Frame serial number (Except for Oceania)

INTRODUCTION

Congratulations on your purchase of the Yamaha DT200FUW). 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 motorcycle, please consult a Yamaha dealer.

U001

NOTE: ______________________________

Some data in this manual may become outdat­ed 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.

U-759

ATHINK OF YOUR SAFETY:

Both motorcycles and mopeds are fascinating vehicles which give a tremendous feeling of freedom to their riders.

They must be correctly maintained at all times in order to ensure optimum perfor­mance. However, as a rider you must also ensure that your physical condition is good, and that you are not tired, in order that you too can optimize your vehicle control. Medicines, drugs and alcohol should not be combined with riding, especially alcohol which increases the individual's likelihood of taking risks. Alcohol is dangerous, even in small quantities.

Correct protective riding gear is just as much a part of motorcycling safety as the safety belt is in the car; a good leather suit and gloves, sturdy boots and a good quality, proper­ly fitting crash helmet are ideal. But beware: good protective clothing can result in the individual being lulled into a false sense of security. When this happens more risks are taken and speeds increase... this particuiarily applies in wet weather. The good motorcyclist therefore rides defensively and protectively in order to minimize risks.

A-305

CONTENTS

DESCRIPTION.......................................... 1-1

MOTORCYCLE IDENTIFICATION..... 2-1

Vehicle identification number

(For Oceania)...................................... 2-1

Frame serial number

(Except for Oceania)........................... 2-1

Engine serial number.......................... 2-2

CONTROL FUNCTIONS........................ 3-1

Main switch.......................................... 3-1

Indicator lights.................................... 3-2

Oil warning light checking method...3-3 "Coolant temp"warning indicator light

checking method (For Oceania).......... 3-5

Speedometer....................................... 3-6

Tachometer (Except for Oceania)...... 3-6

Engine temperature gauge (Except for

Oceania)................................................ 3-7

Handlebar switches............................. 3-7

Clutch lever.......................................... 3-8

Change pedal....................................... 3-9

Front brake fever..:.............................. 3-9

Rear brake pedal................................. 3-9

Fuel tank cap....................................... 3-9

Fuel cock............................................ 3-10

Starter lever (CHOKE)...................... 3-11

Kick starter......................................... 3-12

Steering lock...................................... 3-12

Helmet holder..................................... 3-14

Side cover removal............................ 3-14

Front forks.......................................... 3-15

Rear shock absorber......................... 3-15

Rear carrier (Except for Oceania)....3-16 Note on handling of the Yamaha Energy Induction System (Y.E.I.S.)..3-16 Y.P.V.S, (Yamaha Power Valve

System)........................................... 3-17

Sidestand........................................... 3-18

Sidestand switch operation check...3-18

PRE-OPERATION CHECKS...................... 4-1

Brakes................................................... 4-3

Brake fluid leakage.............................. 4-3

Clutch................................................... 4-4

Throttle grip.......................................... 4-4

Engine oil.............................................. 4-4

Transmission oil.................................. 4-5

Coolant............................................ 4-5

Chain..................................................... 4-5

Tires..................................................... 4-5

Wheels........................................... 4-9

Fittings/Fasteners................................. 4-9

Lights and signals............................... 4-10

Switches.......................................... 4-10

Battery.............................................. 4-10

Fuel..................................................... 4-10

OPERATION AND IMPORTANT RIDING

POINTS................................................... 5-1

Starting a cold engine....................... 5-1

Engine warm-up................................... 5-3

Starting a warm engine..................... 5-3

Shifting................................................. 5-4

Engine break-in.................................. 5-4

Parking............................................ 5-5

PERIODIC MAINTENANCE AND MINOR

REPAIR................................................... 6-1

Tool kit.................................................. 6-1

Periodic maintenance/lubrication........ 6-3

Torque specifications........................... 6-6

Transmission oil level check................ 6-7

Transmission oil replacement.............. 6-8

Cooling system................................ 6-9

Air filter............................................... 6-14

Carburetor adjustment....................... 6-17

Idle speed adjustment........................ 6-17

Throttle cable adjustment............... 6-18

Spark plug inspection......................... 6-19

Front brake adjustment...................... 6-21

Rear brake adjustment...................... 6-22

Brake light switch adjustment............ 6-22

Checking the front and

rear brake pads................................ 6-23

Inspecting the brake fluid level.......... 6-24

Brake fluid replacement..................... 6-25

Clutch adjustment.............................. 6-26

Free play adjustment........................ 6-26

Drive chain slack check.................... 6-27

Drive chain slack adjustment............ 6-28

Drive chain lubrication....................... 6-29

Cable inspection and lubrication........ 6-30

Throttle cable and grip lubrication...6-30

Autolube pump adjustment................ 6-30

Brake and change pedals.................. 6-30

Brake and clutch tevers..................... 6-31

Sidestand............................................ 6-31

Rear suspension................................ 6-31

Front fork inspection.......................... 6-31

Front fork and rear shock absorber

adjustment.......................................... 6-32

Rear shock......................................... 6-34

Rear shock absorber adjustment....6-35 Recommended combinations of the front fork and the rear shock absorber

settings............................................... 6-37

Steering inspection............................. 6-38

Wheel bearings................................... 6-38

Battery................................................ 6-38

Replenishing the battery fluid............. 6-40

Fuse replacement............................. 6-41

Replacing the headlight bulb.............. 6-42

Headlight beam adjustment............... 6-44

Front wheel removal.......................... 6-44

Front wheel installation...................... 6-45

Rear wheel removal.......................... 6-47

Rear wheel installation....................... 6-48

Troubleshooting.................................. 6-48

Troubleshooting chart......................... 6-49

CLEANING AND STORAGE.................. 7-1

A. Cleaning............................................ 7-1

B. Storage.......................................... 7-2

SPECIFICATIONS.............................. 8-1

WIRING DIAGRAM

A-500

DESCRIPTION

1 Tail/Brake tight" 11

2 Rear flasher light 12

3 Side cover 13

4 Air scoop 14

5 Front flasher light 15

6 Radiator 16

7 Kick starter 17.

8 Brake pedal 18

9 Headlight 19
10 Fuel tank

U-002

NOTE: _________

The motorcycle you have purchased may differ slightly from those shown in the photographs.

i-i

A600

MOTORCYCLE IDENTIFICATION

A-602

Engine serial number

The engine serial number is stamped into the left side of the engine.

1 Engine serial number

U-003

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.

2-2

B-OOO

CONTROL FUNCTIONS

B-001

Main switch

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

Except for Oceania

PARKING

LOCK

B005

ON:

Electrical circuits are switched on. The engine can be started. The key cannot be removed in this position.

B-006

OFF:

Ail electrical circuits are switched off. The key can be removed in this position.

B-007

LOCK:

The steering is locked in this position, and all electrical circuits are switched off. The key can be removed in this position. Refer to "Steer­ing lock" (page 3-12) for proper operation.

B-012

PARKING {Except for Oceania):

The steering is locked in this position, and the

tailiight and auxiliary light come on but all other

circuits are off. The key can be removed in this

position.

U-007

NOTE: ______________________________

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

3-1

B-100

Indicator lights

1 "TURN" indicator light 2 "HIGH BEAM" indicator light 3 "NEUTRAL" indicator 4 "OIL" warning indicator light 5 "Coolant temp " warning indicator light

B-101

"TURN" indicator light (orange):

This indicator flashes when the turn switch is

"ON".

B-102

"NEUTRAL" indicator light (green):

This indicator comes on when the transmission

is in neutral.

B-103

"HIGH BEAM" indicator light (blue):

This indicator comes on when the headlight

high beam is used.

S-107

"OIL" warning indicator light (red): This indicator comes on when the oil level is low. This light circuit can be checked by the following procedure.

U-3O0

3-4

"Coolant temp." warning indicator light checking method (For Oceania)

Main switch "ON"

Warning indicator light does not come on.

Warning indicator I light comes on

Wait a few seconds.

Warning indicator light does not go off.

Warning indicator light goes off.

Ask a Yamaha dealer to inspect electrical circuit.

Electrical circuit is OK. Go ahead with riding.

3-5

NOTE: _____________________________

If the main switch is turned off after the warn­ing light goes out and then immediately again the main switch is turned on, the warning light may not come on. This is not because of failure.

B-400

Speedometer

The odometer and trip odometer are built into the speedometer. The trip odometer can be reset to "0" with the reset switch. 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.

B403

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.

3-8

B-aoo

Change pedal

The gear ratios of the constant-mesh 6-speed transmission are ideally spaced. The gears can be shifted by using the change pedal on the left side of the engine.

B-900

Front brake lever

The front brake lever is iocated on the right handlebar. Pull it toward the handlebar to ac­tivate the front brake.

B-901

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.

C-003

Fuel tank cap

1. To remove the tank cap, insert the key in the lock and turn the key 1 /4 turn coun­terclockwise. Rotate the cap 1/4 turn counterclockwise and remove it from the tank.

3-9

1 Fuel tank cap

U-013

NOTE:

2 Open

2. To reinstall the tank cap, set the cap in the filler neck and rotate the cap 1 /4 turn clockwise. Lock the cap by turning the key 1/4 turn clockwise, and remove the key.

U-611

.WARNING:

Fuel cock

The fuel cock supplies fuel from the tank to the

carburetor while filtering the fuel. The fuel cock

has three positions:

3-10

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

ON: With the lever in this position, fuel flows to the carburetor. Normal riding is done with the lever in this position.

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

3-11

C-205

Starter lever (CHOKE)

When cold, the engine requires a richer air-fuel mixture for starting. A separate starter circuit supplies this mixture. Pull the starter lever up to open the circuit for starting. When the en­gine has warmed up, push the lever down to close the circuit.

C602

Kick starter

Rotate the kick starter away from the engine. Push the starter down lightly with your foot un­til the gears engage, then kick smoothly and forcefully to start the engine. This model has a primary-coupled kick starter so the engine can be started in any gear if the clutch is disen­gaged. In normal practice, however, shift to neutral before starting.

C-301

Steering lock

1. Combined with main switch

The steering is locked when the main switch is turned to "LOCK." To lock the steering, turn the handlebars all the way to the left or right. With the key at "OFF," push it into the main switch, turn it coun­terclockwise to "LOCK," and remove it. To release the lock, turn the key clockwise.

3-12

1 Push

2 Release

3 Turn

2. Separate (Except for Oceania)

To lock the steering, turn the handlebars all the way to the right, and insert the key into the steering lock. Turn the key 1 /8 turn counterclockwise, push it in, then turn it 1 /8 turn clockwise. After check­ing to see that the lock is engaged, re­move the key from the lock. To release the lock, reverse the above procedure.

U-614

ZM/VA RIMING:

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

3-13

C-500

Helmet holder

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

U-615

^WARNING:

Side cover removal

Remove the screw. Then remove the side cover by pulling out the knob.

3-14

C-800

Front forks

The front forks of this model are pneu-momechanical; namely, there is a combination air and mechanical coil spring in the inner tubes. By adjusting the air pressure, you can alter the suspension to suit the motorcycle's load and the operating conditions. Refer to page 6-32 for proper adjustment procedures.

C-900

Rear shock absorber

The spring preload and the damping of the rear shock absorber can be adjusted to suit the motorcycle's load (ex: optional accessories etc.) and riding conditions. Refer to page 6-35 for proper adjustment procedures.

3-15

1 Spring preload adjuster 2 Damping adjuster

D550

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 5-2 for an explanation of this system.)

\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 malfunction, you must return the motor­cycle to a Yamaha dealer immediately for repair.

D-30S

PRE-OPERATION CHECK

Before using this motorcycle, check the following points:

4-1

NOTE; _____________________________________________________________________

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

^WARNING:

Brake fluid leakage

Apply each brake for a few minutes. Check to see if any brake fluid leaks out from the pipe joints or the master cylinder(s).

4-3

U-625

\W A RIM ING:

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

E-200

Engine oil

Make sure the engine oil is at the specified lev­el. Add oil as necessary.

4-4

Transmission oil {See page 6-7 for details)

Make sure the transmission oil is at the speci­fied level. Add oil as necessary.

E600

Coolant

Check the coolant level in the reservoir tank when the engine is cold. {The coolant level will vary with engine temperature.} The coolant lev­el is satisfactory if it is between the FULL and LOW marks on the tank. If the coolant level is at or below the LOW level, add tap water (soft water) to bring the level up to FULL. Change the coolant every two years. (See page 6-9 for details.)

4-5

U-626

AWARMIMG:

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

1 Reservoir tank 3. "LOW" level

U-309

Tires

To ensure maximum performance, long serv­ice, and safe operation, note the following: 1. Tire air pressure

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

U-675

AWARNING:

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

4-6

U-677

A WARN ING:

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

*Load is the total weight of cargo, rider, and accessories

2. Tire inspection

Always check the tires before operating the motorcycle. If center tread depth reaches the limit as shown, if the tire has a nail or glass fragments in it, or if the side wall is cracked, contact a Yamaha dealer immediately and have the tire replaced.

4-7

1 Tread depth

2. Side wall

FRONT:

REAR

Minimum tire tread depth (front and rear)

U-678

AWARNING:

After extensive tests, the tires mentioned below have been approved by Yamaha Motor Co., Ltd. for this model. No guaran­tee for handling characteristics can be given if tire combinations other than what is approved are used on this motorcycle. The front and rear tires should be of the same manufacture and design.

EUU12600

MOTE: _____________________________

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.

4-8

U-700

AWARNING:

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 Yama­
ha Service Technician.

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

E-934

Wheels

To ensure maximum performance, long serv­ice, and safe operation, note the following: 1. Always inspect the wheels before a ride. Check for cracks, bends, or warpage of

the wheel; be sure the spokes are tight and undamaged. If any abnormal condi­tion exists in a wheel, consult a Yamaha dealer. Do not attempt even small repairs to the wheel. If a wheel is deformed or cracked, it must be replaced.

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

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

E8S0

Fittings/Fasteners

Always check the tightness of chassis fittings and fasteners before a ride. Use the chart on page 6-6 to find the correct torque.

4-9

E-700

Lights and signals

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

E-704

Switches

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

E-705

Fuel

Make sure there is sufficient fuel in the tank.

U-610

.WARNING:

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

4-10

E809

Recommended fuel: Regular gasoline

For Australia: Unleded fuel only Fuel tank capacity: Total:

10 L (2.2 Imp gal, 2.6 US gal) Reserve:

1.8 L (0.4 Imp gal, 0.5 US gal)

4-11

F-000

5-1

U-709

AWARNING:

Before going through the following steps, check the function of the sidestand switch. (Refer to page 3-19.)

TURN MAIN SWITCH TO "ON" AND ENGINE STOP SWITCH TO "RUN"

_L

IF TRANSMISSION IS IN NEUTRAL AND SIDESTAND IS DOWN

IF TRANSMISSION IS IN GEAR AND SIDESTAND IS UP

KICK THE KICK STARTER, ENGINE WILL START

T

RETRACT SIDESTAND AND PUT TRANSMISSION IN GEAR

±

Engine warm-up

To ensure maximum engine life, always warm up the engine before riding your motorcycle. Never accelerate hard with a cold engine. An engine is warm if it responds normally to the throttle when the starter (CHOKE) is turned off.

F-108

Starting a warm engine

The starter (CHOKE) is not required when the engine is warm.

4. Operate the starter (CHOKE) and com­
pletely close the throttle grip.

5. Kick the kick starter to start the engine.

6. After the engine starts, warm it up for one
or two minutes. Make sure the starter is
returned to its original position before
riding.

U-314

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

5-3

F-200

Shifting

The transmission lets you control the amount of power you have available at a given speed for starting, accelerating, climbing hills, etc. The use of the change pedal is shown in the illustration. (Page 3-9}

To shift into NEUTRAL, depress the change 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.

U-315

1.

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

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

F300

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 materi­al. 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 correct oper­ating clearances. During this period, prolonged full throttle operation, or any condition which might result in excessive heating of the engine, must be avoided.

5-4

F-309 1.

2.

U354

0-500 km (0-300 mi): Avoid operation above 6.000 r/min. Stop the engine and let it cool for 5 to 10 minutes after every hour of operation. Vary the speed of the motorcycle from time to time. Do not operate it at one set throttle position.

500-1,000 km (300-600 mi): Avoid prolonged operation above 7.000 r/min. Rev the motorcycle freely through the gears, but do not use full throttle at any time.

1,000 km (600 mi) and beyond: Full throttle can be used.

U387

Parking

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

5-5

U-630

WARNING:

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

5-6

PERIODIC

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.

6-1

U-671

^WARNING:

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

1 Tool kit

u 060

NOTE: _____________________________

If you do not have a torque wrench available during a service operation requiring one, take your motorcycle to a Yamaha dealer to check the torque settings and adjust them as necessary.

6-2

6-3

Unit km (miles}

It is recommended that these items be serviced by a Yamaha dealer Medium weight wheel bearing grease Lithium soap base grease

6-4

NOTE: _____________________________________________________________________

Brake fluid replacement:

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

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

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

6-5

H 301

Torque specifications

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

6-6

EAH44S00

6-8

5. Add oil through the oil filter hole.

1 Oil filler cap

Periodic oil change: 0.75 L (0.66 Imp qt, 0.79 US qt)

EAHS1300

Cooling system

The coolant is circulated by an impeller type pump mounted on the right-hand crankcase and driven by a gear. The coolant is drawn by the pump from the bottom tank of the radia­tor, through the piped), and discharged into the cylinder and cylinder-head. The coolant passes from the cylinder to the cylinder-head through coolantpassages. After circulating around the combustion chamber jacket, it enters the radiator upper tank via the pipe(2). The heated coolant from the engine then pass­es down through the finned tubes to the bot­tom tank of the radiator. These finned tubes present a large surface area to the air and dis­sipate the heat.

6. After replacement of transmission oil, be sure to check for oil leaks.

6-9

1. If your motorcycle overheats

EUU70500

WVARNING:

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

If overheating is detected, perform the follow­ing checks.

6-10

I Engine overheating

Check the cooling system for leakage.

Wait until the temp gauge indicates lower than 50°C (122°F) line (see page 3-7)

No leakage

OK

Restart the engine If the engine overheats again, ask a Yamaha dealer to inspect and repair it,

EUU04300

NOTE:

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

2. Changing the coolant a. Remove the air scoop and side cover.

6-11

b. Remove the stopper bolt and then remove the radiator cap.

1 Stopper bolt

c. Place a container under the engine.

d. Remove the drain bolt.

1 Dram bolt

e. Disconnect the reservoir tank hose on the reservoir tank side, and drain the reser­voir tank of its coolant.

6-12

1 Reservoir tank hose 2. "FULL" level 3. "LOW" level

f. Drain the coolant completely and
thoroughly flush the cooling system with
clean tap water.

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

Drain bolt torque:

10 Nm {1.0 nrkg, 7.2 ft-lb)

h. Reinstall the reservoir tank hose, i. Pour the recommended coolant into the radiator until the radiator is full.

Recommended coolant:

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

Coolant and water mixed ratio: 50%/50%

Total amount:

1.200 cm³ (1.06 Imp qt, 1.27 US qt)

Reservoir tank capacity: 300 cm³ (0.26 Imp qt, 0.32 US qt)

From LOW to FULL level:

240 cm³ (0.21 Imp qt, 0.25 US qt)

6-13

Air filter

1. Remove the side cover.

6-14

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

3. Side out the guide together with the element.

4. Remove the element from its guide, and clean it with solvent. After cleaning, re­move the remaining solvent by squeezing

the element.

6-15

6.

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 motorcycle is operated in dusty or wet areas.

1 Guide 2 Element

5. Apply recommended oil to the entire sur­face of the filter and squeeze out the ex­cess oil. The element should be wet but not dripping.

U326

Carburetor adjustment

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

U-330

H-901

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.

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

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

6-17

1 Throttle stop screw

Standard idle speed: 1,300-1,400 r/min

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