OWNER’S MANUAL
AT115
5MX-F8199-E0
Engine start procedure
Before pushing start button, make sure to
apply the Front or Rear Brake and that the
Sidestand is retracted.
Engine oil replacement
Engine oil replacement : Every 2000 km.
Recommended oil : SAE20W - 50 type
SF Class Motor Oil
V-belt inspection
Periodic maintenance must be performed
by any authorized Yamaha Dealer (Refer to
the Owner's Manual for details.)
Load limit
Convenience hook : 1 kg, Helmet box: 5 kg
5MX-F835Y-00
EAU00000
INTRODUCTION
Congratulations on your purchase of the Yamaha AT115. This model is the result of
Yamaha’s vast experience in the production of fine sporting, touring, and pacesetting
racing machines. It represents the high degree of craftsmanship and reliability that
have made Yamaha a leader in these fields.
This manual will give you an understanding of the operation, inspection, and basic
maintenance of this motorcycle. If you have any questions concerning the operation
or maintenance of your motorcycle, please consult a Yamaha dealer.
EAU04229*
AT115
OWNER’S MANUAL
©2001 by Yamaha Motor Co., Ltd.
1st edition, December 2001
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Indonesia.
IMPORTANT MANUAL INFORMATION
WARNING
CAUTION:
NOTE:
Particularly important information is distinguished in this manual by the following notations:
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!
Failure to follow WARNING instructions could result in severe injury or death to the
motorcycle operator, a bystander, or a person inspecting or repairing the
motorcycle.
A CAUTION indicates special precautions that must be taken to avoid damage to the
motorcycle.
A NOTE provides key information to make procedures easier or clearer.
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 dealer.
_
WARNING
_
PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING
THIS MOTORCYCLE.
_
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EW000002
EAU00009
5
6
TABLE OF CONTENTS
GIVE SAFETY THE RIGHT OF WAY .................1-1
1
DESCRIPTION ...................................................2-1
2
Left view.............................................................2-1
Right view...........................................................2-2
Controls and instruments ...................................2-3
INSTRUMENT AND CONTROL FUNCTIONS ....3-1
3
Main switch/steering lock ..................................3-1
Indicator lights ...................................................3-2
Speedometer unit ..............................................3-2
Fuel gauge ........................................................3-2
Handlebar switches ...........................................3-3
Front brake lever ...............................................3-4
Rear brake lever ................................................3-4
Fuel tank cap .....................................................3-4
Fuel ...................................................................3-5
Starter (choke) lever .......................................... 3-6
Kickstarter .........................................................3-6
Seat ...................................................................3-6
Helmet box ........................................................3-7
Convenience hook .............................................3-8
PRE-OPERATION CHECKS ...............................4-1
4
Pre-operation check list .....................................4-1
OPERATION AND IMPORTANT RIDING
POINTS................................................................5-1
Starting and warming up a cold engine .............5-1
Starting a warm engine .....................................5-2
Starting off .........................................................5-2
Acceleration and deceleration ...........................5-3
Braking ..............................................................5-3
Engine break-in .................................................5-4
Parking ..............................................................5-5
General note ......................................................5-6
PERIODIC MAINTENANCE AND MINOR
REPAIR................................................................6-1
Owner’s tool kit ..................................................6-1
Periodic maintenance and lubrication chart ......6-2
Removing and installing the cowling and
panels ............................................................6-4
Checking the spark plug ....................................6-7
Engine oil and oil strainer ..................................6-9
Final transmission oil .......................................6-11
Cleaning the air filter element, V-belt case
air filter elements, and check hoses ............6-13
Adjusting the carburetor ..................................6-16
Adjusting the engine idling speed ...................6-17
Adjusting the throttle cable free play ...............6-17
Adjusting the valve clearance .........................6-18
TABLE OF CONTENTS
789
Tires ................................................................ 6-19
Spoke wheels .................................................. 6-21
Checking the front brake lever free play ..........6-21
Adjusting the rear brake lever free play .......... 6-22
Checking the front brake pads and rear
brake shoes .................................................6-23
Checking the brake fluid level .........................6-24
Changing the brake fluid ................................. 6-25
Checking the V-belt ......................................... 6-25
Checking and lubricating the cables ...............6-25
Checking and lubricating the throttle grip
and cable .....................................................6-26
Lubricating the front and rear brake levers .....6-26
Checking and lubricating the centerstand
and sidestand .............................................. 6-27
Checking the front fork .................................... 6-27
Checking the steering ..................................... 6-28
Checking the wheel bearings .......................... 6-29
Battery ............................................................. 6-29
Replacing the fuse .......................................... 6-31
Replacing a headlight bulb ..............................6-33
Replacing a front turn signal light bulb ............ 6-34
Replacing the tail/brake light bulb or a rear
turn signal light bulb .................................... 6-35
Troubleshooting .............................................. 6-37
Troubleshooting chart .....................................6-38
MOTORCYCLE CLEANING AND STORAGE.....7-1
A. CLEANING ....................................................7-1
B. STORAGE ..................................................... 7-1
SPECIFICATIONS...............................................8-1
Specifications .................................................... 8-1
CONSUMER INFORMATION..............................9-1
Identification numbers .......................................9-1
Frame serial number .........................................9-1
Engine serial number ........................................ 9-1
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1-
GIVE SAFETY THE RIGHT OF WAY
Motorcycles are fascinating vehicles, which can give you an unsurpassed feeling of power and
freedom. However, they also impose certain limits, which you must accept; even the best motorcycle
does not ignore the laws of physics.
Regular care and maintenance are essential for preserving value and operating condition of your
motorcycle. Moreover, what is true for the motorcycle is also true for the rider: good performance
depends on being in good shape. Riding under the influence of medication, drugs and alcohol is, of
course, out of the question. Motorcycle riders—more than car drivers—must always be at their mental
and physical best. Under the influence of even small amounts of alcohol, there is a tendency to take
dangerous risks.
Protective clothing is as essential for the motorcycle rider as seat belts are for car drivers and
passengers. Always wear a complete motorcycle suit (whether made of leather or tear-resistant
synthetic materials with protectors), sturdy boots, motorcycle gloves and a properly fitting helmet.
Optimum protective wear, however, should not encourage carelessness. Although full-coverage
helmets and suits, in particular, create an illusion of total safety and protection, motorcyclists will
always be vulnerable. Riders who lack critical self-control run the risk of going too fast and are apt to
take chances. This is even more dangerous in wet weather. The good motorcyclist rides safely,
predictably and defensively—avoiding all dangers, including those caused by others.
Enjoy your ride!
1
2
3
4
5
6
7
8
9
1-1
DESCRIPTION
2-
Left view
2
EAU00026
1. Convenience hook (page 3-8)
2. Throttle stop screw (page 6-17)
3. Helmet box, Owner’s tool kit (page 3-7, page 6-1)
4. Kickstarter (page 3-6)
5. Engine oil drain bolt B (page 6-10)
6. Engine oil drain bolt A (page 6-10)
2-1
Right view
7. Engine oil filler cap (page 6-9)
8. Air filter element (page 6-13)
9. Battery (page 6-29)
10. Fuses (page 6-31)
DESCRIPTION
2
2-2
DESCRIPTION
Controls and instruments
2
1. Rear brake lever (page 3-4)
2. Starter choke lever (page 3-6)
3. Left handlebar switches (page 3-3)
4. Speedometer unit (page 3-2)
5. Fuel gauge (page 3-2)
6. Start switch (page 3-3)
7. Throttle grip (page 6-17)
8. Front brake lever (page 3-4)
2-3
EAU00027
EAU00029
Main switch/steering lock
The main switch/steering lock controls
the ignition and lighting systems, and is
used to lock the steering. The various
positions are described below.
EAU00030*
ON
All electrical systems are supplied with
power, and the meter lighting comes
on, and the engine can be started. The
key cannot be removed.
EAU00038
OFF
All electrical systems are off. The key
can be removed.
INSTRUMENT AND CONTROL FUNCTIONS
3-
1. Push.
LOCK
EAU00040
The steering is locked, and all electrical
systems are off. The key can be re-
2. Turn.
To unlock the steering
Push the key in, and then turn it to
“OFF” while still pushing it.
moved.
WARNING
To lock the steering
1. Turn the handlebars all the way to
the left.
2. Push the key in from the “OFF” position, and then turn it to “LOCK”
while still pushing it.
3. Remove the key.
3-1
_
Never turn the key to “OFF” or
“LOCK” while the motorcycle is
moving, otherwise the electrical
systems will be switched off, which
may result in loss of control or an
accident. Make sure that the motorcycle is stopped before turning the
key to “OFF” or “LOCK”.
_
3
EW000016
INSTRUMENT AND CONTROL FUNCTIONS
3
1. Left turn signal indicator light “”
2. Right turn signal indicator light “”
3. High beam indicator light “”
EAU00056
Indicator lights
EAU04121
Turn signal indicator lights “”
and “”
The corresponding indicator light flashes when the turn signal switch is
pushed to the left or right.
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High beam indicator light “”
This indicator light comes on when the
high beam of the headlight is switched
on.
1. Speedometer
2. Odometer
Speedometer unit
The speedometer unit is equipped with
a speedometer and an odometer. The
speedometer shows riding speed. The
odometer shows the total distance traveled.
EAU00098
1. Fuel gauge
EAU02950*
Fuel gauge
The fuel gauge indicates the amount of
fuel in the fuel tank. The needle moves
towards “E” (Empty) as the fuel level
decreases. When the needle reaches
the red line, refuel as soon as possible.
NOTE:
_
Do not allow the fuel tank to empty
●
itself completely.
Turning the key to “OFF” cancel
●
the fuel gauge reading.
_
3-2
INSTRUMENT AND CONTROL FUNCTIONS
1. Light switch “ / ”
2. Dimmer switch “ / ”
3. Turn signal switch “ / ”
4. Horn switch “HORN”
EAU00118
Handlebar switches
EAU02948*
Light switch “ / ”
Set the light switch to “” to turn on
the headlight and the taillight. Set this
switch to “” to turn them off.
Dimmer switch “ / ”
EAU03888
Set this switch to “” for the high
beam and to “” for the low beam.
EAU03889
Turn signal switch “ / ”
To signal a right-hand turn, push this
switch to “”. To signal a left-hand
turn, push this switch to “”. When
released, the switch returns to the center position. To cancel the turn signal
lights, push the switch in after it has returned to the center position.
EAU00130
Horn switch “HORN”
Press this switch to sound the horn.
1. Start switch “START”
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Start switch “START”
Push this switch to crank the engine
with the starter.
EC000005
CAUTION:
_
See page 5-1 for starting instructions prior to starting the engine.
_
3
3-3
INSTRUMENT AND CONTROL FUNCTIONS
3
1. Front brake lever 1. Rear brake lever 1. Fuel tank cap
EAU03882
Front brake lever
The front brake lever is located on the
right handlebar grip. To apply the front
brake, pull this lever toward the handlebar grip.
Rear brake lever
The rear brake lever is located on the
left handlebar grip. To apply the rear
brake, pull this lever toward the handlebar grip.
EAU00163
a. Open.
b. Close.
Fuel tank cap
To remove the fuel tank cap
EAU03468*
1. Open the seat. (See page 3-6 for
seat opening and closing procedures.)
2. Turn the fuel tank cap counterclockwise and pull it off.
3-4
To install the fuel tank cap
1. Insert the fuel tank cap into the
tank opening and turn it clockwise
until the alignment marks on the
cap and tank are aligned.
2. Close the seat.
EW000024
WARNING
_
Make sure that the fuel tank cap is
properly installed before riding.
_
INSTRUMENT AND CONTROL FUNCTIONS
CAUTION:
_
Immediately wipe off spilled fuel
with a clean, dry, soft cloth, since
fuel may deteriorate painted surfaces or plastic parts.
_
1. Fuel tank filler tube
2. Fuel level
EAU03753
Fuel
Make sure that there is sufficient fuel in
the tank. Fill the fuel tank to the bottom
of the filler tube as shown.
WARNING
_
●
Do not overfill the fuel tank, otherwise it may overflow when the
fuel warms up and expands.
●
Avoid spilling fuel on the hot
engine.
_
EW000130
Recommended fuel:
Regular gasoline
Fuel tank capacity:
Total amount:
4.9 L
EAU00185
EAU00187*
3
3-5
INSTRUMENT AND CONTROL FUNCTIONS
3
1. Starter (choke) lever “” 1. Kickstarter 1. Open.
EAU03839
Starter (choke) lever “”
Starting a cold engine requires a richer
air-fuel mixture, which is supplied by
the starter (choke).
Move the lever in direction a to turn on
the starter (choke).
Move the lever in direction b to turn off
the starter (choke).
Kickstarter
To start the engine, fold out the kickstarter lever, move it down lightly with
your foot until the gears engage, and
then push it down smoothly but forcefully.
EAU00214
EAU03802*
Seat
To open the seat
1. Place the motorcycle on the centerstand.
2. Insert the key into the main switch,
and then turn it counterclockwise.
NOTE:
_
Do not push inward when turning the
key.
_
3. Fold the seat up.
3-6
INSTRUMENT AND CONTROL FUNCTIONS
To close the seat
1. Fold the seat down, and then push
it down to lock it in place.
2. Remove the key from the main
switch if the motorcycle will be left
unattended.
NOTE:
_
Make sure that the seat is properly secured before riding.
_
1. Helmet box
EAU03450*
Helmet box
There is a helmet box under the seat.
(See page 3-6 for seat opening and
closing procedures.)
WARNING
_
●
Do not exceed the load limit of
5 kg for the helmet box.
●
Do not exceed the maximum
load of 116 kg for the vehicle.
_
EWA00005*
EC000010*
CAUTION:
_
Keep the following points in mind
when using the helmet box.
●
Since the helmet box accumulates heat when exposed to the
sun, do not store anything susceptible to heat inside it.
●
To avoid humidity from spreading through the helmet box,
wrap wet articles in a plastic
bag before storing them in the
box.
●
Since the helmet box may get
wet while the motorcycle is being washed, wrap any articles
stored in the box in a plastic
bag.
●
Do not keep anything valuable
or breakable in the helmet box.
_
3
3-7
INSTRUMENT AND CONTROL FUNCTIONS
To store a helmet in the helmet box,
place the helmet upside-down with the
front facing forward.
NOTE:
_
Some helmets cannot be stored in
●
the helmet box because of their
3
size or shape.
Do not leave your motorcycle un-
●
attended with the seat open.
_
1. Convenience hook
Convenience hook
WARNING
_
●
Do not exceed the load limit of
1 kg for the convenience hook.
●
Do not exceed the maximum
load of 116 kg for the vehicle.
_
EAUT0020*
EWT00002*
3-8
EAU01114
PRE-OPERATION CHECKS
4-
The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly,
even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss
of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thorough visual inspection, to check the following points before each ride.
EAU03439
Pre-operation check list
CO-01E
Fuel
Engine oil
Final transmission oil
Front brake
Rear brake
Throttle grip
Control cables
Wheels and tires
ITEM CHECKS PAGE
• Check fuel level in fuel tank.
• Refuel if necessary.
• Check fuel line for leakage.
• Check oil level in engine.
• If necessary, add recommended oil to specified level.
• Check vehicle for oil leakage.
• Check vehicle for oil leakage. 6-11–6-12
• Check operation.
• If soft or spongy, have Yamaha dealer bleed hydraulic system.
• Check fluid level in reservoir.
• If necessary, add recommended brake fluid to specified level.
• Check hydraulic system for leakage.
• Check operation.
• Check lever free play.
• Adjust if necessary.
• Make sure that operation is smooth.
• Check cable free play.
• If necessary, have Yamaha dealer adjust cable free play and lubricate cable and
grip housing.
• Make sure that operation is smooth.
• Lubricate if necessary.
• Check for damage.
• Check tire condition and tread depth.
• Check air pressure.
• Correct if necessary.
4-1
3-5
6-9
6-21–6-24
6-22–6-23
6-17–6-18, 6-26
6-25
6-19–6-21
4
PRE-OPERATION CHECKS
ITEM CHECKS PAGE
Brake levers
Centerstand, sidestand
Chassis fasteners
Instruments, lights, signals
and switches
Battery
4
NOTE:
_
Pre-operation checks should be made each time the motorcycle is used. Such an inspection can be accomplished in a very
short time; and the added safety it assures is more than worth the time involved.
_
WARNING
_
If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operating
the motorcycle.
_
• Make sure that operation is smooth.
• Lubricate lever pivoting points if necessary.
• Make sure that operation is smooth.
• Lubricate pivots if necessary.
• Make sure that all nuts, bolts and screws are properly tightened.
• Tighten if necessary.
• Check operation.
• Correct if necessary.
• Check fluid level.
• Fill with distilled water if necessary.
6-26
6-27
—
—
6-29–6-31
EWA00033
4-2
EAU00372
WARNING
_
Become thoroughly familiar
●
with all operating controls and
their functions before riding.
Consult a Yamaha dealer regarding any control or function
that you do not thoroughly understand.
Never start the engine or oper-
●
ate it in a closed area for any
length of time. Exhaust fumes
are poisonous, and inhaling
them can cause loss of consciousness and death within a
short time. Always make sure
that there is adequate ventilation.
For safety, always start the en-
●
gine with the centerstand.
Before starting out, make sure
●
that the sidestand is up. If the
sidestand is not raised completely, it could contact the
ground and distract the operator, resulting in a possible loss
of control.
_
EAU00373*
OPERATION AND IMPORTANT RIDING POINTS
5-
1. Starter (choke) lever “” 1. Start switch “START”
EAU00416*
Starting and warming up a
cold engine
EC000046
CAUTION:
_
See page 5-4 for engine break-in instructions prior to operating the vehicle for the first time.
_
1. Turn the key to “ON”.
2. Turn on the starter (choke) and
completely close the throttle grip.
(See page 3-6 for starter (choke)
operation.)
2. Kickstarter
3. Start the engine by pushing the
start switch, while applying the
front or rear brake or by pushing
the kickstarter lever down.
NOTE:
_
If the engine fails to start, release the
start switch, wait a few seconds, and
then try again. Each starting attempt
should be as short as possible to preserve the battery. Do not crank the engine more than 5 seconds on any one
attempt. If the engine does not start
with the starter motor, try using the
kickstarter with the motorcycle on the
centerstand.
_
5-1
5
OPERATION AND IMPORTANT RIDING POINTS
4. After starting the engine, move the
starter (choke) back about halfway.
CAUTION:
_
For maximum engine life, always
warm the engine up before starting
off. Never accelerate hard when the
engine is cold!
_
5. When the engine is warm, turn the
starter (choke) off.
5
NOTE:
_
For maximum engine life, always warm
up the engine before riding your motorcycle. Never accelerate hard with a
cold engine.
_
ECA00055
EAU01258
Starting a warm engine
Follow the same procedure as for starting a cold engine with the exception
that the starter (choke) is not required
when the engine is warm.
5-2
EAU00433*
Starting off
NOTE:
_
Before starting off, allow the engine to
warm up.
_
1. While pulling the rear brake lever
with your left hand and holding the
grab bar with your right hand, push
the motorcycle off the centerstand.
2. Sit astride the seat, and then adjust the rear view mirrors.
3. Switch the turn signal on.
4. Check for oncoming traffic, and
then slowly turn the throttle grip
(on the right) in order to take off.
5. Switch the turn signal off.
OPERATION AND IMPORTANT RIDING POINTS
Front Rear
EAU00434
Acceleration and deceleration
The speed can be adjusted by opening
and closing the throttle. To increase the
speed, turn the throttle grip in
direction a. To reduce the speed, turn
the throttle grip in direction b.
EAU00435*
Braking
1. Close the throttle completely.
2. Apply both front and rear brakes
simultaneously while gradually increasing the pressure.
WARNING
_
●
Avoid braking hard or suddenly
(especially when leaning over to
one side), otherwise the motorcycle may skid or overturn.
5-3
EW000057*
●
Railroad crossings, streetcar
rails, iron plates on road construction sites, and manhole
covers become extremely slippery when wet. Therefore, slow
down when approaching such
areas and cross them with caution.
●
Keep in mind that braking on a
wet road is much more difficult.
●
Ride slowly down a hill, as braking downhill can be very difficult.
_
5
OPERATION AND IMPORTANT RIDING POINTS
Engine break-in
There is never a more important period
in the life of your engine than the period
between 0 and 1,000 km. For this reason, you should read the following material carefully.
Since the engine is brand new, do not
put an excessive load on it for the first
1,000 km. The various parts in the engine wear and polish themselves to the
correct operating clearances. During
5
this period, prolonged full-throttle operation or any condition that might result
in engine overheating must be avoided.
EAU00436
0–150 km
EAU00447*
Avoid prolonged operation above
●
1/3 throttle.
After every hour of operation, stop
●
the engine, and then let it cool for
five to ten minutes.
Vary the engine speed from time
●
to time. Do not operate the engine
at one set throttle position.
150–500 km
Avoid prolonged operation above
●
1/2 throttle.
Rev the engine freely through the
●
gears, but do not use full throttle at
any time.
EC000058*
CAUTION:
_
After 500 km of operation, the engine oil and the final transmission
oil must be changed and the engine
oil strainer cleaned.
_
500–1,000 km
Avoid prolonged operation above
3/4 throttle.
1,000 km and beyond
Avoid prolonged full-throttle operation.
Vary the speed occasionally.
EC000049
CAUTION:
_
If any engine trouble should occur
during the engine break-in period,
immediately have a Yamaha dealer
check the vehicle.
_
5-4
EAU00460
Parking
When parking, stop the engine, and
then remove the key from the main
switch.
WARNING
_
●
Since the engine and exhaust
system can become very hot,
park in a place where pedestrians or children are not likely to
touch them.
●
Do not park on a slope or on
soft ground, otherwise the
motorcycle may overturn.
_
EW000058
OPERATION AND IMPORTANT RIDING POINTS
5
5-5
OPERATION AND IMPORTANT RIDING POINTS
General note
Much can be gained from the correct use and maintenance of a motorcycle.
1. THE CUSTOMERS CAN USE THE FULLEST
POTENTIAL OF YAMAHA MOTORCYCLES
5
2. A MOTORCYCLE CAN KEEP ITS PERFORMANCE
CAPABILITY FOR A LONGER TIME
5-6
OPERATION AND IMPORTANT RIDING POINTS
3. FUEL COST AND REPAIR EXPENSES CAN BE
KEPT TO A MINIMUM
4. A MOTORCYCLE CAN DEMAND A HIGH PRICE
WHEN IT IS TRADED IN AS A USED PRODUCT
5
5-7
PERIODIC MAINTENANCE AND MINOR REPAIR
6-
EAU00462
Safety is an obligation of the owner.
Periodic inspection, adjustment and lubrication will keep your vehicle in the
safest and most efficient condition possible. The most important points of inspection, adjustment, and lubrication
are explained on the following pages.
The intervals given in the periodic
maintenance and lubrication chart
should be simply considered as a general guide under normal riding conditions. However, DEPENDING ON THE
WEATHER, TERRAIN, GEOGRAPHICAL LOCATION, AND INDIVIDUAL
6
USE, THE MAINTENANCE INTERVALS MAY NEED TO BE SHORTENED.
WARNING
_
If you are not familiar with motorcycle maintenance work, have a
Yamaha dealer do it for you.
_
EAU00464
EW000060
1. Owner’s tool kit
EAU03846*
Owner’s tool kit
The owner’s tool kit is located on the
bottom of the seat. (See page 3-6 for
seat opening and closing procedures.)
The service information included in this
manual and the tools provided in the
owner’s tool kit are intended to assist
you in the performance of preventive
maintenance and minor repairs. However, additional tools such as a torque
wrench may be necessary to perform
certain maintenance work correctly.
NOTE:
_
If you do not have the tools or experience required for a particular job, have
a Yamaha dealer perform it for you.
_
_
WARNING
EW000063
Modifications not approved by
Yamaha may cause loss of performance and render the vehicle unsafe for use. Consult a Yamaha
dealer before attempting any changes.
_
6-1
PERIODIC MAINTENANCE AND MINOR REPAIR
CP-03E
NO. ITEM CHECK OR MAINTENANCE JOB
Fuel line
1
*
2 Spark plug
3
Valves
*
4 Air filter element
V-belt case air filter
5
elements
6*Battery
7*Front brake
8*Rear brake
9*Wheels
10
Wheel bearings
*
Swingarm
11
*
12*Steering bearings
13
Chassis fasteners
*
14 Sidestand/centerstand
15*Front fork
Periodic maintenance and lubrication chart
• Check fuel hoses and vacuum hose for cracks or damage. √√√√
• Check condition.
• Clean and regap.
• Replace if necessary. √√√
• Check valve clearance.
• Adjust.
• Clean. Replace if necessary. √√√√
• Clean. Replace if necessary. √√√√
• Check electrolyte level and specific gravity.
• Make sure that the breather hose is properly routed.
• Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-3.)
• Replace brake pads if necessary.
• Check operation and adjust brake lever free play.
• Replace brake shoes if necessary.
• Check runout, spoke tightness and for damage.
• Tighten spokes if necessary.
• Check bearing for looseness or damage. √√√√
• Check operation and for excessive play.
• Lubricate with lithium-soap based grease, every 24,000 km.
• Check bearing play and steering for roughness.
• Lubricate with lithium-soap-based grease, every 12,000 km.
• Make sure that all nuts, bolts and screws are properly tightened. √√√√
• Check operation.
• Lubricate.
• Check operation and for oil leakage. √√√√
6-2
EAU00473
ODOMETER READING (×1,000 km)
0.5 2 4 8 12
√√√√√
√√√√√
√√√√
√√√√√
√√√√√
√√√√
√√√√
√√√√√
√√√√
6
PERIODIC MAINTENANCE AND MINOR REPAIR
NO. ITEM CHECK OR MAINTENANCE JOB
Shock absorber
16
*
assemblies
17*Carburetor
18 Engine oil
19
Engine oil strainer
*
20 Final transmission oil
V-belt
21
*
Front and rear brake
22
*
switches
23 Moving parts and cables
6
Lights, signals and
24
*
switches
* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.
NOTE:
_
From 16,000 km, repeat the maintenance intervals starting from 4,000 km.
●
Depending on riding conditions, the V-belt replacement interval may vary.
●
The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
●
Hydraulic brake system
●
• Check operation and shock absorbers for oil leakage. √√√√
• Check starter (choke) operation.
• Adjust engine idling speed.
• Change.
• Check oil level and vehicle for oil leakage.
• Clean. √√
• Check vehicle for oil leakage. √√√√√
• Change. √ Every 10,000 km
• Check the damage and wear. √√√
• Replace. Every 25,000 km (See NOTE.)
• Check operation. √√√√√
• Lubricate. √√√√
• Check operation.
• Adjust headlight beam.
• After disassembling the brake master cylinder, and caliper cylinder, always change the fluid. Regularly check the
brake fluid level and fill reservoir as required.
• Replace the oil seals on the inner parts of the brake master cylinder and caliper cylinder every two years.
• Replace the brake hose every four years or if cracked or damaged.
_
6-3
ODOMETER READING (×1,000 km)
0.5 2 4 8 12
√√√√√
√√ Every 2,000 km
√√√√√
EAU03057*
PERIODIC MAINTENANCE AND MINOR REPAIR
1. Panel A
2. Panel B
3. Cowling B
4. Cowling A
EAU03516
Removing and installing the
cowling and panels
The cowling and panels shown above
need to be removed to perform some
of the maintenance jobs described in
this chapter. Refer to this section each
time the cowling or a panel needs to be
removed and installed.
1. Panel A
2. Screw (× 2)
EAU01074*
Panel A
To remove the panel
Remove the screws, and then pull the
panel off as shown.
6-4
To install the panel
Place the panel in the original position,
and then install the screws.
NOTE:
_
Make sure that the projections fit into
the grommets and that the tabs fit into
the slots.
_
6
PERIODIC MAINTENANCE AND MINOR REPAIR
1. Screw (× 2)
2. Panel B
Panel B
To remove the panel
1. Open the seat. (See page 3-6 for
6
seat opening and closing procedures.)
2. Remove the screws, and then pull
the panel off as shown.
To install the panel
Place the panel in the original position,
and then install the screws.
EAU03971
1. Screw (× 2)
2. Cowling A
3. License plate bracket
EAU03886*
Cowling A
To remove the cowling
1. Remove the license plate bracket
by removing the screws.
6-5
1. Screw (× 2)
2. Cowling A
2. Remove the screws on cowling A.
1. Screw (× 6)
2. Cowling B
3. Remove the screws on cowling B.
PERIODIC MAINTENANCE AND MINOR REPAIR
4. Pull cowling A off as shown.
NOTE:
_
When removing cowling A, pull out on
the areas shown from bottom to top.
_
To install the cowling
1. Align the tabs in cowling A with the
slots of cowling B, and then push
cowling A into the original position.
NOTE:
_
When installing cowling A, push in on
the areas shown from top to bottom.
_
2. Install the screws on cowling B.
3. Install the screws on cowling A.
4. Install the license plate bracket by
installing the screws.
6
6-6
PERIODIC MAINTENANCE AND MINOR REPAIR
1. Spark plug cap 1. Spark plug wrench
Checking the spark plug
The spark plug is an important engine
component, which is easy to check.
Since heat and deposits will cause any
6
spark plug to slowly erode, the spark
plug should be removed and checked
in accordance with the periodic maintenance and lubrication chart. In addition,
the condition of the spark plug can reveal the condition of the engine.
To remove the spark plug
1. Remove panel A. (See page 6-4
for panel removal and installation
procedures.)
2. Remove the spark plug cap.
EAUT0004*
3. Remove the spark plug as shown,
with the spark plug wrench included in the owner’s tool kit.
6-7
To check the spark plug
1. Check that the porcelain insulator
around the center electrode of the
spark plug is a medium-to-light tan
(the ideal color when the motorcycle is ridden normally).
NOTE:
_
If the spark plug shows a distinctly different color, the engine could be defective. Do not attempt to diagnose such
problems yourself. Instead, have a
Yamaha dealer check the motorcycle.
_
2. Check the spark plug for electrode
erosion and excessive carbon or
other deposits, and replace it if
necessary.
Specified spark plug:
CR7HSA (NGK)
a. Spark plug gap
To install the spark plug
1. Measure the spark plug gap with a
wire thickness gauge and, if necessary, adjust the gap to specification.
Spark plug gap:
0.6–0.7 mm
2. Clean the surface of the spark
plug gasket and its mating surface, and then wipe off any grime
from the spark plug threads.
3. Install the spark plug with the
spark plug wrench, and then tighten it to the specified torque.
PERIODIC MAINTENANCE AND MINOR REPAIR
Tightening torque:
Spark plug:
12.5 Nm (1.25 m·kgf)
NOTE:
_
If a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4–1/2 turn
past finger tight. However, the spark
plug should be tightened to the specified torque as soon as possible.
_
4. Install the spark plug cap.
5. Install the panel.
6
6-8
PERIODIC MAINTENANCE AND MINOR REPAIR
EAUT0016*
Engine oil and oil strainer
The engine oil level should be checked
before each ride. In addition, the oil
must be changed and the oil strainer
cleaned at the intervals specified in the
periodic maintenance and lubrication
chart.
To check the engine oil level
1. Place the motorcycle on the centerstand.
NOTE:
_
Make sure that the motorcycle is posi-
6
tioned straight up when checking the oil
level. A slight tilt to the side can result in
a false reading.
_
2. Start the engine, warm it up for
several minutes, and then turn it
off.
1. Engine oil filler cap 1. Dipstick
3. Wait a few minutes until the oil set-
2. Maximum level mark
3. Minimum level mark
tles, remove the oil filler cap, wipe
NOTE:
the dipstick clean, insert it back
into the oil filler hole (without
screwing it in), and then remove it
again to check the oil level.
_
The engine oil should be between the
minimum and maximum level marks.
_
4. If the engine oil is below the minimum level mark, add sufficient oil
of the recommended type to raise
it to the correct level.
6-9
To change the engine oil and clean
the oil strainer
1. Start the engine, warm it up for
several minutes, and then turn it
off.
2. Place an oil pan under the engine
to collect the used oil.
PERIODIC MAINTENANCE AND MINOR REPAIR
1. Engine oil drain bolt A
2. Engine oil drain bolt B
3. Remove the engine oil filler cap
and drain bolts to drain the oil from
the crankcase.
NOTE:
_
When only changing the engine oil, remove engine oil drain bolt A only.
_
6-10
1. Strainer
2. Compression spring
3. O-ring
EC000070*
CAUTION:
_
When removing the engine oil drain
bolt B, the O-ring, spring, and oil
strainer will fall out. Take care not to
lose these parts.
_
4. Clean the oil strainer with solvent,
and then check it for damage and
replace it if necessary.
5. Check the O-ring for damage and
replace it if necessary.
6. Install the oil strainer, spring, O-ring
and engine oil drain bolts, and then
tighten the drain bolts to the specified torque.
6
PERIODIC MAINTENANCE AND MINOR REPAIR
Tightening torques:
Engine oil drain bolt A:
20 Nm (2.0 m·kgf)
Engine oil drain bolt B:
20 Nm (2.0 m·kgf)
NOTE:
_
Make sure that the O-ring is properly
seated.
_
7. Add the specified amount of the
recommended engine oil, and
then install and tighten the engine
oil filler cap.
6
Recommended engine oil:
See page 8-1.
Oil quantity:
Periodic oil change:
0.8 L
Total amount (dry engine):
0.9 L
ECA00105
CAUTION:
_
●
In order to prevent clutch slippage (since the engine oil also
lubricates the clutch), do not
mix any chemical additives with
the oil or use oils of grade “CD”
or higher. In addition, do not
use oils labeled “ENERGY CONSERVING II” or higher.
●
Make sure that no foreign material enters the crankcase.
_
8. Start the engine, and then let it idle
for several minutes while checking
it for oil leakage. If oil is leaking,
immediately turn the engine off
and check for the cause.
9. Turn the engine off, and then
check the oil level and correct it if
necessary.
6-11
1. Oil filler cap
EAU04228*
Final transmission oil
The final transmission case must be
checked for oil leakage before each
ride. If any leakage is found, have a
Yamaha dealer check and repair the
motorcycle. In addition, the final transmission oil must be changed as follows
at the intervals specified in the periodic
maintenance and lubrication chart.
1. Start the engine, warm it up by
riding the motorcycle for several
minutes, and then stop the engine.
2. Place the motorcycle on the centerstand.
3. Place an oil pan under the final
transmission case to collect the
used oil.
1. Final transmission oil drain bolt
4. Remove the oil filler cap and drain
bolt to drain the oil from the final
transmission case.
5. Install the final transmission oil
drain bolt, and then tighten it to the
specified torque.
Tightening torque:
Final transmission oil drain bolt:
22 Nm (2.2 m·kgf)
6. Add the specified amount of the
recommended final transmission
oil, and then install and tighten the
oil filler cap.
PERIODIC MAINTENANCE AND MINOR REPAIR
Recommended final transmission
oil:
See page 8-1.
Oil quantity:
0.1 L
EWA00062
WARNING
_
●
Make sure that no foreign material enters the final transmission case.
●
Make sure that no oil gets on
the tire or wheel.
_
7. Check the final transmission case
for oil leakage. If oil is leaking,
check for the cause.
6
6-12
PERIODIC MAINTENANCE AND MINOR REPAIR
EAUM0058*
Cleaning the air filter element,
V-belt case air filter elements,
and check hoses
The air filter and the V-belt case air filter elements should be cleaned at the
intervals specified in the periodic maintenance and lubrication chart. Clean
both filter elements more frequently if
you are riding in unusually wet or dusty
areas. In addition, the air filter check
hoses must be frequently checked and
cleaned if necessary.
6
Cleaning the air filter element
1. Place the motorcycle on the centerstand.
2. Remove panel A. (See page 6-4
for panel removal and installation
procedures.)
1. Air filter case cover
2. Screw (× 5)
3. Remove the air filter case cover by
removing the screws.
1. Air filter element
4. Pull the air filter element out.
6-13
PERIODIC MAINTENANCE AND MINOR REPAIR
5. Lightly tap the air filter element to
remove most of the dust and dirt,
and then blow the remaining dirt
out with compressed air.
6. Check the air filter element for
damage and replace it if necessary.
7. Insert the air filter element into the
air filter case.
8. Install the air filter case cover by
installing the screws.
9. Install the panel.
1. V-belt case air filter cover A
2. Bolt (× 2)
Cleaning the V-belt case air filter
elements
1. Remove V-belt case air filter cover
A by removing the bolts.
6-14
1. V-belt case air filter cover B
2. Bolt (× 3)
2. Remove V-belt case air filter cover
B by removing the bolts.
6
PERIODIC MAINTENANCE AND MINOR REPAIR
1. Air filter element (× 2)
3. Remove the air filter elements,
and then blow out the dirt with
compressed air as shown.
6
4. Check each air filter element for
damage and replace them if necessary.
5. Install the air filter elements.
6. Install V-belt case air filter cover B
by installing the bolts.
7. Install V-belt case air filter cover A
by installing the bolts.
EC000092*
CAUTION:
_
●
Make sure that each filter element is properly seated in its
case.
●
The engine should never be operated without the air filter element installed, otherwise the
piston and/or cylinder may become excessively worn.
_
6-15
PERIODIC MAINTENANCE AND MINOR REPAIR
1. Check hose (× 2) 1. Check hose
To clean the air filter check hoses
1. Check each hose at the bottom of
the air filter case and the V-belt
case for accumulated dirt or water.
2. If dirt or water is visible, remove
the hose, clean it, and then install
it.
EAU00629
Adjusting the carburetor
The carburetor is an important part of
the engine and requires very sophisticated adjustment. Therefore, most carburetor adjustments should be left to a
Yamaha dealer, who has the necessary professional knowledge and experience. The adjustment described in
the following section, however, may be
serviced by the owner as part of routine
maintenance.
CAUTION:
_
The carburetor has been set and extensively tested at the Yamaha factory. Changing these settings
without sufficient technical knowledge may result in poor performance of or damage to the engine.
_
EC000094
6
6-16
PERIODIC MAINTENANCE AND MINOR REPAIR
Adjusting the engine idling
speed
The engine idling speed must be
checked and, if necessary, adjusted as
follows at the intervals specified in the
periodic maintenance and lubrication
chart.
NOTE:
_
A diagnostic tachometer is needed to
make this adjustment.
_
1. Attach the tachometer to the spark
plug lead.
6
2. Start the engine and warm it up
for several minutes at 1,000–
2,000 r/min while occasionally
revving it to 4,000–5,000 r/min.
NOTE:
_
The engine is warm when it quickly responds to the throttle.
_
EAU01168
1. Throttle stop screw
3. Check the engine idling speed
and, if necessary, adjust it to specification by turning the throttle stop
screw. To increase the engine
idling speed, turn the screw in direction a. To decrease the engine
idling speed, turn the screw in direction b.
Engine idling speed:
1,500–1,700 r/min
NOTE:
_
If the specified idling speed cannot be
obtained as described above, have a
Yamaha dealer make the adjustment.
_
EAU00634*
Adjusting the throttle cable
free play
The throttle cable free play should
measure 3–7 mm at the throttle grip.
Periodically check the throttle cable
free play and, if necessary, adjust it as
follows.
NOTE:
_
The engine idling speed must be correctly adjusted before checking and adjusting the throttle cable free play.
_
6-17
1. Throttle cable free play adjusting nut
2. Locknut
3. Cable cover
c. Throttle cable free play
1. Loosen the locknut.
2. To increase the throttle cable free
play, turn the adjusting nut in direction a. To decrease the throttle
cable free play, turn the adjusting
nut in direction b.
3. Tighten the locknut.
NOTE:
_
After adjusting the throttle free play, be
sure to place the cable cover in the
original position.
_
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU00637
Adjusting the valve clearance
The valve clearance changes with use,
resulting in improper air-fuel mixture
and/or engine noise. To prevent this
from occurring, the valve clearance
must be adjusted by a Yamaha dealer
at the intervals specified in the periodic
maintenance and lubrication chart.
6
6-18
PERIODIC MAINTENANCE AND MINOR REPAIR
Tires
To maximize the performance, durability, and safe operation of your motorcycle, note the following points
regarding the specified tires.
Tire air pressure
The tire air pressure should be
checked and, if necessary, adjusted
before each ride.
WARNING
_
The tire air pressure must be
checked and adjusted on cold tires
6
(i.e., when the temperature of the
tires equals the ambient temperature).
_
EAU03790*
EW000091
CE-24E
(2.00 kgf/cm
CE-07E
Maximum load* 116 kg
* Total weight of rider, passenger, cargo a nd
accessories
Tire air pressure
(measured on cold tires)
Front Rear
200 kPa
2
)
6-19
225 kPa
(2.25 kgf/cm2)
EW000087
WARNING
_
Because loading has an enormous
impact on the handling, braking, performance and safety characteristics
of your motorcycle, you should keep
the following precautions in mind.
●
NEVER OVERLOAD THE
MOTORCYCLE! Operation of an
overloaded motorcycle may result in tire damage, loss of control, or severe injury. Make sure
that the total weight of rider, passenger, cargo, and accessories
does not exceed the specified
maximum load for the vehicle.
●
Do not carry along loosely
packed items, which can shift
during a ride.
●
Securely pack the heaviest
items close to the center of the
motorcycle and distribute the
weight evenly on both sides.
●
Adjust the tire air pressure with
regard to the load.
●
Check the tire condition and air
pressure before each ride.
_
PERIODIC MAINTENANCE AND MINOR REPAIR
1. Sidewall
2. Tire wear indicator
a. Tire tread depth
Tire inspection
The tires must be checked before each
ride. If the tire shows crosswise lines
(minimum tread depth), if the tire has a
nail or glass fragments in it, or if the
sidewall is cracked, have a Yamaha
dealer replace the tire immediately.
CE-23E
Minimum tire tread depth
(front and rear)
NOTE:
_
1.0 mm
The tire tread depth limits may differ
from country to country. Always comply
with the local regulations.
_
WARNING
_
●
Have a Yamaha dealer replace
excessively worn tires. Besides
being illegal, operating the
motorcycle with excessively
worn tires decreases riding stability and can lead to loss of
control.
●
The replacement of all wheeland brake-related parts, including the tires, should be left to a
Yamaha dealer, who has the
necessary professional knowledge and experience.
_
EW000079
Tire information
This motorcycle is equipped with tube
tires.
EW000078
WARNING
_
●
The front and rear tires should
be of the same make and design, otherwise the handling
characteristics of the motorcycle cannot be guaranteed.
●
After extensive tests, only the
tires listed below have been approved for this model by
Yamaha Motor Co., Ltd.
_
CE-10E
FRONT
Manufacturer Size Model
Dunlop 70/90-16 36P D110
REAR
Manufacturer Size Model
Dunlop 80/90-16 43P D110
6
6-20
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU00680
WARNING
_
●
It is dangerous to ride with a
worn-out tire. When a tire tread
begins to show crosswise lines,
have a Yamaha dealer replace
the tire immediately.
●
The replacement of all wheeland brake-related parts, including the tires, should be left to a
Yamaha dealer, who has the
necessary professional knowledge and experience.
●
6
It is not recommended to patch
a punctured tube. If unavoidable, however, patch the tube
very carefully and replace it as
soon as possible with a highquality product.
_
Spoke wheels
To maximize the performance, durability, and safe operation of your motorcycle, note the following points
regarding the specified wheels.
The wheel rims should be checked
●
for cracks, bends or warpage, and
the spokes for looseness or damage before each ride. If any damage is found, have a Yamaha
dealer replace the wheel. Do not
attempt even the smallest repair to
the wheel. A deformed or cracked
wheel must be replaced.
The wheel should be balanced
●
whenever either the tire or wheel
has been changed or replaced. An
unbalanced wheel can result in
poor performance, adverse han-
EAU00685
1. Front brake lever
EAU03851*
Checking the front brake lever
free play
Since this model is equipped with a hydraulic front brake, adjusting the brake
lever free play is not needed.
However, it is necessary to check the
brake fluid level and check the hydraulic system for leakage.
dling characteristics, and a shortened tire life.
Ride at moderate speeds after
●
changing a tire since the tire surface must first be “broken in” for it
to develop its optimal characteristics.
6-21
EW000099*
WARNING
_
A soft or spongy feeling in the brake
lever can indicate the presence of
air in the hydraulic system. If there
is air in the hydraulic system, have a
Yamaha dealer bleed the system before operating the motorcycle. Air in
the hydraulic system will diminish
the braking performance, which
may result in loss of control and an
accident.
_
PERIODIC MAINTENANCE AND MINOR REPAIR
a. Rear brake lever free play 1. Rear brake lever free play adjusting nut
EAU00704*
Adjusting the rear brake lever
free play
The rear brake lever free play should
measure 10–20 mm as shown. Periodically check the rear brake lever free
play and, if necessary, adjust it as follows.
To increase the rear brake lever free
play, turn the adjusting nut at the brake
shoe plate in direction a. To decrease
the rear brake lever free play, turn the
adjusting nut in direction b.
EW000101
WARNING
_
If proper adjustment cannot be obtained as described, have a Yamaha
dealer make this adjustment.
_
6
6-22
PERIODIC MAINTENANCE AND MINOR REPAIR
Checking the front brake pads
and rear brake shoes
The front brake pads and the rear
brake shoes must be checked for wear
at the intervals specified in the periodic
maintenance and lubrication chart.
6
EAU00720
Front
1. Brake pad wear indicator groove (× 3)
EAU03938
Front brake pads
Each front brake pad is provided with
wear indicator grooves, which allow
you to check the brake pad wear without having to disassemble the brake.
To check the brake pad wear, check
the wear indicator grooves. If a brake
pad has worn to the point that the wear
indicator grooves have almost disappeared, have a Yamaha dealer replace
the brake pads as a set.
Rear
1. Brake shoe wear indicator
2. Brake shoe wear limit line
EAU04502
Rear brake shoes
The rear brake is provided with a wear
indicator, which allows you to check the
brake shoe wear without having to disassemble the brake. To check the
brake shoe wear, check the position of
the wear indicator while applying the
brake. If a brake shoe has worn to the
point that the wear indicator reaches
the wear limit line, have a Yamaha
dealer replace the brake shoes as a
set.
6-23
PERIODIC MAINTENANCE AND MINOR REPAIR
1. Minimum level mark
EAU00732
Checking the brake fluid level
Insufficient brake fluid may allow air to
enter the brake system, possibly causing it to become ineffective.
Before riding, check that the brake fluid
is above the minimum level mark and
replenish if necessary. A low brake fluid level may indicate worn brake pads
and/or brake system leakage. If the
brake level is low, be sure to check the
brake pads for wear and the brake system for leakage.
Observe these precautions:
When checking the fluid level,
●
make sure that the top of the master cylinder is level by turning the
handlebars.
Use only the recommended quali-
●
ty brake fluid, otherwise the rubber
seals may deteriorate, causing
leakage and poor braking performance.
Recommended brake fluid: DOT 4
NOTE:
_
If DOT 4 is not available, DOT 3 can be
used.
_
Refill with the same type of brake
●
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking performance.
Be careful that water does not en-
●
ter the master cylinder when refilling. Water will significantly lower
the boiling point of the fluid and
may result in vapor lock.
Brake fluid may deteriorate paint-
●
ed surfaces or plastic parts. Always clean up spilled fluid
immediately.
As the brake pads wear, it is nor-
●
mal for the brake fluid level to
gradually go down. However, if the
brake fluid level goes down suddenly, have a Yamaha dealer
check the cause.
6
6-24
PERIODIC MAINTENANCE AND MINOR REPAIR
Changing the brake fluid
Have a Yamaha dealer change the
brake fluid at the intervals specified in
the NOTE after the periodic maintenance and lubrication chart. In addition,
have the oil seals of the brake master
cylinder and caliper as well as the
brake hose replaced at the intervals
listed below or whenever they are damaged or leaking.
Oil seals: Replace every two
●
years.
Brake hose: Replace every four
●
6
years.
EAU03985
EAU00770*
Checking the V-belt
The V-belt must be checked by a
Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart.
NOTE:
_
It is recommended to replace the V-belt
every 25,000 km.
_
EAU02962
Checking and lubricating the
cables
The operation of all control cables and
the condition of the cables should be
checked before each ride, and the cables and cable ends should be lubricated if necessary. If a cable is damaged
or does not move smoothly, have a
Yamaha dealer check or replace it.
Recommended lubricant:
Engine oil
EW000112
WARNING
_
Damage to the outer sheath may interfere with proper cable operation
and will cause the inner cable to
rust. Replace a damaged cable as
soon as possible to prevent unsafe
conditions.
_
6-25
EAU04034
Checking and lubricating the
throttle grip and cable
The operation of the throttle grip should
be checked before each ride. In addition, the cable should be lubricated or
replaced at the intervals specified in
the periodic maintenance chart.
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU03118
Lubricating the front and rear
brake levers
The pivoting points of the front and rear
brake levers must be lubricated at the
intervals specified in the periodic maintenance and lubrication chart.
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
6
6-26
PERIODIC MAINTENANCE AND MINOR REPAIR
Checking and lubricating the
centerstand and sidestand
The operation of the centerstand and
6
sidestand should be checked before
each ride, and the pivots and metal-tometal contact surfaces should be lubricated if necessary.
WARNING
_
If the centerstand or sidestand does
not move up and down smoothly,
have a Yamaha dealer check or repair it.
_
EAU03371
EW000114
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
EAU02939
Checking the front fork
The condition and operation of the front
fork must be checked as follows at the
intervals specified in the periodic maintenance and lubrication chart.
To check the condition
WARNING
_
Securely support the motorcycle so
that there is no danger of it falling
over.
_
Check the inner tubes for scratches,
damage and excessive oil leakage.
EW000115
6-27
To check the operation
1. Place the motorcycle on a level
surface and hold it in an upright
position.
2. While applying the front brake,
push down hard on the handlebars several times to check if the
front fork compresses and rebounds smoothly.
EC000098
CAUTION:
_
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or repair it.
_
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU00794
Checking the steering
Worn or loose steering bearings may
cause danger. Therefore, the operation
of the steering must be checked as follows at the intervals specified in the periodic maintenance and lubrication
chart.
1. Place a stand under the engine to
raise the front wheel off the
ground.
EW000115
WARNING
_
Securely support the motorcycle so
that there is no danger of it falling
over.
_
2. Hold the lower ends of the front
fork legs and try to move them forward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the steering.
6
6-28
PERIODIC MAINTENANCE AND MINOR REPAIR
Checking the wheel bearings
The front and rear wheel bearings must
be checked at the intervals specified in
the periodic maintenance and lubrication chart. If there is play in the wheel
hub or if the wheel does not turn
smoothly, have a Yamaha dealer
check the wheel bearings.
6
EAU01144
EAU03806*
Battery
A poorly maintained battery will corrode and discharge quickly. The electrolyte level, battery lead connections
and breather hose routing should be
checked before each ride and at the intervals specified in the periodic maintenance and lubrication chart.
To check the electrolyte level
1. Remove panel A. (See page 6-4
for panel removal and installation
procedures.)
1. Negative battery lead
2. Battery band
3. Battery breather hose
2. Unhook the battery band, and then
disconnect the negative battery
lead from the battery.
3. Pull the battery breather hose out
as shown.
4. Pull the battery out of the battery
compartment.
6-29
PERIODIC MAINTENANCE AND MINOR REPAIR
1. Maximum level mark
2. Minimum level mark
5. Place the battery on a level surface, and then check the electrolyte level in the battery.
NOTE:
_
The electrolyte should be between the
minimum and maximum level marks.
_
6. If the electrolyte is at or below the
minimum level mark, add distilled
water to raise the electrolyte to the
maximum level mark.
WARNING
_
●
Electrolyte is poisonous and
dangerous since it contains sulfuric acid, which causes severe
burns. Avoid any contact with
skin, eyes or clothing and always shield your eyes when
working near batteries. In case
of contact, administer the following FIRST AID.
• EXTERNAL: Flush with plenty
of water.
• INTERNAL: Drink large quantities of water or milk and immediately call a physician.
• EYES: Flush with water for
15 minutes and seek prompt
medical attention.
●
Batteries produce explosive hydrogen gas. Therefore, keep
sparks, flames, cigarettes, etc.,
away from the battery and provide sufficient ventilation when
charging it in an enclosed
space.
EW000116
●
KEEP THIS AND ALL BATTERIES OUT OF THE REACH OF
CHILDREN.
_
CAUTION:
_
EC000100
Use only distilled water, as tap water
contains minerals that are harmful
to the battery.
_
7. Check and, if necessary, tighten
the positive battery lead to the
positive battery terminal.
8. Place the battery in the battery
compartment.
9. Connect and tighten the negative
battery lead to the negative battery
terminal.
6
6-30
PERIODIC MAINTENANCE AND MINOR REPAIR
1. Battery breather hose
10. Place the breather hose into the
original position and make sure
that it is properly routed.
11. Hook the battery band onto the
6
holder.
12. Install the panel.
To store the battery
1. If the motorcycle will not be used
for more than one month, remove
the battery, fully charge it, and
then place it in a cool, dry place.
2. If the battery will be stored for
more than two months, check the
specific gravity of the electrolyte at
least once a month and fully
charge the battery whenever necessary.
3. Fully charge the battery before installation.
4. After installation, make sure that
the battery leads are properly connected to the battery terminals and
that the breather hose is properly
routed, in good condition, and not
obstructed.
EC000099
CAUTION:
_
If the breather hose is positioned in
such a way that the frame is exposed to electrolyte or gas expelled
from the battery, the frame could
suffer structural and external damages.
_
EAU01307*
Replacing the fuse
The fuse is located behind panel A.
(See page 6-4 for panel removal and
installation procedures.)
If the fuse is blown, replace it as follows.
1. Turn the key to “OFF” and turn off
all electrical circuits.
2. Pull the battery out of the battery
compartment. (See page 6-29, “To
check the electrolyte level” for battery removal and installation procedures.)
6-31
PERIODIC MAINTENANCE AND MINOR REPAIR
1. Starter relay 1. Fuse
3. Pull the starter relay out.
2. Spare fuse
4. Remove the blown fuse, and then
Specified fuse: 10 A
CAUTION:
_
Do not use a fuse of a higher amperage rating than recommended to
avoid causing extensive damage to
the electrical system and possibly a
fire.
_
5. Place the starter relay into the
original position.
6. Place the battery in the battery
compartment.
7. Turn the key to “ON” and turn on
the electrical circuits to check if the
devices operate.
8. If the fuse immediately blows
again, have a Yamaha dealer
check the electrical system.
install a new fuse of the specified
amperage.
6
EC000103
6-32
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU04134*
Replacing a headlight bulb
If a headlight bulb burns out, replace it
as follows.
CAUTION:
_
It is advisable to have a Yamaha
dealer perform this job.
_
1. Place the motorcycle on the centerstand.
2. Remove cowling A. (See page 6-5
for cowling removal and installation procedures.)
6
EC000107
1. Headlight bulb cover (× 2) 1. Headlight bulb socket (× 2)
3. Remove the headlight bulb cover
by turning it counterclockwise.
4. Remove the socket by pushing it
in and turning it counterclockwise.
5. Remove the defective bulb.
EW000119
WARNING
_
Headlight bulbs get very hot. Therefore, keep flammable products away
from a lit headlight bulb, and do not
touch the bulb until it has cooled
down.
_
6. Place a new headlight bulb into
position.
7. Install the socket by pushing it in
and turning it clockwise.
6-33
PERIODIC MAINTENANCE AND MINOR REPAIR
8. Install the headlight bulb cover by
turning it clockwise.
9. Install the cowling.
10. Have a Yamaha dealer adjust the
headlight beam if necessary.
EAUT0022*
Replacing a front turn signal
light bulb
EC000107
CAUTION:
_
It is advisable to have a Yamaha
dealer perform this job.
_
1. Place the motorcycle on the centerstand.
2. Remove cowling A. (See page 6-5
for cowling removal and installation procedures.)
1. Turn signal light bulb socket (× 2)
3. Remove the socket (together with
the bulb) by turning it counterclockwise.
4. Remove the defective bulb.
5. Insert a new bulb into position.
6. Install the socket (together with
the bulb) by turning it clockwise.
7. Install the cowling.
6
6-34
PERIODIC MAINTENANCE AND MINOR REPAIR
1. Screw (× 2) 1. Tab
EAUS0013*
Replacing the tail/brake light
bulb or a rear turn signal light
bulb
6
CAUTION:
_
It is advisable to have a Yamaha
dealer perform this job.
_
Place the motorcycle on the centerstand.
Tail/brake light bulb
1. Remove panel B. (See page 6-5
for panel removal and installation
procedures.)
EC000107
2. Slot
2. Remove the screws, unhook the
tab from the slot, and then pull the
tail/brake light lens outward.
6-35
1. Tail/brake light bulb
3. Remove the defective bulb by
pushing it in and turning it counterclockwise.
4. Insert a new bulb into the socket,
push it in, and then turn it clockwise until it stops.
5. Place the tail/brake light lens into
the original position, and then install the screws.
EC000108
CAUTION:
_
Do not overtighten the screws, otherwise the lens may break.
_
6. Install the panel.
Turn signal light bulb
1. Remove the tail/brake light lens.
(See “Tail/brake light bulb” for lens
removal and installation procedures.)
PERIODIC MAINTENANCE AND MINOR REPAIR
1. Turn signal light bulb (× 2)
2. Pull the turn signal light lens off. 3. Remove the defective bulb.
4. Insert a new bulb into position.
5. Place the turn signal light lens into
the original position.
6. Install the tail/brake light lens.
6
6-36
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU01008
Troubleshooting
Although Yamaha motorcycles receive
a thorough inspection before shipment
from the factory, trouble may occur during operation. Any problem in the fuel,
compression, or ignition systems, for
example, can cause poor starting and
loss of power.
The following troubleshooting chart
represents a quick and easy procedure
for checking these vital systems yourself. However, should your motorcycle
require any repair, take it to a Yamaha
dealer, whose skilled technicians have
the necessary tools, experience, and
know-how to service the motorcycle
properly.
Use only genuine Yamaha replacement parts. Imitation parts may look
like Yamaha parts, but they are often
inferior, have a shorter service life and
can lead to expensive repair bills.
6-37
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU03473
Troubleshooting chart
WARNING
_
Keep away open flames and do not smoke while checking or working on the fuel system.
_
CT-1FE
1. Fuel
Check the fuel level in
the fuel tank.
There is
enough fuel.
There is
no fuel.
Check the compression.
Supply fuel.
The engine does not start.
Check the compression.
EW000125
2. Compression
Operate the
electric starter.
3. Ignition
Remove the spark plug
and check electrodes.
4. Battery
Operate the
electric starter.
There is compression.
There is no compression.
Wet
Dry
The engine turns over
quickly.
The engine turns over
slowly.
Wipe off with a dry cloth and correct the
spark plug gap, or replace the spark plug.
Have a Yamaha dealer check the vehicle.
Check the ignition.
Have a Yamaha dealer
check the vehicle.
The battery is good.
Check fluid, recharge,
check connections.
6-38
Open the throttle halfway and
operate the electric starter.
The engine does not start.
Check the battery.
The engine does not start. Have a
Yamaha dealer check the vehicle.
6
MOTORCYCLE CLEANING AND STORAGE
7-
EAK00000
A. CLEANING
Frequent, thorough cleaning of your
motorcycle will not only enhance its appearance but will improve its general
performance and extend the useful life
of many components.
1. Rinse the dirt and degreaser off
with a garden hose.
CAUTION:
_
Excessive hose pressure may cause
water seepage and deterioration of
wheel bearings, front fork, brakes,
transmission seals and electrical
parts.
7
2. After cleaning the motorcycle, dry
all surfaces with a chamois, clean
towel, or soft absorbent cloth.
3. Automotive-type wax may be applied to all painted and chromeplated surfaces. When finished,
start the engine and let it idle for
several minutes.
EAK01302*
EUU34602
EAK00700*
B. STORAGE
Long term storage (60 days or more) of
your motorcycle will require some preventive procedures to guard against
deterioration. After thoroughly cleaning
the motorcycle, prepare for storage as
follows:
1. Drain the fuel tank, fuel lines, and
carburetor float bowl(s).
2. Lubricate all control cables.
3. Block up the frame to raise both
wheels off the ground.
4. Tie a plastic bag over the exhaust
pipe outlet to prevent moisture
from entering.
5. If storing in a humid or salt-air atmosphere, coat all exposed metal
surfaces with a light film of oil. Do
not apply oil to any rubber parts or
the seat cover.
6. Remove the battery and charge it.
Store it in a dry place and recharge it once a month. Do not
store the battery in an excessively
warm or cold place (less than 0 °C
or more than 30 °C).
EUU05800
NOTE:
_
Make any necessary repairs before
storing the motorcycle.
7-1
EAU01038
Specifications
CS-01E
Model AT115
Dimensions
Overall length 1,935 mm
Overall width 675 mm
Overall height 1,070 mm
Seat height 755 mm
Wheelbase 1,280 mm
Ground clearance 135 mm
Minimum turning radius 1,900 mm
Basic weight (with oil and full
fuel tank)
Maximum load*
* Total weight of rider, passenger, cargo and accessories
Engine
Engine type Forced air-cooled 4-stroke,
Cylinder arrangement Forward inclined single cylinder
Displacement 113.7 cm
Bore × stroke 50.0 × 57.9 mm
Compression ratio 8.8:1
Starting system Electric and kickstarter
Lubrication system Wet sump
103 kg
116 kg
SOHC
3
SPECIFICATIONS
8-
Engine oil
Ty p e
Capacity
Periodic oil change 0.8 L
Total amount (dry engine) 0.9 L
Final transmission oil
Type SAE 10W-40 API Service “SE”
Quantity 0.1 L
Air filter
Fuel
Type REGULAR GASOLINE
Fuel tank capacity 4.9 L
Carburetor
Manufacturer MIKUNI
Model × quantity BS25 × 1
Spark plug
Manufacturer/Type NGK / CR7HSA
Gap 0.6–0.7 mm
Clutch type
SAE 20W-50 API Service “SF”
type motor oil
type motor oil
Dry element
V-belt automatic
8
8-1
SPECIFICATIONS
Transmission
Primary reduction system Helical gear
Primary reduction ratio 3.133
Secondary reduction system Spur gear
Secondary reduction ratio 3.583
Number of drive chain
sprocket teeth (rear/front) 43/12
Transmission type V-belt automatic
Operation Centrifugal automatic type
Chassis
Frame type Steel tube underbone
Caster angle 25°
Trail 112 mm
Tires
Front
Ty p e Tu b e t ir e
Size 70/90-16 36P
8
Rear
Manufacturer/
model Dunlop/D110
Ty p e Tu b e t ir e
Size 80/90-16 43P
Manufacturer/
model Dunlop/D110
Tire air pressure
(measured on cold tires)
Front 200 kPa (2.00 kgf/cm
Rear 225 kPa (2.25 kgf/cm
Wheels
Front
Type Spoke wheel
Size 16 × 1.40
Rear
Type Spoke wheel
Size 16 × 1.60
Brakes
Front
Type Single disc brake
Operation Right hand
Fluid DOT 3 or 4
Rear
Ty p e
Operation Left hand
Suspension
Front
Ty p e
Rear
Ty p e
Drum brake
Telescopic fork
Unit swing
2
)
2
)
8-2
Spring/shock absorbers
Front Coil spring / oil damper
Rear Coil spring / oil damper
Wheel travel
Front 80 mm
Rear 55 mm
Electrical
Ignition system DC. C.D.I.
Charging system
Type A.C. magneto
Standard output 14 V, 105 W@ 5,000 r/min
Battery
Model Local made
Voltage, capacity 12 V, 7 Ah
Headlight bulb type
Bulb voltage, wattage × quantity
Headlight 12 V, 25/25 W × 2
Tail/brake light 12 V, 5/21 W × 1
Turn signal light 12 V, 10 W × 4
Meter lighting 12 V, 1.7 W × 1
High beam indicator light 12 V, 1.7 W × 1
Turn signal indicator light 12 V, 3.4 W × 2
Fuse
Incandesce bulb
12 V, 3.4 W × 1
10 A
SPECIFICATIONS
8
8-3
CONSUMER INFORMATION
9-
EAU02945*
Identification numbers
Record the key identification number
and engine serial number in the spaces
provided below for assistance when ordering spare parts from a Yamaha
dealer or for reference in case the vehicle is stolen.
EAU01039
1. FRAME SERIAL NUMBER:
CA-02E
2. ENGINE SERIAL NUMBER:
CA-02E
9
1. Frame serial number 1. Engine serial number
EAU01046
Frame serial number
The frame serial number is stamped
into the frame.
NOTE:
_
Engine serial number
The engine serial number is stamped
into the final transmission case.
The frame serial number is used to
identify your motorcycle and may be
used to register your motorcycle with
the licensing authority in your area.
_
9-1
EAU01048*
PRINTED IN INDONESIA
YAMAHA MOTOR CO., LTD.
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