Yamaha PW50Y User Manual

Read this manual carefully before operating this vehicle.

OWNER’S MANUAL

LIT-11626-22-24

PW50Y

5PG-28199-18

EAU10042

Q

Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold.

INTRODUCTION

EAU41062

Congratulations on your purchase of the Yamaha PW50(Y). 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.
The design and manufacture of this Yamaha motorcycle fully comply with the emissions standards for clean air applicable
at the date of manufacture. Yamaha has met these standards without reducing the performance or economy of operation of
the motorcycle. To maintain these high standards, it is important that you and your Yamaha dealer pay close attention to the
recommended maintenance schedules and operating instructions contained within this manual.
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 there is any question concerning this manual, please consult a Yamaha dealer.

WARNING

Please read this manual, the “TIPS AND PRACTICE GUIDE FOR THE OFF HIGHWAY MOTORCYCLIST” and the
“PARENTS, YOUNGSTERS AND OFF-HIGHWAY MOTORCYCLES” booklets carefully and completely before oper­ating or allowing your child to operate this motorcycle. Do not attempt to operate this motorcycle until you have
attained adequate knowledge of its controls and operating features and until you have been trained in safe and
proper riding techniques. Regular inspections and careful maintenance, along with good riding skills, will ensure
that you safely enjoy the capabilities and the reliability of this motorcycle.

WARNING

This motorcycle is designed and manufactured for off-road use only. It is illegal to operate this motorcycle on any
public street, road or highway. Such use is prohibited by law. This motorcycle complies with almost all state
off-highway noise level and spark arrester laws and regulations. Please check your local riding laws and regulations
before operating this motorcycle.

EWA14461

EWA14351

INTRODUCTION

AN IMPORTANT SAFETY MESSAGE:

●

Read this manual, the “PARENTS, YOUNGSTERS AND OFF-HIGHWAY MOTORCYCLES” booklet, and the “TIPS
AND PRACTICE GUIDE FOR THE OFF HIGHWAY MOTORCYCLIST” booklet carefully and completely before oper­ating this motorcycle. Make sure you understand all instructions.

●

Pay close attention to the warning and notice labels on the motorcycle.

●

Never operate a motorcycle without proper training or instruction.

●

Weight of the rider should not exceed 25 kg (55 lb).

AN IMPORTANT NOTE TO PARENTS:

This motorcycle is not a toy. Before you let your child ride this motorcycle, you should understand the instructions and warn­ings in this Owner’s Manual. Then be sure your child understands and will follow them. Also read the “PARENTS, YOUNG­STERS AND OFF-HIGHWAY MOTORCYCLES” and the “TIPS AND PRACTICE GUIDE FOR THE OFF HIGHWAY
MOTORCYCLIST” booklets supplied with this motorcycle when new or available from your Yamaha dealer. Children differ
in skills, physical abilities, and judgment. Some children may not be able to operate a motorcycle safely. Parents should su­pervise their child’s use of the motorcycle at all times. Parents should permit continued use only if they determine that the
child has the ability to operate the motorcycle safely.
Your motorcycle was delivered with an adjustable speed limiter and power reduction plate. Yamaha recommends that all
beginners start off with the speed limiter adjusting screw turned in and the power reduction plate installed in the exhaust man­ifold to limit the power available while they learn. The limiter screw may be gradually turned out to increase maximum speed
as the beginner becomes more familiar with operating the motorcycle. Parents should decide when to adjust the motorcycle
for more power as their youngster’s riding skills improve. Once the rider can operate with skill at the top speed permitted by
adjusting the speed limiter alone, the power reduction plate can be removed. Since removal of this plate will result in a sig­nificant increase in power, turn the speed limiter back in again; adjust it out in stages as you did before.

Motorcycles are single track vehicles. Their safe use and operation are dependent upon the use of proper riding
techniques as well as the expertise of the operator. Every operator should know the following requirements before
riding this motorcycle.

He or she should:

●

Obtain thorough instructions from a competent source on all aspects of motorcycle operation.

●

Observe the warnings and maintenance requirements in this Owner’s Manual.

INTRODUCTION

●

Obtain qualified training in safe and proper riding techniques.

●

Obtain professional technical service as indicated in this Owner’s Manual and/or when made necessary by mechanical
conditions.

IMPORTANT MANUAL INFORMATION

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

This is the safety alert symbol. It is used to alert you to potential personal injury
hazards. Obey all safety messages that follow this symbol to avoid possible injury
or death.

EAU10132

WARNING

NOTICE

TIP

A WARNING indicates a hazardous situation which, if not avoided, could result in
death or serious injury.

A NOTICE indicates special precautions that must be taken to avoid damage to the
vehicle or other property.

A TIP provides key information to make procedures easier or clearer.

IMPORTANT MANUAL INFORMATION

PW50(Y)

OWNER’S MANUAL

©2008 by Yamaha Motor Corporation, U.S.A.

1st edition, March 2008

All rights reserved.

Any reprinting or unauthorized use

without the written permission of

Yamaha Motor Corporation, U.S.A.

is expressly prohibited.

Printed in Japan.

P/N LIT-11626-22-24

EAU10193

TABLE OF CONTENTS

LOCATION OF IMPORTANT
LABELS

SAFETY INFORMATION

DESCRIPTION

INSTRUMENT AND CONTROL
FUNCTIONS

FOR YOUR SAFETY –
PRE-OPERATION CHECKS

..............................................1-1

...................2-1

...................................3-1

Left view ...........................................3-1

Right view .........................................3-2

Controls and instruments..................3-3

........................................4-1

Handlebar switch .............................4-1

Speed limiter and power reduction

plate .............................................4-1

Front brake lever .............................4-2

Rear brake lever ..............................4-3

Fuel tank cap ...................................4-3

Fuel ..................................................4-3

Fuel tank breather hose ...................4-5

2-stroke engine oil ...........................4-5

Fuel cock .........................................4-5

Starter (choke) lever “1” .................4-6

Kickstarter ........................................4-6

Seat .................................................4-7

...............5-1

Pre-operation check list ...................5-2

OPERATION AND IMPORTANT
RIDING POINTS

Starting and warming up a cold

engine .......................................... 6-1

Starting a warm engine ...................6-1

Starting off .......................................6-2

Acceleration and deceleration .........6-2

Braking ............................................ 6-2

Engine break-in ............................... 6-3

Parking ............................................ 6-4

PERIODIC MAINTENANCE AND
ADJUSTMENT

Owner’s tool kit ................................ 7-2

Periodic maintenance chart for the

emission control system .............. 7-3

General maintenance and lubrication

chart ............................................. 7-4

Checking the spark plug .................. 7-6

Removing the power reduction

plate ............................................. 7-7

Transmission oil ..............................7-8

Middle and final gear cases ............ 7-9

Cleaning the air filter element ......... 7-9

Cleaning the spark arrester ...........7-10

Adjusting the carburetor ................ 7-11

Adjusting the engine idling

speed ......................................... 7-11

Checking the throttle cable free

play ............................................ 7-12

Tires .............................................. 7-12

.................................. 6-1

.................................... 7-1

Panel wheels ................................. 7-14

Adjusting the front and rear brake

lever free play ............................ 7-15

Checking the front and rear brake

shoes ......................................... 7-16

Checking and lubricating the

cables ........................................ 7-16

Checking and lubricating the throttle

grip and cable ............................ 7-17

Adjusting the Autolube pump ........ 7-17

Lubricating the front and rear brake

levers ......................................... 7-17

Checking and lubricating the

centerstand ................................ 7-18

Checking the front fork .................. 7-18

Checking the steering ................... 7-19

Checking the wheel bearings ........ 7-19

Front wheel ................................... 7-19

Rear wheel .................................... 7-21

Troubleshooting ............................ 7-24

Troubleshooting chart ................... 7-25

MOTORCYCLE CARE AND
STORAGE

Matte color caution .......................... 8-1

Care ................................................ 8-1

Storage ........................................... 8-3

SPECIFICATIONS

........................................... 8-1

............................. 9-1

TABLE OF CONTENTS

CONSUMER INFORMATION

Identification numbers ...................10-1

Motorcycle noise regulation ........... 10-2

YAMAHA MOTOR CORPORATION,

U.S.A. OFF-ROAD MOTORCYCLE

LIMITED WARRANTY ...............10-3

YAMAHA EXTENDED SERVICE

(Y.E.S.) ......................................10-5

............10-1

LOCATION OF IMPORTANT LABELS

Read and understand all of the labels on your vehicle. They contain important information for safe and proper operation of
your vehicle. Never remove any labels from your vehicle. If a label becomes difficult to read or comes off, a replacement label
is available from your Yamaha dealer.

1

1

2

EAU41371

1-1

1

WARNING

BEFORE YOU OPERATE THIS VEHICLE,
MANUAL AND ALL

NEVER CARRY

control if you carry a passenger.

OPERATE

NEVER

collide with another vehicle if you operate this vehicle on a public road.

ALWAYS

WEAR AN APPROVED MOTORCYCLE HELMET,

protection, and protective clothing.

eye

LABELS.

A PASSENGER.

THIS VEHICLE ON PUBLIC ROADS.

You increase your

READ

THE OWNER’S

risk

of losing

You

can

3PT-2118K-A0

LOCATION OF IMPORTANT LABELS

1

2

3

2

Cold tire normal pressure should be set as
follows.

FRONT :

100 kPa,{1.00 kgf/cm2}, 15 psi
100 kPa,{1.00 kgf/cm2}, 15 psi

:REAR

3RV-21668-A0

4

5

6

7

8

9

1-2

SAFETY INFORMATION

Be a Responsible Owner

As the vehicle’s owner, you are respon­sible for the safe and proper operation

1

of your motorcycle.
Motorcycles are single-track vehicles.

2

Their safe use and operation are de­pendent upon the use of proper riding
techniques as well as the expertise of
the operator. Every operator should
know the following requirements before
riding this motorcycle.
He or she should:

●

Obtain thorough instructions from
a competent source on all aspects
of motorcycle operation.

●

Observe the warnings and mainte­nance requirements in this Own­er’s Manual.

●

Obtain qualified training in safe
and proper riding techniques.

●

Obtain professional technical ser­vice as indicated in this Owner’s
Manual and/or when made neces­sary by mechanical conditions.

Safe Riding

Perform the pre-operation checks each

EAU40933

time you use the vehicle to make sure it
is in safe operating condition. Failure to
inspect or maintain the vehicle properly
increases the possibility of an accident
or equipment damage. See page 5-1
for a list of pre-operation checks.

●

This motorcycle is designed for
off-road use only, therefore, it is il­legal to operate it on public streets,
roads, or highways, even a dirt or
gravel one. Off-road use on public
lands may be illegal. Please check
local regulations before riding.

●

This motorcycle is designed to car­ry the operator only. No passen­gers.

●

The failure of motorists to detect
and recognize motorcycles in traf­fic is the predominating cause of
automobile/motorcycle accidents.
Many accidents have been caused
by an automobile driver who did
not see the motorcycle. Making
yourself conspicuous appears to
be very effective in reducing the
chance of this type of accident.

Therefore:

●

Wear a brightly colored jacket.

2-1

●

Use extra caution when you are
approaching and passing
through intersections, since in­tersections are the most likely
places for motorcycle accidents
to occur.

●

Ride where other motorists can
see you. Avoid riding in another
motorist’s blind spot.

●

Many accidents involve inexperi­enced operators.

●

Make sure that you are qualified
and that you only lend your mo­torcycle to other qualified opera­tors.

●

Know your skills and limits.
Staying within your limits may
help you to avoid an accident.

●

We recommend that you prac­tice riding your motorcycle until
you have become thoroughly fa­miliar with the motorcycle and all
of its controls.

●

Many accidents have been caused
by error of the motorcycle opera­tor. A typical error made by the op­erator is veering wide on a turn
due to excessive speed or under-

SAFETY INFORMATION

cornering (insufficient lean angle
for the speed). Never travel faster
than warranted by conditions.

●

Ride cautiously in unfamiliar ar­eas. You may encounter hidden
obstacles that could cause an ac­cident.

●

The posture of the operator is im­portant for proper control. The op­erator should keep both hands on
the handlebar and both feet on the
operator footrests during operation
to maintain control of the motorcy­cle.

●

Never ride under the influence of
alcohol or other drugs.

Protective apparel

The majority of fatalities from motorcy­cle accidents are the result of head in­juries. The use of a safety helmet is the
single most critical factor in the preven­tion or reduction of head injuries.

●

Always wear an approved helmet.

●

Wear a face shield or goggles.
Wind in your unprotected eyes
could contribute to an impairment
of vision that could delay seeing a

hazard.

●

The use of a jacket, heavy boots,
trousers, gloves, etc., is effective in
preventing or reducing abrasions
or lacerations.

●

Never wear loose-fitting clothes,
otherwise they could catch on the
control levers, footrests, or wheels
and cause injury or an accident.

●

Always wear protective clothing
that covers your legs, ankles, and
feet. The engine or exhaust sys­tem become very hot during or af­ter operation and can cause burns.

Avoid Carbon Monoxide Poisoning

All engine exhaust contains carbon
monoxide, a deadly gas. Breathing car­bon monoxide can cause headaches,
dizziness, drowsiness, nausea, confu­sion, and eventually death.
Carbon Monoxide is a colorless, odor­less, tasteless gas which may be
present even if you do not see or smell
any engine exhaust. Deadly levels of
carbon monoxide can collect rapidly
and you can quickly be overcome and
unable to save yourself. Also, deadly

levels of carbon monoxide can linger
for hours or days in enclosed or poorly
ventilated areas. If you experience any
symptoms of carbon monoxide poison­ing, leave the area immediately, get
fresh air, and SEEK MEDICAL TREAT­MENT.

●

Do not run engine indoors. Even if
you try to ventilate engine exhaust
with fans or open windows and
doors, carbon monoxide can rap­idly reach dangerous levels.

●

Do not run engine in poorly venti­lated or partially enclosed areas
such as barns, garages, or car­ports.

●

Do not run engine outdoors where
engine exhaust can be drawn into
a building through openings such
as windows and doors.

Loading

Adding accessories to your motorcycle
can adversely affect stability and han­dling if the weight distribution of the mo­torcycle is changed. To avoid the
possibility of an accident, use extreme
caution when adding accessories to

1

2

2-2

SAFETY INFORMATION

your motorcycle. Use extra care when
riding a motorcycle that has added ac­cessories. Here are some general
guidelines to follow if adding accesso-

1

ries to your motorcycle:

Operation of an overloaded vehicle

2

could cause an accident.

●

The weight of the operator must
not exceed 25 kg (55 lb).

●

Accessory weight should be kept
as low and close to the motorcycle
as possible. Securely pack your
heaviest items as close to the cen­ter of the vehicle as possible and
make sure to distribute the weight
as evenly as possible on both
sides of the motorcycle to mini­mize imbalance or instability.

●

Shifting weights can create a sud­den imbalance. Make sure that ac­cessories are securely attached to
the motorcycle before riding.
Check accessory mounts fre­quently.

●

Properly adjust the suspension
for your load, and check the con­dition and pressure of your tires.

●

Never attach any large or heavy
items to the handlebar, front
fork, or front fender.

Genuine Yamaha Accessories

Choosing accessories for your vehicle
is an important decision. Genuine
Yamaha accessories, which are avail­able only from a Yamaha dealer, have
been designed, tested, and approved
by Yamaha for use on your vehicle.
Many companies with no connection to
Yamaha manufacture parts and acces­sories or offer other modifications for
Yamaha vehicles. Yamaha is not in a
position to test the products that these
aftermarket companies produce.
Therefore, Yamaha can neither en­dorse nor recommend the use of ac­cessories not sold by Yamaha or
modifications not specifically recom­mended by Yamaha, even if sold and
installed by a Yamaha dealer.

Aftermarket Parts, Accessories,
and Modifications

While you may find aftermarket prod­ucts similar in design and quality to

genuine Yamaha accessories, recog­nize that some aftermarket accessories
or modifications are not suitable be­cause of potential safety hazards to you
or others. Installing aftermarket prod­ucts or having other modifications per­formed to your vehicle that change any
of the vehicle’s design or operation
characteristics can put you and others
at greater risk of serious injury or death.
You are responsible for injuries related
to changes in the vehicle.
Keep the following guidelines in mind,
as well as those provided under “Load­ing” when mounting accessories.

●

Never install accessories that
would impair the performance of
your motorcycle. Carefully inspect
the accessory before using it to
make sure that it does not in any
way reduce ground clearance or
cornering clearance, limit suspen­sion travel, steering travel or con­trol operation.

●

Accessories fitted to the handle­bar or the front fork area can
create instability due to improper
weight distribution. If accesso-

2-3

SAFETY INFORMATION

ries are added to the handlebar
or front fork area, they must be
as lightweight as possible and
should be kept to a minimum.

●

Bulky or large accessories may
seriously affect the stability of
the motorcycle. Wind may at­tempt to lift the motorcycle, or
the motorcycle may become un­stable in cross winds.

●

Certain accessories can dis­place the operator from his or
her normal riding position. This
improper position limits the free­dom of movement of the opera­tor and may limit control ability,
therefore, such accessories are
not recommended.

●

Use caution when adding electri­cal accessories. If electrical acces­sories exceed the capacity of the
motorcycle’s electrical system, an
electric failure could result, which
could cause a dangerous loss of
lights or engine power.

motorcycle were designed to match the
performance capabilities and to provide
the best combination of handling, brak­ing, and comfort. Other tires, rims, siz­es, and combinations may not be
appropriate. Refer to page 7-12 for tire
specifications and more information on
replacing your tires.

1

2

Aftermarket Tires and Rims

The tires and rims that came with your

2-4

DESCRIPTION

Left view

EAU10410

1

2

3

4

5

6

7

8

1. Fuel cock (page 4-5)

2. Throttle stop screw (page 7-11)

9

3. Air filter element (page 7-9)

4. Kickstarter (page 4-6)

5. Centerstand (page 7-18)

123

45

3-1

Right view

DESCRIPTION

EAU10420

2

1

3

4

2

3

4

5

6

7

1. Spark arrester (page 7-10)

2. Seat (page 4-7)

3. Transmission oil filler cap (page 7-8)

4. 2-stroke engine oil tank (page 4-5)

8

9

3-2

DESCRIPTION

Controls and instruments

EAU10430

1

2

3

4

5

6

7

8

1. Rear brake lever (page 4-3)

2. Starter (choke) lever (page 4-6)

9

3. 2-stroke engine oil tank cap (page 4-5)

4. Right handlebar switch (page 4-1)

5. Front brake lever (page 4-2)

6. Throttle grip (page 7-12)

7. Fuel tank cap (page 4-3)

12

345

7

6

3-3

INSTRUMENT AND CONTROL FUNCTIONS

EAU40660

Handlebar switch

1

1. Engine stop switch “OFF/RUN/START”

EAU40674

Engine stop switch “OFF/RUN/
START”

Set this switch to “START” before start­ing the engine. Set this switch to “RUN”
after warming up the engine or before
starting off. Set this switch to “OFF” to
stop the engine.

TIP

The engine cannot be started with

●

this switch set to the “RUN” posi­tion.
The engine speed is limited while

●

this switch is set to the “START”
position, therefore the motorcycle

cannot be ridden in that switch po­sition.

4-1

EAU41041

Speed limiter and power
reduction plate

Your motorcycle was delivered with an
adjustable speed limiter and a power
reduction plate. The speed limiter
keeps the throttle from fully opening,
even when the throttle grip is turned to
the maximum. The power reduction
plate is installed in the exhaust mani­fold to limit the amount of power avail­able while they learn.

Speed limiter

1. Loosen the locknut.

2. To increase the maximum engine
power available and the maximum
speed of the motorcycle, turn the
adjusting screw in direction (a). To
decrease the maximum engine
power available and the maximum
speed of the motorcycle, turn the
adjusting screw in direction (b).

2

3

4

5

6

7

8

9

INSTRUMENT AND CONTROL FUNCTIONS

1

1

1

(b)

2

(a)

3

1. Locknut

2. Adjusting screw

4

3. Tighten the locknut.

5

6

7

8

9

1. No more than 7 mm (0.28 in)

TIP

The adjusting range of the speed limiter
screw is from the fully turned-in position
to 7 mm (0.28 in) turned out. When the

1

screw is turned out to 7 mm (0.28 in),

2

the throttle grip can only be opened ap-

Front brake lever

EAU12900

proximately halfway. If more power is
required, please consult a Yamaha
dealer.

EWA14630

WARNING

Improper adjustment of the speed
limiter could cause improper throttle
operation. You could lose control,
have an accident or be injured. Do
not turn the adjusting screw out

1. Front brake lever

more than 7 mm (0.28 in) before con­sulting a Yamaha dealer. Always
make sure the throttle cable free
play is adjusted to 1.5–3.5 mm
(0.06–0.14 in). (See page 7-12.)

The front brake lever is located on the
right handlebar grip. To apply the front
brake, pull this lever toward the handle­bar grip.

Power reduction plate

Once the rider can operate with skill at
the top speed permitted by adjusting
the speed limiter alone, the power re­duction plate can be removed. (See
page 7-7.)

4-2

INSTRUMENT AND CONTROL FUNCTIONS

EAU12950

Rear brake lever

1

1. 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.

EAU13182

Fuel tank cap

1

1. Fuel tank cap

To remove the fuel tank cap, turn it
counterclockwise, and then pull it off.
To install the fuel tank cap, insert it into
the tank opening, and then turn it clock­wise.

EWA11091

WARNING

Make sure that the fuel tank cap is
properly closed after filling fuel.
Leaking fuel is a fire hazard.

EAU13221

Fuel

Make sure there is sufficient gasoline in
the tank.

EWA10881

WARNING

Gasoline and gasoline vapors are
extremely flammable. To avoid fires
and explosions and to reduce the
risk of injury when refueling, follow
these instructions.

1. Before refueling, turn off the en­gine and be sure that no one is sit­ting on the vehicle. Never refuel
while smoking, or while in the vi­cinity of sparks, open flames, or
other sources of ignition such as
the pilot lights of water heaters and
clothes dryers.

2. Do not overfill the fuel tank. When
refueling, be sure to insert the
pump nozzle into the fuel tank filler
hole. Stop filling when the fuel
reaches the bottom of the filler
tube. Because fuel expands when
it heats up, heat from the engine or
the sun can cause fuel to spill out
of the fuel tank.

2

3

4

5

6

7

8

9

4-3

INSTRUMENT AND CONTROL FUNCTIONS

1

1

2

3

1. Fuel tank filler tube

2. Fuel level

4

3. Wipe up any spilled fuel immedi­ately.

5

NOTICE:

off spilled fuel with a clean, dry,

6

7

soft cloth, since fuel may deteri­orate painted surfaces or plastic
parts.

[ECA10071]

4. Be sure to securely close the fuel
tank cap.

8

WARNING

Gasoline is poisonous and can

9

cause injury or death. Handle gaso­line with care. Never siphon gaso­line by mouth. If you should swallow
some gasoline or inhale a lot of gas­oline vapor, or get some gasoline in

Immediately wipe

2

EWA15151

your eyes, see your doctor immedi­ately. If gasoline spills on your skin,
wash with soap and water. If gaso­line spills on your clothing, change
your clothes.

EAU40681

Recommended fuel:

UNLEADED GASOLINE ONLY

Fuel tank capacity:

2.0 L (0.53 US gal, 0.44 Imp.gal)

Your Yamaha engine has been de­signed to use regular unleaded gaso­line with a pump octane number
[(R+M)/2] of 86 or higher, or a research
octane number of 91 or higher. If
knocking (or pinging) occurs, use a
gasoline of a different brand or premi­um unleaded fuel. Use of unleaded fuel
will extend spark plug life and reduce
maintenance costs.

Gasohol

There are two types of gasohol: gaso­hol containing ethanol and that contain­ing methanol. Gasohol containing
ethanol can be used if the ethanol con-

tent does not exceed 10% (E10). Gas­ohol containing methanol is not
recommended by Yamaha because it
can cause damage to the fuel system
or vehicle performance problems.

4-4

INSTRUMENT AND CONTROL FUNCTIONS

1

Fuel tank breather hose

1

1. Fuel tank breather hose

Before operating the motorcycle:

●

Check the fuel tank breather hose
connection.

●

Check the fuel tank breather hose
for cracks or damage, and replace
it if damaged.

●

Make sure that the fuel tank
breather hose is not blocked, and
clean it if necessary.

EAU13412

EAU13452

2-stroke engine oil

Make sure that there is sufficient
2-stroke engine oil in the oil tank. Add
the recommended 2-stroke engine oil
as necessary.

1

2

1. 2-stroke engine oil tank cap

2. Minimum level mark

Recommended oil:

See page 9-1.

Oil quantity:

0.30 L (0.32 US qt, 0.26 Imp.qt)

TIP

Make sure that the 2-stroke engine oil
tank cap is properly installed.

EAU40701

Fuel cock

The fuel cock supplies fuel from the
tank to the carburetor while filtering it al­so.
The fuel cock has two positions:

S (stop)

1. Arrow mark pointing to “S” (stop)

With the lever in this position, fuel will
not flow. Always return the lever to this
position when the engine is not running.

2

3

4

5

6

7

8

9

4-5

INSTRUMENT AND CONTROL FUNCTIONS

1

O (on)

1

2

3

1. Arrow mark pointing to “O” (on)

4

With the lever in this position, fuel flows
to the carburetor. Normal riding is done

5

with the lever in this position.

6

7

8

9

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Starter (choke) lever “”

1

(a)

Kickstarter

EAU13680

(b)

1

1. 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).

1. 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.

4-6

Seat

To remove the seat

1. Remove the mudguard by remov­ing the bolts and washers.

1

1. Bolt

2. Mudguard

2. Pull the seat off.

EAU40920

2

INSTRUMENT AND CONTROL FUNCTIONS

1

2

1. Seat holder

2. Projection

2. Place the seat in the original posi­tion.

3. Install the mudguard by installing
the washers and bolts.

TIP

Make sure that the seat is properly se­cured before riding.

2

3

4

5

6

7

To install the seat

1. Insert the projection on the front of
the seat into the seat holder as
shown.

8

9

4-7

FOR YOUR SAFETY – PRE-OPERATION CHECKS

Inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition. Always follow the inspection
and maintenance procedures and schedules described in the Owner’s Manual.

1

2

3

4

5

6

7

8

WARNING

Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equipment damage.
Do not operate the vehicle if you find any problem. If a problem cannot be corrected by the procedures provided in
this manual, have the vehicle inspected by a Yamaha dealer.

Before using this vehicle, check the following points:

EAU15595

EWA11151

9

5-1

Pre-operation check list

ITEM CHECKS PAGE

Fuel

2-stroke engine oil

Transmission oil

Middle and final gear cases

Front brake

Rear brake

Throttle grip

Control cables

Wheels and tires

Brake levers

FOR YOUR SAFETY – PRE-OPERATION CHECKS

●

Check fuel level in fuel tank.

●

Refuel if necessary.

●

Check fuel line for leakage.

●

Check oil level in oil tank.

●

If necessary, add recommended oil to specified level.

●

Check vehicle for oil leakage.

●

Check oil level in transmission case.

●

If necessary, add recommended oil to specified level.
Check vehicle for grease leakage. 7-9

●

Check operation.

●

Lubricate cable if necessary.

●

Check lever free play.

●

●

Adjust if necessary.
Check operation.

●

Lubricate cable if necessary.

●

Check lever free play.

●

Adjust if necessary.

●

Make sure that operation is smooth.

●

Check cable free play.

●

If necessary, have Yamaha dealer adjust cable free play and lubricate cable

●

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.

●

Make sure that operation is smooth.

●

Lubricate lever pivoting points if necessary.

●

4-3

4-5

7-8

7-15, 7-16

7-15, 7-16

7-12, 7-17

7-16

7-12, 7-14

7-17

EAU15605

2

3

4

5

6

7

8

9

5-2

FOR YOUR SAFETY – PRE-OPERATION CHECKS

ITEM CHECKS PAGE

●

Centerstand

Chassis fasteners

1

Engine stop switch

2

3

4

5

6

7

8

Make sure that operation is smooth.

●

Lubricate pivot if necessary.

●

Make sure that all nuts, bolts and screws are properly tightened.

●

Tighten if necessary.

●

Check operation. 4-1

7-18

—

9

5-3

OPERATION AND IMPORTANT RIDING POINTS

WARNING

●

This model is designed for
off-road use only. 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.

EAU40771

EWA14531

EAU40886

Starting and warming up a
cold engine

1. Turn the fuel cock lever to “O” (on).

2. Set the engine stop switch to
“START”.

3. Turn the starter (choke) on and
completely close the throttle. (See
page 4-6.)

4. While applying the front or rear
brake, start the engine by pushing
the kickstarter lever down.

5. After starting the engine, move the
starter (choke) back halfway.

NOTICE:

life, always warm the engine up
before starting off. Never accel­erate hard when the engine is
cold!

6. When the engine is warm, turn the
starter (choke) off and set the en­gine stop switch to “RUN”.

TIP

The engine is warm when it responds
normally to the throttle with the starter
(choke) turned off.

For maximum engine

[ECA11131]

EAU16660

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. Instead, start
the engine with the throttle slightly
open.

TIP

If the engine does not start after sever­al kicks, try again with the throttle 1/4
to 1/2 open.

2

3

4

5

6

7

8

9

6-1

OPERATION AND IMPORTANT RIDING POINTS

Starting off

TIP

Before starting off, allow the engine to

1

warm up.

1. While applying the rear brake le-

2

3

4

5

6

7

8

9

ver, push the motorcycle off the
centerstand.

2. Completely close the throttle.

3. Set the engine stop switch to
“RUN”.

4. Check for oncoming off-road vehi­cles, and then slowly turn the throt­tle grip in order to take off.

EAU41001

EAU16780

Acceleration and deceleration

(b)

(a)

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).

Braking

WARNING

●

Avoid braking hard or suddenly
(especially when leaning over to
one side), otherwise the motor­cycle may skid or overturn.
Keep in mind that braking on

●

wet surfaces is much more diffi­cult.
Ride slowly down a hill, as brak-

●

ing downhill can be very diffi­cult.

1. Close the throttle completely.

2. Apply both front and rear brakes
simultaneously while gradually in­creasing the pressure.

EAU41012

EWA14571

6-2

OPERATION AND IMPORTANT RIDING POINTS

Front

Rear

EAU42030

Engine break-in

There is never a more important period
in the life of your engine than the first 5
hours of riding. It is also important to ac­custom the rider to the motorcycle dur­ing this time. Please read the following
information carefully.
Since the engine is brand new, do not
put an excessive load on it for the first 5
hours of operation. The various parts in
the engine wear and polish themselves
to the correct operating clearances.
During this period, prolonged full-throt­tle operation or any condition that might
result in engine overheating must be
avoided. However, momentary
full-throttle operation under load (i.e.,
two to three seconds maximum) does
not harm the engine. Each full-throttle
acceleration should be followed with a
substantial rest period for the engine.
To allow the engine to cool down from
the temporary buildup of heat, cruise at
a lower engine speed.
After the first 5 hours of operation, thor­oughly check the motorcycle for loose
parts, oil leakage and any other prob­lems. Be sure to inspect and make ad-

6-3

justments thoroughly, especially
cables. In addition, check all fittings and
fasteners for looseness, and tighten if
necessary.

ECA10270

NOTICE

If any engine trouble should occur
during the engine break-in period,
immediately have a Yamaha dealer
check the vehicle.

2

3

4

5

6

7

8

9

OPERATION AND IMPORTANT RIDING POINTS

EAU40722

Parking

When parking, stop the engine, and
then turn the fuel cock lever to “S”
(stop).

1

WARNING

2

●

Since the engine and exhaust
system can become very hot,

3

park in a place where pedestri­ans or children are not likely to

4

5

touch them and be burned.
Do not park on a slope or on soft

●

ground, otherwise the vehicle
may overturn, increasing the
risk of a fuel leak and fire.
Do not park near grass or other

●

6

flammable materials which

7

might catch fire.

8

EWA10311

9

6-4

PERIODIC MAINTENANCE AND ADJUSTMENT

EAU41951

Periodic inspection, adjustment, and lu­brication will keep your vehicle in the
safest and most efficient condition pos­sible. Safety is an obligation of the vehi­cle owner/operator. The most important
points of vehicle inspection, adjust­ment, and lubrication are explained on
the following pages.

EWA10321

WARNING

Failure to properly maintain the ve­hicle or performing maintenance ac­tivities incorrectly may increase
your risk of injury or death during
service or while using the vehicle. If
you are not familiar with vehicle ser­vice, have a Yamaha dealer perform
service.

EWA15121

WARNING

Turn off the engine when performing
maintenance unless otherwise
specified.

A running engine has moving

●

parts that can catch on body
parts or clothing and electrical

parts that can cause shocks or
fires.

●

Running the engine while ser­vicing can lead to eye injury,
burns, fire, or carbon monoxide
poisoning – possibly leading to
death. See page 2-1 for more in­formation about carbon monox­ide.

EAU17302

Emission controls not only function to
ensure cleaner air, but are also vital to
proper engine operation and maximum
performance. In the following periodic
maintenance charts, the services relat­ed to emissions control are grouped
separately. These services require
specialized data, knowledge, and
equipment. Maintenance, replacement,
or repair of the emission control devic­es and systems may be performed by
any repair establishment or individual
that is certified (if applicable). Yamaha
dealers are trained and equipped to
perform these particular services.

2

3

4

5

6

7

8

9

7-1

PERIODIC MAINTENANCE AND ADJUSTMENT

EAU17311

Owner’s tool kit

The service information included in this
manual and the tools provided in the
owner’s tool kit are intended to assist

1

you in the performance of preventive
maintenance and minor repairs. How-

2

ever, additional tools such as a torque
wrench may be necessary to perform

3

certain maintenance work correctly.

TIP

4

If you do not have the tools or experi­ence required for a particular job, have
a Yamaha dealer perform it for you.

5

6

7

8

9

7-2

PERIODIC MAINTENANCE AND ADJUSTMENT

Periodic maintenance chart for the emission control system

TIP

From 18 months, repeat the maintenance intervals starting from 6 months.

●

Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical

●

skills.

THEREAFTER

EVERY

NO. ITEM CHECK OR MAINTENANCE JOB

1*Fuel line

2 Spark plug

3 Air filter element

4*Carburetor

Cylinder head and

5*

exhaust system

6*Spark arrester

Check fuel hoses for cracks or damage.
Replace if necessary.
Check condition.
Adjust gap and clean.
Replace if necessary.
Clean with solvent.
Replace if necessary.
Check engine idling speed and starter operation.
Adjust if necessary.
Clean.
Check for leakage.
Tighten if necessary.
Decarbonize if necessary.
Clean.

INITIAL

1

month3 months6 months6 months

EAU41741

2

3

12

months

4

5

6

7

8

9

7-3

PERIODIC MAINTENANCE AND ADJUSTMENT

General maintenance and lubrication chart

EAU41753

1

NO. ITEM CHECK OR MAINTENANCE JOB

2

1*Front brake

3

2*Rear brake

4

3*Wheels

5

4*Tires

6

5*Wheel bearings

7

6*Steering bearings

8

Middle and final gear

7*

9

cases

8*Chassis fasteners

9*Autolube pump

INITIAL

1

month3months6months6months

Check operation.
Adjust brake lever free play.
Replace brake shoes. Whenever worn to the limit
Check operation.
Adjust brake lever free play.
Replace brake shoes. Whenever worn to the limit
Check runout and for damage.
Replace if necessary.
Check tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.
Check bearings for smooth operation.
Replace if necessary.
Check bearing assemblies for looseness.
Moderately repack with lithium-soap-based
grease every 2 years.
Check for grease leakage.
Check gears for damage and wear.
Lubricate gears with lithium-soap-based grease.
Check all chassis fitting and fasteners.
Correct if necessary.
Check operation.
Correct if necessary.
Bleed.

Every 2 years

THEREAFTER

EVERY

12

months

7-4

PERIODIC MAINTENANCE AND ADJUSTMENT

INITIAL

NO. ITEM CHECK OR MAINTENANCE JOB

Check for oil leakage.

10

* Transmission oil

Front and rear brake

11

*

lever pivot

12

* Centerstand pivot

Shock absorber

13

*

assemblies

14

* Control cable

Throttle grip housing

15

*

and cable

Correct if necessary.
Change.

Apply lithium-soap-based grease lightly.

Check operation.
Apply lithium-soap-based grease lightly.

Check operation and for oil leakage.
Replace if necessary.
Apply Yamaha chain and cable lube or engine oil
10W-30 lightly.
Check operation and free play.
Apply Yamaha chain and cable lube or engine oil
10W-30 lightly.

1

month3months6months6months

TIP

The air filter needs more frequent service if you are riding in unusually wet or dusty areas.

THEREAFTER

EVERY

12

months

2

3

4

5

6

7

8

9

7-5

PERIODIC MAINTENANCE AND ADJUSTMENT

1

Checking the spark plug

The spark plug is an important engine
component, which is easy to check.
Since heat and deposits will cause any

1

spark plug to slowly erode, the spark
plug should be removed and checked

2

in accordance with the periodic mainte­nance and lubrication chart. In addition,

3

the condition of the spark plug can re­veal the condition of the engine.

4

To remove the spark plug

1. Remove the spark plug cap.

5

6

7

8

1

9

1. Spark plug cap

2. Remove the spark plug as shown,
with the spark plug wrench includ­ed in the owner’s tool kit.

EAU19603

1

1. Spark plug wrench

To check the spark plug

1. Check that the porcelain insulator
around the center electrode of the
spark plug is a medium-to-light tan
(the ideal color when the vehicle is
ridden normally).

TIP

If the spark plug shows a distinctly dif­ferent color, the engine could be oper­ating improperly. Do not attempt to
diagnose such problems yourself. In­stead, have a Yamaha dealer check
the vehicle.

2. Check the spark plug for electrode
erosion and excessive carbon or

other deposits, and replace it if
necessary.

Specified spark plug:

NGK/BP4HS
DENSO/W14FPL

To install the spark plug

1. Measure the spark plug gap with a
wire thickness gauge and, if nec­essary, adjust the gap to specifica­tion.

1. Spark plug gap

Spark plug gap:

0.6–0.7 mm (0.024–0.028 in)

2. Clean the surface of the spark plug
gasket and its mating surface, and

7-6

PERIODIC MAINTENANCE AND ADJUSTMENT

then wipe off any grime from the
spark plug threads.

3. Install the spark plug with the
spark plug wrench, and then tight­en it to the specified torque.

Tightening torque:

Spark plug:

20 Nm (2.0 m·kgf, 14.5 ft·lbf)

TIP

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.

EAU41102

Removing the power
reduction plate

To obtain full engine performance ca­pability, removing the power reduction
plate is required.

1. Remove the exhaust manifold by
removing the bolts.

Always let the exhaust system
cool prior to touching exhaust
components.

1. Exhaust manifold bolt

[EWA14581]

2. Remove the gasket.

3. Remove the power reduction
plate.

WARNING!

1

1

2

3

1. Exhaust manifold

2. Gasket

3. Power reduction plate

TIP

Store the power reduction plate with the
Owner’s Manual so that it is readily
available whenever you want to reduce
the engine power.

4. Install the exhaust manifold by in­stalling the bolts.

Tightening torque:

Exhaust manifold bolt:

8.5 Nm (0.9 m·kgf, 6.1 ft·lbf)

2

3

4

5

6

7

8

9

7-7

PERIODIC MAINTENANCE AND ADJUSTMENT

Transmission oil

The transmission oil must be checked
for oil leakage before each ride. If any
leakage is found, have a Yamaha deal-

1

er check and repair the motorcycle. In
addition, the transmission oil must be

2

changed at the intervals specified in the
periodic maintenance and lubrication

3

chart.

1. Place the motorcycle on the cen-

4

5

6

7

8

9

terstand.

2. Place an oil pan under the trans­mission to collect the used oil.

3. Remove the oil filler cap and drain
bolt to drain the oil from the trans­mission.

1

1. Transmission oil filler cap

EAU40892

1

1. Transmission oil drain bolt

4. Install the transmission oil drain
bolt, and then tighten it to the spec­ified torque.

Tightening torque:

Transmission oil drain bolt:

14 Nm (1.4 m·kgf, 10.1 ft·lbf)

5. Refill with the specified amount of
the recommended transmission
oil, and then install and tighten the
oil filler cap.

Recommended transmission oil:

See page 9-1.

Oil change quantity:

0.30 L (0.32 US qt, 0.26 Imp.qt)

ECA10452

NOTICE

In order to prevent clutch slip-

●

page (since the transmission oil
also lubricates the clutch), do
not mix any chemical additives.
Do not use oils with a diesel
specification of “CD” or oils of a
higher quality than specified. In
addition, do not use oils labeled
“ENERGY CONSERVING II” or
higher.
Make sure that no foreign mate-

●

rial enters the transmission.

6. Start the engine, and then let it idle
for several minutes while checking
the transmission for oil leakage. If
oil is leaking, immediately turn the
engine off and check for the cause.

7-8

PERIODIC MAINTENANCE AND ADJUSTMENT

1

EAU41711

Middle and final gear cases

The middle and final gear cases must
be checked for grease leakage before
each ride. If any leakage is found, have
a Yamaha dealer check and repair the
motorcycle. In addition, have a
Yamaha dealer check and lubricate the
middle and final gears at the intervals
specified in the periodic maintenance
and lubrication chart.

EAU40902

Cleaning the air filter element

The air filter element should be cleaned
at the intervals specified in the periodic
maintenance and lubrication chart.
Clean the air filter element more fre­quently if you are riding in unusually
wet or dusty areas.

1. Remove the seat. (See page 4-7.)

2. Remove the air filter case cover by
removing the screw.

1

2

1. Air filter case cover

2. Screw

3. Pull the sponge material out, clean
it with solvent, and then squeeze
the remaining solvent out.

1. Sponge material

4. Apply oil of the recommended type
to the entire surface of the sponge
material, and then squeeze the ex­cess oil out.

TIP

The sponge material should be wet but

2

3

4

5

6

7

8

9

7-9

PERIODIC MAINTENANCE AND ADJUSTMENT

1

2

3

not dripping.

Recommended oil:

Yamaha foam air filter oil or other

1

2

quality foam air filter oil

5. Insert the sponge material into the
air filter case.

NOTICE:

that the sponge material is prop-

3

erly seated in the air filter case.
The engine should never be op-

4

erated without the sponge mate­rial installed, otherwise the
piston(s) and/or cylinder(s) may

5

become excessively worn.

6. Install the air filter case cover by in-

6

stalling the screw.

7. Install the seat.

7

8

9

Make sure

[ECA15621]

Cleaning the spark arrester

The spark arrester should be cleaned
at the intervals specified in the periodic
maintenance and lubrication chart.

WARNING

●

Always let the exhaust system
cool prior to touching exhaust
components.
Do not start the engine when

●

cleaning the exhaust system.

TIP

Make sure to select a well-ventilated
area free of combustible materials to
clean the spark arrester.

1. Remove the tailpipe by removing
the screw, and then pulling it out of
the muffler.

EAU41220

EWA10980

1. Tailpipe

2. Screw

3. Muffler

2. Tap the tailpipe lightly, and then
use a wire brush to remove any
carbon deposits from the spark ar­rester portion of the tailpipe and in­side of the tailpipe housing.

7-10

PERIODIC MAINTENANCE AND ADJUSTMENT

1

1. Spark arrester

3. Insert the tailpipe into the muffler,
and then install and tighten the
screw.

TIP

Make sure to align the screw hole when
inserting the tailpipe.

EAU39930

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.

ECA10550

NOTICE

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.

EAU21362

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.

TIP

A diagnostic tachometer is needed to
make this adjustment.

1. Attach the tachometer to the spark
plug lead.

2. Start the engine and warm it up for
several minutes at 1000–2000 r/
min while occasionally revving it to
4000–5000 r/min.

TIP

The engine is warm when it quickly re­sponds to the throttle.

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

2

3

4

5

6

7

8

9

7-11

PERIODIC MAINTENANCE AND ADJUSTMENT

direction (b).

1

2

3

1. Throttle stop screw

4

Engine idling speed:

5

6

1650–1750 r/min

TIP

(b)

1

(a)

If the specified idling speed cannot be
obtained as described above, have a

7

Yamaha dealer make the adjustment.

8

9

EAU21382

Checking the throttle cable
free play

1

1. Throttle cable free play

The throttle cable free play should mea­sure 1.5–3.5 mm (0.06–0.14 in) at the
throttle grip. Periodically check the
throttle cable free play and, if neces­sary, have a Yamaha dealer adjust it.

EAU40911

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

Operation of this vehicle with im­proper tire pressure may cause se­vere injury or death from loss of
control.

The tire air pressure must be

●

checked and adjusted on cold
tires (i.e., when the temperature
of the tires equals the ambient
temperature).
The tire air pressure must be ad-

●

justed in accordance with the
weight of the rider, the riding
speed, and the riding condi­tions.

EWA14381

7-12

PERIODIC MAINTENANCE AND ADJUSTMENT

Standard tire air pressure:

Front:

100 kPa (1.00 kgf/cm

Rear:

100 kPa (1.00 kgf/cm2, 15 psi)

2

, 15 psi)

Tire inspection

2

1

1. Tire sidewall

2. Tire tread depth

The tires must be checked before each
ride. If the center tread depth reaches
the specified limit, 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.

Minimum tire tread depth (front and
rear):

4.0 mm (0.16 in)

Tire information

This motorcycle is equipped with panel
wheels and tube tires.

EWA10461

WARNING

The front and rear tires should be of
the same make and design, other­wise the handling characteristics of
the vehicle may be different, which
could lead to an accident.

After extensive tests, only the tires list­ed below have been approved for this
model by Yamaha Motor Co., Ltd.

Front tire:

Size:

2.50-10 4PR

Manufacturer/model:

BRIDGESTONE/KNOBBY
IRC/KNOBBY

Rear tire:

Size:

2.50-10 4PR

Manufacturer/model:

BRIDGESTONE/KNOBBY
IRC/KNOBBY

WARNING

Have a Yamaha dealer replace

●

excessively worn tires. Operat­ing the motorcycle with exces­sively worn tires decreases
riding stability and can lead to
loss of control.
The replacement of all

●

wheel-and brake-related parts,
including the tires, should be
left to a Yamaha dealer, who has
the necessary professional
knowledge and experience.
It is not recommended to patch

●

a punctured tube. If unavoid­able, however, patch the tube

EWA14390

2

3

4

5

6

7

8

9

7-13

PERIODIC MAINTENANCE AND ADJUSTMENT

very carefully and replace it as
soon as possible with a
high-quality product.

1

Panel wheels

WARNING

The wheels on this model are not de-

EAU40780

EWA10610

signed for use with tubeless tires.

2

3

Do not attempt to use tubeless tires
on this model.

To maximize the performance, durabil­ity, and safe operation of your motorcy-

a tire since the tire must seat itself
on the rim properly. Failure to al­low proper seating may cause tire
failure, which may result in dam­age to the motorcycle and injury to
the rider.

cle, note the following points regarding

4

5

the specified wheels.

●

The wheel rims should be checked
for cracks, bends, warpage or
damage before each ride. If any

6

damage is found, have a Yamaha
dealer replace the wheel. Do not
attempt even the smallest repair to

7

the wheel. A deformed or cracked
wheel must be replaced.

●

8

The wheel should be balanced
whenever either the tire or wheel

9

has been changed or replaced. An
unbalanced wheel can result in
poor performance, adverse han­dling characteristics, and a short­ened tire life.

●

Ride conservatively after changing

7-14

PERIODIC MAINTENANCE AND ADJUSTMENT

1

(a)

(b)

EAU22151

Adjusting the front and rear
brake lever free play

Front

1. Front brake lever free play

Rear

1

The front and rear brake lever free play
should be measured at the positions as
shown.

Front brake lever free play:

10.0–20.0 mm (0.39–0.79 in)

Rear brake lever free play:

10.0–20.0 mm (0.39–0.79 in)

1

Periodically check the front and rear
brake lever free play and, if necessary,
adjust them as follows.
To increase the brake lever free play,
turn the adjusting nut at the brake shoe
plate in direction (a). To decrease the
brake lever free play, turn the adjusting
nut in direction (b).

Front

(a)

Rear

1. Brake lever free play adjusting nut

EWA10650

WARNING

If proper adjustment cannot be ob­tained as described, have a Yamaha
dealer make this adjustment.

2

3

4

5

6

7

8

9

1. Rear brake lever free play

(b)

1. Brake lever free play adjusting nut

7-15

1

PERIODIC MAINTENANCE AND ADJUSTMENT

Checking the front and rear
brake shoes

The front and rear brake shoes must be

1

checked for wear at the intervals spec­ified in the periodic maintenance and
lubrication chart.

2

TIP

The wheels must be removed to check

3

brake shoe lining thickness.

To remove the front wheel: See

●

4

5

6

7

8

9

page 7-19.
To remove the rear wheel: See

●

page 7-21.

Front

EAU41052

Rear

If the lining thickness of a brake shoe is
less than 1.5 mm (0.06 in), have a
Yamaha dealer replace the brake
shoes as a set.

TIP

Be sure to measure the brake lining at
the thinnest portion.

EAU41842

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.

WARNING! Damage to the outer
housing of cables may result in in­ternal rusting and cause interfer­ence with cable movement. Replace
damaged cables as soon as possi­ble to prevent unsafe condi­tions.

[EWA10711]

Recommended lubricant:

Yamaha Chain and Cable Lube or
4-stroke engine oil

7-16

PERIODIC MAINTENANCE AND ADJUSTMENT

EAU23111

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 at
the intervals specified in the periodic
maintenance chart.

EAU23120

Adjusting the Autolube pump

The Autolube pump is a vital and so­phisticated component of the engine,
which must be adjusted by a Yamaha
dealer at the intervals specified in the
periodic maintenance and lubrication
chart.

EAU43631

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

2

3

4

5

6

7

8

9

7-17

PERIODIC MAINTENANCE AND ADJUSTMENT

Checking and lubricating the
centerstand

1

2

3

4

The operation of the centerstand

5

should be checked before each ride,
and the pivots and metal-to-metal con­tact surfaces should be lubricated if

6

necessary.

7

8

9

WARNING

If the centerstand does not move up
and down smoothly, have a Yamaha
dealer check or repair it. Otherwise,
the centerstand could contact the
ground and distract the operator, re­sulting in a possible loss of control.

EAU23192

EWA11301

EAU42081

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

Check the inner tubes for scratches
and damage.

To check the operation

1. Place the vehicle on a level sur­face and hold it in an upright posi­tion.

WARNING! To avoid injury,
securely support the vehicle so
there is no danger of it falling
over.

[EWA10751]

2. While applying the front brake,
push down hard on the handlebars
several times to check if the front
fork compresses and rebounds
smoothly.

ECA10590

NOTICE

If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or re­pair it.

Recommended lubricant:

Lithium-soap-based grease

7-18

PERIODIC MAINTENANCE AND ADJUSTMENT

EAU45511

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 the vehicle on the center­stand.

WARNING! To avoid inju­ry, securely support the vehicle
so there is no danger of it falling
over.

[EWA10751]

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.

EAU23290

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.

EAU24360

Front wheel

EAU41022

To remove the front wheel

EWA10821

WARNING

To avoid injury, securely support the
vehicle so there is no danger of it
falling over.

1. Place the motorcycle on the cen­terstand.

2. Disconnect the brake cable at the
wheel by removing the brake lever
free play adjusting nut, then re­moving the cable from the brake
camshaft lever and brake shoe
plate.

2

3

4

5

6

7

8

9

7-19

PERIODIC MAINTENANCE AND ADJUSTMENT

1

3

1

2

2

3

1. Brake lever free play adjusting nut

2. Brake camshaft lever

4

3. Washer

4. Axle nut

5

5. Brake cable

3. Remove the axle nut and washer.

6

4. Pull the wheel axle out, and then
remove the wheel.

7

4

5

1

To install the front wheel

1. Install the brake shoe plate into the
wheel hub as shown.

2. Lift the wheel up between the fork
legs.

TIP

Make sure that the slot in the brake
shoe plate fits over the retainer on the
fork leg.

EAU41031

1. Retainer

3. Insert the wheel axle from the right
side.

4. Install the washer and axle nut,
and then tighten the axle nut to the
specified torque.

Tightening torque:

Axle nut:

40 Nm (4.0 m·kgf, 28.9 ft·lbf)

8

9

1

1. Wheel axle

5. Connect the brake cable at the
wheel hub, and then install the
brake cable free play adjusting nut.

6. Adjust the brake lever free play.
(See page 7-15.)

7. Take the motorcycle off the center­stand so that the front wheel is on
the ground.

7-20

PERIODIC MAINTENANCE AND ADJUSTMENT

3

1

2

4

2

1

3

8. Push down hard on the handlebar
several times to check for proper
fork operation.

EAU25080

Rear wheel

EAU41082

To remove the rear wheel

WARNING

To avoid injury, securely support the
vehicle so there is no danger of it
falling over.

1. Place the motorcycle on the cen­terstand.

2. Remove the seat. (See page 4-7.)

3. Remove the muffler bolt and
washers.

WARNING! Always let
the exhaust system cool prior to
touching exhaust compo­nents.

[EWA14581]

EWA10821

1. Muffler

2. Washer

3. Muffler bolt

4. Spring clamp

4. Slide the spring clamp down, and
then remove the muffler.

2

3

4

5

6

7

8

9

7-21

1. Exhaust chamber

2. Exhaust chamber bolt

3. Washer

PERIODIC MAINTENANCE AND ADJUSTMENT

1

2

3

5. Remove the exhaust chamber bolt
and washers.

6. Remove the exhaust manifold
bolts, and then remove the ex-

1

2

haust chamber.

3

4

5

1. Exhaust manifold bolt

6

7. Remove the right-side rear shock
absorber mounting bolt and then

7

tilt the rear shock absorber upward
as shown.

8

9

1

1. Rear shock absorber mounting bolt

8. Remove the axle nut while apply-

1

ing the rear brake.

1

1. Axle nut

9. Remove the rear arm by removing
the nuts and washers.

7-22

1. Rear arm

2. Washer

3. Rear arm nut

10. Pull the wheel to the right to sepa­rate it from the final gear case, and
then remove the wheel.

EAU41521

To install the rear wheel

1. Apply a light coating of lithi­um-soap-based grease to the
splines of the final gear case and
wheel hub.

2. Install the wheel by inserting it into
the wheel hub.

3. Install the rear arm by installing the
washers and nuts.

4. Install the axle nut.

5. Install the right-side rear shock ab-

PERIODIC MAINTENANCE AND ADJUSTMENT

sorber by installing the mounting
bolt.

6. While applying the rear brake,
tighten the axle nut to the specified
torque.

7. Tighten the rear arm nuts and rear
shock absorber mounting bolt to
the specified torques.

Tightening torques:

Axle nut:

60 Nm (6.0 m·kgf, 43.4 ft·lbf)

Rear arm nut:

28.5 Nm (2.9 m·kgf, 20.6 ft·lbf)

Rear shock absorber mounting bolt:

22.5 Nm (2.3 m·kgf, 16.3 ft·lbf)

8. Install the exhaust chamber and
then install the exhaust manifold
bolts.

9. Install the washers and exhaust
chamber bolt.

10. Tighten the exhaust manifold bolts
and exhaust chamber bolt to the
specified torques.

Tightening torques:

Exhaust manifold bolt:

8.5 Nm (0.9 m·kgf, 6.1 ft·lbf)

Exhaust chamber bolt:

17.5 Nm (1.8 m·kgf, 12.7 ft·lbf)

11. Install the muffler by sliding the
spring clamp up to its original posi­tion, and then installing the wash­ers and muffler bolt.

TIP

Make sure that the spring clamp is po­sitioned with the projection side facing
inward.

1

2

3

1. Exhaust chamber

2. Spring clamp

3. Muffler

12. Tighten the muffler bolt to the
specified torque.

Tightening torque:

Muffler bolt:

17.5 Nm (1.8 m·kgf, 12.7 ft·lbf)

13. Adjust the brake lever free play.
(See page 7-15.)

14. Install the seat.

2

3

4

5

6

7

8

9

7-23

PERIODIC MAINTENANCE AND ADJUSTMENT

Troubleshooting

Although Yamaha motorcycles receive
a thorough inspection before shipment
from the factory, trouble may occur dur-

1

ing operation. Any problem in the fuel,
compression, or ignition systems, for

2

example, can cause poor starting and
loss of power.

3

The following troubleshooting chart
represents a quick and easy procedure
for checking these vital systems your-

4

self. However, should your motorcycle
require any repair, take it to a Yamaha

5

dealer, whose skilled technicians have
the necessary tools, experience, and

6

know-how to service the motorcycle
properly.
Use only genuine Yamaha replace-

7

ment parts. Imitation parts may look like
Yamaha parts, but they are often inferi-

8

or, have a shorter service life and can
lead to expensive repair bills.

9

WARNING

When checking the fuel system, do
not smoke, and make sure there are
no open flames or sparks in the ar­ea, including pilot lights from water

EAU25851

EWA15141

heaters or furnaces. Gasoline or
gasoline vapors can ignite or ex­plode, causing severe injury or
property damage.

7-24

Troubleshooting chart

PERIODIC MAINTENANCE AND ADJUSTMENT

EAU25972

1. Fuel

Check the fuel level in
the fuel tank.

2. Compression

Operate the kickstarter.

3. Ignition

Remove the spark plug
and check the electrodes.

There is
enough fuel.

There is
no fuel.

There is compression.

There is
no compression.

Wet

Dry

Check the compression.

Supply fuel.

Check the ignition.

Have a Yamaha dealer
check the vehicle.

Wipe off with a dry cloth and correct the
spark plug gap, or replace the spark plug.

Have a Yamaha dealer check the vehicle.

The engine does not start.
Check the compression.

Open the throttle halfway and operate
the kickstarter.

The engine does not start.
Have a Yamaha dealer check the vehicle.

2

3

4

5

6

7

8

9

7-25

MOTORCYCLE CARE AND STORAGE

Matte color caution

NOTICE

Some models are equipped with

1

matte colored finished parts. Be
sure to consult a Yamaha dealer for

2

advice on what products to use be­fore cleaning the vehicle. Using a

3

brush, harsh chemical products or
cleaning compounds when cleaning
these parts will scratch or damage

4

their surface. Wax also should not
be applied to any matte colored fin-

5

ished parts.

6

7

8

9

EAU37833

ECA15192

EAU40633

Care

While the open design of a motorcycle
reveals the attractiveness of the tech­nology, it also makes it more vulnera­ble. Rust and corrosion can develop
even if high-quality components are
used. A rusty exhaust pipe may go un­noticed on a car, however, it detracts
from the overall appearance of a motor­cycle. Frequent and proper care does
not only comply with the terms of the
warranty, but it will also keep your mo­torcycle looking good, extend its life
and optimize its performance.

Before cleaning

1. Cover the muffler outlet with a
plastic bag after the engine has
cooled down.

2. Make sure that all caps and covers
as well as all electrical couplers
and connectors, including the
spark plug cap, are tightly in­stalled.

3. Remove extremely stubborn dirt,
like oil burnt onto the crankcase,
with a degreasing agent and a
brush, but never apply such prod-

8-1

ucts onto seals, gaskets and wheel
axles. Always rinse the dirt and de­greaser off with water.

Cleaning

NOTICE

Avoid using strong acidic wheel

●

cleaners, especially on spoked
wheels. If such products are
used on hard-to-remove dirt, do
not leave the cleaner on the af­fected area any longer than in­structed. Also, thoroughly rinse
the area off with water, immedi­ately dry it, and then apply a cor­rosion protection spray.
Improper cleaning can damage

●

plastic parts such as cowlings,
panels, windshields, headlight
lenses, meter lenses, etc. Use
only a soft, clean cloth or
sponge with mild detergent and
water to clean plastic.
Do not use any harsh chemical

●

products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
contact with strong or abrasive

ECA10771

MOTORCYCLE CARE AND STORAGE

cleaning products, solvent or
thinner, fuel (gasoline), rust re­movers or inhibitors, brake flu­id, antifreeze or electrolyte.

●

Do not use high-pressure wash­ers or steam-jet cleaners since
they cause water seepage and
deterioration in the following ar­eas: seals (of wheel and swing­arm bearings, fork and brakes),
electric components (couplers,
connectors, instruments,
switches and lights), breather
hoses and vents.

●

For motorcycles equipped with
a windshield: Do not use strong
cleaners or hard sponges as
they will cause dulling or
scratching. Some cleaning com­pounds for plastic may leave
scratches on the windshield.
Test the product on a small hid­den part of the windshield to
make sure that it does not leave
any marks. If the windshield is
scratched, use a quality plastic
polishing compound after
washing.

After normal use
Remove dirt with warm water, a mild
detergent, and a soft, clean sponge,
and then rinse thoroughly with clean
water. Use a toothbrush or bottlebrush
for hard-to-reach areas. Stubborn dirt
and insects will come off more easily if
the area is covered with a wet cloth for
a few minutes before cleaning.

After riding in the rain or near the sea
Since sea salt is extremely corrosive,
carry out the following steps after each
ride in the rain or near the sea.

1. Clean the motorcycle with cold wa­ter and a mild detergent, after the
engine has cooled down.

NOTICE:

Do not use warm water
since it increases the corrosive
action of the salt.

[ECA10791]

2. Apply a corrosion protection spray
on all metal, including chrome- and
nickel-plated, surfaces to prevent
corrosion.

After cleaning

1. Dry the motorcycle with a chamois
or an absorbing cloth.

8-2

2. Use a chrome polish to shine
chrome, aluminum and stain­less-steel parts, including the ex­haust system. (Even the thermally
induced discoloring of stain­less-steel exhaust systems can be
removed through polishing.)

3. To prevent corrosion, it is recom­mended to apply a corrosion pro­tection spray on all metal,
including chrome- and nickel-plat­ed, surfaces.

4. Use spray oil as a universal clean­er to remove any remaining dirt.

5. Touch up minor paint damage
caused by stones, etc.

6. Wax all painted surfaces.

7. Let the motorcycle dry completely
before storing or covering it.

EWA14501

WARNING

Contaminants on the brakes or tires
can cause loss of control.

Make sure that there is no oil or

●

wax on the tires.

●

If necessary, wash the tires with
warm water and a mild deter­gent. Before riding at higher
speeds, test the motorcycle’s

2

3

4

5

6

7

8

9

MOTORCYCLE CARE AND STORAGE

braking performance and cor­nering behavior.

NOTICE

1

●

Apply spray oil and wax spar­ingly and make sure to wipe off

2

3

any excess.

●

Never apply oil or wax to any
rubber and plastic parts, but
treat them with a suitable care
product.

4

●

Avoid using abrasive polishing
compounds as they will wear

5

6

away the paint.

TIP

Consult a Yamaha dealer for advice on
what products to use.

7

8

9

ECA10800

EAU40643

Storage

Short-term

Always store your motorcycle in a cool,
dry place and, if necessary, protect it
against dust with a porous cover.

NOTICE

Storing the motorcycle in a

●

poorly ventilated room or cover­ing it with a tarp, while it is still
wet, will allow water and humid­ity to seep in and cause rust.
To prevent corrosion, avoid

●

damp cellars, stables (because
of the presence of ammonia)
and areas where strong chemi­cals are stored.

Long-term

Before storing your motorcycle for sev­eral months:

1. Follow all the instructions in the
“Care” section of this chapter.

2. For motorcycles equipped with a
fuel cock that has an “S” (stop) po­sition: Turn the fuel cock lever to

ECA10810

“S”.

3. Drain the carburetor float chamber
by loosening the drain bolt; this will
prevent fuel deposits from building
up. Pour the drained fuel into the
fuel tank.

4. Fill up the fuel tank and add fuel
stabilizer (if available) to prevent
the fuel tank from rusting and the
fuel from deteriorating.

5. Perform the following steps to pro­tect the cylinder, piston rings, etc.
from corrosion.
a. Remove the spark plug cap

and spark plug.

b. Pour a teaspoonful of engine oil

into the spark plug bore.

c. Install the spark plug cap onto

the spark plug, and then place
the spark plug on the cylinder
head so that the electrodes are
grounded. (This will limit spark­ing during the next step.)

d. Turn the engine over several

times with the starter. (This will
coat the cylinder wall with oil.)

e. Remove the spark plug cap

from the spark plug, and then

8-3

install the spark plug and the
spark plug cap.

WARNING! To
prevent damage or injury
from sparking, make sure to
ground the spark plug elec­trodes while turning the en­gine over.

[EWA10951]

6. Lubricate all control cables and the
pivoting points of all levers and
pedals as well as of the center­stand.

7. Check and, if necessary, correct
the tire air pressure, and then lift
the motorcycle so that both of its
wheels are off the ground. Alterna­tively, turn the wheels a little every
month in order to prevent the tires
from becoming degraded in one
spot.

8. Cover the muffler outlet with a
plastic bag to prevent moisture
from entering it.

TIP

Make any necessary repairs before
storing the motorcycle.

MOTORCYCLE CARE AND STORAGE

2

3

4

5

6

7

8

9

8-4

SPECIFICATIONS

Dimensions:

1

2

3

4

5

Weight:

6

Engine:

7

8

9

Overall length:

1245 mm (49.0 in)

Overall width:

575 mm (22.6 in)

Overall height:

715 mm (28.1 in)

Seat height:

485 mm (19.1 in)

Wheelbase:

855 mm (33.7 in)

Ground clearance:

105 mm (4.13 in)

Minimum turning radius:

1300 mm (51.2 in)

With oil and fuel:

39.0 kg (86 lb)

Engine type:

Air cooled 2-stroke

Cylinder arrangement:

Forward-inclined single cylinder

Displacement:

Bore × stroke:

Compression ratio:

Starting system:

3

49.0 cm

40.0 × 39.2 mm (1.57 × 1.54 in)

6.00 :1

Kickstarter

EAU2633N

Lubrication system:

Separate lubrication (Yamaha autolube)

Engine oil:

Type:

YAMALUBE 2 or 2-stroke engine oil (JASO
FC grade) or (ISO EG-C or EG-D grade)

Engine oil quantity:

Quantity:

0.30 L (0.32 US qt, 0.26 Imp.qt)

Transmission oil:

Type:

YAMALUBE 4 (10W-40) or SAE 10W-40

Oil change quantity:

0.30 L (0.32 US qt, 0.26 Imp.qt)

Air filter:

Air filter element:

Wet element

Fuel:

Recommended fuel:

Unleaded gasoline only

Fuel tank capacity:

2.0 L (0.53 US gal, 0.44 Imp.gal)

Carburetor:

Manufacturer:

MIKUNI

Type × quantity:

VM12SC x 1

Spark plug (s):

Manufacturer/model:

NGK/BP4HS

Manufacturer/model:

DENSO/W14FPL

Spark plug gap:

0.6–0.7 mm (0.024–0.028 in)

Clutch:

Clutch type:

Wet, centrifugal automatic

Transmission:

Primary reduction system:

Spur gear

Primary reduction ratio:

63/33 (1.909)

Secondary reduction system:

Shaft drive

Secondary reduction ratio:

19/15 × 54/11 (6.218)

Chassis:

Frame type:

Steel tube backbone

Caster angle:

25.50 °

Trail:

50.0 mm (1.97 in)

Front tire:

Type:

With tube

Size:

2.50-10 4PR

Manufacturer/model:

BRIDGESTONE/KNOBBY

Manufacturer/model:

IRC/KNOBBY

Rear tire:

Type:

With tube

9-1

SPECIFICATIONS

Size:

2.50-10 4PR

Manufacturer/model:

BRIDGESTONE/KNOBBY

Manufacturer/model:

IRC/KNOBBY

Loading:

Maximum rider weight:

25.0 kg (55 lb)

* (Total weight of rider, cargo and

accessories)

Tire air pressure (measured on cold
tires):

Front:

100 kPa (1.00 kgf/cm2, 15 psi)

Rear:

100 kPa (1.00 kgf/cm2, 15 psi)

Front wheel:

Wheel type:

Panel wheel

Rim size:

10x1.50

Rear wheel:

Wheel type:

Panel wheel

Rim size:

10x1.50

Front brake:

Type:

Drum brake

Operation:

Right hand operation

Rear brake:

Type:

Drum brake

Operation:

Left hand operation

Front suspension:

Type:

Telescopic fork

Spring/shock absorber type:

Coil spring/oil damper

Wheel travel:

60.0 mm (2.36 in)

Rear suspension:

Type:

Unit swing

Spring/shock absorber type:

Coil spring/oil damper

Wheel travel:

50.0 mm (1.97 in)

Electrical system:

Ignition system:

CDI

2

3

4

5

6

7

8

9

9-2

CONSUMER INFORMATION

1

Identification numbers

Record the vehicle identification num­ber and model label information in the
spaces provided below for assistance

1

when ordering spare parts from a
Yamaha dealer or for reference in case

2

the vehicle is stolen.
VEHICLE IDENTIFICATION

3

NUMBER:

4

5

MODEL LABEL INFORMATION:

6

7

8

9

EAU40790

EAU26400

Vehicle identification number

1

1. Vehicle identification number

The vehicle identification number is
stamped into the steering head pipe.
Record this number in the space pro­vided.

TIP

The vehicle identification number is
used to identify your motorcycle and
may be used to register your motorcy­cle with the licensing authority in your
area.

EAU26480

Model label

1. Model label

The model label is affixed to the frame
under the seat. (See page 4-7.) Record
the information on this label in the
space provided. This information will be
needed when ordering spare parts from
a Yamaha dealer.

10

10-1

CONSUMER INFORMATION

EAU26560

Motorcycle noise regulation

TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED:

Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other
than for purposes of maintenance, repair, or replacement of any device or element of design incorporated into any new ve­hicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or (2) the use of
the vehicle after such device or element of design has been removed or rendered inoperative by any person.
“AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW”.
These acts include tampering with the following systems; i.e., modification, removal, etc.

Exhaust system

●

Muffler

●

Exhaust pipe

●

Silencer

Intake system

Air cleaner case

●

Air cleaner element

●

●

Intake duct

2

3

4

5

6

7

8

10-2

9

10

CONSUMER INFORMATION

YAMAHA MOTOR CORPORATION, U.S.A. OFF-ROAD MOTORCYCLE LIMITED WARRANTY

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Yamaha Motor Corporation, USA hereby warrants
that new Yamaha off-road motorcycles purchased
from an authorized Yamaha motorcycle dealer in
the continental United States will be free from
defects in material and workmanship for the peri­od of time stated herein, subject to certain stated
limitations. Covered off-road motorcycles are
those units certified by Yamaha to EPA noise reg­ulations and come equipped from the factory with
USDA-FS approved spark arresters.

THE PERIOD OF WARRANTY for Yamaha off­road motorcycles shall be ninety (90) days from
the date of purchase, with no mileage limitation.

PRODUCT EXCLUDED FROM WARRANTY

include those used for non-Yamaha-authorized
renting, leasing, or other commercial purposes.

DURING THE PERIOD OF WARRANTY any
authorized Yamaha motorcycle dealer will free of
charge, repair or replace, at Yamaha's option, any
part adjudged defective by Yamaha due to faulty
workmanship or material from the factory. Parts
used in warranty repairs will be warranted for the
balance of the product's warranty period. All parts
replaced under warranty become property of
Yamaha Motor Corporation, USA.

GENERAL EXCLUSIONS from this warranty
shall include any failures caused by:

a. Competition or racing use.

b. Installation of parts or accessories that are

not qualitatively equivalent to genuine

Yamaha par ts.
c. Abnormal strain, neglect, or abuse.
d. Lack of proper maintenance.
e. Accident or collision damage.
f. Modification to original parts.
g. Damage due to improper transportation.

SPECIFIC EXCLUSIONS from this warranty shall
include parts replaced due to normal wear or rou­tine maintenance.

THE CUSTOMER'S RESPONSIBILITY under
this warranty shall be to:

1. Operate and maintain the motorcycle as
specified in the appropriate Owner's Manual,
and

2. Give notice to an authorized Yamaha motor­cycle dealer of any and all apparent defects
within ten (10) days after discovery, and make
the motorcycle available at that time for
inspection and repairs at such dealer's place
of business.

WARRANTY TRANSFER: To transfer the warran­ty from the original purchaser to any subsequent
purchaser(s), it is imperative that the motorcycle
be inspected and registered for warranty by an
authorized Yamaha motorcycle dealer. In order for
this warranty to remain in effect, this inspection
and registration must take place within ten (10)
days after transfer of ownership to the subse­quent purchaser. A reasonable dealer imposed
fee may be charged for this inspection.

EMISSION CONTROL SYSTEM WARRANTY

Yamaha Motor Corporation, USA also warrants to
the ultimate purchaser and each subsequent pur­chaser of each 2006 and later model Yamaha
motorcycle covered by this warranty that the vehi­cle is designed, built, and equipped so as to con­form at the time of sale with all U.S. emissions
standards applicable at the time of manufacture
and that it is free from defects in materials and
workmanship which would cause it not to meet
these standards within the period listed immedi­ately below. Failures other than those resulting
from defects in material or workmanship which

arise solely as a result of owner abuse and/or lack
of proper maintenance are not covered by this
warranty.

All Off-Road Models

Thirty (30) months from the original purchase
date

YAMAHA MOTOR CORPORATION, USA
MAKES NO OTHER WARRANTY OF ANY
KIND, EXPRESSED OR IMPLIED. ALL IMPLIED
WARRANTIES OF MERCHANTABILITY AND
FITNESS FOR A PARTICULAR PURPOSE
WHICH EXCEED THE OBLIGATIONS AND
TIME LIMITS STATED IN THIS WARRANTY
ARE HEREBY DISCLAIMED BY YAMAHA
MOTOR CORPORATION, USA AND EXCLUD­ED FROM THIS WARRANTY.

SOME STATES DO NOT ALLOW LIMITATIONS
ON HOW LONG AN IMPLIED WARRANTY
LASTS, SO THE ABOVE LIMITATION MAY NOT
APPLY TO YOU. ALSO EXCLUDED FROM THIS
WARRANTY ARE ANY INCIDENTAL OR CON­SEQUENTIAL DAMAGES INCLUDING LOSS
OF USE. SOME STATES DO NOT ALLOW THE
EXCLUSION OR LIMITATION OF INCIDENTAL
OR CONSEQUENTIAL DAMAGES, SO THE
ABOVE EXCLUSION MAY NOT APPLY TO YOU.

THIS WARRANTY GIVES YOU SPECIFIC
LEGAL RIGHTS, AND YOU MAY ALSO HAVE
OTHER RIGHTS WHICH VARY FROM STATE TO
STATE.

YAMAHA MOTOR CORPORATION, USA

Post Office Box 6555

Cypress, California 90630

EAU38051

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CONSUMER INFORMATION

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CONSUMER INFORMATION

YAMAHA EXTENDED SERVICE (Y.E.S.)

EAU26750

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Keep your Yamaha protected even after your warranty
expires with genuine Yamaha Extended Service (Y.E.S.).

Y.E.S. is designed and administered by Yamaha Motor
Corporation to provide maximum owner satisfaction. You
get uninterrupted factory-backed coverage for extra
peace of mind.

Y.E.S. is flexible. You choose the plan that’s right for
you: 12 months, 24 months, 36 months or, on certain
models, even 48 months beyond your warranty period.

Y.E.S. is designed and administered by the same
Yamaha people who handle your warranty – and it
shows in the comprehensive coverage benefits. There
are no mileage limitations. Coverage isn’t limited to
“moving parts” or the “drive train” like many other plans.
And Y.E.S. covers manufacturing defects just like the
warranty. See the sample contract at your Yamaha
dealer to see how comforting uninterrupted factory­backed protection can be.

You don’t have to pay anything for covered repairs.
There’s no deductible to pay, and repairs aren’t
“pro-rated.” You don’t have any “out-of-pocket” expenses
for covered repairs.

In addition, Travel and Recreation Interruption Protection
(TRIP) is included at no extra cost. TRIP gives you up to
$150 reimbursement per occurrence for any reasonable
expenses you incur because your Yamaha needs
covered service: replacement vehicle rental, emergency
towing, phone calls, even food and lodging when you are
away from home. This superb coverage goes into effect
when you purchase Y.E.S., so it applies to any warranty
repairs as well as covered repairs during your entire
Y.E.S. plan period.

Y.E.S. coverage is honored at any authorized Yamaha
dealer nationwide.

Y.E.S. coverage is transferable to a new owner if you
sell or trade-in. That can make your Yamaha much more
valuable!

This excellent Y.E.S. plan coverage is only available to
Yamaha owners like you, and only while your Yamaha is still
within the Yamaha Limited Warranty period. So visit your
authorized Yamaha dealer to get all the facts. He can show
you how easy it is to protect your investment with Yamaha
Extended Service.

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We urge you to act now. You’ll get the excellent benefits of
TRIP coverage right away, and you’ll rest easy knowing
you’ll have strong factory-backed protection even after your
Yamaha Limited Warranty expires.

A special note:
If visiting your dealer isn’t convenient, contact Yamaha with
your Primary ID number (your frame number). We’ll be
happy to help you get the Y.E.S. coverage you need.

Yamaha Service Marketing
P.O. Box 6555
Cypress, CA 90630
1-(866)-YES-EXTD (1-866-937-3983)

CONSUMER INFORMATION

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INDEX

A

Acceleration and deceleration................... 6-2

Air filter element, cleaning......................... 7-9

Autolube pump, adjusting ....................... 7-17

B

Brake lever, front....................................... 4-2

Brake lever, rear ....................................... 4-3

Brake levers, lubricating.......................... 7-17

Brake shoes, checking............................ 7-16

Braking...................................................... 6-2

C

Cables, checking and lubricating ............ 7-16

Carburetor, adjusting .............................. 7-11

Care .......................................................... 8-1

Centerstand, checking and lubricating.... 7-18

E

Engine break-in......................................... 6-3

Engine idling speed................................. 7-11

Engine oil .................................................. 4-5

Engine, starting a warm ............................ 6-1

Engine stop switch .................................... 4-1

F

Front and rear brake lever free play,

adjusting ............................................... 7-15

Front fork, checking ................................ 7-18

Fuel ........................................................... 4-3

Fuel cock................................................... 4-5

Fuel tank breather hose ............................ 4-5

Fuel tank cap ............................................ 4-3

H

Handlebar switch ...................................... 4-1

I

Identification numbers............................. 10-1

K

Kickstarter..................................................4-6

L

Location of important labels.......................1-1

M

Maintenance and lubrication, periodic .......7-4

Maintenance, emission control system......7-3

Matte color, caution ...................................8-1

Middle and final gear cases.......................7-9

Model label ..............................................10-1

N

Noise regulation.......................................10-2

P

Parking.......................................................6-4

Part locations.............................................3-1

Power reduction plate, removing ...............7-7

Pre-operation check list .............................5-2

S

Safety information......................................2-1

Seat ...........................................................4-7

Spark arrester, cleaning...........................7-10

Spark plug, checking .................................7-6

Specifications.............................................9-1

Speed limiter and power reduction plate ...4-1

Starter (choke) lever ..................................4-6

Starting and warming up a cold engine .....6-1

Starting off .................................................6-2

Steering, checking ...................................7-19

Storage ......................................................8-3

T

Throttle cable free play, checking............7-12

Throttle grip and cable, checking and

lubricating ..............................................7-17

Tires.........................................................7-12

Tool kit.......................................................7-2

Transmission oil ........................................7-8

Troubleshooting....................................... 7-24

Troubleshooting chart.............................. 7-25

V

Vehicle identification number ..................10-1

W

Warranty, extended .................................10-5

Warranty, limited .....................................10-3

Wheel bearings, checking .......................7-19

Wheel (front)............................................ 7-19

Wheel (rear) ............................................7-21

Wheels ....................................................7-14

PRINTED ON RECYCLED PAPER

YAMAHA MOTOR CO., LTD.

PRINTED IN JAPAN

2008.4–0.7×1 !

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