Differential gear oil ............................. 8-31
Coolant ............................................... 8-33
Axle boots .......................................... 8-35
Checking the spark plugs .................. 8-35
Air filter maintenance.......................... 8-37
Cleaning the air filter case check hoses ................................................ 8-41
Cleaning the spark arrester ................ 8-42
Valve clearance .................................. 8-44
Brakes ................................................ 8-44
Checking the front and rear brake
pads.................................................. 8-44
Checking the parking brake pads ...... 8-45
Checking the brake and clutch fluid levels................................................. 8-45
Brake and clutch fluid replacement ... 8-47
Checking the clutch pedal ................. 8-47
Checking the brake pedal .................. 8-48
Checking the accelerator pedal ......... 8-49
Parking brake lever free play adjustment........................................ 8-49
Brake light switch adjustment ............ 8-50
Cable inspection and lubrication........ 8-51 Pedal lubrication .................................8-51
Checking the stabilizer bushes...........8-52
Upper and lower arm pivot
lubrication (left and right) ..................8-52
Rear knuckle upper and lower pivot
lubrication (left and right) ..................8-53
Drive shaft universal joint lubrication .........................................8-53
Steering shaft lubrication....................8-54
Wheel removal ....................................8-54
Checking and tightening the bead lock (YXZ10YMSH) ...........................8-55
Tire replacement .................................8-55
Wheel installation................................8-56
Battery ................................................8-57
Jump-starting .....................................8-60
Fuse replacement ...............................8-61
Headlights...........................................8-63
Headlight beam adjustment ...............8-64
Tail/brake light ....................................8-64
Troubleshooting ..................................8-64
Troubleshooting charts .......................8-66
U2HC7ME0.book Page 3 Tuesday, April 19, 2016 10:33 AM
8-4
8
EBU35770Periodic maintenance chart for the emission control systemFor vehicles equipped with an odometer or an ho ur meter, follow the km (mi) or hours mainte-
nance intervals. However, keep in mind that if the vehicle isn’t used for a long period of time,
the month maintenance intervals should still be followed.
Items marked with an asterisk should be perfor med by a Yamaha dealer as they require special
tools, data and technical skills.NO. ITEM ROUTINE INITIAL
EVERY
Whichev- er comes first month136612
km
(mi) 320
(200) 1300
(800) 2500
(1600) 2500
(1600) 5000
(3200)
hours 20 80 160 160 320
1 *Fuel line • Check fuel hose for cracks or damage.
• Replace if necessary. √√√
2 *Va l v e s • Check valve clearance and adjust if neces-
sary. Every 5000 km (3200 mi).
3 *Spark plugs • Check condition.
• Adjust gap and clean.
• Replace if necessary. √√√√√
4 *Breather system • Check breather hose for cracks or damage.
• Replace if necessary. √√√
5 *Fuel injection • Adjust synchronization. √√√√√
U2HC7ME0.book Page 4 Tuesday, April 19, 2016 10:33 AM
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8
TIPThe radiator fan automatically switches on
or off according to the temperature of the
coolant in the radiator.
If the engine overheats, see page 8-67 for
instructions. EBU32400Axle bootsCheck the axle boots for holes or tears.
If any damage is found, have them replaced
by a Yamaha dealer.
EBU35121Checking the spark plugsThe spark plug is an important engine com-
ponent which should be periodically
checked, preferably by a Yamaha dealer.
Since heat and deposits will cause any spark
plug to slowly erode, the spark plugs should
be removed and checked in accordance with
the periodic maintenance chart for the emis-
sion control system. In addition, the condition
of the spark plugs can reveal the condition of
the engine.
1. Front axle boot
1
1
1. Rear axle boot
1
1
U2HC7ME0.book Page 35 Tuesday, April 19, 2016 10:33 AM
8-36
8
The porcelain insulator around the center
electrode of each spark plug should be a me-
dium-to-light tan color (the ideal color when
the vehicle is ridden normally), and all spark
plugs installed in the engine should have a
similar color. If any spark plug shows a dis-
tinctly different color, the engine could be op-
erating improperly. Do not attempt to
diagnose such problems yourself. Instead,
have a Yamaha dealer check the vehicle.
If a spark plug shows signs of electrode ero-
sion and excessive carbon or other deposits,
it should be replaced.
Before installing a spark plug, the spark plug
gap should be measured with a wire thick-
ness gauge and, if necessary, adjusted to
specification.Clean the surface of the spark plug gasket
and its mating surface, and then wipe off any
grime from the spark plug threads.Specified spark plug:
NGK/CR9EB
1. Spark plug gapSpark plug gap:0.7–0.8 mm (0.028–0.031 in)
Tightening torque: Spark plug:13 N·m (1.3 kgf·m, 9.4 lb·ft)
1
U2HC7ME0.book Page 36 Tuesday, April 19, 2016 10:33 AM
8-66
8
EBU35910Troubleshooting chartsStarting problems or poor engine performanceCheck the fuel level in
the fuel tank.1. Fuel
There is enough fuel.There is no fuel.
Check the battery.
Supply fuel.
The engine does not start.
Check the battery.
Operate the electric starter.4. Compression
There is compression.
There is no compression.
The engine does not start.
Have a Yamaha dealer check the vehicle.Have a Yamaha dealer check the vehicle.
Remove the spark plugs
and check the electrodes.3. Ignition
Wipe off with a dry cloth and correct the
spark plug gaps, or replace the spark plugs. Have a Yamaha dealer check the vehicle.
The engine does not start.
Check the compression.
Operate the electric starter.2. Battery
The engine turns over
quickly.
The engine turns over
slowly.
The battery is good.
DryWet
Operate the electric starter.
Check the battery lead connections,
and have a Yamaha dealer charge
the battery if necessary.
The engine does not start.
Check the ignition.
U2HC7ME0.book Page 66 Tuesday, April 19, 2016 10:33 AM
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9
EBU32720
CLEANING AND STORAGE
EBU35920CleaningFrequent, thorough cleaning of your vehicle
will not only enhance its appearance but will
improve its general performance and extend
the useful life of many components.1. Before cleaning the vehicle: a. Block off the end of the exhaust pipe to prevent water entry. A plastic bag
and strong rubber band may be used.
b. Make sure the spark plugs and all filler caps are properly installed.
2. If the engine case is excessively greasy, apply degreaser with a paint brush. Do
not apply degreaser to the wheel axles.
3. Rinse the dirt and degreaser off with a garden hose. Use only enough pressure
to do the job. WARNING! Test the
brakes after washing. Apply the
brakes several times at slow speeds to
let friction dry the brakes. Wet brakes may have reduced stopping ability, in-
creasing the chance of an accident.
[EWB03471]
NOTICE: Excessive water pres-
sure may cause water seepage and
deterioration of wheel bearings,
brakes, transmission seals and electri-
cal devices. Many expensive repair
bills have resulted from improper high-
pressure detergent applications such
as those available in coin-operated car
washers.
[ECB00712]
4. Once the majority of the dirt has been hosed off, wash all surfaces with warm
water and mild, detergent-type soap. An
old toothbrush or bottle brush is handy
for hard-to-get-at places.
5. Rinse the vehicle off immediately with
clean water and dry all surfaces with a
clean chamois towel or soft, absorbent
cloth.
6. Clean the seats with a vinyl upholstery cleaner to keep the covers pliable and
glossy.
U2HC7ME0.book Page 1 Tuesday, April 19, 2016 10:33 AM
9-2
9
7. Automotive-type wax may be applied toall painted and chrome-plated surfaces.
Avoid combination cleaner-waxes. Many
contain abrasives which may scratch the
paint or protective finish. When finished,
start the engine and let it idle for several
minutes.EBU32741StorageLong term storage (60 days or more) of your
vehicle will require some preventive proce-
dures to guard against deterioration. Make
any necessary repairs before storing the vehi-
cle.
After thoroughly cleaning the vehicle, prepare
for storage as follows:
1. Fill the fuel tank with fresh fuel and add the specified amount of Fuel Med Rx or
another high-quality fuel stabilizer prod-
uct. Follow the instructions on the prod- uct label. Operate the vehicle for at least
5 minutes to distribute treated fuel
through the fuel system.
2. Remove the spark plugs and pour one ta- blespoon of fresh engine oil into each cyl-
inder and then re-install the spark plugs.
Remove the spark plug wires and ground
them. Operate the electric starter to turn
the engine over several times and coat
the cylinder walls with oil.
3. Lubricate all control cables.
4. Put the frame on stands or blocks to raise all wheels off the ground.
5. Tie a plastic bag over the exhaust pipe outlet to prevent moisture from entering.
Specified amount:1 oz of stabilizer to each gallon of fuel (or
7.5 ml of stabilizer to each liter of fuel)
U2HC7ME0.book Page 2 Tuesday, April 19, 2016 10:33 AM
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12
Helmet indicator light .....................................................4-6
High beam indicator light ............................................... 4-3
Hood ............................................................................ 8-10IIdentification number records ...................................... 11-1
Indicator lights and warning lights ................................. 4-2
Instruments, lights and switches, Pre-operation check ........................................................................... 5-8JJump-starting ............................................................... 8-60LLabel locations ............................................................... 1-1
Light switch .................................................................. 4-16
Loading ..........................................................................6-9MMain switch .................................................................... 4-1
Maintenance and lubrication chart ................................8-6
Maintenance chart, emission control system ................ 8-4
Model label ................................................................... 11-1
Multi-function meter unit ................................................ 4-7NNeutral indicator light .....................................................4-2OOn-Command drive knob ............................................ 4-17
Owner’s manual and tool kit .......................................... 8-2PPanels .......................................................................... 8-10
Parking ........................................................................... 6-9
Parking brake indicator light .......................................... 4-3
Parking brake lever ...................................................... 4-20
Parking brake lever free play, adjusting ....................... 8-49 Parking brake pads, checking ..................................... 8-45
Passenger handhold, Pre-operation check ................... 5-7
Pedal, lubrication ......................................................... 8-51
RRear knuckle upper and lower pivot, lubrication ......... 8-53
Reverse gear lock lever ................................................ 4-18
Reverse indicator light ................................................... 4-2SSafety information .......................................................... 2-1
Seat belt indicator light .................................................. 4-6
Seat belts ..................................................................... 4-25
Seat belts, Pre-operation check .................................... 5-7
Seats ............................................................................ 4-22
Shift lever ..................................................................... 4-21
Shift lever operation and reverse driving ....................... 6-3
Shift lever, Pre-operation check .................................... 5-8
Shift timing indicator light .............................................. 4-4
Shock absorber assemblies, adjusting the front ......... 4-30
Shock absorber assemblies, adjusting the rear ........... 4-38
Spark arrester, cleaning ............................................... 8-42
Spark plugs, checking ................................................. 8-35
Specifications .............................................................. 10-1
Stabilizer bushes, checking ......................................... 8-52
Starting the engine ......................................................... 6-2
Steering, Pre-operation check ....................................... 5-7
Steering shaft, lubrication ............................................ 8-54
Steering wheel position ................................................ 4-24
Storage .......................................................................... 9-2
Storage compartments ................................................ 4-26TTail/brake light ............................................................. 8-64
Tire, replacing .............................................................. 8-55
U2HC7ME0.book Page 2 Tuesday, April 19, 2016 10:33 AM