a 3GJ-28199-21nee IDENTIFICATION NUMBERS RECORD 1, KEY IDENTIFICATION NUMBER 2. VEHICLE IDENTIFICATION NUMBER. (For Australia) FRAME SERIAL NUMBER: (Except for Australia} P| Your key identification number is stamped on your key as shown in the following illustration. Record this number in the space provided for reference if you need a new key. [lw key dentifcation number 3 ENGINE SERIAL NUMBER: Record your vehicle identification (or frame serral) number and engine serial number in the spaces provided to assist you in ordering spare parts from your Yamaha dealer or for reference in case your vehicle is stolen. (See page 2-1)TT350A OWNER’S MANUAL ©1989 by Yamaha Motor Co., Ltd. 4st Edition, November 1989 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd, is expressly prohibited. Printed in Japanam INTRODUCTION Congratulations on your purchase of the Yamaha TT350A. This model is the result of Yamaha's vast experience in the production of fine sporting, touring, and pacesetting racing machines. It represents the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields. ‘This manual will give you an understanding of the operation, inspection, and basic maintenance of this motorcycle If you have any questions about the operation or maintenance of your motor- cycle, please consult a Yamaha dealer NOTE: Some data in this manual may become out-dated due to future improvement on this model, If you have any questions about this manual or your motorcycle, please consult a Yamaha dealer TECHNICAL PUBLICATIONS SERVICE DIVISION MOTORCYCLE GROUP YAMAHA MOTOR CO., LTD.aro vent AWARNING PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE. Particularly important imformation is distinguished in this manual by the following notations: a The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! PRUEGMINTA «—Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator, a bystander, or a person inspecting or repairing the motorcycle. ‘CAUTION: < A CAUTION indicates special precautions that must be taken to avoid damage to the motorcycle. NOTE: ANOTE provides key information to make procedures easier or clearer vee NOTE: This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold.SAFETY INFORMATION TWO-WHEELED MOTORCYCLES ARE SINGLE TRACK VEHICLES. THEIR SAFE USE AND OPERATION ARE DEPENDENT UPON THE USE OF PROPER RIDING TECH- NIQUES AS WELL AS THE EXPERTISE OF THE OPERATOR. EVERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIREMENTS BEFORE RIDING. HE OR SHE SHOULD: 1. OBTAIN THOROUGH INSTRUCTIONS FROM A COMPETENT SOURCE ON ALL ASPECTS OF MOTORCYCLE OPERATION. 2, OBSERVE THE WARNINGS AND. MAINTENANCE REQUIREMENTS IN THE OWN- ER’S MANUAL. 3. OBTAIN QUALIFIED TRAINING IN. SAFE AND PROPER RIDING TECHNIQUES. 4. OBTAIN PROFESSIONAL TECHNICAL SERVICE AS INDICATED BY THE OWN- ER’S MANUAL AND/OR WHEN MADE NECESSARY BY MECHANICAL CON. DITIONS. 1. Always make pre-operation checks. Careful checks may help prevent an accident. 2. This motoroycle is designed to carry the operator only. No passengers.3. The failure of motorists to detect and recognize motorcycles in traffic is the predominating cause of automobile/motorcycle accidents. Many accidents have been caused by an automobile driver who did not see the motorcycle. Making yourself conspicuous appears to be very effective in reducing the chance of this type of accident. Therefore: a. Wear a brightly colored jacket. b. Use extra caution when you approach and pass through intersections, since in- tersections are the most likely places for motorcycle accidents. c. Ride where other motorists can see you. Avoid riding in another motorist’s “blind spot.” 4, Many accidents involve inexperienced operators. In fact, many operators who have been involved in accidents do not even have a current motorcycle license. a. Make sure you are qulified. Also, only lend your motorcycle to experienced operators. b. Know your skills and limits. Staying within your limits may help you to avoid an accident. c. We recommend that you practice riding your motorcycle where there is no traffic until you have become thoroughly familiar with your motorcycle and all of its controls.5. Many motorcycle accidents have been caused by motorcycle operator errors. A typical error made by the operator is veering wide on a turn due to EXCESSIVE SPEED or undercornering (insufficient lean angle for the speed). a. Always obey the speed limits and never travel faster than warranted by road and traffic conditions. b. Always signal before turning or changing lanes. Make sure other motorists see you. 6. Operator's posture is important for proper control. The operator should keep both hands on the handlebars and both feet on the operator footrests during opera- tion to maintain control of the motorcycle. 7. Never ride under the influence of alcohol or drugs. The majority of fatalities from motorcycle accidents are the result of head injuries. ‘The use of a safety helmet is the single most critical factor in the prevention or reduc tion of head injuries. 1. Always wear an approved helmet. 2. Wear a face shield or goggles. Wind on your unprotected eyes could contribute to an impairment of vision which could delay seeing a hazard. 3. The use of heavy boots, jacket, trousers, gloves, etc. is effective in preventing or reducing abrations or lacerations. 4. Never wear loose fitting clothing, It could catch on the control levéts, footrests, or wheels and cause injury or accident.5. Never touch the engine or exhaust system during or after operation. They be- come very hot and can cause burns. Always wear protective clothings that covers your legs, ankles, and feet. Modifications made to the motorcycle not approved by Yamaha, or the removal of original equipment, may render your motorcycle unsafe for use and may cause se- vere personal injury. Modifications may also make your motorcycle illegal to use. Adding accessories or cargo to your motorcycle can adversely affect stability and han- dling if the weight distribution of the machine is changed. To avoid the possibility of an accident, extreme caution should be used if adding cargo or accessories to your motorcycle. Use extra care if riding a motorcycle which has added cargo or accesso- ries. Here are some general guidelines to follow if loading cargo or adding accesso- ries to your motorcycle: The total weight of the operator, accessories and cargo must not exceed the maxi- mum load limit of 198 Ibs. (90 kg). When loading within these weight limits, keep the following in mind: 1. Cargo and accessory weight should be kept as low and close to the motorcycle as possible. Be sure to distribute the weight as evenly as possible on both sides of the machine to minimize imbalance or instability.2. Shifting weights can create a sudden imbalance. Make sure that accessories and cargo are securely attached to the motorcycle before riding. Recheck accessory mounts and cargo restraints frequently. 3. Never attach any large or heavy items to the handlebars, front forks, or front fender. These items, including such cargo as sleeping bags, duffle bags, or tents, can create unstable handling or slow steering response. Genuine Yamaha accessories have been specifically designed for use on this motor- cycle. Since Yamaha cannot test all other accessories which may be available, you must personally be responsible for the proper selection, installation and use of non- Yamaha accessories. You should use extreme caution when selecting and installing any accessories. Keep in mind these guidelines for mounting accessories in addition to those provided under “LOADING”. 1. Never install accessories or carry cargo that would impair the performance of your motorcycle. Carefully inspect the accessory before using it to make sure it does not in any way reduce ground clearance or cornering clearance, limit sus- pension travel, steering travel or control operation, or obscure lights or reflectors. a. Accessories fitted to the handlebar or the front fork area can create instability due to improper weight distribution or aerodynamic changes. If accessories are added to the handlebar or front fork area, they must be as light weight as possi- ble and should be kept to a minimum.b. Bulky or large accessories may seriously affect the stability of the motorcycle due to aerodynamic effects. Wind may attempt to lift the motorcycle, or the motor- cycle may become unstable in cross winds. These accessories may also cause instability when being passed by or passing large vehicle. c. Certain accessories can displace the operator from his or her normal riding posi- tion. This improper position limits the freedom of movement of the operator and may limit control ability. Therefore such accessories are not recommended. 2. Caution must be used if adding electrical accessories. If these accessories ex- ceed the capacity of motorcycle's electrical system, an electric failure could result, which could cause a dangerous loss of lights or engine power. 1. GASOLINE IS HIGHLY FLAMMABLE: a. Always turn off the engine when refueling. b, Take care not to spill any gasoline on the engine or exhaust pipe(s)/muffler(s) when refueling. c. Never refuel while smoking or in the vicinity of an open flame. 2. Never start the engine or let it run for any length of time in a closed area. The exhaust fumes are poisonous and may cause loss of consciousness and death within a short time. Always operate your motorycle in an area that has adequate ventilation.Always turn off the engine before leaving the motorcycle unattended and remove the ignition key. When parking the motorcycle, note the following: . The engine and exhaust pipels)/muffler(s) may be hot. Park the motorcycle in a place where pedestrians or children are not likely to touch these hot areas. . Do not park the motorcycle on a slope or soft ground: the motorcycle may fall over. . Do not park the motorcycle near an flammable source, e.g. a kerosene heater, or near an open flame. The motorcycle could catch fire. When transporting the motorcycle in another vehicle, be sure it is kept upright and that the fuel cock(s) is turned to “ON” or “RES (for vacuum typel/OFF” {for manual type). If it should lean over, gasoline may leak out of the carburetor or fuel tank. If you should swallow any gasoline, inhale a lot of gasoline vapor, or allow gaso- line to get in your eye(s), see your doctor immediately. If any gasoline spills on your skin or clothing, immediately wash with soap and water and change your clothes.CONTENTS DESCRIPTION ....... 14 MOTORCYCLE IDENTIFICATION -1 Vehicle identification number (For Australia). ... eee a 24 Frame serial number {Except for Australia)... 0. 1.2... 21 Engine serial number 122 CONTROL FUNCTIONS . 31 Main switch . 31 Speedometer ..... 31 Handlebar switches . vane ee BQ wees 33 Clutch lever Shift pedal ....... “34 Front brake lever. 1.34 Rear brake pedal. 34 Fuel cock ......... .34 Starter knob . : : 34 Kick starter 56... BB Front forks... . a see 2 BE Rear shock absorber ... so 86 Sidestand 37 Sidestand switch operation check . PRE-OPERATION CHECKS .. .. Brakes... Le Brake fluid leakage (Front) Clutch . : Throttle grip Engine ot! Chain. . Tires Wheels .. Fittings/Fasteners . Lights and signals . Switches ..... : Battery. Fuel... OPERATION AND IMPORTANT RIDING POINTS ....... 6. eee eee 5-1 Starting and warming up a cold engine ..... : vee Starting @ warm engine Shifting .. . Engine break-in... ... 51 -. 4 . 65 5-5Parking... PERIODIC MAINTENANCE AND MINOR REPAIR Tool kit PERIODIC MAINTENANCE/ LUBRICATION Torque specifications Engine oil Arr filter Carburetor adjustment . . Idle speed adjustment Throttle cable adjustment Valve clearance adjustment .. - Decompression cable adjustment Spark plug inspection Front brake adjustment Rear brake adjustment . Brake light switch adjustment... -- Checking the front brake pads and rear brake shoes . Inspecting the brake fiuid level 56 61 61 274 73 74 78 7-10 7-10 mM 7-12 7-13. 7-13 7-15, 7-16 77 7-18 7-19 Brake fluid replacement Clutch adjustment. Free play adjustment Drive chain slack check Drive chain slack adjustment Drive chain lubrication . Cable inspection and lubrication Throttle cable and grip lubrication Brake and shift pedals . Brake and clutch levers Sidestand . Rear suspension Front fork oll change Front fork and rear shock absorber adjustment . Rear shock (Monocross suspen “De Carbon” system) Rear shock absorber adjustment Steering inspection Wheel bearings Battery... 7-20 7-20 o. 721 . 722 722 7-23 7-24 7-24 7-25 7-25 +. 7-25 7-25 7-26 7-29 731 731 7-33 7-34 7-34Replenishing the battery fluid Fuse replacement... ...- = Replacing the headlight bulb. .. . Headlight beam adjustment . . Front wheel removal. . Front wheel installation Rear wheel removal . . Rear wheel installation . Troubleshooting .. Troubleshooting chart CLEANING AND STORAGE A. Cleaning . B. Storage . SPECIFICATIONS . .. . NOISE REGULATION (For Australia). WIRING DIAGRAMDESCRIPTION 1 Tail/Brake light 11 Fuel tank 2 Rear flasher light 12 Seat 3. Silencer 1. Shuft pedst 4 Monocross suspension 44. Clutch lever 5 Kick startor 1 Handlebar switch 8 Front fendor 16 Speedometer 7 Brake pedal 17. Broke lever 8 Footrest 18 Throttle grip 9 Front fork 18. Front flasher light 10. Headlight on NOTE: The motorcycle you have purchased may differ slightly from those shown in the photographs.aso MACHINE IDENTIFICATION As Vehicle identification number (For Australia) The vehicle identification number is stamped into the steering head pipe. 1 Vehicle kentification number 0 068 NOTE; —____________ The vehicle identification number is used to identify your motorcycle and may be used to register your motorcycle with the licensing authority in your state. woe Frame serial number {Except for Australia) The frame serial number is stamped into the right side of the steering head pipe. 1. Frame senal numberam Engine serial number The engine serial number is stamped into the night side of the engine. 1 Engine sonal number ons NOTE: — The first three digits of these numbers are for model identification; the remaining digits are the unit production number. Keep a record of these numbers for reference when ordering parts from a Yamaha dealer. 22ous CONTROL FUNCTIONS OFF: All electrical circuits are switched off. The key can be removed in this position. som aco: Main switch The main switch controls the ignition and fighting systems; its operation is described Speedometer The trip odometer is built into the speedometer. Use the odometer to estimate how far you can ride on a tank of fuel before going to “RESERVE”. This information will enable you to plan fuel stops in the future ON Electrical circuits are switched on. The engine canbe started, The key cannot be removed in P this position. 1 Trp odometer 2. Reset knob 34ea Handlebar switches: 1 “UGHTS” switch 2. “LIGHTS” (Dimmert switch 3 TURN” switch 4 "HORN" switch 5 “ENGINE STOP” swrtch 8001 “LIGHTS” (Dimmer) switch Turn the switch to “HI” for the high beam and to “LO” for the low beam. ens “TURN” signal switch This is a three-way switch: the center position is off; turn to the “L” to turn on the left flasher 32 and to the “R” for the right flasher. Be sure to turn the switch off after completing a turn. pen “HORN” switch Press the switch to sound the horn. aw “LIGHTS” switch Turn the light switch to “ON” to turn on the headhght, taillight, and meter lights. ee “ENGINE STOP” switch The engine stop switch is a safety device for use In an emergency such as when the motor- cycle overturns or when trouble occurs in the throttle system. The engine will not run when the engine stop switch 1s turned to “OFF”. In case of emergency, turn the switch to “OFF”.Clutch lever The clutch lever is located on the left handlebar; it disengages or engages the clutch. 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 starts. 200 Shift pedal The gear ratios of the constant-mesh 6-speed transmission are ideally spaced. The gears can be shifted by using the shift pedal on the left side of the engine. N Neutral a8 2600 Front brake lever The front brake lever is located on the right handlebar. Pull it toward the handlebar to ac- tvate the front brake. eee: Rear brake pedal The rear brake pedal is on the right side of the motorcycle. Press down on the brake pedal to activate the rear brake. cam Fuel cock The fuel cock supplys fuel from the tank to car- buretor while filtering the fuel. The fuel cock has the three positions: OFF: With the lever in this position, fuel will not flow. Always return the lever to this position when the engine is not running With the lever in this position, fuel flows to the carburetor. Normal riding is done with the lever in this position. ON:RES: This indicates reserve. If you run out of fuel while riding, move the lever to this position. FILL THE TANK AT THE FIRST OPPORTUNITY. BE SURE TO SET THE LEVER TO “ON” AFTER REFUELING. RES OFF ON 34 cme Starter knob (CHOKE) When cold, the engine requires a richer air-fuel mixture for starting. A separate starter circuit supplies this mixture. Pull the starter knob out to open the circuit for starting. When the engine has warmed up, push the knob in to close the circuit. 1 Starter knobKick starter Rotate the kick starter away from the engine. Push the starter down lightly with your foot un- til 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 disengag- ed. In normal practice, however, shift to neutral before starting. 1 Kick sterter ve NOTE: This model features an autodecomp. device, which frees the operator from the trouble other- wise required. eecme Front forks The front forks of this model are pneumo- mechanical; namely, a combination air and mechanical coil spring in the inner tubes By adjusting the air pressure, you can alter the suspension to suit the machine's load and the operating conditions. Refer to page 7-29 for proper adjustment procedures. 36 cso Rear shock absorber The spring preload and the damping of the rear shock absorber can be adjusted to suit motorcycle’s load (ex optional accessories etc.) and riding conditions. Refer to page 7-31 for proper adjustment procedures. 1. Spring pretoad adjuster 3. Damping adjuster 2 Lock nutoon Sidestand This model is equipped with an ignition circuit cut-off system. The motorcycle must not be ridden when the sidestand is down. The side- stand is located on the left side of the frame. (Refer to page 5-3 for an explanation of this system.) vee A WARNING This motorcycle must not be operated with the sidestand in the down position. If the stand is not properly retracted, it could contact the ground and distract the operator, resulting in a possible loss of control. Yamaha has designed into this motorcycle a lockout system to assist the operator in fulfilling the responsibility of retracting the sidestand. Please check carefully the operating instructions listed below and if there is any indication of a 37 malfunction, you must return the motor- cycle to a Yamaha dealer immediately for repair. ee oss Sidestand switch operation check Check the operation of the sidestand switch against the information below.TURN MAIN SWITCH TO “ON” AND ENGINE STOP SWITCH TO “RUN” ¥ TRANSMISSION IS IN NEUTRAL AND. SIDESTAND 1S DOWN v KICK THE KICK STARTER ¥ ENGINE WILL START + PULL IN CLUTCH LEVER AND PUT TRANSMISSION IN GEAR er Se ENGINE WILL STALL q SIDESTAND SWITCH IS OK veer AWARNING If improper operation is noted, consult a Yamaha dealer immediately. 38PRE-OPERATION CHECKS Before using this motorcycle, check the following points: item Routine Page Front brake Check operation, Tree play fluid level and fluid leakage. 43-44, TAB Top-up with DOT #4 (or #3) brake fluid if necessary 748~7.20 Rear broke Check operation, condition and free play. Adwust f necessary | #3, 7-16~7-18 Guutch Check operation, condition and free play. Adjust if necessary | #4) 7.20~721 Throttle grp/Housmng Check for smooth operation. Lubricate/ Adjust if necessary | 44, 7-11~7-12, 724 Engine oil ‘Check off level/add off as required 44, 74-78) Dave chain Check chain slack and condition Adjust if necessary. 45, 7B-734 Wheels/Tires Check tire pressure, wear, damage and spoke tightness. __| #5—48, 70-7-42 Control/Meter cables Check for smooth operation. Lubricate i necessary 728 Bree ad sh feds! | creck orth epraon Luca once 1 Brake ang clutch lever__| check for smooth operation Lubneate it necossary 728 Sidestand pivot Check for smooth operation Lubricate f necessary 735 Fiungs/fasteners Check all chassis fittings and fasteners Tighten/Adjust, wa78 necessary. Fuel tank Check fuel level/top-up as required Lights Check for proper operation. 48, 757-78 Signals Check for proper operation 48 Battery Check fluid level, top-up with datiled water, necessary | #8 734~7.96 atNOTE: Pre-operation checks should be made each time the motorcycle is used. Such an inspection can be throughly accomplished in a very short time, and the added safety it assures is more than worth the time involved. PZ GRITS If any item in the Pre-Operation Check is not working properly, have it inspected and repaired before operating the motorcycle. 42exo Brakes (See page 7-15 for details) 1, Brake lever and brake pedal Check for correct free play in the front brake lever and rear brake pedal. Make sure they are working properly. Check the brakes at low speed shortly after starting out. If the free play 1s incorrect, adjust it. vss Oe) A soft, spongy feeling in the brake lever indicates a failure in the brake system. Do not operate the motorcycle until the failure in the brake system is corrected. Ask a Yamaha dealer for immediate repairs. A soft, spongy feeling could indicate a hazar- dous condition in the brake system. 2. Brake fluid Check the brake fluid level. Add fluid if necessary. 43 Recommended brake fluid: DOT #4 NOTE: —— If DOT #4 is not available, #3 can be used. 3. Check the disc pads. Refer to page 7-18. 4, Check the brake shoes. Refer to page 7-19. von NOTE: When this brake service is necessary, ask a Yamaha dealer. en Brake fluid leakage (Front) Apply the brake for a few minutes. Check to see if any brake fluid leaks out from the pipe joints or the master cylinder.ves POG If brake fluid leakage is found, ask a Yamaha dealer for immediate repairs. Such leakage could indicate a hazardous condition. Clutch (See page 7-20 for details) Check the free play in the clutch lever, and make sure the lever operates properly. If the free play is incorrect, adjust it ex Throttle grip (See page 7-11 for details) Turn the throttle grip to see if it operates pro- perly, and check the free play. Make sure the grip returns by spring force when released. Ask a Yamaha dealer to make any necessary adjustments. ah 0 Engine oil (See page 7-4 for details) Make sure the engine oil 1s at the specified level. Add oil as necessary. cesan Recommended oil 30°F 40°F 50°F 80°F + SAE 20W40 type SE motor ail - SAE 10WV30 type SE motor ol o'e Bc 1056 Toe "ee ° O1l quantity: Total amount: 1.6 L (1.4 Imp at, 1.7 US at) Periodic oil change 13.L(11 Imp qt, 1.4 US qd) With oil filter replacement: 1.3L (1.1 Imp gt, 1.4 US qt)es Chain (See page 7-22 for details) Check the general condition of the chain and check the chain slack before every nde. Lubricate and adjust the chain as necessary. 04 Tires To ensure maximum performance, long ser- vice, and safe operation, note the following: 1, Tire air pressure Always check and adjust the tire pressure before operating the motorcycle. FRUZGIIO * Tire inflation pressure should be checked and adjusted when the temperature of the tire equals the ambient air temperature. Tire inflation pressure must be adjusted according to total weight of cargo, rider. and accessories (fairing, saddlebags, etc. 45 if approved for this model), and vehicle speed. Front Rear Off-road nding 100 kPa (1.0 kg/em?, 14 pso| 100 kPa (1.0 kg/em?, 14 pail CZGHITS * Proper loading of your motoreyele is im- portant for the handling, braking, and other performance and safety characteris- tics of your motorcycle. Do not carry loosely packed items that can shift. Se- curely pack your heaviest items close to the center of the motorcycle, and destrib- ute the weight evenly from side to side. Properly adjust the suspension for yourload, and check the condition and pres- sure of your tires. NEVER OVERLOAD YOUR MOTORCYCLE. Operation of an overloaded motorcycle could cause tire damage, an accident, or even injury. 2. Tire inspection Always check the tires before operating the motorcycle. If center tread depth teaches the limit as shown, if the tire has a nail or glass fragments in tt, or if the side wall is cracked, contact a Yamaha dealer immediately and have him replace the tire 46 oO T Tread depth 2 Sido wall FRONT Manufacture Size Type Brdgestone 20/100-21_| GRITTY-€015 REAR Manufacture Si Type. Brdgestone Too/i05-18 | GRITTY EDTE Minimum tre weed depth (front and rear) 1.0 mm (0.04 wihNOTE: These limits may be different by regulation from country to country If so, conform to the limits specified by the regulations of your own country. 1 Operating the motorcycle with exces- sively worn tires decrease riding sta- bility and can lead to loss of control. Have excessively worn tires replaced by a Yamaha dealer immediately. Brakes, tires, and related wheel parts replacement should be left to a Yamaha Service Technician. Patching a punctured tube is not recommended. If it is absolutely necessary to do So, use great care and replace the tube as soon as possible with a good quality replacement. 47 esa Wheels To ensure maximum performance, long ser- vice, and safe operation, note the following. in 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 condi- tion exists in a wheel, consult a Yamaha dealer. Do not attempt even small repairs to the wheel. If a wheel is deformed or cracked, it must be replaced. Tires and wheels should be balanced whenever either one is changed ot replac- ed. Failure to have a wheel balanced can result in poor performance, adverse handl- ing characteristics, and shortened tire ife.3. After installing a tire, ride conservatively to allow the tire to seat itself on the rim properly. Failure to allow proper seating may cause trre failure, resulting in damage to the motorcycle and injury to the rider. E00 Fittings/Fasteners Always check the tightness of chassis frttings and fasteners before a ride. Use the chart on page 7-3 to find the correct torque. = max Lights and signals Check the headlight, flasher lights, taillight, and brake light to make sure they are in working condition ea Switches Check the operation of the headlight switch, turn switch, brake light switch, horn switch, main switch, ete. 48 ene Battery (See page 7-34 for details) Check the fluid level and top-up if necessary. Use only distilled water if refilling is necessary. eae Fuel Make sure there is sufficient fuel in the tank usw Do not overfill the fuel tank. Avaid spill- ing fuel on the hot engine. Do not fill the fuel tank above the bottom of the filler tube as shown in the illustration or it may overflow when the fuel heats up later and expands.1, Filer tobe 2 Fuel level co Recommended fuel: Regular gasoline For Australia: Unleaded fuel only Fuel tank capacity: Total: 95 L (2.1 Imp gal, 25 US gal) Reserve: 10 L (0.2 Imp gal, 03 US gal)Pow OPERATION AND IMPORTANT RIDING wn POINTS AWARNING 2. Before starting out, always be sure the sidestand is up. Failure to retract the sidestand completely can result in a serious accident when you try to turn a corner. Before riding this motorcycle, become thoroughly familiar with all operating con- trols and their function. Consult a Yamaha dealer regarding any control or function that you do not thoroughly understand. ves A WARNING 1. Never start your engine or let it run for any length of time in a closed area. The exhaust fumes are poisonous and can cause loss of consciousness and death within a short time. Always operate your motorcycle in an area with adequate ventilation. Starting and warming up a cold engine vow NOTE: This motorcycle is equipped with an ignition circuit cut-off switch. 1. The engine can be started only under the following conditions a. The transmission 1s in neutral. b. The sidestand is up, the transmission is in gear, and the clutch 1s disengaged. 2. The motorcycle must not be ridden when the sidestand is down.709 AWARNING Before going through the following steps, check the function of the sidestand switch. (Refer to page 3-8.)TURN MAIN SWITCH TO “ON” AND ENGINE STOP SWITCH TO “RUN” oT IF TRANSMISSION IS IN NEUTRAL IF TRANSMISSION IS IN GEAR AND SIDESTAND IS DOWN AND SIDESTAND 1S UP + v KICK THE KICK STARTER; PULL IN CLUTCH LEVER AND ENGINE WILL START KICK THE KICK STARTER, + ENGINE WILL START RETRACT SIDESTAND AND PUT TRANSMISSION IN GEAR eS MOTORCYCLE CAN BE RIDDEN MOTORCYCLE CAN BE RIDDEN 531. Turn the fuel cok to “ON”. Turn the ignition key to “ON” and the engine stop switch to “RUN”. Shift transmission into neutral. Fully open the starter (CHOKE), and com- pletely close the throttle grip. Kick the kick starter to start the engine. After starting the engine, turn back the starter (CHOKE) to warming up position (about halfway). a uta NOTE: —————___——— To get maximum engine life, always warm up the engine before starting off. Never accelerate hard with a cold engine! —— 7. After warming up the engine, turn off the starter by pushing it back completely. 64 voor NOTE; ———____—_ The engine is warm when it responds normal- ly to the throttle with the starter turned off. — 08 Starting a warm engine The starter (CHOKE) ts not required when the engine Is warm. vm sGAUTION:: See “Break-in section” prior to operating the motorcycle for the first time.fom Shifting The transmission lets you control the amount of power you have avatlable at a given speed for starting, accelerating, climbing hills, etc The use of the shift pedal is shown in the illus- tration. (Page 3-3) To shift into NEUTRAL, depress the shift pedal repeatedly until it reaches the end of its, travel (you will feel a stop when you are in first gear) then raise the pedal slightly vars CAUTION: 1. Do not coast for long periods with the engine off, and do not tow the motorcycle a long distance Even with gears in neutral, the transmis- sion is only properly lubricated when the engine is running. Inadequate lubrication may damage the trans- mission. 2. Always use the clutch when chang- 55 ing gears. The engine, transmission, and driveline are not designed to withstand the shock of forced shif- ting and can be damaged by shifting ithout the clutch. 0 Engine break-in There is never a more important period in the life of your motorcycle than the period between zero and 1,000 km (600 mi). For this reason we ask that you carefully read the following maternal. Because the engine is brand new, you must not put an excessive load on it for the first 1,000 km (600 mi) The various parts in the ‘engine wear and polish themselves to the cor- rect operating clearances During this period, prolonged full throttle operation or any condi. tion which might result in excessive heating of the engine, must be avoided1, 0~500 km (0~300 mi): Avoid operation above half throttle. Stop the engine and let it coo! for 5 to 10 minutes after every hour of operation. Vary the speed of the motorcycle from time to time. Do not operate it at one set throttle position 2. 800~ 1,000 km (300~600 mi}: Avoid prolonged operation above 3/4 throttle. Rev the motorcycle freely through the gears, but do not use full throttle at any time. CAUTION: After 1,000 km (600 mi} of operation, be sure to replace the engine oil and clean the oil filter element and oil strainer. 3. 1,000 km (600 mi) and beyond: Full throttle can be used. 66 von CAUTION: Never let engine speeds enter the red zone. If any engine trouble should occur during the break-in period, consult a Yamaha dealer immediately. Ft Parking When parking the motorcycle, stop the engine and remove the ignition key. Turn the fuel cock to “OFF” whenever stopping the engine.ven A WARNING The muffler and exhaust pipe are hot. Park the motorcycle in a place where pedes: ans or children are not likely to touch the motorcycle. Do not park the motorcycle on a slope or soft ground; the motorcycle may overturn. 87. PERIODIC MAINTENANCE AND an MINOR REPAIR Periodic inspection, adjustment, and lubrica- tion will keep your motorcycle in the safest and most efficient condition possible. Safety is an obligation of the motorcycle owner. The main- tenance and lubrication schedule chart should be considered strictly as a guide to general maintenance and lubrication intervals. YOU MUST TAKE INTO CONSIDERATION THAT WEATHER, TERRAIN, GEOGRAPHI- CAL LOCATIONS, AND A VARIETY OF IN- DIVIDUAL USES ALL TEND TO DEMAND THAT EACH OWNER ALTER THIS TIME SCHEDULE TO SHORTER INTERVALS TO MATCH HIS ENVIRONMENT. The most im- portant points of motorcycle inspection, adjust- ment, and lubrication are explamed in the following pages. ot use AWARNIN If you are not familiar with motoreycle service, this work should be done by a Yamaha dealer. wm Tool kit The service information included in this manual is intended to provide you, the owner, with the necessary information for completing some of your own preventive maintenance and minor repairs. The tools provided in the owner's tool kit are sufficient for most of these purposes; however a torque wrench is also necessary to properly tighten nuts and bolts.Modifications to this motorcycle not ap- proved by Yamaha may cause loss of per- formance, and render it unsafe for use. Consult a Yamaha dealer before attempt- ing any changes. Tooth wt NOTE: \f you do not have a torque wrench available during a service operation requiting one, take your motorcycle to a Yamaha dealer to check the torque settings and adjust them as necessary. 62PERIODIC MAINTENANCE/LUBRICATION Unit km tmites) EVERY AK. rem REMARKS Po 1600) | 408 (000) | 12,006 18660) ‘or monthe | or 12 months anwar The vaio doorance. Adjust Wracessay | 0 Spark plugis| ____| Check condition Glaan or replace necessary ° Artis [Clan Repiace nocoteary Camuman | Chek le Speedster operation 5 Aust neceseary (Check fue! hose for cracks or damage Replace if necessary enlace (Warm engme before draming! Fue! linet Engine ou fojo} o Jololoj o | o Jojolo) 3 o Oo ° S Engine of filter Clean oS | Engine ol strainer Clean oT . Check operation /flud leskage/ Soe NOTE Front brake’ Comoe! necessary ° | Rear brake Check operation Adjust if necessary oO Clutch Check operation Adjust if necessary oO Decompression aystom® | Check operation Adjust necessary 3 . Check rear arm assambiy for looseness Tr Rear arm pwott | Comoct i necessary. Moderato ropeck.*** oF ° Bem cspensen Ik | check aperation Moderately repack *** ° | ° ° | meee hack baonce/damage/tonoutl spake tahiness To reels! Replace if necessary | Replece if necessary Whee! boonngs" heck bsrmge aes oot age 5 nHUnit_km (miles) EVERY preakin |-———_£ rrena REMARKS. 4.000 1800) | 6.000 (4,600) | 12,000 18,000) or & months | or 12 months Steering besring” necessary Moderately topack every 24,000 (16,000) or | © ° 24 months ** {Front forks” [check operavon/ol leakage Repaw necessary Rear shock absorber | Check operation/oll leakage Repair # necessary Check chain slack/alignment’ Adjust necessary Dave chan eek ort ae EVERY 500 1300) . ‘Chock all chassis fatings and fasteners Fittings/ Fasteners check al chasse fa ° o ° Sidestand™ Check operation Repaw f necessary. o 3 G Sdestand swaich® Chack operation Clean or replace if necessary. of oO © Check specific gravity Check breether pipe for proper 3 Baer | Sb Soe Paces 2 6 * itis recommended that these tems be serviced by @ Yamaha dealer ** Mediu weight whee! bearing grease **+, Lithium soap base grease NOTE: Brake fluid replacement. 1. When disassembling the master cylinder or caliper cylinder, replace the brake fiurd. Norma- ly check the brake fluid {evel and add the flurd as required. 2 Onthe inner parts of the master cylinder and caliper cylinder, replace the oil seals every two years. 3. Replace the brake hoses every four years, or if cracked or damaged. 72Hoo Torque specifications Use a torque wrench to tighten these items. itis recommended that these items be check- ed occasionally, especially before a long trip. Always check the tighteness of these items whenever they are loosened for any reason. cso 7 1 @) © Torque hem 4 Nm | mekg | feeb ‘Spark plug ws | 17 | 126 Engine drain plug @ | 43 | ar 8 fiter cover screw 10 io} 72 Aur bleed screw 5 05 | 36 Front fork pinch bolt B | 23 7 Front fork cap bolt 2 | 23 ” Front wheel axle nut sa | se ja Axle holder nut a 08 | 58 Rear wheel axle nut 100 | 100 | 7wer Engine oil 1. Oil level measurement a Place the motorcycle on a level place and hold tt in an upright position Warm up the engine for several minutes. uae NOTE: Be sure the motorcycle is positioned straight up when checking the oil level; @ slight tlt toward the side can produce false readings b. With the engine stopped, check the otl level through the level window located at the lower part of the right side crankcase cover, 2a 1 Level window 2 Maximum mark 3 Mirumum mark Wait a few minutes until the ol level settles before checking. c. The oil level should be between maximum and minimum marks. If the level is low, add sufficient oil to raise it to the proper level.2. Engine oil replacement a. Warm-up the engine for a few minutes. b. Stop the engine. Place an oil pan under the engine, and remove the oll filer cap. c. Remove the drain plug and the air bleed screw attached to the oil filter cover. 1 Drain plug v6 Nove: The oil filter cover is secured by three screws. The lower one should be removed so that the filter cavity will drain. 78 d. Check each gasket. If damaged, replace it, e. Remove the filter cover screws and re- move the oil filter cover. 1 Aurbloed screw 2 Filter cover serew f. Clean the filter element with solvent. Replace if necessary. g. Check O-ring. If damaged, replace it.h. Reinstall the drain plug, filter element, air bleed screw, and the filter cover screws. 2 1 Filter element 2 ‘Onmng NOTE: —WW Make sure the O-ring is positioned properly 6 Tightening torque: Drain plug: 43 Nm (4.3 mekg, 31 ftelb) Filter cover screw (pan head). 7 Nm (0.7 mekg, 5.1 ftelb) Filter cover screw (internal hexagon head): 10. Nm (1.0 mskg, 7 2 ftelb} Air bleed screw: 5 Nm (0.5 m+kg, 3.6 ft-lb) Add engine oil. Install the oll filler cap and tighten,1 Oi filer cap Oil capacity: See page 4-4 Recommended oil: See page 4-4 vse ‘CAUTION: Do not add any chemical additives. Engine oil also lubricates the clutch and additives could cause clutch slippage. cad va Be sure no foreign material enters the crankcase. j. Start the engine and allow a few minutes of warm-up. While warming up, check for oil leakage. If oll leaks, stop the engine immediately, and check for the cause. k. Stop the engine and check the oil level. After replacing the engine oil, be sure to check the oil pressure as described below. 1. Remove the air bleed screw from oil filter cover. 2. Start the engine and keep it idling un- til oil flows out of the bleed hole. If noweak oil comes out after a lapse of one Air filter minute, turn off the engine i 1. Remove the left side cover. mediately so it will not seize. Insuch 2. Remove the arr filter case fitting band and a case go to the nearest Yamaha the filter case cover. dealer for repairs. 3. After checking, tighten the air bleed screw securely. 3. Oil stramer cleaning Ask a Yamaha dealer to make this service. 1. Drain plug 781 Aw filter element 2. Guide 4. Pull out the element. . 6. Apply recommended oil to the entire sur- 5. Remove the element from its guide, and face of the filter and squeeze out the ex- clean it with solvent. After cleaning, cess oil. The element should be wet but remove the remaining solvent by squeez- not dripping. ing the element. Recommended oil: SAE 10W30 motor oil 797. When installing the element in its case, be sure its sealing surface matches the sealing surface of the case so there is no air leak. The element should be cleaned at the specified intervals. It should be cleaned more often if the motoreycle 1s operated in dusty or wet areas. CAUTION: perience to do so. However, the following point may be serviced by the owner as part of this routine maintenance. v0 CAUTIONS, The carburetor was set at the Yamaha fac- tory after many tests. If the settings are disturbed, poor engine performance and damage may result. The engine should never be run without the air cleaner element; excessive piston and/or cylinder wear may result. He Carburetor adjustment The carburetor is a vital part of the engine and requires very sophisticated adjustment. Most adjustments should be left toa Yamaha dealer who has the professional knowledge and ex- 740 hoo Idle speed adjustment 1 Start the engine and warm it up for a few minutes (normally, 1 or 2 minutes) at ap- proximately 1,000 to 2,000 r/min Occa- sionally rev the engine to 4,000 to 5,000 r/min. The engine is warm when it quickly responds to the throttle.Set the idle to the specified engine speed by adjusting the throttle stop screw; turn the screw in to increase engine speed, turn the screw out to decrease engine speed. Standard idle speed: 1,400 ~ 1,500 r/min 1. Throttle stop serew vos NOTE: If the specified idle speed cannot be obtained by performing the above adjustment, consult a Yamaha dealer. a Throttle cable adjustment vo NOTE: Before adjusting the throttle cable free play, the engine idling speed should be adjusted. —_— The throttle cable should have a specified free play in the turning direction at the grip flange. If the play is incorrect, take the following steps for adjustment. Free play: 2~5 mm (0.08~0.20 tn)