YAMAHA

EAA00100

XTZ660H

OWNER'S MANUAL ©1995 by Yamaha Motor Co., ltd.

1st Edition, September 1995

All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd.

is expressly prohibited.

Printed in Japan

EAA20301

INTRODUCTION

Congratulations on your purchase of the Yamaha XTZ660. This model IS the result of Yamaha's vast experience in the production of fine sporting, touring, and pacesetting racing machines. It represents the high degree of craftsmanship and reliabihtv that have made Yamaha a leader in these fields. This manual will give you an understanding of the operation, inspection, and basic maintenance of thrs motorcycle. If you have any questions about the operation or maintenance of your motorcycle, please consult a Yamaha dealer.

EAA1Q5QQ

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

&

The Safety Alert Symbol means ATTENTIONI BECOME ALERTI YOUR SAFETY IS INVOLVED!

AWARNING

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

f~Q~~f1~~="

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

NOTE:

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

~UUOQQQO

NOTE: __

This manual should be considered a permanent part of this motorcycle and should remarn with it even If the motorcycle is subsequently sold.

EUU138DO

NOTE: _

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 discrepancies between your motorcycle and thrs manual. If there is any question concerning this manual, please consult your Yamaha dealer.

EUU60100

AWARNING

PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE.

EAA30001

---- ---_ -~--~------~~-------

CONTENTS

SAFETY INFORMATION 1-1

LOCATION OF THE IMPORTANT

LABELS 2-1

DESCRIPTION 3-1

MOTORCYCLE IDENTIFICATION 4-1

Identification numbers record 4-1

Key Identification number .4-1

Vehicle identification number 4-2

Model label 4-2

CONTROL FUNCTIONS 5-1

Main switch 5-1

Indicator lights 5-2

Speedometer 5-3

Tachometer 5-3

Engine temperature gauge 5-4

Handlebar switches 5-4

Clutch lever 5-6

Shift pedal 5-6

Front brake lever 5-7

Rear brake pedal 5-7

Fuel tank cap 5-8

Fuel cock . 5-9

Starter "CHOKE" 5-10

Steering lock 5-10

Seat 5-11

Helmet holder 5-12

Tool box 5-12

Left side cover 5-13

Right side cover removal 5-13

Side cowl removal 5-14

Rear shock absorber 5-14

Rear carrier 5-15

Sidestand 5-15

Sidestand/clutch switch

operation check 5-16

PRE-OPERATION CHECKS 6-1

Brakes 6-3

Brake fluid leakage 6-3

Clutch 6-4

Throttle grip. . 6-4

Engine oil. 6-4

Coolant .. 6-5

Chain 6-6

Tires . 6-6

Wheels 6-9

Fittings/Fasteners... . 6-9

Lights a nd signa Is . ..6-9

Switches . .. . . 6-9

Fuel 6-10

OPERATION AND IMPORTANT RIDING

POINTS. .. .. .7-1

Starting and warming up a cold

engine. .. . .. . .7-2

Starting a warm engine 7-5

Shifting. .. .. .. . 7-5

Engine break-in " 7-6

Parking 7-7

PERIODIC MAINTENANCE AND MINOR

REPAIR 8-1

Tool kit , " .. .. .. .8-1

Periodic maintenancejlubricatron 8-3

Torque specifications. . .. . . 8-5

Engine oil 8-6

Cooling system 8-10

Radiator fan 8-14

Air filter 8-14

Carburetor adjustment 8-16

Idle speed adjustment. 8-16

Throttle cable adjustment 8-17

Valve clearance adjustment. 8-18

Spark plug inspection 8-18

Front brake lever free play

adjustment " .. . .. 8-19

Rear brake pedal height

adjustment 8-20

Brake light SWitch adjustment 8-21

Checking the front and

rear brake pads 8-22

Inspecting the brake fluid level. 8-23

Brake fluid replacement 8-24

Clutch lever free play adjustment 8-24

Drive chain slack check 8-25

Drive cham slack adjustment 8-26

Drive chain lubncation 8-28

Cable inspection and lubrication 8-28

Throttle cable and grip lubrication 8-29

Brake and shift pedal lubrication 8-29

Brake and clutch lever lubrication 8-29

Sidestand lubrication 8-29

Rear suspension lubrication 8-30

Front fork inspection 8-30

Rear shock absorber 8-31

Rear shock absorber adjustment 8-32

Steering inspection 8-34

Wheel bearings 8-34

Battery.. .. 3-35

Fuse replacement 8-36

Headlight bulb replacement.... . 8-37

Front wheel removal 8-39

Front wheel installation...... . 8-40

Rear wheel removal..... .. 8-41

Rear wheel installation 8-43

Troubleshooting 8-44

Troubleshooting chart . 8-45

CLEANING AND STORAGE 9-1

A. Cleaning 9-1

B. Storage ...9-2

SPECIFICATIONS 10-1

HOW TO USE THE CONVERSION

TABLE 11-1

NOISE REGULATION (For Australia) ........ 12-1

WIRING DIAGRAM

EUU75S01

ASAFETV INFORMATION

TWO-WHEELED MOTORCYCLES ARE SINGLE TRACK VEHICLES. THEIR SAFE USE AND OPERATION ARE DEPENDENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EXPERTISE OF THE OPERATOR.

EVERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIREMENTS BEFORE RIDING. HE OR SHE SHOULD:

1. OBTAIN THOROUGH INSTRUCTIONS FROM A COMPETENT SOURCE ON ALL ASPECTS OF MOTORCYCLE OPERATION.

2. OBSERVE THE WARNINGS AND MAINTENANCE REQUIREMENTS IN THE OWNER'S MANUAL.

3. OBTAIN QUALIFIED TRAINING IN SAFE AND PROPER RIDING TECHNIQUES.

4. OBTAIN PROFESSIONAL TECHNICAL SERVICE AS INDICATED BY THE OWNER'S MANUAL AND/OR WHEN MADE NECESSARY BY MECHANICAL CONDITIONS.

SAFE RIDING

1. Always make pre-operation checks. Careful checks may help prevent an accident.

2. This motorcycle is designed to carry the operator and a passenger.

1-1

3. The failure of motorists to detect and recognize motorcycles in traffic is the predominating cause of automobile/motorcycle accidents. Many accidents have been caused by an automobile driver who did not see the motorcycle. Making yourself conspicuous appears to be very effective in reducing the chance of this type of accident.

Therefore:

a. Wear a brightly colored jacket.

b. Use extra caution when you approach and pass through intersections, since intersections are the most likely places for motorcycle accidents.

c. Ride where other motorists can see you. Avoid riding in another motorist's "blind spot".

4. Many accidents involve inexperienced operators. In fact, many operators who have been involved in accidents do not even have a current motorcycle license.

a. Make sure you are qualified. Also, only lend your motorcycle to experienced operators.

b. Know your skills and limits. Staying within your limits may help you to avoid an accident.

c. We recommend that you practice riding your motorcycle where there is no traffic until you have become thoroughly familiar with your motorcycle and all of its controls.

1-2

5. Many motorcycle accidents have been caused by motorcycle operator errors. A typical error made by the operator is veering wide on a turn due to EXCESSIVE SPEED or undercornering (insufficient lean angle for the speed).

a. Always obey the speed limits and never travel faster than warranted by road and traffic conditions.

b. Always signal before turning or changing lanes. Make sure other motorists see you. 6. The operator's and passenger's posture are important for proper control.

a. The operator should keep both hands on the handlebars and both feet on the operator footrests during operation to maintain control of the motorcycle.

b. The passenger should always hold on to the operator, or the seat strap or grab bar if the motorcycle is so equipped with both hands and keep both feet on the passenger footrests.

c. Never carry a passenger unless he or she can firmly place both feet on the passenger footrests.

7. Never ride under the influence of alcohol or drugs.

PROTECTIVE APPAREL

The majority of fatalities from motorcycle accidents are the result of head injuries. The use of a safety helmet is the single most critical factor in the prevention or reduction of head injuries.

1. Always wear an approved helmet.

1-3

2. Wear a face shield or goggles. Wind on your unprotected eyes could contribute to an impairment of vision which could delay seeing a hazard.

3. The use of heavy boots, jacket, trousers, gloves, etc. is effective in preventing or reducing abrasions or lacerations.

4. Never wear loose fitting clothing. It could catch on the control levers, footrests, or wheels and cause injury or accident.

5. Never touch the engine or exhaust system during or after operation. They become very hot and can cause burns. Always wear protective clothing that covers your legs, ankles, and feet.

6. A passenger should also observe the above precautions.

MODIFICA nON

Modifications made to the motorcycle not approved by Yamaha, or the removal of original equipment, may render your motorcycle unsafe for use and may cause severe personal injury. Modifications may also make your motorcycle illegal to use.

LOADING AND ACCESSORIES

Adding accessories or cargo to your motorcycle can adversely affect stability and handling if the weight distribution of the machine is changed. To avoid the possibility of an accident, extreme caution should be used if adding cargo or accessories to your motorcycle. Use extra care if riding a motorcycle which has added cargo or accessories. Here are some general guidelines to follow if loading cargo or adding accessories to your motorcycle:

1-4

IClt,ullMCI

The total weight of the operator, passenger, accessories and cargo must not exceed the maximum load limit of 180 kg. When loading within these weight limits, keep the following in mind:

1. Cargo and accessory weight should be kept as low and close to the motorcycle as possible. Be sure to distribute the weight as evenly as possible on both sides of the machine to minimize imbalance or instability.

2. Shifting weights can create a sudden imbalance. Make sure that accessories and cargo are securely attached to the motorcycle before riding. Recheck accessory mounts and cargo restraints frequently.

3. Never attach any large or heavy items to the handlebars, front forks, or front fender. These items, including such cargo as sleeping bags, duffle bags, or tents, can create unstable handling or slow steering response.

Genuine Yamaha accessories have been specifically designed for use on this motorcycle. Since Yamaha cannot test all other accessories which may be available, you must personally be responsible for the proper selection, installation and use of non-Yamaha accessories. You should use extreme caution when selecting and installing any accessories. Keep in mind these guidelines for mounting accessories in addition to those provided under "LOADING".

ACCESSORIES

1-5

1. GASOLINE IS HIGHLY FLAMMABLE:

a. Always turn off the engine when refueling.

1. Never install accessories or carry cargo that would impair the performance of your motorcycle. Carefully inspect the accessory before using it to make sure it does not in any way reduce ground clearance or cornering clearance, limit suspension travel, steering travel or control operation, or obscure lights or reflectors.

a. Accessories fitted to the handlebar or the front fork area can create instability due to improper weight distribution or aerodynamic changes. If accessories are added to the handlebar or front fork area, they must be as lightweight as possible and should be kept to a minimum.

b. Bulky or large accessories may seriously affect the stability of the motorcycle due to aerodynamic effects. Wind may attempt to lift the motorcycle, or the motorcycle may become unstable in cross winds. These accessories may also cause instability when being passed by or passing large vehicles.

c. Certain accessories can displace the operator from his or her normal riding position. This improper position limits the freedom of movement of the operator and may limit control ability. Therefore such accessories are not recommended.

2. Caution must be used if adding electrical accessories. If these accessories exceed the capacity of the motorcycle's electrical system, an electric failure could result, which could cause a dangerous loss of lights or engine power.

GASOLINE AND EXHAUST GAS

1"6

b. Take care not to spill any gasoline on the engine or exhaust pipe(s)/muffler(s) when refueling.

c. Never refuel while smoking or in the vicinity of an open flame.

2. Never start the engine or let it run for any length of time in a closed area. The exhaust fumes are poisonous and may cause loss of consciousness and death within a short time. Always operate your motorcycle in an area that has adequate ventilation.

3. Always turn off the engine before leaving the motorcycle unattended and remove the ignition key. When parking the motorcycle, note the following:

a. The engine and exhaust pipe(s)/muffler(s) may be hot. Park the motorcycle in a place where pedestrians or children are not likely to touch these hot areas.

b. Do not park the motorcycle on a slope or soft ground; the motorcycle may fall over.

c. Do not park the motorcycle near a flammable source, e.g. a kerosene heater, or near an open flame. The motorcycle could catch fire.

4. When transporting the motorcycle in another vehicle, be sure it is kept upright and that the fuel cock(s) is turned to "ON" or "RES" (for vacuum type)/"OFF" (for manual type). If it should lean over, gasoline may leak out of the carburetor or fuel tank.

5. If you should swallow any gasoline, inhale a lot of gasoline vapor, or allow gasoline to get in your eye(s), see your doctor immediately. If any gasoline spills on your skin or clothing, immediately wash it off with soap and water and change your clothes.

1-7

EAA40000

LOCATION OF THE IMPORTANT LABELS

Please read the following labels carefully before operating this motorcycle.

WARNING
Before you operate this vehicle,
read the owner's manual.
English 3HP-2156B-OO 2-2

EAA50000

DESCRIPTION

1 Tall/Brake light 2 Rear flasher light 3 Seat

4 Fuel tank

5 Front flas her II g ht 6 Side cowl

7 Engine guard

8 Rear brake pedal 9 Headlight

10 Side cover

11 Rear carrier 12 Helmet holder 13 Tool box

3-1

14 Sidestand 15 Shift pedal 16 Fuel cock 17 Radiator

1 B Clutch lever

19 Handlebar switches 20 Speedometer

21 Engine temperature gauge 22 Tachometer

23 Front brake lever 24 Throttle gnp

25 Mam switch

EAA60000

MOTORCYCLE IDENTIFICATION

EAA61S00

Identification numbers record

Record the key identification number, vehicle Identification number and model label information in the spaces provided for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen.

1. KEY IDENTIFICATION NUMBER:

2. VEHICLE IDENTIFICATION NUMBER:

3. MODEL LABEL INFORMATION:

EAA61500

Key identification number

The key Identification number is stamped on the key tag.

Record this number in the space provided and use it for reference when obtaining a new key.

Key Identification number

4-1

EAA80000

Vehicle identification number

The vehicle identification number is stamped into the steering head pipe.

EUU00400

NOTE: _

The vehicle Identification number is used to identify your motorcycle and may be used to register your motorcycle with the licensing authority in your state.

1 Velncle identrncauon number

EAA61601

Model label

The model label IS affixed to the frame. Record the Information on this label in the space provided. This information will be needed to order spare parts from your Yamaha dealer.

1 Model label

4-2

EABOOOOO

CONTROL FUNCTIONS

EAB00100

Main switch

The main switch controls the Ignition and lighting systems. Its operation is described below.

ON

LOCK

PARKING

EA801300

ON:

Electrrcal circuits are switched on, and the headlight, meter light, and taillight come on The engine can be started. The key cannot be removed in this position.

EAB00600

OFF:

All electrical circuits are switched off. The key can be removed 10 this position

EA600701

LOCK:

The steering IS locked In this posrtion, and all electrical circuits are switched off The key can be removed in this position. Refer to "Steenng lock" (page 5-10) for operation instructions.

E"B01202

P (Parking):

The steering is locked in this pOSItIOn, and the taillight and auxiliary light come on but all other circuits are off. The key can be removed in this position

EUU007CO

NOTE: _

Always turn the main switch to "OFF" or "LOCK" and remove the key when the motorcycle is unattended.

5-1

EAB10aaa

Indicator lights

1 Turn indicator lights" ¢Ie) "

2 Neutral indicator light "NEUTRAL"

3 High beam indicator light "HIGH BEAM"

EAB12202

Turn indicator lights "TURN"

The corresponding indicator flashes when the turn switch is moved to the left or right.

EAB10201

Neutral Indicator light "NEUTRAL"

This indicator comes on when the transmission is in neutral.

EAB10301

High beam Indicator light "HIGH BEAM"

This indicator comes on when the headlight high beam is used.

5-2

EAB41501

Speedometer

The speedometer shows riding speed. This speedometer IS equipped with an odometer and trip odometer The trip odometer can be reset to "0" with the reset button.

Use the tnp odometer to estimate how far you can nde on a tank of fuel. This information will enable you to plan fuel stops In the future.

1 Speedometer 3 Tnp odometer

2 Odometer

4 Reset butto n

EAB40200

Tachometer

This model is equipped with an electric tachometer so the nder can monitor the engine speed and keep it within the rdeal power range.

1 Tachometer

2 Red zone

EUU3040D

Do not operate in the red zone. Red zone: 7,000 r/min and above

5-3

--- - -_._-----

EAB50100

Engine temperature gauge

This gauge indicates the coolant temperature when the main switch is ON. The engine operating temperature will vary with changes in weather and engine load. If the needle pomts to the red zone or higher, stop your motorcycle and let the engine cool. (See page 8-10 for details)

1 Engine temperature gauge 2 Red zone

EUU30500

When the engine is overheated, do not continue riding.

EABGOOOO

Handlebar switches

1 Pass switch "PASS" 1 Engine stop switch

2 Dimmer switch "LIGHTS" 2 Start switch "START" 3 Turn Signal switch "TURN"

4.Horn SWitch "HORN"

5-4

EA863201

Pass switch "PASS"

Press the switch to operate the passing light

EAB60101

Dimmer switch "LIGHTS"

Turn the swrtch to "HI" for the high beam and to "LO" for the low beam.

EAB62102

Turn signal switch "TURN"

To signal a nght-hand turn, push the switch to the right. To signal a left-hand turn, push the switch to the left. Once the switch IS released It will return to the center position. To cancel the signal, push the switch In after it has returned to the center position.

EABB0201

Horn switch "HORN"

Press the switch to sound the horn.

EA863800

Engine stop switch

The engine stop switch is a safety device for use in an emergency such as when the motorcycle overturns or if trouble occurs in the throttle system. Turn the switch to "0" to start the engine. In case of emergency, turn the switch to "!.5<;)" to stop the engine.

EAB60703

Start switch "START"

The starter motor cranks the engine when pushing the start switch.

EUU30700

See starting instructions prior to starting the engine.

5-5

EAB70003

CI utch lever

The clutch lever is located on the left handlebar, and the ignition circuit cut-off system is incorporated in the clutch [ever holder. Pull the clutch lever to the handlebar to disengage the clutch, and release the lever to engage the clutch. The lever should be pulled rapidly and released slowly for smooth clutch operation. (Refer to the engine starting procedures for a description of the ignition circuit cut-off svstem.)

1 Clutch lever

EAB80001

Shift pedal

This motorcycle is equipped with a constantmesh 5-speed transmission. The shift pedal is located on the left side of the engine and is used in combination with the clutch when shifting.

1 Shift peda I

N Neutral

5-6

EAB90001

Front brake lever

The front brake lever is located on the right handlebar. Pull It toward the handlebar to apply the front brake.

1 Front brake lever

EAB90101

Rear brake pedal

The rear brake pedal is on the right side of the motorcycle. Press down on the brake pedal to apply the rear brake

1 Rea r bra ke pedal

5-7

EAC00301

Fuel tank cap TO OPEN:

Insert the key and turn it 1/4 turn counterclockwise. Turn the cap 1/3 turn counterclockwise and remove it from the tank.

TO CLOSE:

Put the cap In the filler neck and turn it 1/3 turn clockwise. Lock the cap by turning the key 1/4 turn clockwise, and remove the key.

EUU01300

NOTE: ___

The tank cap cannot be reinstalled unless it IS unlocked. The key must remain in the cap until the cap is properly installed and locked onto the fuel tank.

EUU61100

AWARNING

Be sure the cap is properly installed and locked in place before riding the motorcycle.

EAC10l02

Fuel cock

The fuel cock supplies fuel from the tank to the carburetors while filtering it also.

The fuel cock has three positions:

RES

OFF With the lever in this position, fuel will not flow. Always return the lever to this position when the engine is not running.

ON: With the lever In this position, fuel flows to the carburetors Normal ndrnq IS done with the lever in this position.

RES. This indicates reserve If you run out of fuel while riding, move the lever to this position. FILL THE TANK AT THE FIRST OPPORTUNITY BE SURE TO SET THE LEVER TO "ON" AFTER REFUELING.

5-9

<AC20502

Starter "CHOKE"

Starting a cold engine requires a richer airfuel mixture for starting A separate starter circuit supplies this mixture.

Move in direction ® to turn on the starter. Move in direction @ to turn off the starter.

1 Starter knob (CHOKE)

EAC30600

Steering lock

The steering is locked when the main switch is turned to "LOCK". To lock the steering, turn the handlebars all the way to the left. While pushing the key into the main switch, turn it from "OFF" to "LOCK" and remove it. To release the lock, turn the key to "OFF" while pushing.

LOCK

Release

OFF (Push)

OFF

Lock

5-10

CD

1 Push

2 Turn

EUU61400

AWARNING

Never turn the key to "LOCK" when the motorcycle is moving.

EAC45100

Seat

To remove the seat, remove the bolts

When reinstalling the seat, Insert the lobes on the front of the seat into the receptacles on the frame, then tighten the bolts.

EUU01700

NOTE: __

Make sure that the seat is securely fitted.

5-11------------------

EAC50001

Helmet holder

To open the helmet holder, insert the key in the lock and turn it as shown. To lock the helmet holder, replace the holder In Its original position.

1 Helmet holder EUU72900

2. Open

AWARNING

Never ride with a helmet in the helmet holder. The helmet may hit objects, causing loss of control and possibly an accident.

EACSOBOO

Toolbox

The tool box is equipped with security wire to prevent tampering of the tool kit.

To open the tool box, unhook the wire from the helmet holder. Turn the fastener 1/4 turn in either direction. The tool kit is in the tool box.

After using the tool kit, close the tool box, hook the wire in the helmet holder, and lock it.

1 Tool box

2 Open

3 Security wire

5-12

EAC74002

left side cover

To remove the side cover, remove the screw and pull outward on the areas shown. To install, reverse the above steps.

EAC75000

Right side cover removal Remove the seat and screw.

Then remove the side cover by lifting upward at the rear and pulling outward on the front.

EAD61400

Side cowl removal

To remove the side cowl, remove the screws as shown. When reinstalling the side cowl, be sure that the slots in the side cowl CD fit over the tabs ® of the front cowl. Then tighten the screws.

EAC90001

Rear shock absorber

The spring preload and the damping force of the rear shock absorber can be adjusted to suit the rider's preference, motorcycle's load (ex: optional accessories etc.) and riding conditions. Refer to page 8-32 for proper adjustment procedures.

5-14

2 Damping force adjuster

1 Spnng preload adjuster

EAcnooo

Rear carrier

1 Rear earner

EUU76000

AWARNING

Do not exceed maximum load. Maximum load: 5 kg

EA030101

Sidestand

This model is equipped with an Ignition circuit cut-off system. The motorcycle must not be ridden when the sidestand is down. The sidestand is located on the left side of the frame. (Refer to page 7-2 for an explanation of this system)

5-15 1 Srdestand switch

EUU68S01

AWARNING

This motorcycle must not be operated with the sidestand in the down position. If the stand is not properly retracted, it could contact the ground and distract the operator, resulting in a possible loss of control. Yamaha has designed into this motorcycle a lockout system to assist the operator in fulfilling the responsibility of retracting the sidestand. Please check carefully the operating instructions listed below and if there is any indication of a malfunction, return the motorcycle to a Yamaha dealer immediately for repair.

EAD30801

Sidestand/clutch switch operation check Check the operation of the sidestand switch and clutch switch against the mforrnatron below.

TURN MAIN SWITCH TO "ON" AND ENGINE STOP SWITCH TO " 0 JJ.

..

TRANSMISSION IS IN GEAR AND SIDESTAND IS UP.

PULL IN CLUTCH LEVER AND PUSH STARTER SWITCH.

ENGINE WILL START.

CLUTCH SWITCH IS OK

SIDESTAND IS DOWN.

ENGINE WILL STALL

I

SIDESTAND SWITCH IS OK.

EUU6S100

AWARNING

If improper operation is noted, consult a Yamaha dealer immediately.

5-16

PRE-OPERATION CHECKS

Before using this motorcycle, check the following points:

Item Routine Page
Brakes Check operation, free play, fluid level, and flurd leakage 6-3-6-4, 8-19-8-24
Top-up with DOT 4 brake fluid If necessary
Clutch Check operation, condition and free play 6-4, 8-24-8-25
Adjust if necessary
Throttle gnp/Housing Check for smooth operation Lubricate/Adjust If necessary 6-4,8-17-8-18,8-29
Engine 011 Check 011 level/add 011 as required 6-4, 8-6-8-10
Coolant reservoir tank Check coolant level/top-up as required. 6-5, 8-10-8-13
Drrve cham Check chain slack and condition Adjust If necessary 6-6, 8-25-8-28
Wheels/Tires Check tire pressure, wear, damage and spoke tightness. 6-6-6-9,8-39-8-43
Control/Meter cable Check for smooth operation Lubrrcate If necessary 8-28
Brake and shift pedal Check for smooth operation Lubricate If necessary 8-29
shafts
Brake and clutch lever Check for smooth operation Lubrrcate If necessary 8-29
PiVOtS
Sidestand pivot Check for smooth operation Lubrrcate If necessary. 8-29
F rtti n gs / fasteners Check all chaSSIS fittings and fasteners 6-9,8-5
Tiqhten/ Adjust, If necessary 6-1

Item Routine Page
Fuel tank Check fuel level/top-up as required. 6-10
Lights and signals Check for proper operation. 6-9, 8-37 -8-38 NOTE:

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

AWARNING

If any item in the Pre-Operation Check is not working properly, have it inspected and repaired before operating the motorcycle.

6-2

EAE13602

Brakes (See page 8-19 for details)

1. Brake lever and brake pedal

Check for correct free play in the front brake lever and correct rear brake pedal height. Adjust if necessary. Make sure the brakes are working properly by checking at low speed shortly after starting out

EUU61900

AWARNING

A soft, spongy feeling in the brake lever (and/or brake pedal) indicates a failure in the brake system. Do not operate the motorcycle until the failure in the brake system is corrected. Ask a Yamaha dealer for immediate repairs. A soft, spongy feeling could indicate a hazardous condition in the brake system.

2. Brake fturd

Check the brake flurd level Add fluid if

necessary.

Recommended brake fluid: DOT 4

3. Check the disc pads Refer to page 8-22.

EUU02201

NOTE: __

When this brake service is necessary, consult a Yamaha dealer.

EAE10702

Brake fluid leakage

Apply each brake for a few minutes. Check to see if any brake fluid leaks out from the pipe JOints or the master cylinders.

EUU37801

Brake fluid may deteriorate painted surfaces or plastic parts. Never spill any fluid. If spilled, clean it up immediately.

6-3

EUU62500

AWARNING

If brake fluid leakage is found, ask a Yamaha dealer for immediate repairs. Such leakage could indicate a hazardous condition.

EAE20001

Clutch (See page 8-24 for details)

Check the free play in the clutch lever, and make sure the clutch operates properly. If the free play is incorrect, adjust it.

EAE30100

Throttle grip (See page 8-17 for details) Turn the throttle grip to see if it operates properly, and check the free play. Make sure the grip returns by spring force when released. Ask a Yamaha dealer to make any necessary adjustments.

6-4

EAE40103

Engine oil

Make sure the engine oil IS at the specified level. Fill with oil as necessary (see page 8-6 for details).

Recommended oil:

30jO, '1""' 'r 'r SAE20W40 typo SE mow 0<1

. . . ." SAE 10W30 type SE motor 011

o-c 5°C 10°C 15°C

Recommended engine oil classification:

API Service "SE" I "SF" type or equivalent (eg "SF-SE" I "SF-SE-CC", "SF-SE-SD" etc)

Oil quantity:

Total amount: 3.2 L

Periodic all change: 2.6 L

With oil filter replacement:' 2.7 L

EAE60300 Coolant

Check the coolant level in the level check hose when the engine IS cold. (The coolant level will vary with engine temperature.) The coolant level is satisfactory if the level in the level check hose is between the FULL and LOW marks on the tank. If the coolant level is at or below the LOW level, add tap water (soft water) to bring the level up to FULL. Change the coolant every two years. (See page 8-10 for details.)

EUU62600

AWARNING

Do not remove the radiator cap when the engine is hot.

1 Level check hose 2 "FULL" level

3 "LOW" level

EUU30900

CCAuii&'r;F

------------------------

Hard water or salt water is harmful to the engine. You may use distilled water if you can't get soft water.

Reservoir tank capacity' 0.29 L

From LOW to FULL level: 0.17 L

6-5

EAE50001

Chain (See page 8-25 for details)

Check the general condition of the chain and the chain slack before every ride. Lubricate and adjust the chain as necessary.

EAE91302

Tires

To ensure maximum performance, long service, and safe operation, note the following:

1. Tire air pressure

Always check and adjust the tire pressure before operating the motorcycle.

EUU67500

AWARNING

Tire inflation pressure should be checked and adjusted when the temperature of the tire equals the ambient air temperature. Tire inflation pressure must be adjusted according to total weight of cargo, rider, passenger, and accessories (fairing, saddlebags, etc. if approved for this model), and vehicle speed.

Basic weight,
With 011 and full fuel 197 kg
tank
Maximum load" 180 kg
Cold tire pressure: Front Rear
200 kPa 200 kPa
Up to 90 kg load' (2 00 kg/cm', (2 00 kg/em>,
2.00 bar) 2 00 bar)
90 kg load ~ 200 kPa 225 kPa
(2 00 kg/em', (2 25 kg/em',
Maximum load* 2.00 bar) 225 bar) * Load IS the total weight of cargo, rider, passenger, and accessories

6-6

EUU67701

AWARNING

Proper loading of your motorcycle is important for several characteristics of your motorcycle; such as handling, braking, performance and safety. Do not carry loosely packed items that can shift. Securely pack your heaviest items close to the center of the motorcycle, and distribute the weight evenly from side to side. Properly adjust the suspension for your load, and check the condition and pressure of your tires. NEVER OVERLOAD YOUR MOTORCYCLE. Make sure the total weight of the cargo, rider, passenger, and accessories (fairing, saddlebags, etc. if approved for this model) does not exceed the maximum load of the motorcycle. Operation of an overloaded motorcycle could cause tire damage, an accident, or even injury.

2. Tire inspection

Always check the tires before operating the motorcycle If a tire tread shows crosswise lines (minimum tread depth), if the tire has a nail or glass fragments in it, or if the side wall IS cracked, contact a Yamaha dealer immediately and have the tire replaced

1 Tread depth

2 Sidewall

6·7

®

3 Wear mdrcator

FRONT;

Manufacturer Size Type
BRIDGESTONE 90/90-21 54S TRAIL WING-47
DUNLOP 90/90-21 54S TRAIL MAX G REAR

Manufacturer Size Type
BRlDGESTONE 120/90-1764S TRAIL WING-48F
DUNLOP 120/90-17 64S TRAILMAXG Minimum tire tread depth (front and rear)

1 0 mm (0.04 In)

EUU70001

AWARNING

1. Operating the motorcycle with excessively worn tires decrease riding stability and can lead to loss of control. Have excessively worn tires replaced by a Yamaha dealer immediately. Brakes. tires, and related wheel parts replacement should be left to a Yamaha Service Technician.

2. Patching a punctured tube is not recommended. If it is absolutely necessary to do so, use great care and replace the tube as soon as possible with a good quality replacement.

6-8

EAE93400

Wheels

To ensure maximum performance, long service, and safe operation, note the following:

1. Always inspect the wheels before a ride Check for cracks, bends, or warpage of the wheel; be sure the spokes are tight and undamaged. If any abnormal condition exists In a wheel, consult a Yamaha dealer Do not attempt even small repairs to the wheel. If a wheel is deformed or cracked, it must be replaced.

2. Tires and wheels should be balanced whenever either one IS changed or replaced. Failure to have a wheel balanced can result in poor performance, adverse handling characteristics, and shortened tire life.

3. After Installing a tire, ride conservatively to allow the tire to seat itself on the rim properly Failure to allow proper seating may cause tire failure, resulting in damage to the motorcycle and injury to the rider.

EAE85000

Fittings/Fasteners

Always check the tightness of chassis fittings and fasteners before a ride. Use the chart on page 8-5 to find the correct torque.

(AE71300

lights and signals

Check the headlight, flasher lights, auxiliary light, taillight, brake light, meter lights and all the Indicator lights to make sure they are in working condition

rAE70701

Switches

Check the operation of the headlight switch, turn swrtch, brake light switch. horn switch, start swrtch, main switch, etc

6-9

EAE80000

Fuel

Make sure there is sufficient fuel in the tank.

EUU61QOO

AWARNING

Do not overfill the fuel tank. Avoid spilling fuel on the hot engine. Do not fill the fuel tank above the bottom of the filler tube as shown in the illustration or it may overflow when the fuel heats up later and expands.

Filler tube

2 Fuel level

EUU39302

C:t/y-bt""'(j"~H{~;;-'tP~ V!-.fn"f' J

f~CAtJTION},~

~~f~~Hf Ml;\"""""~ {" o., 1 _

Always wipe off spilled fuel immediately with a dry and clean soft cloth. Fuel may deteriorate painted surfaces or plastic parts.

EAEB09DO

Recommended fuel: Regular gasoline For Australia. Unleaded fuel only

Fuel tank capacity:

Total'

20 L Reserve: 3.5 L

6-10

EAFOOOOO

OPERATION AND IMPORTANT RIDING POINTS

EUU67200

AWARNING

Before riding this motorcycle, become thoroughly familiar with all operating controis and their functions. Consult a Yamaha dealer regarding any control or function that you do not thoroughly understand.

EUU62800

AWARNING

1. Never start your engine or let it run for any length of time in a closed area. The exhaust fumes are poisonous and can cause loss of consciousness and death within a short time. Always operate your motorcycle in an area with adequate ventilation.

2. Before starting out, always be sure the sidestand is up. Failure to retract the sidestand completely can result in a serious accident when you try to turn a corner.

7-1

EAF17002

Starting and warming up a cold engine

EUU02800

NOTE: __

This motorcycle is equipped with a starting and an ignition circuit cut-off switch.

1. The engine can be started only under the following conditions:

a. The transmission is in neutral.

b. The sidestand is up, the transmission is In gear, and the clutch is disengaged.

2. The motorcycle must not be ridden when the sidestand is down.

7-2

EUU69200

AWARNING

Before going through the following steps. check the function of the sidestand switch and clutch switch. (Refer to page 5-16.)

TURN THE MAIN SWITCH TO "ON" AND THE ENGINE STOP SWITCH TO " 0 "

IF TRANSMISSION IS IN NEUTRAL AND SIDESTAND IS DOWN

PUSH START SWITCH, ENGINE WILL START

RETRACT SIDESTAND AND PUT TRANSMISSION IN GEAR

MOTORCYCLE CAN BE RIDDEN

IF TRANSMISSION IS IN GEAR AND SIDESTAND IS UP

PULL IN CLUTCH LEVER AND PUSH START SWITCH, ENGINE WILL START

MOTORCYCLE CAN BE RIDDEN

7-3

1. Turn the fuel cock to "ON".

2 Turn the main switch to liON" and the engine stop switch to II 0 ".

3. Shift transmission into neutral.

eUU03001

NOTE: _

When the transmission is In neutral, the neutral indicator light should be on. If the light does not come on, ask a Yamaha dealer to Inspect it.

4. Turn on the starter "CHOKE" and completely close the throttle grip.

5. Start the engine by pushing the start switch

EUU02500

NOTE: __

If the engine fails to start, release the start switch, wait a few seconds, then try again. Each attempt should be as short as possible to preserve the battery. Do not crank the engine more than 10 seconds on anyone attempt

6. After starting the engine, move the starter "CHOKE" to the halfway position.

EUU02600

NOTE: __

For maximum engine life, always warm up the engine before starting off. Never accelerate hard With a cold enginel

7. After the engine IS warm, turn off the starter completely.

EUU02701

NOTE: _

The engine IS warm when it responds normally to the throttle with the starter "CHOKE" turned off.

7-4

EAF10B02

Starting a warm engine

The starter "CHOKE" IS not required when the engine is warm.

EUU31401

CAUTION:

See the "Engine break-in" section prior to operating the motorcycle for the first time.

EAF20003

Shifting

The transmission lets you control the amount of power you have available at a given speed for starting, accelerating, climbing hills, etc The use of the shift pedal IS shown In the Illustration. (Page 5-6)

To shift into neutral, depress the shift pedal repeatedly until It reaches the end of its travel, then raise the pedal slightly.

EUU31501

1 Do not coast for long periods with the engine off, and do not tow the motorcycle a long distance. Even with gears in neutral, the transmission is only properly lubricated when the engine is running. Inadequate lubrication may damage the transmission.

2. Always use the clutch when changing gears. The engine, transmission, and driveline are not designed to withstand the shock of forced shifting and can be damaged by shifting without using the clutch.

7·5

EAF30000

Engine break-in

There is never a more important period in the life of your motorcycle than the period between zero and 1,000 km. For this reason we ask that you carefully read the following material. Because the engine IS brand new, you must not put an excessive load on it for the first 1,000 km. The vanous parts in the engine wear and polish themselves to the correct operating clearances. During this period, prolonged full throttle operation, or any condition which might result In excessive heating of the engine, must be avoided.

EAF30702

1. 0-150km:

Avoid operation above 4,000 r/rnin Stop the engine and let it cool for 5 to 10 minutes after every hour of operation. Vary the speed of the motorcycle from time to time. Do not operate it at one set throttle position

2. 150 - 500 km:

Avoid prolonged operation above 5,000 rim In. Rev the motorcycle freely through the gears, but do not use full throttle at any time.

3. 500 - 1,000 km:

Avoid prolonged full throttle operation. Avoid cruising speeds in excess of 6,000 r/min,

EUU32001

CAOTION:

After 1,000 km of operation, be sure to replace the engine oil and oil filter.

4. 1,000 km and beyond:

Full throttle can be used.

7-6

EUU38701

• Never let engine speeds enter the red zone.

• If any engine trouble should occur during the break-in period, consult a Yamaha dealer immediately.

EAf40100

Parking

When parking the motorcycle. stop the engine and remove the Ignition key. Turn the fuel cock to "OFF" whenever stopping the engine.

EUU63000

AWARNING

The muffler and exhaust pipe are hot. Park the motorcycle in a place where pedestrians or children are not likely to touch the motorcycle. Do not park the motorcycle on a slope or soft ground; the motorcycle may overturn.

7-7

EAHOOOOO

PERIODIC MAINTENANCE AND MINOR REPAIR

EAH00400

Periodic inspection, adjustment and lubrication will keep your motorcycle in the safest and most efficient condition possible. Safety is an obligation of the motorcycle owner. The maintenance and lubrication schedule chart should be considered strictly as a guide to general maintenance and lubrication intervals. YOU MUST TAKE INTO CONSIDERATION THAT WEATHER, TERRAIN, GEOGRAPHICAL LOCATIONS, AND A VARIETY OF INDIVIDUAL USES ALL TEND TO DEMAND THAT EACH OWNER ALTER THIS TIME SCHEDULE TO SHORTER INTERVALS TO MATCH THE ENVIRONMENT. The most important points of motorcycle inspection, adjustment, and lubrication are explained in the following pages.

EUU6320a

AWARNING

If you are not familiar with motorcycle service, this work should be done by a Yamaha dealer.

EAH10101

Tool kit

The service information included in this manual is intended to provide you, the owner, with the necessary information for completing some of your own preventive maintenance and minor repairs. The tools provided in the owner's tool kit are to assist you in the performance of periodic maintenance. However, some other tools such as a torque wrench are also necessary to perform the maintenance correctly.

8-1

1 Tool kit

EUU18500

NOTE: ___

If you do not have necessary tools required during a service operation, take your motorcycle to a Yamaha dealer for service

EUU67100

AWARNING

Modifications to this motorcycle not approved by Yamaha may cause loss of performance, and render it unsafe for use. Consult a Yamaha dealer before attempting any changes.

8-2

PERIODIC MAINTENANCE/LUBRICATION

EVERY
ITEM REMARKS BREAK-IN 6,000 km 12,000 km
1,000 km or6 months or 12 months
Valvsrs)" Check valve clearance Adjust if necessary 0 0 0
Spark plug(s) Check condition Clean or replace If necessary 0 0 0
Air filter Clean Replace If necessary 0 0
Carburetor" Check idle speed/starter operation 0 0 0
Adjust If necessary
Fuel hne" Check fuel hose for cracks or damage 0 0
Replace If necessary
Engine 011 Replace (Warm engine before draining). 0 0 0
Engme 011 filter" Replace 0 0 0
Brake" Check operation/fluid leakage/See NOTE. (Page 8-4) 0 0
Correct If necessa ry.
Clutch Check operation Adjust If necessary 0 0
Rear arm Pivot" Check rear arm assembly for looseness 0 0 0
Correct If necessa ry
Rear suspension link Check operation Modeiatelv repack "** 0 0 0
Pivot"
Wheels" Check balance/damage/runout/spoke tightness 0 0
Repair If necessary
Wheel bearings" Check bearing assembly for looseness/damage 0 0
Replace If damaged 8-3

EVERY
ITEM REMARKS BREAK·IN 6,000 km 12,000 km
1,000 km or 6 months or 12 months
Check bearmg assembly for looseness
Steering beannqs" Correct If necessary Moderately repack every 0 0
24.000 km or 24 months **
Front forks* Check operation/oil leakage Repair If necessary 0 0
Rear shock absorber" Check operation/oil leakage Repair If necessary 0 0
Cooling system Check coolant leakage Repair If necessary 0 0
Replace coolant every 24,000 km or 24 months
Drive chain Check chain slack/alignment Adjust If necessary EVERY 500 km
Clean and lube
Flttlngs/ Fasteners* Check all chaSSIS frttmq and fasteners 0 0 0
Correct If necessa ry
Sidestand" Check operation Repair If necessary 0 0 0
Sidestand swnch" Check operation Clean or replace If necessary 0 0 0 It IS recommended that these Items be serviced by a Yamaha dealer Medium weight wheel bearrng grease

**. Molybdenum disulfide grease

NOTE:

*

Brake fluid replacement:

1. When disassembling the master cylinder or caliper cylinder, replace the brake fluid. Normally check the brake fluid level and add the fluid as required.

2. On the inner parts of the master cylinder and caliper cylinder, replace the oil seals every two years.

3. Replace the brake hoses every four years, or if cracked or damaged

8-4

EAH30100

Torque specifications

Use a torque wrench to tighten these items. It is recommended that these items be checked occasionally, especially before a long trip. Always check the tightness of these items whenever they are loosened for any reason.

General torque
A B specifications
(Nut) (Bolt) Nm m-kq
10 mm 6mm 6 0.6
12mm 8mm 15 1.5
14 mm 10mm 30 3.0
17mm 12 mm 55 5.5
19mm 14 mm 85 8.5
22mm 16mm 130 13.0 Torque
Item
Nm m·kg
Spark plug 18 18
Drain bolt (Crankcase) 30 30
Dram bolt (all tank) 18 18
011 filter cover screw 10 1.0
Air bleed screw 5 05
Coolant drain bolt 10 10
Rear shock absorber locknut 70 70
Front wheel axle 59 59
Front axle holder nut 9 09
Rear wheel axle nut 105 105 8-5

EAH46101

Engine oil

A dry sump lubrication system is used on this model. That is, oil is supplied to the engine by means of the feed pump and returned to the oil tank by means of the scavenging pump Therefore, the 011 level can be checked at the oil tank.

1. 011 level measurement

a. Place the motorcycle on a level place and hold it in an upright position.

b. Remove the 011 tank cap/dipstick, and check the all level.

EUU16400

NOTE: __

When checking, reinsert the oil tank cap/dipstick without screwing it in. Remove the oil tank cap/dipstick again and check the 011 level For accuracy, check with the motorcycle held upright on a level place

c If the oil level is between the minimum and maximum level lines marked on the oil tank cap/dipstick, the engine may be started. If there is no 011 on the 011 tank cap/dipstick, add oil up to the minimum level.

d. Start the engine and warm up until the 011 temperature rises to approximately 70°C.

e Id Ie the engine for at least 10 seconds while keeping the motorcycle upright. Then stop the engine and check the oil level while keeping the motorcycle upright.

f Fill 011 to the maximum level line.

8-6

EUU3000n

f~~n~N~ _

Do not run the motorcycle until you know it has sufficient engine oil.

EUU11501

&WARNING

Never attempt to remove the oil tank cap/ dipstick just after high-speed operation. The heated oil could spout out, causing danger. Wait until the oil cools down to approximately 70°C.

2. Engine oil replacement

a. Start the engine and stop after a few minutes of warm-up.

b. Remove the engine guard.

c. Place an oil pan under the engine.

d. Remove the 011 tank cap/dipstick, drain bolts (at two places), and air bleed screw attached to the oil filter cover.

8-7 1. Dram bolt (Oil tank)

2 Drain bolt (Crankcase)

1 Air bleed screw

e. Check each gasket. If damaged, replace.

f. Remove the filter cover screws and the oil filter cover. Replace the filter element

EUU06800

NOTE: __

The oil filter cover is secured by three screws. The lower one should be removed so that the filter cavity will drain

1 Filter cover screws

9 Check O-ring(s) for damage. Replace if damaged.

1 O-rmgs

2 Filter element

8-8

h. Install the filter cover, screws, air bleed screw and the drain bolts (at two places).

Tightening torque.

Drain bolt (crankcase): 30 Nm (3.0 rn-kq) Drain bolt (oil tank): 18 Nm (1.8 mokg) Filter cover screw:

10 Nm (1.0 rn-kq) Air bleed screw:

5 Nm (0.5 m-kq)

i. Fill engine oil.

Install the oil tank cap/dipstick and tighten.

Recommended oil: 30°F 40°F 50·F 60·F

I '" I I SAE 20W40 type SE motor 011

-4-. --+.---1.,----+-1.. SAE 10W30 type SE motor 011

O·C 5·C 10'C 15·C

Oil quantity:

Total amount. 3.2 L

Periodic oil change: 2.6 L

With 011 filter replacement: 2.7 L

suuoaeoo

NOTE: _

Recommended engine oil classification; API Service "SE", "SF" type or equivalent (e.g. "SF~SE", "SF~SE~CC". "SF-SE-SD" etc.).

8-9

J. Start the engine and warm up for a few minutes While warming up, check for oil leakage. If oil leakage is found, stop the engine immediately and check for the cause.

k. Stop the engine and check the oil level.

EUU37701

CAUTION:

After replacing the engine oil, be sure to check the oil pressure as described below.

1. Remove the air bleed screw from the oil filter cover.

2. Start the engine and keep it idling until oil flows out of the bleed hole. If no oil comes out after one minute, turn off the engine immediately so it will not seize. In such a case go to the nearest Yamaha dealer for repairs.

3. After checking, tighten the air bleed screw securely.

EAH52002

Cooling system

1. If your motorcycle overheats

EUU70501

AWARNING

Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury. Open the radiator cap as follows. Wait until the engine has cooled. Place a thick rag like a towel over the radiator cap and slowly rotate the cap counterclockwise to the detent. This procedure allows any residual pressure to escape. When the hissing sound has stopped, press down on the cap while turning counterclockwise and remove it.

8-10

If overheating is detected, perform the following checks.

Restart the engine Ifthe engine overheats again, ask a Yamaha dealer to Inspect and repair.

EUU04300

NOTE: _

If it is difficult to get the recommended coolant, tap water can be temporarily used, provided that it is changed to the recommended coolant as soon as possible.

2. Changing the coolant

a. Remove the engine guard and right side cowl.

8-11

b. Place a container under the engine.

c. Remove the radiator cap.

1 Radiator cap

d. Remove the drain bolt.

1 Drain bolt

e. Disconnect the hoses from the bottom of the reservoir tank to drain it.

1 Level check hose

2 Reservoir ta nk hose

3 Reservoir tank cap

f After the coolant is completely drained, thoroughly flush the cooling system with clean tap water.

g. Retighten the drain bolt. If the gasket is damaged, replace it.

8-12

Tightening torque:

Drain bolt:

10 Nm (1.0 rn-kq)

h. Reconnect the reservoir tank hose and level check hose.

i. Pour the recommended coolant into the radiator until it's full.

Recommended coolant:

High quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines.

Coolant and water mixed ratio: 50%/50%

Total amount:

12 L

Reservoir tank capacity: 0.29 L

From LOW to FULL level. 0.17 L

EUU30900

Hard water or salt water is harmful to the engine. You may use distilled water if you can't get soft water.

j. Reinstall the radiator cap.

k. Run the engine several minutes to recheck the coolant level in the radiator. If It is low, add more coolant until it reaches the top of the radiator

I. Fill the reservoir tank with coolant up to "FULL" level.

m. Reinstall the reservoir tank cap and check for coolant leakage.

EUU04400

NOTE: __

If you find any leaks, ask a Yamaha dealer to inspect.

n. Reinstall the right side cowl and engine guard.

8·13

EAH70002

Radiator fan Operation

The electric fan operation is completely automatic. It is switched on or off according to the coolant temperature In the radiator

(Fan "ON")

.

(Fan "OFF") "ON" 105'±3'C

"OFF" 98'C

!OAH68500 Air filter

The air filter element should be cleaned at the specified intervals. It should be cleaned more frequently if you are riding in unusually wet or dusty areas.

EUU19900

NOTE: __

There is a check hose at the bottom of the air filter case. If dust or water collects In this hose, remove the hose and empty it. Then clean the air filter element and air filter case .

1 Check hose 8-14

6. Reassemble by reversing the removal procedure.

EUU35701

Make sure the element is properly seated in the filter case.

EUU42400

GeiytfQN~ _

The engine should never be run without the air filter element installed; excessive piston and/or cylinder wear may result.

EAH90001

Carburetor adjustment

The carburetor is a vital part of the engine and requires very sophisticated adjustment. Most adjustments should be left to a Yamaha dealer who has the professional knowledge and experience to do so. However, the following may be serviced by the owner as part of routine maintenance.

EUU33001

The carburetor was set at the Yamaha factory after many tests. If the settings are changed, poor engine performance and damage may result.

EAH90100

Idle speed adjustment

1. Start the engine and warm it up for a few minutes {normally, 1 or 2 minutes at approximately 1,000 to 2,000 r/min. Occasionally rev the engine to 4,000 to 5,000 r/min. The engine is warm when it quickly responds to the throttle.

2. Set the idle to the specified engine speed by adjusting the throttle stop screw; turn the screw in to increase engine speed, and out to decrease engine speed.

8-16

1. Remove the seat and right-hand side cover.

2. Remove the air filter case fitting screws and the filter case cover.

3 Pull out the element.

4. Tap the element lightly to remove most of the dust and dirt and blowout the remaining dirt with compressed air from the mesh side of the element. If the element IS damaged, replace it

1 Element

5 Install the element with the arrow mark on the top pointing inward.

8-15

1. Throttle stop screw

Standard idle speed' 1,200 ~ 1,400 r/min

EUU0450a

NOTE: _

If the specified idle speed cannot be obtained by performing the above adjustment, consult a Yamaha dealer.

EAH92200

Throttle cable adjustment

EUU06400

NOTE: ___

Before adjusting the throttle cable free play, the engine idling speed should be adjusted.

The throttle cable should have a specified free play in the turning direction at the grip flange. If the free play is Incorrect, ask a Yamaha dealer to make adjustment.

Free play: 3~5mm

8-17

a Free play

EAH90801

Valve clearance adjustment

The correct valve clearance changes with use, resulting In improper fuel/air supply or engine noise. To prevent this, the valve clearance must be adjusted regularly This adjustment however, should be left to a professional Yamaha service technician.

EAH20303

Spark plug inspection

The spark plug is an important engine component and IS easy to Inspect. The condition of the spark plug can indicate the condition of the engine.

The ideal color on the white insulator around the center electrode is a medrurn-to-lipht tan color for a motorcycle that is being ridden normally. Do not attempt to diagnose any problems yourself. Instead, take the motorcycle to a Yamaha dealer You should periodically remove and Inspect the spark plug because heat and deposits Will cause the spark plug to slowly break down and erode. If electrode erosion becomes excessive, or if carbon and other deposits are excessive, you should replace the spark plug with the specified plug.

Specified spark plug:

DPR8EA-9 or DPR9EA-9 (NGK)

8-18

Before Installing the spark plug, measure the electrode gap with a wire thickness gauge; adjust the gap to specification as necessary.

Spark plug gap: 0.8 ~ 0.9 mm

1 Spark plug gap

When installing the plug, always clean the gasket surface and use a new gasket. Wipe off any grime from the threads and tighten the spark plug to the specified torque.

Tightening torque:

Spark plug:

18 Nm (1.8 m·kg)

EUU03801

NOTE: _

If a torque wrench is not available when you are installing a spark plug, a good estimate of the correct torque is 1/4 to 1/2 turn past finger tight. Have the spark plug torqued to the correct value as soon as possible with a torque wrench.

EAH80103

Front brake lever free play adjustment

The free play at the front brake lever should be 2 ~ 5 mm.

1. Loosen the locknut.

8-19

a 2-5 mm

2. Turn the adjusting bolt so that the brake lever movement is 2 ~ 5 mm before the bolt contacts the master cylinder piston

3. After adjusting, tighten the locknut.

EUU81500

AWARNING

• Check the brake lever free play. Be sure the brake is working properly.

• A soft or spongy feeling in the brake lever can indicate the presence of air in the brake system. This air must be removed by bleeding the brake svstern before the motorcycle is operated. Air in the system will cause greatly diminished braking capability and can result in loss of control and an accident. Have a Yamaha dealer inspect and bleed the system if necessary.

EAH80402

Rear brake pedal height adjustment

The top of the brake pedal should be positioned 25 mm below the top of the footrest. If not, ask a Yamaha dealer to adjust it.

8-20

a 25mm

EUU79300

AWARNING

A soft or spongy feeling in the brake pedal can indicate the presence of air in the brake system. This air must be removed by bleeding the brake system before the motorcycle is operated. Air in the system will cause greatly diminished braking capability and can result in loss of control and an accident. Have a Yamaha dealer inspect and bleed the system if necessary.

----------------- 8-21

EAH63301

Brake light switch adjustment

The brake light switch is operated by movement of the brake pedal. To adjust, hold the main body of the switch so it does not rotate and turn the adjusting nut.

Proper adjustment is achieved when the brake light comes on just before the brake begins to take effect.

1 Main body

2 Adjusting nut

EAH87300

Checking the front and rear brake pads Check the brake pads for damage and wear.

EAH87401

FRONT

Apply the brake and Inspect the wear indicator.

If the brake pads are worn to the wear limit, have a Yamaha dealer replace the pads.

1 Wear indicator

EAH811AO

REAR

Inspect the pads through the window as shown. If the thickness is less than the specified value, have a Yamaha dealer replace the pads.

1 Wear hrrut 08 mm

8-22

EAH88902

Inspecting the brake fluid level

Insufficient brake fluid may let air enter the brake system, possibly causing the brakes to become ineffective.

Before riding, check that the brake fluid is above the "LOWER" level and replenish when necessary. Observe these precautions:

1. When checking the fluid level, make sure the top of the master cylinder is level by turning the handlebars.

1 Lower level

--------- --- ----------- -- ---------------~----

1 Lower level

2. Use only the designated quality brake fluid. Otherwise, the rubber seals may deteriorate, causing leakage and poor brake performance.

Recommended brake fluid: DOT 4

8-23

3. Refill with the same type of brake fluid MIxing fluids may result in a harmful chemical reaction and lead to poor brake performance.

4. Be careful that water does not enter the master cylinder when refilling Water will significantly lower the boilinq point of the fluid and may result In vapor lock.

5 Brake fluid may deteriorate painted surfaces or plastic parts Always clean up spilled fluid Immediately.

6. Have a Yamaha dealer check the cause ifthe brake fluid level goes down

EAH83501

Brake fluid replacement

1. Complete fluid replacement should be done only by trained Yamaha service personnel

2. Have a Yamaha dealer replace the following components during periodic maintenance or when they are damaged or leaking.

a Replace all rubber seals every two years. b Replace all hoses every four years.

EAIOOS04

Clutch lever free play adjustment

The clutch lever free play should be adjusted to 10 - 15 mm.

If the free play IS incorrect, adjust as follows

Free play:

10 - 15 mm

Loosen the locknut at the handlebar.

1 Locknut 8-24

2 Adjuster

a 10-15mm

2. Turn the adjusting bolt in or out until specified lever free play IS obtained.

3. Tighten the locknut.

4. If the free play is stili incorrect, make an adjustment at the crankcase side.

1 Locknut EUU17800

2 Adjuster

NOTE: _

If proper adjustment cannot be obtained or the clutch does not work correctly, ask a Yamaha dealer to inspect the internal clutch mechanism.

EAI40801

Drive chain slack check

EUU04801

NOTE: ___

Spin the wheel several times and find the tightest position of the chain. Check and/or adjust the chain slack while it's in this tightest position.

To check the chain slack the motorcycle must be held straight up with both wheels on the ground and without rider. Check the slack at the position shown in the illustration Normal slack is approximately 25~40 mm If the slack exceeds 40 mm, adjust,

8-25

a 25-40 mm

EAI42202

Drive chain slack adjustment

1 Remove the cotter pin from the axle nut.

8-26

, Cotter pin 2 Axle nut 3 Lock nut

4 Adjuster 5 Alignment marks

2. Loosen the axle nut.

3. Loosen the locknuts on each side. To tighten the chain, turn the chain adjusting nuts in direction ® To loosen the chain, turn the adjusting nuts In direction @ and push the wheel forward. Turn each adjusting nut exactly the same amount to maintain correct axle alignment. There are marks on each Side of the swingarm. Use these marks to align the rear wheel.

EUU33301

Too little chain slack will overload the engine and other vital parts. Keep the slack within the specified limits.

4. After adjusting, tighten the locknuts.

Then tighten the axle nut to the specified torque.

Tightening torque' Axle nut:

105 Nm (10.5 m-kq)

5. Insert a new cotter pin into the axle nut and bend the end of the cotter pin as shown in the illustration. If the notch in the nut and the cotter pin hole do not match, tighten the nut slightly to align them.

1 Cotter pm

EUU64700

AWARNING

Always use a new cotter pin on the axle nut.

8-27

EAI40701

Drive chain lubrication

The cham consists of many parts which work with each other If the chain is not maintained properly, it will wear out quicklv, Therefore, the chain must be serviced regularly. This service is especially necessary when riding In dusty areas. This motorcycle is equipped with a sealed type chain. Steam cleaning, highpressure washes, and solvents can damage chain so do not use these for cleaning It Use only kerosene to clean the drive cham. Wipe It dry, and thoroughly lubricate It with SAE 30-50W motor oil. Do not use any other lubncants on the drive chain. They may contain solvents that could damage the sealed chain.

EAll0701

Cable inspection and lubrication

EUU64601

AWARNING

Damage to the outer housing of cables may allow internal rusting and cause interference with cable movement. Replace damaged cables as soon as possible to prevent unsafe conditions.

Lubricate the Inner cable and the cable end If it does not operate smoothly, ask a Yamaha dealer to replace them.

Recommended lubricant SAE 10W30 motor oil

EAll0Z0l

Throttle cable and grip lubrication

The throttle twist grip assembly should be greased at the time that the cable is lubricated. since the grip must be removed to get at the end of the throttle cable. After removing the screws. hold the end of the cable up in the air and put in several drops of lubricant. With the throttle grip disassembled. coat the metal surface of the grip assembly with a suitable all-purpose grease.

EAI306D2

Brake and shift pedal lubrication Lubricate the pivoting parts.

Recommended lubricant.

SAE 10W30 motor oil

EAI30701

Brake and clutch lever lubrication Lubricate the pivoting parts.

Recommended lubricant:

SAE 10W30 motor oil

EAI31104

Sidestand lubrication

Lubricate the sidestand pivoting and mating parts. Check to see that the sidestand moves up and down smoothly.

Recommended lubricant:

SAE 10W30 motor oil

EUU70401

AWARNING

If the sidestand does not move smoothly. consult a Yamaha dealer.

8-29

EAI31901

Rear suspension lubrication Lubricate the pivoting parts.

Recommended lubricant:

Molybdenum disulfide grease

EAI20502

Front fork inspection

EUU65700

AWARNING

Securely support the motorcycle so there is no danger of it falling over.

Visual check

Check for scratches or damage on the inner tube and excessive all leakage from the front fork.

8-30

2. Operation check

Place the motorcycle on a level place.

a. Hold the motorcycle In an upright POSItion and apply the front brake.

b. Push down hard on the handlebars several times and check if the fork rebounds smoothly.

EUU42500

~;c{v~)Pii~ _

If any damage or unsmooth movement is found with the front fork, consult a Yamaha dealer.

----------------- 8-31

EAI51502

Rear shock absorber

EUU67301

AWARNING

This shock absorber contains highly pressurized nitrogen gas. Read and understand the following information before handling the shock absorber. The manufacturer cannot be held responsible for property damage or personal injury that may result from improper handling.

1. Do not tamper with or attempt to open the cylinder assembly.

2. Do not subject the shock absorber to an open flame or other high heat source. This may cause the unit to explode due to excessive gas pressure.

3. Do not deform or damage the cylinder in any way. Cylinder damage will result in poor damping performance.

4. Take your shock absorber to a Yamaha dealer for any service.

EAI52903

Rear shock absorber adjustment

This shock absorber is equipped with a spring preload and damping adjuster.

1 Adjust spring preload as follows.

a. Loosen the locknut

b. Turn adjuster in direction ® to Increase spring preload and in direction ® to decrease spring preload.

1 Locknut

A Increase spring preload

2 Spring preload adjuster B Decrease spring preload

1+---.1-- Measurement "A"

8-32

Measurement "Au

Standard length (I nstalled) 37.5 mm

Minimum length (installed) 345 mm

Maximum length (Installed) 44.5 mm

EUU36300

Never attempt to turn the adjuster beyond the maximum or minimum setting.

c. Reinstall the locknut and tighten to the specified torque.

Tightening torque: 70 Nm (7.0 m-kq)

EUU364QO

CAUTION:

Always tighten the locknut against the spring adjuster and torque the locknut to specification.

2. Adjust damping force as follows.

Turn adjuster In direction ® to increase damping force and in direction @ to decrease damping force.

1 Dampmg force adjuster

A. Increase dampmg force

B. Decrease damping force

---------- Hard Standard Soft
Adjusting 5 I 4 I 3 2 1
posrtron 8-33

EUU36300

Never attempt to turn the adjuster beyond the maximum or minimum setting.

EAI60301

Steering inspection

Periodically inspect the condition of the steering Worn out or loose steenng bearings may be dangerous. Place a stand under the engine to raise the front wheel off the ground Hold the lower end of the front forks and try to move them forward and backward. If any free play can be felt, ask a Yamaha dealer to Inspect and adjust the steering. Inspection IS easier If the front wheel rs removed.

EUU65700

AWARNING

Securely support the motorcycle so there is no danger of it falling over.

EAI60201

Wheel bearings

If there is play in the front or rear wheel hub or if the wheel does not turn smoothly, have a Yamaha dealer inspect the wheel beanngs. The wheel bearings should be Inspected according to the Maintenance Schedule.

8-34

EAI84903

Battery

This motorcycle is equipped with a sealedtype battery. Therefore it is not necessary to check the electrolyte or fill the battery with distilled water. If the battery seems to have discharged, consult a Yamaha dealer.

EUU43401

Do not try to remove the sealing caps of the battery cells. You may damage the battery.

EUU55800

AWARNING

Battery electrolyte is poisonous and dangerous, causing severe burns, etc. It contains sulfuric acid. Avoid contact with skin, eyes or clothing.

Antidote:

EXTERNAL: Flush with water.

INTERNAL: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Call a physician immediately.

EYES: Flush with water for 15 minutes and get prompt medical attention. Batteries produce explosive gases. Keep sparks, flame, cigarettes etc., away. Ventilate when charging or using in an enclosed space. Always shield your eyes when working near batteries.

KEEP OUT OF REACH OF CHILDREN.

8-35

Storage

1. When the motorcycle is not used for a month or longer, remove the battery and store It In a cool, dark place. Completely recharge the battery before reinstallation.

EUU43500

:~qAlf:t"~~:;; _

A special battery charger (constant voltage/ampere or constant voltage) is required for recharging the sealed type battery. Using a conventional battery charger may shorten the battery life.

2. Always make sure the connections are correct when putting the battery back in the motorcycle

EAI92001

Fuse replacement

1 There are two fuse cases on this motorcycle. Both the main and other fuse case are located inside the left-hand Side cover.

1 Main fuse

2 Fan motor fuse

2. If a fuse is blown, turn off the ignition SWitch and the switch of the circuit in question. Install a new fuse of proper amperage. Turn on the switches and check if the electrical device operates. If the fuse immediately blows again, consult a Yamaha dealer.

8-36

EUU34400

Do not use fuses of higher amperage rating than those recommended. Substitution of a fuse of improper rating can cause extensive electrical system damage and possibly a fire.

Specified fuse:

Main: 20A

Fan motor: 10 A

EAI86201

Headlight bulb replacement

This motorcycle is equipped with a quartz bulb headlight. If headlight bulb burns out, replace the bulb as follows:

1. Disconnect the headlight leads and remove the cover.

1 Headlight lead

2 Cover

2. Turn the bulb holder counterclockwise to remove it and remove the defective bulb.

8-37

EUU66001

AWARNING

Keep flammable products and your hands away from the bulb while it is on, as it is hot. Do not touch the bulb until it cools down.

3. Put a new bulb into posrtron and secure It in place with the bulb holder.

EUU34100

CAUTION:

Avoid touching the glass part of the bulb. Keep it free from oil; otherwise, the transparency of the glass, life of the bulb, and iIIuminous flux will be adversely affected. If oil gets on the bulb, thoroughly clean it with a cloth moistened with alcohol or lacquer thinner.

4 Reinstall the cover and reconnect the headlight leads. If the headlight beam adjustment is necessary, ask a Yamaha dealer to make adjustment.

8-38

EAJ25402

Front wheel removal

EUU66201

AWARNING

It is advisable to have a Yamaha dealer service the wheel.

EUU65700

AWARNING

Securely support the motorcycle so there is no danger of it falling over.

1. Remove the disc cover.

2. Remove the speedometer cable from the front wheel side.

1 Speedometer cable

2 DIsc cover

3. Elevate the front wheel by placing a SUItable stand under the engine.

4. Loosen the wheel axle holder nuts.

5. Remove the wheel axle and the front wheel. Make sure the motorcycle is properly supported.

8-39

1 Axle holder nuts

2 Front wheel axle

EUU05400

NOTE: _

Do not depress the brake lever when the disc is off the caliper as the brake pads will be forced shut

EAJ2570l

Front wheel installation

When rnstalling the front wheel, reverse the removal procedure

Pay attention to the following pornts:

1 Make sure the wheel hub and the speedometer gear unit housing are rnstalled with the projections meshed into the slots.

2. Make sure there is enough gap between the brake pads before inserting the brake disc.

3. Make sure the slot in the speedometer gear unit fits over the stopper on the front fork outer tube

8-40

4. Tighten the wheel axle to the specified torque.

Tightening torque:

Wheel axle:

59 Nm (5.9 m-kq)

5. Before tightening the holder nuts, stroke the front fork several times to check for proper fork operation.

6. Tighten the axle holder nuts to the specified tightening torque. Tighten the

should be a gap formed at the bottom of the axle holder.

1 1st

Rear wheel removal

EUU66201

AWARNING

It is advisable to have a Yamaha dealer ser-

upper nuts first and then lower ones.

. . vice the wheel.

When tightened In this sequence, there

8-41 _

Tightening torque:

Axle holder nut:

9 Nm (0.9 m-kq)

EAJ39000

EUU65700

AWARNING

Securely support the motorcycle so there is no danger of it falling over.

1. Elevate the rear wheel by placing a suitable stand under the rear arm.

1 Cotter pin 2 Ax Ie nut 3 Lockn ut

4 Adjuster

2 Remove the axle nut cotter pin and the axle nut.

3. Loosen the locknuts and chain adjusters on each Side

4. While supporting the brake caliper, pull

out the wheel axle

5

Push the wheel forward and remove the drive chain.

6 Remove the wheel assembly

EUU05501

NOTE: __

Do not depress the brake pedal when the disc and caliper are separated.

EUU05600

NOTE: __

You do not have to disassemble the chain in order to remove or install the rear wheel.

8-42

EAJ32401

Rear wheel installation

When installing the rear wheel. reverse the removal procedure. Pay attention to the following points:

1. Make sure the slot in the caliper bracket is fit over the stopper on the rear arm.

2. Make sure there IS enough gap between the brake pads before inserting the brake disc.

3. Adjust the drive chain.

4. Make sure the following parts are properly torqued. and a new cotter pin is installed.

EUU64700

AWARNING

Always use a new cotter pin on the axle nut.

Tightening torque:

Axle nut:

105 Nm (10.5 rn-kq)

8-43

EAJ50002

Troubleshooting

Although Yamaha motorcycles receive a nqrd inspection before shipment from the factory, trouble may occur during operation. Any problem In the fuel, compression, or Ignition systems can cause poor starting and loss of power. The troubleshooting chart describes a quick, easy procedure for making checks. If your motorcycle requires any repair, bring it to a Yamaha dealer. The skilled technicians at a Yamaha dealership have the tools, expertence, and know-how to properly service your motorcycle. Use only genuine Yamaha parts on your motorcycle. Imitation parts may look like Yamaha parts, but they are often Inferior. Consequently, they have a shorter service life and can lead to expensive repair bills.

EAJ51600

Troubleshooting chart

EUU66300

A WARNING

Never check the fuel system while smoking or in the vicinity of an open flame.

1 Fuel

Check If there IS fuel In the fuel tank

2 CompreSSion

There IS compression

Compression normal

Use electric starter

Ask Yamaha dealer to Inspect

3 Ignlt,on

Remove spark plug(s) and check electrode

H Ask Yamaha dealer to Inspect '-- __ -'

Dry

4 Battery

[I ~~~'~~ turns over HL_B_att_e_ry_9_0_O_d -,

Engine turns over Recharge, check

slowly connections

Use electnc starter

8-45

No Irregulamy up to fuel cock

Clean filter element and fuel tan k

Fuel cock clogged

EAKOOOOO

CLEANING AND STORAGE

EAK01303

A. CLEANING

Frequent, thorough cleaning of your motorcycle will not only enhance Its appearance but will improve its general performance and extend the useful life of many components.

1. Before cleaning the motorcycle:

a. Block off the end of the exhaust pipe to prevent water entry A plastic bag and strong rubber band may be used.

b Make sure the spark plugs and all filler caps are properly Installed

2. If the engine case is excessively greasy, apply degreaser with a paint brush Do not apply degreaser to the chain, sprockets or wheel axles.

3. Rinse the dirt and degreaser off with a garden hose. Use only enough pressure to do the Job.

EUU34602

Excessive hose pressure may cause water seepage and deterioration of wheel bearings, front fork, brakes, transmission seals and electrical parts. Many expensive repair bills have resulted from improper high pressure detergent applications such as those available in coin-operated car washers.

4 Once the majority of the dirt has been hosed off, wash all surfaces with warm water and mild, detergent-type soap. An old toothbrush or bottle brush IS handy for hard-to-get-at places.

5 Rinse the motorcycle off Immediately With clean water and dry all surfaces With a chamois, clean towel or soft absorbent cloth.

9·1

6. Dry the chain and lubricate It to prevent rust.

7. Windscreen cleaning

EUU37400

Avoid using any alkaline or strong acid cleaner, gasoline, brake fluid, or any other solvent.

Clean the windscreen with a cloth or sponge dampened with a neutral detergent, and after cleaning, thoroughly wash it off with water. Some cleaning compounds for plastics may leave scratches on surfaces of the windscreen. Before using them, make a test by polishing an area which does not affect your visibility.

8. Clean the seat with a vinyl upholstery cleaner to keep the cover pliable and glossy.

9. Automotive-type wax may be applied to all painted and chrome-plated surfaces Avoid combination cleaner-waxes. Many contain abrasives which may mar the paint or protective finish on the fuel tank and side covers. When finished, start the engine and let it idle for several minutes.

EAf(01202

B. STORAGE

Long term storage {60 days or more} of your motorcycle will require some preventive procedures to guard against deterioration. After thoroughly cleaning the motorcycle, prepare for storage as follows:

1. Drain the fuel tank, fuel lines, and carburetor float bowl.

2. Remove the empty fuel tank, pour a cup of SAE 10W30 or 20W40 motor oil in the tank, shake the tank to coat the inner surfaces thoroughly and drain off the excess oil. Reinstall the tank.

9-2

3. Remove the spark plug, pour about one tablespoon of SAE 10W30 or 20W40 motor oil in the spark plug hole and reinstall the spark plug. Turn the engine over several times (ground spark plug lead) to coat the cylinder wall with oil.

EUU66400

AWARNING

When using the starter motor to crank the engine, remove the spark plug wires, and ground them to prevent sparking.

4. Clean the chain and lubricate it (refer to "Dnve cham lubrication").

5. Lubricate all control cables.

6. Block up the frame to raise both wheels off the ground.

7. Tie a plastic bag over the exhaust pipe outlet to prevent moisture from entermg.

8 If storing in a humid or salt-air atmosphere, coat all metal surfaces with a light film of oil. Do not apply oil to any rubber parts or the seat cover.

9. Remove the battery and charge it. Store It in a dry place and recharge it once a month. Do not store the battery in an

excessively than O°C 30°C(90°F».

warm or cold place (less (30°F) or more than

EUU05800

NOTE: __

Make any necessary repairs before storing the motorcycle.

9-3

SPECIFICATIONS

Model XTZ660
Dimension.
Overall length 2,265 mm
Overall width 845mm
Overall height 1,385 mm
Seat height 865mm
Wheelbase 1,495 mm
Minimum ground clearance 245 mm
Basic weight
With oil and full fuel tank 197 kg
Minimum turning radius· 2,400 mm
Engme:
Type liquid cooled, 4-stroke gasoline, SOHC
Cylinder arrangement Single cylinder, Forward inclined
Displacement 660 crrr' 10-1