AG200FEL · 2020. 6. 24. · Introduction EAU10103 Welcome to the Yamaha world of motorcycling! As the owner of the AG200FEL, you are benefiting from Yamaha’s vast experience and

OWNER’S MANUAL

AG200FELBP2-28199-24

q Read this manual carefully before operating this vehicle.

BP2-9-24_Cover.indd 1 2019/08/29 14:00:22

EAU46091

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

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IntroductionEAU10103

Welcome to the Yamaha world of motorcycling!As the owner of the AG200FEL, you are benefiting from Yamaha’s vast experience and newest technology regarding thedesign and manufacture of high-quality products, which have earned Yamaha a reputation for dependability.Please take the time to read this manual thoroughly, so as to enjoy all advantages of your AG200FEL. The Owner’s Manualdoes not only instruct you in how to operate, inspect and maintain your motorcycle, but also in how to safeguard yourself andothers from trouble and injury.In addition, the many tips given in this manual will help keep your motorcycle in the best possible condition. If you have anyfurther questions, do not hesitate to contact your Yamaha dealer.The Yamaha team wishes you many safe and pleasant rides. So, remember to put safety first!Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most cur-rent product information available at the time of printing, there may be minor discrepancies between your motorcycle and thismanual. If there is any question concerning this manual, please consult a Yamaha dealer.

WARNINGEWA10032

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

BP2-9-24-E0.book 1 ページ２０１９年７月２５日　木曜日　午後２時１９分

Important manual informationEAU10134

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

*Product and specifications are subject to change without notice.

This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

A WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.

A NOTICE indicates special precautions that must be taken to avoid damage to the vehicle or other property.

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

WARNING

NOTICE

TIP


Important manual information

EAU10201

AG200FELOWNER’S MANUAL

©2020 by Yamaha Motor Co., Ltd.1st edition, August 2019

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

Yamaha Motor Co., Ltd. is expressly prohibited.

Printed in Japan.


Table of contentsLocation of important labels ........... 1-1

Safety information ........................... 2-1

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

Instrument and control functions... 4-1Main switch..................................... 4-1Indicator light .................................. 4-1Speedometer unit ........................... 4-2Handlebar switches ........................ 4-2Clutch lever..................................... 4-3Shift pedal....................................... 4-4Brake lever ..................................... 4-4Brake pedal .................................... 4-4Fuel tank cap .................................. 4-5Fuel................................................. 4-5Fuel cock ........................................ 4-6Starter (choke) knob ....................... 4-7Kickstarter....................................... 4-8Seat ................................................ 4-8Adjusting the shock absorber

assembly ..................................... 4-9Sidestands.................................... 4-10Starting circuit cut-off system ....... 4-10Auxiliary DC jack .......................... 4-12

For your safety – pre-operation checks .............................................. 5-1

Operation and important riding points ................................................ 6-1

Starting and warming up a cold engine ......................................... 6-1

Starting a warm engine .................. 6-2Shifting ........................................... 6-2Tips for reducing fuel

consumption ............................... 6-3Engine break-in .............................. 6-3Parking ........................................... 6-4

Periodic maintenance and adjustment ....................................... 7-1

Owner’s tool kit............................... 7-2Periodic maintenance chart for

the emission control system ....... 7-3General maintenance and

lubrication chart .......................... 7-4Removing and installing panels ..... 7-7Checking the spark plug................. 7-8Engine oil and oil filter element ...... 7-9Cleaning the air filter element ...... 7-12Adjusting the carburetor ............... 7-13Adjusting the engine idling

speed ........................................ 7-13Checking the throttle grip free

play ........................................... 7-14Valve clearance............................ 7-14

Tires............................................. 7-15Spoke wheels .............................. 7-17Adjusting the clutch lever free

play........................................... 7-17Adjusting the brake lever free

play........................................... 7-18Adjusting the brake pedal height

and free play............................. 7-19Checking the shift pedal .............. 7-21Brake light switches ..................... 7-21Checking the front and rear brake

shoes........................................ 7-21Drive chain slack.......................... 7-22Cleaning and lubricating the drive

chain......................................... 7-24Checking and lubricating

the cables ................................. 7-24Checking and lubricating

the throttle grip and cable......... 7-24Checking and lubricating

the brake and clutch levers ...... 7-25Checking and lubricating

the brake pedal......................... 7-25Checking and lubricating

the sidestands .......................... 7-25Lubricating the rear suspension... 7-26Checking the front fork................. 7-26Checking the steering .................. 7-27Checking the wheel bearings....... 7-27Battery ......................................... 7-27Replacing the fuses ..................... 7-29


Table of contentsReplacing the headlight bulb ........ 7-30Replacing the brake/tail light

bulb ........................................... 7-31Replacing a turn signal light

bulb ........................................... 7-31Supporting the motorcycle............ 7-32Front wheel................................... 7-32Rear wheel ................................... 7-34Troubleshooting............................ 7-36Troubleshooting chart................... 7-38

Motorcycle care and storage .......... 8-1Matte color caution ......................... 8-1Care................................................ 8-1Storage........................................... 8-3

Specifications .................................. 9-1

Consumer information .................. 10-1Identification numbers .................. 10-1Motorcycle noise regulation

(for Australia) ............................ 10-2

Index ............................................... 11-1


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Location of important labelsEAU10385

Read and understand all of the labels on your vehicle. They contain important information for safe and proper operation ofyour vehicle. Never remove any labels from your vehicle. If a label becomes difficult to read or comes off, a replacement labelis available from your Yamaha dealer.

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

5PA-21568-01

Prima di usare il veicolo, leggete il manuale di istruzioni.Lire le manuel du propriétaire avant d’utiliser ce véhicule.Lesen Sie die Bedienungsanleitung bevor Sie dieses Fahrzeug fahren.Antes de conducir este vehículo, lea el Manual del Propietario.

follows.FRONT :

:REAR3GX-21668-00

Cold tire normal pressure should be set as

125 kPa,{1.25 kgf/cm2}, 18 psi150 kPa,{1.50 kgf/cm2}, 22 psi

31

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Safety informationEAU35139

Be a Responsible OwnerAs the vehicle’s owner, you are respon-sible for the safe and proper operationof your motorcycle.Motorcycles are single-track vehicles.Their safe use and operation are de-pendent upon the use of proper ridingtechniques as well as the expertise ofthe operator. Every operator shouldknow the following requirements beforeriding this motorcycle.He or she should: Obtain thorough instructions from

a competent source on all aspectsof motorcycle operation.

Observe the warnings and mainte-nance requirements in this Own-er’s Manual.

Obtain qualified training in safeand proper riding techniques.

Obtain professional technical ser-vice as indicated in this Owner’sManual and/or when made neces-sary by mechanical conditions.

Never operate a motorcycle with-out proper training or instruction.

Take a training course. Beginnersshould receive training from a cer-tified instructor. Contact an autho-rized motorcycle dealer to find outabout the training courses nearestyou.

Safe RidingPerform the pre-operation checks eachtime you use the vehicle to make sure itis in safe operating condition. Failure toinspect or maintain the vehicle properlyincreases the possibility of an accidentor equipment damage. See page 5-1for a list of pre-operation checks. This motorcycle is designed for

off-road use only, therefore, it is il-legal to operate it on public streets,roads, or highways, even a dirt orgravel one. Off-road use on publiclands may be illegal. Please checklocal regulations before riding.

This motorcycle is designed to car-ry the operator only. No passen-gers.

The failure of motorists to detectand recognize motorcycles in traf-fic is the predominating cause ofautomobile/motorcycle accidents.

Many accidents have been causedby an automobile driver who didnot see the motorcycle. Makingyourself conspicuous appears tobe very effective in reducing thechance of this type of accident.Therefore:• Wear a brightly colored jacket.• Use extra caution when you are

approaching and passingthrough intersections, since in-tersections are the most likelyplaces for motorcycle accidentsto occur.

• Ride where other motorists cansee you. Avoid riding in anothermotorist’s blind spot.

• Never maintain a motorcyclewithout proper knowledge. Con-tact an authorized motorcycledealer to inform you on basicmotorcycle maintenance. Cer-tain maintenance can only becarried out by certified staff.

Many accidents involve inexperi-enced operators.• Make sure that you are qualified

and that you only lend your mo-torcycle to other qualified opera-


Safety information

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tors.• Know your skills and limits.

Staying within your limits mayhelp you to avoid an accident.

• We recommend that you prac-tice riding your motorcycle untilyou have become thoroughly fa-miliar with the motorcycle and allof its controls.

Many accidents have been causedby error of the motorcycle opera-tor. A typical error made by the op-erator is veering wide on a turndue to excessive speed or under-cornering (insufficient lean anglefor the speed). Never travel fasterthan warranted by conditions.

Ride cautiously in unfamiliar ar-eas. You may encounter hiddenobstacles that could cause an ac-cident.

The posture of the operator is im-portant for proper control. The op-erator should keep both hands onthe handlebar and both feet on theoperator footrests during operationto maintain control of the motorcy-cle.

Never ride under the influence of

alcohol or other drugs.

Protective ApparelThe majority of fatalities from motorcy-cle accidents are the result of head in-juries. The use of a safety helmet is thesingle most critical factor in the preven-tion or reduction of head injuries. Always wear an approved helmet. Wear a face shield or goggles.

Wind in your unprotected eyescould contribute to an impairmentof vision that could delay seeing ahazard.

The use of a jacket, heavy boots,trousers, gloves, etc., is effective inpreventing or reducing abrasionsor lacerations.

Never wear loose-fitting clothes,otherwise they could catch on thecontrol levers, footrests, or wheelsand cause injury or an accident.

Always wear protective clothingthat covers your legs, ankles, andfeet. The engine or exhaust sys-tem become very hot during or af-ter operation and can cause burns.

Avoid Carbon Monoxide PoisoningAll engine exhaust contains carbonmonoxide, a deadly gas. Breathing car-bon monoxide can cause headaches,dizziness, drowsiness, nausea, confu-sion, and eventually death.Carbon Monoxide is a colorless, odor-less, tasteless gas which may be pres-ent even if you do not see or smell anyengine exhaust. Deadly levels of car-bon monoxide can collect rapidly andyou can quickly be overcome and un-able to save yourself. Also, deadly lev-els of carbon monoxide can linger forhours or days in enclosed or poorlyventilated areas. If you experience anysymptoms of carbon monoxide poison-ing, leave the area immediately, getfresh air, and SEEK MEDICAL TREAT-MENT. Do not run engine indoors. Even if

you try to ventilate engine exhaustwith fans or open windows anddoors, carbon monoxide can rap-idly reach dangerous levels.

Do not run engine in poorly venti-lated or partially enclosed areassuch as barns, garages, or car-ports.


Safety information

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Do not run engine outdoors whereengine exhaust can be drawn intoa building through openings suchas windows and doors.

Genuine Yamaha AccessoriesChoosing accessories for your vehicleis an important decision. GenuineYamaha accessories, which are avail-able only from a Yamaha dealer, havebeen designed, tested, and approvedby Yamaha for use on your vehicle.Many companies with no connection toYamaha manufacture parts and acces-sories or offer other modifications forYamaha vehicles. Yamaha is not in aposition to test the products that theseaftermarket companies produce.Therefore, Yamaha can neither en-dorse nor recommend the use of ac-cessories not sold by Yamaha ormodifications not specifically recom-mended by Yamaha, even if sold andinstalled by a Yamaha dealer.

Aftermarket Parts, Accessories, and ModificationsWhile you may find aftermarket prod-ucts similar in design and quality to

genuine Yamaha accessories, recog-nize that some aftermarket accessoriesor modifications are not suitable be-cause of potential safety hazards to youor others. Installing aftermarket prod-ucts or having other modifications per-formed to your vehicle that change anyof the vehicle’s design or operationcharacteristics can put you and othersat greater risk of serious injury or death.You are responsible for injuries relatedto changes in the vehicle.Keep the following guidelines in mind,as well as those provided under “ Load-ing” when mounting accessories. Never install accessories that

would impair the performance ofyour motorcycle. Carefully inspectthe accessory before using it tomake sure that it does not in anyway reduce ground clearance orcornering clearance, limit suspen-sion travel, steering travel or con-trol operation, or obscure lights orreflectors.• Accessories fitted to the handle-

bar or the front fork area cancreate instability due to improperweight distribution. If accesso-

ries are added to the handlebaror front fork area, they must beas lightweight as possible andshould be kept to a minimum.

• Bulky or large accessories mayseriously affect the stability ofthe motorcycle. Wind may at-tempt to lift the motorcycle, orthe motorcycle may become un-stable in cross winds.

• Certain accessories can dis-place the operator from his orher normal riding position. Thisimproper position limits the free-dom of movement of the opera-tor and may limit control ability,therefore, such accessories arenot recommended.

Use caution when adding electri-cal accessories. If electrical acces-sories exceed the capacity of themotorcycle’s electrical system, anelectric failure could result, whichcould cause a dangerous loss oflights or engine power.

Aftermarket Tires and RimsThe tires and rims that came with yourmotorcycle were designed to match the


Safety information

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performance capabilities and to providethe best combination of handling, brak-ing, and comfort. Other tires, rims, siz-es, and combinations may not beappropriate. Refer to page 7-15 for tirespecifications and more information onreplacing your tires.

Transporting the MotorcycleBe sure to observe following instruc-tions before transporting the motorcy-cle in another vehicle. Remove all loose items from the

motorcycle. Check that the fuel cock (if

equipped) is in the “OFF” positionand that there are no fuel leaks.

Point the front wheel straightahead on the trailer or in the truckbed, and choke it in a rail to pre-vent movement.

Shift the transmission in gear (formodels with a manual transmis-sion).

Secure the motorcycle withtie-downs or suitable straps thatare attached to solid parts of themotorcycle, such as the frame orupper front fork triple clamp (and

not, for example, to rubber-mount-ed handlebars or turn signals, orparts that could break). Choosethe location for the straps carefullyso the straps will not rub againstpainted surfaces during transport.

The suspension should be com-pressed somewhat by thetie-downs, if possible, so that themotorcycle will not bounce exces-sively during transport.


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DescriptionEAU10411

Left view

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1. Headlight (page 7-30)

2. Fuel tank cap (page 4-5)

3. Fuel cock (page 4-6)

4. Main fuse (page 7-29)

5. Owner’s tool kit (page 7-2)

6. Air filter element (page 7-12)

7. Shift pedal (page 4-4)


Description

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EAU10421

Right view

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1. Shock absorber assembly spring preload adjusting ring (page 4-9)

2. Engine oil filter element (page 7-9)

3. Brake pedal (page 4-4)

4. Kickstarter (page 4-8)

5. Battery (page 7-27)

6. Auxiliary DC jack fuse (page 7-29)


Description

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EAU10431

Controls and instruments

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1. Clutch lever (page 4-3)

2. Left handlebar switches (page 4-2)

3. Speedometer unit (page 4-2)

4. Auxiliary DC jack (page 4-12)

5. Starter (choke) knob (page 4-7)

6. Right handlebar switches (page 4-2)

7. Brake lever (page 4-4)

8. Throttle grip (page 7-14)

9. Main switch (page 4-1)


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Instrument and control functionsEAU10452

Main switch

The main switch controls the ignitionand lighting systems. The various mainswitch positions are described below.

EAU10631

ONAll electrical systems are supplied withpower, and the engine can be started.The key cannot be removed.

EAU45752

OFFAll electrical systems are off. The keycan be removed.

WARNINGEWA10073

Never turn the key to “OFF” whilethe vehicle is moving, otherwise the

electrical systems will be switchedoff, which may result in loss of con-trol or an accident.

EAU11011

Indicator light

EAU63680

Neutral indicator lightThis indicator light comes on when thetransmission is in the neutral position.

ONOFF

1. Neutral indicator light

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Instrument and control functions

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EAUT1822

Speedometer unit

The speedometer unit is equipped witha speedometer and an odometer. Thespeedometer shows the riding speed.The odometer shows the total distancetraveled.

EAU1234M

Handlebar switches

Left

Right

EAU12401

Dimmer switch “ / ”Set this switch to “ ” for the highbeam and to “ ” for the low beam.

EAU12461

Turn signal switch “ / ”To signal a right-hand turn, push thisswitch to “ ”. To signal a left-handturn, push this switch to “ ”. When re-leased, the switch returns to the centerposition. To cancel the turn signallights, push the switch in after it has re-turned to the center position.

1. Speedometer

2. Odometer

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1. Light switch “ / ”

2. Dimmer switch “ / ”

3. Turn signal switch “ / ”

4. Horn switch “ ”

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4 1. Engine stop switch “ / ”

2. Start switch “ ”

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EAU12501

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

EAU12582

Light switch “ / ”Set the light switch to “ ” to turn on theheadlight, taillight and meter lighting.Set the switch to “ ” to turn off all thelights.

EAU12662

Engine stop switch “ / ” Set this switch to “ ” before startingthe engine. Set this switch to “ ” tostop the engine in case of an emergen-cy, such as when the vehicle overturnsor when the throttle cable is stuck.

EAU12713

Start switch “ ” Push this switch to crank the enginewith the starter. See page 6-1 for start-ing instructions prior to starting the en-gine.

EAU35002

Clutch lever

The clutch lever is located on the leftside of the handlebar. To disengagethe clutch, pull the lever toward thehandlebar grip. To engage the clutch,release the lever. The lever should bepulled rapidly and released slowly forsmooth clutch operation.The clutch lever is equipped with aclutch switch, which is part of the start-ing circuit cut-off system. (Seepage 4-10.)

A clutch lever lock is provided to keepthe clutch disengaged. To lock theclutch lever, push down the clutch leverlock while holding the clutch leverpulled towards the handlebar grip. Torelease the lever lock, simply pull theclutch lever.

1. Clutch lever

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EAU12872

Shift pedal

The shift pedal is located on the leftside of the motorcycle and is used incombination with the clutch lever whenshifting the gears of the 5-speed con-stant-mesh transmission equipped onthis motorcycle.

EAU12892

Brake lever

The brake lever is located on the rightside of the handlebar. To apply the frontbrake, pull the lever toward the throttlegrip.

EAU12944

Brake pedal

The brake pedal is located on the rightside of the motorcycle. To apply therear brake, press down on the brakepedal.

1. Shift pedal

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1. Brake pedal

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EAU13183

Fuel tank cap

To remove the fuel tank cap, turn itcounterclockwise, and then pull it off.To install the fuel tank cap, insert it intothe tank opening, and then turn it clock-wise.

WARNINGEWA11092

Make sure that the fuel tank cap isproperly closed after filling fuel.Leaking fuel is a fire hazard.

EAU13213

FuelMake sure there is sufficient gasoline inthe tank.

WARNINGEWA10882

Gasoline and gasoline vapors areextremely flammable. To avoid firesand explosions and to reduce therisk of injury when refueling, followthese instructions.

1. Before refueling, turn off the en-gine and be sure that no one is sit-ting on the vehicle. Never refuelwhile smoking, or while in the vi-cinity of sparks, open flames, orother sources of ignition such asthe pilot lights of water heaters andclothes dryers.

2. Do not overfill the fuel tank. Stopfilling when the fuel reaches thebottom of the filler tube. Becausefuel expands when it heats up,heat from the engine or the suncan cause fuel to spill out of thefuel tank.

3. Wipe up any spilled fuel immedi-ately. NOTICE: Immediately wipeoff spilled fuel with a clean, dry,soft cloth, since fuel may deteri-orate painted surfaces or plasticparts.[ECA10072]

4. Be sure to securely close the fueltank cap.

WARNINGEWA15152

Gasoline is poisonous and cancause injury or death. Handle gaso-line with care. Never siphon gaso-line by mouth. If you should swallowsome gasoline or inhale a lot of gas-oline vapor, or get some gasoline in

1. Fuel tank cap

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1. Fuel tank filler tube

2. Maximum fuel level

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your eyes, see your doctor immedi-ately. If gasoline spills on your skin,wash with soap and water. If gaso-line spills on your clothing, changeyour clothes.

EAU53073

NOTICEECA11401

Use only unleaded gasoline. The useof leaded gasoline will cause severedamage to internal engine parts,such as the valves and piston rings,as well as to the exhaust system.

Your Yamaha engine has been de-signed to use regular unleaded gaso-line with a research octane number of91 or higher. If knocking (or pinging) oc-curs, use a gasoline of a different brandor premium unleaded fuel. Use of un-

leaded fuel will extend spark plug lifeand reduce maintenance costs.

GasoholThere are two types of gasohol: gaso-hol containing ethanol and that contain-ing methanol. Gasohol containingethanol can be used if the ethanol con-tent does not exceed 10% (E10). Gas-ohol containing methanol is notrecommended by Yamaha because itcan cause damage to the fuel systemor vehicle performance problems.

EAU13562

Fuel cockThe fuel cock supplies fuel from thetank to the carburetor while filtering it al-so.The fuel cock has three positions:

OFF

With the lever in this position, fuel willnot flow. Always return the lever to thisposition when the engine is not running.

Recommended fuel:Regular unleaded gasoline (Gasohol [E10] acceptable)

Fuel tank capacity:10 L (2.6 US gal, 2.2 Imp.gal)

Fuel reserve amount:2.0 L (0.53 US gal, 0.44 Imp.gal)

1. Arrow mark positioned over “OFF”

RES

ONFUEL

OFF

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ON

With the lever in this position, fuel flowsto the carburetor. Normal riding is donewith the lever in this position.

RES

This indicates reserve. If you run out offuel while riding, move the lever to thisposition. Fill the tank at the first oppor-tunity. Be sure to set the lever back to“ON” after refueling!

EAU13601

Starter (choke) knob “ ”

Starting a cold engine requires a richerair-fuel mixture, which is supplied bythe starter (choke).Move the knob in direction (a) to turn onthe starter (choke).Move the knob in direction (b) to turn offthe starter (choke).

1. Arrow mark positioned over “ON”

1. Arrow mark positioned over “RES”

ONFUEL

RES

OFF

1ON

OFF

ONFUEL

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RES

1. Starter (choke) knob “ ”

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EAU13651

Kickstarter

To start the engine, 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 a pri-mary kickstarter, allowing the engine tobe started in any gear if the clutch isdisengaged. However, shifting thetransmission into the neutral positionbefore starting is recommended.

EAU13962

Seat

To remove the seatRemove the bolts, and then pull theseat off.

To install the seat1. Insert the projections on the front

of the seat into the seat holders asshown.

2. Place the seat in the original posi-tion, and then tighten the bolts.

TIPMake sure that the seat is properly se-cured before riding.

1. Kickstarter

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1. Bolt

1. Bolt

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1. Projection

2. Seat holder

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EAU36465

Adjusting the shock absorber assemblyThis shock absorber assembly isequipped with a spring preload adjust-ing ring.

NOTICEECA10102

To avoid damaging the mechanism,do not attempt to turn beyond themaximum or minimum settings.

Adjust the spring preload as follows.1. Remove the seat. (See page 4-8.)2. To increase the spring preload and

thereby harden the suspension,turn the adjusting ring in direction(a). To decrease the spring pre-load and thereby soften the sus-pension, turn the adjusting ring indirection (b). Align the appropriate notch in

the adjusting ring with the posi-tion indicator on the shock ab-sorber.

Use the special wrench includ-ed in the owner’s tool kit tomake the adjustment.

3. Install the seat.

WARNINGEWA10222

This shock absorber assembly con-tains highly pressurized nitrogengas. Read and understand the fol-lowing information before handlingthe shock absorber assembly. Do not tamper with or attempt to

open the cylinder assembly. Do not subject the shock ab-

sorber assembly to an openflame or other high heat source.This may cause the unit to ex-plode due to excessive gaspressure.

Do not deform or damage thecylinder in any way. Cylinderdamage will result in poordamping performance.

Do not dispose of a damaged orworn-out shock absorber as-sembly yourself. Take the shockabsorber assembly to a Yamahadealer for any service.

1. Special wrench

2. Position indicator

Spring preload setting:Minimum (soft):

1Standard:

1Maximum (hard):

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EAU48861

Sidestands

The sidestands are located on the leftand right side of the frame. Raise a sid-estand or lower it with your foot whileholding the vehicle upright.

WARNINGEWA15411

The vehicle must not be ridden witheither sidestand down, or if a sides-tand cannot be properly moved up(or does not stay up); otherwise thesidestands could contact theground and distract the operator, re-sulting in a possible loss of control.

EAU53131

Starting circuit cut-off systemThe starting circuit cut-off system (com-prising the clutch switch and the neutralswitch) prevents starting when thetransmission is in gear and the clutchlever is not pulled.Periodically check the operation of thestarting circuit cut-off system accordingto the following procedure.

TIPThis check is most reliable if performedwith a warmed-up engine.

1. Sidestand (left)

1. Sidestand (right)

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

The neutral switch may not be working correctly.The motorcycle should not be ridden untilchecked by a Yamaha dealer.

5. Turn the engine off.6. Shift the transmission into gear.7. Keep the clutch lever pulled.8. Push the start switch or push the kickstarter lever down.Does the engine start?

The clutch switch may not be working correctly.The motorcycle should not be ridden untilchecked by a Yamaha dealer.

NOYES

The system is OK. The motorcycle can be ridden.

NOYES

If a malfunction is noted, have a Yamahadealer check the system before riding.

WARNING



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EAU15404

Auxiliary DC jack

NOTICEECA13071

The accessories connected to theauxiliary DC jack should not be usedwith the engine turned off, and theircombined load must never exceed 6A or 72 W, otherwise the battery maydischarge.

The auxiliary DC jack is located on thefront carrier.12-V accessories connected to thisjack can be used when the key is in the“ON” position and should only be usedwhen the engine is running.

Refer to the following chart for correctusage.

Amperage chart

To use the auxiliary DC jack1. Turn the key to “OFF”.2. Remove the dust cap from the re-

ceptacle.3. Insert the accessory plug into the

receptacle and secure it with thescrew-on cap.

4. Turn the key to “ON”, and thenstart the engine. (See page 6-1.)

5. When the auxiliary DC jack is notbeing used, make sure that thedust cap is installed onto the re-ceptacle for protection.

1. Auxiliary DC jack

2. Dust cap

12

Idling speedHeadlight/taillight “ON” 12 V, 3 AHeadlight/taillight “OFF” 12 V, 6 A


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For your safety – pre-operation checksEAU15599

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

WARNINGEWA11152

Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equipment damage.Do not operate the vehicle if you find any problem. If a problem cannot be corrected by the procedures provided inthis manual, have the vehicle inspected by a Yamaha dealer.

Before using this vehicle, check the following points:ITEM CHECKS PAGE

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

4-5

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

7-9

Front brake

• Check operation.• Lubricate cable if necessary.• Check lever free play.• Adjust if necessary.

7-18, 7-21

Rear brake• Check operation.• Check pedal free play.• Adjust if necessary.

7-19, 7-21

Clutch

• Check operation.• Lubricate cable if necessary.• Check lever free play.• Adjust if necessary.

7-17

Throttle grip

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

and grip housing.

7-14, 7-24


For your safety – pre-operation checks

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Control cables • Make sure that operation is smooth.• Lubricate if necessary. 7-24

Drive chain

• Check chain slack.• Adjust if necessary.• Check chain condition.• Lubricate if necessary.

7-22, 7-24

Wheels and tires

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

7-15, 7-17

Shift pedal • Make sure that operation is smooth.• Correct if necessary. 7-21

Brake pedal • Make sure that operation is smooth.• Lubricate pedal pivoting point if necessary. 7-25

Brake and clutch levers • Make sure that operation is smooth.• Lubricate lever pivoting points if necessary. 7-25

Sidestands • Make sure that operation is smooth.• Lubricate pivot if necessary. 7-25

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

Instruments, lights, signals and switches

• Check operation.• Correct if necessary. —

ITEM CHECKS PAGE


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Operation and important riding pointsEAU15952

Read the Owner’s Manual carefully tobecome familiar with all controls. Ifthere is a control or function you do notunderstand, ask your Yamaha dealer.

WARNINGEWA10272

Failure to familiarize yourself withthe controls can lead to loss of con-trol, which could cause an accidentor injury.

EAU52371

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

position. The transmission is in gear with

the clutch lever pulled.See page 4-10 for more informa-tion.

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

sure that the engine stop switch isset to “ ”.

3. Shift the transmission into the neu-tral position. The neutral indicatorlight should come on. If not, ask aYamaha dealer to check the elec-trical circuit.

4. Turn the starter (choke) on andcompletely close the throttle. (Seepage 4-7.)

5. Start the engine by pushing thestart switch or by pushing the kick-starter lever down.If the engine fails to start by push-ing the start switch, release the

switch, wait a few seconds, andthen try again. Each starting at-tempt should be as short as possi-ble to preserve the battery. Do notcrank the engine more than 10seconds on any one attempt. If theengine does not start with thestarter motor, try using the kick-starter.

6. After starting the engine, move thestarter (choke) back halfway.

7. When the engine is warm, turn thestarter (choke) off.

TIPThe engine is warm when it respondsquickly to the throttle with the starter(choke) turned off.

NOTICEECA11043

For maximum engine life, never ac-celerate hard when the engine iscold!


Operation and important riding points

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EAU16641

Starting a warm engineFollow the same procedure as for start-ing a cold engine with the exceptionthat the starter (choke) is not requiredwhen the engine is warm.

EAUE0951

Shifting

Shifting gears lets you control theamount of engine power available forstarting off, accelerating, climbing hills,etc.The gear positions are shown in the il-lustration.

TIPTo shift the transmission into the neu-tral position, press the shift pedal downrepeatedly until it reaches the end of itstravel.

NOTICEECA10261

Even with the transmission inthe neutral position, do notcoast for long periods of timewith the engine off, and do nottow the motorcycle for long dis-tances. The transmission isproperly lubricated only whenthe engine is running. Inade-quate lubrication may damagethe transmission.

Always use the clutch whilechanging gears to avoid damag-ing the engine, transmission,and drive train, which are notdesigned to withstand theshock of forced shifting.

1. Shift pedal

2. Neutral position

1

12345

2



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EAU16801

Tips for reducing fuel consumptionFuel consumption depends largely onyour riding style. Consider the followingtips to reduce fuel consumption: Turn the starter (choke) off as

soon as possible. Shift up swiftly, and avoid high en-

gine speeds during acceleration. Do not rev the engine while shifting

down, and avoid high enginespeeds with no load on the engine.

Turn the engine off instead of let-ting it idle for an extended length oftime (e.g., in traffic jams, at trafficlights or at railroad crossings).

EAU16842

Engine break-inThere is never a more important periodin the life of your engine than the periodbetween 0 and 1600 km (1000 mi). Forthis reason, you should read the follow-ing material carefully.Since the engine is brand new, do notput an excessive load on it for the first1600 km (1000 mi). The various parts inthe engine wear and polish themselvesto the correct operating clearances.During this period, prolonged full-throt-tle operation or any condition that mightresult in engine overheating must beavoided.

EAU17064

0–1000 km (0–600 mi)Avoid prolonged operation above 1/3throttle. NOTICE: After 1000 km (600mi) of operation, the engine oil mustbe changed, the oil filter cartridge orelement replaced, and the oil strain-er cleaned. If any engine troubleshould occur during the enginebreak-in period, immediately have a

Yamaha dealer check the vehi-cle.[ECA10363]

1000–1600 km (600–1000 mi)Avoid prolonged operation above 1/2throttle.

1600 km (1000 mi) and beyondThe vehicle can now be operated nor-mally.



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EAU17172

ParkingWhen parking, stop the engine, removethe key from the main switch, and thenturn the fuel cock lever to “OFF”.

WARNINGEWA10312

Since the engine and exhaustsystem can become very hot,park in a place where pedestri-ans or children are not likely totouch them and be burned.

Do not park on a slope or on softground, otherwise the vehiclemay overturn, increasing therisk of a fuel leak and fire.

Do not park near grass or otherflammable materials whichmight catch fire.


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Periodic maintenance and adjustmentEAU17246

Periodic inspection, adjustment, and lu-brication will keep your vehicle in thesafest and most efficient condition pos-sible. Safety is an obligation of the vehi-cle owner/operator. The most importantpoints of vehicle inspection, adjust-ment, and lubrication are explained onthe following pages.The intervals given in the periodicmaintenance charts should be simplyconsidered as a general guide undernormal riding conditions. However, de-pending on the weather, terrain, geo-graphical location, and individual use,the maintenance intervals may need tobe shortened.

WARNINGEWA10322

Failure to properly maintain the ve-hicle or performing maintenance ac-tivities incorrectly may increaseyour risk of injury or death duringservice or while using the vehicle. Ifyou are not familiar with vehicle ser-vice, have a Yamaha dealer performservice.

WARNINGEWA15123

Turn off the engine when performingmaintenance unless otherwisespecified. A running engine has moving

parts that can catch on bodyparts or clothing and electricalparts that can cause shocks orfires.

Running the engine while ser-vicing can lead to eye injury,burns, fire, or carbon monoxidepoisoning – possibly leading todeath. See page 2-2 for more in-formation about carbon monox-ide.

WARNINGEWA15461

Brake discs, calipers, drums, andlinings can become very hot duringuse. To avoid possible burns, letbrake components cool beforetouching them.

EAU17303

Emission controls not only function toensure cleaner air, but are also vital toproper engine operation and maximumperformance. In the following periodicmaintenance charts, the services relat-ed to emissions control are groupedseparately. These services requirespecialized data, knowledge, andequipment. Maintenance, replacement,or repair of the emission control devic-es and systems may be performed byany repair establishment or individualthat is certified (if applicable). Yamahadealers are trained and equipped toperform these particular services.


Periodic maintenance and adjustment

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EAU35012

Owner’s tool kit

The owner’s tool kit is located inside thetool box.The service information included in thismanual and the tools provided in the

owner’s tool kit are intended to assistyou in the performance of preventivemaintenance and minor repairs. How-ever, additional tools such as a torquewrench may be necessary to performcertain maintenance work correctly.

TIPIf you do not have the tools or experi-ence required for a particular job, havea Yamaha dealer perform it for you.

1. Tool box

1. Owner’s tool kit

1

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EAU46872

TIP The annual checks must be performed every year, except if a kilometer-based maintenance, or for the UK, a

mileage-based maintenance, is performed instead. From 30000 km (17500 mi), repeat the maintenance intervals starting from 6000 km (3500 mi). Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical

skills.

EAU46921

Periodic maintenance chart for the emission control system

NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING

ANNUAL CHECK1000 km

(600 mi)6000 km (3500 mi)

12000 km (7000 mi)

18000 km (10500 mi)

24000 km (14000 mi)

1 * Fuel line • Check fuel hoses for cracks or damage.

2 Spark plug• Check condition.• Clean and regap.

• Replace.

3 * Valves • Check valve clearance.• Adjust.

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



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EAU1771A

General maintenance and lubrication chart


ANNUAL CHECK1000 km

(600 mi)6000 km (3500 mi)

12000 km (7000 mi)

18000 km (10500 mi)

24000 km (14000 mi)

1 Air filter element • Clean.• Replace if necessary.

2 Clutch • Check operation.• Adjust.

3 * Front brake• Check operation and adjust brake

lever free play.

• Replace brake shoes. Whenever worn to the limit

4 * Rear brake• Check operation and adjust brake

pedal free play.

• Replace brake shoes. Whenever worn to the limit

5 * Wheels• Check runout, spoke tightness

and for damage.• Tighten spokes if necessary.

6 * Tires

• Check tread depth and for damage.

• Replace if necessary.• Check air pressure.• Correct if necessary.

7 * Wheel bearings • Check bearings for looseness or damage.

8 * Swingarm

• Check operation and for excessive play.

• Lubricate with lithium-soap-based grease. Every 24000 km (14000 mi)

9 Drive chain

• Check chain slack, alignment and condition.

• Adjust and thoroughly lubricate chain with engine oil.

Every 500 km (300 mi) and after washing the motorcycle, riding in the rain or riding in wet areas



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10 * Steering bearings

• Check bearing play and steering for roughness.

• Lubricate with lithium-soap-based grease. Every 24000 km (14000 mi)

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

12 Brake lever pivot shaft

• Lubricate with lithium-soap-based grease.

13 Brake pedal pivot shaft


14 Clutch lever pivot shaft


15 Sidestands • Check operation.• Lubricate.

16 * Front fork • Check operation and for oil leakage.

17 * Shock absorber assembly

• Check operation and shock absorber for oil leakage.

18 Engine oil• Change.• Check oil level and vehicle for oil

leakage.

19 Engine oil filter element • Clean.

20 * Engine oil strainer • Clean.

21 * Front and rear brake switches • Check operation.

22 Moving parts and cables • Lubricate.


ANNUAL CHECK1000 km

(600 mi)6000 km (3500 mi)

12000 km (7000 mi)

18000 km (10500 mi)

24000 km (14000 mi)



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EAU18691

TIPThe air filter needs more frequent service if you are riding in unusually wet or dusty areas.

23 * Throttle grip

• Check operation.• Check throttle grip free play, and

adjust if necessary.• Lubricate cable and grip housing.

24 * Lights, signals and switches

• Check operation.• Adjust headlight beam.


ANNUAL CHECK1000 km

(600 mi)6000 km (3500 mi)

12000 km (7000 mi)

18000 km (10500 mi)

24000 km (14000 mi)



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EAU18773

Removing and installing panelsThe panels shown need to be removedto perform some of the maintenancejobs described in this chapter. Refer tothis section each time a panel needs tobe removed and installed.

EAU19303

Panels A and B

To remove a panelPull the panel off as shown.

To install a panelPlace the panel in the original position.

1. Panel A

11. Panel B

1. Panel A

1

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1. Panel B

1



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EAU19607

Checking the spark plugThe spark plug is an important enginecomponent, which is easy to check.Since heat and deposits will cause anyspark plug to slowly erode, the sparkplug should be removed and checkedin accordance with the periodic mainte-nance and lubrication chart. In addition,the condition of the spark plug can re-veal the condition of the engine.

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

2. Remove the spark plug as shown,with the spark plug wrench includ-ed in the owner’s tool kit.

To check the spark plug1. Check that the porcelain insulator

around the center electrode of thespark plug is a medium-to-light tan(the ideal color when the vehicle isridden normally).

TIPIf the spark plug shows a distinctly dif-ferent color, the engine could be oper-ating improperly. Do not attempt todiagnose such problems yourself. In-stead, have a Yamaha dealer checkthe vehicle.

2. Check the spark plug for electrodeerosion and excessive carbon orother deposits, and replace it if

necessary.

3. Measure the spark plug gap with awire thickness gauge and, if nec-essary, adjust the gap to specifica-tion.

To install the spark plug1. Clean the surface of the spark plug

gasket and its mating surface, andthen wipe off any grime from thespark plug threads.

1. Spark plug cap

1

1. Spark plug wrench

1

Specified spark plug:NGK/D8EADENSO/X24ES-U

1. Spark plug gap

Spark plug gap:0.6–0.7 mm (0.024–0.028 in)

1



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2. Install the spark plug with thespark plug wrench, and then tight-en it to the specified torque.

TIPIf a torque wrench is not available wheninstalling a spark plug, a good estimateof the correct torque is 1/4–1/2 turnpast finger tight. However, the sparkplug should be tightened to the speci-fied torque as soon as possible.

3. Install the spark plug cap.

EAU19797

Engine oil and oil filter elementThe engine oil level should be checkedbefore each ride. In addition, the oilmust be changed and the oil filter ele-ment cleaned at the intervals specifiedin the periodic maintenance and lubri-cation chart.

To check the engine oil level1. Place the vehicle on a level sur-

face and hold it in an upright posi-tion. A slight tilt to the side canresult in a false reading.

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

3. Wait a few minutes until the oil set-tles, and then check the oil levelthrough the check window locatedat the bottom-right side of thecrankcase.

TIPThe engine oil should be between theminimum and maximum level marks.

4. If the engine oil is below the mini-mum level mark, add sufficient oilof the recommended type to raiseit to the correct level.

To change the engine oil (with or without oil filter element cleaning)

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

2. Place an oil pan under the engineto collect the used oil.

3. Remove the engine oil filler capand drain bolt to drain the oil fromthe crankcase. NOTICE: When

Tightening torque:Spark plug:

18 N·m (1.8 kgf·m, 13 lb·ft)

1. Engine oil level check window

2. Maximum level mark

3. Minimum level mark

12

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removing the engine oil drainbolt, the O-ring, compressionspring, and oil strainer will fallout. Take care not to lose theseparts.[ECA11002]

TIPSkip steps 4–9 if the oil filter element isnot being cleaned.

4. Remove the oil filter element drainbolt to drain the oil from the oil filterelement.

5. Remove the oil filter element coverby removing the bolts.

6. Remove the oil filter element andO-rings.

1. Engine oil filler cap

1. Engine oil drain bolt

1

1

1. Engine oil drain bolt

2. O-ring

3. Compression spring

4. Oil strainer

1234

1. Oil filter element drain bolt

2. Oil filter element cover

3. Oil filter element cover bolt

1. Oil filter element

2. O-ring

123

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7. Check the O-rings for damage andreplace them if necessary.

8. Clean the oil filter element with sol-vent, and then install it.

TIPCheck the oil filter element for damageand replace it if necessary.

9. Install the oil filter element cover byinstalling the bolts and the drainbolt, then tightening them to thespecified torques.

TIPMake sure that the O-rings are properlyseated.

10. Clean the oil strainer with solvent,and then check it for damage andreplace it if necessary.

11. Install the oil strainer, compressionspring, a new O-ring and engine oildrain bolt, and then tighten thedrain bolt to the specified torque.

12. Refill with the specified amount ofthe recommended engine oil, andthen install and tighten the oil fillercap.

TIPBe sure to wipe off spilled oil on anyparts after the engine and exhaust sys-tem have cooled down.

NOTICEECA11621

In order to prevent clutch slip-page (since the engine oil alsolubricates the clutch), do notmix any chemical additives. Donot use oils with a diesel speci-fication of “CD” or oils of a high-er quality than specified. In

addition, do not use oils labeled“ENERGY CONSERVING II” orhigher.

Make sure that no foreign mate-rial enters the crankcase.

13. Start the engine, and then let it idlefor several minutes while checkingit for oil leakage. If oil is leaking, im-mediately turn the engine off andcheck for the cause.

14. Turn the engine off, and thencheck the oil level and correct it ifnecessary.Tightening torques:

Oil filter element cover bolt:10 N·m (1.0 kgf·m, 7.2 lb·ft)

Oil filter element drain bolt:10 N·m (1.0 kgf·m, 7.2 lb·ft)

Tightening torque:Engine oil drain bolt:

43 N·m (4.3 kgf·m, 31 lb·ft)

Recommended engine oil:See page 9-1.

Oil quantity:Oil change:

1.00 L (1.06 US qt, 0.88 Imp.qt)With oil filter removal:

1.10 L (1.16 US qt, 0.97 Imp.qt)



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EAU20864

Cleaning the air filter elementThe air filter element should be cleanedat the intervals specified in the periodicmaintenance and lubrication chart.Clean the air filter element more fre-quently if you are riding in unusuallywet or dusty areas.

1. Remove panel A. (See page 7-7.)2. Remove the air filter case cover by

removing the screws.

3. Remove the wing bolt and the airfilter element plate, and then pullthe air filter element out of the airfilter case.

4. Remove the sponge material fromthe air filter element frame.

5. Clean the sponge material with

solvent, and then squeeze the re-maining solvent out.

6. Apply oil of the recommended typeto the entire surface of the spongematerial, and then squeeze the ex-cess oil out.

TIPThe sponge material should be wet butnot dripping.

7. Install the sponge material ontothe air filter element frame.

8. Insert the air filter element into theair filter case.

9. Install the air filter element plate,and then tighten the wing bolt.

1. Air filter case cover

2. Screw

2

1

1. Wing bolt

2. Air filter element

3. Air filter element plate

1. Sponge material

2. Air filter element frame

2

1

3

1

2

Recommended oil:Foam air filter oil



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NOTICE: Make sure that the airfilter element is properly seatedin the air filter case. The engineshould never be operated with-out the air filter element in-stalled, otherwise the piston(s)and/or cylinder(s) may becomeexcessively worn.[ECA10482]

10. Install the air filter case cover by in-stalling the screws.

11. Install the panel.

EAU21281

Adjusting the carburetorThe carburetor is an important part ofthe engine and requires very sophisti-cated adjustment. Therefore, most car-buretor adjustments should be left to aYamaha dealer, who has the neces-sary professional knowledge and expe-rience. The adjustment described in thefollowing section, however, may be ser-viced by the owner as part of routinemaintenance.

NOTICEECA10551

The carburetor has been set and ex-tensively tested at the Yamaha fac-tory. Changing these settingswithout sufficient technical knowl-edge may result in poor perfor-mance of or damage to the engine.

EAU21341

Adjusting the engine idling speedThe engine idling speed must bechecked and, if necessary, adjusted asfollows at the intervals specified in theperiodic maintenance and lubricationchart.The engine should be warm beforemaking this adjustment.

TIP The engine is warm when it quickly

responds to the throttle. A diagnostic tachometer is needed

to make this adjustment.

1. Attach the tachometer to the sparkplug lead.

2. Check the engine idling speedand, if necessary, adjust it to spec-ification by turning the throttle stopscrew. To increase the engineidling speed, turn the screw in di-rection (a). To decrease the en-gine idling speed, turn the screw indirection (b).



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TIPIf the specified idling speed cannot beobtained as described above, have aYamaha dealer make the adjustment.

EAU21386

Checking the throttle grip free playMeasure the throttle grip free play asshown.

Periodically check the throttle grip freeplay and, if necessary, have a Yamahadealer adjust it.

EAU21402

Valve clearanceThe valve clearance changes with use,resulting in improper air-fuel mixtureand/or engine noise. To prevent thisfrom occurring, the valve clearancemust be adjusted by a Yamaha dealerat the intervals specified in the periodicmaintenance and lubrication chart.

1. Throttle stop screw

Engine idling speed:1300–1400 r/min

1(a)

(b)

1. Throttle grip free play

Throttle grip free play:3.0–5.0 mm (0.12–0.20 in)

1



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EAU64911

TiresTires are the only contact between thevehicle and the road. Safety in all con-ditions of riding depends on a relativelysmall area of road contact. Therefore, itis essential to maintain the tires in goodcondition at all times and replace themat the appropriate time with the speci-fied tires.

Tire air pressureThe tire air pressure should be checkedand, if necessary, adjusted before eachride.

WARNINGEWA10442

Operation of this vehicle with im-proper tire pressure may cause se-vere injury or death from loss ofcontrol. The tire air pressure must be

checked and adjusted on coldtires (i.e., when the temperatureof the tires equals the ambienttemperature).

The tire air pressure must be ad-justed in accordance with theriding speed and with the total

weight of rider, cargo, and ac-cessories approved for thismodel.

WARNINGEWA10512

Never overload your vehicle. Opera-tion of an overloaded vehicle couldcause an accident.

Tire inspection

The tires must be checked before eachride. If the center tread depth reachesthe specified limit, if the tire has a nail orglass fragments in it, or if the sidewall iscracked, have a Yamaha dealer re-place the tire immediately.

TIPThe tire tread depth limits may differfrom country to country. Always complywith the local regulations.

Tire air pressure (measured on cold tires):

Front:125 kPa (1.25 kgf/cm2, 18 psi)

Rear:150 kPa (1.50 kgf/cm2, 22 psi)

1. Tire tread depth

2. Tire sidewall

Minimum tire tread depth (front and rear):

1.5 mm (0.06 in)

2

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Tire informationThis model is equipped with tube tires.Tires age, even if they have not beenused or have only been used occasion-ally. Cracking of the tread and sidewallrubber, sometimes accompanied bycarcass deformation, is an evidence ofageing. Old and aged tires shall bechecked by tire specialists to ascertaintheir suitability for further use.

WARNINGEWA10462

The front and rear tires should be ofthe same make and design, other-wise the handling characteristics ofthe vehicle may be different, whichcould lead to an accident.

After extensive tests, only the tires list-ed below have been approved for thismodel by Yamaha.

WARNINGEWA10572

Have a Yamaha dealer replaceexcessively worn tires. Besidesbeing illegal, operating the mo-torcycle with excessively worntires decreases riding stabilityand can lead to loss of control.

The replacement of all wheel-and brake-related parts, includ-ing the tires, should be left to aYamaha dealer, who has thenecessary professional knowl-edge and experience.

It is not recommended to patcha punctured tube. If unavoid-able, however, patch the tubevery carefully and replace it assoon as possible with a

high-quality product. Ride at moderate speeds after

changing a tire since the tiresurface must first be “brokenin” for it to develop its optimalcharacteristics.

Front tire:Size:

80/100-21 51MManufacturer/model:

IRC/VE-32Rear tire:

Size:4.10-18 59M

Manufacturer/model:IRC/FARM SPECIAL-Z2



7-17

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EAU21944

Spoke wheels

WARNINGEWA10611

The wheels on this model are not de-signed for use with tubeless tires.Do not attempt to use tubeless tireson this model.

To maximize the performance, durabil-ity, and safe operation of your motorcy-cle, note the following points regardingthe specified wheels. The wheel rims should be checked

for cracks, bends, warpage or oth-er damage, and the spokes forlooseness or damage before eachride. If any damage is found, havea Yamaha dealer replace thewheel. Do not attempt even thesmallest repair to the wheel. A de-formed or cracked wheel must bereplaced.

The wheel should be balancedwhenever either the tire or wheelhas been changed or replaced. Anunbalanced wheel can result inpoor performance, adverse han-dling characteristics, and a short-

ened tire life. EAU22047

Adjusting the clutch lever free playMeasure the clutch lever free play asshown.

Periodically check the clutch lever freeplay and, if necessary, adjust it as fol-lows.

1. Slide the rubber cover back at theclutch lever.

2. Loosen the locknut.3. To increase the clutch lever free

1. Clutch lever free play

2. Locknut (clutch lever)

3. Clutch lever free play adjusting bolt

4. Rubber cover

Clutch lever free play:10.0–15.0 mm (0.39–0.59 in)

32

1

4(a)

(b)



7-18

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2

3

4

5

6

7

8

9

10

11

12

play, turn the clutch lever free playadjusting bolt in direction (a). Todecrease the clutch lever free play,turn the adjusting bolt in direction(b).

TIPIf the specified clutch lever free playcould be obtained as described above,skip steps 4–7.

4. Fully turn the adjusting bolt at theclutch lever in direction (a) to loos-en the clutch cable.

5. Loosen the locknut at the crank-case.

6. To increase the clutch lever free

play, turn the clutch lever free playadjusting nut in direction (a). Todecrease the clutch lever free play,turn the adjusting nut in direction(b).

7. Tighten the locknut at the crank-case.

8. Tighten the locknut at the clutch le-ver and then slide the rubber coverto its original position.

EAU49304

Adjusting the brake lever free playMeasure the brake lever free play asshown.

Periodically check the brake lever freeplay and, if necessary, adjust it as fol-lows.

1. Slide the rubber cover back.2. Loosen the locknut at the brake le-

ver.3. To increase the brake lever free

1. Locknut (crankcase)

2. Clutch lever free play adjusting nut

2 1

(a)

(b)

1. Rubber cover

2. Brake lever free play adjusting bolt

3. Locknut

4. Brake lever free play

Brake lever free play:10.0–20.0 mm (0.39–0.79 in)

32

1

4

(a)

(b)



7-19

1

2

3

4

5

6

7

8

9

10

11

12

play, turn the brake lever free playadjusting bolt in direction (a). Todecrease the brake lever free play,turn the adjusting bolt in direction(b).

TIPIf the specified brake lever free playcould be obtained as described above,skip steps 4–7.

4. Fully turn the adjusting bolt at thebrake lever in direction (a) to loos-en the brake cable.

5. Loosen the locknut at the brakeshoe plate.

6. To increase the brake lever freeplay, turn the brake lever free playadjusting nut at the brake shoeplate in direction (a). To decreasethe brake lever free play, turn theadjusting nut in direction (b).

7. Tighten the locknut at the brakeshoe plate.

8. Tighten the locknut at the brake le-ver and then slide the rubber coverback to its original position.

EAU22199

Adjusting the brake pedal height and free play

WARNINGEWA10671

It is advisable to have a Yamahadealer make these adjustments.

Brake pedal heightThe top of the brake pedal should bepositioned at the specified distance be-low the top of the footrest as shown.

Periodically check the brake pedalheight and, if necessary, adjust it as fol-lows.

1. Loosen the brake pedal heightlocknut.

2. To raise the brake pedal, turn thebrake pedal height adjusting bolt indirection (a). To lower the brakepedal, turn the adjusting bolt in di-rection (b).

1. Brake lever free play adjusting nut

2. Locknut

12

(b)

(a)

Brake pedal height:10.0 mm (0.39 in)



7-20

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12

3. Tighten the locknut.

WARNINGEWA11232

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

Brake pedal free play

Measure the brake pedal free play asshown.

Periodically check the brake pedal freeplay and, if necessary, adjust it as fol-lows.To increase the brake pedal free play,turn the brake pedal free play adjustingnut at the brake rod in direction (a). Todecrease the brake pedal free play,turn the adjusting nut in direction (b).

WARNINGEWA10681

After adjusting the drive chainslack or removing and installingthe rear wheel, always check thebrake pedal free play.

If proper adjustment cannot beobtained as described, have aYamaha dealer make this ad-justment.

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

1. Brake pedal height locknut

2. Brake pedal height adjusting bolt

3. Brake pedal height

31

2

(a)

(b)

1. Brake pedal free play

Brake pedal free play:20.0–30.0 mm (0.79–1.18 in)

1

1. Brake pedal free play adjusting nut

2. Brake rod

2

1(a)

(b)



7-21

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EAU44821

Checking the shift pedalThe operation of the shift pedal shouldbe checked before each ride. If opera-tion is not smooth, have a Yamahadealer check the vehicle.

EAU22274

Brake light switches

The brake light, which is activated bythe brake pedal and brake lever, shouldcome on just before braking takes ef-fect. If necessary, adjust the rear brakelight switch as follows, but the frontbrake light switch should be adjustedby a Yamaha dealer.Turn the rear brake light switch adjust-ing nut while holding the rear brake lightswitch in place. To make the brake lightcome on earlier, turn the adjusting nutin direction (a). To make the brake lightcome on later, turn the adjusting nut indirection (b).

EAU22363

Checking the front and rear brake shoes

Front

Rear

1. Rear brake light switch

2. Adjusting nut

1

2

(a)

(b)

1. Brake shoe wear limit line

2. Brake shoe wear indicator

1. Brake shoe wear limit line

2. Brake shoe wear indicator

1

2

2

1



7-22

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10

11

12

The front and rear brake shoes must bechecked for wear at the intervals spec-ified in the periodic maintenance andlubrication chart. Each brake is provid-ed with a wear indicator, which allowsyou to check the brake shoe wear with-out having to disassemble the brake.To check the brake shoe wear, checkthe position of the wear indicator whileapplying the brake. If a brake shoe hasworn to the point that the wear indicatorreaches the wear limit line, have aYamaha dealer replace the brakeshoes as a set.

EAU22762

Drive chain slackThe drive chain slack should bechecked before each ride and adjustedif necessary.

EAU49264

To check the drive chain slack1. Place the motorcycle on the sides-

tand.

TIPWhen checking and adjusting the drivechain slack, there should be no weighton the motorcycle.

2. Shift the transmission into the neu-tral position.

3. Remove the drive chain slackcheck hole cap.

4. Measure the drive chain slack asshown.

5. If the drive chain slack is correct,

1. Drive chain slack check hole cap

1. Drive chain slack

Drive chain slack:20.0–30.0 mm (0.79–1.18 in)

1

1



7-23

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install the check hole cap. If thedrive chain slack is incorrect, ad-just it as follows. NOTICE: Im-proper drive chain slack willoverload the engine as well asother vital parts of the motorcy-cle and can lead to chain slip-page or breakage. To preventthis from occurring, keep thedrive chain slack within thespecified limits.[ECA10572]

EAU35028

To adjust the drive chain slackConsult a Yamaha dealer before ad-justing the drive chain slack.

1. Loosen the brake pedal free playadjusting nut.

2. Loosen the axle nut and the rearsprocket nut.

3. To tighten the drive chain, turn thedrive chain slack adjusting plate oneach side of the swingarm in direc-tion (a). To loosen the drive chain,turn the adjusting plate on eachside of the swingarm in direction(b), and then push the rear wheelforward.

TIPMake sure that both drive chain slackadjusting plates are in the same posi-tion for proper wheel alignment.

4. Tighten the rear sprocket nut andthe axle nut to the specifiedtorques.

5. Adjust the brake pedal free play.(See page 7-19.)

WARNINGEWA10661

After adjusting the brake pedal freeplay, check the operation of thebrake light.

6. Make sure that the drive chainslack adjusting plates are in thesame position, the drive chainslack is correct, and the drivechain moves smoothly.

7. Install the drive chain slack checkhole cap.


1

1. Axle nut

2. Rear sprocket nut

3. Drive chain slack adjusting plate

3

(a)

(b)2

1

Tightening torques:Rear sprocket nut:

85 N·m (8.5 kgf·m, 61 lb·ft)Axle nut:

85 N·m (8.5 kgf·m, 61 lb·ft)



7-24

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EAU23018

Cleaning and lubricating the drive chainThe drive chain must be cleaned andlubricated at the intervals specified inthe periodic maintenance and lubrica-tion chart, otherwise it will quickly wearout, especially when riding in dusty orwet areas. Service the drive chain asfollows.

NOTICEECA10584

The drive chain must be lubricatedafter washing the motorcycle, ridingin the rain or riding in wet areas.

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

TIPFor a thorough cleaning, have aYamaha dealer remove the drive chainand soak it in solvent.

2. Spray Yamaha chain lubricant orother suitable chain lubricant onthe entire chain, making sure thatall side plates and rollers havebeen sufficiently oiled.

EAU23098

Checking and lubricating the cablesThe operation of all control cables andthe condition of the cables should bechecked before each ride, and the ca-bles and cable ends should be lubricat-ed if necessary. If a cable is damagedor does not move smoothly, have aYamaha dealer check or replace it.WARNING! Damage to the outerhousing of cables may result in in-ternal rusting and cause interfer-ence with cable movement. Replacedamaged cables as soon as possi-ble to prevent unsafe condi-tions.[EWA10712]

EAU23115

Checking and lubricating the throttle grip and cableThe operation of the throttle grip shouldbe checked before each ride. In addi-tion, the cable should be lubricated by aYamaha dealer at the intervals speci-fied in the periodic maintenance chart.The throttle cable is equipped with arubber cover. Make sure that the coveris securely installed. Even though thecover is installed correctly, it does notcompletely protect the cable from waterentry. Therefore, use care not to pourwater directly onto the cover or cablewhen washing the vehicle. If the cableor cover becomes dirty, wipe clean witha moist cloth.

Recommended lubricant:Yamaha cable lubricant or other suit-able cable lubricant



7-25

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EAU43612

Checking and lubricating the brake and clutch levers

Brake lever

The operation of the brake and clutchlevers should be checked before eachride, and the lever pivots should be lu-bricated if necessary.

EAU23185

Checking and lubricating the brake pedalThe operation of the brake pedalshould be checked before each ride,and the pedal pivot should be lubricat-ed if necessary.

EAU49251

Checking and lubricating the sidestands

The operation of the sidestands shouldbe checked before each ride, and thesidestand pivots and metal-to-metalcontact surfaces should be lubricated ifnecessary.

WARNINGEWA10732

If the sidestand does not move upand down smoothly, have a Yamahadealer check or repair it. Otherwise,the sidestand could contact theground and distract the operator, re-sulting in a possible loss of control.

Recommended lubricant:Lithium-soap-based grease





7-26

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EAU23252

Lubricating the rear suspension

The pivoting points of the rear suspen-sion must be lubricated by a Yamahadealer at the intervals specified in theperiodic maintenance and lubricationchart.

EAU51951

Checking the front forkThe condition and operation of the frontfork must be checked as follows at theintervals specified in the periodic main-tenance and lubrication chart.

To check the conditionCheck the front fork for damage and ex-cessive oil leakage.

To check the operation1. Place the vehicle on a level sur-

face and hold it in an upright posi-tion. WARNING! To avoid injury,securely support the vehicle sothere is no danger of it fallingover.[EWA10752]

2. While applying the front brake,push down hard on the handlebarsseveral times to check if the frontfork compresses and reboundssmoothly.

NOTICEECA10591

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

1. Grease nipple


1



7-27

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12

EAU23285

Checking the steeringWorn or loose steering bearings maycause danger. Therefore, the operationof the steering must be checked as fol-lows at the intervals specified in the pe-riodic maintenance and lubricationchart.

1. Raise the front wheel off theground. (See page 7-32.)WARNING! To avoid injury, se-curely support the vehicle sothere is no danger of it fallingover.[EWA10752]

2. Hold the lower ends of the frontfork legs and try to move them for-ward and backward. If any freeplay can be felt, have a Yamahadealer check or repair the steering.

EAU23292

Checking the wheel bearings

The front and rear wheel bearings mustbe checked at the intervals specified inthe periodic maintenance and lubrica-tion chart. If there is play in the wheelhub or if the wheel does not turnsmoothly, have a Yamaha dealer checkthe wheel bearings.

EAU23389

Battery

The battery is located behind panel B.(See page 7-7.)This model is equipped with a VRLA(Valve Regulated Lead Acid) battery.There is no need to check the electro-lyte or to add distilled water. However,the battery lead connections need to bechecked and, if necessary, tightened.

WARNINGEWA10761

Electrolyte is poisonous anddangerous since it contains sul-furic acid, which causes severeburns. Avoid any contact with

1. Positive battery lead (red)

2. Battery

3. Negative battery lead (black)

1

2

3



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12

skin, eyes or clothing and al-ways shield your eyes whenworking near batteries. In caseof contact, administer the fol-lowing FIRST AID.• EXTERNAL: Flush with plenty

of water.• INTERNAL: Drink large quan-

tities of water or milk and im-mediately call a physician.

• EYES: Flush with water for 15minutes and seek promptmedical attention.

Batteries produce explosive hy-drogen gas. Therefore, keepsparks, flames, cigarettes, etc.,away from the battery and pro-vide sufficient ventilation whencharging it in an enclosedspace.

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

NOTICEECA10621

Never attempt to remove the batterycell seals, as this would permanent-ly damage the battery.

To charge the batteryHave a Yamaha dealer charge the bat-tery as soon as possible if it seems tohave discharged. Keep in mind that thebattery tends to discharge more quicklyif the vehicle is equipped with optionalelectrical accessories.

NOTICEECA16522

To charge a VRLA (Valve RegulatedLead Acid) battery, a special (con-stant-voltage) battery charger is re-quired. Using a conventional batterycharger will damage the battery.

To store the battery1. If the vehicle will not be used for

more than one month, remove thebattery, fully charge it, and thenplace it in a cool, dry place.NOTICE: When removing thebattery, be sure the key isturned to “OFF”, then discon-nect the negative lead beforedisconnecting the positivelead.[ECA16303]

2. If the battery will be stored for morethan two months, check it at least

once a month and fully charge it ifnecessary.

3. Fully charge the battery before in-stallation. NOTICE: When install-ing the battery, be sure the keyis turned to “OFF”, then con-nect the positive lead beforeconnecting the negativelead.[ECA16841]

4. After installation, make sure thatthe battery leads are properly con-nected to the battery terminals.

NOTICEECA16531

Always keep the battery charged.Storing a discharged battery cancause permanent battery damage.



7-29

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EAU23563

Replacing the fusesThe main fuse is located behind panelA. (See page 7-7.)

The auxiliary DC jack fuse is locatedbehind panel B. (See page 7-7.)

If a fuse is blown, replace it as follows.1. Turn the key to “OFF” and turn off

the electrical circuit in question.2. Remove the blown fuse, and then

install a new fuse of the specifiedamperage. WARNING! Do notuse a fuse of a higher amperagerating than recommended toavoid causing extensive dam-age to the electrical system andpossibly a fire.[EWA15132]

3. Turn the key to “ON” and turn onthe electrical circuit in question tocheck if the device operates.

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

1. Main fuse

2. Spare main fuse

2 11. Auxiliary DC jack fuse

2. Spare fuse

Specified fuses:Main fuse:

20.0 AAuxiliary DC jack fuse:

10.0 A

1

2



7-30

1

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4

5

6

7

8

9

10

11

12

EAU24015

Replacing the headlight bulbIf the headlight bulb burns out, replaceit as follows.

1. Remove the headlight unit by re-moving the bolt.

2. Disconnect the headlight lead con-nectors, and then remove theheadlight bulb cover.

3. Remove the headlight bulb holderby turning it counterclockwise.

4. Remove the burnt-out bulb by turn-ing it counterclockwise.

5. Place a new bulb into position, andthen secure it with the headlightbulb holder.

6. Install the headlight bulb holder byturning it clockwise.

7. Install the bulb cover, and thenconnect the headlight lead con-nectors.

8. Install the headlight unit by install-ing the bolt.

9. Have a Yamaha dealer adjust theheadlight beam if necessary.

1. Bolt

1

1. Headlight lead connector

2. Headlight bulb cover

1. Headlight bulb holder

2. Headlight bulb cover

1

2

2

1

1. Headlight bulb

2. Headlight bulb holder

1 2



7-31

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12

EAU70550

Replacing the brake/tail light bulb

1. Remove the brake/tail light lens byremoving the screws.

2. Remove the burnt-out bulb bypushing it in and turning it counter-clockwise.

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. NOTICE: Do not over-tighten the screws, otherwisethe lens may break.[ECA10682]

EAU24233

Replacing a turn signal light bulb

1. Remove the turn signal lens bypushing it down lightly, then pullingit outward.

TIPThe lens holder will fall out of the turnsignal when removing the lens, so takecare not to loose it.

2. Remove the burnt-out bulb bypushing it in and turning it counter-clockwise.

3. Insert a new bulb into the socket,

push it in, and then turn it clock-wise until it stops.

4. Install the holder, and then placethe lens in the original position.

1. Screw

2. Brake/tail light lens

3. Brake/tail light bulb

3

2 1

1. Turn signal light lens

2. Turn signal light bulb

3. Lens holder

1

2

3



7-32

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EAU24351

Supporting the motorcycleSince this model is not equipped with acenterstand, follow these precautionswhen removing the front and rearwheel or performing other maintenancerequiring the motorcycle to stand up-right. Check that the motorcycle is in astable and level position before startingany maintenance. A strong woodenbox can be placed under the engine foradded stability.

To service the front wheel1. Stabilize the rear of the motorcycle

by using a motorcycle stand or, ifan additional motorcycle stand isnot available, by placing a jack un-der the frame in front of the rearwheel.

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

To service the rear wheelRaise the rear wheel off the ground byusing a motorcycle stand or, if a motor-cycle stand is not available, by placinga jack either under each side of the

frame in front of the rear wheel or undereach side of the swingarm.

EAU24361

Front wheel

EAU56471

To remove the front wheel

WARNINGEWA10822

To avoid injury, securely support thevehicle so there is no danger of itfalling over.

1. Disconnect the speedometer ca-ble from the front wheel by remov-ing the clip, then pulling the cableout.

1. Clip

2. Speedometer cable

1

2



7-33

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12

2. Loosen the locknut at the brakeshoe plate and the brake lever freeplay adjusting nut.

3. Slide the rubber cover back.4. Loosen the locknut at the brake le-

ver, and then fully turn the brakelever free play adjusting bolt in di-rection (a).

5. Disconnect the brake cable fromthe front brake lever, then from thebrake camshaft lever.

6. Loosen the axle nut.7. Lift the front wheel off the ground

according to the procedure in theprevious section “Supporting themotorcycle”.

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

To install the front wheel1. Install the brake shoe plate into the

wheel hub as shown.

2. Lift the wheel up between the forklegs.

TIPMake sure that the slot in the brakeshoe plate fits over the retainer on thefork leg.

1. Brake lever free play adjusting nut

2. Locknut

12

1. Rubber cover

2. Brake lever free play adjusting bolt

3. Locknut

1. Brake cable

2. Brake camshaft lever

3. Axle nut

32

1

(a)

3

2

1



7-34

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11

12

3. Insert the wheel axle from the rightside, and then install the axle nut.

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

5. Connect the brake cable at thebrake shoe plate and then at thehandlebar lever holder.

6. Connect the speedometer cableand install the clip.

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

8. Adjust the brake lever free play.(See page 7-18.)

9. Slide the rubber cover back to itsoriginal position.

EAU25081

Rear wheel

EAU56772

To remove the rear wheel

WARNINGEWA10822

To avoid injury, securely support thevehicle so there is no danger of itfalling over.

1. Disconnect the brake torque rodfrom the brake shoe plate by re-moving the cotter pin, the nut, andthe bolt.

1. Brake shoe plate

2. Slot

3. Retainer

Tightening torque:Axle nut:

39 N·m (3.9 kgf·m, 28 lb·ft)

3

1 2



7-35

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12

2. Remove the brake pedal free playadjusting nut, and then disconnectthe brake rod from the brake cam-shaft lever.

3. Loosen the axle nut and the rearsprocket nut.

4. Lift the rear wheel off the groundaccording to the procedure onpage 7-32.

5. Turn the drive chain slack adjust-ing plate on each side of theswingarm fully in direction (a).

6. Remove the axle nut.7. Pull the wheel axle out together

with the drive chain slack adjustingplate from the right side, and thenremove the collar.

8. Slide the wheel to the right, andthen remove it by pulling it back.

1. Brake torque rod

2. Nut

3. Bolt

4. Cotter pin

5. Brake shoe plate

12

45 3

1. Wheel axle


3. Brake camshaft lever


5. Brake rod

45

3

21

1. Axle nut

2. Rear sprocket nut


1

3

(a)

2



7-36

1

2

3

4

5

6

7

8

9

10

11

12

To install the rear wheel1. Install the drive chain slack adjust-

ing plate and the wheel by insert-ing the wheel axle from the rightside.

TIPMake sure that the drive chain slack ad-justing plate is installed with thepunched side facing to the outside.

2. Install the axle nut.3. Install the brake rod onto the brake

camshaft lever, and then install thebrake pedal free play adjusting nutonto the brake rod.

4. Connect the brake torque rod tothe brake shoe plate by installingthe bolt and the nut, and then tight-en the nut to the specified torque.

5. Insert a new cotter pin.WARNING! Always use a newcotter pin.[EWA10832]

6. Check and adjust the drive chainslack. (See page 7-22.)

7. Check and adjust the brake pedalfree play. (See page 7-19.)

WARNINGEWA10661

After adjusting the brake pedal freeplay, check the operation of thebrake light.

EAU25853

TroubleshootingAlthough Yamaha motorcycles receivea thorough inspection before shipmentfrom the factory, trouble may occur dur-ing operation. Any problem in the fuel,compression, or ignition systems, forexample, can cause poor starting andloss of power.The following troubleshooting chartrepresents a quick and easy procedurefor checking these vital systems your-self. However, should your motorcyclerequire any repair, take it to a Yamahadealer, whose skilled technicians havethe necessary tools, experience, andknow-how to service the motorcycleproperly.Use only genuine Yamaha replace-ment parts. Imitation parts may look likeYamaha parts, but they are often inferi-or, have a shorter service life and canlead to expensive repair bills.

WARNINGEWA15142

When checking the fuel system, donot smoke, and make sure there areno open flames or sparks in the ar-ea, including pilot lights from water

Tightening torque:Brake torque rod nut:

19 N·m (1.9 kgf·m, 14 lb·ft)



7-37

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12

heaters or furnaces. Gasoline orgasoline vapors can ignite or ex-plode, causing severe injury orproperty damage.



7-38

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EAU54872

Troubleshooting chart

Check the fuel level inthe fuel tank.

1. FuelThere is enough fuel.

There is no fuel.

Check the battery.

Supply fuel. The engine does not start. Check the battery.

Operate the electric starteror the kickstarter.

4. CompressionThere is compression.

There is no compression.

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

Have a Yamaha dealercheck the vehicle.

Remove the spark plugand check the electrodes.

3. Ignition Wipe off with a dry cloth and correct thespark plug gap, or replace the spark plug.

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

The engine does not start.Check the ignition.

Operate the electric starter.

2. Battery The engine turns over quickly.

The engine turns over slowly.

The battery is good.

Check the battery lead connections,and have a Yamaha dealer charge the battery if necessary.

Dry

WetOpen the throttle halfway and operatethe electric starter or the kickstarter.


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Motorcycle care and storageEAU37834

Matte color caution

NOTICEECA15193

Some models are equipped withmatte colored finished parts. Besure to consult a Yamaha dealer foradvice on what products to use be-fore cleaning the vehicle. Using abrush, harsh chemical products orcleaning compounds when cleaningthese parts will scratch or damagetheir surface. Wax also should notbe applied to any matte colored fin-ished parts.

EAU26005

CareWhile the open design of a motorcyclereveals the attractiveness of the tech-nology, it also makes it more vulnera-ble. Rust and corrosion can developeven if high-quality components areused. A rusty exhaust pipe may go un-noticed on a car, however, it detractsfrom the overall appearance of a motor-cycle. Frequent and proper care doesnot only comply with the terms of thewarranty, but it will also keep your mo-torcycle looking good, extend its lifeand optimize its performance.

Before cleaning1. Cover the muffler outlet with a

plastic bag after the engine hascooled down.

2. Make sure that all caps and coversas well as all electrical couplersand connectors, including thespark plug cap, are tightly in-stalled.

3. Remove extremely stubborn dirt,like oil burnt onto the crankcase,with a degreasing agent and abrush, but never apply such prod-

ucts onto seals, gaskets, sprock-ets, the drive chain and wheelaxles. Always rinse the dirt and de-greaser off with water.

Cleaning

NOTICEECA10773

Avoid using strong acidic wheelcleaners, especially on spokedwheels. If such products areused on hard-to-remove dirt, donot leave the cleaner on the af-fected area any longer than in-structed. Also, thoroughly rinsethe area off with water, immedi-ately dry it, and then apply a cor-rosion protection spray.

Improper cleaning can damageplastic parts (such as cowlings,panels, windshields, headlightlenses, meter lenses, etc.) andthe mufflers. Use only a soft,clean cloth or sponge with wa-ter to clean plastic. However, ifthe plastic parts cannot be thor-oughly cleaned with water, di-luted mild detergent with watermay be used. Be sure to rinse


Motorcycle care and storage

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off any detergent residue usingplenty of water, as it is harmfulto plastic parts.

Do not use any harsh chemicalproducts on plastic parts. Besure to avoid using cloths orsponges which have been incontact with strong or abrasivecleaning products, solvent orthinner, fuel (gasoline), rust re-movers or inhibitors, brake flu-id, antifreeze or electrolyte.

Do not use high-pressure wash-ers or steam-jet cleaners sincethey cause water seepage anddeterioration in the following ar-eas: seals (of wheel and swing-arm bearings, fork and brakes),electric components (couplers,connectors, instruments,switches and lights), breatherhoses and vents.

For motorcycles equipped witha windshield: Do not use strongcleaners or hard sponges asthey will cause dulling orscratching. Some cleaning com-pounds for plastic may leavescratches on the windshield.

Test the product on a small hid-den part of the windshield tomake sure that it does not leaveany marks. If the windshield isscratched, use a quality plasticpolishing compound afterwashing.

After normal useRemove dirt with warm water, a milddetergent, and a soft, clean sponge,and then rinse thoroughly with cleanwater. Use a toothbrush or bottlebrushfor hard-to-reach areas. Stubborn dirtand insects will come off more easily ifthe area is covered with a wet cloth fora few minutes before cleaning.

After riding in the rain, near the sea oron salt-sprayed roadsSince sea salt or salt sprayed on roadsduring winter are extremely corrosive incombination with water, carry out thefollowing steps after each ride in therain, near the sea or on salt-sprayedroads.

TIPSalt sprayed on roads in the winter may

remain well into spring.

1. Clean the motorcycle with cold wa-ter and a mild detergent, after theengine has cooled down.NOTICE: Do not use warm watersince it increases the corrosiveaction of the salt.[ECA10792]

2. Apply a corrosion protection sprayon all metal, including chrome- andnickel-plated, surfaces to preventcorrosion.

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 stain-less-steel parts, including the ex-haust system. (Even the thermallyinduced discoloring of stain-less-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,



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including chrome- and nickel-plat-ed, surfaces.

5. Use spray oil as a universal clean-er to remove any remaining dirt.

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

7. Wax all painted surfaces.8. Let the motorcycle dry completely

before storing or covering it.

WARNINGEWA11132

Contaminants on the brakes or tirescan cause loss of control. Make sure that there is no oil or

wax on the brakes or tires. If necessary, clean the brake

discs and brake linings with aregular brake disc cleaner or ac-etone, and wash the tires withwarm water and a mild deter-gent. Before riding at higherspeeds, test the motorcycle’sbraking performance and cor-nering behavior.

NOTICEECA10801

Apply spray oil and wax spar-ingly and make sure to wipe off

any excess. Never apply oil or wax to any

rubber and plastic parts, buttreat them with a suitable careproduct.

Avoid using abrasive polishingcompounds as they will wearaway the paint.

TIP Consult a Yamaha dealer for ad-

vice on what products to use. Washing, rainy weather or humid

climates can cause the headlightlens to fog. Turning the headlighton for a short period of time willhelp remove the moisture from thelens.

EAU26153

Storage

Short-termAlways store your motorcycle in a cool,dry place and, if necessary, protect itagainst dust with a porous cover. Besure the engine and the exhaust sys-tem are cool before covering the motor-cycle.

NOTICEECA10811

Storing the motorcycle in apoorly ventilated room or cover-ing it with a tarp, while it is stillwet, will allow water and humid-ity to seep in and cause rust.

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

Long-termBefore storing your motorcycle for sev-eral months:

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



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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 chamberby loosening the drain bolt; this willprevent fuel deposits from buildingup. Pour the drained fuel into thefuel 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 to pro-tect 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 onto

the spark plug, and then placethe spark plug on the cylinderhead so that the electrodes aregrounded. (This will limit spark-ing during the next step.)

d. Turn the engine over severaltimes with the starter. (This willcoat the cylinder wall with oil.)

WARNING! To prevent dam-age or injury from sparking,make sure to ground thespark plug electrodes whileturning the engineover.[EWA10952]

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

6. Lubricate all control cables and thepivoting points of all levers andpedals as well as of the sidestand/centerstand.

7. Check and, if necessary, correctthe tire air pressure, and then liftthe motorcycle so that both of itswheels are off the ground. Alterna-tively, turn the wheels a little everymonth in order to prevent the tiresfrom becoming degraded in onespot.

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 a month.Do not store the battery in an ex-

cessively cold or warm place [lessthan 0 C (30 F) or more than 30C (90 F)]. For more informationon storing the battery, see page7-27.

TIPMake any necessary repairs beforestoring the motorcycle.


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SpecificationsEAU77180Dimensions:

Overall length:2160 mm (85.0 in)

Overall width:930 mm (36.6 in)

Overall height:1155 mm (45.5 in)

Seat height:830 mm (32.7 in)

Wheelbase:1345 mm (53.0 in)

Ground clearance:255 mm (10.04 in)

Minimum turning radius:2.0 m (6.56 ft)

Weight:Curb weight:

128 kg (282 lb)Engine:

Combustion cycle:4-stroke

Cooling system:Air cooled

Valve train:SOHC

Number of cylinders:Single cylinder

Displacement:196 cm3

Bore stroke:67.0 55.7 mm (2.64 2.19 in)

Compression ratio:9.5 : 1

Starting system:Electric starter and kickstarter

Lubrication system:Wet sump

Engine oil:Recommended brand:

YAMALUBESAE viscosity grades:

10W-40Recommended engine oil grade:

API service SG type or higher, JASO stan-dard MA

Engine oil quantity:Oil change:

1.00 L (1.06 US qt, 0.88 Imp.qt)With oil filter removal:

1.10 L (1.16 US qt, 0.97 Imp.qt)Air filter:

Air filter element:Wet element

Fuel:Recommended fuel:

Regular unleaded gasoline (Gasohol [E10] acceptable)

Fuel tank capacity:10 L (2.6 US gal, 2.2 Imp.gal)

Fuel reserve amount:2.0 L (0.53 US gal, 0.44 Imp.gal)

Carburetor:Type quantity:

BS26 1Spark plug(s):

Manufacturer/model:NGK/D8EA

Manufacturer/model:DENSO/X24ES-U

Spark plug gap:0.6–0.7 mm (0.024–0.028 in)

Clutch:Clutch type:

Wet, multiple-discDrivetrain:

Primary reduction ratio:3.700 (74/20)

Final drive:Chain

Secondary reduction ratio:3.857 (54/14)

Transmission type:Constant mesh 5-speed

Gear ratio:1st:

3.182 (35/11)2nd:

2.067 (31/15)3rd:

1.429 (30/21)4th:

0.962 (25/26)5th:

0.710 (22/31)Chassis:

Frame type:Diamond

Caster angle:27.4

Trail:87 mm (3.4 in)


Specifications

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Front tire:Type:

With tubeSize:

80/100-21 51MManufacturer/model:

IRC/VE-32Rear tire:

Type:With tube

Size:4.10-18 59M

Manufacturer/model:IRC/FARM SPECIAL-Z2

Tire air pressure (measured on cold tires):

Front:125 kPa (1.25 kgf/cm2, 18 psi)

Rear:150 kPa (1.50 kgf/cm2, 22 psi)

Front wheel:Wheel type:

Spoke wheelRim size:

21 x 1.60Rear wheel:

Wheel type:Spoke wheel

Rim size:18 x 1.85

Front brake:Type:

Mechanical leading trailing drum brake

Rear brake:Type:

Mechanical leading trailing drum brakeFront suspension:

Type:Telescopic fork

Spring:Coil spring

Shock absorber:Hydraulic damper

Wheel travel:200 mm (7.9 in)

Rear suspension:Type:

SwingarmSpring:

Coil springShock absorber:

Gas-hydraulic damperWheel travel:

155 mm (6.1 in)Electrical system:

System voltage:12 V

Ignition system:CDI

Charging system:AC magneto

Battery:Model:

YTZ7SVoltage, capacity:

12 V, 6.0 Ah (10 HR)

Headlight:Bulb type:

Incandescent bulbBulb wattage:

Headlight:RP35, 45.0 W/45.0 W x 1

Brake/tail light:21.0 W/5.0 W 1

Front turn signal light:10.0 W 2

Rear turn signal light:10.0 W 2

Meter lighting:1.7 W 1

Neutral indicator light:1.7 W 1

Fuse(s):Main fuse:

20.0 AAuxiliary DC jack fuse:

10.0 A


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Consumer informationEAU53562

Identification numbersRecord the vehicle identification num-ber, engine serial number, and themodel label information in the spacesprovided below. These identificationnumbers are needed when registeringthe vehicle with the authorities in yourarea and when ordering spare partsfrom a Yamaha dealer.

VEHICLE IDENTIFICATION NUM-BER:

ENGINE SERIAL NUMBER:

MODEL LABEL INFORMATION:

EAU26401

Vehicle identification number

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

TIPThe vehicle identification number isused to identify your motorcycle andmay be used to register your motorcy-cle with the licensing authority in yourarea.

EAU26442

Engine serial number

The engine serial number is stampedinto the crankcase.

1. Vehicle identification number

1

1. Engine serial number

1


Consumer information

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EAU26461

Model label

The model label is affixed to the loca-tion shown. Record the information onthis label in the space provided. This in-formation will be needed when orderingspare parts from a Yamaha dealer.

EAU26571

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

tive by any person other than forpurposes of maintenance, repairor replacement, of any device orelement of design incorporatedinto any new vehicle for the pur-pose of noise control prior to itssale or delivery to the ultimate pur-chaser or while it is in use; and

The use of the vehicle after suchdevice or element of design hasbeen removed or rendered inoper-ative by any person.

1. Model label

1


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IndexA

Air filter element, cleaning .................... 7-12Auxiliary DC jack .................................. 4-12

BBattery .................................................. 7-27Brake and clutch levers, checking and

lubricating ........................................... 7-25Brake lever ............................................. 4-4Brake lever free play, adjusting ............ 7-18Brake light switches.............................. 7-21Brake pedal ............................................ 4-4Brake pedal, checking and

lubricating ........................................... 7-25Brake pedal height and free play,

adjusting ............................................. 7-19Brake shoes, checking ......................... 7-21Brake/tail light bulb, replacing............... 7-31

CCables, checking and lubricating.......... 7-24Carburetor, adjusting ............................ 7-13Care........................................................ 8-1Clutch lever............................................. 4-3Clutch lever free play, adjusting ........... 7-17

DDimmer switch ........................................ 4-2Drive chain, cleaning and lubricating.... 7-24Drive chain slack .................................. 7-22

EEngine break-in ...................................... 6-3Engine idling speed .............................. 7-13Engine oil and oil filter element............... 7-9Engine serial number............................ 10-1Engine, starting a warm.......................... 6-2Engine stop switch.................................. 4-3

FFront fork, checking...............................7-26Fuel .........................................................4-5Fuel cock.................................................4-6Fuel consumption, tips for reducing ........6-3Fuel tank cap...........................................4-5Fuses, replacing....................................7-29

HHandlebar switches.................................4-2Headlight bulb, replacing.......................7-30Horn switch .............................................4-3

IIdentification numbers ...........................10-1Indicator light...........................................4-1

KKickstarter ...............................................4-8

LLabels, location .......................................1-1Light switch .............................................4-3

MMain switch .............................................4-1Maintenance and lubrication, periodic.....7-4Maintenance, emission control system ...7-3Matte color, caution.................................8-1Model label ............................................10-2

NNeutral indicator light ..............................4-1Noise regulation (for Australia)..............10-2

PPanels, removing and installing ..............7-7Parking ....................................................6-4Part locations ..........................................3-1

RRear suspension, lubricating.................7-26

SSafety information................................... 2-1Seat ........................................................ 4-8Shifting.................................................... 6-2Shift pedal ............................................... 4-4Shift pedal, checking............................. 7-21Shock absorber assembly, adjusting ...... 4-9Sidestands ............................................ 4-10Sidestands, checking and lubricating ... 7-25Spark plug, checking .............................. 7-8Specifications.......................................... 9-1Speedometer unit ................................... 4-2Starter (choke) knob ............................... 4-7Starting and warming up a cold

engine................................................... 6-1Starting circuit cut-off system................ 4-10Start switch ............................................. 4-3Steering, checking ................................ 7-27Storage ................................................... 8-3Supporting the motorcycle .................... 7-32

TThrottle grip and cable, checking and

lubricating ........................................... 7-24Throttle grip free play, checking............ 7-14Tires...................................................... 7-15Tool kit .................................................... 7-2Troubleshooting .................................... 7-36Troubleshooting chart ........................... 7-38Turn signal light bulb, replacing ............ 7-31Turn signal switch ................................... 4-2

VValve clearance .................................... 7-14Vehicle identification number................ 10-1


Index

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WWheel bearings, checking..................... 7-27Wheel (front) ......................................... 7-32Wheel (rear) .......................................... 7-34Wheels .................................................. 7-17


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Documents

AG200FEL · 2020. 6. 24. · Introduction EAU10103 Welcome to the Yamaha world of motorcycling! As the owner of the AG200FEL, you are benefiting from Yamaha’s vast experience and