OWNER’S MANUAL YAMAHA MOTOR CO., LTD.
Engine start procedure Before pushing start button, make sure to apply the Front or Rear Brake and that the Sidestand is retracted. Engine oil replacement Engine oil replacement : Every 2000 km. Recommended oil : SAE20W - 50 type SF Class Motor Oil V-belt inspection Periodic maintenance must be performed by any authorized Yamaha Dealer (Refer to the Owner's Manual for details.
U5MXE0.book Page 1 Thursday, December 20, 2001 2:08 PM INTRODUCTION EAU00000 Congratulations on your purchase of the Yamaha AT115. 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.
U5MXE0.book Page 1 Thursday, December 20, 2001 2:08 PM IMPORTANT MANUAL INFORMATION EAU00005 Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator, a bystander, or a person inspecting or repairing the motorcycle.
U5MXE0.book Page 1 Thursday, December 20, 2001 2:08 PM TABLE OF CONTENTS EAU00009 1 GIVE SAFETY THE RIGHT OF WAY .................1-1 2 DESCRIPTION ...................................................2-1 Left view .............................................................2-1 Right view...........................................................2-2 Controls and instruments ...................................2-3 3 INSTRUMENT AND CONTROL FUNCTIONS ....3-1 Main switch/steering lock ....................
U5MXE0.book Page 2 Thursday, December 20, 2001 2:08 PM TABLE OF CONTENTS Tires ................................................................ 6-19 Spoke wheels .................................................. 6-21 Checking the front brake lever free play .......... 6-21 Adjusting the rear brake lever free play .......... 6-22 Checking the front brake pads and rear brake shoes ................................................. 6-23 Checking the brake fluid level .........................
U5MXE0.book Page 1 Thursday, December 20, 2001 2:08 PM EAU00021 1- GIVE SAFETY THE RIGHT OF WAY Motorcycles are fascinating vehicles, which can give you an unsurpassed feeling of power and freedom. However, they also impose certain limits, which you must accept; even the best motorcycle does not ignore the laws of physics. 1 Regular care and maintenance are essential for preserving value and operating condition of your motorcycle.
U5MXE0.book Page 1 Thursday, December 20, 2001 2:08 PM DESCRIPTION EAU00026 2- Left view 2 1. Convenience hook 2. Throttle stop screw 3. Helmet box, Owner’s tool kit (page 3-8) (page 6-17) (page 3-7, page 6-1) 4. Kickstarter 5. Engine oil drain bolt B 6.
U5MXE0.book Page 2 Thursday, December 20, 2001 2:08 PM DESCRIPTION Right view 2 7. Engine oil filler cap 8. Air filter element 9. Battery 10.
U5MXE0.book Page 3 Thursday, December 20, 2001 2:08 PM DESCRIPTION Controls and instruments 2 1. Rear brake lever 2. Starter choke lever 3. Left handlebar switches 4. Speedometer unit (page 3-4) (page 3-6) (page 3-3) (page 3-2) 5. Fuel gauge 6. Start switch 7. Throttle grip 8.
U5MXE0.book Page 1 Thursday, December 20, 2001 2:08 PM INSTRUMENT AND CONTROL FUNCTIONS EAU00027 3- 3 EAU00029 Main switch/steering lock The main switch/steering lock controls the ignition and lighting systems, and is used to lock the steering. The various positions are described below. EAU00030* ON All electrical systems are supplied with power, and the meter lighting comes on, and the engine can be started. The key cannot be removed.
U5MXE0.book Page 2 Thursday, December 20, 2001 2:08 PM INSTRUMENT AND CONTROL FUNCTIONS 3 1. Left turn signal indicator light “ 2. Right turn signal indicator light “ 3. High beam indicator light “ ” ” 1. Speedometer 2. Odometer ” 1. Fuel gauge EAU02950* EAU00098 EAU00056 Indicator lights EAU04121 Turn signal indicator lights “ ” and “ ” The corresponding indicator light flashes when the turn signal switch is pushed to the left or right.
U5MXE0.book Page 3 Thursday, December 20, 2001 2:08 PM INSTRUMENT AND CONTROL FUNCTIONS EAU03888 Dimmer switch “ / ” Set this switch to “ ” for the high beam and to “ ” for the low beam. EAU03889 1. 2. 3. 4. Light switch “ / ” Dimmer switch “ / Turn signal switch “ Horn switch “HORN” ” / ” EAU00118 Turn signal switch “ / ” To signal a right-hand turn, push this switch to “ ”. To signal a left-hand turn, push this switch to “ ”. When released, the switch returns to the center position.
U5MXE0.book Page 4 Thursday, December 20, 2001 2:08 PM INSTRUMENT AND CONTROL FUNCTIONS 3 1. Front brake lever 1. Rear brake lever EAU03882 EAU00163 Front brake lever Rear brake lever The front brake lever is located on the right handlebar grip. To apply the front brake, pull this lever toward the handlebar grip. The rear brake lever is located on the left handlebar grip. To apply the rear brake, pull this lever toward the handlebar grip. 3-4 1. Fuel tank cap a. Open. b. Close.
U5MXE0.book Page 5 Thursday, December 20, 2001 2:08 PM INSTRUMENT AND CONTROL FUNCTIONS EAU00185 CAUTION: Immediately wipe off spilled fuel with a clean, dry, soft cloth, since fuel may deteriorate painted surfaces or plastic parts. _ _ EAU00187* 3 To install the fuel tank cap 1. Insert the fuel tank cap into the tank opening and turn it clockwise until the alignment marks on the cap and tank are aligned. 2. Close the seat. 1. Fuel tank filler tube 2.
U5MXE0.book Page 6 Thursday, December 20, 2001 2:08 PM INSTRUMENT AND CONTROL FUNCTIONS 3 1. Starter (choke) lever “ ” 1. Kickstarter 1. Open. EAU03839 Starter (choke) lever “ ” Starting a cold engine requires a richer air-fuel mixture, which is supplied by the starter (choke). Move the lever in direction a to turn on the starter (choke). Move the lever in direction b to turn off the starter (choke).
U5MXE0.book Page 7 Thursday, December 20, 2001 2:08 PM INSTRUMENT AND CONTROL FUNCTIONS To close the seat 1. Fold the seat down, and then push it down to lock it in place. 2. Remove the key from the main switch if the motorcycle will be left unattended. NOTE: Make sure that the seat is properly secured before riding. EC000010* CAUTION: Keep the following points in mind when using the helmet box.
U5MXE0.book Page 8 Thursday, December 20, 2001 2:08 PM INSTRUMENT AND CONTROL FUNCTIONS To store a helmet in the helmet box, place the helmet upside-down with the front facing forward. NOTE: ● Some helmets cannot be stored in the helmet box because of their size or shape. ● Do not leave your motorcycle unattended with the seat open. _ 3 1. Convenience hook _ EAUT0020* Convenience hook EWT00002* _ WARNING Do not exceed the load limit of 1 kg for the convenience hook.
U5MXE0.book Page 1 Thursday, December 20, 2001 2:08 PM PRE-OPERATION CHECKS EAU01114 4- The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly, even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss of tire air pressure could have serious consequences.
U5MXE0.book Page 2 Thursday, December 20, 2001 2:08 PM PRE-OPERATION CHECKS ITEM Brake levers Centerstand, sidestand Chassis fasteners Instruments, lights, signals and switches Battery 4 • • • • • • • • • • CHECKS Make sure that operation is smooth. Lubricate lever pivoting points if necessary. Make sure that operation is smooth. Lubricate pivots if necessary. Make sure that all nuts, bolts and screws are properly tightened. Tighten if necessary. Check operation. Correct if necessary. Check fluid level.
U5MXE0.book Page 1 Thursday, December 20, 2001 2:08 PM OPERATION AND IMPORTANT RIDING POINTS EAU00372 5- EAU00373* _ ● ● ● ● _ WARNING Become thoroughly familiar with all operating controls and their functions before riding. Consult a Yamaha dealer regarding any control or function that you do not thoroughly understand. Never start the engine or operate it in a closed area for any length of time.
U5MXE0.book Page 2 Thursday, December 20, 2001 2:08 PM OPERATION AND IMPORTANT RIDING POINTS 4. After starting the engine, move the starter (choke) back about halfway. ECA00055 CAUTION: For maximum engine life, always warm the engine up before starting off. Never accelerate hard when the engine is cold! _ EAU01258 Starting a warm engine Follow the same procedure as for starting a cold engine with the exception that the starter (choke) is not required when the engine is warm. _ 5.
U5MXE0.book Page 3 Thursday, December 20, 2001 2:08 PM OPERATION AND IMPORTANT RIDING POINTS Front Rear EAU00434 Acceleration and deceleration ● Railroad crossings, streetcar rails, iron plates on road construction sites, and manhole covers become extremely slippery when wet. Therefore, slow down when approaching such areas and cross them with caution. ● Keep in mind that braking on a wet road is much more difficult. ● Ride slowly down a hill, as braking downhill can be very difficult.
U5MXE0.book Page 4 Thursday, December 20, 2001 2:08 PM OPERATION AND IMPORTANT RIDING POINTS EAU00436 Engine break-in 5 There is never a more important period in the life of your engine than the period between 0 and 1,000 km. For this reason, you should read the following material carefully. Since the engine is brand new, do not put an excessive load on it for the first 1,000 km. The various parts in the engine wear and polish themselves to the correct operating clearances.
U5MXE0.book Page 5 Thursday, December 20, 2001 2:08 PM OPERATION AND IMPORTANT RIDING POINTS EAU00460 Parking When parking, stop the engine, and then remove the key from the main switch. EW000058 _ WARNING ● Since the engine and exhaust system can become very hot, park in a place where pedestrians or children are not likely to touch them. ● Do not park on a slope or on soft ground, otherwise the motorcycle may overturn.
U5MXE0.book Page 6 Thursday, December 20, 2001 2:08 PM OPERATION AND IMPORTANT RIDING POINTS General note Much can be gained from the correct use and maintenance of a motorcycle. 2. A MOTORCYCLE CAN KEEP ITS PERFORMANCE CAPABILITY FOR A LONGER TIME 1.
U5MXE0.book Page 7 Thursday, December 20, 2001 2:08 PM OPERATION AND IMPORTANT RIDING POINTS 3. FUEL COST AND REPAIR EXPENSES CAN BE KEPT TO A MINIMUM 4.
U5MXE0.book Page 1 Thursday, December 20, 2001 2:08 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU00462 6- EAU00464 6 Safety is an obligation of the owner. Periodic inspection, adjustment and lubrication will keep your vehicle in the safest and most efficient condition possible. The most important points of inspection, adjustment, and lubrication are explained on the following pages.
U5MXE0.book Page 2 Thursday, December 20, 2001 2:08 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU00473 Periodic maintenance and lubrication chart CP-03E NO. 1 ITEM * Fuel line CHECK OR MAINTENANCE JOB ODOMETER READING (× 1,000 km) 0.5 2 4 8 12 √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ • Check fuel hoses and vacuum hose for cracks or damage. 2 Spark plug • Check condition. • Clean and regap. • Replace if necessary. 3 Valves • Check valve clearance. • Adjust.
U5MXE0.book Page 3 Thursday, December 20, 2001 2:08 PM PERIODIC MAINTENANCE AND MINOR REPAIR NO. Shock absorber CHECK OR MAINTENANCE JOB 16 * assemblies • Check operation and shock absorbers for oil leakage. 17 * Carburetor • Check starter (choke) operation. • Adjust engine idling speed. • Change. • Check oil level and vehicle for oil leakage.
U5MXE0.book Page 4 Thursday, December 20, 2001 2:08 PM PERIODIC MAINTENANCE AND MINOR REPAIR 1. 2. 3. 4. Panel A Panel B Cowling B Cowling A 1. Panel A 2. Screw (× 2) EAU01074* EAU03516 Removing and installing the cowling and panels Panel A To remove the panel Remove the screws, and then pull the panel off as shown. The cowling and panels shown above need to be removed to perform some of the maintenance jobs described in this chapter.
U5MXE0.book Page 5 Thursday, December 20, 2001 2:08 PM PERIODIC MAINTENANCE AND MINOR REPAIR 1. Screw (× 2) 2. Panel B EAU03971 6 Panel B To remove the panel 1. Open the seat. (See page 3-6 for seat opening and closing procedures.) 2. Remove the screws, and then pull the panel off as shown. 1. Screw (× 2) 2. Cowling A 3. License plate bracket 1. Screw (× 2) 2. Cowling A 2. Remove the screws on cowling A. EAU03886* Cowling A To remove the cowling 1.
U5MXE0.book Page 6 Thursday, December 20, 2001 2:08 PM PERIODIC MAINTENANCE AND MINOR REPAIR 1. Screw (× 6) 2. Cowling B 4. Pull cowling A off as shown. 3. Remove the screws on cowling B. NOTE: When removing cowling A, pull out on the areas shown from bottom to top. _ _ To install the cowling 1. Align the tabs in cowling A with the slots of cowling B, and then push cowling A into the original position. 6 NOTE: When installing cowling A, push in on the areas shown from top to bottom. _ _ 2.
U5MXE0.book Page 7 Thursday, December 20, 2001 2:08 PM PERIODIC MAINTENANCE AND MINOR REPAIR To check the spark plug 1. Check that the porcelain insulator around the center electrode of the spark plug is a medium-to-light tan (the ideal color when the motorcycle is ridden normally). NOTE: If the spark plug shows a distinctly different color, the engine could be defective. Do not attempt to diagnose such problems yourself. Instead, have a Yamaha dealer check the motorcycle. _ 1. Spark plug cap 1.
U5MXE0.book Page 8 Thursday, December 20, 2001 2:08 PM PERIODIC MAINTENANCE AND MINOR REPAIR Tightening torque: Spark plug: 12.5 Nm (1.25 m·kgf) NOTE: If a torque wrench is not available when installing a spark plug, a good estimate of the correct torque is 1/4–1/2 turn past finger tight. However, the spark plug should be tightened to the specified torque as soon as possible. _ a. Spark plug gap To install the spark plug 1.
U5MXE0.book Page 9 Thursday, December 20, 2001 2:08 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAUT0016* Engine oil and oil strainer The engine oil level should be checked before each ride. In addition, the oil must be changed and the oil strainer cleaned at the intervals specified in the periodic maintenance and lubrication chart. To check the engine oil level 1. Place the motorcycle on the centerstand. NOTE: Make sure that the motorcycle is positioned straight up when checking the oil level.
U5MXE0.book Page 10 Thursday, December 20, 2001 2:08 PM PERIODIC MAINTENANCE AND MINOR REPAIR To change the engine oil and clean the oil strainer 1. Start the engine, warm it up for several minutes, and then turn it off. 2. Place an oil pan under the engine to collect the used oil. 1. Engine oil drain bolt A 2. Engine oil drain bolt B 3. Remove the engine oil filler cap and drain bolts to drain the oil from the crankcase. NOTE: When only changing the engine oil, remove engine oil drain bolt A only. _ 1.
U5MXE0.book Page 11 Thursday, December 20, 2001 2:08 PM PERIODIC MAINTENANCE AND MINOR REPAIR ECA00105 Tightening torques: Engine oil drain bolt A: 20 Nm (2.0 m·kgf) Engine oil drain bolt B: 20 Nm (2.0 m·kgf) _ NOTE: Make sure that the O-ring is properly seated. _ _ 7. Add the specified amount of the recommended engine oil, and then install and tighten the engine oil filler cap. 6 Recommended engine oil: See page 8-1. Oil quantity: Periodic oil change: 0.8 L Total amount (dry engine): 0.
U5MXE0.book Page 12 Thursday, December 20, 2001 2:08 PM PERIODIC MAINTENANCE AND MINOR REPAIR Recommended final transmission oil: See page 8-1. Oil quantity: 0.1 L EWA00062 _ 1. Final transmission oil drain bolt 4. Remove the oil filler cap and drain bolt to drain the oil from the final transmission case. 5. Install the final transmission oil drain bolt, and then tighten it to the specified torque. WARNING Make sure that no foreign material enters the final transmission case.
U5MXE0.book Page 13 Thursday, December 20, 2001 2:08 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAUM0058* Cleaning the air filter element, V-belt case air filter elements, and check hoses The air filter and the V-belt case air filter elements should be cleaned at the intervals specified in the periodic maintenance and lubrication chart. Clean both filter elements more frequently if you are riding in unusually wet or dusty areas.
U5MXE0.book Page 14 Thursday, December 20, 2001 2:08 PM PERIODIC MAINTENANCE AND MINOR REPAIR 5. Lightly tap the air filter element to remove most of the dust and dirt, and then blow the remaining dirt out with compressed air. 6. Check the air filter element for damage and replace it if necessary. 7. Insert the air filter element into the air filter case. 8. Install the air filter case cover by installing the screws. 9. Install the panel. 1. V-belt case air filter cover A 2.
U5MXE0.book Page 15 Thursday, December 20, 2001 2:08 PM PERIODIC MAINTENANCE AND MINOR REPAIR 1. Air filter element (× 2) 3. Remove the air filter elements, and then blow out the dirt with compressed air as shown. 6 4. Check each air filter element for damage and replace them if necessary. 5. Install the air filter elements. 6. Install V-belt case air filter cover B by installing the bolts. 7. Install V-belt case air filter cover A by installing the bolts.
U5MXE0.book Page 16 Thursday, December 20, 2001 2:08 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU00629 Adjusting the carburetor 1. Check hose (× 2) To clean the air filter check hoses 1. Check each hose at the bottom of the air filter case and the V-belt case for accumulated dirt or water. 1. Check hose 2. If dirt or water is visible, remove the hose, clean it, and then install it. The carburetor is an important part of the engine and requires very sophisticated adjustment.
U5MXE0.book Page 17 Thursday, December 20, 2001 2:08 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU01168 EAU00634* Adjusting the engine idling speed Adjusting the throttle cable free play The engine idling speed must be checked and, if necessary, adjusted as follows at the intervals specified in the periodic maintenance and lubrication chart. The throttle cable free play should measure 3–7 mm at the throttle grip. Periodically check the throttle cable free play and, if necessary, adjust it as follows.
U5MXE0.book Page 18 Thursday, December 20, 2001 2:08 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU00637 Adjusting the valve clearance The valve clearance changes with use, resulting in improper air-fuel mixture and/or engine noise. To prevent this from occurring, the valve clearance must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart. 1. 2. 3. c. Throttle cable free play adjusting nut Locknut Cable cover Throttle cable free play 1.
U5MXE0.book Page 19 Thursday, December 20, 2001 2:08 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU03790* CE-24E Tires To maximize the performance, durability, and safe operation of your motorcycle, note the following points regarding the specified tires. Tire air pressure The tire air pressure should be checked and, if necessary, adjusted before each ride. Tire air pressure (measured on cold tires) _ Front Rear 200 kPa (2.00 kgf/cm2) 225 kPa (2.
U5MXE0.book Page 20 Thursday, December 20, 2001 2:08 PM PERIODIC MAINTENANCE AND MINOR REPAIR EW000079 _ 1. Sidewall 2. Tire wear indicator a. Tire tread depth Tire inspection The tires must be checked before each ride. If the tire shows crosswise lines (minimum tread depth), if the tire has a nail or glass fragments in it, or if the sidewall is cracked, have a Yamaha dealer replace the tire immediately. WARNING ● Have a Yamaha dealer replace excessively worn tires.
U5MXE0.book Page 21 Thursday, December 20, 2001 2:08 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU00680 _ 6 _ WARNING ● It is dangerous to ride with a worn-out tire. When a tire tread begins to show crosswise lines, have a Yamaha dealer replace the tire immediately. ● The replacement of all wheeland brake-related parts, including the tires, should be left to a Yamaha dealer, who has the necessary professional knowledge and experience. ● It is not recommended to patch a punctured tube.
U5MXE0.book Page 22 Thursday, December 20, 2001 2:08 PM PERIODIC MAINTENANCE AND MINOR REPAIR EW000099* WARNING A soft or spongy feeling in the brake lever can indicate the presence of air in the hydraulic system. If there is air in the hydraulic system, have a Yamaha dealer bleed the system before operating the motorcycle. Air in the hydraulic system will diminish the braking performance, which may result in loss of control and an accident. _ _ a. Rear brake lever free play 1.
U5MXE0.book Page 23 Thursday, December 20, 2001 2:08 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU00720 Checking the front brake pads and rear brake shoes Front Rear The front brake pads and the rear brake shoes must be checked for wear at the intervals specified in the periodic maintenance and lubrication chart. 1.
U5MXE0.book Page 24 Thursday, December 20, 2001 2:08 PM PERIODIC MAINTENANCE AND MINOR REPAIR Observe these precautions: ● When checking the fluid level, make sure that the top of the master cylinder is level by turning the handlebars. ● Use only the recommended quality brake fluid, otherwise the rubber seals may deteriorate, causing leakage and poor braking performance. 1. Minimum level mark ● Brake fluid may deteriorate painted surfaces or plastic parts. Always clean up spilled fluid immediately.
U5MXE0.book Page 25 Thursday, December 20, 2001 2:08 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU03985 6 EAU00770* Changing the brake fluid Checking the V-belt Have a Yamaha dealer change the brake fluid at the intervals specified in the NOTE after the periodic maintenance and lubrication chart. In addition, have the oil seals of the brake master cylinder and caliper as well as the brake hose replaced at the intervals listed below or whenever they are damaged or leaking.
U5MXE0.book Page 26 Thursday, December 20, 2001 2:08 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU04034 Checking and lubricating the throttle grip and cable The operation of the throttle grip should be checked before each ride. In addition, the cable should be lubricated or replaced at the intervals specified in the periodic maintenance chart.
U5MXE0.book Page 27 Thursday, December 20, 2001 2:08 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU02939 Recommended lubricant: Lithium-soap-based grease (all-purpose grease) Checking the front fork The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart. To check the condition EW000115 WARNING Securely support the motorcycle so that there is no danger of it falling over.
U5MXE0.book Page 28 Thursday, December 20, 2001 2:08 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU00794 Checking the steering To check the operation 1. Place the motorcycle on a level surface and hold it in an upright position. 2. While applying the front brake, push down hard on the handlebars several times to check if the front fork compresses and rebounds smoothly. Worn or loose steering bearings may cause danger.
U5MXE0.book Page 29 Thursday, December 20, 2001 2:08 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU01144 EAU03806* Checking the wheel bearings Battery The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart. If there is play in the wheel hub or if the wheel does not turn smoothly, have a Yamaha dealer check the wheel bearings. A poorly maintained battery will corrode and discharge quickly.
U5MXE0.book Page 30 Thursday, December 20, 2001 2:08 PM PERIODIC MAINTENANCE AND MINOR REPAIR ● EW000116 _ 1. Maximum level mark 2. Minimum level mark 5. Place the battery on a level surface, and then check the electrolyte level in the battery. NOTE: The electrolyte should be between the minimum and maximum level marks. _ _ 6. If the electrolyte is at or below the minimum level mark, add distilled water to raise the electrolyte to the maximum level mark.
U5MXE0.book Page 31 Thursday, December 20, 2001 2:08 PM PERIODIC MAINTENANCE AND MINOR REPAIR 2. If the battery will be stored for more than two months, check the specific gravity of the electrolyte at least once a month and fully charge the battery whenever necessary. 3. Fully charge the battery before installation. 4. After installation, make sure that the battery leads are properly connected to the battery terminals and that the breather hose is properly routed, in good condition, and not obstructed.
U5MXE0.book Page 32 Thursday, December 20, 2001 2:08 PM PERIODIC MAINTENANCE AND MINOR REPAIR 1. Starter relay 3. Pull the starter relay out. 5. Place the starter relay into the original position. 6. Place the battery in the battery compartment. 7. Turn the key to “ON” and turn on the electrical circuits to check if the devices operate. 8. If the fuse immediately blows again, have a Yamaha dealer check the electrical system. 1. Fuse 2. Spare fuse 4.
U5MXE0.book Page 33 Thursday, December 20, 2001 2:08 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU04134* Replacing a headlight bulb If a headlight bulb burns out, replace it as follows. EC000107 CAUTION: It is advisable to have a Yamaha dealer perform this job. _ _ 1. Place the motorcycle on the centerstand. 2. Remove cowling A. (See page 6-5 for cowling removal and installation procedures.) 1. Headlight bulb cover (× 2) 1. Headlight bulb socket (× 2) 3.
U5MXE0.book Page 34 Thursday, December 20, 2001 2:08 PM PERIODIC MAINTENANCE AND MINOR REPAIR 8. Install the headlight bulb cover by turning it clockwise. 9. Install the cowling. 10. Have a Yamaha dealer adjust the headlight beam if necessary. EAUT0022* Replacing a front turn signal light bulb EC000107 CAUTION: It is advisable to have a Yamaha dealer perform this job. _ _ 1. Place the motorcycle on the centerstand. 2. Remove cowling A. (See page 6-5 for cowling removal and installation procedures.
U5MXE0.book Page 35 Thursday, December 20, 2001 2:08 PM PERIODIC MAINTENANCE AND MINOR REPAIR 1. Screw (× 2) EAUS0013* Replacing the tail/brake light bulb or a rear turn signal light bulb 6 1. Tab 2. Slot 1. Tail/brake light bulb 3. Remove the defective bulb by pushing it in and turning it counterclockwise. 4. Insert a new bulb into the socket, push it in, and then turn it clockwise until it stops. 5. Place the tail/brake light lens into the original position, and then install the screws. 2.
U5MXE0.book Page 36 Thursday, December 20, 2001 2:08 PM PERIODIC MAINTENANCE AND MINOR REPAIR Turn signal light bulb 1. Remove the tail/brake light lens. (See “Tail/brake light bulb” for lens removal and installation procedures.) 1. Turn signal light bulb (× 2) 2. Pull the turn signal light lens off. 6-36 3. Remove the defective bulb. 4. Insert a new bulb into position. 5. Place the turn signal light lens into the original position. 6. Install the tail/brake light lens.
U5MXE0.book Page 37 Thursday, December 20, 2001 2:08 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU01008 Troubleshooting Although Yamaha motorcycles receive a thorough inspection before shipment from the factory, trouble may occur during operation. Any problem in the fuel, compression, or ignition systems, for example, can cause poor starting and loss of power. The following troubleshooting chart represents a quick and easy procedure for checking these vital systems yourself.
U5MXE0.book Page 38 Thursday, December 20, 2001 2:08 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU03473 Troubleshooting chart EW000125 WARNING Keep away open flames and do not smoke while checking or working on the fuel system. _ _ CT-1FE 1. Fuel Check the fuel level in the fuel tank. There is enough fuel. Check the compression. There is no fuel. Supply fuel. The engine does not start. Check the compression. 2. Compression There is compression. Check the ignition. There is no compression.
U5MXE0.book Page 1 Thursday, December 20, 2001 2:08 PM MOTORCYCLE CLEANING AND STORAGE EAK00000 7- EAK01302* B. STORAGE Frequent, thorough cleaning of your motorcycle will not only enhance its appearance but will improve its general performance and extend the useful life of many components. 1. Rinse the dirt and degreaser off with a garden hose. Long term storage (60 days or more) of your motorcycle will require some preventive procedures to guard against deterioration.
U5MXE0.book Page 1 Thursday, December 20, 2001 2:08 PM SPECIFICATIONS EAU01038 8- Specifications CS-01E Model AT115 Engine oil Dimensions Overall length Overall width Overall height Seat height Wheelbase Ground clearance Minimum turning radius Basic weight (with oil and full fuel tank) Maximum load* Type 1,935 mm Capacity 675 mm 1,070 mm 755 mm Periodic oil change 0.8 L Total amount (dry engine) 0.
U5MXE0.book Page 2 Thursday, December 20, 2001 2:08 PM SPECIFICATIONS Transmission Tire air pressure (measured on cold tires) Primary reduction system Helical gear Primary reduction ratio 3.133 Front 200 kPa (2.00 kgf/cm2) Spur gear Rear 225 kPa (2.25 kgf/cm2) Secondary reduction system Wheels Secondary reduction ratio 3.583 Number of drive chain sprocket teeth (rear/front) 43/12 Type Spoke wheel Transmission type V-belt automatic Size 16 × 1.
U5MXE0.book Page 3 Thursday, December 20, 2001 2:08 PM SPECIFICATIONS Spring/shock absorbers Front Coil spring / oil damper Rear Coil spring / oil damper Wheel travel Front 80 mm Rear 55 mm Electrical Ignition system DC. C.D.I. Charging system Type A.C.
U5MXE0.book Page 1 Thursday, December 20, 2001 2:08 PM CONSUMER INFORMATION EAU01039 9- EAU02945* Identification numbers Record the key identification number and engine serial number in the spaces provided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen. 1. FRAME SERIAL NUMBER: 1. Frame serial number CA-02E 2. ENGINE SERIAL NUMBER: CA-02E 1.
Engine start procedure Before pushing start button, make sure to apply the Front or Rear Brake and that the Sidestand is retracted. Engine oil replacement Engine oil replacement : Every 2000 km. Recommended oil : SAE20W - 50 type SF Class Motor Oil V-belt inspection Periodic maintenance must be performed by any authorized Yamaha Dealer (Refer to the Owner's Manual for details.
OWNER’S MANUAL YAMAHA MOTOR CO., LTD.
