TABLE OF CONTENTS
LOCATION OF IMPORTANT
LABELS..............................................1-1
SAFETY INFORMATION ...................2-1
DESCRIPTION ...................................3-1
Left view ..........................................3-1
Right view ........................................3-2
Controls and instruments ................3-3
INSTRUMENT AND CONTROL
FUNCTIONS .......................................4-1
Main switch .....................................4-1
Handlebar switches .........................4-1
Shift pedal .......................................4-2
Brake lever ......................................4-2
Brake pedal .....................................4-3
Fuel tank cap ...................................4-3
Fuel ..................................................4-3
Fuel tank breather hose...................4-6
Fuel cock .........................................4-6
Starter (choke) lever .......................4-7
Kickstarter .......................................4-7
Seat .................................................4-8
Shock absorber assembly...............4-8
Sidestand ........................................4-9
Starting circuit cut-off system .........4-9 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................... 6-2
Shifting............................................ 6-2
Engine break-in............................... 6-3
Parking ............................................ 6-4
PERIODIC MAINTENANCE AND
ADJUSTMENT .................................. 7-1
Owner’s tool kit............................... 7-2
Periodic maintenance chart for the emission control system ............. 7-3
General maintenance and lubrication chart .......................... 7-4
Removing and installing panels ...... 7-7
Checking the spark plug................. 7-8
Engine oil ........................................ 7-9
Cleaning the air filter element ....... 7-11
Cleaning the spark arrester .......... 7-13
Adjusting the carburetor ............... 7-14
Adjusting the engine idling
speed......................................... 7-14
Checking the throttle grip free play ............................................ 7-15
Valve clearance............................. 7-15
Tires .............................................. 7-15 Spoke wheels ................................ 7-17
Adjusting the clutch free play........ 7-17
Adjusting the brake lever free
play ............................................ 7-18
Adjusting the brake pedal free
play ............................................ 7-19
Checking the shift pedal ............... 7-20
Checking the front and rear brake shoes ......................................... 7-20
Drive chain slack ........................... 7-21
Cleaning and lubricating the drive chain .......................................... 7-22
Checking and lubricating the cables ........................................ 7-23
Checking and lubricating the throttle grip and cable ............... 7-23
Checking and lubricating the
brake lever ................................. 7-23
Checking and lubricating the brake pedal ................................ 7-24
Checking and lubricating the sidestand ................................... 7-24
Lubricating the swingarm pivots ... 7-24
Checking the front fork ................. 7-25
Checking the steering ................... 7-25
Checking the wheel bearings ........ 7-26
Battery........................................... 7-26
Replacing the fuse ........................ 7-28
Supporting the motorcycle ........... 7-28
Front wheel ................................... 7-29
Rear wheel .................................... 7-31
UB5180E0.book Page 1 Monday, June 9, 2014 1:20 PM
DESCRIPTION
3-1
3
EAU10411
Left view
678
123 4
5
1. Fuel cock (page 4-6)
2. Starter (choke) lever (page 4-7)
3. Fuse (page 7-28)
4. Battery (page 7-26)
5. Clutch adjusting screw (page 7-17)
6. Engine oil drain bolt (page 7-9)
7. Shift pedal (page 4-2)
8. Throttle stop screw (page 7-14)
UB5180E0.book Page 1 Monday, June 9, 2014 1:20 PM
PERIODIC MAINTENANCE AND ADJUSTMENT
7-28
7
EAU50431
Replacing the fuseThe fuse is located inside the battery
coupler. (See page 7-26.)
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. WARNING! Do not
use a fuse of a hi gher ampera ge
ratin g than recommen ded to avoi
d causin g extensive dam-
a g e to the electrical system an d
possi bly a fire.
[EWA15132]
4. Connect the battery coupler.
5. Turn the key to “ON”.
6. If the fuse immediately blows
again, have a Yamaha dealer
check the electrical system.
EAU24351
Supportin g the motorcycleSince this model is not equipped with a
centerstand, follow these precautions
when removing the front and rear
wheel or performing other mainte-
nance requiring the motorcycle to
stand upright. Check that the motorcy-
cle is in a stable and level position be-
fore starting any maintenance. A
strong wooden box can be placed un-
der the engine for added stability.
To service the front wheel
1. Stabilize the rear of the motorcy- cle by using a motorcycle stand
or, if an additional motorcycle
stand is not available, by placing a
jack under the frame in front of the
rear wheel.
2. Raise the front wheel off the ground by using a motorcycle
stand.
To service the rear wheel
Raise the rear wheel off the ground by
using a motorcycle stand or, if a motor-
cycle stand is not available, by placing
1. Battery coupler
2. Fuse
3. Spare fuse
1 3
2
Specified fuse:
10.0 A
UB5180E0.book Page 28 Monday, June 9, 2014 1:20 PM
SPECIFICATIONS
9-3
9
Battery:Model:GT4B-5
Voltage, capacity:
12 V, 2.5 AhFuse:Fuse:10.0 A
EAU51132
For Europe only
The figures quoted are emission levels
and are not necessarily safe working
levels. Whilst there is a correlation be-
tween the emission and exposure lev-
els, this cannot be used reliably to
determine whether or not further pre-
cautions are required. Factors that in-
fluence the actual level of exposure of
work-force include the characteristics
of the work room, the other sources of
noise, etc. i.e. the number of machines
and other adjacent processes, and the
length of time for which an operator is
exposed to the noise. Also the permis-
sible exposure level can vary from
country. This information, however, will
enable the user of the machine to make
a better evaluation of the hazard and
risk.
UB5180E0.book Page 3 Monday, June 9, 2014 1:20 PM
11-1
11
INDEX
AAir filter element, cleaning .................... 7-11BBattery .................................................. 7-26
Brake lever.............................................. 4-2
Brake lever, checking and lubricating........................................... 7-23
Brake lever free play, adjusting ............ 7-18
Brake pedal ............................................ 4-3
Brake pedal, checking and lubricating........................................... 7-24
Brake pedal free play, adjusting ........... 7-19
Brake shoes, checking ......................... 7-20CCables, checking and lubricating ......... 7-23
Carburetor, adjusting............................ 7-14
Care ........................................................ 8-1
Clutch free play, adjusting .................... 7-17DDrive chain, cleaning and lubricating ... 7-22
Drive chain slack .................................. 7-21EEngine break-in ...................................... 6-3
Engine idling speed .............................. 7-14
Engine oil ................................................ 7-9
Engine serial number ............................ 10-1
Engine, starting a warm.......................... 6-2
Engine stop switch ................................. 4-2FFront fork, checking ............................. 7-25
Fuel ......................................................... 4-3
Fuel cock ................................................ 4-6
Fuel tank breather hose.......................... 4-6
Fuel tank cap .......................................... 4-3 Fuse, replacing..................................... 7-28
HHandlebar switches ............................... 4-1IIdentification numbers ......................... 10-1KKickstarter .............................................. 4-7LLabels, location ...................................... 1-1MMain switch ............................................ 4-1
Maintenance and lubrication, periodic... 7-4
Maintenance, emission control
system ................................................. 7-3
Matte color, caution ............................... 8-1
Model label........................................... 10-1PPanels, removing and installing ............. 7-7
Parking ................................................... 6-4
Part locations ......................................... 3-1SSafety information .................................. 2-1
Seat ........................................................ 4-8
Shifting ................................................... 6-2
Shift pedal .............................................. 4-2
Shift pedal, checking ........................... 7-20
Shock absorber assembly ..................... 4-8
Sidestand ............................................... 4-9
Sidestand, checking and lubricating.... 7-24
Spark arrester, cleaning ....................... 7-13
Spark plug, checking ............................. 7-8
Specifications......................................... 9-1
Starter (choke) lever ............................... 4-7 Starting and warming up a cold
engine ................................................... 6-1
Starting circuit cut-off system ................ 4-9
Start switch ............................................. 4-2
Steering, checking ................................ 7-25
Storage ................................................... 8-3
Supporting the motorcycle ................... 7-28
Swingarm pivots, lubricating ................ 7-24
TThrottle grip and cable, checking and lubricating ........................................... 7-23
Throttle grip free play, checking ........... 7-15
Tires ...................................................... 7-15
Tool kit .................................................... 7-2
Troubleshooting .................................... 7-32
Troubleshooting chart........................... 7-34VValve clearance..................................... 7-15
Vehicle Emission Control Information label (For Canada) .............................. 10-2
Vehicle identification number ............... 10-1WWheel bearings, checking .................... 7-26
Wheel (front).......................................... 7-29
Wheel (rear)........................................... 7-31
Wheels .................................................. 7-17
UB5180E0.book Page 1 Monday, June 9, 2014 1:20 PM