BATTERY

1.      Disconnect:
•   Negative lead (1)
•  Positive lead (2)
•  Breather hose (3)

2.      Pull:
•  Battery

3. Check:
• Fluid level

Incorrect — Refill.

Fluid level should be between upper (1) and lower (2) level marks.

Refill with distilled water only; tap water contains minerals harmful to a battery.

2.      Connect:
•   Breather hose

Be sure the hose is properly attached and routed.

3.      Inspect:
•   Breather hose Obstruction — Remove. Damage — Replace.

HOW TO ROUTE BATTERY BREATHER PIPE.

CAUTION:
Always charge a new battery before using it to ensure maximum performance.

Charging Current: 1.4 amps/10 hrs

Specific Gravity: 1.280 at 20°C(68°F)

Battery electrolyte is dangerous; it contains sulfuric acid and therefore is poisonous and highly caustic. Always follow these preventive measure:
•  Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury.
•  Wear protective eye gear when handling or working near batteries.

Antidote (EXTERNAL):
•   SKIN — Flush with water.
•   EYES — Flush with water for 15 minutes and get immediate medical attention.

Antidote (INTERNAL):
•   Drink large quantities of water or milk follow with milk of magnesia) beaten egg, or vegetable oil. Get immediate medical attention.

Batteries also generate explosive hydrogen gas, therefore, you should always follow these preventive measures:
•   Charge batteries in a well-ventilated area.
•   Keep batteries away from fire, sparks, or open flames (e.g., welding equipment, lighted cigarettes, etc.)
•   DO NOT SMOKE when charging or handling batteries.

KEEP BATTERIES AND ELECTROLYTE OUT OF REACH OF CHILDREN.

HEADLIGHT

Headlight Bulb Replacement

1.      Remove:
•   Securing screws (1) (from light unit assembly/headlight body.)

2.      Disconnect:
•   Lead wire

3.      Remove:
•   Light unit assembly

4.      Rotate:
•   Bulb holder (1) Turn it counterclockwise.

5.      Remove:
•   Defective bulb

6. Install:
• Bulb (New)

Secure with bulb holder.

•   Avoid touching glass part of bulb.
•   Keep the bulb free from oil otherwise, transparency of glass, bulb life, and illumi-nous flux will be adversely affected.
•   If oil gets on bulb, clean it with a cloth moistened thoroughly with alcohol or lacquer thinner.

Do not touch the headlight bulb when it is on, as the bulb generates enormous heat; keep flammable objects away.

7. Install:
• Light unit assembly (to headlight body.)

 

Headlight Beam Adjustment 

Horizontal adjustment:

1. Rotate:
• Horizontal adjusting screw (1)

Horizontal Adjustment of Headlight Beam
Adjusting screw	Beam direction
Turn clockwise	- to Right
Turn counterclockwise	- to Left

Vertical adjustment:

1. Rotate:
• Vertical adjusting screw (2)

Vertical Adjustment of Headlight Beam
Adjusting screw	Beam direction
Turn clockwise	1 to Raise
Turn counterclockwise	1 to Lower

FUSE

The fuse box is under the indicator light panel. The main fuse is under the seat.

(1) Main fuse
(2) Other fuse block
(3) Spare fuses

Blown fuse replacement steps.

•  Turn off ignition and the circuit.
•   Install a new fuse of proper amperage.
•  Turn on switches to verify operation of electrical device.
•   If fuse blows immediately again, check circuit in question.

Do not use fuses of higher amperage rating than recommended. Extensive electrical system damage and fire could result from substitution of a fuse of improper amperage.

Proper periodic maintenance is important. 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 engine operation and maximum performance. In the following maintenance tables, the services related to emissions control are grouped separately.

PERIODIC MAINTENANCE EMISSION CONTROL SYSTEM

ITEM	REMARKS	INITIAL ODOMETER READING
		1.000 km (600 mi) or 1 month	*#1 7.000 km (4.400 mi) or 7 months	"2 13,000 km (8,200 mi) or 13 months	19,000 km {12.000 mi) or 19 months	25,000 km [15,800 mi) or 25 months	31,000 km <19.600m or 31 months
Valve clearance	Check and adjust valve clearance when engine is cold.					o
Spark plug	Check condition. Adjust gap and clean. Replace at 13,000 km (or 13 months) and thereafter every 12,000 km (or 12 months).		o	Replace	o	Replace	o
Crankcase ventilation system	Check ventilation hose for cracks or damage. Replace if necessary.		o		o		o
Fuel line	Check fuel hose and vacuum pipe for cracks or damage. Replace if necessary.			o	o	o	o
Exhaust system	Check for leakage. Retighten if necessary. Replace gasket(s) if necessary.		o	o	o	o	o
Idle speed	Check and adjust engine idle speed. Adjust cable free play.		o	o	o	o	o
Carburetor synchronization	Adjust synchronization of carburetors.	o	o	o	o	o	o

•It is recommended that these items be serviced by a Yamaha dealer or other qualified mechanic.

NOTE:

For farther odometer reading, repeat the above maintenance at the period establish; **1: Every 6.000 km (3,800 mi) "2. Every 12,000 km (7,600 mi) intervals.

GENERAL MAINTENANCE/LUBRICATION

No.	ITEM	REMARKS	TYPE	INITIAL ODOMETER READINGS
				1,000 km (600 mi) or 1 month	**1 7,000 km (4,400 mi) or 7 months	**2  13,000 km (8,200 mi) or 13 months	**3 19,000 km (12,000 mi) or 19 months	**4 25,000 km (15.800 mi) or 25 months	31,000 km (19,600 mi or 31 months
1	Engine oil	Warm-up engine before draining.	See page 12	o	o	o	o	o	o
2	Oil filter	Replace.	—	o		o		o
3	Air filter	Clean with compressed air. Replace if necessary.	—		o	o	o	o	o
4	Brake system	Adjust free play. Replace pads if necessary. (Front) Replace shoes if necessary (Rear)		o	o	o	o	o	o
5	Clutch	Adjust free play.	—	o	o	o	o	o	o
6	Final gear oil	Check oil level and leakage. Replace every 24,000 km (15,000 mi) or 24 months.	SAE80 API GL-4 hypoid gear oil	Replace		o		Replace
7	Control and meter cable	Apply chain lube thoroughly.	Yamaha chain and cable lube or SAE 10W30 motor oil.	°	o	o	o	o	o
8	Rear arm pivot shaft	Check bearings assembly for looseness. Moderately repack every 24,000 km (15,200 mi)	Medium weight wheel bearing grease					o
9	Brake/ Clutch ever pivot shaft.	Apply chain lube lightly.	Yamaha chain and cable lube or SAE 10W30 motor oil.		o	o	o	o	o
10	Brake pedal and change pedal shaft	Lubricate Apply chain lube lightly.	Yamaha chain and cable lube or SAE 10W30 motor oil.		o	o	o	o	o
11	Center/Side stant pivots	Check operation and lubricate. Apply chain lube lightly.	Yamaha chain and cable lube or SAE 10W30 motor oil.		o	o	o	o	o
12	Front fork oil	Check operation and leakage.	—		o	o	o	o	o
13	Steering bearings	Check bearings assembly for looseness. Moderately repack every 24,000 km (15,000 mi)	Medium weight wheel bearing grease		O	o	o	o	o
14	Wheel bearings	Check bearings for smooth rotation.	—		o	o	O	o	o
15	Battery	Check specific gravity and breather pipe for proper operation.	—		o	o	o	o	o
16	A.C. Generator	Replace generator brushes.				o		o
17	Sidestand switch	Check and clean or replace if necessary.		O	o	o	o	o	o

■ it is recommended that these items be serviced by a Yamaha Dealer or other qualified mechanic.

NOTE:

For greater odometer readings repeat the above maintenance at the period established, IE: **1: Every 6,000 km (3,800 mi), **2: Every 12,000 km (7,600 mi), **3: Every 18,000 km (11,400 mi), **4: Every, 24,000 km (15,200 mi) intervals.

 

Contents of Engine Maintenance:

 

FINAL GEAR OIL

Oil Level Measurement

1. Place the motorcycle on a level area and place on its centerstand. 

2 Remove:
•  Oil filler cap 

3. Observe:
•  Oil level (2)

Low level— Add oil. (1) Oil

NOTE:
Oil level must be up to the brim of the filler hole.

CAUTION:
Be sure that no foreign material enters the final gear case.

Gear Oil Replacement

1.      Place a receptacle under the final gear case.

2.      Remove:
•  Filler cap
•  Drain plug (1) Drain final gear oil.

3.      Install:
•  Drain plug

23 Nm (2.3 m-kg, 17ftlb)

4. Fill
• Gear case (to specified level.)

Final Gear oil:
SAE80 API "GL-4" Hypoid

gear oil Oil Capacity:
0.20 / (0.18 imp qt, 0.21 qt)

NOTE:
If desired, an SAE 80W90 Hypoid gear oil may be used for all conditions.

5. Install:
• Filler cap

23 Nm (2.3 m-kg, 17 ft-lb)

 

AIR FILTER

1.      Remove:
•  Seat
•  Fuel tank
•   Rubber cover

2.      Remove:
•  Air filter cover (1)

3.      Eliminate:
•   Dust

Use compressed air

4.      Inspect:
•   Element Damage - Replace.

CAUTION:
The engine should never be run without the air/filter element installed; excessive piston and/or cylinder wear may result.

5. Install:
• Element

CAUTION:
Make sure the element cover fits into the corresponding filter case edge.

FRONT BRAKE

 Brake Fluid Inspection

1. Check:
• Brake fluid level

Level low — Replenish.

NOTE:
Use only a designated, quality fluid.

DOT NO. 3

NOTE:

Be sure that:
•  Water does not enter the master cylinder when refilling.
•   Spilled fluid is cleaned up immediately to prevent painted surfaces or plastic parts from eroding.

(1) Lower level

FRONT BRAKE/REAR BRAKE

Front Brake Lever Free Play Adjustment

1.      Loosen:
•  Adjuster lockout (1)

2.      Adjust:
•  Free play (3)

Turn the adjuster (2) until the free play (3) is within the specified limits.

Brake Lever Free Play:

2-5 mm (0.08 ~ 0.2 in)

CAUTION:
Proper level free play is essential to avoid excessive brake drag.

3. Tighten:
• Adjuster locknut

Brake Pad Inspection

1.      Activate the brake lever

2.      Inspect:
• Wear indicator (1) Indicator almost contacts disc (2) — Replace pads. Refer to CHAPTER 5, "CHASSIS."

REAR BRAKE

Rear Brake Pedal Height Adjustment

1.     Loosen:
•  Adjust locknut (1) .

2.      Adjust:
•   Brake pedal height (2).

Turn the adjuster (3) until the brake pedal position is at the specified height.

Brake Pedal Height: 10 mm (0.4 in) Below the Top of the Footrest

Adjust pedal height, then adjust brake pedal free play.

REAR BRAKE

Rear Brake Shoe Inspection

1.      Depress brake pedal

2.      Inspect:
• Wear indicator (2)

Indicator at wear limit line — Replace brake shoes.

(1) Wear limit line

Rear Brake Pedal Free Play Adjustment

1. Rotate:
• Adjuster nut (1)

Turn it clockwise or counterclockwise until proper brake pedal free play is attained.

Brake Pedal Free Play:
20-30 mm (0.8 -1.2 in)

Check to verify correct brake light operation after adjustment.

Brake Light Switch Adjustment

1. Hold the switch body (1) with your hand so that it does not rotate and turn the adjusting nut (2) .

CABLE INSPECTION AND LUBRICATION

Cable inspection and lubrication steps:
•   Remove the two screws that secure throttle housing to handlebar.
•   Hold cable end high and apply several drops of lubricant to cable.
•   Coat metal surface of disassembled throttle twist grip with suitable all-purpose grease to minimize friction.
•  Check for damage to cable insulation. Replace any corroded or obstructed cables.
•  Lubricate any cables that do not operate smoothly.

SAE 10W30 Motor Oil

 

BRAKE AND CHANGE PEDALS/ BRAKE CLUTCH LEVERS

Lubricate pivoting parts of each lever and pedal.

CENTERSTAND AND SIDESTAND

Lubricate centerstand and sidestand at their pivot points.

SAE 10W30 Motor Oil

FRONT FORK OIL CHANGE

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

1.     Place a suitable stand under the engine to raise the front wheel off the ground.

2.     Loosen:
•  Inner tube pinch bolt (1)

3.     Remove:
•  Fork cap (2)
•  Cap bolt (3)

Use the Front Fork Cap Socket (YM-01104) (4)

4. Remove:

• Drain screw (1) Drain the fork oil.

Do not allow any oil to contact the disc brake components. If oil is discovered, be sure to remove it, otherwise diminished braking capacity and damage to the rubber components of the brake assembly will occur.

7.      Inspect:
•  O-ring (1) (Cap-bolt)
•  Gasket (Drain screw) Wear/Damage — Replace.

8.      Install:
•   Drain screw

9.      Fill:
•  Front fork

Each Fork:
383cm³(13.51 impoz, 12.95 USoz)

After filling pump the forks slowly up and down to distribute the oil. 

10. Tighten:
•  Cap-bolt
•   Pinch bolt

Cap Bolt: 23 Nm (2.3 rrvkg, 17ftlb) 
Pinch Bolt: 20 Nm (2.0 mkg, 14ft-lb)

11. Install:
• Fork cap

 

REAR SHOCK ABSORBER ADJUSTMENT

If the spring seat is raised, the spring becomes stiffer, and if lowered, it becomes softer.

Standard Position: B      A. — Softest (1) E. — Stiffest (2)

Always adjust each shock absorber to the same setting. Uneven adjustment can cause poor handling and loss of stability.

 

 

STEERING HEAD ADJUSTMENT

Steering Head Inspection

1.      Place the motorcycle on its centerstand, then elevate the front wheel.

2.      Check:
• Steering assembly bearings

Grasp the bottom of the forks and gently rock the fork assembly back and forth. Looseness — Adjust.

Adjustment

Steering head adjustment steps: 
•   Remove the handlebar securing bolts (1)
•   Remove the handlebars .
•   Remove the steering stem nut (2)
•   Loosen the pinch bolts (3) .
•   Remove the steering crown (4) .
•   Remove the lock washer (5) .
•   Loosen the ring nut (6) ,
•   Tighten the ring nut (7) .

Ring Nut (Lower):
50 Nm (5.0 m-kg, 36 ft-lb)

The tapered side of ring nuts must face downward.

• Loosen the ring nut (7) completely and retighten it to specification.

Ring Nut (Lower):
6Nm(0.6 m-kg,4.3ft-lb)

•   Check the steering stem by turning it lock to lock. If there is any binding, remove the steering stem assembly and inspect the steering bearings 8 .

(See CHAPTER 5, STEERING HEAD for more details.)

•   Hand-tighten the ring nut (6) , then align the slots of both ring nuts. If not aligned, hold the lower ring nut (7) and tighten the other until they are aligned.

•   Install the lock washer (5) .

NOTE:
Make sure the lock washer tab is placed in the slots.

• Install the steering crown (4) and tighten the steering stem nut (2) to specification.

Steering Stem Nut:
110 Nm (11.0 m-kg, 80 ft*]

• Install the handlebar and torque the bolt 0 to specification.

Pinch Bolt: 20Nm(2.0m-kg, 14ft-lb) 
Handlebar Bolt: 20 Nm (2.0 m-kg, 14 ft-lb)

 

 

WHEEL BEARINGS 

 

Front Wheel Bearings

1. Raise the front end of the motorcycle, and spin the wheel by hand. Touch the axle or front fork while spinning the wheel-Excessive vibration — Replace bearings.

Rear Wheel Bearings

1.      Remove: 
•   Rear wheel

2.      Check:
•   Bearing movement Rotate with the fingers. Roughness/Wear — Replace.

 

 

TUBELESS TIRES AND ALUMINUM WHEELS

•   Always inspect aluminum wheels before a ride.
•   Place the motorcycle on its centerstand and check for cracks, bends, or warpage of the wheels.
•   Do not attempt any repairs to the wheel; replace any defective wheel.
•   Do not attempt to use tubeless tires on a wheel designed for use with tube-type tire only. Tire failure and subsequent personal injury may result from sudden deflation.
•   Be sure to install the proper tube when using tube-type tires.
•   New tires have a relatively poor adhesion on the road surface so do not allow them to be subjected to high speed load from maximum speed until after a break-in run of approx. 100 km (60 mi).
•   Always use the correct tire inflation pressure acording to the operating conditions.

Wheel	Tire
Tube type	Tube type only
Tubeless	Tube type or tubeless

A Tire	C Tubeless tire
B Wheel	D Tube type tire

(1)  Air valve
(2)  Aluminum wheel (Tubeless type)
(3)  Tube
(4)  Aluminum wheel (tube type)

Always perform the following steps to ensure safe operation, maximum tire performance, and long service. 1. Measure:

• Tire pressure Out of specification — Adjust.

Basic weight: With oil and full fuel tank	224 kg (494 lb)
Maximum load *	246 kg	542 lb)
Cold tire pressure	Front	Rear
Upto90kg(198lb) load"	177 kPa (1.8 kg/cm2. 26 psi)	196 kPa (2.0 kg/cm2. 28 psi)
90 kg (198 lb) load ~ 246 kg (542 lb) load-	196 kPa (2.0 kg/cm*, 28 psi)	275 kPa (2.8 kg/cm2. 40 psi)
High speed riding	206 kPa (2.1 kg/cm? 30 psi)	225 kPa (2.3 kg/cm2 32 psi)

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

2. Inspect:

• Tire surfaces Wear/Damage — Replace.

Minimum Tire Tread Depth: (Front and Rear) 1.0 mm (0.04 in)

(1) Tread depth

(2)  Side wall

(3) Wear indicator

3. Inspect:
• Aluminum wheels 
Damage/Bends — Replace. Never attempt even small repairs to the wheel.

NOTE:
Always balance the wheel when a tire or wheel has been changed or replace.

Ride conservatively after installing a tire to allow it to seat itself properly on the rim.