TZR 50 2008 user manual

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OWNER’S MANUAL
TZR50
5WX-F8199-E1
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INTRODUCTION
EAU10100
Welcome to the Yamaha world of motorcycling!

As the owner of the TZR50, 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 TZR50. The owner’s manual
does not only instruct you in how to operate, inspect and maintain your motorcycle, but also in how to safeguard your-
self 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!
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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!
s WARNING 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 motorcy-
cle.
CAUTION A CAUTION indicates special precautions that must be taken to avoid damage to
the motorcycle.
NOTE: A NOTE provides key information to make procedures easier or clearer.
NOTE:
● This manual should be considered a permanent part of this motorcycle and should remain with it even if the
motorcycle is subsequently sold.
● 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 dea-
ler.
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EWA10030
s WARNING
PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE.
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EAUS1171
TZR50
OWNER’S MANUAL
©2005 by YAMAHA MOTOR SPAIN S.A.
1st edition, January 2005
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
YAMAHA MOTOR SPAIN S.A.
is expressly prohibited.
Printed in Spain.
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TABLE OF CONTENTS
SAFETY INFORMATION .....................1-1 OPERATION AND IMPORTANT RIDING Drive Chain slack............................6-16
POINTS ................................................5-1 Checking and lubricating the
DESCRIPTION.....................................2-1 Starting a cold engine ......................5-1 cables ..........................................6-17
Left view ...........................................2-1 Shifting..............................................5-2 Checking and lubricating the brake
Right view .........................................2-2 Tips for reducing fuel consumption..5-2 and shift pedals...........................6-17
Controls and instruments .................2-3 Engine break-in.................................5-3 Checking and lubricating the brake
Parking..............................................5-3 and cluctch levers .......................6-18
INSTRUMENT AND CONTROL Checking and lubricating the
FUNCTIONS ........................................3-1 PERIODIC MAINTENANCE AND sidestand .....................................6-18
Main switch/steering lock.................3-1 MINOR RAPAIR...................................6-1 Checking the front fork...................6-18
Indicator lights ..................................3-1 Owner’s tool kit.................................6-1 Checking the steering.....................6-19
Speedometer unit .............................3-2 Periodic maintenance and lubrication Checking the wheel bearings .........6-19
Tachometer .......................................3-3 chart..................................................6-2 Battery ............................................6-19
Handlebar switches ..........................3-3 Removing and installing cowlings ....6-5 Replacing the fuse..........................6-20
Clucht lever.......................................3-4 Checking the spark plug ..................6-6 Replacing the headlight bulb..........6-21
Shift pedal.........................................3-4 Transmission oil ................................6-6 Replacing a turn signal light bulb
Brake lever........................................3-4 To check the coolant level ................6-8 or the tail/brake light bulb ...........6-21
Brake pedal.......................................3-5 Adjusting the carburetor ...................6-9 Replacing the license plate light
Fuel tank cap ....................................3-5 Adjusting the engine idling speed ....6-9 bulb .............................................6-22
Catalytic converter............................3-6 Adjusting the throttle cable free play..6-9 Supporting the mortorcycle............6-22
2-stroke engine oil ............................3-6 Tires ................................................6-10 Troubleshooting ..............................6-23
Fuel cock ..........................................3-6 Cast wheels ....................................6-12 Troubleshooting charts ...................6-24
Starter (choke) lever..........................3-7 Adjusting the clucth lever free play 6-12 Engine overheating .........................6-25
Seat...................................................3-7 Adjusting the brake pedal position
Storage compartment.......................3-7 and free play................................6-13 MOTORCYCLE CARE AND
Sidestand..........................................3-8 Adjusting the rear brake light STORAGE ............................................7-1
Ignition circuit cut-off system ...........3-8 switch ..........................................6-13 Care ..................................................7-1
Front brake pads ............................6-14 Storage ...........................................7-2
PRE-OPERATION CHECKS ...............4-1 Rear brake pads .............................6-14
Pre-operation check list....................4-2 Checking the brake fluid level ........6-14 SPECIFITACIONS ...............................8-1
Changing the brake fluid ................6-15
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TABLE OF CONTENTS
CONSUMER INFORMATION .............9-1
Identification numbers ......................9-1
Frame serial number.........................9-1
Key identification number.................9-1
Model label .......................................9-2
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SAFETY INFORMATION t
EAU10251
● OBTAIN PROFESSIONAL TECH- Therefore:
MOTORCYCLES ARE SINGLE NICAL SERVICE AS INDICATED • Wear a brightly colored jacket.
TRACK VEHICLES. THEIR SAFE USE BY THE OWNER’S MANUAL • Use extra caution when appro-
AND OPERATION ARE DEPENDENT AND/OR WHEN MADE NECES- aching and passing through 1
UPON THE USE OF PROPER RIDING SARY BY MECHANICAL CONDI- intersections, since intersec-
TECHNIQUES AS WELL AS THE TIONS. tions are the most likely places
EXPERTISE OF THE OPERATOR. for motorcycle accidents to
EVERY OPERATOR SHOULD KNOW Safe riding occur.
THE FOLLOWING REQUIREMENTS ● Always make pre-operation • Ride where other motorists can
BEFORE RIDING THIS MOTORCY- checks. Careful checks may help see you. Avoid riding in anot-
CLE. prevent an accident. her motorist’s blind spot.
HE OR SHE SHOULD: ● This motorcycle is designed to ● Many motorcycle accidents
● OBTAIN THOROUGH INSTRUC- carry the operator and a passen- involve inexperienced operators.
TIONS FROM A COMPETENT ger. In fact, many operators who have
SOURCE ON ALL ASPECTS OF ● The failure of motorists to detect been involved in accidents do not
MOTORCYCLE OPERATION. and recognize motorcycles in even have a current motorcycle
● OBSERVE THE WARNINGS AND traffic is the predominating cause license.
MAINTENANCE REQUIRE- of automobile/motorcycle acci- • Make sure that you are quali-
MENTS IN THE OWNER’S dents. Many accidents have fied and that you only lend your
MANUAL. been caused by an automobile motorcycle to other qualified
● OBTAIN QUALIFIED TRAINING driver who did not see the operators.
IN SAFE AND PROPER RIDING motorcycle. Making yourself • Know your skills and limits.
TECHNIQUES. conspicuous appears to be very Staying within your limits may
effective in reducing the chance help you to avoid an accident.
of this type of accident.
1-1
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t SAFETY INFORMATION
• We recommend that you prac- • The operator should keep both ● Always wear an approved hel-
tice riding your motorcycle hands on the handlebar and met.
where there is no traffic until both feet on the operator foo- ● Wear a face shield or goggles.
1 you have become thoroughly trests during operation to Wind in your unprotected eyes
familiar with the motorcycle maintain control of the could contribute to an impair-
and all of its controls. motorcycle. ment of vision which could delay
● Many motorcycle accidents have • The passenger should always seeing a hazard.
been caused by error of the hold onto the operator, seat ● The use of a jacket, heavy boots,
motorcycle operator. A typical strap, or grab bar, if equipped, trousers, gloves, etc., is effective
error made by the operator is with both hands and keep both in preventing or reducing abra-
veering wide on a turn due to feet on the passenger foo- sions or lacerations.
EXCESSIVE SPEED or undercor- trests. ● Never wear loose-fitting clothes,
nering (insufficient lean angle for • Never carry a passenger otherwise they could catch on
the speed). unless he or she can firmly pla- the control levers, footrests, or
• Always obey the speed limit ce both feet on the passenger wheels and cause injury or an
and never travel faster than footrests. accident.
warranted by road and traffic ● Never ride under the influence of ● Never touch the engine or
conditions. alcohol or other drugs. exhaust system during or after
• Always signal before turning or ● This motorcycle is designed for operation. They become very hot
changing lanes. Make sure that on-road use only, therefore, it is and can cause burns. Always
other motorists can see you. not suitable for off-road use. wear protective clothing that
● The posture of the operator and Protective apparel covers your legs, ankles, and
passenger is important for proper The majority of fatalities from feet.
control. motorcycle accidents are the result of ● Passengers should also observe
head injuries. The use of a safety hel- the precautions mentioned abo-
met is the single most critical factor in ve.
the prevention or reduction of head
injuries.
1-2
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Modifications When loading within this weight limit, Accessories
Modifications made to this motorcy- keep the following in mind: Genuine Yamaha accessories have
cle not approved by Yamaha, or the ● Cargo and accessory weight been specifically designed for use on
removal of original equipment, may should be kept as low and close this motorcycle. Since Yamaha can- 1
render the motorcycle unsafe for use to the motorcycle as possible. not test all other accessories that may
and may cause severe personal injury. Make sure to distribute the be available, you must personally be
Modifications may also make your weight as evenly as possible on responsible for the proper selection,
motorcycle illegal to use. both sides of the motorcycle to installation and use of non-Yamaha
Loading and accessories minimize imbalance or instability. accessories. Use extreme caution
Adding accessories or cargo to your ● Shifting weights can create a when selecting and installing any
motorcycle can adversely affect sta- sudden imbalance. Make sure accessories.
bility and handling if the weight distri- that accessories and cargo are Keep the following guidelines in mind,
bution of the motorcycle is changed. securely attached to the as well as those provided under “Loa-
To avoid the possibility of an acci- motorcycle before riding. Check ding” when mounting accessories.
dent, use extreme caution when accessory mounts and cargo res- ● Never install accessories or carry
adding cargo or accessories to your traints frequently. cargo that would impair the per-
motorcycle. Use extra care when ● Never attach any large or heavy formance of your motorcycle.
riding a motorcycle that has added items to the handlebar, front fork, Carefully inspect the accessory
cargo or accessories. Here are some or front fender. These items, before using it to make sure that
general guidelines to follow if loading including such cargo as sleeping it does not in any way reduce
cargo or adding accessories to your bags, duffel bags, or tents, can ground clearance or cornering
motorcycle: create unstable handling or slow clearance, limit suspension tra-
Loading steering response. vel, steering travel or control ope-
The total weight of the operator, pas- ration, or obscure lights or reflec-
senger, accessories and cargo must tors.
not exceed the maximum load limit.
Maximum load:
195 Kg (429,98 lb)
1-3
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t SAFETY INFORMATION
• Accessories fitted to the hand- ● Use caution when adding electri- ● Always turn the engine off before
lebar or the front fork area can cal accessories. If electrical leaving the motorcycle unatten-
create instability due to impro- accessories exceed the capacity ded and remove the key from the
1 per weight distribution or of the motorcycle’s electrical sys- main switch. When parking the
aerodynamic changes. If tem, an electric failure could motorcycle, note the following:
accessories are added to the result, which could cause a dan- • The engine and exhaust sys-
handlebar or front fork area, gerous loss of lights or engine tem may be hot, therefore,
they must be as lightweight as power. park the motorcycle in a place
possible and should be kept to Gasoline and exhaust gas where pedestrians or children
a minimum. ● GASOLINE IS HIGHLY FLAMMA- are not likely to touch these hot
• Bulky or large accessories may BLE: areas.
seriously affect the stability of • Always turn the engine off • Do not park the motorcycle on
the motorcycle due to aerody- when refueling. a slope or soft ground, other-
namic effects. Wind may • Take care not to spill any gaso- wise it may fall over.
attempt to lift the motorcycle, line on the engine or exhaust • Do not park the motorcycle
or the motorcycle may become system when refueling. near a flammable source (e.g. a
unstable in cross winds. These • Never refuel while smoking or kerosene heater, or near an
accessories may also cause in the vicinity of an open flame. open flame), otherwise it could
instability when passing or ● Never start the engine or let it run catch fire.
being passed by large vehicles. for any length of time in a closed ● When transporting the motorcy-
• Certain accessories can dis- area. The exhaust fumes are poi- cle in another vehicle, make sure
place the operator from his or sonous and may cause loss of that it is kept upright and that the
her normal riding position. This consciousness and death within fuel cock is turned to “ON” or
improper position limits the fre- a short time. Always operate your “RES” (for vacuum type) / “OFF”
edom of movement of the ope- motorcycle in an area that has (for manual type). If it should lean
rator and may limit control abi- adequate ventilation. over, gasoline may leak out of the
lity, therefore, such carburetor or fuel tank.
accessories are not recom-
mended.
1-4
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● If you should swallow any gasoli-
ne, inhale a lot of gasoline vapor,
or allow gasoline to get into your
eyes, see your doctor immedia- 1
tely. If any gasoline spills on your
skin or clothing, immediately
wash the affected area with soap
and water and change your clot-
hes.
1-5
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DESCRIPTION
EAU10410
Left view
5 3 4
1 Headlight (page 6-21) 5 Fuel tank cap (page 3-5 )

2 Sidestand (page 3-8) 6 Coolant recovery tank (page 6-8)
3 Fuel cock (page 3-6 )
4 Seat lock (page 3-7)
2-1
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DESCRIPTION
EAU10420
Right view
7 9 10 8
11
12
7 Passenger handle 10 Battery/Fuse box (page 6-19)
8 Rear shock absorber 11 Radiator
9 Seat (page 3-7) 12 Rear brake pedal (page 3-5)
2-2
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DESCRIPTION
EAU10430
Controls and instruments

15
13 16
19
14 18 17
13 Clutch lever (page 3-4) 17 Front brake lever (page 3-4)
14 Left handlebar switch (page 3-3) 18 Right handlebar switch (page 3-3)
15 Controls and instruments (page 3-2) 19 Throttle grip (page 6-9)
16 Main switch/Steering lock (page 3-1)
2-3
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INSTRUMENT AND CONTROL FUNCTIONS

EAU10460 EAU10660
To unlock the steering
Main switch/steering lock OFF Push the key in, and then turn it to
All electrical systems are off. The key “OFF” while still pushing it.
can be removed. EWA10060
s WARNING
EAU10670
Never turn the key to “OFF” or
“f”
“LOCK” while the vehicle is
The 2-stroke engine oil level warning
moving, otherwise the electrical
light should come on. (See page 3-2.) 3
systems will be switched off, which
EAUM1020 may result in loss of control or an
“f” accident. Make sure that the vehi-
The coolant temperature warning light cle is stopped before turning the
The main switch/steering lock con- should come on when the key is tur- key to “OFF” or “LOCK”.
trols the ignition and lighting systems, ned to “f”. (See page 3-2.) EAU10980
and is used to lock the steering. The EAU10680

Indicator lights
various positions are described LOCK 3 2
below. The steering is locked, and all electri-
EAU10640 cal systems are off. The key can be
ON removed.
All electrical circuits are supplied with To lock the steering
power, and the engine can be started. 1. Turn the handlebars all the way to
The key cannot be removed. the left.
2. Push the key in from the “OFF”
NOTE: position, and then turn it to
The headlight, meter lighting and tai- “LOCK” while still pushing it. 4 1
llight come on automatically when the 3. Remove the key. 1. Turn signal indicator light “b”
2. Neutral indicator light “N”
engine is started. 3. Oil level warning light “z”
4. Coolant temperature warning light “y”
3-1
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EAU11020 EAU11440 EAU11620
Turn signal indicator light “b” Coolant temperature warning light Speedometer unit
This indicator light flashes when the “y” 1
turn signal switch is pushed to the left This warning light comes on when the
or right. engine overheats. When this occurs,
stop the engine immediately and
EAU11060
allow the engine to cool.
Neutral indicator light “N”
The electrical circuit of the warning
3 This indicator light comes on when
light can be checked by turning the
the transmission is in the neutral posi-
key to “ON”.
tion.
If the warning light does not come on
EAU11120 for a few seconds, then go off, have a
Oil level warning light “z” Yamaha dealer check the electrical
This warning light comes on when the circuit. 1. Speedometer/Odometer
ECA10020
engine oil level is low.
CAUTION The speedometer unit is equipped
The electrical circuit of the warning
Do not operate the engine if it is with a speedometer and an odometer.
light can be checked by turning the
overheated. The speedometer shows riding spe-
key to “ON”. ed. The odometer shows the total dis-
If the warning light does not come on tance traveled.
for a few seconds, then go off, have a
Yamaha dealer check the electrical
circuit.
NOTE:
Even if the oil level is sufficient, the
warning light may flicker when riding
on a slope or during sudden accelera-
tion or deceleration, but this is not a
malfunction.
3-2
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EAU11880 EAU12343
hand turn, push this switch to the left.
Tachometer Handlebar switches When released, the switch returns to
1 1 2 the center position. To cancel the turn
signal lights, push the switch in after it
has returned to the center position.
EAU12500
3
b
Horn switch “a”
4 a
Press this switch to sound the horn. 3
EAU12660
Engine stop switch “f/e”

1. Tachometer 1. Pass switch “j”
2. Dimmer switch “j/k”
3. Turn signal switch “b”
The tachometer allows the rider to 4. Horn switch “a”
monitor the engine speed and keep it 1
within the ideal power range.
ECA10030 EAU12350 2
CAUTION Pass switch “j”
Do not operate the engine in the Press this switch to flash the head-
tachometer red zone. light.
Red zone: 10000 r/min and above EAU12400 1.Stop switch “f/e”
Dimmer switch “j/k” 2. Start switch “g”
Set this switch to “j” for the high
beam and to “k” for the low beam. Set this switch to “f” before starting
the engine. Set this switch to “e” to
EAU12440 stop the engine in case of an emer-
Turn signal switch “TURN” gency, such as when the motorcycle
To signal a right-hand turn, push this overturns or when the throttle cable is
switch to the right. To signal a left- stuck.
3-3
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EAU12690
The clutch lever is equipped with a EAU12890
Start switch “START” clutch switch, which is part of the Brake lever
Push this switch to crank the engine ignition circuit cut-off system. (See 1
with the starter. page 3-8.)
ECA10050
EAU12870
CAUTION
Shift pedal
See page 5-1 for starting instruc-
tions prior to starting the engine.
3 EAU12820
Clutch lever
1. Brake lever
The brake lever is located at the right

1 handlebar grip. To apply the front bra-
1. Shift pedal ke, pull the lever toward the handle-
bar grip.
The shift pedal is located on the left
1 side of the engine and is used in com-
1. Clutch lever bination with the clutch lever when
shifting the gears of the 6-speed
The clutch lever is located at the left constant-mesh transmission equip-
handlebar grip. To disengage the ped on this motorcycle.
clutch, pull the lever toward the hand-
lebar grip. To engage the clutch, rele-
ase the lever. The lever should be
pulled rapidly and released slowly for
smooth clutch operation.
3-4
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EAU12941
To remove the fuel tank cap
Brake pedal Insert the key into the lock and turn it 2 1
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 posi-
tion with the key inserted in the 3
lock.
2. Turn the key counterclockwise to
the original position, and then 1. Filling tube
1 2. Fuel level
remove it. EAU13270
1. Brake pedal
NOTE: Recommended fuel:
The brake pedal is on the right side of REGULAR UNLEADED GASOLINE
The fuel tank cap cannot be installed
the motorcycle. To apply the rear bra- ONLY
unless the key is in the lock. In addi-
ke, press down on the brake pedal. Fuel tank capacity:
tion, the key cannot be removed if the 13,8 L (3.03 Imp.gal)
EAU13000
cap is not properly installed and loc- Fuel reserve amount:
Fuel tank cap ked. 2,2 L (0.48 Imp.gal)
EWA11140
2 s WARNING
Your Yamaha engine has been desig-
Make sure that the fuel tank cap is
ned to use regular unleaded gasoline
properly installed before riding.
with a research octane number of 91
1 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
1. Key over life and reduce maintenance costs.
2. Open
3-5
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EAU13431 EAU13460
Catalytic converter 2-stroke engine oil Recommended oil:

This model is equipped with a cataly- Yamalube 2 or equivalent 2-stroke
tic converter in the exhaust system. engine oil (JASO grade “FC”, or
ISO grades “EG-C” or “EG-D”)
EWA10860 Oil quantity:
s WARNING 1,35 L (1,18 Imp.qt)
The exhaust system is hot after EAU13560
3 operation. Make sure that the
exhaust system has cooled down
Fuel cock
before doing any maintenance 1
work. 1 2
1. 2-stroke engine oil tank
2. 2-stroke engine oil tank cap
ECA10700
ON
CAUTION
FUEL
Make sure that there is sufficient oil in OFF
The following precautions must be the 2-stroke engine oil tank. Add the RES
observed to prevent a fire hazard or recommended 2-stroke engine oil if

other damages. necessary.
● Use only unleaded gasoline.
The use of leaded gasoline will NOTE: 1. Fuel reserve switch
cause unrepairable damage to Make sure that the 2-stroke engine oil The fuel cock supplies fuel from the
the catalytic converter. tank cap is properly installed. tank to the carburetor while filtering it
● Never park the vehicle near also.
possible fire hazards such as The fuel cock has three positions:
grass or other materials that OFF
easily burn. With the lever in this position, fuel will
● Do not allow the engine to idle not flow. Always return the lever to
too long. this position when the engine is not
running.
3-6
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ON Move the lever in direction (b) to turn 3. Remove the key.
With the lever in this position, fuel off the starter (choke).
flows to the carburetor. Normal riding NOTE:
EAU13940
is done with the lever in this position. Make sure that the seat is properly
RES Seat secured before riding.
This indicates reserve. If you run out 2 1
of fuel while riding, move the lever to EAU14411
this position. Fill the tank at the first Storage compartment 3

opportunity. Be sure to set the lever
back to “ON” after refueling!
EAU13590
Starter (choke) lever “q”

b
1. Seat
2. Seat lock
To remove the seat

1. Insert the key into the seat lock, U-lock
and then turn it clockwise.
This storage compartment is desig-
2. While holding the key in that
ned to hold an optional genuine
position, lift the rear of the seat,
Yamaha U-LOCK. (Other locks may
a and then pull the seat off.
not fit.) When placing a U-LOCK in
To install the seat
Starting a cold engine requires a the storage compartment, securely
1. Insert the projection on the front
richer air-fuel mixture, which is sup- fasten it with the straps. When the U-
of the seat into the seat holder as
plied by the starter (choke). shown. LOCK is not in the storage compart-
Move the lever in direction (a) to turn 2. Push the rear of the seat down to ment, be sure to secure the straps to
on the starter (choke). lock it in place. prevent losing them.
3-7
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When storing the owner’s manual or NOTE: EAU15311
other documents in the storage com- The built-in sidestand switch is part of Ignition circuit cut-off
partment, be sure to wrap them in a the ignition circuit cut-off system, system
plastic bag so that they will not get which cuts the ignition in certain The ignition circuit cut-off system
wet. When washing the motorcycle, situations. (See further down for an (comprising the sidestand switch,
be careful not to let any water enter explanation of the ignition circuit cut- clutch switch and neutral switch) has
the storage compartment. off system.) the following functions.
EWA10240 ● It prevents starting when the
3 EAU15300
s WARNING transmission is in gear and the
Sidestand sidestand is up, but the clutch
The vehicle must not be ridden with
the sidestand down, or if the sides- lever is not pulled.
tand cannot be properly moved up ● It prevents starting when the
(or does not stay up), otherwise the transmission is in gear and the
sidestand could contact the ground clutch lever is pulled, but the
and distract the operator, resulting sidestand is still down.
in a possible loss of control. Yama- ● It cuts the running engine when
ha’s ignition circuit cut-off system the transmission is in gear and
1 has been designed to assist the the sidestand is moved down.
operator in fulfilling the responsibi- Periodically check the operation of
1. Side stand lity of raising the sidestand before the ignition circuit cut-off system
starting off. Therefore, check this according to the following procedure.
EWA10250
The sidestand is located on the left system regularly as described s WARNING
side of the frame. Raise the sidestand below and have a Yamaha dealer
or lower it with your foot while holding If a malfunction is noted, have a
repair it if it does not function pro-
the motorcycle upright. Yamaha dealer check the system
perly.
before riding.
3-8
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With the engine turned off:

NOTE:
1. Move the sidestand down.
2. Make sure that the engine stop switch is turned on.
This check is most reliable if performed with
3. Turn the key on. a warmed-up engine.
4. Shift the transmission into the neutral position.
5. Push the start switch.
Does the engine start?
The neutral switch may be defective. 3
YES NO The motorcycle should not be ridden until
checked by a Yamaha dealer.
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?
The sidestand switch may be defective.
After the engine has stalled:
10. Move the sidestand up.
11. Keep the clutch lever pulled.
12. Push the start switch.
Does the engine start?
The clutch switch may be defective.
The system is OK. The motorcycle can be ridden.
3-9
5WX-F8199-E1.qxd 14/12/2004 15:05 Página 26

NOTE:
This check is most reliable if performed with a warmed-up engine.
3-10
5WX-F8199-E1.qxd 14/12/2004 15:05 Página 27
PRE-OPERATION CHECKS
EAU15591
The condition of a vehicle is the

owner’s responsibility. Vital compo-
nents 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 4
visual inspection, to check the follo-
wing points before each ride.
NOTE:
Pre-operation checks should be
made each time the vehicle is used.
Such an inspection can be accom-
plished 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
5WX-F8199-E1.qxd 14/12/2004 15:05 Página 28
EAU15603
Pre-operation check list

ITEM CHECKS PAGE
• Check fuel level in fuel tank.
Fuel • Refuel if necessary. 3-5
• Check fuel line for leakage.
• Check oil level in oil tank.
2-stroke engine oil • If necessary, add recommended oil to specified level. 3-6
• Check vehicle for oil leakage.
• Check oil level in transmission case.
Transmission oil 6-6
• If necessary, add recommended oil to specified level.
4 • Check coolant level in reservoir.
Coolant • If necessary, add recommended coolant to specified level. 6-8
• Check cooling system for leakage.
• Check operation.
• If soft or spongy, have Yamaha dealer bleed hydraulic system.
• Check lever free play.
• Adjust if necessary.
Front brake • Check brake pads for wear. 6-14
• Replace if necessary.
• Check fluid level in reservoir.
• If necessary, add recommended brake fluid to specified level.
• Check hydraulic system for leakage.
• If soft or spongy, have Yamaha dealer bleed hydraulic system.
• Check brake pads for wear.
Rear brake • Replace if necessary. 6-14
• Check fluid level in reservoir.
• If necessary, add recommended brake fluid to specified level.
• Check hydraulic system for leakage.
• Lubricate cable if necessary.
Clutch 6-12
• Check lever free play.
4-2
5WX-F8199-E1.qxd 14/12/2004 15:05 Página 29
ITEM CHECKS PAGE
• Make sure that operation is smooth.
• Check cable free play.
Throttle grip 6-9
• If necessary, have Yamaha dealer adjust cable free play and
lubricate cable and grip housing.
• Make sure that operation is smooth. 6-17
Control cables • Lubricate if necessary.
• Check chain slack.
Drive chain 6-16
• Check chain condition.
• Lubricate if necessary.
• Check for damage.
• Check tire condition and tread depth. 4
Wheels and tires 6-10
• Check air pressure.
• Correct if necessary.
• Make sure that operation is smooth. 6-18
Brake and clutch levers • Lubricate lever pivoting points if necessary.
• Make sure that operation is smooth.
Sidestand 6-18
• Lubricate pivot if necessary.
• Make sure that all nuts, bolts and screws are properly tightened.
Chassis fasteners —
• Tighten if necessary.
Instruments, lights, signals • Check operation. —
and switches • Correct if necessary.
Engine stop switch • Check operation. 3-3
• Check operation of ignition circuit cut-off system.
Sidestand switch 3-8
• If system is defective, have Yamaha dealer check vehicle.
4-3
5WX-F8199-E1.qxd 14/12/2004 15:05 Página 30
OPERATION AND IMPORTANT RIDING POINTS

EAU16000
NOTE: warning light again. If the warning
Starting a cold engine When the transmission is in the neu- light does not go off after starting
In order for the ignition circuit cut-off tral position, the neutral indicator light with sufficient engine oil, have a
system to enable starting, one of the should be on, otherwise have a Yamaha dealer check the electrical
following conditions must be met: Yamaha dealer check the electrical circuit.
● The transmission is in the neutral circuit.
position. 6. After starting the engine, move
● The transmission is in gear with
4. Turn the starter (choke) on and the starter (choke) back halfway.
ECA11040
the clutch lever pulled and the completely close the throttle.
CAUTION
sidestand up. (See page 3-7.)
EWA10290 5. Start the engine by pushing the For maximum engine life, never
s WARNING start switch. accelerate hard when the engine is
● Before starting the engine,
cold!
5 NOTE:
check the function of the igni- 7. When the engine is warm, turn
tion circuit cut-off system If the engine fails to start, release the the starter (choke) off.
according to the procedure start switch, wait a few seconds, and
described on page 3-9. then try again. Each starting attempt NOTE:
● Never ride with the sidestand should be as short as possible to pre- The engine is warm when it responds
down. serve the battery. Do not crank the normally to the throttle with the starter
engine more than 10 seconds on any (choke) turned off.
1. Turn the fuel cock lever to “ON”. one attempt.
2. Turn the key to “ON” and make ECA11160
sure that the engine stop switch CAUTION
is set to “f”.
If the oil level warning light flickers
3. Shift the transmission into the
or remains on after starting, imme-
neutral position.
diately stop the engine, and then
check the engine oil level and the
vehicle for oil leakage. If necessary,
add engine oil, and then check the
5-1
5WX-F8199-E1.qxd 14/12/2004 15:05 Página 31

EAU16671 ECA10260 EAU16800
Shifting CAUTION Tips for reducing fuel

● Even with the transmission in consumption
6 the neutral position, do not Fuel consumption depends largely on
5 coast for long periods of time your riding style. Consider the follo-
4 with the engine off, and do not wing tips to reduce fuel consumption:
3 tow the motorcycle for long ● Turn the starter (choke) off as
2

N
distances. The transmission is soon as possible.
1 properly lubricated only when ● Shift up swiftly, and avoid high
the engine is running. Inade- engine speeds during accelera-
1 quate lubrication may damage tion.
the transmission. ● Do not rev the engine while shif-
1. Shifting ● Always use the clutch while ting down, and avoid high engine 5
changing gears to avoid dama- speeds with no load on the engi-
Shifting gears lets you control the
ging the engine, transmission, ne.
amount of engine power available for
and drive train, which are not ● Turn the engine off instead of let-
starting off, accelerating, climbing
designed to withstand the ting it idle for an extended length
hills, etc.
shock of forced shifting. of time (e.g., in traffic jams, at
The gear positions are shown in the
illustration. traffic lights or at railroad cros-
sings).
NOTE:
To shift the transmission into the neu-
tral position, press the shift pedal
down repeatedly until it reaches the
end of its travel, and then slightly rai-
se it.
5-2
5WX-F8199-E1.qxd 14/12/2004 15:05 Página 32

EAU16830 EWA10310
150~500 km (90~300 mi)
Engine break-in Avoid prolonged operation above 1/2 s WARNING
There is never a more important throttle. ● Since the engine and exhaust
period in the life of your engine than 500~1000 km (300~600 mi) system can become very hot,
the period between 0 and 1000 km Avoid prolonged operation above 3/4 park in a place where pedes-
(600 mi). For this reason, you should throttle. trians or children are not likely
ECA10280
read the following material carefully. to touch them.
Since the engine is brand new, do not CAUTION
● Do not park on a slope or on
put an excessive load on it for the first After 1000 km (600 mi) of operation, soft ground, otherwise the
1000 km (600 mi). The various parts in the engine oil must be changed. vehicle may overturn.
the engine wear and polish themsel- 1000 km (600 mi) and beyond
ves to the correct operating clearan- Avoid prolonged full-throttle opera-
5 ces. During this period, prolonged tion. Vary the speed occasionally.
full-throttle operation or any condition ECA10270
that might result in engine overhea- CAUTION

ting must be avoided. If any engine trouble should occur
EAU16860
during the engine break-in period,
0~150 km (0~90 mi) immediately have a Yamaha dealer
Avoid prolonged operation above 1/3 check the vehicle.
throttle.
EAU17170
After every hour of operation, stop the
engine, and then let it cool for five to Parking
ten minutes. When parking, stop the engine, remo-
Vary the engine speed from time to ve the key from the main switch, and
time. Do not operate the engine at then turn the fuel cock lever to “OFF”.
one set throttle position.
5-3
5WX-F8199-E1.qxd 14/12/2004 15:05 Página 33
PERIODIC MAINTENANCE AND MINOR REPAIR

EAU17240 EAU17380
NOTE:
Safety is an obligation of the owner. Owner’s tool kit If you do not have the tools or expe-
Periodic inspection, adjustment and rience required for a particular job,
lubrication will keep your vehicle in have a Yamaha dealer perform it for
the safest and most efficient condi- you.
tion possible. The most important EWA10350
points of inspection, adjustment, and s WARNING
lubrication are explained on the follo-
Modifications not approved by
wing pages.
Yamaha may cause loss of perfor-
The intervals given in the periodic
mance and render the vehicle
maintenance and lubrication chart
unsafe for use. Consult a Yamaha
should be simply considered as a 1
dealer before attempting any chan-
general guide under normal riding 1. Owner’s took kit
ges.
conditions. However, DEPENDING
ON THE WEATHER, TERRAIN, GEO- The owner’s tool kit is located under
GRAPHICAL LOCATION, AND INDIVI- the seat. (See page 3-7 for.) 6
DUAL USE, THE MAINTENANCE The service information included in
INTERVALS MAY NEED TO BE this manual and the tools provided in
SHORTENED. the owner’s tool kit are intended to
EWA10320 assist you in the performance of pre-
s WARNING ventive maintenance and minor
If you are not familiar with mainte- repairs. However, additional tools
nance work, have a Yamaha dealer such as a torque wrench may be
do it for you. necessary to perform certain mainte-
nance work correctly.
6-1
5WX-F8199-E1.qxd 14/12/2004 15:05 Página 34

EAU17710
Periodic maintenance and lubrication chart

NOTE:
● The annual checks must be performed every year, except if a kilometer-based maintenance is performed
instead.
● From 30000 km, repeat the maintenance intervals starting from 6000 km.
● Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and
technical skills.
ODOMETER READING (x 1000 Km) ANNUAL
NO ITEM CHEK OR MAINTENANCE JOB 1 6 12 18 24 CHECK
1 * Fuel line Check fuel and vacuum hoses for cracks or damage. √ √ √ √ √
6
2 Spark plug Replace. √ √ √ √ √
Clean. √ √
3 Air filter element
Replace. √ √
Check operation. √ √ √ √ √
4 Clutch Adjust.
Check operation, fluid level and vehicle for fluid leakage. √ √ √ √ √ √
5 * Front brake
Replace brake pads. Whenever worn to the limit
Check operation, fluid level and vehicle for fluid leakage. √ √ √ √ √ √
6 * Rear brake
Replace brake pads. Whenever worn to the limit
Check for cracks or damage. √ √ √ √ √
7 * Brake hose
Replace. Every 4 years
8 * Wheels Check runout and for damage. √ √ √ √
6-2
5WX-F8199-E1.qxd 14/12/2004 15:05 Página 35

Check tread depth and for damage.

Replace if necessary.
9 * Tires √ √ √ √ √
Check air pressure.
Correct if necessary.
10 * Wheel bearings Check bearing for looseness or damage. √ √ √ √
Check operation and for excessive play. √ √ √ √
11 * Swingarm
Lubricate with lithium-soap-based grease. Every 24000 km
Check chain slack, alignment and condition. Every 500 km and after washing
12 Drive chain
Adjust and thoroughly lubricate chain with engine oil. the motorcycle or riding in the rain
Check bearing play and steering for roughness. √ √ √ √ √
13 * Steering bearings
Lubricate with lithium-soap-based grease. Every 24000 km
Make sure that all nuts, bolts and screws are 6
14 * Chassis fasteners √ √ √ √ √
properly tightened.
Check operation.
15 Sidestand √ √ √ √ √
Lubricate.
16 * Sidestand switch Check operation. √ √ √ √ √ √
17 * Front fork Check operation and for oil leakage. √ √ √ √
Shock absorber Check operation and shock absorber for oil leakage.
18 * √ √ √ √
assembly
Check starter (choke) operation.
19 * Carburetor
Adjust engine idling speed. √ √ √ √ √ √
Check operation.
20 * Autolube pump Bleed if necessary. √ √ √ √
Check oil level. √ √ √ √ √ √
21 Transmission oil
Change. √ √
6-3
5WX-F8199-E1.qxd 14/12/2004 15:05 Página 36

Check coolant level and vehicle for coolant leakage. √ √ √ √ √

22 * Cooling system
Change. Every 3 years
Clean. √ √
23 * Air filter element
Replace. √ √
EAU18670
NOTE:
● The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
● Hydraulic brake service
• Regularly check and, if necessary, correct the brake fluid level.
6 • Every two years replace the internal components of the brake master cylinders and calipers, and change the bra-
ke fluid.
• Replace the brake hoses every four years and if cracked or damaged.
6-4
5WX-F8199-E1.qxd 14/12/2004 15:05 Página 37

EAU18781 EAU18880
To install the cowling
Removing and installing Cowling A 1. Insert the tabs on the cowling
cowlings into the slots as shown, and then
push the cowling in until it snaps
into place.
2. Install the cowling screws.
2 EAU18790
Cowling B
1. Screws (x 7 Right side)

1 1. Screws (x 6 Left side)
1. Cowling A
2. Cowling B
To remove the cowling 6

The cowlings shown need to be
removed to perform some of the 1. Remove the cowling screws.
maintenance jobs described in this 2. Push the cowling in lightly, and 1. Screws (x 5 Rechterkant)
chapter. Refer to this section each then pull it back as shown. 1. Screws (x 7 Linkerkant)
time a cowling needs to be removed ECA11200
To remove the cowling
and installed. CAUTION Remove the screws, and then take
Take care not to damage the tabs the cowling off.
on the cowling when removing and To install the cowling
or installing it. Place the cowling in the original posi-
tion, and then install the screws.
6-5
5WX-F8199-E1.qxd 14/12/2004 15:05 Página 38

EAU19620
normally). If the spark plug shows a
Tightening torque:
Checking the spark plug distinctly different color, the engine Spark plug:
could be defective. Do not attempt to 20 Nm (2,0 m•kgf)
diagnose such problems yourself.
Instead, have a Yamaha dealer check NOTE:
the vehicle. If a torque wrench is not available
If the spark plug shows signs of elec- when installing a spark plug, a good
trode erosion and excessive carbon estimate of the correct torque is
or other deposits, it should be repla- 1/4~1/2 turn past finger tight. Howe-
ced. ver, the spark plug should be tighte-
ned to the specified torque as soon
1 Specified spark plug: as possible.
1. Spark plug BR9ES (NGK)
EAUM1270
The spark plug is an important engine Before installing a spark plug, the
6 component, which should be chec- spark plug gap should be measured Transmission oil
ked periodically, preferably by a with a wire thickness gauge and, if 3
Yamaha dealer. Since heat and depo- necessary, adjusted to specification.
sits will cause any spark plug to
slowly erode, it should be removed Spark plug gap:
and checked in accordance with the 0,6 ~ 0,7 mm (0,023~0,027 in) 1
periodic maintenance and lubrication
Clean the surface of the spark plug
chart. In addition, the condition of the
gasket and its mating surface, and
spark plug can reveal the condition of
then wipe off any grime from the
the engine.
spark plug threads. 2
The porcelain insulator around the
center electrode of the spark plug 1. Oil level check bolt
should be a medium-to-light tan (the 2. Oil drain bolt
3. Oil filler cap
ideal color when the vehicle is ridden
6-6
5WX-F8199-E1.qxd 14/12/2004 15:05 Página 39

The transmission oil level should be 3. If the oil is below the brim of the 4. Remove the oil filler cap, add the
checked before each ride. In addition, check hole, remove the oil filler specified amount of the recom-
the oil must be changed at the inter- cap, add sufficient oil of the mended transmission oil, and
vals specified in the periodic mainte- recommended type to raise it to then install and tighten the oil
nance and lubrication chart. the correct level, and then install filler cap.
To check the transmission oil level the oil filler cap.
1. Place the vehicle on a level surfa- 4. Install the oil check bolt, and then Recommended transmission oil:
ce and hold it in an upright posi- tighten it to the specified torque. See page 8-1.
Oil change quantity:
tion.
0,75 L (0,65 imp.qt)
Tightening torque:
NOTE: Oil check bolt:
Make sure that the vehicle is positio- 3 Nm (0,3 m•kgf)
ECAM1020
ned straight up when checking the oil CAUTION

level. A slight tilt to the side can result To change the transmission oil Make sure that no foreign material
in a false reading. 1. Place an oil pan under the trans- enters the transmission case.
mission oil case to collect the used 6
2. Remove the oil check bolt, and oil. 5. Start the engine and let it idle for
then check the oil level. 2. Remove the drain bolt and the oil several minutes while checking
check bolt to drain the oil. the transmission oil case for oil
NOTE:
3. Install the drain bolt and the leakage. If oil is leaking, imme-
The oil should be at the brim of the
check bolt, and then tighten them to diately turn the engine off and
check hole.
the specified torque. check for the cause.
Tightening torque:
Transmission oil drain bolt:
17 Nm (1,7 m•kgf)
Oil check bolt:
3 Nm (0,3 m•kgf)
6-7
5WX-F8199-E1.qxd 14/12/2004 15:05 Página 40

EAU20170 ECA10470
To check the coolant level CAUTION

● If coolant is not available, use
distilled water or soft tap water
instead. Do not use hard water
or salt water since it is harmful
to the engine.
MAX ● If water has been used instead
MIN of coolant, replace it with coo-
lant as soon as possible, other-
1. Panel wise the engine may not be
sufficiently cooled and the coo-
1. Place the vehicle on a level surfa- 2. Remove panel (1). (See page 6-8.)
ling system will not be protec-
ce and hold it in an upright posi- 3. Check the coolant level in the
ted against frost and corrosion.
tion. coolant reservoir.
● If water has been added to the
6
NOTE: coolant, have a Yamaha dealer
NOTE: check the antifreeze content of
● The coolant level must be chec- The coolant should be between the
minimum and maximum level marks. the coolant as soon as possible,
ked on a cold engine since the otherwise the effectiveness of
level varies with engine tempera- 4. If the coolant is at or below the the coolant will be reduced.
ture. minimum level mark, open the
● Make sure that the vehicle is reservoir cap, add coolant to the EWA10380
positioned straight up when maximum level mark, and then s WARNING
checking the coolant level. A close the reservoir cap.
slight tilt to the side can result in Never attempt to remove the radia-
a false reading. tor cap when the engine is hot.
Coolant reservoir capacity:
0,45 L (0.39 Imp.qt) 5. Install the panel.
6-8
5WX-F8199-E1.qxd 14/12/2004 15:05 Página 41

NOTE: The engine idling speed must be NOTE:
If the engine overheats, see page 6-5 checked and, if necessary, adjusted If the specified idling speed cannot be
for further instructions. as follows at the intervals specified in obtained as described above, have a
the periodic maintenance and lubrica- Yamaha dealer make the adjustment.
EAU21300 tion chart. EAU21370
Adjusting the carburetor The engine should be warm before Adjusting the throttle cable
The carburetor is an important part of making this adjustment. free play
the engine and requires very sophisti-
cated adjustment. Therefore, all car- NOTE:
buretor adjustments should be left to The engine is warm when it quickly
a Yamaha dealer, who has the neces- responds to the throttle.
sary professional knowledge and Check the engine idling speed and, if
experience. necessary, adjust it to specification by
EAU21320
turning the throttle stop screw. To a
increase the engine idling speed, turn 6
Adjusting the engine idling the screw in direction (a). To decrease
speed the engine idling speed, turn the
screw in direction (b). (a) Throttle cable free play
The throttle cable free play should
measure 2~5 mm (0,08~0,2 in) at the
Engine idling speed:
throttle grip. Periodically check the
1700 ~ 2000 tpm
throttle cable free play and, if neces-
1 sary, adjust it as follows.
NOTE:
The engine idling speed must be
correctly adjusted before checking
1. Idle aedjusting bolt and adjusting the throttle cable free
play.
6-9
5WX-F8199-E1.qxd 14/12/2004 15:05 Página 42

EWA10450
re of the tires equals the
ambient temperature). s WARNING
● The tire air pressure must be Because loading has an enormous
adjusted in accordance with impact on the handling, braking,
a performance and safety characte-
the riding speed and with the
b total weight of rider, cargo, and ristics of your vehicle, you should
accessories approved for this keep the following precautions in
1. Loosen the locknut. model. mind.
2. To increase the throttle cable free ● NEVER OVERLOAD THE VEHI-
play, turn the adjusting nut in Tire air pressure (measured on cold CLE! Operation of an overloa-
tires): ded vehicle may result in tire
direction (a). To decrease the
Up to 90 kg (198 lb):
throttle cable free play, turn the Front: damage, loss of control, or
adjusting nut in direction (b). 180 kPa (25,6 psi) (1,8 kgf/cm2) severe injury. Make sure that
3. Tighten the locknut. Rear: the total weight of rider, cargo,
EAU21500
200 kPa (28,4 psi) (2,0 kgf/cm2) and accessories does not
6 Tires 90 kg (198 lb) to maximum load: exceed the specified maximum
To maximize the performance, durabi- Front:
190 kPa (27 psi) (1,9 kgf/cm2) load for the vehicle.
lity, and safe operation of your ● Do not carry along loosely pac-
Rear:
motorcycle, note the following points 230 kPa (32,7 psi) (2,3 kgf/cm2) ked items, which can shift
regarding the specified tires. High-speed riding: during a ride.
Tire air pressure Front: ● Securely pack the heaviest
The tire air pressure should be chec- 190 kPa (27 psi) (1,9 kgf/cm2)
Rear: items close to the center of the
ked and, if necessary, adjusted befo- vehicle and distribute the
230 kPa (32,7 psi) (2,3 kgf/cm2)
re each ride. Maximum load*: weight evenly on both sides.
EWA10440
195 kg (429,9 lb) ● Adjust the suspension and tire
s WARNING
* Total weight of rider, cargo and air pressure with regard to the
● The tire air pressure must be accessories
load.
checked and adjusted on cold
● Check the tire condition and air
tires (i.e., when the temperatu-
pressure before each ride.
6-10
5WX-F8199-E1.qxd 14/12/2004 15:05 Página 43

EWA10470
● Always make sure that the val-
s WARNING ve caps are securely installed
● Have a Yamaha dealer replace to prevent air pressure leaka-
excessively worn tires. Besides ge.
being illegal, operating the ● Use only the tire valves and val-
vehicle with excessively worn ve cores listed below to avoid
tires decreases riding stability tire deflation during a high-
and can lead to loss of control. speed ride.
● The replacement of all wheel
and brake related parts, inclu- Front tire:
1. Depth ding the tires, should be left to Size:
2. Side face 100/80-17
a Yamaha dealer, who has the
Tire inspection Manufacturer/model:
necessary professional know- PIRELLI
The tires must be checked before
ledge and experience. Rear tire:
each ride. If the center tread depth
Size:
reaches the specified limit, if the tire Tire information 130/70-17 6
has a nail or glass fragments in it, or if This motorcycle is equipped with cast Manufacturer/model:
the sidewall is cracked, have a Yama- wheels and tubeless tires with valves. PIRELLI
ha dealer replace the tire immediately.
EWA10480
Minimum tire tread depth (front s WARNING EWA10600
and rear): ● The front and rear tires should s WARNING

1.6 mm (0.06 in)
be of the same make and This motorcycle is fitted with
NOTE: design, otherwise the handling super-high-speed tires. Note the
The tire tread depth limits may differ characteristics of the motorcy- following points in order to make
from country to country. Always cle cannot be guaranteed. the most efficient use of these tires.
comply with the local regulations. ● After extensive tests, only the ● Use only the specified replace-
tires listed below have been ment tires. Other tires may run
approved for this model by the danger of bursting at super
Yamaha Motor España, S.A. high speeds.
6-11
5WX-F8199-E1.qxd 14/12/2004 15:05 Página 44

● Brand-new tires can have a ● The wheel should be balanced The clutch lever free play should mea-
relatively poor grip on certain whenever either the tire or wheel sure 2~5 mm (0,08~0,2 in) as shown.
road surfaces until they have has been changed or replaced. Periodically check the clutch lever free
been “broken in”. Therefore, it An unbalanced wheel can result play and, if necessary, adjust it as
is advisable before doing any in poor performance, adverse follows.
high-speed riding to ride con- handling characteristics, and a 1. Loosen the locknut at the clutch
servatively for approximately shortened tire life. lever.
100 km (60 mi) after installing a ● Ride at moderate speeds after 2. To increase the clutch lever free
new tire. changing a tire since the tire sur- play, turn the adjusting bolt in
● The tires must be warmed up face must first be “broken in” for direction (a). To decrease the
before a high-speed run. it to develop its optimal characte- clutch lever free play, turn the
● Always adjust the tire air pres- ristics. adjusting bolt in direction (b).
EAU22041
sure according to the opera-
ting conditions. Adjusting the clutch lever NOTE:
EAU21960 free play If the specified clutch lever free play
6 could be obtained as described abo-
Cast wheels
To maximize the performance, durabi- 1 ve, tighten the locknut and skip the
lity, and safe operation of your rest of the procedure, otherwise pro-
motorcycle, note the following points ceed as follows.
a
regarding the specified wheels. 3. Fully turn the adjusting bolt at the
● The wheel rims should be chec- clutch lever in direction (a) to loo-
ked for cracks, bends or warpage b
sen the clutch cable.
before each ride. If any damage 4. Loosen the locknut at the crank-
is found, have a Yamaha dealer case.
replace the wheel. Do not 5. To increase the clutch lever free
1. Free play
attempt even the smallest repair play, turn the adjusting nut in
to the wheel. A deformed or crac- direction (a). To decrease the
ked wheel must be replaced. clutch lever free play, turn the
6-12
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adjusting nut in direction (b). 1. Loosen the locknut at the brake To increase the brake pedal free play,
6. Tighten the locknut at the clutch pedal. turn the adjusting nut at the brake rod
lever and the crankcase. 2. To raise the brake pedal, turn the in direction (a). To decrease the brake
adjusting bolt in direction (a). To pedal free play, turn the adjusting nut
EAU22220
lower the brake pedal, turn the in direction (b).
Adjusting the brake pedal adjusting bolt in direction (b).
EWA10660
position and free play s WARNING

3. Tighten the locknut.
EWA11230
After adjusting the brake pedal free
s WARNING play, check the operation of the
After adjusting the brake pedal brake light.
position, the brake pedal free play
must be adjusted. EAU22270
Brake pedal free play Adjusting the rear brake light

1
2 switch 1
6
1. Position adjusting bolt

2. Brake pedal position
EWA10670 a
s WARNING
It is advisable to have a Yamaha b

dealer make these adjustments. 1

Brake pedal position 1. Free play 2
The top of the brake pedal should be 1. Switch
The brake pedal free play should
aligned with the top of the footrest as 2. Lock nut
measure 10~15 mm (0,39~59 in) at
shown. Periodically check the brake the brake pedal end. Periodically The rear brake light switch, which is
pedal position and, if necessary, check the brake pedal free play and, if activated by the brake pedal, is pro-
adjust it as follows. necessary, adjust it as follows. perly adjusted when the brake light
6-13
5WX-F8199-E1.qxd 14/12/2004 15:05 Página 46

comes on just before braking takes wear indicator groove has almost 2. Install the brake caliper bolt, and
effect. If necessary, adjust the brake disappeared, have a Yamaha dealer then tighten it to the specified
light switch as follows. replace the brake pads as a set. torque.
Turn the adjusting nut while holding
EAU22480
the rear brake light switch in place. To Tightening torque:
Rear brake pads Brake caliper bolt:
make the brake light come on earlier,
30 Nm (3,0 m•kgf)
turn the adjusting nut in direction (a). EAU22610
To make the brake light come on later,
turn the adjusting nut in direction (b). Checking the brake fluid
level
EAU22420 FRONT
Front brake pads
mín.
6
Each rear brake pad is provided with
a wear indicator groove, which allows
you to check the brake pad wear wit-
hout having to disassemble the brake.
Check the brake pad wear as follows. Insufficient brake fluid may allow air
1. Remove the brake caliper bolt, to enter the brake system, possibly
Each front brake pad is provided with and then tilt the caliper forward to causing it to become ineffective.
a wear indicator groove, which allows inspect the wear indicator groo-
you to check the brake pad wear wit- ve. If a brake pad has worn to the
hout having to disassemble the brake. point that the wear indicator gro-
To check the brake pad wear, check ove has almost disappeared,
the wear indicator groove. If a brake have a Yamaha dealer replace
pad has worn to the point that the the brake pads as a set.
6-14
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Before riding, check that the brake REAR ● As the brake pads wear, it is nor-
fluid is above the minimum level mark mal for the brake fluid level to
and replenish if necessary. A low bra- gradually go down. However, if
ke fluid level may indicate worn brake the brake fluid level goes down
pads and/or brake system leakage. If suddenly, have a Yamaha dealer
máx.
the brake level is low, be sure to mín. check the cause.
check the brake pads for wear and
EAU22720
the brake system for leakage.
Observe these precautions: Changing the brake fluid
● When checking the fluid level, Have a Yamaha dealer change the
make sure that the top of the ● Refill with the same type of brake brake fluid at the intervals specified in
brake fluid reservoir is level by fluid. Mixing fluids may result in a the NOTE after the periodic mainte-
turning the handlebars. harmful chemical reaction and nance and lubrication chart. In addi-
● Use only the recommended qua- lead to poor braking performan- tion, have the oil seals of the brake
lity brake fluid, otherwise the rub- ce. master cylinder and caliper as well as
the brake hose replaced at the inter- 6
ber seals may deteriorate, cau- ● Be careful that water does not
sing leakage and poor braking enter the brake fluid reservoir vals listed below or whenever they are
performance. when refilling. Water will signifi- damaged or leaking.
● Oil seals: Replace every two
cantly lower the boiling point of
Recommended brake fluid: the fluid and may result in vapor years.
DOT 4 ● Brake hose: Replace every four
lock.
● Brake fluid may deteriorate pain- years.
ted surfaces or plastic parts.
Always clean up spilled fluid
NOTE: immediately.
If DOT 4 is not available, DOT 3 can
be used for the front brake system.
6-15
5WX-F8199-E1.qxd 14/12/2004 15:05 Página 48

EAU22760
and then measure the drive chain adjusting nut at each end of the
Drive chain slack slack as shown. swingarm in direction (b), and
then push the rear wheel forward.
Drive chain slack:
40~50 mm (1,5 ~1,9 in)
NOTE:
4. If the drive chain slack is inco- Using the alignment marks on each
rrect, adjust it as follows. side of the swingarm, make sure that
EAU22920
both adjusting nuts are in the same

a To adjust the drive chain slack position for proper wheel alignment.
3 ECA10570

CAUTION
Improper drive chain slack will
(a) Drive chain slack
overload the engine as well as
The drive chain slack should be chec- a
2 4 other vital parts of the motorcycle
ked before each ride and adjusted if
6 b and can lead to chain slippage or
necessary.
EAU22771 breakage. To prevent this from
To check the drive chain slack occurring, keep the drive chain
1. Place the motorcycle on the 1 slack within the specified limits.
1. Cotter pin
sidestand. 2. Axle nut 4. Tighten the locknuts, and then
3. Lock nut
NOTE: 4. Chain tensioner
tighten the axle nut to the speci-
When checking and adjusting the dri- 1. Remove the cotter pin from the axle fied torque.
ve chain slack, there should be no nut, and then loosen the axle nut. Tightening torque:
weight on the motorcycle. 2. Loosen the chain puller locknut Axle nut:
at each end of the swingarm. 90 Nm (9,0 m•kgf)
2. Shift the transmission into the
3. To tighten the drive chain, turn
neutral position. 5. Insert a new cotter pin into the
the adjusting nut at each end of
3. Move the rear wheel by pushing axle nut, and then bend its ends
the swingarm in direction (a). To
the motorcycle to locate the tigh- as shown.
loosen the drive chain, turn the
test portion of the drive chain,
6-16
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NOTE: NOTE: EWA10720
Make sure that two notches in the For a thorough cleaning, have a s WARNING
axle nut are aligned with the hole Yamaha dealer remove the drive Damage to the outer sheath may
through the wheel axle, otherwise chain and soak it in solvent. interfere with proper cable opera-
further tighten the axle nut until they tion and will cause the inner cable
2. Spray Yamaha Chain and Cable to rust. Replace a damaged cable
are.
Lube or a high-quality spray-type as soon as possible to prevent
EWA10700
drive chain lubricant on both unsafe conditions.
s WARNING
sides and on the middle of the
Always use a new cotter pin for the chain, making sure that all side EAU23131
axle nut. plates and rollers have been suf- Checking and lubricating the
ficiently oiled. brake and shift pedals
EAU23012
Lubricating the drive chain

EAU23100
The drive chain must be cleaned and
lubricated at the intervals specified in Checking and lubricating the 6
the periodic maintenance and lubrica- cables
tion chart, otherwise it will quickly The operation of all control cables
wear out, especially when riding in and the condition of the cables
dusty or wet areas. Service the drive should be checked before each ride,
chain as follows. and the cables and cable ends should
ECA10581
be lubricated if necessary. If a cable is
CAUTION
damaged or does not move smoothly,
The drive chain must be lubricated The operation of the brake and shift
have a Yamaha dealer check or repla-
after washing the motorcycle and pedals should be checked before
ce it.
riding in the rain. each ride, and the pedal pivots
Recommended lubricant: should be lubricated if necessary.
1. Remove all dirt and mud from the Engine oil
Recommended lubricant:
drive chain with a brush or cloth. Lithium-soap-based grease (all-
purpose grease)
6-17
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EAU23140 EAU23200 EAU23271
Checking and lubricating the Checking and lubricating the Checking the front fork
brake and clutch levers sidestand
The condition and operation of the

The operation of the brake and clutch The operation of the sidestand should front fork must be checked as follows
levers should be checked before each be checked before each ride, and the at the intervals specified in the perio-
6 dic maintenance and lubrication
ride, and the lever pivots should be sidestand pivot and metal-to-metal
lubricated if necessary. contact surfaces should be lubricated chart.
if necessary. To check the condition
Recommended lubricant: EWA10730 EWA10750
Lithium-soap-based grease (all- s WARNING s WARNING

purpose grease) Securely support the motorcycle so
If the sidestand does not move up
and down smoothly, have a Yama- that there is no danger of it falling
ha dealer check or repair it. over.
Check the inner tubes for scratches,
Recommended lubricant:
Lithium-soap-based grease (all- damage and excessive oil leakage.
purpose grease) To check the operation
1. Place the motorcycle on a level
surface and hold it in an upright
position.
6-18
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2. While applying the front brake, 1. Place a stand under the engine to EAU23440
push down hard on the handle- raise the front wheel off the Battery
1
bars several times to check if the ground.
EWA10750
front fork compresses and
s WARNING
rebounds smoothly.
ECA10590
Securely support the motorcycle so
CAUTION that there is no danger of it falling
If any damage is found or the front over.
fork does not operate smoothly,
2. Hold the lower ends of the front
have a Yamaha dealer check or
fork legs and try to move them
repair it.
forward and backward. If any free
EAU23280
play can be felt, have a Yamaha 1. Battery
Checking the steering dealer check or repair the stee-
ring. This motorcycle is equipped with a
EAU23290
sealed-type (MF) battery, which does 6
not require any maintenance. There is
Checking the wheel bearings no need to check the electrolyte or to
The front and rear wheel bearings
add distilled water.
must be checked at the intervals spe-
To charge the battery
cified in the periodic maintenance and
Have a Yamaha dealer charge the
lubrication chart. If there is play in the
battery as soon as possible if it seems
wheel hub or if the wheel does not
to have discharged. Keep in mind that
turn smoothly, have a Yamaha dealer
the battery tends to discharge more
Worn or loose steering bearings may check the wheel bearings.
quickly if the motorcycle is equipped
cause danger. Therefore, the opera-
with optional electrical accessories.
tion of the steering must be checked
as follows at the intervals specified in
the periodic maintenance and lubrica-
tion chart.
6-19
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EWA10760
● KEEP THIS AND ALL BATTE- ● To charge a sealed-type (MF)
s WARNING RIES OUT OF THE REACH OF battery, a special (constant-
● Electrolyte is poisonous and CHILDREN. voltage) battery charger is
dangerous since it contains required. Using a conventional
To store the battery
sulfuric acid, which causes battery charger will damage
1. If the motorcycle will not be used
severe burns. Avoid any con- the battery. If you do not have
for more than one month, remove
tact with skin, eyes or clothing access to a sealed-type (MF)
the battery, fully charge it, and
and always shield your eyes battery charger, have a Yamaha
then place it in a cool, dry place.
when working near batteries. dealer charge your battery.
2. If the battery will be stored for
In case of contact, administer EAU23480
more than two months, check it
the following FIRST AID. Replacing the fuse
at least once a month and fully
• EXTERNAL: Flush with plenty
charge it if necessary.
of water.
3. Fully charge the battery before
• INTERNAL: Drink large quan-
installation.
tities of water or milk and
6 4. After installation, make sure that
immediately call a physician.
the battery leads are properly 1
• EYES: Flush with water for 15
connected to the battery termi-
minutes and seek prompt
nals.
medical attention. ECA10630
● Batteries produce explosive CAUTION

hydrogen gas. Therefore, ● Always keep the battery char-
keep sparks, flames, cigaret- 1. Fuse
ged. Storing a discharged bat-
tes, etc., away from the battery can cause permanent bat- The fuse box is located under the
tery and provide sufficient tery damage. seat. (See page 3-7.)
ventilation when charging it in
If the fuse is blown, replace it as
an enclosed space.
follows.
1. Turn the key to “OFF” and turn off
all electrical circuits.
6-20
5WX-F8199-E1.qxd 14/12/2004 15:05 Página 53

2. Remove the blown fuse, and then der, and then remove the defecti- EAU24281
install a new fuse of the specified ve bulb. Replacing a turn signal light
EWA10790
amperage.
s WARNING
bulb or the tail/brake light
Specified fuse: bulb
Headlight bulbs get very hot. The-
10 A
refore, keep flammable products
ECA10640
away from a lit headlight bulb, and
CAUTION do not touch the bulb until it has
Do not use a fuse of a higher ampe- cooled down.
rage rating than recommended to
3. Place a new headlight bulb into
avoid causing extensive damage to
position, and then secure it with
the electrical system and possibly a
the bulb holder.
fire. ECA10660
CAUTION
3. Turn the key to “ON” and turn on
the electrical circuits to check if the Do not touch the glass part of the 1. Remove the lens by removing the 6
devices operate. headlight bulb to keep it free from screws.
4. If the fuse immediately blows oil, otherwise the transparency of 2. Remove the defective bulb by
again, have a Yamaha dealer check the glass, the luminosity of the pushing it in and turning it coun-
the electrical system. bulb, and the bulb life will be adver- terclockwise.
sely affected. Thoroughly clean off 3. Insert a new bulb into the socket,
EAU23800
any dirt and fingerprints on the push it in, and then turn it clock-
Replacing the headlight bulb headlight bulb using a cloth mois- wise until it stops.
This model is equipped with a quartz tened with alcohol or thinner.
bulb headlight. If the headlight bulb
4. Connect the headlight lead con-
burns out, replace it as follows.
nectors, and then install the bulb
1. Remove the headlight bulb cover,
cover.
and then disconnect the head-
5. Have a Yamaha dealer adjust the
light lead connectors.
headlight beam if necessary.
2. Unhook the headlight bulb hol-
6-21
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EAUM1460 EAU24350
Replacing the license plate Supporting the motorcycle

light bulb Since this model is not equipped with
a centerstand, follow these precau-
tions when removing the front and
1 rear wheel or performing other main-
tenance requiring the motorcycle to
stand upright. Check that the
motorcycle is in a stable and level
position before starting any mainte-
4. Install the lens by installing the nance. A strong wooden box can be
screws. placed under the engine for added
ECA10680
stability.
CAUTION 1. Auxiliary light To service the front wheel
Do not overtighten the screws, 1. Stabilize the rear of the motorcy-
6 otherwise the lens may break. 1. Remove the license plate light
cle by using a motorcycle stand
cover by removing the screw.
or, if an additional motorcycle
2. Remove the socket (together
stand is not available, by placing
with the bulb) by pulling it out.
a jack under the frame in front of
3. Remove the defective bulb by
the rear wheel.
pulling it out.
2. Raise the front wheel off the
4. Insert a new bulb into the socket.
ground by using a motorcycle
5. Install the socket (together with
stand.
the bulb) by pushing it in.
6. Install the license plate light
cover by installing the screw.
6-22
5WX-F8199-E1.qxd 14/12/2004 15:05 Página 55

To service the rear wheel like Yamaha parts, but they are often
Raise the rear wheel off the ground by inferior, have a shorter service life and
using a motorcycle stand or, if a can lead to expensive repair bills.
motorcycle stand is not available, by
placing a jack either under each side
of the frame in front of the rear wheel
or under each side of the swingarm.
EAU25870
Troubleshooting
Although Yamaha motorcycles recei-
ve a thorough inspection before ship-
ment from the factory, trouble may
occur during operation. Any problem
in the fuel, compression, or ignition 6
systems, for example, can cause poor
starting and loss of power.
The following troubleshooting charts
represent quick and easy procedures
for checking these vital systems your-
self. However, should your motorcy-
cle require any repair, take it to a
Yamaha dealer, whose skilled techni-
cians have the necessary tools, expe-
rience, and know-how to service the
motorcycle properly.
Use only genuine Yamaha replace-
ment parts. Imitation parts may look
6-23
5WX-F8199-E1.qxd 14/12/2004 15:05 Página 56

EAU25921
Troubleshooting charts
Starting problems or poor engine performance
EWA10840
s WARNING
Keep away open flames and do not smoke while checking or working on the fuel system.
1. Fuel
There is enough fuel. Check the compression.
Check the fuel level in
the fuel tank.
The engine does not start.
There is no fuel. Supply fuel.
Check the compression.
2. Compression
There is compression. Check the ignition.
Operate the electric starter.
Have a Yamaha dealer
6 There is no compression.
check the vehicle.
3. Ignition Wipe off with a dry cloth and correct the Open the throttle halfway and operate
Wet
spark plug gap, or replace the spark plug. the electric starter.
Remove the spark plug
and check the electrodes.
The engine does not start.
Dry Have a Yamaha dealer check the vehicle.
Check the battery.
4. Battery The engine turns over

The battery is good.
quickly. The engine does not start.
Operate the electric starter. Have a Yamaha dealer
The engine turns over Check the battery lead connections, check the vehicle.
slowly. and charge the battery if necessary.
6-24
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Engine overheating
EWA10400
s WARNING
● Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be
blown out under pressure, which could cause serious injury. Be sure to wait until the engine has cooled.
● After removing the radiator cap retaining bolt, place a thick rag, like a towel, over the radiator cap, and then
slowly rotate the cap counterclockwise to the detent to allow any residual pressure to escape. When the his-
sing sound has stopped, press down on the cap while turning it counterclockwise, and then remove the cap.
There is Have a Yamaha dealer check

The coolant level is low. leakage. and repair the cooling system.
Check the cooling system
for leakage.
There is
Add coolant. (See NOTE.)
Wait until the Check the coolant level in the no leakage.
engine has cooled. reservoir and radiator. 6
The coolant level Start the engine. If the engine overheats again, have a
is OK. Yamaha dealer check and repair the cooling system.
NOTE:
If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommended
coolant as soon as possible.
6-25
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MOTORCYCLE CARE AND STORAGE

EAU26000
ducts onto seals, gaskets, sproc- cleaning products, solvent or
Care kets, the drive chain and wheel thinner, fuel (gasoline), rust
While the open design of a motorcy- axles. Always rinse the dirt and removers or inhibitors, brake
cle reveals the attractiveness of the degreaser off with water. fluid, antifreeze or electrolyte.
technology, it also makes it more vul- Cleaning ● Do not use high-pressure was-
ECA10770
nerable. Rust and corrosion can hers or steam-jet cleaners sin-
develop even if high-quality compo- CAUTION
ce they cause water seepage
nents are used. A rusty exhaust pipe ● Avoid using strong acidic whe- and deterioration in the follo-
may go unnoticed on a car, however, el cleaners, especially on spo- wing areas: seals (of wheel and
it detracts from the overall appearan- ked wheels. If such products swingarm bearings, fork and
ce of a motorcycle. Frequent and pro- are used on hard-to-remove brakes), electric components
per care does not only comply with dirt, do not leave the cleaner on (couplers, connectors, instru-
the terms of the warranty, but it will the affected area any longer ments, switches and lights),
also keep your motorcycle looking than instructed. Also, tho- breather hoses and vents.
good, extend its life and optimize its roughly rinse the area off with ● For motorcycles equipped with
performance. water, immediately dry it, and a windshield: Do not use strong
Before cleaning then apply a corrosion protec- cleaners or hard sponges as
7 1. Cover the muffler outlet with a tion spray. they will cause dulling or scrat-
plastic bag after the engine has ● Improper cleaning can damage ching. Some cleaning com-
cooled down. windshields, cowlings, panels pounds for plastic may leave
2. Make sure that all caps and and other plastic parts. Use scratches on the windshield.
covers as well as all electrical only a soft, clean cloth or spon- Test the product on a small hid-
couplers and connectors, inclu- ge with mild detergent and den part of the windshield to
ding the spark plug cap, are water to clean plastic. make sure that it does not lea-
tightly installed. ● Do not use any harsh chemical ve any marks. If the windshield
3. Remove extremely stubborn dirt, products on plastic parts. Be is scratched, use a quality
like oil burnt onto the crankcase, sure to avoid using cloths or plastic polishing compound
with a degreasing agent and a sponges which have been in after washing.
brush, but never apply such pro- contact with strong or abrasive
7-1
5WX-F8199-E1.qxd 14/12/2004 15:05 Página 59

After normal use ECA10790
5. Use spray oil as a universal clea-
Remove dirt with warm water, a mild CAUTION ner to remove any remaining dirt.
detergent, and a soft, clean sponge, Do not use warm water since it 6. Touch up minor paint damage
and then rinse thoroughly with clean increases the corrosive action of caused by stones, etc.
water. Use a toothbrush or bottle- the salt. 7. Wax all painted surfaces.
brush for hard-to-reach areas. Stub- 8. Let the motorcycle dry comple-
2. Apply a corrosion protection
born dirt and insects will come off tely before storing or covering it.
spray on all metal, including
more easily if the area is covered with
chrome- and nickel-plated, surfa- EWA10930
a wet cloth for a few minutes before
ces to prevent corrosion. s WARNING
cleaning.
After cleaning ● Make sure that there is no oil or
After riding in the rain, near the sea or
1. Dry the motorcycle with a cha- wax on the brakes or tires. If
on salt-sprayed roads
mois or an absorbing cloth. necessary, clean the brake
Since sea salt or salt sprayed on
2. Immediately dry the drive chain discs and brake linings with a
roads during winter are extremely
and lubricate it to prevent it from regular brake disc cleaner or
corrosive in combination with water,
rusting. acetone, and wash the tires
carry out the following steps after
3. Use a chrome polish to shine with warm water and a mild
each ride in the rain, near the sea or
chrome, aluminum and stainless- detergent. 7
on salt-sprayed roads.
steel parts, including the exhaust ● Before operating the motorcy-
NOTE: system. (Even the thermally indu- cle test its braking performan-
Salt sprayed on roads in the winter ced discoloring of stainless-steel ce and cornering behavior.
may remain well into spring. exhaust systems can be removed
through polishing.) ECA10800
1. Clean the motorcycle with cold 4. To prevent corrosion, it is recom- CAUTION
water and a mild detergent, after mended to apply a corrosion pro-
● Apply spray oil and wax spa-
the engine has cooled down. tection spray on all metal, inclu-
ringly and make sure to wipe
ding chrome- and nickel-plated,
off any excess.
surfaces.
7-2
5WX-F8199-E1.qxd 14/12/2004 15:05 Página 60

● Never apply oil or wax to any and areas where strong chemi- c. Install the spark plug cap onto
rubber and plastic parts, but cals are stored. the spark plug, and then place
treat them with a suitable care the spark plug on the cylinder
Long-term
product. head so that the electrodes are
Before storing your motorcycle for
● Avoid using abrasive polishing grounded. (This will limit sparking
several months:
compounds as they will wear during the next step.)
1. Follow all the instructions in the
away the paint. d. Turn the engine over several
“Care” section of this chapter.
times with the starter. (This will
2. For motorcycles equipped with a
NOTE: coat the cylinder wall with oil.)
fuel cock that has an “OFF” posi-
Consult a Yamaha dealer for advice e. Remove the spark plug cap from
tion: Turn the fuel cock lever to
on what products to use. the spark plug, and then install
“OFF”.
the spark plug and the spark plug
3. Drain the carburetor float cham-
cap.
EAU26150 ber by loosening the drain bolt; EWA10950
Storage this will prevent fuel deposits s WARNING

Short-term from building up. Pour the drai- To prevent damage or injury from
Always store your motorcycle in a ned fuel into the fuel tank. sparking, make sure to ground the
7 cool, dry place and, if necessary, pro- 4. Fill up the fuel tank and add fuel spark plug electrodes while turning
tect it against dust with a porous stabilizer (if available) to prevent the engine over.
cover. the fuel tank from rusting and the
ECA10810
fuel from deteriorating. 6. Lubricate all control cables and
CAUTION the pivoting points of all levers
5. Perform the following steps to
● Storing the motorcycle in a protect the cylinder, piston rings, and pedals as well as of the
poorly ventilated room or cove- etc. from corrosion. sidestand/centerstand.
ring it with a tarp, while it is still a. Remove the spark plug cap and 7. Check and, if necessary, correct
wet, will allow water and humi- spark plug. the tire air pressure, and then lift
dity to seep in and cause rust. b. Pour a teaspoonful of engine oil the motorcycle so that both of its
● To prevent corrosion, avoid into the spark plug bore. wheels are off the ground. Alter-
damp cellars, stables (because natively, turn the wheels a little
of the presence of ammonia) every month in order to prevent
7-3
5WX-F8199-E1.qxd 14/12/2004 15:05 Página 61

the tires from becoming degra-
ded in one spot.
8. Cover the muffler outlet with a
plastic bag to prevent moisture
from entering it.
9. Remove the battery and fully
charge it. Store it in a cool, dry
place and charge it once a
month. Do not store the battery in
an excessively cold or warm pla-
ce [less than 0 °C (30 °F) or more
than 30 °C (90 °F)]. For more
information on storing the bat-
tery, see page 6-19.
NOTE:
Make any necessary repairs before
storing the motorcycle. 7
7-4
5WX-F8199-E1.qxd 14/12/2004 15:05 Página 62
SPECIFICATIONS
EAU26339
Transmission oil Secondary reduction ratio
Dimensions Oil change quantity 47 x 11 (4.270)
Overall length 0.75 L Transmission type
2007 mm Coolant reservoir capacity (up to the maxi- Constant mesh 6-speed
Overall width mum level mark) Gear ratio
675 mm 0.71 L 1st
Overall height Radiator capacity (including all routes) 36 x 12 (3.000)
1065 mm 0.70 L 2nd
Seat height Air filter element 33 x 16 (2.062)
815 mm Wet element 3rd
Wheelbase Fuel 29 x 19 (1.526)
1330 mm Fuel tank capacity 4th
Ground clearance 13.8 L 27 x 22 (1.227)
144 mm Fuel reserve amount 5th
Minimum turning radius 2.2 L 25 x 24 (1.041)
2900 mm Carburetor 6th
Weight Manufacturer 24 x 25 (0.960)
With oil and fuel Dell’Orto Chassis
124.2 kg Type x quantity Frame type
Engine PHBN 16 NS / 1 Double cradle
Engine type Spark plug (s) Caster angle
Liquid cooled 2-stroke Manufacturer/model 25.00 degree
Cylinder arrangement NGK/BR9ES Trail
8
Forward-inclined single cylinder Spark plug gap 92.0 mm
Displacement 0.6-0.7 mm Front tire
49.7 cm3 Clutch type Type
Bore x stroke Wet, multiple-disc Tubeless
40.3 x 39.0 mm Transmission Size
Compression ratio Primary reduction system 100/80-17 52H
6.85 :1 Helical gear Manufacturer/model
Starting system Primary reduction ratio PIRELLI
Electric starter 71 x 20 (3.550) Rear tire
Lubrication system Secondary reduction system Type
Separate lubrication (Yamaha autolube) Chain drive Tubeless
8-1
5WX-F8199-E1.qxd 14/12/2004 15:05 Página 63
SPECIFICATIONS
Size Recommended fluid Bulb voltage, wattage x quantity
130/70-17 62H DOT 4 Headlight
Manufacturer/model Rear brake 12 V, 25 W/25.0 W x 2
PIRELLI Type Tail/brake light
Maximum load Single disc brake 12 V, 5.0 W/21.0 W x 1
195 kg Recommended fluid Front turn signal light
Tire air pressure (measured on cold DOT 4 12 V, 16.0 W
tires) Front suspension Rear turn signal light
Loading condition Type 12 V, 10.0 W x 2
0-90 kg Telescopic fork Neutral indicator light
Front Spring/shock absorber type LED
180 kPa Coil spring/oil damper Oil level warning light
Rear Wheel travel LED
200 kPa 130.0 mm Turn signal indicator light
Loading condition Rear suspension LED
90-180 kg Type Coolant temperature warning light
Front Swingarm LED
190 kPa Spring/shock absorber type Main fuse
Rear Coil-gas spring/oil damper 10.0 A
230 kPa Wheel travel
Front wheel 102.0 mm
Wheel type Electrical system
Cast wheel Ignition system
Rim size DC. CDI 8
MT 2.75x17” Charging system
Rear wheel CDI magneto
Wheel type Model
Cast wheel YT4L-BS
Rim size Voltage, capacity
MT 3.50x17” 12 V, 3.0 Ah
Front brake Bulb type
Type Incandescence
Single disc brake
8-2
5WX-F8199-E1.qxd 14/12/2004 15:05 Página 64
CONSUMER INFORMATION
EAU26351 EAU26420
Identification numbers Frame serial number

Record the key identification number,
vehicle identification number and 1
model label information in the spaces
1
provided below for assistance when
ordering spare parts from a Yamaha
dealer or for reference in case the
vehicle is stolen.
KEY IDENTIFICATION NUMBER:
1. Key identification number
1. Frame serial number EAU26390
Key identification number

The frame serial number is stamped The key identification number is
VEHICLE IDENTIFICATION NUMBER: into the steering head pipe. stamped into the key.Record this
number in the space provided and
NOTE: use it for reference when ordering a
The frame serial number is used to new key.
identify your motorcycle and may be
MODEL LABEL INFORMATION: used to register your motorcycle with
the licensing authority in your area.
9
9-1
5WX-F8199-E1.qxd 14/12/2004 15:05 Página 65
CONSUMER INFORMATION
EAU26480
Model label 1
1. Model label
The model label is affixed to the frame

under the seat. (See page 3-7.)
Record the information on this label in
the space provided. This information
will be needed when ordering spare
parts from a Yamaha dealer.
9-2
5WX-F8199-E1.qxd 14/12/2004 15:05 Página 66
INDEX
A E Replacing the fuse ...................................6-20
Adjusting the brake pedal position and Engine break-in ..........................................5-3 Replacing the headlight bulb ...................6-21
free play .................................................6-13 Engine overheating ..................................6-25 Replacing the license plate light bulb......6-22
Adjusting the carburetor ............................6-9 F Right view ..................................................2-2
Adjusting the clucth lever free play .........6-12 Frame serial number ..................................9-1 S
Adjusting the engine idling speed .............6-9 Front brake pads......................................6-14 Seat ............................................................3-7
Adjusting the rear brake light switch .......6-13 Fuel cock....................................................3-6 Shift pedal..................................................3-4
Adjusting the throttle cable free play.........6-9 Fuel tank cap .............................................3-5 Shifting .......................................................5-2
B H Sidestand ...................................................3-8
Battery......................................................6-19 Handlebar switches ...................................3-3 Speedometer unit ......................................3-2
Brake lever .................................................3-4 I Starter (choke) lever...................................3-7
Brake pedal................................................3-5 Identification numbers ...............................9-1 Starting a cold engine................................5-1
C Ignition circuit cut-off system ....................3-8 Storage.......................................................7-2
Care............................................................7-1 Indicator lights ...........................................3-1 Storage compartment ................................3-7
Cast wheels .............................................6-12 K Supporting the mortorcycle .....................6-22
Catalytic converter .....................................3-6 Key identification number ..........................9-1 T
Clucht lever ................................................3-4 L Tachometer ................................................3-3
Controls and instruments ..........................2-3 Left view.....................................................2-1 Tips for reducing fuel consumption ...........5-2
Changing the brake fluid..........................6-15 Tires .........................................................6-10
M
Checking and lubricating the brake and To check the coolant level .........................6-8
Main switch/steering lock ..........................3-1
cluctch levers.........................................6-18 Transmission oil .........................................6-6
Model label ................................................9-2
Checking and lubricating the brake Troubleshooting .......................................6-23
O Troubleshooting charts ............................6-24
and shift pedals .....................................6-17
Owner’s tool kit ..........................................6-1
Checking and lubricating the cables .......6-17
Checking and lubricating the sidestand ..6-18 P
Parking .......................................................5-3
Checking the brake fluid level .................6-14
Periodic maintenance and lubrication
Checking the front fork ............................6-18
chart.........................................................6-2
Checking the spark plug............................6-6
Pre-operation check list.............................4-2
Checking the steering ..............................6-19
Checking the wheel bearings ..................6-19 R
Rear brake pads ......................................6-14
D
Removing and installing cowlings .............6-5
2-stroke engine oil........................................3-6
Replacing a turn signal light bulb or the
Drive Chain slack........................................6-16
tail/brake light bulb ................................6-21
5WX-F8199-E1.qxd 14/12/2004 15:05 Página 67
YAMAHA MOTOR ESPAÑA, S.A.

PRINTED IN SPAIN
2005.1-Bengar Gràfiques, S.L.
(E)

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5WX-F8199-E1.

qxd 14/12/2004 15:05 Página 1

Welcome to the Yamaha world of motorcycling!

IMPORTANT MANUAL INFORMATION

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

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

IMPORTANT MANUAL INFORMATION

IMPORTANT MANUAL INFORMATION

1 Headlight (page 6-21) 5 Fuel tank cap (page 3-5 )

Controls and instruments

INSTRUMENT AND CONTROL FUNCTIONS

and is used to lock the steering. The EAU10680

INSTRUMENT AND CONTROL FUNCTIONS

INSTRUMENT AND CONTROL FUNCTIONS

Engine stop switch “f/e”

INSTRUMENT AND CONTROL FUNCTIONS

The brake lever is located at the right

INSTRUMENT AND CONTROL FUNCTIONS

INSTRUMENT AND CONTROL FUNCTIONS

Catalytic converter 2-stroke engine oil Recommended oil:

observed to prevent a fire hazard or recommended 2-stroke engine oil if

INSTRUMENT AND CONTROL FUNCTIONS

this position. Fill the tank at the first Storage compartment 3

Starter (choke) lever “q”

To remove the seat

INSTRUMENT AND CONTROL FUNCTIONS

INSTRUMENT AND CONTROL FUNCTIONS

With the engine turned off:

INSTRUMENT AND CONTROL FUNCTIONS

The condition of a vehicle is the

Pre-operation check list

OPERATION AND IMPORTANT RIDING POINTS

OPERATION AND IMPORTANT RIDING POINTS

Shifting CAUTION Tips for reducing fuel

OPERATION AND IMPORTANT RIDING POINTS

that might result in engine overhea- CAUTION

PERIODIC MAINTENANCE AND MINOR REPAIR

PERIODIC MAINTENANCE AND MINOR REPAIR

Periodic maintenance and lubrication chart

ODOMETER READING (x 1000 Km) ANNUAL

NO ITEM CHEK OR MAINTENANCE JOB 1 6 12 18 24 CHECK

PERIODIC MAINTENANCE AND MINOR REPAIR

NO ITEM CHEK OR MAINTENANCE JOB 1 6 12 18 24 CHECK

Check tread depth and for damage.

PERIODIC MAINTENANCE AND MINOR REPAIR

NO ITEM CHEK OR MAINTENANCE JOB 1 6 12 18 24 CHECK

Check coolant level and vehicle for coolant leakage. √ √ √ √ √

PERIODIC MAINTENANCE AND MINOR REPAIR

1. Screws (x 7 Right side)

To remove the cowling 6

PERIODIC MAINTENANCE AND MINOR REPAIR

PERIODIC MAINTENANCE AND MINOR REPAIR

ned straight up when checking the oil CAUTION

PERIODIC MAINTENANCE AND MINOR REPAIR

To check the coolant level CAUTION

PERIODIC MAINTENANCE AND MINOR REPAIR

PERIODIC MAINTENANCE AND MINOR REPAIR

PERIODIC MAINTENANCE AND MINOR REPAIR

Minimum tire tread depth (front s WARNING EWA10600

and rear): ● The front and rear tires should s WARNING