Yamaha TW200N 2000 User Manual [ru]

TW200N TW200NC

SUPPLEMENTARY SERVICE MANUAL

LIT-11616-14-43 2YG-28197-11

FOREWORD

This Supplementary Service Manual has been prepared to introduce new service and data for the TW200EN/TW200ENC. For complete service information procedures it is necessary to use this Supplementary Service Manual together with the following manual.

TW200T/TC ’87 SERVICE MANUAL: LIT-11616-05-93 (2JX-28197-10)

TW200EU/EUC ’88 SUPPLEMENTARY SERVICE MANUAL: LIT-11616-06-26 (2YG-28197-10)

TW200N/TW200NC SUPPLEMENTARY SERVICE MANUAL

First edition, November 2000

Any reproduction or unauthorized use

without the written permission of

Yamaha Motor Corporation, U.S.A.

is expressly prohibited.

Printed in U.S.A.

P/N LIT-11616-14-43

EAS00003

NOTICE

This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehicle unsafe and unfit for use.

This model has been designed and manufactured to perform within certain specifications in regard to performance and emissions. Proper service with the correct tools is necessary to ensure that the vehicle will operate as designed. If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model. This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives.

Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable.

NOTE:

• This Service Manual contains information regarding periodic maintenance to the emission control system. Please read this material carefully.

• Designs and specifications are subject to change without notice.

EAS00004

IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following.

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

WARNING

CAUTION:

NOTE:

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

A CAUTION indicates special precautions that must be taken to avoid damage to the motorcycle.

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

EAS00007

HOW TO USE THIS MANUAL

This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order.

The manual is divided into chapters. An abbreviation and symbol in the upper right corner of

each page indicate the current chapter. Refer to “SYMBOLS”.

Each chapter is divided into sections. The current section title is shown at the top of each page,

except in chapter 3 (“PERIODIC CHECKS AND ADJUSTMENTS”), where the sub-section title(s) appears.

Sub-section titles appear in smaller print than the section title.

To help identify parts and clarify procedure steps, there are exploded diagrams at the start of

each removal and disassembly section. Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a

disassembly step. Symbols indicate parts to be lubricated or replaced.

Refer to “SYMBOLS”. A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of

parts, notes in jobs, etc. Jobs requiring more information (such as special tools and technical data) are described sequen-

tially.

GEN

SPEC

INFO

CHK

ENG

ADJ

CARB

CHAS

EAS00008

SYMBOLS

The following symbols are not relevant to every vehicle. Symbols 1 to 8 indicate the subject of each chapter.

General information

Specifications

Periodic checks and adjustments

Engine

Carburetion

Chassis

Electrical system

Troubleshooting

–+

TRBL

ELEC

SHTG

GHI

Symbols 9 to F indicate the following.

Serviceable with engine mounted

Filling fluid

Lubricant

Special tool

Tightening torque

Wear limit, clearance

Engine speed

Electrical data

Symbols G to L in the exploded diagrams indicate the types of lubricants and lubrication points.

New

JKL

Engine oil

Gear oil

Molybdenum disulfide oil

Wheel bearing grease

Lithium soap base grease

Molybdenum disulfide grease

Symbols M to N in the exploded diagrams indicate the following.

Apply locking agent (LOCTITE

Replace the part

)

CONTENTS

GENERAL INFORMATION

MOTORCYCLE IDENTIFICATION ........................................................... 1

VEHICLE IDENTIFICATION NUMBER ................................................1

MODEL CODE .....................................................................................1

SPECIFICATIONS

GENERAL SPECIFICATIONS .................................................................2

MAINTENANCE SPECIFICATIONS ........................................................ 4

ENGINE ................................................................................................4

TIGHTENING TORQUESS ..................................................................6

CHASSIS ..............................................................................................7

TIGHTENING TORQUESS ..................................................................8

ELECTRICAL ....................................................................................... 9

CABLE ROUTING ..................................................................................10

PERIODIC CHECKS AND ADJUSTMENTS

INTRODUCTION .................................................................................... 18

PERIODIC MAINTENANCE CHART FOR EMISSION

CONTROL SYSTEM ..............................................................................18

GENERAL MAINTENANCE AND LUBRICATION CHART ....................19

ENGINE ..................................................................................................21

ADJUSTING THE THROTTLE CABLE FREE PLAY ......................... 21

CLEANING THE SPARK ARRESTER ...............................................22

CHASSIS ................................................................................................23

ADJUSTING THE FRONT BRAKE .................................................... 23

CHECKING THE BRAKE FLUID LEVEL ...........................................24

CHECKING THE BRAKE PADS ........................................................25

CHECKING THE BRAKE HOSE ........................................................25

BLEEDING THE HYDRAULIC BRAKE SYSTEM .............................. 26

............................................................................................2

...............................................................................1

..................................................18

ENGINE

CARBURETION

...........................................................................................................28

CYLINDER HEAD ..................................................................................28

CHECKING THE TIMING CHAIN TENSIONER ................................29

INSTALLING THE TIMING CHAIN TENSIONER ..............................29

AC MAGNETO .......................................................................................30

STATOR COIL ASSEMBLY AND PICKUP COIL ...............................30

AC MAGNETO ...................................................................................31

..............................................................................................32

CARBURETOR ......................................................................................32

DISASSEMBLING THE CARBURETOR ............................................ 35

CHECKING THE CARBURETOR ......................................................35

ASSEMBLING THE CARBURETOR .................................................. 37

INSTALLING THE CARBURETOR ....................................................38

MEASURING AND ADJUSTING THE FUEL LEVEL .........................39

CHASSIS ........................................................................................................40

FRONT WHEEL AND BRAKE DISC ......................................................40

REMOVING THE FRONT WHEEL ....................................................42

CHECKING THE BRAKE DISC .........................................................42

INSTALLING THE FRONT WHEEL ...................................................44

FRONT BRAKE ......................................................................................46

FRONT BRAKE PADS .......................................................................46

REPLACING THE FRONT BRAKE PADS .........................................47

FRONT BRAKE MASTER CYLINDER ............................................... 50

DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER ........52

CHECKING THE FRONT BRAKE MASTER CYLINDER ..................52

ASSEMBLING AND INSTALLING THE FRONT BRAKE

MATER CYLINDER ............................................................................53

FRONT BRAKE CALIPER .................................................................55

DISASSEMBLING THE FRONT BRAKE CALIPER ........................... 57

CHECKING THE FRONT AND REAR BRAKE CALIPERS ............... 58

ASSEMBLING AND INSTALLING

THE FRONT BRAKE CALIPERS .......................................................59

FRONT FORK ........................................................................................62

STEERING HEAD ..................................................................................63

INSTALLING THE BEARING (RETAINER TYPE) .............................65

ELECTRICAL.................................................................................................. 66

ELECTRICAL COMPONENTS ............................................................... 66

SWITCHES .............................................................................................67

CHECKING SWITCH CONTINUITY ..................................................67

CHECKING THE SWITCHES ................................................................68

IGNITION SYSTEM ................................................................................ 70

CIRCUIT DIAGRAM ...........................................................................70

TROUBLESHOOTING ....................................................................... 71

ELECTRIC STARTING SYSTEM ........................................................... 75

CIRCUIT DIAGRAM ...........................................................................75

STARTING CIRCUIT CUT-OFF SYSTEM OPERATION ................... 76

TROUBLESHOOTING ....................................................................... 77

SIGNALING SYSTEM ............................................................................81

CIRCUIT DIAGRAM ...........................................................................81

TROUBLESHOOTING ....................................................................... 82

CHECKING THE SIGNALING SYSTEM ............................................ 83

TW200EN/TW200ENC WIRING DIAGRAM

MOTORCYCLE IDENTIFICATION

EAS00014

GENERAL INFORMATION

MOTORCYCLE IDENTIFICATION

EAS00017

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number 1 is stamped into the right side of the steering head pipe.

EAS00018

MODEL CODE

The model code label 1 is affixed to the frame. This information will be needed to order spare parts.

GEN

INFO

– 1 –

GENERAL SPECIFICATIONS

SPECIFICATIONS

GENERAL SPECIFICATIONS

Model TW200EN/TW200ENC

Model code number: TW200EN: 5FY8

TW200ENC: 5FY9

Dimensions:

Overall length 2,090 mm (82.3 in) Overall width 820 mm (32.3 in) Overall height 1,120 mm (44.1 in) Seat height 790 mm (31.1 in) Wheelbase 1,325 mm (52.2 in) Minimum ground clearance 265 mm (10.4 in)

Engine:

Engine type Air cooled 4-stroke, SOHC Cylinder arrangement Forward inclined single cylinder Displacement 196 cm Bore × stroke 67.0 × 55.7 mm (2.638 × 2.193 in) Compression ratio 9.5 : 1 Compression pressure (standard) 900 kPa (9 kg/cm Starting system Electric starter

Carburetor:

Type/manufacturer MV28/TEIKEI

Spark plug:

Type/manufacturer DR8EA (NGK), X24ESR-U (N.D.) Gap 0.6 ~ 0.7 mm (0.024 ~ 0.028 in)

Chassis:

Frame type Diamond Caster angle 25.8° Trail 95 mm (3.74 in)

Tire:

Type With tube Size (F) 130/80-18 66P TW31 Size (R) 180/80-14M/C 78P TW34 Wear Limit <1.0 mm (0.04 in)>

(11.96 cu.in)

, 128 psi)

SPEC

– 2 –

GENERAL SPECIFICATIONS

SPEC

Model TW200EN/TW200ENC

Basic weight:

With oil and full fuel tank 126 kg (278 lb)/(TW200EN), 127 kg (280 lb) (TW200ENC) Maximum load* 157 kg (346 lb)/(TW200EN), 156 kg (344 lb) (TW200ENC) Cold tire pressure: Front Rear Up to 80 kg (176 lb) load* 125 kPa

(1.25 kg/cm

, 18 psi)

80 kg (176 lb) ~ Maximum load* 150 kPa

(1.5 kg/cm

, 22 psi)

Off-road riding 125 kPa

(1.25 kg/cm

, 18 psi)

High speed riding 150 kPa

(1.5 kg/cm

, 22 psi)

(1.25 kg/cm2, 18 psi)

(1.75 kg/cm2, 25 psi)

(1.25 kg/cm2, 18 psi)

(1.75 kg/cm2, 25 psi)

125 kPa

175 kPa

125 kPa

175 kPa

Brake:

Front brake type Single disc brake Operation Right hand operation Rear brake type Drum brake Operation Right foot operation

Shock absorber:

Front shock absorber Coil spring/oil damper Rear shock absorber Gas and coil spring/oil damper

Bulb wattage/quantity:

Headlight 12 V, 60 W/55 W × 1 Tail/brake light 12 V, 8 W/27 W × 2 Front turn signal/position light 12 V, 27 W/8 W × 2 Rear turn signal light 12 V, 27 W × 2 Meter light 12 V, 3.4 W × 1

* Load is the total weight of cargo, rider, passenger and accessories.

– 3 –

MAINTENANCE SPECIFICATIONS

ENGINE

Model TW200EN/TW200ENC

Camshaft:

Drive method Chain drive (left) Cam cap inside diameter 25.000 ~ 25.021 mm (0.984 ~ 0.985 in) Camshaft outside diameter 24.96 ~ 24.98 mm (0.983 ~ 0.984 in) Shaft-to-cap clearance 0.020 ~ 0.061 mm (0.0008 ~ 0.0024 in) Cam dimensions:

Intake: “A” 36.538 ~ 36.638 mm (1.439 ~ 1.442 in)

Exhaust:

Camshaft runout limit <0.03 mm (0.0012 in)>

“B” 30.152 ~ 30.252 mm (1.187 ~ 1.191 in) “C” 6.588 mm (0.259 in)

“A” 36.58 ~ 36.68 mm (1.440 ~ 1.444 in) “B” 30.266 ~ 30.366 mm (1.192 ~ 1.196 in) “C” 6.63 mm (0.261 in)

SPEC

Cam chain type/number of links DID 25SH/104 links Cam chain adjustment method Automatic

Piston ring:

Sectional sketch:

Top ring Barrel

B = 1.2 mm (0.047 in) T = 2.7 mm (0.106 in)

2nd ring Taper

B = 1.2 mm (0.047 in)

T = 2.7 mm (0.106 in)

Oil ring Expander

B = 2.5 mm (0.098 in) T = 2.8 mm (0.110 in)

End gap (Installed): Top ring 0.15 ~ 0.30 mm (0.006 ~ 0.012 in)

2nd ring 0.15 ~ 0.35 mm (0.006 ~ 0.014 in) Oil ring 0.3 ~ 0.9 mm (0.012 ~ 0.035 in)

Side clearance Top ring 0.03 ~ 0.07 mm (0.001 ~ 0.003 in)

2nd ring 0.02 ~ 0.06 mm (0.001 ~ 0.002 in)

– 4 –

MAINTENANCE SPECIFICATIONS

Model TW200EN/TW200ENC

Carburetor:

ID mark TW200EN: 5FY10

TW200ENC: 5FY00

Main jet (M.J.) TW200EN: #126

TW200ENC: #128 Main air jet (M.A.J.) 1.2 Jet needle-clip/position (J.N) TW200EN: 5B21-1/1

TW200ENC: 5B21-1/3 Main nozzle (M.N.) 2.600 Pilot jet (P.J.) #31 Pilot air jet (P.A.J.) TW200EN: 0.95

TW200ENC: 1.0 Pilot outlet 0.8 Bypass 0.7 Valve seat (V.S.) 1.6 Starter jet (G.S1.) 0.6

(G.S2.) 0.8 Fuel level (above the line on the float chamber

mating surface) (F.L.) Float height 10 ~ 11 mm (0.39 ~ 0.43 in) Engine idling speed 1,300 ~ 1,500 r/min Vacuum pressure at idling speed 29.3 ~ 34.7 kPa

0.5 ~ 1.5 mm (0.02 ~ 0.06 in)

(220 ~ 260 mmHg, 8.66 ~ 10.24 inHg) or more

SPEC

– 5 –

TIGHTENING TORQUESS

MAINTENANCE SPECIFICATIONS

SPEC

Tightening

Parts to be tightened Part name

Thread

size

Q’ty

torque

Remarks

Nm m·kg ft·lb

Cam sprocket cover Bolt M6 2 10 1.0 7.2 Tappet cover Bolt M6 5 10 1.0 7.2 Timing chain tensioner Bolt M6 2 10 1.0 7.2 Oil filter cover Bolt M6 2 10 1.0 7.2 Muffler protector Screw M6 4 7 0.7 5.1 Crankcase Bolt M6 12 10 1.0 7.2 Crankcase cover (left) Bolt M6 9 10 1.0 7.2 Crankcase cover (right) Bolt M6 12 10 1.0 7.2 Pickup coil lead holder Bolt M6 1 10 1.0 7.2 Apply LOCTITE Pickup coil Bolt M6 2 10 1.0 7.2 Apply LOCTITE Stator coil assembly Bolt M6 3 10 1.0 7.2 Apply LOCTITE

® ® ®

– 6 –

MAINTENANCE SPECIFICATIONS

CHASSIS

Model TW200EN/TW200ENC

Steering system:

Steering bearing type Angular ball

Drive chain:

Type/manufacturer 428HG (I)/DAIDO Number of links 121 links + joint Chain free play 35 ~ 60 mm (1.38 ~ 2.36 in)

Front brake:

Brake type Single-disc brake Disc outside diameter × thickness 220 × 3.5 mm (8.66 × 0.14 in) Max. deflection 0.15 mm (0.006 in) Brake pad lining thickness 5.3 mm (0.21 in) <Limit> <0.8 mm (0.03 in)> Master cylinder inside diameter 11 mm (0.43 in) Caliper cylinder inside diameter 26.9 mm (1.06 in) + 22.2 mm (0.87 in) Recommended fluid DOT4

Rear brake:

Brake type Drum brake (leading and trailing) Drum inside dia. 110 mm (4.33 in) <Limit> <111 mm (4.37 in)> Lining thickness Front 4 mm (0.16 in) <Limit> <2 mm (0.08 in)> Shoe spring free length 50.5 mm (1.99 in)

Brake lever and brake pedal:

Brake lever free play (at lever end) 2 ~ 5 mm (0.08 ~ 0.20 in) Brake pedal free play (at pedal end) 20 ~ 30 mm (0.8 ~ 1.2 in) Brake pedal position 15 mm (0.6 in)

(Vertical height below footrest top.)

Clutch lever free play (at lever end): 10 ~ 15 mm (0.39 ~ 0.59 in)

SPEC

– 7 –

TIGHTENING TORQUESS

MAINTENANCE SPECIFICATIONS

SPEC

Parts to be tightened Thread size

Throttle cable and carburetor M6 × 1.0 5 0.5 3.6 Pivot shaft and frame M12 × 1.25 83 8.3 60 Rear shock absorber and frame M10 × 1.25 56 5.6 41 Drive chain case and swingarm M5 × 0.8 5 0.5 3.6 Handlebar holder upper and upper bracket M8 × 1.25 20 2.0 14 Steering shaft and ring nut M25 × 1.0 18 1.8 13 See NOTE. Front brake master cylinder and handlebar M6 × 1.0 7 0.7 5.1 Front wheel hub and brake disc M6 × 1.0 13 1.3 9.4 Front brake caliper bracket and outer tube M10 × 1.25 30 3.0 22 Front brake caliper and caliper bracket M10 × 1.25 27 2.7 19 Brake hose union bolt M10 × 1.25 30 3.0 22 Air bleeder screw M7 × 1.0 6 0.6 4.3 Passenger footrest and frame M8 × 1.25 15 1.5 11 Rear fender and cover M6 × 1.0 5 0.5 3.6

NOTE:

1. First, tighten the ring nut to approximately 38 Nm (3.8 m • kg, 27 ft • lb) with a torque wrench, then loosen the ring nut completely.

2. Retighten the ring nut to specification.

Tightening torque

Remarks

Nm m·kg ft·lb

– 8 –

MAINTENANCE SPECIFICATIONS

ELECTRICAL

Model TW200EN/TW200ENC

C.D.I.:

Magneto model/manufacturer F5BT/YAMAHA Pickup coil resistance (color) 656 ~ 984 Ω at 20 °C (68 °F) (R–W) Source coil resistance (color) 624 ~ 936 Ω at 20 °C (68 °F) (Br–G) C.D.I. unit-model/manufacturer 5LB/YAMAHA

Ignition coil:

Model/manufacturer 2JN/YAMAHA Minimum spark gap 6 mm (0.24 IN) or more at 500 r/min Primary winding resistance 0.18 ~ 0.28 Ω at 20 °C (68 °F) Secondary winding resistance 6.3 ~ 9.5 kΩ at 20 °C (68 °F)

Charging system:

Type A.C. magneto generator Model/manufacturer 5FBT/YAMAHA Charge coil resistance (color) 0.5 ~ 0.7 Ω at 20 °C (68 °F) (W–W)

Rectifier/regulator:

Type Semi conductor type Model/manufacturer SH629A-12/SHINDENGEN No load regulated voltage 14.1 ~ 14.9 V Capacity 10 A Withstand voltage 200 V

Starter motor:

Model/manufacture 5FY/YAMAHA Output 0.4 kW Armature coil resistance 0.017 ~ 0.021 Brush overall length 10 mm (0.39 in)

Brush spring pressure 560 ~ 840 g (19.8 ~ 29.6 oz)

Commutator dia. 22 mm (0.87 in)

<Limit> <21 mm (0.83 in)> Mica undercut 1.5 mm (0.06 in)

Flasher relay:

Type Full transistor Model/manufacturer FE246BH/DENSO Self cancelling device No. Flasher frequency 75 ~ 95 cycle/min Wattage 27 W × 2 + 3.4 W

Circuit breaker:

Type Fuse Amperage for individual circuit

Main 20 A

Ω

SPEC

– 9 –

CABLE ROUTING

Throttle cable

Front brake light switch lead

Right handlebar switch lead

Clutch cable

Left handlebar switch lead

Clutch switch lead

Front turn signal/position

light lead (left) Main switch lead

CABLE ROUTING

Indicator lights lead

Speedometer cable

Meter light lead

Headlight coupler

Wire harness

Front turn signal/position

light lead (right) Brake hose

SPEC

Fasten the brake hose with a

plastic locking tie to the brake hose grommet. Fasten the wire harness with

a plastic locking tie.

– 10 –

CABLE ROUTING

SPEC

Clutch cable

Left handlebar switch lead

Clutch switch lead

Resonator hose

Main switch lead

Rectifier/regulator lead

Fuel hose

Brake hose

Speedometer cable

Horn lead

Fasten the resonator hose with a plastic band between the resonator

hose protectors so that the fastener does not squeeze the hose. Pass the canister hose through the guide of the frame. (for California)

Fasten the resonator hose with a plastic ban d in front of the resonat or

hose protector. Fasten the rectifier/regulator lead and resonator hose with a plastic

band between the resonator hose protectors so that the fastener does not squeeze the hose. Fasten the brake hose with a plastic locking tie to the brake hose

grommet.

– 11 –

CABLE ROUTING

SPEC

Sidestand switch lead

Crankcase breather hose

Battery negative terminal

Carburetor air vent hose

Carburetor overflow hose

AC magneto lead

Starter motor lead

Neutral switch lead

Fasten the AC magneto leads with a plastic locking tie to the frame at

the section where the frame starts to curve. Fasten the carburetor air vent hose, carburetor overflow hose, and

neutral switch lead with a plastic clip.

– 12 –

CABLE ROUTING

SPEC

Ignition coil

Throttle cable

Horn lead

Canister hose (for California)

Canister (for California)

Spark plug

Starter motor lead

Fasten the wire harness, right handlebar switch lead, front brake light

switch lead, clutch switch lead, main switch lead, and throttle cable with a plastic band. Fasten the wire harness, right handlebar switch lead, front brake light

switch lead, clutch switch lead, main switch lead, and resonator hose with a plastic band. Fasten the throttle cable and canister hose with a plastic clip. Be sure

to face the ends of the clip downward from the frame. (for California) Fasten the throttle cable with a plastic locking tie through the hole in

the frame bracket.

– 13 –

CABLE ROUTING

Fasten the wire harness, right handlebar switch lead, front brake light switch lead, clutch switch lead, main

switch lead, resonator hose, ignition coil lead, ground lead, and horn lead with a plastic band. Fasten the canister hose with a plastic band. (for California)

Pass the canister hose through the engine stay guide. (for California)

SPEC

– 14 –

CABLE ROUTING

SPEC

Diode

Battery positive lead

Starter relay

Starter motor lead

CDI unit

Wire harness

Turn signal relay

Fasten the wire harness with a plastic locking tie at the section just before the

leads split. Pass the battery breather hose inside the battery positive lead.

Pass the rear brake light switch lead in front of the frame so that it is not

squeezed by the side cover and frame. Fasten the rear brake light switch lead and turn signal relay lead with a plastic

locking tie. Face the rear brake light switch lead to the rear of the frame.

Pass the battery breather hose through the hose guide.

Pass the battery breather hose through the hole in the electrical components box.

Fasten the wire harness and diode with a plastic locking tie.

– 15 –

CABLE ROUTING

SPEC

Clutch switch lead

Clutch cable

Brake hose

Throttle cable

Front brake light switch lead

Right handlebar switch lead

Starter motor lead

AC magneto lead

Rectifier/regulator

Battery negative lead

Neutral switch lead

Left handlebar switch lead

Fasten the right handlebar

switch lead and front brake light switch lead with a plastic band. Fasten the AC magneto leads,

starter motor lead, neutral switch lead, and battery negative lead with a plastic locking tie by passing the tie through the hole in th e frame bracket.

Fasten the left handlebar switch

lead and clutch switch lead with a plastic band.

– 16 –

Battery positive lead

Rear turn signal light lead (right)

Tail/brake light lead

Rear turn signal light lead (left)

Sidestand switch lead

Battery negative lead

AC magneto lead

Neutral switch lead

Starter motor lead

CABLE ROUTING

Fasten the wire harness and rear turn signal light lead (right)

with a plastic locking tie at the section behind the hook. Fasten the rear turn signal light lead (left) with a plastic locking

tie.

SPEC

– 17 –

INTRODUCTION/PERIODIC MAINTENANCE CHART

FOR EMISSION CONTROL SYSTEM

CHK

ADJ

PERIODIC CHECKS AND ADJUSTMENTS

INTRODUCTION

This chapter includes all information necessary to perform recommended checks and abjustments.If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a longer service life and reduce the need for costly overhaul work.This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale.All service technicians should be familiar with this entire chapter.

PERIODIC MAINTENANCE CHART FOR EMISSION CONTROL SYSTEM

INITIAL ODOMETER READINGS

No. ITEM ROUTINE

1 * Valve clearance

2 Spark plug

3 * Fuel line

4 * Exhaust system

5 Spark arrester

6 * Idle speed

Evaporative emis-

sion control system**

• Check and adjust valve clearance when engine is cold.

• Check condition.

• Adjust gap and clean.

• Replace at 11,000 km (or 12 months) and thereafter every 10,000 km (or 12 months).

• Check fuel hose for crack or damage.

• Replace if necessary.

• Check for leakage.

• Retighten if necessary.

• Replace gaskets if necessary.

• Clean.

• Check and adjust engine idle speed.

• Adjust cable free play.

• Check control system for damage.

• Replace if necessary.

600 mi

(1,000 km)

or 1 month

√√√√√

4,000 mi

(6,000 km)

or 6 month

√

√√

√√√√

√√√√ √√√√

7,000 mi

(11,000 km)

or 12 month

Replace

√√

10,000 mi

(16,000 km)

or 18 month

√

13,000 mi

(21,000 km)

or 24 month

Replace

*: Since these items require special tools, data and technical skills, have a Yamaha dealer perform the ser-

vice.

**: California type only.

NOTE:

From 16,000 mi (26,000 km) or 30 months, repeat the maintenance intervals starting from 4,000 mi (6,000 km) or 6 months.

– 18 –

GENERAL MAINTENANCE AND LUBRICATION CHART

INITIAL ODOMETER READINGS

No. ITEM ROUTINE TYPE

1)Yamalube 4 (20 W 40) or SAE 20 W 40 type

1Engine oil

2 * Oil filter/strainer

3 * Air filter

4 * Brake system

5*Clutch

6 Drive chain

Control and meter

cable

Rear arm pivot

shaft

Brake/clutch lever

pivot shaft

Brake pedal and

shift pedal shaft

11 * Sidestand pivots

12 * Front fork

13 * Steering bearings

14 * Wheel bearings

• Warm-up engine before draining.

• Clean filter element and oil strainer.

• Replace oil filter and strainer if damaged.

• Wet type filter must be washed and damped with oil.

• Adjust free play.

• Check fluid leakage. (Front) (see NOTE.)

• Correct if necessary.

• Replace pads if necessary. (Front)

• Replace shoes if necessary. (Rear)

• Adjust free play. –

• Check chain condition.

• Adjust and lubricate chain thoroughly.

• Apply chain lube thoroughly.

• Apply until new grease shows.

• Apply chain lube lightly.

• Lubricate.

• Apply chain lube lightly

• Check operation and lubricate.

• Apply chain lube lightly.

• Check operation and leakage.

• Check bearings assembly for looseness.

• Moderately repack every 10,000 mi (16,000 km)

• Check bearings for smooth rotation.

“SE/SF” motor oil.

2)Yamalube 4 (10 W 30) or SAE 10 W 30 type “SE/SF” motor oil.

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

Special O-ring chain lubricant

Yamaha chain and cable lube or engine oil.

Lithium-soap-based grease. (all-purpose grease)

Medium weight wheel bearing grease.

600 mi

(1,000 km)

or 1 month

√√√√√

–

√√√

√√√√√

4,000 mi

(6,000 km)

or 6 month

(11,000 km)

or 12 month

Every 300 mi (500 km)

√√√√

√√

√√√√

7,000 mi

CHK

ADJ

10,000 mi

(16,000 km)

or 18 month

Repack

13,000 mi

(21,000 km)

or 24 month

√

– 19 –

CHK

GENERAL MAINTENANCE AND LUBRICATION CHART

INITIAL ODOMETER READINGS

No. ITEM ROUTINE TYPE

• Check specific gravity.

• Check that the

15 Battery

16 * Sidestand switch

breather pipe is working properly.

• Correct if necessary.

• Check and clean or replace if necessaly.

–

600 mi

(1,000 km)

or 1 month

√√√√√

* Sinc e these items require special tools, data and technical skills, have a Yamaha dealer perform the ser-

vice.

NOTE:

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

2. Hydraulic brake system

• Replace the brake fluid after disassembling the master cylinder or caliper cylinder.

• Check the brake fluid level and add fluid as required.

• Replace the master cylinder and caliper cylinder oil seals every two years.

• Replace the brake hoses every four years or if cracked or damaged.

4,000 mi

(6,000 km)

or 6 month

√√√√

7,000 mi

(11,000 km)

or 12 month

ADJ

10,000 mi

(16,000 km)

or 18 month

13,000 mi

(21,000 km)

or 24 month

– 20 –

ADJUSTING THE THROTTLE CABLE FREE PLAY

ENGINE

ADJUSTING THE THROTTLE CABLE FREE PLAY

NOTE:

Prior to adjusting the throttle cable free play, the engine idling speed should be adjusted properly.

1. Measure:

• throttle cable free play Out of specification → Adjust.

Throttle cable free play (at the flange of the throttle grip)

3 ~ 5 mm (0.12 ~ 0.20 in)

CHK

ADJ

2. Adjust:

• throttle cable free play

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Carburetor side

a. Loosen the locknut 1. b. Turn the adjusting nut 2 in direction a or

until the specified throttle cable free play

is obtained.

Direction

c. Tighten the locknut.

NOTE:

If the specified throttle cable free play cannot be obtained on the carburetor side of the cable, use the adjusting nut on the handlebar side.

Throttle cable free play is increased.

Throttle cable free play is decreased.

– 21 –

ADJUSTING THE THROTTLE CABLE FREE PLAY/

CLEANING THE SPARK ARRESTER

Handlebar side

a. Slide back the rubber cover 3. b. Loosen the locknut 4. c. Turn the adjusting nut 5 in direction c or

until the specified throttle cable free play

is obtained.

CHK

ADJ

Direction

d. Tighten the locknut.

Throttle cable free play is increased.

Throttle cable free play is decreased.

WARNING

After adjusting the throttle cable free play, start the engine and turn the handlebars to the right and to the left to ensure that this does not cause the engine idling speed to change.

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CLEANING THE SPARK ARRESTER

1. Clean:

• Spark arrester

▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼

WARNING

• Do not start the engine when cleaning the exhaust system.

• Always let the exhaust system cool before performing this operation.

a. Remove the screw 1. b. Remove the tail pipe 2 by pulling it out of

the muffler.

c. Top the tail pipe lightly, then use a wire

brush to remove any carbon deposits from the spark arrester 3 portion of the tail pipe.

d. Inser t the tail pipe into the muffler and align

the screw hole.

e. Install the screw and tighten it.

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– 22 –

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