Yamaha AG200FZ Owner'S Manual Download

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TABLE OF CONTENTS

LOCATION OF IMPORTANT
LABELS

............................................. 1-1

SAFETY INFORMATION

.................. 2-1

DESCRIPTION

.................................. 3-1

Left view .......................................... 3-1
Right view ........................................ 3-2
Controls and instruments................. 3-3

INSTRUMENT AND CONTROL
FUNCTIONS

....................................... 4-1

“

”

............... 4-7

Kickstarter ....................................... 4-8
Seat ................................................ 4-8
Adjusting the shock absorber

assembly ..................................... 4-9

Front and rear carriers .................. 4-10
Sidestands .................................... 4-11
Starting circuit cut-off system ....... 4-11

Auxiliary DC jack .......................... 4-13

FOR YOUR SAFETY –
PRE-OPERATION CHECKS

............. 5-1

OPERATION AND IMPORTANT
RIDING POINTS

................................. 6-1

Starting and warming up a cold

engine ......................................... 6-1

Starting a warm engine .................. 6-2
Shifting ........................................... 6-2
Tips for reducing fuel

consumption ............................... 6-3

Engine break-in .............................. 6-3
Parking ........................................... 6-4

PERIODIC MAINTENANCE AND
ADJUSTMENT

................................... 7-1

Owner’s tool kit ............................... 7-1
Periodic maintenance chart for the

emission control system ............. 7-3

General maintenance and

lubrication chart .......................... 7-4

Removing and installing panels  .....  7-7
Checking the spark plug .................  7-8
Engine oil and oil filter element  ......  7-9
Cleaning the air filter element  ......  7-12
Adjusting the carburetor  ...............  7-13
Adjusting the engine idling

speed ........................................ 7-13

Adjusting the throttle cable free

play ........................................... 7-14

Valve clearance  ...........................  7-15
Tires .............................................  7-15
Spoke wheels  ..............................  7-16
Adjusting the clutch lever free

play ........................................... 7-17

Adjusting the brake lever free

play ........................................... 7-18

Adjusting the brake pedal position

and free play ............................. 7-19

Checking the shift pedal .............. 7-20
Brake light switches ..................... 7-21
Checking the front and rear brake

shoes ........................................ 7-21

Drive chain slack .......................... 7-22
Cleaning and lubricating the drive

chain ......................................... 7-23

Checking and lubricating the

cables ....................................... 7-24

Checking and lubricating the

throttle grip and cable ............... 7-24

Checking and lubricating the

brake and clutch levers ............. 7-24

Checking and lubricating the

brake pedal ............................... 7-25

Checking and lubricating the

sidestands ................................ 7-25

Lubricating the rear suspension ...  7-25
Checking the front fork .................  7-26
Checking the steering  ..................  7-26

✼✦✰✥✣✲✣ ✤

Summary of Contents for AG200FZ

Page 1: ...OWNER S MANUAL 53C 28199 20 AG200FZ ...

Page 2: ...Read this manual carefully before operating this vehicle This manual should stay with this vehicle if it is sold EAU46090 Q ...

Page 3: ...rs from trouble and injury In addition the many tips given in this manual will help keep your motorcycle in the best possible condition If you have any further questions do not hesitate to contact your Yamaha dealer The Yamaha team wishes you many safe and pleasant rides So remember to put safety first Yamaha continually seeks advancements in product design and quality Therefore while this manual ...

Page 4: ...personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death A WARNING indicates a hazardous situation which if not avoided could result in death or serious injury A NOTICE indicates special precautions that must be taken to avoid damage to the vehicle or other property A TIP provides key information to make procedures easier or clearer WARNING NOTICE ...

Page 5: ...U10200 AG200FZ OWNER S MANUAL 2009 by Yamaha Motor Co Ltd 1st edition December 2009 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan ...

Page 6: ...7 1 Periodic maintenance chart for the emission control system 7 3 General maintenance and lubrication chart 7 4 Removing and installing panels 7 7 Checking the spark plug 7 8 Engine oil and oil filter element 7 9 Cleaning the air filter element 7 12 Adjusting the carburetor 7 13 Adjusting the engine idling speed 7 13 Adjusting the throttle cable free play 7 14 Valve clearance 7 15 Tires 7 15 Spok...

Page 7: ...ulb 7 31 Replacing a turn signal light bulb 7 31 Supporting the motorcycle 7 32 Front wheel 7 32 Rear wheel 7 34 Troubleshooting 7 36 Troubleshooting chart 7 37 MOTORCYCLE CARE AND STORAGE 8 1 Matte color caution 8 1 Care 8 1 Storage 8 3 SPECIFICATIONS 9 1 CONSUMER INFORMATION 10 1 Identification numbers 10 1 Motorcycle noise regulation for Australia 10 2 ...

Page 8: ...l of the labels on your vehicle They contain important information for safe and proper operation of your vehicle Never remove any labels from your vehicle If a label becomes difficult to read or comes off a replacement label is available from your Yamaha dealer 1 2 3 ...

Page 9: ...te il manuale di istruzioni Lire le manuel du propriétaire avant d utiliser ce véhicule Lesen Sie die Bedienungsanleitung bevor Sie dieses Fahrzeug fahren Antes de conducir este vehículo lea el Manual del Propietario follows FRONT REAR 3GX 21668 00 Cold tire normal pressure should be set as 125 kPa 1 25 kgf cm2 18 psi 150 kPa 1 50 kgf cm2 22 psi 3 1 2 ...

Page 10: ...is il legal to operate it on public streets roads or highways even a dirt or gravel one Off road use on public lands may be illegal Please check local regulations before riding This motorcycle is designed to car ry the operator only No passen gers The failure of motorists to detect and recognize motorcycles in traf fic is the predominating cause of automobile motorcycle accidents Many accidents ha...

Page 11: ...an accident Always wear protective clothing that covers your legs ankles and feet The engine or exhaust sys tem become very hot during or af ter operation and can cause burns Avoid Carbon Monoxide Poisoning All engine exhaust contains carbon monoxide a deadly gas Breathing car bon monoxide can cause headaches dizziness drowsiness nausea confu sion and eventually death Carbon Monoxide is a colorles...

Page 12: ...rcycle Carefully inspect the accessory before using it to make sure that it does not in any way reduce ground clearance or cornering clearance limit suspen sion travel steering travel or con trol operation or obscure lights or reflectors Accessories fitted to the handle bar or the front fork area can create instability due to improper weight distribution If accesso ries are added to the handlebar ...

Page 13: ...2 3 4 5 6 7 8 9 DESCRIPTION EAU10410 Left view 1 2 3 4 5 6 1 Headlight page 7 30 2 Fuel cock page 4 6 3 Main fuse page 7 29 4 Owner s tool kit page 7 1 5 Air filter element page 7 12 6 Shift pedal page 4 4 ...

Page 14: ... EAU10420 Right view 1 3 4 5 6 2 1 Shock absorber assembly spring preload adjusting ring page 4 9 2 Engine oil filter element page 7 9 3 Brake pedal page 4 4 4 Kickstarter page 4 8 5 Battery page 7 27 6 Auxiliary DC jack fuse page 7 29 ...

Page 15: ... 10 1 Clutch lever page 4 3 2 Left handlebar switches page 4 2 3 Speedometer unit page 4 2 4 Auxiliary DC jack page 4 13 5 Starter choke knob page 4 7 6 Right handlebar switches page 4 2 7 Brake lever page 4 4 8 Throttle grip page 7 14 9 Main switch page 4 1 10 Fuel tank cap page 4 5 ...

Page 16: ...be started The key cannot be removed EAU45751 OFF All electrical systems are off The key can be removed WARNING EWA10072 Never turn the key to OFF while the vehicle is moving otherwise the electrical systems will be switched off which may result in loss of con trol or an accident EAU11010 Indicator light EAU11070 Neutral indicator light NEUTRAL This indicator light comes on when the transmission i...

Page 17: ...ch Set this switch to for the high beam and to for the low beam EAU12460 Turn signal switch To signal a right hand turn push this switch to To signal a left hand turn push this switch to When re leased the switch returns to the center position To cancel the turn signal lights push the switch in after it has re turned to the center position 1 Speedometer 2 Odometer 1 2 1 Light switch 2 Dimmer switc...

Page 18: ...e starter See page 6 1 for start ing instructions prior to starting the en gine EAU35000 Clutch lever The clutch lever is located at the left handlebar grip To disengage the clutch pull the lever toward the handle bar grip To engage the clutch release the lever The lever should be pulled rapidly and released slowly for smooth clutch operation The clutch lever is equipped with a clutch switch which...

Page 19: ...e gears of the 5 speed con stant mesh transmission equipped on this motorcycle EAU12890 Brake lever The brake lever is located at the right handlebar grip To apply the front brake pull the lever toward the handle bar grip EAU12941 Brake pedal The brake pedal is on the right side of the motorcycle To apply the rear brake press down on the brake pedal 1 Shift pedal 1 1 Brake lever 1 1 Brake pedal 1 ...

Page 20: ...ever refuel while smoking or while in the vi cinity of sparks open flames or other sources of ignition such as the pilot lights of water heaters and clothes dryers 2 Do not overfill the fuel tank Stop filling when the fuel reaches the bottom of the filler tube Because fuel expands when it heats up heat from the engine or the sun can cause fuel to spill out of the fuel tank 3 Wipe up any spilled fu...

Page 21: ...e with a research octane number of 91 or higher If knocking or pinging oc curs use a gasoline of a different brand or premium unleaded fuel Use of un leaded fuel will extend spark plug life and reduce maintenance costs EAU13561 Fuel cock The fuel cock supplies fuel from the tank to the carburetor while filtering it al so The fuel cock has three positions OFF With the lever in this position fuel wi...

Page 22: ... Fill the tank at the first oppor tunity Be sure to set the lever back to ON after refueling EAU13600 Starter choke knob Starting a cold engine requires a richer air fuel mixture which is supplied by the starter choke Move the knob in direction a to turn on the starter choke Move the knob in direction b to turn off the starter choke 1 Arrow mark positioned over ON 1 Arrow mark positioned over RES ...

Page 23: ... pri mary kickstarter allowing the engine to be started in any gear if the clutch is disengaged However shifting the transmission into the neutral position before starting is recommended EAU14001 Seat To remove the seat 1 Remove panels A and B See page 7 7 2 Remove the bolts and pull the seat off To install the seat 1 Insert the projections on the front of the seat into the seat holders as shown 1...

Page 24: ...ing preload and thereby harden the suspension turn the adjusting ring in direction a To de crease the spring preload and thereby soften the suspension turn the adjust ing ring in direction b Align the appropriate notch in the adjusting ring with the position in dicator on the shock absorber Use the special wrench included in the owner s tool kit to make the ad justment WARNING EWA10221 This shock ...

Page 25: ...e Do not deform or damage the cylinder in any way Cylinder damage will result in poor damping performance Do not dispose of a damaged or worn out shock absorber as sembly yourself Take the shock absorber assembly to a Yamaha dealer for any service EAU15132 Front and rear carriers WARNING EWA11341 Do not exceed the load limits of 2 kg 4 lb for the front carrier and 10 kg 22 lb for the rear carrier ...

Page 26: ... stay up otherwise the sidestands could contact the ground and distract the operator re sulting in a possible loss of control EAU15391 Starting circuit cut off system The starting circuit cut off system com prising the clutch switch and the neutral switch prevents starting when the transmission is in gear and the clutch lever is not pulled Periodically check the operation of the starting circuit c...

Page 27: ...orking correctly The motorcycle should not be ridden until checked by a Yamaha dealer 5 Turn the engine off 6 Shift the transmission into gear 7 Keep the clutch lever pulled 8 Push the start switch Does the engine start The clutch switch may not be working correctly The motorcycle should not be ridden until checked by a Yamaha dealer NO YES The system is OK The motorcycle can be ridden YES NO If a...

Page 28: ...e used when the key is in the ON position and should only be used when the engine is running Refer to the following chart for correct usage Amperage chart To use the auxiliary DC jack 1 Turn the key to OFF 2 Remove the dust cap from the re ceptacle 3 Insert the accessory plug into the receptacle and secure it with the screw on cap 4 Turn the key to ON and then start the engine See page 6 1 5 When ...

Page 29: ... Yamaha dealer Before using this vehicle check the following points ITEM CHECKS PAGE Fuel Check fuel level in fuel tank Refuel if necessary Check fuel line for leakage 4 5 Engine oil Check oil level in engine If necessary add recommended oil to specified level Check vehicle for oil leakage 7 9 Front brake Check operation Lubricate cable if necessary Check lever free play Adjust if necessary 7 18 7...

Page 30: ...7 16 Shift pedal Make sure that operation is smooth Correct if necessary 7 20 Brake pedal Make sure that operation is smooth Lubricate pedal pivoting point if necessary 7 25 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 7 24 Sidestands Make sure that operation is smooth Lubricate pivot if necessary 7 25 Chassis fasteners Make sure that all ...

Page 31: ...t the transmission into the neu tral position See page 6 2 The neutral indicator light should come on If not ask a Yamaha dealer to check the electrical circuit 4 Turn the starter choke on and completely close the throttle See page 4 7 5 Start the engine by pushing the start switch or by pushing the kick starter lever down If the engine fails to start by push ing the start switch release the switc...

Page 32: ...on into the neu tral position press the shift pedal down repeatedly until it reaches the end of its travel and then slightly raise it NOTICE ECA10260 Even with the transmission in the neutral position do not coast for long periods of time with the engine off and do not tow the motorcycle for long dis tances The transmission is properly lubricated only when the engine is running Inade quate lubrica...

Page 33: ... 1600 km 1000 mi For this reason you should read the follow ing material carefully Since the engine is brand new do not put an excessive load on it for the first 1600 km 1000 mi The various parts in the engine wear and polish themselves to the correct operating clearances During this period prolonged full throt tle operation or any condition that might result in engine overheating must be avoided ...

Page 34: ... lever to OFF WARNING EWA10311 Since the engine and exhaust system can become very hot park in a place where pedestri ans or children are not likely to touch them and be burned Do not park on a slope or on soft ground otherwise the vehicle may overturn increasing the risk of a fuel leak and fire Do not park near grass or other flammable materials which might catch fire ...

Page 35: ...0321 Failure to properly maintain the ve hicle or performing maintenance ac tivities incorrectly may increase your risk of injury or death during service or while using the vehicle If you are not familiar with vehicle ser vice have a Yamaha dealer perform service WARNING EWA15121 Turn off the engine when performing maintenance unless otherwise specified A running engine has moving parts that can c...

Page 36: ... you in the performance of preventive maintenance and minor repairs How ever additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly TIP If you do not have the tools or experi ence required for a particular job have a Yamaha dealer perform it for you ...

Page 37: ...sterisk should be performed by a Yamaha dealer as they require special tools data and technical skills EAU46920 Periodic maintenance chart for the emission control system NO ITEM CHECK OR MAINTENANCE JOB ODOMETER READING ANNUAL CHECK 1000 km 600 mi 6000 km 3500 mi 12000 km 7000 mi 18000 km 10500 mi 24000 km 14000 mi 1 Fuel line Check fuel hoses for cracks or damage 2 Spark plug Check condition Cle...

Page 38: ...ake Check operation and adjust brake pedal free play Replace brake shoes Whenever worn to the limit 5 Wheels Check runout spoke tightness and for damage Tighten spokes if necessary 6 Tires Check tread depth and for damage Replace if necessary Check air pressure Correct if necessary 7 Wheel bearings Check bearing for looseness or damage 8 Swingarm Check operation and for excessive play Lubricate wi...

Page 39: ...rease 14 Clutch lever pivot shaft Lubricate with lithium soap based grease 15 Sidestands Check operation Lubricate 16 Front fork Check operation and for oil leakage 17 Shock absorber assembly Check operation and shock absorber for oil leakage 18 Engine oil Change Check oil level and vehicle for oil leakage 19 Engine oil filter ele ment Clean 20 Engine oil strainer Clean 21 Front and rear brake swi...

Page 40: ...rottle grip hous ing and cable Check operation and free play Adjust the throttle cable free play if necessary Lubricate the throttle grip housing and cable 24 Lights signals and switches Check operation Adjust headlight beam NO ITEM CHECK OR MAINTENANCE JOB ODOMETER READING ANNUAL CHECK 1000 km 600 mi 6000 km 3500 mi 12000 km 7000 mi 18000 km 10500 mi 24000 km 14000 mi ...

Page 41: ...d to perform some of the maintenance jobs described in this chapter Refer to this section each time a panel needs to be removed and installed EAU19301 Panels A and B To remove one of the panels Pull the panel off as shown To install the panel Place the panel in the original position 1 Panel A 1 1 Panel B 1 Panel A 1 1 1 Panel B 1 ...

Page 42: ...ound the center electrode of the spark plug is a medium to light tan the ideal color when the vehicle is ridden normally TIP If the spark plug shows a distinctly dif ferent color the engine could be oper ating improperly Do not attempt to diagnose such problems yourself In stead have a Yamaha dealer check the vehicle 2 Check the spark plug for elec trode erosion and excessive car bon or other depo...

Page 43: ...d it in an upright posi tion A slight tilt to the side can result in a false reading 2 Start the engine warm it up for several minutes and then turn it off 3 Wait a few minutes until the oil set tles and then check the oil level through the check window located at the bottom right side of the crankcase TIP The engine oil should be between the minimum and maximum level marks 4 If the engine oil is ...

Page 44: ...is not being cleaned 4 Remove the oil filter element drain bolt to drain the oil from the oil filter element 5 Remove the oil filter element cover by removing the bolts 6 Remove the oil filter element and O rings 1 Engine oil filler cap 1 Engine oil drain bolt 1 1 1 Engine oil drain bolt 2 O ring 3 Compression spring 4 Oil strainer 1 2 3 4 1 Oil filter element cover bolt 2 Oil filter element drain...

Page 45: ...s after the engine and exhaust sys tem have cooled down NOTICE ECA11620 In order to prevent clutch slip page since the engine oil also lubricates the clutch do not mix any chemical additives Do not use oils with a diesel speci fication of CD or oils of a high er quality than specified In addition do not use oils labeled ENERGY CONSERVING II or higher Make sure that no foreign mate rial enters the ...

Page 46: ...f the air filter case 4 Remove the sponge material from the air filter element frame 5 Clean the sponge material with solvent and then squeeze the re maining solvent out 6 Apply oil of the recommended type to the entire surface of the sponge material and then squeeze the ex cess oil out TIP The sponge material should be wet but not dripping 7 Install the sponge material onto the frame 8 Insert the...

Page 47: ...intenance NOTICE ECA10550 The carburetor has been set and ex tensively tested at the Yamaha fac tory Changing these settings without sufficient technical knowl edge may result in poor perfor mance of or damage to the engine EAU21362 Adjusting the engine idling speed The engine idling speed must be checked and if necessary adjusted as follows at the intervals specified in the periodic maintenance a...

Page 48: ...f necessary adjust it as follows TIP The engine idling speed must be cor rectly adjusted before checking and ad justing the throttle cable free play 1 Slide the rubber cover back 2 Loosen the locknut 3 To increase the throttle cable free play turn the adjusting nut in direc tion a To decrease the throttle cable free play turn the adjusting nut in direction b 4 Tighten the locknut and then slide th...

Page 49: ...ide WARNING EWA10441 Operation of this vehicle with im proper tire pressure may cause se vere injury or death from loss of control The tire air pressure must be checked and adjusted on cold tires i e when the temperature of the tires equals the ambient temperature The tire air pressure must be ad justed in accordance with the riding speed and with the total weight of rider cargo and ac cessories a...

Page 50: ...essary professional knowl edge and experience It is not recommended to patch a punctured tube If unavoid able however patch the tube very carefully and replace it as soon as possible with a high quality product EAU21941 Spoke wheels WARNING EWA10610 The wheels on this model are not de signed for use with tubeless tires Do not attempt to use tubeless tires on this model To maximize the performance ...

Page 51: ... To increase the clutch lever free play turn the adjusting bolt in di rection a To decrease the clutch lever free play turn the adjusting bolt in direction b TIP If the specified clutch lever free play could be obtained as described above skip steps 4 7 4 Fully turn the adjusting bolt at the clutch lever in direction a to loos en the clutch cable 5 Loosen the locknut at the crank case 6 To increas...

Page 52: ...brake lever free play turn the adjusting bolt in di rection a To decrease the brake lever free play turn the adjusting bolt in direction b 4 If the specified brake lever free play could be obtained as de scribed above tighten the locknut and skip the rest of the procedure otherwise proceed as follows 5 Fully turn the adjusting bolt at the brake lever in direction a to loos en the brake cable 6 Loo...

Page 53: ...e pedal should be positioned approximately 10 0 mm 0 39 in below the top of the footrest Periodically check the brake pedal po sition and if necessary adjust it as fol lows 1 Loosen the locknut at the brake pedal 2 To raise the brake pedal turn the adjusting bolt in direction a To lower the brake pedal turn the ad justing bolt in direction b 3 Tighten the locknut WARNING EWA11230 After adjusting t...

Page 54: ...ing nut in direction b WARNING EWA10680 After adjusting the drive chain slack or removing and installing the rear wheel always check the brake pedal free play If proper adjustment cannot be obtained as described have a Yamaha dealer make this ad justment After adjusting the brake pedal free play check the operation of the brake light EAU44820 Checking the shift pedal The operation of the shift ped...

Page 55: ...justing nut in direction b EAU22361 Checking the front and rear brake shoes Front Rear The front and rear brake shoes must be checked for wear at the intervals spec ified in the periodic maintenance and lubrication chart Each brake is provid ed with a wear indicator which allows you to check the brake shoe wear with out having to disassemble the brake To check the brake shoe wear check the positio...

Page 56: ...al position 3 Remove the drive chain slack check hole cap 4 Spin the rear wheel several times to locate the tightest portion of the drive chain 5 Measure the drive chain slack as shown 6 If the drive chain slack is correct install the check hole cap If the drive chain slack is incorrect ad just it as follows EAU35022 To adjust the drive chain slack 1 Loosen the brake pedal free play adjusting nut ...

Page 57: ...ARNING EWA10660 After adjusting the brake pedal free play check the operation of the brake light EAU23016 Cleaning and lubricating the drive chain The drive chain must be cleaned and lubricated at the intervals specified in the periodic maintenance and lubrica tion chart otherwise it will quickly wear out especially when riding in dusty or wet areas Service the drive chain as follows NOTICE ECA105...

Page 58: ... cause the in ner cable to rust Replace a damaged cable as soon as possible to prevent unsafe conditions EWA10721 EAU23112 Checking and lubricating the throttle grip and cable The operation of the throttle grip should be checked before each ride In addi tion the cable should be lubricated by a Yamaha dealer at the intervals speci fied in the periodic maintenance chart EAU43611 Checking and lubrica...

Page 59: ... be lubricated if necessary WARNING EWA10731 If the sidestand does not move up and down smoothly have a Yamaha dealer check or repair it Otherwise the sidestand could contact the ground and distract the operator re sulting in a possible loss of control EAU23251 Lubricating the rear suspension The pivoting points of the rear suspen sion must be lubricated by a Yamaha dealer at the intervals specifi...

Page 60: ...s several times to check if the front fork compresses and rebounds smoothly NOTICE ECA10590 If any damage is found or the front fork does not operate smoothly have a Yamaha dealer check or re pair it EAU23283 Checking the steering Worn or loose steering bearings may cause danger Therefore the operation of the steering must be checked as fol lows at the intervals specified in the pe riodic maintena...

Page 61: ...aha dealer check the wheel bearings EAU23385 Battery The battery is located behind panel B See page 7 7 This model is equipped with a VRLA Valve Regulated Lead Acid battery There is no need to check the electro lyte or to add distilled water However the battery lead connections need to be checked and if necessary tightened NOTICE ECA10620 Never attempt to remove the battery cell seals as this woul...

Page 62: ... that the battery tends to discharge more quickly if the vehicle is equipped with optional electrical accessories NOTICE ECA16520 To charge a VRLA Valve Regulated Lead Acid battery a special con stant voltage battery charger is re quired Using a conventional battery charger will damage the battery If you do not have access to a con stant voltage battery charger have a Yamaha dealer charge your bat...

Page 63: ... and then install a new fuse of the specified amperage WARNING Do not use a fuse of a higher amperage rating than recommended to avoid causing extensive dam age to the electrical system and possibly a fire EWA15131 3 Turn the key to ON and turn on the electrical circuit in question to check if the device operates 4 If the fuse immediately blows again have a Yamaha dealer check the electrical syste...

Page 64: ...ckwise 4 Remove the burnt out bulb by turn ing it counterclockwise 5 Place a new bulb into position and then secure it with the bulb holder 6 Install the headlight bulb holder by turning it clockwise 7 Install the bulb cover and then connect the headlight lead con nectors 8 Install the headlight unit by install ing the bolt 9 Have a Yamaha dealer adjust the headlight beam if necessary 1 Bolt 1 1 H...

Page 65: ... lens may break ECA10681 EAU24232 Replacing a turn signal light bulb 1 Remove the turn signal lens by pushing it down lightly then pulling it outward TIP The lens holder will fall out of the turn signal when removing the lens so take care not to loose it 2 Remove the burnt out bulb by pushing it in and turning it counter clockwise 3 Insert a new bulb into the socket push it in and then turn it clo...

Page 66: ...t available by placing a jack un der the frame in front of the rear wheel 2 Raise the front wheel off the ground by using a motorcycle stand To service the rear wheel Raise the rear wheel off the ground by using a motorcycle stand or if a motor cycle stand is not available by placing a jack either under each side of the frame in front of the rear wheel or under each side of the swingarm EAU24360 F...

Page 67: ...the ground according to the procedure on page 7 32 8 Remove the axle nut pull the wheel axle out and then remove the wheel EAU35041 To install the front wheel 1 Install the brake shoe plate into the wheel hub so that the projections mesh with the slots 2 Lift the wheel up between the fork legs TIP Make sure that the slot in the brake shoe plate fits over the retainer on the fork leg 1 Adjusting nu...

Page 68: ...orque 8 Adjust the brake lever free play See page 7 18 9 Slide the rubber cover back to its original position EAU25080 Rear wheel EAU49021 To remove the rear wheel WARNING EWA10821 To avoid injury securely support the vehicle so there is no danger of it falling over 1 Disconnect the brake torque rod from the brake shoe plate by re moving the cotter pin the nut and the bolt 1 Retainer Tightening to...

Page 69: ...d the wheel by inserting the wheel axle from the right hand side TIP Make sure that the drive chain adjust ing plate is installed with the punched side facing to the outside 2 Install the axle nut 3 Install the brake rod onto the brake camshaft lever and then install the brake pedal free play adjusting nut onto the brake rod 4 Connect the brake torque rod to the brake shoe plate by installing the ...

Page 70: ...g chart represents a quick and easy procedure for checking these vital systems your self However should your motorcycle require any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools experience and know how to service the motorcycle properly Use only genuine Yamaha replace ment parts Imitation parts may look like Yamaha parts but they are often inferi or have a sh...

Page 71: ...ha dealer check the vehicle Remove the spark plug and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gap or replace the spark plug Have a Yamaha dealer check the vehicle The engine does not start Have a Yamaha dealer check the vehicle The engine does not start Check the battery Operate the electric starter 4 Battery The engine turns over quickly The engine tur...

Page 72: ...fore cleaning 1 Cover the muffler outlet with a plastic bag after the engine has cooled down 2 Make sure that all caps and covers as well as all electrical couplers and connectors including the spark plug cap are tightly in stalled 3 Remove extremely stubborn dirt like oil burnt onto the crankcase with a degreasing agent and a brush but never apply such prod ucts onto seals gaskets sprock ets the ...

Page 73: ... warm water a mild detergent and a soft clean sponge and then rinse thoroughly with clean water Use a toothbrush or bottlebrush for hard to reach areas Stubborn dirt and insects will come off more easily if the area is covered with a wet cloth for a few minutes before cleaning After riding in the rain near the sea or on salt sprayed roads Since sea salt or salt sprayed on roads during winter are e...

Page 74: ...l or wax to any rubber and plastic parts but treat them with a suitable care product Avoid using abrasive polishing compounds as they will wear away the paint TIP Consult a Yamaha dealer for ad vice on what products to use Washing rainy weather or humid climates can cause the headlight lens to fog Turning the headlight on for a short period of time will help remove the moisture from the lens EAU26...

Page 75: ...NING To prevent dam age or injury from sparking make sure to ground the spark plug electrodes while turning the engine over EWA10951 e Remove the spark plug cap from the spark plug and then install the spark plug and the spark plug cap 6 Lubricate all control cables and the pivoting points of all levers and pedals as well as of the sidestand centerstand 7 Check and if necessary correct the tire ai...

Page 76: ...r higher JASO standard MA Engine oil quantity Without oil filter element removal 1 00 L 1 06 US qt 0 88 Imp qt With oil filter element removal 1 10 L 1 16 US qt 0 97 Imp qt Air filter Air filter element Wet element Fuel Recommended fuel Regular unleaded gasoline only Fuel tank capacity 10 0 L 2 64 US gal 2 20 Imp gal Fuel reserve amount 2 0 L 0 53 US gal 0 44 Imp gal Carburetor Type quantity BS26 ...

Page 77: ...ight hand operation Rear brake Type Drum brake Operation Right foot operation Front suspension Type Telescopic fork Spring shock absorber type Coil spring oil damper Wheel travel 200 0 mm 7 87 in Rear suspension Type Swingarm monocross Spring shock absorber type Coil spring gas oil damper Wheel travel 165 0 mm 6 50 in Electrical system Ignition system DC CDI Charging system AC magneto Battery Mode...

Page 78: ... identification number The vehicle identification number is stamped into the steering head pipe Record this number in the space pro vided TIP The vehicle identification number is used to identify your motorcycle and may be used to register your motorcy cle with the licensing authority in your area EAU26460 Model label The model label is affixed to the loca tion shown Record the information on this...

Page 79: ...r rendering inopera tive by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the pur pose of noise control prior to its sale or delivery to the ultimate pur chaser or while it is in use and The use of the vehicle after such device or element of design has been removed or rendered inoper ative by any per...

Page 80: ... 10 1 Indicator light 4 1 K Kickstarter 4 8 L Labels location 1 1 Light switch 4 3 M Main switch 4 1 Maintenance and lubrication periodic 7 4 Maintenance emission control system 7 3 Matte color caution 8 1 Model label 10 1 N Neutral indicator light 4 1 Noise regulation for Australia 10 2 P Panels removing and installing 7 7 Parking 6 4 Part locations 3 1 R Rear suspension lubricating 7 25 S Safety...

Page 81: ...INDEX W Wheel bearings checking 7 27 Wheel front 7 32 Wheel rear 7 34 Wheels 7 16 ...

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Page 84: ...PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD 2010 01 0 3 1 ...

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