User manual YAMAHA YBR 125 ED

OWNER'S MANUAL YBR125ED 3D9-F8199-EA INTRODUCTION EAU10100 Welcome to the Yamaha world of motorcycling! As the owner of the YBR125ED, 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 YBR125ED. 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 EAU10151 Particularly important information is distinguished in this manual by the following notations: 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. WARNING CAUTION: NOTE: NOTE: G This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold. G 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 WARNING PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE. *Product and specifications are subject to change without notice. IMPORTANT MANUAL INFORMATION EAU37230 YBR125ED OWNER'S MANUAL ©2006 by Yamaha Motor Co., Ltd. 1st edition, December 2006 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in China. TABLE OF CONTENTS SAFETY INFORMATION ..................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 lights ................................3-2 Speedometer unit ...........................3-2 Tachometer ....................................3-3 Fuel gauge ......................................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 Fuel .................................................3-6 Catalytic converter ..........................3-7 Fuel cock ........................................3-7 Starter (choke) lever ........................3-8 Kickstarter .......................................3-9 Adjusting the shock absorber assemblies ..................................3-9 Carrier ...........................................3-10 Luggage strap holders ..................3-10 Sidestand ......................................3-10 Ignition circuit cut-off system ........3-11 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 Tips for reducing fuel consumption ............................... 5-3 Engine break-in .............................. 5-3 Parking ........................................... 5-4 PERIODIC MAINTENANCE AND MINOR REPAIR ................................. 6-1 Owner's tool kit ............................... 6-1 Periodic maintenance and lubrication chart .......................... 6-2 Removing and installing panels ..... 6-6 Checking the spark plug ................. 6-7 Engine oil ....................................... 6-9 Cleaning the air filter element ...... 6-10 Adjusting the carburetor ............... 6-12 Adjusting the engine idling speed ........................................ 6-12 Adjusting the throttle cable free play .................................... 6-13 Valve clearance ............................ 6-14 Tires ............................................. 6-14 Cast wheels .................................. 6-16 Adjusting the clutch lever free play .................................... 6-16 Checking the front brake lever free play .................................... 6-17 Adjusting the brake pedal free play .................................... 6-18 Adjusting the rear brake light switch ................................ 6-18 Checking the front brake pads and rear brake shoes ............... 6-19 Checking the front brake fluid level .................................. 6-20 Changing the brake fluid .............. 6-21 Drive chain slack .......................... 6-21 Cleaning and lubricating the drive chain .......................... 6-22 Checking and lubricating the cables ................................. 6-23 Checking and lubricating the throttle grip and cable ......... 6-23 Checking and lubricating the brake and shift pedals ........ 6-24 Checking and lubricating the brake and clutch levers ...... 6-24 Checking and lubricating the centerstand and sidestand ....... 6-25 Lubricating the swingarm pivots ........................................ 6-25 Checking the front fork ................. 6-26 Checking the steering .................. 6-26 Checking the wheel bearings ....... 6-27 TABLE OF CONTENTS Battery ..........................................6-27 Replacing the fuse ........................6-29 Replacing the headlight bulb ........6-30 Replacing the tail/ brake light bulb ..........................6-32 Replacing a turn signal light bulb ....................................6-32 Replacing the auxiliary light bulb ....................................6-33 Front wheel ...................................6-33 Rear wheel ...................................6-35 Troubleshooting ............................6-37 Troubleshooting chart ...................6-38 MOTORCYCLE CARE AND STORAGE ..........................................7-1 Matte color caution .........................7-1 Care ................................................7-1 Storage ...........................................7-3 SPECIFICATIONS .............................8-1 CONSUMER INFORMATION.............9-1 Identification numbers ....................9-1 SAFETY INFORMATION EAU10251 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: G OBTAIN THOROUGH INSTRUCTIONS FROM A COMPETENT SOURCE ON ALL ASPECTS OF MOTORCYCLE OPERATION. G OBSERVE THE WARNINGS AND MAINTENANCE REQUIREMENTS IN THE OWNER'S MANUAL. G OBTAIN QUALIFIED TRAINING IN SAFE AND PROPER RIDING TECHNIQUES. G OBTAIN PROFESSIONAL TECHNICAL SERVICE AS INDICATED BY THE OWNER'S MANUAL AND/OR WHEN MADE NECESSARY BY MECHANICAL CONDITIONS. G Safe riding G Always make pre-operation checks. Careful checks may help prevent an accident. G This motorcycle is designed to carry the operator and a passenger. G 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. 1-1 G · Ride where other motorists can see you. Avoid riding in another motorist's blind spot. Many motorcycle 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 motorcycle accidents have been caused by error of the motorcycle operator. A typical error made by the operator is veering SAFETY INFORMATION wide on a turn due to EXCESSIVE SPEED or undercornering (insufficient lean angle for the speed). · 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, 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. G This motorcycle is designed for onroad use only, therefore, it is not suitable for off-road use. G G G 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. G Always wear an approved helmet. G Wear a face shield or goggles. Wind in your unprotected eyes could contribute to an impairment of vision which could delay seeing a hazard. G The use of a jacket, heavy boots, trousers, gloves, etc., is effective in preventing or reducing abrasions or lacerations. G Never wear loose-fitting clothes, otherwise they could catch on the control levers, footrests, or wheels and cause injury or an accident. G 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. Passengers should also observe the precautions mentioned above. 1 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. 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: 1-2 SAFETY INFORMATION Loading The total weight of the operator, passenger, accessories and cargo must not exceed the maximum load limit. Maximum load: 198 kg (437 lb) 1 When loading within this weight limit, keep the following in mind: G 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. G 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. G 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 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. G 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. · 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 opera- 1-3 SAFETY INFORMATION tor 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. G G Gasoline and exhaust gas G 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. G 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. G G 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. · 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 is turned to "ON" or "RES" (for vacuum type) / "OFF" (for manual type). If it 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 1-4 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 2 1. 2. 3. 4. 5. 6. 7. 8. Headlight (page 6-30) Fuel cock (page 3-7) Fuse (page 6-29) Battery (page 6-27) Owner's tool kit (page 6-1) Luggage strap holder (page 3-10) Shock absorber assembly spring preload adjusting ring (page 3-9) Engine oil drain bolt (page 6-9) 2-1 9. Shift pedal (page 3-4) DESCRIPTION EAU10420 Right view 2 1. 2. 3. 4. 5. 6. 7. Carrier (page 3-10) Air filter element (page 6-10) Engine oil filler cap (page 6-9) Brake pedal (page 3-5) Kickstarter (page 3-9) Shock absorber assembly spring preload adjusting ring (page 3-9) Luggage strap holder (page 3-10) 2-2 DESCRIPTION EAU10430 Controls and instruments 2 1. 2. 3. 4. 5. 6. 7. 8. Clutch lever (page 3-4) Left handlebar switches (page 3-3) Main switch/steering lock (page 3-1) Speedometer (page 3-2) Fuel gauge (page 3-3) Tachometer (page 3-3) Right handlebar switch (page 3-3) Brake lever (page 3-5) 2-3 9. Throttle grip (page 6-13) 10.Fuel tank cap (page 3-5) INSTRUMENT AND CONTROL FUNCTIONS EAU10460 EAU10660 Main switch/steering lock OFF All electrical systems are off. The key can be removed. EAU43140 To unlock the steering LOCK The steering is locked, and all electrical systems are off. The key can be removed. To lock the steering The main switch/steering lock controls the ignition and lighting systems, and is used to lock the steering. The various positions are described below. EAU33590 3 1. Turn. Insert the key and turn it to "OFF". EWA10060 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". ON All electrical circuits are supplied with power; the meter lighting, taillight and auxiliary light come on, and the engine can be started. The key cannot be removed. NOTE: The headlight comes on automatically when the engine is started and stays on until the key is turned to "OFF", even if the engine stalls. 1. Push. 2. Turn. 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. 3-1 INSTRUMENT AND CONTROL FUNCTIONS EAU10980 EAU11080 EAU11630 Indicator lights High beam indicator light " " This indicator light comes on when the high beam of the headlight is switched on. Speedometer unit 3 1. 2. 3. 4. Left turn signal indicator light " " Neutral indicator light " " High beam indicator light " " Right turn signal indicator light " " EAU11030 1. 2. 3. 4. Speedometer Odometer Tripmeter Tripmeter reset knob Turn signal indicator lights " " and "" The corresponding indicator light flashes when the turn signal switch is pushed to the left or right. EAU11060 Neutral indicator light " " This indicator light comes on when the transmission is in the neutral position. 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. 3-2 INSTRUMENT AND CONTROL FUNCTIONS EAU11851 EAU37051 EAU12347 Tachometer Fuel gauge Handlebar switches Left 3 1. Tachometer 2. Tachometer red zone 1. Fuel gauge 2. Red zone The electric tachometer allows the rider to monitor the engine speed and keep it within the ideal power range. ECA10031 CAUTION: Do not operate the engine in the tachometer red zone. Red zone: 10000 r/min and above The fuel gauge indicates the amount of fuel in the fuel tank. The needle moves towards "E" (Empty) as the fuel level decreases. When the needle reaches the red zone, approximately 1.7 L (0.45 US gal) (0.37 Imp.gal) remain in the fuel tank. If this occurs, refuel as soon as possible. NOTE: G Do not allow the fuel tank to empty itself completely. G The main switch must be turned to "ON" for the fuel gauge to display an accurate fuel level reading. 3-3 1. Dimmer switch " / " 2. Turn signal switch " / " 3. Horn switch " " Right 1. Start switch " " INSTRUMENT AND CONTROL FUNCTIONS EAU12400 EAU12820 EAU12870 Dimmer switch " / " Set this switch to " " for the high beam and to " " for the low beam. EAU12460 Clutch lever Shift pedal 3 Turn signal switch " / " To signal a right-hand turn, push this switch to " ". To signal a left-hand turn, push this switch to " ". 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 1. Clutch lever 1. Shift pedal Horn switch " " Press this switch to sound the horn. EAU12710 Start switch " " Push this switch to crank the engine with the starter. ECA10050 CAUTION: See page 5-1 for starting instructions prior to starting the engine. 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 5-speed constant-mesh transmission equipped on this motorcycle. 3-4 INSTRUMENT AND CONTROL FUNCTIONS EAU12890 EAU12941 EAU13001 Brake lever Brake pedal Fuel tank cap 3 1. Brake lever 1. Brake pedal 1. Unlock. 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. To remove the fuel tank cap Insert the key into the lock and turn it 1/4 turn clockwise. The lock will be released and the fuel tank cap can be removed. To install 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, and then remove it. 3-5 INSTRUMENT AND CONTROL FUNCTIONS EAU13220 ECA10070 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. EWA11140 Fuel CAUTION: Immediately wipe off spilled fuel with a clean, dry, soft cloth, since fuel may deteriorate painted surfaces or plastic parts. EAU13320 WARNING 3 Make sure that the fuel tank cap is properly installed before riding. 1. Fuel tank filler tube 2. Fuel level 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. EWA10880 Recommended fuel: REGULAR UNLEADED GASOLINE ONLY Fuel tank capacity: 12.0 L (3.17 US gal) (2.64 Imp.gal) Fuel reserve amount: 1.7 L (0.45 US gal) (0.37 Imp.gal) ECA11400 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 WARNING G G Do not overfill the fuel tank, otherwise it may overflow when the fuel warms up and expands. Avoid spilling fuel on the hot engine. 3-6 INSTRUMENT AND CONTROL FUNCTIONS or premium unleaded fuel. Use of unleaded fuel will extend spark plug life and reduce maintenance costs. EAU13431 EAU37210 Catalytic converter This model is equipped with a catalytic converter in the exhaust system. EWA10860 Fuel cock The fuel cock supplies fuel from the tank to the carburetor while filtering it also. NOTE: Depending on the model, the positions indicated on the fuel cock differ as shown in the following illustrations. The fuel cock has three positions: "OFF" or " " WARNING The exhaust system is hot after operation. Make sure that the exhaust system has cooled down before doing any maintenance work. ECA10700 3 CAUTION: The following precautions must be observed to prevent a fire hazard or other damages. G Use only unleaded gasoline. The use of leaded gasoline will cause unrepairable damage to the catalytic converter. G Never park the vehicle near possible fire hazards such as grass or other materials that easily burn. G Do not allow the engine to idle too long. 1. Arrow mark pointing to "OFF" or " " With the lever in this position, fuel will not flow. Always return the lever to this position when the engine is not running. 3-7 INSTRUMENT AND CONTROL FUNCTIONS "ON" or " " 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" or " " after refueling! EAU13590 Starter (choke) lever " " 3 1. Arrow mark pointing to "ON" or " " 1. Starter (choke) lever " " With the lever in this position, fuel flows to the carburetor. Normal riding is done with the lever in this position. "RES" or " " 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. Arrow mark pointing to "RES" or " " 3-8 INSTRUMENT AND CONTROL FUNCTIONS EAU43150 EAU14880 EWA10210 Kickstarter Adjusting the shock absorber assemblies WARNING Always adjust both shock absorber assemblies equally, otherwise poor handling and loss of stability may result. Adjust the spring preload as follows. To increase the spring preload and thereby harden the suspension, turn the adjusting ring on each shock absorber assembly in direction (a). To decrease the spring preload and thereby soften the suspension, turn the adjusting ring on each shock absorber assembly in direction (b). NOTE: Align the appropriate notch in the adjusting ring with the position indicator on the shock absorber. Spring preload setting: Minimum (soft): 1 Standard: 2 Maximum (hard): 5 3 1. Kickstarter If the engine fails to start by pushing the start switch, try to start it by using the kickstarter. To start the engine, fold out the kickstarter lever, move it down lightly with your foot until the gears engage, and then push it down smoothly but forcefully. This model is equipped with a primary kickstarter, allowing the engine to be started in any gear if the clutch is disengaged and the sidestand is up. However, shifting the transmission into the neutral position before starting is recommended. 1. Spring preload adjusting ring 2. Position indicator Each shock absorber assembly is equipped with a spring preload adjusting ring. ECA10100 CAUTION: Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings. 3-9 INSTRUMENT AND CONTROL FUNCTIONS EAU15110 EAU15190 EAU15301 Carrier Luggage strap holders Sidestand The sidestand is located on the left side of the frame. Raise the sidestand or lower it with your foot while holding the vehicle 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 cut-off system.) EWA10240 3 1. Carrier EWA10170 1. Luggage strap holder WARNING G G There are four luggage strap holders below the rear of the seat. 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 Do not exceed the load limit of 3 kg (6.6 lb) for the carrier. Do not exceed the maximum load of 198 kg (437 lb) for the vehicle. 3-10 INSTRUMENT AND CONTROL FUNCTIONS below and have a Yamaha dealer repair it if it does not function properly. EAU43160 Ignition circuit cut-off system The ignition circuit cut-off system (comprising the sidestand switch, clutch switch and neutral switch) has the following functions. G It prevents starting when the transmission is in gear and the sidestand is up, but the clutch lever is not pulled. G It prevents starting when the transmission is in gear and the clutch lever is pulled, but the sidestand is still down. G 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. EWA10260 3 WARNING G G The vehicle must be placed on the centerstand during this inspection. If a malfunction is noted, have a Yamaha dealer check the system before riding. 3-11 INSTRUMENT AND CONTROL FUNCTIONS With the engine turned off: 1. Move the sidestand down. 2. Turn the key on. 3. Shift the transmission into the neutral position. 4. Push the start switch or push the kickstarter lever down. Does the engine start? NOTE: This check is most reliable if performed with a warmed-up engine. 3 YES With the engine still running: 5. Move the sidestand up. 6. Keep the clutch lever pulled. 7. Shift the transmission into gear. 8. 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. YES NO The sidestand switch may be defective. The motorcycle should not be ridden until checked by a Yamaha dealer. After the engine has stalled: 9. Move the sidestand up. 10. Keep the clutch lever pulled. 11. Push the start switch or push the kickstarter lever down. Does the engine start? 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. 3-12 PRE-OPERATION CHECKS EAU15592 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 WARNING If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operating the vehicle. 4 4-1 PRE-OPERATION CHECKS EAU15605 Pre-operation check list ITEM Fuel · Check fuel level in fuel tank. · Refuel if necessary. · Check fuel line for leakage. · Check oil level in engine. · If necessary, add recommended oil to specified level. · Check vehicle for oil 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. CHECKS PAGE 3-6 Engine oil 6-9 4 Front brake 6-19, 6-20 Rear brake · Check operation. · Check pedal free play. · Adjust if necessary. · · · · Check operation. Lubricate cable if necessary. Check lever free play. Adjust if necessary. 6-18, 6-19 Clutch 6-16 Throttle grip · Make sure that operation is smooth. · Check cable free play. · If necessary, have Yamaha dealer adjust cable free play and lubricate cable and grip housing. · Make sure that operation is smooth. · Lubricate if necessary. · · · · Check chain slack. Adjust if necessary. Check chain condition. Lubricate if necessary. 4-2 6-13, 6-23 Control cables 6-23 Drive chain 6-21, 6-22 PRE-OPERATION CHECKS ITEM · · · · CHECKS Check for damage. Check tire condition and tread depth. Check air pressure. Correct if necessary. PAGE Wheels and tires 6-14, 6-16 Brake and shift pedals Brake and clutch levers Centerstand, sidestand Chassis fasteners Instruments, lights, signals and switches Sidestand switch Battery · 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 pivots if necessary. · Make sure that all nuts, bolts and screws are properly tightened. · Tighten if necessary. · Check operation. · Correct if necessary. · Check operation of ignition circuit cut-off system. · If system is defective, have Yamaha dealer check vehicle. · Check fluid level. · Fill with distilled water if necessary. 6-24 6-24 6-25 4 -- -- 3-10 6-27 4-3 OPERATION AND IMPORTANT RIDING POINTS EAU15950 EAU43470 Starting a cold engine EWA10270 WARNING G G 5 G 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. 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. 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. In order for the ignition circuit cut-off system to enable starting, one of the following conditions must be met: G The transmission is in the neutral position. G 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 or by pushing the kickstarter lever down. NOTE: If the engine fails to start when using the start switch, release it, 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. If the engine does not start with the starter motor, try using the kickstarter. WARNING G G Before starting the engine, check the function of the ignition circuit cut-off system according to the procedure described on page 3-11. Never ride with the sidestand down. 1. Turn the fuel cock lever to "ON" or " ". 2. Turn the key to "ON". 3. Shift the transmission into the neutral position. 5-1 OPERATION AND IMPORTANT RIDING POINTS ECA11040 EAU16640 EAU16671 CAUTION: For maximum engine life, never accelerate hard when the engine is cold! 6. 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. 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. Shifting 1. Shift pedal 2. Neutral position 5 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. 5-2 OPERATION AND IMPORTANT RIDING POINTS ECA10260 EAU16800 EAU16830 CAUTION: G 5 G 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. 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. Tips for reducing fuel consumption Fuel consumption depends largely on your riding style. Consider the following tips to reduce fuel consumption: G Turn the starter (choke) off as soon as possible. G Shift up swiftly, and avoid high engine speeds during acceleration. G Do not rev the engine while shifting down, and avoid high engine speeds with no load on the engine. G Turn the engine off instead of letting it idle for an extended length of time (e.g., in traffic jams, at traffic lights or at railroad crossings). Engine break-in There is never a more important period in the life of your engine than the period between 0 and 1000 km (600 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. EAU37250 0­500 km (0­300 mi) Avoid prolonged operation above 6000 r/min. 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. 5-3 OPERATION AND IMPORTANT RIDING POINTS 500­1000 km (300­600 mi) Avoid prolonged operation above 7500 r/min. Rev the engine freely through the gears, but do not use full throttle at any time. ECA10280 EAU37200 Parking When parking, stop the engine, remove the key from the main switch, and then turn the fuel cock lever to "OFF" or " ". EWA10310 WARNING G CAUTION: After 1000 km (600 mi) of operation, the engine oil must be changed. 1000 km (600 mi) and beyond The vehicle can now be operated normally. ECA10310 G CAUTION: G G Since the engine and exhaust system can become very hot, park in a place where pedestrians or children are not likely to touch them. Do not park on a slope or on soft ground, otherwise the vehicle may overturn. ECA10380 5 Keep the engine speed out of the tachometer red zone. If any engine trouble should occur during the engine break-in period, immediately have a Yamaha dealer check the vehicle. CAUTION: Never park in an area where there are fire hazards such as grass or other flammable materials. 5-4 PERIODIC MAINTENANCE AND MINOR REPAIR EAU17240 EAU17340 EWA10350 Owner's tool kit 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 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. Owner's tool kit 6 WARNING If you are not familiar with maintenance work, have a Yamaha dealer do it for you. The owner's tool kit is located behind panel B. (See page 6-6.) 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 EAU17711 Periodic maintenance and lubrication chart NOTE: G The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead. G From 30000 km, repeat the maintenance intervals starting from 6000 km. G Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. ODOMETER READING (× 1000 km) NO. 1 * Fuel line 2 * Fuel cock filter 3 Spark plug ITEM CHECK OR MAINTENANCE JOB 1 · Check fuel hoses for cracks or damage. · Check condition. · Check condition. · Clean and regap. · Replace. 4 * Valves 5 Air filter element · Check valve clearance. · Adjust. · Clean. · Replace. · Check electrolyte level and specific gravity. · Make sure that the breather hose is properly routed. · Check operation. · Adjust. · Check operation, fluid level and vehicle for fluid leakage. · Replace brake pads. 6 12 18 24 ANNUAL CHECK 6 6 * Battery 7 Clutch 8 * Front brake Whenever worn to the limit 6-2 PERIODIC MAINTENANCE AND MINOR REPAIR ODOMETER READING (× 1000 km) NO. ITEM CHECK OR MAINTENANCE JOB 1 9 * Rear brake · Check operation and adjust brake pedal free play. · Replace brake shoes. · Check for cracks or damage. · Replace. · Check runout and for damage. · · · · Check tread depth and for damage. Replace if necessary. Check air pressure. Correct if necessary. 6 12 18 24 ANNUAL CHECK Whenever worn to the limit 10 * Brake hose 11 * Wheels Every 4 years 12 * Tires 13 * Wheel bearings 14 * Swingarm pivot bushes · Check bearing for looseness or damage. · Check bush assemblies for looseness. · 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. · Lubricate with lithium-soap-based grease. · Lubricate with lithium-soap-based grease. · Check operation. · Lubricate. 6-3 6 15 Drive chain Every 50000 km Every 1000 km and after washing the motorcycle or riding in the rain 16 * Steering bearings 17 * Chassis fasteners 18 19 20 Brake and clutch lever pivot shafts Brake and shift pedal pivot shafts Sidestand, centerstand Every 24000 km PERIODIC MAINTENANCE AND MINOR REPAIR ODOMETER READING (× 1000 km) NO. ITEM CHECK OR MAINTENANCE JOB 1 21 * Sidestand switch 22 * Front fork 23 * Shock absorber assemblies · Check operation. · Check operation and for oil leakage. · Check operation and shock absorbers for oil leakage. · Check starter (choke) operation. · Adjust engine idling speed. · Change. · Check oil level and vehicle for oil leakage. · Check operation. · Lubricate. · Check operation and free play. · Adjust the throttle cable free play if necessary. · Lubricate the throttle grip housing and cable. · Check the air cut-off valve, reed valve, and hose for damage. · Replace any damaged parts if necessary. · Check operation. · Adjust headlight beam. 6 12 18 24 ANNUAL CHECK 24 * Carburetor 25 26 * 27 Engine oil Front and rear brake switches Moving parts and cables Throttle grip housing and cable 6 28 * 29 * Air induction system Lights, signals and switches EAU18660 30 * NOTE: G The air filter needs more frequent service if you are riding in unusually wet or dusty areas. G Hydraulic brake service · Regularly check and, if necessary, correct the brake fluid level. 6-4 PERIODIC MAINTENANCE AND MINOR REPAIR · Every two years replace the internal components of the brake master cylinder and caliper, and change the brake fluid. · Replace the brake hoses every four years and if cracked or damaged. 6 6-5 PERIODIC MAINTENANCE AND MINOR REPAIR EAU18771 Removing and installing panels The panels shown need to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time a panel needs to be removed and installed. 1. Panel B EAU37070 2. Pull the front of the panel out, and then slide the panel forward to release it in the rear. Panel A To remove the panel 1. Remove the screw. 1. Panel A To install the panel 1. Secure the rear of the panel, and then push the front of the panel in. 6 1. Screw 2. Install the screw. 6-6 PERIODIC MAINTENANCE AND MINOR REPAIR EAU36961 EAU19603 Panel B To remove the panel 1. Slide the panel lock cover open, insert the key into the lock, and then turn it 1/4 turn clockwise. Checking the spark plug The spark plug is an important engine component, which is easy to check. Since heat and deposits will cause any spark plug to slowly erode, the spark plug should be removed and checked in accordance with the periodic maintenance and lubrication chart. In addition, the condition of the spark plug can reveal the condition of the engine. To remove the spark plug 1. Remove the spark plug cap. To install the panel 1. Secure the rear of the panel, and then push the front of the panel in with the key inserted in the lock. 6 1. Panel lock cover 2. Unlock. 2. Pull the front of the panel out with the key inserted in the lock, and then slide the panel forward to release it in the rear. 1. Spark plug cap 2. While pushing the panel inward, turn the key counterclockwise to the original position, remove it, and then close the panel lock cover. 6-7 2. Remove the spark plug as shown, with the spark plug wrench included in the owner's tool kit. PERIODIC MAINTENANCE AND MINOR REPAIR 2. Check the spark plug for electrode erosion and excessive carbon or other deposits, and replace it if necessary. Specified spark plug: NGK/CR6HSA 2. Clean the surface of the spark plug gasket and its mating surface, and then wipe off any grime from the spark plug threads. 3. Install the spark plug with the spark plug wrench, and then tighten it to the specified torque. Tightening torque: Spark plug: 12.5 Nm (1.25 m·kgf, 9.0 ft·lbf) 1. Spark plug wrench To check the spark plug 1. Check that the porcelain insulator around the center electrode of the spark plug is a medium-to-light tan (the ideal color when the vehicle is ridden normally). NOTE: If the spark plug shows a distinctly different color, the engine could be operating improperly. Do not attempt to diagnose such problems yourself. Instead, have a Yamaha dealer check the vehicle. To install the spark plug 1. Measure the spark plug gap with a wire thickness gauge and, if necessary, adjust the gap to specification. NOTE: If a torque wrench is not available when installing a spark plug, a good estimate of the correct torque is 1/4­1/2 turn past finger tight. However, the spark plug should be tightened to the specified torque as soon as possible. 4. Install the spark plug cap. 6