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Yamaha SCORPIO 54D, Owner'S Manual

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-30

6 

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 : Use only distilled : Use only distilled : Use only distilled : Use only distilled : Use only distilled : Use only distilled : Use only distilled : Use only distilled : Use only distilled : Use only distilled : Use only distilled : Use only distilled : Use only distilled : Use only distilled : Use only distilled : Use only distilled : Use only distilled : Use only distilledUse only distilledUse only distilledUse only distilledUse only distilledUse only distilledUse only distilledUse only distilledUse only distilledUse only distilledUse only distilledUse only distilledUse only distilledUse only distilledUse only distilledUse only distilledUse only distilledUse only distilledUse only distilledUse only distilledUse only distilledUse only distilledUse only distilledUse only distilledUse only distilledUse only distilledUse only distilledUse only distilledUse only distilledUse only distilledUse only distilledUse only distilledUse only distilledUse only distilledUse only distilledUse only distilledUse only distilledUse only distilledUse only distilledUse only distilledUse only distilledUse only distilledUse only distilledUse only distilledUse only distilledUse only distilledUse only distilledECA10611ECA10611ECA10611ECA10611ECA10611ECA10611ECA10611ECA10611ECA10611ECA10611ECA10611ECA10611ECA10611ECA10611ECA10611ECA10611ECA10611ECA10611ECA10611ECA10611ECA10611ECA10611ECA10611ECA10611ECA10611ECA10611ECA10611ECA10611ECA10611ECA10611ECA10611ECA10611ECA10611ECA10611ECA10611ECA10611ECA10611ECA10611ECA10611ECA10611ECA10611ECA10611ECA10611ECA10611ECA10611ECA10611ECA10611ECA10611ECA10611ECA10611ECA10611ECA10611ECA10611ECA10611ECA10611ECA10611ECA10611ECA10611ECA10611

U5YPE0E0.book  Page 28  Wednesday, February 23, 2005  4:22 PM

_

4. If the electrolyte is at or below the

minimum level mark, 

Add distilled water to raise the

electrolyte to the maximum level
mar

k. 

NOTICE

 : 

Use only distilled 

 

●

Electrolyte is poisonous and
dangerous since it contains sul-
furic acid, which causes severe

burns. Avoid any contact with
skin, eyes or clothing and al-

ways shield your eyes when
working near batteries. In case
of contact, administer the fol-
lowing FIRST AID.

• EXTERNAL: Flush with plenty

of water.

• INTERNAL: Drink large quan-

tities of water or milk and im-
mediately call a physician.

• EYES: Flush with water for 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.

●

Take care not to spill electrolyte
on the drive chain, as this may
weaken it, shorten chain life and
possibly result in an accident.

●

KEEP THIS AND ALL BATTER-
IES OUT OF THE REACH OF
CHILDREN.

1

. Maximum level mark

2

. Minimum level mark

water, as tap water contains mine-

rals that are harmful to the

 

battery.

[

EWA1077

0]

 

WARNING

EWA1077

0

•

ECA10610

Use only distilled water, as tap water
contains minerals that are harmful
to the battery.

5

. Check and, if necessary, tighten

the battery lead connections and
correct the breather hose routing.

6

. 

Instal the panel. 

NOTICE:

1

2

Summary of Contents for SCORPIO 54D

Page 1: ...A5 yoko_Blank fm Page 1 Tuesday April 8 2003 11 43 AM 54D F8199 E0 OWNER S MANUAL Read this manual carefully before operating this vehicle SX 4 225 ...

Page 2: ...U5YPE0E0 book Page 2 Wednesday February 23 2005 4 22 PM Read this manual carefully before operating this vehicle This manual should stay with this vehicle if it sold EAU46090 ...

Page 3: ...ut 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 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 de...

Page 4: ...onal injury hazards Obey all safety messages that follow this simbol to avoid possible injury A WARNING indicates a hazardous situation which if not avoid 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 NOTICE TIP EAU10122 or death W...

Page 5: ...FORMATION EAUN0020 SCORPIO 54D OWNER S MANUAL 2010 by Yamaha Indonesia Motor Mfg 1st edition October 2010 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Indonesia Motor Manufacturing is expressly prohibited Printed in Indonesia ...

Page 6: ...rake fluid 6 20 Drive chain slack 6 21 Cleaning and lubricating the drive chain 6 23 Checking and lubricating the cables 6 23 Checking and lubricating the throttle grip and cable 6 23 Lubricating the brake lever 6 24 Lubricating the brake pedal 6 24 Checking and lubricating the centerstand and sidestand 6 24 Lubricating the swingarm pivots 6 25 Checking the front fork 6 25 Checking the steering 6 ...

Page 7: ...6 29 Replacing a front turn signal ligh bulb Auxilliary bulb 6 29 Replacing a rear turn signal tail brake light bulb 6 30 Rear wheel 6 32 Troubleshooting charts 6 35 MOTORCYCLE CARE AND STORAGE 7 1 Care 7 1 Storage 7 3 SPECIFICATIONS 8 1 CONSUMER INFORMATION 9 1 Identification numbers 9 1 Front wheel 6 31 ...

Page 8: ... To close the keyhole cover To close the keyhole cover To close the keyhole cover To close the keyhole cover To close the keyhole cover To close the keyhole cover To close the keyhole cover To close the keyhole cover To close the keyhole cover To close the keyhole cover To close the keyhole cover To close the keyhole cover To close the keyhole cover To close the keyhole cover To close the keyhole ...

Page 9: ...e riding this motorcycle The failure of motorists to detect Make sure that you are qualified He or she should and recognize motorcycles in traf and that you only lend your mo Obtain thorough instructions from fic is the predominating cause of torcycle to other qualified opera a competent source on all aspects automobile motorcycle accidents tors of motorcycle operation Many accidents have been Kno...

Page 10: ...ortant for proper could contribute to an impairment Carbon Monoxide is a colorless odor control of vision that could delay seeing a less tasteless gas which may be The operator should keep both hazard present even if you do not see or smell hands on the handlebar and The use of a jacket heavy boots any engine exhaust Deadly levels of both feet on the operator foot trousers gloves etc is effective ...

Page 11: ... bags or keep the following in mind as windows and doors tents can create unstable han Cargo and accessory weight dling or a slow steering re should be kept as low and close to Loading Adding accessories or cargo to your motorcycle can adversely affect stabili ty and handling if the weight distribution of the motorcycle is changed To avoid the possibility of an accident use ex treme caution when a...

Page 12: ... of your motorcycle Care fully inspect the 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 ac...

Page 13: ...February 23 2005 4 22 PM DESCRIPTION 2 EAU10420 Left view 2 1 1 Fuel cock Page 3 7 4 2 Page 6 1 5 Shift pedal Page 3 5 3 Page 3 10 6 Starter choke lever Page 3 8 Air filter element Page 6 10 Helmet holder Owner s tool kit 1 2 3 5 6 4 ...

Page 14: ...uary 23 2005 4 22 PM DESCRIPTION EAU10410 Right view 2 7 Fuse Page 6 32 10 Engine oil level check window Page 6 8 8 Kickstarter Page 3 9 11 Brake pedal Page 3 6 6 18 9 Engine oil filter element Page 6 8 12 Battery Page 6 30 7 8 12 10 11 11 9 ...

Page 15: ...0430 1 Clutch lever Page 3 5 6 17 6 Right handlebar switches Page 3 4 2 Left handlebar switches Page 3 3 7 Brake lever Page 3 5 6 18 3 Speedometer unit Page 3 2 8 Throttle grip Page 6 13 6 26 4 Main switch steering lock Page 3 1 9 Fuek tank cap Page 3 6 5 Tachometer Fuel gauge Page 3 3 1 2 3 4 5 6 7 8 9 ...

Page 16: ...ING NG ARNING 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 Make sure that the vehicle is stopped be fore turning the key to OFF or LOCK 1 Push 2 Turn The main switch steering lock controls the ignition and lighting systems and is used to lock the steering The various positions ...

Page 17: ... equipped with a speedometer an odometer and trip meter The speedometer shows riding speed The odometer shows the total distance traveled The tripmeter shows the distance tra veled since it was last set to zero with the reset knob The tripmeter can be used to estimate the distance that can be traveled with a full tank of fuel This information will enable you to plan future fuel stops EAU10981 EAU1...

Page 18: ...he amount of fuel in the fuel tank The needle moves towards E Empty as the fuel level decreases When the needle reaches When the needle reaches E refuel as soon as possible TIP Do not allow the fuel tank to empty itself completely Handlebar switches EAU12347 Left EAU12590 Light switch 1 Set this switch to to turn on the auxiliary light meter lighting and tail light Set the switch to to turn on the...

Page 19: ... and to for the low beam 1 2 Engine stop switch EAU12660 Set this switch to before starting the engine Set this switch to to stop the engine in case of an emer gency such as when the motorcycle overturns or when the throttle cable is stuck EAU12710 Start switch Push this switch to crank the engine with the starter ECA10050 CAUTION See page 5 1 for starting instruction prior starting the engine NOT...

Page 20: ...ll the lever toward the handle brake press down on the brake pedal bar grip INSTRUMENT AND CONTROL FUNCTIONS 3 5 EAU12941 Brake pedal 3 Shift pedal EAU12880 1 Shift pedal N Neutral The shift pedal is located on the left side of the engine and is used in combination with the clutch lever when shifting the gears of the 5 speed constant mesh transmission equipped on this motorcycle TIP Use your toes ...

Page 21: ... key counterclokwise to the original position remove it and then close the lock cover To close the fuel tank cap TIP The fuel tank cap cannot be closed unless the key is in the lock In addition the key cannot be removed if the cap cap is not properly closed and locked Fuel EAU13212 1 Fuel tank filler tube 2 Fuel level Make sure there is sufficient gasoline in the tank EWA10881 W W W WARNI ARNI ARN...

Page 22: ...a clean dry soft cloth since fuel may dete riorate painted surfaces or plas tic parts ECA10071 4 Be sure to securely close the fuel tank cap EWA15151 W WARNI ARNING NG Gasoline is poisonous and can cau se injury or death Handle gasoline with care Never siphon gasoline by mouth If you should awallow some gasoline or inhale a lot of ga soline vapor or get some gasoline in youreyes see your doctor im...

Page 23: ...ion RES Reserve position RES Reserve position RES Reserve position RES Reserve position RES Reserve position RES Reserve position RES Reserve position RES Reserve position RES Reserve position RES Reserve position RES Reserve position RES Reserve position RES Reserve position RES Reserve position RES Reserve position RES Reserve position RES Reserve position RES Reserve position RES Reserve positi...

Page 24: ...tarter choke lever CHOKE 1 2 1 Kickstarter 2 Footrest EAU13660 Kickstarter 3 9 3 To start the engine fold the right foot rest inward and then fold out the kickstarter lever Move it down lightly with your foot until the gears engage and then push it down smoothly but forcefully Fold the footrest outward to it original position This model is equipped with a primary kickstarter allowing the engine to...

Page 25: ...3 Turn the key counter clockwise TIP Make sure that the seat is properly secured before riding 1 Projection 2 Seat holder Helmet holders EAU14311 1 Helmet holder The helmet holders are located under the seat To secure a helmet to a helmet holder 1 Open the seat See page 3 9 for 2 Attach a helmet to a helmet holder and then securely close the seat WARNI WARNING NG Never ride with a helmet attached ...

Page 26: ...hile holding the vehicle upright EWA14190 WARNING The vehicle must not be ridden with the sidestand down or if the side stand cannot be properly moved up or does not stay up otherwise the sidestand could contact the ground and distract the operator resulting in a possible loss of control WARNING 3 1 To release a helmet to a helmet holder Open the seat remove the helmet from the helmet holder and t...

Page 27: ...nd maintenance procedures and schedules described in the Owner s Manual Before using this vehicles check the following points Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equipment damage Do not operate the vehicle if you find any problem If a problem cannot be corrected by the procedures provided in this manual have the vehicle inspected by a Yam...

Page 28: ... brake pads for wear Replace if necessary Check fluid level in reservoir If necessary add recommended brake fluid to specified level Check hydraulic system for leakage 6 18 6 19 Rear brake Check operation Check pedal free play Adjust if necessary 6 17 Throttle grip Make sure that operation is smooth Check cable free play If necessary have Yamaha dealer adjust cable free play and lubricate cable an...

Page 29: ...ure that operation is smooth Lubricate pedal pivoting point if necessary 6 16 Make sure that operation is smooth Lubricate lever pivoting point if necessary 6 16 Make sure that operation is smooth Lubricate pivots if necessary 6 22 Make sure that all nuts bolts and screws are properly tightened Tighten if necessary Check operation Correct if necessary Check fluid level Fill with distilled water if...

Page 30: ...equate ventila tion Before starting out make sure that the sidestand is up If the sidestand is not raised com pletely it could contact the ground and distract the opera tor resulting in a possible loss of control U5YPE0E0 book Page 1 Wednesday February 23 2005 4 22 PM EAU15942 ECAN0070 NOTICE NOTICE Do not ride through deep water including puddles otherwise the engine may be damaged NOTICE Startin...

Page 31: ...r motor try using the kickstarter OPERATION AND IMPORTANT RIDING POINTS 4 Turn the starter choke on and completely close the throttle See page 3 8 5 Start the engine by pushing the start switch or by pushing the kick starter lever down TIP When the transmission is in the neutral position the neutral indicator light should be on otherwise have a Yamaha dealer check the electrical circuit 6 After st...

Page 32: ...ting EAU16671 5 4 3 2 N 1 1 1 Shift pedal N Neutral position Shifting gears lets you control the amount of engine power available for starting off accelerating climbing hills etc TIP To shift the transmission into the neu tral position press the shift pedal down repeatedly until it reaches the end of its travel and then slightly raise it ECA10260 8 8 Even with the transmission in the neutral posit...

Page 33: ... operating clearances During this period prolonged full throt tle operation or any condition that might result in engine overheating must be avoided EAU16970 0 500 km 500 1 000 km 0 300 mi 300 600 mi 8 Avoid prolonged operation above 8 Avoid prolonged operation above 4 700 r min 6 600 r min 8 After every hour of operation 8 Rev the engine freely through stop the engine and then let it the gears bu...

Page 34: ...destri ans or children are not likely to touch them Do not park on a slope or on soft ground otherwise the vehicle may overturn U5YPE0E0 book Page 5 Wednesday February 23 2005 4 22 PM 1 000 km 600 mi and beyond The vehicle can now be operated normally ECA10310 8 8 Keep the engine speed out of the tachometer red zone 8 8 If any engine trouble should occur during the engine break in period immediate...

Page 35: ...tenance of a motorcycle 1 THE CUSTOMERS CAN USE THE FULLEST 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 ...

Page 36: ...BE KEPT TO A MINIMUM 4 A MOTORCYCLE CAN DEMAND A HIGH PRICE 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 ...

Page 37: ...have the tools or experi ence required for a particular job have a Yamaha dealer perform it for you WARNING EWA10350 Modifications not approved by Yamaha may cause loss of perfor mance and render the vehicle un safe for use Consult a Yamaha dealer before attempting any chang es 1 Owner s tool kit The owner s tool kit is located inside the storage compartment under the seat See page 3 9 The service...

Page 38: ...NNUAL CHECK 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 Air filter element Clean Replace 5 Battery Check electrolyte level and specific gravity Make sure that the breather hose is properly routed 6 Front brake Check operation fluid level and vehicle for fluid leakage Replace brake pads Whe...

Page 39: ...rain 14 Steering bearings Check bearing play and steering for roughness Lubricate with lithium soap based grease Every 24000 km 15 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 16 Sidestand centerstand Check operation Lubricate 17 Front fork Check operation and for oil leakage 18 Shock absorber assem bly Check operation and shock absorber for oil leakage 19 Carb...

Page 40: ...t suspention Check operation Check for oil leakage 23 Front and rear brake switches Check operation 24 Moving parts and ca bles Lubricate 25 Throttle grip housing and cable Check operation and free play Adjust the throttle cable free play if necessary Lubricate the throttle grip housing and cable 26 Air induction system Check the air cut off valve reed valve and hose for dam age Replace any damage...

Page 41: ...o this section each time a cowling or the panel needs to be re moved and installed EAU18771 Removing and installing the cowlings and panel EAU19400 To remove the panel 1 Remove the seat See age 3 8 for seat removal and instalation pro cedures 2 Remove the screws and then pull the panel off as shown To install the panel 1 Pleace the panel in the original po sition and then install the screws TIP Ma...

Page 42: ... plug wrence 1 Spark plug wrence 1 Spark plug wrence 1 Spark plug wrence 1 Spark plug wrence 1 Spark plug wrence 1 Spark plug wrence 1 Spark plug wrence 1 Spark plug wrence 1 Spark plug wrence 1 Spark plug wrence 1 Spark plug wrence 1 Spark plug wrence 1 Spark plug wrence 1 Spark plug wrence 1 Spark plug wrence 1 Spark plug wrence 1 Spark plug wrence 1 Spark plug wrence 1 Spark plug wrence 1 Spark...

Page 43: ...ight However the spark plug should be tightened to the speci fied torque as soon as possible 4 Install the spark plug cap 1 Spark plug gap Spark plug gap 0 7 0 8 mm 0 027 0 031 in 2 Clean the surface of the spark plug gasket and its mating surface and then wipe off any grime from the spark plug threads 3 Install the spark plug with the spark plug wrench and then tight en it to the specified torque...

Page 44: ...n an upright po face and hold it in an upright po face and hold it in an upright po face and hold it in an upright po face and hold it in an upright po face and hold it in an upright po face and hold it in an upright po face and hold it in an upright po face and hold it in an upright po face and hold it in an upright po face and hold it in an upright po face and hold it in an upright po face and h...

Page 45: ...age and replace it if necessary 9 Clean the oil filter element with solvent and then install it TIP Check the oil filter element for damage and repalce it if necessary 10 Install the oil filter element cover by installing the bolts then tightening them to the specified torque Tightening torque Oil filter element cover bolt 10 Nm 1 0 m kgf 7 2 ft lbf TIP Make sure that the O ring is properly seated...

Page 46: ...e page 8 1 Oil quantity With oil filter element removal 1 30 L 1 24 US qt 1 13 Imp qt Without oil filter element removal 1 20 L 1 14 US qt 1 04 Imp qt Total amount dry engine 1 40 L 1 33 US qt 1 21 Imp qt ECA10390 NOTICE In order to prevent clutch slip page since the engine oil also lubricates the clutch do not mix any chemical additives with the oil Make sure that no foreign mate rial enters the ...

Page 47: ...ase cover by removing the screws 3 Pull the air filter out 4 Remove the sponge material from the air filter element frame clean it with solvent and squee ze the remaining solvent out 5 Apply oil of the recommended type to the entire surface of the excess oil out 1 2 3 1 Sponge material 2 Element guide 3 Air filter element frame TIP The sponge material should be wet but not dripping Recommended oil...

Page 48: ...ent into the air filter case NOTICE Make su re 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 otherwise the piston s and or cylinder s may become excessively worn ECA10481 ECA10550 The carburetor has been set and ex tensively tested at the Yamaha fac tory Changing these settings without sufficient t...

Page 49: ...free play Engine idling speed 1300 1500 r min U5YPE0E0 book Page 15 Wednesday February 23 2005 4 22 PM EAU21320 Adjusting the engine idling speed The engine idling speed must be checked and if necessary adjusted as at the intervals specified in the maintenance and lubrication gine should be warm before this adjustment TIP The engine is warm when it quickly responds to the throttle Check the engine...

Page 50: ...ressure should be checked and if necessary adjusted before each ride WARNING EWA10500 The tire air pressure must be checked and adjusted on cold tires i e when the temperature of the tires equals the ambient temperature The tire air pressure must be ad justed in accordance with the riding speed and with the total weight of rider passenger car go and accessories approved for this model U5YPE0E0 boo...

Page 51: ... 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 TIP The tire tread depth limits may differ from country to country Always comply with the local regulations Tire information This motorcycle is equipped with tube tires WARNING EWA10460 The front and rear tires should be of the same make and de sign otherwise the h...

Page 52: ...ufacturer model IRC NR65 U5YPE0E0 book Page 18 Wednesday February 23 2005 4 22 PM W EAU22000 heels WARNING EWA10610 The wheels on this model are not designed for use with tubeless tires Do not attempt to use tube less tires on this model To maximize the performance durabil ity and safe operation of your motor cycle note the following points regarding the specified wheels The wheel rims should be c...

Page 53: ...d above tighten the locknut and skip the rest of the procedure otherwise proceed as follows 4 Fully turn the adjusting bolt in direction a to loosen the clutch cable 1 Locknut clutch lever 2 Adjusting bolt The clutch lever free play should measure 10 15 mm as shown Periodically check the clutch lever free play and if necessary adjust it as follows 1 Loosen the locknut at the clutch lever 2 To incr...

Page 54: ...it as follows EWA10630 WARNING Yamaha dealer bleed the system be fore operating the motorcycle Air in the hydraulic system will diminish the braking performance which may result in loss of control and an acci dent 6 6 18 1 c 2 1 Locknut 2 Adjusting bolt C Free play 1 Loosen the locknut at the brake lever 2 To increase the brake lever free play turn the adjusting bolt in direction a To decrease the...

Page 55: ...this EAU22220 Adjusting the brake pedal position and free play adjustments The top of the brake pedal should be positioned approximately 30 mm 1 18 in below the top of the footrest Periodically check the brake pedal position and if necessary adjust it as follows Brake pedal position 2 To raise the brake pedal turn the adjusting bolt in direction a To lower the brake pedal turn the adjusting bolt i...

Page 56: ...he operation of the brake light U5YPE0E0 book Page 19 Wednesday February 23 2005 4 22 PM 1 Brake pedal free play adjusting nut EAU22270 Adjusting the rear brake light switch 1 2 a b 1 Rear brake light switch 2 Rear brake light switch adjusting nut The rear brake light switch which is ac tivated by the brake pedal is properly adjusted when the brake light comes on just before braking takes effect I...

Page 57: ...eck 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 ...

Page 58: ...ids may result in a harmful chemical reaction and lead to poor braking performance Be careful that water does not en ter the master cylinder when refill ing Water will significantly lower the boiling point of the fluid and may result in vapor lock 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 b...

Page 59: ...Spin the rear wheel several times to locate the tightest portion of the drive chain 4 Measure the drive chain slack as shown Drive chain slack 20 0 30 0 mm 0 78 1 18 in 5 If the drive chain slack is incorrect adjust it as follows EAU22822 To adjust the drive chain slack 1 Loosen the brake pedal free play adjusting nut the axle nut and the chain puller locknut at each end U5YPE0E0 book Page 22 Wedn...

Page 60: ...Nm 1 9 m kgf 64 7 ft lbf U5YPE0E0 book Page 23 Wednesday February 23 2005 4 22 PM en the drive chain turn the adjusting nut at each end of the swingarm in direction b and then push the rear wheel forward NOTICE Im 2 To tighten the drive chain turn the adjusting nut at each end of the swingarm in direction a To loos ECA10571 proper drive chain slack will overload the engine as well as other vital p...

Page 61: ...g the drive chain The drive chain must be cleaned and lubricated at the intervals specified in the periodic maintenance and lubrica tion chart otherwise it will quickly wear out especially when riding in dusty or wet areas Service the drive chain as follows NOTICE ECA10583 e chain must be lubricated ashing the motorcycle and The driv after w riding in area the rain or riding in the wet 1 Clean the...

Page 62: ...cant Engine oil The operation of the brake and shift pedals should be checked before each ride and the pedal pivots should be lubricated if necessary Recommended lubricant Lithium soap based grease all purpose grease EAU23133 Checking and lubricating the brake and shift pedals Checking and lubricating the EAU43610 brake and clutch levers The operation of the brake and clutch levers should be check...

Page 63: ...ING EWA10740 If the centerstand or sidestand does not move up and down smoothly have a Yamaha dealer check or re pair it Recommended lubricant Lithium soap based grease all pur pose grease U5YPE0E0 book Page 25 Wednesday February 23 2005 4 22 PM Lubricating the swingarm EAU23230 pivots The pivoting point of the rear suspen tion must be lubricated at the intervals specified in the periodic maintena...

Page 64: ...it fal 2 While applying the front brake push down hard on the handlebars several times to check if the front fork compresses and rebounds smoothly U5YPE0E0 book Page 26 Wednesday February 23 2005 4 22 PM ling over ECA10590 NOTICE If any damage is found or the front fork does not operate smoothly have a Yamaha dealer check or re pair it EAU45511 Checking the steering Worn or loose steering bearings...

Page 65: ... a Yamaha dealer check the wheel bearings EAU23322 Battery A poorly maintained battery will corrode and discharge quickly The electrolyte level battery lead connections and breather hose routing should be checked before each ride and at the in tervals specified in the periodic mainte nance and lubrication chart To check the electrolyte level 1 Place the vehicle on a level sur face and hold it in a...

Page 66: ...se only distilled Use only distilled Use only distilled Use only distilled Use only distilled Use only distilled Use only distilled Use only distilled Use only distilled Use only distilled Use only distilled Use only distilled Use only distilled Use only distilled Use only distilled Use only distilled Use only distilled Use only distilled Use only distilled Use only distilled Use only distilled Us...

Page 67: ...ds are properly con nected to the battery terminals ECA16530 NOTICE _ Always keep the battery charged Storing a discharged battery can cause permanent battery damage _ NOTICE 1 Fuse The fuse holder is located behind right side panel See page 6 5 for panels removal and installation procedures If the fuse is blown replace it as follows 1 Turn the key to OFF and turn off all electrical circuits Repla...

Page 68: ...lass 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 affected Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with alcohol or thinner 1 Place the motorcycle on the center stand 2 Remove the headlight side cover by removing screws 3 Remove headlight...

Page 69: ... bulb 1 Place the motorcycle on the center stand 2 Remove the headlight side cover by removing screws 3 Remove head light mounting bolt 4 Remove head light adjusting bolt 5 Remove head light from head light stay 1 Position light bulb socket 6 Remove the position light bulb socket together with the bulb by pulling out 7 Insert a new bulb into the socket by pushing it until it stop 8 Install the soc...

Page 70: ...g it counter clockwise 4 Insert a new bulb into the socket push it in and then turn it clock wise until it stops 5 Install the socket together with _ the bulb by turning it clockwise 6 Install the seat EAU24204 Replacing a turn signal light bulb 1 Screw 2 Bulb 3 Lens 6 1 Remove the turn signal light lens by removing the screw 2 Remove the defective bulb by pulling it out 3 Insert a new bulb into t...

Page 71: ...P Make sure that there is enough space between the brake pads before insert ing the brake disc and that the retainer in the speedometer gear unit fits over the slot on the fork leg 1 Speedometer cable 2 Axle nut and washer 4 Pull the wheel axle out and then remove the wheel NOTICE Do not apply the brake after the wheel has been removed toge ther with the brake disc other wise the brake pads will b...

Page 72: ...Locknut drive chain adjusting nut 4 Brake torque rod nut WARNING EAU35080 Rear wheel 3 Insert the wheel axle and then in stall the axle nut 4 Take the motorcycle off the center stand so that the front wheel is on the ground 5 Tighten the axle nut to the speci fied torque 1 Retainer 2 Slot Tightening torque Axle nut 40 Nm 4 0 m kgf 29 ft lbf 6 While applying the front brake push down hard on the ha...

Page 73: ... nut and the wa sher and then pull the wheel axle out 8 Push the wheel forward and then remove the drive chain from the rear sprocket 9 Remove the wheel TIP Do not remove the washer on the right side of the wheel axle so as to not lose it 1 Insert the wheel axle from the left hand side and then install the wa sher and axle nut 2 Install the drive chain onto the rear sprocket 3 Lower the rear wheel...

Page 74: ...s experience and know how to service the motorcycle properly Use only genuine Yamaha replace ment parts Imitation parts may look like Yamaha parts but they are often inferi or have a shorter service life and can lead to expensive repair bills 8 Adjust the brake pedal free play See page 6 18 EWA10660 WARNING After adjusting the brake pedal free play check the operation of the brake light EWA15141 W...

Page 75: ... There is no compression Check the ignition Have a Yamaha dealer check the vehicle Remove the spark plug and check the electrodes 3 Ignition Wet Dry 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 Open the throttle ha...

Page 76: ...ve 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 cor rosion protection spray Improper cleaning 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...

Page 77: ...hrome and nickel plated surfaces to prevent corrosion After cleaning 1 Dry the motorcycle with a chamois or an absorbing cloth 2 Immediately dry the drive chain and lubricate it to prevent it from rusting 3 Use a chrome polish to shine chrome aluminum and stainless steel parts including the exhaust system Even the thermally in duced discoloring of stainless steel exhaust systems can be re moved th...

Page 78: ...where strong chemi cals are stored Long term Before storing your motorcycle for sev eral months 1 Follow all the instructions in the Care section of this chapter 2 For motorcycles equipped with a fuel cock that has an OFF posi tion Turn the fuel cock lever to OFF 3 Drain the carburetor float chamber by loosening the drain bolt this will prevent fuel deposits from building up Pour the drained fuel ...

Page 79: ...the wheels a little every month in order to prevent the tires from becoming degraded in one spot 8 Cover the muffler outlet with a plastic bag to prevent moisture from entering it 9 Remove the battery and fully charge it Store it in a cool dry place and charge it once a month Do not store the battery in an ex cessively cold or warm place less than 0 C 30 F or more than 30 C 90 F For more informati...

Page 80: ...74 24 3 083 Secondary reduction system Chain drive Secondary reduction ratio 44 15 2 933 Transmission type Constant mesh 5 speed Operation Left foot operation Gear ratio 1st 36 14 2 571 2nd 32 19 1 684 3rd 28 22 1 273 4th 26 25 1 040 U5YPE0E0 book Page 1 Wednesday February 23 2005 4 22 PM EAU26320 Lubrication system Wet sump Engine oil Type YAMALUBE 4 T SJ 20W 50 MA or SAE20W40 or SAE20W50 Recomme...

Page 81: ...ition up to 100 kg Front 200 kPa 29 psi 2 00 kgf cm Front brake Type Single disc brake Operation Right hand operation Recommended fluid DOT 3 or 4 Rear brake Type Drum brake Operation Right foot operation Spring shock absorber type Coil spring oil damper Wheel travel 140 0 mm Rear suspension Type Swingarm Monocross suspension Spring shock absorber type Coil spring oil damper Wheel travel 100 0 mm ...

Page 82: ...3 4 W 2 Neutral indicator light 12 V 3 4 W 1 High beam indicator light 12 V 3 4 W 1 Turn signal indicator light 12 V 3 4 W 2 Fuse Fuse 15 A U5YPE0E0 book Page 3 Wednesday February 23 2005 4 22 PM Front turn signal light 12 V 10 0 W 2 Rear turn signal light 12 V 10 0 W 2 ...

Page 83: ... NUMBER Key identification number The key identification number is stamped into the key Record this number in the space provided and use it for reference when ordering a new key Vehicle identification number 1 Key identification number 1 Vehicle identification number The vehicle identification number is stamped into the rear frame TIP The vehicle identification number is used to identify your vehi...

Page 84: ...CONSUMER INFORMATION 9 2 9 Engine serial number 1 Engine serial number The engine serial number is stamped into the crankcase U5YPE0E0 book Page 2 Wednesday February 23 2005 4 22 PM EAU26440 1 ...

Page 85: ...U5YPE0E0 book Page 5 Wednesday February 23 2005 4 22 PM ...

Page 86: ...YAMAHA INDONESIA MOTOR MANUFACTURING PRINTED IN INDONESIA ...

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