Yamaha Yd110 2006 U5kae1

Life
ance Cost
t Smoke
and Tear
IN INDIA
UX
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OWNER'S MANUAL
5KA-F8199-E1
TAKE NECESSARY PRECAUTIONS DURING RUNNING-IN PERIOD.
CRUX
OWNER'S MANUAL
YAMAHA MOTOR INDIA SALES PVT. LIMITED
All rights reserved. Any reprinting or
unauthorised use without the written
permission of
YAMAHA MOTOR LIMITED
is expressly prohibited.
INDIA SALES PVT.
WARNING
PLEASEREADTHISMANUALCAREFULLYANDCOMPLETELYBEFOREOPERATINGTHISMOTORCYCLE.
INTRODUCTION
Congratulations on your purchase of the CRUX This motorcycle has been produced using the
latest technology in our modern plant, to provide you a happy, enjoyable and safe riding for
many thousand kilometers and years. It represents the high degree of craftsmanship and
reliability that have made YMIS a leader in these fields.
This Owners Manual will give you an understanding of the operation, inspection and basic
maintenance of this Motorcycle as recommended in this Owners manual. Always demand
only YMIS Genuine Spare Parts and Yamalube oil. If you have any queries regarding the
operation or maintenance of your Motorcycle, please consult your YMIS DEALER who will be
too happy to help you.
This Owners Manual also includes the GREEN BOOK containing Guidelines, DOs and
DONTs to be followed by the Owner/User of the Motorcycle for keeping Environment Clean
and Green. You are requested to please read the GREEN BOOK carefully.
We provide,
YAMAHA MOTOR INDIA SALES PVT. LTD.
19/6, Mathura Road,
Faridabad-121006 (India)
PG1_55.pmd 9/24/2005, 7:52 AM 1
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PG1_55.pmd 9/24/2005, 7:52 AM 2
IMPORTANT MANUAL INFORMATION
= +| =;-r r+r|
Particularly important information is distinguished in this manual by the following notations:
; - - lllin ni ,ii i( lii i ^^ li î r
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!
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A NOTE provides key information to make procedures easier or clearer.
NOTE :
l>i i ii i(i -- i l i- -- i i ni r|
A CAUTION indicates special precautions that must be taken to avoid damage to the
Motorcycle.
CAUTION :
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Failure to follow WARNING instructions could result in severe injury to the Motorcycle
operator, a bystander or a person inspecting or repairing the Motorcycle.
WARNING
PG1_55.pmd 9/24/2005, 7:52 AM 3
IMPORTANT MANUAL INFORMATION
= +| =;-r r+r|
NOTE:
This manual should be considered a permanent part of this Motorcycle and should remain with it even
of the Motorcycle is subsequently sold.
YMIS 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 this manual. If there is any question concerning this
manual, Please consult your YMIS dealer.
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PG1_55.pmd 9/24/2005, 7:52 AM 4
Clutch lever............................................. 3-3
Shift pedal............................................. 3-4
Front brake lever..................................... 3-4
Rear brake pedal.................................... 3-4
Fuel tank cap......................................... 3-5
Fuel...................................................... 3-5
Fuel cock.............................................. 3-6
Starter Lever .......................................... 3-7
KIck Starter............................................ 3-7
Seat...................................................... 3-8
Storage compartment............................ 3-9
Rear Shocker 3-9
Handle Seat (Luggage Carrier).................3-10
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TABLE OF CONTENTS
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1 ROAD SAFETY TIPS............................... 1-1
2 DESCRIPTION........................................ 2-1
Left view.................................................. 2-1
Right view................................................ 2-2
Controls/Instruments................................ 2-3
3 INSTRUMENT AND CONTROL
FUNCTIONS............................................ 3-1
Main switch cum steering lock................. 3-1
Speedometer............................................3-2
Indicator Lights........................................ 3-2
Handlebar switches.................................. 3-3
ri l-( (-)
lii i i
i i lii i^ (i)
PG1_55.pmd 9/24/2005, 7:52 AM 5
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TABLE OF CONTENTS
Tool kit................................................... 6-1
- l-
Preventive maintenance schedule............. 6-3
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Panel removal and installation.................. 6-7
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Spark plug and installation....................... 6-9
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Engine oil............................................... 6-11
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Air filter................................................... 6-14
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Carburetor adjustment............................. 6-16
i- i - i (----)
Idle speed adjustment.............................. 6-16
i; -i ----
Throttle cable free play adjustment............ 6-18
ii- i i ----
Valve clearance adjustment...................... 6-18
(i-( l i ----
Tyres...................................................... 6-18
-i
Wheels.................................................. 6-21
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4 PRE-OPERATION CHECKS.................... 4-1
ii (i) ( i
Pre-operation check list........................... 4-1
ii ( i i
5 OPERATION AND IMPORTANT RIDING
POINTS................................................. 5-1
i nii (ii i( in
Starting and warming up a
cold engine............................................. 5-1
- ; i i i i iii ^- i
Starting a warm engine............................ 5-2
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Shifting.................................................. 5-2
ll-^
Tips for reducing fuel consumption............ 5-4
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Running-in.............................................. 5-4
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Parking.................................................. 5-5
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6 PERIODIC MAINTENANCE AND MINOR
REPAIR................................................. 6-1
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PG1_55.pmd 9/24/2005, 7:52 AM 6
Front fork inspection................................... 6-31
^ i i i
Steering inspection ..................................... 6-32
--l^ i i
Wheel bearings .......................................... 6-33
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Battery ....................................................... 6-33
-i
Fuse replacement ....................................... 6-36
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Headlight bulb replacement ........................ 6-37
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Turn signal and taillight bulb replacement ... 6-39
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Front wheel removal .................................... 6-40
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Front wheel installaion................................ 6-41
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Rear wheel removal .................................... 6-42
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Rear wheel installation ............................... 6-44
l lr i îi
|r =|
TABLE OF CONTENTS
Clutch lever free play adjustment..............6-22
i( i i ----
Front brake adjustment................... ...... 6-22
î i ----
Rear brake adjustment............................6-23
li i ----
Brake light switch adjustment..................6-24
i;- - (l-() i ----
Checking the brake shoes.......................6-24
i i i
Drive chain slack check...........................6-25
i;( i i i i
Drive chain slack adjustment.................. 6-26
i;( i i i ----
Drive chain lubrication............................. 6-28
i;( i -ii
Cable inspection and lubrication.............. 6-29
i i nii -ii
Throttle cable and grip lubrication........... 6-29
ii- i l^-ii
Brake and shift pedal lubrication............. 6-30
nii li- i -ii
Brake and clutch lever lubrication........... 6-30
nii i( i -ii
Center stand lubrication............................ 6-30
- -- i -ii
PG1_55.pmd 9/24/2005, 7:52 AM 7
TABLE OF CONTENTS
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Troubleshooting ............................................. 6-45
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Troubleshooting chart............................... .. 6-46
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7 CLEANING AND STORAGE.......................... 7-1
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A. Cleaning.................................................... 7-1
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B. Storage ..................................................... 7-3
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8 SPECIFICATIONS ......................................... 8-1
l((i9 9.........................................................
9 CUSTOMER INFORMATION ......................... 9-1
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Key identification number .............................. 9-1
ii i ri .
Frame serial number ..................................... 9-1
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Engine serial number ..................................... 9-1
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Facts related with Exhaust emission control .9-2
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Safety norms ................................................. 9-3
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Warranty 9-5
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10 DETACHMENTS
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Fifteenth paid service coupon............... 10-1
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Fourteenth paid service coupon............ 10-3
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Thirteenth paid service coupon.............. 10-5
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Twelveth paid service coupon............... 10-7
ir(i i^ni l(
Eleventh paid service coupon............... 10-9
ir(i i^ni l(
Tenth bonus free service coupon.......... 10-11
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Ninth bonus free service coupon........... 10-13
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Eighth paid service coupon................... 10-15
i-(i i^ni l(
Seventh paid service coupon................ 10-17
in(i i^ni l(
Sixth free service coupon...................... 10-19
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PG1_55.pmd 9/24/2005, 7:52 AM 8
GREEN BOOK
ril-ni
Address of Area Offices
- iii i ni
|r =|
TABLE OF CONTENTS
ALWAYS KEEP THE ENVIRONMENT CLEAN
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Fifth free service coupon.......................10-21
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Fourth free service coupon.................... 10-23
iii -nl(
Third free service coupon ....................... 10-25
nii -nl(
Second free service coupon................... 10-27
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First free service Coupon ....................... 10-29
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Pre-delivery inspection .......................... 10-31
l(i (ll-ii
Installation ............................................. 10-35
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Delivery certificate ................................. 10-37
l(i l-l- (-iii)
Service record........................................ 10-39
l( ((i) li
PG1_55.pmd 9/24/2005, 7:52 AM 9
SAFE RIDING
=|=rn =r|
1. Before riding, you should learn to ride your motorcycle properly and all the control functions should be
known to you.
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2. Remember that there are no legal rights when it comes to survival as far as Motorcyclists are
concerned. The fact that you may be well within your rights is no guarantee that you will avoid a
collision with a bigger vehicle whose driver fails to see you. Always ride defensively and take nothing
on road for granted.
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3. Develop the ability to react swiftly to any unexpected road hazards or emergencies giving yourself time
to spare for appropriate response.
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4. Develop the ability to get the most out of your Motorcycle, But at the same time get to know its
capabilities and limitations.
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ROAD SAFETY TIPS
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1.1
PG1_55.pmd 9/24/2005, 7:52 AM 10
5. Ride thoughtfully, planning your route well in advance.
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6. Give proper Signals and use Horn and Headlights judiciously.
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7. Dont ride in another motorists blind spot.
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8. Always make pre-ride safety checks before you start the Engine.
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SAFE BRAKING
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Use the basic methods of braking effectively.
l^ ri nii i i^ |
1. Engine Brake : When the Throttle is released, compression backs up and acts as the Engine Brake.
If the riding condition allows, reduce speed by shifting the Gear down.
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2. Front and Rear Brakes : It is important to apply equal force to the Front and Rear Brakes simultaneously.
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ROAD SAFETY TIPS
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1.2
PG1_55.pmd 9/24/2005, 7:52 AM 11
ROAD SAFETY TIPS
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1.3
CAUTION :
Use Front and Rear Brakes simultaneously.
Be sure not to disengage the clutch while braking.
While riding downhill always use Engine as a Brake and never ride in Neutral Gear.
While riding down hill do not switch off ignition while Engine is in gear.
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PG1_55.pmd 9/24/2005, 7:52 AM 12
SALIENT FEATURES
CRUX
1.4
FUEL TANK
Modern graphics
With knee grip
TRENDY MIRROR
360 swivel to suit rider
preference
COLOURS
Yamaha Black
Candy Maroon
IMPROVED TFF
With double lip oil seal
Comfortable suspension
BIG ROUND HEADLIGHT
Deep peneration & wider
illumination with multireflector.
Easily adjustable
Better aestetics
METER PANEL
User friendly
MUDGUARD
Chrome Plated
DOUBLE CRADLE
FRAME
For absolute
stabi l i ty and ruggedness.
ENGINE WITH ADVANCED
TECHNOLOGY
Power - 7.60 PS @7500 RPM
Torque - 0.80 mkgf @ 6000 RPM
Balanced, superior combination of
power and optimum fuel efficiency
thru improved carburetor
Use of AIS to meet Emission
Norms
NEW MUFFLER ASSY.
Meets 2005 Emission
Norms
Smoother exhaust beats
With protecor shield (safety)
Use of Catalyst
DIGITAL CDI
Digitally controlled ignition
for optimum combustion at
all speeds.
TRENDY INDICATORS
Better aesthetics
DOUBLE SADDLE
Extra long and cushined
Comfort for rider and pillion
rider
LOCKABLE SIDE
COVER L.H.
Modern Graphics
SafeStorage of
- Toolkit
- First aid kit
- Registration paper
LUGGAGE CARRIER
Carry 3 Kgs. Max.
PG1_55.pmd 9/24/2005, 7:52 AM 13
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CRUX
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PG1_55.pmd 9/24/2005, 7:52 AM 14
1 2 3 4 5 6 7
10 9 8
DESCRIPTION
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1. Fuel cock (page 3-6)
2. Choke Lever (page 3-7)
3. Fuse (page 6-36)
4. Battery (page 6-33)
5. Storage Compartment (page 3-9)
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6. Toolkit (page 6-1)
7. Handle Seat (Luggage Carrier) (page 3-10)
8. Drive chain free play check window (page 6-25)
9. Side panel (L.H.) lock (page 6-7)
10. Shift pedal (page 3-4)
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Left view
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PG1_55.pmd 9/24/2005, 7:52 AM 15
DESCRIPTION
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2.2
11. Rear shock absorber (page 3-9)
12. Air filter (page 6-14)
13. Kick starter (page 3-7)
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14. Seat (page 3-8)
15. Engine oil filler cap (page 6-11)
16. Rear brake pedal (page 3-4,6-23)
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14 11 12 13
16 15
PG1_55.pmd 9/24/2005, 7:52 AM 16
DESCRIPTION
| >rr,; c = c Control / Instruments
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17. Clutch lever (page 3-3)
18. Left handlebar switches (page 3-3)
With Pass Beam
19. Speedometer (page 3-2)
20. Main switch cum steering lock (page 3-1)
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-ii -i-
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21. Indicator (page 3-2, 3-3)
22. Indicator Lights (page 3-2, 3-3)
23. Front brake lever (page 3.4, 6-22)
24. Throttle grip (page 6-17)
25. Fuel tank cap (page 3-5)
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18
17
19 20 21
23
24
22
25
PG1_55.pmd 9/24/2005, 7:52 AM 17
Main switch cum steering lock
== c rrn c|n r+:
The main switch controls the ignition
and lighting system. Its operation is
described below.
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iili i llin ni r| ;i
l>i i i ^; r|
ON r +r :
Electrical circuit are switched on. The
engine can be started. The key cannot
be removed in this position.
li ii l- i r| ; i
li i ni r| ; rin - ii i
ir ri lii i ni r|
1. Push ii
2. Release ii
3. Turn i-ii
OFF +r :
Engine will be shut off. All electrical
circuits are switched off. The key can
be removed in this position.
; ri iî| li ii
l- r| ; rin - ii i
ir lii i ni r|
LOCK r+ +r :
The steering is locked in this position
and all electrical circuits are switched
off.
l--l^ ; (-ii - i ri ini r i
li ii l- ri in r |
The key can be removed in this
position.
; rin - ii i ir lii i
ni r|
To lock the steering, turn the
handlebars all the way to the left or
right. With the key at OFF, push it
into the main switch and release
it,turn it counterclockwise to LOCK
and remove it. To release the lock,
turn the key to OFF.
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WARNING
Never turn the key to LOCK when
the Motorcycle is moving.
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3.1
INSTRUMENT AND CONTROL FUNCTIONS
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PG1_55.pmd 9/24/2005, 7:52 AM 18
1. Speedometer -ii-i-
2. Odometer ii-i-
Speedometer
|=r=|c
The speedometer shows riding
speed.
-ii-i- -i-i; i ^ln i iini
r |
This speedometer is equipped with
an odometer.
; -ii-i- - ii-i- ii rini
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3.2
1. Neutral indicator light N
- ;l- i;-
2. Turn indicator light
- (-) l ;l- i;-
3. High beam indicator light
-i ii (ri; i-) l ;l- i;-
Indicator lights
;|=+c r;c=
Neutral indicator light N
-c ;|=+c r;c N :
This indicator comes on when the
transmission is in neutral.
-i-ii n--i (-) ri r
;l- lin rini r|
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Turn indicator light
== (c) + | ;|=+c r;c
The indicator flashes when the turn
switch is moved to the left or right.
;l- - i i; i(i i;
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High beam indicator light
n| +rr (;r; |=) +| ;|=+c r;c
This indicator comes on when the
headlight high beam is used.
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1
2
2
1
3
PG1_55.pmd 9/24/2005, 7:53 AM 19
1. Dimmer Switch
l-l-(
2. Light switch
i;- l-(
3. Turn signal cum cancellation
switch
l i(i l i
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4. Horn switch
ri i -
Handlebar switches
;=r + c
Dimmer switch
l- l-(
Turn the switch to for the high
beam and to for the low beam.
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Clutch lever
|
The clutch lever is located on the left
handlebar. 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.
i( r i i; n î ri ni r |
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r i i i ii nii i i
l i( i i | l>i i r
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Turn signal switch
=+n (|=) + c
To signal a right-hand turn, push the switch
to . To signal a left-hand turn, push
the switch to . 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.
i; i - i n l - i ;
lii i nii i; n - i
n l - i ; lii
i | ri - i i ^ - i i - i
i î| l i l (r-i ) l
- (il i - i i , ; i |
Horn switch
;r +r c
Press the switch to sound the horn.
ri i - i i |
Lights switch
r r| + c
Turning the light switch to , turns
on the meter light and taillight. Turning the
light switch to , turns the headlight
on also.
-i- i i;- nii i i i;- i
3.3
>r r |>rr =rn (r-=)
1
2
4
3
1
PG1_55.pmd 9/24/2005, 7:53 AM 20
Shift pedal |rc =
The shift pedal is located on the left
side of the engine and is used in
combination with the clutch when
shifting.
li- ; i; n î rini
r nii lil -^ - ii
;i i^ li ini r|
Use your toe or heel to shift up and
your toe to shift down.
; + i i -i l i i
i(i ^ lr- i i^ nii
i i i i l, (
^ lr- i ri i^ |
Rear brake pedal
|er + =
The rear brake pedal is on the right
side of the Motorcycle. Press down
on the brake pedal to apply the rear
brake.
li -i-i;l ii
n r| î l ;
i i n i|
Front brake lever
n| + +r |
The front brake lever is located on
the right handlebar. Pull it toward the
handlebar to apply the front brake.
î i i( i; n i r i
î rini r| î î
l ; ri i n ri iii|
USE BOTH BRAKES SIMULTANEOUSLY
rr + +r rn =rr=rr +|
3.4
>r r |>rr =rn (r-=)
1
1
1
1. Shift pedal li- 1. Front brake lever î i i( 1. Rear brake pedal li
PG1_55.pmd 9/24/2005, 7:53 AM 21
1. Open iii
Fuel tank cap
;=r +| c+| +r a+
TO OPEN ii l
Insert the key and turn it 1/4 turn
clockwise. The lock will be released
and the cap can be opened.
ii i ;- ii i iii; ii^
n, ; i; i; i in r
i-ii| nii (i) i iî nii
i ii iii i ni r|
TO CLOSE l :
Push the tank cap into position with
the key inserted. To remove the key,
turn it counterclockwise to the original
position.
1. Filter tube l-- -
2. Fuel level ;i i -n (()
Fuel ;=r
Make sure there is sufficient fuel in
the tank. Fill the fuel tank to the
bottom of the filter tube as shown in
the illustration
lln l -i in
;i r| i l li - iii î r|
;i - i l-- - l
lr- n i|
WARNING
Do not overfill the fuel tank, avoid
spilling fuel on the hot engine.
Do not fill fuel tank above the
bottom of the filter tube to avoid its
spillage.
ii i -i ()
i ii, ii ir li l
i; i; i i-in r ; ;i
ri ^r i|
NOTE:
This tank cap cannot be closed
unless the key is in the lock. The key
cannot be removed if the cap is not
locked properly.
r c:
^ ii i - ri ni -i
i ri li i ni|
l ri ni ri li
î ri ni, ii i ir ri lii
i ni|
WARNING
Be sure the cap is properly installed
and locked in place before riding
the Motorcycle
nr|
-i - i; i r r lln
l ( ) -ii -i nr -
î r i (i ) ri î r |
3.5
>r r |>rr =rn (r-=)
1
PG1_55.pmd 9/24/2005, 7:53 AM 22
nr|
;i i -i l-- -i i li
nr + i, ii ;i ^-
ri nii i - ; r -i
ir i ni r| rn r ;i i
^- ; l^ i|
CAUTION :
Always wipe off spilled fuel
immediately with a dry and clean soft
cloth. Fuel may deteriorate painted
surfaces or plastic parts.
1. Arrow mark ni i lii
Fuel cock (;=r) +r+
The fuel cock supplies fuel from the
tank to the carburetor while filtering
it also. The fuel cock has three
positions, which should be set as
shown in the illustrations.
i ;i i -i i- -
i iiii ; i i i- ii
ni r|
;i i i ni (-ii r lr ii ^
lii i (l-in i ilr|
OFF: With the fuel cock in this
position, fuel will not flow.
Always set the fuel cock to this
position when the engine is not
running.
i i i i i (-ii
- i ;i i i(i^-
iî| ; i ri ni
r-ii ;i ( i) i ;i
(-ii - (l-in |
ON : With the fuel cock in this
position, fuel flows to the
carburettor. Set the fuel cock to
this position when starting the
engine and while riding.
i i i i i i l-iln -
i ;i i- i n iî|
; i --i - i ri i
-i-i;l ii ri ni ;i
i i ;i (-ii - i |
IT IS A GOOD PRACTICE TO RETURN THE FUEL COCK LEVER TO OFF POSITION WHEN ENGINE IS NOT RUNNING
; r ;rn = ;r nr +r+ + | +r r= 'r' +| |r|n = r+ =rr + -e| rn ;
3.6
>r r |>rr =rn (r-=)
rr;i i nn -i- i
i rini i | ;i
- i r; nr ( il-- ii
i ii ni r|
=r=rr|:
Recommended Fuel (|=rqn ; =r):
Regular gasoline (Petrol)
i-i ( - i )
Fuel tank capacity (;=r c+| +| =r>rr):
Total () : 11.0L
Reserve (l ( ) : 1.4L
OFF ON
1
1
PG1_55.pmd 9/24/2005, 7:53 AM 23
1. Choke lever i i(
Choke lever r+ |
Starting a cold engine requires a
richer air-fuel mixture. A separate
starter circuit supplies this mixture.
- ; i i (--i-) l
-li r(i nii ;ii l-i i
i(ni rini r| ^ --i-
l- ; l-i i l(ni (i;)
ni r|
Push the Choke Lever in DOWN
direction to turn ON choke.
i i l-iln - i li
i( i i i lii - ii|
RES: This indicates reserve. If you
run out of fuel while riding, set
the fuel cock to this position.
Fill the tank at the first oppor-
tunity. Be sue to set the fuel
cock back to ON after refuel-
ing.
l( r l( i iini r| l
-i -i;l in r ; i
-in rini ri ^ ni ;i i
i i l( i (-ii -
i| ri -ii l-n ri, -i
i i(i | -i i(i
i -i i i l i
lii i|
1. Kick starter l --i-
Push the Choke Lever in UP
direction to turn OFF choke.
i i( i (i)
l ; + i lii - -i|
Kick-starter |++ crc
Raise the right footrest, and rotate
the kick starter away from the engine.
Push the kick starter down lightly with
your foot until the gears engage, then
kick smoothly and forcefully to start
the engine. This model has a
primary-coupled kick starter so the
engine can be started in any gear if
the clutch is disengaged. However,
shifting to neutral before starting is
recommended.
3.7
>r r |>rr =rn (r-=)
RES
1
1
NEVER MIX OIL IN PETROL cr = n +-r| |=r|
PG1_55.pmd 9/24/2005, 7:53 AM 24
ALWAYS USE A HELMET WHILE RIDING FOR YOUR SAFETY
r>rr +n == | ==rr + | ;=rr ;=c +r rn +|
1. Seat Holder i- ri-
2. Projection ii
i^ i n li-in r i|
To install =|c +r nrr
Insert the projection on the rear of
seat in to seat holder. Then push
down on front of the seat and tighten
the bolts on the left and right hand
side of the seat.
ii i i- l lr-
+ i- ri- - -i| i,
i- i i^ i i i i i
n i nii i i i- i i;
nii i; n |
1. Open ii
2. Open ii
Opening of Seat
=|c +r =rrr
To remove r-i l
Open side panels as per
instructions on page 6-8.
i- r-i l 6-8 l ^
lii i i;i i ii|
Remove the two bolts 1 and 2 as
shown in figure. Lift the front of the
seat and slide forward to remove.
ii ^ li i 1 ( 2 i--i
i ii | i- ^ lr- i +
i i -i nii ; r-i l
i; n --- i + i i
-i nii l --i- i ;
i| l --i- i i( i i
n i n l l^ i i
- -( ri i, n ; i i
(--i-) l l i rni
i i î i| ; -i
- iil- i ri l--i-
rini r, l ; i li ii î
-, ^ ri i l-iln - ii
--i- (i) li i ni r| l
; --i- r l^ i
- i (-ii - i i
lili i ini r|
3.8
>r r |>rr =rn (r-=)
2
1
1
2
PG1_55.pmd 9/24/2005, 7:53 AM 25
1. Storage compartment
iii -i
3.9
>r r |>rr =rn (r-=)
1
1. Rear Shock Absorber
l i ii i
Rear Shock Absorber
| er rr+ r
Fixed Type - No adjustment required.
-ii i i (l-in i
i(ni ri r|
Storage compartment
-r=rr +=r
The storage compartment is located
inside the L.H. Side Cover.
iii -i, i i; (
-iiln li î r|
1
PG1_55.pmd 9/24/2005, 7:53 AM 26
1. HandleSeat (Luggage Carrier)
ri- (^ l)
Handle Seat (Luggage Carrier)/
Assist Grip
; ==|c (n + |),|=c |n
Maximum load carrying capacity - 3.0
Kgs.
( i i lin- -i-ni 3.0 l.î.
3.10
>r r |>rr =rn (r-=)
1
PG1_55.pmd 9/24/2005, 7:53 AM 27
Owners are personally responsible for their vehicles condition. Your Motorcycles vital functions can start to deteriorate
quickly and unexpectedly-even if it remains unused (for instance, if it is exposed to the elements). Any damage, fluid
leak or loss of tyre pressure could have serious consequence Therefore it is very important that, in addition to a
thorough visual inspection, you check the following points before each ride.
PRE-OPERATION CHECKS
PRE-OPERATION CHECK LIST
ITEM PAGE CHECKS
Front brake
Rear brake
Clutch
Throttle grip and housing
Engine oil
Drive chain
Wheels and tyres
Control and meter cable
Brake and shift pedal shafts
Check tyre pressure, wear, damage and spoke tightness.
Tighten spokes if necessary.
Check operation, condition and free play.
Adjust if necessary.
Check for smooth operation.
Lubricate if necessary.
Check oil level.
Fill with oil if necessary.
Check chain slack and condition.
3-4, 6-22
3-4, 6-23
3-3-, 6-22
6-17, 6-29
6-11, 6-12
6-29
6-30
6-25, 6-26
6-18 6-21
4.1
PG1_55.pmd 9/24/2005, 7:53 AM 28
4.2
PRE-OPERATION CHECKS
IF WAITING AT TRAFFIC SIGNAL IS FOR LONG, SWITCH OFF THE ENGINE TO PROTECT
THE ENVIRONMENT AND TO LOWER FUEL CONSUMPTION
NOTE :
Pre-operator checks should be made each time the Motorcycle is used. Such an inspection can be accomplished
in a very short time; and the added safety it assures is more than worth the time involved.
WARNING
If any item in the Pre-Operation Check is not working properly, have it inspected and repaired before operating
the Motorcycle.
ITEM PAGE CHECKS
Brake and clutch lever pivots
Center stand pivot
Chassis fasteners
Fuel Tank
Lights, signals and switches
Battery
Check for proper operation.
Make sure that all nuts, bolts, and screws are properly tightened
Tighten if necessary.
Check fuel level.
Fill with fuel if necessary.
6-30
6-30
-
3-5, 3.6
3-2, 6-37
6-33 6-35
Check fluid level.
Fill with distilled water if necessary.
PG1_55.pmd 9/24/2005, 7:53 AM 29
4.3
+r r
(ir -il, -i- i; i rin l -( ri l-i r| l r i^ - ii ri ii ini r, n ii
ii -i- i; i i( l>ii i --in nii ni(ni -i rii i ri ni r| (irin - n-(i
ii, r(i nii l ;-il) - i li ii nr i -iln, ( i li, -i - - i( îi lii-
ri n r| n r lni( r l in l-^n i iiii - iii r, i lllin i;-i
ii i |
+r r|c
n a r
n +
|e +
rrc |n nrr ;r=|=n

; r
=r;
|; nrr cr
|>rr nrr =|c +| nr
+ nrr |rc = rrc
li, l-iln nii i i i |
l i( ri ni, -- |
rl>i l i|
i( ri ni ii |
n -n () i i |
l i( ri ni ;- n ;-il i|
i lilini ( l-iln i i |
i( ri ni ii |
l i( ri ni, -- |
i-i i l i |
l i( ri ni nî il i- |
i-i i l i |
i( ri ni i- |
l i( ri ni, -- |
l i( ri ni, -- |
l i( ri ni nili i |
-i i(, lii(, -iln nii lr i nili i( i i |
3-4, 6-22
3-4, 6-23
3-3-, 6-22
6-17, 6-29
6-11, 6-12
6-29
6-30
6-25, 6-26
6-18 6-21
PG1_55.pmd 9/24/2005, 7:53 AM 30
+r r
| c|+|= rr n+ =+r = r nr rnrr +r =|=rn r nrr ;=r +| =rn +r += +
+ | ; +r + |
4.4
+ nrr | + |c ()
=c c= |c ()
|== + cr-c r|
;=r +| c+|
r;c, |=n nrr c
c|
i-i l>i l i|.
l i( ri ni i- |
ln l>i l i |
lln l r nr -, i--, ri ni ^ r|
l i( ri ni |
;i i -n i |
l i( ri ni ;i i |
i-i l>i l i|.
l i( ri ni i- |
-n i i |
l i( ri ni ll-- (i- i |
n a r
rc :
r i, ii -i- i;l i^ , i( i ( i ilr| ; nr i i rn - -
i i i ni r nii ; nr i lnln -ii - î i -ii li l((i rini r|
nr|
| +r r = +r; | a|+ n; = +r= + ;| ;r nr =rc=r;|+ r = ; ;=+r ||=rr nrr
=-=n +r |
6-30
6-30
-
3-5, 3-6
3-2, 6-37
6-33 6-35
PG1_55.pmd 9/24/2005, 7:53 AM 31
OPERATION AND IMPORTANT RIDING POINTS
2. |+=| =r>r = | nr=| + ;
+r nr +-r| crc + rr ;|
;= rr == n+ nr ; |
; = r; |+ rr =rr
|rr ;rnr ; nrr rr= == = ;|
nr rr = +r +rr
=+nr ;| ;=rr | =rc=r;|+
+r r-n ;rr n; ;| crc
+|
Starting and warming up a cold
engine
a = ; +r cr c +r nr r
=r|=r| n= +r
1. Turn the fuel cock to ON
;i i i i i lii
i|
2. Turn the main switch to ON
- l-( i i lii
i |
3. Shift the transmission into neu-
tral.
- i -ii (î ) i - -
l(lnn |
NOTE :
When the transmission is in neutral,
the neutral indicator light should be
on. If the light does not come on, ask
a YMIS dealer to inspect it.
rc:
-i-ii -(-ii - ri ni
- i ;i- i;- ii i ilr|
l i;- ri ni r ni (i;.-.i;.
. i ;i i i r|
4. Fully press down Choke Lever and
completely close the throttle grip.
i i( i -i nr i i
i i nr i nii ii-l^
i |
5. Kick the kick starter to start the
engine.
; i --i - l
l--i- l î|
6. Ride your Motorcycle with choke
remaining in ON position for
some distance*
iii i n i i i i (-ii -
in r i -i-i;l i i|
WARNING
1. Before riding this Motorcycle,
become thoroughly familiar with
all operating controls and their
functions. Consult a YMIS dealer
regarding any control or function
that you do not thoroughly
understand.
2. 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 you Motorcycle
in an area with adequate
ventilation.
nr|
1. ;= =rc=r;|+ +r r = ;
;=+ =-r| +r==r| |>rrr nrr
=+ =rnr = ||n ;r | |+=|
|>rr rr =rn + | n; =
== = r ;= ==r =
r; .=.r; . =. =| = r=r + |
5.1
+r nrr =r| = = r+ n
PG1_55.pmd 9/24/2005, 7:53 AM 32
rc:
^ ; --i- i( r
(= i lii -) ii- ,ii
i-i lnl>i ni r ni ; ^-
r |
Starting a warm engine.
rr=r n= ; ; +r crc +r|
The Choke Lever may not be
required when the engine is warm.
; ^- ri ni i i( i
i(ni ri r ini r|
CAUTION :
See the Running-in section prior to
operating the Motorcycle for the first
time.
=r=rr| :
ri i i^ r l^ ;
i i |
(*The distance will vary as per the
climatic conditions of your area.)
(r i i -ii (ini(i
li r|)
7. Lift Choke Level to OFF position
immediately after the Engine is
warm.
; ^- ri nn i ri
i i( i i lii
i|
NOTE :
For better engine performance
always warm up the engine. Before
take off. Never open throttle fully
when engine is cold, otherwise
engine tends to stop.
rc :
r, ; i rn i-i-ni
l r-ii ; iiii ^- |
ii ii ; -i ri ni ii- i
i nr ii, ii ; ri
ni r|
NOTE :
The engine is warm when it
responds normally to the throttle with
the Starter Lever in UP direction.
1. Shift pedal li-
2. Neutral -
Shifting |r|cn
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.
-i-ii ,ii iln i -iii
i lii in r i i -, n ^ln
- nii +i; - ;-il -
i ^; ^ln i rini r|
li- i i^ li - iii
î r|
To shift into neutral, depress the shift
pedal repeatedly until it reaches the
end of its travel, then raise the pedal
slightly.
5.2
+r nrr =r| = = r+ n
PG1_55.pmd 9/24/2005, 7:53 AM 33
î i - - i l
li- i n n i i i
in r n l r ln-
i( n r i| i
i iii + i i -i |
CAUTION :
1. Do not ride down hill with
ignition switch in OFF position
and in neutral gear. Always ride
motorcycle with ignition switch
in ON Position & while engine
is in gear.
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.
=r=rr| :
1. ar =nn == ; +r
+ (;|r | +r r
r|r ) =rc=r;+ -c
= -r| +|
ar =nn == ;=rr ;
+r r =r (;|r | +r r
r |r ) =r c=r; + +r
n| = =r|
2. n| n == ;=rr +r
rn +| ;, c r==|r nrr
= r; r; ;= n; = |=r;
;| |+ n ; |+ ; n ;
r|=r+ rr +r =; + =+
+| |r|n = ;rn ; nrr |r|cn
+n == + rn +
= =r|nnn ;r =+n ;|
NEVER RIDE MOTORCYCLE WITH CLUTCH PARTIALLY ENGAGED.
'' + r|r+ = = = ;r +| |r|n = =rc=r;|+ +-r| r|
5.3
+r nrr =r| = = r+ n
PG1_55.pmd 9/24/2005, 7:53 AM 34
Tips for reducing fuel
consumption
;=r +| =rn += + + |c-=
Your Motorcycles fuel consumption
depends to a large extent on your
riding style.
ii -i-i;l - ;i i in,
i i ni li ni r|
The following tips can help reduce fuel
consumption :
i l ^ l- (l(lii) ;i i in
i - - ri ri n r :
1. Warm up the engine before riding.
-i-i;l i r ;
i iii ^- |
2. Lift up the Choke Lever as soon
as possible.
lni -i i( ri i i( i
+ i n -i |
3. Shift up swiftly and avoid high
engine speeds during
acceleration.
î ni i ^ln in
- ; i n li -i
|
4. Do not double-clutch or rev the
engine while shifting down and
avoid high engine speeds with
no load on the engine.
îi i l î - in -
i i^ | nii
; i ri i l-iln -
; ni( (^ |
5. Turn off the engine instead of
letting it idle for an extended
length of time, i.e. in traffic jams,
at traffic lights or rail-road
crossings.
i ii n i ri ni
; i i; n r i
-ii |
iri - l i- - ,i -ii
, ( >il^ ;-il|
6. Do not drive with excessive load
on the Motorcycle.
- i l i ( i i
-i-i;l i|
7. Plan your route in advance.
iii-i^ i ii r
ri i |
8. Avoid frequent braking.
ii î |
9. Always maintain your tyre
pressure as per
recommendation.
i l -nil(n (lili) li
î r, r-ii -i - r(i
i( i i i|
10.Get your motorcycle serviced
periodically after every 2000 kms.
- 2000 l.-i. ni -
i-l -i-i;l i
l( (i|
Running-in |n;
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 various
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. 5.4
+r nrr =r| = = r+ n
PG1_55.pmd 9/24/2005, 7:53 AM 35
The exhaust system is hot. Park
the Motorcycle in a place where
pedestrains or children are not
likely to touch the Motorcycle.Do
not park the Motorcycle on a slope
or soft ground; the Motorcycle may
overturn.
nr|
rc|=c= (=rr r| + |+r=
+| rr|) n= ;rn| ;| =rc=r;|+
+r =| n; =r=r + ;r ;
rr rr -r + =+
= r r| =rc=r;|+ +r
ar r| rr = n; =r=r
+ -rr ; =c =+n| ;|
CAUTION :
Be sure to replace the engine oil as
per recommended schedule.
=r=rr| :
; + n +r nr|n |r=
(=|) + =r |
i -i-i;l i( - 0
1,000 l.-i. i i - (ili
-r-(i r| ;i ii r-ii ni( r
l i lllin i i |
ii 1,000 l.-i. n ; +
-li ( ri ii ilr| ln
il-^ i n i l ;
l(li ii^ ; (ii - -( lin
i ili ri in r| ; (li -
i iiii (l>i) i(i ;
-ili ^- ri (ii l-inii
i ilr|
5.5
IT IS NOT RECOMMENDED TO RIDE THE MOTORCYCLE WITH CONSTANT THROTTLE
OPENING FOR VERY LONG DISTANCE
1,000 km and below :
Avoid prolonged full-throttle
o p e r a t i o n . Va r y s p e e d
occasionally.
1,000 l.-i. nii -
l(-n n i ii- l>i |
( i ^ln n r|
CAUTION :
If any engine trouble should occurs
during the Running-in period,
consult a YMIS dealer immediately.
=r=rr| :
| |n; (>|=+) == + rr
; = +r; =r r| rn| ; nr
r;.=.r;.=. =| = =+ +|
Parking
When parking the Motorcycle, stop
the engine and remove the ignition
key. Turn the fuel cock to OFF
whenever stopping the engine.
+r nrr =r| = = r+ n
i i ri ni, i i
i -ii i|
r|+ n
-i-i;l i ii n - ;
i nii ;îi (() i
ii i ir li | ii ;
WARNING
PG1_55.pmd 9/24/2005, 7:53 AM 36
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
I NTO CONSI DERATI ON THAT
WEAT HE R, T E RRA I N,
G E O G R A P H I C A L
LOCATI ONS, AND A VARI ETY
OF I NDI VI DUAL USES ALL
T E ND T O DE MA ND T HAT
EACH OWNER ALTER THI S
T I ME S CHE DUL E T O
SHORT ER I NT ERVAL S T O
MATCH THE ENVI RONMENT.
The most important points of
Motorcycle inspection, adjustment,
and lubrication are explained in the
following pages.
-- i ^; i, ----
(ni- ), nii - i i, ii
-i-i;l i ln l-in nii ri
n i( ri, -i- (-ii - iî|
-i-i; l -il i i
l-ii r| iii(, -ii i
i- i i-i --i nii -ii
(-ii l îini î; i
nr -ni ilr| ii r in
i - ii ilr l -i-, i l-,
iiîl -ii nii ln ,ii li ni
i^ il ii r -i^ n r l
r -i-i;l -il -iri i
i i l -i i
ii ii - n (ni) -
l(lnn ni r| -i-i;l i
i, ----, nii -ii ln
-r-(i ii i (i ^ -i
li î r|
WARNING
If you are not familiar with
Motorcycle service, this work
should be done by a YMIS DEALER.
nr|
| r =rc=r;|+ +| '=|=' +
+ n|+r = ||n ;| ; nr ; +r
r;.=.r;.=. =| +r ;| + |
1. Tool kit -l-
Tool kit c|+c
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 owners 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.
; îrl-ni ii =|= i
i ri i i r i i
-i-i;l -il i i i
i ii nil -i-i l nii
l(l-( --i (lni iii()
6.1
PERIODIC MAINTENANCE AND MINOR REPAIR
=r=|+ =r=rr nrr =r=| =-=n
1
PG1_55.pmd 9/24/2005, 7:53 AM 37
KEEP YOUR MOTORCYCLE TUNED IN PERFECT CONDITION
| =rc=r;|+ +r ; n; = -e| ;rn = =r|
6.2
=r=|+ =r=rr nrr =r=| =-=n
i i i l i i |
-i-i;l -il i -l- -
i l ^ ii ii -;
iii( i i- - rini n
r| l --i (iii() i ri
ni i l -i
ii rii ii i r|
NOTE :
If you do not have necessary tools
required during a service operation,
take your Motorcycle to a YMIS dealer
for service.
rc :
l l(i l i i
i( ii (i) ri r ni i
-i-i; l i (i; .-.i; . i
i i|
WARNING
Modifications to this Motorcycle not
approved by YMIS may cause loss
of performance, and render it
unsafe for use. Consult a YMIS dealer
before attempting any changes.
nr|
r;.=.r;. =| +| |q|n + |r
=rc=r;|+ = |+=| n; +r r
+r +r+rnr + | ;r|+r+ ;r
=+nr ; | |+=| -r| n; + |n
+ = ; r;.=.r;.=. =| =
r=r |
PG1_55.pmd 9/24/2005, 7:53 AM 38
PREVENTIVE MAINTENANCE SCHEDULE
S.NO. ITEM OPERATION
1. VALVES
2. SPARK PLUG
3. CARBURETOR
4. AIR FILTER*
5. FUEL LINE
6. FUEL FILTER
7. ENGINE OIL
8.
9.
10.
11. CLUTCH
12.
13. WHEELS
Check valve clearances, adjust if necessary.
Check condition, gap;
Clean and reset if necessary.
Check idle speed, Choke lever operation.
Clean, inspect & lubricate. (Replace if necessary)
Check fuel hose, for cracks or damage.
Replace if necessary.
Replace with recommended oil - Yamalube SG Grade
(Warm engine before draining)
Wash with petrol
Check operation./Adjust if necessary.
Grease the brake cam.
Check for wear, replace if necessary.
Check alignment marks on Push Lever and
Crankcase L.H. Adjust if necessary.
Check Rear Arm assembly for looseness.
Tighten with specified Torque if necessary.
Check runout, spoke tightness, damage;
Correct it, if necessary.
Check for free flow of petrol, cleanliness of filter bowl,
ENGINE OIL
FILTER SCREEN
BRAKE FRONT
& REAR
BRAKE SHOES-
FRONT & REAR
REAR ARM
PIVOT
REPLACE EVERY 10,000 km

SERVICE
FREE PAID
EVERY
2000
KM
I-VI VII-VIII IX-X XI-XV
BONUS
FREE
PAID
6.3
=r=|+ =r=rr nrr =r=| =-=n

PG1_55.pmd 9/24/2005, 7:53 AM 39
6.4
14. WHEEL BEARING
15. STEERING BEARING
16. FRONT FORKS
17.
18. DRIVE CHAIN
19.
20.
21. BATTERY
22.
S.NO. ITEM OPERATION
SERVICE
FREE PAID
EVERY
2000
KM
Check Bearing assembly for looseness, damage;
Check Bearing assembly for looseness;
Correct if necessary.
Check operation/oil leakage. Repair if necessary.
Check all Chassis fittings and fasteners for looseness
Tighten as per specification.
Check operation and lubricate if necessary.
Check electrolyte level and top it up if necessary.
Check specific gravity and charge if required.
Check breather pipe for blockage and routing.
Check operation, free play, cable damage
Readjust or replace as required.
Check chain slack, alignment. Adjust if necessary.
Clean & lubricate periodically.
CONTROL CABLES
-THROTTLE
-CLUTCH
-FRONT BRAKE
EVERY 10,000 km

ABSORBER
REAR SHOCK
NUTS, BOLTS AND
FASTENERS
CENTER STAND
Replace grease
Replace grease
Replace oil
EVERY 10,000 km
EVERY 10,000 km
EVERY MONTH
PREVENTIVE MAINTENANCE SCHEDULE
IT IS RECOMMENDED THAT THE ABOVE BE SERVICED BY AUTHORIZED YMIS DEALER.
SERVICE MORE FREQUENTLY WHEN THE VEHICLE IS DRIVEN IN DUSTY AREAS.
I-VI VII-VIII IX-X XI-XV
BONUS
FREE
PAID

Check operation/oil leakage. Repair if necessary.
*
=r=|+ =r=rr nrr =r=| =-=n
PG1_55.pmd 9/24/2005, 7:53 AM 40
6.5
||c =|c= (|n=r =r=rr) =|
1. r-
2. r+ -n
3. +rrc
4. |-c *
5. r;
6. |-c
7. ; r
8.
9.
10.
11.
12.
13. |;
(i-( i i i i |
l i( ri ni (l-in |
l-iln ( ^ i i |
l i( ri ni i |
i i( i i nii ii ^ln i i |
l i( ri ni ri |
l-- i i , i; ( -i-
l i( ri ni |
ri i -iln nii ii l i|
l i( ri ni |
i i i | l i( ri ni (l-in |
( i - î î|)
-i ii|
li n i i (ii i- i i i i |
l i( ri ni ll- -i |
lii( l i|
l i( ri ni |
i; i > nii i i( ln; (i;--)
lri i i | l i( ri ni (l-in |
i+-, niii i( nii -iln i i |
l i( ri ni -i |
-i ri(, l-- i+ i ii; i i |
l i( ri ni |
; r
|-c >|
|e| nrr
n| +
n
|e + r
|e|
r= |c
+ 10,000 |+.=|.

-nil( n |
(r n i ri r ; i iii ^- )
I-VI VII-VIII
=r
= n
+
2000
|+.=|.
IX-X XI-XV
-r nnr r= = n -r nnr

n +r (rr)
>=
= =r
=r=|+ =r=rr nrr =r=| =-=n
PG1_55.pmd 9/24/2005, 7:53 AM 41
14. |; + |n
15. c||n + |n
16. n r+
18. =r;
19.
20.
21. c|
22.
I-VI VII-VIII
-iln ( i l l^ i i i |
l i( ri ni |
lilini l l^ i i i |
l i( ri ni -i |
i i i(i n li( i i |
l i( ri ni ;i --n |
iii i i(i n li( i i |
l i( ri ni ;i --n |
l i ii ll-^ i i-- i lilini l i|
-ii i |
i i i |
l i( ri ni i- |
;-ii;- -n (() i i | l i( ri ni
; + -n n i | il-in i-( i i |l
i( ri ni ; i | (i i (i i;) i
i(- ( ri -i^ l ll-ii |
i lilini, ln;ni i i|
i i i- |
|>rr +
rrc

n| +

|e rr+r
c, r-c nrr
rc=
=cc=
l î i|
l î i|
n |
+ =r=
r -nil(n li ini r l in ii (i lin (i;.-.i;.. i ,ii ri i ii ilr|
(ir (-i-i;l) i ni ;ii - i li iiini l( i|
||c =|c= (|n=r =r=rr) =|
n +r (rr)
=r
= n
+
2000
|+.=|.
>=
= =r
-iln, i, ( i i i |
-i^ i(i i|
+ 10,000 |+.=|.
+ 10,000 |+.=|.
*
IX-X XI-XV
-r nnr -r nnr r= = n

6.6
=r=|+ =r=rr nrr =r=| =-=n
+ 10,000 |+.=|.
17.
PG1_55.pmd 9/24/2005, 7:53 AM 42
1. Panel A
Panel removal and
installation
+r ;crr nrr nrr
The panels illustrated need to be
removed to perform some of the
maintenance described in this
manual. Refer to this section each
time a panel has to be removed or
reinstalled.
i i ^ l i i i ;
îrl-ni - iii( l(i -
i ii nii î r l
i i r-i i n ni r|
ii i r-ii ri ni ; i i
rini |
1. Panel B i
1. Lug ^
2. Panel A
3. Panel Lock i i (nii)
Removal of Panel A
'' +r ;crr
Unlock the panel.
Pull the lug 1 towards you to remove
it from the fuel tank.
Slide the panel A towards the rear
end of the motorcycle for removing
the lug 2 to free the panel.
i (ni) i ii| i
;i i -i ^ r-i l ^
. 1 i i n ii| ^ . 2
i r-i ( i -(ni
^ l i
-i-i;l i li n lii|
6.7
=r=|+ =r=rr nrr =r=| =-=n
1
2
2
1
3
PG1_55.pmd 9/24/2005, 7:53 AM 43
1. Lug ^
2. Panel B i
Removal of Panel B
| +r ;crr
Loosen screw and follow the same
procedure as for removing panel A.
i ii nii (ri nii
i, l i r-i - n
li r|
1. Lug ^
2. Lug ^
Installation of Panel A
'' +r nrr
Slide the panel towards the front of
the motorcycle for inserting the lug
in the slot given in the frame.
Insert and push the lug in the fuel
tank ensuring proper seating.
After proper seating of the panel A,
lock it.
- - l ^ ii (-i-) - ^ .
i -i l i -i-i;l
i- i i ii|
ri nr - l ^ i
; i i -i - -i i i i i
i ; i |
ri ^ - ri i ;
i |
1. Lug ^
2. Lug ^
Installation of Panel B
'|' +r nrr
Following the same procedure as
given for installation of panel A and
tighten the screw for locking.
i î l i nii
ii r, i l i ni
i i i i |
6.8
=r=|+ =r=rr nrr =r=| =-=n
1
2
1 2
1
2
PG1_55.pmd 9/24/2005, 7:53 AM 44
1. Spark plug gap -i ^ i ^
Spark plug inspection
r+ -n +r ||=rr
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 medium-to-light tan color for a
Motorcycle that is being ridden
Normally. Do not attempt to diagnose
any problems yourself. Instead, take
the Motorcycle to a YMIS 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
Before installing the spark plug,
measure the electrode gap with a
wire thickness gauge; adjust the gap
to specification as necessary.
-i ^ î r ;-i
(^) i (i ^ ,ii i | i
ii i( ri ; n i ll-i
((linl(li) (l-in |
.-i ^ i ^:0.9l-.-i.(-0.2 l-.-i.)
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.
^ în - r-ii ^l- n
i i nii i ^l- î|
i (i) î ^î i i i
i ; ll- -i n |
Specified spark plug
ll- li î -i ^
P-RA7HC (Champion)
6.9
A-Spark plug gap: 0.9mm(-0.2 mm)
deposits are excessive, you should
replace the spark plug with the
specified plug.
r+ -n ; i -r-(i i r
nii ;i i i rn i r|
-i ^ i l-iln ; i rin
i ni îi i ni r| i i
;-i ii n ;-
+ ii ^, --r-i ii r i
r ii ni r l -i-i; l i
i-in ri ni ii i ri
r| li i i --ii i li
l -( - |
-i-i;l i r;.=.r;.=. i
i i| ii --
^ ir li i i n
ri ilr, il +-i nii - r
i iiii -i ^ i i;ln
i ii n r i ; - n
r| l ;-i i li (+ i
lr-i) r n ii ii ri ini r
i(i ; i nii -i ii
i lini ini r ni ii ;
-i ^ i ll- l ^ ^
i ilr|
=r=|+ =r=rr nrr =r=| =-=n
PG1_55.pmd 9/24/2005, 7:53 AM 45
ALWAYS USE ONLY THE STANDARD RECOMMENDED MAKE AND TYPE OF SPARK PLUG.
;=rr + nr|+ =r|r+ r= + nrr rr r+ -n ;| rn +|
6.10
=r=|+ =r=rr nrr =r=| =-=n
Tighten torque i ri -i :
Spark plug -i ^ :
12 ft-lb (1.75 m-kg)
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 using a
box spanner.
rc :
-i ^ în - l -i
i ni rii i i
i- iii; iii i
n i-i|
PG1_55.pmd 9/24/2005, 7:53 AM 46
1. Engine oil filter cap
; i l--
Engine oil
; +r n
1. Oil level measurement
n -n i ii|
a. Place the Motorcycle on the
centerstand. Warm up the engine
for several minutes.
. -i-i;l i - -- ii
| ; i ; l--i n
iiii ^- |
1. Maximum level n- -n
2. Minimum level ln- -n
NOTE :
Wait a few minutes until the oil level
settles before checking.
rc :
i r n i i
-n (() l-i ri i n n
l--i l ni-ii |
NOTE :
Be sure the Motorcycle is positioned
straight up when checking the oil
level. A slight tilt toward the side can
result in false readings.
rc :
r lln l n i -n in
- -i-i;l i ^r iii
ii r| n i iii i ii
ni( r il^ ^n ri ni r|
ALWAYS CHANGE ENGINE OIL AT RECOMMENDED INTERVALS
FOR OPTIMUM ENGINE PERFORMANCE AND ENGINE LIFE
6.11
=r=|+ =r=rr nrr =r=| =-=n
PG1_55.pmd 9/24/2005, 7:53 AM 47
b. Unscrew the dipstick and rest it
on the threads of the oil filler hole.
The oil level should be between
the minimum and maximum
mark on the dipstick. If the level
is low, add oil to raise it to the
specified level.
i. lil-- i ii i ;
l l-i | i
i ( lil-- ln- (
n- lii - - rii ilr|
l ( - ^ ni ; i
l ll- -n n n i|
1. Dipstick ll--
2. Engine oil replacement
;n i i
a. Warm up the engine for a few
minutes.
l--i l ; i ^-
|
b. Stop the engine. Place an oil pan
under the engine and remove
the dipstick.
; i | ; i
i (n) i nii
lil-- i ir li |
; +| |=r+ +r=r=nr nrr |r | + | ;r +r ;=rr nr|n
nrr n ;|
6.12
=r=|+ =r=rr nrr =r=| =-=n
1
PG1_55.pmd 9/24/2005, 7:53 AM 48
1. Engine oil drain plug ; i ^
c. Remove the drain plug and drain
the oil.
^ i ii ir li
i n i l |
d. Reinstall the drain plug and
tighten it to the specified torque.
^ i l î i ;
ll- -i n |
f. 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.
; i i i l--i
l iii ^- n - n
li( i i | l n
i ri ri ni ; i nn
i ii i i |
ALWAYS CHANGE ENGINE OIL AT RECOMMENDED GRADE OF ENGINE OIL
;=rr + nr|+ n= +r ;r ;| rn +|
e. Fill engine with oil and install the
dipstick.
; i n i i lil--
i - î |
Tightening torque i î -i
Drain plug ^
14.5 Lt.-lb (2.0 m-kg)
Recommended oil:
YAMALUBE 4 stroke motor oil
(20 W 40 type SG) or equivalent.
Oil quantity:
Total amount : 1.1 L
Periodic oil change : 0.9 L
6.13
-nil( n
i-i-4 --i -i- i
(20 - 40 -i; i) i(i
-i)
n i -iii
-iii 1.1 l.
-- n -
l(n 0.9 l.
=r=|+ =r=rr nrr =r=| =-=n
1
PG1_55.pmd 9/24/2005, 7:53 AM 49
1. Air filter case cover l--
2. Screw ( 3) ( 3)
Air filter |-c
The air filter should be cleaned at
the specified intervals. It should be
cleaned more frequently when riding
in unusually wet or dusty areas.
l-- i ll- -i(iii
i n ri ilr| ni i(i
l(ii -i (i -iii - iii ii ;
ii i i ilr|
1. Remove panel B. (See page 6-8
for removal and installation
procedures.)
i i r-i (; î (
r-i i li l - .
6-8 i|
1. Air filter element l-- i--
2. Remove the air filter case fitting
screws and the air filter case
cover.
l-- - ^ r i
nii l-- (()
i ii ^ r-i |
3. Remove the spring wire.
l-^ (i i - ir li
|
4. Remove the air filter from the
case.
l-- i - ir
li |
6.14
1. Air filter element l-- i-- (2)
2. Frame -
3. Spring Wire l-^ (i
5. Remove the air filter elements
from the frame and clean them
with solvent (kerosene). After
cleaning, remove the remaining
solvent (kerosene) by squeezing
the elements.
l-- - lr-i i -
ir li i r i(
(l-;i n) i | i;
i r i( (l-;i
n) i - lr-i li
^ |
=r=|+ =r=rr nrr =r=| =-=n
2
1
1
PG1_55.pmd 9/24/2005, 7:53 AM 50
CAUTION :
Make sure the air filter is
properly seated in the air filter
case.
The engine should never be run
without the air filter installed.
Excessive piston and/or
cylinder wear may result.
Dirty Element Air Cleaner
causes excessive fuel
consumption and loss of
power.
Clean Element Air Cleaner after
every 2000 kms.
The Element Air Cleaner should
be cleaned and lubricated more
frequently (every 1000 km,s), if
Motorcycle is operated in very
dusty (e.g. unpaved, dust laden
roads) conditions.
=r=rr| :
; =||n + |+ |-c
=;| an = |-c += = a
r|
6. Apply recommended oil to the
entire surface of the each
element and squeeze out the
excess oil. They should be wet
but not dripping.
- - ii^ i i nr
-nil( n ri î i in
n li | ( (- ii^) î
ri ilr l n - r|
Recommended oil
-nil( n :
20W40 type SG
7. Pull the air filter elements over
the frame and install the air filter
in the case.
l-- i-- (-lr-i)
i - + ii nii
l-- i î
|
8. Install the Spring Wire.
l-^ (i ii î|
9. Install the air filter case cover and
panel
l-- ( i
i î |
6.15
=r=|+ =r=rr nrr =r=| =-=n
PG1_55.pmd 9/24/2005, 7:53 AM 51
|-c +r nr |r ;
+-r| -r| ;| rr r|;| ;=+
+rr |c r |== +r |r=r
|=r+ ;r =+nr ;|
=r |=| = -r n |=c
| = n +| =rn ;n a
rn| ; nrr r|n (r) +| =r|n
;rn| ;|
|=c | +r + 2000
|+.=|. + r =r +|
| =rc=r;|+ +r ;n =r|=|
n |r|nr = rr rnr ; nr
|=c | +| =r; nrr
-|+r rr r|rnr = ;rr
r|; (+ 1000 |+.=|. )|
Carburetor adjustment
+rrc +r =c +r
The carburetor is a vital part of the
engine and requires very
sophisticated adjustments. Most
adjustments should be left to a YMIS
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.
ii- ; i -r-(i ii^
rini r i ;i --- -
ni ,ii i ni r| rn i
--- - ( ni - ) i
r; .=.r; .=. i + i
i ilr, lr ; nr i i-
i in i( nii (il ni
r| l lllin i -i-i;l
i -il i- --n i nr
ni r|
6.16
CAUTION :
The carburetor is set at the YMIS
factory after many tests. If the
settings are changed, poor engine
performance and damage may
result.
=r=rr|:
+r cc + + r +rrc +r
r;.=.r;.=. +r=rr = |rn
|+r rnr ;| | ;=+| '=|cn' =
|n rr rnr ; nr ; ; +|
n-e +r=r=nr r =r|n +r +rr
=+n| ;|
Idle speed adjustment
rr n|n +| =c=c
NOTE :
A diagnostic tachometer must be
used for this procedure.
rc :
; li l iîl--
-i-i- i i^ li ii ilr|
1. Attach the tachometer. Start the
engine and warm it up for a few
minutes at approximately 1,000
to 1,500 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.
-i-i- î, ; i i
i l--i l ^- nil
;i ^ln 1,000 1,500
ln l-- n r i| iiii
; 4,000 5,000 ln
l-- ii i| ;
iii ni i i - i
ni r ni r ^- rini r |
=r=|+ =r=rr nrr =r=| =-=n
PG1_55.pmd 9/24/2005, 7:53 AM 52
Adjust the throttle cable by turning the
adjusting nut so that specified free
play at the throttle grip is obtained.
l--^ - i i-i ii-
i (l-in , l l ii- l^
l(li- -(n i in li i
|
Free play i
3 ~ 7 mm
NOTE :
If the specified idle cannot be
obtained by performing the above
adjustment, consult a YMIS dealer.
rc :
l in --- - i i
ii l(liii ^ln in ri
i i ni r ni r;.=.r;.=.
i |
Throttle cable free play
adjustment
rrc + +| | - =c=c
NOTE :
Before checking the throttle cable
free play, the engine idling speed
should be adjusted.
rc:
ii- i i i i
r, ; i ii ^ln i (l-in
li ii ilr|
1. Throttle stop screw
ii- i i i
2. Set the idle to the specified
engine speed by adjusting the
throttle stop screw. Turn the
screw in direction to increase
engine speed and in directions
to decrease engine speed.
ii- i i i i (l-in
n r ; i l(li- ^ln i
ii l-iln - i| ; i
^ln i l i i lii
- i-i| ; i ^ln i-i l
i i i lii - i-i|
Standard idle speed
-- ii ^ln :
1,300 ~ 1,500 ln l--
6.17
=r=|+ =r=rr nrr =r=| =-=n
PG1_55.pmd 9/24/2005, 7:53 AM 53
1. Tread depth - i
2. Side wall i; (i
Tyres cr
To ensure maximum performance, long
service and safe operation, note the
following:
-li i-i-ni, ii l( i l-in
i l lllin i
1. Tyre air pressure
Always check and correct the tyre
pressure before operating the
Motorcycle.
-i - r(i i i(
-i-i; l i r r- ii -i
- r(i i( i i i ;
(l-in |
1. Free play i
2. Locknut i -
3. Adjusting nut l--^ -
1. Loosen the locknut.
i - i ii |
2. Turn the adjusting nut in direction
to increase free play and in
direction to decrease free play.
i i i l l--^ -
i i lii - i-i nii i i
- l ; i lii - i-i|
3. Tighten the locknut.
i - i |
Valve clearance adjustment:
r- +| |= +r nr= :
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 YMIS
dealer.
ln (i-( i i l ; i^
ii ni rni r, ln ; i ,r(i
i i; i(i ; - ii i ii ni
r| ; l (i-( i i
îni (l-in n ri ilr| ( ;
nr --- - ( ni - ) i
r;.=.r;.=. i ,ii ri (ii ii
ilr|
KEEP RECOMMENDED TYRE PRESSURE IN BOTH THE TYRES
rr crr = =r|n rr ;| =r|
6.18
=r=|+ =r=rr nrr =r=| =-=n
1
2
3

PG1_55.pmd 9/24/2005, 7:53 AM 54

WARNING
Tyre inflation pressure should be
checked and adjusted when the
temperature of the tyre equals the
ambient air temperature. Tyre
i nfl ati on pressure must be
adjusted according to total weight
of cargo, rider, passenger, and
accessories (fairing, saddlebags,
etc. approved for this model), and
vehicle speed.
nr|
cr +r nr=r r+ (rr r)
+ r nr=r + r ;r r nr
cr + rr r +| r +|
r|;| cr + rr r +r
=r c =r ; | + =r =r =r ,
=rc=r; |+ r+, =rc=r; |+
=r nrr ==| (|n, nc| +
n ;r| r ;= =r= + =rr |qn
| + n ; ) + + r
=rc=r; |+ +| n|n + =r ;|
=c +r r|;|
WARNING
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
Motorcycles, and distribute the
weight evenly from side to side.
Check the conditionand pressure of
your tyres. NEVER OVERLOAD YOUR
MOTORCYCLE. Make sure the total
weight of the cargo, rider,
and accessories (fairing,
saddlebags, etc. approved for this
model) does not exceed the
maximum load of the Motorcycle.
Operation of an overloaded
Motorcycle could cause tyre
damage, an accident, or even injury.
nr|
r +| =r c =r ; | + +| +r
||rcnrr = |+ ; =|n, |+n,
+r=r=nr r ==rr + | =;| n|+
= r|=n r+ ;| a| n|+ =
r=r| n; (+ +| n;) nr, nr |+
;= r = == r | ;n| ; , =- ;
=rc=r;|+ r| =|=rn
an = + +| n; -rr|-r+= nr
+r =rc=r;|+ + | = =r r
=+ +r =rc=r;|+ + rr
n =r=r = = |-rr|n +| |
=rc=r;|+ + crr +| |r|n
;r + r +| -r| r + | +-r|
-r| | =rc=r;|+ =n =
rr =r| ; =||n +
|+ =r=r, =rc=r;|+ r+,
6.19
=r=|+ =r=rr nrr =r=| =-=n
-i -i i(:
90 l.î. n
90 kg ii ~
lin- ii*
î li
Cold tyre pressure:
Up to 90 kg
90 kg Load ~
maximum load*
Front Rear
25 psi
(1.75kg/cm
2
)
25 psi
(1.75 kg/cm
2
)
32 psi
(2.25 kg/cm
2
)
32 psi
(2.25 kg/cm
2
)
PG1_55.pmd 9/24/2005, 7:53 AM 55
r>r| (=r) r ==| r ;= =r=
+ | |qn |+ n ;, +r +
, =rc=r;|+ + |=r+n= r=
= rr ;r r| =rc=r;|+ +
|=r+n= r= = rr ;r r|
=rc=r;|+ +r 'rr=' +| |r|n
= r cr +r +=r ;r =+nr
;, rcr rc =+n| ;|
2. Tyre inspection
Always check the tyres before
operating the Motorcycle. If a tyre
tread shows crosswise lines
(minimum tread depth), if the tyre
has a nail or glass fragments in
it, or if the side wall is cracked,
contact a YMIS dealer
immediately and have the tyre
replaced.
-i i i
r-ii -i-i;l i r
-ii i i | l -i
i -, >i i r; i; iini
r (n- - ^ri;), l -i
i i(i iii - lii;
6.20
r ri i(i -i i;
> ^ ri ri ni n n
r;.=.r;.=. i
i -i i (i |
WARNING
1. It is dangerous to ride with a
worn-out tyre. When a tyre
tread begins to show wear,
have a YMIS dealer replace
the tyre immediately.
nr|
1. |r= ; cr + =rr nr=| rr
=rnr+ ;| cr = c== =
rr |r=r r= ;r r nr n-n
r;.=.r;.=. =| rr cr
|
=r=|+ =r=rr nrr =r=| =-=n
Minimum tyre tread
depth:
(front and rear)
1.0 mm
Rear tyre size l -i i i;:
2.75-18 6PR
Front tyre size ^ -i i i; :
2.50-18 4PR
n- -i - ^ri;
(î ( li)
pg56_96.pmd 9/24/2005, 7:53 AM 56
3. Ride at moderate speeds after
changing a tyre since the tyre
surface must first be broken in
for it to develop its optimal
characteristics.
-i i -i-i;l
i r-i -i ii ilr
l l -i - l-in l(li-nii
i -i(i ri l l- - -
i |
Wheels |;
To ensure maximum performance,
long service, and safe operation, note
the following
-ili iini, iii( nii
l-in i lln l
lllin ini i
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 YMIS dealer. Do not
attempt even small repairs to the
wheel. If a wheel is deformed or
cracked, it must be replaced.
r-ii -i-i;l i r
lri i i | lr -
6.21
2. ;; c |n (= +
c+=) nr +r nr|+ ;| |+r
nr ;| | =r +r ;n ;|
r+ ;r r, nr ; =r=rr|
n r |n| -| =-r ;r ;=
c +r + -e| r|c| +|
c = |
> , - i- i ri (i ;
lii( i i | lln
l lr i -i i r;
ri i -iln ^-n ri| l lr
- i; i-i l-iln lii; ni
r ni, (i;.-.i;.. i
ir | lr - -i-i i --n
i i i - |
l lri l(n ri î r i(i
- (>) î r ni ;
i ilr|
2. Tyre 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
tyre life.
ii -i i(i lri - li
i i î ri ni -i i
lr i nln rii ilr| lr
i rii, n i -i-ni,
l(in rl^ l(li-nii i -i
i l-i (-) - ri i ii
ni r|
=r=|+ =r=rr nrr =r=| =-=n
pg56_96.pmd 9/24/2005, 7:53 AM 57
1. Locknut i-
2. Adjusting Nut l--^ -
3. Free play i
Clutch lever free play
adjustment
| +| |- +|
=c=c
The clutch lever free play should
be adjusted to 10 ~ 15 mm. If the
free play is incorrect, adjust as
follows.
i( i i i 10 15
l-.-i. n -- i ilr| l
i ri i ri ri ni ; i l
^ ni --
1. Loosen the locknut.
i - i ii |
2. Turn the adjusting bolt at the
clutch lever in direction to
increase free play or in direction
to decrease free play.
i i l i(
l--^ i-- i i lii -
i-i i(i -(ni (i) i i-i
l i( i-- i i i
lii - i-i|
i - i |
NOTE :
If proper adjustment cannot be
obtained or the clutch does not work
correctly, ask a YMIS dealer to inspect
the internal clutch mechanism.
rc :
l ri ^ ---- ri ri i
ri ri i(i i ni i-
ni ri ni r;.=.r;.=. i
inl -l- i i
i r|
1. Locknut i-
2. Adjusting Bolt l--^ i--
3. Free play i
Front brake adjustment
n| + +| =c=c
The front brake level free play should
be adjusted to 10 ~ 15 mm.
^ i( i i i 10 15
l-.-i. n -- i ilr|
1. Loosen the locknut
i- i ii |
2. Turn the adjusting bolt in direction
to decrease free play and
direction to increase free play.
i - l l--^
i-- i i lii - i-i nii
i i i l ; i i
lii - i-i|
6.22
=r=|+ =r=rr nrr =r=| =-=n
1
2
1
2
3
pg56_96.pmd 9/24/2005, 7:53 AM 58
1. Adjusting Nut l--^ -
Rear brake adjustment
|e| + +| =c=c
The rear brake pedal free pl ay
should be adjusted to 20 ~ 30 mm
at the brake pedal end. Turn the
adj usti ng nut i n di recti on to
increase free play and in direction
to decrease free play.
li l
i i (ii) 20 30 l-.-i.
n -- i ilr| i
(ii) i i l l--^
- i i lii - i-i i i
(ii) i - l - i
i i lii - i-i|
a. Freeplay i
WARNING
When it is impossible to make
the proper adjustment, ask a
YMIS dealer.
Check the operation of the
brake light after adjusting the
rear brake.
nr|
=;| n| + = =r =
(=c=c) rr|n +r =-r
n ;r ;r nr r; .=.r; .=. =|
= r=r +|
|e| + +r =c=c + +
r + r;c +| |>r +| r
+|
6.23
i - i |
WARNING
When it is impossible to make the
proper adjustment, ask a YMIS
dealer
nr|
| =;| n|+ = =c=c +r
=-r n ;r ;r nr r;.=.r;.=.
=| = rn +|
=r=|+ =r=rr nrr =r=| =-=n
pg56_96.pmd 9/24/2005, 7:53 AM 59

1. Wear limit line (i ll-- i;
2. Wear indicator (i ;i-
Checking the brake shoes
+ r +| r
A wear indicator is provided on each
brake. Thi s i ndi cat or al l ows
i nspecti on of shoe wear wi thout
disassembling the brake. Apply the
brake and inspect the position of the
indicator reaches to the wear limit
line, ask a YMIS dealer to replace
the shoes.
r l (i;i-
îi î r| r ;l- i li
ii r, i i i - ri rini
r| î i ;i- i (-ii
i li-ii | l ;i- (i i
i -i i i n r i ni r ni
(i; .-.i; .. i ; i i
n i r|
1. Brake light switch i;- i l-(
Brake light switch adjustment
+ r;c + | +| =c=c
The rear brake light switch is
activated by the brake pedal and is
properly adjusted when the brake
light comes on just before braking
takes effect. To adjust the rear brake
light switch, hold the switch body so
it does not rotate while turning the
adjusting nut.
Turn the adjusting nut in direction
to make the brake light come on
earlier.
Turn the adjusting nut in direction
to make the brake light come on later.
li i i;- i l-( (-)
l>il(n rini r i ;
nr -- li ini r l
^ i ii( li r ri i
-ii (i;-) -ni r| li
- (l-() i -- l
l-( i ; nr nil
l--^ - i iin - l-( i-
|
i;- i iiini r i
l l--^ - i i lii -
i-i|
i;- i i - i l
l--^ - i i i lii - i-i|
6.24
=r=|+ =r=rr nrr =r=| =-=n

1
2
2
1
pg56_96.pmd 9/24/2005, 7:53 AM 60
Inspect the drive chain when the
Motorcycle is on the centerstand.
Check the slack at the position
shown in the illustration. Normal
slack is approximately 20 ~ 30 mm.
If the slack exceeds 30 mm, adjust.
i;( i i nii
-i-i;l - -- ii ri|
ii ^ li i ri i
i i i | i-in ii
î^ 20 30 l-.-i. n rini r|
l r 30 l-.-i. ii li r ni ;
(l-in |
1. Wear limit line (i ll-- i;
2. Wear indicator (i ;i-
1. Free play i
Drive chain slack check
=r; +| |r|rnr +r ||=rr
NOTE :
Spin the wheel several times and find
the tightest position of the chain.
Check and/or adjust the chain slack
while its in this tightest position.
rc :
lr i ; i i-i i i
i r; riin - i|
i r; (-ii - ri ni ;i lilini
(ii) i i i(i ; --
|
6.25
=r=|+ =r=rr nrr =r=| =-=n
20~30 mm
1
2
1
pg56_96.pmd 9/24/2005, 7:53 AM 61
1. Chain joint i
If the chain is disassembled, be
sure the chain lock is placed in the
correct direction when installing.
l i ii ^ li
î r ni r lln l ; l
în - i i ri lii -
îi i|
2. Cotter pin i- l
3. Axle nut l i -
Driven chain slack adjustment
=r; +| a| +r =r=
(=c= c)
1. Loosen the rear brake pedal
free play adjusting nut.
li i
l--^ - i ii |
2. Remove the cotter pin from the
axle nut.
- i-l i ^
r-i |
3. Loosen the axle nut.
- i ii |
6.26
1. Locknut i -
2. Adjusting hex screw l--^ r
4. Loosen t he chai n adj ust i ng
locknuts on each chain puller.
To tighten the chain, turn the
chain adjusting hex screw in
di rect i on(a). To l oosen t he
chain, turn the chain adjusting
hex screw in direction (B) and
push the wheel forward. Turn
each chai n adj ust i ng hex
screw exactly the same amount
t o mai nt ai n correct axl e
alignment. There are marks on
each chain puller. Use these
makes to align the rear wheel.
- ^ l--^
i -i (i) i ii |
i l, l--^
=r=|+ =r=rr nrr =r=| =-=n
1
2
3
2
1
pg56_96.pmd 9/24/2005, 7:53 AM 62
6.27
=r=|+ =r=rr nrr =r=| =-=n
i- (r->) i i lii
- i-i nii ; ii ,
l--^ i- (r->) i
i i lii - i-i i lr
i^ i i i( i| i
ri i;- - ( ln;ni) i
lniln (--) l -
l--^ i- (r->)
i -i nr -i i n
i-i| - lii
^ r r| l lr i ri
nr î l ; lri i
i^ |
CAUTION :
Mai ntai n chai n sl ackness
within specified limits as per
specifications.
To mai ntai n correct axl e
alignment, Ensure the notch
on the adjuster is on the same
Mark on Left and Ri ght
Side.
=r=rr| :
+| |r|rnr +r |rr = =
|rn ||c +| n; =|=rr = ;|
|nr|n (=c) +|
|= +| =;| r;=c |nr|n
+ + | ; =||n + |+
=c nr ;r |rr r;
nrr r; r = + ;| |-; (|rr)
|=n| ;|
5. Af t er adj ust i ng, be sure t o
tighten each chain adjusting
locknut. Then tighten the axle
nut to the specified torque.
---- i r
l--^ i - i (
| n-in l - i ll-
-i n |
Tightening torque i î -i:
Axle nut l -
65 ft-lb (9.05 m-kg)
1. Cotter pin i- l
6. Insert a new cotter pin into the axle
nut and bend the end of the cotter
pin as shown. If the notch in the
axle nut and the cotter pin hole do
not match, tighten the nut slightly
to align them.
l - - i i- l
î, i i l li - liii
î r, i- l l i -i
| l l - i i (i)
nii i-l i ii l-
ri ini r ni ;r i - l-i
l - i iiii |
WARNING
Always use a new cotter pin on the
axle nut.
pg56_96.pmd 9/24/2005, 7:53 AM 63
nr|
|= c + | ;=rr +rc |
+r ;| rn +|
7. Adjust the free play in the brake
pedal.
i i --
|
WARNING
Check the operation of the brake
light after adjusting the rear brake.
nr|
|e| + +r =c + + r
+ +| -r| (r;c) +| |>r +r r
|
6.28
Drive chain lubrication
=r; +| -|+r
The chain consists of many parts
which work with each other. If the
chain is not maintained properly, it
will wear out quickly. Therefore, the
chain must be serviced regularly.
Thi s servi ce i s especi al l y
necessary when riding in dusty
areas.
- rn lr- rin r i
l i- n r| l i
iii ri nr i i ni r
-i li ini r| ;l îni
;i l( i i ii ilr|
ni ;ii - -i-i;l in
- ; nr i l( ii rn
i ri ini r|
1. The dri ve chai n shoul d be
lubricated every 5,000 km.
i;( i - 5,000 l.-i.
i -i- i ilr|
2. To clean the chain thoroughly,
remove it from the Motorcycle,
dip it in solvent, and clean out
as much di rt as possi bl e.
Then, take the chain out of the
solvent to dry it, and then dip
t he chai n i n oi l of 20W40.
Remove the chain and hang it
on a peg for a while till the
excess oi l dri ps down
completely. Then using a clean
cloth wipe the chain.
i ini i l
; -i-i;l ni , i(
(i(-) - i i lni ii
i( ri il-;i i i |
i i ii l
i( ir li i l
20W40 i (i) n - i
liî | n-in i ir
li n n i-i -i^ ,
n l in n ;- i
nr l i| n i
i i |
=r=|+ =r=rr nrr =r=| =-=n
pg56_96.pmd 9/24/2005, 7:53 AM 64
Throttle cable and grip
lubrication
rrc + r |n -|+c
+r|
The throttl e twi st gri p assembl y
should be greased at the time that
the cable is lubricated, since the
grip must be removed to get at the
end of t he t hrot t l e cabl e. Af t er
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.
l - i -i- li ini
r i - ii- -l(-- l^ i
nii i ^lniii n nii
lii i - | l ri ni
i- ri ri ri ni (i; .-.i; ..
i ; n i r |
i lî^ ii i ii ilr| ii- i
l l ii- l^ i
ii| r-i i ni ()
l (li) i r(i - r
i -i- i rn i
i| ii- l^ i ii (^^
) ii l^ i i iin
n iii, rii (i )
î i il-^ |
Cable inspection and
lubrication
+ +r ||=rr -|+r
WARNING
Damage to the outer housing of
cabl es may l ead to i nternal
rusting and interfere with the
cabl e movement. Repl ace
damaged cabl es as soon as
possi bl e to prevent unsafe
conditions.
nr|
+ (nrr ) +| r;| ;r=|=n +
=r|nnn ;r = ; = n +=
=+n| ; r ;== + +r = |
==c + = =|+ r =+n| ;|
=|=rn |r|nr (;rrnr) = +
| =r|nnn nrr (+) +r |n|
-| ;r =+ |
Lubri cate the cabl es and cabl e
ends with anticorrosive oil . If a
cable does not operate smoothly,
ask a YMIS dealer to replace it.
Recommended lubricant
-nil( i-
20W40 Type SG
6.29
=r=|+ =r=rr nrr =r=| =-=n
pg56_96.pmd 9/24/2005, 7:53 AM 65
Brake and shift pedal
Greasing
+ nrr |rc= +| n||n
Grease the pivoting parts.
iiii iiî i li (î) |
Brake and clutch lever
Greasing
+ nrr |rc= +| n||n
Grease the pivoting parts.
iiii iiî i li (î) |
Center stand Greasing
=c c= +r n||n
Grease the pivoting and mating
joints.
Check to see that the center stand
move up and down smoothly.
iiii i i - l- (i ii
i î |
i l - -- + i i
ri ii- i|
6.30
=r=|+ =r=rr nrr =r=| =-=n
Recommended lubricant
-nil(n î
Multipurpose Grease
rli î
pg56_96.pmd 9/24/2005, 7:53 AM 66
Front fork inspection
c r+ +r ||=rr
WARNING
Securely support the Motorcycle
so there is no danger of it falling
over.
nr|
=|=rn n|+ = =rc=r;|+ +r =;rr
, |== ;=+ |n +r =rnr ;|
1. Visual check
Check f or scrat ches or
damage on the inner tube and
traces if oil leakage from the
front fork.
l-^n ( ii) i
i^ ^ i - -li n
li( i i - iii
nii ; -iln^-n ri i i
|
2. Operation check
Place the Motorcycle on a level
place.
l>i i i
-i-i;l i ( l r
(i-) -ii ii |
a. Hol d t he Mot orcycl e i n an
upright position and apply the
front brake.
-i-i;l i iii + -i
i i î i i^ |
b. Push down hard on t he
handlebars several times and
check i f t he f ork bounds
smoothly.
rli i ; i i i
i i i i ; in i i
l i i ii- i
ni r|
6.31
WARNING
If the center stand does not move
smoothly, consult a YMIS dealer.
nr|
| =rc=r;|+ +r =c c= rr=
= (|r |+=| =+rc +) +r= ;|
+nr ;r nr r;.=.r;.=. =| =
=+ +|
=r=|+ =r=rr nrr =r=| =-=n
pg56_96.pmd 9/24/2005, 7:53 AM 67
l ; i -- î |
^ i l l i
i i r i^ nii i i i
i i - | l li nr
i -(ni (i) -r li i ri
ri ni r;.=.r;.=. i --l^
i i i -- i
r| l i^ i lri r-i li i
ni i i ii ri ini r|
WARNING
Securely support the Motorcycle
so there is no danger of it falling
over.
nr|
=rc=r;|+ +r =|=rn n|+ = =;rr
+ =r nr|+ ;=+ c + |n
+r =rnr ;|
Steering inspection
c|n +| r
Periodically inspect the condition
of the steering. Worn out or loose
st eeri ng beari ngs 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 YMIS
dealer to inspect and adjust the
steering. Inspection is easier if the
front wheel removed.
-- --l^ i l-iln i
li-ii n r| --l^ i lii r;
i(i ii l^ ini ri ni r|
^ lr i -i + -i
6.32
CAUTION :
I f any damage or unsmooth
movement is found with the front
fork, consult a YMIS dealer.
=r=rr| :
| n r+ +r +r + = +r;
=+rc r ;| ; rr ; +;| =
=r|nnn ;r nr ; nr r;.=.r;.=.
=| = r=r |
=r=|+ =r=rr nrr =r=| =-=n
pg56_96.pmd 9/24/2005, 7:53 AM 68
1. Maximum level mark
lin- -n i lii
2. Minimum level mark
n- -n i lii
Battery c|
1. Battery is located inside the
L.H. side panel (for removal &
installation of L.H. side panel
please refer page 6-7).
-i i; n - l-in r
(i; i i r-i ( î
l i - . 6-7 i i)
2. Open the lid.
l i ii |
3. Check the level of the battery
electrolyte and make sure that
the terminals are tight.
3. -i ;-ii;- -n (()
i i i lln
l -i -l-- i nr
r ri|
Top up with distilled water if the
electrolyte level is low.
l ;- ii;- i -n - ri ni
; + n ll--- (i- i |
CAUTION :
When inspecting the battery, be
sure the breather hose is routed
correctly. If the breather hose is
positioned in such a way as to cause
battery electrolyte or gas to exit
onto the frame, structural and
cosmetic damage to the
Motorcycle can occur.
=r=rr| :
c| +| r +n == ; =||n
+ |+ '| ;r' =;| =rn
+r= + ;r ;r| | '| ;r' +r
;= n; = =rr nr ; |+ c| +r
';crr;c' rr ;=+| n= r;
|++ = r r, ;==
=rc=r;|+ +| rc nrr =nr
+r +=r ;r =+nr ;|
6.33
Wheel bearings
|; +| |n
If there is play in the front or rear
wheel hub or if the wheel does not
turn smoothly, have a YMIS dealer
inspect the wheel bearings.
l ^ nii l lr r -
li nr i r i(i lri ri
ni ri i-ni r ni r;.=.r;.=.
i lr l i i
i r|
=r=|+ =r=rr nrr =r=| =-=n
1 MAX
2 MIN
pg56_96.pmd 9/24/2005, 7:53 AM 69
Antidote |r rr+ :
EXTERNAL: Flush with water.
r;| (r;) : r| = -e| n; =
=rr |
INTERNAL: Drink large quantities
of water or milk. Follow with milk
of magnesi a, beaten egg, or
vegetable oil. Call a physician
immediately.
rn|+ : ;n |=r+ =r>rr = r|
rr =r | | r = = |=cc|
n =r, cr ;r =r rr |n
n +r = +| ||+=+ +r nn
r |
EYES: Flush with water for 15
minutes and get prompt medical
attenti on Batteri es produce
explosive gases. Keep sparks,
fl ame, ci garettes 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.
r=r : r=rr +r 15 |=c n+ r| =
-e| n; = =rr r -| = =rc
+r |=rr| c|, = |rc+ n=
|+n| ;, |nr| rn +| c (r)
nrr |=nc ;r| = ;= =r|
rr ;= r +n ==
rr rn +n == ;r + rr
+ rr +r =rr =r| c| + |+
+r= +n == ;=rr | r=rr +r
a++ =r| ;= -r +| ; =
;| =r|
ENSURE THAT BATTERY ELECTROLYTE LEVEL IS MAINTAINED BETWEEN
MAX. AND MIN. MARKS. IF REQUIRED, ADD DISTILLED WATER ONLY
6.34
WARNING
Battery electrolyte is poisonous
and dangerous, causing severe
burns, etc. It contains sulfuric acid.
Avoid contact with skin, eyes or
clothing.
nr|
c | +r '; c r r; c' |r r r
=rnr+ ;rnr ; |=+ =+ = r
n ;r| ;rn| ;| ;==
=-|+ - ;rnr ;| ;= r,
r=rr nrr +=r + =rr =+ ;r =
r|
=r=|+ =r=rr nrr =r=| =-=n
pg56_96.pmd 9/24/2005, 7:53 AM 70
Replenishing the battery fluid
c| = (-=) +r : -rr
A poorly maintained battery will
corrode and discharge quickly. The
battery fluid should be checked at
l east once a mont h. The l evel
should be between the minimum
level and maximum level marks.
Use only distilled water if refilling
is necessary.
ri nr iii -i
^ ni r i -i l-i ri
ini r| -i ( i -ri - -
- i ( i i ilr|
( i -n (() n- nii lin-
lri - rii ilr| ; l
i l ( ll--- (i- i
i^ |
CAUTION :
Normal tap water contai ns
minerals which are harmful to a
battery; therefore, refill only with
distilled water.
=r=rr| :
c+| + =r=rrr r| = =r| rr
;rn ;| r c| + | ;r|+r+ ;r
=+n ;| ;=| + |=|c-= rc
= ;| ;= : -r|
WARNING
nr|
;= rn +r =r =r |+ c| +r
=r c=r;|+ +| |=r
r| c| +r -= +r +=r
+ =+nr ;, |== +| +r= +
+| |=r += ;r =+n| ; r =-rn:
;== +r; rcr -r| rc =+n| ;|
=||n + |+ ';c rr;c' +r n -n= nrr |=r+n= |rrr + | = ;| ;|
| =n = nr + '|=|c-= rc' +r ;| rn +|
6.35
Take care not to spill battery fluid
on the chain causing shorter chain
life and possibly result in an
accident.
=r=|+ =r=rr nrr =r=| =-=n
pg56_96.pmd 9/24/2005, 7:53 AM 71
Battery storage
c| +r -r=rr (cr) :
1. When the Motorcycle will not be
used for a month or l onger,
remove the battery, fully charge
it and store it in a cool, dry place.
Completely recharge the battery
before reinstallation.
l -i-i;l i -ri i
li - n i^ ri
li i ri ri ni -i i ir
li , ; i nr i
i - nii i -ii ii
(--i) i| î r
; ini ii i |
2. If the battery will be stored for
longer than two months, check
the specific gravity of the fluid
at least once a month and fully
recharge the battery when it is
too low.
l - i i i -ri li
- --i ii î ri ni
-ri - - - i ;
( il-i i-( (-l- ^l(-i)
i i i l rn ii
- ^ ni -i i ini i
|
3. Al ways make sure t he
connections are correct when
putting the battery back in the
mot orcycl e. Make sure t he
breat her hose i s properl y
connect ed and i s not
damaged or obstructed.
ii -i i ii î r
lln l -i i
ri ni ^ ri | r ii
lln l i ri i -i
ni îi (-) î ri
i r -iln^-n i(i i ri
ri |
6.36
1. Main fuse - (-)
Fuse replacement
+r r
The fuse is located behind panel
A. (See page 6-7 for panel remove
and installation procedures.)
i î rini r|
i î i r-i i l>i
l - i 6-7 i i)|
If the fuse is blown, turn off the
main switch. Install a new fuse of
proper amperage. Turn on the
switches and see if the electrical
devi ce operat es. I f t he f use
immediately blows again, consult
a YMIS dealer.
=r=|+ =r=rr nrr =r=| =-=n
2
pg56_96.pmd 9/24/2005, 7:53 AM 72
1. Bezel
Headlight bulb replacement
;= r;c + - +r r
If the headlight bulb burns out,
replace the bulb as follows
l r i;- i - ii ri ini r
ni ; i i ^; l(li
1. Remove the two screws from
the bezel assy of the headlight.
i i i i ii
r-i |
2. Unscrew the bulb holder from
reflector assy.
- ri- i l-i
- ii li |
CAUTION :
Do not use fuse of hi gher
amperage rati ng than those
recommended. Substitution of a
fuse of i mproper rati ng can
cause extensi ve el ectri cal
system damage and possibly a
fire.
=r=rr| :
nr|n |+ n + |n|n,
+r; =r =- =| =r>rr +r
rn +| |+- + = = |n
=r>rr +r || + |n n rr|
+r +=r ;r =+nr ; r =-rn:
;== rn -r| n =+n| ;|
Specified fuse ll- li î : 10A
l î ri, ni - l-( i
i-i i l- i i
l | -ln i i
i î| -i i i-i i
i l i li ii -i nr
i- r r| l nn l
ini r ni r;.=.r;.=. i
l |
=r=|+ =r=rr nrr =r=| =-=n
6.37
1
pg56_96.pmd 9/24/2005, 7:53 AM 73
1. Bulb -
WARNING
Keep flammable products and
your hands away from the bulb
while it is on, as it is hot. Do not
touch the bul b unti l i t cool s
down.
nr| :
|= == - ;r ;r r n= ;r
nr r| nr r ;rrr +r
;== =r| == n n+ - +r
;rr nr n+ ; a=r ;r
r|
1. Bulb holder - ri-
3. Remove the defective bulb.
ii - i ir li |
4. Put a new bulb into position
and secure it in place with the
bulb holder.
- i ln -ii î
i - riii l-in
-ii i |
5. Install the Bezel Assy.
i i î|
6. I f t he headl i ght beam
adjustment is necessary, ask
a YMI S deal er t o make
adjustment.
l ri;- i i- i ----
i i ( ri ni
r; .=.r; .=. i ;
-- i r|
6.38
=r=|+ =r=rr nrr =r=| =-=n
1
1
pg56_96.pmd 9/24/2005, 7:53 AM 74
1. Indicator Screw (x 2)
;i- (x 2)
Turn signal and taillight bulb
replacement
r=rr =+n+ (|=) nrr |e|
'r;c' + - +r r|
1. Remove t he screw and t he
lense.
i i i ii ^
|
2. Push the bulb inward and turn
it counterclockwise.
- i i n i i
; i; i; i i-i|
3. Place a new bulb inward and
t urn i t cl ockwi se unt i l i t
engages into the socket.
1. Taillamp Screws (x 2)
i ( 2)
CAUTION :
Do not overtighten the screws as
the lense may break.
=r=rr| :
r +r =n = rr += -rr
= cc =+nr ;|
3. i- - i - î | - i
i n i i ; i;
i; i n n i-i n r
i- -i nr -
i|
4. I nst al l t he l ense and t he
screws.
i i i l î |
6.39
=r=|+ =r=rr nrr =r=| =-=n
1
1
pg56_96.pmd 9/24/2005, 7:53 AM 75
1. Brake cable adjusting nut
i ni i l--^ -|
1. Place the Motorcycle on the
centerstand.
-i-i;l i i (i --
î ii |
2. Fully loosen the brake cable
adjusting nut at the wheel hub
and remove the cable from the
brake cam lever.
lr r ^ i ni
l--^ - i i ii i
ni () i - i( -
ir li |
Front wheel removal
n |; +r ;crr
WARNING
It is advisable to have a YMIS
dealer service the wheel.
Securely support the
Motorcycle so there is no
danger of it falling over.
nr|
=n ;| ; |+ r;.=.r;.=.
=| = ;| |; +| '=|=' +r;
r|
=rc=r;|+ +r =|=rn n|+ =
=;rr nr|+ ;= c + |n
+r =rnr ;|
6.40
=r=|+ =r=rr nrr =r=| =-=n
1
pg56_96.pmd 9/24/2005, 7:53 AM 76
1. Stopper --i
Front wheel installation
n |; +r nrr
When installing the front wheel,
reverse the removal procedure.
^ lr i îi ri ni lri
r-i i l>i i - |
lllin ni i |
1. Make sure the slot in the brake
shoe plate fits over the stopper
on the front fork outer tube.
r lln l i
i - - i r i -i -, ^
i i iri - ^ --i
ii l- (-i nr - i)
ri i|
1. Cotter pin i l
2. Axle nut -
5. Remove the cotter pin and axle
nut.
i - l nii - i ii
ir li |
6. Remove the wheel axle. Make
sure the Motorcycle is properly
supported.
lr i ir li |
lln l -i-i;l i
ln rii l-ni r|
1. Clip l
2. Speedometer cable -i i-i-
4. Remove t he speedomet er
cable from the front wheel side.
First remove the clip and then
pull the cable out.
-i i-i- i ^ lr
r-i | r l i r-i
i i i ii |
6.41
=r=|+ =r=rr nrr =r=| =-=n
2
1
2
1
1
pg56_96.pmd 9/24/2005, 7:53 AM 77
Rear wheel removal
|e |; +r ;crr
WARNING
It is advisable to service the
wheel by YMIS dealer.
Securely support the
Motorcycle so there is no
danger of it falling over.
nr|
=n ;| ; |+ |; +| '=|='
r;.=.r;.=. =| = ;| +r;
r|
=rc=r;|+ +r =|=rn n|+ =
=;rr + =r=r +| nr|+ ;=
c + |n +r =rnr ;|
Axle nut torque - i -i
33 ft.-lb (4.55 m-kg)
2. Make sure t he axl e nut i s
properly torqued and a new
cotter pin is installed.
r lln l -
i ri ni i ri ri i
i i- l î ri|
WARNING
Always use a new cotter pin.
nr|
;=rr +rc | +r rn +|
3. Adjust the free play in the brake
lever.
i( i i --
|
1. Nut -
2. Cotter pin i- l
3. Tension bar -i i
1. Place the Motorcycle on the
centerstand.
-i-i;l i i --
ii |
2. Remove the cotter pin and nut.
Then remove the tension bar
from the brake shoes plate.
i- l i - i r-i |
i i- - -ii i
ir li |
6.42
=r=|+ =r=rr nrr =r=| =-=n
2
1
3
pg56_96.pmd 9/24/2005, 7:53 AM 78
1. Rear axle li
4. Remove the axle nut cotter pin
and the axle nut.
- i -
i-l i ii ir li
|
5. Pull out the rear axle.
l i ir i n ii|
6. Remove the wheel assembly.
lr i i i ir li
|
1. Axle nut -
2. Cotter pin i- l
3. Brake rod i ( i )
4. Brake adjusting nut i l--^-
3. Remove the brake adjusting
nut and brake rod from the
brake cam lever.
-i( - i
l--^ - i i (i)
i ir li |
ALWAYS USE YMIS GENUINE SPARE PARTS
;=rr 'r=r;r' + =| r +r rn +|
6.43
=r=|+ =r=rr nrr =r=| =-=n
1
2
3
4
pg56_96.pmd 9/24/2005, 7:53 AM 79
Rear wheel installation
|e |; +r nrr
1. Install the rear wheel and the
axle.
l lr i i î|
2. Install the axle nut.
- i î|
3. Insert the brake rod into the
brake cam lever and install the
brake free play adjusting nut.
i i - i( -
-i (i ) i i l--^
- i (ri î |
4. Install the tension bar on to the
brake shoe plate and tighten
t he t ensi on bar nut t o t he
specified tightening torque.
i - -i i i î
nii i -i i - i ll-
-i |
5. Take the Motorcycl e off the
centerstand.
-i-i;l i - -- i
ni |
Specified torque ll- -i
Tension bar nut -ii i -
14 ft-lb (1.9 mkg)
Axle nut -
65 ft-lb (9.05 mkg)
6. Ti ght en t he axl e nut t o t he
speci f i ed t i ght eni ng t orque.
Then install a new cotter pin.
- i ll- -i n
i i nr |
n-in i i- l î|
WARNING
Always use a new cotter pin.
nr|
;=rr +rc| +r rn +|
7. Adjust the rear brake pedal free
play. (See page 6-23)
li i -(ni (i)
i -- |
( - i 6-23 i)
WARNING
Check the operation of the brake
light after adjusting the rear
brake.
nr|
|e| + +r =c + + r
+ r;c +| +rrr| +| r +|
6.44
=r=|+ =r=rr nrr =r=| =-=n
pg56_96.pmd 9/24/2005, 7:53 AM 80
Troubleshooting
==r ==r=rr
Although YMIS Motorcycle receive
a rigid 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 l oss of power. The
troubleshooting chart describes a
quick, easy procedure for making
checks. If your Motorcycle requires
any repair, bring it to a YMIS dealer.
The skilled technicians at a YMIS
deal ershi p have t he t ool s,
experi ence, and know-how t o
properly service your Motorcycle.
Use only genuine YMIS parts on
your Motorcycle. Imitation parts
may look like YMIS parts, but they
are often inferior. Consequently,
they have a shorter service life
and can lead to expensive repair
bills.
nl r;.=.r;.=. -i-i;l
i iii ir l r
i ini î ni r,
l
ii i ii ln i ni r|
;i, i i(i riii, (;ii
l---) - i (ii --i, n
--il-^ i iln (i() ai (-i)
i i i ni r |
--i-iii i-, ri nr i
i n, ( ii l>i i ii
ni r| l ii -i-i;l i
li nr i --n i n ni
; r;.=.r;.=. i i
i| r;.=.r;.=. i i (ii
i -iilii i ii
-i-i;l i ri ni l(
l ii, i( ( iii
-i rni r|
| =r c=r;|+ + | +
r;.=.r;.=. + =| r +r rn
+ | r r r (r c =)
r;.=.r;.=. r +| n; ;| |=rr;
=+n ;, n r: ; |- r|c|
+ ;rn ;| =rr ;| (,rc=) ;n
+= == n+ a|+ = +r= + rn ;
r =r c=r;|+ +| =-=n (| |n )
+ | +r rr =r|r ;| rn ;|
6.45
=r=|+ =r=rr nrr =r=| =-=n
pg56_96.pmd 9/24/2005, 7:53 AM 81
Enough fuel Go to compression check
No fuel Supply fuel
Engine doesnt start, go to
compression check.
There is compression Go to Ignition check.
No compression Ask YMIS dealer to inspect.
Wipe clean with dry cloth
and correct spark plug
or replace spark plug.
Wet
Open the throttle halfway
and start the engine.
If Engine does not start
Contact YMIS dealer.
Ask YMIS
dealer to inspect.
Dry with
Black Soot
Check if there is fuel
in the fuel tank
Use kick starter.
Remove spark
plug and check
electrode.
Troubleshooting chart - For Starting
WARNING
Never Check the fuel system while smoking or in the vicinity of an open flame.
1. Fuel
2. Compression
3. Ignition
6.46
=r=|+ =r=rr nrr =r=| =-=n
pg56_96.pmd 9/24/2005, 7:53 AM 82
==r==r=rr rc r=rn + |
nr|
+-r| -r| rn +| r (=) + |+c rr |=nc |n == ;=r +| rr| +| r +|
1. ;i
2. i
3. ( (;ii)
in ;i i i i |
; i ri
r |
; i i
i; |
; --i- ri ri ri r| i
i i |
i r| ;ii ( i i |
i ri r|
(i;.-.i;.. i ri i
i r|
i, i i i
-i ^ i -i |
îi r
ii- i iii ii i ;
i --i- |
l ; --i- ri ri ri
ri ni (i; .-.i; .. i
|
(i; .-.i; .. i
ri i i r|
il-i l r
i r|
;i i -i - -i ;i
i i |
l --i- i i^
|
-i ^ i ir
l i i
;-i i i |
6.47
=r=|+ =r=rr nrr =r=| =-=n
pg56_96.pmd 9/24/2005, 7:53 AM 83
1. Before cleaning the Motorcycle :
-i-i;l i i;
r
a. Block off the end of the exhaust
pipe to prevent water entry; a
plastic bag and string rubber
band may be used.
i-- i; (lii;) ii
(i i i l i;
l i il-- ^ i
i i^ , li i
ni r|
b. Make sure the spark plug and all
filler caps are properly installed.
lln l -i ^ i
ii l- -i nr î
^ ri|
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.
l ; i -ili
li r ni - i i rini
; li; (ii î|
, -i- i(i lr i
lî i i^ |
A. CLEANING =r;
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.
-i-i, i nr i; (
ii -i-i;l i i - i
ini r l- ;i iiii i-i-ni
- ii ini r i ; rn
i i - ( l, ri ni r
CAUTION :
Improper cleaning can damage
the cowlings, panels and other
plastic parts. Use only a soft,
clean cloth or sponge with mild
detergent and water to clean
plastic.
Do not use any harsh chemical
products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
contact with strong or abrasive
cleaning products, solvent or
thinner, fuel (gasoline), rust
removers or inhibitors, brake
fluid, antifreeze or electrolyte.
=r=rr| :
nn n|+ = +| n; =r; =
=rc=r;|+ + +r=|n, nrr
- -r|c+ + =rr ;r =+n
;| -r|c+ + r +r =r +
+ | =;| |=cc r r| +
=rr + =r, =r= += +r
;| rn +|
-r|c+ + (+rc=) + |
|+=| n +=|+-= +r rn
+| =||n + |+ = +=r
rr + rn = r r r
r|nrr| rr |= =r;
=rr, r+, rr |r, ;=r,
(n =) n | nr =r +r r r
n|= +r , + + ; =r, r|n
|r =r| ( c||) rr ; c r r;c
+ =+ = r rn ;|
7.1
CLEANING AND STORAGE
=r; nrr -r=rr
pg56_96.pmd 9/24/2005, 7:54 AM 84
3. Rinse the dirt and degreaser off
with a garden hose. Use only
enough pressure to do the job.
îri i - il---i
i lî i (i) i +
-i | ; i i l
( in i( i ;-n-i |
CAUTION :
Excessive hose pressure may
cause water seepage and
deterioration of wheel bearings,
front fork, brakes, transmission
seals and electrical parts.
=r=rr| :
r|=r+ r| + r = |; +|
|n, n r+, =, cr==|r +|
=|, r || + r = r| +r
=r ;r =+nr ; r c ;r =+n
; |
4. After riding on dirty roads, wash
the Motorcycle with cold water
immediately. Do not use warm
water to clean the tyre.
4. - n i îi i
i -i-i;l i nn - ii
ii| -i i l
^- ii i ;-n-i |
5. 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.
i rn i i r- i,
ii -iii i ^ ^ ii i - i-
l-- i nr i ii|
- l r (i -iii i
i; l i -ii i(i
ini i ;-n-i |
6. Rinse the Motorcycle off
immediately with clean water
and dry all surfaces with a
chamois, clean towel, or soft
absorbent cloth.
-i-i;l i ii i,
; nn -i ii i
ii -iii i i nil i(i
- i ii |
7. Dry the chain and lubricate it to
prevent rust.
i ii, ; ^ i
l ; î î |
8. Clean the seat with a vinyl
upholstery cleaner to keep the
cover pliable and glossy.
-i -i;l i i- i ii
i -i i l l(i;
i--i i i |
9. Automotive-type wax may be
applied to all painted and
chromeplated surface. Avoid
combination cleaner waxes.
Many contain abrasive which may
mar the paint or protective finish.
When finished, start the engine
and let it idle for several minutes.
ii - l r i i--
l r -i i i l
i-i-il-(-i; ( i i^ li
i ni r | l-i n (
i i i^ | rn
( - i -i rn r
i - l r i(i lli l
r -iii i ril ri n r|
i; i i- i ri i ;
i l--i n iii ri
|
7.2
=r; nrr -r=rr
pg56_96.pmd 9/24/2005, 7:54 AM 85
2. ;i i iii -i i ir li
, -i - SAE 10W30 or
20W40 i i -i- i i,
l -i i nr i il-^
l -i i i nr
lri i in n i ir li
| -i i l ii-ii
î |
3. Remove the spark plug, pour
about one tablespoon of SAE
10W30 or 20W40 motor oil in the
spark plug hole. Reinstall spark
plug. Kick the engine over several
times (with the ignition off) to coat
the cylinder wall with oil.
-i ^ i ir li , SAE
10W30 or 20W40 i i i
- i -i ^ -
(ri) i i ; l (i
î | ; i - n
l în r (;i i in
r) l li i l(ii i
iil-^ ri i|
4. Remove the drive chain.
Thoroughly clean the chain
withsolvent and lubricate it.
Reinstall the chain or store it in a
B. STORAGE
|. -r=rr (cr)
Long term storage (60 days or more)
of your Motorcycle will require more
preventive procedures to guard
against deterioration. After thoroughly
cleaning the Motorcycle, prepare for
storage as follows:
ii -i-i;l i i (li n
(60 l i +) --i
i ; - ri i l
i(iii(i l>i ii ni
r| -i-i;l i i nr i;
i, lllin ini i i
, ; --i i nii
1. Drain the fuel tank, fuel lines, and
carburetor float bowl.
;i i -i, ;i i i;i, i
i- i-i+ i iii
|
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 tank
to coat the inner surfaces
thoroughly and drain off the excess
oil. Reinstall the tank.
plastic bag (tied to frame for
safekeeping).
i;( i ir li |
; i nr i( (i-(-)
i i ; î ;-il
î | i l î
i(i ; il-- ^ -
--i i | (l-in i
l - ii ii )|
5. Lubricate all control cables.
ii -ii (nii) i îl^
|
6. Block up the frame to raise both
wheels off the ground.
ii lri i -i + -i
l - i i i|
7. Tie a plastic bag over the
exhaust pipe outlet to prevent
moisture from entering.
-i i i --i; (lii)
i i l i;
i ir il-- ^
(-) |
=r; nrr -r=rr
7.3
pg56_96.pmd 9/24/2005, 7:54 AM 86
8. If storing in a humid or salt-air
atmosphere, coat all exposed
parts with anti corrasive chemical
to prevent moisture from
entering.
l (ini(i - li -i ( -
i -iii li r ni iin ii
-r-( i i- ^ nii ii i
i ;-n-i |
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
warm or cold place (less than 0C
or more than 30C)
9. -i i ir li i ;
i | ; i -ii
ii i i -ri -
i l i | - i i
-ili ^- i(i - -ii
i| (0
0
-i^ i i 30
0
-i^ +)|
7.4
NOTE :
Make any necessary repairs before
storing the Motorcycles.
rc :
-i-i;l i iii r
r nr i n--n (l)
i |
=r; nrr -r=rr
pg56_96.pmd 9/24/2005, 7:54 AM 87
SPECIFICATIONS
Model CRUX
Dimensions:
Overall length 2,000 mm
Overall width 735 mm
Overall height 1,075 mm
Seal height 780 mm
Wheelbase 1,260 mm
Ground clearance 160 mm
Minimum turning radius 2,000 mm
Weight : ( With oil & 90% fuel ) 113 kg
Engine :
Engine type Air cooled 4-stroke,
SOHC
Cylinder arrangement Forward inclined
single cylinder
Displacement 105.6 cm
3
Boer Stroke 4956 mm
Compression ratio 9.0 : 1
Starting system Kick starter
Lubrication system Wet sump
Maximum power 7.60 PS(5.59kw) @ 7500 RPM
Maximum torque 0.8 Mkg @ 6000 RPM
EngineOil
Type:
CAUTION :
Be sure to use motor oils that do not contain
antifriction modifiers. Passenger car motor oils
(often labelled Energy conserving) contain anti-
friction additives which will cause clutch/or
starter clutch slippage, resulting in reduced
component life and poor engine performance.
Capacity :
Periodic oil change 0.9 L
Total amount 1.1 L
Air filter: Foam type element
Fuel :
Type Regular gasoline
(petrol)
Fuel tank capacity 11.0 Litres
Reserve amount 1.4 Litres
Carburetor:
Type VM17SH
Manufacture MIKUNI
SPECIFICATIONS
|rr |r
8.1
YAMALUBE
4-Stroke motor oil (20W40)
Type SG
pg56_96.pmd 9/24/2005, 7:54 AM 88
|rr r :
=r = >=
=r;=r-= (|=rr):
i; 2,000 -i.-i.
ii; 735 -i.-i.
+i; 1,075 -i.-i.
i- i +i; 780 -i.-i.
lr i 1,260 -i.-i.
î+ i 160 -i.-i.
n- -l^ l 2,000 -i.-i.
(r; r 90%) ;=r 113 |+.nr.
; :
; i l-- 4 --i
SOHC
l i (-ii i^ i n ni ri l^
l
l--- 105.6 .-i.
3
i --i 4956 -i.-i.
i ii 9.0 : 1
--il-îii l--i-
-ii iii i
lin- iln 7.60 PS (5.59kw) @ 7500
ln l-- i -iii
lin- -i 0.8 Mkg @ 6000
ln l-- i -iii
; +r n
l-- (-i;) i-iri- 4--i -i-
i (20W40 type SG)
=r=rr|:
; =||n + = =rc r +r rn |+r r, r
rrr |nr=r| ==rr+ ;r| r>r|+r =rc r, (r:
| =r = =rr +r nr ;rnr ; ) ;=
rr r |r=r| =+ rr|= ;rn ;| |== r
crc | ;r rn ;| +rc +| == += ;rn| ;
r ; +| +r+rnr |-n +| ;r rn| ;|
=r>rr:
-- n l(n 0.9 i.
-iii 1.1 i.
|-c: i- l-- i n
(i- -)
; =r:
l-- i-i îi (-i)
;i i -i i -i-ni 11.0 i.
l( -iii 1.4 i.
+rrc:
l-- VM17SH
l-ii -ii l-i
8.2
SPECIFICATIONS
|rr |r
pg56_96.pmd 9/24/2005, 7:54 AM 89
Spark plug :
Type/Manufacture P-RA7HC (Champion)
Spark plug gap 0.9 mm (-0.2mm)
Clutch type : Wet, multiple-disk
Transmission :
Primary reduction system Spur gear
Primary reduction ratio 3.722 (67/18)
Secondary reduction system Chain drive
Secondary reduction ratio 3.143 (44/14)
Transmission type Constant mesh 4
speed
Operation Left foot operation
Gear ratio 1st 3.000
2nd 1.688
3rd 1.200
4th 0.875
Chassis:
Frame type Double Cradle
Caster angle 26.4 deg
Tyre with Tube
Size
Front 2.50 ~ 18 4PR
Rear 2.75 ~ 18 6PR
Air pressure (cold tyre):
Single Rider
Front 25 psi (1.75 Kgf/cm)
Rear 32 psi (2.25 Kgf/cm)
With Pillion and rider
Front 25 psi (1.75 Kgf/cm)
Rear 32 psi (2.25 Kgf/cm)
8.3
SPECIFICATIONS
|rr |r
pg56_96.pmd 9/24/2005, 7:54 AM 90
r+-n :
l--,l-ii -ii P-RA7HC (-l)
-i^ i ^ 0.9 -i.-i.(-0.2-i.-i)
+| |+= i, ---il-
c r==|r:
i;-i li iii - î
i;-i li ii 3.722 (67/18)
i li iii i;(
i li ii 3.143 (44/14)
-i-ii i l-- l-in (i--) -i 4 -i
i i (l>i) i i( i l>i
î ii ri 3.000
i 1.688
nii 1.200
iii 0.875
|==
- i l-- >
i-- ii 26.4 deg
c + =rr
-i
î 2.50 ~ 18 4PR
li 2.75 ~ 18 6PR
r(i i i( (- -i -)
( i ii
î 25 psi (1.75 Kgf/cm)
li 32 psi (2.25 Kgf/cm)
i ( (ii ii
î 25 psi (1.75 Kgf/cm)
li 32 psi (2.25 Kgf/cm)
8.4
SPECIFICATIONS
|rr |r
pg56_96.pmd 9/24/2005, 7:54 AM 91
Wheels:
Type:
Front Spoke wheel
Rear Spoke wheel
Size: Front 1.60 18
Rear 1.60 18
Brake:
Front :
Type Drum brake
operation right Hand lever
Rear :
Type Drum brake
Operation Right foot operation
Suspention :
Front Telescopic fork
Rear Swing arm
Shock absorber:
Front Coil spring/oil damper
Rear Coil spring/oil damper
Wheels travel:
Front 110 mm
Rear 70 mm
Electrical:
Ignition system: CDI (Digitally
Controlled)
Generator system:
Type Flywheel magneto
Standard output 12V
Battery:
Type Lead acid
Voltage, capacity 12V 2.5AH
Bulb voltage, Wattage Quantity:
Headlight 12V 35W/35W 1
Tail/Brake light 12V 21W/5W 1
Front flasher light 12V 10W 2
Rear flasher light 12V 10W 2
Meter light 12V 2W 1
Neutral indicator light 12V 3.4W 1
High beam indicator light 12V 3.4W 1
Turn indicator light 12V 3.4W 1
Fuse:
Main 10A
8.5
SPECIFICATIONS
|rr |r
pg56_96.pmd 9/24/2005, 7:54 AM 92
|; :
l--
î -i ii
li -i ii
ii
î 1.60 18
li 1.60 18
+ :
î
-i; -
i i i; rii i i(
li
-i; -
ii (l>i) i i( i l>i
=r :
î -l-i i
li l-(^ i-
rr+ r
î i l-^,n
li i l-^,n
|; +r c :
î 110 mm
li 70 mm
;c|+ :
(iii CDI (ll-
lii)
- iii
-i; i; ri --i
-- i+-- 12(i--
-i
l-- l
(i--, -i-ni 12(i-- 2.5AH
- r-c, rc =r>rr :
r i;- 12V 35W/35W 1
li i;- 12V 21W/5W 1
î ii;- 12V 10W 2
li ii;- 12V 10W 2
-i- i i;- 12V 2W 1
- ;i- i i;- 12V 3.4W 1
ri; i- i ;i- i;- 12V 3.4W 1
- ;i- i i;- 12V 3.4W 1
:
- (- ) 10A
8.6
SPECIFICATIONS
|rr |r
pg56_96.pmd 9/24/2005, 7:54 AM 93
1. Key identification number
ii i ri
Key identification number
r| +r ;r
The key identification number is
stamped on the Tag.
Record this number, use it for
reference when obtaining a new key.
ii i ri ii ii ^
-^ rini r| ; i li
i ; ii in i ri ni
;i i rini |
1. Frame serial number
- i ii
Frame serial number
= +r =||
The frame serial number is
stamped into the steering head pipe
on right hand side.
- i ii , --il^ r i;
- i; n ii (lii) rini r|
1. Engine serial number
; i ii
Engine serial number
; +r =||
The engine serial number is
stamped on the right hand
crankcase.
; i ii i; n
> ii (lii) rini r|
CUSTOMER INFORMATION
9.1
nr;+ =r
pg56_96.pmd 9/24/2005, 7:54 AM 94
The exhaust gas of an Engine pollutes air with such gases which are very dangerous for mankind. In order to ensure
clean and healthy environment, strict regulations have been enforced to control pollution. As per regulations CO
emissions by petrol driven Two Wheelers must be less than 3.5% (by volume) during Idling of the Engine.
; ir l (ii ^ r(i i î lin ni r i -i( i( l rn ini r| ;i i
- i i -(-i (ini(i i lln l ii lii rn n ii i i(ii li î r| ;ri ii
nrn -i (i lri (iri ; iii i (-ii - i.i. i (ir 3.5% - rii ilr|
Non Compliance with emission standards is treated as a punishable offence.
=r|r+ r; + =r =;rn + +r =r=+ r=r +| n; =rr rnr ;|
As a Manufacture, YAMAHA MOTOR INDIA SALES PVT. LTD. ensure that your Vehicle meets the exhaust emission
standards before leaving the Factory.
l-ini - i-iri -i- ;li - i;(- ll-- r lln ni r l ii -i-i;l -i ir
i r li (ir i -ilinii i r nr i ni r|
Please note that when new, the Vehicle has a Factory tuned Carburetor, where the Air Screw is optimally adjusted to
meet the requirement of exhaust emission. This screw must not be tampered with as it may cause variation in pre-
controlled CO emission levels. Subsequently, it becomes very important that it should always be within the recom-
mended limit, when checked by a properly calibrated CO Measuring Equipment.
i i i, i ri ii -i-i;l - -i - ri - li î ii- î rini r, ri -> i i--
(li)(ir i i(ni i -- li ini r| iiii li nr i i ri i ii
ilr, il i (lii i-iiii; (ir -ni - lini i ni r| ii ri, r rn
i( ri ini r l ; ri ni i- (ni) l ^ i-iiii; -ii ii i
i r r-ii -nil( i-i ri rii ilr|
FACTS RELATED WITH EXHAUST EMISSION CONTROL
9.2
r;|>rr = =|=rn n
pg56_96.pmd 9/24/2005, 7:54 AM 95
If the owner of the Vehicle does not comply with above legal requirement, the Vehicle may be
deregistered or penalty may be imposed by the authorities.
;fn okgu&ekfyd mijDr dkuwuh ekx d Lohdkj ugh djrk gS r okgu dk iathdj.k j g ldrk gS vFkok
ml ij tqekZuk yxk;k tk ldrk gSA
The following points may be checked and suitable corrective action if required, to ensure emission levels to remain
within acceptable limits.
-ii -ni i -(iii i-ii n^n i i l lllin ni i ( i( ri ni iii
i i(iri |
1. Clean and oil Air Filter Element periodically and replace it when required.
-- l-- i-- i i i ;- n in r nii i(ni ni ; |
2. Clean, inspect and adjust spark Plug Gap periodically.
-- -i ^ i i , ; i i ; ^ (n) i -- |
3. Use only recommended Spark Plug. Replace it as per recommendations.
( -nil(n -i ^ i ri i^ | -nil( -ii ri i ^ î|
4. Use only recommended grade (SG) of genuine engine oil of superior quality.
( (il-i i -nil(n ^ (SG) i i ; n ri i^ |
5. Get your Vehicle serviced and tuned periodically as per recommended schedule.
-nil(n li -nil -- (ir i l( i -l^ in r|
6. Use unadulterated Petrol.
l-i(- lrn -i i i^ |
SAFETY NORMS
9.3
lqj{kk&flkr
pg97_103.pmd 9/24/2005, 7:54 AM 97
SAFETY NORMS
9.4
lqj{kk&flkr
Certain Safety norms have been mandated for the Two Wheelers to prevent accidents. The following items have
been provided in the Vehicle for your safety.
-ii l;in CMVR l-i i, i lri (iri i i-i i l lln -ii l;in i ^ r| ii
-ii l -i-i;l - lllin (-n i i ^; r|
It is recommended to use Saree Guard, when driving with female as a pillion rider.
li (ii - -lri ii i;l(^ n r r -nil(n li î r l -i-i; - ii î îi
i|
In the interest of your own safety you are requested to always keep the above items (and the Vehicle in general) in
good working condition to avoid any Accident.
ii -ii lrn - i iii r l in (-ni i li ii i-i i l i il-iln - i|
1. Horn
ri|
2. Rear View Mirror
i i l iiii|
3. Efficient Front & Rear Brakes (To be applied simultaneously)
î ( li (i iiii î; ini r)|
4. Grip for Pillion Rider
i - r ln l l^|
5. Head Light/Tail Light
r i;-| i i i;-|
6. Indicators
; l -
pg97_103.pmd 9/24/2005, 7:54 AM 98
WARRANTY
9.5
okja Vh
Yamaha Motor India Sales Private Limited (hereinafter referred to as YAMAHA)
thank you for having purchased this YAMAHA Motorcycle. In the unlikely event of
your YAMAHA Motorcycle requiring warranty service please contact the nearest
authorized dealer. We advise that you read instruction manual carefully before
you get in touch with our Authorized Dealer to avoid any inconvenience.
i-iri -i- ;li - i;(- ll-l- (; i i-iri li^) i-iri i -i-i;l
ii ii i(i ni r| li ii l- ll-ilni - ^ ii i-iri i (i-i
(i in i r ni i lin i | li ii i i l(ii
l lin i ( i ; l i l-ni i ii iiln |
YAMAHA will replace or repair at its Authorised Dealership free of charge, those
parts which may be found on examination to have manufacturing defect, within 2
years from the date of sale of Motorcycle or first 30,000 kilometres of its operation,
whichever occurs first, to the purchaser.
-i-i;l i l(> lnli i i i(i 30000 li-i- i ii r i ri i
n^n l li i- - l-iiiii iii (-l^ iii) ii ini r ni i-iri îr
i i- i lin ili ,ii -n î i -i (i î|
YAMAHA warrants the products to be free from manufacturing defects for a period
of two (2) years from the date of sale of the Motorcycle or first 30,000 kilometres
of its operation, whichever occurs first. If during this period of warranty the
Motorcycle proves to be defective due to material or workmanship, YAMAHA through
its Authorised Dealers will repair the Motorcycle without charging the labour or
parts value as per the terms and conditions mentioned below:
V
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pg97_103.pmd 9/24/2005, 8:39 AM 99
WARRANTY
9.6
okja Vh
-i-i;l i l(> lnli i i i 30000 li -i- i ii r i ri i-iri -i
(i-i i ni r| ^ ; ii -i-i;l - i; l-iiiii iii (-l^ iii) ii
ini r ni i-iri lin i ,ii li i; i i- i i-n l ; -i (i
î l l l- ( in i i ^; r|
The claim for replacement or repair of part (s) shall be considered only when:
i- i i -i l nii l(i li iî
1. The Customer ensures that immediately upon occurrence of the defect
he approach the nearest YAMAHA Authorised Dealer with the affected
Motorcycle. The expenses if any, to bring the Motorcycle to YAMAHAS
Authorised Dealer shall be borne by the customer.
+ iini r lln ni r l iii i ni ^ nn i (r -i-i;l i
l i-iri lin i i iî| -i-i;l i i-iri
lin i i i i li ii nr i i iini ,ii -( (r li
iî|
2. The Customer produces the Owners Manual in original to enable
YAMAHAS Authorized Dealer to verify the Motorcycle details and servicing
details. YAMAHA reserves the right to refuse warranty, if the Owners Manual
is not presented or if the information contained in is incomplete or
tampered.
iini i -i-i;l ( i l( ;-il i iii l i - i
- ln i-iri lin i i -nn i riî| ^ i - (l i l-ni)
i - ln -nn ri i ini i - i ^; iii ii r i ii i;
i i ^; r ni i-iri (i-i -(ii i lii l-in ini r|
o
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j
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pg97_103.pmd 9/24/2005, 8:39 AM 100
WARRANTY
9.7
okja Vh
WARRANTY ON PROPRIETARY ITEMS
izksijk;Vjh mRiknksa ij okjaVh%&
Warranty claims in respect of proprietary items like Tyres, Tubes, Battery and Spark Plug are warranted by their
respective manufacturers and shall be claimed on directly by the customer as per their warranty terms. YAMAHA
and its Authorised Dealers will give all assistance in taking up such claims with the manufacturer of said items.
-(il--( i;--i (i;-i i;--i) -i, -, -i i -i ^ lin (i-i i( (-) l-inii ini ( l-i
i iini ,ii ii ri li iî| i-iri i ; lin i, in (-ni l-inii ii, ; nr i(i
(-) l-i l iini i rini ^|
THIS WARRANTY SHALL NOT BE APPLICABLE TO
;g *okjaVh^ fuEu ifjfLFkfr;ksa esa ykxw ugh gksxh tSls %
1. Normal maintenance operations such as Engine tune-up, Decarbonising, Fuel System Cleaning, Wheels,
Brakes and Clutch adjustments as well as any other normal adjustment.
i-i --n i, l ; i -l^, liii;l^, ;i iii i i;, lri, i i ----
iiii i; i iiii ----|
2. Normal replacement of service wear and tear items, i.e. Break Shoes, Fasteners/Shims/Washers, Gaskets
and Rubber or Plastic Components, ( other than tyres & tubes ) oil seals, Cables electrical wiring and
Electrical Items like Bulbs, Filters, Spark Plugs, Drive Chain, Sprocket, Clutch plate, Race Bearing & Element
Air Cleaner and wheel rim misalignment or bend.
-i-i;l i ii li nii ii r i- irin i, i--,li-,(ii, ^l- nii i il--
i- (-i ( - ;i(i), i i-, ni i ;-i i;-- l -, l--, -i ^, i;(, -il-,
-, l^ i i-- i nii ri l- i l-i;-- i -i rii|
pg97_103.pmd 9/24/2005, 8:39 AM 101
3. Part(s) of the Motorcycle that have been subjected to misuse, accident, negligent treatment or which have
been used in conjunction with parts and equipment not manufactured or recommended for use by YAMAHA
such use prematurely affects the performance and reliability of the motorcycle.
-i-i;l i- li i^ li î ri, i-i ii r ri i i(iri i i ^; ri i(i lr
i- nii ii ii i i^ li î ri lr i-iri ,ii -nil(n i(i ll-n ri li î ri, ; nr ;
i- i i-l i^ -i-i;l i iini i l((ini i iil(n ni r|
4. Use of non-genuine parts, non-genuine oil and lubricants.
i -i-, n nii i i- i i^|
5. Parts of the Motorcycle getting rusty due to atmospheric effects because of Industrial Pollution.
-i-i;l ( i- i l inil^ ii ii ri (i (ini(i ii(i i (r ^ n r|
6. Parts of Motorcycle that have been altered and modified or replaced in unauthorised manner and which in
the sole judgement of YAMAHA affects its performance and reliability.
-i-i;l ( i- lr lin l(lnn li î ri, iii î ri i(i i î ri i i i-iri li
n^n -i-i;l i iini nii l((ini ii( in ri|
7. Motorcycle that has not been got serviced by YAMAHAS Authorised Dealers as per the service schedule
described in this Owners Manual vide the 6 Free Services, 2 Bonus Services and 7 Paid Service Coupons
(attached in this book) or which has not been operated or maintained in accordance with the instructions
mentioned in this Manual (especially during Running in Period).
îr l-ni - l ^ 6 i l( i, 2 i i l( i i 7 i^ni l( i (i ; l-ni ii r)
i(i ; - (l(i i l^; il -) - l l( liiln - i i-i ( --n i l
l -i-i;l i i-iri lin i l( ri ii î ri|
WARRANTY
okja Vh
pg97_103.pmd 9/24/2005, 8:39 AM 102
8. Motorcycle used for any competition or race and/or for attempting to set up any kind of record. YAMAHA
undertakes no liability in the matter of any consequential loss or damage caused due to failure of the
part(s).
-i-i;l l li lnil^ni i(i i i(i ; li nr i i; li i- i - li î ri ni i-iri
; -i- - i-,i- ii ri ii li nr i i(i -iln l -iii ri riî|
9. For motorcycles which have been used for any commercial purposes & Loading such as taxi etc.
-i-i;l i l i(il ii i -i ;-il - i^ li î ri
10. For normal phenomenon like noise, vibration, oil seepage, which do not affect the performance of the
Motorcycle?
i-i i-i i(i, , n i li( ;-il l -i-i;l i iini - i; ii( ri ni|
11. For maintenance repairs required due to misuse while driving or due to adulteration of oil, petrol or due to
bad road conditions.
i --n li ii in - ;i ri ;-n-i i, n, -i - l-i(- i i i i-ni rin ri|
12. If any part of the vehicle is tampered / repaired by unauthorised persons/workshops etc.
l îi i; ii iiii i i ^; ri i ;i --n li lin (ii i i-i ,ii i ^; ri|
13. For consumables like oil, grease etc. used during free services or used during warranty repairs.
(i-i i -n l( - i^ i ^ i i î ;-il|
14. If there is any damage due to modification or fitting of accessories other than the ones recommended by
YAMAHA.
l i; l(n i i -i i i-iri ,ii llin ri r l ,ii i; iii i; ri|
WARRANTY
okja Vh
pg97_103.pmd 9/24/2005, 8:39 AM 103
okja Vh
WARRANTY
9.8
15. For claims made for any consequential damage due to any previous malfunction.
i - l- li ii iii ii i ri ri|
16. If there is any damaged caused due to usage of improper oil/grease, non genuine parts.
i i i,î ;-il i^ ,ii i ri nii i i- ;-n-i ii i ri|
17. This warranty does not cover the risks like accidents, lightening, water, fire other acts of God, improper
handling or any external cause beyond the control of YAMAHA.
ili- i-i, li l^ r i, ii, i^ i i iln iii ,ii, îi i ri ;-n-i ( i
ll-ilni i i-iri lii ir ri|
18. This warranty does not affect the customers statutory rights under applicable Indian laws, nor the consumers
rights against the Dealer arising from their sales/purchase contract.
r (i-i iin i n^n îr (iil lii i ii(ln ri ni i ri i ,ii >,l(> l(i
îr liii i iil(n ni r|
This Warranty is the entire written warranty given by YAMAHA for the Motorcycle and no other person, including the
Authorized Dealer or his agent or employee is authorised to extend or enlarge terms or this Warranty.
i-iri ,ii i ^; r (i-i ii -i-i;l l nl- (;-i) llin (i-i r i i; ii i ln l i i(i
i - -ii ; (i-i i ini i i i(i - l(-ni i l l lin ri r|
FARIDABAD COURTS SHALL HAVE EXCLUSIVE JURISDICTION TO ENTERTAIN ANY DISPUTES ARISING
OUT OR IN ANY WAY TOUCHING OR CONCERNING THIS WARRANTY POLICY
bl okjaVh ikWyhlh ds fo:/k o bl lEcU/k esa mRiUu fdlh Hkh rjg ds fookn ds fy, Qjhnkckn U;k;ky; ds ikl ,dkfUrd :i ls bUgs Lohdkj
djus ds vf/kdkj gSaA
pg97_103.pmd 9/24/2005, 8:39 AM 104
pg97_103.pmd 9/24/2005, 7:54 AM 105
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This coupon entitles the owner to the paid service as detailed overleaf
and is mandatory for eligibility of warranty benefits.
Cost of Oil & Gaskets will be chargeable at actuals.
No.
SELLING DLR'S STAMP, SIGN & CODE
SERVICING DLR'S STAMP, SIGN & CODE
CUSTOMER'S CERTIFICATION
The jobs as detailed overleaf have been
executed to my entire satisfaction.
Sig. :
Name :
FRAME NO. :
ENGINE NO. :
DATE OF SALE :
JOB CARD NO :
SERVICE DATE :
KILOMETERS :
VALIDITY : WITHIN 28500-29000 KMS FROM THE DATE OF PURCHASE OF MOTORCYCLE
OR WITHIN 60 DAYS FROM PREVIOUS SERVICE WHICHEVER IS EARLIER.
15
FIFTEENTH PAID SERVICE COUPON
SERVICING DEALER TO ENSURE THAT SERVICE RECORD IS DULY ENTERED ON PAGE 10-41.
10-1
DETGREEN.pmd 9/24/2005, 7:59 AM 1
JOBS TO BE CARRIED OUT DURING FIFTEENTH PAID SERVICE
1. Note down the customers observations.
2. Wash Motorcycle and blow it dry with compressed air.
3. Clean Spark Plug and reset the gap if necessary.
4. Check Valve clearance, adjust if necessary.
5. Clean and tune Carburettor, set the idle RPM, as recommended. Check for the easy operation of Choke Lever.
6. Open and clean Fuel Cock and Fuel Filter. Check for any cracks or damage on Fuel Hose.
7. Clean Air Filter Element and lubricate it with (4T) oil.
8. Replace Engine Oil and check for any leakages.
9. Wash Engine Oil Filter Screen with petrol.
10. Check operation of Front & Rear Brakes, adjust if necessary. Grease the Brake Cam.
11. For proper Clutch functioning, check alignment marks on Crank Case L.H., Adjust if necessary.
12. Check for Wheel Runout/Spokes looseness, repair if necessary.
13. Check Wheel Bearings (Front & Rear) for looseness, damage.
14. Check for Steering looseness / tightness, adjust if required.
15. Check Front Fork operation / oil leakages, repair if reqrired.
16. Check for Rear Shock Absorber operation.
17. Check Chain Slackness, alignment. Adjust if necessary. Clean and lubricate.
18. Clean Battery, check electrolyte level and proper routing of Breather Pipe.
19. Tighten all Nuts and Bolts. Specially, Cylinder Head, Engine Mounting, Rear Swing Fork, Front & Rear Wheel
Axles & Rear Shock Absorber Mountings to the specified torque.
20. Check all electrical operations.
21. Check and correct air pressure in Front and Rear Tyres.
22. Lubricate all the pivot points.
23. Check exhaust emission for CO level at idling, correct if required.
24. Clean and polish Motorcycle after taking ROAD TEST.
10-2
DETGREEN.pmd 9/24/2005, 7:59 AM 2
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No.
Sig. :
Name :
FRAME NO. :
ENGINE NO. :
DATE OF SALE :
JOB CARD NO :
SERVICE DATE :
KILOMETERS :
FOURTEENTH PAID SERVICE COUPON
14
10-3
DETGREEN.pmd 9/24/2005, 7:59 AM 3
JOBS TO BE CARRIED OUT DURING FOURTEENTH PAID SERVICE
10-4
DETGREEN.pmd 9/24/2005, 7:59 AM 4
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No.
Sig. :
Name :
FRAME NO. :
ENGINE NO. :
DATE OF SALE :
JOB CARD NO :
SERVICE DATE :
KILOMETERS :
THIRTEENTH PAID SERVICE COUPON
13
10-5
DETGREEN.pmd 9/24/2005, 7:59 AM 5
JOBS TO BE CARRIED OUT DURING THIRTEENTH PAID SERVICE
10-6
DETGREEN.pmd 9/24/2005, 7:59 AM 6
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No.
Sig. :
Name :
FRAME NO. :
ENGINE NO. :
DATE OF SALE :
JOB CARD NO :
SERVICE DATE :
KILOMETERS :
TWELVETH PAID SERVICE COUPON
12
10-7
DETGREEN.pmd 9/24/2005, 7:59 AM 7
JOBS TO BE CARRIED OUT DURING TWELVETH PAID SERVICE
10-8
DETGREEN.pmd 9/24/2005, 7:59 AM 8
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No.
Sig. :
Name :
FRAME NO. :
ENGINE NO. :
DATE OF SALE :
JOB CARD NO :
SERVICE DATE :
KILOMETERS :
ELEVENTH PAID SERVICE COUPON
11
10-9
DETGREEN.pmd 9/24/2005, 7:59 AM 9
JOBS TO BE CARRIED OUT DURING ELEVENTH PAID SERVICE
10-10
DETGREEN.pmd 9/24/2005, 7:59 AM 10
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No.
Sig. :
Name :
FRAME NO. :
ENGINE NO. :
DATE OF SALE :
JOB CARD NO :
SERVICE DATE :
KILOMETERS :
TENTH BONUS FREE SERVICE COUPON
10
10-11
DETWHITE.pmd 9/24/2005, 7:59 AM 1
JOBS TO BE CARRIED OUT DURING TENTH BONUS FREE SERVICE
10-12
DETWHITE.pmd 9/24/2005, 7:59 AM 2
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No.
Sig. :
Name :
FRAME NO. :
ENGINE NO. :
DATE OF SALE :
JOB CARD NO :
SERVICE DATE :
KILOMETERS :
NINTH BONUS FREE SERVICE COUPON
9
NOTE : ABOVE COUPAN TO BE DESPATCHED ONLY AFTER FILLING IN THE PAID SERVICE RECORD PRINTED OVERLEAF
10-13
DETWHITE.pmd 9/24/2005, 7:59 AM 3
JOBS TO BE CARRIED OUT DURING NINTH BONUS FREE SERVICE
5. Clean and tune Carburettor, set the idle RPM, as recommended. Check for the easy
operation of Choke Lever.
11. For proper Clutch functioning, check alignment marks on Crank Case L.H., Adjust if
necessary.
19. Tighten all Nuts and Bolts. Specially, Cylinder Head, Engine Mounting, Rear Swing Fork,
Front & Rear Wheel Axles & Rear Shock Absorber Mountings to the specified torque.
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10-14
DETWHITE.pmd 9/24/2005, 7:59 AM 4
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No.
Sig. :
Name :
FRAME NO. :
ENGINE NO. :
DATE OF SALE :
JOB CARD NO :
SERVICE DATE :
KILOMETERS :
8
EIGHTH PAID SERVICE COUPON
10-15
DETGREEN.pmd 9/24/2005, 7:59 AM 11
JOBS TO BE CARRIED OUT DURING EIGHTH PAID SERVICE
10-16
DETGREEN.pmd 9/24/2005, 7:59 AM 12
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No.
Sig. :
Name :
FRAME NO. :
ENGINE NO. :
DATE OF SALE :
JOB CARD NO :
SERVICE DATE :
KILOMETERS :
7
SEVENTH PAID SERVICE COUPON
10-17
DETGREEN.pmd 9/24/2005, 7:59 AM 13
JOBS TO BE CARRIED OUT DURING SEVENTH PAID SERVICE
10-18
DETGREEN.pmd 9/24/2005, 7:59 AM 14
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No.
Sig. :
Name :
FRAME NO. :
ENGINE NO. :
DATE OF SALE :
JOB CARD NO :
SERVICE DATE :
KILOMETERS :
VALIDITY : WITHIN 10500-11000 KMS OR 360 DAYS FROM THE DATE OF
PURCHASE OF MOTORCYCLE WHICHEVER IS EARLIER.
6
SIXTH FREE SERVICE COUPON
10-19
DETWHITE.pmd 9/24/2005, 7:59 AM 5
JOBS TO BE CARRIED OUT DURING SIXTH FREE SERVICE
10-20
DETWHITE.pmd 9/24/2005, 7:59 AM 6
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No.
Sig. :
Name :
FRAME NO. :
ENGINE NO. :
DATE OF SALE :
JOB CARD NO :
SERVICE DATE :
KILOMETERS :
FIFTH FREE SERVICE COUPON
5
10-21
DETWHITE.pmd 9/24/2005, 7:59 AM 7
JOBS TO BE CARRIED OUT DURING FIFTH FREE SERVICE
10-22
DETWHITE.pmd 9/24/2005, 7:59 AM 8
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No.
Sig. :
Name :
FRAME NO. :
ENGINE NO. :
DATE OF SALE :
JOB CARD NO :
SERVICE DATE :
KILOMETERS :
FOURTH FREE SERVICE COUPON
4
10-23
DETWHITE.pmd 9/24/2005, 7:59 AM 9
JOBS TO BE CARRIED OUT DURING FOURTH FREE SERVICE
10-24
DETWHITE.pmd 9/24/2005, 7:59 AM 10
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No.
Sig. :
Name :
FRAME NO. :
ENGINE NO. :
DATE OF SALE :
JOB CARD NO :
SERVICE DATE :
KILOMETERS :
THIRD FREE SERVICE COUPON
3
10-25
DETWHITE.pmd 9/24/2005, 7:59 AM 11
JOBS TO BE CARRIED OUT DURING THIRD FREE SERVICE
10-26
DETWHITE.pmd 9/24/2005, 7:59 AM 12
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No.
Sig. :
Name :
FRAME NO. :
ENGINE NO. :
DATE OF SALE :
JOB CARD NO :
SERVICE DATE :
KILOMETERS :
SECOND FREE SERVICE COUPON
2
10-27
DETWHITE.pmd 9/24/2005, 7:59 AM 13
JOBS TO BE CARRIED OUT DURING SECOND FREE SERVICE
10-28
DETWHITE.pmd 9/24/2005, 7:59 AM 14
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No.
Sig. :
Name :
FRAME NO. :
ENGINE NO. :
DATE OF SALE :
JOB CARD NO :
SERVICE DATE :
KILOMETERS :
FIRST FREE SERVICE COUPON
1
10-29
DETWHITE.pmd 9/24/2005, 7:59 AM 15
JOBS TO BE CARRIED OUT DURING FIRST FREE SERVICE
10-30
DETWHITE.pmd 9/24/2005, 7:59 AM 16
10-31
1. Check for any missing item(s), scratches in painted/plated part(s), saddle or other external
visual damages and take corrective action.
Check each of the following items individually and mention the corrective action (as per the
recommended specifications) in the boxes provided.
2. Check for missing part(s), if any.
A. FRAME
a. Brakes
Front : Free Play at Lever End (10 ~ 15 mm)
Rear : Free Play at Rear Brake (20 ~ 30 mm)
b. Clutch : Free Play at Lever End (10 ~ 15 mm)
c. Throttle : Free Play at Throttle Grip (3 ~7 mm)
d. Steering : Check for Free Movement
e. Suspension
Front Fork : Check for any sticky movement
Rear Shock Abs : For Free Stroking
(To be filled in by the Dealer on receipt of the Motorcycle from YMI)
Odo-Meter
Reading
Date of
Inspection
Frame
No.
Engine
No.
Date of
Sale
Found OK Set Right Replaced Cleaned Lubricated
R C L S
PRE-DELIVERY INSPECTION REPORT
No.
SERVICE2.pmd 9/24/2005, 8:01 AM 1
f. Wheels
Tyre : Tyre pressure Solo Double
(PSI)
Front 25 25
Rear 32 32
Ri m : Runout - Radial - 1.5 mm (Max)
- Lateral - 1.5 mm (Max)
Spokes : No loosenes
g. Locks Operation : Ignition
Steering
Fuel Tank Cap
Side Cover (L.H.)
h. Fasteners Specified Torque
(Ft-Lb)
1. Front Wheel Axle Nuts 25-40
2. Front Fork (Crown Handle & Inner Tube) 13-20
2. Front Fork under Bracket Stem Nut 18-22
3. Handle Bar Mounting Bolts 13-20
4. Rear Shock Absorber Mounting Bolts 22-35
5. Rear Swing Arm Pivot Shaft Nut 32-52
6. Rear Wheel Axle/Sprocket. Shaft Nuts 60-70
B. ENGINE
a. Engine Oil : Oil Level (For checking - Refer Pg. 6-11)
Check for any Leakages
10-32
SERVICE2.pmd 9/24/2005, 8:01 AM 2
b. Spark Plug : Recommended No. (P-RA7HC - Champion)
Gap 0.9 0.2 mm
c. Valve Clearance : (Cold condition)
(If required) Inlet 0.08 ~ 0.12 mm
Exhaust 0.10 ~ 0.14 mm
(After matching of the mark on sprocket cam chain with mark on Cylinder
Head Casting and ensuring the Piston at TDC of compression stroke.)
d. Kick Operation : For free Movement
e. Carburetor : Idle RPM In warmed up condition(1300~1500 RPM)
Check for Overflow
f. Drive Chain : Alignment
Slackness (20 ~ 30 mm)
g. Fasteners Specified Torque
(Ft-Lb)
1. Cylinder Head Bolts 14-17
2. Engine Mounting
a) Engine Mounting Front and Stay Front 25-29
b) Stay Engine Front and Frame 25-29
c) Engine Mounting Rear and Frame 25-29
d) Engine Mounting Upper &
Stay Engine Upper 25-29
e) Stay Engine Upper and Frame 25-29
f) Engine Mounting Front Lower and Frame 25-29
3. Front and Rear Silencer Mounting Nut 9-12
4. Crown Handle Centre Bolt 20-31
10-33
SERVICE2.pmd 9/24/2005, 8:01 AM 3
10-34
C. ELECTRICAL
a. Ignition Switch Operation
b. Left Hand Switch Operation & Pass Beam
Horn
Indicator
Head Light
c. All Bulbs - Functioning
d. Battery
Electrolyte Level
Specific Gravity
Routing of Breather Pipe
Fuse
Routing of Positive Wire (Red) Below Breather Pipe
D. ROAD TEST
a. Starting
b. Gear Shifting Operation
c. Clutch Operation
d. Application of Brakes (Front and Rear)
e. Speedo/ Odo Meter Operation
EXPLAINED BY:
SIGNATURE : NAME :
MAIN SELLING DLR'S STAMP, SIGN & CODE
CUSTOMERS SIGNATURE:
SERVICE2.pmd 9/24/2005, 8:01 AM 4
10-35
1. Operation of all the locks (Ignition, Steering, Fuel Tank Cap, Side Cover L.H.).
2. Fuel Cock Lever Operation and its reserve position; Fuel Tank Capacity including reserve.
3. Operation and function of Choke Lever.
4. Operation of Kick Lever.
5. Operation of Throttle.
6. Operation of Handle Bar Switches, their Functions and Pass Beam.
7. Disadvantages of riding on half Clutch (Never ride with clutch pressed).
8. Gear shifting pattern.
9. Tyre inflation pressure : Front - 25 Psi Rear - 32 Psi (Solo), 32 Psi (Double)
10. Never give sudden acceleration; always accelerate gradually
11. Simultaneous use of Front and Rear Brakes.
12. Never ride with your foot on Rear brake Pedal.
13. Whenever parking the Motorcycle on the Main Stand, ensure that the Fuel Cock Lever is in closed
position.
INSTALLATION
Procedures to be explained to the customer on delivery of the Motorcycle by the Dealer's
Representative.
SERVICE2.pmd 9/24/2005, 8:01 AM 5
14. Location of Storage and Tool Kit compartments and their use.
15. Procedure of opening and closing of L. H. Side Panel.
16. Battery Maintenance : Checking of electrolyte level (To add only distilled water if required &
to maintain its Specified Level)
17. Correct Drive Chain Slackness (20 ~30 mm).
18. Correct type of Spark Plug and Spark Plug gap.
19. Engine Oil (in Gear Box), level checking and explaining the importance of replacing the Engine
Oil after every 2000 KMS Always use YAMALUBE 4T OIL SG Grade.
20. TFF oil to be replaced after every 10000 Kms.
21. Running- In Period/ Preventive Maintenance Schedule Instructions
22. Information of emission and safety norms alongith Catcon & AIS.
23. Importance and schedule of Free Services
24. Warranty Terms and Conditions.
INSTALLATION
IMPORTANT CAUTION
EXPLAINED BY:
SIGNATURE : NAME :
MAIN SELLING DLR'S STAMP, SIGN & CODE
10-36
SERVICE2.pmd 9/24/2005, 8:01 AM 6
DELIVERY CERTIFICATE
(To be filled in at the time of delivery of Motorcycle)
CUSTOMERS NAME
ADDRESS
No.
Please Tick against
appropriate Nos.
Engine No.
1. Colour :
Date of sale :
9. Vehicle Owned :
2. Marital Status :
3. Age Group :
4. Family Income (PM) :
5. Education :
6. Occupation :
7. Mode of Purchase :
8. What Prompted you to :
Purchase Vehicle
Frame No. :
Dealer SSO Sub Dealer Branch Consultant
D D M M Y Y Y Y
1 Single Married 2
1 18-24 2 25-29 3 30-34 4 35-39 >40 5
1 <5000 2 5000-10000 10000-15000 3 15000-20000 >20000 4 5
1 High School Under Graduate 2 Graduate Post Graduate 3 4
Student 1 Business 2 Service Agriculture 3 4
Cash 1 Finance 2 Institutional 3
News Paper/Magazine 1 Friends Hoarding 2 3 Mechanics 4 5 TV
5 1 Black 2 White 3 Red 4 Brown Blue / Dark Blue
6 Gold 7 Green 8 Silver / Gray 10 Other 9 Maroon
1 2 3 4 5
Sold by :
First 2 Wheeler 1 Previous 2 wheeler 1 2 2 3 HH TVS BAJAJ LML 4
10-37
SERVICE2.pmd 9/24/2005, 8:01 AM 7
10-38
CUSTOMER CERTIFICATION :
1. This is to certify that I have taken possession of CRUX motorcycle with the Tool Kit and First Aid Kit.
The Dealer Representative has explained and demonstrated the Important Functions and Company Policy
also.
SELLING DLRS STAMP, SIGN & CODE
10. Which Motorcycle :
you considered
before buying Yamaha
12. Main uses of :
Commuting 1 2 Business 3 Leisure Ride 4 Shopping
Single Riding 1 2 Pillion Riding 13. Usage Pattern : % %
motorcycle
11. What influenced the :
Purchase
(Choose any Three)
Styling 1 Coloring 2 3 Fit and Finish 4 Price 5 Fuel consumption
Engine performance 6 7 Engine CC size 8 Handling 9 Rider comfort
Riding Position 10 11 Passenger comfort 12 Availability 13 Physical size
Reliability / Durability 14 15 Resale value 16 Dealer 17 New Model
Reputation by friend/magazine 18 19 Brand Reputation 20 Other
DELIVERY CERTIFICATE
Model 2
HH TVS BAJAJ LML 1 3 4 2
SERVICE2.pmd 9/24/2005, 8:01 AM 8
* Service to be availed within specified kms from date of Purchase or 60 days after
previous service.
CUSTOMER'S NAME & ADDRESS
MOTORCYCLE IDENTIFICATION
DATE OF SALE OF MOTORCYCLE
30
90
180
SERVICE/WARRANTY RECORD
500-
700
2500-
2700
4500-
5000
S.
NO.
SERVICED AT
KMS / ON DATE
SERVICING DLR'S
NAME & ADDRESS
JOB DETAILS/
CARD NO
SELLING DLR'S
STAMP, SIGN & CODE
VALIDITY*
KMS / DAY DATE
FRAME NO. :
ENGINE NO. :
1
2
3
No.
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SERVICE RECORD
10-39
SERVICE2.pmd 9/24/2005, 8:01 AM 9
SERVICE RECORD
240
300
360
6500-
7000
8500-
9000
10500-
11000
S.
NO.
SERVICED AT
KMS / ON DATE
SERVICING DLR'S
NAME & ADDRESS
JOB DETAILS/
CARD NO
VALIDITY*
KMS / DAY DATE
4
5
6
12500-13000
14500 -15000
SERVICED AT
KMS / ON DATE
SERVICING DLR'S
NAME & ADDRESS
JOB DETAILS/
CARD NO
VALIDITY*
KMS DATE
previous service.
S.
NO.
7
8
F
R
E
E

S
E
R
V
I
C
E

R
E
C
O
R
D
P
A
I
D

S
E
R
V
I
C
E

R
E
C
O
R
D
10-40
SERVICE2.pmd 9/24/2005, 8:01 AM 10
SERVICE RECORD
11
16500-17000
18500-19000
20500-21000
S.
NO.
SERVICED AT
KMS / ONDATE
SERVICING DLR'S
NAME & ADDRESS
JOB DETAILS/
CARD NO
VALIDITY*
KMS DATE
9
10
22500-23000
24500-25000
26500-27000
S.
NO.
SERVICED AT
KMS / ON DATE
SERVICING DLR'S
NAME & ADDRESS
JOB DETAILS/
CARD NO
VALIDITY*
KMS DATE
12
13
14
28500-29000
B
O
N
U
S

F
R
E
E
S
E
R
V
I
C
E

R
E
C
O
R
D
P
A
I
D

S
E
R
V
I
C
E

R
E
C
O
R
D
previous service.
15
10-41
SERVICE2.pmd 9/24/2005, 8:01 AM 11
SERVICE RECORD
10-42
(i) Cost of Oil for the Free Services will be Chargeable at actuals and to be borne by
the Customer.
(ii) Please ensure that the Servicing Dealer Column is duly Stamped & signed by the
Servicing Dealer.
(iii) For the validity of "Warranty" benefits, It is mandatory that all Services, Bonus
Free Services and Paid Services are availed by the customer as per the
recommended Schedule, as given in the Owner's Manual.
(iv) Please ensure that each service is availed within 60 days from date of previous
service or as per the recomended service schedule whichever is earlier.
I
M
P
O
R
T
A
N
T
SERVICE2.pmd 9/24/2005, 8:01 AM 12
(PLEASE READ THIS BOOK CAREFULLY)
LET US
KEEP OUR ENVIRONMENT
CLEAN
G
R
E
E
N

B
O
O
K
greenbook.pmd 9/24/2005, 8:00 AM 1
CONTENTS
Government Regulations 1
Action by Yamaha Motor India Sales Pvt. Ltd. 1
Guidelines to be followed by the Owners/Users of Motorcycles. 1
DOS & DONTS for the Motorcycle 2-3
Procedure for measurement of CO Emission Level. 4
List of Components impacting Emission 5
Log Sheets 6
IMPORTANT GUIDELINES
1. GOVERNMENT REGULATIONS
1.1 Exhaust emission has harmful effect on our environment / public health.
1.2 To safeguard environment from getting polluted, Govt. of India has enforced specific regulations to
control Automobile exhaust emission.
1.3 The Center Motor Vehicle Rule (CMVR) states that for Motorcycles, Carbon Monoxide Emission,
during idling shall always be less than 3.5% (By Volume).
1.4 Non compliance with above standard is a punishable offence.
2. ACTION YAMAHA MOTOR INDIA SALES PVT. LTD.
2.1 YMIS as a manufacturer ensures that all Motorcycles leaving the Factory meet the exhaust emission
norms as specified by CMVR.
2.2 Special note has been included in the Owners Manual for reference and attention by the Owner/User.
3. GUIDELINES TO BE FOLLOWED BY THE OWNERS/USERS OF MOTORCYCLES.
3.1 Please ensure that the CO Emission is got checked by Authorised Agencies registered with the Appro-
priate Authorities.
3.2 Please ensure that the CO is within specified limits of 3.5% (by volume). If it is not so, it should be got
reset by YMIS Authorised Dealer.
3.3 Do not tamper with the Carburetor settings done by the Factory/YMIS Authorised Dealer.
3.4 Please maintain the Log Sheet provided in the Green Book.
3.5 Proper Installation : The Owner/User must clearly understand, from the Dealer, all the points related to
proper Installation of the Motorcycle as described in the Owners Manual.
1
3.6 KEEP OUR ENVIRONMENT CLEAN.
Please follow simple steps
DOS ()
1 Always use genuine spare parts purchased from YMIS Authorised Dealers.
2 Always use only genuine oils
4T - 20W/40 SG grade - YAMALUBE 4T
3 Always keep your engine well tuned. Save environment and also improve Fuel Efficiency
4 ALWAYS GET YOUR MOTORCYCLE REPAIRED AND MAINTAINED ONLY AT YMIS AUTHORISED
DEALER.
YMIS serves you through a large network of Authorised Dealers.
5. Check the Following at every scheduled service:-
a) Spark Plug : Check/Reset Gap/Replace as per the recommendations
in this Owners Manual (page no 6-7)
b) Carburetor : Cleaning/Adjustment Every 4500 kms
c) Air Filter : Clean every 2000 kms as per the environment conditions.
d) Piston/Rings/Cylinder : Check / Clean / Replace if necessary
e) Exhaust System : Check / Replace if necessary
f) Valve Timing : Check / Adjust every 4500 kms
g) Compression pressure : Check / Diagnose.
DOS AND DONTS FOR THE MOTORCYCLE
2
DOS AND DONTS FOR THE MOTORCYCLE
6 Always drive with Starter Lever in OFF position.
7 Use Starter Lever for minimum possible period (1 to 2 minutes) only to start and warm up Engine
(may be required only in winter)
8 If misfiring, get your Motorcycle diagnosed & attended immediately without running even for a KM.
9 Get Motorcycle maintained regularly as per details and schedule given in Owners Manual.
10 Get emission of your Motorcycle inspected at least once every 3 months.
11 Please follow good driving habits in varying traffic conditions.
12 Switch OFF the engine while waiting at signal point.
DONTS ()
1. Dont overload/overspeed your Motorcycle.
2. Dont alter or modify you Motorcycle.
3. Never drive with Ignition OFF while moving down a slope.
4. Dont turn off the Engine or interrupt the Ignition when the Transmission is in Gear & the Motor
cycle is in motion.
5. Dont idle the Engine for a prolonged period.
6. Dont use Non-Genuine Parts.
7. Dont buy adulterated Petrol/Oil.
3
4. PROCEDURE FOR MEASUREMENT OF CO EMISSION LEVEL
4.1 IMPORTANT : CO Measurement Equipment must be duly calibrated.
4.2 Check for NO LEAKAGE from Exhaust System.
4.3 Starter Lever should be in OFF position.
4.4 All Electricals should be in OFF position.
4.5 Set the Idle speed of the Engine in warmed up condition of Motorcycle as specified.
4.6 Insert the Sampling probe of the Exhaust Gas Analyser inside the Exhaust Muffler of the
Motorcycle.
4.7 If the reading is within specified limits then it is acceptable.
If the reading exceeds the norm of 3.5% (by volume) have it adjusted by YMIS Authorised
Dealer.
4.8 YMIS serves you through an extensive network of
Authorised Dealers
Authorised Service Points.
Trained Private Workshop (Garage) Owners.
CO EMISSION LEVEL MEASUREMENT
4
MODEL IDLE R.P.M.
1300 - 1500 RPM CRUX
5. LIST OF COMPONENTS IMPACTING EMISSION
a. Air Filter
b. Carburetor
c. Cylinder
d. Piston Ring & Piston
e. Cylinder Head
f. Rocker Arm
g. Valves
h. Cam Shaft
i. Valve Seals
j. Timing Chain
k. Air Intake System
l. Ignition Coil, CDI, Magneto
m. Spark Plug
n. Exhaust System
o. Catcon
p. AIS
CO EMISSION LEVEL MEASUREMENT
5
Customer Name : Date of Purchase :
Address : Vehicle Reg. No. :
Selling Dealer :
SL.
No.
Date KM
Reading
Job Card
No.
Service
(Free/Paid)
Parts Replaced Oil Fill Qty.
4T, Gear Box
CO Level
Date/Value)
Serv. Dealer
LOG SHEET (To be Filled in by Owner/User)
6
YAMAHA MOTOR INDIA PVT. LTD.
77- A - 78 SRI AURBINDO MARG
ADCHINI
NEW DELHI-110017
PH. : 011-51644455/51645566
ao-delhi@yamaha-motor-india.com
B-1/1, L.PARK
MAHANAGAR EXTENTION
LUCKNOW-226006, UTTAR PRADESH.
PH. : 0522-2320275, FAX : 0522-2377847
ao-lucknow@yamaha-motor-india.com
502, SAROVAR COMPLEX
JAIN DERASAR LANE, OFF.C.G.ROAD
AHMEDABAD-380009, GUJARAT
PH. : 0792-6406939, FAX : 079-6565941
ao-ahmedabad@yamaha-motor-india.com
3RD FLOOR JELITTA TOWERS,
21/1, MISSION ROAD,
BANGLORE-560027, KARNATAKA
PH. : 080-22129289, Fax: 2126353
ao-blr@yamaha-motor-india.com
2nd FLOOR, ATKINSON PLACE
2, JOTHI VENKATACHALAM VEPERY
ROAD, CHENNAI - 600007, TAMILNADU
PH. : 044-25611940 FAX : 25611941
ao-madras@yamaha-motor-india.com
C.L. BHAWAN
56/2, HAZARA ROAD
KOLKATA-700019 (WB)
PH. : 033-24860533/24544748
ao-cal@yamaha-motor-india.com
K-MANSION BUILDING, BLOCK-K-3,
340 GAUTAM NAGAR,
BHUBANESHWAR-751 014
PH. : 0674-2435160
ao-bhuv@yamaha-motor-india.com
6-3-883, FLAT NO. 602, TOPAZ
BUILDING
PANJAGUTTA, HYDERABAD - 500 482
ao-hyd@yamaha-motor-india.com
PH. : 040-55103888/55108039
406, ADARSH PLAZA,
JAIPUR-320001, RAJASTHAN
ao-jaipur@yamaha-motor-india.com
KHASA KOTHI
CROSSING
PH. : 0141-2200393 / 2207228,
FAX : 0141-200393
2A & 2B, MAYFAIR TOWERS,
WAKDE WADE,SHIVAJI NAGAR,
PUNE- 411005, MAHARASHTRA
PHONE (020) - 25530327, 25530781
ao-pune@yamaha-motor-india.com
C/O GREEN VALLEY TRAVELS BLDG.
G.N. BARDOLI ROAD, SILPUKHRI
GUWAHATI-781003, ASSAM
PH. : 0361-2661950, FAX : 0361-2661950
ao-gwh@yamaha-motor-india.com
22, 1 FLOOR, HAPPY CHAMBERS,
179 ZONE-2, BHOPAL-462001,
MADHYA PRADESH
,
ao-bhopal@yamaha-motor-india.com
ST
PH. : 0755-2554305 FAX : 0755-2574307
35/279, SUBURBAN COMPLEX
PALARIVATTOM, KOCHI-682025,
KERALA
PH. : 0484-2341218, FAX : 0484-2341218
ao-cochin@yamaha-motor-india.com
504, HARIOM TOWERS, 6TH FLOOR
OPP. WOMENS COLLEGE
RANCHI - JHARKHAND
PH. : 0651-2563271
Longer Engine Life
Lower Maintenance Cost
Lower Exhaust Smoke
Reduces Wear and Tear
YAMAHA MOTOR INDIA SALES PRIVATE LIMITED
19/6, Mathura Road, Faridabad - 121 006 INDIA
PRINTED IN INDIA
5KA6 - CRUX
1Y15(OM-01)233-09-05-E/H
SG
4 STROKE MOTOR OIL
20W40
4
Parts & Accessories
Always use

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