Owner`s manual

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10D-28199-15

TW200BC

OWNER’S MANUAL

Read this manual carefully before operating this vehicle.

LIT-11626-25-04

TW200B

Summary of content (100 pages)

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Read this manual carefully before operating this vehicle.
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EAU10042 Q Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold.
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10D-9-15.book 1 ページ２０１１年３月７日月曜日午後３時６分 INTRODUCTION EAU10083 Congratulations on your purchase of the Yamaha TW200B/TW200BC. 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.
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10D-9-15.book 1 ページ２０１１年３月７日月曜日午後３時６分 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 A WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.
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10D-9-15.book 2 ページ２０１１年３月７日月曜日午後３時６分 IMPORTANT MANUAL INFORMATION EAU10193 TW200B/TW200BC OWNER’S MANUAL ©2011 by Yamaha Motor Corporation, U.S.A. 1st edition, February 2011 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in Japan.
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10D-9-15.book 1 ページ２０１１年３月７日月曜日午後３時６分 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 ........................................
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10D-9-15.book 2 ページ２０１１年３月７日月曜日午後３時６分 TABLE OF CONTENTS Lubricating the swingarm pivots ... Checking the front fork ................. Checking the steering ................... Checking the wheel bearings ....... Battery .......................................... Replacing the fuse ........................ Replacing the headlight bulb ........ Replacing the tail/brake light bulb ........................................... Replacing a turn signal light bulb ...........................................
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10D-9-15.book 1 ページ２０１１年３月７日月曜日午後３時６分 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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10D-9-15.book 2 ページ２０１１年３月７日月曜日午後３時６分 LOCATION OF IMPORTANT LABELS 5 1 WARNING LOAD LIMIT BEFORE YOU OPERATE THIS VEHICLE, READ THE OWNER’S MANUAL AND ALL LABELS. ALWAYS WEAR AN APPROVED MOTORCYCLE HELMET, eye protection, and protective clothing. 1 3 kg {7 lbs} 3TB-24877-A0 2 6 5GK-2118K-00 2 California only 3 WARNING This unit contains high pressure nitrogen gas. Mishandling can cause explosion. Read owner's manual for instructions. Do not incinerate, puncture or open. CARB.
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D-9-15.
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10D-9-15.book 4 ページ２０１１年３月７日月曜日午後３時６分 LOCATION OF IMPORTANT LABELS 1 1 Read owner’s manual before servicing battery. Electrolyte will damage metal parts or paint. If electrolyte spills, wash area with fresh water immediately. Be sure to connect breather hose after installing battery.
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10D-9-15.book 1 ページ２０１１年３月７日月曜日午後３時６分 SAFETY INFORMATION EAU1031A 1 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.
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10D-9-15.book 2 ページ２０１１年３月７日月曜日午後３時６分 SAFETY INFORMATION ed by road and traffic 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. • The operator should keep both hands on the handlebar and both feet on the operator footrests during operation to maintain control of the motorcycle.
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10D-9-15.book 3 ページ２０１１年３月７日月曜日午後３時６分 SAFETY INFORMATION 1 2 3 4 5 6 7 8 9 motorcycle can adversely affect stability and handling if the weight distribution of the motorcycle is changed. To avoid the possibility of an accident, use extreme caution when adding cargo or accessories to your motorcycle. Use extra care when riding a motorcycle that has added cargo or accessories.
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10D-9-15.book 4 ページ２０１１年３月７日月曜日午後３時６分 SAFETY INFORMATION of the vehicle’s design or operation characteristics can put you and others at greater risk of serious injury or death. You are responsible for injuries related to changes in the vehicle. Keep the following guidelines in mind, as well as those provided under “Loading” when mounting accessories.  Never install accessories or carry cargo that would impair the performance of your motorcycle.
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10D-9-15.book 5 ページ２０１１年３月７日月曜日午後３時６分 SAFETY INFORMATION 1 2 3 parts that could break). Choose the location for the straps carefully so the straps will not rub against painted surfaces during transport.  The suspension should be compressed somewhat by the tie-downs, if possible, so that the motorcycle will not bounce excessively during transport.
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10D-9-15.book 1 ページ２０１１年３月７日月曜日午後３時６分 DESCRIPTION EAU10410 Left view 3 1 2 4 2 3 4 5 6 7 87 6 1. Fuel tank cap (page 4-5) 5 8. Shift pedal (page 4-4) 2. Fuel cock (page 4-7) 3. Helmet holder (page 4-9) 4. Luggage strap holder (page 4-10) 5. Drive chain slack adjusting plate (page 7-26) 6. Air filter element (page 7-15) 7.
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10D-9-15.book 2 ページ２０１１年３月７日月曜日午後３時６分 DESCRIPTION EAU10420 Right view 1 1 2 2 3 4 5 6 7 8 9 8 7 6 5 4 1. Carrier (page 4-10) 3 8. Spark arrester (page 7-16) 2. Battery (page 7-31) 3. Engine oil level check window (page 7-12) 4. Brake pedal (page 4-5) 5. Fuse (page 7-33) 6. Owner’s tool kit (page 7-2) 7.
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10D-9-15.book 3 ページ２０１１年３月７日月曜日午後３時６分 DESCRIPTION EAU10430 Controls and instruments 1 2 3 4 5 6 7 8 2 3 4 5 6 7 8 1. Clutch lever (page 4-4) 8. Throttle grip (page 7-17) 2. Left handlebar switches (page 4-3) 3. Speedometer unit (page 4-2) 4. Main switch/steering lock (page 4-1) 5. Indicator lights (page 4-2) 6. Right handlebar switches (page 4-3) 7.
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10D-9-15.book 1 ページ２０１１年３月７日月曜日午後３時６分 INSTRUMENT AND CONTROL FUNCTIONS EAU10460 Main switch/steering lock 1 OFF EWA10061 WARNING Never turn the key to “OFF” or “LOCK” while the vehicle is moving. Otherwise the electrical systems will be switched off, which may result in loss of control or an accident. ON 2 3 EAU10711 LOCK 4 5 6 The main switch/steering lock controls the ignition and lighting systems, and is used to lock the steering. The various positions are described below.
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10D-9-15.book 2 ページ２０１１年３月７日月曜日午後３時６分 INSTRUMENT AND CONTROL FUNCTIONS EAU10981 Indicator lights 1 2 high beam of the headlight is switched on. EAU11630 Speedometer unit 3 1 4 2 3 2 3 4 1. Turn signal indicator light “ 2. High beam indicator light “ 3. Neutral indicator light “ ” 1. Speedometer ” 2. Odometer ” 5 3. Tripmeter 4. Reset knob 6 EAU11020 The speedometer unit is equipped with a speedometer, an odometer and a tripmeter. The speedometer shows riding speed.
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10D-9-15.book 3 ページ２０１１年３月７日月曜日午後３時６分 INSTRUMENT AND CONTROL FUNCTIONS EAU12348 Handlebar switches 1 Right EAU12500 Horn switch “ ” Press this switch to sound the horn. Left 1 1 2 2 EAU12660 Engine stop switch “ / ” Set this switch to “ ” before starting the engine. Set this switch to “ ” to stop the engine in case of an emergency, such as when the vehicle overturns or when the throttle cable is stuck. 2 3 4 1. Engine stop switch “ 3 5 2. Start switch “ 1. Dimmer switch “ / 2.
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10D-9-15.book 4 ページ２０１１年３月７日月曜日午後３時６分 INSTRUMENT AND CONTROL FUNCTIONS EAU12820 Clutch lever EAU12871 Shift pedal EAU12890 Brake lever 1 1 2 3 1 1. Clutch 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.
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10D-9-15.book 5 ページ２０１１年３月７日月曜日午後３時６分 INSTRUMENT AND CONTROL FUNCTIONS EAU12941 Brake pedal EAU32281 Fuel tank cap 1 2 EWA10121 1 3 1. Brake pedal 5 6 7 2 1 4 The brake pedal is on the right side of the motorcycle. To apply the rear brake, press down on the brake pedal. 1. Unlock. 2. Fuel tank cap To remove the fuel tank cap 1. Insert the key into the lock and turn it 1/3 turn counterclockwise. 2. Turn the fuel tank cap 1/3 turn counterclockwise and pull it off.
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10D-9-15.book 6 ページ２０１１年３月７日月曜日午後３時６分 INSTRUMENT AND CONTROL FUNCTIONS EAU13212 Fuel 1 Make sure there is sufficient gasoline in the tank. 2 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. Before refueling, turn off the engine and be sure that no one is sitting on the vehicle.
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10D-9-15.book 7 ページ２０１１年３月７日月曜日午後３時６分 INSTRUMENT AND CONTROL FUNCTIONS 1 2 3 4 5 um unleaded fuel. Use of unleaded fuel will extend spark plug life and reduce maintenance costs. Gasohol There are two types of gasohol: gasohol containing ethanol and that containing methanol. Gasohol containing ethanol can be used if the ethanol content does not exceed 10% (E10). Gasohol containing methanol is not recommended by Yamaha because it can cause damage to the fuel system or vehicle performance problems.
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10D-9-15.book 8 ページ２０１１年３月７日月曜日午後３時６分 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 “ ” Seat 1 (b) EAU13971 To remove the seat Remove the bolts, and then pull the seat off. 2 3 (a) 4 1.
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10D-9-15.book 9 ページ２０１１年３月７日月曜日午後３時６分 INSTRUMENT AND CONTROL FUNCTIONS EAU14282 2 Helmet holder 1 2 1 3 1. Seat holder 2. Projection 5 2. Place the seat in the original position, and then tighten the bolts. 6 TIP Make sure that the seat is properly secured before riding. 7 8 9 Shock absorber assembly EWA10221 1 4 EAU46021 1. Helmet holder To open the helmet holder, insert the key into the lock, and then turn the key as shown.
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10D-9-15.book 10 ページ２０１１年３月７日月曜日午後３時６分 INSTRUMENT AND CONTROL FUNCTIONS EAU15112 Carrier EAU15170 Luggage strap holders EWA10171 WARNING  Do not exceed the load limit of 3 kg (7 lb) for the carrier.  Do not exceed the maximum load of 179 kg (395 lb) (CAL) 180 kg (397 lb) (U49) for the vehicle. 1 1 1 1. Luggage strap holder There are four luggage strap holders below the carrier. 1. Carrier 4-10 EAU15305 Sidestand The sidestand is located on the left side of the frame.
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10D-9-15.book 11 ページ２０１１年３月７日月曜日午後３時６分 INSTRUMENT AND CONTROL FUNCTIONS Yamaha dealer repair it if it does not function properly. 1 2 3 4 5 6 7 8 9 EAU15314 Ignition circuit cut-off system The ignition circuit cut-off system (comprising the sidestand switch, clutch switch and neutral switch) has the following functions.  It prevents starting when the transmission is in gear and the sidestand is up, but the clutch lever is not pulled.
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10D-9-15.book 12 ページ２０１１年３月７日月曜日午後３時６分 INSTRUMENT AND CONTROL FUNCTIONS With the engine turned off: 1. Move the sidestand down. 2. Make sure that the engine stop switch is set to “ 3. Turn the key on. 4. Shift the transmission into the neutral position. 5. Push the start switch. Does the engine start? YES WARNING If a malfunction is noted, have a Yamaha dealer check the system before riding. ”. 2 The neutral switch may not be working correctly.
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10D-9-15.book 1 ページ２０１１年３月７日月曜日午後３時６分 FOR YOUR SAFETY – PRE-OPERATION CHECKS EAU15596 1 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 2 3 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.
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10D-9-15.book 2 ページ２０１１年３月７日月曜日午後３時６分 FOR YOUR SAFETY – PRE-OPERATION CHECKS ITEM Throttle grip Control cables Drive chain Wheels and tires Shift pedal Brake pedal Brake and clutch levers Sidestand Chassis fasteners Instruments, lights, signals and switches Sidestand switch Battery CHECKS • Make sure that operation is smooth. • Check throttle grip free play. • If necessary, have Yamaha dealer adjust throttle grip free play and lubricate cable and grip housing.
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10D-9-15.book 1 ページ２０１１年３月７日月曜日午後３時６分 OPERATION AND IMPORTANT RIDING POINTS EAU15951 1 2 3 4 5 6 7 8 9 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.
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10D-9-15.book 2 ページ２０１１年３月７日月曜日午後３時６分 OPERATION AND IMPORTANT RIDING POINTS ECA11042 NOTICE For maximum engine life, never accelerate hard when the engine is cold! 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. 2 5 4 3 2 2 3 N 1 1 4 1. Shift pedal 5 2.
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10D-9-15.book 3 ページ２０１１年３月７日月曜日午後３時６分 OPERATION AND IMPORTANT RIDING POINTS 1 2 3 4 5 the neutral position, do not coast for long periods of time with the engine off, and do not tow the motorcycle for long distances. The transmission is properly lubricated only when the engine is running. Inadequate lubrication may damage the transmission.
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10D-9-15.book 4 ページ２０１１年３月７日月曜日午後３時６分 OPERATION AND IMPORTANT RIDING POINTS EAU16841 Engine break-in There is never a more important period in the life of your engine than the period between 0 and 1600 km (1000 mi). 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 1600 km (1000 mi). The various parts in the engine wear and polish themselves to the correct operating clearances.
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10D-9-15.book 1 ページ２０１１年３月７日月曜日午後３時６分 PERIODIC MAINTENANCE AND ADJUSTMENT EAU17244 1 2 3 4 5 6 7 8 9 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.
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10D-9-15.book 2 ページ２０１１年３月７日月曜日午後３時６分 PERIODIC MAINTENANCE AND ADJUSTMENT EAU17341 Owner’s tool kit 1 2 3 4 1. Owner’s tool kit 5 The owner’s tool kit is located behind panel B. (See page 7-9.) The service information included in this manual and the tools provided in the owner’s tool kit are intended to assist you in the performance of preventive maintenance and minor repairs. However, additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly.
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10D-9-15.book 3 ページ２０１１年３月７日月曜日午後３時６分 PERIODIC MAINTENANCE AND ADJUSTMENT EAU48470 TIP 1  From 19000 mi (31000 km) or 36 months, repeat the maintenance intervals starting from 7000 mi (11000 km) or 12 2  Items marked with an asterisk require special tools, data and technical skills, have a Yamaha dealer perform the service. months. 3 EAU17581 Periodic maintenance chart for the emission control system 4 INITIAL 5 600 mi (1000 km) or 1 month No.
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10D-9-15.book 4 ページ２０１１年３月７日月曜日午後３時６分 PERIODIC MAINTENANCE AND ADJUSTMENT INITIAL No. ITEM ROUTINE 7 * Evaporative emission control system (for California only) • Check control system for damage. • Replace if necessary.
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10D-9-15.book 5 ページ２０１１年３月７日月曜日午後３時６分 PERIODIC MAINTENANCE AND ADJUSTMENT EAU32165 General maintenance and lubrication chart INITIAL 1 No. ITEM ROUTINE 2 3 1 Air filter element 2 * Battery 3 * Clutch 4 * Front brake 5 * Rear brake 6 * Brake hose 4 5 6 7 8 9 7 * Wheels 8 * Tires • Clean with solvent. • Replace if necessary. • Check specific gravity and breather hose for proper operation. • Check operation. • Adjust or replace cable.
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10D-9-15.book 6 ページ２０１１年３月７日月曜日午後３時６分 PERIODIC MAINTENANCE AND ADJUSTMENT INITIAL No. ITEM 9 * Wheel bearings 10 * Swingarm pivot bushes 11 Drive chain 12 * Steering bearings 13 * Chassis fasteners 14 15 16 17 Brake lever pivot shaft Brake pedal pivot shaft Clutch lever pivot shaft Sidestand pivot ROUTINE • Check bearings for smooth operation. • Replace if necessary. • Check bush assemblies for looseness. • Apply lithium-soap-based grease until new grease shows.
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10D-9-15.book 7 ページ２０１１年３月７日月曜日午後３時６分 PERIODIC MAINTENANCE AND ADJUSTMENT INITIAL No. 600 mi (1000 km) or 1 month 4000 mi (6000 km) or 6 months 7000 mi (11000 km) or 12 months 10000 mi (16000 km) or 18 months 13000 mi (21000 km) or 24 months 16000 mi (26000 km) or 30 months • Check operation and replace if necessary. • Check operation and for oil leakage. • Replace if necessary. • Check operation and for oil leakage. • Replace if necessary. • Change (warm engine before draining).
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10D-9-15.book 8 ページ２０１１年３月７日月曜日午後３時６分 PERIODIC MAINTENANCE AND ADJUSTMENT EAU17620 TIP  The air filter needs more frequent service if you are riding in unusually wet or dusty areas.  Hydraulic brake system • When disassembling the master cylinder or caliper cylinder, always replace the brake fluid. Check the brake fluid level regularly and fill as required. • Replace the oil seals on the inner parts of the master cylinder and caliper cylinder every two years.
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10D-9-15.book 9 ページ２０１１年３月７日月曜日午後３時６分 PERIODIC MAINTENANCE AND ADJUSTMENT To install the cowling Place the cowling in the original position, and then install the screw. EAU18722 Removing and installing the cowling and panels 1 2 3 1 The cowling and panels shown need to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time the cowling or a panel needs to be removed and installed.
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10D-9-15.book 10 ページ２０１１年３月７日月曜日午後３時６分 PERIODIC MAINTENANCE AND ADJUSTMENT EAU19604 Checking the spark plug The spark plug is an important engine component, which is easy to check. Since 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. In addition, the condition of the spark plug can reveal the condition of the engine. Panel B To remove the spark plug 1.
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10D-9-15.book 11 ページ２０１１年３月７日月曜日午後３時６分 PERIODIC MAINTENANCE AND ADJUSTMENT necessary. Specified spark plug: NGK/DR8EA DENSO/X24ESR-U 1 2 3 4 5 6 7 8 9 1 3. Measure the spark plug gap with a wire thickness gauge and, if necessary, adjust the gap to specification. 1. Spark plug wrench To check the spark plug 1. Check that the porcelain insulator around the center electrode of the spark plug is a medium-to-light tan (the ideal color when the vehicle is ridden normally).
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10D-9-15.book 12 ページ２０１１年３月７日月曜日午後３時６分 PERIODIC MAINTENANCE AND ADJUSTMENT EAU19681 Canister (for California only) 1 4 2 3 1. Rollover valve 2. Canister 3. Canister breather 4. Carburetor This model is equipped with a canister to prevent the discharging of fuel vapor into the atmosphere. Before operating this vehicle, make sure to check the following:  Check each hose connection.  Check each hose and canister for cracks or damage. Replace if damaged.
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10D-9-15.book 13 ページ２０１１年３月７日月曜日午後３時６分 PERIODIC MAINTENANCE AND ADJUSTMENT 1 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 1 3 2 3 2 3 2 1 4 5 6 1. Engine oil filler cap 7 1. Oil strainer 1. Oil filter element cover 2. Compression spring 2. Oil filter element drain bolt 3. O-ring 3. Oil filter element cover bolt TIP Skip steps 4–9 if the oil filter element is not being cleaned. 5.
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10D-9-15.book 14 ページ２０１１年３月７日月曜日午後３時６分 PERIODIC MAINTENANCE AND ADJUSTMENT 7. Check the O-rings for damage and replace them if necessary. 8. Clean the oil filter element with solvent, and then install it. TIP Check the oil filter element for damage and replace it if necessary. 9. Install the oil filter element cover by installing the bolts and the drain bolt, then tightening them to the specified torques. Tightening torques: Oil filter element cover bolt: 10 Nm (1.0 m·kgf, 7.
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10D-9-15.book 15 ページ２０１１年３月７日月曜日午後３時６分 PERIODIC MAINTENANCE AND ADJUSTMENT EAU20822 Cleaning the air filter element and check hose 1 2 3 4 5 6 The air filter element should be cleaned at the intervals specified in the periodic maintenance and lubrication chart. Clean the air filter element more frequently if you are riding in unusually wet or dusty areas. In addition, the air filter check hose must be frequently checked and cleaned if necessary. To clean the air filter element 1. Remove panel A.
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10D-9-15.book 16 ページ２０１１年３月７日月曜日午後３時６分 PERIODIC MAINTENANCE AND ADJUSTMENT EAU21236 Cleaning the spark arrester The spark arrester should be cleaned at the intervals specified in the periodic maintenance and lubrication chart. use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe and inside of the tailpipe housing. EWA10980 1 1. Air filter check hose 2. If dirt or water is visible, remove the hose, clean it, and then install it.
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10D-9-15.book 17 ページ２０１１年３月７日月曜日午後３時６分 PERIODIC MAINTENANCE AND ADJUSTMENT EAU21251 Carburetor 1 2 3 The carburetor is an important part of the engine and its emission control system, which requires very sophisticated adjustment. Therefore, carburetor adjustments should be left to Yamaha dealer, who has the necessary professional knowledge and experience.
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10D-9-15.book 18 ページ２０１１年３月７日月曜日午後３時６分 PERIODIC MAINTENANCE AND ADJUSTMENT EAU21401 EAU21575 Valve clearance Tires The valve clearance changes with use, resulting in improper air-fuel mixture and/or engine noise. To prevent this from occurring, the valve clearance must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart.
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10D-9-15.book 19 ページ２０１１年３月７日月曜日午後３時６分 PERIODIC MAINTENANCE AND ADJUSTMENT with the local regulations. Tire inspection 1 1 2 3 2 3 4 1. Tire tread depth 5 6 7 8 9 2. Tire wear indicator 3. Tire sidewall The tires must be checked before each ride. If the tire shows crosswise lines (minimum tread depth), if the tire has a nail or glass fragments in it, or if the sidewall is cracked, have a Yamaha dealer replace the tire immediately. Minimum tire tread depth (front and rear): 1.0 mm (0.
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10D-9-15.book 20 ページ２０１１年３月７日月曜日午後３時６分 PERIODIC MAINTENANCE AND ADJUSTMENT EAU21943 Spoke wheels EWA10610 WARNING The wheels on this model are not designed for use with tubeless tires. Do not attempt to use tubeless tires on this model. To maximize the performance, durability, and safe operation of your motorcycle, note the following points regarding the specified wheels.
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10D-9-15.book 21 ページ２０１１年３月７日月曜日午後３時６分 PERIODIC MAINTENANCE AND ADJUSTMENT 1 7. Tighten the locknut at the crankcase. 8. Tighten the locknut at the clutch lever and then slide the rubber cover to its original position. EAU48442 Adjusting the brake lever free play 3 1 2 2 EWA10630 (b) 3 (a) WARNING 4 4 5 1. Locknut 2. Brake lever free play adjusting screw 6 3. Brake lever free play 4. Rubber cover 7 8 9 The brake lever free play should measure 5.0–8.0 mm (0.20–0.31 in) as shown.
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10D-9-15.book 22 ページ２０１１年３月７日月曜日午後３時６分 PERIODIC MAINTENANCE AND ADJUSTMENT EAU22193 Adjusting the brake pedal height 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). pedal free play and, if necessary, adjust it as follows. 2 3 1 1 3 (a) 4 1 (b) 2 1. Brake pedal free play 1. Brake pedal height EWA10670 WARNING It is advisable to have a Yamaha dealer make these adjustments.
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10D-9-15.book 23 ページ２０１１年３月７日月曜日午後３時６分 PERIODIC MAINTENANCE AND ADJUSTMENT EWA10680 WARNING  After adjusting the drive chain 1 2 3 4 5 slack or removing and installing the rear wheel, always check the brake pedal free play.  If proper adjustment cannot be obtained as described, have a Yamaha dealer make this adjustment.  After adjusting the brake pedal free play, check the operation of the brake light.
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10D-9-15.book 24 ページ２０１１年３月７日月曜日午後３時６分 PERIODIC MAINTENANCE AND ADJUSTMENT EAU22380 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. EAU22430 Front brake pads peared, have a Yamaha dealer replace the brake pads as a set.
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10D-9-15.book 25 ページ２０１１年３月７日月曜日午後３時６分 PERIODIC MAINTENANCE AND ADJUSTMENT  1  2 3  4 5 6 7  performance. Clean the filler cap before removing. Use only DOT 4 brake fluid from a sealed container. Use only the specified brake fluid; otherwise, the rubber seals may deteriorate, causing leakage. Refill with the same type of brake fluid. Adding a brake fluid other than DOT 4 may result in a harmful chemical reaction. Be careful that water does not enter the brake fluid reservoir when refilling.
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10D-9-15.book 26 ページ２０１１年３月７日月曜日午後３時６分 PERIODIC MAINTENANCE AND ADJUSTMENT EAU22760 1 Drive chain slack The drive chain slack should be checked before each ride and adjusted if necessary. (a) EAU22774 To check the drive chain slack 1. Place the motorcycle on the sidestand. TIP When checking and adjusting the drive chain slack, there should be no weight on the motorcycle. 2. Shift the transmission into the neutral position. 3. Measure the drive chain slack as shown. Drive chain slack: 35.0–60.
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10D-9-15.book 27 ページ２０１１年３月７日月曜日午後３時６分 PERIODIC MAINTENANCE AND ADJUSTMENT in the specified limits.[ECA10571] 1 2 TIP Make sure that both adjusting plates are in the same position for proper wheel alignment. 4. Tighten the axle nut to the specified torque. 3 4 Tightening torque: Axle nut: 90 Nm (9.0 m·kgf, 65 ft·lbf) 5 6 WARNING After adjusting the brake pedal free play, check the operation of the brake light. EWA10660 8 9 6.
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10D-9-15.book 28 ページ２０１１年３月７日月曜日午後３時６分 PERIODIC MAINTENANCE AND ADJUSTMENT EAU23114 Checking and lubricating the throttle grip and cable The operation of the throttle grip should be checked before each ride. In addition, the cable should be lubricated by a Yamaha dealer at the intervals specified in the periodic maintenance chart. The throttle cable is equipped with a rubber cover. Make sure that the cover is securely installed.
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10D-9-15.book 29 ページ２０１１年３月７日月曜日午後３時６分 PERIODIC MAINTENANCE AND ADJUSTMENT EAU23182 Checking and lubricating the brake pedal EAU23202 Checking and lubricating the sidestand EAUM1652 Lubricating the swingarm pivots 1 2 1 3 4 5 6 7 8 9 The operation of the brake pedal should be checked before each ride, and the pedal pivot should be lubricated if necessary.
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10D-9-15.book 30 ページ２０１１年３月７日月曜日午後３時６分 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.
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10D-9-15.book 31 ページ２０１１年３月７日月曜日午後３時６分 PERIODIC MAINTENANCE AND ADJUSTMENT EAU23291 Checking the wheel bearings 1 2 3 4 EAU23365 medical attention. Battery  Batteries produce explosive hy- The battery is located under the seat. (See page 4-8.) A poorly maintained battery will corrode and discharge quickly. The electrolyte level, battery lead connections and breather hose routing should be checked before each ride and at the intervals specified in the periodic maintenance and lubrication chart.
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10D-9-15.book 32 ページ２０１１年３月７日月曜日午後３時６分 PERIODIC MAINTENANCE AND ADJUSTMENT 3 4 1 2 1 1 2 2 3 5 1. Battery 1. Maximum level mark 2. Battery band 2. Minimum level mark 3. Battery breather hose 4. Positive battery lead (red) 5. Negative battery lead (black) 5. Place the battery on a level surface, and then check the electrolyte level in the battery. TIP The electrolyte should be between the minimum and maximum level marks. 6.
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10D-9-15.book 33 ページ２０１１年３月７日月曜日午後３時６分 PERIODIC MAINTENANCE AND ADJUSTMENT tive (-) terminal. 11. Install the seat. 1 2 3 4 5 6 7 8 9 To store the battery 1. If the vehicle will not be used for more than one month, remove the battery, fully charge it, and then place it in a cool, dry place. NOTICE: When removing the battery, be sure the key is turned to “OFF”, then disconnect the negative lead before disconnecting the positive lead.[ECA16302] 2.
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10D-9-15.book 34 ページ２０１１年３月７日月曜日午後３時６分 PERIODIC MAINTENANCE AND ADJUSTMENT EAU23816 Specified fuse: 20.0 A 3. Turn the key to “ON” and turn on the electrical circuits to check if the devices operate. 4. If the fuse immediately blows again, have a Yamaha dealer check the electrical system. Replacing the headlight bulb This model is equipped with a halogen bulb headlight. If the headlight bulb burns out, replace it as follows.
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10D-9-15.book 35 ページ２０１１年３月７日月曜日午後３時６分 PERIODIC MAINTENANCE AND ADJUSTMENT then secure it with the bulb holder. 6. Install the bulb cover, and then connect the coupler. 7. Place the headlight unit in the original position, and then install the bolts. bulb cover. 2 1 1 2 EAU24133 Replacing the tail/brake light bulb 1. Remove the tail/brake light lens by removing the screws. 1 3 4 1. Headlight bulb cover 5 6 2. Headlight coupler 4.
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10D-9-15.book 36 ページ２０１１年３月７日月曜日午後３時６分 PERIODIC MAINTENANCE AND ADJUSTMENT EAU24204 1 Replacing a turn signal light bulb 1 1. Remove the turn signal light lens by removing the screw. 2 1 2 3 1. Tail/brake light bulb 3. Insert a new bulb into the socket, push it in, and then turn it clockwise until it stops. 4. Install the lens by installing the screws. NOTICE: Do not overtighten the screws, otherwise the lens may break.[ECA10681] 1. Turn signal light bulb 1. Screw 2.
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10D-9-15.book 37 ページ２０１１年３月７日月曜日午後３時６分 PERIODIC MAINTENANCE AND ADJUSTMENT EAU24350 Supporting the motorcycle 1 2 3 4 5 6 7 8 9 frame in front of the rear wheel or under each side of the swingarm. 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. Check that the motorcycle is in a stable and level position before starting any maintenance.
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10D-9-15.book 38 ページ２０１１年３月７日月曜日午後３時６分 PERIODIC MAINTENANCE AND ADJUSTMENT 4. Remove the axle nut and the washer. 5. Pull the wheel axle out. 6. Remove the spacer, speedometer gear unit and the wheel. NOTICE: Do not apply the brake after the wheel has been removed together with the brake disc, otherwise the brake pads will be forced shut.[ECA11071] 1 2 1 1. Speedometer gear unit EAU51411 To install the front wheel 1. Install the spacer into the right side of the wheel hub. 2.
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10D-9-15.book 39 ページ２０１１年３月７日月曜日午後３時６分 PERIODIC MAINTENANCE AND ADJUSTMENT EAU25080 Rear wheel 1 2 3 4 EAU51421 To remove the rear wheel EAU51431 EWA10821 2 3 4 5 6 7 8 9 8. Remove the spacers, the drive chain slack adjusting plates and the wheel. WARNING To avoid injury, securely support the vehicle so there is no danger of it falling over. 1. Loosen the axle nut. 2. Remove the brake pedal free play adjusting nut, and then disconnect the brake rod from the brake camshaft lever. 3.
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10D-9-15.book 40 ページ２０１１年３月７日月曜日午後３時６分 PERIODIC MAINTENANCE AND ADJUSTMENT EWA10660 WARNING After adjusting the brake pedal free play, check the operation of the brake light. 1 1. Retainer 5. Install the axle nut. 6. Adjust the drive chain slack. (See page 7-26.) 7. Lower the rear wheel so that it is on the ground. 8. Tighten the axle nut to the specified torque. Tightening torque: Axle nut: 90 Nm (9.0 m·kgf, 65 ft·lbf) 9.
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10D-9-15.book 41 ページ２０１１年３月７日月曜日午後３時６分 PERIODIC MAINTENANCE AND ADJUSTMENT 1 heaters or furnaces. Gasoline or gasoline vapors can ignite or explode, causing severe injury or property damage.
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10D-9-15.book 42 ページ２０１１年３月７日月曜日午後３時６分 PERIODIC MAINTENANCE AND ADJUSTMENT EAU25963 Troubleshooting chart 1. Fuel Check the fuel level in the fuel tank. There is enough fuel. Check the compression. There is no fuel. Supply fuel. The engine does not start. Check the compression. 2. Compression 3 There is compression. Check the ignition. There is no compression. Have a Yamaha dealer check the vehicle. Operate the electric starter. 3.
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10D-9-15.book 1 ページ２０１１年３月７日月曜日午後３時６分 MOTORCYCLE CARE AND STORAGE EAU37833 Matte color caution Care ECA15192 1 2 3 4 5 EAU26004 NOTICE Some models are equipped with matte colored finished parts. Be sure to consult a Yamaha dealer for advice on what products to use before cleaning the vehicle. Using a brush, harsh chemical products or cleaning compounds when cleaning these parts will scratch or damage their surface. Wax also should not be applied to any matte colored finished parts.
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10D-9-15.book 2 ページ２０１１年３月７日月曜日午後３時６分 MOTORCYCLE CARE AND STORAGE off any detergent residue using plenty of water, as it is harmful to plastic parts.  Do not use any harsh chemical products on plastic parts. Be sure to avoid using cloths or sponges which have been in contact with strong or abrasive cleaning products, solvent or thinner, fuel (gasoline), rust removers or inhibitors, brake fluid, antifreeze or electrolyte.
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10D-9-15.book 3 ページ２０１１年３月７日月曜日午後３時６分 MOTORCYCLE CARE AND STORAGE 1 2 3 including chrome- and nickel-plated, surfaces. 5. Use spray oil as a universal cleaner to remove any remaining dirt. 6. Touch up minor paint damage caused by stones, etc. 7. Wax all painted surfaces. 8. Let the motorcycle dry completely before storing or covering it. EWA11131 4 5 6 7 8 9 WARNING Contaminants on the brakes or tires can cause loss of control.  Make sure that there is no oil or wax on the brakes or tires.
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10D-9-15.book 4 ページ２０１１年３月７日月曜日午後３時６分 MOTORCYCLE CARE AND STORAGE fuel cock that has an “OFF” position: Turn the fuel cock lever to “OFF”. 3. Drain the carburetor float chamber by loosening the drain bolt; this will prevent fuel deposits from building up. Pour the drained fuel into the fuel tank. 4. Fill up the fuel tank and add fuel stabilizer (if available) to prevent the fuel tank from rusting and the fuel from deteriorating. 5.
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10D-9-15.book 1 ページ２０１１年３月７日月曜日午後３時６分 SPECIFICATIONS Dimensions: 1 2 3 4 5 6 Overall length: 2090 mm (82.3 in) Overall width: 820 mm (32.3 in) Overall height: 1120 mm (44.1 in) Seat height: 790 mm (31.1 in) Wheelbase: 1325 mm (52.2 in) Ground clearance: 265 mm (10.43 in) Minimum turning radius: 1900 mm (74.
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10D-9-15.book 2 ページ２０１１年３月７日月曜日午後３時６分 SPECIFICATIONS 4th: 1.040 (26/25) 5th: 0.821 (23/28) Chassis: Frame type: Diamond Caster angle: 26.00  Trail: 96 mm (3.
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10D-9-15.book 3 ページ２０１１年３月７日月曜日午後３時６分 SPECIFICATIONS Bulb voltage, wattage  quantity: 1 2 3 4 5 6 Headlight: 12 V, 60 W/55 W  1 Tail/brake light: 12 V, 8.0 W/27.0 W  1 Front turn signal/position light: 12 V, 27 W/8.0 W  2 Rear turn signal light: 12 V, 27.0 W  2 Meter lighting: 12 V, 3.4 W  1 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  1 Fuse: Fuse: 20.
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10D-9-15.book 1 ページ２０１１年３月７日月曜日午後３時６分 CONSUMER INFORMATION EAU26353 Identification numbers EAU26390 Key identification number Record the key identification number, vehicle identification number and model label information in the spaces provided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen. EAU26400 Vehicle identification number 1 1 2 3 KEY IDENTIFICATION NUMBER: 4 1.
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10D-9-15.book 2 ページ２０１１年３月７日月曜日午後３時６分 CONSUMER INFORMATION EAU26460 Model label EAU48061 Vehicle Emission Control Information label 1 2 1 3 4 1 1. Model label 5 6 7 8 The model label is affixed to the location shown. Record the information on this label in the space provided. This information will be needed when ordering spare parts from a Yamaha dealer. 1.
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10D-9-15.book 3 ページ２０１１年３月７日月曜日午後３時６分 CONSUMER INFORMATION EAU26551 Reporting safety defects If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Yamaha Motor Corporation, U.S.A.
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10D-9-15.
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10D-9-15.book 5 ページ２０１１年３月７日月曜日午後３時６分 CONSUMER INFORMATION EAU26611 Maintenance record Copies of work orders and/or receipts for parts purchased and installed on your motorcycle will be required to document that maintenance has been completed in accordance with the emissions warranty. The chart below is printed only as a reminder that maintenance work is required. It is not acceptable proof of maintenance work.
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10D-9-15.
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10D-9-15.book 7 ページ２０１１年３月７日月曜日午後３時６分 CONSUMER INFORMATION EAU26663 YAMAHA MOTOR CORPORATION, U.S.A. STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY Yamaha Motor Corporation, U.S.A. hereby warrants that new Yamaha motorcycles 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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10D-9-15.book 8 ページ２０１１年３月７日月曜日午後３時６分 CONSUMER INFORMATION 1 WARRANTY QUESTIONS AND ANSWERS CUSTOMER SERVICE Q. What costs are my responsibility during the warranty period? A. The customer’s responsibility includes all costs of normal maintenance services, non-warranty repairs, accident and collision damages, and oil, oil filters, air filters, spark plugs, and brake shoes.
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10D-9-15.book 9 ページ２０１１年３月７日月曜日午後３時６分 CONSUMER INFORMATION EAU26751 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.
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10D-9-15.book 10 ページ２０１１年３月７日月曜日午後３時６分 CONSUMER INFORMATION 1 2 3 4 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.
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10D-9-15.book 11 ページ２０１１年３月７日月曜日午後３時６分 INDEX A Engine idling speed, checking................. 7-17 Engine oil and oil filter element ............... 7-12 Engine, starting a warm ............................ 6-2 Engine stop switch .................................... 4-3 Air filter element and check hose, cleaning .................................................7-15 B Battery .....................................................7-31 Brake and clutch levers, checking and lubricating ...............
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10D-9-15.book 12 ページ２０１１年３月７日月曜日 INDEX Turn signal light bulb, replacing ...............7-36 Turn signal switch ......................................4-3 V Valve clearance .......................................7-18 Vehicle Emission Control Information label .......................................................10-2 Vehicle identification number ...................10-1 W Warranty, extended..................................10-9 Warranty, limited ......................................
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YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2011.03–0.