MAINTENANCE INTERVALS CHARTS

Model(s)

xjcdadmin Thu, 06/04/2009 - 12:15

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 tables
of periodic maintenance, the services related to emissions control are grouped separately.

PERIODIC MAINTENANCE EMISSION CONTROL SYSTEM

NO.	ITEM	REMARKS	INITIAL RREAK-IN		THEREAFTER EVERY
NO.	ITEM	REMARKS	1.000 km (1600 mi) or 1 month	5.000 km (3.000 mi) 7 months	4.000 km (2,500 mi) 6 months	8,000 km (5,000 mi) 12 months
1	Valve Clearance	Check and adjust valve clearance when engine is cold.		o		o
2	Spark plug	Check condition. Adjust gap. Clean. Replace after initial 13.000 km (8.000 mi) or 18 months and thereafter every 12.000 km (7.500 mi) or 18 months.		o	o	Replace every 12,000 km (7,500 mi) or 18 months
3	Crankcase Ventilation	Check ventilation hose 'or cracks or damage. Replace if necessary.		o		o
4	Fuel Line	Check fuel hose and vacuum pipe for cracks or damage. Replace if necessary.		o		o
5	Intake/Exhaust System	Check for leakage. Retighten as necessary. Replace gasket(s) if necessary.		o	o
6	Idle Speed	Check and adjust engine idle speed. Adjust cable free play if necessary.		o	o
7	Carburetor Synchronization	Adjust synchronization of carburetors.		o	o

GENERAL MAINTENANCE/LUBRICATION

NO'.	ITEM	REMARKS	TYPE	INITIAL BREAK-IN		THEREAFTER EVERY
NO'.	ITEM	REMARKS	TYPE	1,000 km (600 mi) or 1 month	5.000 km (3,000 mi) or 7 months	4,000 km (2,500 mi) or 6 months	8,000 km (5,000 mil or 12 months	16.000 km (l0,000mi) or 24 months
1	Engine Oil	Warm up engine before draining	Yamalube 4 cycle oil or SAE 2OW40 type SE motor oil	o	o	o
2 3	Oil Filter	Replace	—	o	o		o
2 3	Air Filter	Clean with compressed air.	-		o		o
4	Brake System	Adjust free play. Replace pads if necessary. (Front) Replace shoes if necessary (Rear)	-	o	o	o
5	Clutch	Adjust free play.	-	o	o	o
6	Final Gear Oil	Replace	SAE 80 API "GL-4" Hypoid gear oil	o			o
7	Control and Meter Cable	Apply chain lube thoroughly.	Y.irTidhj chain and cable lube or SAE 10W 30 motor oil	o	o	o

NOTE. 1. The air filter should be cleaned more often than at specified intervals if machine is operated in extremely dusty areas. 2- The lubrication chart must be adhered to strictly. Observe the following service hints to ensure that the oil will meet the demands placed on it by the engine.

Observe all periodic inspections as outlined. Use only the oil grade* specified. Keep the oil level at the specified level.

NO	ITEM	REMARKS	TYPE	INITIAL BREAK-IN		THEREAFTER EVERY
NO	ITEM	REMARKS	TYPE	1,000 km (600 mi) or 1 month	5.000 km (3,000 mi) or 7 months	4.000 km (2,500 mi) or 6 months	8.000 km (5,000 mi) or 12 months	16,000 km (10,000 mi) or 24 months
8.	Rear Arm Pivot Bearing	Check bearings assembly for looseness. Moderately repack every 16,000 km (10,000 mi)	Medium weight bearing grease.					Repack
9	Centre- and Side- stand Pivots	Apply lightly	Yamaha chain and cable lube or SAE 10W30 motor oil		O	o
10.	Front Fork Oil	Drain completely. Refill to specification	Yamaha fork oil 10 wt or equivalent					O
11,	Steering Ball Bearing and Race*	Check bearings assembly for looseness. Moderately repack every 16,000 km (10.000 mil	Medium weight wheel bearing grease		O	o		Repack
12.	Wheel Bearings	Check bearings for smooth rotation. Replace if necessary.	-		O	o
13.	Battery	Check specific gravity. Check breather pipe for proper operation.	-		O	o
14.	Change/ Brake Pedal shaft Pivot	Apply lightly	Yamaha chain and cable lube or SAE 10w30 motor oil		O	o
15.	AC Generator	Replace generator brushes. Replace at initial 13.000 km (8,000 mi) and thereafter every 16,000 km (10,000 mi)	-					Replace
16.	Apply lightly	Apply lightly	Yamaha chain and cable lube or SAE 10W30 motor oil		o	o