Handleiding Yamaha FZS1000S (pagina 7 van 94) (Engels)

514287

Verklein

Vergroot

Pagina terug

1/94

Pagina verder

PRINTED ON RECYCLED PAPER

YAMAHA MOTOR CO., LTD.

PRINTED IN JAPAN

2004.08-0.3×1 CR

(E)

1C2-28199-EA

FZS1000

FZS1000S

OWNER’S MANUAL

U1C2E1E0.book Page 2 Wednesday, August 4, 2004 11:57 AM

INTRODUCTION

EAU10100

Welcome to the Yamaha world of motorcycling!

As the owner of the FZS1000/FZS1000S, you are benefiting from Yamaha’s vast experience and newest technology regard-

ing the design and manufacture of high-quality products, which have earned Yamaha a reputation for dependability.

Please take the time to read this manual thoroughly, so as to enjoy all advantages of your FZS1000/FZS1000S. The owner’s

manual does not only instruct you in how to operate, inspect and maintain your motorcycle, but also in how to safeguard

yourself and others from trouble and injury.

In addition, the many tips given in this manual will help keep your motorcycle in the best possible condition. If you have any

further questions, do not hesitate to contact your Yamaha dealer.

The Yamaha team wishes you many safe and pleasant rides. So, remember to put safety first!

U1C2E1E0.book Page 1 Wednesday, August 4, 2004 11:57 AM

IMPORTANT MANUAL INFORMATION

EAU10150

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

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.

WARNING

EWA10030

PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE.

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

INVOLVED!

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 motor-

cycle.

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

the motorcycle.

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

WARNING

CAUTION:

NOTE:

U1C2E1E0.book Page 1 Wednesday, August 4, 2004 11:57 AM

IMPORTANT MANUAL INFORMATION

EAU10200

FZS1000/FZS1000S

OWNER’S MANUAL

1st edition, July 2004

Any reprinting or unauthorized use

without the written permission of

Yamaha Motor Co., Ltd.

is expressly prohibited.

Printed in Japan.

U1C2E1E0.book Page 2 Wednesday, August 4, 2004 11:57 AM

TABLE OF CONTENTS

SAFETY INFORMATION ..................1-1

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

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

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

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

INSTRUMENT AND CONTROL

FUNCTIONS .......................................3-1

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

Indicator and warning lights ............3-2

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

Tachometer unit ..............................3-4

Self-diagnosis devices ....................3-5

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

Anti-theft alarm (optional) ...............3-6

Handlebar switches ........................3-6

Clutch lever .....................................3-7

Shift pedal .......................................3-8

Brake lever .....................................3-8

Brake pedal ....................................3-8

Fuel tank cap ..................................3-9

Fuel .................................................3-9

Fuel tank breather hose ................3-10

Catalytic converter ........................3-11

Starter (choke) lever .....................3-11

Seat ..............................................3-11

Helmet holder ...............................3-12

Storage compartment ...................3-12

Adjusting the front fork ..................3-13

Adjusting the shock absorber

assembly ...................................3-15

EXUP system ............................... 3-17

Sidestand .....................................3-17

Ignition circuit cut-off system ........ 3-18

PRE-OPERATION CHECKS ............. 4-1

Pre-operation check list .................. 4-2

OPERATION AND IMPORTANT

RIDING POINTS................................. 5-1

Starting a cold engine ....................5-1

Starting a warm engine .................. 5-3

Shifting ........................................... 5-3

Tips for reducing fuel

consumption ............................... 5-4

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

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

PERIODIC MAINTENANCE AND

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

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

Periodic maintenance and

lubrication chart .......................... 6-2

Removing and installing panels ..... 6-6

Checking the spark plugs ............... 6-7

Engine oil and oil filter cartridge ..... 6-8

Coolant ......................................... 6-11

Cleaning the air filter element ...... 6-14

Adjusting the carburetors ............. 6-16

Adjusting the engine idling

speed ........................................ 6-16

Checking the throttle cable free

play ........................................... 6-17

Valve clearance ........................... 6-17

Tires ............................................. 6-17

Cast wheels ................................. 6-20

Adjusting the clutch lever free

play ........................................... 6-20

Adjusting the rear brake light

switch ....................................... 6-21

Checking the front and rear

brake pads ................................ 6-21

Checking the brake fluid level ...... 6-22

Changing the brake fluid .............. 6-23

Drive chain slack .......................... 6-23

Lubricating the drive chain ........... 6-25

Checking and lubricating the

cables ....................................... 6-25

Checking and lubricating the

throttle grip and cable ............... 6-26

Checking and lubricating the

brake and shift pedals .............. 6-26

Checking and lubricating the

brake and clutch levers ............ 6-26

Checking and lubricating the

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

Lubricating the swingarm

pivots ........................................ 6-27

Lubricating the rear

suspension ............................... 6-27

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TABLE OF CONTENTS

Checking the front fork .................6-28

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

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

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

Replacing the fuses ......................6-31

Replacing a headlight bulb ...........6-32

Replacing a tail/brake light bulb ...6-33

Replacing a turn signal light

bulb ...........................................6-34

Replacing an auxiliary light bulb ...6-34

Front wheel ...................................6-35

Rear wheel ...................................6-36

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

Troubleshooting charts .................6-39

MOTORCYCLE CARE AND

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

Care ................................................7-1

Storage ...........................................7-3

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

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

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

U1C2E1E0.book Page 2 Wednesday, August 4, 2004 11:57 AM

1-1

SAFETY INFORMATION

EAU10271

MOTORCYCLES ARE SINGLE

TRACK VEHICLES. THEIR SAFE USE

AND OPERATION ARE DEPENDENT

UPON THE USE OF PROPER RIDING

TECHNIQUES AS WELL AS THE EX-

PERTISE OF THE OPERATOR. EV-

ERY OPERATOR SHOULD KNOW

THE FOLLOWING REQUIREMENTS

BEFORE RIDING THIS MOTOR-

CYCLE.

HE OR SHE SHOULD:

● OBTAIN THOROUGH INSTRUC-

TIONS FROM A COMPETENT

SOURCE ON ALL ASPECTS OF

MOTORCYCLE OPERATION.

● OBSERVE THE WARNINGS AND

MAINTENANCE REQUIRE-

MENTS IN THE OWNER’S MAN-

UAL.

● OBTAIN QUALIFIED TRAINING

IN SAFE AND PROPER RIDING

TECHNIQUES.

● OBTAIN PROFESSIONAL TECH-

NICAL SERVICE AS INDICATED

BY THE OWNER’S MANUAL

AND/OR WHEN MADE NECES-

SARY BY MECHANICAL CONDI-

TIONS.

Safe riding

● Always make pre-operation

checks. Careful checks may help

prevent an accident.

● This motorcycle is designed to car-

ry the operator and a passenger.

● The failure of motorists to detect

and recognize motorcycles in traf-

fic is the predominating cause of

automobile/motorcycle accidents.

Many accidents have been caused

by an automobile driver who did

not see the motorcycle. Making

yourself conspicuous 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-

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 inexperi-

enced operators. In fact, many op-

erators who have been involved in

accidents do not even have a cur-

rent motorcycle license.

• Make sure that you are qualified

and that you only lend your

motorcycle to other qualified op-

erators.

• Know your skills and limits.

Staying within your limits may

help you to avoid an accident.

• We recommend that you prac-

tice riding your motorcycle

where there is no traffic until you

have become thoroughly famil-

iar with the motorcycle and all of

its controls.

● Many accidents have been caused

by error of the motorcycle opera-

tor. A typical error made by the op-

erator is veering wide on a turn

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SAFETY INFORMATION

1-2

due to EXCESSIVE SPEED or un-

dercornering (insufficient lean an-

gle for the speed).

• Always obey the speed limit and

never travel faster than warrant-

ed 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 foot-

rests during operation to main-

tain control of the motorcycle.

• The passenger should always

hold onto the operator, the seat

strap or grab bar, if equipped,

with both hands and keep both

feet on the passenger footrests.

• Never carry a passenger unless

he or she can firmly place both

feet on the passenger footrests.

● Never ride under the influence of

alcohol or other drugs.

● This motorcycle is designed for on-

road use only. It is not suitable for

off-road use.

Protective apparel

The majority of fatalities from motor-

cycle accidents are the result of head

injuries. The use of a safety helmet is

the single most critical factor in the pre-

vention or reduction of head injuries.

● Always wear an approved helmet.

● Wear a face shield or goggles.

Wind in your unprotected eyes

could contribute to an impairment

of vision that could delay seeing a

hazard.

● The use of a jacket, heavy boots,

trousers, gloves, etc., is effective in

preventing or reducing 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

cause burns. Always wear protec-

tive 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 re-

moval of original equipment, may ren-

der 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 stabili-

ty and handling if the weight distribution

of the motorcycle is changed. To avoid

the possibility of an accident, use ex-

treme 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 acces-

sories to your motorcycle:

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SAFETY INFORMATION

1-3

The total weight of the operator, pas-

senger, accessories and cargo must

not exceed the maximum load limit.

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 imbal-

ance or instability.

● Shifting weights can create a sud-

den imbalance. Make sure that ac-

cessories 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, in-

cluding 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 re-

sponsible for the proper selection, in-

stallation and use of non-Yamaha

accessories. Use extreme caution

when selecting and installing any ac-

cessories.

Keep the following guidelines in mind,

as well as those provided under “Load-

ing” when mounting accessories.

● Never install accessories or carry

cargo that would impair the perfor-

mance of your motorcycle. Care-

fully inspect the accessory before

using it to make sure that it does

not in any way reduce ground

clearance or cornering clearance,

limit suspension travel, steering

travel or control operation, or ob-

scure lights or reflectors.

• Accessories fitted to the handle-

bar or the front fork area can

create instability due to improper

weight distribution or aerody-

namic 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 aerody-

namic effects. Wind may at-

tempt to lift the motorcycle, or

the motorcycle may become un-

stable in cross winds. These ac-

cessories may also cause

instability when passing or being

passed by large vehicles.

• Certain accessories can dis-

place the operator from his or

her normal riding position. This

improper position limits the free-

dom of movement of the opera-

Maximum load:

189 kg (417 lb)

U1C2E1E0.book Page 3 Wednesday, August 4, 2004 11:57 AM

SAFETY INFORMATION

1-4

tor and may limit control ability,

therefore, such accessories are

not recommended.

● Use caution when adding electri-

cal accessories. If electrical acces-

sories 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 FLAMMA-

BLE:

• Always turn the engine off when

refueling.

• Take care not to spill any gaso-

line 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 poi-

sonous and may cause loss of

consciousness and death within a

short time. Always operate your

motorcycle in an area that has ad-

equate ventilation.

● Always turn the engine off before

leaving the motorcycle unattended

and remove the key from the main

switch. When parking the motor-

cycle, note the following:

• The engine and exhaust system

may be hot, therefore, park the

motorcycle in a place where pe-

destrians or children are not like-

ly 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 ker-

osene 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 gaso-

line, 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

or clothing, immediately wash the

affected area with soap and water

and change your clothes.

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DESCRIPTION

2-1

EAU10410

Left view

1. Front fork compression damping force adjusting screw (page 3-13)

2. Front fork rebound damping force adjusting screw (page 3-13)

3. Front fork spring preload adjusting bolt (page 3-13)

4. Air filter element (page 6-14)

5. Main fuse (page 6-31)

6. Fuse box (page 6-31)

7. Storage compartment (page 3-12)

8. Grab bar

9. Seat lock/helmet holder (page 3-11/page 3-12)

10.Shock absorber assembly compression damping force adjusting screw

(page 3-15)

11.Shock absorber assembly spring preload adjusting ring (page 3-15)

12.Shock absorber assembly rebound damping force adjusting knob

(page 3-15)

13.Shift pedal (page 3-8)

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DESCRIPTION

2-2

EAU10420

Right view

1. Owner’s tool kit (page 6-1)

2. Rear brake fluid reservoir (page 6-22)

3. Battery (page 6-29)

4. Front brake fluid reservoir (page 6-22)

5. Radiator cap (page 6-11)

6. Engine oil filter cartridge (page 6-8)

7. Engine oil level check window (page 6-8)

8. Brake pedal (page 3-8)

9. Coolant reservoir (page 6-11)

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DESCRIPTION

2-3

EAU10430

Controls and instruments

1. Clutch lever (page 3-7)

2. Left handlebar switches (page 3-6)

3. Starter (choke) lever (page 3-11)

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 3-6)

9. Brake lever (page 3-8)

10.Throttle grip (page 6-17)

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INSTRUMENT AND CONTROL FUNCTIONS

3-1

EAU10460

Main switch/steering lock

The main switch/steering lock controls

the ignition and lighting systems, and is

used to lock the steering. The various

positions are described below.

EAU26810

All electrical circuits are supplied with

power; the meter lighting, taillights and

auxiliary lights come on, and the engine

can be started. The key cannot be re-

moved.

NOTE:

The headlights come on automatically

when the engine is started and stay on

until the key is turned to “OFF”.

EAU10660

OFF

All electrical systems are off. The key

can be removed.

EAU10680

LOCK

The steering is locked, and all electrical

systems are off. The key can be re-

moved.

To lock the steering

1. Turn the handlebars all the way to

the left.

2. Push the key in from the “OFF” po-

sition, and then turn it to “LOCK”

while still pushing it.

3. Remove the key.

To unlock the steering

Push the key in, and then turn it to

“OFF” while still pushing it.

WARNING

EWA10060

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 be-

fore turning the key to “OFF” or

“LOCK”.

1. Push.

2. Turn.

1. Push.

2. Turn.

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INSTRUMENT AND CONTROL FUNCTIONS

3-2

EAU10910

(Parking)

The steering is locked, the taillights and

auxiliary lights are on, and the hazard

light can be turned on, but all other

electrical systems are off. The key can

be removed.

The steering must be locked before the

key can be turned to “”.

CAUTION:

ECA11020

Do not use the parking position for

an extended length of time, other-

wise the battery may discharge.

EAU11002

Indicator and warning lights

EAU11030

Turn signal indicator lights “” and

“”

The corresponding indicator light flash-

es when the turn signal switch is

pushed to the left or right.

EAU11060

Neutral indicator light “”

This indicator light comes on when the

transmission is in the neutral position.

EAU11080

High beam indicator light “”

This indicator light comes on when the

high beam of the headlight is switched

on.

EAU11120

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 cir-

cuit.

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 mal-

function.

1. Left turn signal indicator light “”

2. Neutral indicator light “”

3. High beam indicator light “”

4. Oil level warning light “”

5. Right turn signal indicator light “”

6. Coolant temperature warning light “”

7. Fuel level warning light “”

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INSTRUMENT AND CONTROL FUNCTIONS

3-3

EAU11350

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 cir-

cuit.

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 cir-

cuit.

CAUTION:

ECA10020

Do not operate the engine if it is

overheated.

EAU11810

Speedometer unit

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 tripme-

ters can be used together with the fuel

gauge to estimate the distance that can

1. Speedometer

2. Odometer/tripmeters

3. “SELECT” button

4. “RESET” button

U1C2E1E0.book Page 3 Wednesday, August 4, 2004 11:57 AM

INSTRUMENT AND CONTROL FUNCTIONS

3-4

be traveled on a full tank of fuel. This in-

formation 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

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.

EAU11891

Tachometer unit

The electric tachometer allows the rider

to monitor the engine speed and keep it

within the ideal power range.

CAUTION:

ECA10031

Do not operate the engine in the ta-

chometer red zone.

Red zone: 11500 r/min and above

This tachometer unit is equipped with a

clock.

To set the clock

1. Push both the “SELECT” and “RE-

SET” buttons for at least two sec-

onds.

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 flash-

ing, 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.

1. Tachometer

2. Tachometer red zone

3. Clock

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INSTRUMENT AND CONTROL FUNCTIONS

3-5

EAU12100

Self-diagnosis devices

This model is equipped with a self-diag-

nosis 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:

Use the chart below to identify the

faulty electrical circuit.

If the tachometer displays such an error

code, note the circuit-specific number

of r/min, and then have a Yamaha deal-

er check the vehicle.

CAUTION:

ECA10040

When the tachometer displays an er-

ror code, the vehicle should be

checked as soon as possible in or-

der to avoid engine damage.

EAU12110

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.

NOTE:

Do not allow the fuel tank to empty itself

completely.

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

Current

engine

speed for

3 seconds

Circuit-specific

number of r/min

for 2.5 seconds

(See the table

below.)

0 r/min for

3 seconds

1. Fuel gauge

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INSTRUMENT AND CONTROL FUNCTIONS

3-6

EAU12330

Anti-theft alarm (optional)

This model can be equipped with an

optional anti-theft alarm by a Yamaha

dealer. Contact a Yamaha dealer for

more information.

EAU12343

Handlebar switches

Left

Right

EAU12370

Pass switch “PASS”

Press this switch to flash the head-

lights.

EAU12400

Dimmer switch “ / ”

Set this switch to “” for the high

beam and to “” for the low beam.

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 re-

leased, the switch returns to the center

1. Pass switch “PAS S”

2. Dimmer switch “ / ”

3. Turn signal switch “ / ”

4. Horn switch “”

5. Hazard switch “”

1. Engine stop switch “ / ”

2. Start switch “”

U1C2E1E0.book Page 6 Wednesday, August 4, 2004 11:57 AM

INSTRUMENT AND CONTROL FUNCTIONS

3-7

position. To cancel the turn signal

lights, push the switch in after it has re-

turned to the center position.

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 emergen-

cy, 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.

CAUTION:

ECA10050

See page 5-1 for starting instruc-

tions prior to starting the engine.

EAU12731

Hazard switch “”

With the key in the “ON” or “” posi-

tion, use this switch to turn on the haz-

ard light (simultaneous flashing of all

turn signal lights).

The hazard light is used in case of an

emergency or to warn other drivers

when your vehicle is stopped where it

might be a traffic hazard.

CAUTION:

ECA10060

Do not use the hazard light for an ex-

tended length of time, otherwise the

battery may discharge.

EAU12820

Clutch lever

The clutch lever is located at the left

handlebar grip. To disengage the

clutch, pull the lever toward the handle-

bar 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 igni-

tion circuit cut-off system. (See page

3-18.)

1. Clutch lever

U1C2E1E0.book Page 7 Wednesday, August 4, 2004 11:57 AM

INSTRUMENT AND CONTROL FUNCTIONS

3-8

EAU12870

Shift pedal

The shift pedal is located on the left

side of the engine and is used in com-

bination with the clutch lever when

shifting the gears of the 6-speed con-

stant-mesh transmission equipped on

this motorcycle.

EAU12930

Brake lever

The brake lever is located at the right

handlebar grip. To apply the front

brake, pull the lever toward the handle-

bar grip.

The brake lever is equipped with a po-

sition adjusting dial. To adjust the dis-

tance 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.

EAU12941

Brake pedal

The brake pedal is on the right side of

the motorcycle. To apply the rear

brake, press down on the brake pedal.

1. Shift pedal

1. Brake lever

2. Brake lever position adjusting dial

3. Arrow mark

4. Distance between brake lever and handlebar

grip

1. Brake pedal

U1C2E1E0.book Page 8 Wednesday, August 4, 2004 11:57 AM

INSTRUMENT AND CONTROL FUNCTIONS

3-9

EAU13070

Fuel tank cap

To open the fuel tank cap

Open the fuel tank cap lock cover, in-

sert the key into the lock, and then turn

it 1/4 turn clockwise. The lock will be re-

leased and the fuel tank cap can be

opened.

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.

NOTE:

The fuel tank cap cannot be closed un-

less the key is in the lock. In addition,

the key cannot be removed if the cap is

not properly closed and locked.

WARNING

EWA11090

Make sure that the fuel tank cap is

properly closed before riding.

EAU13210

Fuel

Make sure that there is sufficient fuel in

the tank. Fill the fuel tank to the bottom

of the filler tube as shown.

WARNING

EWA10880

● Do not overfill the fuel tank, oth-

erwise it may overflow when the

fuel warms up and expands.

● Avoid spilling fuel on the hot en-

gine.

1. Fuel tank cap lock cover

2. Unlock.

1. Fuel tank filler tube

2. Fuel level

U1C2E1E0.book Page 9 Wednesday, August 4, 2004 11:57 AM

INSTRUMENT AND CONTROL FUNCTIONS

3-10

CAUTION:

ECA10070

Immediately wipe off spilled fuel

with a clean, dry, soft cloth, since

fuel may deteriorate painted surfac-

es or plastic parts.

EAU13320

CAUTION:

ECA11400

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 de-

signed to use regular unleaded gaso-

line with a research octane number of

91 or higher. If knocking (or pinging) oc-

curs, use a gasoline of a different brand

or premium unleaded fuel. Use of un-

leaded fuel will extend spark plug life

and reduce maintenance costs.

EAU13410

Fuel tank breather hose

Before operating the motorcycle:

● Check the fuel tank breather hose

connection.

● Check the fuel tank breather hose

for cracks or damage, and replace

it if damaged.

● Make sure that the end of the fuel

tank breather hose is not blocked,

and clean it if necessary.

Recommended fuel:

REGULAR 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)

1. Fuel tank breather hose

2. Original position (white mark)

U1C2E1E0.book Page 10 Wednesday, August 4, 2004 11:57 AM

INSTRUMENT AND CONTROL FUNCTIONS

3-11

EAU13440

Catalytic converter

This vehicle is equipped with a catalytic

converter in the muffler.

WARNING

EWA10860

The exhaust system is hot after op-

eration. Make sure that the exhaust

system has cooled down before do-

ing any maintenance work.

CAUTION:

ECA10700

The following precautions must be

observed to prevent a fire hazard or

other damages.

● Use only unleaded gasoline.

The use of leaded gasoline will

cause unrepairable damage to

the catalytic converter.

● Never park the vehicle near pos-

sible fire hazards such as grass

or other materials that easily

burn.

● Do not allow the engine to idle

too long.

EAU13590

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).

EAU13940

Seat

To remove the seat

1. Insert the key into the seat lock,

and then turn it clockwise.

2. While holding the key in that posi-

tion, lift the rear of the seat, and

then pull the seat off.

To install the seat

1. Insert the projection on the front of

the seat into the seat holder as

shown.

1. Starter (choke) lever “”

1. Seat lock

2. Unlock.

U1C2E1E0.book Page 11 Wednesday, August 4, 2004 11:57 AM

INSTRUMENT AND CONTROL FUNCTIONS

3-12

2. Push the rear of the seat down to

lock it in place.

3. Remove the key.

NOTE:

Make sure that the seat is properly se-

cured before riding.

EAU14350

Helmet holder

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 re-

move it.

WARNING

EWA10160

Never ride with a helmet attached to

the helmet holder, since the helmet

may hit objects, causing loss of con-

trol and possibly an accident.

EAU14411

Storage compartment

This storage compartment is designed

to hold an optional genuine Yamaha U-

LOCK. (Other locks may not fit.) When

placing a U-LOCK in the storage com-

partment, securely fasten it with the

straps. When the U-LOCK is not in the

storage compartment, be sure to se-

cure the straps to prevent losing them.

1. Projection

2. Seat holder

1. Helmet holder

2. Unlock.

1. Storage compartment

U1C2E1E0.book Page 12 Wednesday, August 4, 2004 11:57 AM

INSTRUMENT AND CONTROL FUNCTIONS

3-13

When storing the owner’s manual or

other documents in the storage com-

partment, be sure to wrap them in a

plastic bag so that they will not get wet.

When washing the motorcycle, 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 damp-

ing force adjusting screws and com-

pression damping force adjusting

screws.

WARNING

EWA10180

Always adjust both fork legs equal-

ly, otherwise poor handling and loss

of stability may result.

Spring preload

To increase the spring preload and

thereby harden the suspension, turn

the adjusting bolt on each fork leg in di-

rection (a). To decrease the spring pre-

load and thereby soften the

suspension, turn the adjusting bolt on

each fork leg in direction (b).

NOTE:

Align the appropriate groove on the ad-

justing mechanism with the top of the

front fork cap bolt.

1. U-LOCK bar (optional)

2. Strap

3. Yamaha U-LOCK (optional)

1. Spring preload adjusting bolt

1. Current setting

2. Front fork cap bolt

Spring preload setting:

Minimum (soft):

Standard:

Maximum (hard):

* Adjusting bolt fully turned in direction

(b)

U1C2E1E0.book Page 13 Wednesday, August 4, 2004 11:57 AM

INSTRUMENT AND CONTROL FUNCTIONS

3-14

Rebound damping force

To increase the rebound damping force

and thereby harden the rebound damp-

ing, 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 di-

rection (b).

Compression damping force

To increase the compression damping

force and thereby harden the compres-

sion damping, turn the adjusting screw

on each fork leg in direction (a). To de-

crease the compression damping force

and thereby soften the compression

damping, turn the adjusting screw on

each fork leg in direction (b).

CAUTION:

ECA10100

Never attempt to turn an adjusting

mechanism beyond the maximum or

minimum settings.

NOTE:

Although the total number of clicks of a

damping force adjusting mechanism

may not exactly match the above spec-

ifications 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 num-

ber of clicks of each damping force ad-

justing mechanism and to modify the

specifications as necessary.

1. Rebound damping force adjusting screw

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)

1. Compression damping force adjusting screw

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)

U1C2E1E0.book Page 14 Wednesday, August 4, 2004 11:57 AM

INSTRUMENT AND CONTROL FUNCTIONS

3-15

EAU15041

Adjusting the shock absorber

assembly

This shock absorber assembly is

equipped with a spring preload adjust-

ing ring, a rebound damping force ad-

justing knob and a compression

damping force adjusting screw.

CAUTION:

ECA10100

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 de-

crease the spring preload and thereby

soften the suspension, turn the adjust-

ing ring in direction (b).

NOTE:

● Align the appropriate notch in the

adjusting ring with the position in-

dicator on the shock absorber.

● Use the special wrench included in

the owner’s tool kit to make the ad-

justment.

Rebound damping force

To increase the rebound damping force

and thereby harden the rebound damp-

ing, turn the adjusting knob in direction

(a). To decrease the rebound damping

force and thereby soften the rebound

damping, turn the adjusting knob in di-

rection (b).

1. Spring preload adjusting ring

2. Special wrench

3. Position indicator

Spring preload setting:

Minimum (soft):

Standard:

Maximum (hard):

1. Rebound damping force adjusting knob

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)

U1C2E1E0.book Page 15 Wednesday, August 4, 2004 11:57 AM

INSTRUMENT AND CONTROL FUNCTIONS

3-16

Compression damping force

To increase the compression damping

force and thereby harden the compres-

sion damping, turn the adjusting screw

in direction (a). To decrease the com-

pression damping force and thereby

soften the compression damping, turn

the adjusting screw in direction (b).

NOTE:

Although the total number of clicks of a

damping force adjusting mechanism

may not exactly match the above spec-

ifications 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 num-

ber of clicks of each damping force ad-

justing mechanism and to modify the

specifications as necessary.

WARNING

EWA10220

This shock absorber contains highly

pressurized nitrogen gas. For prop-

er handling, read and understand

the following information before

handling the shock absorber. The

manufacturer cannot be held re-

sponsible for property damage or

personal injury that may result from

improper handling.

● Do not tamper with or attempt to

open the gas cylinder.

● Do not subject the shock ab-

sorber 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 per-

formance.

● Always have a Yamaha dealer

service the shock absorber.

1. Compression damping force adjusting screw

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)

U1C2E1E0.book Page 16 Wednesday, August 4, 2004 11:57 AM

INSTRUMENT AND CONTROL FUNCTIONS

3-17

EAU15280

EXUP system

This model is equipped with Yamaha’s

EXUP (EXhaust Ultimate Power valve)

system. This system boosts engine

power by means of a valve that regu-

lates the diameter of the exhaust pipe.

The EXUP system valve is constantly

adjusted in accordance with the engine

speed by a computer-controlled servo-

motor.

CAUTION:

ECA10190

● 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 dam-

age to the engine.

● If the EXUP system does not op-

erate, have a Yamaha dealer

check it.

EAU15300

Sidestand

The sidestand is located on the left side

of the frame. Raise the sidestand or

lower it with your foot while holding the

vehicle upright.

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.)

WARNING

EWA10240

The vehicle must not be ridden with

the sidestand down, or if the side-

stand cannot be properly moved up

(or does not stay up), otherwise the

sidestand could contact the ground

and distract the operator, resulting

in a possible loss of control.

Yamaha’s ignition circuit cut-off

system has been designed to assist

the operator in fulfilling the respon-

sibility of raising the sidestand be-

fore starting off. Therefore, check

this system regularly as described

below and have a Yamaha dealer re-

pair it if it does not function proper-

ly.

U1C2E1E0.book Page 17 Wednesday, August 4, 2004 11:57 AM

INSTRUMENT AND CONTROL FUNCTIONS

3-18

EAU15321

Ignition circuit cut-off system

The ignition circuit cut-off system (com-

prising the sidestand switch, clutch

switch and neutral switch) has the fol-

lowing functions.

● It prevents starting when the trans-

mission is in gear and the side-

stand is up, but the clutch lever is

not pulled.

● It prevents starting when the trans-

mission is in gear and the clutch le-

ver is pulled, but the sidestand is

still down.

● It cuts the running engine when the

transmission is in gear and the sid-

estand is moved down.

Periodically check the operation of the

ignition circuit cut-off system according

to the following procedure.

WARNING

EWA10260

● The vehicle must be placed on

the centerstand during this in-

spection.

● If a malfunction is noted, have a

Yamaha dealer check the sys-

tem before riding.

U1C2E1E0.book Page 18 Wednesday, August 4, 2004 11:57 AM

INSTRUMENT AND CONTROL FUNCTIONS

3-19

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?

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?

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?

The system is OK. The motorcycle can be ridden.

This check is most reliable if performed with

a warmed-up engine.

The neutral switch may be defective.

The motorcycle should not be ridden until

checked by a Yamaha dealer.

The sidestand switch may be defective.

The motorcycle should not be ridden until

checked by a Yamaha dealer.

The clutch switch may be defective.

The motorcycle should not be ridden until

checked by a Yamaha dealer.

YES NO

NOTE:

U1C2E1E0.book Page 19 Wednesday, August 4, 2004 11:57 AM

PRE-OPERATION CHECKS

4-1

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 inspec-

tion, 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.

WARNING

EWA11150

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

the vehicle.

U1C2E1E0.book Page 1 Wednesday, August 4, 2004 11:57 AM

PRE-OPERATION CHECKS

4-2

EAU15603

Pre-operation check list

ITEM CHECKS PAGE

Fuel

• Check fuel level in fuel tank.

• Refuel if necessary.

• Check fuel line for leakage.

3-9

Engine oil

• Check oil level in engine.

• If necessary, add recommended oil to specified level.

• Check vehicle for oil leakage.

6-8

Coolant

• Check coolant level in reservoir.

• If necessary, add recommended coolant to specified level.

• Check cooling system for leakage.

6-11

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.

6-21, 6-22

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.

6-21, 6-22

Clutch

• Check operation.

• Lubricate cable if necessary.

• Check lever free play.

• Adjust if necessary.

6-20

U1C2E1E0.book Page 2 Wednesday, August 4, 2004 11:57 AM

PRE-OPERATION CHECKS

4-3

Throttle grip

• Make sure that operation is smooth.

• Check cable free play.

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

grip housing.

6-17, 6-26

Control cables

• Make sure that operation is smooth.

• Lubricate if necessary.

6-25

Drive chain

• Check chain slack.

• Adjust if necessary.

• Check chain condition.

• Lubricate if necessary.

6-23, 6-25

Wheels and tires

• Check for damage.

• Check tire condition and tread depth.

• Check air pressure.

• Correct if necessary.

6-17, 6-20

Brake and shift pedals

• Make sure that operation is smooth.

• Lubricate pedal pivoting points if necessary.

6-26

Brake and clutch levers

• Make sure that operation is smooth.

• Lubricate lever pivoting points if necessary.

6-26

Centerstand, sidestand

• Make sure that operation is smooth.

• Lubricate pivots if necessary.

6-27

Chassis fasteners

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

• Tighten if necessary.

—

Instruments, lights, signals

and switches

• Check operation.

• Correct if necessary.

—

Sidestand switch

• Check operation of ignition circuit cut-off system.

• If system is defective, have Yamaha dealer check vehicle.

3-17

ITEM CHECKS PAGE

U1C2E1E0.book Page 3 Wednesday, August 4, 2004 11:57 AM

OPERATION AND IMPORTANT RIDING POINTS

5-1

EAU15950

WARNING

EWA10270

● Become thoroughly familiar

with all operating controls and

their functions before riding.

Consult a Yamaha dealer re-

garding any control or function

that you do not thoroughly un-

derstand.

● Never start the engine or oper-

ate it in a closed area for any

length of time. Exhaust fumes

are poisonous, and inhaling

them can cause loss of con-

sciousness and death within a

short time. Always make sure

that there is adequate ventila-

tion.

● Before starting out, make sure

that the sidestand is up. If the

sidestand is not raised com-

pletely, it could contact the

ground and distract the opera-

tor, resulting in a possible loss

of control.

EAU16220

Starting 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 sid-

estand up.

WARNING

EWA10290

● Before starting the engine,

check the function of the igni-

tion circuit cut-off system ac-

cording to the procedure

described on page 3-18.

● Never ride with the sidestand

down.

1. Turn the key to “ON” and make

sure that the engine stop switch is

set to “”.

CAUTION:

ECA11430

The oil level warning light, coolant

temperature warning light and fuel

level warning light should come on

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 neu-

tral 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 cir-

cuit.

3. Turn the starter (choke) on and

completely close the throttle. (See

page 3-11.)

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 pre-

serve the battery. Do not crank the en-

gine more than 10 seconds on any one

attempt.

U1C2E1E0.book Page 1 Wednesday, August 4, 2004 11:57 AM

OPERATION AND IMPORTANT RIDING POINTS

5-2

CAUTION:

ECA11490

● If the oil level warning light flick-

ers or remains on after starting,

immediately stop the engine,

and then check the engine oil

level and the vehicle for oil leak-

age. 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 elec-

trical circuit.

● If the coolant temperature warn-

ing 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 warn-

ing 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 elec-

trical circuit.

● If the fuel level warning light re-

mains 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.

CAUTION:

ECA11040

For maximum engine life, never ac-

celerate hard when the engine is

cold!

6. When the engine is warm, turn the

starter (choke) off.

NOTE:

The engine is warm when it responds

normally to the throttle with the starter

(choke) turned off.

U1C2E1E0.book Page 2 Wednesday, August 4, 2004 11:57 AM

OPERATION AND IMPORTANT RIDING POINTS

5-3

EAU16640

Starting a warm engine

Follow the same procedure as for start-

ing a cold engine with the exception

that the starter (choke) is not required

when the engine is warm.

EAU16671

Shifting

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 il-

lustration.

NOTE:

To shift the transmission into the neu-

tral position, press the shift pedal down

repeatedly until it reaches the end of its

travel, and then slightly raise it.

CAUTION:

ECA10260

● Even with the transmission in

the neutral position, do not

coast for long periods of time

with the engine off, and do not

tow the motorcycle for long dis-

tances. The transmission is

properly lubricated only when

the engine is running. Inade-

quate lubrication may damage

the transmission.

● Always use the clutch while

changing gears to avoid damag-

ing the engine, transmission,

and drive train, which are not

designed to withstand the

shock of forced shifting.

1. Shift pedal

2. Neutral position

U1C2E1E0.book Page 3 Wednesday, August 4, 2004 11:57 AM

OPERATION AND IMPORTANT RIDING POINTS

5-4

EAU16800

Tips for reducing fuel

consumption

Fuel consumption depends largely on

your riding style. Consider the following

tips to reduce fuel consumption:

● Turn the starter (choke) off as

soon as possible.

● Shift up swiftly, and avoid high en-

gine speeds during acceleration.

● Do not rev the engine while shifting

down, and avoid high engine

speeds with no load on the engine.

● Turn the engine off instead of let-

ting it idle for an extended length of

time (e.g., in traffic jams, at traffic

lights or at railroad crossings).

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 follow-

ing 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-throt-

tle 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.

CAUTION:

ECA10301

After 1000 km (600 mi) of operation,

the engine oil must be changed and

the oil filter cartridge or element re-

placed.

1600 km (1000 mi) and beyond

The vehicle can now be operated nor-

mally.

CAUTION:

ECA10310

● Keep the engine speed out of

the tachometer red zone.

● If any engine trouble should oc-

cur during the engine break-in

period, immediately have a

Yamaha dealer check the vehi-

cle.

U1C2E1E0.book Page 4 Wednesday, August 4, 2004 11:57 AM

OPERATION AND IMPORTANT RIDING POINTS

5-5

EAU17212

Parking

When parking, stop the engine, and

then remove the key from the main

switch.

WARNING

EWA10310

● Since the engine and exhaust

system can become very hot,

park in a place where pedestri-

ans or children are not likely to

touch them.

● Do not park on a slope or on soft

ground, otherwise the vehicle

may overturn.

CAUTION:

ECA10380

Never park in an area where there

are fire hazards such as grass or

other flammable materials.

U1C2E1E0.book Page 5 Wednesday, August 4, 2004 11:57 AM

PERIODIC MAINTENANCE AND MINOR REPAIR

6-1

EAU17240

Safety is an obligation of the owner. Pe-

riodic inspection, adjustment and lubri-

cation will keep your vehicle in the

safest and most efficient condition pos-

sible. The most important points of in-

spection, adjustment, and lubrication

are explained on the following pages.

The intervals given in the periodic

maintenance and lubrication chart

should be simply considered as a gen-

eral guide under normal riding condi-

tions. However, DEPENDING ON THE

WEATHER, TERRAIN, GEOGRAPHI-

CAL LOCATION, AND INDIVIDUAL

USE, THE MAINTENANCE INTER-

VALS MAY NEED TO BE SHORT-

ENED.

WARNING

EWA10320

If you are not familiar with mainte-

nance work, have a Yamaha dealer

do it for you.

EAU17520

Owner’s tool kit

The owner’s tool kit is located inside the

storage compartment under the seat.

(See page 3-11.)

The service information included in this

manual and the tools provided in the

owner’s tool kit are intended to assist

you in the performance of preventive

maintenance and minor repairs. How-

ever, additional tools such as a torque

wrench may be necessary to perform

certain maintenance work correctly.

NOTE:

If you do not have the tools or experi-

ence required for a particular job, have

a Yamaha dealer perform it for you.

WARNING

EWA10350

Modifications not approved by

Yamaha may cause loss of perfor-

mance and render the vehicle un-

safe for use. Consult a Yamaha

dealer before attempting any chang-

es.

1. Owner’s tool kit

U1C2E1E0.book Page 1 Wednesday, August 4, 2004 11:57 AM

PERIODIC MAINTENANCE AND MINOR REPAIR

6-2

EAU17705

Periodic maintenance and lubrication chart

NOTE:

● The annual checks must be performed every year, except if a kilometer-based maintenance is performed in-

stead.

● From 50000 km, repeat the maintenance intervals starting from 10000 km.

● Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical

skills.

NO. ITEM CHECK OR MAINTENANCE JOB

ODOMETER READING (× 1000 km)

ANNUAL

CHECK

1 10203040

1 * Fuel line • Check fuel hoses for cracks or damage. √√√√ √

2 * Fuel filter • Check condition. √√

3 Spark plugs

• Check condition.

• Clean and regap.

√√

• Replace. √√

4 * Valves

• Check valve clearance.

• Adjust.

Every 40000 km

5 Air filter element

• Clean. √√

• Replace. √√

6Clutch

• Check operation.

• Adjust.

√√√√√

7 * Front brake

• Check operation, fluid level and vehicle for fluid leakage. √√√√√ √

• Replace brake pads. Whenever worn to the limit

8 * Rear brake

• Check operation, fluid level and vehicle for fluid leakage. √√√√√ √

• Replace brake pads. Whenever worn to the limit

U1C2E1E0.book Page 2 Wednesday, August 4, 2004 11:57 AM

PERIODIC MAINTENANCE AND MINOR REPAIR

6-3

9 * Brake hoses

• Check for cracks or damage. √√√√ √

• Replace. Every 4 years

10 * Wheels • Check runout and for damage. √√√√

11 * Tires

• Check tread depth and for damage.

• Replace if necessary.

• Check air pressure.

• Correct if necessary.

√√√√ √

12 * Wheel bearings • Check bearing for looseness or damage. √√√√

13 * Swingarm

• Check operation and for excessive play. √√√√

• Lubricate with lithium-soap-based grease. Every 50000 km

14 Drive chain

• Check chain slack, alignment and condition.

• Adjust and lubricate chain with a special O-ring chain lu-

bricant thoroughly.

Every 1000 km and after washing the motorcycle or

riding in the rain

15 * Steering bearings

• Check bearing play and steering for roughness. √√√√√

• Lubricate with lithium-soap-based grease. Every 20000 km

16 * Chassis fasteners

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

tightened.

√√√√ √

17 Sidestand, centerstand

• Check operation.

• Lubricate.

√√√√ √

18 * Sidestand switch • Check operation. √√√√√ √

19 * Front fork • Check operation and for oil leakage. √√√√

20 *

Shock absorber assem-

bly

• Check operation and shock absorber for oil leakage. √√√√

21 *

Rear suspension relay

arm and connecting

arm pivoting points

• Check operation. √√√√

• Lubricate with lithium-soap-based grease. √√

NO. ITEM CHECK OR MAINTENANCE JOB

ODOMETER READING (× 1000 km)

ANNUAL

CHECK

1 10203040

U1C2E1E0.book Page 3 Wednesday, August 4, 2004 11:57 AM

PERIODIC MAINTENANCE AND MINOR REPAIR

6-4

EAU18670

NOTE:

● The air filter needs more frequent service if you are riding in unusually wet or dusty areas.

22 * Carburetors

• Check starter (choke) operation.

• Adjust engine idling speed and synchronization.

√√√√√ √

23 Engine oil

• Change.

• Check oil level and vehicle for oil leakage.

√√√√√ √

Engine oil filter car-

tridge

• Replace. √√√

25 * Cooling system

• Check coolant level and vehicle for coolant leakage. √√√√ √

• Change. Every 3 years

26 *

Front and rear brake

switches

• Check operation. √√√√√ √

Moving parts and ca-

bles

• Lubricate. √√√√ √

28 *

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.

√√√√ √

29 * Air induction system

• Check the air cut-off valve, reed valve, and hose for dam-

age.

• Replace the entire air induction system if necessary.

√√√√ √

30 *

Muffler and exhaust

pipe

• Check the screw clamp for looseness. √√√√√

31 *

Lights, signals and

switches

• Check operation.

• Adjust headlight beam.

√√√√√ √

NO. ITEM CHECK OR MAINTENANCE JOB

ODOMETER READING (× 1000 km)

ANNUAL

CHECK

1 10203040

U1C2E1E0.book Page 4 Wednesday, August 4, 2004 11:57 AM

PERIODIC MAINTENANCE AND MINOR REPAIR

6-5

● Hydraulic brake service

• Regularly check and, if necessary, correct the brake fluid level.

• 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.

U1C2E1E0.book Page 5 Wednesday, August 4, 2004 11:57 AM

PERIODIC MAINTENANCE AND MINOR REPAIR

6-6

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.

EAU19292

Panels A and C

To remove one of the panels

Remove the screw, and then pull the

panel off as shown.

To install the panel

Place the panel in the original position,

and then install the screw.

1. Panel A

2. Panel B

1. Panel C

2. Panel D

1. Panel A

2. Screw

1. Panel C

2. Screw

U1C2E1E0.book Page 6 Wednesday, August 4, 2004 11:57 AM

PERIODIC MAINTENANCE AND MINOR REPAIR

6-7

EAU36570

Panels B and D

To remove a panel

Remove the screws and the bolt, and

then take the panel off.

To install the panel

Place the panel in the original position,

and then install the screws and the bolt.

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 mainte-

nance and lubrication chart. In addition,

the condition of the spark plugs can re-

veal the condition of the engine.

To remove a spark plug

1. Remove the spark plug cap.

2. Remove the spark plug as shown,

with the spark plug wrench includ-

ed in the owner’s tool kit.

To check the spark plugs

1. Check that the porcelain insulator

around the center electrode on

each spark plug is a medium-to-

light 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 dif-

ferent color, the engine could be defec-

tive. Do not attempt to diagnose such

problems yourself. Instead, have a

Yamaha dealer check the vehicle.

1. Panel B

2. Screw

3. Bolt

1. Spark plug cap

1. Spark plug wrench

U1C2E1E0.book Page 7 Wednesday, August 4, 2004 11:57 AM

PERIODIC MAINTENANCE AND MINOR REPAIR

6-8

3. Check each spark plug for elec-

trode erosion and excessive car-

bon or other deposits, and replace

it if necessary.

To install a spark plug

1. Measure the spark plug gap with a

wire thickness gauge and, if nec-

essary, adjust the gap to specifica-

tion.

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 tight-

en it to the specified torque.

TE:

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 speci-

fied torque as soon as possible.

4. Install the spark plug cap.

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 car-

tridge replaced at the intervals speci-

fied in the periodic maintenance and

lubrication chart.

To check the engine oil level

1. Place the vehicle on the center-

stand.

TE:

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 set-

tles, and then check the oil level

through the check window located

at the bottom-right side of the

crankcase.

Specified spark plug:

NGK/CR9E

DENSO/U27ESR-N

1. Spark plug gap

Spark plug gap:

0.7–0.8 mm (0.028–0.031 in)

Tightening torque:

Spark plug:

12.5 Nm (1.25 m·kgf, 9.0 ft·lbf)

U1C2E1E0.book Page 8 Wednesday, August 4, 2004 11:57 AM

PERIODIC MAINTENANCE AND MINOR REPAIR

6-9

NOTE:

The engine oil should be between the

minimum and maximum level marks.

4. If the engine oil is below the mini-

mum 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 replace-

ment)

1. Start the engine, warm it up for

several minutes, and then turn it

off.

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.

TE:

● Skip steps 4–6 if the oil filter car-

tridge 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.

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 car-

tridge.

1. Engine oil filler cap

2. Engine oil level check window

3. Maximum level mark

4. Minimum level mark

1. Engine oil drain bolt

1. Oil filter wrench

2. Oil filter cartridge

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-10

TE:

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.

7. Install the engine oil drain bolt, and

then tighten it to the specified

torque.

8. Add the specified amount of the

recommended engine oil, and then

install and tighten the oil filler cap.

CAUTION:

ECA11620

● In order to prevent clutch slip-

page (since the engine oil also

lubricates the clutch), do not

mix any chemical additives. Do

not use oils with a diesel speci-

fication of “CD” or oils of a high-

er quality than specified. In

addition, do not use oils labeled

“ENERGY CONSERVING II” or

higher.

● Make sure that no foreign mate-

rial enters the crankcase.

9. Start the engine, and then let it idle

for several minutes while checking

it for oil leakage. If oil is leaking, im-

mediately turn the engine off and

check for the cause.

1. O-ring 1. Torque wrench

Tightening torque:

Oil filter cartridge:

17 Nm (1.7 m·kgf, 12 ft·lbf)

Tightening torque:

Engine oil drain bolt:

43 Nm (4.3 m·kgf, 31 ft·lbf)

Recommended engine oil:

See page 8-1.

Oil quantity:

Without oil filter cartridge replace-

ment:

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)

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-11

NOTE:

After the engine is started, the engine

oil level warning light should go off if the

oil level is sufficient.

CAUTION:

ECA10400

If the oil level warning light flickers

or remains on, immediately turn the

engine off and have a Yamaha dealer

check the vehicle.

10. Turn the engine off, and then

check the oil level and correct it if

necessary.

EAU20070

Coolant

The coolant level should be checked

before each ride. In addition, the cool-

ant must be changed at the intervals

specified in the periodic maintenance

and lubrication chart.

EAU20101

To check the coolant level

1. Place the vehicle on the center-

stand.

NOTE:

● The coolant level must be checked

on a cold engine since the level

varies with engine temperature.

● Make sure that the vehicle is posi-

tioned 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 cool-

ant reservoir.

NOTE:

The coolant should be between the

minimum and maximum level marks.

3. If the coolant is at or below the

minimum level mark, remove pan-

el A (See page 6-6.), remove the

reservoir cap, add coolant to the

maximum level mark, and then in-

stall the reservoir cap and the pan-

el.

1. Coolant reservoir

2. Maximum level mark

3. Minimum level mark

Coolant reservoir capacity (up to the

maximum level mark):

0.30 L (0.32 US qt) (0.26 Imp.qt)

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-12

CAUTION:

ECA10470

● 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 cool-

ant as soon as possible, other-

wise the engine may not be

sufficiently cooled and the cool-

ing 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.

WARNING

EWA10380

Never attempt to remove the radiator

cap when the engine is hot.

NOTE:

● The radiator fan is automatically

switched on or off according to the

coolant temperature in the radia-

tor.

● If the engine overheats, see page

6-39 for further instructions.

EAU20431

To change the coolant

1. Place the vehicle on the center-

stand and let the engine cool if

necessary.

2. Remove panels A and B. (See

page 6-6.)

3. Place a container under the engine

to collect the used coolant.

4. Remove the radiator cap.

WARNING

EWA10380

Never attempt to remove the radiator

cap when the engine is hot.

5. Remove the coolant drain bolt to

drain the cooling system.

6. After the coolant is completely

drained, thoroughly flush the cool-

ing system with clean tap water.

1. Radiator cap

1. Coolant drain bolt

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-13

7. Install the coolant drain bolt, and

then tighten it to the specified

torque.

NOTE:

Check the washer for damage and re-

place it if necessary.

8. Pour the recommended coolant

into the radiator until it is full.

CAUTION:

ECA10470

● 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 cool-

ant as soon as possible, other-

wise the engine may not be

sufficiently cooled and the cool-

ing 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 min-

utes, and then turn it off.

10. Remove the radiator cap to check

the coolant level in the radiator. If

necessary, add sufficient coolant

until it reaches the top of the radia-

tor, and then install the radiator

cap.

11. Check the coolant level in the res-

ervoir. 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.

Tightening torque:

Coolant drain bolt:

7 Nm (0.7 m·kgf, 5 ft·lbf)

Recommended antifreeze:

High-quality ethylene glycol anti-

freeze 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)

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-14

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 fre-

quently if you are riding in unusually

wet or dusty areas.

1. Remove the seat. (See page

3-11.)

2. Remove the fuel tank bolts.

3. Lift the fuel tank to position it away

from the air filter case. (Do not dis-

connect the fuel hoses!)

WARNING

EWA10410

● Make sure that the fuel tank is

well supported.

● 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 6-6.)

5. Pull the rubber cover off its hold-

ers.

6. Remove the air filter case cover by

removing the screws.

7. Pull the air filter element out.

8. Lightly tap the air filter element to

remove most of the dust and dirt,

and then blow the remaining dirt

1. Bolt

1. Rubber cover

2. Rubber cover holder

1. Air filter case cover

2. Screw

1. Air filter element

U1C2E1E0.book Page 14 Wednesday, August 4, 2004 11:57 AM

PERIODIC MAINTENANCE AND MINOR REPAIR

6-15

out with compressed air as shown.

If the air filter element is damaged,

replace it.

9. Insert the air filter element into the

air filter case.

CAUTION:

ECA11330

The engine should never be operat-

ed without the air filter element in-

stalled, otherwise the piston(s)

and/or cylinder(s) may become ex-

cessively worn.

10. Install the air filter case cover by in-

stalling the screws.

11. Place the rubber cover in the origi-

nal position.

12. Install the panels.

13. Install the fuel tank by installing the

bolts.

WARNING

EWA11290

● 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, other-

wise 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 po-

sition.

14. Install the seat.

1. Air filter element

1. Fuel tank breather hose

2. Original position (white mark)

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-16

EAU21290

Adjusting the carburetors

The carburetors are important parts of

the engine and require very sophisticat-

ed adjustment. Therefore, most carbu-

retor adjustments should be left to a

Yamaha dealer, who has the neces-

sary professional knowledge and expe-

rience. The adjustment described in the

following section, however, may be ser-

viced by the owner as part of routine

maintenance.

CAUTION:

ECA10560

The carburetors have been set and

extensively tested at the Yamaha

factory. Changing these settings

without sufficient technical knowl-

edge may result in poor perfor-

mance of or damage to the engine.

EAU21320

Adjusting the engine idling

speed

The engine idling speed must be

checked and, if necessary, adjusted as

follows at the intervals specified in the

periodic maintenance and lubrication

chart.

The engine should be warm before

making this adjustment.

TE:

The engine is warm when it quickly re-

sponds to the throttle.

Check the engine idling speed and, if

necessary, adjust it to specification by

turning the throttle stop screw. To in-

crease the engine idling speed, turn the

screw in direction (a). To decrease the

engine idling speed, turn the screw in

direction (b).

TE:

If the specified idling speed cannot be

obtained as described above, have a

Yamaha dealer make the adjustment.

1. Throttle stop screw

Engine idling speed:

1050–1150 r/min

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-17

EAU21381

Checking the throttle cable

free play

The throttle cable free play should mea-

sure 3.0–5.0 mm (0.12–0.20 in) at the

throttle grip. Periodically check the

throttle cable free play and, if neces-

sary, have a Yamaha dealer adjust it.

EAU21401

Valve clearance

The valve clearance changes with use,

resulting in improper air-fuel mixture

and/or engine noise. To prevent this

from occurring, the valve clearance

must be adjusted by a Yamaha dealer

at the intervals specified in the periodic

maintenance and lubrication chart.

EAU21771

Tires

To maximize the performance, durabil-

ity, and safe operation of your motor-

cycle, 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.

WARNING

EWA10500

● 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 ad-

justed in accordance with the

riding speed and with the total

weight of rider, passenger, car-

go, and accessories approved

for this model.

1. Throttle cable free play

U1C2E1E0.book Page 17 Wednesday, August 4, 2004 11:57 AM

PERIODIC MAINTENANCE AND MINOR REPAIR

6-18

WARNING

EWA11020

Because loading has an enormous

impact on the handling, braking,

performance and safety characteris-

tics of your motorcycle, you should

keep the following precautions in

mind.

● NEVER OVERLOAD THE

MOTORCYCLE! Operation of an

overloaded motorcycle may re-

sult in tire damage, loss of con-

trol, or severe injury. Make sure

that the total weight of rider,

passenger, cargo, and accesso-

ries does not exceed the speci-

fied maximum load for the

vehicle.

● Do not carry along loosely

packed items, which can shift

during a ride.

● Securely pack the heaviest

items close to the center of the

motorcycle and distribute the

weight evenly on both sides.

● Adjust the suspension and tire

air pressure with regard to the

load.

● Check the tire condition and air

pressure before each ride.

Tire inspection

The tires must be checked before each

ride. If the center tread depth reaches

the specified limit, if the tire has a nail or

glass fragments in it, or if the sidewall is

cracked, have a Yamaha dealer re-

place the tire immediately.

NOTE:

The tire tread depth limits may differ

from country to country. Always comply

with the local regulations.

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)

90–189 kg (198–417 lb):

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*:

189 kg (417 lb)

* Total weight of rider, passenger, car-

go and accessories

1. Tire sidewall

2. Tire tread depth

Minimum tire tread depth (front and

rear):

1.6 mm (0.06 in)

U1C2E1E0.book Page 18 Wednesday, August 4, 2004 11:57 AM

PERIODIC MAINTENANCE AND MINOR REPAIR

6-19

WARNING

EWA10470

● Have a Yamaha dealer replace

excessively worn tires. Besides

being illegal, operating the vehi-

cle with excessively worn tires

decreases riding stability and

can lead to loss of control.

● The replacement of all wheel

and brake related parts, includ-

ing the tires, should be left to a

Yamaha dealer, who has the

necessary professional knowl-

edge and experience.

Tire information

This motorcycle is equipped with cast

wheels and tubeless tires with valves.

WARNING

EWA10480

● The front and rear tires should

be of the same make and de-

sign, otherwise the handling

characteristics of the motor-

cycle cannot be guaranteed.

● After extensive tests, only the

tires listed below have been ap-

proved 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.

WARNING

EWA10600

This motorcycle is fitted with super-

high-speed tires. Note the following

points in order to make the most ef-

ficient use of these tires.

● Use only the specified replace-

ment tires. Other tires may run

the danger of bursting at super

high speeds.

● Brand-new tires can have a rela-

tively poor grip on certain road

surfaces until they have been

“broken in”. Therefore, it is ad-

visable before doing any high-

1. Tire air valve

2. Tire air valve core

3. Tire air valve cap with seal

Front tire:

Size:

120/70 ZR17M/C (58W)

Manufacturer/model:

METZELER/MEZ4Y FRONT

Rear tire:

Size:

180/55 ZR17M/C (73W)

Manufacturer/model:

METZELER/MEZ4Y

FRONT and REAR:

Tire air valve:

TR412

Valve core:

#9000A

U1C2E1E0.book Page 19 Wednesday, August 4, 2004 11:57 AM

PERIODIC MAINTENANCE AND MINOR REPAIR

6-20

speed riding to ride conserva-

tively 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 pres-

sure according to the operating

conditions.

EAU21960

Cast wheels

To maximize the performance, durabil-

ity, 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 be-

fore each ride. If any damage is

found, have a Yamaha dealer re-

place 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 han-

dling characteristics, and a short-

ened tire life.

● Ride at moderate speeds after

changing a tire since the tire sur-

face must first be “broken in” for it

to develop its optimal characteris-

tics.

EAU22080

Adjusting the clutch lever free

play

The clutch lever free play should mea-

sure 10.0–15.0 mm (0.39–0.59 in) as

shown. Periodically check the clutch le-

ver 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).

1. Clutch lever free play adjusting bolt

2. Clutch lever free play

U1C2E1E0.book Page 20 Wednesday, August 4, 2004 11:57 AM

PERIODIC MAINTENANCE AND MINOR REPAIR

6-21

NOTE:

If the specified free play cannot be ob-

tained as described above or if the

clutch does not operate correctly, have

a Yamaha dealer check the internal

clutch mechanism.

EAU22270

Adjusting the rear brake light

switch

The rear brake light switch, which is ac-

tivated 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).

EAU22321

Checking the front and rear

brake pads

Front brake

Rear brake

1. Rear brake light switch

2. Rear brake light switch adjusting nut

1. Brake pad wear indicator groove

U1C2E1E0.book Page 21 Wednesday, August 4, 2004 11:57 AM

PERIODIC MAINTENANCE AND MINOR REPAIR

6-22

The front and rear brake pads must be

checked for wear at the intervals spec-

ified 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 disassem-

ble 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.

EAU22580

Checking the brake fluid level

Front brake

Rear brake

Insufficient brake fluid may allow air to

enter the brake system, possibly caus-

ing it to become ineffective.

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 perfor-

mance.

● Refill with the same type of brake

fluid. Mixing fluids may result in a

harmful chemical reaction and

lead to poor braking performance.

1. Minimum level mark

Recommended brake fluid:

DOT 4

U1C2E1E0.book Page 22 Wednesday, August 4, 2004 11:57 AM

PERIODIC MAINTENANCE AND MINOR REPAIR

6-23

● Be careful that water does not en-

ter 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 paint-

ed surfaces or plastic parts. Al-

ways clean up spilled fluid

immediately.

● As the brake pads wear, it is nor-

mal for the brake fluid level to grad-

ually go down. However, if the

brake fluid level goes down sud-

denly, have a Yamaha dealer

check the cause.

EAU22730

Changing the brake fluid

Have a Yamaha dealer change the

brake fluid at the intervals specified in

the NOTE after the periodic mainte-

nance and lubrication chart. In addition,

have the oil seals of the master cylin-

ders 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.

EAU22760

Drive chain slack

The drive chain slack should be

checked before each ride and adjusted

if necessary.

EAU22791

To check the drive chain slack

1. Place the motorcycle on the cen-

terstand.

2. Shift the transmission into the neu-

tral 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.

1. Drive chain slack

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-24

5. If the drive chain slack is incorrect,

adjust it as follows.

EAU22940

To adjust the drive chain slack

1. Loosen the axle nut and the lock-

nut 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 loos-

en the drive chain, turn the adjust-

ing 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 posi-

tion for proper wheel alignment.

CAUTION:

ECA10570

Improper drive chain slack will over-

load 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.

Drive chain slack:

40.0–50.0 mm (1.57–1.97 in)

1. Axle nut

2. Drive chain slack adjusting bolt

3. Locknut

4. Alignment marks

Tightening torque:

Axle nut:

150 Nm (15.0 m·kgf, 108 ft·lbf)

U1C2E1E0.book Page 24 Wednesday, August 4, 2004 11:57 AM

PERIODIC MAINTENANCE AND MINOR REPAIR

6-25

EAU23021

Lubricating the drive chain

The drive chain must be cleaned and

lubricated at the intervals specified in

the periodic maintenance and lubrica-

tion chart, otherwise it will quickly wear

out, especially when riding in dusty or

wet areas. Service the drive chain as

follows.

CAUTION:

ECA10581

The drive chain must be lubricated

after washing the motorcycle and

riding in the rain.

1. Clean the drive chain with kero-

sene and a small soft brush.

CAUTION:

ECA11120

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.

CAUTION:

ECA11110

Do not use engine oil or any other lu-

bricants for the drive chain, as they

may contain substances that could

damage the O-rings.

EAU23100

Checking and lubricating the

cables

The operation of all control cables and

the condition of the cables should be

checked before each ride, and the ca-

bles and cable ends should be lubricat-

ed if necessary. If a cable is damaged

or does not move smoothly, have a

Yamaha dealer check or replace it.

WARNING

EWA10720

Damage to the outer sheath may in-

terfere with proper cable operation

and will cause the inner cable to

rust. Replace a damaged cable as

soon as possible to prevent unsafe

conditions.

Recommended lubricant:

Engine oil

U1C2E1E0.book Page 25 Wednesday, August 4, 2004 11:57 AM

PERIODIC MAINTENANCE AND MINOR REPAIR

6-26

EAU23110

Checking and lubricating the

throttle grip and cable

The operation of the throttle grip should

be checked before each ride. In addi-

tion, the cable should be lubricated or

replaced at the intervals specified in the

periodic maintenance chart.

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 lu-

bricated if necessary.

EAU23140

Checking and lubricating the

brake and clutch levers

The operation of the brake and clutch

levers should be checked before each

ride, and the lever pivots should be lu-

bricated if necessary.

Recommended lubricant:

Lithium-soap-based grease (all-pur-

pose grease)

Recommended lubricant:

Lithium-soap-based grease (all-pur-

pose grease)

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-27

EAU23210

Checking and lubricating the

centerstand and sidestand

The operation of the centerstand and

sidestand should be checked before

each ride, and the pivots and metal-to-

metal contact surfaces should be lubri-

cated if necessary.

WARNING

EWA10740

If the centerstand or sidestand does

not move up and down smoothly,

have a Yamaha dealer check or re-

pair it.

EAUM1650

Lubricating the swingarm

pivots

The swingarm pivots must be lubricat-

ed at the intervals specified in the peri-

odic maintenance and lubrication chart.

EAU23250

Lubricating the rear

suspension

The pivoting points of the rear suspen-

sion must be lubricated at the intervals

specified in the periodic maintenance

and lubrication chart.

Recommended lubricant:

Lithium-soap-based grease (all-pur-

pose grease)

Recommended lubricant:

Lithium-soap-based grease

Recommended lubricant:

Lithium-soap-based grease

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-28

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 main-

tenance and lubrication chart.

To check the condition

WARNING

EWA10750

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 sur-

face and hold it in an upright posi-

tion.

2. While applying the front brake,

push down hard on the handlebars

several times to check if the front

fork compresses and rebounds

smoothly.

CAUTION:

ECA10590

If any damage is found or the front

fork does not operate smoothly,

have a Yamaha dealer check or re-

pair it.

EAU23280

Checking the steering

Worn or loose steering bearings may

cause danger. Therefore, the operation

of the steering must be checked as fol-

lows at the intervals specified in the pe-

riodic maintenance and lubrication

chart.

1. Place a stand under the engine to

raise the front wheel off the

ground.

WARNING

EWA10750

Securely support the vehicle so that

there is no danger of it falling over.

2. Hold the lower ends of the front

fork legs and try to move them for-

ward and backward. If any free

play can be felt, have a Yamaha

dealer check or repair the steering.

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6-29

EAU23290

Checking the wheel bearings

The front and rear wheel bearings must

be checked at the intervals specified in

the periodic maintenance and lubrica-

tion 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.

EAU33650

Battery

This model is equipped with a sealed-

type (MF) battery, which does not re-

quire any maintenance. There is no

need to check the electrolyte or to add

distilled water.

WARNING

EWA10760

● Electrolyte is poisonous and

dangerous since it contains sul-

furic acid, which causes severe

burns. Avoid any contact with

skin, eyes or clothing and al-

ways shield your eyes when

1. Negative battery terminal

2. Positive battery terminal

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-30

working near batteries. In case

of contact, administer the fol-

lowing FIRST AID.

• EXTERNAL: Flush with plenty

of water.

• INTERNAL: Drink large quan-

tities of water or milk and im-

mediately call a physician.

• EYES: Flush with water for 15

minutes and seek prompt

medical attention.

● Batteries produce explosive hy-

drogen gas. Therefore, keep

sparks, flames, cigarettes, etc.,

away from the battery and pro-

vide sufficient ventilation when

charging it in an enclosed

space.

● KEEP THIS AND ALL BATTER-

IES OUT OF THE REACH OF

CHILDREN.

To charge the battery

Have a Yamaha dealer charge the bat-

tery as soon as possible if it seems to

have discharged. Keep in mind that the

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 in-

stallation.

4. After installation, make sure that

the battery leads are properly con-

nected to the battery terminals.

CAUTION:

ECA10630

● Always keep the battery

charged. Storing a discharged

battery can cause permanent

battery damage.

● To charge a sealed-type (MF)

battery, a special (constant-volt-

age) battery charger is required.

Using a conventional battery

charger will damage the battery.

If you do not have access to a

sealed-type (MF) battery charg-

er, have a Yamaha dealer

charge your battery.

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-31

EAU23622

Replacing the fuses

The main fuse and the fuse box, which

contains the fuses for the individual cir-

cuits, are located under the seat. (See

page 3-11.)

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.

CAUTION:

ECA10640

Do not use a fuse of a higher amper-

age 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.

1. Main fuse

2. Headlight fuse

3. Radiator fan fuse

4. Ignition fuse

5. Signaling system fuse

6. Backup fuse (for odometer and clock)

7. Turn signal light and hazard fuse

8. Spare fuse

9. Spare main fuse

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

Turn signal light and hazard fuse:

10.0 A

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6-32

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 re-

placing the right headlight bulb).

(See page 6-6.)

2. Disconnect the headlight coupler,

and then remove the headlight

bulb cover.

3. Unhook the headlight bulb holder,

and then remove the defective

bulb.

WARNING

EWA10790

Headlight bulbs get very hot. There-

fore, keep flammable products away

from a lit headlight bulb, and do not

touch the bulb until it has cooled

down.

4. Place a new headlight bulb into po-

sition, and then secure it with the

bulb holder.

CAUTION:

ECA10650

Take care not to damage the follow-

ing parts:

● Headlight bulb

Do not touch the glass part of

the headlight bulb to keep it free

from oil, otherwise the transpar-

ency of the glass, the luminosity

of the bulb, and the bulb life will

be adversely affected. Thor-

oughly clean off any dirt and fin-

gerprints on the headlight bulb

using a cloth moistened with al-

cohol 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.

1. Headlight bulb cover

2. Headlight coupler

1. Headlight bulb holder

1. Do not touch the glass part of the bulb.

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-33

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

3-11.)

2. Remove the tail/brake light bulb

cover.

3. Remove the socket (together with

the bulb) by turning it counter-

clockwise.

4. Remove the defective bulb by

pushing it in and turning it counter-

clockwise.

5. Insert a new bulb into the socket,

push it in, and then turn it clock-

wise until it stops.

6. Install the socket (together with the

bulb) by turning it clockwise.

7. Install the bulb cover.

8. Install the seat.

1. Tail/brake light bulb cover

1. Tail/brake light bulb socket

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6-34

EAU24201

Replacing a turn signal light

bulb

1. Remove the turn signal light lens

by removing the screw.

2. Remove the defective bulb by

pushing it in and turning it counter-

clockwise.

3. Insert a new bulb into the socket,

push it in, and then turn it clock-

wise until it stops.

4. Install the lens by installing the

screw.

CAUTION:

ECA11190

Do not overtighten the screw, other-

wise the lens may break.

EAU27010

Replacing an auxiliary light

bulb

This model is equipped with two auxil-

iary lights. If an auxiliary light bulb burns

out, replace it as follows.

1. Remove panel D (if replacing the

left auxiliary light bulb) or panel B

(if replacing the right auxiliary light

bulb). (See page 6-6.)

2. Remove the auxiliary light socket

(together with the coupler) by turn-

ing the socket counterclockwise.

3. Remove the defective bulb by pull-

ing it out.

4. Insert a new bulb into the socket.

5. Install the auxiliary light socket (to-

gether with the coupler) by push-

ing it in and turning it clockwise.

1. Screw

1. Auxiliary light bulb socket

1. Auxiliary light bulb

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6-35

EAU24360

Front wheel

EAU24470

To remove the front wheel

WARNING

EWA10820

● It is advisable to have a Yamaha

dealer service the wheel.

● Securely support the motor-

cycle so that there is no danger

of it falling over.

1. Place the motorcycle on the cen-

terstand.

2. Loosen the front wheel axle pinch

bolt, then the wheel axle and the

brake caliper bolts.

3. Remove the brake hose holder on

each side by removing the bolts.

4. Remove the brake caliper on each

side by removing the bolts.

CAUTION:

ECA11050

Do not apply the brake after the

brake calipers have been removed,

otherwise the brake pads will be

forced shut.

5. Pull the wheel axle out, and then

remove the wheel.

EAU25020

To install the front wheel

1. Lift the wheel up between the fork

legs.

2. Insert the wheel axle.

3. Lower the front wheel so that it is

on the ground.

4. Install the brake calipers by install-

ing the bolts.

NOTE:

Make sure that there is enough space

between the brake pads before install-

ing the brake calipers onto the brake

discs.

5. Install the brake hose holders by

installing the bolts.

6. Tighten the wheel axle, the wheel

axle pinch bolt and the brake cali-

per bolts to the specified torques.

1. Wheel axle

2. Front wheel axle pinch bolt

1. Bolt

2. Brake hose holder

3. Brake caliper bolt

4. Brake caliper

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)

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6-36

7. Push down hard on the handlebar

several times to check for proper

fork operation.

EAU25080

Rear wheel

EAU25201

To remove the rear wheel

WARNING

EWA10820

● It is advisable to have a Yamaha

dealer service the wheel.

● Securely support the motor-

cycle so that there is no danger

of it falling over.

1. Loosen the axle nut and the brake

caliper bolts.

2. Place the motorcycle on the cen-

terstand.

3. Disconnect the brake torque rod

from the brake caliper by removing

the nut and the bolt.

4. Remove the axle nut, then the

brake caliper by removing the

bolts.

CAUTION:

ECA11300

Do not apply the brake after the

brake caliper has been removed,

otherwise the brake pads will be

forced shut.

5. Loosen the locknut on each side of

the swingarm.

1. Axle nut

1. Brake caliper bolt

2. Brake torque rod

3. Brake torque rod bolt

4. Brake torque rod nut

5. Brake caliper bracket

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6-37

6. Turn the drive chain slack adjust-

ing bolts fully in direction (a).

7. Push the wheel forward, and then

remove the drive chain from the

rear sprocket.

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.

EAU25841

To install the rear wheel

1. Place the wheel and the brake cal-

iper 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 6-23.)

4. Connect the brake torque rod to

the brake caliper bracket by install-

ing the bolt and the nut.

5. Install the brake caliper by install-

ing the bolts.

NOTE:

Make sure that there is enough space

between the brake pads before install-

ing the brake caliper onto the brake

disc.

6. Take the motorcycle off the center-

stand 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.

1. Drive chain slack adjusting bolt

2. Locknut

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)

U1C2E1E0.book Page 37 Wednesday, August 4, 2004 11:57 AM

PERIODIC MAINTENANCE AND MINOR REPAIR

6-38

EAU25870

Troubleshooting

Although Yamaha motorcycles receive

a thorough inspection before shipment

from the factory, trouble may occur dur-

ing 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 your-

self. 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 replace-

ment parts. Imitation parts may look like

Yamaha parts, but they are often inferi-

or, have a shorter service life and can

lead to expensive repair bills.

U1C2E1E0.book Page 38 Wednesday, August 4, 2004 11:57 AM

PERIODIC MAINTENANCE AND MINOR REPAIR

6-39

EAU25911

Troubleshooting charts

Starting problems or poor engine performance

WARNING

EWA10840

Keep away open flames and do not smoke while checking or working on the fuel system.

Check the fuel level in

the fuel tank.

1. Fuel

There is enough fuel.

There is no fuel.

Check the compression.

Supply fuel.

The engine does not start.

Check the compression.

Operate the electric starter.

2. Compression

There is compression.

There is no compression.

Check the ignition.

Have a Yamaha dealer

check the vehicle.

Remove the spark plugs

and check the electrodes.

3. Ignition

Wipe off with a dry cloth and correct the

spark plug gaps, or replace the spark plugs.

Have a Yamaha dealer check the vehicle.

The engine does not start.

Have a Yamaha dealer

check the vehicle.

The engine does not start.

Check the battery.

Operate the electric starter.

4. Battery

The engine turns over

quickly.

The engine turns over

slowly.

The battery is good.

Check the battery lead connections,

and charge the battery if necessary.

Dry

Wet

Open the throttle halfway and operate

the electric starter.

U1C2E1E0.book Page 39 Wednesday, August 4, 2004 11:57 AM

PERIODIC MAINTENANCE AND MINOR REPAIR

6-40

Engine overheating

WARNING

EWA10400

● 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.

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.

Wait until the

engine has cooled.

Check the coolant level in the

reservoir and radiator.

The coolant level

is OK.

The coolant level is low.

Check the cooling system

for 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.

There is

leakage.

There is

no leakage.

U1C2E1E0.book Page 40 Wednesday, August 4, 2004 11:57 AM

MOTORCYCLE CARE AND STORAGE

7-1

EAU26010

Care

While the open design of a motorcycle

reveals the attractiveness of the tech-

nology, it also makes it more vulnera-

ble. Rust and corrosion can develop

even if high-quality components are

used. A rusty exhaust pipe may go un-

noticed on a car, however, it detracts

from the overall appearance of a motor-

cycle. 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 in-

stalled.

3. Remove extremely stubborn dirt,

like oil burnt onto the crankcase,

with a degreasing agent and a

brush, but never apply such prod-

ucts onto seals, gaskets, sprock-

ets, the drive chain and wheel

axles. Always rinse the dirt and de-

greaser off with water.

Cleaning

CAUTION:

ECA10770

● 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 af-

fected area any longer than in-

structed. Also, thoroughly rinse

the area off with water, immedi-

ately dry it, and then apply a cor-

rosion 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

cleaning products, solvent or

thinner, fuel (gasoline), rust re-

movers or inhibitors, brake flu-

id, antifreeze or electrolyte.

● Do not use high-pressure wash-

ers or steam-jet cleaners since

they cause water seepage and

deterioration in the following ar-

eas: seals (of wheel and swing-

arm 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 com-

pounds for plastic may leave

scratches on the windshield.

Test the product on a small hid-

den 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.

U1C2E1E0.book Page 1 Wednesday, August 4, 2004 11:57 AM

MOTORCYCLE CARE AND STORAGE

7-2

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.

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 wa-

ter and a mild detergent, after the

engine has cooled down.

CAUTION:

ECA10790

Do not use warm water since it in-

creases 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 stainless-

steel parts, including the exhaust

system. (Even the thermally in-

duced discoloring of stainless-

steel exhaust systems can be re-

moved through polishing.)

4. To prevent corrosion, it is recom-

mended to apply a corrosion pro-

tection spray on all metal,

including chrome- and nickel-plat-

ed, surfaces.

5. Use spray oil as a universal clean-

er 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.

WARNING

EWA10930

● 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 ac-

etone, and wash the tires with

warm water and a mild deter-

gent.

● Before operating the motor-

cycle test its braking perfor-

mance and cornering behavior.

CAUTION:

ECA10800

● Apply spray oil and wax spar-

ingly and make sure to wipe off

any excess.

U1C2E1E0.book Page 2 Wednesday, August 4, 2004 11:57 AM

MOTORCYCLE CARE AND STORAGE

7-3

● 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.

CAUTION:

ECA10810

● Storing the motorcycle in a

poorly ventilated room or cover-

ing it with a tarp, while it is still

wet, will allow water and humid-

ity to seep in and cause rust.

● To prevent corrosion, avoid

damp cellars, stables (because

of the presence of ammonia)

and areas where strong chemi-

cals are stored.

Long-term

Before storing your motorcycle for sev-

eral 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” posi-

tion: Turn the fuel cock lever to

“OFF”.

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 pro-

tect 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 spark-

ing 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.

U1C2E1E0.book Page 3 Wednesday, August 4, 2004 11:57 AM

MOTORCYCLE CARE AND STORAGE

7-4

WARNING

EWA10950

To prevent damage or injury from

sparking, make sure to ground the

spark plug electrodes while turning

the engine over.

6. Lubricate all control cables and the

pivoting points of all levers and

pedals as well as of the side-

stand/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. Alterna-

tively, 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 ex-

cessively cold or warm place [less

than 0 °C (30 °F) or more than 30

°C (90 °F)]. For more information

on storing the battery, see page

6-29.

NOTE:

Make any necessary repairs before

storing the motorcycle.

U1C2E1E0.book Page 4 Wednesday, August 4, 2004 11:57 AM

SPECIFICATIONS

8-1

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)

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:

SAE10W30 or SAE10W40 or SAE15W40

or SAE20W40 or SAE20W50

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:

Regular 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)

Carburetor:

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

-20 -10 0

20 30

50 ˚C

SAE 10W-30

SAE 15W-40

SAE 20W-40

SAE 20W-50

SAE 10W-40

U1C2E1E0.book Page 1 Wednesday, August 4, 2004 11:57 AM

SPECIFICATIONS

8-2

Operation:

Left foot operation

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:

Type:

Tubeless

Size:

120/70 ZR17M/C (58W)

Manufacturer/model:

METZELER/MEZ4Y FRONT

Rear tire:

Type:

Tubeless

Size:

180/55 ZR17M/C (73W)

Manufacturer/model:

METZELER/MEZ4Y

Loading:

Maximum load:

189 kg (417 lb)

(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:

90–189 kg (198–417 lb)

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

Rear wheel:

Wheel type:

Cast wheel

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:

Ignition system:

Transistorized coil ignition (digital)

U1C2E1E0.book Page 2 Wednesday, August 4, 2004 11:57 AM

SPECIFICATIONS

8-3

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 light:

12 V, 21.0 W × 2

Rear turn signal light:

12 V, 21.0 W × 2

Auxiliary light:

12 V, 5.0 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

Turn signal light and hazard fuse:

10.0 A

Backup fuse:

10.0 A

U1C2E1E0.book Page 3 Wednesday, August 4, 2004 11:57 AM

CONSUMER INFORMATION

9-1

EAU26351

Identification numbers

Record the key identification number,

vehicle identification number and mod-

el label information in the spaces pro-

vided below for assistance when

ordering spare parts from a Yamaha

dealer or for reference in case the vehi-

cle is stolen.

KEY IDENTIFICATION NUMBER:

VEHICLE IDENTIFICATION

NUMBER:

MODEL LABEL INFORMATION:

EAU26381

Key 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.

EAU26400

Vehicle identification number

The vehicle identification number is

stamped into the steering head pipe.

Record this number in the space pro-

vided.

TE:

The vehicle identification number is

used to identify your motorcycle and

may be used to register your motor-

cycle with the licensing authority in your

area.

1. Key identification number 1. Vehicle identification number

U1C2E1E0.book Page 1 Wednesday, August 4, 2004 11:57 AM

CONSUMER INFORMATION

9-2

EAU26480

Model label

The model label is affixed to the frame

under the seat. (See page 3-11.)

Record the information on this label in

the space provided. This information

will be needed when ordering spare

parts from a Yamaha dealer.

1. Model label

U1C2E1E0.book Page 2 Wednesday, August 4, 2004 11:57 AM

INDEX

Air filter element, cleaning .................... 6-14

Anti-theft alarm (optional) ....................... 3-6

Auxiliary light bulb, replacing ................ 6-34

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

Brake and clutch levers, checking and

lubricating........................................... 6-26

Brake and shift pedals, checking and

lubricating........................................... 6-26

Brake fluid, changing ............................ 6-23

Brake fluid level, checking .................... 6-22

Brake lever ............................................. 3-8

Brake pedal ............................................ 3-8

Cables, checking and lubricating.......... 6-25

Carburetors, adjusting .......................... 6-16

Care........................................................ 7-1

Catalytic converter................................ 3-11

Centerstand and sidestand, checking

and lubricating .................................... 6-27

Clutch lever............................................. 3-7

Clutch lever free play, adjusting ........... 6-20

Coolant ................................................. 6-11

Coolant temperature warning light.......... 3-3

Dimmer switch ........................................ 3-6

Drive chain, lubricating ......................... 6-25

Drive chain slack .................................. 6-23

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

Engine idling speed .............................. 6-16

Engine oil and oil filter cartridge ............. 6-8

Engine, starting a warm.......................... 5-3

Engine stop switch ..................................3-7

EXUP system ........................................3-17

Front and rear brake pads, checking ....6-21

Front fork, adjusting ..............................3-13

Front fork, checking...............................6-28

Fuel .........................................................3-9

Fuel consumption, tips for reducing ........5-4

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

Fuel level warning light............................3-3

Fuel tank breather hose ........................3-10

Fuel tank cap...........................................3-9

Fuses, replacing....................................6-31

Handlebar switches.................................3-6

Hazard switch..........................................3-7

Headlight bulb, replacing.......................6-32

Helmet holder........................................3-12

High beam indicator light.........................3-2

Horn switch .............................................3-7

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

Ignition circuit cut-off system.................3-18

Indicator and warning lights ....................3-2

Key identification number........................9-1

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

Model label..............................................9-2

Neutral indicator light ..............................3-2

Oil level warning light ..............................3-2

Panels, removing and installing .............. 6-6

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

Part locations.......................................... 2-1

Pass switch............................................. 3-6

Periodic maintenance and lubrication

chart...................................................... 6-2

Pre-operation check list .......................... 4-2

Rear brake light switch, adjusting ......... 6-21

Rear suspension, lubricating ................ 6-27

Safety information................................... 1-1

Seat ...................................................... 3-11

Self-diagnosis devices ............................ 3-5

Shifting.................................................... 5-3

Shift pedal............................................... 3-8

Shock absorber assembly, adjusting .... 3-15

Sidestand.............................................. 3-17

Spark plugs, checking............................. 6-7

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

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

Starter (choke) lever ............................. 3-11

Starting a cold engine ............................. 5-1

Start switch ............................................. 3-7

Steering, checking ................................ 6-28

Storage ...................................................7-3

Storage compartment ........................... 3-12

Swingarm pivots, lubricating ................. 6-27

Tachometer unit...................................... 3-4

Tail/brake light bulb, replacing .............. 6-33

Throttle cable free play, checking ......... 6-17

U1C2E1E0.book Page 1 Wednesday, August 4, 2004 11:57 AM

INDEX

Throttle grip and cable, checking and

lubricating ...........................................6-26

Tires......................................................6-17

Tool kit ....................................................6-1

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

Troubleshooting charts ......................... 6-39

Turn signal indicator lights ......................3-2

Turn signal light bulb, replacing ............ 6-34

Turn signal switch ................................... 3-6

Valve clearance ....................................6-17

Vehicle identification number..................9-1

Wheel bearings, checking..................... 6-29

Wheel (front) ......................................... 6-35

Wheel (rear) .......................................... 6-36

Wheels .................................................. 6-20

U1C2E1E0.book Page 2 Wednesday, August 4, 2004 11:57 AM

U1C2E1E0.book Page 3 Wednesday, August 4, 2004 11:57 AM

PRINTED ON RECYCLED PAPER

YAMAHA MOTOR CO., LTD.

PRINTED IN JAPAN

2004.08-0.3×1 CR

(E)

1C2-28199-EA

FZS1000

FZS1000S

OWNER’S MANUAL

Yamaha FZS1000S Handleiding

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