--~----" ~VAMAHA A. Read this manual carefully before operating this vehicle . • , .. OWNER'S MANUAL 8199-E1 http://mototh.
,1) .~" SPO YS199 __ EI,book Page 1 Tlm rscb y January 15, 2009 1 10 PM I . -" i\ .1It.., .,, ( Ct " & Read this manual carefully before operating this vehicle. This manual should stay with this veh icle if it is sold. --.- 1 http://mototh.
IiiI ;" .... \ I. ••. / INTRODUCTION Welcome to the Yamaha world of motorcycling! As the owner of the AT135, you are benefiting fro m Yamaha's vast experience and newest technology regarding the design and manufacture of high-quality prod ucts, wh ich have earned Yamaha a reputation for dependability. Please take the time to read this manual thorou ghly, so as to enjoy all advantages of your AT135.
~ - 1' 1 1 ~ _._~__ _ ---(~~) . IMPORTANT MANUAL INFORMATION EAU10 132 Particularly important information is distingu ished in this manual by the following notations: This is the safety alert symbol. 11 is Llsed to alert you t o potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possibl1e injury or death. ~WARNING A WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.
-k (:1)--I__ IMPORTANT MANUAL INFORMATION EAUJ7430 AT135 OWNER'S MANUAL ©2008 by Thai Yamaha Motor Co., Ltd. 1st edition, October 2008 All rights reserved. Any reprinting or unauthori zed use without the written perm ission of Thai Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Thailand. http://mototh.
sro ( , (1; I 1'> FSl99 _El book Page I Thu"day , January 15,2009 1:1 0 PM ...... \ ' TABLE OF CONTENTS LOCATION OF IMPORTANT LABELS """""""""""""""""""""""""""""""" ""' " 1- 1 FOR YOUR SAFETY - PREOPERATION CHECKS ........ "" SAFETY INFORMATION ........ .. ""."" "",2-1 Hel mets """" """"" """" """"",., .. ... " .. "." .. 2-5 OPERATION AND IMPORTANT RIDING POINTS ........ ... .................... .. 6-1 Starting a cold engine ... " ..... . ... ..... 6-1 Starting off .......... .......... ... .......
5 PO_F SI 99 Ef .boo k Pagc2 Th ursday , January 15,2009 l I Q PI\·1 .. \ \ • •- ,i { --.--' TABLE OF CONTENTS Replacing the tail/brake lig ht bulb .... ...... ........................ .7-31 Replacing a turn signal lig ht bulb .......... ... ................. ......7-32 Replacing a front turn signal light bulb ....... ...... ............. .......... 7-33 Replacing an auxiliary ligh! bulb ................................. .......... 7-33 Troubleshooting .. .. ....... ............. ....
(~) 5PO FS 1
( " ... " ~."j ill SAFETY INFORMATION El\UH1313 (~) Be a Responsible Owner As tt1e vehicle' s owner, you a re responsible for the safe and proper operation of your motorcycle. Motorcycles are single-t rack vehicles. Their safe use and operation are dependent upon the use of prope r riding techniques as well as the expertise of the operator. Every operator should know the following requirements before riding this motorcycle.
ill SAFETY INFORMATION • the operator is veering wide on a turn due to excessive speed or undercornering (insufficient lean angie for the speed). • Always obey the speed limit and never travel faste r than warranted by road and traffi c conditions. • Always signal before turning or changing lanes. Make sure that other motorists can see you. • The posture of the operator and passenger is important for proper control.
/1' 1-+....'\ -I \l--i 5PO ___ FS I99 _EI.book Page :' r hursday , J an ua ry 15 , 2009 1 i O P r-., ,1 ill SAFETY INFORMATION • Do not ru n engine indoors. Even if you try to ventilate engine exhaust with fans or open windows and doors, carbon monoxide can rapidly reach dangerous levels. • Do not run engine in poorly ventilated or partially enclosed areas such as barns, garages, or carports.
, ( ~'~. .1 I '-f.. . \~~J 5PO_F8 199_ 1·: l. hook Page 4. Th ursday. Janua ry 15,2009 I 10 PI\·! • Aftermarket Parts, Accessories, and Modificatio ns While you may find aftermarket products similar in design and quality to genuine Yamaha accessories, recognize that some aftermarket accessories or modifi cations are not suitable because of potential safety hazards to you or othe rs.
I ,~ ··.J···I I ill SAFETY INFORMATION provide the best combination of handling, braking , and comfort. Other tires, rims, sizes , and combinations may not be appropriate. Refer to page 7 -18 for tire specifications and more information on replacing your tires. EAUU0030 Helmets Operating this ve hicle without an approved motorcycle helmet increases you r chances of a seve re head injury or death in the event of an accident.
I·" \ •• ;.! ( ... 1I i ~". 'i 5PO_ F8 199_ FI book Page 6 Thursday , January 15,2009 {.I O PI'\"1 ", 1• • • '",--~ ..... : f & SAFETY INFORMATION Types of helmets and thei r usage • Half-type use only for riding at low speeds • • FUll-type: use only for riding at low to mid-range speeds • Full-face-type: use for riding at mid-range to high speeds 2-6 http://mototh.
-41{~ I -r----~-:-~ -Ef)-SPOfSI99_Elbook Page I Thursday, January 15,2009 110 PM DESCRIPTION EAU10410 left view J 2 4 6 7 5 i i -~~ I 12 11 ZAUU0345 1. 2. 3. 4. 5. 6. HeadlighUauxiliary lights (page 7-30, 7-33) Front tum signal lights (page 7-33) Convenience hook (page 4-10) Throttle stop screw (page 7-16) Owner's tool kit (page 7-1) Tail/brake light (page 7-31) . 11t - 8 7. Rear tum signal lights (page 7-32) 8. Kickstarter (page 4-9) 9. Engine oil drain bolt A (page 7-9) 10.
E!), - -~~jl -SPOF8199 - El.book Page 2 Thursday, January 15,2009 1:10PM e t DESCRIPTION EAU 10420 Right view 1 2 3 4 5 6 7 8 ZAUU0346 1, 2. 3. 4_ 5. 6. 7. 8. Fuel tank cap (page 4-6) Fuse/starter relay (page 7-29) Storage compartment (page 4-11 ) Battery (page 7-28) Seat lock (page 4-9) Front brake fluid reservoir (page 7-22) Coolant reservoir (page 7-12) Dipstick (page 7-9) I I --(f;- eJ lt - 3-2 http://mototh.
DESCRIPTION )ls and instruments 1 2 345 6 7 oJf,L- - a + ZAUU03oI7 rake lever (page 4-6) rlCIebar switches (page 4-5) luge (page 4-4) ;meIer (page 4-3) coolant temperature gauge/odometer (page 4-4) andlebar swrtches (page 4-5) rake lever (page 4-5) Nitchlsteering lock (page 4-1 ) http://mototh.com I .
-4l ~ ,t INSTRUMENT AND CONTROL FUNCTIONS To lock the steering ~ Main switch/steering lock ON All electrical circuits are supplied with power, and the engine can be started. The key cannot be removed. TIP ________~~~--~ The headlight, auxiliary lights, meter lighting and taillight come on automatically when the engine is started. The main switch/steering lock controls the ignition and lighting systems, and is used to lock the steering, and is used to open the seat also.
-@ INSTRUMENT AND CONTROL FUNCTIONS I To unlock the steering tum the key to the lett to open the cov- Keyhole cover er. 2 To close the keyhole cover 1 Insert the key and turn it to "OFF". 1. Ignition key 2 . Salely key To open the keyhole cover Insert the key head into the keyhole cover receptacle as shown, and then tum the key to the right to close the cover. Insert the key head into the keyhole cover receptacle as shown, and then 4-' -t -- http://mototh.
~,~)l~_. €>,, If INSTRUMENT AND CONTROL FUNCTIONS £AU""'" Indicator and warning lights EAU1l484 Engine trouble warning light "6" This warning light comes on if a problem is detected in the electrical circuit monitoring the engine. If this occurs, have a Yamaha dealer check the selldiagnosis system. The electrical circuit of the warning light can be checked by turning the key to "ON The warning light should come on for a few seconds, and then go off.
(~) INSTRUMENT AND CONTROL FUNCTIONS Fuel gauge 1 2 np~~~~~~~~~~~~ Do not allow the fuel tank to empty itself completely. Digital coolant temperature gauge/odometer ~ e.·u~ . ' GG - GG/A 3 ~ . UU~3S7 ~ 1. Fucl gauge • 21 I 2. Fuel gauge needle 1 Digital cooIant lemperature gauge 3. Red 2:onc 2_ Digital odometer The fuel gauge indicates the amount of fuel in the fuel tank.
INSTRUMENT AND CONTROL FUNCTIONS Handlebar switches Left 1:::---'::: ? 1. Dimmer switch " 101110 " Tum signal switch "9/ 9" To signal a rig,t-hand tum, push this switch to " 0 ", To signal a left-hand lum , push this switch to ~ ¢ ". When released, the switch returns to the center posllion. To cancel the tum signal lights, push the switch in after it has returned to the center position. 2. Tum signal switch "0/0" 3. Horn switch " Ioo:r ' Right Horn switch " Ioo:r " Press this switch to sound the hom .
(!l I INSTRUMENT AND CONTROL FUNCTIONS To install the fuel tank cap Fuel tank cap Rear brake lever 1 ./1 1 Rear brake lever The rear brake lever is located on the left handlebar grip. To apply the rear brake, pull this lever toward the handlebar grip. 1. Fuel tank cap a. Open. b. Close. To remove the fuel tank cap 1. Open the seat. (See page 4-9.) 2. Tum the fuel lank cap counlerck>ckwise and pull it off. ! -$ • !lrr- 4-6 http://mototh.com 1.
INSTRUMENT AND CONTROL FUNCTIONS """''''2 Fuel r 1~ ""=~ 1. Fuel tank filler tube I 4)- 2. Fucl ievcl 2 I / " " Make sure there is sufficient gasoli ne in the tank. f WAH)$$l A WARNING Gasoline and gasoline vapors are extremely flammable. To avoid fires and explosions and to reduce the risk of injury when refueling, follow these instructions. 1. Before refueling, tum off the engine and be sure that no one is sitting on the vehicle.
99 ] 1.b<>oI< PaS" ~ n ,ursdoy. Jan .... ')' 15. 2009 1.111 PM INSTRUMENT AND CONTROL FUNCTII m filling with gasohol, cold engine rting may be difficult. Therefore, be e 10 follow the procedures in UStarta cold engine H • EC,""",,'" IT/CE ing gasohol may cause engine uble depending on the engine. If .ohol is used and engine trouble :urs, contact your Yamaha dealIS soon as possible_ Catalytic converter fA"""'" This model is equipped with a catalytic converter in the exhaust system.
--4 q=~ I!l i) INSTRUMENT AND CONTROL FUNCTIONS Kickstarter To close the seat Seal To open the seat 1. Place the motorcycle on the centerstand. 2. Insert the key into the main switch, and then tum it counterclockwise 1. Fold the seat down, and then push it down to lock it in place. 2. Remove the key from the main switch if the motorcycle will be left unattended. np ____~~--~----~_ Make sure that the seat is properly secured before riding. to "QPEW. 1. Kickstarter .
I . .,I ~', ~ -~ I'O- - F8 199 E Lb<:><>l P.gclO ' 'Itomdoy, JanuaryI S.2009 I. IOP,"" INSTRUMENT AND CONTROL FUNCTIONS Helmet holders I 11' To release a helmet from a helmet holder Open the seat. remove the helmet from the helmet holder, and then close the seat. Convenience hook 1. Corwenience hook 1. Helmel holder The helmet holders are located under the seat. . . WARNING • Do not exceed the load limit of 1.0 kg (2.2 Ib) for the conve- To secure a helmet to a helmet holder 1. Open the seat.
( ~) INSTRUMENT AND CONTROL FUNCTIONS E C~ "'o"" Storage compartment I. Storage compartment 2. Cover There is a storage compartment equipped with a lid under the seat. (See page 4-9 for seat opening and closing procedures.) . . WARNING • Do not exceed the load limit of 5.0 kg (11.0 Ib) for the storage compartment. • Do not exceed the maximum load of 160 kg (353Ib) for the vehicle. Keep the following points in mind when using the storage compartment.
, ·J)I~ ~- -{~ --:'\':,":} 5POf8199_El.book Page I Thursday, January 15, 2009 1:10 PM (~) FOR YOUR SAFETY - PRE-OPERATION CHECKS I 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 A WARNING Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equipment damage.
1 - (~:r·--5PO-"8 1 99 _E l.book t i Page 2 Thursday, January 15,2009 110 PM FOR YOUR SAFETY - PRE-OPERATION CHECKS ITEM CHECKS Rear brake Throttle grip • Make sure that operation is smooth. • Check cable free play. • If necessary. have Yamaha dealer adjust cable free play and lubricate cable and grip housing. Control cables • Make sure that operation is smooth. • Lubricate if necessary. Wheels and tires • • • • Brake levers • Make sure that operation is smooth.
i $ ''''f''''_ ''''' ~,< , ,,,,,,,,,,,,~.., ,,,,,,, ,,'''M -- OPERATION AND IMPORTANT RIDING POINTS EAVT1IOI Starling a cold engine Read the Owner's Manual carefully to become familiar with all controls. If there is a control or function you do not understand, ask your Yamaha dealer. A WARNING Failure to familiarize yourseH with the controls can lead to loss of control, which CQuid cause an accident or injury.
@ I OPERATION AND IMPORTANT RIDING POINTS fAtu.... £AU .." , Starting off Acceleration and deceleration TIP Before starting off, allow the engine to uu,~ Braking Front 1 warm up. 1. While pulling the rear brake lever with your left hand and hokling the -, , grab bar with your right hand, push the scooter off the centerstand. 2. Sit astride the seal, and then adjust the rear view mirrors. 3. Switch the tum signals on. 4.
- 41• ~ (-!) WOJ 8 199. t l bo.:>/; P.gc ) Th....wy. January l '.20()9 I 1(1 I'M @ I OPERATION AND IMPORTANT RIDING POINTS A • • • • WARNING Avoid braking hard or suddenly (especially when leaning over to one side), otherwise the scooter may skid or overturn. Railroad crossings, streetcar rails, iron plates on road construction sites, and manhole covers become extremely slippery when weL Therefore, slow down when approaching such areas and cross them with caution.
OPERATION AND IMPORTANT RIDING POINTS 0--150 km (C}-9() mil Avoid prolonged operation above 314 throttle. 150-500 km (90-300 mil 150-500Km 1/2 Avoid prolonged operation above 113 throttle . After every hour of operation, stop the engine, and then let it cool for five to len minutes. Vary the engine speed from time to lime. Do not operate the engine al one set throttle position. Avoid prolonged operation above 1/2 throttle.
(~+5POf8199_ELbook - Page 5 Thursday , January 15,2009 110 PM t .... OPERATION AND IMPORTANT RIDING POINTS -+~) L._ ~ t EAU17213 Parking When parking, stop the engine, and then remove the key from the main switch. EWA10311 A WARNING • Since the engine and exhaust system can become very hot, park in a place where pedestrians or children are not likely to touch them and be burned.
-~4 1 'f @ ! OPERATION AND IMPORTANT RIDING POINTS EAW .... ' General note Much can be gained from the correct use and maintenance 01a motorcycle. 1. THE CUSTOMERS CAN USE THE FULLEST POTENTIAL OF YAMAHA MOTORCYCLES 2. A MOTORCYCLE CAN KEEP ITS PERFORMANCE CAPABILITY FOR A lONGEATIME Compariso n of wear on engine parts (piston, piston ring. cylinder, etc.) HX)'. Wilt! maintenance _ ( ~Q:Q ~ .~ WithOllI O ~~ maintenance ~ G ~ °<)<> &8 c <>~ Q<> .~~~----~.
OPERATION AND IMPORTANT RIDING POI 3. FUEL COST AND REPAIR EXPENSES CAN BE KEPTTO A MIN IMUM Distance covered (km) I @ 4. A MOTORCYCLE CAN DEMAND A HIGH PRICE WHEN IT IS TRADED IN AS A USED PRODUCT ~ Cu stomer·s running cost (fuel cosl plu s maintenance and repair e)(pen ses) W,thout maintenance t 5 (3ig repairs at higher expenses <;).,<=>°<>0 U 0 ,,0 0 000 0 00 ., ~ '" '" '" '" '" Witt1 maintenance {} "'" Distance covered (km) ~ 6-7 http://mototh.
@ I PERIODIC MAINTENANCE AND ADJUSTMENT Periodic inspection, adjustment , and lubrication will keep your vehicte in the salest and most efficient condition possible. Safety is an obligation of the vehicle owner/operator. The most important points of vehicle inspection. adjustment , and lubrication are explained on the following pages. The intervats given in the periodic maintenance and lubrication chart should be simply considered as a general guide under normal riding conditions.
e 1-i+--ci1apter7.fu, Page 2 Monday. January --(tJi e 19.2009 4:07 PM if PERIODIC MAINTENANCE AND ADJUSTMENT EAU46880 TIP ______________________ ~ _______________________________________________________ • The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead. • From 16000 km , repeat the maintenance intervals starting from 4000 km.
{~) '--v 5POJ8199_ELbook Page 3 Thursday, January 15,2009 1:10 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAUU0091 General maintenance and lubrication chart ODOMETER READING (km) ITEM NO. 1 Air filter element 2 V-belt case air filter element 3 4 5 6 7 8 9 10 11 CHECK OR MAINTENANCE JOB • Check condition. 1000 4000 -J -J 7000 10000 13000 -J -J ANNUAL CHECK -J • Replace. Every 16000 km (10000 mil • Clean. -J ,j -J -J Battery -J ,j ~ -J -J · • Check battery voltage.
---4lj~ i ,--j., -(~}'-5POf8 1 99_E lbook Page4 Thursday , January 15, 2009 I 10 PM PERIODIC MAINTENANCE AND ADJUSTMENT NO. 12 13 · · 14 15 16 · · 17 18 19 · · 20 21 · 22 · 23 24 25 ITEM Steering bearings CHECK OR MAINTENANCE JOB • Check bearing play and steering for roughness. ODOMETER READING (km) 1000 4000 .,j .,j • Lubricate with lithium-soap-based grease. 7000 10000 13000 .,j ..J ANNUAL CHECK .
I I - I I 1-®sPi5j8 199_E l. book PageS Thursday, January\S ,2009 1:10PM -~ --r-- ~ t PERIODIC MAINTENANCE AND ADJUSTMENT EAUI 8660 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.
--®I r' • PERIODIC MAINTENANCE AND ADJUSTMENT Removing and installing cowlings and panels The cowlings and panels shown need to be removed to per10rm some of the maintenance jobs described in this chapter. Refer to this section each time a cowling or panel needs to be removed and installed. To install the cowling Place the cowling in the original position, and then install the screws.
i ' ~ JJ4- SPO_Hl99_e l bool ~ r.8~ 7 Thllnd.y . January 1 ~.2009 -~l~ 1:10 PM t @, ,, PERIODIC MAINTENANCE AND ADJUSTMENT Panels A and B To remove one of the panels To install the panel Place the panel in the original position , and then install the screw. Remove the screw, and then pull the panel off as shown. I. Screw (x4) To install the cowling 1. Place the cowling in the original position, and then install the bolts and screws. 2. Inslall cowlings A and B. + 1. Panel B 2.
, -(.?) ~) PERIODIC MAINTENANCE AND ADJUSTME I stead, have a Yamaha dealer ( the vehide. Checking the spark plug The spark plug is an important engine 2. Check the spark plug for elec erosion and excessive carbl other deposits, and replace necessary. component, which is easy to check. Sinee heat and deposits will cause any spark plug to slowly erode, the spark plug should be removed and checked in accordance with the periodic maintenance and lubrication chart.
~ ! (~) \a~. Jo,,1U/)" 51'0 1'8 1'"19 £ 1 book Pogc'l Th ...... IS.!OO9 1101',,", PERIODIC MAINTENANCE AND ADJUSTMENT ~, Spark plug gap: 0.7-0.8 mm (0.027-0.031 in) , , 2. Clean the surlace of the spark plug gasket and its mating surface, and then wipe off any grime from the sparK plug threads. 3. Install the spark plug with the spark plug wrench , and then tighten it to the specifi ed torque. TIghtening torque: Spark plug: 12.5 Nm (1.25 m·kgl, 9.
+ PERIODIC MAINTENANCE AND ADJUSTMENT 5. Insert lhe dipstick into the oi ll~ ler hole, and then tighten the oil liller cap. dra in bolt, the O·ring , compres· s ion s pring , and oil strainer will fall out. Take care nol to lose these parts. ((CAI100'1 To change the engine oil and clean the oil strainer 1. Start the engine, warm it up for several minutes, and then tum it off. 2. Place an oil pan under the engine ~- , g-2 @- 3 10 collect the used oil. 1. Strainer 2. Compression spring 2 1 I.
-----+-- (~) • SI'(l H I99. E I.booI< I'''lIC II Thuc-.J.>y. Jo ..... ')" IS.2009 1- IOI' M PERIODIC MAINTENANCE AND ADJUSTMENT np ______ ~~~~---- Be sure to wipe off spi11ed oil on any parts after the engine and exhaust system have cooled down. I -f • In order to prevent clutch slippage (since the engine oil also lubricates the clutch), do not m ix any chemical additives. Do not use oils with a diesel specification of " CD" or oils of a higher quality than specified.
(0) . PERIODIC MAINTENANCE AND ADJUSTMENT 6. Refill with the specified amount of the recommended final transmission oil, and then install and tighten the oil filler cap. WARNING! Make sure that no foreign material enters the final transmission case. Make sure that no oil gets on the tire or wheel. {EWA1I 3I1 1 The coolant level should be checked before each ride. In addition. the coolant must be changed at the intervals specified in the periodic maintenance and lubrication chart.
PERIODIC MAINTENANCE AND ADJUSTMENT ant, replace it with coolant as soon as possible, otherwise the cooling system will not be protected against Irost and corrosion. If water has been added to the coolant, have a Yamaha dealer cheek the anti· freeze content of the coolant as soon as possible, otherwise the effectiveness of the coolant will be reduced. IECIo.l""~ np ~__~~~__~~__~__ • The radiator fan switches on when the engine is started and switches off when the engine is stopped.
-""-'y SPOJ 819'lJ: lbook r'!:Ic I4 llt~y. J ... uary IS. 2009 UOPM -@ PERIODIC MAINTENANCE AND ADJUSTMENT ! 2. Remove panel A. (See page 7-6 for panel removal and installation procedures.) 3. Remove the air filter case cover by removing the screws. 4. Remove the air filter element by pulling it out. 1 1. Air filter element (Wet type) 6. Place the air fiher element in its original position. 7. Install the air filter case cover by installing the screws. 8. Install the panel. , ® 1.
PERIODIC MAINTENANCE AND ADJUSTMENT np ~__~~~~~~~~ The element should be wet but not dripping. Recommended oil: Yamaha foam air filter oil or other quality foam air filter oil 7. Install the element into the filter case. 4. Clean the element with solvent, and then squeeze the remaining solvent out. 5. Check the element for damage and replace it if necessary. 6. Apply oil of the recommended type to the entire surface of the element, and then squeeze the excess oil out.
~JJ ~J8199_EI boo!< Page 16 TlIUfod>.y. J ... lUJ}' IS . 2009 I. IOI'M J (~, PERIODIC MAINTENANCE AND ADJUSTMENT I ~ Adjusting the carburetor The carburetor is an important part of the engine and requires very sophisticated adjustment. Therefore. most carburetor adjustments should be left to a Yamaha dealer. who has the necessary professional knowledge and experience. The adjustment described in the following section, however, may be serviced by the owner as part of rou tine maintenance.
PERIODIC MAINTENANCE AND ADJUSTMENT ( A U~"'7~ Adjusting the throttle cable free play ~ / I 2. To increase the IhroWe cable free play, tum the adjusting nut in direction (a). To decrease the throt- tle cable free play, tum the (~lb)~~!l'-L:;;;;;;':;-iJ) , -@ 1. loosen the locknut. adjusting nut in direction (b). 3. Tighten the locknut. 2 1. Thronle cable free play adjusting nut 2. Locknut 3. Cable cover c. ThroCUe cable free play The throttle cable free play should measure 3.0-7.0 mm (0.
~ (co) PERIODIC MAINTENANCE AND ADJUSTMENT ! Tires To maximize the perfonnance, durability, and safe operation of your motorcycle, note the following points regarding the specified tires. Tire air pressure The ti re air pressure should be checked and, if necessary, adjusted before each ride. EV/Al ",",' A WARNING Operation of this vehicle with improper tire pressure may cause severe injury or death from loss of control. • The tire air pressure must be checked and adjusted on cold tires (i.e.
, I I $ s1'O]8 199. E I,boo/; ?gc 1'1 lhur«lay . 13IIuMy IS, 2009 1:10 I'M PERIODIC MAINTENANCE AND ADJUSTMENT Minimum tire tread depth (front and rear): 1.0 mm (0.04 in) TIP -0----:---:-:---::-::---::-----;:::;The tire tread depth limits may differ from country to country. Always comply with the local regulations.
!-!) SPOjSI99~l:i l.booI: I'ag~ 2(} ThursJ.y, Janu:lJ)' l'i , 2009 1:10 PM PERIODIC MAINTENANCE AND ADJUSTMENT Wheels To maximize the perfonnance, durability, and safe operation of your motorcycle, note the following points regarding the specified wheels. • The wheel rims should be checked lor cracks, bends or warpage, and the spokes for looseness (for spoke wheel model) or damage before each ride. II any damage is found, have a Yamaha dealer replace the wheel.
PERIODIC MAINTENANCE AND ADJUSTMENT suit in loss of control and an accide nt. [Au."", Adjusting the rear brake lever free play 1 """"'" '--'---t'- 1. Rear brake IeVCf free play The brake lever free play should measure 10.0-20.0 mm (0.394-0.787 in) as shown. Periodically check the brake lever free play and. if necessary, adjust it as follows. To increase the brake lever free play, lum the adjusting nut at the brake shoe plate in direction (a).
Ii J _ ;J~ _ ' POfSI 9'9 -"'1."""'* P.gc22 'fItur.o:by, J-.ary 1$, 200? I 10 PM ! --®- PERIODIC MAINTENANCE AND ADJUSTMENT I ~- Checking the front brake pads and rear brake shoes The front brake pads and the rear brake shoes must be checked for wear at the intervals specified in the periodic maintenance and lubrication chart. peared, have a Yamaha dealer replace the brake pads as a set. ~. Checking the brake fluid level Rear brake shoes Front brake pads i t- 1. Minimum level mark -@ 1.
-4 I l~ T • When checking the fluid level, make sure that the top 01 the master cylinder is level by turning the handlebars. • Use only the recommended quality brake fluid, otherwise the rubber seals may deteriorate, causing leakage and poor braking performance. I -®- f PERIODIC MAINTENANCE AND ADJUSTMENT • As the brake pads wear, it is nor- mal for the brake fluid level to gradually go down. However, if the brake fluid level goes down suddenly, have a Yamaha dealer check the cause.
(~ PERIODIC MAINTENANCE AND ADJUSTMENT I Checking the V-belt The V-be" must be checked and replaced by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart E.oUJ» l1l Checking and lubricating the throttle grip and cable The operation of all control cables and The operation of the throttle grip should be checked before each ride. In addition, the cable should be lubricated at the intervals specified in the periodic maintenance chart.
~i I " \:::J 0'-5PO ~ 8 1 99 EI. ~ f'agcH l lnu'Sday, January 15, 2009 1:10 PM PERIODIC MAINTENANCE AND ADJUSTMENT ~AV232') ~, Lubricating the front and rear brake levers Recommended lubricant: lithium-soap-based grease , The pivoting points of the front and fear brake levers must be lubricated at the intervals specified in the periodic maintenance and lubrication chart.
PERIODIC MAINTENANCE AND ADJUSTMENT Recommended lubricant: Ulhium-soap-based grease Checking the front fork The condition and operation of the front lork must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart. To check the condition Check the inner tubes for scratches, damage and excessive oil leakage. To check the operation 1. Place the vehicle Ofl a level surface and hold it in an upright position.
* ~I-- , (.:!) SPO]& I99 . F. l. book Pise 27 1'bunoday Ja..."ary IS , 2009 u n I'M PERIODIC MAINTENANCE AND ADJUSTMENT Checking the steering Worn or loose steering bearings may cause danger. Therefore, the operation of the steering must be checked as follows at the intervals specified in the pe.riodic maintenance and lubrication 2. Hold the lower ends of the front fork legs and try to move them for- ward and backward. II any free play can be felt, have a Yamaha dealer check or repair the steering.
~ ~-'''''-'' ' ... "" ' " " -" ' •. '~~ry -41 " . ' ''''' , '" '" @ • PERIODIC MAINTENANCE AND ADJUSTMENT I Battery This model is equipped with a VRLA (Valve Regulated Lead Acid) battery. There is no need to check the electrolyte or to add distilled water. However, the battery lead connections need to be checked and, if necessary, tightened. ways shield your eyes when working near batteries. In case of contact, administer the following FIRST AID. • EXTERNAL: Flush with plenty of water.
---4-ll~ f PERIODIC MAINTENANCE AND ADJUSTMENT stant-voltage) battery charger is required. Using a conventional battery charger will damage the battery. If you do not have access to a con· stant-voltage battery charger, have a Yamaha dealer charge your bat- tery. 4. After installation , make sure that the battery leads are properly connected to the battery terminals. Replacing the fuse TlCE Always keep the battery charged.
PERIODIC MAINTENANCE AND ADJUSTMENT 6. Instali lhe starter relay cover by installing the screw. 7. Tum the key to ~ONM and tum on the electrical circuits to check if the devices operate. 8. If the fuse immediately blows again, have a Yamaha dealer check the electrical system. ~Lay ave the blown fuse, and then II a new fu se of the specified ~ rage . WARNING! Do not a fuse of a higher amperrating than recommended avoid causing extensive age to the electrical sysand possibly a fire. 1I="~ ' SI"1 I'.M.
PERIODIC MAINTENANCE AND ADJUSTMENT ~" 1. Place the motorcycle on the cen· tersland. 2. Remove cowling C. (See page 7-6 for removing procedure.) Replacing the taillbrake light bulb 1. Open the seal. (See page 4-9.) 2. Remove the panel by removing the screws, and then pulling the panel outward. 1. Headlight but> holder 5. Place a new bulb into position, and then secu re it with the bulb holder. i -
@ - f""POjll99_"I .booI.: Ptgdl n......s.y. J-.wy IS. 2009 1 10 PM PERIODIC MAINTENANCE AND ADJUSTMENT 5. Insert a new bulb into the socket, push it in. and then tum it clockwise until it stops. 6. Install the socket (together with the bulb) by tuming it clockwise. 7. Install the panel and the seat. -.~ Replacing a tum signal light bulb 1. Tailltlfake Iiglt bub socItet 3. Remove the socket (together with the bulb) by tuming it counterclockwise. 4.
-4·L~!_ (f) PERIODIC MAINTENANCE AND ADJUSTMENT ~ Replacing a front turn signal lighl bulb If a front turn signal light bulb bums out, replace it as follows. 1. Remove cowling A (if replacing the left lurn signal light bulb) or cowling B (if replacing the right tum signallight bulb). (See page 7-6. For 4. Insert a new bulb into the socket. 5. Install the turn signal light socket (together with the bulb) by turning it clockwise . 6. Install the cowli ng. removal and installation procedures.) 2.
PERIODIC MAINTENANCE AND ADJUSTMENT 5. Install the auxiliary light socket (together with the bulb) by turning it clockwise. 6 . Instailihe cowling. Troubleshooting Although Yamaha motorcycles receive a thorough inspection before shipment from the factory, trouble may occurduring operation. Any problem in the fuel, compression, or ignition systems, for example, can cause poor starting and loss of power.
~ : -~4-~ , -ti \~5POjgI99_El.book Page 35 Thursday, January 15, 2009 1:10 PM f PERIODIC MAINTENANCE AND ADJUSTMENT EAU25922 Troubleshooting charts Starting problems or poor engine performance 1. Fuel There is enough lueL Check the luel level in the fuel tank. The engine does not start. Check the compression. There is no fuel. I 2. Compression There is compression, Check the ignition, + Operate the electric starter, There is no compression . • 3.
-(~Ll· PERIODIC MAINTENANCE AND ADJUSTMENT if Engine overheating ( WA."""'l A WARNING • Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury. Be sure to wait until the engine has cooled. • After removing the radiator cap retaining bolt, place a thick rag, like a towel, over the radiator cap, and then slowly rotate the cap counterclockwise to the detent to allow any residual pressure to escape.
. ~.~ ~ '"'_""'_" ""'" ,," , Th....,.,•...., ''"''''" '.''''M ~, I MOTORCYCLE CARE AND STORAGE Care While the open design of a motorcycle reveals the attractiveness of the technology. it also makes il more vulnera- ble. Rust and corrosion can develop even if high-quality components are used. A rusty exhaust pipe may go un- noticed on a car, however, il detracts from the overall appearance of a motorcycle.
I , ~ -@ Sf'O _FS l99 _E Lbvok POSo 2 l1'...-..hy. J",.uary IS. 2009 1.1 0 PM MOTORCYCLE CARE AND STORAGE I 1 I instruments, switches and lights), breather hoses and vents. • For scooters equipped with a windshield: 00 not use strong cleaners or hard sponges as they will cause dulling or scratching. Some cleaning compounds for plastic may leave scratches on the wind· shield. Test the product on a small hidden part of the w indshield to make sure that it does not leave any marks.
MOTORCYCLE CARE AND STORAGE • Before operating the scooter test its braking perfonnance and cornering behavior. OTIC • Apply spray oil and wax sparingly and make sure to wipe off any excess. • Never apply oil or wax to any rubber parts, plastic parts or headlight, taillight and meter lenses, but treat them with a suitable care product • Avoid using abrasive polishing compounds as they will wear away the paint. np ~--~~--~~~~---c • Consuh a Yamaha dealer for advice on what products to use.
MOTORCYCLE CARE AND STORAGE make sure to ground the spark plug electrodes while turning the engine over. t(W""09!i' l 5. I -@ , I 6. 7. 8. e. Remove the spark plug cap from the spark plug, and then install the spark plug and the spark plug cap. Lubricate all control cables and the pivoting points of all levers and pedals as well as of the sideslandJ centerstand. Check and , if necessary, correct the lire air pressure, and then lift the scooter so that both 01 its wheels are off the ground.
SPECIFICATIONS Dimensions; OveraJllengtfl: 1950 mm (76.8 in) Overall widlh: 678 mm (26.7 in) Overall height: 1057 mm {41.6 in) Seat height: 770 mm (30.3 in) Wheelbase: 1290 mm (SO.8 in) Ground clearance: 130mm(5.1 in) Minimum turning radius : 1938 mm (76.3 in) Weight: With oil and fuol: 11 0.6 kg (243.81b) Engine: Engine type: Liquid cooled 4-51roke. SOHC Cylinder arrangement: Forward-inclined single cylinder Displacement: 132.6 cm 3 (8.1 cu.in) Bore x stroke: 54.0 x 57.9 mm (2.13 x 2.
---4 1_ ~_ SPECIFICATIONS Front tire: Type: With l ube (Spoke wheel)! Tutleless (Cast wheel) Size: 70190- 1636P Manufaclurerlmodel: IRCTIIF59 e OUNlOP!Ul 10 M, Dl l OL Rear tire: Type: -
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-4-SPO_F8199_El.bOOk Pagel Tlwrsday, January 15,2009 1:10PM CONSUMER INFORMATION EAU26450 Engine serial number 1. Engine serial number --+i +, l The engine serial number is stamped into the final gear case. I ~ ell't- 10-2 http://mototh.
