User manual YAMAHA TDR125-2002

OWNER'S MANUAL TDR125 5AE-28199-E5 EAU03338 INTRODUCTION Welcome to the Yamaha world of motorcycling! As the owner of a TDR125, 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 TDR125. 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! 1 EAU00005 IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following notations: 1 Q w 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. cC NOTE: 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 you have any questions concerning this manual, please consult your Yamaha dealer. IMPORTANT MANUAL INFORMATION w EW000002 PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE. 1 1 EAU03337 TDR125 OWNER'S MANUAL ©2001 by Yamaha Motor Co., Ltd. 1st Edition, May 2001 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 and instruments ............................... 2-3 INSTRUMENT AND CONTROL FUNCTIONS ..... 3-1 Main switch/steering lock ............................... 3-1 Indicator and warning lights ........................... 3-2 Speedometer unit ........................................... 3-3 Tachometer .................................................... 3-3 Coolant temperature gauge ........................... 3-4 Handlebar switches ........................................ 3-4 Clutch lever .................................................... 3-6 Shift pedal ...................................................... 3-6 Brake lever ..................................................... 3-7 Brake pedal .................................................... 3-7 Fuel tank cap ................................................. 3-7 Fuel (except for Switzerland and Austria) ...... 3-8 Fuel (for Switzerland and Austria)................... 3-8 Catalytic converter (for Switzerland and Austria) ........................ 3-9 2-stroke engine oil ........................................ 3-10 Fuel cock ...................................................... 3-11 Starter (choke) lever .................................... 3-12 Seat .............................................................. 3-12 Helmet holder ............................................... 3-13 Adjusting the shock absorber assembly ........3-13 YEIS handling precautions ........................... 3-14 YPVS ........................................................... 3-15 Sidestand ..................................................... 3-15 Ignition circuit cut-off system ........................ 3-16 3 4 PRE-OPERATION CHECKS ............................ 4-1 Pre-operation check list ................................. 4-1 OPERATION AND IMPORTANT RIDING POINTS ............................................................. 5-1 Starting a cold engine .................................... 5-1 Starting a warm engine .................................. 5-2 Shifting ........................................................... 5-3 Recommended shift points (for Switzerland only) ................................... 5-3 Tips for reducing fuel consumption ............... 5-4 Engine break-in .............................................. 5-4 Parking ........................................................... 5-5 PERIODIC MAINTENANCE AND MINOR REPAIR ............................................................. 6-1 Owner's tool kit .............................................. 6-1 Periodic maintenance and lubrication chart ... 6-2 Removing and installing the cowlings and panel ............................................................ 6-5 5 6 TABLE OF CONTENTS Checking the spark plug ................................ 6-7 Transmission oil ............................................. 6-8 Coolant ......................................................... 6-10 Cleaning the air filter element ..................... 6-13 Adjusting the carburetor ............................... 6-15 Adjusting the engine idling speed ................ 6-16 Adjusting the throttle cable free play ............ 6-17 Tires ............................................................. 6-17 Cast wheels ................................................. 6-19 Adjusting the clutch lever free play .............. 6-20 Adjusting the brake lever free play ............... 6-21 Adjusting the brake pedal position ............... 6-22 Adjusting the rear brake light switch ............ 6-22 Checking the front and rear brake pads ....... 6-23 Checking the brake fluid level ...................... 6-24 Changing the brake fluid .............................. 6-25 Drive chain slack .......................................... 6-25 Lubricating the drive chain ........................... 6-26 Checking and lubricating the cables ............ 6-27 Checking and lubricating the throttle grip and cable ................................................... 6-28 Adjusting the Autolube pump ....................... 6-28 Checking and lubricating the brake and shift pedals ................................................. 6-29 Checking and lubricating the brake and clutch levers .................................................6-29 Checking and lubricating the sidestand ....... 6-29 Lubricating the rear suspension ................... 6-30 Checking the front fork ................................. 6-30 Checking the steering .................................. 6-31 Checking the wheel bearings ....................... 6-32 Battery .......................................................... 6-32 Replacing the fuse ....................................... 6-33 Replacing a headlight bulb ........................... 6-34 Replacing the tail/brake light bulb ................ 6-35 Replacing a turn signal light bulb ................. 6-36 Supporting the motorcycle ........................... 6-37 Front wheel .................................................. 6-37 Rear wheel ................................................... 6-39 Troubleshooting ........................................... 6-41 Troubleshooting charts ................................ 6-42 7 MOTORCYCLE CARE AND STORAGE ........... 7-1 Care ............................................................... 7-1 Storage .......................................................... 7-4 SPECIFICATIONS ............................................ 8-1 Conversion table ............................................ 8-5 CONSUMER INFORMATION .............................9-1 Identification numbers .................................... 9-1 Key identification number ............................... 9-1 Vehicle identification number ......................... 9-1 Model label ..................................................... 9-2 8 9 EAU00021 QGIVE SAFETY THE RIGHT OF WAY 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 value and operating condition of your motorcycle. 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. Although 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 1-1 EAU00026 DESCRIPTION Left view 1 2 3 4 2 7 1. 2. 3. 4. 5. Headlight Fuel cock 2-stroke engine oil tank Helmet holder Starter (choke) lever 6 5 6. YEIS 7. YPVS (page 3-14) (page 3-15) (page 6-34) (page 3-11) (page 3-10) (page 3-13) (page 3-12) 2-1 DESCRIPTION Right view 89 10 11 2 14 13 12 8. 9. 10. 11. 12. 13. Owner's tool kit Fuse Air filter element Radiator cap Brake pedal Coolant reservoir tank (page 6-1) 14. Shock absorber spring preload (page 6-33) adjusting ring (page 6-13) (page 6-11) (page 3-7, 6-22) (page 6-10) 2-2 (page 3-13) DESCRIPTION Controls and instruments 1 2 3 4 5 6 7 2 10 9 8 1. 2. 3. 4. 5. Clutch lever Left handlebar switches Speedometer unit Coolant temperature gauge Tachometer (page 3-6, 6-20) (page 3-4) (page 3-3) (page 3-4) (page 3-3) 6. 7. 8. 9. 10. 2-3 Right handlebar switches Brake lever Throttle grip Fuel tank cap Main switch/steering lock (page 3-6) (page 3-7, 6-21) (page 6-17, 6-28) (page 3-7) (page 3-1) EAU00027 INSTRUMENT AND CONTROL FUNCTIONS OFF O PUSH ON ON FF YM -8 a b w EW000016 LOCK PARKING P IG N I TI EAU00029 a. Push. b. Turn. EAU00040 Never turn the key to "OFF" or "LOCK" while the motorcycle is moving, otherwise the electrical systems will be switched off, which may result in loss of control or an accident. Make sure that the motorcycle is stopped before turning the key to "OFF" or "LOCK". EAU01574 O Main switch/steering lock The main switch/steering lock controls the ignition and lighting systems, and is used to lock the steering. The various positions are described below. EAU00036 ON All electrical systems are supplied with power, and the engine can be started. The key cannot be removed. EAU00038 OFF All electrical systems are off. The key can be removed. LO C N 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 . (Parking) The steering is locked, and the taillights and auxiliary lights are on, but all other electrical systems are off. The key can be removed. The steering must be locked before the key can be turned to ".". cC ECA00043 Do not use the parking position for an extended length of time, otherwise the battery may discharge. INSTRUMENT AND CONTROL FUNCTIONS EAU04304 EAU00061 1 2 3 1. 2. 3. 4. 4 3 2-stroke engine oil level warning light "7" This warning light comes on when the 2-stroke engine oil level is low. The electrical circuit of the warning light can be checked according to the following procedure. 1. Set the engine stop switch to "#" and turn the key to "ON". 2. Shift the transmission into the neutral position or pull the clutch lever. 3. Push the start switch. If the warning light does not come on while pushing the start switch, have a Yamaha dealer check the electrical circuit. NOTE: Even if the 2-stroke engine oil level is sufficient, the warning light may flicker when riding on a slope or during sudden acceleration or deceleration, but this is not a malfunction. 3-2 Neutral indicator light "N" This indicator light comes on when the transmission is in the neutral position. Turn signal indicator light "5" High beam indicator light "&" 2-stroke enjine oil level warning light "7" Neutral indicator light "N" EAU03034 Indicator and warning lights EAU00057 Turn signal indicator light "5" This indicator light flashes when the turn signal switch is pushed to the left or right. EAU00063 High beam indicator light "&" This indicator light comes on when the high beam of the headlight is switched on. INSTRUMENT AND CONTROL FUNCTIONS 2 1 NOTE: Only for the German model equipped with a speed limiter: The speed limiter prevents the motorcycle from exceeding a riding speed of 80 km/h. 1 2 3 1. Tachometer 2. Red zone EAU00102 4 3 1. 2. 3. 4. Speedometer Odometer Tripmeter Reset knob EAU01087 Tachometer The tachometer allows the rider to monitor the engine speed and keep it within the ideal power range. Speedometer unit 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. 3-3 cC EC000003 Do not operate the engine in the tachometer red zone. Red zone: 10,000 r/min and above INSTRUMENT AND CONTROL FUNCTIONS EAU03889 1 2 1 2 3 1. Coolant temperature gauge 2. Red zone EAU01652 3 4 Turn signal switch "4/6" To signal a right-hand turn, push this switch to "6". To signal a left-hand turn, push this switch to "4". 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. Coolant temperature gauge With the key in the "ON" position, the coolant temperature gauge indicates the temperature of the coolant. The coolant temperature varies with changes in the weather and engine load. If the needle reaches or enters the red zone, stop the motorcycle and let the engine cool. (See page 6-43 for further instructions.) 1. 2. 3. 4. Light switch "9/'/:" Dimmer switch "&/%" Turn signal switch "4/6" Horn switch "*" EAU00118 EAU00129 Handlebar switches EAU03898 Horn switch "*" Press this switch to sound the horn. Light switch "9/'/:" Set this switch to "'" to turn on the auxiliary light, meter lighting and taillight. Set the switch to ":" to turn on the headlight also. Set the switch to "9" to turn off all the lights. EAU03888 cC EC000002 Do not operate the engine if it is overheated. Dimmer switch "&/%" Set this switch to "&" for the high beam and to "%" for the low beam. 3-4 INSTRUMENT AND CONTROL FUNCTIONS EAU00136 Headlight variations Left 1 Right ' ' 3 : High beam light on , : Auxiliary light on 2 : Low beam light on Destination Bulb to be used Halogen bulb Halogen bulb 12V 60/55W 12V 60/55W & % 3 ' 2 3 2 France Sweden Portugal Spain Greece Belgium Germany Switzerland Finland Austria England Ireland 2 & % 3 2 3 12V 35/35W 12V 35/35W NOTE: Right and left are defined as seen when standing in front of the motorcycle. 3-5 INSTRUMENT AND CONTROL FUNCTIONS 1 1 3 2 1. Engine stop switch "#/$" 2. Start switch "," EAU03890 1 1. Clutch lever EAU00152 1. Shift pedal EAU00157 Engine stop switch "#/$" Set this switch to "#" before starting the engine. Set this switch to "$" to stop the engine in case of an emergency, such as when the motorcycle overturns or when the throttle cable is stuck. EAU00143 Clutch lever 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 3-16 for an explanation of the ignition circuit cut-off system.) Shift pedal 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. Start switch "," Push this switch to crank the engine with the starter. cC EC000005 See page 5-1 for starting instructions prior to starting the engine. 3-6 INSTRUMENT AND CONTROL FUNCTIONS 1 b a 1 1 1. Brake lever EAU00158 3 1. Brake pedal EAU00162 Brake lever The brake lever is located at the right handlebar grip. To apply the front brake, pull the lever toward the handlebar grip. Brake pedal 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 lock cover a. Open. b. Unlock. EAU02935 Fuel tank cap To open the fuel tank cap Open the fuel tank cap lock cover, insert the key into the lock, and then turn it 1/4 turn clockwise. The lock will be released and the fuel tank cap can be opened. To close the fuel tank cap 1. Push the fuel tank cap into position with the key inserted in the lock. 2. Turn the key counterclockwise to the original position, remove it, and then close the lock cover. 3-7 INSTRUMENT AND CONTROL FUNCTIONS NOTE: The fuel tank cap cannot be closed unless the key is in the lock. In addition, the key cannot be removed if the cap is not properly closed and locked. 3 2 2 1 4 5 1 3 w EWA00025 Make sure that the fuel tank cap is properly closed before riding. 1. Filler tube 2. Fuel level EAU03753 Fuel (except for Switzerland and Austria) Make sure that there is sufficient fuel in the tank. Fill the fuel tank to the bottom of the filler tube as shown. 1. 2. 3. 4. 5. Pump nozzle Fuel tank filler hole Filler tube Fuel level Leaf valve EAU03754 Fuel (for Switzerland and Austria) 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. w EW000130 8 Do not overfill the fuel tank, otherwise it may overflow when the fuel warms up and expands. 8 Avoid spilling fuel on the hot engine. 3-8 INSTRUMENT AND CONTROL FUNCTIONS w EW000130 EAU04206 EAU01084 8 Do not overfill the fuel tank, otherwise it may overflow when the fuel warms up and expands. 8 Avoid spilling fuel on the hot engine. Recommended fuel: REGULAR UNLEADED GASOLINE ONLY Fuel tank capacity: Total amount: 11.0 L Reserve amount: 2.2 L 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. Catalytic converter (for Switzerland and Austria) This motorcycle is equipped with a catalytic converter in the exhaust chamber. w EW000128 cC EAU00185 Immediately wipe off spilled fuel with a clean, dry, soft cloth, since fuel may deteriorate painted surfaces or plastic parts. The exhaust system is hot after operation. Make sure that the exhaust system has cooled down before doing any maintenance work. 3 3-9 INSTRUMENT AND CONTROL FUNCTIONS cC EC000114 1 3 The following precautions must be observed to prevent a fire hazard or other damages. 8 Use only unleaded gasoline. The use of leaded gasoline will cause unrepairable damage to the catalytic converter. 8 Never park the motorcycle near possible fire hazards such as grass or other materials that easily burn. 8 Do not allow the engine to idle too long. Recommended oil: Yamalube 2 or equivalent 2-stroke engine oil (JASO grade "FC", or ISO grades "EG-C" or "EG-D") Oil quantity: 1.2 L 1. 2-stroke engine oil tank cap EAU03750 2-stroke engine oil 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. 3-10 INSTRUMENT AND CONTROL FUNCTIONS OFF: closed position ON: normal position RES: reserve position RES OFF 1 1. Arrow mark positioned over "OFF" EAU03050 1 ON 1 1. Arrow mark positioned over "RES" 3 1. Arrow mark positioned over "ON" 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. 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! 3-11 INSTRUMENT AND CONTROL FUNCTIONS a a 1 1 3 b 1. Starter (choke) lever "1" EAU03839 2 a. Unlock. EAU01619 1. Projection 2. Seat holder Starter (choke) lever "1" 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). Seat To remove the seat 1. Insert the key into the seat lock, and then turn it clockwise. 2. Pull the seat off. To install the seat 1. Insert the projection on the front of the seat into the seat holder as shown. 2. Push the rear of the seat down to lock it in place. 3. Turn the key counterclockwise, and then remove it. NOTE: Make sure that the seat is properly secured before riding. 3-12 INSTRUMENT AND CONTROL FUNCTIONS EAU00295 Adjusting the shock absorber assembly a This shock absorber assembly is equipped with a spring preload adjusting ring. 1 b a 3 1. Spring preload adjusting ring cC a. Open. EAU00260 EC000015 Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings. Helmet holder To open the helmet holder, insert the key into the lock, and then turn the key as shown. To lock the helmet holder, place it in the original position, and then remove the key. Adjust the spring preload as follows. To increase the spring preload and thereby harden the suspension, turn the adjusting ring in direction a. To decrease the spring preload and thereby soften the suspension, turn the adjusting ring in direction b. NOTE: Align the appropriate notch in the adjusting ring with the position indicator on the shock absorber. w EW000030 Never ride with a helmet attached to the helmet holder, since the helmet may hit objects, causing loss of control and possibly an accident. 3-13 EAU00027 INSTRUMENT AND CONTROL FUNCTIONS 1 2 3 4 5 6 7 8 9 w EAU00315 3 1 1. Position indicator Setting Minimum (soft) Standard Maximum (hard) 1 4 9 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. 8 Do not tamper with or attempt to open the gas cylinder. 8 Do not subject the shock absorber to an open flame or other high heat sources, otherwise it may explode due to excessive gas pressure. 8 Do not deform or damage the gas cylinder in any way, as this will result in poor damping performance. 8 Always have a Yamaha dealer service the shock absorber. 1 1. YEIS EAU00325 YEIS handling precautions 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. cC EC000022 Do not attempt to modify the YEIS in any way. 3-14 INSTRUMENT AND CONTROL FUNCTIONS cC 1 EC000023 EAU00330 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. 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.) 3 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: 8 When the key is turned to "ON" and the engine is started. 8 When the engine stalls with the key in the "ON" position. 1. YPVS EAU00326 YPVS 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. cC EC000024 If the YPVS does not operate, have a Yamaha dealer check it. 3-15 INSTRUMENT AND CONTROL FUNCTIONS w EW000044 EAU03720 3 The motorcycle 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. Ignition circuit cut-off system The ignition circuit cut-off system (comprising the sidestand switch, clutch switch and neutral switch) has the following functions. 8 It prevents starting when the transmission is in gear and the sidestand is up, but the clutch lever is not pulled. 8 It prevents starting when the transmission is in gear and the clutch lever is pulled, but the sidestand is still down. 8 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. w EW000045 If a malfunction is noted, have a Yamaha dealer check the system before riding. 3-16 INSTRUMENT AND CONTROL FUNCTIONS With the engine turned off: 1. Move the sidestand down. 2. Make sure that the engine stop switch is set to "#". 3. Turn the key to "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. 3-17 EAU01114 PRE-OPERATION CHECKS 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. EAU03439 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 lever free play. Adjust if necessary. Check fluid level in reservoir. If necessary, add recommended brake fluid to specified level. Check hydraulic system for leakage. PAGE 3-7­3-9 4 2-stroke engine oil Transmission oil Coolant 3-10 6-8­6-10 6-10­6-13 Front brake 3-7, 6-21, 6-23­6-24 4-1 PRE-OPERATION CHECKS ITEM · · · · · · · · · · · · · · · · · · · · · · · · · · · · CHECKS Check operation. If soft or spongy, have Yamaha dealer bleed hydraulic system. 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 free play. If neccessary, have Yamaha dealer make adjustment or lubricate. 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. PAGE Rear brake 3-7, 6-22­6-24 Clutch 3-6, 6-20­6-21 Throttle grip Control cables 6-17, 6-28 4 6-27 Drive chain 6-25­6-27 Wheels and tires 6-17­6-19 Brake and shift pedals Brake and clutch levers Sidestand 6-29 6-29 6-29­6-30 4-2 PRE-OPERATION CHECKS ITEM Chassis fasteners Instruments, lights, signals and switches Sidestand switch · · · · CHECKS Make sure that all nuts, bolts and screws are properly tightened. Tighten if necessary. Check operation. Correct if necessary. PAGE -- 3-2­3-6 3-15­3-17 · Check operation of ignition circuit cut-off system. · If system is defective, have Yamaha dealer check vehicle. 4 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 EWA00033 If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operating the motorcycle. 4-3 EAU00372 OPERATION AND IMPORTANT RIDING POINTS w EAU00373 EAU04271 Starting a cold engine In order for the ignition circuit cut-off system to enable starting, one of the following conditions must be met: 8 The transmission is in the neutral position. 8 The transmission is in gear with the clutch lever pulled and the sidestand up. 3. Shift the transmission into the neutral position. 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 3-12 for starter (choke) operation.) 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. 8 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. 8 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. 8 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. w EW000054 8 Before starting the engine, check the function of the ignition circuit cut-off system according to the procedure described on page 3-17. 8 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 "#". 5 5-1 OPERATION AND IMPORTANT RIDING POINTS cC ECA00106 cC ECA00045 EAU01258 Starting a warm engine 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. 5 The 2-stroke engine oil level warning light should come on when the start switch is pushed, and it should go off when the start switch is released. If the warning light flickers or remains on after starting, immediately stop the engine, and then check the 2-stroke engine oil level and the vehicle for oil leakage. If necessary, add 2-stroke engine oil, and then check the warning light again. If the warning light does not come on when pushing the start switch, or if it does not go off after starting with sufficient 2-stroke engine oil, have a Yamaha dealer check the electrical circuit. 6. After starting the engine, move the starter (choke) lever back halfway. For maximum engine life, never accelerate hard when the engine is cold! 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. 5-2 OPERATION AND IMPORTANT RIDING POINTS cC 6 5 4 3 2 N 1 EC000048 EAU02937 1 1. Shift pedal N. Neutral position EAU00423