Yamaha Nouvo LX 135CC Service Manual. Written in English.

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.. OWNER'S MANUAL

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Read this manual carefully before operating this vehicle. This manual should stay with this veh icle if it is sold.

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INTRODUCTION Welcome to the Yamaha world of motorcycling! As the owner of the AT135, you are benefiting fro m Yamaha's vast experience and newest technology regarding the design and manufacture of high-quality prod ucts, wh ich have earned Yamaha a reputation for dependability. Please take the time to read this manual thorou ghly, so as to enjoy all advantages of your AT135. Tile Owne r's Manual does not only instruct you in how to operate, inspect and maintain your motorcycle , but also in how to safeguard you rself and others from trouble and injury. In addition, the many tips given in this manual will help keep you r motorcycl e 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 fi rst! Yamaha continually seeks advancements in product design and quality. Therefore, wh ile this manual contains the most cu rre nt product information available at the time of printing, the re may be minor discrepancies between you r motorcycle and this manual. If there is any question concern ing this manual, please consult a Yamaha dealer. EWA 10031

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Please read thi s manual carefully and completely before operating this motorcycle.

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IMPORTANT MANUAL INFORMATION EAU10 132

Particularly important information is distingu ished in this manual by the following notations: This is the safety alert symbol. 11 is Llsed to alert you t o potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possibl1e injury or death.

~WARNING

A WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. A NOTICE indicates special precaut ions that must be taken to avoid damage to the vehicle or other property. A TIP provides key information to make procedu res easier or clearer,


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IMPORTANT MANUAL INFORMATION

EAUJ7430

AT135 OWNER'S MANUAL ©2008 by Thai Yamaha Motor Co., Ltd. 1st edition, October 2008 All rights reserved. Any reprinting or unauthori zed use without the written perm ission of Thai Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Thailand.


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TABLE OF CONTENTS LOCATION OF IMPORTANT LABELS """""""""""""""""""""""""""""""" ""' " 1- 1

FOR YOUR SAFETY - PREOPERATION CHECKS ........ ""

SAFETY INFORMATION ........ .. ""."" "",2-1 Hel mets """" """"" """" """"",., .. ... " .. "." .. 2-5

OPERATION AND IMPORTANT RIDING POINTS ........ ... .................... .. 6-1 Starting a cold engine ... " ..... . ... ..... 6-1 Starting off .......... .......... ... ............. .. 6-2 Acceleration and deceleration .. .. .... 6-2 Braking ........................................... 6-2 Tips for reducing fuel consum ption .............. ........... ...... 6-3 Engine break-in ........ ....... .. ............. 6-3 Parking ............... ....... " .. ......... .. ...... 6-5 General note ...... ............. .... ........... 6-6

DESCRIPTION "" ... .. "" ....... "." .... " ........ 3- 1 Left view " ..... ..... "" ..... .. .......... " ... ..... 3-1 Right view ."""" """"""""" "" ,,,"",,,"",, ,,,,,, "" 3-2 Controls and instruments ""." .. " "",, ,3-3 INSTRUMENT AN D CONTROL FUNCTIONS ............ " ........ """"'"""""""..4- 1 Main switch/steering lock ... " .. ..... ... .4-1 Keyho le cover ... ........ ... ....... .. ... ...... .4-2 Indicato r and warning lights .... ... ... .4-3 Speedometer ...... ............. ......... ..... .4-3 Fuel gauge ...... ....... ... .... ....... .. ...... " .4-4 Digital coolant temperature gauge/odomete r ......... .... ............ .4-4 Handlebar switches ....................... .4-5 Front brake lever ................ ... .. ... ... .4-5 Rear brake lever .......... .......... ... .. .. . .4-6 Fuel tank cap ....... .... ................ .. .. .. .4-6 Fuel ............ .. . " ... ,'" .................. "" ... 4-7 Catalytic converter .... ...... ............. ...4-8 Kickstarter " ............... ... ....... ... ... ... ...4-9 Seat ..... .............. ..... ....................... .4-9 Helme! holders ....... ..................... .4-1 0 Convenience hook ... .... .. ........... ... .4-10 Sto rage compartment ............. ..... .4-11

PERIODIC MAINTENANCE AND ADJUSTMENT .............. .. ....... .. ... "" 7-1 Owner's tool kit ..... .......................... 7-1 Periodic maintenance chart for the emission control system ..... .. 7-2 General maintenance and lubrication chart .......................... . 7-3 Removing and installing cowlings and panels ............. .. ... ................ 7-6 Checking the spark plug ................. 7-8 Engine oil and oil stra ine r ............... 7-9 Final transmissio n oil .................... 7-11 Coolant ...... .. ........ .. .. ........ .. " ........ 7- 12 Air filter and V-belt case air filter elements ... ..... ...... .. .... .... ........... 7 -1 3 Adjusting the carburetor ...... ......... 7-16


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Adjusting t he engine idl ing speed .... .... ..... .. ................ ........ . 7- 16 Adjusting the throttle cable free play ............... .. ... ... ........ ..... 7- 17 Valve cl ea ran ce .................... ... .... 7- 17 T ires ..... ... .. .. ...." ........... ... .... .. ..... .. 7- 18 Wheels ............. .............. ....... ....... 7-20 Checking the f ront brake lever free play .... ..... .................... ....... 7-20 Adjusting the rear brake lever free play ............. .................. ... .. 7-21 Checking the front b rake pads and rear brake shoes ............... 7-22 Checking the brake fluid level .. .... 7-22 Changi ng the brake fluid ...... ... .... 7-23 Check ing the V-belt .. ......... .. .... .. .. 7-24 Checking and lubricating the cables ....... ....................... ... ...... 7-24 Checking and lubricating th e throttle grip and cable .......... ..... 7-24 Lubricating the front and rear brake levers ................... ........... 7-25 Checking and lubricating the centerstand and sidestand ... .... 7-25 Checking t he front fork ..... .... ........ 7-26 Checking the steering ........... ....... 7-27 Checking the wheel bearings .. ... .. 7-27 Battery ...... ............................ .... .. . 7-28 Replacing the fuse ..... ... ...... ....... .. 7-29 Replacing a headlight bulb .......... 7-30

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TABLE OF CONTENTS Replacing the tail/brake lig ht bulb .... ...... ........................ .7-31 Replacing a turn signal lig ht bulb .......... ... ................. ......7-32 Replacing a front turn signal light bulb ....... ...... ............. .......... 7-33 Replacing an auxiliary ligh! bulb ................................. .......... 7-33 Troubleshooting .. .. ....... ............. .... 7-34 Troubleshooting charts ................. 7-35 MOTORCYCLE CAR E AND STORAGE ... .... ............... ............. . 8-1 Care .. ........... ...... .... ..... .. .. .... ...... ... ... 8- 1 Stora ge . __ ...... .. .................... ...... ..... . 8-3 SPECIFICATIONS ... ..................... ... ... 9-1 CONSUM ER INFORMATION ....... .... 10-1 Identification numbers ..... .. ........... 10- 1


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LOCATION OF IMPORTANT LABELS E AU t 0383

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Read and understand all of the labels on your vehicle . They contain important information fo r safe and proper operation of you r 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 Ya maha dealer.

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ill SAFETY INFORMATION El\UH1313

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Be a Responsible Owner As tt1e vehicle' s owner, you a re responsible for the safe and proper operation of your motorcycle. Motorcycles are single-t rack vehicles. Their safe use and operation are dependent upon the use of prope r riding techniques as well as the expertise of the operator. Every operator should know the following requirements before riding this motorcycle. He or she should: • Obtain thorough instruct ions from a competent source on all aspects of motorcycle operation. • Observe the warnings and maintenance requ irements in this Owner' s Manual. • Obtai n 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.

Safe Riding Perform the pre-operation checks eac h time you use the vehicle to make sure it is in safe operating condition. Failure to inspect or maintain the vehicle properly increases the possibility of an accident or eq uipment damage. See page 5- 1 for a list of pre-operation checks. • Th is motorcycle is designed to carry the operator and a passenger. • The failure of motorists to detect and recog nize motorcycles in traffic is the predom inating cause of automobile/motorcycle accidents. been Many accidents have caused by an automobile driver who did not see the moto rcycle . Making you rse lf conspicuous appears to be very effective in reducing the chance of this type of accident. Therefore: • Wea r a brightly colored jacket. • Use extra caution when you are approaching and passing through intersections, since in2-1


tersections are the most likely places for motorcycle accidents to occur. • Ride w here oth er motorists can see you. Avoid riding in another • motorist's bl in d spot. • Many acciden ts involve inexperienced operators . In fact, many operators who have been involved in accidents do not even have a cu rren t motorcycle license. • Make sure that you are qualified and that you only lend your moto rcycle to other qualifi ed operato rs. • Know you r ski lls and limits. Staying with in your lim its may help you to avoid an accident. • We recommend that you practice riding your motorcycle where there is no traffic unti l you have become thoroughly familia r with the motorcycle and all of its controls. • Many accidents have been caused by error of the motorcycle operator. A typical error made by

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the operator is veering wide on a turn due to excessive speed or undercornering (insufficient lean angie for the speed). • Always obey the speed limit and never travel faste r than warranted by road and traffi c conditions. • Always signal before turning or changing lanes. Make sure that other motorists can see you. • The posture of the operator and passenger is important for proper control. • The operator should keep both hands on the handleba r and both feet on the operator footrests during operation to maintain control of the motorcycle . • The passe nger should always hold onto the ope rator, the seat strap or grab bar, if eq uipped, with both hands and keep both feet on the passenger footrests. Neve r carry a passenger unless he or she can fi rmly place both feet on the passenger footrests.

• Never ride under the influence of alcohol or other drugs.

Protective apparel The majority of fatal ities from motorcycle accidents are the result of head injuries. The use of a safety helmet is the single most critical factor in the prevention or reduction of head injuri es. • 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 use of a jacket, heavy boots, trousers, gloves, etc., is effective in preventing or reduc ing abrasions or lacerations. • Never wear loose-fitting clothes, otherwise they could catch on the control levers , footrests, or wheels and cause inju ry or an accident. • Always wear protective cloth ing that covers your legs, an kles, and feet. The engine or exhaust sys2-2


tem become very hot during or after operation and can cause bu rns. • A passenger should also obse rve the above precautions .

Avoid Carbon Monoxide Poisoning All engine exhaust contains ca rbon monoxide, a deadly gas. Breath ing carbon monoxide ca n cause headaches, dizziness, drowsiness, nausea, confusion, and eventually death. Carbon Monoxide is a colorless , odorless, tasteless gas which may be present even if you do not see or smell any engine exh aust. Deadly levels of carbon monoxide can collect rapidly and you can qu ic kly be overcome and unable to save yourself. Also, deadly levels of carbon monoxide can linger for hou rs or days in enclosed o r poorly ventilated areas. If you experience any symptoms of carbon monoxid e poisoning, leave the area immediately, get fresh air, and SEEK MEDICAL TREATMENT.

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ill SAFETY INFORMATION • Do not ru n engine indoors. Even if you try to ventilate engine exhaust with fans or open windows and doors, carbon monoxide can rapidly reach dangerous levels. • Do not run engine in poorly ventilated or partially enclosed areas such as barns, garages, or carports. • Do not run engine outdoors where engine exhaust can be drawn into a building through openings such as windows and doors.

loading Addi ng accesso ries or cargo to your motorcycle can adve rsely affect stabi lity and handling if the weight distribution of the motorcycle is changed. To avoid the possibility of an accident, use extreme caution when adding cargo or accessories to your motorcycle. Use extra care when riding a motorcycle that has added cargo or accessories. Here, along with the information about accessories below, are some general

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guidelines to follow if loading cargo to your motorcycle : The total weight of the operato r, passenger, accessories and cargo must not exceed the maximum load limit. Operat ion of an overloaded vehicle could cause an accident. Maximum load :

160 kg (353 Ib) When loading within this we ight limit, keep the following in mind: • Cargo and accessory weight should be kept as low and close to the motorcycle as possible. Securely pack your heaviest items as close to the center of the vehicle as possible and make sure to distri bute the weight as evenly as possible on both sides of the motorcycle to minimize imbalance o r instability. • Shifting weights can create a sudden imbalance. Make su re that accessori es and cargo are securely

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attached to the motorcycle before riding. Check accessory mounts and cargo restraints frequ ently. • Properly adjust the suspension for your load, and check the condition and pressure of your tires. • Never attach any large or heavy items to the handlebar, front fork, or front fende r. These items, including such cargo as sleeping bags, duff el bags, or tents, can create unstable handling or a slow steering response. • This vehicle is not designed t o pull a trailer o r t o be attached to a sidecar.

Genuine Yamaha Accessories Choos ing accessories for your vehicle is an important decision. Genuine Yamaha accessories, which are available only from a Yamaha dealer, have been designed, tested, and approved by Yamaha for use on your vehicle.

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Aftermarket Parts, Accessories, and Modificatio ns While you may find aftermarket products similar in design and quality to genuine Yamaha accessories, recognize that some aftermarket accessories or modifi cations are not suitable because of potential safety hazards to you or othe rs. Installing aftermarket products or having other modifications performed to you r vehicle that change any of the vehicle's design or operation characteristics can put you and others at greater risk of serious injury or death.

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You are responsible for injuries related to changes in the veh icle. Keep the followi ng guidel ines in mind, as well as those provided under "Loading" when mounting accessories . • Never install accessories or carry carg o that would impair the performance of your motorcycle. Carefully inspect the accessory before using it to make sure that it does not in any way reduce ground clearance or come rin g clearance, limit suspension travel, steering travel or contro l operation, or obscure lights or refl ectors. • Accessories fitted to the handlebar or the front fork area can create instabil ity due to improper weight distribution or aerodynamic changes. If accessories are added to the handlebar or front fork area, they must be as lightweight as poss ible and sho uld be kept to a minimum. • Bulky or large accessories may seriously affect the stabi lity of the motorcycle due to aerody2-4

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ill SAFETY INFORMATION Many companies with no connection to Yamaha manufacture parts and accessories or offer other modifications for Yamaha vehicles. Yamaha is not in a position to test the prod ucts that these aftermarket companies produce. Therefore, Yamaha can neither endorse nor recommend the use of accessories not sold by Yamaha or modifications not specifically recommended by Yamaha, even if sold and installed by a Yamaha dealer.

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namic effects. Wind may attempt to lift the motorcycle, or the motorcycle may become unstable in cross winds. These accessories may also cause instability when passing o r being passed by large vehicles. • Certain accessories can displace the operator from his or her normal riding position. This improper position limits the freedom of movement of the operator and may limit control ability, therefore, such accessories are not recomme nded. • Use caution when adding electri cal accessories. If electrical accessories exceed the capacity of the moto rcycle's electrical system, an electric failure cou ld result, which could cause a dangerous loss of lights or engine power. Aftermarket Tires and Rims The tires and rims that came with your motorcycle were designed to match the performance capabilities and to

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ill SAFETY INFORMATION provide the best combination of handling, braking , and comfort. Other tires, rims, sizes , and combinations may not be appropriate. Refer to page 7 -18 for tire specifications and more information on replacing your tires.

EAUU0030

Helmets Operating this ve hicle without an approved motorcycle helmet increases you r chances of a seve re head injury or death in the event of an accident. The majority of fatalities from motorcycle or scoote r accidents are the result of head injuries. The use of a safety hel met is the single most critical factor in the prevention or red uction of head inju ries.

Always select an approved motorcycle helmet Pay attention to th e following when choosing a motorcyc le helmet. • The helmet must meet the safety standard "TIS". • The helmet size must match the size of the rider's head. • Never subject a helmet to heavy shocks.

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Correctly helmet wearing

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Inco rrectly helmet wearing

Wearing the helmet correctly Always connect the chi n strap. In the case of an accident, the helmet has a much less chance of coming off if the chi n strap is connected. 2-5


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5PO_ F8 199_ FI book Page 6 Thursday , January 15,2009 {.I O PI'\"1

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& SAFETY INFORMATION Types of helmets and thei r usage • Half-type use only for riding at low speeds

• • FUll-type: use only for riding at low to mid-range speeds

• Full-face-type: use for riding at mid-range to high speeds

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DESCRIPTION EAU10410

left view

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4

6 7

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1. 2. 3. 4. 5. 6.

HeadlighUauxiliary lights (page 7-30, 7-33) Front tum signal lights (page 7-33) Convenience hook (page 4-10) Throttle stop screw (page 7-16) Owner's tool kit (page 7-1) Tail/brake light (page 7-31)

7. Rear tum signal lights (page 7-32) 8. Kickstarter (page 4-9) 9. Engine oil drain bolt A (page 7-9) 10. Engine oil drain bolt B (page 7-9) 11. V-belt case air filter element (page 7-13) 12. Air filter element (page 7-13)

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DESCRIPTION EAU 10420

Right view 1

2 3 4

5

6

7

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1, 2. 3. 4_ 5. 6. 7. 8.

Fuel tank cap (page 4-6) Fuse/starter relay (page 7-29) Storage compartment (page 4-11 ) Battery (page 7-28) Seat lock (page 4-9) Front brake fluid reservoir (page 7-22) Coolant reservoir (page 7-12) Dipstick (page 7-9)

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DESCRIPTION

)ls and instruments 1

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rake lever (page 4-6) rlCIebar switches (page 4-5)

luge (page 4-4) ;meIer (page 4-3) coolant temperature gauge/odometer (page 4-4) andlebar swrtches (page 4-5) rake lever (page 4-5) Nitchlsteering lock (page 4-1 )


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INSTRUMENT AND CONTROL FUNCTIONS To lock the steering

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Main switch/steering lock

ON All electrical circuits are supplied with power, and the engine can be started. The key cannot be removed. TIP ________~~~--~ The headlight, auxiliary lights, meter lighting and taillight come on automatically when the engine is started.

The main switch/steering lock controls the ignition and lighting systems, and is used to lock the steering, and is used to open the seat also. The variou s main switch positions are described below. TIP ______~~~--~~_ The main switch is equipped with a keyhole oover. (See page 4-2 for keyhole cover opening and dosing procedures.)

OFF All electrical systems are off. The key can be removed.

AWAANING Never tum the key to " OFP' or " LOCK" while the vehicle is moving. Otherwise the electrical system s will be switched off, which may result in lo ss of control or an accident.

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LOCK The steering is locked, and all electrical systems are off, The key can be removed.

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"""". 1. Tum the handlebars a1l lhe way 10 the left. 2. Push Ihe key in from the ~OFF" position, release it, and then tum it to "LOCK". 3. Remove the key.

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INSTRUMENT AND CONTROL FUNCTIONS

I To unlock the steering

tum the key to the lett to open the cov-

Keyhole cover

er.

2

To close the keyhole cover

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Insert the key and turn it to "OFF". 1. Ignition key 2 . Salely key

To open the keyhole cover

Insert the key head into the keyhole cover receptacle as shown, and then tum the key to the right to close the

cover.

Insert the key head into the keyhole cover receptacle as shown, and then

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INSTRUMENT AND CONTROL FUNCTIONS £AU""'"

Indicator and warning lights

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Engine trouble warning light "6" This warning light comes on if a problem is detected in the electrical circuit monitoring the engine. If this occurs, have a Yamaha dealer check the selldiagnosis system. The electrical circuit of the warning light can be checked by turning the key to "ON The warning light should come on for a few seconds, and then go off. If the warning light does not come on initially when lhe key is turned to ~ON", or if the warning light remains on, have a Yamaha dealer check the electrical circuit.

Speedometer 12

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1. Left-Ium signal indicatollight ".0-

2. Engine trouble warning light' 6 • 3. High beam indicator light "ro" " Do.U1I02O

Turn signal indicator light " ¢ 0" This indicator light flashes when the tum signal switch is pushed to the left or right. Uo.U110110

High beam indicator light" ro " This indicator light comes on when the high beam of the headlight is switched

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1. Speedometer 2. Speedometer noodle

The speedometer shows the riding speed. When the key is turned to "OW, the speedometer needle will sweep once across the speed range and then return to zero in order 10 test the electrical circuit.

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INSTRUMENT AND CONTROL FUNCTIONS Fuel gauge 1 2

np~~~~~~~~~~~~ Do not allow the fuel tank to empty itself completely.

Digital coolant temperature gauge/odometer

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1. Fucl gauge

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2. Fuel gauge needle

1 Digital cooIant lemperature gauge

3. Red 2:onc

2_ Digital odometer

The fuel gauge indicates the amount of fuel in the fuel tank. When the key is turned to kON ~, the fuel gauge needle will sweep once across the fuel level range and then return to "P' (Empty) in order to test the electrical circuit. The needle moves towards "E" as the fuel level decreases. When the needle reaches the red zone, approximately 1.0 L (0.26 US gal) (0.22 Imp.gal) remain in the fuel tank. If this occurs, refuel as soon as possible.

When the key is turned to kON", the display segments of the digital coolant temperature gauge will sweep once across the temperature range and then return to "C" in order to test the electrical circuit. The odometer shows the total distance traveled.

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Do not continue to operate the engine if it is overheating. 4-4

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INSTRUMENT AND CONTROL FUNCTIONS Handlebar switches Left

1:::---'::: ? 1. Dimmer switch " 101110 "

Tum signal switch "9/ 9" To signal a rig,t-hand tum, push this switch to " 0 ", To signal a left-hand lum , push this switch to ~ ¢ ". When released, the switch returns to the center posllion. To cancel the tum signal lights, push the switch in after it has returned to the center position.

2. Tum signal switch "0/0" 3. Horn switch " Ioo:r '

Right

Horn switch " Ioo:r " Press this switch to sound the hom . Start s witc h " (i)"

Push this switch while applying the front or rear brake to crank the engine with the starter. See page 6- 1 lor starting instructions prior to starting the engine.

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Dimmer switch " 10/ 10" Set this switch to MK) ~ for the high beam and to · .Y for the low beam.

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Front brake lever

1. Front brake lever

The front brake lever is located on the right handlebar grip. To apply the I ront brake, pull this lever toward the handlebar grip.

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INSTRUMENT AND CONTROL FUNCTIONS To install the fuel tank cap

Fuel tank cap

Rear brake lever

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./1 1 Rear brake lever

The rear brake lever is located on the left handlebar grip. To apply the rear brake, pull this lever toward the handlebar grip.

1. Fuel tank cap

a. Open. b. Close.

To remove the fuel tank cap 1. Open the seat. (See page 4-9.)

2. Tum the fuel lank cap counlerck>ckwise and pull it off.

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1. Insert the fuel tank cap into the tank opening and tum it clockwise until the ~ t:.. ~ marks on the cap and tank are aligned. 2. Close the seal. "WARNING Make sure that the fuel tank cap is properly closed after filling fuel. Leaking fuel is a fire hazard.

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INSTRUMENT AND CONTROL FUNCTIONS """''''2

Fuel

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Make sure there is sufficient gasoli ne in the tank. f WAH)$$l

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WARNING Gasoline and gasoline vapors are extremely flammable. To avoid fires and explosions and to reduce the risk of injury when refueling, follow these instructions.

1. Before refueling, tum off the engine and be sure that no one is sitting on the vehicle. Never refuel while smoking, or while in the vicinity 01 spar1
other sources of ignition such as the pilot lights of water heaters and clothes dryers. 2. Do not averiill the fuel lank. Stop fillin g when the fuel reaches the bottom of the filler tube. Because fuel expands 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 immediately_ NOTICE: Immediately wipe off spilled fuel with a clean, dry, soft cloth, since fuel may deteriorate painted surfaces or plastic parts. l.eAl OO"1 4. Be sure to securely close the fuel lank cap.

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WARNING Gasoline is poisonous and can cause injury or death. Hand~ gasoline with care. Never siphon gasoline by mouth. H you should swallow some gasoline or inhale a lot of gasoline vapor, or get some gasoline in your eyes, see your doctor immedi-

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ately. If gasoline spills on your skin, wash with soap and water. ff gasoline spills on your clothing, change your clothes.

Recommended fuel:

Regular unleaded gasoline or gasohol (91 min. pump octane) Fuel tank capacity: 4.8 L (1.27 US gal) (l .06 lmp.gal)

OTICE 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. Gasohol Gasohol is a mixture of unleaded gasoline and ethanol. Gasohol contains 90% gasoline and 10% ethanol which is called "E l 0". Yamaha products can use gasohol IE10] Octane 91 or higher. However,

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INSTRUMENT AND CONTROL FUNCTII

m filling with gasohol, cold engine rting may be difficult. Therefore, be e 10 follow the procedures in UStarta cold engine H

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ing gasohol may cause engine uble depending on the engine. If .ohol is used and engine trouble :urs, contact your Yamaha dealIS soon as possible_

Catalytic converter

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This model is equipped with a catalytic converter in the exhaust system.

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WARNING

The exhaust system is hot after operation. To prevent a fire hazard or burns: • Do not park the vehicle near possible fire hazards such as grass or other materials that easily burn. • Park the vehicle in a place where pedestrians or children are not likely to touch the hot exhaust system. • Make sure that the exhaust system has cooled down before doing any maintenance work. • 00 not allow the engine to idle more than a few minutes. long idling can cause a build-up of heat. http://www.motorcycle.in.th

Use only unleaded gasolin use of leaded gasoline will unrepairable damage to the co converter.

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INSTRUMENT AND CONTROL FUNCTIONS Kickstarter

To close the seat

Seal To open the seat 1. Place the motorcycle on the centerstand. 2. Insert the key into the main switch, and then tum it counterclockwise

1. Fold the seat down, and then push it down to lock it in place.

2. Remove the key from the main switch if the motorcycle will be left unattended.

np ____~~--~----~_ Make sure that the seat is properly secured before riding.

to "QPEW.

1. Kickstarter

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If the engine fails to start by pushing the start switch, try 10 start it by using the kickstarter. To start the engine, fold out the kickstarter lever, move it down lightly with your foot until the gears engage,

and then push it down smoothly but forcefully.

1. Seal lock 2. Seat

np ____~--~~--~~_ Do not push inward when turning the key. 3. Fold the seat up.


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INSTRUMENT AND CONTROL FUNCTIONS Helmet holders

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To release a helmet from a helmet holder Open the seat. remove the helmet from the helmet holder, and then close the seat.

Convenience hook

1. Corwenience hook

1. Helmel holder

The helmet holders are located under the seat.

. . WARNING • Do not exceed the load limit of 1.0 kg (2.2 Ib) for the conve-

To secure a helmet to a helmet holder 1. Open the seat. (See page 4-9.) 2. Attach a helmet to a helmet holder, and then securely close the seat. WARNING! Never ride with a helmet attached to the helmet holder, since the helmet may hit objects, causing loss of control and possibly an accident. IEWA,O'61 )

nience hook.

• Do not exceed the maximum load of 160 kg (353 Ib) for the motorcycle.


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INSTRUMENT AND CONTROL FUNCTIONS E C~ "'o""

Storage compartment

I. Storage compartment 2. Cover

There is a storage compartment equipped with a lid under the seat. (See page 4-9 for seat opening and closing procedures.)

. . WARNING • Do not exceed the load limit of 5.0 kg (11.0 Ib) for the storage compartment. • Do not exceed the maximum load of 160 kg (353Ib) for the vehicle.

Keep the following points in mind when using the storage compartment. • Since the storage compartment accumulates heat when exposed to the sun, do not store anything susceptible to heat insideil. • To avoid humidity from spreading th rough the storage compartment, wrap wet articles in a plastic bag before storing them in the compartment. • Since the storage compartment may get wet while the scooter is being washed, wrap any articles stored in the compartment in a plastic bag. • Do not keep anything valuable or breakable in the storage compartment. To store a helmet in the storage compartment, place the helmet upsidedown with the lront facing forward. 4 - 11

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• Some helmets cannot be stored in the storage compartment because 01their size or shape. • Do not leave your motorcycle unattended with the seat open.

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FOR YOUR SAFETY - PRE-OPERATION CHECKS

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Inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the Owner's Manual. EWA11151

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WARNING 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 Yamaha dealer. Before using this vehicle, check the following points: CHECKS

ITEM

- (~)

PAGE

Fuel

• Check fuel level in fuel tank. • Refuel if necessary. • Check fuel line lor leakage.

4-7

Engine oil

• Check oil level in engine, • II necessary, add recommended oil to specified level. • Check vehicle for oil leakage,

7-9

Final transmission oil

• Check vehicle for oil leakage.

7-1 1

Coolant

• Check coolant level in reservoir. • If necessary, add recommended coolant to specified level. • Check cooling system lor leakage.

7-12

Front brake

• • • • • • •

7-22

,

Check operation. If soft or spongy, have Yamaha dealer bleed hydraulic system. Check brake pads for wear. Replace il necessary. Check fluid level in reservoir. II necessary, add recommended brake fluid to specified level. Check hydraulic system for leakage.


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Page 2 Thursday, January 15,2009 110 PM

FOR YOUR SAFETY - PRE-OPERATION CHECKS ITEM

CHECKS

Rear brake

Throttle grip

• Make sure that operation is smooth. • Check cable free play. • If necessary. have Yamaha dealer adjust cable free play and lubricate cable and grip housing.

Control cables

• Make sure that operation is smooth. • Lubricate if necessary.

Wheels and tires

• • • •

Brake levers

• Make sure that operation is smooth. • Lubricate lever pivoting pOints if necessary.

7-25

Centerstand, sidestand

• Make sure that operation is smooth. • Lubricate pivots if necessary.

7-25

Chassis fasteners

• Make sure that all nuts, bolts and screws are properly tightened. • Tighten if necessary.

-

Instruments, lights, signals and switches

• Check operation. • Correct if necessary.

-

Check operation_ Lubricate cable if necessary_ Check lever free play, Adjust if necessary.

7-21,7-24

Check for damage. Check tire condition and tread depth. Check air pressure. Correct if necessary.

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• • • •

5-2


7-17,7-24

7-24

7-18,7-20

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OPERATION AND IMPORTANT RIDING POINTS EAVT1IOI

Starling a cold engine Read the Owner's Manual carefully to become familiar with all controls. If there is a control or function you do not understand, ask your Yamaha dealer.

A

WARNING Failure to familiarize yourseH with the controls can lead to loss of control, which CQuid cause an accident or injury.

See page 6-3 for engine break-in instructions prior to operating the vehicle for the first time. 1. Turn the key to "ON", 2. Close the throttle grip completely.

1. Start switch -6)-

3. Start the engine by pushing the start switch or by kicking the kickstarter, while applying the front or rear brake. NOTICE: For maximum engine life, never accelerate hard when the engine is

cold!

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4. If the engine fail s to start by pushing the start switch, release the switch, wait a few seconds, and then try again. Each starting attempt should be as short as possible to preserve the battery. Do not crank the engine more than 5 seconds on anyone attempt. If the engine does not start with the starter motor, try using the kickstarter.

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OPERATION AND IMPORTANT RIDING POINTS fAtu....

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Starting off

Acceleration and deceleration

TIP Before starting off, allow the engine to

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Braking Front

1

warm up.

1. While pulling the rear brake lever with your left hand and hokling the

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grab bar with your right hand, push the scooter off the centerstand. 2. Sit astride the seal, and then adjust the rear view mirrors. 3. Switch the tum signals on.

4. Check for oncoming traffic, and then slowly turn the throttle grip (on the right) in ord er to take off. 5. Switch the turn signals off.

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1. Throttle grip

The speed can be adjusted by opening and closing the throttle. To increase the speed, lurn the throttle grip in direction (a). To reduce the speed , lum the throttle grip in direction (b).

Rear

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A •

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• •

WARNING Avoid braking hard or suddenly (especially when leaning over to one side), otherwise the scooter may skid or overturn. Railroad crossings, streetcar rails, iron plates on road construction sites, and manhole covers become extremely slippery when weL Therefore, slow down when approaching such areas and cross them with caution. Keep in mind that braking on a wet road is much more difficult. Ride slowly down a hill, as braking downhill can be very diffi-

Tips for reducing fuel consumption Fuel consumption depends largely on your riding style. Consider the following tips to reduce fuel consumption: • Avoid high engine speeds during acceleration. • Avoid high engine speeds with no load on the engine. • Tum the engine oft instead of letting it idle for an extended length of time (e.g., in traffic jams, at traffic lights or at railroad crossings).

cult. 1. Close the throttle completely.

2. Apply both front and rear brakes simultaneously while gradually increasing the pressure.

6-3


Engine break-in There is never a more important period in the life of your engine than the period between 0 and 1000 km (600 mil. For this reason, you should read the following material carefully. Since the engine is brand new, do not put an excessive load on it for the first 1000 km (600 mil. The various parts in the engine wear and polish themselves to the correct operating clearances. During this period, prolonged full-throttle operation or any condition that might result in engine overheating must be avoided.

"

OPERATION AND IMPORTANT RIDING POINTS 0--150 km (C}-9() mil

Avoid prolonged operation above 314 throttle.

150-500 km (90-300 mil

150-500Km

1/2

Avoid prolonged operation above 113 throttle . After every hour of operation, stop the engine, and then let it cool for five to len minutes. Vary the engine speed from time to lime. Do not operate the engine al one set throttle position.

Avoid prolonged operation above 1/2 throttle. Rev the engine freely through the gears, but do not use full throttle at any time. 500-1000 km (300-600 mil

~ 500- 1 000Km~ , : .... i I 3/4


1000 km (600 mil and beyond

~

1000Km-

I Avoid prolonged full-throttle operation. Vary the engine speed occasionally. NOTICE: After 1000 km (600 mil of operation, the engine oil must be changed. the oil filter cartridge or element replaced, and the oil strainer cleaned. It any engine trouble should occur during the engine break-in period, immediately h\ve a Yamaha dealer check the vehicle.

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Page 5 Thursday , January 15,2009 110 PM

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OPERATION AND IMPORTANT RIDING POINTS

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EAU17213

Parking When parking, stop the engine, and then remove the key from the main switch. EWA10311

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WARNING • Since the engine and exhaust system can become very hot, park in a place where pedestrians 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.

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General note Much can be gained from the correct use and maintenance 01a motorcycle.

1. THE CUSTOMERS CAN USE THE FULLEST POTENTIAL OF YAMAHA MOTORCYCLES

2. A MOTORCYCLE CAN KEEP ITS PERFORMANCE

CAPABILITY FOR A lONGEATIME Compariso n of wear on engine parts

(piston, piston ring. cylinder, etc.) HX)'.

Wilt! maintenance

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boring. piston ring change, etc.

OPERATION AND IMPORTANT RIDING POI 3. FUEL COST AND REPAIR EXPENSES CAN BE KEPTTO A MIN IMUM

Distance covered (km)

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Cu stomer·s running cost (fuel cosl plu s maintenance and repair e)(pen ses)

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PERIODIC MAINTENANCE AND ADJUSTMENT Periodic inspection, adjustment , and lubrication will keep your vehicte in the salest and most efficient condition possible. Safety is an obligation of the vehicle owner/operator. The most important points of vehicle inspection. adjustment , and lubrication are explained on the following pages. The intervats given in the periodic maintenance and lubrication chart should be simply considered as a general guide under normal riding conditions. However, depending on the weather, terrain, geographical location. and individual use, the maintenance intervals may need to be shortened. ..

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AWAANING Failure to properly maintain the vehicle or performing maintenance activities 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.

Owner's tool kit

AWAANING Turn off the engine when performing maintenance unless otherwise specified. • A running engine has moving parts that can c~tch on body parts or clothing and e~ctrical parts that can cause shocks or fires. • Running the engine while servicing can lead to eye injury, burns, fire, or carbon monoxide poisoning - poss ibly leading to death. See page 2-2 for more information about carbon monoxide.

1. Owner's tool kH

The owner's 1001 kil is located under the passenger seal. (See page 4-9.) The service infonnalion included in this manual and the lools provided in the owner's tool kit are intended to ' assist you in the periormance of preventive maintenance and minor repa irs. However. additional tools such as a torque wrench may be necessary to periorm certain maintenance work correctly. TlP _ _ _ _ _ _ __ __

If you do not have the tools or experience required for a particular job, have a Yamaha dealer perlonn it for you. 7-1


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PERIODIC MAINTENANCE AND ADJUSTMENT EAU46880

TIP ______________________

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• The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead. • From 16000 km , repeat the maintenance intervals starting from 4000 km. • Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. EAU46930

Periodic maintenance chart for the emission control system ODOMETER READING (km) NO.

ITEM

CHECK OR MAINTENANCE JOB

1000 1 2

3 4

5 6

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· ·

· · ·

Fuel line

• Check fuel and vacuum hoses for cracks or damage.

Spark plug

• Check condition. • Clean and regap.

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• Replace. Valves

• Check valve clearance. • Adjust.

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Carburetor

• Adjust engine idling speed.

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Muffler and exhaust pipe

• Check the screw c1amp(s) for looseness.

Air induction system

• Check the air cut·off valve, reed valve, and hose for damage. • Replace any damaged parts if necessary.

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ANNUAL

7000 10000 13000 CHECK oJ

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5POJ8199_ELbook Page 3 Thursday, January 15,2009 1:10 PM

PERIODIC MAINTENANCE AND ADJUSTMENT EAUU0091

General maintenance and lubrication chart ODOMETER READING (km) ITEM

NO.

1

Air filter element

2

V-belt case air filter element

3 4

5 6 7 8

9

10 11

CHECK OR MAINTENANCE JOB

• Check condition.

1000

4000

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7000 10000 13000

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ANNUAL CHECK

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• Replace.

Every 16000 km (10000 mil

• Clean.

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Battery

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• Check battery voltage. • Change battery if necessary,

Front brake

• Check operation, fluid level and vehicle for fluid leakage.

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Rear brake

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Whenever worn to the limit

• Replace brake pads, • Check operation and adjust brake lever free play,

Brake hose

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Whenever worn to the limit

• Replace brake shoes,

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Every 4 years

• Replace, Wheels

• Check runout and for damage,

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Wheels

• Check runout, spoke tightness and for damage. • Tighten spokes if necessary,

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Tires

• • • •

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Check tread depth and for damage. Replace if necessary, Check air pressure, Correct if necessary,

Wheel bearings

• Check bearing for looseness or damage.

Swingarm

• Check operation and for excessive play, • Lubricate with lithium-soap-based grease.

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Page4 Thursday , January 15, 2009 I 10 PM

PERIODIC MAINTENANCE AND ADJUSTMENT NO.

12 13

· ·

14 15 16

· ·

17 18 19

· ·

20 21

·

22

·

23 24

25

ITEM Steering bearings

CHECK OR MAINTENANCE JOB • Check bearing play and steering for roughness.

ODOMETER READING (km)

1000

4000

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• Lubricate with lithium-soap-based grease.

7000 10000 13000 .,j

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Chassis fasteners

• Make sure that all nuts, bolts and screws are properly tightened.

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Sidestand, centerstand

• Check operation. • Lubricate.

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Front fork

• Check operation and for oil leakage.

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Shock absorber assemblies

• Check operation and shock absorbers lor oil leakage.

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Engine oil

• Change, • Check oil level and vehicle for oil leakage,

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Engine oil strainer

• Clean,

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Cooling system

• Check coolant level and vehicle for coolant leakage.

" " "

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• Change. Final transmission oil

• Check vehicle for oil leakage.

V-belt

• Check for damage and wear.

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• Check operation.

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Moving parts and cables

• Lubricate.

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.

Lights, signals and switches

• Check operation. • Adjust headlight beam.

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PERIODIC MAINTENANCE AND ADJUSTMENT EAUI 8660

TIP ______

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• The air filter needs more frequent service if you are riding in unusually wet or dusty areas. • Hydraulic brake service • Regularly check and, if necessary, correct the brake fluid level. • Every two years replace the intemal components of the brake master cylinder and caliper, and change the brake fluid. • Replace the brake hoses every four years and if cracked or damaged.

+-


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PERIODIC MAINTENANCE AND ADJUSTMENT Removing and installing cowlings and panels

The cowlings and panels shown need to be removed to per10rm some of the

maintenance jobs described in this chapter. Refer to this section each time a cowling or panel needs to be removed and installed.

To install the cowling Place the cowling in the original position, and then install the screws.

CowlingC To remove the cowling

Cowlings A and B To remove one of the cowlings Remove the cowling screws, and then pull the cowling off as shown.

1. Remove cowlings A and B. (See page 7-6.) 2. Remove the bolts and screws shown, and then take the cowling off.

1. Cowling A

2. Cowling C 3. Panel A

2 --_--'

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ZAUU0376

1. Cowling A

1. Cowling C

2. Screw (x7)

2. Screw (~) 3. Bolt ( ~1 )

1. Cowling B 2. Panel B 7-6


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PERIODIC MAINTENANCE AND ADJUSTMENT Panels A and B

To remove one of the panels

To install the panel Place the panel in the original position , and then install the screw.

Remove the screw, and then pull the panel off as shown.

I. Screw (x4)

To install the cowling 1. Place the cowling in the original position, and then install the bolts and screws. 2. Inslall cowlings A and B.

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2. Screw (x3)

7-7


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PERIODIC MAINTENANCE AND ADJUSTME

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stead, have a Yamaha dealer ( the vehide.

Checking the spark plug The spark plug is an important engine

2. Check the spark plug for elec erosion and excessive carbl other deposits, and replace necessary.

component, which is easy to check. Sinee heat and deposits will cause any spark plug to slowly erode, the spark plug should be removed and checked in accordance with the periodic maintenance and lubrication chart. In addition, the condition of the spark plug can reveal the condition of the engine_

I

-4

To remove the spark plug 1. Place the vehicle on the centerstand. 2. Remove panelS. (See page 7-6.) 3. Remove the spark plug cap.

Specified spark plug: NGKlCR7E 1. Spark plug wrench

4. Remove the spark plug as shown, with the spark plug wrench included in the owner's tool kit.

To check the spark plug

To install the spark plug 1. Measure the spark plug gap ~

wire thickness gauge and, if essary, adjust the gap to spe< tion.

1. Check thai the porcelain insulator around the center electrode of the spark plug is a medium-to-light Ian (the ideal color when the vehicle is ridden normally).

np, __~~~____~____ If the spark plug shows a distinctly different color, the engine could be operating improperly. Do not attempt to diagnose such problems yourself. In1. Sparl!.plug


1

I. Spark plug gap

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PERIODIC MAINTENANCE AND ADJUSTMENT ~,

Spark plug gap: 0.7-0.8 mm (0.027-0.031 in)

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2. Clean the surlace 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 tighten it to the specifi ed torque. TIghtening torque: Spark plug: 12.5 Nm (1.25 m·kgl, 9.0 ft·fbl) TIP ______- -______- -

Engine oil and oil strainer The engine 'oil level should be checked before each ride. In addition, the oil must be changed and the oil strainer cleaned at the intervals specified in the periodic maintenance and lubrication chart.

3. Wait a few minutes until the oil setties, remove the oil filler cap, wipe the dipstick dean, insert it back into the oil filler hole (without screwing it in), and then remove it again to check: the oil level.

To check the engine oil level 1. Place the vehicle on the centerstand. A slight tilt to the side can result in a false reading. 2. Start the engine, warm it up for several minutes. and then tum it off.

If a torque wrench is not available when

1. Dipstick

installing a spark plug, a good estimate of the correct torque is 1/4-1 /2 tum past finger tight. However, the spark plug should be tightened to the specified torque as soon as possible.

2. Maximum level mar1\:

3. Minimum leve! miU1<.

TlP ______-

______-

__-

The engine oil should be between the minimum and maximum level marks.

4. Install the spark plug cap. 5. Install the panel.

4. If the engine oil is at or below the minimum level mark, add sufficient oil of the recommended type to raise it to the correct level.

1. OiIliler cap

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PERIODIC MAINTENANCE AND ADJUSTMENT 5. Insert lhe dipstick into the oi ll~ ler hole, and then tighten the oil liller

cap.

dra in bolt, the O·ring , compres· s ion s pring , and oil strainer will fall out. Take care nol to lose these parts. ((CAI100'1

To change the engine oil and clean the oil strainer 1. Start the engine, warm it up for several minutes, and then tum it off. 2. Place an oil pan under the engine

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10 collect the used oil.

1. Strainer 2. Compression spring

2

1

I. Engine Oil drain bolt A

2. Engine Oil drain bolt B

3. Remove the engine oil filler cap and drain bolt A to drain the oil from the crankcase. NOnCE: When removing the eng ine oil

6. Install the engine oil strainer, compression spring , a -ring and engine oil drain bolt, and then tighten the drain bolt to the specified torque.

np ____~~~~~----~ Make sure that the O-ring is property seated. Tightening torque: Engine oil drain bolt A: 20 Nm (2.0 m .kgf, 15 ft·lbf) Engine oil drain boll B: 20 Nm (2.0 m.kgf, 15 ft.lbt)

7. Refill with the specified amount of

3. ().ring

the recommended engine oil, and then install and tighten the oil filler

np __~__~__- -__--~

cap.

When only changing the engine oil, remove drain bolt A. When changing the

engine oil and cleaning the engine oil strainer. remove drain bolt B also. 4. Clean the engine oil strainer with solvent, and then check it for damage and replace it if necessary. 5. Check the O-ring for damage and replace it if necessary. 1- 10 http://www.motorcycle.in.th

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Recommended engine oil: See page 9-1. Oil quantity: 0.80 l (0.85 US qt) (0.70 tmp.ql)

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PERIODIC MAINTENANCE AND ADJUSTMENT np ______

~~~~----

Be sure to wipe off spi11ed oil on any parts after the engine and exhaust system have cooled down.

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• In order to prevent clutch slippage (since the engine oil also lubricates the clutch), do not m ix any chemical additives. Do not use oils with a diesel specification of " CD" or oils of a higher quality than specified. In addition, do not use oils labeled " ENERGY CONSERVING II" or higher. • Make sure that no foreign material enters the crankcase. 8. Start the engine, and then let it idle for several minutes while checking it for oil leakage. If oil is leaking. immediately turn the engine off and check for the cause. 9. Tum the engine off, and then check the oil level and correct it if

necessary.

Final transmission oil

1. Anal transmission oil d rain bah 1. Final transmission oil 'iller cap

The final transmission case must be checked for oil leakage before each ride. If any leakage is found, have a Yamaha dealer check and repair the scooter. In addition. the final transmission oil must be changed as follows at the intervals specified in the periodic maintenance and lubrication chart. 1. Start the engine, warm up the final transmission oil by riding the scooter for severaf minutes, and then stop the engine. 2. Place the scooler on the centerstand. 7-11


3. Place an oil pan under the fin al transmission case 10 collect the used oil. 4. Remove the final transmission oil filler cap and final transmission drain bolt to drain the oil from the final transmission case. 5. Install the final transmission oil drain bolt, and then tighten it to the specified torque. Tightening tOfque: Final transmission oil drain bolt: 22 Nm (22 m·kgf. 162 1t·1:>f)

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.

PERIODIC MAINTENANCE AND ADJUSTMENT 6. Refill with the specified amount of the recommended final transmission oil, and then install and tighten the oil filler cap. WARNING! Make sure that no foreign material enters the final transmission case. Make sure that no oil gets on the tire or wheel. {EWA1I 3I1 1

The coolant level should be checked before each ride. In addition. the coolant must be changed at the intervals specified in the periodic maintenance and lubrication chart.

Recommended final transmi ssion oil:

To check the coolant level 1. Place the vehicle on the centerstand.

See page 9-1.

Oil quantity: 0. 12 L (0.13 US qt, 0.1 1 Imp.qt)

7. Check the final transmission case for oil leakage. If oil is leaking, check for the cause.

Coolant

TIP .,,-_ _ _ __ _ _ ____

• The coolanllevel must be checked on a cold engine since the level varies with engine temperature. • Make sure that the vehicle is positioned straight up when checking the coolant level. A slight tilt to the side can result in a false reading.

2. Check the coolant level in the coolant reservoir.

np --~~~~~~~----c The coolant should be between the minimum and maximum level marks.

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1. Maximum level mark 2. Minimum level mark

3. If the coolant is at or below the minimum level mark, remove panel B (See page 7-6.), remove the reservoir cap. add coolant 10 the maximum level mark, and then install the reservoir cap and the panel. WARNING! Never anempt to remove the radiator cap when the engine is haL [EWA10Je l[ NOTICE: If coolant is not available, use distilled water or soft tap water instead. Do not use hard water or salt w ater since it is harmful to the engine. If water has been u sed instead of cool-

+-

PERIODIC MAINTENANCE AND ADJUSTMENT ant, replace it with coolant as soon as possible, otherwise the cooling system will not be

protected against Irost and corrosion. If water has been added to the coolant, have a Yamaha dealer cheek the anti· freeze content of the coolant as soon as possible, otherwise the effectiveness of the coolant will be reduced. IECIo.l""~

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• The radiator fan switches on when the engine is started and switches off when the engine is stopped.

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Air filter and V-belt case air filter elements

tervals specified in the periodic mainte-

The air filter element should be checked and replace if necessary and the V-belt case air filter element should be cleaned at the intervals specified in the periodic maintenance and lubrication chart. Service the air filter elements more frequentty if you are riding in unusually wei or dusty areas.

nance and lubrication chart. Have a Yamaha dealer change the coolant. WARNING ! Never attempt to remove the radiator cap when the engine is hot_ I[W~'O>&'I

Checking and replacing the air filter element 1. Place the vehicle on the centerstand.

• If the engine overtleals, see page 7-35 for furth er instructions. Changing the coolant The coolant must be changed at the in-

I. CooIan\ rasetVOir cap

Coolant reservoir capacity (up to the maximum tevel mark): 0.25 l (0.26 US qt) (0.22 Imp.ql) 1. Air tiller case coyer 2. Screw (~6)

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PERIODIC MAINTENANCE AND ADJUSTMENT

! 2. Remove panel A. (See page 7-6 for panel removal and installation procedures.) 3. Remove the air filter case cover by removing the screws. 4. Remove the air filter element by pulling it out.

1 1. Air filter element (Wet type)

6. Place the air fiher element in its original position. 7. Install the air filter case cover by installing the screws. 8. Install the panel.

,

® 1. Air fiHer element (Wet type)

5. Check the air filter element for excessive dirt or damage and replace it if necessary.

1. V-be1t case air filter cover 2. Bolt (x4)

3. Remove the element by pulling it out.

Cleaning the V-belt case air fitter element 1. Place the vehicle on the centerstand. 2. Remove the V-belt air filter case cover by removing the bolts. 1. V-belt air filter eiemeol

7-14


PERIODIC MAINTENANCE AND ADJUSTMENT np ~__~~~~~~~~

The element should be wet but not dripping. Recommended oil:

Yamaha foam air filter oil or other quality foam air filter oil 7. Install the element into the filter

case. 4. Clean the element with solvent, and then squeeze the remaining solvent out. 5. Check the element for damage and replace it if necessary. 6. Apply oil of the recommended type to the entire surface of the element, and then squeeze the excess oil out. WARNING! Use only a dedicated parts cleaning solvent. To avoid the risk of fire or explosion, do nol use gasoline or solvents with a low flash point. [EW~'
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8. Place the air filter case cover in its original position, and then install the bolls. NOTICE: Make sure that each filter element is properly seated in its case. The en-

1. Air filter check hose 2. Clamp

gine should never be operated without the filter elements installed, otherwise the piston(s) andlor cylinder(s) may become excessively worn. lle~1om1 1 Cleaning the air fiher check hose and caps 1. Check each cap at the bottom left and right side of the air filler case and the hose at the bottom of the V-belt case for accumulated dirt or waler. 7· 15


1. Check hose 2. Clamp

2. If dirt or water is visible, remove the cap or hose, clean it, and then install it.

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Adjusting the carburetor The carburetor is an important part of the engine and requires very sophisticated adjustment. Therefore. most carburetor adjustments should be left to a Yamaha dealer. who has the necessary professional knowledge and experience. The adjustment described in the following section, however, may be serviced by the owner as part of rou tine maintenance.

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The carburetor has been set and extensively tested at the Yamaha factory. Changing these settings without sufficient technical knowledge may result in poor performance of o r damage to the engine.

Adjusting the engine idling speed The engine idling speed must be checked and, if necessary, adjusted as follows at the intervals specified in the periodic maintenance and lubrication chart. The engine should be warm before making this adjustment.

TlP _ _ _ _ _ _ _ _ _

5. Remove the rubber cap and insert a Phillips screwdriver into the thronle stop screw hole. 6. To increase the engine idling speed, tum the screw in direction (a). To decrease the engine idling speed, tum the screw in direction (b).

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• The engine is warm when it quickly responds to the throttle. • A diagnostic tachometer is needed to make this adjustment.

1. Open the seat. (See page 4-9 lor seat opening and closing procedures.) 2. Remove panel B. (See page 7-6 lor panel removal and installation procedures.) 3. Attach the tachometer to the spa(\( plug lead. 4 . Check the engine idling speed and, if necessary, adjust it to specification as follows. 7·16


1. Th rottle stop screw

Engine idling speed: 1400-1600 r/min

TlP _~~~~~~~~

If the specified idling speed cannot be obtained as described above, have a Yamaha dealer make the adjustment. 7. Install the panel and close the seal.

PERIODIC MAINTENANCE AND ADJUSTMENT ( A U~"'7~

Adjusting the throttle cable free play

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2. To increase the IhroWe cable free play, tum the adjusting nut in direction (a). To decrease the throt-

tle cable free play, tum the

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1. loosen the locknut.

adjusting nut in direction (b). 3. Tighten the locknut.

2

1. Thronle cable free play adjusting nut

2. Locknut

3. Cable cover c. ThroCUe cable free play

The throttle cable free play should measure 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, adjust it as follows.

TIP _ _--,--,_ _ _ _ _ __ The engine idling speed must be correctly adjusted before checking and adjusting the throttle cable free play. 7-17


EAU',.., Valve clearance The valve clearance changes with use,

resulting in improper air-fuel mixture and/or engine noise. To prevent this from occurring, the valve clearance must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart.

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! Tires To maximize the perfonnance, durability, and safe operation of your motorcycle, note the following points regarding the specified tires.

Tire air pressure The ti re air pressure should be checked and, if necessary, adjusted before each ride. EV/Al ",",'

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WARNING

Operation of this vehicle with improper tire pressure may cause severe injury or death from loss of control. • 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 adjusted in accordance with the riding speed and with the total

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weight of rider, passenger, cargo, and accessories approved for this model. Tire air pressure (measured on cold

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WARNING

Never overload your vehicle. Operation of an overloaded vehicle could cause an accident.

tires): Up to 90 kg (198Ib): Front: ' 200 kPa (2.00 kgflcm 2• 29 psi) Rear: 225 kPa (2.25 kgflcm 2, 33 psi) 90 kg (l98lb) to ma xi mum load: Front: 200 kPa (2.00 kgflcm 2, 29 psi) Rear: 225 kPa (2.25 kgflcm>', 33 psi)

Maximum load': 160 kg (353 Ib) Total weight of rider. passenger, cargo and accessories

7" http://www.motorcycle.in.th

Tire inspection

+1. Tire sidewall

2. Ti re wear indicator 3. Tire tread depth

The tires must be checked before each ride. If the tire shows crosswise lines (minimum tread depth), if the tire has a nail or glass fragments in it. or if the sidewall is cracked, have a Yamaha dealer replace the tire immediately.

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PERIODIC MAINTENANCE AND ADJUSTMENT Minimum tire tread depth (front and rear): 1.0 mm (0.04 in)

TIP -0----:---:-:---::-::---::-----;:::;The tire tread depth limits may differ from country to country. Always comply with the local regulations.

Front tire: Size: 70190-14MIC 36P Manufacturer/model:

IAC/NF59E, (TUBElESS) DUNLOPID 11 0M,DllOL Rear tire: Size: 80190-16MIC 48P Manufacturer/mode l: IAC/NR76E, (TUBELESS)

Tire information

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This motorcycle is equipped with tube tires.

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WARNING The front and rear tires should be of the same make and design, otherwise the handling characteristics of the vehicle may be different, which could lead to an accident After extensive tests, only the tires listed below have been approved for this model by Yamaha Motor Co., Ltd.

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WARNING • It is dangerous to ride with a worn-out tire. When a tire tread begins to show crosswise lines, have a Yamaha dealer replace the tire immediately. • The replacement of all wheeland brake-related parts, including the tires, should be len to a Yamaha dealer, who has the necessary professional knowledge and experience.


• It is not recommended to patch a punctured tUbe. If unavoid· able, however, patch the tube very carefully and replace it as soon as possible with a highquality product.

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PERIODIC MAINTENANCE AND ADJUSTMENT Wheels To maximize the perfonnance, durability, and safe operation of your motorcycle, note the following points regarding the specified wheels. • The wheel rims should be checked lor cracks, bends or warpage, and the spokes for looseness (for spoke wheel model) or damage before each ride. II any damage is found, have a Yamaha dealer replace the wheel. Do not attempt even the smallest repair to the wheel. A deformed or cracked wheel must be replaced. • The wheel should be balanced whenever either the tire or wheel has been changed or replaced. An unbalanced wheel can result in poor performance, adverse handling characteristics, and a shortened tire life.

• Ride at moderate speeds after changing a tire since the tire surface must first be "broken in" for it to develop its optimal characteristics.

Checking the front brake lever free play

There should be no free play at the brake lever end. If there is free play, have a Yamaha dealer inspect the brake system. . . WARNING A soft or spongy feeling in the brake lever can indicate the presence of air in the hydraulic system. tf there is air in the hydraulic system, have a Yamaha dealer bleed the system before operating the vehicle. Air in the hydraulic system will diminish the braking performance, which may re7-20

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PERIODIC MAINTENANCE AND ADJUSTMENT suit in loss of control and an accide nt.

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Adjusting the rear brake lever free play

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1. Rear brake IeVCf free play

The brake lever free play should measure 10.0-20.0 mm (0.394-0.787 in) as shown. Periodically check the brake lever free play and. if necessary, adjust it as follows. To increase the brake lever free play, lum the adjusting nut at the brake shoe plate in direction (a). To decrease the brake lever free play, tum the adjusting nul in direction (b). http://www.motorcycle.in.th

1_ Rear brake lever free play adjusting n

""WARNING H proper adjustment cannot I tained as described, have a Vi dealer make this adjustment.

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Checking the front brake pads and rear brake shoes

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

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

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Checking the brake fluid level

Rear brake shoes

Front brake pads

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1. Minimum level mark

-@ 1. Brake shoe wear indicator 2. Brake shoe wear limit line

out having to disassemble the brake. To check the brake pad wear, check the wear indicator grooves. If a brake

The rear brake is provided with a wear indicator, which allows you to check the brake shoe wear without having to disassemble the brake. To check the brake shoe wear, check the position of the wear indicator while applying the brake. If a brake shoe has wom to the point that the wear indicator reaches the wear limit line, have a Yamaha dealer replace the brake shoes as a

pad has worn to the point that the wear

set.

1. Brake pad wear indicator groove (x2)

Each Iront brake pad is provided with wear indicator grooves, which allow you to check the brake pad wear with-

Insufficient brake fluid may allow air to enter the brake system, possibly causing it 10 become ineffective. Before riding, check that the brake fluid is above the minimum level mark and replenish if necessary. A low brake fluid level may indicate wom brake pads and/Of brake system leakage. If the brake fluid level is low, be sure to check the brake pads fOf wear and the brake system lor leakage. ObselVe these precautions:

indicator grooves have almost disap7-22

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• When checking the fluid level, make sure that the top 01 the master cylinder is level by turning the handlebars. • Use only the recommended quality brake fluid, otherwise the rubber seals may deteriorate, causing leakage and poor braking performance.

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PERIODIC MAINTENANCE AND ADJUSTMENT • As the brake pads wear, it is nor-

mal for the brake fluid level to gradually go down. However, if the brake fluid level goes down suddenly, have a Yamaha dealer check the cause.

Recommended brake lIuid: DOT 4

• Refill with the same type of brake fluid. Mixing fluids may result in a harmful chemical reaction and lead to poor braking performance. • Be careful that water does nol enter the master cylinder when refitting. Water will significantly lower the boiting point of the flui d and may result in vapor lock. • Brake fluid may deteriorate painted surfaces or plastic parts. Always clean up spilled fluid immediately.

7·23


Changing the brake fluid Have a Yamaha dealer change the brake fluid at the intervals specified in the TIP after the periodic maintenance and lubrication chart. In addition. have the oil seals 01 the brake master cylinder and caliper as well as the brake hose replaced at the intervals listed below or whenever they are damaged or leaking. • Oil seals: Replace every two years. • Brake hose: Replace every four years.

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I Checking the V-belt The V-be" must be checked and replaced by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart

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Checking and lubricating the throttle grip and cable

The operation of all control cables and

The operation of the throttle grip should be checked before each ride. In addition, the cable should be lubricated at the intervals specified in the periodic maintenance chart.

the condition of the cables should be checked before each ride, and the cables and cable ends should be lubricated jf necessary. If a cable is damaged

or does not move smoothly, have a yamaha dealer check or replace it. WARNING! Damage to the outer sheath may interfere with proper cable operation and will cause the inner cable to rust. Replace a damaged cable as soon as possible to prevent unsafe conditions. IEWA 10721 J

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Recommended lubricant: Engine oil

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Checking and lubricating the cables

7-24


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PERIODIC MAINTENANCE AND ADJUSTMENT ~AV232')

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Lubricating the front and rear brake levers

Recommended lubricant:

lithium-soap-based grease

,

The pivoting points of the front and fear brake levers must be lubricated at the intervals specified in the periodic maintenance and lubrication chart.

Checking and lubricating the centerstand and sidestand

The operation of the centerstand and sidestand should be checked before each ride , and the pivots and metal-Iometal contact surfaces should be lubri cated if necessary.

A

WARNING H the centerstand or sidestand does not move up and down smoothly, have a Yamaha dealer check or repair il Otherwise, the centerstand or sidesland could contact the ground and distract the operator, resulting in a possibte loss of control.

I 7-25

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PERIODIC MAINTENANCE AND ADJUSTMENT Recommended lubricant: Ulhium-soap-based grease

Checking the front fork The condition and operation of the front lork must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart.

To check the condition Check the inner tubes for scratches, damage and excessive oil leakage. To check the operation 1. Place the vehicle Ofl a level surface and hold it in an upright position. WARNING! To avoid injury, securely support the vehicle so there Is no danger of it falling

over. lI',""I075'1 2. While applying the front brake, push down hard on the handlebars several times 10 check if the front fork compresses and rebounds smoothly.

'-26 http://www.motorcycle.in.th

If any damage is found or the front fork does not operate smoothly, have 8 Yamaha dealer check or re-

pair it.

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SPO]& I99 . F. l. book Pise 27 1'bunoday Ja..."ary IS , 2009 u n I'M

PERIODIC MAINTENANCE AND ADJUSTMENT Checking the steering Worn or loose steering bearings may cause danger. Therefore, the operation of the steering must be checked as follows at the intervals specified in the pe.riodic maintenance and lubrication

2. Hold the lower ends of the front fork legs and

try to move them for-

ward and backward. II any free play can be felt, have a Yamaha dealer check or repair the steering.

1>

The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrica-

tion chart II there is play in the wheel hub or if the wheel does not tum smoothly, have a Yamaha dealer

chart.

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Checking the wheel bearings

check the wheel bearings.

1. Place a stand under the engine to raise the front wheel off the ground. (See page 7-25 for more information.) WARNING! To

+-

avoid injury, securely support the vehicle so there is no danger of It falling over. I(WA, 01$'1

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7-27


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I Battery This model is equipped with a VRLA (Valve Regulated Lead Acid) battery. There is no need to check the electrolyte or to add distilled water. However, the battery lead connections need to be checked and, if necessary, tightened.

ways shield your eyes when working near batteries. In case of contact, administer the following FIRST AID. • EXTERNAL: Flush with plenty

of water. • INTERNAL: Drink large quantities of water or milk and immediately call a physician. • EVES: Rush with water for 15 minutes and seek prompt

medical attention.

1. Batteey band

• Batteries produce explosive hy-

drogen gas. Therefore, keep sparks, flames, cigarettes, etc., away from the battery and provide sufficient ventilation when 1 Ba1tery cover

2. Screw (x2)

A

WARNING • Electrolyte is poisonous and dangerous since it contains sui· furic acid, which causes severe burns. Avoid any contact with skin, eyes or clothing and al·

2. Remove the battery cover by removing the screws.

charging

it

in

an

enclosed

space. • KEEP THIS AND ALL SATIERIES OUT OF THE REACH OF CHILDREN. To access the battery 1. Open the seat. (See page 4-9.)

7-28


2. Satteey 3. Positive ballery lead 4 . Negative battery lead

To charge the battery Have a Yamaha dealer charge the battery as soon as possible if it seems to have discharged. Keep in mind that the battery tends to discharge more quickly if the vehicle is equipped with optional electrical accessories.

To charge a VRLA (Valve Regulated Lead Acid) battery, a special (corr

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PERIODIC MAINTENANCE AND ADJUSTMENT stant-voltage) battery charger is required. Using a conventional battery charger will damage the battery. If you do not have access to a con· stant-voltage battery charger, have a Yamaha dealer charge your bat-

tery.

4. After installation , make sure that the battery leads are properly connected to the battery terminals.

Replacing the fuse

TlCE Always keep the battery charged. Storing a discharged battery can cause permanent battery damage_

To store the battery 1. If the vehicle will not be used for more than one month, remove the battery, fully charge iI , and then place it in a cool, dry place. NOnCE: When removing the battery, be sure the key is turned to " OFF". then disconnect the negative lead before disconnecting the positive lead. [EC"'63021 2. If the battery will be stored for more than two months, check it al least once a month and full y charge it if necessary. 3. Fully charge the battery before installation.

1. Fuse cover 2. Screw (x l)

The fuse holder is located in the storage compartment under the seat, behind the starter relay cover. (See page 4-9 for seat opening procedures.) If the fu se is blown, replace it as follows. 1. Tum the key to "OFF' and turn off all electrical circuits. 2. Remove the starter relay cover by removing the screw. 3. Pull the starter relay out.

7-29


PERIODIC MAINTENANCE AND ADJUSTMENT 6. Instali lhe starter relay cover by installing the screw. 7. Tum the key to ~ONM and tum on the electrical circuits to check if the devices operate. 8. If the fuse immediately blows again, have a Yamaha dealer check the electrical system.

~Lay

ave the blown fuse, and then II a new fu se of the specified ~ rage . WARNING! Do not a fuse of a higher amperrating than recommended avoid causing extensive age to the electrical sysand possibly a fire. 1I="~ ' SI"1

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Replacing a headlight bulb If a headlight bulb bums Qut, replace

it

as fol1ows.

Do not touch the glass part of the headlight bulb to keep it fTee 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 w ith alcohol or thinner.

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ad fuse:

e the starter relay into the

,a1 position .

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PERIODIC MAINTENANCE AND ADJUSTMENT ~"

1. Place the motorcycle on the cen· tersland. 2. Remove cowling C. (See page 7-6 for removing procedure.)

Replacing the taillbrake light bulb

1. Open the seal. (See page 4-9.) 2. Remove the panel by removing the screws, and then pulling the panel outward.

1. Headlight but> holder

5. Place a new bulb into position, and then secu re it with the bulb holder.

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1. Headlight bllib covo r (1'2)

3. Remove the headlight bulb cover by turning i' counterclockwise. 4. Remove the headlight bulb holder by pushing it inward and turning it counterclockwise, and lhen remove the bulb.

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1. 00 noI touch \he glass pari 01 the bub.

6. Inslailihe cowling. 7. Have a Yamaha dealer adjust the headlight beam if necessary. 7-31


1. Rear panel 2. Screw (x2) 3. Rubbercap

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PERIODIC MAINTENANCE AND ADJUSTMENT 5. Insert a new bulb into the socket, push it in. and then tum it clockwise until it stops. 6. Install the socket (together with the bulb) by tuming it clockwise. 7. Install the panel and the seat.

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Replacing a tum signal light bulb

1. Tailltlfake Iiglt bub socItet

3. Remove the socket (together with the bulb) by tuming it counterclockwise. 4. Remove the bumt out bulb by pushing it in and tuming it counterclockwise.

1. Rear 1urn signal

~ght

lens

2. Screw

1. Remove the tum signal light lens by removing the screw. 2. Remove the bumt-out bulb by pushing it in and tuming it counter-

clockwise. 3. Insert a new bulb into the socket, push it in, and then tum it clockwise until it stops. 4. Install the lens by installing the screw. NOTICE: Do not overtighten the screw, otherwise the lens may break. {EGA ' ''", '

I. TaiUbfake Mght bulb

'·32 http://www.motorcycle.in.th

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PERIODIC MAINTENANCE AND ADJUSTMENT ~

Replacing a front turn signal

lighl bulb If a front turn signal light bulb bums out, replace it as follows. 1. Remove cowling A (if replacing the left lurn signal light bulb) or cowling B (if replacing the right tum signallight bulb). (See page 7-6. For

4. Insert a new bulb into the socket. 5. Install the turn signal light socket (together with the bulb) by turning it clockwise . 6. Install the cowli ng.

removal and installation procedures.) 2. Remove the lum signal light socket (together with the bulb) by luming it counterclockwise. 3. Remove the defective bulb by pulling it out.

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Replacing an auxiliary light

bulb This model is equipped with two auxiliary lights. If an auxiliary light bulb bums out, replace it as follows. 1. Remove cowling C. (Seepage 7-6 for removal and installation proce. dures.) 2. Remove the auxiliary light socket (together with the bulb) by turning it counterclockwise.

1.

Aux~ia'Y

light bulb

3. Remove the burnt out bulb by pulling it out. 4. Insert a new bulb into the socket. 1. Front tum signal light bulb

' ·33 http://www.motorcycle.in.th

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PERIODIC MAINTENANCE AND ADJUSTMENT 5. Install the auxiliary light socket (together with the bulb) by turning it clockwise. 6 . Instailihe cowling.

Troubleshooting Although Yamaha motorcycles receive a thorough inspection before shipment from the factory, trouble may occurduring operation. Any problem in the fuel, compression, or ignition systems, for example, can cause poor starting and loss of power. The following troubleshooting charts represent quick and easy procedures lor checking these vital systems yourself. 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 replacement parts. Imitation parts may look like Yamaha parts, but they are often inferior, have a shorter service life and can lead to expensive repair bills. ~W"' 5' "

. . WARNING When checking the fuel system, do not smoke, and make sure there are 7-34


no open names or sparks in the area, including pilot lights from water heaters or furnaces. Gasoline or gasoline vapors can igni te or explode, causing severe injury or property damage.

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-ti \~5POjgI99_El.book Page 35 Thursday, January 15, 2009 1:10 PM

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PERIODIC MAINTENANCE AND ADJUSTMENT EAU25922

Troubleshooting charts Starting problems or poor engine performance 1. Fuel There is enough lueL Check the luel level in the fuel tank.

The engine does not start. Check the compression.

There is no fuel.

I

2. Compression There is compression,

Check the ignition,

+

Operate the electric starter, There is no compression .

•

3. Ignition Remove the spark plug and check the electrodes,

4. Battery

Have a Yamaha dealer check the vehicle.

Wipe off with a dry cloth and correct the spark plug gap, or replace the spark plug,

B-1

Have a Yamaha dealer check the vehicle.

The engine turns over quickly.

The battery is good,

The engine turns over slowly,

Check the battery lead connections, and charge the battery if necessary.

Operate the electric starter,

7-35

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The engine does not start. Have a Yamaha dealer check the vehicle.

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-(~Ll· PERIODIC MAINTENANCE AND ADJUSTMENT

if

Engine overheating ( WA."""'l

A

WARNING • Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury. Be sure to wait until the engine has cooled. • After removing the radiator cap retaining bolt, place a thick rag, like a towel, over the radiator cap, and then slowly rotate the cap counterclockwise to the detent to allow any residual pressure to escape. When the hissing sound has stopped, press down on the cap while turning it counterclockwise, and then remove the cap.

@

The coolant ~vel is low. Check the cooling system lor leakage.

Wait unlil lhe engine lias cooled.

Have a Yamaha dealer chock and repair the cooling sysklm.

Add coolant (See TIP.)

Ched< the coolant level in the reservoir and radiator.

The coolant level is OK.

Start tho engine. If \he engine overheats again, have a Yamalla deale. clleck and dle cooling system.

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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.

7-36


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MOTORCYCLE CARE AND STORAGE Care While the open design of a motorcycle reveals the attractiveness of the technology. it also makes il more vulnera-

ble. Rust and corrosion can develop even if high-quality components are used. A rusty exhaust pipe may go un-

noticed on a car, however, il detracts from the overall appearance of a motorcycle. Frequent and proper care does nol only comply with the terms 01 the warranty, but it will also keep your motorcycle looking good, extend its life and optimize its petiormance.

Before cleaning 1. Cover the muffler outlet with a plastic bag after the engine has cooled down. 2. Make sure that all caps and covers

as well as all electrical couplers and connectors, including the spark plug cap, are tightly installed.

3. Remove extrem ~y stubborn dirt, like oil burnt onto the crankcase, with a degreasing agent and a brush, but never apply such prod· ucts onto seals, gaskets and wheel axles. Always rinse the dirt and degreaser off with water. Cleaning

• Avoid using strong acidic wheel cleaners, especially on spoked wheels. If such products are used on hard-to-remove dirt, do not leave the cleaner on the affected area any longer than instructed. Also, thoroughly rinse the area off with water, immediately dry it, and then apply a corrosion protection spray. • Improper cleaning can damage plastic parts (such as cowlings, panels, windshields, headlight lenses, meter lenses, etc.) and the mufflers. Use only a soft, clean cloth or sponge with wa-

ler to clean plastic. However, if the plastic parts cannot be thoroughly cleaned with waler, diluted mild detergent with water may be used. Be sure to rinse off any detergent residue using plenty of water, as it is harmful to plastic parts. • Do not use any harsh chemical products on plastic parts. Be sure to avoid using cloths or sponges which have been in contact with strong or abrasive cleaning products, solvent or thinner, fuel (gasoline), rust removers or inhibitors, brake lIuid, antifreeze or electrolyte. • Do not use high-pressure washers or steam-jet cleaners since they cause water seepage and deterioration in the following areas: seals (of wheel and swingarm bearings, fork and brakes), electric components {couplers, connectors,

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MOTORCYCLE CARE AND STORAGE

I

1 I

instruments, switches and lights), breather hoses and vents. • For scooters equipped with a windshield: 00 not use strong cleaners or hard sponges as they will cause dulling or scratching. Some cleaning compounds for plastic may leave scratches on the wind· shield. Test the product on a small hidden part of the w indshield to make sure that it does not leave any marks. II the windshield is scratched, use a quality plastic polishing compound after washing. After normal use Remove dirt with warm water, a mild detergent, and a soft, clean sponge, and then rinse thoroughly with clean water. Use a toothbrush or bonlebrush for hard-la-reach areas. Stubborn dirt and insects will come off more easily if

the area is covered with a wet cloth lor a few minutes before cleaning. After riding in the rain or near the sea ince sea salt is extremely corrosive carry out the following steps after each ride in the rain or near the sea. 1. Clean the motorcycle with cold water and a mild detergent after the engine has cooled down. NOTICE: Do not use warm water since it increases the corrosive action of the salt. I(G~ ' 011l \ 1 2. Apply a corrosion protection spray on all metal, including chromeand nickel-plated, surlaces to prevent corrosion. After cleaning 1. Dry the motorcycle with a chamois or an abSOlbing cloth. 2. Use a chrome polish 10 shine chrome, aluminum and stainlesssleel parts, including the exhaust system. (Even the Ihermally in-

8-2


3.

4.

5. 6. 7.

A

duced discoloring of stainlesssleel exhaust systems can be removed through polishing.) To prevent corrosion, it is recommended to apply a corrosion protection spray on all metal, including chrome- and nickel-plated , surtaces. Use spray oil as a universal cleaner to remove any remaining dirt. Touch up minor paint damage caused by stones, etc. Wax all painted surfaces. Let the motorcycle dry completely before storing or covering it.

WARNING

Contaminants on the brakes or tires can cause loss of control. • Make sure that there is no oil or wax on the brakes or tires. H necessary, clean the brake discs and brake linings with a regular brake disc cleaner or acetone, and wash the tires with warm water and a mild detergent

,~~

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MOTORCYCLE CARE AND STORAGE • Before operating the scooter test its braking perfonnance and cornering behavior.

OTIC • Apply spray oil and wax sparingly and make sure to wipe off any excess. • Never apply oil or wax to any rubber parts, plastic parts or headlight, taillight and meter lenses, but treat them with a suitable care product • Avoid using abrasive polishing compounds as they will wear away the paint.

np ~--~~--~~~~---c

• Consuh a Yamaha dealer for advice on what products to use. • Washing, rainy weather or humid climates can cause the headlight lens to fog. Turning the headlight on for a short period of time will help remove the moisture from the lens.

~,

Storage Short-term Always store your scooter in a cool, dry place and, if necessary, protect it against dust with a porous cover.

N • Storing the scooter in a poorly ventilated room or covering it with a tarp, while it is still wet, will allow water and humidity to seep in and cause rust. • To prevent corrosion, avoid damp cellars, stables (because of the presence of ammonia) and areas where strong chemicals are stored. Long-term Before storing your scooter for several months: 1. Follow all the instructions in the ~Care" section of this chapter.


2. Drain the carburetor float chamber by loosening the drain boit; this will prevent fuel deposits from building up. Pour the drained fuel into the fuel tank. 3. Fill up the fu el tank and add fuel stabilizer (if available) to prevent the fuel tank hom rusting and the fuel from deteriorating. 4. Per10rm the following steps 10 proteet the cylinder, piston rings, etc. from corrosion. a. Remove the spark plug cap and spark plug. b. Pour a teaspoonful of engine oil inlo the spark plug bore. c. Install the spark plug cap onto the spark plug , and then place the spark plug on the cylinder head so that the electrodes are grounded. (This will limit spark~ ing during the next step.) d. Tum lhe engine over several times with the starter. (This will coat the cylinder wall with oil.) WARNING! To prevent damage or injury from sparking,

MOTORCYCLE CARE AND STORAGE make sure to ground the spark plug electrodes while turning the engine over. t(W""09!i' l

5.

I

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6.

7.

8.

e. Remove the spark plug cap from the spark plug, and then install the spark plug and the spark plug cap. Lubricate all control cables and the pivoting points of all levers and pedals as well as of the sideslandJ centerstand. Check and , if necessary, correct the lire air pressure, and then lift the scooter so that both 01 its wheels are off the ground. Aherna· lively, tum the wheels a litHe every month in order to prevent the tires from becoming degraded in one spot. Cover the muffler outlet with a plastic bag to prevent moisture from entering it. Remove the banery 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 OF) or more than 30 °C (90 °F)I. For more infonnation on storing the battery, see page 7-28.

np ____________~~~Make any necessary repairs before storing the scooter.

+-


SPECIFICATIONS Dimensions; OveraJllengtfl:

1950 mm (76.8 in) Overall widlh: 678 mm (26.7 in) Overall height: 1057 mm {41.6 in)

Seat height: 770 mm (30.3 in) Wheelbase:

1290 mm (SO.8 in) Ground clearance: 130mm(5.1 in) Minimum turning radius :

1938 mm (76.3 in)

Weight: With oil and fuol: 11 0.6 kg (243.81b)

Engine: Engine type:

Liquid cooled 4-51roke. SOHC Cylinder arrangement: Forward-inclined single cylinder

Displacement: 132.6 cm 3 (8.1 cu.in) Bore x stroke: 54.0 x 57.9 mm (2.13 x 2.28 in) Compression ratio:

10.80 :1 Starting system: Bectric starter and kickstarter Lubrication system:

Engine oil:

carburetor:

Type: SAE20W-40 or SAE20W-SO Recommendecl engine oil grade: API service SG type or higher, JASO standard MA Of MB

Engine oil Quantity: Periodic o~ change: 0.80 L (0.85 US ql) (0.70 Imp.QI)

Final transmissian oil:

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Spark plug (s): Manulacturerlmodel: NGK/CR7E Spark. plug gap: 0.7-{}.8 mm (0.028--0.031 in)

Clutch:

Type: Yamalube 4 Stroke or SAE 10W-30 API Service "SE" type motor 011 Final transmission oil quantity: 0.23 L (0.24 US ql) (0.20 Imp.qI)

Cooling system: Recommended coolant: YAMAHA GENUINE COOLANT only Coolant reservoir capacity (up to the maximum level mark): 0.25 L (0.26 US qt) (0.22 Imp.qI) Radiator capacity (induding al routes) : 0.51 L (0.54 US qt) (0.45 Imp.qt)

Air filter: Air lilter element: Wet element

Fuel: Recommended fuel; REl{JJ1ar unleaded gasoline or gasohol (91 min . pump oclane) Fuel tank capacity: 4.8 L (1.27 US gal) (1.06 Imp.gal)

Wet somp

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Manufacturer: MIKUNI Type x quantity: BS26 x 1

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Clulch type: Dry, centrifugal automalic

Transmission: Primary reduction system: Helical gear Primary reduction ratio: 42/16 (2.625) Secondary reduction system: Helical gear Soc.:ondary reduction ratio: 46112 (3.833) Single speed automatic (rearlffOnt):

2.273-0.822: I Transmission type: V-beII automatic Operation: Centrifugal automalic

Chassis: Frame type : Sleefluoo underbone Caster angle: 26.00 • Trai: 110 .5 mm (4.35 in)

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---4 1_ ~_ SPECIFICATIONS Front tire: Type: With l ube (Spoke wheel)!

Tutleless (Cast wheel) Size:

70190- 1636P Manufaclurerlmodel:

IRCTIIF59 e OUNlOP!Ul 10 M, Dl l OL

Rear tire: Type:

-
With tube (Spoke wheel)! Tubeless (Cast wheel) Size: B
Loading: 160 kg (353Ib)

(Total weight 01 rider. passenger. cargo and accessories)

Tire air pressure (measured on cold tires): Front:

200 kPa (29 psi) (2.00 kgllW) Rear: 225 kPa (33 psi) (2.25 kgf/cm 2)

Front wheel: Wheel type: Spoke wheeVCasl wheel Rim size: 16x 1.40/16xMT1.6

E~trical

Rear wheel: Wheel type: Spoke wheellCast wheel Rim size :

16xl.6OI16xMT1.6

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system:

Ignition system:

DC. COl Charging system: AC magneto

Battery:

Front brake: Type:

Model:

Single disc brake Operation: Right hand opera~on Recommended fluid:

Voltage, capacity: 12 V, 3.5 Ah

GTZSS

Headlight: Bulb type: Incandescence

DOH Rear brake:

Bulb voltage, wattage x quantity:

Type: Drum brake Operation: left hand operation

Front suspension: Type: Telescopic fork Sprin9'shocl< absorber type: Coil spring/oil damper Wheel travel: 100.0 mm (3.94 in) Rear suspension:

Type: Unit swing Springlshock absorber type: Coil springloil damper Wheel travel: 90.0 mm (3.54 in)

Headlight:

12V, 25WI25.0Wx2

Tailibrake light: 12 V, 5 .0 W121.0 W x 1 Front turn Sigoollight:

12V,10.0Wx2 Rear tum signal light:

12V, 10.0W x2 Auxiliary light:

12V,3.4Wx2 Meter lighting: LED High beam indicator light:

12V,1 .4 Wx l Tum signal indicator light: LEO Engina trouble waming ligI"It: LEO

Fuse: Fuse: 10.0 A


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CONSUMER INFORMATION EAU26450

Engine serial number

1. Engine serial number

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The engine serial number is stamped into the final gear case.

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10-2


Yamaha Nouvo LX 135CC Service Manual. Written in English.

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