Yamaha Libero 65, Owner'S Manual

Page 1: ...INTED IN INDIA 2Y14 OM 01 284 11 06 E ger Engine Life wer Maintenance Cost wer Exhaust Smoke uces Wear and Tear SG SG 4 STROKE MOTOR OIL 20W40 4 OWNER S MANUAL 1B5 F8199 E0 1B56 YAMAHA YAMAHA 1B5 F8199 E0 ...

Page 2: ...R S MANUAL YAMAHA MOTOR INDIA PVT LIMITED All rights reserved Any reprinting or unauthorised use without the written permission of YAMAHA MOTOR LIMITED is expressly prohibited INDIA PVT WARNING PLEASEREADTHISMANUALCAREFULLYANDCOMPLETELYBEFOREOPERATINGTHISMOTORCYCLE ...

Page 3: ... please take due care and ensure proper maintenance of your Motorcycle as recommended in this Owner s Manual Always demand only Genuine Spare Parts and Yamalube oil If you have any queries regarding the operation or maintenance of your Motorcycle please consult your DEALER who will be too happy to help you This Owner s Manual also includes the GREEN BOOK containing Guidelines DO s and DON Ts to be...

Page 4: ...ailable at the time of printing there may be minor discrepancies between your Motorcycle and this manual If there is any question concerning this manual please consult yourYAMAHA dealer The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED NOTE CAUTION WARNING Failure to follow WARNING instructions to the Motorcycle operator a bystander or a person inspecting or repairing th...

Page 5: ... 7 Seat 3 8 Storage compartment 3 9 Rear shock absorber adjustment 3 9 Handle Seat Lifting Handle stay Lock 3 10 PRE OPERATION CHECKS 4 1 Pre operation check list 4 1 OPERATION AND IMPORTANT RIDING POINTS 5 1 Starting and warming up a cold engine 5 1 Starting a warm engine 5 2 Shifting 5 2 Tips for reducing fuel consumption 5 3 Running in 5 3 Parking 5 4 PERIODIC MAINTENANCE AND MINOR REPAIR 6 1 T...

Page 6: ...t pedal lubrication 6 22 Brake and clutch lever lubrication 6 22 Center and sidestand lubrication 6 22 Front fork inspection 6 23 Steering inspection 6 23 Wheel bearings 6 24 Battery 6 24 Fuse replacement 6 26 Headlight bulb replacement 6 27 Turn signal and taillight bulb replacement 6 28 Front wheel removal 6 28 Front wheel installation 6 30 Rear wheel removal 6 30 Rear wheel installation 6 32 Tr...

Page 7: ...to know its capabili ties and limitations 5 Ride thoughtfully planning your route well in advance 6 Give proper Signals and use Horn and Headlights judiciously 7 Don t ride in another motorist s blind spot 8 Always make pre ride safety checks before you start the Engine SAFE BRAKING Use the basic methods of braking effectively 1 Engine Brake When the Throttle is released compression backs up and a...

Page 8: ...hain free play check window page 6 19 9 Side panel L H lock page 6 5 10 Shift pedal page 3 4 1 Fuel cock page 3 6 2 Starter Lever page 3 7 3 Fuse page 6 26 4 Battery page 6 24 5 Storage Compartment page 3 9 STANDARD VEHICLE 1 3 4 2 8 9 10 7 5 6 Libero5TS8 pmd 11 3 2006 8 50 PM 4 ...

Page 9: ...Rear shock absorber page 3 9 12 Air filter page 6 10 13 Kick starter page 3 7 14 Seat page 3 8 15 Engine oil filler cap page 6 8 16 Rear brake pedal page 3 4 6 17 STANDARD VEHICLE 15 11 12 13 14 16 Libero5TS8 pmd 11 3 2006 8 50 PM 5 ...

Page 10: ...switch Cum Steering Lock Page 3 1 21 Fuel Gauge page 3 2 22 Front Brake Lever page 3 4 6 16 23 Throttle Grip page6 12 24 Fuel Tank Cap page 3 5 25 Turn Indicator Switch page 3 2 Controls Instruments DESCRIPTION STANDARD VEHICLE 2 3 24 17 18 19 20 21 23 25 22 Libero5TS8 pmd 11 3 2006 8 50 PM 6 ...

Page 11: ... be removed in this position 1 Push 2 Release 3 Turn LOCK The steering is locked in this position and all electrical circuits are switched off The key can be removed in this position To lock the steering turn the handle bars all the way to the left or right With the key at OFF push it into the main switch and release it turn it counter clockwise to LOCK and remove it To release the lock turn the k...

Page 12: ...y of the remaining petrol in the fuel tank The gauge needle moves from F Full to E Empty as the fuel level decreases When the needle comes below E please refill the fuel tank at the earliest Indicator lights 1 Turn indicator light 2 Neutral indicator light N 3 High beam indicator light The indicator flashes when the turn switch is moved to the left or right This indicator comes on when the transmi...

Page 13: ...ight switch to turns the headlight on also 1 Clutch lever Clutch lever The clutch lever is located on the left handlebar Pull the clutch lever to the handlebar to disengage the clutch and release the lever to engage the clutch The lever should be pulled rapidly and released slowly for smooth clutch operation INSTRUMENT AND CONTROL FUNCTIONS 3 3 1 PassSwitch 2 Dimmer Switch 3 Light switch 4 Turn si...

Page 14: ... toe to shift down 1 Front brake lever Front brake lever The front brake lever is located on the right handlebar Pull it toward the handlebar to apply the front brake 1 Rear brake pedal Rear brake pedal The rear brake pedal is on the right side of the Motorcycle Press down on the brake pedal to apply the rear brake INSTRUMENT AND CONTROL FUNCTIONS USE BOTH BRAKES SIMULTANEOUSLY 3 4 ...

Page 15: ...not overfill the fuel tank Avoid spilling fuel on the hot engine Do not fill the fuel tank above the bottom of the filler tube to avoid Spillage 1 Open Fuel tank cap TO OPEN Insert the key and turn it 1 4 turn clockwise The lock will be released and the cap can be opened TO CLOSE Push the tank cap into position with the key inserted To remove the key turn it counterclockwise to the original positi...

Page 16: ...he fuel cock has three positions which should be set as shown in the illustrations OFF With the fuel cock in this position fuel will not flow Always set the fuel cock to this position when the engine is not running 1 Arrow mark ON With the fuel cock in this position fuel flows to the carburettor Set the fuel cock to this position when starting the engine and while riding INSTRUMENT AND CONTROL FUN...

Page 17: ...the gears engage then kick smoothly and forcefully to start the engine This model has a primary coupled kick starter so the engine can be started in any gear if the clutch is disengaged However shifting to neutral before starting is recommended kick INSTRUMENT AND CONTROL FUNCTIONS 3 7 NEVER MIX OIL IN PETROL 1 Starter lever Starter lever Starting a cold engine requires a richer air fuel mixture A...

Page 18: ...o bolts 1 and 2 as shown in figure Lift the front of the seat and slide forward to remove 1 Seat Holder 2 Projection To install Insert the projection on the rear of seat in to seat holder Then push down on front of the seat and tighten the bolts on the left and right hand side of the seat ALWAYS USE A HELMET WHILE RIDING FOR YOUR SAFETY 1 ...

Page 19: ... preload as follows Turn the adjusting ring in direction a to increase spring preload and in direction b to decrease spring preload Make sure that the appropriate notch in the adjusting ring is aligned with the position indicator on the rear shock absorber Always adjust each shock absorber to the same setting Uneven adjustment can cause poor handling and loss of stability INSTRUMENT AND CONTROL FU...

Page 20: ...INSTRUMENT AND CONTROL FUNCTIONS 3 10 1 HandleSeat 1 1 Stay Lock Stay Lock For mounting Helmet Lock ...

Page 21: ...ol and meter cable Wheels and tyres Drive chain Clutch Throttle grip and housing Rear brake Front brake Lubricate if necessary Check tyre pressure wear damage and spoke tightness Lubricate if necessary Check for smooth operation Lubricate if necessary Check for smooth operation Tighten spokes if necessary Adjust if necessary 6 21 6 22 6 13 6 15 6 18 6 21 Check oil level Fill with oil if necessary ...

Page 22: ...and sidestand pivot Make sure that all nuts bolts and screws are properly tightened Tighten if necessary Check fuel level Fill with fuel if necessary Fill with distilled water if necessary Check fluid level Check for proper operation 6 24 6 26 3 3 6 27 6 28 3 5 3 7 Lubricate if necessary Check for smooth operation Lubricate if necessary Check for smooth operation ITEM CHECKS 6 22 PAGE 6 22 IF WAIT...

Page 23: ...rner Starting and warming up a cold engine 1 Turn the fuel cock to ON 2 Turn the main switch to ON 3 Shift the transmission into neutral When the transmission is in neutral the neutral indicator light should be on If the light does not come on ask a YAMAHA dealer to inspect it 4 Fully open the Starter Lever and completely close the throttle grip 5 Kick the kick starter to start the engine 6 After ...

Page 24: ... The use of the shift pedal is shown in the illustration To shift into neutral depress the shift pedal repeatedly until it reach es the end of its travel then raise the pedal slightly Do not ride downhill with Ignition Switch in OFF Position in Neutral Gear Always ride motor cycle with Ignition Switch in ON Position in Neutral Gear Always use the clutch when changing gears The engine transmission ...

Page 25: ...s never a more important period in the life of your Motorcycle than the period between zero and 1 000 kms For this reason we ask that you carefully read the following material Because the engine is brand new you must not put an excessive load on it for the first 1 000 kms The various parts in the engine wear and polish themselves to the correct operating clearances During this period prolonged ful...

Page 26: ...king When parking the Motorcycle stop the engine and remove the ignition key Turn the fuel cock to OFF whenever stopping the engine The exhaust system is 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 WARNING ...

Page 27: ...T EACH OWNER ALTER THIS TIME SCHEDULE TO SHORTER INTERVALS TO MATCH THE ENVIRONMENT The most impor tant points of Motorcycle inspection adjustment and lubrication are explained in the following pages If you are not familiar with Motorcycle service this work should be done by a YAMAHA dealer 1 Tool kit Tool kit The service information included in this manual is intended to provide you the owner wit...

Page 28: ...ou do not have necessary tools required during a service operation take your Motorcycle to a YAMAHA dealer for service Modifications to this Motorcycle not approved by YAMAHA may cause loss of performance and render it unsafe for use Consult a YA M A H A d e a l e r b e f o r e attempting any changes 6 2 ...

Page 29: ...lter bowl replace if necessary Replace with recommended oil Yamalube SG Grade Warm engine before draining Wash with petrol Check operation Adjust if necessary Grease the brake cam ITEM OPERATION SNO 1 2 3 5 4 6 7 8 9 WHEELS 13 FRONT REAR REAR ARM PIVOT CLUTCH 12 11 BRAKE SHOES 10 Check runout spoke tightness damage Correct it if necessary Check for wear replace if necessary Check alignment marks o...

Page 30: ...s for looseness Tighten as per specification Check operation and lubricate if necessary Check electrolyte level and top it up if necessary Check specific gravity and charge if required Check breather pipe for blockage and routing CONTROL CABLES THROTTLE CLUTCH FRONT BRAKE 18 19 20 21 BATTERY 22 Readjust or replace as required Check operation free play cable damage EVERY MONTH IT IS RECOMMENDED THA...

Page 31: ...Refer to this section each time a panel has to be removed or reinstalled 2 Panel B PERIODIC MAINTENANCE AND MINOR REPAIR 6 5 1 Lug 2 Panel A 3 Lug Removal of Panel A Unlock the panel Pull the lug 1 towards you to remove it from the fuel tank Slide the panel A towards the Front of the motorcycle for removing the lug 3 to free the panel 2 3 1 2 1 ...

Page 32: ...n of Panel A Slide the panel towards the Rear of the motorcycle for inserting the lug 2 in the slot given in the frame Insert and push the lug 1 in the fuel tank ensuring proper seating After proper seating of the panel A lock it 1 Lug 2 Lug Installation of Panel B Follow the same procedure as given for installation of panel A and tighten the screw for locking 2 1 1 2 1 2 1 ...

Page 33: ... sive or if carbon and other deposits are excessive you should replace the spark plug with the specified plug Before installing the spark plug measure the electrode gap with a wire thickness gauge adjust the gap to specification as necessary PERIODIC MAINTENANCE AND MINOR REPAIR 6 7 A Spark plug gap 0 8 0 1 mm When installing the plug always clean the gasket surface and use a new gasket Wipe off a...

Page 34: ... side can result in false readings 1 Maximum level 2 Minimum level Wait a few minutes until the oil level settles before checking b Unscrew the dipstick and rest it on the threads of the oil filler hole The oil level should be between the minimum and maximum mark on the dip stick If the level is low add oil to raise it to the specified level PERIODIC MAINTENANCE AND MINOR REPAIR 6 8 NOTE 1 Dipstic...

Page 35: ... Drain plug 14 5 It lb 2 0 m kg e Fill engine with oil and install the dipstick Recommended oil YAMALUBE 4 stroke motor oil 20W40 type SG Oil quantity Total amount 1 2 L Periodic oil change 1 0 L PERIODIC MAINTENANCE AND MINOR REPAIR 6 9 f Start the engine and warm up for a few minutes While warming up check for oil leak age If oil leakage is found stop the engine immediately and check for the cau...

Page 36: ...ation procedures 2 Remove the air filter case fitting screws and the air filter case cover 1 Air filter element 2 Lockable SpringWire PERIODIC MAINTENANCE AND MINOR REPAIR 6 10 3 Remove the air filter from the case 4 Unlock the spring wire 1 Air filter element 2 Frame 6 Apply recommended oil to the entire surface of the each element and squeeze out the excess oil They should be wet but not drippin...

Page 37: ...tor is a vital part of the engine and requires very sophisti cated adjustments Most adjust ments should be left to a YAMAHA dealer who has the professional knowledge and experience to do so However the following may be serviced by the owner as part of routine maintenance The carburetor is set at the YAMAHA factory after many tests If the settings are changed poor engine performance and damage may ...

Page 38: ...eed by adjusting the throttle stop screw Turn the screw in direction a to increase engine speed and in direction b to decrease engine speed Standard idle speed 1 300 1 500 r min If the specified idle speed cannot be obtained by performing the above adjustment consult a dealer YAMAHA Throttle cable free play adjustment Before checking the throttle cable free play the engine idling speed should be a...

Page 39: ...e clearance changes with use resulting in improper fuel air supply or engine noise To prevent this the valve clearance must be adjusted regularly This adjustment however should be left to a YAMAHA dealer 1 Tread depth 2 Side wall Tyres To ensure maximum performance long service and safe operation note the following 1 Tyre air pressure Always check and correct the tyre pressure before operating the...

Page 40: ...adjust the suspension for your load and check the condition and pressure of your tyres NEVER O V E R L O A D Y O U R MOTORCYCLE Make sure the total weight of the cargo rider passenger and accessories fairing saddlebags etc approved for this model does not exceed the maximum load of the Motorcycle Operation of an over loaded Motorcycle could cause tyre damage an accident or even injury 2 Tyre inspe...

Page 41: ...maged If any abnormal condition exists in a wheel consult a YAMAHA dealer Do not attempt even small repairs to the wheel If a wheel is deformed or cracked it must be replaced 2 Tyres and wheels should be balanced whenever either one is changed or replaced Failure to have a wheel balanced can result in poor performance adverse handling characteristics and shortened tyre life 3 Ride at moderate spee...

Page 42: ...ghten the locknut è ç If proper adjustment cannot be obtained or the clutch does not work correctly ask a dealer to inspect the internal clutch mechanism YAMAHA 1 Adjusting nut 2 Free play Front brake adjustment The front brake lever free play should be adjusted to 10 15 mm 1 Turn the adjusting nut in direction to increase free play and direction to decrease free play ç è When it is impossible to ...

Page 43: ...ing the rear brake 1 Brake light switch 2 Adjusting nut Brake light switch adjustment The rear brake light switch is acti vated by the brake pedal and is properly adjusted when the brake light comes on just before braking takes effect To adjust the rear brake light switch hold the switch body so it does not rotate while turning the adjusting nut Turn the adjusting nut in direction ç to make the br...

Page 44: ...AMAHA dealer to replace the shoes 1 Wear limit line 2 Wear indicator 1 Free play Drive chain slack check Spin the wheel several times and find the tightest position of the chain Check and or adjust the chain slack while it s in this tightest position Inspect the drive chain when the Motorcycle is on the centerstand Check the slack at the position shown in the illustration Normal slack is approxima...

Page 45: ...sen the axle nut 1 Locknut 2 Adjusting hex screw 4 Loosen the chain adjusting locknuts on each chain puller To tighten the chain turn the chain adjusting hex screw in direction b to loosen the chain turn the chain adjusting hex screw in direction a and push the wheel forward Turn each chain adjusting hex screw exactly the same amount to maintain correct axle alignment There are marks on each chain...

Page 46: ... Left and Right Side Tightening torque Axle nut 65 ft lb 9 05 m kg 1 Cotter pin 6 Insert a new cotter pin into the axle nut and bend the end of the cotter pin as shown If the notch in the axle nut and the cotter pin hole do not match tighten the nut slightly to align them Always use a new cotter pin on the axle nut 7 Adjust the free play in the brake pedal Check the operation of the brake light af...

Page 47: ...hain Cable inspection and lubrication Damage to the outer housing of cables may lead to internal rusting and interfere with the cable movement Replace damaged cables as soon as possible to prevent unsafe conditions Lubricate the cables with anti corrosive oil and cable ends If a cable does not operate smoothly ask a YAMAHA dealer to replace it Recommended lubricant 20W40Type SG Throttle cable and ...

Page 48: ...ing parts MULTIPURPOSE Recommended Grease Center and sidestand lubrication Lubricate the pivoting and mating joints Check to see that the center and sidestand move up and down smoothly Recommended lubricant If the center and or sidestand does not move smoothly consult aYAMAHA dealer 20W40Type SG PERIODIC MAINTENANCE AND MINOR REPAIR 6 22 WARNING ...

Page 49: ... and check if the fork rebounds smoothly If any damage or unsmooth movement is found with the front fork consult aYAMAHAdealer Steering inspection Periodically inspect the condition of the steering Worn out or loose steering bearings may be danger ous Place a stand under the engine to raise the front wheel off the ground Hold the lower end of the front forks and try to move them forward and backwa...

Page 50: ...spect the wheel bearings 1 Maximum level mark 2 Minimum level mark Battery 1 Battery is located inside the L H side panel for removal installation of L H side panel please refer page 6 5 2 Open the lid 3 Check the level of the battery electrolyte and make sure that the terminals are tight Top up with distilled water if the electrolyte level is low PERIODIC MAINTENANCE AND MINOR REPAIR 6 24 WARNING...

Page 51: ...sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Always shield your eyes when working near batteries KEEP OUT OF REACH OF CHILDREN Replenishing the battery fluid Normal tap water contains minerals which are harmful to a battery therefore refill only with distilled water Take care not to spill battery fluid on the chain Battery fluid may weaken the chain causin...

Page 52: ... motorcycle Make sure the breather hose is properly connected and is not damaged or obstructed 1 Main fuse Fuse replacement The fuse is located behind panel A See page 6 6 for panel removal and installation procedures If the fuse is blown turn off the main switch Install a new fuse of proper amperage Turn on the switches and see if the electrical device operates If the fuse immediately blows again...

Page 53: ...ght bulb holder from bezel 1 Bulb Halogen Keep flammable products and your hands away from the bulb while it is on as it is hot Do not touch the bulb until it cools down 4 Remove the defective bulb 5 Put a new bulb into position and secure it in place with the bulb holder 6 Install the Head LightAssy 7 If the headlight beam adjustment is necessary ask a YAMAHA dealer to make adjustment PERIODIC MA...

Page 54: ... inward and turn it clockwise until it engages into the socket 4 Install the lense and the screws 1 Tail lamp Screws 2 Nos Do not over tighten the screws as the lense may break Front wheel removal It is advisable to have a YAMAHA dealer service the wheel S e c u r e l y s u p p o r t t h e Motorcycle so there is no danger of it falling over PERIODIC MAINTENANCE AND MINOR REPAIR 6 28 WARNING CAUTIO...

Page 55: ...usting nut at the wheel hub and remove the cable from the brake cam lever 1 Clip 2 Speedometer cable 4 Remove the speedometer cable from the front wheel side First remove the clip and then pull the cable out 1 Cotter pin 2 Axle nut 5 Remove the cotter pin and axle nut 6 Remove the wheel axle Make sure the Motorcycle is properly supported PERIODIC MAINTENANCE AND MINOR REPAIR 6 29 ...

Page 56: ...ork outer tube 2 Make sure the axle nut is properly torqued and a new cotter pin is installed Always use a new cotter pin Axle nut torque 33 ft lb 4 55 m kg 3 Adjust the free play in the brake lever PERIODIC MAINTENANCE AND MINOR REPAIR 6 30 WARNING Rear wheel removal It is advisable to service the wheel by aYAMAHAdealer S e c u r e l y s u p p o r t t h e Motorcycle so there is no danger of it fa...

Page 57: ...e brake shoe plate 1 Axle nut 2 Cotter pin 3 Brake rod 4 Brake adjusting nut 3 Remove the brake adjusting nut and brake rod from the brake cam lever 4 Remove the axle nut cotter pin and the axle nut 1 Rear axle 5 Pull out the rear axle 6 Remove the wheel assembly PERIODIC MAINTENANCE AND MINOR REPAIR 6 31 ALWAYS USE YAMAHA GENUINE SPARE PARTS ...

Page 58: ...t the rear brake pedal free play See page 6 17 Troubleshooting Although YAMAHA Motorcycles receive a rigid inspection before shipment from the factory trouble may occur during operation Any problem in the fuel compression or ignition systems can cause poor starting and loss of power The troubleshooting chart describes a quick easy procedure for making checks If your Motorcycle requires any repair ...

Page 59: ...ition check Enough fuel No fuel GO TO compression check in the fuel tank Check if there is fuel Supply fuel Open the throttle half way and start the engine or replace spark plug WARNING Never Check the fuel system while smoking or in the vicinity of an open flame PERIODIC MAINTENANCE AND MINOR REPAIR 6 33 Ask YAMAHA dealer to inspect Troubleshooting chart For Starting 1 Fuel 2 Compression 3 Igniti...

Page 60: ...Bearing Front Fork Brakes Transmission Seals Electrical Parts there by leading to its Detorioration 7 1 Improper cleaning can damage the cowlings panels and other plastic parts Use only a soft clean cloth or sponge with mild detergent and water to clean plastic Do not use any harsh chemical products on plastic parts Alaways use clean cloth or sponge for cleaning the Motorcycle CAUTION 4 After ridi...

Page 61: ... tank 3 Remove the spark plug pour about one tablespoon of SAE 10W30 or 20W40 motor oil in the spark plug hole and reinstall the spark plug Kick the engine over several times with the ignition off to coat the cylinder wall with oil 4 Remove the drive chain Thoroughly clean the chain with solvent and lubricate it Reinstall the chain or store it in a plastic bag tied to frame for safe keeping 5 Lubr...

Page 62: ...ard inclined single cylinder 106 cm mm Kick starter Wet sump PS 5 59 KW 7500 Kgm 6000 3 RPM RPM EngineOil Capacity Air filter Fuel Carburettor Type Periodic oil change 1 0 Total amount Type G Fuel tank capacity Reserve amount Type Variable Venturi Type Manufacturer M S Keihin Fie Private Be sure to use motor oils that do not contain antifriction modifiers Passenger car motor oils often labelled En...

Page 63: ... 14 Transmission type Constant mesh 4 speed Operation Gear ratio 1st 3 2nd 1 688 27 16 3rd 1 200 24 20 4th 0 875 21 24 Frame type Double Cradle Caster angle Trail 91mm Wet multiple disc Left foot operation 000 33 11 26 4o Tyre with Tube Size Front Rear 3 00 Air pressure cold tyre Single Rider Front Rear 33 With Pillion and rider Front Rear 2 75 x18 4PR X18 6PR 25 psi 1 75 Kgf cm psi 2 25Kgf cm 25 ...

Page 64: ...l Electrical Bulb voltage Wattage x Quantity Fuse Front 120 mm Rear 90 mm Ignition system CDI Digitally Timing Generator system Type Standard output 12V Battery Type Voltage capacity Headlight Tail Brake light Front flasher light Rear flasher light Meter light Neutral indicator light High beam indicator light Turn indicator light Tuning Fork Logo 12V 3 4 W x 1 Main Advanced Flywheel magneto Lead a...

Page 65: ... the space provided and use it for reference when obtaining a new key 1 Frame serial number The frame serial number is stamped into the steering head pipe on right hand side Frame serial number 1 Engine serial number The engine serial number is stamped into the right hand crankcase Engine serial number CUSTOMER INFORMATION 9 1 ...

Page 66: ...y at Lever End 10 15 mm Rear Free Play at Rear Brake 20 30 mm b Clutch Free Play at Lever End 10 15 mm c Throttle Free Play at Throttle Grip 3 7 mm d Steering Check for Free Movement e Suspension Front Fork Check for any sticky movement Rear Shock Abs For Free Stroking Setting on both To be filled in by the Dealer on receipt of the Motorcycle from YMIS Odo Meter Reading Date of Inspection Frame No...

Page 67: ...H h Fasteners Specified Torque Ft Lb 1 Front Wheel Axle Nuts 25 40 2 Front Fork Crown Handle Inner Tube 13 20 2 Front Fork under Bracket Stem Nut 18 22 3 Handle Bar Mounting Bolts 13 20 4 Rear Shock Absorber Mounting Bolts 22 35 5 Rear Swing Arm Pivot Shaft Nut 32 52 6 Rear Wheel Axle Sprocket Shaft Nuts 60 70 B ENGINE a Engine Oil Oil Level For checking Refer Pg 6 9 Check for any Leakages 10 2 se...

Page 68: ...ition 1300 1500 RPM Check for Overflow f Drive Chain Alignment Slackness 20 30 mm g Fasteners Specified Torque Ft Lb 1 Cylinder Head Bolts 14 17 2 Engine Mounting a Engine Mounting Front and Stay Front 25 29 b Stay Engine Front and Frame 25 29 c Engine Mounting Rear and Frame 25 29 d Engine Mounting Upper Stay Engine Upper 25 29 e Stay Engine Upper and Frame 25 29 f Engine Mounting Front Lower and...

Page 69: ...e Level Specific Gravity Routing of Breather Pipe Fuse Routing of Positive Wire Red Below Breather Pipe D ROAD TEST a Starting b Gear Shifting Operation c Clutch Operation d Application of Brakes Front and Rear e Speedo Odo Meter Operation f Fuel gauge Operation EXPLAINED BY SIGNATURE _____________ NAME CUSTOMER S SIGN MAIN SELLING DLR S STAMP SIGNATURE service2 pmd 11 3 2006 8 50 PM 4 ...

Page 70: ...lutch pressed 8 Gear shifting pattern 9 Tyre inflation pressure Front 25 Psi Rear 33 Psi Solo 36 Psi Double 10 Never give sudden acceleration always accelerate gradually 11 Simultaneous use of Front and Rear Brakes 12 Never ride with your foot on Rear brake Pedal 13 Whenever parking the Motorcycle on the Side Stand ensure that the Fuel Cock Lever is in closed position 14 Always adjust both the rig...

Page 71: ...in Gear Box level checking and explaining the importance of replacing the Engine Oil after every 2000 KMS Always use YAMALUBE 4T OIL SG Grade 21 TFF oil to be replaced after every 10000 Kms 22 Running In Period Preventive Maintenance Schedule Instructions 23 Information of emission and safety norms AIS CATCON 24 Importance and schedule of Free Services 25 Warranty Terms and Conditions INSTALLATION...

Page 72: ...NOTES NOTES pmd 11 4 2006 10 05 AM 2 ...

Page 73: ...NOTES NOTES pmd 11 4 2006 10 05 AM 3 ...

Page 74: ...NOTES NOTES pmd 11 4 2006 10 05 AM 4 ...

Page 75: ...CONTENTS DO S DON TS for the Motorcycle 1 Procedure for measurement of CO Emission Level 2 List of Components impacting Emission 3 greenbook pmd 11 3 2006 8 50 PM 1 ...

Page 76: ...Plug Check Reset Gap Replace as per the recommendations in this Owner s Manual page no 6 7 b Carburetor Cleaning Adjustment Every 4500 kms c Air Filter Clean every 2000 kms as per the environment conditions d Piston Rings Cylinder Check Clean Replace if necessary e Exhaust System Check Replace if necessary f Valve Timing Check Adjust every 4500 kms g Compression pressure Check Diagnose 6 Always dr...

Page 77: ...good driven habits in varying traffic conditions 12 Switch OFF the engine while waiting at signal point DON TS 1 Don t overload overspeed your Motorcycle 2 Don t after or modify you Motorcycle 3 Never drive with Ignition OFF while moving down a slope 4 Don t turn off the Engine or interrupt the Ignition when the Transmission is in Gear the Motor cycle is in motion 5 Don t idle the Engine for a pro...

Page 78: ...rt the Sampling probe of the Exhaust Gas Analyser inside the Exhaust Muffler of the Motorcycle 2 7 If the reading is within specified limits then it is acceptable If the reading exceeds the norm of 3 5 by volume have it adjusted by YMI Authorised Dealer CO EMISSION LEVEL MEASUREMENT 4 MODEL IDLE R P M 1300 1500 RPM LIBERO a Air Filter b Carburetor c Cylinder d Piston Ring Piston e Cylinder Head f ...

Page 79: ...DUSTRIAL AREA NOIDA DADRI ROAD SURAJPUR 201 306 UP INDIA PRINTED IN INDIA 2Y14 OM 01 284 11 06 E Longer Engine Life Lower Maintenance Cost Lower Exhaust Smoke Reduces Wear and Tear SG 4 STROKE MOTOR OIL 20W40 4 Parts Accessories Always use 1B56 1B5 F8199 E0 ...