Yamaha CRYPTON T110C Page 66 Owner'S Manual Download

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PERIODIC MAINTENANCE AND ADJUSTMENT

6-35

EAU25080

Rear wheel

EAU55240

To remove the rear wheel

WARNING

EWA10821

To avoid injury, securely support the
vehicle so there is no danger of it
falling over.

1. Place the motorcycle on the cen-

terstand.

2. Loosen the wheel axle nut.

3. Remove the drive chain case by

removing the bolts.

4. Loosen the locknut and the drive

chain slack adjusting nut on both
ends of the swingarm.

5. Disconnect the brake torque rod

from the brake shoe plate by re-
moving the cotter pin, the nut, the
washer and the bolt.

6. Remove the brake pedal free play

adjusting nut, and then disconnect
the brake rod from the brake cam-
shaft lever.

1. Wheel axle nut

1. Drive chain case
2. Bolt

1. Locknut
2. Drive chain slack adjusting nut

1. Brake torque rod
2. Cotter pin

3. Brake torque rod nut and bolt

4. Washer

U40BE2E0.book Page 35 Wednesday, October 10, 2012 8:01 AM

Summary of Contents for CRYPTON T110C

Page 1: ...DIC183 T110C OWNER S MANUAL Read this manual carefully before operating this vehicle 40B F8199 E2 English E ...

Page 2: ...EAU46090 Read this manual carefully before operating this vehicle This manual should stay with this vehicle if it is sold U40BE2E0 book Page 1 Wednesday October 10 2012 8 01 AM ...

Page 3: ...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 rent pro...

Page 4: ...ial 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 NOT...

Page 5: ... 2012 by Yamaha Motor Co Ltd 1st edition September 2012 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in China U40BE2E0 book Page 2 Wednesday October 10 2012 8 01 AM ...

Page 6: ...6 3 General maintenance and lubrication chart 6 4 Removing and installing the cowling and panel 6 7 Checking the spark plug 6 8 Engine oil 6 9 Cleaning the air filter element 6 11 Adjusting the carburetor 6 12 Adjusting the engine idling speed 6 12 Checking the throttle grip free play 6 13 Valve clearance 6 13 Tires 6 14 Cast wheels 6 16 Checking the brake lever free play 6 16 Adjusting the brake ...

Page 7: ...ht bulb 6 30 Replacing a rear turn signal light bulb 6 31 Replacing the license plate light bulb 6 31 Replacing an auxiliary light bulb 6 32 Front wheel 6 33 Rear wheel 6 35 Troubleshooting 6 37 Troubleshooting chart 6 38 MOTORCYCLE CARE AND STORAGE 7 1 Matte color caution 7 1 Care 7 1 Storage 7 3 SPECIFICATIONS 8 1 CONSUMER INFORMATION 9 1 Identification numbers 9 1 U40BE2E0 book Page 2 Wednesday...

Page 8: ...u 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 vehicle properly increases the possibility of an accident or equipment damage See page 4 1 for a list of pre operation checks This motorcycle is designed to car ry the operator and a passenger The failure of motorists to detect and recognize...

Page 9: ...main 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 Never ride under the influence of alcohol or other drugs This motorcycle is designed for on road use only It is not s...

Page 10: ...e is changed To avoid the possibility of an accident use ex treme 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 mu...

Page 11: ...ge 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 Never install accessories or carry cargo that would impair the perfor mance of your motorcycle Care fu...

Page 12: ... tions before transporting the motorcy cle in another vehicle Remove all loose items from the motorcycle Check that the fuel cock if equipped is in the OFF position and that there are no fuel leaks Point the front wheel straight ahead on the trailer or in the truck bed and choke it in a rail to pre vent movement Shift the transmission in gear for models with a manual transmis sion Secure the motor...

Page 13: ... 1 Battery page 6 26 2 Fuse page 6 28 3 Storage compartment page 3 9 4 Owner s tool kit page 6 2 5 Fuel tank cap page 3 5 6 Seat lock page 3 8 7 Engine oil drain bolt page 6 9 8 Shift pedal page 3 4 U40BE2E0 book Page 1 Wednesday October 10 2012 8 01 AM ...

Page 14: ...5 1 Carrier page 3 10 2 Helmet holder page 3 8 3 Kickstarter page 3 8 4 Front brake fluid reservoir page 6 19 5 Air filter element page 6 11 6 Brake pedal page 3 5 7 Engine oil filler cap page 6 9 U40BE2E0 book Page 2 Wednesday October 10 2012 8 01 AM ...

Page 15: ...7 4 1 Left handlebar switches page 3 3 2 Speedometer unit page 3 3 3 Fuel gauge page 3 3 4 Main switch steering lock page 3 1 5 Right handlebar switch page 3 3 6 Brake lever page 3 4 7 Throttle grip page 6 13 U40BE2E0 book Page 3 Wednesday October 10 2012 8 01 AM ...

Page 16: ...atically when the engine is started and stays on until the key is turned to EAU47791 off All electrical systems are off The key can be removed WARNING EWA15350 Never turn the key to or while the vehicle is moving Other wise the electrical systems will be switched off which may result in loss of control or an accident EAU47801 lock The steering is locked and all electrical systems are off The key c...

Page 17: ...when the transmission is in the neutral position EAU37611 Gear position indicator lights 1 2 3 and 4 The respective indicator light comes on when the transmission is in the 1st 2nd 3rd or 4th gear position EAU11080 High beam indicator light This indicator light comes on when the high beam of the headlight is switched on 1 Turn signal indicator light 2 Neutral indicator light 3 Gear position indica...

Page 18: ... towards E Empty as the fuel level decreases When the needle reaches the red zone approximately 1 0 L 0 26 US gal 0 22 Imp gal remain in the fuel tank If this occurs refuel as soon as possible TIP The main switch must be turned to for the fuel gauge to display an accu rate fuel level reading EAU1234B Handlebar switches Left Right 1 Speedometer 2 Odometer 1 2 1 Fuel gauge 2 Red zone 1 2 1 Dimmer sw...

Page 19: ...und the horn EAU12711 Start switch Push this switch to crank the engine with the starter See page 5 1 for start ing instructions prior to starting the en gine EAU37461 Shift pedal The shift pedal is located on the left side of the motorcycle This motorcycle is equipped with a constant mesh 4 speed transmission TIP Use your toes to shift up and your heel to shift down EAU12891 Brake lever The brake...

Page 20: ... 3 8 2 Turn the fuel tank cap counter clockwise and pull it off To install the fuel tank cap 1 Insert the fuel tank cap into the tank opening and turn it clockwise until the marks on the cap and tank are aligned 2 Close the seat WARNING EWA11091 Make sure that the fuel tank cap is properly closed after filling fuel Leaking fuel is a fire hazard 1 Brake pedal 1 1 Fuel tank cap 2 mark 1 2 2 U40BE2E0...

Page 21: ...stic parts ECA10071 4 Be sure to securely close the fuel tank cap WARNING EWA15151 Gasoline is poisonous and can cause injury or death Handle gaso line with care Never siphon gaso line by mouth If you should swallow some gasoline or inhale a lot of gas oline vapor or get some gasoline in your eyes see your doctor immedi ately If gasoline spills on your skin wash with soap and water If gaso line sp...

Page 22: ...m Make sure that the exhaust sys tem has cooled down before do ing any maintenance work Do not allow the engine to idle more than a few minutes Long idling can cause a build up of heat NOTICE ECA10701 Use only unleaded gasoline The use of leaded gasoline will cause unre pairable damage to the catalytic converter EAU13590 Starter choke lever Starting a cold engine requires a richer air fuel mixture...

Page 23: ... up To close the seat 1 Fold the seat down and then push it down to lock it in place 2 Remove the key TIP Make sure that the seat is properly se cured before riding EAU37481 Helmet holders The helmet holders are located under the seat To secure a helmet to a helmet hold er 1 Open the seat See page 3 8 2 Attach a helmet to a helmet holder and then securely close the seat WARNING Never ride with a h...

Page 24: ...ring the Owner s Manual or other documents in the storage com partment be sure to wrap them in a plastic bag so that they will not get wet When washing the vehicle be careful not to let any water enter the storage compartment WARNING EWA10961 Do not exceed the load limit of 1 0 kg 2 2 lb for the storage compartment Do not exceed the maximum load of 167 kg 368 lb for the ve hicle 1 Storage compartm...

Page 25: ...sidestand is located on the left side of the frame Raise the sidestand or lower it with your foot while holding the vehicle upright WARNING EWA14190 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 Carrier 1 ...

Page 26: ...CHECKS PAGE Fuel Check fuel level in fuel tank Refuel if necessary Check fuel line for leakage 3 6 Engine oil Check oil level in engine If necessary add recommended oil to specified level Check vehicle for oil leakage 6 9 Front brake Check operation If soft or spongy have Yamaha dealer bleed hydraulic system Check brake pads for wear Replace if necessary Check fluid level in reservoir If necessary...

Page 27: ...h Correct if necessary 6 17 Brake pedal Make sure that operation is smooth Lubricate pedal pivoting point if necessary 6 24 Brake lever Make sure that operation is smooth Lubricate lever pivoting point if necessary 6 23 Centerstand sidestand for sidestand equipped models Make sure that operation is smooth Lubricate pivots if necessary 6 24 Chassis fasteners Make sure that all nuts bolts and screws...

Page 28: ...e vehicle is placed on the centerstand 4 Turn the starter choke on and completely close the throttle See page 3 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 switch wait a few seconds and then try again Each starting at tempt should be as short as possi ble to preserve the battery Do ...

Page 29: ... for starting off accelerating climbing hills etc When shifting gears fully return the throttle grip The use of the shift pedal is shown in the illustration NOTICE ECA15180 Make sure that the transmission is completely shifted into gear Be sure to fully close the throttle grip when shifting Make sure the neutral indicator light comes on when the trans mission is in the neutral posi tion 1 Shift pe...

Page 30: ...xcessive load on it for the first 1000 km 600 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 EAU16863 0 150 km 0 90 mi Avoid prolonged operation above 1 3 throttle After every hour of operation stop the engine and then let...

Page 31: ...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 U40BE2E0 book Page 4 Wednesday October 10 2012 8 01 AM ...

Page 32: ...performing maintenance unless otherwise specified A running engine has moving parts that can catch on body parts or clothing and electrical parts that can cause shocks or fires Running the engine while ser vicing can lead to eye injury burns fire or carbon monoxide poisoning possibly leading to death See page 1 3 for more in formation about carbon monox ide WARNING EWA15460 Brake discs calipers dr...

Page 33: ...he owner s tool kit are intended to assist 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 1 Owner s tool kit 1 U40BE2E0 book Page 2 Wednesday October...

Page 34: ...s 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 and vacuum hoses for cracks or damage 2 Spark plug Check condition Clean and regap Replace 3 Valves Check valve clearance Adjust 4 Carburetor Check starter chok...

Page 35: ...age Replace brake pads Whenever worn to the limit 3 Rear brake Check operation and adjust brake pedal free play Replace brake shoes Whenever worn to the limit 4 Brake hose Check for cracks or damage Check for correct routing and clamping Replace Every 4 years 5 Brake fluid Replace Every 2 years 6 Wheels Check runout and for damage 7 Tires Check tread depth and for dam age Replace if necessary Chec...

Page 36: ... 24000 km 14000 mi 12 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 13 Brake lever pivot shaft Lubricate with silicone grease 14 Brake pedal pivot shaft Lubricate with lithium soap based grease 15 Centerstand side stand for side stand equipped models Check operation Lubricate with lithium soap based grease 16 Front fork Check operation and for oil leak age 17 Sh...

Page 37: ...if cracked or damaged 18 Engine oil Change See page 6 9 Check oil level and vehicle for oil leakage Every 3000 km 1800 mi 19 Front and rear brake switches Check operation 20 Moving parts and cables Lubricate 21 Throttle grip Check operation Check throttle grip free play and adjust if necessary Lubricate cable and grip housing 22 Lights signals and switches Check operation Adjust headlight beam NO ...

Page 38: ...d EAU18853 Cowling A To remove the cowling Remove the screws and then pull the cowling off as shown To install the cowling Place the cowling in the original posi tion and then install the screws EAU47650 Panel A To remove the panel 1 Remove the screw 2 Slide the panel backward to un hook its projection from the slot and then pull the panel off 1 Cowling A 2 Panel A 2 1 1 Screw 2 Cowling A 1 1 2 1 ...

Page 39: ...ion of the spark plug can re veal the condition of the engine To remove the spark plug 1 Remove the spark plug cap 2 Remove the spark plug as shown with the spark plug wrench includ ed in the owner s tool kit To check the spark plug 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 vehicle is ridden normally TIP If ...

Page 40: ...ened to the speci fied torque as soon as possible 3 Install the spark plug cap EAU47692 Engine oil The engine oil level should be checked before each ride In addition the oil must be changed at the intervals spec ified 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 Sta...

Page 41: ...ket and then tighten it to the specified torque 5 Refill with the specified amount of the recommended engine oil and then install and tighten the oil filler cap TIP Be sure to wipe off spilled oil on any parts 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 D...

Page 42: ...r filter element should be cleaned or replaced at the intervals specified in the periodic maintenance and lubrica tion chart Clean or if necessary re place the air filter element more frequently if you are riding in unusually wet or dusty areas 1 Remove the air filter case cover by removing the screws 2 Pull the air filter element out 3 Lightly tap the air filter element to remove most of the dust...

Page 43: ...art of routine maintenance 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 EAU21340 Adjusting the engine idling speed The engine idling speed must be checked and if necessary adjusted as follows at the intervals specified in the perio...

Page 44: ...ally check the throttle grip free play and if necessary have a Yamaha deal er adjust it EAU21401 Valve clearance The valve clearance changes with use resulting in improper air fuel mixture and or engine noise To prevent this from occurring the valve clearance must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart 1 Throttle stop screw Engin...

Page 45: ...h the total weight of rider passenger car go and accessories approved for this model WARNING EWA10511 Never overload your vehicle Opera tion of an overloaded vehicle could cause an accident Tire inspection The tires must be checked before each ride If the tire shows crosswise lines minimum tread depth if the tire has a nail or glass fragments in it or if the sidewall is cracked have a Yamaha deale...

Page 46: ... Yamaha Motor Co Ltd WARNING EWA10562 It is dangerous to ride with a worn out tire When a tire tread begins to show crosswise lines have a Yamaha dealer replace the tire immediately The replacement of all wheel and brake related parts includ ing the tires should be left to a Yamaha dealer who has the necessary professional knowl edge and experience It is not recommended to patch a punctured tube I...

Page 47: ...heel 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 EAU37913 Checking the brake lever free play There should be no free play at the brake lever end If there is free play have a Yamaha dealer inspect the brake system WARNING EWA14211 A soft or spongy fee...

Page 48: ...adjusting 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 shi...

Page 49: ... brake light come on later turn the adjusting nut in direction b 3 Install the panel EAU22380 Checking the front brake pads and rear brake shoes The front brake pads and the rear brake shoes must be checked for wear at the intervals specified in the periodic main tenance and lubrication chart EAU22430 Front brake pads Each front brake pad is provided with wear indicator grooves which allow you to ...

Page 50: ...80 Improper maintenance can result in loss of braking ability Observe these precautions Insufficient brake fluid may al low air to enter the brake sys tem reducing braking performance Clean the filler cap before re moving Use only DOT 3 or DOT 4 brake fluid from a sealed con tainer Use only the specified brake flu id otherwise the rubber seals may deteriorate causing leak age Refill with the same ...

Page 51: ...iodic maintenance and lubrica tion chart In addition have the oil seals of the brake master cylinder and caliper as well as the brake hose replaced at the intervals listed below or whenever they are damaged or leaking Oil seals Replace every two years Brake hose Replace every four years EAU22760 Drive chain slack The drive chain slack should be checked before each ride and adjusted if necessary EA...

Page 52: ...on a To loosen the drive chain turn the adjusting nut at each end of the swingarm in direction b and then push the rear wheel for ward NOTICE Improper drive chain slack will overload the en gine as well as other vital parts of the motorcycle and can lead to chain slippage or breakage To prevent this from occurring keep the drive chain slack with in the specified limits ECA10571 TIP Using the align...

Page 53: ...nd lubrica tion chart otherwise it will quickly wear out especially when riding in dusty or wet areas Service the drive chain as follows NOTICE ECA10583 The drive chain must be lubricated after washing the motorcycle riding in the rain or riding in wet areas 1 Remove all dirt and mud from the drive chain with a brush or cloth TIP For a thorough cleaning have a Yamaha dealer remove the drive chain ...

Page 54: ...Replace damaged cables as soon as possi ble to prevent unsafe conditions EWA10711 EAU49920 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 EAU23154 Checking and lubricating the brake lever The operati...

Page 55: ...d and sidestand should be checked before each ride and the pivots and metal to metal contact surfaces should be lubri cated if necessary WARNING EWA10741 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 Recommen...

Page 56: ...k the 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 EWA10751 2 While applying the front brake push down hard on the handlebars several times to check if the front fork compresses and rebounds sm...

Page 57: ...ion 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 EAU47812 Battery The battery is located under the seat See page 3 8 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 ne...

Page 58: ...e quired Using a conventional battery charger will damage the battery To store the battery 1 If the vehicle 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 then disconnect the negative lead before discon necting the positive lead ECA17710 2 If the battery will be stored f...

Page 59: ...a Yamaha dealer check the electrical system 7 Install the battery box cover by in stalling the screw 8 Close the seat EAU47761 Replacing the headlight bulb If the headlight bulb burns out replace it as follows NOTICE ECA10650 Take care not to damage the follow ing parts Headlight bulb Do not touch the glass part of the headlight bulb to keep it free from oil otherwise the transpar ency of the glas...

Page 60: ... stops 6 Install the bulb holder together with the bulb by turning it clock wise 7 Install the headlight bulb cover 8 Install the cowling 9 Have a Yamaha dealer adjust the headlight beam if necessary EAU47660 Replacing the tail brake light bulb 1 Remove the tail brake light outer lens by removing the screws 2 Remove the inner lens by pulling it out 1 Do not touch the glass part of the bulb 1 Headl...

Page 61: ...A10681 EAU47741 Replacing a front turn signal light bulb 1 Remove cowling A See page 6 7 2 Remove the turn signal light bulb socket together with the bulb by turning it counterclockwise 3 Remove the burnt out bulb by pushing it in and turning it counter clockwise 4 Insert a new bulb into the socket push it in and then turn it clock wise until it stops 5 Install the socket together with the bulb by...

Page 62: ...turn it clock wise until it stops 4 Install the lens by installing the screw NOTICE Do not over tighten the screw otherwise the lens may break ECA11191 EAU47910 Replacing the license plate light bulb 1 Remove the license plate light cov er by removing the screw 2 Remove the burnt out bulb by pull ing it out from the socket 1 Screw 1 1 Turn signal light bulb 1 1 License plate light cover 2 Screw 1 ...

Page 63: ...ght bulb burns out replace it as follows 1 Remove cowling A See page 6 7 2 Remove the auxiliary light bulb socket together with the bulb by pulling it out 3 Remove the burnt out bulb by pull ing it out 4 Insert a new bulb into the socket 5 Install the auxiliary light bulb sock et together with the bulb by push ing it in 6 Install the cowling 1 Auxiliary light bulb socket 1 1 Auxiliary light bulb 1...

Page 64: ...the wheel axle nut and the washer 5 Pull the wheel axle out and then remove the wheel NOTICE Do not apply the brake after the wheel has been removed to gether with the brake disc oth erwise the brake pads will be forced shut ECA11071 EAU55200 To install the front wheel 1 Install the speedometer gear unit into the wheel hub so that the pro jection on the wheel hub fits in ei ther slot of the speedo...

Page 65: ...peci fied torque TIP When tightening the axle nut hold the wheel axle with a wrench to keep it from turning 5 Take the motorcycle off the center stand 6 While applying the front brake push down hard on the handlebars several times to check if the front fork compresses and rebounds smoothly 7 Place the motorcycle on the cen terstand 8 Install the rubber cap 9 Connect the speedometer cable 1 Project...

Page 66: ...nut and the drive chain slack adjusting nut on both ends of the swingarm 5 Disconnect the brake torque rod from the brake shoe plate by re moving the cotter pin the nut the washer and the bolt 6 Remove the brake pedal free play adjusting nut and then disconnect the brake rod from the brake cam shaft lever 1 Wheel axle nut 1 1 Drive chain case 2 Bolt 1 Locknut 2 Drive chain slack adjusting nut 1 2 ...

Page 67: ...ake rod 5 Connect the brake torque rod to the brake shoe plate by installing the bolt the washer and the nut 6 Adjust the drive chain slack See page 6 20 7 Tighten the brake torque rod nut and axle nut to the specified torques TIP When tightening the axle nut hold the wheel axle with a wrench to keep it from turning 8 Insert a new cotter pin 9 Adjust the brake pedal free play See page 6 17 WARNING...

Page 68: ...uire 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 shorter service life and can lead to expensive repair bills WARNING EWA15141 When checking the fuel system do not smoke and m...

Page 69: ...ck 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 Have a Yamaha dealer check the vehicle The engine does not start Check the compression The engine does not start Check the ignition Operate the electric starter 2 Battery The engine turns over quickly The engine turns over slowly The battery is good...

Page 70: ...tlet 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 drive chain and wheel axles Always r...

Page 71: ...d 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 corrosiv...

Page 72: ...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 EAU26152 Stora...

Page 73: ...wall with oil WARNING 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 side stand centerstand 7 Check and if necessary c...

Page 74: ...ype or higher JASO standard MA Engine oil quantity Periodic oil change 0 80 L 0 85 US qt 0 70 Imp qt Air filter Air filter element Dry element Fuel Recommended fuel Regular gasoline Fuel tank capacity 4 2 L 1 11 US gal 0 92 Imp gal Fuel reserve amount 1 0 L 0 26 US gal 0 22 Imp gal Carburetor Type quantity MP17 x 1 Spark plug s Manufacturer model NGK CR6HSA Spark plug gap 0 6 0 7 mm 0 024 0 028 in...

Page 75: ...f cm 41 psi Front wheel Wheel type Cast wheel Rim size 17x1 40 Rear wheel Wheel type Cast wheel Rim size 17x1 60 Front brake Type Single disc brake Operation Right hand operation Specified brake fluid DOT 3 or 4 Rear brake Type Drum brake Operation Right foot operation Front suspension Type Telescopic fork Spring shock absorber type Coil spring oil damper Wheel travel 95 0 mm 3 74 in Rear suspensi...

Page 76: ...cense plate light 12 V 5 0 W 1 Meter lighting 12 V 1 7 W 1 Neutral indicator light 12 V 1 7 W 1 Gear position indicator light 12 V 3 0 W 4 High beam indicator light 12 V 1 7 W 1 Turn signal indicator light 12 V 1 7 W 1 Fuse Fuse 10 0 A U40BE2E0 book Page 3 Wednesday October 10 2012 8 01 AM ...

Page 77: ...n FRAME SERIAL NUMBER ENGINE SERIAL NUMBER EAU26431 Frame serial number The frame serial number is stamped into the frame TIP The frame serial number is used to identify your vehicle and may be used to register your vehicle with the licens ing authority in your area EAU26440 Engine serial number The engine serial number is stamped into the crankcase 1 Frame serial number 1 1 Engine serial number 1...

Page 78: ...lacing 6 28 G Gear position indicator lights 3 2 H Handlebar switches 3 3 Headlight bulb replacing 6 28 Helmet holders 3 8 High beam indicator light 3 2 Horn switch 3 4 I Identification numbers 9 1 Indicator lights 3 2 K Kickstarter 3 8 L License plate light bulb replacing 6 31 M Main switch steering lock 3 1 Maintenance and lubrication periodic 6 4 Maintenance emission control system 6 3 Matte co...

Page 79: ...ignal light bulb rear replacing 6 31 Turn signal switch 3 4 V Valve clearance 6 13 W Wheel bearings checking 6 26 Wheel front 6 33 Wheel rear 6 35 Wheels 6 16 U40BE2E0 book Page 2 Wednesday October 10 2012 8 01 AM ...

Page 80: ...A5 yoko_Blank fm Page 1 Thursday December 8 2011 2 18 PM ...

Page 81: ...A5 yoko_Blank fm Page 1 Thursday December 8 2011 2 18 PM ...

Page 82: ...PRINTED IN CHINA 2012 10 0 3 1 CR E DIC183 ...

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