Table of contents
Location of important la bels ........... 1-1
Safety information ............................ 2-1
Description ....................................... 3-1
Left view ......................................... 3-1
Right view ....................................... 3-2
Controls and instruments ............... 3-3
Instrument an d 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 ................................................. 4-4
Fuel tank breather hose.................. 4-6
Fuel cock ........................................ 4-7
Starter (choke) lever ...................... 4-8
Kickstarter ...................................... 4-8
Seat ................................................ 4-9
Shock absorber assembly .............. 4-9
Sidestand ..................................... 4-10
Starting circuit cut-off system ...... 4-10
For your safety – pre-operation
checks ............................................... 5-1
Operation an d important ri din g
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
Perio dic maintenance an d
a d justment ........................................ 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...... 7-6 Checking the spark plug ................. 7-7
Engine oil......................................... 7-8
Cleaning the air filter element ....... 7-10
Cleaning the spark arrester ........... 7-12
Adjusting the carburetor ............... 7-13
Adjusting the engine idling
speed ......................................... 7-13
Checking the throttle grip free
play ............................................ 7-14
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 ............... 7-19
Checking the front and rear brake shoes ......................................... 7-20
Drive chain slack ........................... 7-20
Cleaning and lubricating the drive chain .......................................... 7-22
Checking and lubricating the cables ........................................ 7-22
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 ... 7-25
Checking the front fork ................. 7-25
Checking the steering ................... 7-26
Checking the wheel bearings ........ 7-26
Battery........................................... 7-27
Replacing the fuse ........................ 7-28
Supporting the motorcycle ........... 7-29
Front wheel ................................... 7-29
Rear wheel .................................... 7-31
Troubleshooting ............................ 7-33
Troubleshooting chart ................... 7-34
UB5181E0.book Page 1 Monday, April 6, 2015 9:22 AM
Description
3-1
3
EAU63371
Left view
678
123 45
1. Fuel cock (page 4-7)
2. Starter (choke) lever (page 4-8)
3. Fuse (page 7-28)
4. Battery (page 7-27)
5. Clutch adjusting screw (page 7-17)
6. Engine oil drain bolt (page 7-8)
7. Shift pedal (page 4-2)
8. Throttle stop screw (page 7-13)
UB5181E0.book Page 1 Monday, April 6, 2015 9:22 AM
Periodic maintenance an d a djustment
7-28
7
3. Fully charge the battery before
installation. NOTICE: When in-
stallin g the b attery, be sure the
key is turned to “OFF” before
connectin g the coupler.
[ECA16931]
NOTICE
ECA16531
Always keep the b attery charged .
Storin g a d ischar ged battery can
cause permanent b attery damag e.
EAU50431
Replacin g the fuse
The fuse is located inside the battery
coupler. (See page 7-27.)
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.
1. Battery coupler
2. Fuse
3. Spare fuse
Specified fuse:
10.0 A
1 3
2
UB5181E0.book Page 28 Monday, April 6, 2015 9:22 AM
Specifications
9-2
9
Transmission type:Constant mesh 4-speed
Operation: Left foot operation
Gear ratio:
1st:3.166 (38/12)
2nd:
1.941 (33/17)
3rd: 1.380 (29/21)
4th: 1.095 (23/21)
Chassis:
Frame type:
Backbone
Caster angle: 26.00 °
Trail: 60 mm (2.4 in)
Front tire:
Type:With tube
Size: 2.50-14 4PR
Manufacturer/model:
CHEN SHIN/C-803-2
Speed rating: 120 km/h (75 mph)
Rear tire:
Type:
With tube
Size: 3.00-12 4PR
Manufacturer/model: CHEN SHIN/C-803-2
Speed rating:
120 km/h (75 mph)
Loa din g:
Maximum rider weight:
60.0 kg (132 lb)
Tire air pressure (measure d on col d
tires):
Front:
100 kPa (1.00 kgf/cm², 15 psi)
Rear:
100 kPa (1.00 kgf/cm², 15 psi)
Front wheel:
Wheel type:Spoke wheel Rim size:
14x1.40
Rear wheel:
Wheel type:
Spoke wheel
Rim size: 12x1.60
Front brake:
Type:
Drum brake
Operation: Right hand operation
Rear brake:
Type:
Drum brake
Operation:
Right foot operation
Front suspension:
Type:Telescopic fork
Spring/shock absorber type:
Coil spring/oil damper
Wheel travel: 115 mm (4.5 in)
Rear suspension:
Type:
Swingarm
Spring/shock absorber type: Coil spring/gas-oil damper
Wheel travel: 110 mm (4.3 in)
Electrical system:
System voltage:12 V
Ignition system: DC CDI
Charging system:
AC magneto
Battery:
Model:GT4B-5
Voltage, capacity:
12 V, 2.5 Ah
Fuse:
Fuse:10.0 A
UB5181E0.book Page 2 Monday, April 6, 2015 9:22 AM
11-1
11
Index
A
Air filter element, cleaning .................... 7-10
B
Battery .................................................. 7-27
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 ......................... 7-20
C
Cables, checking and lubricating ......... 7-22
Carburetor, adjusting ............................ 7-13
Care ........................................................ 8-1
Clutch free play, adjusting .................... 7-17
D
Drive chain, cleaning and lubricating .... 7-22
Drive chain slack................................... 7-20
E
Engine break-in....................................... 6-3
Engine idling speed .............................. 7-13
Engine oil ................................................ 7-8
Engine serial number ............................ 10-1
Engine, starting a warm .......................... 6-2
Engine stop switch ................................. 4-1
F
Front fork, checking .............................. 7-25
Fuel ......................................................... 4-4
Fuel cock ................................................ 4-7
Fuel tank breather hose .......................... 4-6
Fuel tank cap .......................................... 4-3
Fuse, replacing ..................................... 7-28
H
Handlebar switches ................................ 4-1
I
Identification numbers .......................... 10-1
K
Kickstarter............................................... 4-8
L
Labels, location....................................... 1-1
M
Main switch ............................................. 4-1
Maintenance and lubrication, periodic ... 7-4
Maintenance, emission control
system .................................................. 7-3
Matte color, caution ................................ 8-1
Model label ........................................... 10-1
P
Panels, removing and installing.............. 7-6
Parking ................................................... 6-4
Part locations ......................................... 3-1
S
Safety information .................................. 2-1
Seat ........................................................ 4-9
Shifting ................................................... 6-2
Shift pedal .............................................. 4-2
Shift pedal, checking ............................ 7-19
Shock absorber assembly ...................... 4-9
Sidestand ............................................. 4-10
Sidestand, checking and lubricating .... 7-24
Spark arrester, cleaning ....................... 7-12
Spark plug, checking ............................. 7-7
Specifications ......................................... 9-1
Starter (choke) lever ............................... 4-8
Starting and warming up a cold engine .................................................. 6-1
Starting circuit cut-off system .............. 4-10
Start switch ............................................ 4-1
Steering, checking................................ 7-26
Storage ................................................... 8-4
Supporting the motorcycle................... 7-29
Swingarm pivots, lubricating ................ 7-25
T
Throttle grip and cable, checking and lubricating .......................................... 7-23
Throttle grip free play, checking........... 7-14
Tires ...................................................... 7-15
Tool kit.................................................... 7-2
Troubleshooting ................................... 7-33
Troubleshooting chart .......................... 7-34
V
Valve clearance .................................... 7-15
Vehicle Emission Control Information label (For Canada) .............................. 10-2
Vehicle identification number ............... 10-1
W
Wheel bearings, checking .................... 7-26
Wheel (front) ......................................... 7-29
Wheel (rear) .......................................... 7-31
Wheels .................................................. 7-17
UB5181E0.book Page 1 Monday, April 6, 2015 9:22 AM