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PERIODIC MAINTENANCE AND MINOR REPAIR
6-13
6 3. Insert the tailpipe into the muffler,
and then install and tighten the
bolts to the specified torque.
NOTE:
Make sure to align the bolt holes wheninserting the tailpipe.
EAU39930
Adjusting the carburetor The carburetor is an important part of
the engine and requires very sophisti-
cated adjustment. Therefore, most car-
buretor adjustments should be left to a
Yamaha dealer, who has the neces-
sary professional knowledge and expe-
rience. The adjustment described in the
following section, however, may be ser-
viced by the owner as part of routine
maintenance.CAUTION:
ECA10550
The carburetor has been set and ex-
tensively tested at the Yamaha fac-
tory. Changing these settings
without sufficient technical knowl-
edge may result in poor perfor-mance of or damage to the engine.
EAU21362
Adjusting the engine idling
speed The engine idling speed must be
checked and, if necessary, adjusted as
follows at the intervals specified in the
periodic maintenance and lubrication
chart.NOTE:
A diagnostic tachometer is needed tomake this adjustment.
1. Attach the tachometer to the spark
plug lead.
2. Start the engine and warm it up for
several minutes at 1000–2000
r/min while occasionally revving it
to 4000–5000 r/min.NOTE:The engine is warm when it quickly re-sponds to the throttle.
3. Check the engine idling speed
and, if necessary, adjust it to spec-
ification by turning the throttle stop
screw. To increase the engine
idling speed, turn the screw in di-
Tightening torque:
Tailpipe bolt:
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
U5B680E0.book Page 13 Tuesday, July 17, 2007 9:11 AM
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-14
6rection (a). To decrease the en-
gine idling speed, turn the screw in
direction (b).
NOTE:
If the specified idling speed cannot be
obtained as described above, have aYamaha dealer make the adjustment.
EAU21382
Checking the throttle cable
free play The throttle cable free play should mea-
sure 4.0–6.0 mm (0.16–0.24 in) at the
throttle grip. Periodically check the
throttle cable free play and, if neces-
sary, have a Yamaha dealer adjust it.
EAU21401
Valve clearance The valve clearance changes with use,
resulting in improper air-fuel mixture
and/or engine noise. To prevent this
from occurring, the valve clearance
must be adjusted by a Yamaha dealer
at the intervals specified in the periodic
maintenance and lubrication chart.
1. Throttle stop screwEngine idling speed:
1600–1800 r/min
1(a) (b)
1
1. Throttle cable free play
1
U5B680E0.book Page 14 Tuesday, July 17, 2007 9:11 AM
Page 51 of 78
PERIODIC MAINTENANCE AND MINOR REPAIR
6-15
6
EAU39820
Tires To maximize the performance, durabil-
ity, and safe operation of your motor-
cycle, 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.
WARNING
EWA14380
The tire air pressure must be
checked and adjusted on cold
tires (i.e., when the temperature
of the tires equals the ambient
temperature).
The tire air pressure must be ad-
justed in accordance with the
weight of the rider, the riding
speed, and the riding condi-tions.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 re-
place the tire immediately.
Tire information
This motorcycle is equipped with spoke
wheels and tube tires.
WARNING
EWA10460
The front and rear tires should
be of the same make and de-
sign, otherwise the handling
characteristics of the vehicle
cannot be guaranteed.
After extensive tests, only the
tires listed below have been ap-
proved for this model byYamaha Motor Co., Ltd.WARNING
EWA14390
Have a Yamaha dealer replace
excessively worn tires. Operat-
ing the motorcycle with exces-
Standard tire air pressure:
Front:
100 kPa (15 psi) (1.00 kgf/cm²)
Rear:
100 kPa (15 psi) (1.00 kgf/cm²)
1. Tire sidewall
2. Tire tread depth
Minimum tire tread depth (front and
rear):
4.0 mm (0.16 in)
12
Front tire:
Size:
2.50-14 4PR
Manufacturer/model:
CHEN SHIN/C-803
Rear tire:
Size:
3.00-12 4PR
Manufacturer/model:
CHEN SHIN/C-803
U5B680E0.book Page 15 Tuesday, July 17, 2007 9:11 AM
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-16
6sively worn tires decreases
riding stability and can lead to
loss of control.
The replacement of all wheel-
and brake-related parts, includ-
ing the tires, should be left to a
Yamaha dealer, who has the
necessary professional knowl-
edge and experience.
It is not recommended to patch
a punctured tube. If unavoid-
able, however, patch the tube
very carefully and replace it as
soon as possible with a high-quality product.
EAU21940
Spoke wheels To maximize the performance, durabil-
ity, and safe operation of your motor-
cycle, note the following points
regarding the specified wheels.
The wheel rims should be checked
for cracks, bends or warpage, and
the spokes for looseness or dam-
age before each ride. If any dam-
age is found, have a Yamaha
dealer replace the wheel. Do not
attempt even the smallest repair to
the wheel. A deformed or cracked
wheel must be replaced.
The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced. An
unbalanced wheel can result in
poor performance, adverse han-
dling characteristics, and a short-
ened tire life.
Ride at moderate speeds after
changing a tire since the tire sur-
face must first be “broken in” for it
to develop its optimal characteris-
tics.
EAU40431
Accessories and replacement
parts
WARNING
EWA14481
The accessories or replacement
parts you choose for your vehicle
should be designed specifically for
this model, and they must be se-
curely mounted to maintain the in-
herent stability of the original
design. Genuine Yamaha Parts and
Accessories are designed and test-
ed to be compatible with your vehi-
cle. Yamaha recommends the use of
Genuine Yamaha Parts and Acces-
sories before making a purchase.
Use of non-Yamaha-approved ac-
cessories or replacement parts may
cause loss of handling stability and
riding safety. Since Yamaha cannot
control the quality of accessories or
parts manufactured by other compa-
nies, Yamaha cannot be held liable
for any consequences caused by
the use of items which have notbeen approved by Yamaha.
U5B680E0.book Page 16 Tuesday, July 17, 2007 9:11 AM
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-17
6
EAU44661
Adjusting the clutch free play The clutch free play must be checked
and, if necessary, adjusted as follows
at the intervals specified in the periodic
maintenance and lubrication chart.
1. Loosen the locknut.
2. Slowly turn the clutch adjusting
screw in direction (a) until resis-
tance is felt, and then turn it 1/8
turn in direction (b).NOTE:Turning the clutch adjusting screw in di-
rection (a) decreases clutch free play
and turning it in direction (b) increasesclutch free play.3. Tighten the locknut to the specified
torque.
NOTE:
When tightening the locknut, hold the
clutch adjusting screw with a screwdriv-
er so that it does not turn together withthe locknut.
EAU44880
Adjusting the brake lever free
play The brake lever free play should mea-
sure 10.0–20.0 mm (0.39–0.79 in) as
shown. Periodically check the brake le-
ver free play and, if necessary, adjust it
as follows.
1. Loosen the locknut at the brake le-
ver.
2. To increase the brake lever free
play, turn the adjusting bolt in di-
rection (a). To decrease the brake
lever free play, turn the adjusting
bolt in direction (b).
1. Locknut
2. Clutch adjusting screw
12
(a)
(b)
Tightening torque:
Locknut:
8.0 Nm (0.8 m·kgf, 5.8 ft·lbf)
1. Brake lever free play adjusting bolt
2. Locknut
3. Brake lever free play
2
1
(b)3
(a)
U5B680E0.book Page 17 Tuesday, July 17, 2007 9:11 AM
Page 54 of 78
PERIODIC MAINTENANCE AND MINOR REPAIR
6-18
63. If the specified brake lever free
play could be obtained as de-
scribed above, tighten the locknut
and skip the rest of the procedure,
otherwise proceed as follows.
4. Fully turn the adjusting bolt at the
brake lever in direction (a) to loos-
en the brake cable.
5. Loosen the locknut at the brake
shoe plate.
6. To increase the brake lever free
play, turn the adjusting bolt in di-
rection (a). To decrease the brake
lever free play, turn the adjusting
bolt in direction (b).
7. Tighten the locknut at the brake
shoe plate and at the brake lever.
EAU44670
Adjusting the brake pedal free
play The brake pedal free play should mea-
sure 10.0–20.0 mm (0.39–0.79 in) at
the brake pedal end as shown. Period-
ically check the brake pedal free play
and, if necessary, adjust it as follows.
To increase the brake pedal free play,
turn the adjusting nut at the brake rod in
direction (a). To decrease the brake
pedal free play, turn the adjusting nut in
direction (b).
WARNING
EWA14820
After adjusting the drive chain
slack or removing and installing
the rear wheel, always check the
brake pedal free play.
If proper adjustment cannot be
obtained as described, have a
Yamaha dealer make this ad-justment.
1. Locknut
2. Brake lever free play adjusting bolt
21(b)
(a)
1. Brake pedal free play adjusting nut
2. Brake pedal free play
U5B680E0.book Page 18 Tuesday, July 17, 2007 9:11 AM
Page 55 of 78
PERIODIC MAINTENANCE AND MINOR REPAIR
6-19
6
EAU44820
Checking the shift pedal The operation of the shift pedal should
be checked before each ride. If opera-
tion is not smooth, have a Yamaha
dealer check the vehicle.
EAU22361
Checking the front and rear
brake shoes Front
RearThe front and rear brake shoes must be
checked for wear at the intervals spec-
ified in the periodic maintenance and
lubrication chart. Each brake is provid-
ed with a wear indicator, which allows
you to check the brake shoe wear with-
out having to disassemble the brake.
To check the brake shoe wear, check
the position of the wear indicator while
applying the brake. If a brake shoe has
worn to the point that the wear indicator
reaches the wear limit line, have a
Yamaha dealer replace the brake
shoes as a set.1. Brake shoe wear indicator
2. Brake shoe wear limit line
1. Brake shoe wear indicator
2. Brake shoe wear limit line
2 11 2
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-20
6
EAU22760
Drive chain slack The drive chain slack should be
checked before each ride and adjusted
if necessary.
EAU22773
To check the drive chain slack
1. Place the motorcycle on the side-
stand.NOTE:When checking and adjusting the drive
chain slack, there should be no weighton the motorcycle.
2. Shift the transmission into the neu-
tral position.
3. Move the rear wheel by pushing
the motorcycle to locate the tight-
est portion of the drive chain, and
then measure the drive chain slack
as shown.4. If the drive chain slack is incorrect,
adjust it as follows.
EAU40110
To adjust the drive chain slack
1. Loosen the brake pedal free play
adjusting nut, axle nut, and locknut
at each end of the swingarm.2. To tighten the drive chain, turn the
adjusting nut at each end of the
swingarm in direction (a). To loos-
en the drive chain, turn the adjust-
ing nut at each end of the
swingarm in direction (b), and then
push the rear wheel forward.
NOTE:Using the alignment marks on each
side of the swingarm, make sure that
both adjusting nuts are in the same po-sition for proper wheel alignment.
Drive chain slack:
40.0–56.0 mm (1.57–2.20 in)
1. Drive chain slack
1
1. Brake pedal free play adjusting nut
2. Locknut
3. Drive chain slack adjusting nut
U5B680E0.book Page 20 Tuesday, July 17, 2007 9:11 AM
