Introduction and Intervals

Submitted by xjcdadmin on Fri, 06/18/2010 - 01:46

Model(s)

INTRODUCTION

This chapter includes all information necessary to perform recommended inspection and adjustments. These preventative maintenance procedures, if followed, will insure more reliable vehicle operation and a longer service life. The need for costly overhaul work will be greatly reduced. This information applies not only to vehicles already in service, but also to new vehicles that are being prepared for sale. Any service technician performing preparation work should be familiar with this entire chapter.

MAINTENANCE INTERVALS CHARTS

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 break-in		Thereafter every
No.	Item	Remarks	1,000 km (600 mil 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
1*	Cam chain	Adjust chain tension.	o	0		O
2*	Valve clearance	Check and adjust valve clearance when engine is cold.		o		O
3	Spark plugs	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
4*	Crankcase ventilation system	Check ventilation hose for cracks or damage. Replace if necessary.		o		o
5*	Fuel line	Check fuel hose and vacuum pipe for cracks or damage. Replace if necessary.		o		O
6"	Exhaust system	Check for leakage. Retighten as necessary. Replace gasket(s) if necessary.		o	O
7'	Carburetor synchronization	Adjust synchronization of carburetors.		o	O
8'	Idle speed	Check and adjust engine idle speed. Adjust cable free play if necessary.		o	o

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

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 km) or 12 months	16.000 km (10,000 mi) or 24 months
1	Engine oil	Warm-up engine before draining.	Refer to page 2-9.	O	O	O
2	Oil filter	Replace.	-	o	O		O
3	Air filter	Clean with compressed air.	-		O		O
4*	Brake system	Adj uSt free play Front: Replace pads if necessary. Rear: Replace shoes if necessary.	-	O	o	0
5"	Clutch	Adjust free play	-	o	o	o
6	Drive chain	Check chain condition. Adjust and lubricate chain thoroughly.	Yamaha chain and cable lube or SAE 10W/30 motor oil	CHECK CHAIN TENSION AND LUBE EVERY 500 km (300 mi).
7*	Control and meter cable	Apply chain lube thoroughly.	Yamaha chain and cable lube or SAE 10W/30 motor oil	O	o	o
8	A.C. generator	Replace generator brushes. Replace at initial 13.000 km (8,000 mil and thereafter every 16.000 km 110,000 mi)						Replace
9	Brake/clutch lever pivot shaft	Apply chain lube lightly.	Yamaha chain and cable lube or 10W/ 30 motor oil		o	o
10	Change/Brake pedal shaft pivot	Apply chain lube lightly.	Yamaha chain and cable lube or 10W/ 30 motor oil		o	o
11	Center and side stand pivots	Apply chain lube lightly.	Yamaha chain and cable lube or 10W/ 30 motor oil		0	o
12	Front fork oil	Drain completely. Refill to specification.	Yamaha fork oil 10 wt or equivalent					O
13	Steering Ball Bearing and races	Check bearings assembly for looseness. Moderately repack every 16,000 km (10,000 mi).	Medium weight wheel bearing grease		o	o		Repack
14	Wheel bearings	Check bearings for smooth rotation, Replace if necessary.	_		o	o
15	Battery	Check specific gravity. Check breather pipe for proper operation.	-		o	0

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

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