Chassis Maintenance

Submitted by xjcdadmin on Mon, 05/10/2010 - 18:49

Fuel Petcock


If the fuel petcock is leaking or excessively contaminated, it should be removed from the fuel tank and inspected.

1.    Remove the fuel tank and position it so that fuel will not spill when the petcock is removed.

2.    Remove the petcock and inspect the filter screen. Replace the filter if seriously contaminated.

3.    Remove the screws on the front and rear of the petcock and remove the plate, gaskets, lever, and diaphragm.

  Inspect all components and replace any that are damaged. If the
diaphragm is in any way damaged, or the petcock body gasket surfaces
scratched or corroded, the petcock assembly must be replaced. If there
is abrasive damage to any component, the fuel tank must be drained and

5.    Reassemble the petcock and install it on the fuel tank.

B. Front and Rear Brake

1. Brake adjustment

Front brake lever free play adjustment. The brake can be adjusted by
simply adjusting the free play of the brake lever. The piston in the
caliper moves forward as the brake pad wears out, automatically
adjusting the clearance between the brake pads and brake disc.


Proper lever free play is essential to avoid excessive brake drag.

1. Adjuster 2. Lock nut a. 5~8 mm (0.2 ~ 0.3 in)

1)   Loosen the adjuster lock nut on the brake lever.

Turn the adjuster so that the brake lever movement at the lever end is
5- 8 mm (0.2 ~ 0.3 in) before the adjuster contacts the master cylinder

3)  After adjusting, tighten the lock nut.

b. Rear brake pedal height adjustment

1)   Loosen the adjuster lock nut (for pedal height).

 By turning the adjuster bolt clockwise or counterclockwise, adjust the
brake pedal position so that its top end is approximately 20 mm (0.78
in) below the footrest top end.

3)  Secure the adjuster lock nut.


After adjusting the pedal height, the brake pedal free play should be adjusted.

c. Rear brake pedal free play adjustment

1. Adjuster bolt

3. Footrest

(for pedal height)

4. Pedal height 20 mm [0.8 in)

2. Lock nut

5. Free play 20~ 30 mm (0.8-^ 1.2 in)

the adjuster on the brake rod clockwise or counterclockwise to provide
the brake pedal end with a free play of 20 — 30 mm (0.8-1.2 in).


Check to see whether or not the brake light operates correctly after adjusting.

2. Front brake pad and rear brake shoe

check a. Front brake pad

To check, look at the pad in front. If any pad is worn to the wear limit, replace the both pads in the caliper.


1. Wear indicator

b. Rear brake shoe

check, see the wear indicator position while depressing the brake
pedal. If the indicator reaches to the wear limit line, replace the

1. Wear limit 2. Wear indicator

3. Brake fluid

brake fluid may allow air to enter the brake system, possibly causing
the brake to become ineffective. Check the brake fluid level and
replenish when necessary observing these precautions:

1. Lower level

 Use only the designated quality brake fluid; otherwise, the rubber
seals may deteriorate, causing leakage and poor brake performance.

Recommended brake fluid: DOT #3

 Refill with the same type and brand of brake fluid; mixing fluids may
result in a harmful chemical reaction and lead to poor performance.

 Be careful that water or other contamination does not enter the master
cylinder when refilling. Water will significantly lower the boiling
point and may result in vapor lock.

d.   Brake fluid may erode painted surfaces or plastic parts. Always clean up spilled fluid immediately.

C. Tubeless Tires and Aluminum Wheels

motorcycle is equipped with aluminum wheels designed to be compatible
with either tube or tubeless tires. Tubeless tires are installed as
standard equipment.


not attempt to use tubeless tires on a wheel designed for use only with
tube-type tires. Tire failure and personal injury may results from
sudden deflation. Tube-type Wheel — Tube-type tires only Tubeless-type
Wheel — Tube-type or
Tubeless tires When using tube-type tires, be sure to install the proper tube also.

To insure maximum performance, long service, and safe operation, note the following precautions:

1.   Check tire pressure, before riding, adjust as necessary.

  Before operation, always check the tire surfaces for wear and/or
damage; look for cracks, glass, nails, metal fragments, stones, etc.
Correct any such hazard before riding.

 Always inspect the aluminum wheels before a ride. Place the motorcycle
on the center stand and check for cracks, bends or warpage of the
wheels. Do not attempt even small repairs to the wheel. If a wheel is
deformed or cracked, it must be replaced.

 Tires and wheels should be balanced whenever either one is changed or
replaced. Failure to have a wheel assembly balanced can result in poor
performance, adverse handling characteristics, and shortened tire life.

5.   After installing a tire, ride conservatively to allow
the tire to seat itself on the rim properly. Failure to allow proper
seating may cause tire failure resulting in damage to the motorcycle
and injury to the rider.

6.   After
repairing or replacing a tire, check to be sure the valve stem lock nut
is securely fastened. If not, torque it as specified.

Tightening torque:                                        

0.15 m-kg (1.1 ft-lb)

D. Front Fork Oil Change


Fork oil leakage can cause loss of stbility and safe handling. Oil may
contaminate front brakes causing loss of braking ability. Have any
problem corrected before operating the motorcycle.

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

1.    Raise
the motorcycle or remove the front wheel so that there is no weight on
the front end of the motorcycle. Remove the handlebar if necessary.

2.    Unscrew the rubber cap from the top of each fork and remove it.

1. Rubber cap

3. Keep the valve open by pressing it for several seconds so that the air can be let out of the inner tube.

4. The spring seat is retained by a stopper ring (spring wire clip). It is necessary to depress the spring seat and fork spring with a seat compresser to remove the stopper ring. Remove the stopper ring by carefully prying out one end with a screw-driver.

1.  Cap                  4. Stopper ring
2.  Valve               5. Spring seat
3. O-ring              6. O-ring

5. Place an open container under each drain hole. Remove the drain screw.


not allow oil to contact the disc brake components. If any oil should
contact the brake components it must be removed before the motorcycle
is operated. Oil will cause diminished braking capacity and will damage
the rubber components of the brake assembly.

1. Drain screw

6.   When most of oil has drained, slowly raise and lower the outer tubes to pump out the remaining oil.

7.    Inspect the drain screw gasket. Replace if damaged. Re install the drain screw.

8.    Pour the specified amount of oil into the inner tube.

Fork oil capacity: 278 cm3 (9.4 US oz)

Recommended oil: Yamaha fork oil 10 wt or equivalent

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

10. Inspect the O-ring on the spring seat. Replace O-ring if damaged.

1.  Spring seat
2.  O-ring

11. Reinstall the spring seat and fill the fork with air using a manual air pump.


Always use a new stopper ring (spring wire circlip).

Maximum air pressure: 1.2 kg/cm2 (17 psi) Do not exceed this amount.

E. Rear Shock Absorber

1. Spring preload

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

Standard position — A

A. position — Softest

E. position - Stiffest

Adjust both the right and left sides to the same position.

Compatibility chart

Recommended combinations of the front Use this table as guidance to meet specific rid-fork and the rear shock absorber.                              ing conditions and motorcycle load.


Front fork

Rear shock absorber

Loading condition

Air pressure

Spring seat

Solo rider

With passenger

With accessory equipment

With accessory equipments and passenger


0.4 — 0.8 kg/cm2 (5.7-11.4 psi)





0.4- 0.8 kg/cm2 (5.7-11.4 psi)






0-4-0.8 kg/cm2 (5.7-11.4 psi)

C- E






0.8-1.2 kg/cm2 (11.4-17.1 psi)

----------------------- .






F. Steering Head Adjustment

The steering assembly should be checked periodically for looseness.

1.    Raise the front end of the motorcycle so that there is no weight on the front wheel.

2.    Grasp the bottom of the forks and gently rock the fork assembly backward and forward, checking for looseness in the steering assembly bearings.

3.    If there is looseness in the steering head, loosen the steering stem and front fork pinch bolts and steering fitting bolt.

4.    Use a steering nut wrench to loosen top steering fitting nut. The top nut serves as a lock nut.

5.   Tighten the lower steering fitting nut until the steering head is tight, but does not bind when forks are turned.

6.    Retighten the top steering fitting nut, steering fitting bolt and steering stem and front fork pinch bolts, in that order.

7.    Recheck steering adjustment to make sure there is no binding when the forks are moved from lock to lock. If necessary, repeat adjustment procedure.

G. Cable Inspection and Lubrication


to the outer housing of the various cables, may cause corrosion and
often free movement will be obstructed. An unsafe condition may result
so replace such cables as soon as possible.

1. If the inner cables do not operate smoothly, lubricate or replace them.

Recommended lubricant:

Yamaha Chain and Cable Lube or SAE 10W/30 motor oil

H. Throttle Cable and Grip Lubrication

The throttle twist grip assembly should be greased when the cable is lubricated, since the grip must be removed to get at the end of the throttle cable. Two screws clamp the throttle housing to the handlebar. Once these two are removed, the end of the cable can be held high to pour in several drops of lubricant. With the throttle grip disassembled, coat the metal surface of the grip assembly with a suitable all-purpose grease to cut down friction.

I. Rear Arm Pivot Bearings

The swing arm must pivot freely on its bearings but not have any excess play. Check and adjust pivot bearings if necessary. (Refer to CHAPTER 5. SWING ARM).

J. Brake and Change Pedals/Brake and Clutch Levers

Lubricate the pivoting parts of each lever and pedal.

Recommended lubricant: Yamaha Chain and Cable Lube or SAE 10W/30 motor oil

K.Center and Side Stand Pivots

Lubricate the center and side stands at their pivot points.

Recommended lubricants: Yamaha Chain and Cable Lube or SAE 10W/30 motor oil