Tires .................................................................6-16
Spoke wheels ..................................................6-19
Adjusting the clutch lever free play ..................6-19
Adjusting the brake lever free play...................6-20
Adjusting the brake pedal position and
free play .........................................................6-21
Adjusting the rear brake light switch ................6-22
Checking the front brake pads and
rear brake shoes ............................................6-23
Checking the brake fluid level ..........................6-24
Changing the brake fluid ..................................6-25
Drive chain slack ..............................................6-25
Lubricating the drive chain ...............................6-27
Checking and lubricating the cables ................6-28
Checking and lubricating the brake and
shift pedals.....................................................6-28
Checking and lubricating the brake and
clutch levers ...................................................6-29
Checking and lubricating the sidestand ...........6-29
Checking the front fork .....................................6-29
Checking the steering ......................................6-30
Checking the wheel bearings ...........................6-31
Battery..............................................................6-31
Replacing the fuses .........................................6-33
Replacing the headlight bulb ...........................6-34
Replacing a turn signal light bulb .....................6-36Replacing the tail/brake light bulb ....................6-36
Supporting the motorcycle ...............................6-37
Front wheel ......................................................6-38
Rear wheel .......................................................6-39
Troubleshooting ...............................................6-41
Troubleshooting chart ......................................6-42
MOTORCYCLE CARE AND STORAGE .............7-1
Care ...................................................................7-1
Storage ..............................................................7-4
SPECIFICATIONS ...............................................8-1
Specifications .....................................................8-1
Conversion table ................................................8-5
CONSUMER INFORMATION ..............................9-1
Identification numbers ........................................9-1
Key identification number...................................9-1
Vehicle identification number .............................9-1
Model label.........................................................9-2
TABLE OF CONTENTS
7
8
9
5JX-9-E0 4/9/0 4:11 AM Page 6
EAU01114
PRE-OPERATION CHECKS
1
2
3
4
5
6
7
8
9
4-1
The condition of a vehicle is the ownerís responsibility. Vital components can start to deteriorate quickly and unexpect-
edly, even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leak-
age or loss of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thor-
ough visual inspection, to check the following points before each ride.
EAU00340*
Pre-operation check list
ITEM CHECKS PAGE
Front brake9Check operation, free play, fluid level and vehicle for fluid leakage.
3-5, 6-20–6-21, 6-23–6-25
9Add DOT 4 brake fluid if necessary.
Rear brake9Check operation and free play.
3-6, 6-21–6-23
9Adjust if necessary.
Clutch9Check operation and free play.
3-5, 6-19–6-20
9Adjust if necessary.
Throttle grip and housing9Check smooth operation.
6-15
9Lubricate.
Engine oil9Check oil level.
6-9–6-10
9Add oil if necessary.
Drive chain9Check chain slack and condition.
6-25–6-27
9Adjust if necessary.
Wheels and tires9Check tire pressure, wear, damage and spoke tightness.
6-16–6-19
9Tighten spokes if necessary.
Control and meter cable9Check smooth operation.
6-28
9Lubricate if necessary.
Brake and shift pedal shafts9Check smooth operation.
6-28
9Lubricate if necessary.
Brake and clutch lever pivots9Check smooth operation.
6-29
9Lubricate if necessary.
5JX-9-E0 4/9/0 4:11 AM Page 22
6-2
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU00473
Periodic maintenance and lubrication chart
No. ITEM CHECKS AND MAINTENANCE JOBSInitial
1,000 kmEvery
6,000 kmEvery
12,000 kmAnnual
check
1
*Fuel line¥ Check fuel hoses and vacuum hose for cracks or damage.
¥ Replace if necessary.ÖÖ
2 Spark plugs¥ Check condition.
¥ Clean, regap or replace if necessary.Ö
3
*Valves¥ Check valve clearance.
¥ Adjust if necessary.Ö
4 Air filter element¥ Clean or replace if necessary.Ö
5 Clutch¥ Check operation.
¥ Adjust or replace cable.ÖÖ
6
*Front brake¥ Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)
¥ Correct accordingly.
¥ Replace brake pads if necessary.ÖÖ Ö
7
*Rear brake¥ Check operation.
¥ Adjust brake pedal freeplay and replace brake shoes if necessary.ÖÖ Ö
8
*Brake hose¥ Check for cracks or damage.
¥ Replace if necessary.ÖÖ
9
*Wheels¥ Check balance, runout, spoke tightness and for damage.
¥ Tighten spokes and rebalance, replace if necessary.Ö
10
*Tires¥ Check tread depth and for damage.
¥ Replace if necessary.
¥ Check air pressure.
¥ Correct accordingly.Ö
11
*Wheel bearings¥ Check bearings for looseness or damage.
¥ Replace if necessary.Ö
12
*Swingarm¥ Check swingarm pivoting point for play.
¥ Correct if necessary.
¥ Lubricate with molybdenum disulfide grease every 24,000 km or 24
months (whichever comes first).Ö
5JX-9-E0 4/9/0 4:11 AM Page 30
6-16
1
2
3
4
5
6
7
8
9
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU00637
Adjusting the valve
clearance
The valve clearance changes with
use, resulting in improper air-fuel mix-
ture and/or engine noise. To prevent
this from occurring, the valve clear-
ance must be adjusted by a Yamaha
dealer at the intervals specified in the
periodic maintenance and lubrication
chart.
EAU00647
Tires
To ensure maximum performance as
well as the long and safe operation of
your motorcycle, note the following
points regarding the specified tires.
Tire air pressure
The tire air pressure should be
checked and, if necessary, adjusted
before each ride.
EW000082
w
8The tire air pressure must be
checked and adjusted on cold
tires (i.e., when the tempera-
ture of the tires equals the
ambient temperature).
8The tire air pressure must be
adjusted in accordance with
the riding speed and with the
total weight of rider, passen-
ger, cargo, and accessories
approved for this model.
*Total weight of rider, passenger, cargo and
accessories
Tire air pressure (measured on cold tires)
Load* Front Rear
175 kPa 200 kPa
Up to 90 kg (1.75 kg/cm
2, (2.0 kg/cm2,1.75 bar) 2.00 bar)
90 kg load–225 kPa 225 kPa
maximum load*(2.25 kg/cm
2, (2.25 kg/cm2,
2.25 bar) 2.25 bar)
Maximum load* 183 kg
5JX-9-E0 4/9/0 4:11 AM Page 44
1
2
3
4
5
6
7
8
9
6-17
PERIODIC MAINTENANCE AND MINOR REPAIR
EWA00012
w
Because loading has an enormous
impact on the handling, braking,
performance and safety character-
istics of your motorcycle, you
should keep the following precau-
tions in mind.
8NEVER OVERLOAD THE
MOTORCYCLE! Operation of
an overloaded motorcycle may
result in tire damage, loss of
control, or severe injury. Make
sure that the total weight of
rider, passenger, cargo, and
accessories does not exceed
the specified maximum load
for the vehicle.
8Do not carry along loosely
packed items, which can shift
during a ride.
8Securely pack the heaviest
items close to the center of the
motorcycle and distribute the
weight evenly on both sides.8Adjust the suspension and tire
air pressure with regard to the
load.
8Check the tire condition and
air pressure before each ride.
Tire inspection
The tires must be checked before
each ride. If the center tread depth
reaches the specified limit, if the tire
has a nail or glass fragments in it, or
if the sidewall is cracked, have a
Yamaha dealer replace the tire imme-
diately.
NOTE:
The tire tread depth limits may differ
from country to country. Always com-
ply with the local regulations.
1. Tread depth
2. Side wall
1
2
Minimum tire tread
depth (front and rear)1.6 mm
5JX-9-E0 4/9/0 4:11 AM Page 45
6-18
1
2
3
4
5
6
7
8
9
PERIODIC MAINTENANCE AND MINOR REPAIR
EW000079
w
8Have a Yamaha dealer replace
excessively worn tires.
Besides being illegal, operat-
ing the motorcycle with exces-
sively worn tires decreases
riding stability and can lead to
loss of control.
8The replacement of all wheel-
and brake-related parts,
including the tires, should be
left to a Yamaha dealer, who
has the necessary profession-
al knowledge and experience.
Tire information
This motorcycle is equipped with tube
tires.
EW000078
w
8The front and rear tires should
be of the same make and
design, otherwise the handling
characteristics of the motorcy-
cle cannot be guaranteed.
8After extensive tests, only the
tires listed below have been
approved for this model by
Yamaha Motor Co., Ltd.
EAU00681
w
8Have a Yamaha dealer replace
excessively worn tires.
Besides being illegal, operat-
ing the motorcycle with exces-
sively worn tires decreases
riding stability and can lead to
loss of control.
8The replacement of all wheel-
and brake-related parts,
including the tires, should be
left to a Yamaha dealer, who
has the necessary profession-
al knowledge and experience.
8It is not recommended to
patch a punctured tube. If
unavoidable, however, patch
the tube very carefully and
replace it as soon as possible
with a high-quality product.
Manufacturer Size Model
CHENG SHIN 80/100-18 47P C-916
INOUE 80/100-18 47PMARBELLA
NF27
FRONT
Manufacturer Size Model
CHENG SHIN130/90-15 M/C 66PC-915
INOUE
130/90-15 M/C 66PMARBELLA
NR31
REAR
5JX-9-E0 4/9/0 4:11 AM Page 46
MOTORCYCLE CARE AND STORAGE
7
7-3
After cleaning
1. Dry the motorcycle with a
chamois or an absorbing cloth.
2. Immediately dry the drive chain
and lubricate it to prevent it from
rusting.
3. Use a chrome polish to shine
chrome, aluminum and stainless-
steel parts, including the exhaust
system. (Even the thermally
induced discoloring of stainless-
steel exhaust systems can be
removed through polishing.)
4. To prevent corrosion, it is recom-
mended to apply a corrosion pro-
tection spray on all metal, includ-
ing chrome- and nickel-plated,
surfaces.
5. Use spray oil as a universal
cleaner to remove any remaining
dirt.
6. Touch up minor paint damage
caused by stones, etc.7. Wax all painted surfaces.
8. Let the motorcycle dry complete-
ly before storing or covering it.
EWA00001
w
8Make sure that there is no oil
or wax on the brakes or tires.
If necessary, clean the brake
discs and brake linings with a
regular brake disc cleaner or
acetone, and wash the tires
with warm water and a mild
detergent.
8Before operating the motorcy-
cle test its braking perfor-
mance and cornering behav-
ior.
ECA00013
cC
8Apply spray oil and wax spar-
ingly and make sure to wipe
off any excess.
8Never apply oil or wax to any
rubber and plastic parts, but
treat them with a suitable care
product.
8Avoid using abrasive polish-
ing compounds as they will
wear away the paint.
NOTE:
Consult a Yamaha dealer for advice
on what products to use.
5JX-9-E0 4/9/0 4:11 AM Page 73
7
MOTORCYCLE CARE AND STORAGE
7-5
7. Check and, if necessary, correct
the tire air pressure, and then lift
the motorcycle so that both of its
wheels are off the ground.
Alternatively, turn the wheels a
little every month in order to pre-
vent the tires from becoming
degraded in one spot.
8. Cover the muffler outlets with
plastic bags to prevent moisture
from entering them.
9. Remove the battery and fully
charge it. Store it in a cool, dry
place and charge it once a
month. Do not store the battery
in an excessively cold or warm
place (less than 0 °C or more
than 30 °C). For more informa-
tion on storing the battery, see
page 6-31.
NOTE:
Make any necessary repairs before
storing the motorcycle.
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