Yamaha YBR125 Custom Owner'S Manual Download Page 37

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-5

EAU18721

Removing and installing the
cowling and panels

The cowling and panels shown need to
be removed to perform some of the
maintenance jobs described in this
chapter. Refer to this section each time
the cowling or a panel needs to be re-
moved and installed.

EAU37082

Cowling

To remove the cowling

1. Remove panels A and B. (See

pages 6-5.)

2. Remove the bolt on each side of

the seat and pull the seat off.

3. Remove the carrier by removing

the bolts.

4. Remove the screws, and then pull

the cowling off as shown.

1. Panel A

2. Cowling

1. Panel B

1. Bolt

2. Carrier

U3D9E0E0.book Page 5 Saturday, December 25, 2004 11:35 AM

Summary of Contents for YBR125 Custom

Page 1: ...3D9 F8199 E0 YBR125ED OWNER S MANUAL ...

Page 2: ...U3D9E0E0 book Page 2 Saturday December 25 2004 11 35 AM ...

Page 3: ... enjoy all advantages of your YBR125ED 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 contact your Yamaha deale...

Page 4: ...ur motorcycle and this manual If you have any questions concerning this manual please consult your Yamaha dealer WARNING EWA10030 PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator a byst...

Page 5: ...L 2004 by Yamaha Motor Co Ltd 1st edition December 2004 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in China U3D9E0E0 book Page 2 Saturday December 25 2004 11 35 AM ...

Page 6: ... 6 2 Removing and installing the cowling and panels 6 5 Checking the spark plug 6 8 Engine oil 6 9 Cleaning the air filter element 6 11 Adjusting the carburetor 6 12 Adjusting the engine idling speed 6 13 Adjusting the throttle cable free play 6 13 Valve clearance 6 14 Tires 6 14 Cast wheels 6 16 Adjusting the clutch lever free play 6 17 Checking the front brake lever free play 6 18 Adjusting the ...

Page 7: ...acing a turn signal light bulb 6 33 Replacing the auxiliary light bulb 6 33 Front wheel 6 34 Rear wheel 6 36 Troubleshooting 6 37 Troubleshooting chart 6 38 MOTORCYCLE CARE AND STORAGE 7 1 Care 7 1 Storage 7 3 SPECIFICATIONS 8 1 CONSUMER INFORMATION 9 1 Identification numbers 9 1 U3D9E0E0 book Page 2 Saturday December 25 2004 11 35 AM ...

Page 8: ...s have been caused by an automobile driver who did not see the motorcycle Making yourself conspicuous appears to be very effective in reducing the chance of this type of accident Therefore Wear a brightly colored jacket Use extra caution when ap proaching and passing through intersections since intersec tions are the most likely places for motorcycle accidents to oc cur Ride where other motorists ...

Page 9: ... shield or goggles Wind in your unprotected eyes could contribute to an impairment of vision which could delay seeing a hazard The use of a jacket heavy boots trousers gloves etc is effective in preventing or reducing abrasions or lacerations Never wear loose fitting clothes otherwise they could catch on the control levers footrests or wheels and cause injury or an accident Never touch the engine ...

Page 10: ...s Use extreme caution when selecting and installing any ac cessories Keep the following guidelines in mind as well as those provided under Load ing when mounting accessories Never install accessories or carry cargo that would impair the perfor mance 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 clea...

Page 11: ...f before leaving the motorcycle unattended and remove the key from the main switch When parking the motor cycle note the following The engine and exhaust system may be hot therefore park the motorcycle in a place where pe destrians or children are not like ly to touch these hot areas Do not park the motorcycle on a slope or soft ground otherwise it may fall over Do not park the motorcycle near a f...

Page 12: ...3 7 3 Fuse page 6 30 4 Battery page 6 28 5 Owner s tool kit page 6 1 6 Luggage strap holder page 3 10 7 Shock absorber assembly spring preload adjusting ring page 3 9 8 Engine oil drain bolt page 6 9 9 Shift pedal page 3 4 U3D9E0E0 book Page 1 Saturday December 25 2004 11 35 AM ...

Page 13: ...Air filter element page 6 11 3 Engine oil filler cap page 6 9 4 Brake pedal page 3 5 5 Kickstarter page 3 9 6 Shock absorber assembly spring preload adjusting ring page 3 9 7 Luggage strap holder page 3 10 U3D9E0E0 book Page 2 Saturday December 25 2004 11 35 AM ...

Page 14: ...bar switches page 3 3 3 Main switch steering lock page 3 1 4 Speedometer page 3 2 5 Fuel gauge page 3 3 6 Tachometer page 3 3 7 Right handlebar switch page 3 3 8 Brake lever page 3 5 9 Throttle grip page 6 13 10 Fuel tank cap page 3 5 U3D9E0E0 book Page 3 Saturday December 25 2004 11 35 AM ...

Page 15: ...l electrical systems are off The key can be removed EAU10680 LOCK The steering is locked and all electrical systems are off The key can be re moved To lock the steering 1 Turn the handlebars all the way to the left 2 Push the key in from the OFF po sition and then turn it to LOCK while still pushing it 3 Remove the key To unlock the steering Push the key in and then turn it to OFF while still push...

Page 16: ...r unit The speedometer unit is equipped with a speedometer an odometer and a tripmeter The speedometer shows riding speed The odometer shows the total distance traveled The tripmeter shows the distance traveled 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 en able you to plan ...

Page 17: ... towards E Empty as the fuel level decreases When the needle reaches the red line approximately 3 0 L 0 79 US gal 0 66 Imp gal remain in the fuel tank If this occurs refuel as soon as possible NOTE Do not allow the fuel tank to empty itself completely The main switch must be turned to ON for the fuel gauge to display an accurate fuel level reading EAU12343 Handlebar switches Left Right 1 Tachomete...

Page 18: ...page 5 1 for starting instruc tions prior to starting the engine EAU31640 Clutch lever The clutch lever is located at the left handlebar grip To disengage the clutch pull the lever toward the handle bar grip To engage the clutch release the lever The lever should be pulled rapidly and released slowly for smooth clutch operation The clutch lever is equipped with a clutch switch which is part of the...

Page 19: ...ke press down on the brake pedal EAU13000 Fuel tank cap To remove the fuel tank cap Insert the key into the lock and turn it 1 4 turn clockwise The lock will be re leased and the fuel tank cap can be re moved To install the fuel tank cap 1 Push the fuel tank cap into position with the key inserted in the lock 2 Turn the key counterclockwise to the original position and then re move it 1 Brake leve...

Page 20: ...Avoid spilling fuel on the hot en gine CAUTION ECA10070 Immediately wipe off spilled fuel with a clean dry soft cloth since fuel may deteriorate painted surfac es or plastic parts EAU13320 CAUTION ECA11400 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 Your Yamaha engine ha...

Page 21: ...d gasoline The use of leaded gasoline will cause unrepairable damage to the catalytic converter Never park the vehicle near pos sible fire hazards such as grass or other materials that easily burn Do not allow the engine to idle too long EAU37210 Fuel cock The fuel cock supplies fuel from the tank to the carburetor while filtering it al so NOTE Depending on the model the positions indicated on the...

Page 22: ...ank at the first oppor tunity Be sure to set the lever back to ON or after refueling EAU13590 Starter choke lever Starting a cold engine requires a richer air fuel mixture which is supplied by the starter choke Move the lever in direction a to turn on the starter choke Move the lever in direction b to turn off the starter choke 1 Arrow mark pointing to ON or 1 Arrow mark pointing to RES or 1 Start...

Page 23: ...just ing ring CAUTION ECA10100 Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings WARNING EWA10210 Always adjust both shock absorber assemblies equally otherwise poor handling and loss of stability may result Adjust the spring preload as follows To increase the spring preload and thereby harden the suspension turn the adjusting ring on each shock ab sorber assembly...

Page 24: ...U36950 Starting circuit cut off system The starting circuit cut off system com prising the clutch switch and the neutral switch prevents starting when the transmission is in gear and the clutch lever is not pulled Periodically check the operation of the starting circuit cut off system according to the following procedure WARNING EWA10250 If a malfunction is noted have a Yamaha dealer check the sys...

Page 25: ... until checked by a Yamaha dealer 4 Turn the engine off 5 Shift the transmission into gear 6 Keep the clutch lever pulled 7 Push the start switch Does the engine start The clutch switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer NO NOTE a warmed up engine YES The system is OK The motorcycle can be ridden YES NO This check is most reliable if performed wit...

Page 26: ...ences Therefore it is very important in addition to a thorough visual inspec tion to check the following points before each ride NOTE Pre operation checks should be made each time the vehicle is used Such an inspection can be accomplished in a very short time and the added safety it assures is more than worth the time involved WARNING EWA11150 If any item in the Pre operation check list is not wor...

Page 27: ...recommended brake fluid to specified level Check hydraulic system for leakage 6 20 6 20 Rear brake Check operation Check pedal free play Adjust if necessary 6 20 Clutch Check operation Lubricate cable if necessary Check lever 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...

Page 28: ...ry 6 24 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 25 Centerstand Make sure that operation is smooth Lubricate pivot if necessary 6 26 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened Tighten if necessary Instruments lights signals and switches Check operation Correct if necessary ITEM CHECKS PAGE U3D9E...

Page 29: ... lever pulled WARNING EWA14160 Before starting the engine check the operation of the starting circuit cut off system according to the pro cedure described on page 3 10 1 Turn the fuel cock lever to ON or 2 Turn the key to ON 3 Shift the transmission into the neu tral position NOTE When the transmission is in the neutral position the neutral indicator light should be on otherwise have a Yamaha deal...

Page 30: ...is not required when the engine is warm EAU16671 Shifting Shifting gears lets you control the amount of engine power available for starting off accelerating climbing hills etc The gear positions are shown in the il lustration NOTE 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 1 Shift peda...

Page 31: ...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 EAU16841 Engine break in There is never a more important period in the life of your engine than the period between 0 and 1600 km 1000 mi For this reason you should read the follow ing material carefully Sin...

Page 32: ... trouble should oc cur during the engine break in period immediately have a Yamaha dealer check the vehi cle EAU37200 Parking When parking stop the engine remove the key from the main switch and then turn the fuel cock lever to OFF or WARNING EWA10310 Since the engine and exhaust system can become very hot park in a place where pedestri ans or children are not likely to touch them Do not park on a...

Page 33: ...are not familiar with mainte nance work have a Yamaha dealer do it for you EAU17340 Owner s tool kit The owner s tool kit is located behind panel B See page 6 5 The service information included in this manual and the tools provided in the owner s tool kit are intended to assist you in the performance of preventive maintenance and minor repairs How ever additional tools such as a torque wrench may ...

Page 34: ...O ITEM CHECK OR MAINTENANCE JOB ODOMETER READING 1000 km ANNUAL CHECK 1 6 12 18 24 1 Fuel line Check fuel hoses for cracks or damage 2 Fuel cock filter Check condition 3 Spark plug Check condition Clean and regap Replace 4 Valves Check valve clearance Adjust 5 Air filter element Clean Replace 6 Battery Check electrolyte level and specific gravity Make sure that the breather hose is properly routed...

Page 35: ...5 Drive chain Check chain slack alignment and condition Adjust and lubricate chain with a special O ring chain lu bricant thoroughly Every 1000 km and after washing the motorcycle or riding in the rain 16 Steering bearings Check bearing play and steering for roughness Lubricate with lithium soap based grease Every 24000 km 17 Chassis fasteners Make sure that all nuts bolts and screws are properly ...

Page 36: ...just engine idling speed 22 Engine oil Change Check oil level and vehicle 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 ...

Page 37: ...section each time the cowling or a panel needs to be re moved and installed EAU37082 Cowling To remove the cowling 1 Remove panels A and B See pages 6 5 2 Remove the bolt on each side of the seat and pull the seat off 3 Remove the carrier by removing the bolts 4 Remove the screws and then pull the cowling off as shown 1 Panel A 2 Cowling 1 Panel B 1 Bolt 1 Bolt 2 Carrier U3D9E0E0 book Page 5 Satur...

Page 38: ...in the original posi tion and then tighten the bolts 4 Install the panels EAU37070 Panel A To remove the panel 1 Remove the screw 2 Pull the front of the panel out and then slide the panel forward to re lease it in the rear To install the panel 1 Secure the rear of the panel and then push the front of the panel in 1 Screw 2 Cowling Tightening torque Carrier bolt 30 Nm 3 0 m kgf 22 ft lbf 1 Screw U...

Page 39: ... the panel out with the key inserted in the lock and then slide the panel forward to re lease it in the rear To install the panel 1 Secure the rear of the panel and then push the front of the panel in with the key inserted in the lock 2 Turn the key counterclockwise to the original position remove it and then close the panel lock cover 1 Panel lock cover 2 Unlock U3D9E0E0 book Page 7 Saturday Dece...

Page 40: ...ctrode of the spark plug is a medium to light tan the ideal color when the vehicle is ridden normally NOTE If the spark plug shows a distinctly dif ferent color the engine could be defec tive Do not attempt to diagnose such problems yourself Instead have a Yamaha dealer check the vehicle 2 Check the spark plug for electrode erosion and excessive carbon or other deposits and replace it if necessary...

Page 41: ... lubrication chart To check the engine oil level 1 Place the vehicle on the center stand NOTE Make sure that the vehicle is positioned straight up when checking the oil level 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 inse...

Page 42: ...the engine oil fill er cap CAUTION ECA11620 In order to prevent clutch slip page since the engine oil also lubricates the clutch do not mix any chemical additives Do not use oils with a diesel speci fication of CD or oils of a high er quality than specified In addition do not use oils labeled ENERGY CONSERVING II or higher Make sure that no foreign mate rial enters the crankcase 6 Start the engine...

Page 43: ...lter element to remove most of the dust and dirt and then blow the remaining dirt out with compressed air on the mesh side as shown If the air filter element is damaged replace it 6 Clean the sponge material with solvent then squeeze the remain ing solvent out and be sure to let the sponge material dry before in stalling it into the air filter element If the sponge material is damaged replace it W...

Page 44: ...r water and if necessary drain it by removing the clamp and then removing the plug 10 Install the plug into the check hose and then install the clamp 11 Install the panel EAU21280 Adjusting the carburetor The carburetor is an important part of the engine and requires very sophisti cated adjustment Therefore most car buretor adjustments should be left to a Yamaha dealer who has the neces sary profe...

Page 45: ... in direction a To decrease the engine idling speed turn the screw in direction b NOTE If the specified idling speed cannot be obtained as described above have a Yamaha dealer make the adjustment EAU21370 Adjusting the throttle cable free play The throttle cable free play should mea sure 3 0 7 0 mm 0 12 0 28 in at the throttle grip Periodically check the throttle cable free play and if neces sary ...

Page 46: ... periodic maintenance and lubrication chart EAU21540 Tires To maximize the performance durabil ity and safe operation of your motor cycle note the following points regarding the specified tires Tire air pressure The tire air pressure 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 temperatur...

Page 47: ...e suspension and tire air pressure with regard to the load Check the tire condition and air pressure before each ride Tire inspection The tires must be checked before each ride If the center tread depth reaches the specified limit if the tire has a nail or glass fragments in it or if the sidewall is cracked have a Yamaha dealer re place the tire immediately NOTE The tire tread depth limits may dif...

Page 48: ... and replace it as soon as possible with a high quality product EAU22000 Cast wheels WARNING EWA10610 The wheels on this model are not de signed for use with tubeless tires Do not attempt to use tubeless 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 checked for cra...

Page 49: ...locknut at the clutch le ver 2 To increase the clutch lever free play turn the adjusting bolt in di rection a To decrease the clutch lever free play turn the adjusting bolt in direction b NOTE If the specified clutch lever free play could be obtained as described above tighten the locknut and skip the rest of the procedure otherwise proceed as follows 3 Fully turn the adjusting bolt at the clutch ...

Page 50: ...tem WARNING EWA10640 An incorrect brake lever free play in dicates a hazardous condition in the brake system Do not operate the motorcycle until the brake system has been checked or repaired by a Yamaha dealer EAU22181 Adjusting the brake pedal free play The brake pedal free play should mea sure 20 0 30 0 mm 0 79 1 18 in at the brake pedal end as shown Period ically check the brake pedal free play...

Page 51: ... switch which is ac tivated 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 1 Remove panel A See page 6 5 2 Turn the adjusting nut while hold ing 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 o...

Page 52: ...ws 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 EAU37000 Checking the front brake fluid level Insufficient brake fluid may allow air...

Page 53: ...f 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 brake fluid level to grad ually go down However if the brake fluid level goes down sud denly have a Yamaha dealer check the cause EAU22720 Changing the brake fluid Have a Yamaha dealer change the brake fluid ...

Page 54: ...od nut and axle nut 2 Loosen the chain puller locknut at each end of the swingarm 3 To tighten the drive chain turn the adjusting bolt at each end of the swingarm in direction a To loos en the drive chain turn the adjust ing bolt at each end of the swingarm in direction b and then push the rear wheel forward NOTE Using the alignment marks on each side of the swingarm make sure that both chain pull...

Page 55: ...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 CAUTION ECA10581 The drive chain must be lubricated after washing the motorcycle and riding in the rain 1 Clean the drive chain with kero sene and a small soft brush CAUTION ECA11120 To prevent damaging the O rings do not clean the drive cha...

Page 56: ... and will cause the inner cable to rust Replace a damaged cable as soon as possible to prevent unsafe conditions EAU23111 Checking and lubricating the throttle grip and cable The operation of the throttle grip should be checked before each ride In addi tion the cable should be lubricated at the intervals specified in the periodic maintenance chart EAU23131 Checking and lubricating the brake and sh...

Page 57: ...er The operation of the brake and clutch levers should be checked before each ride and the lever pivots should be lu bricated if necessary Recommended lubricant Lithium soap based grease all pur pose grease Recommended lubricant Lithium soap based grease all pur pose grease U3D9E0E0 book Page 25 Saturday December 25 2004 11 35 AM ...

Page 58: ...ork The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic main tenance and lubrication chart To check the condition WARNING EWA10750 Securely support the vehicle so that there is no danger of it falling over Check the inner tubes for scratches damage and excessive oil leakage To check the operation 1 Place the vehicle on a level sur fac...

Page 59: ...ust be checked as fol lows at the intervals specified in the pe riodic maintenance and lubrication chart 1 Place a stand under the engine to raise the front wheel off the ground WARNING EWA10750 Securely support the vehicle so that there is no danger of it falling over 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...

Page 60: ...ck the electrolyte level 1 Place the vehicle on a level sur face and hold it in an upright posi tion NOTE Make sure that the vehicle is positioned straight up when checking the electro lyte level 2 Remove panel B See page 6 5 3 Check the electrolyte level in the battery NOTE The electrolyte should be between the minimum and maximum level marks 4 If the electrolyte is at or below the minimum level ...

Page 61: ...IES OUT OF THE REACH OF CHILDREN CAUTION 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 Install the panel To store the battery 1 If the vehicle will not be used for more than one month remove the battery fully charge it and then place it in a cool ...

Page 62: ...5 If the fuse is blown replace it as fol lows 1 Turn the key to OFF and turn off all electrical circuits 2 Remove the blown fuse and then install a new fuse of the specified amperage CAUTION ECA10640 Do not use a fuse of a higher amper age rating than recommended to avoid causing extensive damage to the electrical system and possibly a fire 3 Turn the key to ON and turn on the electrical circuits ...

Page 63: ...adlight bulbs get very hot There fore keep flammable products away from a lit headlight bulb and do not touch the bulb until it has cooled down 4 Insert a new bulb into the socket push it in and then turn it clock wise until it stops CAUTION ECA10660 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...

Page 64: ...1 Remove the cowling See page 6 5 2 Remove the tail brake light lens by removing the screws 3 Remove the defective bulb by pushing it in and turning 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 lens by installing the screws CAUTION ECA10680 Do not overtighten the screws oth erwise the lens may break 6 Install the cowli...

Page 65: ...ighten the screw other wise the lens may break EAU37270 Replacing the auxiliary light bulb If the auxiliary light bulb burns out re place it as follows 1 Remove the headlight unit by re moving the screws 2 Remove the socket together with the bulb by pulling it out 3 Remove the defective bulb by pull ing it out 4 Insert a new bulb into the socket 5 Install the socket together with the bulb by pushi...

Page 66: ...r caps from the ends of the wheel axle by pulling them off 4 Remove the axle nut and the washer 5 Pull the wheel axle out and then remove the wheel CAUTION ECA11070 Do not apply the brake after the wheel has been removed together with the brake disc otherwise the brake pads will be forced shut EAU37030 To install the front wheel 1 Install the speedometer gear unit into the wheel hub so that the pr...

Page 67: ...g outward and then install 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 and then install both rubber caps so that they fit over the washers 6 While applying the front brake push down hard on the handlebars several times to check if the front fork compresses and rebounds smoothly 7 Connect the speedo...

Page 68: ...moving the cotter pin the nut and the bolt 3 Place the motorcycle on the cen terstand 4 Remove the brake pedal free play adjusting nut and then disconnect the brake rod from the brake cam shaft lever 5 Loosen the chain puller locknut and the drive chain slack adjusting bolt on both ends of the swingarm 1 Axle nut 2 Brake torque rod 3 Brake torque rod cotter pin 4 Brake torque rod nut and bolt 1 Br...

Page 69: ...rques 9 Insert a new cotter pin 10 Adjust the brake pedal free play See page 6 18 WARNING EWA10660 After adjusting the brake pedal free play check the operation of the brake light EAU25850 Troubleshooting Although Yamaha motorcycles receive a thorough inspection before shipment from the factory trouble may occur dur ing operation Any problem in the fuel compression or ignition systems for example ...

Page 70: ...n 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 halfway and operate the e...

Page 71: ...t 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 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 plas...

Page 72: ... 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 through polishing 4 To prevent corrosion it is recom me...

Page 73: ...ructions in the Care section of this chapter 2 Turn the fuel cock lever to OFF or 3 Drain the carburetor float chamber by loosening the drain bolt this will prevent fuel deposits from building up Pour the drained fuel into the fuel tank 4 Fill up the fuel tank and add fuel stabilizer if available to prevent the fuel tank from rusting and the fuel from deteriorating 5 Perform the following steps to...

Page 74: ...ls 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 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...

Page 75: ...r Engine oil quantity Periodic oil change 1 00 L 1 06 US qt 0 88 Imp qt Air filter Air filter element Dry element Fuel Recommended fuel Regular unleaded gasoline only Fuel tank capacity 12 0 L 3 17 US gal 2 64 Imp gal Fuel reserve amount 3 0 L 0 79 US gal 0 66 Imp gal Carburetor Manufacturer MIKUNI Type quantity VM22SH x 1 Spark plug s Manufacturer model NGK CR6HSA Spark plug gap 0 6 0 7 mm 0 024 ...

Page 76: ...r 280 kPa 41 psi 2 80 kgf cm Front wheel Wheel type Cast wheel Rim size J18x1 60 Rear wheel Wheel type Cast wheel Rim size J18x1 85 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 Front suspension Type Telescopic fork Spring shock absorber type Coil spring oil damper Wheel travel 110 0 mm 4 33 ...

Page 77: ... 0 W 2 Auxiliary light 12 V 5 0 W 1 Meter lighting 12 V 1 7 W 4 Neutral indicator light 14 V 3 0 W 1 High beam indicator light 14 V 3 0 W 1 Turn signal indicator light 14 V 3 0 W 2 Fuse Fuse 15 0 A U3D9E0E0 book Page 3 Saturday December 25 2004 11 35 AM ...

Page 78: ...fication number The key identification number is stamped into the key tag Record this number in the space provided and use it for reference when ordering a new key EAU26400 Vehicle identification number The vehicle identification number is stamped into the steering head pipe Record this number in the space pro vided NOTE The vehicle identification number is used to identify your motorcycle and may...

Page 79: ...el is affixed to the frame behind panel B See page 6 5 Record the information on this label in the space provided This information will be needed when ordering spare parts from a Yamaha dealer 1 Model label U3D9E0E0 book Page 2 Saturday December 25 2004 11 35 AM ...

Page 80: ...cing 6 30 H Handlebar switches 3 3 Headlight bulb replacing 6 31 High beam indicator light 3 2 Horn switch 3 4 I Identification numbers 9 1 Indicator lights 3 2 K Key identification number 9 1 Kickstarter 3 9 L Luggage strap holders 3 10 M Main switch steering lock 3 1 Model label 9 2 N Neutral indicator light 3 2 P Parking 5 4 Part locations 2 1 Periodic maintenance and lubrication chart 6 2 Pre ...

Page 81: ...INDEX V Valve clearance 6 14 Vehicle identification number 9 1 W Wheel bearings checking 6 28 Wheel front 6 34 Wheel rear 6 36 Wheels 6 16 U3D9E0E0 book Page 2 Saturday December 25 2004 11 35 AM ...

Page 82: ...A5 yoko_Blank fm Page 1 Tuesday April 8 2003 11 43 AM ...

Page 83: ...A5 yoko_Blank fm Page 1 Tuesday April 8 2003 11 43 AM ...

Page 84: ...YAMAHA MOTOR CO LTD PRINTED IN CHINA 2005 01 0 3 1 CR E ...

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