Yamaha FZS1000T FZS1000T(C) Owner's Manual User To The 096e89b9 F275 4918 849e 9e8ef22ca375
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OWNER’S MANUAL FZS1000T FZS1000TC YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2004.10-1.1×1 CR (E) LIT-11626-18-52 1C2-28199-10 U1C210E0.book Page 1 Tuesday, September 21, 2004 1:28 PM EAU10041 U1C210E0.book Page 1 Tuesday, September 21, 2004 1:28 PM INTRODUCTION EAU10080 Congratulations on your purchase of the Yamaha FZS1000/FZS1000C. 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. The design and manufacture of this Yamaha motorcycle fully comply with the emissions standards for clean air applicable at the date of manufacture. Yamaha has met these standards without reducing the performance or economy of operation of the motorcycle. To maintain these high standards, it is important that you and your Yamaha dealer pay close attention to the recommended maintenance schedules and operating instructions contained within this manual. U1C210E0.book Page 1 Tuesday, September 21, 2004 1:28 PM IMPORTANT MANUAL INFORMATION EAU10130 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. EWA10010 WARNING PLEASE READ THIS MANUAL AND THE “YOU AND YOUR MOTORCYCLE: RIDING TIPS” BOOKLET CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE. DO NOT ATTEMPT TO OPERATE THIS MOTORCYCLE UNTIL YOU HAVE ATTAINED ADEQUATE KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES U1C210E0.book Page 2 Tuesday, September 21, 2004 1:28 PM IMPORTANT MANUAL INFORMATION AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES. REGULAR INSPECTIONS AND CAREFUL MAINTENANCE, ALONG WITH GOOD RIDING SKILLS, WILL ENSURE THAT YOU SAFELY ENJOY THE CAPABILITIES AND THE RELIABILITY OF THIS MOTORCYCLE. U1C210E0.book Page 3 Tuesday, September 21, 2004 1:28 PM IMPORTANT MANUAL INFORMATION EAU10192 AFFIX DEALER LABEL HERE FZS1000T/FZS1000TC OWNER’S MANUAL ©2004 by Yamaha Motor Corporation, U.S.A. 1st edition, September 2004 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in Japan. P/N LIT-11626-18-52 U1C210E0.book Page 1 Tuesday, September 21, 2004 1:28 PM TABLE OF CONTENTS SAFETY INFORMATION ..................1-1 Location of important labels ...........1-5 Sidestand ..................................... 3-15 Ignition circuit cut-off system ....... 3-16 DESCRIPTION ..................................2-1 Left view ..........................................2-1 Right view ........................................2-2 Controls and instruments ................2-3 PRE-OPERATION CHECKS ............. 4-1 Pre-operation check list ................. 4-2 INSTRUMENT AND CONTROL FUNCTIONS .......................................3-1 Main switch/steering lock ................3-1 Indicator and warning lights ............3-2 Speedometer unit ...........................3-3 Tachometer unit .............................3-4 Self-diagnosis devices ....................3-4 Fuel gauge .....................................3-5 Handlebar switches ........................3-5 Clutch lever ....................................3-6 Shift pedal ......................................3-7 Brake lever .....................................3-7 Brake pedal ....................................3-7 Fuel tank cap ..................................3-8 Fuel ................................................3-8 Starter (choke) lever .......................3-9 Seat ..............................................3-10 Helmet holder ...............................3-10 Storage compartment ...................3-11 Adjusting the front fork .................3-11 Adjusting the shock absorber assembly ...................................3-13 EXUP system ...............................3-15 OPERATION AND IMPORTANT RIDING POINTS ................................ 5-1 Starting and warming up a cold engine ......................................... 5-1 Starting a warm engine .................. 5-3 Shifting ........................................... 5-3 Engine break-in .............................. 5-4 Parking ........................................... 5-5 PERIODIC MAINTENANCE AND MINOR REPAIR................................. 6-1 PERIODIC MAINTENANCE .......... 6-1 Owner’s tool kit .............................. 6-1 Periodic maintenance chart for the emission control system ............. 6-3 General maintenance and lubrication chart .......................... 6-5 Removing and installing panels ..... 6-9 Checking the spark plugs ............ 6-10 Canister (for California only) ........ 6-11 Engine oil and oil filter cartridge ... 6-12 Coolant ........................................ 6-14 Cleaning the air filter element ...... 6-17 Carburetors .................................. 6-19 Checking the throttle cable free play .................................... 6-19 Valve clearance ............................ 6-20 Tires ............................................. 6-20 Cast wheels .................................. 6-23 Accessories and replacement parts .......................................... 6-23 Adjusting the clutch lever free play .................................... 6-24 Adjusting the rear brake light switch ........................................ 6-24 Checking the front and rear brake pads .......................................... 6-25 Checking the brake fluid level ...... 6-25 Changing the brake fluid .............. 6-26 Drive chain slack .......................... 6-27 Lubricating the drive chain ........... 6-28 Checking and lubricating the cables ....................................... 6-29 Checking and lubricating the throttle grip and cable ............... 6-29 Checking and lubricating the brake and shift pedals ............... 6-29 Checking and lubricating the brake and clutch levers ............. 6-30 Checking and lubricating the centerstand and sidestand ........ 6-30 Lubricating the swingarm pivots ... 6-30 Lubricating the rear suspension ... 6-31 Checking the front fork ................. 6-31 Checking the steering .................. 6-32 U1C210E0.book Page 2 Tuesday, September 21, 2004 1:28 PM TABLE OF CONTENTS Checking the wheel bearings .......6-32 Battery ..........................................6-33 Replacing the fuses ......................6-34 Replacing a headlight bulb ...........6-35 Replacing a tail/brake light bulb ....6-36 Replacing a turn signal light bulb ...........................................6-37 Front wheel ...................................6-37 Rear wheel ...................................6-38 Troubleshooting ............................6-40 Troubleshooting charts .................6-41 MOTORCYCLE CARE AND STORAGE ..........................................7-1 Care ................................................7-1 Storage ...........................................7-3 SPECIFICATIONS .............................8-1 CONSUMER INFORMATION.............9-1 Identification numbers ....................9-1 Reporting safety defects .................9-3 Motorcycle noise regulation ............9-4 Maintenance record ........................9-5 YAMAHA MOTOR CORPORATION, U.S.A. STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY ................................9-7 YAMAHA EXTENDED SERVICE (Y.E.S.) ........................................9-9 U1C210E0.book Page 1 Tuesday, September 21, 2004 1:28 PM SAFETY INFORMATION EAU10272 MOTORCYCLES ARE SINGLE TRACK VEHICLES. THEIR SAFE USE AND OPERATION ARE DEPENDENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EXPERTISE OF THE OPERATOR. EVERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIREMENTS BEFORE RIDING THIS MOTORCYCLE. HE OR SHE SHOULD: ● OBTAIN THOROUGH INSTRUCTIONS FROM A COMPETENT SOURCE ON ALL ASPECTS OF MOTORCYCLE OPERATION. ● OBSERVE THE WARNINGS AND MAINTENANCE REQUIREMENTS IN THE OWNER’S MANUAL. ● OBTAIN QUALIFIED TRAINING IN SAFE AND PROPER RIDING TECHNIQUES. ● OBTAIN PROFESSIONAL TECHNICAL SERVICE AS INDICATED BY THE OWNER’S MANUAL AND/OR WHEN MADE NECESSARY BY MECHANICAL CONDITIONS. Safe riding ● Always make pre-operation checks. Careful checks may help prevent an accident. ● This motorcycle is designed to carry the operator and a passenger. ● The failure of motorists to detect and recognize motorcycles in traffic 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 appears to be very effective in reducing 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- 1-1 ● ● 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. Many accidents involve inexperienced operators. In fact, many operators who have been involved in accidents do not even have a current motorcycle license. • Make sure that you are qualified and that you only lend your motorcycle to other qualified operators. • Know your skills and limits. Staying within your limits may help you to avoid an accident. • We recommend that you practice riding your motorcycle where there is no traffic until you have become thoroughly familiar 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 1 U1C210E0.book Page 2 Tuesday, September 21, 2004 1:28 PM SAFETY INFORMATION 1 ● ● turn due to EXCESSIVE SPEED or undercornering (insufficient lean angle for the speed). • Always obey the speed limit and never travel faster than warranted by road and traffic conditions. • Always signal before turning 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 footrests during operation to maintain 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 onroad use only. It is not suitable for off-road use. ● Protective apparel The majority of fatalities from motorcycle accidents are the result of head injuries. The use of a safety helmet is the single most critical factor in the prevention 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 abrasions or lacerations. ● Never wear loose-fitting clothes, otherwise they could catch on the control levers, footrests, or wheels and cause injury or an accident. ● Never touch the engine or exhaust system during or after operation. They become very hot and can 1-2 cause burns. Always wear protective clothing that covers your legs, ankles, and feet. A passenger should also observe the above precautions. Modifications Modifications made to this motorcycle not approved by Yamaha, or the removal of original equipment, may render the motorcycle unsafe for use and may cause severe personal injury. Modifications may also make your motorcycle illegal to use. Loading and accessories Adding accessories or cargo to your motorcycle can adversely affect stability and handling if the weight distribution of the motorcycle is changed. To avoid the possibility of an 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 are some general guidelines to follow if loading cargo or adding accessories to your motorcycle: U1C210E0.book Page 3 Tuesday, September 21, 2004 1:28 PM SAFETY INFORMATION Loading The total weight of the operator, passenger, accessories and cargo must not exceed the maximum load limit. Maximum load: 188 kg (414 lb) (CAL) 189 kg (417 lb) (U49) When loading within this weight limit, keep the following in mind: ● Cargo and accessory weight should be kept as low and close to the motorcycle as possible. Make sure to distribute the weight as evenly as possible on both sides of the motorcycle to minimize imbalance or instability. ● Shifting weights can create a sudden imbalance. Make sure that accessories and cargo are securely attached to the motorcycle before riding. Check accessory mounts and cargo restraints frequently. ● Never attach any large or heavy items to the handlebar, front fork, or front fender. These items, including such cargo as sleeping bags, duffel bags, or tents, can create unstable handling or a slow steering response. Accessories Genuine Yamaha accessories have been specifically designed for use on this motorcycle. Since Yamaha cannot test all other accessories that may be available, you must personally be responsible for the proper selection, installation and use of non-Yamaha accessories. Use extreme caution when selecting and installing any accessories. Keep the following guidelines in mind, as well as those provided under “Loading” when mounting accessories. ● Never install accessories or carry cargo that would impair the performance of your motorcycle. Carefully inspect the accessory before using it to make sure that it does not in any way reduce ground clearance or cornering clearance, 1-3 limit suspension travel, steering travel or control operation, or obscure lights or reflectors. • Accessories fitted to the handlebar or the front fork area can create instability due to improper weight distribution or aerodynamic changes. If accessories are added to the handlebar or front fork area, they must be as lightweight as possible and should be kept to a minimum. • Bulky or large accessories may seriously affect the stability of the motorcycle due to aerodynamic effects. Wind may attempt to lift the motorcycle, or the motorcycle may become unstable in cross winds. These accessories may also cause instability when passing or being passed by large vehicles. • Certain accessories can displace the operator from his or her normal riding position. This improper position limits the freedom of movement of the opera- 1 U1C210E0.book Page 4 Tuesday, September 21, 2004 1:28 PM SAFETY INFORMATION 1 ● tor and may limit control ability, therefore, such accessories are not recommended. Use caution when adding electrical accessories. If electrical accessories exceed the capacity of the motorcycle’s electrical system, an electric failure could result, which could cause a dangerous loss of lights or engine power. Gasoline and exhaust gas ● GASOLINE IS HIGHLY FLAMMABLE: • Always turn the engine off when refueling. • Take care not to spill any gasoline on the engine or exhaust system when refueling. • Never refuel while smoking or in the vicinity of an open flame. ● Never start the engine or let it run for any length of time in a closed area. The exhaust fumes are poisonous and may cause loss of consciousness and death within a short time. Always operate your motorcycle in an area that has adequate ventilation. ● ● ● Always turn the engine off before leaving the motorcycle unattended and remove the key from the main switch. When parking the motorcycle, note the following: • The engine and exhaust system may be hot, therefore, park the motorcycle in a place where pedestrians or children are not likely to touch these hot areas. • Do not park the motorcycle on a slope or soft ground, otherwise it may fall over. • Do not park the motorcycle near a flammable source, (e.g., a kerosene heater, or near an open flame), otherwise it could catch fire. When transporting the motorcycle in another vehicle, make sure that it is kept upright. If the motorcycle should lean over, gasoline may leak out of the carburetor or fuel tank. If you should swallow any gasoline, inhale a lot of gasoline vapor, or allow gasoline to get into your eyes, see your doctor immediately. If any gasoline spills on your skin 1-4 or clothing, immediately wash the affected area with soap and water and change your clothes. U1C210E0.book Page 5 Tuesday, September 21, 2004 1:28 PM SAFETY INFORMATION EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle. 1 1-5 U1C210E0.book Page 6 Tuesday, September 21, 2004 1:28 PM SAFETY INFORMATION 1 5 CAUTION 1 Cleaning with alkaline or acid cleaner, gasoline or solvent will damage windshield. Use neutral detergent. 5JW-00 2 6 3 Improper loading can cause loss of control. 3JJ-28446-A1 7 4 1-6 California only U1C210E0.book Page 1 Tuesday, September 21, 2004 1:28 PM DESCRIPTION EAU10410 Left view 2 11.Shock absorber assembly spring preload adjusting ring (page 3-13) 12.Shock absorber assembly rebound damping force adjusting knob (page 3-13) 13.Shift pedal (page 3-7) 1. Front fork compression damping force adjusting screw (page 3-11) 2. Front fork rebound damping force adjusting screw (page 3-11) 3. Front fork spring preload adjusting bolt (page 3-11) 4. Air filter element (page 6-17) 5. Main fuse (page 6-34) 6. Fuse box (page 6-34) 7. Storage compartment (page 3-11) 8. Grab bar 9. Seat lock/helmet holder (page 3-10/page 3-10) 10.Shock absorber assembly compression damping force adjusting screw (page 3-13) 2-1 U1C210E0.book Page 2 Tuesday, September 21, 2004 1:28 PM DESCRIPTION EAU10420 Right view 2 1. 2. 3. 4. 5. 6. 7. 8. 9. Owner’s tool kit (page 6-1) Rear brake fluid reservoir (page 6-25) Battery (page 6-33) Front brake fluid reservoir (page 6-25) Radiator cap (page 6-14) Engine oil filter cartridge (page 6-12) Engine oil level check window (page 6-12) Brake pedal (page 3-7) Coolant reservoir (page 6-14) 2-2 U1C210E0.book Page 3 Tuesday, September 21, 2004 1:28 PM DESCRIPTION EAU10430 Controls and instruments 2 1. Clutch lever (page 3-6) 2. Left handlebar switches (page 3-5) 3. Starter (choke) lever (page 3-9) 4. Speedometer unit (page 3-3) 5. Main switch/steering lock (page 3-1) 6. Tachometer unit (page 3-4) 7. Fuel gauge (page 3-5) 8. Right handlebar switches (page 3-5) 9. Brake lever (page 3-7) 10.Throttle grip (page 6-19) 2-3 U1C210E0.book Page 1 Tuesday, September 21, 2004 1:28 PM INSTRUMENT AND CONTROL FUNCTIONS EAU10460 Main switch/steering lock EAU10680 LOCK The steering is locked, and all electrical systems are off. The key can be removed. To unlock the steering To lock the steering 3 1. Push. 2. Turn. The main switch/steering lock controls the ignition and lighting systems, and is used to lock the steering. The various positions are described below. EAU10510 ON All electrical systems are supplied with power, and the headlight, meter lighting, taillight and position lights come on, and the engine can be started. The key cannot be removed. EAU10660 Push the key in, and then turn it to “OFF” while still pushing it. EWA10060 WARNING 1. Push. 2. Turn. 1. Turn the handlebars all the way to the left. 2. Push the key in from the “OFF” position, and then turn it to “LOCK” while still pushing it. 3. Remove the key. OFF All electrical systems are off. The key can be removed. 3-1 Never turn 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. Make sure that the vehicle is stopped before turning the key to “OFF” or “LOCK”. U1C210E0.book Page 2 Tuesday, September 21, 2004 1:28 PM INSTRUMENT AND CONTROL FUNCTIONS EAU11002 Indicator and warning lights EAU11080 EAU11350 High beam indicator light “ ” This indicator light comes on when the high beam of the headlight is switched on. Fuel level warning light “ ” This warning light comes on when the fuel level drops below approximately 4.1 L (1.08 US gal) (0.90 Imp.gal). When this occurs, refuel as soon as possible. The electrical circuit of the warning light can be checked by turning the key to “ON”. If the warning light does not come on for a few seconds, then go off, have a Yamaha dealer check the electrical circuit. EAU11120 1. 2. 3. 4. 5. 6. 7. Left turn signal indicator light “ ” Neutral indicator light “ ” High beam indicator light “ ” Oil level warning light “ ” Right turn signal indicator light “ ” Coolant temperature warning light “ Fuel level warning light “ ” ” EAU11030 Turn signal indicator lights “ ” and “ ” The corresponding indicator light flashes when the turn signal switch is pushed to the left or right. Oil level warning light “ ” This warning light comes on when the engine oil level is low. The electrical circuit of the warning light can be checked by turning the key to “ON”. If the warning light does not come on for a few seconds, then go off, have a Yamaha dealer check the electrical circuit. NOTE: Even if the oil level is sufficient, the warning light may flicker when riding on a slope or during sudden acceleration or deceleration, but this is not a malfunction. EAU11060 Neutral indicator light “ ” This indicator light comes on when the transmission is in the neutral position. 3-2 EAU11440 Coolant temperature warning light “ ” This warning light comes on when the engine overheats. When this occurs, stop the engine immediately and allow the engine to cool. The electrical circuit of the warning light can be checked by turning the key to “ON”. If the warning light does not come on for a few seconds, then go off, have a Yamaha dealer check the electrical circuit. 3 U1C210E0.book Page 3 Tuesday, September 21, 2004 1:28 PM INSTRUMENT AND CONTROL FUNCTIONS ECA10020 CAUTION: EAU11810 Speedometer unit Do not operate the engine if it is overheated. be traveled on a full tank of fuel. This information will enable you to plan future fuel stops. To set a mode Push the “SELECT” button to change between the odometer mode “ODO”, and the tripmeter modes “TRIP 1” and “TRIP 2” in the following order: ODO → TRIP 1 → TRIP 2 → ODO 3 1. 2. 3. 4. Speedometer Odometer/tripmeter “SELECT” button “RESET” button The speedometer unit is equipped with the following: ● an odometer ● two tripmeters When set to “ODO”, the vehicle’s total mileage is indicated. When set to “TRIP 1” or “TRIP 2”, the vehicle’s mileage since the tripmeter was last reset is indicated. The tripmeters can be used together with the fuel gauge to estimate the distance that can 3-3 To reset a meter To reset either tripmeter 1 or 2 to 0.0, select either by pushing the “SELECT” button, and then push the “RESET” button for at least one second. U1C210E0.book Page 4 Tuesday, September 21, 2004 1:28 PM INSTRUMENT AND CONTROL FUNCTIONS EAU11891 Tachometer unit 1. Tachometer 2. Tachometer red zone 3. Clock The electric tachometer allows the rider to monitor the engine speed and keep it within the ideal power range. ECA10031 CAUTION: To set the clock 1. Push both the “SELECT” and “RESET” buttons for at least two seconds. 2. When the hour digits start flashing, push the “RESET” button to set the hours. 3. Push the “SELECT” button to change the minutes. 4. When the minute digits start flashing, push the “RESET” button to set the minutes. 5. Push the “SELECT” button to start the clock. NOTE: After setting the clock, be sure to push the “SELECT” button before turning the key to “OFF”, otherwise the clock will not be set. Do not operate the engine in the tachometer red zone. Red zone: 11500 r/min and above EAU12101 Self-diagnosis devices This model is equipped with a self-diagnosis device for the following electrical circuits: ● throttle position sensor ● speed sensor ● EXUP system ● overturn switch If any of those circuits are defective, the tachometer will repeatedly display the following error code: 0 r/min for 3 seconds Circuit-specific number of r/min for 2.5 seconds (See the table below.) Current engine speed for 3 seconds Use the chart below to identify the faulty electrical circuit. Specific r/min for the faulty circuit Throttle position sensor: 3000 r/min Speed sensor: 4000 r/min EXUP system: 7000 r/min Overturn switch: 9000 r/min This tachometer unit is equipped with a clock. 3-4 3 U1C210E0.book Page 5 Tuesday, September 21, 2004 1:28 PM INSTRUMENT AND CONTROL FUNCTIONS If the tachometer displays such an error code, note the circuit-specific number of r/min, and then have a Yamaha dealer check the vehicle. EAU12110 Fuel gauge EAU12343 Handlebar switches Left ECA10040 CAUTION: 3 When the tachometer displays an error code, the vehicle should be checked as soon as possible in order to avoid engine damage. 1. 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 “E”, approximately 4.1 L (1.08 US gal) (0.90 Imp.gal) of fuel remain in the fuel tank. If this occurs, refuel as soon as possible. 1. Dimmer switch “ / ” 2. Turn signal switch “ / ” 3. Horn switch “ ” Right NOTE: Do not allow the fuel tank to empty itself completely. 1. Engine stop switch “ 2. Start switch “ ” 3-5 / ” U1C210E0.book Page 6 Tuesday, September 21, 2004 1:28 PM INSTRUMENT AND CONTROL FUNCTIONS EAU12400 Dimmer switch “ / ” Set this switch to “ ” for the high beam and to “ ” for the low beam. ECA10050 EAU12820 Clutch lever CAUTION: See page 5-1 for starting instructions prior to starting the engine. EAU12460 Turn signal switch “ / ” To signal a right-hand turn, push this switch to “ ”. To signal a left-hand turn, push this switch to “ ”. When released, the switch returns to the center position. To cancel the turn signal lights, push the switch in after it has returned to the center position. 3 1. Clutch lever The clutch lever is located at the left handlebar grip. To disengage the clutch, pull the lever toward the handlebar grip. To engage the clutch, release 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 ignition circuit cut-off system. (See page 3-16.) EAU12500 Horn switch “ ” Press this switch to sound the horn. EAU12660 Engine stop switch “ / ” Set this switch to “ ” before starting the engine. Set this switch to “ ” to stop the engine in case of an emergency, such as when the vehicle overturns or when the throttle cable is stuck. EAU12710 Start switch “ ” Push this switch to crank the engine with the starter. 3-6 U1C210E0.book Page 7 Tuesday, September 21, 2004 1:28 PM INSTRUMENT AND CONTROL FUNCTIONS EAU12870 Shift pedal EAU12930 Brake lever EAU12941 Brake pedal The brake lever is located at the right handlebar grip. To apply the front brake, pull the lever toward the handlebar grip. 3 1. Shift pedal 1. Brake pedal The shift pedal is located on the left side of the engine and is used in combination with the clutch lever when shifting the gears of the 6-speed constant-mesh transmission equipped on this motorcycle. The brake pedal is on the right side of the motorcycle. To apply the rear brake, press down on the brake pedal. 1. 2. 3. 4. Brake lever Brake lever position adjusting dial Arrow mark Distance between brake lever and handlebar grip The brake lever is equipped with a position adjusting dial. To adjust the distance between the brake lever and the handlebar grip, turn the adjusting dial while holding the lever pushed away from the handlebar grip. Make sure that the appropriate setting on the adjusting dial is aligned with the arrow mark on the brake lever. 3-7 U1C210E0.book Page 8 Tuesday, September 21, 2004 1:28 PM INSTRUMENT AND CONTROL FUNCTIONS EAU13070 Fuel tank cap EAU13210 NOTE: The fuel tank cap cannot be closed unless the key is in the lock. In addition, the key cannot be removed if the cap is not properly closed and locked. Fuel EWA11090 WARNING 3 Make sure that the fuel tank cap is properly closed before riding. 1. Fuel tank cap lock cover 2. Unlock. 1. Fuel tank filler tube 2. Fuel level Make sure that there is sufficient fuel in the tank. Fill the fuel tank to the bottom of the filler tube as shown. To open the fuel tank cap Open the fuel tank cap lock cover, insert the key into the lock, and then turn it 1/4 turn clockwise. The lock will be released and the fuel tank cap can be opened. EWA10880 WARNING ● To close the fuel tank cap 1. Push the fuel tank cap into position with the key inserted in the lock. 2. Turn the key counterclockwise to the original position, remove it, and then close the lock cover. ● 3-8 Do not overfill the fuel tank, otherwise it may overflow when the fuel warms up and expands. Avoid spilling fuel on the hot engine. U1C210E0.book Page 9 Tuesday, September 21, 2004 1:28 PM INSTRUMENT AND CONTROL FUNCTIONS ECA10070 CAUTION: Immediately wipe off spilled fuel with a clean, dry, soft cloth, since fuel may deteriorate painted surfaces or plastic parts. EAU13300 3 Recommended fuel: UNLEADED GASOLINE ONLY Fuel tank capacity: 21.0 L (5.55 US gal) (4.62 Imp.gal) Fuel reserve amount: 4.1 L (1.08 US gal) (0.90 Imp.gal) knocking (or pinging) occurs, use a gasoline of a different brand or premium unleaded fuel. Use of unleaded fuel will extend spark plug life and reduce maintenance costs. Gasohol There are two types of gasohol: gasohol containing ethanol and that containing methanol. Gasohol containing ethanol can be used if the ethanol content does not exceed 10%. Gasohol containing methanol is not recommended by Yamaha because it can cause damage to the fuel system or vehicle performance problems. ECA11400 CAUTION: 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. Your Yamaha engine has been designed to use regular unleaded gasoline with a pump octane number [(R+M)/2] of 86 or higher, or a research octane number of 91 or higher. If 3-9 EAU13590 Starter (choke) lever “ 1. 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). U1C210E0.book Page 10 Tuesday, September 21, 2004 1:28 PM INSTRUMENT AND CONTROL FUNCTIONS EAU13940 EAU14350 Seat Helmet holder To remove the seat 1. Insert the key into the seat lock, and then turn it clockwise. 3 1. Projection 2. Seat holder 2. Push the rear of the seat down to lock it in place. 3. Remove the key. 1. Seat lock 2. Unlock. 2. While holding the key in that position, lift the rear of the seat, and then pull the seat off. NOTE: Make sure that the seat is properly secured before riding. 1. Helmet holder 2. Unlock. To open the helmet holder, insert the key into the seat lock, and then turn the key as shown. To lock the helmet holder, turn the key to the original position, and then remove it. EWA10160 WARNING To install the seat 1. Insert the projection on the front of the seat into the seat holder as shown. Never ride with a helmet attached to the helmet holder, since the helmet may hit objects, causing loss of control and possibly an accident. 3-10 U1C210E0.book Page 11 Tuesday, September 21, 2004 1:28 PM INSTRUMENT AND CONTROL FUNCTIONS EAU14451 Storage compartment When washing the vehicle, be careful not to let any water enter the storage compartment. EAU14751 Adjusting the front fork This front fork is equipped with spring preload adjusting bolts, rebound damping force adjusting screws and compression damping force adjusting screws. EWA10180 WARNING 3 Always adjust both fork legs equally, otherwise poor handling and loss of stability may result. 1. Storage compartment The storage compartment is located under the seat. (See page 3-10.) Spring preload EWA10961 WARNING ● ● Do not exceed the load limit of 3 kg (7 lb) for the storage compartment. Do not exceed the maximum load of 188 kg (414 lb) (CAL) 189 kg (417 lb) (U49) for the vehicle. 1. Spring preload adjusting bolt When storing the owner’s manual or other documents in the storage compartment, be sure to wrap them in a plastic bag so that they will not get wet. To increase the spring preload and thereby harden the suspension, turn the adjusting bolt on each fork leg in direction (a). To decrease the spring pre3-11 U1C210E0.book Page 12 Tuesday, September 21, 2004 1:28 PM INSTRUMENT AND CONTROL FUNCTIONS load and thereby soften the suspension, turn the adjusting bolt on each fork leg in direction (b). Rebound damping force Compression damping force NOTE: Align the appropriate groove on the adjusting mechanism with the top of the front fork cap bolt. 3 1. Current setting 2. Front fork cap bolt Spring preload setting: Minimum (soft): 5* Standard: 2 Maximum (hard): 1 * Adjusting bolt fully turned in direction (b) 1. Rebound damping force adjusting screw 1. Compression damping force adjusting screw To increase the rebound damping force and thereby harden the rebound damping, turn the adjusting screw on each fork leg in direction (a). To decrease the rebound damping force and thereby soften the rebound damping, turn the adjusting screw on each fork leg in direction (b). To increase the compression damping force and thereby harden the compression damping, turn the adjusting screw on each fork leg in direction (a). To decrease the compression damping force and thereby soften the compression damping, turn the adjusting screw on each fork leg in direction (b). Rebound damping setting: Minimum (soft): 17 click(s) in direction (b)* Standard: 7 click(s) in direction (b)* Maximum (hard): 1 click(s) in direction (b)* * With the adjusting screw fully turned in direction (a) 3-12 Compression damping setting: Minimum (soft): 21 click(s) in direction (b)* Standard: 6 click(s) in direction (b)* Maximum (hard): 1 click(s) in direction (b)* * With the adjusting screw fully turned in direction (a) U1C210E0.book Page 13 Tuesday, September 21, 2004 1:28 PM INSTRUMENT AND CONTROL FUNCTIONS ECA10100 CAUTION: Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings. 3 NOTE: Although the total number of clicks of a damping force adjusting mechanism may not exactly match the above specifications due to small differences in production, the actual number of clicks always represents the entire adjusting range. To obtain a precise adjustment, it would be advisable to check the number of clicks of each damping force adjusting mechanism and to modify the specifications as necessary. EAU15041 Adjusting the shock absorber assembly This shock absorber assembly is equipped with a spring preload adjusting ring, a rebound damping force adjusting knob and a compression damping force adjusting screw. ECA10100 CAUTION: Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings. Spring preload To increase the spring preload and thereby harden the suspension, turn the adjusting ring in direction (a). To decrease the spring preload and thereby soften the suspension, turn the adjusting ring in direction (b). NOTE: ● Align the appropriate notch in the adjusting ring with the position indicator on the shock absorber. ● Use the special wrench included in the owner’s tool kit to make the adjustment. Spring preload setting: Minimum (soft): 1 Standard: 6 Maximum (hard): 11 1. Spring preload adjusting ring 2. Special wrench 3. Position indicator 3-13 U1C210E0.book Page 14 Tuesday, September 21, 2004 1:28 PM INSTRUMENT AND CONTROL FUNCTIONS Rebound damping force Compression damping force 1. Rebound damping force adjusting knob 1. Compression damping force adjusting screw To increase the rebound damping force and thereby harden the rebound damping, turn the adjusting knob in direction (a). To decrease the rebound damping force and thereby soften the rebound damping, turn the adjusting knob in direction (b). To increase the compression damping force and thereby harden the compression damping, turn the adjusting screw in direction (a). To decrease the compression damping force and thereby soften the compression damping, turn the adjusting screw in direction (b). Rebound damping setting: Minimum (soft): 20 click(s) in direction (b)* Standard: 10 click(s) in direction (b)* Maximum (hard): 3 click(s) in direction (b)* * With the adjusting knob fully turned in direction (a) Compression damping setting: Minimum (soft): 1 click(s) in direction (a)* Standard: 7 click(s) in direction (a)* Maximum (hard): 12 click(s) in direction (a)* * With the adjusting screw fully turned in direction (b) 3-14 NOTE: Although the total number of clicks of a damping force adjusting mechanism may not exactly match the above specifications due to small differences in production, the actual number of clicks always represents the entire adjusting range. To obtain a precise adjustment, it would be advisable to check the number of clicks of each damping force adjusting mechanism and to modify the specifications as necessary. EWA10220 WARNING This shock absorber contains highly pressurized nitrogen gas. For proper handling, read and understand the following information before handling the shock absorber. The manufacturer cannot be held responsible for property damage or personal injury that may result from improper handling. ● Do not tamper with or attempt to open the gas cylinder. 3 U1C210E0.book Page 15 Tuesday, September 21, 2004 1:28 PM INSTRUMENT AND CONTROL FUNCTIONS ● ● 3 ● Do not subject the shock absorber to an open flame or other high heat sources, otherwise it may explode due to excessive gas pressure. Do not deform or damage the gas cylinder in any way, as this will result in poor damping performance. Always have a Yamaha dealer service the shock absorber. EAU15281 EAU15300 EXUP system Sidestand This model is equipped with Yamaha’s EXUP (EXhaust Ultimate Power valve) system. This system boosts engine power by means of a valve that regulates the diameter of the exhaust pipe. The EXUP system valve is constantly adjusted in accordance with the engine speed by a computer-controlled servomotor. 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. ECA10191 CAUTION: ● ● The EXUP system has been set and extensively tested at the Yamaha factory. Changing these settings without sufficient technical knowledge may result in poor performance of or damage to the engine. If the EXUP system cannot be heard when the main switch is turned on, have a Yamaha dealer check it. 3-15 NOTE: The built-in sidestand switch is part of the ignition circuit cut-off system, which cuts the ignition in certain situations. (See further down for an explanation of the ignition circuit cut-off system.) EWA10240 WARNING The vehicle must not be ridden with the sidestand down, or if the sidestand 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. Yamaha’s ignition circuit cut-off system has been designed to assist the operator in fulfilling the responsibility of raising the sidestand before starting off. Therefore, check this system regularly as described U1C210E0.book Page 16 Tuesday, September 21, 2004 1:28 PM INSTRUMENT AND CONTROL FUNCTIONS below and have a Yamaha dealer repair it if it does not function properly. EAU15321 Ignition circuit cut-off system The ignition circuit cut-off system (comprising the sidestand switch, clutch switch and neutral switch) has the following functions. ● It prevents starting when the transmission is in gear and the sidestand is up, but the clutch lever is not pulled. ● It prevents starting when the transmission is in gear and the clutch lever is pulled, but the sidestand is still down. ● It cuts the running engine when the transmission is in gear and the sidestand is moved down. Periodically check the operation of the ignition circuit cut-off system according to the following procedure. EWA10260 WARNING ● ● The vehicle must be placed on the centerstand during this inspection. If a malfunction is noted, have a Yamaha dealer check the system before riding. 3-16 3 U1C210E0.book Page 17 Tuesday, September 21, 2004 1:28 PM INSTRUMENT AND CONTROL FUNCTIONS With the engine turned off: 1. Move the sidestand down. 2. Make sure that the engine stop switch is turned on. 3. Turn the key on. 4. Shift the transmission into the neutral position. 5. Push the start switch. Does the engine start? NOTE: This check is most reliable if performed with a warmed-up engine. 3 YES NO The neutral switch may be defective. The motorcycle should not be ridden until checked by a Yamaha dealer. NO The sidestand switch may be defective. The motorcycle should not be ridden until checked by a Yamaha dealer. NO The clutch switch may be defective. The motorcycle should not be ridden until checked by a Yamaha dealer. With the engine still running: 6. Move the sidestand up. 7. Keep the clutch lever pulled. 8. Shift the transmission into gear. 9. Move the sidestand down. Does the engine stall? YES After the engine has stalled: 10. Move the sidestand up. 11. Keep the clutch lever pulled. 12. Push the start switch. Does the engine start? YES The system is OK. The motorcycle can be ridden. 3-17 U1C210E0.book Page 1 Tuesday, September 21, 2004 1:28 PM PRE-OPERATION CHECKS EAU15591 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 inspection, to check the following points before each ride. NOTE: Pre-operation checks should be made each time the vehicle 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. EWA11150 WARNING If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operating the vehicle. 4-1 4 U1C210E0.book Page 2 Tuesday, September 21, 2004 1:28 PM PRE-OPERATION CHECKS EAU15603 Pre-operation check list ITEM 4 CHECKS PAGE Fuel • Check fuel level in fuel tank. • Refuel if necessary. • Check fuel line for leakage. 3-8 Engine oil • Check oil level in engine. • If necessary, add recommended oil to specified level. • Check vehicle for oil leakage. 6-12 Coolant • Check coolant level in reservoir. • If necessary, add recommended coolant to specified level. • Check cooling system for leakage. 6-14 Front brake • • • • • • • Check operation. If soft or spongy, have Yamaha dealer bleed hydraulic system. Check brake pads for wear. Replace if necessary. Check fluid level in reservoir. If necessary, add recommended brake fluid to specified level. Check hydraulic system for leakage. 6-25, 6-25 Rear brake • • • • • • • Check operation. If soft or spongy, have Yamaha dealer bleed hydraulic system. Check brake pads for wear. Replace if necessary. Check fluid level in reservoir. If necessary, add recommended brake fluid to specified level. Check hydraulic system for leakage. 6-25, 6-25 Clutch • • • • Check operation. Lubricate cable if necessary. Check lever free play. Adjust if necessary. 6-24 4-2 U1C210E0.book Page 3 Tuesday, September 21, 2004 1:28 PM PRE-OPERATION CHECKS ITEM CHECKS PAGE 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. Control cables • Make sure that operation is smooth. • Lubricate if necessary. Drive chain • • • • Check chain slack. Adjust if necessary. Check chain condition. Lubricate if necessary. Wheels and tires • • • • Check for damage. Check tire condition and tread depth. Check air pressure. Correct if necessary. Brake and shift pedals • Make sure that operation is smooth. • Lubricate pedal pivoting points if necessary. 6-29 Brake and clutch levers • Make sure that operation is smooth. • Lubricate lever pivoting points if necessary. 6-30 Centerstand, sidestand • Make sure that operation is smooth. • Lubricate pivots if necessary. 6-30 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. — Sidestand switch • Check operation of ignition circuit cut-off system. • If system is defective, have Yamaha dealer check vehicle. 6-19, 6-29 6-29 6-27, 6-28 4-3 4 6-20, 6-23 3-15 U1C210E0.book Page 1 Tuesday, September 21, 2004 1:28 PM OPERATION AND IMPORTANT RIDING POINTS EAU15950 EWA10270 WARNING ● ● 5 ● Become thoroughly familiar with all operating controls and their functions before riding. Consult a Yamaha dealer regarding any control or function that you do not thoroughly understand. Never start the engine or operate it in a closed area for any length of time. Exhaust fumes are poisonous, and inhaling them can cause loss of consciousness and death within a short time. Always make sure that there is adequate ventilation. Before starting out, make sure that the sidestand is up. If the sidestand is not raised completely, it could contact the ground and distract the operator, resulting in a possible loss of control. EAU16210 Starting and warming up a cold engine In order for the ignition 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 and the sidestand up. EWA10290 WARNING ● ● Before starting the engine, check the function of the ignition circuit cut-off system according to the procedure described on page 3-16. Never ride with the sidestand down. 1. Turn the key to “ON” and make sure that the engine stop switch is set to “ ”. ECA11430 CAUTION: The oil level warning light, coolant temperature warning light and fuel level warning light should come on 5-1 for a few seconds, then go off. If a warning light does not go off, have a Yamaha dealer check the electrical circuit. 2. Shift the transmission into the neutral position. NOTE: When the transmission is in the neutral position, the neutral indicator light should be on, otherwise have a Yamaha dealer check the electrical circuit. 3. Turn the starter (choke) on and completely close the throttle. (See page 3-9.) 4. Start the engine by pushing the start switch. NOTE: If the engine fails to start, release the start switch, wait a few seconds, and then try again. Each starting attempt should be as short as possible to preserve the battery. Do not crank the engine more than 10 seconds on any one attempt. U1C210E0.book Page 2 Tuesday, September 21, 2004 1:28 PM OPERATION AND IMPORTANT RIDING POINTS ECA11490 CAUTION: ● ● If the oil level warning light flickers or remains on after starting, immediately stop the engine, and then check the engine oil level and the vehicle for oil leakage. If necessary, add engine oil, and then check the warning light again. If, when the key is turned to “ON”, the warning light does not come on for a few seconds, then go off, or if it does not go off after starting with sufficient engine oil, have a Yamaha dealer check the electrical circuit. If the coolant temperature warning light flickers or remains on after starting, immediately stop the engine, and then check the coolant level and the vehicle for coolant leakage. If necessary, add coolant, and then check the warning light again. If, when the key is turned to “ON”, the warning light does not come on for a few seconds, then go off, or if it does not go off after starting ● with sufficient coolant, have a Yamaha dealer check the electrical circuit. If the fuel level warning light remains on after starting, stop the engine, and then check the fuel level. If necessary, refuel as soon as possible, and then check the warning light again. If, when the key is turned to “ON”, the warning light does not come on for a few seconds, then go off, or if it does not go off after starting with sufficient fuel, have a Yamaha dealer check the electrical circuit. 5. After starting the engine, move the starter (choke) back halfway. ECA11130 CAUTION: For maximum engine life, always warm the engine up before starting off. Never accelerate hard when the engine is cold! 6. When the engine is warm, turn the starter (choke) off. 5-2 NOTE: The engine is warm when it responds normally to the throttle with the starter (choke) turned off. To avoid the possibility of excessive exhaust emissions, never leave the starter (choke) on longer than necessary. The time necessary for starter (choke) use depends upon the ambient temperature. Temperatures above 10 °C (50 °F) require about 10 seconds of starter (choke) use and temperatures below 10 °C (50 °F) require about 35 seconds with the starter (choke) turned on, then about 2.5 minutes with the starter (choke) in the halfway position. 5 U1C210E0.book Page 3 Tuesday, September 21, 2004 1:28 PM OPERATION AND IMPORTANT RIDING POINTS EAU16640 Starting a warm engine EAU16671 Shifting Follow the same procedure as for starting a cold engine with the exception that the starter (choke) is not required when the engine is warm. 5 ECA10260 CAUTION: ● 1. Shift pedal 2. Neutral position ● Shifting gears lets you control the amount of engine power available for starting off, accelerating, climbing hills, etc. The gear positions are shown in the illustration. 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 distances. The transmission is properly lubricated only when the engine is running. Inadequate lubrication may damage the transmission. Always use the clutch while changing gears to avoid damaging the engine, transmission, and drive train, which are not designed to withstand the shock of forced shifting. EAU16680 NOTE: To shift the transmission into the neutral position, press the shift pedal down repeatedly until it reaches the end of its travel, and then slightly raise it. 5-3 To start out and accelerate 1. Pull the clutch lever to disengage the clutch. 2. Shift the transmission into first gear. The neutral indicator light should go out. 3. Open the throttle gradually, and at the same time, release the clutch lever slowly. U1C210E0.book Page 4 Tuesday, September 21, 2004 1:28 PM OPERATION AND IMPORTANT RIDING POINTS 4. At the recommended shift points shown in the following table, close the throttle, and at the same time, quickly pull the clutch lever in. 5. Shift the transmission into second gear. (Make sure not to shift the transmission into the neutral position.) 6. Open the throttle part way and gradually release the clutch lever. 7. Follow the same procedure when shifting to the next higher gear. NOTE: Always shift gears at the recommended shift points. EAU16700 To decelerate 1. Apply both the front and the rear brakes to slow the motorcycle. 2. Shift the transmission into first gear when the motorcycle reaches 25 km/h (15.5 mi/h). If the engine is about to stall or runs very roughly, pull the clutch lever in and use the brakes to stop the motorcycle. 3. Shift the transmission into the neutral position when the motorcycle is almost completely stopped. The neutral indicator light should come on. EAU16740 Recommended shift points The recommended shift points during acceleration and deceleration are shown in the table below. Shift up points: 1st → 2nd: 16 km/h (9.9 mi/h) 2nd → 3rd: 24 km/h (14.9 mi/h) 3rd → 4th: 32 km/h (19.9 mi/h) 4th → 5th: 40 km/h (24.9 mi/h) 5th → 6th: 48 km/h (29.8 mi/h) Shift down points: 6th → 5th: 25 km/h (15.5 mi/h) 5th → 4th: 25 km/h (15.5 mi/h) 4th → 3rd: 25 km/h (15.5 mi/h) 3rd → 2nd: 25 km/h (15.5 mi/h) 2nd → 1st: 25 km/h (15.5 mi/h) 5-4 EAU16841 Engine break-in There is never a more important period in the life of your engine than the period between 0 and 1600 km (1000 mi). For this reason, you should read the following material carefully. Since the engine is brand new, do not put an excessive load on it for the first 1600 km (1000 mi). The various parts in the engine wear and polish themselves to the correct operating clearances. During this period, prolonged full-throttle operation or any condition that might result in engine overheating must be avoided. EAU17091 0–1000 km (0–600 mi) Avoid prolonged operation above 5800 r/min. 1000–1600 km (600–1000 mi) Avoid prolonged operation above 6900 r/min. 5 U1C210E0.book Page 5 Tuesday, September 21, 2004 1:28 PM OPERATION AND IMPORTANT RIDING POINTS ECA10301 EAU17200 CAUTION: Parking After 1000 km (600 mi) of operation, the engine oil must be changed and the oil filter cartridge or element replaced. When parking, stop the engine, and then remove the key from the main switch. 1600 km (1000 mi) and beyond The vehicle can now be operated normally. EWA10310 WARNING ● ECA10310 CAUTION: ● 5 ● Keep the engine speed out of the tachometer red zone. If any engine trouble should occur during the engine break-in period, immediately have a Yamaha dealer check the vehicle. ● Since the engine and exhaust system can become very hot, park in a place where pedestrians or children are not likely to touch them. Do not park on a slope or on soft ground, otherwise the vehicle may overturn. 5-5 U1C210E0.book Page 1 Tuesday, September 21, 2004 1:28 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU17231 EAU17301 PERIODIC MAINTENANCE Safety is an obligation of the owner. Periodic inspection, adjustment and lubrication will keep your vehicle in the safest and most efficient condition possible. The most important points of motorcycle inspection, adjustment, and lubrication are explained on the following pages. Maintenance, replacement, or repair of the emission control devices and systems may be performed by any repair establishment or individual that is certified (if applicable). EWA10320 WARNING If you are not familiar with maintenance work, have a Yamaha dealer do it for you. PROPER PERIODIC MAINTENANCE OF YOUR VEHICLE IS IMPORTANT IN ORDER TO ENJOY LONG, PLEASURABLE SERVICE. ESPECIALLY IMPORTANT ARE THE MAINTENANCE SERVICES RELATED TO EMISSIONS CONTROL. THESE CONTROLS NOT ONLY FUNCTION TO ENSURE CLEANER AIR, BUT ARE ALSO VITAL TO PROPER ENGINE OPERATION AND MAXIMUM PERFORMANCE. IN THE FOLLOWING PERIODIC MAINTENANCE CHARTS, THE SERVICES RELATED TO EMISSIONS CONTROL ARE GROUPED SEPARATELY. THESE SERVICES REQUIRE SPECIALIZED DATA, KNOWLEDGE, AND EQUIPMENT. YAMAHA DEALERS ARE TRAINED AND EQUIPPED TO PERFORM THESE PARTICULAR SERVICES. EAU17510 Owner’s tool kit 1. Owner’s tool kit The owner’s tool kit is located inside the storage compartment under the seat. (See page 3-10.) 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. However, additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly. NOTE: If you do not have the tools or experience required for a particular job, have a Yamaha dealer perform it for you. 6-1 6 U1C210E0.book Page 2 Tuesday, September 21, 2004 1:28 PM PERIODIC MAINTENANCE AND MINOR REPAIR EWA10340 WARNING Modifications not approved by Yamaha may cause loss of performance, excessive emissions, and render the vehicle unsafe for use. Consult a Yamaha dealer before attempting any changes. 6 6-2 U1C210E0.book Page 3 Tuesday, September 21, 2004 1:28 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU17600 Periodic maintenance chart for the emission control system INITIAL No. ITEM ROUTINE 1 * Fuel line • Check fuel hoses for cracks or damage. • Replace if necessary. 2 * Fuel filter • Replace. 3 Spark plugs • Check condition. • Adjust gap and clean. • Replace every 8000 mi (13000 km) or 12 months. 4 * Valve clearance • Check and adjust valve clearance when engine is cold. 5 * Crankcase breather system • Check breather hose for cracks or damage. • Replace if necessary. 6 * Carburetor synchronization • Adjust synchronization of carburetors. 7 * Idle speed 8 * 9 * 600 mi (1000 km) or 1 month ODOMETER READINGS 4000 mi (7000 km) or 6 months √ 8000 mi 12000 mi 16000 mi 20000 mi (13000 km) (19000 km) (25000 km) (31000 km) or or or or 12 months 18 months 24 months 30 months √ √ √ √ Replace. √ Replace. √ Replace. √ Every 26600 mi (42000 km) 6 √ √ √ √ √ √ √ √ √ √ • Check and adjust engine idle speed. √ √ √ √ √ Exhaust system • Check for leakage. • Tighten if necessary. • Replace gasket(s) if necessary. √ √ √ √ √ Evaporative emission control system (For California only) • Check control system for damage. • Replace if necessary. √ √ 6-3 √ U1C210E0.book Page 4 Tuesday, September 21, 2004 1:28 PM PERIODIC MAINTENANCE AND MINOR REPAIR INITIAL No. 10 * ITEM Air induction system ROUTINE 600 mi (1000 km) or 1 month • Check the air cut-off valve, reed valve, and hose for damage. • Replace any damaged parts. ODOMETER READINGS 4000 mi (7000 km) or 6 months √ 8000 mi 12000 mi 16000 mi 20000 mi (13000 km) (19000 km) (25000 km) (31000 km) or or or or 12 months 18 months 24 months 30 months √ * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. 6 6-4 √ √ √ U1C210E0.book Page 5 Tuesday, September 21, 2004 1:28 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU32183 General maintenance and lubrication chart INITIAL No. ITEM ROUTINE 600 mi (1000 km) or 1 month ODOMETER READINGS 4000 mi (7000 km) or 6 months 8000 mi 12000 mi 16000 mi 20000 mi (13000 km) (19000 km) (25000 km) (31000 km) or or or or 12 months 18 months 24 months 30 months 1 * Air filter element • Clean with compressed air. • Replace if necessary. 2 * Clutch • Check operation. • Adjust or replace cable. 3 * Front brake 4 * Rear brake 5 * Brake hoses 6 * Wheels • Check runout and for damage. • Replace if necessary. √ √ 7 * Tires • Check tread depth and for damage. • Replace if necessary. • Check air pressure. • Correct if necessary. √ 8 * Wheel bearings • Check bearings for smooth operation. • Replace if necessary. √ √ √ √ √ √ √ √ √ √ √ √ • Check operation, fluid level, and for fluid leakage. • Replace brake pads if necessary. √ √ √ √ √ √ • Check operation, fluid level, and for fluid leakage. • Replace brake pads if necessary. √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ • Check for cracks or damage. • Replace. Every 4 years 6-5 6 U1C210E0.book Page 6 Tuesday, September 21, 2004 1:28 PM PERIODIC MAINTENANCE AND MINOR REPAIR INITIAL No. ROUTINE Swingarm pivot bearings • Check bearing assemblies for looseness. • Moderately repack with lithiumsoap-based grease. Drive chain • Check chain slack, alignment and condition. • Adjust and lubricate chain with a special O-ring chain lubricant thoroughly. 11 * Steering bearings • Check bearing assembly for looseness. • Moderately repack with lithiumsoap-based grease every 10000 mi (16000 km) or 18 months. 12 * Chassis fasteners 13 9 * 10 6 ITEM 600 mi (1000 km) or 1 month ODOMETER READINGS 4000 mi (7000 km) or 6 months 8000 mi 12000 mi 16000 mi 20000 mi (13000 km) (19000 km) (25000 km) (31000 km) or or or or 12 months 18 months 24 months 30 months √ Repack. Every 600 mi (1000 km) and after washing the motorcycle or riding in the rain √ √ √ Repack. √ √ • Check all chassis fitting and fasteners. • Correct if necessary. √ √ √ √ √ Brake and clutch lever pivot shafts • Apply lithium-soap-based grease (all-purpose grease) lightly. √ √ √ √ √ 14 Brake and shift pedal pivot shafts • Apply lithium-soap-based grease (all-purpose grease) lightly. √ √ √ √ √ 15 * Centerstand and sidestand pivots • Check operation. • Apply lithium-soap-based grease (all-purpose grease) lightly. √ √ √ √ √ 16 * Sidestand switch • Check operation and replace if necessary. √ √ √ √ √ √ 6-6 U1C210E0.book Page 7 Tuesday, September 21, 2004 1:28 PM PERIODIC MAINTENANCE AND MINOR REPAIR INITIAL No. ITEM ROUTINE 600 mi (1000 km) or 1 month ODOMETER READINGS 4000 mi (7000 km) or 6 months 8000 mi 12000 mi 16000 mi 20000 mi (13000 km) (19000 km) (25000 km) (31000 km) or or or or 12 months 18 months 24 months 30 months 17 * Front fork • Check operation and for oil leakage. • Replace if necessary. √ √ √ √ √ 18 * Shock absorber assembly • Check operation and for oil leakage. • Replace if necessary. √ √ √ √ √ 19 * Rear suspension link pivots • Apply lithium-soap-based grease lightly. 20 Engine oil • Change (warm engine before draining). √ 21 * Engine oil filter cartridge • Replace. √ 22 * Cooling system √ • Check hoses for cracks or damage. • Replace if necessary. √ √ √ √ √ √ √ √ √ √ • Change with ethylene glycol antifreeze coolant every 24 months. √ 6 √ Change. 23 * Front and rear brake switches • Check operation. √ √ √ √ √ √ 24 * Control cables • Apply Yamaha chain and cable lube or engine oil SAE 10W-30 thoroughly. √ √ √ √ √ √ 6-7 U1C210E0.book Page 8 Tuesday, September 21, 2004 1:28 PM PERIODIC MAINTENANCE AND MINOR REPAIR INITIAL No. ITEM ROUTINE 25 * Throttle grip housing and cable • Check operation and free play. • Adjust the throttle cable free play if necessary. • Lubricate the throttle grip housing and cable. 26 * Lights, signals and switches • Check operation. • Adjust headlight beam. 600 mi (1000 km) or 1 month √ ODOMETER READINGS 4000 mi (7000 km) or 6 months 8000 mi 12000 mi 16000 mi 20000 mi (13000 km) (19000 km) (25000 km) (31000 km) or or or or 12 months 18 months 24 months 30 months √ √ √ √ √ √ √ √ √ √ * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. NOTE: From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi (13000 km) or 12 months. 6 EAU17630 NOTE: ● The air filter needs more frequent service if you are riding in unusually wet or dusty areas. ● Hydraulic brake service • After disassembling the brake master cylinders and calipers, always change the fluid. Regularly check the brake fluid levels and fill the reservoirs as required. • Every two years replace the internal components of the brake master cylinders and calipers, and change the brake fluid. • Replace the brake hoses every four years and if cracked or damaged. 6-8 U1C210E0.book Page 9 Tuesday, September 21, 2004 1:28 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU18771 Removing and installing panels 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. 1. Cowling C 2. Cowling D 1. Panel C 2. Screw EAU19292 Panels A and C 1. Panel A 2. Panel B To remove one of the panels Remove the screw, and then pull the panel off as shown. 1. Panel A 2. Screw 6-9 To install the panel Place the panel in the original position, and then install the screw. 6 U1C210E0.book Page 10 Tuesday, September 21, 2004 1:28 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU36570 Panels B and D To remove a panel Remove the screws and the bolt, and then take the panel off. EAU19543 Checking the spark plugs The spark plugs are important engine components, which are easy to check. Since heat and deposits will cause any spark plug to slowly erode, the spark plugs should be removed and checked in accordance with the periodic maintenance and lubrication chart. In addition, the condition of the spark plugs can reveal the condition of the engine. To remove a spark plug 1. Remove the spark plug cap. 6 1. Panel B 2. Screw 3. Bolt To install the panel Place the panel in the original position, and then install the screws and the bolt. 1. Spark plug cap 2. Remove the spark plug as shown, with the spark plug wrench included in the owner’s tool kit. 6-10 1. Spark plug wrench To check the spark plugs 1. Check that the porcelain insulator around the center electrode on each spark plug is a medium-tolight tan (the ideal color when the vehicle is ridden normally). 2. Check that all spark plugs installed in the engine have the same color. NOTE: If any spark plug shows a distinctly different color, the engine could be defective. Do not attempt to diagnose such problems yourself. Instead, have a Yamaha dealer check the vehicle. U1C210E0.book Page 11 Tuesday, September 21, 2004 1:28 PM PERIODIC MAINTENANCE AND MINOR REPAIR 3. Check each spark plug for electrode erosion and excessive carbon or other deposits, and replace it if necessary. Specified spark plug: NGK/CR9E DENSO/U27ESR-N To install a spark plug 1. Measure the spark plug gap with a wire thickness gauge and, if necessary, adjust the gap to specification. 2. Clean the surface of the spark plug gasket and its mating surface, and then wipe off any grime from the spark plug threads. 3. Install the spark plug with the spark plug wrench, and then tighten it to the specified torque. EAU19672 Canister (for California only) Tightening torque: Spark plug: 12.5 Nm (1.25 m·kgf, 9.0 ft·lbf) NOTE: If a torque wrench is not available when installing a spark plug, a good estimate of the correct torque is 1/4–1/2 turn past finger tight. However, the spark plug should be tightened to the specified torque as soon as possible. 4. Install the spark plug cap. 1. Spark plug gap Spark plug gap: 0.7–0.8 mm (0.028–0.031 in) 6-11 This model is equipped with a canister to prevent the discharging of fuel vapor into the atmosphere. ● Check each hose connection. ● Check each hose and canister for cracks or damage. Replace if damaged. ● Make sure the vent hose is not blocked. Clean it if necessary. 6 U1C210E0.book Page 12 Tuesday, September 21, 2004 1:28 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU19890 Engine oil and oil filter cartridge The engine oil level should be checked before each ride. In addition, the oil must be changed and the oil filter cartridge replaced at the intervals specified in the periodic maintenance and lubrication chart. NOTE: 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 filler cap and drain bolt to drain the oil from the crankcase. To check the engine oil level 1. Place the vehicle on the centerstand. 6 NOTE: Make sure that the vehicle is positioned straight up when checking the oil level. A slight tilt to the side can result in a false reading. 2. Start the engine, warm it up for several minutes, and then turn it off. 3. Wait a few minutes until the oil settles, and then check the oil level through the check window located at the bottom-right side of the crankcase. 1. 2. 3. 4. Engine oil filler cap Engine oil level check window Maximum level mark Minimum level mark 4. If the engine oil is below the minimum level mark, add sufficient oil of the recommended type to raise it to the correct level. To change the engine oil (with or without oil filter cartridge replacement) 1. Start the engine, warm it up for several minutes, and then turn it off. 6-12 1. Engine oil drain bolt NOTE: ● Skip steps 4–6 if the oil filter cartridge is not being replaced. ● When draining the engine oil, use a funnel or similar device to keep the oil away from the exhaust pipe. 4. Remove the oil filter cartridge with an oil filter wrench. U1C210E0.book Page 13 Tuesday, September 21, 2004 1:28 PM PERIODIC MAINTENANCE AND MINOR REPAIR 1. Oil filter wrench 2. Oil filter cartridge NOTE: An oil filter wrench is available at a Yamaha dealer. 5. Apply a thin coat of engine oil to the O-ring of the new oil filter cartridge. 1. O-ring 1. Torque wrench NOTE: Make sure that the O-ring is properly seated. 6. Install the new oil filter cartridge with an oil filter wrench, and then tighten it to the specified torque with a torque wrench. Tightening torque: Oil filter cartridge: 17 Nm (1.7 m·kgf, 12 ft·lbf) 7. Install the engine oil drain bolt, and then tighten it to the specified torque. Tightening torque: Engine oil drain bolt: 43 Nm (4.3 m·kgf, 31 ft·lbf) 8. Add the specified amount of the recommended engine oil, and then install and tighten the oil filler cap. 6-13 6 U1C210E0.book Page 14 Tuesday, September 21, 2004 1:28 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU20070 Recommended engine oil: See page 8-1. Oil quantity: Without oil filter cartridge replacement: 2.80 L (2.96 US qt) (2.46 Imp.qt) With oil filter cartridge replacement: 3.00 L (3.17 US qt) (2.64 Imp.qt) ECA11620 CAUTION: ● 6 ● In order to prevent clutch slippage (since the engine oil also lubricates the clutch), do not mix any chemical additives. Do not use oils with a diesel specification of “CD” or oils of a higher quality than specified. In addition, do not use oils labeled “ENERGY CONSERVING II” or higher. Make sure that no foreign material enters the crankcase. NOTE: After the engine is started, the engine oil level warning light should go off if the oil level is sufficient. Coolant CAUTION: The coolant level should be checked before each ride. In addition, the coolant must be changed at the intervals specified in the periodic maintenance and lubrication chart. If the oil level warning light flickers or remains on, immediately turn the engine off and have a Yamaha dealer check the vehicle. To check the coolant level 1. Place the vehicle on the centerstand. ECA10400 10. Turn the engine off, and then check the oil level and correct it if necessary. EAU20101 NOTE: ● The coolant level must be checked on a cold engine since the level varies with engine temperature. ● Make sure that the vehicle is positioned straight up when checking the coolant level. A slight tilt to the side can result in a false reading. 2. Check the coolant level in the coolant reservoir. 9. Start the engine, and then let it idle for several minutes while checking it for oil leakage. If oil is leaking, immediately turn the engine off and check for the cause. NOTE: The coolant should be between the minimum and maximum level marks. 6-14 U1C210E0.book Page 15 Tuesday, September 21, 2004 1:28 PM PERIODIC MAINTENANCE AND MINOR REPAIR ECA10470 CAUTION: ● ● 1. Coolant reservoir 2. Maximum level mark 3. Minimum level mark 3. If the coolant is at or below the minimum level mark, remove panel A (See page 6-9.), remove the reservoir cap, add coolant to the maximum level mark, and then install the reservoir cap and the panel. Coolant reservoir capacity (up to the maximum level mark): 0.30 L (0.32 US qt) (0.26 Imp.qt) ● If coolant is not available, use distilled water or soft tap water instead. Do not use hard water or salt water since it is harmful to the engine. If water has been used instead of coolant, replace it with coolant as soon as possible, otherwise the engine may not be sufficiently cooled and the cooling system will not be protected against frost and corrosion. If water has been added to the coolant, have a Yamaha dealer check the antifreeze content of the coolant as soon as possible, otherwise the effectiveness of the coolant will be reduced. EWA10380 WARNING Never attempt to remove the radiator cap when the engine is hot. 6-15 NOTE: ● The radiator fan is automatically switched on or off according to the coolant temperature in the radiator. ● If the engine overheats, see page 6-41 for further instructions. EAU20431 To change the coolant 1. Place the vehicle on the centerstand and let the engine cool if necessary. 2. Remove panels A and B. (See page 6-9.) 3. Place a container under the engine to collect the used coolant. 4. Remove the radiator cap. EWA10380 WARNING Never attempt to remove the radiator cap when the engine is hot. 6 U1C210E0.book Page 16 Tuesday, September 21, 2004 1:28 PM PERIODIC MAINTENANCE AND MINOR REPAIR 7. Install the coolant drain bolt, and then tighten it to the specified torque. ECA10470 CAUTION: ● NOTE: Check the washer for damage and replace it if necessary. ● 1. Radiator cap 5. Remove the coolant drain bolt to drain the cooling system. 6 1. Coolant drain bolt 6. After the coolant is completely drained, thoroughly flush the cooling system with clean tap water. Tightening torque: Coolant drain bolt: 7 Nm (0.7 m·kgf, 5 ft·lbf) 8. Pour the recommended coolant into the radiator until it is full. Recommended antifreeze: High-quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines Antifreeze/water mixture ratio: 1:1 Coolant quantity: Radiator capacity (including all routes): 2.40 L (2.54 US qt) (2.11 Imp.qt) Coolant reservoir capacity: 0.30 L (0.32 US qt) (0.26 Imp.qt) 6-16 ● If coolant is not available, use distilled water or soft tap water instead. Do not use hard water or salt water since it is harmful to the engine. If water has been used instead of coolant, replace it with coolant as soon as possible, otherwise the engine may not be sufficiently cooled and the cooling system will not be protected against frost and corrosion. If water has been added to the coolant, have a Yamaha dealer check the antifreeze content of the coolant as soon as possible, otherwise the effectiveness of the coolant will be reduced. 9. Install the radiator cap, start the engine, let it idle for several minutes, and then turn it off. 10. Remove the radiator cap to check the coolant level in the radiator. If necessary, add sufficient coolant U1C210E0.book Page 17 Tuesday, September 21, 2004 1:28 PM PERIODIC MAINTENANCE AND MINOR REPAIR until it reaches the top of the radiator, and then install the radiator cap. 11. Check the coolant level in the reservoir. If necessary, remove the coolant reservoir cap, add coolant to the maximum level mark, and then install the cap. 12. Start the engine, and then check the vehicle for coolant leakage. If coolant is leaking, have a Yamaha dealer check the cooling system. 13. Install the panels. EAU20681 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 frequently if you are riding in unusually wet or dusty areas. 1. Remove the seat. (See page 3-10.) 2. Remove the fuel tank bolts. ● Do not tilt or pull the fuel tank too much, otherwise the fuel hoses may come loose, which could cause fuel leakage. 4. Remove panels A and C. (See page 6-9.) 5. Pull the rubber cover off its holders. 6 1. Rubber cover 2. Rubber cover holder 1. Bolt 3. Lift the fuel tank to position it away from the air filter case. (Do not disconnect the fuel hoses!) EWA10410 WARNING ● Make sure that the fuel tank is well supported. 6-17 6. Remove the air filter case cover by removing the screws. U1C210E0.book Page 18 Tuesday, September 21, 2004 1:28 PM PERIODIC MAINTENANCE AND MINOR REPAIR out with compressed air as shown. If the air filter element is damaged, replace it. 13. Install the fuel tank by installing the bolts. EWA11290 WARNING ● 1. Air filter case cover 2. Screw 7. Pull the air filter element out. ● 1. Air filter element 9. Insert the air filter element into the air filter case. 6 ECA11330 CAUTION: 1. Air filter element 8. Lightly tap the air filter element to remove most of the dust and dirt, and then blow the remaining dirt ● Before installing the fuel tank, make sure that the fuel hoses are not damaged. If any fuel hose is damaged, do not start the engine but have a Yamaha dealer replace the hose, otherwise fuel may leak. Make sure that the fuel hoses are properly connected and routed, and not pinched. Be sure to place the fuel tank breather hose in the original position. The engine should never be operated without the air filter element installed, otherwise the piston(s) and/or cylinder(s) may become excessively worn. 10. Install the air filter case cover by installing the screws. 11. Place the rubber cover in the original position. 12. Install the panels. 6-18 1. Fuel tank breather hose 2. Original position (white mark) U1C210E0.book Page 19 Tuesday, September 21, 2004 1:28 PM PERIODIC MAINTENANCE AND MINOR REPAIR 14. Install the seat. EAU21271 Carburetors The carburetors are important parts of the engine and emission control system, which require very sophisticated adjustment. Therefore, all carburetor adjustments should be left to a Yamaha dealer, who has the necessary professional knowledge and experience. EAU21381 Checking the throttle cable free play 1. Throttle cable free play The throttle cable free play should measure 3.0–5.0 mm (0.12–0.20 in) at the throttle grip. Periodically check the throttle cable free play and, if necessary, have a Yamaha dealer adjust it. 6-19 6 U1C210E0.book Page 20 Tuesday, September 21, 2004 1:28 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU21401 EAU21750 Valve clearance Tires 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. To maximize the performance, durability, and safe operation of your motorcycle, note the following points regarding the specified tires. Tire air pressure The tire air pressure should be checked and, if necessary, adjusted before each ride. EWA10500 WARNING ● 6 ● The tire air pressure must be checked and adjusted on cold tires (i.e., when the temperature of the tires equals the ambient temperature). The tire air pressure must be adjusted in accordance with the riding speed and with the total weight of rider, passenger, cargo, and accessories approved for this model. 6-20 Tire air pressure (measured on cold tires): 0–90 kg (0–198 lb): Front: 250 kPa (36 psi) (2.50 kgf/cm²) Rear: 270 kPa (39 psi) (2.70 kgf/cm²) 90–188 kg (198–414 lb) (CAL) 90–189 kg (198–417 lb) (U49): Front: 250 kPa (36 psi) (2.50 kgf/cm²) Rear: 290 kPa (42 psi) (2.90 kgf/cm²) High-speed riding: Front: 250 kPa (36 psi) (2.50 kgf/cm²) Rear: 290 kPa (42 psi) (2.90 kgf/cm²) Maximum load*: 188 kg (414 lb) (CAL) 189 kg (417 lb) (U49) * Total weight of rider, passenger, cargo and accessories EWA10510 WARNING Proper loading of your vehicle is important for several characteristics of your vehicle, such as handling, braking, performance and safety. Do not carry loosely packed items that can shift. Securely pack your heavi- U1C210E0.book Page 21 Tuesday, September 21, 2004 1:28 PM PERIODIC MAINTENANCE AND MINOR REPAIR est items close to the center of the vehicle, and distribute the weight evenly from side to side. Properly adjust the suspension for your load, and check the condition and pressure of your tires. NEVER OVERLOAD YOUR VEHICLE. Make sure that the total weight of the cargo, rider, passenger, and accessories (cowling, saddlebags, etc. if approved for this model) does not exceed the maximum load of the vehicle. Operation of an overloaded vehicle could cause tire damage, an accident, or even injury. Tire inspection EWA10580 WARNING ● ● 1. Tire sidewall 2. Tire wear indicator 3. Tire tread depth Always check the tires before operating the motorcycle. If a tire tread shows crosswise lines (minimum tread depth), if the tire has a nail or glass fragments in it, or if the sidewall is cracked, contact a Yamaha dealer immediately and have the tire replaced. It is dangerous to ride with a worn-out tire. When a tire tread begins to show crosswise lines, have a Yamaha dealer replace the tire immediately. The replacement of all wheeland brake-related parts, including the tires, should be left to a Yamaha dealer, who has the necessary professional knowledge and experience. Tire information Minimum tire tread depth (front and rear): 1.0 mm (0.04 in) 1. Tire air valve 2. Tire air valve core 3. Tire air valve cap with seal 6-21 6 U1C210E0.book Page 22 Tuesday, September 21, 2004 1:28 PM PERIODIC MAINTENANCE AND MINOR REPAIR This motorcycle is equipped with cast wheels and tubeless tires with valves. EWA10480 WARNING ● ● ● 6 ● The front and rear tires should be of the same make and design, otherwise the handling characteristics of the motorcycle cannot be guaranteed. After extensive tests, only the tires listed below have been approved for this model by Yamaha Motor Co., Ltd. Always make sure that the valve caps are securely installed to prevent air pressure leakage. Use only the tire valves and valve cores listed below to avoid tire deflation during a high-speed ride. Front tire: Size: 120/70 ZR17M/C (58W) Manufacturer/model: BRIDGESTONE/BT020F U Rear tire: Size: 180/55 ZR17M/C (73W) Manufacturer/model: BRIDGESTONE/BT020R U FRONT and REAR: Tire air valve: TR412 Valve core: #9000A (original) ● ● EWA10600 WARNING This motorcycle is fitted with superhigh-speed tires. Note the following points in order to make the most efficient use of these tires. ● Use only the specified replacement tires. Other tires may run the danger of bursting at super high speeds. ● Brand-new tires can have a relatively poor grip on certain road surfaces until they have been “broken in”. Therefore, it is advisable before doing any high6-22 speed riding to ride conservatively for approximately 100 km (60 mi) after installing a new tire. The tires must be warmed up before a high-speed run. Always adjust the tire air pressure according to the operating conditions. U1C210E0.book Page 23 Tuesday, September 21, 2004 1:28 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU21960 Cast wheels To maximize the performance, durability, and safe operation of your vehicle, note the following points regarding the specified wheels. ● The wheel rims should be checked for cracks, bends or warpage before each ride. If any damage is found, have a Yamaha dealer replace the wheel. Do not attempt even the smallest repair to the wheel. A deformed or cracked wheel must be replaced. ● The wheel should be balanced whenever either the tire or wheel has been changed or replaced. An unbalanced wheel can result in poor performance, adverse handling characteristics, and a shortened tire life. ● Ride at moderate speeds after changing a tire since the tire surface must first be “broken in” for it to develop its optimal characteristics. EAU22011 Accessories and replacement parts any consequences caused by the use of items which have not been approved by Yamaha. EWA10621 WARNING This vehicle is not designed to pull a trailer or to be attached to a sidecar. The accessories or replacement parts you choose for your vehicle should be designed specifically for this model, and they must be securely mounted to maintain the inherent stability of the original design. Genuine Yamaha Parts and Accessories are designed and tested to be compatible with your vehicle. Please consider Genuine Yamaha Parts and Accessories before making a purchase. Use of nonYamaha-approved accessories or replacement parts may cause loss of handling stability and riding safety. Since Yamaha cannot control the quality of accessories or parts manufactured by other companies, Yamaha cannot be held liable for 6-23 6 U1C210E0.book Page 24 Tuesday, September 21, 2004 1:28 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU22080 Adjusting the clutch lever free play 6 EAU22270 NOTE: If the specified free play cannot be obtained as described above or if the clutch does not operate correctly, have a Yamaha dealer check the internal clutch mechanism. Adjusting the rear brake light switch 1. Clutch lever free play adjusting bolt 2. Clutch lever free play 1. Rear brake light switch 2. Rear brake light switch adjusting nut The clutch lever free play should measure 10.0–15.0 mm (0.39–0.59 in) as shown. Periodically check the clutch lever free play and, if necessary, adjust it as follows. To increase the clutch lever free play, turn the adjusting bolt in direction (a). To decrease the clutch lever free play, turn the adjusting bolt in direction (b). The rear brake light switch, which is activated by the brake pedal, is properly adjusted when the brake light comes on just before braking takes effect. If necessary, adjust the brake light switch as follows. Turn the adjusting nut while holding the rear brake light switch in place. To make the brake light come on earlier, turn the adjusting nut in direction (a). To make the brake light come on later, turn the adjusting nut in direction (b). 6-24 U1C210E0.book Page 25 Tuesday, September 21, 2004 1:28 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU22321 Checking the front and rear brake pads Front brake The front and rear brake pads must be checked for wear at the intervals specified in the periodic maintenance and lubrication chart. Each brake pad is provided with a wear indicator groove, which allows you to check the brake pad wear without having to disassemble the brake. To check the brake pad wear, check the wear indicator grooves. If a brake pad has worn to the point that the wear indicator groove has almost disappeared, have a Yamaha dealer replace the brake pads as a set. 1. Brake pad wear indicator groove EAU22580 Checking the brake fluid level Front brake 1. Minimum level mark Rear brake 6 Rear brake 1. Minimum level mark 1. Brake pad wear indicator groove Insufficient brake fluid may allow air to enter the brake system, possibly causing it to become ineffective. 6-25 U1C210E0.book Page 26 Tuesday, September 21, 2004 1:28 PM PERIODIC MAINTENANCE AND MINOR REPAIR 6 Before riding, check that the brake fluid is above the minimum level mark and replenish if necessary. A low brake fluid level may indicate worn brake pads and/or brake system leakage. If the brake fluid level is low, be sure to check the brake pads for wear and the brake system for leakage. Observe these precautions: ● When checking the fluid level, make sure that the top of the brake fluid reservoir is level. ● Use only the recommended quality brake fluid, otherwise the rubber seals may deteriorate, causing leakage and poor braking performance. ● ● ● Be careful that water does not enter the brake fluid reservoir when refilling. Water will significantly lower the boiling point of the fluid and may result in vapor lock. Brake fluid may deteriorate painted surfaces or plastic parts. Always clean up spilled fluid immediately. As the brake pads wear, it is normal for the brake fluid level to gradually go down. However, if the brake fluid level goes down suddenly, have a Yamaha dealer check the cause. Recommended brake fluid: DOT 4 ● Refill with the same type of brake fluid. Mixing fluids may result in a harmful chemical reaction and lead to poor braking performance. 6-26 EAU22730 Changing the brake fluid Have a Yamaha dealer change the brake fluid at the intervals specified in the NOTE after the periodic maintenance and lubrication chart. In addition, have the oil seals of the master cylinders and calipers as well as the brake hoses replaced at the intervals listed below or whenever they are damaged or leaking. ● Oil seals: Replace every two years. ● Brake hoses: Replace every four years. U1C210E0.book Page 27 Tuesday, September 21, 2004 1:28 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU22760 Drive chain slack The drive chain slack should be checked before each ride and adjusted if necessary. Drive chain slack: 40.0–50.0 mm (1.57–1.97 in) 5. If the drive chain slack is incorrect, adjust it as follows. EAU22791 To check the drive chain slack 1. Place the motorcycle on the centerstand. 2. Shift the transmission into the neutral position. 3. Spin the rear wheel several times to locate the tightest portion of the drive chain. 4. Measure the drive chain slack as shown. EAU22940 To adjust the drive chain slack 1. Loosen the axle nut and the locknut on each side of the swingarm. 2. To tighten the drive chain, turn the adjusting bolt on each side of the swingarm in direction (a). To loosen the drive chain, turn the adjusting bolt on each side of the swingarm in direction (b), and then push the rear wheel forward. NOTE: Using the alignment marks on each side of the swingarm, make sure that both chain pullers are in the same position for proper wheel alignment. 1. 2. 3. 4. Axle nut Drive chain slack adjusting bolt Locknut Alignment marks ECA10570 CAUTION: Improper drive chain slack will overload the engine as well as other vital parts of the motorcycle and can lead to chain slippage or breakage. To prevent this from occurring, keep the drive chain slack within the specified limits. 3. Tighten the locknuts, and then tighten the axle nut to the specified torque. 1. Drive chain slack 6-27 6 U1C210E0.book Page 28 Tuesday, September 21, 2004 1:28 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23021 Tightening torque: Axle nut: 150 Nm (15.0 m·kgf, 108 ft·lbf) CAUTION: The drive chain must be cleaned and lubricated at the intervals specified in the periodic maintenance and lubrication chart, otherwise it will quickly wear out, especially when riding in dusty or wet areas. Service the drive chain as follows. Do not use engine oil or any other lubricants for the drive chain, as they may contain substances that could damage the O-rings. ECA10581 CAUTION: The drive chain must be lubricated after washing the motorcycle and riding in the rain. 6 ECA11110 Lubricating the drive chain 1. Clean the drive chain with kerosene and a small soft brush. ECA11120 CAUTION: To prevent damaging the O-rings, do not clean the drive chain with steam cleaners, high-pressure washers or inappropriate solvents. 2. Wipe the drive chain dry. 3. Thoroughly lubricate the drive chain with a special O-ring chain lubricant. 6-28 U1C210E0.book Page 29 Tuesday, September 21, 2004 1:28 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23090 EAU23110 Checking and lubricating the cables Checking and lubricating the throttle grip and cable The operation of all control cables and the condition of the cables should be checked before each ride, and the cables and cable ends should be lubricated if necessary. If a cable is damaged or does not move smoothly, have a Yamaha dealer check or replace it. The operation of the throttle grip should be checked before each ride. In addition, the cable should be lubricated or replaced at the intervals specified in the periodic maintenance chart. Recommended lubricant: Yamaha Chain and Cable Lube or engine oil SAE 10W-30 (API SE) EAU23131 Checking and lubricating the brake and shift pedals The operation of the brake and shift pedals should be checked before each ride, and the pedal pivots should be lubricated if necessary. EWA10710 WARNING Damage to the outer housing of cables may result in internal rusting and cause interference with cable movement. Replace damaged cables as soon as possible to prevent unsafe conditions. Recommended lubricant: Lithium-soap-based grease (all-purpose grease) 6-29 6 U1C210E0.book Page 30 Tuesday, September 21, 2004 1:28 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23140 Checking and lubricating the brake and clutch levers EAU23210 Checking and lubricating the centerstand and sidestand EAUM1650 Lubricating the swingarm pivots The swingarm pivots must be lubricated at the intervals specified in the periodic maintenance and lubrication chart. Recommended lubricant: Lithium-soap-based grease 6 The operation of the brake and clutch levers should be checked before each ride, and the lever pivots should be lubricated if necessary. Recommended lubricant: Lithium-soap-based grease (all-purpose grease) The operation of the centerstand and sidestand should be checked before each ride, and the pivots and metal-tometal contact surfaces should be lubricated if necessary. EWA10740 WARNING If the centerstand or sidestand does not move up and down smoothly, have a Yamaha dealer check or repair it. Recommended lubricant: Lithium-soap-based grease (all-purpose grease) 6-30 U1C210E0.book Page 31 Tuesday, September 21, 2004 1:28 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23250 Lubricating the rear suspension The pivoting points of the rear suspension must be lubricated at the intervals specified in the periodic maintenance and lubrication chart. EAU23271 Checking the front fork The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart. To check the condition Recommended lubricant: Lithium-soap-based grease EWA10750 WARNING Securely support the vehicle so that there is no danger of it falling over. Check the inner tubes for scratches, damage and excessive oil leakage. To check the operation 1. Place the vehicle on a level surface and hold it in an upright position. 2. While applying the front brake, push down hard on the handlebars several times to check if the front fork compresses and rebounds smoothly. 6-31 ECA10590 CAUTION: If any damage is found or the front fork does not operate smoothly, have a Yamaha dealer check or repair it. 6 U1C210E0.book Page 32 Tuesday, September 21, 2004 1:28 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23280 EAU23290 Checking the steering Checking the wheel bearings Worn or loose steering bearings may cause danger. Therefore, the operation of the steering must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart. 1. Place a stand under the engine to raise the front wheel off the ground. The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart. If there is play in the wheel hub or if the wheel does not turn smoothly, have a Yamaha dealer check the wheel bearings. EWA10750 WARNING Securely support the vehicle so that there is no danger of it falling over. 6 2. Hold the lower ends of the front fork legs and try to move them forward and backward. If any free play can be felt, have a Yamaha dealer check or repair the steering. 6-32 U1C210E0.book Page 33 Tuesday, September 21, 2004 1:28 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU33650 Battery ● 1. Negative battery terminal 2. Positive battery terminal This model is equipped with a sealedtype (MF) battery, which does not require any maintenance. There is no need to check the electrolyte or to add distilled water. EWA10760 WARNING ● Electrolyte is poisonous and dangerous since it contains sulfuric acid, which causes severe burns. Avoid any contact with skin, eyes or clothing and always shield your eyes when ● working near batteries. In case of contact, administer the following FIRST AID. • EXTERNAL: Flush with plenty of water. • INTERNAL: Drink large quantities of water or milk and immediately call a physician. • EYES: Flush with water for 15 minutes and seek prompt medical attention. Batteries produce explosive hydrogen gas. Therefore, keep sparks, flames, cigarettes, etc., away from the battery and provide sufficient ventilation when charging it in an enclosed space. KEEP THIS AND ALL BATTERIES OUT OF THE REACH OF CHILDREN. To charge the battery Have a Yamaha dealer charge the battery as soon as possible if it seems to have discharged. Keep in mind that the 6-33 battery tends to discharge more quickly if the vehicle is equipped with optional electrical accessories. To store the battery 1. If the vehicle will not be used for more than one month, remove the battery, fully charge it, and then place it in a cool, dry place. 2. If the battery will be stored for more than two months, check it at least once a month and fully charge it if necessary. 3. Fully charge the battery before installation. 4. After installation, make sure that the battery leads are properly connected to the battery terminals. ECA10630 CAUTION: ● ● Always keep the battery charged. Storing a discharged battery can cause permanent battery damage. To charge a sealed-type (MF) battery, a special (constant-voltage) battery charger is required. Using a conventional battery charger will damage the battery. 6 U1C210E0.book Page 34 Tuesday, September 21, 2004 1:28 PM PERIODIC MAINTENANCE AND MINOR REPAIR If you do not have access to a sealed-type (MF) battery charger, have a Yamaha dealer charge your battery. 6 EAU23622 Replacing the fuses 1. 2. 3. 4. 5. 6. 7. 8. Main fuse Headlight fuse Radiator fan fuse Ignition fuse Signaling system fuse Backup fuse (for odometer and clock) Spare fuse Spare main fuse The main fuse and the fuse box, which contains the fuses for the individual circuits, are located under the seat. (See page 3-10.) If a fuse is blown, replace it as follows. 1. Turn the key to “OFF” and turn off the electrical circuit in question. 2. Remove the blown fuse, and then install a new fuse of the specified amperage. 6-34 Specified fuses: Main fuse: 30.0 A Headlight fuse: 20.0 A Radiator fan fuse: 10.0 A Ignition fuse: 20.0 A Signaling system fuse: 20.0 A Backup fuse: 10.0 A ECA10640 CAUTION: Do not use a fuse of a higher amperage rating than recommended to avoid causing extensive damage to the electrical system and possibly a fire. 3. Turn the key to “ON” and turn on the electrical circuit in question to check if the device operates. 4. If the fuse immediately blows again, have a Yamaha dealer check the electrical system. U1C210E0.book Page 35 Tuesday, September 21, 2004 1:28 PM PERIODIC MAINTENANCE AND MINOR REPAIR ● EAU23900 Replacing a headlight bulb This model is equipped with quartz bulb headlights. If a headlight bulb burns out, replace it as follows. 1. Remove panel D (if replacing the left headlight bulb) or panel B (if replacing the right headlight bulb). (See page 6-9.) 2. Disconnect the headlight coupler, and then remove the headlight bulb cover. 1. Headlight bulb holder EWA10790 WARNING Headlight bulbs get very hot. Therefore, keep flammable products away from a lit headlight bulb, and do not touch the bulb until it has cooled down. ● Headlight bulb Do not touch the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the luminosity of the bulb, and the bulb life will be adversely affected. Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with alcohol or thinner. Headlight lens Do not affix any type of tinted film or stickers to the headlight lens. Do not use a headlight bulb of a wattage higher than specified. 4. Place a new headlight bulb into position, and then secure it with the bulb holder. 1. Headlight bulb cover 2. Headlight coupler 3. Unhook the headlight bulb holder, and then remove the defective bulb. ECA10650 CAUTION: Take care not to damage the following parts: 1. Do not touch the glass part of the bulb. 6-35 6 U1C210E0.book Page 36 Tuesday, September 21, 2004 1:28 PM PERIODIC MAINTENANCE AND MINOR REPAIR 5. Install the headlight bulb cover, and then connect the coupler. 6. Install the panel. 7. Have a Yamaha dealer adjust the headlight beam if necessary. EAU24160 Replacing a tail/brake light bulb 1. Remove the seat. (See page 3-10.) 2. Remove the tail/brake light bulb cover. 1. Tail/brake light bulb socket 6 1. Tail/brake light bulb cover 3. Remove the socket (together with the bulb) by turning it counterclockwise. 6-36 4. Remove the defective bulb by pushing it in and turning it counterclockwise. 5. Insert a new bulb into the socket, push it in, and then turn it clockwise until it stops. 6. Install the socket (together with the bulb) by turning it clockwise. 7. Install the bulb cover. 8. Install the seat. U1C210E0.book Page 37 Tuesday, September 21, 2004 1:28 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU24201 Replacing a turn signal light bulb 1. Remove the turn signal light lens by removing the screw. EAU24360 Front wheel EAU33680 To remove the front wheel EWA10820 3. Remove the brake hose holder and reflector on each side by removing the bolts. 4. Remove the brake caliper on each side by removing the bolts. WARNING ● ● 1. Screw 2. Remove the defective bulb by pushing it in and turning it counterclockwise. 3. Insert a new bulb into the socket, push it in, and then turn it clockwise until it stops. 4. Install the lens by installing the screw. It is advisable to have a Yamaha dealer service the wheel. Securely support the motorcycle so that there is no danger of it falling over. 1. Place the motorcycle on the centerstand. 2. Loosen the front wheel axle pinch bolt, then the wheel axle and the brake caliper bolts. Reflector Brake hose holder Brake caliper bolt Brake caliper 6 ECA11050 CAUTION: Do not apply the brake after the brake calipers have been removed, otherwise the brake pads will be forced shut. ECA11190 CAUTION: Do not overtighten the screw, otherwise the lens may break. 1. 2. 3. 4. 1. Wheel axle 2. Front wheel axle pinch bolt 6-37 5. Pull the wheel axle out, and then remove the wheel. U1C210E0.book Page 38 Tuesday, September 21, 2004 1:28 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU33691 To install the front wheel 1. Lift the wheel up between the fork legs. 2. Insert the wheel axle. 3. Install the brake calipers by installing the bolts. NOTE: Make sure that there is enough space between the brake pads before installing the brake calipers onto the brake discs. 6 EAU25080 Tightening torques: Wheel axle: 72 Nm (7.2 m·kgf, 52 ft·lbf) Front wheel axle pinch bolt: 19 Nm (1.9 m·kgf, 14 ft·lbf) Brake caliper bolt: 40 Nm (4.0 m·kgf, 29 ft·lbf) Rear wheel EAU25201 To remove the rear wheel EWA10820 WARNING ● 7. Push down hard on the handlebar several times to check for proper fork operation. ● It is advisable to have a Yamaha dealer service the wheel. Securely support the motorcycle so that there is no danger of it falling over. 1. Loosen the axle nut and the brake caliper bolts. 4. Install the brake hose holder and reflector on each side by installing the bolts. 5. Take the motorcycle off the centerstand so that the front wheel is on the ground. 6. Tighten the wheel axle, the front wheel axle pinch bolt and the brake caliper bolts to the specified torques. 1. Axle nut 2. Place the motorcycle on the centerstand. 6-38 U1C210E0.book Page 39 Tuesday, September 21, 2004 1:28 PM PERIODIC MAINTENANCE AND MINOR REPAIR 3. Disconnect the brake torque rod from the brake caliper by removing the nut and the bolt. 1. 2. 3. 4. 5. Brake caliper bolt Brake torque rod Brake torque rod bolt Brake torque rod nut Brake caliper bracket 6. Turn the drive chain slack adjusting bolts fully in direction (a). 7. Push the wheel forward, and then remove the drive chain from the rear sprocket. EAU25841 To install the rear wheel 1. Place the wheel and the brake caliper bracket in the original position. 2. Insert the wheel axle through the brake caliper bracket and wheel from the right-hand side, and then install the axle nut. 3. Install the drive chain onto the rear sprocket, and then adjust the drive chain slack. (See page 6-27.) 1. Drive chain slack adjusting bolt 2. Locknut 4. Remove the axle nut, then the brake caliper by removing the bolts. ECA11300 CAUTION: Do not apply the brake after the brake caliper has been removed, otherwise the brake pads will be forced shut. NOTE: The drive chain does not need to be disassembled in order to remove and install the rear wheel. 8. While supporting the wheel, pull the wheel axle out. 9. Remove the wheel. 5. Loosen the locknut on each side of the swingarm. 6-39 6 4. Connect the brake torque rod to the brake caliper bracket by installing the bolt and the nut. 5. Install the brake caliper by installing the bolts. U1C210E0.book Page 40 Tuesday, September 21, 2004 1:28 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU25870 NOTE: Make sure that there is enough space between the brake pads before installing the brake caliper onto the brake disc. 6. Take the motorcycle off the centerstand so that the rear wheel is on the ground. 7. Tighten the axle nut, brake caliper bolts and brake torque rod nut to the specified torques. 6 Tightening torques: Axle nut: 150 Nm (15.0 m·kgf, 108 ft·lbf) Brake caliper bolt: 40 Nm (4.0 m·kgf, 29 ft·lbf) Brake torque rod nut: 23 Nm (2.3 m·kgf, 17 ft·lbf) Troubleshooting Although Yamaha motorcycles receive a thorough inspection before shipment from the factory, trouble may occur during operation. Any problem in the fuel, compression, or ignition systems, for example, can cause poor starting and loss of power. The following troubleshooting charts represent quick and easy procedures for checking these vital systems yourself. However, should your motorcycle require any repair, take it to a Yamaha dealer, whose skilled technicians have the necessary tools, experience, and know-how to service the motorcycle properly. Use only genuine Yamaha replacement parts. Imitation parts may look like Yamaha parts, but they are often inferior, have a shorter service life and can lead to expensive repair bills. 6-40 U1C210E0.book Page 41 Tuesday, September 21, 2004 1:28 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU25911 Troubleshooting charts Starting problems or poor engine performance EWA10840 WARNING Keep away open flames and do not smoke while checking or working on the fuel system. 1. Fuel There is enough fuel. Check the compression. There is no fuel. Supply fuel. There is compression. Check the ignition. There is no compression. Have a Yamaha dealer check the vehicle. Check the fuel level in the fuel tank. The engine does not start. Check the compression. 2. Compression 6 Operate the electric starter. 3. Ignition Wet Wipe off with a dry cloth and correct the spark plug gaps, or replace the spark plugs. Open the throttle halfway and operate the electric starter. Dry Have a Yamaha dealer check the vehicle. The engine does not start. Check the battery. Remove the spark plugs and check the electrodes. 4. Battery The engine turns over quickly. The battery is good. The engine turns over slowly. Check the battery lead connections, and charge the battery if necessary. Operate the electric starter. 6-41 The engine does not start. Have a Yamaha dealer check the vehicle. U1C210E0.book Page 42 Tuesday, September 21, 2004 1:28 PM PERIODIC MAINTENANCE AND MINOR REPAIR Engine overheating EWA10400 WARNING ● ● Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury. Be sure to wait until the engine has cooled. After removing the radiator cap retaining bolt, place a thick rag, like a towel, over the radiator cap, and then slowly rotate the cap counterclockwise to the detent to allow any residual pressure to escape. When the hissing sound has stopped, press down on the cap while turning it counterclockwise, and then remove the cap. The coolant level is low. Check the cooling system for leakage. Wait until the engine has cooled. 6 Check the coolant level in the reservoir and radiator. The coolant level is OK. There is leakage. There is no leakage. Have a Yamaha dealer check and repair the cooling system. Add coolant. (See NOTE.) Start the engine. If the engine overheats again, have a Yamaha dealer check and repair the cooling system. NOTE: If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommended coolant as soon as possible. 6-42 U1C210E0.book Page 1 Tuesday, September 21, 2004 1:28 PM MOTORCYCLE CARE AND STORAGE ucts onto seals, gaskets, sprockets, the drive chain and wheel axles. Always rinse the dirt and degreaser off with water. EAU26010 Care While the open design of a motorcycle reveals the attractiveness of the technology, it also makes it more vulnerable. Rust and corrosion can develop even if high-quality components are used. A rusty exhaust pipe may go unnoticed on a car, however, it detracts from the overall appearance of a motorcycle. Frequent and proper care does not only comply with the terms of the warranty, but it will also keep your motorcycle looking good, extend its life and optimize its performance. Before cleaning 1. Cover the muffler outlet with a plastic bag after the engine has cooled down. 2. Make sure that all caps and covers as well as all electrical couplers and connectors, including the spark plug caps, are tightly installed. 3. Remove extremely stubborn dirt, like oil burnt onto the crankcase, with a degreasing agent and a brush, but never apply such prod- ● Cleaning ECA10770 CAUTION: ● ● ● Avoid using strong acidic wheel cleaners, especially on spoked wheels. If such products are used on hard-to-remove dirt, do not leave the cleaner on the affected area any longer than instructed. Also, thoroughly rinse the area off with water, immediately dry it, and then apply a corrosion protection spray. Improper cleaning can damage windshields, 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. Be sure to avoid using cloths or sponges which have been in contact with strong or abrasive 7-1 ● cleaning products, solvent or thinner, fuel (gasoline), rust removers or inhibitors, brake fluid, antifreeze or electrolyte. Do not use high-pressure washers or steam-jet cleaners since they cause water seepage and deterioration in the following areas: seals (of wheel and swingarm bearings, fork and brakes), electric components (couplers, connectors, instruments, switches and lights), breather hoses and vents. For motorcycles equipped with a windshield: Do not use strong cleaners or hard sponges as they will cause dulling or scratching. Some cleaning compounds for plastic may leave scratches on the windshield. Test the product on a small hidden part of the windshield to make sure that it does not leave any marks. If the windshield is scratched, use a quality plastic polishing compound after washing. 7 U1C210E0.book Page 2 Tuesday, September 21, 2004 1:28 PM MOTORCYCLE CARE AND STORAGE After normal use Remove dirt with warm water, a mild detergent, and a soft, clean sponge, and then rinse thoroughly with clean water. Use a toothbrush or bottlebrush for hard-to-reach areas. Stubborn dirt and insects will come off more easily if the area is covered with a wet cloth for a few minutes before cleaning. 7 After riding in the rain, near the sea or on salt-sprayed roads Since sea salt or salt sprayed on roads during winter are extremely corrosive in combination with water, carry out the following steps after each ride in the rain, near the sea or on salt-sprayed roads. NOTE: Salt sprayed on roads in the winter may remain well into spring. 1. Clean the motorcycle with cold water and a mild detergent, after the engine has cooled down. ECA10790 CAUTION: Do not use warm water since it increases the corrosive action of the salt. 2. Apply a corrosion protection spray on all metal, including chrome- and nickel-plated, surfaces to prevent corrosion. After cleaning 1. Dry the motorcycle with a chamois or an absorbing cloth. 2. Immediately dry the drive chain and lubricate it to prevent it from rusting. 3. Use a chrome polish to shine chrome, aluminum and stainlesssteel parts, including the exhaust system. (Even the thermally induced discoloring of stainlesssteel exhaust systems can be removed through polishing.) 4. To prevent corrosion, it is recommended to apply a corrosion protection spray on all metal, including chrome- and nickel-plated, surfaces. 7-2 5. Use spray oil as a universal cleaner to remove any remaining dirt. 6. Touch up minor paint damage caused by stones, etc. 7. Wax all painted surfaces. 8. Let the motorcycle dry completely before storing or covering it. EWA10930 WARNING ● ● Make sure that there is no oil or wax on the brakes or tires. If necessary, clean the brake discs and brake linings with a regular brake disc cleaner or acetone, and wash the tires with warm water and a mild detergent. Before operating the motorcycle test its braking performance and cornering behavior. ECA10800 CAUTION: ● Apply spray oil and wax sparingly and make sure to wipe off any excess. U1C210E0.book Page 3 Tuesday, September 21, 2004 1:28 PM MOTORCYCLE CARE AND STORAGE ● ● Never apply oil or wax to any rubber and plastic parts, but treat them with a suitable care product. Avoid using abrasive polishing compounds as they will wear away the paint. NOTE: Consult a Yamaha dealer for advice on what products to use. EAU26160 Storage Short-term Always store your motorcycle in a cool, dry place and, if necessary, protect it against dust with a porous cover. ECA10810 CAUTION: ● ● Storing the motorcycle in a poorly ventilated room or covering it with a tarp, while it is still wet, will allow water and humidity to seep in and cause rust. To prevent corrosion, avoid damp cellars, stables (because of the presence of ammonia) and areas where strong chemicals are stored. Long-term Before storing your motorcycle for several months: 1. Follow all the instructions in the “Care” section of this chapter. 2. For motorcycles equipped with a fuel cock that has an “OFF” position: Turn the fuel cock lever to “OFF”. 7-3 3. Drain the carburetor float chamber by loosening the drain bolt; this will prevent fuel deposits from building up. Pour the drained fuel into the fuel tank. 4. Fill up the fuel tank and add fuel stabilizer (if available) to prevent the fuel tank from rusting and the fuel from deteriorating. 5. Perform the following steps to protect the cylinders, piston rings, etc. from corrosion. a. Remove the spark plug caps and spark plugs. b. Pour a teaspoonful of engine oil into each spark plug bore. c. Install the spark plug caps onto the spark plugs, and then place the spark plugs on the cylinder head so that the electrodes are grounded. (This will limit sparking during the next step.) d. Turn the engine over several times with the starter. (This will coat the cylinder walls with oil.) e. Remove the spark plug caps from the spark plugs, and then install the spark plugs and the spark plug caps. 7 U1C210E0.book Page 4 Tuesday, September 21, 2004 1:28 PM MOTORCYCLE CARE AND STORAGE EWA10950 WARNING To prevent damage or injury from sparking, make sure to ground the spark plug electrodes while turning the engine over. 7 °C (90 °F)]. For more information on storing the battery, see page 6-33. NOTE: Make any necessary repairs before storing the motorcycle. 6. Lubricate all control cables and the pivoting points of all levers and pedals as well as of the sidestand/centerstand. 7. Check and, if necessary, correct the tire air pressure, and then lift the motorcycle so that both of its wheels are off the ground. Alternatively, turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot. 8. Cover the muffler outlet with a plastic bag to prevent moisture from entering it. 9. Remove the battery and fully charge it. Store it in a cool, dry place and charge it once a month. Do not store the battery in an excessively cold or warm place [less than 0 °C (30 °F) or more than 30 7-4 U1C210E0.book Page 1 Tuesday, September 21, 2004 1:28 PM SPECIFICATIONS Dimensions: Overall length: 2125 mm (83.7 in) Overall width: 765 mm (30.1 in) Overall height: 1190 mm (46.9 in) Seat height: 820 mm (32.3 in) Wheelbase: 1450 mm (57.1 in) Ground clearance: 140 mm (5.51 in) Minimum turning radius: 2900 mm (114.2 in) Weight: With oil and fuel: 231.0 kg (509 lb) (U49) 232.0 kg (511 lb) (CAL) Engine: Engine type: Liquid cooled 4-stroke, DOHC Cylinder arrangement: Forward-inclined parallel 4-cylinder Displacement: 998.0 cm³ (60.90 cu.in) Bore × stroke: 74.0 × 58.0 mm (2.91 × 2.28 in) Compression ratio: 11.40 :1 Starting system: Electric starter Lubrication system: Wet sump Engine oil: Type: YAMALUBE 4, SAE10W30 or SAE20W40 Fuel tank capacity: 21.0 L (5.55 US gal) (4.62 Imp.gal) Fuel reserve amount: 4.1 L (1.08 US gal) (0.90 Imp.gal) Carburetor: 0° 10° 30° 50° 70° 90° 110° 130°F YAMALUBE 4 (10W30) or SAE 10W30 YAMALUBE 4 (20W40) or SAE 20W40 –20° –10° 0° 10° 20° 30° 40° 50°C Recommended engine oil grade: API service SE, SF, SG type or higher Engine oil quantity: Without oil filter cartridge replacement: 2.80 L (2.96 US qt) (2.46 Imp.qt) With oil filter cartridge replacement: 3.00 L (3.17 US qt) (2.64 Imp.qt) Cooling system: Coolant reservoir capacity (up to the maximum level mark): 0.30 L (0.32 US qt) (0.26 Imp.qt) Radiator capacity (including all routes): 2.40 L (2.54 US qt) (2.11 Imp.qt) Air filter: Air filter element: Dry element Fuel: Recommended fuel: Unleaded gasoline only 8-1 Manufacturer: MIKUNI Type x quantity: BSR37 x 4 Spark plug(s): Manufacturer/model: NGK/CR9E Manufacturer/model: DENSO/U27ESR-N Spark plug gap: 0.7–0.8 mm (0.028–0.031 in) Clutch: Clutch type: Wet, multiple-disc Transmission: Primary reduction system: Spur gear Primary reduction ratio: 68/43 (1.581) Secondary reduction system: Chain drive Secondary reduction ratio: 44/16 (2.750) Transmission type: Constant mesh 6-speed Operation: Left foot operation 8 U1C210E0.book Page 2 Tuesday, September 21, 2004 1:28 PM SPECIFICATIONS Gear ratio: 1st: 35/14 (2.500) 2nd: 35/19 (1.842) 3rd: 30/20 (1.500) 4th: 28/21 (1.333) 5th: 30/25 (1.200) 6th: 29/26 (1.115) Chassis: Frame type: Double cradle Caster angle: 26.00 ° Trail: 104.0 mm (4.09 in) Front tire: 8 Type: Tubeless Size: 120/70 ZR17M/C (58W) Manufacturer/model: BRIDGESTONE/BT020F U Rear tire: Type: Tubeless Size: 180/55 ZR17M/C (73W) Manufacturer/model: BRIDGESTONE/BT020R U Loading: Maximum load: 188 kg (414 lb) (CAL) 189 kg (417 lb) (U49) (Total weight of rider, passenger, cargo and accessories) Tire air pressure (measured on cold tires): Loading condition: 0–90 kg (0–198 lb) Front: 250 kPa (36 psi) (2.50 kgf/cm²) Rear: 270 kPa (39 psi) (2.70 kgf/cm²) Loading condition: 90–188 kg (198–414 lb) (CAL) 90–189 kg (198–417 lb) (U49) Front: 250 kPa (36 psi) (2.50 kgf/cm²) Rear: 290 kPa (42 psi) (2.90 kgf/cm²) High-speed riding: Front: 250 kPa (36 psi) (2.50 kgf/cm²) Rear: 290 kPa (42 psi) (2.90 kgf/cm²) Front wheel: Wheel type: Cast wheel Rim size: 17M/C x MT3.50 Rim size: 17M/C x MT5.50 Front brake: Type: Dual disc brake Operation: Right hand operation Recommended fluid: DOT 4 Rear brake: Type: Single disc brake Operation: Right foot operation Recommended fluid: DOT 4 Front suspension: Type: Telescopic fork Spring/shock absorber type: Coil spring/oil damper Wheel travel: 140.0 mm (5.51 in) Rear suspension: Type: Swingarm (link suspension) Spring/shock absorber type: Coil spring/gas-oil damper Wheel travel: 135.0 mm (5.31 in) Electrical system: Rear wheel: Ignition system: Transistorized coil ignition (digital) Wheel type: Cast wheel 8-2 U1C210E0.book Page 3 Tuesday, September 21, 2004 1:28 PM SPECIFICATIONS Charging system: AC magneto Battery: Model: GT14B-4 Voltage, capacity: 12 V, 12.0 Ah Headlight: Bulb type: Halogen bulb Bulb voltage, wattage x quantity: Headlight: 12 V, 60 W/55.0 W × 2 Tail/brake light: 12 V, 5.0 W/21.0 W × 2 Front turn signal/position light: 12 V, 27 W/8.0 W × 2 Rear turn signal light: 12 V, 27.0 W × 2 Meter lighting: 12 V, 2.0 W × 3 Neutral indicator light: 14 V, 1.4 W × 1 High beam indicator light: 14 V, 1.4 W × 1 Oil level warning light: 14 V, 1.4 W × 1 Turn signal indicator light: 14 V, 1.4 W × 2 Fuel level warning light: 12 V, 2.0 W × 1 Coolant temperature warning light: LED Fuses: Main fuse: 30.0 A Headlight fuse: 20.0 A Signaling system fuse: 20.0 A Ignition fuse: 20.0 A Radiator fan fuse: 10.0 A Backup fuse: 10.0 A 8 8-3 U1C210E0.book Page 1 Tuesday, September 21, 2004 1:28 PM CONSUMER INFORMATION EAU26351 Identification numbers EAU26381 EAU26400 Key identification number Vehicle identification number 1. Key identification number 1. Vehicle identification number The key identification number is stamped into the key tag. Record this number in the space provided and use it for reference when ordering a new key. The vehicle identification number is stamped into the steering head pipe. Record this number in the space provided. Record the key identification number, vehicle identification number and model label information in the spaces provided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen. KEY IDENTIFICATION NUMBER: VEHICLE IDENTIFICATION NUMBER: MODEL LABEL INFORMATION: 9 9-1 NOTE: The vehicle identification number is used to identify your motorcycle and may be used to register your motorcycle with the licensing authority in your area. U1C210E0.book Page 2 Tuesday, September 21, 2004 1:28 PM CONSUMER INFORMATION EAU26480 Model label 1. Model label The model label is affixed to the frame under the seat. (See page 3-10.) Record the information on this label in the space provided. This information will be needed when ordering spare parts from a Yamaha dealer. 9 9-2 U1C210E0.book Page 3 Tuesday, September 21, 2004 1:28 PM CONSUMER INFORMATION EAU26550 Reporting safety defects If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Yamaha Motor Corporation, U.S.A. If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in individual problems between you, your dealer, or Yamaha Motor Corporation, U.S.A. To contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1-800-424-9393 (or 366-0123 in Washington, D.C. area) or write to: NHTSA, U.S. Department of Transportation, Washington, D.C. 20590. You can also obtain other information about motor vehicle safety from the Hotline. 9 9-3 U1C210E0.book Page 4 Tuesday, September 21, 2004 1:28 PM CONSUMER INFORMATION EAU26560 Motorcycle noise regulation TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. “AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW”. These acts include tampering with the following systems; i.e., modification, removal, etc. Exhaust system • Muffler • Exhaust pipe • Silencer Intake system • Air cleaner case • Air cleaner element • Intake duct 9 9-4 U1C210E0.book Page 5 Tuesday, September 21, 2004 1:28 PM CONSUMER INFORMATION EAU26632 Maintenance record Copies of work orders and/or receipts for parts purchased and installed on your vehicle will be required to document that maintenance has been completed in accordance with the emissions warranty. The chart below is printed only as a reminder that maintenance work is required. It is not acceptable proof of maintenance work. Maintenance interval 9 Date of service Servicing dealer name and address Mileage 600 mi (1000 km) or 1 month 4000 mi (7000 km) or 6 months 8000 mi (13000 km) or 12 months 12000 mi (19000 km) or 18 months 16000 mi (25000 km) or 24 months 20000 mi (31000 km) or 30 months 24000 mi (37000 km) or 36 months 28000 mi (43000 km) or 42 months 32000 mi (49000 km) or 48 months 9-5 Remarks U1C210E0.book Page 6 Tuesday, September 21, 2004 1:28 PM CONSUMER INFORMATION Maintenance interval Date of service Servicing dealer name and address Mileage Remarks 36000 mi (55000 km) or 54 months 40000 mi (61000 km) or 60 months 9 9-6 U1C210E0.book Page 7 Tuesday, September 21, 2004 1:28 PM CONSUMER INFORMATION EAU26661 YAMAHA MOTOR CORPORATION, U.S.A. STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY 9 9-7 U1C210E0.book Page 8 Tuesday, September 21, 2004 1:28 PM CONSUMER INFORMATION 9 9-8 U1C210E0.book Page 9 Tuesday, September 21, 2004 1:28 PM CONSUMER INFORMATION EAU26750 YAMAHA EXTENDED SERVICE (Y.E.S.) Keep your Yamaha protected even after your warranty expires with genuine Yamaha Extended Service (Y.E.S.). In addition, Travel and Recreation Interruption Protection (TRIP) is included at no extra cost. TRIP gives you up to $150 reimbursement per occurrence for any reasonable expenses you incur because your Yamaha needs covered service: replacement vehicle rental, emergency towing, phone calls, even food and lodging when you are away from home. This superb coverage goes into effect when you purchase Y.E.S., so it applies to any warranty repairs as well as covered repairs during your entire Y.E.S. plan period. Y.E.S. is designed and administered by Yamaha Motor Corporation to provide maximum owner satisfaction. You get uninterrupted factory-backed coverage for extra peace of mind. Y.E.S. is flexible. You choose the plan that’s right for you: 12 months, 24 months, 36 months or, on certain models, even 48 months beyond your warranty period. Y.E.S. coverage is honored at any authorized Yamaha dealer nationwide. Y.E.S. is designed and administered by the same Yamaha people who handle your warranty – and it shows in the comprehensive coverage benefits. There are no mileage limitations. Coverage isn’t limited to “moving parts” or the “drive train” like many other plans. And Y.E.S. covers manufacturing defects just like the warranty. See the sample contract at your Yamaha dealer to see how comforting uninterrupted factorybacked protection can be. Y.E.S. coverage is transferable to a new owner if you sell or trade-in. That can make your Yamaha much more valuable! This excellent Y.E.S. plan coverage is only available to Yamaha owners like you, and only while your Yamaha is still within the Yamaha Limited Warranty period. So visit your authorized Yamaha dealer to get all the facts. He can show you how easy it is to protect your investment with Yamaha Extended Service. You don’t have to pay anything for covered repairs. There’s no deductible to pay, and repairs aren’t “pro-rated.” You don’t have any “out-of-pocket” expenses for covered repairs. 9 9-9 U1C210E0.book Page 10 Tuesday, September 21, 2004 1:28 PM CONSUMER INFORMATION We urge you to act now. You’ll get the excellent benefits of TRIP coverage right away, and you’ll rest easy knowing you’ll have strong factory-backed protection even after your Yamaha Limited Warranty expires. A special note: If visiting your dealer isn’t convenient, contact Yamaha with your Primary ID number (your frame number). We’ll be happy to help you get the Y.E.S. coverage you need. Yamaha Service Marketing P.O. Box 6555 Cypress, CA 90630 1-(866)-YES-EXTD (1-866-937-3983) 9 9-10 U1C210E0.book Page 1 Tuesday, September 21, 2004 1:28 PM INDEX A F Accessories and replacement parts...... 6-23 Air filter element, cleaning..................... 6-17 B Battery................................................... 6-33 Brake and clutch levers, checking and lubricating .................................... 6-30 Brake and shift pedals, checking and lubricating .................................... 6-29 Brake fluid, changing ............................ 6-26 Brake fluid level, checking .................... 6-25 Brake lever.............................................. 3-7 Brake pedal............................................. 3-7 D Dimmer switch ........................................ 3-6 Drive chain, lubricating.......................... 6-28 Drive chain slack................................... 6-27 E Engine break-in....................................... 5-4 Engine oil and oil filter cartridge............ 6-12 Engine, starting a warm .......................... 5-3 Engine stop switch .................................. 3-6 EXUP system........................................ 3-15 Oil level warning light .............................. 3-2 P Panels, removing and installing ..............6-9 Parking ....................................................5-5 Part locations .......................................... 2-1 Pre-operation check list...........................4-2 R Rear brake light switch, adjusting ......... 6-24 Rear suspension, lubricating................. 6-31 H Handlebar switches ................................ 3-5 Headlight bulb, replacing ...................... 6-35 Helmet holder ....................................... 3-10 High beam indicator light ........................ 3-2 Horn switch............................................. 3-6 C Cables, checking and lubricating .......... 6-29 Canister (for California only) ................. 6-11 Carburetors ........................................... 6-19 Care ........................................................ 7-1 Centerstand and sidestand, checking and lubricating ..................... 6-30 Clutch lever ............................................. 3-6 Clutch lever free play, adjusting............ 6-24 Coolant.................................................. 6-14 Coolant temperature warning light .......... 3-2 O Front and rear brake pads, checking.... 6-25 Front fork, adjusting.............................. 3-11 Front fork, checking .............................. 6-31 Fuel......................................................... 3-8 Fuel gauge.............................................. 3-5 Fuel level warning light ........................... 3-2 Fuel tank cap .......................................... 3-8 Fuses, replacing ................................... 6-34 S Safety defects, reporting .........................9-3 Safety information ...................................1-1 Seat....................................................... 3-10 Self-diagnosis devices ............................ 3-4 Shifting ....................................................5-3 Shift pedal ............................................... 3-7 Shock absorber assembly, adjusting ....3-13 Sidestand ..............................................3-15 Spark plugs, checking ...........................6-10 Specifications .......................................... 8-1 Speedometer unit.................................... 3-3 Starter (choke) lever................................ 3-9 Starting and warming up a cold engine ................................................... 5-1 Start switch..............................................3-6 Steering, checking.................................6-32 Storage....................................................7-3 Storage compartment............................ 3-11 Swingarm pivots, lubricating ................. 6-30 I Identification numbers ............................ 9-1 Ignition circuit cut-off system ................ 3-16 Indicator and warning lights.................... 3-2 K Key identification number ....................... 9-1 L Labels, location of................................... 1-5 M Main switch/steering lock........................ 3-1 Maintenance and lubrication, periodic .... 6-5 Maintenance, emission control system... 6-3 Maintenance, periodic ............................ 6-1 Maintenance record................................ 9-5 Model label ............................................. 9-2 N Neutral indicator light.............................. 3-2 Noise regulation...................................... 9-4 T Tachometer unit ...................................... 3-4 Tail/brake light bulb, replacing ..............6-36 Throttle cable free play, checking ......... 6-19 U1C210E0.book Page 2 Tuesday, September 21, 2004 1:28 PM INDEX Throttle grip and cable, checking and lubricating .................................... 6-29 Tires...................................................... 6-20 Tool kit .................................................... 6-1 Troubleshooting.................................... 6-40 Troubleshooting charts ......................... 6-41 Turn signal indicator lights ...................... 3-2 Turn signal light bulb, replacing............ 6-37 Turn signal switch................................... 3-6 V Valve clearance .................................... 6-20 Vehicle identification number.................. 9-1 W Warranty, extended ................................ 9-9 Warranty, limited..................................... 9-7 Wheel bearings, checking .................... 6-32 Wheel (front) ......................................... 6-37 Wheel (rear).......................................... 6-38 Wheels.................................................. 6-23 OWNER’S MANUAL FZS1000T FZS1000TC YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2004.10-1.1×1 CR (E) LIT-11626-18-52 1C2-28199-10
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