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OWNERS MANUAL
SX-4 225
54D-F8199-E0
U5YPE0E0.book Page 2 Wednesday, February 23, 2005 4:22 PM
EAU46090
Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it sold.
U5YPE0E0.book Page 1 Wednesday, February 23, 2005 4:22 PM
EAU10050
INTRODUCTION
EAU10102
WARNING
Please read this manual carefully and completely before operating this motorcycle.
IMPORTANT MANUAL INFORMATION EAU10122
EAU10132
WARNING A WARNING indicates a hazardous situation which, if not avoid, could result
in death or serious injury.
EAUN0020
SCORPIO (54D)
OWNERS MANUAL
2010 by Yamaha Indonesia Motor Mfg
1st edition, October 2010
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Indonesia Motor Manufacturing
is expressly prohibited.
Printed in Indonesia
U5YPE0E0.book Page 1 Wednesday, February 23, 2005 4:22 PM
TABLE OF CONTENTS
EAU10210
SAFETY INFORMATION ..................1-1 OPERATION AND IMPORTANT Checking the brake lever
RIDING POINTS................................. 5-1 free play .................................... 6-18
DESCRIPTION ..................................2-1 Starting and warming up a Adjusting the brake pedal
Left view ...........................................2-1 cold engine ................................. 5-1 free play .................................... 6-18
Right view.........................................2-2 Starting a warm engine .................. 5-2 Adjusting the rear brake light
Controls and instruments.................2-3 Shifting ........................................... 5-2 switch ....................................... 6-19
Tips for reducing fuel Checking the front brake pads and
INSTRUMENT AND CONTROL consumption ............................... 5-3 rear brake shoes ...................... 6-19
FUNCTIONS .......................................3-1 Engine break-in .............................. 5-3 Checking the front brake
Main switch/steering lock ................3-1 Parking ........................................... 5-5 fluid level .................................. 6-20
Key hole cover ................................3-2 General note .................................. 5-6 Changing the brake fluid .............. 6-20
Indicator lights ................................3-2 Drive chain slack .......................... 6-21
Speedometer unit ...........................3-2 PERIODIC MAINTENANCE AND Cleaning and lubricating the
Fuel gauge ......................................3-3 MINOR REPAIR ................................. 6-1 drive chain ................................ 6-23
Handlebar switches ........................3-3 Owners tool kit ............................... 6-1 Checking and lubricating the
Shift pedal .......................................3-4 Periodic maintenance and cables ....................................... 6-23
Brake lever .....................................3-4 lubrication chart .......................... 6-2 Checking and lubricating the
Brake pedal ....................................3-4 Removing and installing the throttle grip and cable ............... 6-23
Fuel tank cap ..................................3-5 cowlings and panel ..................... 6-5 Lubricating the brake lever .......... 6-24
Fuel .................................................3-5 Checking the spark plug ................. 6-8 Lubricating the brake pedal ......... 6-24
Starter (choke) lever ........................3-6 Engine oil .................................... 6-10 Checking and lubricating the
Kickstarter .......................................3-7 Engine oil filter element ................... 6-11 centerstand and sidestand ....... 6-24
Seat ................................................3-7 Cleaning the air filter element ...... 6-12 Lubricating the
Helmet holders ...............................3-8 Adjusting the carburetor ............... 6-13 swingarm pivots ........................ 6-25
Storage compartment .....................3-8 Adjusting the engine idling Checking the front fork ................. 6-25
Sidestand ........................................3-8 speed ........................................ 6-14 Checking the steering .................. 6-26
Adjusting the throttle cable Checking the wheel bearings ....... 6-26
PRE-OPERATION CHECKS ..............4-1 free play .................................... 6-14 Battery ......................................... 6-27
Pre-operation check list ..................4-2 Valve clearance ............................ 6-15 Replacing the fuse ....................... 6-28
Tires ............................................. 6-15
Wheels ......................................... 6-17
U5YPE0E0.book Page 2 Wednesday, February 23, 2005 4:22 PM
TABLE OF CONTENTS
Replacing the head light bulb ............ 6-29
Replacing a front turn signal ligh
bulb/Auxilliary bulb ......................... 6-29
Replacing a rear turn signal/tail/
brake/light bulb .............................. 6-30
Front wheel ....................................... 6-31
Rear wheel ......................................... 6-32
Troubleshooting charts ..................... 6-35
EAU45762
Read and understand all of the labels on your vehicle. They contain important information for safe and proper operation of
your vehicle. Never remove any labels from your vehicle. If a label becomes difficult to read or comes off, a replacement label
is available from your Yamaha dealer.
1
U5YPE0E0.book Page 1 Wednesday, February 23, 2005 4:22 PM
EAU10222
SAFETY INFORMATION
EAU10313
Safe Riding tersections are the most likely
Be a Responsible Owner
Perform the pre-operation checks each places for motorcycle accidents
As the vehicles owner, you are respon-
time you use the vehicle to make sure it to occur.
sible for the safe and proper operation
is in safe operating condition. Failure to Ride where other motorists can 1
of your motorcycle.
inspect or maintain the vehicle properly see you. Avoid riding in another
Motorcycles are single-track vehicles.
increases the possibility of an accident motorists blind spot.
Their safe use and operation are de-
or equipment damage. See page 5-1 Many accidents involve inexperi-
pendent upon the use of proper riding
for a list of pre-operation checks. enced operators. In fact, many op-
techniques as well as the expertise of
This motorcycle is designed to erators who have been involved in
the operator. Every operator should
carry the operator and a passen- accidents do not even have a cur-
know the following requirements before
ger. rent motorcycle license.
riding this motorcycle.
The failure of motorists to detect Make sure that you are qualified
He or she should:
and recognize motorcycles in traf- and that you only lend your mo-
Obtain thorough instructions from
fic is the predominating cause of torcycle to other qualified opera-
a competent source on all aspects
automobile/motorcycle accidents. tors.
of motorcycle operation.
Many accidents have been Know your skills and limits.
Observe the warnings and mainte-
caused by an automobile driver Staying within your limits may
nance requirements in this Own-
who did not see the motorcycle. help you to avoid an accident.
ers Manual.
Making yourself conspicuous ap- We recommend that you prac-
Obtain qualified training in safe
pears to be very effective in reduc- tice riding your motorcycle
and proper riding techniques.
ing the chance of this type of where there is no traffic until you
Obtain professional technical ser-
accident. have become thoroughly famil-
vice as indicated in this Owners
Therefore: iar with the motorcycle and all of
Manual and/or when made neces-
Wear a brightly colored jacket. its controls.
sary by mechanical conditions.
Use extra caution when you are Many accidents have been
approaching and passing caused by error of the motorcycle
through intersections, since in- operator. A typical error made by
1-1
U5YPE0E0.book Page 2 Wednesday, February 23, 2005 4:22 PM
SAFETY INFORMATION
the operator is veering wide on a Never ride under the influence of tem become very hot during or af-
turn due to excessive speed or un- alcohol or other drugs. ter operation and can cause
dercornering (insufficient lean an- burns.
1 gle for the speed). Protective apparel A passenger should also observe
Always obey the speed limit and The majority of fatalities from motorcy- the above precautions.
never travel faster than warrant- cle accidents are the result of head in-
ed by road and traffic condi- juries. The use of a safety helmet is the Avoid Carbon Monoxide Poisoning
tions. single most critical factor in the preven- All engine exhaust contains carbon
Always signal before turning or tion or reduction of head injuries. monoxide, a deadly gas. Breathing car-
changing lanes. Make sure that Always wear an approved helmet. bon monoxide can cause headaches,
other motorists can see you. Wear a face shield or goggles. dizziness, drowsiness, nausea, confu-
The posture of the operator and Wind in your unprotected eyes sion, and eventually death.
passenger is important for proper could contribute to an impairment Carbon Monoxide is a colorless, odor-
control. of vision that could delay seeing a less, tasteless gas which may be
The operator should keep both hazard. present even if you do not see or smell
hands on the handlebar and The use of a jacket, heavy boots, any engine exhaust. Deadly levels of
both feet on the operator foot- trousers, gloves, etc., is effective carbon monoxide can collect rapidly
rests during operation to main- in preventing or reducing abra- and you can quickly be overcome and
tain control of the motorcycle. sions or lacerations. unable to save yourself. Also, deadly
The passenger should always Never wear loose-fitting clothes, levels of carbon monoxide can linger
hold onto the operator, the seat otherwise they could catch on the for hours or days in enclosed or poorly
strap or grab bar, if equipped, control levers, footrests, or wheels ventilated areas. If you experience any
with both hands and keep both and cause injury or an accident. symptoms of carbon monoxide poison-
feet on the passenger footrests. Always wear protective clothing ing, leave the area immediately, get
Never carry a passenger unless that covers your legs, ankles, and fresh air, and SEEK MEDICAL TREAT-
he or she can firmly place both feet. The engine or exhaust sys- MENT.
feet on the passenger footrests.
1-2
U5YPE0E0.book Page 3 Wednesday, February 23, 2005 4:22 PM
SAFETY INFORMATION
Do not run engine indoors. Even if guidelines to follow if loading cargo to attached to the motorcycle before
you try to ventilate engine exhaust your motorcycle: riding. Check accessory mounts
with fans or open windows and The total weight of the operator, and cargo restraints frequently.
doors, carbon monoxide can rap- passenger, accessories and cargo Properly adjust the suspension 1
idly reach dangerous levels. must not exceed the maximum load for your load, and check the
Do not run engine in poorly venti- limit. Operation of an overloaded ve- condition and pressure of your
lated or partially enclosed areas hicle could cause an accident. tires.
such as barns, garages, or car- Never attach any large or heavy
ports. Maximum load: items to the handlebar, front
Do not run engine outdoors where 180 kg (397 lb) fork, or front fender. These
engine exhaust can be drawn into items, including such cargo as
When loading within this weight limit,
a building through openings such sleeping bags, duffel bags, or
keep the following in mind:
as windows and doors. tents, can create unstable han-
Cargo and accessory weight
dling or a slow steering re-
Loading should be kept as low and close to
sponse.
Adding accessories or cargo to your the motorcycle as possible. Se-
This vehicle is not designed to
motorcycle can adversely affect stabili- curely pack your heaviest items as
pull a trailer or to be attached to
ty and handling if the weight distribution close to the center of the vehicle
a sidecar.
of the motorcycle is changed. To avoid as possible and make sure to dis-
the possibility of an accident, use ex- tribute the weight as evenly as Genuine Yamaha Accessories
treme caution when adding cargo or possible on both sides of the mo- Choosing accessories for your vehicle
accessories to your motorcycle. Use torcycle to minimize imbalance or is an important decision. Genuine
extra care when riding a motorcycle instability. Yamaha accessories, which are avail-
that has added cargo or accessories. Shifting weights can create a sud- able only from a Yamaha dealer, have
Here, along with the information about den imbalance. Make sure that ac- been designed, tested, and approved
accessories below, are some general cessories and cargo are securely by Yamaha for use on your vehicle.
1-3
U5YPE0E0.book Page 4 Wednesday, February 23, 2005 4:22 PM
SAFETY INFORMATION
Many companies with no connection to characteristics can put you and others Bulky or large accessories may
Yamaha manufacture parts and acces- at greater risk of serious injury or death. seriously affect the stability of
sories or offer other modifications for You are responsible for injuries related the motorcycle due to aerody-
1 to changes in the vehicle. namic effects. Wind may at-
Yamaha vehicles. Yamaha is not in a
position to test the products that these Keep the following guidelines in mind, tempt to lift the motorcycle, or
aftermarket companies produce. as well as those provided under Load- the motorcycle may become un-
Therefore, Yamaha can neither en- ing when mounting accessories. stable in cross winds. These ac-
dorse nor recommend the use of ac- Never install accessories or carry cessories may also cause
cessories not sold by Yamaha or cargo that would impair the perfor- instability when passing or be-
modifications not specifically recom- mance of your motorcycle. Care- ing passed by large vehicles.
mended by Yamaha, even if sold and fully inspect the accessory before Certain accessories can dis-
installed by a Yamaha dealer. using it to make sure that it does place the operator from his or
not in any way reduce ground her normal riding position. This
Aftermarket Parts, Accessories, and clearance or cornering clearance, improper position limits the free-
Modifications limit suspension travel, steering dom of movement of the opera-
While you may find aftermarket prod- travel or control operation, or ob- tor and may limit control ability,
ucts similar in design and quality to scure lights or reflectors. therefore, such accessories are
genuine Yamaha accessories, recog- Accessories fitted to the handle- not recommended.
nize that some aftermarket accessories bar or the front fork area can Use caution when adding electri-
or modifications are not suitable be- create instability due to improp- cal accessories. If electrical acces-
cause of potential safety hazards to er weight distribution or aerody- sories exceed the capacity of the
you or others. Installing aftermarket namic changes. If accessories motorcycles electrical system, an
products or having other modifications are added to the handlebar or electric failure could result, which
performed to your vehicle that change front fork area, they must be as could cause a dangerous loss of
any of the vehicles design or operation lightweight as possible and lights or engine power.
should be kept to a minimum.
1-4
U5YPE0E0.book Page 1 Wednesday, February 23, 2005 4:22 PM
DESCRIPTION
EAU10420
Left view
1 2 3
4 5 6
2-1
U5YPE0E0.book Page 2 Wednesday, February 23, 2005 4:22 PM
DESCRIPTION
EAU10410
Right view 7 8
12 11 10 9
7. Fuse (Page 6-32) 10.Engine oil level check window (Page 6-8)
8. Kickstarter (Page 3-9) 11.Brake pedal (Page 3-6,6-18)
9. Engine oil filter element (Page 6-8) 12.Battery (Page 6-30)
2-2
U5YPE0E0.book Page 3 Wednesday, February 23, 2005 4:22 PM
DESCRIPTION
EAU10430
8
9
2-3
U5YPE0E0.book Page 1 Wednesday, February 23, 2005 4:22 PM
EAU10460
To lock the steering To unlock the steering
Main switch/steering lock
3 3
1. Push.
1. Push. 2. Turn
2. Turn
The main switch/steering lock controls
the ignition and lighting systems, and is EAU10700 Push the key in to the main switch,
used to lock the steering. The various LOCK and then turn it to "OFF" while still pu-
positions are described below. The steering is locked, and all electrical shing it.
EAU37441
systems are off. The key can be re-
ON moved. EWA10060
3-1
U5YPE0E0.book Page 2 Wednesday, February 23, 2005 4:22 PM
3
4
3
1 2 3 1 1. Speedometer
1. Turn signal indicator light " 5 " 2. Odometer
2. Neutral indicator light "N" 3. Tripmeter
4. Reset knob
3. High beam indicator light " & "
EAU11040 The speedometer unit is equipped with
Turn signal indicator light a speedometer, an odometer and trip-
This indicator light flashes when the meter. The speedometer shows riding
turn signal switch is pushed to the left speed. The odometer shows the total
or right. distance traveled.
EAU11060
EAU11080 The tripmeter shows the distance tra-
Neutral indicator light " "
veled since it was last set to zero with
This indicator light comes on when the reset knob. The tripmeter can be
the transmission is in the neutral used to estimate the distance that can
position. be traveled with a full tank of fuel.
This information will enable you to plan
future fuel stops.
3-2
12140
1
3
The fuel gauge indicates the amount of Left
1 2 3
fuel in the fuel tank. The needle moves
towards E (Empty) as the fuel level
decreases. When the needle reaches
When the needle reaches "E", refuel
as soon as possible.
3
TIP:
2
Do not allow the fuel tank to empty 5 4
1. Tachometer itself completely.
2. Red zone 1. Light switch : /'/1
3. Fuel gauge 2. Pass switch &
3. Dimmer switch /
4. Turn signal switch
The tachometer allows the rider to mo- 5. Horn switch HORN
nitor the engine speed and keep it wi- EAU12590
thin the ideal power range. Light switch " : / '/1 "
ECA10031 Set this switch to ' to turn on
NOTICE :
the auxiliary light, meter lighting and tail-
Do not operate the engine in the light. Set the switch to : to turn on
Tachometer red zone. the headlight also. Set the switch to
Red zone: 10.000 r/min and above. 1 to turn off all the lights.
3-3
INSTRUMENT AND CONTROL FUNCTIONS
EAU12400
Right 1 Clutch lever
EAU12850
Dimmer switch /
Set this switch to for the high
beam and to for the low beam.
EAU12460
Turn signal switch /
To signal a right-hand turn, push this
3 1
switch to . To signal a left-hand
turn, push this switch to . When re- 2 3
leased, the switch returns to the center
position. To cancel the turn signal
1. Engine stop switch " #/$ "
lights, push the switch in after it has re-
2. Start switch " " 1. Clutch lever
turned to the center position.
EAU12660
EAU12500 Engine stop switch #/$ The clutch lever is located at the left
Horn switch HORN
Set this switch to # before starting handlebar grip. To disengage the
Press this switch to sound the horn.
the engine. Set this switch to $ to clutch, pull the lever toward the han-
stop the engine in case of an emer- dlebar grip. To engage the clutch,
gency, such as when the motorcycle release the lever. The lever should
overturns or when the throttle cable is be pulled rapidly and released slowly
stuck. EAU12710
for smooth clutch operation.
Start switch ,
Push this switch to crank the engine
with the starter.
ECA10050
NOTICE :
CAUTION:
See page 5-1 for starting instruction
prior starting the engine.
3-4
er
1
5 1
4
3
3 2
N
1 .
1
1. Shift pedal 1. Brake lever 1. Brake pedal.
N. Neutral
The brake lever is located at the right The brake pedal is on the right side of
The shift pedal is located on the left handlebar grip. To apply the front the motorcycle. To apply the rear
side of the engine and is used in brake, pull the lever toward the handle- brake, press down on the brake pedal.
combination with the clutch lever bar grip.
when shifting the gears of the
5-speed constant-mesh transmission
equipped on this motorcycle.
TIP:
Use your toes or heel to shift up and
your toes to shift down.
3-5
l)
Fuel
1. Push the fuel tank cap into the po-
sition with the key inserted in the
> lock.
2. Turn the key counterclokwise to
=
the original position, remove it,
and then close the lock cover.
3
TIP:
The fuel tank cap cannot be closed
1 unless the key is in the lock. In addition,
the key cannot be removed if the cap 1. Fuel tank filler tube
1. Fuel tank cap lock cover cap is not properly closed and locked. 2. Fuel level
a. Open
b. Unlock Make sure there is sufficient gasoline
EWA11091
Open the fuel tank cap lock cover, WARNING in the tank.
insert the key into the lock and turn it Make sure that the fuel tank cap is EWA10881
1/4 turn clockwise. The lock will be properly closed after filling fuel. WARNING
W
W ARNI
ARNINGNG
NG
be released and the fuel tank cap can Leaking fuel is a fire hazard. Gasoline and gasoline vapors are
be opened. extremely flammable. To avoid fires
and explosions and to reduce the
risk of injury when refueling, follow
these instructions.
3-6
A5-yoko_Blank.fm Page 1 Tuesday, April 8, 2003 11:43 AM
3-7
RES: Reserve position
3-8
A5-yoko_Blank.fm Page 1 Tuesday, April 8, 2003 11:43 AM
3-9
U5YPE0E0.book Page 8 Wednesday, February 23, 2005 4:22 PM
a 1
3
1. Projection
2. Seat holder
a. Unlock. 1. Helmet holder
To remove the seat To install the seat The helmet holders are located under
the seat.
1. Insert the key into the seat lock, and 1. Insert the projection on the front
then turn it clockwise of the seat into the seat holder To secure a helmet to a helmet holder
as shown. 1. Open the seat. (See page 3-9 for
2. Pull the seat off.
2. Push the rear of the seat down to removal and installation prose-
lock it in place. dures.)
3. Turn the key counter clockwise 2. Attach a helmet to a helmet holder,
and then remove it. and then securely close the seat.
WARNI!NGNever ride with a
WARNING
TIP: helmet attached to the helmet
Make sure that the seat is properly holder, since the helmet may
secured before riding. hit objects, causing loss of control
and possibly an accident. [EWA10161]
3-10
1
WARNING
3 The vehicle must not be ridden with
the sidestand down, or if the side-
stand cannot be properly moved up
(or does not stay up), otherwise the
sidestand could contact the ground
and distract the operator, resulting
in a possible loss of control.
3-11
U5YPE0E0.book Page 1 Wednesday, February 23, 2005 4:22 PM
EAU15582
PRE-OPERATION CHECKS
EAU15596
Inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition. Always follow the
inspection and maintenance procedures and schedules described in the Owner's Manual.
EWA11151
WARNING
Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equipment damage.
Do not operate the vehicle if you find any problem. If a problem cannot be corrected by the procedures provided
in this manual, have the vehicle inspected by a Yamaha dealer.
Before using this vehicles, check the following points:
4-1
U5YPE0E0.book Page 2 Wednesday, February 23, 2005 4:22 PM
PRE-OPERATION CHECKS
EAU15610
Check operation
Front and rear suspension 6-23
Check oil suspention for leakage.
4
Check operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check brake pads for wear.
Front brake Replace if necessary. 6-18, 6-19
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.
Check operation.
Rear brake Check pedal free play. 6-17
Adjust if necessary.
Make sure that operation is smooth.
Check cable free play.
Throttle grip 6-12, 6-13
If necessary, have Yamaha dealer adjust cable free play and lubricate cable and
grip housing.
Make sure that operation is smooth.
Control cables 6-21
Lubricate if necessary.
Check chain slack.
Adjust if necessary.
Drive chain 6-19, 6-20
Check chain condition.
Lubricate if necessary.
4-2
U5YPE0E0.book Page 3 Wednesday, February 23, 2005 4:22 PM
PRE-OPERATION CHECKS
ITEM CHECKS PAGE
4-3
U5YPE0E0.book Page 1 Wednesday, February 23, 2005 4:22 PM
EAU16540
EAU15951
Before starting out, make sure Starting and warming up a
Read the Owner's Manual carefully to that the sidestand is up. If the cold engine
become familiar with all controls. If sidestand is not raised com-
there is a control or function you do not pletely, it could contact the
understand, ask your Yamaha dealer. ground and distract the opera-
RES
tor, resulting in a possible loss
WARNING
EWA10270
of control. OFF
FUEL
Become thoroughly familiar ECAN0070
ON
with all operating controls and NOTICE
NOTICE:::
NOTICE
their functions before riding. ON
Do not ride through deep water
Consult a Yamaha dealer re- (including puddles), otherwise the
5
garding any control or function engine may be damaged.
that you do not thoroughly un- In order for the ignition circuit cut-off
derstand. system to enable starting, one of the
following conditions must be met:
Never start the engine or oper-
ate it in a closed area for any
The transmission is in the neutral
length of time. Exhaust fumes position.
are poisonous, and inhaling The transmission is in gear with the
them can cause loss of con- clutch lever pulled.
sciousness and death within a 1. Turn the fuel cock lever to ON
short time. Always make sure 2. Turn the key to ON and make
that there is adequate ventila- sure that the engine stop switch
tion. is set to # .
3. Shift the transmission into the
neutral position.
5-1
U5YPE0E0.book Page 2 Wednesday, February 23, 2005 4:22 PM
5-2
U5YPE0E0.book Page 3 Wednesday, February 23, 2005 4:22 PM
TIP:
To shift the transmission into the neu-
tral position, press the shift pedal
down repeatedly until it reaches the
end of its travel, and then slightly
raise it.
5-3
U5YPE0E0.book Page 4 Wednesday, February 23, 2005 4:22 PM
5-4
U5YPE0E0.book Page 5 Wednesday, February 23, 2005 4:22 PM
WARNING
Since the engine and exhaust
system can become very hot,
park in a place where pedestri-
ans or children are not likely to
5 touch them.
The vehicle can now be operated
Do not park on a slope or on soft
normally.
ECA10310
ground, otherwise the vehicle
NOTICE: may overturn.
8 Keep the engine speed out of
the tachometer red zone.
8 If any engine trouble should
occur during the engine break-
in period, immediately have a
Yamaha dealer check the vehicle.
5-5
U5YPE0E0.book Page 6 Wednesday, February 23, 2005 4:22 PM
General note
Much can be gained from the correct use and maintenance of a motorcycle.
1. THE CUSTOMERS CAN USE THE FULLEST 2. A MOTORCYCLE CAN KEEP ITS PERFORMANCE
POTENTIAL OF YAMAHA MOTORCYCLES CAPABILITY FOR A LONGER TIME
Perfect operative
condition
Without 5
maintenance
Distance
covered (km) Engine overhaul, cylinder
boring, piston ring change, etc.
5-6
U5YPE0E0.book Page 7 Wednesday, February 23, 2005 4:22 PM
3. FUEL COST AND REPAIR EXPENSES CAN BE 4. A MOTORCYCLE CAN DEMAND A HIGH PRICE
KEPT TO A MINIMUM WHEN IT IS TRADED IN AS A USED PRODUCT
Fuel consumption
With maintenance
100%
Without
maintenance
Distance covered (km)
5-7
U5YPE0E0.book Page 1 Wednesday, February 23, 2005 4:22 PM
TIP :
Safety is an obligation of the owner. Pe- If you do not have the tools or experi-
riodic inspection, adjustment and lubri- 1 ence required for a particular job, have
cation will keep your vehicle in the a Yamaha dealer perform it for you.
safest and most efficient condition pos-
sible. The most important points of in- EWA10350
6-1
U5YPE0E0.book Page 2 Wednesday, February 23, 2005 4:22 PM
1 * Fuel line Check fuel and vacuum hoses for cracks or damage.
Check condition.
2 Spark plug Clean and regap.
6 Replace.
Check valve clearance.
3 * Valves
Adjust.
Clean.
4 Air filter element
Replace.
Check electrolyte level and specific gravity.
5 * Battery
Make sure that the breather hose is properly routed.
Check operation, fluid level and vehicle for fluid leakage.
6 * Front brake
Replace brake pads. Whenever worn to the limit
Check operation and adjust brake pedal free play.
7 * Rear brake
Replace brake shoes. Whenever worn to the limit
Check for cracks or damage.
8 * Brake hose
Replace. Every 4 years
6-2
U5YPE0E0.book Page 3 Wednesday, February 23, 2005 4:22 PM
6-3
U5YPE0E0.book Page 4 Wednesday, February 23, 2005 4:22 PM
Check operation
22 * Front suspention
Check for oil leakage
Front and rear brake
23 * Check operation.
switches
Moving parts and ca-
24 Lubricate.
bles
Check operation and free play.
Throttle grip housing
25 * Adjust the throttle cable free play if necessary.
and cable
Lubricate the throttle grip housing and cable.
Check the air cut-off valve, reed valve, and hose for dam-
26 * Air induction system age.
Replace any damaged parts if necessary.
Lights, signals and Check operation.
6 27 *
switches Adjust headlight beam.
EAU18660
TIP :
The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
Hydraulic brake service
Regularly check and, if necessary, correct the brake fluid level.
Every two years replace the internal components of the brake master cylinder and caliper, and change the brake fluid.
Replace the brake hoses every four years and if cracked or damaged.
6-4
U5YPE0E0.book Page 5 Wednesday, February 23, 2005 4:22 PM
1. Panel/cover 1. Projection
2. Screw 2. Holder
EAU19400
6-5
1. Spark plug wrence
wrence1. Spark plug wrence
6-6
U5YPE0E0.book Page 8 Wednesday, February 23, 2005 4:22 PM
TIP :
If a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/41/2 turn
past finger tight. However, the spark
1. Spark plug gap plug should be tightened to the speci-
To install the spark plug fied torque as soon as possible.
1. Measure the spark plug gap with a
wire thickness gauge and, if nec- 4. Install the spark plug cap.
essary, adjust the gap to specifica-
6
tion.
Spark plug gap:
0.70.8 mm (0.0270.031 in)
6-7
face and hold it in an upright po-
6-8
U5YPE0E0.book Page 11 Wednesday, February 23, 2005 4:22 PM
2 Tightening torque:
Oil filter element cover bolt:
10 Nm (1.0 mkgf, 7.2 ftlbf)
1
1 TIP:
Make sure that the O-ring is properly
1. Oil filter element drain bolt seated.
1. Oli filter element
2. Oli filter element cover
2. O-ring (3)
3. Bolt (2)
11. Install the oil filter element drain
5. Remove the oil filter element drain 6. Remove the oil filter element cover bolt, and then tighten it to the
bolt to drain the oil from the oil fil- by removing the bolts. specified torque.
6
ter element. 7. Remove the oil filter element and 12. Install the engine oil drain bolt, and
TIP : O-rings. and then tighten it to the specified
Skip step 6-10 if the oil filter element is 8. Check the O-rings for damage and torque.
not being cleaned. replace it if necessary.
9. Clean the oil filter element with Tightening torque:
solvent, and then install it. Oil filter element drain bolt:
10 Nm (1.0 mkgf, 7.2 ftlbf)
TIP :
Engine oil drain bolt:
Check the oil filter element for damage 20 Nm (2.0 mkgf, 14.4 ftlbf)
and repalce it if necessary.
6-9
U5YPE0E0.book Page 13 Wednesday, February 23, 2005 4:22 PM
13. Refill with the specified amount 14. Start the engine, and then let it idle Cleaning the air filter element
of the recommended oil, and then for several minutes while checking and check hose
install and tighten the oil filler bolt. it for oil leakage. If oil is leaking, im-
The air filter element should be cleaned
mediately turn the engine off and
at the intervals specified in the perio-
Recommended engine oil: check for the cause.
See page 8-1. dic maintenance and lubrication chart.
15. Turn the engine off, and then
Oil quantity: Clean the air filter element more fre-
check the oil level and correct it if
With oil filter element removal: quently if you are riding in unusually
1.30 L (1.24 US qt) (1.13 Imp.qt) necessary.
wet or dusty areas.
Without oil filter element removal:
In addition, the air filter check hose
1.20 L (1.14 US qt) (1.04 Imp.qt)
must be frequently checked and cle-
Total amount (dry engine)
aned if necessary.
1.40 L (1.33 US qt) (1.21 Imp.qt)
ECA10390
66 NOTICE:
In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives
with the oil.
Make sure that no foreign mate-
rial enters the crankcase.
6-10
A5-yoko_Blank.fm Page 1 Tuesday, April 8, 2003 11:43 AM
2
1
2
1
3
1. Sponge material
1. Air filter case cover 2. Element guide
2. Screw (4) 3. Air filter element frame TIP :
The sponge material should be wet
To clean the air filter element but not dripping.
1. Remove left side panel (See 3. Pull the air filter out.
page 6-5) 4. Remove the sponge material 6
2. Remove the air filter case cover from the air filter element frame, Recommended oil:
by removing the screws. clean it with solvent, and squee- _
6-11
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6-12
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6-13
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6-14
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WARNING
EWA10510
The front and rear tires should 6
WARNING
be of the same make and de-
Proper loading of your motorcycle is sign, otherwise the handling
important for several characteristics characteristics of the vehicle
of your motorcycle; such as han- cannot be guaranteed.
dling, braking, performance and 1. Tire sidewall After extensive tests, only the
safety. Do not carry loosely packed 2. Tire wear indicator tires listed below have been ap-
items that can shift. Securely pack 3. Tire tread depth proved for this model by
your heaviest items close to the cen- Yamaha Motor Co., Ltd.
The tires must be checked before each
ter of the motorcycle, and distribute
ride. If the tire shows crosswise lines
the weight evenly from side to side.
(minimum tread depth), if the tire has a
Check the condition and pressure of
nail or glass fragments in it, or if the
your tires. NEVER OVERLOAD
sidewall is cracked, have a Yamaha
YOUR MOTORCYCLE. Make sure
dealer replace the tire immediately.
6-15
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6-16
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6-17
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6-18
A5-yoko_Blank.fm Page 1 Tuesday, April 8, 2003 11:43 AM
WARNING
It is advisable to have a Yamaha dea- 1 C
ler make this adjustments. c
2 b a
6-19
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6-20
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6-21
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6-22
U5YPE0E0.book Page 22 Wednesday, February 23, 2005 4:22 PM
EAU22793
To check the drive chain slack 1 b
a
1. Place the motorcycle on the cen- 3
terstand. 4
2. Shift the transmission into the neu-
1. Drive chain slack 1. Axle nut
tral position.
2. Lock nut
3. Spin the rear wheel several times 4. Measure the drive chain slack as
3. Adjusting nut
to locate the tightest portion of the shown.
4. Alignment mark
drive chain.
Drive chain slack: EAU22822
20.030.0 mm (0.781.18 in) To adjust the drive chain slack 6
5. If the drive chain slack is incorrect, 1. Loosen the brake pedal free play
adjust it as follows. adjusting nut, the axle nut, and the
chain puller locknut at each end
of the swingarm.
6-23
U5YPE0E0.book Page 23 Wednesday, February 23, 2005 4:22 PM
6 ECA10571
TIP : WARNING
Using the alignment marks on each After adjusting the brake pedal free
side of the swingarm, make sure that play, check the operation of the
both chain pullers are in the same posi- brake light.
tion for proper wheel alignment.
6-24
U5YPE0E0.book Page 24 Wednesday, February 23, 2005 4:22 PM
NOTICE:
The drive chain must be lubricated
after washing the motorcycle and
riding in the rain or riding in the wet The operation of all control cables and
area. the condition of the cables should be
checked before each ride, and the ca- 6
1. Clean the drive chain with kerosene bles and cable ends should be lubricat-
and small soft brush. NOTICE: To ed if necessary. If a cable is damaged
prevent damaging the O-rings, or does not move smoothly, have a
do not clean the drive chain with Yamaha dealer check or replace it.
steam cleaners, high-pressure wa- WARNING ! Damage to the outer
shers or inappropriate solvents. sheath may interfere with proper ca-
[ECA11121] ble operation and will cause the
2. Wipe the drive chain dry. inner cable to rust. Replace a dama-
ged cable as soon as possible to
prevent unsafe conditions. [EWA10721]
6-25
A5-yoko_Blank.fm Page 1 Tuesday, April 8, 2003 11:43 AM
Recommended lubricant: Checking and lubricating the Checking and lubricating the
Engine oil brake and shift pedals brake and clutch levers
EAU23111
The operation of the brake and shift The operation of the brake and clutch
6 pedals should be checked before levers should be checked before
each ride, and the pedal pivots should each ride, and the lever pivots should
be lubricated if necessary. be lubricated if necessary.
6-26
U5YPE0E0.book Page 25 Wednesday, February 23, 2005 4:22 PM
Recommended lubricant:
Lithium-soap-based grease
Recommended lubricant:
Lithium-soap-based grease (all-pur-
pose grease)
The operation of the centerstand and
6
sidestand should be checked before
each ride, and the pivots and metal-to-
metal contact surfaces should be lubri-
cated if necessary.
EWA10740
WARNING
If the centerstand or sidestand does
not move up and down smoothly,
have a Yamaha dealer check or re-
pair it.
6-27
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6-28
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6-29
ry: lead
Use
ECA10611
Use
only
from
only
distilled
the
distilled
battery.
ECA10610
ways shield your eyes when NOTICE:
working near batteries. In case
Use only distilled water, as tap water
of contact, administer the fol-
1 contains minerals that are harmful
lowing FIRST AID.
to the battery.
EXTERNAL: Flush with plenty
2 of water. 5. Check and, if necessary, tighten
INTERNAL: Drink large quan- the battery lead connections and
tities of water or milk and im- correct the breather hose routing.
1. Maximum level mark
mediately call a physician. 6. Instal the panel.
EYES: Flush with water for 15
2. Minimum level mark
minutes and seek prompt
4. If the electrolyte is at or below the medical attention.
minimum level mark, Batteries produce explosive hy-
Add distilled water to raise the drogen gas. Therefore, keep
electrolyte to the maximum level sparks, flames, cigarettes, etc.,
6 mark. NOTICE : Use only distilled away from the battery and pro-
water, as tap water contains mine- vide sufficient ventilation when
rals that are harmful to the battery. charging it in an enclosed
[EWA10770]
space.
Take care not to spill electrolyte
WARNING EWA10770
6-30
s.
.
6-31
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6-32
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6-33
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6-34
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6-35
U5YPE0E0.book Page 35 Wednesday, February 23, 2005 4:22 PM
TIP :
When tightening the axle nut, hold the
wheel axle with a wrench to keep it from
turning.
5. Tighten the axle nut to the speci- To remove the rear wheel
EWA10821
fied torque. WARNING
WARNING
6-36
U5YPE0E0.book Page 35 Wednesday, February 23, 2005 4:22 PM
6. Remove the brake pedal free play To install the rear wheel
adjusting nut, and then disconnect 1. Insert the wheel axle from the left-
the brake rod from the brake cam- hand side, and then install the wa-
shaft lever. sher and axle nut.
7. Remove the axle nut and the wa- 2. Install the drive chain onto the rear
sher, and then pull the wheel axle sprocket.
out. 3. Lower the rear wheel so that it is
TIP : on the ground, and then put the
Do not remove the washer on the right sidestand down.
side of the wheel axle so as to not 4. Install the brake rod onto the brake
lose it. camshaft lever, and then install the
1. Brake camshaft lever brake pedal free play adjusting nut
2. Brake pedal free play adjusting nut
8. Push the wheel forward, and then onto the brake rod.
3. Brake torque rod nut and bolt
remove the drive chain from the 5. Connect the brake torque rod to 6
4. Brake rod
5. Washer and Axle nut rear sprocket. the brake shoe plate by installing
TIP : the bolt and the nut, and then tigh-
3. Loosen the brake torque rod nut at The drive chain does not need to be ten the nut to the specified torque.
the brake shoe plate. disassembled in order to remove and
4. Disconnect the brake torque rod install the wheel. Tightening torques:
from the brake shoe plate by remo- Brake torque rod nut:
ving the cotter pin, the nut, the wa- 19 Nm (1.9 mkgf, 14 ftlbf)
9. Remove the wheel.
sher and the bolt.
5. Place the motorcycle on the center-
stand.
6-37
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6-38
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Troubleshooting charts
WARNING
Keep away open flames and do not smoke while checking or working on the fuel system.
1. Fuel There is
Check the compression.
enough fuel.
Check the fuel level in
the fuel tank.
There is The engine does not start.
Supply fuel.
no fuel. Check the compression.
2. Compression
There is compression. Check the ignition.
Operate the
electric starter or the 6
kickstarter. Have a Yamaha dealer
There is no compression.
check the vehicle.
3. Ignition Wipe off with a dry cloth and correct the Open the throttle halfway and
Wet
spark plug gap, or replace the spark plug. operate the electric starter.
Remove the spark plug
and check the electrodes.
The engine does not start.
Dry Have a Yamaha dealer check the vehicle.
Check the battery.
6-39
U5YPE0E0.book Page 1 Wednesday, February 23, 2005 4:22 PM
EAU26000
ucts onto seals, gaskets, sprock- cleaning products, solvent or
Care ets, the drive chain and wheel thinner, fuel (gasoline), rust re-
While the open design of a motorcycle axles. Always rinse the dirt and de- movers or inhibitors, brake flu-
reveals the attractiveness of the tech- greaser off with water. id, antifreeze or electrolyte.
nology, it also makes it more vulnera- Do not use high-pressure wash-
ble. Rust and corrosion can develop Cleaning
ECA10770
ers or steam-jet cleaners since
even if high-quality components are they cause water seepage and
used. A rusty exhaust pipe may go un- NOTICE:
deterioration in the following ar-
noticed on a car, however, it detracts Avoid using strong acidic wheel
eas: seals (of wheel and swing-
from the overall appearance of a motor- cleaners, especially on spoked
arm bearings, fork and brakes),
cycle. Frequent and proper care does wheels. If such products are
electric components (couplers,
not only comply with the terms of the used on hard-to-remove dirt, do
connectors, instruments,
warranty, but it will also keep your not leave the cleaner on the af-
switches and lights), breather
motorcycle looking good, extend its life fected area any longer than in-
hoses and vents.
and optimize its performance. structed. Also, thoroughly rinse
For motorcycles equipped with
the area off with water, immedi-
a windshield: Do not use strong
Before cleaning ately dry it, and then apply a cor-
cleaners or hard sponges as
7 1. Cover the muffler outlet with a rosion protection spray.
they will cause dulling or
plastic bag after the engine has Improper cleaning can damage
scratching. Some cleaning com-
cooled down. windshields, cowlings, panels
pounds for plastic may leave
2. Make sure that all caps and covers and other plastic parts. Use only
scratches on the windshield.
as well as all electrical couplers a soft, clean cloth or sponge
Test the product on a small hid-
and connectors, including the with mild detergent and water to
den part of the windshield to
spark plug cap, are tightly in- clean plastic.
make sure that it does not leave
stalled. Do not use any harsh chemical
any marks. If the windshield is
3. Remove extremely stubborn dirt, products on plastic parts. Be
scratched, use a quality plastic
like oil burnt onto the crankcase, sure to avoid using cloths or
polishing compound after
with a degreasing agent and a sponges which have been in
washing.
brush, but never apply such prod- contact with strong or abrasive
7-1
U5YPE0E0.book Page 2 Wednesday, February 23, 2005 4:22 PM
and insects will come off more easily if 1. Dry the motorcycle with a chamois WARNING
the area is covered with a wet cloth for or an absorbing cloth. Make sure that there is no oil or
a few minutes before cleaning. 2. Immediately dry the drive chain wax on the brakes or tires. If
and lubricate it to prevent it from necessary, clean the brake
After riding in the rain, near the sea or rusting. discs and brake linings with a
on salt-sprayed roads 3. Use a chrome polish to shine regular brake disc cleaner or ac-
Since sea salt or salt sprayed on roads chrome, aluminum and stainless- etone, and wash the tires with
during winter are extremely corrosive in steel parts, including the exhaust warm water and a mild deter-
combination with water, carry out the system. (Even the thermally in- gent.
following steps after each ride in the duced discoloring of stainless- Before operating the motor-
rain, near the sea or on salt-sprayed steel exhaust systems can be re- cycle test its braking perfor-
roads. moved through polishing.) mance and cornering behavior. 7
TIP : 4. To prevent corrosion, it is recom-
Salt sprayed on roads in the winter may mended to apply a corrosion pro- ECA10800
7-2
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7-3
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7-4
U5YPE0E0.book Page 1 Wednesday, February 23, 2005 4:22 PM
SPECIFICATIONS
EAU26320
8-1
U5YPE0E0.book Page 2 Wednesday, February 23, 2005 4:22 PM
SPECIFICATIONS
Chassis: Front suspension:
Frame type: Rear: Type:
Double cradle 200 kPa (29 psi) (2.00 kgf/cm) Telescopic fork
Caster angle: Loading condition:
Spring/shock absorber type:
25.3 100 kg - Maximum load
Coil spring/oil damper
Front:
Trail: Wheel travel:
85.0 mm 200 kPa (29 psi) (2.00 kgf/cm)
140.0 mm
Rear:
Front tire: Rear suspension:
225 kPa (33 psi) (2.25 kgf/cm)
Type: Type:
With tube
Front wheel:
Swingarm (Monocross suspension)
Wheel type:
Size: Spring/shock absorber type:
Casting wheel
80/100-18 47P Coil spring/oil damper
Rim size:
Manufacturer/model: Wheel travel:
18x1.60
IRC/NR65 100.0 mm
Rear wheel:
Rear tire: Electrical system:
Wheel type:
Type: Ignition system:
Casting wheel
With tube DC. CDI
Rim size:
Size: Charging system:
18x2.15
100/90-18 56P CDI magneto
Front brake:
Manufacturer/model: Battery:
Type:
IRC/NR65 Model:
Single disc brake
Loading: GM 7B-4B/YB 7B-B
Operation:
Maximum load:
Right hand operation
Voltage, capacity: 8
180 kg (397 lb) 12 V, 7,0 Ah
Recommended fluid:
(Total weight of rider, passenger, cargo
DOT 3 or 4
Headlight:
and accessories) Bulb type:
Rear brake:
Tire air pressure (measured on cold Halogen bulb
Type:
tires): Drum brake
Bulb voltage, wattage quantity:
Loading condition: Headlight:
Operation:
up to 100 kg 12 V, 35 W/36.5 W 1
Right foot operation
Front: Tail/brake light:
200 kPa (29 psi) (2.00 kgf/cm) 12 V, 5.0 W/21.0 W 1
8-2
U5YPE0E0.book Page 3 Wednesday, February 23, 2005 4:22 PM
SPECIFICATIONS
Front turn signal light:
12 V, 10.0 W 2
Rear turn signal light:
12 V, 10.0 W 2
Position light:
12 V, 3.4 W 1
Meter lighting:
12 V, 3.4 W 2
Neutral indicator light:
12 V, 3.4 W 1
High beam indicator light:
12 V, 3.4 W 1
Turn signal indicator light:
12 V, 3.4 W 2
Fuse:
Fuse:
15 A
8-3
U5YPE0E0.book Page 1 Wednesday, February 23, 2005 4:22 PM
EAU26343
CONSUMER INFORMATION
EAU26390 EAU26410
EAU26360
9-1
U5YPE0E0.book Page 2 Wednesday, February 23, 2005 4:22 PM
CONSUMER INFORMATION
EAU26440
9-2
U5YPE0E0.book Page 5 Wednesday, February 23, 2005 4:22 PM
YAMAHA INDONESIA MOTOR MANUFACTURING
PRINTED IN INDONESIA