Yamaha CRUX REV YD110-1 2016 Owner'S Manual Download Page 51 | Manualshive

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background image

Perio

d

ic maintenance an

d

a

d

justment

7-18

7

Tires age, even if they have not been
used or have only been used occasion-
ally. Cracking of the tread and sidewall
rubber, sometimes accompanied by
carcass deformation, is an evidence of
ageing. Old and aged tires shall be
checked by tire specialists to ascertain
their suitability for further use.

WARNING

EWA10462

The front an

d

rear tires shoul

d

b

e of

the same make an

d

d

esi

g

n, other-

wise the han

d

lin

g

characteristics of

the vehicle may

b

e

d

ifferent, which

coul

d

lea

d

to an acci

d

ent.

After extensive tests, only the tires list-
ed below have been approved for this
model by Yamaha.

EAU49712

Spoke wheels

To maximize the performance, durabil-
ity, and safe operation of your vehicle,
note the following points regarding the
specified wheels.

z

The wheel rims should be
checked for cracks, bends, warp-
age or other damage, and the
spokes for looseness or damage
before each ride. If any damage is
found, have a Yamaha dealer re-
place the wheel. Do not attempt
even the smallest repair to the
wheel. A deformed or cracked
wheel must be replaced.

z

The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced. An
unbalanced wheel can result in
poor performance, adverse han-
dling characteristics, and a short-
ened tire life.

EAU69930

A

d

justin

g

the clutch lever free

play

The clutch lever free play should mea-
sure 10.0–15.0 mm (0.39–0.59 in) as
shown. Periodically check the clutch
lever free play and, if necessary, adjust
it as follows.

1. Loosen the locknut at crankcase

side.

2. To increase the clutch lever free

play, turn the adjusting nut in di-
rection (a). To decrease the clutch
lever free play, turn the adjusting
nut in direction (b).

Front tire:

Size:

2.75-17 41P

Manufacturer/model:

TVS/ATT625

Rear tire:

Size:

3.00-17 50P

Manufacturer/model:

TVS/ATT925

1. Clutch lever free play

1

ZAUE2592

UBY1E0E0.book Page 18 Monday, April 10, 2017 1:27 PM

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Summary of Contents for CRUX REV YD110-1 2016

Page 1: ...DIC183 YD110 1 OWNER S MANUAL Read this manual carefully before operating this vehicle BY1 F8199 E0 English E ...

Page 2: ...EAU46091 Read this manual carefully before operating this vehicle This manual should stay with this vehicle if it is sold UBY1E0E0 book Page 1 Monday April 10 2017 1 27 PM ...

Page 3: ...y 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 contains the most cur ren...

Page 4: ...ential 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 ...

Page 5: ...016 by India Yamaha Motor Pvt Ltd 1st edition August 2016 All rights reserved Any reprinting or unauthorized use without the written permission of India Yamaha Motor Pvt Ltd is expressly prohibited Printed in India UBY1E0E0 book Page 2 Monday April 10 2017 1 27 PM ...

Page 6: ...system 7 2 General maintenance and lubrication chart 7 3 Removing and installing panels 7 7 Checking the spark plug 7 9 Engine oil 7 10 Servicing the air filter 7 12 Adjusting the carburetor 7 14 Adjusting the engine idling speed 7 15 Adjusting the throttle grip free play 7 15 Valve clearance 7 16 Tires 7 16 Spoke wheels 7 18 Adjusting the clutch lever free play 7 18 Adjusting the brake lever free...

Page 7: ...gnal light bulb 7 32 Front wheel 7 33 Rear wheel 7 35 Troubleshooting 7 37 Troubleshooting chart 7 39 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 Index 11 1 UBY1E0E0 book Page 2 Monday April 10 2017 1 27 PM ...

Page 8: ...le 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 ZAUE2543 UBY1E0E0 book Page 1 Monday April 10 2017 1 27 PM ...

Page 9: ...Location of important labels 1 2 1 1 2 ZAUE2544 3 MAX LOAD 3kg 100kPa 1bar kPa psi kPa psi 175 25 225 33 175 25 280 41 B44 F1668 00 UBY1E0E0 book Page 2 Monday April 10 2017 1 27 PM ...

Page 10: ...st you Safe Riding Perform the pre operation checks each time you use the vehicle to make sure it is in safe operating condition Failure to inspect or maintain the vehi cle properly increases the possibility of an accident or equipment damage See page 5 1 for a list of pre operation checks z This motorcycle is designed to carry the operator and a passen ger z The failure of motorists to detect and...

Page 11: ...n tain control of the motorcycle The passenger should always hold onto the operator the seat strap or grab bar if equipped with both hands and keep both feet on the passenger footrests Never carry a passenger unless he or she can firmly place both feet on the passenger footrests z Never ride under the influence of alcohol or other drugs z This motorcycle is designed for on road use only It is not ...

Page 12: ...cycle is changed To avoid the possibility of an accident use extreme caution when adding cargo or accessories to your motorcycle Use extra care when riding a motorcycle that has added cargo or accessories Here along with the information about accessories below are some general guidelines to follow if loading cargo to your motorcycle The total weight of the operator pas senger accessories and cargo...

Page 13: ... change any of the vehicle s design or operation characteristics can put you and others at greater risk of serious injury or death You are responsible for injuries related to changes in the vehicle Keep the following guidelines in mind as well as those provided under Load ing when mounting accessories z Never install accessories or carry cargo that would impair the per formance of your motorcycle ...

Page 14: ...uc tions before transporting the motorcy cle in another vehicle z Remove all loose items from the motorcycle z Check that the fuel cock if equipped is in the OFF position and that there are no fuel leaks z Point the front wheel straight ahead on the trailer or in the truck bed and choke it in a rail to pre vent movement z Shift the transmission in gear for models with a manual transmis sion z Secu...

Page 15: ...UE2545 1 2 3 4 5 8 7 6 1 Fuel cock page 4 6 2 Starter choke lever page 4 7 3 Battery page 7 28 4 Fuse page 7 30 5 Seat page 4 8 6 Owner s tool kit page 7 1 7 Panel lock 8 Shift pedal page 4 3 UBY1E0E0 book Page 1 Monday April 10 2017 1 27 PM ...

Page 16: ...ZAUE2546 1 2 3 4 5 6 1 Rear shock absorber page 4 9 2 Air filter page 7 12 3 Kickstarter page 4 7 4 Engine oil filler cap page 7 10 5 Brake pedal page 4 4 6 Rear brake light switch page 7 20 UBY1E0E0 book Page 2 Monday April 10 2017 1 27 PM ...

Page 17: ...ments 1 Clutch lever page 4 3 2 Left handlebar switches page 4 2 3 Speedometer page 4 2 4 Main switch steering lock page 4 1 5 Fuel tank cap page 4 4 6 Throttle grip page 7 15 7 Brake lever page 4 4 UBY1E0E0 book Page 3 Monday April 10 2017 1 27 PM ...

Page 18: ... to OFF or LOCK while the vehicle is moving Otherwise the electrical systems will be switched off which may result in loss of control or an accident EAU10696 LOCK The steering is locked and all electrical systems are off The key can be re moved To lock the steering 1 Turn the handlebars all the way to the left or right 2 With the key in the OFF position push the key in and turn it to LOCK 3 Remove...

Page 19: ...s the riding speed The odometer shows the total distance traveled EAU1234K Handlebar switches Left EAU12401 Dimmer switch Set this switch to for the high beam and to for the low beam EAU12461 Turn signal switch To signal a right hand turn push this switch to To signal a left hand turn push this switch to When released the switch returns to the cen 1 Neutral indicator light 2 Turn signal indicator ...

Page 20: ...lever is located on the left side of the handlebar To disengage the clutch pull the lever toward the handlebar grip To engage the clutch release the lever The lever should be pulled rapidly and released slowly for smooth clutch operation EAU12872 Shift pedal The shift pedal is located on the left side of the motorcycle and is used in combination with the clutch lever when shifting the gears of the...

Page 21: ...own on the brake pedal EAUE0041 Fuel tank cap To remove the fuel tank cap Insert the key into the lock and turn it 1 4 turn clockwise The lock will be re leased and the fuel tank cap can be re moved To install the fuel tank cap 1 Push the fuel tank cap into posi tion with the key inserted in the lock TIP The mark on the fuel tank cap must be pointing forward 1 Brake lever ZAUE2556 1 1 Brake pedal ...

Page 22: ...oking 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 fuel immedi ately NOTI...

Page 23: ...uretor while filtering it also The fuel cock has three positions OFF With the lever in this position fuel will not flow Always return the lever to this position when the engine is not run ning ON With the lever in this position fuel flows to the carburetor Normal riding is done with the lever in this position RES Recommended fuel Regular unleaded gasoline Gasohol E10 acceptable Fuel tank capacity ...

Page 24: ...y the starter choke Move the lever in direction a to turn on the starter choke Move the lever in direction b to turn off the starter choke EAUE3321 Kickstarter Use the kickstarter to start the engine See page 6 1 To use the kickstarter shift the trans mission into neutral Fold out the kick starter lever move it down lightly with your foot until the gears engage and then kick it down smoothly but f...

Page 25: ...he seat 1 Insert the projection on the back of the seat into the seat holder as shown 2 Place the seat in the original posi tion and then tighten the bolts 3 Install the panels TIP Make sure that the seat is properly se cured before riding 1 Bolt ZAUE2564 1 1 Seat 1 Projection 2 Seat holder ZAUE2565 1 2 2 ZAUE2566 1 Tightening torque Bolt 8 N m 0 8 kgf m 5 8 lb ft UBY1E0E0 book Page 8 Monday April...

Page 26: ...th shock absorber assemblies equally otherwise poor handling and loss of stability may re sult Each shock absorber assembly is equipped with a spring preload adjust ing ring NOTICE ECA10102 To avoid damaging the mechanism do not attempt to turn beyond the maximum or minimum settings Adjust the spring preload as follows To increase the spring preload and thereby harden the suspension turn the adjus...

Page 27: ...ated on the left side of the frame Raise the sidestand or lower it with your foot while holding the vehicle upright WARNING EWA14191 The vehicle must not be ridden with the sidestand down or if the side stand cannot be properly moved up or does not stay up otherwise the sidestand could contact the ground and distract the operator resulting in a possible loss of control 1 Spring preload adjusting r...

Page 28: ...res provided in this manual have the vehicle inspected by a 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 10 Front brake Check operation Lubricate cable e...

Page 29: ... Check for damage Check tire condition and tread depth Check air pressure Correct if necessary 7 16 7 18 Brake and shift pedals Make sure that operation is smooth Lubricate pedal pivoting points if necessary 7 25 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 7 25 Centerstand sidestand Make sure that operation is smooth Lubricate pivots if n...

Page 30: ...N 3 Shift the transmission into the neutral position The neutral indi cator 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 kickstarter lever down 6 After starting the engine move the starter choke back halfway 7 When the engine is warm turn the starter choke...

Page 31: ...dal down repeatedly until it reaches the end of its travel z Use your toe to shift down and your heel to shift up NOTICE ECA10261 z 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 lubrication may damage th...

Page 32: ... 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 EAU16953 0 150 km 0 90 mi Avoid prolonged operation above 1 3 throttle After every hour of operation stop the engine and then let it cool for five to ten minutes Vary the engine speed from ...

Page 33: ...ce 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 z Do not park on a slope or on soft ground otherwise the vehicle may overturn increasing the risk of a fuel leak and fire z Do not park near grass or other flammable materials which might catch fire UBY1E0E0 book Page 4 Monday April 10 2017 1 27 PM ...

Page 34: ...f the engine when performing maintenance unless otherwise specified z A running engine has moving parts that can catch on body parts or clothing and electrical parts that can cause shocks or fires z Running the engine while ser vicing can lead to eye injury burns fire or carbon monoxide poisoning possibly leading to death See page 2 3 for more in formation about carbon monox ide WARNING EWA15461 B...

Page 35: ...tenance chart for the emission control system NO ITEM CHECK OR MAINTENANCE JOB ODOMETER READING whichever comes first ANNUAL CHECK 1000 km or 1 month 4000 km or 4 months 8000 km or 8 months 12000 km or 12 months 16000 km or 16 months 1 Fuel line Check fuel hoses for cracks or damage 2 Fuel cock filter Check condition and clean if nec essary 3 Spark plug Check condition Clean and regap Replace Ever...

Page 36: ...tery output voltage Check electrolyte level and spe cific gravity Make sure that the breather hose is properly routed 3 Clutch Check operation Adjust 4 Front brake Check operation and adjust brake lever free play Replace brake shoes Whenever worn to the limit 5 Rear brake Check operation and adjust brake pedal free play Replace brake shoes Whenever worn to the limit 6 Wheels Check runout spoke tig...

Page 37: ...11 Steering bearings Check bearing play and steering for roughness Lubricate with lithium soap based grease Every 12000 km 7500 mi 12 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 13 Brake lever pivot shaft Lubricate with lithium soap based grease 14 Brake pedal pivot shaft Lubricate with lithium soap based grease 15 Clutch lever pivot shaft Lubricate with lithi...

Page 38: ...age 21 Engine oil strainer Clean Every 12000 km 7500 mi 22 Front and rear brake switches Check operation 23 Moving parts and cable ends Lubricate 24 Throttle grip Check operation Check throttle grip free play and adjust if necessary Lubricate cable end and grip housing 25 Lights signals and switches Check operation Adjust headlight beam NO ITEM CHECK OR MAINTENANCE JOB ODOMETER READING whichever c...

Page 39: ...eaned lubricated and re used The secondary filter element is an oil coated paper type which must only be replaced To avoid damaging the air filter elements do not attempt to clean it with compressed air by tapping it z The air filter needs to be serviced more frequently when riding in unusually wet are dusty areas UBY1E0E0 book Page 6 Monday April 10 2017 1 27 PM ...

Page 40: ...e removed and installed EAUE2920 Panel A To remove the panel 1 Insert the key into the lock and turn it clockwise 2 Without removing the key pull the front of the panel out to release the projection Then slide the pan el forward to release it in the rear 1 Panel A 2 Panel lock ZAUE2573 1 2 1 Panel B 2 Screw ZAUE2574 2 1 1 Panel lock 2 Unlock 1 Panel A 2 Panel lock ZAUE2575 ZAUE2576 1 UBY1E0E0 book...

Page 41: ... lever 3 Pull the front of the panel out to re lease the projection and then slide the panel forward to release it in the rear To install the panel 1 Secure the rear of the panel first then push the front of the panel in to insert the projection into the hole 2 Install the screw 3 Fold the kickstarter lever inward to its original position 1 Hole 2 Projection 3 Panel A ZAUE2577 2 1 3 1 Panel B 2 Sc...

Page 42: ...g 1 Check that the porcelain insulator around the center electrode of the spark plug is a medium to light tan the ideal color when the vehi cle 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 electrode er...

Page 43: ...nd the oil strainer cleaned at the intervals specified in the periodic maintenance and lubrication chart To check the engine oil level 1 Place the vehicle on the center stand 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 remove the oil filler cap wipe the dipstick clean inse...

Page 44: ... oil filler cap NOTICE ECA11621 z 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 z Make sure that no foreign mate rial enters the crankcase 6 Start the engine and the...

Page 45: ...emoving the screws 3 Remove the primary air filter ele ment by pulling it out 4 Clean the primary air filter element with kerosene or diesel After cleaning gently squeeze the ele ment to remove the excess kero sene or diesel WARNING Use only a dedicated parts cleaning solvent To avoid the risk of fire or explosion do not use gaso line or solvents with a low flash point EWA10432 NOTICE To avoid dam...

Page 46: ...nstalling the screws TIP When installing the air filter element into the air filter case cover make sure their sealing surfaces are aligned to prevent any air leaks 8 Install the panel Replacing the secondary air filter el ement 1 Remove panel B See page 7 7 2 Remove the air filter case cover by removing the screws 3 Remove the secondary air filter el ement along with primary air filter element 1 ...

Page 47: ...e air filter case cover by installing the screws TIP When installing the air filter element into the air filter case cover make sure their sealing surfaces are aligned to prevent any air leaks 6 Install the panel EAU21281 Adjusting the carburetor The carburetor is an important part of the engine and requires very sophisti cated adjustment Therefore most carburetor adjustments should be left to a Y...

Page 48: ...gine idling speed turn the screw in direction a To decrease the en gine idling speed turn the screw in direction b TIP If the specified idling speed cannot be obtained as described above have a Yamaha dealer make the adjustment EAUE1572 Adjusting the throttle grip free play The throttle grip free play should mea sure 3 0 7 0 mm 0 12 0 28 in at the inner edge of the throttle grip Periodi cally chec...

Page 49: ...ct between the vehicle and the road Safety in all con ditions of riding depends on a relatively small area of road contact Therefore it is essential to maintain the tires in good condition at all times and replace them at the appropriate time with the speci fied tires Tire air pressure The tire air pressure should be checked and if necessary adjusted before each ride WARNING EWA10504 Operation of ...

Page 50: ...he tires should be left to a Yamaha dealer who has the necessary professional knowl edge and experience z 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 z Ride at moderate speeds after changing a tire since the tire surface must first be broken in for it to develop its optimal char...

Page 51: ...er damage and the spokes for looseness or damage before each ride If any damage is found have a Yamaha dealer re place the wheel Do not attempt even the smallest repair to the wheel A deformed or cracked wheel must be replaced z The wheel should be balanced whenever either the tire or wheel has been changed or replaced An unbalanced wheel can result in poor performance adverse han dling characteri...

Page 52: ...y adjust it as fol lows To increase the brake lever free play turn the brake lever free play adjusting nut at the brake shoe plate in direction a To decrease the brake lever free play turn the adjusting nut in direction b WARNING EWA10651 If proper adjustment cannot be ob tained as described have a Yamaha dealer make this adjustment 1 Locknut 2 Clutch lever free play adjusting nut ZAUE2593 b a 1 2...

Page 53: ...After adjusting the brake pedal free play check the operation of the brake light EAU22274 Brake light switches The brake light which is activated by the brake pedal and brake lever should come on just before braking takes effect If necessary adjust the rear brake light switch as follows but the front brake light switch should be adjusted by a Yamaha dealer Turn the rear brake light switch adjust i...

Page 54: ... wear indica tor reaches the wear limit line have a Yamaha dealer replace the brake shoes as a set EAU22762 Drive chain slack The drive chain slack should be checked before each ride and adjusted if necessary EAUE2940 To check the drive chain slack 1 Place the motorcycle on the cen terstand 2 Shift the transmission into the neutral position 3 To check the drive chain slack re move the cover by pul...

Page 55: ...ust the drive chain slack Consult a Yamaha dealer before ad justing the drive chain slack 1 Loosen the brake pedal free play adjusting nut 2 Loosen the axle nut 3 Loosen the drive chain puller lock nut at each end of the swingarm 4 To tighten the drive chain turn the drive chain slack adjusting bolt at each end of the swingarm in direc tion a To loosen the drive chain turn the adjusting bolt at ea...

Page 56: ...ls 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 ECA10584 The drive chain must be lubricated after washing the motorcycle riding in the rain or riding in wet areas 1 Clean the drive chain with kero sene and a small soft brush 2 Rinse off any remaining dirt and th...

Page 57: ...on as possible to prevent unsafe conditions EWA10712 EAUE1191 Checking and lubricating the throttle grip and cable end The operation of the throttle grip should be checked before each ride In addition the cable end should be lubri cated by a Yamaha dealer at the inter vals specified in the periodic maintenance chart The throttle cable is equipped with a rubber cover Make sure that the cover is sec...

Page 58: ...ots should be lu bricated if necessary Brake pedal Shift pedal EAU43612 Checking and lubricating the brake and clutch levers Brake lever Clutch lever The operation of the brake and clutch levers should be checked before each ride and the lever pivots should be lu bricated if necessary ZAUE2605 ZAUE2606 Recommended lubricant Lithium soap based grease UBY1E0E0 book Page 25 Monday April 10 2017 1 27 ...

Page 59: ...ould be lubri cated if necessary WARNING EWA10742 If the centerstand or sidestand does not move up and down smoothly have a Yamaha dealer check or re pair it Otherwise the centerstand or sidestand could contact the ground and distract the operator resulting in a possible loss of control Recommended lubricant Lithium soap based grease ZAUE2609 Recommended lubricant Lithium soap based grease UBY1E0E...

Page 60: ...e inner tubes for scratches damage and excessive oil leakage To check the operation 1 Place the vehicle on a level sur face and hold it in an upright posi tion WARNING To avoid injury securely support the vehicle so there is no danger of it falling over EWA10752 2 While applying the front brake push down hard on the handle bars several times to check if the front fork compresses and re bounds smoo...

Page 61: ...tion chart If there is play in the wheel hub or if the wheel does not turn smoothly have a Yamaha dealer check the wheel bearings EAU23315 Battery A poorly maintained battery will cor rode and discharge quickly The elec trolyte level battery lead connections and breather hose routing should be checked before each ride and at the in tervals specified in the periodic main tenance and lubrication cha...

Page 62: ...s minerals that are harmful to the battery ECA10612 4 Check and if necessary tighten the battery lead connections and correct the breather hose routing To store the battery 1 If the motorcycle will not be used for more than one month remove the battery fully charge it and then place it in a cool dry place NOTICE When removing the battery be sure the key is turned to OFF then discon nect the negati...

Page 63: ...the fuse is blown replace it as fol lows 1 Turn the key to OFF and turn off all electrical circuits 2 Remove panel A See page 7 7 3 Remove the battery band 4 Remove the fuse holder from fuse holder bracket by pulling it out ward 5 Open fuse box cover by pressing lock as shown 6 Remove the blown fuse and then install a new fuse of the specified amperage WARNING Do not use a fuse of a higher amperag...

Page 64: ... Turn the key to ON and turn on the electrical circuits to check if the devices operate 12 If the fuse immediately blows again have a Yamaha dealer check the electrical system EAU34242 Replacing a headlight bulb This model is equipped with halogen bulb headlights If a headlight bulb burns out have a Yamaha dealer re place it and if necessary adjust the headlight beam 1 Fuse 2 Spare fuse Specified ...

Page 65: ... it clock wise until it stops 4 Install the lens by installing the screws NOTICE Do not over tighten the screws otherwise the lens may break ECA10682 EAU24205 Replacing a turn signal light bulb 1 Remove the turn signal light lens by removing the screw 2 Remove the burnt out bulb by pushing it in and turning it coun terclockwise 1 Tail brake light lens 2 Screw ZAUE2618 1 Bulb ZAUE2619 1 1 Turn sign...

Page 66: ... no danger of it falling over 1 Loosen the wheel axle nut 2 Place the motorcycle on the cen terstand 3 Disconnect the brake cable from the brake camshaft lever by re moving the brake lever free play adjusting nut and then remove the cable from the brake shoe plate 4 Slide the rubber cover back and then disconnect the speedometer cable by pressing the lock 5 Remove the wheel axle nut and the washer...

Page 67: ...ightening the axle nut hold the wheel axle with a wrench to keep it from turning 5 Install the brake cable to the brake shoe plate and then connect the cable to the brake camshaft lever by installing the brake lever free play adjusting nut 6 Adjust the brake lever free play See page 7 19 7 While applying the front brake push down hard on the handle bars several times to check if the front fork com...

Page 68: ...pin the nut the washer and the bolt 3 Remove the bolts and collars from the drive chain case 4 Unhook the drive chain case lock and remove the drive chain case 5 Remove the brake pedal free play adjusting nut disconnect the brake rod from the brake cam shaft lever and remove the spring and washer from the brake rod 1 Nut 2 Cotter pin 3 Brake torque rod 4 Washer 5 Bolt 1 Drive chain case 2 Bolt and...

Page 69: ...der to remove and install the wheel 9 Remove the wheel To install the rear wheel 1 Install the drive chain onto the rear sprocket 2 Install the wheel by inserting the collars and wheel axle from the left side 3 Install the washer and the axle nut 4 Install the washer and spring onto the brake rod connect the brake rod to the brake camshaft lever 1 Brake camshaft lever 2 Drive chain puller locknut ...

Page 70: ... a thorough inspection before shipment from the factory trouble may occur during operation Any problem in the fuel compression or ignition systems for example can cause poor starting and loss of power The following troubleshooting 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...

Page 71: ...riodic maintenance and adjustment 7 38 7 heaters or furnaces Gasoline or gasoline vapors can ignite or ex plode causing severe injury or prop erty damage UBY1E0E0 book Page 38 Monday April 10 2017 1 27 PM ...

Page 72: ... compression There is no compression The engine does not start Have a Yamaha dealer check the vehicle Have a Yamaha dealer check the vehicle Remove the spark plug and check the electrodes 2 Ignition Wet Dry 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 Check the compression Open the throttle halfw...

Page 73: ...tlet with a plastic bag after the engine has cooled down 2 Make sure that all caps and cov ers as well as all electrical cou plers 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 drive chain and wheel axles Always...

Page 74: ...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 extremely cor...

Page 75: ... to any rubber and plastic parts but treat them with a suitable care product z Avoid using abrasive polishing compounds as they will wear away the paint TIP z Consult a Yamaha dealer for ad vice on what products to use z 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 EAUE120...

Page 76: ...park plug cap from the spark plug and then install the spark plug and the spark plug cap WARNING To prevent damage or injury from sparking make sure to ground the spark plug elec trodes while turning the en gine over EWA10952 6 Lubricate all control cable ends and the pivoting points of all levers and pedals as well as of the side stand centerstand 7 Check and if necessary correct the tire air pre...

Page 77: ...e or higher JASO standard MA Engine oil quantity Oil change 0 90 L 0 95 US qt 0 79 Imp qt Air filter Air filter element Oil coated paper element Fuel Recommended fuel Regular unleaded gasoline Gasohol E10 acceptable Fuel tank capacity 7 2 L 1 9 US gal 1 6 Imp gal Fuel reserve amount 1 0 L 0 26 US gal 0 22 Imp gal Carburetor Type quantity VM17 1 Spark plug s Manufacturer model NGK CR6HSA Spark plug...

Page 78: ... drum brake Front suspension Type Telescopic fork Spring Coil spring Shock absorber Hydraulic damper Wheel travel 120 mm 4 7 in Rear suspension Type Swingarm Spring Coil spring Shock absorber Hydraulic damper Wheel travel 100 mm 3 9 in Electrical system System voltage 12 V Ignition system TCI Charging system AC magneto Battery Model AB2 5L C 4 Model 12MX2 5L C 5 Voltage capacity 12 V 2 5 Ah 10 HR ...

Page 79: ...U26401 Vehicle 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 EAU26442 Engine serial number The engine serial number is stamped into the crankcase 1 ...

Page 80: ...cator light 4 2 Horn switch 4 3 I Identification numbers 10 1 Indicator lights 4 2 K Kickstarter 4 7 L Labels location 1 1 Light switch 4 3 M Main switch steering lock 4 1 Maintenance and lubrication periodic 7 3 Maintenance emission control system 7 2 Matte color caution 8 1 N Neutral indicator light 4 2 P Panels removing and installing 7 7 Parking 6 4 Part locations 3 1 S Safety information 2 1 ...

Page 81: ...Index 11 2 11 W Wheel bearings checking 7 28 Wheel front 7 33 Wheel rear 7 35 Wheels 7 18 UBY1E0E0 book Page 2 Monday April 10 2017 1 27 PM ...

Page 82: ...BY1 F8199 E0 PRINTED IN INDIA 2Y121 OM 01 919 07 16 E ...

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