Yamaha TT-R110EX User Manual

OWNER’S MANUAL

TT-R110EX

LIT-11626-21-48

5B6-28199-10

EAU10041

INTRODUCTION

EAU41730

Congratulations on your purchase of the Yamaha TT-R110EX. 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.

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 CAUTION LABELS ON THE MOTORCYCLE.

● NEVER OPERATE A MOTORCYCLE WITHOUT PROPER TRAINING OR INSTRUCTION.

● WEIGHT OF THE RIDER SHOULD NOT EXCEED 60 kg (132 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.

INTRODUCTION

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 THE OWNER’S MANUAL.

● OBTAIN QUALIFIED TRAINING IN SAFE AND PROPER RIDING TECHNIQUES.

● OBTAIN PROFESSIONAL TECHNICAL SERVICE AS INDICATED BY THE 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:

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!

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WARNING

Failure to follow WARNING instructions could result in severe injury or death
motorcycle operator, a bystander or a person inspecting or repairing the motor-

to the

cycle.

CAUTION:

NOTE:

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.

IMPORTANT MANUAL INFORMATION

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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.

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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.

*Product and specifications are subject to change without notice.

IMPORTANT MANUAL INFORMATION

AFFIX DEALER

LABEL HERE

TT-R110EX

OWNER’S MANUAL

©2007 by Yamaha Motor Corporation, U.S.A.

1st edition, June 2007

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-11626-21-48

EAU10192

TABLE OF CONTENTS

SAFETY INFORMATION ..................1-1

Safe riding ......................................1-1

Location of important labels ............1-4

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

Left view ..........................................2-1

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

Controls and instruments.................2-3

INSTRUMENT AND CONTROL

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

Main switch .....................................3-1

Handlebar switches ........................3-1

Shift pedal .......................................3-2

Brake lever .....................................3-2

Brake pedal ....................................3-2

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

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

Fuel tank breather hose ..................3-4

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

Starter (choke) lever .......................3-5

Kickstarter .......................................3-6

Seat ................................................3-6

Sidestand ........................................3-7

Starting circuit cut-off system .........3-7

PRE-OPERATION CHECKS..............4-1

Pre-operation check list ..................4-2

OPERATION AND IMPORTANT

RIDING POINTS.................................5-1

Starting and warming up a cold

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

Starting a warm engine .................. 5-2

Shifting ...........................................5-2

Engine break-in ..............................5-3

Parking ...........................................5-4

PERIODIC MAINTENANCE AND

MINOR REPAIR ................................. 6-1

PERIODIC MAINTENANCE ........... 6-1

Owner’s tool kit ...............................6-2

Periodic maintenance chart for

the emission control system ....... 6-3

General maintenance and

lubrication chart ..........................6-4

Removing and installing panels ..... 6-6

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

Engine oil .......................................6-8

Cleaning the air filter element ......6-10

Cleaning the spark arrester .......... 6-12

Adjusting the carburetor ............... 6-13

Adjusting the engine idling

speed ........................................6-13

Checking the throttle cable

free play .................................... 6-14

Valve clearance ............................ 6-14

Tires .............................................6-15

Spoke wheels ...............................6-16

Accessories and replacement

parts ......................................... 6-16

Adjusting the clutch free play ....... 6-17

Adjusting the brake lever free

play ........................................... 6-17

Adjusting the brake pedal free

play ........................................... 6-18

Checking the shift pedal .............. 6-19

Checking the front and

rear brake shoes ...................... 6-19

Drive chain slack .......................... 6-20

Cleaning and lubricating

the drive chain .......................... 6-21

Checking and lubricating

the cables ................................. 6-22

Checking and lubricating

the throttle grip and cable ......... 6-22

Checking and lubricating

the brake lever .......................... 6-23

Checking and lubricating

the brake pedal ......................... 6-23

Checking and lubricating

the sidestand ............................ 6-23

Lubricating the swingarm

pivots ........................................ 6-24

Checking the front fork ................. 6-24

Checking the steering .................. 6-25

Checking the wheel bearings ....... 6-25

Battery ......................................... 6-26

Replacing the fuse ....................... 6-27

Supporting the motorcycle ........... 6-28

Front wheel ...................................6-28

Rear wheel ...................................6-30

Troubleshooting ............................6-31

Troubleshooting chart ...................6-32

MOTORCYCLE CARE AND

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

Matte color caution .........................7-1

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

Storage ...........................................7-3

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

CONSUMER INFORMATION.............9-1

Identification numbers ....................9-1

Motorcycle noise regulation ............9-3

YAMAHA MOTOR CORPORATION,

U.S.A. OFF-ROAD
MOTORCYCLE LIMITED

WARRANTY ...............................9-4

YAMAHA EXTENDED SERVICE

(Y.E.S.) .......................................9-6

TABLE OF CONTENTS

SAFETY INFORMATION

Safe riding

● Always make pre-operation

1

checks. Careful checks may help
prevent an accident.

● 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 car-

ry the operator only. No passen­gers.

● Many accidents involve inexperi-

enced operators.

• Make sure that the operator is
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.

● 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 un-

EAU39313

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

● Ride cautiously in unfamiliar ar-

eas. You may encounter hidden
obstacles that could cause an ac­cident.

● The posture of the operator is im-

portant 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.

● Be sure the transmission is in neu-

tral before starting the engine.

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.

● Never touch the engine or exhaust

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

Modifications

Modifications made to this motorcycle
not approved by Yamaha, or the re­moval of original equipment, may ren­der the motorcycle unsafe for use and
may cause severe personal injury.
Modifications may also make your
motorcycle illegal to use.

1-1

SAFETY INFORMATION

Loading and accessories

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

● The weight of the operator must

not exceed 60 kg (132 lb).

● Accessory weight should be kept

as low and close to the motorcycle
as possible. Make sure to distrib­ute the weight as evenly as possi­ble on both sides of the motorcycle
to minimize imbalance or instabili­ty.

● Shifting weights can create a sud-

den imbalance. Make sure that ac­cessories are securely attached to
the motorcycle before riding.
Check accessory mounts fre­quently.

● Never attach any large or heavy

items to the handlebar, front fork,

or front fender.
Accessories
Genuine Yamaha accessories have
been specifically designed for use on
this motorcycle. Since Yamaha cannot
test all other accessories that may be
available, you must personally be re­sponsible for the proper selection, in­stallation and use of non-Yamaha
accessories. Use extreme caution
when selecting and installing any ac­cessories.
Keep these guidelines in mind for
mounting accessories in addition to
those provided under “Loading”.

● Never install accessories or 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 suspen-

sion travel, steering travel or con-

trol operation.

• Accessories fitted to the handle­bar or the front fork area can
create instability due to improper

1-2

weight distribution or aerody­namic changes. If accessories
are added to the handlebar or
front fork area, they must be as
lightweight as possible and
should be kept to a minimum.

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

• 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 electri-

cal 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
engine power.

1

SAFETY INFORMATION

Gasoline and exhaust gas

● GASOLINE IS HIGHLY FLAMMA-

BLE:

1

• Always turn the engine off when
refueling.

• Take care not to spill any gaso­line on the engine or exhaust
pipe(s)/muffler(s) when refuel­ing.

• Never refuel while smoking or in
the vicinity of an open flame.

● Never start the engine or let it run

for any length of time in a closed
area. The exhaust fumes are poi­sonous and may cause loss of
consciousness and death within a
short time. Always operate your
motorcycle in an area that has ad­equate ventilation.

● Always turn the engine off before

leaving the motorcycle unattended
and remove the key from the main
switch. When parking the motor­cycle, note the following:

• The engine and exhaust pipe(s)/
muffler(s) may be hot, therefore,
park the motorcycle in a place

where pedestrians or children
are not likely to touch these hot
areas.

• Do not park the motorcycle on a
slope or soft ground, otherwise it
may fall over.

• Do not park the motorcycle near
a flammable source (e.g., a ker­osene heater, or near an open
flame), otherwise it could catch
fire.

● When transporting the motorcycle

in another vehicle, make sure that
it is kept upright and that the fuel
cock(s) are turned to “ON” or
“RES” (for vacuum type)/“OFF”
(for manual type). If the motorcycle
should lean over, gasoline may
leak out of the carburetor or fuel
tank.

● If you should swallow any gaso-

line, inhale a lot of gasoline vapor,
or allow gasoline to get into your
eyes, see your doctor immediately.
If any gasoline spills on your skin
or clothing, immediately wash the
affected area with soap and water
and change your clothes.

1-3

Location of important labels

Please read the following important labels carefully before operating this vehicle.

SAFETY INFORMATION

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1

21 3

1-4

1

Cold tire normal pressure should be set as
follows.
FRONT : 100 kPa, {1.00 kgf/cm2}, 15 psi
REAR : 100 kPa, {1.00 kgf/cm

TIRE INFOMATION

2

2

3

BEFORE YOU OPERATE THIS VEHICLE, READ THE OWNER’S
MANUAL AND ALL LABELS.

NEVER CARRY A PASSENGER. You increase your risk of losing

control if you carry a passenger.
NEVER OPERATE THIS VEHICLE ON PUBLIC ROADS. You can
collide with another vehicle if you operate this vehicle on a public road.
ALWAYS WEAR AN APPROVED MOTORCYCLE HELMET,
eye protection, and protective clothing.

WARNING

}, 15 psi

3RV-21668-A0

3PT-2118K-A0

DESCRIPTION

Left view

2

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123 4

1. Fuel cock (page 3-4)

2. Starter (choke) lever (page 3-5)

3. Fuse (page 6-27)

4. Battery (page 6-26)

5. Clutch adjusting screw (page 6-17)

6. Engine oil drain bolt (page 6-8)

7. Shift pedal (page 3-2)

8. Throttle stop screw (page 6-13)

2-1

678

5

Right view

DESCRIPTION

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123 4

2

1. Spark arrester (page 6-12)

2. Seat (page 3-6)

3. Fuel tank (page 3-3)

4. Air filter element (page 6-10)

5. Spark plug cap (page 6-7)

6. Engine oil filler cap (page 6-8)

7. Brake pedal (page 3-2)

8. Kickstarter (page 3-6)

857

6

2-2

DESCRIPTION

Controls and instruments

2

1. Left handlebar switch (page 3-1)

2. Main switch (page 3-1)

3. Right handlebar switch (page 3-1)

4. Brake lever (page 3-2)

5. Throttle grip (page 6-14)

6. Fuel tank cap (page 3-3)

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1234

56

2-3

INSTRUMENT AND CONTROL FUNCTIONS

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Main switch

The main switch controls the ignition
system. The main switch positions are
described below.

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ON

All electrical systems are supplied with
power, and the engine can be started.
The key cannot be removed.

EAU10660

OFF

All electrical systems are off. The key
can be removed.

Handlebar switches

Left

1. Engine stop switch “ / ”

Right

1

1. Start switch “”

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Engine stop switch “ / ”

EAU12660

Set this switch to “” before starting
the engine. Set this switch to “” to
stop the engine in case of an emergen­cy, such as when the vehicle overturns
or when the throttle cable is stuck.

EAU12710

Start switch “”

Push this switch to crank the engine
with the starter.

ECA10050

CAUTION:

See page 5-1 for starting instruc­tions prior to starting the engine.

3

3-1

INSTRUMENT AND CONTROL FUNCTIONS

Shift pedal

3

1

1. Shift pedal

This motorcycle is equipped with a con­stant-mesh 4-speed transmission. The
shift pedal is located on the left side of
the engine. Neutral is at the bottom po­sition.

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Brake lever

1

1. Brake lever

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

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Brake pedal

1

1. Brake pedal

The brake pedal is on the right side of
the motorcycle. To apply the rear
brake, press down on the brake pedal.

3-2

INSTRUMENT AND CONTROL FUNCTIONS

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Fuel tank cap

1. Fuel tank cap 1. Fuel tank filler tube

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 clock-

Fuel

2. Fuel level

Make sure that there is sufficient fuel in
the tank. Fill the fuel tank to the bottom
of the filler tube as shown.

wise.

EWA11090

WARNING

Make sure that the fuel tank cap is
properly closed before riding.

WARNING

● Do not overfill the fuel tank, oth-

erwise it may overflow when the
fuel warms up and expands.

● Avoid spilling fuel on the hot en-

gine.

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EWA10880

ECA10070

CAUTION:

Immediately wipe off spilled fuel
with a clean, dry, soft cloth, since
fuel may deteriorate painted surfac­es or plastic parts.

EAU13300

Recommended fuel:

UNLEADED GASOLINE ONLY

Fuel tank capacity:

3.8 L (1.00 US gal) (0.84 Imp.gal)

Fuel reserve amount:

0.5 L (0.13 US gal) (0.11 Imp.gal)

ECA11400

CAUTION:

Use only unleaded gasoline. The use
of leaded gasoline will cause severe
damage to internal engine parts,
such as the valves and piston rings,
as well as to the exhaust system.

Your Yamaha engine has been de­signed to use regular unleaded gaso­line with a pump octane number
[(R+M)/2] of 86 or higher, or a research
octane number of 91 or higher. If

3

3-3

INSTRUMENT AND CONTROL FUNCTIONS

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 contain-

3

ing methanol. Gasohol containing
ethanol can be used if the ethanol con­tent does not exceed 10%. Gasohol
containing methanol is not recom­mended by Yamaha because it can
cause damage to the fuel system or ve­hicle performance problems.

EAU13412

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.

EAU13561

Fuel cock

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

OFF

1. Arrow mark positioned over “OFF”

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

3-4

INSTRUMENT AND CONTROL FUNCTIONS

ON

1. Arrow mark positioned over “ON”

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

RES

This indicates reserve. If you run out of
fuel while riding, move the lever to this
position. Fill the tank at the first oppor­tunity. Be sure to set the lever back to
“ON” after refueling!

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Starter (choke) lever “”

3

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. Arrow mark positioned over “RES”

3-5

INSTRUMENT AND CONTROL FUNCTIONS

Kickstarter

1

3

1. Kickstarter lever

If the engine fails to start by pushing the
start switch, try to start it by using the
kickstarter. To start the engine, fold out
the kickstarter lever, move it down light­ly with your foot until the gears engage,
and then push it down smoothly but
forcefully.

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Seat

To remove the seat

Remove the bolts, and then pull the
seat off.

1

1. Bolt

To install the seat

1. Insert the projections on the front
of the seat into the seat holders as
shown.

1

2

1. Projection

2. Seat holder

2. Place the seat in the original posi­tion, and then tighten the bolts.

NOTE:

Make sure that the seat is properly se­cured before riding.

3-6

INSTRUMENT AND CONTROL FUNCTIONS

EAU37490

Sidestand

The sidestand is located on the left side
of the frame. Raise the sidestand or
lower it with your foot while holding the
vehicle upright.

EWA14190

WARNING

The vehicle must not be ridden with
the sidestand down, or if the side­stand cannot be properly moved up
(or does not stay up), otherwise the
sidestand could contact the ground
and distract the operator, resulting
in a possible loss of control.

EAU41610

Starting circuit cut-off system

The starting circuit cut-off system pre­vents starting when the transmission is
in gear.
Periodically check the operation of the
starting circuit cut-off system according
to the following procedure.

EWA10250

WARNING

If a malfunction is noted, have a
Yamaha dealer check the system be­fore riding.

3

3-7

INSTRUMENT AND CONTROL FUNCTIONS

With the engine turned off:

3

1. Make sure that the engine stop switch is set to “

2. Turn the key to “ON”.

3. Shift the transmission into gear.

4. Keep the front or rear brake applied.

5. Push the start switch.

Does the engine start?

NO

6. Shift the transmission into the neutral position.

7. Push the start switch.

Does the engine start?

YES

The system is OK. The motorcycle can be ridden.

YES

NO

”.

3-8

NOTE:

This check is most reliable if performed with
a warmed-up engine.

The neutral switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.

The neutral switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.

PRE-OPERATION CHECKS

EAU15593

The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly,
even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss
of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thorough visual inspec­tion, to check the following points before each ride.

NOTE:

Pre-operation checks should be made each time the vehicle is used. Such an inspection can be accomplished in a very short
time; and the added safety it assures is more than worth the time involved.

EWA11150

WARNING

If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operating
the vehicle.

4

4-1

PRE-OPERATION CHECKS

Pre-operation check list

ITEM CHECKS PAGE

Fuel

Engine oil

Front brake

4

Rear brake

Throttle grip

Control cables

Drive chain

Wheels and tires

Shift pedal

• Check fuel level in fuel tank.

• Refuel if necessary.

• Check fuel line for leakage.

• Check oil level in engine.

• If necessary, add recommended oil to specified level.

• Check vehicle for oil leakage.

• Check operation.

• Lubricate cable if necessary.

• Check lever free play.

• Adjust if necessary.

• Check operation.

• Check pedal 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 chain slack.

• Adjust if necessary.

• Check chain condition.

• Lubricate if necessary.

• Check for damage.

• Check tire condition and tread depth.

• Check air pressure.

• Correct if necessary.

• Make sure that operation is smooth.

• Correct if necessary.

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3-3

6-8

6-17, 6-19

6-18, 6-19

6-14, 6-22

6-22

6-20, 6-21

6-15, 6-16

6-19

4-2

PRE-OPERATION CHECKS

ITEM CHECKS PAGE

Brake pedal

Brake lever

Sidestand

Chassis fasteners

Engine stop switch • Check operation. 3-1

• Make sure that operation is smooth.

• Lubricate pedal pivoting point if necessary.

• Make sure that operation is smooth.

• Lubricate lever pivoting point if necessary.

• Make sure that operation is smooth.

• Lubricate pivot if necessary.

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

• Tighten if necessary.

6-23

6-23

6-23

—

4

4-3

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-

5

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.

● 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.

EAU41680

EWA14620

EAU44810

Starting and warming up a cold engine

1. Turn the fuel cock lever to “ON”.

2. Turn the key to “ON” and make
sure that the engine stop switch is
set to “”.

3. Shift the transmission into the neu­tral position.

EWA14410

WARNING

● Be sure to shift the transmis-

sion into neutral before starting
the engine.

● Never ride with the sidestand

down.

4. Turn the starter (choke) on and
completely close the throttle. (See
page 3-5.)

5. Start the engine by pushing the
start switch or by pushing the kick­starter lever down.

ECA11130

CAUTION:

For maximum engine 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.

NOTE:

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

5-1

OPERATION AND IMPORTANT RIDING POINTS

EAU16640

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.

EAU39901

Shifting

4
3
2
1

2

1

1. Shift pedal

2. Neutral position

This motorcycle has a 4-speed trans­mission with a centrifugal, automatic
clutch. Shifting gears lets you control
the amount of engine power available
for starting off, accelerating, climbing
hills, etc.
The gear positions are shown in the il­lustration.

NOTE:

To shift the transmission into the neu­tral position, press the shift pedal down
repeatedly until it reaches the end of its
travel.

ECA15441

CAUTION:

● Even with the transmission in

the neutral position, do not
coast for long periods of time
with the engine off, and do not
tow the motorcycle for long dis­tances. The transmission is
properly lubricated only when
the engine is running. Inade­quate lubrication may damage
the transmission.

● Always release the throttle grip

before changing gears to avoid
damaging the engine, transmis­sion, and drive train, which are
not designed to withstand the
shock of shifting when the throt­tle grip is open.

EAU39910

To start out and accelerate

1. Close the throttle.

2. Shift into first gear and release the
shift pedal.

5

5-2

OPERATION AND IMPORTANT RIDING POINTS

CAUTION:

Always close the throttle before
shifting gears, otherwise damage to
the engine and drive train may re­sult.

3. Open the throttle gradually.

4. Once the motorcycle has reached
a speed high enough to change
gears, close the throttle.

5. Shift into second gear and release
the shift pedal.

5

6. Open the throttle gradually.

7. Follow the same procedure when
shifting to the next higher gear.

To decelerate

1. Close the throttle and apply both
the front and the rear brakes to
slow the motorcycle.

2. Downshift through the gears and
shift the transmission into the neu­tral position when the motorcycle
is almost completely stopped.

ECA15460

EAU16710

EAU39920

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 full­throttle 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-

justments thoroughly, especially cable
and drive chain slack and loose
spokes. In addition, check all fittings
and fasteners for looseness, and tight­en if necessary.

ECA10270

CAUTION:

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

5-3

EAU17170

Parking

When parking, stop the engine, remove
the key from the main switch, and then
turn the fuel cock lever to “OFF”.

EWA10310

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 vehicle
may overturn.

OPERATION AND IMPORTANT RIDING POINTS

5

5-4

PERIODIC MAINTENANCE AND MINOR REPAIR

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
motorcycle inspection, adjustment, and
lubrication are explained on the follow­ing pages.

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).

6

WARNING

If you are not familiar with mainte­nance work, have a Yamaha dealer
do it for you.

EAU41950

EWA10320

EAU40350

PERIODIC MAINTENANCE

PROPER PERIODIC MAINTENANCE
OF YOUR VEHICLE IS IMPORTANT
IN ORDER TO ENJOY LONG, PLEA­SURABLE SERVICE. ESPECIALLY
IMPORTANT ARE THE MAINTE­NANCE SERVICES RELATED TO
EMISSIONS CONTROL. THESE
CONTROLS NOT ONLY FUNCTION
TO ENSURE CLEANER AIR, BUT
ARE ALSO VITAL TO PROPER EN-

6-1

EAU17310

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
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.

EWA10340

WARNING

Modifications not approved by
Yamaha may cause loss of perfor­mance, excessive emissions, and
render the vehicle unsafe for use.
Consult a Yamaha dealer before at­tempting any changes.

PERIODIC MAINTENANCE AND MINOR REPAIR

6

6-2

PERIODIC MAINTENANCE AND MINOR REPAIR

Periodic maintenance chart for the emission control system

NOTE:

● From 7000 km (4200 mi) or 18 months, repeat the maintenance intervals starting from 3000 km (1800 mi) or 6 months.

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

skills.

INITIAL ODOMETER READINGS

No. ITEM CHECKS AND MAINTENANCE JOBS

1 * Fuel line

2 Spark plug

6

3 * Valve clearance • Check and adjust valve clearance when engine is cold. √

4 * Air filter element

Crankcase breather sys-

5 *

tem

6 * Carburetor

7 Exhaust system

8 Engine oil • Change (warm engine before draining). √√√

• Check fuel hoses for cracks or damage.

• Replace if necessary.

• Check condition.

• Adjust gap and clean.

• Clean with solvent.

• Replace if necessary.

• Check ventilation hose for cracks or damage and drain

any deposits.

• Replace if necessary.

• Check engine idling speed and starter operation.

• Adjust if necessary.

• Check for leakage.

• Tighten if necessary.

• Replace gasket(s) if necessary.

1000 km
(600 mi) or
1 month or

30 hours

√√√

√√√

3000 km
(1800 mi) or
6 months or

90 hours

√√

√√

√√

√√

5000 km

(3000 mi) or

12 months or

150 hours

EAU39943

6-3

PERIODIC MAINTENANCE AND MINOR REPAIR

General maintenance and lubrication chart

No. ITEM CHECKS AND MAINTENANCE JOBS

1 * Clutch

2 * Front brake

3 * Rear brake

4 * Wheels

5 * Tires

6 * Wheel bearings

7 * Swingarm pivot bearings

8Drive chain

9 * Steering bearings

• Check operation.

• Adjust if necessary.

• Check operation.

• Adjust brake lever free play and replace brake shoes if

necessary.

• Check operation.

• Adjust brake pedal free play and replace brake shoes if

necessary.

• Check runout, spoke tightness and for damage.

• Tighten spokes 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.

• Check chain slack/alignment and condition.

• Adjust and lubricate chain with Yamaha chain and cable

lube thoroughly.

• Check bearing assemblies for looseness.

• Moderately repack with lithium-soap-based grease.

EAU35348

INITIAL ODOMETER READINGS

1000 km

(600 mi) or

1 month or

30 hours

√√√

√√√

√√√

√√√

√√

3000 km
(1800 mi) or
6 months or

90 hours

√√

√√

√√

Every ride

5000 km

(3000 mi) or

12 months or

150 hours

6

6-4

PERIODIC MAINTENANCE AND MINOR REPAIR

INITIAL ODOMETER READINGS

No. ITEM CHECKS AND MAINTENANCE JOBS

10 * Chassis fasteners

11 Brake lever pivot shaft • Apply lithium-soap-based grease lightly. √√
12 Brake pedal pivot shaft • Apply lithium-soap-based grease lightly. √√

13 Sidestand pivot

14 * Spark arrester • Clean. √

15 * Front fork

Shock absorber assem-

16 *

6

bly

17 * Control cables

Throttle grip housing and

18 *

cable

• Check all chassis fitting and fasteners.

• Correct if necessary.

• Check operation.

• Apply lithium-soap-based grease lightly.

• Check operation and for oil leakage.

• Replace if necessary.

• Check operation and for oil leakage.

• Replace if necessary.

• Apply Yamaha chain and cable lube or engine oil 10W-30

thoroughly.

• Check operation and free play.

• Adjust the throttle cable free play if necessary.

• Lubricate the throttle grip housing and cable.

1000 km
(600 mi) or
1 month or

30 hours

√√√

√√

√√√

√√√

3000 km
(1800 mi) or
6 months or

90 hours

√√

5000 km

(3000 mi) or

12 months or

150 hours

√

EAU40000

NOTE:

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

6-5

EAU18771

Removing and installing pan­els

The panels shown need to be removed
to perform some of the maintenance
jobs described in this chapter. Refer to
this section each time a panel needs to
be removed and installed.

PERIODIC MAINTENANCE AND MINOR REPAIR

1

2

3

3

1

1. Panel A

1

1. Panel B

EAU41110

Panel A

To remove the panel

1. Remove the seat. (See page 3-6.)

2. Remove the bolts and the quick
fastener screws, and then take the
panel off.

6-6

1. Panel A

2. Bolt

3. Quick fastener screw

To install the panel

1. Place the panel in the original posi­tion, and then install the bolts and
the quick fastener screws.

2. Install the seat.

EAU33020

Panel B

To remove the panel

1. Remove the seat. (See page 3-6.)

2. Remove the bolt, and then pull the
panel off as shown.

6

PERIODIC MAINTENANCE AND MINOR REPAIR

1

2

1. Panel B

2. Bolt

3. Projection

To install the panel

1. Place the panel in the original posi-

6

tion, and then install the bolt.

2. Install the seat.

3

Checking the spark plug

The spark plug is an important engine
component, which is easy to check.
Since heat and deposits will cause any
spark plug to slowly erode, the spark
plug should be removed and checked
in accordance with the periodic mainte­nance and lubrication chart. In addition,
the condition of the spark plug can re­veal the condition of the engine.

To remove the spark plug

1. Remove the spark plug cap.

1. Spark plug cap

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

1

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).

NOTE:

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

6-7

PERIODIC MAINTENANCE AND MINOR REPAIR

2. Check the spark plug for electrode
erosion and excessive carbon or
other deposits, and replace it if
necessary.

Specified spark plug:

NGK/CR6HSA

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
then wipe off any grime from the
spark plug threads.

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

Tightening torque:

Spark plug:

12.5 Nm (1.25 m·kgf, 9.0 ft·lbf)

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.

EAU39841

Engine oil

The engine oil level should be checked
before each ride. In addition, the oil
must be changed at the intervals spec­ified in the periodic maintenance and
lubrication chart.

To check the engine oil level

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

NOTE:

Make sure that the motorcycle is posi­tioned 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.

3. Wait a few minutes until the oil set­tles, remove the oil filler cap, wipe
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.

6

6-8

PERIODIC MAINTENANCE AND MINOR REPAIR

2

3
4

1. Engine oil filler cap

2. Dipstick

3. Maximum level mark

4. Minimum level mark

NOTE:

6

The engine oil should be between the
minimum and maximum level marks.

4. If the engine oil is at or below the
minimum level mark, add sufficient
oil of the recommended type to
raise it to the correct level.

5. Insert the dipstick into the oil filler
hole, and then tighten the oil filler
cap.

To change the engine oil

1. Start the engine, warm it up for
several minutes, and then turn it

1

off.

5. Add the specified amount of the
recommended engine oil, and then
install and tighten the engine oil fill­er cap.

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

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

Recommended engine oil:

See page 8-1.

Oil change quantity:

0.80 L (0.85 US qt) (0.70 Imp.qt)

ECA11620

CAUTION:

1

● In order to prevent clutch slip-

page (since the engine 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

1. Engine oil drain bolt

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

Tightening torque:

Engine oil drain bolt:

20 Nm (2.0 m·kgf, 14 ft·lbf)

addition, do not use oils labeled
“ENERGY CONSERVING II” or
higher.

● Make sure that no foreign mate-

rial enters the crankcase.

6. 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.

6-9

PERIODIC MAINTENANCE AND MINOR REPAIR

7. Turn the engine off, and then
check the oil level and correct it if
necessary.

EAU41633

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.

To clean the air filter element

1. Remove panel A. (See page 6-6.)

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

1

2

1. Air filter case cover

2. Screw

3. Pull the sponge material and the
mesh out.

1

2

1. Sponge material

2. Air filter mesh

4. Clean the mesh with solvent, and
then wipe the solvent off.

5. Clean the sponge material with
solvent, and then squeeze the re­maining solvent out.

EWA10430

WARNING

Use only a dedicated parts cleaning
solvent. To avoid the risk of fire or
explosion, do not use gasoline or
solvents with a low flash point.

ECA10510

CAUTION:

To avoid damaging the foam materi­al, handle it gently and carefully, and
do not twist or wring it.

6

6-10

PERIODIC MAINTENANCE AND MINOR REPAIR

1

1

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

NOTE:

6

The sponge material should be wet but
not dripping.

Recommended oil:

Yamaha foam air filter oil or other
quality foam air filter oil

7. Insert the mesh and the sponge
material into the air filter case.

ECA15571

CAUTION:

● Make sure that the mesh and the

sponge material are properly
seated in the air filter case.

● The engine should never be op-

erated without the mesh and the
sponge material installed, oth­erwise the piston(s) and/or cyl­inder(s) may become
excessively worn.

8. Install the air filter case cover by in­stalling the screws.

NOTE:

Make sure that the spark plug cable is
routed as shown.

6-11

1. Spark plug cable

9. Install the panel.

To clean the air filter check hose

1. Check the hoses at the bottom of
the air filter case for accumulated
dirt or water.

1

1. Air filter check hose

PERIODIC MAINTENANCE AND MINOR REPAIR

2. If dirt or water is visible, remove
the hoses, clean them, and then
reinstall them.

EAU40421

Cleaning the spark arrester

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

EWA10980

WARNING

● Always let the exhaust system

cool prior to touching exhaust
components.

● Do not start the engine when

cleaning the exhaust system.

NOTE:

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

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

1

2

1. Tailpipe

2. Bolt

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.

1

6

6-12

1. Spark arrester

PERIODIC MAINTENANCE AND MINOR REPAIR

3. Insert the tailpipe into the muffler,
and then install and tighten the
bolts to the specified torque.

Tightening torque:

Tailpipe bolt:

10 Nm (1.0 m·kgf, 7.2 ft·lbf)

NOTE:

Make sure to align the bolt holes when
inserting the tailpipe.

6

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

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.

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.

NOTE:

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.

NOTE:

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 di-

6-13

PERIODIC MAINTENANCE AND MINOR REPAIR

rection (a). To decrease the en­gine idling speed, turn the screw in
direction (b).

(a) (b)

1

1

1. Throttle stop screw

Engine idling speed:

1600–1800 r/min

NOTE:

If the specified idling speed cannot be
obtained as described above, have a
Yamaha dealer make the adjustment.

EAU21382

Checking the throttle cable free play

1

1. Throttle cable free play

The throttle cable free play should mea­sure 4.0–6.0 mm (0.16–0.24 in) at the
throttle grip. Periodically check the
throttle cable free play and, if neces­sary, have a Yamaha dealer adjust it.

EAU21401

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

6-14

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

6

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.

Standard tire air pressure:

Front :

100 kPa (15 psi) (1.00 kgf/cm²)

Rear:

100 kPa (15 psi) (1.00 kgf/cm²)

EAU39820

EWA14380

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 spoke
wheels and tube tires.

EWA10460

WARNING

● The front and rear tires should

be of the same make and de­sign, otherwise the handling
characteristics of the vehicle
cannot be guaranteed.

● After extensive tests, only the

tires listed below have been ap­proved for this model by
Yamaha Motor Co., Ltd.

Front tire:

Size:

2.50-14 4PR

Manufacturer/model:

CHEN SHIN/C-803

Rear tire:

Size:

3.00-12 4PR

Manufacturer/model:

CHEN SHIN/C-803

EWA14390

WARNING

● Have a Yamaha dealer replace

excessively worn tires. Operat­ing the motorcycle with exces-

6-15

PERIODIC MAINTENANCE AND MINOR REPAIR

sively 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
very carefully and replace it as
soon as possible with a high­quality product.

EAU21940

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 han­dling 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.

EAU40431

Accessories and replacement parts

EWA14481

WARNING

The accessories or replacement
parts you choose for your vehicle
should be designed specifically for
this model, and they must be se­curely mounted to maintain the in­herent stability of the original
design. Genuine Yamaha Parts and
Accessories are designed and test­ed to be compatible with your vehi­cle. Yamaha recommends the use of
Genuine Yamaha Parts and Acces­sories before making a purchase.
Use of non-Yamaha-approved ac­cessories or replacement parts may
cause loss of handling stability and
riding safety. Since Yamaha cannot
control the quality of accessories or
parts manufactured by other compa­nies, Yamaha cannot be held liable
for any consequences caused by
the use of items which have not
been approved by Yamaha.

6

6-16

PERIODIC MAINTENANCE AND MINOR REPAIR

Adjusting the clutch free play

The clutch free play must be checked
and, if necessary, adjusted as follows
at the intervals specified in the periodic
maintenance and lubrication chart.

1. Loosen the locknut.

2. Slowly turn the clutch adjusting
screw in direction (a) until resis­tance is felt, and then turn it 1/8
turn in direction (b).

6

(b)

1

1. Locknut

2. Clutch adjusting screw

NOTE:

Turning the clutch adjusting screw in di­rection (a) decreases clutch free play
and turning it in direction (b) increases
clutch free play.

(a)

2

EAU44661

3. Tighten the locknut to the specified
torque.

Tightening torque:

Locknut:

8.0 Nm (0.8 m·kgf, 5.8 ft·lbf)

NOTE:

When tightening the locknut, hold the
clutch adjusting screw with a screwdriv­er so that it does not turn together with
the locknut.

EAU44880

Adjusting the brake lever free play

3

2

1

(b)

(a)

1. Brake lever free play adjusting bolt

2. Locknut

3. Brake lever free play

The brake lever free play should mea­sure 10.0–20.0 mm (0.39–0.79 in) as
shown. Periodically check the brake le­ver free play and, if necessary, adjust it
as follows.

1. Loosen the locknut at the brake le­ver.

2. To increase the brake lever free
play, turn the adjusting bolt in di­rection (a). To decrease the brake
lever free play, turn the adjusting
bolt in direction (b).

6-17

PERIODIC MAINTENANCE AND MINOR REPAIR

3. If the specified brake lever free
play could be obtained as de­scribed above, tighten the locknut
and skip the rest of the procedure,
otherwise proceed as follows.

4. Fully turn the adjusting bolt at the
brake lever in direction (a) to loos­en the brake cable.

5. Loosen the locknut at the brake
shoe plate.

6. To increase the brake lever free
play, turn the adjusting bolt in di­rection (a). To decrease the brake
lever free play, turn the adjusting
bolt in direction (b).

(a)

(b)

2

1

1. Locknut

2. Brake lever free play adjusting bolt

EAU44670

Adjusting the brake pedal free play

1. Brake pedal free play adjusting nut

2. Brake pedal free play

The brake pedal free play should mea­sure 10.0–20.0 mm (0.39–0.79 in) at
the brake pedal end as shown. Period­ically check the brake pedal free play
and, if necessary, adjust it as follows.
To increase the brake pedal free play,
turn the adjusting nut at the brake rod in
direction (a). To decrease the brake
pedal free play, turn the adjusting nut in
direction (b).

EWA14820

WARNING

● After adjusting the drive chain

slack or removing and installing
the rear wheel, always check the
brake pedal free play.

● If proper adjustment cannot be

obtained as described, have a
Yamaha dealer make this ad­justment.

6

7. Tighten the locknut at the brake
shoe plate and at the brake lever.

6-18

PERIODIC MAINTENANCE AND MINOR REPAIR

Checking the shift pedal

The operation of the shift pedal should
be checked before each ride. If opera­tion is not smooth, have a Yamaha
dealer check the vehicle.

6

EAU44820

EAU22361

Checking the front and rear brake shoes

Front

1

2

1. Brake shoe wear indicator

2. Brake shoe wear limit line

Rear

2

1

The front and rear brake shoes must be
checked for wear at the intervals spec­ified in the periodic maintenance and
lubrication chart. Each 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.

1. Brake shoe wear indicator

2. Brake shoe wear limit line

6-19

EAU22760

Drive chain slack

The drive chain slack should be
checked before each ride and adjusted
if necessary.

PERIODIC MAINTENANCE AND MINOR REPAIR

To check the drive chain slack

EAU22773

1. Place the motorcycle on the side­stand.

NOTE:

When checking and adjusting the drive
chain slack, there should be no weight
on the motorcycle.

2. Shift the transmission into the neu­tral position.

3. Move the rear wheel by pushing
the motorcycle to locate the tight­est portion of the drive chain, and
then measure the drive chain slack
as shown.

Drive chain slack:

40.0–56.0 mm (1.57–2.20 in)

1

1. Drive chain slack

4. If the drive chain slack is incorrect,
adjust it as follows.

EAU40110

To adjust the drive chain slack

1. Loosen the brake pedal free play
adjusting nut, axle nut, and locknut
at each end of the swingarm.

6-20

1. Brake pedal free play adjusting nut

2. Locknut

3. Drive chain slack adjusting nut

2. To tighten the drive chain, turn the
adjusting nut at each end of the
swingarm in direction (a). To loos­en the drive chain, turn the adjust­ing nut at each end of the
swingarm in direction (b), and then
push the rear wheel forward.

NOTE:

Using the alignment marks on each
side of the swingarm, make sure that
both adjusting nuts are in the same po­sition for proper wheel alignment.

6

PERIODIC MAINTENANCE AND MINOR REPAIR

1. Axle nut

2. Drive chain slack adjusting nut

3. Locknut

4. Alignment marks

CAUTION:

6

Improper drive chain slack will over­load the engine as well as other vital
parts of the motorcycle and can lead
to chain slippage or breakage. To
prevent this from occurring, keep
the drive chain slack within the
specified limits.

3. Tighten both locknuts and the axle
nut to the specified torques.

ECA10570

Tightening torques:

Locknut:

7.0 Nm (0.7 m·kgf, 5.1 ft·lbf)

Axle nut:

60 Nm (6.0 m·kgf, 43 ft·lbf)

4. Adjust the brake pedal free play.
(See page 6-18.)

EAU23013

Cleaning and lubricating the drive chain

The drive chain must be cleaned and
lubricated at the intervals specified in
the periodic maintenance and lubrica­tion chart, otherwise it will quickly wear
out, especially when riding in dusty or
wet areas. Service the drive chain as
follows.

ECA10581

CAUTION:

The drive chain must be lubricated
after washing the motorcycle and
riding in the rain.

1. Remove all dirt and mud from the
drive chain with a brush or cloth.

NOTE:

For a thorough cleaning, have a
Yamaha dealer remove the drive chain
and soak it in solvent.

2. Spray Yamaha Chain and Cable
Lube or a high-quality spray-type
drive chain lubricant on both sides
and on the middle of the chain,

6-21

PERIODIC MAINTENANCE AND MINOR REPAIR

making sure that all side plates
and rollers have been sufficiently
oiled.

EAU23091

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:

Yamaha Chain and Cable Lube or
engine oil SAE 10W-30

EWA10710

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.

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.

6

6-22

PERIODIC MAINTENANCE AND MINOR REPAIR

Checking and lubricating the brake lever

The operation of the brake lever should
be checked before each ride, and the
lever pivots should be lubricated if nec-

6

essary.

Recommended lubricant:

Lithium-soap-based grease

EAU43621

EAU23182

Checking and lubricating the brake pedal

The operation of the brake pedal
should be checked before each ride,
and the pedal pivot should be lubricat­ed if necessary.

Recommended lubricant:

Lithium-soap-based grease

EAU23201

Checking and lubricating the sidestand

The operation of the sidestand should
be checked before each ride, and the
sidestand pivot and metal-to-metal
contact surfaces should be lubricated if
necessary.

EWA10730

WARNING

If the sidestand does not move up
and down smoothly, have a Yamaha
dealer check or repair it.

6-23

Recommended lubricant:

Lithium-soap-based grease

PERIODIC MAINTENANCE AND MINOR REPAIR

EAUM1650

Lubricating the swingarm piv­ots

The swingarm pivots must be lubricat­ed at the intervals specified in the peri­odic maintenance and lubrication chart.

Recommended lubricant:

Lithium-soap-based grease

EAU23271

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

EWA10750

WARNING

Securely support the vehicle so that
there is no danger of it falling over.

Check the inner tubes for scratches,
damage and excessive oil leakage.

To check the operation

1. Place the vehicle 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.

ECA10590

CAUTION:

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

6

6-24

PERIODIC MAINTENANCE AND MINOR REPAIR

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.

WARNING

Securely support the vehicle so that
there is no danger of it falling over.

6

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.

EAU23280

EWA10750

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.

6-25

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU23390

Battery

2

3

1

1. Battery coupler

2. Battery band

3. Battery

The battery is located behind panel B.
(See page 6-6.)
This model is equipped with a sealed­type (MF) battery, which does not re­quire any maintenance. There is no
need to check the electrolyte or to add
distilled water.

To charge the battery

Have a Yamaha dealer charge the bat­tery as soon as possible if it seems to
have discharged. Keep in mind that the

battery tends to discharge more quickly
if the vehicle is equipped with optional
electrical accessories.

EWA10760

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 hy-

drogen gas. Therefore, keep
sparks, flames, cigarettes, etc.,
away from the battery and pro­vide sufficient ventilation when
charging it in an enclosed
space.

6-26

● KEEP THIS AND ALL BATTER-

IES OUT OF THE REACH OF
CHILDREN.

To store the battery

1. If the model 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 it at least
once a month and fully charge it if
necessary.

3. Fully charge the battery before in­stallation.

4. After installation, make sure that
the battery leads are properly con­nected to the battery terminals.

ECA10630

CAUTION:

● Always keep the battery

charged. Storing a discharged
battery can cause permanent
battery damage.

● To charge a sealed-type (MF)

battery, a special (constant-volt­age) battery charger is required.
Using a conventional battery

6

PERIODIC MAINTENANCE AND MINOR REPAIR

charger will damage the battery.
If you do not have access to a
sealed-type (MF) battery charg­er, have a Yamaha dealer
charge your battery.

Replacing the fuse

2

1

EAU42021

CAUTION:

Do not use a fuse of a higher amper­age rating than recommended to
avoid causing extensive damage to

ECA10640

the electrical system and possibly a
fire.

4. Connect the battery coupler.

5. Turn the key to “ON” and turn on
the electrical circuits to check if the

1. Fuse

2. Spare fuse

The fuse is located inside the battery

6

coupler. (See page 6-26.)

devices operate.

6. If the fuse immediately blows
again, have a Yamaha dealer
check the electrical system.

If the fuse is blown, replace it as fol­lows.

1. Turn the key to “OFF” and turn off
all electrical circuits.

2. Disconnect the battery coupler.

3. Remove the blown fuse, and then
install a new fuse of the specified
amperage.

Specified fuse:

10.0 A

6-27

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU24350

Supporting the motorcycle

Since this model is not equipped with a
centerstand, follow these precautions
when removing the front and rear
wheel or performing other maintenance
requiring the motorcycle to stand up­right. Check that the motorcycle is in a
stable and level position before starting
any maintenance. A strong wooden
box can be placed under the engine for
added stability.

To service the front wheel

1. Stabilize the rear of the motorcycle
by using a motorcycle stand or, if
an additional motorcycle stand is
not available, by placing a jack un­der the frame in front of the rear
wheel.

2. Raise the front wheel off the
ground by using a motorcycle
stand.

To service the rear wheel

Raise the rear wheel off the ground by
using a motorcycle stand or, if a motor­cycle stand is not available, by placing

a jack either under each side of the
frame in front of the rear wheel or under
each side of the swingarm.

EAU24360

Front wheel

To remove the front wheel

WARNING

● It is advisable to have a Yamaha

dealer service the wheel.

● Securely support the motor-

cycle so that there is no danger
of it falling over.

1. Loosen the locknut at the brake le­ver, and then turn the adjusting
bolt fully in direction (a).

2

1

(a)

1. Brake lever free play adjusting bolt

2. Locknut

2. Loosen the axle nut.

EAU41810

EWA10820

6

6-28

PERIODIC MAINTENANCE AND MINOR REPAIR

1. Axle nut

2. Washer

3. Lift the front wheel off the ground
according to the procedure on
page 6-28.

4. Remove the axle nut and washer.

6

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

1. Wheel axle

To install the front wheel

EAU41691

1. Lift the wheel up between the fork
legs.

2. Insert the wheel axle from the
right-hand side.

NOTE:

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

2

1

1. Slot

2. Retainer

3. Lower the front wheel so that it is
on the ground.

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

Tightening torque:

Axle nut:

35 Nm (3.5 m·kgf, 25 ft·lbf)

5. Adjust the brake lever free play.
(See page 6-17.)

6. While applying the front brake,
push down hard on the handlebar
several times to check for proper
fork operation.

6-29

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU25080

Rear wheel

EAU41642

To remove the rear wheel

EWA10820

WARNING

● It is advisable to have a Yamaha

dealer service the wheel.

● Securely support the motor-

cycle so that there is no danger
of it falling over.

1. Disconnect the brake torque rod
from the brake shoe plate by re­moving the cotter pin, the nut and
the bolt.

2. Remove the brake pedal free play
adjusting nut, and then disconnect
the brake rod at the brake cam­shaft lever.

1. Brake rod

2. Brake pedal free play adjusting nut

3. Brake camshaft lever

4. Wheel axle

3. Loosen the locknut and the drive
chain slack adjusting nut on both
ends of the swingarm.

3

1

1. Axle nut

2. Washer

3. Drive chain slack adjusting nut

4. Locknut

4. Loosen the axle nut.

5. Lift the rear wheel off the ground
according to the procedure on
page 6-28.

6. Remove the axle nut and washer,
and then pull the wheel axle out.

7. Push the wheel forward, and then
remove the drive chain from the
rear sprocket.

2

4

6

1. Brake torque rod

2. Cotter pin

3. Brake torque rod bolt and nut

4. Brake shoe plate

6-30

PERIODIC MAINTENANCE AND MINOR REPAIR

NOTE:

The drive chain does not need to be
disassembled in order to remove and
install the wheel.

6

8. Remove the wheel.

To install the rear wheel

1. Install the drive chain onto the rear
sprocket.

2. Insert the wheel axle from the
right-hand side.

3. Adjust the drive chain slack. (See
page 6-20.)

4. Lower the rear wheel so that it is
on the ground.

EAU41652

5. Install the brake rod onto the brake
camshaft lever, and then install the
brake pedal free play adjusting nut
onto the brake rod.

6. Connect the brake torque rod to
the brake shoe plate by installing
the bolt and nut, and then tighten
the nut to the specified torque.

7. Insert a new cotter pin.

8. Tighten the axle nut to the speci­fied torque.

Tightening torques:

Brake torque rod nut:

26 Nm (2.6 m·kgf, 19 ft·lbf)

Axle nut:

60 Nm (6.0 m·kgf, 43 ft·lbf)

9. Adjust the brake pedal free play.
(See page 6-18.)

EAU25850

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.

6-31

PERIODIC MAINTENANCE AND MINOR REPAIR

Troubleshooting chart

WARNING

Keep away open flames and do not smoke while checking or working on the fuel system.

EAU25901

EWA10840

1. Fuel

Check the fuel level in
the fuel tank.

2. Compression

Operate the electric starter.

3. Ignition

Remove the spark plug
and check the electrodes.

4. Battery

Operate the electric starter.

There is enough fuel.

There is no fuel.

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 compression.

Supply fuel.

Check the ignition.

Have a Yamaha dealer
check the vehicle.

The battery is good.

Check the battery lead connections,
and charge the battery if necessary.

The engine does not start.
Check the compression.

6-32

6

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.

MOTORCYCLE CARE AND STORAGE

Matte color caution

CAUTION:

Some models are equipped with
matte colored finished parts. Be
sure to consult a Yamaha dealer for
advice on what products to use be­fore cleaning the vehicle. Using a
brush, harsh chemical products or
cleaning compounds when cleaning
these parts will scratch or damage
their surface. Wax also should not
be applied to any matte colored fin­ished parts.

7

EAU37833

ECA15192

EAU40462

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-

7-1

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

Cleaning

ECA10771

CAUTION:

● 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

MOTORCYCLE CARE AND STORAGE

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

● Do not use high-pressure wash-

ers 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.

ECA10790

CAUTION:

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

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

7-2

After cleaning

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

2. Immediately dry the drive chain
and lubricate it to prevent it from
rusting.

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

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

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

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

7. Wax all painted surfaces.

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

EWA14500

WARNING

● Make sure that there is no oil or

wax on the tires.

7

MOTORCYCLE CARE AND STORAGE

● If necessary, wash the tires with

warm water and a mild deter­gent. Before riding at higher
speeds, test the motorcycle’s
braking performance and cor­nering behavior.

CAUTION:

● Apply spray oil and wax spar-

ingly and make sure to wipe off
any excess.

● Never apply oil or wax to any

rubber and plastic parts, but
treat them with a suitable care
product.

● Avoid using abrasive polishing

7

compounds as they will wear
away the paint.

NOTE:

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

ECA10800

EAU26150

Storage

Short-term

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

ECA10810

CAUTION:

● 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 “OFF” posi­tion: Turn the fuel cock lever to
“OFF”.

7-3

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
install the spark plug and the
spark plug cap.

MOTORCYCLE CARE AND STORAGE

EWA10950

WARNING

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

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

9. Remove the battery and fully
charge it. Store it in a cool, dry
place and charge it once a month.
Do not store the battery in an ex­cessively cold or warm place [less
than 0 °C (30 °F) or more than 30

°C (90 °F)]. For more information
on storing the battery, see page
6-26.

NOTE:

Make any necessary repairs before
storing the motorcycle.

7

7-4

SPECIFICATIONS

Dimensions:

Weight:

Engine:

8

Overall length:

1565 mm (61.6 in)

Overall width:

680 mm (26.8 in)

Overall height:

923 mm (36.3 in)

Seat height:

670 mm (26.4 in)

Wheelbase:

1080 mm (42.5 in)

Ground clearance:

180 mm (7.09 in)

Minimum turning radius:

1660 mm (65.4 in)

With oil and fuel:

72.0 kg (159 lb)

Engine type:

Air cooled 4-stroke, SOHC

Cylinder arrangement:

Forward-inclined single cylinder

Displacement:

110.0 cm³

Bore × stroke:

51.0 × 54.0 mm (2.01 × 2.13 in)

Compression ratio:

9.30 :1

Starting system:

Electric starter and kickstarter

Lubrication system:

Wet sump

Engine oil:

Type:

YAMALUBE 4, SAE10W-30 or SAE20W­40

10˚ 30˚ 50˚ 70˚ 90˚

YAMALUBE 4 (10W-30)
or SAE 10W-30

YAMALUBE 4 (20W-40)
or SAE 20W-40

–20˚

˚ 0˚ 10˚ 20˚ 30˚

–10

110˚0˚130 ˚F

40˚

Recommended engine oil grade:

API service SG type or higher, JASO
standard MA

Engine oil quantity:

Periodic oil change:

0.80 L (0.85 US qt) (0.70 Imp.qt)

Air filter:

Air filter element:

Wet element

Fuel:

Recommended fuel:

Unleaded gasoline only

Fuel tank capacity:

3.8 L (1.00 US gal) (0.84 Imp.gal)

Fuel reserve amount:

0.5 L (0.13 US gal) (0.11 Imp.gal)

50 ˚C

Carburetor:

Manufacturer:

MIKUNI

Type × quantity:

VM16 x 1

Spark plug (s):

Manufacturer/model:

NGK/CR6HSA

Spark plug gap:

0.6–0.7 mm (0.024–0.028 in)

Clutch:

Clutch type:

Wet, multiple-disc and centrifugal
automatic

Transmission:

Primary reduction system:

Spur gear

Primary reduction ratio:

67/18 (3.722)

Secondary reduction system:

Chain drive

Secondary reduction ratio:

35/14 (2.500)

Transmission type:

Constant mesh 4-speed

Operation:

Left foot operation

Gear ratio:

1st:

38/12 (3.166)

2nd:

33/17 (1.941)

3rd:

29/21 (1.380)

8-1

SPECIFICATIONS

4th:

23/21 (1.095)

Chassis:

Frame type:

Steel tube backbone

Caster angle:

26.00 °

Trail:

60.0 mm (2.36 in)

Front tire:

Type:

With tube

Size:

2.50-14 4PR

Manufacturer/model:

CHEN SHIN/C-803

Rear tire:

Type:

With tube

Size:

3.00-12 4PR

Manufacturer/model:

CHEN SHIN/C-803

Loading:

Maximum rider weight:

60.0 kg (132 lb)

Tire air pressure (measured on cold
tires):

Front:

100 kPa (15 psi) (1.00 kgf/cm²)

Rear:

100 kPa (15 psi) (1.00 kgf/cm²)

Front wheel:

Wheel type:

Spoke wheel

Rim size:

14x1.40

Rear wheel:

Wheel type:

Spoke wheel

Rim size:

12x1.60

Front brake:

Type:

Drum brake

Operation:

Right hand operation

Rear brake:

Type:

Drum brake

Operation:

Right foot operation

Front suspension:

Type:

Telescopic fork

Spring/shock absorber type:

Coil spring/oil damper

Wheel travel:

115.0 mm (4.53 in)

Rear suspension:

Type:

Swingarm (monocross)

Spring/shock absorber type:

Coil spring/gas-oil damper

Wheel travel:

110.0 mm (4.33 in)

8-2

Electrical system:

Ignition system:

DC. CDI

Charging system:

AC magneto

Battery:

Model:

GT4B-5

Voltage, capacity:

12 V, 2.5 Ah

Fuse:

Fuse:

10.0 A

8

CONSUMER INFORMATION

Identification numbers

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

VEHICLE IDENTIFICATION
NUMBER:

MODEL LABEL INFORMATION:

9

EAU26351

Key identification number

1. Key identification number 1. Vehicle identification number

The key identification number is
stamped into the key. Record this num­ber in the space provided and use it for
reference when ordering a new key.

EAU26390

Vehicle identification number

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

NOTE:

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.

EAU26400

1

9-1

CONSUMER INFORMATION

Model label

EAU36980

1

1. Model label

The model label is affixed to the frame
behind panel B. (See page 6-6.)
Record the information on this label in
the space provided. This information
will be needed when ordering spare
parts from a Yamaha dealer.

9

9-2

CONSUMER INFORMATION

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

9

EAU26560

9-3

CONSUMER INFORMATION

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

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

9

9-4

CONSUMER INFORMATION

9

9-5

YAMAHA EXTENDED SERVICE (Y.E.S.)

CONSUMER INFORMATION

EAU26750

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.

9

9-6

CONSUMER INFORMATION

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)

9

9-7

INDEX

A

Accessories and replacement parts ..... 6-16

Air filter element, cleaning .................... 6-10

B

Battery .................................................. 6-26

Brake lever ............................................. 3-2

Brake lever, checking and lubricating ... 6-23

Brake lever free play, adjusting ............ 6-17

Brake pedal ............................................ 3-2

Brake pedal, checking and

lubricating........................................... 6-23

Brake pedal free play, adjusting ........... 6-18

Brake shoes, checking ......................... 6-19

C

Cables, checking and lubricating.......... 6-22

Carburetor, adjusting ............................ 6-13

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

Clutch free play, adjusting .................... 6-17

D

Drive chain, cleaning and lubricating .... 6-21

Drive chain slack .................................. 6-20

E

Engine break-in ...................................... 5-3

Engine idling speed .............................. 6-13

Engine oil................................................ 6-8

Engine, starting a warm.......................... 5-2

Engine stop switch.................................. 3-1

F

Front fork, checking .............................. 6-24

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

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

Fuel tank breather hose.......................... 3-4

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

Fuse, replacing..................................... 6-27

H

Handlebar switches .................................3-1

I

Identification numbers .............................9-1

K

Key identification number........................9-1

Kickstarter ...............................................3-6

L

Labels, location of ...................................1-4

M

Main switch .............................................3-1

Maintenance and lubrication, periodic..... 6-4

Maintenance, emission control system ...6-3

Maintenance, periodic .............................6-1

Matte color, caution.................................7-1

Model label..............................................9-2

N

Noise regulation ......................................9-3

P

Panels, removing and installing ..............6-6

Parking....................................................5-4

Part locations ..........................................2-1

Pre-operation check list...........................4-2

S

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

Seat.........................................................3-6

Shifting ....................................................5-2

Shift pedal ...............................................3-2

Shift pedal, checking .............................6-19

Sidestand ................................................3-7

Sidestand, checking and lubricating......6-23

Spark arrester, cleaning ........................6-12

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

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

Starter (choke) lever ...............................3-5

Starting and warming up

a cold engine ........................................5-1

Starting circuit cut-off system.................. 3-7

Start switch .............................................3-1

Steering, checking ................................ 6-25

Storage ................................................... 7-3

Supporting the motorcycle .................... 6-28

Swingarm pivots, lubricating ................. 6-24

T

Throttle cable free play, checking ......... 6-14

Throttle grip and cable,

checking and lubricating ..................... 6-22

Tires...................................................... 6-15

Tool kit .................................................... 6-2

Troubleshooting .................................... 6-31

Troubleshooting chart ........................... 6-32

V

Valve clearance .................................... 6-14

Vehicle identification number.................. 9-1

W

Warranty, extended ................................ 9-6

Warranty, limited.....................................9-4

Wheel bearings, checking..................... 6-25

Wheel (front) ......................................... 6-28

Wheel (rear).......................................... 6-30

Wheels.................................................. 6-16

PRINTED ON RECYCLED PAPER

YAMAHA MOTOR CO., LTD.

PRINTED IN JAPAN

2007.07-2.1×1 CR

(E)