Yamaha YZ65J Owner'S Manual Download Page 74

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Periodic maintenance and adjustment

7-25

EAU85250

Lubricating the rear suspen-
sion

The pivoting points of the rear suspen-
sion must be lubricated by a Yamaha
dealer at the intervals 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

UBR880E0.book Page 25 Friday, April 6, 2018 11:11 AM

Summary of Contents for YZ65J

Page 1: ...EITUNG Read this manual carefully before oper ating this vehicle Il convient de lire attentivement ce manuel avant la premi re utilisation du v hicule Bitte lesen Sie diese Bedienungsanlei tung sorgf...

Page 2: ...DIC183 Original instructions Notice originale Originalbetriebsanleitung PRINTED ON RECYCLED PAPER IMPRIM SUR PAPIER RECYCL AUF RECYCLINGPAPIER GEDRUCKT PRINTED IN JAPAN 2018 03 1 9 2 CR E F G...

Page 3: ...Read this manual carefully before oper ating this vehicle OWNER S MANUAL YZ65 MOTORCYCLE YZ65 YZ65J BR8 28199 80 E0 UBR880E0 book Page 1 Friday April 6 2018 11 10 AM...

Page 4: ...EAU46094 Read this manual carefully before operating this vehicle This manual should stay with this vehicle if it is sold UBR880E0 book Page 1 Friday February 16 2018 8 32 AM...

Page 5: ...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 sp...

Page 6: ...g 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 a...

Page 7: ...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 oth...

Page 8: ...aning 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 leve...

Page 9: ...Table of contents Specifications 9 1 Consumer information 10 1 Identification numbers 10 1 Index 11 1 UBR880E0 book Page 2 Friday February 16 2018 8 32 AM...

Page 10: ...ain 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 fr...

Page 11: ...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 211...

Page 12: ...de perte de contr le NE JAMAIS ROULER SUR DES CHEMINS PUBLICS Vous pourriez entrer en collision avec un autre v hicule TOUJOURS PORTER UN CASQUE DE MOTOCYCLISTE APPROUVE des lunettes et des v tements...

Page 13: ...Location of important labels 1 4 1 For Europe 2 3 1 UBR880E0 book Page 4 Friday February 16 2018 8 32 AM...

Page 14: ...t 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 UBR880E0 book Page 5 Friday Febru...

Page 15: ...ear 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...

Page 16: ...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 con...

Page 17: ...Location of important labels 1 8 1 For Australia 1 2 3 UBR880E0 book Page 8 Friday February 16 2018 8 32 AM...

Page 18: ...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...

Page 19: ...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 r...

Page 20: ...talities 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 appro...

Page 21: ...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 motorc...

Page 22: ...ust 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 motorc...

Page 23: ...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 t...

Page 24: ...8 3 Fuel tank cap page 4 3 4 Fuel cock page 4 6 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 11 9 Throttle stop screw page 7 12...

Page 25: ...ression damping force adjuster page 4 11 3 Kickstarter page 4 7 4 Spark plug cap page 7 6 5 Bleed screw page 4 10 6 Coolant drain bolt page 7 9 7 Brake pedal page 4 3 8 Transmission oil drain bolt pag...

Page 26: ...ion 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 UBR880E0 book Page 3 Friday February 16 2018...

Page 27: ...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...

Page 28: ...ed 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 loc...

Page 29: ...83 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...

Page 30: ...f knocking or pinging occurs use a gasoline of a different brand If the recommended 2 stroke engine oil is not available use an equivalent oil Gasohol There are two types of gasohol gaso hol containin...

Page 31: ...xpands when it heats up heat from the engine or the sun can cause fuel to spill out of the fuel tank 3 Wipe up any spilled fuel immedi ately NOTICE Immediately wipe off spilled fuel with a clean dry s...

Page 32: ...1 Fuel cock The fuel cock supplies fuel from the tank to the carburetor while filtering it also The fuel cock has two positions OFF With the lever in this position fuel will not flow Always return the...

Page 33: ...Kickstarter To start the engine fold out the kick starter lever move it down lightly with your foot until the gears engage and then push it down smoothly but force fully This model is equipped with a...

Page 34: ...ojection on the fuel tank while inserting the projection on the middle of the seat into the seat holder 2 Make sure the seat is in its original position 3 Install the bolt at the rear of the seat TIP...

Page 35: ...adjusting screw on each fork leg in direction a To decrease the rebound damping force and thereby soften the rebound damping turn the ad justing screw on each fork leg in direction b 3 Install the pro...

Page 36: ...ondi tions the air temperature and pressure in the front 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 WAR...

Page 37: ...nd 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 p...

Page 38: ...adjusting nut in direction b A special wrench can be ob tained at a Yamaha dealer to make this adjustment The spring preload setting is determined by measuring distance A shown in the illus tration Th...

Page 39: ...ue 11 Place the panels in their original position and then install the bolts 12 Tighten the clamp bolt 13 Install the seat Rebound damping force To increase the rebound damping force and thereby harde...

Page 40: ...WA10222 This shock absorber assembly con tains highly pressurized nitrogen gas Read and understand the fol lowing information before handling the shock absorber assembly Do not tamper with or attempt...

Page 41: ...sembly 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...

Page 42: ...s 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 suff...

Page 43: ...k 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 Ch...

Page 44: ...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 10 4 11 7 26 Chassis fasteners Ma...

Page 45: ...8 Starting and warming up a cold engine 1 Turn the fuel cock lever to ON 2 Shift the transmission into the neutral position 3 Turn the starter choke on and completely close the throttle See page 4 7 4...

Page 46: ...etc The gear positions are shown in the il lustration 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 sl...

Page 47: ...the motorcycle is almost completely stopped EAU41506 Engine break in WARNING EWA10322 Failure to properly maintain the vehi cle or performing maintenance ac tivities incorrectly may increase your risk...

Page 48: ...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 co...

Page 49: ...haust system can become very hot park in a place where pedestri ans or children are not likely to touch them and be burned Do not park on a slope or on soft ground otherwise the vehicle may overturn i...

Page 50: ...erly 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 se...

Page 51: ...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 da...

Page 52: ...n 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...

Page 53: ...s 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 eleme...

Page 54: ...wear or damage Replace if necessary 26 Rear suspension Check operation and tighten if necessary Lubricate with lithium soap based grease Check operation free play and tighten if necessary 27 Steering...

Page 55: ...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 dist...

Page 56: ...nd 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 engi...

Page 57: ...71 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...

Page 58: ...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 sur face and let the eng...

Page 59: ...ervals 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...

Page 60: ...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...

Page 61: ...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 Adjustin...

Page 62: ...ottle 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 t...

Page 63: ...ce 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 b...

Page 64: ...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 stabi...

Page 65: ...rmance 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 p...

Page 66: ...er 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 ther...

Page 67: ...ed 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 di...

Page 68: ...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 b...

Page 69: ...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 car...

Page 70: ...n 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 specif...

Page 71: ...ance 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...

Page 72: ...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 th...

Page 73: ...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 l...

Page 74: ...ervals 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 mainten...

Page 75: ...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...

Page 76: ...eck 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 washi...

Page 77: ...emove 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 pa...

Page 78: ...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...

Page 79: ...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 experien...

Page 80: ...ith a dry cloth and correct the spark plug gap or replace the spark plug 2 Ignition Wet Dry There is compression There is no compression The engine does not start Have a Yamaha dealer check the vehicl...

Page 81: ...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 re...

Page 82: ...appearance of a mo torcycle Frequent and proper care does not only comply with the terms of the warranty but it will also keep your motorcycle looking good extend its life and optimize its performanc...

Page 83: ...t clean sponge and then rinse thoroughly with clean water Use a toothbrush or bottlebrush for hard to reach areas Stubborn dirt and insects will come off more easily if the area is covered with a wet...

Page 84: ...dry place and if necessary protect it against dust with a porous cover Be sure the engine and the exhaust sys tem are cool before covering the mo torcycle NOTICE ECA10811 Storing the motorcycle in a...

Page 85: ...cap WARNING To prevent damage or injury from sparking make sure to ground the spark plug elec trodes while turning the en gine over EWA10952 5 Lubricate all control cables and the pivoting points of...

Page 86: ...higher or Gear 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 Air filter Air filter element Wet element Fuel Recom...

Page 87: ...Rear wheel Wheel type Spoke wheel Rim size 1 60 x 12 Front brake Type Hydraulic single disc brake Specified brake fluid DOT 4 Rear brake Type Hydraulic single disc brake Specified brake fluid DOT 4 F...

Page 88: ...MBER 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...

Page 89: ...4 6 Fuel tank cap 4 3 H Handlebar switch 4 1 I Identification numbers 10 1 K Kickstarter 4 7 L Labels location 1 1 M Matte color caution 8 1 P Parking 6 5 Part locations 3 1 Periodic maintenance and...

Page 90: ...ther 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 i...

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