USO E MANUTENZIONE OWNER’S MANUAL …...wear a complete motorcycle suit (whether made of leather...

USO E MANUTENZIONE

OWNER’S MANUALMANUEL DU PROPRIÉTAIRE

BEDIENUNGSANLEITUNG

MANUAL DEL PROPIETARIO

5JN-F8199-A0

BT1100

INTRODUCTIONEAU03338

Welcome to the Yamaha world of motorcycling!

As the owner of a BT1100, you are benefiting from Yamaha’s vast experience and newest technology regardingthe design and manufacture of high-quality products, which have earned Yamaha a reputation for dependability.

Please take the time to read this manual thoroughly, so as to enjoy all advantages of your BT1100. The owner’smanual does not only instruct you in how to operate, inspect and maintain your motorcycle, but also in how to safe-guard yourself and others from trouble and injury.

In addition, the many tips given in this manual will help keep your motorcycle in the best possible condition. If youhave any further questions, do not hesitate to contact your Yamaha dealer.

The Yamaha team wishes you many safe and pleasant rides. So, remember to put safety first!

IMPORTANT MANUAL INFORMATION EAU00005

Particularly important information is distinguished in this manual by the following notations:

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator, a bystander, or a person inspecting or repairing the motorcycle.

A CAUTION indicates special precautions that must be taken to avoid damage to themotorcycle.

NOTE A NOTE provides key information to make procedures easier or clearer.

WARNING

NOTE:• This manual should be considered a permanent part of this motorcycle and should remain with it even if

the motorcycle is subsequently sold.• Yamaha continually seeks advancements in product design and quality. Therefore, while this manual

contains the most current product information available at the time of printing, there may be minor dis-crepancies between your motorcycle and this manual. If you have any questions concerning this manu-al, please consult your Yamaha dealer.

CAUTION:

IMPORTANT MANUAL INFORMATIONEAU00005

EW000002

WARNING0PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THISMOTORCYCLE.

BT1100OWNER’S MANUAL

2001 by Belgarda S.p.A.1st edition, july 2001All rights reserved.

Any reprinting or unauthorized usewithout the written permission of

Belgarda S.p.A. is expressly prohibited.

Printed in Italy.

EAUBOOOO

1

2

3

4

5

6

7

8

9

GIVE SAFETY THE RIGHT OF WAY

DESCRIPTION

INSTRUMENT AND CONTROL FUNCTIONS

PRE-OPERATION CHECKS

OPERATION AND IMPORTANT RIDING POINTS

PERIODIC MAINTENANCE AND MINOR REPAIR

MOTORCYCLE CARE AND STORAGE

SPECIFICATIONS

CONSUMER INFORMATION

INDEX

TABLE OF CONTENTSEAU00009

1

Give safety the right of way ................................................................ 1-1

GIVE SAFETY THE RIGHT OF WAYEAU00021

EAU00021

1

GIVE SAFETY THE RIGHT OF WAY

1-1

EW000015

Motorcycles are fascinating vehicles, which can give you an unsurpassed feeling of power and freedom. Howev-er, they also impose certain limits, which you must accept; even the best motorcycle does not ignore the laws ofphysics.

Regular care and maintenance are essential for preserving value and operating condition of your motorcycle.Moreover, what is true for the motorcycle is also true for the rider: good performance depends on being in goodshape. Riding under the influence of medication, drugs and alcohol is, of course, out of the question. Motorcycleriders––more than car drivers––must always be at their mental and physical best. Under the influence of evensmall amounts of alcohol, there is a tendency to take dangerous risks.

Protective clothing is as essential for the motorcycle rider as seat belts are for car drivers and passengers. Alwayswear a complete motorcycle suit (whether made of leather or tear-resistant synthetic materials with protectors),sturdy boots, motorcycle gloves and a properly fitting helmet. Optimum protective wear, however, should not en-courage carelessness. Although full-coverage helmets and suits, in particular, create an illusion of total safety andprotection, motorcyclists will always be vulnerable. Riders who lack critical self-control run the risk of going too fastand are apt to take chances. This is even more dangerous in wet weather. The good motorcyclist rides safely, pre-dictably and defensively––avoiding all dangers, including those caused by others.

Enjoy your ride!

2

Left view................................................................................................2-1

Right view ............................................................................................2-2

Controls and instruments ......................................................................2-3

DESCRIPTIONEAU00026

1 2

3

456

1. Starter (choke) lever (page 3-12)2. Storage compartment (page 3-14)3. Tool kit (page 6-1)4. Spring preload adjusting ring (shock absorber assembly) (page 3-15)5. Shift pedal (page 3-10)6. Engine oil level window (page 6-6)

DESCRIPTION

Left view

EAU00026

2-1

2

7 8 9 10

12 11

DESCRIPTIONEAU00026

2-2

2

7. Fuse box (page 6-28)8. Battery (page 6-26)9. Helmet holders (page 3-14)10. Air filter element (page 6-10)11. Engine oil filter element (page 6-6)12. Brake pedal (page 3-10)

Right view

220

200

180

160140120

100

80

60

40

20

km/h

34 5 6

7210

3 4 5 6 721

8

DESCRIPTION EAU00026

2-3

2

1. Clutch lever (page 3-9)2. Left handlebar switches (page 3-8)3. Instruments and warning lights (page 3-2)4. Main switch and steering lock (page 3-1)5. Right handlebar switches (page 3-9)6. Throttle grip (page 6-13)7. Front brake lever (page 3-10)8. Fuel tank cap (page 3-11)

Controls and instruments

3

Main switch/steering lock .................................................................... 3-1

Indicator and warning lights ................................................................ 3-2

Speedometer unit ................................................................................ 3-3

Tachometer ........................................................................................ 3-6

Self-diagnosis device .......................................................................... 3-6

Anti-theft alarm (optional) .................................................................... 3-8

Handlebar switches ............................................................................ 3-8

Clutch lever ........................................................................................ 3-9

Shift pedal ........................................................................................ 3-10

Brake lever ........................................................................................ 3-10

Brake pedal ...................................................................................... 3-10

Fuel tank cap .................................................................................... 3-11

Fuel .................................................................................................. 3-11

Fuel tank breather hose .................................................................... 3-12

Starter (choke) lever ........................................................................ 3-12

Seat .................................................................................................. 3-13

Helmet holders .................................................................................. 3-14

Storage compartment ...................................................................... 3-14

Adjusting the front fork ...................................................................... 3-15

Adjusting the shock absorber assembly .......................................... 3-15

Sidestand .......................................................................................... 3-16

Ignition circuit cut-off system ............................................................ 3-17

INSTRUMENT AND CONTROL FUNCTIONSEAU00027

LOCK

P

OFF

ONPUSH

1 2

EAU00029

Main switch/steering lockThe main switch/steering lock controls theignition and lighting systems, and is usedto lock the steering. The various positionsare described below.

EAU00036

I ON

All electrical systems are supplied withpower, and the engine can be started. Thekey cannot be removed.

EAU00038

B OFF

All electrical systems are off. The key canbe removed.

EAU00040

D LOCK

The steering is locked, and all electricalsystems are off. The key can be removed.

To lock the steering1. Turn the handlebars all the way to the

left.2. Push the key in from the B (OFF) po-

sition, and then turn it to D (LOCK)while still pushing it.

3. Remove the key.

To unlock the steeringPush the key in, and then turn it to B(OFF) while still pushing it.

1. Push2. Turn

EAU00027

3-1

3


EW000016

WARNING0Never turn the key to B (OFF) or D(LOCK) while the motorcycle is mov-ing, otherwise the electrical systemswill be switched off, which may resultin loss of control or an accident. Makesure that the motorcycle is stoppedbefore turning the key to B (OFF) or D(LOCK).

LOCK

OFF (Premere)

Bloccare Sbloccare

LOCK(Premere)

OFF

Lock

(push)

Unlock

(push)


220

200

180

160140120

100

80

60

40

20

km/h

34 5 6

72

1

0

N

3 4 51 2EAU01590

F (Parking)

The steering is locked, and the taillight andauxiliary light are on, but all other electricalsystems are off. The key can be removed.The steering must be locked before thekey can be turned to “F ” .

ECA00043

Do not use the parking position for anextended length of time, otherwise thebattery may discharge.

CAUTION:

EAU03034

Indicator and warning lightsEAUB0001

Oil level warning light “v”

This warning light comes on when the en-gine oil level is low.The electrical circuit of the warning lightcan be checked according to the followingprocedure.

1. Turn the key to “I” (ON). The warn-ing light should come on for a fewseconds.

1. Oil level warning light “v”2. Turn signal indicator light “yy”3. Neutral indicator light “N”4. High beam indicator light “1”5. Fuel level warning light “K”

2. If the warning light does not come on,have a Yamaha dealer check theelectrical circuit.

NOTE:Even if the oil level is sufficient, the warn-ing light may flicker when riding on a slopeor during sudden acceleration or decelera-tion, but this is not a malfunction.

NOTE:This model is equipped with a self-diagno-sis device for the oil level warning light cir-cuit. (See page 3-6 for an explanation ofthe self-diagnosis device).

EAU00057

Turn signal indicator light “yy”

This indicator light flashes when the turnsignal switch is pushed to the left or right.

EAU00061

Neutral indicator light “N”

This indicator light comes on when thetransmission is in the neutral position.

3-2

3

EAU00027


2

1

5

43

1

2

6

54

3

EAU00063

High beam indicator light “1”

This indicator light comes on when thehigh beam of the headlight is switched on.

EAUB0002

Fuel level warning light “K”

This warning light comes on when the fuellevel drops below approximately 5.8 L.When this occurs, refuel as soon as possi-ble.The electrical circuit of the warning lightcan be checked according to the followingprocedure.

1. Turn the key to “I” (ON).

2. If the warning light does not come on,have a Yamaha dealer check theelectrical circuit.

NOTE:This model is equipped with a self-diagno-sis device for the fuel level warning lightcircuit. (See page 3-6 for an explanation ofthe self-diagnosis device).

EAUB0003

Speedometer unitThe speedometer unit is equipped with thefollowing:

• a speedometer (which shows ridingspeed)

• a tachometer (which shows enginer/min)

• an odometer (which shows the totaldistance traveled)

1. Speedometer set to km/h2. Tachometer3. Odometer/ tripmeter/ fuel reserve tripmeter/clock display4. “SET” button5. “RESET” button

• two tripmeters (which show the dis-tance traveled since they were lastset to zero)

• a fuel reserve tripmeter (which showsthe distance traveled on the fuel re-serve)

• an oil change indicator (which is dis-played when the oil needs to bechanged)

• a clock.

1. Speedometer set to km/h2. Speedometer set to mph3. Tachometer4. Odometer/ tripmeter/ fuel reserve tripmeter/clock display5. “SET” button6. “RESET” button

EAU00027

3-3

3


NOTE:Depending on the market where themotorcycle is sold, the speedometer canbe set to either mph or km/h. When thespeedometer is set to mph, the odometercounts in miles (1 mile = 1.61 km).

Odometer and tripmeter modes

Pushing the “SET” button switches the dis-play between the odometer mode “ODO”and the tripmeter modes “TRIP 1” and“TRIP 2” in the following order: ODO 6TRIP 1 6 TRIP 2 6 ODO When the fuel warning light comes on, thedisplay will automatically change to the fu-el reserve tripmeter mode “TRIP F” andstart counting the distance traveled fromthat point. In that case, pushing the “SET”button switches the display between thevarious tripmeter and odometer modes inthe following order: TRIP F 6 TRIP 1 6TRIP 2 6 ODO 6 TRIP FTo reset a tripmeter, select it by pushingthe “SET” button, and then push the “RE-SET” button for at least one second. If youdo not reset the fuel reserve tripmetermanually, it will reset itself automaticallyand the display will return to the priormode after refueling and traveling severalkilometers.

Oil change indicator

At the initial 1,000 km (620 mi) and every10,000 km (6,200 mi) thereafter, the mes-sage “OIL CHANGE” appears in the dis-play for a few seconds when the key isturned to “ON”, to indicate that the engineoil should be changed.After changing the engine oil, reset the oilchange indicator.If the engine oil is changed before the oilchange indicator appears in the display(i.e. before the periodic oil change intervalhas been reached), the indicator must bereset after the oil change for the next peri-odic oil change to be indicated at the cor-rect time.

NOTE:When the message “OIL CHANGE”appears in the display, be sure to changethe engine oil as soon as possible. In addi-tion to these kilometer-based oil changes,be sure to have a Yamaha dealer performthe annual checks specified in the period-ic maintenance and lubrication chart onpage 6-2.

EAU00027

3-4

3


To reset the periodic maintenance and lu-brication indicator:

1. Turn the key to “B” (OFF).

2. Push the “RESET” button and hold itdown while turning the key to “I”(ON).

Clock mode

NOTE:The clock can only be set while thespeedometer unit is in the odometermode.

To set the clock:


2. Push the “RESET” button and “SET”button together for at least two sec-onds.

3. When the hour digits start flashing,push the “RESET” button to set thehours (between 1 and 12).

4. Push the “SET” button, and the first ofthe two minute digits will start flash-ing.

5. Push the “RESET” button to set thefirst minute digit (between 0 and 5).

6. Push the “SET” button, and the sec-ond of the two minute digits will startflashing.

7. Push the “RESET” button to set thesecond minute digit (between 0 and 9).

8. Push the “SET” button, and then re-lease it to start the clock.

EAU00027

3-5

3


NOTE:The clock can only be set when the motor-cycle is stopped. The clock does not auto-matically adjust for Daylight Saving Time.Therefore, when the time changes fromStandard Time to Daylight Saving Time(and vice versa), the clock must be setmanually.

EAU00101

TachometerThe electric tachometer allows the rider tomonitor the engine speed and keep it with-in the ideal power range.

EC000003

Do not operate the engine in thetachometer red zone.Red zone: 6,400 r/min and above.

CAUTION:

EAUB0004

Self-diagnosis deviceNOTE:When the key is turned to “I” (ON), thetachometer and speedometer needlesshould move to the maximum, then backto zero. In addition, the oil level warninglight and fuel level warning light shouldcome on for a few seconds, then go off. Ifthe tachometer or speedometer needledoes not move as described or either ofthe warning lights does not come on, havea Yamaha dealer check the electrical cir-cuits.

This model is equipped with a self-diagno-sis device for the following electrical cir-cuits:

• speedometer

• tachometer

• oil level warning light

• throttle position sensor

• speed sensor.

3-6

31

2

1. Tachometer2. Red zone

EAU00027

INSTRUMENT AND CONTROL FUNCTIONS EAU00027

3-7

3

If any of the above circuits are defective,the tachometer will repeatedly display thefollowing error code:

Use the chart below to identify the faultyelectrical circuit.

If the tachometer displays such an errorcode, note the circuit-specific number ofr/min, and then have a Yamaha dealercheck the motorcycle.

EC000004

When the tachometer displays an errorcode, the motorcycle should bechecked as soon as possible in orderto avoid engine damage.

CAUTION:

0 r/min (for 3 seconds)

Circuit-specific number of r/min for 2.5 seconds (see the table below).

Specific Faulty electrical r/min circuit

3,000 r/min Throttle position sensor

4,000 r/min Speed sensor

Current engine speed for 3 seconds

EAU00119

Pass switch “1”

Press this switch to flash the headlight.

EAU00121

Dimmer switch “2 /1”

Set this switch to “1” for the high beamand to “2” for the low beam.

EAU00129

Horn switch “o”

Press this switch to sound the horn.


3-8

3

3

1

2

4

EAU00109

Anti-theft alarm (optional)This motorcycle can be equipped with anoptional anti-theft alarm by a Yamahadealer. Contact a Yamaha dealer for moreinformation.

EAU00118

Handlebar switchesEAU03889

Turn signal switch “yy”

To signal a right-hand turn, push thisswitch to “∆∆”. To signal a left-hand turn,push this switch to “ŸŸ”. When released,the switch returns to the center position. Tocancel the turn signal lights, push theswitch in after it has returned to the centerposition.

1. Turn signal switch “yy”2. Pass switch “1”3. Dimmer switch “2 / 1”4. Horn switch “o”

EAU00027


2

1

3

1

EAU03890

Engine stop switch “I/B”

Set this switch to “I” before starting theengine. Set this switch to “B” to stop theengine in case of an emergency, such aswhen the motorcycle overturns or whenthe throttle cable is stuck.

EAU03898

Light switch “G/E/H”

Set this switch to “G” to turn on the aux-iliary light, meter lighting and taillight. Setthe switch to “E” to turn on the headlightalso. Set the switch to “H” to turn off all thelights.

EAU00143

Start switch “J”

Push this switch to crank the engine withthe starter.

EC000005

See page 5-1 for starting instructionsprior to starting the engine.

CAUTION:EAU00152

Clutch leverThe clutch lever is located at the left han-dlebar grip. To disengage the clutch, pullthe lever toward the handlebar grip. To en-gage the clutch, release the lever. Thelever should be pulled rapidly and re-leased slowly for smooth clutch operation.The clutch lever is equipped with a clutchswitch, which is part of the ignition circuitcut-off system. (See page 3-18 for an ex-planation of the ignition circuit cut-off sys-tem).

3-9

3

1. Engine stop switch “I/B”2. Light switch “G/E/H”3. Start switch “J”

1. Clutch lever

EAU00027


1

1 2

1

2

3

4

3

1

EAU00157

Shift pedalThe shift pedal is located on the left side ofthe engine and is used in combination withthe clutch lever when shifting the gears ofthe 5-speed constant-mesh transmissionequipped on this motorcycle.

EAU00161

Brake leverThe brake lever is located at the right han-dlebar grip. To apply the front brake, pullthe lever toward the handlebar grip.The brake lever is equipped with a positionadjusting dial. To adjust the distance be-tween the brake lever and the handlebargrip, turn the adjusting dial while holdingthe lever pushed away from the handlebargrip. Make sure that the appropriate set-ting on the adjusting dial is aligned with thearrow mark on the brake lever.

EAU00162

Brake pedalThe brake pedal is on the right side of themotorcycle. To apply the rear brake, pressdown on the brake pedal.

3-10

3

1. Shift pedal 1. Brake lever2. Position adjusting dial3. Arrow mark

1. Brake pedal

EAU00027


1

2

1

2

EAU02935

Fuel tank capTo open the fuel tank cap

Open the fuel tank cap lock cover, insertthe key into the lock, and then turn it 1/4turn clockwise. The lock will be releasedand the fuel tank cap can be opened.

To close the fuel tank cap

1. Push the fuel tank cap into positionwith the key inserted in the lock.

2. Turn the key counterclockwise to theoriginal position, remove it, and thenclose the lock cover.

NOTE:The fuel tank cap cannot be closed unlessthe key is in the lock. In addition, the keycannot be removed if the cap is not prop-erly closed and locked.

EWA00025WARNING0Make sure that the fuel tank cap isproperly closed before riding.

EAU03753

FuelMake sure that there is sufficient fuel in thetank. Fill the fuel tank to the bottom of thefiller tube as shown.

EW000130WARNING0• Do not overfill the fuel tank, other-

wise it may overflow when the fuelwarms up and expands.

• Avoid spilling fuel on the hotengine.

3-11

3

1. Lock cover2. Open

1. Fuel tank filler tube2. Fuel level

EAU00027


1

EAU00185

Immediately wipe off spilled fuel with aclean, dry, soft cloth, since fuel maydeteriorate painted surfaces or plasticparts.

CAUTION:

EAU00191

NOTE:If knocking (or pinging) occurs, use gaso-line of a different brand or with a higheroctane grade.

Recommended fuel:Regular unleaded gasoline with aresearch octane number of 91 orhigher

Fuel tank capacity:Total amount:

20 LReserve amount:

5.8 L

1. Fuel tank breather hose

EAU02955

Fuel tank breather hoseBefore operating the motorcycle:Check the fuel tank breather hose connec-tion.Check the fuel tank breather hose forcracks or damage, and replace it if dam-aged.Make sure that the end of the fuel tankbreather hose is not blocked, and clean it ifnecessary.

EAU03839

Starter (choke) lever Starting a cold engine requires a richer air-fuel mixture, which is supplied by thestarter (choke).Move the lever in direction b to turn onthe starter (choke).Move the lever in direction a to turn offthe starter (choke).

1

b

a

1. Starter (choke) lever

3-12

3

EAU00027

Belgarda Belgarda

Belgarda Belgarda


1

� �ECA00038

Do not use the starter (choke) for morethan 3 minutes as the exeaust pipe maydiscolor from excessive heat. In addi-tion, extended use of the starter(choke) will cause afterburning. If thisoccurs, turn off the starter (choke).

CAUTION:

EAU01726

SeatTo remove the seat

1. Insert the key into the seat lock, andthen turn it clockwise.

2. Pull the seat off.

1. Open 1. Projection 2. Seat holder

To install the seat

1. Insert the projections on the front ofthe seat into the seat holders asshown.

2. Push the rear of the seat down to lockit in place.

3. Remove the key.

NOTE:Make sure that the seat is properlysecured before riding.

EAU00027

3-13

3

13


1. Helmet holders

12

1. Storage compartment2. Yamaha U-LOCK

1

1. Tool kit compartment

EAUB0005

Helmet holdersThe helmet holders are located under theseat. Each of the two helmet-holding ca-bles provided can be used to secure a hel-met to either helmet holder

To secure a helmet to a helmet holder

1. Remove the seat. (See page 3-13 forremoval and installation procedures).

2. Pass the helmet holding cablethrough the buckle on the helmetstrap as shown, and then hook thecable loop over the helmet holder.

3. Install the seat.

EWA00015

WARNING0Never ride with a helmet attached to ahelmet holder, since the helmet may hitobjects, causing loss of control andpossibly an accident.

EAUB0006

Storage compartmentThe storage compartment is located underthe seat. (See page 3-13 for seat removaland installation procedures).This storage compartment is designed tohold a genuine Yamaha U-LOCK. (Otherlocks may not fit).

The tool kit is located at the back of thestorage compartment and held in placewith a strap.When storing the owner’s manual or otherdocuments in the storage compartment,be sure to wrap them in a plastic bag sothat they will not get wet. When washingthe motorcycle, be careful not to let anywater enter the storage compartment.

3-14

EAU00027


1. Spring preload adjusting bolt 1. Setting2. Front fork cap bolt

��

�

��

1. Spring preload adjusting nut2. Locknut

EAU00285

Adjusting the front forkThis front fork is equipped with spring pre-load adjusting bolts.

EW000035WARNING0Always adjust both fork legs equally,otherwise poor handling and loss ofstability may result.

Adjust the spring preload as follows.To increase the spring preload and therebyharden the suspension, turn the adjustingbolt on each fork leg in direction a. To de-

crease the spring preload and therebysoften the suspension, turn the adjustingbolt on each fork leg in direction b.

NOTE:Align the appropriate groove on the adjust-ing mechanism with the top of the frontfork cap bolt.

EAUB0007

Adjusting the shock absorberassemblyThis shock absorber assembly is equippedwith a spring preload adjusting nut.

EC000015

Never attempt to turn an adjustingmechanism beyond the maximum orminimum settings.

Adjust the spring preload as follows.

1. Loosen the locknut.

2. To increase the spring preload andthereby harden the suspension, turnthe adjusting nut in direction a. To

CAUTION:

3-15

3

EAU00027

Minimum (soft) Standard Maximum (hard)

Setting 1 2 3 4 5 6 7


decrease the spring preload andthereby soften the suspension, turnthe adjusting nut in direction b.

NOTE:Use the special wrench included in theowner’s tool kit to make the adjustment.The spring preload setting is determinedby measuring distance A, shown in theillustration. The longer distance A is, thehigher the spring preload; the shorter dis-tance A is, the lower the spring preload.With each complete turn of the adjustingnut, distance A changes by 1.5 mm.

3. Tighten the locknut to the specifiedtorque.

• Always have a Yamaha dealer ser-vice the shock absorber.

EAU00330

SidestandThe sidestand is located on the left side ofthe frame. Raise the sidestand or lower itwith your foot while holding the motorcycleupright.

NOTE:The built-in sidestand switch is part of theignition circuit cut-off system, which cutsthe ignition in certain situations. (See fur-ther down for an explanation of the ignitioncircuit cut-off system).

3-16

3

Spring preload:Minimum (soft):

Distance A = 170 mmStandard:

Distance A = 162 mmMaximum (hard):

Distance A = 154 mm

Tightening torque:Locknut:

45 Nm (4.5 m•kg)

EAU00315

WARNING0This shock absorber contains highlypressurized nitrogen gas. For properhandling, read and understand the fol-lowing information before handling theshock absorber. The manufacturer can-not be held responsible for propertydamage or personal injury that mayresult from improper handling.

• Do not tamper with or attempt toopen the gas cylinder.

• Do not subject the shock absorberto an open flame or other high heatsources, otherwise it may explodedue to excessive gas pressure.

• Do not deform or damage the gascylinder in any way, as this willresult in poor damping perfor-mance.

EAU00027

Belgarda Belgarda

Belgarda Belgarda


EW000044

WARNING0The motorcycle must not be riddenwith the sidestand down, or if the side-stand cannot be properly moved up (ordoes not stay up), otherwise the side-stand could contact the ground anddistract the operator, resulting in a pos-sible loss of control. Yamaha’s ignition circuit cut-off sys-tem has been designed to assist theoperator in fulfilling the responsibilityof raising the sidestand before startingoff. Therefore, check this system regu-larly as described below and have aYamaha dealer repair it if it does notfunction properly.

EAU03720

Ignition circuit cut-off systemThe ignition circuit cut-off system (com-prising the sidestand switch, clutch switchand neutral switch) has the following func-tions.• It prevents starting when the trans-

mission is in gear and the sidestandis up, but the clutch lever is notpulled.

• It prevents starting when the trans-mission is in gear and the clutch leveris pulled, but the sidestand is stilldown.

• It cuts the running engine when thetransmission is in gear and the side-stand is moved down.

Periodically check the operation of the ig-nition circuit cut-off system according tothe following procedure.

EW000045WARNING0If a malfunction is noted, have a Yamahadealer check the system before riding.

3-17

3

EAU00027

INSTRUMENT AND CONTROL FUNCTIONSEAU00027

3-18

3

With the engine turned off:

1. Move the sidestand down.

2. Make sure that the engine stop switch is set to “I”.


4. Shift the transmission into the neutral position.

5. Push the start switch.

Does the engine start?

With the engine still running:6. Move the sidestand up.7. Keep the clutch lever pulled.8. Shift the transmission into gear.9. Move the sidestand down.Does the engine stall?

The neutral switch may be defective.The motorcycle should not be ridden until checked by aYamaha dealer.

The sidestand switch may be defective.The motorcycle should not be ridden until checked by aYamaha dealer.

The clutch switch may be defective.The motorcycle should not be ridden until checked by aYamaha dealer.

After the engine has stalled:10. Move the sidestand up.11. Keep the clutch lever pulled.12. Push the start switch.Does the engine start?

The system is OK. The motorcycle can be ridden.

NOTE:This check is most reliable if performed with a warmed-upengine.

NOYES

NOYES

NOYES

Pre-operation check list ...................................................................... 4-1

4

PRE-OPERATION CHECKSEAU01114

EAU01114PRE-OPERATION CHECKS

4-1

The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly, even if the vehicle remains unused (for example, as a result of ex-posure to the elements). Any damage, fluid leakage or loss of tire air pressure could have serious consequences. Therefore, it is very important, in addition to athorough visual inspection, to check the following points before each ride.

EAU03439

Pre-operation check list

ITEM CHECK PAGE

• Check fuel level in fuel tank.Fuel • Refuel if necessary. 3-11

• Check fuel line for leakage.

• Check oil level in engine.Engine oil • If necessary, add recommended oil to specified level. 6-6

• Check vehicle for oil leakage.

Final gear oil • Check vehicle for oil leakage. 6-8

• Check operation.• If soft or spongy, have Yamaha dealer bleed

hydraulic system.Front brake • Check fluid level in reservoir. 3-10, 6-19

• If necessary, add recommended brake fluid to specified level.• Check hydraulic system for leakage.

• Check operation.• If soft or spongy, have Yamaha dealer bleed

hydraulic system.Rear brake • Check fluid level in reservoir. 3-10, 6-19

• If necessary, add recommended brake fluid to specified level.• Check hydraulic system for leakage.

4

PRE-OPERATION CHECKSEAU01114

4-2

4

ITEM CHECK PAGE

• Check operation.• Lubricate cable if necessary.

Clutch • Check lever free play. 3-9, 6-17, 6-23

• Adjust if necessary.

• Make sure that operation is smooth.• Lubricate throttle grip, housing and cables

Throttle grip if necessary. 6-13, 6-22• Check free play.• If necessary, have Yamaha dealer make adjustment.

• Make sure that operation is smooth.Control cables • Lubricate if necessary. 6-22

• Check for damage.• Check tire condition and tread depth.

Wheels and tires • Check air pressure. 6-13, 6-16

• Correct if necessary.

Brake and shift • Make sure that operation is smooth.pedals • Lubricate pedal pivoting points if necessary. 6-23

Brake and clutch • Make sure that operation is smooth.levers • Lubricate lever pivoting points if necessary. 6-23

• Make sure that operation is smooth.Sidestand • Lubricate pivot if necessary. 6-24

Chassis • Make sure that all nuts, bolts and screws are properly tightened.fasteners • Tighten if necessary. –

Instruments, lights, • Check operation.signals and switches • Correct if necessary. 3-2, 3-3, 3-8, 3-9

Engine stop switch • Check operation. 3-9

Sidestand • Check operation of ignition circuit cut-off system.switch • If system is defective, have Yamaha dealer check vehicle. 3-18

PRE-OPERATION CHECKS

NOTE:Pre-operation checks should be made each time the motorcycle is used. Such an inspection can be accomplished in a very short time;and the added safety it assures is more than worth the time involved.

EWA00033WARNING0If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operating the motor-cycle.

EAU01114

4-3

4

5

Starting the engine .............................................................................. 5-1

Starting a warm engine ...................................................................... 5-3

Shifting ................................................................................................ 5-3

Tips for reducing fuel consumption .................................................... 5-4

Engine break-in .................................................................................. 5-4

Parking ................................................................................................ 5-5

OPERATION AND IMPORTANT RIDING POINTSEAU00372


EAU00373

WARNING0• Become thoroughly familiar with

all operating controls and theirfunctions before riding. Consult aYamaha dealer regarding any con-trol or function that you do notthoroughly understand.

• Never start the engine or operate itin a closed area for any length oftime. Exhaust fumes are poiso-nous, and inhaling them can causeloss of consciousness and deathwithin a short time. Always makesure that there is adequate ventila-tion.

• Before starting out, make sure thatthe sidestand is up. If the side-stand is not raised completely, itcould contact the ground and dis-tract the operator, resulting in apossible loss of control.

EAU03818

Starting the engineIn order for the ignition circuit cut-off sys-tem to enable starting, one of the followingconditions must be met:• The transmission is in the neutral po-

sition.• The transmission is in gear with the

clutch lever pulled and the sidestandup.

EW000054WARNING0• Before starting the engine, check

the function of the ignition circuitcut-off system according to theprocedure described on page 3-18.

• Never ride with the sidestanddown.

1. Turn the key to “I” (ON) and makesure that the engine stop switch is setto “I”.

EC000035

If the fuel level warning light comes on,check the fuel level, and, if necessary,refuel as soon as possible.

2. Shift the transmission into the neutralposition.When the transmission is in the neu-tral position, the neutral indicator lightshould be on, otherwise have aYamaha dealer check the electricalcircuit.

3. Turn the starter (choke) on and com-pletely close the throttle. (See page3-12 for starter (choke) operation).

CAUTION:

5-1

5

EAU00372


1

b

a

4. Start the engine by pushing the startswitch.

NOTE:If the engine fails to start, release the startswitch, wait a few seconds, and then tryagain. Each starting attempt should be asshort as possible to preserve the battery.Do not crank the engine more than 10 sec-onds on any one attempt.

1. Starter (choke) levera. Starter (choke) turned onb. Starter (choke) turned off

EC000038

The oil level warning light and fuel lev-el warning light should come on whenthe start switch is pushed, and theyshould go off when the start switch isreleased. If the oil level warning light flickers orremains on after starting, immediatelystop the engine, and then check theengine oil level and the vehicle for oilleakage. If necessary, add engine oil,and then check the warning light again.If the warning light does not come onwhen pushing the start switch, or if itdoes not go off after starting with suffi-cient engine oil, have a Yamaha dealercheck the electrical circuit.If the fuel level warning light remainson after starting, stop the engine, andthen check the fuel level. If necessary,refuel as soon as possible, and thencheck the warning light again. If thewarning light does not come on whenpushing the start switch, or if it doesnot go off after starting with sufficientfuel, have a Yamaha dealer check theelectrical circuit.

CAUTION: 5. After starting the engine, move thestarter (choke) knob/lever backhalfway.

ECA00045

For maximum engine life, never accel-erate hard when the engine is cold!

6. When the engine is warm, turn thestarter (choke) off.

NOTE:The engine is warm when it responds nor-mally to the throttle with the starter (choke)turned off.

CAUTION:

EAU00372

5-2

5


1

5432N 1

EAU01258

Starting a warm engineFollow the same procedure as for startinga cold engine with the exception that thestarter (choke) is not required when theengine is warm.

EAU00423

ShiftingShifting gears lets you control the amountof engine power available for starting off,accelerating, climbing hills, etc.The gear positions are shown in the illus-tration.

NOTE:To shift the transmission into the neutralposition, press the shift pedal downrepeatedly until it reaches the end of itstravel, and then slightly raise it.

EC000048

• Even with the transmission in theneutral position, do not coast forlong periods of time with theengine off, and do not tow themotorcycle for long distances. Thetransmission is properly lubricat-ed only when the engine is run-ning. Inadequate lubrication maydamage the transmission.

• Always use the clutch whilechanging gears to avoid damagingthe engine, transmission, and dri-ve train, which are not designed towithstand the shock of forcedshifting.

CAUTION:

5-3

5

1. Shift pedalN. Neutral position

EAU00372


EAU00424

Tips for reducing fuel consumptionFuel consumption depends largely on yourriding style. Consider the following tips toreduce fuel consumption:• Thoroughly warm up the engine.• Turn the starter (choke) off as soon

as possible.• Shift up swiftly, and avoid high engine

speeds during acceleration.• Do not rev the engine while shifting

down, and avoid high engine speedswith no load on the engine.

• Turn the engine off instead of letting itidle for an extended length of time(e.g., in traffic jams, at traffic lights orat railroad crossings).

5-4

5

EAU00372

EAU01128

Engine break-inThere is never a more important period inthe life of your engine than the period be-tween 0 and 1,600 km (1,000 mi). For thisreason, you should read the following ma-terial carefully.Since the engine is brand new, do not putan excessive load on it for the first 1,600km (1,000 mi). The various parts in the en-gine wear and polish themselves to thecorrect operating clearances. During thisperiod, prolonged full-throttle operation orany condition that might result in engineoverheating must be avoided.

EAU01171

0-1,000 km (0-600 mi)Avoid prolonged operation above 1/3 throt-tle.

1,000-1,600 km (600-1,000 mi)Avoid prolonged operation above 1/2 throt-tle.

EC000056

After 1,000 km (600 mi) of operation,the engine oil and final gear oil must bechanged, and the oil filter cartridge/ele-ment replaced.

1,600 km (1,000 mi) and beyondThe vehicle can now be operated normal-ly.

EC000049

If any engine trouble should occur dur-ing the engine break-in period, immedi-ately have a Yamaha dealer check thevehicle.

CAUTION:

CAUTION:


EAU00460

ParkingWhen parking, stop the engine, and thenremove the key from the main switch.

EW000058WARNING0• Since the engine and exhaust sys-

tem can become very hot, park in aplace where pedestrians or chil-dren are not likely to touch them.

• Do not park on a slope or on softground, otherwise the motorcyclemay overturn.

5-5

5

EAU00372

6

Owner’s tool kit .............................................................. 6-1

Periodic maintenance and lubrication chart .................... 6-2

Removing and installing panels ...................................... 6-5

Checking the spark plugs ................................................ 6-5

Engine oil and oil filter element........................................ 6-7

Final gear oil .................................................................... 6-9

Cleaning the air filter element .......................................... 6-10

Adjusting the carburetors ................................................ 6-12

Adjusting the engine idling speed .................................... 6-12

Adjusting the throttle cable free play................................ 6-13

Adjusting the valve clearance .......................................... 6-13

Tires ................................................................................ 6-14

Cast wheels .................................................................... 6-16

Adjusting the clutch lever free play .................................. 6-17

Adjusting the brake pedal position .................................. 6-18

Checking the front and rear brake pads .......................... 6-19

Checking the brake fluid level.......................................... 6-19

Changing the brake fluid.................................................. 6-21

Adjusting the shift pedal position .................................... 6-21

Checking and lubricating the cables ................................ 6-22

Checking and lubricating the throttle grip and cable ...................................................... 6-22

Checking and lubricating the brake and shift pedals .............................................................................. 6-23

Checking and lubricating the brake and clutch levers .................................................................... 6-23

Checking and lubricating the sidestand .......................... 6-24

Checking the front fork .................................................... 6-24

Checking the steering ...................................................... 6-25

Checking the wheel bearings .......................................... 6-25

Battery ............................................................................ 6-26

Replacing the fuses ........................................................ 6-28

Replacing the headlight and auxiliary light bulb .............. 6-29

Replacing a turn signal light bulb .................................... 6-31

Replacing the tail/brake light bulb.................................... 6-31

Replacing the license plate light bulb .............................. 6-32

Front wheel ...................................................................... 6-32

Rear wheel ...................................................................... 6-33

Troubleshooting .............................................................. 6-35

Troubleshooting chart ...................................................... 6-36

PERIODIC MAINTENANCE AND MINOR REPAIREAU00462

EAU00462PERIODIC MAINTENANCE AND MINOR REPAIR

1EAU00464

Safety is an obligation of the owner. Peri-odic inspection, adjustment and lubricationwill keep your vehicle in the safest andmost efficient condition possible. The mostimportant points of inspection, adjustment,and lubrication are explained on the fol-lowing pages. The intervals given in the periodic mainte-nance and lubrication chart should be sim-ply considered as a general guide undernormal riding conditions. However, DE-PENDING ON THE WEATHER, TER-RAIN, GEOGRAPHICAL LOCATION,AND INDIVIDUAL USE, THE MAINTE-NANCE INTERVALS MAY NEED TO BESHORTENED.

EW000060WARNING0If you are not familiar with motorcyclemaintenance work, have a Yamahadealer do it for you.

1. Owner’s tool kit

EAU01129

Owner’s tool kitThe owner’s tool kit is located inside thestorage compartment (see page 3-13 forstorage compartment opening proce-dures).The service information included in thismanual and the tools provided in the own-er’s tool kit are intended to assist you inthe performance of preventive mainte-nance and minor repairs. However, addi-tional tools such as a torque wrench maybe necessary to perform certain mainte-nance work correctly.

NOTE:If you do not have the tools or experiencerequired for a particular job, have a Yama-ha dealer perform it for you.

EW000063WARNING0Modifications not approved by Yamahamay cause loss of performance andrender the vehicle unsafe for use. Con-sult a Yamaha dealer before attemptingany changes.

6-1

6

EAU00462 PERIODIC MAINTENANCE AND MINOR REPAIR

EAU03685

Periodic maintenance and lubrication chartNOTE:• The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.• From 50,000 km, repeat the maintenance intervals starting from 10,000 km.• Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.

6-2

6

ODOMETER READING (x 1,000 km) ANNUALN0. ITEM CHECK OR MAINTENANCE JOB1 10 20 30 40 CHECK

1 * Fuel line • Check fuel hoses and vacuum hose for cracks √ √ √ √ √or damage.

2 * Fuel filter • Check condition. √ √

• Check condition. √ √3 Spurk plugs • Clean and regap.

• Replace. √ √

4 * Valves • Check valve clearance. √ √ √ √• Adjust.

5 Air filter element• Clean. √ √

• Replace. √ √

6 Clutch • Check operation. √ √ √ √ √• Adjust.

• Check operation,fluid level and vehicle for fluid leakeage. √ √ √ √ √ √

7 * Front brake (See NOTE on page 6-4).

• Replace brake pads. Whenever worm to the limit

EAU00462


• Check operation, fluid level and vehicle for fluid leakage. √ √ √ √ √ √

8 * Rear brake (See NOTE on page 6-4).

• Replace brake pads. Whenever worm to the limit

9 * Brake hoses• Check for cracks or damage. √ √ √ √ √

• Replace. (See NOTE on page 6-4). Every 4 years

10 * Wheels • Check runout and for damage. √ √ √ √

• Check tread depth and for damage.

11 * Tires • Replace if necessary. √ √ √ √• Check air pressure.• Correct if necessary.

12 * Wheel bearings • Check bearing for looseness or damage. √ √ √ √

13 * Swingarm• Check operation and for excessive play. √ √ √ √

• Lubrificate with lithium-soap-based grease. Every 50,000 km

14 * Steering bearings• Check bearing play and steering for roughness. √ √ √ √ √

• Lubrificate with lithium-soap-based grease. Every 20,000 km

15 * Chassis fasteners • Make sure that all nuts, bolts and screws are properly √ √ √ √ √tightened.

16 Sidestand • Check operation. √ √ √ √ √• Lubricate.

17 *Sidestand • Check operation and for oil leakage. √ √ √ √ √ √switch

18 * Front fork • Check operation and for oil leakage. √ √ √ √

19 *Rear shock absorber • Check operation and shock absorber for oil leakage. √ √ √ √assembly


6-3

6


EAU03884

NOTE:• The air filter needs more frequent service if you are riding in unusually wet or dusty areas.• Hydraulic brake service

• Regularly check and, if necessary, correct the brake fluid level. • Every two years replace the internal components of the brake master cylinders and calipers, and change the brake fluid.• Replace the brake hoses every four years and if cracked or damaged.

6-4

6


Rear suspension • Check operation. √ √ √ √20 *

relay arm and connecting arm

• Lubricate with lithium-soap-based grease. √ √pivoting points

• Check starter (choke) operation.21 * Carburators • Adjust engine idling speed and √ √ √ √ √ √

synchronization.

22 Engine oil • Change. √ √ √ √ √ √

23 Engine oil filter • Replace. √ √ √element

• Check oil level and vehicle for oil √ √ √24 Final gear leakage.

oil• Change. √ √ √

25 Moving parts and • Lubricate. √ √ √ √ √cables

• Check the air cut valve and reed valve for

26 *Air induction damage. √ √ √ √ √system • Replace the entire air induction system if

necessary.

27 *Lights, signals and • Check operation. √ √ √ √ √ √switches • Adjust headlight beam.


12

12

1. Rear cylinder spark plug cover2. Spark plug cap

1. Front cylinder spark plug cover2. Spark plug cap

To install the panel

Place the panel in the original position,and then install the screw.

EAU01673

Checking the spark plugsThe spark plugs are important enginecomponents, which are easy to check.Since heat and deposits will cause anyspark plug to slowly erode, the spark plugsshould be removed and checked in accor-dance with the periodic maintenance andlubrication chart. In addition, the conditionof the spark plugs can reveal the conditionof the engine.

EAU01122

Removing and installing panelsThe panels shown above need to be re-moved to perform some of the mainte-nance jobs described in this chapter. Referto this section each time a panel needs tobe removed and installed.

EAU00488

Panel

To remove the panel

Remove the screw, and then pull the pan-el off as shown.

To remove a spark plug

1. Remove the appropriate spark plugcover (rear right or front left) bypulling it off as shown.

2. Remove the spark plug cap.

3. Remove the spark plug as shown,with the spark plug wrench includedin the owner’s tool kit.

6-5

6

1

1. Panel mounting screw


To install a spark plug

1. Measure the spark plug gap with awire thickness gauge and, if neces-sary, adjust the gap to specification.

2. Clean the surface of the spark pluggasket and its mating surface, andthen wipe off any grime from thespark plug threads.

3. Install the spark plug with the sparkplug wrench, and then tighten it to thespecified torque.

NOTE:If a torque wrench is not available wheninstalling a spark plug, a good estimate ofthe correct torque is 1/4–1/2 turn past fin-ger tight. However, the spark plug shouldbe tightened to the specified torque assoon as possible.

4. Install the spark plug cap.

5. Place the spark plug cover in the orig-inal position.

6-6

6

a. Spark plug gap

To check the spark plugs

1. Check that the porcelain insulatoraround the center electrode on eachspark plug is a medium-to-light tan(the ideal color when the motorcycleis ridden normally).

2. Check that all spark plugs installed inthe engine have the same color.

NOTE:If any spark plug shows a distinctly differ-ent color, the engine could be defective.Do not attempt to diagnose such problemsyourself. Instead, have a Yamaha dealercheck the motorcycle.

3. Check each spark plug for electrodeerosion and excessive carbon or oth-er deposits, and replace it if neces-sary.

Specified spark plug:BPR7ES (NGK) or W22EPR-U (DENSO)

Tightening torque:Spark plug:

20 Nm (2.0 m·kgf)

Spark plug gap:0.7-0.8 mm

EAU00462

1. Engine oil filler cap


1

NOTE:Make sure that the motorcycle is posi-tioned straight up when checking the oillevel. A slight tilt to the side can result in afalse reading.

2. Start the engine, warm it up for sever-al minutes, and then turn it off.

3. Wait a few minutes until the oil set-tles, and then check the oil levelthrough the check window located atthe bottom-left side of the crankcase.

NOTE:The engine oil should be between the min-imum and maximum level marks.

4. If the engine oil is below the minimumlevel mark, add sufficient oil of therecommended type to raise it to thecorrect level.

To change the engine oil without oilfilter element replacement

1. Start the engine, warm it up for sever-al minutes, and then turn it off.

2. Place an oil pan under the engine tocollect the used oil.

3. Remove the engine oil filler cap anddrain bolt to drain the oil from thecrankcase.

6-7

6

2

3

1

EAU01712

Engine oil and oil filter elementThe engine oil level should be checked be-fore each ride. In addition, the oil must bechanged and the oil filter element replacedat the intervals specified in the periodicmaintenance and lubrication chart.

To check the engine oil level

1. Place the motorcycle on a level sur-face and hold it in an upright position.

1. Engine oil level window2. Maximum level mark3. Minimum level mark


EC000072

• In order to prevent clutch slippage(since the engine oil also lubri-cates the clutch), do not mix anychemical additives with the oil oruse oils of a higher grade than“CD”. In addition, do not use oilslabeled "ENERGY CONSERVING II"or higher.

• Make sure that no foreign materialenters the crankcase.

CAUTION:

6. Start the engine, and then let it idle forseveral minutes while checking it foroil leakage. If oil is leaking, immedi-ately turn the engine off and check forthe cause.

NOTE:After the engine is started, the engine oillevel warning light should go off if the oillevel is sufficient.

EC000067

If the oil level warning light flickers orremains on, immediately turn theengine off and have a Yamaha dealercheck the vehicle.

7. Turn the engine off, and then checkthe oil level and correct it if neces-sary.

NOTE:Have a Yamaha dealer replace the oil filterelement when necessary.

CAUTION:

1. Engine oil drain bolt

6-8

6

1

4. Install the engine oil drain bolt, andthen tighten it to the specified torque.

5. Add the specified amount of the rec-ommended engine oil, and then in-stall and tighten the oil filler cap.

Tightening torque:Engine oil drain bolt:

43 Nm (4.3 m·kgf)

Recommended engine oil:See page 8-1.

Oil quantity:Without oil filter element replacement:

3.0 LWith oil filter element replacement:

3.1 LTotal amount (dry engine):

3.6 L


3

1

2

To check the final gear oil level


NOTE:• The final gear oil level must be

checked on a cold engine.• Make sure that the motorcycle is posi-

tioned straight up when checking theoil level. A slight tilt to the side canresult in a false reading.

2. Remove the oil filler bolt, and thencheck the oil level in the final gearcase.

NOTE:The oil level should be at the brim of thefiller hole.

3. If the oil is below the brim of the fillerhole, add sufficient oil of the recom-mended type to raise it to the correctlevel.

To change the final gear oil

1. Place an oil pan under the final gearcase to collect the used oil.

2. Remove the oil filler bolt and drainbolt to drain the oil from the final gearcase.

6-9

6

1. Final gear oil drain bolt2. Final gear oil filler bolt3. Oil level

EAU04083

Final gear oilThe final gear case must be checked for oilleakage before each ride. If any leakage isfound, have a Yamaha dealer check andrepair the motorcycle. In addition, the finalgear oil level must be checked and the oilchanged as follows at the intervals speci-fied in the periodic maintenance and lubri-cation chart.

EW000066WARNING0• Make sure that no foreign material

enters the final gear case.• Make sure that no oil gets on the

tire or wheel.


21

6. Check the final gear case for oil leak-age. If oil is leaking, check for thecause.

EAUB0008

Cleaning the air filter elementThe air filter element should be cleaned atthe intervals specified in the periodic main-tenance and lubrication chart. Clean theair filter element more frequently if you areriding in unusually wet or dusty areas.

4. Add the recommended final gear oilto the brim of the filler hole.

NOTE:GL4 is a quality rating. Hypoid gear oilsrated GL5 or GL6 may also be used.

5. Install and tighten the oil filler bolt.

1. Remove the seat. (See page 3-13 forseat removal and installation proce-dures).

2. Remove panels 1 and 2. (See page6-5 for panel removal and installationprocedures).

3. Remove the fuel tank bolts.

6-10

6

Tightening torque:Final gear oil drain bolt:

23 Nm (2.3 m·kgf)

Recommended final gear oil:Hypoid gear oil SAE 80 (API GL4) or multi-grade hypoid gear oil SAE 80W-90

Oil quantity:0.2 L

3. Install the final gear oil drain bolt, andthen tighten it to the specified torque.

1. Fuel tank right bolt (x 2)2. Fuel tank left bolt (x 2)

��

1. Left panel2. Right panel


2 3

1

5. Remove the air filter case cover byremoving the screws.

6. Pull the air filter element out.

7. Lightly tap the air filter element to re-move most of the dust and dirt, andthen blow the remaining dirt out withcompressed air as shown. If the air fil-ter element is damaged, replace it.

8. Insert the air filter element into the airfilter case.

1. Screw2. Air filter case cover3. Air filter

ECA00089

The engine should never be operatedwithout the air filter element installed,otherwise the piston(s) and/or cylin-der(s) may become excessively worn.

9. Install the air filter case cover by in-stalling the screws.

10. Install the fuel tank by installing thebolts.

11. Install the panels.

CAUTION:

EAU00462

6-11

6

4. Lift the fuel tank to position it awayfrom the air filter case. (Do not dis-connect the fuel hoses!).

EW000071WARNING0Make sure that the fuel tank is well sup-ported. Do not tilt or pull the fuel tank too much,otherwise the fuel hoses may comeloose, which could cause fuel leakage.


EAU00630

Adjusting the carburetorsThe carburetors are important parts of theengine and require very sophisticated ad-justment. Therefore, most carburetor ad-justments should be left to a Yamaha deal-er, who has the necessary professionalknowledge and experience. The adjust-ment described in the following section,however, may be serviced by the owner aspart of routine maintenance.

EC000095

The carburetors have been set andextensively tested at the Yamaha facto-ry. Changing these settings withoutsufficient technical knowledge mayresult in poor performance of or dam-age to the engine.

CAUTION:

EAU01168

Adjusting the engine idlingspeedThe engine idling speed must be checkedand, if necessary, adjusted as follows atthe intervals specified in the periodic main-tenance and lubrication chart.

NOTE:A diagnostic tachometer is needed tomake this adjustment.

1. Attach the tachometer to the sparkplug lead.

2. Start the engine and warm it up forseveral minutes at 1,000-2,000 r/minwhile occasionally revving it to 4,000-5,000 r/min.

NOTE:The engine is warm when it quicklyresponds to the throttle.

6-12

6

12

1. Pin (x 2)2. Pin seat (x 2)

EWA00052

WARNING0Before installing the fuel tank, makesure that the fuel hoses are not dam-aged. If any fuel hose is damaged, donot start the engine but have a Yamahadealer replace the hose, otherwise fuelmay leak.Make sure that the fuel hoses are prop-erly connected and routed, and notpinched.Be sure to place the fuel tank breatherhose in the original position.

12. Install the seat.


a

EAU00635

Adjusting the throttle cable free playThe throttle cable free play should mea-sure 3-5 mm at the throttle grip. Periodical-ly check the throttle cable free play and, ifnecessary, have a Yamaha dealer adjustit.

EAU00637

Adjusting the valve clearanceThe valve clearance changes with use, re-sulting in improper air-fuel mixture and/orengine noise. To prevent this from occur-ring, the valve clearance must be adjustedby a Yamaha dealer at the intervals speci-fied in the periodic maintenance and lubri-cation chart.

6-13

6

a. Throttle cable free play

1

b a

3. Check the engine idling speed and, ifnecessary, adjust it to specification byturning the throttle stop screw. To in-crease the engine idling speed, turnthe screw in direction a. To decreasethe engine idling speed, turn the screwin direction b.

Engine idling speed:950-1,050 r/min

NOTE:If the specified idling speed cannot beobtained as described above, have aYamaha dealer make the adjustment.

1. Throttle stop screw


EWA00012

WARNING0Because loading has an enormousimpact on the handling, braking, per-formance and safety characteristics ofyour motorcycle, you should keep thefollowing precautions in mind.• NEVER OVERLOAD THE MOTOR-

CYCLE! Operation of an over-loaded motorcycle may result intire damage, loss of control, orsevere injury. Make sure that thetotal weight of rider, passenger,cargo, and accessories does not

exceed the specified maximumload for the vehicle.

• Do not carry along loosely packeditems, which can shift during aride.

• Securely pack the heaviest itemsclose to the center of the motorcy-cle and distribute the weight even-ly on both sides.

• Adjust the suspension and tire airpressure with regard to the load.

• Check the tire condition and airpressure before each ride.

6-14

6

EAU00658

TiresTo maximize the performance, durability,and safe operation of your motorcycle,note the following points regarding thespecified tires.

Tire air pressureThe tire air pressure should be checkedand, if necessary, adjusted before eachride.

EW000082WARNING0• The tire air pressure must be

checked and adjusted on cold tires(i.e., when the temperature of thetires equals the ambient tempera-ture).

• The tire air pressure must beadjusted in accordance with theriding speed and with the totalweight of rider, passenger, cargo,and accessories approved for thismodel.

Tire air pressure(measured on cold tires)

Load* Front Rear

230 kPa 250 kPaUp to 90 kg 2.30 kg/cm2 2.50 kg/cm2

2.30 bar 2.50 bar

250 kPa 270 kPa90 kg-maximum 2.50 kg/cm2 2.70 kg/cm2

2.50 bar 2.70 bar

Maximum load* 200 kg

* Total weight of rider, passenger, cargo and acces-sories.


NOTE:The tire tread depth limits may differ fromcountry to country. Always comply with thelocal regulations.

EW000079WARNING0• Have a Yamaha dealer replace

excessively worn tires. Besidesbeing illegal, operating the motor-cycle with excessively worn tiresdecreases riding stability and canlead to loss of control.

• The replacement of all wheel- andbrake-related parts, including thetires, should be left to a Yamahadealer, who has the necessary pro-fessional knowledge and experi-ence.

Tire information

This motorcycle is equipped with castwheels and tubeless tires with valves.

EW000080WARNING0• The front and rear tires should be

of the same make and design, oth-erwise the handling characteris-tics of the motorcycle cannot beguaranteed.

• After extensive tests, only the tireslisted below have been approvedfor this model by Yamaha MotorCo., Ltd.

• Always make sure that the valvecaps are securely installed to pre-vent air pressure leakage.

• Use only the tire valves and valvecores listed below to avoid tiredeflation during a high-speed ride.

6-15

6

Tire inspectionThe tires must be checked before each ride.If the center tread depth reaches the speci-fied limit, if the tire has a nail or glass frag-ments in it, or if the sidewall is cracked,have a Yamaha dealer replace the tire im-mediately.

1. Tire sidewalla. Tire tread depth

Minimum tire tread depth 1.6 mm(front and rear)


EAU00684

WARNING0• This motorcycle is fitted with

super-high-speed tires. Note thefollowing points in order to makethe most efficient use of thesetires.

• Use only the specified replace-ment tires. Other tires may run thedanger of bursting at super highspeeds.

• Brand-new tires can have a rela-tively poor grip on certain roadsurfaces until they have been“broken in”.

• Therefore, it is advisable beforedoing any high-speed riding toride conservatively for approxi-mately 100 km (60 mi) afterinstalling a new tire.

• The tires must be warmed upbefore a high-speed run.

• Always adjust the tire air pressureaccording to the operating condi-tions.

EAU03773

Cast wheelsTo maximize the performance, durability,and safe operation of your motorcycle,note the following points regarding thespecified wheels.The wheel rims should be checked forcracks, bends or warpage before eachride. If any damage is found, have a Yama-ha dealer replace the wheel. Do not at-tempt even the smallest repair to thewheel. A deformed or cracked wheel mustbe replaced.The wheel should be balanced whenevereither the tire or wheel has been changedor replaced. An unbalanced wheel can re-sult in poor performance, adverse han-dling characteristics, and a shortened tirelife.

6-16

6

FRONT

REAR

Manufacturer Size Type

Dunlop 120/70-ZR17 (58W) D205F TL

Metzeler 120/70-ZR17 (58W) MEZ3F TL

Manufacturer Size Type

Dunlop 170/60-ZR17 (72W) D205 TL

Metzeler 170/60-ZR17 (72W) MEZ3 TL

Belgarda Belgarda


2 1

c

b

a

Ride at moderate speeds after changing atire since the tire surface must first be “bro-ken in” for it to develop its optimal charac-teristics.

1. Locknut2. Free play adjusting boltc. Clutch lever free play

EAU00692

Adjusting the clutch lever free playThe clutch lever free play should measure5-10 mm as shown. Periodically check theclutch lever free play and, if necessary, ad-just it as follows.

1. Loosen the locknut at the clutch lever.2. To increase the clutch lever free play,

turn the adjusting bolt in direction a.To decrease the clutch lever free play,turn the adjusting bolt in direction b.

3. Tighten the locknut.

NOTE:If the specified free play cannot beobtained as described above or if theclutch does not operate correctly, have aYamaha dealer check the internal clutchmechanism.

6-17

6


A

a

EAU00712

Adjusting the brake pedal positionThe top of the brake pedal should be posi-tioned approximately 43 mm below the topof the footrest as shown. Periodicallycheck the brake pedal position and, if nec-essary, have a Yamaha dealer adjust it.

EW000109

WARNING0A soft or spongy feeling in the brakepedal can indicate the presence of airin the hydraulic system. If there is air inthe hydraulic system, have a Yamahadealer bleed the system before operat-ing the motorcycle. Air in the hydraulicsystem will diminish the braking per-formance, which may result in loss ofcontrol and an accident.a. Distance between brake pedal and footrest

6-18

6

1. Front brake pad wear indicator groove


1 1

2

1

EAU00715

Checking the front and rearbrake padsThe front and rear brake pads must bechecked for wear at the intervals specifiedin the periodic maintenance and lubrica-tion chart. Each brake pad is provided witha wear indicator, which allows you tocheck the brake pad wear without havingto disassemble the brake.

To check the brake pad wear, check theposition of the wear indicator while apply-ing the brake. If a brake pad has worn tothe point that the wear indicator almosttouches the brake disc, have a Yamahadealer replace the brake pads as a set.

EAU03776

Checking the brake fluid levelInsufficient brake fluid may allow air to en-ter the brake system, possibly causing it tobecome ineffective.Before riding, check that the brake fluid isabove the minimum level mark and replen-ish if necessary.A low brake fluid level may indicate wornbrake pads and/or brake system leakage.If the brake level is low, be sure to checkthe brake pads for wear and the brake sys-tem for leakage.

EAU00462

6-19

6

1. Front brake master cylinder2. Minimum level mark

1. Rear brake pad wear indicator groove


1

2

Observe these precautions:• When checking the fluid level, make

sure that the top of the brake fluidreservoir is level.

• Use only the recommended qualitybrake fluid, otherwise the rubberseals may deteriorate, causing leak-age and poor braking performance.

• Refill with the same type of brake flu-id. Mixing fluids may result in a harm-ful chemical reaction and lead to poorbraking performance.

• Be careful that water does not enterthe brake fluid reservoir when refill-ing. Water will significantly lower theboiling point of the fluid and may re-sult in vapor lock.

• Brake fluid may deteriorate paintedsurfaces or plastic parts. Alwaysclean up spilled fluid immediately.

• As the brake pads wear, it is normalfor the brake fluid level to graduallygo down. However, if the brake fluidlevel goes down suddenly, have aYamaha dealer check the cause.

6-20

6

1. Screw (x 2)2. Right panel

2

1

1. Pin (x 2)2. Pin seat (x 2)

Recommended brake fluid: DOT 4

2

1

1. Rear brake fluid reservoir2. Minimum level mark


a

A

EAU03976

Changing the brake fluidHave a Yamaha dealer change the brakefluid at the intervals specified in the NOTEafter the periodic maintenance and lubri-cation chart. In addition, have the oil sealsof the master cylinders and calipers aswell as the brake hoses replaced at the in-tervals listed below or whenever they aredamaged or leaking.• Oil seals: Replace every two years.• Brake hoses: Replace every four

years.

a. Distance between shift pedal and footrest

EAUB0011

Adjusting the shift pedal positionThe top of the shift pedal should be posi-tioned approximately 45 mm below the topof the footrest as shown.

Periodically check the shift pedal positionand, if necessary, have a Yamaha dealeradjust it.

6-21

6


EAU02962

Checking and lubricating thecablesThe operation of all control cables and thecondition of the cables should be checkedbefore each ride, and the cables and cableends should be lubricated if necessary. If acable is damaged or does not movesmoothly, have a Yamaha dealer check orreplace it.

EW000112WARNING0Damage to the outer sheath may inter-fere with proper cable operation andwill cause the inner cable to rust.Replace a damaged cable as soon aspossible to prevent unsafe conditions.

EAU03209

Checking and lubricating thethrottle grip and cableThe operation of the throttle grip and thecondition of the throttle cable should bechecked before each ride, and the cableshould be lubricated or replaced if neces-sary.

NOTE:Since the throttle grip must be removed toaccess the throttle cable end, the throttlegrip and the cable should always be lubri-cated at the same time.

1. Remove the throttle grip by removingthe screws.

2. Disconnect the throttle cable, hold itup, and then apply several drops ofoil to the cable end, allowing it to trick-le into the sheath.

3. Connect the throttle cable, and thengrease the inside of the throttle griphousing.

4. Grease the metal-to-metal contactsurface of the throttle grip, and theninstall the grip by installing thescrews.

6-22

6

Recommended lubricant:Engine oil

Recommended lubricant:Throttle cable:

Engine oilThrottle grip housing and grip:

Lithium-soap-based grease (all-purpose grease)


EAU03370

Checking and lubricating thebrake and shift pedalsThe operation of the brake and shift pedalsshould be checked before each ride, andthe pedal pivots should be lubricated ifnecessary.

EAU03164

Checking and lubricating thebrake and clutch leversThe operation of the brake and clutchlevers should be checked before eachride, and the lever pivots should be lubri-cated if necessary.

EAU00462

6-23

6

Recommended lubricant:Lithium-soap-based grease (all-purpose grease)



EAU02939

Checking the front forkThe condition and operation of the frontfork must be checked as follows at the in-tervals specified in the periodic mainte-nance and lubrication chart.

To check the condition

EW000115WARNING0Securely support the motorcycle sothat there is no danger of it falling over.

Check the inner tubes for scratches, dam-age and excessive oil leakage.

To check the operation


2. While applying the front brake, pushdown hard on the handlebars severaltimes to check if the front fork com-presses and rebounds smoothly.

EC000098

If any damage is found or the front forkdoes not operate smoothly, have aYamaha dealer check or repair it.

CAUTION:

6-24

6

EAU03165

Checking and lubricating thesidestandThe operation of the sidestand should bechecked before each ride, and the side-stand pivot and metal-to-metal contact sur-faces should be lubricated if necessary.

EW000113WARNING0If the sidestand does not move up anddown smoothly, have a Yamaha dealercheck or repair it.



EAU00794

Checking the steeringWorn or loose steering bearings maycause danger. Therefore, the operation ofthe steering must be checked as follows atthe intervals specified in the periodic main-tenance and lubrication chart.

1. Place a stand under the engine toraise the front wheel off the ground.

EW000115

WARNING0Securely support the motorcycle sothat there is no danger of it falling over.

2. Hold the lower ends of the front forklegs and try to move them forwardand backward. If any free play can befelt, have a Yamaha dealer check orrepair the steering.

EAU01144

Checking the wheel bearingsThe front and rear wheel bearings must bechecked at the intervals specified in theperiodic maintenance and lubricationchart. If there is play in the wheel hub or ifthe wheel does not turn smoothly, have aYamaha dealer check the wheel bearings.

6-25

6


EAU00800

BatteryThis motorcycle is equipped with a sealed-type (MF) battery, which does not requireany maintenance. There is no need tocheck the electrolyte or to add distilled wa-ter.

EC000101

Never attempt to remove the batterycell seals, as this would permanentlydamage the battery.

EW000116WARNING0• Electrolyte is poisonous and dan-

gerous since it contains sulfuricacid, which causes severe burns.Avoid any contact with skin, eyesor clothing and always shield youreyes when working near batteries.In case of contact, administer thefollowing FIRST AID.

CAUTION:

• EXTERNAL: Flush with plenty ofwater.

• INTERNAL: Drink large quanti-ties of water or milk and imme-diately call a physician.

• EYES: Flush with water for 15minutes and seek prompt med-ical attention.

• Batteries produce explosivehydrogen gas. Therefore, keepsparks, flames, cigarettes, etc.,away from the battery and providesufficient ventilation when charg-ing it in an enclosed space.

• KEEP THIS AND ALL BATTERIESOUT OF THE REACH OF CHIL-DREN.

6-26

6

1 2

1

2

+

-

1. Screw (x 2)2. Storage compartment

1. Positive battery terminal2. Negative battery terminal


To charge the battery

Have a Yamaha dealer charge the batteryas soon as possible if it seems to have dis-charged. Keep in mind that the batterytends to discharge more quickly if the mo-torcycle is equipped with optional electricalaccessories.

To store the battery

1. If the motorcycle will not be used formore than one month, remove thebattery, fully charge it, and then placeit in a cool, dry place.

2. If the battery will be stored for morethan two months, check it at leastonce a month and fully charge it ifnecessary.

3. Fully charge the battery before instal-lation.

4. After installation, make sure that thebattery leads are properly connectedto the battery terminals.

EC000102

• Always keep the battery charged.Storing a discharged battery cancause permanent battery damage.

• To charge a sealed-type (MF) bat-tery, a special (constant-voltage)battery charger is required. Usinga conventional battery charger willdamage the battery. If you do nothave access to a sealed-type (MF)battery charger, have a Yamahadealer charge your battery.

CAUTION:

6-27

6


1 2 81

792

35 4

6

EAUB0012

Replacing the fusesThe fuse box is located under the seat.(See page 3-13 for seat removal and in-stallation procedures). If a fuse is blown,replace it as follows.

1. Turn the key to “B” (OFF) and turnoff the electrical circuit in question.

2. Remove the blown fuse, and then in-stall a new fuse of the specified am-perage.

1. Screw (x 2)2. Storage compartment

EC000103

Do not use a fuse of a higher amperagerating than recommended to avoidcausing extensive damage to the elec-trical system and possibly a fire.

3. Turn the key to “I” (ON) and turn onthe electrical circuit in question tocheck if the device operates.

4. If the fuse immediately blows again,have a Yamaha dealer check theelectrical system.

CAUTION:

1. Fuse box cover2. Main fuse3. Headlight fuse4. Signaling system fuse5. Ignition fuse6. Backup fuse (odometer)7. Carburetor heater fuse8. Spare fuse (x 4)

6-28

6

Specified fuses:

Main fuse: 30 A

Backup fuse (odometer): 5 A

Ignition fuse: 10 A

Headlight fuse: 15 A

Carburetor heater fuse 15 A

Signaling system fuse: 10 A

1. Screw (x 2)2. Cowling


2

11

2

1

1

EAUB0013

Replacing the headlight andauxiliary light bulbThis motorcycle is equipped with a quartzbulb headlight. If the headlight bulb or aux-iliary light bulb burns out, replace it as fol-lows.

NOTE:Skip steps 6-10 if only the headlight bulb isbeing replaced. Skip steps 2-5 if only theauxiliary light bulb is being replaced.

1. Remove the headlight by removingthe screws, then tilt the cowling for-ward.

2. Disconnect the headlight coupler andthe auxiliary light leads, and then re-move the headlight bulb cover.

3. Remove the headlight bulb holder byturning it counterclockwise, and thenremove the defective bulb.

EW000119

WARNING0Headlight bulbs get very hot. There-fore, keep flammable products awayfrom a lit headlight bulb, and do nottouch the bulb until it has cooled down.

4. Place a new bulb into position, andthen secure it with the bulb holder.

EAU00462

6-29

6

1. Headlight bulb cover2. Auxiliary light bulb holder

1. Headlight coupler


11

2

EC000105

Do not touch the glass part of the head-light bulb to keep it free from oil, other-wise the transparency of the glass, theluminosity of the bulb, and the bulb lifewill be adversely affected. Thoroughly clean off any dirt and fin-gerprints on the headlight bulb using acloth moistened with alcohol or thin-ner.

CAUTION: 5. Install the headlight bulb cover, andthen connect the coupler and auxil-iary light leads.

6. Remove the socket (together with thebulb) by turning it counterclockwise.

7. Remove the defective bulb by push-ing it in and turning it counterclock-wise.

8. Insert a new bulb into the socket,push it in, and then turn it clockwiseuntil it stops.

9. Install the socket (together with thebulb) by turning it clockwise.

10. Connect the auxiliary light bulb leads.

11. Tilt the cowling back to the originalposition, and then install the headlightby installing the screws.

EAU00462

6-30

6

1. Headlight bulb holder 1. Do not touch this area 1. Auxiliary light bulb holder2. Auxiliary light bulb

EAU00462

1. Screw2. Turn signal light len


1

2

1. Screw (x 2)

1 1

NOTE:Before installing the headlight, be sure tohook the headlight and auxiliary light bulbleads into the guide to the left of the head-light as shown.

12. Have a Yamaha dealer adjust theheadlight beam if necessary.

EAU03497

Replacing a turn signal lightbulb

1. Remove the turn signal light lens byremoving the screw.



4. Install the lens by installing the screw.EC000065

Do not overtighten the screw, other-wise the lens may break.

CAUTION:

EAU01623

Replacing the tail/brake lightbulb

1. Remove the tail/brake light lens by re-moving the screws.



4. Install the lens by installing thescrews.

EC000108

Do not overtighten the screws, other-wise the lens may break.

CAUTION:

6-31

6

1

1. Leads guide

EAU00462

1. Nut (x 2) 1. Bulb socket2. Bulb


11

2

1. Brake caliper (x 2)2. Wheel axle pinch bolt3. Wheel axle4. Spacer (x 2)

�

�

�

�

�

�

EAUB0019

Replacing the license platelight bulb

1. Remove the license plate light by re-moving the nuts.

2. Remove the bulb socket from the li-cense plate light by pulling it out.

3. Remove the defective bulb by pullingit out.

4. Insert a new bulb into the socket.5. Install the bulb socket into the license

plate light.6. Install the license plate light by in-

stalling the nuts.

EAUB0015

Front wheelTo remove the front wheel

EW000122WARNING0It is advisable to have a Yamaha dealerservice the wheel.Securely support the motorcycle sothat there is no danger of it falling over.

1. Mark either side of the wheel so that itcan be installed in the original runningdirection.

2. Remove the brake calipers by remov-ing the bolts.

ECA00047

Do not pull the brake lever after thebrake caliper has been removed, other-wise the brake pads will be forced shut.

3. Loosen the front wheel axle pinchbolt, then the wheel axle.

4. Pull the wheel axle out together withthe spacers, and then remove thewheel.

CAUTION:

6-32

6


EAB00016

To install the front wheel

1. Lift the wheel up between the forklegs.

2. Install the spacers and insert thewheel axle.

3. Lower the front wheel so that it is onthe ground.

4. Install the brake calipers by installingthe bolts.

NOTE:Make sure that there is enough spacebetween the brake pads before installingthe brake calipers onto the brake discs.

5. Tighten the wheel axle, then the frontwheel axle pinch bolt, and the brakecaliper bolts to the specified torques.

EAUB0017

Rear wheelTo remove the rear wheel

EW000122WARNING0It is advisable to have a Yamaha dealerservice the wheel.Securely support the motorcycle sothat there is no danger of it falling over.

1. Loosen the rear wheel axle pinchbolt, and then remove the axle nut.

6-33

6

6. Push down hard on the handlebarseveral times to check for proper forkoperation.

Tightening torques:

Wheel axle:75 Nm (7.5 m·kgf)

Front wheel axle pinch bolt:25 Nm (2.5 m·kgf)

Brake caliper bolt:42 Nm (4.2 m·kgf)

1. Wheel axle pinch bolt2. Axle nut3. Brake torque rod bolt

�

�

�


2. Remove the brake torque rod boltfrom the brake caliper bracket, andthen turn the caliper up, away fromthe disc.

3. Remove the wheel axle together withthe spacers.

4. Pull the wheel to the right to separateit from the final gear case, and thenremove it.

ECA00062

Do not push the brake pedal after thewheel has been removed together withthe brake disc, otherwise the brakepads will be forced shut.

CAUTION:

EAUB0018

To install the rear wheel

1. Apply a light coating of lithium-soap-based grease to the splines of the fi-nal gear case and wheel hub.

2. Install the wheel by inserting thewheel axle, then installing the axlenut.

3. Turn the caliper down so that it fitsover the brake disc.

NOTE:Make sure that there is enough spacebetween the brake pads before installingthe brake caliper onto the brake disc.

4. Install the wheel axle pinch bolt.

5. Install the brake torque rod bolt at thebrake caliper bracket.

6. Install the wheel axle pinch bolt.

7. Lower the rear wheel so that it is onthe ground.

8. Tighten the axle nut, wheel axle pinchbolt, and brake torque rod bolt to thespecified torques.

6-34

6

Tightening torques:Axle nut:

110 Nm (11.0 m·kgf)Wheel axle pinch bolt:

22 Nm (2.2 m·kgf)Brake torque rod bolt:

35 Nm (3.5 m·kgf)


EAU01008

TroubleshootingAlthough Yamaha motorcycles receive athorough inspection before shipment fromthe factory, trouble may occur during oper-ation. Any problem in the fuel, compres-sion, or ignition systems, for example, cancause poor starting and loss of power.The following troubleshooting chart repre-sents a quick and easy procedure forchecking these vital systems yourself.

However, should your motorcycle requireany repair, take it to a Yamaha dealer,whose skilled technicians have the neces-sary tools, experience, and know-how toservice the motorcycle properly.Use only genuine Yamaha replacementparts. Imitation parts may look like Yama-ha parts, but they are often inferior, have ashorter service life and can lead to expen-sive repair bills.

6-35

6


EAU01297

Troubleshooting chartEW000125WARNING0

Keep away open flames and do not smoke while checking or working on the fuel system.

6-36

6

Check the fuel level in thefuel tank.

1. Fuel

2. Compression

3. Ignition

4. Battery

There is enough fuel.

There is no fuel.

Check the compression.

Supply fuel. The engine does not start. Check the compression.

There is compression. Check the ignition.

Have a Yamaha dealer checkthe vehicle.

Wipe off with a dry cloth and correct the sparkplug gaps, or replace the spark plugs.

Open the throttle halfway and operate theelectric starter.

Have a Yamaha dealer check the vehicle.

The engine does not start.Check the battery.

The engine turns over slowly.Have a Yamaha dealer checkthe vehicle.

There is no compres-sion.

Wet.

Dry

The engine turns over quickly. The battery is good.

Check the battery lead connections, andcharge the battery if necessary.The engine does not start.

Operate the electricstarter.

Remove the spark plugs and check the electrodes.

Operate the electricstarter.

7

Care ......................................................................................................7-1

Storage ................................................................................................7-4

MOTORCYCLE CARE AND STORAGEEAU03412


CareWhile the open design of a motorcycle re-veals the attractiveness of the technology,it also makes it more vulnerable. Rust andcorrosion can develop even if high-qualitycomponents are used. A rusty exhaustpipe may go unnoticed on a car, however,it detracts from the overall appearance of amotorcycle. Frequent and proper caredoes not only comply with the terms of thewarranty, but it will also keep your motor-cycle looking good, extend its life and opti-mize its performance.

Before cleaning

1. Cover the muffler outlets with plasticbags after the engine has cooleddown.

2. Make sure that all caps and covers aswell as all electrical couplers and con-nectors, including the spark plugcaps, are tightly installed.

3. Remove extremely stubborn dirt, likeoil burnt onto the crankcase, with adegreasing agent and a brush, butnever apply such products ontoseals, gaskets and wheel axles. Al-ways rinse the dirt and degreaser offwith water.

Cleaning

ECA00010

• Avoid using strong acidic wheelcleaners, especially on spokedwheels. If such products are usedon hard-to-remove dirt, do notleave the cleaner on the affectedarea any longer than instructed.Also, thoroughly rinse the area offwith water, immediately dry it, andthen apply a corrosion protectionspray.

• Improper cleaning can damagewindshields, cowlings, panels andother plastic parts. Use only a soft,clean cloth or sponge with milddetergent and water to clean plas-tic.

CAUTION:

EAU03412

7-1

7


• Do not use any harsh chemicalproducts on plastic parts. Be sureto avoid using cloths or spongeswhich have been in contact withstrong or abrasive cleaning prod-ucts, solvent or thinner, fuel (gaso-line), rust removers or inhibitors,brake fluid, antifreeze or elec-trolyte.

• Do not use high-pressure washersor steam-jet cleaners since theycause water seepage and deterio-ration in the following areas: seals(of wheel and swingarm bearings,fork and brakes), electric compo-nents (couplers, connectors,instruments, switches and lights),breather hoses and vents.

• For motorcycles equipped with awindshield: Do not use strongcleaners or hard sponges as theywill cause dulling or scratching.Some cleaning compounds forplastic may leave scratches on thewindshield. Test the product on a

small hidden part of the wind-shield to make sure that it doesnot leave any marks. If the wind-shield is scratched, use a qualityplastic polishing compound afterwashing.

After normal useRemove dirt with warm water, a mild deter-gent, and a soft, clean sponge, and thenrinse thoroughly with clean water. Use atoothbrush or bottlebrush for hard-to-reachareas. Stubborn dirt and insects will comeoff more easily if the area is covered with awet cloth for a few minutes before clean-ing.

After riding in the rain, near the sea or onsalt-sprayed roadsSince sea salt or salt sprayed on roadsduring winter are extremely corrosive incombination with water, carry out the fol-lowing steps after each ride in the rain,near the sea or on salt-sprayed roads.

NOTE:Salt sprayed on roads in the winter mayremain well into spring.

1. Clean the motorcycle with cold waterand a mild detergent, after the enginehas cooled down.

ECA00012

Do not use warm water since it increas-es the corrosive action of the salt.

2. After drying the motorcycle, apply acorrosion protection spray on all met-al, including chrome- and nickel-plat-ed, surfaces to prevent corrosion.

CAUTION:

EAU03412

7-2

7


After cleaning

1. Dry the motorcycle with a chamois oran absorbing cloth.

2. Use a chrome polish to shine chrome,aluminum and stainless-steel parts,including the exhaust system. (Eventhe thermally induced discoloring ofstainless-steel exhaust systems canbe removed through polishing).

3. To prevent corrosion, it is recom-mended to apply a corrosion protec-tion spray on all metal, includingchrome- and nickel-plated, surfaces.

4. Use spray oil as a universal cleanerto remove any remaining dirt.

5. Touch up minor paint damage causedby stones, etc.

6. Wax all painted surfaces.7. Let the motorcycle dry completely be-

fore storing or covering it.

EWA00031

WARNING0• Make sure that there is no oil or

wax on the brakes or tires.• If necessary, clean the brake discs

and brake linings with a regularbrake disc cleaner or acetone, andwash the tires with warm waterand a mild detergent. Before ridingat higher speeds, test the motorcy-cle’s braking performance and cor-nering behavior.

ECA00013

• Apply spray oil and wax sparinglyand make sure to wipe off anyexcess.

• Never apply oil or wax to any rub-ber and plastic parts, but treatthem with a suitable care product.

• Avoid using abrasive polishingcompounds as they will wear awaythe paint.

NOTE:Consult a Yamaha dealer for advice onwhat products to use.

CAUTION:

7-3

7

EAU03412


StorageShort-term

Always store your motorcycle in a cool, dryplace and, if necessary, protect it againstdust with a porous cover.

ECA00014

• Storing the motorcycle in a poorlyventilated room or covering it witha tarp, while it is still wet, will allowwater and humidity to seep in andcause rust.

• To prevent corrosion, avoid dampcellars, stables (because of thepresence of ammonia) and areaswhere strong chemicals arestored.

CAUTION:

Long-term

Before storing your motorcycle for severalmonths:

1. Follow all the instructions in the“Care” section of this chapter.

2. For motorcycles equipped with a fuelcock that has an “OFF” position: Turnthe fuel cock lever to “OFF”.

3. Drain the carburetor float chambersby loosening the drain bolts; this willprevent fuel deposits from buildingup. Pour the drained fuel into the fueltank.

4. Fill up the fuel tank and add fuel sta-bilizer (if available) to prevent the fueltank from rusting and the fuel fromdeteriorating.

5. Perform the following steps to protectthe cylinders, piston rings, etc. fromcorrosion.

a. Remove the spark plug caps andspark plugs.

b. Pour a teaspoonful of engine oil intoeach spark plug bore.

c. Install the spark plug caps onto thespark plugs, and then place the sparkplugs on the cylinder head so that theelectrodes are grounded. (This willlimit sparking during the next step).

d. Turn the engine over several timeswith the starter. (This will coat thecylinder walls with oil).

e. Remove the spark plug caps from thespark plugs, and then install the sparkplugs and the spark plug caps.

EWA00003WARNING0To prevent damage or injury fromsparking, make sure to ground thespark plug electrodes while turning theengine over.

7-4

7

EAU03412


6. Lubricate all control cables and thepivoting points of all levers and ped-als as well as of the sidestand/center-stand.

7. Check and, if necessary, correct thetire air pressure, and then lift the mo-torcycle so that both of its wheels areoff the ground. Alternatively, turn thewheels a little every month in order toprevent the tires from becoming de-graded in one spot.

8. Cover the muffler outlets with plasticbags to prevent moisture from enter-ing them.

9. Remove the battery and fully chargeit. Store it in a cool, dry place andcharge it once a month. Do not storethe battery in an excessively cold orwarm place (less than 0 °C or morethan 30 °C). For more information onstoring the battery, see page 6-27.

NOTE:Make any necessary repairs before stor-ing the motorcycle.

7-5

7

EAU03412

8

Specifications ...................................................................................... 8-1

SPECIFICATIONSEAU01038

SPECIFICATIONS EAU01038

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Specifications

Model BT1100

Dimensions

Overall length 2,200 mm

Overall width 800 mm

Overall height 1,140 mm

Seat height 812 mm

Wheelbase 1,530 mm

Ground clearance 168 mm

Minimum turning radius 2,980 mm

Basic weight

(with oil and full fuel tank) 250.5 kg

Engine

Engine type Air-cooled 4-stroke,

SOHC

Cylinder arrangement V type 2-cylinder

Displacement 1,063 cm3

Bore x stroke 95.0 x 75.0 mm

Compression ratio 8.3 : 1

Starting system Electric starter

Lubrication system Wet sump

Engine oil

Type

Recommended API Service SE, SF, SG orengine oil classification higher

Be sure to use motor oils that do not contain anti-friction modifiers.Passenger car motor oils (often labeled “ENERGY CONSERVING II”)contain anti-friction additives which will cause clutch and/ or starterclutch slippage, resulting in reduced component life and poorengine performance.8

Quantity

Without oil filter cartridge replacement 3.0 L

With oil filter cartridge replacement 3.1 L

Total amount(dry engine) 3.6 L

CAUTION:

-20 -10 0 10 20 30 40 50 °C

SAE 10W-30

SAE 10W-40

SAE 20W-40

SAE 15W-50

SAE 15W-40

SPECIFICATIONSEAU01038

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Final gear oilType Hypoid gear oil SAE 80

(API GL4) or multigrade hypoidgear oil SAE 80W-90

Quantity 0.2 L

Air filter Dry type element

Fuel

Type Regular unleaded gasoline

Fuel tank capacity 20 L

Fuel reserve amount 5.8 L

Carburetor

Manufacturer MIKUNI

Model x quantity BSR37 x 2

Spark plugManufacturer/model NGK / BPR7ES or

DENSO / W22EPR-U

Gap 0.7–0.8 mm

Clutch type Wet, multiple-disc

Transmission

Primary reduction system Spur gear

Primary reduction ratio 1.660

Secondary reductionsystem Shaft drive

Secondary reductionratio 2.875

Transmission type Constant mesh 5-speed

Operation Left foot

Gear ratio 1st 2,353

2nd 1,667

3rd 1,286

4th 1,032

5th 0,853

Chassis

Frame type Twin tube Backbone

Caster angle 25°

Trail 106 mm

Tires

Front

Type Tubeless

Size 120/70-ZR17 (58W)

Manufacturer/ Dunlop / D205F TLmodel Metzeler / MEZ3F TL

Rear

Type Tubeless

Size 170/60-ZR17 (72W)

Manufacturer/ Dunlop / D205 TLmodel Metzeler / MEZ3 TL

Maximum load* 200 kg

Belgarda Belgarda

SPECIFICATIONS

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EAU01038

Tire air pressure(measured on cold tires)

Up to 90 kg*

Front 230 kPa; 2.30 kg/cm2; 2.30 bar

Rear 250 kPa; 2.50 kg/cm2; 2.50 bar

90 kg–maximum*

Front 250 kPa; 2.50 kg/cm2; 2.50 bar

Rear 270 kPa; 2.70 kg/cm2; 2.70 bar

* Total weight of rider, passenger, cargo and accessories

Wheels

Front

Type Cast wheel

Size 17 x MT 3.50

Rear

Type Cast wheel

Size 17 x MT 5.50

Brakes

Front:

Type Dual disc brake

Operation Right hand

Fluid DOT 4

Rear:

Type Single disc brake

Operation Right foot

Fluid DOT 4

Suspension

Front: Telescopic fork

Rear: Swingarm (link suspension)

Spring/shock absorber

Front: Coil spring / oil damper

Rear: Coil spring / gas-oil damper,spring preload adjustable

Wheel travel

Front: 130 mm

Rear: 113 mm

Electrical system

Ignition system Transistorized coil ignition (digital)

Charging system

Type A.C. magneto

Standard output 14V, 350W at 5,000 r/min

SPECIFICATIONS

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EAU01038

Battery

Model GT14B-4

Voltage, capacity 12 V, 12 Ah

Headlight type Quartz bulb (halogen)

Bulb voltage, wattage x quantity

Headlight 12 V 60 W / 55 W x 1

Auxiliary light 12 V 5 W x 1

Tail/brake light 12 V 5 W / 21 W

Turn signal indicator light 12 V 10 W x 4

Meter lighting 14 V - 1.2 W x 4

Oil level warning light LED x 1

Neutral indicator light LED x 1

Turn signal light LED x 1

High beam indicator light LED x 1

Fuel level warning light LED x 1

Fuses

Main fuse 30 A

Backup fuse (odometer) 5 A

Ignition fuse 10 A

Headlight fuse 15 A

Carburetor heater fuse 15 A

Signaling system fuse 10 A

SPECIFICATIONS EAU01038

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EAU01064

Conversion table All specification data in this manual arelisted in SI and METRIC UNITS.Use this table to convert METRIC unit da-ta to IMPERIAL unit data.

Example

METRIC MULTIPLIER IMPERIAL** mm x 0.03937 = ** in2 mm x 0.03937 = 0. 08 in

Conversion table

METRIC TO IMPERIAL

Metric unit Multiplier Imperial unit

m·kg 7.233 ft·lbTorque m·kg 86.794 in·lb

cm·kg 0.0723 ft·lbcm·kg 0.8679 in·lb

Weight kg 2.205 lbg 0.03527 oz

Speed km/h 0.6214 mi/h

km 0.6214 mim 3.281 ft

Distance m 1.094 ydcm 0.3937 inmm 0.03937 in

cc (cm3) 0.03527 oz (IMP liq.)Volume, cc (cm3) 0.06102 cu·inCapacity L (liter) 0.8799 qt (IMP liq.)

L (liter) 0.2199 gal (IMP liq.)

kg/mm 55.997 lb/inMiscellaneous kg/cm2 14.2234 psi (lb/in2)

Centigrade (°C) 9/5 + 32 Fahrenheit (°F)

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Identification numbers ..........................................................................9-1

Key identification number......................................................................9-1

Vehicle identification number ................................................................9-1

Model label............................................................................................9-2

CONSUMER INFORMATIONEAU01039

1. Key identification number


1 1

EAU02944

Identification numbersRecord the key identification number, vehi-cle identification number and model labelinformation in the spaces provided belowfor assistance when ordering spare partsfrom a Yamaha dealer or for reference incase the vehicle is stolen.

1. KEY IDENTIFICATION NUMBER:

2. VEHICLE IDENTIFICATION NUM-BER:

3. MODEL LABEL INFORMATION:

EAU01041

Key identification numberThe key identification number is stampedinto the key tag.Record this number in the space providedand use it for reference when ordering anew key.

EAU01044

Vehicle identification numberThe vehicle identification number isstamped into the frame.The vehicle identification number is usedto identify your motorcycle and may beused to register your motorcycle with the li-censing authority in your area.

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ç

1. Vehicle identification number

EAU01039

1. Model label


1

EAU01050

Model labelThe model label is affixed to the frame un-der the seat. (See page 3--13 for seat re-moval and installation procedures).Record the information on this label in thespace provided. This information will beneeded when ordering spare parts from aYamaha dealer.

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EAU01039

INDEX

AAir filter element, cleaning ....................6-10Anti-theft alarm (optional) ......................3-8Auxiliary light bulb, replacing................6-29

BBattery ..................................................6-26Brake and clutch levers, checking

and Lubricating ..................................6-23Brake and shift pedals, checking

and Lubricating ..................................6-23Brake fluid, changing ............................6-21Brake fluid level, checking....................6-19Brake lever ..........................................3-10Brake pads, checking ..........................6-19Brake pedal ..........................................3-10Brake pedal position, adjusting ............6-18

CCables, checking and lubricating..........6-22Carburetors, adjusting ..........................6-12Care ........................................................7-1Clock ......................................................3-5Clutch lever ............................................3-9Clutch lever free play, adjusting ..........6-17Consumer information ............................9-1Controls ..................................................2-3Conversion table ....................................8-5

DDescription..............................................2-1

Controls and instrument ......................2-3

Left view ..............................................2-1Right view ............................................2-2

EEngine break-in ......................................5-4Engine idling speed, adjusting..............6-12Engine oil and oil filter element ..............6-7Engine stop switch..................................3-9

FFinal gear oil ..........................................6-9Front fork

Adjusting ............................................3-15Checking ............................................6-24

Front wheelInstalling ............................................6-33Removing ..........................................6-32

Fuel ......................................................3-11Fuel consumption, tips for reducing ......5-4Fuel level warning light ..........................3-3Fuel tank breather hose ......................3-12Fuel tank cap ........................................3-11Fuses, replacing ..................................6-28

HHandlebar switches ................................3-8Headlight bulb, replacing ......................6-29Helmet holders ....................................3-14High beam indicator light........................3-3Horn switch ............................................3-8

IIdentification numbers ............................9-1Idling speed, adjusting..........................6-12Ignition circuit cut-off system ................3-17Instrument and control functions ............2-3Instruments ............................................2-3

KKey identification number ......................9-1

LLicense plate light bulb, replacing ........6-32Light switch ............................................3-9

MMain switch/steering lock ..........................3-1Model label ................................................9-2

NNeutral indicator light..............................3-2

OOil level warning light ............................3-2Operation and important riding points ....5-1

PPanels, removing and installing..............6-5Parking....................................................5-5Pass switch ............................................3-8Periodic maintenance and lubrication

chart ....................................................6-2

INDEX

Periodic maintenance and minor repair ..................................6-1

Pre-operation check list ..........................4-1Pre-operation checks..............................4-1

RRear wheel

Installing ............................................6-34Removing ..........................................6-33

SSafety information ..................................1-1Seat ......................................................3-13Self-diagnosis device..............................3-6Shift pedal ............................................3-10

Adjusting the pedal position ..............6-21Shifting....................................................5-3Shock absorber assembly

adjusting ............................................3-15Sidestand..............................................3-16Sidestand, checking

and lubricating....................................6-24Spark plugs, checking ............................6-5Specifications..........................................8-1

Conversion table ..................................8-5Speedometer unit ..................................3-3Starter (choke) lever ............................3-12Starting a cold engine ............................5-1Starting a warm engine ..........................5-3Start switch ............................................3-9Steering, checking ................................6-25Steering lock ..........................................3-1

Storage ..................................................7-4Storage compartment ..........................3-14

TTachometer ............................................3-6Tail/brake light bulb, replacing ..............6-31Throttle cable free play, adjusting ........6-13Throttle grip and cable, checking and

lubricating ..........................................6-22Tires......................................................6-14

Air pressure........................................6-14Tool kit ....................................................6-1Troubleshooting ....................................6-35Troubleshooting chart ..........................6-36Turn signal indicator light........................3-2Turn signal light bulb, replacing............6-31Turn signal switch ..................................3-8

VValve clearance, adjusting....................6-13Vehicle identification number..................9-1

WWheel bearings, checking ....................6-25Wheels, cast ........................................6-16

PRINTED IN ITALY

distributrice esclusiva per l’Italia20050 Gerno di Lesmo (MI) - Via Tinelli, 67/69Telefono (039) 60961 Ricerca automatica

s.p.a.

USO E MANUTENZIONE OWNER’S MANUAL …...wear a complete motorcycle suit (whether made of leather...

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Transcript of USO E MANUTENZIONE OWNER’S MANUAL …...wear a complete motorcycle suit (whether made of leather...