This model is equipped with a tachometer so the rider can monitor the engine speed and keep it within the ideal power range. Speedometer The speedometer shows riding speed. This speedometer is equipped with an odometer and trip odometer. The trip odometer can be reset to "0" with the reset knob. Use the trip odometer to estimate how far you can ride on a tank of fuel. This information will enable you to plan fuel stops in the future. cC EC000003 8 9 Do not operate in the red zone. Red zone: 10,500 r/min and above 3-3 INSTRUMENT AND CONTROL FUNCTIONS 1 2 1 2 3 4 5 6 7 8 9 1. Coolant temperature gauge 2. Red zone EAU01652 12 EAU00127 4 1. 2. 3. 4. Lights switch Dimmer switch Turn signal switch Horn switch "*" 3 Turn signal switch To signal a right-hand turn, push the switch to "6". To signal a left-hand turn, push the switch to "4". Once the switch is released it will return to the center position. To cancel the signal, push the switch in after it has returned to the center position. EAU00129 Coolant temperature gauge This gauge indicates the coolant temperature when the main switch is on. The engine operating temperature will vary with changes in weather and engine load. If the needle points to the red zone or higher, stop your motorcycle and let the engine cool. (See page 6-13 for details.) EAU00118 Horn switch "*" Press the switch to sound the horn. Handlebar switches EAU00134 cC EC000002 Lights switch Turning the light switch to "'", turns on the auxiliary light, meter lights and taillight. Turning the light switch to ":", turns the headlight on also. EAU00121 When the engine is overheated, do not continue riding. Dimmer switch Turn the switch to "&" for the high beam and to "%" for the low beam. 3-4 INSTRUMENT AND CONTROL FUNCTIONS 1 6 5 4 3 2 N 1 1 2 1 1. Engine stop switch EAU00138 1 1. Clutch lever EAU00155 3 4 EAU00157 1. Shift pedal N. Neutral Engine stop switch The engine stop switch is a safety device for use in an emergency such as when the motorcycle overturns or if trouble occurs in the throttle system. Turn the switch to "#" to start the engine. In case of emergency, turn the switch to "$" to stop the engine. Clutch lever The clutch lever is located on the left handlebar. Pull the clutch lever to the handlebar to disengage the clutch, and release the lever to engage the clutch. The lever should be pulled rapidly and released slowly for smooth clutch operation. Shift pedal This motorcycle is equipped with a constant-mesh 6-speed transmission. The shift pedal is located on the left side of the engine and is used in combination with the clutch when shifting. 5 6 7 8 9 3-5 INSTRUMENT AND CONTROL FUNCTIONS 1 1 2 1 2 1 3 3 4 5 6 7 8 9 1. Front brake lever EAU00158 1. Rear brake pedal EAU00162 Front brake lever The front brake lever is located on the right handlebar. Pull it toward the handlebar to apply the front brake. Rear brake pedal The rear brake pedal is on the right side of the motorcycle. Press down on the brake pedal to apply the rear brake. 1. Fuel tank cap 2. Unlock 3. Open EAU00177 Fuel tank cap To open Insert the key and turn it 1/4 turn counterclockwise. Turn the cap 1/3 turn counterclockwise and remove it from the tank. To close Put the cap in the filler neck and turn it 1/3 turn clockwise. Lock the cap by turning the key 1/4 turn clockwise, and remove the key. 3-6 INSTRUMENT AND CONTROL FUNCTIONS NOTE: The tank cap cannot be reinstalled unless it is unlocked. The key must remain in the cap until the cap is properly installed and locked onto the fuel tank. 2 1 2 4 3 1 1 2 3 1. Filler tube 2. Fuel level EAU01183 w EW000023 Be sure the cap is properly installed and locked in place before riding the motorcycle. Fuel (except for Switzerland and Austria) Make sure there is sufficient fuel in the tank. Fill the fuel tank to the bottom of the filler tube as shown in the illustration. 1. 2. 3. 4. Filler tube Filling nozzle Leaf valve Fuel level EAU01184 4 5 6 7 8 9 Fuel (for Switzerland and Austria) Make sure there is sufficient fuel in the tank. When refueling, be sure to insert the filling nozzle into the filler hole and fill the tank to the bottom of the filler tube as shown in the illustration. w EW000130 Do not overfill the fuel tank. Avoid spilling fuel on the hot engine. Do not fill the fuel tank above the bottom of the filler tube or it may overflow when the fuel heats up later and expands. 3-7 INSTRUMENT AND CONTROL FUNCTIONS w 1 2 3 4 5 6 7 8 9 EW000130 EAU00191 EAU01084 Catalyzer Recommended fuel: Regular unleaded gasoline with a research octane number of 91 or higher. Fuel tank capacity: Total: 10.0 L Reserve: 1.8 L NOTE: If knocking or pinging occurs, use a different brand of gasoline or higher octane grade. (for Switzerland and Austria) This motorcycle is equipped with a catalytic converter in the exhaust chamber. Do not overfill the fuel tank. Avoid spilling fuel on the hot engine. Do not fill the fuel tank above the bottom of the filler tube or it may overflow when the fuel heats up later and expands. w EW000128 cC EAU00185 Always wipe off spilled fuel immediately with a dry and clean soft cloth. Fuel may deteriorate painted surfaces or plastic parts. The exhaust system is hot during and directly after engine operation. Make sure the exhaust system has cooled down before making any adjustment to or lubricating the motorcycle. 3-8 INSTRUMENT AND CONTROL FUNCTIONS cC EC000114 OFF: closed position 1 RES The following must be observed to prevent a fire hazard or other damages. 8 Use only unleaded gasoline. Use of leaded gasoline will cause unrepairable damage to the catalytic converter. 8 Never park this motorcycle in an area that would cause a fire hazard such as grass or other materials that may easily burn. 8 Do not allow the engine to idle for very long. 1 2 2 OFF ON FUEL 1 1. Oil tank cap 2. Stopper EAU02956 3 4 5 6 7 1. Arrow mark positioned "OFF" EAU03050 Two-stroke engine oil Make sure there is sufficient twostroke engine oil in the oil tank. Add the recommended oil as necessary. Recommended oil: Yamalube 2 or 2-stroke engine oil (JASO FC grade or ISO EG-C, EG-D grade) Oil quantity: 1.2 L Fuel cock The fuel cock supplies fuel from the tank to the carburetor while filtering it also. The fuel cock has three positions: OFF With the lever in this position, fuel will not flow. Always return the lever to this position when the engine is not running. 8 9 3-9 INSTRUMENT AND CONTROL FUNCTIONS ON: normal position 1 OFF RES RES FUEL OFF ON FUEL RES: reserve position RES a 1 b 2 ON 1 3 4 5 6 7 8 9 ON 1 1. Arrow mark positioned "ON" 1. Arrow mark positioned "RES" 1. Starter (choke) "1" EAU02976 ON With the lever in this position, fuel flows to the carburetor. Normal riding is done with the lever in this position. RES This indicates reserve. If you run out of fuel while riding, move the lever to this position. Fill the tank at the first opportunity. Be sure to set the lever back to "ON" after refueling! Starter (choke) "1" Starting a cold engine requires a richer air-fuel mixture. A separate starter circuit supplies this mixture. Move in direction a to turn on the starter (choke). Move in direction b to turn off the starter (choke). 3-10 INSTRUMENT AND CONTROL FUNCTIONS 1 To unlock the steering Insert the key, push it in and turn it 1/8 turn counterclockwise so that it moves out. Then, release and remove the key. 1 2 3 1 1. Kick starter EAU00212 1. Steering lock EAU02934 4 5 6 7 8 9 Kick starter Rotate the kick starter away from the engine. Push the starter down lightly with your foot until the gears engage, then kick smoothly and forcefully to start the engine. This model has a primary-coupled kick starter so the engine can be started in any gear if the clutch is disengaged. However, shifting to neutral before starting is recommended. Steering lock To lock the steering Turn the handlebars all the way to the right and open the steering lock cover. Insert the key and turn it 1/8 turn counterclockwise. Then, push the key in while turning the handlebars slightly to the left and turn the key 1/8 turn clockwise. Check that the steering is locked, remove the key and close the lock cover. 3-11 INSTRUMENT AND CONTROL FUNCTIONS 1 1 2 3 4 5 6 7 8 9 1. Bolt (×2) EAU01648 1 1. Open Seat To remove 1. Remove panels D and E. (See page 6-9 for panel removal and installation procedures.) 2. Remove the seat bolts and lift the seat upward. To install 1. Insert the projections on the front of the seat into the holders, then tighten the seat bolts. 2. Install the panels. NOTE: Make sure that the seat is securely fitted. EAU00261 Helmet holder To open the helmet holder, insert the key in the lock and turn it as shown. To lock the helmet holder, turn the key to its original position. w EW000030 Never ride with a helmet in the helmet holder. The helmet may hit objects, causing loss of control and possibly an accident. 3-12 INSTRUMENT AND CONTROL FUNCTIONS b a 2 1 3. Tighten the locknut to the specified torque. "A" Tightening torque: Locknut: 55 Nm (5.5 m0kg) 1 2 EC000018 cC 1. Locknut 2. Adjusting nut EAU01650 3 4 5 6 7 8 9 Rear shock absorber adjustment This shock absorber is equipped with a spring preload adjuster. Adjust spring preload as follows. 1. Loosen the locknut. 2. Turn the adjusting nut in direction a to increase spring preload and in direction b to decrease spring preload. The spring preload is determined by the spring set length. Shortening the spring set length increases spring preload, lengthening the spring set length decreases spring preload. Spring preload: Minimum (soft): Distance "A" = 235 mm Standard: Distance "A" = 230 mm Maximum (hard): Distance "A" = 220 mm Always tighten the locknut against the spring adjusting nut and tighten the locknut to the specified torque. cC EC000015 Never attempt to turn an adjuster beyond the maximum or minimum setting. 3-13 INSTRUMENT AND CONTROL FUNCTIONS w 1 2 3 4 5 6 7 8 9 EAU00315 1 1 This shock absorber contains highly pressurized nitrogen gas. Read and understand the following information before handling the shock absorber. The manufacturer cannot be held responsible for property damage or personal injury that may result from improper handling. 8 Do not tamper with or attempt to open the cylinder assembly. 8 Do not subject the shock absorber to an open flame or other high heat source. This may cause the unit to explode due to excessive gas pressure. 8 Do not deform or damage the cylinder in any way. Cylinder damage will result in poor damping performance. 8 Take your shock absorber to a Yamaha dealer for any service. 2 1. Rear carrier EAU00320 1. Air chamber 2. Hose EAU00325 Rear carrier w EW000032 Do not exceed the load limit of 2 kg. Note on handling of the Yamaha Energy Induction System (Y.E.I.S.) Handle the air chamber and hose with special care. Improper installation or damaged parts will result in poor performance. Replace any cracked or damaged parts immediately. No modification of this system in any form can be made. cC EC000022 Never attempt to modify the Yamaha Energy Induction System. 3-14 INSTRUMENT AND CONTROL FUNCTIONS 1 cC EC000023 EAU00330 Sidestand This model is equipped with an ignition circuit cut-off system. The motorcycle must not be ridden when the sidestand is down. The sidestand is located on the left side of the frame. (Refer to page 5-1 for an explanation of this system.) 1 2 3 4 5 6 7 8 9 The Y.P.V.S. was set at the Yamaha factory after many tests. If the settings are disturbed by someone without sufficient technical knowledge, poor engine performance and damage may result. 1. Y.P.V.S. EAU00326 Y.P.V.S. (Yamaha Power Valve System) The Y.P.V.S. is a vital part of the engine and requires very sophisticated adjustment. Adjustment should be left to a Yamaha dealer who has the professional knowledge and experience to do so. The Y.P.V.S. operation can be heard in the following instances: 8 When the main switch is turned on and the engine is started. 8 When the engine stalls while the main switch is on. cC EC000024 If the Y.P.V.S. does not operate, ask a Yamaha dealer to inspect the vehicle. 3-15 INSTRUMENT AND CONTROL FUNCTIONS w 1 2 3 4 5 6 7 8 9 EW000044 EAU00333 This motorcycle must not be operated with the sidestand in the down position. If the stand is not properly retracted, it could contact the ground and distract the operator, resulting in a possible loss of control. Yamaha has designed into this motorcycle a lockout system to assist the operator in fulfilling the responsibility of retracting the sidestand. Please check carefully the operating instructions listed below and if there is any indication of a malfunction, return the motorcycle to a Yamaha dealer immediately for repair. Sidestand switch operation check Check the operation of the sidestand switch against the information below. TURN THE MAIN SWITCH TO "ON" AND THE ENGINE STOP SWITCH TO "#". TRANSMISSION IS IN NEUTRAL AND SIDESTAND IS DOWN. KICK THE KICK STARTER. ENGINE WILL START. PULL IN THE CLUTCH LEVER AND PUT TRANSMISSION IN GEAR. ENGINE WILL STALL. SIDESTAND SWITCH IS OK. EW000045 w If improper operation is noted, consult a Yamaha dealer immediately. 3-16 EAU01114 PRE-OPERATION CHECKS Owners are personally responsible for their vehicle's condition. Your motorcycle's vital functions can start to deteriorate quickly and unexpectedly, even if it remains unused (for instance, if it is exposed to the elements). Any damage, fluid leak or loss of tire pressure could have serious consequences. Therefore, it is very important that, in addition to a thorough visual inspection, you check the following points before each ride. EAU00340 1 2 3 4 5 6 PRE-OPERATION CHECK LIST ITEM Front brake Rear brake Clutch Throttle grip and housing Engine oil Transmission oil Coolant Drive chain Wheels and tires Control and meter cable 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 CHECKS Check operation, free play, fluid level and vehicle for fluid leakage. Fill with DOT 4 (or DOT 3) brake fluid if necessary. Check operation, free play, fluid level and vehicle for fluid leakage. Fill with DOT 4 (or DOT 3) brake fluid if necessary. Check operation, condition and free play. Adjust if necessary. Check for smooth operation. Lubricate. Adjust throttle cable free play if necessary. Check oil level. Fill with oil if necessary. Check oil level. Fill with oil if necessary. Check coolant level. Fill with coolant if necessary. Check chain slack and condition. Adjust if necessary. Check tire pressure, wear, damage and spoke tightness. Tighten spokes if necessary. Check for smooth operation. Lubricate if necessary. PAGE 3-6, 6-21 ~ 6-25 3-5, 6-21 6-17, 6-27 3-9 6-11 ~ 6-12 6-12 6-26 ~ 6-27 7 8 9 6-18 ~ 6-20 6-27 4-1 PRE-OPERATION CHECKS ITEM 9 Brake and shift pedal shafts 9 9 Brake and clutch lever pivots 9 9 Sidestand pivot 9 9 Chassis fasteners 9 9 Fuel tank 9 Lights, signals and 9 switches 9 Battery 9 CHECKS Check for smooth operation. Lubricate if necessary. Check for smooth operation. Lubricate if necessary. Check for smooth operation. Lubricate if necessary. Make sure that all nuts, bolts and screws are properly tightened. Tighten if necessary. Check fuel level. Fill with fuel if necessary. Check for proper operation. Check fluid level. Fill with distilled water if necessary. PAGE 1 2 3 4 5 6 7 6-28 6-29 -- 3-6 ~ 3-8 6-33 ~ 6-35 6-31 ~ 6-32 NOTE: Pre-operation checks should be made each time the motorcycle 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. w 8 9 If any item in the Pre-Operation Check is not working properly, have it inspected and repaired before operating the motorcycle. 4-2 EAU00372 OPERATION AND IMPORTANT RIDING POINTS w EAU00373 EAU01177 Starting the engine NOTE: This motorcycle is equipped with an ignition circuit cut-off system. The engine can be started only under one of the following conditions: 8 The transmission is in neutral. 8 The sidestand is up, the transmission is in gear and the clutch is disengaged. The motorcycle must not be ridden when the sidestand is down. 1 2 3 4 5 6 7 8 9 8 Before riding this motorcycle, become thoroughly familiar with all operating controls and their functions. Consult a Yamaha dealer regarding any control or function that you do not thoroughly understand. 8 Never start your engine or let it run for any length of time in a closed area. The exhaust fumes are poisonous and can cause loss of consciousness and death within a short time. Always operate your motorcycle in an area with adequate ventilation. 8 Before starting out, always be sure the sidestand is up. Failure to retract the sidestand completely can result in a serious accident when you try to turn a corner. w EW000056 Before going through the following steps, check the function of the sidestand switch. (Refer to page 3-16.) 5-1 OPERATION AND IMPORTANT RIDING POINTS TURN THE MAIN SWITCH TO "ON" AND THE ENGINE STOP SWITCH TO "#". 1 2 3 4 5 6 7 8 9 RETRACT SIDESTAND AND PUT TRANSMISSION IN GEAR. MOTORCYCLE CAN BE RIDDEN. MOTORCYCLE CAN BE RIDDEN. IF TRANSMISSION IS IN NEUTRAL AND SIDESTAND IS DOWN, KICK THE KICK STARTER. ENGINE WILL START. IF TRANSMISSION IS IN GEAR AND SIDESTAND IS UP, APPLY THE CLUTCH LEVER AND KICK THE KICK STARTER. ENGINE WILL START. 5-2 OPERATION AND IMPORTANT RIDING POINTS 1. Turn the fuel cock to "ON". 2. Turn the main switch to "ON" and the engine stop switch to "#". 3. Shift the transmission into neutral. NOTE: When the transmission is in neutral, the neutral indicator light should be on. If the light does not come on, ask a Yamaha dealer to inspect it. 4. Turn on the starter (choke) and completely close the throttle grip. 5. Kick the kick starter to start the engine. 6. After starting the engine, move the starter (choke) to the halfway position. NOTE: For maximum engine life, never accelerate hard with a cold engine! 7. After the engine is warm, turn off the starter (choke) completely. NOTE: The engine is warm when it responds normally to the throttle with the starter (choke) turned off. EAU01258 Starting a warm engine The starter (choke) is not required when the engine is warm. 1 2 3 4 5 6 7 8 9 EC000046 cC See the "Engine break-in" section prior to operating the motorcycle for the first time. 5-3 OPERATION AND IMPORTANT RIDING POINTS cC 1 2 3 4 5 6 7 8 9 N. Neutral 1. Shift pedal EAU00423 EC000048 EAU02937 6 5 4 3 2 N 1 1 Shifting The transmission lets you control the amount of power you have available at a given speed for starting, accelerating, climbing hills, etc. The use of the shift pedal is shown in the illustration. To shift into neutral, depress the shift pedal repeatedly until it reaches the end of its travel, then raise the pedal slightly. 8 Do not coast for long periods with the engine off, and do not tow the motorcycle a long distance. Even with gears in neutral, the transmission is only properly lubricated when the engine is running. Inadequate lubrication may damage the transmission. 8 Always use the clutch when changing gears. The engine, transmission, and driveline are not designed to withstand the shock of forced shifting and can be damaged by shifting without using the clutch. Recommended shift points (for Switzerland only) The recommended shift points are shown in the table below. Acceleration shift point km/h 1st 2nd 2nd 3rd 3rd 4th 4th 5th 5th 6th 20 30 40 50 60 NOTE: When shifting two gears down from 5th to 3rd, bring your motorcycle to a speed of 35 km/h. 5-4 OPERATION AND IMPORTANT RIDING POINTS EAU00424 EAU00436 EAU00453 Tips for reducing fuel consumption Your motorcycle's fuel consumption depends to a large extent on your riding style. The following tips can help reduce fuel consumption: 8 Warm up the engine before riding. 8 Turn off the starter (choke) as soon as possible. 8 Shift up swiftly and avoid high engine speeds during acceleration. 8 Do not double-clutch or rev the engine while shifting down and avoid high engine speeds with no load on the engine. 8 Turn off the engine instead of letting it idle for an extended length of time, i.e. in traffic jams, at traffic lights or railroad crossings. Engine break-in There is never a more important period in the life of your motorcycle than the period between zero and 1,000 km. For this reason we ask that you carefully read the following material. Because the engine is brand new, you must not put an excessive load on it for the first 1,000 km. The various parts in the engine wear and polish themselves to the correct operating clearances. During this period, prolonged full throttle operation, or any condition which might result in excessive heating of the engine, must be avoided. 0 ~ 500 km Avoid operation above 6,000 r/min. Stop the engine and let it cool for 5 to 10 minutes after every hour of operation. Vary the speed of the motorcycle from time to time. Do not operate it at one set throttle position. 500 ~ 1,000 km Avoid prolonged operation above 7,000 r/min. Rev the motorcycle freely through the gears, but do not use full throttle at any time. 1 2 3 4 5 6 7 8 9 cC EC000060 After 1,000 km of operation, be sure to replace the transmission oil. 5-5 OPERATION AND IMPORTANT RIDING POINTS 1,000 km and beyond EAU00458 Full throttle can be used. 1 2 3 4 5 6 7 8 9 Parking EC000053 cC 8 Never let engine speeds enter the red zone. 8 If any engine trouble should occur during the break-in period, consult a Yamaha dealer immediately. When parking the motorcycle, stop the engine and remove the ignition key. Turn the fuel cock to "OFF" whenever stopping the engine. w EW000058 The exhaust system is hot. Park the motorcycle in a place where pedestrians or children are not likely to touch the motorcycle. Do not park the motorcycle on a slope or soft ground; the motorcycle may overturn. cC EC000062 Never park this motorcycle in an area that would cause a fire hazzard such as grass or other materials that may easily burn. 5-6 EAU00462 PERIODIC MAINTENANCE AND MINOR REPAIR EAU00464 Periodic inspection, adjustment and lubrication will keep your motorcycle in the safest and most efficient condition possible. Safety is an obligation of the motorcycle owner. The maintenance and lubrication schedule chart should be considered strictly as a guide to general maintenance and lubrication intervals. YOU MUST TAKE INTO CONSIDERATION THAT WEATHER, TERRAIN, GEOGRAPHICAL LOCATIONS, AND A VARIETY OF INDIVIDUAL USES ALL TEND TO DEMAND THAT EACH OWNER ALTER THIS TIME SCHEDULE TO SHORTER INTERVALS TO MATCH THE ENVIRONMENT. The most important points of motorcycle inspection, adjustment, and lubrication are explained in the following pages. w