User manual YAMAHA DT125R-2006

OWNER'S MANUAL DT125R DT125X 1D0-F8199-E2 INTRODUCTION EAU10100 Welcome to the Yamaha world of motorcycling! As the owner of the DT125R/X, you are benefiting from Yamaha's vast experience and newest technology regarding the design and manufacture of high-quality products, which have earned Yamaha a reputation for dependability. Please take the time to read this manual thoroughly, so as to enjoy all advantages of your DT125R/X. The owner's manual does not only instruct you in how to operate, inspect and maintain your motorcycle, but also in how to safeguard yourself and others from trouble and injury. In addition, the many tips given in this manual will help keep your motorcycle in the best possible condition. If you have any further questions, do not hesitate to contact your Yamaha dealer. The Yamaha team wishes you many safe and pleasant rides. So, remember to put safety first! IMPORTANT MANUAL INFORMATION EAU10150 Particularly important information is distinguished in this manual by the following notations: t 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. A NOTE provides key information to make procedures easier or clearer. s WARNING CAUTION NOTE: NOTE: q This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold. q Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most current product information available at the time of printing, there may be minor discrepancies between your motorcycle and this manual. If you have any questions concerning this manual, please consult your Yamaha dealer. EWA10030 s WARNING PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE. IMPORTANT MANUAL INFORMATION EAUS1171 DT125R/X OWNER'S MANUAL ©2004 by YAMAHA MOTOR SPAIN S.A. 1st edition, July 2004 All rights reserved Any reprinting or unauthorized use without the written permission of YAMAHA MOTOR SPAIN S.A. is expressly prohibited. Printed in Spain. TABLE OF CONTENTS SAFETY INFORMATION .....................1-1 DESCRIPTION.....................................2-1 Left view ...........................................2-1 Right view .........................................2-2 Controls and instruments .................2-3 INSTRUMENTS AND CONTROL FUNCTIONS ........................................3-1 Main switch/steering lock.................3-1 Indicator and warning lights .............3-2 Speedometer unit .............................3-3 Handlebar switches ..........................3-3 Clutch lever.......................................3-4 Shift pedal.........................................3-4 Brake lever........................................3-5 Brake pedal.......................................3-5 Fuel tank cap ....................................3-5 Catalytic converter............................3-6 2-stroke engine oil ............................3-7 Fuel cock ..........................................3-7 Starter (choke) lever..........................3-8 Seat...................................................3-8 Shock absorber ................................3-9 YEIS handling precautions ...............3-9 YPVS.................................................3-9 Sidestand........................................3-10 Ignition circuit cut-off system .........3-10 PRE-OPERATION CHECKS ...............4-1 Pre-operation check list....................4-2 OPERATION AND IMPORTANT RIDING POINTS ................................................5-1 Starting a cold engine ......................5-1 Starting a warm engine ....................5-2 Shifting..............................................5-2 Engine break-in.................................5-2 Parking..............................................5-3 PERIODIC MAINTENANCE AND MINOR REPAIR...................................6-1 Owner's tool kit.................................6-1 Periodic maintenance and lubrication chart ............................6-2 Removing and installing cowlings and panels.....................................6-5 Checking the spark plug ..................6-6 Transmission oil ................................6-7 Coolant .............................................6-8 Cleaning the air filter element and check hose...........................6-10 Ajusting the carburetor ...................6-11 Adjusting the engine idling speed...........................................6-12 Ajusting the throttle cable free play ..............................................6-12 Tires ................................................6-13 Spoke wheels .................................6-15 Adjusting the clutch lever free play ..............................................6-15 Adjusting the brake lever free play ..............................................6-16 Adjusting the brake pedal position and free play................................6-17 Adjusting the rear brake light switch ..........................................6-17 Checking the front and rear brake pads ..................................6-18 Changing the brake fluid ................6-19 Checking the drive chain slack ......6-19 Adjusting the drive chain slack.......6-20 Lubricating the drive chain .............6-20 Checking and lubricating the cables ..........................................6-21 Checking and lubricating the throttle grip and cable .................6-21 Adjusting the autolube pump .........6-21 Checking and lubricating the brake and shift pedals.................6-21 Checking and lubricating the breake and clutch levers .............6-21 Checking and lubricating the sidestand .....................................6-21 Checking the front fork...................6-22 Checking the steering.....................6-22 Checking the wheel bearings .........6-23 Replacing the fuse..........................6-24 Replacing the headlight bulb..........6-24 Replacing the tail/brake light bulb .............................................6-25 Replacing the turn signal light bulb .............................................6-26 Supporting the motorcycle .............6-26 TABLE OF CONTENTS Front wheel .....................................6-26 Rear wheel ......................................6-28 Troubleshooting ..............................6-29 MOTORCYCLE CARE AND STORAGE ........................................7-1 Care ..................................................7-1 Storage .............................................7-3 SPECIFICATIONS ...............................8-1 Specifications ...................................8-1 CONSUMER INFORMATION .............9-1 Identification numbers ......................9-1 t SAFETY INFORMATION EAU10310 1 MOTORCYCLES ARE SINGLE TRACK VEHICLES. THEIR SAFE USE AND OPERATION ARE DEPENDENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EXPERTISE OF THE OPERATOR. EVERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIREMENTS BEFORE RIDING THIS MOTORCYCLE. HE OR SHE SHOULD: q OBTAIN THOROUGH INSTRUCTIONS FROM A COMPETENT SOURCE ON ALL ASPECTS OF MOTORCYCLE OPERATION. q OBSERVE THE WARNINGS AND MAINTENANCE REQUIREMENTS IN THE OWNER'S MANUAL. q OBTAIN QUALIFIED TRAINING IN SAFE AND PROPER RIDING TECHNIQUES. q OBTAIN PROFESSIONAL TECHNICAL SERVICE AS INDICATED BY THE OWNER'S MANUAL AND/OR WHEN MADE NECESSARY BY MECHANICAL CONDITIONS. Safe riding q Always make pre-operation checks. Careful checks may help prevent an accident. q This motorcycle is designed to carry the operator and a passenger. q The failure of motorists to detect and recognize motorcycles in traffic is the predominating cause of automobile/motorcycle accidents. Many accidents have been caused by an automobile driver who did not see the motorcycle. Making yourself conspicuous appears to be very effective in reducing the chance of this type of accident. Therefore: · Wear a brightly colored jacket. · Use extra caution when approaching and passing through intersections, since intersections are the most likely places for motorcycle accidents to occur. · Ride where other motorists can see you. Avoid riding in another motorist's blind spot. 1-1 q q Many accidents involve inexperienced operators. In fact, many operators who have been involved in accidents do not even have a current motorcycle license. · Make sure that you are qualified and that you only lend your motorcycle to other qualified operators. · Know your skills and limits. Staying within your limits may help you to avoid an accident. · We recommend that you practice riding your motorcycle where there is no traffic until you have become thoroughly familiar with the motorcycle and all of its controls. Many accidents have been caused by error of the motorcycle operator. A typical error made by the operator is veering wide on a turn due to EXCESSIVE SPEED or undercornering (insufficient lean angle for the speed). SAFETY INFORMATION t · Always obey the speed limit and never travel faster than warranted by road and traffic conditions. · Always signal before turning or changing lanes. Make sure that other motorists can see you. The posture of the operator and passenger is important for proper control. · The operator should keep both hands on the handlebar and both feet on the operator footrests during operation to maintain control of the motorcycle. · The passenger should always hold onto the operator, the seat strap or grab bar, if equipped, with both hands and keep both feet on the passenger footrests. · Never carry a passenger unless he or she can firmly place both feet on the passenger footrests. Never ride under the influence of alcohol or other drugs. Protective apparel The majority of fatalities from motorcycle accidents are the result of head injuries. The use of a safety helmet is the single most critical factor in the prevention or reduction of head injuries. q Always wear an approved helmet. q Wear a face shield or goggles. Wind in your unprotected eyes could contribute to an impairment of vision that could delay seeing a hazard. q The use of a jacket, heavy boots, trousers, gloves, etc., is effective in preventing or reducing abrasions or lacerations. q Never wear loose-fitting clothes, otherwise they could catch on the control levers, footrests, or wheels and cause injury or an accident. Never touch the engine or exhaust system during or after operation. They become very hot and can cause burns. Always wear protective clothing that covers your legs, ankles, and feet. q Passengers should also observe the precautions mentioned above. Modifications Modifications made to this motorcycle not approved by Yamaha, or the removal of original equipment, may render the motorcycle unsafe for use and may cause severe personal injury. Modifications may also make your motorcycle illegal to use. q 1 q q 1-2 t SAFETY INFORMATION Shifting weights can create a sudden imbalance. Make sure that accessories and cargo are securely attached to the motorcycle before riding. Check accessory mounts and cargo restraints frequently. q Never attach any large or heavy items to the handlebar, front fork, or front fender. These items, including such cargo as sleeping bags, duffel bags, or tents, can create unstable handling or a slow steering response. Accessories Genuine Yamaha accessories have been specifically designed for use on this motorcycle. Since Yamaha cannot test all other accessories that may be available, you must personally be responsible for the proper selection, installation and use of non-Yamaha accessories. Use extreme caution when selecting and installing any accessories. Keep the following guidelines in mind, as well as those provided under "Loading" when mounting accessories. q 1-3 q 1 Loading and accessories Adding accessories or cargo to your motorcycle can adversely affect stability and handling if the weight distribution of the motorcycle is changed. To avoid the possibility of an accident, use extreme caution when adding cargo or accessories to your motorcycle. Use extra care when riding a motorcycle that has added cargo or accessories. Here are some general guidelines to follow if loading cargo or adding accessories to your motorcycle: Loading The total weight of the operator, passenger, accessories and cargo must not exceed the maximum load limit of 178 kg (392 lb) DT125R, 180 kg (396 lb) DT125X. When loading within this weight limit, keep the following in mind: q Cargo and accessory weight should be kept as low and close to the motorcycle as possible. Make sure to distribute the weight as evenly as possible on both sides of the motorcycle to minimize imbalance or instability. Never install accessories or carry cargo that would impair the performance of your motorcycle. Carefully inspect the accessory before using it to make sure that it does not in any way reduce ground clearance or cornering clearance, limit suspension travel, steering travel or control operation, or obscure lights or reflectors. · Accessories fitted to the handlebar or the front fork area can create instability due to improper weight distribution or aerodynamic changes. If accessories are added to the handlebar or front fork area, they must be as lightweight as possible and should be kept to a minimum. SAFETY INFORMATION t · Bulky or large accessories may seriously affect the stability of the motorcycle due to aerodynamic effects. Wind may attempt to lift the motorcycle, or the motorcycle may become unstable in cross winds. These accessories may also cause instability when passing or being passed by large vehicles. · Certain accessories can displace the operator from his or her normal riding position. This improper position limits the freedom of movement of the operator and may limit control ability, therefore, such accessories are not recommended. Use caution when adding electrical accessories. If electrical accessories exceed the capacity of the motorcycle's electrical system an electric failure could result, which could cause a dangerous loss of lights or engine power. Gasoline and exhaust gas q GASOLINE IS HIGHLY FLAMMABLE: · Always turn the engine off when refueling. · Take care not to spill any gasoline on the engine or exhaust system when refueling. · Never refuel while smoking or in the vicinity of an open flame. q Never start the engine or let it run for any length of time in a closed area. The exhaust fumes are poisonous and may cause loss of consciousness and death within a short time. Always operate your motorcycle in an area that has adequate ventilation. q Always turn the engine off before leaving the motorcycle unattended and remove the key from the main switch. When parking the motorcycle, note the following: · The engine and exhaust system may be hot, therefore, park the motorcycle in a place where pedestrians or children are not likely to touch these hot areas. 1-4 q q q · Do not park the motorcycle on a slope or soft ground, otherwise it may fall over. · Do not park the motorcycle near a flammable source (e.g., a kerosene heater, or near an open flame), otherwise it could catch fire. When transporting the motorcycle in another vehicle, make sure that it is kept upright and that the fuel cock(s) are turned to "ON" or "RES" (for vacuum type)/"OFF" (for manual type). If the motorcycle should lean over, gasoline may leak out of the carburetor or fuel tank. If you should swallow any gasoline, inhale a lot of gasoline vapor, or allow gasoline to get into your eyes, see your doctor immediately. If any gasoline spills on your skin or clothing, immediately wash the affected area with soap and water and change your clothes. 1 DESCRIPTION EAU10410 Left view 1 2 7 9 2 1. 2. 3. 4. 5. 6. 7. 8. 9. Headlight (page 6-24) Radiator cover (page 6-5) Fuel cock (page 3-7) Air filter (page 6-10) Choke lever (page 3-8) Shift pedal (page 3-4) Y.E.I.S (page 3-9) Y.P.V.S. (page 3-9) Oil tank (page 3-7) 8 5 63 4 2-1 DESCRIPTION EAU10420 Right view 13 11 2 12 14 11. 12. 13. 14. Tool kit (page 6-1) Fuse (page 6-24) Coolant tank (page 6-8) Rear brake pedal (page 3-5) 2-2 DESCRIPCION EAU10430 Controls and instruments 16 2 17 18 19 20 22 y 20 0 60 80 100 40 0 0 0 0 1 5 120 km/h 130 0008 24 25 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. Clutch lever (page 3-4) Left handlevar swicht (page 3-3) Speedometer (Page 3-3) Coolant temperature warning lamp (page 3-3) Indicators (page 3-2) Right handlevar swicht (page 3-3) Front brake lever (page 3-5) Throttle grip (page 6-12) Fuel tank cap (page 3-5) Main Switch (page 3-1) 21 23 2-3 INSTRUMENT AND CONTROL FUNCTIONS EAU10460 Main switch/steering lock PUS H O FF ON NOTE: The headlights come on automatically when the engine is started and stay on until the key is turned to "OFF", even if the engine stalls. EAU10660 EWA10060 IG NI TI OFF All electrical systems are off. The key can be removed. EAU10680 s WARNING Never turn the key to "OFF" or "LOCK" while the vehicle is moving, otherwise the electrical systems will be switched off, which may result in loss of control or an accident. Make sure that the vehicle is stopped before turning the key to "OFF" or "LOCK". O N The main switch/steering lock controls the ignition and lighting systems, and is used to lock the steering. The various positions are described below. EAU10550 ON All electrical circuits are supplied with power, the meter lighting, taillight, license plate light and auxiliary lights come on, and the engine can be started. The key cannot be removed. LO C K 3 LOCK The steering is locked, and all electrical systems are off. The key can be removed. To lock the steering 1. Turn the handlebars all the way to the left. 2. Push the key in from the "OFF" position, and then turn it to "LOCK" while still pushing it. 3. Remove the key. To unlock the steering Push the key in, and then turn it to "OFF" while still pushing it. 3-1 INSTRUMENT AND CONTROL FUNCTIONS EAU11002 EAU11080 ECA10010 Indicator and warning lights 1 y 60 100 40 000015 120 20 km/h 0 130 80 bj z N High beam indicator light "j" This indicator light comes on when the high beam of the headlight is switched on. EAU11180 CAUTION Do not operate the vehicle until you know that the engine oil level is sufficient. EAU11430 0008 3 2 3 4 1. 2. 3. 4. Turn signal indicator light "b" Dimmer indicator light "j" Neutral indicator light "N" Oil level warning light "z" EAU11030 Turn signal indicator lights "c" and "d" The corresponding indicator light flashes when the turn signal switch is pushed to the left or right. EAU11070 Oil level warning light "z" This warning light comes on when the key is in the "ON" position or when the oil level in the 2-stroke engine oil tank is low during operation. If the warning light comes on during operation, stop immediately and fill the oil tank with Yamalube 2 or equivalent 2stroke engine oil of either JASO grade "FC" or ISO grades "EG-C" or "EGD". The warning light should go off after the 2-stroke engine oil tank has been refilled. NOTE: If the warning light does not come on when the key is in the "ON" position or does not go off after the 2-stroke engine oil tank has been refilled, have a Yamaha dealer check the electrical circuit. Coolant temperature warning light "y" This warning light comes on when the engine overheats. When this occurs, stop the engine immediately and allow the engine to cool. ECA10020 CAUTION Do not operate the engine if it is overheated. Neutral indicator light "N" This indicator light comes on when the transmission is in the neutral position. 3-2 INSTRUMENT AND CONTROL FUNCTIONS EAU11640 Speedometer unit 1 4 y 60 80 100 40 000015 120 20 km/h 0 130 bj z N NOTE: Only for the German model equipped with a speed limiter: The speed limiter prevents the vehicle from exceeding a riding speed of 80 km/h. EAU12343 EAU12460 0008 Handlebar switches 3 1. 2. 3. 4. Turn signal switch "c/d" To signal a right-hand turn, push this switch to "d". To signal a left-hand turn, push this switch to "c". When released, the switch returns to the center position. To cancel the turn signal lights, push the switch in after it has returned to the center position. EAU12500 3 2 41 Odometer Tripmeter Reset button Coolant temperature warning lamp Horn switch "a" Press this switch to sound the horn. EAU12660 Engine stop switch "f/e" 1 3 1. 2. 3. 4. The speedometer unit is equipped with a speedometer, an odometer and a tripmeter. The speedometer shows riding speed. The odometer shows the total distance traveled. The tripmeter shows the distance traveled since it was last set to zero with the reset knob. The tripmeter can be used to estimate the distance that can be traveled with a full tank of fuel. This information will enable you to plan future fuel stops. 2 Dimmer switch "j/k" Horn switch "a" Turn signal switch "c/d" Hazard switch " " EAU12400 Dimmer switch "j/k" Set this switch to "j" for the high beam and to "k" for the low beam. 2 1. Stop switch "f/e" 2. Start switch "g" Set this switch to "f" before starting the engine. Set this switch to "e" to 3-3 INSTRUMENT AND CONTROL FUNCTIONS stop the engine in case of an emergency, such as when the motorcycle overturns or when the throttle cable is stuck. EAU12710 EAU12820 EAU12880 Clutch lever 1 Shift pedal 3 Start switch "g" Push this switch to crank the engine with the starter. ECA10050 CAUTION See page 5-1 for starting instructions prior to starting the engine. EAU12763 1 1. Clutch lever N. Neutral 1. Shift pedal Hazard switch " " With the key in the "ON" position, turn this switch to " " to turn on the hazard lights (simultaneous flashing of all turn signal lights). The hazard lights are used in case of an emergency or to warn other drivers when your vehicle is stopped where it might be a traffic hazard. ECA10060 CAUTION Do not use the hazard light for an extended length of time, otherwisethe battery may discharge. The clutch lever is located at the left handlebar grip. To disengage the clutch, pull the lever toward the handlebar grip. To engage the clutch, release the lever. The lever should be pulled rapidly and released slowly for smooth clutch operation. The clutch lever is equipped with a clutch switch, which is part of the ignition circuit cut-off system. (See page 3-11.) The shift pedal is located on the left side of the engine and is used in combination with the clutch lever when shifting the gears of the 6-speed constant-mesh transmission equipped on this motorcycle. NOTE: Use your toes or heel to shift up and your toes to shift down. 3-4 INSTRUMENT AND CONTROL FUNCTIONS EAU12890 EAU12941 EAU13150 Brake lever 1 Brake pedal Fuel tank cap To remove the fuel tank cap 1. Insert the key into the lock and turn it 1/4 turn counterclockwise. 2. Turn the fuel tank cap 1/3 turn counterclockwise and pull it off. 3 2 1 1. Brake lever 1. Brake pedal 1 3 The brake lever is located at the right handlebar grip. To apply the front brake, pull the lever toward the handlebar grip. The brake pedal is on the right side of the motorcycle. To apply the rear brake, press down on the brake pedal. 1. Fuel tank cap 2. Unlock 3. Open To install the fuel tank cap 1. Insert the fuel tank cap into the tank opening with the key inserted in the lock, and then turn the cap 1/3 turn clockwise. 2. Turn the key 1/4 turn clockwise, and then remove it. 3-5 INSTRUMENT AND CONTROL FUNCTIONS NOTE: The fuel tank cap cannot be installed unless the key is in the lock. In addition, the key cannot be removed if the cap is not properly installed and locked. EWA10120 EWA10880 ECA11400 3 s WARNING Make sure that the fuel tank cap is properly closed and locked before riding. EAU13220 s WARNING q Do not overfill the fuel tank, otherwise it may overflow when the fuel warms up and expands. q Avoid spilling fuel on the hot engine. ECA10070 CAUTION Use only unleaded gasoline. The use of leaded gasoline will cause severe damage to internal engine parts, such as the valves and piston rings, as well as to the exhaust system. Your Yamaha engine has been designed to use regular unleaded gasoline with a research octane number of 91 or higher. If knocking (or pinging) occurs, use a gasoline of a different brand or premium unleaded fuel. Use of unleaded fuel will extend spark plug life and reduce maintenance costs. EAU13430 Fuel Make sure that there is sufficient fuel in the tank. When refueling, be sure to insert the pump nozzle into the fuel tank filler hole and to fill the tank to the bottom of the filler tube as shown. 1 2 CAUTION Immediately wipe off spilled fuel with a clean, dry, soft cloth, since fuel may deteriorate painted surfaces or plastic parts. EAU13320 Recommended fuel: REGULAR UNLEADED GASOLINE ONLY Fuel tank capacity: 10,7 L (2,82 US gal) (2,35 Imp.gal) Fuel reserve amount: 1,8 L (0,48 US gal) (0,40 Imp.gal) Catalytic converter This model is equipped with a catalytic converter in the exhaust chamber. EWA10860 1. Filing pipe 2. Fuel level 3-6 s WARNING The exhaust system is hot after operation. Make sure that the exhaust system has cooled down before doing any maintenance work. INSTRUMENT AND CONTROL FUNCTIONS ECA10700 CAUTION The following precautions must be observed to prevent a fire hazard or other damages. q Use only unleaded gasoline. The use of leaded gasoline will cause unrepairable damage to the catalytic converter. q Never park the vehicle near possible fire hazards such as grass or other materials that easily burn. q Do not allow the engine to idle too long. EAU13460 Make sure that there is sufficient oil in the 2-stroke engine oil tank. Add the recommended 2-stroke engine oil if necessary. NOTE: Make sure that the 2-stroke engine oil tank cap is properly installed. OFF 1 Recommended oil: Yamalube 2 or equivalent 2-stroke engine oil (JASO grade "FC", or ISO grades "EG-C" or "EG-D") Oil quantity: 1,3 L (1,37 US qt) (0,29 Imp.qt) 1. Arrow mark 3 EAU13560 With the lever in this position, fuel will not flow. Always return the lever to this position when the engine is not running. ON 2-stroke engine oil Fuel cock The fuel cock supplies fuel from the tank to the carburetor while filtering it also. The fuel cock has three positions: 1 2 1 With the lever in this position, fuel flows to the carburetor. Normal riding is done with the lever in this position. 3-7 1. Oil tank cap 2. Sensor INSTRUMENT AND CONTROL FUNCTIONS RES Starting a cold engine requires a richer air-fuel mixture, which is supplied by the starter (choke). Move the lever in direction (a) to turn on the starter (choke). Move the lever in direction (b) to turn off the starter (choke). 1 EAU13960 To install the seat 1. Insert the projections on the front of the seat into the seat holders as shown. 3 Seat 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! EAU13590 To remove the seat Remove the bolts, and then pull the seat off. 1 2. Place the seat in the original position, and then tighten the bolts. NOTE: Make sure that the seat is properly secured before riding. 1. Bolt (x2) Starter (choke) lever "q" 1. Choke lever 3-8 INSTRUMENT AND CONTROL FUNCTIONS EAU15090 EAU15250 EAU15260 Shock absorber EWA10220 YEIS handling precautions 1 YPVS s WARNING This shock absorber contains highly pressurized nitrogen gas. For proper handling, 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. q Do not tamper with or attempt to open the gas cylinder. q Do not subject the shock absorber to an open flame or other high heat sources, otherwise it may explode due to excessive gas pressure. q Do not deform or damage the gas cylinder in any way, as this will result in poor damping performance. q Always have a Yamaha dealer service the shock absorber. 1 3 1. YEIS 1. YPVS Improper installation of or damage to any part of the YEIS (Yamaha Energy Induction System) will result in poor performance. Therefore, handle the YEIS air chamber and air chamber hose with special care and immediately replace any cracked or damaged parts. ECA10140 CAUTION Do not attempt to modify the YEIS in any way. This model is equipped with the YPVS (Yamaha Power Valve System). This system boosts engine performance and efficiency by means of a variable valve in the exhaust port. The YPVS valve is constantly adjusted in accordance with the engine speed by a computer-controlled servomotor. Since the YPVS is an important part of the engine and requires very sophisticated adjustment, have a Yamaha dealer, who has the necessary professional knowledge and experience, make this adjustment. 3-9 INSTRUMENT AND CONTROL FUNCTIONS ECA10150 3 CAUTION The YPVS has been set and extensively tested at the Yamaha factory. Changing these settings without sufficient technical knowledge may result in poor performance of or damage to the engine. YPVS operation noises can be heard in the following instances: q When the key is turned to "ON" and the engine is started. q When the engine stalls with the key in the "ON" position. ECA10160 NOTE: The built-in sidestand switch is part of the ignition circuit cut-off system, which cuts the ignition in certain situations. (See further down for an explanation of the ignition circuit cutoff system.) EWA10240 EAU15311 Ignition circuit cut-off system The ignition circuit cut-off system (comprising the sidestand switch, clutch switch and neutral switch) has the following functions. q It prevents starting when the transmission is in gear and the sidestand is up, but the clutch lever is not pulled. q It prevents starting when the transmission is in gear and the clutch lever is pulled, but the sidestand is still down. q It cuts the running engine when the transmission is in gear and the sidestand is moved down. Periodically check the operation of the ignition circuit cut-off system according to the following procedure. EWA10250 CAUTION If the YPVS does not operate, have a Yamaha dealer check it. EAU15300 Sidestand The sidestand is located on the left side of the frame. Raise the sidestand or lower it with your foot while holding the motorcycle upright. s WARNING The vehicle must not be ridden with the sidestand down, or if the sidestand cannot be properly moved up (or does not stay up), otherwise the sidestand could contact the ground and distract the operator, resulting in a possible loss of control. Yamaha's ignition circuit cut-off system has been designed to assist the operator in fulfilling the responsibility of raising the sidestand before starting off. Therefore, check this system regularly as described below and have a Yamaha dealer repair it if it does not function properly. s WARNING If a malfunction is noted, have a Yamaha dealer check the system before riding. 3-10 INSTRUMENT AND CONTROL FUNCTIONS 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? NOTE: This check is most reliable if performed with a warmed-up engine. YES 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? NO The neutral switch may be defective. The motorcycle should not be ridden until checked by a Yamaha dealer. 3 YES 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? NO The sidestand switch may be defective. The motorcycle should not be ridden until checked by a Yamaha dealer. YES NO The clutch switch may be defective. The motorcycle should not be ridden until checked by a Yamaha dealer. The system is OK. The motorcycle can be ridden. NOTE: This check is most reliable if performed with a warmed-up engine. 3-11 PRE-OPERATION CHECKS EAU15591 4 The condition of a vehicle is the owner's responsibility. Vital components can start to deteriorate quickly and unexpectedly, even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thorough visual inspection, to check the following points before each ride. NOTE: Pre-operation checks should be made each time the vehicle is used. Such an inspection can be accomplished in a very short time; and the added safety it assures is more than worth the time involved. EWA11150 s WARNING If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operating the vehicle. 4-1 PRE-OPERATION CHECKS EAU15603 Pre-operation check list ITEM Fuel CHECKS · Check fuel level in fuel tank. · Refuel if necessary. · Check fuel line for leakage. · Check oil level in oil tank. · If necessary, add recommended oil to specified level. · Check vehicle for oil leakage. · Check oil level in transmission case. · If necessary, add recommended oil to specified level. · Check coolant level in reservoir. · If necessary, add recommended coolant to specified level. · Check cooling system for leakage. · Check operation. · If soft or spongy, have Yamaha dealer bleed hydraulic system. · Check brake pads for wear. · Replace if necessary. · Check fluid level in reservoir. · If necessary, add recommended brake fluid to specified level. · Check hydraulic system for leakage. · Check operation. · If soft or spongy, have Yamaha dealer bleed hydraulic system. · Check brake pads for wear. · Replace if necessary. · Check fluid level in reservoir. · If necessary, add recommended brake fluid to specified level. · Check hydraulic system for leakage. · Check operation. · Lubricate cable if necessary. · Check lever free play. · Adjust if necessary. · Make sure that operation is smooth. · Check cable free play. · If necessary, have Yamaha dealer adjust cable free play and lubricate cable andgrip housing. 4-2 PAGE 3-6 2-stroke engine oil Transmission oil Coolant 3-7 6-7 4 6-8 Front brake 6-16/6-18 Rear brake 6-16/6-18 Clutch 6-15 Throttle grip 6-12/6-21 PRE-OPERATION CHECKS Control cables · · · · · · · · · · · · · · · · · · · · · · · Make sure that operation is smooth. Lubricate if necessary. Check chain slack. Adjust if necessary. Check chain condition. Lubricate if necessary. Check for damage. Check tire condition and tread depth. Check air pressure. Correct if necessary. Make sure that operation is smooth. Lubricate pedal pivoting points if necessary. Make sure that operation is smooth. Lubricate lever pivoting points if necessary. Make sure that operation is smooth. Lubricate pivot if necessary. Make sure that all nuts, bolts and screws are properly tightened. Tighten if necessary. Check operation. Correct if necessary. Check operation. Check operation of ignition circuit cut-off system. If system is defective, have Yamaha dealer check vehicle. 6-21 Drive chain 6-19/6-20 Wheels and tires Brake and shift pedals 6-13 6-21 6-21 6-21 ­ ­ 3-3 3-11 4 Brake and clutch levers Sidestand Chassis fasteners Instruments, lights, signals and switches Engine stop switch Sidestand switch 4-3 OPERATION AND IMPORTANT RIDING POINTS EAU15950 EWA10270 EAU16060 s WARNING q Become thoroughly familiar with all operating controls and their functions before riding. Consult a Yamaha dealer regarding any control or function that you do not thoroughly understand. q Never start the engine or operate it in a closed area for any length of time. Exhaust fumes are poisonous, and inhaling them can cause loss of consciousness and death within a short time. Always make sure that there is adequate ventilation. q Before starting out, make sure that the sidestand is up. If the sidestand is not raised completely, it could contact the ground and distract the operator, resulting in a possible loss of control. Starting a cold engine In order for the ignition circuit cut-off system to enable starting, one of the following conditions must be met: q The transmission is in the neutral position. q The transmission is in gear with the clutch lever pulled and the sidestand up. EWA10290 NOTE: When the transmission is in the neutral position, the neutral indicator light should be on, otherwise have a Yamaha dealer check the electrical circuit. 4. Turn the starter (choke) on and completely close the throttle. (See page 3-8.) 5. Start the engine by pushing the start switch. NOTE: If the engine fails to start, release the start switch, wait a few seconds, and then try again. Each starting attempt should be as short as possible to preserve the battery. Do not crank the engine more than 10 seconds on any one attempt. 6. After starting the engine, move the starter (choke) back halfway. ECA11040 s WARNING q Before starting the engine, check the function of the ignition circuit cut-off system according to the procedure described on page 3-11. q 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 is set to "f". 3. Shift the transmission into the neutral position. 5 CAUTION For maximum engine life, never accelerate hard when the engine is cold! 5-1 OPERATION AND IMPORTANT RIDING POINTS 7. When the engine is warm, turn the starter (choke) off. NOTE: The engine is warm when it responds normally to the throttle with the starter (choke) turned off. 1 EAU16640 q Always use the clutch while changing gears to avoid damaging the engine, transmission, and drive train, which are not designed to withstand the shock of forced shifting. EAU16830 Starting a warm engine 5 Follow the same procedure as for starting a cold engine with the exception that the starter (choke) is not required when the engine is warm. EAU16671 Engine break-in N. Neutral 1. Shift pedal Shifting Shifting gears lets you control the amount of engine power available for starting off, accelerating, climbing hills, etc. The gear positions are shown in the illustration. NOTE: To shift the transmission into the neutral position, press the shift pedal down repeatedly until it reaches the end of its travel, and then slightly raise it. ECA10260 CAUTION q Even with the transmission in the neutral position, do not coast for long periods of time with the engine off, and do not tow the motorcycle for long distances. The transmission is properly lubricated only when the engine is running. Inadequate lubrication may damage the transmission. 5-2 There is never a more important period in the life of your engine than the period between 0 and 1000 km (600 mi). For this reason, you should read the following material carefully. Since the engine is brand new, do not put an excessive load on it for the first 1000 km (600 mi). The various parts in the engine wear and polish themselves to the correct operating clearances. During this period, prolonged full-throttle operation or any condition that might result in engine overheating must be avoided. EAU17150 0­150 km (0­90 mi) Avoid prolonged operation above 1/3 throttle. OPERATION AND IMPORTANT RIDING POINTS After every hour of operation, stop the engine, and then let it cool for five to ten minutes. Vary the engine speed from time to time. Do not operate the engine at one set throttle position. 150­500 km (90­300 mi) Avoid prolonged operation above 1/2 throttle. Rev the engine freely through the gears, but do not use full throttle at any time. 500­1000 km (300­600 mi) Avoid prolonged operation above 3/4 throttle. ECA10370 ECA10270 CAUTION If any engine trouble should occur during the engine break-in period, immediately have a Yamaha dealer check the vehicle. EAU17180 Parking When parking, stop the engine, remove the key from the main switch, and then turn the fuel cock lever to "OFF". EWA10310 CAUTION After 1000 km (600 mi) of operation, the transmission oil must be changed. 1000 km (600 mi) and beyond Avoid prolonged full-throttle operation. Vary the engine speed occasionally. s WARNING q Since the engine and exhaust system can become very hot, park in a place where pedestrians or children are not likely to touch them. q Do not park on a slope or on soft ground, otherwise the vehicle may overturn. ECA10380 5 CAUTION Never park in an area where there are fire hazards such as grass or other flammable materials. 5-3 PERIODIC MAINTENANCE AND MINOR REPAIR EAU17240 EAU17320 EWA10350 6 Safety is an obligation of the owner. Periodic inspection, adjustment and lubrication will keep your vehicle in the safest and most efficient condition possible. The most important points of inspection, adjustment, and lubrication are explained on the following pages. The intervals given in the periodic maintenance and lubrication chart should be simply considered as a general guide under normal riding conditions. However, DEPENDING ON THE WEATHER, TERRAIN, GEOGRAPHICAL LOCATION, AND INDIVIDUAL USE, THE MAINTENANCE INTERVALS MAY NEED TO BE SHORTENED. EWA10320 Owner's tool kit 1 s WARNING Modifications not approved by Yamaha may cause loss of performance and render the vehicle unsafe for use. Consult a Yamaha dealer before attempting any changes. 1. Tool kit s WARNING If you are not familiar with maintenance work, have a Yamaha dealer do it for you. The service information included in this manual and the tools provided in the owner's tool kit are intended to assist you in the performance of preventive maintenance and minor repairs. However, additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly. NOTE: If you do not have the tools or experience required for a particular job, have a Yamaha dealer perform it for you. 6-1 PERIODIC MAINTENANCE AND MINOR REPAIR EAU17710 Periodic maintenance and lubrication chart NOTE: q The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead. q From 30000 km, repeat the maintenance intervals starting from 6000 km. q Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. ODOMETER READING (x 1000 Km) No ANNUAL CHECK ITEM CHECK OR MAINTENANCE JOB · Check fuel hoses for cracks or damage. · Replace. · Clean. · Replace. · Check operation. · Adjust. · Check operation, fluid level and vehicle for fluid leakage. · Replace brake pads. · Check operation, fluid level and vehicle for fluid leakage. · Replace brake pads. · Check for cracks or damage. · Replace. · Check runout, spoke tightness and for damage. · Tighten spokes if necessary. 6-2 1 6 12 18 24 1 * Fuel line 2 3 4 Spark plug Air filter element Clutch 6 5 * Front brake 6 * Rear brake 7 * Brake hoses 8 * Wheels Whenever worn to the limit Whenever worn to the limit Every 4 years PERIODIC MAINTENANCE AND MINOR REPAIR ODOMETER READING (x 1000 Km) No ANNUAL CHECK ITEM · · · · CHECK OR MAINTENANCE JOB Check tread depth and for damage. Replace if necessary. Check air pressure. Correct if necessary. 1 6 12 18 24 9 * Tires 10 * Wheel bearings 11 * Swingarm · Check bearing for looseness or damage. · Check operation and for excessive play. · Lubricate with lithium-soap-based grease. · Check chain slack, alignment and condition. · Adjust and lubricate chain with a special O-ring chain lubricant thoroughly. · Check bearing play and steering for roughness. · Lubricate with lithium-soap-based grease. · Make sure that all nuts, bolts and screws are properly tightened. · Check operation. · Lubricate. · Check operation. · Check operation and for oil leakage. Every 24000 km 12 Drive chain Every 500 km and after washing the motorcycle or riding in the rain Every 50000 km 13 * Steering bearings 6 14 * Chassis fasteners 15 Sidestand 16 * Sidestand switch 17 * Front fork 18 * Shock absorber assembly ·Check operation and shock absorber for oil leakage. Rear suspension relay · Check operation. 19 * arm and connecting arm · Lubricate with lithium-soap-based grease. pivoting points 20 * Carburetor 21 * Autolube pump · Check starter (choke) operation. · Adjust engine idling speed. · Check operation. · Bleed if necessary. 6-3 PERIODIC MAINTENANCE AND MINOR REPAIR ODOMETER READING (x 1000 Km) No ANNUAL CHECK ITEM Transmission oil CHECK OR MAINTENANCE JOB · Check oil level. · Change. · Check coolant level and vehicle for coolant leakage. · Change. · Check operation. 1 6 12 18 24 22