คู่มือรถจักรยานยนต์ YAMAHA SR-400

PERIODIC MAINTENANCE AND ADJUSTMENT

Spoke wheels EAU21944 ened tire life. EAU48291 1
EWA10611 2
WARNING Adjusting the clutch lever free 3
play 4
The wheels on this model are not de- 5
signed for use with tubeless tires. 2 34
Do not attempt to use tubeless tires 1
on this model.
(a)
To maximize the performance, durabil-
ity, and safe operation of your motorcy- (b)
cle, note the following points regarding
the specified wheels. 1. Clutch lever free play 6
7
 The wheel rims should be checked 2. Rubber cover 8
for cracks, bends, warpage or oth- 9
er damage, and the spokes for 3. Locknut (clutch lever) 10
looseness or damage before each 11
ride. If any damage is found, have 4. Clutch lever free play adjusting bolt 12
a Yamaha dealer replace the
wheel. Do not attempt even the The clutch lever free play should mea-
smallest repair to the wheel. A de- sure 5.0–10.0 mm (0.20–0.39 in) as
formed or cracked wheel must be shown. Periodically check the clutch le-
replaced. ver free play and, if necessary, adjust it
as follows.
 The wheel should be balanced
whenever either the tire or wheel 1. Slide the rubber cover back at the
has been changed or replaced. An clutch lever.
unbalanced wheel can result in
poor performance, adverse han- 2. Loosen the locknut.
dling characteristics, and a short- 3. To increase the clutch lever free

play, turn the adjusting bolt in di-
rection (a). To decrease the clutch

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PERIODIC MAINTENANCE AND ADJUSTMENT

lever free play, turn the adjusting EAU48443 decrease the brake lever free play,
turn the adjusting screw in direc-
1 bolt in direction (b). Adjusting the brake lever free tion (b).
4. Tighten the locknut, and then slide
4. Tighten the locknut and then slide play the rubber cover back to its original
position.
2 the rubber cover to its original po- The brake lever free play should mea-
EWA10631
sition. sure 5.0–8.0 mm (0.20–0.31 in) as
WARNING
3 TIP shown. Periodically check the brake le-
ver free play and, if necessary, adjust it  After adjusting the brake lever
If the specified free play cannot be ob- as follows. free play, check the free play
4 tained as described above or if the and make sure that the brake is
3 working properly.
clutch does not operate correctly, have 1 2 4
(a)  A soft or spongy feeling in the
5 a Yamaha dealer check the internal brake lever can indicate the
clutch mechanism. presence of air in the hydraulic
system. If there is air in the hy-
6 draulic system, have a Yamaha
dealer bleed the system before
(b) operating the motorcycle. Air in
the hydraulic system will dimin-
7 ish the braking performance,
which may result in loss of con-
8 trol and an accident.

1. Locknut
2. Brake lever free play adjusting screw

9 3. Rubber cover

4. Brake lever free play

10 1. Slide the rubber cover back at the
brake lever.

11 2. Loosen the locknut.
3. To increase the brake lever free

12 play, turn the brake lever free play
adjusting screw in direction (a). To

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PERIODIC MAINTENANCE AND ADJUSTMENT

EAU60900 brake pedal height adjusting bolt in Brake pedal free play 1
direction (a). To lower the brake 2
Adjusting the brake pedal pedal, turn the adjusting bolt in di-
height and free play rection (b).

1 (a) (b) 13
2
4

1 5
6
1. Brake pedal height 1. Brake pedal free play 7
8
EWA10671 1. Locknut The brake pedal free play should mea- 9
2. Brake pedal height adjusting bolt sure 20.0–30.0 mm (0.79–1.18 in) as 10
WARNING shown. Periodically check the brake 11
pedal free play and, if necessary, adjust 12
It is advisable to have a Yamaha 3. Tighten the locknut. EWA11232 it as follows.
dealer make these adjustments. WARNING To increase the brake pedal free play,
turn the brake pedal free play adjusting
Brake pedal height After adjusting the brake pedal nut at the brake rod in direction (a). To
The top of the brake pedal should be height, the brake pedal free play decrease the brake pedal free play,
positioned approximately 20.0 mm must be adjusted. turn the adjusting nut in direction (b).
(0.79 in) below the top of the footrest.
Periodically check the brake pedal
height and, if necessary, adjust it as fol-
lows.

1. Loosen the locknut at the frame.
2. To raise the brake pedal, turn the

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PERIODIC MAINTENANCE AND ADJUSTMENT

EAU44821 EAU22274

1 Checking the shift pedal Brake light switches

The operation of the shift pedal should

2 be checked before each ride. If opera-

(a) (b) tion is not smooth, have a Yamaha (a) 2

3 dealer check the vehicle.

41 1 (b)

5 1. Brake pedal free play adjusting nut

EWA10681

6 WARNING 1. Rear brake light switch adjusting nut
 After adjusting the drive chain
2. Rear brake light switch
7 slack or removing and installing
the rear wheel, always check the The brake light, which is activated by
the brake pedal and brake lever, should
brake pedal free play. come on just before braking takes ef-
8  If proper adjustment cannot be fect. If necessary, adjust the rear brake
light switch as follows, but the front
obtained as described, have a brake light switch should be adjusted
by a Yamaha dealer.
9 Yamaha dealer make this ad- Turn the rear brake light switch adjust-
ing nut while holding the rear brake light
justment. switch in place. To make the brake light
come on earlier, turn the adjusting nut
10  After adjusting the brake pedal in direction (a). To make the brake light
free play, check the operation of come on later, turn the adjusting nut in
direction (b).
the brake light.
11

12

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PERIODIC MAINTENANCE AND ADJUSTMENT

EAU22382 indicator grooves have almost disap- EAU32346 1
peared, have a Yamaha dealer replace 2
Checking the front brake pads the brake pads as a set. Checking the brake fluid level 3
and rear brake shoes 4
EAU22541 Before riding, check that the brake fluid 5
The front brake pads and the rear brake is above the minimum level mark. 6
shoes must be checked for wear at the Rear brake shoes Check the brake fluid level with the top
intervals specified in the periodic main- of the reservoir level. Replenish the
tenance and lubrication chart. 2 brake fluid if necessary.

EAU22432

Front brake pads

1 1
2 1

1. Brake shoe wear indicator 1. Minimum level mark 7
8
1. Brake pad 2. Brake shoe wear limit line Specified brake fluid: 9
2. Brake pad wear indicator groove DOT 4 10
The rear brake is provided with a wear 11
Each front brake pad is provided with indicator, which allows you to check the EWA15991 12
wear indicator grooves, which allow brake shoe wear without having to dis-
you to check the brake pad wear with- assemble the brake. To check the WARNING
out having to disassemble the brake. brake shoe wear, check the position of
To check the brake pad wear, check the wear indicator while applying the Improper maintenance can result in
the wear indicator grooves. If a brake brake. If a brake shoe has worn to the
pad has worn to the point that the wear point that the wear indicator reaches loss of braking ability. Observe
the wear limit line, have a Yamaha
dealer replace the brake shoes as a these precautions:
set.
 Insufficient brake fluid may al-
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tem, reducing braking

PERIODIC MAINTENANCE AND ADJUSTMENT

performance. check the brake pads for wear and the EAU22724

1  Clean the filler cap before re- brake system for leakage. If the brake Changing the brake fluid

moving. Use only DOT 4 brake fluid level goes down suddenly, have a Have a Yamaha dealer change the

2 fluid from a sealed container. Yamaha dealer check the cause before brake fluid at the intervals specified in

 Use only the specified brake flu- further riding. the periodic maintenance and lubrica-

3 id; otherwise, the rubber seals tion chart. In addition, have the oil seals
may deteriorate, causing leak- of the brake master cylinder and caliper

age. as well as the brake hose replaced at
4  Refill with the same type of the intervals listed below or whenever

brake fluid. Adding a brake fluid they are damaged or leaking.
 Oil seals: Replace every two
5 other than DOT 4 may result in a
harmful chemical reaction. years.
 Brake hose: Replace every four
6  Be careful that water does not
enter the brake fluid reservoir years.

when refilling. Water will signifi-
7 cantly lower the boiling point of

the fluid and may result in vapor

8 lock.

ECA17641

9 NOTICE
Brake fluid may damage painted sur-

10 faces or plastic parts. Always clean
up spilled fluid immediately.

11 As the brake pads wear, it is normal for
the brake fluid level to gradually go
down. A low brake fluid level may indi-

12 cate worn brake pads and/or brake sys-
tem leakage; therefore, be sure to

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PERIODIC MAINTENANCE AND ADJUSTMENT

EAU22762

Drive chain slack 41

The drive chain slack should be 3 2
2
checked before each ride and adjusted 5
1
if necessary. 3

EAU59591 1 64

To check the drive chain slack 1. Drive chain slack 1. Brake pedal free play adjusting nut 5
1. Place the motorcycle on the cen- 6
terstand. 5. If the drive chain slack is incorrect, 2. Drive chain slack adjusting bolt 7
2. Shift the transmission into the neu- adjust it as follows. 8
tral position. 3. Drive chain puller locknut 9
3. Push on the drive chain at the cen- EAU59641 10
ter point between the drive axle 4. Axle nut 11
and the rear wheel axle with a To adjust the drive chain slack 5. Brake torque rod nut 12
force of 50 N (5.0 kgf, 11 lbf). Consult a Yamaha dealer before ad-
4. Measure drive chain slack as justing the drive chain slack. 6. Brake torque rod
shown.
1. Take the motorcycle off the center- 3. Loosen the drive chain puller lock-
Drive chain slack: stand, and then put the sidestand nut at each end of the swingarm.
30.0–40.0 mm (1.18–1.57 in) down.
4. Place the motorcycle on the cen-
2. Loosen the brake pedal free play terstand.
adjusting nut, brake torque rod nut,
and axle nut. 5. To tighten the drive chain, turn the
drive chain slack adjusting bolt at
each end of the swingarm in direc-
tion (a). To loosen the drive chain,
turn the adjusting bolt at each end
of the swingarm in direction (b),
and then push the rear wheel for-
ward. NOTICE: Improper drive
chain slack will overload the en-

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PERIODIC MAINTENANCE AND ADJUSTMENT

gine as well as other vital parts down. EAU23026
1 of the motorcycle and can lead 7. Tighten both drive chain puller
Cleaning and lubricating the
to chain slippage or breakage. locknuts, and then tighten the axle drive chain
2 To prevent this from occurring, nut and brake torque rod nut to
their specified torques. The drive chain must be cleaned and
keep the drive chain slack with- lubricated at the intervals specified in
3 in the specified limits.[ECA10572] Tightening torques: the periodic maintenance and lubrica-
Drive chain puller locknut: tion chart, otherwise it will quickly wear
TIP 16 Nm (1.6 m·kgf, 12 ft·lbf) out, especially when riding in dusty or
Axle nut: wet areas. Service the drive chain as
4 Using the alignment marks on each 129 Nm (12.9 m·kgf, 92 ft·lbf) follows.
Brake torque rod nut:
side of the swingarm, make sure that 19 Nm (1.9 m·kgf, 14 ft·lbf) ECA10584

5 both drive chain pullers are in the same NOTICE
position for proper wheel alignment.

6 4 8. Adjust the brake pedal free play. The drive chain must be lubricated
(See page 6-18.) after washing the motorcycle, riding
3
7 (b) EWA10661 in the rain or riding in wet areas.

WARNING 1. Clean the drive chain with kero-

8 After adjusting the brake pedal free sene and a small soft brush.

play, check the operation of the NOTICE: To prevent damaging

(a) brake light. the O-rings, do not clean the

9 9. Make sure that the drive chain pull- drive chain with steam cleaners,
ers are in the same position, the high-pressure washers or inap-
21 drive chain slack is correct, and propriate solvents.[ECA11122]
the drive chain moves smoothly. 2. Wipe the drive chain dry.
10 1. Axle nut 3. Thoroughly lubricate the drive
chain with a special O-ring chain
2. Drive chain puller locknut lubricant. NOTICE: Do not use
engine oil or any other lubri-
11 3. Drive chain slack adjusting bolt cants for the drive chain, as they

4. Alignment marks

12 6. Take the motorcycle off the center-
stand, and then put the sidestand

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PERIODIC MAINTENANCE AND ADJUSTMENT

may contain substances that EAU23098 EAU23115 1
could damage the O-rings.[ECA11112] 2
Checking and lubricating the Checking and lubricating the 3
cables throttle grip and cable 4
5
The operation of all control cables and The operation of the throttle grip should 6
the condition of the cables should be be checked before each ride. In addi- 7
checked before each ride, and the ca- tion, the cable should be lubricated by a 8
bles and cable ends should be lubricat- Yamaha dealer at the intervals speci- 9
ed if necessary. If a cable is damaged fied in the periodic maintenance chart.
or does not move smoothly, have a The throttle cable is equipped with a
Yamaha dealer check or replace it. rubber cover. Make sure that the cover
WARNING! Damage to the outer is securely installed. Even though the
housing of cables may result in in- cover is installed correctly, it does not
ternal rusting and cause interfer- completely protect the cable from water
ence with cable movement. Replace entry. Therefore, use care not to pour
damaged cables as soon as possi- water directly onto the cover or cable
ble to prevent unsafe condi- when washing the vehicle. If the cable
tions.[EWA10712] or cover becomes dirty, wipe clean with
a moist cloth.
Recommended lubricant:
Yamaha cable lubricant or other suit-
able cable lubricant

10

11

12

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PERIODIC MAINTENANCE AND ADJUSTMENT

EAU23144 Clutch lever EAU23184

1 Checking and lubricating the Checking and lubricating the
brake and clutch levers brake pedal

2 The operation of the brake and clutch The operation of the brake pedal
levers should be checked before each should be checked before each ride,
and the pedal pivot should be lubricat-
3 ride, and the lever pivots should be lu- ed if necessary.
bricated if necessary.

4 Brake lever

5
Recommended lubricants:

Brake lever:

6 Silicone grease
Clutch lever:

Lithium-soap-based grease
7

8 Recommended lubricant:
Lithium-soap-based grease

9

10

11

12

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PERIODIC MAINTENANCE AND ADJUSTMENT

EAU23215 Recommended lubricant: EAUM1653 1
Lithium-soap-based grease 2
Checking and lubricating the Lubricating the swingarm
centerstand and sidestand pivots

3

4

5

The operation of the centerstand and The swingarm pivots must be lubricat- 6
sidestand should be checked before ed by a Yamaha dealer at the intervals 7
each ride, and the pivots and met- specified in the periodic maintenance 8
al-to-metal contact surfaces should be and lubrication chart. 9
lubricated if necessary.
Recommended lubricant:
EWA10742 Lithium-soap-based grease

WARNING 10

If the centerstand or sidestand does 11
not move up and down smoothly,
have a Yamaha dealer check or re-
pair it. Otherwise, the centerstand or
sidestand could contact the ground
and distract the operator, resulting
in a possible loss of control.

12

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PERIODIC MAINTENANCE AND ADJUSTMENT

EAU51951 EAU45512

1 Checking the front fork Checking the steering

The condition and operation of the front Worn or loose steering bearings may

2 fork must be checked as follows at the cause danger. Therefore, the operation
intervals specified in the periodic main- of the steering must be checked as fol-

3 tenance and lubrication chart. lows at the intervals specified in the pe-
riodic maintenance and lubrication

To check the condition chart.
4 Check the front fork for damage and ex- 1. Place the vehicle on the center-

cessive oil leakage. stand. WARNING! To avoid inju-
ry, securely support the vehicle
5 ECA10591 so there is no danger of it falling
To check the operation over.[EWA10752]
NOTICE 2. Hold the lower ends of the front
fork legs and try to move them for-
1. Place the vehicle on a level sur- If any damage is found or the front ward and backward. If any free
6 face and hold it in an upright posi- fork does not operate smoothly,

tion. WARNING! To avoid injury, have a Yamaha dealer check or re-

7 securely support the vehicle so pair it.

there is no danger of it falling play can be felt, have a Yamaha

8 over.[EWA10752] dealer check or repair the steering.
2. While applying the front brake,

push down hard on the handlebars
9 several times to check if the front

fork compresses and rebounds

10 smoothly.

11

12

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PERIODIC MAINTENANCE AND ADJUSTMENT

EAU23292 Battery EAU40447 ways shield your eyes when 1
working near batteries. In case 2
Checking the wheel bearings 1 of contact, administer the fol- 3
lowing FIRST AID. 4
The front and rear wheel bearings must 1. Battery • EXTERNAL: Flush with plenty 5
be checked at the intervals specified in 6
the periodic maintenance and lubrica- The battery is located under the seat. of water. 7
tion chart. If there is play in the wheel (See page 3-11.) • INTERNAL: Drink large quan- 8
hub or if the wheel does not turn This model is equipped with a VRLA 9
smoothly, have a Yamaha dealer check (Valve Regulated Lead Acid) battery. tities of water or milk and im- 10
the wheel bearings. There is no need to check the electro- mediately call a physician. 11
lyte or to add distilled water. However, • EYES: Flush with water for 15 12
the battery coupler connection needs to minutes and seek prompt
be checked to make sure that it is se- medical attention.
curely connected.  Batteries produce explosive hy-
drogen gas. Therefore, keep
EWA10761 sparks, flames, cigarettes, etc.,
away from the battery and pro-
WARNING vide sufficient ventilation when
charging it in an enclosed
 Electrolyte is poisonous and space.
dangerous since it contains sul-  KEEP THIS AND ALL BATTER-
furic acid, which causes severe IES OUT OF THE REACH OF
burns. Avoid any contact with CHILDREN.
skin, eyes or clothing and al-
To charge the battery
6-28 Have a Yamaha dealer charge the bat-
http://www.motorcycle.in.th tery as soon as possible if it seems to
have discharged. Keep in mind that the
battery tends to discharge more quickly

PERIODIC MAINTENANCE AND ADJUSTMENT

if the vehicle is equipped with optional ECA16531 EAU59441

1 electrical accessories. NOTICE Replacing the fuses

2 NOTICE ECA16522 Always keep the battery charged. The main fuse is located inside the bat-

Storing a discharged battery can tery coupler. (See page 6-28.)

To charge a VRLA (Valve Regulated cause permanent battery damage. 3
3 Lead Acid) battery, a special (con-

stant-voltage) battery charger is re-

quired. Using a conventional battery 1
4 charger will damage the battery.

5 To store the battery 2
1. If the vehicle will not be used for
1. Battery coupler
6 more than one month, remove the 2. Main fuse
battery, fully charge it, and then 3. Spare main fuse

7 place it in a cool, dry place. If the main fuse is blown, replace it as
NOTICE: When removing the follows.
battery, be sure the key is
1. Turn the key to “OFF” and turn off
8 turned to “OFF” before discon- all electrical circuits.
necting the coupler.[ECA16323]
2. Remove the seat. (See
9 2. If the battery will be stored for more page 3-11.)
than two months, check it at least
3. Remove the battery by removing
10 once a month and fully charge it if the battery band.
necessary.
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3. Fully charge the battery before in- http://www.motorcycle.in.th
11 stallation. NOTICE: When install-

ing the battery, be sure the key
12 is turned to “OFF” before con-

necting the coupler.[ECA16931]

PERIODIC MAINTENANCE AND ADJUSTMENT

12 rating than recommended to 1 1
avoid causing extensive dam- 2 2
1. Battery age to the electrical system and 3 3
2. Battery band possibly a fire.[EWA15132] 4 4
5 5
4. Disconnect the battery coupler. Specified fuse: 6
30.0 A 76 7
1 8
6. Connect the battery coupler. 1. Headlight fuse 9
1. Battery coupler 7. Install the battery by installing the 2. Signaling system fuse 10
3. Ignition fuse 11
5. Remove the blown fuse, and then battery band. 4. Backup fuse 12
install a new fuse of the specified 8. Install the seat. 5. Fuel injection system fuse
amperage. WARNING! Do not 9. Turn the key to “ON”. 6. Parking lighting fuse
use a fuse of a higher amperage 10. If the fuse immediately blows 7. Spare fuse

again, have a Yamaha dealer If a fuse is blown, replace it as follows.
check the electrical system. 1. Turn the key to “OFF” and turn off
The fuse box, which contains the fuses the electrical circuit in question.
for the individual circuits, is located un- 2. Remove the seat. (See
der the seat. (See page 3-11.) page 3-11.)
3. Remove the blown fuse, and then
1 install a new fuse of the specified
amperage. WARNING! Do not
1. Fuse box use a fuse of a higher amperage
6-30 rating than recommended to
avoid causing extensive dam-
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PERIODIC MAINTENANCE AND ADJUSTMENT

possibly a fire.[EWA15132] EAU23799
1
Replacing the headlight bulb

Specified fuses: This model is equipped with a halogen
bulb headlight. If the headlight bulb
2 Main fuse: burns out, replace it as follows.
30.0 A
ECA10651
Signaling system fuse:
NOTICE
3 15.0 A
Headlight fuse:

15.0 A Take care not to damage the follow- 1. Do not touch the glass part of the bulb.
4 Ignition fuse: ing parts:
1. Remove the headlight unit by re-
10.0 A  Headlight bulb moving the screws.
Backup fuse: Do not touch the glass part of
5 7.5 A the headlight bulb to keep it free
Fuel injection system fuse: from oil, otherwise the transpar-
ency of the glass, the luminosity
7.5 A of the bulb, and the bulb life will
6 Parking lighting fuse:

7.5 A

7 4. Turn the key to “ON” and turn on be adversely affected. Thor-

the electrical circuit in question to oughly clean off any dirt and fin-

8 check if the device operates. gerprints on the headlight bulb

5. If a fuse immediately blows again, using a cloth moistened with al-

9 have a Yamaha dealer check the cohol or thinner.
electrical system.  Headlight lens

Do not affix any type of tinted 1

10 film or stickers to the headlight

lens. 1. Screw

11 Do not use a headlight bulb of a
wattage higher than specified.

12

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PERIODIC MAINTENANCE AND ADJUSTMENT

bulb. EAU24134 1
2
1 Replacing the tail/brake light 3
bulb 4
1
1. Remove the tail/brake light lens by
removing the screws.

2

1. Screw 1. Headlight bulb holder 5

2. Disconnect the headlight coupler, 4. Place a new headlight bulb into po- 1
and then remove the headlight sition, and then secure it with the
bulb cover. bulb holder. 6

1 5. Install the bulb cover, and then 1. Screw 7
2 connect the coupler. 2. Tail/brake light lens 8
9
6. Install the headlight unit by install- 2. Remove the burnt-out bulb by
ing the screws. pushing it in and turning it counter-
clockwise.
7. Have a Yamaha dealer adjust the
headlight beam if necessary.

10

1. Headlight coupler 11
2. Headlight bulb cover 12

3. Unhook the headlight bulb holder,
and then remove the burnt-out

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PERIODIC MAINTENANCE AND ADJUSTMENT

1 EAU60010

21 Replacing a turn signal light
bulb
3
1. Remove the turn signal light lens,
turn signal light rim and gasket by
removing the screws.

41 3
12

5 1. Tail/brake light bulb 1. Turn signal light lens

3. Insert a new bulb into the socket, 2. Turn signal light rim

6 push it in, and then turn it clock- 3. Gasket

wise until it stops. 2 2. Remove the burnt-out bulb by

7 4. Install the lens by installing the pushing it in and turning it counter-
screws. NOTICE: Do not over- clockwise.
tighten the screws, otherwise 1. Turn signal light lens 3. Insert a new bulb into the socket,
2. Screw push it in, and then turn it clock-
8 the lens may break.[ECA10682] wise until it stops.
4. Install the gasket, rim and lens by
9 installing the screws with the notch
on the rim and lens facing to in-
10 ward as shown. NOTICE: Do not
overtighten the screws, other-
11 wise the lens may break.[ECA10682]

12

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PERIODIC MAINTENANCE AND ADJUSTMENT

EAU33416 2. Remove the socket (together with 1
the bulb) by pushing it in and turn- 2
Replacing the auxiliary light ing it counterclockwise. 3
bulb
1
If the auxiliary light bulb burns out, re-
place it as follows.

1. Remove the headlight unit by re-
moving the screws.

4

5

1 1. Auxiliary light bulb socket 6
7
1. Screw 3. Remove the burnt-out bulb by 8
pushing it in and turning it counter- 9
clockwise. 10

1

2

1 11
12
1. Auxiliary light bulb socket
1. Screw 2. Auxiliary light bulb

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PERIODIC MAINTENANCE AND ADJUSTMENT

4. Insert a new bulb into the socket, EAU24361

1 push it in, and then turn it clock- Front wheel

wise until it stops.

2 5. Install the socket (together with the EAU59600

bulb) by pushing it in and turning it

3 clockwise until it stops. To remove the front wheel
6. Install the headlight unit by install-
EWA10822

ing the screws. WARNING 1
4

To avoid injury, securely support the

5 vehicle so there is no danger of it 1. Axle holder nut
falling over.
3. Place the motorcycle on the cen-
1. Loosen the wheel axle nut.
6 terstand.

4. Disconnect the speedometer ca-

7 ble from the front wheel.

81
91

10

1. Wheel axle nut

11 2. Loosen the wheel axle holder nuts.

1. Speedometer cable

12 5. Remove the wheel axle nut and
the washer.

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PERIODIC MAINTENANCE AND ADJUSTMENT

6. Pull the wheel axle out, and then legs. axle holder nuts to their specified 1
remove the collar and wheel. TIP torques 2
NOTICE: Do not apply the brake Make sure that there is enough space 3
after the wheel and brake disc between the brake pads before insert- Tightening torques: 4
have been removed, otherwise ing the brake disc and that the slot in Axle nut: 5
the brake pads will be forced the speedometer gear unit fits over the 104 Nm (10.4 m·kgf, 74 ft·lbf) 6
shut.[ECA11073] retainer on the fork leg. Wheel axle holder nut:
9 Nm (0.9 m·kgf, 6.5 ft·lbf)
To install the front wheel 12
1. Install the speedometer gear unit 7. While applying the front brake,
into the wheel hub so that the pro- push down hard on the handlebars
jections mesh with the slots. several times to check if the front
fork compresses and rebounds
12 smoothly.
3
8. Connect the speedometer cable.

7

1. Slot 1. Retainer 8
2. Speedometer gear unit 2. Slot 9
3. Projection 10
4. Insert the wheel axle from the 11
2. Install the collar into the right side left-hand side, and then install the 12
of the wheel hub. washer and axle nut.

3. Lift the wheel up between the fork 5. Take the motorcycle off the center-
stand so that the front wheel is on
the ground, and then put the side-
stand down.

6. Tighten the axle nut and the wheel

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PERIODIC MAINTENANCE AND ADJUSTMENT

1 Rear wheel EAU25081 6 78 swingarm.
EAU59611 25
2 1
4
3 To remove the rear wheel 39 234

EWA10822 7 1. Drive chain slack adjusting bolt
2. Drive chain puller locknut
4 WARNING 1 10 3. Axle nut
To avoid injury, securely support the 4. Washer
1. Brake rod
5 vehicle so there is no danger of it 2. Brake camshaft lever 6. Remove the axle nut and washer.
falling over. 3. Brake pedal free play adjusting nut 7. While supporting the rear wheel,
4. Drive chain slack adjusting bolt
6 1. Loosen the axle nut and the brake 5. Drive chain puller locknut pull the wheel axle out.
torque rod nut at the brake shoe 6. Drive chain puller 8. Remove the chain puller assem-
7. Washer
plate. 8. Axle nut blies and the spacer.
7 2. Disconnect the brake torque rod 9. Brake torque rod nut
10.Brake torque rod
from the brake shoe plate by re-
3. Place the motorcycle on the cen-
8 moving the nut, washer and the terstand.
bolt.
4. Remove the brake pedal free play
9 adjusting nut, and then disconnect
the brake rod from the brake cam-
10 shaft lever.

11 5. Loosen the drive chain puller lock-
nut and the drive chain slack ad-
12 justing bolt on both ends of the

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PERIODIC MAINTENANCE AND ADJUSTMENT

4. Install the washer and axle nut. brake light. 1
5. Install the brake rod onto the brake 2
1 3
camshaft lever, and then install the 4
1. Drive chain brake pedal free play adjusting nut 5
onto the brake rod. 6
9. Push the wheel forward, and then 6. Connect the brake torque rod to 7
remove the drive chain from the the brake shoe plate by installing 8
rear sprocket. the bolt, washer and nut. 9
7. Adjust the drive chain slack. (See 10
TIP page 6-22.) 11
The drive chain does not need to be 8. Take the motorcycle off the center- 12
disassembled in order to remove and stand so that the rear wheel is on
install the wheel. the ground, and then put the side-
stand down.
To install the rear wheel 9. Tighten the brake torque rod nut
1. Install the spacer into left side of and axle nut to the specified
the wheel hub. torques.
2. Install the chain pullers and the
wheel by inserting the wheel axle Tightening torques:
from the left-hand side. Brake torque rod nut:
3. Install the drive chain onto the rear 19 Nm (1.9 m·kgf, 14 ft·lbf)
sprocket. Axle nut:
129 Nm (12.9 m·kgf, 92 ft·lbf)

10. Adjust the brake pedal free play.
(See page 6-18.)

EWA10661

WARNING

After adjusting the brake pedal free
play, check the operation of the

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PERIODIC MAINTENANCE AND ADJUSTMENT

1 Troubleshooting EAU25852 heaters or furnaces. Gasoline or
gasoline vapors can ignite or ex-

Although Yamaha motorcycles receive plode, causing severe injury or

2 a thorough inspection before shipment property damage.

from the factory, trouble may occur dur-

3 ing operation. Any problem in the fuel,
compression, or ignition systems, for

example, can cause poor starting and
4 loss of power.

The following troubleshooting chart

5 represents a quick and easy procedure
for checking these vital systems your-

self. However, should your motorcycle
6 require any repair, take it to a Yamaha

dealer, whose skilled technicians have

7 the necessary tools, experience, and

know-how to service the motorcycle

8 properly.
Use only genuine Yamaha replace-

ment parts. Imitation parts may look like
9 Yamaha parts, but they are often inferi-

or, have a shorter service life and can

10 lead to expensive repair bills.

EWA15142

WARNING
11

When checking the fuel system, do

not smoke, and make sure there are
12 no open flames or sparks in the ar-

ea, including pilot lights from water

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PERIODIC MAINTENANCE AND ADJUSTMENT

EAU60030

Troubleshooting chart 1

1. Fuel There is enough fuel. Check the battery. 2
There is no fuel. 3
Check the fuel level in Supply fuel. The engine does not start. 4
the fuel tank. Check the battery. 5
6
2. Battery The turn signal flashes The battery is good. Operate the kickstarter. 7
brightly. If the engine does not 8
With the key in the on Check the battery lead connections, start, check the ignition.
position, operate the turn The turn signal does and have a Yamaha dealer charge
signal switch. not flash or is weak. the battery if necessary.

3. Ignition Wet Wipe off with a dry cloth and correct the Operate the kickstarter.
spark plug gap, or replace the spark plug.
Remove the spark plug
and check the electrodes. Dry Have a Yamaha dealer check the vehicle. The engine does not start.
Check the compression.
4. Compression
There is compression. The engine does not start. 9
Operate the kickstarter. There is no compression. Have a Yamaha dealer check the vehicle. 10
11
Have a Yamaha dealer check the vehicle.

12

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MOTORCYCLE CARE AND STORAGE

EAU37834 EAU26005 ucts onto seals, gaskets, sprock-
ets, the drive chain and wheel
1 Matte color caution Care

2 NOTICE ECA15193 While the open design of a motorcycle axles. Always rinse the dirt and de-
reveals the attractiveness of the tech- greaser off with water.

Some models are equipped with nology, it also makes it more vulnera-

3 matte colored finished parts. Be ble. Rust and corrosion can develop Cleaning ECA10773
sure to consult a Yamaha dealer for even if high-quality components are

advice on what products to use be- used. A rusty exhaust pipe may go un- NOTICE

4 fore cleaning the vehicle. Using a noticed on a car, however, it detracts  Avoid using strong acidic wheel

brush, harsh chemical products or from the overall appearance of a motor- cleaners, especially on spoked
wheels. If such products are
5 cleaning compounds when cleaning cycle. Frequent and proper care does used on hard-to-remove dirt, do
not leave the cleaner on the af-
these parts will scratch or damage not only comply with the terms of the fected area any longer than in-

6 their surface. Wax also should not warranty, but it will also keep your mo-
be applied to any matte colored fin- torcycle looking good, extend its life

ished parts. and optimize its performance. structed. Also, thoroughly rinse
7 the area off with water, immedi-
Before cleaning ately dry it, and then apply a cor-
8 1. Cover the muffler outlet with a rosion protection spray.
plastic bag after the engine has  Improper cleaning can damage

9 cooled down. plastic parts (such as cowlings,
2. Make sure that all caps and covers panels, windshields, headlight

as well as all electrical couplers lenses, meter lenses, etc.) and

10 and connectors, including the the mufflers. Use only a soft,

spark plug cap, are tightly in- clean cloth or sponge with wa-

11 stalled. ter to clean plastic. However, if

3. Remove extremely stubborn dirt, the plastic parts cannot be thor-

12 like oil burnt onto the crankcase, oughly cleaned with water, di-
with a degreasing agent and a luted mild detergent with water

brush, but never apply such prod- may be used. Be sure to rinse

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MOTORCYCLE CARE AND STORAGE

off any detergent residue using Test the product on a small hid- remain well into spring. 1
den part of the windshield to 2
plenty of water, as it is harmful make sure that it does not leave 1. Clean the motorcycle with cold wa- 3
any marks. If the windshield is ter and a mild detergent, after the 4
to plastic parts. scratched, use a quality plastic engine has cooled down. 5
polishing compound after NOTICE: Do not use warm water 6
 Do not use any harsh chemical washing. since it increases the corrosive 7
action of the salt.[ECA10792] 8
products on plastic parts. Be After normal use 9
Remove dirt with warm water, a mild 2. Apply a corrosion protection spray 10
sure to avoid using cloths or detergent, and a soft, clean sponge, on all metal, including chrome- and 11
and then rinse thoroughly with clean nickel-plated, surfaces to prevent 12
sponges which have been in water. Use a toothbrush or bottlebrush corrosion.
for hard-to-reach areas. Stubborn dirt
contact with strong or abrasive and insects will come off more easily if After cleaning
the area is covered with a wet cloth for 1. Dry the motorcycle with a chamois
cleaning products, solvent or a few minutes before cleaning. or an absorbing cloth.
2. Immediately dry the drive chain
thinner, fuel (gasoline), rust re- After riding in the rain, near the sea or and lubricate it to prevent it from
on salt-sprayed roads rusting.
movers or inhibitors, brake flu- Since sea salt or salt sprayed on roads 3. Use a chrome polish to shine
during winter are extremely corrosive in chrome, aluminum and stain-
id, antifreeze or electrolyte. combination with water, carry out the less-steel parts, including the ex-
following steps after each ride in the haust system. (Even the thermally
 Do not use high-pressure wash- rain, near the sea or on salt-sprayed induced discoloring of stain-
roads. less-steel exhaust systems can be
ers or steam-jet cleaners since removed through polishing.)
TIP 4. To prevent corrosion, it is recom-
they cause water seepage and Salt sprayed on roads in the winter may mended to apply a corrosion pro-
tection spray on all metal,
deterioration in the following ar- 7-2
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eas: seals (of wheel and swing-

arm bearings, fork and brakes),

electric components (couplers,

connectors, instruments,

switches and lights), breather

hoses and vents.

 For motorcycles equipped with

a windshield: Do not use strong

cleaners or hard sponges as

they will cause dulling or

scratching. Some cleaning com-

pounds for plastic may leave

scratches on the windshield.

MOTORCYCLE CARE AND STORAGE

including chrome- and nickel-plat- any excess. EAU43203

1 ed, surfaces.  Never apply oil or wax to any Storage

5. Use spray oil as a universal clean- rubber and plastic parts, but

2 er to remove any remaining dirt. treat them with a suitable care Short-term

6. Touch up minor paint damage product. Always store your motorcycle in a cool,

3 caused by stones, etc.  Avoid using abrasive polishing dry place and, if necessary, protect it
7. Wax all painted surfaces. compounds as they will wear against dust with a porous cover. Be

8. Let the motorcycle dry completely away the paint. sure the engine and the exhaust sys-

4 before storing or covering it. tem are cool before covering the motor-

TIPEWA11132 cycle.

5 WARNING  Consult a Yamaha dealer for ad- ECA10811
vice on what products to use.
Contaminants on the brakes or tires NOTICE
 Washing, rainy weather or humid
6 can cause loss of control. climates can cause the headlight  Storing the motorcycle in a
 Make sure that there is no oil or lens to fog. Turning the headlight poorly ventilated room or cover-
on for a short period of time will ing it with a tarp, while it is still
wax on the brakes or tires. help remove the moisture from the wet, will allow water and humid-
7  If necessary, clean the brake lens. ity to seep in and cause rust.

discs and brake linings with a  To prevent corrosion, avoid
damp cellars, stables (because
8 regular brake disc cleaner or ac- of the presence of ammonia)
and areas where strong chemi-
etone, and wash the tires with cals are stored.

9 warm water and a mild deter-
gent. Before riding at higher

speeds, test the motorcycle’s

10 braking performance and cor-

nering behavior. Long-term

11 ECA10801 Before storing your motorcycle for sev-

NOTICE eral months:

12  Apply spray oil and wax spar- 1. Follow all the instructions in the
ingly and make sure to wipe off “Care” section of this chapter.

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MOTORCYCLE CARE AND STORAGE

2. Fill up the fuel tank and add fuel 4. Lubricate all control cables and the 1
stabilizer (if available) to prevent pivoting points of all levers and 2
the fuel tank from rusting and the pedals as well as of the sidestand/ 3
fuel from deteriorating. centerstand. 4
5
3. Perform the following steps to pro- 5. Check and, if necessary, correct 6
tect the cylinder, piston rings, etc. the tire air pressure, and then lift 7
from corrosion. the motorcycle so that both of its 8
a. Remove the spark plug cap wheels are off the ground. Alterna- 9
and spark plug. tively, turn the wheels a little every 10
b. Pour a teaspoonful of engine oil month in order to prevent the tires 11
into the spark plug bore. from becoming degraded in one 12
c. Install the spark plug cap onto spot.
the spark plug, and then place
the spark plug on the cylinder 6. Cover the muffler outlet with a
head so that the electrodes are plastic bag to prevent moisture
grounded. (This will limit spark- from entering it.
ing during the next step.)
d. Turn the engine over several 7. Remove the battery and fully
times with the starter. (This will charge it. Store it in a cool, dry
coat the cylinder wall with oil.) place and charge it once a month.
e. Remove the spark plug cap Do not store the battery in an ex-
from the spark plug, and then cessively cold or warm place [less
install the spark plug and the than 0 C (30 F) or more than 30
spark plug cap. WARNING! To C (90 F)]. For more information
prevent damage or injury on storing the battery, see page
from sparking, make sure to 6-28.
ground the spark plug elec-
trodes while turning the en- TIP
gine over.[EWA10952] Make any necessary repairs before
storing the motorcycle.

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SPECIFICATIONS

Dimensions: EAU5091H Engine oil: Fuel tank capacity:
1 Overall length: 12.0 L (3.17 US gal, 2.64 Imp.gal)
Recommended brand:

2085 mm (82.1 in) YAMALUBE Fuel reserve amount:

2 Overall width: Type: 2.2 L (0.58 US gal, 0.48 Imp.gal)
750 mm (29.5 in) SAE 10W-30, 10W-40, 10W-50, 15W-40,
Fuel injection:

Overall height: 20W-40 or 20W-50 Throttle body:

3 1095 mm (43.1 in) 0 10 30 50 70 90 110 130 ˚F ID mark:
2RD1 00
Seat height:
785 mm (30.9 in) Spark plug(s):

4 Wheelbase: SAE 10W-30 Manufacturer/model:
SAE 10W-40 NGK/BPR6ES
1410 mm (55.5 in) SAE 10W-50
SAE 15W-40 Spark plug gap:
Ground clearance: 0.7–0.8 mm (0.028–0.031 in)

5 130 mm (5.1 in) Clutch type:

Minimum turning radius:

2400 mm (94.5 in) SAE 20W-40 Wet, multiple-disc
SAE 20W-50
6 Weight: –20 –10 0 10 20 30 40 50 ˚C Transmission:

Curb weight: Recommended engine oil grade: Primary reduction ratio:
2.567 (77/30)
7 174 kg (384 lb)
Final drive:
Engine:

Engine type: API service SG type or higher, JASO stan- Chain

8 Air cooled 4-stroke, SOHC dard MA Secondary reduction ratio:
Engine oil quantity: 2.947 (56/19)
Cylinder arrangement:

Single cylinder Without oil filter element replacement: Transmission type:

9 Displacement: 2.00 L (2.11 US qt, 1.76 Imp.qt) Constant mesh 5-speed
With oil filter element replacement: Operation:
399 cm3

Bore  stroke: 2.10 L (2.22 US qt, 1.85 Imp.qt) Left foot operation
Gear ratio:
10 87.0  67.2 mm (3.43  2.65 in) Air filter:

Compression ratio: Air filter element: 1st:
Oil-coated paper element 2.357 (33/14)
8.50 : 1
Fuel: 2nd:
11 Starting system: 1.556 (28/18)
Recommended fuel:
Kickstarter Regular unleaded gasoline (Gasohol (E10) 3rd:
acceptable) 1.190 (25/21)
Lubrication system:

12 Dry sump

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SPECIFICATIONS

4th: Front: Front suspension: 1
0.917 (22/24) 175 kPa (1.75 kgf/cm2, 25 psi) 2
Type: 3
5th: Rear: Telescopic fork 4
0.778 (21/27) 200 kPa (2.00 kgf/cm2, 29 psi) 5
Spring/shock absorber type: 6
Chassis: Loading condition: Coil spring/oil damper 7
90–150 kg (198–331 lb) 8
Frame type: Front: Wheel travel: 9
Semi double cradle 200 kPa (2.00 kgf/cm2, 29 psi) 150 mm (5.9 in) 10
Rear: 11
Caster angle: 225 kPa (2.25 kgf/cm2, 33 psi) Rear suspension: 12
27.70 
Front wheel: Type:
Trail: Swingarm
111 mm (4.4 in) Wheel type:
Spoke wheel Spring/shock absorber type:
Front tire: Coil spring/oil damper
Rim size:
Type: 18x1.85 Wheel travel:
With tube 105 mm (4.1 in)
Rear wheel:
Size: Electrical system:
90/100-18M/C 54S Wheel type:
Spoke wheel Ignition system:
Manufacturer/model: TCI
METZELER/ME77 Front Rim size:
18x2.15 Charging system:
Rear tire: AC magneto
Front brake:
Type: Battery:
With tube Type:
Single disc brake Model:
Size: GT4B-5
110/90-18M/C 61S Operation:
Right hand operation Voltage, capacity:
Manufacturer/model: 12 V, 2.5 Ah
METZELER/ME77 Specified brake fluid:
DOT 4 Headlight:
Maximum load:
150 kg (331 lb) Rear brake: Bulb type:
Halogen bulb
* (Total weight of rider, passenger, cargo Type:
and accessories) Drum brake Bulb voltage, wattage  quantity:

Tire air pressure (measured on cold Operation: Headlight:
tires): Right foot operation 12 V, 60.0 W/55.0 W  1

Loading condition: Tail/brake light:
0–90 kg (0–198 lb) 12 V, 5.0 W/21.0 W  1

Front turn signal light:
12 V, 21.0 W  2

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SPECIFICATIONS

Rear turn signal light:

1 12 V, 21.0 W  2

Auxiliary light:

12 V, 4.0 W  1

2 Meter lighting:

12 V, 1.7 W  4

3 Neutral indicator light:
12 V, 1.7 W  1

High beam indicator light:

4 12 V, 1.7 W  1

Turn signal indicator light:

12 V, 1.7 W  1

5 Fuel level warning light:

12 V, 3.0 W  1

Engine trouble warning light:

6 12 V, 1.7 W  1

Fuses:

Main fuse:

7 30.0 A

Headlight fuse:

8 15.0 A
Signaling system fuse:

15.0 A

9 Ignition fuse:

10.0 A

Parking lighting fuse:

10 7.5 A

Fuel injection system fuse:

7.5 A

11 Backup fuse:

7.5 A

12

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CONSUMER INFORMATION

EAU53562 EAU26401 EAU26441

Identification numbers Vehicle identification number Engine serial number 1
2
Record the vehicle identification num- 1 1 3
ber, engine serial number, and the 4
model label information in the spaces 1. Vehicle identification number 1. Engine serial number 5
provided below. These identification 6
numbers are needed when registering The vehicle identification number is The engine serial number is stamped 7
the vehicle with the authorities in your stamped into the steering head pipe. into the crankcase. 8
area and when ordering spare parts Record this number in the space pro- 9
from a Yamaha dealer. vided. 10
TIP 11
VEHICLE IDENTIFICATION The vehicle identification number is
NUMBER: used to identify your motorcycle and
may be used to register your motorcy-
ENGINE SERIAL NUMBER: cle with the licensing authority in your
area.
MODEL LABEL INFORMATION:

12

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CONSUMER INFORMATION

1 Model label EAU26481
2
1

3

4

5

1. Model label

6
The model label is affixed to the frame
under the seat. (See page 3-11.) Re-

7 cord the information on this label in the
space provided. This information will be

8 needed when ordering spare parts from
a Yamaha dealer.

9

10

11

12

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INDEX

A Engine serial number ................................ 9-1 Parking.......................................................5-4 1
Engine stop switch .................................... 3-5 Part locations .............................................2-1 2
Air filter element, replacing ......................6-12 Engine trouble warning light ...................... 3-3 Pass switch ................................................3-4 3
Auxiliary light bulb, replacing ...................6-34 4
F S 5
B 6
Front fork, checking................................. 6-27 Safety information......................................1-1 7
Battery .....................................................6-28 Fuel ........................................................... 3-7 Seat .........................................................3-11 8
Brake and clutch levers, checking and Fuel cock ................................................. 3-10 Shifting .......................................................5-2 9
Fuel consumption, tips for reducing .......... 5-3 Shift pedal ..................................................3-6 10
lubricating ..............................................6-25 Fuel level warning light.............................. 3-3 Shift pedal, checking................................6-19 11
Brake fluid, changing ...............................6-21 Fuel tank breather/overflow hose.............. 3-9 Shock absorber assemblies, adjusting ....3-12 12
Brake fluid level, checking .......................6-20 Fuel tank cap............................................. 3-7 Sidestand .................................................3-12
Brake lever ................................................3-6 Fuses, replacing...................................... 6-29 Spark plug, checking .................................6-8
Brake lever free play, adjusting ...............6-17 Specifications.............................................8-1
Brake light switches .................................6-19 H Speedometer unit ......................................3-3
Brake pads and shoes, checking.............6-20 Starting the engine.....................................5-1
Brake pedal ...............................................3-6 Handlebar switches ................................... 3-4 Starting the engine, trouble........................5-2
Brake pedal, checking and lubricating.....6-25 Hazard switch............................................ 3-5 Steering, checking ...................................6-27
Brake pedal height and free play, Headlight bulb, replacing......................... 6-31 Storage ......................................................7-3
High beam indicator light........................... 3-3 Swingarm pivots, lubricating ....................6-26
adjusting ................................................6-18 Horn switch ............................................... 3-5
T
C I
Tachometer................................................3-4
Cables, checking and lubricating .............6-24 Identification numbers ............................... 9-1 Tail/brake light bulb, replacing .................6-32
Care ........................................................... 7-1 Ignition circuit cut-off system ................... 3-13 Throttle grip and cable, checking and
Catalytic converter.....................................3-9 Indicator lights and warning lights ............. 3-2
Centerstand and sidestand, checking lubricating ..............................................6-24
K Throttle grip free play, checking...............6-13
and lubricating .......................................6-26 Tires .........................................................6-14
Clutch lever................................................3-5 Kickstarter ............................................... 3-10 Tool kit .......................................................6-2
Clutch lever free play, adjusting ..............6-16 Troubleshooting .......................................6-39
M Troubleshooting chart ..............................6-40
D Turn signal indicator light ...........................3-2
Main switch/steering lock .......................... 3-1 Turn signal light bulb, replacing ...............6-33
Decompression lever ...............................3-11 Maintenance and lubrication, periodic....... 6-4 Turn signal switch ......................................3-4
Dimmer switch ...........................................3-4 Maintenance, emission control system ..... 6-3
Drive chain, cleaning and lubricating.......6-23 Matte color, caution................................... 7-1 V
Drive chain slack .....................................6-22 Model label ................................................ 9-2
Valve clearance .......................................6-13
E N

Engine break-in .........................................5-3 Neutral indicator light ................................ 3-2
Engine idling speed, checking .................6-13
Engine oil and oil filter element..................6-9 P

Panel, removing and installing .................. 6-7

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INDEX

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

1W

Wheel bearings, checking........................6-28

2 Wheel (front) ............................................6-35
Wheel (rear) .............................................6-37

Wheels .....................................................6-16

3

4

5

6

7

8

9

10

11

12

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Original instructions

PRINTED ON RECYCLED PAPER PRINTED IN JAPAN
2013.12-0.1×1 !
http://www.motorcycle.in.th (E)