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PERIODIC CHECKS AND MAINTENANCE

D-2

CHK ADJ

CABLE ROUTING SPEC CABLE ROUTING SPEC

C-12

Ø Right handlebar switch Ø Left handlebar switch Ø Front brake switch

Rear brake switch

Ø Throttle cable

Rear brake hose

Ø Front brake hose

     
CHK ADJ

PERIODIC CHECKS AND MAINTENANCE

    No.     ITEM     CHECK OR MAINTENANCE JOB     ODEMETER READING ( x 1.000 km)   ANNUAL CHECK
* Sidestand switch • Check operation. Ö Ö Ö Ö Ö Ö
* Front fork • Check operation and for oil leakage.   Ö Ö Ö Ö  
    * Rear shock absorber assemblies • Check operation and shock absorbers for oil leakage.     Ö   Ö   Ö   Ö  
    *   Carburetor • Check starter (choke) operation. • Adjust engine idling speed.   Ö   Ö   Ö   Ö   Ö   Ö
  Engine oil • Change. Ö When the oil change indicator light comes on (every 3,000 km)
* Engine oil strainer • Clean. Ö   Ö   Ö  
        *     Cooling system • Check coolant level and vehicle for coolant leakage.     Ö   Ö   Ö   Ö   Ö
• Change.   Every 3 years
  Final gear oil • Check oil level and vehicle for oil leakage. Ö Ö   Ö    
• Change. Ö   Ö   Ö  
* V-belt • Change.     Ö   Ö  
* Front and rear brake switches   • Check operation.   Ö   Ö   Ö   Ö   Ö   Ö
  Moving parts and cables   • Lubricate.     Ö   Ö   Ö   Ö   Ö
* Muffler and exhaust pipe • Check the screw clamp for looseness.     Ö   Ö   Ö   Ö  
* Lights, signals and switches • Check operation. • Adjust headlight beam.   Ö   Ö   Ö   Ö   Ö   Ö
PERIODIC CHEKS AND MAINTENACE

INTRODUCTION

This chapter includes all information necessary to carry out inspections and adjustments recommen- ded. These preventive maintenance procedures, if they are correctly followed, will ensure the most reliable operation of the vehicle and a longer useful life. The need for overhauls and costly repairs will be greatly reduced. This applies both to vehicles which are already in service and to new vehicles which are ready for sale. All service technicians should familiarise themselves with the entire chapter.

PERIODIC MAINTENANCE/LUBRICATION INTERVALS

  No.   ITEM   CHECK OR MAINTENANCE JOB   ODEMETER READING ( x 1.000 km)   ANNUAL CHECK
    *   Fuel line • Check fuel hoses and vacuum hose for cracks or damage.     Ö   Ö   Ö   Ö   Ö
* Fuel filter • Check condition.     Ö   Ö  
      Spark plug • Check condition. • Clean and regap.     Ö     Ö    
• Replace.     Ö   Ö  
    *   Valves • Check valve clearance. • Adjust.       Ö     Ö  
      Air filter element • Clean.   Ö   Ö    
• Replace.     Ö   Ö  
  V-belt case air filter element   • Clean.       Ö   Ö   Ö   Ö
        *     Battery • Check electrolyte level and specific gravity. • Make sure that the breather hose is properly routed.       Ö     Ö     Ö     Ö     Ö
    *   Front brake • Check operation, fluid level and vehicle for fluid leakage. (See NOTE)   Ö   Ö   Ö   Ö   Ö   Ö
• Replace brake pads. Whenever worn to the limit
    *   Rear brake • Check operation, fluid level and vehicle for fluid leakage. (See NOTE).   Ö   Ö   Ö   Ö   Ö   Ö
• Replace brake pads. Whenever worn to the limit
    *   Brake hoses • Check for cracks or damage.   Ö Ö Ö Ö Ö
• Replace. (See NOTE). Every 4 years
* Wheels • Check runout and for damage.   Ö Ö Ö Ö  
    *   Tires • Check tread depth and for damage. • Replace if necessary. • Check air pressure. • Correct if necessary.     Ö   Ö   Ö   Ö  
* Wheel bearings • Check bearing for looseness or damage.   Ö Ö Ö Ö  
* Steering bearings • Check bearing play and steering for roughness Ö Ö Ö Ö Ö  
• Lubricate with lithium-soap-based grease Every 24,000 km
* Chassis fasteners • Make sure that all nuts, bolts and screws are properly tightened.     Ö   Ö   Ö   Ö   Ö
  Sidestand/ centerstand • Check operation. • Lubricate.     Ö   Ö   Ö   Ö   Ö
NOTE:

• The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.

• From 30,000 km, repeat the maintenance intervals starting from 6,000 km.

• Items marked with an asterisk should be performed by a Yamaha/MBK dealer as they require spe- cial tools, data and technical skills.

NOTE:

• The air filter needs more frequent service if you are riding in unusually wet or dusty areas.

• Hydraulic brake service

•• Regularly check and, if necessary, correct the brake fluid level.

•• Every two years replace the 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.


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