Yamaha DT501988 Owner'S Manual Download Page 1

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Summary of Contents for DT501988

Page 1: ... YAMAHA f sr OWNER S MANUAL 38K 28199 71 ...

Page 2: ... on your key as shown in the following illus tration Record this number in the space provided for reference if you need a new key Key number Record your vehicle and engine numbers in the spaces provided to assist you in ordering spare parts from your Yamaha dealer or for reference in case your vehicle is stolen See page 3 1 ...

Page 3: ...ER S MANUAL 1988 by Yamaha Motor Co Ltd 1st Edition June 1988 All rights reserved Any reprinting or unauthorized use without the written permission of yamaha Motor Co Ltd is expressly prohibited Printed in Japan ...

Page 4: ...se fields This manual will give you an understanding of the operation inspection and basic maintenance of this motorcycle If you have any questions about the operation or main tenance of your motorcycle please consult a Yamaha dealer U 001 NOTE Some data in this manual may become out dated due to future improvement on this model If you have any questions about this manual or your motorcycle please...

Page 5: ...make procedures easier or clearer A CAUTION indicates special procedures that must be followed to avoid damage to the motorcycle WARNING A WARNING indicates special procedures that must be followed to avoid injury to a motorcycle operator or person inspecting or repairing the motorcycle U 000 NOTE This manual should be considered a perma nent part of this motorcycle and should re main with it even...

Page 6: ...KNOW THE FOLLOWING REQUIREMENTS BE FORE RIDING HE OR SHE SHOULD 1 OBTAIN THOROUGH INSTRUCTIONS FROM A COMPETENT SOURCE ON ALL ASPECTS OF MOTORCYCLE OPERATION 2 OBSERVE THE WARNINGS AND MAINTENANCE REQUIREMENTS IN THE OWNER S MANUAL 3 OBTAIN QUALIFIED TRAINING IN SAFE AND PROPER RIDING TECHNIQUES 4 OBTAIN PROFESSIONAL TECHNICAL SERVICE AS INDICATED BY THE OWNER S MANUAL AND OR WHEN MADE NECESSARY B...

Page 7: ...self conspicuous appears to be very effective in reducing the chance of this type of accident Therefore a Wear a brightly colored jacket b Use extra caution when you approach and pass through intersections since intersections are the most likely places for motorcycle accidents c Ride where other motorists can see you Avoid riding in another motorist s blind spot 4 Many accidents involve inexperien...

Page 8: ...or the speed a Always obey the speed limits and never travel faster than warranted by road and traffic conditions b Always signal before turning or changing lanes Make sure other motorists see you 6 Operator s posture is important for proper control The operator should keep both hands on the handlebars and both feet on the operator footrests during operation to maintian control of the motorcycle 7...

Page 9: ...othing It could catch on the control levers footrests or wheels and cause injury or accident 5 Never touch the engine or exhaust system during or after operation They become very hot and can cause burns Always wear protective clothings that covers your legs ankles and feet MODIFICATION Modifications made to the motorcycle not approved by Yamaha or the removal of original equipment may render your ...

Page 10: ...ding accessories to your motorcycle LOADING The total weight of the operator accessories and cargo must not exceed the maximum load limit of 157 lbs 71 kg When loading within these weight limits keep the following in mind 1 Cargo and accessory weight should be kept as low and close to the motorcycle as possible Be sure to distribute the weight as evenly as possible on both sides of the machine to ...

Page 11: ...rsonally be responsible for the proper selection instal lation and use of non Yamaha accessories You should use extreme caution when selecting and installing any accessories Keep in mind these guidelines for mounting accessories in addition to those provided under LOADING 1 Never install accessories or carry cargo that would impair the performance of your motorcycle Carefully inspect the accessory...

Page 12: ...e mo torcycle or the motorcycle may become unstable in cross winds These accessories may also cause instability when being passed by or passing large vehicle 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 accessories are not recommended 2 Cautio...

Page 13: ...d death within a short time Always operate your motorycle in an area that has adequate ventilation 3 Always turn off the engine before leaving the motorcycle unattended and remove the ignition key When parking the motorcycle note the following a The engine and exhaust pipe s muffler s may be hot Park the motorcycle in a place where pedestrians or children are not likely to touch these hot areas b ...

Page 14: ...pe OFF for manual type If it should lean over gasoline may leak out of the car buretor or fuel tank 5 If you should swallow any gasoline inhale a lot of gasoline vapor or allow gasoline to get in your eye s see your doctor immediately If any gasoline spills on your skin or clothing immediately wash with soap and water and change your clothes ...

Page 15: ...ngine serial number 3 1 Energy Induction system 4 10 Sidestand 4 11 CONTROL FUNCTIONS 4 1 Sidestand switch operation check 4 11 Main switch 4 1 Indicator lights 4 2 PRE OPERATION CHECKS 5 1 Oil warning light checking method 4 3 Brakes 5 3 Speedometer 4 4 Clutch 5 3 Tachometer 4 4 Throttle grip 5 3 Engine temperature gauge 4 4 Engine oil 5 3 Handlebar switches 4 5 Transmission oil 5 4 Clutch lever ...

Page 16: ...17 Engine warm up 6 3 Brake light switch adjustment 7 18 Starting a warm engine 6 3 Checking the brake shoes 7 19 Shifting 6 3 Clutch adjustment 7 19 Engine break in 6 4 Mechanism adjustment 7 20 Parking 6 5 Drive chain slack check 7 20 Drive chain slack adjustment 7 21 PERIODIC MAINTENANCE AND Drive chain lubrication 7 22 MINOR REPAIR 7 1 Cable inspection and lubrication 7 23 Tool kit 7 1 Throttl...

Page 17: ...IONS 9 1 Wheel bearings 7 27 Battery 7 27 WIRING DIAGRAM Replenishing the battery fluid 7 28 Fuse replacement 7 29 Replacing the headlight bulb 7 30 Headlight beam adjustment 7 30 Replacing the taillight and flasher light bulb 7 31 Front wheel removal 7 31 Front wheel installation 7 32 Rear wheel removal 7 33 Rear wheel installation 7 34 Troubleshooting 7 35 Troubleshooting chart 7 36 ...

Page 18: ...A 400 LOCATION OF THE IMPORTANT LABELS Please read following labels carefully before operating this motorcycle 2 3 4 1 1 ...

Page 19: ...UFACTURE SHOWN ABOVE VEHICLE ID NO 8 TYPE CLASSIFICATION MOTORCYCLE HOW TO LAYOUT IBATTERYI BREATHER PIPE 21A 00 CAUTION BATTERY REMOVAL ANO INSTALLATION 1 Bc careful 001 10 SPiash tho electrolyte to the drive chain 2 Remove the breather pipe before demountrng the baucry 3 After insrnlling the battery be sure 10 connect the breather pipe into place 1 2 I WARNING I OPERATOR ONLY NO PASSENGERS I AVE...

Page 20: ...lever 4 Kick starter 15 Handlebar switch 5 Front fender 16 Speedometer 6 Brake pedal 17 Main switch 7 Footrest 18 Tachometer 8 Front fork 19 Brake lever 9 Headlight 20 Throttle grip 10 Fuet tank 21 Front flasher light 11 Seat 22 Radiator U 002 NOTE The motorcycle you have purchased may differ slightly from those shown in the photographs ...

Page 21: ...ur motorcycle and may be used to register your motorcycle with the licensing authority in your state 3 1 A 701 Engine serial number The engine serial number is stamped into the right side of the engine 1 Engine serial number U 003 NOTE ____________ The first three digits of these numbers are for model identification the remaining digits are the unit production number Keep a record of these numbers...

Page 22: ...headlight and meter lights come on automatically and the lights stay on until the main switch is turned to OFF even if the engine stalls B 006 OFF All electrical circuits are switched off The key can be removed in this position 8 007 LOCK The steering is locked in this position and all electrical circuits are switched off The key can be removed in this position Refer to Steering lock Page 4 9 for ...

Page 23: ...2 NEUTRAL indicator light green This indicator comes on when the trans mission is in neutral 4 2 B 103 HIGH BEAM indicator light blue This indicator comes on when the headlignt high beam is used B 107 OIL warning indicator light red This indicator comes on when the oil level is low This light circuit can be checked by the following procedure U 300 Do not run the motorcycle until you know the motor...

Page 24: ... Oil warning indicator light does not come on light comes on j Shift into gear I t I Oil warning indicator light Oil warning indicator does not come on light comes on I I Ask a Yamaha Engine oil level and elec supply engine oil I dealer to inspect trical circuit are OK Go electrical circuit ahead with riding 4 3 ...

Page 25: ...d keep it within the ideal power range 4 4 U 304 Do not operate in the red zone Red zone 10 000 r min and above B 501 Engine temperature gauge This gauge indicates the coolant temperature when the main switch is ON The engine operating temperature will vary with changes in weather and engine load If the needle points to the red zone or higher stop your motorcycle and let the engine cool See page 7...

Page 26: ...es 2 1 LIGHTS Dimmer switch 2 TURN switch 3 HORN switch B 601 LIGHTS Dimmer switch Turn the switch to HI for the high beam and to LO for the low beam B 605 TURN signal switch This is a three way switch the center position is off turn to the L to turn on the left flasher and to the R for the right flasher Be sure to turn the switch off after completing a turn ...

Page 27: ...turn the switch to OFF 1 ENGINE STOP switch B 701 Clutch lever The clutch lever is located on the left han dlebar it disengages or engages the clutch Pull the clutch lever to the handlebar to dis engage the clutch and release the lever to engage the clutch The lever should be pulled rapidly and released slowly for smooth starts B 800 Change pedal The gear ratios of the constant mesh 6 speed transm...

Page 28: ...rom the tank to carburetor while filtering the fuel The fuel cock has the three positions 4 7 ON 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 This indicates reserve If you run out of fuel while r...

Page 29: ... up push the knob in to close the circuit 1 Starter knob 4 S C 602 Kick starter Rotate the kick starter away from the engine Push the starter down lightly with your foot until the gears engage then kick smoothly and forcefully to start the engine This model has a primary kick starter so the engine can be started in any gear if the clutch is disen gaged In normal practices however shift to neutral ...

Page 30: ...to the main switch turn the key countertlockwise to LOCK and remove the key To release the lock turn the key clockwise OFF 4 9 1 Push U 614 L1 WARNING 2 Release 3 Turn Never turn the key to LOCK when the motorcycle is moving C 500 Helmet holder To open the helmet holder insert the key in the lock and turn it as shown To lock the helmet holder replace the holder in its original position ...

Page 31: ...dling of the Yamaha Energy Induction System Y E l S Handle the air chamber and hose with special care Improper installation or damaged parts will result in poor performance Replace any cracked or damaged parts immediately No modification of this system in any form is not allowed U 376 1tt a blrt i ll W f c o C if 0 c _ _ _ _ _ _ _ _ _ __ Never attempt to modify the Yamaha Energy Induction System ...

Page 32: ...perator resulting in a possible loss of control Yamaha has designed into this motorcycle a lockout system to assist the operator in ful filling his responsibility of retracting the sidestand Please check carefully the operating instructions listed below and if there is any indication of a mal function you must return the motor 4 11 cycle to a Yamaha dealer immediately for repair D 305 Sidestand sw...

Page 33: ... IENGINE WILL START l PULL IN CLUTCH LEVER AND PUT TARANSMISSION IN GEAR IENGINE WILL STALL ISIDESTAND SWITCH IS OK U 691 WARNING If improper operation is noted consult a Yamaha dealer immediately 4 12 ...

Page 34: ...ired 7 24 Transmission oil Check oil level top up as required 5 4 5 5 7 6 7 8 Coolant reservoir tank Check coolant level top up as required 5 5 5 6 7 8 7 11 Drive chain Check chain slack and condition Adjust if necessary 5 6 7 20 7 23 Wheels Tires Check tire pressure wear damage and spoketightness 5 6 5 9 Fittings Fasteners Check all chassis fittings and fasteners 5 9 7 5 Tighten Adjust if necessa...

Page 35: ...ch an inspection can be throughly accomplished in a very short time and the added safety it assures is more than worth the time involved LL WARNING If any item in the Pre Operation Check is not working properly have it inspected and repaired before operating the motorcycle 5 2 ...

Page 36: ...ke service is necessary ask a Yamaha dealer E 200 Clutch See page 7 19 for more detail Check the free play in the clutch lever and make sure the lever operates properly If the free play is incorrect adjust it 5 3 E 301 Throttle grip See page 7 23 for more detail Turn the throttle grip to see if it operates properly and check the free play Make sure the grip returns by spring force when released As...

Page 37: ...sh the cap into the filler neck until it is properly seated 5 4 E 404 Transmission oil See page 7 6 for more detail Make sure the transmission oil is at the spe cified level Add oil as necessary Recommended oil YAMALUBE 4 10W30 or SAE 1OW30 type SE motor oil Oil quantity Total amount 0 75 L 0 66 Imp qt 0 79 US qt Periodic oil change 0 7 L 0 61 Imp qt 0 74 US qt ...

Page 38: ...lant every two years See page 7 8 for more detail CD 1 FULL level 2 LOW level 5 5 U 626 Lh WARNING Do not remove the radiator cap when the engine is hot Hard water or salt water is harmful to the engine You may use distilled water if you can t get soft water Reservoir tank capacity E 500 Total 0 38 L 0 33 Imp qt 0 40 US qt From LOW to FULL level 0 20 L 0 18 Imp qt 0 21 US qt Chain See page 7 20 fo...

Page 39: ... for this model and vehicle speed 5 6 CES 01 Basic weight 86 kg 190 lb With oil and full fuel tank Maximum load 71 kg 157 lb Cold tire pressure Front Rear 0 kg 0 lb 130 kPa 130 kPa 1 3 kg cm2 1 3 kg cm2 Maximum load 18 psi 18 psi Load is the total weight of cargo rider and accessories U 711 WARNING Proper loading of your motorcycle is important for the handling braking and other performance and sa...

Page 40: ...spection Always check the tires before operating the motorcycle If a tire tread shows crosswise lines minimum tread depth if the tire has a nail or glass fragments in it or if the side wall is cracked contact a Yamaha dealer or other qualified me chanic immediately and have him replace the tire 5 7 1 Tread depth 2 Side wall 3 Wear indicator CE9 02 FRONT Manufacture INOUE REAR I Manufacture INOUE M...

Page 41: ...8 1 Always inspect the wheels before a ride Check for cracks bends or warpage of the wheel be sure the spokes are tight and undamaged If any abnormal con dition exists in awheel consult aYamaha dealer Do not attempt even small repairs to the wheel If a wheel is deformed or cracked it must be replaced 2 Tires and wheels should be balanced whenever either one is changed or re placed Failure to have ...

Page 42: ...tion of the headlight switch turn switch brake light switch horn switch main switch etc E 705 Battery See page 7 27 for more detail Check the fluid level and top up if necessary Use only distilled water if refilling is neces sary 5 9 E 800 Fuel Make sure there is sufficient fuel in the tank 1 Filler tube 2 Fuel level U 610 WARNING Do not overfill the fuel tank Avoid spilling fuel on the hot engine...

Page 43: ...rs use a different brand of gasoline or premium unleaded fuel Unleaded fuel will give you longer spark plug life and reduced maintenance cost If un leaded gasoline is not available then leaded regular gasoline can be used Gasohol There are two types of gasohol gasohol containing ethanol and that containing methanol Gasohol containing ethanol can 5 10 be used if ethanol content does not exceed 10 G...

Page 44: ... death within a short time Always operate your motor cycle in an area with adequate ventilation 6 1 2 Before starting out always be sure the sidestand is up Failure to re tract the sidestand completely can result in a serious accident when you try to turn a corner F 123 Starting a cold engine U 074 NOTE _____________ This motorcycle is equipped with an ignition circuit cut off switch 1 The engine ...

Page 45: ...ON AND ENGINE STOP SWITCH TO RUN I j IF TRANSMISSION IS IN NEUTRAL IF TRANSMISSION IS IN GEAR AND SIDESTAND IS DOWN AND SIDESTAND IS UP I KICK THE KICK STARTER PULL IN CLUTCH LEVER AND KICK ENGINE WILL START THE KICK STARTER ENGINE WILL START I RETRACT SIDESTAND AND PUT TRANSMISSION IN GEAR I MOTORCYCLE CAN BE RIDDEN MOTORCYCLE CAN BE RIDDEN 6 2 ...

Page 46: ... is returned to its original position before riding F 110 Engine warm up To ensure maximum engine life always warm up the engine before riding your motorcycle Never accelerate hard with a cold engine An engine is warm if it responds normally to the throttle when the starter CHOKE is turned off F 108 Starting a warm engine The starter CHOKE is not required when the engine is warm U 314 See Break in...

Page 47: ...by shifting without the clutch 6 4 F 300 Engine break in There is never a more important period in the life of your motorcycle than the period be tween zero and 1 000 km 600 mi For this reason we ask that you carefully read the following material Because the engine is brand new you must not put an excessive load on it for the first 1 000 km 600 mi The various parts in the engine wear and polish th...

Page 48: ...engine speeds enter the red zone U 322 If any engine trouble should occur during the break in period consult a Yamaha dealer immediately 6 5 F 401 Parking When parking the motorcycle stop the en gine and remove the ignition key Turn the fuel cock to OFF whenever stopping the engine WARNING The muffler and exhaust pipe are hot Park the motorcycle in a place where pedestrians or children are not lik...

Page 49: ...MAND THAT EACH OWNER ALTER THIS TIME SCHEDULE TO SHORTER IN TERVALS TO MATCH HIS ENVIRONMENT The most important points of motorcycle in spection adjustment and lubrication are explained in the following pages 7 1 U 632 Lt WARNING If you are not familiar with motorcycle service this work should be done by a Yamaha dealer H 101 Tool kit The service information included in this ma nual is intended to...

Page 50: ...ion requiring one take your motorcycle to a Yamaha dealer to check the torque settings a d adjust them as nec essary 7 2 lJ 671 WARNING Modifications to this motorcycle not approved by Yamaha may cause loss of performance and render it unsafe for use Consult a Yamaha dealer be fore attempting any changes ...

Page 51: ...n oil Replace every 12 000 8 000 or 24 months REPLACE 0 0 Warm engine before draining Autofube pump Check operation Correct if necessary 0 0 0 Air bleeding Brake Check operation Adjust it necessary 0 0 Clutch Check operation Adjust if necessarry 0 0 Wheels Check ba ance damage runout spoke tightness 0 0 Repair if necesarry Wheel bearings Check bearings assembly for looseness damage 0 0 Replace if ...

Page 52: ...erners Correct if necessary Sideststand Check operation Repair if necessary Sidestand switch Check operation Clean or replace if necessary Check specific gravity Battery Check breather pipe for proper operation Correct if necessary It is recommended that these items be serviced by a Yamaha dealer Medium weight wheel bearing grease 7 4 EVERY BREAK IN 3 000 6 000 1 000 600 2 000 or 4 000 or 6 months...

Page 53: ...r any reason hem Torque Nm m kg ft lb Spark plug 25 2 5 18 Drain plug Transmission 20 2 0 14 Front wheel axle 45 4 5 32 Rear wheel axle 60 6 0 43 Drain bolt Cylinder side 14 1 4 10 Drain bolt Housing cover 8 0 8 6 side Tension bar bolt 18 1 8 13 7 5 0 General torque A B specifications Nut Bolt Nm m kg ft lb 10 mm 6mm 6 0 6 4 3 12 mm 8mm 15 1 5 11 14 mm 10mm 30 3 0 22 17 mm 12 mm 55 5 5 40 19 mm 14...

Page 54: ...level stop the ef1gine and rer ove the dip stick Rest the dip stick on the threads of the hole 3 The dip stick has a minimum and maxi mum mark the oil level should be be tween the two If the level is low add oil to raise it to the proper level 1 Oil filler cap 7 6 1 Dip stick 2 Maximum level 3 Minimum level Recommended oil YAMALUBE 4 1 OW30 or SAE 1OW30 type SE motor oil Oil quantity 0 75 L 0 66 I...

Page 55: ...rankcase H 404 Transmission oil replacement 1 To drain the oil warm up the engine for several minutes 2 Place an oil pan under the engine 3 Remove the drain plug and drain the oil 1 Drain plug 4 Reinstall the drain plug make sure it is tight Drain plug torque 20 Nm 2 0 m kg 14 ft lb 5 Add oil through the dip stick hoJe Periodic oil change 0 7 L 0 61 Imp qt 0 74 US qt ...

Page 56: ...asses down through the finned tubes to the bottom tank of the radiator These finned tubes present a large surface area to the air and dissipate the heat 7 8 1 If your motorcycle overheats U 705K WARNING Do not remove the radiator cap when the engine and radiator are hot Scalding hot fluid and steam may be blown out under pressure which could cause serious injury When the engine has cooled open the...

Page 57: ...kage Add coolant Ask a Yamaha dealer to inspect and repair NOTE ___________ If it is difficult to get the recommended coo lant tap water can be temporarily used provided that it is changed to the recom mended coolant as soon as possible 7 9 2 Changing the coolant a Remove the radiator cover and radiator cap b Place a container under the engine c Remove the drain bolts 1 Drain bolts 2 Hosing cover ...

Page 58: ... water mixed ratio 50 50 Total amount O L 0 53 Imp qt 0 63 US qt Reservoir tanJ capacity 0 3fl L 0 33 Imp qt 0 40 US qt From LOW to FULL level 0 20 L 0 18 Imp qt 0 21 US qt 7 10 U 309 Hard water or salt water is harmful to the engine You may use distilled water if you can t get soft water g Reinstall the radiator cap h Run the engine several munutes to re check the coolant level in the radiator If...

Page 59: ...mes blocked fuel cannot enter the carburetor 1 First turn the cock lever to the OFF then remove the filter cup and clean the bottom of the cup with solvent 7 11 2 After removing the filter cup remove and clean the filter screen At the same time you should examine the condition of the filter gasket Replace if damaged 3 When reassembling be careful not to clamp the filter cup too tightly as this may...

Page 60: ... should be wet but not dripping Recommended oil Yamalube 2 cycle oil or air cooled 2 stroke engine oil 7 12 5 When installing the element in its case be sure its sealing surface matches the sealing surface of the case sothere is no air leak 6 The element should be cleaned at the specified intervals It should be cleaned more often if tl te motorcycle is operated in dusty or wet areas ...

Page 61: ... routine maintenance U 330 f 1 ii 7i il ll ifj J J 1 t i l ftf l Y i _f i The carburetor was set at the Yamaha factory after many tests If the settings are disturbed poor engine perform ance and damage may result 7 13 H 901 Idle speed adjustment 1 Start the engine and warm it up for a few minutes normally 1 or 2 minutes at approximately 1 000 to 2 000 r min Occasionally rev the engine to 4 000 to ...

Page 62: ...adjusting the throttle cable free play the engine idling speed should be adjusted The throttle cable should have a specified free play in the turning direction at the grip flange If the play is incorrect take the following steps for adjustment Free play 2 5 mm 0 08 0 2 in 7 14 1 Lock nut 2 Adjuster a 2 5 mm 0 08 0 2 in 1 Loosen the lock nut 2 Turn the adjuster in or out until the ad justment is su...

Page 63: ... periodically re move and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode If electrode erosion becomes excessive or if carbon and other deposits are excessive you should re place the spark plug with a proper type plug Standard spark plug BRSES NGK 7 15 1 Spark plug gap Before installing the spark plug measure the electrode gap with a wire t...

Page 64: ...s soon as possible with a torque wrench H 855 Front brake adjustment The front brake should be adjusted to suit the rider s preference but free play at the brake lever pivot point should be 5 8 mm 0 2 0 3 in Adjustment is accomplished at the front brake hub To adjust turn the adjuster clockwise to reduce play turn it counter clockwise to increase play 7 16 a 5 8 mm 0 2 0 3 in U 732K 6 WARNING When...

Page 65: ...r counterclockwise adjust the brake peaal position so that its top end is approx 20 mm 0 8 in belovythetopofthefootrest c Secure the adjuster lock nut U 644 WARNING After adjusting the pedal height adjust brake pedal free play 2 Free play The rear brake should be adjusted to suit the rider s preference but free play at the brake pedal end must be 20 30 mm 0 8 1 2 in Turn the adjuster on the brake ...

Page 66: ...oved and then reinstalled 2 Check the operation of the brake light after adjusting the rear brake H 833 Brake light switch adjustment The brake light switch is operated by move ment of the brake pedal To adjust hold the main body of the switch with your hand so it does not rotate and turn the adjusting nut Proper adjustment is achieved when the brake light comes on just before the brake begins to ...

Page 67: ... pedal or pulling the brake lever If the indicator reaches o the wear limit line ask a Yamaha dealer to replace shoes 7 19 2 1 Wear limit 2 Wear indicator 1 012 Cluch adjustment The clutch should be adjusted to suit the rider s preference but free play at the lever pivot should be 2 3 mm 0 08 0 12 in Loosen the adjuster lock nut Next turn the length adjuster either in or out until proper lever fre...

Page 68: ...he rear wheel through several revolutions Check the chain slack several times to find the point where the chain is the tightest Check and or adjust the chain slack where the rear wheel is in this tight chain position To check the chain slack the motorcycle must stand vertically with its both wheels on the ground and without a rider Check the slack at the position shown in the illustration The norm...

Page 69: ... the adjuster counterclockwise and push the wheel forward Turn each adfuster ex actly the same amount to maintain cor rect axle alignment There are marks 7 21 on each side of swingarm and on each chain adjuster use them to check for proper alignment 3 1 Cotterpin 2 Axle nut 3 Adjuster 4 Marks for alignment U 333 i f i i o t Qkf Ili tg i 2 _ _ _ _ _ __ Too small chain slack will overload the engine...

Page 70: ...ole do not match tighten the nut slightly to align them U 647 di WARNING Always use a new cotter pin on the axle nut 7 22 7 Adjust the free play in the brake pedal U 645 di WARNING Check the operation of the brake light after adjusting the rear brake 1 406 Drive chain lubrication The chain consists of many parts which work against each other If the chain is not main tained properly it will wear ou...

Page 71: ...arious cables may cause corrosion and interfere with the movement of the 7 23 cable An unsafe condition may result so replace such cables as soon as pos sible Lubricate the inner cable and the cable end If they do not operate smoothly ask a Yamaha dealer to replace them Recommended lubricant 1 102 Yamaha Chain and Cable Lube or SAE 1OW30 motor oil Throttle cable and grip lubrication The throttle t...

Page 72: ...nd Cable Lube or SAE 1OW30 motor oil Brake and clutch levers Lubricate the pivoting parts Recommended lubricant Yamaha Chain and Cable Lube or SAE 1OW30 motor oil 7 24 312 Sidestand Lubricate the pivoting parts Check to see that the sidestand move up and down smoothly Recommended lubricant U 704 Yamaha Chain and Cable Lube or SAE 1OW30 motor oil WARNING If the sidestand movement is not smooth cons...

Page 73: ...or damage ask aYamaha dealer to inspect 2 Operation check Place the motorcycle on a level place a Hold the motorcycle on an upright po sition with a rider s hands on the han dlebar and apply the front brake b Pump the front fork up and down for several times 7 25 U 122K NOTE ____________ If the front fork movement is not smooth consult a Yamaha dealer ...

Page 74: ...t source This may cause the unit to explode due to excessive gas pressure 3 Do not deform or damage the cyl inder in any way Cylinder damage 7 26 will result in poor damping per formance 4 Bring your shock absorber to a Yamaha dealer for any service 1 603 Steering inspection Periodically inspect the condition of the steering Worn out or loose steering bearings may be dangerous Place a block under ...

Page 75: ...0 Battery Check the level of the battery electrolyte and see that the terminals are tight Add distilled water if the electrolyte level is low U 336 When inspecting the battery be sure the breather pipe is routed correctly If the breather pipe touches the frame or exits in such a way as to cause bat tery electrolyte or gas to exit onto the frame structural and cosmetic damage to the motorcycle can ...

Page 76: ... your eyes when working near batteries KEEP OUT OF REACH OF CHILDREN 1 704 Replenishing the battery fluid A poorly maintained battery will deteriorate quickly The battery fluid should be checked at least once a month 1 _The level should be between the upper and lower level marks Use only distilled water if refilling is necessary 7 28 1 Upper level U 338 CJ GS 2 Lower level Normal tap water contain...

Page 77: ...attery when it is too low 4 Always make sure the connections are correct when putting the battery back in the motorcycle Make sure the breather pipe is properly connected and is not damaged or ob structed 7 29 1 910 Fuse replacement If a fuse is blown turn off the ignition switch and the switch in the circuit in question In stall a new fuse of proper amperage Turn on the switches and see if the el...

Page 78: ...ler to replace the bulb and adjust the unit 1 819 Headlight beam adjustment U 343 i 1 1 t IJl f For the headlight beam adjustment be sure to proceed as follows It is advisable to have a Yamaha dealer make this adjustment 7 30 1 Horizontal adjustment To adjust the beam to the right turn the adjuster clockwise To adjust the beam to the left turn the adjuster counterclockwise 2 Vertical adjustment To...

Page 79: ...s positioned properly J 204 Front wheel removal 1 Elevate the front wheel by placing a suitable stand under the engine 2 Remove the speedometer cable from front brake shoe plate first remove the clip and then pull cable out 7 31 1 Speedometer cable 3 Remove the brake cable loosen all cable adjusters and remove the cable from handlebar lever holder Then remove the cable from cam lever at the front ...

Page 80: ...tention to the following points 1 Make sure the wheel hub and the brake shoe plate assembly are installed with the projections meshed into the slots 7 32 2 Be sure the boss on the outer fork tube correctly engages with the locating slot on the brake shoe plate 3 Make sure the axle nut is properly tor qued and a new cotter piri is installed U 647 WARNING Always use a new cotter pin on the axle nut ...

Page 81: ...ension bar and the brake rod from the brake shoe plate The rension bar can be removed by removing the cotter pin and nut from the tension bar blot The brake rad can be removed by removing the adjuster 7 33 1 Adjuster 2 Brake rod 3 Tention bar 3 Disconnect the drive chain 4 Remove the cotter pin from the wheel axle and remove the rear wheel axle nut 5 Then the rear wheel assembly collar chain pulle...

Page 82: ...e fol lowing points 1 When connecting the chain make cer tain the closed end of the master link clip is facing the direction of rotation 7 34 2 Adjust the drive chain 3 Make sure the axle nut and tension bar bolt are properly torqued and a new cotter pin is installed U 647 6WARNING Always use a new cotter pin on the axle nut ...

Page 83: ... may occur during operation Any problem in the fuel compression or ignition systems can cause poor starting and a loss of power The troubleshooting chart de scribes a quick easy procedure for checking these systems If your motorcycle requires any repair bring it to a Yamaha dealer The skilled technicians at a Yamaha dealer have the tools experience and know how to properly service your motorcycle ...

Page 84: ...ll of fuel Water or dirt mixed in fuel No fuel Restart engine Kick the kick lever to see if there is compression There is compression Compression normal 3 Ignition Remove plug and check electrode No compression Ask Yamaha dealer to inspect Wipe clean with dry cloth Attach plug cap and ground to chassis Turn switch on and kick strongly 7 36 Check fuel flow Clean filter cup Fuel cock clogged No irre...

Page 85: ...ets or wheel axles 3 Rinse the dirt and degreaser off with a garden hose use only enough pressure to do the job 8 1 Excessive hose pressure may cause water seepage and contamination of wheel bearings front forks brakes and transmission seals Many expensive repair bills have resulted from im proper high pressure detergent appli cations such as those available in coin operated car washers 4 Once the...

Page 86: ... SAE 1OW30 or 20W40 motor oil in tank shake the tank to coat the inner 8 2 surfaces thoroughly and drain off the excess oil Reinstall the tank 3 Remove the spark plug s pour about one tablespoon of SAE 1OW30 or 20W40 motor oil in spark plug hole s and reinstall spark plugs Kick the engine over several times with ignition off to coat the cylinder walls with oil 4 Remove the drive chain Thoroughly c...

Page 87: ... it Store it in a dry place and recharge it once a month Do not store the battery in an excessively warm or cold place less than O C 30 F or more than 30 C 90 F U 058 NOTE Make any necessary repairs before storing the motorcycle 8 3 ...

Page 88: ...learance 265 mm 10 4 in Basic weight With oil and full fuel tank 86 kg 190 lb Minimum turning radius 2 000 mm 78 7 in Engine Type Liquid cooled 2 stroke gasoline Model 3BK4 Cylinder arrangement Single cylinder Forward inclined Displacement 49 cm3 Bore x Stroke 40 0 x 39 2 mm 1 57 x 1 54 in Compression ratio 6 5 1 Starti g system Kick starter Lubrication system Separate lubrication Yamaha Autolube ...

Page 89: ...oil change 0 7 L 0 61 Imp qt 0 74 US qt Total amount 0 75 L 0 66 Imp qt 0 79 US qt Radiator capacity Including all routes 0 6 L 0 53 Imp qt 0 63 US qt Air filter Wet type element Fuel Type REGULAR UNLEADED GASOLINE Tank capacity 8 5 L 1 9 Imp gal 2 2 US gal Reserve amount 2 0 L 0 4 Imp gal 0 5 US gal Carburetor Type manufacturer VM16SS MIKUNI Spark plug Type Manufacturer BR8ES NGK Gap 0 7 0 8 mm 0...

Page 90: ...drive Secondary reduction ratio 48 13 3 692 Transmission type Constant meth 6 speed Operation Left foot operation Gear ratio 1st 39 12 3 250 2nd 34 16 2 125 3rd 31 20 1 550 4th 27 22 1 227 5th 26 25 1 040 6th 24 26 0 923 Chassis Frame type Semi double cradle Caster angle 28 33 Trail 98 mm 3 86 in Tire Type With tube Size Front 2 50 19 4PR Rear 3 00 17 4PR 9 3 ...

Page 91: ...spension Front Telescopic fork Rear Swing arm Monocross suspension Shock absorber Front Air Coil spring Oil damper Rear Gas Coil spring Oil damper Wheel travel Front 170 mm 6 7 in Rear 150 mm 5 9 in Electrical Ignition system CDI magneto Generator system Flywheel magneto Battery type capacity 6N48 2A 6V 4AH Headlight type Sealed beam 9 4 ...

Page 92: ...Model DTSOW Bulb wattage quantity Headlight 25W 25W Tail brake light 5 3W 25W Flasher light 17W x 4 Meter light 3Wx2 Indicator light wattage quantity NEUTRAL 3W HIGH BEAM 3W OIL 3W TURN 3W 9 5 ...

Page 93: ... MEMO ...

Page 94: ... MEMO v ...

Page 95: ... MEMO ...

Page 96: ...YAMAHA MOTOR CO LTD WATA JAPAN PRINTED IN JAPAN 88 6 0 5 x 1 CR I I ...

Page 97: ...Jaune L Blue Ch Bleu l H o ___r L jf f f f _ _ _ c tt rt t t f 1 f f Con actcur d avcrtisscur HORN TURN switch Commutatcur dl S Cnmmutatcur de fcu de clignotants TURN crois emcnt LIGHTS Dimmer Handlebar switch Left Commutatcur sur guidon Gauche Red Br Brown Rouge Brun Pink Sb Sky blue Rose Bleu ciel B R B W Orange Dg Dark green G Y Orange Vert fence Chocolate W White G R Chocolat Blanc Black Red N...

Page 98: ...que ala figure sui vante Enregistrez ce numero aJ endroit prevu pour reference si vous avez besoin d une nouvelle c1e Num6ro de c16 c J YW Ii Enregistrez les numeros de vehicule et de moteur aux emplacements prevus pour vous permettre de commander des pieces de rc change a votre concessionnaire Yamaha ou COmme reference dans Je cas OU VOtre vehicu e scrait vole Voir page 3 1 ...

Page 99: ...L 66L8Z l9 VHVWVA ...

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Yamaha DT501988, Owner'S Manual

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