| INTRODUCTION i | Welcome to the Yamaha world of motorcycling! As the owner of the FZ-S (FZN150D), you are benefiting from Yamaha's vast experience and newest technology regardi ° . in ; the design and manufacture of high-quality products, which have eamed Yamaha a reputation for dependebity, " Please take the time to read this manual thoroughly, so as to enjoy all advantages of your FZ-S (FZN150D). The Owner's Manual does not only instruct you in how to operate, inspect and maintain your motorcycle, but also in how to safeguard ourself and others from trouble and injury. addition, the many tips given in this manual will help keep your motorcycle in the best possible condition. if you have any durther questions, do not hesitate to contact your Yamaha dealer. | The Yamaha team wishes you many safe and pleasant rides. So, remember to put safety first! ! Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most cur- | tent product information available at the time of printing, there may be minor discrepancies between your motorcycle and | this manual. If there is any question conceming this manual, please consult a Yamaha dealer. | Please read this manual carefully and completely before operating this motorcycle.IMPORTANT MANUAL INFORMATION SS 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 personal injuny | a hazards. Obey all safety messages that follow this symbol to avoid possible injy or death. ‘A WARNING indicates a hazardous situation which, f not avoided, could result in | PN death or serious injury. aa : . ; ries A NOTICE indicates special precautions that must be taken to avoid damage to te vehicle or other property. TIP l ATIP provides key information to make procedures easier or clearer. “Product and specifications are subject to change without notice. oreoIMPORTANT MANUAL INFORMATION FZ-S (FZN150D) OWNER’S MANUAL ©2015 by India Yamaha Motor Pvt. Ltd. ‘1st edition, July 2015 All rights reserved. Any reprinting or unauthorized use without the written permission of India Yamaha Motor Pvt. Ltd. is expressly prohibited. Printed in India.TABLE OF CONTENTS ‘SAFETY INFORMATION 1-1 Shifting. swsmnson6-2 Checking the front brake pads Tips for reducing fuel and rear brake shoes DESCRIPTION .. 24 consumption Checking the brake fluid level Left view. 2-1 Engine break- ‘Changing the brake fluid Right view. 22 Parking.. Drive chain slack... Controls and instruments. 28 Cleaning and lubricating the drive PERIODIC MAINTENANCE AND chain. INSTRUMENT AND CONTROL. 6-1 Checking and lubricating the FUNCTIONS 34 6-4 cables. Main switch/steering lock. 3-1 Periodic maintenance chart for the ‘Checking and lubricating the Indicator lights and waming light .. 3-2 emission control SySteM .runn6-2 throttle grip and cable end....... 62 Multi-function display... Handlebar switches... Clutch lever . Helmet holder. Sidestand....... Starting circuit cut-off system... FOR YOUR SAFETY - PRE-OPERATION CHECKS..... OPERATION AND IMPORTANT RIDING POINTS. General maintenance and lubrication chart. Removing and instaling panels Checking the spark plug. Canister. Engine oil and oil fiter element Cleaning the air fitter element Adjusting the engine idling speed om Adjusting the throttle grip free ‘Adjusting the clutch lever free play Adjusting the brake pedal free Play. Brake light switches Checking and lubricating the brake and shift pedals. 62 Checking and lubricating the brake and clutch levers nn 6: Checking and lubricating the centerstand and sidestand.......6: Lubricating the swingarm. pivots. Checking the front fork Checking the steerin i Checking the wheel bearings......6: Battery Replacing the fuse Replacing a headlight bulb.. Auxiliary light bulb... the tail/brake light Replacing a tum signal light bulb Front wheelTABLE OF COl Rear wheel... Troubleshooting .. Troubleshooting chart MOTORCYCLE ‘CARE AND GE ... Matte color caution SPECIFICATIONS. CONSUMER INFORMATION. Identification numbers... secon4 SAFETY INFORMATION Be a Responsible Owner ‘As the vehicle's owner, you are re- ‘sponsible for the safe and proper oper- ation of your motorcycle. Motorcycles are single-track vehicles. Their safe use and operation are de- Pendent upon the use of proper riding techniques as weil as the expertise of the operator. Every operator should know the following requirements be- fore riding this motorcycle. He or she should: © Obtain thorough instructions from a competent source on all aspects of motorcycle operation. (© Observe the wamings and mainte- nance requirements in this Own- ers Manual. © Obtain quaified training in safe and proper riding techniques. © Octain professional technical ser- vice as indicated in this Owner's Manual and/or when made neces- ‘sary by mechanical conditions. @ Never operate a motorcycle with- out proper training or instruction. Take a training course. Beginners should receive training from a cer- tified instructor. Contact an autho- rized motorcycle dealer to find out about the training courses nearest you. Perform the re-operation checks each time you use the vehicle to make sure it is in safe operating condition. Failure to inspect or maintain the vehi- cle property increases the possibility of an accident or equipment damage. See page 4-1 for a list of pre-operation checks. © This motorcycle is designed to carry the operator and a passen- ger. © The failure of motorists to detect and recognize motorcycles in traf- fic is the predominating cause of automobile/motorcycle accidents. Many accidents have been caused by an automobile driver who did not see the motorcycle. Making yourself conspicuous ap- ry pears to be very effective in reduc- ing the chance of this type of accident. Therefore: * Wear a brightly colored jacket. * Use extra caution when you are approaching and passing through intersections, since in- tersections are the most likely places for motorcycle accidents to occur. ‘+ Ride where other motorists can ‘see you. Avoid riding in another motorist’s blind spot. * Never maintain a motorcycle without proper knowledge. Contact an authorized motorcy- cle dealer to inform you on ba- sic motorcycle maintenance. Certain maintenance can only be carried out by certified staf.> Many accidents involve inexperi- enced operators. In fact, many op- erators who have been involved in accidents do not even have a cur- rent motorcycle license, * Make sure that you are qualified and that you only lend your mo- torcycle to other qualified oper- ators. * Know your skills and limits. Staying within your limits may help you to avoid an accident. * We recommend that you prac- tice riding your motorcycle where there is no traffic until you have become thoroughly famil- iar with the motorcycle and all of its controls. ) Many accidents have been caused by error of the motorcycle ‘operator. A typical error made by the operator is veering wide on a tum due to excessive speed or un- dercomering (insufficient lean an- gle for the speed). * Always obey the speed limit and never travel faster than warrant- ed by road and traffic condi- tions. 4\ SAFETY INFORMATION * Always signal before turing or changing lanes. Make sure that other motorists can see you. The posture of the operator and passenger is important for proper control. * The operator should keep both hands on the handlebar and both feet on the operator foot- rests during operation to main- tain control of the motorcycle. * The passenger should always hold onto the operator, the seat ‘strap or grab bar, if equipped, with both hands and keep both feet on the passenger footrests. Never carry a passenger unless he or she can firmly place both feet on the passenger footrests. Never ride under the influence of alcohol or other drugs. This motorcycle is designed for ‘on-road use only. It is not suitable for off-road use. 12 Protective Apparel The majority of fatalities from motorcy- cle accidents are the result of head in- juries. The use of a safety helmet is the single most critical factor in the pre- vention or reduction of head injuries. © Always wear an approved helmet. © Wear a face shield or goggles. Wind in your unprotected eyes could contribute to an impairment of vision that could delay seeing a hazard. © The use of a jacket, heavy boots, trousers, gloves, etc., is effective in preventing or reducing abra- sions or lacerations. ‘© Never wear loose-fitting clothes, otherwise they could catch on the control levers, footrests, or wheels and cause injury or an accident. ‘© Always wear protective clothing that covers your legs, ankles, and feet. The engine or exhaust sys- tem become very hot during or af- ter operation and can cause bums. © A passenger should also observe the above precautions.2\ SAFETY INFORMATION ‘Avoid Carbon Monoxide Poisoning All engine exhaust contains carbon monoxide, a deadly gas. Breathing carbon monoxide can cause head- aches, dizziness, drowsiness, nausea, confusion, and eventually death. Carbon Monoxide is a colorless, odor- less, tasteless gas which may be pres- ent even if you do not see or smell any ‘engine exhaust. Deadly levels of car- bon monoxide can collect rapidly and you can quickly be overcome and un- able to save yourself. Also, deadly lev- els of carbon monoxide can linger for hours or days in enclosed or poorly ventilated areas. if you experience any symptoms of carbon monoxide poi- soning, leave the area immediately, get fresh air, and SEEK MEDICAL TREAT- MENT. © Donot run engine indoors. Even if you try to ventilate engine exhaust with fans or open windows and doors, carbon monoxide can rap- idly reach dangerous levels. © Do not run engine in poorly venti- lated or partially enclosed areas such as bams, garages, or car- Ports. © Donotrun engine outdoors where When loading within this weight limit, engine exhaust can be drawn into keep the following in mind: a building through openings such as windows and doors. Loading ‘Adding accessories or cargo to your motorcycle can adversely affect stabil- ity and handling if the weight distribu- tion of the motorcycle is changed. To avoid the possibilty ofan accident, use extreme caution when adding cargo or accessories to your motorcycle. Use extra care when riding a motorcycle that has added cargo or accessories. Here, along with the information about accessories below, are some general guidelines to follow if loading cargo to your motorcycle: The total weight of the operator, pas- ‘senger, accessories and cargo must not exceed the maximum load limit. Operation of an overloaded vehicle could cause an accident. Maximum load: 198 kg (437 Ib) 1a © Cargo and accessory weight should be kept as low and close to the motorcycle as possible. Se | curely pack your heaviest items at close to the center of the vehicle ; as possible and make sure to dis- tribute the weight as evenly as possible on both sides of the mo- torcycle to minimize imbalance or instability. © Shifting weights can create a sud- | den imbalance. Make sure that | accessories and cargo are se- | curely attached to the motorcycle ! before riding. Check accessory mounts and cargo restraints fre- quently. * Properly adjust the suspension for your load (suspension-ad- justable models only), and check the condition and pres} sure of your tires. * Never attach any large or heavy items to the handlebar, front | fork, or front fender. Thes? j items, including such cargo # | sleeping bags, duffel bags, iA SAFETY INFORMATION SS DSAFEDEINFORMATION tents, can create unstable han- dling or a slow steering re- sponse. @ This vehicle is not designed to pull a trailer or to be attached to a sidecar. Genuine Yamaha Accessories Choosing accessories for your vehicle is an important decision. Genuine Yamaha accessories, which are avail- able only from a Yamaha dealer, have been designed, tested, and approved by Yamaha for use on your vehicle. ny companies with no connection ha manufacture parts and ac- 5 or offer other modifications a vehicles. Yamaha is not in to test the products that 6 produc Aftermarket Parts, Accessories, and Modifications While you may find aftermarket prod- ucts similar in design and quality to genuine Yamaha accessories, recog- nize that some aftermarket accesso- ries or modifications are not suitable because of potential safety hazards to you or others. Installing aftermarket products or having other modifications performed to your vehicle that change any of the vehicle's design or operation characteristics can put you and others at greater risk of serious injury or death. You are responsible for injuries related to changes in the vehicle. Keep the following guidelines in mind, ‘as well as those provided under “Load- 7g" when mounting accessories. © Never install accessones or cary cargo that would impair the per- formance of your motorcycle. Carefully inspect the accessory before using it to make sure that it does not in any way reduce ground clearance or comening Clearance, lint suspension travel, steering travel or control opera tion, oF obscure lights or reftec tors. * Accessones fitted to the han lear or the front fork area ca create instabilty due to improp ‘er weight distribution or aerody namic changes. If accessor: are added to the handlebar o front fork area, they must be a: lightweight as possible anc should be kept to a minimum, © Bulky or large accessones ma seriously affect the stabiity 0 the motorcycle due to aerody namic effects. Wind may at tempt to lit the motorcycle, o accessones may also cause in- stability when passing or beng passed by large vehicles. © Certain accessones can dis:&\ SAFETY INFORMATION SSAFETY INFORMATION Operator and may limit control ability, therefore, such accesso- ties are not recommended. ‘© Use caution when adding electri- cal accessories. If electrical ac- Cessories exceed the capacity of the motorcycle’s electrical sys- tem, an electric failure could re- sult, which could cause a dangerous loss of lights or engine power. Aftermarket Tires and Rims The tires and rims that came with your motorcycle were designed to match the performance capabilities and to provide the best combination of han- dling, braking, and comfort. Other tires, rims, sizes, and combinations may not be appropriate. Refer to page 6-14 for tire specifications and more in- formation on replacing your tires. ‘Transporting the Motorcycle Be sure to observe following instruc- tions before transporting the motorcy- cle in another vehicle. ‘@ Remove all loose items from the motorcycle. © Check that ‘the fuel cook (if equipped) is in the “OFF” position and that there are no fuel leaks. © Point the front wheel straight ahead on the trailer or in the truck bed, and choke it in a rail to pre- vent movement. © Shift the transmission in gear (for models with a manual transmis- sion). © Secure the motorcycle with tie- downs or suitable straps that are attached to solid parts of the mo- torcycle, such as the frame or up- Per front fork triple clamp (and not, for example, to rubber-mounted handlebars or tum signals, or parts that could break). Choose the location for the straps carefully so the straps will not rub against painted surfaces during transport. ‘© The suspension should be com- pressed somewhat by the tie- downs, if possible, so that the mo- torcycle will not bounce exces- sively during transport. 15DESCRIPTION 1. Air filter element (page 6-12) ‘Owner's toolkit (page 6-1) Seat lock (page 3-9) Shift pedal (page 3-5) ‘ae adjusting screw (page 6-13) 4 [ 24 eeDESCRIPTION 3. Brake Mid reservoir (page 6-19) 4. Engine oil iter element (page 6-9) 5. Engine oil dipstick (page 6-9) 6. Brake pedal (page 3-6) 7. Rear brake tight switch (page 6-18)DESCRIPTION Controls and instruments ZAUEISS2 1. Clutch lever (page 3-5) 2. Left handlebar switches (page 3-4) 3, Multi-function display (page 3-3) 4, Main switch/steering lock (page 3-1) 6. Tachometer 6. Right handlebar switches (page 3-4) 7. Throttle grip (page 6-13) 8. Brake lever (page 3-6) 23INSTRUMENT AND CONTROL FUNCTIONS 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. laa twee Al electrical systems are supplied with Power, the meter lighting comes on ‘and the engine can be started. The key cannot be removed. OFF Al Gectrical systems are off. The key can be removed. BEES Never tum the key to “OFF” or “LOCK” while the vehicle is moving. Otherwise the electrical systems will be switched off, which may result in loss of control or an accident. Lock The steering is locked, and all electrical systems are off. The key can be re- moved. To lock the steering 1, Push, 2. Tum 1. Tum the handlebars all the way t. the left or right. ni an 2. Push the key in from the “OF position, and then tum it tp “LOCK” while stil pushing it, 3, Remove the key. To unlock the steering 1 U zeus 1. Push, 2. Tun, Push the key into the main switch, and then tum it to “OFF” while still pushing it ' rIndicator lights and warming” light 41. Turn signal indicator ight “<> o>" 2. Engine trouble warning ight "23" 3, Neutral indicator light “N™ 4, High beam indicator light “ZO” 5. Eco indicator “ECO” | Tum signal indicator light “<2 >” This indicator light flashes when the turn signal switch is pushed to the left | or right. Neutral indicator light “N” This indicator light comes on when the transmission is in the neutral position. INSTRUMENT AND CONTROL FUNCTIONS High beam indicator light “20” This indicator light comes on when the high beam of the headlight is switched on. Engine trouble warming light “" This warning light comes on or flashes if aproblem is detected in the electrical circuit monitoring the engine. If this oc- curs, have a Yamaha dealer check the self-diagnosis system. The electrical circuit of the warming light can be checked by turning the key to “ON*. The waming light should ‘come on for a few seconds, and then go oft if the waming light does not come on initially when the key is tumed to “ON”, or if the warming light remains on, have a Yamaha dealer check the electrical circuit. 32 Eco indicator “ECO” This indicator comes on when the vehi- cle is being operated in an environ- mentally friendly, fuel-efficient manner. The indicator goes off when the vehicle is stopped. CT auueaa Consider the following tips to reduce fuel consumption: © Avoid the high speed acceleration © Travel at constant speed © Select the transmission gear that is appropriate for the vehicle speed.ONTROL FUNCTIONS INSTRUMENT AND C Red zone: 9000 r/min and above Mutti-function display eae To tum the key 10 “ON” before ‘Odometer and tripmeter motes 1. Muitunetion display 2, Selection button “SELECT” Mean Be sure to stop the vehicle before making any setting changes to the multi-function meter unit. Changing ‘settings while riding can distract the operator and increase the risk of an accident. The multifunction display unit is equipped with the following: ‘© aspeadometer © atachometer © an odometer © attipmeter © afuel meter using the “SELECT” button. Tachometer 1. Tachometer 2, Tachometer red zone The electric tachometer allows the rid- er to monitor the engine speed and keep it within the ideal power range. When the key is turned to “ON”, all the tachometer segments will come on and then go off in order to test the elec- trical circuit. eT Do not operate the engine in the ta. chometer red zone. oxo 33 A brief push (less than one the “SELECT” button al switches the display between ¢ ‘odometer mode “ODO” and tripe, mode*TRIP”. While the display is set to tripms mode, a long push (more than thy seconds) on the “SELECT” button reset the tripmeter. Fuel meter 2AUE 450 1. Fuel meter The fuel meter indicates the amout! fuel in the fuel tank. The display ents of the fuel meter disapped'* wards “E" (Empty) as the fel ®decreases. When approximately 2.4 L (0.63 US gal, 0.53 [Link]) of fuel re- mains in the fuel tank, the last segment of the fuel meter will start flashing. When this occurs, refuel as soon as | possible. TIP © Ifthe last segment of fuel meter is flashing, refuel as soon as possi- ble. If flashing continues after fuel- ing, have a Yamaha dealer check the electrical system. © This fuel meter is equipped with a self-diagnosis system. If a prob- lem is detected in the electrical circuit, all display segments of the fuel meter will start flashing. If this occurs have a Yamaha dealer check the electrical system. Teter ee INSTRUMENT AND CONTROL FUNCTIONS oe Right Handlebar switches 1. Pass switch "PASS" 2. Dimmer switch "EO/EO” 3, Turn signal switch "" 4, Horn switch " Pex” 1. Engine stop switch "RI" 2 Light switch *E/ 8. Start switch *@) Pass switch “PASS” fi Press this switch to flash the headlight. Dimmer switch “0/50” Set this switch to*EO” for the high beam and to “£0” for the low beam. ‘Tum signal switch “>” To signal a right-hand tur, push this switch to“e>". To signal a left-hand tum, push this switch to"<”. When released, the switch retums to the cenINSTRUMENT AND CONTROL FUNCTIONS ter position. To cancel the turn signal lights, push the switch in after it has re- tumed to the center position. Hom switch “be” Press this switch to sound the horn. Light switch “1/0 a= Set this switch to“ to tum on the auxiliary light, meter lighting and tailight. Set the switch to “i” to turn on the headlight also. Set the switch to “e” to tum off all the lights. Engine stop switch “O/)” Set this switch to “C)” before starting the engine. Set this switch to “7” to stop the engine in case of an emergen- cy, such as when the vehicle overtums (or when the throttle cable is stuck. Start switch “@)” Push this switch to crank the engine with the starter. See page 5-1 for start- olnseuctons Prior to starting the en- Clutch lever averse 1. Clutch lever The clutch lever is located at the left handlebar grip. To disengage the clutch, pull the lever toward the han- dlebar grip. To engage the clutch, re- lease the lever. The lever should be Pulled rapidly and released slowly for smooth clutch operation. The clutch lever is equipped with a Clutch switch, which is part of the start- ing circuit cut-off ot) system. (See page Shift pedal Sy, 1. Shift pedal The shift pedal is located on thel side of the motorcycle and is wet combination with the clutch lever we shifting the gears of the 5-speed o* ‘stant-mesh transmission equipped? this motorcycle.Brake lever 1. Brake lever, The brake lever is located on the right side of the handlebar. To apply the front brake, pull the lever toward the throttle grip. INSTRUMENT AND CONTROL FUNCTIONS Brake pedal mueiaes 1. Brake pedal “The brake pedal is located on the right side of the motorcycle. To apply the rear brake, press down on the brake pedal. 26 Fuel tank cap 1. Fuel tank cap 2. Arrow mark To remove the fuel tank cap Insert the key into the lock and tum it 11/4 tum clockwise. The lock will be re- leased and the fuel tank cap can be re- moved. To install the fuel tank cap 1. Push the fuel tank cap into posi- tion with the key inserted in the lock. Te __ ‘The mark on the fuel tank cap must be pointing forward. pointing forward,INSTRUMENT AND CONTROL FUNCTIONS 2, Tum the key counterclockwise to the original position, and then re- move it. ju ‘The fuel tank cap cannot be installed unless the key is in the lock. In addi- tion, the key cannot be removed if the cap is not properly installed and locked. EXT Make sure that the fuel tank cap is Property installed before riding. Leaking fuel is a fire hazard. Fuel Make sure there is sufficient gasoline in the tank. Gasoline and gasoline vapors are extremely flammable. To avoid fires and explosions and to reduce the risk of injury when refueling, follow these instructions. 1. Before refueling, turn off the en- gine and be sure that no one is sit- ting on the vehicle. Never refuel while smoking, or while in the vi- cinity of sparks, open flames, or other sources of ignition such as the pilot lights of water heaters and clothes dryers. 2. Do not overfill the fuel tank. Stop filling when the fuel reaches the bottom of the filler tube. Because fuel expands when it heats up, heat from the engine or the sun can. cause fuel to spill out of the fuel tank. ate wa tin yo zaveoo19 1. Fuel tank filer tube 2. Maximum fuel level 3. Wipe up any spilled fuel immed ately. NOTICE: Immediate} wipe off spilled fuel with a cleayy dry, soft cloth, since fuel mo deteriorate painted surfaces a Plastic parts. rossara 3 4, Be sure to securely close the fu tank cap. i Gasoline is poisonous and cause injury or death. Handle 92s? line with care. Never siphon gasolit by mouth. If you should swallt ‘some gasoline or inhale alot o oline vapor, or get some Gasol your eyes, see your doctor inately. If gasoline spills on your skin, }wash with soap and water. If gaso- line spills on your clothing, change ‘your clothe: eC Recommended fuel: Regular unleaded gasoline only Fuel tank capacity: 12.0 L (@.17 US gal, 2.64 [Link]) TICE Use only unleaded gasoline. The use of leaded gasoline will cause severe damage to internal engine Parts, such as the valves and piston rings, as well as to the exhaust system. INSTRUMENT AND CONTROL FUNCTIONS Catalytic converter nn This model is equipped with a catalytic Converter in the exhaust system. PO The exhaust system is hot after op- eration. To prevent a fire hazard or bums: © Do not park the vehicle near possible fire hazards such as grass or other materials that easily bum. © Park the vehicle in a place where pedestrians or children are not likely to touch the hot exhaust system. © Make sure that the exhaust sys- tem has cooled down before doing any maintenance work. © Do not allow the engine to idle more than a few minutes. Long idling can cause a build-up of 38 TICE Ec Use only unleaded gasoline. The use of leaded gasoline will cause unre- Pairable damage to the catalytic converter.INSTRUMENT AND CONTROL FUNCTIONS “wea? To install the passenger seat = Seats 1. Insert the projection on the rear of a the passenger seat into the seat fee rn holder as shown, and then push the front of the seat down to lock To remove the jer seat it in place. 1. Insert the key into the seat lock, and then tum it clockwise. seve 1. Rider seat 2. Batt To install the rider seat 1. Insert the projection on the front: the seat into the seat holder « shown, then place the seat inh original position. 2. While holding the key in position “2", lift the front of the passenger ‘seat and pull it forward. 2. Remove the rider seat by remov- ing the bolts then lift the rear ofthe 21470 rider seat and pull it backward. 1. Projection 2. Seat holder. Install the two bolts of the rider seat. . Install the passenger seat. bE ake sure that the seats are property cured before riding. INSTRUMENT AND CONTROL FUNCTIONS Helmet holder Nt ce 1. Helmet holder The helmet holder is located on the bottom of the passenger seat. To secure a helmet to the helmet holder 1. Remove the passenger seat. (See page 3-9.) 2. Attach the helmet to the helmet holder, and then securely install the passenger seat. WARNING! Never ride with a helmet at- tached to the helmet holder, since the helmet may hit ob- jects, causing loss of control and possibly an accident. ew nieuwe 1. Helmet 2. Passenger seat vw To release the helmet from the hel- met holder Remove the passenger seat, remove the helmet from the helmet holder, and then install the seat.INSTRUMENT AND CONTROL FUNCTIONS Sidestand The sidestand is located on the left side of the frame. Raise the sidestand or lower it with your foot while holding the vehicle upright. He The vehicle must not be ridden with the sidestand down, or if the side- stand cannot be properly moved up (or does not stay up), otherwise the sidestand could contact the ground and distract the operator, resulting in a possible loss of control. ours Starting circuit cut-off system The starting circuit cut-off system (comprising the clutch switch and the neutral switch) prevents starting when the transmission is in gear and the clutch lever is not pulled. Periodically check the operation of the starting circuit cut-off system accord- ing to the following procedure. TIP This check is most reliable if performed with a warmed-up engine.With the engine turned off: 1. Make sure that the engine stop switch is set to“. [Link] the key on. 3. Shift the transmission into the neutral position. 4, Push the start switch. Does the engine start? YES NO 5. Tum the engine off. 6. Shift the transmission into gear. 7. Keep the clutch lever pulled. 8, Push the start switch. Does the engine start? YES NO PWG if a malfunction is noted, have a Yamaha dealer check the system before riding. The neutral switch may not be working correctly. The motorcycle should not be ridden until ‘checked by a Yamaha dealer. The clutch switch may not be working correctly. The motorcycle should not be ridden until checked by a Yamaha dealer.FOR YOUR SAFETY - PRE-OPERATION CHECKS ® lnspect your vehicle each time you use it to make sure the vehicle is in safe operating condition. Always follow the ingp, and maintenance procedures and schedules described in the Owner’s Manual. . AAWARNING faite to inspect or maintain the vehicle properly increases the possibilty of an accident or equipment day Do not operate the vehicle if you find any problem. If a problem this manual, have the vehicle inspected by a Yamaha dealer. Before using this vehicle, check the following points: cannot be corrected by the procedures proviu; TEM ‘CHECKS * Check ol level in engine, otf * Check vehicle for oil leakage. , add recommended oil to specified level. 69 * Check operat * Check brake pads for wear. Front brake ‘* Replace if necessary. ‘= Check fluid level in reservoir. ‘operation. soft or spongy, have Yariaha dealer bleed hydraulic system, + tf necessary, add specified brake fluid to specified level “Check hydraulic system for leakage. * Check operation. '* Check pedal free play. Rear brake ‘Adjust if necessary. * Check brake shoe wear. ‘+ Replace if necessary. 6-18, 6-19 dee 617,618CHECKS PAGE * Check operation. * Lubricate cable end if necessary. * Check lever free play. * Adjust if necessary. 6-16 * Make sure that operation is smooth. * Check throttle grip free play. ‘lf necessary, have Yamaha dealer adjust throttle grip free play and lubricate ca- ble end and grip housing. 6-13, 6-23 * Make sure that operation is smooth. * Lubricate cable ends if necessary. 6-23 * Check chain slack. * Adjust if necessary. * Check chain condition. * Lubricate if necessary. 6-20, 6-22 Check for damage. * Check tire condition and tread depth. © Check air pressure. * Correct if necessary. 6-14, 6-16OPERATION AND IMPORTANT RIDING POINTS Read the Owner's Manual carefully to ,ecome familiar with all controls. If here is a control or function you do not inderstand, ask your Yamaha dealer. PWG Failure to familiarize yourself with he controls can lead to loss of con- rol, which could cause an accident or injury. Starting the engine In order for the starting circuit cut-off system to enable starting, one of the following conditions must be met: ‘© The transmission is in the neutral position. © The transmission is in gear with the clutch lever pulled. See page 3-11 for more information. 1. Tum the key to “ON” and make sure that the engine stop switch is set to “0”. The following warming lights and indicator light should come on for a few seconds, then go off. © Neutral indicator light ‘© Tum signal indicator light @ High beam indicator light © ECO indicator light © Engine trouble waming light ff a waming or indicator light does not come on initially when the key is turned to “ON?, or if a warning or in- dicator light remains on, see page 32 for the corresponding warning and inetin NOTICE) For maximum engine life, never a celerate hard when the engine cold! } 2. Shift the transmission into neutral position. The neutral ing ator light should come on. I ng ask a Yamaha dealer to check 4, electrical circuit. 3. Start the engine by pushing» start switch. If the engine fails to start, reas the start switch, wait a few sx onds, and then try again, Ex starting attempt should be ¢ short as possible to preserve t battery. Do not crank the engi more than 10 seconds on any attempt.Shifting 1. Shift pedal 2. Neutral position Shifting gears lets you control the amount of engine power available for starting off, accelerating, climbitg hills, etc. The gear positions are shown in the il- lustration TIP To shift the transmission into the neu- tral position, press the shift pedal down epeatedly until it reaches the end of its baka and then slightly raise it. | ) OPERATION AND IMPORTANT RIDING POINTS NonIcE soon SA ‘© Even with the transmission in the neutral position, do not Coast for long periods of time with the engine off, and do not tow the motorcycle for long dis- tances. The transmission is Properly lubricated only when the engine is running. Inade- quate lubrication may damage the transmission. @ Always use the clutch while changing gears to avoid dam- aging the engine, transmission, and drive train, which are not designed to withstand the shock of forced shifting. Tips for reducing fuel con.” ‘sumption Fuel consumption depends largely on your riding style. Consider the follow- ing tips to reduce fuel consumption: © ‘Shift up swiftly, and avoid high en- gine speeds during acceleration, © Do not rev the engine while shift- ing down, and avoid high engine ‘speeds with no load on the en- gine. © Turn the engine off instead of let- ting it idle for an extended length of time (e.g., in traffic jams, at traf- fic lights or at railroad crossings).OPERATION AND IMPORTANT RIDING POINTS. Engine break-in There is never a more important period in the life of your engine than the period between 0 and 1000 km (600 mi). For this reason, you should read the fol- lowing material carefully. Since the engine is brand new, do not Put an excessive load on it for the first 1000 km (600 mi). The various parts in the engine wear and polish themselves to the correct operating clearances. During this period, prolonged full-throt- tle operation or any condition that might result in engine overheating must be avoided. (0-500 km (0-300 mi) Avoid prolonged operation above 4500 timin, After every hour of operation, stop the engine, and then let it cool for five to ten minutes. Vary the engine speed from time to time. Do not operate the engine at one set throttle position. 500-1000 km (300-600 mi) ‘Avoid prolonged operation above 6 min. Rev the engine freely through the gears, but do not use full throttle at any time. NOTICE: After 1000 km (600 mi) of operation, the engine oil must be changed, the oil filter cartridge or el- ‘ment replaced, and the oil strainer cleaned. rcxvea 1000 km (600 mi) and beyond The vehicle can now be operated nor- mally NOTICE ee © Keep the engine speed out of the tachometer red zone. © If any engine trouble should oc- cur during the engine break-in period, immediately have a Yamaha dealer check the vehi- cle, 000 Parking When parking, stop the engin, x then remove the key from the ma switch, 2 WARNING © Since the engine and extas system can become very hy Park in a place where pede ans or children are not likey te touch them and be burned. ®@ Donot park ona slope or on sot ground, otherwise the vehick may overturn, increasing th risk of a fuel leak and fire. © Do not park near grass or othe flammable materials whic might catch fire. FPeriodic inspection, adjustment, and lubrication will Keep your vehicle in the safest and most efficient condition possible. Safety is an obligation of the "vehicle owner/operator. The most im- ‘portant points of vehicle inspection, ‘adjustment, and lubrication are ex. plained on the following pages. The intervals given in the periodic maintenance charts should be simply considered as a general guide under normal riding conditions. However, de- pending on the weather, terrain, geo- graphical location, and individual use, the maintenance intervals may need to be shortened. PGI Failure to property maintain the vehi- Cle oF performing maintenance ac- piites incorrectly may increase risk of injury or death during ice OF while using the vehicle. If ™. 2re not familiar with vehicle ser- ; have a Yamaha dealer perform [ARNING Tum off the engine wh maintenance Specified, © A running engine has moving Parts that can catch on Parts or clothing and electrical arts that can cause shocks or fires. © Running the engine while ser- vicing can lead to eye injury, burns, fire, or carbon monoxide Poisoning - possibly leading to death. See page 1-3 for more in- formation about carbon monox- ide. 7 WG) Brake discs, calipers, drums, and linings can become very hot during use. To avoid possible bums, let brake components cool before touching them. zuesere 1. Owner's too! kit The owner's tool kit is located under I the passenger seat. (See page 3-9.) The service information included in this manual and the tools provided in the ‘owner's tool kit are intended to assist you in the performance of preventive maintenance and minor repairs. How- ever, additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly. Se AMM If you do not have the tools or experi- ence required for a particular job, have a Yamaha dealer perform it for you. _ODOMETER READING No. TEM CHECK OR MAINTENANCE JOB [7909 km | 9000km | 6000km | 9000 km ] 12000 km (600 mi) | (1900mi) | (3700 mi) | (5600 mi) | (7500 mi) i ‘* Check fuel hoses for cracks — 1]+| Fuettine selieeeiehinieael y y y y 7 ‘Check condition. y 1 1 — 2| | Spark plug * Clean and regap. Vv + Replace. - 5 Check valve clearance. Adjust if t+——_ 3] "| Valves V v Y v ’ 4 || Fuel injection * Adjust engine idling speed. y 1 Y ee v sl le ive emis |" Check control system for dam- , p-— | sion control system |, Reciace if necessary.eral maintenance and lubrication chart aml ‘ODOMETER READING CHECK OR MAINTENANCE JOB |1099 km | 3000km ] 6000km | 0000 km | 12000km | 15000 km {600 mi) | (1900 mi) | (3700 mi) | (6600 mi) | (7500 mi) | (9300 mi) Aicftor element -*222. 7 y y v y v * Replace, Every 12000 km (7500 mi *Oh Battery Hal in y 1 1 1 4 1 Chuten im 1 1 1 4 1 1 * Check operation, fluid level and 7 7 7 y y 7 Front brake vehicle fr fu leakage. + Replace brake pads. Whenever worn to the limit Check operation andagustbrake | 7 7 7 7 ; Rear brake Pedal free play. “+ Replace brake shoes. Whenever worn to the limit ~ Check for cracks or damage. : * Check for correct routing and y v 1 v v 1 | Brake hose clamping, Replace. Every 4 years Brake fuld + Replace. Every 2 years Wools * Check runout and for damage. y y v v 7 v * Check tread depth and for dam- age. a“ + Repiace if necessary y v y y q v * Check air pressure. * Correct if necessarv.‘ODOMETER READING No. Tem (CHECK OR MAINTENANCE JOB |“jo90 km | 9000 km | 6000Km | 9000 km | 42000 km | 1e00n,| (600 mi) | (1900 mi) | (3700 mi) | (8600 mi) | (7500 mi) | (9300 4| N * Check bearing for looseness or 1 Y v Y y 1 a fl 10] * | Wheel bearings te ferns wee * Lubricate with ithium-soap- oe Every 10000 km (6000 mi) * Check operation and for exces- y v v v y 4 sive play. 11] | swingarm Tides aan i “Lubricate with ithium-soap- atadgease Every 12000 km (7500 mi) * Check chain slack, alignment and condition. Every 2000 km (1200 mi) and after intial 500 km (300mi) and after }12|_ | Drive chain * Adjust and thoroughly lubricate ‘washing the motoreycle, riding in the rain or riding in wet areas chain with engine oll ‘Check bearing play and steering Y Y Y 7 a A for roughness. Y y + | steering bearings * Lubricate with lthium-soap- frome Every 12000 km (7500 mi) 7 ‘ ‘Make sure that allt, botts and | q : ; 114] °| Chassis fasteners | ene oC operty tightened. au a 7 7 115] | Brake lever pivot | « ubvicate with slicone grease. 1 v v v y v 6|. | Brake pedal pivot | » Lubricate with ithium-soap- Y 1 v y y : shaft based grease. v 17| | Clutch lever pivot |» Lubricate with Ithium-soap- Y ¥ Y 1 ee shaft based grease. qJ ‘ODOMETER READING 15000 km a mew (CHECK OR MAINTENANCE JOB |909km | s000Km | 6000km | 9000km | 12000km | 1 (600 mi) | (1900 mi) | (3700 mi | (6600 mi) | (7500 mi) | (9300 mi) gat '* Check operation, yg] | Sidestanch center: | ricate with ithium-soap- v v v y v y stand based grease. ‘Check operation and fr alleak= | y Y y v v Front fork age. Repair itnecessary. [+ Repiace oi Every 10000 km (6000 mi) .| Shock absorber as- | + Check operation and shock ab- a y a sembly sorber for oil leakage. 4 : : _ i * Change. (8 2) v v v v v \22| | Engine oil jetta dad * Check vehicle for oil leakage. Every 3000 km (1800 mi) \23| ee ‘Replace. v v v Vv Vv v Proreandear | «check operation. v Y y y y YPERIODIC MAINTENANCE AND ADJUSTMENT. mp © 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 intemal components of the brake master cylinder and caliper, and change the fluid. ‘+ Replace the brake hoses every four years and if cracked or damaged.PERIODIC MAINTENANCE AND ADJUSTMENT Removing and installing pan. els The panels shown need to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time a panel needs to be removed and installed. Panel A and B a i 1. Place the panel in the original po- ke q sition, and then install the screws. Toremove a pane! 1. Remove the rider seat. (See page 2. Install the seats. E 3-9) 2. Remove the screws from the pan- al 3. To remove the panel, pull the top side outward and lift up. To install aPERIODIC MAINTENANCE AND ADJUSTMENT Checking the spark plug The spark plug is an important engine ‘component, which is easy to check Since heat and deposits will cause any spark plug to slowly erode, the spark plug should be removed and checked in accordance with the periodic main- tenance and lubrication chart. In addi- tion, the condition of the spark plug can reveal the condition of the engine. To remove the spark plug 1. Remove the spark plug cap. 2. Remove the spark plug as shown, with the spark plug wrench includ- €d in the owner's tool kit. 1. Spark plug wrench 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 vehi- cle is ridden normally). TP If the spark plug shows a distinctly dif- ferent color, the engine could be oper- ating improperly. Do not attempt to diagnose such problems yourself. In- stead, have a Yamaha dealer check the vehicle. peat a 2. Check the spark plug for electey in erosion and excessive caryoy T other deposits, and replace 1, necessary. Specified spark plug: ~ NGK/CPR8EA-9 Ls 3. Measure the spark plug gap with, wire thickness gauge and, if neo essary, adjust the gap to speci cation. 1. Spark plug gap Spark plug gap: 0.8-0.9 mm (0.031-0.085 in)oinstall the spark plug 4, Clean the surface of the spark plug gasket and its mating sur- face, and then wipe off any grime from the spark plug threads. Install the spark plug with the spark plug wrench, and then tight- en it to the specified torque. | Tightening torque: ‘Spark plug: 13 Nm (1.3 m-kgf, 9.4 ft-bf) ae Ee if @ torque wrench is not available when installing a spark plug, a good estimate of the correct torque is 1/4 ‘V/2tum past finger tight. However, the spark plug should be tightened to the ‘Specified torque as soon as possible. 3. Install the spark plug cap. PERIODIC MAINTENANCE AND ADJUSTMENT Canister THROTTLE Booy Cr FROM ; FUEL TANK CANISTER TO ATMOSPHERE zave nes This model is equipped with a canister to prevent the discharging of fuel vapor into the atmosphere. Before operating this vehicle, make sure to check the following: © Check each hose connection. © Check each hose and canister for cracks or damage. Replace if damaged. @ Make sure that the canister breather is not blocked, and if necessary, clean it. Engine oil and oil fitter ele.” ment The engine oil level ‘should be checked before each ride. In addition, the oi Must be changed and the oil filter ele- ‘ment replaced at the intervals. ‘specified in the periodic maintenance and lubri- cation chart To check the engine oil level 1. Place the vehicle on the center- stand. A slight tilt to the side can result in a false reading. 2. Start the engine, warm it up for ‘several minutes, and then tum it oft 3. Wait a few minutes until the olset- tles, remove the engine oil filer cap, wipe the dipstick clean, insert it back into the oil filler hole (with- out screwing it in), and then re- ‘move it again to check the oil level NOTICE: Do not operate the ve~ hicle until you know that the en- gine oil level is sufficient. rowsPERIODIC MAINTENANCE AND ADJUSTMENT 4. If the engine oil is below the mini mum level mark, add sufficient oil of the recommended type to raise itto the correct level. 5. Install and tighten engine oil filler cap. To change the engine oil (with or metas without oil filter element replace- # i filler Cap 9 Engine oi 1. Start the engine, warm it up for ua several minutes, and then turn it off. The engine oil should be between the minimum and maximum level marks. 2+ Place an oil pan under the engine to collect the used oil. 3. Remove the engine oil filer cap with the O-ring, then the engine oil Oey drain bolt to drain the oil from the 7 crankcase. 2 7 i—3 ie meres 1. Dipstick 1. Engine oil drain bolt Le Skip steps 4-6 if the oil fitter elem Not being replaced. 4. Remove the oil filter element oot by removing the bolts. 1. Bott 2. Oilfiter element coverand replace the oil fiter clement and O-ring. fete element 100g 6. stall the oil filter element cover by instaling the bolts, then tight- fing them to the specified torque. Tightening torque: Otter element cover bolt: 10Nm (1.0 mkgf, 7.2 fbf Th. re ele sure that the O-ring is properly ime e O-ring is pi jo 7. Isalthe engine ol drain bott, and new gasket, and then tighten the | Pottto the specified torque. PERIODIC MAINTENANCE AND ADJUSTMENT Tightening torque: Engine oil drain bott: 20 Nim (2.0 mk, 14 feb) 8. Refill wth the specified amount of the recommended engine oil, and then install and tighten the oil filer cap. Recommended engine oi: See page 8-1 il quantity: Without ol iter element replace- ‘ment 4.00 L (1.08 US qf, 0.88 [Link]) With oil iter element replacement: 4.10 L (1.16 US at, 0.97 [Link]) . ————— ah @ In order to prevent clutch slip- page (since the engine oil aso lubricates the clutch), do not mix any chemical additives. Do not use oils with a diesel spect- fication of “CD” or oils of a high- er quality than specified. In ‘addition, do not use oils labeled "ENERGY CONSERVING I!” or higher. att (© Make sure that no foreign mate- tial enters the crankcase, ee eee 9. Startthe engine, and then letitidle {or several minutes while checking it for oil leakage. If ois leaking, immediately tum the engine off and check for the cause, ‘Tum the engine off, wait for afew minutes until the oil sets, and then check the oil level and oor- rect tif necessary. 10.PERIODIC MAINTENANCE AND ADJUSTMENT Cleaning the air filter element The air filter element should be cleaned at the intervals specified in the periodic maintenance and lubrication chart. Clean the air filter element more fre- quently if you are riding in unusually wet or dusty areas. 1. Remove the rider seat. (See page 3-9) 2, Remove panel A. (See page 6-7.) 3. Remove the air filter case cover by removing the screws, and then pull the air filter element out. 1. Air fit element 4. Lightly tap the air filter element to remove most of the dust and dirt, and then blow the remaining dirt out with compressed air as shown. If the air filter element is damaged, replace it. 1. Air filter element 5. Insert the air filter element into air filter case. NOTICE: sure that the air filter element, properly seated in the air fity case. The engine should neve be operated without the air fite element installed, otherwise th piston(s) and/or cylinder(s) ma become excessively won once 6. Install the air filter case cover b installing the screws. TIP. If dust or water collects in the air fite check hose, remove the clamp from! and then remove the plug to drain th hose. 7. Install the panel and seats. eS eS con ee KO ea onpeuonneodweaes I >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 engine should be warm and head- ight should be ON before making this adjustment. Check the engine idling speed and, if necessary, adjust it to specification by uming the idle adjusting screw. To in- crease the engine idling speed, tum he screw in direction (a). To decrease he engine idling speed, turn the screw n direction (b).. 1 Ile acsting screw ing speed: 1300-1500 r/min TIP. SS eA CT If the specified idl 19 speed cannot be obtained as described above, have a Yamaha dealer make the adjustment. EE eater make the adjustment, zweraat 4. Throttle grip free play a The throttle grip free play should mea- ‘sure 3,0-5.0 mm (0.12-0.20 in) at the inner edge of the throttle grip, Periodi- cally check the throttle grip free play and, if necessary, adjust it as follows. TIP The engine idling speed rust be cor- rectly adjusted before checking and adjusting the throttle grip free play. 1. Slide the rubber cover baok at the throttle cable. 2. Loosen the locknut.PERIODIC MAINTENANCE AND ADJUSTMENT 4, To increase the throttle grip free play, tun the throttle grip free play agjusting nut in direction (a). To decrease the throttle grip free play, tum the adjusting nut in di- rection (b). 3, Adjusting nut 4. Tighten the locknut. 5. Slide the rubber cover back to its original position. 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. Tires a Tires are the only contact between vehicle and the road. Safety inal cg ditions of riding depends on area = small area of road contact. Therefor, is essential to maintain the tires inom condition at all times and replace te at the appropriate time with the spes fied tires t t ‘ Tire air pressure The tire air pressure should b checked and, if necessary, adjust before each ride. Operation of this vehicle with in proper tire pressure may cause & - vere injury or death from loss # control. © The tire air pressure must checked and adjusted on 0 tires (Le., when the temperati! of the tires equals the ambie temperature). r © The tire air pressure a. adjusted in accordance with riding speed and with the t cweight of rider, passenger, car. go, and accessories approved for this model. eaten Ae LI ————————— Tire air pressure (measured o fate n cold Front: 200 kPa (2.00 kat/cme, pts gf/cm?, 29 psi) 225 kPa (2.25 kgt/cm?, 33 psi) Maximum load": 198 kg (437 Ib) * Total weight of rider, passenger, car- go and accessories iever overload your vehicle. Opera- ion of an overloaded vehicle could cause an accident. —$—$— PI ERIODIC MAINTENANCE AND ADJUSTMENT Tire inspection zane 1. Tire sidewall 2. Tire tread depth The tires must be checked before each ride. If the tire tread shows crosswise lines (minimum tread depth), if the tire hhas a nail or glass fragments in it, or if the sidewall is cracked, have a Yamaha dealer replace the tire immediately. Minimum tire tread depth (front and rea nh: 4.0. mm (0.04 in) | Cn clisiiaaiahal eT 7G ______—_ @ Have a Yamaha dealer replace cle with excessively wom tires decreases riding stability and can lead to loss of control. © The replacement of all wheel and brake-related parts, includ- ing the tires, should be left to a Yamaha dealer, who has the Necessary professional know!- ‘edge and experience to do so. © Ride at moderate speeds after changing a tire since the tire surface must first be “broken in” for it to develop its optimal eae Tire information This model is equipped with tubeless tires and tire air valves. Tires age, even if they have not been used or have only been used occasion- ally. Cracking of the tread and sidewall rubber, sometimes accompanied by carcass deformation, is an evidence of ageing. Old and aged tires shall be checked by te specialists to ascertain their suitability for further use.easower pany Cast wheels To maximize the performance, durabil- ity, and safe operation of your vehicle, note the following points regarding the 2 front and rear tires should be of 2 same make and design, other- se the handling characteristics of > vehicle may be different, which Specified wheels. wuld lead to an accident. @ The wheel rims should be checked for cracks, bends, warp- age or other damage before each ride. If any damage is found, have a Yamaha dealer replace the eee Heroes EL ter extensive tests, only the tires list- 4 below have been approved for this rodel by Yamaha. $$ wheel. Do not attempt even the Front tire: smallest repair to the wheel. A de- formed or cracked wheel must be Size: 400/80-17M/C 52P ‘Manufacturer/model: MRF/ZAPPER-FX1 replaced. The wheel should be balanced whenever either the tire or wheel Manufacturer/model: GEAT/ZOOM PLUS F has been changed or replaced. An eT unbalanced wheel can result in Size y60-RI7M/C 63P poor performance, adverse han- Manufacturer/model: dling characteristics, and a short- MRF/revz-Y ened tire life. Manufacturer/model: ‘CEAT/ZOOM-RAD Adjusting the clutch levers play 1, Rubber cover 2. Locknut 3, Clutch lever free play adjusting bolt 4, Clutch lever free play The clutch lever free play should m sure 10.0-15.0 mm (0.39-0.59 i) shown. Periodically check the cl lever free play and, if necessary, 24 it as follows. 1. Slide the rubber cover back at clutch lever. 2. Loosen the locknut. ast lever f