Yamaha E115M Owner'S Manual Download Page 40 | Manualshive

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PERIODIC MAINTENANCE AND MINOR REPAIR

Adjusting the brake pedal free play

1. Brake pedal free play

The brake pedal free play should
measure 20.0–30.0 mm at the brake
pedal end as shown. Periodically check
the brake pedal free play and, if
necessary, adjust it as follows. To
increase the brake pedal free play, turn
the adjusting nut in direction (a). To
decrease the brake pedal free play, turn
the adjusting nut in direction (b).

1. Brake pedal free play adjusting nut

WARNING

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
adjustment.
After adjusting the brake pedal free
play, check the operation of the
brake light.

Adjusting the rear brake light switch

1. Rear brake light switch
2. Rear brake light switch adjusting nut

The rear brake light switch, which is
activated by the brake pedal, is properly
adjusted when the brake light comes on
just before braking takes effect. If
necessary, adjust the brake light switch
as follows.Turn the adjusting nut while
holding the rear brake light switch in
place. To make the brake light come on
earlier, turn the adjusting nut in direction
(a). To make the brake light come on
later, turn the adjusting nut in direction
(b).

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Summary of Contents for E115M

Page 1: ......

Page 2: ...Get your 2 Two free service coupon from your motorcycle dealers Sila dapatkan 2 Dua kupon servis percuma dari pengedar penjual motosikal anda 䇋 ᙼⱘ ऩ䔺 ҷ ଚ乚প 2 ϸ ᓴ ܡ 䌍ⱘ㓈ׂो ...

Page 3: ...nual thoroughly so as to enjoy all advantages of your JYM110 2 The Owner s Manual does not only instruct you in how to operate inspect and maintain your motorcycle but also in how to safeguard yourself and others from trouble and injury In addition the many tips given in this manual will help keep your motorcycle in the best possible condition If you have any further questions do not hesitate to c...

Page 4: ... JYM110 2 OWNER S MANUAL 2014 by Yamaha Motor Co Ltd 1st edition October 2014 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Malaysia ...

Page 5: ...hicle or other property A TIP provides key information to make procedures easier or clearer This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold Yamaha continually seeks advancements in product design and quality Therefore while this manual contains the most current product information available at the time of pr...

Page 6: ...ulb or front position light bulb 6 22 Replacing a front turn signal light bulb 6 23 Replacing a rear turn signal light tail light brake light bulb 6 24 Front wheel 6 24 Rear wheel 6 25 Troubleshooting 6 27 Troubleshooting charts 6 28 Motorcycle Care And Storage 7 1 Matte colour warning 7 1 Care 7 1 Storage 7 3 Specifications 8 1 Consumer Information 9 1 Product label 9 1 Vehicle identification num...

Page 7: ...riding in another motorist s blind spot Many accidents involve inexperi enced operators In fact many operators who have been involved in accidents do not even have a current motorcycle license Know your skills and limits Staying within your limits may help you to avoid an accident We recommend that you practice riding your motorcycle where there is no traffic until you have become thoroughly famil...

Page 8: ...if you try to ventilate engine exhaust with fans or open windows and doors carbon monoxide can rapidly reach dangerous levels Do not run engine in poorly ventilated or partially enclosed area such as barns garages or carpoch Do not run engine outdoors where engine exhaust can be drawn into a building through openings such as windows and doors If you experience any symptoms of carbon monoxide poiso...

Page 9: ...ain 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 Use caution when adding electrical accessories If electrical accessories exceed the capacity of the motorcycle s electrical system an electric failure could result which co...

Page 10: ...rn signal light page 6 23 2 Headlight front position lights page 6 22 3 Starter choke lever page 3 6 4 Rear brake light switch page 6 14 5 Owner s tool kit page 6 1 6 Tail light brake light page 6 24 7 Shift pedal page 3 4 8 Engine oil drain bolt page 6 7 ...

Page 11: ... DESCRIPTION Right view 1 Motorcycle rack page 3 6 2 Fuel tank cap page 3 5 3 Battery page 6 20 4 Helmet holder page 3 6 5 Kick starter page 3 6 6 Engine oil filler cap page 6 8 7 Brake pedal page 3 4 8 Air filter page 6 10 ...

Page 12: ... 1 2 3 4 5 6 DESCRIPTION Controls and instruments 1 Left handlebar switches page 3 3 2 Speedometer unit page 3 2 3 Fuel meter page 3 3 4 Main switch page 3 1 5 Right handlebar switches page 3 3 6 Throttle grip page 6 12 ...

Page 13: ...be removed The steering is locked and all electrical systems are off The key can be removed To lock the steering 1 Push 2 Turn 1 Turn Turn the handlebars all the way to the left Push the key in from the OFF position and then turn it to LOCK while still pushing it Remove the key 1 2 3 To unlock the steering Insert the key in and then turn it to OFF WARNING Never turn the key to OFF or LOCK while th...

Page 14: ... indicator light This indicator light flashes when the turn signal switch is pushed to the left or right 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 Neutral indicator light N This indicator light comes on when the transmission is in the neutral position The speedometer unit is equipped with a sp...

Page 15: ...itch Set this switch to for the high beam and to for the low beam Turn signal switch To signal a right hand turn push this switch to To signal a left hand turn push this switch to When released the switch returns to the center position To cancel the turn signal lights push the switch in after it has returned to the center position Horn switch Press this switch to sound the horn Starter switch Push...

Page 16: ... is equipped with a constant mesh 4 speed transmission Brake lever 1 Brake lever The brake lever is located on the right side of the handlebar To apply the front brake pull the lever towards the throttle grip Brake pedal 1 Brake pedal The brake pedal is on the right side of the motorcycle To apply the rear brake press down on the brake pedal ...

Page 17: ... clean dry soft cloth since fuel may deteriorate painted surfaces or plastic parts Recommended fuel 93 or above unleaded gasoline fuel Fuel tank capacity 4 2 L Use only unleaded gasoline The use of leaded gasoline will cause severe damage to internal engine parts such as the valves and piston rings as well as to the exhaust system Make sure that there is sufficient fuel in the tank Fill the fuel t...

Page 18: ...tion a and when the engine is running shift it back to position b Catalytic converter This vehicle is equipped with a catalytic converter in the exhaust pipe NOTICE The exhaust pipe will be hot after operation Make sure that the exhaust pipe is cool down before doing any maintenance work The following precautions must be observed to prevent a fire hazard or burns Use only unleaded gasoline The use...

Page 19: ...rter Seat 1 Seat lock To open the seat Place the motorcycle on the centerstand Insert the key into the seat lock switch and then turn the key Open the seat 1 2 3 TIP TIP Do not push inward when turning the key To close the seat Fold the seat down and then push it down to lock it in place Remove the key from the seat lock if the motorcycle is left unattended 1 2 Make sure that the seat is properly ...

Page 20: ...r pressure could have serious consequences Therefore it is very important in addition to a thorough visual inspection to check the following points before each ride TIP Pre operation checks should be made each time the vehicle is used Such an inspection can be accomplished in a very shorttime and the added safety it assures is more than worth the time involved If any item in the Pre operation chec...

Page 21: ...ottle cable free play if necessary Lubricate the throttle grip housing and cable Check for chain slack alignment and condition Adjust and thoroughly lubricate chain Check bearing free play and steering for roughness Replace if necessary Check the operating conditions and for oil leakage Check the operating conditions and for oil leakage Check the operating conditions Lubricate Check the electrolyt...

Page 22: ...4 4 3 PRE OPERATION CHECKS ITEM CHECKS OR REPAIRS PAGE Exhaust pipe Check for abnormal noise Check for loose bolts and nuts ...

Page 23: ... the neutral indicator light should be on otherwise have a Yamaha dealer check the electrical circuit Start the engine by pushing the start switch or by kicking the kickstarter lever down 3 If the engine fails to start in cold weather turn on the choke lever during starting and return it back to the original position when the engine is running See page 3 6 If the engine fails to start by pushing t...

Page 24: ...When the motorcycle attain a higher speed close the throttle grip Shift to the second gear Increase the throttle grip gradually to increase the accelaration Shift to a higher gear as in earlier procedure Increase or decrease the throttle grip to manipulate the accelaration and speed Turning towards oneself increases the speed and turning away from oneself reduces the speed 2 3 4 5 6 7 8 Increasing...

Page 25: ...al carefully Since the engine is brand new do not put an excessive load on it for the first 1000 km The various parts in the engine wear and polish themselves to the correct operating clearances During this period prolonged full throttle operation or any condition that might result in engine overheating must be avoided Avoid prolonged operation above 1 3 throttle After every hour of operation stop...

Page 26: ...n system AIS for the protection of the enviroment and the exhaust pipe is located inside together with the catalytic converter matching the country exhaust standard If large amount of incomplete combustion gas mixture flows into the catalytic converter it will produces reburning phenomenon and causes overheating of the exhaust pipe and accelerate the aging of the catalytic converter To prevent thi...

Page 27: ...rforming 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 servicing can lead to eye injury burns fire or carbon monoxide poisoning possibly leading to death Owner s tool kit 1 Owner s tool kit The owner s tool kit is located under the seat See page 3 7 The s...

Page 28: ...e special tools data and technical skills NO ITEM CHECK OR MAINTENANCE JOB ODOMETER READING x 1000km Or 1 2 year Or 1 year Spark plug Fuel line Valves Air filter Battery Clutch Front brake Rear brake Wheels Check fuel and vacuum hoses for cracks or damage Check condition replace if have problem Clean and regap Replace Check valve clearance Adjust Clean Replace when necessary Check operation Adjust...

Page 29: ...Check chain slack alignment and condition Adjust and thoroughly lubricate chain with specified lubricant Steering bearings Check bearing play and steering for roughness Lubricate with lithium soap based grease Engine and chassis fasteners Make sure that all nuts bolts and screws are properly tightened Sidestand Centerstand Check operation Lubricate Check operation Front fork Connecting and pivot a...

Page 30: ...ate Check operation and free play Adjust the throttle cable free play if necessary Lubricate the throttle grip housing and cable Throttle grip housing and cable Air induction system Check the air cut off valve reed valve and hose for damage Replace any damaged parts if necessary Lights signals and switches Check operation Adjust headlight beam Check for abnormality sound Check for loosens bolts an...

Page 31: ...ing 2 Panel Removing and installing the cowling To remove the cowling 1 Remove group A screws 2 pcs 2 Remove group B screws 10 pcs Removing and installing the panel To remove the panel To install the panel 1 Place the panel in the original position 2 Install the screws To install the cowling 1 Place the cowling in the original position 2 Install the screws 1 Remove the screws 6 pcs 2 Remove the pa...

Page 32: ... TIP If the spark plug shows a distinctly different color the engine could be defective Do not attempt to diagnose such problems yourself Instead have a Yamaha dealer check the vehicle Check the spark plug for electrode erosion and excessive carbon or other deposits and replace it if necessary Specified spark plug To install the spark plug Measure the spark plug gap with a wire thickness gauge and...

Page 33: ...screwing it in and then remove it again to check the oil level 2 3 1 Engine oil filler cap The engine oil should be between the minimum and maximum level marks 1 Dipstick 2 Maximum level mark 3 Minimum level mark If the engine oil is at or below the minimum level mark add sufficient oil of the recommended type to raise it to the correct level Insert the dipstick into the oil filler hole and then t...

Page 34: ...ue 7 Tightening torque Engine oil drain bolt Add the specified amount of the recommended engine oil and then install and tighten the oil filler cap Recommended engine oil See page 8 1 Engine oil quantity Total amount 1L Periodic oil change 0 80L In order to prevent clutch slippage since the engine oil also lubricates the clutch do not mix any chemical additives Make sure that no foreign material e...

Page 35: ...lement to remove most of the dust and dirt and then blow the remaining dirt out with compressed air as shown If the air filter element is damaged replace it 3 1 Air filter element Insert the air filter element into the air filter case 4 NOTICE Make sure that the air filter element is properly seated in the air filter case The engine should never be operated without the air filter element installed...

Page 36: ...ling speed The engine idling speed must be checked and if necessary adjusted as per the intervals specified in the periodic maintenance and lubrication chart The engine should be warm up before making this adjustment TIP When the engine is warm it will quickly responds to the throttle A diagnostic tachometer is needed to make this adjustment Remove cowling See page 6 5 Attach the diagnostic tachom...

Page 37: ... 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 Tires To maximize the performance durability and safe operation of your motorcycle note the following points regarding the specified tires Tire air pressure The tire air pressure should be checked and if necessary adjusted before...

Page 38: ...m side to side Adjust the tire pressure according to the load Check the condition and pressure of the tire before riding Tire inspection 1 Tire sidewall 2 Tire tread depth 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 dealer replace the tire immediately Min...

Page 39: ...spokes for looseness for spoke wheel If any damage is found have a Yamaha dealer replace the wheel Do not attempt even the smallest repair to the wheel A deformed or cracked wheel must be replaced Ride at moderate speeds after changing a tire since the tire surface must first be broken in for it to develop its optimal charac teristics Checking the brake lever free play 1 Brake lever free play The ...

Page 40: ...r wheel always check the brake pedal free play If proper adjustment cannot be obtained as described have a Yamaha dealer make this adjustment After adjusting the brake pedal free play check the operation of the brake light Adjusting the rear brake light switch 1 Rear brake light switch 2 Rear brake light switch adjusting nut The rear brake light switch which is activated by the brake pedal is prop...

Page 41: ... The front brake is provided with a wear indicator which allows you to check the brake shoe wear without having to disassemble the brake To check the brake shoe wear check the position of the wear indicator while applying the brake If a brake shoe has worn to the point that the wear indicator reaches the wear limit line have a Yamaha dealer replace the brake shoes as a set Drive chain slack The dr...

Page 42: ...sure that both chain pullers are in the same position for proper wheel alignment 1 Drive chain slack adjusting bolt 2 Drive chain slack locknut 3 Axle nut 4 Brake torque rod nut 5 Brake pedal free play adjusting nut NOTICE Improper drive chain slack will overload the engine as well as other vital parts of the motorcycle and can lead to chain slippage or breakage To prevent this from occurring keep...

Page 43: ...dition the cable should be lubricated at the intervals specified in the periodic maintenance chart NOTICE The drive chain must be lubricated after washing the motorcycle riding in the rain or riding in wet areas 1 2 3 4 5 Remove the screw x4 remove drive chain cover Clean the drive chain with kerosene and a small soft brush Wipe the drive chain dry Thoroughly lubricate the drive chain with a speci...

Page 44: ...ore each ride and the lever pivot should be lubricated if necessary The operation of the centerstand and sidestand should be checked before each ride and the pivots and metal to metal contact surfaces should be lubricated if necessary Recommeded lubricant Lithium soap based grease general type lubricant Recommeded lubricant Lithium soap based grease general type lubricant Recommeded lubricant Lith...

Page 45: ...d in the periodic maintenance and lubrication chart To check the condition Check the inner tubes for scratches damage and excessive oil leakage To check the operation Place the vehicle on a level surface and hold it in an upright position 1 While applying the front brake push down hard on the handlebars several times to check if the front fork compresses and rebounds smoothly 2 To avoid injury sec...

Page 46: ...maintenance chart To check the battery fluid level Place the vehicle on a level surface and hold it in an upright position WARNING To avoid injury securely support the vehicle so that there is no danger of it falling over To check the battery fluid level vehicle must be an upright position Battery fluid level should be between the minimum and maximum level marks Only use distilled water because pi...

Page 47: ...k and immediately call a physician Eyes Flush with water for 15 minutes and seek prompt medical attention WARNING 5 6 7 Check the battery connection and condition adjusting if necessary Place the battery cover to original position and then install the battery fastener Close the seat 2 3 4 If the battery will be stored for more than two months check it at least once a month and fully charge it if n...

Page 48: ...lockwise and then remove the defective bulb Place the new bulb into position and then secure it with the bulb holder Install the panel Have a Yamaha dealer adjust the headlight beam if necessary NOTICE Replacing the fuse 1 Spare fuse The fuse holder is located under the seat See page 3 7 If the fuse is blown replace it as follows Specified fuse 7 50 A Do not use a fuse of a higher amperage rating ...

Page 49: ...on the headlight bulb using a cloth moistened with alcohol or thinner 1 Do not touch the glass part of the bulb 1 Front turn signal light bulb socket 1 2 3 4 Place the motorcycle on the centerstand Remove the cowlings See page 6 5 Remove the socket together with the bulb by turning it counterclockwise Remove the defective bulb 1 Front turn signal light bulb 5 6 7 Insert a new bulb into the socket ...

Page 50: ...and Disconnect the speedometer cable from the front wheel 1 Remove the screw lampshade on both sides of the hook pulling slightly outward remove the lampshade PERIODIC MAINTENANCE AND MINOR REPAIR Replacing a rear turn signal light tail light brake light bulb 1 Screw 1 Hook x2 2 Lampshade NOTICE Do not over tighten the screw otherwise the lens may break Front wheel To remove the front wheel WARNIN...

Page 51: ...he brake pedal free play adjusting nut 5 6 While applying the front brake push down hard on the handlebars several times to check if the front fork compresses and rebounds smoothly Connect the speedometer cable 4 Pull the wheel axle out and then remove the wheel 1 Axle nut To install the front wheel Tightening torque Axle nut 40 Nm WARNING Rear wheel To remove the rear wheel 1 Axle nut 2 Brake tor...

Page 52: ...torque rod to the brake shoe plate by installing the bolt washer and nut Adjusting the drive chain slack See page 6 15 Take the motorcycle off the centerstand so that the rear wheel is on the ground Tighten the brake torque rod nut and axle nut to the specified torque 9 Remove the wheel 9 10 Insert one new cotter Adjust the brake pedal free play See page 6 14 3 4 5 Loosen the brake torque rod nut ...

Page 53: ...or example can cause poor starting and loss of power The following troubleshooting charts represent quick and easy procedures for checking these vital systems yourself However should your motorcycle require any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools experience and know how to service the motorcycle properly Use only genuine Yamaha replacement parts Imi...

Page 54: ...way and operate the electric starter The battery is good There is no fuel Supply fuel Remove the spark plug and check the electrodes Wet Dry Check the compression The engine does not start Check the compression Operate the electric starter or the kickstarter There is no compression Have a Yamaha dealer check the vehicle Operate the electric starter The engine turn over quickly The engine turn over...

Page 55: ...ing can damage windshields cowlings panels and other plastic parts Use only a soft clean cloth or sponge with mild detergent and water to clean plastic Do not use any harsh chemical products on plastic parts Be sure to avoid using cloths or sponges which have been in contact with strong or abrasive cleaning products solvent or thinner fuel gasoline rust removers or inhibitors brake fluid antifreez...

Page 56: ...t After normal use After riding in the rain near the sea or on salt sprayed roads Remove dirt with warm water a mild detergent and a soft clean sponge and then rinse thoroughly with clean water Use a toothbrush or bottlebrush for hard to reach areas Stubborn dirt and insects will come off more easily if the area is covered with a wet cloth for a few minutes before cleaning Since sea salt or salt s...

Page 57: ...d then lift the motorcycle so that both of its wheels are off the ground Alternatively turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot Cover the muffler outlet with a plastic bag to prevent moisture from entering it 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 exce...

Page 58: ... oil quantity Periodic oil change 0 80L Total Capacity 1 0L Air filter Air filter element Dry element Fuel Recommended fuel 93 or above unleaded gasoline Fuel tank capacity 4 2L Fuel tank storage 2 8L Spark plug s Manufacturer model NGK CR6HSA Spark plug gap 0 6 0 7mm Clutch Clutch type Wet multiple disc Transmission Primary reduction system Slanter gear Primary reduction ratio 69 21 Secondary red...

Page 59: ...t suspension Type Telescopic Fork Spring shock absorber type Coil spring oil damper Travel 100mm Rear suspension Type Swingarm Spring shock absorber type Coil spring oil damper Travel 70mm Electrical system Ignition system Transistor coil ignition Charging system AC magneto Battery Voltage capacity 12V 5 0Ah Headlight Bulb type Incandescent Bulb voltage wattage quantity Headlight 12V 35 0W 1 Tail ...

Page 60: ...s provided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen Vehicle identification number Product label The vehicle identification number is punched in the bottom seat cushion The product label is riveted at the bottom of the frame after the front fender The vehicle identification number is used to identify your vehicle and may be u...

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