Clubdediagramas - Serv T110 Crypton 2009 - 103948

2009
SUPPLEMENTARY
SERVICE MANUAL
T110C
40B-F8197-E0
FOREWORD
This Supplementary Service Manual has been prepared to introduce new service and data for the
T110C. For complete service information procedures it is necessary to use this Supplementary
Service manual together with the following manual.
T110LE SERVICE MANUAL: 3P9-F8197-E0
EAS00000
T110C
SUPPLEMENTARY
SERVICE MANUAL
©2009 by Yamaha Motor Co., Ltd.
First edition, February, 2009
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
EAS00002
IMPORTANT
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha deal-
ers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in
one manual. Therefore, anyone who uses this book to perform maintenance and repairs on
Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair
these types of vehicles. Repair and maintenance work attempted by anyone without this knowl-
edge is likely to render the vehicle unsafe and unfit for use.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and
significant changes in specifications or procedures will be forwarded to all authorized Yamaha deal-
ers and will appear in future editions of this manual where applicable.
TIP
Designs and specifications are subject to change without notice.
EAS00004
IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following notations.
This is the safety alert symbol. It is used to alert you to potential per-
sonal injury hazards. Obey all safety messages that follow this symbol
to avoid possible injury or death.
A WARNING indicates a hazardous situation which, if not avoided,

WARNING
could result in death or serious injury.
A NOTICE indicates special precautions that must be taken to avoid

NOTICE damage to the vehicle or other property.
TIP A TIP provides key information to make procedures easier or clearer.

HOW TO USE THIS MANUAL
CONSTRUCTION OF THIS MANUAL
This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”)
1st title 1:This is a chapter with its symbol on the upper right of each page.
2nd title 2:This title appears on the upper of each page on the left of the chapter symbol. (For the
chapter “Periodic inspection and adjustment” the 3 rd title appears.)
3rd title 3:This is a final title.
MANUAL FORMAT
All of the procedures in this manual are organized in a sequential, step - by - step format. The
information has been compiled to provide the mechanic with a easy to read, handy reference that
contains comprehensive explanations of all disassembly, repair, assembly, and inspections.
A set of particularly important procedure 4 is placed between a line of mark “▼” or “▲” with each
procedure preceded by “8”.
IMPORTANT FEATURES
8Data and a special tool are framed in a box preceded by a relevant symbol 5 .
8An encircled numeral 6 indicates a part name, and an encircled alphabetical letter date or an
alignment mark 7, the others being indicated by an alphabetical letter in a box 8 .
8A condition of a faulty component will precede an arrow symbol and the course of action
required the symbol 9 .
EXPLODED DIAGRAM
Each chapter provides exploded diagrams before each disassembly section for ease in identifying
correct disassembly and assembly procedures.
1 2 SYMBOLS
The following symbols are not relevant to
GEN SPEC every vehicle.
INFO Symbols 1 to 8 indicate the subject of each
chapter.
3 4
1 General information
CHK 2 Specifications
ENG
ADJ 3 Periodic checks and adjustments
4 Engine
5 6 5 Carburetor
6 Chassis
7 Electrical system
CARB CHAS 8 Troubleshooting
7 8 Symbols 9 to y indicate the following.
TRBL 9 Serviceable with engine mounted

ELEC SHTG 0 Filling fluid
q Lubricant
9 0 w Special tool
e Tightening torque
r Wear limit, clearance
t Engine speed
y Electrical data
q w
Symbols u to f in the exploded diagrams
indicate the types of lubricants and lubrication
points.
e r u Engine oil
i Gear oil
o Molybdenum-disulfide oil
p Brake fluid
a Wheel-bearing grease
s Lithium-soap-based grease
t y d Molybdenum-disulfide grease
f Silicone grease
Symbols g to h in the exploded diagrams

indicate the following.
u i o p
g Apply locking agent (LOCTITE®)
h Replace the part
BF
a s d f
g h
LT New
CONTENTS
GENERAL INFORMATION
VEHICLE IDENTIFICATION …………………………………………………1
VEHICLE IDENTIFICATION NUMBER …………………………………1
ENGINE SERIAL NUMBER………………………………………………1
SPECIFICATIONS
GENERAL SPECIFICATIONS ………………………………………………2
MAINTENANCE SPECIFICATIONS ………………………………………4
ENGINE ……………………………………………………………………4
TIGHTENING TORQUES …………………………………………………5
CHASSIS …………………………………………………………………7
TIGHTENING TORQUES …………………………………………………9
ELECTRICAL ………………………………………………………………11
LUBRICATION POINTS AND LUBRICANT TYPES………………………12
ENGINE ……………………………………………………………………12
CHASSIS …………………………………………………………………14
CABLE ROUTING ……………………………………………………………15
PERIODIC CHECKS AND ADJUSTMENTS

INTRODUCTION ………………………………………………………………24
PERIODIC MAINTENANCE CHART FOR THE EMISSION
CONTROL SYSTEM…………………………………………………………24
GENERAL MAINTENANCE AND LUBRICATION CHART………………25
CHASSIS ………………………………………………………………………27
CHECKING THE FRONT BRAKE PADS ………………………………27
BLEEDING THE HYDRAULIC BRAKE SYSTEM ……………………27
ADJUSTING THE DRIVE CHAIN SLACK ………………………………29
CHECKING THE BRAKE FLUID LEVEL ………………………………31
ELECTRICAL SYSTEM ………………………………………………………32
CHECKING AND CHARGING THE BATTERY…………………………32
CHASSIS
FRONT WHEEL AND BRAKE DISC ………………………………………39
REMOVING THE FRONT WHEEL ………………………………………40
CHECKING THE FRONT WHEEL ………………………………………41
CHECKING THE BRAKE DISC …………………………………………43
CHECKING THE SPEEDOMETER GEAR UNIT ………………………44
INSTALLING THE FRONT WHEEL ……………………………………44
FRONT BRAKE ………………………………………………………………46
FRONT BRAKE CALIPER ………………………………………………46
REPLACING THE FRONT BRAKE PADS ………………………………47
DISASSEMBLING THE FRONT BRAKE CALIPER……………………49
CHECKING THE FRONT BRAKE CALIPER …………………………51
ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPER …52
FRONT BRAKE MASTER CYLINDER …………………………………55
DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER ……56
CHECKING THE FRONT BRAKE MASTER CYLINDER ……………58
ASSEMBLING AND INSTALLING
THE FRONT BRAKE MASTER CYLINDER …………………………59
GEN
VEHICLE IDENTIFICATION INFO
EAS00014
GENERAL INFORMATION
1 VEHICLE IDENTIFICATION
EAS00017
VEHICLE IDENTIFICATION NUMBER

The number 1 is stamped into the frame as
shown.
ENGINE SERIAL NUMBER

1
The engine serial number 1 is stamped into
the crankcase.
TIP
Designs and specifications are subject to
change without notice.
–1–
GENERAL SPECIFICATIONS SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
Model T110C
Model code 40B1
Dimensions
Overall length 1885 mm (74.2 in)
Overall width 675 mm (26.6 in)
Overall height 1040 mm (40.9 in)
Seat height 770 mm (30.3 in)
Wheelbase 1200 mm (47.2 in)
Minimum ground clearance 130 mm (5.12 in)
Minimum turning radius 1900 mm (74.8 in)
Weight
Wet (with oil and full fuel tank) 101 kg (223 lb)
Maximum load 159 kg (351 lb)
Engine oil
Type SAE 10W-30, SAE 10W-40,
SAE 20W-40, SAE 20W-50 or SAE 5W-30
Lubrication system Wet sump
Fuel
Recommended fuel Regular unleaded gasoline only
Fuel tank capacity 4.2 L (1.11 US gal, 0.92 lmp gal)
Fuel reserve amount 1.0 L (0.26 US gal, 0.22 lmp gal)
Spark plug
Type A7RTC/CR6HSA
Manufacturer TORCH/NGK
Spark plug gap 0.6 − 0.7 mm (0.024 − 0.028 in)
Chassis
Frame type Steel tube underbone
Caster angle 26.55°
Trail 77 mm (3.03 in)
Tire
Type With tube
Size front 70/90-17M/C 38P
rear 80/90-17M/C 44P
Model (manufacturer) front DUNLOP
rear DUNLOP
Min. tire tread depth front 1.6 mm (0.06 in)
rear 1.6 mm (0.06 in)
–2–
GENERAL SPECIFICATIONS SPEC
Model T110C
Tire pressure (cold tire)
Up to 90 kg load front 200 kPa (2.00 kgf/cm2, 29 psi)
rear 225 kPa (2.25 kgf/cm2, 33 psi)
90 kg − maximum load* front 200 kPa (2.00 kgf/cm2, 29 psi)
rear 270 kPa (2.70 kgf/cm2, 39 psi)
Brake
Front brake type Single disc brake
operation Right hand operation
Rear brake type Drum brake
operation Right foot operation
Wheel travel
Front wheel travel 95 mm (3.74 in)
Rear wheel travel 76 mm (2.99 in)
Electrical
Ignition system DC. C.D.I.
Generator system A.C. magneto
Battery type MTX7L-BS
Battery capacity 12 V 6 AH
Bulbs (voltage/wattage × quantity)
Headlight 12 V, 35 W/35 W × 1
Tail/brake light 12 V, 5 W/21 W × 1
Front turn signal light 12 V, 21 W × 2
Rear turn signal light 12 V, 10 W × 2
Meter light 12 V, 1.7 W × 1
High beam indicator light 12 V, 1.7 W × 1
Neutral indicator light 12 V, 1.7 W × 1
Turn signal indicator light 12 V, 1.7 W × 1
Gear position indicator light 12 V, 3.0 W × 4
Auxiliary light 12 V, 5 W × 2
* Load is the total weight of cargo, rider, passenger,and accessories.
–3–
MAINTENANCE SPECIFICATIONS SPEC
MAINTENANCE SPECIFICATIONS
ENGINE
Item Standard Limit
Piston
Piston-to-cylinder clearance 0.020 − 0.025 mm (0.0008 − 0.0010 in) 0.15 mm
(0.0059 in)
Piston size “D” 50.970 − 50.985 mm (2.0067 − 2.0073 in) ----
Offset 0.5 mm (0.0197 in) ----
Offset direction D Intake side ----
Piston pin bore inside diameter 13.002 − 13.013 mm (0.5119 − 0.5123 in) 13.043 mm
(0.5135 in)
Piston pin outside diameter 12.996 − 13.000 mm (0.5117 − 0.5118 in) 12.976 mm
(0.5109 in)
Carburetor
Type VM17SH ----
I.D. mark 4S91 00 ----
Main jet (M.J) #105 ----
Main air jet (M.A.J) ø1.2 ----
Jet needle (J.N) 4BLY23-2 ----
Needle jet (N.J) E-8M ----
Pilot outlet (P.O) ø0.8 (pitch: 1.70) ----
Pilot jet (P.J) #17.5 ----
Pilot air screw turns out 1 ----
Valve seat size ø1.5 ----
Starter jet 1 #22.5 ----
Starter jet 2 ø0.5 ----
Throttle valve size #3.5 ----
Fuel level 4.0 mm (0.16 in) ----
–4–
TIGHTENING TORQUES
ENGINE
Tightening
Thread
Part to be tightened Part name Q’ty torque Remarks
size
Nm m·kg ft·lb
Cylinder head Nut M8 4 22 2.2 16
Cylinder head (timing chain side) Bolt M6 2 10 1.0 7.2
Spark plug — M10 1 12.5 1.25 9.0
Camshaft sprocket cover Screw M6 2 7 0.7 5.0
Tappet cover (intake and exhaust side) — M45 2 18 1.8 13
Stud bolt (cylinder head) Bolt M6 2 7 0.7 5.0
Generator rotor Nut M12 1 70 7.0 5.0
Timing chain guide (intake side) Bolt M6 2 10 1.0 7.2 LT
Valve adjusting screw locknut (intake Nut M5 2 7 0.7 5.0

and exhaust side)
Camshaft sprocket Bolt M8 1 20 2.0 15
Camshaft retainer Bolt M6 1 10 1.0 7.2 LT
Timing chain tensioner cap bolt Bolt M6 1 8 0.8 5.8

Timing chain tensioner Bolt M6 2 10 1.0 7.2
Oil pump assembly Bolt M6 2 7 0.7 5.0
Engine oil drain bolt Bolt M12 1 20 2.0 15
Intake manifold (engine side) Bolt M6 2 10 1.0 7.2
Carburetor assembly Bolt M6 2 10 1.0 7.2
Exhaust pipe Nut M6 2 7 0.7 5.0
Exhaust pipe (center) Bolt M6 1 10 1.0 7.2
Muffler band Bolt M8 1 12 1.2 8.6
Muffler and muffler bracket Bolt M8 1 16 1.6 12
Muffler and passenger footrest Bolt M10 1 38 3.8 28
Air cut-off valve assembly Bolt M6 2 7 0.7 5.0
Air induction system pipe Bolt M6 2 10 1.0 7.2
Air filter (Air induction system) Screw M6 2 12 1.2 8.6
Air filter case Screw M5 4 2 0.2 1.4
Crankcase Bolt M6 9 10 1.0 7.2
Crankcase cover (left) Bolt M6 8 10 1.0 7.2
Drive sprocket cover Bolt M6 2 7 0.7 5.0
Crankcase cover (right) Bolt M6 9 10 1.0 7.2
Center plug — M32 1 7 0.7 5.0
Timing check plug — M14 1 7 0.7 5.0
Stud bolt (crankcase) Bolt M8 4 13 1.3 9.4
Kickstarter lever Bolt M6 1 10 1.0 7.2
Starter clutch Bolt M6 3 14 1.4 10.1 stake
Clutch shoe housing Nut M12 1 50 5.0 36
Clutch pressure plate Bolt M5 4 6 0.6 4.3
Clutch boss Nut M14 1 70 7.0 50
Clutch release adjusting locknut Nut M6 1 8 0.8 5.8
Shift pedal Bolt M6 1 10 1.0 7.2
–5–
Tightening
Thread
Part to be tightened Part name Q’ty torque Remarks
size
Nm m·kg ft·lb
Shift drum segment Bolt M6 1 12 1.2 8.6 LT
Boss Bolt M6 2 10 1.0 7.2 LT
Pickup coil Bolt M6 2 10 1.0 7.2 LT
Stator coil Bolt M6 3 10 1.0 7.2 LT
Neutral switch Bolt M5 2 4 0.4 2.9 LT
–6–
CHASSIS
Item Standard Limit

Front suspension
Front fork travel 95 mm (3.74 in) ----
Fork spring free length 275.7 mm (10.85 in) 270.2 mm
(10.24 in)
Installed length 273.7 mm (10.78 in) ----
Spring rate (K1) 11 N/mm (1.12 kgf/mm, 62.81 lb/in) ----
(K2) 15.60 N/mm (1.59 kgf/mm, 89.08 lb/in) ----
Stroke (K1) 0 − 53 mm (0.00 − 2.09 in) ----
(K2) 53 − 95 mm (2.09 − 3.74 in) ----
Optional spring available No ----
Oil capacity 0.059 L (59 cm3) ----
Oil level 100.0 mm (3.94 in) ----
Recommended oil Fork oil 10W or equivalent ----
Inner tube outer diameter 26 mm ----
Inner tube bend limit ---- 0.2 mm
(0.008 in)
Rear suspension
Shock absorber stroke 70 mm (2.76 in) ----
Spring free length 221.4 mm (9.72 in) 218.0 mm
(8.58 in)
Installed length 216.4 mm (10.29 in) ----
Spring rate (K1) 17.42 N/mm (1.78 kgf/mm, 99.47 lb/in) ----
(K2) 36.68 N/mm (3.74 kgf/mm, 209.44 lb/in) ----
Stroke (K1) 0 − 36 mm (0 − 1.42 in) ----
(K2) 36 − 70 mm (1.42 − 2.76 in) ----
Optional spring available No ----
Front wheel
Type Cast wheel ----
Rim size 17 × 1.40 ----
Rim material Aluminum ----
Max. radial wheel runout ---- 1.0 mm
(0.04 in)
Max. lateral wheel runout ---- 0.5 mm
(0.02 in)
–7–
Item Standard Limit

Rear wheel
Type Cast wheel ----
Rim size 17 × 1.40 ----
Rim material Aluminum ----
Max. radial wheel runout ---- 1.0 mm
(0.04 in)
Max. lateral wheel runout ---- 0.5 mm
(0.02 in)
Drive chain
Type/manufacturer 428/LOCAL MADE ----
Link quantity 98 ----
Drive chain slack 25 − 35 mm (0.98 − 1.38 in) ----
15-link length limit 190.8 mm ----
Front brake
Disc outside diameter × thickness 220 × 3.5 mm (8.66 × 0.14 in) ----
Brake pod lining thickness (inner) 5.3 mm (0.21 in) 0.8 mm
(0.03 in)
Brake pod lining thickness (outer) 5.3 mm (0.21 in) 0.8 mm
(0.03 in)
Master cylinder inside diameter 11.00 mm (0.43 in) ----
Caliper cylinder inside diameter 33.30 mm (1.31 in) ----
Recommended fluid DOT3 or DOT4 ----
Front brake lever free play 5.0 − 8.0 mm (0.20 − 0.31 in) ----
–8–
TIGHTENING TORQUES
CHASSIS
Tightening torque
Part to be tightened Thread size Remarks
Nm m·kg ft·lb
Handlebar bracket and lower bracket M10 43 4.3 30
Handlebar and handlebar bracket M8 16 1.6 12
Front brake master cylinder M6 11 1.1 7.9
Front wheel axle nut M10 39 3.9 28
Lower bracket and front fender M6 10 1.0 7.2
Front fork cap bolt M20 20 2.0 15
Front brake hose guide (front fork) M6 10 1.0 7.2
Front brake caliper bracket M10 35 3.5 25
Front brake hose guide (head pipe) M6 7 0.7 5.1
Front brake hose guide (lower bracket) M6 7 0.7 5.1
Front brake disc M8 23 2.3 17 LT
Lower bracket pinch bolt M10 38 3.8 27

Damper rod bolt M8 23 2.3 17 LT
Upper ring nut M25 75 7.5 54 See TIP

Lower ring nut M25 38 3.8 27 See TIP
Brake camshaft and brake camshaft lever M6 7 0.7 5.0
Driven sprocket and rear wheel drive hub M8 30 3.0 22
Rear wheel axle nut M12 60 6.0 43
Rear shock absorber and frame M10 32 3.2 23
Rear shock absorber and swingarm M10 32 3.2 23
Swingarm pivot nut M12 51 5.1 37
Engine mounting nut M8 34 3.4 25
Swingarm and drive chain case M6 7 0.7 5.0
Drive chain adjuster locknut M6 7 0.7 5.0
Swingarm and brake torque rod M8 16 1.6 12
Brake shoe plate and brake torque rod M8 19 1.9 14
Rider footrest and crankcase M8 23 2.3 17
Passenger footrest and frame M8 30 3.0 22
Rear brake pedal and frame M8 23 2.3 17
Front cowling bracket and crankcase cover M6 7 0.7 5.0
(left and right)
Main switch and frame M6 10 1.0 7.2
Ignition coil and frame M6 7 0.7 5.0
Fuel tank and frame M8 16 1.6 12
Fuel cock and frame M6 10 1.0 7.2
Seat and seat bracket M6 7 0.7 5.0
–9–
TIP
1. First tighten the lower ring nut 38 Nm (3.8 m • kg, 27 ft • lb) by using a torque wrench, then
loosen the ring nut 1/4 turn.
2. Then, tighten the lower ring nut 14Nm (1.4 m • kg, 10 ft • lb) by using a torque wrench.
3. Install the plain washer.
4. Install the center ring nut.
5. Install the special washer.
6. Then, hold the lower ring nut and tighten the upper ring nut 75 Nm (7.5 m • kg, 54 ft • lb) by
using a torque wrench.
–10–
ELECTRICAL
Item Standard Limit

Rectifier/regulator
Regulator type Semiconductor short-circuit ----
No load regulated voltage (DC) 14.1 − 14.9 V ----
(AC) 12.6 − 13.6 V ----
Rectifier capacity (AC) 12 A ----
Battery
Specific gravity 1.320 ----
Electric starting system
Starter motor
Operation voltage 12 V ----
Power output 0.30 kW ----
Armature coil resistance 0.0630 − 0.0770 Ω at 20 °C(68 °F) ----
Brush overall length 7 mm (0.28 in) 3.5 mm
(0.14 in)
Spring force 3.92 − 5.88 N ----
(400 − 600 gf, 14.11 − 21.17 oz)
Commutator diameter 17.6 mm (0.69 in) 16.6 mm
(0.65 in)
Mica undercut (depth) 1.35 mm (0.05 in) ----
Starter relay
Model/manufacturer G4R-D/OMRON ----
Amperage rating 50 A ----
Coil resistance 90 − 110 Ω at 20 °C(68 °F) ----
–11–
LUBRICATION POINTS AND LUBRICANT TYPES SPEC
LUBRICATION POINTS AND LUBRICANT TYPES
ENGINE
Lubrication point Lubricant
Oil seal lips
Bearings
O-rings
Cylinder head tightening nut and stud bolt thread
Rocker arm inner surfaces
Rocker arm shaft
Camshaft
Timing chain sprocket
Valve stem (IN, EX)
Valve stem guide (IN, EX)
Crank pin
Connecting rod big end face and thrust end face
Piston pin
Piston outside and ring groove
Piston ring
Cylinder inner surface
Starter clutch gear inner surface
Starter idle gear inner surface
Kickstarter ratchet gear
Kickstarter gear
Kickstarter shaft
Primary driven gear inner surface
Clutch push rod
Clutch pressure plate
Friction plate
Clutch shoe housing inner surface
Cage
Clutch shoe housing boss
Clutch shoe housing inside surface at one way
Clutch boss tightening portion
Oil pump assembly
Shift guide inner surface
Shift fork guide bar
Shift shaft thrust surface
Shift lever inner surface
Shift shaft stopper lever inner surface
Timing chain
–12–

Transmission wheel gears inner surface
Transmission side plate inner surface
Transmission pinion gears inner surface
Main axle assembly
Drive axle assembly
Shift pin contact areas with crankcase
Starter motor guard bolt Yamaha bond No.1215
Generator lead grommet Yamaha bond No.1215
Cylinder head bolt (chain chamber side) Yamaha bond No.1215
Crankcase cover bolt Yamaha bond No.1215
Crankcase mating surface Yamaha bond No.1215
–13–
CHASSIS

Front wheel oil seal lips
Rear wheel oil seal lips
Speedometer driven gear
Front brake caliper slide pin moving surface
Front brake master cylinder moving surface
Speedometer drive gear
Rear wheel oil seal lips
Rear brake camshaft
Brake torque rod bolt
Front wheel axle
Rear wheel axle
Throttle grip tube guide inner surface
Steering head bearing inner race
Steering head bearing outer race
Steering head upper bearing
Steering head lower bearing
Sidestand pivot bolt
Swingarm pivot shaft
Centerstand pivot shaft
–14–
CABLE ROUTING SPEC
CABLE ROUTING
1 Clamp ∫ Fasten the handlebar switch lead with a clamp
2 Starter cable avoiding taped area.
3 Headlight unit ç Connect the couplers and place it between the
4 Wire harness handlebar and speedometer unit.
5 Brake hose ∂ Pass through the left handlebar switch lead
6 Throttle cable behind the handlebar.
7 Tape (black) ´ Hook the wire strap on the wire guide.
8 Speedometer cable ƒ To headlight unit
© To turn signal light
å Pass through the right handlebar switch lead ˙ To front brake light switch
behind the handlebar.
–15–
CABLE ROUTING SPEC
1 Wire harness å Pass the wire harness above the cable guide.
2 Cable guide ∫ Align the plastic locking tie with the white tape on
3 Starter cable the wire harness.
4 Throttle cable ç Pass the wire harness avoiding stick out from
5 Cable holder
6 Speedometer cable the handle cover.
7 Brake hose ∂ Fasten the wire harness and cables using a
8 Main switch lead plastic locking tie with its buckle pointing the left
side of the vehicle.
–16–
CABLE ROUTING SPEC
1 Clamp w Fuel cock
2 Wire harness e Starter motor lead
3 Air vent hose r Carburetor overflow hose
4 Air induction system vacuum hose t Air filter case drain hose
5 A.C. magneto lead y Throttle cable
6 Neutral switch lead u Starter cable
7 Turn signal relay i Main switch lead
8 Battery negative lead o Frame complete
9 Fuel tank overflow hose
0 Air induction system hose
(air filter to air cut-off valve assembly)
q Fuel hose (fuel tank to fuel cock)
–17–
CABLE ROUTING SPEC
å Pass the wire harness, starter cable and throttle © Direct the clip end toward bottom of the vehicle.
cable through the guide. ˙ Pass the fuel tank overflow hose through the
∫ Pass the fuel hose (fuel cock to carburetor) and guide.
fuel cock vacuum hose through the guide.
ç Pass the starter motor lead, neutral switch lead
and A.C. magneto lead through the guide.
∂ Pass the carburetor overflow hose through the
guide.
´ Pass the air filter case drain hose through the
guide.
ƒ Avoid the clip touching the fuel cock vacuum
hose.
–18–
CABLE ROUTING SPEC
1 Fuel tank overflow hose e Turn signal relay
2 Rectifier/regulator r Neutral switch lead
3 Wire harness t A.C. magneto lead
4 Ignition coil y Protector
5 Air vent hose u Main switch
6 Main switch lead i Starter motor cover
7 Cover o Starter motor
8 Horn p Starter motor lead
9 Brake hose holder a Footrest
0 Brake hose
q Guide å Insert the end of the air vent hose into the hole in
w Spark plug lead the frame.
–19–
CABLE ROUTING SPEC
1 Fuel sender e Battery
2 Starter motor lead r C.D.I. unit
3 Rear brake light switch t Box
4 License plate light lead y Battery positive lead
5 Rear right turn signal light lead u Wire harness
6 Rear left turn signal light lead i Rear brake light switch lead
7 Frame
8 Plastic locking tie
9 Stay
0 Battery negative lead
q Fuse
w Starter relay
–20–
CABLE ROUTING SPEC
å Fasten the protected area of the leads with a ´ Insert end of the plastic locking tie between the
plastic locking tie without slack. Insert end of the frame and stay.
plastic locking tie between the stay and frame. ƒ Pass the license plate light lead through notch of
∫ Pass the license plate light lead and rear right the rear fender.
turn signal light lead through hole in the rear
fender.
ç Make sure the licence plate light lead and rear
right turn signal lead are not hanging loose.
∂ Pass the license plate light lead through hole in
the rear fender.
–21–
CABLE ROUTING SPEC
1 Wire harness w Starter relay
2 Rectifier/regulator e Turn signal relay
3 Battery r Neutral switch lead
4 C.D.I. unit t A.C. magneto lead
5 Fuel sender y Battery positive lead
6 Wire harness (license plate light lead, rear turn
signal light leads, tail/brake light lead)
7 Rear turn signal light
8 Tail/brake light
9 Fuel sender lead
0 Battery negative lead
q Fuel tank overflow hose
–22–
CABLE ROUTING SPEC
å Fasten the fuel sender lead to the fuel tank. ˚ To the starter relay
∫ Pass the rear left turn signal light lead through
hole in the rear fender.
ç Fasten the fuel sender lead on white tape using
a clamp.
∂ To the starter motor
´ To the wire harness
ƒ To the battery
© To the battery positive terminal
˙ To the fuse
ˆ To the starter motor
∆ To the C.D.I. unit.
–23–
INTRODUCTION/
PERIODIC MAINTENANCE CHART CHK
FOR THE EMISSION CONTROL SYSTEM ADJ
EAS00036
PERIODIC CHECKS AND ADJUSTMENTS

INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments.
If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a
longer service life and reduce the need for costly overhaul work. This information applies to vehi-
cles already in service as well as to new vehicles that are being prepared for sale. All service tech-
nicians should be familiar with this entire chapter.
TIP
9The annual checks must be performed every year, except if a kilometer- based mainte-
nance, or for the UK, a mileage- based maintenance, is performed instead.
9From 30000 km (17500 mi), repeat the maintenance intervals starting from 6000 km (3500 mi).
9Items marked with an asterisk should be performed by a Yamaha dealer as they require special
tools, data and technical skills.
EAU46920
PERIODIC MAINTENANCE CHART

FOR THE EMISSION CONTROL SYSTEM
ODOMETER READING
CHECK OR MAINTENANCE ANNUAL
NO. ITEM
JOB 1000 km 6000 km 12000 km 18000 km 24000 km CHECK
(600 mi) (3500 mi) (7000 mi) (10500 mi) (14000 mi)
• Check fuel and vacuum hoses

1 * Fuel line for cracks or damage. √ √ √ √ √
• Check condition.
• Clean and regap. √ √
2 Spark plug
• Replace. √ √
• Check valve clearance.
3 * Valves
• Adjust.
√ √ √ √
• Check starter (choke) operation.
4 * Carburetor
• Adjust engine idling speed. √ √ √ √ √ √
• Check the air cut- off valve,
reed valve, and hose for dam-
5 * Air induction sys- age. √ √ √ √ √
tem
• Replace any damaged parts if
necessary.
–24–
CHK
GENERAL MAINTENANCE AND LUBRICATION CHART ADJ
EAU17716
GENERAL MAINTENANCE AND LUBRICATION CHART

ODOMETER READING
NO. ITEM
(600 mi) (3500 mi) (7000 mi) (10500 mi) (14000 mi)
• Clean. √ √
1 Air filter element
• Replace. √ √
• Check operation, fluid level
and vehicle for fluid leakage. √ √ √ √ √ √
2 * Front brake
• Replace brake pads. Whenever worn to the limit
• Check operation and adjust
brake pedal free play.
√ √ √ √ √ √
3 * Rear brake
• Replace brake shoes. Whenever worn to the limit
• Check for cracks or damage. √ √ √ √ √
4 * Brake hose
• Replace. Every 4 years
5 * Wheels • Check runout and for damage. √ √ √ √

• Check tread depth and for
damage.
6 * Tires • Replace if necessary. √ √ √ √ √
• Check air pressure.
• Correct if necessary.
• Check bearing for looseness
7 * Wheel bearings
or damage.
√ √ √ √
• Check operation and for

excessive play. √ √ √ √
8 * Swingarm
• Lubricate with lithium- soap-
Every 24000 km (14000 mi)
based grease.
• Check chain slack, alignment

and condition. Every 500 km (300 mi) and after washing the motorcycle or
9 Drive chain
• Adjust and thoroughly lubrica- riding in the rain
techain with engine oil.
• Check bearing play and steer-

ing for roughness. √ √ √ √ √
10 * Steering bearings
• Lubricate with lithium- soap-
Every 24000 km (14000 mi)
based grease.
• Make sure that all nuts, bolts and

11 * Chassis fasteners screws are properly tightened. √ √ √ √ √
Brake lever pivot
12
shaft
• Lubricate with silicone grease. √ √ √ √ √
Brake pedal pivot • Lubricate with lithium- soap-

13
shaft based grease. √ √ √ √ √
• Check operation.
14 Centerstand
• Lubricate.
√ √ √ √ √
• Check operation and for oil
15 * Front fork leakage. √ √ √ √
Shock absorber • Check operation and shock
16 * assemblies absorbers for oil leakage. √ √ √ √
• Change.
17 Engine oil • Check oil level and vehicle for √ Every 3000 km (1800 mi)
oil leakage.
Front and rear
18 *
brake switches
• Check operation. √ √ √ √ √ √
–25–
CHK
GENERAL MAINTENANCE AND LUBRICATION CHART ADJ
ODOMETER READING
NO. ITEM
(600 mi) (3500 mi) (7000 mi) (10500 mi) (14000 mi)
Moving parts and

19
cables
• Lubricate. √ √ √ √ √
• Check operation and free play.
• Adjust the throttle cable free
Throttle grip hous-
20 * play if necessary. √ √ √ √ √
ing and cable
• Lubricate the throttle grip
housing and cable.
Lights, signals • Check operation.
21 *
and switches • Adjust headlight beam. √ √ √ √ √ √
TIP
9The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
9Hydraulic brake service
• Regularly check and, if necessary, correct the brake fluid level.
• Every two years replace the internal components of the brake master cylinder and caliper,
and change the brake fluid.
• Replace the brake hoses every four years and if cracked or damaged.
–26–
CHECKING THE FRONT BRAKE PADS/ CHK
BLEEDING THE HYDRAULIC BRAKE SYSTEM ADJ
EAS00109
CHASSIS
EAS00120
CHECKING THE FRONT BRAKE PADS

The following procedure applies to all of the
1 1 brake pads.
1. Operate the brake.
2. Check:
9 front brake pad
Wear indicator groove 1 almost disap-
peared → Replace the brake pads as a
set. Refer to “REPLACING THE FRONT
BRAKE PADS”.
EAS00133
BLEEDING THE HYDRAULIC BRAKE

SYSTEM
WARNING
Bleed the hydraulic brake system whenev-
er:
9 the system is disassembled.
9 a brake hose is loosened, disconnected
or replaced.
9 the brake fluid level is very low.
9 brake operation is faulty.
TIP
9 Be careful not to spill any brake fluid or allow
the brake master cylinder reservoir to over-
flow.
9 When bleeding the hydraulic brake system,
make sure there is always enough brake fluid
before applying the brake. Ignoring this pre-
caution could allow air to enter the hydraulic
brake system, considerably lengthening the
bleeding procedure.
9 If bleeding is difficult, it may be necessary to
let the brake fluid settle for a few hours.
Repeat the bleeding procedure when the tiny
bubbles in the hose have disappeared.
–27–
CHK
BLEEDING THE HYDRAULIC BRAKE SYSTEM ADJ
1. Bleed:
9 hydraulic brake system
2 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Fill the brake fluid reservoir to the proper
level with the recommended brake fluid.
b. Install the brake master cylinder reservoir
diaphragm.
c. Connect a clear plastic hose 1 tightly to
1
the bleed screw 2.
d. Place the other end of the hose into a
container.
e. Slowly apply the brake lever several times.
f. Fully pull the brake lever without releasing
it.
g. Loosen the bleed screw.
TIP
Loosening the bleed screw will release the
pressure and cause the brake lever to contact
the throttle grip.
h. Tighten the bleed screw and then release

the brake lever.
i. Repeat steps (e) to (h) until all of the air
bubbles have disappeared from the brake
fluid in the plastic hose.
j. Tighten the bleed screw to specification.
Bleed screw
5 Nm (0.5 m·kg, 3.6 ft·lb)
k. Fill the brake fluid reservoir to the proper
level with the recommended brake fluid.
Refer to “CHECKING THE BRAKE FLUID
LEVEL”.
WARNING
After bleeding the hydraulic brake system,
check the brake operation.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
–28–
CHK
ADJUSTING THE DRIVE CHAIN SLACK ADJ
EAS00140
ADJUSTING THE DRIVE CHAIN SLACK

TIP
The drive chain slack must be checked at the
tightest point on the chain.
NOTICE
A drive chain that is too tight will overload
the engine and other vital parts, and one
that is too loose can skip and damage the
swingarm or cause an accident. Therefore,
keep the drive chain slack within the spec-
ified limits.
1. Stand the vehicle on a level surface.

WARNING
Securely support the vehicle so that there
is no danger of it falling over.
TIP
Place the vehicle on the centerstand so that
the rear wheel is elevated.
2. Remove the drive chain slack check hole

1 cap 1.
3. Spin the rear wheel several times and find

the tightest position of the drive chain.
4. Check:
9 drive chain slack a
Out of specification → Adjust.
Drive chain slack

a
25–35 mm (0.98–1.38 in)
–29–
CHK
ADJUSTING THE DRIVE CHAIN SLACK ADJ
5. Adjust:
3 4 9 drive chain slack
2
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Loosen the brake torque rod nut 1.
b
b. Loosen the wheel axle nut 2.
c. Loosen both locknuts 3.
a d. Turn both adjusting nuts 4 in direction a
or b until the specified drive chain slack
1 is obtained.
Direction a Drive chain is tightened.
Direction b Drive chain is loosened.
TIP
To maintain the proper wheel alignment,adjust
both sides evenly.
e. Tighten both locknuts to specification.

Locknut
7 Nm (0.7 m·kg, 5.0 ft·lb)
f. Tighten the wheel axle nut to specifica-
tion.
Wheel axle nut
60 Nm (6.0 m·kg, 43 ft·lb)
g. Tighten the brake torque rod nut to speci-
fication.
Brake torque rod nut
19 Nm (1.9 m·kg, 13 ft·lb)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
–30–
CHK
CHECKING THE BRAKE FLUID LEVEL ADJ
EAS00115
CHECKING THE BRAKE FLUID LEVEL

1. Stand the motorcycle on a level surface.
a TIP
Make sure the motorcycle is upright.
2. Check:
9 brake fluid level
Below the minimum level mark a → Add
the recommended brake fluid to the prop-
er level.
Recommended brake fluid
DOT 4
WARNING
9Use only the designated brake fluid.
Other brake fluids may cause the rubber
seals to deteriorate, causing leakage and
poor brake performance.
9Refill with the same type of brake fluid
that is already in the system. Mixing
brake fluids may result in a harmful
chemical reaction, leading to poor brake
performance.
9When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor
lock.
NOTICE
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
TIP
In order to ensure a correct reading of the
brake fluid level, make sure the top of the
brake fluid reservoir is horizontal.
–31–
CHK
CHECKING AND CHARGING THE BATTERY ADJ
EAS00178
ELECTRICAL SYSTEM
CHECKING AND CHARGING THE
BATTERY
WARNING
Batteries generate explosive hydrogen gas
and contain electrolyte which is made of
poisonous and highly caustic sulfuric
acid.
Therefore, always follow these preventive
measures:
9 Wear protective eye gear when handling
or working near batteries.
9 Charge batteries in a well-ventilated area.
9 Keep batteries away from fire, sparks or
open flames (e.g., welding equipment,
lighted cigarettes).
9 DO NOT SMOKE when charging or han-
dling batteries.
9 KEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN.
9 Avoid bodily contact with electrolyte as it
can cause severe burns or permanent
eye injury.
FIRST AID IN CASE OF BODILY CONTACT:
EXTERNAL
9 Skin — Wash with water.
9 Eyes — Flush with water for 15 minutes
and get immediate medical attention.
INTERNAL
9 Drink large quantities of water or milk fol-
lowed with milk of magnesia, beaten egg
or vegetable oil. Get immediate medical
attention.
NOTICE
9 This is a VRLA (Valve Regulated Lead
Acid) battery. Never remove the sealing
caps because the balance between cells
will not be maintained and battery perfor-
mance will deteriorate.
–32–
CHK
9 Charging time, charging amperage and
charging voltage for a VRLA (Valve
Regulated Lead Acid) battery are differ-
ent from those of conventional batteries.
The VRLA (Valve Regulated Lead Acid)
battery should be charged as explained
in the charging method illustrations. If
the battery is overcharged, the electrolyte
level will drop considerably. Therefore,
take special care when charging the bat-
tery.
TIP
Since VRLA (Valve Regulated Lead Acid) bat-
teries are sealed, it is not possible to check
the charge state of the battery by measuring
the specific gravity of the electrolyte.
Therefore, the charge of the battery has to be
checked by measuring the voltage at the bat-
tery terminals.
2 1. Open the seat.
2. Remove:
9 screw 1
9 battery box cover 2
3. Disconnect:
3 9 battery leads
(from the battery terminals)
1
NOTICE
First, disconnect the negative battery lead
1, and then positive battery lead 2.
2
4. Remove:
9 battery 3
5. Check:
9 battery terminals
Dirt → Clean with a wire brush.
–33–
CHK
6. Check:
9 battery charge
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect a pocket tester to the battery ter-
minals.
Positive tester probe →

positive battery terminal
Negative tester probe →
negative battery terminal
Relationship between the open-circuit voltage
and the charging time at 20 °C (68 °F)
Open-circuit voltage (V)
TIP
9 The charge state of a VRLA (Valve
Regulated Lead Acid) batter y can be
checked by measuring its open-circuit volt-
age (i.e., the voltage when the positive bat-
tery terminal is disconnected).
Charging time (hours)
These values vary with the temperature, the condition of 9 No charging is necessary when the open-
the battery plates, and the electrolyte level. circuit voltage equals or exceeds 12.8 V.
b. Check the charge of the battery, as shown

in the charts and the following example.
Example
c. Open-circuit voltage = 12.0 V
d. Charging time = 6.5 hours
e. Charge of the battery = 20 ~ 30%
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7. Charge:
9 battery
Charging
Ambient temperature 20 °C (68 °F) (refer to the appropriate charging method
illustration)
WARNING
Do not quick charge a battery.
Time (minutes) NOTICE

Check the open-circuit
voltage. 9 Do not use a high-rate battery charger
since it forces a high-amperage current
into the battery quickly and can cause
Ambient tem-
battery overheating and battery plate
perature
20 °C (68 °F) damage.
9 If it is impossible to regulate the charging
current on the battery charger, be careful
not to overcharge the battery.
Charging condition of the battery (%)
–34–
CHK
9 When charging a battery, be sure to
remove it from the vehicle. (If charging
has to be done with the battery mounted
on the vehicle, disconnect the negative
battery lead from the battery terminal.)
9 To reduce the chance of sparks, do not
plug in the battery charger until the bat-
tery charger leads are connected to the
battery.
9 Before removing the battery charger lead
clips from the battery terminals, be sure
to turn off the battery charger.
9 Make sure the battery charger lead clips
are in full contact with the battery termi-
nal and that they are not shorted. A cor-
roded battery charger lead clip may gen-
erate heat in the contact area and a weak
clip spring may cause sparks.
9 If the battery becomes hot to the touch at
any time during the charging process,
disconnect the battery charger and let
the battery cool before reconnecting it.
Hot batteries can explode!
9 As shown in the following illustration, the
open-circuit voltage of an VRLA (Valve
Regulated Lead Acid) battery stabilizes
about 30 minutes after charging has been
completed. Therefore, wait 30 minutes
after charging is completed before mea-
suring the open-circuit voltage.
–35–
CHK
Charging method using a variable-current (voltage) charger
Charger
Ammeter TIP
Leave the battery unused for
Measure the open-circuit more than 30 minutes before
measuring its open-circuit voltage.
voltage prior to charging.
TIP
Set the charging voltage to
Connect a charger and
16 ~ 17 V. (If the charging
ammeter to the battery and
voltage is lower, charging will
start charging.
be insufficient, if it is higher,
the battery will be over-
charged.)
Is the amperage higher
YES than the standard charging NO
amperage written on the
battery?
Adjust the charging voltage to

20 ~ 25 V.
YES Monitor the amperage for 3 ~ 5

Adjust the voltage to obtain the minutes. Is the standard charg-
standard charging amperage. ing amperage exceeded?
NO
If the amperage does not

Set the timer to the charging exceed the standard charging
time determined by the open- amperage after 5 minutes,
circuit voltage. replace the battery.
Refer to “CHECKING AND
CHARGING THE BATTERY”.
If the required charging time exceeds 5 hours, it is advisable to check the

charging amperage after 5 hours. If there is any change in the amperage,
readjust the voltage to obtain the standard charging amperage.
Leave the battery unused for more than 30 minutes before measuring its
open-circuit voltage.
12.8 V Charging is complete.
12.0 ~ 12.7 V Recharging is required.
Under 12.0 V Replace the battery.
–36–
CHK
Charging method using a constant voltage charger
Measure the open-circuit

TIP
Leave the battery unused for
voltage prior to charging. more than 30 minutes before
measuring its open-circuit voltage.
Connect a charger and

ammeter to the battery and
start charging.
Is the amperage higher

YES NO
than the standard charging
amperage written on the
battery?
Charge the battery until the charging This type of battery charger cannot
voltage reaches 15 V. charge an VRLA (Valve Regulated
Lead Acid) battery. A variable voltage
charger is recommended.
TIP
Set the charging time to a maxi-
mum of 20 hours.
Charger
Leave the battery unused for more than 30 Ammeter

minutes before measuring its open-circuit Voltmeter
voltage.
12.8 V Charging is complete.
12.0 ~ 12.7 V Recharging is required.
Under 12.0 V Replace the battery.
NOTICE
Constant amperage chargers are not
suitable for charging VRLA (Valve
Regulated Lead Acid) batteries.
–37–
CHK
8. Install:
1 9 battery 1
9. Lubricate:
3 9 battery terminals
10. Connect:
2 9 battery leads
(to the battery terminals)
NOTICE
First, connect the positive battery lead 2,
and then the negative battery lead 3.
11. Install:
1 9 battery box cover 1
9 screw 2
12. Close the seat.
–38–
FRONT WHEEL AND BRAKE DISC CHAS
EASF0044
CHASSIS
FRONT WHEEL AND BRAKE DISC
1 Rubber cap
2 Front wheel axle
3 Spacer
4 Speedometer gear unit
5 Oil seal
6 Bearing
7 Spacer
8 Brake disc
3
5
6
23 Nm (2.3 m•kg,17 ft•lb)
7
6
39 Nm (3.9 m•kg,28 ft•lb)
–39–
EAS00519
REMOVING THE FRONT WHEEl

1. Stand the motorcycle on a level surface.
WARNING
Securely support the motorcycle so that
there is no danger of it falling over.
2. Remove:
9 speedometer cable 1
9 rubber cap 2
9 axle nut 3
9 washer 4
3. Elevate:
4 9 front wheel
3 TIP
Place the motorcycle on a suitable stand so
2 that the front wheel is elevated.
4. Remove:
1 9 front wheel axle 1
9 spacer
9 speedometer gear unit
9 front wheel
5. Remove:
1
9 brake disc 1
–40–
EAS00526
CHECKING THE FRONT WHEEL

1. Check:
9 wheel axle
Roll the wheel axle on a flat surface.
Bends → Replace.
WARNING
Do not attempt to straighten a bent wheel
axle.
2. Check:
9 tire
9 front wheel
Damage/wear → Replace.
Refer to “CHECKING THE TIRES” in
chapter 3 (Manual No.:3P9-F8197-E0).
3. Measure:
9 front wheel radial runout a
9 front wheel lateral runout b
Over the specified limits → Replace.
Front wheel radial runout limit
1.0 mm
Front wheel lateral runout limit
0.5 mm
4. Check:
9 spacers
WARNING
9 After mounting a new tire, ride conserva-
tively for a while to become accustomed
to the “feel” of the new tire and to allow
the tire to seat itself properly in the rim.
Failure to do so could lead to an accident
with possible injury to the rider or dam-
age to the motorcycle.
9 After a tire has been repaired or replaced,
be sure to tighten the tire air valve stem
locknut 1 properly.
–41–
5. Check:
9 wheel bearings
Front wheel turns roughly or is loose →
Replace the wheel bearings.
9 oil seals
6. Replace:
9 wheel bearings
2 9 oil seals
1 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Clean the outside of the front wheel hub.
b. Remove the oil seals 1 with a flat-head
screwdriver.
TIP
To prevent damaging the wheel, place a rag
2 between the screwdriver and the wheel
surface.
c. Remove the wheel bearings 3 with a

general bearing puller.
d. Install the new wheel bearings and oil

seals in the reverse order of disassembly.
NOTICE
Do not contact the wheel bearing inner
race 4 or balls 5 . Contact should be
made only with the outer race 6.
TIP
Use a socket 7 that matches the diameter of
the wheel bearing outer race and oil seal.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
–42–
EAS00527
CHECKING THE BRAKE DISC

1. Check:
9 brake disc
Damage/galling → Replace.
2. Measure:
9 brake disc deflection
Out of specification → Correct the brake
disc deflection or replace the brake disc.
Brake disc deflection limit (maxi-

mum)
0.15 mm
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Place the motorcycle on a suitable stand
so that the front wheel is elevated.
b. Before measuring the front brake disc
deflection, turn the handlebar to the left or
right to ensure that the front wheel is sta-
tionary.
c. Remove the brake caliper.
d. Hold the dial gauge at a right angle
against the brake disc surface.
e. Measure the deflection 5 ~ 10 mm below
the edge of the brake disc.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Measure:
9 brake disc thickness
Measure the brake disc thickness at a few
different locations.
Out of specification → Replace.
Brake disc thickness limit (mini-
mum)
3.0 mm
4. Adjust:
9 brake disc deflection
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the brake disc.
b. Rotate the brake disc by one bolt hole.
c. Install the brake disc.
TIP
Tighten the brake disc bolts in stages and in a
LT crisscross pattern.
–43–
Brake disc bolt
23 Nm (2.3 m·kg, 17 ft·lb)
LOCTITE®
d. Measure the brake disc deflection.
e. If out of specification, repeat the adjust-
ment steps until the brake disc deflection
is within specification.
f. If the brake disc deflection cannot be
brought within specification, replace the
brake disc.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS00535
CHECKING THE SPEEDOMETER GEAR

UNIT
1. Check:
9 speedometer clutch
Bends/damage/wear → Replace.
EAS00542
INSTALLING THE FRONT WHEEL

1. Lubricate:
9 wheel axle
9 wheel bearings
9 oil seal lips
9 speedometer gear unit
Recommended lubricant
Lithium-soap-based grease
2. Install:
1 9 speedometer gear unit 1
a
TIP
9 Make sure that the speedometer gear unit
and the wheel hub are installed with the pro-
jection a of the wheel hub inserted in a slot
b of the speedometer gear unit.
b
–44–
9 When installing the speedometer gear unit,
make sure that the projection on the wheel
hub does not damage the lip of the
speedometer gear unit oil seal.
3. Install:
9 brake disc
9 front wheel
9 spacer
9 front wheel axle
a 9 washer
b
9 axle nut
9 rubber cap
Refer to “CHECKING THE BRAKE DISC”.
TIP
Make sure the projection a on the
speedometer gear unit fits between the pro-
jections b on the outer tube.
4. Tighten:
9 wheel axle nut 39 Nm (3.9 m·kg, 28 ft·Ib)
5. Connect:
b
a TIP
Be sure that the speedometer cable meshes
a inserted securely to the hole b on the
2 speedometer gear unit 2.
1
WARNING
Make sure the brake cable is routed prop-
erly.
NOTICE
Before tightening the wheel axle nut, push
down hard on the handlebar several times
and check if the front fork rebounds
smoothly.
–45–
FRONT BRAKE CHAS
FRONT BRAKE
EASF0052
FRONT BRAKE CALIPER

1 Brake caliper 9 Upper brake caliper boot
2 Brake pad retaining pin 0 Brake caliper piston
3 Brake pad q Brake caliper piston dust seal
4 Brake pad shim w Brake caliper piston seal
5 Brake pad clip e Air bleed screw
6 Brake pad support
7 Brake caliper bracket
8 Lower brake caliper boot
5 Nm (0.5 m•kg,3.6 ft•lb)
7
e
S 1
w 5 3
q
4
6
BF
S
35 Nm (3.5 m•kg,26 ft•lb)
–46–
FRONT BRAKE CHAS
EAS00579
NOTICE
Disc brake components rarely require dis-
assembly.
Therefore, always follow these preventive
measures:
9 Never disassemble brake components
unless absolutely necessary.
9 If any connection on the hydraulic brake
system is disconnected, the entire brake
system must be disassembled, drained,
cleaned, properly filled, and bled after
reassembly.
9 Never use solvents on internal brake
components.
9 Use only clean or new brake fluid for
cleaning brake components.
9 Brake fluid may damage painted surfaces
9 Avoid brake fluid coming into contact
with the eyes as it can cause serious
injury.
FIRST AID FOR BRAKE FLUID ENTERING
THE EYES:
9 Flush with water for 15 minutes and get
immediate medical attention.
EAS00581
REPLACING THE FRONT BRAKE PADS

TIP
When replacing the brake pads, it is not nec-
essary to disconnect the brake hose or disas-
semble the brake caliper.
1. Remove:
9 brake caliper bolts 1
9 brake caliper 2
1
–47–
FRONT BRAKE CHAS
2. Remove:
9 clips
9 brake pad retaining pin
9 brake pads 1
9 brake pad spring
3. Measure:
9 brake pad wear limit a
Out of specification → Replace the brake
a
pads as a set.
Brake pad wear limit

0.8 mm (0.031 in)
4. Install:
9 brake pad spring
9 brake pads
TIP
Always install new brake pads and a new
brake pad spring as a set.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect a clear plastic hose 1 tightly to
the bleed screw 2. Put the other end of
1 the hose into an open container.
b. Loosen the bleed screw and push the
brake caliper pistons into the brake
caliper with your finger.
c. Tighten the bleed screw.
2
Bleed screw
5 Nm (0.5 m·kg, 3.6 ft·lb)
d. Install new brake pads and a new brake
pad spring.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
–48–
FRONT BRAKE CHAS
5. Lubricate:
Recommended lubricant
Silicone grease
NOTICE
9 Do not allow grease to contact the brake
pads.
9 Remove any excess grease.
6. Install:
9 brake caliper bolts
35 Nm (3.5 m·kg, 26 ft·lb)
7. Check:
9 brake fluid level
a the recommended brake fluid to the prop-
er level.
LEVEL”.
8. Check:
9 brake lever operation
Soft or spongy feeling → Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM”.
EAS00618
DISASSEMBLING THE FRONT BRAKE

CALIPER
TIP
Before disassembling the brake caliper, drain
the brake fluid from the entire brake system.
–49–
FRONT BRAKE CHAS
1. Remove:
9 union bolt 1
3 9 copper washers 2
9 brake hose
9 brake caliper bolt 3
9 brake caliper 4
1
TIP
2 Put the end of the brake hose into a container
4 and pump out the brake fluid carefully.
2. Remove:
9 pin
9 brake pads
9 brake pad support
9 brake pad clip
3. Remove:
1 9 brake caliper bracket 1
4. Remove:
9 brake caliper piston 1
9 brake caliper piston dust seal 2
3 9 brake caliper piston seal 3
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
2 a. Blow compressed air into the brake hose
joint opening to force out the piston from
the brake caliper.
1
WARNING
9 Cover the brake caliper piston with a rag.
Be careful not to get injured when the pis-
ton are expelled from the brake caliper.
9 Never try to pry out the brake caliper pis-
ton.
b. Remove the brake caliper piston seal and

brake caliper dust seal.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
–50–
FRONT BRAKE CHAS
EAS00631
CHECKING THE FRONT BRAKE

CALIPER
Recommended brake component

replacement schedule
Brake pads If necessary
Piston seal Every two years
Piston dust seal Every two years
Brake hose Every four years
Every two years and
Brake fluid whenever the brake
is disassembled
1. Check:
3 9 brake caliper piston 1
Rust/scratches/wear → Replace the brake
2 caliper pistons.
9 brake caliper cylinder 2
Scratches/wear → Replace the brake
caliper assembly.
1 9 brake caliper body 3
Cracks/damage → Replace the brake
caliper assembly.
9 brake fluid delivery passages
(brake caliper body)
Obstructions → Blow out with compressed
air.
WARNING
Whenever a brake caliper is disassembled,
replace the piston seals.
2. Check:
9 brake caliper bracket 1
Cracks/damage → Replace.
–51–
FRONT BRAKE CHAS
EAS00634
ASSEMBLING AND INSTALLING THE

FRONT BRAKE CALIPER
WARNING
9 Before installation, all internal brake com-
ponents should be cleaned and lubricat-
ed with clean or new brake fluid.
components as they will cause the piston
seals to swell and distort.
9 Whenever a brake caliper is disassem-
bled, replace the brake caliper piston
seals.

DOT 4
TIP
If DOT 4 brake fluid is not available, DOT 3
brake fluid can be used.
1. Install:
9 brake caliper piston seal 1
9 brake caliper piston dust seal 2
1 9 brake caliper piston 3
2 2. Install:
b
9 brake caliper 1
(temporarily)
9 copper washers
9 brake hose 2
a 9 union bolt 3 26 Nm (2.6 m·kg, 19 ft·lb)
3
–52–
FRONT BRAKE CHAS
WARNING
Proper brake hose routing is essential to
insure safe vehicle operation. Refer to
“CABLE ROUTING”.
NOTICE
When installing the brake hose onto the
brake caliper 1, make sure the brake pipe
a touches the projection b on the brake
caliper.
3. Remove:
9 brake caliper
4. Install:
9 brake pad support
9 brake pads
9 pin
9 brake caliper 35 Nm (3.5 m·kg, 26 ft·lb)
Refer to “REPLACING THE FRONT
BRAKE PADS”.
5. Fill:
9 brake master cylinder reservoir
(with the specified amount of the recom-
mended brake fluid)
DOT 4
WARNING
9 Use only the designated brake fluid.
9 Refill with the same type of brake fluid
performance.
9 When refilling, be careful that water does
not enter the brake master cylinder reser-
voir. Water will significantly lower the
boiling point of the brake fluid and could
cause vapor lock.
–53–
FRONT BRAKE CHAS
NOTICE
TIP
6. Bleed:
9 brake system
BRAKE SYSTEM”.
7. Check:
9 brake fluid level
a the recommended brake fluid to the prop-
er level.
LEVEL”.
8. Check:
system.
BRAKE SYSTEM”.
–54–
FRONT BRAKE CHAS
EASF0050
FRONT BRAKE MASTER CYLINDER

1 Brake master cylinder 9 Front brake light switch
2 Brake lever 0 Copper washer
3 Brake master cylinder kit q Union bolt
4 Brake master cylinder reservoir cap w Brake hose
5 Brake master cylinder reservoir diaphragm
holder
6 Brake master cylinder reservoir diaphragm
7 Plate
8 Brake master cylinder bracket
2 Nm (0.2 m•kg,1.5 ft•lb)
4
5
11 Nm (1.1 m•kg,8.0 ft•lb)
6
3
7
BF S 8
1
0
2 q
6 Nm (0.6 m•kg,4.3 ft•lb) 9
26 Nm (2.6 m•kg,19 ft•lb)
26 Nm (2.6 m•kg,19 ft•lb)
q
0
–55–
FRONT BRAKE CHAS
EAS00588
DISASSEMBLING THE FRONT BRAKE

MASTER CYLINDER
TIP
Before disassembling the front brake master
cylinder, drain the brake fluid from the entire
brake system.
1. Remove:
9 front cowling
Refer to “REMOVING THE FRONT
COWLING AND LEG SHIELD” in chapter
3 (Manual No.:3P9-F8197-E0).
2 2. Remove:
9 screws 1
9 headlight assembly 2
1 1
1 5 1 3. Remove:
9 rear view mirrars
9 screws 1
4. Disconnect:
3 9 speedometer cable 2
2 9 meter assembly couplers 3
4
9 high beam indicator light connector
(yellow) 4
5. Remove:
9 meter assembly 5
–56–
FRONT BRAKE CHAS
6. Remove:
9 union bolt 1
9 copper washers 2
9 brake hose 3
9 brake lever 4
TIP
To collect any remaining brake fluid, place a
container under the master cylinder and the
end of the brake hose.
7. Remove:
9 front brake light switch 1
8. Remove:
9 brake master cylinder bracket 1
2 9 brake master cylinder 2
9. Remove:
2 9 dust boot 1
1 9 brake master cylinder kit 2
10.Remove:
9 brake master cylinder reservoir cap 1
9 brake master cylinder reservoir diaphragm
holder 2
diaphragm 3
9 plate 4
–57–
FRONT BRAKE CHAS
11. Remove:
9 brake hose holder 1
1 9 brake hose guide 2
9 brake hose 3
2
EAS00590
CHECKING THE FRONT BRAKE

MASTER CYLINDER
1. Check:
9 brake master cylinder 1
Damage/scratches/wear → Replace.
9 brake fluid delivery passages 2
(brake master cylinder body)
Obstruction → Blow out with compressed
air.
2. Check:
9 brake master cylinder kit
Damage/scratches/wear → Replace.
3. Check:
9 brake master cylinder reservoir 1
Cracks/damage → Replace.
9 brake master cylinder reservoir diaphragm 2
4. Check:
9 brake hose 1
Cracks/damage/wear → Replace.
–58–
FRONT BRAKE CHAS
EAS00598
ASSEMBLING AND INSTALLING THE

FRONT BRAKE MASTER CYLINDER
For assembly and installation, reverse the dis-
assembly and removal procedure.
WARNING
9 Before installation, all internal brake com-
ponents should be cleaned and lubricat-
ed with clean or new brake fluid.
components.

DOT 4
TIP
1. Install:
9 brake hose
9 brake hose holder
7 Nm (0.7 m·kg, 5.1 ft·lb)
9 brake hose guide
10 Nm (1.0 m·kg, 7.2 ft·lb)
2. Install:
9 plate 1
holder
9 brake master cylinder reservoir cap
1
TIP
Install the plate in the direction shown.
b
3. Install:
9 brake master cylinder 1
9 brake master cylinder bracket 2
2 9 brake master cylinder bracket upper bolt
a
11 Nm (1.1 m·kg, 8.0 ft·lb)
9 brake master cylinder bracket lower bolt
(temporarily)
TIP
9 Install the brake master cylinder bracket with
the “UP” mark a facing up.
9 Align the end of the brake master cylinder
holder with the punch mark b on the handle-
bar.
9 First, tighten the upper bolt, then the lower
bolt.
–59–
FRONT BRAKE CHAS
4. Install:
9 brake lever 1
9 copper washers 2
9 brake hose 3
9 union bolt 4 26 Nm (2.6 m·kg, 19 ft·lb)
WARNING
Proper brake hose routing is essential to
insure safe vehicle operation. Refer to
“ CABLE ROUTING”.
a TIP
9 Install the break hose to the master cylinder
within the 30-40 degree angle a as shown.
9 Turn the handlebar to the left and right to
make sure the brake hose does not touch
other par ts (e.g., wire harness, cables,
leads). Correct if necessary.
5. Fill:
(with the specified amount of the recom-
mended brake fluid)
DOT 4
WARNING
9 Use only the designated brake fluid.
9 Refill with the same type of brake fluid
performance.
9 When refilling, be careful that water does
not enter the brake master cylinder reser-
voir. Water will significantly lower the
boiling point of the brake fluid and could
cause vapor lock.
NOTICE
–60–
FRONT BRAKE CHAS
TIP
6. Bleed:
9 brake system
BRAKE SYSTEM”.
7. Check:
9 brake fluid level
the recommended brake fluid to the prop-
er level.
a Refer to “CHECKING THE BRAKE FLUID
LEVEL”.
8. Check:
system.
BRAKE SYSTEM”.
9. Install:
9 meter assembly 1
TIP
When installing the meter assembly make
sure that the gap between the brake master
cylinder bracket 2 and the meter assembly 1
is uniform. If the gap is not uniform, loosen
a the bolt in the hole a in the meter assembly
1 2 cover and adjust the position of the brake
master cylinder bracket.
–61–
FRONT BRAKE CHAS
4 4 10. Connect:
9 high beam indicator light connector
(yellow) 1
9 meter assembly couplers 2
2 Refer to "CABLE ROUTING".
3 11 .Install:
1
9 screws 4
9 rear view mirrors
12. Tighten:
9 rear view mirror nuts
1 13. Install:
9 headlight assembly 1
9 screws 2
2 2
–62–
YAMAHA MOTOR CO., LTD.
2500 SHINGAI IWATA SHIZUOKA JAPAN
T110C WIRING DIAGRAM
1 Main switch
2 Fuse
3 Battery
4 Starter relay
5 Starter motor
1 6 Right handlebar switch
OFF 7 Start switch
ON
8 Rectifier/regulator
Br B O
R W 9 A. C. magneto
0 C. D. I. unit
W W R R q Ignition coil
Br R
8 9 0 O O
q
R Y Y W W
w Spark plug
B
W
R
B
Y
W
Y
W
Y
e Rear brake light switch
R B B
Br B
w r Front brake light switch
B
W R R W B t Turn signal relay
R R/W Br Br y Horn
2 Br L/W L/W L/W
u Left handlebar switch
R Br Br i Horn switch
R R o Dimmer switch
4 p Turn signal switch
R R/W R/W
R/W
L/W
R/W
L/W
6 a Tail/brake light
L/W 7 s License plate light
R R
R
Br L/W
d Rear right turn signal light
3 OFF
ON L/W L/W f Rear left turn signal light
5 B B
g Front right turn signal light
B h Front left turn signal light
j Headlight
k Auxilialy light
Br Br
Br
l Neutral switch
; Fuel sender
y Br/W
B
r z Meter assembly
Br
t B Br e x Fuel gauge
Y
z Br L Ch Dg
B G/Y
c Meter light
Br B (BLACK) (BLACK)
P Br/W
v High beam indicator light
Y/W Sb Sb Y/W
u P L/B Br/W G/Y
b Turn signal indicator light
W
L/W P
W
P L/W c vb n m , . / G/Y
(BLACK) (BLACK)
i o p n Neutral indicator light
L
x PUSH
OFF HI
LO N
P Dg
B Br/W
Dg P
Br/W B
G/Y L L m 1st gear position indicator light
L Br Br L
R L/B Ch Ch L/B , 2nd gear position indicator light
Dg Ch
B G
Ch Dg
G B
(RED) (RED) Y a s . 3rd gear position indicator light
B
Y G
Ch Dg / 4th gear position indicator light
L L
G B Sb W P Y/W L/W G/Y
Y
B B
Sb W P Y/W L/W YY G
L/R Ch Dg Ch Dg B B
G
l k h g
L /R L /R
G G ; B/W B f d
B B j B
B B/L
P W W P Ch Ch
Y/W Sb Sb Y/W B Dg Dg
B B
L/W L/W
B/W B/L B B
B
COLOR CORD
B...................Black P...................Pink L/B................Blue/Black
Br .................Brown R...................Red L/R................Blue/Red
Ch ................Chocolate W .................White L/W ..............Blue/White
Dg ................Dark green Y...................Yellow R/W ..............Red/White
G ..................Green B/L................Black/Blue Y/R ...............Yellow/Red
L ...................Blue B/W ..............Black/White Y/W ..............Yellow/White
O ..................Orange Br/W.............Brown/White
Sb ................Sky blue G/Y...............Green/Yellow

Clubdediagramas - Serv T110 Crypton 2009 - 103948

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2009

T110LE SERVICE MANUAL: 3P9-F8197-E0

IMPORTANT MANUAL INFORMATION

A WARNING indicates a hazardous situation which, if not avoided,

A NOTICE indicates special precautions that must be taken to avoid

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

7 8 Symbols 9 to y indicate the following.

TRBL 9 Serviceable with engine mounted

Symbols g to h in the exploded diagrams

PERIODIC CHECKS AND ADJUSTMENTS

VEHICLE IDENTIFICATION NUMBER

ENGINE SERIAL NUMBER

Valve adjusting screw locknut (intake Nut M5 2 7 0.7 5.0

Timing chain tensioner cap bolt Bolt M6 1 8 0.8 5.8

Boss Bolt M6 2 10 1.0 7.2 LT

Pickup coil Bolt M6 2 10 1.0 7.2 LT

Stator coil Bolt M6 3 10 1.0 7.2 LT

Neutral switch Bolt M5 2 4 0.4 2.9 LT

Item Standard Limit

Item Standard Limit

Lower bracket pinch bolt M10 38 3.8 27

Upper ring nut M25 75 7.5 54 See TIP

Item Standard Limit

Lubrication point Lubricant

Lubrication point Lubricant

PERIODIC CHECKS AND ADJUSTMENTS

PERIODIC MAINTENANCE CHART

• Check fuel and vacuum hoses

GENERAL MAINTENANCE AND LUBRICATION CHART

5 * Wheels • Check runout and for damage. √ √ √ √

• Check operation and for

• Check chain slack, alignment

• Check bearing play and steer-

• Make sure that all nuts, bolts and

Brake pedal pivot • Lubricate with lithium- soap-

Moving parts and

CHECKING THE FRONT BRAKE PADS

BLEEDING THE HYDRAULIC BRAKE

h. Tighten the bleed screw and then release

ADJUSTING THE DRIVE CHAIN SLACK

1. Stand the vehicle on a level surface.

2. Remove the drive chain slack check hole

3. Spin the rear wheel several times and find

Drive chain slack

e. Tighten both locknuts to specification.

CHECKING THE BRAKE FLUID LEVEL

2 1. Open the seat.

Positive tester probe →

b. Check the charge of the battery, as shown

Time (minutes) NOTICE

Charging condition of the battery (%)

Adjust the charging voltage to

YES Monitor the amperage for 3 ~ 5

If the amperage does not

If the required charging time exceeds 5 hours, it is advisable to check the

Measure the open-circuit

Connect a charger and

Is the amperage higher

Leave the battery unused for more than 30 Ammeter

23 Nm (2.3 m•kg,17 ft•lb)

39 Nm (3.9 m•kg,28 ft•lb)

REMOVING THE FRONT WHEEl