Yamaha YZ65 Owner'S Manual Download

Page: 63 / 92

Perio

ic maintenance an

justment

7-13

EAU48434

justin

the throttle

rip free

play

Measure the throttle grip free play as
shown.

Periodically check the throttle grip free
play and, if necessary, adjust it as fol-
lows.

TIP

The engine idling speed must be cor-
rectly adjusted before checking and
adjusting the throttle grip free play.

1. Slide the rubber cover back.
2. Loosen the locknut.
3. To increase the throttle grip free

play, turn the adjusting nut in di-
rection (a). To decrease the throt-
tle grip free play, turn the adjusting
nut in direction (b).

4. Tighten the locknut and then slide

the rubber cover to its original po-
sition.

1. Throttle grip free play

Throttle

rip free play:

3.0–6.0 mm (0.12–0.24 in)

1. Locknut
2. Throttle grip free play adjusting nut
3. Rubber cover

(a)

(b)

UBR881E0.book Page 13 Tuesday, April 2, 2019 9:44 AM

Summary of Contents for YZ65

Page 1: ...LEITUNG Read this manual carefully before oper ating this vehicle Il convient de lire attentivement ce manuel avant la première utilisation du véhicule Bitte lesen Sie diese Bedienungsanlei tung sorgfältig durch bevor Sie das Fahr zeug in Betrieb nehmen YZ65 MOTORCYCLE MOTO MOTORRAD ...

Page 2: ...DIC183 Original instructions Notice originale Originalbetriebsanleitung PRINTED ON RECYCLED PAPER IMPRIMÉ SUR PAPIER RECYCLÉ AUF RECYCLINGPAPIER GEDRUCKT PRINTED IN JAPAN 2019 04 1 0 1 CR E F G ...

Page 3: ...Read this manual carefully before oper ating this vehicle OWNER S MANUAL YZ65 MOTORCYCLE YZ65 YZ65L BR8 28199 81 E0 UBR881E0 book Page 1 Tuesday April 2 2019 9 44 AM ...

Page 4: ...EAU46094 Read this manual carefully before operating this vehicle This manual should stay with this vehicle if it is sold UBR881E0 book Page 1 Tuesday April 2 2019 9 44 AM ...

Page 5: ...ff road use only It is il legal to operate this motorcycle on any public street road or highway Such use is prohibited by law This motorcycle complies with almost all state off highway noise level and spark arrester laws and regulations Please check your local riding laws and regulations before operating this motorcycle AN IMPORTANT SAFETY MESSAGE Read this manual completely before operating your ...

Page 6: ...ing this motorcycle He or she should Obtain thorough instructions from a competent source on all aspects of mo torcycle operation Observe the warnings and maintenance requirements in this Owner s Manu al Obtain qualified training in safe and proper riding techniques Obtain professional technical service as indicated in this Owner s Manual and or when made necessary by mechanical conditions UBR881E...

Page 7: ...ath 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 vehi cle or other property A TIP provides key information to make proce dures easier or clearer YZ65 YZ65L OWNER S MANUAL 2020 by Yamaha Motor Co Ltd 1st edition March 2019 All rights reserved Any reprinting or u...

Page 8: ...Cleaning the air filter element 7 10 Adjusting the carburetor 7 12 Adjusting the engine idling speed 7 12 Adjusting the throttle grip free play 7 13 Tires 7 14 Spoke wheels 7 16 Adjusting the clutch lever free play 7 16 Checking the brake lever free play 7 17 Checking the shift pedal 7 18 Checking the front and rear brake pads 7 18 Checking the brake fluid level 7 19 Changing the brake fluid 7 20 ...

Page 9: ...Table of contents Specifications 9 1 Consumer information 10 1 Identification numbers 10 1 Index 11 1 UBR881E0 book Page 2 Tuesday April 2 2019 9 44 AM ...

Page 10: ...ontain important in formation 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 For Canada 1 2 3 6 7 4 5 8 9 10 UBR881E0 book Page 1 Tuesday April 2 2019 9 44 AM ...

Page 11: ...C ROADS You can collide with another vehicle if you operate this vehicle on a public road ALWAYS WEAR AN APPROVED MOTORCYCLE HELMET eye protection and protective clothing EXPERIENCED RIDER ONLY 5PA 2118K 00 Cold tire normal pressure should be set as follows FRONT REAR 100kPa 1 00kgf cm2 15psi 100kPa 1 00kgf cm2 15psi 3RV 21668 A0 TIRE INFORMATION La pression des pneus à froid doit normalement être...

Page 12: ...perte de contrôle NE JAMAIS ROULER SUR DES CHEMINS PUBLICS Vous pourriez entrer en collision avec un autre véhicule TOUJOURS PORTER UN CASQUE DE MOTOCYCLISTE APPROUVE des lunettes et des vêtements de protection EXCLUSIVEMENT POUR L USAGE D UN CONDUCTEUR EXPERIMENTE 5PA 2118K 10 C M V S S CANADA N S V A C T RANSPOR T 506 4SR 2416E 00 4AA 22259 70 CAN ICES 2 NMB 2 8KM 82377 30 6 10 9 8 7 UBR881E0 bo...

Page 13: ...Location of important labels 1 4 1 For Europe 2 3 1 UBR881E0 book Page 4 Tuesday April 2 2019 9 44 AM ...

Page 14: ...tant labels 1 5 1 For Europe 5PG 2816R 00 100 kPa 1 00 kgf cm 15 psi 100 kPa 1 00 kgf cm 15 psi 4AA 22259 40 YAMAHA MOTOR CO LTD SHIZUOKA JAPAN YAMAHA 4GB 2155A 00 3 1 2 UBR881E0 book Page 5 Tuesday April 2 2019 9 44 AM ...

Page 15: ...e gear Use from 6 years old Operation of this motorcycle by children under the age of 6 increase the risk of severe injury or death Adult supervision required for children Never use on paved roads Never carry passengers This unit contains high pressure nitrogen gas Mishandling can cause an explosion Do not incinerate puncture or open UBR881E0 book Page 6 Tuesday April 2 2019 9 44 AM ...

Page 16: ...ter riding to avoid draining the battery Use unleaded gasoline only Measure the tire pressure when the tires are cold Adjust the tire pressure Improper tire pressure can cause loss of control Loss of control can result in severe injury or death UBR881E0 book Page 7 Tuesday April 2 2019 9 44 AM ...

Page 17: ...Location of important labels 1 8 1 For Australia 1 2 3 UBR881E0 book Page 8 Tuesday April 2 2019 9 44 AM ...

Page 18: ...ER OPERATE THIS VEHICLE ON PUBLIC ROADS You can collide with another vehicle if you operate this vehicle on a public road ALWAYS WEAR AN APPROVED MOTORCYCLE HELMET eye protection and protective clothing EXPERIENCED RIDER ONLY 5PA 2118K 00 Cold tire normal pressure should be set as follows FRONT REAR 100kPa 1 00kgf cm2 15psi 100kPa 1 00kgf cm2 15psi 3RV 21668 A0 TIRE INFORMATION 3 2 1 UBR881E0 book...

Page 19: ...e to make sure it is in safe operating condition Failure to inspect or maintain the vehi cle properly increases the possibility of an accident or equipment damage See page 5 1 for a list of pre operation checks This motorcycle is designed for off road use only therefore it is il legal to operate it on public streets roads or highways even a dirt or gravel one Off road use on public lands may be il...

Page 20: ...the engine Protective Apparel The majority of fatalities from motorcy cle accidents are the result of head in juries The use of a safety helmet is the single most critical factor in the pre vention or reduction of head injuries Always wear an approved helmet Wear a face shield or goggles Wind in your unprotected eyes could contribute to an impairment of vision that could delay seeing a hazard The ...

Page 21: ...o the motorcy cle as possible Securely pack your heaviest items as close to the center of the vehicle as possible and make sure to distribute the weight as evenly as possible on both sides of the motorcycle to minimize imbalance or instability Shifting weights can create a sud den imbalance Make sure that accessories are securely attached to the motorcycle before riding Check accessory mounts fre ...

Page 22: ...y must be as lightweight as possible and should be kept to a minimum Bulky or large accessories may seriously affect the stability of the motorcycle Wind may at tempt to lift the motorcycle or the motorcycle may become unstable in cross winds Certain accessories can dis place the operator from his or her normal riding position This improper position limits the freedom of movement of the operator a...

Page 23: ... to solid parts of the mo torcycle such as the frame or up per front fork triple clamp and not for example to rubber mounted handlebars or turn signals or parts that could break Choose the location for the straps carefully so the straps will not rub against painted surfaces during transport The suspension should be com pressed somewhat by the tie downs if possible so that the mo torcycle will not ...

Page 24: ... 7 8 3 Fuel tank cap page 4 3 4 Fuel cock page 4 7 5 Starter choke knob page 4 7 6 Air filter element page 7 10 7 Seat page 4 8 8 Rebound damping force adjuster page 4 12 9 Throttle stop screw page 7 12 10 Shift pedal page 4 2 11 Compression damping force adjuster page 4 9 UBR881E0 book Page 1 Tuesday April 2 2019 9 44 AM ...

Page 25: ...ompression damping force adjuster page 4 12 3 Kickstarter page 4 8 4 Spark plug cap page 7 6 5 Bleed screw page 4 11 6 Coolant drain bolt page 7 9 7 Brake pedal page 4 3 8 Transmission oil drain bolt page 7 7 9 Transmission oil filler cap page 7 7 UBR881E0 book Page 2 Tuesday April 2 2019 9 44 AM ...

Page 26: ...iption 3 3 3 EAU63401 Controls and instruments 1 3 2 4 1 Clutch lever page 4 1 2 Engine stop switch page 4 1 3 Brake lever page 4 2 4 Throttle grip page 7 13 UBR881E0 book Page 3 Tuesday April 2 2019 9 44 AM ...

Page 27: ...oth clutch operation The clutch lever is equipped with a clutch lever position adjusting bolt Ad just the distance between the clutch le ver and the handlebar grip as follows 1 Loosen the locknut 2 While holding the clutch lever pulled slightly towards the handle bar grip turn the adjusting bolt in direction a to increase the dis tance and in direction b to de crease it 3 Tighten the locknut 1 Eng...

Page 28: ...ped with a brake lever position adjusting bolt Ad just the distance between the brake le ver and the throttle grip as follows 1 Slide the rubber cover toward the end of the brake lever 2 Loosen the locknut 3 While holding the lever pushed away from the throttle grip turn the adjusting bolt in direction a to increase the distance and in di rection b to decrease it 4 Tighten the locknut 5 Slide the ...

Page 29: ...3183 Fuel tank cap To remove the fuel tank cap turn it counterclockwise and then pull it off To install the fuel tank cap insert it into the tank opening and then turn it clockwise WARNING EWA11092 Make sure that the fuel tank cap is properly closed after filling fuel Leaking fuel is a fire hazard 1 Brake pedal 1 1 Fuel tank cap 1 UBR881E0 book Page 3 Tuesday April 2 2019 9 44 AM ...

Page 30: ...age of the base oil s qualities and blend in the ideal balance of addi tives to make sure the final oil clears our performance standards Thus Yamalube mineral semisynthetic and synthetic oils have their own distinct characters and value Yamaha s expe rience gained over many years of re search and development into oil since the 1960 s helps make Yamalube the best choice for your Yamaha engine If th...

Page 31: ...w these instructions 1 Before refueling turn off the en gine and be sure that no one is sit ting on the vehicle Never refuel while smoking or while in the vi cinity of sparks open flames or other sources of ignition such as the pilot lights of water heaters and clothes dryers 2 Do not overfill the fuel tank Stop filling when the fuel reaches the bottom of the filler tube Because fuel expands when ...

Page 32: ...breather hose Before operating the motorcycle Check the fuel tank breather hose connection Check the fuel tank breather hose for cracks or damage and replace it if necessary Make sure that the fuel tank breather hose is not blocked and clean it if necessary 1 Fuel tank breather hose 1 UBR881E0 book Page 6 Tuesday April 2 2019 9 44 AM ...

Page 33: ...N With the lever in this position fuel flows to the carburetor Normal riding is done with the lever in this position EAU13641 Starter choke knob Starting a cold engine requires a richer air fuel mixture which is supplied by the starter choke Move the knob in direction a to turn on the starter choke Move the knob in direction b to turn off the starter choke 1 Arrow mark positioned over OFF 1 Arrow ...

Page 34: ...ar if the clutch is disengaged However shifting the transmission into the neutral position before starting is recommended EAU84041 Seat To remove the seat 1 Pull up the rear of the seat and re move the bolt 2 Pull the seat upwards and rear ward to remove it To install the seat 1 Fit the slot on the front of the seat onto the projection on the fuel tank while inserting the projection on the middle ...

Page 35: ...equipped with re bound damping force adjusting screws and compression damping force ad justing screws NOTICE ECA10102 To avoid damaging the mechanism do not attempt to turn beyond the maximum or minimum settings Rebound damping force 1 Remove the protector 2 Turn the adjusting screw in direc tion a to increase the rebound damping force Turn the adjusting screw in direction b to decrease the reboun...

Page 36: ... Turn the adjusting screw in direction b to decrease the compression damp ing force To set the compression damping force turn the adjuster in direction a until it stops and then count the clicks in direction b 3 Install the rubber cap TIP When turning the damping force adjuster in direction a the 0 click position and the 1 click position may be the same 1 Rebound damping force adjusting screw Rebo...

Page 37: ...fork will rise This will in crease the spring preload and harden the front suspension If this occurs bleed the air from each front fork leg WARNING EWA10201 Always bleed both fork legs other wise poor handling and loss of sta bility may result To bleed the front fork legs 1 Remove the protector 2 Place the motorcycle on a suitable stand See page 7 27 3 Make sure the front wheel is off the ground a...

Page 38: ...ound damping force ad justing screw and a compression damping force adjusting screw NOTICE ECA10102 To avoid damaging the mechanism do not attempt to turn beyond the maximum or minimum settings Spring preload Adjust the spring preload as follows 1 Remove the seat See page 4 8 2 Loosen the clamp bolt 3 Remove the bolts and then take the panels off 1 Bleed screw 1 1 1 Clamp bolt 1 Bolt 2 Panel 1 1 2...

Page 39: ...a Yamaha dealer to make this adjustment The spring preload setting is determined by measuring distance A shown in the illus tration The longer distance A is the lower the spring pre load the shorter distance A is the higher the spring pre load With each complete turn of the adjusting nut dis tance A is changed by 1 5 mm 0 06 in 1 Bolt 2 Panel 1 Muffler 2 Muffler bolt 1 Rear frame assembly 2 Rear f...

Page 40: ...t 13 Install the seat Rebound damping force Turn the adjusting screw in direction a to increase the rebound damping for ce Turn the adjusting screw in direction b to decrease the rebound damping for ce To set the rebound damping force turn the adjuster in direction a until it stops and then count the clicks in di rection b 1 Distance A Spring preload Minimum soft Distance A 205 5 mm 8 09 in Standa...

Page 41: ...ction a the 0 click position and the 1 click position may be the same When turning the damping force adjuster in direction b it may click beyond the stated specifica tions however such adjustments are ineffective and may damage the suspension WARNING EWA10222 This shock absorber assembly con tains highly pressurized nitrogen gas Read and understand the fol lowing information before handling the sh...

Page 42: ...amaged or worn out shock absorber as sembly yourself Take the shock absorber assembly to a Yamaha dealer for any service EAU41382 Removable sidestand This motorcycle is equipped with a re movable sidestand TIP Make sure that the sidestand is proper ly secured when the motorcycle is be ing supported or is being transported WARNING EWA14602 Never apply force on the motor cycle while it is on the sid...

Page 43: ...sts engine power by means of a valve that controls exhaust port opening aperture NOTICE ECA26380 The YPVS system has been exten sively tested and set up by Yamaha Changing the YPVS settings without sufficient technical knowledge can result in reduced engine perfor mance or even engine damage UBR881E0 book Page 17 Tuesday April 2 2019 9 44 AM ...

Page 44: ...eck hose connection 4 4 4 6 Transmission oil Check for leakage 7 7 Coolant Check coolant level If necessary add recommended coolant to specified level Check cooling system for leakage 7 8 Front brake Check operation If soft or spongy have Yamaha dealer bleed hydraulic system Check brake pads for wear Replace if necessary Check fluid level in reservoir If necessary add specified brake fluid to spec...

Page 45: ...r can be turned smoothly and has no excessive play 7 26 Front fork and rear shock absorber as sembly Check that they operate smoothly and there is no oil leakage 4 9 4 11 4 12 7 26 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened Check all cotter pins for damage and correct install ment Tighten or replace if necessary Moving parts and ca bles Check the control cabl...

Page 46: ... have a Yamaha dealer perform service TIP Before starting the engine for the first time the air filter must be lubricated See page 7 10 Engine break in procedure 1 Fill the fuel tank with a break in oil fuel mixture as follows 2 Start and warm up the engine Check the operation of the con trols and the engine stop switch See page 4 1 3 Operate the motorcycle in the low er gears at moderate throttle...

Page 47: ...es Stop the engine and check the spark plug condition It should be gin to lighten in color 9 Restart the motorcycle and ride it for about 10 to 15 more minutes Stop the engine and check the spark plug condition See page 7 6 10 Lastly thoroughly check the mo torcycle for loose parts oil leak age and any other problems Check all fittings and fasteners and tighten as necessary TIP Be sure to inspect ...

Page 48: ...TIP The engine is warm when it responds quickly to the throttle with the starter choke turned off NOTICE ECA11043 For maximum engine life never ac celerate hard when the engine is cold EAU16661 Starting a warm engine Follow the same procedure as for starting a cold engine with the excep tion that the starter choke is not re quired when the engine is warm Instead start the engine with the throt tle...

Page 49: ...which are not designed to withstand the shock of forced shifting EAU16691 To start out and accelerate 1 Pull the clutch lever to disengage the clutch 2 Shift the transmission into first gear 3 Open the throttle gradually and si multaneously release the clutch lever slowly 4 Once the motorcycle has reached a speed high enough to change gears close the throttle and at the same time quickly pull the ...

Page 50: ... exhaust 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 vehicle may overturn increasing the risk of a fuel leak and fire Do not park near grass or other flammable materials which might catch fire UBR881E0 book Page 5 Tuesday April 2 2019 9 44 AM ...

Page 51: ...roperly maintain the vehi cle or performing maintenance ac tivities incorrectly may increase your risk of injury or death during service or while using the vehicle If you are not familiar with vehicle ser vice have a Yamaha dealer perform service WARNING EWA15123 Turn off the engine when performing maintenance unless otherwise specified A running engine has moving parts that can catch on body part...

Page 52: ...as they require special tools data and technical skills NO ITEM ROUTINE After break in Every race Every third race Every fifth race As required 1 Piston Check piston for carbon deposits and cracks or damage Clean Replace 2 Piston rings Check piston ring end gap and rings for damage Replace 3 Piston pin and small end bearing Check piston pin and small end bearing for damage Replace 4 Cylinder head ...

Page 53: ...ean and regap Replace Check chain slack alignment and condition 16 Drive chain Adjust and thoroughly lubricate chain with Yamaha chain and cable lube or equivalent Replace NO ITEM ROUTINE After break in Every race Every third race Every fifth race As required 7 Clutch Check clutch housing friction plates clutch plates and clutch springs for wear or damage Adjust Replace 8 Transmission Change the t...

Page 54: ...acks or damage Check radiator cap spring operation Change coolant Every 2 years Every year Check all chassis fitting and fasteners 18 Chassis fasteners Correct or tighten if necessary 19 Air filter element Clean Replace 20 Frame Clean and check for damage 21 Fuel line Clean and check for leakage 22 Brakes Adjust lever position and pedal height Lubricate pivot points Check brake disk surface Check ...

Page 55: ...operation and tighten if necessary Lubricate with molybdenum disulfide grease Check operation free play and tighten if necessary Steering head Clean and lubricate with lithium soap based grease Replace bearings Check tire air pressure wheel runout spokes for looseness and tires for wear Tighten sprocket bolts if necessary Tires and wheels Check wheel bearings for looseness Lubricate wheel bearings...

Page 56: ...k 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 vehi cle 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 vehicle 2 Check the spark plug for electro...

Page 57: ...ound have a Yamaha deal er check and repair the motorcycle In addition the transmission oil must be changed at the intervals specified in the periodic maintenance and lubrica tion chart 1 Start the engine warm it up for several minutes and then turn it off 2 Place the motorcycle on a level surface and hold it in an upright position 3 Place an oil pan under the trans mission case to collect the use...

Page 58: ...0071 Coolant The coolant level should be checked before each ride In addition the cool ant must be changed at the intervals specified in the periodic maintenance and lubrication chart EAUM1296 To check the coolant level 1 Place the vehicle on a level surfa ce and hold it in an upright posi tion TIP The coolant level must be checked on a cold engine since the level varies with engine tem perature M...

Page 59: ...eze con tent of the coolant as soon as possible otherwise the effec tiveness of the coolant will be reduced ECA10473 EAUM1318 To change the coolant 1 Place the vehicle on a level surfa ce and let the engine cool if neces sary 2 Place a container under the en gine to collect the used coolant 3 Remove the radiator cap and then the coolant drain bolt and its gasket to drain the cooling sys tem WARNIN...

Page 60: ...ntervals specified in the periodic maintenance and lubrication chart Service the air filter element more fre quently if you often ride in wet or dusty conditions 1 Remove the seat See page 4 8 2 Remove the air filter element by removing the wing bolt and its washer 3 Remove the sponge material from the air filter element frame 4 Clean the sponge material with solvent or YAMALUBE foam air fil ter c...

Page 61: ...ert the air filter element into the air filter case by aligning the pro jection on the element with the slot in the case and then install the wing bolt and its washer NOTICE Make sure that the air filter element is properly seated in the air filter case The engine should never be operated with out the air filter element in stalled otherwise the piston s and or cylinder s may become excessively wor...

Page 62: ...r has been set and ex tensively tested at the Yamaha fac tory Changing these settings without sufficient technical knowl edge may result in poor perfor mance of or damage to the engine EAU44391 Adjusting the engine idling speed The engine idling speed must be ad justed when necessary 1 Start the engine and thoroughly warm it up 2 Turn the throttle stop screw until the engine runs at the lowest pos...

Page 63: ...hrottle grip free play 1 Slide the rubber cover back 2 Loosen the locknut 3 To increase the throttle grip free play turn the adjusting nut in di rection a To decrease the throt tle grip free play turn the adjusting nut in direction b 4 Tighten the locknut and then slide the rubber cover to its original po sition 1 Throttle grip free play Throttle grip free play 3 0 6 0 mm 0 12 0 24 in 1 Locknut 2 ...

Page 64: ...ance with the weight of the rider the riding speed and the riding condi tions Tire inspection The tires must be checked before each ride NOTICE ECA15582 Make sure the bead stopper is tightened A loose bead stopper will cause the tire to slip off the rim if tire pressure is too low Make sure the valve stem is po sitioned straight A tilted valve stem indicates that the tire has slipped from its orig...

Page 65: ...ist ed below have been approved for this model by Yamaha WARNING EWA14391 Have a Yamaha dealer replace excessively worn tires Operat ing the motorcycle with exces sively worn tires decreases riding stability and can lead to loss of control 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 ex...

Page 66: ...formance adverse han dling characteristics and a short ened tire life EAU65775 Adjusting the clutch lever free play Measure the clutch lever free play as shown Periodically check the clutch lever free play and if necessary adjust it To increase the clutch lever free play turn the clutch lever free play adjuster in direction a To decrease the clutch lever free play turn the adjuster in di rection b...

Page 67: ...lever end If there is free play have a Yamaha dealer inspect the brake system WARNING EWA14212 A soft or spongy feeling in the brake lever can indicate the presence of air in the hydraulic system If there is air in the hydraulic system have a Yamaha dealer bleed the system be fore operating the vehicle Air in the hydraulic system will diminish the braking performance which may re sult in loss of c...

Page 68: ...fied in the periodic maintenance and lubrication chart EAU22411 Front brake pads Each front brake pad is provided with a wear indicator which allows you to check the brake pad wear without hav ing to disassemble the brake To check the brake pad wear check the position of the wear indicator while applying the brake If a brake pad has worn to the point that the wear indicator almost touches the brak...

Page 69: ...set EAU22583 Checking the brake fluid level Before riding check that the brake fluid is above the minimum level mark Check the brake fluid level with the res ervoir in an upright position Replenish the brake fluid if necessary NOTICE ECA17641 Brake fluid may damage painted surfaces or plastic parts Always clean up spilled fluid immediately Front brake Rear brake As the brake pads wear it is normal...

Page 70: ...ed brake flu id otherwise the rubber seals may deteriorate causing leak age Refill with the same type of brake fluid Adding a brake fluid other than DOT 4 may result in a harmful chemical reaction Be careful that water does not enter the brake fluid reservoir when refilling Water will signifi cantly lower the boiling point of the fluid and may result in vapor lock EAU51721 Changing the brake fluid...

Page 71: ...hain slack will overload the engine as well as other vital parts of the motorcy cle and can lead to chain slip page or breakage To prevent this from occurring keep the drive chain slack within the specified limits ECA10572 EAU84060 To adjust the drive chain slack Consult a Yamaha dealer before ad justing the drive chain slack 1 Loosen the axle nut and the lock nut on each side of the swingarm 2 To...

Page 72: ...tenance 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 ECA10584 The drive chain must be lubricated after washing the motorcycle riding in the rain or riding in wet areas 1 Remove all dirt and mud from the drive chain with a brush or cloth TIP For a thorough cleaning have a Yamaha dealer remove the dri...

Page 73: ...2 EAU23115 Checking and lubricating the throttle grip and cable The operation of the throttle grip should be checked before each ride In addition the cable should be lubricat ed by a Yamaha dealer at the intervals specified in the periodic maintenance chart The throttle cable is equipped with a rubber cover Make sure that the cover is securely installed Even though the cover is installed correctly...

Page 74: ...be lu bricated if necessary Brake lever Clutch lever EAU23185 Checking and lubricating the brake pedal The operation of the brake pedal should be checked before each ride and the pedal pivot should be lubricat ed if necessary Recommended lubricants Brake lever Silicone grease Clutch lever Lithium soap based grease Recommended lubricant Lithium soap based grease UBR881E0 book Page 24 Tuesday April ...

Page 75: ...tervals specified in the periodic maintenance and lubrication chart EAUM2701 Lubricating the swingarm piv ots The swingarm pivots must be lubricat ed at the intervals specified in the peri odic maintenance and lubrication chart Recommended lubricant Molybdenum disulfide grease Recommended lubricant Molybdenum disulfide grease UBR881E0 book Page 25 Tuesday April 2 2019 9 44 AM ...

Page 76: ...al times to check if the front fork compresses and re bounds smoothly NOTICE ECA10591 If any damage is found or the front fork does not operate smoothly have a Yamaha dealer check or re pair it EAU23285 Checking the steering Worn or loose steering bearings may cause danger Therefore the operation of the steering must be checked as fol lows at the intervals specified in the periodic maintenance and...

Page 77: ...check the wheel bearings EAU75190 Supporting the motorcycle Since this model is not equipped with a centerstand use a maintenance stand when removing the front or rear wheel adjusting the chain or washing the ve hicle etc Check that the motorcycle is in a stable and level position before starting any maintenance TIP If a suitable maintenance stand is not available a strong wooden box can be used i...

Page 78: ...5 Remove the wheel NOTICE Do not apply the brake after the wheel and brake disc have been removed otherwise the brake pads will be forced shut ECA11073 To install the front wheel 1 Make sure the brake pads have not been forced shut 2 Lift up the wheel between the fork legs 3 Insert the wheel axle from the right side 4 Install the washer and axle nut 5 Tighten the axle nut to the speci fied torque ...

Page 79: ... A rubber mallet may be useful to tap the wheel axle out The drive chain pullers may fall out when removing the wheel axle 7 Remove the wheel NOTICE Do not apply the brake after the wheel and brake disc have been removed otherwise the brake pads will be forced shut ECA11073 TIP If the drive chain is difficult to re move remove the wheel axle first For easy installation rest the drive chain on top ...

Page 80: ...ick and easy procedures for checking these vital systems 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 ...

Page 81: ...orrect the spark plug gap or replace the spark plug s 2 Ignition Wet Dry There is compression There is no compression The engine does not start Have a Yamaha dealer check the vehicle Have a Yamaha dealer check the vehicle The engine does not start Check the compression Have a Yamaha dealer check the vehicle Remove the spark plug and check the electrodes Try starting the engine Check the fuel level...

Page 82: ... 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 Add coolant See TIP The coolant level is OK There is no leakage There is le...

Page 83: ...ct the condition of the vehicle more frequently Be sure to wash the vehicle after riding in the rain or near the sea because salt is corro sive to metals TIP The roads of heavy snowfall areas may be sprayed with salt as a de icing method This salt can stay on the roads well into spring so be sure to wash the underside and chassis parts after riding in such areas Genuine Yamaha care and main tenanc...

Page 84: ...g 1 Rinse off any degreaser and spray down the vehicle with a garden hose Use only enough pressure to do the job Avoid spraying wa ter directly into the muffler instru ment panel air inlet or other inner areas such as underseat storage compartments 2 Wash the vehicle with a quality au tomotive type detergent mixed with cool water and a soft clean towel or sponge Use an old tooth brush or plastic b...

Page 85: ...l painted surfaces using a non abrasive wax or use a detail spray for motorcycles 8 When finished cleaning start the engine and let it idle for several mi nutes to help dry any remaining moisture 9 If the headlight lens has fogged up start the engine and turn on the headlight to help remove the moisture 10 Let the vehicle dry completely be fore storing or covering it NOTICE ECA26320 Do not apply w...

Page 86: ...o the off posi tion 6 For vehicles with a carburetor To prevent fuel deposits from build ing up drain the fuel in the carbu retor float chamber into a clean container Retighten the drain bolt and pour the fuel back into the fuel tank 7 Use a quality engine fogging oil according to product instructions If engine fogging oil is not avail able perform the following steps for each cylinder a Remove th...

Page 87: ...aded in one spot 10 Cover the muffler outlet with a plastic bag to prevent moisture from entering it 11 For vehicles with a battery Re move and fully charge it or attach a maintenance charger NOTICE Confirm that the battery and its charger are compatible Do not charge a VRLA battery with a conventional charger ECA26330 UBR881E0 book Page 5 Tuesday April 2 2019 9 44 AM ...

Page 88: ... oil SAE 85W GL 3 Quantity 0 50 L 0 53 US qt 0 44 Imp qt Coolant quantity Radiator including all routes 0 38 L 0 40 US qt 0 33 Imp qt Fuel Recommended fuel Unleaded gasoline E10 acceptable Octane number RON 98 Fuel tank capacity 3 5 L 0 9 US gal 0 8 Imp gal Carburetor Type quantity PWK28 1 Drivetrain Gear ratio 1st 2 455 27 11 2nd 1 882 32 17 3rd 1 529 26 17 4th 1 263 24 19 5th 1 095 23 21 6th 0 9...

Page 89: ...NUMBER EAU26401 Vehicle identification number The vehicle identification number is stamped into the steering head pipe Record this number in the space pro vided TIP The vehicle identification number is used to identify your motorcycle and may be used to register your motorcy cle with the licensing authority in your area EAU26442 Engine serial number The engine serial number is stamped into the cra...

Page 90: ...k breather hose 4 6 Fuel tank cap 4 3 H Handlebar switch 4 1 I Identification numbers 10 1 K Kickstarter 4 8 L Labels location 1 1 M Matte color caution 8 1 P Parking 6 5 Part locations 3 1 Periodic maintenance and lubrication chart 7 2 R Rear suspension lubricating 7 25 S Safety information 2 1 Seat 4 8 Shifting 6 4 Shift pedal 4 2 Shift pedal checking 7 18 Shock absorber assembly adjusting 4 12 ...

Page 91: ...UBR881E0 book Page 2 Tuesday April 2 2019 9 44 AM ...

Page 92: ...other vehicle with a passenger passengers affect balance and steering and increase risk of losing control ALWAYS use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns avoid paved surfaces pavement may seriously affect handling and control ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PAVED ROADS NEVER CARRY PASSENGERS PRINTED ON RECYCLED P...

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Yamaha YZ65, Owner'S Manual

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