DT 230 Manual PDF

OWNER’S MANUAL
YAMAHA MOTOR CO., LTD.

DT230(N)
PRINTED ON RECYCLED PAPER PRINTED IN JAPAN
2000·7–0.1×1(E) ! 4TP-28199-21
4TP-9-21 7/25/00 3:46 PM Page 1
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INTRODUCTION
Congratulations on your purchase of the Yamaha DT230. This model is the result of Yamaha’s vast
1
experience in the production of fine sporting, touring, and pacesetting racing machines. It represents
the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields.
2
This manual will give you an understanding of the operation, inspection, and basic maintenance of
this motorcycle. If you have any questions concerning the operation or maintenance of your motorcy-
cle, please consult a Yamaha dealer.
4
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IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following notations:
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
1 Q INVOLVED!
2 Failure to follow WARNING instructions could result in severe injury or death to the
w
motorcycle operator, a bystander, or a person inspecting or repairing the motorcycle.
3
cC A CAUTION indicates special precautions that must be taken to avoid damage to

4 the motorcycle.
5 NOTE: A NOTE provides key information to make procedures easier or clearer.
7
NOTE:
8 8 This manual should be considered a permanent part of this motorcycle and should remain
with it even if the motorcycle is subsequently sold.
9 8 Yamaha continually seeks advancements in product design and quality. Therefore, while this
manual contains the most current product information available at the time of printing, there
may be minor discrepancies between your motorcycle and this manual. If you have any ques-
tions concerning this manual, please consult your Yamaha dealer.
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IMPORTANT MANUAL INFORMATION

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PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING
THIS MOTORCYCLE. 1
9
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5
EAU03337
6 DT230 (N)
OWNER’S MANUAL
7 ©2000 by Yamaha Motor Co., Ltd.
1st Edition, July 2000
8 All rights reserved.
Any reprinting or unauthorized use
9 without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Japan.
4TP-9-21 7/25/00 3:46 PM Page 5
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TABLE OF CONTENTS
1 SAFETY INFORMATION.....................................1-1 Starter (choke) lever “1”................................3-10

Safe riding.........................................................1-1 Seat ................................................................3-10
Protective apparel .............................................1-3 Helmet holder .................................................3-11
1
Modification.......................................................1-3 Adjusting the front fork ....................................3-11
Loading and accessories ..................................1-3 Adjusting the shock absorber assembly .........3-12
Gasoline and exhaust gas ................................1-5 YPVS ..............................................................3-15 2
Location of important labels ..............................1-7 Sidestand ........................................................3-16
Ignition circuit cut-off system ..........................3-16 3
DESCRIPTION ....................................................2-1
2
Left view............................................................2-1 PRE-OPERATION CHECKS ...............................4-1 4
4
Right view .........................................................2-2 Pre-operation check list ....................................4-1
Controls and instruments ..................................2-3 5
OPERATION AND IMPORTANT RIDING
5
INSTRUMENT AND CONTROL FUNCTIONS ....3-1 POINTS................................................................5-1
3 6
Main switch/steering lock ..................................3-1 Starting and warming up a cold engine ............5-1
Indicator and warning lights ..............................3-2 Starting a warm engine .....................................5-2
7
Speedometer unit .............................................3-3 Shifting ..............................................................5-2
Handlebar switches ..........................................3-5 Tips for reducing fuel consumption ...................5-3
Clutch lever .......................................................3-6 Engine break-in.................................................5-3 8
Shift pedal .........................................................3-6 Parking..............................................................5-4
Brake lever........................................................3-6 9
Brake pedal.......................................................3-7 PERIODIC MAINTENANCE AND MINOR
6
Fuel tank cap ....................................................3-7 REPAIR................................................................6-1
Fuel ...................................................................3-8 Owner’s tool kit .................................................6-1
2-stroke engine oil ............................................3-8 Periodic maintenance and lubrication chart ......6-2
Fuel cock ..........................................................3-9 Removing and installing cowlings .....................6-5
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TABLE OF CONTENTS
Removing and installing panels ........................6-6 Checking and lubricating the brake and clutch
Checking the spark plug ...................................6-7 levers ............................................................6-29
Transmission oil ................................................6-9 Checking and lubricating the sidestand ..........6-29
1
Coolant ...........................................................6-10 Lubricating the rear suspension......................6-30
Changing the coolant ......................................6-12 Checking the front fork....................................6-30
2 Cleaning the air filter element .........................6-14 Checking the steering .....................................6-31
Adjusting the carburetor..................................6-15 Checking the wheel bearings..........................6-31
3 Adjusting the engine idling speed ...................6-16 Battery ............................................................6-32
Adjusting the throttle cable free play...............6-16 Replacing the fuse ..........................................6-33
4 Tires ................................................................6-17 Replacing the headlight bulb ..........................6-34
Spoke wheels .................................................6-20 Replacing a turn signal light bulb ....................6-36
5 Adjusting the clutch lever free play .................6-20 Replacing the tail/brake light bulb ...................6-37
Adjusting the brake lever free play .................6-21 Replacing the license plate light bulb .............6-37
Adjusting the brake pedal position ..................6-22 Supporting the motorcycle ..............................6-38
6
Adjusting the rear brake light switch ...............6-23 Front wheel .....................................................6-39
Checking the front and rear brake pads .........6-23 Rear wheel......................................................6-40
7
Checking the brake fluid level .........................6-24 Troubleshooting ..............................................6-42
Changing the brake fluid .................................6-25 Troubleshooting charts ...................................6-43
8 Drive chain slack.............................................6-25
Lubricating the drive chain ..............................6-26 MOTORCYCLE CARE AND STORAGE .............7-1
7
9 Checking and lubricating the cables ...............6-27 Care ..................................................................7-1
Checking and lubricating the throttle grip and Storage .............................................................7-4
cable .............................................................6-28
Adjusting the Autolube pump ..........................6-28 SPECIFICATIONS ...............................................8-1
8
Checking and lubricating the brake and shift How to use the conversion table.......................8-5
pedals ...........................................................6-29
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TABLE OF CONTENTS
9 CONSUMER INFORMATION..............................9-1
Identification numbers record ...........................9-1
Key identification number .................................9-1
1
Vehicle identification number ............................9-1
Model label .......................................................9-2
Motorcycle noise regulation (for Australia) .......9-2 2
9
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Q SAFETY INFORMATION
MOTORCYCLES ARE SINGLE TRACK VEHICLES. THEIR SAFE USE AND OPERATION ARE
DEPENDENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EXPER-
TISE OF THE OPERATOR. EVERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIRE-
1
MENTS BEFORE RIDING THIS MOTORCYCLE.
HE OR SHE SHOULD:
2 1. OBTAIN THOROUGH INSTRUCTIONS FROM A COMPETENT SOURCE ON ALL ASPECTS
OF MOTORCYCLE OPERATION.
3 2. OBSERVE THE WARNINGS AND MAINTENANCE REQUIREMENTS IN THE OWNER’S MAN-
UAL.
4 3. OBTAIN QUALIFIED TRAINING IN SAFE AND PROPER RIDING TECHNIQUES.
4. OBTAIN PROFESSIONAL TECHNICAL SERVICE AS INDICATED BY THE OWNER’S MANUAL
5 AND/OR WHEN MADE NECESSARY BY MECHANICAL CONDITIONS.
Safe riding
6
1. Always make pre-operation checks. Careful checks may help prevent an accident.
2. This motorcycle is designed to carry the operator and a passenger.
7 3. The failure of motorists to detect and recognize motorcycles in traffic is the predominating cause
of automobile/motorcycle accidents. Many accidents have been caused by an automobile driver
8 who did not see the motorcycle. Making yourself conspicuous appears to be very effective in
reducing the chance of this type of accident.
9
Therefore:
a. Wear a brightly colored jacket.
b. Use extra caution when approaching and passing through intersections, since intersections
are the most likely places for motorcycle accidents to occur.
c. Ride where other motorists can see you. Avoid riding in another motorist’s blind spot.
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4. Many accidents involve inexperienced operators. In fact, many operators who have been
involved in accidents do not even have a current motorcycle license.
a. Make sure that you are qualified and that you only lend your motorcycle to other qualified oper-
1
ators.
b. Know your skills and limits. Staying within your limits may help you to avoid an accident.
c. We recommend that you practice riding your motorcycle where there is no traffic until you have 2
become thoroughly familiar with the motorcycle and all of its controls.
5. Many accidents have been caused by error of the motorcycle operator. A typical error made by 3
the operator is veering wide on a turn due to EXCESSIVE SPEED or undercornering (insufficient
lean angle for the speed). 4
a. Always obey the speed limit and never travel faster than warranted by road and traffic condi-
tions. 5
b. Always signal before turning or changing lanes. Make sure that other motorists can see you.
6. The posture of the operator and passenger is important for proper control.
6
a. The operator should keep both hands on the handlebar and both feet on the operator footrests
during operation to maintain control of the motorcycle.
7
b. The passenger should always hold onto the operator, the seat strap or grab bar, if equipped,
with both hands and keep both feet on the passenger footrests.
c. Never carry a passenger unless he or she can firmly place both feet on the passenger 8
footrests.
7. Never ride under the influence of alcohol or other drugs. 9
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Protective apparel
The majority of fatalities 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 injuries.
1
1. Always wear an approved helmet.
2. Wear a face shield or goggles. Wind in your unprotected eyes could contribute to an impairment
2 of vision that could delay seeing a hazard.
3. The use of a jacket, heavy boots, trousers, gloves, etc., is effective in preventing or reducing
3 abrasions or lacerations.
4. Never wear loose-fitting clothes, otherwise they could catch on the control levers, footrests, or
4 wheels and cause injury or an accident.
5. Never touch the engine or exhaust system during or after operation. They become very hot and
5 can cause burns. Always wear protective clothing that covers your legs, ankles, and feet.
6. Passengers should also observe the precautions mentioned above.
6 Modifications
Modifications made to this motorcycle not approved by Yamaha, or the removal of original equipment,
7 may render the motorcycle unsafe for use and may cause severe personal injury. Modifications may
also make your motorcycle illegal to use.
8 Loading and accessories
Adding accessories or cargo to your motorcycle can adversely affect stability and handling if the
9 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 motorcy-
cle that has added cargo or accessories. Here are some general guidelines to follow if loading cargo
or adding accessories to your motorcycle:
1-3
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Loading
The total weight of the operator, passenger, accessories and cargo must not exceed the maximum
load limit of 180 kg. When loading within this weight limit, keep the following in mind:
1. Cargo and accessory weight should be kept as low and close to the motorcycle as possible. 1
Make sure to distribute the weight as evenly as possible on both sides of the motorcycle to mini-
mize imbalance or instability. 2
2. Shifting weights can create a sudden imbalance. Make sure that accessories and cargo are
securely attached to the motorcycle before riding. Check accessory mounts and cargo restraints 3
frequently.
3. Never attach any large or heavy items to the handlebar, front fork, or front fender. These items, 4
including such cargo as sleeping bags, duffel bags, or tents, can create unstable handling or a
slow steering response.
5
Accessories
Genuine Yamaha accessories have been specifically designed for use on this motorcycle. Since 6
Yamaha cannot test all other accessories that may be available, you must personally be responsible
for the proper selection, installation and use of non-Yamaha accessories. Use extreme caution when 7
selecting and installing any accessories.
Keep the following guidelines in mind, as well as those provided under “Loading” when mounting
8
accessories.
1-4
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1. Never install accessories or carry cargo 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 cornering clearance, limit suspension travel, steering travel or control opera-
1
tion, or obscure lights or reflectors.
a. Accessories fitted to the handlebar or the front fork area can create instability due to improper
2 weight distribution or aerodynamic changes. If accessories are added to the handlebar or front
fork area, they must be as lightweight as possible and should be kept to a minimum.
3 b. Bulky or large accessories may seriously affect the stability of the motorcycle due to aerody-
namic effects. Wind may attempt to lift the motorcycle, or the motorcycle may become unstable
4 in cross winds. These accessories may also cause instability when passing or being passed by
large vehicles.
5 c. 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 recommended.
6
2. Use caution when adding electrical accessories. If electrical accessories exceed the capacity of
the motorcycle’s electrical system an electric failure could result, which could cause a dangerous
7
loss of lights or engine power.
8 Gasoline and exhaust gas

1. GASOLINE IS HIGHLY FLAMMABLE:
9 a. Always turn the engine off when refueling.
b. Take care not to spill any gasoline on the engine or exhaust system when refueling.
c. Never refuel while smoking or in the vicinity of an open flame.
1-5
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2. Never start the engine or let it run for any length of time in a closed area. The exhaust fumes are
poisonous and may cause loss of consciousness and death within a short time. Always operate
your motorcycle in an area that has adequate ventilation.
1
3. Always turn the engine off before leaving the motorcycle unattended and remove the key from
the main switch. When parking the motorcycle, note the following:
a. The engine and exhaust system may be hot, therefore, park the motorcycle in a place where 2
pedestrians or children are not likely to touch these hot areas.
b. Do not park the motorcycle on a slope or soft ground, otherwise it may fall over. 3
c. Do not park the motorcycle near a flammable source (e.g., a kerosene heater, or near an open
flame), otherwise it could catch fire. 4
4. When transporting the motorcycle in another vehicle, make sure that it is kept upright and that the
fuel cock(s) are turned to “ON” or “RES” (for vacuum type)/”OFF” (for manual type). If the motor- 5
cycle should lean over, gasoline may leak out of the carburetor or fuel tank.
5. If you should swallow any gasoline, inhale a lot of gasoline vapor, or allow gasoline to get into
6
your eyes, see your doctor immediately. If any gasoline spills on your skin or clothing, immediate-
ly wash the affected area with soap and water and change your clothes.
7
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Location of important labels

Please read the following important labels carefully before operating this motorcycle.
1
2 1
1
3 WARNING
Before you operate this vehicle,
4 read the owner’s manual.
English 3HP-21568-00
6
2
7
2
4AA-22259-40
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DESCRIPTION
Left view
1 23 4 5 6 7
7
12 11 10 9 8
8 1. Headlight (page 6-34) 8. Rear shock absorber spring preload
2. Rear shock absorber compression adjusting nut (page 3-13)
9 damping adjusting knob (page 3-14) 9. Rear shock absorber rebound damping
3. Fuel cock (page 3-9) adjusting dial (page 3-14)
4. Starter (choke) lever “1” (page 3-10) 10. Shift pedal (page 3-6)
5. Air filter element (page 6-14) 11. YPVS (page 3-15)
6. 2-stroke engine oil tank (page 3-8) 12. Front fork compression damping
7. Helmet holder (page 3-11) adjusting screw (page 3-12)
2-1
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DESCRIPTION
Right view
13 14 15 16 17
7
18
13. Coolant reservoir (page 6-11) 8
14. Owner’s tool kit (page 6-1)
15. Battery (page 6-32) 9
16. Fuse (page 6-33)
17. Radiator cap (page 6-12)
18. Brake pedal (page 3-7, 6-22)
2-2
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DESCRIPTION
Controls and instruments
1 2 3 4 5 6
1
8 8 7
9
1. Clutch lever (page 3-6, 6-20) 6. Brake lever (page 3-6, 6-21)
2. Left handlebar switches (page 3-5) 7. Throttle grip (page 6-16, 6-28)
3. Speedometer unit (page 3-3) 8. Fuel tank cap (page 3-7)
4. Main switch/steering lock (page 3-1)
5. Right handlebar switches (page 3-5)
2-3
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EAU00027
INSTRUMENT AND CONTROL FUNCTIONS

EW000016
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ON
OFF
Never turn the key to “OFF” or
ON
FF “LOCK” while the motorcycle is 1
O
H
PUS
moving, otherwise the electrical

LOC
systems will be switched off, 2

N
K
O
I
LOCK IG NI
T which may result in loss of control
or an accident. Make sure that the 3
motorcycle is stopped before turn-
ing the key to “OFF” or “LOCK”. 4
EAU00029 EAU00040
Main switch/steering lock LOCK

The main switch/steering lock controls The steering is locked, and all electri- 5
the ignition and lighting systems, and cal systems are off. The key can be
is used to lock the steering. The vari- removed. 6
ous positions are described below.
EAU00031 To lock the steering 7
ON 1. Turn the handlebars all the way
All electrical systems are supplied to the left.
8
with power, and the headlight, meter 2. Push the key in from the “OFF”
lighting, taillight and license plate position, and then turn it to
light come on, and the engine can be “LOCK” while still pushing it. 9
started. The key cannot be removed. 3. Remove the key.
EAU00038
OFF To unlock the steering

All electrical systems are off. The key Push the key in, and then turn it to
can be removed. “OFF” while still pushing it.
3-1
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8 When the coolant temperature is If the warning light does not come on,
1 2 3 4 5
too high, the warning light comes have a Yamaha dealer inspect the
on and symbol “ ” flashes. electrical circuit.
1
Stop the motorcycle and allow it EC000118
to idle until the coolant tempera-

cC
2 ture goes down. If the tempera- 8 Do not operate the motorcycle
ture does not go down, stop the until you know that the engine
6
3 engine. (See the “Engine over- oil level is sufficient.
heating” section on page 6-44 for 8 Do not operate the engine if it
1. Oil level/coolant temperature warning
4 light “WARNING” further instructions.) is overheated.
2. Oil level symbol “7” 8 When the engine oil level is low
3. Coolant temperature symbol “ ” NOTE:
5 4. Turn signal indicator light “5”
and the coolant temperature is
5. High beam indicator light “&” too high, the warning light flash- Even if the oil is filled to the specified
6. Neutral indicator light “N” es and symbols “7” and “ ” level, the indicator light may flicker
6 EAU03034
come on. when riding on a slope or during sud-
Indicator and warning lights
den acceleration or deceleration, but
7 this is normal.
EAU03587 To check that the warning light is
Oil level/coolant temperature working properly:
8 warning light “WARNING” 8 Put the transmission in neutral or EAU00057
This warning light has the following apply the clutch lever. Turn signal indicator light “5”
9 three functions. 8 Turn the engine stop switch to This indicator light flashes when the
8 When the engine oil level is low, “#” and the key to “ON”. turn signal switch is pushed to the left
the warning light comes on and 8 The light will come on and sym- or right.
symbol “7” flashes. If this bol “7” will appear in the dis-
occurs, stop the engine immedi- play.
ately and add engine oil to the
specified level.
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When in mode “A”:
1 2 3 4 5 1 2 3 4
8 The upper tripmeter can be reset
to zero.
1
8 The display can be switched
between the clock and the
odometer. 2
6 8 The clock can be set.

6 5 3
When in mode “B”:
1. Oil level/coolant temperature warning 1. Reset button “RESET”
light “WARNING” 2. Upper trip odometer 8 The lower tripmeter can be reset. 4
2. Oil level symbol “7” 3. Lower trip odometer 8 The lower tripmeter can be
3. Coolant temperature symbol “ ” 4. Digital speedometer
4. Turn signal indicator light “5” 5. Odometer/Clock “ODO/CLOCK”
switched between forward count 5
5. High beam indicator light “&” 6. Mode select button “SELECT” and reverse count.
6. Neutral indicator light “N” EAU00100
EAU00063
Speedometer unit 6
Select the modes as follows:
High beam indicator light “&” The speedometer unit is equipped 1. Turn the key to “ON”.
This indicator light comes on when with a digital speedometer, an 7
the high beam of the headlight is odometer, two tripmeters and a clock.
switched on. The speedometer shows riding 8
EAU00061
speed. The odometer shows the total
Neutral indicator light “N”
distance traveled. The tripmeter 9
This indicator light comes on when
shows the distance traveled since it
the transmission is in the neutral
was last set to zero.
position.
The mode select button is used to
switch between modes “A” and “B”.
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Mode “A” Mode “B”
1 2 3 4 To set the upper tripmeter to zero, To set the lower tripmeter to zero,
push the reset button for at least one push the reset button for at least one
1 second. second.
To display the clock or odometer To switch the tripmeter between for-
2 reading, push the mode select button ward count and reverse count, push
for one to three seconds. the mode select button for one to
3 6 5 three seconds. A minus sign – will
To set the clock: appear when in the reverse count
1. Reset button “RESET” 1. Push the mode select button mode.
4 2. Upper trip odometer
3. Lower trip odometer until the hour digits flash.
4. Digital speedometer 2. Push the reset button to change To set the reverse count distance:
5 5. Odometer/Clock “ODO/CLOCK”
6. Mode select button “SELECT” the hour digits. 1. Push the mode select button
3. Push the mode select button, until the digit for the hundreds
6 NOTE:
and the minute digits will flash. flashes.
When the key is turned to “ON”, the
4. Push the reset button to change 2. Push the reset button to change
7 speedometer displays “188 km/h” for
the minute digits. the hundreds.
a few seconds, during which time the
5. Push the mode select button 3. Repeat this procedure to change
electrical circuit is being checked.
8 again to set the clock. the tens and ones.
4. Push the mode select button
2. Push the mode select button to
9 again to set the tripmeter.
display a mode.
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EAU00129
1 2 Horn switch “*” 1
Press this switch to sound the horn.
1
3 2 3
1. Dimmer switch 1. Engine stop switch

2. Turn signal switch 2. Start switch “,” 4
3. Horn switch “*” EAU00138
EAU00118
Engine stop switch 5
Handlebar switches
EAU00121
Set this switch to “$” to stop the
Dimmer switch engine in case of an emergency, 6
Set this switch to “&” for the high such as when the motorcycle over-
beam and to “%” for the low beam. turns or when the throttle cable is
7
EAU00127 stuck.
Turn signal switch EAU00143
To signal a right-hand turn, push this Start switch “,” 8

switch to “6”. To signal a left-hand Push this switch to crank the engine
turn, push this switch to “4”. When with the starter. 9
EC000005
released, the switch returns to the
center position. To cancel the turn
cC
signal lights, push the switch in after See page 5-1 for starting instruc-
it has returned to the center position. tions prior to starting the engine.
3-5
4TP-9-21 7/25/00 3:46 PM Page 24
1 1
6 1
1 5
4
3
2 2
N
1
3
1. Clutch lever 1. Shift pedal 1. Brake lever

4 N. Neutral
EAU00152 EAU00158
EAU00157
Clutch lever Shift pedal Brake lever
5 The clutch lever is located at the left The brake lever is located at the right
The shift pedal is located on the left
handlebar grip. To disengage the handlebar grip. To apply the front
side of the engine and is used in
6 clutch, pull the lever toward the han- brake, pull the lever toward the han-
combination with the clutch lever
dlebar grip. To engage the clutch, dlebar grip.
when shifting the gears of the
7 release the lever. The lever should
6-speed constant-mesh transmission
be pulled rapidly and released slowly
equipped on this motorcycle.
8 for smooth clutch operation.
The clutch lever is equipped with a
clutch switch, which is part of the igni-
9
tion circuit cut-off system. (See page
3-16 for an explanation of the ignition
circuit cut-off system.)
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4TP-9-21 7/25/00 3:46 PM Page 25

NOTE:
b The fuel tank cap cannot be installed
1
1 a unless the key is in the lock. In addi-
1
tion, the key cannot be removed if the
cap is not properly installed and
locked. 2
EW000023 3
w
1. Brake pedal 1. Fuel tank cap
a. Unlock Make sure that the fuel tank cap is 4
EAU00162
b. Open properly closed and locked before
Brake pedal EAU00177
riding. 5
The brake pedal is on the right side Fuel tank cap
of the motorcycle. To apply the rear To remove the fuel tank cap
brake, press down on the brake 1. Insert the key into the lock and 6
pedal. turn it 1/4 turn counterclockwise.
2. Turn the fuel tank cap 1/3 turn 7
counterclockwise and pull it off.
8
To install the fuel tank cap
1. Insert the fuel tank cap into the
9
tank opening with the key insert-
ed in the lock, and then turn the
cap 1/3 turn clockwise.
2. Turn the key 1/4 turn clockwise,
and then remove it.
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4TP-9-21 7/25/00 3:46 PM Page 26

EAU00185
1 cC 1
2
Immediately wipe off spilled fuel
1 with a clean, dry, soft cloth, since
fuel may deteriorate painted sur-
2 faces or plastic parts. 2
3 EAU00192
1. Filler tube Recommended fuel: 1. 2-stroke engine oil tank cap

4 2. Fuel level 2. 2-stroke engine oil tank
Regular gasoline
EAU01183 EAU01413
Fuel For Australia:
5 Unleaded fuel only 2-stroke engine oil
Make sure that there is sufficient fuel Make sure that there is sufficient oil in
in the tank. Fill the fuel tank to the Fuel tank capacity:
6 Total amount: the 2-stroke engine oil tank. If neces-
bottom of the filler tube as shown in sary, add oil as follows.
the illustration. 11.0 L
Reserve amount: 1. Remove panel A. (See page 6-6
7 EW000130
w 2.0 L for panel removal and installation

procedures.)
8 8 Do not overfill the fuel tank, 2. Remove the 2-stroke engine oil
otherwise it may overflow tank cap and add the recom-
9 when the fuel warms up and mended oil.
expands. 3. Install the 2-stroke engine oil
8 Avoid spilling fuel on the hot tank cap and the panel.
engine.
3-8
4TP-9-21 7/25/00 3:46 PM Page 27

NOTE: OFF: Closed position ON: Normal position
Make sure that the 2-stroke engine
oil tank cap is properly closed. RES
RES 1
OFF
OFF
FUEL 2
Recommended oil: FUEL ON
ON
Yamalube 2 or equivalent
1 ON 1 3
2-stroke engine oil (JASO
grade “FC”) 1. Arrow mark positioned over “OFF” 1. Arrow mark positioned over “ON”
Oil quantity: 4
EAU03050
ON
1.3 L Fuel cock With the lever in this position, fuel
The fuel cock supplies fuel from the 5
flows to the carburetor. Normal riding
tank to the carburetor while filtering it is done with the lever in this position.
also. 6
The fuel cock has three positions:
7
OFF
With the lever in this position, fuel will 8
not flow. Always return the lever to
this position when the engine is not
9
running.
3-9
4TP-9-21 7/25/00 3:46 PM Page 28

RES: Reserve position
RES
1
RES a
1
2 OFF
FUEL 1
ON b
3 1
1. Arrow mark positioned over “RES” 1. Starter (choke) lever “1” 1. Bolt (×2)
4
RES EAU02976 EAU00240
This indicates reserve. If you run out Starter (choke) lever “1” Seat
5 Starting a cold engine requires a rich- To remove the seat
of fuel while riding, move the lever to
this position. Fill the tank at the first er air-fuel mixture, which is supplied Remove the bolts, and then pull the
6 opportunity. Be sure to set the lever by the starter (choke). seat off.
back to “ON” after refueling! Move the lever in direction a to turn
7 on the starter (choke).
Move the lever in direction b to turn
8 off the starter (choke).
3-10
4TP-9-21 7/25/00 3:46 PM Page 29

EAU03589
1 Adjusting the front fork
1 This front fork is equipped with damp-
ing force adjusting screws. 1
a EW000035
w
2
Always adjust both fork legs
2 equally, otherwise poor handling
3
and loss of stability may result.
1. Projection (×2) 1. Helmet holder
2. Seat holder (×2) a. Open 4
To install the seat EAU00260
1. Insert the projections on the front

Helmet holder 5
To open the helmet holder, insert the
of the seat into the seat holders
key into the lock, and then turn the
as shown. 6
key as shown.
2. Place the seat in the original
position, and then tighten the 7
To lock the helmet holder, place it in
bolts.
the original position, and then remove
the key. 8
NOTE:
EW000030
Make sure that the seat is properly w
secured before riding. 9
Never ride with a helmet attached
to the helmet holder, since the hel-
met may hit objects, causing loss
of control and possibly an acci-
dent.
3-11
4TP-9-21 7/25/00 3:46 PM Page 30

EAU03672
Minimum (soft) 17 clicks in direction b*
Standard 14 clicks in direction b* Adjusting the shock
Maximum (hard) 1 click in direction b* absorber assembly
1 1 * With the adjusting screw fully turned in direction a This shock absorber assembly is
equipped with a spring preload
2 3. Install the rubber caps. adjusting nut, a rebound damping
a ECA00034
force adjusting dial and a compres-
cC
3 b sion damping force adjusting knob.
Be sure to install the rubber caps EC000015
1. Compression damping adjusting screw to prevent dust, etc. from entering cC

4 the fork legs.
Adjust the damping force as follows. Never attempt to turn an adjusting
1. Remove the rubber cap from the mechanism beyond the maximum
5 or minimum settings.
bottom of each fork leg.
2. To increase the damping force
6
and thereby harden the suspen-
sion, turn the adjusting screw in
7 direction a. To decrease the
damping force and thereby soft-
8 en the suspension, turn the
adjusting screw in direction b.
9 NOTE:
To determine the maximum damping
force setting, push the adjusting
screw up, turn it in direction a until it
stops, and then one click in direction
b.
3-12
4TP-9-21 7/25/00 3:46 PM Page 31
1 Spring preload:
a Minimum (soft):
1 Distance A = 252 mm 1
Standard:
Distance A = 244 mm 2
b Maximum (hard):
a
2 Distance A = 234 mm
3
1. Special wrench 1. Adjusting nut 3. Tighten the locknut to the speci-

2. Locknut 4
Spring preload fied torque.
a. Distance “A”
1. Loosen the locknut.
NOTE: Tightening torque: 5
2. To increase the spring preload
8 Use the special wrench included Locknut:
and thereby harden the suspen-
in the owner’s tool kit to make 41 Nm (4.1 m0kg) 6
sion, turn the adjusting nut in
the adjustment.
direction a. To decrease the ECA00076
8 The spring preload setting is cC
spring preload and thereby soft- 7
determined by measuring dis-
en the suspension, turn the Always tighten the locknut against
tance A, shown in the illustration.
adjusting nut in direction b. the adjusting nut, and then tighten 8
The shorter distance A is, the
higher the spring preload; the the locknut to the specified torque.
longer distance A is, the lower 9
the spring preload.
3-13
4TP-9-21 7/25/00 3:46 PM Page 32

NOTE:
Although the total number of clicks of
1 a damping force adjusting mecha-
1 1
a nism may not exactly match the
b a above specifications due to small dif-
2 ferences in production, the actual
b number of clicks always represents
3 the entire adjusting range. To obtain
a precise adjustment, it would be
1. Adjusting dial 1. Adjusting knob
4 advisable to check the number of
Rebound damping force Compression damping force clicks of each damping force adjust-
To increase the rebound damping To increase the compression damping mechanism and to modify the
5
force and thereby harden the ing force and thereby harden the specifications as necessary.
rebound damping, turn the adjusting compression damping, turn the
6 dial in direction a. To decrease the adjusting knob in direction a. To
rebound damping force and thereby decrease the compression damping
7 soften the rebound damping, turn the force and thereby soften the com-
adjusting dial in direction b. pression damping, turn the adjusting
8 knob in direction b.
Minimum (soft) 16 clicks in direction b*
Standard 9 clicks in direction b* Minimum (soft) 5 clicks in direction a*
9 Maximum (hard) 1 click in direction b* Standard 8 clicks in direction a*
* With the adjusting dial fully turned in direction a Maximum (hard) 22 clicks in direction a*
* With the adjusting knob fully turned in direction b
3-14
4TP-9-21 7/25/00 3:46 PM Page 33

EW000041
Since the YPVS is an important part
w
of the engine and requires very
This shock absorber contains 1
sophisticated adjustment, have a
highly pressurized nitrogen gas. 1
Yamaha dealer, who has the neces-
For proper handling, read and sary professional knowledge and
understand the following informa- experience, make this adjustment. 2
tion before handling the shock EC000023
absorber. The manufacturer can- cC 3

not be held responsible for proper- The YPVS has been set and exten-
ty damage or personal injury that 1. YPVS
sively tested at the Yamaha facto- 4
EAU00326
may result from improper han- ry. Changing these settings with-
YPVS
dling. out sufficient technical knowledge
This model is equipped with the 5
8 Do not tamper with or attempt may result in poor performance of
YPVS (Yamaha Power Valve
to open the gas cylinder. or damage to the engine.
System). This system boosts engine 6
8 Do not subject the shock
performance and efficiency by means
absorber to an open flame or YPVS operation noises can be heard
of a variable valve in the exhaust 7
other high heat sources, other- in the following instances:
port. The YPVS valve is constantly
wise it may explode due to 8 When the key is turned to “ON”
adjusted in accordance with the
excessive gas pressure. and the engine is started. 8
engine speed by a computer-con-
8 Do not deform or damage the 8 When the engine stalls with the
trolled servomotor.
gas cylinder in any way, as key in the “ON” position. 9
this will result in poor damp- EC000024
ing performance. cC
8 Always have a Yamaha dealer If the YPVS does not operate, have
service the shock absorber. a Yamaha dealer check it.
3-15
4TP-9-21 7/25/00 3:46 PM Page 34

EAU00330 EW000044 EAU00331
Sidestand w Ignition circuit cut-off

The sidestand is located on the left system
The motorcycle must not be ridden
1 side of the frame. Raise the side- The ignition circuit cut-off system
with the sidestand down, or if the
stand or lower it with your foot while (comprising the sidestand switch,
sidestand cannot be properly
2 holding the motorcycle upright. clutch switch and neutral switch) has
moved up (or does not stay up),
otherwise the sidestand could con- the following functions.
NOTE:
3 tact the ground and distract the 8 It prevents starting when the
The built-in sidestand switch is part of
operator, resulting in a possible transmission is in gear and the
the ignition circuit cut-off system,
loss of control. Yamaha’s ignition sidestand is up, but the clutch
4 which cuts the ignition in certain situ-
circuit cut-off system has been lever is not pulled.
ations. (See further down for an
designed to assist the operator in 8 It It prevents starting when the
5 explanation of the ignition circuit cut-
fulfilling the responsibility of rais- transmission is in gear and the
off system.)
ing the sidestand before starting clutch lever is pulled, but the
6 sidestand is still down.
off. Therefore, check this system
regularly as described below and 8 It It cuts the running engine when
7 have a Yamaha dealer repair it if it the sidestand is moved down.
does not function properly. Periodically check the operation of
8 the ignition circuit cut-off system
according to the following procedure.
EW000045
9 w
If a malfunction is noted, have a
Yamaha dealer check the system
before riding.
3-16
4TP-9-21 7/25/00 3:46 PM Page 35
With the engine turned off: NOTE:

1. Move the sidestand down. This check is most reliable if performed with
2. Make sure that the engine stop switch is set to “#”. a warmed-up engine. 1
3. Turn the key to “ON”.
4. Shift the transmission into the neutral position.
5. Push the start switch. 2
Does the engine start?
The neutral switch may be defective.
YES NO The motorcycle should not be ridden until 3
checked by a Yamaha dealer.
With the engine still running:
4
6. Move the sidestand up.
7. Keep the clutch lever pulled.
8. Shift the transmission into gear. 5
9. Move the sidestand down.
Does the engine stall?
The sidestand switch may be defective. 6
YES NO The motorcycle should not be ridden until
After the engine has stalled: 7
10. Move the sidestand up.
11. Keep the clutch lever pulled. 8
12. Push the start switch.
Does the engine start?
The clutch switch may be defective. 9
YES NO The motorcycle should not be ridden until
The system is OK. The motorcycle can be ridden.
3-17
4TP-9-21 7/25/00 3:46 PM Page 36
EAU01114
PRE-OPERATION CHECKS
The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpect-
edly, even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leak-
age or loss of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thor-
1
ough visual inspection, to check the following points before each ride.
EAU03439
2 Pre-operation check list
ITEM CHECKS PAGE
3 • Check fuel level in fuel tank.
Fuel • Refuel if necessary. 3-7–3-8
• Check fuel line for leakage.
4
• Check oil level in oil tank.
Two-stroke engine oil • If necessary, add recommended oil to specified level. 3-8–3-9
5 • Check vehicle for oil leakage.
• Check oil level in transmission case.
Transmission oil 6-9–6-10
6 • If necessary, add recommended oil to specified level.
• Check coolant level in reservoir.
Coolant • If necessary, add recommended coolant to specified level. 6-10–6-13
7 • Check cooling system for leakage.
• Check operation.
8 • If soft or spongy, have Yamaha dealer bleed hydraulic system.
• Check lever free play.
Front brake • Adjust if necessary. 3-6, 6-21–6-25
9 • Check fluid level in reservoir.
• If necessary, add recommended brake fluid to specified level.
• Check hydraulic system for leakage.
• If soft or spongy, have Yamaha dealer bleed hydraulic system.
Rear brake • Check fluid level in reservoir. 3-7, 6-22–6-25
• If necessary, add recommended brake fluid to specified level.
• Check hydraulic system for leakage.
4-1
4TP-9-21 7/25/00 3:46 PM Page 37
ITEM CHECKS PAGE
• Lubricate cable if necessary.
Clutch 3-6, 6-20–6-21 1
• Check lever free play.
• Adjust if necessary.
• Make sure that operation is smooth. 2
• Lubricate throttle grip, housing and cable if necessary.
Throttle grip 6-16–6-17, 6-28
• Check free play.
• Adjust if necessary. 3
• Make sure that operation is smooth.
Control cables 6-27
• Lubricate if necessary.
4
• Check chain slack.
• Adjust if necessary.
Drive chain 6-25–6-27
• Check chain condition. 5
• Lubricate if necessary.
• Check for damage.
6
• Check tire condition and tread depth.
Wheels and tires 6-17–6-20
• Check air pressure.
• Correct if necessary. 7
Brake and shift pedals 6-29
• Lubricate pedal pivoting points if necessary.
8
Brake and clutch levers 6-29
• Lubricate lever pivoting points if necessary.
• Make sure that operation is smooth. 9
Sidestand 6-29
• Lubricate pivot if necessary.
4-2
4TP-9-21 7/25/00 3:46 PM Page 38
ITEM CHECKS PAGE
• Make sure that all nuts, bolts and screws are properly tightened.
Chassis fasteners —
• Tighten if necessary.
1 Instruments, lights, sig- • Check operation.
3-5, 6-34–6-38
nals and switches • Correct if necessary.
2 • Check operation of ignition circuit cut-off system.
Sidestand switch 3-16–3-17
• If system is defective, have Yamaha dealer check vehicle.
3 NOTE:
Pre-operation checks should be made each time the motorcycle is used. Such an inspection can be accomplished in a
4 very short time; and the added safety it assures is more than worth the time involved.
5 EWA00033
w
6 If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operat-
ing the motorcycle.
7
4-3
4TP-9-21 7/25/00 3:46 PM Page 39
EAU00372
OPERATION AND IMPORTANT RIDING POINTS

EAU00373 EAU01860
1. Turn the fuel cock lever to “ON”.
w Starting and warming up a 2. Turn the key to “ON” and make
8 Become thoroughly familiar cold engine sure that the engine stop switch
with all operating controls and In order for the ignition circuit cut-off 1
is set to “#”.
their functions before riding. system to enable starting, one of the 3. Shift the transmission into the
Consult a Yamaha dealer following conditions must be met: neutral position. 2
regarding any control or func- 8 The transmission is in the neutral
tion that you do not thorough- position. NOTE: 3
ly understand. 8 The transmission is in gear with When the transmission is in the neu-
8 Never start the engine or oper- the clutch lever pulled and the tral position, the neutral indicator light 4
ate it in a closed area for any sidestand up. should be on, otherwise have a
EW000054
length of time. Exhaust fumes Yamaha dealer check the electrical
w 5
are poisonous, and inhaling circuit.
them can cause loss of con- 8 Before starting the engine,
check the function of the igni- 6
sciousness and death within a 4. Turn the starter (choke) on and
short time. Always make sure tion circuit cut-off system completely close the throttle.
that there is adequate ventila- according to the procedure (See page 3-10 for starter 7
tion. described on page 3-17. (choke) operation.)
8 Before starting out, make sure 8 Never ride with the sidestand 5. Start the engine by pushing the 8
that the sidestand is up. If the down. start switch.
sidestand is not raised com- 9
pletely, it could contact the
ground and distract the opera-
tor, resulting in a possible loss
of control.
5-1
4TP-9-21 7/25/00 3:46 PM Page 40

EAU01258
NOTE:
If the engine fails to start, release the
Starting a warm engine
Follow the same procedure as for 6
1
start switch, wait a few seconds, and 1
starting a cold engine with the excep- 5
then try again. Each starting attempt 4
tion that the starter (choke) is not
should be as short as possible to pre- 3
2 required when the engine is warm. 2
serve the battery. Do not crank the N
engine more than 10 seconds on any 1
3 one attempt.
1. Shift pedal
4 6. After starting the engine, move N. Neutral
the starter (choke) knob/lever EAU00423
5 back halfway. Shifting

ECA00045 Shifting gears lets you control the
cC amount of engine power available for
6
For maximum engine life, never starting off, accelerating, climbing
accelerate hard when the engine is hills, etc.
7 The gear positions are shown in the
cold!
illustration.
8
7. When the engine is warm, turn
NOTE:
the starter (choke) off.
9 To shift the transmission into the neu-
NOTE: tral position, press the shift pedal
The engine is warm when it responds down repeatedly until it reaches the
normally to the throttle with the starter end of its travel, and then slightly
(choke) turned off. raise it.
5-2
4TP-9-21 7/25/00 3:46 PM Page 41

EC000048 EAU00424 EAU00436
cC Tips for reducing fuel Engine break-in

8 Even with the transmission in consumption There is never a more important peri-
the neutral position, do not Fuel consumption depends largely on od in the life of your engine than the 1
coast for long periods of time your riding style. Consider the follow- period between 0 and 1,000 km. For
with the engine off, and do not ing tips to reduce fuel consumption: this reason, you should read the fol- 2
tow the motorcycle for long 8 Thoroughly warm up the engine. lowing material carefully.
distances. The transmission is 8 Turn the starter (choke) off as Since the engine is brand new, do 3
properly lubricated only when soon as possible. not put an excessive load on it for the
the engine is running. 8 Shift up swiftly, and avoid high first 1,000 km. The various parts in
4
Inadequate lubrication may engine speeds during accelera- the engine wear and polish them-
damage the transmission. tion. selves to the correct operating clear-
5
8 Always use the clutch while 8 Do not rev the engine while shift- ances. During this period, prolonged
changing gears to avoid dam- ing down, and avoid high engine full-throttle operation or any condition
speeds with no load on the that might result in engine overheat- 6
aging the engine, transmis-
sion, and drive train, which are engine. ing must be avoided.
not designed to withstand the 8 Turn the engine off instead of let- 7
shock of forced shifting. ting it idle for an extended length
of time (e.g., in traffic jams, at 8
traffic lights or at railroad cross-
ings). 9
5-3
4TP-9-21 7/25/00 3:46 PM Page 42

EAU00455
1,000 km and beyond EAU00457
0–150 km Parking
Avoid prolonged full-throttle opera-
8 Avoid prolonged operation above When parking, stop the engine,
tion. Vary the engine speed occa-
1 1/3 throttle. remove the key from the main switch,
sionally.
8 After every hour of operation, EC000049 and then turn the fuel cock lever to
2 stop the engine, and then let it cC “OFF”.
cool for five to ten minutes. EW000058
If any engine trouble should occur
8 Vary the engine speed from time w
3 during the engine break-in period,
to time. Do not operate the 8 Since the engine and exhaust
immediately have a Yamaha dealer
engine at one set throttle posi- system can become very hot,
4 check the vehicle.
tion. park in a place where pedestri-
ans or children are not likely
5 150–500 km
to touch them.
8 Avoid prolonged operation above
8 Do not park on a slope or on
6 1/2 throttle.
soft ground, otherwise the
8 Rev the engine freely through
motorcycle may overturn.
the gears, but do not use full
7
throttle at any time.
8 500–1,000 km
Avoid prolonged operation above 3/4
9 throttle.
EC000060
cC
After 1,000 km of operation, the
transmission oil must be changed.
5-4
4TP-9-21 7/25/00 3:46 PM Page 43
EAU00462
PERIODIC MAINTENANCE AND MINOR REPAIR

EAU00464
NOTE:
Safety is an obligation of the owner. 1
If you do not have the tools or experi-
Periodic inspection, adjustment and
ence required for a particular job,
lubrication will keep your vehicle in 1
have a Yamaha dealer perform it for
the safest and most efficient condi-
you.
tion possible. The most important 2
points of inspection, adjustment, and EW000063
lubrication are explained on the fol- w 3
lowing pages.
Modifications not approved by
The intervals given in the periodic 1. Owner’s tool kit
Yamaha may cause loss of perfor- 4
maintenance and lubrication chart EAU01175
mance and render the vehicle
should be simply considered as a Owner’s tool kit
unsafe for use. Consult a Yamaha 5
general guide under normal riding The owner’s tool kit is located behind
dealer before attempting any
conditions. However, DEPENDING panel B. (See page 6-7 for panel
changes. 6
ON THE WEATHER, TERRAIN, removal and installation procedures.)
GEOGRAPHICAL LOCATION, AND The service information included in
INDIVIDUAL USE, THE MAINTE- this manual and the tools provided in 7
NANCE INTERVALS MAY NEED TO the owner’s tool kit are intended to
BE SHORTENED. assist you in the performance of pre- 8
EW000060 ventive maintenance and minor
w repairs. However, additional tools
9
If you are not familiar with motor- such as a torque wrench may be nec-
cycle maintenance work, have a essary to perform certain mainte-
Yamaha dealer do it for you. nance work correctly.
6-1
4TP-9-21 7/25/00 3:46 PM Page 44

EAU03540
Periodic maintenance and lubrication chart

NOTE:
1 8 The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.
8 From 30,000 km, repeat the maintenance intervals starting from 6,000 km.
2 8 Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and
technical skills.
3
ODOMETER READING (×1,000 km) ANNUAL
NO. ITEM CHECK OR MAINTENANCE JOB
4 1 6 12 18 24 CHECK
1 * Fuel line • Check fuel hoses for cracks or damage. √ √ √ √ √
5 2 Spark plug • Replace. √ √ √ √ √

• Clean. √ √
3 Air filter element
• Replace. √ √
6
4 Clutch √ √ √ √ √
• Adjust.
7 • Check operation, fluid level and vehicle for fluid leakage.
√ √ √ √ √ √
5 * Front brake (See NOTE on page 6-4.)
• Replace brake pads. Whenever worn to the limit
8 • Check operation, fluid level and vehicle for fluid leakage.
√ √ √ √ √ √
6 * Rear brake (See NOTE on page 6-4.)
• Replace brake pads. Whenever worn to the limit
9
• Check for cracks or damage. √ √ √ √ √
7 * Brake hoses
• Replace. (See NOTE on page 6-4.) Every 4 years
• Check runout, spoke tightness and for damage.
8 * Wheels √ √ √ √
• Tighten spokes if necessary.
6-2
4TP-9-21 7/25/00 3:46 PM Page 45

1 6 12 18 24 CHECK
• Check tread depth and for damage.
9 Tires
• Replace if necessary.
√ √ √ √ 1
* • Check air pressure.
• Correct if necessary.
10 * Wheel bearings • Check bearing for looseness or damage. √ √ √ √ 2
11 * Swingarm • Check operation and for excessive play. √ √ √ √
• Check chain slack.
Every 500 km and after washing the motorcycle
3
12 Drive chain • Make sure that the rear wheel is properly aligned.
or riding in the rain.
• Clean and lubricate.
• Check bearing play and steering for roughness. √ √ √ √ √ 4
13 * Steering bearings
• Lubricate with lithium-soap-based grease Every 24,000km
14 * Chassis fasteners • Make sure that all nuts, bolts and screws are properly tightened. √ √ √ √ √ 5
15 Sidestand √ √ √ √ √
• Lubricate.
16 Sidestand switch • Check operation. √ √ √ √ √ √
6
*
17 * Front fork • Check operation and for oil leakage. √ √ √ √
Rear shock absorber 7
18 * • Check operation and shock absorber for oil leakage. √ √ √ √
assembly
Rear suspension relay • Check operation. √ √ √ √ 8
19 * arm and connecting arm
pivoting points • Lubricate with molybdenum disulfide grease. √ √
• Check starter (choke) operation. 9
20 * Carburetor √ √ √ √ √ √
• Adjust engine idling speed.
21 * Autolube pump √ √ √ √
• Bleed if necessary.
6-3
4TP-9-21 7/25/00 3:46 PM Page 46

1 6 12 18 24 CHECK
• Check oil level and vehicle for leakage. √ √ √ √ √ √
1 22 Transmission oil
• Change. √ √
• Check coolant level and vehicle for coolant leakage. √ √ √ √ √
23 * Cooling system
2 • Change. Every 3 years
Front and rear brake
24 * • Check operation. √ √ √ √ √ √
switches
3 25 Moving parts and cables • Lubricate. √ √ √ √ √
Lights, signals and • Check operation.
26 * √ √ √ √ √ √
4 switches • Adjust headlight beam.
EAU03541
5 NOTE:
8 The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
8 Hydraulic brake service
6
8 Regularly check and, if necessary, correct the brake fluid level.
8 Every two years replace the internal components of the brake master cylinder and caliper, and change the brake fluid.
7 8 Replace the brake hoses every four years and if cracked or damaged.
6-4
4TP-9-21 7/25/00 3:46 PM Page 47
2 1 1 1
1
1. Cowling A 1. Screw (×4) 1. Screw (×3)

2. Cowling B 4
EAU00484 EAU00482
EAU01065
Cowling A Cowling B
Removing and installing To remove the cowling To remove the cowling 5
cowlings Remove the cowling screws, and Remove the screws, and then take
The cowlings shown above need to the cowling off. 6
then pull the cowling off as shown.
be removed to perform some of the
maintenance jobs described in this To install the cowling
To install the cowling 7
chapter. Refer to this section each Place the cowling in the original posi-
Place the cowling in the original posi-
time a cowling needs to be removed tion, and then install the screws.
tion, and then install the screws. 8
and installed.
6-5
4TP-9-21 7/25/00 3:46 PM Page 48
1 1 1
1. Panel A 1. Panel B 1. Screw

4
EAU01122 EAU00488
Refer to this section each time a
Removing and installing panel needs to be removed and Panel A
5 panels To remove the panel
installed.
The panels shown above need to be Remove the screw, and then pull the
6 removed to perform some of the panel off as shown.
maintenance jobs described in this
7 chapter. To install the panel
Place the panel in the original posi-
8 tion, and then install the screw.
6-6
4TP-9-21 7/25/00 3:46 PM Page 49
1 1
1. Screw 1. Spark plug cap 1. Spark plug wrench

EAU00488 EAU01833
2. Remove the spark plug as
Panel B Checking the spark plug
shown, with the spark plug
To remove the panel The spark plug is an important
wrench included in the owner’s
Remove the screw, and then pull the engine component, which is easy to
tool kit.
panel off as shown. check. Since heat and deposits will 6
cause any spark plug to slowly erode,
To install the panel the spark plug should be removed
Place the panel in the original posi- and checked in accordance with the
tion, and then install the screw. periodic maintenance and lubrication
chart. In addition, the condition of the
spark plug can reveal the condition of
the engine.
To remove the spark plug

1. Remove the spark plug cap.
6-7
4TP-9-21 7/25/00 3:46 PM Page 50

To check the spark plug
Tightening torque:
1. Check that the porcelain insula-
Spark plug:
tor around the center electrode
1 20 Nm (2.0 m0kg)
of the spark plug is a medium-to-
light tan (the ideal color when the
NOTE:
2 motorcycle is ridden normally). a If a torque wrench is not available
NOTE: when installing a spark plug, a good
3
If the spark plug shows a distinctly estimate of the correct torque is
different color, the engine could be a. Spark plug gap 1/4–1/2 turn past finger tight.
4 However, the spark plug should be
defective. Do not attempt to diagnose To install the spark plug
such problems yourself. Instead, tightened to the specified torque as
1. Measure the spark plug gap with
5 soon as possible.
have a Yamaha dealer check the a wire thickness gauge and, if
motorcycle. necessary, adjust the gap to
6 specification. 4. Install the spark plug cap.
2. Check the spark plug for elec- Spark plug gap:
7 trode erosion and excessive car- 0.7–0.8 mm
bon or other deposits, and
8 replace it if necessary. 2. Clean the surface of the spark
plug gasket and its mating sur-
9 Specified spark plug: face, and then wipe off any grime
BR9ES (NGK) from the spark plug threads.
3. Install the spark plug with the
spark plug wrench, and then
tighten it to the specified torque.
6-8
4TP-9-21 7/25/00 3:46 PM Page 51

EAU03109
Transmission oil 2 1 1
Oil level inspection
1. Place the motorcycle on a level 1
place and hold it in an upright 3
position. Warm up the engine for 2
several minutes.
3
NOTE:
Be sure the motorcycle is positioned 1. Oil level window 1. Oil filler cap
2. Maximum level 4
straight up when checking the oil Transmission oil replacement
3. Minimum level
level. A slight tilt toward the side can 1. Warm up the engine for several
result in false readings. 2. With the engine stopped, check 5
the oil level through the level minutes.
window located at the right side 2. Stop the engine. Place an oil pan
under the engine to catch the oil 6
crankcase cover.
and remove the oil filler cap.
NOTE: 7
Wait a few minutes until the oil level
settles before checking. 8
3. The oil level should be between 9

the maximum and minimum level
on the level window. If the level
is low, add sufficient oil to raise it
to the specified level.
6-9
4TP-9-21 7/25/00 3:46 PM Page 52

EAU01808
Recommended oil: Coolant
See page 8-1. To check the coolant level
1 1 Oil quantity: 1. Place the motorcycle on a level
Total amount: 0.85 L surface and hold it in an upright
2 Periodic oil change: 0.8 L position.
EC000079
NOTE:
3 cC 8 The coolant level must be
1. Drain bolt In order to prevent clutch slippage checked on a cold engine since
4 (since the transmission oil also the level varies with engine tem-
3. Remove the drain bolt and drain
lubricates the clutch), do not mix perature.
5 the oil.
any chemical additives with the oil. 8 Make sure that the motorcycle is
4. Install the drain bolt and tighten it
positioned straight up when
to the specified torque.
6 6. Start the engine and warm up for checking the coolant level. A
Tightening torque: a few minutes. While warming slight tilt to the side can result in
7 Drain bolt: up, check for oil leakage. If oil a false reading.
15 Nm (1.5 m0kg) leakage is found, stop the engine
8 immediately and check for
5. Fill the engine with sufficient oil cause.
to reach the specified level.
9
Install the oil filler cap and tight-
en it.
6-10
4TP-9-21 7/25/00 3:46 PM Page 53

EW000067
3
Coolant reservoir capacity: w
0.36 L
Never attempt to remove the radia-
1 EC000080 tor cap when the engine is hot. 1
2 cC
8 If coolant is not available, use 5. Install the panel. 2
distilled water or soft tap water
instead. Do not use hard water NOTE: 3
or salt water since it is harmful If the engine overheats, see page
1. Maximum level mark 6-44 for further instructions.
2. Minimum level mark to the engine. 4
3. Coolant reservoir 8 If water has been used instead
2. Remove panel B. (See page 6-7 of coolant, replace it with 5
for panel removal and installation coolant as soon as possible,
procedures.) otherwise the engine may not
6
3. Check the coolant level in the be sufficiently cooled and the
coolant reservoir. cooling system will not be pro-
tected against frost and corro- 7
NOTE: sion.
The coolant should be between the 8 If water has been added to the 8
minimum and maximum level marks. coolant, have a Yamaha dealer
check the antifreeze content of 9
4. If the coolant is at or below the the coolant as soon as possi-
minimum level mark, open the ble, otherwise the effective-
reservoir cap, add coolant to the ness of the coolant will be
maximum level mark, and then reduced.
close the reservoir cap.
6-11
4TP-9-21 7/25/00 3:46 PM Page 54
2
1
1 1
2
2
1 3
3
1. Radiator cap stopper bolt 1. Coolant drain bolt 1. Maximum level mark
4 2. Radiator cap 2. Minimum level mark
EAU03101 4. Place a container under the 3. Reservoir tank hose
5 Changing the coolant engine and remove the coolant 5. Disconnect the reservoir tank
1. Put the motorcycle on a level drain bolt. hose on the reservoir tank side
6 place. and drain the coolant from the
2. Remove cowling B and panel B. reservoir tank.
(See pages 6-5 and 6-7 for cowl- 6. After draining the coolant, thor-
7
ing and panel removal and instal- oughly flush the cooling system
lation procedures.) with clean tap water.
8 3. Remove the radiator cap stopper 7. Replace the coolant drain bolt
bolt and the radiator cap. washer if it is damaged and tight-
9 en the coolant drain bolt to the
specified torque.
Tightening torque:
Coolant drain bolt:
10 Nm (1.0 m0kg)
6-12
4TP-9-21 7/25/00 3:46 PM Page 55

EC000080
8. Install the reservoir tank hose. 10. Install the radiator cap.
cC
9. Pour the recommended coolant 11. Run the engine several minutes.
into the radiator until it is full. 8 If coolant is not available, use Stop the engine and recheck the
distilled water or soft tap water 1
coolant level in the radiator. If it
Recommended antifreeze: instead. Do not use hard water is low, add more coolant until it
High quality ethylene glycol or salt water since it is harmful reaches the top of the radiator. 2
antifreeze containing corrosion to the engine. 12. Install the radiator cap stopper
inhibitors for aluminum 8 If water has been used instead bolt. 3
engines. of coolant, replace it with 13. Fill the reservoir tank with
Antifreeze and water mixing ratio: coolant as soon as possible, coolant up to maximum level. 4
1:1 otherwise the engine may not 14. Install the reservoir tank cap and
Total amount: be sufficiently cooled and the check for coolant leakage. 5
1.26 L cooling system will not be pro-
Reservoir tank capacity: tected against frost and corro- NOTE:
6
0.36 L sion. If any leakage is found, ask a
8 If water has been added to the Yamaha dealer to inspect the cooling
coolant, have a Yamaha dealer system. 7
check the antifreeze content of
the coolant as soon as possi- 15. Install the cowling and the panel. 8
ble, otherwise the effective-
ness of the coolant will be 9
reduced.
6-13
4TP-9-21 7/25/00 3:46 PM Page 56
1 2 3 4
1
2 1
2
3
1. Screw (×3) 1. Air filter element guide

4 2. Air filter case cover 2. Air filter element frame
EAU03671 3. Pull the air filter element out from 3. Sponge material
the air filter case. 4. Wing nut
5 Cleaning the air filter
element 4. Remove the wing nut , and then
The air filter element should be pull the air filter element off of
6 the guide.
cleaned at the intervals specified in
the periodic maintenance and lubrica- 5. Remove the sponge material
7 from the air filter element frame.
tion chart. Clean the air filter element
more frequently if you are riding in
8 unusually wet or dusty areas.
1. Remove panel A. (See page 6-6
9 for removal and installation pro-
cedures.)
2. Remove the air filter case cover
by removing the screws.
6-14
4TP-9-21 7/25/00 3:46 PM Page 57

EAU00629
1 2 8. Install the sponge material onto
the frame, place the air filter ele- Adjusting the carburetor
ment in the original position on The carburetor is an important part of
the engine and requires very sophisti- 1
the guide, and then tighten the
wing nut. cated adjustment. Therefore, most
3 4 carburetor adjustments should be left
9. Insert the air filter element into 2
the air filter case. to a Yamaha dealer, who has the
EC000082 necessary professional knowledge 3
cC and experience. The adjustment
8 Make sure that the air filter ele- described in the following section,
4
6. Clean the sponge material with ment is properly seated in the however, may be serviced by the
solvent, and then squeeze the air filter case. owner as part of routine mainte-
5
remaining solvent out. 8 The engine should never be nance.
EC000094
7. Apply oil of the recommended operated without the air filter cC 6
type to the entire surface of the element installed, otherwise
sponge material, and then the piston(s) and/or cylinder(s) The carburetor has been set and
squeeze the excess oil out. may become excessively extensively tested at the Yamaha 7
worn. factory. Changing these settings
NOTE: without sufficient technical knowl- 8
The sponge material should be wet edge may result in poor perfor-
10. Install the air filter case cover by
but not dripping. mance of or damage to the engine. 9
installing the screws.
11. Install the panel.
Recommended oil:
2-stroke engine oil
6-15
4TP-9-21 7/25/00 3:46 PM Page 58

EAU01168
Adjusting the engine idling 1 a

speed
1 The engine idling speed must be
checked and, if necessary, adjusted a
b
2 as follows at the intervals specified in
the periodic maintenance and lubrica-
3 tion chart.
NOTE: 1. Throttle stop screw a. Throttle cable free play

4
A diagnostic tachometer is needed to EAU00634
3. Check the engine idling speed
make this adjustment.
and, if necessary, adjust it to Adjusting the throttle cable
5 free play
specification by turning the throt-
1. Attach the tachometer to the tle stop screw. To increase the The throttle cable free play should
6 spark plug lead. engine idling speed, turn the measure 3–5 mm at the throttle grip.
2. Start the engine and warm it up screw in direction a. To Periodically check the throttle cable
7 for several minutes at decrease the engine idling free play and, if necessary, adjust it
1,000–2,000 r/min while occa- speed, turn the screw in direction as follows.
8 sionally revving it to 4,000–5,000 b.
r/min. NOTE:
Engine idling speed: The engine idling speed must be cor-
9 1,300–1,400 r/min
NOTE: rectly adjusted before checking and
The engine is warm when it quickly NOTE: adjusting the throttle cable free play.
responds to the throttle. If the specified idling speed cannot
be obtained as described above,
have a Yamaha dealer make the
adjustment.
6-16
4TP-9-21 7/25/00 3:46 PM Page 59

EAU03593 Tire air pressure
Tires (measured on cold tires)
1 2 Load* Front Rear
To maximize the performance, dura-
125 kPa 150 kPa 1
bility, and safe operation of your
Up to 88 kg 1.25 kg/cm2 1.50 kg/cm2
b motorcycle, note the following points 1.25 bar 1.50 bar
regarding the specified tires. 88 kg–
150 kPa 175 kPa 2
1.50 kg/cm2 1.75 kg/cm2
maximum
a 1.50 bar 1.75 bar
Tire air pressure 3
The tire air pressure should be
Maximum load* 180 kg
1. Adjusting nut checked and, if necessary, adjusted
2. Locknut * Total weight of rider, passenger, cargo and 4
before each ride. accessories
1. Loosen the locknut. EW000082
2. To increase the throttle cable w 5

free play, turn the adjusting nut 8 The tire air pressure must be
in direction a. To decrease the checked and adjusted on cold 6
throttle cable free play, turn the tires (i.e., when the tempera-
adjusting nut in direction b. ture of the tires equals the 7
3. Tighten the locknut. ambient temperature).
8 The tire air pressure must be 8
adjusted in accordance with
the riding speed and with the 9
total weight of rider, passen-
ger, cargo, and accessories
approved for this model.
6-17
4TP-9-21 7/25/00 3:46 PM Page 60

EWA00012
8 Adjust the suspension and tire
w air pressure with regard to the
a
Because loading has an enormous load.
1 impact on the handling, braking, 8 Check the tire condition and
performance and safety character- air pressure before each ride. 2
2 1
istics of your motorcycle, you
should keep the following precau-
3 tions in mind.
8 NEVER OVERLOAD THE
MOTORCYCLE! Operation of 1. Side wall
4 2. Wear indicator
an overloaded motorcycle may a. Tread depth
result in tire damage, loss of Tire inspection
5
control, or severe injury. Make The tires must be checked before
sure that the total weight of each ride. If the tire shows crosswise
6
rider, passenger, cargo, and lines (minimum tread depth), if the
accessories does not exceed tire has a nail or glass fragments in it,
7 the specified maximum load or if the sidewall is cracked, have a
for the vehicle. Yamaha dealer replace the tire imme-
8 8 Do not carry along loosely diately.
packed items, which can shift
Minimum tire tread depth
during a ride. 1.0 mm
9 (front and rear)
8 Securely pack the heaviest
items close to the center of the NOTE:
motorcycle and distribute the The tire tread depth limits may differ
weight evenly on both sides. from country to country. Always com-
ply with the local regulations.
6-18
4TP-9-21 7/25/00 3:46 PM Page 61

EW000079 EW000078 EAU00680
w w w
8 Have a Yamaha dealer replace 8 The front and rear tires should 8 It is dangerous to ride with a
excessively worn tires. be of the same make and worn-out tire. When a tire 1
Besides being illegal, operat- design, otherwise the handling tread begins to show cross-
ing the motorcycle with exces- characteristics of the motorcy- wise lines, have a Yamaha 2
sively worn tires decreases cle cannot be guaranteed. dealer replace the tire immedi-
riding stability and can lead to 8 After extensive tests, only the ately. 3
loss of control. tires listed below have been 8 The replacement of all wheel-
8 The replacement of all wheel- approved for this model by and brake-related parts, 4
and brake-related parts, Yamaha Motor Co., Ltd. including the tires, should be
including the tires, should be left to a Yamaha dealer, who
5
left to a Yamaha dealer, who FRONT
has the necessary profession-
has the necessary profession- Manufacturer Size Type al knowledge and experience.
6
al knowledge and experience. INOUE 3.00-21 51P GP-21F 8 It is not recommended to
CHENG SHIN 3.00-21 51P M-6033 patch a punctured tube. If
Tire information unavoidable, however, patch 7
REAR
This motorcycle is equipped with tube Manufacturer Size Type the tube very carefully and
tires. INOUE 4.60-18 63P GP-22R replace it as soon as possible 8
CHENG SHIN 4.60-18 63P M-6034 with a high-quality product.
9
6-19
4TP-9-21 7/25/00 3:46 PM Page 62

EAU00685
8 Ride at moderate speeds after
Spoke wheels changing a tire since the tire sur-
To maximize the performance, dura- face must first be “broken in” for a
1 bility, and safe operation of your it to develop its optimal charac-
motorcycle, note the following points teristics.
2 regarding the specified wheels.
8 The wheel rims should be
3 checked for cracks, bends or
warpage, and the spokes for
looseness or damage before a. Clutch lever free play
4
each ride. If any damage is EAU02996
found, have a Yamaha dealer Adjusting the clutch lever

5 free play
replace the wheel. Do not
attempt even the smallest repair The clutch lever free play should
6 to the wheel. A deformed or measure 10–15 mm as shown.
cracked wheel must be replaced. Periodically check the clutch lever
7 8 The wheel should be balanced free play and, if necessary, adjust it
whenever either the tire or wheel as follows.
8 has been changed or replaced.
An unbalanced wheel can result
9 in poor performance, adverse
handling characteristics, and a
shortened tire life.
6-20
4TP-9-21 7/25/00 3:46 PM Page 63

4. Fully turn the adjusting bolt in
1 2 a 3 4 a
direction a to loosen the clutch 1 2
cable. b c
1
5. Loosen the locknut further down
the clutch cable.
b 2
b 6. To increase the clutch lever free a
play, turn the adjusting nut in
direction a. To decrease the 3
clutch lever free play, turn the
1. Locknut (Clutch lever) 1. Locknut
2. Adjusting bolt adjusting nut in direction b. 2. Adjusting bolt 4
3. Locknut (Clutch cable) 7. Tighten both locknuts. c. Brake lever free play
4. Adjusting nut EAU00696
5
1. Loosen the locknut at the clutch Adjusting the brake lever
lever. free play
6
2. To increase the clutch lever free The brake lever free play should
play, turn the adjusting bolt in measure 2–5 mm as shown.
direction a. To decrease the Periodically check the brake lever 7
clutch lever free play, turn the free play and, if necessary, adjust it
adjusting bolt in direction b. as follows. 8
3. If the specified clutch lever free 1. Loosen the locknut at the brake
play could be obtained as lever. 9
described above, tighten the 2. To increase the brake lever free
locknut and skip the rest of the play, turn the adjusting bolt in
procedure, otherwise proceed as direction a. To decrease the
brake lever free play, turn the
follows.
adjusting bolt in direction b.
3. Tighten the locknut.
6-21
4TP-9-21 7/25/00 3:46 PM Page 64

EW000099 EW000109
w w
8 After adjusting the brake lever 1 A soft or spongy feeling in the
1 free play, check the free play brake pedal can indicate the pres-
and make sure that the brake ence of air in the hydraulic system.
2 is working properly. a If there is air in the hydraulic sys-
8 A soft or spongy feeling in the tem, have a Yamaha dealer bleed
3 brake lever can indicate the the system before operating the
presence of air in the motorcycle. Air in the hydraulic
hydraulic system. If there is air 1. Footrest system will diminish the braking
4 a. Brake pedal position
in the hydraulic system, have EAU00712
performance, which may result in
a Yamaha dealer bleed the Adjusting the brake pedal loss of control and an accident.
5
system before operating the position
motorcycle. Air in the The top of the brake pedal should be
6
hydraulic system will diminish positioned approximately 15 mm
the braking performance, below the top of the footrest as
7 which may result in loss of shown. Periodically check the brake
control and an accident. pedal position and, if necessary,
8 have a Yamaha dealer adjust it.
6-22
4TP-9-21 7/25/00 3:46 PM Page 65

FRONT REAR
1
1 1
2 1
a
b 2
1. Brake light switch 1. Indicator groove 1. Indicator groove

2. Adjusting nut 4
EAU01314
EAU00713
To check the brake pad wear, check
Checking the front and rear the wear indicator grooves. If a brake
Adjusting the rear brake light brake pads 5
switch pad has worn to the point that the
The front and rear brake pads must wear indicator groove has almost dis-
The rear brake light switch, which is 6
be checked for wear at the intervals appeared, have a Yamaha dealer
activated by the brake pedal, is prop-
specified in the periodic maintenance replace the brake pads as a set.
erly adjusted when the brake light
and lubrication chart. Each brake pad 7
comes on just before braking takes
is provided with a wear indicator
effect. If necessary, adjust the brake
groove, which allows you to check 8
light switch as follows.
the brake pad wear without having to
Turn the adjusting nut while holding
disassemble the brake.
the rear brake light switch in place. 9
To make the brake light come on ear-
lier, turn the adjusting nut in direction
a. To make the brake light come on
later, turn the adjusting nut in direc-
tion b.
6-23
4TP-9-21 7/25/00 3:46 PM Page 66

FRONT REAR 8 Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
1
lead to poor braking perfor-
1 mance.
2 1
8 Be careful that water does not
enter the master cylinder when
3 refilling. Water will significantly
lower the boiling point of the fluid
1. Minimum level mark 1. Minimum level mark
4 and may result in vapor lock.
EAU03196
Observe these precautions: 8 Brake fluid may deteriorate paint-
Checking the brake fluid 8 When checking the fluid level, ed surfaces or plastic parts.
5 level make sure that the top of the Always clean up spilled fluid
Insufficient brake fluid may allow air master cylinder or brake fluid immediately.
6 to enter the brake system, possibly reservoir is level. 8 As the brake pads wear, it is nor-
causing it to become ineffective. 8 Use only the recommended qual- mal for the brake fluid level to
7 Before riding, check that the brake ity brake fluid, otherwise the rub- gradually go down. However, if
fluid is above the minimum level mark ber seals may deteriorate, caus- the brake fluid level goes down
8 and replenish if necessary. A low ing leakage and poor braking suddenly, have a Yamaha dealer
brake fluid level may indicate worn performance. check the cause.
brake pads and/or brake system
9
leakage. If the brake level is low, be Recommended brake fluid:
sure to check the brake pads for DOT 4
wear and the brake system for leak-
age.
6-24
4TP-9-21 7/25/00 3:46 PM Page 67

EAU03073 EAU00744
Changing the brake fluid Drive chain slack

Have a Yamaha dealer change the The drive chain slack should be
brake fluid at the intervals specified in checked before each ride and adjust- 1
the periodic maintenance and lubrica- ed if necessary.
tion chart. In addition, have the oil 2
seals of the master cylinder and To check the drive chain slack
caliper as well as the brake hoses 1. Place the motorcycle on a level
a
3
replaced at the intervals listed below surface and hold it in an upright
or whenever they are damaged or position. a. Drive chain slack
4
leaking. 3. Move the rear wheel by pushing
8 Oil seals: Replace every two NOTE:
the motorcycle to locate the tight- 5
years. When checking and adjusting the
est portion of the drive chain,
8 Brake hoses: Replace every four drive chain slack, the motorcycle
and then measure the drive
years. should be positioned straight up and 6
chain slack as shown.
there should be no weight on it.
Drive chain slack: 7
2. Shift the transmission into the 40–60 mm
neutral position. 8
4. If the drive chain slack is incor-
rect, adjust it as follows.
9
6-25
4TP-9-21 7/25/00 3:46 PM Page 68

EC000096 EAU03006
cC Lubricating the drive chain

1
Improper drive chain slack will The drive chain must be cleaned and
1 overload the engine as well as lubricated at the intervals specified in
a other vital parts of the motorcycle the periodic maintenance and lubrica-
2 b and can lead to chain slippage or tion chart, otherwise it will quickly
breakage. To prevent this from wear out, especially when riding in
3 2 occurring, keep the drive chain dusty or wet areas. Service the drive
slack within the specified limits. chain as follows.
1. Axle nut EC000097
4 2. Chain adjusting plate cC
EAU03594 3. Tighten the axle nut to the speci-
To adjust the drive chain slack fied torque. The drive chain must be lubricated
5 after washing the motorcycle or
1. Loosen the axle nut.
2. To tighten the drive chain, turn Tightening torque: riding in the rain.
6 Axle nut:
the adjusting plate on each side
of the swingarm in direction a. 104 Nm (10.4 m0kg) 1. Clean the drive chain with
7 To loosen the drive chain, turn kerosene and a small soft brush.
ECA00053
the adjusting plate on each side
cC
8 of the swingarm in direction b,
and then push the rear wheel for- To prevent damaging the O-rings,
9 ward. do not clean the drive chain with
steam cleaners, high-pressure
NOTE: washers or inappropriate solvents.
Make sure that both adjusting plates
are in the same position for proper 2. Wipe the drive chain dry.
wheel alignment.
6-26
4TP-9-21 7/25/00 3:46 PM Page 69

EW000112
3. Thoroughly lubricate the drive
w
chain with a special O-ring chain
lubricant. Damage to the outer sheath may
ECA00052 interfere with proper cable opera- 1
cC tion and will cause the inner cable
Do not use engine oil or any other to rust. Replace a damaged cable 2
lubricants for the drive chain, as as soon as possible to prevent
they may contain substances that unsafe conditions. 3
could damage the O-rings.
4
EAU02962
Checking and lubricating the

cables 5
The operation of all control cables
and the condition of the cables 6
should be checked before each ride,
and the cables and cable ends 7
should be lubricated if necessary. If a
cable is damaged or does not move 8
smoothly, have a Yamaha dealer
check or replace it.
9
Recommended lubricant:
Engine oil
6-27
4TP-9-21 7/25/00 3:46 PM Page 70

EAU03209 EAU00774
4. Grease the metal-to-metal con-
Checking and lubricating the tact surface of the throttle grip, Adjusting the Autolube
throttle grip and cable and then install the grip by pump
1 The operation of the throttle grip and The Autolube pump is a vital and
installing the screws.
the condition of the throttle cable sophisticated component of the
2 should be checked before each ride, engine, which must be adjusted by a
and the cable should be lubricated or Yamaha dealer at the intervals speci-
Throttle cable:
3 replaced if necessary. fied in the periodic maintenance and
Engine oil
lubrication chart.
Throttle grip housing and grip:
NOTE:
4 Lithium-soap-based grease
Since the throttle grip must be
(all-purpose grease)
removed to access the throttle cable
5 end, the throttle grip and the cable
should always be lubricated at the
6 same time.
7 1. Remove the throttle grip by

removing the screws.
8 2. Disconnect the throttle cable,
hold it up, and then apply several
9 drops of oil to the cable end,
allowing it to trickle into the
sheath.
3. Connect the throttle cable, and
then grease the inside of the
throttle grip housing.
6-28
4TP-9-21 7/25/00 3:46 PM Page 71
4
EAU03370 EAU03164 EAU03165
Checking and lubricating the Checking and lubricating the Checking and lubricating the
brake and shift pedals brake and clutch levers sidestand 5
The operation of the brake and shift The operation of the brake and clutch The operation of the sidestand should
pedals should be checked before levers should be checked before be checked before each ride, and the 6
each ride, and the pedal pivots each ride, and the lever pivots should sidestand pivot and metal-to-metal
should be lubricated if necessary. be lubricated if necessary. contact surfaces should be lubricated 7
if necessary.
Recommended lubricant: Recommended lubricant: EW000113
Lithium-soap-based grease Lithium-soap-based grease w 8
(all-purpose grease) (all-purpose grease) If the sidestand does not move up

and down smoothly, have a 9
Yamaha dealer check or repair it.
Lithium-soap-based grease
(all-purpose grease)
6-29
4TP-9-21 7/25/00 3:46 PM Page 72

EAU02939
1 Checking the front fork
The condition and operation of the
1 front fork must be checked as follows
at the intervals specified in the peri-
2 odic maintenance and lubrication
chart.
3
To check the condition
1. Grease nipple (×2) EW000115
4 w
EAU00790
To check the operation
Lubricating the rear Securely support the motorcycle 1. Place the motorcycle on a level
5 suspension so that there is no danger of it surface and hold it in an upright
The pivoting points of the rear sus- falling over. position.
6 pension must be lubricated at the 2. While applying the front brake,
intervals specified in the periodic Check the inner tubes for scratches, push down hard on the handle-
7 maintenance and lubrication chart. damage and excessive oil leakage. bars several times to check if the
front fork compresses and
8 rebounds smoothly.
Molybdenum disulfide grease EC000098
cC
9
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or
repair it.
6-30
4TP-9-21 7/25/00 3:46 PM Page 73

EAU00794 EAU01144
Checking the steering Checking the wheel bearings

Worn or loose steering bearings may The front and rear wheel bearings
cause danger. Therefore, the opera- must be checked at the intervals 1
tion of the steering must be checked specified in the periodic maintenance
as follows at the intervals specified in and lubrication chart. If there is play 2
the periodic maintenance and lubrica- in the wheel hub or if the wheel does
tion chart. not turn smoothly, have a Yamaha 3
1. Place a stand under the engine dealer check the wheel bearings.
to raise the front wheel off the
ground. 4
EW000115
2. Hold the lower ends of the front
w fork legs and try to move them 5
forward and backward. If any
Securely support the motorcycle
free play can be felt, have a
so that there is no danger of it 6
Yamaha dealer check or repair
falling over.
the steering.
7
6-31
4TP-9-21 7/25/00 3:46 PM Page 74

EW000116
8 KEEP THIS AND ALL BATTER-
1 w IES OUT OF THE REACH OF
8 Electrolyte is poisonous and CHILDREN.
1 dangerous since it contains
sulfuric acid, which causes To charge the battery
2 severe burns. Avoid any con- Have a Yamaha dealer charge the
tact with skin, eyes or clothing battery as soon as possible if it
3 and always shield your eyes seems to have discharged. Keep in
when working near batteries. mind that the battery tends to dis-
1. Battery In case of contact, administer
4 charge more quickly if the motorcycle
the following FIRST AID. is equipped with optional electrical
EAU00800 8 EXTERNAL: Flush with accessories.
5 Battery plenty of water.
This motorcycle is equipped with a 8 INTERNAL: Drink large
6 sealed-type (MF) battery, which does quantities of water or milk
not require any maintenance. There and immediately call a
7 is no need to check the electrolyte or physician.
to add distilled water. 8 EYES: Flush with water for
EC000101
8 15 minutes and seek prompt
cC medical attention.
9 8 Batteries produce explosive
Never attempt to remove the bat-
hydrogen gas. Therefore, keep
tery cell seals, as this would per-
sparks, flames, cigarettes,
manently damage the battery.
etc., away from the battery and
provide sufficient ventilation
when charging it in an
enclosed space.
6-32
4TP-9-21 7/25/00 3:46 PM Page 75

To store the battery EC000102
1. If the motorcycle will not be used cC 1 2

for more than one month, 8 Always keep the battery
remove the battery, fully charge charged. Storing a discharged 1
it, and then place it in a cool, dry battery can cause permanent
place. battery damage. 2
2. If the battery will be stored for 8 To charge a sealed-type (MF)
more than two months, check it battery, a special (constant- 3
at least once a month and fully voltage) battery charger is
charge it if necessary. required. Using a conventional 1. Fuse
2. Spare fuse 4
3. Fully charge the battery before battery charger will damage EAU00804
installation. the battery. If you do not have Replacing the fuse 5

4. After installation, make sure that access to a sealed-type (MF) If the fuse is blown, replace it as fol-
the battery leads are properly battery charger, have a lows. 6
connected to the battery termi- Yamaha dealer charge your 1. Turn the key to “OFF” and turn
nals. battery. off all electrical circuits.
7
2. Remove the blown fuse, and
then install a new fuse of the
specified amperage. 8
Specified fuse: 9
30A
6-33
4TP-9-21 7/25/00 3:46 PM Page 76

EC000103 EAU03592
cC Replacing the headlight bulb 1

Do not use a fuse of a higher This motorcycle is equipped with a
1 amperage rating than recommend- quartz bulb headlight. If the headlight
ed to avoid causing extensive bulb burns out, replace it as follows:
2 damage to the electrical system 1. Remove cowling A together with
and possibly a fire. the headlight unit. (See page 6-5
3 for cowling removal and installa-
3. Turn the key to “ON” and turn on tion procedures.)
1. Headlight coupler
4 the electrical circuits to check if
the devices operate. 2. Disconnect the headlight cou-
5 4. If the fuse immediately blows pler, and then remove the head-
again, have a Yamaha dealer light bulb cover.
check the electrical system.
6
6-34
4TP-9-21 7/25/00 3:46 PM Page 77
1 1
a
1
1. Headlight bulb cover 1. Headlight bulb holder a. Do not touch this area
4
EC000106
3. Unhook the headlight bulb hold-
cC
er, and then remove the defec- 5
tive bulb. Avoid touching the glass part of
EW000119 the bulb. Keep it free from oil; oth-
w erwise, the transparency of the 6
Headlight bulbs get very hot. glass, life of the bulb, and lumi-
Therefore, keep flammable prod- nous flux will be adversely affect- 7
ucts away from a lit headlight bulb, ed. If oil gets on the bulb, thor-
and do not touch the bulb until it oughly clean it with a cloth 8
has cooled down. moistened with alcohol or lacquer
thinner. 9
4. Put a new bulb into position, and
then secure it with the bulb hold- 5. Install the bulb cover, and then
er. connect the coupler.
6-35
4TP-9-21 7/25/00 3:46 PM Page 78

6. Install the cowling together with
the headlight unit. 1 2
1
7. Have a Yamaha dealer adjust
1
the headlight beam if necessary.
1. Screw 1. Bulb
4 2. Lens
EAU03497 2. Remove the defective bulb by
5 Replacing a turn signal light pushing it in and turning it coun-
bulb terclockwise.
1. Remove the turn signal light lens 3. Insert a new bulb into the socket,
6
by removing the screw. push it in, and then turn it clock-
wise until it stops.
7 4. Install the lens by installing the
screw.
8 ECA00065
cC
9 Do not overtighten the screw, oth-
erwise the lens may break.
6-36
4TP-9-21 7/25/00 3:46 PM Page 79
1 1
1
2
2
1
3
1. Screw (×2) 1. Bulb 1. Nut (×2)

2. Lens 4
EAU01624
EAU01623 2. Remove the defective bulb by
Replacing the tail/brake light pushing it in and turning it coun- Replacing the license plate
light bulb 5
bulb terclockwise.
3. Insert a new bulb into the socket, 1. Remove the license plate light by
1. Remove the tail/brake light lens
removing the nuts. 6
by removing the screws. push it in, and then turn it clock-
wise until it stops.
4. Install the lens by installing the 7
screws.
EC000108 8
cC
Do not overtighten the screws, 9
otherwise the lens may break.
6-37
4TP-9-21 7/25/00 3:46 PM Page 80

EAU01579
1 Supporting the motorcycle

Since this model is not equipped with
1 a centerstand, follow these precau-
tions when removing the front and
2 1 rear wheel or performing other main-
tenance requiring the motorcycle to
3 stand upright. Check that the motor-
cycle is in a stable and level position
1. Nut (×2) 1. Bulb (×2) before starting any maintenance. A
4
2. Remove the license plate light 3. Remove the defective bulb by strong wooden box can be placed
lens by removing the nuts. pulling it out. under the engine for added stability.
5
4. Insert a new bulb into the socket.
5. Install the lens by installing the To service the front wheel
6 1. Stabilize the rear of the motorcy-
nuts.
6. Install the license plate light by cle by using a motorcycle stand
7 installing the nuts. or, if an additional motorcycle
stand is not available, by placing
8 a jack under the frame in front of
the rear wheel.
9 2. Raise the front wheel off the
ground by using a motorcycle
stand.
6-38
4TP-9-21 7/25/00 3:46 PM Page 81

To service the rear wheel 3. Pull the wheel axle out, and then
Raise the rear wheel off the ground remove the wheel.
by using a motorcycle stand or, if a ECA00048
motorcycle stand is not available, by 1 cC 1

placing a jack either under each side Do not apply the brake after the
of the frame in front of the rear wheel wheel has been removed together 2
2
or under each side of the swingarm. with the brake disc, otherwise the
brake pads will be forced shut. 3
1. Axle holder nut (×4)

2. Wheel axle 4
EAU00879
Front wheel 5
To remove the front wheel
EW000122
w 6
8 It is advisable to have a
Yamaha dealer service the 7
wheel.
8 Securely support the motorcy- 8
cle so that there is no danger
of it falling over. 9
1. Loosen the wheel axle holder

nuts, then the wheel axle.
2. Lift the front wheel off the ground
according to the procedure on
page 6-38.
6-39
4TP-9-21 7/25/00 3:46 PM Page 82

EAU03678
NOTE:
To install the front wheel
Tighten the upper nuts first, and then 1
1. Lift the wheel up between the
the lower ones. When the nuts are
1 fork legs and guide the brake
tightened in this sequence, there
disc between the brake pads.
should be a gap at the bottom of the
2 axle holder.
NOTE:
Make sure that there is enough
3
space between the brake pads Tightening torque:
before inserting the brake disc. Axle holder nut: 1. Axle nut
4
10 Nm (1.0 m0kg) EAU03588
2. Insert the wheel axle. Rear wheel

5 5. Push down hard on the handle- To remove the rear wheel
3. Lower the front wheel so that it is
bar several times to check for EW000122
on the ground.
6 4. Tighten the wheel axle to the
proper fork operation. w
specified torque. 8 It is advisable to have a
7 Yamaha dealer service the
Tightening torque: wheel.
Wheel axle: 8 Securely support the motorcy-
8 58 Nm (5.8 m0kg) cle so that there is no danger
5. Tighten the axle holder nuts to of it falling over.
9
the specified torque.
1. Loosen the axle nut.
2. Lift the rear wheel off the ground
according to the procedure on
page 6-38.
6-40
4TP-9-21 7/25/00 3:46 PM Page 83

EAU01806
To install the rear wheel

1 1. Install the drive chain onto the
rear sprocket, and then insert the 1
wheel axle from the left side.
2
NOTE:
Make sure that there is enough
3
space between the brake pads
1. Swingarm end bolt (×2) before inserting the brake disc
4
between the pads.
3. Remove the swingarm end bolt 4. Push the wheel forward, and
from each end of the swingarm. then remove the drive chain from 5
the rear sprocket. 2. Install the swingarm end bolts,
and then lower the rear wheel so
NOTE: that it is on the ground. 6
The drive chain does not need to be 3. Adjust the drive chain slack.
disassembled in order to remove and (See page 6-26 for drive chain 7
install the rear wheel. slack adjustment procedures.)
4. Tighten the axle nut and 8
5. Remove the wheel. swingarm end bolts to the speci-
ECA00048 fied torques. 9
cC
Do not apply the brake after the Tightening torque:
wheel has been removed together Axle nut:
with the brake disc, otherwise the 103 Nm (10.3 m0kg)
brake pads will be forced shut. Swingarm end bolts:
3 Nm (0.3 m0kg)
6-41
4TP-9-21 7/25/00 3:46 PM Page 84

EAU03087
Troubleshooting
Although Yamaha motorcycles
1 receive a thorough inspection before
shipment from the factory, trouble
2 may occur during operation. Any
problem in the fuel, compression, or
3 ignition systems, for example, can
cause poor starting and loss of
power.
4
The following troubleshooting charts
represent quick and easy procedures
5
for checking these vital systems your-
self. However, should your motorcy-
6 cle require any repair, take it to a
Yamaha dealer, whose skilled techni-
7 cians have the necessary tools,
experience, and know-how to service
8 the motorcycle properly.
Use only genuine Yamaha replace-
9 ment 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.
6-42
4TP-9-21 7/25/00 3:46 PM Page 85

EAU01581
Troubleshooting charts
Starting problems or poor engine performance
EW000125 1
w
Keep away open flames and do not smoke while checking or working on the fuel system. 2
1. Fuel Enough fuel. Go to compression check. 3

Check if there is fuel
in the fuel tank.
4
Engine doesn’t start, go to
No fuel. Supply fuel.
compression check.
5
2. Compression There is compression. Go to ignition check.
Use electric starter. 6
No compression. Ask a Yamaha dealer to inspect.
3. Ignition
Wipe clean with dry cloth and correct Open throttle half-way and start 7
Wet.
Remove spark spark gap or replace spark plug. the engine.
plug and check
electrodes.
8
Dry. Ask a Yamaha dealer to inspect. Engine doesn’t start, go to battery
check.
9
4. Battery
Engine turns over
Battery good.
quickly.
Engine doesn’t start, ask a
Use electric starter. Yamaha dealer to inspect.
Engine turns over Check connections or
slowly. recharge.
6-43
4TP-9-21 7/25/00 3:46 PM Page 86

Engine overheating
EW000070
w
1 8 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.
2 8 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
3 hissing sound has stopped, press down on the cap while turning it counterclockwise, and then remove the
cap.
4
5 Ask a Yamaha dealer to inspect

Leakage. and repair the cooling system.
Level is low, check the
cooling system for leakage.
6 No
Add coolant (See NOTE.)
Wait until the engine Check the coolant level in the leakage.
has cooled. reservoir tank and/or radiator.
7
Level is OK. Restart the engine. If the engine overheats again, ask a
Yamaha dealer to inspect and repair the cooling system.
8
NOTE:
9 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.
6-44
4TP-9-21 7/25/00 3:46 PM Page 87
EAU03521
MOTORCYCLE CARE AND STORAGE

Care Before cleaning Cleaning
While the open design of a motorcy- 1. Cover the muffler outlet with a ECA00010
plastic bag after the engine has

cC
cle reveals the attractiveness of the
cooled down. 8 Avoid using strong acidic 1
technology, it also makes it more vul-
nerable. Rust and corrosion can 2. Make sure that all caps and cov- wheel cleaners, especially on
develop even if high-quality compo- ers as well as all electrical cou- spoked wheels. If such prod- 2
nents are used. A rusty exhaust pipe plers and connectors, including ucts are used on hard-to-
may go unnoticed on a car, however, the spark plug cap, are tightly remove dirt, do not leave the 3
it detracts from the overall appear- installed. cleaner on the affected area
ance of a motorcycle. Frequent and 3. Remove extremely stubborn dirt, any longer than instructed. 4
proper care does not only comply like oil burnt onto the crankcase, Also, thoroughly rinse the area
with the terms of the warranty, but it with a degreasing agent and a off with water, immediately dry
5
will also keep your motorcycle looking brush, but never apply such it, and then apply a corrosion
good, extend its life and optimize its products onto seals, gaskets, protection spray.
8 Improper cleaning can damage 6
performance. sprockets, the drive chain and
wheel axles. Always rinse the dirt windshields, cowlings, panels
and degreaser off with water. and other plastic parts. Use 7
only a soft, clean cloth or
sponge with mild detergent 8
and water to clean plastic.
9
7-1
4TP-9-21 7/25/00 3:46 PM Page 88

8 Do not use any harsh chemical 8 For motorcycles equipped After riding in the rain, near the sea
products on plastic parts. Be with a windshield: Do not use or on salt-sprayed roads
sure to avoid using cloths or strong cleaners or hard Since sea salt or salt sprayed on
1 sponges which have been in sponges as they will cause roads during winter are extremely
contact with strong or abra- dulling or scratching. Some corrosive in combination with water,
2 sive cleaning products, sol- cleaning compounds for plas- carry out the following steps after
vent or thinner, fuel (gasoline), tic may leave scratches on the each ride in the rain, near the sea or
3 rust removers or inhibitors, windshield. Test the product on salt-sprayed roads.
brake fluid, antifreeze or elec- on a small hidden part of the
4 trolyte. windshield to make sure that it NOTE:
8 Do not use high-pressure does not leave any marks. If Salt sprayed on roads in the winter
washers or steam-jet cleaners the windshield is scratched, may remain well into spring.
5
since they cause water seep- use a quality plastic polishing
age and deterioration in the compound after washing. 1. Clean the motorcycle with cold
6
following areas: seals (of water and a mild detergent, after
wheel and swingarm bearings, After normal use the engine has cooled down.
7 fork and brakes), electric com- ECA00012
Remove dirt with warm water, a mild
ponents (couplers, connec- detergent, and a soft, clean sponge,
cC
8 tors, instruments, switches and then rinse thoroughly with clean Do not use warm water since it
and lights), breather hoses water. Use a toothbrush or bottle- increases the corrosive action of
9 and vents. brush for hard-to-reach areas. the salt.
Stubborn dirt and insects will come
off more easily if the area is covered 2. Apply a corrosion protection
with a wet cloth for a few minutes spray on all metal, including
before cleaning. chrome- and nickel-plated, sur-
faces to prevent corrosion.
7-2
4TP-9-21 7/25/00 3:46 PM Page 89

After cleaning 8. Let the motorcycle dry complete- ECA00013
1. Dry the motorcycle with a cC

ly before storing or covering it.
chamois or an absorbing cloth. EWA00001 8 Apply spray oil and wax spar-
2. Immediately dry the drive chain w ingly and make sure to wipe 1
and lubricate it to prevent it from 8 Make sure that there is no oil off any excess.
rusting. or wax on the brakes or tires. 8 Never apply oil or wax to any 2
3. Use a chrome polish to shine If necessary, clean the brake rubber and plastic parts, but
chrome, aluminum and stainless- discs and brake linings with a treat them with a suitable care 3
steel parts, including the exhaust regular brake disc cleaner or product.
system. (Even the thermally acetone, and wash the tires 8 Avoid using abrasive polish- 4
induced discoloring of stainless- with warm water and a mild ing compounds as they will
steel exhaust systems can be detergent. wear away the paint.
5
removed through polishing.) 8 Before operating the motorcy-
4. To prevent corrosion, it is recom- cle test its braking perfor- NOTE:
Consult a Yamaha dealer for advice 6
mended to apply a corrosion pro- mance and cornering behav-
tection spray on all metal, includ- ior. on what products to use.
ing chrome- and nickel-plated, 7
surfaces.
5. Use spray oil as a universal 8
cleaner to remove any remaining
dirt. 9
6. Touch up minor paint damage
caused by stones, etc.
7. Wax all painted surfaces.
7-3
4TP-9-21 7/25/00 3:46 PM Page 90

Storage Long-term c. Install the spark plug cap onto
Short-term Before storing your motorcycle for the spark plug, and then place
Always store your motorcycle in a several months: the spark plug on the cylinder
1 1. Follow all the instructions in the
cool, dry place and, if necessary, pro- head so that the electrodes
tect it against dust with a porous “Care” section of this chapter. are grounded. (This will limit
2 cover. 2. For motorcycles equipped with a sparking during the next step.)
ECA00014 fuel cock that has an “OFF” posi- d. Turn the engine over several
3 cC tion: Turn the fuel cock lever to times with the starter. (This
8 Storing the motorcycle in a “OFF”. will coat the cylinder wall with
4 poorly ventilated room or cov- 3. Drain the carburetor float cham- oil.)
ering it with a tarp, while it is ber by loosening the drain bolt; e. Remove the spark plug cap
still wet, will allow water and this will prevent fuel deposits from the spark plug, and then
5
humidity to seep in and cause from building up. Pour the install the spark plug and the
rust. drained fuel into the fuel tank. spark plug cap.
6
8 To prevent corrosion, avoid 4. Fill up the fuel tank and add fuel EWA00003
damp cellars, stables (because stabilizer (if available) to prevent w

7 of the presence of ammonia) the fuel tank from rusting and the To prevent damage or injury from
and areas where strong chemi- fuel from deteriorating. sparking, make sure to ground the
8 cals are stored. 5. Perform the following steps to spark plug electrodes while turn-
protect the cylinder, piston rings, ing the engine over.
9 etc. from corrosion.
a. Remove the spark plug cap
and spark plug.
b. Pour a teaspoonful of engine
oil into the spark plug bore.
7-4
4TP-9-21 7/25/00 3:46 PM Page 91

6. Lubricate all control cables and 9. Remove the battery and fully
the pivoting points of all levers charge it. Store it in a cool, dry
and pedals as well as of the place and charge it once a
1
sidestand/centerstand. month. Do not store the battery
7. Check and, if necessary, correct in an excessively cold or warm
the tire air pressure, and then lift place (less than 0°C or more 2
the motorcycle so that both of its than 30°C). For more information
wheels are off the ground. on storing the battery, see page 3
Alternatively, turn the wheels a 6-33.
little every month in order to pre- 4
vent the tires from becoming NOTE:
degraded in one spot. Make any necessary repairs before
5
8. Cover the muffler outlet with a storing the motorcycle.
plastic bag to prevent moisture
6
from entering it.
7-5
4TP-9-21 7/25/00 3:46 PM Page 92
EAU01038
SPECIFICATIONS
Specifications
Model DT230(N) Engine oil

1
Dimensions Type 2-stroke engine oil
Overall length 2,225 mm Capacity
2
Overall width 800 mm Total amount 1.3 L
Overall height 1,200 mm Transmission oil
3
Seat height 865 mm Type SAE 10W30 type SE motor oil
Wheel base 1,410 mm Capacity
4
Ground clearance 300 mm Periodic oil change 0.8 L
Minimum turning radius 2,100 mm Total amount 0.85 L
5
Basic weight Cooling system capacity
(with oil and full fuel tank) 133 kg
(total amount) 1.26 L
6 Engine
Air filter Wet type element
Engine type Liquid cooled 2-stroke
Fuel
7 Cylinder arrangement Forward inclined single
Type Regular gasoline
cylinder
(except for Australia)
Displacement 224 cm3 Unleaded fuel only
8 (for Australia)
Bore × Stroke 66.8 × 64.0 mm
Fuel tank capacity 11 L
Compression ratio 6.5:1
9 Reserve amount 2L
Starting system Electric starter
Carburetor
Lubrication system Separate lubrication
(Yamaha autolube) Manufacturer MIKUNI
Model×quantity TM30×1
8-1
4TP-9-21 7/25/00 3:46 PM Page 93
SPECIFICATIONS
Spark plug Tires

1
Manufacturer/model NGK/BR9ES Type With tube
Gap 0.7–0.8 mm Front
2
Clutch type Wet, multiple-disc Size 3.00-21 51P
Transmission Manufacturer/ INOUE/GP-21F
model CHENG SHIN/M-6033 3
Primary reduction system Helical gear
Rear
Primary reduction ratio 54/21 (2.571)
Size 4.60-18 63P 4
Secondary reduction system Chain drive
Manufacturer/ INOUE/GP-22R
Secondary reduction ratio 3.437 model CHENG SHIN/M-6034
5
Number of drive chain Maximum load* 180 kg
sprocket teeth (rear/front) 55/16
Air pressure (cold tire)
Transmission type Constant mesh 6-speed 6
up to 88 kg load*
Operation Left foot
Front 125 kPa (1.25 kg/cm2, 1.25 bar)
Gear ratio 1st 2.750 7
Rear 150 kPa (1.50 kg/cm2, 1.50 bar)
2nd 1.875
88 kg load–Maximum
3rd 1.411 load* 8
4th 1.142 Front 150 kPa (1.50 kg/cm2, 1.50 bar)
5th 0.956 Rear 175 kPa (1.75 kg/cm2, 1.75 bar) 9
6th 0.818 * Load is total weight of cargo, rider, passenger and accessories.
Chassis
Frame type Semi double cradle
Caster angle 27°
Trail 114 mm
8-2
4TP-9-21 7/25/00 3:46 PM Page 94
SPECIFICATIONS
Wheels Spring/shock absorber

1
Front Front Coil spring/oil damper
Type Spoke wheel Rear Coil-gas spring/oil damper
2
Size 1.60 × 21 Wheel travel
Rear Front 250 mm
3
Type Spoke wheel Rear 240 mm
Size 2.15 × 18 Electrical system
4
Brakes Ignition system C.D.I.
Front Charging system
5
Type Single disc brake Type C.D.I. magneto
Operation Right hand Standard output 14 V, 12 A @5,000 r/min
6
Fluid DOT 4 Battery
Rear Type GT6B-3
7
Type Single disc brake Voltage, capacity 12 V, 6 AH
Operation Right foot Headlight type Halogen bulb
8 Fluid DOT 4 Bulb voltage, wattage × quantity
Suspension Headlight 12 V, 60/55W × 1
9 Front Telescopic fork Tail/brake light 12 V, 5/21W × 1
Rear Swingarm Front turn signal light 12 V, 21W × 2
(new monocross)
Rear turn signal light 12 V, 21W × 2
Licence plate light 12 V, 5W × 2
8-3
4TP-9-21 7/25/00 3:46 PM Page 95
SPECIFICATIONS
Neutral indicator light 12 V, 3W × 1

1
High beam indicator light 12 V, 3W × 1
Turn signal indicator light 12 V, 3W × 1
2
Oil level/coolant temperature
warning light LED
Fuse 30A 3
8-4
4TP-9-21 7/25/00 3:46 PM Page 96
SPECIFICATIONS
EAU01064
Conversion table CONVERSION TABLE

All specification data in this manual are listed in SI and METRIC TO IMPERIAL
1 METRIC UNITS. Metric unit Multiplier Imperial unit
Use this table to convert METRIC unit data to m • kg 7.233 ft • lb
m • kg 86.794 in• lb
2 IMPERIAL unit data. Torque
cm • kg 0.0723 ft • lb
cm • kg 0.8679 in • lb
Ex. kg 2.205 lb
3 Weight
g 0.03527 oz
Speed km/hr 0.6214 mph
METRIC MULTIPLIER IMPERIAL km 0.6214 mi
4 m 3.281 ft
Distance m 1.094 yd
** mm × 0.03937 = ** in cm 0.3937 in
5
×
mm 0.03937 in
2 mm 0.03937 = 0.08 in
cc (cm3) 0.03527 oz (IMP liq.)
Volume/ cc (cm3) 0.06102 cu • in
6 Capacity L (liter) 0.8799 qt (IMP liq.)
L (liter) 0.2199 gal (IMP liq.)
kg/mm 55.997 lb/in
7 Misc. kg/cm2 14.2234 psi (lb/in2)
Centigrade (°C) 9/5 + 32 Fahrenheit (°F)
8-5
4TP-9-21 7/25/00 3:46 PM Page 97
EAU01039
CONSUMER INFORMATION
EAU02944
Identification numbers
Record the key identification number, 1
vehicle identification number and 1
model label information in the spaces
provided below for assistance when 2
ordering spare parts from a Yamaha 1
dealer or for reference in case the 3
vehicle is stolen.
1. KEY IDENTIFICATION 1. Key identification number 1. Vehicle identification number
4
NUMBER: EAU01041 EAU01043
Key identification number Vehicle identification number

The key identification number is The vehicle identification number is 5
stamped into the key tag. stamped into the steering head pipe.
Record this number in the space pro- Record this number in the space pro- 6
2. VEHICLE IDENTIFICATION vided and use it for reference when vided.
NUMBER: ordering a new key. 7
NOTE:
The vehicle identification number is
8
used to identify your motorcycle and
3. MODEL LABEL INFORMATION: may be used to register your motor-
9
cycle with the licensing authority in
your area.
1
6
9-1
4TP-9-21 7/25/00 3:46 PM Page 98
CONSUMER INFORMATION
EAU01388
Motorcycle noise regulation

1 (for Australia)
1 TAMPERING WITH NOISE CON-
TROL SYSTEM PROHIBITED:
2 Owners are warned that the law may
prohibit:
3 (a) The removal or rendering inoper-
ative by any person other than
1. Model label for purposes of maintenance,
4
EAU01049 repair or replacement, of any
Model label device or element of design
5 The model label is affixed to the loca- incorporated into any new vehi-
tion shown in the figure. Record the cle for the purpose of noise con-
6 information on this label in the space trol prior to its sale or delivery to
provided. This information will be the ultimate purchaser or while it
7 needed when ordering spare parts is in use; and
from a Yamaha dealer. (b) The use of the vehicle after such
8 device or element of design has
been removed or rendered inop-
9 erative by any person.
9-2
4TP-9-21 7/25/00 3:46 PM Page 99
9
4TP-9-21 7/25/00 3:46 PM Page 100
OWNER’S MANUAL
YAMAHA MOTOR CO., LTD.

DT230(N)
PRINTED ON RECYCLED PAPER PRINTED IN JAPAN
2000·7–0.1×1(E) ! 4TP-28199-21

DT 230 Manual PDF

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OWNER’S MANUAL

YAMAHA MOTOR CO., LTD.

IMPORTANT MANUAL INFORMATION

cC A CAUTION indicates special precautions that must be taken to avoid damage to

5 NOTE: A NOTE provides key information to make procedures easier or clearer.

IMPORTANT MANUAL INFORMATION

1 SAFETY INFORMATION.....................................1-1 Starter (choke) lever “1”................................3-10

8 Gasoline and exhaust gas

Location of important labels

INSTRUMENT AND CONTROL FUNCTIONS

moving, otherwise the electrical

systems will be switched off, 2

Main switch/steering lock LOCK

OFF To unlock the steering

INSTRUMENT AND CONTROL FUNCTIONS

to idle until the coolant tempera-

INSTRUMENT AND CONTROL FUNCTIONS

6 8 The clock can be set.

INSTRUMENT AND CONTROL FUNCTIONS

INSTRUMENT AND CONTROL FUNCTIONS

1. Dimmer switch 1. Engine stop switch

To signal a right-hand turn, push this Start switch “,” 8

INSTRUMENT AND CONTROL FUNCTIONS

1. Clutch lever 1. Shift pedal 1. Brake lever

INSTRUMENT AND CONTROL FUNCTIONS

INSTRUMENT AND CONTROL FUNCTIONS

1. Filler tube Recommended fuel: 1. 2-stroke engine oil tank cap

w 2.0 L for panel removal and installation

INSTRUMENT AND CONTROL FUNCTIONS

INSTRUMENT AND CONTROL FUNCTIONS

INSTRUMENT AND CONTROL FUNCTIONS

1. Insert the projections on the front

INSTRUMENT AND CONTROL FUNCTIONS

1. Compression damping adjusting screw to prevent dust, etc. from entering cC

INSTRUMENT AND CONTROL FUNCTIONS

1. Special wrench 1. Adjusting nut 3. Tighten the locknut to the speci-

INSTRUMENT AND CONTROL FUNCTIONS

INSTRUMENT AND CONTROL FUNCTIONS

absorber. The manufacturer can- cC 3

INSTRUMENT AND CONTROL FUNCTIONS

Sidestand w Ignition circuit cut-off

INSTRUMENT AND CONTROL FUNCTIONS

With the engine turned off: NOTE:

OPERATION AND IMPORTANT RIDING POINTS

OPERATION AND IMPORTANT RIDING POINTS

5 back halfway. Shifting

OPERATION AND IMPORTANT RIDING POINTS

cC Tips for reducing fuel Engine break-in

OPERATION AND IMPORTANT RIDING POINTS

PERIODIC MAINTENANCE AND MINOR REPAIR

PERIODIC MAINTENANCE AND MINOR REPAIR

Periodic maintenance and lubrication chart

5 2 Spark plug • Replace. √ √ √ √ √

PERIODIC MAINTENANCE AND MINOR REPAIR

PERIODIC MAINTENANCE AND MINOR REPAIR

PERIODIC MAINTENANCE AND MINOR REPAIR

1. Cowling A 1. Screw (×4) 1. Screw (×3)

PERIODIC MAINTENANCE AND MINOR REPAIR

1. Panel A 1. Panel B 1. Screw

PERIODIC MAINTENANCE AND MINOR REPAIR

1. Screw 1. Spark plug cap 1. Spark plug wrench

To remove the spark plug

PERIODIC MAINTENANCE AND MINOR REPAIR