Yamaha Nouv AT135 Owner'S Manual Download Page 59 | Manualshive

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PERIODIC MAINTENANCE AND ADJUSTMENT

7-22

7

EAU22380

Checking the front brake pads
and rear brake shoes

The front brake pads and the rear
brake shoes must be checked for wear
at the intervals specified in the periodic
maintenance and lubrication chart.

EAU22430

Front brake pads

Each front brake pad is provided with
wear indicator grooves, which allow
you to check the brake pad wear with-
out having to disassemble the brake.
To check the brake pad wear, check
the wear indicator grooves. If a brake
pad has worn to the point that the wear
indicator grooves have almost disap-

peared, have a Yamaha dealer replace
the brake pads as a set.

EAU22540

Rear brake shoes

The rear brake is provided with a wear
indicator, which allows you to check the
brake shoe wear without having to dis-
assemble 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.

EAU32344

Checking the brake fluid level

Insufficient brake fluid may allow air to
enter the brake system, possibly caus-
ing it to become ineffective.
Before riding, check that the brake fluid
is above the minimum level mark and
replenish if necessary. A low brake flu-
id level may indicate worn brake pads
and/or brake system leakage. If the
brake fluid level is low, be sure to check
the brake pads for wear and the brake
system for leakage.
Observe these precautions:

1. Brake pad wear indicator groove (x2)

ZAUU0083

1. Brake shoe wear indicator

2. Brake shoe wear limit line

1

2

ZAUU0402

1. Minimum level mark

1

ZAUU0404

5P0_F8199_E1.book Page 22 Thursday, January 15, 2009 1:10 PM

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Summary of Contents for Nouv AT135

Page 1: ...DIC183 Read this manual carefully before operating this vehicle 5P0 F8199 E1 AT135 OWNER S MANUAL cover1 1 fm Page 1 Monday January 19 2009 4 36 PM ...

Page 2: ...Read this manual carefully before operating this vehicle This manual should stay with this vehicle if it is sold 5P0_F8199_E1 book Page 1 Thursday January 15 2009 1 10 PM ...

Page 3: ...ition the many tips given in this manual will help keep your motorcycle in the best possible condition If you have any further questions do not hesitate to contact your Yamaha dealer The Yamaha team wishes you many safe and pleasant rides So remember to put safety first Yamaha continually seeks advancements in product design and quality Therefore while this manual contains the most cur rent produc...

Page 4: ...all safety messages that follow this symbol to avoid possible injury or death A WARNING indicates a hazardous situation which if not avoided could result in death or serious injury A NOTICE indicates special precautions that must be taken to avoid damage to the vehicle or other property A TIP provides key information to make procedures easier or clearer WARNING NOTICE TIP 5P0_F8199_E1 book Page 1 ...

Page 5: ...y Thai Yamaha Motor Co Ltd 1st edition October 2008 All rights reserved Any reprinting or unauthorized use without the written permission of Thai Yamaha Motor Co Ltd is expressly prohibited Printed in Thailand 5P0_F8199_E1 book Page 2 Thursday January 15 2009 1 10 PM ...

Page 6: ... chart for the emission control system 7 2 General maintenance and lubrication chart 7 3 Removing and installing cowlings and panels 7 6 Checking the spark plug 7 8 Engine oil and oil strainer 7 9 Final transmission oil 7 11 Coolant 7 12 Air filter and V belt case air filter elements 7 13 Adjusting the carburetor 7 16 Adjusting the engine idling speed 7 16 Adjusting the throttle cable free play 7 ...

Page 7: ...g a front turn signal light bulb 7 33 Replacing an auxiliary light bulb 7 33 Troubleshooting 7 34 Troubleshooting charts 7 35 MOTORCYCLE CARE AND STORAGE 8 1 Care 8 1 Storage 8 3 SPECIFICATIONS 9 1 CONSUMER INFORMATION 10 1 Identification numbers 10 1 5P0_F8199_E1 book Page 2 Thursday January 15 2009 1 10 PM ...

Page 8: ... your vehicle They contain important information for safe and proper operation of your vehicle Never remove any labels from your vehicle If a label becomes difficult to read or comes off a replacement label is available from your Yamaha dealer 2 3 1 ZAUU0344 5P0_F8199_E1 book Page 1 Thursday January 15 2009 1 10 PM ...

Page 9: ...operator and a passen ger The failure of motorists to detect and recognize motorcycles in traf fic 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 conspicuous ap pears to be very effective in reduc ing the chance of this type of accident Therefore Wear a brightly colored jacket Use ...

Page 10: ... shield or goggles Wind in your unprotected eyes could contribute to an impairment of vision that could delay seeing a hazard The use of a jacket heavy boots trousers gloves etc is effective in preventing or reducing abra sions or lacerations Never wear loose fitting clothes otherwise they could catch on the control levers footrests or wheels and cause injury or an accident Always wear protective ...

Page 11: ...within this weight limit keep the following in mind Cargo and accessory weight should be kept as low and close to the motorcycle as possible Se curely pack your heaviest items as close to the center of the vehicle as possible and make sure to dis tribute the weight as evenly as possible on both sides of the mo torcycle to minimize imbalance or instability Shifting weights can create a sud den imba...

Page 12: ...accessory before using it to make sure that it does not in any way reduce ground clearance or cornering clearance limit suspension travel steering travel or control operation or ob scure lights or reflectors Accessories fitted to the handle bar or the front fork area can create instability due to improp er weight distribution or aerody namic changes If accessories are added to the handlebar or fro...

Page 13: ...esult of head injuries The use of a safety helmet is the single most critical factor in the pre vention or reduction of head injuries Always select an approved motorcycle helmet Pay attention to the following when choosing a motorcycle helmet The helmet must meet the safety standard TIS The helmet size must match the size of the rider s head Never subject a helmet to heavy shocks Wearing the helme...

Page 14: ...r usage Half type use only for riding at low speeds Full type use only for riding at low to mid range speeds Full face type use for riding at mid range to high speeds ZAUU0004 ZAUU0005 ZAUU0006 5P0_F8199_E1 book Page 6 Thursday January 15 2009 1 10 PM ...

Page 15: ...7 16 5 Owner s tool kit page 7 1 6 Tail brake light page 7 31 7 Rear turn signal lights page 7 32 8 Kickstarter page 4 9 9 Engine oil drain bolt A page 7 9 10 Engine oil drain bolt B page 7 9 11 V belt case air filter element page 7 13 12 Air filter element page 7 13 2 5 6 7 3 1 12 10 9 8 11 4 ZAUU0345 1 DESCRIPTION 5P0_F8199_E1 book Page 1 Thursday January 15 2009 1 10 PM ...

Page 16: ... starter relay page 7 29 3 Storage compartment page 4 11 4 Battery page 7 28 5 Seat lock page 4 9 6 Front brake fluid reservoir page 7 22 7 Coolant reservoir page 7 12 8 Dipstick page 7 9 2 8 7 1 6 3 5 4 ZAUU0346 5P0_F8199_E1 book Page 2 Thursday January 15 2009 1 10 PM ...

Page 17: ...witches page 4 5 3 Fuel gauge page 4 4 4 Speedometer page 4 3 5 Digital coolant temperature gauge odometer page 4 4 6 Right handlebar switches page 4 5 7 Front brake lever page 4 5 8 Main switch steering lock page 4 1 1 7 2 8 3 6 5 4 ZAUU0347 5P0_F8199_E1 book Page 3 Thursday January 15 2009 1 10 PM ...

Page 18: ...ht auxiliary lights meter lighting and taillight come on automati cally when the engine is started _ EAU10661 OFF All electrical systems are off The key can be removed EWA10061 WARNING _ Never turn the key to OFF or LOCK while the vehicle is moving Otherwise the electrical systems will be switched off which may result in loss of control or an accident _ EAU10701 LOCK The steering is locked and all...

Page 19: ... into the keyhole cover receptacle as shown and then turn the key to the left to open the cov er To close the keyhole cover Insert the key head into the keyhole cover receptacle as shown and then turn the key to the right to close the cover ZAUU0350 1 Ignition key 2 Safety key ZAUU0351 2 1 ZAUU0352 ZAUU0353 5P0_F8199_E1 book Page 2 Thursday January 15 2009 1 10 PM ...

Page 20: ...arning light can be checked by turning the key to ON The warning light should come on for a few seconds and then go off If the warning light does not come on initially when the key is turned to ON or if the warning light remains on have a Yamaha dealer check the electrical circuit EAU11601 Speedometer The speedometer shows the riding speed When the key is turned to ON the speedometer needle will s...

Page 21: ...urs re fuel as soon as possible TIP _ Do not allow the fuel tank to empty itself completely _ EAUU0361 Digital coolant temperature gauge odometer When the key is turned to ON the dis play segments of the digital coolant temperature gauge will sweep once across the temperature range and then return to C in order to test the electri cal circuit The odometer shows the total distance traveled ECA10021...

Page 22: ...e turned to the center position EAU12500 Horn switch Press this switch to sound the horn EAUM1132 Start switch Push this switch while applying the front or rear brake to crank the engine with the starter See page 6 1 for start ing instructions prior to starting the en gine EAU12900 Front brake lever The front brake lever is located on the right handlebar grip To apply the front brake pull this lev...

Page 23: ...he fuel tank cap counter clockwise and pull it off To install the fuel tank cap 1 Insert the fuel tank cap into the tank opening and turn it clockwise until the marks on the cap and tank are aligned 2 Close the seat EWA11091 WARNING _ Make sure that the fuel tank cap is properly closed after filling fuel Leaking fuel is a fire hazard _ 1 Rear brake lever 1 ZAUU0361 1 Fuel tank cap a Open b Close 1...

Page 24: ...inted surfac es or plastic parts ECA10071 4 Be sure to securely close the fuel tank cap EWA15151 WARNING _ Gasoline is poisonous and can cause injury or death Handle gaso line with care Never siphon gaso line by mouth If you should swallow some gasoline or inhale a lot of gas oline vapor or get some gasoline in your eyes see your doctor immedi ately If gasoline spills on your skin wash with soap a...

Page 25: ...NG _ The exhaust system is hot after op eration To prevent a fire hazard or burns Do not park the vehicle near possible fire hazards such as grass or other materials that easily burn Park the vehicle in a place where pedestrians or children are not likely to touch the hot exhaust system Make sure that the exhaust sys tem has cooled down before do ing any maintenance work Do not allow the engine to...

Page 26: ...he seat 1 Place the motorcycle on the cen terstand 2 Insert the key into the main switch and then turn it counterclockwise to OPEN TIP _ Do not push inward when turning the key _ 3 Fold the seat up To close the seat 1 Fold the seat down and then push it down to lock it in place 2 Remove the key from the main switch if the motorcycle will be left unattended TIP _ Make sure that the seat is properly...

Page 27: ...since the helmet may hit objects causing loss of control and possibly an acci dent EWA10161 To release a helmet from a helmet holder Open the seat remove the helmet from the helmet holder and then close the seat EAUU0390 Convenience hook EWAU0010 WARNING _ Do not exceed the load limit of 1 0 kg 2 2 lb for the conve nience hook Do not exceed the maximum load of 160 kg 353 lb for the motorcycle _ 1 ...

Page 28: ...ptible to heat in side it To avoid humidity from spread ing through the storage com partment wrap wet articles in a plastic bag before storing them in the compartment Since the storage compartment may get wet while the scooter is being washed wrap any articles stored in the compartment in a plastic bag Do not keep anything valuable or breakable in the storage compartment _ To store a helmet in the...

Page 29: ...llowing points ITEM CHECKS PAGE Fuel Check fuel level in fuel tank Refuel if necessary Check fuel line for leakage 4 7 Engine oil Check oil level in engine If necessary add recommended oil to specified level Check vehicle for oil leakage 7 9 Final transmission oil Check vehicle for oil leakage 7 11 Coolant Check coolant level in reservoir If necessary add recommended coolant to specified level Che...

Page 30: ... if necessary 7 24 Wheels and tires Check for damage Check tire condition and tread depth Check air pressure Correct if necessary 7 18 7 20 Brake levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 7 25 Centerstand sidestand Make sure that operation is smooth Lubricate pivots if necessary 7 25 Chassis fasteners Make sure that all nuts bolts and screws are properl...

Page 31: ...to ON 2 Close the throttle grip completely 3 Start the engine by pushing the start switch or by kicking the kick starter while applying the front or rear brake NOTICE For maxi mum engine life never acceler ate hard when the engine is cold ECA11041 4 If the engine fails to start by push ing the start switch release the switch wait a few seconds and then try again Each starting at tempt should be as...

Page 32: ...rors 3 Switch the turn signals on 4 Check for oncoming traffic and then slowly turn the throttle grip on the right in order to take off 5 Switch the turn signals off EAU16780 Acceleration and deceleration The speed can be adjusted by opening and closing the throttle To increase the speed turn the throttle grip in direction a To reduce the speed turn the throt tle grip in direction b EAU16793 Braki...

Page 33: ...epends largely on your riding style Consider the following tips to reduce fuel consumption Avoid high engine speeds during acceleration Avoid high engine speeds with no load on the engine 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 crossings EAU16830 Engine break in There is never a more important period in the...

Page 34: ... engine freely through the gears but do not use full throttle at any time 500 1000 km 300 600 mi Avoid prolonged operation above 3 4 throttle 1000 km 600 mi and beyond Avoid prolonged full throttle operation Vary the engine speed occasionally NOTICE After 1000 km 600 mi of operation the engine oil must be changed the oil filter cartridge or element replaced and the oil strain er cleaned If any eng...

Page 35: ...haust system can become very hot park in a place where pedestri ans or children are not likely to touch them and be burned Do not park on a slope or on soft ground otherwise the vehi cle may overturn increasing the risk of a fuel leak and fire Do not park near grass or other flammable materials which might catch fire _ 5P0_F8199_E1 book Page 5 Thursday January 15 2009 1 10 PM ...

Page 36: ...ST POTENTIAL OF YAMAHA MOTORCYCLES 2 A MOTORCYCLE CAN KEEP ITS PERFORMANCE CAPABILITY FOR A LONGER TIME Comparison of wear on engine parts piston piston ring cylinder etc 100 Perfect operative condition Without maintenance Distance covered km Engine overhaul cylinder boring piston ring change etc With maintenance 5P0_F8199_E1 book Page 6 Thursday January 15 2009 1 10 PM ...

Page 37: ...CE WHEN IT IS TRADED IN AS A USED PRODUCT Fuel consumption 100 Without maintenance Distance covered km With maintenance Customer s running cost fuel cost plus maintenance and repair expenses Without maintenance With maintenance Big repairs at higher expenses Distance covered km S 5P0_F8199_E1 book Page 7 Thursday January 15 2009 1 10 PM ...

Page 38: ...maha dealer perform service _ EWA15121 WARNING _ Turn off the engine when performing maintenance unless otherwise specified A running engine has moving parts that can catch on body parts or clothing and electrical parts that can cause shocks or fires Running the engine while ser vicing can lead to eye injury burns fire or carbon monoxide poisoning possibly leading to death See page 2 2 for more in...

Page 39: ...iodic maintenance chart for the emission control system NO ITEM CHECK OR MAINTENANCE JOB ODOMETER READING km ANNUAL CHECK 1000 4000 8000 12000 16000 1 Fuel line Check fuel and vacuum hoses for cracks or damage 2 Spark plug Check condition Clean and regap Replace 3 Valves Check valve clearance Adjust 4 Carburetor Adjust engine idling speed 5 Muffler and exhaust pipe Check the screw clamp s for loos...

Page 40: ...Whenever worn to the limit 5 Rear brake Check operation and adjust brake lever free play Replace brake shoes Whenever worn to the limit 6 Brake hose Check for cracks or damage Replace Every 4 years 7 Wheels Check runout and for damage 8 Wheels Check runout spoke tightness and for damage Tighten spokes if necessary 9 Tires Check tread depth and for damage Replace if necessary Check air pressure Cor...

Page 41: ...gine oil strainer Clean 19 Cooling system Check coolant level and vehicle for coolant leakage Change Every 3 years 20 Final transmission oil Check vehicle for oil leakage Change Every 10000 km 6000 mi 21 V belt Check for damage and wear Replace Every 25000 km 16000 mi 22 Front and rear brake switches Check operation 23 Moving parts and cables Lubricate 24 Throttle grip housing and cable Check oper...

Page 42: ...usty areas Hydraulic brake service Regularly check and if necessary correct the brake fluid level Every two years replace the internal components of the brake master cylinder and caliper and change the brake fluid Replace the brake hoses every four years and if cracked or damaged _ 5P0_F8199_E1 book Page 5 Thursday January 15 2009 1 10 PM ...

Page 43: ...lings 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 EAU37730 Cowling C To remove the cowling 1 Remove cowlings A and B See page 7 6 2 Remove the bolts and screws shown and then take the cowling off 1 Cowling A 2 Cowling C 3 Panel A 1 Cowling B 2 Panel B 1 2 3 ZAUU0374 1 2 ZAUU0375 1 Co...

Page 44: ... 2 Install cowlings A and B EAU19292 Panels A and B To remove one of the panels Remove the screw and then pull the panel off as shown To install the panel Place the panel in the original position and then install the screw 1 Screw x4 1 1 ZAUU0378 1 Panel B 2 Screw x3 2 1 2 ZAUU0379 ZAUU0380 5P0_F8199_E1 book Page 7 Thursday January 15 2009 1 10 PM ...

Page 45: ... owner s tool kit To check the spark plug 1 Check that the porcelain insulator around the center electrode of the spark plug is a medium to light tan the ideal color when the vehicle is ridden normally TIP _ If the spark plug shows a distinctly dif ferent color the engine could be oper ating improperly Do not attempt to diagnose such problems yourself In stead have a Yamaha dealer check the vehicl...

Page 46: ...ecified in the periodic maintenance and lubrication chart To check the engine oil level 1 Place the vehicle on the center stand A slight tilt to the side can result in a false reading 2 Start the engine warm it up for several minutes and then turn it off 3 Wait a few minutes until the oil set tles remove the oil filler cap wipe the dipstick clean insert it back into the oil filler hole without scr...

Page 47: ...iner remove drain bolt B also _ 4 Clean the engine oil strainer with solvent and then check it for dam age and replace it if necessary 5 Check the O ring for damage and replace it if necessary 6 Install the engine oil strainer com pression spring O ring and engine oil drain bolt and then tighten the drain bolt to the specified torque TIP _ Make sure that the O ring is properly seated _ 7 Refill wi...

Page 48: ...The final transmission case must be checked for oil leakage before each ride If any leakage is found have a Yamaha dealer check and repair the scooter In addition the final transmis sion oil must be changed as follows at the intervals specified in the periodic maintenance and lubrication chart 1 Start the engine warm up the final transmission oil by riding the scooter for several minutes and then ...

Page 49: ...emperature Make sure that the vehicle is posi tioned straight up when checking the coolant level A slight tilt to the side can result in a false reading _ 2 Check the coolant level in the cool ant reservoir TIP _ The coolant should be between the minimum and maximum level marks _ 3 If the coolant is at or below the minimum level mark remove pan el B See page 7 6 remove the reservoir cap add coolan...

Page 50: ...dic mainte nance and lubrication chart Have a Yamaha dealer change the coolant WARNING Never attempt to re move the radiator cap when the en gine is hot EWA10381 EAUU0411 Air filter and V belt case air filter elements The air filter element should be checked and replace if necessary and the V belt case air filter element should be cleaned at the intervals specified in the periodic maintenance and ...

Page 51: ...r element in its original position 7 Install the air filter case cover by installing the screws 8 Install the panel Cleaning the V belt case air filter el ement 1 Place the vehicle on the center stand 2 Remove the V belt air filter case cover by removing the bolts 3 Remove the element by pulling it out 1 Air filter element Wet type 1 ZAUU0391 1 Air filter element Wet type 1 ZAUU0392 1 V belt case ...

Page 52: ...into the filter case 8 Place the air filter case cover in its original position and then install the bolts NOTICE Make sure that each filter element is prop erly seated in its case The en gine should never be operated without the filter elements in stalled otherwise the piston s and or cylinder s may become excessively worn ECA10531 Cleaning the air filter check hose and caps 1 Check each cap at t...

Page 53: ...ance and lubrication chart The engine should be warm before making this adjustment TIP _ The engine is warm when it quick ly responds to the throttle A diagnostic tachometer is needed to make this adjustment _ 1 Open the seat See page 4 9 for seat opening and closing proce dures 2 Remove panel B See page 7 6 for panel removal and installation procedures 3 Attach the tachometer to the spark plug le...

Page 54: ...he throttle cable free play turn the adjusting nut in di rection a To decrease the throt tle cable free play turn the adjusting nut in direction b 3 Tighten the locknut EAU21401 Valve clearance The valve clearance changes with use resulting in improper air fuel mixture and or engine noise To prevent this from occurring the valve clearance must be adjusted by a Yamaha dealer at the intervals specif...

Page 55: ...tal weight of rider passenger car go and accessories approved for this model _ EWA10511 WARNING _ Never overload your vehicle Opera tion of an overloaded vehicle could cause an accident _ Tire inspection The tires must be checked before each ride If the tire shows crosswise lines minimum tread depth if the tire has a nail or glass fragments in it or if the sidewall is cracked have a Yamaha dealer ...

Page 56: ...ride with a worn out tire When a tire tread begins to show crosswise lines have a Yamaha dealer replace the tire immediately The replacement of all wheel and brake related parts includ ing the tires should be left to a Yamaha dealer who has the necessary professional knowl edge and experience It is not recommended to patch a punctured tube If unavoid able however patch the tube very carefully and ...

Page 57: ...nbalanced wheel can result in poor performance adverse han dling characteristics and a short ened tire life Ride at moderate speeds after changing a tire since the tire sur face must first be broken in for it to develop its optimal characteris tics EAU37912 Checking the front brake lever free play There should be no free play at the brake lever end If there is free play have a Yamaha dealer inspec...

Page 58: ...ary adjust it as follows To increase the brake lever free play turn the adjusting nut at the brake shoe plate in direction a To decrease the brake lever free play turn the adjusting nut in direction b EWA10650 WARNING _ If proper adjustment cannot be ob tained as described have a Yamaha dealer make this adjustment _ 1 Rear brake lever free play 1 ZAUU0400 1 Rear brake lever free play adjusting nut...

Page 59: ...ar without having to dis assemble 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 EAU32344 Checking the brake fluid level Insufficient brake fluid may allow air to enter the brake system possibly cau...

Page 60: ...k Brake fluid may deteriorate paint ed surfaces or plastic parts Al ways clean up spilled fluid immediately As the brake pads wear it is nor mal for the brake fluid level to gradually go down However if the brake fluid level goes down sud denly have a Yamaha dealer check the cause EAU22721 Changing the brake fluid Have a Yamaha dealer change the brake fluid at the intervals specified in the TIP af...

Page 61: ...sary If a cable is damaged or does not move smoothly have a Yamaha dealer check or replace it WARNING Damage to the outer sheath may interfere with proper cable operation and will cause the inner cable to rust Replace a dam aged cable as soon as possible to prevent unsafe conditions EWA10721 EAU23111 Checking and lubricating the throttle grip and cable The operation of the throttle grip should be ...

Page 62: ...nterstand and sidestand should be checked before each ride and the pivots and metal to metal contact surfaces should be lubri cated if necessary EWA10741 WARNING _ If the centerstand or sidestand does not move up and down smoothly have a Yamaha dealer check or re pair it Otherwise the centerstand or sidestand could contact the ground and distract the operator resulting in a possible loss of contro...

Page 63: ...he vehicle on a level sur face and hold it in an upright posi tion WARNING To avoid injury securely support the vehicle so there is no danger of it falling over EWA10751 2 While applying the front brake push down hard on the handlebars several times to check if the front fork compresses and rebounds smoothly ECA10590 NOTICE _ If any damage is found or the front fork does not operate smoothly have ...

Page 64: ...y securely support the vehicle so there is no dan ger of it falling over EWA10751 2 Hold the lower ends of the front fork legs and try to move them for ward and backward If any free play can be felt have a Yamaha dealer check or repair the steering EAU23290 Checking the wheel bearings The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubri...

Page 65: ... 15 minutes and seek prompt medical attention Batteries produce explosive hy drogen gas Therefore keep sparks flames cigarettes etc away from the battery and pro vide sufficient ventilation when charging it in an enclosed space KEEP THIS AND ALL BATTER IES OUT OF THE REACH OF CHILDREN _ To access the battery 1 Open the seat See page 4 9 2 Remove the battery cover by re moving the screws To charge ...

Page 66: ... than two months check it at least once a month and fully charge it if necessary 3 Fully charge the battery before in stallation 4 After installation make sure that the battery leads are properly con nected to the battery terminals ECA16530 NOTICE _ Always keep the battery charged Storing a discharged battery can cause permanent battery damage _ EAUU0421 Replacing the fuse The fuse holder is locat...

Page 67: ...devices operate 8 If the fuse immediately blows again have a Yamaha dealer check the electrical system EAUU0121 Replacing a headlight bulb If a headlight bulb burns out replace it as follows ECA10660 NOTICE _ Do not touch the glass part of the headlight bulb to keep it free from oil otherwise the transparency of the glass the luminosity of the bulb and the bulb life will be adversely af fected Tho...

Page 68: ...ce a new bulb into position and then secure it with the bulb holder 6 Install the cowling 7 Have a Yamaha dealer adjust the headlight beam if necessary EAUU0451 Replacing the tail brake light bulb 1 Open the seat See page 4 9 2 Remove the panel by removing the screws and then pulling the panel outward 1 Headlight bulb cover x2 1 ZAUU0416 1 Headlight bulb holder 1 Do not touch the glass part of the...

Page 69: ...e seat EAU24204 Replacing a turn signal light bulb 1 Remove the turn signal light lens by removing the screw 2 Remove the burnt out bulb by pushing it in and turning it counter clockwise 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 NOTICE Do not over tighten the screw otherwise the lens may break ECA11191 1 Tai...

Page 70: ...t 4 Insert a new bulb into the socket 5 Install the turn signal light socket together with the bulb by turning it clockwise 6 Install the cowling EAUU0441 Replacing an auxiliary light bulb This model is equipped with two auxil iary lights If an auxiliary light bulb burns out replace it as follows 1 Remove cowling C See page 7 6 for removal and installation proce dures 2 Remove the auxiliary light ...

Page 71: ...stems your self 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 replace ment parts Imitation parts may look like Yamaha parts but they are often inferior have a shorter service life and can lead to expensive repair bills EWA15141 WARNING...

Page 72: ...ck the vehicle Remove the spark plug and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gap or replace the spark plug Have a Yamaha dealer check the vehicle The engine does not start Have a Yamaha dealer check the vehicle The engine does not start Check the battery Operate the electric starter 4 Battery The engine turns over quickly The engine turns over slowl...

Page 73: ...ing sound has stopped press down on the cap while turning it counterclockwise and then remove the cap _ TIP _ If coolant is not available tap water can be temporarily used instead provided that it is changed to the recommended coolant as soon as possible _ Wait until the engine has cooled Check the coolant level in the reservoir and radiator The coolant level is OK The coolant level is low Check t...

Page 74: ...pecially on spoked wheels If such products are used on hard to remove dirt do not leave the cleaner on the af fected area any longer than in structed Also thoroughly rinse the area off with water immedi ately dry it and then apply a corrosion protection spray Improper cleaning can damage plastic parts such as cowlings panels windshields headlight lenses meter lenses etc and the mufflers Use only a...

Page 75: ...ngine has cooled down NO TICE Do not use warm water since it increases the corrosive action of the salt ECA10791 2 Apply a corrosion protection spray on all metal including chrome and nickel plated surfaces to pre vent corrosion After cleaning 1 Dry the motorcycle with a chamois or an absorbing cloth 2 Use a chrome polish to shine chrome aluminum and stainless steel parts including the exhaust sys...

Page 76: ...y to seep in and cause rust To prevent corrosion avoid damp cellars stables because of the presence of ammonia and areas where strong chemi cals are stored _ Long term Before storing your scooter for several months 1 Follow all the instructions in the Care section of this chapter 2 Drain the carburetor float chamber by loosening the drain bolt this will prevent fuel deposits from building up Pour ...

Page 77: ...o that both of its wheels are off the ground Alterna tively turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot 7 Cover the muffler outlet with a plastic bag to prevent moisture from entering it 8 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 ex cessively cold or warm p...

Page 78: ...nsmission oil quantity 0 23 L 0 24 US qt 0 20 Imp qt Cooling system Recommended coolant YAMAHA GENUINE COOLANT only Coolant reservoir capacity up to the maximum level mark 0 25 L 0 26 US qt 0 22 Imp qt Radiator capacity including all routes 0 51 L 0 54 US qt 0 45 Imp qt Air filter Air filter element Wet element Fuel Recommended fuel Regular unleaded gasoline or gasohol 91 min pump octane Fuel tank...

Page 79: ...ion Recommended fluid DOT 4 Rear brake Type Drum brake Operation Left hand operation Front suspension Type Telescopic fork Spring shock absorber type Coil spring oil damper Wheel travel 100 0 mm 3 94 in Rear suspension Type Unit swing Spring shock absorber type Coil spring oil damper Wheel travel 90 0 mm 3 54 in Electrical system Ignition system DC CDI Charging system AC magneto Battery Model GTZ5...

Page 80: ...ntification number The key identification number is stamped into the key Record this num ber in the space provided and use it for reference when ordering a new key EAU26410 Vehicle identification number The vehicle identification number is stamped into the frame TIP _ The vehicle identification number is used to identify your motorcycle and may be used to register your motorcy cle with the licensi...

Page 81: ...MER INFORMATION 10 2 10 EAU26450 Engine serial number The engine serial number is stamped into the final gear case 1 Engine serial number 1 ZAUU0426 5P0_F8199_E1 book Page 2 Thursday January 15 2009 1 10 PM ...

Page 82: ...1 CONSUMER INFORMATION 5P0_F8199_E1 book Page 1 Thursday January 15 2009 1 10 PM ...

Page 83: ...5P0_F8199_E1 book Page 2 Thursday January 15 2009 1 10 PM ...

Page 84: ...PRINTED IN THAILAND 5P0_F8199_E1 book Page 1 Thursday January 15 2009 1 10 PM ...

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