dt175(n) owner’s manualyamahaownershandbook.com.au/lib/download.php?f=3fj-28199-2c.pdf · may be...

PRINTED ON RECYCLED PAPER PRINTED IN JAPAN

2000·6–0.2´1(E) !

OWNER’S MANUAL

3FJ-28199-2C

DT175(N)YAMAHA MOTOR CO., LTD.

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INTRODUCTION

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Congratulations on your purchase of the Yamaha DT175. This model is the result of Yamaha’s vastexperience in the production of fine sporting, touring, and pacesetting racing machines. It representsthe high degree of craftsmanship and reliability that have made Yamaha a leader in these fields.

This manual will give you an understanding of the operation, inspection, and basic maintenance ofthis motorcycle. If you have any questions concerning the operation or maintenance of your motorcy-cle, please consult a Yamaha dealer.

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IMPORTANT MANUAL INFORMATION

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Particularly important information is distinguished in this manual by the following notations:

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY ISINVOLVED!

Failure to follow WARNING instructions could result in severe injury or death to themotorcycle operator, a bystander, or a person inspecting or repairing the motorcycle.

A CAUTION indicates special precautions that must be taken to avoid damage tothe motorcycle.

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

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NOTE:

NOTE:8 This manual should be considered a permanent part of this motorcycle and should remain

with it even if the motorcycle is subsequently sold.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, theremay 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 INFORMA TION

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PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATINGTHIS MOTORCYCLE.

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DT175(N)OWNER’S MANUAL

©2000 by Yamaha Motor Co., Ltd.1st Edition, June 2000

All rights reserved.Any reprinting or unauthorized use without the written permission of

Yamaha Motor Co., Ltd.is expressly prohibited.

Printed in Japan.

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TABLE OF CONTENTS

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SAFETY INFORMATION.....................................1-1Safe riding.........................................................1-1Protective apparel .............................................1-3Modifications.....................................................1-3Loading and accessories ..................................1-3Gasoline and exhaust gas ................................1-5Location of important labels..............................1-7

DESCRIPTION ....................................................2-1Left view............................................................2-1Right view .........................................................2-2Controls and instruments..................................2-3

INSTRUMENT AND CONTROL FUNCTIONS ....3-1Main switch/steering lock..................................3-1Indicator and warning lights ..............................3-2Speedometer unit .............................................3-3Tachometer.......................................................3-3Handlebar switches ..........................................3-3Clutch lever .......................................................3-4Shift pedal .........................................................3-5Brake lever........................................................3-5Brake pedal.......................................................3-5Fuel tank cap ....................................................3-6Fuel ...................................................................3-62-stroke engine oil ............................................3-7

Fuel cock ..........................................................3-8Starter (choke) knob .........................................3-9Kickstarter .........................................................3-9Seat ................................................................3-10Helmet holder .................................................3-11Adjusting the shock absorber assembly .........3-11YEIS handling precautions .............................3-13Sidestand........................................................3-13Ignition circuit cut-off system ..........................3-14

PRE-OPERATION CHECKS ...............................4-1Pre-operation check list ....................................4-1

OPERATION AND IMPORTANT RIDINGPOINTS................................................................5-1

Starting and warming up a cold engine ............5-1Starting a warm engine.....................................5-2Shifting..............................................................5-2Tips for reducing fuel consumption...................5-3Engine break-in.................................................5-3Parking..............................................................5-4

PERIODIC MAINTENANCE AND MINORREPAIR................................................................6-1

Owner’s tool kit .................................................6-1Periodic maintenance and lubrication chart ......6-2

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Removing and installing the cowling andpanels .............................................................6-5

Checking the spark plug ...................................6-6Transmission oil ................................................6-8Cleaning the air filter element .........................6-10Adjusting the carburetor..................................6-11Adjusting the engine idling speed ...................6-12Adjusting the throttle cable free play...............6-12Tires................................................................6-13Spoke wheels .................................................6-15Adjusting the clutch lever free play .................6-16Adjusting the brake lever free play .................6-17Adjusting the brake pedal position andfree play ........................................................6-17

Adjusting the rear brake light switch ...............6-19Checking the front brake pads andrear brake shoes...........................................6-19

Checking the brake fluid level .........................6-20Changing the brake fluid.................................6-21Drive chain slack.............................................6-21Lubricating the drive chain..............................6-23Checking and lubricating the cables ...............6-24Checking and lubricating the throttle gripand cable ......................................................6-24

Adjusting the autolube pump ..........................6-25

Checking and lubricating the brake andshift pedals....................................................6-25

Checking and lubricating the brake andclutch levers..................................................6-26

Checking and lubricating the sidestand ..........6-26Lubricating the rear suspension......................6-26Checking the front fork....................................6-27Checking the steering .....................................6-27Checking the wheel bearings..........................6-28Battery ............................................................6-28Replacing the fuse ..........................................6-30Replacing the headlight bulb ..........................6-31Replacing a turn signal light bulb....................6-33Replacing the tail/brake light bulb...................6-33Supporting the motorcycle ..............................6-33Front wheel .....................................................6-34Rear wheel......................................................6-36Troubleshooting ..............................................6-37Troubleshooting chart .....................................6-38

MOTORCYCLE CARE AND STORAGE .............7-1Care ..................................................................7-1Storage .............................................................7-4

SPECIFICATIONS...............................................8-1Conversion table...............................................8-5

TABLE OF CONTENTS

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TABLE OF CONTENTS

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CONSUMER INFORMATION..............................9-1Identification numbers.......................................9-1Key identification number .................................9-1Vehicle identification number............................9-1Model label .......................................................9-2Motorcycle noise regulation (for Australia) .......9-2

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Q SAFETY INFORMATION

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MOTORCYCLES ARE SINGLE TRACK VEHICLES. THEIR SAFE USE AND OPERATION AREDEPENDENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EXPER-TISE OF THE OPERATOR. EVERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIRE-MENTS BEFORE RIDING THIS MOTORCYCLE.

HE OR SHE SHOULD:

1. OBTAIN THOROUGH INSTRUCTIONS FROM A COMPETENT SOURCE ON ALL ASPECTSOF MOTORCYCLE OPERATION.

2. OBSERVE THE WARNINGS AND MAINTENANCE REQUIREMENTS IN THE OWNER’S MAN-UAL.

3. OBTAIN QUALIFIED TRAINING IN SAFE AND PROPER RIDING TECHNIQUES.4. OBTAIN PROFESSIONAL TECHNICAL SERVICE AS INDICATED BY THE OWNER’S MANUAL

AND/OR WHEN MADE NECESSARY BY MECHANICAL CONDITIONS.

Safe riding1. Always make pre-operation checks. Careful checks may help prevent an accident.2. This motorcycle is designed to carry the operator and a passenger.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 driverwho did not see the motorcycle. Making yourself conspicuous appears to be very effective inreducing the chance of this type of accident.

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 beeninvolved 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-

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

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

the operator is veering wide on a turn due to EXCESSIVE SPEED or undercornering (insufficientlean angle for the speed).a. Always obey the speed limit and never travel faster than warranted by road and traffic condi-

tions.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.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.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

footrests.7. Never ride under the influence of alcohol or other drugs.

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Protective apparelThe majority of fatalities from motorcycle accidents are the result of head injuries. The use of a safetyhelmet is the single most critical factor in the prevention or reduction of head injuries.

1. Always wear an approved helmet.2. Wear a face shield or goggles. Wind in your unprotected eyes could contribute to an impairment

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

abrasions or lacerations.4. Never wear loose-fitting clothes, otherwise they could catch on the control levers, footrests, or

wheels and cause injury or an accident.5. Never touch the engine or exhaust system during or after operation. They become very hot and

can cause burns. Always wear protective clothing that covers your legs, ankles, and feet.6. Passengers should also observe the precautions mentioned above.

ModificationsModifications made to this motorcycle not approved by Yamaha, or the removal of original equipment,may render the motorcycle unsafe for use and may cause severe personal injury. Modifications mayalso make your motorcycle illegal to use.

Loading and accessoriesAdding accessories or cargo to your motorcycle can adversely affect stability and handling if theweight distribution of the motorcycle is changed. To avoid the possibility of an accident, use extremecaution 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 cargoor adding accessories to your motorcycle:

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LoadingThe total weight of the operator, passenger, accessories and cargo must not exceed the maximumload 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.Make sure to distribute the weight as evenly as possible on both sides of the motorcycle to mini-mize imbalance or instability.

2. Shifting weights can create a sudden imbalance. Make sure that accessories and cargo aresecurely attached to the motorcycle before riding. Check accessory mounts and cargo restraintsfrequently.

3. Never attach any large or heavy items to the handlebar, front fork, or front fender. These items,including such cargo as sleeping bags, duffel bags, or tents, can create unstable handling or aslow steering response.

AccessoriesGenuine Yamaha accessories have been specifically designed for use on this motorcycle. SinceYamaha cannot test all other accessories that may be available, you must personally be responsiblefor the proper selection, installation and use of non-Yamaha accessories. Use extreme caution whenselecting and installing any accessories.

Keep the following guidelines in mind, as well as those provided under “Loading” when mountingaccessories.

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 reduceground clearance or cornering clearance, limit suspension travel, steering travel or control opera-tion, or obscure lights or reflectors.

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a. Accessories fitted to the handlebar or the front fork area can create instability due to improperweight distribution or aerodynamic changes. If accessories are added to the handlebar or frontfork area, they must be as lightweight as possible and should be kept to a minimum.

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 unstablein cross winds. These accessories may also cause instability when passing or being passed bylarge vehicles.

c. Certain accessories can displace the operator from his or her normal riding position. Thisimproper position limits the freedom of movement of the operator and may limit control ability,therefore, such accessories are not recommended.

2. Use caution when adding electrical accessories. If electrical accessories exceed the capacity ofthe motorcycle’s electrical system an electric failure could result, which could cause a dangerousloss of lights or engine power.

Gasoline and exhaust gas1. GASOLINE IS HIGHLY FLAMMABLE:

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.

2. Never start the engine or let it run for any length of time in a closed area. The exhaust fumes arepoisonous and may cause loss of consciousness and death within a short time. Always operateyour motorcycle in an area that has adequate ventilation.

3. Always turn the engine off before leaving the motorcycle unattended and remove the key fromthe main switch. When parking the motorcycle, note the following:

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a. The engine and exhaust system may be hot, therefore, park the motorcycle in a place wherepedestrians 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.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. 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-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 intoyour 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.

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Location of important labelsPlease read the following important labels carefully before operating this motorcycle.

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WARNINGBefore you operate this vehicle,read the owner’s manual.

English 3HP-21568-00

4AA-22259-40

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DESCRIPTION

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Left view

1. Headlight (page 6-31)2. YEIS (Yamaha Energy Induction

System) (page 3-13)3. Fuel cock (page 3-8)4. Rear shock absorber spring preload

adjusting ring (page 3-11)

5. Air filter element (page 6-10)6. Shift pedal (page 3-5, 5-2)7. Starter (choke) knob (page 3-9)

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DESCRIPTION

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2-2

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Right view

8. Helmet holder (page 3-11)9. Owner’s tool kit (page 6-1)

10. 2-stroke engine oil tank (page 3-7)11. Brake pedal (page 3-5, 6-17)12. Kick starter (page 3-9)

13. Battery (page 6-28)14. Fuse (page 6-30)

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DESCRIPTION

2-3

1. Clutch lever (page 3-4, 6-16)2. Left handlebar switches (page 3-3)3. Speedometer unit (page 3-3)4. Main switch/steering lock (page 3-1)5. Tachometer (page 3-3)

6. Right handlebar switch (page 3-4)7. Brake lever (page 3-5, 6-17)8. Throttle grip (page 6-12, 6-24)9. Fuel tank cap (page 3-6)

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Controls and instruments

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LOCK

OFFON

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Main switch/steering lockThe main switch/steering lock con-trols the ignition and lighting systems,and is used to lock the steering. Thevarious positions are describedbelow.

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ONAll electrical circuits are supplied withpower, and the engine can be start-ed. The key cannot be removed.

NOTE:The headlight, meter lighting and tail-light come on automatically when theengine is started.

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OFFAll electrical systems are off. The keycan be removed.

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LOCKThe steering is locked, and all electri-cal systems are off. The key can beremoved.

To lock the steering1. Turn the handlebars all the way

to the left or right.2. Push the key in from the “OFF”

position, release it, and then turnit to “LOCK”.

3. Remove the key.

To unlock the steeringInsert the key and turn it to “OFF”.

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Never turn the key to “LOCK”while the motorcycle is moving.

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INSTRUMENT AND CONTROL FUNCTIONS

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1. Push.2. Release.3. Turn.

OFF (Push)

LOCK

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Turn signal indicator light “TURN”This indicator light flashes when theturn signal switch is pushed to the leftor right.

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Do not operate the motorcycleuntil you know that the engine oillevel is sufficient.

NOTE:Even if the oil level is sufficient, thewarning light may flicker when ridingon a slope or during sudden acceler-ation or deceleration, but this is not amalfunction.

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High beam indicator light “HIGHBEAM”This indicator light comes on whenthe high beam of the headlight isswitched on.

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Neutral indicator light “NEUTRAL”This indicator light comes on whenthe transmission is in the neutralposition.


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Indicator and warning lights

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Oil level warning light "OIL"This warning light comes on whenthe engine oil level is low.The electrical circuit of the warninglight can be checked according to thefollowing procedure.

1. Turn the key to "ON".2. Shift the transmission into the

neutral position.3. If the warning light does not

come on, have a Yamaha dealercheck the electrical circuit.

1. Oil level warning light “OIL”2. High beam indicator light “HIGH BEAM”3. Neutral indicator light “NEUTRAL”4. Turn indicator light “TURN”

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1. Tachometera. Red zone

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TachometerThis model is equipped with atachometer so the rider can monitorthe engine speed and keep it withinthe ideal power range.

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Do not operate the engine in thetachometer red zone.Red zone: 8,500 r/min and above

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Speedometer unit The speedometer unit is equippedwith a speedometer, an odometerand a tripmeter. The speedometershows riding speed. The odometershows the total distance traveled.The tripmeter shows the distancetraveled since it was last set to zerowith the reset knob. The tripmetercan be used to estimate the distancethat can be traveled with a full tank offuel. This information will enable youto plan future fuel stops.

1. Speedometer2. Odometer3. Tripmeter4. Reset knob

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1. Dimmer switch 2. Turn signal switch3. Horn switch “*”

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Handlebar switches

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Dimmer switchSet this switch to “&” for the highbeam and to “%” for the low beam.

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Engine stop switchSet this switch to “$” to stop theengine in case of an emergency,such as when the motorcycle over-turns or when the throttle cable isstuck.

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Turn signal switchTo signal a right-hand turn, push thisswitch to “6”. To signal a left-handturn, push this switch to “4”. Whenreleased, the switch returns to thecenter position. To cancel the turnsignal lights, push the switch in afterit has returned to the center position.

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Horn switch “ *”Press this switch to sound the horn.

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1. Clutch lever

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Clutch leverThe clutch lever is located at the lefthandlebar grip. To disengage theclutch, pull the lever toward the han-dlebar grip. To engage the clutch,release the lever. The lever shouldbe pulled rapidly and released slowlyfor smooth clutch operation.

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1. Dimmer switch 2. Turn signal switch3. Horn switch “*”

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Shift pedalThe shift pedal is located on the leftside of the engine and is used incombination with the clutch leverwhen shifting the gears of the 6-speed constant-mesh transmissionequipped on this motorcycle.

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Brake pedalThe brake pedal is on the right sideof the motorcycle. To apply the rearbrake, press down on the brakepedal.

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1. Shift pedalN. Neutral

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Brake leverThe brake lever is located at the righthandlebar grip. To apply the frontbrake, pull the lever toward the han-dlebar grip.

1. Brake lever

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1. Fuel tank capa. Unlockb. Open

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Fuel tank cap

To remove the fuel tank cap1. Insert the key into the lock and

turn it 1/4 turn counterclockwise.2. Turn the fuel tank cap 1/3 turn

counterclockwise and pull it off.

To install the fuel tank cap1. Insert the fuel tank cap into the

tank opening with the key insert-ed in the lock, and then turn thecap 1/3 turn clockwise.

2. Turn the key 1/4 turn clockwise,and then remove it.

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FuelMake sure that there is sufficient fuelin the tank. Fill the fuel tank to thebottom of the filler tube as shown inthe illustration.

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8 Do not overfill the fuel tank,otherwise it may overflowwhen the fuel warms up andexpands.

8 Avoid spilling fuel on the hotengine.

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Make sure that the fuel tank cap isproperly closed and locked beforeriding.

1. Filler tube2. Fuel level

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2-stroke engine oil Make sure that there is sufficient oil inthe 2-stroke engine oil tank. If neces-sary, add the recommended 2-strokeengine oil as follows.

NOTE:The motorcycle must be placed on alevel surface and resting on the side-stand for an accurate oil level read-ing.

1. Remove panel B. (See page 6-6for panel removal and installationprocedures.)

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Immediately wipe off spilled fuelwith a clean, dry, soft cloth, sincefuel may deteriorate painted sur -faces or plastic parts.

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2. Remove the wing nut, and thenslightly pull the 2-stroke engineoil tank out.

3. Remove the 2-stroke engine oiltank cap.

4. Fill the oil tank with the recom-mended 2-stroke engine oil, andthen install the cap.

Recommended fuel:Regular gasoline

For Australia:Unleaded fuel only

Fuel tank capacity:Total amount:

9.5 LReserve amount:

1.0 L

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1. 2-stroke engine oil tank2. Oil tank filler cap3. Wing nut

Recommended oil:Yamalube 2 or equivalent 2-stroke engine oil (JASO grade “FC”)

Oil quantity:Total amount

0.9 L

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NOTE:Make sure that the 2-stroke engineoil tank cap is properly installed.

5. Place the 2-stroke engine oiltank in the original position, andthen install and tighten the wingnut.

6. Install the panel.

PRIRESRES

ON

FUEL

11. Arrow mark positioned over “RES”

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Fuel cockThis motorcycle is equipped with anegative pressure fuel cock. The fuelcock supplies fuel from the tank tothe carburetors while also filtering it.The fuel cock lever positions areexplained as follows and shown inthe illustrations.

ONWith the fuel cock lever in this posi-tion, fuel flows to the carburetor whenthe engine is running. Turn the fuelcock lever to this position when start-ing the engine and riding.

RESThis indicates reserve. With the fuelcock lever in this position, the fuelreserve is made available. Quicklyturn the fuel cock lever to this posi-tion if you run out of fuel while riding,otherwise the engine may stall andwill have to be primed (see “PRI”).After turning the fuel cock lever to“RES”, refuel as soon as possibleand be sure to turn the fuel cocklever back to “ON”!

PRIRES

ON

ON

FUEL

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1. Arrow mark positioned over “ON”

RES: reserve positionON: normal position

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PRIThis indicates prime. With the fuelcock lever in this position, the enginecan be “primed”. Turn the fuel cocklever to this position when the enginehas been allowed to run out of fuel.This sends fuel directly to the carbu-retor, which will make starting easier.After the engine has started, be sureto turn the lever to “ON” (or “RES” ifyou have not refueled yet).

PRI PRIRES

ON

FUEL

11. Arrow mark positioned over “PRI”

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EAU03029

Starter (choke) knobStarting a cold engine requires a rich-er air-fuel mixture, which is suppliedby the starter (choke).Move the knob in direction a to turnon the starter (choke).Move the knob in direction b to turnoff the starter (choke).

1. Starter (choke) knob

1

EAU00213

KickstarterTo start the engine, raise the rightpassenger footrest, fold out the kick-starter lever, move it down lightly withyour foot until the gears engage, andthen push it down smoothly but force-fully. This model is equipped with aprimary kickstarter, allowing theengine to be started in any gear if theclutch is disengaged. However, shift-ing the transmission into the neutralposition before starting is recom-mended.

1. Kickstarter

PRI: priming position

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EAU03572

Seat

To remove the seat1. Remove panels A and B. (See

page 6-6 for panel removal andinstallation procedures.)

2. Remove the bolts and pull theseat off.

1. Bolt (×2) 1. Bolt (×2)

12

To install the seat1. Insert the projection on the front

of the seat into the seat holderas shown.

2. Place the seat in the originalposition, and then tighten thebolts.

3. Install the panels.

NOTE:Make sure that the seat is properlysecured before riding.

1. Projection2. Seat holder

LEFT RIGHT

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EAU00261

Helmet holderTo open the helmet holder, insert thekey into the lock, and then turn thekey as shown.To lock the helmet holder, turn thekey to the original position, and thenremove it.

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Never ride with a helmet attachedto the helmet holder, since the hel -met may hit objects, causing lossof control and possibly an acci -dent.

1. Helmet holder

1

2

EAU03525

Adjusting the shockabsorber assemblyThis shock absorber assembly isequipped with a spring preloadadjusting ring.

EC000015

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Never attempt to turn an adjustingmechanism beyond the maximumor minimum settings.

Adjust the spring preload as follows.1. Remove panels A and B. (See

page 6-6 for panel removal andinstallation procedures.)

1. Vacuum hose2. Fuel hose

2. Remove the seat. (See page 3-10 for seat removal and instal-lation procedures.)

3. Turn the fuel cock lever to “ON”(or “RES”), and then disconnectthe vacuum hose and fuel hose.

4. Remove the fuel tank by remov-ing the bolt.

1

1. Bolt

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5. To increase the spring preloadand thereby harden the suspen-sion, turn the adjusting ring indirection a. To decrease thespring preload and thereby soft-en the suspension, turn theadjusting ring in direction b.

NOTE:8 Align the appropriate notch in the

adjusting ring with the positionindicator on the shock absorber.

8 Use the special wrench includedin the owner’s tool kit to makethe adjustment.

1

6. Connect the vacuum hose andfuel hose, and then install thefuel tank by installing the bolt.

7. Install the seat and the panels.

1. Special wrench

b a

1

1. Spring preload adjusting ring

EAU00315

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This shock absorber containshighly pressurized nitrogen gas.For proper handling, read andunderstand the following informa -tion before handling the shockabsorber. The manufacturer can -not be held responsible for proper -ty damage or personal injury thatmay result from improper han -dling.8 Do not tamper with or attempt

to open the gas cylinder.8 Do not subject the shock

absorber to an open flame orother high heat sources, other -wise it may explode due toexcessive gas pressure.

8 Do not deform or damage thegas cylinder in any way, asthis will result in poor damp -ing performance.

8 Always have a Yamaha dealerservice the shock absorber.

Minimum (soft) Stan- Maximum (hard)dard

Setting 1 2 3 4 5

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EAU00325

YEIS handling precautions Improper installation of or damage toany part of the YEIS (YamahaEnergy Induction System) will resultin poor performance. Therefore, han-dle the YEIS air chamber and airchamber hose with special care andimmediately replace any cracked ordamaged parts.

EC000022

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Do not attempt to modify the YEISin any way.

1EAU00330

SidestandThe sidestand is located on the leftside of the frame. Raise the side-stand or lower it with your foot whileholding the motorcycle upright.

NOTE:The built-in sidestand switch is part ofthe ignition circuit cut-off system,which cuts the ignition in certain situ-ations. (See further down for anexplanation of the ignition circuit cut-off system.)

1. Y.E.I.S.

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The motorcycle must not be riddenwith the sidestand down, or if thesidestand cannot be properlymoved up (or does not stay up),otherwise the sidestand could con -tact the ground and distract theoperator, resulting in a possibleloss of control. Yamaha’s ignitioncircuit cut-off system has beendesigned to assist the operator infulfilling the responsibility of rais -ing the sidestand before startingoff. Therefore, check this systemregularly as described below andhave a Yamaha dealer repair it if itdoes not function properly.

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EAU03571

Ignition circuit cut-off systemThe ignition circuit cut-off system(comprising the sidestand switch andneutral switch) has the following func-tions.8 It prevents starting when the

transmission is in gear and thesidestand is still down.

8 It cuts the running engine whenthe transmission is in gear andthe sidestand is moved down.

Periodically check the operation ofthe ignition circuit cut-off systemaccording to the following procedure.

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If a malfunction is noted, have aYamaha dealer check the systembefore riding.

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With the engine turned off:1. Move the sidestand down.2. Make sure that the engine stop switch is set to “#”.3. Turn the key to “ON”. 4. Shift the transmission into the neutral position.5. Push the kickstarter lever down.Does the engine start?

The neutral switch may be defective.The motorcycle should not be ridden until checked by a Yamaha dealer.

With the engine still running:6. Move the sidestand up.7. Keep the clutch lever pulled.8. Shift the transmission into gear.9. Move the sidestand down.Does the engine stall?

The sidestand switch may be defective.The motorcycle should not be ridden until checked by a Yamaha dealer.

NO

NOTE:This check is most reliable if performed witha warmed-up engine.

YES

YES NO

The system is OK. The motorcycle can be ridden.

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EAU01114

PRE-OPERATION CHECKS

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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-ough visual inspection, to check the following points before each ride.

EAU03439

Pre-operation check listITEM CHECKS PAGE

Front brake 9 Check operation, free play, fluid level and for fluid leakage. 3-5, 6-17, 6-19–6-219 Fill with DOT 4 brake fluid if necessary.

Rear brake 9 Check operation, condition and free play. 3-5, 6-17–6-209 Adjust if necessary.

Clutch 9 Check operation, condition and free play. 3-4, 6-169 Adjust if necessary.

Throttle grip and housing 9 Check for smooth operation. 6-12–6-13, 6-249 Lubricate if necessary.

Engine oil 9 Check oil level. 3-7–3-89 Add oil if necessary.

Transmission oil 9 Check oil level. 6-8–6-109 Add oil if necessary.

Drive chain 9 Check chain slack and condition. 6-21–6-239 Adjust if necessary.

Wheels and tires 9 Check tire pressure, wear, damage and for spoke tightness. 6-13–6-169 Tighten spokes if necessary.

Control cables 9 Check smooth operation. 6-24–6-259 Lubricate if necessary.

Brake and shift pedal shafts 9 Check smooth operation. 6-259 Lubricate if necessary.

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PRE-OPERATION CHECKS

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ITEM CHECKS PAGE

Brake and clutch lever pivots 9 Check smooth operation. 6-269 Lubricate if necessary.

Sidestand pivot 9 Check smooth operation. 6-269 Lubricate if necessary.

Chassis fasteners 9 Make sure that all nuts, bolts and screws are properly tightened. —9 Tighten if necessary.

Fuel tank 9 Check fuel level. 3-6–3-79 Add fuel if necessary.

Lights, signals and9 Check proper operation. 3-3–3-4, 6-31–6-33switches

Battery 9 Check fluid level. 6-28–6-309 Add distilled water if necessary.

NOTE:Pre-operation checks should be made each time the motorcycle is used. Such an inspection can be accomplished in avery short time; and the added safety it assures is more than worth the time involved.

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If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operat -ing the motorcycle.

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EAU00372

OPERATION AND IMPORTANT RIDING POINTS

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EAU01432

Starting and warming up acold engineIn order for the ignition circuit cut-offsystem to enable starting, one of thefollowing conditions must be met:8 The transmission is in the neutral

position.8 The transmission is in gear with

the clutch lever pulled and thesidestand up.

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8 Before starting the engine,check the function of the igni-tion circuit cut-off systemaccording to the proceduredescribed on page 3-14.

8 Never ride with the sidestanddown.

EAU00373

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8 Become thoroughly familiarwith all operating controls andtheir functions before riding.Consult a Yamaha dealerregarding any control or func-tion that you do not thorough-ly understand.

8 Never start the engine or oper-ate it in a closed area for anylength of time. Exhaust fumesare poisonous, and inhalingthem can cause loss of con-sciousness and death within ashort time. Always make surethat there is adequate ventila-tion.

8 Before starting out, make surethat the sidestand is up. If thesidestand is not raised com-pletely, it could contact theground and distract the opera-tor, resulting in a possible lossof control.

1. Turn the fuel cock lever to “ON”.2. Turn the key to “ON” and make

sure that the engine stop switchis set to “#”.

3. Shift the transmission into theneutral position.

NOTE:When the transmission is in the neu-tral position, the neutral indicator lightshould be on, otherwise have aYamaha dealer check the electricalcircuit.

PRIRES

ON

ON

FUEL

1

1. Arrow mark positioned over “ON”

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4. Turn the starter (choke) on andcompletely close the throttle.(See page 3-9 for starter (choke)operation.)

5. Start the engine by pushing thekickstarter lever down.

6. After starting the engine, movethe starter (choke) knob/leverback halfway.

ECA00055

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For maximum engine life, alwayswarm the engine up before startingoff. Never accelerate hard whenthe engine is cold!

7. When the engine is warm, turnthe starter (choke) off.

NOTE:The engine is warm when it respondsnormally to the throttle with the starter(choke) turned off.

EAU01258

Starting a warm engineFollow the same procedure as forstarting a cold engine with the excep-tion that the starter (choke) is notrequired when the engine is warm.

EAU00423

ShiftingShifting gears lets you control theamount of engine power available forstarting off, accelerating, climbinghills, etc.The gear positions are shown in theillustration.

NOTE:To shift the transmission into the neu-tral position, press the shift pedaldown repeatedly until it reaches theend of its travel, and then slightlyraise it.

1

5432

1N

6

1. Shift pedalN. Neutral

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EC000048

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8 Even with the transmission inthe neutral position, do notcoast for long periods of timewith the engine off, and do nottow the motorcycle for longdistances. The transmission isproperly lubricated only whenthe engine is running.Inadequate lubrication maydamage the transmission.

8 Always use the clutch whilechanging gears to avoid dam -aging the engine, transmis -sion, and drive train, which arenot designed to withstand theshock of forced shifting.

EAU00424

Tips for reducing fuel consumptionFuel consumption depends largely onyour riding style. Consider the follow-ing tips to reduce fuel consumption:8 Thoroughly warm up the engine.8 Turn the starter (choke) off as

soon as possible.8 Shift up swiftly, and avoid high

engine speeds during accelera-tion.

8 Do not rev the engine while shift-ing down, and avoid high enginespeeds with no load on theengine.

8 Turn the engine off instead of let-ting it idle for an extended lengthof time (e.g., in traffic jams, attraffic lights or at railroad cross-ings).

EAU00436

Engine break-inThere is never a more important peri-od in the life of your engine than theperiod between 0 and 1,000 km. Forthis reason, you should read the fol-lowing material carefully.Since the engine is brand new, donot put an excessive load on it for thefirst 1,000 km. The various parts inthe engine wear and polish them-selves to the correct operating clear-ances. During this period, prolongedfull-throttle operation or any conditionthat might result in engine overheat-ing must be avoided.

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EAU00453

0–500 km8 Avoid prolonged operation above

4,000 r/min.8 After every hour of operation,

stop the engine, and then let itcool for five to ten minutes.

8 Vary the engine speed from timeto time. Do not operate theengine at one set throttle posi-tion.

500–1,000 km 8 Avoid prolonged operation above

5,000 r/min.8 Rev the engine freely through

the gears, but do not use fullthrottle at any time.

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After 1,000 km of operation, thetransmission oil must be changed.

1,000 km and beyondThe vehicle can now be operatednormally.

EC000053

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8 Keep the engine speed out ofthe tachometer red zone.

8 If any engine trouble shouldoccur during the engine break-in period, immediately have aYamaha dealer check the vehi -cle.

EAU00460

ParkingWhen parking, stop the engine, andthen remove the key from the mainswitch.

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8 Since the engine and exhaustsystem can become very hot,park in a place where pedestri -ans or children are not likelyto touch them.

8 Do not park on a slope or onsoft ground, otherwise themotorcycle may overturn.

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EAU00462

PERIODIC MAINTENANCE AND MINOR REPAIR

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EAU00464

Safety is an obligation of the owner.Periodic inspection, adjustment andlubrication will keep your vehicle inthe safest and most efficient condi-tion possible. The most importantpoints of inspection, adjustment, andlubrication are explained on the fol-lowing pages. The intervals given in the periodicmaintenance and lubrication chartshould be simply considered as ageneral guide under normal ridingconditions. However, DEPENDINGON THE WEATHER, TERRAIN,GEOGRAPHICAL LOCATION, ANDINDIVIDUAL USE, THE MAINTE-NANCE INTERVALS MAY NEED TOBE SHORTENED.

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If you are not familiar with motor-cycle maintenance work, have aYamaha dealer do it for you.

1

EAU01175

Owner’s tool kitThe owner’s tool kit is located behindpanel B. (See page 6-6 for panelremoval and installation procedures.)The service information included inthis manual and the tools provided inthe owner’s tool kit are intended toassist you in the performance of pre-ventive maintenance and minorrepairs. However, additional toolssuch as a torque wrench may be nec-essary to perform certain mainte-nance work correctly.

1. Owner’s tool kit

NOTE:If you do not have the tools or experi-ence required for a particular job,have a Yamaha dealer perform it foryou.

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Modifications not approved byYamaha may cause loss of perfor-mance and render the vehicleunsafe for use. Consult a Yamahadealer before attempting anychanges.

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EAU03540

Periodic maintenance and lubrication chart

NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (×1,000 km) ANNUAL

CHECK1 6 12 18 24

1 * Fuel line • Check fuel hoses and vacuum hose for cracks or damage. √ √ √ √ √

2 Spark plug • Replace. √ √ √ √ √

3 Air filter element• Clean. √ √• Replace. √ √

4 * Battery • Check electrolyte level and specific gravity.• Make sure that the breather hose is properly routed. √ √ √ √ √

5 Clutch • Check operation.• Adjust. √ √ √ √ √

6 * Front brake• Check operation, fluid level and vehicle for fluid leakage.

(See NOTE on page 6-4.) √ √ √ √ √ √

• Replace brake pads. Whenever worn to the limit

7 * Rear brake• Check operation and adjust brake pedal freeplay. √ √ √ √ √ √• Replace brake shoes. Whenever worn to the limit

8 * Brake hose• Check for cracks or damage. √ √ √ √ √• Replace. (See NOTE on page 6-4.) Every 4 years

NOTE:8 The annual checks must be performed every year, except if kilometer-based maintenance is performed instead.8 From 30,000 km, repeat the maintenance intervals starting from 6,000 km.8 Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and

technical skills.

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9 * Wheels • Check runout, spoke tightness and for damage.• Tighten spokes if necessary. √ √ √ √

10 * Tires

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

√ √ √ √

11 * Wheel bearings • Check bearing for looseness or damage. √ √ √ √

12 * Swingarm• Check swingarm pivoting point for play. √ √ √ √• Lubricate with lithium-soap-based grease. Every 24,000km

13 Drive chain• Check chain slack.• Make sure that the rear wheel is properly aligned.• Clean and lubricate.

Every 500 km and after washing the motorcycle or riding in the rain

14 * Steering bearings• Check bearing play and steering for roughness. √ √ √ √ √• Lubricate with lithium-soap-based grease Every 24,000km

15 * Chassis fasteners • Make sure that all nuts, bolts and screws are properly tightened. √ √ √ √ √

16 Sidestand • Check operation.• Lubricate. √ √ √ √ √

17 * Sidestand switch • Check operation. √ √ √ √ √ √

18 * Front fork • Check operation and for oil leakage. √ √ √ √

19 *Rear shock absorber assembly

• Check operation and shock absorber for oil leakage. √ √ √ √• Lubricate the pivoting points with lithium-soap-based

grease. √ √


CHECK1 6 12 18 24

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EAU03541

NOTE:8 The air filter needs more frequent service if you are riding in unusually wet or dusty areas.8 Hydraulic brake service9 Regularly check and, if necessary, correct the brake fluid level. 9 Every two years replace the internal components of the brake master cylinder and caliper, and change the brake

fluid.9 Replace the brake hoses every four years and if cracked or damaged.

20 * Carburetor • Check starter (choke) operation.• Adjust engine idling speed. √ √ √ √ √ √

21 * Autolube pump • Check operation.• Bleed if necessary. √ √ √ √

22 Transmission oil• Check oil level and vehicle for leakage. √ √ √ √ √ √• Change. √ √

23 *Front and rear brake switches • Check operation. √ √ √ √ √ √

24 Moving parts and cables • Lubricate. √ √ √ √ √

25 *Lights, signals and switches

• Check operation.• Adjust headlight beam. √ √ √ √ √ √


CHECK1 6 12 18 24

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EAU03516

Removing and installing thecowling and panelsThe cowling and panels shown aboveneed to be removed to perform someof the maintenance jobs described inthis chapter. Refer to this sectioneach time the cowling or a panelneeds to be removed and installed.

1. Bolt (×3)

EAU01491

Cowling A

To remove the cowlingRemove the cowling bolts, and thenpull the cowling off as shown.

To install the cowlingPlace the cowling in the original posi-tion, and then install the bolts.

1

1. Panel B

2

1

1. Cowling A2. Panel A

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b

a

a. Unlockb. Lock

EAU00493

Panel B

To remove the panel1. Insert the key into the lock, and

then turn it clockwise.2. Pull the panel off as shown.

To install the panel1. Place the panel in the original

position.2. Insert the key, turn it counter-

clockwise, and then remove it.

1

1. Screw

EAU00488

Panel A

To remove the panelRemove the screw, and then pull thepanel off as shown.

To install the panelPlace the panel in the original posi-tion, and then install the screw.

1

EAU01833

Checking the spark plugThe spark plug is an importantengine component, which is easy tocheck. Since heat and deposits willcause any spark plug to slowly erode,the spark plug should be removedand checked in accordance with theperiodic maintenance and lubricationchart. In addition, the condition of thespark plug can reveal the condition ofthe engine.

To remove the spark plug1. Remove the spark plug cap.

1. Spark plug cap

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2. Remove the spark plug asshown, with the spark plugwrench included in the owner’stool kit.

To check the spark plug1. Check that the porcelain insula-

tor around the center electrodeof the spark plug is a medium-to-light tan (the ideal color when themotorcycle is ridden normally).

NOTE:If the spark plug shows a distinctlydifferent color, the engine could bedefective. Do not attempt to diagnosesuch problems yourself. Instead,have a Yamaha dealer check themotorcycle.

2. Check the spark plug for elec-trode erosion and excessive car-bon or other deposits, andreplace it if necessary.

1

1. Spark plug wrench

Specified spark plug:B8ES (NGK)

To install the spark plug1. Measure the spark plug gap with

a wire thickness gauge and, ifnecessary, adjust the gap tospecification.

2. Clean the surface of the sparkplug gasket and its mating sur-face, and then wipe off any grimefrom the spark plug threads.

a

a. Spark plug gap

Spark plug gap:0.7–0.8 mm

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3

3. Install the spark plug with thespark plug wrench, and thentighten it to the specified torque.

NOTE:If a torque wrench is not availablewhen installing a spark plug, a goodestimate of the correct torque is1/4–1/2 turn past finger tight.However, the spark plug should betightened to the specified torque assoon as possible.

4. Install the spark plug cap.

EAU02994

Transmission oilThe transmission oil level should bechecked before each ride. In addition,the transmission oil must be changedat the intervals specified in the peri-odic maintenance and lubricationchart.

To check the transmission oil level1. Place the motorcycle on a level

surface and hold it in an uprightposition.

NOTE:Make sure that the motorcycle ispositioned straight up when checkingthe oil level. A slight tilt to the sidecan result in a false reading.

1. Oil filler cap2. Maximum level mark3. Minimum level mark

Tightening torque:Spark plug:

25 Nm (2.5 m0kg)

2. Start the engine, warm it up forseveral minutes, and then turn itoff.

3. Wait a few minutes until the oilsettles, remove the oil filler cap,wipe the dipstick clean, insert itback into the oil filler hole (with-out screwing it in), and thenremove it again to check the oillevel.

NOTE:The transmission oil should bebetween the minimum and maximumlevel marks.

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1

To change the transmission oil1. Start the engine, warm it up for

several minutes, and then turn itoff.

2. Place an oil pan under the trans-mission to collect the used oil.

3. Remove the oil filler cap anddrain bolt to drain the oil from thetransmission.

4 Install the transmission oil drainbolt, and then tighten it to thespecified torque.

5. Add the specified amount of therecommended transmission oil,and then install and tighten theoil filler cap.

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8 In order to prevent clutch slip -page (since the transmissionoil also lubricates the clutch),do not mix any chemical addi -tives with the oil.

8 Make sure that no foreignmaterial enters the transmis -sion.

1. Transmission oil drain bolt

Tightening torque:Transmission oil drain bolt:

20 Nm (2.0 m0kg)

Recommended transmission oil:See page 8-1.

Oil quantity:Periodic oil change:

0.60 LTotal amount (dry transmission):

0.65 L

4. If the oil is below the minimumlevel mark, add sufficient oil ofthe recommended type to raise itto the correct level.

5. Insert the dipstick into the oil fillerhole, and then tighten the oil fillercap.

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6. Start the engine, and then let itidle for several minutes whilechecking the transmission for oilleakage. If oil is leaking, immedi-ately turn the engine off andcheck for the cause.

EAU03602*

Cleaning the air filter elementThe air filter element should becleaned at the intervals specified inthe periodic maintenance and lubrica-tion chart. Clean the air filter elementmore frequently if you are riding inunusually wet or dusty areas.

1. Remove panel A. (See page 6-6for panel removal and installationprocedures.)

2. Remove the air filter case coverby removing the holding clips.

12

1. Holding clip (×2)2. Air filter case cover

3. Pull the air filter element out ofthe air filter case.

4. Remove the sponge materialfrom the air filter element frame.

1

1. Air filter element

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EAU00629

Adjusting the carburetorThe carburetor is an important part ofthe engine and requires very sophisti-cated adjustment. Therefore, mostcarburetor adjustments should be leftto a Yamaha dealer, who has thenecessary professional knowledgeand experience. The adjustmentdescribed in the following section,however, may be serviced by theowner as part of routine mainte-nance.

EC000094

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The carburetor has been set andextensively tested at the Yamahafactory. Changing these settingswithout sufficient technical knowl -edge may result in poor perfor -mance of or damage to the engine.

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EC000082

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8 Make sure that the air filter ele -ment is properly seated in theair filter case.

8 The engine should never beoperated without the air filterelement installed, otherwisethe piston(s) and/or cylinder(s)may become excessivelyworn.

8. Install the panel.

5. Clean the sponge material withsolvent, and then squeeze theremaining solvent out.

6. Apply oil of the recommendedtype to the entire surface of thesponge material, and thensqueeze the excess oil out.

NOTE:The sponge material should be wetbut not dripping.

7. Install the sponge material ontothe frame, insert the air filter ele-ment into the air filter case, andthen install the holding clips.

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3 4

Recommended oil:2-stroke engine oil

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2. Check the engine idling speedand, if necessary, adjust it tospecification by turning the throt-tle stop screw. To increase theengine idling speed, turn thescrew in direction a. Todecrease the engine idling speed,turn the screw in direction b.

NOTE:If the specified idling speed cannotbe obtained as described above,have a Yamaha dealer make theadjustment.

EAU00632

Adjusting the engine idlingspeedThe engine idling speed must bechecked and, if necessary, adjustedas follows at the intervals specified inthe periodic maintenance and lubrica-tion chart.

1. Start the engine and warm it upfor several minutes at1,000–2,000 r/min while occa-sionally revving it to 4,000–5,000r/min.

NOTE:The engine is warm when it quicklyresponds to the throttle.

Standard idle speed:1,300–1,400 r/min

b

a

1

1. Throttle stop screw

EAU00634

Adjusting the throttle cablefree playThe throttle cable free play shouldmeasure 3–5 mm at the throttle grip.Periodically check the throttle cablefree play and, if necessary, adjust itas follows.

NOTE:The engine idling speed must be cor-rectly adjusted before checking andadjusting the throttle cable free play.

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1. Locknut2. Adjusting nutc. Free play

1. Loosen the locknut.2. To increase the throttle cable

free play, turn the adjusting nutin direction a. To decrease thethrottle cable free play, turn theadjusting nut in direction b.

3. Tighten the locknut.

EAU03573

TiresTo maximize the performance, dura-bility, and safe operation of yourmotorcycle, note the following pointsregarding the specified tires.

Tire air pressureThe tire air pressure should bechecked and, if necessary, adjustedbefore each ride.

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8 The tire air pressure must bechecked and adjusted on coldtires (i.e., when the tempera -ture of the tires equals theambient temperature).

8 The tire air pressure must beadjusted in accordance withthe riding speed and with thetotal weight of rider, passen -ger, cargo, and accessoriesapproved for this model.

Tire air pressure(measured on cold tires)

Load* Front Rear

Up to 90 kg150 kPa

1.50 kg/cm2

1.50 bar

200 kPa2.00 kg/cm2

2.00 bar

90 kg–maximum

150 kPa1.50 kg/cm2

1.50 bar

225 kPa2.25 kg/cm2

2.25 bar

Off-road riding150 kPa

1.50 kg/cm2

1.50 bar

200 kPa2.00 kg/cm2

2.00 bar

Maximum load* 180 kg

* Total weight of rider, passenger, cargo andaccessories

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Tire inspectionThe tires must be checked beforeeach ride. If the tire tread showscrosswise lines (minimum treaddepth), if the tire has a nail or glassfragments in it, or if the sidewall iscracked, have a Yamaha dealerreplace the tire immediately.

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Because loading has an enormousimpact on the handling, braking,performance and safety character -istics of your motorcycle, youshould keep the following precau -tions in mind.8 NEVER OVERLOAD THE

MOTORCYCLE! Operation ofan overloaded motorcycle mayresult in tire damage, loss ofcontrol, or severe injury. Makesure that the total weight ofrider, passenger, cargo, andaccessories does not exceedthe specified maximum loadfor the vehicle.

8 Do not carry along looselypacked items, which can shiftduring a ride.

8 Securely pack the heaviestitems close to the center of themotorcycle and distribute theweight evenly on both sides.

8 Adjust the suspension and tire airpressure with regard to the load.

8 Check the tire condition andair pressure before each ride.

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a

1. Side wall2. Wear indicatora. Tread depth

NOTE:The tire tread depth limits may differfrom country to country. Always com-ply with the local regulations.

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8 Have a Yamaha dealer replaceexcessively worn tires.Besides being illegal, operat -ing the motorcycle with exces -sively worn tires decreasesriding stability and can lead toloss of control.

8 The replacement of all wheel-and brake-related parts,including the tires, should beleft to a Yamaha dealer, whohas the necessary profession -al knowledge and experience.

Minimum tire tread depth (front and rear)

1.0 mm

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Tire informationThis motorcycle is equipped with tubetires.

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8 The front and rear tires shouldbe of the same make anddesign, otherwise the handlingcharacteristics of the motorcy -cle cannot be guaranteed.

8 After extensive tests, only thetires listed below have beenapproved for this model byYamaha Motor Co., Ltd.

EAU00685

Spoke wheelsTo maximize the performance, dura-bility, and safe operation of yourmotorcycle, note the following pointsregarding the specified wheels.8 The wheel rims should be

checked for cracks, bends orwarpage, and the spokes forlooseness or damage beforeeach ride. If any damage isfound, have a Yamaha dealerreplace the wheel. Do notattempt even the smallest repairto the wheel. A deformed orcracked wheel must be replaced.

8 The wheel should be balancedwhenever either the tire or wheelhas been changed or replaced.An unbalanced wheel can resultin poor performance, adversehandling characteristics, and ashortened tire life.


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8 It is dangerous to ride with aworn-out tire. When a tiretread begins to show cross -wise lines, have a Yamahadealer replace the tire immedi -ately.

8 The replacement of all wheel-and brake-related parts,including the tires, should beleft to a Yamaha dealer, whohas the necessary profession -al knowledge and experience.

8 It is not recommended topatch a punctured tube. Ifunavoidable, however, patchthe tube very carefully andreplace it as soon as possiblewith a high-quality product.

FRONT

Manufacturer Size Type

BRIDGESTONE 2.75-21 45P TW15

REAR

Manufacturer Size Type

BRIDGESTONE 4.10-18 59P TW12

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8 Ride at moderate speeds afterchanging a tire since the tire sur-face must first be “broken in” forit to develop its optimal charac-teristics.


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1. Locknut (Clutch lever)2. Adjusting bolt 3. Locknut (Clutch cable)4. Adjusting nutc. Free play

EAU02996

Adjusting the clutch leverfree playThe clutch lever free play shouldmeasure 10–15 mm as shown.Periodically check the clutch leverfree play and, if necessary, adjust itas follows.

1. Loosen the locknut at the clutchlever.

2. To increase the clutch lever freeplay, turn the adjusting bolt indirection a. To decrease theclutch lever free play, turn theadjusting bolt in direction b.

3. If the specified clutch lever freeplay could be obtained asdescribed above, tighten thelocknut and skip the rest of theprocedure, otherwise proceed asfollows.

4. Fully turn the adjusting bolt indirection a to loosen the clutchcable.

5. Loosen the locknut further downthe clutch cable.

6. To increase the clutch lever freeplay, turn the adjusting nut indirection a. To decrease theclutch lever free play, turn theadjusting nut in direction b.

7. Tighten both locknuts.

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EAU00696

Adjusting the brake leverfree playThe brake lever free play shouldmeasure 2–5 mm as shown.Periodically check the brake leverfree play and, if necessary, adjust itas follows.

1. Loosen the locknut at the brakelever.

2. To increase the brake lever freeplay, turn the adjusting bolt indirection a. To decrease thebrake lever free play, turn theadjusting bolt in direction b.


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b

c

1. Adjusting bolt2. Locknutc. Free play

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8 After adjusting the brake leverfree play, check the free playand make sure that the brakeis working properly.

8 A soft or spongy feeling in thebrake lever can indicate thepresence of air in thehydraulic system. If there is airin the hydraulic system, havea Yamaha dealer bleed thesystem before operating themotorcycle. Air in thehydraulic system will diminishthe braking performance,which may result in loss ofcontrol and an accident.

EAU00707

Adjusting the brake pedalposition and free play

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It is advisable to have a Yamahadealer make these adjustments.

Brake pedal positionThe top of the brake pedal should bepositioned approximately 10 mmbelow the top of the footrest.Periodically check the brake pedalposition and, if necessary, adjust it asfollows.

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a

1. Locknut2. Adjusting boltc. Brake pedal position

1. Loosen the locknut at the brakepedal.

2. To raise the brake pedal, turn theadjusting bolt in direction a. Tolower the brake pedal, turn theadjusting bolt in direction b.


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After adjusting the brake pedalheight, the brake pedal free playmust be adjusted.

1a

b

1. Adjusting nut

Brake pedal free playThe brake pedal free play shouldmeasure 20–30 mm as shown.Periodically check the brake pedalfree play and, if necessary, adjust itas follows.To increase the brake pedal freeplay, turn the adjusting nut at thebrake rod in direction a. Todecrease the brake pedal free play,turn the adjusting nut in direction b.

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8 After adjusting the drive chainslack or removing andinstalling the rear wheel,always check the brake pedalfree play.

8 If proper adjustment cannot beobtained as described, have aYamaha dealer make thisadjustment.

8 After adjusting the brake pedalfree play, check the operationof the brake light.

a

a. Brake pedal free play

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EAU00713

Adjusting the rear brake lightswitchThe rear brake light switch, which isactivated by the brake pedal, is prop-erly adjusted when the brake lightcomes on just before braking takeseffect. If necessary, adjust the brakelight switch as follows.Turn the adjusting nut while holdingthe rear brake light switch in place.To make the brake light come on ear-lier, turn the adjusting nut in directiona. To make the brake light come onlater, turn the adjusting nut in direc-tion b.

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2

ab

1. Brake light switch2. Adjusting nut

EAU00720

Checking the front brakepads and rear brake shoesThe front brake pads and the rearbrake shoes must be checked forwear at the intervals specified in theperiodic maintenance and lubricationchart.

1

1. Wear indicator grooves

FRONT

EAU01119

Front brake padsEach front brake pad is provided withwear indicator grooves, which allowyou to check the brake pad wearwithout having to disassemble thebrake. To check the brake pad wear,check the wear indicator grooves. If abrake pad has worn to the point thatthe wear indicators have almost dis-appeared, have a Yamaha dealerreplace the brake pads as a set.

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EAU00727

Rear brake shoesThe rear brake is provided with awear indicator, which allows you tocheck the brake shoe wear withouthaving to disassemble the brake. Tocheck the brake shoe wear, checkthe position of the wear indicatorwhile applying the brake. If a brakeshoe has worn to the point that thewear indicator reaches the wear limitline, have a Yamaha dealer replacethe brake shoes as a set.

2

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1. Wear limit line2. Wear indicator

REAR

EAU03196

Checking the brake fluidlevelInsufficient brake fluid may allow airto enter the brake system, possiblycausing it to become ineffective.Before riding, check that the brakefluid is above the minimum level markand replenish if necessary. A lowbrake fluid level may indicate wornbrake pads and/or brake systemleakage. If the brake level is low, besure to check the brake pads forwear and the brake system for leak-age.

Observe these precautions:8 When checking the fluid level,

make sure that the top of themaster cylinder or brake fluidreservoir is level.

8 Use only the recommended qual-ity brake fluid, otherwise the rub-ber seals may deteriorate, caus-ing leakage and poor brakingperformance.

8 Refill with the same type of brakefluid. Mixing fluids may result in aharmful chemical reaction andlead to poor braking perfor-mance.

8 Be careful that water does notenter the master cylinder whenrefilling. Water will significantlylower the boiling point of the fluidand may result in vapor lock.

1

1. Minimum level mark

FRONT

Recommended brake fluid:DOT 4

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8 Brake fluid may deteriorate paint-ed surfaces or plastic parts.Always clean up spilled fluidimmediately.

8 As the brake pads wear, it is nor-mal for the brake fluid level togradually go down. However, ifthe brake fluid level goes downsuddenly, have a Yamaha dealercheck the cause.

EAU03238

Changing the brake fluidHave a Yamaha dealer change thebrake fluid at the intervals specified inthe periodic maintenance and lubrica-tion chart. In addition, have the oilseals of the brake master cylinderand caliper as well as the brake hosereplaced at the intervals listed belowor whenever they are damaged orleaking.8 Oil seals: Replace every two

years.8 Brake hose: Replace every four

years.

EAU00744

Drive chain slackThe drive chain slack should bechecked before each ride and adjust-ed if necessary.

To check the drive chain slack1. Place the motorcycle on a level


NOTE:When checking and adjusting thedrive chain slack, the motorcycleshould be positioned straight up andthere should be no weight on it.

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a

a. Chain slack

2. Shift the transmission into theneutral position.

3. Move the rear wheel by pushingthe motorcycle to locate the tight-est portion of the drive chain,and then measure the drivechain slack as shown.

4. If the drive chain slack is incor-rect, adjust it as follows.

Drive chain slack:35–60 mm

EAU03526

To adjust the drive chain slack1. Loosen the brake pedal free play

adjusting nut and the axle nut.

2. To tighten the drive chain, turnthe adjusting plate on each sideof the swingarm in direction a.To loosen the drive chain, turnthe adjusting plate on each sideof the swingarm in direction b,and then push the rear wheel for-ward.

NOTE:Make sure that both adjusting platesare in the same position for properwheel alignment.

1

1. Brake pedal free play adjusting nut

2

1

a b

1. Axle nut2. Adjusting plate

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Improper drive chain slack willoverload the engine as well asother vital parts of the motorcycleand can lead to chain slippage orbreakage. To prevent this fromoccurring, keep the drive chainslack within the specified limits.

3. Tighten the brake pedal free playadjusting nut, and then tightenthe axle nut to the specifiedtorque.

4. Adjust the brake pedal free play.(See page 6-18 for brake pedalfree play adjustment proce-dures.)

Tightening torque:Axle nut:

85 Nm (8.5 m0kg)

EAU01106

Lubricating the drive chainThe drive chain must be cleaned andlubricated at the intervals specified inthe periodic maintenance and lubrica-tion chart, otherwise it will quicklywear out, especially when riding industy or wet areas. Service the drivechain as follows.

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The drive chain must be lubricatedafter washing the motorcycle orriding in the rain.

1. Remove all dirt and mud from thedrive chain with a brush or cloth.

2. Spray a drive chain lubricant onboth sides and on the middle ofthe chain, making sure that allside plates and rollers have beensufficiently oiled.

NOTE:For a thorough cleaning, have aYamaha dealer remove the drivechain and soak it in solvent.

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After adjusting the brake pedalfree play, check the operation ofthe brake light.

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EAU02962

Checking and lubricating thecablesThe operation of all control cablesand the condition of the cablesshould be checked before each ride,and the cables and cable endsshould be lubricated if necessary. If acable is damaged or does not movesmoothly, have a Yamaha dealercheck or replace it.

Recommended lubricant:Engine oil

EAU03209

Checking and lubricating thethrottle grip and cableThe operation of the throttle grip andthe condition of the throttle cableshould be checked before each ride,and the cable should be lubricated orreplaced if necessary.

NOTE:Since the throttle grip must beremoved to access the throttle cableend, the throttle grip and the cableshould always be lubricated at thesame time.

1. Remove the throttle grip byremoving the screws.

2. Disconnect the throttle cable,hold it up, and then apply severaldrops of oil to the cable end,allowing it to trickle into thesheath.

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Damage to the outer sheath mayinterfere with proper cable opera -tion and will cause the inner cableto rust. Replace a damaged cableas soon as possible to preventunsafe conditions.

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3. Connect the throttle cable, andthen grease the inside of thethrottle grip housing.

4. Grease the metal-to-metal con-tact surface of the throttle grip,and then install the grip byinstalling the screws.

Recommended lubricant:Throttle cable:

Engine oilThrottle grip housing and grip:

Lithium-soap-based grease (all-purpose grease)

EAU00774

Adjusting the AutolubepumpThe Autolube pump is a vital andsophisticated component of theengine, which must be adjusted by aYamaha dealer at the intervals speci-fied in the periodic maintenance andlubrication chart.

EAU03370

Checking and lubricating thebrake and shift pedalsThe operation of the brake and shiftpedals should be checked beforeeach ride, and the pedal pivotsshould be lubricated if necessary.

Recommended lubricant:Lithium-soap-based grease (all-purpose grease)

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EAU03164

Checking and lubricating thebrake and clutch leversThe operation of the brake and clutchlevers should be checked beforeeach ride, and the lever pivots shouldbe lubricated if necessary.


EAU03165

Checking and lubricating thesidestandThe operation of the sidestandshould be checked before each ride,and the sidestand pivot and metal-to-metal contact surfaces should belubricated if necessary.

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If the sidestand does not move upand down smoothly, have aYamaha dealer check or repair it.

EAU03166

Lubricating the rear suspensionThe pivoting points of the rear sus-pension must be lubricated at theintervals specified in the periodicmaintenance and lubrication chart.



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EAU02939

Checking the front forkThe condition and operation of thefront fork must be checked as followsat the intervals specified in the peri-odic maintenance and lubricationchart.

To check the conditionEW000115

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Securely support the motorcycleso that there is no danger of itfalling over.

Check the inner tubes for scratches,damage and excessive oil leakage.

To check the operation1. Place the motorcycle on a level


2. While applying the front brake,push down hard on the handle-bars several times to check if thefront fork compresses andrebounds smoothly.

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If any damage is found or the frontfork does not operate smoothly,have a Yamaha dealer check orrepair it.

EAU00794

Checking the steeringWorn or loose steering bearings maycause danger. Therefore, the opera-tion of the steering must be checkedas follows at the intervals specified inthe periodic maintenance and lubrica-tion chart.

1. Place a stand under the engineto raise the front wheel off theground.

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Securely support the motorcycleso that there is no danger of itfalling over.

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2. Hold the lower ends of the frontfork legs and try to move themforward and backward. If anyfree play can be felt, have aYamaha dealer check or repairthe steering.

EAU01144

Checking the wheel bearingsThe front and rear wheel bearingsmust be checked at the intervalsspecified in the periodic maintenanceand lubrication chart. If there is playin the wheel hub or if the wheel doesnot turn smoothly, have a Yamahadealer check the wheel bearings.

EAU01071

BatteryA poorly maintained battery will cor-rode and discharge quickly. The elec-trolyte level, battery lead connectionsand breather hose routing should bechecked before each ride and at theintervals specified in the periodicmaintenance and lubrication chart.

To check the electrolyte level1. Place the motorcycle on a level


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NOTE:Make sure that the motorcycle ispositioned straight up when checkingthe electrolyte level.

2. Check the electrolyte level in thebattery.

NOTE:The electrolyte should be betweenthe minimum and maximum levelmarks.

3. If the electrolyte is at or belowthe minimum level mark, add dis-tilled water to raise it to the maxi-mum level mark.

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8 Electrolyte is poisonous anddangerous since it containssulfuric acid, which causessevere burns. Avoid any con -tact with skin, eyes or clothingand always shield your eyeswhen working near batteries.In case of contact, administerthe following FIRST AID.8 EXTERNAL: Flush with

plenty of water.8 INTERNAL: Drink large

quantities of water or milkand immediately call aphysician.

8 EYES: Flush with water for15 minutes and seek promptmedical attention.

8 Batteries produce explosivehydrogen gas. Therefore, keepsparks, flames, cigarettes,etc., away from the battery andprovide sufficient ventilationwhen charging it in anenclosed space.

8 Take care not to spill elec -trolyte on the drive chain, asthis may weaken it, shortenchain life and possibly resultin an accident.

8 KEEP THIS AND ALL BATTER -IES OUT OF THE REACH OFCHILDREN.

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Use only distilled water, as tapwater contains minerals that areharmful to the battery.

4. Check and, if necessary, tightenthe battery lead connections andcorrect the breather hose rout-ing.

1. Maximum level mark2. Minimum level mark

1

2

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To store the battery1. If the motorcycle will not be used

for more than one month,remove the battery, fully chargeit, and then place it in a cool, dryplace.

2. If the battery will be stored formore than two months, check thespecific gravity of the electrolyteat least once a month and fullycharge the battery whenevernecessary.

3. Fully charge the battery beforeinstallation.

1. Battery2. Breather hose

1

2

EAU01307

Replacing the fuseThe fuse holder is located behindpanel B. (See page 6-6 for panelremoval and installation procedures.)If the fuse is blown, replace it as fol-lows.

1. Turn the key to “OFF” and turnoff all electrical circuits.

2. Remove the blown fuse, andthen install a new fuse of thespecified amperage.

1. Fuse2. Spare fuse

2

1

Specified fuse:10A

4. After installation, make sure thatthe battery leads are properlyconnected to the battery termi-nals and that the breather hoseis properly routed, in good condi-tion, and not obstructed.

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If the breather hose is positionedin such a way that the frame isexposed to electrolyte or gasexpelled from the battery, theframe could suffer structural andexternal damages.

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Do not use a fuse of a higheramperage rating than recommend -ed to avoid causing extensivedamage to the electrical systemand possibly a fire.

3. Turn the key to “ON” and turn onthe electrical circuits to check ifthe devices operate.

4. If the fuse immediately blowsagain, have a Yamaha dealercheck the electrical system.

1. Bolt (×2)

1

1. Headlight coupler2. Headlight bulb cover

2

1

EAU01528

Replacing the headlight bulbThis motorcycle is equipped with aquartz bulb headlight. If the headlightbulb burns out, replace it as follows.

1. Remove cowling A. (See page 6-6 for cowling removal andinstallation procedures.)

2. Remove the headlight unit byremoving the bolts.

3. Disconnect the headlight cou-pler, and then remove the head-light bulb cover.

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1. Headlight bulb holder

4. Remove the headlight bulb hold-er by turning it counterclockwise,and then remove the defectivebulb.

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Headlight bulbs get very hot.Therefore, keep flammable prod -ucts away from a lit headlight bulb,and do not touch the bulb until ithas cooled down.

5. Place a new bulb into position,and then secure it with the bulbholder.

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Do not touch the glass part of theheadlight bulb to keep it free fromoil, otherwise the transparency ofthe glass, the luminosity of thebulb, and the bulb life will beadversely affected. Thoroughlyclean off any dirt and fingerprintson the headlight bulb using a clothmoistened with alcohol or thinner.

6. Install the bulb cover, and thenconnect the coupler.

1. Do not touch this area

1

7. Install the headlight unit byinstalling the bolts.

8. Install the cowling.9. Have a Yamaha dealer adjust

the headlight beam if necessary.

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EAU03218

Replacing a turn signal lightbulb

1. Remove the turn signal lens byremoving the screws.

2. Remove the defective bulb bypushing it in and turning it coun-terclockwise.

3. Insert a new bulb into the socket,push it in, and then turn it clock-wise until it stops.

4. Install the lens by installing thescrews.

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Do not overtighten the screws,otherwise the lens may break.

1

2

3

1. Screw (×2)2. Lens3. Bulb

EAU01579

Supporting the motorcycleSince this model is not equipped witha centerstand, follow these precau-tions when removing the front andrear wheel or performing other main-tenance requiring the motorcycle tostand upright. Check that the motor-cycle is in a stable and level positionbefore starting any maintenance. Astrong wooden box can be placedunder the engine for added stability.

To service the front wheel1. Stabilize the rear of the motorcy-

cle by using a motorcycle standor, if an additional motorcyclestand is not available, by placinga jack under the frame in front ofthe rear wheel.

2. Raise the front wheel off theground by using a motorcyclestand.

EAU01623

Replacing the tail/brake lightbulb

1. Remove the tail/brake light lensby removing the screws.

2. Remove the defective bulb bypushing it in and turning it coun-terclockwise.

3. Insert a new bulb into the socket,push it in, and then turn it clock-wise until it stops.

4. Install the lens by installing thescrews.

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Do not overtighten the screws,otherwise the lens may break.

1. Screw (×2)2. Lens3. Bulb

1

2

3

1

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To service the rear wheelRaise the rear wheel off the groundby using a motorcycle stand or, if amotorcycle stand is not available, byplacing a jack either under each sideof the frame in front of the rear wheelor under each side of the swingarm.

2

1

EAU03517

Front wheel

To remove the front wheelEW000122

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8 It is advisable to have aYamaha dealer service thewheel.

8 Securely support the motorcy -cle so that there is no dangerof it falling over.

1. Disconnect the speedometercable from the front wheel.

2. Loosen the axle nut.

1. Speedometer cable2. Axle nut

3. Lift the front wheel off the groundaccording to the procedure onpage 6-33.

4. Remove the axle nut, pull thewheel axle out, and then removethe wheel.

ECA00048

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Do not apply the brake after thewheel has been removed togetherwith the brake disc, otherwise thebrake pads will be forced shut.

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1. Speedometer gear unit

EAU03518

To install the front wheel1. Install the speedometer gear unit

into the wheel hub so that theprojections mesh with the slots.

2. Lift the wheel up between thefork legs.

6. Connect the speedometer cable.

1

1. Retainer

NOTE:Make sure that there is enoughspace between the brake padsbefore inserting the brake disc andthat the slot in the speedometer gearunit fits over the retainer on the forkleg.

3. Insert the wheel axle, and theninstall the axle nut.

4. Lower the front wheel so that it ison the ground.

5. Tighten the axle nut to the speci-fied torque.


90 Nm (9.0 m·kg)

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1. Brake pedal free play adjusting nut2. Brake rod3. Brake camshaft lever

EAU03519

Rear wheel

To remove the rear wheelEW000122

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8 It is advisable to have a Yamahadealer service the wheel.

8 Securely support the motorcy -cle so that there is no dangerof it falling over.

1. Loosen the axle nut.2. Remove the brake pedal free

play adjusting nut, and then dis-connect the brake rod from thebrake camshaft lever.

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1

a

1. Axle nut2. Chain adjusting plate

3. Turn the drive chain adjustingplate on each side of theswingarm fully in direction a.

4. Lift the rear wheel off the groundaccording to the procedure onpage 6-33.

5. Remove the axle nut, and thenpull the wheel axle out.

6. Push the wheel forward, andthen remove the drive chain fromthe rear sprocket.

NOTE:The drive chain does not need to bedisassembled in order to remove andinstall the wheel.

7. Remove the wheel.

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EAU03574

To install the rear wheel1. Insert the wheel axle from the

right-hand side.

NOTE:Make sure that the drive chain adjust-ing plates are installed with thepunched sides facing to the outsideand that the slot in the brake shoeplate fits over the retainer on theswingarm.

2. Install the drive chain onto therear sprocket, and then adjustthe drive chain slack. (See page6-22 for drive chain slack adjust-ment procedures.)

3. Install the axle nut, and thenlower the rear wheel so that it ison the ground.

4. Tighten the axle nut to the speci-fied torque.

5. Install the brake rod onto thebrake camshaft lever, and theninstall the brake pedal free playadjusting nut onto the brake rod.

6. Adjust the brake pedal free play.(See page 6-18 for brake pedalfree play adjustment proce-dures.)

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After adjusting the brake pedalfree play, check the operation ofthe brake light.

EAU01008

TroubleshootingAlthough Yamaha motorcyclesreceive a thorough inspection beforeshipment from the factory, troublemay occur during operation. Anyproblem in the fuel, compression, orignition systems, for example, cancause poor starting and loss ofpower.The following troubleshooting chartrepresents a quick and easy proce-dure for checking these vital systemsyourself. However, should yourmotorcycle require any repair, take itto a Yamaha dealer, whose skilledtechnicians have the necessary tools,experience, and know-how to servicethe motorcycle properly.Use only genuine Yamaha replace-ment parts. Imitation parts may looklike Yamaha parts, but they are ofteninferior, have a shorter service lifeand can lead to expensive repairbills.


85 Nm (8.5 m0kg)

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EAU01532

Troubleshooting chartEW000125

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Keep away open flames and do not smoke while checking or working on the fuel system.

1. Fuel

2. Compression

3. Ignition

Use the kick starter.

Remove spark

There is compression. Go to ignition check.

No compression. Ask a Yamaha dealer to inspect.

Wet.

Dry.

Wipe clean with dry cloth and correct Open throttle half-way and start

Ask a Yamaha dealer to inspect.

Check if there is fuel

Enough fuel.

No fuel.

Go to compression check.

Supply fuel.

in the fuel tank.

electrodes.plug and check

Engine doesn’t start, ask a Yamaha dealer to inspect.

the engine.spark gap or replace spark plug.

Engine doesn’t start, go to compression check.

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EAU03521

MOTORCYCLE CARE AND STORAGE

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CareWhile the open design of a motorcy-cle reveals the attractiveness of thetechnology, it also makes it more vul-nerable. Rust and corrosion candevelop even if high-quality compo-nents are used. A rusty exhaust pipemay go unnoticed on a car, however,it detracts from the overall appear-ance of a motorcycle. Frequent andproper care does not only complywith the terms of the warranty, but itwill also keep your motorcycle lookinggood, extend its life and optimize itsperformance.

Before cleaning1. Cover the muffler outlet with a

plastic bag after the engine hascooled down.

2. Make sure that all caps and cov-ers as well as all electrical cou-plers and connectors, includingthe spark plug cap, are tightlyinstalled.

3. Remove extremely stubborn dirt,like oil burnt onto the crankcase,with a degreasing agent and abrush, but never apply suchproducts onto seals, gaskets,sprockets, the drive chain andwheel axles. Always rinse the dirtand degreaser off with water.

CleaningECA00010

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8 Avoid using strong acidicwheel cleaners, especially onspoked wheels. If such prod-ucts are used on hard-to-remove dirt, do not leave thecleaner on the affected areaany longer than instructed.Also, thoroughly rinse the areaoff with water, immediately dryit, and then apply a corrosionprotection spray.

8 Improper cleaning can damagewindshields, cowlings, panelsand other plastic parts. Useonly a soft, clean cloth orsponge with mild detergentand water to clean plastic.

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MOTORCYCLE CARE AND ST ORAGE

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8 Do not use any harsh chemicalproducts on plastic parts. Besure to avoid using cloths orsponges which have been incontact with strong or abra -sive cleaning products, sol -vent or thinner, fuel (gasoline),rust removers or inhibitors,brake fluid, antifreeze or elec -trolyte.

8 Do not use high-pressurewashers or steam-jet cleanerssince they cause water seep -age and deterioration in thefollowing areas: seals (ofwheel and swingarm bearings,fork and brakes), electric com -ponents (couplers, connec -tors, instruments, switchesand lights), breather hosesand vents.

8 For motorcycles equippedwith a windshield: Do not usestrong cleaners or hardsponges as they will causedulling or scratching. Somecleaning compounds for plas -tic may leave scratches on thewindshield. Test the producton a small hidden part of thewindshield to make sure that itdoes not leave any marks. Ifthe windshield is scratched,use a quality plastic polishingcompound after washing.

After normal useRemove dirt with warm water, a milddetergent, and a soft, clean sponge,and then rinse thoroughly with cleanwater. Use a toothbrush or bottle-brush for hard-to-reach areas.Stubborn dirt and insects will comeoff more easily if the area is coveredwith a wet cloth for a few minutesbefore cleaning.

After riding in the rain, near the seaor on salt-sprayed roadsSince sea salt or salt sprayed onroads during winter are extremelycorrosive in combination with water,carry out the following steps aftereach ride in the rain, near the sea oron salt-sprayed roads.

NOTE:Salt sprayed on roads in the wintermay remain well into spring.

1. Clean the motorcycle with coldwater and a mild detergent, afterthe engine has cooled down.

ECA00012

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Do not use warm water since itincreases the corrosive action ofthe salt.

2. Apply a corrosion protectionspray on all metal, includingchrome- and nickel-plated, sur-faces to prevent corrosion.

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After cleaning1. Dry the motorcycle with a

chamois or an absorbing cloth.2. Immediately dry the drive chain

and lubricate it to prevent it fromrusting.

3. Use a chrome polish to shinechrome, aluminum and stainless-steel parts, including the exhaustsystem. (Even the thermallyinduced discoloring of stainless-steel exhaust systems can beremoved through polishing.)

4. To prevent corrosion, it is recom-mended to apply a corrosion pro-tection spray on all metal, includ-ing chrome- and nickel-plated,surfaces.

5. Use spray oil as a universalcleaner to remove any remainingdirt.

6. Touch up minor paint damagecaused by stones, etc.

7. Wax all painted surfaces.

8. Let the motorcycle dry complete-ly before storing or covering it.

EWA00001

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8 Make sure that there is no oilor wax on the brakes or tires.If necessary, clean the brakediscs and brake linings with aregular brake disc cleaner oracetone, and wash the tireswith warm water and a milddetergent.

8 Before operating the motorcy -cle test its braking perfor -mance and cornering behav -ior.

ECA00013

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8 Apply spray oil and wax spar -ingly and make sure to wipeoff any excess.

8 Never apply oil or wax to anyrubber and plastic parts, buttreat them with a suitable careproduct.

8 Avoid using abrasive polish -ing compounds as they willwear away the paint.

NOTE:Consult a Yamaha dealer for adviceon what products to use.

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StorageShort-termAlways store your motorcycle in acool, dry place and, if necessary, pro-tect it against dust with a porouscover.

ECA00014

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8 Storing the motorcycle in apoorly ventilated room or cov -ering it with a tarp, while it isstill wet, will allow water andhumidity to seep in and causerust.

8 To prevent corrosion, avoiddamp cellars, stables (becauseof the presence of ammonia)and areas where strong chemi -cals are stored.

Long-termBefore storing your motorcycle forseveral months:

1. Follow all the instructions in the“Care” section of this chapter.

2. For motorcycles equipped with afuel cock that has an “OFF” posi-tion: Turn the fuel cock lever to“OFF”.

3. Drain the carburetor float cham-ber by loosening the drain bolt;this will prevent fuel depositsfrom building up. Pour thedrained fuel into the fuel tank.

4. Fill up the fuel tank and add fuelstabilizer (if available) to preventthe fuel tank from rusting and thefuel from deteriorating.

5. Perform the following steps toprotect the cylinder, piston rings,etc. from corrosion.a. Remove the spark plug cap

and spark plug.b. Pour a teaspoonful of engine

oil into the spark plug bore.

c. Install the spark plug cap ontothe spark plug, and then placethe spark plug on the cylinderhead so that the electrodesare grounded. (This will limitsparking during the next step.)

d. Turn the engine over severaltimes with the starter. (Thiswill coat the cylinder wall withoil.)

e. Remove the spark plug capfrom the spark plug, and theninstall the spark plug and thespark plug cap.

EWA00003

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To prevent damage or injury fromsparking, make sure to ground thespark plug electrodes while turn -ing the engine over.

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6. Lubricate all control cables andthe pivoting points of all leversand pedals as well as of thesidestand/centerstand.

7. Check and, if necessary, correctthe tire air pressure, and then liftthe motorcycle so that both of itswheels are off the ground.Alternatively, turn the wheels alittle every month in order to pre-vent the tires from becomingdegraded in one spot.

8. Cover the muffler outlet with aplastic bag to prevent moisturefrom entering it.

9. Remove the battery and fullycharge it. Store it in a cool, dryplace and charge it once amonth. Do not store the batteryin an excessively cold or warmplace (less than 0°C or morethan 30°C). For more informationon storing the battery, see page6-30.

NOTE:Make any necessary repairs beforestoring the motorcycle.

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EAU01038

SPECIFICATIONS

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Specifications

Model DT175(N)

Dimensions

Overall length 2,110 mm

Overall width 855 mm

Overall height 1,150 mm

Seat height 825 mm

Wheelbase 1,345 mm

Ground clearance 260 mm

Minimum turning radius 2,100 mm

Basic weight (with oil and fullfuel tank) 111 kg

Engine

Engine type Air cooled 2-stroke

Cylinder arrangement Forward inclined singlecylinder

Displacement 171 cm3

Bore × Stroke 66.0 × 50.0 mm

Compression ratio 6.7:1

Starting system Kick starter

Lubrication system Separate lubrication(Yamaha Autolube)

Engine oil (2-cycle)

Type Yamalube 2 or equivalent 2-stroke engine oil (JASO grade “FC”)

Capacity

Total amount 0.9 L

Transmission oil

Type SAE 10W30 type SE motor oil

Capacity

Periodic oil change 0.6 L

Total amount 0.65 L

Air filter Wet type element

Fuel

Type Regular gasoline (except for Australia)

Unleaded fuel only (for Australia)

Fuel tank capacity 9.5 L

Reserve amount 1.0 L

Carburetor

Manufacturer MIKUNI

Type×quantity VM24SS×1

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SPECIFICATIONS

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Spark plug

Manufacturer/type NGK/B8ES

Spark plug gap 0.7–0.8 mm

Clutch type Wet, multiple-disc

Transmission

Primary reduction system Helical gear

Primary reduction ratio 71/22 (3.227)

Secondary reduction system Chain drive

Secondary reduction ratio 3.062

Number of drive chainsprocket teeth (rear/front) 49/16

Transmission type Constant mesh 6-speed

Operation Left foot

Gear ratio 1st 3.181

2nd 1.933

3rd 1.368

4th 1.090

5th 0.956

6th 0.840

Chassis

Frame type Semi double cradle

Caster angle 30°

Trail 125 mm

Tires

Type With tube

Front

Size 2.75-21 45P

Manufacturer/ BRIDGESTONE / TW15Model

Rear

Size 4.10-18 59P

Manufacturer/ BRIDGESTONE / TW12Model

Maximum load* 180 kg

Air pressure (cold tire)

up to 90 kg load*

Front 150 kPa (1.50 kgf/cm2, 1.50 bar)

Rear 200 kPa (2.00 kgf/cm2, 2.00 bar)

90 kg load–Maximumload*



Off-road riding



*Load is total weight of cargo, rider, passenger and accessories.

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SPECIFICATIONS

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Wheels

Front

Type Spoke wheel

Size 1.60 × 21

Rear

Type Spoke wheel

Size 1.85 × 18

Brakes

Front

Type Single disc brake

Operation Right hand

Fluid DOT 4

Rear

Type Drum brake

Operation Right foot

Suspension

Front

Type Telescopic fork

Rear

Type Swingarm (Monocrosssuspension)

Shock absorbers

Front Coil spring/oil damper

Rear Coil spring/gas-oil damper

Wheel travel

Front 200 mm

Rear 153 mm

Electrical

Ignition system: C.D.I.

Charging system

Type C.D.I. magneto

Battery

Type GM3-3B

Capacity 12 V, 3AH

Headlight bulb type Halogen bulb

Bulb voltage, wattage × quantity

Headlight 12 V, 35/35W × 1

Tail/brake light 12 V, 5/21W × 1

Front turn signal light 12 V, 21W × 2

Rear turn signal light 12 V, 21W × 2

Meter lighting 12 V, 3.4W × 2

Neutral indicator light 12 V, 3.4W × 1

High beam indicator light 12 V, 3.4W × 1

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SPECIFICATIONS

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Oil level warning light 12 V, 3.4W × 1

Turn signal indicator light 12 V, 3.4W × 1

Fuse 10A

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EAU01064

Conversion tableAll specification data in this manual are listed in SI andMETRIC UNITS.Use this table to convert METRIC unit data to IMPERIAL unit data.

Ex.

METRIC MULTIPLIER IMPERIAL

** mm × 0.03937 = ** in2 mm × 0.03937 = 0.08 in

METRIC TO IMPERIAL

Metric unit Multiplier Imperial unit

m • kg 7.233 ft • lb

Torquem • kg 86.794 in • lbcm • kg 0.0723 ft • lbcm • kg 0.8679 in • lb

Weightkg 2.205 lbg 0.03527 oz

Speed km/hr 0.6214 mph

km 0.6214 mim 3.281 ft

Distance m 1.094 ydcm 0.3937 inmm 0.03937 in

cc (cm3) 0.03527 oz (IMP liq.)Volume/ cc (cm3) 0.06102 cu • inCapacity L (liter) 0.8799 qt (IMP liq.)

L (liter) 0.2199 gal (IMP liq.)

kg/mm 55.997 lb/inMisc. kg/cm2 14.2234 psi (lb/in2)

Centigrade (°C) 9/5 + 32 Fahrenheit (°F)

CONVERSION TABLE

3FJ-9-2C (ENG) 6/28/00 11:16 AM Page 87

EAU02944

Identification numbersRecord the key identification number,vehicle identification number andmodel label information in the spacesprovided below for assistance whenordering spare parts from a Yamahadealer or for reference in case thevehicle is stolen.

1. KEY IDENTIFICATION NUMBER:

2. VEHICLE IDENTIFICATION NUMBER:

3. MODEL LABEL INFORMATION:

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EAU01039

CONSUMER INFORMATION

16

1

1. Key identification number

EAU01042

Key identification numberThe key identification number isstamped into the key.Record this number in the space pro-vided and use it for reference whenordering a new key.

1

1. Vehicle identification number

EAU01043

Vehicle identification numberThe vehicle identification number isstamped into the steering head pipe.Record this number in the space pro-vided.

NOTE:The vehicle identification number isused to identify your motorcycle andmay be used to register your motor-cycle with the licensing authority inyour area.

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EAU01049

Model labelThe model label is affixed to the loca-tion shown in the figure. Record theinformation on this label in the spaceprovided. This information will beneeded when ordering spare partsfrom a Yamaha dealer.

1. Model label

EAU01388

Motorcycle noise regulation(for Australia)TAMPERING WITH NOISE CON-TROL SYSTEM PROHIBITED:Owners are warned that the law mayprohibit:(a) The removal or rendering inoper-

ative by any person other thanfor purposes of maintenance,repair or replacement, of anydevice or element of designincorporated into any new vehi-cle for the purpose of noise con-trol prior to its sale or delivery tothe ultimate purchaser or while itis in use; and

(b) The use of the vehicle after suchdevice or element of design hasbeen removed or rendered inop-erative by any person.

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PRINTED ON RECYCLED PAPER PRINTED IN JAPAN

2000·6–0.2´1(E) !

OWNER’S MANUAL

3FJ-28199-2C

DT175(N)YAMAHA MOTOR CO., LTD.

dt175(n) owner’s manualyamahaownershandbook.com.au/lib/download.php?f=3fj-28199-2c.pdf · may be...

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