User manual YAMAHA 20DEMO SERVICE MANUAL

[. . . ] 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. 1 EAA10500 EUU13800* Particularly important information is distinguished in this manual by the following notations: Q The Safety Alert Symbol means ATTENTION!YOUR SAFETY IS INVOLVED! w 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. cC A CAUTION indicates special precautions that must be taken to avoid damage to the motorcycle. [. . . ] Downshift through the gears and when the motorcycle is almost completely stopped, shift into nutral. Recommend shift point: Gear position 4th ¡ 3rd 3rd ¡ 2rd 2nd ¡ 1st Recommend speed 0~40 km/h 0~30 km/h 0~15 km/h 33 EAF30000* 0~150Km 1/3 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. Because the engine is brand new, prolonged full throttle operation, or any condition which might result in excessive heating of the engine must be avoided during this period. EAF30800 0~500Km 1/2 1. Rev the engine freely through the gears, but do not use full throttle at any time. 34 500~1000Km 3. 500~1, 000 km: Avoid cruising speeds in excess of 3/4 throttle. EUU40400 cC 3/4 After 1, 000 km of operation, be sure to replace the engine oil. Vary speed occasionally. EUU32200 1000Km~ cC If any engine trouble should occur during the break-in period, consult a Yamaha dealer immediately. 35 EAF40000 Parking When parking the motorcycle, stop the engine and remove the ignition key. EUU63000 w 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. 36 EAH00000 PERIODIC MAINTENANCE AND MINOR REPAIR EAH00400 Periodic inspection, adjustment and lubrication will keep your motorcycle in the safest and most efficient condition possible. The maintenance and lubrication schedule chart should be considered strictly as a guide to general maintenance and lubrication intervals. EUU63200 w If you are not familiar with motorcycle service, this work should be done by a Yamaha dealer. 37 EAH10101* Tool kit The tools provided in the owner's tool kit are to assist you in the performance of periodic maintenance. However, some other tools such as a torque wrench are also necessary to perform the maintenance correctly. EUU67100 1 Tool kit w 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. 38 PERIODIC MAINTENANCE/LUBRICATION INITIAL ITEM REMARKS 500 km 2 2 2, 000 km 2 2 EVERY 4, 000 km 2 2 2 2 2 2 2 2 2 2 2 8, 000 km 2 2 2 2 2 * Valve(s) Spark plug Air filter * Carburetor * Fuel line Engine oil * Engine oil filter Front brake * (T105SE) * Front brake (T105E) Check valve clearance. Free play: 3~7 mm 46 EAH92300 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. Standard idle speed: 1, 400~1, 600 r/min 1 Tachometer EAH92000 Idle speed adjustment 1. 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. 1 Throttle stop screw 47 EAH20304 Standard spark plug: C7HSA/NGK U22FS-U/DENSO Spark plug inspection The spark plug is an important engine component and is easy to inspect. The condition of the spark plug can indicate the condition of the engine. The ideal color on the white insulator around the center electrode is a medium-to-light tan color for a motorcycle that is being ridden normally. You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode. If electrode erosion becomes excessive, or if carbon and other deposits are excessive, you should replace the spark plug with the specified plug. 1 Spark plug gap 48 Spark plug gap: 0. 6 ~ 0. 7 mm Spark plug torque: 12. 5 Nm (1. 25 m·kg) Before installing the spark plug, measure the electrode gap with a wire thickness gauge; adjust the gap to specification as necessary. When installing the plug, always clean the gasket surface and use a new gasket. Wipe off any grime from the threads and tighten the spark plug to the specified torque. EUU03801 NOTE: If a torque wrench is not available when you are installing a spark plug, a good estimate of the correct torque is 1/4 to 1/2 turn past finger tight. Have the spark plug torqued to the correct value as soon as possible with a torque wrench. 49 EAH85201 a 1 Front brake adjustment (T105E) The front brake lever free play should be adjusted to 8~12 mm at the brake lever end. [. . . ] First, remove all dirt and mud from the chain with a brush or cloth, then apply lubricant between both rows of side plates and on all center rollers. If the chain is too dirty or rusty, take the motorcycle for repair. 59 EAI30601 Brake lever and pedal Lubricate the pivoting parts. Recommended lubricant: Yamalube 4 or SAE 20W40 motor oil EAI30801 Center and sidestand Lubricate the pivoting parts. Recommended lubricant: Yamalube 4 or SAE 20W40 motor oil 60 EAH20501 Front fork inspection EUU65700 w Securely support the motorcycle so there is no danger of it falling over. [. . . ]