Read this manual carefully before operating this vehicle. YAMAHA MOTOR DA AMAZÔNIA LTDA.
U1C617E0.book Page 1 Wednesday, April 14, 2010 10:27 AM EAU10042 Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold.
U1C617E0.book Page 1 Wednesday, April 14, 2010 10:27 AM INTRODUCTION EAU10083 Congratulations on your purchase of the Yamaha TT-R230A. This model is the result of Yamaha’s vast experience in the production of fine sporting, touring, and pacesetting racing machines. It represents the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields. This manual will give you an understanding of the operation, inspection, and basic maintenance of this motorcycle.
U1C617E0.book Page 1 Wednesday, April 14, 2010 10:27 AM IMPORTANT MANUAL INFORMATION EAU10132 Particularly important information is distinguished in this manual by the following notations: This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. WARNING NOTICE TIP A WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.
U1C617E0.book Page 2 Wednesday, April 14, 2010 10:27 AM IMPORTANT MANUAL INFORMATION EAUW0710 TT-R230A OWNER’S MANUAL ©2010 by Yamaha Motor da Amazônia Ltda. 1st edition, June 2010 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor da Amazônia Ltda. is expressly prohibited. Printed in Brazil.
U1C617E0.book Page 1 Wednesday, April 14, 2010 10:27 AM TABLE OF CONTENTS LOCATION OF IMPORTANT LABELS .............................................1-1 FOR YOUR SAFETY – PRE-OPERATION CHECKS ............. 5-1 SAFETY INFORMATION ..................2-1 OPERATION AND IMPORTANT RIDING POINTS................................. 6-1 Starting and warming up a cold engine ......................................... 6-1 Starting a warm engine .................. 6-2 Shifting ...........................................
U1C617E0.book Page 2 Wednesday, April 14, 2010 10:27 AM TABLE OF CONTENTS Front wheel ...................................7-30 Rear wheel ...................................7-31 Troubleshooting ............................7-32 Troubleshooting chart ...................7-33 MOTORCYCLE CARE AND STORAGE ..........................................8-1 Care ................................................8-1 Storage ...........................................8-3 SPECIFICATIONS .............................
U1C617E0.book Page 1 Wednesday, April 14, 2010 10:27 AM LOCATION OF IMPORTANT LABELS EAU10384 1 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.
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U1C617E0.book Page 1 Wednesday, April 14, 2010 10:27 AM SAFETY INFORMATION EAU41465 2 Be a Responsible Owner As the vehicle’s owner, you are responsible for the safe and proper operation of your motorcycle. Motorcycles are single-track vehicles. Their safe use and operation are dependent upon the use of proper riding techniques as well as the expertise of the operator. Every operator should know the following requirements before riding this motorcycle.
U1C617E0.book Page 2 Wednesday, April 14, 2010 10:27 AM SAFETY INFORMATION ● ● ● ● ● Many accidents have been caused by error of the motorcycle operator. A typical error made by the operator is veering wide on a turn due to excessive speed or undercornering (insufficient lean angle for the speed). Never travel faster than warranted by conditions. Ride cautiously in unfamiliar areas. You may encounter hidden obstacles that could cause an accident.
U1C617E0.book Page 3 Wednesday, April 14, 2010 10:27 AM SAFETY INFORMATION ● 2 Do not run engine outdoors where engine exhaust can be drawn into a building through openings such as windows and doors. Genuine Yamaha Accessories Choosing accessories for your vehicle is an important decision. Genuine Yamaha accessories, which are available only from a Yamaha dealer, have been designed, tested, and approved by Yamaha for use on your vehicle.
U1C617E0.book Page 4 Wednesday, April 14, 2010 10:27 AM SAFETY INFORMATION electric failure could result, which could cause a dangerous loss of lights or engine power. ● ● Aftermarket Tires and Rims The tires and rims that came with your motorcycle were designed to match the performance capabilities and to provide the best combination of handling, braking, and comfort. Other tires, rims, sizes, and combinations may not be appropriate.
U1C617E0.book Page 1 Wednesday, April 14, 2010 10:27 AM DESCRIPTION EAU10410 Left view 3 1. 2. 3. 4.
U1C617E0.book Page 2 Wednesday, April 14, 2010 10:27 AM DESCRIPTION EAU10420 Right view 3 1. 2. 3. 4. 5.
U1C617E0.book Page 3 Wednesday, April 14, 2010 10:27 AM DESCRIPTION EAU10430 Controls and instruments 3 1. 2. 3. 4. 5. 6.
U1C617E0.book Page 1 Wednesday, April 14, 2010 10:27 AM INSTRUMENT AND CONTROL FUNCTIONS EAUW1880 Ignition switch EAU12348 Handlebar switches Left EAU12670 “ENGINE STOP” button Hold this button pushed until the engine stops in case of an emergency, such as when the vehicle overturns or when the throttle cable is stuck. EAU12711 The ignition switch controls the ignition system. The ignition switch positions are described below. Start switch “ ” Push this switch to crank the engine with the starter.
U1C617E0.book Page 2 Wednesday, April 14, 2010 10:27 AM INSTRUMENT AND CONTROL FUNCTIONS EAU31640 EAU12870 EAU12890 Clutch lever Shift pedal Brake lever 1. Clutch lever 1. Shift pedal 1. Brake lever The clutch lever is located at the left handlebar grip. To disengage the clutch, pull the lever toward the handlebar grip. To engage the clutch, release the lever. The lever should be pulled rapidly and released slowly for smooth clutch operation.
U1C617E0.book Page 3 Wednesday, April 14, 2010 10:27 AM INSTRUMENT AND CONTROL FUNCTIONS EAU12941 Brake pedal EAU13182 Fuel tank cap EAU13212 Fuel Make sure there is sufficient gasoline in the tank. EWA10881 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. Brake pedal The brake pedal is on the right side of the motorcycle. To apply the rear brake, press down on the brake pedal.
U1C617E0.book Page 4 Wednesday, April 14, 2010 10:27 AM INSTRUMENT AND CONTROL FUNCTIONS ately. If gasoline spills on your skin, wash with soap and water. If gasoline spills on your clothing, change your clothes. EAU13313 4 1. Fuel tank filler tube 2. Maximum fuel level 3. Wipe up any spilled fuel immediately. NOTICE: Immediately wipe off spilled fuel with a clean, dry, soft cloth, since fuel may deteriorate painted surfaces or plastic parts. [ECA10071] 4. Be sure to securely close the fuel tank cap.
U1C617E0.book Page 5 Wednesday, April 14, 2010 10:27 AM INSTRUMENT AND CONTROL FUNCTIONS EAU13412 Fuel tank breather hose EAU13561 Fuel cock ON The fuel cock supplies fuel from the tank to the carburetor while filtering it also. The fuel cock has three positions: OFF 1. Arrow mark positioned over “ON” 1. Fuel tank breather hose Before operating the motorcycle: ● Check the fuel tank breather hose connection. ● Check the fuel tank breather hose for cracks or damage, and replace it if damaged.
U1C617E0.book Page 6 Wednesday, April 14, 2010 10:27 AM INSTRUMENT AND CONTROL FUNCTIONS This indicates reserve. If you run out of fuel while riding, move the lever to this position. Fill the tank at the first opportunity. Be sure to set the lever back to “ON” after refueling! EAU13600 Starter (choke) knob “ ” EAU13960 Seat To remove the seat Remove the bolts, and then pull the seat off. 4 1.
U1C617E0.book Page 7 Wednesday, April 14, 2010 10:27 AM INSTRUMENT AND CONTROL FUNCTIONS EAU14816 Adjusting the shock absorber assembly This shock absorber assembly is equipped with a spring preload adjusting nut. ECA10101 NOTICE 1. Projection 2. Seat holder 2. Place the seat in the original position, and then tighten the bolts. To avoid damaging the mechanism, do not attempt to turn beyond the maximum or minimum settings. Adjust the spring preload as follows. 1. Loosen the locknut.
U1C617E0.book Page 8 Wednesday, April 14, 2010 10:27 AM INSTRUMENT AND CONTROL FUNCTIONS 3. Tighten the locknut to the specified torque. NOTICE: Always tighten the locknut against the adjusting nut, and then tighten the locknut to the specified torque. [ECA10121] Tightening torque: Locknut: 70 Nm (7.0 m·kgf, 51 ft·lbf) 4 ● ● Do not deform or damage the cylinder in any way. Cylinder damage will result in poor damping performance. Do not dispose of a damaged or worn-out shock absorber assembly yourself.
U1C617E0.book Page 9 Wednesday, April 14, 2010 10:27 AM INSTRUMENT AND CONTROL FUNCTIONS EAUW0801 Starting circuit cut-off system The starting circuit cut-off system (comprising the clutch switch and the neutral switch) prevents starting when the transmission is in gear and the clutch lever is not pulled. Periodically check the operation of the starting circuit cut-off system according to the following procedure. 4 TIP This check is most reliable if performed with a warmed-up engine.
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U1C617E0.book Page 1 Wednesday, April 14, 2010 10:27 AM FOR YOUR SAFETY – 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.
U1C617E0.book Page 2 Wednesday, April 14, 2010 10:27 AM FOR YOUR SAFETY – PRE-OPERATION CHECKS ITEM CHECKS Clutch • • • • 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. Drive chain • • • • Check chain slack. Adjust if necessary. Check chain condition. Lubricate if necessary.
U1C617E0.book Page 1 Wednesday, April 14, 2010 10:27 AM OPERATION AND IMPORTANT RIDING POINTS EAU15951 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. EWA10271 WARNING Failure to familiarize yourself with the controls can lead to loss of control, which could cause an accident or injury.
U1C617E0.book Page 2 Wednesday, April 14, 2010 10:27 AM OPERATION AND IMPORTANT RIDING POINTS EAU16640 Starting a warm engine EAU16671 Shifting Follow the same procedure as for starting a cold engine with the exception that the starter (choke) is not required when the engine is warm. ● 1. Shift pedal 2. Neutral position 6 ECA10260 NOTICE ● Shifting gears lets you control the amount of engine power available for starting off, accelerating, climbing hills, etc.
U1C617E0.book Page 3 Wednesday, April 14, 2010 10:27 AM OPERATION AND IMPORTANT RIDING POINTS EAU16850 Engine break-in There is never a more important period in the life of your engine than the first 20 hours of riding. For this reason, you should read the following material carefully. Since the engine is brand new, do not put an excessive load on it for the first 20 hours of operation. The various parts in the engine wear and polish themselves to the correct operating clearances.
U1C617E0.book Page 1 Wednesday, April 14, 2010 10:27 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU41952 ● Periodic inspection, adjustment, and lubrication will keep your vehicle in the safest 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.
U1C617E0.book Page 2 Wednesday, April 14, 2010 10:27 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU39944 Periodic maintenance chart for the emission control system TIP ● ● From 7000 km (4200 mi) or 18 months, repeat the maintenance intervals starting from 3000 km (1800 mi) or 6 months. Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. INITIAL No.
U1C617E0.book Page 3 Wednesday, April 14, 2010 10:27 AM PERIODIC MAINTENANCE AND ADJUSTMENT INITIAL No. 10 ITEM Engine oil filter element CHECKS AND MAINTENANCE JOBS • Clean. • Check engine oil level and for leakage.
U1C617E0.book Page 4 Wednesday, April 14, 2010 10:27 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU3534B General maintenance and lubrication chart TIP ● ● From 7000 km (4200 mi) or 18 months, repeat the maintenance intervals starting from 3000 km (1800 mi) or 6 months. Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. INITIAL No.
U1C617E0.book Page 5 Wednesday, April 14, 2010 10:27 AM PERIODIC MAINTENANCE AND ADJUSTMENT INITIAL CHECKS AND MAINTENANCE JOBS 1000 km (600 mi) or 1 month or 30 hours No. ITEM 8 * Swingarm pivot bearings • Check bearing assemblies for looseness. • Moderately repack with lithium-soap-based grease. 9 Drive chain • Check chain slack/alignment and condition. • Adjust and lubricate chain with Yamaha chain and cable lube thoroughly. 10 * Steering bearings • Check bearing assemblies for looseness.
U1C617E0.book Page 6 Wednesday, April 14, 2010 10:27 AM PERIODIC MAINTENANCE AND ADJUSTMENT INITIAL No. ITEM CHECKS AND MAINTENANCE JOBS ODOMETER READINGS 1000 km (600 mi) or 1 month or 30 hours 3000 km (1800 mi) or 6 months or 90 hours 5000 km (3000 mi) or 12 months or 150 hours 20 * Control cables • Apply Yamaha chain and cable lube or engine oil thoroughly. √ √ √ 21 * Throttle grip housing and cable • Check operation and free play. • Adjust the throttle cable free play if necessary.
U1C617E0.book Page 7 Wednesday, April 14, 2010 10:27 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU18751 EAU19622 Removing and installing the panel Checking the spark plug The panel shown needs to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time the panel needs to be removed and installed. 1. Screw 2. Panel To install the panel Place the panel in the original position, and then install the screws. 7 1.
U1C617E0.book Page 8 Wednesday, April 14, 2010 10:27 AM PERIODIC MAINTENANCE AND ADJUSTMENT Before installing a spark plug, the spark plug gap should be measured with a wire thickness gauge and, if necessary, adjusted to specification. EAUW0612 TIP If a torque wrench is not available when installing a spark plug, a good estimate of the correct torque is 1/4–1/2 turn past finger tight. However, the spark plug should be tightened to the specified torque as soon as possible.
U1C617E0.book Page 9 Wednesday, April 14, 2010 10:27 AM PERIODIC MAINTENANCE AND ADJUSTMENT 4. Remove the engine oil filler bolt and drain bolt to drain the oil from the crankcase. NOTICE: When removing the engine oil drain bolt, the O-ring, compression spring, and oil strainer will fall out. Take care not to lose these parts. [ECA11001] 1. Engine oil level check window 2. Maximum level mark 3. Minimum level mark 1. 2. 3. 4. 4.
U1C617E0.book Page 10 Wednesday, April 14, 2010 10:27 AM PERIODIC MAINTENANCE AND ADJUSTMENT 9. Clean the oil filter element with solvent, and then install it. TIP Check the oil filter element for damage and replace it if necessary. 10. Install the oil filter element cover by installing the bolts, then tightening them to the specified torque. 1. Oil filter element cover 2. Oil filter element drain bolt 7. Remove the oil filter element and O-rings.
U1C617E0.book Page 11 Wednesday, April 14, 2010 10:27 AM PERIODIC MAINTENANCE AND ADJUSTMENT ● Make sure that no foreign material enters the crankcase. 14. Start the engine, and then let it idle for several minutes while checking it for oil leakage. If oil is leaking, immediately turn the engine off and check for the cause. 15. Turn the engine off, and then check the oil level and correct it if necessary. EAUW0633 Cleaning the air filter element 1.
U1C617E0.book Page 12 Wednesday, April 14, 2010 10:27 AM PERIODIC MAINTENANCE AND ADJUSTMENT 1. Air filter element 3. Remove the wing nut and washer from the air filter element. 1. Sponge material 2. Air filter element guide 5. Clean the sponge material with solvent, and then squeeze the remaining solvent out. WARNING! To avoid the risk of fire or explosion, do not use gasoline or solvents with a low flash point.
U1C617E0.book Page 13 Wednesday, April 14, 2010 10:27 AM PERIODIC MAINTENANCE AND ADJUSTMENT in the air filter case. The engine should never be operated without the air filter element installed, otherwise the piston(s) and/or cylinder(s) may become excessively worn. [ECA10481] 9. Install the air filter case cover and screws. EAU40421 Cleaning the spark arrester The spark arrester should be cleaned at the intervals specified in the periodic maintenance and lubrication chart. 1.
U1C617E0.book Page 14 Wednesday, April 14, 2010 10:27 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU39930 TIP Make sure to align the bolt holes when inserting the tailpipe. 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.
U1C617E0.book Page 15 Wednesday, April 14, 2010 10:27 AM PERIODIC MAINTENANCE AND ADJUSTMENT rection (a). To decrease the engine idling speed, turn the screw in direction (b). 1. Adjusting bolt Engine idling speed: 1400–1600 r/min 7 TIP If the specified idling speed cannot be obtained as described above, have a Yamaha dealer make the adjustment. EAU21383 Checking the throttle cable free play 1. Throttle cable free play The throttle cable free play should measure 3.0–5.0 mm (0.12–0.
U1C617E0.book Page 16 Wednesday, April 14, 2010 10:27 AM PERIODIC MAINTENANCE AND ADJUSTMENT glass fragments in it, or if the sidewall is cracked, have a Yamaha dealer replace the tire immediately. EAUW2201 Tires To maximize the performance, durability, and safe operation of your motorcycle, note the following points regarding the specified tires. Front: 100 kPa (1.00 kgf/cm², 15 psi) Rear: 100 kPa (1.
U1C617E0.book Page 17 Wednesday, April 14, 2010 10:27 AM PERIODIC MAINTENANCE AND ADJUSTMENT very carefully and replace it as soon as possible with a highquality product. Front tire: Size: 80/100-21 NHS Manufacturer/model: PIRELLI/MT320H Rear tire: Size: 100/100-18 NHS Manufacturer/model: PIRELLI/MT320 To maximize the performance, durability, and safe operation of your motorcycle, note the following points regarding the specified wheels.
U1C617E0.book Page 18 Wednesday, April 14, 2010 10:27 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU22034 Adjusting the clutch lever free play decrease the clutch lever free play, turn the adjusting bolt in direction (b). EAU37913 Checking the brake lever free play TIP If the specified clutch lever free play could be obtained as described above, skip steps 4–7. 1. 2. 3. 4. 5.
U1C617E0.book Page 19 Wednesday, April 14, 2010 10:27 AM PERIODIC MAINTENANCE AND ADJUSTMENT braking performance, which may result in loss of control and an accident. EAUW0650 Adjusting the brake pedal position and free play 2. To raise the brake pedal, turn the adjusting bolt in direction (a). To lower the brake pedal, turn the adjusting bolt in direction (b). 3. Tighten the locknut. EWA11230 WARNING After adjusting the brake pedal position, the brake pedal free play must be adjusted.
U1C617E0.book Page 20 Wednesday, April 14, 2010 10:27 AM PERIODIC MAINTENANCE AND ADJUSTMENT To increase the brake pedal free play, turn the adjusting nut at the brake rod in direction (a). To decrease the brake pedal free play, turn the adjusting nut in direction (b). Checking the front brake pads and rear brake shoes the point that a wear indicator almost touches the brake disc, have a Yamaha dealer replace the brake pads as a set.
U1C617E0.book Page 21 Wednesday, April 14, 2010 10:27 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU37001 Checking the front brake fluid level ● ● When checking the fluid level, make sure that the top of 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. Recommended brake fluid: DOT 4 1.
U1C617E0.book Page 22 Wednesday, April 14, 2010 10:27 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU22721 EAU22760 Changing the brake fluid Drive chain slack Have a Yamaha dealer change the brake fluid at the intervals specified in the TIP after the periodic maintenance and lubrication chart. In addition, have the oil seals of the brake master cylinder and caliper as well as the brake hose replaced at the intervals listed below or whenever they are damaged or leaking. ● Oil seals: Replace every two years.
U1C617E0.book Page 23 Wednesday, April 14, 2010 10:27 AM PERIODIC MAINTENANCE AND ADJUSTMENT of the motorcycle and can lead to chain slippage or breakage. To prevent this from occurring, keep the drive chain slack within the specified limits. [ECA10571] 5. Adjust the brake pedal free play. (See page 7-19.
U1C617E0.book Page 24 Wednesday, April 14, 2010 10:27 AM PERIODIC MAINTENANCE AND ADJUSTMENT may contain substances that could damage the O-rings. [ECA11111] EAU23093 EAU23113 Checking and lubricating the cables Checking and lubricating the throttle grip and cable The operation of all control cables and the condition of the cables should be checked before each ride, and the cables and cable ends should be lubricated if necessary.
U1C617E0.book Page 25 Wednesday, April 14, 2010 10:27 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU23142 Checking and lubricating the brake and clutch levers EAU23182 EAU23202 Checking and lubricating the brake pedal Checking and lubricating the sidestand The operation of the brake pedal should be checked before each ride, and the pedal pivot should be lubricated if necessary.
U1C617E0.book Page 26 Wednesday, April 14, 2010 10:27 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU23272 EAU23283 Checking the front fork Checking the steering The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart. 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 periodic maintenance and lubrication chart. 1.
U1C617E0.book Page 27 Wednesday, April 14, 2010 10:27 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU23291 Checking the wheel bearings EAU23387 EWA10760 Battery WARNING The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart. If there is play in the wheel hub or if the wheel does not turn smoothly, have a Yamaha dealer check the wheel bearings. ● 1. Battery 7 The battery is located behind panel A. (See page 7-7.
U1C617E0.book Page 28 Wednesday, April 14, 2010 10:27 AM PERIODIC MAINTENANCE AND ADJUSTMENT ● KEEP THIS AND ALL BATTERIES OUT OF THE REACH OF CHILDREN. To charge the battery Have a Yamaha dealer charge the battery as soon as possible if it seems to have discharged. Keep in mind that the battery tends to discharge more quickly if the vehicle is equipped with optional electrical accessories.
U1C617E0.book Page 29 Wednesday, April 14, 2010 10:27 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU24350 Specified fuse: 10.0 A 3. Push the ignition switch to set it to “ON”. 4. If the fuse immediately blows again, have a Yamaha dealer check the electrical system. 7 Supporting the motorcycle Since this model is not equipped with a centerstand, follow these precautions when removing the front and rear wheel or performing other maintenance requiring the motorcycle to stand upright.
U1C617E0.book Page 30 Wednesday, April 14, 2010 10:27 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU24360 Front wheel EAUW0542 To remove the front wheel EWA10821 WARNING To avoid injury, securely support the vehicle so there is no danger of it falling over. 1. Loosen the axle nut. 2. Lift the front wheel off the ground according to the procedure in “Supporting the motorcycle” on page 7-29. 3. Remove the axle nut and washer. 4. Pull the wheel axle out, and then remove the wheel.
U1C617E0.book Page 31 Wednesday, April 14, 2010 10:27 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU25080 EAU25762 EAU25421 To install the rear wheel 1. Insert the wheel axle from the lefthand side. Rear wheel To remove the rear wheel EWA10821 WARNING To avoid injury, securely support the vehicle so there is no danger of it falling over. 1. Loosen the axle nut. 7 1. 2. 3. 4. Adjusting nut Brake rod Brake camshaft lever Axle nut 2.
U1C617E0.book Page 32 Wednesday, April 14, 2010 10:27 AM PERIODIC MAINTENANCE AND ADJUSTMENT 5. Tighten the axle nut to the specified torque. Tightening torque: Axle nut: 80 Nm (8.0 m·kgf, 58 ft·lbf) 6. Install the brake rod onto the brake camshaft lever, and then install the brake pedal free play adjusting nut onto the brake rod. 7. Adjust the brake pedal free play. (See page 7-19.) EWA10660 WARNING After adjusting the brake pedal free play, check the operation of the brake light.
U1C617E0.book Page 33 Wednesday, April 14, 2010 10:27 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU25902 Troubleshooting chart 1. Fuel There is enough fuel. Check the compression. There is no fuel. Supply fuel. There is compression. Check the ignition. There is no compression. Have a Yamaha dealer check the vehicle. Check the fuel level in the fuel tank. The engine does not start. Check the compression. 2. Compression Operate the electric starter. 3.
U1C617E0.book Page 1 Wednesday, April 14, 2010 10:27 AM MOTORCYCLE CARE AND STORAGE ucts onto seals, gaskets, sprockets, the drive chain and wheel axles. Always rinse the dirt and degreaser off with water. EAU41356 Care While the open design of a motorcycle reveals the attractiveness of the technology, it also makes it more vulnerable. Rust and corrosion can develop even if high-quality components are used.
U1C617E0.book Page 2 Wednesday, April 14, 2010 10:27 AM MOTORCYCLE CARE AND STORAGE Test the product on a small hidden part of the windshield to make sure that it does not leave any marks. If the windshield is scratched, use a quality plastic polishing compound after washing. 8 After normal use Remove dirt with warm water, a mild detergent, and a soft, clean sponge, and then rinse thoroughly with clean water. Use a toothbrush or bottlebrush for hard-to-reach areas.
U1C617E0.book Page 3 Wednesday, April 14, 2010 10:27 AM MOTORCYCLE CARE AND STORAGE EAU26152 TIP Consult a Yamaha dealer for advice on what products to use. Storage Short-term Always store your motorcycle in a cool, dry place and, if necessary, protect it against dust with a porous cover. Be sure the engine and the exhaust system are cool before covering the motorcycle.
U1C617E0.book Page 4 Wednesday, April 14, 2010 10:27 AM MOTORCYCLE CARE AND STORAGE WARNING! To prevent damage or injury from sparking, make sure to ground the spark plug electrodes while turning the engine over. [EWA10951] 6. 7. 8 8. 9. 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 sidestand/centerstand.
U1C617E0.book Page 1 Wednesday, April 14, 2010 10:27 AM SPECIFICATIONS Dimensions: Overall length: 2065 mm (81.3 in) Overall width: 800 mm (31.5 in) Overall height: 1180 mm (46.5 in) Seat height: 870 mm (34.3 in) Wheelbase: 1385 mm (54.5 in) Ground clearance: 295 mm (11.61 in) Minimum turning radius: 2100 mm (82.7 in) Weight: With oil and fuel: 114 kg (251 lb) Engine: Engine type: Air cooled 4-stroke, SOHC Cylinder arrangement: Forward-inclined single cylinder Displacement: 223 cm³ Bore × stroke: 70.
U1C617E0.book Page 2 Wednesday, April 14, 2010 10:27 AM SPECIFICATIONS Trail: 111.0 mm (4.37 in) Front tire: Type: With tube Size: 80/100-21 NHS Manufacturer/model: PIRELLI/MT320H Rear tire: Type: With tube Size: 100/100-18 NHS Manufacturer/model: PIRELLI/MT320 Tire air pressure (measured on cold tires): Front: 100 kPa (1.00 kgf/cm², 15 psi) Rear: 100 kPa (1.00 kgf/cm², 15 psi) Front wheel: 9 Wheel type: Spoke wheel Rim size: 21x1.60 Rear wheel: Wheel type: Spoke wheel Rim size: 18x1.
U1C617E0.book Page 1 Wednesday, April 14, 2010 10:27 AM CONSUMER INFORMATION EAU40791 Identification numbers EAU26400 EAU26460 Vehicle identification number Model label 1. Vehicle identification number 1. Model label The vehicle identification number is stamped into the steering head pipe. Record this number in the space provided. The model label is affixed to the location shown. Record the information on this label in the space provided.
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U1C617E0.book Page 3 Wednesday, April 14, 2010 10:27 AM CONSUMER INFORMATION EAU26651 Maintenance record Have a Yamaha dealer complete this record when the motorcycle is serviced.
U1C617E0.book Page 4 Wednesday, April 14, 2010 10:27 AM CONSUMER INFORMATION EAU38051 YAMAHA MOTOR CORPORATION, U.S.A. OFF-ROAD MOTORCYCLE LIMITED WARRANTY Yamaha Motor Corporation, USA hereby warrants that new Yamaha off-road motorcycles purchased from an authorized Yamaha motorcycle dealer in the continental United States will be free from defects in material and workmanship for the period of time stated herein, subject to certain stated limitations.
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U1C617E0.book Page 6 Wednesday, April 14, 2010 10:27 AM CONSUMER INFORMATION EAU26750 YAMAHA EXTENDED SERVICE (Y.E.S.) Keep your Yamaha protected even after your warranty expires with genuine Yamaha Extended Service (Y.E.S.). In addition, Travel and Recreation Interruption Protection (TRIP) is included at no extra cost.
U1C617E0.book Page 7 Wednesday, April 14, 2010 10:27 AM CONSUMER INFORMATION We urge you to act now. You’ll get the excellent benefits of TRIP coverage right away, and you’ll rest easy knowing you’ll have strong factory-backed protection even after your Yamaha Limited Warranty expires. A special note: If visiting your dealer isn’t convenient, contact Yamaha with your Primary ID number (your frame number). We’ll be happy to help you get the Y.E.S. coverage you need. Yamaha Service Marketing P.O.
U1C617E0.book Page 1 Wednesday, April 14, 2010 10:27 AM INDEX A B Battery................................................... 7-27 Brake and clutch levers, checking and lubricating ........................................... 7-25 Brake fluid, changing ............................ 7-22 Brake fluid level, checking .................... 7-21 Brake lever.............................................. 4-2 Brake lever free play, checking............. 7-18 Brake pads and shoes, checking .......... 7-20 Brake pedal..
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Read this manual carefully before operating this vehicle. YAMAHA MOTOR DA AMAZÔNIA LTDA.