Yamaha Nouvo LX 135CC Service Manual. Written in English.

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Read this manual carefully before operating this vehicle. This manual should stay with this veh icle if it is sold.

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INTRODUCTION Welcome to the Yamaha world of motorcycling! As the owner of the AT135, you are benefiting fro m Yamaha's vast experience and newest technology regarding the design and manufacture of high-quality prod ucts, wh ich have earned Yamaha a reputation for dependability. Please take the time to read this manual thorou ghly, so as to enjoy all advantages of your AT135. Tile Owne r's Manual does not only instruct you in how to operate, inspect and maintain your motorcycle , but also in how to safeguard you rself and others from trouble and injury. In addition, the many tips given in this manual will help keep you r motorcycl e in the best possible condition. If you have any further questions, do not hesitate to contact your Yamaha dealer. The Yamaha team wishes you many safe and pleasant rides. So, remember to put safety fi rst! Yamaha continually seeks advancements in product design and quality. Therefore, wh ile this manual contains the most cu rre nt product information available at the time of printing, the re may be minor discrepancies between you r motorcycle and this manual. If there is any question concern ing this manual, please consult a Yamaha dealer. EWA 10031

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Please read thi s manual carefully and completely before operating this motorcycle.

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IMPORTANT MANUAL INFORMATION EAU10 132

Particularly important information is distingu ished in this manual by the following notations: This is the safety alert symbol. 11 is Llsed to alert you t o potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possibl1e injury or death.

~WARNING

A WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. A NOTICE indicates special precaut ions that must be taken to avoid damage to the vehicle or other property. A TIP provides key information to make procedu res easier or clearer,

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IMPORTANT MANUAL INFORMATION

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AT135 OWNER'S MANUAL ©2008 by Thai Yamaha Motor Co., Ltd. 1st edition, October 2008 All rights reserved. Any reprinting or unauthori zed use without the written perm ission of Thai Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Thailand.

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TABLE OF CONTENTS LOCATION OF IMPORTANT LABELS """""""""""""""""""""""""""""""" ""' " 1- 1

FOR YOUR SAFETY - PREOPERATION CHECKS ........ ""

SAFETY INFORMATION ........ .. ""."" "",2-1 Hel mets """" """"" """" """"",., .. ... " .. "." .. 2-5

OPERATION AND IMPORTANT RIDING POINTS ........ ... .................... .. 6-1 Starting a cold engine ... " ..... . ... ..... 6-1 Starting off .......... .......... ... ............. .. 6-2 Acceleration and deceleration .. .. .... 6-2 Braking ........................................... 6-2 Tips for reducing fuel consum ption .............. ........... ...... 6-3 Engine break-in ........ ....... .. ............. 6-3 Parking ............... ....... " .. ......... .. ...... 6-5 General note ...... ............. .... ........... 6-6

DESCRIPTION "" ... .. "" ....... "." .... " ........ 3- 1 Left view " ..... ..... "" ..... .. .......... " ... ..... 3-1 Right view ."""" """"""""" "" ,,,"",,,"",, ,,,,,, "" 3-2 Controls and instruments ""." .. " "",, ,3-3 INSTRUMENT AN D CONTROL FUNCTIONS ............ " ........ """"'"""""""..4- 1 Main switch/steering lock ... " .. ..... ... .4-1 Keyho le cover ... ........ ... ....... .. ... ...... .4-2 Indicato r and warning lights .... ... ... .4-3 Speedometer ...... ............. ......... ..... .4-3 Fuel gauge ...... ....... ... .... ....... .. ...... " .4-4 Digital coolant temperature gauge/odomete r ......... .... ............ .4-4 Handlebar switches ....................... .4-5 Front brake lever ................ ... .. ... ... .4-5 Rear brake lever .......... .......... ... .. .. . .4-6 Fuel tank cap ....... .... ................ .. .. .. .4-6 Fuel ............ .. . " ... ,'" .................. "" ... 4-7 Catalytic converter .... ...... ............. ...4-8 Kickstarter " ............... ... ....... ... ... ... ...4-9 Seat ..... .............. ..... ....................... .4-9 Helme! holders ....... ..................... .4-1 0 Convenience hook ... .... .. ........... ... .4-10 Sto rage compartment ............. ..... .4-11

PERIODIC MAINTENANCE AND ADJUSTMENT .............. .. ....... .. ... "" 7-1 Owner's tool kit ..... .......................... 7-1 Periodic maintenance chart for the emission control system ..... .. 7-2 General maintenance and lubrication chart .......................... . 7-3 Removing and installing cowlings and panels ............. .. ... ................ 7-6 Checking the spark plug ................. 7-8 Engine oil and oil stra ine r ............... 7-9 Final transmissio n oil .................... 7-11 Coolant ...... .. ........ .. .. ........ .. " ........ 7- 12 Air filter and V-belt case air filter elements ... ..... ...... .. .... .... ........... 7 -1 3 Adjusting the carburetor ...... ......... 7-16

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Adjusting t he engine idl ing speed .... .... ..... .. ................ ........ . 7- 16 Adjusting the throttle cable free play ............... .. ... ... ........ ..... 7- 17 Valve cl ea ran ce .................... ... .... 7- 17 T ires ..... ... .. .. ...." ........... ... .... .. ..... .. 7- 18 Wheels ............. .............. ....... ....... 7-20 Checking the f ront brake lever free play .... ..... .................... ....... 7-20 Adjusting the rear brake lever free play ............. .................. ... .. 7-21 Checking the front b rake pads and rear brake shoes ............... 7-22 Checking the brake fluid level .. .... 7-22 Changi ng the brake fluid ...... ... .... 7-23 Check ing the V-belt .. ......... .. .... .. .. 7-24 Checking and lubricating the cables ....... ....................... ... ...... 7-24 Checking and lubricating th e throttle grip and cable .......... ..... 7-24 Lubricating the front and rear brake levers ................... ........... 7-25 Checking and lubricating the centerstand and sidestand ... .... 7-25 Checking t he front fork ..... .... ........ 7-26 Checking the steering ........... ....... 7-27 Checking the wheel bearings .. ... .. 7-27 Battery ...... ............................ .... .. . 7-28 Replacing the fuse ..... ... ...... ....... .. 7-29 Replacing a headlight bulb .......... 7-30

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TABLE OF CONTENTS Replacing the tail/brake lig ht bulb .... ...... ........................ .7-31 Replacing a turn signal lig ht bulb .......... ... ................. ......7-32 Replacing a front turn signal light bulb ....... ...... ............. .......... 7-33 Replacing an auxiliary ligh! bulb ................................. .......... 7-33 Troubleshooting .. .. ....... ............. .... 7-34 Troubleshooting charts ................. 7-35 MOTORCYCLE CAR E AND STORAGE ... .... ............... ............. . 8-1 Care .. ........... ...... .... ..... .. .. .... ...... ... ... 8- 1 Stora ge . __ ...... .. .................... ...... ..... . 8-3 SPECIFICATIONS ... ..................... ... ... 9-1 CONSUM ER INFORMATION ....... .... 10-1 Identification numbers ..... .. ........... 10- 1

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INSTRUMENT AND CONTROL FUNCTIONS £AU""'"

Indicator and warning lights

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Engine trouble warning light "6" This warning light comes on if a problem is detected in the electrical circuit monitoring the engine. If this occurs, have a Yamaha dealer check the selldiagnosis system. The electrical circuit of the warning light can be checked by turning the key to "ON The warning light should come on for a few seconds, and then go off. If the warning light does not come on initially when lhe key is turned to ~ON", or if the warning light remains on, have a Yamaha dealer check the electrical circuit.

Speedometer 12

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1. Left-Ium signal indicatollight ".0-

2. Engine trouble warning light' 6 • 3. High beam indicator light "ro" J

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Rear brake

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Whenever worn to the limit

• Replace brake pads, • Check operation and adjust brake lever free play,

Brake hose

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Whenever worn to the limit

• Replace brake shoes,

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• Check for cracks or damage.

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Every 4 years

• Replace, Wheels

• Check runout and for damage,

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Wheels

• Check runout, spoke tightness and for damage. • Tighten spokes if necessary,

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Tires

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Check tread depth and for damage. Replace if necessary, Check air pressure, Correct if necessary,

Wheel bearings

• Check bearing for looseness or damage.

Swingarm

• Check operation and for excessive play, • Lubricate with lithium-soap-based grease.

7-3

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Every 13000 km (8000 mil

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PERIODIC MAINTENANCE AND ADJUSTMENT NO.

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14 15 16

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17 18 19

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23 24

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ITEM Steering bearings

CHECK OR MAINTENANCE JOB • Check bearing play and steering for roughness.

ODOMETER READING (km)

1000

4000

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ANNUAL CHECK

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Chassis fasteners

• Make sure that all nuts, bolts and screws are properly tightened.

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Sidestand, centerstand

• Check operation. • Lubricate.

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Front fork

• Check operation and for oil leakage.

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Shock absorber assemblies

• Check operation and shock absorbers lor oil leakage.

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Engine oil

• Change, • Check oil level and vehicle for oil leakage,

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Engine oil strainer

• Clean,

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Cooling system

• Check coolant level and vehicle for coolant leakage.

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• Change. Final transmission oil

• Check vehicle for oil leakage.

V-belt

• Check for damage and wear.

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Every 3000 km (1800 mil

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Every 3 years

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Every 10000 km (6000 mil

• Change.

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Every 25000 km (16000 mil

• Replace. Front and rear brake switches

• Check operation.

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Moving parts and cables

• Lubricate.

Throttle grip housing and cable

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• Check operation and free play. • Adjust the throttle cable free play if necessary. • Lubricate the throttle grip housing and cable.

Lights, signals and switches

• Check operation. • Adjust headlight beam.

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PERIODIC MAINTENANCE AND ADJUSTMENT EAUI 8660

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• The air filter needs more frequent service if you are riding in unusually wet or dusty areas. • Hydraulic brake service • Regularly check and, if necessary, correct the brake fluid level. • Every two years replace the intemal components of the brake master cylinder and caliper, and change the brake fluid. • Replace the brake hoses every four years and if cracked or damaged.

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PERIODIC MAINTENANCE AND ADJUSTMENT Removing and installing cowlings and panels

The cowlings and panels shown need to be removed to per10rm some of the

maintenance jobs described in this chapter. Refer to this section each time a cowling or panel needs to be removed and installed.

To install the cowling Place the cowling in the original position, and then install the screws.

CowlingC To remove the cowling

Cowlings A and B To remove one of the cowlings Remove the cowling screws, and then pull the cowling off as shown.

1. Remove cowlings A and B. (See page 7-6.) 2. Remove the bolts and screws shown, and then take the cowling off.

1. Cowling A

2. Cowling C 3. Panel A

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1. Cowling A

1. Cowling C

2. Screw (x7)

2. Screw (~) 3. Bolt ( ~1 )

1. Cowling B 2. Panel B 7-6

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PERIODIC MAINTENANCE AND ADJUSTMENT Panels A and B

To remove one of the panels

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

Remove the screw, and then pull the panel off as shown.

I. Screw (x4)

To install the cowling 1. Place the cowling in the original position, and then install the bolts and screws. 2. Inslall cowlings A and B.

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1. Panel B

2. Screw (x3)

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Checking the spark plug The spark plug is an important engine

2. Check the spark plug for elec erosion and excessive carbl other deposits, and replace necessary.

component, which is easy to check. Sinee heat and deposits will cause any spark plug to slowly erode, the spark plug should be removed and checked in accordance with the periodic maintenance and lubrication chart. In addition, the condition of the spark plug can reveal the condition of the engine_

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To remove the spark plug 1. Place the vehicle on the centerstand. 2. Remove panelS. (See page 7-6.) 3. Remove the spark plug cap.

Specified spark plug: NGKlCR7E 1. Spark plug wrench

4. Remove the spark plug as shown, with the spark plug wrench included in the owner's tool kit.

To check the spark plug

To install the spark plug 1. Measure the spark plug gap ~

wire thickness gauge and, if essary, adjust the gap to spe< tion.

1. Check thai the porcelain insulator around the center electrode of the spark plug is a medium-to-light Ian (the ideal color when the vehicle is ridden normally).

np, __~~~____~____ If the spark plug shows a distinctly different color, the engine could be operating improperly. Do not attempt to diagnose such problems yourself. In1. Sparl!.plug

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I. Spark plug gap

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Spark plug gap: 0.7-0.8 mm (0.027-0.031 in)

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2. Clean the surlace of the spark plug gasket and its mating surface, and then wipe off any grime from the sparK plug threads. 3. Install the spark plug with the spark plug wrench , and then tighten it to the specifi ed torque. TIghtening torque: Spark plug: 12.5 Nm (1.25 m·kgl, 9.0 ft·fbl) TIP ______- -______- -

Engine oil and oil strainer The engine 'oil level should be checked before each ride. In addition, the oil must be changed and the oil strainer cleaned at the intervals specified in the periodic maintenance and lubrication chart.

3. Wait a few minutes until the oil setties, remove the oil filler cap, wipe the dipstick dean, insert it back into the oil filler hole (without screwing it in), and then remove it again to check: the oil level.

To check the engine oil level 1. Place the vehicle on the centerstand. A slight tilt to the side can result in a false reading. 2. Start the engine, warm it up for several minutes. and then tum it off.

If a torque wrench is not available when

1. Dipstick

installing a spark plug, a good estimate of the correct torque is 1/4-1 /2 tum past finger tight. However, the spark plug should be tightened to the specified torque as soon as possible.

2. Maximum level mar1\:

3. Minimum leve! miU1y. Jo ..... ')" IS.2009 1- IOI' M

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Be sure to wipe off spi11ed oil on any parts after the engine and exhaust system have cooled down.

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• In order to prevent clutch slippage (since the engine oil also lubricates the clutch), do not m ix any chemical additives. Do not use oils with a diesel specification of " CD" or oils of a higher quality than specified. In addition, do not use oils labeled " ENERGY CONSERVING II" or higher. • Make sure that no foreign material enters the crankcase. 8. Start the engine, and then let it idle for several minutes while checking it for oil leakage. If oil is leaking. immediately turn the engine off and check for the cause. 9. Tum the engine off, and then check the oil level and correct it if

necessary.

Final transmission oil

1. Anal transmission oil d rain bah 1. Final transmission oil 'iller cap

The final transmission case must be checked for oil leakage before each ride. If any leakage is found, have a Yamaha dealer check and repair the scooter. In addition. the final transmission oil must be changed as follows at the intervals specified in the periodic maintenance and lubrication chart. 1. Start the engine, warm up the final transmission oil by riding the scooter for severaf minutes, and then stop the engine. 2. Place the scooler on the centerstand. 7-11

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3. Place an oil pan under the fin al transmission case 10 collect the used oil. 4. Remove the final transmission oil filler cap and final transmission drain bolt to drain the oil from the final transmission case. 5. Install the final transmission oil drain bolt, and then tighten it to the specified torque. Tightening tOfque: Final transmission oil drain bolt: 22 Nm (22 m·kgf. 162 1t·1:>f)

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PERIODIC MAINTENANCE AND ADJUSTMENT 6. Refill with the specified amount of the recommended final transmission oil, and then install and tighten the oil filler cap. WARNING! Make sure that no foreign material enters the final transmission case. Make sure that no oil gets on the tire or wheel. {EWA1I 3I1 1

The coolant level should be checked before each ride. In addition. the coolant must be changed at the intervals specified in the periodic maintenance and lubrication chart.

Recommended final transmi ssion oil:

To check the coolant level 1. Place the vehicle on the centerstand.

See page 9-1.

Oil quantity: 0. 12 L (0.13 US qt, 0.1 1 Imp.qt)

7. Check the final transmission case for oil leakage. If oil is leaking, check for the cause.

Coolant

TIP .,,-_ _ _ __ _ _ ____

• The coolanllevel must be checked on a cold engine since the level varies with engine temperature. • Make sure that the vehicle is positioned straight up when checking the coolant level. A slight tilt to the side can result in a false reading.

2. Check the coolant level in the coolant reservoir.

np --~~~~~~~----c­ The coolant should be between the minimum and maximum level marks.

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1. Maximum level mark 2. Minimum level mark

3. If the coolant is at or below the minimum level mark, remove panel B (See page 7-6.), remove the reservoir cap. add coolant 10 the maximum level mark, and then install the reservoir cap and the panel. WARNING! Never anempt to remove the radiator cap when the engine is haL [EWA10Je l[ NOTICE: If coolant is not available, use distilled water or soft tap water instead. Do not use hard water or salt w ater since it is harmful to the engine. If water has been u sed instead of cool-

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PERIODIC MAINTENANCE AND ADJUSTMENT ant, replace it with coolant as soon as possible, otherwise the cooling system will not be

protected against Irost and corrosion. If water has been added to the coolant, have a Yamaha dealer cheek the anti· freeze content of the coolant as soon as possible, otherwise the effectiveness of the coolant will be reduced. IECIo.l""~

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• The radiator fan switches on when the engine is started and switches off when the engine is stopped.

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Air filter and V-belt case air filter elements

tervals specified in the periodic mainte-

The air filter element should be checked and replace if necessary and the V-belt case air filter element should be cleaned at the intervals specified in the periodic maintenance and lubrication chart. Service the air filter elements more frequentty if you are riding in unusually wei or dusty areas.

nance and lubrication chart. Have a Yamaha dealer change the coolant. WARNING ! Never attempt to remove the radiator cap when the engine is hot_ I[W~'O>&'I

Checking and replacing the air filter element 1. Place the vehicle on the centerstand.

• If the engine overtleals, see page 7-35 for furth er instructions. Changing the coolant The coolant must be changed at the in-

I. CooIan\ rasetVOir cap

Coolant reservoir capacity (up to the maximum tevel mark): 0.25 l (0.26 US qt) (0.22 Imp.ql) 1. Air tiller case coyer 2. Screw (~6)

7-1 3

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PERIODIC MAINTENANCE AND ADJUSTMENT

! 2. Remove panel A. (See page 7-6 for panel removal and installation procedures.) 3. Remove the air filter case cover by removing the screws. 4. Remove the air filter element by pulling it out.

1 1. Air filter element (Wet type)

6. Place the air fiher element in its original position. 7. Install the air filter case cover by installing the screws. 8. Install the panel.

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® 1. Air fiHer element (Wet type)

5. Check the air filter element for excessive dirt or damage and replace it if necessary.

1. V-be1t case air filter cover 2. Bolt (x4)

3. Remove the element by pulling it out.

Cleaning the V-belt case air fitter element 1. Place the vehicle on the centerstand. 2. Remove the V-belt air filter case cover by removing the bolts. 1. V-belt air filter eiemeol

7-14

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PERIODIC MAINTENANCE AND ADJUSTMENT np ~__~~~~~~~~

The element should be wet but not dripping. Recommended oil:

Yamaha foam air filter oil or other quality foam air filter oil 7. Install the element into the filter

case. 4. Clean the element with solvent, and then squeeze the remaining solvent out. 5. Check the element for damage and replace it if necessary. 6. Apply oil of the recommended type to the entire surface of the element, and then squeeze the excess oil out. WARNING! Use only a dedicated parts cleaning solvent. To avoid the risk of fire or explosion, do nol use gasoline or solvents with a low flash point. [EW~'.y. J ... lUJ}' IS . 2009 I. IOI'M

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Adjusting the carburetor The carburetor is an important part of the engine and requires very sophisticated adjustment. Therefore. most carburetor adjustments should be left to a Yamaha dealer. who has the necessary professional knowledge and experience. The adjustment described in the following section, however, may be serviced by the owner as part of rou tine maintenance.

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The carburetor has been set and extensively tested at the Yamaha factory. Changing these settings without sufficient technical knowledge may result in poor performance of o r damage to the engine.

Adjusting the engine idling speed The engine idling speed must be checked and, if necessary, adjusted as follows at the intervals specified in the periodic maintenance and lubrication chart. The engine should be warm before making this adjustment.

TlP _ _ _ _ _ _ _ _ _

5. Remove the rubber cap and insert a Phillips screwdriver into the thronle stop screw hole. 6. To increase the engine idling speed, tum the screw in direction (a). To decrease the engine idling speed, tum the screw in direction (b).

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• The engine is warm when it quickly responds to the throttle. • A diagnostic tachometer is needed to make this adjustment.

1. Open the seat. (See page 4-9 lor seat opening and closing procedures.) 2. Remove panel B. (See page 7-6 lor panel removal and installation procedures.) 3. Attach the tachometer to the spa(\( plug lead. 4 . Check the engine idling speed and, if necessary, adjust it to specification as follows. 7·16

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1. Th rottle stop screw

Engine idling speed: 1400-1600 r/min

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If the specified idling speed cannot be obtained as described above, have a Yamaha dealer make the adjustment. 7. Install the panel and close the seal.

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Adjusting the throttle cable free play

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2. To increase the IhroWe cable free play, tum the adjusting nut in direction (a). To decrease the throt-

tle cable free play, tum the

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adjusting nut in direction (b). 3. Tighten the locknut.

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1. Thronle cable free play adjusting nut

2. Locknut

3. Cable cover c. ThroCUe cable free play

The throttle cable free play should measure 3.0-7.0 mm (0.12--0.28 in) at the throttle grip. Periodically check.the throttle cable free play and, if neces· sary, adjust it as follows.

TIP _ _--,--,_ _ _ _ _ __ The engine idling speed must be correctly adjusted before checking and adjusting the throttle cable free play. 7-17

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EAU',.., Valve clearance The valve clearance changes with use,

resulting in improper air-fuel mixture and/or engine noise. To prevent this from occurring, the valve clearance must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart.

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PERIODIC MAINTENANCE AND ADJUSTMENT

! Tires To maximize the perfonnance, durability, and safe operation of your motorcycle, note the following points regarding the specified tires.

Tire air pressure The ti re air pressure should be checked and, if necessary, adjusted before each ride. EV/Al ",",'

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WARNING

Operation of this vehicle with improper tire pressure may cause severe injury or death from loss of control. • The tire air pressure must be checked and adjusted on cold tires (i.e., when the temperature of the tires equals the ambient temperature). • The tire air pressure must be adjusted in accordance with the riding speed and with the total

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weight of rider, passenger, cargo, and accessories approved for this model. Tire air pressure (measured on cold

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WARNING

Never overload your vehicle. Operation of an overloaded vehicle could cause an accident.

tires): Up to 90 kg (198Ib): Front: ' 200 kPa (2.00 kgflcm 2• 29 psi) Rear: 225 kPa (2.25 kgflcm 2, 33 psi) 90 kg (l98lb) to ma xi mum load: Front: 200 kPa (2.00 kgflcm 2, 29 psi) Rear: 225 kPa (2.25 kgflcm>', 33 psi)

Maximum load': 160 kg (353 Ib) Total weight of rider. passenger, cargo and accessories

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Tire inspection

+1. Tire sidewall

2. Ti re wear indicator 3. Tire tread depth

The tires must be checked before each ride. If the tire shows crosswise lines (minimum tread depth), if the tire has a nail or glass fragments in it. or if the sidewall is cracked, have a Yamaha dealer replace the tire immediately.

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PERIODIC MAINTENANCE AND ADJUSTMENT Minimum tire tread depth (front and rear): 1.0 mm (0.04 in)

TIP -0----:---:-:---::-::---::-----;:::;The tire tread depth limits may differ from country to country. Always comply with the local regulations.

Front tire: Size: 70190-14MIC 36P Manufacturer/model:

IAC/NF59E, (TUBElESS) DUNLOPID 11 0M,DllOL Rear tire: Size: 80190-16MIC 48P Manufacturer/mode l: IAC/NR76E, (TUBELESS)

Tire information

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DU NLOPID11 0M, Dl10l

This motorcycle is equipped with tube tires.

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WARNING The front and rear tires should be of the same make and design, otherwise the handling characteristics of the vehicle may be different, which could lead to an accident After extensive tests, only the tires listed below have been approved for this model by Yamaha Motor Co., Ltd.

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WARNING • It is dangerous to ride with a worn-out tire. When a tire tread begins to show crosswise lines, have a Yamaha dealer replace the tire immediately. • The replacement of all wheeland brake-related parts, including the tires, should be len to a Yamaha dealer, who has the necessary professional knowledge and experience.

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• It is not recommended to patch a punctured tUbe. If unavoid· able, however, patch the tube very carefully and replace it as soon as possible with a highquality product.

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PERIODIC MAINTENANCE AND ADJUSTMENT Wheels To maximize the perfonnance, durability, and safe operation of your motorcycle, note the following points regarding the specified wheels. • The wheel rims should be checked lor cracks, bends or warpage, and the spokes for looseness (for spoke wheel model) or damage before each ride. II any damage is found, have a Yamaha dealer replace the wheel. Do not attempt even the smallest repair to the wheel. A deformed or cracked wheel must be replaced. • The wheel should be balanced whenever either the tire or wheel has been changed or replaced. An unbalanced wheel can result in poor performance, adverse handling characteristics, and a shortened tire life.

• Ride at moderate speeds after changing a tire since the tire surface must first be "broken in" for it to develop its optimal characteristics.

Checking the front brake lever free play

There should be no free play at the brake lever end. If there is free play, have a Yamaha dealer inspect the brake system. . . WARNING A soft or spongy feeling in the brake lever can indicate the presence of air in the hydraulic system. tf there is air in the hydraulic system, have a Yamaha dealer bleed the system before operating the vehicle. Air in the hydraulic system will diminish the braking performance, which may re7-20

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PERIODIC MAINTENANCE AND ADJUSTMENT suit in loss of control and an accide nt.

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Adjusting the rear brake lever free play

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1. Rear brake IeVCf free play

The brake lever free play should measure 10.0-20.0 mm (0.394-0.787 in) as shown. Periodically check the brake lever free play and. if necessary, adjust it as follows. To increase the brake lever free play, lum the adjusting nut at the brake shoe plate in direction (a). To decrease the brake lever free play, tum the adjusting nul in direction (b). http://www.motorcycle.in.th

1_ Rear brake lever free play adjusting n

""WARNING H proper adjustment cannot I tained as described, have a Vi dealer make this adjustment.

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PERIODIC MAINTENANCE AND ADJUSTMENT

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Checking the front brake pads and rear brake shoes

The front brake pads and the rear brake shoes must be checked for wear at the intervals specified in the periodic maintenance and lubrication chart.

peared, have a Yamaha dealer replace the brake pads as a set.

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Checking the brake fluid level

Rear brake shoes

Front brake pads

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1. Minimum level mark

-@ 1. Brake shoe wear indicator 2. Brake shoe wear limit line

out having to disassemble the brake. To check the brake pad wear, check the wear indicator grooves. If a brake

The rear brake is provided with a wear indicator, which allows you to check the brake shoe wear without having to disassemble the brake. To check the brake shoe wear, check the position of the wear indicator while applying the brake. If a brake shoe has wom to the point that the wear indicator reaches the wear limit line, have a Yamaha dealer replace the brake shoes as a

pad has worn to the point that the wear

set.

1. Brake pad wear indicator groove (x2)

Each Iront brake pad is provided with wear indicator grooves, which allow you to check the brake pad wear with-

Insufficient brake fluid may allow air to enter the brake system, possibly causing it 10 become ineffective. Before riding, check that the brake fluid is above the minimum level mark and replenish if necessary. A low brake fluid level may indicate wom brake pads and/Of brake system leakage. If the brake fluid level is low, be sure to check the brake pads fOf wear and the brake system lor leakage. ObselVe these precautions:

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• When checking the fluid level, make sure that the top 01 the master cylinder is level by turning the handlebars. • Use only the recommended quality brake fluid, otherwise the rubber seals may deteriorate, causing leakage and poor braking performance.

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PERIODIC MAINTENANCE AND ADJUSTMENT • As the brake pads wear, it is nor-

mal for the brake fluid level to gradually go down. However, if the brake fluid level goes down suddenly, have a Yamaha dealer check the cause.

Recommended brake lIuid: DOT 4

• Refill with the same type of brake fluid. Mixing fluids may result in a harmful chemical reaction and lead to poor braking performance. • Be careful that water does nol enter the master cylinder when refitting. Water will significantly lower the boiting point of the flui d and may result in vapor lock. • Brake fluid may deteriorate painted surfaces or plastic parts. Always clean up spilled fluid immediately.

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Changing the brake fluid Have a Yamaha dealer change the brake fluid at the intervals specified in the TIP after the periodic maintenance and lubrication chart. In addition. have the oil seals 01 the brake master cylinder and caliper as well as the brake hose replaced at the intervals listed below or whenever they are damaged or leaking. • Oil seals: Replace every two years. • Brake hose: Replace every four years.

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PERIODIC MAINTENANCE AND ADJUSTMENT

I Checking the V-belt The V-be" must be checked and replaced by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart

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Checking and lubricating the throttle grip and cable

The operation of all control cables and

The operation of the throttle grip should be checked before each ride. In addition, the cable should be lubricated at the intervals specified in the periodic maintenance chart.

the condition of the cables should be checked before each ride, and the cables and cable ends should be lubricated jf necessary. If a cable is damaged

or does not move smoothly, have a yamaha dealer check or replace it. WARNING! Damage to the outer sheath may interfere with proper cable operation and will cause the inner cable to rust. Replace a damaged cable as soon as possible to prevent unsafe conditions. IEWA 10721 J

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Recommended lubricant: Engine oil

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Checking and lubricating the cables

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PERIODIC MAINTENANCE AND ADJUSTMENT ~AV232')

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Lubricating the front and rear brake levers

Recommended lubricant:

lithium-soap-based grease

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The pivoting points of the front and fear brake levers must be lubricated at the intervals specified in the periodic maintenance and lubrication chart.

Checking and lubricating the centerstand and sidestand

The operation of the centerstand and sidestand should be checked before each ride , and the pivots and metal-Iometal contact surfaces should be lubri cated if necessary.

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WARNING H the centerstand or sidestand does not move up and down smoothly, have a Yamaha dealer check or repair il Otherwise, the centerstand or sidesland could contact the ground and distract the operator, resulting in a possibte loss of control.

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PERIODIC MAINTENANCE AND ADJUSTMENT Recommended lubricant: Ulhium-soap-based grease

Checking the front fork The condition and operation of the front lork must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart.

To check the condition Check the inner tubes for scratches, damage and excessive oil leakage. To check the operation 1. Place the vehicle Ofl a level surface and hold it in an upright position. WARNING! To avoid injury, securely support the vehicle so there Is no danger of it falling

over. lI',""I075'1 2. While applying the front brake, push down hard on the handlebars several times 10 check if the front fork compresses and rebounds smoothly.

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If any damage is found or the front fork does not operate smoothly, have 8 Yamaha dealer check or re-

pair it.

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SPO]& I99 . F. l. book Pise 27 1'bunoday Ja..."ary IS , 2009 u n I'M

PERIODIC MAINTENANCE AND ADJUSTMENT Checking the steering Worn or loose steering bearings may cause danger. Therefore, the operation of the steering must be checked as follows at the intervals specified in the pe.riodic maintenance and lubrication

2. Hold the lower ends of the front fork legs and

try to move them for-

ward and backward. II any free play can be felt, have a Yamaha dealer check or repair the steering.

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The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrica-

tion chart II there is play in the wheel hub or if the wheel does not tum smoothly, have a Yamaha dealer

chart.

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Checking the wheel bearings

check the wheel bearings.

1. Place a stand under the engine to raise the front wheel off the ground. (See page 7-25 for more information.) WARNING! To

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avoid injury, securely support the vehicle so there is no danger of It falling over. I(WA, 01$'1

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PERIODIC MAINTENANCE AND ADJUSTMENT

I Battery This model is equipped with a VRLA (Valve Regulated Lead Acid) battery. There is no need to check the electrolyte or to add distilled water. However, the battery lead connections need to be checked and, if necessary, tightened.

ways shield your eyes when working near batteries. In case of contact, administer the following FIRST AID. • EXTERNAL: Flush with plenty

of water. • INTERNAL: Drink large quantities of water or milk and immediately call a physician. • EVES: Rush with water for 15 minutes and seek prompt

medical attention.

1. Batteey band

• Batteries produce explosive hy-

drogen gas. Therefore, keep sparks, flames, cigarettes, etc., away from the battery and provide sufficient ventilation when 1 Ba1tery cover

2. Screw (x2)

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WARNING • Electrolyte is poisonous and dangerous since it contains sui· furic acid, which causes severe burns. Avoid any contact with skin, eyes or clothing and al·

2. Remove the battery cover by removing the screws.

charging

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space. • KEEP THIS AND ALL SATIERIES OUT OF THE REACH OF CHILDREN. To access the battery 1. Open the seat. (See page 4-9.)

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2. Satteey 3. Positive ballery lead 4 . Negative battery lead

To charge the battery Have a Yamaha dealer charge the battery as soon as possible if it seems to have discharged. Keep in mind that the battery tends to discharge more quickly if the vehicle is equipped with optional electrical accessories.

To charge a VRLA (Valve Regulated Lead Acid) battery, a special (corr

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PERIODIC MAINTENANCE AND ADJUSTMENT stant-voltage) battery charger is required. Using a conventional battery charger will damage the battery. If you do not have access to a con· stant-voltage battery charger, have a Yamaha dealer charge your bat-

tery.

4. After installation , make sure that the battery leads are properly connected to the battery terminals.

Replacing the fuse

TlCE Always keep the battery charged. Storing a discharged battery can cause permanent battery damage_

To store the battery 1. If the vehicle will not be used for more than one month, remove the battery, fully charge iI , and then place it in a cool, dry place. NOnCE: When removing the battery, be sure the key is turned to " OFF". then disconnect the negative lead before disconnecting the positive lead. [EC"'63021 2. If the battery will be stored for more than two months, check it al least once a month and full y charge it if necessary. 3. Fully charge the battery before installation.

1. Fuse cover 2. Screw (x l)

The fuse holder is located in the storage compartment under the seat, behind the starter relay cover. (See page 4-9 for seat opening procedures.) If the fu se is blown, replace it as follows. 1. Tum the key to "OFF' and turn off all electrical circuits. 2. Remove the starter relay cover by removing the screw. 3. Pull the starter relay out.

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PERIODIC MAINTENANCE AND ADJUSTMENT 6. Instali lhe starter relay cover by installing the screw. 7. Tum the key to ~ONM and tum on the electrical circuits to check if the devices operate. 8. If the fuse immediately blows again, have a Yamaha dealer check the electrical system.

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ave the blown fuse, and then II a new fu se of the specified ~ rage . WARNING! Do not a fuse of a higher amperrating than recommended avoid causing extensive age to the electrical sysand possibly a fire. 1I="~ ' SI"1

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Replacing a headlight bulb If a headlight bulb bums Qut, replace

it

as fol1ows.

Do not touch the glass part of the headlight bulb to keep it fTee from oil, otherwise the transparency of the glass, the luminosity of the bulb, and the bulb life will be adversely affected. Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened w ith alcohol or thinner.

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ad fuse:

e the starter relay into the

,a1 position .

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PERIODIC MAINTENANCE AND ADJUSTMENT ~"

1. Place the motorcycle on the cen· tersland. 2. Remove cowling C. (See page 7-6 for removing procedure.)

Replacing the taillbrake light bulb

1. Open the seal. (See page 4-9.) 2. Remove the panel by removing the screws, and then pulling the panel outward.

1. Headlight but> holder

5. Place a new bulb into position, and then secu re it with the bulb holder.

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