Yamaha NOUVO AT115 Owner's manual

5MX-F8199-E0

AT115

PRINTED IN INDONESIA

YAMAHA MOTOR CO., LTD.

OWNER’S MANUAL

Engine start procedure

Engine oil replacement

V-belt inspection

Load limit

Before pushing start button, make sure to

apply the Front or Rear Brake and that the

Sidestand is retracted.

Engine oil replacement : Every 2000 km.

Recommended oil : SAE20W - 50 type

SF Class Motor Oil

Convenience hook : 1 kg, Helmet box: 5 kg

5MX-F835Y-00

Periodic maintenance must be performed

by any authorized Yamaha Dealer (Refer to

the Owner's Manual for details.)

EAU00000

INTRODUCTION

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. If you have any questions concerning the operation

or maintenance of your motorcycle, please consult a Yamaha dealer.

EAU04229*

AT115

OWNER’S MANUAL

1st edition, December 2001

Any reprinting or unauthorized use

without the written permission of

Yamaha Motor Co., Ltd.

is expressly prohibited.

Printed in Indonesia.

U5MXE0.book Page 1 Thursday, December 20, 2001 2:08 PM

EAU00005

IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following notations:

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS

INVOLVED!

WARNING

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.

CAUTION:

A CAUTION indicates special precautions that must be taken to avoid damage to the

motorcycle.

NOTE:

A NOTE provides key information to make procedures easier or clearer.

NOTE:

_

●

This manual should be considered a permanent part of this motorcycle and should remain

with it even if the motorcycle is subsequently sold.

●

Yamaha continually seeks advancements in product design and quality. Therefore, while

this manual contains the most current product information available at the time of printing,

there may be minor discrepancies between your motorcycle and this manual. If you have

any questions concerning this manual, please consult your Yamaha dealer.

_

EW000002

WARNING

_

PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING

THIS MOTORCYCLE.

_

U5MXE0.book Page 1 Thursday, December 20, 2001 2:08 PM

EAU00009

TABLE OF CONTENTS

GIVE SAFETY THE RIGHT OF WAY .................1-1

DESCRIPTION ...................................................2-1

Left view.............................................................2-1

Right view...........................................................2-2

Controls and instruments ...................................2-3

INSTRUMENT AND CONTROL FUNCTIONS ....3-1

Main switch/steering lock ..................................3-1

Indicator lights ...................................................3-2

Speedometer unit ..............................................3-2

Fuel gauge ........................................................3-2

Handlebar switches ...........................................3-3

Front brake lever ...............................................3-4

Rear brake lever ................................................3-4

Fuel tank cap .....................................................3-4

Fuel ...................................................................3-5

Starter (choke) lever ..........................................3-6

Kickstarter .........................................................3-6

Seat ...................................................................3-6

Helmet box ........................................................3-7

Convenience hook .............................................3-8

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

Starting off .........................................................5-2

Acceleration and deceleration ...........................5-3

Braking ..............................................................5-3

Engine break-in .................................................5-4

Parking ..............................................................5-5

General note ......................................................5-6

PERIODIC MAINTENANCE AND MINOR

REPAIR................................................................6-1

Owner’s tool kit ..................................................6-1

Periodic maintenance and lubrication chart ......6-2

Removing and installing the cowling and

panels ............................................................6-4

Checking the spark plug ....................................6-7

Engine oil and oil strainer ..................................6-9

Final transmission oil .......................................6-11

Cleaning the air filter element, V-belt case

air filter elements, and check hoses ............6-13

Adjusting the carburetor ..................................6-16

Adjusting the engine idling speed ...................6-17

Adjusting the throttle cable free play ...............6-17

Adjusting the valve clearance .........................6-18

1

2

3

4

5

6

U5MXE0.book Page 1 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 ......................... 6-24

Changing the brake fluid .................................6-25

Checking the V-belt ......................................... 6-25

Checking and lubricating the cables ...............6-25

Checking and lubricating the throttle grip

and cable ..................................................... 6-26

Lubricating the front and rear brake levers .....6-26

Checking and lubricating the centerstand

and sidestand ..............................................6-27

Checking the front fork ....................................6-27

Checking the steering ..................................... 6-28

Checking the wheel bearings .......................... 6-29

Battery ............................................................. 6-29

Replacing the fuse ..........................................6-31

Replacing a headlight bulb ..............................6-33

Replacing a front turn signal light bulb ............6-34

Replacing the tail/brake light bulb or a rear

turn signal light bulb ....................................6-35

Troubleshooting ..............................................6-37

Troubleshooting chart ..................................... 6-38

MOTORCYCLE CLEANING AND STORAGE.....7-1

A. CLEANING ....................................................7-1

B. STORAGE .....................................................7-1

SPECIFICATIONS...............................................8-1

Specifications ....................................................8-1

CONSUMER INFORMATION..............................9-1

Identification numbers ....................................... 9-1

Frame serial number .........................................9-1

Engine serial number ........................................9-1

7

8

9

U5MXE0.book Page 2 Thursday, December 20, 2001 2:08 PM

1

2

3

4

5

6

7

8

9

1-1

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.

Regular care and maintenance are essential for preserving value and operating condition of your

motorcycle. Moreover, what is true for the motorcycle is also true for the rider: good performance

depends on being in good shape. Riding under the influence of medication, drugs and alcohol is, of

course, out of the question. Motorcycle riders—more than car drivers—must always be at their mental

and physical best. Under the influence of even small amounts of alcohol, there is a tendency to take

dangerous risks.

Protective clothing is as essential for the motorcycle rider as seat belts are for car drivers and

passengers. Always wear a complete motorcycle suit (whether made of leather or tear-resistant

synthetic materials with protectors), sturdy boots, motorcycle gloves and a properly fitting helmet.

Optimum protective wear, however, should not encourage carelessness. Although full-coverage

helmets and suits, in particular, create an illusion of total safety and protection, motorcyclists will

always be vulnerable. Riders who lack critical self-control run the risk of going too fast and are apt to

take chances. This is even more dangerous in wet weather. The good motorcyclist rides safely,

predictably and defensively—avoiding all dangers, including those caused by others.

Enjoy your ride!

U5MXE0.book Page 1 Thursday, December 20, 2001 2:08 PM

2-1

2

EAU00026

2-

DESCRIPTION

Left view

1. Convenience hook (page 3-8)

2. Throttle stop screw (page 6-17)

3. Helmet box, Owner’s tool kit (page 3-7, page 6-1)

4. Kickstarter (page 3-6)

5. Engine oil drain bolt B (page 6-10)

6. Engine oil drain bolt A (page 6-10)

U5MXE0.book Page 1 Thursday, December 20, 2001 2:08 PM

DESCRIPTION

2-2

2

Right view

7. Engine oil filler cap (page 6-9)

8. Air filter element (page 6-13)

9. Battery (page 6-29)

10. Fuses (page 6-31)

U5MXE0.book Page 2 Thursday, December 20, 2001 2:08 PM

DESCRIPTION

2-3

2

Controls and instruments

1. Rear brake lever (page 3-4)

2. Starter choke lever (page 3-6)

3. Left handlebar switches (page 3-3)

4. Speedometer unit (page 3-2)

5. Fuel gauge (page 3-2)

6. Start switch (page 3-3)

7. Throttle grip (page 6-17)

8. Front brake lever (page 3-4)

U5MXE0.book Page 3 Thursday, December 20, 2001 2:08 PM

3-1

3

EAU00027

3-

INSTRUMENT AND CONTROL FUNCTIONS

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.

EAU00038

OFF

All electrical systems are off. The key

can be removed.

EAU00040

LOCK

The steering is locked, and all electrical

systems are off. The key can be re-

moved.

To lock the steering

1. Turn the handlebars all the way to

the left.

2. Push the key in from the “OFF” po-

sition, and then turn it to “LOCK”

while still pushing it.

3. Remove the key.

To unlock the steering

Push the key in, and then turn it to

“OFF” while still pushing it.

EW000016

WARNING

_

Never turn the key to “OFF” or

“LOCK” while the motorcycle is

moving, otherwise the electrical

systems will be switched off, which

may result in loss of control or an

accident. Make sure that the motor-

cycle is stopped before turning the

key to “OFF” or “LOCK”.

_

1. Push.

2. Turn.

U5MXE0.book Page 1 Thursday, December 20, 2001 2:08 PM

INSTRUMENT AND CONTROL FUNCTIONS

3-2

3

EAU00056

Indicator lights

EAU04121

Turn signal indicator lights “”

and “”

The corresponding indicator light flash-

es when the turn signal switch is

pushed to the left or right.

EAU00063

High beam indicator light “”

This indicator light comes on when the

high beam of the headlight is switched

on.

EAU00098

Speedometer unit

The speedometer unit is equipped with

a speedometer and an odometer. The

speedometer shows riding speed. The

odometer shows the total distance trav-

eled.

EAU02950*

Fuel gauge

The fuel gauge indicates the amount of

fuel in the fuel tank. The needle moves

towards “E” (Empty) as the fuel level

decreases. When the needle reaches

the red line, refuel as soon as possible.

NOTE:

_

●

Do not allow the fuel tank to empty

itself completely.

●

Turning the key to “OFF” cancel

the fuel gauge reading.

_

1. Left turn signal indicator light “”

2. Right turn signal indicator light “”

3. High beam indicator light “”

1. Speedometer

2. Odometer

1. Fuel gauge

U5MXE0.book Page 2 Thursday, December 20, 2001 2:08 PM

INSTRUMENT AND CONTROL FUNCTIONS

3-3

3

EAU00118

Handlebar switches

EAU02948*

Light switch “ / ”

Set the light switch to “” to turn on

the headlight and the taillight. Set this

switch to “” to turn them off.

EAU03888

Dimmer switch “ / ”

Set this switch to “” for the high

beam and to “” for the low beam.

EAU03889

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 cen-

ter position. To cancel the turn signal

lights, push the switch in after it has re-

turned to the center position.

EAU00130

Horn switch “HORN”

Press this switch to sound the horn.

EAU00143

Start switch “START”

Push this switch to crank the engine

with the starter.

EC000005

CAUTION:

_

See page 5-1 for starting instruc-

tions prior to starting the engine.

_

1. Light switch “ / ”

2. Dimmer switch “ / ”

3. Turn signal switch “ / ”

4. Horn switch “HORN”

1. Start switch “START”

U5MXE0.book Page 3 Thursday, December 20, 2001 2:08 PM

INSTRUMENT AND CONTROL FUNCTIONS

3-4

3

EAU03882

Front brake lever

The front brake lever is located on the

right handlebar grip. To apply the front

brake, pull this lever toward the handle-

bar grip.

EAU00163

Rear brake lever

The rear brake lever is located on the

left handlebar grip. To apply the rear

brake, pull this lever toward the handle-

bar grip.

EAU03468*

Fuel tank cap

To remove the fuel tank cap

1. Open the seat. (See page 3-6 for

seat opening and closing proce-

dures.)

2. Turn the fuel tank cap counter-

clockwise and pull it off.

1. Front brake lever 1. Rear brake lever 1. Fuel tank cap

a. Open.

b. Close.

U5MXE0.book Page 4 Thursday, December 20, 2001 2:08 PM

INSTRUMENT AND CONTROL FUNCTIONS

3-5

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.

EW000024

WARNING

_

Make sure that the fuel tank cap is

properly installed before riding.

_

EAU03753

Fuel

Make sure that there is sufficient fuel in

the tank. Fill the fuel tank to the bottom

of the filler tube as shown.

EW000130

WARNING

_

●

Do not overfill the fuel tank, oth-

erwise it may overflow when the

fuel warms up and expands.

●

Avoid spilling fuel on the hot

engine.

_

EAU00185

CAUTION:

_

Immediately wipe off spilled fuel

with a clean, dry, soft cloth, since

fuel may deteriorate painted surfac-

es or plastic parts.

_

EAU00187*

1. Fuel tank filler tube

2. Fuel level

Recommended fuel:

Regular gasoline

Fuel tank capacity:

Total amount:

4.9 L

U5MXE0.book Page 5 Thursday, December 20, 2001 2:08 PM

INSTRUMENT AND CONTROL FUNCTIONS

3-6

3

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).

EAU00214

Kickstarter

To start the engine, fold out the kick-

starter lever, move it down lightly with

your foot until the gears engage, and

then push it down smoothly but force-

fully.

EAU03802*

Seat

To open the seat

1. Place the motorcycle on the cen-

terstand.

2. Insert the key into the main switch,

and then turn it counterclockwise.

NOTE:

_

Do not push inward when turning the

key.

_

3. Fold the seat up.

1. Starter (choke) lever “” 1. Kickstarter 1. Open.

U5MXE0.book Page 6 Thursday, December 20, 2001 2:08 PM

INSTRUMENT AND CONTROL FUNCTIONS

3-7

3

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 se-

cured before riding.

_

EAU03450*

Helmet box

There is a helmet box under the seat.

(See page 3-6 for seat opening and

closing procedures.)

EWA00005*

WARNING

_

●

Do not exceed the load limit of

5 kg for the helmet box.

●

Do not exceed the maximum

load of 116 kg for the vehicle.

_

EC000010*

CAUTION:

_

Keep the following points in mind

when using the helmet box.

●

Since the helmet box accumu-

lates heat when exposed to the

sun, do not store anything sus-

ceptible to heat inside it.

●

To avoid humidity from spread-

ing through the helmet box,

wrap wet articles in a plastic

bag before storing them in the

box.

●

Since the helmet box may get

wet while the motorcycle is be-

ing washed, wrap any articles

stored in the box in a plastic

bag.

●

Do not keep anything valuable

or breakable in the helmet box.

_

1. Helmet box

U5MXE0.book Page 7 Thursday, December 20, 2001 2:08 PM

INSTRUMENT AND CONTROL FUNCTIONS

3-8

3

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 un-

attended with the seat open.

_

EAUT0020*

Convenience hook

EWT00002*

WARNING

_

●

Do not exceed the load limit of

1 kg for the convenience hook.

●

Do not exceed the maximum

load of 116 kg for the vehicle.

_

1. Convenience hook

U5MXE0.book Page 8 Thursday, December 20, 2001 2:08 PM

4-1

4

EAU01114

4-

PRE-OPERATION CHECKS

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. Therefore, it is very important, in addition to a thorough visual inspec-

tion, to check the following points before each ride.

EAU03439

Pre-operation check list

CO-01E

ITEM CHECKS PAGE

Fuel

• Check fuel level in fuel tank.

• Refuel if necessary.

• Check fuel line for leakage.

3-5

Engine oil

• Check oil level in engine.

• If necessary, add recommended oil to specified level.

• Check vehicle for oil leakage.

6-9

Final transmission oil

• Check vehicle for oil leakage. 6-11–6-12

Front brake

• Check operation.

• If soft or spongy, have Yamaha dealer bleed hydraulic system.

• Check fluid level in reservoir.

• If necessary, add recommended brake fluid to specified level.

• Check hydraulic system for leakage.

6-21–6-24

Rear brake

• Check operation.

• Check lever free play.

• Adjust if necessary.

6-22–6-23

Throttle grip

• Make sure that operation is smooth.

• Check cable free play.

• If necessary, have Yamaha dealer adjust cable free play and lubricate cable and

grip housing.

6-17–6-18, 6-26

Control cables

• Make sure that operation is smooth.

• Lubricate if necessary.

6-25

Wheels and tires

• Check for damage.

• Check tire condition and tread depth.

• Check air pressure.

• Correct if necessary.

6-19–6-21

U5MXE0.book Page 1 Thursday, December 20, 2001 2:08 PM

PRE-OPERATION CHECKS

4-2

4

NOTE:

_

Pre-operation checks should be made each time the motorcycle is used. Such an inspection can be accomplished in a very

short time; and the added safety it assures is more than worth the time involved.

_

EWA00033

WARNING

_

If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operating

the motorcycle.

_

Brake levers

• Make sure that operation is smooth.

• Lubricate lever pivoting points if necessary.

6-26

Centerstand, sidestand

• Make sure that operation is smooth.

• Lubricate pivots if necessary.

6-27

Chassis fasteners

• Make sure that all nuts, bolts and screws are properly tightened.

• Tighten if necessary.

—

Instruments, lights, signals

and switches

• Check operation.

• Correct if necessary.

—

Battery

• Check fluid level.

• Fill with distilled water if necessary.

6-29–6-31

ITEM CHECKS PAGE

U5MXE0.book Page 2 Thursday, December 20, 2001 2:08 PM

Page is loading ...

Yamaha NOUVO AT115 Owner's manual

Yamaha NOUVO AT115 Owner's manual

Related papers

Other documents