TABLE OF CONTENTSSAFETY INFORMATION ..................1-1
Location of important labels ............1-4
DESCRIPTION ..................................2-1
Left view ..........................................2-1
Right view ........................................2-2
Controls and instruments.................2-3
INSTRUMENT AND CONTROL
FUNCTIONS.......................................3-1
Main switch .....................................3-1
Handlebar switches ........................3-1
Speed limiter ...................................3-2
Shift pedal .......................................3-2
Brake lever .....................................3-3
Brake pedal ....................................3-3
Fuel tank cap ..................................3-3
Fuel .................................................3-4
Fuel tank breather hose ..................3-5
Fuel cock ........................................3-5
Starter (choke) lever .......................3-6
Seat ................................................3-7
Sidestand ........................................3-7
Starting circuit cut-off system .........3-8
PRE-OPERATION CHECKS..............4-1
Pre-operation check list ..................4-2OPERATION AND IMPORTANT
RIDING POINTS................................. 5-1
Starting and warming up a cold
engine ......................................... 5-1
Starting a warm engine .................. 5-2
Shifting ........................................... 5-2
Engine break-in .............................. 5-3
Parking ........................................... 5-4
PERIODIC MAINTENANCE AND
MINOR REPAIR................................. 6-1
PERIODIC MAINTENANCE ........... 6-1
Periodic maintenance chart for the
emission control system ............. 6-2
General maintenance and
lubrication chart .......................... 6-3
Checking the spark plug ................. 6-5
Engine oil ....................................... 6-6
Cleaning the air filter element ........ 6-8
Cleaning the spark arrester ............ 6-9
Adjusting the carburetor ............... 6-10
Adjusting the engine idling
speed ........................................ 6-11
Adjusting the throttle cable free
play ........................................... 6-11
Valve clearance ............................ 6-12
Tires ............................................. 6-12
Spoke wheels ............................... 6-14
Accessories and replacement
parts .......................................... 6-14Adjusting the brake lever free
play ........................................... 6-14
Adjusting the brake pedal free
play ........................................... 6-15
Checking the front and rear
brake shoes .............................. 6-16
Drive chain slack .......................... 6-16
Cleaning and lubricating the
drive chain ................................ 6-18
Checking and lubricating the
cables ....................................... 6-19
Checking and lubricating the
throttle grip and cable ............... 6-19
Checking and lubricating the
brake and shift pedals .............. 6-19
Checking and lubricating the
brake lever ................................ 6-20
Checking and lubricating the
sidestand .................................. 6-20
Lubricating the swingarm
pivots ........................................ 6-20
Checking the front fork ................. 6-21
Checking the steering .................. 6-21
Checking the wheel bearings ....... 6-22
Battery ......................................... 6-22
Replacing the fuse ....................... 6-24
Supporting the motorcycle ........... 6-25
Front wheel .................................. 6-25
Rear wheel ................................... 6-27
Troubleshooting ........................... 6-29
Troubleshooting chart .................. 6-30U1P681E0.book Page 1 Tuesday, April 18, 2006 2:38 PM
DESCRIPTION
2-1
2
EAU10410
Left view
12 34 5
76
1. Fuel cock (page 3-5)
2. Throttle stop screw (page 6-11)
3. Air filter element (page 6-8)
4. Fuse (page 6-24)
5. Battery (page 6-22)
6. Engine oil drain bolt (page 6-6)
7. Shift pedal (page 3-2)
U1P681E0.book Page 1 Tuesday, April 18, 2006 2:38 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
6-24
6 sealed-type (MF) battery charg-
er, have a Yamaha dealer
charge your battery.
EAU42020
Replacing the fuse The fuse is located inside the battery
coupler.
If the fuse is blown, replace it as fol-
lows.
1. Turn the key to “OFF” and turn off
all electrical circuits.
2. Disconnect the battery coupler.
3. Remove the blown fuse, and then
install a new fuse of the specified
amperage.
CAUTION:
ECA10640
Do not use a fuse of a higher amper-
age rating than recommended to
avoid causing extensive damage to
the electrical system and possibly afire.
4. Connect the battery coupler.
5. Turn the key to “ON” and turn on
the electrical circuits to check if the
devices operate.
6. If the fuse immediately blows
again, have a Yamaha dealer
check the electrical system.
1. Fuse
2. Spare fuse
Specified fuse:
10.0 A
U1P681E0.book Page 24 Tuesday, April 18, 2006 2:38 PM
SPECIFICATIONS
8-2
8
Primary reduction ratio:
67/18 (3.722)
Secondary reduction system:
Chain drive
Secondary reduction ratio:
37/13 (2.846)
Transmission type:
Constant mesh 3-speed
Operation:
Left foot operation
Gear ratio:
1st:
39/12 (3.250)
2nd:
33/19 (1.736)
3rd:
28/23 (1.217)Chassis:Frame type:
Steel tube backbone
Caster angle:
25.50 °
Trail:
34.0 mm (1.34 in)Front tire:Type:
With tube
Size:
2.50-10 4PR
Manufacturer/model:
CHENG SHIN/KNOBBYRear tire:Type:
With tubeSize:
2.50-10 4PR
Manufacturer/model:
CHENG SHIN/KNOBBY
Tire air pressure (measured on cold
tires):
Front:
100 kPa (15 psi) (1.00 kgf/cm²)
Rear:
100 kPa (15 psi) (1.00 kgf/cm²)
Front wheel:Wheel type:
Spoke wheel
Rim size:
10x1.40Rear wheel:Wheel type:
Spoke wheel
Rim size:
10x1.40Front brake:Type:
Drum brake
Operation:
Right hand operationRear brake:Type:
Drum brake
Operation:
Right foot operationFront suspension:Type:
Telescopic forkSpring/shock absorber type:
Coil spring
Wheel travel:
96.0 mm (3.78 in)
Rear suspension:Type:
Swingarm (monocross)
Spring/shock absorber type:
Coil spring/oil damper
Wheel travel:
71.0 mm (2.80 in)Electrical system:Ignition system:
CDI
Charging system:
AC magnetoBattery:Model:
YT4B-BS/GT4B-5
Voltage, capacity:
12 V, 2.3 Ah/12 V, 2.5 AhFuse:Fuse:
10.0 A
U1P681E0.book Page 2 Tuesday, April 18, 2006 2:38 PM
INDEXAAccessories and replacement parts ...... 6-14
Air filter element, cleaning....................... 6-8BBattery................................................... 6-22
Brake and shift pedals,
checking and lubricating ..................... 6-19
Brake lever .............................................. 3-3
Brake lever, checking and lubricating ... 6-20
Brake lever free play, adjusting............. 6-14
Brake pedal ............................................. 3-3
Brake pedal free play, adjusting............ 6-15
Brake shoes, checking .......................... 6-16CCables, checking and lubricating .......... 6-19
Carburetor, adjusting ............................ 6-10
Care ........................................................ 7-1DDrive chain, cleaning and lubricating .... 6-18
Drive chain slack ................................... 6-16EEngine break-in ....................................... 5-3
Engine idling speed............................... 6-11
Engine oil ................................................ 6-6
Engine, starting a warm .......................... 5-2
Engine stop switch .................................. 3-1FFront fork, checking .............................. 6-21
Fuel ......................................................... 3-4
Fuel cock................................................. 3-5
Fuel tank breather hose .......................... 3-5
Fuel tank cap .......................................... 3-3
Fuse, replacing ..................................... 6-24
HHandlebar switches ................................ 3-1IIdentification numbers ............................ 9-1KKey identification number ....................... 9-1LLabels, location of................................... 1-4MMain switch ............................................. 3-1
Maintenance and lubrication, periodic .... 6-3
Maintenance, emission control system... 6-2
Maintenance, periodic ............................ 6-1
Model label ............................................. 9-2PParking ................................................... 5-4
Part locations .......................................... 2-1
Pre-operation check list .......................... 4-2SSafety information................................... 1-1
Seat ........................................................ 3-7
Shifting.................................................... 5-2
Shift pedal............................................... 3-2
Sidestand................................................ 3-7
Sidestand, checking and lubricating ..... 6-20
Spark arrester, cleaning ......................... 6-9
Spark plug, checking .............................. 6-5
Specifications ......................................... 8-1
Speed limiter........................................... 3-2
Starter (choke) lever ............................... 3-6
Starting and warming up a cold
engine .................................................. 5-1
Starting circuit cut-off system ................. 3-8
Start switch ............................................. 3-1Steering, checking................................. 6-21
Storage.................................................... 7-3
Supporting the motorcycle .................... 6-25
Swingarm pivots, lubricating ................. 6-20
TThrottle cable free play, adjusting ......... 6-11
Throttle grip and cable,
checking and lubricating ..................... 6-19
Tires ...................................................... 6-12
Troubleshooting .................................... 6-29
Troubleshooting chart ........................... 6-30VValve clearance..................................... 6-12
Vehicle identification number .................. 9-1WWheel bearings, checking ..................... 6-22
Wheel (front) ......................................... 6-25
Wheel (rear) .......................................... 6-27
Wheels .................................................. 6-14
U1P681E0.book Page 1 Tuesday, April 18, 2006 2:38 PM