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Yamaha DT230, Owner'S Manual

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Yamaha DT230 Owner'S Manual Download Page 62

6-19

PERIODIC MAINTENANCE AND MINOR REPAIR

1

2

3

4

5

6

7

8

9

EAU00680

w

8

It is dangerous to ride with a
worn-out tire. When a tire
tread begins to show cross-
wise lines, have a Yamaha
dealer replace the tire immedi-
ately.

8

The replacement of all wheel-
and brake-related parts,
including the tires, should be
left to a Yamaha dealer, who
has the necessary profession-
al knowledge and experience.

8

It is not recommended to
patch a punctured tube. If
unavoidable, however, patch
the tube very carefully and
replace it as soon as possible
with a high-quality product.

EW000078

w

8

The front and rear tires should
be of the same make and
design, otherwise the handling
characteristics of the motorcy-
cle cannot be guaranteed.

8

After extensive tests, only the
tires listed below have been
approved for this model by
Yamaha Motor Co., Ltd.

EW000079

w

8

Have a Yamaha dealer replace
excessively worn tires.
Besides being illegal, operat-
ing the motorcycle with exces-
sively worn tires decreases
riding stability and can lead to
loss of control.

8

The replacement of all wheel-
and brake-related parts,
including the tires, should be
left to a Yamaha dealer, who
has the necessary profession-
al knowledge and experience.

Tire information
This motorcycle is equipped with tube
tires.

FRONT

Manufacturer

Size

Type

INOUE

3.00-21 51P

GP-21F

CHENG SHIN

3.00-21 51P

M-6033

REAR

Manufacturer

Size

Type

INOUE

4.60-18 63P

GP-22R

CHENG SHIN

4.60-18 63P

M-6034

4TP-9-21  7/25/00 3:46 PM  Page 61

Summary of Contents for DT230

Page 1: ...PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2000 7 0 1 1 E OWNER S MANUAL 4TP 28199 21 DT230 N YAMAHA MOTOR CO LTD ...

Page 2: ...esetting racing machines It represents the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields This manual will give you an understanding of the operation inspection and basic maintenance of this motorcycle If you have any questions concerning the operation or maintenance of your motorcy cle please consult a Yamaha dealer 4TP 9 21 7 25 00 3 46 PM Page 1 ...

Page 3: ...must be taken to avoid damage to the motorcycle A NOTE provides key information to make procedures easier or clearer Q w cC NOTE NOTE 8 This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold 8 Yamaha continually seeks advancements in product design and quality Therefore while this manual contains the most current p...

Page 4: ...IMPORTANT MANUAL INFORMATION 1 2 4 5 6 7 8 9 EW000002 w PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE 4TP 9 21 7 25 00 3 46 PM Page 3 ...

Page 5: ... 2000 by Yamaha Motor Co Ltd 1st Edition July 2000 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan EAU03337 4TP 9 21 7 25 00 3 46 PM Page 4 ...

Page 6: ...7 Fuel tank cap 3 7 Fuel 3 8 2 stroke engine oil 3 8 Fuel cock 3 9 Starter choke lever 1 3 10 Seat 3 10 Helmet holder 3 11 Adjusting the front fork 3 11 Adjusting the shock absorber assembly 3 12 YPVS 3 15 Sidestand 3 16 Ignition circuit cut off system 3 16 PRE OPERATION CHECKS 4 1 Pre operation check list 4 1 OPERATION AND IMPORTANT RIDING POINTS 5 1 Starting and warming up a cold engine 5 1 Star...

Page 7: ...bles 6 27 Checking and lubricating the throttle grip and cable 6 28 Adjusting the Autolube pump 6 28 Checking and lubricating the brake and shift pedals 6 29 Checking and lubricating the brake and clutch levers 6 29 Checking and lubricating the sidestand 6 29 Lubricating the rear suspension 6 30 Checking the front fork 6 30 Checking the steering 6 31 Checking the wheel bearings 6 31 Battery 6 32 R...

Page 8: ...5 6 7 8 9 CONSUMER INFORMATION 9 1 Identification numbers record 9 1 Key identification number 9 1 Vehicle identification number 9 1 Model label 9 2 Motorcycle noise regulation for Australia 9 2 9 4TP 9 21 7 25 00 3 46 PM Page 7 ...

Page 9: ...ing 1 Always make pre operation checks Careful checks may help prevent an accident 2 This motorcycle is designed to carry the operator and a passenger 3 The failure of motorists to detect and recognize motorcycles in traffic is the predominating cause of automobile motorcycle accidents Many accidents have been caused by an automobile driver who did not see the motorcycle Making yourself conspicuou...

Page 10: ...r is veering wide on a turn due to EXCESSIVE SPEED or undercornering insufficient lean angle for the speed a Always obey the speed limit and never travel faster than warranted by road and traffic condi tions b Always signal before turning or changing lanes Make sure that other motorists can see you 6 The posture of the operator and passenger is important for proper control a The operator should ke...

Page 11: ...r after operation They become very hot and can cause burns Always wear protective clothing that covers your legs ankles and feet 6 Passengers should also observe the precautions mentioned above Modifications Modifications made to this motorcycle not approved by Yamaha or the removal of original equipment may render the motorcycle unsafe for use and may cause severe personal injury Modifications ma...

Page 12: ...torcycle before riding Check accessory mounts and cargo restraints frequently 3 Never attach any large or heavy items to the handlebar front fork or front fender These items including such cargo as sleeping bags duffel bags or tents can create unstable handling or a slow steering response Accessories Genuine Yamaha accessories have been specifically designed for use on this motorcycle Since Yamaha...

Page 13: ...namic effects Wind may attempt to lift the motorcycle or the motorcycle may become unstable in cross winds These accessories may also cause instability when passing or being passed by large vehicles c Certain accessories can displace the operator from his or her normal riding position This improper position limits the freedom of movement of the operator and may limit control ability therefore such...

Page 14: ...ch these hot areas b Do not park the motorcycle on a slope or soft ground otherwise it may fall over c Do not park the motorcycle near a flammable source e g a kerosene heater or near an open flame otherwise it could catch fire 4 When transporting the motorcycle in another vehicle make sure that it is kept upright and that the fuel cock s are turned to ON or RES for vacuum type OFF for manual type...

Page 15: ...Location of important labels Please read the following important labels carefully before operating this motorcycle 1 2 WARNING Before you operate this vehicle read the owner s manual English 3HP 21568 00 4AA 22259 40 2 1 4TP 9 21 7 25 00 3 46 PM Page 14 ...

Page 16: ...1 8 1 2 3 4 5 6 7 8 9 4TP 9 21 7 25 00 3 46 PM Page 15 ...

Page 17: ... 9 4 Starter choke lever 1 page 3 10 5 Air filter element page 6 14 6 2 stroke engine oil tank page 3 8 7 Helmet holder page 3 11 8 Rear shock absorber spring preload adjusting nut page 3 13 9 Rear shock absorber rebound damping adjusting dial page 3 14 10 Shift pedal page 3 6 11 YPVS page 3 15 12 Front fork compression damping adjusting screw page 3 12 4TP 9 21 7 25 00 3 46 PM Page 16 ...

Page 18: ...7 8 9 2 2 13 14 15 16 17 18 Right view 13 Coolant reservoir page 6 11 14 Owner s tool kit page 6 1 15 Battery page 6 32 16 Fuse page 6 33 17 Radiator cap page 6 12 18 Brake pedal page 3 7 6 22 4TP 9 21 7 25 00 3 46 PM Page 17 ...

Page 19: ...ar switches page 3 5 3 Speedometer unit page 3 3 4 Main switch steering lock page 3 1 5 Right handlebar switches page 3 5 6 Brake lever page 3 6 6 21 7 Throttle grip page 6 16 6 28 8 Fuel tank cap page 3 7 1 2 3 4 5 6 7 8 Controls and instruments 4TP 9 21 7 25 00 3 46 PM Page 18 ...

Page 20: ...7 INSTRUMENT AND CONTROL FUNCTIONS 1 2 3 4 5 6 7 8 9 EW000016 w Never turn the key to OFF or LOCK while the motorcycle is moving otherwise the electrical systems will be switched off which may result in loss of control or an accident Make sure that the motorcycle is stopped before turn ing the key to OFF or LOCK EAU00040 LOCK The steering is locked and all electri cal systems are off The key can b...

Page 21: ...or further instructions 8 When the engine oil level is low and the coolant temperature is too high the warning light flash es and symbols 7 and come on To check that the warning light is working properly 8 Put the transmission in neutral or apply the clutch lever 8 Turn the engine stop switch to and the key to ON 8 The light will come on and sym bol 7 will appear in the dis play If the warning lig...

Page 22: ...ween modes A and B When in mode A 8 The upper tripmeter can be reset to zero 8 The display can be switched between the clock and the odometer 8 The clock can be set When in mode B 8 The lower tripmeter can be reset 8 The lower tripmeter can be switched between forward count and reverse count Select the modes as follows 1 Turn the key to ON 1 Reset button RESET 2 Upper trip odometer 3 Lower trip od...

Page 23: ...eat this procedure to change the tens and ones 4 Push the mode select button again to set the tripmeter INSTRUMENT AND CONTROL FUNCTIONS 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 1 Reset button RESET 2 Upper trip odometer 3 Lower trip odometer 4 Digital speedometer 5 Odometer Clock ODO CLOCK 6 Mode select button SELECT Mode A To set the upper tripmeter to zero push the reset button for at least one second To ...

Page 24: ...urned to the center position EAU00129 Horn switch Press this switch to sound the horn EAU00138 Engine stop switch Set this switch to to stop the engine in case of an emergency such as when the motorcycle over turns or when the throttle cable is stuck EAU00143 Start switch Push this switch to crank the engine with the starter EC000005 cC See page 5 1 for starting instruc tions prior to starting the...

Page 25: ...h 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 is part of the igni tion circuit cut off system See page 3 16 for an explanation of the ignition circuit cut off system EAU00157 Shift pedal The shift pedal is located on the left side of the engine and is used in combination with the clutch...

Page 26: ...p 1 Insert the fuel tank cap into the tank opening with the key insert ed in the lock and then turn the cap 1 3 turn clockwise 2 Turn the key 1 4 turn clockwise and then remove it 1 Brake pedal 1 Fuel tank cap a Unlock b Open INSTRUMENT AND CONTROL FUNCTIONS 1 2 3 4 5 6 7 8 9 NOTE The fuel tank cap cannot be installed unless the key is in the lock In addi tion the key cannot be removed if the cap ...

Page 27: ...183 Fuel Make sure that there is sufficient fuel in the tank Fill the fuel tank to the bottom of the filler tube as shown in the illustration EW000130 w 8 Do not overfill the fuel tank otherwise it may overflow when the fuel warms up and expands 8 Avoid spilling fuel on the hot engine EAU00185 cC Immediately wipe off spilled fuel with a clean dry soft cloth since fuel may deteriorate painted sur f...

Page 28: ... carburetor 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 running RES ON FUEL OFF 1 1 Arrow mark positioned over OFF OFF Closed position ON FUEL RES OFF 1 ON 1 Arrow mark positioned over ON ON With the lever in this position fuel flows to the carburetor Normal riding i...

Page 29: ... 1 RES 1 Arrow mark positioned over RES RES Reserve position b a 1 EAU02976 Starter choke lever 1 Starting a cold engine requires a rich er air fuel mixture which is supplied by 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 1 Starter choke lever 1 1 EAU00240 Seat To remove the seat Remove the bolts and then ...

Page 30: ...elmet holder insert the key into the lock and then turn the key as shown To lock the helmet holder place it in the original position and then remove the key EW000030 w Never ride with a helmet attached to the helmet holder since the hel met may hit objects causing loss of control and possibly an acci dent 1 Helmet holder a Open EAU03589 Adjusting the front fork This front fork is equipped with dam...

Page 31: ...b 1 Compression damping adjusting screw Adjust the damping force as follows 1 Remove the rubber cap from the bottom of each fork leg 2 To increase the damping force and thereby harden the suspen sion turn the adjusting screw in direction a To decrease the damping force and thereby soft en the suspension turn the adjusting screw in direction b NOTE To determine the maximum damping force setting pus...

Page 32: ...preload 1 Loosen the locknut 2 To increase the spring preload and thereby harden the suspen sion turn the adjusting nut in direction a To decrease the spring preload and thereby soft en the suspension turn the adjusting nut in direction b NOTE 8 Use the special wrench included in the owner s tool kit to make the adjustment 8 The spring preload setting is determined by measuring dis tance A shown i...

Page 33: ...amping turn the adjusting knob in direction a To decrease the compression damping force and thereby soften the com pression damping turn the adjusting knob in direction b b a 1 1 Adjusting dial Rebound damping force To increase the rebound damping force and thereby harden the rebound damping turn the adjusting dial in direction a To decrease the rebound damping force and thereby soften the rebound...

Page 34: ... the engine YPVS operation noises can be heard in the following instances 8 When the key is turned to ON and the engine is started 8 When the engine stalls with the key in the ON position EC000024 cC If the YPVS does not operate have a Yamaha dealer check it EW000041 w This shock absorber contains highly pressurized nitrogen gas For proper handling read and understand the following informa tion be...

Page 35: ... when the transmission is in gear and the clutch lever is pulled but the sidestand is still down 8 It It cuts the running engine when the sidestand is moved down Periodically check the operation of the ignition circuit cut off system according to the following procedure EW000045 w If a malfunction is noted have a Yamaha dealer check the system before riding EW000044 w The motorcycle must not be ri...

Page 36: ...d up 7 Keep the clutch lever pulled 8 Shift the transmission into gear 9 Move the sidestand down Does the engine stall After the engine has stalled 10 Move the sidestand up 11 Keep the clutch lever pulled 12 Push the start switch Does the engine start The sidestand switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer The clutch switch may be defective The mo...

Page 37: ...necessary add recommended oil to specified level Check vehicle for oil leakage 3 8 3 9 Transmission oil Check oil level in transmission case If necessary add recommended oil to specified level 6 9 6 10 Coolant Check coolant level in reservoir If necessary add recommended coolant to specified level Check cooling system for leakage 6 10 6 13 Front brake Check operation If soft or spongy have Yamaha ...

Page 38: ...y 6 27 Drive chain Check chain slack Adjust if necessary Check chain condition Lubricate if necessary 6 25 6 27 Wheels and tires Check for damage Check tire condition and tread depth Check air pressure Correct if necessary 6 17 6 20 Brake and shift pedals Make sure that operation is smooth Lubricate pedal pivoting points if necessary 6 29 Brake and clutch levers Make sure that operation is smooth ...

Page 39: ...ration check list is not working properly have it inspected and repaired before operat ing the motorcycle Chassis fasteners Make sure that all nuts bolts and screws are properly tightened Tighten if necessary Instruments lights sig nals and switches Check operation Correct if necessary 3 5 6 34 6 38 Sidestand switch Check operation of ignition circuit cut off system If system is defective have Yam...

Page 40: ...up a cold engine In order for the ignition circuit cut off system to enable starting one of the following conditions must be met 8 The transmission is in the neutral position 8 The transmission is in gear with the clutch lever pulled and the sidestand up EW000054 w 8 Before starting the engine check the function of the igni tion circuit cut off system according to the procedure described on page 3...

Page 41: ...choke off NOTE The engine is warm when it responds normally to the throttle with the starter choke turned off EAU01258 Starting a warm engine Follow the same procedure as for starting a cold engine with the excep tion that the starter choke is not required when the engine is warm EAU00423 Shifting Shifting gears lets you control the amount of engine power available for starting off accelerating cl...

Page 42: ...ine 8 Turn the starter choke off as soon as possible 8 Shift up swiftly and avoid high engine speeds during accelera tion 8 Do not rev the engine while shift ing down and avoid high engine speeds with no load on the engine 8 Turn the engine off instead of let ting it idle for an extended length of time e g in traffic jams at traffic lights or at railroad cross ings EAU00436 Engine break in There i...

Page 43: ...e 3 4 throttle EC000060 cC After 1 000 km of operation the transmission oil must be changed EAU00457 Parking When parking stop the engine remove the key from the main switch and then turn the fuel cock lever to OFF EW000058 w 8 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 8 Do not park on a slope or on soft grou...

Page 44: ...n in the periodic maintenance and lubrication chart should be simply considered as a general guide under normal riding conditions However DEPENDING ON THE WEATHER TERRAIN GEOGRAPHICAL LOCATION AND INDIVIDUAL USE THE MAINTE NANCE INTERVALS MAY NEED TO BE SHORTENED EW000060 w If you are not familiar with motor cycle maintenance work have a Yamaha dealer do it for you 1 EAU01175 Owner s tool kit The ...

Page 45: ...DOMETER READING 1 000 km ANNUAL CHECK 1 6 12 18 24 1 Fuel line Check fuel hoses for cracks or damage 2 Spark plug Replace 3 Air filter element Clean Replace 4 Clutch Check operation Adjust 5 Front brake Check operation fluid level and vehicle for fluid leakage See NOTE on page 6 4 Replace brake pads Whenever worn to the limit 6 Rear brake Check operation fluid level and vehicle for fluid leakage S...

Page 46: ...bricate with lithium soap based grease Every 24 000km 14 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 15 Sidestand Check operation Lubricate 16 Sidestand switch Check operation 17 Front fork Check operation and for oil leakage 18 Rear shock absorber assembly Check operation and shock absorber for oil leakage 19 Rear suspension relay arm and connecting arm pivot...

Page 47: ... and caliper and change the brake fluid 8 Replace the brake hoses every four years and if cracked or damaged 22 Transmission oil Check oil level and vehicle for leakage Change 23 Cooling system Check coolant level and vehicle for coolant leakage Change Every 3 years 24 Front and rear brake switches Check operation 25 Moving parts and cables Lubricate 26 Lights signals and switches Check operation ...

Page 48: ...d and installed 1 Cowling A 2 Cowling B 1 Screw 4 EAU00484 Cowling A To remove the cowling Remove the cowling 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 EAU00482 Cowling B To remove the cowling Remove the screws and then take the cowling off To install the cowling Place the cowling in the original pos...

Page 49: ... Panel A To remove the panel Remove the screw and then pull the panel off as shown To install the panel Place the panel in the original posi tion and then install the screw 1 1 Panel A EAU01122 Removing and installing panels The panels shown above need to be removed to perform some of the maintenance jobs described in this chapter 4TP 9 21 7 25 00 3 46 PM Page 48 ...

Page 50: ... The spark plug is an important engine component which is easy to check Since heat and deposits will cause any spark plug to slowly erode the spark plug should be removed and checked in accordance with the periodic maintenance and lubrication chart In addition the condition of the spark plug can reveal the condition of the engine To remove the spark plug 1 Remove the spark plug cap 2 Remove the sp...

Page 51: ...nstall the spark plug 1 Measure the spark plug gap with a wire thickness gauge and if necessary adjust the gap to specification 2 Clean the surface of the spark plug gasket and its mating sur face and then wipe off any grime from the spark plug threads 3 Install the spark plug with the spark plug wrench and then tighten it to the specified torque NOTE If a torque wrench is not available when insta...

Page 52: ...opped check the oil level through the level window located at the right side crankcase cover NOTE Wait a few minutes until the oil level settles before checking 3 The oil level should be between the maximum and minimum level on the level window If the level is low add sufficient oil to raise it to the specified level 1 Oil level window 2 Maximum level 3 Minimum level 1 1 Oil filler cap Transmissio...

Page 53: ...inutes While warming up check for oil leakage If oil leakage is found stop the engine immediately and check for cause EAU01808 Coolant To check the coolant level 1 Place the motorcycle on a level surface and hold it in an upright position NOTE 8 The coolant level must be checked on a cold engine since the level varies with engine tem perature 8 Make sure that the motorcycle is positioned straight ...

Page 54: ...coolant as soon as possi ble otherwise the effective ness of the coolant will be reduced EW000067 w Never attempt to remove the radia tor cap when the engine is hot 5 Install the panel NOTE If the engine overheats see page 6 44 for further instructions Coolant reservoir capacity 0 36 L 2 3 1 2 Remove panel B See page 6 7 for panel removal and installation procedures 3 Check the coolant level in th...

Page 55: ... bolt to the specified torque 6 12 EAU03101 Changing the coolant 1 Put the motorcycle on a level place 2 Remove cowling B and panel B See pages 6 5 and 6 7 for cowl ing and panel removal and instal lation procedures 3 Remove the radiator cap stopper bolt and the radiator cap PERIODIC MAINTENANCE AND MINOR REPAIR 1 2 3 4 5 6 7 8 9 1 2 1 Radiator cap stopper bolt 2 Radiator cap 1 1 Coolant drain bol...

Page 56: ...uced 10 Install the radiator cap 11 Run the engine several minutes Stop the engine and recheck the coolant level in the radiator If it is low add more coolant until it reaches the top of the radiator 12 Install the radiator cap stopper bolt 13 Fill the reservoir tank with coolant up to maximum level 14 Install the reservoir tank cap and check for coolant leakage NOTE If any leakage is found ask a ...

Page 57: ...or dusty areas 1 Remove panel A See page 6 6 for removal and installation pro cedures 2 Remove the air filter case cover by removing the screws 1 2 1 Screw 3 2 Air filter case cover 3 Pull the air filter element out from the air filter case 1 3 2 4 4 Remove the wing nut and then pull the air filter element off of the guide 5 Remove the sponge material from the air filter element frame 1 Air filter...

Page 58: ...art of the engine and requires very sophisti cated adjustment Therefore most carburetor adjustments should be left to a Yamaha dealer who has the necessary professional knowledge and experience The adjustment described in the following section however may be serviced by the owner as part of routine mainte nance EC000094 cC The carburetor has been set and extensively tested at the Yamaha factory Ch...

Page 59: ...ing speed and if necessary adjust it to specification by turning the throt tle stop screw To increase the engine idling speed turn the screw in direction a To decrease the engine idling speed turn the screw in direction b NOTE If the specified idling speed cannot be obtained as described above have a Yamaha dealer make the adjustment Engine idling speed 1 300 1 400 r min a EAU00634 Adjusting the t...

Page 60: ...ust be adjusted in accordance with the riding speed and with the total weight of rider passen ger cargo and accessories approved for this model 1 Loosen the locknut 2 To increase the throttle cable free play turn the adjusting nut in direction a To decrease the throttle cable free play turn the adjusting nut in direction b 3 Tighten the locknut 2 1 b a 1 Adjusting nut 2 Locknut Tire air pressure m...

Page 61: ...can shift during a ride 8 Securely pack the heaviest items close to the center of the motorcycle and distribute the weight evenly on both sides 8 Adjust the suspension and tire air pressure with regard to the load 8 Check the tire condition and air pressure before each ride Tire inspection The tires must be checked before each ride If the tire shows crosswise lines minimum tread depth if the tire ...

Page 62: ...design otherwise the handling characteristics of the motorcy cle cannot be guaranteed 8 After extensive tests only the tires listed below have been approved for this model by Yamaha Motor Co Ltd EW000079 w 8 Have a Yamaha dealer replace excessively worn tires Besides being illegal operat ing the motorcycle with exces sively worn tires decreases riding stability and can lead to loss of control 8 Th...

Page 63: ...wheel A deformed or cracked wheel must be replaced 8 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 handling characteristics and a shortened tire life 8 Ride at moderate speeds after changing a tire since the tire sur face must first be broken in for it to develop its optimal charac teristics a ...

Page 64: ...s 1 Loosen the locknut at the brake lever 2 To increase the brake lever free play turn the adjusting bolt in direction a To decrease the brake lever free play turn the adjusting bolt in direction b 3 Tighten the locknut 1 Locknut 2 Adjusting bolt c Brake lever free play a a b 1 2 3 4 b 1 Loosen the locknut at the clutch lever 2 To increase the clutch lever free play turn the adjusting bolt in dire...

Page 65: ...oss of control and an accident a 1 EAU00712 Adjusting the brake pedal position The top of the brake pedal should be positioned approximately 15 mm below the top of the footrest as shown Periodically check the brake pedal position and if necessary have a Yamaha dealer adjust it 1 Footrest a Brake pedal position EW000109 w A soft or spongy feeling in the brake pedal can indicate the pres ence of air...

Page 66: ...e point that the wear indicator groove has almost dis appeared have a Yamaha dealer replace the brake pads as a set 1 1 Indicator groove REAR EAU00713 Adjusting the rear brake light switch The rear brake light switch which is activated by the brake pedal is prop erly adjusted when the brake light comes on just before braking takes effect If necessary adjust the brake light switch as follows Turn t...

Page 67: ...ds and or brake system leakage If the brake level is low be sure to check the brake pads for wear and the brake system for leak age 1 1 Minimum level mark FRONT 1 1 Minimum level mark REAR Recommended brake fluid DOT 4 8 Refill with the same type of brake fluid Mixing fluids may result in a harmful chemical reaction and lead to poor braking perfor mance 8 Be careful that water does not enter the m...

Page 68: ...hain slack 3 Move the rear wheel by pushing the motorcycle to locate the tight est portion of the drive chain and then measure the drive chain slack as shown 4 If the drive chain slack is incor rect adjust it as follows Drive chain slack 40 60 mm EAU03073 Changing the brake fluid Have a Yamaha dealer change the brake fluid at the intervals specified in the periodic maintenance and lubrica tion cha...

Page 69: ...heel for ward NOTE Make sure that both adjusting plates are in the same position for proper wheel alignment a 1 2 b 1 Axle nut 2 Chain adjusting plate Tightening torque Axle nut 104 Nm 10 4 m0kg EAU03006 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 especial...

Page 70: ...ll control cables and the condition of the cables should be checked before each ride and the cables and cable ends should be lubricated if necessary If a cable is damaged or does not move smoothly have a Yamaha dealer check or replace it Recommended lubricant Engine oil 3 Thoroughly lubricate the drive chain with a special O ring chain lubricant ECA00052 cC Do not use engine oil or any other lubri...

Page 71: ...t the throttle cable hold it up and then apply several drops of oil to the cable end allowing it to trickle into the sheath 3 Connect the throttle cable and then grease the inside of the throttle grip housing EAU00774 Adjusting the Autolube pump The Autolube pump is a vital and sophisticated component of the engine which must be adjusted by a Yamaha dealer at the intervals speci fied in the period...

Page 72: ...icating the brake and clutch levers The operation of the brake and clutch levers should be checked before each ride and the lever pivots should be lubricated if necessary Recommended lubricant Lithium soap based grease all purpose grease Recommended lubricant Lithium soap based grease all purpose grease EAU03370 Checking and lubricating the brake and shift pedals The operation of the brake and shi...

Page 73: ... the operation 1 Place the motorcycle on a level surface and hold it in an upright position 2 While applying the front brake push down hard on the handle bars several times to check if the front fork compresses and rebounds smoothly EC000098 cC If any damage is found or the front fork does not operate smoothly have a Yamaha dealer check or repair it EAU00790 Lubricating the rear suspension The piv...

Page 74: ...s of the front fork legs and try to move them forward and backward If any free play can be felt have a Yamaha dealer check or repair the steering EAU00794 Checking the steering Worn or loose steering bearings may cause danger Therefore the opera tion of the steering must be checked as follows at the intervals specified in the periodic maintenance and lubrica tion chart 1 Place a stand under the en...

Page 75: ...s In case of contact administer the following FIRST AID 8 EXTERNAL Flush with plenty of water 8 INTERNAL Drink large quantities of water or milk and immediately call a physician 8 EYES Flush with water for 15 minutes and seek prompt medical attention 8 Batteries produce explosive hydrogen gas Therefore keep sparks flames cigarettes etc away from the battery and provide sufficient ventilation when ...

Page 76: ...l constant voltage battery charger is required Using a conventional battery charger will damage the battery If you do not have access to a sealed type MF battery charger have a Yamaha dealer charge your battery 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 2 If the battery will be stored fo...

Page 77: ...l and installa tion procedures 2 Disconnect the headlight cou pler and then remove the head light bulb cover 1 1 Headlight coupler EC000103 cC Do not use a fuse of a higher amperage rating than recommend ed to avoid causing extensive damage to the electrical system and possibly a fire 3 Turn the key to ON and turn on the electrical circuits to check if the devices operate 4 If the fuse immediately...

Page 78: ...ulb into position and then secure it with the bulb hold er 1 1 Headlight bulb holder EC000106 cC Avoid touching the glass part of the bulb Keep it free from oil oth erwise the transparency of the glass life of the bulb and lumi nous flux will be adversely affect ed If oil gets on the bulb thor oughly clean it with a cloth moistened with alcohol or lacquer thinner 5 Install the bulb cover and then ...

Page 79: ...ive bulb by pushing it in and turning it coun terclockwise 3 Insert a new bulb into the socket push it in and then turn it clock wise until it stops 4 Install the lens by installing the screw ECA00065 cC Do not overtighten the screw oth erwise the lens may break 6 Install the cowling together with the headlight unit 7 Have a Yamaha dealer adjust the headlight beam if necessary 4TP 9 21 7 25 00 3 4...

Page 80: ...t clock wise until it stops 4 Install the lens by installing the screws EC000108 cC Do not overtighten the screws otherwise the lens may break 1 1 Nut 2 EAU01624 Replacing the license plate light bulb 1 Remove the license plate light by removing the nuts 1 2 1 Screw 2 2 Lens EAU01623 Replacing the tail brake light bulb 1 Remove the tail brake light lens by removing the screws 4TP 9 21 7 25 00 3 46...

Page 81: ...aced under the engine for added stability To service the front wheel 1 Stabilize the rear of the motorcy cle by using a motorcycle stand or if an additional motorcycle stand is not available by placing a jack under the frame in front of the rear wheel 2 Raise the front wheel off the ground by using a motorcycle stand 1 1 Bulb 2 3 Remove the defective bulb by pulling it out 4 Insert a new bulb into...

Page 82: ... 2 Lift the front wheel off the ground according to the procedure on page 6 38 3 Pull the wheel axle out and then remove the wheel ECA00048 cC Do not apply the brake after the wheel has been removed together with the brake disc otherwise the brake pads will be forced shut To service the rear wheel Raise the rear wheel off the ground by using a motorcycle stand or if a motorcycle stand is not avail...

Page 83: ...isc between the brake pads NOTE Make sure that there is enough space between the brake pads before inserting the brake disc 2 Insert the wheel axle 3 Lower the front wheel so that it is on the ground 4 Tighten the wheel axle to the specified torque 5 Tighten the axle holder nuts to the specified torque Tightening torque Wheel axle 58 Nm 5 8 m0kg NOTE Tighten the upper nuts first and then the lower...

Page 84: ...the drive chain onto the rear sprocket and then insert the wheel axle from the left side NOTE Make sure that there is enough space between the brake pads before inserting the brake disc between the pads 2 Install the swingarm end bolts and then lower the rear wheel so that it is on the ground 3 Adjust the drive chain slack See page 6 26 for drive chain slack adjustment procedures 4 Tighten the axl...

Page 85: ...er The following troubleshooting charts represent quick and easy procedures for checking these vital systems your self However should your motorcy cle require any repair take it to a Yamaha dealer whose skilled techni cians 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 th...

Page 86: ...e electric starter Wet Dry Wipe clean with dry cloth and correct Open throttle half way and start Ask a Yamaha dealer to inspect Check if there is fuel Enough fuel No fuel Go to compression check Supply fuel in the fuel tank electrodes plug and check Engine doesn t start go to battery check the engine spark gap or replace spark plug Engine turns over Engine turns over Battery good Check connection...

Page 87: ... pressure to escape When the hissing sound has stopped press down on the cap while turning it counterclockwise and then remove the cap Level is OK Wait until the engine has cooled Restart the engine If the engine overheats again ask a Yamaha dealer to inspect and repair the cooling system Check the coolant level in the reservoir tank and or radiator Add coolant See NOTE Level is low check the cool...

Page 88: ...s as well as all electrical cou plers and connectors including the spark plug cap are tightly installed 3 Remove extremely stubborn dirt like oil burnt onto the crankcase with a degreasing agent and a brush but never apply such products onto seals gaskets sprockets the drive chain and wheel axles Always rinse the dirt and degreaser off with water Cleaning ECA00010 cC 8 Avoid using strong acidic wh...

Page 89: ...t does not leave any marks If the windshield is scratched use a quality plastic polishing compound after washing After normal use Remove dirt with warm water a mild detergent and a soft clean sponge and then rinse thoroughly with clean water Use a toothbrush or bottle brush 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...

Page 90: ...Touch up minor paint damage caused by stones etc 7 Wax all painted surfaces 8 Let the motorcycle dry complete ly before storing or covering it EWA00001 w 8 Make sure that there is no oil or wax on the brakes or tires If necessary clean the brake discs and brake linings with a regular brake disc cleaner or acetone and wash the tires with warm water and a mild detergent 8 Before operating the motorc...

Page 91: ... drain bolt this will prevent fuel deposits from building up Pour the drained fuel into the fuel tank 4 Fill up the fuel tank and add fuel stabilizer if available to prevent the fuel tank from rusting and the fuel from deteriorating 5 Perform the following steps to protect the cylinder piston rings etc from corrosion a Remove the spark plug cap and spark plug b Pour a teaspoonful of engine oil int...

Page 92: ...e wheels a little every month in order to pre vent the tires from becoming degraded in one spot 8 Cover the muffler outlet with a plastic bag to prevent moisture from entering it 9 Remove the battery and fully charge it Store it in a cool dry place and charge it once a month Do not store the battery in an excessively cold or warm place less than 0 C or more than 30 C For more information on storin...

Page 93: ...ement 224 cm3 Bore Stroke 66 8 64 0 mm Compression ratio 6 5 1 Starting system Electric starter Lubrication system Separate lubrication Yamaha autolube Engine oil Type 2 stroke engine oil Capacity Total amount 1 3 L Transmission oil Type SAE 10W30 type SE motor oil Capacity Periodic oil change 0 8 L Total amount 0 85 L Cooling system capacity total amount 1 26 L Air filter Wet type element Fuel Ty...

Page 94: ...st 2 750 2nd 1 875 3rd 1 411 4th 1 142 5th 0 956 6th 0 818 Chassis Frame type Semi double cradle Caster angle 27 Trail 114 mm Tires Type With tube Front Size 3 00 21 51P Manufacturer INOUE GP 21F model CHENG SHIN M 6033 Rear Size 4 60 18 63P Manufacturer INOUE GP 22R model CHENG SHIN M 6034 Maximum load 180 kg Air pressure cold tire up to 88 kg load Front 125 kPa 1 25 kg cm2 1 25 bar Rear 150 kPa ...

Page 95: ...hock absorber Front Coil spring oil damper Rear Coil gas spring oil damper Wheel travel Front 250 mm Rear 240 mm Electrical system Ignition system C D I Charging system Type C D I magneto Standard output 14 V 12 A 5 000 r min Battery Type GT6B 3 Voltage capacity 12 V 6 AH Headlight type Halogen bulb Bulb voltage wattage quantity Headlight 12 V 60 55W 1 Tail brake light 12 V 5 21W 1 Front turn sign...

Page 96: ...7 8 9 SPECIFICATIONS Neutral indicator light 12 V 3W 1 High beam indicator light 12 V 3W 1 Turn signal indicator light 12 V 3W 1 Oil level coolant temperature warning light LED Fuse 30A 4TP 9 21 7 25 00 3 46 PM Page 95 ...

Page 97: ...ric unit Multiplier Imperial unit m kg 7 233 ft lb Torque m kg 86 794 in lb cm kg 0 0723 ft lb cm kg 0 8679 in lb Weight kg 2 205 lb g 0 03527 oz Speed km hr 0 6214 mph km 0 6214 mi m 3 281 ft Distance m 1 094 yd cm 0 3937 in mm 0 03937 in cc cm3 0 03527 oz IMP liq Volume cc cm3 0 06102 cu in Capacity L liter 0 8799 qt IMP liq L liter 0 2199 gal IMP liq kg mm 55 997 lb in Misc kg cm2 14 2234 psi l...

Page 98: ...ATION EAU01041 Key identification number The key identification number is stamped into the key tag Record this number in the space pro vided and use it for reference when ordering a new key EAU01043 Vehicle identification number The vehicle identification number is stamped into the steering head pipe Record this number in the space pro vided NOTE The vehicle identification number is used to identi...

Page 99: ...RING WITH NOISE CON TROL SYSTEM PROHIBITED Owners are warned that the law may prohibit a The removal or rendering inoper ative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehi cle for the purpose of noise con trol prior to its sale or delivery to the ultimate purchaser or while it is in use and b The use of...

Page 100: ...1 2 3 4 5 6 7 8 9 4TP 9 21 7 25 00 3 46 PM Page 99 ...

Page 101: ...4TP 9 21 7 25 00 3 46 PM Page 100 ...

Page 102: ...PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2000 7 0 1 1 E OWNER S MANUAL 4TP 28199 21 DT230 N YAMAHA MOTOR CO LTD ...

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